Vdocument - in - Voiht Retarder VR 115

Voith Turbo
Aftersales Service Manual Voith Retarder VR 5E
153.00009710 I 2005-11

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents
Table of Contents
1 About this Document 5
1.1 Purpose of this Document 6

1.2 Target Groups 6
1.3 Other Applicable Documents 6
1.4 Symbols and Identifications 7
1.5 Item Numbers 7
1.6 Legal/Contact Information 7
2 Basic Safety Information 8
2.1 Product Safety 9

2.2 Staff Qualification 9
2.3 Safety-Conscious Working 9
2.4 Environmental Protection 9
2.5 Troubleshooting 9
2.6 Maintenance and Repair 9
2.7 Driving Mode 9
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3 Design and Function 11
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3.1 Overview of the Modules 12
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Controller Identification (VERATM)
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3.4 Controller Identification (Digiprop) 16
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3.5 Function and Control Scheme 17

3.6 Function Description 19
4 Maintenance and Service 20
4.1 Maintenance Intervals 21

4.2 Oil Change 22
4.3 Checking the Oil Level 25
4.4 Draining the Coolant 28
5 Diagnosis and Troubleshooting 30
5.1 Troubleshooting Chart 31

5.2 Constant-Air Pressure Control Loop 36
5.3 Pump Pressure (pdyn) 39
5.4 Proportional Valve Current 42
6 Removing and Installing the Retarder 44
7 Repair 51
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7.1 Components Overview 52
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7.9 Non-Return Valve Inlet 79
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7.10 Non-Return Valve Outlet 81

7.11 Oil Temperature Sensor 84
7.12 Coolant Temperature Sensor 86
7.13 Pressure Sensor 88
7.14 Proportional Valve and Damping Plate 89
8 Appendix 91
8.1 Tightening Torques 92
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document
1. About this Document
1.1 Purpose of this Document 6

1.2 Target Groups 6
1.3 Other Applicable Documents 6
1.4 Symbols and Identifications 7
1.5 Item Numbers 7
1.6 Legal/Contact Information 7
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document Purpose of this Document
1.1 Purpose of this Document
This Aftersales Service Manual provides information

and instructions on maintenance and repair of the
Voith Retarder VR 115 E.
1.2 Target Groups
This Aftersales Service Manual is intended for service

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

Voith retarder oil change intervals/oil specification list Oil change intervals and approved oil types 153.000831xx
Operating instructions for Voith Retarder VR 115 E Information on the safe, professional and economical operation of the H67.2964xx
Voith Retarder VR 115 E
Cooling water quality list Approved coolants H67.2224xx
1
Operating instructions for retarder tester Measured values for constant-air pressure and pump pressure Included in scope of delivery of
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the retarder tester(153.001085xx)
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Operating instructions for Diana-Lite test software Information on the testing of: Included in the scope of delivery
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I • Constant-Air Pressure Control Loop of the Diana-Lite test software
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(153.000776xx)
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5 Operating instructions for the WinDia diagnostic Instructions on PC diagnosis for the Digiprop and VERATM controllers 3623-020900
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Gearbox-specific documents on the retarder Information on safe, professional installation and removal of the retarder On request
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document Symbols and Identifications
1.4 Symbols and Identifications 1.5 Item Numbers

WARNING
Structure of warnings The item numbers used are usually found in the spare
Potentially hazardous situation which, if not avoided,
parts lists.
could result in death or serious injury.
LEVEL OF DANGER Exceptions:
Type and source of danger!
Possible consequences if not observed.
DANGER • One- or two-digit item numbers
 Measures for the prevention of danger and its Imminently hazardous situation which, if not • Item numbers with a slash
consequences. avoided, will result in death or serious injury.
1.6 Legal/Contact Information
Levels of danger Notes
For questions and work procedures not described in
The warnings are categorized into four levels of
these documents, contact the respective organisation
danger: NOTE
for your area.
Information on easier and safer work with the
Voith Turbo
CAUTION retarder.
Produktgruppe Retarder
 Measures for easier and safer work with the
Potentially hazardous situation which, if not avoided, retarder.
may result in property damage. Postfach 1555
74555 Crailsheim
Distinctions
Deutschland
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CAUTION  One-step action instruction.
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Phone: 00 49 79 51 / 32-401, 32-422, 32-1860
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Potentially hazardous situation which, if not avoided, 1. First step of an action instruction. Other steps
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Fax: 00 49 79 51 / 32-756
I may result in minor or moderate injury. follow and are numbered in sequence.
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service-retarder@voith.com
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information
2. Basic Safety Information
2.1 Product Safety 9

2.2 Staff Qualification 9
2.3 Safety-Conscious Working 9
2.4 Environmental Protection 9
2.5 Troubleshooting 9
2.6 Maintenance and Repair 9
2.7 Driving Mode 9
2.8 Warranty 10
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information Product Safety
2.1 Product Safety 2.4 Environmental Protection Damage to property via soiled parts!
Considerable damage or malfunctions may occur due
The retarder is constructed according to state of the  Drained fuels and fluids, consumables and old parts
to soiling.
art technology and acknowledged safety regulations. must be disposed of properly.
 Ensure cleanliness.
Nevertheless, hazardous situations and property
2.5 Troubleshooting
damage may occur as a result of improper usage, Damage to property via improper cleaning!
maintenance and repair. Voith provides a warranty/goodwill service for
 Do not aim the jet of a high-pressure cleaner
 Observe safety and warning information. defective parts only.
(steam-jet device) at valves, pressure sensors or
 Do not replace parts on mere speculation. ventilators of the retarder.
2.2 Staff Qualification
2.6 Maintenance and Repair 2.7 Driving Mode
 Allow only qualified professionals to carry out repair
and maintenance work.
Danger of burning and scalding via squirting oil!  Ensure that the retarder is fully functional for all
The oil in the retarder may be hot. vehicle maneuvers, i.e.:
2.3 Safety-Conscious Working - Retarder properly filled with oil
 Work carefully.
Voith does not assume any liability for personal injury - Retarder electronics connected and functional
and/or property damage caused by improper and Danger of burning and scalding via hot coolant! - Pneumatic control connected and functional
unprofessional work.
The coolant may be hot.
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 Observe the following regulations:
1
-  Work carefully.
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- Accident-prevention regulations
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- Other generally acknowledged safety Danger of burns via hot parts!
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regulations and occupational health Parts of the retarder may be hot.
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 Work carefully.
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information Warranty
Driving after repair/oil change Failure while driving

Oil ejection! During failure of the retarder, or while temperature
adaptation is active, only the service brake is
De-aeration not performed.
functional.
 De-aerate retarder.
 Adjust the speed of the vehicle with the service
- Switch off retarder foot control if present and brake.
possible
 Engage the lowest possible gear to achieve a high
- Move vehicle at 50 km/h
engine speed.
- Activate retarder at brake stage one five times
for approx. 5 sec. each time  Continue driving in this way until the retarder is
available at full capacity again.
Towing
 Tow vehicle with retarder max. 100 km at max. 2.8 Warranty

40 km/h.
Voith accepts no liability for damage caused by
changes to the retarder or the use of spare parts,
Parking
accessories, attachments and special features not
 Do not use retarder as a parking brake, as it does tested and approved by Voith.
not act as a brake when the vehicle is standing still.
 Use only parts approved by Voith to ensure the
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function
3. Design and Function
3.1 Overview of the Modules 12

3.2 Retarder Identification 14
3.3 Controller Identification (VERATM) 15
3.4 Controller Identification (Digiprop) 16
3.5 Function and Control Scheme 17
3.6 Function Description 19
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Overview of the Modules
3.1 Overview of the Modules

2810
Item No. Designation
3700
100 Retarder housing
4100
1600 Valve cover (non-return valve outlet)
1900 Non-return valve inlet
2810 Vent and air filter
3700 Proportional valve
4100 Screw plug M30x1.5 (oil filler plug)
1900
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Overview of the Modules

103 Screw plug M12x1.5
107 Screw plug M24x1.5 (oil drain plug)
5500/1
3500 Screw plug M30x1.5
4200 Screw plug M24x1.5 (oil drain plug)
5200/2 Coolant temperature sensor M14x1.5
5500/1 Ventilation
6400 Heat exchanger 6400
20000 Water neck
3500
20000
103
5200/2
20000
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3 4200
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Retarder Identification
3.2 Retarder Identification
NOTE
 Specify the following data in case you have
questions or are ordering spare parts:
- Serial number (Serien-Nr.)
- Voith item number (Voith-Sach-Nr.)
Typ VR115E; Serien-Nr.
i Ret. = 2.03 KW/Jahr
Voith-Sach-Nr.
r.
Kd.-Sach-Nr.
n-N
Serie r
E; / Jah
R115 KW
Typ V 2.03
t = r.
i Re h-N
-Sac r.
Voith ach-N
Kd.-S
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Controller Identification (VERATM)
3.3 Controller Identification (VERATM)
Example:
NOTE
 Specify the following data in case you have 4
8
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2
2
0

1
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questions or are ordering spare parts: 0

2
M T 6 6 .
T T 2 8
A M - 7
- Serial number (Serial-No.) E R M
V J - 0 -
t J J .
6
.
H u s
B 3
i
n J 1 v o X
2
X /
l U E 0 E
r o - 5 /
- Part number (Part No.) o
C X
t
n X
X .
X
X . H 3
D 3
A 6
R 0 4 4
1
X 2
r .
e E
o
r d l -
N . V 0 0
t a i a o .
N N o
 Specify the following data of the retarder (see R e
e r t -
S a r M -
P E 1
X
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h
page 14):
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H
T
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- Serial number (Serien-Nr.)

- Voith item number (Voith-Sach-Nr.)
1 o TM
1
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r Retarder Control Unit VERA
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Serial-No. XXXXXX / JJJJ-MM-TT 4
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V Part-No. VERA.D.H-E02.10-H67.2866.20 0
2
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I OEM-No. 0004463315 / EvoBus 0
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Controller Identification (Digiprop)
3.4 Controller Identification (Digiprop)
Example:
NOTE
 Specify the following data in case you have
questions or are ordering spare parts:
- Basic number (Basis-Nr.:)
- Serial number (Serien-Nr.:)
 Specify the following data of the retarder (see
page 14): Ba
Cosis-N
Se de-N r.:
- Serial number (Serien-Nr.) VOrien- r.: 53
ITH Nr.: .
xx xxxx
x .12
xx
- Voith item number (Voith-Sach-Nr.) xx
/
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Serien-Nr.:
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Function and Control Scheme
3.5 Function and Control Scheme

C
B E F
A
A Compressed-air line (pressure
controller)
D
P
B Four-circuit protection valve G A R
2810 2300 J
9000 3700
C Compressed-air line (brake circuit 2)
D Compressed-air line (brake circuit 1) I
H
E Compressed-air line (parking brake) 5200/1 6400
F Air tank for auxiliary equipment 1900
G Supply-air pressure (pv) "P" Vehicle

electronics
H Constant-air pressure (py) "A"
I Ventilation line "R"

J Oil tank 5200/2
K Rising duct
107 Oil drain plug 300
5500
200 Stator 200
2200
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300 Rotor
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2
I 1900 Non-return valve (inlet)
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I 2100 Non-return valve (outlet) 4200 K
0 107
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9 2200 Pressure control valve
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Oil sump Coolant
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Supply-air pressure pv Pump pressure pdyn
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Constant-air pressure py
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Function and Control Scheme

2300 Casing ventilation C
B E F
A
2810 Ventilation filter
D
P
4200 Oil drain plug G A R
2810 2300 J
9000 3700
5200/1 Oil temperature sensor
5200/2 Coolant temperature sensor I
H
5500 Ventilation
5200/1 6400
6400 Heat exchanger 1900
9000 Pressure sensor Vehicle

electronics
5200/2
300
5500
200
1
2200
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2100
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Oil sump Coolant
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Supply-air pressure pv Pump pressure pdyn
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service
4. Maintenance and Service
4.1 Maintenance Intervals 21

4.2 Oil Change 22
4.3 Checking the Oil Level 25
4.4 Draining the Coolant 28
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Maintenance Intervals
4.1 Maintenance Intervals
The maintenance intervals depend on the stress put

on the retarder.
Activity Interval See

Change oil See document: Oil Page 22
change intervals/
oil specification list
153.000831xx
Check oil – Page 25
level
Drain coolant Observe Page 28
specifications of
vehicle
manufacturer
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Oil Change
4.2 Oil Change
4100
107 Screw plug M24x1.5, 4150
hexagon socket head, w.a.f. 12,
with copper sealing ring: 80 Nm
with integrated sealing ring: 47 Nm
108 Sealing ring A24x29, replace
3500 Screw plug M30x1.5,
4200 Screw plug M24x1,5, ac
h-N .
r.
.-S -Nr
Kd ch

-Sa
ith
Vo
108
1
1
- with integrated sealing ring: 47 Nm 107
5
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2
I 4250 Sealing ring A24x29, replace 4250 4250
d
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3550
a
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3500 4200 4200
0
NOTE
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 Lubricate sealing rings, O-rings and shaft
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grease before installation.
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Page 22

• Tighten screw plugs of retarder basic module to

NOTE the specified tightening torque (see page 91). CAUTION
 Observe the reduced tightening torque with the • Tighten fastening screws at retarder heat Hot screw plugs!
integrated sealing ring. exchanger with the specified tightening torque Hands could be burned.
The copper sealing ring variant is described in the (see page 91).  Work carefully.
instructions.  Wear protective gloves or use cloths if necessary.
Requirements
CAUTION
• Vehicle is horizontal 2. Unscrew the screw plug (4100).
Incorrect tightening torque!
• Oil is at operating temperature (> 60 °C) 3. Unscrew the screw plugs (107 and 4200).
Leaky retarder.
 Observe the proper tightening torque. • Retarder switched off 4. Drain oil into an oil collecting pan.
• Ignition switched off 5. Lubricate the new sealing rings (108 and 4250)
Oil quantity
with silicone-free, non-corrosive grease.
Service filling (oil check, oil change) 7.0 l Draining the oil
6. Screw in the screw plugs (107) with sealing rings
After replacement of the heat exchanger 7.5 l
1. Place oil collecting pan below the retarder. (108) and tighten to 80 Nm.
Refilling after complete disassembly, 7.8 l
cleaning and emptied heat exchanger WARNING 7. Screw in the screw plug (4200) with sealing ring
(4250) and tighten to 80 Nm.
Maintenance work during each oil change Hot exiting oil!
1
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Face and hands could be burned.
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• Visual inspection of retarder for leaks before and  Ensure that the retarder and ignition are switched
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after the oil change. off.
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7 • Check prop shaft screws for proper seating and
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manufacturer).
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Pressure control valve 2. Lubricate the new sealing ring (4150) with
silicone-free, non-corrosive grease.
NOTE
3. Screw in the screw plug (4100) with sealing ring
There are two variants of the pressure control (4150) and tighten to 130 Nm.
valve.
- Pressure control valve variant 1 without sieve. De-aerating the retarder
Sieve is at the screw plug (3500)
- Variant 2; sieve is located directly in the CAUTION
pressure control valve
Oil ejection!
1. Unscrew the screw plug (3500).
2. Drain any oil that has accumulated in the oil
collecting pan. 1. Switch off the retarder foot control if present and
possible.
3. Lubricate the new sealing ring (3550) with
silicone-free, non-corrosive grease. 2. Move vehicle at 50 km/h.
4. Screw in the screw plug (3500) with sealing ring 3. Activate retarder at brake stage one five times for
(3550) and tighten to 130 Nm. approx. 5 sec. each time.
Filling in the oil

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1. Fill in oil via the hole of the screw plug (4100).
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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Checking the Oil Level
4.3 Checking the Oil Level
4100
107 Screw plug M24x1.5, 4150
r.
h-N .
ac
.-S -Nr
Kd ch
-Sa
ith
Vo
NOTE 108
1
1
-
107
5
0  Lubricate sealing rings, O-rings and shaft
0
2
I sealing rings with silicone-free, non-corrosive 4250 4250
d
t
r
r grease before installation.
a
I 4200 4200
0
1
7
9
0
0
0
0
.
3
5
1
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Page 25

NOTE CAUTION CAUTION

 Observe the reduced tightening torque with the Hot screw plugs! Wrong oil type!
integrated sealing ring. Hands could be burned. Damage to/failure of the retarder.
The copper sealing ring variant is described in the  Work carefully.  Use only approved oil (see oil specification list).
instructions.  Wear protective gloves or use cloths if necessary.
2. If oil is missing, top up oil.
Oil quantity 2. Unscrew the screw plug (4100).
Service filling (oil check, 7.0 l Filling in the oil
oil change) 3. Unscrew the screw plugs (107 and 4200).
1. Fill in oil via the hole of the screw plug (4100).
4. Drain oil into an oil collecting pan.
Requirements
5. Lubricate the new sealing rings (108 and 4250) 2. Lubricate the new sealing ring (4150) with
• Vehicle is horizontal silicone-free, non-corrosive grease.
• Oil is at operating temperature (> 60 °C) 3. Screw in the oil filler plug (4100) with sealing ring
6. Screw in the screw plugs (107) with sealing rings
(108) and tighten to 80 Nm. (4150) and t ighten to 130 Nm.
• Retarder switched off
• Ignition switched off 7. Screw in the screw plugs (4200) with sealing ring
(4250) and tighten to 80 Nm.
Draining the oil
Measuring the volume
1
1
-
1. Place oil collecting pan below the retarder.
5
0
0
2
1. Measure the volume of the drained oil.
I
d
t
r
r
WARNING
a
I
0
NOTE
1
7
9
Hot exiting oil!
0
0
0 Face and hands could be burned.  If oil is missing, check the retarder for leaks.
0
.
3
5
1
I
 Ensure that the retarder and ignition are switched
o
b
r
u off.
T 5
0
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Page 26

De-aerating the retarder
CAUTION
Oil ejection!
1. Switch off the retarder foot control if present and

possible.
2. Move vehicle at 50 km/h.
3. Activate retarder at brake stage one five times for

approx. 5 sec. each time.
1
1
-
5
0
0
2
I
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a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
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Page 27

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Draining the Coolant
4.4 Draining the Coolant

20000 Water neck
hexagon insert bit, w.a.f. 13,
32 Nm
NOTE
Requirements
• Ignition switched off

r.
h-N .
ac
.-S -Nr
Kd ch
CAUTION
-Sa
ith
20000
Vo
1
1
-
5
0
0
2
I Hot parts and coolant! 20400
d
t
r
r
a Burns and scalding could occur. 20300
I
0
1
7
9  Work carefully.
0
0
0
0
.  Wear protective gloves or use cloths if necessary.
3
5
1
I
o
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Page 28

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Draining the Coolant
CAUTION
Incorrect coolant!
Damage to vehicle and retarder cooling circuits.
 Observe the specifications of the vehicle
manufacturer or those of Voith Turbo cooling
water quality list.
1. Unscrew the screw plug (20300) and drain the

coolant into a clean collecting vessel.
2. Replace the sealing ring (20400) and lubricate it

1
1
-
5
0
0
2
I
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a
I
0
1
7
9
0
0
0
0
.
3
5
1
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Page 29

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting
5. Diagnosis and Troubleshooting
5.1 Troubleshooting Chart 31

5.2 Constant-Air Pressure Control Loop 36
5.3 Pump Pressure (pdyn) 39
5.4 Proportional Valve Current 42
1
1
-
5
0
0
2
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0
1
7
9
0
0
0
0
.
3
5
1
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Page 30

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Troubleshooting Chart
5.1 Troubleshooting Chart
A
Retarder
pilot light
(standard
type)*
Oil loss via

Complaint
D Other external
leak** Retarder
VR 115 E
ventilation (5500)
or vent and air
filter (2810)
B
1
1
-
5
0
0
2
No or
I * insufficient
d
t
r
r
On-board diagnosis is possible if the
a
I OEM equipment allows it (display). brake efficiency
0
1
7
9 Observe the specifications of the
0
0
0
0
vehicle manufacturer.
.
3
5
1
**
C
I
o
b
r
Before troubleshooting, ensure that there
u
T 5
0
are no leaks at the screw plugs or sealing rings!
h 0
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Page 31

Instruct the driver!
Check the
Retarder operation (for NIO Replace
*
A pilot light Temperature retarder braking, temperature
FLASHING?
(standard adaptation nominal speed sensor
type)* of the engine, IO Check
NIO
if possible) temperature
sensors
(oil/coolant)
(see page 84 onw.) IO Check vehicle
cooling system
in accordance
with the
information from
1 the vehicle
1
-
5 manufacturer
0
0
2
I
d
t
r
r
a
I
* On-board diagnosis is possible if the
0
1
7 OEM equipment allows it (display).
9
0
0
0
Observe the specifications of the
0
.
3
5
vehicle manufacturer.
1
I
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IO = in order
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NIO = not in order 28014_en
Page 32

Replace casing
Oil loss via Replace casing NIO ventilation
ventilation (5500) 2810 ventilation
B or vent and air

filter (2810)
Oil loss
via
5500
(see page 63 onw.) IO
If the gearbox oil level is too low and the retarder

Water in the oil level is too high:
oil (emulsion)? Check gearbox ventilation and repair (clean)
Replace heat Check heat if necessary!
exchanger
NIO
exchanger Yes No Correct the
IO (see page 71 onw.) retarder and/or Troubleshooting is now complete!
gearbox oil level If the problem reoccurs:
- Proceed to the next test step!
Check oil level
Possible entry of water from outside of retarder
into the retarder system: and gearbox
- via ventilation (5500 and 2810) (see page 25) Outlet valve
.11 and greater?
C
via steam jet unit, for example Replace
or: IO NIO
Yes No outlet valve
- via leaks in the retarder housing
1
1
-
5
0
0
Check
2
I outlet valve
d
t
r
r (see page 81 onw.)
a
I
0
Contact Replace
1 Voith IO NIO
7
9
outlet valve
0
0
0
0
.
3
5
1
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0
IO = in order
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No or External leak Yes Repair retarder
C insufficient
brake efficiency
(except for
retarder ventilation) No
Check the prop.

Water in the current as well
oil (emulsion)? as leads and
plug connections
B Yes No (see page 42 onw.)
NIO IO
Check
P (dynamic) and
py (static)
If the static and dynamic
pressure are in order,
(see page 39 onw.) the complaint mentioned
Check oil level
of retarder and above cannot be made.
Check NIO IO Clarify the complaint
gearbox temperature
(see page 25) again with the customer
sensors and or perform the tests
B NIO IO
leads
(see page 84 onw.) Contact Voith
once again.
NIO IO
Check constant-
air pressure
control loop
(see page 36) Replace Contact Voith
temperature
1
1
- sensors or leads
5
0
NIO IO
0
2
I
d
t
r
r
a
I Check damping
0
1
7 plate
9
0
0 (see page 89)
0
0
.
3 Replace damping
5 Replace pressure sensor or
1
I plate NIO IO proportional valve
o
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0
IO = in order
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NIO = not in order 28176_en_shb
Page 34

Leaky near the

top oil tank
cover (2000)
(see page 59 onw.)
or:
Leaky near Leaky near Leaky near
the heat the casing bottom oil tank non-return
exchanger ventilation cover (2500)? valve inlet (1900)
(800)? cover (2800)?
(see page 71 onw.) (see page 63 onw.) (see page 61 onw.) (see page 79 onw.)
D Other external
leak**
Yes No Yes No Yes No Yes No Contact Voith
Check gasket (2900); top: Model with integrated sealing ring:

replace if necessary Check intermediate Check gasket; replace non-return valve
washer (8000); replace inlet (1900) if necessary
1.) Check retarder housing for leaks Cool- if necessary. Insert Model with copper sealing ring (1950):
Oil? combined hex head Replace sealing ring (1950) and insert
near the heat exchanger; ant?
contact Voith if necessary screw (3300 and 3100) non-return valve inlet (1900) with
2.) Check heat exchanger (6400) with thread seal thread seal
Replace heat bottom:
and O-rings (7300 and 7500);
exchanger (6400) Check gasket (2600);
replace if necessary Check gaskets
replace if necessary.
at the water
necks
Check sealing ring
Check heat NIO (see page 70 onw.) at coolant
exchanger (6400) temperature
1 IO Check hose NIO IO sensor
1
-
5
0
connections
0 (see page 86 onw.)
2 at the retarder
I
d
t
r
r Replace hose connections Replace gaskets NIO IO
a
I in accordance with information NIO IO
0
1
7 ** from the vehicle manufacturer
9
0
0
Before troubleshooting, ensure that there
0
0
. are no leaks at the screw plugs or sealing rings! Replace Contact Voith
3
5
1
sealing ring
I
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0
IO = in order
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Page 35

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Constant-Air Pressure Control Loop
5.2 Constant-Air Pressure Control

Loop

99/32
3700 Proportional valve 9000
9000 Pressure sensor

99/30 Retarder tester
99/31 Cable 1 (to the proportional valve) 99/31 3700
99/30
99/32 Cable 2 (to the pressure sensor)
99/34
99/33 Cable 3 (to temperature sensors) 99/33
99/34 Cable 4 (to the vehicle voltage supply/
PC interface)
NOTE
The measurement of the constant-air pressure
control loop provides information on
- internal and external leaks
- proper functioning
1
1
-
5
0
0
- proper control of the retarder Kd
.-S
ac
-Sa
h-N
ch
r.
-Nr
.
2
ith
Vo
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a
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0
1
7
9
0
0
0
0
.
3
5
1
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Page 36

Requirements Test scope

Special tools
CAUTION
Hot parts!
• Battery voltage 18–32 V Hands could be burned.
 Work carefully.
• Supply-air pressure in auxiliary circuit 8–11 bar  Wear protective gloves or use cloths if necessary.
• Oil level checked and in order
153.001085xx H53.1403xx 1. Connect the retarder tester (99/30) (see Test set-
• Electrical system of vehicle checked and in order up diagram Page 36 and operating instructions of
Retarder tester Air pressure (see specifications of vehicle manufacturer) the retarder tester):
in a case compl. gauge - Connect cable 1 (99/31) to proportional valve
• Electrical connections of the retarder are
0–6 bar (3700).
completely disconnected from the vehicle
99/29 99/7 - Connect cable 2 (99/32) to pressure sensor
(9000).
comprising:
99/30–99/35 - Connect cable 3 (99/33) to oil temperature
99/40 sensors (5200/1) and coolant (5200/2).
50/35 & 50/36 - Connect cable 4 (99/34) to the vehicle voltage
supply/PC interface.
1
1
-
NOTE 2. Select the retarder type at the retarder
5
0
0
2 tester (99/30).
I
d
With the test software "Diana-Lite" (99/40),
t
r
r
a
I
measured values can be read out and stored via the 3. Vehicle ignition: ON
0
1
7
PC in addition to the tests with the retarder tester.
9
0
0
0
The stored measured values can be transmitted to 4. Toggle switch at the retarder tester in position "EIN
0
.
3
5 the Voith customer service for evaluation (see mit Regelkreis“.
1
I
o
b
operating instructions on CD-ROM).
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5. With the multimeter (measuring type: volts), 8. After approx. 20 seconds, the value "Act.setting
measure the voltage at the retarder tester socket pressure" displayed in Diana-Lite and the value
"U_Versorgung". displayed on the air pressure gauge (99/7) have to
The value must lie between 4.75 and 5.25 V. lie between 2.6 and 3.1 bar.
If this value is not reached: Replace proportional If these values are not reached: Replace
valve (3700). proportional valve (3700).
6. With the multimeter (measuring type: volts), 9. Retarder tester switch "Stelldruck“ in position
measure the voltage at the retarder tester socket "0%".
"U_py IST".
10.Toggle switch at the retarder tester in position
The value must lie between 0.3 and 0.7 V.
"AUS".
If this value is not reached: Replace proportional 11.Vehicle ignition: OFF

valve (3700).
12.Detach the retarder tester (99/30) and pressure
7. Retarder tester switch "Stelldruck“ in position gauge (99/7), complete the retarder and vehicle.
"100%".
NOTE
To assess the operation of the proportional valve
1
(3700), the results of the following test are only
1
-
5
0
valid during a testing period of 60 seconds
0
2
I maximum.
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
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Page 38

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Pump Pressure (pdyn)
5.3 Pump Pressure (pdyn)

100 Retarder housing
99/32
9000
9000 Pressure sensor
50/36 Pressure sensor: 0–30 bar
99/31 3700
99/30 Retarder tester
99/30
99/31 Cable 1 (to the proportional valve) 99/34
99/32 Cable 2 (to the pressure sensors) 99/33
99/33 Cable 3 (to temperature sensors)

99/34 Cable 4 (to the vehicle voltage supply/
PC interface)
100
NOTE
Checking the pump pressure pdyn provides
information on
1
- the mechanical status of the rotor parts
1
-
5
0
0
2
- internal leaks Kd
Vo
.-S
ith
ac
-Sa
h-N
ch
r.
-Nr
.
I
d
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r - proper functioning of the retarder
a
I 50/36
0
1
7
9
0
0
0
0
.
3
5
1
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Page 39

Requirements Test scope

Special tools
CAUTION
Hot parts and oil!
• Compressed-air pressure 6–11 bar Hands can be burned and scalded.
 Work carefully.
• Oil level checked and in order  Wear protective gloves or use cloths if necessary.
• Electrical system of vehicle checked and in order
153.001085xx
(see specifications of vehicle manufacturer)
NOTE
Retarder tester • Electrical connections of the retarder are
Due to construction, a small amount of oil may leak
in case compl. completely disconnected from the vehicle
out; this does, however, not affect retarder
99/29 • No external leaks detected at retarder operation.
comprising:
99/30–99/35 • Vehicle secured
99/40
• Prop shaft at the retarder removed from the
NOTE
50/35 & 50/36
flanges (see specifications of vehicle  Observe the reduced tightening torque with the
manufacturer) integrated sealing ring.
NOTE The copper sealing ring variant is described in the
instructions.
1
1
- With the test software "Diana-Lite" (99/40),
5
0
0
2
measured values can be read out and stored via the
I
d
t PC in addition to the tests with the retarder tester.
r
r
a NOTE
I
0
The stored measured values can be transmitted to
1
7
9
0
the Voith customer service for evaluation (see  Lubricate sealing rings, O-rings and shaft
0
0
0
.
operating instructions on CD-ROM). sealing rings with silicone-free, non-corrosive
3
5
1
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Page 40

3. Connect the retarder tester (99/30) (see Test set-

103 up diagram Page 39 and operating instructions of NOTE
104
the retarder tester):
If the setpoint of the constant-air pressure (py) is
- Connect cable 1 (99/31) to proportional valve reached, but the pump pressure (pdyn) is
(3700). undershot, the retarder has an internal defect.
- Connect cable 2 (99/32) to pressure sensor (50/  Contact Voith.
36) and (9000).
- Connect cable 3 (99/33) to oil temperature 8. Disconnect the retarder tester (99/30) and all
sensors (5200/1) and coolant (5200/2). cables.
- Connect cable 4 (99/34) to the vehicle voltage 9. Disconnect the pressure sensor (50/36) and
28026
supply/PC interface. remove the sealing ring (104).
1. Unscrew screw plug (103) and remove sealing ring 4. Select the retarder type at the retarder tester.
10.Lubricate the new sealing ring (104) with silicone-
(104).
5. Switch on the vehicle ignition and start the engine. free, non-corrosive grease.
11.Screw in the screw plug (103) with sealing ring

50/36 104 NOTE (104) and tighten to 20 Nm.
 Shift in direct gear (ratio 1:1). The engine speed
12.Remove prop shaft at the retarder from the flanges
1,000 r.p.m. then corresponds to the prop shaft
speed of 1,000 r.p.m.. (see specifications of vehicle manufacturer).
1
1
-
5
6. Check pump pressure at engine speed 1000 min-1
0
0
2
I
(see operating instructions of the retarder tester).
d
t
r
r
a
I
0
7. Compare the measured pump pressure to the
1
7 28027
9
0 minimum dynamic pump pressure in accordance
0
0
0
.
3
with the specifications of the retarder tester.
5
1 2. Connect pressure sensor (50/36) to retarder
I
o
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r
u
housing (100) with sealing ring (104).
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Page 41

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Proportional Valve Current
5.4 Proportional Valve Current Requirements Test scope
• Ignition switched off 3700

Special tools
98/8
• Battery voltage 24–28 V
• Electrical system of vehicle checked and in order

(see specifications of vehicle manufacturer)
• Fuse for retarder controller tested and in order
H53.8198xx • Male and female plug connectors at proportional

99/3
valve checked for damage or wear (notch 28019
Measuring scratches)
adapter 1. Disconnect the plug from the proportional valve
• Electrical lead and plug connections checked
99/3 (visual inspection) and in order (3700) and connect it to the measuring adapter
(99/3).
2. Connect the plug of the measuring adapter to the

NOTE
proportional valve (3700).
When performing measurements using a
commercially available multimeter (without real 3. Connect the multimeter (98/8).
1
1
- r.m.s. value measurement), exact readout of these Measuring type: mA.
5
0
0
2
I
measured values is not possible (display jumps).
d
t
r
4. Turn the "Propventil" (prop valve) switch at the
r
a
I
0
measuring adapter to position "I".
1
7
9
0
0
0
Commercially available tool 5. Switch on ignition.
0
.
3
5
1
I
o Multimeter (98/8) with real r.m.s. value 6. Shift the retarder to the highest gear.
b
r
u
T 5
0
measurement, e.g. Fluke 179
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Page 42

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Proportional Valve Current
Controller Item number/ Measured

NOTE
Code number value
Due to continuous readjustment in the control loop, VERA TM H67.2763.xx 440–640 mA
the measured values may not be constant, but are
H67.2866.xx
within the specified range.
H67.3449.xx
7. Read measured value and compare to the H67.3457.xx
specified values: H67.3658.xx
Controller Item number/ Measured 153.000586.xx
Code number value
8. Disconnect multimeter.
Digiprop 138, 152, 155 396–596 mA
150 365–565 mA 9. Pull the plug from the measuring adapter (99/3)
and connect it to the proportional valve (3700).
151 379–579 mA
153 423–623 mA
157, 158 409–609 mA
159 534–546 mA
179, 180, 440–640 mA
502, 504, 508, 512,
514
1
1
-
5
0
510 430–630 mA
0
2
I
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t
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a
I
0
1
7
9
0
0
0
0
.
3
5
1
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Page 43

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder
6. Removing and Installing the Retarder
1
1
-
5
0
0
2
I
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t
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a
I
0
1
7
9
0
0
0
0
.
3
5
1
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Page 44

DANGER
Retarder can fall!
Your body can be crushed severely.
 Secure retarder against falling.
 Use a suitabe device for hanging it up.
CAUTION
Improper removal/installation!
Damage to/failure of the retarder.
Warranty is voided.
 Request and use gearbox-specific documents
and special tools from VOITH.
CAUTION
Hot parts!
Hands could be burned.
1
 Work carefully.
1
-
5
0  Wear protective gloves or use cloths if necessary.
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
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Page 45


800 Inside part
850 Outer ring
Remove only if the taper roller bearing 25300
is replaced or a new shim is fitted 25000
25300
4100 Screw plug M30x1.5, 850
25200
25000 Shim
25100 O-ring 14x4, replace
25200 Hex head screw M10x70,
hexagon insert bit, w.a.f. 16, 58 Nm
25300 Hex head screw M10x60, 4150 25100
hexagon insert bit, w.a.f. 16, 58 Nm 4100
NOTE
1
1
-
5 sealing rings with silicone-free, non-corrosive
0
0
2 grease before installation.
I
d
t
25200
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
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800
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h 0
t
i 2
o 28046
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Page 46

Removal
Special tools NOTE
25200
 The shim must always be redetermined if 25300
- the inside part (800) is replaced
- the retarder is attached to the gearbox
- the retarder has been repaired
- the gearbox has been repaired
FJ 6280 0
486 265
H67.3224xx H67.3320xx H67.3319xx Requirements
• Retarder switched off 25200

Measuring Puller Drive-in tool 28029
device for bearing outer • Ignition switched off
ring 1. Unscrew the hex head screws (25200) and
• Supply-air pressure discharged
98/1 98/3 98/4 (25300).
• Retarder oil discharged (see page 22)
2. Remove retarder from the gearbox with a suitable
Tools for self-fabrication • Coolant drained (see page 28) lifting device.
• Gearbox oil discharged
• Propeller shaft at gearbox flange removed

1
1
-
5
0 0 15
0
2 1 • Output flange removed
I 80
d
t
M
r
r
a
I • Speedometer sensor removed
0
1
28028
7
9
0
0
0
• Retarder with gearbox removed from vehicle
0
.
3
5
1
Material: St37-2, DIN 17100 (1.80)
I
o
b
r
u
T 5
2 x Threaded bolt
0
h 0
t
i 2
o
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Page 47

Determining the shim
NOTE
 Carry out measurements at the retarder and 850
25000 gearbox in the vertical position at room
850 temperature.
800
 The retarder and gearbox must have cooled
98/4
down.
0 5
6
2
0
8 6
2
6 8
J 4
F
25100
28036 28032
3. Remove O-rings (25100) from the gearbox. 2. Place the bearing outer ring (850) onto the inside
part (800).
NOTE
B
 For easier removal, heat the housing near the Pos.1 Pos. 2
bearing outer ring to approx. 80 °C.
98/1
4. Remove outer ring (850) with the puller for the
bearing outer ring (98/4) and remove the 28031
shim (25000).
1
1
-
5
0 1. Measure the distance "B" between the bearing
0
2
I
d
t
surface on the retarder side of the gearbox
r
r
a
I housing and the bearing surface of the shim and
0
1
7
9
write down the value. 28033
0
0
0
0
.
3
5
1 3. Place the measuring device (98/1) onto the
I
o
b
r
u
retarder housing. Tighten the hex head screws to
T 5
0
h 0
t
i 2
10 Nm.
o
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Page 48

4. Move lever from position 1 to position 2. A defined Installation

pre-stress is applied to the drive shaft.
NOTE
5. Turn the pinion clockwise 15 times by hand and
anticlockwise 15 times.  To reach the compensating dimension, several
shims may be needed.
 Always put the thicker shim first into the gearbox
housing.
28035
7. Place the depth caliper gauge on the measuring 25000

surface of the measuring disk. 850
28034 CAUTION 98/4
6. Place the depth caliper gauge on the retarder Dimension A outside tolerance range!
housing interface and zero it. Damage to/failure of the retarder.
 Contact Voith. 28135
1
1
8. Measure dimension A from the measuring surface 1. Fit the shim (25000) into the gearbox housing.
-
5
0
0
of the measuring disk to the interface of the
2
I
d
t
r
retarder housing and write down the value. NOTE
r
a
I Tolerance of dimension A is 131.031–
0
1
7
 Replace bearing outer ring (850) if taper roller
9
0
132.171 mm. bearing (800) is replaced.
0
0
0
.
3
5
1
9. Determine the thickness of the shim.
I
o
b
r Shim thickness = dimension B – dimension A –
u
T 5
0
h 0
t
i 2
0.02 mm.
o
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Page 49

NOTE 25200 25200

25100
 For easier mounting, heat the housing near the
25200
bearing outer ring to approx. 80 °C.
2. Fit bearing outer ring (850) into the gearbox

housing and drive it in with the drive-in tool (98/3)
until it stops.
25300
1
28038 28039
5. Clean sealing surface of the gearbox housing and 8. Place retarder on the gearbox housing.
apply surface seal A002989712010 (Voith item
9. Screw in hex head screws (25200).
No. H53.3305xx).
10.Screw out threaded bolts M10x80.
6. Lubricate the new O-rings (25100) with silicone-
free, non-corrosive grease and insert them into 11.Tighten hex head screws (25200) to 58 Nm.
gearbox housing.
28037 12.Screw in hex head screws (25300) and tighten to
NOTE 58 Nm.
3. Clean sealing surface of the retarder housing (1).
1
1
-
5
The threaded bolts are necessary for mounting the
0
0
2 4. Position gearbox vertically with sealing surface sealing surface of the gearbox/retarder
I
d
t
r
r upward. congruently.
a
I
0
1
7
9
0
0 7. Screw two threaded bolts M10x80 (see arrows)
0
0
.
3
5
into the gearbox housing.
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 50

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair
7. Repair
7.1 Components Overview 52

7.2 Top Oil Tank Cover 59
7.3 Bottom Oil Tank Cover 61
7.4 Casing Ventilation 63
7.5 Retarder Ventilation 69
7.6 Water Neck 70
7.7 Heat Exchanger 71
7.8 Pressure Control Valve 76
7.9 Non-Return Valve Inlet 79
7.10 Non-Return Valve Outlet 81
7.11 Oil Temperature Sensor 84
7.12 Coolant Temperature Sensor 86
7.13 Pressure Sensor 88
7.14 Proportional Valve and Damping Plate 89
1
1
-
5
0
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
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Page 51

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview
7.1 Components Overview

4100
5901 4150
Item No. Designation 5900 3300
100 Retarder housing 3100
9000
hexagon socket head, w.a.f. 12, 6101
with copper sealing ring: 80 Nm 6100 2000
with integrated sealing ring: 47 Nm 5901 2810 6101
8000
108 Sealing ring A24x29, replace 2301 6600
3300
1600 Valve cover 100
2800 2300 6700
1700 O-ring 60x3, replace 5300
6600
1900 Non-return valve "inlet" M48x1.5, 3850 5200/1
hexagon insert bit, w.a.f. 55, 3800 6700
2801 3850 7600
with integrated sealing ring: 280 Nm 3900 7500
7300
2900 7300
7300 7500
6400
NOTE 5600 2206 6700
5500
4000 108 6600
 Lubricate sealing rings, O-rings and shaft 5400 3700 2600
3500 20100
sealing rings with silicone-free, non-corrosive 107 1950 20000
3550
1 2200
1
-
5
2500
0
0 3100 1900
2
I
d
t
r
r
NOTE 4250 20200
a
I
2105 4250 5200/2
0 4200 4200
1
7  Observe the reduced tightening torque with the 2100 6700 5300
9
0
0
0 integrated sealing ring. 2106 6600 20200
0
.
3 3100
The copper sealing ring variant is described in the 1700 1600
5
1
I 20000
o
b
r instructions. 20100 20400 20300
u
T 5
0
h 0
t
i 2
o 28047
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Page 52

Item No. Designation 4100

5901 4150
3100
2000 Top oil tank cover
9000
2100 Non-return valve "outlet"
6101
2105 O-ring 34x3, replace 6100 2000
2106 O-ring 54x3, replace 5901 2810 6101
8000
2200 Pressure control valve 3300 2301 6600
2206 O-ring 21.5x2.5, replace 100
2800 2300 6700
2300 Casing ventilation 5300
6600
2301 O-ring 55x3, replace 3850 5200/1
3800 6700
2500 Bottom oil tank cover 2801 3850 7600
3900 7500
2600 Cover gasket bottom, replace
7300
2900 7300
7300 7500
6400
NOTE 5600 2206 6700
5500
4000 108 6600
3500 20100
3550
1
1
2200
-
5 2500
0
0
2
3100 1900
I
d
t
r
r NOTE 4250 20200
a
I 2105 4250 5200/2
0 4200 4200
1
7
0
0
0
0
integrated sealing ring. 2106 6600 20200
.
3 3100
1700 1600
5
1
I The copper sealing ring variant is described in the 20000
o
b
r
u
instructions. 20100 20400 20300
T 5
0
h 0
t
i 2
o
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28047
Page 53


5901 4150
2800 Cover of casing ventilation 5900 3300
3100
2801 Cover
9000
2810 Vent and air filter M12x1.5,
6100 2000
2900 Gasket, replace 5901 6101
2810
8000
3100 Combined hex head screw M8x30.
hexagon insert bit, w.a.f. 13, 30 Nm 3300 2301 6600
100
2800 2300 6700
3300 Combined hex head screw M8x80,
6600
3500 Screw plug M30x1.5, 3850 5200/1
3800 6700
2801 3850 7600
3900 7500
7300
2900 7300
7300 7500
6400
NOTE 5600 2206 6700
5500
4000 108 6600
3500 20100
3550
1
1
2200
-
5 2500
0
0
2
3100 1900
I
d
t
r
r NOTE 4250 20200
a
I 2105 4250 5200/2
0 4200 4200
1
7
0
0
0
0
integrated sealing ring. 2106 6600 20200
.
3 3100
1700 1600
5
1
o
b
r
u
instructions. 20100 20400 20300
T 5
0
h 0
t
i 2
o
V ©
28047
Page 54


5901 4150
3100
9000
3800 Damping plate
6101
3850 O-ring 16x3, replace 6100 2000
3900 Combined hex head screw M8x20, 5901 2810 6101
8000
3300 2301 6600
4000 Hex head nut M8, 100
2800 2300 6700
4100 Screw plug M30x1.5, 5300
6600
hexagon socket head, w.a.f. 17, 3850 5200/1
3800 6700
2801 3850 7600
3900 7500
4150 Sealing ring A30x36, replace 7300
2900 7300
7300 7500
6400
5600
NOTE 5500
2206 6700
4000 108 6600
5400 3700 2600
 Lubricate sealing rings, O-rings and shaft 3500 20100
107 1950 20000
sealing rings with silicone-free, non-corrosive 3550
grease before installation. 2200
1
1
-
5 2500
0
0
2
3100 1900
I
d
t
r 4250 20200
r
a
I NOTE 2105 4250 5200/2
0 4200 4200
1
7
9
2100 6700 5300
0  Observe the reduced tightening torque with the
0
0 2106 6600 20200
0
.
3
integrated sealing ring. 3100
1700 1600
5
1
I
The copper sealing ring variant is described in the 20000
o
b
r
u
20100 20400 20300
T 5
0
instructions.
h 0
t
i 2
o
V ©
28047
Page 55


5901 4150
4200 Screw plug M24x1.5, 5900 3300
hexagon socket head, w.a.f. 12, 3100
with copper sealing ring: 80 Nm 9000
6101
5200/1 Oil temperature sensor M14x1.5, 5901 2810 6101
8000
3300 2301 6600
5200/2 Coolant temperature sensor M14x1.5, 100
2800 2300 6700
6600
3850 5200/1
5400 Corrugated spring 3800 6700
2801 3850 7600
5500 Disc silencer
3900 7500
5600 Circlip JL30x1.2 7300
2900 7300
7300 7500
6400
5600
NOTE 5500
2206 6700
4000 108 6600
5400 3700 2600
 Lubricate sealing rings, O-rings and shaft 3500 20100
107 1950 20000
1
1
-
5 2500
0
0
2
3100 1900
I
d
t
r 4250 20200
r
a
I NOTE 2105 4250 5200/2
0 4200 4200
1
7
9
2100 6700 5300
0  Observe the reduced tightening torque with the
0
0 2106 6600 20200
0
.
3
1700 1600
5
1
I
The copper sealing ring variant is described in the 20000
o
b
r
u
20100 20400 20300
T 5
0
instructions.
h 0
t
i 2
o
V ©
28047
Page 56


5901 4150
5900 Pipe 5900 3300
3100
5901 O-ring 15.3x2.4, replace
9000
6100 Pipe
6101
6101 O-ring 15.3x2.4, replace 6100 2000
6400 Heat exchanger 5901 2810 6101
8000
6600 Hex head screw M14x45, 3300 2301 6600
2800 2300 6700
6700 Washer A14
5300
7300 O-ring 15x4, replace 6600
3850 5200/1
3800 6700
2801 3850 7600
7600 O-ring 25x4, replace 3900 7500
7300
8000 Intermediate washer 196x144x2 2900 7300
7300 7500
6400
5600 2206 6700
NOTE 5500
6600
4000 108 2600
5400 3700 3500 20100
3550
1
1
-
5 2500
0
0
2
3100 1900
I
d
t
r
r
4250 20200
a 2105 5200/2
I
0 NOTE 4250 4200 4200
1
7
9
2100 6700 5300
0
0
0
0
 Observe the reduced tightening torque with the 2106 6600 20200
.
3
1700 1600
5
1
I 20000
o
b
r
u
The copper sealing ring variant is described in the 20100 20400 20300
T 5
0
h 0
t
i 2
instructions.
o
V ©
28047
Page 57


5901 4150
9000 Pressure sensor M16x1.5, 5900 3300
20000 Water neck 9000
20100 Gasket, replace 6101

6100 2000
20200 Combined hex head screw M8x80, 5901 6101
2810
20300 Screw plug M14x1.5, 3300 2301 6600
2800 2300 6700
6600
3850 5200/1
3800 6700
NOTE 2801 3850 7600
3900 7500
 Lubricate sealing rings, O-rings and shaft 7300
2900 7300
7300 7500
5600 2206 6700
5500
4000 108 6600
5400 3700 2600
3500 20100
NOTE 3550
107 1950 20000
1
1
 Observe the reduced tightening torque with the 2200
- 2500
5
0
0
2
I
1900
d
t
r
The copper sealing ring variant is described in the 4250 20200
r
a
I instructions. 2105 4250 5200/2
0 4200 4200
1
7
9
2100 6700 5300
0
0
0
0 2106 6600 20200
.
3 3100
1700 1600
5
1
I 20000
o
b
r
u
20100 20400 20300
T 5
0
h 0
t
i 2
o
V ©
28047
Page 58

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Top Oil Tank Cover
7.2 Top Oil Tank Cover

6101
Item No. Designation 3300 9000

6100
2000 Top oil tank cover
6101
6100 Pipe, mind mounting position 3100

8000 Intermediate plate 196x144x2, replace 2000
9000 Pressure sensor M16x1.5,
NOTE
1
1
-
5
0
0
2
I
Sealing agent
d
t
r
r
a
I Thread seal Loctite 572
0
1
7
9
0
0
0
0
.
Requirements
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o • Ignition switched off 28072
V ©
Page 59

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Top Oil Tank Cover

CAUTION free, non-corrosive grease and pull them on the
pipe (6100).
Hot parts!
NOTE
 Work carefully.
 Wear protective gloves or use cloths if necessary. Ensure proper installation position of the pipe
(6100) in the top oil tank cover (2000).
Removal
5. Insert pipe (6100) into top oil tank cover (2000)
1. Unscrew the combined hex head screws (3100 and cover of casing ventilation (2800).
and 3300).
6. Screw on top oil tank cover (2000) with the
2. Remove top oil tank cover (2000). combined hex head screws (3100 and 3300).
3. Remove the intermediate washer (8000). 7. Tighten combined hex head screws (3100 and
3300) crosswise to 30 Nm.
4. Remove the pipe (6100).
Installation
NOTE
1
Use sealing agent Loctite 572 with retarders
1
-
5
0
starting with Voith item No. H67.1500.30.
0
2
I
d
t
r
r
a
I 1. Clean sealing surface on retarder housing (100)
0
1
7
9 and top oil tank cover (2000).
0
0
0
0
.
3
5
1
2. Apply sealing agent inside the holes of the
I
o
b
r
combined hex head screws (3100 and 3300).
u
T 5
0
h 0
t
i 2
o
V ©
3. Insert new intermediate washer (8000).
Page 60

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Bottom Oil Tank Cover
7.3 Bottom Oil Tank Cover

2500 Bottom oil tank cover
2600 Cover gasket bottom, replace
2600
NOTE
2500
3100
1
1
NOTE
-
5
0
0
2
I
 Observe the reduced tightening torque with the
d
t
r
r integrated sealing ring.
a
I 4250
0
1
7
The copper sealing ring variant is described in the
9
0
0
0
instructions.
0
.
3
4200
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V © 28073
Page 61

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Bottom Oil Tank Cover
Requirements
CAUTION
Incorrect sequence when tightening the
• Ignition switched off combined hex head screws!
• Retarder oil discharged (see page 22) Cover can buckle.

 Screw tight combined hex head screws in the
CAUTION prescribed sequence.
Hot parts!
 Work carefully.
 Wear protective gloves or use cloths if necessary. 6
5 7
Removal 4 3 8
17 2 1
9
1. Unscrew the combined hex head screws (3100).
16 10
2. Remove bottom oil tank cover (2500). 15 11
14 12
3. Remove cover gasket bottom (2600).
13 28074
Installation
1
1
4. Screw tight combined hex head screws in the
-
5
0
0
2
1. Clean sealing surface on retarder housing (100) prescribed sequence to 30 Nm.
I
d
t
r
r
and bottom cover (2500).
a
I
0
1
7
9 2. Insert new cover gasket bottom (2600).
0
0
0
0
.
3
5
1
3. Screw on cover (2500) with the combined hex
I
o
b
r
head screws (3100).
u
T 5
0
h 0
t
i 2
o
V ©
Page 62

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation
7.4 Casing Ventilation

3300
2300 Casing ventilation
2300/1 Valve insert 2800
2810 6101
2300/2 Float, specified weight max. 12 g
2300/3 Float cage 6100
2800 Cover of casing ventilation
2801 6101
2801 Cover
2810 Vent and air filter
2900 Casing ventilation cover gasket,
replace 2900

hexagon insert bit, w.a.f. 13, 30 Nm 2300/1
6100 Pipe, mind mounting position

2300 2301
2300/2
1
1
-
5
0
0 NOTE
2
I
2300/3
d
t
r
r
a
I
0
1 sealing rings with silicone-free, non-corrosive
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
Cleaning agent
T 5
0
h 0
t
i 2
o
Float Spirit
V © 28048
Page 63

Tools for self-fabrication

CAUTION CAUTION
Incorrect adapter! Hot parts!
Damage to casing ventilation. Hands could be burned.
 Use only the adapter (98/9) as from item number  Work carefully.
H53.942811. Ø 40.5 mm  Wear protective gloves or use cloths if necessary.
m
Ø 60 mm m
7
Material: St 37 Removal
Special tools
Weight: 0.085 kg 28049_en
Test ring
99/4 3300
The test ring (99/4) can be ordered from Voith Turbo:

item No. H67.2757xx.
H53.7712xx H53.9428xx
Requirements
Impact puller Adapter • Retarder switched off

28050
99/5 98/9 • Ignition switched off
1
1
- • Proportional valve and damping plate removed 1. Unscrew the combined hex head screws (3300).
5
0
0
2
I
(see page 89)
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 64

2800 99/5
100
2300/1
98/9
2900
2301
28051 28053 28055
2. Remove cover of casing ventilation (2800). 5. Knock valve insert (2300/1) with the impact puller 7. Take O-ring (2301) out of the groove in the valve
(99/5) and the adapter (98/9) upward from the insert (2300/1).
3. Remove casing ventilation cover gasket (2900).
retarder housing (100).
6101
2300/2
6100 100
6101
2300/3
1
1
-
5
0
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0 28052
0
0
28054
.
3
5
1
I
o 4. Remove the pipe (6100).
b
r
u
6. Remove float (2300/2) and float cage
T 5
0
h 0
t
i 2
(2300/3) from the retarder housing (100)
o
V ©
Page 65

Checking Installation
1. Check the casing ventilation (2300) for dirt/sludge

99/7 CAUTION
and clean it.
2300/2 Lubrication of the radial shaft sealing ring!
Retarder fault.
 Do not lubricate the radial shaft sealing ring.
2300/1
2300/2
28057
2300/1
5. Check the sealing edge of the radial shaft sealing

ring (arrow) in the valve insert (2300/1):
28056
- For this purpose, place the float (2300/2) on a
suitable object (e.g. hex head nut).
2. Check the float (2300/2) for damaged surfaces
2301
and sealing areas (arrow). - Place the valve insert (2300/1) on the float
(2300/2) and weigh it down using the test ring
28058
3. Weight float (2300/2): Specified weight: max. 12 g. (99/4).
4. For exceeded specified weight: replace the entire - Fill empty space between float (2300/2) and 1. Apply silicone-free and non-corrosive grease to a
1 casing ventilation (2300). upper edge of valve insert with spirit. new O-ring (2301) and pull it onto the valve insert
1
-
5
0
0
If the sealing edge is undamaged, the fluid level (2300/1).
2
I
d
t
remains constant over 1 minute.
r
r
a
I
0
1
7
6. Replace casing ventilation (2300) if sealing edge
9
0
0
0 is damaged.
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
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Page 66


99/5 free, non-corrosive grease and pull them on the
2300/1 100 pipe (6100).
NOTE
2300/2 98/9 Ensure proper installation position of the pipe
(6100) in the top oil tank cover (2000).
2300/3 9. Insert pipe (6100) into top oil tank cover (2000).
28059 28053
2. Clean float with spirit. 7. Press valve insert (2300/1) carefully into the
retarder housing with the impact puller (99/5) and 2900
3. Insert float (2300/2) into the float cage (2300/3).
the adapter (98/9).
4. Place valve insert (2300/1) on float cage (2300/3). 2000
5. Clean sealing surface on retarder housing (100) 6100

and cover of casing ventilation (2800). 6101
6. Coat hole of casing ventilation in the retarder 28136
1
housing with silicone-free and non-corrosive
1
-
5
0 grease. 10.Insert new gasket (2900).
0
2
I
d
t
r
r
a
11.Lubricate hole for the pipe (6100) in the cover of
I
0
1
7
casing ventilation (2800) with silicone-free, non-
9
0
0
0 28060
corrosive grease.
0
.
3
5
1
I 12.Slide cover of casing ventilation (2800) onto the
o
b
r
u
T 5
pipe (6100).
0
h 0
t
i 2
o
V ©
Page 67

6100
3300
2800
28061
13.Screw on cover of casing ventilation (2800) with

the combined hex head screws (3300).
14.Tighten combined hex head screws (3300)

crosswise to 30 Nm.
1
1
-
5
0
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 68

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Retarder Ventilation
7.5 Retarder Ventilation

DANGER
Item No. Designation Heavily soiled or painted-over retarder
ventilation!
5400 Corrugated spring
Retarder reduces braking power after a delay.
5500 Check, clean and blow out disc
 Replace retarder ventilation.
silencer with compressed air
5600 Circlip
CAUTION
5400 Retarder ventilation mechanically defective!
5500
Retarder fault.
 Replace retarder ventilation.
5600 Requirements

-Nr.
Sach -Nr.

Kd.- -Sach
Voith
28062
1
1
-
5
0
0
Cleaning agent
2
I
d
t
r
Retarder ventilation Benzine
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 69

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Water Neck
7.6 Water Neck

20000 Water neck
20100 Gasket, replace
NOTE 20100

Requirements

20100
• Coolant drained (see page 28) Kd
.-S
ith-
ach
Sa
-N
ch
r.
-Nr
.
Vo
1 20000
1
-
5
0
0
2
CAUTION
I
d
20200
t
r
r
a Hot parts!
I
0
1
7 Hands could be burned.
9
0
0
0
0
 Work carefully.
.
3
5
1
I
 Wear protective gloves or use cloths if necessary.
o
b
r
u
T 5
0
h 0
t
i 2
o 28063
V ©
Page 70

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Heat Exchanger
7.7 Heat Exchanger

with integrated sealing ring: 47 Nm 6700

hexagon socket head, w.a.f. 12
with integrated sealing ring: 47 Nm 6600
7600
7500
6400 Heat exchanger
7300
6600 Hex head screw M14x45, 7300
6700 Washer A14

4250
7500 O-ring 45x5, replace 108 4250
107 4200 7300
1
1
7600 O-ring 25x4, replace 4200 7500
-
5 6700
0
0
2
I
d
6600
t
NOTE
r
r
a
I
0
1
7
9
0
0
0
0
. sealing rings with silicone-free, non-corrosive
3
5 6700
1
I grease before installation.
o
b
r
6600
u
T 5
0
h 0
t
i 2
o 28064
V ©
Page 71

Requirements Removal
NOTE
integrated sealing ring. • Ignition switched off
The copper sealing ring variant is described in the
instructions.
• Retarder oil discharged (see page 23) 6600
Special tools • Coolant drained (see page 28) 6700
• Water neck removed (see page 70) 6700

6600
6700
CAUTION 6600 28066
Hot parts!
1. Unscrew the hex head screws (6600).
 Work carefully. 2. Remove the heat exchanger (6400).
H67.1948xx  Wear protective gloves or use cloths if necessary.
Pressure test
equipment DANGER
7600
1
50/22 Heat exchanger can fall! 7500
1
-
5 7300
0
0
Your body can be crushed severely.
2
I
7300
d
t
r
Sealing agent  Secure heat exchanger against falling.
r
a
I
0 Heat exchanger Elring Sealing Mass Dirko-S  Use a suitable device for hanging it up.
1
7
9
0
Profi press HT; black;
0
0
0
.
temperature resistant from 7300
3
5 –50 °C ... 250 °C; 7500 28067
1
I
o
b
r
Elring No. 129.400;
u
T 5
0
h 0
Voith item No. 190.00169710 3. Remove the O-rings (7300, 7500 and 7600).
t
i 2
o
V ©
Page 72

Checking 4. Repeat Steps 1 through 3 at connections "B" and

"C".
50/22 6400
C
A B
28068
CAUTION
Heat exchanger leaky!
Retarder fault.
 If air bubbles appear in the water or an external
leak is detected, replace the heat exchanger.
1
1
-
1. Attach pressure test equipment (50/22) to heat
5
0
0
2 exchanger (6400) with O-rings and attach the
I
d
t
r
r
compressed-air line to the connection.
a
I
0
1
7
9 2. Fill cooling water section of heat exchanger (6400)
0
0
0
0
.
with hot water (approx. 70 °C).
3
5
1
I
o
b
r
3. Slowly pressurize heat exchanger (6400) with
u
T 5
0
h 0
t
compressed air from 0 to max. 10 bar.
i 2
o
V ©
Page 73

Installation 2. Apply sealing agent (arrow) to the retarder housing

100
(100) near the heat exchanger (6400) (see dashed
NOTE line/figure).
The water and oil section of new heat exchangers 7600

6400
are coated with anti-corrosion oil. 7500
 Before installing, discharge any anti-corrosion 7300
7300
oil which as accumulated and rinse with hot
water on the water side.
6600
7300 6700
CAUTION 7500 28070
6700
Possible water residue in retarder! 6600
1. Lubricate the new O-rings (7300, 7500 and 7600) 6700
Oil ejection via ventilation.
with silicone-free, non-corrosive grease and insert 6600 28066
Retarder fault.
into retarder housing (100).
 Fill retarder with 7.0 litres of engine oil or flush 3. Place the heat exchanger (6400) onto the retarder
oil. Apply brakes lightly several times to flush the
100 housing (100).
retarder system. Discharge flush oil. Repeat 2 to
3 times.
4. Screw in hex head screws (6600) with washers
 De-oil the cooling circuit and heating system (6700).
according to the vehicle manufacturer’s
instructions. 5. Tighten hex head screws (6600) crosswise to
1
1
-
5 150 Nm.
0
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
28174
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 74

100
6400
28175
6. With housing models up to retarder serial number

963 690, the gap at the top between the heat
exchanger (6400) and the retarder housing (100)
must be sealed with sealing agent (arrow) (see
dashed line/figure).
1
1
-
5
0
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 75

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Pressure Control Valve
7.8 Pressure Control Valve

2200 Complete pressure control valve
NOTE .-S
-N
ach Nr.
r.
Kd ac
h-
th-S
Voi

NOTE 2206

1
1
- integrated sealing ring. 3500
5
0
0
2
d
t
r
r
a
instructions.
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o 28075
V ©
Page 76

Requirements
Special tool
• Retarder oil discharged (see page 22) Kd

Vo
.-S
ith
ac
-S
h-N
ac
r.
h-N
r.
CAUTION
Hot parts! 99/5
H53.7712xx
 Work carefully. 28077
Impact puller  Wear protective gloves or use cloths if necessary.
99/5
Removal NOTE
Tools for self-fabrication There are two variants of the pressure control
valve.
- Pressure control valve variant 1 without sieve.
M8
Sieve is at the screw plug (3500)
- Variant 2; sieve is located directly in the
pressure control valve
Nr.
ach-
.-S h-Nr.
Kd ac
ith-S
Vo
1
1
-
 With variant 1, the pressure control valve (2200)
5
0
0 is only removed with the impact puller (99/5).
2
I
3550
d
t M 20x1.5
r
r 3500
a
I 2. Knock out pressure control valve (2200) with the
0
1
7
9 impact puller (99/5) and the screw plug (50/43)
0
Screw plug 28076
0
0
0
.
from the retarder housing.
3
5
1
I
50/43 1. Unscrew the screw plug (3500).
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 77

Installation
r .
h-N
ac r .
.-S h-N
Kd ac
h-S
Voit
2206
2200 28078
1. Lubricate the new O-ring (2206) with silicone-free,

non-corrosive grease and pull it onto the pressure
control valve (2200).
2. Carefully press pressure control valve (2200) with

the impact puller (99/5) and the screw plug (50/43)
into the retarder housing.
1
1
-
5
0
silicone-free, non-corrosive grease.
0
2
I
d
t
r
r
a
4. Screw in the screw plug (3500) with sealing ring
I
0
1 (3550) and tighten to 130 Nm.
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 78

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Inlet
7.9 Non-Return Valve Inlet

1900 Non-return valve inlet, complete
1900/1 Guide M48x1.5,
1900/2 Spring
1900/3 Piston
NOTE
1950
sealing rings with silicone-free, non-corrosive 1900/3
grease before installation. 1900/2
1900/1
Sealing agent
Nr.
h-
ac
.-S h-Nr.
Kd ac
ith-S
Vo
1
1
-
Thread seal Loctite 572
5
0
0
2
1900
I
d
t
r
r
Requirements
a
I
0
1
7
9 • Retarder switched off
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o 28079
V ©
Page 79

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Inlet
Installation
CAUTION
Hot parts! NOTE
Hands could be burned.  Use sealing agent Loctite 572 with retarders
 Work carefully. starting with Voith item No. H67.1500.30.
 Wear protective gloves or use cloths if necessary. Only in conjunction with copper sealing ring.
Removal 1. Apply sealing agent to the thread of the guide

(1900/1).
1. Screw out guide (1900/1).
2. Remove spring (1900/2) and piston (1900/3) from silicone-free, non-corrosive grease.
retarder housing.
3. Screw in the non-return valve inlet (1900) complete
Checking with sealing ring (1950).
1. Check rubber coating of the piston (1900/3) for 4. Tighten non-return valve inlet (1900) with 280 Nm.
damage.
Replace the complete non-return valve inlet (1900)
if necessary.
2. Check guide (1900/1) and spring (1900/2) for wear.

1
1
-
Replace the complete non-return valve inlet (1900)
5
0
0
2
if necessary.
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 80

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Outlet
7.10 Non-Return Valve Outlet

1600 Valve cover, mind mounting position
2100 Non-return valve outlet, complete.
Mind mounting position
NOTE
grease before installation. Kd.
ch-
-Sa h-Nr.
ith-
Sac
Nr.
Vo
2105
1
1
2106
-
5
0 1700
0
2
I 1600
d
t
r
r
a
I
0 2100 3100
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o 28080
V ©
Page 81

Removal Checking
Special tool
1. Unscrew the combined hex head screws (3100). 2100
2105
2. Remove the valve cover (1600). 1
153.000052xx
Puller
for non-return 28158
valve outlet
1. Check rubber coating of the valve plate (1) for
50/1
50/1 28153 damage.
Requirements Replace the complete non-return valve outlet
3. Slide the puller for the non-return valve (50/1) onto (2100) if necessary.
• Retarder switched off the non-return valve outlet (2100) until it engages.
2. Check the hole or sleeve (arrow) for wear and
• Ignition switched off 4. Pull the non-return valve outlet (2100) out of the uncircularity.
retarder housing. Replace the complete non-return valve outlet
• Retarder oil discharged (see page 22)
1
1
-
(2100) if necessary.
5
0 5. Remove the O-rings (1700, 2105 and 2106).
0
2
I
d
CAUTION 3. Press the valve plate (1) flush in and check the
t
r
r
a
I guide piston (2) for wear.
0
1
Hot parts!
7
9
Replace the complete non-return valve outlet
0
0
0
0
.
(2100) if necessary.
3
5
 Work carefully.
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 82

Installation
1. Apply silicone-free and non-corrosive grease to the

new O-rings (2105 and 2106) and pull them onto
the non-return valve outlet (2100).
100
2100
28178
2. Press the non-return valve outlet (2100) into the

retarder housing (100) in the correct installation
position (arrow) with a suitable tool.
3. Apply silicone-free and non-corrosive grease to O-

1
1
-
5 ring (1700) and pull it onto the valve cover (1600).
0
0
2
I
d
t
r
r
4. Screw on valve cover (1700) with the combined
a
I
0
1
hex head screws (3100).
7
9
0
0
0
0
.
5. Tighten combined hex head screws (3100)
3
5
1
I
crosswise to 30 Nm.
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 83

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Oil Temperature Sensor
7.11 Oil Temperature Sensor

5200/1 Oil temperature sensor M14x1.5,
NOTE
Requirements

5300
CAUTION
5200/1
1
1
-
5
Hot parts!
0
0
2
I
d
t
r
r
a
 Work carefully.
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o 28115
V ©
Page 84

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Oil Temperature Sensor
Checking the internal resistance
NOTE
Measuring in one temperature range is usually
sufficient.
Polarity is irrelevant.
Temperature Resistance
20 °C ± 10 °C 1039–1117 Ω
60 °C ± 10 °C 1194–1271 Ω
80 °C ± 10 °C 1271–1347 Ω
1
1
-
5
0
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 85

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Coolant Temperature Sensor
7.12 Coolant Temperature Sensor

5200/2 Coolant temperature sensor M14x1.5,
NOTE 5200/2

Requirements
• Coolant drained (see page 28)
CAUTION
1
1
-
5
0
0
2
I
d
t
r
Hot parts!
r
a
I
0
1
7
9
0  Work carefully.
0
0
0
.
3  Wear protective gloves or use cloths if necessary.
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o 28114
V ©
Page 86

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Coolant Temperature Sensor
Checking the internal resistance
NOTE
Measuring in one temperature range is usually
sufficient.
Polarity is irrelevant.
Temperature Resistance
20 °C ± 10 °C 1039–1117 Ω
60 °C ± 10 °C 1194–1271 Ω
80 °C ± 10 °C 1271–1347 Ω
1
1
-
5
0
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 87

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Pressure Sensor
7.13 Pressure Sensor

9000 Pressure sensor M16x1.5,
NOTE 9000

Requirements
CAUTION
Hot parts!
1
1
-
5
0
0
2
 Work carefully.
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o 28116
V ©
Page 88

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Proportional Valve and Damping Plate
7.14 Proportional Valve and Damping

Plate
G Supply-air pressure (pv)
L Electrical connecting lead

3800 3850
3800 Damping plate, replace if damaged
3900
4000
4000 Hex head nut M8, L
3900
NOTE 3700
4000
 Lubricate sealing rings, O-rings and shaft G
1
1
-
5
0
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o 28113
V ©
Page 89

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Proportional Valve and Damping Plate
Requirements
• Compressed-air line disconnected
• Electrical connection lead disconnected from

proportional valve. Male and female connector
checked for damage or wear (notch scratches)
NOTE
 Check damping plate (3800) for mechanical and
aging damage and replace if necessary.
1
1
-
5
0
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 90

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Appendix
8. Appendix
8.1 Tightening Torques 92
1
1
-
5
0
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 91

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Appendix Tightening Torques
8.1 Tightening Torques
Item No. Designation Dimensions Tightening torque

102 Throttle M14x1.5 –
103 Screw plug M12x1.5, hexagon socket head, w.a.f. 6 With copper sealing ring: 20 Nm
With integrated sealing ring: 13 Nm
1400 Dodecagonal nut M38x1.5, SW55 426 Nm
1900/1 Guide of non-return valve inlet M48x1.5, hexagon insert bit, w.a.f. 55 With copper sealing ring: 280 Nm
2810 Vent and air filter M12x1.5, hexagon insert bit, w.a.f. 17 10 Nm
3100 Combined hex head screw M8x30, hexagon insert bit, w.a.f. 13 30 Nm
1
1
-
3400 Dowel screw M14x48, hexagon insert bit, w.a.f. 19 Observe tightening sequence:
5
0
0
2
I
Initial torque: 50 Nm
d
t
r
r
a
I
Final torque: 30° Angle
0
1
7
9 3500 Screw plug M30x1.5, hexagon socket head, w.a.f. 17 With copper sealing ring: 130 Nm
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
4000 Hex head nut M8, hexagon insert bit, w.a.f. 13 18 Nm
t
i 2
o
V ©
Page 92

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Appendix Tightening Torques
Item No. Designation Dimensions Tightening torque

5200/1 Oil temperature sensor M14x1.5, hexagon insert bit, w.a.f. 21 32 Nm
5200/2 Coolant temperature sensor M14x1.5, hexagon insert bit, w.a.f. 21 32 Nm
9000 Pressure sensor M16x1.5, hexagon insert bit, w.a.f. 27 32 Nm
20200 Screw plug M8x80, hexagon insert bit, w.a.f. 13 30 Nm
20300 Screw plug M14x1.5, hexagon insert bit, w.a.f. 13 32 Nm
25200 Hex head screw M10x70, hexagon insert bit, w.a.f. 16 58 Nm
25300 Hex head screw M10x60, hexagon insert bit, w.a.f. 16 58 Nm
1
1
-
5
0
0
2
I
d
t
r
r
a
I
0
1
7
9
0
0
0
0
.
3
5
1
I
o
b
r
u
T 5
0
h 0
t
i 2
o
V ©
Page 93

Voith Turbo
Produktgruppe Retarder
Postfach 1555
74555 Crailsheim
Deutschland
Phone: 00 49 79 51 / 32-0
Fax: 00 49 79 51 / 32-756
service-retarder@voith.com
www.voith.com
Engineered reliability.

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Aftersales Service Manual Voith Retarder VR 5E

1 About this Document 5

1.1 Purpose of this Document 6

2 Basic Safety Information 8

2.1 Product Safety 9

3.5 Function and Control Scheme 17

4 Maintenance and Service 20

4.1 Maintenance Intervals 21

5 Diagnosis and Troubleshooting 30

5.1 Troubleshooting Chart 31

6 Removing and Installing the Retarder 44

7.10 Non-Return Valve Outlet 81

8.1 Tightening Torques 92

1. About this Document

1.1 Purpose of this Document 6

1.1 Purpose of this Document

This Aftersales Service Manual provides information

1.2 Target Groups

This Aftersales Service Manual is intended for service

1.3 Other Applicable Documents

Documents Information Item number

1.4 Symbols and Identifications 1.5 Item Numbers

2. Basic Safety Information

2.1 Product Safety 9

Driving after repair/oil change Failure while driving

 Tow vehicle with retarder max. 100 km at max. 2.8 Warranty

3. Design and Function

3.1 Overview of the Modules 12

3.1 Overview of the Modules

Item No. Designation

20000 Water neck

3.2 Retarder Identification

Typ VR115E; Serien-Nr.

i Ret. = 2.03 KW/Jahr

3.3 Controller Identification (VERATM)

questions or are ordering spare parts: 0

- Serial number (Serien-Nr.)

3.4 Controller Identification (Digiprop)

3.5 Function and Control Scheme

G Supply-air pressure (pv) "P" Vehicle

I Ventilation line "R"

Item No. Designation

9000 Pressure sensor Vehicle

4. Maintenance and Service

4.1 Maintenance Intervals 21

4.1 Maintenance Intervals

The maintenance intervals depend on the stress put

Activity Interval See

4.2 Oil Change

hexagon socket head, w.a.f. 12,

• Tighten screw plugs of retarder basic module to

Filling in the oil

4.3 Checking the Oil Level

NOTE CAUTION CAUTION

De-aerating the retarder

1. Switch off the retarder foot control if present and

2. Move vehicle at 50 km/h.

3. Activate retarder at brake stage one five times for

4.4 Draining the Coolant