VOITH Retarder 115 Actors After Sales Service Manual

Aftersales Service Manual
VOITH Retarder 115 Actros
cbtd 00-07
53.2693.10
Content Table of Content
1 Preface ......................................................................................................................... 1/1
2 General ......................................................................................................................... 2/1

2.1 Retarder Data ............................................................................................................................... 2/2
2.2 Identification Retarder Control Unit................................................................................................ 2/3
2.3 Assembly Overview ...................................................................................................................... 2/4
2.4 Function- and Operation Scheme ................................................................................................. 2/6
2.5 Vehicle-CAN-Bus ........................................................................................................................ 2/13
3 Maintenance ................................................................................................................. 3/1

3.1 Maintenance Work / Oil Change Intervals .................................................................................... 3/2
3.2 Checking Oil Level ........................................................................................................................ 3/5
3.3 Oil Change .................................................................................................................................... 3/8
3.4 Activate Service Function of Retarder ......................................................................................... 3/12
cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

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4 Diagnosis / Troubleshooting ......................................................................................... 4/1

4.1 Troubleshooting Diagram ............................................................................................................. 4/3
Electrical Connections Diagram R 115 H ..................................................................................... 4/8
4.2 Troubleshooting and Remedies .................................................................................................... 4/9
- Layout of Components ............................................................................................................ 4/10
- Layout of Plug Connections and Plug Arrangement ............................................................... 4/12
- Note for Diagnostic Activities ................................................................................................... 4/19
- Error Code / Read Out of Instantaneous Value........................................................................ 4/20
- Delete Fault Memory ................................................................................................................ 4/21
- Overview Error Codes ............................................................................................................. 4/22
- Troubleshooting with Actual Error Code .................................................................................. 4/27
- Troubleshooting with Stored Error Code ................................................................................. 4/35
4.3 Overview Control Parts ............................................................................................................... 4/36
4.4 Checking Supply-Air Pressure .................................................................................................... 4/37
4.5 Checking Constant-Air Pressure (py )........................................................................................... 4/38
4.6 Checking Control Current of Proportional Valve ......................................................................... 4/40
4.7 Checking Temperature Adaption ................................................................................................ 4/42
- Version Inter-Solution .............................................................................................................. 4/43
- Version Serial-Solution ............................................................................................................ 4/46
4.8 Checking Pump Pressure ........................................................................................................... 4/49
4.9 Table of Measurements .............................................................................................................. 4/54
4.10 Operational Check ...................................................................................................................... 4/55
- Operational Check via Instantaneous Values (Measurements and Binary Values) ................ 4/55
- Functional Control in Standstill and by Test Trial .................................................................... 4/63

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5 Removing, Installing Retarder ....................................................................................... 5/1

5.1 Removing, Installing Retarder ....................................................................................................... 5/2
6 Repair ........................................................................................................................... 6/1

6.1 Overall Illustration of Main Components ....................................................................................... 6/2
- Version Inter-Solution ................................................................................................................ 6/2
- Version Serial-Solution .............................................................................................................. 6/3
6.2 Removing, Checking and Installing Casing Ventilation ................................................................. 6/4
6.3 Removing, Cleaning and Installing Silencer ................................................................................ 6/13
6.4 Removing, Checking and Installing Heat Exchanger................................................................... 6/14
6.5 Removing, Installing Top Oil Tank Cover .................................................................................... 6/20
- Version Serial-Solution ............................................................................................................ 6/21
6.6 Removing, Installing Bottom Oil Tank Cover .............................................................................. 6/22
6.7 Removing, Installing Oil Tank...................................................................................................... 6/24
- Version Serial-Solution ............................................................................................................. 6/27

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7 Control Parts ................................................................................................................ 7/1

7.1 Removing, Installing Proportional Valve ........................................................................................ 7/2
7.2 Removing, Installing Cooling-Water Temperatur Pick-Up ............................................................. 7/3
7.3 Removing, Installing Oil Temperatur Pick-Up ............................................................................... 7/5
8 Annex ........................................................................................................................... 8/1

Data Sheet
Conversion Tables
Tightening Torques

53.2693.10 Page IHV/4
Preface 1 Preface
The present service manual serves as training material of the basic course. The information and
instruction which is given to you furthermore provide the basis for appropriate and professional
maintenance and repair at the Voith Retarder 115 H 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.
Note
is associated for general notices for a better handling during maintenance of the retarder.

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Preface 1 Preface
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Caution!
• The switched-on retarder will not secure the parked vehicle!
• During a failure of the retarder, or while the temperature-adaptation is effective, the

vehicle-speed must be settled by using the service-brake and the lowest possible gear (increase of
the engine-speed). This vehicle condition must be held as long as the retarder is available with its
full performance again.
• Unauthorized changes at the retarder as well as the application of spare parts, accessories,
attachments and special-productions, not tested and released from Voith, can influence the
security of the entire vehicle negatively. No liability takes place for damages resulting from it.
• The retarder is built after the the state-of -the-art technology and the recognized safety-related
rules. Nevertheless dangers and damages can originate during improper use, maintenance and
repair.
• We will take on no liability for injuries and/or damages, that originate through non-observance of the
security-hints of the service manual or through injuries of the diligence-duty with the handling, at the
service, with the care and maintenance or repair of the retarder.
• Repair and maintenance work may only be enforced by qualified specialist-staff.

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Preface 1 Preface
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Note
• The used position numbers in this manual correspond to the position numbers in the spare parts
lists in chapter „Annex“.
Exception:
Items or parts with one -, as well as two-digit position-numbers are no spare parts and not listed in
the spare parts lists.
Also items or components shown with an oblique-number are no spare parts and not listed in the
spare parts lists.
• For Voith it is not possible to warn expressly of all possible situations at each position in this
service manual, that could have a risk of injury for the worker and/or a damage for the retarder
to the consequence. Therefore it is desperately necessary, that everyone, entrusted with the
service, care, maintenance or repair of the retarder, does not endanger its own security through the
chosen operation and that the retarder gets no negative impairments, especially of safety-related
types.
Voith is not liable for injury to persons and or damages caused through improper and
unprofessional work.
• The pertinent accident-prevention-regulation, other broadly rules of the security-technology and

working-medicine and the traffic admission law are to be kept. Voith is not liable for damages, that
originate through contempt of these rugulations.

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Preface 1 Preface
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• When getting in contact with oils, greases and other chemical substances, the current safety
regulations for these products are to be heeded!
• Caution with the contact with hot fuels! Danger of burn and scald!
• Please take the hints to the safe, proper and economic operation of the retarder from the operating
instruction.
• According to production-time period of the vehicle, different electrical wiring-harnesses were

obstructed for the retarder:
To chassis-end-No. 303 057 (inter-solution):

Central-plugs for proportional valve and cooling-water temperature pick-up, separated plug and sok-
ket connection for oil temperature pick-up. Both plug and socket connections are fortified at the gear
box.
From chassis-end-No. 303 058 (series-solution):

Central-plugs for proportional valve, cooling-water temperature pick-up and oil temperature
pick-up.The central-plug is fortified at the retarder.
The serial-solution is represented in the illustrations of this service manual in each case.
Deviating the work-courses of the serial- and inter-solution from each other, the corresponding
work-steps are described separately.

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Preface 1 Preface
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• Should you have any queries about the descriptions, please contact the responsible person in the
appropriate organisation of the country involved or:
VOITH TURBO GmbH & Co. KG

Department retarder;
Voithstraße 1
PO box 15 55
D-74564 Crailsheim
Telephone xx49 - (0)7951 32-401, -422

Telefax xx49 - (0)7951 32-756
e-mail: retarder@voith.de
Copyright July 2000 - Voith Turbo

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General 2 General
2.1 Retarder Data......................................................................................... 2/2
2.2 Identification Retarder Control Unit ........................................................ 2/3
2.3 Assembly Overview ................................................................................ 2/4
2.4 Function- and Operation Scheme .......................................................... 2/6
2.5 Vehicle-CAN-Bus ................................................................................ 2/13

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General 2.1 Retarder Data
The data plate (2900/1) is mounted at the

oil tank on the lower right side.
2900/1
The retarder data plate provides the following M+P-07A-1944
information:
1. Serial number (6-digit number)
2. Retarder transmission ratio (i R e t)
3. Year of manufacture
4. Code number (8-digit number)
5. Part-No. vehicle manufacturer
Note
Please, always quote the serial number and the

item number when submitting queries or
ordering spare parts.
12001

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General 2.2 Identification Retarder Control Unit
The retarder control unit (2) is located in the

driver cabin on the right in the E-box.
Depending on the vehicle equipping the
location of the retarder control unit in the E-box
XX
XX
X
XX X
X
M+P-07A-1945
XX X.X X
XX X
a
.X X
XX X X
-N
r.: XX
ith XX
Vo r.: X
may differ. MB
-N
The labeling of the Dipiprop-control unit (data

plate) is fixed on the control unit and provides
the following information: XXX XXX XX XX
Voith-Nr.: XX.XXXX.XX
b
• Date of manufaction (a) MB-Nr.: XXX XXX XX XX
• Serial number (b)
12002

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General 2.3 Assembly Overview
Illustration Voith retarder 115 H Digiprop

basic group with heat exchanger 3700
M+P-07A-1946
94/5 Blind hole (without function)
2909 Oil filler plug M 30 x 1,5 2909
2922 Oil check plug M 24 x 1,5 2909
3300 Heat exchanger
3700 Proportional valve
3700/1 Electrical connection proportional
valve
7000 Ventilation
3700/1
94/5
3300
7000
2922
12003

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General 2.3 Assembly Overview
(Continue)
Illustration Voith retarder 115 H Digiprop

basic group with heat exchanger
(Continue) M+P-07A-1815
2919 Central oil-drain plug

3300 Heat exchanger
4700 Screw plug with sieve 4700
M 30 x 1,5
2919 3300
12004

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General 2.4 Function- and Operation Scheme
Function scheme Voith Retarder 115 H with Digiprop control unit
4 5 8
M+P-07A-1947
16
26 A R
23 42 21
36
20 25
41
1
63
2
19
46
15
22 44
64
27
28 62
29 43
55
17 Oilsump Coolant (Water)
Supply air pressure p V Pump pressure p P
Constant air pressure p y
12085
Note
The refernce numbers indicated in section 2.2 are not identical with the
reference numbers of the spare parts lists.
1 Heat exchanger 26 Supply-air pressure line (pv )

2 Retarder control unit 27 Signal „desired retarder-torque“
3 Vehicle CAN-Bus 28 Signal „gearbox output revolution“
4 Connection terminal 15 29 Instrument (INS)
5 Connection terminal 30 36 Ventilation line „R“
8 Connection ground 41 Rising duct
15 ABS/BS-signal 42 Oil tank
16 Actuating lever engine regulation/continous brake 43 Oil sump
17 Retarder pilot light 44 Stator
19 Cooling-water temperature pick-up 46 Rotor
20 Oil temperature pick-up 55 Central oil-drain plug
21 Proportional valve 62 Pressure regulating valve
22 Ventilation 63 Non-return valve inlet
23 Casing ventilation 64 Non-return valve outlet
25 Constant-air pressure line „A“ (p y )

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Description of function
The Voith retarder 115 H Actros is a powerful, hydrodynamic continous brake of compact design.
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 revolution
ranges with the compactest configuration (small rotor/stator).
Retarder braking torque is sustained even when gear changes are made.
Caution!
A switched-on retarder will not secure a parked vehicle.
In the event of a retarder failure or when the temperature adaption is effective, the service brake must
be used to regulate the vehicle speed.

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Operation of retarder R 115 H with Digiprop control unit

c
Through actuating of the actuating-lever of engine control/continous brake (16), the control unit retarder
(2) gets an input signal, which is changed to a CAN-message and sent. With these and other data the 002
desired value of the retarder braking torque will be calculated in the control unit FR (drive control) and
then sent via the CAN-Bus (3).
The control unit retarder (2) receives the signals „retarder-torque-desired value“and „gearbox-output re- a b
volution“ via the vehicle CAN-Bus (3). With these values a control current will be calculated by a
characteristic operation and sent to the proportional valve (21).
If the control unit retarder (2) is set into the AUTO-mode, a defined valve current will be sent directly to
the proportional valve (21) in accordance to the position of the actuating lever engine control/continous
brake (16).
12006
At the proportional valve (21), compressed air is headed, which is taken from the compressed air The hydrodynamic principle
reservoir (71) (supply-air pressure pv). a Rotor (46)
b Stator (44)
According to the value of the control current a pneumatic constant-air pressure (py) is sent from the c Oil flow
proportional valve (21) to the oil sump (43) of the retarder.
Through the constant-air pressure (py) in the oil sump (43) a certain amount of oil according to operating
condition (short propeller shaft-speed) will be pressed into the working chamber between rotor (46) and
stator (44). At the same time the air which is still in the working circuit at the beginning of the braking
process is pressed out by the oil via the casing ventilation (23).
The rotor (46) is connected with the driveshaft of the retarder, the stator (44) fixed with the retarder
housing. The rotation of the rotor (46) 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.

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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 (1) and via
filling ducts to join the circulating flow again.
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.
The retarder-braking torque is adapted on to protection of the vehicle-cooling system and the
retarder accordingly in order to prevent an overstepping of the maximum cooling-water and
oil temperature pre-determined in the retarder control unit (2) and to use the maximum cooling capacity
of the vehicle
To this, the retarder control unit (2) gets constantly information from the temperature pick-ups about the
cooling-water- and oil temperature.
The retarder braking torque is adapted by

• too high cooling-water temperature
• too high retarder oil temperature
• too fast increasing of retarder-oil temperature
In the event of a retarder failure or when the temperature adaption is effective, the service brake must
be used to regulate the vehicle speed.

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Braking torque adaption at too high cooling-water temperature

If, during a retarder braking the cooling-water temperature rises up to the temperature adaption area, the
control current to the proportional valve (21) is linear cutted-back for a short time. It follows an adaption
of the constant-air pressure (py) and so an adaption of the retarder braking torque.
An adaptation becomes active subsequent at a constant cooling-water temperature, i.e., is the

measured temperature more less than the allowable maximum temperature the constant-air pressure
(py) become increase continuing (at most until no more adaptation is active).
In the reverse case, the constant-air pressure (py) become decrease (in the extreme-case until 0).
The braking torque and therefor the heat obtained adapt itself as long as a balance between incurring
retarder-braking energy leading heat occurs which come via the vehicle-cooling system.
While the braking torque adaptation is effective through to high cooling-water temperature, the retarder
pilot light flashes.

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Brakin torque adaption at too high retarder oil temperature

If, during a retarder braking the oil temperature rises up to the temperature adaption area, the control
current to the proportional valve (21) is linear cutted-back. It follows an adaption of the constant-air
pressure (py) and so an adaption of the retarder braking torque.
If the retarder oil temperature rises above the temperature adaption range, there is no more braking
torque output.
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 via the
vehicle cooling system.
While the braking torque adaptation is effective through to high cooling-water temperature, the retarder
pilot light flashes.

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Braking torque adaption at too high retarder oil temperature gradient

The temperature-gradient marks a temperature-change in a certain time.
A high temperature-gradient marks a temperature-change in a relatively short time, a low temperature-
gradient marks a temperature-change in a relatively long time.
The control unit of the retarder (2) adapts at too fast increase of the retarder-oil temperature
(independently from the actual retarder oil temperature) the braking torque.
Rises during a retarder braking the retarder-oil temperature-gradient up into the adaptation-range, the
control current is adapted on to the proportional valve (21). It follows an adaption of the constant-air
pressure (py) and so an adaption of the retarder braking torque.
While the braking torque adaptation is effective through to high oil temperature gradient, the retarder pilot
light doesn´t flash.

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Temperature pick-up cooling-water (19), temperature pick-up oil (20)

The temperature pick-ups are installed in the cooling system of the vehicle (cooling-return circle from
retarder to heat exchanger) and in the retarder-oil duct and transmit signals on cooling-water- and oil
temperature to the control unit (2).
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.
Non-return valve (63) inlet

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

The oil pressure in the working space opens the non-return valve (64), causing the oil to enter
the heat exchanger (1), to be cooled and returned to the working circuit.

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General 2.5 Vehicle-CAN-Bus
CAN (Controller Area Network) was developed for the use in the vehicle for communication between
sensors, actuators and control units from approximately 1983.
It is a data channel, that transports all relevant information in the vehicle reliably and quickly via leads.
The data bus can be named as a type of „data-highway“.
The total-system in the vehicle, existing from a number of control units, as well as the applied data buses,
became summarized from DaimlerChrysler under the term „IES“ (Integrated Electronics System).
The network is technical realized through one 2- as well as 4-pole connecting lead with central reunion
(star point).
Two implementations of CAN-Buses are differentiated on the basis of different requests at the
transmission speed and -safety:
• HS-CAN (High Speed CAN)

• LS-CAN (Low Speed CAN)
The retarder control unit DIGIPROP works with the HS-CAN, the transaction rate here is 500 kBauds
(500.000 bits/sec.). The data of the control unit, relevant for the vehicle-system (for example position of
the actuating lever engine control/continous brake, the cooling-water temperature etc) becomes
cyclically transfers every 20 msec., i.e. 50-times in the second.

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General 2.5 Vehicle-CAN-Bus
(Continue)
Network of components:
2 Retarder control unit
3 HS-CAN Bus1) M+P-07A-1817
3/1 LS-CAN Bus 2 ) (engine)
3/2 LS-CAN Bus 2 ) (clutch)
3/3 LS-CAN Bus 2 ) (brake)
29 Instrument
70 Control unit FR (FMR) 73
72 Control unit FTCO 77 77
73 Diagnostic plug 76
(Only to be read out with the
DaimlerChrysler Diagnostic-
system HHT or DAS) 29
76 K-lead 78
77 Other control units 72
78 Basic-module
1) HS-CAN Bus = High-Speed-CAN Bus

2) LS-CAN Bus = Low-Speed-CAN Bus
77 77 70 77 77 2 77 77 77
3/1 3/2 3/3
77 77 77
12007

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Maintenance 3 Maintenance
3.1 Maintenance Work / Oil Change Intervals ............................................. 3/2
3.2 Checking Oil Level ................................................................................ 3/5
3.3 Oil Change ............................................................................................ 3/8
3.4 Activate Service Function of Retarder ................................................. 3/12

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Maintenance 3.1 Maintenance Work / Oil Change Intervals
Maintenance Work
At each oil change

• Clean sieve of pressure regulating valve.
• Check fastening screws of 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 complete retarder.

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Oil change intervals, operating specifications

Remark:
The statements of the vehicle-manufacturer are valid. Following defaults are to be heeded, if no
statements are available.
1) 1)
Single-grad-mineral oil Synthetic. / part synthetic oil
Normal duty 90.000 km 2) 135.000 km 2)
Heavy duty 45.000 km 2) 90.000 km 2)
1) Operating specifications, see annex

2) Change oil at the latest after 2 years if fewer kilometres are travelled.
1. „Normal duty“
Example:
– - Long distance traffic
2. „Heavy duty“
Subject to more than normal stress.
Examples:
- Use in regions with high ambient temperatures
- Vehicles at construction sites and timber lorries
- High max. permissible weight with low rated engine power (< 5,9 kW/metric ton)
- Stretches with lots of hills and valleys
- Extreme short-distance traffic with lots of gradients

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The given maximum specified figures can be lowered, if overall maintenance cycles for the vehicle are
improved.
With a total-life of the retarder of more than 10%, covered on the vehicle-performance, as well as other
factors not mentioned here also affect the ageing of the oil, it may be necessary to shorten the intervals
between oil changes in individual cases.
For use in extremely cold zones, oils in an appropriately lower viscosity class
(TransmaxZ or SEA 5W-40) must be used.
In doubts, please contact our customer service.
Oil types admitted to the application must fill following specifications:
Material group Identification letter Viscosity class Performance class

from DIN 51502 from DIN 51511
Single-grade-mineral HC SAE 10W API - CC/SF

oil SAE 20W 20 and higher
SAE 30
Synthetic oil / HC SAE 0W 40 API - CC/SF

part synthetic oil SAE 5W 30 and higher
SAE 5W 40
SAE 5W 50
SAE 10W 30
SAE 10W 40
Please heed the oil specification list in the appendix!

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Maintenance 3.2 Checking Oil Level
Illustration checking oil level

2909 2909
2909 Oil filler plug M30x1,5
Inhex.-head, w.a.f. 17 M+P-07A-1948 2910
150 Nm 2910
2910 Sealing ring A30x36, renew
2922 Oil check plug M24x1,5
Inhex.-head, w.a.f. 12
80 Nm
2923 Sealing ring A24x29, renew
2923
2922
12008

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Note
For satisfactory retarder operation, it is important to adhere to the specified service filling (see page 3/9)
and to use only oils specified in the operating specifications (see page 3/3) for operating the retarder in
the relevant application.
The oil level check must be carried out with the vehicle in a horizontal position.
For checking oil level, the temperature of the retarder-oil must reach operating temperature.
Job scope
1. Activate service function of retarder (see page 3/12).
2. Switch actuating lever engine control/continous brake in highest stage of continous brake function
and after approx. 5 seconds again in stage 0.
Repeat this procedure twice.
3. Switch actuating lever engine control/continous brake in stage 0 and wait for 5 minutes.

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Caution! Risk of injury! M+P-07A-1821
The oil check plug (2922) and oil filler plug (2909) is hot (oil temperature)!
The retarder must be switched-off during oil level check!

Risk of injury exists at nonobservance, by hot leaving oil when screw out oil check plug and/or oil filler
plug during working step 4 (increased pressure)!
4. Screw out oil check plug (2922) and remove sealing ring (2923).
The oil level is correct, if it is at the lower edge (arrow) of the oil check hole. 2923
2922
5. Top up slowly any lacking oil via the hole for the oil filler plug (2909) according to operating 12009
specifications (depending on accessibility).
2909
Note
M+P-07A-1949
With determined lacking oil quantity, check retarder for a possible outer leakage.
2909
6. Screw oil filler plug (2909) with new sealing ring (2910) tight.
Tightening torque oil filler plug (2909): 150 Nm. 2910
7. Screw oil check plug (2922) with new sealing ring (2923) tight.
Tightening torque oil check plug (2922): 80 Nm.
12010

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Maintenance 3.3 Oil Change
Illustration oil change

2909 2909
2909 Oil filler plug M30x1,5
Inhex.-head, w.a.f. 17, 150 Nm M+P-07A-1950 2910
2910 Sealing ring A30x36 renew 2910
2918 Sealing ring A20x26 renew
2919 Central oil-drain plug M20x1,5
Inhex.-head, w.a.f. 10, 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,
for installation
4700 Screw plug with sieve
M30x1,5, Inhex.-head, w.a.f. 17,
150 Nm, clean sieve with
appropriate cleaning agent 2921
(Benzine) and blow out with
compressed air 4800 2920
4800 Sealing ring A30x36, renew 2918
4700
Lubricants and cleaning agents
O-ring Silicone-free and 2919

12011
Sieve in screw Benzine
plug

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Note
For satisfactory retarder operation, it is important to adhere to the specified service filling (see table
below) and to use only oil specified in the operating specifications (chapter 3.1: „Maintenance Work / Oil
Change Intervals“ and chapter 8: „Annex“) for operating the retarder in the relevant application.
The retarder-oil temperature must reach 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!
Service filling with heat exchanger

Service filling (oil change, checking oil level) 5,9 Litre
After complete taking apart and cleaning as well as 6,5 Litre

emptied heat exchanger (corresponds new filling)

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Job scope
1. Push an oil collecting pan under retarder.
Caution! Risk of injury!

2921
The central oil-drain plug (2919) is hot (oil temperature)! 2920
2918
2. Screw out central oil-drain plug (2919) on the retarder and drain oil.
3. Coat new O-rings (2920 und 2921) with silicone-free and non-corrosive grease and fit them on the 2919
12012
central oil-drain plug (2919).
4. Screw central oil-drain plug (2919) with a new sealing ring (2918) tight.
Tightening torque central oil-drain plug (2919): 55 Nm.
5. Screw out screw plug (4700) of retarder housing and remove sealing ring (4800).
6. Clean sieve (arrow) in screw plug (4700) with appropriate cleaning agent (benzine) and blow out
with compressed air.
7. Screw screw plug (4700) with a new sealing ring (4800) tight.
Tightening torque screw plug (4700): 150 Nm.
4800
4700
12013

53.2693.10 Page 3/10
(Continue)
8. Screw out oil filler plug (2909) (depending on accessibility).

2909
9. Fill in slowly the quantity of oil specified (see page 3/9) in accordance with the operating specifi-
cations (see page 3/3: „Oil Change“ and chapter 8: „Annex“).
2909
10. Screw oil filler plug (2909) with new sealing ring (2910) tight.
Tightening torque oil filler plug (2909): 150 Nm. 2910
11. Activate service function of retarder (see page 3/12).
12. Operate retarder quickly 3-times in stage 2 or 3.
12010

53.2693.10 Page 3/11
Maintenance 3.4 Activate Service Function of Retarder
Note
A service-function can be activated in order to be able to enforce certain examinations at the retarder in the vehicle-standstill.
Certain proportional-valve-currents become selected with it in dependence of the position of the actuating lever engine control continous braking.
Prerequisite for the activation of the service-function:

– The vehicle is in standstill
– The actuating lever of engine control/continous braking is in stage 0 of continous braking function
Service function activated:

The service-function is activated when the ignition is switched-on and all prerequisites are filled.

53.2693.10 Page 3/12
Diagnosis / 4 Diagnosis / Troubleshooting
Troubleshooting
4.1 Troubleshooting Diagram ...................................................................................................... 4/3

Electrical Connections Diagram R 115 H .............................................................................. 4/8
4.2 Troubleshooting and Remedies ............................................................................................ 4/9

- Layout of Components ..................................................................................................... 4/10
- Layout of Plug Connections and Plug Arrangement ........................................................ 4/12
- Note for Diagnostic Activities ........................................................................................... 4/19
- Error Code / Read Out if Instantaneous Value................................................................. 4/20
- Delete Fault Memory........................................................................................................ 4/21
- Overview Error Codes...................................................................................................... 4/22
- Troubleshooting with Actual Error Code .......................................................................... 4/27
- Troubleshooting with Stored Error Code.......................................................................... 4/35
4.3 Overview Control Parts ....................................................................................................... 4/36
4.4 Checking Supply-Air Pressure ............................................................................................ 4/37
4.5 Checking Constant-Air Pressure (py ) .................................................................................. 4/38
4.6 Checking Control Current of Proportional Valve ................................................................. 4/40

53.2693.10 Page 4/1
Diagnosis / 4 Diagnosis / Troubleshooting
Troubleshooting (Continue)
4.7 Checking Temperature Adaption......................................................................................... 4/42

- Version Inter-Solution....................................................................................................... 4/43
- Version Series-Solution.................................................................................................... 4/46
4.8 Checking Pump Pressure.................................................................................................... 4/49
4.9 Table of Measurements....................................................................................................... 4/55
4.10 Operational Check............................................................................................................... 4/56

- Operational Check via Instantaneous Values (Measurements and Binary Values) ........ 4/56
- Operational Check in Standstill and by Test Trial ........................................................... 4/64

53.2693.10 Page 4/2
Diagnosis / 4.1 Troubleshooting Diagram
Troubleshooting
A
Oil loss via
ventilation
Error display in
D B
the red field of Complaint Retarder
the display matrix R 115 H pilot light
(dashboard) Actros
No respectively
too insufficient
retarder braking
effect
C
12086

53.2693.10 Page 4/3
0901
A
Oil loss via
ventilation
Check
retarder oil level
OK NOK
Water in oil Water in oil

(emulsion) (emulsion)
No Yes Yes No
Check Check
casing ventilation heat exchanger
(chapter 6.2)
see chapter 6.4
OK NOK Check
retarder oil level
too too
Replace high low
C
casing ventilation
(chapter 6.2)
Check
gearbox oil level
OK NOK
Check
gearbox oil level
NOK OK Check
gearbox oil level
too too
high low
Check
gearbox oil level Correct Check
retarder oil level casing ventilation
too too (chapter 6.2)
high low Contact Correct retarder-
Voith and
OK NOK gearbox oil level
Correct
Contact
retarder- and
Voith
gearbox oil level
C
Replace
casing ventilation
If oil loss via ventilation occurs again

after a test trial, continue with diagram "C".
12087

53.2693.10 Page 4/4
0902
B
Retarder
pilot
light
no
flashes
function
Check pilot light

After switch on
and its lead,
vehicle ignition system
renew
if necessary
Yes No
Contact
Voith Actuating lever
engine control/ Temperature
continous braking adaption!
not in position 0
after switching on
Check operation
(during braking with
retarder nominal engine
speed, if possible)
OK NOK
Check temperature
adaption or temperature Instruct driver!
pick-ups (oil/water)
and its leads
(see chapter 4)
OK NOK
Check vehicle cooling Replace

system: temperature
pick-ups and leads
- Coolant level (see chapter 7)
- Thermostat
- Coolant pump
- Radiator fan
- Radiator grill for
dirtiness 12088

53.2693.10 Page 4/5
0903 C
No respectively
too insufficient
retarder braking
effect
Check
retarder oil level
Water in oil OK NOK Water in oil

(emulsion) (emulsion)
No Yes Check Yes No

heat exchanger
see
Check chapter6.4 Check
py (static) retarder oil level
(chapter 4.5) too too
high low
OK NOK
Check
Check
gearbox oil level
p (dynamic)
(chapter 4.8)
OK NOK
OK NOK
Correct Check
Check current
retarder oil level gearbox oil level
proportional valve
Is the static and dynamic pressure Contact as well as leads too too
ok, then it is not possible to get the Voith and connector high low
above mentioned complaint. (chapter 4.6)
Please, clarify this complaint with
your customer again, as well as NOK
carrying out the checks again.
OK Correct
Contact
retarder- and
Voith
gearbox oil level
Check supply-air Check temperature

pressure adaption or
(chapter 4.4) temperature pick-ups
(oil/water) and leads
OK NOK (see chapter 4)
OK NOK
Check vehicle
Proportional valve or compressed-air
damping plate system
mechanically defect Contact Replace temperature
OK NOK Voith pick-ups or leads
(chapter 7.2 and 7.3)
Interrupted or leaking Contact

compressed-air pressure vehicle manufacturer
12089
pipe to proportional valve

53.2693.10 Page 4/6
D
0904
Error display in
the red field of
display matrix
(dashboard)
Read out
error code
(chapter 4.2)
Rectify
error!
(chapter 6 and 7)
12090

53.2693.10 Page 4/7
Electrical connections diagram R 115 H

3 Vehicle CAN-Bus M+P-07A-1952
4 Terminal 15 16 8 5 4 3700 5900/1 5900/2
5 Terminal 30
8 Terminal ground
16 Actuating lever engine control/con- 2 1
tinous brake 2 1 7 6 5 4 3
– + + – + –

5900/1 Cooling-water temperature pick-up 3
5900/2 Oil temperature pick-up
1 2 3 12 11 17 10 8 9 4 5 6 14 18 16 15 13 7
x1 2 3 1 6 5 4 9 8 7
x2
12020

53.2693.10 Page 4/8
Diagnosis / 4.2 Troubleshooting and Remedies
Troubleshooting
Troubleshooting and remedies
Requirements for check

• Battery voltage 22,5 to 29,5 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 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.
Note
Prior to any troubleshooting, retarder oil level must be checked and corrected, if necessary
(see chapter 3.3).

53.2693.10 Page 4/9
Layout of components
The retarder control unit (2) is located in the M+P-07A-1827

driver cabin on the right in the E-box.
Note
Depending on the vehicle equipping the

location of the retarder control unit in the E-box
may differ.
12021

53.2693.10 Page 4/10
Layout of components
(Continue)
M+P-07A-1953
3700
100 Retarder housing
2900 Oil tank
5900/2
3300 Heat exchanger
5900/1 Cooling-water temperature pick-up
5900/2 Oil temperature pick-up 3300
5900/1
100
2900
12022

53.2693.10 Page 4/11
Layout of plug connection and

plug arrangement 83
M+P-07A-1954
80 Plug-board cabin grommet
81 Plug connection actuating lever 80
engine control/continous brake
82 Plug connection retarder
(lateral at gearbox)
83 Plug connection central plug 82
(serial-solution)
84 Plug connection central plug
(inter-solution)
85 Plug connection oil temperature
pick-up (inter-solution)
Note
81
Alternative may be installed connection plugs
(84 and 85, inter-solution) or connection plugs 84
(83, serial-solution).
85
12023

53.2693.10 Page 4/12
Note M+P-07A-1830
All plugs illustrated from plug-in side (i.e. leads at back).
16 13 10 7 4 1
Retarder Control Unit, Plug X1 (18-pole)
17 14 11 8 5 2
1 CAN-Low
2 CAN-GND
3 CAN-High 18 15 12 9 6 3
4 Actuating lever engine control/continous brake, position 3
5 Actuating lever engine control/continous brake, position 2 12024
7 Basic module, Terminal 15
10 Actuating lever engine control/continous brake (+)
11 Not in use
12 Not in use
14 Not in use
16 Not in use
17 Actuating lever engine control/continous brake, position 0 (safety contact)
18 Not in use

53.2693.10 Page 4/13
Retarder Control Unit, Plug X2 (9-pole)

1 Not in use
2 Proportional valve (–) M+P-07A-1831
3 Proportional valve (+)
4 Cooling-water temperature pick-up (–)
5 Cooling-water temperature pick-up (+) 10 7 4 1
6 Not in use
7 Not in use
8 Oil temperature pick-up (–) 11 8 5 2
9 Oil temperature pick-up (+)
12 9 6 3
12025
Plug Actuating Lever Engine Control/Continous Brake (15-pole)

1 Retarder control unit (+)
M+P-07A-1832
2 Retarder control unit, stage 0 (safety contact)
3 Retarder control unit, stage 1
5 Retarder control unit, stage 3 13 10 7 4 1
14 11 8 5 2
15 12 9 6 3
12026

53.2693.10 Page 4/14
Plug-Board Cabin Grommet,

Plug X2/3 (18-pole)
9 Proportional valve (+) M+P-07A-1833 1 2 3
10 Proportional valve (–)
11 Cooling-water 4 5 6
temperature pick-up (+)
12 Cooling-water 7 8 9
temperature pick-up (–)
13 Oil temperature pick-up (+) 10 11 12
14 Oil temperature pick-up (–)
13 14 15
4 4 4 4 4
16 17 18
Note 3 3
3 3 3 3 3
The plug-board cabin grommet is the interface
of the cabling between the framework and the
cabin wiring harnesses. It is installed at the
front-side of the cabin and consists of 2 2 2 2 2 2 2
28 outlets, that are engaged according to
production of the vehicle.
1 1 1 1 1 1 1
X7 X6 X5 X4 X3 X2 X1
12027

53.2693.10 Page 4/15
Plug Connection Retarder (at gearbox), Plug X40 (7-pole)

2 Proportional valve (–) M+P-07A-1834
3 Cooling-water temperature pick-up (+)
4 Cooling-water temperature pick-up (–) 2
5 Oil temperature pick-up (+) 3
6 Oil temperature pick-up (–) 1
6 4
5
12028
Plug Proportional Valve (4-pole)

M+P-07A-1835
3 Not in use 4 2
4 Not in use 1
3
12029

53.2693.10 Page 4/16
Plug Connection Central Plug, 7-pole

(Version B)
1 Proportional valve (+) M+P-07A-1834
3 Cooling-water temperature pick-up (+) 2
5 Oil temperature pick-up (+) 1
6 Oil temperature pick-up (–) 6 4
5
12028
Plug Connection Central Plug (at retarder), 4-pole

(Version A)
M+P-07A-1835
2 Proportional valve (–) 4 2
3 Cooling-water temperature pick-up (+) 1
12029

53.2693.10 Page 4/17
Plug Connection Oil Temperature Pick-up, 2-pole

(Version A)
1 Oil temperature pick-up (+) M+P-07A-1955
2 Oil temperature pick-up (–)
1 2
12030

53.2693.10 Page 4/18
Notes for Diagnostic Operation

74 75
Is a general vehicle CAN-Bus-error available, then it is shown a "!" in the red coloured field of the M+P-07A-1837
display-matrix (74).
Is a vehicle CAN-Bus-error with the retarder control unit available, then it is shown "RS" (retarder control)
in the red coloured field of the display-matrix (74) (exception: CAN-communication error with the
valence „0 “).
Note
Before version 1.4 of the retarder control unit ( Voith-item number 53.8150.13) became shown instead
12031
of the abbreviation „RS“ the abbreviation „RET “.
In the diagnostic operation the control units can be read out one after the other of all connected electronic
systems. Data of the respective system are shown on the green coloured field of the display-matrix (75).
Additionally, the error-memory of the respective control units can become deleted.

53.2693.10 Page 4/19
Read out Error Code / Instantaneous Value
Normal operation (Ambient temperature-display with thermometer-symbol) M+P-07A-1838
1. Press button „SYSTEM“ (65) three times. 65 66

– the short sign of the first electronic system (FSS) is shown on the green coloured field of the 67
SYSTEM QUIT INFO
display-matrix. 68
2. Press button „SYSTEM“ (65) as much until the short sign „RS“ is shown on the green coloured field
INSTR RESET
of the display-matrix.
3. By pressing the button „INFO“ (67) several times

– the DaimlerChrysler-item number,
12032
– the error codes (currently existing and saved error codes) and
– the instantaneous value (measure values and binary values) is displayed one after the other.
4. Press button „QUIT“ (66) to change again into normal operation.

53.2693.10 Page 4/20
Delete error memory
1. Activate diagnostic operation of retarder control unit. M+P-07A-1838
65 66
67
SYSTEM QUIT INFO
Note 68
Before delete of error memory, call up and list all error-codes for a later troubleshooting.
INSTR RESET
2. Press button „RESET“ (68) for delete, keep pressed, then additionally press button „QUIT“ (66) –
on the green coloured field of the display-matrix becomes shown for 2 seconds „RS RESET“ in
order to confirm the delete.
12032
3. Press button „QUIT“ (66) in order to change into normal-operation again.

53.2693.10 Page 4/21
Overview Error Code
Error Code Error Text Cause / Remedy
0 02 11 ABS/BS sends constantly or at times wrong Check ABS or BS (EPB).

system-signal
0 02 12 ABS/BS: constantly or at times lacking Check ABS or BS (EPB).

CAN-telegram
0 03 11 FR sends constantly or at times wrong Check FR (FMR).

system-signal
0 03 12 FR: constantly or at times lacking Check FR (FMR).

CAN-telegram

CAN-telegram
0 05 11 GS/FR sends constantly or at times wrong Check GS (EPS) or FR (FMR).

system-signal
0 05 12 GS/FR: constantly or at times lacking Check GS (EPS) or FR (FMR).

CAN-telegram

CAN-telegram
0 07 11 INS sends constantly or at times wrong Check INS.

system-signal
0 07 12 INS: constantly or at times lacking Check INS.

CAN-telegram

53.2693.10 Page 4/22
0 11 05 Actuating lever engine control/continous brake: I – –I + Short-cut after Ubat in the signal-path of the activity-lever engine control/con-
tinous brake (16).
see page 4/27.
0 11 40 Actuating lever engine control/continous brake: Short-cut to ground or interruption in the signal-path to
mechanical defect, –//– or I– – I - activity-lever engine control/continous brake (16).
see page 4/28.
0 15 07 Cooling-water temperature pick-up: I– – I - Short-cut to ground in the signal-path to cooling-water

temperature pick-up (19)
see page 4/30.
0 15 41 Cooling-water temperature pick-up: I– – I + or –//– Short-cut to Ubat or interruption in the signal-path to

cooling-water temperature pick-up (19).
see page 4/30.
0 16 07 Oil temperature pick-up: I – –I - Short-cut to ground in the signal-path to oil temperature pick-up (20).
see page 4/31.
0 16 41 Oil temperature pick-up: I – –I + or –//– Short-cut to Ubat or interruption in the signal-path to

oil temperature pick-up (20).
see page 4/31.

53.2693.10 Page 4/23
1 01 10 CAN-terminal of retarder control unit or Retarder control unit (2) does not receive data-telegram from
CAN-star point: Malfunction of communication vehicle CAN-Bus.
Check CAN-Bus.
1 01 13 CAN-terminal of retarder control unit: –//– Malfunction of communication between retarder control unit (2) and
star point vehicle CAN-Bus.
Check connections, leads and star point vehicle CAN-Bus.
1 02 11 ABS/BS sends constantly or at times wrong Check ABS or BS (EPB).

system-signal
1 02 12 ABS/BS: constantly or at times lacking Check ABS or BS (EPB).

CAN-telegram
1 03 11 FR sends constantly or at times wrong Check FR (FMR).

system-signal
1 03 12 FR: constantly or at times lacking CAN-telegram Check FR (FMR).
1 08 20 Retarder control unit: Internal fault Replace retarder control unit.
1 09 02 Connection Terminal 30: Undervoltage or –//– Undervoltage (< 17,5 V) at connection terminal 30 or line break in the signal
path to basic module.
see page 4/32.

53.2693.10 Page 4/24
1 10 01 Connection terminal 15: Overvoltage Overvoltage (> 33 V) at connection terminal 15.
see page 4/32.
1 10 02 Connection terminal 15: Undervoltage or –//– Undervoltage (< 17,5 V) at connection terminal 15 or line break in the signal
path to basic module.
see page 4/32.
1 13 30 Proportional valve-outputs: I– –I + Shortcut to Ubat in signal path to proportional valve (21) or shortcut of both out-
puts to proportional valve (21).
see page 4/33.
1 13 31 Proportional valve-outputs: –//– or I– – I - Shortcut to ground or interrupt in signal path to proportional valve (21).
see page 4/33
1 13 32 Proportional valve-outputs Replace retarder control unit.

(The fault is only recognized with activation of the proportional-valve after 10
seconds)

53.2693.10 Page 4/25
1 15 07 Cooling-water temperature pick-up: I– – I - Shortcut to ground in signal path to cooling-water temperature pick-up (19).
see page 4/34.
1 15 41 Cooling-water temperature pick-up: I– – I + or –//– Shortcut to Ubat or interruption in signal path to cooling-water temperature
pick-up (19).
see page 4/34.

53.2693.10 Page 4/26
Troubleshooting with actual error code
Note
Meaning of entries in „Measurement/test connection“ column: X 1/15 Ω X3/11

Pin 15 to plug X1 (retarder control unit), Multimeter set for Ohms, Pin 11 to plug X3 (retarder control unit)
Fault Fault text Fault Trigger Requirement / Measurement/ Result/ Cause/

class time Operation Test Set point Remedy 2)
connection1 )
Code Test step
0 11 05 1 Actuating lever slight – - Ignition: OFF X1/15 V X1/4 <2V Check lead, plug and
engine control/ - Disconnect plug X1/5 actuating lever engi-
continous brake: X1 of retarder X1/6 ne control/continous
I – –I + control unit (2) X1/8 brake (16)
- Ignition: ON X1/9
X1/10
X1/17

53.2693.10 Page 4/27

class time Operation Test Set point Remedy 2)
connection 1 )
Code Test step
0 11 40 1 Actuating lever slight – - Ignition: OFF X1/10 Ω X1/17 < 5Ω Check lead, plug and
engine control/ - Disconnect plug X1 actuating lever engi-
continous brake: of retarder control ne control/continous
mechanical de- unit (2) brake (16)
fect, –//– or I– – I - Switch actuating le-
- ver engine control/
continous brake (16)
in stage 0 of conti-
nous brake function
2 - Ignition: OFF X1/10 Ω X1/4 < 5Ω Check lead, plug and

- Disconnect plug X1 X1/5 actuating lever engi-
of retarder control X1/6 ne control/continous
unit (2) X1/8 brake (16)
- Switch actuating le- X1/9
ver engine control/
in highest stage of
continous brake
function

53.2693.10 Page 4/28

class time Test Set point Remedy 2)
Operation
connection 1 )
Code Test step
0 11 40 3 - Ignition: OFF X1/15 Ω X1/4 > 5Ω Check lead, plug and

ver engine control/ X1/10
continous brake (16) X1/17
in highest stage of
continous brake
function
4 - Ignition: OFF X1/10 Ω X1/17 > 5Ω Check lead, plug and

- Disconnect plug X1 actuating lever engi-
of retarder control ne control/continous
unit (2) brake (16)
- Switch actuating le-
ver engine control/
in highest stage of
continous brake
function

53.2693.10 Page 4/29

Operation
connection 1 )
Code Test step
0 11 40 5 - Ignition: OFF X1/10 Ω X1/4 > 5Ω Check lead, plug and

ver engine control/
in stage 0 of conti-
nous brake function
0 15 07 Cooling-water slight – - Ignition: OFF – error code Check leads, plugs

temperature - Disconnect plug X2 0 15 41 or and cooling-water
pick-up: of retarder control 1 15 41 temperature pick-up
I – –I - unit (2) actual (19)
- Ignition: ON
- Read out actual error
code
0 15 41 1 Cooling-water slight – - Ignition: OFF X2/5 Ω X2/4 < 2 kΩ Check leads, plugs
temperature - Disconnect plug X1 and cooling-water
pick-up: of retarder control temperature pick-up
I – –I + or –//– unit (2) (19)

53.2693.10 Page 4/30

Operation
connection 1 )
Code Test step
0 15 41 2 - Ignition: OFF X2/5 V X2/4 0V Check leads, plugs

- Disconnect plug X2 and cooling-water
of retarder control temperature pick-up
unit (2) (19)
- Ignition: ON
0 16 07 Oil temperature slight – - Ignition: OFF – error code Check leads, plugs
pick-up: I– –I - - Disconnect plug X2 0 16 41 or and oil temperature
of retarder control 1 16 41 pick-up (20)
unit (2) actual
- Ignition: ON
code
0 16 41 1 Oil temperature slight – - Ignition: OFF X2/9 Ω X2/8 < 2 kΩ Check leads, plugs
pick-up: - Disconnect plug X2 and oil temperature
I – –I + or –//– of retarder control pick-up (20)
unit (2)
2 - Disconnect plug X2 X2/9 V X2/8 0V Check leads, plugs

of retarder control and oil temperature
unit (2) pick-up (20)
- Ignition: ON

53.2693.10 Page 4/31

Operation
connection 1 )
Code Test step
1 09 02 Connection ter- heavy 60 s - Ignition: OFF X1/15 V X1/13 > 17,5 V Check battery volta-
minal 30: Under- - Disconnect plug X1 ge, leads and plugs
voltage or –//– of retarder control
unit (2)
- Ignition: ON
1 10 01 Connection ter- heavy 10 s - Ignition: OFF X1/15 V X1/7 < 33 V Check regulator and
minal 15: Over- - Disconnect plug X1 generator
voltage of retarder control
unit (2)
- Ignition: ON
- Start engine and let
run in the middle
speed range
1 10 02 Connection ter- heavy 60 s - Ignition: OFF X1/15 V X1/7 > 17,5 V Check battery volta-
minal 15: Under- - Disconnect plug X1 ge, leads and plugs
voltage or –//– of retarder control
unit (2)
- Ignition: ON

53.2693.10 Page 4/32

Operation
connection 1 )
Code Test step
1 13 30 1 Proportional val- heavy 1s - Ignition: OFF X1/15 V X2/3 < 10 V Check leads, plugs
ve -outputs: - Disconnect plug X1 and proportional val-
I – –I + and X2 of retarder ve
control unit (2)
- Ignition: ON
1 13 30 2 - Ignition: OFF X2/3 Ω X2/2 ≥ 18 Ω Check leads, plugs

- Disconnect plug X1 and proportional val-
of retarder control ve
unit (2)
1 13 31 1 Proportional val- heavy 60 s 3)

- Ignition: OFF X2/3 Ω X2/2 ≤ 25 Ω Check leads, plugs
ve -outputs: –//– - Disconnect plug X2 and proportional val-
or I– – I - of retarder control ve
unit (2)
2 - Ignition: OFF X1/15 Ω X2/2 > 2 kΩ Check leads, plugs

- Disconnect plug X2 X2/3 and proportional val-
of retarder control ve
unit (2)
- Disconnect plug X1
of retarder control
unit (2)
3)
Bis Steuergeräte-Version 13: Fehler wird erst bei Ansteuerung des Proportionalventils erkannt

53.2693.10 Page 4/33

Operation
connection 1 )
Code Test step
1 15 07 Cooling-water heavy – - Ignition: OFF – error code Check leads, plugs

temperature - Disconnect plug X2 0 15 41 or and cooling-water
pick-up: of retarder control 1 15 41 temperature pick-up
I – –I - unit (2) actual (19)
- Ignition: ON
code
1 15 41 1 Cooling-water heavy – - Ignition: OFF X2/5 Ω X2/4 < 2 kΩ Check leads, plugs
temperature - Disconnect plug X2 and cooling-water
pick-up: of retarder control temperature pick-up
I – –I + or –//– unit (2) (19)
2 - Ignition: OFF X2/5 V X2/4 0V Check leads, plugs

- Disconnect plug X2 and cooling-water
of retarder control temperature pick-up
unit (2) (19)
- Ignition: ON
1)
X1/15 = Ground control unit
2) Only, if no fault is recognizable after a complete check of the periphery: change control unit.

53.2693.10 Page 4/34
Troubleshooting with memorized error code
M+P-07A-1839 75
Jobe scope
1. Read error codes out of error memory and note them
(green coloured field of display-matrix (75), see page 4/20).
2. Determine relevant component(s), on the basis of the error code (see page 4/22).
3. Check cables, plugs, plug and socket connections, fuses and electric components on damage, right
connection, loose contact, corrosion and so on, renew if necessary.
4. Delete error memory (see page 4/21).

12033
5. Perform functional check (see page 4/55).

53.2693.10 Page 4/35
Diagnosis / 4.3 Overview Control Parts
Troubleshooting
Illustration Control Scheme
2 Retarder control unit M+P-07A-1840 11

11 Connection proportional valve
current 71 33
25 Constant-air pressure line p y 32
25 61
(connection A)
26 Supply-air pressure line pv A
31 Compressed-air line P
(pressure regulator-four circuit R
protection valve) 26
32 Compressed-air line (four circuit 36 3700
protection valve air tank for auxiliary 31
equipment) with test connection 35 34
33 Compressed-air line (Brake circuit 1)
34 Compressed-air line (Brake circuit 2)
40
35 Compressed-air line (Parking brake)
36 Ventilation line „R“ 2
39 Electrical lead (cooling-water 39 5900/2
temperature pick-up to control unit, 5900/1
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
3300 Heat exchanger
5900/1 Cooling-water temperature pick-up
5900/2 Oil temperature pick-up
3300
12034

53.2693.10 Page 4/36
Diagnosis / 4.4 Checking Supply-Air Pressure
Troubleshooting
Job scope test

1. Connect test pressure gauge (99/1) to test connection of compressed-air line (32)
(four circuit protection valve - air tank for auxiliary equipment) and check supply-air pressure p v . M+P-07A-1841
Minimum pressure: 6 bar
Maximum pressure: 11 bar
Note
If the pressure is not within the specified range, the service brake must be checked to the manufacturer´s 32 12035
data.

53.2693.10 Page 4/37
Diagnosis / 4.5 Checking Constant-Air Pressure (py)
Troubleshooting

• Battery voltage 22,5 - 29,5 V.
satisfactory.
• Compressed air 6 - 11 bar.
• Vehicle ignition system: OFF
Special tool
53.1403.10
Compressed-air gauge
0 - 6 bar

53.2693.10 Page 4/38
Diagnosis / 4.5 Checking Constant-Air Pressure (py)
Job scope test

1. Screw out screw plug (2909) and remove sealing ring (2910) (depending on accessability). 2909
M+P-07A-1949
2909
2910
12014
2. Connect pressure gauge (99/1) at bore of oil filler plug (M 30 x 1,5, 2909).
99/1
3. Activate service function of retarder (see chapter 3.4). M+P-07A-1956
4. Switch actuating lever engine control/continous brake (16) in highest stage of continous brake
function and compare read-off value with determined value of constant-air pressure (p y ) according
to table on page 4/55.
5. Disconnect pressure gauge (99/1).
6. Screw in screw plug (2909) with new sealing ring (2910) tight.
12037
99/1 Pressure gauge 53.1403.10

53.2693.10 Page 4/39
Diagnosis / 4.6 Checking Control Current of Proportional Valve
Troubleshooting

satisfactory.
• Check plug at proportional valve and socket for damage as well as wear (notch scratches).
• Ignition: OFF
Special tool
53.8198.10
Measuring adapter
prop current
Commercially available tool
Multimeter recommended: Fluke 87

53.2693.10 Page 4/40
Diagnosis / 4.6 Checking Control Current of Proportional Valve
Job scope test

99/8
1. Disconnect plug at proportional valve (3700) and connect with measuring adapter prop current
(99/3). M+P-07A-1843
3700
2. Connect plug of measuring adapter prop current (99/3) to proportional valve (3700).
3. Connect multimeter (98/8). Switch position: mA.
4. Turn switch „prop current“ at measuring adapter in position „I“.
5. Activate service function of retarder (see chapter 3.4).

99/3
6. Switch actuating lever engine control/cintinous brake (16) in highest stage of continous brake
12038
function and compare value with determined value according to table on page 4/55.
99/3 Measuring adapter „Prop current“ 53.8198.10
99/8 Multimeter

53.2693.10 Page 4/41
Diagnosis / 4.7 Checking Temperature Adaption
Troubleshooting
Prior job
• Connected air-pressure gauge (53.1403.10)
(see chapter 4.5 „Checking constant-air pressure „p y “, page 4/38).

satisfactory.
• Ignition OFF
Note
The working steps for serial- and inter-solution differ from each other.
– Inter-solution: see page 4/43.

(Central-plug for proportional valve and cooling-water temperature pick-up, separate plug-connec-
tion for oil temperature pick-up)
– Serial-solution: see page 4/46.

(Central-plug for proportional valve, cooling-water temperature pick-up and oil temperature pick-up)

53.2693.10 Page 4/42
Version inter-solution
(Central-plug for proportional valve and cooling-water temperature pick-up, separate plug-connection for
oil temperature pick-up)
Special tools
Wasser Öl
53.1403.10 53.8207.10 53.8277.10
Compressed-air gauge Temperature simulator Adapter cable

0-6 bar

53.2693.10 Page 4/43
Job scope test

1. Disconnect connector central plug (84) .
M+P-07A-1844
2. Disconnect connector (85) for oil temperature pick-up. 84
3. Disconnect plug of connecting lead from proportional valve.
85
12039
4. Connect adapter lead (99/8) to central plug (84).
5. Connect temperature simulator (99/2) with appropriate lead of adapter lead (99/8). 99/8
M+P-07A-1845
6. Connect appropriate lead of adapter lead (99/8) to proportional valve.
7. Connect temperature simulator (99/2) to connecting lead (85) of oil temperature pick-up. 84
Note
Heed labeling of plugs. 99/2

85 12040
99/8 Adapter lead 53.8277.10

99/2 Temperature simulator 53.8207.10

53.2693.10 Page 4/44

99/8
9. Set rotary switch of temperature simulator (99/2) to 95°C cooling-water temperature and 165°C oil M+P-07A-1845
temperature.
10. Shift actuating lever of engine control/continous brake in highest stage of continous brake function. 84
Temperature adaption cooling-water:
11. Set rotary switch of temperature simulator (99/2) to 105 °C cooling-water temperature.
- The constant-air pressure (p y ) must drop approx. 1 bar for around 5 seconds and then slowly
99/2
rising.
85 12040
12. Set rotary switch of temperature simulator (99/2) to 125 °C cooling-water temperature. 99/8 Adapter lead 53.8277.10
- There must be no more output of constant-air pressure (p y ). 99/2 Temperature simulator 53.8207.10
13. Set rotary switch of temperature simulator (99/2) again to 95 °C cooling-water temperature.
Temperature adaption oil:
14. Set rotary switch of temperature simulator (99/2) to 185 °C oil temperature.
- The constant-air pressure (p y ) must drop approx. 0,5 bar.
- There must be no more output of constant-air pressure (p y ).
16. Disconnect adapter lead (99/8) and temperature simulator (99/2) and complete the vehicle.

53.2693.10 Page 4/45
Version serial-solution
(Central-plug for proportional valve, cooling-water temperature pick-up and oil temperature pick-up)
Sonderwerkzeuge
Wasser Öl
53.1403.10 53.8207.10 53.8278.10
Compressed-air gauge Temperature simulator Adapter lead

0-6 bar

53.2693.10 Page 4/46
Job scope test

1. Disconnect connector central plug (83).
M+P-07A-1846
83
2. Disconnect plug of connecting lead from proportional valve.
12041
3. Connect adapter lead (99/9) to central plug (83).

83
99/9
4. Connect temperature simulator (99/2) with appropriate lead of adapter lead (99/9). M+P-07A-1847
Note
Heed labeling of plugs.
5. Connect appropriate lead of adapter lead (99/9) to proportional valve. 99/2

12042
99/2 Temperature simulator 53.8207.10

99/9 Adapter lead 53.8278.10

53.2693.10 Page 4/47

83
99/9
7. Set rotary switch of temperature simulator (99/2) to 95°C cooling-water temperature and 165°C oil M+P-07A-1847
temperature.
8. Shift actuating lever of engine control/continous brake in highest stage of continous brake function.
Temperature adaption cooling-water:
9. Set rotary switch of temperature simulator (99/2) to 105 °C cooling-water temperature.

- The constant-air pressure (p y ) must drop approx. 1 bar for around 5 seconds and then slowly
99/2
rising.
12042
10. Set rotary switch of temperature simulator (99/2) to 125 °C cooling-water temperature. 99/2 Temperature simulator 53.8207.10
- There must be no more output of constant-air pressure (p y ). 99/9 Adapter lead 53.8278.10
11. Set rotary switch of temperature simulator (99/2) again to 95 °C cooling-water temperature.
Temperature adaption oil:
- The constant-air pressure (p y ) must drop approx. 0,5 bar.
- There must be no more output of constant-air pressure (p y ).
14. Disconnect adapter lead (99/9) and temperature simulator (99/2) and complete the vehicle.

53.2693.10 Page 4/48
Diagnosis / 4.8 Checking Pump Pressure
Troubleshooting
Illustration checking pump pressure
111 Sealing ring A12x18, renew M+P-07A-1957

112 Screw plug M12x1,5
Inhex.-head, w.a.f. 6, 25 Nm
111
112
12043

53.2693.10 Page 4/49
Prior jobs for test

satisfactory.
• Compressed-air pressure 6 - 11 bar.
• No outer leaks at retarder.
• Ignition: OFF
Note
The pump pressure check provides information on mechanical condition of rotating parts, internal leaks
and the correct operation of the retarder.
Special tools
Vo
Coith Sa
Se de-N ch
Kurien- r.: -Nr.:
nd Nr 53
en .:
-N xx .xxxx
r.: xxx .12
xx
/ Da
tum
53.4788.10 53.8293.01
Compressed-air gauge Test control unit

0 – 25 bar

53.2693.10 Page 4/50
Job scope test

1. Open electronic-box of the vehicle.
M+P-07A-1849
2. Pull out retarder control unit and disconnect plugs.
3. Connect plugs with test control unit (91/1) and push back into electronic-box.
Note 91/1
The test control unit (91/1) must lock.

12044
91/1 Test control unit 53.8293.01

4. Screw out screw plug (112) and remove sealing ring (111).
M+P-07A-1850
Caution!
Little oil-exit is construction-conditional possible, however has no effect on the function of the retarder.
111
112
12045

53.2693.10 Page 4/51
5. Connect pressure gauge (99/1) to retarder housing.
6. The necessary prop shaft-speed during the trip depends on the retarder-ratio. M+P-07A-1851
At retarder-ratio iRet = 2 drive with prop shaft-speed 1000 r.p.m..
At retarder-ratio iRet = 1,85 drive with prop shaft-speed 1100 r.p.m..
99/1
Hinweis
Shift direct gear (gear ratio 1:1). Engine speed corresponds than prop shaft-speed.
7. Shift, while on the move, actuating lever engine control/continous brake in highest continous brake
function and read pump pressure off test pressure gauge (99/1) at prop shaft speed mentioned 12046
above. 99/1 Pressure gauge 53.4788.10
8. Compare read-off pump pressure with the minimum value of dynamic pump pressure according to
table on page 4/55.
Caution!
If the constant-air pressure (p y ) is obtained in the test at a standstill (see page 4/38) but the minimum
value of the dynamic pump pressure is not reached, please contact your Voith service partner.
Hot oil may escape when disconnecting the pressure gauge (99/1)!

53.2693.10 Page 4/52
9. Screw in screw plug (112) with new sealing (111) tight.

M+P-07A-1850
111
112
12045
10. Pull out test control unit (91/1) and disconnect plugs.
11. Connect plugs to retarder control unit und push it back into electronic-box. M+P-07A-1849
Note
The retarder control unit must lock.

91/1
5. Lock electronic-box of vehicle.

12044
6. Read out error-memory (see page 4/20) and delete error-codes, if necessary (see page 4/21).
91/1 Test control unit 53.8293.01

53.2693.10 Page 4/53
Diagnosis / 4.9 Table of Measurements
Troubleshooting
Control current 1 ) 2 ) 3) Constant-air pressure (py) 1 ) 4)

Pump pressure (dynamic) 1)
[mA] (static) Minimum value

[bar] [bar]
534 – 546 2,7 – 3,0 19
1)
Actuating lever engine control/continous brake (16) in highest stage of continous brake function.
2)
If a commercially available multimeter is used for measurements (without real effective measuring) exact readings
cannot be made (indication jumps!).
3)
Because of continuous controlling in the control circuit the values conceivably are not constant, however within the
stated area.
4)
Decisive is the pressure which has built up itself after 10 seconds (stabilized, constant pressure).
Note
These values represent the state of the art at the time going to print.The manufacturer reserves the right to make further
modifications.

53.2693.10 Page 4/54
Diagnosis / 4.10 Operational Control
Troubleshooting
Functional test via instantaneous value (measuring values and binary values)
M+P-07A-1839 75
• Battery voltage 22,5 bis 29,5 V.
satisfactory.
Read out measuring values

Switch on diagnosis-operation of the retarder and call constantaneous values (see page 4/20).
The constantaneous values MW01 until MW12 are shown on the green coloured field of the
display-matrix (75).
12033
Display-examples measurements: RS MW01
+25
Note
Before version 1.4 of the retarder control unit (Voith-item number 53.8150.13) became shown abbrevia-
tion "RS" instead of the abbreviation „RET“.
If, on the green coloured field of the display-matrix (75) instead of the constantaneous values only lines
are shown, the measuring value is not available.
Display-examples measurements: RS MW01

– – – –– –

53.2693.10 Page 4/55
RS-constan- Constantaneous value Prerequisite Desired value Hints, Cause / Remedy

taneous va- meaning Actuation
lue No.
MW01 Temperature cooling-water Ignition: ON Current cooling-water

temperature
Display-examples: R S MW0 1
+2 5
The current cooling-water tempe-
rature is shown in °C
Constantaneous-value Troubleshooting according chapter 4.1 „Troubles-
range: hooting-Diagram“, page 4/3.
– 50 to + 200 °C
MW02 Temperature retarder oil Ignition: ON Current retarder-oil tem-

perature
+2 5
The current retarder-oil tempera-
ture is shown in °C
– 30 bis + 220 °C
MW03 Position actuating lever

engine control/continous brake
Ignition: ON Current position of the
actuating lever engine
3
control/continous brake
The current position of the actua-
Troubleshooting according chapter 4.1 „Troubles-
ting lever engine control/continous
Constantaneous-value hooting-Diagram“, page 4/3.
brake is shown.
range:
0 bis 5

53.2693.10 Page 4/56
RS-constanta- Constantaneous value Prerequisite Desired value Hints, Cause / Remedy

neous value meaning Actuation
No.
MW04 Ratio Ignition: ON Momentary ratio

The momentary ratio gearbox
Constantaneous-value Note
output speed/vehicle speed is
range:
shown.
500 bis 6500 The ratio becomes, after switching on the ignition,
The constantaneous value
shown only from a vehicle speed of at least 10 km/hs
corresponds to one hundredth of
the indicated value: constanta-
neous value = indicated value /
150 0
100
hooting-Diagram“, page 4/3.
MW05 Maximum retarder torque Ignition: ON Maximum retarder-bra-

king torque
310 0
The maximum retarder braking
torque is shown in Nm.
0 bis 3100
MW06 Retarder torque (desired) Ignition: ON Ordered retarder-bra-

king torque
0
The retarder-braking torque
ordered by the control unit FR
(FMR) is shown in Nm
0 bis 3100

53.2693.10 Page 4/57

No.
MW07 Retarder torque (actual) Ignition: ON Momentary retarder-bra-

king torque
0
The momentary retarder-braking
torque is shown in Nm
0 bis 3100
MW08 Proportionalventilstrom Ignition: ON Momentary proportional

valve current
0
The momentary current is shown
in mA, which operates the retar-
der proportional valve.
0 bis 600
MW09 Gearbox-output speed Ignition: ON Momentary gearbox-

output speed
0
The momentary gearbox-output
speed is shown in r.p.m..
0 bis 3000
MW10 Engine speed Ignition: ON Momentary engine

speed
0
The momentary engine speed is
shown in r.p.m..

53.2693.10 Page 4/58

No.
MW11 Vehicle speed Ignition: ON Momentary vehicle

speed.
0
The momentary vehicle speed is
shown in km/h.
MW12 Battery voltage

(Terminal 15)
Ignition: ON Momentary battery
voltage
24 0
The momentary battery voltage
at terminal 15 is shown in Volt.
The constantaneous value cor-
responds to one hundredths of
the indicated value:
constantaneous value =
indicated value / 10

53.2693.10 Page 4/59
Read-out of binary values

Switch on diagnostic operation of retarder and call instantaneous values (see page 4/20).
The instantaneous values BW01 to BW02 are shown on the green coloured field of the display-matrix M+P-07A-1839 75
(75).
Display example measuring values:
R S B W 0 1
BW1 0 0 0 0 0 0 0 0
Bit 0 12033
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7

53.2693.10 Page 4/60

No.
BW01 Cruise control Ignition: ON 00 = not active

01 = active
Display-examples: R S BW0 1
00 01 00 00
It is shown whether the cruise
Bit 7 and 6 control is switched on.
Bit 5 and 4 Idling Ignition: ON 00 = not active Display-examples: R S BW0 1

01 = active 00 01 00 00
It is shown whether the idling-
switch is actuated
Bit 3 and 2 ABS-Control Ignition: ON 00 = not active Display-examples: R S BW0 1

01 = active 00 01 00 00
It is shown whether the ABS is
active.
Bit 1 and 0 Retarder condition Ignition: ON 00 = not active Display-examples: R S BW0 1

01 = active 00 01 00 00
It is shown whether the retarder
is in operation.

53.2693.10 Page 4/61

No.
BW02 Pilot light Ignition: ON 00 = off

01 = on
Display-examples: R S BW0 2
00 00 01 11
It is shown whether the retarder
Bit 7 and 6 10 = flashing
pilot light is getting contact.
Bit 5 and 4 Generator D + Ignition: ON 00 = no malfunction Display-examples: R S BW0 2

10 = malfunction 00 00 01 11
It is shown whether the genera-
tor has got a malfunction.
Bit 3 and 2 Speedometer signal „Zero“ Ignition: ON 00 = not zero Display-examples: R S BW0 2
01 = zero 00 00 01 11
It is shown whether the vehicle is
in standstill condition.
Bit 1 and 0 No signal Ignition: ON 11 = Signal not Display-examples: R S BW0 2

available 00 00 01 11

53.2693.10 Page 4/62
Operational control in standstill and by test trial
Test Scope of Requirement / Result / Desired value Hints, Cause / Remedy

step check Operation
1 Retarder Engine: In idling From the proportional valve, Test-step 2

Vehicle: standstill pressure becomes charge
Shift actuating lever engine control/continous (pulsatile blowing noise).
brake in stage 3 to 5 of continous brake function
From the proportional valve, Troubleshooting according chapter 4.1
no pressure becomes charge, „Troubleshooting-Diagram“, page 4/3.
error code is displayed.
2 Retarder Vehicle: moving On the red coloured field of End of test

Shift actuating lever engine control/continous the display-matrix, no error is
brake in stage 3 to 5 of continous brake function shown and the retarder
brakes faultlessly
On the red coloured field of Troubleshooting according chapter 4.1

the display-matrix, a current „Troubleshooting-Diagram“, page 4/3.
error is shown or the retarder
doesn't brake correct.

53.2693.10 Page 4/63
Retarder Remo- 5 Removing, Installing Retarder
ving, Installing
5.1 Removing, Installing Retarder ............................................................... 5/2

53.2693.10 Page 5/1
Retarder Remo- 5.1 Removing, Installing Retarder
ving, Installing
Illustration removing, installing retarder
M+P-07A-1958
83 60
26
700
84
95/1
97
85
96
12047
Prior jobs Lubricants and locking agents

• Ignition OFF
• Retarder OFF O-ring Silicone-free and
• Discharged supply-air pressure non-corrosive grease
• Drained oil of retarder (see chapter 3.3)
Collar nut Loctite 270
26 Supply-air pressure pipe (p v )

60 Retarder
83 Plug connection central-plug
(only at serial-solution) Caution!
84 Plug connection central-plug
(only at inter-solution) Observe Voith installation instructions! These have to be requested from
85 Plug connection oil temperature pick-up Voith Turbo.
(only at inter-solution) Should these installation instructions be disregarded, the retarder may be
95/1 Collar nut with rib toothing completely wrecked.
96 Hose clamp
97 Connecting piece
700 O-ring 164x3 renew
Note
If retarder is stored with installed heat exchanger longer than 6 weeks in

Note stock, the heat exchanger must be removed and preserved.
For preservation fill heat exchanger on oil-side with engine oil and on water-
Alternative are the plug connections (84 and 85, inter-solution) or the plug side with coolant. Lock openings of heat exchanger with plastic-plugs
connections (83, serial-solution) installed. afterwards.
The preservation-process must be repeated after at the latest 3 years.

53.2693.10 Seite 5/2
ving, Installing (Continue)
Removing, Installing
1. Push an oil collecting pan under the retarder.
M+P-07A-1853
96
The coolant is hot!
2. Release hose clamps (96) left and right and remove carefully connecting piece (97) 97
from heat exchanger.
12048
3. Disconnect supply-air pressure pipe (26).
M+P-07A-1959
26
12049

53.2693.10 Page 5/3
Note M+P-07A-1844
Alternative are plug connections (84 and 85, inter-solution) or plug connections (83, serial-solution) 84
installed.
4. Inter-solution:
Disconnect plug connection retarder (84 and 85) and lay bare electrical connection leads to the
retarder. 85
12039
Serial-solution:
Disconnect plug connection (83).
M+P-07A-1846
83
12041

53.2693.10 Page 5/4
5. Support retarder (60).
6. Unscrew collar-nuts (95/1). M+P-07A-1960 700

60
Note for installation:
The tightening torque for collar nuts (95/1) is 110 Nm.
7. Remove retarder (60) from gearbox and downward out.
8. Remove O-ring (700).

Coat new O-ring (700) with silicone-free and non-corrosive grease. 95/1
12050
9. Proceed with installation in reverse sequence.
10. Fill in coolant into cooling-system and check for leak.

Heed statements of the manufacturer respecting coolant-quality
as well as the statements of Voith Turbo.

53.2693.10 Page 5/5
Repair 6 Repair
6.1 Overall Illustration of Main Components .......................................................................... 6/2

- Version Inter-Solution..................................................................................................... 6/2
- Version Serial-Solution................................................................................................... 6/3
6.2 Removing, Checking and Installing Casing Ventilation ..................................................... 6/4
6.3 Removing, Cleaning and Installing Silencer.................................................................... 6/13
6.4 Removing, Checking and Installing Heat Exchanger ...................................................... 6/14
6.5 Removing, Installing Top Oil Tank Cover........................................................................ 6/20

- Version Inter-Solution................................................................................................... 6/20
- Version Serial-Solution................................................................................................. 6/21
6.6 Removing, Installing Bottom Oil Tank Cover................................................................... 6/22
6.7 Removing, Installing Oil Tank.......................................................................................... 6/24

- Version Inter-Solution................................................................................................... 6/24
- Version Serial-Solution................................................................................................. 6/27

53.2693.10 Page 6/1
Repair 6.1 Overall Illustration of Main Components
Illustration main components R 115 H
2905
2909
M+P-07A-1961 3850
2910 6500
3800
2800 2913
3850
6500 2904
2700
3900
4100
2906
2909
3700
2400 2500 2910
6600 4000
3000
2600 2923
3600 2300 2922
6700
2301 6710
100
5900/2
3600 2900 3000 5200
3000 5000 3500
3100
3500
2000 5900/1
2915 6720
3600 2912
3000 3300
2911
111 2921 2914
2913
112 2920
7100 7000 4800 2918
2000
2919
4700
12051
100 Retarder housing 2922 Oil check plug M24x1,5

111 Sealing ring A12x18 2923 Sealing ring A24x29
112 Screw plug M12x1,5 3000 O-ring 15x4
2000 O-ring 60x5 3100 O-ring 45x5
2300 Casing ventilation 3300 Heat exchanger
2301 O-ring 55x3 3500 Anti-fatigue screw M14x65
2400 Cover casing ventilation 3600 Anti-fatigue screw M14x150
2500 Gasket 3700 Proportionalventil
2600 Spacer D60/41x2 3800 Damping plate
2700 Hex.-head screw M8x80 3850 O-ring 16 x 3
2800 Hex.-head screw M8x30 3900 Hex.-head screw M8x60
2900 Oil tank 4000 Hex.-head nut M8
2904 Top oil tank cover 4100 Hex.-head screw M8x65
2905 Hex.-head screw M8x40 4700 Screw plug with sieve M30x1,5
2906 Gasket 4800 Sealing ring A30x36
2909 Oil filler plug M30x1,5 5000 O-ring 10x3
2910 Sealing ring A30x36 5200 Washer 31/31x4 D14,5
2911 Bottom oil tank cover 5900/1 Cooling-water temperature pick-up
2912 Gasket 5900/2 Oil temperature pick-up
2913 Hex.-head screw M8x30 6500 Fastener
2915 O-ring 7x2,5 6700 Fastener
2918 Sealing ring A20x26 6710 Hex.-head screw M6x16
2919 Central oil-drain plug M20x1,5 6720 Hex.-head nut M6
2920 O-ring 10x3 7000 Disc (silencer) D30x4
2921 O-ring 6x3 7100 Circlip JL30x1,2

53.2693.10 Page 6/2
Repair 6.1 Overall Illustration of Main Components
(Continue)
Illustration main components R 115 H
2905
2909
M+P-07A-1962 3850
2910 6500
2800 3800
6700 2913
3850
2700
2904
6800
3900
4100
2906
2909
3700
2400 2500 2910
6600 4000
3000
2600 2923
3600 2300 2922
2301
100
5900/2
3600 2900 3000 5200
3000 5000 3500
3100
3500
2000 5900/1
2915
3600
2912
3000 3300
2911
111 2921 2914
2913
112 2920
7100 7000 4800 2918
2000
2919
4700
12052
100 Retarder housing 2922 Oil check plug M24x1,5

111 Sealing ring A12x18 2923 Sealing ring A24x29
112 Screw plug M12x1,5 3000 O-ring 15x4
2000 O-ring 60x5 3100 O-ring 45x5
2300 Casing ventilation 3300 Heat exchanger
2301 O-ring 55x3 3500 Anti-fatigue screw M14x65
2400 Cover casing ventilation 3600 Anti-fatigue screw M14x150
2500 Gasket 3700 Proportionalventil
2600 Spacer D60/41x2 3800 Damping plate
2700 Hex.-head screw M8x80 3850 O-ring 16 x 3
2800 Hex.-head screw M8x30 3900 Hex.-head screw M8x60
2900 Oil tank 4000 Hex.-head nut M8
2904 Top oil tank cover 4100 Hex.-head screw M8x65
2905 Hex.-head screw M8x40 4700 Screw plug with sieve M30x1,5
2906 Gasket 4800 Sealing ring A30x36
2909 Oil filler plug M30x1,5 5000 O-ring 10x3
2910 Sealing ring A30x36 5200 Washer 31/31x4 D14,5
2911 Bottom oil tank cover 5900/1 Cooling-water temperature pick-up
2912 Gasket 5900/2 Oil temperature pick-up
2915 O-ring 7x2,5 6700 Fastener
2918 Sealing ring A20x26 6800 Fastener
2919 Central oil-drain plug M20x1,5 7000 Disc (silencer) D30x4
2920 O-ring 10x3 7100 Circlip JL30x1,2
2921 O-ring 6x3

53.2693.10 Page 6/3
Repair 6.2 Removing, Checking and Installing
Casing Ventilation
Illustration casing ventilation

2800 2905
M+P-07A-1963 4100
Prior jobs
2700
2300/1 6700
• Ignition OFF
• Retarder OFF
2800
2301 2700
2300 Casing ventilation
2400
2300/1 Valve insert 2300
2300/2 Float, specified weight: 10 - 12 g 2300/2
2300/3 Float cage 2500 6800
2301 O-ring 55x3 2300/3
2400 Cover casing ventilation
2500 Gasket, renew
2600 Spacer D60/41x2 2600
2700 Hex.-head screw M8x80
Hex.-head, w.a.f. 13
renew, 25 Nm
Hex.-head, w.a.f. 13 2800
renew, 25 Nm
2905 Hex.-head screw M8x40 6500
renew, initial torque: 17 Nm
Final turn: 25 Nm
(remove only in serial-solution)
renew, 25 Nm 12053
6500 Fastener (only at inter-solution)

6700 Fastener (only at serial-solution)
6800 Fastener (only at serial-solution)

53.2693.10 Page 6/4
Casing Ventilation (Continue)
Lubricants and sealing agents
O-ring Silicone-free and

Float Methylated Spirit
Special tools Tool for local fabrication
Ø 40,5 mm
Ø 7 mm
Ø 60 mm
53.7712.10 53.9428.10 Material: St 37

Weight: 0,085 kg 12091
Impact puller Adapter Test ring

53.2693.10 Page 6/5
To remove
2700
M+P-07A-1860
Note 2800 4100
Alternative are either a Fastener (6500, inter-solution) or two fastener (6700 and 6800, serial-solution)
installed. 6500
1. Inter-solution:
Screw out hex.-head screws (2700, 2800 and 4100) and remove fastener (6500).
12055
Serial-solution:
Screw out hex.-head screw (2905) as well as all hex.-head screws (2700, 2800 and 4100) and
remove fastener (6700 and 6800). 2800 2905
M+P-07A-1964
6700 4100
2700
6800
12056

53.2693.10 Page 6/6
2. Remove cover casing ventilation (2400) with gasket (2500) from retarder housing.
3. Remove spacer (2600). 2400M+P-07A-1861
2500
2600
12057
4. Use the impact tool (99/5) and adapter (98/9) to extract the valve insert.
M+P-07A-1862
99/5
98/9
12058
98/9 Adapter 53.9428.10

99/5 Impact puller 53.7712.10

53.2693.10 Page 6/7
5. Take float (2300/2) and float cage (2300/3) out of retarder housing.
2300/2
M+P-07A-1863
2300/3
12059
6. Lever O-ring (2301) out of groove in the valve insert (2300/1) and remove it.
M+P-07A-1885
2300/1
2301
12060

53.2693.10 Page 6/8
To check
1. Check float (2300/2) for damage to the surface (arrow).
M+P-07A-1886
2. Weight float (2300/2).
Specified weight 10 to 12 gramm. If weight is more than specified weight, renew the
complete casing ventilation.
2300/2
Note
Oil has penetrated into the float, the retarder is impaired in its operation.
12061
3. Check sealing edge of shaft sealing ring (arrow) in the valve insert (2300/1).
Put down valve insert (2300/1) on the float (2300/2), than weigh down valve insert with the test ring M+P-07A-1730 99/7
(99/7). Fill up the hollow space between float and upper edge of valve insert with methylated spirit.
If sealing edge is not damaged, the fluid level must not alter in the course of 1 minute. 2300/2
If necessary, renew complete casing ventilation.
2300/1
12062

53.2693.10 Page 6/9
To install
1. Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on to the valve
insert (2300/1). M+P-07A-1885
2300/1
2301
12060
2. Fit float (2300/2) and float cage (2300/3) into the valve insert (2300/1).
M+P-07A-1888
2300/1
2300/2
2300/3
12063

53.2693.10 Page 6/10
3. Fit casing ventilation into the retarder housing.
4. Use impact tool (99/5) and adapter (98/9) to knock the casing ventilation in. M+P-07A-1862
99/5
98/9
12058
98/9 Adapter 53.9428.10

99/5 Impact puller 53.7712.10
5. Place spacer (2600) on the casing ventilation (2300).
6. Position cover (2400) with new sealing (2500) on the retarder housing. 2400M+P-07A-1861
2500
Note
2600
7. Mind mounting position of gasket (2500) and cover casing ventilation (2400)!
12057

53.2693.10 Page 6/11
8. Inter-solution:
Place fastener (6500) screw in new hex.-head screws (2700, 2800 and 4100) tight. 2700
Tightening torque hex.-head screws (2700, 2800 and 4100): 25 Nm M+P-07A-1860
2800 4100
6500
12055
Serial-solution:
Place fastener (6700 und 6800) screw in new hex.-head screws (2700, 2800, 2905 and 4100) tight.
Tightening torque hex.-head screws (2700, 2800 and 4100): 25 Nm. 2800 2905
Tightening torque hex.-head screw (2905): Initial torque 17 Nm, final torque 25 Nm.
M+P-07A-1964
6700 4100
2700
6800
12056

53.2693.10 Page 6/12
Repair 6.3 Removing, Cleaning and Installing Silencer
Illustration silencer
M+P-07A-1965
7000
Note
This job sequence can be performed with the 7100

retarder removed or in situ.
7000 Disc (silencer) D30x4,

clean with suitable cleaning agent
(benzine) and blast out with
compressed air
7100 Circlip JL 30 x 1,2,
convex side must face the silencer
Cleaning agents
Silencer Benzine
12064

53.2693.10 Page 6/13
Heat Exchanger
Illustration heat exchanger
M+P-07A-1966
3600
3000 3600
3100
3000
3600
5000 5200
3500
3100
3300
12065
Prior jobs
• Ignition OFF
• Supply-air pressure discharged
• Retarder-oil drained (see chapter 3.3)
• Retarder removed (see chapter 5.1)
• Cooling-water temperature pick-up removed (see chapter 7.2)
3000 O-ring 15x4, renew

coat with silicone-free and non-corrisive grease for installation
3300 Heat exchanger
3500 Anti-fatigue screw M14x65, renew
Initial torque: 50 Nm
Final turn: 40° angle
3600 Anti-fatigue screw M14x150, renew
5200 Washer 31/31x4 D14,5
Lubricants
O-ring Silicone-free and


53.2693.10 Page 6/14
Heat Exchanger (Continue)
Special tool
67.1960.10
Pressure-test equipment
Turning angle measuring tool 3/4“ e.g.

Messrs Richard Abr. Herder
Post box 10 08 67
D-42659 Solingen
Tel. 0212/ 888-0
Ordering No. 8200-02
cbtd 00-07 Aftersales Manual VOITH Retarder 115 H - Actros

53.2693.10 Page 6/15
To remove
1. Screw out anti-fatigue screws (3600).
M+P-07A-1967
3600
3600
12066
2. Screw out anti-fatigue screws (3500 und 3600) and remove washer (5200).
3. Remove heat exchanger (3300). M+P-07A-1968

3000
4. Remove O-rings (3000, 3100 and 5000).
Note 3600 5200
If retarder is stored with installed heat exchanger longer than 6 weeks in stock, the heat exchanger must 3100
be removed and preserved. 5000
For preservation fill heat exchanger on oil-side with engine oil and on water-side with coolant. Lock 3500
3300 12067
openings of heat exchanger with plastic-plugs afterwards.
The preservation-process must be repeated after at the latest 3 years.

53.2693.10 Page 6/16
To check
1. Fit pressure-test equipment (99/6) together with O-rings to heat exchanger (3300).
Connect compressed-air line to bottom connection (arrow). M+P-07A-1868
2. Fill cooling-water section of heat exchanger (3300) with hot water (approx. 70°C).
3. Slowly pressurize the heat exchanger (3300) from 0 to max. 10 bar overpressure (oil section of
heat exchanger).
Note
99/6 3300
12068
If air bubbles form in the hot water, the heat exchanger leaks and must be renewed.
99/6 Pressure test-equipment
4. Connect compressed-air pipe to top connection (arrow).
5. Slowly pressurize heat exchanger (3300) from 0 to max. 10 bar overpressure (oil section of the M+P-07A-1869
heat exchanger).
Note
If air bubbles form in the hot water, the heat exchanger leaks and must be renewed.
6. Unscrew pressure test-equipment (99/6) of heat exchanger (3300) and remove O-rings.
99/6 3300
12069
99/6 Pressure test-equipment

53.2693.10 Page 6/17
To install
M+P-07A-1968
Note 3000
New heat exchangers are wetted with corrosion-inhibiting oil in the water- and oil section of the
heat exchanger.
Prior to installing a new heat exchanger, drain any corrosion-inhibiting oil which may have collected and 5200
flush it out with hot water in the water section of the heat exchanger. 3600
3100
5000
1. Fit new O-rings (3000, 3100 and 5000) in the drilled holes. 3500
3300 12067
2. Position heat exchanger (3300) on the oil tank, place washer (5200) on top and screw four new
anti-fatigue screws (3500 and 3600) tight.
Tightening torque anti-fatigue screw (3500): Initial torque: 50 Nm, final turn: 40° angle.
Tightening torque anti-fatigue screw (3600): Initial torque: 50 Nm, final turn: 90° angle.
3. Install retarder (see chapter 5.1). M+P-07A-1967
3600
3600
12066

53.2693.10 Page 6/18
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 via 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.
If the heat exchanger was leaky:

1. Fill retarder for flushing with engine- or flush oil (see chapter 3.3). Flush retarder system by several
slight brakings and drain oil (see chapter 3.3). Repeed this process 2 to 3 times
2. Deoil cooling - and heating-system of the vehicle in accordance with the manufacturer-instructions.

53.2693.10 Page 6/19
Repair 6.5 Removing, Installing Top Oil Tank Cover
Illustration top oil tank cover
2905
M+P-07A-1870
8
6 10
6500
1 4
2905
3 2
5
9
2913 7
2904
2906
12070
Prior jobs
• Ignition OFF
• Retarder OFF
• Proportional valve and damping plate removed (see chapter 7.1).
Caution!
The retarder housing is hot!
2904 Top oil tank cover

Hex.-head, w.a.f. 13, renew
Heed tightening sequence!
Final torque: 25 Nm
2906 Gasket
Final torque: 25 Nm
6500 Fastener
Note for installation

Heed mounting-situation of gasket and oil tank cover.
Tight all hex.-head screws in stipulated sequence 1 to 10 first with 17 Nm.
Afterwards, the hex.-head screws are tightened in same sequence with 25
Nm.

53.2693.10 Page 6/20
Repair 6.5 Removing, Installing Top Oil Tank Cover
(Continue)
Illustration top oil tank cover
M+P-07A-1969
2905 8
2905
2905
6 10
1 4
2800 3 2
5
6700 9
2913 7
2904
2906
12071
Prior jobs
• Ignition OFF
• Retarder OFF
• Proportional valve and damping plate removed (see chapter 7.1).
Caution!

renew, 25 Nm
2904 Top oil tank cover
Final torque: 25 Nm
2906 Gasket
Final torque: 25 Nm
6700 Fastener

Tight all hex.-head screws in stipulated sequence 1 to 10 first with 17 Nm.
Afterwards, the hex.-head screws are tightened in same sequence with 25
Nm.

53.2693.10 Page 6/21
Repair 6.6 Removing, Installing Bottom Oil Tank Cover
Illustration bottom oil tank cover
M+P-07A-1872
Prior jobs
• Ignition OFF
• Retarder OFF
• Retarder oil drained (see chapter 3.3)
2915
Caution!
2911 Bottom oil tank cover

2912 Gasket, renew
Final torque: 25 Nm
2911
Final torque: 25 Nm
2915 O-ring 7x2,5 renew, 2914
non-corrosive grease 12072
for installation

53.2693.10 Page 6/22
Repair 6.6 Removing, Installing Bottom Oil Tank Cover
(Continue)
Lubricants
O-ring Silicone-free and M+P-07A-1873

non-corrosive grease 5
3 7
1
Tight all hex.-head screws in stipulated sequence 1 to 10 first with 17 Nm. 8 2
Afterwards, the hex.-head screws are tightened in same sequence with 25 Nm.
4
6 12077

53.2693.10 Page 6/23
Repair 6.7 Removing, Installing Oil Tank
Illustration oil tank
M+P-07A-1874
3000
3600
3000
3500
2000
2900
12073
Prior jobs
• Ignition OFF
• Retarder OFF
• Proportional valve removed (see chapter 7.1)
• Heat exchanger removed (see page 6/14)

2000 O-ring 60x5 renew,
coat with silicone-free and non-corrosive grease for installation
Turning angle measuring tool 3/4“ e.g.
2900 Oil tank
Messrs Richard Abr. Herder
Post box 10 08 67
D-42659 Solingen
3500 Anti-fatigue screw M14x65
Tel. 0212/ 888-0
renew
renew

53.2693.10 Page 6/24
(Continue)
To remove
1. Screw out anti-fatigue screws (3500 and 3600).
M+P-07A-1876
3600
3500 12074
2. Remove oil tank (2900).

M+P-07A-1877 3000
Note
Keep an eye on it that the behind-lying valves are not extracted while removing oil tank.
3. Remove O-rings (2000 and 3000). 3000

2000
2900 12075

53.2693.10 Page 6/25
(Continue)
To install
1. Coat new O-rings (2000 and 3000) with silicone-free and non-corrosive grease.
M+P-07A-1877
3000
2. Insert new O-rings (2000 and 3000) into the grooves of the retarder housing.
3. Put oil tank (2900) on retarder housing.
3000
2000
2900 12075
4. Screw in new anti-fatigue screws (3500 and 3600) and tight them easily by hand.
M+P-07A-1876
Note
The oil tank still must be movable so that the heat exchanger can be installed afterwards.
3600
5. Install heat exchanger.
6. Tighten anti-fatigue screws (3500).

Tightening torque anti-fatigue screw (3500): Initial torque 50 Nm, Final torque: 40° angle.
3500 12074

53.2693.10 Page 6/26
(Continue)
Illustration oil tank
M+P-07A-1970 2800 2905
6700
3000
3000
3600
2000
3500
2900
12076
Prior jobs
• Ignition OFF
• Retarder OFF
• Heat exchanger removed (see page 6/14)
2000 O-ring 60x5 renew, Commercially available tool

Turning angle measuring tool 3/4“ e.g. Messrs Richard Abr. Herder
Post box 10 08 67
renew, 25 Nm
D-42659 Solingen
2900 Oil tank
Tel. 0212/ 888-0
renew,
Final torque: 25 Nm
renew
renew
6700 Fastener

53.2693.10 Page 6/27
(Continue)
To remove
2800 2905
1. Screw out hex.-head screws (2800 and 2905) and remove fastener (6700).
M+P-07A-1971
2. Screw out anti-fatigue screws (3500 and 3600). 6700
3600
3500
12078
3. Remove oil tank (2900).
M+P-07A-1972
3000
Note
Keep an eye on it that the behind-lying valves are not extracted while removing oil tank.
4. Remove O-rings (2000 and 3000).

3000
2000
2900 12079

53.2693.10 Page 6/28
(Continue)
To install
1. Coat new O-rings (2000 and 3000) with silicone-free and non-corrosive grease.
M+P-07A-1972
3000
2. Insert new O-rings (2000 and 3000) into the grooves of the retarder housing.
3. Put oil tank (2900) on retarder housing.
3000
2000
2900 12079

53.2693.10 Page 6/29
(Continue)
4. Screw in new anti-fatigue screws (3500 and 3600) and tight them easily by hand.
2800 2905
M+P-07A-1971
6700
Note
The oil tank must still be movable so that the heat exchanger can be installed afterwards.
3600
5. Install heat exchanger.
6. Tighten anti-fatigue screws (3500).

3500
Tightening torque anti-fatigue screw (3500): Initial torque 50 Nm, Final turn: 40° angle. 12078
7. Place fastener (6700) and screw it with new hex.-head screws (2800 and 2905) tight.
Tightening torque hex.-head screw (2800): 25 Nm.
Tightening torque hex.-head screw (2905): Initial torque 17 Nm, Final torque 25 Nm.

53.2693.10 Page 6/30
Control Parts 7 Control Parts
7.1 Removing, Installing Proportional Valve................................................. 7/2
7.2 Removing, Installing Cooling-Water Temperature Pick-Up.................... 7/3

- Version Inter-Solution.......................................................................... 7/3
- Version Serial-Solution........................................................................ 7/4
7.3 Removing, Installing Oil Temperature Pick-Up ...................................... 7/5

- Version Inter-Solution.......................................................................... 7/5
- Version Serial-Solution........................................................................ 7/6

53.2693.10 Page 7/1
Control Parts 7.1 Removing, Installing Proportional Valve
Prior jobs
• Ignition OFF
• Retarder OFF M+P-07A-1973
• Check plug at proportional valve and
socket for damage as well as wear (notch 39
scratches).
26 Supply-air pressure pipe (p v )

39 Electrical lead
3800 Damping plate, renew if necessary
3850 O-ring 16 x 3, renew if necessary 26
renew, 30 Nm 3900 3850
4000 Hex.-head nut M8, renew, 18 Nm
6500 Fastener
(only at version serial-solution) 6600 3800
6600 Fastener
Caution!
If hex.-head nuts (4000) or hex.-head screws 4000

(3900) have to be unscrewed in case of repair
work, the damping plate (3800) and O-rings 3700 6500
4000 3900 12080
(3850) must be checked and renewed, if neces-
sary for mechanical and aging damages.

53.2693.10 Page 7/2
Control Parts 7.2 Removing, Installing Cooling-Water
Temperature Pick-Up
M+P-07A-1881
Illustration cooling-water temperature pick- 84
up

5900/1 Cooling-water temperature pick-up,
pin out electrical connection lead of
central plug
28 Nm

5900/1
Hot coolant may escape when screwing out
cooling-water temperature pick-up (19)!
12081

53.2693.10 Page 7/3
Control Parts 7.2 Removing, Installing Cooling-Water
Temperature Pick-Up (Continue)
M+P-07A-1974
Illustration cooling-water temperature pick-
up

5900/1 Cooling-water temperature pick-up,
central plug
28 Nm 83
5900/1
Hot coolant may escape when screwing out

cooling-water temperature pick-up (19)!
12082

53.2693.10 Page 7/4
Control Parts 7.3 Removing, Installing Oil Temperature Pick-Up
M+P-07A-1883
Illustration oil temperature pick-up
85 Plug connection oil temperature

pick-up
5900/2 Oil temperature pick-up 85
28 Nm
Hot oil may escape when screwing out

5900/2
oil temperature pick-up (19)!
12083

53.2693.10 Page 7/5
Control Parts 7.3 Removing, Installing Oil Temperature Pick-Up
(Continue)
M+P-07A-1975
Illustration oil temperature pick-up
83 Plug connection central plug 5900/2

5900/2 Oil temperature pick-up,
central plug
28 Nm
83
Hot oil may escape when screwing out

oil temperature pick-up (19)!
12084

53.2693.10 Page 7/6
Annex 8 Annex
Data Sheet
Conversion Table
Tightening torques
Operating Specifications
- Oil Specifications
- Cooling-Water Quality
Spare Parts Lists
Other Information

53.2693.10 Page 8/1
Annex 8 Annex
(Continue)
Data Sheet Voith Retarder 115 H
Max. possible braking torque at prop shaft M(Br) m ax 3200 Nm

at retarder ratio 1 : 2,03
Max. possible braking torque at prop shaft M(Br) m ax 2900 Nm

at retarder ratio 1 : 1,68
Max. retarder revolution 5000 r.p.m.

at n p s = 2500 r.p.m. (i R e t = 2,03)
at n p s = 3000 r.p.m. (i R e t = 1,68)
Working medium Oil grade given in Operating Specifications
Service filling: *
service filling (oil change, checking oil level) 5,9 Litre
after complete taking apart and cleaning 6,5 Litre

as well as emptied heat exchanger
Overall weight (with heat exchanger, without oil- / coolant filling) ca. 62,5 kg

53.2693.10 Page 8/2
Annex 7 Annex
(Continue)
D GB USA D GB USA
-30 oC -22 °F -22 °F 110 Nm 81.4 lbf-ft 81.4 lbf-ft
-50 oC -58 °F -58 °F 150 Nm 111 lbf-ft 111 lbf-ft
95 oC 203 oF 203 oF 3,100 Nm 2,294 lbf-ft 2,294 lbf-ft
105 oC 221 oF 221 oF 0 - 6 bar 0 - 87 psi 0 - 87 psi
185 oC 365 oF 365 oF 2,7 - 3,0 bar 39.15 - 43.5 psi 39.15 - 43.5 psi
200 °C 392 °F 392 °F 6 - 11 bar 87 - 160 psi 87 - 160 psi
225 oC 437 oF 437 oF 6 bar 87 psi 87 psi
17 Nm 12.58 lbf-ft 12.58 lbf-ft 11 bar 160 psi 160 psi
18 Nm 13.32 lbf-ft 13.32 lbf-ft 19 bar 275.5 psi 275.5 psi
25 Nm 18 lbf-ft 18 lbf-ft 10 - 12 g 0.35 - 0.42 oz 0.35 - 0.42 oz
28 Nm 20.72 lbf-ft 20.72 lbf-ft 5,9 l 1.298 UK gal 1.558 US gal
30 Nm 22.2 lbf-ft 22.2 lbf-ft 6,5 l 1.430 UK gal 1.716 US gal
50 Nm 37 lbf-ft 37 lbf-ft 45,000 km 27,963 miles 27,963 miles
55 Nm 40.7 lbf-ft 40.7 lbf-ft 90,000 km 55,926 miles 55,926 miles
80 Nm 59.2 lbf-ft 59.2 lbf-ft 135,000 km 83,889 miles 83,889 miles

53.2693.10 Page 8/3
Annex 8 Annex
(Continue)
Pos.-No. Naming (mounting place) Dimension Tightening torque
112 Screw plug (measuring place pump pressure) M 12 x 1,5, Inhex.-head, w.a.f. 6 25 Nm
2700 Hex.-head screw M 8 x 80, External hex.-head, w.a.f. 13 25 Nm
2905 Hex.-head screw M 8 x 40, External hex.-head, w.a.f. 13 Heed tightening torque sequence!
Final torque: 25 Nm
2909 Oil filling plug M 30 x 1,5, Inhex.-head, w.a.f. 17 150 Nm
Final torque: 25 Nm
Final torque: 25 Nm
2919 Central oil-drain plug M 20 x 1,5, Inhex.-head, w.a.f. 10 55 Nm
2922 Oil check plug M 24 x 1,5, Inhex.-head, w.a.f. 12 80 Nm
3500 Anti-fatigue screw M 14 x 65, External hex.-head, w.a.f. 19 Initial torque: 50 Nm

Final torque: 40° angle
3600 Anti-fatigue screw M 14 x 150, External hex.-head, w.a.f. 19 Initial torque: 50 Nm

Final torque: 90° angle

53.2693.10 Page 8/4
Annex 8 Annex
(Continue)
Pos.-No. Naming (mounting place) Dimension Tightening torque
4000 Hex.-head nut M 8, External hex.-head, w.a.f. 13 18 Nm
4700 Screw plug with sieve M 30 x 1,5, Inhex.-head, w.a.f. 17 150 Nm
5900/1 Cooling-water temperature pick-up M 14 x 1,5, External hex.-head, w.a.f. 19 28 Nm
5900/2 Oil temperature pick-up M 14 x 1,5, External hex.-head, w.a.f. 19 28 Nm

53.2693.10 Page 8/5

VOITH Retarder 115 Actors After Sales Service Manual

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VOITH Retarder 115 Actors After Sales Service Manual

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Aftersales Service Manual

VOITH Retarder 115 Actros

1 Preface ......................................................................................................................... 1/1

2 General ......................................................................................................................... 2/1

3 Maintenance ................................................................................................................. 3/1

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

4 Diagnosis / Troubleshooting ......................................................................................... 4/1

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

5 Removing, Installing Retarder ....................................................................................... 5/1

6 Repair ........................................................................................................................... 6/1

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

7 Control Parts ................................................................................................................ 7/1

8 Annex ........................................................................................................................... 8/1

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

• The switched-on retarder will not secure the parked vehicle!

• During a failure of the retarder, or while the temperature-adaptation is effective, the

• Repair and maintenance work may only be enforced by qualified specialist-staff.

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

• The pertinent accident-prevention-regulation, other broadly rules of the security-technology and

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

• According to production-time period of the vehicle, different electrical wiring-harnesses were

To chassis-end-No. 303 057 (inter-solution):

From chassis-end-No. 303 058 (series-solution):

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

VOITH TURBO GmbH & Co. KG

Telephone xx49 - (0)7951 32-401, -422

Copyright July 2000 - Voith Turbo

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

2.1 Retarder Data......................................................................................... 2/2

2.2 Identification Retarder Control Unit ........................................................ 2/3

2.3 Assembly Overview ................................................................................ 2/4

2.4 Function- and Operation Scheme .......................................................... 2/6

2.5 Vehicle-CAN-Bus ................................................................................ 2/13

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

The data plate (2900/1) is mounted at the

1. Serial number (6-digit number)

2. Retarder transmission ratio (i R e t)

4. Code number (8-digit number)

5. Part-No. vehicle manufacturer

Please, always quote the serial number and the

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

The retarder control unit (2) is located in the

The labeling of the Dipiprop-control unit (data

• Serial number (b)

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

Illustration Voith retarder 115 H Digiprop

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

Illustration Voith retarder 115 H Digiprop

2919 Central oil-drain plug

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

Function scheme Voith Retarder 115 H with Digiprop control unit

1 Heat exchanger 26 Supply-air pressure line (pv )

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

A switched-on retarder will not secure a parked vehicle.

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

Operation of retarder R 115 H with Digiprop control unit

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros

The retarder braking torque is adapted by

cbtd 00-07 Aftersales Service Manual VOITH Retarder 115 H - Actros