Manual de Servicio Retardador

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92,7+5HWDUGHU
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R 115 H EATON Digiprop
R 115 H EATON Logoprop
R 115 H Daimler-Benz SK
R 120 Digiprop
R 120 Logoprop
R 133-2 Digiprop
R 133 Logoprop
Date: August, 1st 1998
Training $IWHUVDOHV6HUYLFH0DQXDO
92,7+5HWDUGHU+(DWRQ576'LJLSURS
cbtd 98-01
53.2664.10
Content 7DEOHRI&RQWHQWV
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
3.3 Checking Oil Level .............................................................................3.3/1
4. Diagnosis/Troubleshooting......................................................................4/1
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
5. Removing, Installing Retarder .................................................................5/1

5.1 Removing, Installing Retarder ..............................................................5.1/1
cbtd 98-01
53.2664.10 Aftersales Service Manual VOITH Retarder 115 H - Eaton RTS/O Digiprop
Page IHV/1
(Continue)
6. Retarder Basic Group Repair ..................................................................6/1

6.2 Removing, Checking and Installing Casing Ventilation .............................6.2/1
6.3 Removing, Checking and Installing Silencer ...........................................6.3/1
6.4 Removing, Checking and Installing Heat Exchanger ................................6.4/1
6.5 Removing and Installing Oil Tank Cover ................................................6.5/1
Upper Oil Tank Cover.........................................................................6.5/1
Lower Oil Tank Cover.........................................................................6.5/3
6.6 Removing and Installing Oil Tank .........................................................6.6/1
7. Control Parts ...........................................................................................7/1

7.1 Control Parts ....................................................................................7.1/1
8. Annex ......................................................................................................8/1
Data Sheet
Miscellaneous Conversions
Operating Specifications
Spare Parts Lists
Other Information
cbtd 98-01
Page IHV/2
General
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 115 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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General
(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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General
(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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Page 1/3
General
(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
cbtd 98-01
Page 1/4
General

2.1 Assembly Overview....................................................................................2.1/1
2.2 Function and Operation Scheme................................................................2.2/1
2.3 Retarder Data.............................................................................................2.3/1
cbtd 98-01
Page 2/1
General
Illustration VOITH Retarder 115 H Digiprop

basic group with heat exchanger
94/5 Blind hole (not used) 3700

2909 Oil filler plug (M 30 x 1,5) 2909 2909
2923 Oil check plug (M 24 x 1,5)
3300 Heat exchanger
3700 Proportional valve
3700/1 Electrical connection,
3700/1
Proportional valve
7000 Ventilation
3300
94/5
7000
2923
FD911
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General
(Continue)
Illustration VOITH Retarder 115 H Digiprop

(Continue)
2919 Central oil-drain plug

3300 Heat exchanger
4700 Screw plug (M 30 x 1,5)
with sieve
3300
2919
4700
FD902
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General
Illustration VOITH Retarder 115 H with Digiprop control system
Notice
The reference numbers indicated in Section 2.2 are not identical with the reference numbers of the spare parts lists.
70 47 15 17 4
26 A R
42 21
23
18
36
25
20
2
63
1
19
46
22
6
44
64
69 8 5 4 16
62
43
55
Oil sump Coolant (water)

Supply-air pressure p V Pump pressure p P
Constant-air pressure p y
FD913
1 Heat exchanger
2 Control unit
4 Connection terminal 15
6 Fuses (8A)
8 Connection ground
15 ABS-Signal
16 Retarder stage switch
17 Retarder pilot light
18 Stop light relay
19 Cooling water temperature pick-up
20 Oil temperature pick-up
22 Ventilation
23 Casing ventilation
25 Constant-air pressure line py
26 Supply-air pressure line pv
36 Ventilation line
42 Oil tank
43 Oil sump
44 Stator
46 Rotor
47 Speedometer signal
62 Pressure regulation valve
63 Check valve (inlet)
64 Check valve (outlet)
69 ISO interface plug
70 Extra operations plug
cbtd 98-01 Aftersales Service Manual VOITH Retarder 115 H - Eaton RTS/O Digiprop
53.2664.10 Page 2.2/1
General

(Continue)
Description of the function

The VOITH retarder R 115 H is a powerful, hydrodynamic, continuous brake of compact design for
commercial vehicles of the heavy-duty range with a prop-shaft speed up to 2708 r.p.m. max.
The retarder is driven and braking torque is transmitted by a pair gearwheels in the gearbox.
The transmission ratio enables the retarder to achieve high braking torques right down
to low r.p.m. ranges with the compactest configuration (small rotor/stator).
Retarder braking torque is sustained even when gear changes are made.
A 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 FD985
used to regulate the vehicle speed.
FD986
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General

(Continue)
Description of operation of retarder R 115 H with digiprop control system

c
A retarder stage switch (16) with 5 switching stages is used to operate the VOITH retarder R 115 H.
In a special version, the retarder stage switch (16) in conjunction with ABS can be combined with
a 3-stage running-plate valve or a 4-stage pressure-switch unit for the service brake.
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 a b
of the maximum braking torque.
If the retarder is switched off (0 position), or if a braking stage is engaged (position 2 to 5), the memorized
constant speed is deleted. If the constant speed function is re-activated, the new present speed
is memorized.
FD299
If the retarder stage switch (16) is shifted to positions 2 to 5, the retarder brakes in braking stage 1 to 4.
The hydrodynamic principle
In the maximum position of the retarder stage switch (16), the braking torque of the VOITH retarder a Rotor (46)
is at maximum. b Stator (44)
c Oil flow
The control medium for the VOITH retarder R 115 H is compressed air, which is taken from the
vehicle air tank for auxiliary equipment.
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 is passed on to the
proportional valve (21).
The proportional valve (21), depending on the magnitude of the control current, provides a
constant-air pressure py on the oil sump (43).
The constant-air pressure py 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).
The rotor (46) is connected with the drive shaft of the retarder, the stator (44) is fixed
to the retarder housing.
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General

(Continue)
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.
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 py 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

(Continue)
Pressure regulating valve (62)

The pressure regulating valve (62) adjusts the lubrication in the no-load operation of the retarder.
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.
Check valve (63) inlet

When the retarder is switched on, the oil sump is pressurized, causing the check valve (63) to open and
the oil to enter the working space.
Check valve (64) outlet

The oil pressure in the working space opens the check valve (64), causing the oil to enter
the heat exchanger (1), to be cooled and to be returned to the working circuit.
Notice
If the check valve (outlet) must be renewed during a repair operation, please contact VOITH TURBO
or a responsible contracting party.
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Page 2.2/5
General !
The retarder data plate (2) is on the oil tank at the bottom on the right in the direction of travel.
The retarder data plate (2) provides the following information: 2900/1
VOITH
Retarder
1. Serial-Number: Six-digit number Typ R115 H Fabr. Nr.
i Ret. = Baujahr 1993
00.0000.00
2. Retarder transmission ratio (i retarder) 00.0000.00
3. Year of manufacture
4. Code-Number: Eight-digit number
With Digiprop H
ITer
VO tard
control system Re . 93
Nr 19
br.
Fa
.00
r
ah
urj
00 0
H Ba
15
Ty
p R1
.00 0.0
f. = 00 00
i Re
.0
00
FD910
53.7386.30
67.0001.20
5. Vehicle manufacturer´s Part No., if any.
Notice
Please, always quote the retarder serial-No. and code-No. when submitting queries
or ordering spare parts.
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Page 2.3/1
Maintenance "

3.1 Maintenance Work .....................................................................................3.1/1
3.2 Oil Change .................................................................................................3.2/1
3.3 Checking Oil Level .....................................................................................3.3/1
53.2664.10 Page 3/1
Maintenance "

#$
Overview of maintenance work
At each oil change

• Clean the sieve for the pressure regulating valve.
• Check the fastening screws of the heat exchanger and oil storage tank on correct fitment.
• Check all oil filler plugs (retarder main components and heat exchanger) on sealing and
correct fitment.
• Carry out visual inspection on leaks at the complete retarder.
The oil change intervals and operating specifications have to be taken from the annex!
53.2664.10 Page 3.1/1
Maintenance %
&
Illustration oil change 2909

2910
2909 Oil filler plug (M 30 x 1,5), 150 Nm 2909
2910 Sealing ring (A 30 x 36), renew
2918 Sealing ring (A 20 x 26), renew 2910
2919 Central oil-drain plug, 55 Nm
2920 O-ring (10 x 3), renew,
coat with silicone-free and non-
corrosive grease for installation
2921 O-ring (6 x 3), renew,
4700 Screw plug with sieve, 150 Nm,
clean sieve with appropriate
cleaning agent (benzine) and blow
out with compressed air
Lubricants and cleaning agents
O-ring Silicone-free and 2921

non-corrosive grease 4800
2920
Sieve in Benzine 2918
screw plug 4700
2919
FD917
53.2664.10 Page 3.2/1
Maintenance %
&
(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.
The retarder oil temperature must be higher than 60°C (operating temperature) for the oil to be drained.
While the oil is being changed, make sure that no constant-air pressure is acting on the retarder.
The retarder must have been switched off!
Caution! Risk of injury!
Central oil-drain plug is heated up (oil temperature)

!
Service filling with heat exchanger
Service filling (oil change, checking oil level) 5,4 l
After exchange of heat exchanger 5,6 l
After complete taking apart and cleaning as well as

emptied heat exchanger (corresponds new filling) 6,0 l
53.2664.10 Page 3.2/2
Maintenance %
&
(Continue)
Job scope
1. Push an oil collecting pan under retarder.
Central oil drain plug is heated up (oil temperature)!
2. Screw out the central oil-drain plug (2919) on the retarder and drain the oil. 2921
2920
3. Coat new O-rings (2920 und 2921) with silicone-free and non-corrosive grease and fit them on the
2918
central oil-drain plug (2919).
2919
FD344
4. Screw the central oil-drain plug (2919) tight with a new sealing ring (2918).
Tightening torque 55 Nm
5. Screw the screw plug (4700) out of the retarder housing and remove the sealing ring (4800).
6. Clean sieve in the screw plug (4700) with appropriate cleaning agent (benzine) and blow out with
compressed air.
7. Screw the screw plug (4700) tight with a new sealing ring (4800). Tightening torque 150 Nm
4800
4700
FD438
53.2664.10 Page 3.2/3
Maintenance %
&
(Continue)
8. Screw out the oil filler plug (2909) with sealing ring (2910) depending on accessibility.
9. Fill in slowly the quantity of oil specified (see table page 3.2/2) in accordance with the operating
specifications (see annex).
10. Screw the oil filler plug (2909) tight with new sealing ring (2910). Tightening torque 150 Nm
11. Check the oil level (see Section 3.3).
53.2664.10 Page 3.2/4
Maintenance %$
& '
Illustration checking oil level

2909
2910
2923 Oil check plug (M 24 x 1,5), 80 Nm 2910
2924
2923
FD915
53.2664.10 Page 3.3/1
Maintenance %$
& '
(Continue)
Notice
(see table, page 3.2/2) and to use only oils specified in the operating specifications (see annex) for
operating the retarder in the relevant application.
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.
Oil filler plug is heated up (oil temperature)!
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 plug (2909 and 2923)!
53.2664.10 Page 3.3/2
Maintenance %$
& '
(Continue)
Check requirements
• Vehicle ignition system ON
• Service pressure
Job scope
1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and 2924
switch it off after approx. 5 sec. 2923
Repeat this procedure twice.
2. Switch off the retarder and wait 5 minutes (control function).
FD901
The oil check plug is heated up (oil temperature)!
3. Screw out the oil check plug (2923) and remove sealing ring (2924).
2909
The oil level is correct if it is at the lower edge (arrow) of the oil check hole.
2910 2909
4. Top up any lacking oil through the hole for the oil filler plug (2909), depending on accessibility.
5. Screw the oil filler plug (2909) tight with a new sealing ring (2910). Tightening torque 150 Nm
6. Screw the oil check plug (2923) tight with a new sealing ring (2924). Tightening torque 80 Nm
FD921
53.2664.10 Page 3.3/3
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
53.2664.10 Page 4/1
Diagnosis /
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).
Contact
Correct oil level of VOITH Correct oil level of
retarder and retarder and
gear box gear box
too too too too

high low Correct oil level of high low
Check oil level retarder(*) Check oil level
of gear box of gear box
NOK OK OK NOK
Contact Renew casing
VOITH ventilation Check oil level Check oil level
of gear box of gear box
too too
OK NOK
high low
Check casing see chapter 6.4
Check oil level of Check cooling system:
ventilation retarder
(chapter 6.2) Check -coolant level
heat exchanger -thermostat
NO YES YES NO -coolant pump
-radiator fan
OK NOK -radiator grill for
Water in the oil? Water in the oil?
dirtiness
(emulsion) (emulsion)
Check oil level of
retarder Retarder:
Check Temp.-sensor
(oil/water) Driver instruction!
Oil leak
by ventilation
OK NOK
Temperature
flashes
limit! Check operation (by
braking with retarder
nominal engine
speed,
if possible)
Complaint
Retarder Pilot
R 115 Light
Digiprop
Activate flash code

Permanent Clear faults and
and read out trouble
lighting delete fault memory
code
No respectively
too insufficient
retarder braking
effect
Check oil level of

retarder
(emulsion) OK NOK (emulsion)
NO Yes Yes NO
Check
heat exchanger
Check py (static) Check oil level of
(chapter 4.4) retarder
see chapter 6.4
too too
OK NOK
high low
Check p (dynamic) Check oil level of

(chapter 4.3) Contact gear box
VOITH
OK NOK OK NOK
Check voltage of Check oil level of

proportional valve Correct oil level of gear box
Contact Contact
(chapter 4.4) retarder
VOITH VOITH too too
OK NOK high low
Check control unit

(chapter 4.4) Contact Correct oil level of
VOITH retarder and
OK NOK gear box
Check compressed-
-air supply Contact Contact
VOITH VOITH
OK NOK *
Do you get oil leakage after a trail
run again:
Check vehicle
compressed
Mechanical fault of
proportional valve or
air-supply continue at "Checking casing
antivibration plate OK NOK ventilation"
Contact
Contact
vehicle
VOITH FD 1598
manufacturer
53.2664.10 Page 4.1/1
Diagnosis/ ( *
& !&
Troubleshooting
Illustration electrical connections diagram 70 47 15 21 19 20

14 13 11 12 10 1 9 5 8 4 3 2 7 6
18
2 Control unit
30
2 1
4 Terminal 15
87 87a
– + + – – +
5 Terminal 30
15 ABS signal
18 Stop light relay
19 Cooling-water temperature pick-up
20 Oil-temperature pick-up 17 x3 x2
21 Proportional valve 8 11 10 12 7 9 4 5 6 1 2 3 2 3 1 6 5 4 9 8 7
47 Speedometer signal 4
69 ISO interface plug 2
70 Extra operations plug
18 17 16 6 5 4 9 8 10 11 12 13 14 15 7 3 2 1
x1
7 6 5 2 3 8 4
4
3 2 1 4
69 5
16
FD983
53.2664.10 Page 4.1/2
Diagnosis/ ( *
&

Troubleshooting
Troubleshooting and remedies

Check requirements
• 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).
53.2664.10 Page 4.2/1
Diagnosis/ ( *
&

Troubleshooting (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.
FD844
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.
53.2664.10 Page 4.2/2
Diagnosis/ ( *
&

Connector arrangement and pin assignment
Notice: All plugs illustrated from plug-in side (i.e. leads at back).
Plug X1 Control unit

1 Not in use
2 Not in use
3 Not in use
4 Retarder stage switch, position 3 -(or)
5 Retarder stage switch, position 2 -(bl)
6 Retarder stage switch, position 1 -(pi)
7 Terminal 15 (rd)
8 Retarder stage switch, position 5 -(gr)
9 Retarder stage switch, position 4 -(wh)
10 Retarder stage switch + (vi)
16 13 10 7 4 1
11 ISO-interface, L-lead (or/wh)
12 ISO-interface, K-lead (bl/wh) 17 14 11 8 5 2
13 Terminal 30 (bl)
18 15 12 9 6 3
14 Not in use
15 Terminal 31 (br)
16 Output / high side 2 „HS2“ (bl/wh)
17 Output / low side 1 „LS1“ (ye/gr)
18 Output / high side 1 „HS1“ (be) FD846
53.2664.10 Page 4.2/3
Diagnosis/ ( *
&


1 Not operational/usable for applications (or)
2 Proportional valve - (gr)
3 Proportional valve + (pi)
4 Cooling water temperature pick-up - (bl)
7 4 1
5 Cooling water temperature pick-up + (ye/gr)
6 Not operational/ground (be) 8 5 2
7 Not in use
8 Oil temperature pick-up - (wh) 9 6 3
9 Oil temperature pick-up + (vi)
FD848

1 Input / pull up „DIU 1“ (wh)
2 Speedometer signal (bl)
3 ABS-Signal (bl/wh)
4 Input / pull down „DID 2“ (br/wh) 10 7 4 1
5 Input / pull down „DID 1“ (bl/wh)
11 8 5 2
6 Input / pull up „DIU 2“ (pi)
7 Input / (0...5V) „INA-U“ (gr/bl)
12 9 6 3
8 Retarder pilot light (ye/gr)
9 Input / pull down „DID 3“ (or/wh)
10 Input / (0...20 mA) „INA-I“ (rd/wh)
11 Stop light relay (or)
12 Input / pull down / PWM-in „DID4“ (gr) FD847
53.2664.10 Page 4.2/4
Diagnosis/ ( *
&

Extra operations plug

3 Input / pull down „DID 2“ (br/wh)
5 Input / pull down / PWM -in „DID 4“ (gr) 2 4 6 8 10 12 14
7 Input / pull up „DIU 2“ (pi) 1 3 5 7 9 11 13
10 Output / high side 1 „HS1“ (be)
FD849
13 Terminal 15 (rd)
14 Terminal 31 (br)
ISO-Interface plug
1 K-lead (bl/wh)
2 K-lead (or/wh)
3 Terminal 15 (rd)
4 Terminal 31 (br) 4 3
2 1
FD854
53.2664.10 Page 4.2/5
Diagnosis/ ( *
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Cooling water temperature pick-up plug

Oil temperature pick-up plug
FD851
Proportional valve plug

2 Proportional valve + (gr)
3 Not operational (or) 4 2
4 Not operational (be) 1 3
FD850
53.2664.10 Page 4.2/6
Diagnosis/ ( *
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Retarder stage switch plug

1 Not in use
2 Position 5 - (gr)
3 Position 4 - (wh)
5 Position 3 - (or) 5 6 7 8
6 Position 2 - (bl)
1 2 3 4
7 Position 1 - (pi)
8 Bridge to pin 4
FD853
53.2664.10 Page 4.2/7
Diagnosis/ ( *
&

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.
53.2664.10 Page 4.2/8
Diagnosis/ ( *
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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.
FD844
Fault memory read-out with service cable
(Digiprop-Version 0.2)
Requirements
l Retarder stage switch in position 0
l Vehicle in parking position, Ignition ON
1. 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
l long blinking signals (2 sec.) tens unit.
l short blinking signals (0,5 sec.) single unit.
53.2664.10 Page 4.2/9
Diagnosis/ ( *
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Digiprop-Version 1.0
The blinking code can be triggered analogous to V 0.2, the conditions are the same. Additionally the
blinking code can be triggered with the help of the retarder stage switch during the service function:
1. Shift RSS-Position 0
2. Shift RSS-Position 1 ( ≥ 2 Seconds)
4. Blinking code of first fault is indicated
5. 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.
Display example: Fault code 23
Display example for fault code 23:
E Retarder stage switch on
A Retarder stage switch off
The number of tens will be indicated first as long ON-time: each 2 seconds t Time
The number of singles afterwards will be indicated as short ON-time: each 0,5 seconds
Breaks between each ON-time: each 1 second
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.
53.2664.10 Page 4.2/10
Diagnosis/ ( *
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Delete fault memory

No marginal conditions in accordance with read-out of fault memory.
1. Ignition: OFF
2. Service interface L-lead connected to ground. For this purpose, press push-button of
3. Ignition: ON
4. Disconnect after ≥ 2 seconds the L-lead of ground.
53.2664.10 Page 4.2/11
Diagnosis/ ( *
&

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 text Fault Trigger time Requirement / Measurement/ Result/ Cause/

class Operation test Set point Remedy 2)
1)
connection
Fault
Code (Check)
01 Stop light relay/ slight 1s - Ignition: OFF X 3/11 W X 1/15 Relay is Check lead, plugs
- Pull plug X3 out of installed: and relay
Short circuit to control unit 250 - 350 W or consumers
ground
02 LS 1 output slight 400 ms - Ignition: OFF X 1/17 V X 1/15 0V Check lead, plugs
- Pull plug X1 out of and relay
Short circuit to control unit or consumers
battery - Disconnect plug
for extra operation
(e.g. lamp or
relay)
- Ignition: ON
1)
X 1/15 = ground control unit
2)
Only, if no fault is recognizable after a complete check of the periphery: swap control unit.
53.2664.10 Page 4.2/12
Diagnosis/ ( *
&

Table 2

class test connection Set point Remedy
Fault Operation
Code (Check)
03 HS 1 output slight 1s - Ignition: OFF X 1/18 W X 1/ With relay Check lead, plugs
- Pull plug X1 out of 15 installed: and relay
Short circuit control unit 250 - 350 W or consumers
04 HS 2 output slight 1s - Ignition: OFF X 1/16 W X 1/15 With relay Check lead, plugs
05 Terminal 15 serious 60 s - Ignition: OFF X 1/7 V X 1/15 ≥ 17,5 V Check lead, plugs
- Pull plug X1 out of and fuses
Undervoltage control unit
- Ignition: ON
06 Terminal 15 serious 10 s - Ignition: OFF X 1/7 V X 1/15 ≤ 32,5 V Checking electrical

- Pull plug X1 out of installation of vehicle
Undervoltage control unit (see manufacturer
- Ignition: ON instructions)
- Start engine
(idle speed)
53.2664.10 Page 4.2/13
Diagnosis/ ( *
&

Table 3
Fault text Fault Trigger time Requirement / Measure- Result/ Cause/

class ment/ Set point Remedy
Fault Operation
test connec-
tion
Code (Check)
08 Water tempera- 1s - Ignition: OFF X 2/5 W X 2/4 20°C ± 10 °C = Check lead and
09 ture - Pull plug X2 out of 1039 - 1117W sensor
serious/ control unit
Discontinuity / slight * 60°C ± 10 °C =
Short circuit to 1099 - 1271W
battery
80°C ± 10 °C =
1271 - 1347W
Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.
* Fault is in serious class, if temperature sensor for oil and water are defective at the same time.
53.2664.10 Page 4.2/14
Diagnosis/ ( *
&

Table 4

class test connec- Set point Remedy
Fault Operation
tion
Code (Check)
11 Oil temperature 1s - Ignition: OFF X 2/9 W X 2/8 20°C ± 10 °C = Check lead and
12 serious/ - Pull plug X2 out of 1039 - 1117W sensor
Discontinuity / slight * control unit
Short circuit to 60°C ± 10 °C =
battery 1099 - 1271W
80°C ± 10 °C =
1271 - 1347W
Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.
53.2664.10 Page 4.2/15
Diagnosis/ ( *
&

Table 5

Fault Operation
Code (Check)
13 1 Retarder stage serious 100 ms - Ignition: ON X 1/10 V X 1/15 ≥ 17,5 V Check lead, plug and
switch - Retarder stage retarder stage switch
Undefined as of switch: X 1/6 V X 1/15 0V
switch state V 1.2 = 1 s Position 0 X 1/5 V X 1/15 0V
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V
13 2 - Ignition: ON X 1/10 V X 1/15 ≥ 17,5 V Check lead, plug and

- Retarder stage X 1/6 V X 1/15 ≥ 17,5 V retarder stage switch
switch:
Position 1 X 1/5 V X 1/15 0V
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 2
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V
53.2664.10 Page 4.2/16
Diagnosis/ ( *
&

Table 6

Fault Operation
Code (Check)

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 3 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 4 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 ≥ 17,5 V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 5 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 ≥ 17,5 V
X 1/8 V X 1/15 ≥ 17,5 V
53.2664.10 Page 4.2/17
Diagnosis/ ( *
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Table 7

Fault Operation
tion
Code (Check)
14 Retarder stage serious 10 s - Ignition: OFF X 1/10 V X 1/15 0 V Check lead and
switch - Pull plug X1 out of plug
Short circuit to control unit
battery - Ignition: ON
- Retarder stage switch:
Position 0
15 Retarder stage serious 1s - Ignition: OFF X 1/10 Ω X 1/15 Resistor Single check of
switch - Pull plug X1 out of infinite stages for
Short circuit to control unit short circuit
battery - Retarder stage switch:
Position 5
16 Speedometer serious 2s - Ignition: ON X 3/2 V X 1/15 ≤ Check lead and

signal speedometer
Discontinuity
53.2664.10 Page 4.2/18
Diagnosis/ ( *
&

Table 8

Fault Operation
tion
Code (Check)
18 Speedometer signal serious 2s - Ignition: OFF X 3/2 V X 1/15 ≤ Check lead and
- Pull plug X3 out of speedometer
Short circuit to battery control unit
- Ignition: ON
19 ABS serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ Check lead,

Short circuit to ground relay and ABS-
control unit
21 ABS-Signal serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ Check lead,

relay and ABS-
Undefined control unit
22 Internal fault serious 1s - - − Replace control

ABS-current path unit
23 Proportional valve serious 1s - Ignition: OFF X 2/3 V X 1/15 ≤ Check lead

Fault No. 1: - Pull plug X2 out of
- Ignition: ON
53.2664.10 Page 4.2/19
Diagnosis/ ( *
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Table 9

Fault Operation
tion
Code (Check)
24 1 Proportional valve serious 1s - Ignition: ON X 2/2 Ω X 2/3 18-25 Ω Check lead and
Fault No. 2: - Pull plug X2 out proportional
- Short circuit proportional of control unit valve (valve
valve magnetic block)
- Short circuit connection
lead proportional valve
- Discontinuity proportio-
nal valve magnetic
Valve magnetic
- Discontinuity connec-
tion lead proportional
valve
- Short circuit to ground at
proportional valve
- Prop.- and shift valve
interchanged
2 - Ignition: OFF X 2/3 Ω X 1/15 Resistor Check lead and

- Pull plug X2 out infinite proportional
of control unit valve (valve
block)
53.2664.10 Page 4.2/20
Diagnosis/ ( *
&

Table 10

Fault Operation
tion
Code (Check)
24 3 - Ignition: OFF X 2/2 Ω X 1/15 Resistor Check lead and

- Pull plug X2 out of infinite proportional
control unit valve (valve
block)
25 Proportional valve serious 10 s Replace

Fault No. 3: control unit
defective control unit
27 Proportional valve serious 2s Replace

28 Terminal 30 serious 60 s - Ignition: OFF X 1/13 V X 1/15 ≥

Check lead,
- Pull plug X1 out of plug and fuse
- Ignition: ON
53.2664.10 Page 4.2/21
Diagnosis/ ( *
&

Table 11

Fault Operation
tion
Code (Check)
29 Fault control unit serious 180 ms Replace

control unit
31 Control unit: serious 100 ms Provide new

Coding fault parameters for
control unit
32 Retarder pilot light: serious 3s - Ignition: OFF X 3/8 V X 1/15 ≥

Check lead,
Discontinuity / - Pull plug X3 out of retarder pilot
Short circuit to ground control unit light and fuse
- Ignition: ON
33 Retarder pilot light: serious 3s - Ignition: ON X 3/8 V X 1/15 ≤ 2V Check lead and
Short circuit to battery - Retarder stage retarder pilot
switch: light
Position 1
53.2664.10 Page 4.2/22
Diagnosis/ ( *
&

Table 12

Fault Operation
tion
Code (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 OEM-
respectively
VOITH-
instructions
53.2664.10 Page 4.2/23
Diagnosis/ ( *
&

B. Without fault code
Notice
Retarder faults without fault code are not recognized electronically.
53.2664.10 Page 4.2/24
Diagnosis/ ( %$
&
Troubleshooting
Illustration checking pump pressure

Preconditions for checking
• Retarder stage switch in position 0

112 Screw plug (M 12 x 1,5)
(pump pressure measuring point),
25 Nm
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 111

112
53.4788.10
FD918
Pressure gauge
0 - 25 bar
53.2664.10 Page 4.3/1
Diagnosis/ ( %$
&
Check requirements
• Electrical system checked in accordance with the Owner´s Manual for the vehicle
• No external leaks at the retarder
53.2664.10 Page 4.3/2
Diagnosis/ ( %$
&
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.
1. Screw out screw plug (112) and remove together with sealing ring (111).
Caution!
Oil can leave, this does not have any meaning however. 99/1
FD900
2. Connect up pressure gauge (99/1) to retarder housing.
99/1 Pressure gauge 53.4788.10
3. Shift retarder stage switch (16) to the highest braking stage with the vehicle in parking position
and read-off 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).
53.2664.10 Page 4.3/3
Diagnosis/ ( %$
&
Setting [NM] Pump pressure static *1) Pump pressure dynamic 1)

(Setpoint) [bar] vps = 1000 r.p.m.
(minimum value) [bar]
2900 2,65 - 3,05 19
1) Retarder stage switch in highest position

* Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
Notice
The data represent the state of the art at the time of going to print. The manufacturer reserves the right
to make further modifications.
Caution!
If the measurement in parking position falls short of the setpoint, either the retarder is leaking or
the control system is defective (see page 4.1/1 „Troubleshooting diagram“).
5. Drive the vehicle with a prop-shaft speed of v ps = 1000 r.p.m.
6. Shift the retarder stage switch to position 5 while on the move at vps = 1000 r.p.m. and read-off
pump pressure at pressure gauge.
53.2664.10 Page 4.3/4
Diagnosis/ ( %$
&
7. Compare read-off pump pressure with the value of dynamic pump pressure
(see table page 4.3/4).
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!
When disconnecting the pressure gauge, hot oil can leave!
8. Disconnect the pressure gauge (99/1). Screw in screw plug (112) with new sealing ring (111).
53.2664.10 Page 4.3/5
Diagnosis /
Troubleshooting
Illustration control system

11
33
Notice 71
32 61
The reference numbers indicated in Section 4.4 25
are not identical with the reference numbers of
the spare parts lists. A
P
1 Heat exchanger R
21 26
2 Control unit 36
31
current connection
19 Temperature pick-up
35 34
(cooling-water)
20 Temperature pick-up (oil) 40
25 Constant-air pressure line py 2
26 Supply-air pressure line pv 39 20
31 Compressed-air line 29
(pressure regulator - four-circuit
protection valve)
32 Compressed-air pressure line
(four-circuit protection valve -
air tank for auxiliary equipment
with test connection
33 Compressed-air line
(brake circuit No. 1)
(parking brake)
FD919
36 Ventilation line „R“
39 Electrical lead (cooling-water
temperature pick-up to control unit,
2 wires)
40 Electrical lead (oil temperature
pick-up to control unit, 2 wires)
61 Four-circuit protection valve
71 Air tank for auxiliary equipment
53.2664.10 Page 4.4/1
Diagnosis/ (( %$
& %

Check requirements
• Retarder stage switch in Position 0
• Ignition OFF
Special tools
Wasser Öl
53.4788.10 53.8207.10 53.8198.10
Pressure gauge
0-25 bar
53.2664.10 Page 4.4/2
Diagnosis/ (( %$
& %

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 p v.
Minimum pressure: 6 bar
Maximum pressure: 11 bar
Notice
32
If the pressure is not within the specified range, the service brake must be checked FD122
to the manufacturer´s data.
Test set-up job scope

1. Disconnect electrical lead cooling water (39) and oil (40) from the temperature pick-ups
cooling water (19) and oil (20) and connect them to the temperature simulator (99/2). 39
40
Set the temperature range on the temperature tester to 120°C.
99/2
Notice
Pay attention to the correct connection of the plugs for cooling water and oil.
Wasser Öl
FD920
99/2 Temperature simulator 53.8207.10
53.2664.10 Page 4.4/3
Diagnosis/ (( %$
& %

2. Screw out oil filler plug (2909) with sealing ring (2910), depending on accessibility.
2909
2910 2909
FD921
3. Connect pressure gauge (99/1) to top oil tank cover (2904) or to drilled hole (arrow).
99/1
FD922
53.2664.10 Page 4.4/4
Diagnosis/ (( %$
& %

4. Connect up „Propstrom“ measuring adapter (99/3):

21
• Disconnect plug from proportional valve (21) and connect it up
to „Propstrom“ measuring adapter (99/3). 98/8
• Connect plug of „Propstrom“ measuring adapter (99/3) to proportional valve (21).
• Connect up multimeter (98/8) to measure mA.
• Set switch „Propvalve“ on „Propstrom“ measuring adapter (99/3) to position „I“.
99/3
FD923
99/3 „Propstrom“ measuring adapter 53.819.10
53.2664.10 Page 4.4/5
Diagnosis/ (( %$
& %

Job scope test

39
40
• 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. 99/2
The constant-air pressure py 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 py must drop to at least 0.2 bar below the set maximum pressure. Set rotary
switch of the temperature simulator (99/2) to 125oC cooling water temperature. There must be no Wasser Öl
more output of constant-air pressure py. FD920

Set rotary switch of temperature simulator (99/2) again to 95oC cooling water temperature.
3. Set the rotary switch of the temperature simulator (99/2) to 185oC oil temperature.
The constant-air pressure must drop to at least 0.1 bar below the set maximum pressure. Set the
rotary switch of the temperature simulator (99/2) to 225oC oil temperature. There must be no more
output of constant-air pressure py.
4. Carry out measurements for current and constant-air pressure regarding the following table
(see page 4.4/7).
5. Screw oil filler plug (2909) tight with new sealing ring (2910). Tightening torque 80 Nm
6. Reconnect electrical lead for cooling water (39) oil (40) to temperature pick-ups cooling water (19)
and oil (20).
53.2664.10 Page 4.4/6
Diagnosis/ (( %$
& %

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] Code Number 1) Control current Constant-air pressure py 3)*

[mA] 2)* [bar]
2900 Nm 021 535 - 545 2,65 - 3,05
1)
The Code Number is to be found on the control unit.
2)
If a commercially available multimeter is used for measurements (without real effective measuring)
exact readings cannot be made (indication jumps!).
3)
Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
*
Retarder stage switch in highest position.
53.2664.10 Page 4.4/7
Diagnosis/ (+
%$
Troubleshooting
Requirements for check

• Electrical system checked in accordance with the Owner´s Manual for the vehicle R
• Constant-air pressure 6 -11 bar
• Retarder oil level satisfactory
The following operational states are indicated by the retarder pilot light (arrow):
Retarder pilot light without indication

FD844
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.
53.2664.10 Page 4.5/1
Diagnosis/ (+
%$
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
- 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!
53.2664.10 Page 4.5/2
Diagnosis/ (+
%$
Test step Scope of check Requirement / Result / Set point Note, Cause / Remedy
Operation
1 Retarder pilot light Ignition: ON Retarder pilot light comes on and Retarder pilot light trouble-free
goes off after approx. 5 sec.
Retarder pilot light does not come Troubleshooting as on page 4.1/1

on, or does not go off.
2 Retarder Vehicle on move Retarder pilot light comes on, Retarder operates trouble-free.
- Shift retarder stage retarder brakes in stages 1 to 5.
switch
to stage 1 to 5. Retarder pilot light does not come Troubleshooting as on page 4.1/1
on, or retarder does not brake
properly.
53.2664.10 Page 4.5/3
Retarder Remo- +
&, -

&
ving, Installing
5.1 Removing, Installing Retarder ....................................................................5.1/1
53.2664.10 Page 5/1
Retarder Remo- +
&, -

&
ving, Installing
Illustration removing, installing retarder

Preconditions for job
• Drain oil from retarder (see Section 3.2)
• Drain oil from gear box
Notice 3700
One of the mill-cut sides of the prop-shaft must 26 96 97

700
show in direction of the retarder housing.
26 Supply-air pressure line p v

39 Electrical lead
95/1 Collar nut with rib toothing,
200 - 240 Nm
39
96 Hose clamp
97 Hose-connection
700 O-Ring (164 x 3), renew,
coat with silicone-free and
non-corrosive grease
for installation H 95/1
IT er
3700 Proportional valve Ty

p
R1
15
VOtard
Re
=
H
19
Fa
Ba
93
br
ur
.
ja
hr
Nr
.
0.
00 00
.0 0.
00
i Re
f.
00 000
.
00
95/1
FD930
53.2664.10 Page 5.1/1
Retarder Remo- +
&, -

&
ving, Installing (Continue)
Lubricants and locking agents
O-Ring Silicone-free and

Collar nut with rib toothing Loctite 270
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.
The cooling water is heated up!
To remove, install
1. Loosen the hose clamps (96) on left and right and pull off carefully the hose connections (97)
of heat exchanger.
2. Disconnect the supply-air pressure line (26) and electrical lead (38) from
3. Prop up the retarder.
53.2664.10 Page 5.1/2
Retarder Remo- +
&, -

&
4. Unscrew collar nuts (95/1).

95/1
Notes for installation

700
The tightening torque for the collar nuts (95/1) for installation is 200 - 240 Nm.
5. Remove retarder from gearbox and move out downwards.
6. Remove the O-ring (700).
Note for installation

FD933
Apply coat of silicone-free and non-corrosive grease to new O-ring (700).
7. Install in reverse sequence.
8. Fill in oil into gearbox. Observe manufacturer´s instructions.
53.2664.10 Page 5.1/3
Repair .
6.2 Removing, Checking and Installing Casing Ventilation ..............................6.2/1
6.3 Removing, Checking and Installing Silencer ..............................................6.3/1
6.4 Removing, Checking and Installing Heat Exchanger .................................6.4/1
6.5 Removing and Installing Oil Tank Cover ....................................................6.5/1

Upper Oil Tank Cover......................................................................................6.5/1
Lower Oil Tank Cover......................................................................................6.5/3
6.6 Removing and Installing Oil Tank...............................................................6.6/1
53.2664.10 Page 6/1
Repair !
2700 6200 2905 2927

2909
6500 2928
3600 2910
2904 2927
2800 2925
2926
2400
2909 6300
2500 3900
3000
3500 2910
2000
2600
2900 2906
2300/1 3800
3500 3000 3900
3750
2301
2300
3600 3700
2300/2 3000
3000
2300/3
2000
4000 5200
3100
3600
111
112 2924
7000
7100 2923 2915
3300
2912
2911
4800 2913
4700 2921 2914
2922 2920
2918
2919
FD1578
llustration assembly overview R 115 H with Digiprop control system
111 Sealing ring (A 12 x 18) 2924 Sealing ring (A 24 x 29)

112 Screw plug (M 12 x 1,5) 2926 Angle sheet metal (22 x 4 x 62,5)
2000 O-ring (60 x 5) 2927 Hex.-head screw (M 8 x 45)
2300 Casing ventilation 3000 O-ring (15 x 4)
2300/1 Valve insert 3100 O-ring (40 x 5)
2300/2 Float 3300 Heat exchanger
2300/3 Float cage 3400 Distributor
2301 O-ring (55 x 3) 3500 Anti-fatigue screw (M 14 x 65)
2400 Cover casing ventilation 3600 Anti-fatigue screw (M 14 x 150)
2500 Sealing 3700 Proportional valve
2600 Spacer (D 60 / 41 x 2) 3750 Hexagon nut (M 8)
2700 Hex.-head screw (M 8 x 80) 3800 Anti-vibration plate (160 x 70 x 22)
2800 Hex.-head screw (M 8 x 30) 3900 Hex.-head screw (M 8 x 25)
2900 Oil tank 4000 O-ring (7 x 2,5)
2904 Upper cover 4700 Screw plug with sieve
2905 Hex.-head screw (M 8 x 40) 4800 Sealing ring (A 30 x 36)
2906 Upper gasket 5200 Disc (31/31 x 4 D 14,5)
2909 Oil filling screw (M 30 x 1,5) 6000 Clamp (3 x 20 x 90)
2910 Sealing ring (A 30 x 36) 6200 Angle sheet metal (22 x 4 x 62,5)
2911 Lower cover 6300 Clamp
2912 Lower gasket 7000 Disc (Silencer) (D 30 x 4)
2913 Hex.-head screw (M 8 x 25) 7100 Circlip (JL 30 x 1,2)
2914 Hex.-head screw (M 8 x 35)
2915 O-ring (7 x 2,5)
2918 Sealing ring (A 20 x 26)
2919 Oil-drain plug
2920 O-ring (10 x 3)
2921 O-ring (6 x 3)
53.2664.10 Page 6.1/1
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Illustration casing ventilation
Notice
This step can be performed with the retarder removed or in situ.

Before removing heat up the retarder housing in the area of the hex.-head screws (2800, 2700, 4100)
to approx. 80°C.

• Ignition OFF
• Retarder switched-off
The retarder housing is heated up!
53.2664.10 Page 6.2/1
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2300 Casing ventilation (D 30 x 38)
2300/1 Valve insert 6200
2300/2 Float 6500
2300/1
specified weight 11 g ± 1 g
2300/3 Float cage 2700
2301 O-ring (55 x 3), renew, 2301
2800
coat of silicone-free and non-
2300
2300/2
2400 Casing ventilation cover
2500 Sealing, renew
2600 Spacer (D 60 / 41 x 2) 2400 2300/3
2700 Hex.-head screw (M 8 x 80),
renew, 25 Nm
renew, 25 Nm
2500
6200 Angle sheet metal (22 x 4 x 62,5)
6500 Fixing sheet metal 2600
O-ring Silicone-free and

Float Methylated Spirit
FD934
53.2664.10 Page 6.2/2
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Special tools
53.7712.10 53.9428.10
To remove
1. Screw out the hex.-head screws (2800 and 2700).
2. Remove the cover (2400) with sealing (2500) from the retarder housing.
Clean the sealing surface.
3. Remove the spacer (2600).
53.2664.10 Page 6.2/3
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4. Use the impact tool (99/5) and adapter (98/9) to extract the valve insert.
99/5
5. Take float (2300/2) and float cage (2300/3) out of the retarder housing.
98/9
FD935
99/5 Impact tool 53.7712.10

98/9 Adapter 53.9428.10
6. Lever O-ring (2301) out of the groove in the valve insert (2300/1) and remove it.
2300/1
2301
FD1020
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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 2300/2
complete casing ventilation.
Notice
Oil has penetrated into the float, the retarder is impaired in its operation.
FD194
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)
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
2300/1
FD1021
53.2664.10 Page 6.2/5
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To install
1. Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on 99/5
to the valve insert (2300/1).
2. Fit the float (2300/2) and float cage (2300/3) into the valve insert (2300/1).
98/9
3. Fit the casing ventilation into the retarder housing.
4. Use the impact tool (99/5) and adapter (98/9) to knock the casing ventilation in.
FD935
99/5 Impact tool 53.7712.10

98/9 Adapter 53.9428.10
5. Place the spacer (2600) on the casing ventilation (2300) such that the rounded-off face (arrows)
is at the top.
6. Position the cover (2400) with new sealing on the retarder housing.
2600
Notice
2300
Pay attention to the mounting position of the sealing and the cover!
7. Screw eight new hex.-head screws (2800 and 2700) tight. Tightening torque 30 Nm
FD969
53.2664.10 Page 6.2/6
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Illustration silencer
Notice
7000
This step can be performed with the retarder
removed or in situ.
7100
107 Disc (Silencer) (D 30 x 4), clean

with suitable cleaning agent
(benzine) and blow out
with compressed air
108 Circlip (JL 30 x 1,2),
concave side must face silencer
Cleaning agents
Silencer Benzine
FD1611
53.2664.10 Page 6.3/1
Repair " # $ %
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3000
3100
3000
5200
3600
3600
4000
2900
2921 3100
2920
2918
2919
3300 FD978
Illustration heat exchanger

• Ignition OFF
• Retarder removed (see Section 5.1)
This job sequence can also be performed with the retarder installed.
With retarder installed:
• Proportional valve and anti-vibration plate removed (see Section 6.7)
2900 Oil tank

2920 O-ring (10 x 3), renew, coat of silicone-free and non-corrosive grease for installation
3300 Heat exchanger
3400 Distributor
3600 Anti-fatigue screw (M 14 x 150), renew,
Initial torque: 50 Nm,
Final turn: 90° turn
4000 O-ring (7 x 2,5), renew, coat of silicone-free and non-corrosive grease for installation
5200 Disc (31/31 x 4 x 62,5)
Lubrication

53.2664.10 Page 6.4/1
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Special tool
53.7711.10
Torque angle gauge 3/4“ e.g. Messrs Richard Abr. Herder

Post box 10 08 67
D-42659 Solingen
Tel. 0212/ 888-0
Ordering No. 8200-02
53.2664.10 Page 6.4/2
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Notice
If this job sequence is performed with the retarder in situ, the following prior jobs must be performed:
1. Screw out central oil-drain plug (2919), remove sealing ring (2918) and drain the oil.
3300
2918
2919
FD909
53.2664.10 Page 6.4/3
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To remove
3600
1. Screw out the anti-fatigue screws (3600) and remove together with washer (5200).
2. Screw out the four anti-fatigue screws (3600).
3. Remove heat exchanger (3300). 5200
3300
3600
3600
FD979
4. Remove O-rings (3000, 3100 und 4000).

3000 4000
3100
FD980
53.2664.10 Page 6.4/4
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To check
1. Fit pressure-test equipment (99/6) together with O-rings to heat exchanger (3300). 99/6
Connect compressed-air line to bottom connection (arrow).
2. Fill the cooling-water section of the heat exchanger (3300) with hot water (approx. 70°C).
3. Slowly pressurize the heat exchanger (3300) from 0 to max. 10 bar excess pressure
(oil section of the heat exchanger).
Notice
If air bubbles form in the hot water, the heat exchanger leaks and must be renewed. 3300
FD436
99/6 Pressure-test equipment 53.7711.10
4. Connect compressed-air line to top connection (arrow).
Notice
If air bubbles form in the hot water, the heat exchanger leaks and must be renewed.
99/6 3300
FD097
53.2664.10 Page 6.4/5
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If the heat exchanger is renewed:
Remove distributor (3400) from defective heat exchanger and install in new heat exchanger.
Notice
New heat exchanger are moisted with corrosion-preventive oil in the water- and oil section.
Prior to installing a new heat exchanger, drain any corrosion-preventive oil which may have collected
and flush out with hot water in the water section of the heat exchanger.
To install
1. Fit new O-rings (3000, 3100 und 4000) in the drilled holes.
2. Position heat exchanger (3300) on the oil tank, place washer (5200) on top and screw four new
anti-fatigue screws (3600) tight.
Initial torque: 50 Nm
Caution!
If the oil tank has been removed, screw the anti-fatigue screws (3500) tight.
53.2664.10 Page 6.4/6
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3. Install the retarder, if necessary (see Section 5.1, „Removing, Installing Retarder“).
4. Fill in cooling-water and bleed cooling-water circuit.
Notice
Pay attention to the instructions regarding the quality of the cooling-water given
from the manufacturer or VOITH TURBO.
Caution!
If the heat exchanger leaks, there is water present in the retarder. If the retarder is filled up, a mixture of
oil and water is created, causing the oil in the retarder to foam and escape through the casing ventilation
system to the atmosphere.
For this reason, it is indispensible to flush out the retarder after repairs!
While flushing, apply the brake gently several times to prevent the retarder oil warming up excessively.
5. Flush the retarder, if the heat exchanger leaked:

To flush the retarder, fill it with 5,4 litres of engine- or flushing oil. Apply the brakes gently several
times to flush out the retarder system and drain the oil through the central oil-drain plug (2919).
Repeat the procedure 2 or 3 times.
Coat new O-rings (2918 und 2920) with silicone-free and non-corrosive grease and fit them on to 2921
the central oil-drain plug (2919).
2920
Screw central oil-drain plug (2919) tight with new sealing ring (2921). Tightening torque 55 Nm
Fill in retarder oil (see Section 3.2). 2918
2919 FD905
53.2664.10 Page 6.4/7
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Illustration oil tank cover

Upper oil tank cover
2925
Notice
2904
removed or in situ.
Before removing heat up the retarder housing
in the area of the hex.-head screws
(2800, 2700, 4100) to approx. 80°C.
2906
2900
2900 Oil tank

2904 Cover
renew, note tightening sequence!
Initial torque: 14 -19 Nm
Final torque: 25 Nm
2906 Gasket, renew
FD943
53.2664.10 Page 6.5/1
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Pay attention to the mounting position of the gasket and the cover. 9 3 1 6 8
Tighten all hex.-head screws in defined sequence from 1 to 10 initially with 14 - 19 Nm torque.
Then tighten in the same sequence with 25 Nm torque.
7 5 2 4 10
FD1024
53.2664.10 Page 6.5/2
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Lower oil tank cover

• Retarder OFF
• Ignition OFF
• Heat exchanger removed (see Section 6.4)
Notice
to approx. 80°C.
53.2664.10 Page 6.5/3
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2900
2900 Oil tank

2911 Cover
2912 Gasket, renew 2912
Initial torque: 14 - 19 Nm,
Final torque: 25 Nm
renew, note tightening sequence! 2911
Final turn: 25 Nm
2915 O-ring (7 x 2,5), renew,
2915
Final turn: 25 Nm
Lubricants
2914
FD361
53.2664.10 Page 6.5/4
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#
Pay attention to the mounting position of the gasket and the cover.
Then tighten in the same sequence with 25 Nm torque. 9 3 1 6 8
7 5 2 4 10
FD1005
53.2664.10 Page 6.5/5
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Illustration oil tank

• Heat exchanger removed
(see Section 6.4) 3000
This job sequence can also be performed with
the retarder installed.
2000 O-ring (60 x 5), renew,

2900 Oil tank
3000 O-ring (15 x 4), renew, 2900
3500 2000
3500 Anti-fatigue screw (M 14 x 65),
renew, screw hand-tight and screw
tight after installation of
heat exchanger
3000 2000
FD971
53.2664.10 Page 6.6/1
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2900

Post box 10 08 67
D-42659 Solingen
Tel. 0212/ 888-0
Ordering-No. 8200-02
To remove
1. Screw out anti-fatigue screws (3500) and remove oil tank (2900). 3500
FD972
2. Remove O-rings (2000 and 3000).
Notice
If removing the oil tank, do not pull out the valves behind the oil tank.
53.2664.10 Page 6.6/2
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To install 3000
1. Fit new O-rings (2000 and 3000) in the grooves. 2000
2000
3000
FD1027
2. Place oil tank (2900) on the retarder housing and slightly tighten the new
anti-fatigue screws (3500).
Notice 2900
It must be possible to shift the oil tank, so that the heat exchanger can be installed.
3. Once the heat exchanger has been installed, screw the anti-fatigue screws (3500) tight.
Initial torque: 50 Nm 3500

FD973
53.2664.10 Page 6.6/3
Control Parts 3 %

7.1 Control Parts ..............................................................................................7.1/1
53.2664.10 Page 7/1
Control Parts 3 %

Illustration proportional valve

Removing, installing proportional valve
• Discharge supply air
26 Compressed-air line pv
39 Electrical lead 6300
3750 Hexagon nut (M 8), renew, 18 Nm 3900
3800 Anti-vibration plate
3900 Hex.-head screw (M 8 x 25), 3900
renew, 25 Nm
6300 Clamp
Caution!
If, during maintenance or repair, the hexagon

nuts (3750) or hex-head screws (3900) are 3800
39
unlocked, the anti-vibration plate must be
checked for mechanical or ageing damages
and renewed if necessary.
3700
26
3750
FD926
53.2664.10 Page 7.1/1
Control Parts 3 %

(Continue)
Removing, installing temperature pick-up

• Drain cooling-water
The cooling-water is heated up!
Job scope
1. Screw out cooling-water temperature pick-up (19). Tightening torque 28 Nm
The electrical lead of the temperature pick-up is poured.
Notice
Pay attention to the instructions regarding the quality of the cooling-water given from the
manufacturer or VOITH TURBO.
53.2664.10 Page 7.1/2
Annex 4
2
Data Sheet
Conversion Table
Spare Part Lists
Other Information
53.2664.10 Page 8/1
Data Sheet VOITH Retarder 115 H
with Digiprop Control System
Max. braking torque at prop shaft M(Br) max 2900 Nm *
Max. retarder speed (= max. prop shaft speed) v(max.) 5000 r.p.m. at vps = 2708 r.p.m.
Working medium Oil grade given in

Operating Specification
Service filling:
- Service filling (Oil change, checking oil level) 5,4 Litre
- After renewal of heat exchanger 6,0 Litre
- After complete taking apart and cleaning 5,6 Litre

as well as emptied heat exchanger (corresponds new filling)
Overall weight (with flange and heat exchanger, without oil filling) ca. 65 kg *
* Max. braking torque at prop shaft with retarder gear ratio 1:1,846
Wartung, Diagnose, Instandsetzung VOITH Retarder 115 H - Eaton RTS/O Digiprop

Seite 8/2
Miscellaneous Conversions Retarder 115 with Digiprop Control
D GB USA D GB USA
10 oC 50 oF 50 oF 50 Nm 37 lbf-ft 37 lbf-ft
20 oC 68 oF 68 oF 55 Nm 40,7 lbf-ft 40,7 lbf-ft
80 oC 176 oF 176 oF 200 - 240 Nm 148 - 177,6 lbf-ft 148 - 177,6 lbf-ft
105 oC 221 oF 221 oF 2,65 - 3,05 bar 38,43 - 44,23 psi 38,43 - 44,23 psi
120 oC 248 oF 248 oF 0 - 10 bar 0 - 145 psi 0 - 145 psi
185 oC 365 oF 365 oF 0,2 bar 2,9 psi 2,9 psi
14 - 19 Nm 10,36 - 14,06 lbf-ft 10,36 - 14,06 lbf-ft 19 bar 275,5 psi 275,5 psi
18 Nm 13,32 lbf-ft 13,32 lbf-ft 11 g ± 1 g 0,38 ± 0,035 oz 0,38 ± 0,035 oz
25 Nm 18 lbf-ft 18 lbf-ft 5,4 l 1,188 UK gal 1,426 US gal
28 Nm 20,72 lbf-ft 24 lbf-ft 5,6 l 1,232 UK gal 1,478 US gal
30 Nm 22,2 lbf-ft 22,2 lbf-ft 6,0 l 1,320 UK gal 1,584 US gal

VOITH TURBO
Powertransmission
VOITH Retarder
Cooling Water Quality / Corrosion Preventive and Antifreezing Agent
Position as per: August 1997
Generally the information coming from the vehicle manufacturer is applicable and to be observed!
However, if no information is available, please observe the following specifications.
1. Water
1.1 Use clean water for treatment of the cooling medium, as specified in chapters 2.1, 2.2 and
2.3. Drinking water normally, but not always, meets the requirements. Not suitable are sea water,
brackish water, salt water and industrial waste water. Avoid suspended particles in the water,
especially those containing copper.
For any information required on the water quality please contact the local waterworks or the
water supply plant in charge. In case that information on the water quality is not available
use distilled or demineralized water for mixing. If the water does not meet the admissible
analysis values, treat the water suitably.
Please refer to chapter 2 regarding admissible analysis values.
2. Composition of coolant
2.1 Normal case
50 % by volume water
50 % by volume corrosion preventive and antifreezing agent*; antifreeze down to approx. -37 °C
Admissible analysis values:
Sum of alkaline earths (water hardness): max. 3.6 mmol/l = max. 20° German hardness
= max. 36° French hardness
= max. 25° British hardness
= max. 21° American hardness
pH-value at 20 °C: 6.5 to 8.5

Chlorine ion content: max. 100 mg/l
Sum chlorides + sulphates: max. 200 mg/l
max. admissible usability: 3 years
*see chapter 4
cbtddoku/kühlwa/en.xls Page 1/10 67.2224.10

2.2 Use in frost-proof countries
Field of application: at permanent ambient temperatures above the freezing point.
10 % by volume corrosion preventive additive (coolant additive)**; admissible deviation ± 1 % by volume
Sum of alkaline earths (water hardness): max. 2.7 mmol/l C91= max. 15° German hardness

max. admissible usability: 1 year
**see chapter 5
Attention:
Do not mix corrosion preventive additives with corrosion preventive/antifreezing agent or processing
agent!
2.3 Exception in frost-proof countries
Field of application: at permanent ambient temperatures above the freezing point and if provably
neither released corrosion preventive and antifreezing agent nor coolant additive are available,
the coolant may have the following mixing:
1 % by volume processing agent***

Chloride ion content: max. 80 mg/l
max. admissible usability: 6 months
***see chapter 6
For topping up, use an emulsion of 0.5 - 1.0 % by volume. Use 1.5 % by volume in case
of new filling or filling after a complete cleaning.
Attention:
Too high concentrations (> 1.5 % by volume) have a detrimental effect on sealings and hoses!

3. Miscellaneous
3.1 Disposal
It is not allowed to pass the coolant into the sewerage, but to recycle or dispose it.
The legal regulations or waste water regulations may deviate from country to country but have
to be observed when disposing used coolants.
3.2 Safety
Before using the coolants stated from chapter 4, observe and adhere to the safety data sheets and
product information of the respective supplier.

4. Recommended antifreezing agent with corrosion preventive
4.1 Engine type: CATERPILLAR - Commercial Vehicle (CV)
We do not have a list of the engine manufacturer naming antifreezing agents with corrosion preventive.
However, the coolants used have to conform to CATERPILLAR’s specifications. Please consult
Voith Turbo in case of queries.
4.2 Engine type: CUMMINS - CV
However, the coolants used have to conform to CUMMINS’s specifications. Please consult
4.3 Engine type: DAF - CV
We do not have a list of the commercial vehicle manufacturer naming antifreezing agents with
corrosion preventive. However, the coolants used have to conform to DAF Standard 74001.
Please consult Voith Turbo in case of queries.
4.4 Engine type: Daimler-Benz - CV
Except for: OM 601, OM 602, OM 603, M 102
Attention:
Generally: Never mix coolants of various types!
Supplier Designation
Agip Petroli S.p.A., Rome / Italy Agip Antifreeze Plus

Agip Petroli S.p.A., Rome / Italy Agip Long Life Antifreeze
Aral AG, Bochum Aral Cooler Antifreeze A
Aral AG, Bochum Aral Cooler Protection D
Aral AG, Bochum Aral Cooler Protection Extra
Augros GmbH & Co., Ostfildern Augros C197Cooler Protection
Avia Mineralöl-AG, Munich Avia Antifreeze APN
Avia Mineralöl-AG, Munich Avia Antifreeze
BASF AG, Ludwigshafen Glysantin
BASF AG, Ludwigshafen Glysantin with Protect Plus
BP Chemicals Ltd., London / England BP Napgel C 2270/1
BP Oil Deutschland GmbH, Hamburg BP anti-frost X 2270 A
Bremin Mineralöl GmbH + Co., Mülheim a.d. Ruhr Glyco Star
Bucher + Cie. AG, Langenthal / Switzerland Antifreeze Motorex
Caltex Services (UK) Ltd., London / England Caltex Engine Coolant DB
Castrol Ltd., Swindon / England Castrol Anti-Freeze 0
Chem. Industrielle Ges. mbH & Co., Hamburg Gusofrost LV 505
Deutsche Shell Chemie GmbH, Eschborn Glyco Shell
Dow Europe S.A., Horgen / Switzerland Automotive Coolant DOW 007/400 F
Dow Europe S.A., Horgen / Switzerland Automotive Coolant DOW D 542/1993

Elf Lubrifiants, Paris / France Glaself SX

ESA, Burgdorf / Switzerland ESA Antifreeze MB blue+C197
Eurol Mineralöl, Ried / Austria Eurol Afrostin
Fouman Chimie Co., Teheran / Iran Caspian Super Antifreeze
Fuchs Mineralölwerke GmbH NL West, Eschw. Long Life Cooler Antifreeze
Fuchs Mineralölwerke GmbH NL West, Eschw. Long Life Plus NF
Fuchs Mineralölwerke GmbH, Mannheim Fricofin
Georg Oest Mineralölwerke, Freudenstadt Oest-Antifreeze
Ginouves Georges S.A., La Farléde / France York LT 716
Henkel Härtol GmbH, Magdeburg Frostox MB 02
Igol France, Paris / France Igol Antigel Type DB
Karipol, Leipzig Cooler Antifreeze Super
Karl Käppler, Stuttgart Frostop Cooler Antifreeze
Labo Industrie, Nanterre Cedex / France Labo FP 100
Mobil Oil AG, Hamburg Antifreeze 500
Motul S.A., Aubervilliers / France Motul Anti-Freeze
ÖMV AG, Vienna / Austria ÖMV-Antifreeze
Orly International, Vieux-Thann / France Orlygel 3002
Shell International, London / England Shell Safe Premium
Sotragal S.A., St. Pries / France Antigel DB 486
Total Deutschland GmbH, Düsseldorf OZO Antifreeze S
Total Deutschland GmbH, Düsseldorf Total Multiprotect
Total Raffinage Distr., La Défense / Frankreich Total Antigel S-MB 486
Valvoline International, Dordrecht / Niederlande Valvoline Anti-Freeze
Veedol International Ltd., Swindon / England Veedol Antifreeze 0
The products stated under Chapter 4.5 can also be used for this application.

subject to revisions by the engine manufacturer.
4.5 Engine type: Daimler-Benz passenger car engine (e.g. OM 601)
Attention:
Aral AG, Bochum Aral Antifreeze

Aral AG, Bochum Aral Cooler Antifreeze
Avia Mineralöl-AG, Munich Avia Cooler Antifreeze
BASF AG, Ludwigshafen Glysantin Anticorrosion
BP Southern Africa (PTY) LTD, Roggebaai BP Isocool
Bucher + Cie. AG, Langenthal / Switzerland Antifreeze Motorex Glysantin
Bucher + Cie. AG, Langenthal / Switzerland Anti-Korrosion G05
Caltex Service (UK) Ltd., London / England Caltex CX Antifreeze Coolant
Castrol Ltd., Swindon / England Castrol AF
Castrol Ltd., Swindon / England Castrol Anti-Freeze MB
Daimler-Benz AG, Stuttgart MB Corrosion Preventive and Antifreezing Agent
Daimler-Benz AG, Stuttgart 000 989 08 25
Deutsche Shell Chemie GmbH, Eschborn GlycoShell N
Engen Marketing Ltd., Kapstadt / South Africa Engen Antifreeze and Summer Coolant

Engen Marketing Ltd., Kapstadt / South Africa Trek Antifreeze and Summer Coolant
ESA, Burgdorf / Switzerland ESA Antifreeze G05
Henkel Härtol GmbH, Magdeburg Frostox MB
Hoechst AG, Frankfurt/Main Genantin Super
Mobil Oil AG, Hamburg Mobil Antifreeze 911 plus
Raloy Lubricantes, S.A. de C.V., Santiago, Mex. Antifreeze RL-Plus
Sasol Oil, Johannesburg 2000 / South Africa Sasol Freezol
Shell South Africa, Cape Town / South Africa Shell Tri Guard
Total (Pty) Ltd., Johannesburg / South Africa Total Antifreeze and Summer Coolant
Total Deutschland GmbH, Düsseldorf Total frost-proof
Unico Manufacturing Co., Durban / South Africa Engman's - Super Antifreeze Coolant
Valvoline International, Dordrecht/The Netherlands Valvoline Antifreeze ALU G05
Veedol International Ltd., Swindon / England Veedol AF
Veedol International Ltd., Swindon / England Veedol Antifreeze MB

4.6 Engine type: Detroit Diesel - CV
We do not have a list of the engine supplier naming antifreezing agents with corrosion preventive.
However, the coolants used have to correspond to Detroit Diesel's specifications. Please consult
4.7 Engine type: Hino
Attention:
Hino Hino Diesel LLC-EX

4.8 Engine type: IVECO
Attention:
FIAT LUBRIFICANTI S.P.A. Paraflu 11


4.9 Engine type: LIAZ
Attention:
Spolana Neratovice Fridiol K

Spolana Neratovice Fridiol Extra
Spolana Neratovice Fridex Super
Spolana Neratovice Fridex - eco

subject to revisions by the engine manufacture.
4.10 Engine type: MAN - CV
Attention:
Agip Deutschland AG Agip Antifreeze Plus

Agip Schmiertechnik Autol-Werke GmbH Agip / Autol Long Life Antifreeze
Aral AG Aral Cooler Antifreeze A
Aral AG Aral Kühlerschutz Extra
Avia-Mineralöl AG Avia Antifreeze
Avia-Mineralöl AG Avia Antifreeze APN
BASF / USA BC Antifreeze G 9313
BASF AG Glysantin 9313
BASF AG Glysantin G 48
BASF AG Glysantin with Protect Plus
Bucher u. Cie. AG / Switzerland Antifreeze Motorex
Caltex Services Ltd. Caltex CX Engine Coolant
DEA Mineralöl AG DEA Cooler Antifreeze
Deutsche Shell Chemie GmbH GlycoShell
DOW Chemical Europe S.A. DOW Antifreeze D 824-13F
DOW Chemical Europe S.A. DOW Coolant D 542/1993
Elf Lub / France Elf Antifreeze Special
Elf Lub / France Glacelf SX
EUROL Mineralölhandels GmbH Eurol Afrostin
EVVA / Austria EVVA Antifreeze
Fina Europe S.A. Fina Termidor P 100
Fuchs Mineralölwerke GmbH Fricofin Cooler Antifreeze
Genol Genol Antifreeze
Hoechst Genantin Extra (8021 S)
INA Industrija Zagreb / Croatia INA Antifriz Al Super
Mobil Oil AG Antifreeze 500
Mobil Oil AG Antifreeze 500 Plus
ÖMV AG ÖMV Antifreeze
Ravensberger Ravenol Alu-Kühlerfrostschutz
Shell Aseol AG / Switzerland Aseol Antifreeze 26-30
Shell Aseol AG / Switzerland Aseol FN 26-33

Shell Austria AG Glycoshell AF 511

SRS GmbH Salzbergen Wintershall Cooler Antifreeze
Texaco Technology Europe Ghent Texaco Cooler Antifreeze NF (ETX 6024)
Total Deutschland GmbH Total OZO Antifreeze S
Total Deutschland GmbH Total Multiprotect

4.11 Engine type: MMC FUSO (Mitsubishi)
Attention:
KATO Kato genuine LLC

KOBELCO Kobelco genuine LLC
MITSUBISHI Fuso Diesel LLC
TADANO Tadano genuine LLC

4.12 Engine type: ND (Nissan Diesel)
Attention:

4.13 Engine type: RVI (Renault)
Attention:
Huiles Renault Diesel Ultra cooling D

Mixture ready for use; do not add water!


4.14 Engine type: Volvo Bus
Attention:
Volvo Parts; Götheburg, Sweden Coolant 1089240

subject to revisions by the engine manufacturer.B487

5. Recommended corrosion preventive additives without antifreeze
5.1 Engine type: Daimler-Benz - CV+B524
except for: OM 601, OM 602, OM 603
Attention:
Generally: Never mix corrosion preventive additives of various types!
Daimler-Benz AG, Stuttgart DB-Corrosion Preventive

A 000 989 13 25 10
Hoechst Burghausen VP 1749

6. Recommended cooling water processing agent (corrosion preventive oil)
Attention:
Generally: Never mix processing agents of various types!
Deutsche Shell AG, Hamburg Shell Oil 9156

Daimler-Benz AG, Stuttgart DB-Processing Agent 000 989 20 22

Voith Turbo GmbH & Co. KG VOITH TURBO GmbH & Co.
Product Group Retarder
Training / Documentation
D-74564 Crailsheim
cb-Dept.; Voithstraße 1
i. V. i. V. Phone (07951) 32-0
Telefax (07951) 32-756
Jürgen Friedrich Guido Künzel Direct dial no.:
Service Tel./Spare Parts Dept.
32-401 / 32-422

92,7+5HWDUGHU+(DWRQ576/RJRSURS
cbtd 98-01
53.2663.10
1. Preface ....................................................................................................1/1
2. General....................................................................................................2/1
2.3 Retarder Data ...................................................................................2.3/1
3. Maintenance............................................................................................3/1
3.2 Oil Change .......................................................................................3.2/1

cbtd 98-01
Aftersales Service Manual VOITH Retarder 115 H - Eaton RTS/O Logoprop
53.2663.10
Page IHV/1
(Continue)

6.3 Removing, Cleaning and Installing Silencer ............................................6.3/1
7. Control Parts ...........................................................................................7/1

7.1 Control Parts ....................................................................................7.1/1
8. Annex ......................................................................................................8/1
Data Sheet
Spare Part Lists
Other Information
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Preface
appropriate and professional maintenance and repair at the VOITH Retarder 115 with Logoprop control.
Caution!
Notice
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Preface
(Continue)
Caution!
Notice
• Serial-Number
• Code-Number
Notice
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Preface
(Continue)
Caution!
Notice
professionally.
Notice
Notice
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Preface
(Continue)
damage incurred.
prior notification.

D-74564 Crailsheim

Telefax (07951) 32-756
Extensions:
32-401 / 32-422
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General

2.3 Retarder Data.............................................................................................2.3/1
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General
Illustration VOITH Retarder 115 H Logoprop

3700
94/5 Blind hole (not used)
107 Ventilation 2909
2909 Oil filler plug (M 30 x 1,5) 2909
3300 Heat exchanger
3700 Proportional valve 3700/1
(Herion 4088369)
3700/1 Electrical connection,
proportional valve
3300
94/5
107
2923
FD987
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General
(Continue)
Illustration VOITH Retarder 115 H Logoprop

(Continue)

3300 Heat exchanger
4700 Screw plug (M 30 x 1,5)
with sieve
3300
2919
4700
FD902
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General
Illustration VOITH retarder 115 H with Logoprop control system
Notice
The reference numbers indicated in Section 2.2 are not identical with the reference numbers of the spare part lists.
42 25 36
23
63
R A 21 26 14
7 4
1
19
2
46 16
44
22 17
64
47
62
43
55 18

FD903
1 Heat exchanger
2 Control unit
7 Fuse (5 A)
8 Connection ground
14 ABS cut-out relay
18 Stop light relay
22 Ventilation
36 Ventilation line
42 Oil tank
43 Oil sump
44 Stator
46 Rotor
55 Central oil drain plug
62 Pressure regulation valve
63 Check valve (inlet)
64 Check valve (outlet)
cbtd 98-01 Aftersales Service Manual VOITH Retarder 115 H - Eaton RTS/O Logoprop
53.2663.10 Page 2.2/1
General

(Continue)

The VOITH retarder R 115 H is a powerful, hydrodynamic, continuous brake of compact design for
commercial vehicles of the heavy-duty range with a prop-shaft speed up to 2708 r.p.m. max.
In the event of a retarder failure or when the temperature limit is effective, the service brake must be FD985
FD986
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General

(Continue)
Description of retarder R 115 H operation with logoprop control system

c
A retarder stage switch (16) with 5 switch stages is used to operate the VOITH retarder R 115 H.
In a special version, the retarder stage switch (16) in conjunction with ABS can be combined with
a 3-stage running-plate valve or a 4-stage pressure-switch unit for the service brake.
The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limit a b
If the retarder is switched off (0 position), or if a braking stage is engaged (position 2 to 5), the memorized
constant speed is cancelled. If the constant speed function is re-activated, the new present speed
is memorized.
FD299
If the retarder stage switch (16) is shifted to positions 2 to 5, the retarder brakes in braking stage 1 to 4.
The hydrodynamic principle
In the maximum position of the retarder stage switch (16), the braking torque of the VOITH retarder a Rotor (46)
is at maximum. b Stator (44)
c Oil flow
vehicle air tank for auxiliary equipment.
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 is passed on to the
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General

(Continue)
The rotation of the retarder sets the oil in motion and circulates it in a closed circuit between
During braking, the deceleration energy is transformed into heat. To dissipate this heat, part of the oil in
the working circuit is pumped continuously by the rotor (46) through the heat exchanger (3300) and
filling ducts and returned to the circuit again.
Cooling water temperature pick-up (19)

The temperature pick-up (19) installed in the retarder cooling water return pipe monitors the
cooling water temperature and transmits appropriate signals to the control unit (2).
This temperature pick-up guarantees that the maximum permissible cooling water temperature
is not exceeded.
If the cooling water in the return pipe heats up to a predefined temperature of =96°C, the
constant-air pressure py is limited linearly over a temperature limit range of approx. 10°C at the
highest braking stage.
If the temperature limit range of approx. 10°C is exceeded while braking, braking torque output
is stopped to protect the vehicle cooling system.
While the temperature limit is operative or whenever there is a retarder failure, the service brake must
be used to control the speed of the vehicle.
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General

(Continue)




Notice
If the check valve (outlet) must be renewed during a repair operation, please contact VOITH TURBO
or a responsible contracting party.
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General !
The retarder data plate (2) provides the following information: 2
VOITH
Retarder
1. Serial-Number: Six-digit number Typ R115 H Fabr. Nr.
i Ret. = Baujahr
00.0000.00
2. Retarder transmission ratio (i retarder) 00.0000.00
3. Year of manufacture
4. Code-Number: Eight-digit number
With Logoprop H
ITer
VO tard
control system Ty
i Re
p R1
15
f. =
Re
H
Fa
Ba
br.
urj
ah
.00 0.0
00 00
.0
Nr
r
.
.00
00 0
00
FD1014
53.7386.20
67.0001.10
67.0002.10
67.0003.10
67.0004.10
5. Vehicle manufacturer´s Part No., if any.
Notice
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Maintenance "

3.2 Oil Change .................................................................................................3.2/1
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Maintenance "

#$
At each oil change

correct fitment.
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Maintenance %
&
Illustration oil change

2909
2910 2909
2909 Oil filler plug (M 30 x 1,5), 150 Nm
2920 O-ring (10 x 3), renew,

non-corrosive grease 4800 2920
screw plug 4700
2919
FD990
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Maintenance %
&
(Continue)
Notice
Central oil-drain plug is heated up (oil temperature)!

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Maintenance %
&
(Continue)
Job scope
2920
3. Coat new O-rings (2920 und 2921) with silicone-free and non-corrosive grease and fit them on the
2918
2919
FD344
compressed air.
4800
4700
FD438
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Maintenance %
&
(Continue)
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Maintenance %$
& '

2909
2910
2923 Oil check plug (M 24 x 1,5), 80 Nm 2910
2924
2923
FD988
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Maintenance %$
& '
(Continue)
Notice
Caution!
been switched off!
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Maintenance %$
& '
(Continue)
Check requirements
Job scope
switch it off after approx. 5 sec. 2923
FD901
3. Screw out the oil check plug (2923) and remove sealing ring (2924). 2909
The oil level is correct if it is at the lower edge (arrow) of the oil check hole. 2910
2909
FD974
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Diagnosis / ( !&
) *
&
Troubleshooting

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Diagnosis /

Troubleshooting
Notice
Before starting with troubleshooting the oil level of the retarder must be checked and corrected
(see chapter 3.3 „Checking oil level“).
(see chapter 3.2 „Oil change“ and annex).
Contact
gear box gear box
too too too too

Check oil level of retarder (*) Check oil level of
gear box gear box
NOK OK OK NOK
VOITH ventilation Check oil level of Check oil level of
gear box gear box
too too
OK NOK
high low
see chapter 6.4
Check casing Check oil level of
ventilation retarder
Check Check cooling system:
heat exchanger
-coolant level
NO YES YES NO -thermostat
-coolant pump
Water in the oil? OK NOK Water in the oil? -radiator fan
(emulsion) (emulsion) -radiator grill for
Check oil level of dirtiness Driver instruction!
retarder
Oil leak OK NOK

by ventilation
Check operation
(by braking with
retarder nominal
engine speed,
if possible)
Complaint
Retarder Pilot
clear faults Temperature limit
R 115 Light
Logoprop
NOK OK
No respectively flashes
too insufficient
retarder braking Check lead to
effect temperature pick-up
and short circuit,
lead discontinuity
Check oil level of

retarder
NO YES YES NO
Check
heat exchanger
Check py (static) Check oil level of
(Chapter 4.4) retarder
see chapter 6.4
too too
OK NOK
high low

(Chapter 4.3) Contact gear box
VOITH
OK NOK OK NOK

Contact Contact
(Chapter 4.4) retarder
VOITH VOITH too too
OK NOK high low
Contact Correct oil level of

Check control unit VOITH retarder and
and retarder gear box
stage switch
(Chapter 4.4)
Check compressed- OK NOK
-air supply
(Chapter 4.4)
OK NOK
Contact Contact *
VOITH VOITH Do you get oil leakage after a trail
Check vehicle run again:
compressed-air
Mechanical fault of supply
proportional valve or continue at "Checking casing
antivibration plate OK NOK
ventilation"
Contact
Contact
vehicle FD 1600
VOITH
manufacturer
cbtd 98-01 Aftersales Service Manual Voith Retarder 115 H Eaton RTS/O Logoprop
53.2663.10 Page 4.1/1
Diagnosis / ( *
& !&
Illustration electrical connections diagram

4
6 16 19
2 Control unit
4 Terminal 15
6 Fuse (8 A)
14 ABS cut-out relay 1 2 3 4 5
18 Stop light relay
87 87a
30
ye/gn
blue
pi
pur
wh
gn
rd
bl
bl
14
U U
U U U U U U
2 10 9 8 7 6 5 11 12
1 3 4 13 14
2
U U I
ye/gn
br
bl
br
or
30
87 87a
47
18 17
21 FD126
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Diagnosis / ( *
&

Troubleshooting

Check requirements
Notice
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Diagnosis / ( %$
&
Troubleshooting


(pump pressure measuring point),
25 Nm
Notice

of the retarder.
111
Special tool
112
53.4788.10 FD976
Pressure gauge
0 - 25 bar
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Diagnosis / ( %$
&
Check requirements
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Diagnosis / ( %$
&
Caution!
Caution!
FD410
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Diagnosis / ( %$
&
Setting [NM] Pump pressure static *1) Pump pressure dynamic 1)

2900 2,65 - 3,05 19

Notice
Caution!
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Diagnosis / ( %$
&
Caution!
cbtd 98-01
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Diagnosis / (( %$
& %

Check requirements
• Retarder stage switch in highest position
• For checks with multimeter, ground must be connected to pin 1 of control unit (2) and
vehicle voltage (terminal 15) to pin 2.
Special tools
101103105
99 107
97 111
95 113
93 115
o o
120 C 200 C
53.4377.10 53.4788.10 53.8167.10
Pressure gauge
0 - 25 bar
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Diagnosis / (( %$
& %


Notice
32

1. Disconnect electrical lead (38) from the temperature pick-up (19) and connect it to 19
the temperature tester (99/4).
Notice
101103105
99 107
97 111
95 113
The temperature tester (99/4) is delivered with flat plugs. If the lead (38) is delivered with round plugs 93 115
38
make a plug converter by yourself.
o o
120 C 200 C
FD441
99/4 Temperature tester 53.4377.10
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Diagnosis / (( %$
& %

2909
2910
2909
FD974
99/1
2904
FD975
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Diagnosis / (( %$
& %

4. Connect up socket box (99/8):
• Ignition: OFF 2
• Disconnect plug on control unit (2).
• Connect vehicle wiring harness to appropriate connector of socket box (99/8).
• Connect appropriate plug of socket box (99/8) to control unit (2).
99/8
FD875
99/8 Socket box 53.8167.10
5. Connect multimeter to both sockets „13 Propv.“ (arrows) of socket box (99/8)
(Measurements: mA).
6. Open switch for lead disconnection (98/4).
98/4
FD870
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Diagnosis / (( %$
& %

Job scope test

Preconditions for checking 19
• Ignition ON
1. Set the rotary switch of the temperature tester (99/4) one step below the specified start of
temperature limit (e.g. to 95°C for a specified start of temperature limit at 96°C) and operate the
retarder at the highest stage. 101103105
99 107
97 111
95 113
93 115
The constant-air pressure py and the control current must reach the values given in table on the 38
o o
120 C 200 C
FD441
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Diagnosis / (( %$
& %

Setting [Nm]* DIL-Switch Setting Control current Constant-air

[mA]**1) pressure py [bar]1)2)
2900 DIL 3, 4 and 5 OFF 322 - 328 2,65 - 3,05
* The setting is to be found on the control unit.

** If a commercially available multimeter is used for measurements (without real effective measuring)

2) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
Notice
The data represent the state of the art at the time going to print.
Control units to which other data apply still are in use. The manufacturer reserves the right
cbtd 98-01
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Diagnosis / (( %$
& %

Notice
If both values are not reached, the electrical system must be checked as follows.
2. Set the rotary switch of the temperature tester two steps above the specified start of
temperature limit (e.g., 98°C for a specified start of temperature limit at 96°C).
The constant-air pressure py must drop approx. 0,6 bar below the set maximum value.
If the start of temperature limit is exceeded by approx. 10°C no more constant-air pressure py
must be provided.
Notice
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Diagnosis / (( %$
& %

3. Disconnect presure gauge (99/1).

2909
2910
2909
FD974
5. Connect the electrical lead (38) with the temperature pick-up (19).
38
19
FD440
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Diagnosis / (( %$
& %

Checking R 115 H electrical system
Notice
All checks have to be made with the socket box. In the column „Measuring equipment/test connection“ mesauring is done as follows:
Pin - multimeter - measuring mode V or W - Pin.
Step Scope of check Measuring equip./ Requirement/ Result/ Cause/

test connection Action Set point Remedy
1 Voltage 1-V+2 Ignition: ON ≥ 20 V - End of check
< 20 V - Step 1.2
1.2 1-V+2 Ignition: OFF ≥ 20 V - Renew control unit

- Disconnect plug from
control unit < 20 V - Lead discontinuity
Ignition: ON - Lead short circuit
2.1 Retarder 1-V+4 Ignition: ON <1V - Step 2.2

pilot light - Retarder stage switch on
position 0 ≥1V - Lead short circuit
- Fault in retarder stage switch
- Fault in control unit
2.2 1-V+4 Ignition: ON ≥ 20 V - End of check

- Retarder stage switch on
position 1 to 5 < 20 V - Lead discontinuity
- Lead short circuit
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Diagnosis / (( %$
& %


3.1 Stop light relay 1-V+3 Ignition: ON <1V - Step 3.2

- Retarder stage switch on
position 0 ≥1V - Lead short circuit
3.2 1-V+3 - Retarder stage switch on ≥ 20 V - End of check

position 1 to 5
< 20 V - Lead discontinuity
4.1 Retarder stage 1-V+5 Ignition: ON ≥ 7,7 V - Step 4.2

switch input - Retarder stage switch on
position 5 < 7,7 V - Lead discontinuity
4.2 1-V+5 ≤ 8,3 V - End of check
> 8,3 V - Lead discontinuity

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Diagnosis / (( %$
& %


5.1 Retarder stage 1- V +6 Ignition: ON ≥ 14,7 V - Step 5.2

switch output 1- V +7 - Retarder stage switch on
1- V +8 position 0 < 14,7 V - Lead discontinuity
1- V +9 - Lead short circuit
1- V +10 - Fault in retarder stage switch
5.2 1- V +6 ≤ 15,3 V - End of check

1- V +7
1- V +8 > 15,3 V - Lead discontinuity
1- V +9 - Lead short circuit
1- V +10 - Fault in retarder stage switch
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Diagnosis / (( %$
& %


6.1 Temperature 11 - Ω + 12 Ignition: OFF - Check leads and temperature

pick-up - Disconnect plug from pick-up
control unit
Temperature of cooling water

Notice:
The measuring in one
temperature range normally
is sufficient.
+ 20°C Ω
+ 60°C 134 ± 13 Ω
+ 90°C Ω
+ 100°C 38,5 ± 3,5 Ω
7.1 Speedometer - Check in accordance with

signal* details from manufacturer
* only relevant, if vconst without function.
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Diagnosis / (+
%$
Troubleshooting


FD844
The retarder is switched off.
Retarder pilot light comes on permanently

The retarder is switched on, i.e., the retarder stage switch is switched to one of its five possible
switch positions.

1 on moving off
This flashing occurs at low ambient temperatures in braking stage 1 to 5 and goes off as soon as
the vehicle has reached its operating temperature.
However, the retarder itself is completely ready for operation.
2 during braking with the retarder

• The temperature limit is effective - the retarder regulates its braking torque down.
• The control unit identifies a discontinuity to the temperature pick-up.
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Diagnosis / (+
%$
Step Scope of check Requirement Result / Set point Notice, Cause / Remedy
Action
1 Retarder pilot light, Vehicle on move Retarder pilot light comes Retarder performs
retarder - Retarder stage on, satisfactory
switch in switch Braking of retarder in switch
position 1 to 5 position 1 to 5
Retarder pilot light does not

come on, and/or insufficient Troubleshooting as on
braking of the retarder Troubleshooting diagram
(see page 4.1/1)
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Retarder Remo- +
&, -

&
ving, Installing
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Retarder Remo- +
&, -

&
ving, Installing

Notice
3700
One of the mill-cut sides of the prop-shaft must 96 97
show in direction of the retarder housing. 26 700
26 Supply-air pressure line p v

38 Electrical lead
200 - 240 Nm
96 Hose clamps 38
97 Hose-connection
700 O-Ring (164 x 3), renew,
for installation
H
IT r
VOtarde
Re 93 .
Nr
.
95/1
19 br
00
Fa
hr
0.
H ja
ur
15
00 00
R1 Ba
p
Ty =
.0 0.
i Re
f.
00 000
.
00
95/1
FD991
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Retarder Remo- +
&, -

&
O-Ring Silicone-free and

Caution!
Observe VOITH Installation Instructions! These have to be requested

from VOITH TURBO.
To remove, install
of heat exchanger.
2. Disconnect the supply-air pressure line (26) and electrical lead (38) from
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Retarder Remo- +
&, -

&
4. Unscrew collar nuts (95/1).

95/1

700

FD993
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Repair .

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Repair
2700 6200 2927

2909 2926
2800 2910 2905

3600
2904
2400 6000
2909
3800 3900
2500 2900
3000
3500 2910
2000 3750
2600
2906
2300/1 3000 3900
3500
2301
2300
3700
3600
2300/2 3000
3000
2300/3
2000
4000 5200
3100
111
3600
112
107 2924
108
2923 2915
3400
2912
2911
4800 2913 3300
4700 2921 2914
2922 2920
2918
2919
FD1579
Illustration assembly overview R 115 H with Logoprop control system
107 Disc (Silencer) 2918 Sealing ring (A 20 x 26)

108 Circlip (JL 30 x 1,2) 2919 Oil-drain plug
111 Sealing ring (A 12 x 18) 2920 O-ring (10 x 3)
112 Screw plug (M 12 x 1,5) 2921 O-ring (6 x 3)
2300 Casing ventilation 2923 Oil check plug (M 24 x 1,5)
2300/1 Valve insert 2924 Sealing ring (A 24 x 29)
2300/2 Float 2926 Angle sheet metal (22 x 4 x 62,5)
2300/3 Float cage 2927 Hex.-head screw (M 8 x 45)
2301 O-ring (55 x 3) 3000 O-ring (15 x 4)
2400 Cover casing ventilation 3100 O-ring (40 x 5)
2500 Sealing 3300 Heat exchanger
2600 Spacer (D 60 / 41 x 2) 3400 Distributor
2700 Hex.-head screw (M 8 x 80) 3500 Anti-fatigue screw (M 14 x 65)
2900 Oil tank 3700 Proportional valve (Herion 4088369)
2904 Upper cover 3750 Hexagon nut (M 8)
2905 Hex.-head screw (M 8 x 40) 3800 Anti-vibration plate (160 x 70 x 22)
2906 Upper gasket 3900 Hex.-head screw (M 8 x 25)
2909 Oil filling screw (M 30 x 1,5) 4000 O-ring (7 x 2,5)
2910 Sealing ring (A 30 x 36) 4700 Screw plug with sieve
2911 Lower cover 4800 Sealing ring (A 30 x 36)
2912 Lower gasket 5200 Disc (31/31 x 4 D 14,5)
2913 Hex.-head screw (M 8 x 25) 6000 Clamp (3 x 20 x 90)
2914 Hex.-head screw (M 8 x 35) 6200 Angle sheet metal (22 x 4 x 62,5)
2915 O-ring (7 x 2,5)
53.2663.10 Page 6.1/1
Repair .
&, %$
&
-

& %
&
/

Notice
This step can be performed with the retarder removed or installed.

to approx. 80°C.

• Ignition OFF
cbtd 98-01
53.2663.10
Page 6.2/1
Repair .
&, %$
&
-

& %
&
/

(Continue)
2300/2 Float
specified weight 11 g ± 1 g
2300/3 Float cage 2700 2300/1
2301 O-ring (55 x 3), renew,
2800
coat of silicone-free and non- 2301
2400 Casing ventilation cover 2300
2500 Sealing, renew 2300/2
2600 Spacer (D 60 / 41 x 2) 2400
2700 Hex.-head screw (M 8 x 80), 2300/3
renew, 25 Nm
renew, 25 Nm
2500
6200 Angle sheet metal (22 x 4 x 62,5)
2600

FD995
cbtd 98-01
53.2663.10
Page 6.2/2
Repair .
&, %$
&
-

& %
&
/

(Continue)
Special tools
53.7712.10 53.9428.10
To remove
1. Screw out the hex.-head screws (2800 and 2700).
cbtd 98-01
53.2663.10
Page 6.2/3
Repair .
&, %$
&
-

& %
&
/

(Continue)
5. Take float (2300/2) and float cage (2300/3) out of the retarder housing. 99/5
98/9
FD1153
99/5 Impact tool 53.7712.10

98/9 Adapter 53.9428.10
2300/1
2301
FD1020
cbtd 98-01
53.2663.10
Page 6.2/4
Repair .
&, %$
&
-

& %
&
/

(Continue)
To check

Specified weight 11g ± 1 Gramm. If the weight is more than the specified weight, renew the 2300/2
Notice
FD194
2300/2
2300/1
FD1021
cbtd 98-01
53.2663.10
Page 6.2/5
Repair .
&, %$
&
-

& %
&
/

(Continue)
To install
1. Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on
99/5

98/9
FD1153
99/5 Impact tool 53.7712.10

98/9 Adapter 53.9428.10
is at the top.
2600
Notice
Pay attention to the mounting position of the sealing and the cover! 2300
FD1018
cbtd 98-01
53.2663.10
Page 6.2/6
Repair .
&, %

&
-

&

Notice
107
removed or installed.
108
107 Disc (Silencer) (D 30 x 4), clean

with compressed air
108 Circlip (JL 30 x 1,2),
Cleaning agents
Silencer Benzine
FD335
cbtd 98-01
53.2663.10
Page 6.3/1
Repair
!
3000
3100
3000
5200
3600
3600
4000
2900
3100
2921
3400
2920
2918
2919
3300
FD998

• Ignition OFF
With retarder installed:
• Proportional valve and anti-vibration plate removed (see Section 6.7)
2900 Oil tank

3300 Heat exchanger
3400 Distributor
3600 Anti-fatigue screw (M 14 x 150), renew,
Initial torque: 50 Nm,
4000 O-ring (7 x 2,5), renew, coat of silicone-free and non-corrosive grease for installation
5200 Disc (31/31 x 4 x 62,5)
Lubrication

53.2663.10 Page 6.4/1
Repair .(
&, %$
&
-

& 0
12
& (Continue)
Special tool
53.7711.10

Post box 10 08 67
D-42659 Solingen
Tel. 0212/ 888-0
cbtd 98-01
53.2663.10
Page 6.4/2
Repair .(
&, %$
&
-

& 0
12
& (Continue)
Notice
If this job sequence is performed with the retarder installed, the following prior jobs must be performed:
3300
2918
2919
FD909
cbtd 98-01
53.2663.10
Page 6.4/3
Repair .(
&, %$
&
-

& 0
12
& (Continue)
To remove
3600
3300
3600
3600
FD999
4. Remove O-rings (3000, 3100 und 4000).

3000 4000
3100
FD1000
cbtd 98-01
53.2663.10
Page 6.4/4
Repair .(
&, %$
&
-

& 0
12
& (Continue)
To check
1. Fit pressure-test equipment (99/6) together with O-rings to heat exchanger (3300). 99/6
Notice
FD436
Notice
99/6 3300
FD097
cbtd 98-01
53.2663.10
Page 6.4/5
Repair .(
&, %$
&
-

& 0
12
& (Continue)
Remove distributor (3400) from defective heat exchanger and install in new heat exchanger. 3300
3400
Notice
To install
FD098
1. Fit new O-rings (3000, 3100 und 4000) in the drilled holes.
Caution!
cbtd 98-01
53.2663.10
Page 6.4/6
Repair .(
&, %$
&
-

& 0
12
& (Continue)
Notice
from the manufacturer or VOITH TURBO.
Caution!
5. Flush the retarder, if the heat exchanger leaked:

times to flush out the retarder system and drain the oil through the central oil-drain plug (2919).
Coat new O-rings (2918 und 2920) with silicone-free and non-corrosive grease and fit them on to 2921
2920
Fill in retarder oil (see Section 3.2). 2918
2919 FD905
cbtd 98-01
53.2663.10
Page 6.4/7
Repair .+
&
-

& *
$ %

Upper oil tank cover
2905
Notice 2904

in the area of the hex.-head screws
(2800, 2700, 4100) to approx. 80°C. 2906
2900
2900 Oil tank

2904 Cover
Final turn: 25 Nm
2906 Gasket, renew
FD1003
cbtd 98-01
53.2663.10
Page 6.5/1
Repair .+
&
-

& *
$ %
(Continue)
7 5 2 4 10
FD1004
cbtd 98-01
53.2663.10
Page 6.5/2
Repair .+
&
-

& *
$ %
(Continue)

• Retarder OFF
• Ignition OFF
Notice
to approx. 80°C.
cbtd 98-01
53.2663.10
Page 6.5/3
Repair .+
&
-

& *
$ %
(Continue)

2900
2900 Oil tank

2911 Cover
Final turn: 25 Nm
Final turn: 25 Nm
2915 O-ring (7 x 2,5), renew,
2915
Final torque: 25 Nm
Lubricants
2914
FD361
cbtd 98-01
53.2663.10
Page 6.5/4
Repair .+
&
-

& *
$ %
(Continue)
7 5 2 4 10
FD1005
cbtd 98-01
53.2663.10
Page 6.5/5
Repair ..
&
-

& *
$

• Heat exchanger removed
3000
(see Section 6.4)
2000 O-ring (60 x 5), renew,

2900 Oil tank
3000 O-ring (15 x 4), renew, 2900
corrosive grease for installation 3500
3500 Anti-fatigue screw (M 14 x 65), 2000
heat exchanger
3000 2000
FD1006
cbtd 98-01
53.2663.10
Page 6.6/1
Repair ..
&
-

& *
$
(Continue)
2900

Post box 10 08 67
D-42659 Solingen
Tel. 0212/ 888-0
To remove 3500
FD1007
1. Screw out anti-fatigue screws (3500) and remove oil tank (2900).
Notice
cbtd 98-01
53.2663.10
Page 6.6/2
Repair ..
&
-

& *
$
(Continue)
To install 3000
2000
3000
FD367
Notice 2900
3. Once the heat exchanger has been installed, screw the anti-fatigue screws (3500) tight.
Initial torque: 50 Nm 3500

FD1008
cbtd 98-01
53.2663.10
Page 6.6/3
Control Parts 3 %

7.1 Control Parts ..............................................................................................7.1/1
cbtd 98-01
53.2663.10
Page 7/1
Control Parts 3 %


• Discharge supply air
38 Electrical lead
3700 Proportional valve 3900 6000
3750 Hexagon nut (M 8), renew, 18 Nm
3800 Anti-vibration plate (160 x 70 x 22)
3900 Hex.-head screw (M 8 x 25), 3900
renew, 25 Nm
6000 Clamp
3800
Caution!
If, during maintenance or repair, the hexagon 38

nuts (3750) or hex-head screws (3900) are
unlocked, the anti-vibration plate must be
checked for mechanical or ageing damages
and renewed if necessary. 3700
26
3750
FD929
cbtd 98-01
53.2663.10
Page 7.1/1
Control Parts 3 %

(Continue)
Illustration temperature pick-up

19 Temperature pick-up(M 14 x 1,5),

32 Nm (or M 18 x 1,5)
38 Electrical lead
38
Notice
Pay attention to the instructions regarding the 19

quality of the cooling-water given from the
FD440
cbtd 98-01
53.2663.10
Page 7.1/2
Annex 4
2
Data Sheet
Spare Part Lists
Other Information
cbtd 98-01
53.2663.10
Page 8/1
Data Sheet VOITH Retarder 115 H
with Logoprop Control System
Max. retarder speed (= max. prop shaft speed) v(max.) 4870 r.p.m. at vps = 2400 r.p.m.

Service filling:
- Service filling (Oil change, checking oil level) 5,4 Litre
- After renewal of heat exchanger 5,6 Litre
- After complete taking apart and cleaning 6,0 Litre

as well as emptied heat exchanger (corresponds new filling)
Overall weight (with flange and heat exchanger, without oil filling) approx. 65 kg *
* Max. braking torque at prop shaft with retarder gear ratio 1:1,846
Wartung, Diagnose, Instandsetzung VOITH Retarder 115 H - Eaton RTS/O Logoprop

Seite 8/2
Miscellaneous Conversions Retarder 115 H with Logoprop Control System
D GB USA D GB USA
96 oC 205 oF 205 oF 2,65 - 3,05 bar 38 - 44 psi 38 - 44 psi
14 - 19 Nm 10,36 - 14,06 lbf-ft 10,36 - 14,06 lbf-ft 19 bar 275 psi 275 psi
18 Nm 13,32 lbf-ft 13,32 lbf-ft 11 g ± 1 g 0,38 ± 0,035 oz 0,38 ± 0,035 oz

VOITH TURBO
Powertransmission
VOITH Retarder
1. Water
2.1 Normal case

*see chapter 4


**see chapter 5
Attention:
agent!

***see chapter 6
Attention:

3. Miscellaneous
3.1 Disposal
3.2 Safety

Attention:




Attention:



Attention:

Attention:


Attention:


Attention:




Attention:


Attention:

Attention:



Attention:


Training $IWHUVDOHV˜6HUYLFH˜0DQXDO
92,7+˜5HWDUGHU˜−ž˜/RJRSURS
cbtd 98-01
53.2658.10
Content $IWHUVDOHV6HUYLFH0DQXDO
92,7+5HWDUGHU+'DLPOHU%HQ]6.
cbte 98-01
53.2662.10
1. Preface ....................................................................................................1/1
2. General....................................................................................................2/1
2.3 Retarder Data ...................................................................................2.3/1
3. Maintenance............................................................................................3/1
3.2 Oil Change .......................................................................................3.2/1
Electrcal Connections Diagram ............................................................4.1/2

cbte 98-01
Aftersales Service Manual VOITH Retarder 115 H - Daimler Benz SK
53.2662.10
Page IHV/1
(Continue)

6.3 Removing, Checking and Installing Silencer ...........................................6.3/1
7. Control Parts ...........................................................................................7/1

7.1 Control Parts ....................................................................................7.1/1
8. Annex ......................................................................................................8/1
Data Sheet
Spare Parts Lists
Other Information
cbte 98-01
53.2662.10
Page IHV/2
Preface
The information and instructions which are given to you furthermore provide the basis for appropriate
and professional maintenance and repair at the VOITH Retarder 115 H in Daimler Benz SK.
Caution!
Notice
cbtd 98-01 Aftersales Service Manual VOITH Retarder 115 H - Daimler Benz SK
53.2662.10 Page 1/1
Preface
(Continue)
Caution!
Notice
• Serial-Number
• Code-Number
Notice
in the spare parts lists in the annex. Items or components shown with an oblique-number are not
available in the spare parts lists.
53.2662.10 Page 1/2
Preface
(Continue)
Caution!
Notice
professionally.
Notice
Shield retarder proportional valve from direct jet of high-pressure cleaner (steam jet cleaner).
Notice
53.2662.10 Page 1/3
Preface
(Continue)
damage incurred.
prior notification.

D-74564 Crailsheim

Telefax (07951) 32-756
Extensions:
32-401 / 32-422
53.2662.10 Page 1/4
General

2.3 Retarder Data.............................................................................................2.3/1
53.2662.10 Page 2/1
General
Illustration VOITH Retarder 115 H

94/5 Blind hole (not used) 3700

107/7000 Ventilation 2909
2909 Oil filler plug (M 30 x 1,5) 2909
3300 Heat exchanger
3700 Adapter plate
3300
94/5
107/7000
2923
FD1138
53.2662.10 Page 2.1/1
General
(Continue)

basic group with heat exchanger (Continue)

3300 Heat exchanger
4700 Screw plug (M 30 x 1,5)
with sieve
3300
2919
4700
FD902
53.2662.10 Page 2.1/2
General )XQFWLRQDQG2SHUDWLRQ6FKHPH
Oil sump
Supply-air pressure pv
Constant-air pressure py
Coolant (water)
Pump pressure pp
42 25 36
23
R A 21 26 14
63
7 3
1
19
2 3
46 16
22
44
17
65 3
62
43 55
24
FD1146
Notice
1 Heat exchanger
2 Control unit
3 Connection electrictrical power supply 24 V
7 Fuse (5 A)
8 Connection ground
14 ABS-switch off relay
19 Temperature pick-up cooling water
22 Ventilation
24 Relay for engine brake or
constant throttle
36 Ventilation line
42 Oil tank
43 Oil sump
44 Stator
46 Rotor
62 Valve group (D 26 x 36,5)
63 Check valve (input)
65 Check valve (output)
(alternatively with torque-limitation valve)
53.2662.10 Page 2.2/1
General

(Continue)

The VOITH retarder 115 H is a powerful, hydrodynamic continous brake of compact design for
commercial vehicles of the heavy-duty range (SK-range) with a prop-shaft speed
up to 2500 r.p.m. max.

FD326
In the event of a retarder failure or when the temperature limit is effective, the service brake must be
53.2662.10 Page 2.2/2
General

(Continue)
Description of retarder R 115 H operation

c
A retarder stage switch (16) with 5 switch stages is used to operate the VOITH retarder 115 H.
The retarder stage switch (16) has 4 braking stages and an additional function (engine brake or
constant throttle).
When the retarder stage switch (16) is shifted to position 1, the engine brake or constant throttle
is activated. a b
If the retarder stage switch (16) is shifted to positions 2 to 5 the retarder brakes in
braking stage 1 to 4. Engine brake or constant throttle are switched on in addition.
In the maximum position of the retarder stage switch (16), the braking torque of the VOITH retarder
is at maximum.
FD299
vehicle air tank for auxiliary equipment. The hydrodynamic principle
a Rotor (46)
When the retarder stage switch (16) is operated, an input signal is fed to the control unit (2). From this b Stator (44)
input signal, the control unit (2) provides a control current which is passed on to the c Oil flow
53.2662.10 Page 2.2/3
General

(Continue)
The rotation of the retarder sets the oil in motion and circulates it in a closed circuit between
During braking, the deceleration energy is transformed into heat. To dissipate this heat, part of the oil in
the working circuit is pumped continuously by the rotor (46) through the heat exchanger (3300) and
filling ducts and returned to the circuit again.
Cooling water temperature pick-up (19)

The temperature pick-up (19) installed in the retarder cooling water return pipe monitors the
cooling water temperature and transmits appropriate signals to the control unit (2).
This temperature pick-up ensures that the maximum permissible temperature of the cooling water does
not exceed.
If the cooling water in the return pipe heats up to a predefined temperature of =96°C, the
constant-air pressure py is limited linearly over a temperature limit range of approx. 10°C at the
highest braking stage.
If the temperature limit range of approx. 10°C is exceeded while braking, braking torque output
is stopped to protect the vehicle cooling system.
While the temperature limit is operative or whenever there is a retarder failure, the service brake must
be used to control the speed of the vehicle.
53.2662.10 Page 2.2/4
General

(Continue)




There may be installed in alternative a check valve (outlet) with a valve with torque limitation or a
check valve (outlet) without a valve with torque limitation.
Caution!
The different alternative check valves (outlet) may not be changed among themselves or refitted.
If the check valve (outlet) must be renewed during a repair operation, please contact VOITH TURBO or
a responsible contracting party.
53.2662.10 Page 2.2/5
General ! " #
Fixing place 1
2
The retarder data plate (2) is on the retarder housing at the top left in the direction of travel.
VOITH
Retarder
Typ R115 H Fabr. Nr.
i Ret = Baujahr
Fixing place 2 00.0000.00

00.0000.00
ITH
VOtarder
Re Nr.
br.
Fa
r
.00
ah
The retarder data plate provides the following information:

H urj
15 Ba
p R1
00 0
.00
Ty
i Re
f. =
00 000.0
.0
00
FD322
1. Serial-Number: Six-digit number
2. Retarder transmission ratio (i. retarder)
3. Year of manufacture 2
VOITH
Retarder
4. Code-Number: Eight-digit number Typ R115 H Fabr. Nr.
i Ret. = Baujahr
00.0000.00
5. Vehicle manufacturer´s Part No., if any. 00.0000.00
Notice
H
ITer
VO tard
Re br.
Nr
.
Fa
.00
r
ah
urj
00 0
H Ba
15
Ty
p R1
.00 0.0
f. = 00 00
i Re
.0
00
FD442
53.2662.10 Page 2.3/1
Maintenance ! $

3.2 Oil Change .................................................................................................3.2/1
53.2662.10 Page 3/1
Maintenance ! $

%
At each oil change

correct fitment.
53.2662.10 Page 3.1/1
Maintenance ! &
'
Illustration oil change

2909
2910
2920 O-ring (10 x 3), renew,
3700 Adapter plate (131 x 70 x 40)
Lubricants and cleaning agents 2921

4800 2920
2918
screw plug
FD1133
53.2662.10 Page 3.2/1
Maintenance ! &
'
(Continue)
Notice

53.2662.10 Page 3.2/2
Maintenance ! &
'
(Continue)
Job scope
2920
3. Coat new O-rings (2920 und 2921) with silicone-free and non-corrosive grease and fit them on the 2918
2919
FD344
compressed air.
4800
4700
FD438
53.2662.10 Page 3.2/3
Maintenance ! &
'
(Continue)
53.2662.10 Page 3.2/4
Maintenance !! &
' (

2909
2923 Oil check plug (M 24 x 1,5), 80 Nm
2910
2924
2923
FD1136
53.2662.10 Page 3.3/1
Maintenance !! &
' (
(Continue)
Notice
Caution!
been switched off!
53.2662.10 Page 3.3/2
Maintenance !! &
' (
(Continue)
Check requirements
Job scope
switch it off after approx. 5 sec.
Repeat this procedure twice. 2923
FD1135
3. Screw out the oil check plug (2923) and remove sealing ring (2924). 2909
2909
2910
The oil level is correct, if it is at the lower edge (arrow) of the oil check hole.
FD 1147
53.2662.10 Page 3.3/3
Diagnosis / ) #'
* +
'
Troubleshooting

53.2662.10 Page 4/1
Diagnosis / 7URXEOHVKRRWLQJ'LDJUDP
Troubleshooting
Notice
Contact
gear box gear box
too too too too

Check oil level of retarder (*) Check oil level of
gear box gear box
NOK OK OK NOK
VOITH ventilation Check oil level of Check oil level of
gear box gear box
OK NOK too too Check cooling

high low system:
Check casing see chapter6.4
ventilation Correct oil level of
-coolant level
(Chapter6.2) retarder
Check heat -thermostat
exchanger -coolant pump
-radiator fan Driver instruction!
NO YES YES NO -radiator grill for
dirtiness
Water in the oil? OK NOK Water in the oil?
(emulsion) (emulsion)
Check oil level of
retarder
OK NOK
Check operation
(by braking with
retarder nominal
Oil leak by
engine speed,
ventilation
Check idle speed if possible
Check retarder see vehicle
pilot light and lead manufacturer´s
instruction
Clear faults Temperature limit!
Complaint
OK NOK
Retarder pilot light Retarder pilot light
without function
R 115 H flashes
Retarder brakes Daimler Benz
Logoprop
NOK OK
Check lead to
temperature pick-
up and short
No respectively circuit, lead
too insufficient discontinuity
retarder braking
effect
Check oil level of

retarder
NO YES YES NO
Check heat
exchanger
Check p
y
(static) Check oil level of
see chapter6.4
too too
OK NOK
high low

(Chapter4.3) Contact gear box
VOITH
OK NOK OK NOK

Contact Contact
VOITH VOITH too too
OK NOK high low
Check control unit

and retarder
Contact Correct oil level of
stage switch
VOITH retarder and
(Chapter4.4)
gear box
OK NOK
Check
compressed-
-air supply Contact Contact
(Chapter4.4) VOITH VOITH
OK NOK
Check vehicle * If you get oil leakage after a trail run again:
compressed-air
Mechanical fault of continue at ‘‘Checking casing ventilation‘‘
supply
proportional valve
OK NOK
Contact Contact vehicle

VOITH manufacturer
FD 1705
cbtd 98-01 Aftersales Service Manual Voith Retarder 115 H Daimler Benz SK
53.2662.10 Page 4.1/1
Diagnosis / ) +
' #'
Illustration electrical connections diagram 4

29
(without ABS) bl bl/ye gn
28
7 bl bl/rd
2 Control unit
4 Terminal 15
bl/wh
bl 16
7 Fuse (5 A) 6/6
bl
30 86 86 87 87a
17 Retarder pilot light 1 2 3 4 5
19 Cooling water temperature pick-up
0 12 3 4 5
21 Proportional valve 87a 87 85 85 30
24 Relay for engine brake or 6/5 6/4 6/3 6/2 6/1
br
constant throttle 72 24
28 Idle speed switch (closed if
accelerator pedal actuated)
gn/ye wh
17
bl/rd wh
bl/gn/rd
29 Clutch switch (open if clutch is
br/bl
2
wh
gn
ye
actuated)
pi
bl
72 Relay retarder stage switch
2 4 10 9 8 7 6 5 3
1 14 13 12 11
br/ye wh
br/gn bl
ye/wh
ye/bl
br
14/1 14/2 14/3 14/4
21 19 FD433
53.2662.10 Page 4.1/2
Diagnosis / ) +
' #'
Illustration electrical connections diagram

4
(with ABS) 29
bl bl/ye gn
28
2 Control unit 7 bl bl/rd
4 Terminal 15
bl/wh
bl 16
7 Fuse (5 A) 6/6
bl
30 86 86 87 87a
17 Retarder pilot light 1 2 3 4 5
19 Cooling water temperature pick-up 14
bl
21 Proportional valve 0 12 3 4 5
87a 87 85 85 30
24 Relay for engine brake or 86 87 87a 6/5 6/4 6/3 6/2 6/1
br
constant throttle
72 24
27 To ABS-control unit pin 11
28 Idle speed switch (closed if 85 30
gn/ye wh
bl/rd wh
bl/gn/rd
17
accelerator pedal actuated)
bl/br ye
br/bl
29 Clutch switch (open if clutch is 2
wh
gn
ye
pi
actuated)
72 Relay retarder stage switch 2 4 10 9 8 7 6 5 3
1 14 13 12 11
br/ye wh
br/ye bl
ye/wh
ye/bl
27
br
14/1 14/2 14/3 14/4
21 19 FD432
53.2662.10 Page 4.1/3
Diagnosis / ) +
'
"
Troubleshooting

Check requirements
Notice
53.2662.10 Page 4.2/1
Diagnosis / )! &
'
Troubleshooting


(pump-pressure measuring point),
25 Nm
Notice

of the retarder.
111
Special tool
112
53.4788.10 FD1131
Pressure gauge
0 - 25 bar
53.2662.10 Page 4.3/1
Diagnosis / )! &
'
Check requirements
53.2662.10 Page 4.3/2
Diagnosis / )! &
'
Caution!
Caution!
FD410
53.2662.10 Page 4.3/3
Diagnosis / )! &
'
Retarder stage switch Pump pressure static *1) Pump pressure dynamic1)
5 2,65 - 3,05 19

Notice
Caution!
53.2662.10 Page 4.3/4
Diagnosis / )! &
'
Caution!
53.2662.10 Page 4.3/5
Diagnosis / &KHFNLQJ&RQWURO6\VWHP
Troubleshooting

11
Notice 71
26 33 61
32
The reference numbers indicated in Section 4.4
the spare parts lists.
25
1 Heat exchanger
2 Control unit A
11 Proportional valve 31
current connection R 21
19 Cooling water temperature pick-up 34
21 Proportional valve 36 35
25 Constant-air presure line py
31 Compressed-air line (pressure
regulator - four-circuit protection
valve) 38
32 Compressed-air pressure line 19
(parking brake)
36 Ventilation line
38 Electrical lead (temperature pick-up
to control unit, 2 wires)
1
FD1619
cbtd 98-01
53.2662.10 Aftersales Service Manual Voith Retarder 115 H - Daimler Benz SK
Page 4.4/1
Diagnosis / )) &
' &

Check requirements
Special tools
101103105
99 107
97 111
95 113
93 115
o o
120 C 200 C
53.4377.10 53.4788.10
Pressure gauge
0 - 25 bar
53.2662.10 Page 4.4/2
Diagnosis / )) &
' &


valve - air tank for auxiliary equipment) and check supply-air pressure p v
Notice
32

1. Disconnect electrical lead (38) from the temperature pick-up (19) and connect it to 19
the temperature tester (99/4).
Notice
101103105
99 107
97 111
95 113
93 115
The temperature tester (99/4) is delivered with flat plugs. If the lead (38) is delivered with round plugs 38
make a plug converter by yourself.
o o
120 C 200 C
FD441
53.2662.10 Page 4.4/3
Diagnosis / )) &
' &

2909
2909
2910
FD 1147
99/1
2904
FD411
53.2662.10 Page 4.4/4
Diagnosis / )) &
' &

Job scope test

1. Set the rotary switch of the temperature tester (99/4) one step below the specified start of
temperature limit (e.g. to 95°C for a specified start of temperature limit at 96°C) and operate the
retarder at the highest stage.
The constant-air pressure py must reach the values given in Section 4.3 .
2. Set the rotary switch of the temperature tester (99/4) two steps above the specified start of
temperature limit (e.g. to 98°C for a specified start of temperature limit at 96°C).
If the start of temperature limit is exceeded by approx. 10°C, no more constant-air pressure py
must be provided.
Notice
If the temperature limitation does not work properly, the control unit or the electrical lead are may be
defectively
3. Connect electrical lead (38) with temperature pick-up (19).
4. Disconnect temperature tester (99/1).

Screw oil filler plug (2909) tight with new sealing ring (2910). Tightening torque 150 Nm
38
19
FD440
53.2662.10 Page 4.4/5
Diagnosis / )) &
' &

Illustration cheking cooling water

temperature pick-up
19 Temperature pick-up, 32 Nm
38 Electrical lead 38
19
FD448
53.2662.10 Page 4.4/6
Diagnosis / )) &
' &

Job scope test

1. Disconnect electrical lead (38) at temperature pick-up (19).
2. The measurements for resistance have to be done as shown on the following table:
Temperatur of cooling water Value of resistance

(Setpoint) 38
20°C 500 . . . 700 Ohm 19
60°C 134 ± 13 Ohm
90°C 52 ± 4 Ohm FD440
100°C 38,5 ± 3,5 Ohm
Notice
Renew the temperature pick-up, if setpoints are not reached.
53.2662.10 Page 4.4/7
Diagnosis / )) &
' &

Illustration checking proportional valve
current connection
25 Constant-air presure line py 25 36
31 Compressed-air line (pressure
regulator - four-circuit protection A R
valve) 21
33
(brake circuit No. 1) 11 71
34 Compressed-air line 26 32 61
(parking brake)
36 Ventilation line
31
35
34
FD434
53.2662.10 Page 4.4/8
Diagnosis / )) &
' &

Special tool
53.4788.10
Presure gauge
0 - 25 bar
53.2662.10 Page 4.4/9
Diagnosis / )) &
' &


Notice
32
Checking supply-air pressure py and current proportional valve

11
1. Disconnect plug (arrow) at proportional valve (21). Connect multimeter with pin of current
proportional valve (11) at the proportional valve and at the plug.
A
21
FD225
53.2662.10 Page 4.4/10
Diagnosis / )) &
' &

2909
2909
2910
FD 1147
99/1
4. The measurements of the current and constant-air pressure must reach the values given on the
table on the next page.
2904
5. Disconnect the pressure gauge.
FD1151
53.2662.10 Page 4.4/11
Diagnosis / )) &
' &

Retarder stage switch Control current Constant-air

position [mA]*) pressure py [bar]1)
5 322 - 328 2,65 - 3,05
1) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
* If a commercially available multimeter is used for measurements (without real effective measuring),
Notice
The data represent the state of the art at the time going to print. The manufacturer reserves the right
Hinweise
53.2662.10 Page 4.4/12
Diagnosis / )) &
' &

Illustration checking retarder stage switch
Notice
The numbers of the plugs indicated in this

section are not identical with the reference
numbers of the electrical connections diagram 2
and the reference numbers of the spare parts 16 4
6
lists.
2 4 6
1 Pin 1
(retarder stage switch position 4)
2 Pin 2 1 3 5
3 Pin 3
4 Pin 4
5 Pin 5
(engine brake or constant throttle)
6 Pin 6 (voltage supply)
Commercially available tool FD444
53.2662.10 Page 4.4/13
Diagnosis / )) &
' &

Job scope
1. Pin diagram socket retarder stage switch:
2 4 6
1 Retarder brake stage 4
5 Engine brake or constant throttle
6 Voltage supply
2. Take the measurements of resistance at the retarder stage switch by following the table below.
No contact should be between all no named pins.
1 3 5
FD445
Position at Contact exclusively
retarder stage switch
from pin to pin
0 - -
1 6 5
2 6 4, 5
3 6 3, 4, 5
4 6 2, 3, 4, 5,
5 6 1, 2, 3, 4, 5
53.2662.10 Page 4.4/14
Diagnosis / )) &
' &

Illustration checking control unit

14 12 10 8 6 4 2
1 Ground control unit
2 Power supply control unit
3 Output relay for engine brake or
constant throttle
alternative: output relay for
stop light
4 Output retarder pilot light 13 11 9 7 5 3 1
5 Input retarder stage switch
(setpoint)
6 Output retarder stage switch
brake stage 4
brake stage 3
brake stage 2
brake stage 1
„engine brake or constant throttle“
11 Output temperature pick-up
(signal)
12 Input temperature pick-up (ground)
13 Output proportional valve
(current proportional valve)
14 Input proportional valve
(current proportional valve)
FD113
53.2662.10 Page 4.4/15
Diagnosis / )) &
' &

Troubleshooting (Fortsetzung)
Special tool
101103105
99 107
97 111
95 113
93 115
o o
120 C 200 C
53.4377.10
53.2662.10 Page 4.4/16
Diagnosis / )) &
' &

Checking power supply control unit

• Ignition ON
1. The measurements for voltage are taken at input power supply control unit (PIN 2).
Colour of cable: black/blue/yellow
Requirements for measurement:

• No cut-off of power supply by idle speed switch or ABS-switch off
Setpoint: U = 24 V + 8 / - 4 V
Checking output relay engine brake or constant throttle

alternative: output relay stop light
1. The measurements for voltage are taken at output relay engine brake or constant throttle
(PIN 3). Colour of cable: brown/black
Measurement 1: PIN 3 V PIN 2

Requirements:
Setpoint: U = 23 + 8 / - 4 V

Requirements:
• Retarder stage switch in position 1 - 5
Setpoint: U = 1 . . . 4 V
53.2662.10 Page 4.4/17
Diagnosis / )) &
' &

Checking output retarder pilot light

1. The measurements for voltage are taken at output retarder pilot light (PIN 4).
Colour of cable: grey/yellow/white

Requirements:
Setpoint: U = 23 + 8 / - 4 V

Requirements:
• Retarder stage switch in position 1 - 5
Setpoint: U = 1 . . . 4 V
Checking output retarder stage switch

1. The measurements for voltage are taken at outputs retarder stage switch (PIN 6 - 10).
Colour of cable:
PIN 6: green V PIN 1
PIN 7: yellow V PIN 1
PIN 8: white V PIN 1
PIN 9: black/green/red V PIN 1
PIN 10: pink V PIN 1
Requirements:
Setpoint: U = 15 V ± 0,3 V
53.2662.10 Page 4.4/18
Diagnosis / )) &
' &

Checking input retarder stage switch

1. The measurements for voltage are taken at input retarder stage switch (PIN 5).
Colour of cable: black/red/white
PIN 5 V PIN 1
Measurement Position of Setpoint of voltage

1 0 U=0V
2 1 U = approx. 2,0 V
3 2 U = approx. 5,5 V
4 3 U = approx. 7,2 V
5 4 U = approx. 8,5 V
6 5 U = approx. 10,0 V
Notice
The data represent the state of the art at the time going to print. The manufacturer reserves the right to
make further modifications.
53.2662.10 Page 4.4/19
Diagnosis / )) &
' &

Checking output temperature pick-up

1. Disconnect the electrical lead (38) of the temperature pick-up (19) and connect these to the
temperature tester (99/4).
2. Set values of temperature given in table below on temperature tester (99/4).
3. The measurements for voltage are taken at output temperature pick-up (PIN 11).
Colour of cable: yellow/white
PIN 11 V PIN 1
Measurement Value taken from Setpoint of voltage

temperature pick-up
1 T = - 15 °C U = ca. 12,5 V
2 T = + 20 °C U = ca. 8,5 V
3 T = + 60 °C U = ca. 3,0 V
4 T = + 90 °C U = 1,4 V
5 T = + 100 °C U = 1,07 V
6 T = + 110 °C U = 0,84 V
53.2662.10 Page 4.4/20
Diagnosis / ),
&
Troubleshooting


FD844

switch positions.

1 on moving off

53.2662.10 Page 4.5/1
Diagnosis / ),
&
Action
position 1 to 5 position 1 to 5
Retarder pilot light does not

come on, and/or insufficient Troubleshooting as on
braking of the retarder Troubleshooting diagram
(see page 4.1/1)
53.2662.10 Page 4.5/2
Retarder Remo-, , "
'- .

' "
ving, Installing
cbtd 98-01
53.2662.10 Page 5/1
Retarder Remo-, , "
'- .

' "
ving, Installing

Notice
96 97
One of the mill-cut sides of the prop-shaft 700
must show in direction of the retarder
housing.
25
25 Supply-air pressure line p y

36 Ventilation line
92/1 Collar screw with rib toothing
(M 14 x 40), 200 - 240 Nm
200 - 240 Nm
96 Hose clamp
97 Hose-connection 36
700 O-ring (164 x 3), renew, Re
ITH
VOtarder
Nr
.
19
93
95/1
br.

Fa
r
ah 0
0.0
H urj
15 Ba
p R1 0
Ty
.00 .00
i Re
f. =
00 000
.0
00
for installation
92/1
FD1056
cbtd 98-01
53.2662.10 Page 5.1/1
Retarder Remo-, , "
'- .

' "
O-ring silicone-free and

Caution!
Observe VOITH Installation Instructions! These have to be requested from VOITH TURBO.
The cooling water is heated up (water temperature)!
To remove, install
of heat exchanger.
2. Disconnect the supply-air pressure line (26) and ventilation line (36).
53.2662.10 Page 5.1/2
Retarder Remo-, , "
'- .

' "
4. Unscrew collar nuts (95/1) and collar screws (92/1).

95/1
Apply coat of collar screws (92/1) with sealant Omnifit. 700


FD1057
53.2662.10 Page 5.1/3
Repair / "

53.2662.10 Page 6/1
Repair $VVHPEO\2YHUYLHZ
Illustration assembly overview version „A“

4100 2700 2400 2800 2905
2800 2909
3600
2910
2904
2400 2910
2500 3000 2909
2906
2000 2900
3500
2600
3000
2300/1 5300
3200
3800 5400
2301 3100
2300
3600
3000
2300/2
3000
2300/3
2000 3700
3900
4000 3200
111 3100 3600
112 5200
3200
107 2915 3300

2924
108 3400
2923
2912
2911
2913
4800
2921 2914
4700 2922
2918 2920
2919
FD1577
107 Disc (Silencer) 2918 Sealing ring (A 20 x 26)

108 Circlip (JL 30 x 1,2) 2919 Central oil-drain plug
112 Screw plug (M 12 x 1,5) 2921 O-ring (6 x 3)
2300 Casing ventilation 2923 Oil check plug (M 24 x 1,5)
2300/1 Valve insert 2924 Sealing ring (A 24 x 29)
2300/2 Float 3000 O-ring (15 x 4)
2300/3 Float cage 3100 O-ring (40 x 5)
2301 O-ring (55 x 3) 3200 Spacer (D 24 / 14,5 x 3)
2400 Cover casing ventilation 3300 Heat exchanger
2500 Sealing 3400 Distributor
2600 Spacer (D 60 / 41 x 2) 3500 Anti-fatigue screw (M 14 x 65)
2800 Hex.-head screw (M 8 x 30) 3700 Adapter plate (131 x 70 x 40)
2900 Oil tank 3800 O-ring (15 x 4)
2904 Upper cover 3900 Hex.-head screw (M 8 x 60)
2905 Hex.-head screw (M 8 x 40) 4000 O-ring (7 x 2,5)
2906 Upper gasket 4100 Hex.-head screw (M 8 x 65)
2909 Oil filling screw (M 30 x 1,5) 4700 Screw plug with sieve
2910 Sealing ring (A 30 x 36) 4800 Sealing ring (A 30 x 36)
2911 Lower cover 5200 Spacer (31 / 31 x 4 D 14,5)
2912 Lower gasket 5300 Screw plug (M 22 x ,5)
2915 O-ring (7 x 2,5)
53.2662.10 Page 6.1/1
Repair $VVHPEO\2YHUYLHZ
(Continue)
Illustration assembly overview version „C“

4100 2700
2905
2800 3600 2909
2910
2904
2400 2910
2500 3000 2909
2906
2000 2900
2600 3500
3000
2300/1 5300
3800 5400
2301 3100
2300
3600
2300/2 3000
3000
2300/3
3700
2000 3900
4000
111 3100 3600
112 5200
2915 3300
7000 2924
3400
7100 2923 2912
2911
2913
4800
2921 2914
4700 2922
2918 2920
2919
FD1576
2000 O-ring (60 x 5) 2920 O-ring (10 x 3)

2300 Casing Ventilation (D 30 x 38) 2921 O-ring (6 x 3)
2300/1 Valve insert 2922 Hex.-head screw (M 8 x 20)
2300/2 Float 2923 Screw plug (M 24 x 1,5)
2300/3 Float cage 2924 Sealing ring (A 24 x 29)
2301 O-ring (55 x 3) 3000 O-ring (15 x 4)
2400 Cover casing ventilation 3100 O-ring (40 x 5)
2500 Sealing 3300 Heat exchanger
2600 Spacer (D 60 / 41 x 2) 3400 Distributor
2900 Oil tank 3700 Adapter plate (131 x 70 x 40)
2904 Upper cover 3800 O-ring (15 x 4)
2905 Hex.-head screw (M 8 x 40) 3900 Hex.-head screw (M 8 x 60)
2906 Upper gasket 4000 O-ring (7 x 2,5)
2909 Oil filling screw (M 30 x 1,5) 4100 Hex.-head screw (M 8 x 65)
2910 Sealing ring (A 30 x 36) 4700 Screw plug with sieve
2911 Lower cover 4800 Sealing ring (A 30 x 36)
2912 Lower gasket 5200 Spacer (31 / 31 x 4 D 14,5)
2913 Hex.-head screw (M 8 x 25) 5300 Screw plug (M 22 x ,5)
2915 O-ring (7 x 2,5) 7000 Disc (Silencer) (D 30 x 4)
2918 Sealing ring (A 20 x 26) 7100 Circlip (JL 30 x 1,2)
53.2662.10 Page 6.1/2
Repair / "
'- &
'
.

'
&
' 0

Notice
This step can be performed with the retarder removed or in situ.

to approx. 80°C.

• Ignition OFF
53.2662.10 Page 6.2/1
Repair / "
'- &
'
.

'
&
' 0

(Continue)
2300/1 Valve insert
2700
2300/2 Float
specified weight 11 g ± 1 g 2800 2300/1
2300/3 Float cage
2301 O-ring (55 x 3), renew, 2700
coat of silicone-free and non- 2301
2400 Casing ventilation cover 2800 4100 2300/2 2300
2500 Sealing, renew
2600 Spacer (D 60 / 41 x 2) 2400
2300/3
renew, 25 Nm
renew, 25 Nm
4100 Hex.-head screw (M 8 x 65), 2400
renew, 25 Nm
2500
Notice
It can be used a casing ventilation cover with

step or without step.
2600

non-corrosive grease FD1149
cbtd 98-01
53.2662.10
Page 6.2/2
Repair / "
'- &
'
.

'
&
' 0

(Continue)
Special tools
53.7712.10 53.9428.10
To remove
1. Screw out hex.-head screws (2800, 2700 und 4100).
Notice
If the casing ventilation cover without a step is used, only hex.-head screws with two different lenghtes
are used.
53.2662.10 Page 6.2/3
Repair / "
'- &
'
.

'
&
' 0

(Continue)
5. Take float (2300/2) and float cage (2300/3) out of the retarder housing. 99/5
98/9
FD331
99/5 Impact tool 53.7712.10

98/9 Adapter 53.9428.10
2300/1
2301
FD1164
cbtd 98-01
53.2662.10
Page 6.2/4
Repair / "
'- &
'
.

'
&
' 0

(Continue)
To check

2300/2
Specified weight 11g ± 1 Gramm. If the weight is more than the specified weight, renew the
Notice
FD1165
2300/2
2300/1
FD1166
cbtd 98-01
53.2662.10
Page 6.2/5
Repair / "
'- &
'
.

'
&
' 0

(Continue)
To install
to the valve insert (2300/1). 99/5

98/9
FD1153
99/5 Impact tool 53.7712.10

98/9 Adapter 53.9428.10
is at the top.
2600
2300
FD334
cbtd 98-01
53.2662.10
Page 6.2/6
Repair / "
'- &
'
.

'
&
' 0

(Continue)
Notice
• If the casing ventilation cover without a step is used only hex.-head screws with two different
lenghtes are used.
• Check cover sheet metal plate in the cover for correct fit or fix it with two
additional welded joint (see arrows).
FD1647
FD1628
53.2662.10 Page 6.2/7
Repair /! "
'- &

'
.

'

Notice
107/7000

108/7100
107/7000 Disc (Silencer) (D 30 x 4), clean

with compressed air
108/7100 Circlip (JL 30 x 1,2),
Cleaning agents
Silencer Benzine
FD335
cbtd 98-01
53.2662.10
Page 6.3/1
Repair 5HPRYLQJ&KHFNLQJDQG,QVWDOOLQJ
+HDW([FKDQJHU
3000
3000
3200
3800
3700 98/2
5200
36
3100
3000
3600
3600
4000 3900 25
3200
2900
3300
2921 3200 3400
2920
3100
2918
2919
FD421

• Ignition OFF
25 Constant-air pressure line py 3200 Washer (alternative)

36 Ventilation line 3300 Heat exchanger
98/2 Sealing ring, renew 3400 Distributor
2900 Oil tank 3600 Anti-fatigue screw (M 14 x 150)
2918 Sealing ring (A 20 x 26), renew Initial torque: 50 Nm,
2919 Central oil-drain plug, 55 Nm Final turn: 90° turn
2920 O-ring (10 x 3), renew, coat with silicone-free and 3700 Adapter plate (131 x 70 x 40)
non-corrisive grease for installation 3800 O-ring (15 x 4), renew, coat with silicone-free and
2921 O-ring (6 x 3), renew, coat with silicone-free and non-corrisive grease for installation
non-corrisive grease for installation 3900 Hex.-head screw (M 8 x 60), 25 Nm
3000 O-ring (15 x 4), renew, coat with silicone-free and 4000 O-ring (7 x 2,5), renew, coat with silicone-free and
non-corrisive grease for installation non-corrisive grease for installation
3100 O-ring (40 x 5), renew, coat with silicone-free and 5200 Disc (31 / 31 x 4 D 14,5)
non-corrisive grease for installation
Lubrication

53.2662.10 Page 6.4/1
Repair /) "
'- &
'
.

'
1 23
' (Continue)
Special Tool
53.7711.10

Post box 10 08 67
D-42659 Solingen
Tel. 0212/ 888-0
cbtd 98-01
53.2662.10
Page 6.4/2
Repair /) "
'- &
'
.

'
1 23
' (Continue)
Notice
If this job sequence is performed with the retarder in situ, the following prior jobs must be performed:
3300
2918
2919
FD909
2. Disconnect constant-air pressure line (25) and ventilation line (36).
25
36 FD397
cbtd 98-01
53.2662.10
Page 6.4/3
Repair /) "
'- &
'
.

'
1 23
' (Continue)
To remove
3600
3300
3600
3600
FD999
4. Remove O-rings (3000, 3100 und 4000), and if necessary the discs (3200).
3000 3200
4000
3200
3200 3100
FD341
cbtd 98-01
53.2662.10
Page 6.4/4
Repair /) "
'- &
'
.

'
1 23
' (Continue)
To check
99/6
1. Fit pressure-test equipment (99/6) together with O-rings to heat exchanger (3300).
Notice
FD436
Notice
99/6 3300
FD097
cbtd 98-01
53.2662.10
Page 6.4/5
Repair /) "
'- &
'
.

'
1 23
' (Continue)
Remove distributor (3400) from defective heat exchanger and install in new heat exchanger. 3300
3400
Notice
To install
1. Fit new O-rings (3000, 3100 und 4000) and, if mounted, discs (3200) in the drilled holes. FD098
Final tightening: 90° turn
Caution!
Final tightening: 40° Drehwinkel
cbtd 98-01
53.2662.10
Page 6.4/6
Repair /) "
'- &
'
.

'
1 23
' (Continue)
3. Coat new O-rings with silicone-free and non-corrosive grease and insert these into the
adapter plate (3700). 3700
4. Screw four hex.-head screws (3900) tight. Tightening torque 30 Nm

3900
Notice
from the manufacturer or VOITH TURBO. FD399
7. Connect the constant-air pressure line and the ventilation line.
cbtd 98-01
53.2662.10
Page 6.4/7
Repair /) "
'- &
'
.

'
1 23
' (Continue)
Caution!
2921
2920
5. Flush the retarder, if the heat exchanger leaked: 2918
times to flush out the retarder system and drain the oil through the central oil-drain plug (2919). 2919
FD344
Coat new O-rings (2918 und 2920) with silicone-free and non-corrosive grease and fit them on to
Fill in retarder oil (see Section 3.2).
53.2662.10 Page 6.4/8
Repair /, "
'
.

' +
&

Upper oil tank cover 2905
2904
Notice

removed or installed. 2906
in the area of the hex.-head screws 2900
(2800, 2700, 4100) to approx. 80°C.
2900 Oil tank

2904 Cover
Final turn: 25 Nm
2906 Gasket, renew
FD1132
cbtd 98-01
53.2662.10
Page 6.5/1
Repair /, "
'
.

' +
&
(Continue)
7 5 2 4 10
FD1004
cbtd 98-01
53.2662.10
Page 6.5/2
Repair /, "
'
.

' +
&
(Continue)

• Retarder OFF
• Ignition OFF
Notice
to approx. 80°C.
53.2662.10 Page 6.5/3
Repair /, "
'
.

' +
&
(Continue)

2900
2900 Oil tank

2911 Cover
Final turn: 25 Nm
Final turn: 25 Nm
2915 O-ring (7 x 2,5), renew,
2915
Final torque: 25 Nm
Lubricants
2914
2913
FD361
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53.2662.10
Page 6.5/4
Repair /, "
'
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' +
&
(Continue)
7 5 2 4 10
FD1005
cbtd 98-01
53.2662.10
Page 6.5/5
Repair // "
'
.

' +


• Heat exchanger removed 3000
(see Section 6.4)
2000 O-ring (60 x 5), renew,

2900 Oil tank
3000 O-ring (15 x 4), renew, 2900
3500 Anti-fatigue screw (M 14 x 65), 2000
heat exchanger
3000 2000
Notice
When a check valve (outlet) with torque

limitation valve is installed (alternatively), the FD1139
cylinder at the check valve (arrow) must show

downwards.
cbtd 98-01
53.2662.10
Page 6.6/1
Repair // "
'
.

' +

(Continue)
2900

Post box 10 08 67
D-42659 Solingen
Tel. 0212/ 888-0
To remove 3500
FD1007
1. Screw out anti-fatigue screws (3500) and remove oil tank (2900).
Notice
cbtd 98-01 Aftersales Service Manual Retarder 115 H - Daimler Benz SK

53.2662.10 Page 6.6/2
Repair // "
'
.

' +

(Continue)
To install 3000
2000
3000
FD367
Notice 2900
3. Once the heat exchanger has been installed, screw the anti-fatigue screws (3500) tight
3500

FD1008
53.2662.10 Page 6.6/3
Control Parts 4 &

7.1 Control Parts ..............................................................................................7.1/1
cbtd 98-01
53.2662.10 Page 7/1
Control Parts 4 &


• Discharge supply air 1400
1500
26 Constant-air pressure line p v

38 Electrical lead
98/1 Banjo bolt
98/2 Sealing ring, renew
1200 O-ring (15 x 4), renew, coat of
silicone-free and non-corrosive 1200
grease for installation
1400 Hex.-head screw
1500 O-ring (9 x 2), renew, coat of
silicone-free and non-corrosive 38 98/2
1600 Washer (B 8,4)
1700 Hex.-head screw (M 8), renew, 1100
18 Nm
1600
1700
Lubricants
98/2
non-corrosive grease 98/1
FD1163
cbtd 98-01
53.2662.10
Page 7.1/1
Control Parts 4 &

(Continue)

38
19
19 Temperature pick-up, 32 Nm
38 Electrical lead
Notice
Pay attention to the instructions regarding the

quality of the cooling-water given from the
FD448
cbtd 98-01
53.2662.10
Page 7.1/2
Annex 5
3
Data Sheet
Spare Parts Lists
Other Information
cbtd 98-01
53.2662.10 Page 8/1
Data Sheet VOITH Retarder 115 H Daimler-Benz SK
Max. braking torque at prop shaft M(Br) max 3200 Nm
Max. retarder speed (= max. prop shaft speed) v(max.) 4870 r.p.m. at vps= 2400 r.p.m.

Service filling:
- Service filling (Oil change, checking oil level) 5,4 Liter
- After renewal of heat exchanger 5,6 Liter
- After complete taking apart and cleaning

as well as emptied heat exchanger (corresponds new filling) 6,0 Liter
* The overall weight can differ depending on the retarder version
Service-Handbuch VOITH Retarder 115 H - Daimler Benz SK

Seite 8/2
Miscellaneous Conversions Retarder 115 H Daimler Benz SK
D GB USA D GB USA
-15 oC 5 oF 5 oF 32 Nm 24 lbf-ft 24 lbf-ft
120 oC 248 oF 248 oF 19 bar 275,5 psi 275,5 psi
14 - 19 Nm 10,36 - 14,06 lbf-ft 10,36 - 14,06 lbf-ft 11 g ± 1 g 0,38 ± 0,035 oz 0,38 ± 0,035 oz
18 Nm 13,32 lbf-ft 13,32 lbf-ft 5,4 l 1,188 UK gal 1,426 US gal

VOITH TURBO
Powertransmission
VOITH Retarder
1. Water
2.1 Normal case

*see chapter 4


**see chapter 5
Attention:
agent!

***see chapter 6
Attention:

3. Miscellaneous
3.1 Disposal
3.2 Safety

Attention:




Attention:



Attention:

Attention:


Attention:


Attention:




Attention:


Attention:

Attention:



Attention:


Training $IWHUVDOHV˜6HUYLFH˜0DQXDO
92,7+˜5HWDUGHU˜−ž˜/RJRSURS
cbtd 98-01
53.2658.10
92,7+5HWDUGHUZLWK'LJLSURS&RQWURO
cbtd 98-01
53.2659.10
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
3.2 Oil Change .......................................................................................3.2/1
With Stainless-Steel Heat Exchanger ....................................................3.2/1
With Aluminium Heat Exchanger ..........................................................3.2/5
3.4 Cleaning Line Filter (Optional extra) ......................................................3.4/1
Elektrical Connections Diagram ...........................................................4.1/2

5.1 Removing, Installing Retarder (Free Mount Installation)............................5.1/1
5.2 Removing, Installing Retarder (Gearbox Attachment) ...............................5.2/1
cbtd 98-01
53.2659.10 Aftersales Service Manual VOITH Retarder 120 Digiprop
Page IHV/1
(Continue)
6. Retarder Basic Group Repair (Gearbox Attachment)..............................6/1

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
6.6 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),
7. Retarder Basic Group Repair (Free Mount Installation) ..........................7/1

7.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation) .......7.3/1
(Stainless-Steel Heat Exchanger) .........................................................7.4/1
cbtd 98-01
Page IHV/2
(Continue)

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 Ring (Output Side),
Renewing Radial Shaft Sealing Ring ...................................................7.10/1
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
Spare Parts Lists
Other Information
cbtd 98-01
Page IHV/3
Preface
appropriate and professional maintenance and repair at the VOITH Retarder 120 with Digiprop control.
Caution!
Notice
cbtd 98-01
Page 1/1
Preface
(Continue)
Caution!
Notice
• Serial-Number
• Code-Number
Notice
cbtd 98-01
Page 1/2
Preface
(Continue)
Caution!
Notice
professionally.
Notice
Notice
cbtd 98-01
Page 1/3
Preface
(Continue)
damage incurred.
prior notification.

D-74564 Crailsheim

Telefax (07951) 32-756
Extensions:
32-401 / 32-422
cbtd 98-01
Page 1/4
General


With Stainless-Steel Heat Exchanger .................................................................2.1/1
With Aluminium Heat Exchanger .......................................................................2.1/3
2.3 Retarder Data.............................................................................................2.3/1
cbtd 98-01
Page 2/1
General
Illustration VOITH Retarder R 120

with Digiprop control system 100/3
basic group with stainless-steel
heat exchanger
100/1 Retarder data

100/2 Constant-air pressure
connection py „A“
100/3 Ventilation connection „R“ 100/2
1000 Heat exchanger
1900 Oil filler/check plug (M 30 x 1,5)
100/1
1900
1000
FD1183
cbtd 98-01
Page 2.1/1
General
(Continue)

with Digiprop control system
heat exchanger
(Continue)
1000 Heat exchanger

1000/1 Leakage oil drain plug
(M 14 x 1,5)
1000/5 Cooling water drain plug 1700
(M 18 x 1,5)
1700 Retarder oil drain plug
(M 22 x 1,5)
1000/1
1000/5
1000
FD1184
cbtd 98-01
Page 2.1/2
General
(Continue)

with Digiprop control system 100/3
basic group with aluminium heat exchanger
100/1 Retarder data

100/3 Ventilation connection „R“
1000 Heat exchanger
1000/5 Cooling water drain plug 100/2
(M 12 x 1,5)
1900
100/1
1000
1000/5
FD1653
cbtd 98-01
Page 2.1/3
General
(Continue)

with Digiprop control system
(Continue)
1000 Heat exchanger

(M 10 x 1)
1000/3 Heat exchanger oil drain plug
(M 12 x 1,5)
(M 12 x 1,5)
(M 22 x 1,5)
1000/3 1000/1
1000/5
1000
FD1416
cbtd 98-01
Page 2.1/4
General
Illustration of VOITH Retarder 120 with Digiprop control system
25
21 A R
44 12 50 67
16 4 5 8 69
46 P
26 37
7
23
52
20
2
19
45
18 4 7 17 15 47 70
53 43 56 66 1

FD1278
Notice
1 Heat exchanger 43 Oil sump

2 Control unit 44 Stator
4 Connection terminal 15 45 Stator pin
5 Connection terminal 30 46 Rotor
7 Fuses (5A) 47 Speedometer signal
8 Connection ground 50 Output restrictor D1
12 Pump pressure test connection 52 Filling restrictor D2
15 ABS-Signal 53 Filling duct
16 Retarder stage switch 56 Leakage oil return line
17 Retarder pilot light 66 Check valve
18 Stop light relay (stainless-steel heat exchanger)
19 Temperature pick-up cooling water 67 Check valve
20 Oil temperature pick-up (casing ventilation cover)
21 Proportional valve 69 ISO interface plug
23 Casing ventilation 70 Extra operations plug
25 Constant-air pressure line py „A“
26 Supply-air pressure line pv „P“
37 Ventilation line „ R“
cbtd 98-01
Aftersales Service Manual VOITH Retarder 120 Digiprop
53.2659.10
Page 2.2/1
General

(Continue)

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
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.
The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limit
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.
cbtd 98-01
cbtd 98-01
53.2640.10 Page 2.2/2
General

(Continue)
Description of operation of retarder R 120 with digiprop control system

c
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. 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.
FD299
The control medium for the Voith Retarder 120 is compressed air, which is taken from the air tank for
auxiliary equipment on the vehicle. The hydrodynamic principle
a Rotor (46)
When the retarder stage switch (16) is operated, an input signal is fed to the control unit (2). b Stator (44)
From this input signal, the control unit (2) provides a control current which flows to the c Oil flow
The constant-air pressure py 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).
cbtd 98-01
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53.2640.10 Page 2.2/3
General

(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
cbtd 98-01
cbtd 98-01
53.2640.10 Page 2.2/4
General

(Continue)

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).
oil temperature.
cbtd 98-01
cbtd 98-01
53.2640.10 Page 2.2/5
General

(Continue)

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.
cbtd 98-01
cbtd 98-01
53.2640.10 Page 2.2/6
General
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 FD1181
cbtd 98-01
Page 2.3/1
Maintenance !

3.2 Oil Change .................................................................................................3.2/1

Stainless-steel Heat Exchanger ........................................................................3.2/1
Aluminium Heat Exchanger ..............................................................................3.2/5
3.4 Cleaning Line Filter (Optional Extra) ..........................................................3.4/1
cbtd 98-01
Page 3/1
Maintenance !

"#
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
cbtd 98-01
Page 3.1/1
Maintenance $
%
Illustration oil change R 120

with stainless-steel heat exchanger
1900 1000/6 1000/5
(M 10 x 1), 13 Nm
1000/2 Sealing ring (A 10 x 13,5), renew
1000/5 Cooling water drain plug
(M12 x 1,5), 25 Nm
1000/6 Sealing ring (A12 x 18), renew
1800
1700 Retarder oil drain plug 1000/2
(M 22 x 1,5), 66 Nm
1000/1
1900 Oil filler/check plug
(M 30 x 1,5), 150 Nm 1600
1700
FD1189
cbtd 98-01
Page 3.2/1
Maintenance $
%
(Continue)
Notice
(see table below) and to use only oils specified in the operating specifications (see Annex) for
Heat exchanger Service filling After complete After exchange of

taking apart and heat exchanger
cleaning, as well as
emptied heat
exchanger
Stainless-steel
heat exchanger 4,5 l 5,8 l 6,5 l
(L+R)
The retarder oil temperature must be higher than 60 oC (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!
cbtd 98-01
Page 3.2/2
Maintenance $
%
(Continue)
Job scope
1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and
Switch off the retarder and ignition and wait 5 minutes (control function).
The oil filler/check plug is heated up (oil temperature)!
The retarder oil drain plug is heated up (oil temperature)!
4. Screw out the retarder oil drain plug (1700) and remove sealing ring (1600) and drain oil.
cbtd 98-01
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53.2640.10 Page 3.2/3
Maintenance $
%
(Continue)
5. 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): Tightening torque 66 Nm

Leakage oil drain plug (1000/1): Tightening torque 13 Nm
7. Fill in slowly, in the hole of the oil filler/check plug (1900), the quantity of oil specified
(see page 3.2/2) in accordance with the operating specifications (see Annex).
8. Screw the oil filler/check plug (1900) tight with a new sealing ring (1800). Tightening torque: 150 Nm
cbtd 98-01
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53.2640.10 Page 3.2/4
Maintenance $
%
(Continue)

with aluminium heat exchanger
1000/1 Leakage oil drain plug 1900

(M 10 x 1), 13 Nm
1000/3 Heat exchanger oil drain plug 1000/4
(M 12 x 1,5), 25 Nm 1000/3
1700 Retarder oil drain plug 1800
(M 22 x 1,5), 66 Nm 1000/2
1900 Oil filler/check plug 1000/1
(M 30 x 1,5), 150 Nm 1600
1700
FD1661
cbtd 98-01
Page 3.2/5
Maintenance $
%
(Continue)
Notice
Heat exchanger Service filling New filling

Aluminium heat exchanger (AKG) 5,5 l 6,0 l
to be drained.
Caution!
cbtd 98-01
Page 3.2/6
Maintenance $
%
(Continue)
Job scope
3. Screw out the oil filler/check plug (1900) and remove sealing ring (1800).
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.
cbtd 98-01
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53.2640.10 Page 3.2/7
Maintenance $
%
(Continue)
Notice
(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).

Heat exchanger oil drain plug (1000/3): Tightening torque 25 Nm
cbtd 98-01
cbtd 98-01
53.2640.10 Page 3.2/8
Maintenance $#
% &

1900
Notice
The oil change intervals and operating

specifications have to be taken from the annex.
1800
1900 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.
FD1186
cbtd 98-01
Page 3.3/1
Maintenance $#
% &
(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).
cbtd 98-01
cbtd 98-01
53.2640.10 Page 3.3/2
Maintenance $#
% &
(Continue)
Notice
Difference between min. and max. mark on oil filler/check plug is approx. 0,5 l.
Job scope
Caution!
been switched off!
Risk of injury exists at nonobservance, by hot leaving oil when screw out oil filler/check plug!
The oil filler/check plug (1900) is heated up (oil temperature)!
Wipe off oil of the oil filler/check plug.
cbtd 98-01
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53.2640.10 Page 3.3/3
Maintenance $#
% &
(Continue)
4. Position oil filler/check plug (1900) plane at the thread.

Do not screw in the oil filler/check plug!
1900
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.
Max
6. Top up slowly any lacking oil through the hole for the oil filler/check plug.
Min
7. Screw the oil filler/check plug (1900) tight with new sealing ring (1800). Tightening torque 150 Nm
FD011
cbtd 98-01
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53.2640.10 Page 3.3/4
Maintenance '

% &

(Optional Extra)
Illustration line filter
12000 Complete line filter

12000/1 Pressure spring 12000/1
12000/2 Intermediate plate
12000/3 Cover
12000/4 Holding plate 12000/6
12000/5 Pressure spring
12000/6 Filter housing 12111
12111 Filter insert
12112 O-ring (36,2 x 3), renew,
coat with silicone-free and 12000/2
non-corossive grease
for installation 12000
12000/5
Lubricants

12000/3
12000/4
FD427
cbtd 98-01
Page 3.4/1
Maintenance '

% &

(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
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.
cbtd 98-01
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53.2640.10 Page 3.4/2
Maintenance '

% &

(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.
cbtd 98-01
cbtd 98-01
53.2640.10 Page 3.4/3
Diagnosis / ' %
( )$
%
Troubleshooting

cbtd 98-01
Page 4/1
Diagnosis /
Troubleshooting
Notice
Renew non-return Contact

valve VOITH
NOK OK
Check non-return
Renew casing valve in cover of
ventilation casing ventilation
(Chapter 6.3)
NOK OK
Correct oil level of
Check casing see chapter 6.4
retarder (*)
ventilation Check cooling system:
(Chapter 6.2) Check heat
exchanger -coolant level
-thermostat
NO YES YES NO -coolant pump
-radiator fan
Water in the oil? OK NOK Water in the oil? -radiator grill for
(emulsion) (emulsion) dirtiness
Check oil level of
retarder Retarder:
Check Temp.-Sens. Driver instruction!
(oil/water)
Oil leak by
ventilation
OK NOK
flashes Temperature limit!
Check operation
(by braking with
retarder nominal
engine speed,
if possible
If the retarder is Complaint
Empty chamber of
still leaking, or the return of leakage oil Oil leak input side Retarder pilot
chamber of
leakage oil is filled
(at heat exchanger) or output side R 120 light
(Chapter 3.3)
again with oil after Digiprop
1000 km,
renew radial shaft
seal
Activate flash code
Clear faults and
Permanent and read out
delete fault memory
lighting trouble code
(Chapter 4.2)
No respectively (Chapter 4.2)
too insufficient
retarder braking
effect
Check oil level of

retarder
NO YES YES NO
Check heat
exchanger
Check py (static)
(Chapterl 4.4) Correct oil level of
see chapter 6.4
retarder
OK NOK
Check p (dynamic)
(Kapitel 4.3)
OK NOK Check voltage of

proportional valve
(Chapter 4.4)
OK NOK
Contact Contact
VOITH VOITH
Check control unit
(Chapter 4.4)
OK NOK
Contact Contact
VOITH VOITH
Check compressed-
-air supply
(Chapter 4.4)
OK NOK
Check vehicle
Mechanical fault of
compressed-air * If you get oil leakage after a trail run again:
supply
proportional valve continue at ´Ćhecking casing ventilation´´
OK NOK
Contact Contact vehicle

VOITH manufacturer
FD 1601
cbtd 98-01
53.2659.10
Page 4.1/1
Diagnosis /
Electrical Diagram Version 1
Connecting plug 4 pins

"ISO Interface"
3 1 2 4
"Retarder Stage Switch"
Digiprop 3 CAN-high
2 CAN-Ground Lead E-Box
1 CAN-low
6 Position 1 pink 7 Position 1
5 Position 2 blue 6 Position 2
4 Position 3 orange 5 Position 3
9 Position 4 white
weiß 3 Position 4
8 Position 5 grey 2 Position 5
7 T 15 (Ignition lock) red 8 Retarder Stage Switch`+`
X1. red 4
12 ISO K blue/white
18pins 11 ISO L orange/white
10 Retarder Stage Switch`+` purple
purple
15 T 31 (Ground) brown T 15 (Ignition lock) +
14 brown T 31 (Ground)
13 T 30 (Battery) black T 30 (Battery) +
18 Output / high side 1 `HS 1` beige
17 Output / low side 1 `LS 1` yellow/green
16 Output / high side `HS 2` black/white
Lead Retarder
3 Prop valve `+` pink Pin 1 Prop valve `+`
2 Prop valve `-` grey 2 Prop valve `-`
1 Changeover valve `+` orange 3 Changeover valve `+`
4
X2. 6 Changeover valve `-` beige Changeover valve `-`
5 Water temp.`+` yellow/green Water temp.`+`
9pins Water temp.`-` blue Water temp.`-`
4
9 Oil temp.`+` purple Oil temp.`+`
8 Oil temp.`-` white Oil temp.`-`
7
3 ABS black/white ABS

2 Speedometer signal blue Speedometer signal
1 Input / pull-up `DIU 1` white
6 Input / pull-up `DIU 2` pink
5 Input / pull-down `DID 1` blue/white
4 Input / pull-down `DID 2` brown/white
X3. Input / pull-down `DID 3 ` orange/white
9
12pins 8 Retarder pilot light yellow/green Retarder pilot light +
7 Input / (m 0...5V ) ÌNA-U ` grey/black
12 Input / p.-down / PWM-in `DID 4 ` grey
grey
11 Stop light relay orange Stop light relay
10 Input / (0...20mA ) ÌNA-I ´ red/white
1 9 5 8 4 3 2 7 6 1112101314
Connecting plug 14 ins

"Additional Functions" FD1602
Electrical Diagram Version 2
"ISO Interface"
3 1 2 4
Digiprop 3 CAN-high
1 CAN-low
9 Position 4 white
weiß 3 Position 4
X1. red 4
12 ISO K blue/white
10 Retarder Stage Switch`+` purple
purple
Lead Retarder
4
X2. 6 Changeover valve `-` beige
Pin 1
Changeover valve `-`
9pins 5 Water temp.`+` yellow/green Water temp.`+`
4 Water temp.`-` blue 2 Water temp.`-`
9 Oil temp.`+` purple 3 Oil temp.`+`
8 Oil temp.`-` white 4 Oil temp.`-`
7

X3. Input / pull-down `DID 3 ` orange/white
9
grey
1 9 5 8 4 3 2 7 6 1112101314

cbtd 98-01
53.2659.10
Page 4.1/2
Diagnosis / ' )$
%

Troubleshooting
Check requirements
l For check with the multimeter, pin 15 (plug X1) on the control unit (2)
Notice
cbtd 98-01
Page 4.2/1
Diagnosis / ' )$
%

Notice
R
- slight fault
- serious fault
FD844
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.
cbtd 98-01
Page 4.2/2
Diagnosis / ' )$
%


1 Not in use
2 Not in use
3 Not in use
7 Terminal 15 (rd)
16 13 10 7 4 1
13 Terminal 30 (bl)
18 15 12 9 6 3
14 Not in use
15 Terminal 31 (br)
cbtd 98-01
Page 4.2/3
Diagnosis / ' )$
%


5 Cooling water temperature pick-up + (ye/gr) 7 4 1

7 Not in use
FD848

4 Input / pull down „DID 2“ (br/wh) 10 7 4 1
6 Input / pull up „DIU 2“ (pi) 11 8 5 2

12 9 6 3
12 Input / pull down / PWM-in „DID4“ (gr) / engine-speed signal FD847
cbtd 98-01
Page 4.2/4
Diagnosis / ' )$
%


12 Output / low side 1 „LS1“ (ye/gr) FD849
13 Terminal 15 (rd)
14 Terminal 31 (br)
ISO-Interface plug
1 K-lead (bl/wh)
2 K-lead (or/wh)
3 Terminal 15 (rd)
4 Terminal 31 (br) 4 3
2 1
FD854
cbtd 98-01
Page 4.2/5
Diagnosis / ' )$
%


FD851

4 2
3 Not operational (or)
4 Not operational (be) 1 3
FD850
cbtd 98-01
Page 4.2/6
Diagnosis / ' )$
%


1 Not in use
2 Position 5 - (gr)
3 Position 4 - (wh)
5 Position 3 - (or) 5 6 7 8
6 Position 2 - (bl)
1 2 3 4
7 Position 1 - (pi)
8 Bridge to pin 4
FD853
cbtd 98-01
Page 4.2/7
Diagnosis / ' )$
%

A. With fault code

Special tool
53.8224.10
Notice
cbtd 98-01
Page 4.2/8
Diagnosis / ' )$
%

R
Notice
Exception:
FD844
Requirements
- Retarder stage switch in position 0
- Vehicle in parking position, Ignition ON

Meaning
- long blinking signals (2 sec.) tens unit.
- short blinking signals (0,5 sec.) single unit.
cbtd 98-01
Page 4.2/9
Diagnosis / ' )$
%

cbtd 98-01
Page 4.2/10
Diagnosis / ' )$
%

Delete fault memory

1. Ignition: OFF
3. Ignition: ON
cbtd 98-01
Page 4.2/11
Diagnosis / ' )$
%

Notice

Table 1:
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
connection1)
Code (Check)
ground
for extra operation
(e.g. lamp or
relay)
- Ignition: ON
1)
2)
Only, if no fault is recognizable after a complete check of the periphery: change control unit.
cbtd 98-01
Page 4.2/12
Diagnosis / ' )$
%

Table 2:

Fault Operation
Code (Check)
- Ignition: ON

Overvoltage control unit (see manufacturer
- Start engine
(idle speed)
cbtd 98-01
Page 4.2/13
Diagnosis / ' )$
%

Table 3:

Fault Operation
tion
Code (Check)
09 ture sensor - Pull plug X2 out of 1039 - 1117W sensor
battery
80°C ± 10 °C =
1271 - 1347W
Notice:
The measuring in
one temperature
range
normally is
sufficient.
cbtd 98-01
Page 4.2/14
Diagnosis / ' )$
%

Table 4:

Fault Operation
tion
Code (Check)
12 sensor serious/ - Pull plug X2 out of 1039 - 1117W sensor
slight * control unit
Discontinuity / 60°C ± 10 °C =
battery
80°C ± 10 °C =
1271 - 1347W
Notice:
The measuring in
one temperature
range
normally is
sufficient.
cbtd 98-01
Page 4.2/15
Diagnosis / ' )$
%

Table 5:

Fault Operation
Code (Check)
Undefined switch: X 1/6 V X 1/15 0V
switch state Position 0 X 1/5 V X 1/15 0V
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

switch:
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 2
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V
cbtd 98-01
Page 4.2/16
Diagnosis / ' )$
%

Table 6:

Fault Operation
Code (Check)

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 3 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 4 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 ≥ 17,5 V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 5 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 ≥ 17,5 V
X 1/8 V X 1/15 ≥ 17,5 V
cbtd 98-01
Page 4.2/17
Diagnosis / ' )$
%

Table 7:

Fault Operation
Code (Check)
14 Retarder stage serious 10 s - Ignition: OFF X 1/10 V X 1/15 0V Check lead and plug
switch - Pull plug X1 out of
- Retarder stage
switch:
Position 0
15 Retarder stage serious 1s - Ignition: OFF X 1/10 W X 1/15 Resistor Single check of
switch - Pull plug X1 out of infinite stages for
battery - Retarder stage
switch:
Position 5
cbtd 98-01
Page 4.2/18
Diagnosis / ' )$
%

Table 8:

Fault Operation
tion
Code (Check)
16 Speedometer serious 2s - Ignition: ON X 3/2 V X 1/15 ≤ Check lead and

signal speedometer
Discontinuity
18 Speedometer si- serious 2s - Ignition: OFF X 3/2 V X 1/15 ≤ Check lead and
gnal - Pull plug X3 out of speedometer
control unit
Short circuit to - Ignition: ON
battery
19 ABS serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ Check lead,

Short circuit to relay and ABS-con-
ground trol unit
cbtd 98-01
Page 4.2/19
Diagnosis / ' )$
%

Table 9:

Fault Operation
tion
Code (Check)
21 ABS-Signal undefined serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ Check lead,

relay and ABS-
control unit

23 Proportional valve serious 1s - Ignition: OFF X 2/3 V X 1/15 ≤ Check lead

- Ignition: ON
cbtd 98-01
Page 4.2/20
Diagnosis / ' )$
%

Table 10:

Fault Operation
tion
Code (Check)
24 1 Proportional valve serious 1s - Ignition: ON X 2/2 W X 2/3 18-25 W Check lead and
nal valve magnetic
Valve magnetic
valve
proportional valve
interchanged
24 2 - Ignition: OFF X 2/3 W X 1/15 Resistor Check lead and

block)
cbtd 98-01
Page 4.2/21
Diagnosis / ' )$
%

Table 11:

Fault Operation
tion
Code (Check)

block)


28 Terminal 30 serious 60 s - Ignition: OFF X 1/13 V X 1/15 ≥ 17,5 V Check lead,

- Ignition: ON
cbtd 98-01
Page 4.2/22
Diagnosis / ' )$
%

Table 12:

Fault Operation
tion
Code (Check)

control unit

control unit
32 Retarder pilot light: serious 3s - Ignition: OFF X 3/8 V X 1/15 ≥ 17,5 V Check lead,
- Ignition: ON
switch: light
Position 1
cbtd 98-01
Page 4.2/23
Diagnosis / ' )$
%

Table 13:

Fault Operation
tion
Code (Check)

control unit
37 Fault pedal operation slight 100 ms / 1 s Check installati-

on relating to
OEM-
respectively
VOITH-
instructions
cbtd 98-01
Page 4.2/24
Diagnosis / ' )$
%

Notice
cbtd 98-01
Page 4.2/25
Diagnosis / ' $#
% *
Troubleshooting

• Ignition OFF 101
101 Hex.-head screw (M 12 x 1,5), 102
(Pump pressure measuring point)
25 Nm
102 Sealing ring (A 12 x 15,5), renew
Notice

of the retarder.
Special tool
53.4788.10
FD1195
Pressure gauge
0 - 25 bar
cbtd 98-01
Page 4.3/1
Diagnosis / ' $#
% *
99/1
The screw plug is heated up!
Job scope
1. Screw out screw plug (101) with sealing ring (102) at the 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). FD510
4. Compare read-off pump pressure with the setpoint of the static pump pressure 99/1 Pressure gauge 53.4788.10
(see following table page 4.3/3).
Caution!
If the measurement of the static pump pressure falls short of the setpoint, either the retarder is leaking or
the control system is defective (see troubleshooting diagram).
cbtd 98-01
Page 4.3/2
Diagnosis / ' $#
% *
Setting [Nm] Code Number 3) Pump pressure static Pump pressure dynamic 1)
Setpoint [bar] vps = 1000 r.p.m.
Minimum value [bar]
1000 027 1,15 – 1,45 7
1250 028 1,45 – 1,75 9
1500 029 1,75 – 2,05 12
1750 030 2,05 – 2,35 14
2000 031 2,35 – 2,65 16
1)
Retarder stage switch in highest position
2)
Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure)
3)
The code number is to be found at the control unit
Notice
The data represent the state of the art at the time of going to print.
Control units with different values are still in circulation. The manufacturer reserves the right to make
further modifications.
cbtd 98-01
Page 4.3/3
Diagnosis / ' $#
% *
Job scope dynamic

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).
Caution!
The screw of the pressure gauge and the retarder are heated up!
4. Disconnect the pressure gauge (99/1). Screw in screw plug (101) with new sealing ring.
cbtd 98-01
Page 4.3/4
Diagnosis /
Troubleshooting
Illustration checking control system
25 33
Notice 71
32 61
The reference numbers indicated in Section 4.4 21
are not identical with the reference numbers of A R
P
37
1 Heat exchanger 11 31
2 Control unit
11 Proportional valve 26 35 34
current connection
19 Temperatur pick-up cooling water 40
alternative: positions 19 and 20
joining in the central-plug (see elec- 2
39 20
trical diagram Version 2)
20 Temperature pick-up oil 19
25 Constant-air pressure line p y
(Connection A)
(Connection P)
31 Compressed air line
protection valve)
32 Compressed-air pressure line 1
(four-circuit protection valve -
with test connection FD1287
(parking brake)
2 wires)
cbtd 98-01
53.2659.10
Page 4.4/1
Diagnosis / '' $#
%

Check requirements
• Ignition OFF
Special tools
Wasser Öl
53.4788.10 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.
cbtd 98-01
cbtd 98-01
53.2640.10 Page 4.4/2
Diagnosis / '' $#
%


Notice
32

Pressure gauge 53.1403.10
Test set-up job scope 57

98/5
1. Connect temperature simulator (99/2) with the adapter lead (98/5) at the temperature pick-up (57).
99/2
Notice
FD1455
cbtd 98-01
cbtd 98-01
53.2640.10 Page 4.4/3
Diagnosis / '' $#
%

2. Screw out oil filler/check plug (1900) with sealing ring (1800).
1900
1800
FD1187
3. Connect pressure gauge (99/7) to retarder housing.
99/7
FD1198
cbtd 98-01
Page 4.4/4
Diagnosis / '' $#
%

4. Connect up „Propstrom“ measuring adapter (99/3).

21
99/3
FD923
99/3 „Propstrom“ measuring adapter 53.8198.10

99/8 Multimeter
cbtd 98-01
Page 4.4/5
Diagnosis / '' $#
%

Job scope test

57
Preconditions for checking 98/5
• Ignition ON
99/2
165°C oil temperature operate the retarder at the highest stage.
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 125oC cooling water temperature. There must
FD1455
be no more output of constant-air pressure py.
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 225oC oil temperature. There must be no more
(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
53.2640.10 Page 4.4/6
Diagnosis / '' $#
%

Notice
If both values are not reached, please see Section 4.2 „Troubleshooting and Remedies“.
Setting [Nm] Code Number1) Control current Constant-air pressure py

[mA] 2) [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
1)
2)
3)
cbtd 98-01
Page 4.4/7
Diagnosis / '+ *
$#
Troubleshooting

R
Retarder pilot light without indication FD844

- slight fault
- serious fault
cbtd 98-01
Page 4.5/1
Diagnosis / '+ *
$#
Notice
is going off.

cbtd 98-01
Page 4.5/2
Diagnosis / '+ *
$#
Troubleshooting
Operation

switch
properly.
cbtd 98-01
Page 4.5/3
Retarder Remo- +
%, -

%
ving, Installing
5.1 Removing, Installing Retarder (Free Mount Installation) ............................5.1/1
5.2 Removing, Installing Retarder (Gearbox Attachment)................................5.2/1
cbtd 98-01
Page 5/1
Retarder Remo- !" #
ving, Installing $ % # &
Illustration Retarder (Free mount installation)
1300
1300
1400
1400
1200
1200
94
95 92
36
92
25
1100
93 96
97
1000
96
57
1000/6
1200
1000-5
1200/1
1500
FD1199

• 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 Constant-air pressure line py „A“ 1000/5 Drain plug cooling water (M 18 x 1,5), 50 Nm
36 Ventilation line „R“ 1000/6 Sealing ring (A 18 x 22), renew
57 Plug temperature pick-up 1100 Suspension complete
92 Prop-shaft 1200 Megi-pads, check, renew if necessary
93 Hex.-head screw 1200/1 Spacer tube
94 Spring washer 1300 Hex.-head screw (M 16 x 90)
95 Hex.-head screw 1400 Washer (B 16)
96 Hose clamp 1500 Hex.-head nut (M 16) self-locking, renew, 110 Nm
97 Hose connection
1000 Heat exchanger
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
Page 5.1/1
Retarder Remo- +
%, -

%
ving, Installing . / $
0
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.
cbtd 98-01
Page 5.2/1
Repair Gearbox

Attachment

6.3 Removing, Installing Non-Return Valve (Casing Ventilation) .....................6.3/1
(Stainless-Steel Heat Exchanger) ..............................................................6.4/1
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)
cbtd 98-01
Page 6/1
Repair Gearbox ' ( !!)
Attachment
Illustration assembly overview (retarder basic group)
2800
3200 2900 2700
3100
2500
4600 2902 2600

4400 2901
2903 2300/1
4500 3000
2301
4300 2300
101
102 2300/2
2300/3
2400
1900
1800
700
850
800
900
104
103
103
104 1200
1300 1100
1400 1000
1600
1500 1700
FD1570
101 Hex.-head screw (M 12 x 1,5) 2301 O-ring (55 x 3)

102 Sealing ring (A 12 x 15,5) 2400 Sieve (D 60 x 23)
103 Silencer-ventilation (30 x 4) 2500 Cover sheet metal
104 Circlip (JL 30 x 1,2) 2600 Spacer (D 50/42 x 15,5)
700 Raduial shaft sealing ring (80 x 100 x 10) 2700 Washer (B 6,4)
800 Labyrinth cover 2800 Cap screw (M 6 x 12)
850 O-ring (125 x 2,5) 2900 Top cover
900 Hex.-head screw (M 8 x 25) with 7 threads for M 6
1000 Cover 2901 Valve internal part
1100 O-ring (82 x 4) 2902 Spring
1200 Gasket 2903 Connector
1300 Bottom cover 3000 Gasket
1400 Washer (B 8,4) for 7 fixing screws M 6
1500 Cap screw (M 6 x 20) 3100 Washer (B 6,4)
1600 Sealing ring (A 22 x 29) 3200 Cap screw (M 6 x 30)
1700 Screw plug (M 22 x 1,5) 4300 Radial shaft sealing ring (85 x 105 x 13)
1800 Sealing ring (A 30 x 36) 4400 Centering cover (D 180 x 70)
1900 Oil filler/check plug (M 30 x 1,5) 4500 O-ring (130 x 4)
2300 Casing ventilation (D 30 x 38) 4600 Hex.-head screw (M 8 x 20)
contents Position 2301
2300/1 Valve insert
2300/2 Float
2300/3 Float cage
cbtd 98-01
53.2659.10
Page 6.1/1
Repair Gearbox
Attachment
2800
Preconditions for job 2700

3200
• Retarder removed (see Section 5.1).
3100 2500
• Ignition OFF
2600
2900
2300/1 Valve insert 2300/1
2300/2 Float checking, renew if necessary
2300/3 Float cage 2300
2301
2301 O-ring (55 x 3), renew,
3000 2300/2
2400 Mesh strainer clean with benzine
2500 Cover plate 2300/3
2600 Spacer
2700 Washer (B 6,4)
2800 Hex.-head screw (M 6 x 12), 10 Nm 2400
2900 Cover
3000 Gasket, renew
3100 Washer (B 6,4)
3200 Cap screw (M 6 x 30), 10 Nm
FD1252
cbtd 98-01
Page 6.2/1
Repair Gearbox
Attachment (Continue)
Mesh strainer Benzine

Special tools
53.7712.10 53.9428.10
To remove
1. Screw out hex.-head screws (3200).
2. Remove washer (3100).
cbtd 98-01
Page 6.2/2
Repair Gearbox
3. Remove the cover (2900) from the retarder housing.
99/5
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).
FD638
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).
2300/1
11. Remove the mesh strainer (2400), check and wash with benzine, if necessary.
2301
2300/3
FD027
cbtd 98-01
Page 6.2/3
Repair Gearbox
To check

2300/2
Notice
FD028
and upper edge of the valve insert (2300/1) with methylated spirit. If the sealing edge is not 2300/2
2300/1
FD029
cbtd 98-01
Page 6.2/4
Repair Gearbox
To install
1. Install the mesh strainer (2400).
2300/1
3. Fit the float (2300/2) into float cage (2300/3).
2301
Notice
If the float only has one polished surface fit float with this surface on top.
FD032
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
Page 6.2/5
Repair Gearbox
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. Fit cap screws (3200) and washers (3100) and screw tight. Tightening torque 10 Nm
cbtd 98-01
Page 6.2/6
Repair Gearbox ! "#$
Attachment
Illustration non-return valve
(casing ventilation)
2902 2901 2903
2901 Valve internal components,
check for damage, renew complete
non-return valve, if necessary
2902 Spring,
2903 Connector,
install with Loctite 270 locking
agent, 100 Nm
check valve seat, renew complete
Locking agent
Connector Loctite 270
FD1452
cbtd 98-01
Page 6.3/1
Repair Gearbox % "#$
Attachment &#& ' (
(stainless-steel heat exchanger)
1400
1200 Non-return valve (stainless-steel
heat exchanger) 1300
1200/1 Valve cover
1200/2 Valve housing
1200/3 O-ring , renew, 1200/1
corrosive grease for installation 1200/2
1200/4 Spring, check for fatigue, renew
complete non-return valve (1200), 1200/3
if necessary 1200
1200/5 Valve piston, check valve seat in
1200/4
heat exchanger and vulcanization,
renew complete non-return valve
(1200), if necessary.
1300 Spring washer, renew 1200/5
1400 Cap screw (M 8 x 20), 25 Nm
Lubricants

FD1454
cbtd 98-01
Page 6.4/1
Repair Gearbox ) &
Attachment
Illustration Silencer

• Ignition OFF
Notice

103 Silencer (30 x 4)

103
clean with Benzine and blow out 104
with compresse-air
104 Circlip (JL 30 x 1,2),
Cleaning agents
Silencer Benzine
103
104
FD1280
cbtd 98-01
Page 6.5/1
Repair Gearbox *
Attachment
Illustration bottom cover

• Oil drained from retarder (see Section 3.2)
• Ignition OFF
1200 Gasket, renew

1300 Bottom cover
1400 Washer (B 6,4)
1500 Cap screw (M 6 x 20), 10 Nm
1200
1300
1400
1500
FD1231
cbtd 98-01
Page 6.6/1
Repair Gearbox +
Attachment , '$
Special tool
1000
53.7712.10
99/5
To check
1100 1000 FD1479
1. 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. Coat new O-rings (1100) with thin coat of silicone-free and non-corossive grease
and install together with closing covers (1000).
cbtd 98-01
cbtd 98-01
53.2640.10 Page 6.7/1
Repair Gearbox - ./ (Output
Attachment Side) 0 &, &
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 0 700 850
• Ignition OFF
800
Notice 900
This job can be performed with the retarder

700 Radial shaft sealing ring

(80 x 100 x 10), renew,
for installation
800 Labyrinth cover, coat with Hylomar
sealant around leakage oil return
bore
850 O-ring (125 x 2,5), renew,
for installation
900 Hex.-head screw (M 8 x 25) FD1269
self-locking, renew, 23 Nm
cbtd 98-01
Page 6.8/1
Attachment Side) 0 &, & (Cont.)
Sealants and locking agents
Housing sealing surfaces Hylomar

Special tool
53.0742.10
Job scope
1. Screw out hex.-head screw (900).
800
2. Use two hex.-head screws (M 8 x 25) (arrows) to press the labyrinth cover (800) off the
rotor housing.
FD1271
cbtd 98-01
cbtd 98-01
53.2640.10 Page 6.8/2
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. 800 700
5. Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (700).
FD660
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). 94/4
Position for installation: Sealing lip at top.
700 800
FD661
94/4 Press-in equipment 53.0742.10
cbtd 98-01
cbtd 98-01
53.2640.10 Page 6.8/3
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
FD067
cbtd 98-01
cbtd 98-01
53.2640.10 Page 6.8/4
Repair Gearbox 1 (Input
Attachment Side) 0 &, &
Illustration centering cover (input side)

Prior job
• Retarder removed (see Section 5)

(85 x 105 x 13), renew,
for installation
4400 Centering cover
4500 O-ring (130 x 4), renew, 4600
for installation
Lubricants

4500 4300 4400

FD1268
cbtd 98-01
Page 6.9/1
Special tool
53.0742.10
Job scope
2. Use two hex.-head screws (M 8 x 30) (arrows) to press centering cover (4400) off 4500 4400
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
guaranteed, please contact VOITH TURBO. FD653
cbtd 98-01
Page 6.9/2
94/4
Position for installation: Sealing lip at top. 4300
4400
FD655
7. Apply thin coat of silicone-free and non-corossive grease to new O-ring (4500) and fit in 4600
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)
4500
are in alignment.
9. Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm
4400
FD656
cbtd 98-01
Page 6.9/3
Repair Free Mount + 2 3$
Installation

7.2 Removing, Checking and Installation Casing Ventilation ...........................7.2/1
7.3 Removing, Installing Non-Return Valve (Casing Ventilation) .....................7.3/1
(Stainless-Steel Heat Exchanger) ..............................................................7.4/1
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
7.10 Removing and Installing Labyrinth Cover (input side)
cbtd 98-01
Page 7/1
Repair Free Mount * ( !!)
Installation
2800
3200 2900 2700
3100
2500
4700
2902 2600
800
2901
3000 2903 2300/1
850
2301
2300
101
700 102 2300/2
5400 2300/3
5500 2400
1900
1800
5500
5400 700
850
800
104
900
103
103
104 1200
1300 1100
1400 1000
1600
1500 1700
FD1571
101 Hex.-head screw (M 12 x 1,5) 2301 O-ring (55 x 3)

102 Sealing ring (A 12 x 15,5) 2400 Sieve (D 60 x 23)
103 Silencer-ventilation (30 x 4) 2500 Cover sheet metal
104 Circlip (JL 30 x 1,2) 2600 Spacer (D 50/42 x 15,5)
700 Raduial shaft sealing ring (80 x 100 x 10) 2700 Washer (B 6,4)
800 Labyrinth cover 2800 Cap screw (M 6 x 12)
850 O-ring (125 x 2,5) 2900 Top cover
900 Hex.-head screw (M 8 x 25) with 7 threads for M 6
1000 Cover 2901 Valve internal part
1100 O-ring (82 x 4) 2902 Spring
1200 Gasket 2903 Connector
1300 Bottom cover 3000 Gasket
1400 Washer (B 8,4) for 7 fixing screws M 6
1500 Cap screw (M 6 x 20) 3100 Washer (B 6,4)
1600 Sealing ring (A 22 x 29) 3200 Cap screw (M 6 x 30)
1700 Screw plug (M 22 x 1,5) 4300 Radial shaft sealing ring
1800 Sealing ring (A 30 x 36) (95 x 115 x 10)
1900 Oil filler/check plug (M 30 x 1,5) 4700 Hex.-head screw (M 8 x 30),
2300 Casing ventilation (D 30 x 38) self-locking
contents Position 2301 5400 Race
2300/1 Valve insert 5500 O-ring (80 x 3)
2300/2 Float 5600 O-ring (125 x 2,5)
2300/3 Float cage
cbtd 98-01
53.2659.10
Page 7.1/1
Repair Free Mount +
Installation
Illustration casing ventilation 2800
3200
2700
The job in this section can be performed with 3100 2500
the retarder removed or installed.
• Retarder stage switch in position 0 2600
• Ignition OFF
2900
2300 Casing ventilation 2300/1
2300/2 Float checking, renew if necessary 3000
2301
2300/3 Float cage
2301 O-ring (55 x 3), renew, 2300/2
2500 Cover plate 2400
2600 Spacer
2700 Washer (B 6,4)
2800 Hex.-head screw (M 6 x 12), 10 Nm
2900 Cover
3000 Gasket, renew
3100 Washer (B 6,4)
FD461
cbtd 98-01
Page 7.2/1
Repair Free Mount +
Installation (Continue)

Special tools
53.7712.10 53.9428.10
To remove
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.2/2
Repair Free Mount +
3. Remove the cover (2900) from the retarder housing. 99/5
5. Screw out hex.-head screws (2800) and remove Washer (2700).

99/9
6. Remove cover plate (2500).
FD1209
99/9 Adapter 53.9428.10

99/5 Impact tool 53.7712.10
10. Lever O-ring (2301) out of the groove of the valve insert (2300/1). 2300/1
11. Remove the mesh strainer (2400), check and wash with benzine, if necessary. 2301
2300/3
FD027
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.2/3
Repair Free Mount +
To check

2300/2
Notice
FD028
2300/1
FD029
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.2/4
Repair Free Mount +
To install
2300/1
2301
Notice
FD032
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.2/5
Repair Free Mount +
Caution!
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.2/6
Repair Free Mount +! "#$
Installation
(casing ventilation)
2902 2901 2903
2901 Valve internal components,
non-return valve if necessary
2902 Spring,
2903 Connector,
install with Loctite 270 locking
agent, 100 Nm
check valve seat, renew complete
Locking agent
Connector Loctite 270
FD1451
cbtd 98-01
Page 7.3/1
Repair Free Mount +% "#$
Installation &#& ' (
(stainless-steel heat exchanger)
1400
1200 Non-return valve
(stainless-steel heat exchanger) 1300
1200/1 Valve cover
1200/2 Valve housing
1200/3 O-ring , renew, 1200/1
1200/4 Spring, check for fatigue, renew
complete non-return valve (1200), 1200/3
if necessary 1200
1200/5 Valve piston, check valve seat in
1200/4
heat exchanger and vulcanization,
renew complete non-return valve
(1200), if necessary.
1300 Spring washer, renew 1200/5
1400 Cap screw (M 8 x 20), 25 Nm
Lubricants

FD1454
cbtd 98-01
Page 7.4/1
Repair Free Mount +) &
Installation

• Ignition OFF
Notice


104 103
clean with Benzine and blow out
with compressed-air
104 Circlip (JL 30 x 1,2),
Cleaning agents
Silencer Benzine
103
104
FD1250
cbtd 98-01
Page 7.5/1
Repair Free Mount + *
Installation

• Ignition OFF
1200 Gasket, renew

1300 Bottom cover
1400 Washer (B 6,4)
1500 Cap screw (M 6 x 20), 10 Nm
1200
1300
1400
1500
FD1231
cbtd 98-01
Page 7.6/1
Repair Free Mount ++ 4 &, 2
Installation
Illustration prop shafts flanges
Prior jobs
93/1
• Prop shafts flanges removed
Notice 97/6 97/8
The jobs in this section can be performed with

97/9 98
93/1 Hex.-head screw (M 20 x 180)
95/2 Hex.-head nut (M 20), 375 Nm
97/6 Prop shaft flange
(output side) 95/2
97/7 Prop shaft screw, renew
97/8 Guard ring (output side)
97/9 Guard ring (input side)
98 Prop shaft flange
(input side)
97/7
FD1232
cbtd 98-01
Page 7.7/1
Repair Free Mount ++ 4 &, 2
Removing and installing

1. Screw out hex.-head screw (95/2).
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. 97/7 97/8
97/9
4. Remove guard rings (97/8, 97/9).
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.

FD016
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.7/2
Repair Free Mount +-
Installation , '$
Special tool
99/5 1000 1100
53.7712.10 1000
To check FD1222
1. Check closing cover (1000) for leaks, renew O-ring (1100) if necessary.
To remove
To install
1. Coat new O-rings (1100) with thin coat of silicone-free and non-corossive grease
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.8/1
Repair Free Mount +1 ./ (Output
Installation Side) 0 &, &
Illustration labyrinth cover

Prior jobs
(see VOITH-installation schemes) 5500
5400
700 850
Notice 900


(80 x 100 x 10), renew, coat with
silicone-free and non-corossive
bore
850 O-ring (125 x 2,5), renew, coat with
5400 Race FD1239
5500 O-ring (80 x 3), renew, coat with

cbtd 98-01
Page 7.9/1
Installation Side) 0 &, & (Cont.)
Housing sealing surfaces Hylomar 900

Special tool
FD1240
53.0742.10
Job scope
800
rotor housing.
FD1241
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.9/2
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 800 700
race if necessary.
Notice FD065
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 5400
will go.
10. Apply thin coat of silicone-free and non-corossive grease to new radial shaft ring (700).
FD1242
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.9/3
700
800
FD066
are in alignment.
800
FD067
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.9/4
Repair Free Mount +56 ./ (Input
Installation Side) 0 &, &

Prior jobs
(see Section 7.7)
5500 5400
700
Notice 850
800


bore 4700
5400 Race
5500 O-ring (80 x 3), renew, coat with si- FD1235
licone-free and non-corossive grea-

se for installation
cbtd 98-01
Page 7.10/1

Special tool
53.0742.10
Job scope
800
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. FD1237
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.10/2
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. FD058
Recommendation:
9. Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it
will go.
FD1238
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.10/3
700 800
FD059
are in alignment.
800
FD061
cbtd 98-01
cbtd 98-01
53.2640.10 Page 7.10/4
Repair -
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
cbtd 98-01
Page 8/1
Repair + !" #
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
14000
12000 FD1216
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 Hose clamp 5000 Hex.-head nut M 8, self-locking, renew, 23 Nm

97 Cooling water hose 7000 Hex.-head screw (M 8 x 35), 23 Nm
1000 Heat exchanger 8000 Pin screw (M 10 x 50)
1000/1 Leaking oil drain plug (M 14 x 1,5), 32 Nm 9000 O-ring (45 x 4) renew, coat with silicone-free and
1000/2 Sealing ring (A 14 x 18), renew non-corrosive grease
1000/5 Cooling water drain plug (M 18 x 1,5), 50 Nm 9500 O-ring (8 x 2) renew, coat with silicone-free and non-corrosive
1000/6 Sealing ring (A 18 x 22), renew grease
1600 Sealing ring (A 22 x 29), renew 12000 Connecting piece
1700 Retarder oil drain plug (M 22 x 1,5), 66 Nm 13000 Connecting piece
2000 Throttle disc (outlet throttle) 14000 Sealing ring, renew
3000 O-ring (36 x 4), renew, coat with silicone-free and 15000 Hex.-head screw (M 10 x 65), 46 Nm
non-corrosive grease 16000 Hex.-head screw (M 10 x 35), 46 Nm
4000 Washer (B 8,4) 17000 Washer (B 10,6)
Data
Pressure test (oil section) max.10 bar
Lubricants

cbtd 98-01 Aftersales Service Manual VOITH Retarder 120 Digiprop

53.2659.10 Page 8.1/1
Repair -5
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.
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.
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.
cbtd 98-01
Page 8.1/2
Repair -5
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.
cbtd 98-01
Page 8.1/3
Repair -5
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
Page 8.1/4
Repair -5
6. 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.
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
1700
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. FD1265
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. If heat exchanger (1000) had been leaking, deoil vehicle cooling and heating system in
accordance with vehicle manufacturer´s data.
cbtd 98-01
Page 8.1/5
Repair + !" #
Heat Exchanger ( , -.
Illustration aluminium heat exchanger
1000/4
9500 1000/3
1000/6 1000/2
3000 1000/5 1000/1
2000
8000 20
4000 93/9
4000
9000
7000
4000 1600
1700 5000
5000
1000
97
96 FD1266
Prior jobs
This job sequence van also be performed with the retarder installed, if necessary.
• Retarder stage switch in stage position 0
• Ignition OFF
20 Oil temperature pick-up (M 14 x 1,5), 32 Nm 1700 Heat exchanger oil drain plug (M 22 x 1,5), 66 Nm
96 Hose clamp 2000 Throttle disc (outlet throttle)
97 Cooling water hose 3000 O-ring (36 x 4), renew, coat with silicone-free and non-corrosive
93/9 Sealing ring (A 14 x 20), renew grease
1000 Heat exchanger 4000 Washer (B 8,4)
1000/1 Leaking oil drain plug (M 14 x 1,5), 32 Nm 5000 Hex.-head nut M 8, self-locking, renew, 23 Nm
1000/2 Sealing ring (A14 x 18), renew 7000 Hex.-head screw (M 8 x 35), 23 Nm
1000/3 Oil drain plug heat exchanger (M 12 x 1,5), 25 Nm 8000 Pin screw (M 10 x 50)
1000/4 Sealing ring (A 12 x 15,5), renew 9000 O-ring (45 x 4), renew, coat with silicone-free and non-corrosive
1000/5 Cooling water drain plug (M 18 x 1,5), 50 Nm grease
1000/6 Sealing ring (A12 x 15,5), renew 9500 O-ring (8 x 2), renew, coat with silicone-free and non-corrosive
1600 Sealing ring (A 22 x 29), renew grease
Data
Pressure test (oil section) max.10 bar
Special tool
Lubricants

53.4786.10
cbtd 98-01 Aftersales Service Manual VOITH Retarder 120 Digiprop

53.2659.10 Page 8.2/1
Repair -
Heat Exchanger $$ ' ( (Continue)
Notice
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.
1000/1, 1000/3) with new sealing rings (1600, 1000/2, 1000/4) tight.
cbtd 98-01
Page 8.2/2
Repair -
To remove
Notice
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).
99/6
3. Pressurize the heat exchanger (1000) slowly from 0 to max. 10 bar overpressure (oil section).
Notice
If air bubbles form in the hot water, the heat exchanger is leaking and must be renewed. 1000
FD046
99/6 Pressure-test plate 53.4786.10
cbtd 98-01
Page 8.2/3
Repair -
4. Remove the pressure-test plate (99/6).
To install
Notice
right bore.
Notice

cbtd 98-01
Page 8.2/4
Repair -
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.
and annex).
cbtd 98-01
Page 8.2/5
Control Parts 1 4
9.1 Proportional valve.................................................................. in preparation

Cooling Water Temperature Pick-up ..................................................................9.1/1
Oil Temperature Pick-up ..................................................................................9.1/2
cbtd 98-01
Page 9/1
Control Parts 15 4
Removing and installing cooling water

temperature pick-up
The temperature pick-up is heated up

(cooling water temperature)!
Job scope
1. Disconnect cooloing water temperature
pick-up (19). Tightening torque 28 Nm
The electrical lead of the temperature
pick-up is pured alternatively.
38
2. Screw out temperature pick-up (19) and
lock the opening immediately with one 19
stuffing.
3. Mount the temperature pick-up (19) in

reverse sequence.
FD440
cbtd 98-01
Page 9.1/1
Control Parts 15 4
(Continue)
Removing and installing oil temperature pick-up
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.
cbtd 98-01
cbtd 98-01
53.2640.10 Page 9.1/2
Annex 56
Data Sheet
Spare Parts Lists
Other Information
cbtd 98-01
53.2659.10 Aftersales Service Manual VOITH Retarder R 120 Digiprop
Page 10/1
Data Sheet VOITH Retarder 120 Digiprop
Max. retarder speed (= max. prop shaft speed v(max.) 4870 r.p.m. at vps = 2400 r.p.m.
with stainless-steel heat exchanger v(max.) = 3000 r.p.m.
with aluminium heat exchanger v(max.) = 2800 r.p.m.
Working medium Oil grade given in Operating Specification
Service filling: With AKG heat exchanger With heat exchanger L+R
- 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 will depend on the retarder version.
** Emptied heat exchanger
Service-Handbuch VOITH Retarder R 120 Digiprop

Seite 10/2
Miscellaneous Conversions Retarder 120 with Digiprop Control
D GB USA D GB USA
10 Nm 7 lbf-ft 7 lbf-ft 1,75 - 2,05 bar 25,4 - 29,7 psi 25,4 - 29,7 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

Miscellaneous Conversions Retarder 120 with Digiprop Control (Continue)
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

VOITH TURBO
Powertransmission
VOITH Retarder
1. Water
2.1 Normal case

*see chapter 4


**see chapter 5
Attention:
agent!

***see chapter 6
Attention:

3. Miscellaneous
3.1 Disposal
3.2 Safety

Attention:




Attention:



Attention:

Attention:


Attention:


Attention:




Attention:


Attention:

Attention:



Attention:


Attention:

A 000 989 13 25 10

Attention:


D-74564 Crailsheim
i. V. i. V. Phone (07951) 32-0
Telefax (07951) 32-756
32-401 / 32-422

92,7+5HWDUGHU/RJRSURS
cbtd 98-01
53.2658.10
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
3.2 Oil Change .......................................................................................3.2/1
With Stainless-steel Heat Exchanger ....................................................3.2/1

cbtd 98-01 Aftersales Service Manual VOITH Retarder R 120 Logoprop

53.2658.10 Page IHV/1
(Continue)

6.5 Checking, Removing and Installing Casing Cover of Retarder Housing .......6.5/1
6.6 Removing and Installing Labyrinth Ring (Output Side)
6.7 Removing and Installing Centering Cover (Input Side)

7.6 Checking, Removing and Installing Casing Cover of Retarder Housing .......7.6/1
7.8 Removing and Installing Labyrinth Ring (Output Side)
7.9 Removing and Installing Centering Cover (Input Side)
cbtd 98-01 Aftersales Service Manual VOITH Retarder R120 Logoprop

53.2658.10 Page IHV/2
(Continue)

8.1 Stainless-steel Heat Exchanger ...........................................................8.1/1
8.2 Aluminium Heat Exchanger .................................................................8.2/1
9. Control Parts ...........................................................................................9/1

9.1 Control Parts...................................................................................................9.1/1
10. Annex ....................................................................................................10/1

Data Sheet
Spare Parts Lists
Other Information
cbtd 98-01 Aftersales Service Manual VOITH Retarder R120 Logoprop

53.2658.10 Page IHV/3
Preface 3UHIDFH
Caution!
Notice
cbtd 98-01 Aftersales Service Manual VOITH Retarder 120 Logoprop

53.2658.10 Page 1/1
Preface
(Continue)
Caution!
Notice
• Serial-Number
• Code-Number
Notice

53.2658.10 Page 1/2
Preface
(Continue)
Caution!
Notice
professionally.
Notice
Notice

53.2658.10 Page 1/3
Preface
(Continue)
damage incurred.
prior notification.

D-74564 Crailsheim

Telefax (07951) 32-756
Extensions:
32-401 / 32-422

53.2658.10 Page 1/4
General


With Stainless-Steel Heat Exchanger .................................................................2.1/1
2.3 Retarder Data.............................................................................................2.3/1
cbtd 98-01
53.2658.10
53.2640.10 Page 2/1
General

with Logoprop control system 100/3
heat exchanger
100/1 Retarder data

100/3 Ventilation connection „R“ 100/2
1000 Heat exchanger
100/1
1900
1000
FD1183

53.2658.10 Page 2.1/1
General
(Continue)

with Logoprop control system
heat exchanger
(Continue)
1000 Heat exchanger

(M 14 x 1,5)
(M 18 x 1,5)
(M 22 x 1,5)
1000/1
1000/5
1000
FD1184

53.2658.10 Page 2.1/2
General
(Continue)

with Logoprop control system 100/3
basic group with aluminium heat exchanger 1700
100/1 Retarder data

1000/1 1000/5
100/3 Ventilation connection „R“
1000 Heat exchanger
1000/1 Leakage oil drain plug (M 10 x 1) 1000/3
1000/3 Oil drain plug heat exchanger 100/2 1000
(M 12 x 1,5), alternatively at the
front or lower side
1000/5 Cooling water drain plug 100/1
(M 12 x 1,5)
1900
1700 Retarder oil drain plug (M 22 x 1,5)
1000/3
1000
1000/5
FD451

53.2658.10 Page 2.1/3
General
Illustration VOITH Retarder 120 with Logoprop control system
26
25
44 12 50
46
A
R
21
23 14
36
6 3
52
2
19
16
17
45
18
53 43 41 56 1
Supply-air pressure p V Pump pressure p
FD529
Notice
1 Heat exchanger 25 Constant-air pressure line py „A“

2 Control unit 26 Supply-air pressure line pv
3 Connection vehicle battery supply 24 V 36 Ventilation line „R“
6 Fuse (8 A) 41 Filling duct
8 Connection ground 43 Oil sump
12 Pump presure test connection 44 Stator
14 ABS-switch off relay 45 Stator pin
16 Retarder stage switch 46 Rotor
17 Retarder pilot light 50 Output restrictor D1
18 Stop light relay 52 Filling restrictor D2
19 Cooling water temperature pick-up 53 Filling duct
21 Proportional valve 56 Leakage oil return line

53.2658.10 Page 2.2/1
General

(Continue)

The VOITH Retarder 120 - 120S is a powerful hydrodynamic continous brake of compact design for
buses and commercial vehicles of the medium range. The VOITH Retarder 120 -120S is located
between the gearbox and the rear axle of the vehicle. The retarder braking torque is sustained even
when gear changes are made.
VOITH Retarders 120 - 120S. A special version combines the retarder stage switch (16) with ABS,
a) Operation with function ,,Constant speed"

The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limit
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.
cbtd 98-01
53.2658.10
53.2640.10 Page 2.2/2
General

(Continue)
b) Operation without function ,,Constant speed"

When the retarder stage switch is shifted to position 1to 5 the retarder is braking in brake stage 1 to 5.
The maximum braking torque is obtained when the retarder stage switch is in position 5.
There are two versions of the retarder:
Retarder 120
with a prop shaft speed of max. 2800 r.p.m.
Retarder 120 S
with a prop shaft speed of max. 4800 r.p.m.

This retarder has a „S“ at the end of the retarder number.
If you have any questions, please contact VOITH TURBO.
Both retarder versions are identical in operation and maintenance.
cbtd 98-01
53.2658.10
53.2640.10 Page 2.2/3
General

(Continue)
Description of operation of retarder R 120 - 120 S with logoprop control system

c
The control medium for the Voith Retarder 120 - 120 S 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 py on the oil sump (43). a b
and stator (44).
The rotor (46) is connected with the retarder drive shaft, the stator (44) is stationary with the retarder
FD299
housing.
The rotation of the rotor sets the oil in motion and circulates it in a closed circuit between The hydrodynamic principle
the rotor (46) and stator (44). a Rotor (46)
The reduction of the velocity of the oil flow in the chambers of the stator (44) leads to braking of b Stator (44)
the rotor (46) and consequently to braking of the vehicle. c Oil flow
cbtd 98-01
53.2658.10
53.2640.10 Page 2.2/4
General

(Continue)
Temperatur pick-up water (19)

The temperature pick-up installed in the retarder cooling water return pipe monitors the cooling water
temperature and trnsmits appropriate signals to the control unit (2).
This temperature pick-up guarantees that the maximum permissible cooling water temperatures are not
exceeded.
If the cooling water in the return pipe heats up to a preselected temperature, the constant-air
pressure py decreases linearly over a range of approx. 10o C at the highest braking stage.
between the braking energy of the retarder and the amount of heat which can be dissipated by the
vehicle cooling system.
If the limit range of approx. 10o C is exceeded while braking, braking torque output is stopped to protect
cbtd 98-01
53.2658.10
53.2640.10 Page 2.2/5
General

(Continue)

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.
cbtd 98-01
53.2658.10
53.2640.10 Page 2.2/6
General
The retarder data (arrows) of the retarder 120 - 120 S are punched on the left side on the
retarder housing. It also can be punched alternatively at two different places (see arrows).
The retarder data plate (2) provides the following information:
1. Serial number:
Six-digit number
The retarder 120 S is punched on the retarder data field with an „S“ after the retarder No.
2. Code number:
Eight-digit number
Notice FD450
cbtd 98-01
53.2658.10
53.2640.10 Page 2.3/1
Maintenance !

3.2 Oil Change .................................................................................................3.2/1

Stainless-steel Heat Exchanger ........................................................................3.2/1
Aluminium Heat Exchanger ..............................................................................3.2/5

53.2658.10 Page 3/1
Maintenance !

"#

l Check hex.-head screws of prop shaft on correct fitment, or tighten.
Observe guidelines and instructions!
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

53.2658.10 Page 3.1/1
Maintenance $
%

1900 1000/6 1000/5
with stainless-steel heat exchanger

(M 10 x 1), 13 Nm
(M12 x 1,5), 25 Nm
1000/6 Sealing ring (A12 x 18), renew 1800
1000/2
1700 Retarder oil drain plug 1000/1
(M 22 x 1,5), 66 Nm
1900 Oil filler/check plug 1700
(M 30 x 1,5), 150 Nm
FD1189

53.2658.10 Page 3.2/1
Maintenance $
%
(Continue)
Notice
operating the retarder in the relevant application..
Heat Exchanger Service- With emptied heat ex- New filling

filling changer
Stainless-steel 4,5 l 5,8 l 6,5 l

heat exchanger (L+R)
to be drained.
Caution!

53.2658.10 Page 3.2/2
Maintenance $
%
(Continue)
Job scope
4. Screw out the retarder oil drain plug (1700) and remove sealing ring (1600) and drain oil.

53.2658.10 Page 3.2/3
Maintenance $
%
(Continue)
5. Screw out the leakage oil drain plug (1000/1) and remove sealing ring (1000/2) and drain the
accumulated oil.
Notice
(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).


53.2658.10 Page 3.2/4
Maintenance $
%
(Continue)

with Aluminium heat exchanger 1900

(M 10 x 1), 13 Nm 1000/4
1000/2 Sealing ring (A 10 x 13,5), renew 1000/3
1000/3 Heat exchanger oil drain plug
(M 12 x 1,5), 25 Nm
1000/4 Sealing ring (A 12 x 15,5), renew 1800
1000/2
(M 22 x 1,5), 66 Nm
1000/1
1600
1900 Oil filler/check plug 1700
(M 30 x 1,5), 150 Nm
FD1192

53.2658.10 Page 3.2/5
Maintenance $
%
(Continue)
Notice
.
Heat exchanger Service filling New filling

Aluminium heat exchanger (AKG) 5,5 l 6,0 l
to be drained.
Caution!

53.2658.10 Page 3.2/6
Maintenance $
%
(Continue)
Job scope
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.

53.2658.10 Page 3.2/7
Maintenance $
%
(Continue)
Notice
(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).

Heat exchanger oil drain plug (1000/3): Tightening torque 25 Nm

53.2658.10 Page 3.2/8
Maintenance $#
% &

1900
Notice
The oil change intervals and operating specifi-

cations have to be taken from the annex.
1800
150 Nm
Notice
The illustration shows a retarder 120 with

stainless-steel heat exchanger. A version with
aliminium heat exchanger is possible.
FD1186

53.2658.10 Page 3.3/1
Maintenance $#
% &
(Continue)
Notice
Service filling


53.2658.10 Page 3.3/2
Maintenance $#
% &
(Continue)
Notice
Difference between min. and max. mark on oil filler/check plug is approx. 0,5 l.
Job scope
Caution!
been switched off!
Risk of injury exists at nonobservance, by hot leaving oil when screw out oil filler/check plug!
The oil Filler/check plug (1900) is heated up (oil temperature)!
3. Screw out the oil Filler/check plug (1900) and remove sealing ring (1800).

53.2658.10 Page 3.3/3
Maintenance $#
% &
(Continue)
4. Position oil filler/check plug (1900) plane at the thread.

Do not screw in the oil filler/check plug!
1900
Oil level is correct bewteen min. and max. mark of the oil filler/check plug.
Max
6. Top up slowly any lacking oil through the hole for the oil filler/check plug.
Min
7. Screw the oil filler/check plug (1900) tight with new sealing ring (1800). Tightening torque 150 Nm
FD011

53.2658.10 Page 3.3/4
Maintenance '

% &

(Optional Extra)

12000/3 Cover
12111 Filter insert
12112 O-ring (36,2 x 3), renew,
12000/5
Lubricants

12000/3
12000/4
FD427

53.2658.10 Page 3.4/1
Maintenance '

% &

(Continue)
Notice
Job scope
Mind fall in pressure in the compressed air circuit for auxiliary equipment (e.g. air springs)!
damages and renew, if necessary.

53.2658.10 Page 3.4/2
Maintenance '

% &

(Continue)
Notice
If complete filter (12000) has to be removed, mind the correct installing position.

53.2658.10 Page 3.4/3
Diagnosis / ' %
()$
%
Troubleshooting


53.2658.10 Page 4/1
Diagnosis /
Troubleshooting
Notice
(see Section 3.3 ‘‘Checking oil level‘‘).
(see Section 3.2 ‘‘Oil change‘‘ and annex).
Renew non-return Contact

valve VOITH
NOK OK
Renew casing Check non-return

ventilation valve at proportional
valve (Chapter 4.4)
NOK OK
Check oil level of
Check casing see chapter 8
retarder(*)
ventilation
(Chapter 6.2) Check heat Check cooling system:
exchanger
-coolant level
-coolant pump
Check oil level of dirtiness
Driver instruction
retarder
Oil leakage by OK NOK

ventilation
Check operation
(by braking with
retarder nominal
engine speed,
if possible)
If the retarder is
still leaking, or the
Empty chamber of Complaint
return of leakage oil Oileak input side Retarder pilot
chamber of (at heat exchanger) or output side
R 120 light
leakage oil is filled (Chapter 3.3) Logoprop
again with oil after
1000 km,
renew radial shaft
seal
NOK OK
No respectively flashes
too insufficient
retarder braking Check lead to
effect temperature pick-up
and short circuit,
lead discontinuity
Check oil level of

Retarder
NO YES YES NO
Check heat
exchanger
Check py (static)
(Chapter 4.4) Correct oil level of
see chapter 8 retarder
OK NOK
Check p (dynamic)
(Chapter 4.3)
OK NOK
Check voltage of
Contact proportional valve
Contact
VOITH (Chapter 4.4)
VOITH
OK NOK
Check control unit

and
(Chapter 4.4)
Check compressed-
-air supply OK NOK *
(Chapter 4.4) If you get oil leakage after a trail run again:
OK NOK continue at ´Ćhecking casing ventilation´´
Contact Contact
Check vehicle VOITH VOITH
compressed-air
Mechanical fault of
supply
proportional valve
OK NOK
Contact Contact
VOITH vehicle manufacturer
FD 1602

53.2658.10 Page 4.1/1
Diagnosis / ' )$
% %
Electrical diagram
4
6 16
2 Control unit 19
4 Terminal 15
6 Fuse (8 A)
14 ABS-switch off relay
1 2 3 4 5
18 Stop light relay
19 Cooling water temperature pick-up 87 87a
47 Speedometer signal 30
ye/gn
(only with control system with the
blu
blu
wh
pu
rd
gr
pi
bl
function „Constant Speed“) 14
U U
U U U U U U
2 10 9 8 7 6 5 11 12
1 3 4 13 14
2
U U I
ye/gn
br
bl
br
or
30
87 87a
47 18 17
21 FD018

53.2658.10 Page 4.1/2
Diagnosis / ' )$
%

Troubleshooting

Checking requirements
Notice
(see table, Section 3.2).

53.2658.10 Page 4.2/1
Diagnosis / ' $#
% * *
Troubleshooting

101
• Ignition OFF
101 Hex.- head screw (M 12 x 1,5), 102
(Pump pressure measuring point)
25 Nm
102 Sealing ring (A 12 x 15,5), renew
Notice
The pump-pressure check provides

information on the mechanical condition of ro-
tating parts, on internal leaks and on the
operation of the retarder.
Special tool
53.4788.10 FD508
Pressure gauge
0-25 bar

53.2658.10 Page 4.3/1
Diagnosis / ' $#
% *
99/1
Job scope
and read-off after 30 sec. the pump pressure from the pressure gauge (99/1). FD510
4. Compare read-off pump pressure with the setpoint of the static pump pressure 99/1 Pressure gauge 53.4788.10
Caution!
or the control system is defective (see troubleshooting diagram).

53.2658.10 Page 4.3/2
Diagnosis / ' $#
% *
Setting [NM] Pump pressure static 1)2) Pump pressure dynamic 1) Pump pressure dynamic 1)
(Setpoint) [bar] vps = 1000 r.p.m. vps = 2000 - 2200 r.p.m.
(Minimum value) [bar] (Minimum value) [bar]
Retarder 120 Retarder 120 S Retarder 120 Retarder 120 S
2000 Nm 2,50 - 0,15 2,50 - 0,15 16 21
1750 Nm 2,20 - 0,25 2,20 - 0,25 14 18,5
1500 Nm 1,90 - 0,25 1,90 - 0,25 12 16
1360 Nm 1,71 - 0,25 1,71 - 0,25 10 14,5
1250 Nm 1,56 - 0,25 1,56 - 0,25 9 13
1140 Nm 1,41 - 0,25 1,41 - 0,25 8 12
1000 Nm 1,26 - 0,25 1,26 - 0,25 7 11
930 Nm 1,18 - 0,25 1,18 - 0,25 6,5 10
1)
2)
Notice

53.2658.10 Page 4.3/3
Diagnosis / ' $#
% *
Job scope dynamic

1. Retarder 120
Drive the vehicle with a prop-shaft speed of v ps = 1000 r.p.m.
Retarder 120 S
Drive the vehicle with a prop-shaft speed of vps = 2000 - 2200 r.p.m.
2. Shift the retarder stage switch (16) to the highest position while on the move at the appropriate
prop shaft speed and read-off pump pressure at pressure gauge (99/1).
Caution!

53.2658.10 Page 4.3/4
Diagnosis /
Troubleshooting

11
26 71 33
Notice 61
32

25
A
1 Heat exchanger 31
2 Control unit R 21
current connection 36 35
19 Temperature pick-up (coolant)
25 Constant-air pressure line p y „A“
(pressure regulator four-circuit 19
protection valve) 2
(four-circuit protection valve -air
tank for auxiliary equipment with
test connection)
(brake circuit no. 1)
(brake circuit no. 2) 47
1
(parking brake)
FD924
38 Electrical lead (Cooling water
2 wires)
47 Speedometer signal (alternatively)

53.2658.10 Page 4.4/1
Diagnosis / '' $#
%

Check requirements
Special tools
101103105
99 107
97 111
95 113
93 115
o o
120 C 200 C
53.4377.10 53.4788.10 53.8167.10
Pressure gauge
0 - 25 bar

53.2658.10 Page 4.4/2
Diagnosis / '' $#
%


Notice
32

1. Disconnect the electrical lead (38) at temperature pick-up (19) and connect it with the temperature 38
simulator (99/4).
Set temperature range at temperature simulator to 120°C.
99/4
101103105
99 107
97 111
19 95
93
113
115
o o
120 C 200 C
FD107

53.2658.10 Page 4.4/3
Diagnosis / '' $#
%

1900
FD457
3. Connect pressure gauge (99/1) to the bore of the retarder housing.
99/1
FD512

53.2658.10 Page 4.4/4
Diagnosis / '' $#
%

Prior jobs
• Ignition: OFF
• Disconnect plug on control unit (2). 2
4. Connect up socket box (99/8).
• Connect wiring harness to appropriate connector of socket box.

• Connect appropriate plug of socket box to control unit (2). 99/8
FD875
99/8 Socket box 53.8167.10
(measurements: mA).
98/4
FD870

53.2658.10 Page 4.4/5
Diagnosis / '' $#
%

Job scope test

• Ignition: ON
1. Set the rotary switch of the temperature tester (99/4) one step below the specified start of 99/4
temperature limit (e.g. to 95°C for a specified start of temperature limit at 96°C) and operate the 99
101103105
107
97 111
retarder at the highest stage. 19 95
93
113
115
next page (page 4.4/7). o o
120 C 200 C
Notice FD107


53.2658.10 Page 4.4/6
Diagnosis / '' $#
%

Setting DIL-Switch Setting Control current Constant-air pressure

[Nm] [mA] 1)
py [bar] 2)
2000 DIL 3, 4 and 5 OFF 299 - 305 2,35 - 2,65
1750 DIL 3 ON 279 - 285 1,95 - 2,45
1500 DIL 4 ON 258 - 264a 1,65 - 2,15
1300 DIL 3 and 4 ON 247 - 251 1,46 - 1,96
1250 DIL 5 ON 237 - 241 1,31 - 1,81
1150 DIL 3 and 5 ON 228 - 232 1,16 - 1,66
1050 DIL 4 and 5 ON 217 - 221 1,01 - 1,51
950 DIL 3, 4 and 5 ON 211 - 215 0,93 - 1,43
a Special comparison R 120 (TADANO): 260 - 266 mA

1)
2)
Notice
• If a commercially available multimeter is used for measurements (without real effective measu-
ring) exact readings cannot be made (indication jumps!).
• The data represent the state of the art at the time going to print. Control units to which other data
apply still are in use. The manufacturer reserves the right to make further modifications.

53.2658.10 Page 4.4/7
Diagnosis / '' $#
%

Notice
must be provided.
Notice

53.2658.10 Page 4.4/8
Diagnosis / '' $#
%

3. Disconnect presure gauge (99/1).
1900
FD457
38
19
FD109

53.2658.10 Page 4.4/9
Diagnosis / '' $#
%

Notice
Pin - multimeter - measuring mode V or W - Pin.
Step Scope of check Measuring equipment / Requirement / Action Result / Set point Cause / Remedy
test connection
1 Voltage 1-V- 2 Ignition: ON ≥ 20 V - End of check
< 20 V - Step 1.2
1.2 1-V- 2 Ignition: OFF ≥ 20 V - Renew control unit

control unit
Ignition: ON < 20 V - Lead discontinuity
2.1 Retarder pilot light 1-V- 4 Ignition: ON <1V - Step 2.2

- Retarder stage switch in stage
position 0 - Lead discontinuity
≥1V - Fault in retarder stage
switch
2.2 1-V- 4 Ignition: ON ≥ 20 V - End of check

- Retarder stage switch-
in stage position 1 to 5 - Lead discontinuity
< 20 V - Lead short circuit
- Fault in retarder stage
switch

53.2658.10 Page 4.4/10
Diagnosis / '' $#
%

test connection
3.1 Stop light relay 1-V- 3 Ignition: ON <1V - Prüfschritt 3.2

- Retarder stage switch in
stage position 0 ≥1V - Lead short circuit
switch
3.2 1-V- 3 - Retarder stage switch in ≥ 20 V - End of check

stage position 1 to 5

switch
4.1 Input retarder stage 1-V- 5 Ignition: ON ≥ 7,7 V - Step 4.2

switch - Retarder stage switch in
stage position 5
< 7,7 V - Lead discontinuity
switch
4.2 1-V- 5 ≤ 8,3 V - End of check
- Lead discontinuity
> 8,3 V - Lead short circuit
switch

53.2658.10 Page 4.4/11
Diagnosis / '' $#
%

test connection
5.1 Output retarder stage 1-V- 6 Ignition: ON ≥ 14,7 V - Step 5.2

switch 1-V- 7 - Retarder stage switch in stage
1-V- 8 position 0
1-V- 9 < 14,7 V - Lead discontinuity
1 - V - 10 - Lead short circuit
switch
5.2 1-V- 6 ≤ 15,3 V - End of check

1-V- 7
1-V- 8
1-V- 9 > 15,3 V - Lead discontinuity
switch

53.2658.10 Page 4.4/12
Diagnosis / '' $#
%

test connection
6.1 Temperature pick-up 11 - W - 12 Ignition: OFF - Check electrical lead and

- Disconnect plug from control temperature pick-up
unit

Notice:
is sufficient.
+ 20°C 500 ... 700 Ω
+ 60°C 134 ± 13 Ω
+ 90°C 52 ± 4 Ω
+ 100°C 38,5 ± 3,5 Ω
6.2 11 - W - 12 ≥ 54 Ω -Lead discontinuity

-Lead short circuit
< 54 Ω -End of check
If fault is still existing,

renew temperature pick-up.

53.2658.10 Page 4.4/13
Diagnosis / '+ *
$#
Troubleshooting

R

FD844

switch positions.

1 on moving off


53.2658.10 Page 4.5/1
Diagnosis / '+ *
$#
Action
1 Retarder pilot light, Vehicle on move Retarder pilot light Retarder performs
retarder - Retarder stage switch in comes on, satisfactory
switch position 1 to 5 Braking of retarder
in switch position
1 to 5
Retarder pilot light Troubleshooting as on

does not come on, Troubleshooting diagram
and/or insufficient (see page 4.1/1)
braking of the retar-
der

53.2658.10 Page 4.5/2
Retarder Remo- +
%, -

%
ving, Installing

53.2658.10 Page 5/1
Retarder Remo- !" #
Illustration retarder (free mount installation)
1300
1300
1300
1400
1200
1400 1400
94 1200 1200
95
92
36
92
25
1100
96
93 97
1000 96
1200
1200 1600
1000/6
1600
1000/5 1500
FD521

• Ignition OFF
Notice
When stainless-steel heat exchanger is installed, oil can not be drained from the heat exchanger..
25 Constant-air pressure line py „A“ 1100 Suspension complete

36 Ventilation line „R“ 1300 Hex.-head screw (M 16 x 90)
57 Plug temperature pick-up 1400 Washer (B 16)
92 Prop-shaft 1500 Hex.-head nut (M 16) self-locking, renew, 110 Nm
93 Hex.-head screw 1600 Spacer tube
94 Spring washer
95 Hex.-head screw
96 Hose clamp
97 Hose connection
1000 Heat exchanger
1000/5 Drain plug cooling water (M 18 x 1,5), 50 Nm
1000/6 Sealing ring (A 18 x 22), renew
Caution!


53.2658.10 Page 5.1/1
Retarder Remo- +
%, -

%
ving, Installing . / $
0
To install the retarder 120 - 120 S according to regulations to the gearbox or to remove from the gearbox,
Caution!


53.2658.10 Page 5.2/1
Repair Gearbox 5HSDLU*HDUER[$WWDFKPHQW
Attachment



53.2658.10 Page 6/1
Repair Gearbox ' ( !!)
Attachment
Illustration assembly overview (Retarder basic group)

2800
3200
2900 2700
3100
2500
4600 2600
4400
3000
4500 2300/1
4300 2301
101 2300
102 2300/2
2300/3
2400
1900
1800
700
850
800
104
900
103
103
104
1200
1300 1100
1400 1000
1600
1500 1700
FD1572
101 Hex.-head screw (M 12 x 1,5) 2300/1 Valve insert

102 Sealing ring (A 12 x 15,5) 2300/2 Float
103 Silencer-ventilation (30 x 4) 2300/3 Float cage
104 Circlip (JL 30 x 1,2) 2301 O-ring (55 x 3)
700 Raduial shaft sealing ring (80 x 100 x 10) 2400 Sieve (D 60 x 23)
800 Labyrinth cover 2500 Cover sheet metal
850 O-ring (125 x 2,5) 2600 Spacer (D 50/42 x 15,5)
900 Hex.-head screw (M 8 x 25), self-locking 2700 Washer (B 6,4)
1000 Cover 2800 Cap screw (M 6 x 12)
1100 O-ring (82 x 4) 2900 Top cover
1200 Gasket with 7 threads for M 6
1300 Bottom cover 2901 Valve internal part
1400 Washer (B 8,4) 2902 Spring
1500 Cap screw (M 6 x 20) 2903 Connector
1600 Sealing ring (A 22 x 29) 3000 Gasket
1700 Screw plug (M 22 x 1,5) for 7 fixing screws M 6
1800 Sealing ring (A 30 x 36) 3100 Washer (B 6,4)
1900 Oil filler/check plug (M 30 x 1,5) 3200 Cap screw (M 6 x 30)
2300 Casing ventilation (D 30 x 38) 4300 Radial shaft sealing ring (85 x 105 x 13)
contents Position 2301 4400 Centering cover (D 180 x 70)
4500 O-ring (130 x 4)
4600 Hex.-head screw (M 8 x 20), self-locking

53.2658.10 Page 6.1/1
Repair Gearbox
Attachment
2700
Preconditions for job 3200
• Retarder removed (see Section 5.1). 3100 2500

2900

2300/3 Float cage
2301 O-ring (55 x 3), renew, 3000 2300/2
2500 Cover plate
2400
2600 Spacer
2700 Washer (B 6,4)
2900 Cover
3000 Gasket, renew
3100 Washer (B 6,4)
3200 Cap screw (M 6 x 30), 10 Nm
FD634

53.2658.10 Page 6.2/1
Repair Gearbox

Special tools
53.7712.10 53.9428.10
To remove

53.2658.10 Page 6.2/2
Repair Gearbox
99/5
5. Screw out hex.-head screws (2800) and remove Washer (2700). 98/7
FD638
98/7 Adapter 53.9428.10

99/5 Impact tool 53.7712.10
2300/3
FD027

53.2658.10 Page 6.2/3
Repair Gearbox
To check

2300/2
Notice
FD028
2300/1
FD029

53.2658.10 Page 6.2/4
Repair Gearbox
To install
2300/1
2301
Notice
FD032

53.2658.10 Page 6.2/5
Repair Gearbox
Caution!

53.2658.10 Page 6.2/6
Repair Gearbox ! "
Attachment

• Ignition OFF
Notice

removed or in situ.

103
clean with Benzine and blow out 104
with compressed-air
104 Circlip (JL 30 x 1,2),
Cleaning agents
Silencer Benzine
103
104
FD675

53.2658.10 Page 6.3/1
Repair Gearbox # $
Attachment

• Ignition OFF
1200 Gasket, renew

1300 Bottom cover
1500 Cap screw (M 6 x 20), 10 Nm 1200
1300
1500
FD488

53.2658.10 Page 6.4/1
Repair Gearbox %
Attachment & '(
• Ignition OFF
• Heat exchanger removed (see Section 8)
1000 1100
To check
Check closing cover (1000) for leaks, renew O-ring (1100), if necessary. 1000
Notice
FD484
There may be found two variants.
Variant with bridge
1. Remove closing cover (1000) with O-ring (1100).
2. Coat new O-rings (1100) thin with silicone-free and non-corossive grease

53.2658.10 Page 6.5/1
Repair Gearbox %
Attachment & '( (Continue)
Variant with threaded hole
Special tool
1000
99/5
53.7712.10
1100 1000 FD647
99/5 Impact tool 53.7712.10


53.2658.10 Page 6.5/2
Repair Gearbox )* (Output
Attachment Side) + "& "

Prior jobs
(see VOITH-installation schemes)
• Retarder stage switch in position 0 700 850
• Ignition OFF
800
Notice 900


(80 x 100 x 10), renew,
for installation
bore
850 O-ring (125 x 2,5), renew,
for installation
900 Hex.-head screw (M 8 x 25) FD657

53.2658.10 Page 6.6/1
Attachment Side) + "& " (Cont.)
Locking agents
Special tool
53.0742.10
Job scope
800
rotor housing.
FD659

53.2658.10 Page 6.6/2
Notice
guaranteed, please contact VOITH TURBO. 800 700
FD660
6. Use a press-in equipment (94/4) to press the radial shaft sealing ring (700) as far as it will go into 94/4
the labyrinth cover (800).
700 800
FD661

53.2658.10 Page 6.6/3
are in alignment.
800
FD067

53.2658.10 Page 6.6/4
Repair Gearbox , (Input
Attachment Side) + "& "
Illustration centering cover

Prior job
• Retarder removed (see Section 5)

(85 x 105 x 13), renew,
coat with silicone-free and 4600
for installation
4400 Centering cover
4500 O-ring (130 x 4), renew,
for installation
Lubricants

4500 4300 4400
FD651

53.2658.10 Page 6.7/1
Special tool
53.0742.10
Job scope
2. Use two hex.-head screws (M 8 x 30) (arrows) to press centering cover (4400) off 4500 4400
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
Notice
4400
guaranteed, please contact VOITH TURBO. FD653

53.2658.10 Page 6.7/2
94/4
4300
4400
FD655
the centering cover. 4600
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.
4500
9. Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm
4400
FD656

53.2658.10 Page 6.7/3
Repair Free Mount , - .(
Installation
7.6 Removing and Installing Prop Shaft Flanges .............................................7.6/1



53.2658.10 Page 7/1
Repair Free Mount * ( !!)
Installation
2800
3200 2900 2700
3100
2500
4700
2600
800
3000 2300/1
850
2301
700 101 2300
102 2300/2
5400 2300/3
5500
2400
1900
1800
5500
5400 700
850
800
104
900
103
103
104 1200
1300 1100
1400 1000
1600
1500 1700
FD1573
101 Hex.-head screw (M 12 x 1,5) 2300/1 Valve insert

102 Sealing ring (A 12 x 15,5) 2300/2 Float
103 Silencer-ventilation (30 x 4) 2300/3 Float cage
104 Circlip (JL 30 x 1,2) 2301 O-ring (55 x 3)
700 Raduial shaft sealing ring (80 x 100 x 10) 2400 Sieve (D 60 x 23)
800 Labyrinth cover 2500 Cover sheet metal
850 O-ring (125 x 2,5) 2600 Spacer (D 50/42 x 15,5)
900 Hex.-head screw (M 8 x 25), self-locking 2700 Washer (B 6,4)
1000 Cover 2800 Cap screw (M 6 x 12)
1100 O-ring (82 x 4) 2900 Top cover
1200 Gasket 3000 Gasket
1300 Bottom cover 3100 Washer (B 6,4)
1400 Washer (B 8,4) 3200 Cap screw (M 6 x 30)
1500 Cap screw (M 6 x 20) 4700 Hex.-head screw (M 8 x 30)
1600 Sealing ring (A 22 x 29) self-locking
1700 Screw plug (M 22 x 1,5) 5400 Race
contents Position 2301

53.2658.10 Page 7.1/1
Repair Free Mount ,
Installation
3200
2700
• Retarder removed (see Section 5.1). 3100 2500
2900
2301
2300/3 Float cage
2301 O-ring (55 x 3), renew, 2300/2
2500 Cover plate 2400
2600 Spacer
2700 Washer (B 6,4)
2900 Cover
3000 Gasket, renew
3100 Washer (B 6,4)
3200 Cap screw (M 6 x 30), 10 Nm
FD461

53.2658.10 Page 7.2/1
Repair Free Mount ,

Special tools
53.7712.10 53.9428.10
To remove

53.2658.10 Page 7.2/2
Repair Free Mount ,
99/5
5. Screw out hex.-head screws (2800) and remove Washer (2700).

98/7
FD504
98/7 Adapter 53.9428.10

99/5 Impact tool 53.7712.10
2300/3
FD027

53.2658.10 Page 7.2/3
Repair Free Mount ,
To check

2300/2
Notice
FD028
2300/1
FD029

53.2658.10 Page 7.2/4
Repair Free Mount ,
To install
2300/1
2301
Notice
FD032

53.2658.10 Page 7.2/5
Repair Free Mount ,
Caution!

53.2658.10 Page 7.2/6
Repair Free Mount ,! "
Installation

• Ignition OFF
Notice


clean with Benzine and blow out 104 103
with compressed-air
104 Circlip (JL 30 x 1,2),
Cleaning agents
Silencer Benzine
103
104
FD527

53.2658.10 Page 7.3/1
Repair Free Mount ,# $
Installation

• Ignition OFF
1200 Gasket, renew

1300 Bottom cover
1500 Cap screw (M 6 x 20), 10 Nm 1200
1300
1500
FD488

53.2658.10 Page 7.4/1
Repair Free Mount ,%
Installation & '(
• Ignition OFF
• Heat exchanger removed (see Section 8)
1000 1100
To check
Check closing cover (1000) for leaks, renew O-ring (1100), if necessary. 1000
Notice
FD484
There may be found two variants.
Variant with bridge
1. Remove closing cover (1000) with O-ring (1100).

53.2658.10 Page 7.5/1
Repair Free Mount ,%
Installation & '( (Continue)
Variant with threaded hole
Special tool
1000
99/5
53.7712.10
1100 1000 FD647
99/5 Impact tool 53.7712.10


53.2658.10 Page 7.5/2
Repair Free Mount , / "& -
Installation
Illustration prop shafts flanges
Prior jobs
• Prop shafts flanges removed 93
Notice
The jobs in this section can be performed with

97/9 98

95 Hex.-head nut (M 20), 375 Nm
(output side)
97/7 Prop shaft screw, renew 97/6
97/8 Guard ring (output side) 97/8
97/9 Guard ring (input side)
98 Prop shaft flange
(input side)
97/7 95
FD489

53.2658.10 Page 7.6/1
Repair Free Mount , / "& -
Removing and installing

1. Screw out hex.-head nut (95).
Screw hex.-head nut (95/2) tight. Tightening torque 375 Nm

2. Pull out hex.-head screw (93) 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).
Renew prop shaft screws (97/7).

Align hole patterns of both prop shaft flanges prior to installation. 97/7 97/8
Maximum permissible offset 5°. 97/9
5. Install the prop shafts in accordance to the vehicle manufacturer instructions.
FD016

53.2658.10 Page 7.6/2
Repair Free Mount ,, )* (Output
Installation Side) + "& "

Prior jobs
(see VOITH-installation schemes) 5500
5400
• Retarder stage switch in position 0 700
800
900
Notice


bore
5400 Race FD496


53.2658.10 Page 7.7/1
Installation Side) + "& " (Cont.)
Housing sealing surfaces Hylomar 900

Special tool
FD497
53.0742.10
Job scope
800
rotor housing.
FD498

53.2658.10 Page 7.7/2
7. Check race for scores and radial shaft sealing ring for uneven surface and renew 800 700
race if necessary.
Notice FD065
Recommendation:
9. Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it 5400
will go.
FD499

53.2658.10 Page 7.7/3
700
800
FD066
are in alignment.
800
FD067

53.2658.10 Page 7.7/4
Repair Free Mount ,0 )* (Input
Installation Side) + "& "

Prior jobs
(see Section 7.7)
5500
5400
700
Notice 850
800

bore
850 O-ring (125 x 2,5), renew, coat with 4700
5400 Race
FD492

53.2658.10 Page 7.8/1

Special tool
53.0742.10
Job scope
800
2. Use two hex.-head screws (M 8 x 40) (arrows) to press labyrinth cover (4400) off
retarder housing.

FD494

53.2658.10 Page 7.8/2
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. FD058
Recommendation:
9. Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it
will go.
FD495

53.2658.10 Page 7.8/3
700 800
FD059
are in alignment.
800
FD067

53.2658.10 Page 7.8/4
Repair 0
Heat Exchanger ' 1

53.2658.10 Page 8/1
Repair + !" #
Heat Exchanger / , -.
1000/6
1000/5
9500
3000 1000/2
2000
8000
1000/1
15000
9000 17000
1600
7000 4000
1700
4000
16000
4000
17000
5000 13000
14000
97 5000
96
1000
17000
16000
14000
12000 FD1259
Prior jobs
This job sequence can also be performed with the retarder installed, if necesary.
• Retarder stage switch on stage position 0
• Ignition OFF
96 Hose clamp Lubricants

97 Cooling water hose
O-rings, Throttle disc Silicone-free and
1000 Heat exchanger
(alternatively) non-corrossive grease
1000/1 Leaking oil drain plug (M 14 x 1,5), 32 Nm
1000/5 Cooling water drain plug (M 18 x 1,5), 50 Nm Data
1000/6 Sealing ring (A 18 x 22), renew Pressure test (oil section) max.10 bar
1700 Retarder oil drain plug (M 22 x 1,5), 66 Nm
2000 Throttle disc (outlet throttle)
3000 O-ring (36 x 4), renew, coat with silicone-free and
4000 Washer (B 8,4)
5000 Hex.-head nut M 8, self-locking, renew, 23 Nm
8000 Pin screw (M 10 x 50)
9000 O-ring (45 x 4) renew, coat with silicone-free and
9500 O-ring (8 x 2) renew, coat with silicone-free and
12000 Connecting piece
13000 Connecting piece
14000 Sealing ring, renew
17000 Washer (B 10,6)

53.2658.10 Page 8.1/1
Repair 02
Heat Exchanger "3 ' 1 (Continue)
Notice
3. Screw out the oil drain plugs (1700, 1000/1) and remove the sealing rings (1600, 1000/2).
Drain the oil.
1000/1) with new sealing rings (1600, 1000/2) tight.

53.2658.10 Page 8.1/2
Repair 02
To remove
Notice
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.

53.2658.10 Page 8.1/3
Repair 02
To install
Notice
right bore.
Notice


53.2658.10 Page 8.1/4
Repair 02
1700
Screw oil drain plug (1700) tight with new sealing ring. FD1265
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. If heat exchanger (1000) had been leaking, deoil vehicle cooling and heating system in
accordance with vehicle manufacturer´s data.

53.2658.10 Page 8.1/5
Repair + !" #
Heat Exchanger ( , -.
1000/3
1000/4
9500
1000/2
1000/6
3000 1000/1
2000 1000/5
8000
4000
4000
9000
1600
7000
4000 1700
5000
5000
1000/3
97 1000
96 FD641
Prior jobs
This job sequence van also be performed with the retarder installed, if necessary.
• Ignition OFFschalter auf Schaltstufe 0

97 Cooling water hose
O-rings, Throttle discs Silicone-free and
1000 Heat exchanger
(alternatively) non-corrosive grease
1000/1 Leaking oil drain plug (M 14 x 1,5), 32 Nm
1000/3 Oil drain plug heat exchanger (M 12 x 1,5), 25 Nm Data
1000/4 Sealing ring (A 12 x 15,5), renew Pressure test (oil section) max.10 bar
1000/5 Cooling water drain plug (M 18 x 1,5), 50 Nm
1000/6 Sealing ring (A 18 x 22), renew Special tool
1700 Heat exchanger oil drain plug (M 22 x 1,5) 66 Nm
2000 Throttle disc (outlet throttle)
4000 Washer (B 8,4)
5000 Hex.-head nut M 8, self-locking, renew, 23 Nm
8000 Pin screw (M10 x 50)
9000 O-ring (45 x 4), renew, coat with silicone-free and 53.4786.10

53.2658.10 Page 8.2/1
Repair 0
Heat Exchanger (( ' 1 (Continue)
Notice
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.
1000/1, 1000/3) with new sealing rings (1600, 1000/2, 1000/4) tight.

53.2658.10 Page 8.2/2
Repair 0
To remove
Notice
To check
pressure minimizer.
99/6
Notice
If air bubbles form in the hot water, the heat exchanger is leaking and must be renewed. 1000
FD046

53.2658.10 Page 8.2/3
Repair 0
To install
Notice
right bore.
Notice


53.2658.10 Page 8.2/4
Repair 0
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.
and annex).

53.2658.10 Page 8.2/5
Control Parts 4 /
9.1 Control Parts ..............................................................................................9.1/1

53.2658.10 Page 9/1
Control Parts 42 /
Prior jobs 26
• Discharge supply-air pressure 21000
Escaping compressed-air!
21000/1
26 Compressed-air pressure line pv
36 Ventilation line
5000/1 Proportional valve
current connection
21000/1 Hex.-head screw (M 8), 18 Nm
5000/1 25
36
FD883

53.2658.10 Page 9.1/1
Annex 25
Data Sheet
Spare Parts Lists
Other Information
cbtd 98-01 Aftersales Service Manual VOITH Retarder R 120 Logoprop

53.2658.10 Page 10/1
Data Sheet VOITH Retarder 120
Max. retarder speed (= max. prop shaft speed) v(max.) 2800 r.p.m.
- Service filling (Oil change, checking oil level) 5,5 Litre 4,5 Litre ***
- after complete taking apart and cleaning 6,0 Litre 6,5 Litre **
(corresponds new filling)
Overall weight (with flange and heat exchanger, without oil filling) approx. 59,5 kg *
*** If the heat exchanger was emptied completely during an oil change, 5,8 Litre oil have to be filled in.
Service-Handbuch VOITH Retarder R 120 Logoprop

Seite 9/2
Data Sheet VOITH Retarder 120 S 1)
- Service filling (Oil change, checking oil level) 5,5 Litre 4,5 Litre ***
- after complete taking apart and cleaning 6,0 Litre 6,5 Litre **
Overall weight (with flange and heat exchanger, without oil filling) ca. 59,5 kg *
1)
The retarder 120 S is punched on the retarder data field with an „S“ after the retarder number.
*** If the heat exchanger was emptied completely during an oil change, 5,8 Litre oil have to be filled in.
Miscellaneous Conversions Retarder 120 - 120 S with Logoprop Control System
D GB USA D GB USA
10 Nm 7 lbf-ft 7 lbf-ft 1050 Nm 777 lbf-ft 777 lbf-ft

(Continue)
D GB USA D GB USA
0 - 10 bar 0 - 145 psi 0 - 145 psi 1,90 - 0,25 bar 27,55 - 3,63 psi 27,55 - 3,63 psi
0 - 25 bar 0 - 362,5 psi 0 - 362,5 psi 1,95 - 2,45 bar 28,28 - 35,53 psi 28,28 - 35,53 psi
0,93 - 1,43 bar 13,49 - 20,74 psi 13,49 - 20,74 psi 2,20 - 0,25 bar 31,90 - 3,63 psi 31,90 - 3,63 psi
1,16 - 1,66 bar 16,82 - 24,07 psi 16,82 - 24,07 psi 6,5 bar 94,25 psi 94,25 psi
1,18 - 0,25 bar 17,11 - 3,63 psi 17,11 - 3,63 psi 7 bar 101,5 psi 101,5 psi
1,26 - 0,25 bar 18,27 - 3,63 psi 18,27 - 3,63 psi 9 bar 130,5 psi 130,5 psi
(Continue)
D GB USA D GB USA
10 bar 145 psi 145 psi 21 bar 304,5 psi 304,5 psi
12 bar 174 psi 174 psi 0,2 l 0,044 UK gal 0,053 US gal
13 bar 188,5 psi 188,5 psi 0,5 l 0,110 UK gal 0,132 US gal
14,5 bar 210,25 psi 210,25 psi 5,5 l 1,210 UK gal 1,452 US gal
18,5 bar 268,25 psi 268,25 psi 1000 km 621,4 miles 621,4 miles
VOITH TURBO
Powertransmission
VOITH Retarder
1. Water
2.1 Normal case

*see chapter 4


**see chapter 5
Attention:
agent!

***see chapter 6
Attention:

3. Miscellaneous
3.1 Disposal
3.2 Safety

Attention:




Attention:



Attention:

Attention:


Attention:


Attention:




Attention:


Attention:

Attention:



Attention:


Attention:

A 000 989 13 25 10

Attention:


D-74564 Crailsheim
i. V. i. V. Phone (07951) 32-0
Telefax (07951) 32-756
32-401 / 32-422

92,7+5HWDUGHU
cbtd 98-01
53.2661.10
1. Preface ....................................................................................................1/1
2. General....................................................................................................2/1
2.3 Retarder Data ...................................................................................2.3/1
3. Maintenance............................................................................................3/1
3.2 Oil Change .......................................................................................3.2/1

cbtd 98-01 Aftersales Service Manual VOITH Retarder R 133-2

53.2661.10 Page IHV/1
(Continue)

6.3 Removing, Checking and Installing Sump Check Valve ...........................6.3/1
6.5 Removing and Installing Housing Pressure Changeover Valve ..................6.5/1
6.6 Removing and Installing Labyrinth Cover (Output Side),

7.3 Removing, Checking and Installing Oil Sump Check Valve .......................7.3/1
7.5 Removing and Installing Housing Pressure-Switch Valve .........................7.5/1
7.8 Removing and Installing Labyrinth Cover (Input Side),

53.2661.10 Page IHV/2
(Continue)

8.1 Removing, Checking and Installing Stainless-steel Heat Exchanger ...........8.1/1
9. Control Parts ...........................................................................................9/1

9.1 Control Parts ....................................................................................9.1/1
10. Annex ....................................................................................................10/1

Data Sheet
Spare Parts Lists
Other Information

53.2661.10 Page IHV/3
Preface 3UHIDFH
appropriate and professional maintenance and repair at the VOITH Retarder 133-2 with Digiprop control.
Caution!
Notice
cbtd 98-01 Aftersales Service Manual VOITH Retarder 133-2

53.2661.10 Page 1/1
Preface
(Continue)
Caution!
Notice
• Brake-Number
• Basic group-Number
Notice

53.2661.10 Page 1/2
Preface
(Continue)
Caution!
Notice
professionally.
Notice
Notice

53.2661.10 Page 1/3
Preface
(Continue)
damage incurred.
prior notification.

D-74564 Crailsheim

Telefax (07951) 32-756
Extensions:
32-401 / 32-422

53.2661.10 Page 1/4
General

2.3 Retarder Data.............................................................................................2.3/1

53.2661.10 Page 2/1
General
Illustration VOITH Retarder R 133-2

basic group with stainless-steel 21000
heat exchanger 22000
1000 Heat exchanger 34000

1010/1 Retarder data 2260
1030 Check connection
housing pressure pG
37000
1040 Oil level plug, (M 24 x 1,5)
1030
2260 Oil filler plug (M 24 x 1,5),
alternatively (M 18 x 1,5) 1010/1
31000
22000 Anti-vibration plate
31000 Supply-air pressure line p v „A1“
(zu Gehäusedruck-Schaltventil)
40000 Temperature pick-up oil
40000 Temperature pick-up cooling water 1060
40000
Notice
The illustration shows the retarder 133-2 with

built-on proportional valve. 1000
It is possible to locate the proportional valve
elsewhere. 1040 FD837

53.2661.10 Page 2.1/1
General
(Continue)
Illustration VOITH Retarder R 133-2

heat exchanger (Continue) 1070
1000 Heat exchanger

1000/3 Cooling-water drain plug
(M 18 x 1,5)
1440
(M 30 x 1,5)
1440 Silencer
2105 Sump check valve plug
(M 22 x 1,5)
1000/3
1000
FD857

53.2661.10 Page 2.1/2
General
Illustration VOITH Retarder R 133-2 with Digiprop control system
70 47 15 17 7 26
P 21
R A A1
30
36 46 10
18
23 25
44
56
49
20
45 51
19
22
7
58
60
8 5 4
69 16
54 68 59 43 53 1
Supply-air pressure p V Pump pressure P

FD839
Notice
1 Heat exchanger 30 Supply-air pressure line pv

2 Control unit (to housing pressure changeover valve)
4 Connection terminal 15 36 Ventilation line
5 Connection terminal 30 43 Oil sump
7 Fuses (5A) 44 Stator
8 Connection ground 45 Stator pin
10 Housing pressure pG test connection 46 Rotor
15 ABS signal 47 Speeometer signal
16 Retarder stage switch 49 Output restrictor p1
17 Retarder pilot light 51 Filling restrictor p2
18 Stop light relay 53 Filling duct
19 Cooling water temperature pick-up 54 Duct
20 Oil temperature pick-up 56 Leakage oil return line
21 Proportional valve 58 Sump check valve
22 Breather 59 Sump flap valve
23 Casing ventilation 60 Housing pressure changeover valve
25 Constant-air pressure line p y 68 Auxiliary chambers
26 Supply-air pressure line pv 69 ISO-Interface plug
(to proportional valve) 70 Extra operations plug

53.2661.10 Page 2.2/1
General

!

(Continue)

The VOITH Retarder 133-2 is a powerful, hydrodynamic, continuous brake of compact design for buses
and commercial vehicles in the heavy range. The VOITH Retarder 133-2 is located in a vehicle drive
train between gearbox and rear axle. In this way, the retarder braking torque is sustained even when
gear changes are made. The switched-on retarder will not secure a parked vehicle.
VOITH Retarder 133-2. A special version combines the retarder stage switch (16) with ABS,

When the retarder stage switch is shifted to position 1, the momentary speed is transferred to memory
and the retarder holds the vehicle speed downhill constant within the limits of the maximum braking tor-
que.
If after activation of „constant speed“ operation 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.

53.2661.10 Page 2.2/2
General

!

(Continue)
Description of operation of retarder R 133-2 with digiprop control system

c
The control medium for the Voith Retarder 133-2 is compressed air, which is taken from the air tank for
auxiliary equipment on the vehicle.
proportional valve (21). a b
and stator (44).
FD299
The rotor (46) is connected with the retarder drive shaft, the stator (44) is stationary with the retarder The hydrodynamic principle
housing. a Rotor (46)
The rotation of the rotor sets the oil in motion and circulates it in a closed circuit between b Stator (44)
the rotor (46) and stator (44). c Oil flow

53.2661.10 Page 2.2/3
General

!

(Continue)

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).
oil temperature.


53.2661.10 Page 2.2/4
General

!

(Continue)
Sump check valve (58)

Any small amounts of leakage oil present on the shaft sealing rings are collected by the labyrinth and
returned via the leakage oil return line (56), the sump check valve and the duct (54) into the auxiliary
chambers (68), and thus to the oil sump (43).
When the retarder is switched off, the compressed air escapes via the auxiliary chambers (68) and the
breather (22) into the open air and simultaneously acts on the sump check valve via the duct (54).
The aluminium disc is pushed upwards by the compressed-air and closes the leakage oil return line (56).
Oil is thus prevented from escaping via the labyrinth selas when the retarder is switched off.
Sump flap valve (59)

When the retarder is switched on, the oil sump (43) is pressurized with compressed air.
The oil sump (43) is seperated from the auxiliary chambers (68).
After the retarder has been switched off, the sump flap valve opens again and the oil can level out
between the oil sump (43) and the auxiliary chambers (68).

53.2661.10 Page 2.2/5
General

!

(Continue)
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). This causes a power loss. 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.
Housing pressure changeover valve (60)

The housing pressure changeover valve (60) regulates bearing lubrication when the retarder is idling.

53.2661.10 Page 2.2/6
General " #
The data (arrow) of the retarder 133-2 punched on the output side of the retarder housing on the left give
the following information:
1. Number of the brake (Br.Nr.):
5/91
Six-digit number.
F = fixed bearing
L = moveable bearing RETARDER 133
No data = Free mount installation BrNr
GrNr
2. Basic group number (Gr.Nr.): M = 4000 Nm
n =
Eight-digit number
At the end of the basic group number the retarder R133-2 has a "-2".
3. Max. braking torque on prop shaft (M):
FD158
M = 4000 Nm.
Notice
Max. braking torque is set for the specific vehicle. Observe the vehicle manufacturer´s data.
4. Max. retarder r.p.m. (max. prop shaft r.p.m.):
R 133-2, n = 2800 r.p.m.
Notice
Please, always quote the No. of the brake and basic group No. when submitting queries

53.2661.10 Page 2.3/1
Maintenance $

3.2 Oil Change .................................................................................................3.2/1

53.2661.10 Page 3/1
Maintenance $

%

l Check hex.-head screws of prop shaft on correct fitment, or tighten. Observe guidelines and
instructions!
torque (see Annex) except all fastening nuts of the heat exchanger (see Section 8)!
Caution!
The fastening nuts of the heat exchanger (Dilavar) only may be tightened in the case of an unambiguous
leakage. Tightening torque 46 Nm
Achtung!
Don´t tight with an impact tool.

When studs (Dilavar) are tightened too high this causes a damage of the studs and may crack at once
or during the driving session.

53.2661.10 Page 3.1/1
Maintenance &
'
Illustration oil change R 133-2 with

stainless-steel heat exchanger
2260

1060 Oil filler/check plug (M 24 x 1,5), 2270
80 Nm
1070 Retarder oil drain plug (M 30 x 1,5),
150 Nm
2105 Screw plug sump check valve
(M 22 x 1,5), 66 Nm
2260 Oil filler plug (M 24 x 1,5), 1080
80 Nm, 1070
alternatively (M 18 x 1,5), 50 Nm
2270 Sealing ring (A 24 x 29, A 18 x 24), 2090 2105
renew
1050
FD881

53.2661.10 Page 3.2/1
Maintenance &
'
(Continue)
Notice
operating the retarder in the relevant application. The retarder oil temperature
must be higher than 60 oC (operating temperature) for the oil to be drained.
Notice
If it is necessary to drain the cooling water during a service, remove end empty retarder on oil side com-
pletely (see following table service filling). This process also must be enforced with strongly spent oil.
Then install heat exchanger with new sealing rings.
Heat exchanger Heat exchanger

L&R small L&R large
VOITH item number 67.0481.11 67.0567.11
Service filling 6 Litre 6 Litre
After exchange of heat exchanger 7,5 Litre 8,2 Litre
After complete taking apart and cleaning, as

well as emptied heat exchanger 9 Litre 9,5 Litre

53.2661.10 Page 3.2/2
Maintenance &
'
(Continue)
Job scope
switch it off after approx. 5 sec. Repeat this procedure twice.
The retarder oil drain plug and screw plug is heated up (oil temperature)!
3. Screw out the retarder oil check plug (1070) and remove sealing ring (1800). Drain the oil.
Notice
The heat exchanger „Stainless-steel small“ as well as „Stainless-steel large“ have no oil drain plug.
4. Screw the retarder oil check plug (1070) tight with new sealing ring (1080)
5. Screw out check plug (2105) and remove sealing ring (2090) and drain collected leakage oil.
6. Screw the check plug (2105) tight with new sealing ring (2090).
7. Fill in slowly, in the hole of the oil filler/check plug (1060) or the hole of the filling plug (2260), the
quantity of oil specified (see page 3.2/2) in accordance with the operating specifications
(see Annex).

53.2661.10 Page 3.2/3
Maintenance &
'
(Continue)
Notice
If the oil is filled in too quickly at the housing cover, there is an oil backflow and the oil may emerge throu-
gh the ventilation system (silencer).
8. Provide the oil filling plug (2260) with a new sealing ring (2270) and screw it tight.
Tightening torques:
Oil filling plug (M 24 x 1,5) = 80 Nm
9. Check oil level (see Section 3.3).

53.2661.10 Page 3.2/4
Maintenance &
' (

2260
Notice 2270
The oil change intervals and operating

specifications have to be taken from the annex.
1040 Oil level plug (M 24 x 1,5), 1060

80 Nm
80 Nm
2260 Oil filling plug (M 24 x 1,5), 80 Nm,
alternatively (M 18 x 1,5), 50 Nm 1050
2270 Sealing ring (A 24 x 29, A 18 x 24),
renew
1050
1040
FD876

53.2661.10 Page 3.3/1
Maintenance &
' (
(Continue)
Notice
Service filling
For versions which are not listed in the table „Service filling R 133-2“ (see Section 3.2/2) please, contact
VOITH TURBO regarding the service filling.


53.2661.10 Page 3.3/2
Maintenance &
' (
(Continue)
Notice
Difference between min. and max. mark on oil filler/check plug is approx. 1,0 Litre oil.
The oil level check on the VOITH Retarder 133-2 can be carried out either with the oil filler/check plug
(1060) or with the oil level plug (1040), depending on access on the vehicle.
Job scope
• Ignition ON
• Operating pressure
Oil level check with oil filler/check plug

4. Position oil filler/check plug (1060) plane at the thread. Do not screw in the oil filler/check plug!

53.2661.10 Page 3.3/3
Maintenance &
' (
(Continue)
Oil level check with oil filler/check plug (Continue)

Oil level is correct bewteen min. and max. mark of the oil filler/check plug. 1060
6. Top up slowly any lacking oil through the hole for the oil filler/check plug. Max
Min
Notice
If the oil is filled in too quickly at the housing cover, there is an oil backflow and the oil may emerge
through the ventilation system (silencer).
7. Screw the oil filler/check plug (1060) with new sealing ring or, as the case may be, FD878
the oil filler plug (2260) tight with new sealing ring (2270).
Tightening torques:
Oil filler/check plug 80 Nm

Oil filler plug (M 24 x 1,5) 80Nm

53.2661.10 Page 3.3/4
Maintenance &
' (
(Continue)
Oil level check with screw plug

The screw plug is heated up (oil temperature)! 1020

1040
FD860
3. Screw out the screw plug (1040) and remove sealing ring (1050).
Oil level is correct, when it reaches the lower edge of the threaded bore (arrow).
4. Top up slowly any lacking oil through the hole for the oil filling plug in the housing cover.
Observe the following tightening torques:
Oil level plug = 80 Nm

Oil filling plug (M 24 x 1,5 = 80 Nm

53.2661.10 Page 3.3/5
Maintenance ) &

' (

(Optional Extra)

12000/3 Cover
12111 Filter insert
12112 O-ring (36,2 x 3), renew,
12000
for installation
12000/5
Lubricants

non-corossive grease 12112
12000/3
12000/4
FD427

53.2661.10 Page 3.4/1
Maintenance ) &

' (

(Continue)
Notice
Job scope

53.2661.10 Page 3.4/2
Maintenance ) &

' (

(Continue)
Notice

53.2661.10 Page 3.4/3
Diagnosis / ) #'
*+
'
Troubleshooting

Electrical Connections Diagram Version 1 and 2 ..........................................................4.1/2
4.3 Checking Housing Pressure.......................................................................4.3/1

53.2661.10 Page 4/1
Diagnosis /
Troubleshooting
Notice

VOITH ventilation
OK NOK
Check casing see chapter 8
retarder (*) Check cooling
ventilation
system:
(Chapter 6.2) Check heat
exchanger
-coolant level
-coolant pump
Check oil level of dirtiness
retarder
Retarder:
Driver instruction!
Temp.-Sens.
(oil/water)
Oil leak by
ventilation
Check or renew OK NOK
radial shaft seal
Oil leak when flashes Temperature limit!
input side or
switch on retarder Check operation
output side
(by braking with
(Chapter 6.6 u. 6.7)
retarder nominal
engine speed,
if possible)
Complaint
Oil leak input side Retarder pilot
or output side R 133-2 light
Digiprop
Activate flash code

Check or renew oil Oil leak at the Clear faults and
and read out
sump shut-off valve moment when Permanent lighting delete fault memory
trouble code
(Chapter 6.3) switch off retarder (see chapter 4.2)
No respectively (see chapter 4.2)
too insufficient
retarder braking
effect
Check oil level of

retarder
NO YES YES NO
Check heat
exchanger
8 Correct oil level of

see chapter
retarder

OK NOK
Check p (dynamic)
(Chapter 4.3)
NOK OK Check voltage of

Proportional valve
(Chapter 4.4)
Check shift valve OK NOK
of retarder housing
pressure Contact
(Chapter 6.5) VOITH
OK NOK
Check control unit
(Chapter 4.4)
Take Renew shift valve OK NOK

measurements of of retarder housing
inner diameter of pressure
outlet throttle and respectively
contact VOITH proportional valve
Check
Contact Contact
compressed- VOITH VOITH
-air supply
(Chapter 4.4)
OK NOK
Mechanical fault of Check vehicle

proportional valve, compressed-air
antivibration plate supply
or shift valve of
OK NOK
retarder housing
pressure
Contact
Contact
vehicle
VOITH *
manufacturer If you get oil leakage after a trail run again:
continue at ´Ćhecking casing ventilation´´
FD 1710

53.2661.10 Page 4.1/1
Diagnosis /
Electrical connections diagram version 1

"ISO Interface"
3 1 2 4
Digiprop 3 CAN-high
2 CAN-Ground Lead E- Box
1 CAN-low
9 Position 4 white
weiß 3 Position 4
7 T 15 (Ignition lock) red 8 Stage switch`+`
X1. red 4
12 ISO K blue/white
10 Stage switch`+` purpel
purpel
Lead Retarder
3 Prop valve `+` pink Pin 1 Prop valve`+`
1 Changeover valve `+` orange 3 Changeover valve`+`
4
X2. 6 Changeover valve `-` beige Changeover valve`-`
4 Water temp.`-` blue Water temp.`-`
9 Oil temp.`+` purpel Oil temp.`+`
8 Oil temp.`-` white Oil temp.`-`
7

2 Speedometer signal blau Speedometer signal
X3. 4 Input / pull-down `DID 2` brown/white
9 Input / pull-down `DID 3 ` orange/white
grey
1 9 5 8 4 3 2 7 6 1112101314

Electrical connections diagram version 2
"ISO Interface"
3 1 2 4
Digiprop 3 CAN-high
1 CAN-low
9 Position 4 white
weiß 3 Position 4
X1. red 4
12 ISO K blue/white
10 Retarder stage switch`+` purple
purple
Lead Retarder
4
X2. 6 Changeover valve `-` beige
Pin 1
Changeover valve `-`
4 Water temp.`-` blue 2 Water temp.`-`
9 Oil temp.`+` purple 3 Oil temp.`+`
8 Oil temp.`-` white 4 Oil temp.`-`
7

X3. orange/white
9 Input / pull-down `DID 3 `
grey
1 9 5 8 4 3 2 7 6 1112101314


53.2661.10 Page 4.1/2
Diagnosis / ) +
'
"
Troubleshooting
Check requirements
l For check with the multimeter, pin 15 (plug X1) on the control unit (2)
Notice

53.2661.10 Page 4.2/1
Diagnosis / ) +
'
"
Notice R
- slight fault
- serious fault
FD844
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.

53.2661.10 Page 4.2/2
Diagnosis / ) +
'
"

1 Not in use
2 Not in use
3 Not in use
7 Terminal 15 (rd)
10 Retarder stage switch + (vi) 16 13 10 7 4 1
13 Terminal 30 (bl)
18 15 12 9 6 3
14 Not in use
15 Terminal 31 (br)

53.2661.10 Page 4.2/3
Diagnosis / ) +
'
"

5 Cooling water temperature pick-up + (ye/gr) 7 4 1

7 Not in use
FD848

10 7 4 1
6 Input / pull up „DIU 2“ (pi)
7 Input / (0...5V) „INA-U“ (gr/bl) 11 8 5 2
12 9 6 3
12 Input / pull down / PWM-in „DID4“ (gr)/engine-speed signal
FD847

53.2661.10 Page 4.2/4
Diagnosis / ) +
'
"


12 Output / low side 1 „LS1“ (ye/gr) FD849
13 Terminal 15 (rd)
14 Terminal 31 (br)
ISO-Interface plug
1 K-lead (bl/wh)
2 K-lead (or/wh)
3 Terminal 15 (rd)
4 3
4 Terminal 31 (br)
2 1
FD854

53.2661.10 Page 4.2/5
Diagnosis / ) +
'
"

FD851
Tempretaure pick-up plug Version 2 (4-pin plug)

1 Cooling water temperature pick-up + (pi)
2 Cooling water temperature pick-up - (gr) 4 2
3 Oil temperature pick-up + (or)
1 3
4 Oil temperature pick-up - (be)
FD850

53.2661.10 Page 4.2/6
Diagnosis / ) +
'
"

3 Not operational (or) 4
4 Not operational (be)
2
1 3
FD850

1 Not in use
2 Position 5 - (gr)
3 Position 4 - (wh)
4 Retarder stage switch + (vi) 5 6 7 8
5 Position 3 - (or)
6 Position 2 - (bl) 1 2 3 4
7 Position 1 - (pi)
8 Bridge to pin 4
FD853

53.2661.10 Page 4.2/7
Diagnosis / ) +
'
"
A. With fault code

Special tool
53.8224.10
Notice

53.2661.10 Page 4.2/8
Diagnosis / ) +
'
"
R
Notice
Exception:
FD844
Requirements
- Retarder stage switch in position 0
- Vehicle in parking position, Ignition ON

Meaning
- long blinking signals (2 sec.) tens unit.
- short blinking signals (0,5 sec.) single unit.

53.2661.10 Page 4.2/9
Diagnosis / ) +
'
"

53.2661.10 Page 4.2/10
Diagnosis / ) +
'
"
Delete fault memory

1. Ignition: OFF
3. Ignition: ON

53.2661.10 Page 4.2/11
Diagnosis / ) +
'
"
Notice


connection1)
Code (Check)
ground
for extra operation
(e.g. lamp or
relay)
- Ignition: ON
1)
2)
Only, if no fault is recognizable after a complete check of the periphery: change control unit.

53.2661.10 Page 4.2/12
Diagnosis / ) +
'
"
Table 2:
class Operation test Set point Remedy
connection
Code (Check)
- Ignition: ON

Overvoltage control unit (see manufacturer
- Start engine
(idle speed)

53.2661.10 Page 4.2/13
Diagnosis / ) +
'
"
Table 3:
connection
Code (Check)
07 Changeover val- serious 1s - Ignition: OFF X 2/1 W X 2/6 100-150 W Check lead, plug and
ve - Pull plug X2 out of changeover valve
Discontinuity control unit (valve block)
09 ture - Pull plug X2 out of 1039 - 1117W sensor
battery
80°C ± 10 °C =
1271 - 1347W
Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.

53.2661.10 Page 4.2/14
Diagnosis / ) +
'
"
Table 4:
connection
Code (Check)
12 serious/ - Pull plug X2 out of 1039 - 1117W sensor
Discontinuity / slight * control unit
Short circuit to 60°C ± 10 °C =
battery 1099 - 1271W
80°C ± 10 °C =
1271 - 1347W
Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.

53.2661.10 Page 4.2/15
Diagnosis / ) +
'
"
Table 5:
connection
Code (Check)
Undefined switch: X 1/6 V X 1/15 0V
switch state Position 0 X 1/5 V X 1/15 0V
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

switch:
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 2
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

53.2661.10 Page 4.2/16
Diagnosis / ) +
'
"
Table 6:
connection
Code (Check)

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 3 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 4 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 ≥ 17,5 V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 5 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 ≥ 17,5 V
X 1/8 V X 1/15 ≥ 17,5 V

53.2661.10 Page 4.2/17
Diagnosis / ) +
'
"
Table 7:
Fault Fault text Fault Trigger time Requirement / Operati- Measurement/ Result/ Cause/
class on test Set point Remedy
connection
Code (Check)
14 Retarder stage serious 10 s - Ignition: OFF X 1/10 V X 1/15 0 V Check lead and
switch - Pull plug X1 out of plug
- Retarder stage switch:
Position 0
15 Retarder stage serious 1s - Ignition: OFF X 1/10 W X 1/ Resistor Single check of

switch - Pull plug X1 out of 15 infinite stages for
battery - Retarder stage switch:
Position 5
16 Speedometer serious 2s - Ignition: ON X 3/2 V X 1/15 ≤ 1 V Check lead and

signal speedometer
Discontinuity
17 Changeover val- schwer 1s - Ignition: OFF X 2/1 W X 2/6 100-150 W Check lead, plug
ve - Pull plug X2 out of and changeover
Short circuit to control unit valve (valve block)
battery

53.2661.10 Page 4.2/18
Diagnosis / ) +
'
"
Table 8:
connection
Code (Check)
18 Speedometer signal serious 2s - Ignition: OFF X 3/2 V X 1/15 ≤ 9V Check lead and
- Pull plug X3 out of speedometer
- Ignition: ON
19 ABS serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ 3,5 V Check lead,

Short circuit to ground relay and ABS-
control unit
21 ABS-Signal serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ 16,5 V Check lead,

relay and ABS-
Undefined control unit

23 Proportional valve serious 1s - Ignition: OFF X 2/3 V X 1/15 ≤ 10 V Check lead

- Ignition: ON

53.2661.10 Page 4.2/19
Diagnosis / ) +
'
"
Table 9:
connection
Code (Check)
24 1 Proportional valve serious 1s - Ignition: ON X 2/2 W X 2/3 18-25 W Check lead and
nal valve magnetic
Valve magnetic
valve
proportional valve
interchanged

block)

53.2661.10 Page 4.2/20
Diagnosis / ) +
'
"
Table 10:
connection
Code (Check)

block)


28 Terminal 30 serious 60 s - Ignition: OFF X 1/13 V X 1/15 ≥ 17,5 V Check lead,

- Ignition: ON

53.2661.10 Page 4.2/21
Diagnosis / ) +
'
"
Table 11:
connection
Code (Check)

control unit

control unit
32 Retarder pilot light: serious 3s - Ignition: OFF X 3/8 V X 1/15 ≥ 17,5 V Check lead,
- Ignition: ON
switch: light
Position 1

53.2661.10 Page 4.2/22
Diagnosis / ) +
'
"
Table 12:
connection
Code (Check)

control unit
36 1 Fault housing pressure slight variabel - Retarder: OFF Check housing

changeover valve pressure chan-
(Pos. 1500) geover valve
(Pos. 1500)
(see Section
4.3)
36 2 - Ignition: OFF X 2/9 W X 2/8 ≤ 1684 W Check lead and

- Plug X2 out of (= 180°C) oil temperature
control unit sensor
37 Fault pedal operation slight 100 ms / 1 s Check installati-

on relating to
OEM-
respectively
VOITH-
instructions

53.2661.10 Page 4.2/23
Diagnosis / ) +
'
"
Notice

53.2661.10 Page 4.2/24
Diagnosis / ) &
' ,
'
Troubleshooting
Illustration checking housing pressure

• Ignition OFF
Notice

on the mechanical condition of rotating parts, 1020
on internal leaks and on the operation of the 1030
retarder.
1030 Screw plug (M 12 x 1,5),

25 Nm
Special tool
FD788
53.4788.10
Pressure gauge
0-25 bar

53.2661.10 Page 4.3/1
Diagnosis / ) &
' ,
'
Job scope static
Caution! Risk of injury! 99/1

Job scope
3. Shift retarder stage switch to the highest braking stage with the vehicle in parking position and
FD790
read-off the housing pressure from the pressure gauge (99/1).
4. Compare read-off pump pressure with the setpoint of the static housing pressure
Caution!

53.2661.10 Page 4.3/2
Diagnosis / ) &
' ,
'
Setting [Nm] Code Housing pressure static Housing pressure dynamic 1)

vps = 1000 r.p.m.
Number 3) Setpoint [bar] 1) 2) Minimum value [bar]
4000 014/089/091 1,80 - 2,20 7,5
3750 013 1,65 - 2,05 7,0
3500 012/087/088/ 1,51 - 1,91 6,5

092/093
3250 011/086/090 1,35 - 1,75 5,5
3000 010/094/096/ 1,21 - 1,61 5,0

098
2750 009 1,05 - 1,45 4,0
2500 008/097 0,91 - 1,31 3,0

2) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure)
3) The code number is to be found at the control unit
Notice

53.2661.10 Page 4.3/3
Diagnosis / ) &
' ,
'
Job scope dynamic

2. Shift the retarder stage switch (16) to position 5 while on the move at vps = 1000 r.p.m. and
read-off housing pressure at pressure gauge (99/1).
3. Compare read-off housing pressure with the value of dynamic housing pressure
Caution!
4. Disconnect the pressure gauge. Screw in screw plug (1030) with new sealing ring (1040).

53.2661.10 Page 4.3/4
Diagnosis /
Troubleshooting

33
11 71
Notice 30 32 61
A1
are not identical with the reference numbers of P
25
A2 26
1 Heat exchanger R 21
2 Control unit 31
current connection 35 34
19 Temperatur pick-up cooling water
alternative: positions 19 and 20
joining in the central-plug 40
(see electrical diagram Version 2)
20 Temperature pick-up oil 2
39
25 Constant-air pressure line p y 19
(Connection A)
(Connection P)
30 Supply-air pressure line „A1“
31 Compressed air line
protection valve)
(four-circuit protection valve - 1
FD840
(parking brake)
2 wires)

53.2661.10 Page 4.4/1
Diagnosis / )) &
' &

Check requirements
• Ignition OFF
Special tools
Wasser Öl
53.4788.10 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.

53.2661.10 Page 4.4/2
Diagnosis / )) &
' &


Notice
32
against the manufacturer´s data.
39
1. Disconnect the electrical lead cooling water (39) and the electrical lead oil (40) at cooling water 40
temperature pick-up cooling water (19) and oil (20) and connect these at the temperature
simulator (99/2).
99/2
Notice
Wasser Öl
FD886

53.2661.10 Page 4.4/3
Diagnosis / )) &
' &


1060
1050
FD862
3. Connect pressure gauge (99/1) to retarder housing.
99/1
FD863

53.2661.10 Page 4.4/4
Diagnosis / )) &
' &

4. Connect up „Propstrom“ measuring adapter (99/3).

21000
99/3
FD887
99/3 Measuring adapter „Propstrom“ 53.8198.10

98/8 Multimeter

53.2661.10 Page 4.4/5
Diagnosis / )) &
' &

Job scope test

39
40
• Ignition ON
165°C oil temperature operate the retarder at the highest stage. 99/2
constant-air pressure p y must drop to at least 7% below the set maximum pressure. Set rotary
switch of the temperature simulator (99/2) to 125oC cooling water temperature. There must be no Wasser Öl
more output of constant-air pressure py. FD886

The constant-air pressure must drop to at least 4% below the set maximum pressure. Set the ro-
tary switch of the temperature simulator (99/2) to 225oC oil temperature. There must be no more
(see page 4.4/7).
5. Screw oil filler/check plug (1060) tight with new sealing ring (1050). Tightening torque 150 Nm
6. Reconnect electrical lead (39) for cooling water and oil (40) to temperature pick-ups for
cooling water (19) and oil (20).

53.2661.10 Page 4.4/6
Diagnosis / )) &
' &

Notice
If both values are not reached, please see Section 4.2 „Troubleshooting and Remedies“

2)
[mA] [bar] 3)
2500 Nm 008 421 - 429 0,91 - 1,31
2750 Nm 009 430 - 438 1,05 - 1,45
3000 Nm 010 441 - 449 1,21 - 1,61
3250 Nm 011 448 - 458 1,35 - 1,75
3500 Nm 012 458 - 468 1,51 - 1,91
3750 Nm 013 468 - 478 1,65 - 2,05
4000 Nm 014 477 - 487 1,80 - 2,20
3250 Nm 086 448 - 458 1,35 - 1,75
1)
2)
3)

53.2661.10 Page 4.4/7
Diagnosis / )) &
' &


[mA] 2) [bar] 3)
3500 Nm 087 458 - 468 1,51 - 1,91
3500 Nm 088 458 - 468 1,51 - 1,91
4000 Nm 089 477 - 487 1,80 - 2,20
3250 Nm 090 448 - 458 1,35 - 1,75
4000 Nm 091 477 - 487 1,80 - 2,20
3500 Nm 092 458 - 468 1,51 - 1,91
3500 Nm 093 458 - 468 1,51 - 1,91
3000 Nm 094 441 - 449 1,21 - 1,61
3000 Nm 096 441 - 449 1,21 - 1,61
2500 Nm 097 421 - 429 0,91 - 1,31
3000 Nm 098 441 - 449 1,21 - 1,61
1)
2)
3)

53.2661.10 Page 4.4/8
Diagnosis / )- !
&
Troubleshooting


FD844

- slight fault
- serious fault

53.2661.10 Page 4.5/1
Diagnosis / )- !
&
Notice
is going off.


53.2661.10 Page 4.5/2
Diagnosis / )- !
&
Operation

switch
properly.

53.2661.10 Page 4.5/3
Retarder Remo- - "
'. /

' "
ving, Installing

53.2661.10 Page 5/1
Retarder Remo- !" #
1300
1300
1400
1400
1200
1300 1200
1400
1100
1200
1300
1400
92
1200
1200
94 1400 1200 1100
95/2 1300
1200
1400
1500
3700
96
93 1000 96
1000/4
3400 97
1200
1000/3 1400
92
1500
FD308

• Ignition OFF
92 Prop shaft 1100 Suspension

93 Hex.-head screw 1200 Megi pad with washer,
94 Spring washer, renew check, renew if necessary
95/2 Hex.-head nut 1300 Hex.-head screw (M 16 x 90)
96 Hose clamp 1400 Washer (B16)
97 Hose connection 1500 Hex.-head nut (M 16)
1000 Heat exchanger self-locking, renew, 110 Nm
1000/3 Cooling water drain plug 34000 Constant-air pressure line py
(M 12 x 1,5), 25 Nm 37000 Ventilation line
Caution!


53.2661.10 Page 5.1/1
Retarder Remo- - "
'. /

' "
ving, Installing 0 1
2
To install the retarder 133-2 according to regulations to the gearbox or to remove from the gearbox,
Caution!


53.2661.10 Page 5.2/1
Repair Gearbox 3 "! 1

Attachment
6.4 Removing, Cleaning and Installing Silencer...............................................6.4/1
6.5 Removing, Checking and Installing Housing Pressure Changeover Valve 6.5/1



53.2661.10 Page 6/1
Repair Gearbox ' ( !!) $ * + &
Attachment
1250
4090 4080
1260
2260 1060
2120 1030
1020 1200
2110 2270
1050
1210
1020 1220/1
1030
1050 2301
1220/2
1040 1220
1510 1220/3
1500
1520
1370
4020
1150
1080
2080 1160
1070
3030
2100
2090 1420
1170 1190
2105 1440 1180
1450 FD1568
1020 Sealing ring (A 12 x 18) 1420 Silencer

1030 Screw plug (M 12 x 1,5) 1440 Cover plate
1040 Screw plug (M 24 x 1,5 ) 1450 Cap screw (M 6 x 16)
1050 Sealing ring (A 24 x 29) 1500 2/2-way valve (Herion 4021338)
1060 Oil check plug (M 24 x 1,5/ DIN908) 1510 O-ring (10 x 2,2)
1070 Oil drain plug retarder (M 30 x 1,5) 1520 O-ring (28,24 x 2,62)
1080 Sealing ring (A 30 x 36) 2080 Sealing disc (D 15 x 2)
1150 Radial shaft sealing ring (115 x 140 x 10) 2090 Sealing ring (A 22 x 29)
1160 Back-up ring 2100 Retainer
1170 Labyrinth cover 2105 Screw plug (M 22 x 1,5)
1180 Cap screw CV 84 (M 10 x 35) 2110 Radial shaft sealing ring (115 x 140 x 10)
1190 Washer (10,5) 2120 Back-up ring
1200 Cover for casing ventilation 2260 Oil filler plug (M 24 x 1,5)
1210 Gasket for casing ventilation alternatively ((M 18 x 1,5)
1220 Casing ventilation 2270 Sealing ring (A 24 x 29)
1220/1 Ventil insert alternatively (A 18 x 24)
1220/2 Float 2301 O-ring (55 x 3)
1220/3 Float cage 3030 Bearing race
1250 Hex. -head screw (M 8 x 25) 4020 O-ring (95 x 4,5)
1260 Washer (B 8,4) 4080 Centering cover
1370 O-ring (196,52 x 2,62) 4090 Hex. -head screw (M 8 x 16)
alternatively (M 8 x 20)
cbtd 98-01

53.2661.10 6.1/1
Repair Gearbox 3 "
'. &
'
/

'
Attachment &
' 4


1250
1260
Notice
This step can be performed with the retarder 1200

1210
1030 Check plug (M 12 x 1,5), 25 Nm
1200 Casing ventilation cover,
apply thin coat of Hylamar sealant
to sealing surface 1220/1
1210 Gasket, renew
1220/2 Float, check, renew if necessary 1220
Specified weight: 11g ± 1 g 1220/2
1220/3 Float cage
1260 Washer (B 8,4) 1220/3
2301 O-ring (55 x 3), renew,
coat of silicone-free and
1030
FD824

53.2661.10 Page 6.2/1
Repair Gearbox 3 "
'. &
'
/

'
Attachment &
' 4

(Continue)

Special tools
53.9428.10 53.7712.10

53.2661.10 Page 6.2/2
Repair Gearbox 3 "
'. &
'
/

'
Attachment &
' 4

(Continue)
Checking (installed)
1. Screw out screw plug (1030) with sealing ring (1020).
2. Place a measuring beaker at the hole and operate the retarder in highest stage. 1020
Specified leakage oil: 1030

Leakage oil quantity each time brake is fully applied: max. 25 -50 cm3
Duration of leakage oil escape: max. 2 -3 sec.
Notice
FD155
A small follow-up escape of oil up to 10 cm3 is acceptable.
If the specified quantity is exceeded, the casing ventilation must be check after removal (Section 6.2/5).
3. Provide the screw plug (1030) with new sealing ring (1020) and screw it tight.
Anziehdrehmoment 25 Nm
0
100
750
500
250
FD156

53.2661.10 Page 6.2/3
Repair Gearbox 3 "
'. &
'
/

'
Attachment &
' 4

(Continue)
To remove
1. Screw out hex.-head screws (1250). 99/5
2. Remove washers (1260).
3. Remove casing ventilation cover (1200) with gasket (1210) from retarder housing.
98/7
4. Use impact tool (99/5) and adapter (98/7) to extract casing ventilation (1220).
Notice
FD890
The valve insert may be an early version with 3 ribs.
98/7 Adapter 53.9428.10
5. Remove the valve insert (1200/1) from the float cage (1220/3). 99/5 Impact tool 53.7712.10
6. Lever the O-ring (2301) out of the groove in the valve insert (1220/1).
7. Remove the float (1220/2) and the float cage (1220/3) from the retarder housing.
1220/1
2301
FD891

53.2661.10 Page 6.2/4
Repair Gearbox 3 "
'. &
'
/

'
Attachment &
' 4

(Continue)
To check
1. Check the float (1220/2) for damage to the surface and to the sealing surface (arrow).
2. Weigh the float (1220/2).

Specified weight 11 ± 1 Gramm. If the actual weight is above the specified weight, the float must
be renewed.
1220/2
Notice
FD1627
Set the valve insert (1220/1) down on the float (1220/2) and fill up the cavity between float and upper
edge of the valve insert with methylated spirit. If the sealing edge is not damaged, the fluid level must 1220/2
not change within 1 minute. If necessary, renew the complete casing ventilation.
1220/1
FD892

53.2661.10 Page 6.2/5
Repair Gearbox 3 "
'. &
'
/

'
Attachment &
' 4

(Continue)
To install
2. Fit the float cage (1220/3) in the retarder housing.
3. Fit the float (1220/2) and the float cage (1220/3) into the valve insert (1220/1). 1200
5. Knock in the casing ventilation (1220) with impact tool (99/5) and adapter (98/7) carefully in as
far as it will go.
FD251
6. Coat sealing surface on retarder housing and on cover (1200) with thin coat of Hylomar sealant.
7. Place a new gasket on the retarder housing with the graphite side facing downwards.
8. Place the cover (1200) on the retarder haousing, insert hex.-head screws (1250) with
washers (1260) and screw them tight. Tightening torque 23 Nm

53.2661.10 Page 6.2/6
Repair Gearbox 3 "
'. &
'
/

'
Attachment ! & 4
Illustration sump check valve
2080 Sealing disc, check,
renew if necessary
2100 Retainer 25 Nm, check, renew if
necessary, install with Loctite 242
locking agent
2105 Screw plug (M 22 x 1,5),
66 Nm
Locjking agent
Thread on retainer: Loctite 242
To check sump check valve

Operate retarder in highest stage and switch off
after approx. 5 s. If oil emerges at the labyrinth
seal covers on the output or on the input side,
the sump check valve is defective.
Prior job 2080
• Drain oil of retarder (see Section 3.2)
2100
Notice
Install only in vertical position! 2090

Do not use an impact driving tool! 2105
FD300
Install in reverse sequence.

53.2661.10 Page 6.3/1
Repair Gearbox 3) "
'. &

'
/

'

Attachment
Notice

1420 Silencer,
with compressed-air
1440 Cover plate
1450 Cap screw (M 6 x 16), 8 Nm
Cleaning agent
1420
Silencer Benzine
1440 1450
1450
FD303

53.2661.10 Page 6.4/1
Repair Gearbox 3- "
'. &
'
/

'
Attachment ,
' &
' 4
Illustration housing pressure changeover
valve 21000
Prior jobs
• Check changeover valve (Prop. -valve)
98/1 Banjo bolt

1500 Housing pressure changeover
valve, renew, 25 Nm
1510 O-ring (10 x 2,2), renew,
for installation 1510 31000
1520 O-ring (28,24 x 2,62), renew, 1500
coat of silicone-free and 1520
for installation
31000 Compressed-air pressure line A 1
98/2
Lubricants
98/1 98/2
O-ring Silicone-free and 98/2
FD834

53.2661.10 Page 6.5/1
Repair Gearbox 3- "
'. &
'
/

'
Attachment ,
' &
' 4 (Continue)
Special tool
Pressure gauge
0 - 25 bar
53.4788.10
Checking step 1
1. Remove the housing pressure changeover valve (1500) and seal the screw-in thread (M 32 x 1,5)
in the retarder housing with an appropriate screw plug and sealing ring.
2. Screw in the compressed-air pressure line (31000) with the banjo bolts (98/1) and the sealing
rings (98/2) in the thread of the housing pressure changeover valve.
Notice
For a better access the upper banjo bolt of the compressed-air pressure line (31000) can be losen to
twist the line. Tighten the upper banjo bolt again.
3. Switch retarder stage switch into stage 5.
Notice
If air escapes through the 4 holes (arrow) of the housing pressure changeover valve, the valve has to be
renewed.

53.2661.10 Page 6.5/2
Repair Gearbox 3- "
'. &
'
/

'
Attachment ,
' &
' 4 (Continue)
Checking step 2
1. Remove the complete compressed-air pressure line (31000).
2. Connect the pressure gauge (99/1) at the adapter.
3. Switch retarder stage switch in stage 5 and check the pressure.

Notice
Check and renew if necessary, if the minimum pressure of 5 bar is not reached and the air-supply pres-
sure pV is in the setting area:
Lead, plugs and plug connections on damage, correct connection, loose connection, corrosion etc.
No remedy is reached:
Renew the proportional valve (21000).

53.2661.10 Page 6.5/3
Repair Gearbox '' ! # , ! (Output
Attachment Side)" ) -
Prior jobs
• Prop shafts removed from flanges
(see vehicle manufacturer´s instruction)
• Prop shaft flanges removed
(see VOITH installing instruction)
97/4
Notice

1150
97/4 Hollow shaft 1160
(115 x 140 x 10), renew, 3030
1160 Back-up ring
1170 Labyrinth cover,
apply thin coat of Hylomar sealant
to sealing surface
1180 Cap screw CV 84 (M10 x 35) self-
locking, renew, 46 Nm
1190 Washer (10,5)
1370 O-ring (196,52 x 2,62), renew,
1190
1180
for installation FD159
3030 Bearing race, checking,
renew if necessary
4020 O-ring (95 x 4,5), renew,
for installation
cbtd 98-01

53.2661.10 6.6/1
Repair Gearbox 33 "
'
/

' (
& (Output
Attachment Side). "

' "
' "
' (Cont.)

!"

#$
Sealants and lubricants


53.1180.10 53.1373.10 53.1372.10

53.2661.10 Page 6.6/2
Repair Gearbox 33 "
'
/

' (
& (Output
Attachment Side). "

' "
' "
' (Cont.)
Job scope
1. Screw out cylinder screws (1180) with the box spanner 53.1180.10 and remove together 1170
with washers (1190).
2. Press off the labyrinth cover (1170) with two hex.-head screws (M 10 x 65) (arrows)
from the retarder housing.
3. Use the three inner hex.-head screws to clamp the bearing race puller (94/4) in the
bearing race (3030), making sure that the bearing race does not become out of round.
FD161
4. Remove the bearing race (3030) with the bearing race puller (94/4) of the hollow shaft (97/4).
Then remove the back-up ring.
5. Remove the radial shaft sealing ring (1150), without damaging the sealing surface of the retarder
3030
housing.
94/4
97/4
FD162
94/4 Bearing race puller 53.1373.10

53.2661.10 Page 6.6/3
Repair Gearbox 33 "
'
/

' (
& (Output
Attachment Side). "

' "
' "
' (Cont.)
6. Remove the O-ring (4020) for the hollow shaft (97/4).
97/4
97/4
Notice
Check race of radial shaft sealing ring at the hollow shaft for scores and uneven surface. 4020 4020
Notice

1150
Recommendation:
FD163
1150
8. Knock in the radial shaft sealing ring (1150) with the press-in equipment (97/1) flush
in the retarder housing.
4020 97/4
Notice
Retarder version with short labyrinth (bearing race Pos. 3030 = 27 mm long):
Set back-up ring (1160) together with the radial shaft sealing ring (1150) onto the
press-in equipment (97/1) and knock in flush into the retarder housing.
97/1
9. Coat new O-ring (4020) thin with silicone-free and non-corrosive grease and fit it onto the hollow
FD164
shaft (97/4).

53.2661.10 Page 6.6/4
Repair Gearbox 33 "
'
/

' (
& (Output
Attachment Side). "

' "
' "
' (Cont.)
10. Put the back-up ring (1160) to the radial shaft sealing ring. Use a suitable drift to press the
bearing race (3030) as far as they will go.
97/4
1160
Notice
Retarder version with short labyrinth (bearing race Pos. 3030 = 27 mm long): 3030
In this case the back-up ring is already installed.
11. Coat new O-ring (1370) thin with silicone-free and non-corrosive grease and fit it into the labyrinth
cover (1170).
FD165
12. Apply a thin coat of Hylomar sealant to the sealing surface of the labyrinth cover (1170) around
the holes ilustrated and install it in such a way that the groove in the retarder housing and the
channel in the labyrinth cover (arrow) for the leakage oil return face each other.
13. Tighten new cap screws (1180) with washers (1190).

1370
1170
FD166

53.2661.10 Page 6.6/5
Repair Gearbox 35 "
'
/

' &

' & (Input
Attachment Side). "

' "
' "
'
Prior jobs
2110
2110 Radial shaft sealing ring 2120
(115 x 140 x 10),renew, 4080
for installation
2120 Back-up ring
4080 Centering cover,
to sealing surface
4090 Hex.-head screw (M 8 x 16,
M 8 x 20), self-locking,
renew, 23 Nm
Housing sealing Hylomar

surfaces
O-rings Silicone-free and

4090
FD294

53.2661.10 Page 6.7/1
Repair Gearbox 35 "
'
/

' &

' & (Input
Attachment Side). "

' "
' "
' (Cont.)
Job scope
2. Press centering cover (4080) off housing cover.
3. Remove back-up ring (2120).
4. Remove radial shaft sealing ring (2110) without damaging the sealing surface on the
housing cover.
Notice
Check race of radial shaft sealing ring (2110) at the hollow shaft for scores and uneven surface.
Notice
If the race of the radial shaft sealing ring is uneven, please contact VOITH TURBO.

53.2661.10 Page 6.7/2
Repair Gearbox 35 "
'
/

' &

' & (Input
Attachment Side). "

' "
' "
' (Cont.)
6. Join new radial shaft sealing ring (2110) to hollow shaft.

4080 4090
7. Join back-up ring (2120) to radial shaft sealing ring.
8. Apply a thin coat of Hylomar sealant to the sealant surface of the centering cover (4080) and install
it in such a way that the groove faces the leakage oil return hole in the housing cover (arrow)
downwards.
9. Knock in carefully the centering cover into the housing cover using a plastic hammer.
10. Screw the housing cover with the new self-locking hex.-head screws (4090) tight. FD293

53.2661.10 Page 6.7/3
Repair Free 5 "! $
/

Mount Installation
7.3 Removing, Checking and Installing Sump Check Valve ............................7.3/1
7.5 Removing, Checking and Installing Housing Pressure Changeover Valve 7.5/1



53.2661.10 Page 7/1
Repair Free . ( !!) $ * + &
Mount Installation
2210 2220 2200

1370 1250
1260
4110 2260 1060
1030 1200
1020
2120 2270
2110
4020 1210
1050
1020 1220/1
1030
1040 2301
1050
1220/2
1220
1510
1220/3
1500
1520
1370
4020
1150
1080
2080 1160
1070
3030
2100
2090 1420
1170 1190
2105 1440 1180
1450
FD1569

1200 Cover for casing ventilation 2200 Labyrinth cover
1210 Gasket for casing ventilation 2210 Cap screw CV 84 (M 10 x 35)
1220 Casing ventilation 2220 Washer (10,5)
1220/1 Ventil insert 2260 Oil filler plug (M 24 x 1,5)
1220/2 Float 2270 Sealing ring (A 24 x 29)
1220/3 Float cage 2301 O-ring (55 x 3)
1250 Hex. -head screw (M 8 x 25) 3030 Bearing race
1260 Washer (B 8,4) 4020 O-ring (95 x 4,5)
1370 O-ring (196,52 x 2,62) 4110 Back-up ring

53.2661.10 Page 7.1/1
Repair Free 5 "
'. &
'
/

'
Mount Installation &
' 4


1250
1260
Notice

1210
1030 Check plug (M 12 x 1,5), 25 Nm
to sealing surface 1220/1
1210 Gasket, renew
1220 Casing ventilation 2301
1220/2 Float, check, renew if necessary
1220/2
Specified weight: 11g ± 1 g
1220/3 Float cage
1250 Hex.-head screw (M 8 x 25), 23 Nm 1220/3
1260 Washer (B 8,4)
2301 O-ring (55 x 3), renew,
for installation
1020
1030
FD791

53.2661.10 Page 7.2/1
Repair Free 5 "
'. &
'
/

'
' 4

(Continue)

Special tools
53.7712.10 53.9428.10

53.2661.10 Page 7.2/2
Repair Free 5 "
'. &
'
/

'
' 4

(Continue)

Notice
FD155
0
100
750
500
250
FD156

53.2661.10 Page 7.2/3
Repair Free 5 "
'. &
'
/

'
' 4

(Continue)
To remove
98/7
Notice
FD890
99/5 Impact tool 53.7712.10
5. Remove the valve insert (1200/1) from the float cage (1220/3). 98/7 Adapter 53.9428.10
1220/1
2301
FD891

53.2661.10 Page 7.2/4
Repair Free 5 "
'. &
'
/

'
' 4

(Continue)
To check

be renewed.
1220/2
Notice
FD1627
1220/1
FD892

53.2661.10 Page 7.2/5
Repair Free 5 "
'. &
'
/

'
' 4

(Continue)
To install
far as it will go.
FD251

53.2661.10 Page 7.2/6
Repair Free 5 "
'. &
'
/

'
Mount Installation ! & 4
renew if necessary
locking agent
2105 Screw plug (M 22 x 1,5),
66 Nm
Locjking agent

Prior job 2080
2100
Notice

Do not use an impact driving tool!
2105
FD300

53.2661.10 Page 7.3/1
Repair Free 5) "
'. &

'
/

'

Mount Installation
Notice

1420 Silencer,
with compressed-air
1440 Cover plate
1450 Cap screw (M 6 x 16), 8 Nm
Cleaning agent 1420

Silencer Benzine
1440 1450
1450
FD303

53.2661.10 Page 7.4/1
Repair Free 5- "
'. &
'
/

'
Mount Installation ,
' &
' 4
Illustration housing pressure changeover
valve 21000
Prior jobs
• Check changeover valve (Prop. -valve)
98/1 Banjo bolt

1500 Housing pressure changeover
valve, renew, 25 Nm
1510 O-ring (10 x 2,2), renew,
1520 O-ring (28,24 x 2,62), renew, 31000
1500
for installation
31000 Compressed-air pressure line A 1
98/2
Lubricants
98/1 98/2
O-ring Silicone-free and 98/2
FD807

53.2661.10 Page 7.5/1
Repair Free 5- "
'. &
'
/

'
' &
' 4 (Continue)
Special tool
Pressure gauge
0 - 25 bar
53.4788.10
Checking step 1
1. Remove the housing pressure changeover valve (1500) and seal the screw-in thread (M 32 x 1,5)
in the retarder housing with an appropriate screw plug and sealing ring.
2. Screw in the compressed-air pressure line (31000) with the banjo bolts (98/1) and the sealing
rings (98/2) in the thread of the housing pressure changeover valve.
Notice
For a better access the upper banjo bolt of the compressed-air pressure line (31000) can be losen to
twist the line. Tighten the upper banjo bolt again.
3. Switch retarder stage switch into stage 5.
Notice
If air escapes through the 4 holes (arrow) of the housing pressure changeover valve, the valve has to be
renewed.

53.2661.10 Page 7.5/2
Repair Free 5- "
'. &
'
/

'
' &
' 4 (Continue)
Checking step 2
1. Remove the complete compressed-air pressure line (31000).
2. Connect the pressure gauge (99/1) at the adapter.
3. Switch retarder stage switch in stage 5 and check the pressure.

Notice
Check and renew if necessary, if the minimum pressure of 5 bar is not reached and the air-supply pres-
sure pV is in the setting area:
Lead, plugs and plug connections on damage, correct connection, loose connection, corrosion etc.
No remedy is reached:
Renew the proportional valve (21000).

53.2661.10 Page 7.5/3
Repair Free 53 "
'
/

' !
'
Mount Installation
Illustration prop shaft flanges
Prior job
• Prop shafts removed from flanges 97/6 97/7
97/5 Flange fastening screw 97/8
(M 24 x 200), renew,
(use phosphated version),
Final torque: 90° turning angle
97/7 Prop shaft screw, renew
97/8 Guard ring
97/8
Hinweis
97/6
This job sequence can be performed with the
retarder removed or installed. 97/7

Tightening angle measuring tool 3/4 97/5
E.g. Messrs Richard Abr. Herder KG
Postfach 10 08 67
D - 42569 Solingen
Tel. 0212/888-0 /
FD186

53.2661.10 Page 7.6/1
Repair Free 53 "
'
/

' !
'
Mount Installation (Continue)
To remove, install
1. Unscrew flange fastening screw(97/5) on output side prop shaft flange (97/6).
Not for installation 97/6
When renewing flange fastening screw (97/5) use phosphated version only.
(VOITH item-No. 53.7416.10)
97/5
FD187
2. Pull both prop shaft flanges (97/6) out of the retarder housing.
97/6
97/6
FD188

53.2661.10 Page 7.6/2
Repair Free 53 "
'
/

' !
'
Mount Installation (Continue)
3. Remove guard rings (97/8).

97/7
97/8
Renew prop shaft screws (97/7). Align hole patterns of both prop shaft flanges prior to installation.
The maximum permissible offset should be 5° .
FD189

53.2661.10 Page 7.6/3
Repair Free .. ! # , ! (Output
Mount Installation Side)" ) -
Prior jobs
97/4
Notice
4020
removed or installed. 1150

3030
(115 x 140 x 10), renew,
1160 Back-up ring
to sealing surface
1190 Washer (10,5)
1370 O-ring (196,52 x 2,62), renew, 1190
for installation
FD249
renew if necessary
4020 O-ring (95 x 4,5), renew,
for installation

53.2661.10 Page 7.7/1
Repair Free 55 "
'
/

' (
& (Output
Mount Installation Side). "

' "
' "
' (Cont.)
Notice

Special tools
53.1180.10 53.1373.10 53.1372.10

53.2661.10 Page 7.7/2
Repair Free 55 "
'
/

' (
& (Output

' "
' "
' (Cont.)
Job scope
with washers (1190). #$% &' ()
FD254
5. Remove the radial shaft sealing ring (1150), without damaging the sealing surface of the retarder 3030
housing.
97/2
97/4
FD255
94/4 Bearing race roller 53.1373.10

53.2661.10 Page 7.7/3
Repair Free 55 "
'
/

' (
& (Output

' "
' "
' (Cont.)
Notice 97/4
Check race of radial shaft sealing ring at the hollow shaft for scores and uneven surface. 4020
4020
Notice

1150
Recommendation:
FD289
1150
with the retarder housing.
4020 97/4
9. Coat new O-ring (4020) thin with silicone-free and non-corrosive grease and fit it into the hollow
shaft (97/4).
97/1
FD257

53.2661.10 Page 7.7/4
Repair Free 55 "
'
/

' (
& (Output

' "
' "
' (Cont.)
bearing race (3030) as far as they will go.
97/4
1160
cover (1170).
3030
FD256

1370
1170
FD166

53.2661.10 Page 7.7/5
Repair Free 56 "
'
/

' &

' & (Input

' "
' "
'
Prior jobs
97/4
97/4 Hollow shaft

1370 O-ring (196,52 x 2,62), renew,
2110
2120
1370
(115 x 140 x 10), renew,
for installation
2120 Back-up ring
to sealing surface
2210 Cap screw CV 84 2220
2210
(M 10 x 35) self-locking,
renew, 46 Nm
2220 Washer (10,5)
4110 Bearing race, check,
renew if necessary
4020 O-ring (95 x 4,5), renew,
non-corrosive grease FD270
for installation

53.2661.10 Page 7.8/1
Repair Free 56 "
'
/

' &

' & (Input

' "
' "
' (Cont.)
Notice

Special tools
53.1180.10 53.1373.10 53.1372.10

53.2661.10 Page 7.8/2
Repair Free 56 "
'
/

' &

' & (Input

' "
' "
' (Cont.)
Job scope
1. Screw out cylinder screws (2210) with the wedge insert 53.1180.10 and remove together
with washers.
2200
FD272
Then remove the back-up ring. 4110
94/4
housing.
FD805

53.2661.10 Page 7.8/3
Repair Free 56 "
'
/

' &

' & (Input

' "
' "
' (Cont.)

4020
Notice #$% &' ()

97/4
2120
4020
Check race of radial shaft sealing ring at the hollow shaft for scores and uneven surface,
renew if necessary.
97/4
Notice
Recommendation: FD806
2110 97/1
4020
64
shaft (97/4).
FD275

53.2661.10 Page 7.8/4
Repair Free 56 "
'
/

' &

' & (Input

' "
' "
' (Cont.)
bearing race (4110) as far as they will go. 97/4
11. Coat new O-ring (1370) thin with silicone-free and non-corrosive grease and fit it into the labyrinth #$% &' () 2120
cover (1170). 4110
FD276
12. Apply a thin coat of Hylomar sealant to the sealing surface of the labyrinth cover (2200) around 1370
channel in the labyrinth cover (arrow) for the leakage oil return face each other. 2200

2200
FD277

53.2661.10 Page 7.8/5
Repair 6 "
'. &
'
/

'
Heat Exchanger , 71
'

53.2661.10 Page 8./1
Repair / !" #
Heat Exchanger 0 1 23
1000/4
1000/3
1000
4000 6000
3000
2000 8000
5000 3000
1080
4000
1070
9000
10000
10000
9000
97 4000
96 5000
4000
6000
4000
7000
FD874
Notice
In case of a mehanical damage or a leakage the heat exchanger may be sealed new or some parts may be changed
(see Aftersales-Information 11/96 in the annex).
Prior jobs
• This job can also be performed, if retarder is installed.
Caution!
If another heat exchanger version is used, the matching throttle-disc must be installed.
Please, contact VOITH TURBO!

97 Hose connection
O-rings, Throttle disc Silicone-free and
1000 Heat exchanger
1070 Retarder oil drain plug (M 30 x 1,5), 150 Nm Data
1080 Sealing ring (A 30 x 36), renew Pressure for pressure test (oil section): max. 10 bar
2000 Throttle disc (D 35 / 11 x 3) (alternatively), pressed-in,
coat with silicone-free and non-corrosive grease Special tool
for installation
3000 O-ring (36 x 4), renew,
coat with silicone-free and non-corrosive grease
for installation
4000 Washer ( B 10,5)
5000 Hex. nut (M10), self-locking, renew 46 Nm
8000 Stud (M 10 x 50), (hand-tight; max. 10 Nm)
53.1369.10

53.2661.10 Page 8.1/1
Repair 6 "
'. &
'
/

'
Heat Exchanger
, 71
' (Continue)
To remove
Notice
If this job sequence is performed with the retarder installed, the following jobs must be first performed:
Caution ! Risk of injury!

1000/3
The cooling water drain plug and the cooling water are heated up!
1000/4
1000
1. Screw out the cooling water drain plug (1000/3) and drain the cooling water in a clean vessel.
FD1623
2. Loosen hose clamps (96) on the left and on the right and remove hose connection (97) from the
heat exchanger (1000).
3. Screw in cooling water drain plug (1000/3) again with new sealing ring (1000/4) and tighten.
96
4. Place oil pan underneath the retarder.
Caution ! Risk of injury! 97
5. Screw out oil drain plug (1070) on the retarder and drain the oil.
1080
1070 FD1624

53.2661.10 Page 8.1/2
Repair 6 "
'. &
'
/

'
Heat Exchanger
, 71
' (Continue)
6. Screw the oil drain plug (1070) together with a new sealing ring (1080) into its hole and tighten.
7. Unscrew the four hex. nuts (5000) with the washers (4000) and the hex.-head screws (7000) with
the washers (4000).
Notice
If the heat exchanger is an „stainless-steel large (L+R) version, unscrew six hex. nuts. If DILAVAR studs
have been installed, they may be screwed out together with the hex. nuts when the latter are unscrewed.
Remedy:
Clamp the stud in a vice (do not damage the thread) and unscrew the hex. nut. Without using a locking
agent, screw the stud hand-tight (max. 10 Nm) into the retarder housing again.
Caution !
Damaged studs must be renewed!
8. Remove the heat exchanger (1000).
9. Remove two O-rings (3000) from the retarder housing.

53.2661.10 Page 8.1/3
Repair 6 "
'. &
'
/

'
Heat Exchanger
, 71
' (Continue)
To check
1. Fit the pressure-test equipment (97/3) to the heat exchanger (1000) and connect up the
compressed-air line with pressure minimizer. 1000
2. Fill the heat exchanger (1000) with hot water (approx. 70°C) on water section.
3. Pressurize the heat exchanger (1000) slowly to max. 10 bar overpressure (oil section).
Notice
If air bubbles form in the hot water, either the oil cooling inserts or the plane gaskets are defective in oil
section. 97/3 FD1650
4. Remove the pressure-test equipment (97/3). 97/3 Pressure-test equipment 53.1369.10

53.2661.10 Page 8.1/4
Repair 6 "
'. &
'
/

'
Heat Exchanger
, 71
' (Continue)
To install
Notice
1 Apply thin coat of silicone-free and non-corrosive grease to the new O-ring (3000) and fit them in
the bores of the retarder housing.
2. Install the heat exchanger (1000) on the retarder housing and use new
self-locking hex. nuts (5000), washers (4000), hex.-head screws (7000) and washers (4000) to
screw it tight on the retarder housing. Tightening torque 46 Nm
3. Install hose connections (97) on the heat exchanger (1000) and screw the hose clamps (96) tight.
4. Install retarder, if necessary (see Section 5.1 „Removing and Installing Heat Exchanger“).
5. Fill in cooling water and bleed cooling water circuit in accordance with the vehicle manufacturer´s
instruction.
Notice
Heed the statements of the vehicle-manufacturer respecting the cooling water-quality, as well as the
VOITH cooling water-list in the appendix.

53.2661.10 Page 8.1/5
Repair 6 "
'. &
'
/

'
Heat Exchanger
, 71
' (Continue)
Fill retarder with 9 litres engine oil or flushing oil. Flush the retarder system by braking several
Tightening torque:
Retarder oil drain plug (1070): 150 Nm
Notice
If the retarder oil has entered the cooling water-system, the vehicle cooling-system must be cleaned in
accordance with the vehicle manufacturer´s instruction.

53.2661.10 Page 8.1/6
Repair 6 "
'. &
'
/

'
Heat Exchanger
, 71
' (Continue)
Notice
Brake slightly several times to avoid the retarder oil overheating.
Oil and cooling water are heated up!
The oil-water mixture in the retarder may cause the oil in the retarder to foam and escape through casing
ventilation to the open air.
7. Screw out the screw plug of the sump check valve (2105) and drain any leakage oil and water
which has collected.
8. Fill the retarder only with the specified oil (see Section 3.2 „Oil Change“).

53.2661.10 Page 8.1/7
Control Parts 8 &

9.1 Control Parts ..............................................................................................9.1/1

53.2661.10 Page 9/1
Control Parts 4 5
23000
11
Notice
23000 21000
The valve also can alternatively be fix to the

frame. 22000
5000/1
Prior job
• Supply air discharged.
Caution! Risk of injury! 24000
Escaping compressed air! 25000
11 Constant-air pressure line pv

5000/1 Connector proportional valve
22000 Damping plate, renew if necessary
23000 Hex. nut, self-locking with collar
(M8), renew, 18 Nm
renew, 24 Nm
25000 O-ring (10 x 2), renew,
for installation.
Caution!
If in case of repair working the hex. nuts

(23000) or hex.-head screws (24000) have to
FD842
be loosen and the damping plate has to be
checked for aging damages and mechanical
damages, and to be renewed if necessary.

53.2661.10 Page 9.1/1
Control Parts 8 &

(Continue)

cooling water
Prior jobs
• Ignition OFF
Job Scope
1. Disconnect electrical lead (39) from 39

temperature pick-up cooling water
(4000).
2. Screw out temperature pick-up cooling

water (4000).
The electrical lead (39) is pured
alternatively.
3. Remove tempreature pick-up.
4. Install temperature pick-up in reverse FD1648

sequence.

53.2661.10 Page 9.1/2
Control Parts 8 &

(Continue)
Illustration temperature pick-up oil
The temperature pick-up is heated up

(oil temperature)!
Prior jobs
• Ignition OFF
Job scope
1. Disconnect electrical lead (39) of
temperature pick-up oil (4000). 39
2. Screw out temperature pick-up oil(4000).

The electrical lead is pured.
4. Install temperature pick-up in reverse

sequence.
FD1649

53.2661.10 Page 9.1/3
Annex 9
1
Data Sheet
Spare Parts Lists
Other Information
cbtd 98-01 Aftersales Service Manual Voith Retarder 133-2

53.2661.10 Page 10/1
Data Sheet VOITH Retarder 133-2
Service filling: With heat exchanger L+R
- Service filling (Oil change, checking oil level) 6,0 Litre (heat exchanger L+R small)
6,0 Litre (heat exchanger L+R large)
- after changing heat exchanger 7,5 Litre (heat exchanger L+R small)
8,2 Litre (heat exchanger L+R large)
- after complete taking apart and cleaning 9,0 Litre (heat exchanger L+R small) **
(corresponds new filling) 9,5 Litre (heat exchanger L+R large) **
Overall weight (with flange and heat exchanger, without oil) approx. 79 kg *
Service-Handbuch Voith Retarder 133-2

Seite 10/2
Miscellaneous Conversions Retarder 133-2 with Digiprop Control System
D GB USA D GB USA
125oC 257 oF 257 oF 150 Nm 111 lbf-ft 111 lbf-ft
25 Nm 18 lbf-ft 18 lbf-ft 11 g ± 1 g 0,38 ± 0,035 oz 0,38 ± 0,035 oz
46 Nm 34 lbf-ft 34 lbf-ft 0 - 25 bar 0 - 369 psi 0 - 369 psi

Miscellaneous Conversions Retarder 133-2 with Digiprop Control System
(Continue)
D GB USA D GB USA
1,8 - 2,2 bar 26 - 32 psi 26 - 32 psi 7 bar 102 psi 102 psi
1,65 - 2,05 bar 24 - 30 psi 24 - 30 psi 7,5 bar 109 psi 109 psi
1,21 - 1,61 bar 18 - 23 psi 18 - 23 psi 6,0 l 1,320 UK gal 1,584 US gal
3 bar 43 psi 43 psi 9l 1,980 UK gal 2,376 US gal
5 bar 72 psi 72 psi 27 mm 1,063 inch 1,063 inch
5,5 bar 80 psi 80 psi 31 mm 1,221 inch 1,221 inch
6 bar 87 psi 87 psi 10 cm3 0,61 cubic inch 0,61 cubic inch
6,5 bar 94 psi 94 psi 25 - 50 cm3 1,525 - 3,050 cubic inch 1,525 - 3,050 cubic inch
VOITH TURBO
Powertransmission
VOITH Retarder
1. Water
2.1 Normal case

*see chapter 4


**see chapter 5
Attention:
agent!

***see chapter 6
Attention:

3. Miscellaneous
3.1 Disposal
3.2 Safety

Attention:




Attention:



Attention:

Attention:


Attention:


Attention:




Attention:


Attention:

Attention:



Attention:


Attention:

A 000 989 13 25 10

Attention:


D-74564 Crailsheim
i. V. i. V. Phone (07951) 32-0
Telefax (07951) 32-756
32-401 / 32-422

92,7+5HWDUGHU/RJRSURS
neues Bild
ohne Bildnummern
fd1616
cbtd 98-01
53.2660.10
1. Preface ....................................................................................................1/1
2. General....................................................................................................2/1
2.3 Retarder Data ...................................................................................2.3/1
3. Maintenance............................................................................................3/1
3.2 Oil Change .......................................................................................3.2/1
With Stainless-steel Heat Exchanger ....................................................3.2/1

5.1 Removing, Installing Retarder (Free Mount Installation) ..................................5.1/1
5.2 Removing, Installing Retarder (Gearbox Attachment)......................................5.2/1
cbtd 98-01 Aftersales Service Manual VOITH Retarder 133

53.2660.10 Page IHV/1
(Continue)

7. IRetarder Basic Group Repair (Free Mount Installation) .........................7/1

7.3 Removing, Checking and Installing Oil Sump Check Valve .......................7.3/1
7.7 Removing and Installing Labyrinth Cover (Input Side),

53.2660.10 Page IHV/2
(Continue)

8.1 Removing, Checking and Installing Aluminium Heat Exchanger .................8.1/1
8.2 Removing, Checking and Installing Stainless-steel Heat Exchanger ...........8.2/1
9. Control Parts ...........................................................................................9/1

9.1 Control Parts ....................................................................................9.1/1
10. Annex ....................................................................................................10/1

Data Sheet
Spare Parts Lists
Other Information

53.2660.10 Page IHV/3
Preface 3UHIDFH
Caution!
Notice

53.2660.10 Page 1/1
Preface
(Continue)
Caution!
Notice
• Brake-Number
• Basic group-Number
Notice

53.2660.10 Page 1/2
Preface
(Continue)
Caution!
Notice
professionally.
Notice
Notice

53.2660.10 Page 1/3
Preface
(Continue)
damage incurred.
prior notification.

D-74564 Crailsheim

Telefax (07951) 32-756
Extensions:
32-401 / 32-422

53.2660.10 Page 1/4
General

2.3 Retarder Data.............................................................................................2.3/1

53.2660.10 Page 2/1
General
Illustration VOITH Retarder R 133 Logoprop

1030
1000 Heat exchanger 2260

1000/1 Oil drain plug retarder (M 12 x 1,5)
1010/1 Retarder data
1010/2 Constant-air pressure py
connection
1010/3 Connection ventilation
1030 Test connection
housing pressure pG 1010/1
1040 Oil level plug (M 24 x 1,5) 1010/3
2260 Oil filling plug (M 24 x 1,5)
1010/2
1060
1040
1000
1000/1
FD190

53.2660.10 Page 2.1/1
General
(Continue)

2105
basic group with aluminium heat exchanger 1070
(Continue)
1000 Heat exchanger

1000/1 Oil drain plug heat exchanger
(M 12 x 1,5)
1440
(M 12 x 1,5)
1070 Oil drain plug retarder
(M 30 x 1,5)
1440 Silencer
2105 Sump check valve plug
(M 22 x 1,5)
1000/3
1000
1000/1
FD191

53.2660.10 Page 2.1/2
General
(Continue)

heat exchanger
2260
1000 Heat exchanger

1010/1 Retarder data
1010/3 Connection ventilation
1030 Test connection
housing pressure pG
1040 Oil level plug (M 24 x 1,5) 1010/1
1060 Screw plug (M 24 x 1,5) 1010/3
2260 Oil filling plug (M 24 x 1,5),
alternatively (M 18 x 1,5)
1060
1040
1000
FD1605

53.2660.10 Page 2.1/3
General
(Continue)

2105
heat exchanger (Continue)
1070
1000 Heat exchanger
(M 18 x 1,5)
(M 30 x 1,5)
1440 Silencer 1440
2105 Sump check valve plug (M 22 x 1,5)
1000/3
1000
FD857

53.2660.10 Page 2.1/4
General
Illustration VOITH Retarder R 133 with Logoprop Control System
25
Oil sump
Supply-air pressure p V
P Constant-air pressure p y
Coolant (water)
26 Housing pressure p G
A
46 10 36 R
21
23
49
14 6 3
44
56
51
1 2 16
45
19
22
17
47
58
54 68 59 43 53 18
FD247
Notice
1 Heat exchanger 36 Ventilation line

2 Control unit 43 Oil sump
3 Connection vehicle voltage 24 V 44 Stator
6 Fuses (8 A) 45 Stator pin
8 Connection ground 46 Rotor
10 Test connection housing pressure pG 47 Speedometer signal
14 ABS switch-off relay 49 Output restrictor p1
16 Retarder stage switch 51 Filling restrictor p2
17 Retarder pilot light 53 Filling duct
18 Stop light relay 54 Duct
19 Cooling water temperature pick-up 56 Leakage oil return line
21 Proportional valve 58 Sump check valve
22 Ventilation 59 Sump flap valve
23 Casing ventilation 68 Auxiliary chambers
(to proportional valve)

53.2660.10 Page 2.2/1
General

(Continue)

The VOITH Retarder 133 is a powerful, hydrodynamic, continuous brake of compact design for buses
and commercial vehicles in the heavy range. The VOITH Retarder 133 is located in a vehicle drive train
between gearbox and rear axle. In this way, the retarder braking torque is sustained even when gear
changes are made. The switched-on retarder will not secure a parked vehicle.
VOITH Retarder 133. A special version combines the retarder stage switch (16) with ABS,

When the retarder stage switch is shifted to position 1, the momentary speed is transferred to memory
and the retarder holds the vehicle speed downhill constant within the limits of the maximum braking tor-
que.
If after activation of „constant speed“ operation 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.
cbtd 98-01 Service-Handbuch VOITH Retarder 133

53.2660.10 Seite 2.2/2
General

(Continue)
b) Control system without ,,constant speed"

When the retarder stage switch is shifted to stage 1 to 5, the retarder brakes through braking stage
1 to 5. Maximum braking torque is obtained in braking stage 5.

53.2660.10 Page 2.2/3
General

(Continue)
Description of operation of retarder R 133 with logoprop control system

c
The control medium for the Voith Retarder 133 is compressed air, which is taken from the air tank for
auxiliary equipment on the vehicle.
proportional valve (21). a b
and stator (44).
FD299
The rotor (46) is connected with the retarder drive shaft, the stator (44) is stationary with the retarder The hydrodynamic principle
housing. a Rotor (46)
The rotation of the rotor sets the oil in motion and circulates it in a closed circuit between b Stator (44)
the rotor (46) and stator (44). c Oil flow
In the heat exchanger (1), 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.

53.2660.10 Page 2.2/4
General

(Continue)
Temperature pick-up cooling water (19)

The temperature pick-up installed in the retarder cooling water return pipe monitors the cooling water
temperature and transmits appropriate signals to the control unit (2).
This temperature pick-up guarantees that the maximum permissible cooling water temperatures are not
exceeded.
If the cooling water in the return pipe heats up to a preselected value, the constant-air pressure py
decreases linearly over a range of approx. 10°C at the highest braking stage.
between the braking energy of the retarder and the amount of heat which can be dissipated by the
vehicle cooling system.
If the limit range of approx. 10°C is exceeded while braking, graking torque output is stopped to protect

53.2660.10 Page 2.2/5
General

(Continue)

Sump check valve (58)
Any small amounts of leakage oil present on the shaft sealing rings are collected by the labyrinth and
returned via the leakage oil return line (56), the sump check valve and the duct (54) into the auxiliary
chambers (68), and thus to the oil sump (43).
When the retarder is switched off, the compressed air escapes via the auxiliary chambers (68) and the
breather (22) into the open air and simultaneously acts on the sump check valve via the duct (54).
The aluminium disc is pushed upwards by the compressed-air and closes the leakage oil return line (56).
Oil is thus prevented from escaping via the labyrinth selas when the retarder is switched off.

53.2660.10 Page 2.2/6
General

(Continue)
Sump flap valve (59)

When the retarder is switched on, the oil sump (43) is pressurized with compressed air.
The oil sump (43) is seperated from the auxiliary chambers (68).
After the retarder has been switched off, the sump flap valve opens again and the oil can level out
between the oil sump (43) and the auxiliary chambers (68).
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). This causes a power loss. 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.

53.2660.10 Page 2.2/7
General !
The data (arrow) of the retarder punched on the output side of the retarder housing on the left give the
following information:
1. Number of the brake (Br.Nr.):
5/91
Six-digit number.
The retarder 133-S has a „S“ at the end of the brake No.
F = fixed bearing RETARDER 133
L = moveable bearing BrNr
GrNr
No data = Free mount installation M = 4000 Nm
n =
2. Basic group number (Gr.Nr.):
Eight-digit number
3. Max. braking torque on prop shaft (M):
FD158
M = 4000 Nm.
Notice
Max. braking torque is set for the specific vehicle. Observe the vehicle manufacturer´s data.
4. Max. retarder r.p.m. (max. prop shaft r.p.m.):
4.1 R 133: n = 2000 r.p.m.
4.2 R 133-S: n = 2500 r.p.m.
Notice
Please, always quote the No. of the brake and basic group No. when submitting queries

53.2660.10 Page 2.3/1
Maintenance "

3.2 Oil Change .................................................................................................3.2/1

With Stainless-steel Heat Exchanger 3.2/5
3.4 Cleaning Line Filter (Extra Optional) ..........................................................3.4/1

53.2660.10 Page 3/1
Maintenance "

#$

l Check hex.-head screws of prop shaft on correct fitment, or tighten. Observe guidelines and
instructions!
torque (see Annex) except all fastening nuts of the heat exchanger (see Section 8)!
Caution!
The fastening nuts of the heat exchanger (Dilavar) only may be tightened in the case of an unambiguous
leakage. Tightening torque 46 Nm
Achtung!
Don´t tight with an impact tool.

When studs (Dilavar) are tightened too high this causes a damage of the studs and may crack at once
or during the driving session.

53.2660.10 Page 3.1/1
Maintenance %
&
Illustration oil change R 133 with

aluminium heat exchanger 1000/1
1000/2
1000/1 Oil drain plug heat exchanger 2260

(M 12 x 1,5), 25 Nm
1000/2 Sealing ring (A 12 x 15,5),
2270
renew
1050 Sealing ring (A 24 x 29), 1060
renew
1060 Oil level plug (M 24 x 1,5), 80 Nm
(M 30 x 1,5), 150 Nm
1080 Sealing ring (A 30 x 36), 1070
renew 1080
1050
(M 22 x 1,5), 66 Nm 2090
2105
2090 Sealing ring (A 22 x 29),
renew
2260 Oil filling plug (M 24 x 1,5), 80 Nm,
renew
FD235

53.2660.10 Page 3.2/1
Maintenance %
&
(Continue)
Notice
The service filling of the complete retarder system depend on the heat exchanger version installed.
The service filling will change, if other heat exchanger version are refitted.
The VOITH item No. or the AKG- (aluminium heat exchanger) No. can be found at the version plate on
the top of the retarder.
Heat exchanger Heat exchanger Heat exchanger

aluminium standard aluminium LKW 1 aluminium LKW 2
AKG 0591 069 0591 136 0591 162

item No. 0591 033
0591 039
0591 070
0591 071
0591 110
Service filling 9,0 Litre 10,5 Litre 9,5 Litre

53.2660.10 Page 3.2/2
Maintenance %
&
(Continue)
Notice
For satisfactory retarder operation, it is important to adhere to the specified service filling 1000/1
(see table below) and to use only oils specified in the operating specifications (see Annex) for 1000/2
to be drained.
1080
Caution! Risk of injury! 1070
FD313
Job scope
2. Screw out the oil drain plug retarder (1070) and the oil drain plug heat exchanger (1000/1)
and drain oil.
3. Provide the oil drain plugs (1070, 1000/1) with new sealing rings (1080, 1000/2) and screw them
tight in the appropriate holes.
Tightening torque:
Oil drain plug retarder 150 Nm
Oil drain plug heat exchanger 25 Nm

53.2660.10 Page 3.2/3
Maintenance %
&
(Continue)
4. Screw out screw plug (2105), remove sealing ring (2090) and drain any leakage oil
5. Provide the screw plug (2105) with a new sealing ring (2090) and screw it tight.
6. Slowly fill in through the bore of the oil level plug (1060) or the bore of the oil filling plug (2260)
specified quantity of oil (see Section 3.2/2 and annex) in accordance with Operating Specifications
(see annex).
2090
Notice 2105
If the oil is filled in to quickly at the housing cover, there is an oil backflow and the oil emerge through the FD236
ventilation system (silencer).
Tightening torques:
Oil filling plug (M 24 x 1,5) 80 Nm

8 Check oil level (see Section 3.3).

53.2660.10 Page 3.2/4
Maintenance %
&
Illustration oil change R 133 with

stainless-steel heat exchangerr
2260

1060 Oil filler/check plug (M 24 x 1,5), 2270
80 Nm
1070 Retarder oil drain plug (M 30 x 1,5),
150 Nm
(M 22 x 1,5), 66 Nm
2260 Oil filler plug (M 24 x 1,5), 1080
80 Nm, 1070
2090 2105
renew
1050
FD1651

53.2660.10 Page 3.2/5
Maintenance %
&
(Continue)
Notice
operating the retarder in the relevant application. The retarder oil temperature
must be higher than 60 oC (operating temperature) for the oil to be drained.
Notice
If it is necessary to drain the cooling water during a service, remove end empty retarder on oil side com-
pletely (see following table service filling). This process also must be enforced with strongly spent oil.
Then install heat exchanger with new sealing rings.
Heat exchanger Heat exchanger

L&R small L&R large
VOITH item number 67.0481.11 67.0567.11
Service filling 7,5 Litre 7,5 Litre
After exchange of heat exchanger 9 Litre 9,7 Litre
After complete taking apart and cleaning, as

well as emptied heat exchanger 10 Litre 11 Litre

53.2660.10 Page 3.2/6
Maintenance %
&
(Continue)
Job scope
3. Screw out the retarder oil check plug (1070) and remove sealing ring (1800). Drain the oil.
Notice
The heat exchanger „Stainless-steel small“ as well as „Stainless-steel large“ have no oil drain plug.
4. Screw the retarder oil check plug (1070) tight with new sealing ring (1080)
5. Screw out check plug (2105) and remove sealing ring (2090) and drain collected leakage oil.
6. Screw the check plug (2105) tight with new sealing ring (2090).
7. Fill in slowly, in the hole of the oil filler/check plug (1060) or the hole of the filling plug (2260), the
quantity of oil specified (see page 3.2/2) in accordance with the operating specifications
(see Annex).

53.2660.10 Page 3.2/7
Maintenance %
&
(Continue)
Notice
If the oil is filled in too quickly at the housing cover, there is an oil backflow and the oil may emerge throu-
gh the ventilation system (silencer).
Tightening torques:
9. Check oil level (see Section 3.3).

53.2660.10 Page 3.2/8
Maintenance %$
& '
Checking oil level

2260
Notice
2270
The oil change intervals and operating specifi-
cations have to be taken from the annex!
1060
1040 Oil level plug (M 24 x 1,5),
80 Nm
1060 Oil check plug (M 24 x 1,5),
80 Nm
1050 Sealing ring (A 24 x 29),
renew 1050
2260 Oil filling plug (M 24 x 1,5),
80 Nm,
alternatively (M 18 x 1,5),
50 Nm
renew
1050
1040
FD214

53.2660.10 Page 3.3/1
Maintenance %$
& '
(Continue)
Notice
Service filling
For versions which are not listed in the table „Service filling R 133“ (see Section 3.2/2 and 3.2/6)
please, contact VOITH TURBO regarding the service filling.


53.2660.10 Page 3.3/2
Maintenance %$
& '
(Continue)
Notice
Difference between min. and max. mark on oil filler/check plug is approx. 1,0 Litre oil.
The oil level check on the VOITH Retarder 133 can be carried out either with the oil filler/check plug
(1060) or with the oil level plug (1040), depending on access on the vehicle.
Job scope
• Ignition ON
• Operating pressure
Oil level check with oil filler/check plug

4. Position oil filler/check plug (1060) plane at the thread. Do not screw in the oil filler/check plug!

53.2660.10 Page 3.3/3
Maintenance %$
& '
(Continue)
Oil level check with oil filler/check plug (Continue)

Oil level is correct bewteen min. and max. mark of the oil filler/check plug. 1060
6. Top up slowly any lacking oil through the hole for the oil filler/check plug. Max
Min
Notice
If the oil is filled in too quickly at the housing cover, there is an oil backflow and the oil may emerge
through the ventilation system (silencer).
7. Screw the oil filler/check plug (1060) with new sealing ring or, as the case may be, FD1652
the oil filler plug (2260) tight with new sealing ring (2270).
Tightening torques:
Oil filler/check plug 80 Nm


53.2660.10 Page 3.3/4
Maintenance %$
& '
(Continue)
Oil level check with screw plug

The screw plug is heated up (oil temperature)! 1050

1040
FD217
3. Screw out the screw plug (1040) and remove sealing ring (1050) and wipe the oil off the wire hook.
Oil level is correct, when it reaches the lower edge of the threaded bore (arrow).
4. Insert the oil level plug (1040) with wire hook into the threaded bore.
5. Pull the oil level plug (1040) out again.

The minimum oil level is reached when the tip of the wire hook (arrow) is wetted with oil.
6. Top up slowly any lacking oil through the hole for the oil filling plug (2260) in the housing cover.
1040
FD218

53.2660.10 Page 3.3/5
Maintenance %$
& '
(Continue)
Oil level check with screw plug (Continue)

7. Screw the oil level plug (1040) and the oil filling plug (2260) tight with a new sealing ring.
2260
Observe the following tightening torques:
Oil level plug 80 Nm

Oil filling plug (M 24 x 1,5 80 Nm
1040
FD219

53.2660.10 Page 3.3/6
Maintenance ( %

& '

(Extra Optional)

12000/3 Cover
12111 Filter insert
12112 O-ring (36,2 x 3), renew,
12000
for installation
12000/5
Lubricants

12000/3
12000/4
FD427

53.2660.10 Page 3.4/1
Maintenance ( %

& '

(Continue)
Notice
Job scope

53.2660.10 Page 3.4/2
Maintenance ( %

& '

(Continue)
Notice

53.2660.10 Page 3.4/3
Diagnosis / ( !&
)*
&
Troubleshooting

Electrical Connections Diagram.....................................................................................4.1/2

53.2660.10 Page 4/1
Diagnosis
Troubleshooting
Notice

VOITH ventilation
OK NOK
Check casing see chapter 6.5 retarder (*)
ventilation
Check cooling
(Chapter 6.2) Check heat system:
exchanger
-coolant level
-coolant pump
Check oil level of dirtiness Driver instruction!
retarder
OIl leak by OK NOK

ventilation
Check or renew
Check operation
radial shaft seal Oil leak when (by braking with
input side or switch on retarder retarder nominal
output side
engine speed,
(Chapter 6.6 u.
if possible
6.7)
Complaint
Oil leak input side Retarder pilot
or output side R 133 light
Logoprop
Check or renew oil

Oil leak at the
sump shut-off
moment when
valve NOK OK
switch off retarder
(Chapter 6.3) No respectively flashes
too insufficient
Check lead to
retarder braking
temperature pick-
effect
up and short
circuit, lead
discontinuity
Check oil level of

retarder
NO YES YES NO
Check heat
exchanger
Check p y (static)
(Chapter 4.4) Correct oil level of
see chapter 6.5
retarder
OK NOK
Check p (dynamic)
(Chapter 4.3)
OK NOK
Check voltage of
proportional valve
Contact Contact (Chapter 4.4)
VOITH VOITH
OK NOK
Check control unit

and retarder stage
Check switch
compressed- (Chapter 4.4)
-air supply
(Chapter 4.4) OK NOK
OK NOK
Check vehicle
compressed-air Contact Contact
Mechanical fault of VOITH VOITH
supply
proportional valve
OK NOK *If you get oil leakage after a trail run again:
continue at ´Ćhecking casing ventilation
Contact
Contact
vehicle
VOITH
manufacturer
FD 1711

53.2660.10 Page 4.1/1
Diagnosis / ( *
& !&
Electrical connections diagram

4
6 16
2 Control unit 19
4 Terminal 15
6 Fuse (8 A)
14 ABS switch-off relay
1 2 3 4 5
18 Stop light relay
19 Cooling water temperature pick-up 87 87a
47 Speedometer signal (only with the 30
ye/gn
control system with function
blu
blu
vio
wh
pi
rd
gr
bl
„constant speed“)
14
U U
U U U U U U
2 10 9 8 7 6 5 11 12
1 3 4 13 14
2
U U I
ye/gn
br
br
or
bl
30
87 87a
47
18 17
21 FD128

53.2660.10 Page 4.1/2
Diagnosis / ( *
&

Troubleshooting
Check requirements
Notice

53.2660.10 Page 4.2/1
Diagnosis / ( %$
& +
&
Troubleshooting
Illustration checking housing pressure

1030
Notice

on internal leaks and on the operation of the
retarder.
1030 Screw plug (M 12 x 1,5),

25 Nm
Special tool
53.4788.10
FD221
Pressure gauge
0 - 25 bar

53.2660.10 Page 4.3/1
Diagnosis / ( %$
& +
&
Job scope static

Job scope
3. Shift retarder stage switch to the highest braking stage with the vehicle in parking position and
read-off the housing pressure from the pressure gauge (99/1). FD223

4. Compare read-off pump pressure with the setpoint of the static housing pressure
Caution!

53.2660.10 Page 4.3/2
Diagnosis / ( %$
& +
&
Setting Stage switch Housing pressure static Housing pressure dynamic 1)

[Nm] vps = 1000 r.p.m.
Setpoint [bar] 1) 2) Minimum value [bar]
4000 5 2,52 -2,92 6,5
3750 5 2,36 - 2,76 5,5
3500 5 2,20 - 2,60 5,0
3250 5 2,04 - 2,44 4,5
3000 5 1,87 - 2,27 4,0
2400 5 1,48 - 1,88 2,8
1)
2)
Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure)
Notice

53.2660.10 Page 4.3/3
Diagnosis / ( %$
& +
&
Job scope dynamic

2. Shift the retarder stage switch (16) to position 5 while on the move at v ps = 1000 r.p.m. and
read-off housing pressure at pressure gauge (99/1).
3. Compare read-off housing pressure with the value of dynamic housing pressure
Caution!
4. Disconnect the pressure gauge. Screw in screw plug (1030) with new sealing ring (1040).

53.2660.10 Page 4.3/4
Diagnosis
Troubleshooting

11
Notice 71 33
26 32 61
are not identical with the refrence numbers of
the spare parts lists. P
1 Heat exchanger
2 Control unit
11 Proportional valve A 31
current connection
R
19 Temperatur pick-up cooling water 21
25 35
36
(pressure regulator four-circuit
protection valve)
38
(four-circuit protection valve -air 19
tank for auxiliary equipment with 2
test connection)
(parking brake)
47
36 Ventilation line „R“ 1
38 Electrical lead (Cooling water
temperature pick-up to control unit, FD869
2 wires)
(only with control system with
function „constant speed“)
Page 4.1/1

53.2660.10 Page 4.4/1
Diagnosis / (( %$
& %

Check requirements
• Retarder stage switch in highest braking stage .
• Lock pin to limit stages (on retarder stage switch) in position 6
l For checks with the multimeter, pin 1 of the control unit (2) must be connected to ground
and pin 2 to terminal 15.
Special tools
101103105
99 107
97 111
95 113
93 115
o o
120 C 200 C
53.4377.10 53.4788.10 53.8167.10
Presure gauge
0 - 25 bar

53.2660.10 Page 4.4/2
Diagnosis / (( %$
& %


Notice
32
against the manufacturer´s data.
1. Disconnect the lead (38) from the temperature pick-up (19) and connect it to the temperature 38
simulator (99/2).
99/4
101103105
99 107
97 111
19 95
93
113
115
o o
120 C 200 C
FD107

53.2660.10 Page 4.4/3
Diagnosis / (( %$
& %


1060
2. Screw out oil filler/check plug (1060) with sealing ring (1050). 1050
FD215
3. Connect pressure gauge (99/1) (see arrow) to the retarder housing.
FD227

53.2660.10 Page 4.4/4
Diagnosis / (( %$
& %

Prior jobs
• Ignition: OFF
• Disconnect plug on control unit (2). 2
4. Connect up socket box (99/8).
• Connect wiring harness to appropriate connector of socket box.

• Connect appropriate plug of socket box to control unit (2). 99/8
FD875
99/8 Socket box 53.8167.10

(measurements: mA).
98/4
FD870

53.2660.10 Page 4.4/5
Diagnosis / (( %$
& %

Job scope test

• Ignition: ON
1. Set the rotary switch of the temperature tester (99/4) one step below the specified start of 99/4
temperature limit (e.g. to 95°C for a specified start of temperature limit at 96°C) and operate the 99
101103105
107
97 111
retarder at the highest stage. 19 95
93
113
115
next page (page 4.4/7). o o
120 C 200 C
Notice FD107


53.2660.10 Page 4.4/6
Diagnosis / (( %$
& %

Setting DIL-Switch Setting Control current Constant-air pressure

[Nm] [mA] 1)
py [bar] 2)
4000 DIL 3, 4 und 5 OFF 314 - 320 2,52 - 2,92
3750 DIL 3 ON 300 - 310 2,36 - 2,76
3500 DIL 4 ON 288 - 300 2,20 - 2,60
3250 DIL 3 und 4 ON 277 - 291 2,04 - 2,44
3000 DIL 5 ON 266 - 280 1,87 - 2,27
2400 DIL 3, 4 und 5 ON 240 - 254 1,48 - 1,88
1)
2)
Notice
• If a commercially available multimeter is used for measurements (without real effective measu-
ring) exact readings cannot be made (indication jumps!).
• The data represent the state of the art at the time going to print. Control units to which other data
apply still are in use. The manufacturer reserves the right to make further modifications.

53.2660.10 Page 4.4/7
Diagnosis / (( %$
& %

Notice
must be provided.
Notice

53.2660.10 Page 4.4/8
Diagnosis / (( %$
& %

3. Disconnect presure gauge.
4. Screw oil filler plug (2909) tight with new sealing ring (2910).
Tightening torque 150 Nm 1060
1050
FD215
38
19
FD109

53.2660.10 Page 4.4/9
Diagnosis / (( %$
& %

Notice
Pin - multimeter - measuring mode V or W - Pin
test connection
1 Voltage 1-V- 2 Ignition: ON ≥ 20 V - End of check
< 20 V - Step 1.2
1.2 1-V- 2 Ignition: OFF ≥ 20 V - Renew control unit

control unit
Ignition: ON < 20 V - Lead discontinuity
2.1 Retarder pilot light 1-V- 4 Ignition: ON <1V - Step 2.2

- Retarder stage switch in stage
position 0 - Lead discontinuity
≥1V - Fault in retarder stage
switch
2.2 1-V- 4 Ignition: ON ≥ 20 V - End of check

- Retarder stage switch-
in stage position 1 to 5 - Lead discontinuity
< 20 V - Lead short circuit
switch

53.2660.10 Page 4.4/10
Diagnosis / (( %$
& %

test connection
3.1 Stop light relay 1-V- 3 Ignition: ON <1V - Prüfschritt 3.2

- Retarder stage switch in
stage position 0 ≥1V - Lead short circuit
switch
3.2 1-V- 3 - Retarder stage switch in ≥ 20 V - End of check

stage position 1 to 5

switch
4.1 Input retarder stage 1-V- 5 Ignition: ON ≥ 7,7 V - Step 4.2

switch - Retarder stage switch in
stage position 5
< 7,7 V - Lead discontinuity
switch
4.2 1-V- 5 ≤ 8,3 V - End of check
- Lead discontinuity
> 8,3 V - Lead short circuit
switch

53.2660.10 Page 4.4/11
Diagnosis / (( %$
& %

test connection
5.1 Output retarder stage 1-V- 6 Ignition: ON ≥ 14,7 V - Step 5.2

switch 1-V- 7 - Retarder stage switch in stage
1-V- 8 position 0
1-V- 9 < 14,7 V - Lead discontinuity
switch
5.2 1-V- 6 ≤ 15,3 V - End of check

1-V- 7
1-V- 8
1-V- 9 > 15,3 V - Lead discontinuity
switch

53.2660.10 Page 4.4/12
Diagnosis / (( %$
& %

test connection
6.1 Temperature pick-up 11 - W - 12 Ignition: OFF - Check electrical lead and

- Disconnect plug from control temperature pick-up
unit

Notice:
is sufficient.
+ 20°C 500 ... 700 W
+ 60°C 134 ± 13 W
+ 90°C 52 ± 4 W
+ 100°C 38,5 ± 3,5 W
6.2 11 - W - 12 ≥ 54 Ω -Lead discontinuity

-Lead short circuit
< 54 Ω -End of check
If fault is still existing,

renew temperature pick-up.

53.2660.10 Page 4.4/13
Diagnosis / (,
%$
Troubleshooting


FD844

switch positions.

1 on moving off


53.2660.10 Page 4.5/1
Diagnosis / (,
%$
Action
position 1 to 5 position
1 to 5
Retarder pilot light does not Troubleshooting as on

come on, and/or insufficient Troubleshooting diagram
braking of the retarder (see page 4.1/1)

53.2660.10 Page 4.5/2
Retarder Remo- ,
&- .

&
ving, Installing

53.2660.10 Page 5/1
Retarder Remo- !" #
1300
1300
1400
1400
1200
1300 1200
1400
1100
1200
1300
1400
92
1200
1200
94 1400 1200 1100
95/2 1300
1200
1400
1500
3700
96
93 1000 96
1000/4
3400 97
1200
1000/3 1400
92
1500
FD308

Hinweis:
The oil can not be drained from the heat exchanger, if a „stainless-steel“ heat exchanger is installed.
92 Prop shaft 1200 Megi pad with washer,

93 Hex.-head screw check, renew if necessary
94 Spring washer, renew 1300 Hex.-head screw (M 16 x 90)
95/2 Hex.-head nut 1400 Washer (B16)
96 Hose clamp 1500 Hex.-head nut (M 16)
97 Hose connection self-locking, renew, 110 Nm
1000 Heat exchanger 34000 Constant-air pressure line py
1000/3 Cooling water drain plug 37000 Ventilation line
(M 12 x 1,5), 25 Nm
Caution!

cbtd 98-01 Service-Handbuch VOITH Retarder 133

53.2660.10 Seite 5.1/1
Retarder Remo- ,
&- .

&
ving, Installing / 0
1
To install the retarder 133 according to regulations to the gearbox or to remove from the gearbox,
Caution!


53.2660.10 Page 5.2/1
Repair Gearbox 2
Attachment



53.2660.10 Page 6/1
Repair Gearbox ' ( !!) $ * + &
Attachment
1250
4090 4080
1260
2260 1060
2120
1200
2110 2270
1210
1050
1220/1
1020
1030
2301
1220/2
1040 1220
1050
1220/3
4020
1370
1150
1080
2080 1160
1070
2100 3030
2090 1420
1170 1190
2105 1440 1180
1450 FD1574
1020 Sealing ring (A 12 x 18) 1250 Hex. -head screw (M 8 x 25)

1200 Cover for casing ventilation 2260 Oil filler plug (M 24 x 1,5)
1210 Gasket for casing ventilation alternatively ((M 18 x 1,5)
1220 Casing ventilation 2270 Sealing ring (A 24 x 29)
1220/1 Ventil insert alternatively (A 18 x 24)
1220/2 Float 2301 O-ring (55 x 3)
1220/3 Float cage 3030 Bearing race
1260 Washer (B 8,4) 4020 O-ring (95 x 4,5)
1370 O-ring (196,52 x 2,62) 4080 Centering cover
1420 Silencer 4090 Hex. -head screw (M 8 x 16)
alternatively (M 8 x 20)

53.2660.10 Page 6.1/1
Repair Gearbox 2
&- %$
&
.

&
Attachment %
& 3


1250
1260
Notice

1210
1030 Check plug (M 12 x 1,5), 25 Nm
1220/1
to sealing surface
1210 Gasket, renew
1220/2
1220/3 Float cage
1260 Washer (B 8,4)
2301 O-ring (55 x 3), renew,
for installation
1020
1030
FD791
Aftersales Service Manual VOITH Retarder 133

Page 6.2/1
Repair Gearbox 2
&- %$
&
.

&
Attachment %
& 3

(Continue)

Specia tools
53.7712.10 53.9428.10

53.2660.10 Page 6.2/2
Repair Gearbox 2
&- %$
&
.

&
Attachment %
& 3

(Continue)

Notice
FD155
0
100
750
500
250
FD156

53.2660.10 Page 6.2/3
Repair Gearbox 2
&- %$
&
.

&
Attachment %
& 3

(Continue)
To remove
98/7
Notice
FD890
98/7 Adapter 53.9428.10
1220/1
2301
FD891

53.2660.10 Page 6.2/4
Repair Gearbox 2
&- %$
&
.

&
Attachment %
& 3

(Continue)
To check

be renewed.
1220/2
Notice
FD1627
1220/1
FD892

53.2660.10 Page 6.2/5
Repair Gearbox 2
&- %$
&
.

&
Attachment %
& 3

(Continue)
To install
far as it will go.
FD251

53.2660.10 Page 6.2/6
Repair Gearbox 2
&- %$
&
.

&
Attachment %$ 3
renew if necessary
locking agent
2105 Screw plug (M 22 x 1,5),
66 Nm
Locjking agent

Prior job 2080
2100
Notice

Do not use an impact driving tool! 2105
FD300

Page 6.3/1
Repair Gearbox 2(
&- %

&
.

&

Attachment
Notice

1420 Silencer,
with compressed-air
1440 Cover plate
1450 Cap screw (M 6 x 16), 8 Nm
Cleaning agent
1420
Silencer Benzine
1440 1450
1450
FD303

Page 6.4/1
Repair Gearbox ' ! # , ! (Output
Attachment Side)" ) -
Prior jobs
97/4
Notice

1150
(115 x 140 x 10), renew, 3030
for installation
1170
1160 Back-up ring
to sealing surface
1190 Washer (10,5)
1370 O-ring (196,52 x 2,62), renew,
for installation
FD1631
renew if necessary
4020 O-ring (95 x 4,5), renew,
for installation

53.2660.10 Page 6.5/1
Repair Gearbox 2,
&
.

& '
% (Output
Attachment Side)-

&
&
& (Cont.)
Notice

Observe the possibility of two retrader versions:
- with standard labyrinth: race (3030) = 31 mm long

- with short labyrinth: race (3030) = 27 mm long
Observe therefore the installing sequence.

Special tools
53.1180.10 53.1373.10 53.1372.10

53.2660.10 Page 6.5/2
Repair Gearbox 2,
&
.

& '
% (Output
Attachment Side)-

&
&
& (Cont.)
Job scope
with washers (1190). M+P-07A-638
FD1630
3030
housing. 94/4
97/4
FD1641

53.2660.10 Page 6.5/3
Repair Gearbox 2,
&
.

& '
% (Output
Attachment Side)-

&
&
& (Cont.)

97/4
Notice M+P-07A-638
97/4
4020
Notice 1150
Recommendation:
FD1645
1150
4020 97/4
Notice
97/1
Set back-up ring (1160) together with the radial shaft sealing ring (1150) onto the
press-in equipment (97/1) and knock in flush into the retarder housing.
FD1646
shaft (97/4).

53.2660.10 Page 6.5/4
Repair Gearbox 2,
&
.

& '
% (Output
Attachment Side)-

&
&
& (Cont.)
97/4
bearing race (3030) as far as they will go. 1160
Notice 3030
In this case the back-up ring is already installed.
cover (1170).
FD1636

1370
1370
1170
FD1637

53.2660.10 Page 6.5/5
Repair Gearbox 22
&
.

& %

& % (Input
Attachment Side)-

&
&
& (Cont.)
Prior jobs
• Retarder removed (see Section 5.2) 2110
2120
4080
(115 x 140 x 10),renew,
for installation
2120 Back-up ring
4080 Centering cover,
to sealing surface
4090 Hex.-head screw (M 8 x 16,
M 8 x 20), self-locking,
renew, 23 Nm
Housing sealing Hylomar

surfaces

4090
FD294

53.2660.10 Page 6.6/1
Repair Gearbox 22
&
.

& %

& % (Input
Attachment Side)-

&
&
& (Cont.)
Job scope
2. Press centering cover (4080) off housing cover.
3. Remove back-up ring (2120).
4. Remove radial shaft sealing ring (2110) without damaging the sealing surface on the
housing cover.
Notice
Check race of radial shaft sealing ring (2110) at the hollow shaft for scores and uneven surface.
Notice

53.2660.10 Page 6.6/2
Repair Gearbox 22
&
.

& %

& % (Input
Attachment Side)-

&
&
& (Cont.)
6. Join new radial shaft sealing ring (2110) to hollow shaft.
4080 4090
7. Join back-up ring (2120) to radial shaft sealing ring.
8. Apply a thin coat of Hylomar sealant to the sealant surface of the centering cover (4080) and install
it in such a way that the groove faces the leakage oil return hole in the housing cover (arrow)
downwards.
9. Knock in carefully the centering cover into the housing cover using a plastic hammer.
10. Screw the housing cover with the new self-locking hex.-head screws (4090) tight. FD293

53.2660.10 Page 6.6/3
Repair Free Mount 4
Installation
7.3 Removing, Checking and Installing Sump Check Valve ............................7.3/1



53.2660.10 Page 7/1
Repair Free Mount . ( !!) $ * + &
Installation
2210 2220 2200

1370 1250
1260
4110 2260 1060
1200
2120 2270
2110
1210
4020 1050
1220/1
1020
1030
2301
1220/2
1040 1220
1050
1220/3
4020
1370
1150
1080
2080 1160
1070 3030
2100
2090 1420
1170 1190
2105 1180
1440
1450 FD1575

1060 Oil check plug (M 24 x 1,5/ DIN908) 2090 Sealing ring (A 22 x 29)
1070 Oil drain plug retarder (M 30 x 1,5) 2100 Retainer
1080 Sealing ring (A 30 x 36) 2105 Screw plug (M 22 x 1,5)
1150 Radial shaft sealing ring (115 x 140 x 10) 2110 Radial shaft sealing ring (115 x 140 x 10)
1160 Back-up ring 2120 Back-up ring
1170 Labyrinth cover 2200 Labyrinth cover
1180 Cap screw CV 84 (M 10 x 35) 2210 Cap screw CV 84 (M 10 x 35)
1190 Washer (10,5) 2220 Washer (10,5)
1200 Cover for casing ventilation 2301 O-ring (55 x 3)
1210 Gasket for casing ventilation 3030 Bearing race
1220 Casing ventilation 4020 O-ring (95 x 4,5)
1220/1 Ventil insert 4110 Back-up ring
1220/2 Float
1220/3 Float cage
1250 Hex. -head screw (M 8 x 25)
1260 Washer (B 8,4)
1370 O-ring (196,52 x 2,62)

53.2660.10 Page 7.1/1
Repair Free Mount 4
&- %$
&
.

&
Installation %
& 3


1250
1260
Notice

1210
1030 Check plug (M 12 x 1,5), 25 Nm
1220/1
to sealing surface
1210 Gasket, renew
1220/2
1220/3 Float cage
1260 Washer (B 8,4)
2301 O-ring (55 x 3), renew,
for installation
1020
1030
FD791

53.2660.10 Page 7.2/1
Repair Free Mount 4
&- %$
&
.

&
Installation %
& 3

(Continue)

Special tools
53.7712.10 53.9428.10

53.2660.10 Page 7.2/2
Repair Free Mount 4
&- %$
&
.

&
Installation %
& 3

(Continue)

Notice
FD155
0
100
750
500
250
FD156

53.2660.10 Page 7.2/3
Repair Free Mount 4
&- %$
&
.

&
Installation %
& 3

(Continue)
To remove
98/7
Notice
FD890
98/7 Adapter 53.9428.10
1220/1
2301
FD891

53.2660.10 Page 7.2/4
Repair Free Mount 4
&- %$
&
.

&
Installation %
& 3

(Continue)
To check

be renewed.
1220/2
Notice
FD1627
Set the valve insert (1220/1) down on the float (1220/2) and fill up the cavity between float and
upper edge of the valve insert with methylated spirit. If the sealing edge is not damaged, the fluid 1220/2
level must not change within 1 minute. If necessary, renew the complete casing ventilation.
1220/1
FD892

53.2660.10 Page 7.2/5
Repair Free Mount 4
&- %$
&
.

&
Installation %
& 3

(Continue)
To install
far as it will go.
FD251

53.2660.10 Page 7.2/6
Repair Free Mount 4
&- %$
&
.

&
Installation %$ 3
renew if necessary
locking agent
2105 Screw plug (M 22 x 1,5),
66 Nm
Locjking agent

Prior job 2080
2100
Notice

Do not use an impact driving tool!
2105
FD300

53.2660.10 Page 7.3/1
Repair Free Mount 4(
&- %

&
.

&

Installation
Notice

1420 Silencer,
with compressed-air
1440 Cover plate
1450 Cap screw (M 6 x 16), 8 Nm
Cleaning agent
1420
Silencer Benzine
1440 1450
1450
FD303

53.2660.10 Page 7.4/1
Repair Free Mount 4,
&
.

&
&
Installation
Illustration prop shaft flanges
Prior job
97/5 Flange fastening screw 97/6

(M 24 x 200), renew,
(use phosphated version), 97/8 97/7
97/7 Prop shaft screw, renew 97/8
97/8 Guard ring 97/6
97/7
Hinweis
97/5
This job sequence can be performed with the
retarder removed or installed.
Tightening angle measuring tool 3/4

E.g. Messrs Richard Abr. Herder KG
Postfach 10 08 67
D - 42569 Solingen
FD1635
Tel. 0212/888-0 /

53.2660.10 Page 7.5/1
&
.

&
&
To remove, install
1. Unscrew flange fastening screw(97/5) on output side prop shaft flange (97/6). 97/6
Not for installation

97/5
When renewing flange fastening screw (97/5) use phosphated version only.
(VOITH item-No. 53.7416.10)
FD1638
2. Pull both prop shaft flanges (97/6) out of the retarder housing.
97/6
97/6
FD1639

53.2660.10 Page 7.5/2
&
.

&
&
3. Remove guard rings (97/8).

97/7
97/8
Renew prop shaft screws (97/7). Align hole patterns of both prop shaft flanges prior to installation.
The maximum permissible offset should be 5° .
FD189

53.2660.10 Page 7.5/3
Repair Free Mount .' ! # , ! (Output
Installation Side)" ) -
Prior jobs
97/4
Notice

1150
(115 x 140 x 10), renew, 3030
for installation
1170
1160 Back-up ring
to sealing surface
1190 Washer (10,5)
1370 O-ring (196,52 x 2,62), renew,
for installation
FD1631
renew if necessary
4020 O-ring (95 x 4,5), renew,
for installation

53.2660.10 Page 7.6/1
Repair Free Mount 42
&
.

& '
% (Output
Installation Side)-

&
&
& (Cont.)
Notice

Special tools
53.1180.10 53.1373.10 53.1372.10

53.2660.10 Page 7.6/2
&
.

& '
% (Output
Installation Side)-

&
&
& (Cont.)
Job scope
FD1633
3030
housing. 94/4
97/4
FD1641

53.2660.10 Page 7.6/3
&
.

& '
% (Output
Installation Side)-

&
&
& (Cont.)

97/4
Notice M+P-07A-638
97/4
4020
Notice 1150
Recommendation:
FD1645
1150
with the retarder housing.
4020 97/4
9. Coat new O-ring (4020) thin with silicone-free and non-corrosive grease and fit it into the hollow
shaft (97/4). 97/1
FD1646

53.2660.10 Page 7.6/4
&
.

& '
% (Output
Installation Side)-

&
&
& (Cont.)
97/4
bearing race (3030) as far as they will go. 1160
11. Coat new O-ring (1370) thin with silicone-free and non-corrosive grease and fit it into the labyrinth 3030
cover (1170).
FD1636

1370
1370
1170
FD1637

53.2660.10 Page 7.6/5
&
.

& %

& % (Input
Installation Side)-

&
&
&
Prior jobs
• Retarder removed (see Section 5.1) 97/4
97/4 Hollow shaft

1370 O-ring (196,52 x 2,62), renew,
2110
2120
1370
(115 x 140 x 10), renew,
for installation
2120 Back-up ring
to sealing surface
2210 Cap screw CV 84 2220
2210
(M 10 x 35) self-locking,
renew, 46 Nm
2220 Washer (10,5)
4110 Bearing race, check,
renew if necessary
4020 O-ring (95 x 4,5), renew,
FD270
for installation

53.2660.10 Page 7.7/1
&
.

& %

& % (Input
Installation Side)-

&
&
& (Cont.)
Notice

Special tools
53.1180.10 53.1373.10 53.1372.10

53.2660.10 Page 7.7/2
&
.

& %

& % (Input
Installation Side)-

&
&
& (Cont.)
Job scope
1. Screw out cylinder screws (2210) with the wedge insert 53.1180.10 and remove together
with washers.
2200
FD272
Then remove the back-up ring. 4110
94/4
housing.
FD805

53.2660.10 Page 7.7/3
&
.

& %

& % (Input
Installation Side)-

&
&
& (Cont.)

4020
97/4
Notice 2120
4020
Check race of radial shaft sealing ring at the hollow shaft for scores and uneven surface,
renew if necessary.
97/4
Notice
Recommendation: FD806
2110 97/1
4020
64
shaft (97/4).
FD275

53.2660.10 Page 7.7/4
&
.

& %

& % (Input
Installation Side)-

&
&
& (Cont.)
bearing race (4110) as far as they will go. 97/4
2120
cover (1170). 4110
FD276
12. Apply a thin coat of Hylomar sealant to the sealing surface of the labyrinth cover (2200) around 1370
channel in the labyrinth cover (arrow) for the leakage oil return face each other. 2200

2200
FD277

53.2660.10 Page 7.7/5
Repair 5
&- %$
&
.

&
Heat Exchanger + 60
&

53.2660.10 Page 8/1
Repair / !" #
Heat Exchanger ( 0 12
1000/1
1000/2
1000
1000/4
1000/3
3000
2000 1000
3000
1080
7000
1070
4000
4000
5000
97
96
FD813
Prior Job
• Removing retarder (see Section 5.1)
• This job sequence can also be performed with the retarder installed, if necessary.
Caution!
If another version of the heat exchanger is built on to the retarder 133, the appropriate throttle disc must be fitted!
96 Hose clamps Lubricants

97 Hose connections O-ring, Throttle disc Silicone-free and
1000 Heat exchanger (alternatively) non-corrosive grease
1000/1 Oil drain plug heat exchanger (M 12 x 1,5), 25 Nm
1000/3 Cooling water drain plug (M 12 x 1,5), 25 Nm Data
1000/4 Sealing ring (A 12 x 15,5), erneuern Pressure for pressure test (oil section): max. 10 bar
1070 Oil drain plug retarder (M 30 x 1,5), 150 Nm
1080 Sealing ring (A 30 x 36), renew Special tool
2000 Throttle disc (D 35 / 11 x 3) (alternatively) pressed in,
for installation
3000 O-ring (36 x 4), renew,
for installation
4000 Washer (10,5)
5000 Hex. nut (M10), self-locking, renew, 46 Nm
53.1369.10

53.2660.10 Page 8.1/1
Repair 5
&- %$
&
.

&
Heat Exchanger
+ 60
& (Continue)
To remove
Notice
96
Caution! Risk of injury! 1000/4

97 1000
1000/3
FD792
the heat exchanger (1000).
2. Remove the cooling water hoses (96) on the left and on the right and remove the connecting
hoses (97) from the retarder (1000).
3. Screw the coolant drain plug (1000/3) with new sealing ring (1000/4) tight.

53.2660.10 Page 8.1/2
Repair 5
&- %$
&
.

&
Heat Exchanger
+ 60
& (Continue)

1000/1
The oil drain plugs are heated up (oil temperature)! 1000/2
5. Screw out the oil drain plug (1070) at the retarder and drain oil.
6. Screw out also oildrain plug (1000/1) at the heat exchanger and drain oil.
7. Screw the oil drain plug (1070) of the retarder with new sealing ring (1080) into its hole and tighten. 1080
Tightening torque 150 Nm 1070
FD313

53.2660.10 Page 8.1/3
Repair 5
&- %$
&
.

&
Heat Exchanger
+ 60
& (Continue)
8. Screw the oil drain plug (1000/1) of the retarder with new sealing ring (1000/2) into its hole and
tighten. Tightening torque 25 Nm
9. Unscrew the four hex. nuts (5000) with washers (4000) and the hex.-head screws (7000)
Notice
If the heat exchanger is an „L+R large“ version, unscrew 6 hex. nuts. If DILAVAR studs have been in-
stalled, they may be screwed out together with the hex. nuts when the latter are unscrewed.
4000
Remedy: 5000
FD149
agent, screw the staud hand-tight into the retarder housing again. Damaged stauds must be renewed!
Caution !
Damaged stauds must be renewed!

53.2660.10 Page 8.1/4
Repair 5
&- %$
&
.

&
Heat Exchanger
+ 60
& (Continue)
7000
4000
1000
12. Remove throttle disc (2000) (alternatively).
Notice
The throttle disc may be pressed-in.
7000
Caution!
4000 FD150
If another version of the heat exchanger is built on to the retarder 133, the appropriate throttle disc must
be fitted! Please, contact VOITH TURBO!

53.2660.10 Page 8.1/5
Repair 5
&- %$
&
.

&
Heat Exchanger
+ 60
& (Continue)
To check
pressure minimizer.
1000
Notice
If air bubbles form in the hot water, the heat exchanger is leaking and must be renewed.
97/3 FD831

53.2660.10 Page 8.1/6
Repair 5
&- %$
&
.

&
Heat Exchanger
+ 60
& (Continue)
To install
Notice
1. Apply thin coat of silicone-free and non-corrosive grease to the new O-ring (3000).
right bore.
4. Install hose connection (97) on the heat exchanger (1000) and screw the hose clamps (96) tight.
Caution!
Do not use any impact screw drivers!
5. Install retarder, if necessary (see Section 5.1 „Removing and installing retarder“).
6. Fill in cooling water and bleed the cooling water circuit.

53.2660.10 Page 8.1/7
Repair 5
&- %$
&
.

&
Heat Exchanger
+ 60
& (Continue)
Notice
Notice
If replacing aluminium heat exchanger (AKG) with stainless-steel heat exchanger (L+R) observe
the replacement instruction 1427.10.
Fill retarder with specified quantity of engine oil or flushing oil. Flush the retarder system by braking se-
veral times and drain the oil through the oil drain plugs (1070, 1000/1). Repeat the procedure two or three
times until no more oil is visible in the water. Screw oil drain plug (1070, 1000/1) tight with new sealing
rings (1080, 1000/2).
Tightening torque:
Oil drain plug retarder (1070): 150 Nm

Oil drain plug heat exchanger (1000/1): 25 Nm

53.2660.10 Page 8.1/8
Repair 5
&- %$
&
.

&
Heat Exchanger
+ 60
& (Continue)
Notice
Brake slightly several times to avoid the retarder oil overheating. The oil-water mixture in the retarder
may cause the oil in the retarder to foam and escape through the casing ventilation to the open air.
The screw plug is heated up (oil temperature)!
9. Fill the retarder with the specified oil (see Section 3.2 „Oil change“).

53.2660.10 Page 8.1/9
Repair / !" #
Heat Exchanger 3 0 12
1000/4
1000/3
1000
4000 6000
3000
2000 8000
5000 3000
1080
4000
1070
9000
10000
10000
9000
97 4000
96 5000
4000
6000
4000
7000
FD874
Notice
In case of a mechanical damage or a leakage, the heat exchanger may be sealed new or parts may be replaced
(see Aftersales Information 11/96 in the annex).
Prior Job
• Removing retarder (see Section 5.1)
• This job sequence can also be performed with the retarder installed, if necessary.
Caution!
If another version of the heat exchanger is built on to the retarder 133, the appropriate throttle disc must be fitted!
96 Hose clamps Lubricants

97 Hose connection
O-ring, Throttle disc Silicone-free and
1000 Heat exchanger
1070 Oil drain plug retarder (M 30 x 1,5), 150 Nm Data
1080 Sealing ring (A 30 x 36), renew Pressure for pressure test (oil section): max. 10 bar
2000 Throttle disc (D 35 / 11 x 3) (alternatively) pressed in,
coat with silicone-free and non-corrosive grease Special tool
for installation
3000 O-ring (36 x 4), renew,
for installation
4000 Washer (10,5)
5000 Hex. nut (M10), self-locking, renew 46 Nm
53.1369.10

53.2660.10 Page 8.2/1
Repair 5
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Heat Exchanger
7 + 60
& (Continue)
To remove
Notice
If this job sequence is performed with the retarder installed, the following jobs must be first performed:
Caution ! Risk of injury!

1000/3
The cooling water drain plug and the cooling water are heated up!
1000/4
1000
1. Screw out the cooling water drain plug (1000/3) and drain the cooling water in a clean vessel.
FD1623
2. Loosen hose clamps (96) on the left and on the right and remove hose connection (97) from the
heat exchanger (1000).
3. Screw in cooling water drain plug (1000/3) again with new sealing ring (1000/4) and tighten.
96
4. Place oil pan underneath the retarder.
Caution ! Risk of injury! 97
5. Screw out oil drain plug (1070) on the retarder and drain the oil. 1080
1070 FD1624

53.2660.10 Page 8.2/2
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6. Screw the oil drain plug (1070) together with a new sealing ring (1080) into its hole and tighten.
7. Unscrew the four hex. nuts (5000) with the washers (4000) and the hex.-head screws (7000) with
the washers (4000).
Notice
If the heat exchanger is an „stainless-steel large (L+R) version, unscrew six hex. nuts. If DILAVAR studs
have been installed, they may be screwed out together with the hex. nuts when the latter are unscrewed.
Remedy:
agent, screw the stud hand-tight (max. 10 Nm) into the retarder housing again.
Caution !
Damaged studs must be renewed!

53.2660.10 Page 8.2/3
Repair 5
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Heat Exchanger
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To check
1. Fit the pressure-test equipment (97/3) to the heat exchanger (1000) and connect up the
compressed-air line with pressure minimizer. 1000
2. Fill the heat exchanger (1000) with hot water (approx. 70°C) on water section.
3. Pressurize the heat exchanger (1000) slowly to max. 10 bar overpressure (oil section).
Notice
If air bubbles form in the hot water, either the oil cooling inserts or the plane gaskets are defective in oil
section. 97/3 FD1650
4. Remove the pressure-test equipment (97/3). 97/3 Pressure-test equipment 53.1369.10

53.2660.10 Page 8.2/4
Repair 5
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To install
Notice
1 Apply thin coat of silicone-free and non-corrosive grease to the new O-ring (3000) and fit them in
the bores of the retarder housing.
2. Install the heat exchanger (1000) on the retarder housing and use new
self-locking hex. nuts (5000), washers (4000), hex.-head screws (7000) and washers (4000) to
screw it tight on the retarder housing. Tightening torque 46 Nm
3. Install hose connections (97) on the heat exchanger (1000) and screw the hose clamps (96) tight.
4. Install retarder, if necessary (see Section 5.1 „Removing and Installing Heat Exchanger“).
5. Fill in cooling water and bleed cooling water circuit in accordance with the vehicle manufacturer´s
instruction.
Notice

53.2660.10 Page 8.2/5
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Fill retarder with 9 litres engine oil or flushing oil. Flush the retarder system by braking several
Tightening torque:
Retarder oil drain plug (1070): 150 Nm
Notice
If the retarder oil has entered the cooling water-system, the vehicle cooling-system must be cleaned in
accordance with the vehicle manufacturer´s instruction.

53.2660.10 Page 8.2/6
Repair 5
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Notice
Brake slightly several times to avoid the retarder oil overheating.
Oil and cooling water are heated up!
The oil-water mixture in the retarder may cause the oil in the retarder to foam and escape through casing
ventilation to the open air.
8. Fill the retarder only with the specified oil (see Section 3.2 „Oil Change“).

53.2660.10 Page 8.2/7
Control Parts 8 %

9.1 Control Parts ..............................................................................................9.1/1

53.2660.10 Page 9/1
Control Parts 8 %

26
Prior job
• Supply-air discharged or switched off 21000
Escaping compressed-air!
21000/1
36 Ventilation line
5000/1 Plug proportional valve
21000/1 Hex. nut
5000/1 25
36
FD883

53.2660.10 Page 9.1/1
Control Parts 8 %

(Continue)

cooling water
Prior jobs
• Ignition OFF
Job Scope
1. Disconnect electrical lead (38) from

temperature pick-up cooling water (19). 38
2. Screw out temperature pick-up cooling

19
water (19).
The electrical lead (38) is pured
alternatively.
4. Install temperature pick-up in reverse

sequence. FD440

53.2660.10 Page 9.1/2
Annex 9
0
Data Sheet
Spare Parts Lists
Other Information
cbtd 98-01 Aftersales Service Manual VOITH Retarder R 133

53.2660.10 Page 10/1
Data Sheet VOITH Retarder 133, 133 S
Max. retarder speed R 133 (= max. prop shaft speed) v(max.) 2000 r.p.m.
Max. retarder speed R 133 S (= max. prop shaft speed) v(max.) 2500 r.p.m.
Working medium Oil grade given in Operating Specifications
- Service filling (Oil change, checking oil level) 9,0 Litre (heat exchanger Standard) 7,5 Litre (L+R klein)
10,5 Litre (heat exchanger NKW 1) 7,5 Litre (L+R groß)
9,5 Litre (heat exchanger NKW 2)
- after changing heat exchanger - 9,0 Litre (L+R klein)

9,7 Litre (L+R groß)
- after complete taking apart and cleaning - 10,0 Litre (L+R klein) **
(corresponds new filling) 11,0 Litre (L+R groß) **
* Overall weight will depend on the retarder version

Miscellaneous Conversions Retarder 133 with Logoprop Control System
D GB USA D GB USA
120 oC 248 oF 248 oF 11 g ± 1 g 0,38 ± 0,035 oz 0,38 ± 0,035 oz
25 Nm 18 lbf-ft 18 lbf-ft 0 - 25 bar 0 - 369 psi 0 - 369 psi
46 Nm 34 lbf-ft 34 lbf-ft 0,6 bar 9 psi 9 psi
50 Nm 37 lbf-ft 37 lbf-ft 2,8 bar 41 psi 41 psi

Miscellaneous Conversions Retarder 133 with Logoprop Control System
(Continue)
D GB USA D GB USA
4,5 bar 65 psi 65 psi 9l 1,980 UK gal 2,376 US gal
5,5 bar 80 psi 80 psi 9,7 l 2,134 UK gal 2,561 US gal
6,5 bar 94 psi 94 psi 10,5 l 2,310 UK gal 2,772 US gal
1,48 - 1,88 bar 22 - 27 psi 22 - 27 psi 27 mm 1,063 inch 1,063 inch
1,87 - 2,27 bar 27 - 33 psi 27 - 33 psi 31 mm 1,221 inch 1,221 inch
2,04 - 2,44 bar 30 - 35 psi 30 - 35 psi 10 cm3 0,61 cubic inch 0,61 cubic inch
2,20 - 2,60 bar 32 - 38 psi 32 - 38 psi 25 - 50 cm3 1,525 - 3,050 cubic inch 1,525 - 3,050 cubic inch
2,36 - 2,76 bar 34 - 40 psi 34 - 40 psi
2,52 - 2,92 bar 37 - 42 psi 37 - 42 psi
1,0 l 0,22 UK gal 0,264 US gal
7,5 l 1,650 UK gal 1,980 US gal

VOITH TURBO
Powertransmission
VOITH Retarder
1. Water
2.1 Normal case

*see chapter 4


**see chapter 5
Attention:
agent!

***see chapter 6
Attention:

3. Miscellaneous
3.1 Disposal
3.2 Safety

Attention:




Attention:



Attention:

Attention:


Attention:


Attention:




Attention:


Attention:

Attention:



Attention:


Attention:

A 000 989 13 25 10

Attention:


D-74564 Crailsheim
i. V. i. V. Phone (07951) 32-0
Telefax (07951) 32-756
32-401 / 32-422

Manual de Servicio Retardador

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R 115 H EATON Digiprop

R 115 H EATON Logoprop

5. Removing, Installing Retarder .................................................................5/1

6. Retarder Basic Group Repair ..................................................................6/1

7. Control Parts ...........................................................................................7/1

The switched-on retarder will not secure the parked vehicle.

VOITH TURBO GmbH & Co. KG

Department cb; Voithstraße 1

2.1 Assembly Overview....................................................................................2.1/1

2.2 Function and Operation Scheme................................................................2.2/1

2.3 Retarder Data.............................................................................................2.3/1

Illustration VOITH Retarder 115 H Digiprop

94/5 Blind hole (not used) 3700

Illustration VOITH Retarder 115 H Digiprop

2919 Central oil-drain plug

Illustration VOITH Retarder 115 H with Digiprop control system

Oil sump Coolant (water)

Description of the function

A switched-on retarder will not secure a parked vehicle.

Description of operation of retarder R 115 H with digiprop control system

Temperatur pick-ups, water (19), oil (20)

Pressure regulating valve (62)

Casing ventilation (23)

Check valve (63) inlet

Check valve (64) outlet

i Ret. = Baujahr 1993

4. Code-Number: Eight-digit number

5. Vehicle manufacturer´s Part No., if any.

3.1 Maintenance Work .....................................................................................3.1/1

3.2 Oil Change .................................................................................................3.2/1

3.3 Checking Oil Level .....................................................................................3.3/1

Overview of maintenance work

At each oil change

• Carry out visual inspection on leaks at the complete retarder.

Illustration oil change 2909

Lubricants and cleaning agents

O-ring Silicone-free and 2921

Caution! Risk of injury!

Central oil-drain plug is heated up (oil temperature)

Service filling with heat exchanger

Service filling (oil change, checking oil level) 5,4 l

After exchange of heat exchanger 5,6 l

After complete taking apart and cleaning as well as

Caution! Risk of injury!

Central oil drain plug is heated up (oil temperature)!

11. Check the oil level (see Section 3.3).

Illustration checking oil level

Caution! Risk of injury!

Oil filler plug is heated up (oil temperature)!

2. Switch off the retarder and wait 5 minutes (control function).

The oil check plug is heated up (oil temperature)!

4.1 Troubleshooting Diagram ...........................................................................4.1/1

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

Illustration troubleshooting diagram

too too too too

19 ABS serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ Check lead,

21 ABS-Signal serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ Check lead,