Transmissão Voith Retarder 120-3 131 Pag.

Training
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Aftersales Service Manual
VOITH Retarder 120-3
cbtd 2000-01
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Content
Table of Contents
1. Preface....................................................................................................1/1
2. General....................................................................................................2/1
2.1 Retarder Data ................................................................................................. .2.1/1
2.2 Assembly Overview......................................................................................... 2.2/1
With Stainless-Steel Heat Exchanger.............................................................. 2.2/1
With Aluminium Heat Exchanger ..................................................................... 2.2/3
2.3 Function and Operation Scheme..................................................................... 2.3/1
3. Maintenance............................................................................................3/1
3.1 Maintenance Work / Oil Change Intervals ....................................................... 3.1/1
3.2 Checking Oil Level ...........................................................................................3.2/1
3.3 Oil Change.......................................................................................................3.3/1
With Stainless-Steel Heat Exchanger.............................................................. 3.3/1
With Aluminium Heat Exchanger ..................................................................... 3.3/5
4. Diagnosis / Troubleshooting....................................................................4/1
4.1 Troubleshooting Diagram A to D ..................................................................... 4.1/1
Electrical Connections Diagram....................................................................... 4.1/6
4.2 Troubleshooting and Remedies....................................................................... 4.2/1
4.3 Illustration Control System...............................................................................4.3/1
4.4 Checking Supply-Air Pressure.........................................................................4.4/1
4.5 Checking Constant-Air Pressure ..................................................................... 4.5/1
4.6 Checking Control Current of Proportional Valve.............................................. 4.6/1
4.7 Checking Temperature Adaption..................................................................... 4.7/1
4.8 Checking Pressure Sensor .............................................................................. 4.8/1
Aftersales Service Manual VOITH Retarder 120-3
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Content
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Table of Contents
(Continue)
4.9 Checking Pump Pressure ...................................................................4.9/1
4.10 Table of Measurements................................................................................. 4.10/1
4.11 Operational Check .........................................................................................4.11/1
5. Removing, Installing Retarder .................................................................5/1
5.1 Removing, Installing Retarder (Gearbox Attachment) ..................................... 5.1/1
6. Repair .....................................................................................................6/1
6.1 Overall Illustration of Main Components.......................................................... 6.1/1
6.2 Removing, Checking and Installing Casing Ventilation ................................... 6.2/1
6.3 Removing, Checking and Installing
Non-Return Valve (Stainless-Steel Heat Exchanger)...................................... 6.3/1
6.4 Removing, Cleaning and Installing Silencer .................................................... 6.4/1
6.5 Removing, Installing Bottom Cover ................................................................. 6.5/1
6.6 Checking, Removing and Installing Closing Cover Retarder Housing............. 6.6/1
6.7 Removing, Installing Labyrinth Ring (Output Side),
Renewing Radial Shaft Sealing Ring............................................................... 6.7/1
6.8 Removing, Installing Centering Cover (Input Side)
Renewing Radial Shaft Sealing Ring............................................................... 6.8/1
7. Removing, Checking and Installing Heat Exchanger ..............................7/1
7.1 Removing, Checking and Installing Stainless-Steel Heat Exchanger..............7.1/1
7.2 Removing, Checking and Installing Aluminium Heat Exchanger..................... 7.2/1
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Content
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Table of Contents
(Continue)
8. Control Parts ...........................................................................................8/1
8.1 Removing, Installing Proportional Valve and Damping Plate ..........................8.1/1
8.2 Removing, Installing Adapter and Pipes.......................................................... 8.2/1
8.3 Removing, Installing Cooling-Water Temperature Pick-Up .............................8.3/1
8.4 Removing, Installing Oil Temperature Pick-Up................................................ 8.4/1
9. Annex ......................................................................................................9/1
Data Sheet
Conversion Tables
Tightening Torques
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Preface
1 Preface
The present service manual serves as training materi al of the basics course.
The i nformati on and instructi ons which is given to you furthermore provide the basis for appropriate and
professi onal maintenance and repair at the VOITH Retarder 120-3.
We ask you fi rml y to noti ce the safety and warning notes which you will find in these instructions.
Caution!
is associated for safety instructi ons and for warning notes at dangerous si tuati ons for persons,
at reduction of qual ity of workmanship and the possi bil ity of damage to property.
Notice
is associated for general notices for a better handling duri ng mai ntenance of the retarder.
Aftersal es Servi ce Manual VOITH Retarder 120-3
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Preface
1 Preface
(Continue)
Caution!
The switched-on retarder will not secure the parked vehicle.
During a fai lure of the Retarders, or whil e the temperature-adaptati on i s effective, the vehicle-
speed must be settled by using the service-brake and the lowest possible gear is in use (i ncrease
of the engine-speed). This vehicle condition must be held as long as the retarder i s availabl e with
its full performance again.
Unauthorized changes at the retarder 120-3 as well as the application of spare parts, accessories,
attachments and special -productions, not tested and rel eased from VOITH, can influence the secu-
rity of the entire vehicle negatively. No l iabili ty takes place for damages resul ti ng from it.
The retarder 120-3 is buil t after the the state-of -the-art technology and the recogni zed safety-rela-
ted rules. Nevertheless dangers and damages can originate during i mproper use, maintenance and
repai r.
VOITH wi ll take on no liabi lity for i njuri es and/or damages, that ori ginate through non-observance of
the security-hi nts of the servi ce manual or through i njuri es of the dili gence-duty with the handling,
at the servi ce, with the care and maintenance or repair of the retarders 120-3.
Repair and maintenance work may only be enforced by quali fi ed special ist-staff.
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Preface
1 Preface
(Continue)
Note
The used positi on numbers used in this manual corresponds to the positi on numbers in the spare
parts lists in chapter 9 Annex.
Exception:
Items or parts wi th one -, as wel l as two-digit positi on-numbers are no spare parts and not listed in
the spare parts lists.
Items or components shown with an oblique-number are not avai lable.
For VOITH It is not possi ble to warn expressly of all possible si tuati ons at each position in this
service manual, that could have a ri sk of i njury for the worker and/or a damage for the retarder
120-3 to the consequence. Therefore it is desperately necessary, that everyone, entrusted wi th the
service, care, mai ntenance or repai r of the retarder 120-3, does not endanger i ts own security
through the chosen operation and that the retarder gets no negative impairments, especi ally of
safety-related types.
VOITH i s not liable for injury to persons and or damages caused through improper and unprofes-
sional work.
The pertinent accident-prevention-regul ation, other broadly rules of the security-technology and
worki ng-medicine and the traffic admi ssion law are to be kept. VOITH is not li able for damages, that
ori ginate through contempt of these rugulati ons.
With the 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 scal d!
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Preface
1 Preface
(Continue)
Inevitably, it is i mpossible for VOITH TURBO GmbH & Co. KG in the last analysi s to assess all situations
whi ch mi ght entail the risk of injury for the person carryi ng out the work. It is therefore imperative that
any person carrying out repair work on VOITH retarders uses his professional knowledge to make sure
that his own safety is not endangered and that the retarder suffers no negative effects, in parti cular
safety-wise, through the chosen worki ng procedure. For these reasons, no l iabili ty can be assumed for
damage incurred.
It is therefore expressly pointed out that all worki ng procedures described must be carried out only in
compli ance with the valid general directions and regul ations of the local ly responsible authorities, of the
heal th protection, accident preventi on and environmental protection organisati ons.
The technical status of the present instructions can be seen from the date (see footer on l eft). There may
be discrepancies between the actual technical status of the retarders and the descripti ons owi ng to
continuous devel opment and improvement of the retarders.
VOITH TURBO GmbH & Co. KG reserves the right to make modifications at any time and wi thout pri or
notification.
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Preface
1 Preface
(Continue)
Pl ease read in the operati on manual the hints to the safe, proper and economi c operation
of the retarder 120-3,
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 cb; Voithstrae 1
PO box 15 55
D-74564 Crailshei m
Telephone xx49 - (0)7951 32-0
Telefax xx49 - (0)7951 32-756
Telex 74 338
e-mai l: retarder@voith.de
Extensions:
Customer telephone and Spare Parts Service
32-401 / 32-422
Page 1/5
General
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2 General
2.1 Retarder Data.............................................................................................2.1/1
2.2 Assembly Overview....................................................................................2.2/1
With Stainless-Steel Heat Exchanger .................................................................2.2/1
With Aluminium Heat Exchanger .......................................................................2.2/3
2.3 Function and Operation Scheme................................................................2.3/1
Page 2/1
General
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2.1 Retarder Data
The retarder data (arrow) of the retarder 120-3 is punched on the output side of the retarder housing.
The retarder data plate provides the following information:
1. Serial number:
six-digit number
2. Item number:
eight -di git number
Notice
Pl ease, al ways quote the retarder serial-No. and i tem-No. when submitting queries or orderi ng
spare parts.
Page 2.1/1
18001
General
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2.2 Assembly Overview
Illustration VOITH Retarder R 120-3
Basic group with stainless-steel
heat exchanger
100/1 Retarder data plate
1000 Heat exchanger
1200 Non-return valve
1900 Oil fi ller/check plug M 30 x 1,5
Combi ned hex.-head, w.a.f. 24
21000 Dampi ng plate
22000 Proporti onal valve
26000 Constant-air pressure line p
y
30000 Pressure pick-up
33000 Oil temperature pick-up
34000 Cooling-water temperature pi ck-up
1900
100/1
1000
22000
33000
30000
34000
21000
26000
1200
18002
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(Continue)
Basic group with stainless-steel
heat exchanger (Continue)
1000 Heat exchanger
1001 Coolant drai n pl ug
M 18 x 1,5
Inhex.-head, w.a.f. 8
1700 Retarder oil drain plug
M 22 x 1,5
1700
1001
1000
18003
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(Continue)
Basic group with aluminium heat exchanger
100/1 Retarder data plate
1000 Heat exchanger
1001 Coolant drai n pl ug M 12 x 1,5
y
30000 Pressure pick-up
Note
The cooling-water temperature pick-up is
placed in the pipeline.
1900
100/1
1001
1000
22000
33000
30000
21000
26000
18004
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(Continue)
Basic group with aluminium heat exchanger
(Continue)
1000 Heat exchanger
1001 Cooling-water drain plug
M 12 x 1,5
1002 Oil drain plug heat exchanger
M 12 x 1,5
1700 Oil drain plug retarder
M 22 x 1,5
18005
1700
1001
1000
1002
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General
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2.3 Function and Operating Scheme
Illustration of VOITH Retarder 120-3
Note
The reference numbers i ndicated in Section 2.3 are not i dentical with the reference numbers of the spare parts li sts.
1 Heat exchanger
2 Control unit
4 Connection terminal 15
7 Fuses (5A)
8 Connection ground
12 Pump pressure test connection
15 ABS-Signal
16 Retarder stage switch
17 Retarder pilot l ight
18 Stop light relay
23 Casi ng venti lation
y
A
26 Supply-air pressure li ne p
v
P
37 Ventilati on line R
38 Pressure sensor
43 Oil sump
44 Stator
45 Stator pins
46 Rotor
47 Speedometer signal
50 Output restrictor D
1
52 Fil ling restrictor D
2
53 Fil ling duct
66 Non-return valve
(stainless-steel heat exchanger)
67 Non-return valve
(casing ventilation cover)
69 ISO interface plug (4-pole)
70 ISO interface plug (14-pole)
R
P
A
25
V
y
P
46
44 12 50
52
45
23
53
19
37
67
26
21
7 4 16 8
2
70 15 47 17 7 4 18
69
43 1 66
20
38
18006e
Supply-air pressure p
Oil sump
Constant-air pressure p
Coolant (water)
Pump pressure p
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General
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2.3 Function and Operation Scheme
(Continue)
Description of the function
The VOITH Retarder 120-3 is a powerful hydrodynamic continous brake of compact design for buses
and commercial vehicl es of the medium range. The VOITH Retarder 120-3 i s mounted between the
gearbox and the rear axle of the vehicl e.
The retarder braking torque is sustained even when gear changes are made.
The switched-on retarder will not secure a parked vehi cle.
A retarder stage swi tch (16) wi th a maximum of 5 switchi ng stages is used to control the
VOITH Retarders 120-3. A special version combines the retarder stage switch (16) with ABS, a 3-stage
pedal-operated brake valve or a servi ce-brake pressure switch.
Operation with function ,,Constant speed"
The retarder i s operated by a 5-stage retarder stage switch.
When the retarder stage swi tch (16) is shifted to position 1, the Constant Speed functi on i s activated.
The present speed is memorized and the retarder holds the vehicle to this speed downhi ll within the li mit
of the maxi mum braking torque.
If the retarder i s switched off (0 position), or switched to braking stage (posi ti on 2 to 5), the memorized
constant speed is del eted. If the constant speed function is re-acti vated, the new present speed
is memorized.
When the retarder stage swi tch is shi fted to position 2 to 5, braki ng stage 1 to 4 i s energized.
Maximum braking torque i s obtained when the retarder stage switch i s i n the maximum position.
When oversteppi ng the maximum possi ble cooling performance, the retarder braking torque
will be adapted.
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As a special version, the control system is avail able wi th push button operation for constant speed.
The retarder i s operated in this case by a 4-stage retarder stage swi tch.
When the push button is pushed in any posi ti on of the retarder stage swi tch, the momentary speed is
transferred to memory. In the 0 braki ng stage, this transfer to memory takes effect and the retarder hol ds
the vehi cle speed downhill constant withi n the limi ts of the maximum braking torque. Another push on
the push button i n any switch posi ti on will del ete the speed data.
On a downhill run wi th constant speed operation, the vehicl e can be slowed down within the l imits of
the maximum braking torque and the temperature limi t, for an obstacl e ahead (e.g. bend) by shi fting to
braking positions 1 to 4. If the retarder stage switch is then shifted to position 0, the vehicle accelerates
to the speed previously transferred to memory.
Description of operation of retarder R 120-3
The control medium for the Voith Retarder 120 is compressed ai r, which is taken from the air tank for
auxiliary equipment on the vehicl e.
When the retarder stage swi tch (16) i s operated, an input signal is fed to the control unit (2).
From this input signal , the control unit (2) provides a control current which flows to the
proporti onal valve (21).
The proporti onal valve (21), depending on the magnitude of the control current, provides a
constant-ai r pressure p
y
on the oil sump (43).
The constant-ai r pressure p
y
in the oi l sump (43), depending on the operating condi ti ons (prop shaft
speed), forces a certai n quantity of oi l into the working chamber between rotor (46) and stator (44).
c
a b
18007
The hydrodynami c pri nciple
a Rotor (46)
b Stator (44)
c Oil flow
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(Continue)
The rotor (46) is connected with the retarder dri ve shaft, the stator (44) is stationary wi th the retarder
housi ng.
The rotation of the rotor sets the oil i n motion and circulates it in a closed ci rcui t between the rotor (46)
and stator (44).
The reducti on of the velocity of the oil flow in the chambers of the stator (44) leads to braking of
the rotor (46) and consequentl y to braking of the vehicle.
During braking, the kinetic energy of a deceleration is transformed i nto heat. To di ssipate this heat, part
of the circulating oil is pumped continuously by the rotor (46) through the heat exchanger (3300) and vi a
fi lling ducts to join the circulating flow again.
In the heat exchanger (3300), the heat energy of the oi l i s transferred to the cool ing water of the vehicle
and dissipated via the vehicl e radi ator to the ambient ai r.
If the vehicle ignition is switched on the pul s lubricati on i s activated and l ubricates the retarder bearings
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General
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(Continue)
Temperatur pick-up, cooling-water (19), oil (20)
The temperature pick-ups are installed in the cool ing system of the vehicl e (cooling return ci rcle from the
retarder to the the heat exchanger) and in the retarder oi l duct and transmit signal s on cooling water and
oil temperature to the control unit (2).
To prevent the temperatures preset in the control uni t (2) for water and oil being exceeded, the retarder
braking torque i s l imited to protect the vehicl e cooli ng system and the retarder.
The constant-ai r pressure p
y
i s l imited.
The braking torque and consequentl y the heat generated are reduced until a balance is obtained bet-
ween the braking energy of the retarder and the amount of heat which can be dissipated by the vehicle
cooling system.
If the cooling water temperature ri ses into the temperature adaption range, the consequence is a
limi tation of the retarder braki ng torque to protect the vehicl e cooling system. If the temperature ri ses
above the
temperature adapti on range, there is no more braking torque output.
While the temperature adaption i s effective or if there is a retarder failure, the servi ce brake must be used
to control the vehi cle speed.
Addi ti onal ly the control unit adapts the braking torque if oil temperature rises too rapidly, irrespective of
actual oil temperature.
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General
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(Continue)
Casing ventilation (23)
During braki ng, the oi l displaces the ai r present in the working circui t via the casing ventilation (23) and
the ventil ation system (22) out of the retarder.
Once the working circui t is free of air, a float rises and closes the casing ventilati on.
Stator pins (45)
When the working chamber i s empty, the rotor (46) sets up in it an air fl ow, which is retarded by the stator
(44). To minimize this loss, automati call y operating stator pins have been instal led in the outer zone of
the stator blades. The pin plates steer the accel erated ai rflow past the stator blades and prevent the
build-up of an effecti ve flow. When the working chamber i s full of oi l, the oil presses the plates back on
their seats against the force of the spring and the ful l space between the blades is available.
Non-return valve (66) stainless-steel heat exchanger
The non-return valve (66) prevents the airflow emptying the heat exchanger i nsert of oil when idling.
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Maintenance
3 Maintenance
3.1 Maintenance Work / Oil Change Intervals..................................................3.1/1
3.2 Checking Oil Level .....................................................................................3.2/1
3.3 Oil Change .................................................................................................3.3/1
With Stainless-Steel Heat Exchanger ............................................................................3.3/1
With Aluminium Heat Exchanger ................................................................................... 3.3/5
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Maintenance
3.1 Maintenance Work / Oil Change Intervals
Overview of maintenance work
Carry out the following maintenance work at each oil change
Carry out visual inspection on leaks at the complete retarder
Check hex.-head screws of prop shaft on correct fitment, or tighten if necessary.
Observe guidelines and instructions!
Tighten all screw pl ugs of the heat exchanger and retarder basic groups with the appropriate
torque (see annex)
Excerpt of this are the fastening nuts and -screws of the heat exchanger (see chapter 7).
Caution!
Tighten fastening nuts and -screws of the heat exchanger only in case of leakage between
heat exchanger and retarder.
Tightening torque: 23 Nm
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Maintenance
(Continue)
1) Operating specifications, see annex
2) Change oil at the latest after 2 years if fewer kilometres are travel led.
Single-grade
mineral oil
1)
Multi-grade
mineral oil
1)
Synthetic /
part synthetic oil
1)
Truck
Normal duty
90.000 km
2)
-
135.000 km
2)
Truck
Heavy duty
45.000 km
2)
-
90.000 km
2)
BUS
Normal duty
135.000 km
2)
90.000 km
2)
180.000 km
2)
BUS
Heavy duty
60.000 km
2)
45.000 km
2)
90.000 km
2)
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Maintenance
(Continue)
1. Normal duty
Example:
- Long di stance traffic
2. Heavy duty
Subj ect to more than normal stress.
Examples:
- Use i n regi ons with high ambient temperatures
- Vehicles at construction sites and timber l orries
- High max. permi ssibl e weight with low rated engine power (< 6 kW/metric ton)
- Stretches with l ots of hi lls and valleys
- Extreme short-distance traffic with lots of gradients
The given maximum specified fi gures can be lowered, if overal l mai ntenance cycles for the vehi cle 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 agei ng of the oil, it may be necessary to shorten the intervals
between oil changes in indi vidual cases.
For use i n extremely cold zones, oils in an appropriately lower viscosity cl ass
(TransmaxZ or SEA 5W-40) must be used.
In doubts, please contact VOITH TURBO.
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Maintenance
3.2 Checking Oil Level
Illustration checking oil level
Note
The oil change intervals are li sted i n chapter
3.1, the operati ng specificati ons are listed in the
annex.
1800 Seal ing ring A 30 x 36
renew
Combi ned hex.-head, w.a.f. 24,
150 Nm
Note
The illustrati on shows a retarder 120-3 with
stainless-steel heat exchanger.
Checking oil level wi th al umi nium
heat exchanger version i s i dentical.
1800
1900
18008
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Maintenance
(Continue)
Note
For satisfactory retarder operation, it i s important to use onl y oil s specified i n the operating specifications
(see Annex) for operating the retarder in the relevant application.
Service filling
The service fill ing for the complete retarder system depends on the version of the mounted
heat exchanger, see table on page 3.3/2 and of the mounti ng position (see data sheet i n chapter 9).
For relevant application approved oils
Use onl y approved oi ls specified in the operati ng specifications (see Annex).
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Maintenance
(Continue)
Note
For the oil level check, the temperature of the retarder oil must be higher than 60C (operati ng tempera-
ture).
The oil l evel check must be carried out with the vehi cle in a horizontal position.
Mind the slanted mounting position.
The difference between min. and max. mark on oil fill er/check plug is approx. 0,5 l.
Job scope
1. Operate the retarder at the highest stage (highest braking stage) with vehi cle stati onary and
switch it off after approx. 5 sec.
Repeat thi s procedure twice.
Caution!
While the oil level is bei ng checked, make sure that retarder and i gnition system must have
been switched off!
Risk of injury exists at nonobservance, by hot leavi ng oil when screw out oil fill er/check plug!
2. Switch off the retarder and wait 5 mi nutes (control function).
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Maintenance
(Continue)
Caution! Risk of injury!
The oil fil ler/check plug (1900) is heated up (oil temperature)!
3. Screw out the oi l fi ller/check plug (1900) and remove sealing ri ng (1800).
Wi pe oil off of oil fill er/check plug.
4. Position oil fill er/check plug (1900) plane at the thread.
Do not screw in the oil filler/check plug!
5. Pull out again the oil filler/check pl ug (1900).
Oil level i s correct bewteen min. and max. mark of the oil fil ler/check plug.
6. Top up slowly any lacking oil through the hole for the oil fi ller/check plug.
7. Screw the oil filler/check plug (1900) tight with new sealing ri ng (1800).
Tighteni ng torque 150 Nm
Max
Min
1900
18009
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Maintenance
3.3 Oil Change
Illustration oil change R 120 -3
with stainless-steel heat exchanger
1700 Retarder oil drain plug M 22 x 1,5
Inhex.-head, w.a.f. 10, 66 Nm
1800 Seal ing ring A 30 x 36, Copper,
renew
150 Nm
Page 3.3/1
1900
1800
1700
18010
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Maintenance
3.3 Oil Change
(Continue)
Note
For satisfactory retarder operation, it i s important to adhere to the speci fi ed service filling (see tabl e be-
low) and to use only oil s speci fi ed i n the operating specifications (see Annex) for operating the retarder
in the relevant application.
* with slant mounted position of the retarder up to
approx. 4 - reduce service filli ng of approx. 0,25 Litre,
approx. 8 - reduce service filli ng of approx. 0,50 Litre.
The retarder oil temperature must be higher than 60
o
C (operating temperature) for the oi l
to be checked.
Caution!
While the oil is being changed, make sure that no constant-air pressure is acting on the retarder.
The retarder and the ignition must be switched off!
Type of heat exchanger
Service-
filling *
after complete taking apart
and cleaning, as well as
emptied heat exchanger *
after exchange of
heat exchanger *
Stainl ess-steel
heat exchanger
4,5 Li tre 5,8 Litre 6,5 Li tre
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Maintenance
3.3 Oil Change
(Continue)
Job scope
1. Operate the retarder at the highest stage (highest braking stage) with vehi cle stati onary and
switch it off after approx. 5 sec. Repeat this procedure twice.
Switch off the retarder and igni ti on and wait 5 minutes (control functi on).
The oil fil ler/check plug is hot! Oi l temperature!
2. Push an oil col lecting pan under retarder.
3. Screw out the oil check plug (1900) and remove seali ng ring (1800).
The retarder oil drain plug is hot! Oil temperature!
4. Screw out the retarder oil drai n plug (1700) and drain oi l.
Page 3.3/3
cbtd 2000-01
53.2688.10
Maintenance
3.3 Oil Change
(Continue)
5. Check seali ng ring of oil drai n pl ug on damages and replace oil drain plug, if necessary.
6. Place oi l drain plug (1700) in bore and screw ti ght.
7. Fil l in slowly, in the hole of the oi l fi ller/check plug (1900), the quanti ty of oil specified
(see page 3.3/2) in accordance with the operating speci fi cations (see Annex).
8. Screw the oil filler/check plug (1900) tight with a new seali ng ring (1800).
Note
Pl ease read the oil change intervals in chapter 3.1 and operating specifications in the annex!
Page 3.3/4
cbtd 2000-01
53.2688.10
Maintenance
3.3 Oil Change
(Continue)
Illustration oil change R 120-3
with aluminium heat exchanger
1002 Heat exchanger oil drain pl ug
M 12 x 1,5
1700 Retarder oil drain plug M 22 x 1,5
1800 Seal ing ring A 30 x 36
renew
150 Nm
Page 3.3/5
1800
1900
1002
1700
18011
cbtd 2000-01
53.2688.10
Maintenance
3.3 Oil Change
(Continue)
Note
For satisfactory retarder operation, it is important to adhere to the specified service fil ling
(see table bel ow) and to use only oils specified in the operating specificati ons (see Annex) for
operating the retarder in the relevant application.
* with slant mounted position of the retarder up to
approx. 4 - reduce service filli ng of approx. 0,25 Litre,
approx. 8 - reduce service filli ng of approx. 0,50 Litre.
The retarder oil temperature must be higher than 60
o
C (operating temperature) for the oi l
to be drained.
Caution!
While the oil is being changed, make sure that no constant-air pressure is acting on the retarder.
The retarder and the ignition must have been switched off!
Type of heat exchanger Service filling * New filling *
Al umi nium heat exchanger 5,5 l 6,0 l
Page 3.3/6
cbtd 2000-01
53.2688.10
Maintenance
3.3 Oil Change
(Continue)
Job scope
The oil fil ler/check plug is hot! Oi l temperature!
1. Push an oil collecting pan under retarder.
2. Screw out the oi l fi ller/check plug (1900) and remove sealing ri ng (1800).
The oil -drai n plugs are hot! Oil temperature!
3. Screw out the retarder oil drain pl ug (1700) and the heat exchanger oil drain pl ug (1002) and drai n
oil.
4. Check seali ng ring of oil drai n pl ug on damages and replace oil drain plug, if necessary.
Page 3.3/7
cbtd 2000-01
53.2688.10
Maintenance
3.3 Oil Change
(Continue)
5. Place oi l drain plug (1700 and 1002) i n its appropriate bore and screw them tight.
Retarder oil drain plug (1700), Tightening torque 66 Nm
Oil drai n plug heat exchanger (1002), Tightening torque 25 Nm
6. Fil l in slowly, in the hole of the oi l fi ller/check plug (1900), the quanti ty of oil specified
(see page 3.3/6) in accordance with the operating speci fi cations (see Annex).
7. Screw the oil filler/check plug (1900) tight with a new seali ng ring (1800).
Note
Pl ease read the oil change intervals in chapter 3.1 and operating specifications in the annex!
Page 3.3/8
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4 Diagnosis / Troubleshooting
4.1 Troubleshooting Diagram...........................................................................4.1/1
Troubleshooting Diagram A to D ................................................................................... 4.1/1
Electrical Connections Diagram Variant 1 and 2 ........................................................... 4.1/6
4.2 Troubleshooting and Remedies .................................................................4.2/1
4.3 Illustration Control System .........................................................................4.3/1
4.4 Checking Supply-Air Pressure ...................................................................4.4/1
4.5 Checking Constant-Air Pressure................................................................4.5/1
4.6 Checking Control Current of Proportional Valve ........................................4.6/1
4.7 Checking Temperature Adaption................................................................4.7/1
4.8 Checking Pressure Sensor.........................................................................4.8/1
4.9 Checking Pump Pressure...........................................................................4.9/1
4.10 Table of Measurements..............................................................................4.10/1
4.11 Operational Check......................................................................................4.11/1
Page 4/1
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.1 Troubleshooting Diagram
Illustration troubleshooting diagram main groups
Note
Before starti ng troubleshooti ng the oil level of the retarder must be checked and corrected, if necessary (see chapter 3.2 Checking Oil Level).
It is important that the specific service fill ing is kept for a trouble-free operati on of the retarder (see chapter 3.3 Oil Change and annex).
Complaint
R 120-3
Oil loss
through
ventilation
Retarder
pilot light
Oil loss
input / output
side
No respectively
too insufficient
retarder braking
effect
B
A
C
D
18012e
Aftersal es Service Manual VOITH Retarder 120-3
Page 4.1/1
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Illustration troubleshooting diagram group A
Oil loss
through
ventilation
A
18013e
Check
retarder oil level
NOK OK
Yes No
Water in oil?
(emulsion)
Yes No
Water in oil?
(emulsion)
see chapter 7
Check
heat exchanger
Contact
VOITH
OK NOK
Check
casing ventilation
(chapter 6.2)
Replace
casing ventilaton
(chapter 6.2)
Check non-return valve
in stainless steel
heat exchanger
(chapter 6.3)
OK NOK
Replace non-return valve
in stainless steel
heat exchanger
(chapter 6.3)
too
high
too
low
Check
retarder oil level
Correct
retarder oil level
Check
control system
(chapter 4.4 - 4.9)
Aftersales Servi ce Manual VOITH Retarder 120-3
Page 4.1/2
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Illustration troubleshooting diagram group B
Retarder
pilot light
18014e
B
NOK OK
NOK OK
Check temp. pick-up
(water, oil)
and its electrical leads
(see chapter 4.7)
Check vehicle cooling
system:
- coolant level
- thermostat
- coolant pump
- radiator fan
- radiator grill for
dirtiness
Check operation
(during braking with
retarder nominal engine
speed, if possible)
Permanent light
in position 0
after light test
Read out
fault code
(see chapter 4.2)
Rectify fault and
delete fault memory
(see chapter 4.2)
Driver instruction
Temperature
adaptation
Replace
temperature pick-up
or its electrical leads
(see chapter 8.3, 8.4)
no function
Contact
VOITH
flashes
Page 4.1/3
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Illustration troubleshooting diagram group C
Oil loss
input / output
side
18015e
C
NO YES
Water in oil
(emulsion)
Replace
heat exchanger
(see chapter 8)
Check
radial shaft sealing ring on
input or output side
(see chapter 6.7, 6.8)
If problem occours again
after a test trial
contact VOITH
Page 4.1/4
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Illustration troubleshooting diagram group D
Check oil level
of retarder
OK NOK
Yes No
Water in oil
(emulsion)
Yes No
Water in oil
(emulsion)
see chapter 7
Check
heat exchanger
Correct oil level
of retarder *
OK NOK
OK NOK
Check
p (dynamic)
(see chapter 4.9) NOK OK
Check proportional
valve current
(see chapter 4.6)
NOK OK
Check
temperature
pick-up and
pressure sensor
(chapter 4.7, 4.8)
NOK OK
Check vehicle
compressed-air
supply
Check
p (static)
(see chapter 4.5)
y
NOK OK
Check supply-air
pressure
(see chapter 4.4)
Contact
vehicle manufacturer
No respectively
too insufficient
retarder braking
effect
D
Contact
VOITH
Contact
VOITH
Contact
VOITH
Contact
VOITH
Proportional valve
or damping plate
mechanically
defect
Contact
VOITH
* If problem occours again after a test trial
continue at "Checking casing ventilation"
18016e
Page 4.1/5
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Electrical connections diagram variant 1 (splitted connections of temperature pick-ups)
Electrical connections diagram variant 2 (united connection of temperature pick-up)
Pressure sensor + 5V
Stop light relais
Speed signal
Propvalve +
Output / low side 1 LS 1
Output / high side HS 2
Output / high side 1 HS 1
Propvalve -
T 30 (Battery)
T 31 (Ground)
Stage switch+
ISO L
ISO K
Position 5
Poition 4
Position 3
Position 2
Position 1
CAN-low
CAN-Masse
CAN-high
T 15 (Ignition lock)
Switch valve -
Switch valve +
Water temp.-
Water temp.+
Oiltemp.+
Oilltemp.-
ABS
blue
white
white
white
black
rosa
pink
blue/white
blue/white
brown/white
orange/white
orange/white
orange
orange
yellow/green
yellow/green
grey/black
grey
blue
violett
3
2
3
12
11
10
15
14
13
18
17
16
2
1
6
5
4
9
8
7
7
3
2
1
6
5
4
9
8
1
6
5
4
9
8
7
12
12pol.
X3.
9pol.
X2.
18pol.
X1.
Digiprop
11
10
grey
brown
brown
beige
beige
red
red
grey
grey
pink
blue
black/white
black/white
yellow/green
Input / p.-down / PWM-in DID 4
Pressure sensor signal
Input / pull-down DID 3
Input / pull-up DIU 1
Pressure sensor - Ground
Pilot light
violett
violett
Stop light relais
Speedom. signal
T 31 (Ground)
Position 5
Position 4
Position 3
Position 2
Position 1
Propvalve +
Propvalve -
Switch valve -
Switch valve +
Water temp.-
Water temp.+
Oil temp.+
Oil temp.-
ABS
Pilot light
9 5 4 3 2 7 6 10 1112 1314 8 1
Connection 14 pole
"Optional Functions"
"ISO Interface"
Connection 4 pole
7
6
5
3
2
8
4
3 2 1 4
Stage switch +
"Stage switch"
Connection 8 pole
+
+
Cable Retarder
Cable E-Fach
3
4
2
1 Pin
orange
3 2 1 4
red/white
Connection 4 pole
"Pressure sensor"
18017e
Pressure sensor + 5V
Stop light relais
Speed signal
Prop valve +
Output / low side 1 LS 1
Output / high side HS 2
Output / high side 1 HS 1
Prop valve -
T 30 (Battery)
T 31 (Ground)
Stage switch +
ISO L
ISO K
Position 5
Position 4
Position 3
Position 2
Position 1
CAN-low
CAN-Ground
CAN-high
Switch valve -
Switch valve +
Water temp.-
Water temp.+
Oil temp.+
Oil temp.-
ABS 3
2
3
12
11
10
15
14
13
18
17
16
2
1
6
5
4
9
8
7
7
3
2
1
6
5
4
9
8
1
6
5
4
9
8
7
12
12pol.
X3.
9pol.
X2.
18pol.
X1.
Digiprop
11
10
Input / p.-down / PWM-in DID 4
Pressure sensor signal
Input / pull-up DIU 1
Pressure sensor - Ground
Pilot light
Stop light relais
Speedom. signal
T 31 (Ground)
Position 5
Position 4
Position 3
Position 2
Position 1
Prop valve +
Prop valve -
Switch valve -
Switch valve +
Water temp.-
Water temp.+
Oil temp.+
Oil temp.-
ABS
Pilot light
9 5 4 3 2 7 6 10 1112 1314 8 1
Connection 14 pole
"Optional functions"
"ISO Interface"
Connection 4 pole
7
6
5
3
2
8
4
3 2 1 4
Stage switch +
"Stage switch"
Connection 8 pole
+
+
Cable Retarder
Cable E-Fach
3
4
2
1 Pin
3 2 1 4
Connection 4 pole
"Pressure sensor"
blue
white
rosa
blue/white
brown/white
orange/white
yellow/green
grey/black
grey
grey
black/white
orange
red/white
white
pink
orange
yellow/green
blue
violett
beige
grey
white
black
blue/white
orange/white
orange
brown
brown
beige
red
red
grey
pink
blue
black/white
yellow/green
violett
violett
18018e
Page 4.1/6
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.2 Troubleshooting and Remedies
Troubleshooting and remedies
Requirements for check
Battery voltage 18 - 32 V
Vehicle electrical system checked in accordance wi th the Owners Manual for the vehicle and
found satisfactory.
Fuse for retarder control unit checked and found sati sfactory.
Compressed-air pressure 6 - 11 bar
To check with the mul ti meter, pi n 15 (plug X1) on the control unit (2) must be connected to
ground (terminal 31), at pin 7 (plug X1) and pi n 13 (plug X1) must be connected termi nal 15.
Note
Prior to any troubl eshooting, the retarder oi l level must be checked and corrected, if necessary
(see chapter 3.2 Checki ng Oi l Level ).
For trouble-free retarder operati on, i t is important that the fi lling quantity specified is adhered to
(see tables chapter 3.3 Oi l Change).
Page 4.2/1
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Note
The retarder pilot light addi ti onall y has the function of a fault code:
Permanent l ight i n position 0 - 5 of retarder stage swi tch
- slight fault
Braking i s still possible to limited extent.
- serious fault
Braking i s no longer possible - the retarder is switched off.
Notice
If the ignition is switched off and on, the retarder is in operation again and the retarder pilot light goes off.
If a serious fault remains present or reoccurs, the retarder switches off agai n and the retarder pilot li ght
comes on permanently in position 0 to 5 of the retarder stage switch.
Page 4.2/2
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
18019
1 4 7 10 13 16
2 5 8 11 14 17
3 6 9 12 15 18
(Continue)
Connector arrangement and pin assignment
Notice
Al l plugs il lustrated from plug-in si de (i.e. leads at back).
Plug X1 Control unit
1 Not in use
2 Not in use
3 Not in use
4 Retarder stage swi tch, position 3 (or)
5 Retarder stage swi tch, position 2 (bl)
6 Retarder stage swi tch, position 1 (pi)
7 Terminal 15 (rd)
8 Retarder stage swi tch, position 5 (gr)
9 Retarder stage swi tch, position 4 (wh)
10 Retarder stage swi tch + (vi)
11 ISO-interface, L-lead (or/wh)
12 ISO-interface, K-lead (bl/wh)
13 Connected with terminal 15 (bl)
14 Not in use
15 Terminal 31 (br)
16 Output / high side 2 HS2 (bl/wh)
17 Output / low si de 1 LS1 (ye/gr)
18 Output / high side 1 HS1 (be)
Page 4.2/3
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
1 Not operational (or)
2 Proportional val ve - (gr)
3 Proportional val ve - (pi)
4 Cooling water temperature pi ck-up - (bl)
5 Cooling water temperature pi ck-up + (ye/gr)
6 Not operational/ground (be)
7 Not in use
8 Oil temperature pi ck-up - (wh)
9 Oil temperature pi ck-up + (vi)
1 Input / pull up DIU 1 (wh)
2 Speedometer signal (bl)
3 ABS-Signal (bl/wh)
4 Input / pull down DID 2 (br/wh)
5 Input / pull down DID 1 (bl/wh)
6 Pressure sensor ground (pi)
7 Pressure sensor signal voltage (gr/bl)
8 Retarder pi lot light (ye/gr)
9 Input / pull down DID 3 (or/wh)
10 Pressure sensor suppl y voltage (rd/wh)
11 Stop light relay (or)
12 Input / pull down / PWM-in DID4 (gr)
18020
1 4 7
2 5 8
3 6 9
18021
1 4 7 10
2 5 8 11
3 6 9 12
Page 4.2/4
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Extra operations plug
2 Input / pull down DID 1 (bl/wh)
3 Input / pull down DID 2 (br/wh)
4 Input / pull down DID 3 (or/wh)
5 Input / pull down / PWM -in DID 4 (gr)
6 Input / pull up DIU 1 (wh)
7 Pressure sensor ground (pi)
8 Pressure sensor signal voltage (gr/bl)
9 Pressure sensor suppl y voltage (rd/wh)
10 Output / high side 1 HS1 (be)
11 Output / high side 2 HS2 (bl/wh)
12 Output / low si de 1 LS1 (ye/gr)
13 Terminal 15 (rd)
14 Terminal 31 (br)
ISO-Interface plug
1 K-lead (bl/wh)
2 L-lead (or/wh)
3 Terminal 15 (rd)
4 Terminal 31 (br)
2
1
4
3
6
5
8
7
10
9
12
11
14
13
18022
2 1
4 3
18023
Page 4.2/5
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Bajonet socket cooling-water temperature pick-up
Variant 1
1 Cooling-water temperature pick-up + (ye/gn)
2 Cooling-water temperature pick-up - (bl )
3 Not operational
4 Not operational
Plug cooling-water temperature pick-up
Variant 2
1
2
3
4
18024
Page 4.2/6
18025
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Proportional valve plug
1 Proportional val ve + (pi)
2 Proportional val ve - (gr)
3 Not operational
4 Not operational
Retarder stage switch plug
1 Not in use
2 Posi ti on 5 - (gr)
3 Posi ti on 4 - (wh)
5 Posi ti on 3 - (or)
6 Posi ti on 2 - (bl)
7 Posi ti on 1 - (pi)
8 Bridge to pin 4
18026
1 2 3 4
5 6 7 8
Page 4.2/7
1
2
3
4
18024
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Plug pressure sensor
1 Pressure sensor - 5V (rd/wh)
2 Pressure sensor - Si gnal (gr/bl)
3 Not i n use
4 Pressure sensor - ground (pi)
1
2
3
4
18024
Page 4.2/8
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
A. With fault code
Special tool

Commercially available tool
Note
The blinking code of the retarder pilot light (as of Digiprop-Version 1.0) can be used to obtai n a read-out
from the fault memory.
Addi ti onal ly a di agnosis via PC-Software Digi Dia and PC-Interface is possible.
Therefore, please contact VOITH TURBO or one of our service partner.
Multimeter recommended: Fluke 87
53.8224.10
Page 4.2/9
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Fault memory readout via retarder pilot light blinking code
Note
If several faults have been stored in the memory, they are output in the sequence of their occurence, but
always only one faul t per triggering.
Before and after each output of the bli nking code you have a break of 3 seconds. The retarder pil ot l ight
is off during thi s break.
If an actual fault is avail able (before triggering the bl inki ng code the retarder pilot l ight is switched ON)
the retarder pilot li ght switches to permanent li ght again after the bl inki ng code.
Is onl y one stored fault avail able, the retarder pilot light is OFF after the output.
The number of tens units first indicated as long ON time: each 2 seconds
The number of si ngle uni t then i s i ndicated as short ON time: each 0,5 seconds
Breaks between each ON time: each 1 second
Excerption:
The fault Coding faulty i s not stored, but the bli nking code is di splayed.
Page 4.2/10
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
There are two possibilities for activating the blinking code:
a) Fault memory readout via retarder pilot light blinking code
During the service functi on (speed = 0, igni ti on OFF, i gnition ON) the bl inki ng code can be displ ayed
by using the retarder pil ot light:
1. Retarder stage switch - engage position 0
2. Retarder stage switch - engage position 1 ( 2 seconds)
3. Retarder stage switch - engage position 0
4. First fault as blinking code output
5. Repeat working step 1 to 3 for further bli nking code outputs
b) Fault memory readout via service cable
Requirements
Retarder stage switch i n position O.
Vehicle at standstill , igni ti on ON
1. Servi ce interface L-lead connected to ground 2s. For this pupose, press L - push button at
service cable.
2. First fault as blinking code output.
3. Repeat working step 2 and 3 for further blinking code ouputs
Page 4.2/11
18027
2

s
e
c
1

s
e
c
1

s
e
c
1

s
e
c
1

s
e
c
2

s
e
c
0
,
5

s
e
c
0
,
5

s
e
c
0
,
5

s
e
c
Displ ay example for fault code 23
E Retarder pil ot light ON
A Retarder pil ot light OFF
t Time
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Delete fault memory
No read outs according to fault memory.
1. Ignition: OFF
2. Service interface L-lead connected to ground.
For this pupose, press L - push button at service cable.
3. Ignition: ON
4. Disconnect L-lead of ground after more than 2 seconds.
Page 4.2/12
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Notice
Meaning of entries in Measurement/test connecti on column: X 1/15 X3/11 Pin 15 to plug X1,
Multimeter set for Ohms, Pi n 11 to pl ug X3
1)
X 1/15 = ground control unit
2)
Onl y, if no fault i s recognizabl e after a compl ete check of the peri phery: change control unit.
Fault Fault text Fault
class
Trigger time Requirement /
Operation
Measurement/
Test connection
1)
Result/
Set point
Cause/
Remedy
2)
Code Test step
01 Stop l ight rel ay/
Short circuit to
ground
sli ght 1 s - Ignition: OFF
- Pul l plug X3 out of
control unit
X 3/11 X 1/15 Relay i s
install ed:
250-350
Check lead, plugs
and rel ay or
consumers
02 LS 1 output
Short circuit to
battery
sli ght 400 ms - Ignition: OFF
control unit
- Di sconnect plug
for extra operati on
(e.g. lamp or
relay)
- Ignition: ON
X 1/17 V X 1/15 0 V Check lead, plugs
and rel ay or
consumers
Page 4.2/13
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
class
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
03 HS 1 output
Short circuit
control unit
X 1/18 X 1/15 Rel ay is
installed:
250-350
Check lead, plugs
and rel ay
or consumers
04 HS 2 output
Short circuit
control unit
X 1/16 X 1/15 Rel ay is
installed:
250-350
Check lead, plugs
and rel ay
or consumers
05 Termi nal 15
Undervoltage
serious 60 s - Ignition: OFF
control unit
- Ignition: ON
X 1/7 V X 1/15 17,5 V Check lead, plugs
and fuses
06 Termi nal 15
Overvol tage
control unit
- Ignition: ON
- Start engine
(i dle speed)
X 1/7 V X 1/15 32,5 V Checki ng electrical
install ation of vehicle
(see manufacturer
instructions)
Seite 4.2/14
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
* Fault is in seri ous class, if temperature pick-up for oi l and water are defect at the same time.
class
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
08
09
Cool ing-water
temperature
pick-up
Di sconti nuity /
Short circuit to
battery
serious/
sli ght *
1 s - Ignition: OFF
control unit
X 2/5 X 2/4 20C 10C =
1039 - 1117
60C 10C =
1099 - 1271
80C 10C =
1271 - 1347
Notice:
The measuring
in one tempera-
ture range
normall y i s
sufficient.
Check lead and
temperature pick-up
Page 4.2/15
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
* Fault is in seri ous class, if temperature pick-up for oi l and water are defect at the same time.
class
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
11
12
Oil temperature
pick-up
Di sconti nuity /
Short circuit to
battery
serious/
sli ght *
1 s - Ignition: OFF
control unit
X 2/9 X 2/8 20C 10C =
1039 - 1117
60C 10C =
1099 - 1271
80C 10C =
1271 - 1347
Notice:
The measuring
in one tempera-
ture range
normall y i s
sufficient.
Check lead and
temperature pick-up
Page 4.2/16
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
class
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
13 1 Retarder stage
swi tch
Undefined
swi tch state
serious 100 ms - Ignition: ON
- Retarder stage
switch:
Position 0
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
17,5 V
0 V
0 V
0 V
0 V
0 V
Check l ead, plug and
retarder stage switch
13 2 - Ignition: ON
- Retarder stage
switch:
Position 1
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
17,5 V
17,5 V
0 V
0 V
0 V
0 V
13 3 - Ignition: ON
- Retarder stage
switch:
Position 2
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
17,5 V
17,5 V
17,5 V
0 V
0 V
0 V
Page 4.2/17
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
class
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
13 4 - Ignition: ON
- Retarder stage
switch:
Posi ti on 3
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
17,5 V
17,5 V
17,5 V
17,5 V
0 V
0 V
13 5 - Ignition: ON
- Retarder stage
switch:
Posi ti on 4
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
17,5 V
17,5 V
17,5 V
17,5 V
17,5 V
0 V
13 6 - Ignition: ON
- Retarder stage
switch:
Posi ti on 5
X 1/10 V X 1/15
X 1/6 V X 1/15
X 1/5 V X 1/15
X 1/4 V X 1/15
X 1/9 V X 1/15
X 1/8 V X 1/15
17,5 V
17,5 V
17,5 V
17,5 V
17,5 V
17,5 V
Page 4.2/18
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
class
Trigger time Requirement / Operati-
on
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
14 Retarder stage
swi tch
Short circuit to
battery
control unit
- Ignition: ON
- Retarder stage switch:
Posi ti on 0
X 1/10 V X 1/15 0 V Check l ead and
plug
15 Retarder stage
swi tch
Short circuit to
battery
control unit
- Retarder stage switch:
Posi ti on 5
X 1/10 X 1/15 Resistor
i nfinite
Single check of
stages for
short circui t
16 Speedometer
signal
Di sconti nuity
serious 2 s - Ignition: ON X 3/2 V X 1/15 1 V Check l ead and
speedometer
Page 4.2/19
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
class
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
18 Speedometer signal
Short circuit to battery
seri ous 2 s - Igni ti on: OFF
- Pull plug X3 out of
control uni t
- Igni ti on: ON
X 3/2 V X 1/15 9 V Check lead and
speedometer
19 ABS
Short circuit to ground
seri ous 60 s - Igni ti on: ON X 3/3 V X 1/15 3,5 V Check lead,
relay and
ABS-control unit
21 ABS-Signal undefined seri ous 60 s - Igni ti on: ON X 3/3 V X 1/15 16,5 V Check lead,
relay and
ABS-control unit
22 Internal fault
ABS-current path
seri ous 1 s - - - Repl ace control
unit
23 Proportional val ve
Faul t No. 1:
seri ous 1 s - Igni ti on: OFF
control uni t
- Igni ti on: ON
X 2/3 V X 1/15 10 V Check lead
Page 4.2/20
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
class
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
24 1 Proportional val ve
Faul t No. 2:
- Short circuit proportional
valve magnetic
- Short circui t connection
lead proportional val ve
- Discontinuity proportio-
nal valve magnetic
Valve magnetic
- Discontinuity connec-
tion l ead proportional
valve
- Short circuit to ground at
proportional valve
- Prop.- and shift valve
interchanged
serious 1 s - Ignition: ON
- Pull plug X2 out
of control unit
X 2/2 X 2/3 18-25 Check lead and
proportional
valve
(valve bl ock)
24 2 - Ignition: OFF
- Pull plug X2 out
of control unit
i nfinite
Check lead and
proportional
valve
(valve bl ock)
Page 4.2/21
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
class
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
24 3 - Ignition: OFF
control unit
i nfinite
Check lead and
proportional
valve
(valve bl ock)
Faul t No. 3:
defecti ve control unit
seri ous 10 s Replace
control unit
Faul t No. 5:
defecti ve control unit
seri ous 2 s Replace
control unit
28 Termi nal 30
Undervoltage
seri ous 60 s - Ignition: OFF
control unit
- Ignition: ON
X 1/13 V X 1/15 17,5 V Check l ead,
plug and fuse
Page 4.2/22
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
class
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
29 Faul t control unit serious 180 ms Replace
control unit
31 Control unit:
Codi ng faul t
serious 100 ms Provi de new para-
meters for control
unit
32 Retarder pi lot light:
Di sconti nuity /
Short circuit to ground
control unit
- Ignition: ON
X 3/8 V X 1/15 17,5 V Check lead,
retarder pil ot
light and fuse
33 Retarder pi lot light:
serious 3 s - Ignition: ON
- Retarder stage
switch:
Position 1
X 3/8 V X 1/15 2 V Check lead and
retarder pil ot
light
35 Faul t control unit serious 500 ms / 123 s Replace
control unit
37 Faul t foot operation slight 100 ms / 1 s Check install ation
according to
OEM- e.g.
Voith i nstructions
Page 4.2/23
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
class
Operation
Measurement/
Test connection
Result/
Set point
Cause/
Remedy
Code Test step
38 1 Faul t Constant-air
pressure
slight 1 s to 10 s Ignition: ON
Posi ti on 0
X 3/7 V X 1/15
X 3/10 V X 1/15
0 bar =
0,3-0,7 V
2,5 bar=
2,8 - 3,2 V
4,75-
5,25 V
Pressure pick-up
Wiring harness
At deviati ons:
Step 2
2 Troubleshooti ng in
wi ring harness,
pressure pi ck-up,
proportional valve,
supply-air pressure,
ECU (contact VOITH
TURBO)
Page 4.2/24
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
B. Without fault code
Note
Retarder faults without faul t code are not recognized electronical ly.
Page 4.2/25
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.3 Illustration Control System
Illustration checking control system
Note
The reference numbers indicated in Section 4.3
are not identical with the reference numbers of
the spare parts li sts.
1 Heat exchanger
2 Control unit
current connection
19 Temperatur pick-up cooli ng water
al ternative: posi ti ons 19 and 20
joining i n the central -pl ug
(see electri cal diagram Version 2)
20 Temperature pick-up oil
y

(Connection A)
26 Supply-air pressure li ne p
v

(Connection P)
31 Compressed air line
(pressure regulator - four-circuit
protection valve)
32 Compressed-air pressure li ne
(four-circuit protection valve -
ai r tank for auxiliary equipment
with test connection
33 Compressed-air line
(brake circuit No. 1)
(brake circuit No. 2)
(parki ng brake)
37 Venti lation li ne R
39 El ectrical lead (cooli ng-water
temperature pick-up to control unit,
2 wires)
40 El ectrical lead (oil temperature
pi ck-up to control unit, 2 wires)
61 Four-circuit protection valve
71 Ai r tank for auxili ary equipment
P
A
71
32
33
31
34
35
61
39
19
1
40
20
2
25
11
21
26
18028
Page 4.3/1
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.4 Checking Supply-Air Pressure
Checking supply-air pressure p
v
1. Connect test pressure gauge (99/1) to test connection of compressed-air line (32)
(four ci rcui t protection val ve - air tank for auxil iary equipment) and check suppl y-ai r pressure p
v
.
Mi nimum pressure 6 bar
Maximum pressure 11 bar
Note
If the pressure i s not withi n the speci fi ed range, the service brake must be checked to the manufacturers
data.
Page 4.4/1
18029
32
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.5 Checking Constant-Air Pressure
Retarder stage switch i n position 0
Vehicle ignition system OFF
Special tool
Compressed-air gauge
0 to 6 bar
53.1403.10
Page 4.5/1
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.5 Checking Constant-Air Pressure
(Continue)
Job scope test
1. Screw out oil fil ler/check pl ug M 30x1,5 (1900) and remove sealing ri ng (1800).
2. Connect pressure gauge (99/7) to the retarder housing.
3. Shift the retarder stage switch to switch position 5 and compare read-off val ue wi th the given values
of the constant-air pressure p
y
on table in chapter 4.10.
4. Screw oi l fi ller/check plug (1900) tight with new seal ing ring (1800).
Tightening torque 150 Nm
1800
1900
18030
99/7
18031
99/7 Pressure gauge 53.1403.10
Page 4.5/2
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.6 Checking Control Current of Proportional Valve
Vehi cle electrical system checked in accordance with the Owners Manual for the vehicle and found
satisfactory.
Fuse for retarder control unit checked and found satisfactory.
Plug at proportional valve and socket for damage as well as wear (notch scratches) checked and
found satisfactory.
Special tool
Measuring adapter
53.8198.10
Page 4.6/1
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.6 Checking Control Current of Proportional Valve
(Continue)
Job scope
1. Disconnect plug at proportional valve (21) and connect with measuri ng adapter (99/3).
2. Connect plug of measuring adapter (99/3) with the proportional valve (21).
3. Connect the Multimeter (98/8). Switch position: mA or A
4. Turn switch Propvalve at measuri ng adapter (99/3) in position I .
5. Shift the retarder stage switch in position 5 and compare the read-off val ue with the given values
of the control current of the proportional val ve in accordance with the tables (see page 4.10).
Notice
If the control current i s reached but the constant-air pressure p
y
is not, there are ei ther outer leakyness,
or the proportional valve is defective and must be renewed.
If both values are not reached, please read chapter 4.2 Troubleshooting and Remedies.
99/3 Measuring adapter Propstrom 53.8198.10
98/8 Multimeter
Page 4.6/2
18032
98/8
99/3
21
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.7 Checking Temperature Adaption
Vehicle ignition system OFF
Pressure gauge constant-air pressure (99/7) connected
Connected measuri ng adapter (99/3)
Vehicle electrical system checked in accordance with the Owners Manual for the vehicle and
found satisfactory.
Fuse for retarder control unit checked and found sati sfactory.
Special tool
Temperature- Adapter cable
simulator
Page 4.7/1
Wasser l
53.8207.10 53.8279.10
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Job scope test set-up
1. Connect temperature simulator (99/2) with the adapter cable (98/5) to plug of temperature
pick-up (57).
Note
Mind the correct connection of the plugs for cooli ng-water and oi l!
The oil temperature adaption can not be tested by thi s method!
57
98/5
99/2
18033
99/2 Temperature simulator 53.8207.10
98/5 Adapter cable 53.8279.10
Page 4.7/2
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Job scope test
Prior job
Ignition ON
1. Set the rotary switch of the temperature simulator (99/2) to 95C cool ing water temperature and
165C oil temperature operate the retarder at the highest stage.
The constant-air pressure p
y
and the control current must reach the values (see page 4.10/1).
2. Set the rotary swi tch of the temperature simulator (99/2) to 105
o
C cool ing water temperature. The
constant-air pressure p
y
must drop temporary below the set maxi mum value. Set rotary swi tch of
the temperature si mul ator (99/2) to 125
o
C cooling water temperature. There must be no more out-
put of constant-ai r pressure p
y
.
3. Ignition OFF
4. Reconnect ell ectrical connection to temperatur pick-ups for cooling-water (39) and oil (19).
57
98/5
99/2
18033
99/2 Temperature simulator 53.8207.10
Page 4.7/3
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.8 Checking Pressure Sensor
Ignition OFF
Pressure gauge constant-air pressure connected
Special tool
Measuring adapter
53.8198.10
Page 4.8/1
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.8 Checking Pressure Sensor
(Continue)
Job scope test
1. Disconnect plug from pressure pi ck-up (38) and connect to measuring adapter (99/3).
2. Connect plug of measuri ng adapter (99/3) to pressure sensor (38).
3. Connect ground lead of multimeter (98/8) to measuring plug 4 of the adapter (99/3).
4. Turn switch Propvalve at measuring adapter (99/3) downwards (not in position I ).
5. Connect the positive l ead of multimeter to measuring plug 1.
6. If igni tion is ON, the measured voltage must be between 4,75 and 5,25 V.
7. Connect the positive l ead of multimeter to measuring plug 2.
8. Compare measured voltage in dependency of the constant-air pressure with the fol lowi ng values :
0 bar = 0,3 - 0,7 V
2,5 bar = 2,8 - 3,2 V
9. Ignition OFF
10. After removing the measuring adapter, connect again electrical l ead with pressure sensor (38).
Page 4.8/2
18034
98/8
99/3
38
18035
98/8
99/3
38
Measurements of the signal vol tage at
measuring pl ug 2 and measuring plug 4
Measurements of the supply voltage at
measuring pl ug 1 and measuring plug 4
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.9 Checking Pump Pressure
Illustration checking pump pressure
Prior jobs
Ignition OFF
101 Hex.-head screw M 12 x 1,5
25 Nm (pump pressure measuring
point)
Note
The pump-pressure check provides i nformati on
on i nternal leaks and on the operati on of the
retarder.
Special tool
Oil pressure gauge
0-25 bar
53.4788.10
101
18036
Page 4.9/1
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Preconditions for test
Constant-air pressure (p
y
) checked and found sati sfactory
No outer leakages at the retarder
The screw plug is hot!
Job scope
1. Screw out hex.-head screw M12x1,5 (101) at retarder housing.
2. Connect up pressure gauge (99/1) to retarder housing.
99/1
18037
99/1 Pressure gauge 53.4788.10
Page 4.9/2
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Job scope dynamic
1. Drive the vehicle with a prop shaft speed of v
ps
= 1000 r.p.m..
Engage direct gear (gear ratio 1:1), and drive wi th an engi ne speed of 1000 r.p.m..
2. While on the move, shift the retarder stage swi tch (16) to posi ti on 5 and read dynamic
pump pressure off test pressure gauge (99/1) at prop shaft speed v
ps
= 1000 r.p.m..
3. Compare read-off pump pressure with the value of dynamic pump pressure according to the table
(see page 4.10/1).
Caution!
If the setpoint i s obtained in the test at a standsti ll (see chapter 4.5), but the mini mum value is not
reached in the dynamic test, please contact VOITH TURBO!
The screwings of the pressure gauge and retarder are hot!
4. Disconnect the pressure gauge.
5. Check seali ng ring of screw plug on damages; renew screw plug, if necessary.
6. Screw screw plug (101) tight.
Page 4.9/3
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.10 Table of Measurements
The data represent the state of the art at the time of going to print.
The manufacturer reserves the ri ght to make further modificati ons.
1)
The code number is to be found on the control uni t.
2)
If a commercial ly avail able mul ti meter i s used for measurements (wi thout real effecti ve measuring),
exact readings cannot be made (indicati on jumps).
3)
Decisive is the pressure which has buil t up itself after 10 seconds (stabil ized, constant pressure).
4)
Retarder stage switch i n hi ghest braki ng stage.
5)
As a result of permanent readjustments in the control circui t, the values may under ci rcumstances
not be constant (but wi thin the specified range).
Setting [Nm]
Code Number
1)
Control current [mA]
2) 4) 5)
Constant-air pressure p
y

3) 4)

(static)
set point [bar]
Pump pressure dynamic
4)
v
ps
= 1000 r.p.m.
minimum value [bar]

1500 034 376 - 576 1,75 2,05 12
1750 035 396 - 596 2,05 2,35 14
2000 036, 054 416 - 616 2,35 2,65 16
Page 4.10/1
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
4.11 Operational Check
Electrical system checked in accordance wi th the Owners Manual for the vehicle
and found satisfactory.
Constant-ai r pressure 6 -11 bar
Retarder oil level satisfactory
The following operational states are indicated by the retarder pi lot light (arrow):
Retarder pilot light without indication
The retarder i s switched off. There is no faul t in the memory.
Retarder pilot light permanently on
The retarder i s switched on, i.e., one of the four possible retarder braki ng stages or
Constant Speed operation has been selected wi th the retarder stage switch.
The retarder pilot light addi ti onall y has the function of a fault indicator.
The retarder pilot light is permanentl y on i n position 0 to 5 of the retarder stage switch.
- slight fault
Braking operations are possible (the retarder operates with li mited braki ng torque).
- serious fault
There are no more braking operations possible - the retarder is swi tched off.
Page 4.11/1
R
18038
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Note
If the ignition is swi tched off and on again, the retarder i s i n operati on and the retarder pilot l ight
is going off.
If the fault occurs again, the retarder switches off again and the retarder pi lot light is permanently on in
position 0 to 5 of the retarder stage switch.
Retarder pilot light flashes
- while the retarder is braking
The temperature limitation is functioning, the retarder cuts back i ts braking torque.
This flashing function only is real ized at defined control variants!
Page 4.11/2
Diagnosis /
Troubleshooting
cbtd 2000-01
53.2688.10
(Continue)
Test step Scope of check Requirement /
Operation
Result / Set point Note, Cause / Remedy
1 Retarder pilot li ght Ignition: ON Retarder pilot li ght comes on and
goes off after approx. 5 sec.
Retarder pilot light does not come
on, or does not go off.
Retarder pilot li ght trouble-free
Troubleshooting as on page 4.1/1
2 Retarder Vehicle on move
- Shift retarder stage
switch to stage 1 to 5.
Retarder pilot li ght comes on,
retarder brakes in stages 1 to 5.
Retarder pilot light does not come
on, or retarder does not brake
properl y.
Retarder operates trouble-free.
Troubleshooting as on page 4.1/1
Page 4.11/3
Retarder, Remo-
ving, Installing
cbtd 2000-01
53.2688.10
5 Removing, Installing Retarder
5.1 Removing, Installing Retarder (Gearbox Attachment)................................5.1/1
Page 5/1
Retarder, Remo-
ving, Installing
cbtd 2000-01
53.2688.10
5.1 Removing, Installing (Gearbox Attachment)
To install the retarder 120-3 according to regul ations to the gearbox or to remove from the gearbox,
specific working steps requiring speci al tools have to be carried out!
Caution!
Observe Voi th-Installation instructions and gear-box specific install ation instructions.
These have to be requested from Voith Turbo.
Should these installation instructions be disregarded, the retarder may be completely wrecked!
Page 5.1/1
cbtd 2000-01
53.2688.10
Repair Gearbox
Attachment
6 Repair (Gearbox Attachment)
6.1 Overall Illustration of Main Components ....................................................6.1/1
6.2 Checking, Removing and Installing Casing Ventilation..............................6.2/1
Non-Return Valve (Stainless-Steel Heat Exchanger).................................6.3/1
6.4 Removing, Cleaning and Installing Silencer...............................................6.4/1
6.5 Removing, Installing Bottom Cover ............................................................6.5/1
6.6 Checking, Removing and Installing Closing Cover Retarder Housing.......6.6/1
6.7 Removing, Installing Labyrinth Ring (Output Side)
Renewing Radial Shaft Sealing Ring .........................................................6.7/1
6.8 Removing, Installing Centering Cover (Input Side)
Renewing Radial Shaft Sealing Ring .........................................................6.8/1
Page 6/1
Repair Gearbox
Attachment
cbtd 2000-01
53.2688.10
6.1 Assembly Overview (Retarder Basic Group)
1900
1800
700 850 800
900
2500
2800
2700
2600
2300
2300/3
2300/2
2301
2300/1
4300
4500
4400
4600
101
1100
1000
1200
1300
1700
1500
1400
2900
3200
3100
3000
3700
18039
3500
3600
101 Screw plug M12x1.5
hexagonal recess, w.a.f. 6, 25 Nm
700 Radial shaft seal ing ring (80x100x10)
800 Labyrinth cover
850 O-ring 125x2.5
900 Hex.-head screw M8x25, w.a.f. 13, 30 Nm
external hex.-head screw
1000 Cover
1100 O-ring 82x4
1200 Gasket
1300 Bottom cover
1400 Washer B8.4
1500 Cap screw M6x20
1700 Screw plug M22x1,5
1800 Seal ing ring A30x36
1900 Oil/fi ller check plug M30x1,5, w.a.f. 24, 150 Nm
2300 Casi ng venti lation, contains item no. 2301
2300/1 Valve insert
2300/2 Float body
2300/3 Float cage
2301 O-ring 55x3
2500 Screening plate
2600 Spacer D50/42x15.5
2700 Washer B6.4
2900 Top cover
with 7 threads for M6
3000 Space pl ate wi th gasket
3100 Washer B6.4
hexagonal recess 5, 10 Nm
3500 Sil encer 30x4
3600 Circl ip JL30x1.2
3700 Corrugated spring SSB-0118
4300 Radial shaft seal ing ring 85 x 105 x 13
4400 Centering cover D 152 x 43
4500 O-ring 115 x 3
4600 Hex.-head screw M 8 x 20
Page 6.1/1
Illustration assembly overview (retarder basic group) for attachment to DaimlerChrysler gearbox G0160 and G0210
Repair Gearbox
Attachment
cbtd 2000-01
53.2688.10
6.1 Assembly Overview (Retarder Basic Group)
(Continue)
Illustration assembly overview (retarder basic group) for attachment to ZF gearbox S6-1600 and S6-85
1900
1800
700 850 800
900
2500
2800
2700
2600
2300
2300/3
2300/2
2301
2300/1
101
1100
1000
1200
1300
1700
1500
1400
2900
3200
3100
3000
3700
18040
3500
3600
Caution!
How to renew the input side radial shaft sealing ring for the gearbox attachment illustrated above is not described in this Aftersal es service manual!
101 Screw plug M12x1.5
700 Radial shaft seal ing ring (80x100x10)
800 Labyrinth cover
850 O-ring 125x2.5
900 Hex.-head screw M8x25, w.a.f. 13, 30 Nm
1000 Cover
1100 O-ring 82x4
1200 Gasket
1300 Bottom cover
1400 Washer B8.4
1700 Screw plug M22x1,5
1800 Seal ing ring A30x36
1900 Oil/fi ller check plug M30x1,5, w.a.f. 24, 150 Nm
2300 Casi ng venti lation, contains item no. 2301
2300/1 Valve insert
2300/2 Float body
2300/3 Float cage
2301 O-ring 55x3
2500 Screening plate
2600 Spacer D50/42x15.5
2700 Washer B6.4
2900 Top cover
with 7 threads for M6
3000 Space pl ate wi th gasket
3100 Washer B6.4
3500 Sil encer 30x4
3600 Circl ip JL30x1.2
3700 Corrugated spring SSB-0118
Page 6.1/2
cbtd 2000-01
53.2688.10
Repair Gearbox
Attachment
6.2 Checking, Removing and Installing
Casing Ventilation
Illustration casing ventilation
Prior jobs
Retarder stage switch in switch position 0
Igni ti on OFF
Proporti onal valve and adapter plate
removed (see chapter 8.1 and 8.2)
2300 Casi ng venti lation
2300/1 Valve insert
2300/2 Float checking, renew if necessary
2300/3 Float cage
2301 O-ring, 55 x 3, renew,
coat of silicone-free and
non-corrosi ve grease
for install ation
2500 Cover plate
2600 Spacer
2700 Washer, B 6,4
2800 Hex.-head screw M 6 x 12
2900 Cover
3000 Partion metal sheet with gasket,
renew
3100 Washer B 6,4
3200 Cap screw M 6 x 30
Page 6.2/1
2500
2800
2700
2600
2300
2300/3
2300/2
2301
2300/1
2900
3200
3100
3000
18041
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53.2688.10
Repair Gearbox
Attachment
Casing Ventilation (Continue)
Special tools Tool for local fabrication
Note
The tool for local fabrication can also be ordered from Voi th Turbo - Voith code number 67.2757.10.
Lubricants and cleaning agents
Mesh strainer Benzine
O-ring Sil icone-free and
Float Methyl ated Spirit
53.7712.10
53.9428.10
Page 6.2/2
40,5 mm

7

m
m
60 mm
18042e
Material: St 37
Weight: 0,085 kg
cbtd 2000-01
53.2688.10
Repair Gearbox
Attachment
To remove
1. Screw out hex.-head screws (3200).
2. Remove washer (3100).
3. Remove the cover (2900) from the retarder housi ng.
4. Remove the partion metal sheet wi th gasket (3000) and clean the sealing surface at the cover and
the retarder housing.
5. Screw out hex.-head screws (2800) and remove Washer (2700).
6. Remove cover plate (2500).
7. Remove spacer (2600).
8. Use the impact puller (99/5) and adapter (98/7) to extract the casing ventilati on (2300).
9. Extract the valve insert (2300/1) from fl oat cage (2300/3).
10. Lever O-ring (2301) out of the groove of the valve insert (2300/1).
Page 6.2/3
2300
18043
98/7
99/5
98/7 Adapter 53.9428.10
99/5 Impact pull er 53.7712.10
18044
2301
2300/1
2300/3
cbtd 2000-01
53.2688.10
Repair Gearbox
Attachment
To check
1. Check the float (2300/2) for damage to the surface and to the sealing surfaces (arrow).
2. Weight the fl oat (2300/2).
Specified weight 11g 1 Gramm. If the wei ght is more than the specified weight, renew the
compl ete casing ventilation.
Note
Oi l has penetrated into the fl oat, the retarder is impaired in its operati on.
3. Check seali ng edge of shaft seali ng ring (arrow) i n the valve insert (2300/1).
Put down the valve insert (2300/1) on the float (2300/2) than weigh down the valve insert with the
test ring (99/7). Fill up the hollow space between float and upper edge of valve insert wi th methy-
lated spirit. If the seali ng edge is not damaged, the fluid level must not alter in the course of
1 minute. If necessary, renew the compl ete casing ventilation.
2300/2
18045
Page 6.2/4
2300/2
2300/1
99/7
18046
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53.2688.10
Repair Gearbox
Attachment
To install
1. Pull new O-ring (2301) on to the valve insert (2300/1) and coat with si licone-free and
non-corrosive grease.
2. Fit the fl oat (2300/2) into float cage (2300/3).
Note
If the fl oat onl y has one polished surface fit float with thi s surface on top.
3. Fit the fl oat cage (2300/3) into the valve i nsert (2300/1).
4. Inserte casing ventilation (2300) i nto the retarder housi ng.
5. Use the impact pull er (99/5) and adapter (98/9) to knock in carefully the casing ventil ation (2300).
Page 6.2/5
18047
2300/1
2301
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53.2688.10
Repair Gearbox
Attachment
7. Position the spacer (2600).
8. Position cover plate (2500).
9. Screw new hex.-head screws (2800) with washer (2700) ti ght.
Caution!
Make sure the gasket (3000) and the partion metal sheet is properl y l ocated.
10. Position new partion metal sheet with gasket (3000) and the cover (2900) at the retarder housing.
11. Fit cap screws (3200) and washers (3100) and screw tight.
Page 6.2/6
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53.2688.10
Repair Gearbox
Attachment
6.3 Removing, Checking, Installing Non-Return
Valve (Stainless-Steel Heat Exchanger)
Illustration non-return valve
Note
The non-return valve is only installed in
stainless-steel heat exchanger.
1200 Non-return valve (stainless-steel
heat exchanger)
1200/1 Valve cover
1200/2 Valve housing
1200/3 O-ring, renew,
coat with sili cone-free and
for install ation
1200/4 Spring, check for fatigue, renew
complete non-return valve (1200) if
necessary
1200/5 Valve piston, check valve seat i n
heat exchanger and vul canizati on,
renew complete non-return
valve (1200)
1400 Combi ned hex.-head screw
M 8 x 20 , combined hex.-head,
w.a.f. 13, 23 Nm
Lubricants
O-rings Sili cone-free and
non-corrosive grease
Page 6.3/1
1200/5
1200/4
1200/3
1200
1200/2
1200/1
1400
18048
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53.2688.10
Repair Gearbox
Attachment
6.4 Removing, Cleaning and Installing Silencer
Illustration silencer
Prior jobs
Retarder stage switch in switch position 0
Igni ti on OFF
3500 Si lencer 30 x 4
3600 Circl ip JL 30 x 1,2
The convex side must face sil encer
3700 Corrugated spri ng SSB-0118
Cleaning agents
Si lencer Benzine
Page6.4/1
3700
3500
3600
18049
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53.2688.10
Repair Gearbox
Attachment
6.5 Removing, Installing Bottom Cover
Illustration bottom cover
Prior jobs
Oi l drained from retarder (see Secti on 3.3)
Retarder stage switch in position 0
Igni ti on OFF
1200 Gasket, renew
1300 Bottom cover
1400 Washer B 6,4
1500 Cap screw, M 6 x 20,
Page 6.5/1
1500
1300
1200
1400
18050
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53.2688.10
Repair Gearbox
Attachment
Closing Cover Retarder Housing
Special tool

To check
1. Check closing cover (1000) for seal ing and renew O-rings (1100), if necessary.
To remove
1. Drive out closing cover (1000) with impact pul ler (99/5) and remove O-ri ngs (1100).
To install
1. Coat new O-ri ngs (1100) wi th thin coat of si licone-free and non-corossive grease and i nstal l
closing cover (1000) together wi th O-ring (1100) in the retarder housing.
53.7712.10
1100 1000
99/5
1000
18051
Page 6.6/1
99/5 Impact puller 53.7712.10
cbtd 2000-01
53.2688.10
Repair Gearbox
Attachment
Illustration labyrinth ring (output side)
Prior jobs
Prop shaft removed from flange
(see vehicle manufacturer i nstructions)
Prop shaft flange removed
(see VOITH-installation schemes)
Retarder stage switch in position 0
Igni ti on OFF
Note
Thi s j ob can be performed with the retarder
removed or install ed.
700 Radial shaft seal ing ring
80 x 100 x 10, renew, coat with sil i-
cone-free and non-corossive
grease for installati on
800 Labyrinth cover,
coat with Hylomar sealant around
leakage oil return bore
850 O-ring 125 x 2,5, renew, coat with
silicone-free and non-corossive
900 Hex.-head screw (M 8 x 25),
self-locki ng, renew,
Hex.-head, w.a.f. 13, 30 Nm
Page 6.7/1
800
700
850
900
18052
Renewing Radial Shaft Sealing Ring
cbtd 2000-01
53.2688.10
Repair Gearbox
Attachment
Special tool
Job scope
1. Screw out hex.-head screw (900).
2. Use two hex.-head screws (M 8 x 25) (arrows) to press the labyrinth ring (800) off the
rotor housing.
53.0742.10
800
18053
Page 6.7/2
Renewing Radial Shaft Sealing Ring (Continue)
cbtd 2000-01
53.2688.10
Repair Gearbox
Attachment
3. Place the l abyrinth ri ng (800) on a pi ece of pipe.
4. Use an appropriate drift to knock the radi al shaft sealing ri ng (700) out of the labyrinth ring (800)
through the two bores (arrows).
Note
Check race of radial shaft sealing ring for scores and uneven surface. If seali ng function is no longer
guaranteed, pl ease contact Voith Turbo.
5. Apply thin coat of sil icone-free and non-corossive grease to a new radial shaft seal ing ring (700).
6. Use the press-in tool (94/4) to press the radial shaft sealing ri ng (700) into the l abyrinth ring (800)
as far as it wil l go.
Position for installation: Seal ing lip at top.
18054
800 700
94/4
800
700
18055
94/4 Press-in tool 53.0742.10
Page 6.7/3
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53.2688.10
Repair Gearbox
Attachment
7. Apply thin coat of si licone-free and non-corossive grease to new O-ring (850) and fit it in
the labyri nth ring (800).
8. Insert new sel f-locking hex.-head screws into the l abyrinth ring and screw them ti ght.
800
850
18056
Page 6.7/4
cbtd 2000-01
53.2688.10
Repair Gearbox
Attachment
Illustration centering cover
Caution!
The radial shaft seal ing ring can not be
renewed as described in the Aftersales Service
Manual for ZF-gearbox attachment S6-1600 /
S6-85.
Prior job
Retarder removed (see Section 5)
4300 Radial shaft seal ing ring
85 x 105 x 13, renew, coat with
4400 Centering cover
4500 O-ring 130 x 4, renew, coat with
4600 Hex.-head screw M 8 x 20,
self-locki ng, renew,
hex.-head, w.a.f. 13, 25 Nm
Lubricants
O-ring Si licone-free and
non-corossive grease
Page 6.8/1
4500 4300 4400
4600
18057
6.8 Removing, Installing Centering Cover (Input Side),
Renewing Radial Shaft Sealing Ring
cbtd 2000-01
53.2688.10
Repair Gearbox
Attachment
Special tool
Job scope
1. Screw out cap screws (4600), alternative hex.-head screws.
2. Use two hex.-head screws M 8 x 30 (arrows) to press the centeri ng cover (4400) off the
rotor housing.
3. Remove the O-ring (4500) from the centering cover (4400).
4. Use an appropriate punch to knock the radial shaft seali ng ring (4300) out of
the centeri ng cover (4400) without damagi ng its seal ing surface.
Note
Check race of radial shaft sealing ring for scores and uneven surface. If seali ng function is no longer
guaranteed, pl ease contact Voith Turbo.
53.0742.10
4400
18058
4500 4400
Page 6.8/2
cbtd 2000-01
53.2688.10
Repair Gearbox
Attachment
5. Apply thin coat of silicone-free and non-corossi ve grease to a new radial shaft sealing ring (4300).
6. Use a press-in tool (94/4) to press the radi al shaft sealing ri ng (4300) into the
centering cover (4400) as far as it will go.
Position for installation: Seal ing lip at top.
7. Fit in new O-ring (4500) to the centeri ng cover (4400) and appl y thin coat of sil icone-free and
non-corossi ve grease.
8. Install centering cover (4400) such that leakage oi l return bores in the rotor housi ng and in the
centering cover face each other.
Caution!
The rectangular section ring i n the retarder hol low shaft must not face above its groove. Otherwise the
rectangular ring can be cut off during instal ling.
9. Insert new cap screws (4600), alternati ve hex.-head screws and screw them tight.
Cap screws tightening torque 10 Nm
Hex.-head screws tightening torque 25 Nm
Caution!
It must be possi ble to turn the retarder hol low shaft by hand after install ing the centering cover (4400).
18060
4400
4600
4500
94/4
4400
18059
4300
94/4 Press-i n tool 53.0742.10
Page 6.8/3
Repair
Heat Exchanger
cbtd 2000-01
53.2688.10
7 Removing, Checking and Installing
Heat Exchanger
7.1 Removing, Checking and Installing Stainless-Steel Heat Exchanger ........7.1/1
7.2 Removing, Checking and Installing Aluminium Heat Exchanger ...............7.2/1
Page 7/1
Repair
Heat Exchanger
cbtd 2000-01
53.2688.10
Stainless-Steel Heat Exchanger
Illustration stainless-steel heat exchanger
1000
15000
16000
13000
14000
97
96
16000
12000
14000
5000
5000
8000
2000
3000
9000
1700
7000
1001
18061
34000
Prior jobs
Retarder removed (chapter 5.1)
This job sequence can also be performed with the retarder installed.
Retarder stage switch in stage position 0
Vehi cle igni ti on system OFF
96 Hose clamp
97 Cooling-water hose
1000 Heat exchanger
1001 Cooling-water drain plug M 18 x 1,5
1700 Oil drain plug retarder M 22 x 1,5
2000 Throttle disc (outlet)
3000 O-ring 36 x 4, renew, coat with sili cone-free and
non-corrosi ve grease for installation
5000 Col lar nut M 8, self-l ocking, renew,
7000 Combi ned hex.-head screw M 8 x 35,
Data
Pressure test oil secti on: max.10 bar
8000 Pi n screw M 10 x 50
9000 O-ring 45 x 4, renew, coat with silicone-free and non-corrosive
grease for i nstallation
12000 Connecting piece
13000 Connecting piece
14000 Gasket, renew
15000 Combined hex.-head screw M 10 x 65
34000 Cooling-water temperature pick-up
Lubricants
O-rings Sil icone-free and
Special tool
53.4786.10
Aftersal es Servi ce Manual VOITH Retarder R 120-3
Page 7.1/1
Repair
Heat Exchanger
cbtd 2000-01
53.2688.10
Stainless-Steel Heat Exchanger (Continue)
Note
If thi s j ob sequence is performed with the retarder installed, the foll owi ng j obs must be performed
prior to removal of the heat exchanger:
The coolant drain plug and the temperature pick-up are hot!
1. Screw out cool ant drain plug (1001) and drai n cooli ng water from the heat exchanger. Remove
the cooling water hoses (97) from the retarder.
2. Push an oil collecting pan under the retarder.
The oil drain plug is hot! Oi l temperature!
3. Screw out oil drai n plug (1700) and drain the oil.
4. Screw the cool ant drain plug (1001) and the oil drain plug (1700) tight.
Page 7.1/2
cbtd 2000-01
53.2688.10
Repair
Heat Exchanger
To remove
1. Remove cooli ng-water temperature pi ck-up.
2. Unscrew four coll ar nuts (5000).
Caution!
A small amount of oil remains in the stainless-steel heat exchanger!
3. Screw out two combined hex.-head screws (7000) and remove heat exchanger (1000).
4. Remove the two O-ri ngs (9000, 3000) and the throttle disc (2000) from retarder.
Note
Do not remove the insert (93/8) with the throttle disc.
4. Check closing cover (1000) for l eaks, renew O-ring (1100), if necessary
(see chapter 6.6 Checking, Removi ng and Installing Cl osing Cover Retarder Housing).
Page 7.1/3
2000
3000
9000
93/8
18062
Repair
Heat Exchanger
cbtd 2000-01
53.2688.10
To install
Note
New heat exchanger are wetted with preservi ng oil i n the cooling-water section and in the oi l section.
Prior to i nstallati on of a new heat exchanger, drain any preserving oi l which has collected and flush out
the cool ing-water section with hot water.
1. Apply thin coat of si licone-free and non-corrosi ve grease to the O-ri ngs (9000, 3000).
Fit them in the feed bores of the retarder housi ng.
2. Apply thin coat of si licone-free and non-corrosive grease to the throttle disc (2000) and fit it in the
ri ght-hand bore.
3. Install the heat exchanger (1000) on the retarder housing. Screw tight with new sel f-locki ng collar-
nuts (5000) and combined hex.-head screws (7000) at the retarder housing.
4. Install retarder, i f necessary (see chapter 5.1).
5. Screw in cooli ng-water temperature pick-up (see chapter 8.3). Fil l in cool ant and bleed cooling-
water circui t according to the instructions of the vehicl e manufacturer.
Note
Heed the statements of the vehicle manufacturer respecting the cooling-water qual ity, as wel l as the
Voith cool ing-water l ists i n the annex.
Page 7.1/4
1700
18063
Repair
Heat Exchanger
cbtd 2000-01
53.2688.10
6. If the heat exchanger (1000) had been leaking i n the oil section, splush the retarder:
While flushing, brake slightel y several times to avoi d the retarder oil overheating.
Fil l the retarder with 4,0 Litre engine oil or flushing oil . Flush the retarder system by braking li ghtely
several times and drain the oi l through oil drai n plug (1700).
Repeat the procedure 2 or 3 times unti l no more oil is visible i n the water.
Screw oil drain plug (1700).
7. Fil l in retarder oi l in accordance with the operating speci fi cations (see chapter 3.3 Oi l Change
and Annex).
Note
If retarder oi l has entered the cooling-water system, the vehicle cooling-system must be cleaned i n
accordance wi th the i nstructions of the vehicle manufacturer.
8. If the heat exchanger (1000) had been leaking, deoil vehicle cooling and heating system in
accordance with vehicl e manufacturers data.
Page 7.1/5
cbtd 2000-01
53.2688.10
Repair
Heat Exchanger
Aluminium Heat Exchanger
1002
1001
2000
8000
3000
9000
1000
1700
97
96
5000
5000
18064
7000
Prior jobs
Retarder removed (chapter 5.1)
This job sequence can also be performed with the retarder installed.
Vehi cle igni ti on system OFF
96 Hose clamp
97 Cooling-water hose
1000 Heat exchanger
1001 Cooling-water drain plug M 18 x 1,5
1002 Oil-drain plug heat exchanger M 12 x 1,5
1700 Oil-drain plug heat exchanger M 22 x 1,5
2000 Throttle disc (Outl et throttl e)
Data
Pressure test oil secti on max.10 bar
5000 Col lar nut M 8, self-locking, renew,
8000 Pi n screw M 10 x 50
Lubricants
O-ring Sil icone-free and
Special tool
53.4786.10
Illustration aluminium heat exchanger
Page 7.2/1
Repair
Heat Exchanger
cbtd 2000-01
53.2688.10
Aluminium Heat Exchanger (Continue)
Note
If thi s j ob sequence is performed with the retarder installed, the foll owi ng j obs must be performed
prior to removal of the heat exchanger:
The coolant drain plug i s hot!
1. Screw out coolant drain plug (1001) and drain the cooli ng-water into a clean vessel . Remove the
cooli ng-water hoses (97) from the heat exchanger.
2. Push an oil collecting pan under the retarder.
The oil drain plugs are hot! Oil temperature!
3. Screw out the oi l drain plugs (1002 and1700) and drain oil.
4. Screw the cool ant drain plug (1001) and the oil drain plugs (1002 and 1700) tight.
Page 7.2/2
Repair
Heat Exchanger
cbtd 2000-01
53.2688.10
To remove
1. Screw out four collar-nuts (5000).
2. Screw out the two combined hex.-head screws (7000) and remove heat exchanger (1000).
3. Remove the two O-ri ngs (9000, 3000) and the throttle disc (2000) from the retarder.
Note
Do not remove insert (93/8) wi th throttl e disc.
4. Check closing cover (1000) for l eaks, renew O-ring (1100), if necessary
(see chapter 6.6 Checking, Removi ng and Installing Cl osing Cover Retarder Housing).
To check
1. Install pressure-test plate (99/6) on heat exchanger (1000) and connect up compressed ai r line
with pressure regulator.
2. Fil l the heat exchanger (1000) with hot water (approx. 70C) in the cooli ng-water section.
3. Pressuri ze the heat exchanger (1000) slowly to max. 10 bar overpressure (oil section).
Note
If air bubbles form i n the hot water, the heat exchanger is leaking and must be renewed.
4. Remove the pressure-test pl ate (99/6).
Page 7.2/3
18065
99/6 1000
99/6 Pressure-test pl ate 53.4786.10
2000
3000
9000
93/8
18062
Repair
Heat Exchanger
cbtd 2000-01
53.2688.10
To install
Note
New heat exchangers are wetted with preservi ng oil i n the cooling water section and in the oil secti on.
Prior to i nstallati on of a new heat exchanger, drain any preserving oi l which has collected and flush out
the cool ing water secti on with hot water.
1. Apply thin coat of si licone-free and non-corrosi ve grease to the new O-rings (9000, 3000).
Fit them in the feed bores of the retarder housi ng.
2. Apply thin coat of si licone-free and non-corrosive grease to the throttle disc (2000) and fit it in the
ri ght-hand bore.
3. Fit heat exchanger (1000) to the retarder housi ng. Use new self-locking col lar-nuts (5000),
combi ned hex.-head screws (7000) and screw them tight on the retarder housing.
4. Install retarder, i f necessary (see chapter 5.1).
5. Fil l in cooli ng water and bleed coolant ci rcuit accordi ng to the instructi ons
of the vehicle manufacturer.
Note
Heed the statements of the vehicle manufacturer respecting the cooling-water qual ity, as wel l as the
Voith cool ing-water l ists i n the annex.
Page 7.2/4
cbtd 2000-01
53.2688.10
Repair
Heat Exchanger
6. If the heat exchanger (1000) had been leaking i n the oil section, splush the retarder:
While flushing, brake lightel y several times to avoi d the retarder oil overheating.
Fil l the retarder with 5,0 Litre engine oil or flushing oil . Flush the retarder system by braking li ghtely
several times and drain the oi l through oil drai n plugs (1700).
Repeat the procedure 2 or 3 times unti l no more oil is visible i n the water.
Screw oil drain plugs (1002, 1700) tight wi th new sealing rings.
Tighteni ng torque
Oil drai n plug retarder (1002) 25 Nm
Oil drai n plug heat exchanger (1700) 66 Nm
7. Fil l in retarder oi l in accordance with the operating speci fi cations
(see chapter 3.3 Oil Change and annex).
Page 7.2/5
Control Parts
cbtd 2000-01
53.2688.10
8 Control Parts
8.1 Removing and Installing Proportional Valve...............................................8.1/1
8.2 Removing and Installing Adapter and Pipes ..............................................8.2/1
8.3 Removing and Installing Cooling-Water Temperature Pick-Up..................8.3/1
8.4 Removing and Installing Oil Temperature Pick-Up ....................................8.4/1
Page 8/1
Control Parts
cbtd 2000-01
53.2688.10
8.1 Removing and Installing Proportional Valve
22000
21000
33000
34000
25000
25000
32000
24000
24000
23000
23000
18066
Note
Al ternative the valve also may be install ed at the frame.
Prior jobs
Supply-air pressure discharged
Plug at proportional valve and socket for damages as well as wear (notch scratches) checked and found satisfactory.
Bajonet plug di sconnected from proportional val ve
Igni ti on OFF
Escapi ng compressed-air!
23000 Combi ned hex.-head screw M8x20, renew, 23 Nm
24000 Self-locking hex.-head nut with coll ar M8, renew, 18 Nm
25000 O-ring 16x3, renew
32000 Hol ding plate for baj onet pl ug proportional valve and temperature pick-up
33000 El ectrical lead proporti onal valve, pressure sensor and oil temperature pick-up
Caution!
If the proportional valve (22000) and / or the damping pl ate (21000) have to be removed in case of repai r work, the damping pl ate must be checked and
renewed, if necessary for mechanical and aging damages.
Page 8.1/1
Illustration proportional valve
Control Parts
cbtd 2000-01
53.2688.10
8.2 Removing and Installing Adapter and Pipes
30000
29000
21000
35000
29000
27000
26000
28000
36000
18067
Prior jobs
Supply-air pressure discharged
Proporti onal valve removed (see chapter 8.1)
Escapi ng compressed-air!
21000 O-ring 30x3, renew
26000 Pi pe "A" for constant-air pressure
27000 Banj o bolt, 80 Nm
28000 L-connector, 80 Nm
29000 Seal ing ring A22x27 Copper
30000 Pressure sensor, w.a.f. 27, 30 Nm
35000 Adapter plate
36000 Combi ned hex.-head screw M8x45, w.a.f. 13, 23Nm
Page 8.2/1
Illustration adapter and pipes
cbtd 2000-01
53.2688.10
Control Parts
8.3 Removing and Installing
Cooling-Water Temperature Pick-Up
The cooling-water temperature pick-up is hot! Cool ant!
Prior job
Coolant drained
34000 Cooling-water temperature pi ck-up with baj onet pl ug
Note
The following j ob scope is only relevant for the vari ant wi th Stainless-steel heat exchanger.
Al ternative the cool ing-water temperature pick-up may installed i n the cooling-water pi pe.
Job scope
1. Disconnect the electrical lead to the temperature pick-up at the bajonet connecti on.
2. Unscrew the bajonet plug from holding plate and remove cable tie.
3. Unscrew cool ing-water temperature pick-up (34000).
4. Instal l the temperature pick-up in reverse sequence. Mind the correct fitment of the
el ectrical lead with the cable ti e.
Page 8.3/1
34000
18068
cbtd 2000-01
53.2688.10
Control Parts
8.4 Removing and Installing
Oil Temperature Pick-Up
Page 8.4/1
The oil temperature pick-up is hot! Oi l temperature!
Prior jobs
Igni ti on OFF
17000 Oil temperature pick-up with cable (cable not il lustrated)
Job scope
1. Disconnect the electrical lead to the temperature pick-up at the bajonet connecti on.
2. Remove cable tie.
3. Disconnect plug from proportional valve and pressure pick-up.
4. Unscrew oil temperature pi ck-up (17000).
5. Instal l the temperature pick-up in reverse sequence.
18069
17000
cbtd 2000-01
53.2688.10
Annex
9 Annex
Data Sheet
Conversion Tables
Tightening Torques
Operating Specifications - Oil specifactions
- Cooling-water quality
Spare Parts Lists
Other Information
Page 9/1
cbtd 2000-01
53.2688.10
Annex
9 Data Sheet
* Wi th slant mounted posi ti on of the retarder up to
approx. 4 - reduce service filli ng of approx. 0,25Litre
approx. 8 - reduce service filli ng of approx. 0,50Litre
** Emptied heat exchanger
*** Overall weight will depend on the retarder version.
Data Sheet VOITH Retarder 120-3
Max. braking torque at prop shaft M
(Br)

max
2000 Nm
Max. retarder speed = max. prop shaft speed v
(max.)
3000 r.p.m.
Working medium Oil grade given in Operating Specificati on
Service filling:
- service filling (Oi l change, checking oil level)
- after complete taking apart and cleaning
- new fil ling
With aluminium heat exchanger With stainless-steel heat exchanger
4,5 Litre 5,5 Litre
5,8 Litre ** -
6,5 Litre 6,0 Litre
Overall weight (wi th fl ange and heat exchanger, without oil filling) ca. 70 kg *** ca. 65 kg ***
Page 9/2
cbtd 2000-01
53.2688.10
Annex
9 Conversion Table

D GB USA D GB USA
10
o
C 50
o
F 50
o
F
110 Nm 81 lbf-ft 81 lbf-ft
20
o
C 68
o
F 68
o
F
150 Nm 111 l bf-ft 111 lbf-ft
60
o
C 140
o
F 140
o
F
70
o
C 158
o
F 158
o
F
80
o
C 176
o
F 176
o
F
95
o
C 203
o
F 203
o
F
1500 Nm 1110 lbf-ft 1110 lbf-ft
105
o
C 221
o
F 221
o
F
1750 Nm 1295 lbf-ft 1295 lbf-ft
125
o
C 257
o
F 257
o
F
2000 Nm 1480 lbf-ft 1480 lbf-ft
185
o
C 365
o
F 365
o
F
1,15 - 1,45 bar 16,7 - 21,0 psi 16,7 - 21,0 psi
225
o
C 437
o
F 437
o
F
1,45 - 1,75 bar 21,0 - 25,4 psi 21,0 - 25,4 psi
10 Nm 7 l bf-ft 7 l bf-ft 1,75 - 2,05 bar 25,4 - 29,7 psi 25,4 - 29,7 psi
13 Nm 10 lbf-ft 10 lbf-ft 2,05 - 2,35 bar 29,7 - 34,1 psi 29,7 - 34,1 psi
23 Nm 17 lbf-ft 17 lbf-ft 2,35 - 2,65 bar 34,1 - 38,4 psi 34,1 - 38,4 psi
25 Nm 18 lbf-ft 18 lbf-ft 7 bar 101,5 psi 101,5 psi
32 Nm 24 lbf-ft 24 lbf-ft 9 bar 130,5 psi 130,5 psi
Page 9/3
cbtd 2000-01
53.2688.10
Annex
9 Conversion Table
(Continue)

D GB USA D GB USA
50 Nm 37 lbf-ft 37 lbf-ft 0,25 l 0,055 UK gal 0,066 US gal
12 bar 174 psi 174 psi 5,50 l 1,210 UK gal 1,452 US gal
14 bar 203 psi 203 psi 5,80 l 1,276 UK gal 1,531 US gal
16 bar 232 psi 232 psi 6,00 1,320 UK gal 1,584 US gal
0 - 25 bar 0 - 362,5 psi 0 - 362,5 psi 6,50 l 1,430 UK gal 1,716 US gal
0 - 10 bar 145 psi 145 psi 1000 km 621,4 mil es 621,4 mi les
Page 9/4
cbtd 2000-01
53.2688.10
Annex
9 Tightening Torques

Item no. Description (place of installation) Dimension
Tightening
torque
101 Screw pl ug (measuring poi nt pump pressure) M 12 x 1,5, external hex.-head screw, w.a.f. 13 25 Nm
900 Hex.-head screw (l abyrinth cover) M 8 x 25, external hex.-head screw, w.a.f. 13 30 Nm
1001 Cooling water drain plug (heat exchanger) M 18 x 1,5, hexagonal recess, w.a.f. 8 50 Nm
1002 Oil drain plug (heat exchanger) M 12 x 1,5, hexagonal recess, w.a.f. 6 25 Nm
1400 Combined hex.-head screw (non-return valve) M 8 x 20, external hex.-head screw, w.a.f. 13 23 Nm
1500 Cap screw (bottom cover) M 6 x 20, hexagonal recess, w.a.f. 5 10 Nm
1700 Oil drain plug (retarder) M 22 x 1,5, hexagonal recess, w.a.f. 10 66 Nm
1900 Oil fil ler/check plug (retarder) M 30 x 1,5, external hex.-head screw, w.a.f. 24 150 Nm
2800 Cap screw (screening pl ate) M 6 x 12, hexagonal recess, w.a.f. 5 10 Nm
3200 Cap screw (casing ventil ation cover) M 6 x 30, hexagonal recess, w.a.f. 5 10 Nm
4600 Hex.-head screw (centering cover) M 8 x 20, external hex.-head screw, w.a.f. 13 23 Nm
5000 Coll ar nut (heat exchanger) M 8, external hex.-head screw, w.a.f. 13 23 Nm
7000 Combined hex.-head screw (heat exchanger) M 8 x 35, external hex.-head screw, w.a.f. 13 23 Nm
Page 9/5
cbtd 2000-01
53.2688.10
Annex
9 Tightening Torques
(Continue)
Item no. Description (Place of installation) Dimension
Tightening
torque
15000 Combined hex.-head screw (heat exchanger socket) M 10 x 65, external hex.-head screw, w.a.f. 17 46 Nm
16000 Combined hex.-head screw (heat exchanger socket) M 10 x 35, external hex.-head screw, w.a.f. 17 46 Nm
17000 Oil temperature pick-up (retarder) M 14 x 1,5, external hex.-head screw, w.a.f. 19 25 Nm
23000 Combined hex.-head screw (damping plate) M 8 x 20, external hex.-head screw, w.a.f. 13 23 Nm
24000 Coll ar nuts (proportional val ve) M 8, external hex.-head screw, w.a.f. 13 18 Nm
27000 Banjo bolt (pi pe A for constant-air pressure) M 22 x 1,5, external hex.-head screw, w.a.f. 27 80 Nm
28000 Screwed pipe joi nt (pipe A for constant-air pressure) M 22 x 1,5, external hex.-head screw, w.a.f. 27 80 Nm
30000 Pressure sensor (adapter pl ate) M 16 x 1,5, external hex.-head screw, w.a.f. 27 30 Nm
34000 Cooling water temperature pi ck-up (water socket) M 14 x 1,5, external hex.-head screw, w.a.f. 19 25 Nm
36000 Combined hex.-head screw (adapter pl ate) M 8 x 45, external hex.-head screw, w.a.f. 13 23 Nm
Page 9/6

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