Aftersales Service Manual Voith Retarder VR 123

Voith Turbo
Aftersales Service Manual Voith Retarder VR 123
153.000182.10 I 2005-05
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Table of Contents
Table of Contents
1 About this Document 5

1.1 Purpose of this Document 6
1.2 Target Groups 6
1.3 Other Applicable Documents 6
1.4 Symbols and Identifications 7
1.5 Item Numbers 7
1.6 Legal/Contact Information 7
2 Basic Safety Instructions 8

2.1 Product Safety 9
2.2 Staff Qualification 9
2.3 Safety-Conscious Working 9
2.4 Environmental Protection 9
2.5 Troubleshooting 9
2.6 Maintenance and Repair 9
2.7 Driving Mode 9
Voith Turbo I 153.000182.10 I arrtd I 2005-05
2.8 Warranty 10
3 Design and Function 11

3.1 Overview of the Modules 12
3.2 Retarder Identification 14
3.3 VERATM Controller Identification 15
3.4 Digiprop Controller Identification 16
© 2005
Seite 2
3.5 Function and Control Scheme 17

3.6 Function Description 18
4 Maintenance and Service 19

4.1 Maintenance Intervals 20
4.2 Oil Change 21
4.3 Checking the Oil Level 23
4.4 Draining the Coolant 25
4.5 Proportional Valve and Damping Plate 27
5 Diagnosis and Troubleshooting 28

5.1 Troubleshooting Chart 29
5.2 Electrical Connections Diagram and Pin Assignment (VERATM) 33
5.3 Troubleshooting (VERATM) 36
5.4 Electrical Connections Diagram and Pin Assignment (Digiprop) 46
5.5 Troubleshooting (Digiprop) 51
5.6 Constant-Air Pressure (py) 61
5.7 Pump Pressure (pdyn) 64
5.8 Proportional Valve Current 67
6 Removing and Installing the Retarder 69
7 Repair 70
7.1 Components Overview 71
7.2 Top Cover 75
7.3 Casing Ventilation 77
© 2005
7.4 Retarder Ventilation 81
Seite 3
7.5 Non-Return Valve 82

7.6 Heat Exchanger 84
7.7 Water Neck 87
7.8 Oil Temperature Sensor 89
7.9 Coolant Temperature Sensor 91
7.10 Pressure Sensor 93
8 Appendix 98
8.1 Tightening Torques 99
© 2005
Seite 4
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I About this Document
1. About this Document
1.1 Purpose of this Document 6

1.2 Target Groups 6
1.3 Other Applicable Documents 6
1.4 Symbols and Identifications 7
1.5 Item Numbers 7
1.6 Legal/Contact Information 7
© 2005
Page 5
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I About this Document Purpose of this Document
1.1 Purpose of this Document
This Aftersales Service Manual provides information

and instructions on maintenance and repair of the
Voith Retarder VR 123.
1.2 Target Groups
This Aftersales Service Manual is intended for service

people for service and diagnoses only and may not be
reproduced or given to third parties.
1.3 Other Applicable Documents
Documents Information Item number

Voith retarder oil change intervals/oil specification list Oil change intervals and approved oil types 153.000831xx
Operating instructions for Voith Retarder VR 123 Information on the safe, professional and economical operation of the 153.00102710
Voith Retarder VR 123
Cooling water quality list Approved coolants H67.2224xx
Operating instructions for retarder tester Measured values for constant-air pressure and pump pressure Included in scope of delivery of
the retarder tester
(153.001085xx)
Operating instructions for Diana-Lite test software Information on the testing of: Included in the scope of delivery
• constant-air pressure (py) of the Diana-Lite test software
(153.000776xx)
• pump pressure (pdyn)
Operating instructions for the WinDia diagnostic soft- Instructions on PC diagnosis for the Digiprop and VERATM controllers 3623-020900
ware
© 2005
Gearbox-specific documents on the retarder Information on safe, professional installation and removal of the retarder on request
Page 6
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I About this Document Symbols and Identifications
1.4 Symbols and Identifications 1.5 Item Numbers

WARNING
Structure of warnings The item numbers used are usually found in the spare
Potentially hazardous situation which, if not avoided,
parts lists.
could result in death or serious injury.
LEVEL OF DANGER Exceptions:
Type and source of danger!
Possible consequences if not heeded. DANGER • one- or two-digit item numbers
Ö Measures for the prevention of danger and its Imminently hazardous situation which, if not avoid- • item numbers with a slash
consequences. ed, will result in death or serious injury.
1.6 Legal/Contact Information
Levels of danger Notes
For questions and work procedures not described in
The warnings are categorised into four levels of dan-
these documents, contact the respective organisation
ger: NOTE for your area.
Information on easier and safer work with the re-
CAUTION tarder.
Voith Turbo
Produktgruppe Retarder
Ö Measures for easier and safer work with the re-
Potentially hazardous situation which, if not avoided,
tarder. Postfach 1555
may result in property damage.
74555 Crailsheim
Distinctions Deutschland
CAUTION
Ö One-step action instruction. Phone: 00 49 79 51 / 32-401, 32-422, 32-1860

Potentially hazardous situation which, if not avoided, Fax: 00 49 79 51 / 32-756
1. First step of an action instruction. Other steps fol-
service-retarder@voith.com
may result in minor or moderate injury. low and are numbered in sequence.
www.voith.com
© 2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Basic Safety Instructions
2. Basic Safety Instructions
2.1 Product Safety 9

2.2 Staff Qualification 9
2.3 Safety-Conscious Working 9
2.4 Environmental Protection 9
2.5 Troubleshooting 9
2.6 Maintenance and Repair 9
2.7 Driving Mode 9
2.8 Warranty 10
© 2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Basic Safety Instructions Product Safety
2.1 Product Safety 2.4 Environmental Protection Damage to property by soiled parts!
Considerable damage or malfunctions may occur due
The retarder is constructed according to state of the Ö Drained fuels and fluids, consumables and old parts
to soiling.
art technology and acknowledged safety regulations. must be disposed of properly.
Ö Ensure cleanliness.
Nevertheless, hazardous situations and property
2.5 Troubleshooting
damage may occur as a result of improper usage, Damage to property by improper cleaning!
maintenance and repair. Voith provides a warranty/goodwill service for defec-
Ö Do not aim the jet of a high-pressure cleaner
Ö Observe safety and warning information. tive parts only.
(steam-jet device) at valves, pressure sensors or
Ö Do not replace parts on mere speculation. ventilators of the retarder.
2.2 Staff Qualification
2.6 Maintenance and Repair 2.7 Driving Mode
Ö Allow only qualified professionals to carry out repair
and maintenance work. Ö Ensure that the retarder is fully functional for all ve-
Danger of burning and scalding by squirting oil!
The oil in the retarder may be hot. hicle manoeuvres, i.e.:
2.3 Safety-Conscious Working - Retarder properly filled with oil
Ö Switch off the retarder and ignition so that the oil is
Voith does not assume any liability for personal injury - Retarder electronics connected and functional
not fed by impulse lubrication.
and/or property damage caused by improper and un- - Pneumatic control connected and functional
professional work. Danger of burning and scalding by hot coolant!
Driving after repair/oil change
Ö Observe the following regulations: The coolant may be hot.
- Accident-prevention regulations Ö For proper ventilation of the retarder system, do not

Ö Work carefully.
activate the retarder until you are driving:
- Other generally acknowledged safety regula-
tions and occupational health Danger of burns by hot parts! - Min. speed: 50 km/h
- Motor vehicle regulations Parts of the retarder may be hot. - Retarder braking stage 1
- Safety regulations for handling chemical sub- - Activate five times for 5 s each
Ö Work carefully.
stances such as oils and greases
© 2005
Ö Wear protective gloves or use cloths if necessary.
Page 9
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Basic Safety Instructions Warranty
Towing 2.8 Warranty

Ö Tow vehicle with retarder max. 100 km at max. Voith accepts no liability for damage caused by
40 km/h. changes to the retarder or the use of spare parts, ac-
cessories, attachments and special features not test-
Parking ed and approved by Voith.
Ö Do not use retarder as a parking brake, as it does Ö Use only parts approved by Voith to ensure the
not act as a brake when the vehicle is standing still. safety of the vehicle.
Failure while driving

During failure of the retarder, or while temperature ad-
aptation is active, only the service brake is functional.
Ö Adjust the speed of the vehicle with the service

brake.
Ö Engage the lowest possible gear to achieve a high

engine speed.
Ö Continue driving in this way until the retarder is

available at full capacity again.
© 2005
Page 10
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function
3. Design and Function
3.1 Overview of the Modules 12

3.2 Retarder Identification 14
TM
3.3 VERA Controller Identification 15
3.4 Digiprop Controller Identification 16
3.5 Function and Control Scheme 17
3.6 Function Description 18
© 2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function Overview of the Modules
3.1 Overview of the Modules
Item No. Designation 3000 2800

5100
100 Retarder housing
5000
1500 Screw plug M14x1.5
(test connection) 7000
1900 Non-return valve 100

2000 Cover of retarder housing
2800 Oil filler plug M30x1.5
3000 Top cover
5000 Proportional valve
5100 Damping plate
7000 Pressure sensor
1500
1900 2000
© 2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function Overview of the Modules
Item No. Designation

20000
8000 Oil temperature sensor
9000 Rating plate 8000
20000 Water neck inlet 9000
20100 Water neck outlet
20200 Coolant drain plug M14x1.5
20600 Coolant temperature sensor
20600
TYP
VR
123
FABR
.Nr.
Bauj
ahr
iRET
= 1.
Kd.-S 00
ach-
Voith Nr.
-Sac
h-Nr
.
20100
20200
1500
1700
© 2005
32003
Page 13
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function Retarder Identification
3.2 Retarder Identification
NOTE
Ö Specify the following data in case you have
questions or are ordering spare parts:
- Serial number (FABR.Nr.)
- Voith part number (Voith-Sach-Nr.)
TYP VR 123
FABR.Nr.
Baujahr
iRET = 1.00
TYP VR 123
FABR.Nr.
Kd.-Sach-Nr.
Baujahr
iRET = 1.00
Voith-Sach-Nr.
Kd.-Sach-Nr.
Voith-Sach-Nr.
© 2005
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Page 14
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function VERATM Controller Identification
3.3 VERATM Controller Identification
NOTE
84
20
XX
02
e1
X
XX
- Serial number (Serial-No.) XX
XX
T XX
-T
M X-X
- Part number (Part No.) n
-M X
it JJ XX. XX
J X3
l U / J - X XX
tro XX .X XX
on XX A.E XX
Ö Specify the following data of the retarder (see e r C . X ER XXX
rd No V X
X2
ta al- o. . X
page 14): Re eri rt N No
S a M
X1
o
P E
rb
Tu
O
ith
Vo
- Serial number (FABR.Nr.)
H
IT
VO
- Voith part number (Voith-Sach-Nr.)
Voith Turbo
Retarder Control Unit

Serial-No. XXXXX / JJJJ-MM-TT
Part No. VERA.E.X - XXX.XX-XXXXXXXXXXXX
e1 022084
OEM No. XXXXXXXXXXXXX
VOITH
X1 X2 X3
© 2005
32006
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function Digiprop Controller Identification
3.4 Digiprop Controller Identification
NOTE
- Basic number (Basis-Nr.:)
- Serial number (Serien-Nr.:)
Ö Specify the following data of the retarder (see
page 14):
- Serial number (FABR.Nr.) Ba
s
Co is-N
Se de-N r.:
- Voith part number (Voith-Sach-Nr.) r
VO ien- r.:
IT Nr. 53
.
H : xx xxxx
x .12
xx
xx
/
Basis-Nr.:
Code-Nr.:
Serien-Nr.:
VOITH
© 2005
32084
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function Function and Control Scheme
3.5 Function and Control Scheme

A Compressed-air line (pressure controller)
A B C
B Four-circuit protection valve E F G
C Compressed-air line (brake circuit 2)
D Compressed-air line (brake circuit 1)
E Compressed-air line (parking brake) D P
H
F Air tank for auxiliary equipment 7000 A R
2300 2800
G Supply-air pressure (pv) "P" 5000
3300
H Constant-air pressure (py) "A"
I Ventilation line "R"
J
J Oil tank I
K Rising duct 8000
300 Stator Vehicle
1500 Oil drain plug electro- 6000
1700 Oil drain plugs
1900 Non-return valve
2300 Casing ventilation 4000
2800 Oil filler plug (measuring point Py) 1900 20600
3300 Retarder ventilation
4000 Rotor
6000 Heat exchanger

300
7000 Pressure sensor 1500
8000 Oil temperature sensor K 1700
Oil sump Coolant
Supply-air pressure pv Pump Pressure Pdyn
Constant-air pressure py
© 2005
32007
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Design and Function Function Description
3.6 Function Description Pressure sensor (7000) The controller also adjusts the braking torque if the
The pressure sensor (7000) measures the pneumatic temperature of the oil increases rapidly, regardless of
Application and point of installation constant-air pressure. A deviation from the allowed the actual temperature of the oil.
The Voith Retarder VR 123 is a compact hydrodynam- pressure tolerance is recognized as a fault and dis-
During temperature adaptation or failure of the retard-
ic sustained-action brake for mid-sized omnibuses played by the controller.
er, you must use the service brake to slow down the
and commercial vehicles up to 18 tonnes. vehicle.
By installing it between the gearbox and rear axle, the Temperature sensors for oil (8000) and coolant
braking torque of the retarder also remains in tact (20600)
while shifting gears. The temperature sensors are screwed into the cooling
system of the vehicle (return pipe from retarder to heat
Non-return valve (1900) exchanger) and in the oil duct of the retarder. The
The non-return valve (1900) is located in the outlet temperature sensors pass on information on the tem-
duct and prevents the heat exchanger being emptied perature of the coolant and oil to the controller.
during idling.
Maximum values for the temperature of coolant and
oil are set in the controller for protection of the cooling
Casing ventilation (2300)
system and the retarder. To prevent the values being
At the beginning of the braking process, the oil expels exceeded, the controller adapts the braking torque of
the air located in the system circuit from the retarder the retarder accordingly via the constant-air
via the casing ventilation (2300). pressure py.
Once the system circuit is free of air, a float will rise
and seal the casing ventilation. The braking torque and the heat produced regulate
themselves until an equilibrium has been reached be-

Proportional valve (5000) tween the braking force and the heat dissipated via
Depending on the intensity of the electric input signal, the vehicle cooling system.
the proportional valve (5000) issues a pneumatic con-
If the temperature limit is exceeded during braking,
stant-air pressure which acts on the oil tank of the re-
the braking torque is adapted to protect the cooling
tarder.
system and retarder.
© 2005
If the critical temperature threshold has been exceed-

ed, the braking torque is no longer active.
Page 18
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service
4. Maintenance and Service
4.1 Maintenance Intervals 20

4.2 Oil Change 21
4.3 Checking the Oil Level 23
4.4 Draining the Coolant 25
© 2005
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service Maintenance Intervals
4.1 Maintenance Intervals
The maintenance intervals depend on the stress put

on the retarder.
Activity Interval See

Change oil ÖSee document: Oil Page 21
change intervals/
oil specification list
153.000831xx
Check oil – Page 23
level
Drain coolant ÖObserve specifica- Page 25
tions of vehicle
manufacturer
Replace pro- For vehicles used in Page 27
portional city traffic:
valve 120,000 km
© 2005
Page 20
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service Oil Change
4.2 Oil Change

2800
1400 Sealing ring A14x18, replace 2900
1500 Screw plug M14x1.5,
hexagon socket head, w.a.f. 6,
25 Nm
1600 Sealing ring A24x29, replace
80 Nm
2800 Oil filler plug M30x1.5,
130 Nm
NOTE
Ö Lubricate sealing rings, O-rings and shaft seal-
ing rings with silicone-free, non-corrosive
grease before installation.
1400
Oil quantity
1500
Service filling (oil check, oil change) 6.0 l
After replacement of heat exchanger 6.5 l
1600 1600
1700 1700
© 2005
32008
Page 21
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service Oil Change
Maintenance work during each oil change Filling in the oil

CAUTION
• Visual inspection of retarder for leaks before and
after the oil change. Hot oil filler plug (2800) and screw plugs (1500 CAUTION
and 1700)! Wrong oil type!
• Check prop shaft screws for proper seating and Hands could be burned. Damage to/failure of the retarder.
tighten if necessary (See specifications of vehicle
Ö Work carefully. Ö Use only oil approved by Voith (see oil specifica-
manufacturer).
Ö Wear protective gloves or use cloths if necessary. tion list).
• Tighten screw plugs of retarder basic module to
the specified tightening torque (see page 98). 1. Fill in oil via the hole of the oil filler plug (2800).
2. Unscrew the oil filler plug (2800).
Requirements 2. Lubricate the new sealing ring (2900) with sili-
3. Unscrew the screw plugs (1500 and 1700).
cone-free, non-corrosive grease.
• Vehicle is horizontal 4. Drain oil into an oil collecting pan.
3. Screw in the oil filler plug (2800) with sealing ring
• Oil is at operating temperature (> 60 °C) 5. Lubricate the new sealing rings (1400 and 1600) (2900) and tighten to 130 Nm.
with silicone-free, non-corrosive grease.
• Retarder switched off
NOTE
• Ignition switched off 6. Screw in screw plugs (1500 and 1700) with sealing
Ö For proper ventilation of the retarder system, do
rings (1400 and 1600).
not activate the retarder until you are driving:
Draining the oil 7. Tighten screw plug (1500) to 25 Nm. - Min. speed: 50 km/h
1. Place oil pan below the retarder. - Retarder braking stage 1
8. Tighten screw plugs (1700) to 80 Nm.

- Activate five times for 5 s each
WARNING
Hot exiting oil!
Face and hands could be burned.
Ö Ensure that the retarder and ignition are switched
off.
© 2005
Page 22
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service Checking the Oil Level
4.3 Checking the Oil Level

2800

2900
25 Nm
80 Nm
2800 Oil filler plug M30x1.5,
130 Nm
NOTE
1400
Oil quantity
1500
Service filling (oil check, 6.0 l
oil change)
1600 1600
1700 1700
© 2005
32008
Page 23
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service Checking the Oil Level
Requirements 2. Unscrew the oil filler plug (2800). Filling in the oil
• Vehicle is horizontal 3. Unscrew the screw plugs (1500 and 1700). 1. Fill in oil via the hole of the oil filler plug (2800).
• Oil is at operating temperature (> 60 °C) 4. Drain oil into an oil collecting pan. NOTE
• Retarder switched off 5. Lubricate the new sealing rings (1400 and 1600) Ö If oil was missing, check the retarder for leaks.
• Ignition switched off
6. Screw in screw plugs (1500 and 1700) with sealing 2. Lubricate the new sealing ring (2900) with sili-
Drain the oil rings (1400 and 1600). cone-free, non-corrosive grease.
1. Place oil pan below the retarder. 7. Tighten screw plug (1500) to 25 Nm. 3. Screw in the oil filler plug (2800) with sealing ring
(2900) and tighten to 130 Nm.
WARNING 8. Tighten screw plugs (1700) to 80 Nm.
NOTE
Hot exiting oil! Measuring the volume
Ö For proper ventilation of the retarder system, do
Face and hands could be burned.
1. Measure the volume of the drained oil. not activate the retarder until you are driving:
Ö Ensure that the retarder and ignition are switched
- Min. speed: 50 km/h
off.
CAUTION - Retarder braking stage 1
Wrong oil type! - Activate five times for 5 s each
CAUTION Damage to/failure of the retarder.
Ö Use only oil approved by Voith (see oil specifica-
Hot oil filler plug (2800) and screw plugs (1500

tion list).
and 1700)!
Hands could be burned.
2. If oil is missing, top up oil.
Ö Work carefully.
© 2005
Page 24
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service Draining the Coolant
4.4 Draining the Coolant

25 Nm
NOTE
Requirements
TYP R 123
• Retarder switched off FABR.Nr.

Baujahr
iRET = 1.00
Kd.-Sach-Nr.
Voith-Sach-Nr.

CAUTION
20100
Hot parts and coolant!
Burns and scalding could occur. 20300
Ö Work carefully.
Ö Wear protective gloves or use cloths if necessary. 20200
© 2005
32085
Page 25
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service Draining the Coolant
NOTE
Ö Observe the specifications of the vehicle manu-
facturer or those of Voith Turbo cooling water
quality list.
1. Unscrew the screw plug (20200) and drain the

coolant into a clean collecting vessel.
2. Replace the sealing ring (20300) and lubricate it

© 2005
Page 26
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Maintenance and Service Proportional Valve and Damping Plate
4.5 Proportional Valve and Damping

Plate
NOTE
Ö For vehicles used in city traffic: Replace propor-
tional valve at intervals of 120,000 km (see
page 96).
© 2005
Page 27
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting
5. Diagnosis and Troubleshooting
5.1 Troubleshooting Chart 29

TM
5.2 Electrical Connections Diagram and Pin Assignment (VERA ) 33
TM
5.3 Troubleshooting (VERA ) 36
5.4 Electrical Connections Diagram and Pin Assignment (Digiprop) 46
5.5 Troubleshooting (Digiprop) 51
5.6 Constant-Air Pressure (py) 61
5.7 Pump Pressure (pdyn) 64
5.8 Proportional Valve Current 67
© 2005
Page 28
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting Troubleshooting Chart
5.1 Troubleshooting Chart
A
* Retarder
pilot light
(standard type)
Oil leak Complaint No or

**Contact
VOITH
on drive
or output side
Voith Retarder
VR 123
insufficient
brake efficiency
B
Oil leaks via

retarder ventilation
(item 3300)
* On-board diagnosis is possible if the or holes in lid of
OEM equipment allows it (display). casing ventilation
Observe the specifications of the
vehicle manufacturer.
** This fault may be due to a leak in

the transmission or in the retarder. C
© 2005
A thorough analysis is therefore necessary. 32034_e
Page 29
Retarder on: Braking torque greater than 0

ON
Retarder off: Fault (fault code ?)
** Retarder
A pilot light
(standard type)
No function
with ignition ON
Contact the vehicle
manufacturer
Instruct
the driver!
Check the
operation NIO
Temperature (for retarder braking, Replace
FLASHES adaptation defective part
nominal speed of
the engine, IO Check
NIO
if possible) temperature
sensors
(oil/coolant)
* On-board diagnosis is possible if the (see page 89 IO Check the vehicle
onw.) cooling system:
OEM equipment allows it (display).
- coolant level
Observe the specifications of the - thermostat
vehicle manufacturer. - coolant pump
- fan
- radiator net
IO = in order for dirt
© 2005
NIO = not in order

32035_e
Page 30
External oil leak

No or
(except for retarder
B insufficient
brake efficiency
ventilation item 3300)?
Repair
No Yes the retarder
If the problem
Correct retarder occurs again:
Check the NIO oil level
retarder oil level continue with
(see page 23) IO
Check the
p (dyn) casing ventilation
(see page 77)
Check NIO
p (dyn) and p y (static) Replace the
NIO IO NIO casing ventilation
p y (static) NIO
The retarder
If the static and dynamic pressure are oil level must be
in order, the complaint mentioned correct for checking! IO
(see page 61) Heavy air consumption
above cannot be made. Contact
via retarder ventilation
Clarify the complaint again with the VOITH
(item 3300)?
customer or perform the tests once again.
No Yes Check the
damping plate
Check the damping Check the supply- (see page 96)
plate. Are/is there air pressure
Contact
NIO IO
(an) outward leak? Check the vehicle Check the prop. VOITH
(see page 96) IO NIO pneumatic current as well
system as leads and
No Yes Replace the plug connections Replace the
damping plate IO NIO (see page 67) damping plate
Check the proportional IO NIO Check the

Replace
valve, replace if necessary Compressed-air line temperature sensors NIO defective part
(see page 96) Repair compressed-air (oil/coolant), pressure
to the proportional Contact
line according to sensor and leads
valve interrupted the vehicle
vehicle manufacturer IO Check the
IO = in order or leaky manufacturer
(see page 89 onw.)
© 2005
control system
NIO = not in order 32036_e
Page 31
C
Oil leaks via
retarder ventilation
(item 3300) or
holes in lid of
casing ventilation
Retarder Holes in cover

ventilation of casing
(item 3300) ventilation
Is there water
Check the in the oil? Check the
retarder oil level casing ventilation
(see page 23) (see page 77)
No Yes
IO NIO IO NIO
Check heat
Correct
exchanger
oil level (see
page 84)
Contact Replace
VOITH If the problem casing ventilation
occurs again:
IO = in order
© 2005
Contact VOITH
NIO = not in order 32069_e
Page 32
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting Electrical Connections Diagram and Pin Assignment (VERATM)
5.2 Electrical Connections Diagram

and Pin Assignment (VERATM)

P U 72 21
2 Controller 20 19
1 2 4
4 Terminal 15
16 Actuating lever for engine control/
+ - + - + -
sustained-action brake
17 Retarder pilot light (option)
20 Oil temperature sensor
21 Proportional valve X3
X2
9 7 8 10 11 12 3 4 5 6 2 1 8 7 6 4 5 9 3 2 1
72 Pressure sensor
83 ISO diagnosis 2
17
. 16 15 4 5 6 8 9 18 10 17 11 12 13 14 7 3 2 1
X1
4
CAN 4
83
16
© 2005
32010
Page 33
Item No. Designation Plug X3 controller

NOTE
7 Terminal 15 = battery voltage
The diagrams show the plugs from the plug-in side.
sustained-action brake, position 3
Plug X1 controller
sustained-action brake, position 4 10 7 4 1
10 Actuating lever for engine control/ 11 8 5 2

sustained-action brake +
12 9 6 3
11 not assigned
16 13 10 7 4 1 12 ISO interface, K-lead

32043
17 14 11 8 5 2
13 not assigned
18 15 12 9 6 3
14 Terminal 31 = Ground
15 Retarder pilot light (option)
1 Coolant temperature sensor –
16 not assigned
32041 2 Coolant temperature sensor +
17 not assigned
3 Proportional valve +
Item No. Designation sustained-action brake, position 5 4 Proportional valve –
1 CAN-LOW 5 Oil temperature sensor +
2 CAN-GROUND
6 Oil temperature sensor –

3 CAN-HIGH 7 Signal voltage pressure sensor
4 Actuating lever for engine control/ 8 Ground pressure sensor
sustained-action brake, safety contact
9 Supply voltage pressure sensor
sustained-action brake, position 1 10 not assigned
6 Actuating lever for engine control/ 11 not assigned

© 2005
sustained-action brake, position 2 12 not assigned
Page 34
Plug of coolant and oil temperature sensors Plug proportional valve Plug pressure sensor
2 2 4 2
1 1 1 3
32044 32045 32066
Item No. Designation Item No. Designation Item No. Designation

1 Temperature sensor, any polarity 1 Proportional valve, any polarity 1 Sensor supply
2 Temperature sensor, any polarity 2 Proportional valve, any polarity 2 Signal
3 Core for pressure compensation
4 Ground
© 2005
Page 35
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting Troubleshooting (VERATM)
5.3 Troubleshooting (VERATM) Requirements
• Battery voltage: 18–32 V

NOTE • Compressed air: 6–11 bar
The fault memory can be read out in the following
• Oil level checked and in order
ways:
• with Win-Dia (see operating instructions of Win- • Electrical system of vehicle checked and in order
Dia diagnostic software) (see specifications of vehicle manufacturer)
• on-board diagnosis (display) (see specifications
of vehicle manufacturer) • Fuses for retarder controller tested and in order
Special tools
Procedure
1. Read out the fault memory:

- with Win-Dia (see operating instructions of Win-
VT
VC Nr.:
53.8206.12
PC Interface Dia diagnostic software)

- on-board diagnosis (see specifications of vehi-
cle manufacturer)
H53.8206.12 2. Evaluate fault code and remedy fault (see
“Troubleshooting with fault codes (VERATM)” on

Connecting page 37).
cable
PC interface 3. Clear fault memory (see operating instructions of
WinDia diagnostic software).
© 2005
Page 36
Troubleshooting with fault codes (VERATM)

(type: Daimler Chrysler) NOTE
Only if no fault is detected during complete check of
NOTE the periphery:
Ö Replace controller.
When performing measurements using a commer-
cially available multimeter (without real r.m.s. value
measurement), exact readout of these measured
values is not possible (display jumps).
NOTE
X1/10 Ω X1/18 in the "Measurement" column, for
example, means the following:
• Pin 10 to plug X1 (retarder controller)
Commercially available tool
• Multimeter measuring type: ohms
Multimeter (98/8) with real r.m.s. value measure-
ment, e.g. Fluke 179 • Pin 18 to plug X1 (retarder controller)
Requirements
• Ground (terminal 31) connected to pin 15 (plug X1)
• Battery voltage (terminal 15) connected to pins 13

and 7 (plug X1)

© 2005
Page 37
Fault Fault text Cause Fault Detec- Remedy Test Requirement / Measurement Setpoint
code class tion time step Action
0 0512 GS/FR: perma- – slight approx. ÖGS (EPS) or FR. – – – –
nently or tempo- 0.1 s
rarily missing
CAN telegram
0 1105 Actuating lever Short-circuit to Ubat in slight approx. ÖCheck the lead, plug 1 Ignition switched off X1/14 V X1/4 <2V
for engine control/ the signal path of the 1s and actuating lever ÖPull plug X1. X1/5
sustained-action actuating lever for en- for engine control/
brake: short-cir- gine control/sustained- sustained-action ÖSwitch on ignition. X1/6
cuit to battery action brake brake. X1/8
X1/9
X1/10
X1/18
© 2005
Page 38
0 1140 Actuating lever Short-circuit to ground slight approx. ÖCheck the lead, plug 1 Ignition switched off X1/10 Ω X1/4 <5Ω
for engine control/ –or–
1s and actuating lever ÖSwitch actuating lever for
sustained-action for engine control/ engine control/sus-
brake: mechani- Interruption in signal sustained-action tained-action brake to
cal defect, im- path of the actuating le- brake. step 0.
plausible ver for engine control/
sustained-action brake 2 ÖSwitch actuating lever for X1/10 Ω X1/5 <5Ω
engine control/sus- X1/6
tained-action brake to
highest step. X1/8
X1/9
X1/18
3 X1/10 Ω X1/4 > 1 MΩ
infinite
4 ÖSwitch actuating lever for X1/10 Ω X1/5 > 1 MΩ
engine control/sus- X1/6 infinite
step 0. X1/8
X1/9
X1/18
© 2005
Page 39
0 1607 Oil temperature Short-circuit to ground slight 1s ÖCheck lead, plug and 1 Ignition switched off X3/5 Ω X1/14 > 1 MΩ
sensor: short-cir- in the signal path to the oil temperature sen- ÖPull plug X3. infinite
cuit to ground oil temperature sensor sor.
0 1641 Oil temperature Short-circuit to Ubat slight 1s ÖCheck leads, plugs 1 Ignition switched off X3/5 Ω X3/6 Note:
sensor: short-cir- –or–
and oil temperature ÖPull plug X3. Measure-
cuit to battery or sensor. ment in one
interruption Interruption in signal tempera-
path to oil temperature ture range
sensor is usually
sufficient.
10 °C to
30 °C =
1,039 Ω to
1,117 Ω
50 °C to
70 °C =
1,194 Ω to
1,271 Ω
70 °C to
90 °C =
1,271 Ω to
1,347 Ω
0 1808 Pressure sensor: Short-circuit to Ubat slight 1s ÖCheck lead and pres- 1 Ignition switched on X3/7 V X3/8 0.3–0.7 V
battery short-cir- in signal path sure sensor.
ÖSwitch actuating lever for
cuit signal
engine control/sus-
step 0.
© 2005
Page 40
0 1840 Pressure sensor: – slight 10 s ÖCheck lead and pres- 1 Ignition switched on X3/7 V X3/8 0.3–0.7 V
signal implausible sure sensor. ÖSwitch actuating lever for
engine control/sus-
step 0.
0 1842 Pressure sensor: – slight 1s ÖCheck lead and pres- 1 Ignition switched off X3/7 Ω X1/14 > 1 MΩ
signal interruption sure sensor.
ÖPull plugs X1 and X3. infinite
or short-circuit to
ground
0 1843 Pressure sensor: – slight 0.5 s ÖCheck lead and pres- 1 Ignition switched on X3/9 V X3/8 4.75–
Supply voltage sure sensor. 5.25 V
outside admitted
range
0 2012 FR: permanently – slight approx. ÖCheck the FR. – – – –
or temporarily 0.1 s
missing CAN tele-
gram
1 0110 CAN connection Retarder controller serious – ÖCheck CAN bus. – – – –
to retarder con- does not receive any
troller or CAN- data telegrams from the
starpoint commu- vehicle CAN bus

nication faulted
(Bus Off)
1 0113 CAN connection Communication fault serious – ÖCheck plug connec- – – – –
to retarder con- between controller and tions, leads and vehi-
troller vehicle CAN-bus star- cle CAN-bus
point starpoint.
© 2005
Page 41
1 0212 ABS/BS: perma- – serious approx. ÖCheck ABS or BS. – – – –
nently or tempo- 0.1 s
rarily missing
CAN telegram
1 0820 Retarder control- – serious – ÖReplace controller. – – – –
ler: Internal error
1 0821 Parameterisation – serious – ÖContact Voith. – – – –
faulty
1 1001 Terminal 15: Overvoltage (> 33 V) at serious 10 s ÖCheck the controller 1 Ignition switched off X1/14 V X1/7 < 33 V
overvoltage terminal 15 and generator. ÖPull plug X1.
ÖSwitch on ignition.
ÖStart engine and run in
medium r.p.m. range.
1 1002 Terminal 15: Undervoltage (< 17.5 V) serious 60 s ÖCheck the battery 1 Ignition switched off X1/14 V X1/7 > 17.5 V
undervoltage at terminal 15 or inter- voltage, leads and
ÖPull plug X1.
ruption in the signal plugs.
path to the basic mod- ÖSwitch on ignition.
ule
1 1330 Proportional Short-circuit to Ubat in serious max. 1 s ÖCheck the leads, 1 Ignition switched off X1/14 V X3/4 <2V
valve outlets: signal path to propor- plugs and proportion- ÖPull plugs X1 and X3.
short-circuit to tional valve al valve.
battery ÖSwitch on ignition.
–or–
2 Ignition switched off X3/4 Ω X3/3 18–25 Ω
Short-circuit of both out-
puts to proportional Pull plug X3.
valve
© 2005
Page 42
1 1331 Proportional Short-circuit to ground serious max. 60 s ÖCheck the leads, 1 Ignition switched off X3/4 Ω X3/3 18–25 Ω
valve outlets: –or–
plugs and proportion- ÖPull plug X3.
short-circuit to al valve.
ground Interruption in signal 2 ÖPull plug X1. X1/14 Ω X3/3 > 1 MΩ
path to proportional infinite
X3/4
valve
1 1332 Proportional Controller defective serious max. 60 s ÖReplace controller. – – – –
valve outputs
1 1507 Coolant tempera- Short-circuit to ground serious 1 s ÖCheck leads, plugs 1 Ignition switched off X3/2 Ω X1/14 > 1 MΩ
ture sensor: in the signal path to the and coolant tempera- infinite
ÖPull plug X3.
short-circuit to coolant temperature ture sensor.
ground sensor
© 2005
Page 43
1 1541 Coolant tempera- Short-circuit to Ubat or serious 1 s ÖCheck leads, plugs 1 Ignition switched off X3/2 Ω X3/1 Note:
ture sensor: interruption in the signal and coolant tempera-
ÖPull plug X3.
Measure-
short-circuit to path to the coolant tem- ture sensor. ment in one
battery perature sensor tempera-
ture range
is usually
sufficient.
10 °C to
30 °C =
1,039 Ω to
1,117 Ω
50 °C to
70 °C =
1,194 Ω to
1,271 Ω
70 °C to
90 °C =
1,271 Ω to
1,347 Ω
1 1705 Retarder pilot – serious 3 s ÖCheck lead and re- 1 Ignition switched on X 1/15 V X 1/14 ≤ 2 V
light: short-circuit tarder pilot light.
ÖSwitch actuating lever for
to battery engine control/sus-

step 1.
© 2005
Page 44
1 1742 Retarder pilot – serious 1 s ÖCheck lead, retarder 1 Ignition switched off X 1/15 V X 1/14 ≥ 17.5 V
light: Short-circuit pilot light and fuse.
ÖPull plug X1.
to ground or inter-
ruption ÖSwitch on ignition.
© 2005
Page 45
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting Electrical Connections Diagram and Pin Assignment (Digiprop)
5.4 Electrical Connections Diagram

and Pin Assignment (Digiprop)

2 Controller P U 72
4 Terminal 15
70 47 15 21 19 20
1 2 4 14 13 11 12 10 1 9 5 8 4 3 2 7 6
15 ABS signal 18
.
87 87a 30
- +
16 Actuating lever for engine control/ + - + -
17 Retarder pilot light .
.
18 Stop light relays
20 Oil temperature sensor 17 X3 X2
8 11 10 12 7 9 4 5 6 1 2 3 2 3 1 6 5 4 9 8 7
4
47 Speedometer signal 2
69 ISO interface plug 18 17 16 6 5 4 9 8 10 11 12 13 14 15 7 3 2 1

X1
70 Additional functions plug
72 Pressure sensor
7 6 5 2 3 8 4 4
3 2 1 4
69
16
© 2005
32086
Page 46
Item No. Designation Plug X2 controller

NOTE
7 Terminal 15 = battery voltage
The diagrams show the plugs from the plug-in side.
Plug X1 controller
sustained-action brake, position 4 7 4 1
10 Actuating lever for engine control/ 8 5 2

9 6 3
11 ISO-interface, L-lead
16 13 10 7 4 1 12 ISO interface, K-lead
17 14 11 8 5 2
13 connected to terminal 15 32087
18 15 12 9 6 3
14 not assigned
15 Terminal 31 = Ground Item No. Designation
16 Universal output 1 No function

32041
17 not assigned 2 Proportional valve –
18 Universal output 3 Proportional valve +

4 Coolant temperature sensor –
1 not assigned
5 Coolant temperature sensor +
2 not assigned
6 No function
3 not assigned
7 not assigned
8 Oil temperature sensor –
5 Actuating lever for engine control/ 9 Oil temperature sensor +
© 2005
Page 47
Plug X3 controller Plug of coolant and oil temperature sensors

12 Universal input
2
1
10 7 4 1
11 8 5 2
12 9 6 3
32043 32044
Item No. Designation Item No. Designation

1 Universal input 1 Temperature sensor, any polarity
2 Speedometer signal 2 Temperature sensor, any polarity
3 ABS signal
4 Universal input
5 Universal input
6 Ground pressure sensor

7 Signal voltage pressure sensor
8 Retarder pilot light
9 Universal input
11 Stop light relays
© 2005
Page 48
Plug proportional valve Plug pressure sensor Plug ISO interface cable
2 4 2
1 1 3
4 3
2 1
32045 32066 32088
Item No. Designation Item No. Designation Item No. Designation

1 Proportional valve, any polarity 1 Sensor supply 1 K-line
2 Proportional valve, any polarity 2 Signal 2 L-line
3 Core for pressure compensation 3 Terminal 15
4 Ground 4 Terminal 31
© 2005
Page 49
Plug additional functions cable Item No. Designation

12 No function
13 Terminal 15
14 Terminal 31
2 4 6 8 10 12 14
1 3 5 7 9 11 13
32089

2 Universal input
3 Universal input
4 Universal input
5 Universal input
6 Universal input
7 Ground pressure sensor
8 Signal voltage pressure sensor
10 Universal output
© 2005
11 Universal output
Page 50
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting Troubleshooting (Digiprop)
5.5 Troubleshooting (Digiprop) Requirements Display example of fault code 23

Meanings:
NOTE • Compressed air: 6–11 bar
• long signal (2 s): steps of ten
The fault memory can be read out in the following • short signal (0.5 s): steps of one
ways:
• Pause (1.0 s) between the signals
• with a service cable • Electrical system of vehicle checked and in order
• via the actuating lever for engine control/ (see specifications of vehicle manufacturer)
• Fuses for retarder controller tested and in order
• with Win-Dia (see operating instructions of Win-
Dia diagnostic software)
Procedure
0.5 s
0.5 s
0.5 s
2s
2s
1s
1s
1s
1s
1. Read out the fault memory:
NOTE - with a service cable (see page 52)
- via the actuating lever for engine control/
Faults are saved in the sequence in which they oc-
sustained-action brake (see page 52)
cur.
Exception: - with Win-Dia (see operating instructions of Win- 32047_e
Fault code 31 "Controller coding fault" is not saved, Dia diagnostic software)
but it is output.
2. Evaluate fault code and remedy fault (see Item No. Designation
E ON signal
page 53).
A OFF signal
3. Clear fault memory:
t Time
- with a service cable (see page 52)
- with Win-Dia (see operating instructions of Win- Faults are output in the sequence in which they occur.
Dia diagnostic software) There is a pause of 3 seconds after each fault code.
The OFF signal remains if there is only one fault in
memory.
© 2005
Page 51
Reading out the fault memory via the service cable 1. Connect service interface L-lead to ground for Reading out fault memory via actuating lever for
≥ 2 s. For this purpose, press "L-pushbutton" on engine control/sustained-action brake
Special tools service cable.
The fault code of the first fault is output via the Requirements
retarder pilot light.
• Service mode activated:
2. Repeat Step 1 for additional fault code output. - Vehicle not running
VC Nr.:
VT 53.8206.12
PC Interface
- Ignition switched on
Clearing the fault memory
1. Turn ignition off.

1. Switch actuating lever for engine control/
H53.8224xx H53.8206.12
2. Connect service interface L-lead to ground. For sustained-action brake to position 0.
this purpose, press "L-pushbutton" on service
Service cable Connecting 2. Switch actuating lever for engine control/
cable.
cable sustained-action brake to position 1.
PC interface 3. Switch on ignition.
3. Switch actuating lever for engine control/
99/53 sustained-action brake to position 0.
4. Disconnect the L-lead from ground after ≥ 2 s.
The fault code of the first fault is output via the
Requirements
retarder pilot light.
4. Repeat Steps 1–3 for additional fault code output.
• Vehicle not running
• Ignition switched on
© 2005
Page 52
Troubleshooting with fault code

(type: Daimler Chrysler) NOTE
X1/15 Ω X3/11 in the "Measurement" column, for
Commercially available tool
example, means the following:
ment, e.g. Fluke 179 • Pin 15 to plug X1
• Multimeter measuring type: ohms
• Pin 11 to plug X3
NOTE
When performing measurements using a commer-
cially available multimeter (without real r.m.s. value
Requirements
• Ground (terminal 31) connected to pin 15 (plug X1)
• Battery voltage (terminal 15) connected to pin 7

(plug X1)
NOTE
Only if no fault is detected during complete check of
the periphery:
Ö Replace controller.
© 2005
Page 53
Fault Fault text Fault Detection Remedy Test Requirement / Measurement Setpoint
code class time step Action
01 Stop light relays, short- slight 1s ÖCheck lead, plug and re- 1 Ignition switched off X3/11 Ω X1/15 Relays is installed:
circuit to ground lays or consumers. 250–350 Ω
ÖPull plugs X1 and X3.
03 Output HS 1, short-cir- slight 1s ÖCheck lead, plug and re- 1 Ignition switched off X1/18 Ω X1/15 Relays is installed:
cuit to ground lays or consumers. 250–350 Ω
ÖPull plug X1.
04 Output HS 2, short-cir- slight 1s ÖCheck lead, plug and re- 1 Ignition switched off X1/16 Ω X 1/15 Relays is installed:
cuit to ground lays or consumers. ÖPull plug X1. 250–350 Ω
05 Terminal 15 undervolt- serious 60 s ÖCheck lead, plugs and 1 Ignition switched off X1/7 V X1/15 ≥ 17.5 V
age fuse. ÖPull plug X1.
06 Terminal 15 overvoltage serious 10 s ÖCheck electrical system 1 Ignition switched off X1/7 V X1/15 ≤ 32.5 V
of vehicle (see specifica- ÖPull plug X1.
tions of vehicle manu-
facturer) ÖSwitch on ignition.
ÖStart engine (idle).
© 2005
Page 54
08 Coolant temp. sensor serious/ 1 s ÖCheck lead and sensor. 1 Ignition switched off X2/5 Ω X2/4 Note:
09 short-circuit to battery or slight a) Measurement in one
ÖPull plug X2.
ground or interruption temperature range is
usually sufficient.
10 °C to 30 °C = 1,039 Ω
to 1,117 Ω
50 °C to 70 °C = 1,194 Ω
to 1,271 Ω
70 °C to 90 °C = 1,271 Ω
to 1,347 Ω
11 Oil temperature sensor, serious/ 1 s ÖCheck lead and sensor. 1 Ignition switched off X2/9 Ω X2/8 Note:
12 short-circuit to battery or slight a) Measurement in one
ÖPull plug X2.
ground or interruption temperature range is
usually sufficient.
10 °C to 30 °C = 1,039 Ω
to 1,117 Ω
50 °C to 70 °C = 1,194 Ω
to 1,271 Ω
70 °C to 90 °C = 1,271 Ω
to 1,347 Ω
a) If oil and coolant temperature sensors are simultaneously defective, this is considered a serious fault.
© 2005
Page 55
13 Actuating lever for engine serious 1 s ÖCheck the lead, plug and 1 Ignition switched on X1/10 V X1/15 ≥ 17.5 V
control/sustained-action actuating lever for en- ÖSwitch actuating lever X1/6 V X1/15 0V
brake in undefined state gine control/sustained- for engine control/sus-
action brake. X1/5 V X1/15 0V
position 0. X1/4 V X1/15 0V
X1/9 V X1/15 0V
X1/8 V X1/15 0V
2 ÖSwitch actuating lever X1/10 V X1/15 ≥ 17.5 V
for engine control/sus- X1/6 V X1/15 ≥ 17.5 V
position 1. X1/5 V X1/15 0V
X1/4 V X1/15 0V
X1/9 V X1/15 0V
X1/8 V X1/15 0V
3 ÖSwitch actuating lever X1/10 V X1/15 ≥ 17.5 V
for engine control/sus-
X1/6 V X1/15 ≥ 17.5 V
position 2. X1/5 V X1/15 ≥ 17.5 V
X1/4 V X1/15 0V
X1/9 V X1/15 0V
X1/8 V X1/15 0V
© 2005
Page 56
14 Actuating lever for engine serious 10 s ÖCheck lead and plugs. – Ignition switched off X1/10 V X1/15 0 V
control/sustained-action ÖPull plug X1.
brake, battery short-cir-
cuit ÖSwitch on ignition.
ÖSwitch actuating lever
position 0.
15 Actuating lever for engine serious 1 s ÖCheck each stage for – Ignition switched off X1/10 Ω X1/15 > 1 MΩ
control/sustained-action short-circuit to ground.
ÖPull plug X1. infinite
brake, short-circuit to
ground ÖSwitch actuating lever
position 5.
16 Speedometer signal inter- serious 2 s ÖCheck lead and speed- – Ignition switched on X3/2 V X1/15 ≤ 1 V
rupted ometer.
18 Speedometer battery serious 2 s ÖCheck lead and speed- – Ignition switched off X3/2 V X1/15 ≤9V
short-circuit/undefined ometer.
signal
19 ABS Short-circuit to serious 60 s ÖCheck lead, relays and – Ignition switched on X3/3 V X1/15 ≥ 3.5 V
ground ABS controller.
21 ABS signal undefined serious 1 s ÖCheck lead, relays and – Ignition switched on X3/3 V X1/15 ≥ 16.5 V
ABS controller.
22 Internal fault ABS current serious 1 s ÖReplace controller. – – – –
path
© 2005
Page 57
23 Proportional valve fault 1: serious 1 s ÖCheck lead. – Ignition switched off X2/3 V X1/15 < 2 V
short-circuit to battery ÖPull plugs X1 and X2.
24 Proportional valve fault 2: serious 1 s ÖCheck lead and propor- 1 Ignition switched on X2/2 Ω X2/3 18–25 Ω
tional valve (valve
• Short-circuit to prop. ÖPull plug X2.
block).
valve magnet
2 ÖTurn ignition off. X2/3 Ω X1/15 Resistance infinite
• Short-circuit to con-
ÖPull plug X1.
necting cable, prop.
valve interruption 3 – X2/2 Ω X1/15 Resistance infinite
• Prop. valve magnet
• Interruption of con-
necting cable, prop.
valve ground short-cir-
cuit at prop. valve
© 2005
Page 58
25 Proportional valve fault 3: serious 60 s ÖReplace controller. – – – –
Controller defective
27 Proportional valve fault 5: serious 3 s ÖReplace controller. – – – –
Controller defective
28 Terminal 30 Undervolt- serious 60 s ÖCheck lead, plug and – Ignition switched off X1/13 V X1/15 ≥ 17.5 V
age fuse. ÖPull plugs X1 and X3.
29 Fault in controller serious approx. 0.2 s ÖReplace controller. – – – –
31 Controller: coding incor- serious approx. 0.1 s ÖCode controller proper- – – – –
rect ly.
32 Retarder pilot light: Inter- serious 1 s ÖCheck lead, retarder pi- – Ignition switched off X3/8 V X1/15 ≥ 17.5 V
ruption or short-circuit to lot light and fuse.
ground
© 2005
Page 59
33 Retarder pilot light: short- serious 3 s ÖCheck lead and retarder – Ignition switched on X3/8 V X1/15 ≤2V
circuit to battery pilot light. ÖSwitch actuating lever
position 1.
35 Fault in controller serious max. 9 min. ÖReplace controller. – – – –
37 Fault in pedal operation slight 1s ÖCheck system according – – – –
to specifications of OEM
or VOITH.
38 Constant-air pressure slight max. 10 s ÖCheck the pressure sen- 1 Ignition switched on X3/7 V X1/15 0.3–0.7 V
fault sor cable harness. ÖSwitch actuating lever and
ÖIn case of deviation: for engine control/sus-
X3/10 V X1/15 4.75–5.25 V
Test Step 2. tained-action brake to
position 0.
ÖTroubleshoot in cable 2 – – –
harness, pressure sen-
sor, proportional valve,
supply air, ECU (contact
Voith).
© 2005
Page 60
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting Constant-Air Pressure (py)
5.6 Constant-Air Pressure (py)

7000 Pressure sensor
99/30 Retarder tester
99/31 Cable 1 (to the proportional valve)
99/32 Cable 2 (to the pressure sensor)
7000
99/33 Cable 3 (to temperature sensors)
99/34 Cable 4 (to the vehicle voltage supply/
PC interface) 99/31
5000
NOTE
The constant-air pressure py measurement pro-
vides information on
99/32
• internal and external leaks 99/30
• proper functioning 99/34
• proper control of the retarder

99/33
© 2005
32091
Page 61
Requirements Test scope

Special tools
CAUTION
Hot parts!
• Battery voltage: 18–32 V Hands could be burned.
Ö Work carefully.
• Supply-air pressure in auxiliary circuit: 8–11 bar Ö Wear protective gloves or use cloths if necessary.
153.001085xx 153.000776xx H53.1403xx 1. Connect the retarder tester (99/30) (see Test set-
• Electrical system of vehicle checked and in order up diagram Page 61 and operating instructions of
Retarder tester Test software Air pressure (see specifications of vehicle manufacturer) the retarder tester):
in a case compl. Diana-Lite gauge - Connect cable 1 (99/31) to proportional valve
• Electrical connections of the retarder are com-
0–6 bar (5000).
pletely disconnected from the vehicle.
99/29 99/40 99/7 - Connect cable 2 (99/32) to pressure sensor
(7000).
comprising:
99/30–99/35 - Connect cable 3 (99/33) to oil temperature sen-
50/35 a. 50/36 sor (8000) and coolant sensor (20600).
- Connect cable 4 (99/34) to the vehicle voltage
supply/PC interface.
NOTE
2. Select the retarder type at the retarder tester.

With the test software "Diana-Lite" (99/40), meas-
ured values can be read out and stored comfortably 3. Check constant-air pressure (see operating
via the PC in addition to the tests with the retarder instructions of retarder tester).
tester.
The stored measured values can be transmitted to 4. Compare measured values (see operating instruc-
the Voith customer service for evaluation (see options of retarder tester).
erating instructions on CD-ROM).
© 2005
Page 62
NOTE
If the measured constant-air pressure value (py) is
below the required setpoint, either the retarder is
leaking or the control system is defective (see trou-
bleshooting diagram Page 29).
5. Disconnect the retarder tester (99/30) and all

cables.
6. Restore connections between vehicle electronics

and retarder.
© 2005
Page 63
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting Pump Pressure (pdyn)
5.7 Pump Pressure (pdyn)

50/36 Pressure sensor: 0–30 bar
99/30 Retarder tester
99/31 Cable 1 (to the proportional valve)
99/32 Cable 2 (to the pressure sensor) 99/31 100 5000
99/33 Cable 3 (to temperature sensors)
99/34 Cable 4 (to the vehicle voltage supply/
PC interface)
50/36
NOTE
99/30 99/32
Checking the pump pressure pdyn provides infor-
99/34
mation on
• the mechanical status of the rotor parts
99/33
• internal leaks
• proper functioning of the retarder

© 2005
32092
Page 64
Requirements Test scope

Special tools
CAUTION
Hot parts and oil!
• Compressed air: 6–11 bar Hands can be burned and scalded.
Ö Work carefully.
• Oil level checked and in order Ö Wear protective gloves or use cloths if necessary.
• Electrical system of vehicle checked and in order
--- 153.001085xx 153.000776xx
(see specifications of vehicle manufacturer)
NOTE
Pressure sensor Retarder tester Test software • Electrical connections of the retarder are com-
Due to construction, a small amount of oil may leak
0–30 bar in case compl. Diana-Lite pletely disconnected from the vehicle.
out; this does, however, not affect retarder opera-
50/36 99/29 99/40 • No external leaks detected at retarder tion.
comprising:
99/30–99/35 • Vehicle secured
50/35 a. 50/36
• Prop shaft at the retarder removed from the flang-
es (see specifications of vehicle manufacturer)
NOTE
With the test software "Diana-Lite" (99/40), meas-
ured values can be read out and stored comfortably

via the PC in addition to the tests with the retarder
tester.
The stored measured values can be transmitted to
the Voith customer service for evaluation (see op-
erating instructions on CD-ROM).
© 2005
Page 65
3. Connect the retarder tester (99/30) (see Test set-

up diagram Page 64 and operating instructions of NOTE
the retarder tester):
If the setpoint of the constant-air pressure (py) is
- Connect cable 1 (99/31) to proportional valve reached, but the pump pressure (pdyn) is under-
(5000). shot, the retarder has an internal defect.
- Connect cable 2 (99/32) to pressure sensor (50/ Ö Check rotor parts.
36).
- Connect cable 3 (99/33) to oil temperature sen- 9. Disconnect the retarder tester (99/30) and all
1400 cables.
sor (8000) and coolant (20600).
1500
- Connect cable 4 (99/34) to the vehicle voltage 10.Disconnect the pressure sensor (50/36) and
32078
supply/PC interface. remove the sealing ring (1400).
1. Unscrew screw plug (1500) and remove sealing 4. Select the retarder type at the retarder tester. 11.Lubricate the new sealing ring (1400) with sili-
ring (1400).
5. Switch on ignition. cone-free, non-corrosive grease.
12.Screw in the screw plug (1500) with the sealing

100
NOTE ring (1400).
Shift in direct gear (ratio 1:1). The engine speed
13.Tighten the screw plug (1500) to 25 Nm.
1,000 min-1 then corresponds to the prop shaft
speed of 1,000 r.p.m.
1400 14.Remove prop shaft at the retarder from the flanges
50/36 (see specifications of vehicle manufacturer).
6. Drive the vehicle with a prop shaft speed of

nps = 1,000 r.p.m..
7. Check pump pressure (see operating instructions

32093
of retarder tester).
2. Connect pressure sensor (50/36) to retarder hous- 8. Compare measured values (see operating instruc-
ing (100) with sealing ring (1400). tions of retarder tester).
© 2005
Page 66
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting Proportional Valve Current
5.8 Proportional Valve Current Requirements Test scope

21
Special tools
98/8
• Electrical system of vehicle checked and in order

(see specifications of vehicle manufacturer)
• Fuse for retarder controller tested and in order
--- • Male and female plug connectors at proportional 99/3

valve checked for damage or wear (notch scratch- 32059
Measuring es).
adapter 1. Disconnect the plug from the proportional valve
• Electrical lead and plug connections checked (vis-
99/3 ual inspection) and in order (21) and connect it to the measuring adapter (99/3).
2. Connect the plug of the measuring adapter to the
NOTE proportional valve (21).
When performing measurements using a commer- 3. Connect the multimeter (98/8). Measuring type:
cially available multimeter (without real r.m.s. value mA.

4. Turn the "Propventil" (prop valve) switch at the
measuring adapter to position "I".
5. Switch on ignition.
Commercially available tool 6. Shift the retarder to the highest gear.
ment, e.g. Fluke 179
© 2005
Page 67
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Diagnosis and Troubleshooting Proportional Valve Current
NOTE
Due to continuous readjustment in the control loop,
the measured values may not be constant, but are
within the specified range.
7. Read measured value and compare to the speci-

fied values:
Controller Item number/ Measured

Code number value
Digiprop 117/153.000863xx 440–640 mA
118/153.000967xx
119/153.000976xx
120/153.000999xx
TM
VERA 153.000107xx 440–640 mA
8. Disconnect multimeter.
9. Pull the plug from the measuring adapter (99/3)

and connect it to the proportional valve (21).
© 2005
Page 68
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Removing and Installing the Retarder
6. Removing and Installing the Retarder
DANGER CAUTION
Retarder can fall! Hot parts!
Your body can be crushed severely. Hands could be burned.
Ö Secure retarder against falling. Ö Work carefully.
Ö Use a suitabe device for hanging it up. Ö Wear protective gloves or use cloths if necessary.
CAUTION
Improper removal/installation!
Damage to/failure of the retarder.
Warranty is voided.
Ö Request and use gearbox-specific documents
and special tools from VOITH.

© 2005
Page 69
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair
7. Repair
7.1 Components Overview 71

7.2 Top Cover 75
7.3 Casing Ventilation 77
7.4 Retarder Ventilation 81
7.5 Non-Return Valve 82
7.6 Heat Exchanger 84
7.7 Water Neck 87
7.8 Oil Temperature Sensor 89
7.9 Coolant Temperature Sensor 91
7.10 Pressure Sensor 93
© 2005
Page 70
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Components Overview
7.1 Components Overview

1000 O-ring 158.34x3.53, replace 2800
2900
3600 5100
1500 Screw plug M14x1.5, 5200
5200 5000
hexagon socket head, w.a.f. 6, 25 Nm
3000 5400
1700 Screw plug M24x1.5, 3500
hexagon socket head, w.a.f. 12, 80 Nm 3200
3400
1900 Non-return valve M48x1.5, 3300
hexagon insert bit, w.a.f. 55, 280 Nm 7000
2300
20000 100 8100
1950 Sealing ring A48x55, replace 20500 2301
8000 6000
2000 Cover of retarder housing 20400 6100
6150 2000 3600
6150
2100 O-ring 228.2x3.53, replace 6200
20600
2300 Casing ventilation 20100 20700
2301 O-ring 55x3, replace 2100
20400
1000
2800 Oil filler plug M30x1.5, 4800

130 Nm
20300 6100
20500 1400 6150
20200 4702 1950 6150
1500 1900 6300
NOTE 4703
1400
1500 1600
4800
Ö Lubricate sealing rings, O-rings and shaft seal- 1700

© 2005
32012
Page 71

3000 Top cover
2800
3200 Sealing top cover, replace
2900
3300 Disc silencer 5300
3600 5100
3400 Corrugated spring 5200
5200 5000
3500 Circlip JL30x1.2 3000 5400
3600 Hex head screw M8x45,
hexagon insert bit, w.a.f. 13, 3500
Initial torque: 17 Nm, 3200
3400
Final torque: 30 Nm
3300
7000
20000 100 8100
4703 Screw plug M8x1, hexagon socket 20500 2301
head, w.a.f. 5, 10 Nm 8000 6000
20400 6100
6150 2000 3600
4800 Hex head screw M8x70, 6150
20600
Initial torque: 17 Nm, 20100 20700
Final torque: 30 Nm 2100
20400
5000 Proportional valve 1000
4800
5100 Damping plate

5200 O-ring 16x3, replace 20300 6100
20500 1400 6150
20200 4702 1950 6150
1400 1500 1900 6300
4703 4800
NOTE 1500 1600
1700
© 2005

32012
Page 72

5300 Hex head screw M8x20, replace
hexagon insert bit, w.a.f. 13, 30 Nm
5400 Hex head nut M8, replace 2800
5300
6000 Heat exchanger 3600 5100
5200
6100 O-ring 25x2.5 (brown), replace 5200 5000
6150 O-ring 25x2.5 (black), replace 3000 5400
6200 Hex head screw with flange M10x40, 3500

3400
6300 Hex head screw with flange M10x70,
3300
2300
7000 Pressure sensor M16x1.5, 20000 100 8100
20500 2301
hexagon insert bit, w.a.f. 27, 30 Nm 8000 6000
20400 6100
8000 Oil temperature sensor M14x1.5, 6150 2000 3600
6150
20600
2100
20400
1000
NOTE 4800

20300 6100
ing rings with silicone-free, non-corrosive 20500 1400 6150
grease before installation. 20200 4702 1950 6150
1400 1500 1900 6300
4703 4800
1500 1600
1700
© 2005
32012
Page 73

20000 Water neck inlet
2800
hexagon socket head, w.a.f. 6, 2900
5300
25 Nm 3600 5100
5200
20400 Hex head screw M8x45, 3000 5400

hexagon insert bit, w.a.f. 13,
30 Nm 3500
3200
20500 O-ring 55.56x3.53, replace 3400
3300
20600 Coolant temperature sensor M14x1.5, 7000
20000 100 8100
28 Nm 20500 2301
8000 6000
6150 2000 3600
6150
6200
20600
NOTE 20100 20700
2100
1000
ing rings with silicone-free, non-corrosive 4800

20300 6100
20500 1400 6150
20200 4702 1950 6150
1400 1500 1900 6300
4703 4800
1500 1600
1700
© 2005
32012
Page 74
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Top Cover
7.2 Top Cover

3000
3600
3000 Top cover
3200 Sealing top cover, replace
3200
Initial torque: 17 Nm,
Final torque: 30 Nm
Requirements
• Retarder switched off 100

© 2005
32013
Page 75
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Top Cover
CAUTION CAUTION
Hot parts! Incorrect sequence when tightening the hex
Hands could be burned. head screws!
Ö Work carefully. Cover can buckle.
Ö Wear protective gloves or use cloths if necessary. Ö Tighten hex head screws in the prescribed se-
quence.
Removal
1. Unscrew the hex head screw (3600).

5
2. Remove the cover (3000). 3 6
1 4
2
Checking 8
7
1. Check the holes in the cover (3000) for accessibil- 10 9
ity with compressed air. 12 11
13
Installation
1. Insert new seal (3200). 32014
2. Screw on cover (3000) with the hex head screws 3. Tighten hex head screws (3600) in the sequence
(3600). 1 to 13 (see diagram) with an initial torque of

17 Nm.
4. Tighten hex head screws in the same sequence

with a final torque of 30 Nm.
© 2005
Page 76
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Casing Ventilation
7.3 Casing Ventilation
Item No. Designation 2300/1

2300 Casing ventilation
2301 O-ring 55x3, replace 2301
2300
2300/1 Valve insert
2300/2
2300/2 Float, specified weight max. 12 g, clean
2300/3 Float cage
2300/3
NOTE
Cleaning agent
Float Methylated spirit
© 2005
32015
Page 77
NOTE Tools for self-fabrication

CAUTION
Ö Use only the adapter (98/9) as from item number Hot parts!
H53.942811. Hands could be burned.
Ö Work carefully.
Special tools Ø 40.5 mm Ö Wear protective gloves or use cloths if necessary.
7 mm
Ø 60 mm
Material:St
Material: St37
37 Removal
Weight:
Weight: 0.085
0.085kg
kg 32016e
99/5
Test ring
99/4
The test ring (99/4) can be ordered from Voith Turbo 98/9
H53.7712xx H53.9428xx
GmbH & Co. KG: Item number H67.2757xx. 2300/1
Impact puller Adapter

Requirements
99/5 98/9
32017
• Top cover removed and checked (see page 75) 1. Knock valve insert (2300/1) with the impact puller
(99/5) and the adapter (98/9) upward from the
retarder housing.
© 2005
Page 78
Checking
2300/2
1. Check the casing ventilation (2300) for dirt/sludge
99/4
and clean it.
2300/3
2300/2
2300/1
2300/2
32018 32021
2. Float (2300/2) and float cage (2300/3) are to be 5. Check the sealing edge of the radial shaft sealing
removed from retarder housing. ring (arrow) in the valve insert (2300/1):
32020
- For this purpose, place the float (2300/2) on a
suitable object (e.g. hex head nut).
2. Check the float (2300/2) for damaged surfaces
and sealing areas (arrow). - Place the valve insert (2300/1) on the float
2300/1 (2300/2) and weigh it down using the test ring
3. Weight float (2300/2): Specified weight: max. 12 g. (99/4).
4. For exceeded specified weight: replace the entire - Fill empty space between float (2300/2) and up-
casing ventilation (2300). per edge of valve insert with methylated spirit.
If the sealing edge is undamaged, the fluid level re-

2301
mains constant over 1 minute.
32019
3. Take O-ring (2301) out of the groove in the valve

insert (2300/1).
© 2005
Page 79
1. Apply silicone-free and non-corrosive grease to a

99/5
NOTE new O-ring (2301) and pull it on the valve insert
(2300/1).
Changing the radial shaft sealing ring leads to mal-
functions of the retarder.
Ö If the radial shaft sealing ring is damaged: re- 98/9
place the entire casing ventilation (2300). 2300/1
2300/1
Ö Do not replace the radial shaft sealing ring.
6. Replace casing ventilation (2300) if sealing edge 2300/2

is damaged.
32024
Installation 2300/3
6. Press valve insert (2300/1) carefully into the
NOTE 32023 retarder housing with the impact puller (99/5) and
the adapter (98/9).
Lubricating the radial shaft sealing ring leads to 2. Clean float with methylated spirit.
malfunctions of the retarder. 7. Assemble retarder.
Ö Do not lubricate the radial shaft sealing ring. 3. Insert float (2300/2) into the float cage (2300/3).
4. Place valve insert (2300/1) on float cage (2300/3).
5. Coat bore of casing ventilation in the retarder

housing with silicone-free and non-corrosive
grease.
2300/1
2301
© 2005
32022
Page 80
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Retarder Ventilation
7.4 Retarder Ventilation
Item No. Designation 3400
3300 Check, clean and blow out disc silenc-

er with compressed air
3300
3400 Corrugated spring
3500 Circlip
3500
Cleaning agent
Retarder ventilation Benzine
DANGER
Heavily soiled or painted-over retarder ventila-
tion!
Retarder reduces braking power after a delay.
Ö Replace retarder ventilation.
NOTE
Ö Replace retarder ventilation in case of mechan-

ical damage.
Requirements

© 2005

32025
Page 81
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Non-Return Valve
7.5 Non-Return Valve

1900 Non-return valve
1900/1 Guide M48x1.5,
280 Nm
1900/2 Spring
1900/3 Check spool for damage and soiling
and replace entire non-return valve if
necessary.
NOTE
ing rings with silicone-free, non-corrosive 1900/3
1900/2
1900/1
1950
1900
© 2005
32027
Page 82
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Non-Return Valve
Requirements
• Oil drained (see page 22)
CAUTION
Hot parts!
Ö Work carefully.
© 2005
Page 83
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Heat Exchanger
7.6 Heat Exchanger

1000 O-ring 158.34x3.53, replace
2000 Cover of retarder housing
Final torque: 30 Nm 6150 2000 3600
6200
Final torque: 30 Nm
6000 Heat exchanger
6100 O-ring 25x2.5 (brown), replace 6300
6150 O-ring 25x2.5 (black), replace

6150 2100
hexagon insert bit, w.a.f. 15, 46 Nm 1000 4800
6100
hexagon insert bit, w.a.f. 15, 46 Nm
NOTE
© 2005
32028
Page 84
Checking
Special tools
CAUTION
Hot parts!
Hands could be burned. 50/22
Ö Work carefully.
Removal
6000
153.000769xx
1. Unscrew hex head screws (3600, 4800, 6200 and
6300).
Pressure test
32094
equipment 2. Remove the cover (2000).
50/22 3. Remove heat exchanger (6000). 1. Attach pressure test equipment (50/22) to heat
exchanger (6000) with O-rings and attach the
Requirements compressed-air line to the connection.
• Retarder switched off 2. Place heat exchanger (6000) with pressure test
equipment (50/22) in a water bath (approx. 40 °C).
3. Slowly pressurise heat exchanger (6000) with
• Supply-air pressure discharged
compressed air from 0 to max. 10 bar.
• Oil drained (see page 22)

4. If air bubbles appear in the water, replace the heat
• Coolant drained (see page 25) exchanger.
© 2005
Page 85
Installation
NOTE CAUTION
6100 6150 Ö When inserting the heat exchanger (6000), en- Incorrect sequence when tightening the hex
6000 sure correct installation position (see arrow in head screws!
the diagram).
Cover can buckle.
Ö Ensure that the sealing surfaces are not dam- Ö Screw tight hex head screws in the prescribed se-
aged.
quence.
3. Fit in heat exchanger (6000).

6. Tighten hex head screws (3600, 4800) in the pre-
4. Lubricate the new O-ring (2100) with silicone-free, scribed sequence 1 to 7 (see diagram) with an ini-
1000 6100 non-corrosive grease and pull it on. tial torque of 17 Nm.
6150
32095
7. Tighten hex head screws (3600, 4800) in the same
3 7 sequence to a final torque of 30 Nm.
4800
NOTE 3600
3600 4800
8. Screw in hex head screws (6200 and 6300) and
2000
Ö Ensure that the brown O-rings (6100) and the 6 tighten to 46 Nm.
black O-rings (6150) are not inadvertently 6200 1
4800
swapped. 9. Fill in the oil (see “Oil Change” on page 21).
6300
1. Apply silicone-free and non-corrosive grease to the 4800 4800

new O-rings (6100) and (6150) and pull them on 2
the heat exchanger (6000). 5 4

32064
2. Lubricate the new O-ring (1000) with silicone-free,
non-corrosive grease and pull it on. 5. Screw on cover (2000) with the hex head screws
(3600, 4800).
© 2005
Page 86
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Water Neck
7.7 Water Neck

20000 Water neck inlet
25 Nm
30 Nm
20600 Coolant temperature sensor M14x1.5,
28 Nm
20700 Sealing ring A14x20, replace TYP
FABR
R 12
.Nr.
Bauja
hr
3
0
= 1.0
iRET -Nr.
ach
Kd.-S -Nr.
-Sach
Voith
20000
NOTE

20700
20400
20600 20400
20100
20200 20400
© 2005
20300 20400
32029
Page 87
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Water Neck
Requirements
• Coolant drained (see page 25)
CAUTION
Hot parts!
Ö Work carefully.
© 2005
Page 88
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Oil Temperature Sensor
7.8 Oil Temperature Sensor

8000 Temperature sensor M14x1.5,
28 Nm
NOTE
Requirements
• Ignition switched off TYP R 123

FABR.Nr.
Baujahr
8000 iRET = 1.00

Kd.-Sach-Nr.
Voith-Sach-Nr.
CAUTION
Hot parts!
Ö Work carefully.
© 2005
32032
Page 89
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Oil Temperature Sensor
NOTE
Measuring in one temperature range is usually suf-
ficient.
Temperature Resistance
20 °C ± 10 °C 1,039–1,117 Ω
60 °C ± 10 °C 1,194–1,271 Ω
80 °C ± 10 °C 1,271–1,347 Ω
© 2005
Page 90
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Coolant Temperature Sensor
7.9 Coolant Temperature Sensor

20600 Temperature sensor M14x1.5,
28 Nm
NOTE
Requirements
• Retarder switched off 20700
• Ignition switched off TYP R 123

FABR.Nr.
Baujahr
iRET = 1.00
Kd.-Sach-Nr.
• Coolant drained (see page 25) Voith-Sach-Nr.

CAUTION 20600
Hot parts!
Ö Work carefully.
© 2005
32033
Page 91
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Coolant Temperature Sensor
NOTE
Ö Observe the specifications of the vehicle manu-
facturer on coolant quality or those of Voith Tur-
bo cooling water quality list.
NOTE
Measuring in one temperature range is usually suf-
ficient.
Temperature Resistance
20 °C ± 10 °C 1,039–1,117 Ω
60 °C ± 10 °C 1,194–1,271 Ω
80 °C ± 10 °C 1,271–1,347 Ω
© 2005
Page 92
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Pressure Sensor
7.10 Pressure Sensor

7000

7000 Pressure sensor M16x1.5 with integrat-
ed FPM sealing ring,
30 Nm
NOTE
Ö Lubricate FPM sealing ring on both sides with
silicone-free, non-corrosive grease before in-
stallation.
Special tools
H53.8198xx
Measuring
adapter
99/3
© 2005
32031
Page 93
Test scope 3. Connect the ground lead of the multimeter (98/8)

NOTE to test socket 4 (ground) of the measuring adapter.
When performing measurements using a commer- 98/8 4. Turn the "Propventil" (prop valve) switch at the
cially available multimeter (without real r.m.s. value measuring adapter (99/3) to position "Propventil"
measurement), exact readout of these measured (prop valve).
5. Switch on ignition.
38
6. Connect the positive lead of the multimeter (98/8)
Commercially available tool to test socket 1 (positive) of the measuring
Multimeter (98/8) with real r.m.s. value measure- 99/3 adapter.
ment, e.g. Fluke 179
7. Measure voltage: setpoint 4.75–5.25 V.
32060
NOTE
Requirements
• Retarder switched off 1. Pull plug from pressure sensor (38).

In case of a fault (cable or sensor), the controller
• Ignition switched off 2. Connect the plug of the measuring adapter (99/3) switches of the supply voltage.
to the pressure sensor (38). Ö Check cable or sensor and replace if necessary.
• Constant-air pressure gauge connected
• Electrical leads and plug connections checked 8. Connect the positive lead of the multimeter (98/8)
(visual inspection) and in order to test socket 2 (positive).
9. Measure voltage.
CAUTION
Hot parts!
Ö Work carefully.
© 2005
Page 94
10.Compare measured values of constant-air pres- Voltage measurement at pressure sensor

sure against the values (see diagram).
11.Turn ignition off.

5
12.Disconnect measuring adapter (99/3). 4.5
13.Connect electrical connection to pressure sensor. 4

3.5
3
[ V ] 2.5
2
1.5
1
0.5
0
0.5 1 1.5 2 2.5 3 3.5 4
0
[ BAR ]
32062_e
© 2005
Page 95
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Proportional Valve and Damping Plate
7.11 Proportional Valve and Damping

Plate

5100 Damping plate, replace if damaged
5200 5100
5200 O-ring 16x3, replace 5200 5000 5400
5300 Hex head screw M8x20, replace
30 Nm
5400 Hex head nut M8, replace
5300
18 Nm 5400
NOTE
NOTE
Ö For vehicles used in city traffic: Replace propor-
tional valve at intervals of 120,000 km.
© 2005
32030
Page 96
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Repair Proportional Valve and Damping Plate
Requirements
• Supply-air pressure discharged
• Compressed-air line disconnected
• Electrical connection lead disconnected from pro-

portional valve. Male and female connector
checked for damage or wear (notch scratches)
NOTE
Ö Check damping plate (5100) for mechanical and
aging damage and replace if necessary.
© 2005
Page 97
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Appendix
8. Appendix
8.1 Tightening Torques 99

© 2005
Page 98
Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Appendix Tightening Torques
8.1 Tightening Torques
Item No. Designation Dimensions Tightening torque

1500 Screw plug M14x1.5, hexagon socket head, w.a.f. 6 25 Nm
1700 Oil drain plug M24x1.5, hexagon socket head, w.a.f. 12 80 Nm
1900 Non-return valve outlet M48x1.5, hexagon insert bit, w.a.f. 55 280 Nm
2800 Oil filler plug M30x1.5, hexagon socket head, w.a.f. 17 130 Nm
3600 Hex head screw M8x45, hexagon insert bit, w.a.f. 13 Observe tightening sequence:
Initial torque: 17 Nm
Final torque: 30 Nm
4703 Screw plug M8x1, hexagon socket head, w.a.f. 5 10 Nm
4800 Hex head screw M8x70, hexagon insert bit, w.a.f. 13 Observe tightening sequence:
Initial torque: 17 Nm
Final torque: 30 Nm
5300 Hex head screw M8x20, hexagon insert bit, w.a.f. 13 30 Nm
5400 Hex head nut M8, hexagon insert bit, w.a.f. 13 18 Nm
6200 Hex head screw with flange M10x40, hexagon insert bit, w.a.f. 15 46 Nm
7000 Pressure sensor M16x1.5, hexagon insert bit, w.a.f. 27 30 Nm
8000 Oil temperature sensor M14x1.5, hexagon insert bit, w.a.f. 27 28 Nm

20200 Screw plug M14x1.5, hexagon socket head, w.a.f. 6 25 Nm
20600 Coolant temperature sensor M14x1.5, hexagon insert bit, w.a.f. 27 28 Nm
© 2005
Page 99
Voith Turbo
Produktgruppe Retarder
Postfach 1555
74555 Crailsheim
Deutschland
Phone: 00 49 79 51 / 32-0
Fax: 00 49 79 51 / 32-756
service-retarder@voith.com
www.voith.com
Engineered reliability.

Aftersales Service Manual Voith Retarder VR 123

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Aftersales Service Manual Voith Retarder VR 123

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Aftersales Service Manual Voith Retarder VR 123

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Voith Turbo

Aftersales Service Manual Voith Retarder VR 123

1 About this Document 5

2 Basic Safety Instructions 8

3 Design and Function 11

3.5 Function and Control Scheme 17

4 Maintenance and Service 19

5 Diagnosis and Troubleshooting 28

6 Removing and Installing the Retarder 69

7.4 Retarder Ventilation 81

7.5 Non-Return Valve 82

1. About this Document

1.1 Purpose of this Document 6

1.1 Purpose of this Document

This Aftersales Service Manual provides information

1.2 Target Groups

This Aftersales Service Manual is intended for service

1.3 Other Applicable Documents

Documents Information Item number

1.4 Symbols and Identifications 1.5 Item Numbers

Ö One-step action instruction. Phone: 00 49 79 51 / 32-401, 32-422, 32-1860

2. Basic Safety Instructions

2.1 Product Safety 9

- Accident-prevention regulations Ö For proper ventilation of the retarder system, do not

Ö Wear protective gloves or use cloths if necessary.

Towing 2.8 Warranty

Failure while driving

Ö Adjust the speed of the vehicle with the service

Ö Engage the lowest possible gear to achieve a high

Ö Continue driving in this way until the retarder is

3. Design and Function

3.1 Overview of the Modules 12

3.1 Overview of the Modules

Item No. Designation 3000 2800

1900 Non-return valve 100

Item No. Designation

3.2 Retarder Identification

3.3 VERATM Controller Identification

Retarder Control Unit

3.4 Digiprop Controller Identification

3.5 Function and Control Scheme

6000 Heat exchanger

Supply-air pressure pv Pump Pressure Pdyn

themselves until an equilibrium has been reached be-

If the critical temperature threshold has been exceed-

4. Maintenance and Service

4.1 Maintenance Intervals 20

4.1 Maintenance Intervals

The maintenance intervals depend on the stress put

Activity Interval See

4.2 Oil Change

Maintenance work during each oil change Filling in the oil

8. Tighten screw plugs (1700) to 80 Nm.

4.3 Checking the Oil Level

Item No. Designation

Hot oil filler plug (2800) and screw plugs (1500

4.4 Draining the Coolant

Item No. Designation

• Retarder switched off FABR.Nr.