Voith Turbo

Aftersales Service Manual Voith Retarder VR 123

153.00018210 I 2008-07
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Table of Contents

Table of Contents

1 About this document 5

1.1 Purpose of this document 6
1.2 Target groups 6
1.3 Other applicable documents 6
1.4 Symbols and identifications 8
1.5 Item numbers 8
1.6 Imprint 8

2 Basic safety information 9

2.1 Product safety 10
2.2 Staff qualification 10
2.3 Safety-conscious working 10
2.4 Environmental protection 10
2.5 Special tools 10
2.6 Diagnosis and troubleshooting 10
2.7 Maintenance and repair 10
Voith Turbo I 153.00239410 I arrtd I 2008-11

2.8 Driving mode 11

2.9 Storage 11
2.10 Warranty 12

3 Design and function 13

3.1 Overview of the modules 14
3.2 Retarder identification 16
© 2008

3.3 VERA™ control-unit identification 17

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 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Table of Contents

3.4 Digiprop control-unit identification 18

3.5 Function and control scheme 19
3.6 Function description 20

4 Maintenance and service 22

4.1 Maintenance intervals 23
4.2 Oil change 24
4.3 Checking the oil level 27
4.4 Draining the coolant 29
4.5 Proportional valve 31

5 Diagnosis and troubleshooting 32

5.1 Overview of the possible complaints 33
5.2 Checking the constant-air pressure control loop 40
5.3 Checking the dynamic pressure (pdyn) 44
5.4 Checking the proportional valve current 48

6 Removing and installing the retarder 50

Voith Turbo I 153.00239410 I arrtd I 2008-11

7 Repair 51
7.1 Components overview 52
7.2 Top cover 57
7.3 Casing ventilation 59
7.4 Retarder ventilation 63
7.5 Non-return valve 65
7.6 Oil cooler 67
© 2008

7.7 Water neck 71

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 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Table of Contents

7.8 Return valve 73

7.9 Oil temperature sensor 76
7.10 Coolant temperature sensor 78
7.11 Pressure sensor 80
7.12 Proportional valve and damping plate 81

8 Overview of the tools 83

8.1 Diagnosis 84
8.2 Repair 86
Voith Turbo I 153.00239410 I arrtd I 2008-11
© 2008

Page 4
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I About this document

1. About this document

1.1 Purpose of this document 6

1.2 Target groups 6
1.3 Other applicable documents 6
1.4 Symbols and identifications 8
1.5 Item numbers 8
1.6 Imprint 8
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 5
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I About this document Purpose of this document

1.1 Purpose of this document

This Aftersales Service Manual provides information

and instructions on the maintenance and repair of the
Voith Retarder VR 123.

1.2 Target groups

This Aftersales Service Manual is intended only for

service personnel for maintenance and diagnostics
and may not be reproduced or given to third parties.

1.3 Other applicable documents

Documents Information Item number
Voith Retarder oil change intervals/Oil selection list Oil change intervals and approved oil types 153.000900xx
Cooling water quality list Approved coolants H67.2224xx
Operating Instructions Voith Retarder VR 123 Information on the safe, proper and economical operation of the Voith 153.00102710
Retarder VR 123
Operating instructions for retarder tester Measured values for constant-air and dynamic pressure 153.001355xx
Included in scope of delivery of
the retarder tester
(153.001085xx)
Voith Turbo I 153.00018210 I arrtd I 2008-07

Operating Instructions for Diana-Lite test software Information on the testing of: Included in the scope of delivery
• Constant-air pressure control loop of the Diana-Lite test software
(153.000776xx)
• Dynamic pressure (pdyn)
Operating Instructions for the "WinDia®" diagnostic Instructions on PC diagnosis for the Digiprop and VERATM control-units 3623-020900
software
© 2008

Page 6
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I About this document Other applicable documents

Documents Information Item number

ECU specifications Instructions on diagnosis for the Digiprop and VERA™ control-units on request
Device-specific documentation on the retarder Information on the safe and proper removal and installation of the on request
retarder
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 7
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I About this document Symbols and identifications

1.4 Symbols and identifications 1.5 Item numbers

WARNING
Structure of warnings The item numbers used are usually found in the spare
Potentially hazardous situation which, if not avoided,
part lists.
could result in death or serious injury.
LEVEL OF DANGER
Exceptions:
Type and source of danger!
Possible consequences if not heeded. DANGER • one- or two-digit item numbers
Ö Measures for the prevention of danger and its Imminently hazardous situation which, if not • item numbers with a slash
consequences. avoided, will result in death or serious injury.
1.6 Imprint
Levels of danger Notes
The warnings are categorized into four levels of For questions and work procedures not described in
danger: NOTE these documents, contact the respective organization
for your area.
Information on easier and safer work with the
CAUTION retarder. Voith Turbo
Ö Measures for easier and safer work with the Produktgruppe Retarder
Potentially hazardous situation which, if not avoided,
retarder.
may result in property damage. Postfach 1555
74555 Crailsheim
Distinctions
Deutschland
CAUTION
Voith Turbo I 153.00018210 I arrtd I 2008-07

Ö One-step action instruction.

Phone: +49 79 51 / 32-401, 32-422, 32-1860
Potentially hazardous situation which, if not avoided, 1. First step of an action instruction. Other steps Fax: +49 79 51 / 32-756
may result in minor or moderate injury. follow and are numbered in sequence. [email protected]
www.voith.com
© 2008

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 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Basic safety information

2. Basic safety information

2.1 Product safety 10

2.2 Staff qualification 10
2.3 Safety-conscious working 10
2.4 Environmental protection 10
2.5 Special tools 10
2.6 Diagnosis and troubleshooting 10
2.7 Maintenance and repair 10
2.8 Driving mode 11
2.9 Storage 11
2.10 Warranty 12
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 9
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Basic safety information Product safety

2.1 Product safety 2.4 Environmental protection Danger of accidents if the retarder tester is used
improperly!
The retarder is constructed according to the state of Ö Drained fuels and fluids, consumables and old parts
Diagnosis while the vehicle is traveling results in an
the art in technology and acknowledged safety must be disposed of properly. uncontrollable operating state of the vehicle.
regulations.
2.5 Special tools Ö Carry out diagnosis only while the vehicle is
Nevertheless, hazardous situations and property standing still.
damage may occur as a result of improper usage,
Damage to property if false special tools are used!
maintenance and repair.
The special tools required are described in the 2.7 Maintenance and repair
Ö Observe safety and warning information. respective action instructions.
The chapter "Overview of the tools" contains an Danger of burning and scalding via squirting oil!

2.2 Staff qualification overview of the special tools. The oil in the retarder may be hot.

In the case of special tools that may only be used from Ö Switch off the retarder and ignition so that oil is not
Ö Allow only qualified professionals to carry out repair
a specific version on, the version number is contained fed via pulse lubrication.
and maintenance work.
in the last two digits of the Voith item no. Example:
H53.942811. Ö Work carefully.
2.3 Safety-conscious working
Ö Only use special tools from the specified version Danger of burning and scalding via hot coolant!
Voith does not assume any liability for personal injury on. The coolant may be hot.
and/or property damage caused by improper and Ö Take the last two digits of the Voith item no. into
unprofessional work. Ö Work carefully.
account in the graphics of the special tools.
Voith Turbo I 153.00018210 I arrtd I 2008-07

Ö Observe the following regulations:

- accident-prevention regulations 2.6 Diagnosis and troubleshooting
- other generally acknowledged safety Voith provides a warranty/goodwill service for
regulations and occupational health defective parts only.
- Motor Vehicle Regulations
Ö Do not replace parts on mere speculation.
- safety regulations for handling chemical
© 2008

substances such as oils and greases

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 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Basic safety information Driving mode

Danger of burns via hot parts! 2.8 Driving mode Failure or performance reduction while driving
Parts of the retarder may be hot. During failure of the retarder, or while temperature
Ö Ensure that the retarder is fully functional for all adaptation is active:
Ö Work carefully. vehicle maneuvers, i.e.:
Ö Adjust the speed of the vehicle with the engine/
Ö Wear protective gloves or use cloths if necessary. - retarder properly filled with oil
service brake.
- retarder electronic equipment connected and
Damage to property via soiled parts! functional Ö Engage the lowest possible gear in order to achieve
Considerable damage or malfunctions may occur due - pneumatic control connected and functional a high engine speed.
to soiling. - retarder connected to the vehicle's cooling
Ö During a temperature adaptation continue driving in
system
Ö Ensure cleanliness. this way until the retarder is available at full capacity
again.
Driving after oil change/checking the oil level
Damage to property via improper cleaning!
Ö When starting driving: Activate the retarder briefly in 2.9 Storage
Ö Do not aim the jet of a high-pressure cleaner
braking stage 2 or 3.
(steam-jet device) at valves, pressure sensors or Ö Store or transport the retarder vertically, otherwise
the ventilation of the retarder. oil may escape.
Towing

Ö Tow the vehicle with the retarder rotating for max. Ö Use transportation supports to center and secure
100 km at max. 40 km/h. the sleeve shaft.

Ö Voith recommendation: Remove the propeller shaft.

Voith Turbo I 153.00018210 I arrtd I 2008-07

Parking

Ö Do not use retarder as a parking brake, as it does

not act as a brake when the vehicle is standing still.
© 2008

Page 11
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 I Basic safety information Warranty

2.10 Warranty

Voith accepts no liability for damage caused by

changes to the retarder or the use of spare parts,
accessories, attachments and special features not
tested and approved by Voith.

Ö Use only parts approved by Voith to ensure the

safety of the vehicle and functioning of the
retarder.
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 12
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Design and function

3. Design and function

3.1 Overview of the modules 14

3.2 Retarder identification 16
3.3 VERA™ control-unit identification 17
3.4 Digiprop control-unit identification 18
3.5 Function and control scheme 19
3.6 Function description 20
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 13
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Design and function Overview of the modules

3.1 Overview of the modules

A

Item No. Name 3300

A Casing ventilation duct 3000 2800

5100
100 Retarder housing
5000
1500 Screw plug M 14 x 1.5
(test connection pdyn) 7000

1900 Non-return valve 100

2000 Retarder housing cover
2800 Oil filler plug M 30 x 1.5
3000 Top cover
3300 Retarder ventilation
5000 Proportional valve
5100 Damping plate
7000 Pressure sensor
Voith Turbo I 153.00018210 I arrtd I 2008-07

1500
© 2008

1900 2000
32002

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 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Design and function Overview of the modules

Item No. Name

1500 Oil drain plug M 14 x 1.5
20000
1700 Oil drain plug M 24 x 1.5
8000 Oil temperature sensor
9000 Data plate 8000
20000 Water-inlet neck 9000
20100 Water-outlet neck
20200 Coolant drain plug M 14 x 1.5
20600 Coolant temperature sensor
20600
Example display
TY
P VR
FABR 123
.Nr.
Bauj
ah
iRET r
=
Kd.-S 1.00
ach-
Voith Nr.
-Sac
h-N
r.

20100
Voith Turbo I 153.00018210 I arrtd I 2008-07

20200

1500

1700
© 2008

32003

Page 15
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Design and function Retarder identification

3.2 Retarder identification

NOTE
Ö Specify the following data in case you have
questions or are ordering spare parts:
- Serial number (FABR.Nr.)
- Voith item number (Voith Sach-Nr.)

TYP VR 123
FABR.Nr.

Baujahr
iRET = 1.00
TYP VR 123
FABR.Nr.
Kd.-Sach-Nr.
Baujahr
iRET = 1.00
Kd.-Sach-Nr.
Voith-Sach-Nr.
Voith Turbo I 153.00018210 I arrtd I 2008-07

Voith-Sach-Nr.
© 2008

32004

Page 16
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Design and function VERA™ control-unit identification

3.3 VERA™ control-unit identification

NOTE
Ö Specify the following data in case you have
questions or are ordering spare parts (marked in

84
20
XX

02
gray):

e1
XX
XXX
X
T XX
-T -XX
- Serial number (Serial-No.) -
M
M .XX
t J
ni JJ XX XX
X X3
lU /J -X X
ro XX .X XX
- Item number (Part No.) t
n X .E X
Co XX RA XX
X
er . E X X2
rd No V X
ta ial- o. . X
Ö Specify the following data of the retarder (see e
R er rt N N
S a M
o
P E
X1

o
rb
Tu
O
Page 16):

th i
Vo

H
IT
VO
- Serial number (FABR.Nr.)
- Voith item number (Voith Sach-Nr.)

Example display
Voith Turbo I 153.00018210 I arrtd I 2008-07

Voith Turbo

Retarder Control Unit

Serial-No. XXXXX / JJJJ-MM-TT
Part No. VERA.X.X - XXX.XX-XXX.XXXXXXXX

e1 032084
OEM No. XXXXXXXXXXXXX
VOITH

X1 X2 X3
© 2008

32006

Page 17
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Design and function Digiprop control-unit identification

3.4 Digiprop control-unit identification

NOTE
Ö Specify the following data in case you have
questions or are ordering spare parts:
- Code number (Code-Nr.)
- Voith item number (Voith)
Ö Specify the following data of the retarder (see
Page 16):
- Serial number (FABR.Nr.) Ba
s
Co is-N
d r.
Se e-N :
- Voith item number (Voith Sach-Nr.) r r
VO ien-N.: 53
ITH r.: .
xx xxxx
x .12
xx
xx
/
Example display
Voith Turbo I 153.00018210 I arrtd I 2008-07

Basis-Nr.:
Code-Nr.:
Serien-Nr.:
VOITH
© 2008

32084

Page 18
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Design and function Function and control scheme

3.5 Function and control scheme

Item No. Name

A
A Four-circuit protection valve B C
B Air tank for auxiliary equipment
C Supply-air pressure (pv) "P"
D Constant-air pressure (py) "A" D “P”
7000 “A” “R”
E Ventilation duct "R" 3000 2600
2800
2300 5000
F Oil tank 3300
G Rising duct
H Outlet throttle (no-load mode)
F
105 Inlet throttle E
300 Stator 8000
1500 Oil drain plug
Vehicle
1700 Oil drain plug 6000
electronics
1900 Non-return valve
105
2300 Casing ventilation
2400 Outlet throttle (braking mode) 4000
2600 Return valve 1900 20600
2800 Oil filler plug (test connection py)
3000 Top cover
3300 Retarder ventilation
Voith Turbo I 153.00018210 I arrtd I 2008-07

4000 Rotor
300 2400 H G
5000 Proportional valve
1500 1700
6000 Oil cooler
7000 Pressure sensor
8000 Oil temperature sensor Oil sump Coolant
20600 Coolant temperature sensor
Supply-air pressure pv Dynamic pressure pdyn
© 2008

Constant-air pressure py 32107

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 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Design and function Function description

3.6 Function description Stator (300) Bore for casing ventilation in cover at top (3000)
In the stator (300) the oil is re-directed and is returned Connects the retarder circuit with the atmosphere.
Air and vent duct "A" constant-air pressure py (D) to the rotor (4000) at the internal diameter of the Aerates and deaerates the retarder circuit via the
Air and vent duct for constant-air pressure py between working chamber. casing ventilation (2300).
proportional valve (5000) and oil tank (F).
Non-return valve (1900) Retarder ventilation "R" (3300)
Ventilation duct "R" (E) The non-return valve (1900) prevents the oil cooler When the retarder is switched off, the compressed air
Ventilation duct for constant-air pressure py between (6000) from being emptied in no-load mode. in the oil tank (F) is emitted to the atmosphere via
proportional valve (5000) and retarder ventilation "R" retarder ventilation "R" (3300).
(3300). Casing ventilation (2300)
At the start of the braking process, the oil displaces the Rotor (4000)
Rising duct (G) air in the retarder in the system circuit. The air is The rotor (4000) must include the oil in its rotation and
Connection between oil tank (F), retarder circuit and oil displaced via the casing ventilation (2300) and the bore accelerate it.
cooler (6000). During braking, oil flows from the oil tank for casing ventilation in the cover at the top (3000).
(F) via the rising duct (G) and the inlet throttle (105) into Proportional valve (5000)
Once the system circuit is free of air, the casing
the retarder circuit. When switched off, the oil coming The proportional valve (5000) is connected to the
ventilation (2300) closes.
from the oil cooler (6000) flows via the rising duct (G) compressed-air system of the vehicle (auxiliary
back into the oil tank (F). equipment circuit). As soon as the proportional valve
Outlet throttle (braking mode) (2400)
(5000) receives an electrical input signal from the
Outlet throttle (no-load mode) (H) In braking mode, the oil reaches the oil cooler (6000)
retarder control-unit, it issues a pneumatic constant-air
through the outlet throttle (2400) from the working
In no-load mode, the oil reaches the oil cooler (6000) pressure py which depends on the intensity of the
chamber, cooled and fed back into the system circuit.
Voith Turbo I 153.00018210 I arrtd I 2008-07

through the outlet throttle (H) from the working electrical input signal and which acts on the oil tank (F)
chamber. of the retarder.
Return valve (2600)

Inlet throttle (105) The oil that was separated from the cut-of air via the Oil cooler (6000)
opened return valve (2600) is returned to the oil tank
When the retarder is switched on, the oil sump is The oil cooler (6000) dissipates the generated heat to
(F). If the oil sump is pressurized, the return valve
pressurized and the oil reaches the retarder circuit via the vehicle cooling system.
(2600) closes. This prevents oil from exiting via the
the inlet throttle (105).
© 2008

retarder ventilation "R" (3300).

Page 20
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Design and function Function description

Pressure sensor (7000)

The pressure sensor (7000) measures the pneumatic
constant-air pressure py.

Temperature sensors for oil (8000) and coolant

(20600)
The temperature sensors forward information about the
temperature of oil and coolant to the retarder control-
unit in the vehicle.

Limiting points and maximum values for the coolant

and oil temperature are set in the control-unit to protect
the cooling system and the retarder.

If one of the temperature limit points is exceeded during

a braking operation, the braking torque is adjusted via
the constant-air pressure py. The braking torque is
adjusted until an equilibrium is achieved between the
produced braking energy and the heat dissipated via
the vehicle cooling system.

If one of the maximum values is exceeded, the braking

torque is no longer actuated (corresponds to a
Voith Turbo I 153.00018210 I arrtd I 2008-07

reduction to 0).

In addition the braking torque is adjusted if the oil

temperature rises rapidly (gradient), regardless of the
actual oil temperature.

The vehicle speed has to be adjusted with the service

brake while the adjustment is active.
© 2008

Page 21
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Maintenance and service

4. Maintenance and service

4.1 Maintenance intervals 23

4.2 Oil change 24
4.3 Checking the oil level 27
4.4 Draining the coolant 29
4.5 Proportional valve 31
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 22
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Maintenance and service Maintenance intervals

4.1 Maintenance intervals

The maintenance intervals depend on the stress put

on the retarder and the oil sorts used.

CAUTION
Exceeding of the maintenance intervals/
incorrect oil sort!
Damage to/failure of the retarder.
Ö Observe the maintenance intervals.
Ö Use only approved oils.

Activity Interval See

Change oil ÖObserve the specifications of the vehicle Page 24
manufacturer.
ÖIf no specifications available: Observe Voith
Retarder oil change intervals/Oil selection list.
Checking the oil – Page 27
level
ÖObserve the specifications of the vehicle
Voith Turbo I 153.00018210 I arrtd I 2008-07

Draining the coolant Page 29

manufacturer.
Replace the 120,000 km Page 31
proportional valve
(only for vehicles
used in city traffic)
© 2008

Page 23
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Maintenance and service Oil change

4.2 Oil change

2800

Item No. Name

2900
1400 Sealing ring A 14 x 18; replace
1500 Screw plug M 14 x 1.5
hexagon socket head, w.a.f. 6;
25 Nm
1600 Sealing ring A 24 x 29; replace
1700 Screw plug M 24 x 1.5;
hexagon socket head, w.a.f. 12;
80 Nm
2800 Screw plug M 30 x 1.5;
hexagon socket head, w.a.f. 17;
130 Nm
2900 Sealing ring A 30 x 36; replace

NOTE
Ö Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free and non-
corrosive grease before installation.
Voith Turbo I 153.00018210 I arrtd I 2008-07

1400
1500

1600 1600

1700
© 2008

1700
32008

Page 24
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Maintenance and service Oil change

Draining the oil 5. Lubricate the new sealing rings (1400 and 1600)
Oil quantity
with silicone-free and non-corrosive grease.
Initial filling (new unit) 6.0 l 1. Place oil pan below the retarder.
6. Screw in the screw plugs (1500 and 1700) with
Initial filling (replacement unit) 6.8 l
WARNING sealing rings (1400 and 1600).
Service filling (checking of the oil 6.0 l
level, oil change) Hot exiting oil! 7. Tighten the screw plug (1500) to 25 Nm.
After replacing the oil cooler and 6.0 l Face and hands could be burned.
Ö Ensure that the retarder and ignition are switched 8. Tighten the screw plugs (1700) to 80 Nm.
rinsing the retarder
After replacement of the oil 6.5 l off.
cooler

Maintenance work during each oil change CAUTION

• Visual inspection of retarder for leaks before and Hot screw plugs!
after the oil change. Hands could be burned.
Ö Work carefully.
• Check prop shaft screws for proper seating and
Ö Wear protective gloves or use cloths if necessary.
tighten if necessary (see specifications of vehicle
manufacturer).
2. Unscrew the screw plug (2800).
• Tighten screw plugs of the retarder basic
3. Unscrew the screw plugs (1500 and 1700).
component to the specified tightening torque.
4. Drain oil into an oil pan.
Voith Turbo I 153.00018210 I arrtd I 2008-07

Requirements

• Vehicle is horizontal
NOTE
Ö If the oil contains water: Check the oil cooler
• Oil at operating temperature (>60°C) (see Page 67).
• Retarder switched off
© 2008

• Ignition switched off

Page 25
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Maintenance and service Oil change

Filling in the oil

CAUTION
Wrong oil type!
Damage to/failure of the retarder.
Ö Fill in only approved oil (see Voith Retarder oil
change interval/Oil selection list).

1. Slowly fill in oil via the bore of the screw plug

(2800).

2. Lubricate the new sealing ring (2900) with

silicone-free and non-corrosive grease.

3. Screw in the screw plug (2800) with sealing ring

(2900) and tighten to 130 Nm.

NOTE
When starting driving:
Ö Activate the retarder briefly in braking stage 2 or
3.
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 26
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Maintenance and service Checking the oil level

4.3 Checking the oil level

2800
Item No. Name
1400 Sealing ring A 14 x 18; replace 2900
1500 Screw plug M 14 x 1.5;
hexagon socket head, w.a.f. 6;
25 Nm
1600 Sealing ring A 24 x 29; replace
1700 Screw plug M 24 x 1.5;
hexagon socket head, w.a.f. 12;
80 Nm
2800 Screw plug M 30 x 1.5;
hexagon socket head, w.a.f. 17;
130 Nm
2900 Sealing ring A 30 x 36; replace

NOTE
Ö Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free and non-
corrosive grease before installation.
Voith Turbo I 153.00018210 I arrtd I 2008-07

Oil quantity 1400

Service filling (checking of the oil 6.0 l 1500
level, oil change)

1600 1600
© 2008

1700 1700
32008
Page 27
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Maintenance and service Checking the oil level

Requirements 4. Drain oil into an oil pan.

CAUTION
• Vehicle is horizontal NOTE Wrong oil type!
• Oil at operating temperature (> 60°C) Ö If the oil contains water: Check the oil cooler Damage to/failure of the retarder.
(see Page 67). Ö Add only Voith-approved oil (see oil selection
• Retarder switched off
list).
• Ignition switched off 5. Lubricate the new sealing rings (1400 and 1600)
with silicone-free and non-corrosive grease. 2. If necessary correct the oil volume.
Draining the oil
6. Screw in the screw plugs (1500 and 1700) with
sealing rings (1400 and 1600). Filling in oil
1. Place oil pan below the retarder.
1. Slowly fill in oil via the bore of the oil filler plug
WARNING 7. Tighten the screw plug (1500) to 25 Nm.
(2800).
Hot exiting oil! 8. Tighten the screw plugs (1700) to 80 Nm.
2. Lubricate the new sealing ring (2900) with
Face and hands could be burned. silicone-free and non-corrosive grease.
Measuring the volume
Ö Ensure that the retarder and ignition are switched
off. 1. Measure the volume of the drained oil. 3. Screw in the screw plug (2800) with sealing ring
(2900) and tighten to 130 Nm.
NOTE
CAUTION NOTE
Ö If oil was missing, check the retarder for leaks.
Hot screw plugs! When starting driving:
Voith Turbo I 153.00018210 I arrtd I 2008-07

Hands could be burned. Ö Activate the retarder briefly in braking stage 2

or 3.
Ö Work carefully.
Ö Wear protective gloves or use cloths if necessary.

2. Unscrew the screw plug (2800).

3. Unscrew the screw plugs (1500 and 1700).

© 2008

Page 28
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Maintenance and service Draining the coolant

4.4 Draining the coolant

NOTE
Depending on the vehicle manufacturer, the design
of the water neck can differ.
Ö If the screw plug (20200) does not exist: Drain
the coolant at the vehicle (see specifications of
vehicle manufacturer).

Item No. Name

20100 Water-outlet neck
20200 Screw plug M 14 x 1.5;
hexagon socket head, w.a.f. 6;
25 Nm
20300 Sealing ring A 14 x 18; replace

TYP R 123

NOTE
FABR.Nr.
Baujahr
iRET = 1.00
Kd.-Sach-Nr.

Voith-Sach-Nr.

Ö Lubricate sealing rings, O-rings and shaft

sealing rings with silicone-free and non-
Voith Turbo I 153.00018210 I arrtd I 2008-07

corrosive grease before installation.

20100

20300

20200
© 2008

32085

Page 29
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Maintenance and service Draining the coolant

Requirements
CAUTION
• Retarder switched off
Wrong coolant type!
• Ignition switched off Damage to the vehicle and retarder cooling circuit.
Ö Observe the specifications of the vehicle
Draining the coolant
manufacturer or those of Voith Turbo coolant
1. Place a clean coolant collecting pan under the quality list.
retarder.
5. Fill the vehicle and retarder cooling circuit (see
CAUTION specifications of vehicle manufacturer).

Hot parts and coolant!

Burns and scalding could occur.
Ö Work carefully.
Ö Wear protective gloves or use cloths if necessary.

2. Unscrew the screw plug (20200) and drain the

coolant.

3. Lubricate the new sealing ring (20300) with

silicone-free and non-corrosive grease.
Voith Turbo I 153.00018210 I arrtd I 2008-07

4. Screw in the screw plug (20200) with sealing ring

(20300) and tighten to 25 Nm.
© 2008

Page 30
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Maintenance and service Proportional valve

4.5 Proportional valve

NOTE
Ö For vehicles used mainly in city traffic: Replace
the proportional valve every 120,000 km (see
Page 81).
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 31
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting

5. Diagnosis and troubleshooting

5.1 Overview of the possible complaints 33

5.2 Checking the constant-air pressure control loop 40
5.3 Checking the dynamic pressure (pdyn) 44
5.4 Checking the proportional valve current 48
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 32
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Overview of the possible complaints

5.1 Overview of the possible

complaints

No. Complaint See

A Retarder pilot light (standard type): Page 34
On-board diagnosis is possible at some vehicle
manufacturers (display).
ÖObserve the specifications of the vehicle
manufacturer.
B No or insufficient brake efficiency Page 37
C Oil leak at the retarder ventilation (3300) or bore for Page 39
casing ventilation in the cover at the top (3000)
D Oil leaking on drive or output side: –
Leak may be in gearbox or retarder. For this reason,
further analysis is necessary.
ÖContact Voith.
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 33
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Overview of the possible complaints

A Retarder pilot light (standard type)

NOTE
On-board diagnosis is possible at some vehicle
manufacturers (display).
Ö Observe the specifications of the vehicle
manufacturer.

Overview of the possible states

No. State See

A1 Retarder pilot light does not go out after the lamp test Page 35
A2 Retarder pilot light does not illuminate when retarder is Page 35
active
A3 Retarder pilot light flashes Page 36
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 34
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Overview of the possible complaints

A1 Retarder pilot light does not go out after the lamp test

No. Activity Result Continue with No.

® ®
1. ÖCarry out diagnosis with WinDia (see WinDia – –
Operating Instructions).
–or–
ÖCarry out off-board diagnosis (see specifications of
vehicle manufacturer).

A2 Retarder pilot light does not illuminate when retarder is active

No. Activity Result Continue with No.

1. ÖCheck the fuse, replace if necessary. – –
–or–
ÖCheck whether the ABS signal or gas pedal is active.
–or–
ÖCheck the bulb of the retarder pilot light, replace if
necessary.
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 35
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Overview of the possible complaints

A3 Retarder pilot light flashes

No. Activity Result Continue with No.

1. ÖCheck the operation (for retarder braking, nominal NOK 2.
speed of the engine, if possible).
OK 3.
2. ÖInstruct the driver. In doing so, observe the operating – –
conditions.
3. ÖCheck the oil temperature sensor (see Page 76etc.). NOK 4.
ÖCheck the coolant temperature sensor (see OK 5.
Page 78etc.).
4. ÖReplace the oil temperature sensor. – –
–and/or–
ÖReplace the coolant temperature sensor.
5. ÖCheck cooling system of vehicle (see specifications – –
of vehicle manufacturer).

NOK = does not work correctly

OK = works correctly
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 36
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Overview of the possible complaints

B No or insufficient brake efficiency

No. Activity Result Continue with No.

1. ÖCheck whether an external leak is visible at the Yes 2.
retarder (except retarder ventilation).
No 3.
2. ÖRepair retarder. –
3. ÖCheck the retarder oil level (see Page 27etc.). NOK C, No. 3., Page 39
OK 4.
4. ÖCheck constant-air pressure control loop (see NOK 5.
Page 40etc.).
OK 8.
5. ÖCheck the damping plate (see Page 81etc.) NOK 6.
OK 7.
6. ÖReplace the damping plate. – –
7. ÖReplace the pressure sensor. – –
–and/or–
ÖReplace the proportional valve.
8. ÖCheck the proportional valve current as well as leads NOK 9.
and plug connections (see Page 48etc.).
OK 12.
Voith Turbo I 153.00018210 I arrtd I 2008-07

9. ÖCheck oil temperature sensor and supply line (see NOK 10.
Page 76etc.).
ÖCheck coolant temperature sensor and supply line OK 11.
(see Page 78etc.).

NOK = does not work correctly

OK = works correctly
© 2008

Page 37
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Overview of the possible complaints

No. Activity Result Continue with No.

10. ÖReplace the oil or supply line temperature sensor. – –
–and/or–
ÖReplace the coolant or supply line temperature
sensor.
11. ÖCarry out diagnosis with WinDia® (see WinDia® – –
Operating Instructions). Use Voith ECU specification
for this (Diagnosis and connection diagram chapter).
–or–
ÖCarry out off-board diagnosis (see specifications of
vehicle manufacturer).
12. ÖCheck the dynamic pressure pdyn (see Page 44etc.). NOK 13.
OK 16.
13. ÖCheck the casing ventilation (see Page 59etc.). NOK 14.
OK 15.
14. ÖReplace the casing ventilation. – –
15. ÖContact Voith. – –
16. Complaint mentioned above is not possible. – –
ÖClarify the complaint again with the customer or
Voith Turbo I 153.00018210 I arrtd I 2008-07

perform the tests once again.

NOK = does not work correctly

OK = works correctly
© 2008

Page 38
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Overview of the possible complaints

C Oil leak at the retarder ventilation (3300) or bore for casing ventilation in the cover at the top (3000)

No. Activity Result Continue with No.

1. ÖCheck whether the retarder leaks oil via the retarder Yes 2.
ventilation (3300).
No 8.
2. ÖCheck the retarder oil level (see Page 27etc.). NOK 3.
OK 5.
3. ÖCheck whether water is contained in the oil Yes 4.
(emulsion).
No 5.
4. ÖCheck the oil cooler, replace if necessary (see – –
Page 67etc.).
5. ÖCheck the return valve (see Page 73). NOK 6.
OK 7.
6. ÖReplace the return valve. – –
7. ÖContact Voith. – –
8. Retarder leaking oil via bore for casing ventilation in NOK 9.
cover at top (3000).
Voith Turbo I 153.00018210 I arrtd I 2008-07

ÖCheck profile ventilation (see Page 81etc.). OK 3.

9. ÖReplace the casing ventilation. – –

NOK = does not work correctly

OK = works correctly
© 2008

Page 39
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Checking the constant-air pressure control loop

5.2 Checking the constant-air

pressure control loop

NOTE 2800
99/7
2900
The constant-air pressure control loop check
provides information about
• internal and external leaks of the retarder
• proper functioning of the retarder
• proper control of the retarder

7000
Item No. Name
2800 Screw plug M 30 x 1.5; 6
50/56b
hexagon socket head, w.a.f. 17; 5000
130 Nm
2900 Sealing ring A 30 x 36; replace
5000 Proportional valve
7000 Pressure sensor
50/56a Retarder tester 50/56c
Voith Turbo I 153.00018210 I arrtd I 2008-07

50/56b Cable 1: to the proportional valve 50/56a

50/56e
50/56c Cable 2: to the pressure sensor
50/56d Cable 3: to the temperature sensors 50/56d
50/56e Cable 4: to the vehicle voltage supply/
PC interface
99/7 Pressure gauge 0–6 bar
© 2008

32091

Page 40
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Checking the constant-air pressure control loop

NOTE NOTE DANGER

Ö Lubricate sealing rings, O-rings and shaft In addition to the tests with the retarder tester, Danger of accidents if the retarder tester is used
sealing rings with silicone-free and non- measured values can also be read out and stored improperly!
corrosive grease before installation. using the testing software "Diana Lite" (50/56i) on Uncontrollable operating state of the vehicle.
the PC.
Ö Carry out diagnosis only while the vehicle is
The stored measured values can be transmitted to
Special tools Voith customer service for evaluation (see standing still.
Operating Instructions on CD-ROM).

CAUTION
Commercially available tools
Hot parts!
Multimeter Hands could be burned.
Ö Work carefully.
Requirements
Ö Wear protective gloves or use cloths if necessary.
153.001085xx H53.1403xx 153.000776xx
• Ignition switched off
Connecting the pressure gauge
Retarder tester, Pressure gauge Test software • Retarder switched off
complete in a 0–6 bar "DIANA Lite" 1. Unscrew the screw plug (2800) with the sealing
case • Battery voltage: 18–32 V ring (2900).

50/56 99/7 50/56i • Supply-air pressure in auxiliary circuit 6–11 bar 2. Connect the pressure gauge (99/7) to the bore of
Voith Turbo I 153.00018210 I arrtd I 2008-07

the screw plug (2800).

• Oil level checked and in order (see Page 27)

• Electrical system of vehicle checked and in order

(see specifications of vehicle manufacturer)

• Electrical connections of the retarder completely

disconnected from the vehicle
© 2008

Page 41
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Checking the constant-air pressure control loop

Connecting the retarder tester Checking the supply voltage of the pressure Checking the proportional valve
sensor
15.Switch the toggle switch to the position "EIN ohne
VR 123
5000
6. Switch on the vehicle ignition Regelkreis" (on without control loop).
50/56b 10
833
1 153.000
2 50/56c 7. Set the "RETARDERTYP" (retarder type) switch at 16.Start the "DIANA-Lite" test software.
50/56a 153.00
08341 the retarder tester (50/56a) to "5".
3 50 0 7000
15
3.0
/56 17.Load the template for the retarder tester (see
4
00
d
83
51 8000 8. Switch the toggle switch to the position "EIN mit Operating Instructions of "DIANA-Lite" test
0
Regelkreis" (on with control loop). software).
20600
50/56e 9. Connect the multimeter to the "U_Versorgung" 18.Set the "STELLDRUCK" (constant-air pressure)
153.00083610
(U_Supply) socket (measuring type: V). switch at the retarder tester to "25%".
32105
10.Read the measured value: Nominal value 4.75– NOTE
5.25 V.
1. Connect cable 1 (50/56b) to the proportional valve
To assess the operation of the proportional valve
(5000). 11.If the value deviates: Replace the pressure sensor (5000), the results of the following test are only
(7000) (see Page 80). valid during a testing period of 60 seconds
2. Connect cable 2 (50/56c) to pressure sensor
maximum.
(7000).
Checking the signal value of the pressure sensor
3. Connect cable 3 (50/56d) to the oil (8000) and 19.In "DIANA-Lite" read the "Stelldruck Ist" (constant-
12.Connect the multimeter to the "U_py IST" (U_py
coolant (20600) temperature sensors. air pressure actual) measured value and the
actual) socket (measuring type: V). measured value at the pressure gauge (99/7):
Voith Turbo I 153.00018210 I arrtd I 2008-07

4. Connect cable 4 (50/56e) to the vehicle voltage Nominal value after approx. 20 seconds:
supply/PC interface. 13.Read the measured value: Nominal value 0.275–
0.725 V.
5. Connect all the cables to the retarder tester (50/
56a) (see also the Operating Instructions of the 14.If the value deviates: Replace the pressure sensor
retarder tester). (9000) (see Page 105).
© 2008

Page 42
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Checking the constant-air pressure control loop

26.Disconnect the pressure gauge (99/7).

Position of Nominal value
"STELLDRUCK" Constant-air 27.Lubricate the new sealing ring (2900) with
(constant-air pressure py silicone-free and non-corrosive grease.
pressure) switch
0% 0 28.Screw in the screw plug (2800) with sealing ring
(2900) and tighten to 130 Nm.
25% 0,55–1,05
50% 1,24–1,74 29.Complete the retarder and vehicle.

75% 1,80–2,30
100% 2,60–3,10

20.Repeat the test in the switch positions "50%",

"75%" and "100%".

21.If one of the values deviates: Check the

proportional valve (5000) and damping plate
(5100), replace if necessary (see Page 81).

Disconnecting the retarder tester

22.Set the "STELLDRUCK" (constant-air pressure)

switch at the retarder tester to "0%".
Voith Turbo I 153.00018210 I arrtd I 2008-07

23.Switch the toggle switch to the "AUS" (off)

position.

24.Switch off the vehicle ignition.

25.Disconnect the retarder tester (50/56a) and all

cables.
© 2008

Page 43
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Checking the dynamic pressure (pdyn)

5.3 Checking the dynamic pressure

(pdyn)

NOTE
Checking the dynamic pressure pdyn provides
information about
• the mechanical status of the rotor parts
• internal leaks
• proper functioning of the retarder 7000

Item No. Name 50/56b 100 5000

100 Retarder housing
1400 Sealing ring A 14 x 18; replace
1500 Screw plug M 14 x 1.5;
hexagon socket head, w.a.f. 6; 25 Nm
5000 Proportional valve
50/56a Retarder tester 50/56a 50/56c
50/56b Cable 1: to the proportional valve 50/56e
Voith Turbo I 153.00018210 I arrtd I 2008-07

50/56c Cable 2: to the pressure sensor (9000)

and to the pressure sensor (50/56g) 50/56d
50/56d Cable 3: to the temperature sensors
1400
50/56e Cable 4: to the vehicle voltage supply/PC 1500 50/56g
interface
50/56g Pressure sensor pdyn 0–30 bar
© 2008

7000 Pressure sensor 32092

Page 44
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Checking the dynamic pressure (pdyn)

• Vehicle secured
NOTE NOTE
• Prop shaft at retarder removed from flanges and
Ö Lubricate sealing rings, O-rings and shaft In addition to the tests with the retarder tester, secured (see specifications of vehicle
sealing rings with silicone-free and non- measured values can also be read out and stored manufacturer)
corrosive grease before installation. using the testing software "Diana Lite" (50/56i) on
the PC.
The stored measured values can be transmitted to
DANGER
Special tools Voith customer service for evaluation (see Danger of accidents if the retarder tester is used
Operating Instructions on CD-ROM). improperly!
Uncontrollable operating state of the vehicle.
Requirements Ö Carry out diagnosis only while the vehicle is
standing still.
• Ignition switched off

• Retarder switched off

NOTE
153.001085xx 153.000776xx • Battery voltage: 18–32 V
If the propeller shaft screws are screwed in from the
• Compressed air: 6–11 bar transmission side:
Retarder tester, Test software
• Oil level checked and in order (see Page 27) Ö Ensure that the propeller shaft screws are
complete in a "DIANA Lite"
screwed out at the drive-side flange.
case
• Electrical system of vehicle checked and in order –or–
50/56 50/56i (see specifications of vehicle manufacturer) Ö Secure the propeller shaft screws.
Voith Turbo I 153.00018210 I arrtd I 2008-07

• Electrical connections of the retarder completely

disconnected from the vehicle

• Constant-air pressure control loop checked and in

order (see Page 40)

• No external leaks detected at retarder

© 2008

Page 45
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Checking the dynamic pressure (pdyn)

3. Connect cable 1 (50/56b) to the proportional valve

CAUTION (5000).
100
Hot parts and oil! 4. Connect cable 2 (50/56c) to pressure sensor
Hands can be burned and scalded. (7000) and pressure sensor (50/56g).
Ö Work carefully.
1400 5. Connect cable 3 (50/56d) to the oil (8000) and
Ö Wear protective gloves or use cloths if necessary.
coolant (20600) temperature sensors.
50/56g
Connecting the pressure sensor 6. Connect cable 4 (50/56e) to the vehicle voltage
supply/PC interface.
NOTE
32093 7. Connect all the cables to the retarder tester (50/
Due to construction, a small amount of oil may leak 56a) (see also the Operating Instructions of the
out; this does, however, not affect retarder 2. Connect the pressure sensor (50/56g) with retarder tester).
operation. sealing ring (1400) to retarder housing (100).
Checking the dynamic pressure pdyn
Connecting the retarder tester
8. Switch on the vehicle ignition
VR 123
9. Set the "RETARDERTYP" (retarder type) switch at
50/56b 5000
1 3.00083
310 the retarder tester (50/56a) to "5".
15
7000
2 50/56c
50/56a 153.00
08341 50/56g 10.Switch the toggle switch to the position "EIN mit
3 50 0
/56 Regelkreis" (on with control loop).
Voith Turbo I 153.00018210 I arrtd I 2008-07

15
4 3.0 d
00
83 8000
51
0
11.Start the "DIANA-Lite" test software.
1400 20600
1500 50/56e 12.Load the template for the retarder tester (see
153.00083610
32078 Operating Instructions of "DIANA-Lite" test
32106
software).
1. Unscrew screw plug (1500) and remove sealing
© 2008

ring (1400).

Page 46
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Checking the dynamic pressure (pdyn)

13.Start the engine and warm it up to operating

temperature. NOTE
NOTE Test when the "STELLDRUCK" (constant-air
pressure) switch is set to "100%":
Ö Shift in direct gear (ratio 1:1). "Gehäusedruck Ist" (housing pressure actual)
nominal value >12 bar.
The engine speed 1500 min-1 then corresponds to
Is normally not possible with the retarder tester
the prop shaft speed of 1500 min-1.
when the vehicle is standing still.

14.Adjust the engine speed to 1500 min-1 Disconnecting the pressure sensor and retarder
tester
15.Set the "STELLDRUCK" (constant-air pressure)
switch at the retarder tester to "25%". 19.Set the "STELLDRUCK" (constant-air pressure)
switch at the retarder tester to "0%".
16.Adjust the engine speed to 1500 min-1 once
again. 20.Disconnect the retarder tester (50/56a) and all
cables.
17.Set the "STELLDRUCK" (constant-air pressure)
switch at the retarder tester to "50%". 21.Disconnect the pressure sensor (50/56g).

18.With a engine speed of 1500 min-1, read the 22.Lubricate the new sealing ring (1400) with
"Gehäusedruck Ist" (housing pressure actual) silicone-free and non-corrosive grease.
measurement value in "DIANA Lite":
23.Screw in the screw plug (1500) with the sealing
Voith Turbo I 153.00018210 I arrtd I 2008-07

Nominal value > 7 bar.

ring (1400).

NOTE 24.Tighten the screw plug (1500) to 25 Nm.

If the nominal value of the constant-air pressure 25.Flange the propeller shaft at the retarder (see
(py) is reached, but the dynamic pressure (pdyn) is
specifications of vehicle manufacturer).
undershot, the retarder has an internal defect.
Ö Contact Voith. 26.Complete the retarder and vehicle.
© 2008

Page 47
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Checking the proportional valve current

5.4 Checking the proportional valve Scope of work – testing

current Commercially available tool
5000
Multimeter (98/8) with real r.m.s. value
Special tools measurement, e.g. 98/8
METRIX MTX 3281

Requirements

• Ignition switched off

• Retarder switched off

• Battery voltage: 18–32 V 99/3

H53.8198xx 32059
• Electrical system of vehicle checked and in order
Measuring (see specifications of vehicle manufacturer) 1. Disconnect the plug from the proportional valve
adapter (5000) and connect it to the measuring adapter
• Fuse for retarder control-unit checked and in order
(99/3).
99/3
• Male and female plug connectors at proportional
2. Connect the plug of the measuring adapter to the
valve checked for damage or wear (notch
proportional valve (5000).
NOTE scratches)
3. Connect the multimeter (98/8) (measuring type:
When performing measurements using a • Electrical lead and plug connections checked
Voith Turbo I 153.00018210 I arrtd I 2008-07

commercially available multimeter (without real mA).

(visual inspection) and in order
r.m.s. value measurement), exact readout of these
4. Turn the "Propventil" (proportional valve) switch to
measured values is not possible (display jumps).
position "I" on the measurement adapter.

5. Switch on the ignition.

© 2008

Page 48
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Diagnosis and troubleshooting Checking the proportional valve current

6. Activate the service function and switch the

retarder to the highest gear.
If there is no service function:
Switch the retarder to the highest gear using
WinDia or OEM diagnostic tool.

NOTE
Due to continuous readjustment in the control loop,
the measured values may not be constant, but are
within the specified range.

7. Read the measured value at the multimeter (98/8)

and compare it to the specified nominal value (see
Voith ECU specification).

8. If the value deviates: Check the leads, connectors

and retarder control-unit and replace them, if
necessary.

9. Disconnect the multimeter.

10.Pull the plug from the measuring adapter (99/3)

Voith Turbo I 153.00018210 I arrtd I 2008-07

and connect it to the proportional valve (5000).

© 2008

Page 49
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Removing and installing the retarder

6. Removing and installing the retarder

DANGER CAUTION
Retarder can fall! Hot parts!
Your body can be crushed severely. Hands could be burned.
Ö Secure retarder against falling. Ö Work carefully.
Ö Use a suitable lifting device. Ö Wear protective gloves or use cloths if necessary.

CAUTION CAUTION
Improper removal/installation! Unsecured sleeve shaft!
Damage to/failure of the retarder. Damage to radial shaft sealing rings.
Warranty is voided. Ö Use transportation supports to center the sleeve
Ö Request and use gearbox-specific documents shaft.
Voith Turbo I 153.00018210 I arrtd I 2008-07

and special tools from VOITH.

© 2008

Page 50
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair

7. Repair

7.1 Components overview 52

7.2 Top cover 57
7.3 Casing ventilation 59
7.4 Retarder ventilation 63
7.5 Non-return valve 65
7.6 Oil cooler 67
7.7 Water neck 71
7.8 Return valve 73
7.9 Oil temperature sensor 76
7.10 Coolant temperature sensor 78
7.11 Pressure sensor 80
7.12 Proportional valve and damping plate 81
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 51
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Components overview

7.1 Components overview Replace component

Item No. Name Check component
100 Retarder housing according to specifications
and replace if necessary
1000 O-ring 158.34 x 3.53
1400 Sealing ring A 14 x 18 Perform visual inspection
2800
and replace if necessary
1500 Screw plug M 14 x 1.5; 2900
hexagon socket head, w.a.f. 6; 25 Nm 5300
3600 5100
5200
1600 Sealing ring A 24 x 29 5200 5000
1700 Screw plug M 24 x 1.5; 3000 5400
hexagon socket head, w.a.f. 12; 80 Nm
3500
1900 Non-return valve M 48 x 1.5;
3200
hexagon insert bit, w.a.f. 55; 280 Nm 3400
2600
1950 Sealing ring A 48 x 55 3300 2700
2300 7000
2000 Retarder housing cover 20000 100 8100
20500 2301
2100 O-ring 228.2 x 3.53 8000 6000
20400 6100
6150 2000 3600
2300 Casing ventilation 6150
6200
2301 O-ring 55 x 3 20600
20100 20700
2100
Voith Turbo I 153.00018210 I arrtd I 2008-07

20400
NOTE 1000
4800
Ö Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free and non- 20300 6100
20500 1400 6150
corrosive grease before installation. 1950 6150
20200 4702 6300
1400 1500 1900
4703 4800
1500 1600
1700
© 2008

32012

Page 52
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Components overview

Item No. Name Replace component

2600 Valve piece M 24 x 1.5; Check component

hexagon socket head, w.a.f. 12; 46 Nm according to specifications
glue in with Loctite 572 and replace if necessary
2700 Washer
Perform visual inspection
2800
2800 Screw plug M 30 x 1.5; and replace if necessary
hexagon socket head, w.a.f. 17; 2900
5300
130 Nm 3600 5100
5200
2900 Sealing ring A 30 x 36 5200 5000
3000 5400
3000 Top cover
3200 Sealing upper cover 3500
3300 Washer silencer 3200
3400
2600
3400 Wave spring 3300 2700
3500 Circlip JL 30 x 1.2 2300 7000
20000 100 8100
20500 2301
3600 Hex.-head screw M 8 x 45; 8000 6000
hexagon insert bit, w.a.f. 13; 20400 6100
6150 2000 3600
Initial torque: 17 Nm, 6150
Final torque: 30 Nm 6200
20600
20100 20700
2100
NOTE
Voith Turbo I 153.00018210 I arrtd I 2008-07

20400
1000
4800
Ö Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free and non- 6100
20300 20500 1400
corrosive grease before installation. 6150
20200 4702 1950 6150
1400 1500 1900 6300
4703 4800
1500 1600
1700
© 2008

32012

Page 53
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Components overview

Item No. Name Replace component

4702 Sealing ring A 8 x 12 Check component

according to specifications
4703 Screw plug M 8 x 1;
hexagon socket head, w.a.f. 5; 10 Nm and replace if necessary

4800 Hex.-head screw M 8 x 70; Perform visual inspection

2800
hexagon insert bit, w.a.f. 13; and replace if necessary
Initial torque: 17 Nm, 2900
5300
Final torque: 30 Nm 3600 5100
5200
5000 Proportional valve 5200 5000
3000 5400
5100 Damping plate
5200 O-ring 16 x 3 3500
5300 Hex.-head screw M 8 x 20; 3200
3400
hexagon insert bit, w.a.f. 13; 30 Nm 2600
3300 2700
5400 Hex.-head nut M 8; 2300 7000
hexagon insert bit, w.a.f. 13; 18 Nm 20000 100 8100
20500 2301
8000 6000
20400 6100
6150 2000 3600
NOTE 6150
6200
20600
Ö Lubricate sealing rings, O-rings and shaft 20100 20700
sealing rings with silicone-free and non- 2100
Voith Turbo I 153.00018210 I arrtd I 2008-07

corrosive grease before installation. 20400

1000
4800

20300 6100
20500 1400 6150
20200 4702 1950 6150
1400 1500 1900 6300
4703 4800
1500 1600
1700
© 2008

32012

Page 54
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Components overview

Item No. Name Replace component

6000 Oil cooler Check component

according to specifications
6100 O-ring 25 x 2.5
and replace if necessary
6150 O-ring 25 x 2.5
Perform visual inspection
6200 Hex.-head screw M 10 x 40; 2800
hexagon insert bit, w.a.f. 15; 46 Nm and replace if necessary
2900
5300
6300 Hex.-head screw M 10 x 70; 3600 5100
hexagon insert bit, w.a.f. 15; 46 Nm 5200
5200 5000
7000 Pressure sensor M 16 x 1.5; 3000 5400
hexagon insert bit, w.a.f. 27; 30 Nm
8000 Oil temperature sensor M 14 x 1.5; 3500
hexagon insert bit, w.a.f. 27; 28 Nm 3200
3400
2600
8100 Sealing ring A 14 x 20 3300 2700
2300 7000
20000 100 8100
20500 2301
NOTE 20400
8000 6000
6100 2000 3600
6150 6150
Ö Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free and non- 6200
20600
corrosive grease before installation. 20100 20700
2100
Voith Turbo I 153.00018210 I arrtd I 2008-07

20400
1000
4800

20300 6100
20500 1400 6150
20200 4702 1950 6150
1400 1500 1900 6300
4703 4800
1500 1600
1700
© 2008

32012

Page 55
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Components overview

Replace component
Item No. Name
20000 Water neck inlet (optional) Check component
according to specifications
20100 Water neck outlet (optional)
and replace if necessary
20200 Screw plug M 14 x 1.5;
hexagon socket head, w.a.f. 6; 25 Nm Perform visual inspection
2800
and replace if necessary
20300 Sealing ring A 14 x 18 2900
5300
20400 Hex.-head screw M 8 x 45; 3600 5100
5200
hexagon insert bit, w.a.f. 13; 30 Nm 5200 5000
20500 O-ring 55.56 x 3.53 3000 5400
20600 Coolant temperature sensor
M 14 x 1.5; 3500
hexagon insert bit, w.a.f. 27; 28 Nm 3200
3400
2600
20700 Sealing ring A 14 x 20 3300 2700
2300 7000
20000 100 8100
20500 2301
NOTE 20400
8000
6100
6000
6150 2000 3600
Ö Lubricate sealing rings, O-rings and shaft 6150
6200
sealing rings with silicone-free and non- 20600
20100 20700
corrosive grease before installation.
2100
Voith Turbo I 153.00018210 I arrtd I 2008-07

20400
1000
4800

20300 6100
20500 1400 6150
20200 4702 1950 6150
1400 1500 1900 6300
4703 4800
1500 1600
1700
© 2008

32012

Page 56
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Top cover

7.2 Top cover

3000
3600
Item No. Name
100 Retarder housing
3000 Top cover
3200 Sealing top cover, replace
3200
3600 Hex.-head screw M 8 x 45;
hexagon insert bit, w.a.f. 13;
Initial torque: 17 Nm,
Final torque: 30 Nm

Requirements

• Retarder switched off 100

• Ignition switched off

• Proportional valve and damping plate removed

(see Page 81)
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

32013

Page 57
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Top cover

CAUTION A
5
Hot parts! 3 6
1 4
Hands could be burned. 2
Ö Work carefully. 8
7
Ö Wear protective gloves or use cloths if necessary. 10 9
12 11
Removing 3000
13
1. Unscrew the hex.-head screws (3600).
32113 32014
2. Remove the cover (3000).

3. Remove the gasket (3200). 2. Fill compressed air into the open side of the duct 3. Tighten the hex.-head screws (3600) in the
(A) and check the bore in the cover (3000) for air prescribed sequence (see diagram) to 17 Nm.
Checking flow (see arrow).
4. Tighten the hex.-head screws (3600) in the
prescribed sequence (see diagram) to 30 Nm.
Installing

1. Insert new gasket (3200).

2. Screw on the cover (3000) with the hex.-head

screws (3600).
A
Voith Turbo I 153.00018210 I arrtd I 2008-07

CAUTION
Incorrect sequence when tightening the hex.-
A head screws!
32111
Cover can buckle.
1. Seal the duct (A) airtight on one side. Ö Tighten the hex.-head screws in the prescribed
sequence.
© 2008

Page 58
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Casing ventilation

7.3 Casing ventilation

Item No. Name 2300/1

2300 Casing ventilation
2300/1 Valve insert 2301
2300
2300/2 Float; specified weight max. 12 g;
2300/2
for casing ventilation from Voith item
no. H53.133214 upwards take
installation position into account: the
side marked "O" faces upwards
2300/3
2300/3 Float cage
2301 O-ring 55 x 3; replace

NOTE
Ö Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free and non-
corrosive grease before installation.

Aids
Voith Turbo I 153.00018210 I arrtd I 2008-07

Ethyl alcohol for float

© 2008

32015

Page 59
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Casing ventilation

CAUTION Tools for self-fabrication

CAUTION
False special tools! Hot parts!
Damage to components. Hands could be burned.
Ö Only use special tools in the specified version. Ö Work carefully.
Ö Take the last two digits of the Voith item no. into Ø 40.5 mm Ö Wear protective gloves or use cloths if necessary.

7 mm
account in the graphics of the special tools. Ø 60 mm
Removing
H67.2757xx
Special tools 99/5
Test ring

99/4

Material: St 37 98/9
Weight: 0.085 kg 2300/1

The test ring (99/4) can be ordered from Voith Turbo

H53.7712xx H53.942811 GmbH & Co. KG: Voith item no. H67.2757xx.

Impact puller Adapter Requirements 32017

99/5 98/9
• Retarder switched off
1. Screw the impact puller (99/5) to the adapter (98/9).
Voith Turbo I 153.00018210 I arrtd I 2008-07

• Ignition switched off

2. Use the impact puller (99/5) including the adapter
• Proportional valve and damping plate removed (98/9) to pull the valve insert (2300/1) upwards
(see Page 81) and out.

• Top cover removed and checked (see Page 57)

© 2008

Page 60
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Casing ventilation

Checking
.

2300/2
1. Check the casing ventilation (2300) for soiling and
99/4
sludge and clean it.
2300/3
2300/2

2300/1

2300/2

32018 32021

3. If necessary, remove the float (2300/2) and the 5. Check the sealing edge of the radial shaft sealing
float cage (2300/3) from the retarder housing. ring (arrow) in the valve insert (2300/1):
32020
- place the float (2300/2) on a suitable object
(e.g. hex.-head nut)
2. Check the float (2300/2) for damaged surfaces
and sealing areas (arrow). - place the valve insert (2300/1) on the float and
2300/1 weigh it down using the test ring (99/4)
3. Weigh the float (2300/2): Specified weight:
- fill the empty space between the float (2300/2)
max. 12 g.
and upper edge of the valve insert with ethyl
4. For exceeded specified weight: Replace the entire alcohol
Voith Turbo I 153.00018210 I arrtd I 2008-07

casing ventilation (2300).

2301
NOTE
The sealing edge is damaged, if the fluid level
32019
drops within 1 minute.
4. Take the O-ring (2301) out of the groove in the
valve insert (2300/1). 6. If the sealing edge is damaged: Replace the
casing ventilation (2300).
© 2008

Page 61
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Casing ventilation

Installing 7. Lubricate the seating of the casing ventilation in

the retarder housing with silicone-free and non-
CAUTION corrosive grease.
2300/1
Grease at the radial shaft sealing ring! 99/5
Malfunction of the retarder.
Ö Do not lubricate the radial shaft sealing ring. 2300/2

98/9
2300/3 2300/1

32023
2300/1
2. Clean the float with ethyl alcohol.
32024
NOTE
8. Carefully press the casing ventilation (2300) into
For casing ventilation from Voith item no.
2301 the retarder housing with the impact puller (99/5)
H53.133214 upwards:
and adapter (98/9).
Ö Observe the installation position of the float: The
32022
side marked "O" faces upwards. 9. Complete the retarder.
1. Lubricate the new O-ring (2301) with silicone-free
3. Place the float (2300/2) onto the float cage (2300/3).
and non-corrosive grease and pull it on the valve
Voith Turbo I 153.00018210 I arrtd I 2008-07

insert (2300/1). 4. Place the valve insert (2300/1) onto the float cage
(2300/3).

5. Check the float (2300/2) for ease of movement

when installed.

6. Clean the sealing surfaces at the retarder housing

© 2008

and at the cover

Page 62
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Retarder ventilation

7.4 Retarder ventilation

Item No. Name 3400

3300 Disc silencer; check, clean and blow
out with compressed air
3400 Wave spring 3300

3500 Circlip

3500
Aids
Benzene for disc silencer
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

32025

Page 63
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Retarder ventilation

Requirements

• Retarder switched off

• Ignition switched off

DANGER
Heavily soiled or painted-over retarder
ventilation!
Retarder reduces braking power after a delay.
Ö Replace retarder ventilation.

CAUTION
Mechanically damaged retarder ventilation!
Malfunction of the retarder.
Ö Replace retarder ventilation.
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 64
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Non-return valve

7.5 Non-return valve

Item No. Name

1900 Non-return valve, complete
1900/1 Guide M 48 x 1.5
hexagon insert bit, w.a.f. 55;
280 Nm
1900/2 Spring
1900/3 Piston
1950 Sealing ring A 48 x 55; replace

NOTE
Ö Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free and non-
corrosive grease before installation.
1900/3

1900/2

1900/1
Voith Turbo I 153.00018210 I arrtd I 2008-07

1950
1900
© 2008

32027

Page 65
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Non-return valve

Requirements Checking

• Retarder switched off 1900/1

• Ignition switched off

• Oil drained (see Page 25)

CAUTION
1900/3
Hot parts!
Hands could be burned.
Ö Work carefully.
Ö Wear protective gloves or use cloths if necessary. 1900/2
32108
Removing
1. Check the rubber coating of the piston (1900/3) for
1. Unscrew the guide (1900/1). damage. If necessary, replace the entire non-
2. Remove the spring (1900/2) and piston (1900/3) return valve (1900).
from the retarder housing. 2. Check the guide (1900/1) and spring (1900/2) for
wear. If necessary, replace the entire non-return
valve (1900).
Voith Turbo I 153.00018210 I arrtd I 2008-07

Installing

1. Lubricate the new sealing ring (1950) with

silicone-free and non-corrosive grease.

2. Screw in the non-return valve (1900) with sealing

ring (1950).
© 2008

3. Tighten the non-return valve (1900) to 280 Nm.

Page 66
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Oil cooler

7.6 Oil cooler

Item No. Name

1000 O-ring 158.34 x 3.53; replace
2000 Cover for retarder housing
2100 O-ring 228.2 x 3.53; replace
3600 Hex.-head screw M 8 x 45;
hexagon insert bit, w.a.f. 13;
Initial torque: 17 Nm, 6100
Final torque: 30 Nm 6150 2000 3600
6200
4800 Hex.-head screw M 8 x 70;
hexagon insert bit, w.a.f. 13; 4800
Initial torque: 17 Nm, 6000
Final torque: 30 Nm
6000 Oil cooler
6100 O-ring 25 x 2.5; replace 6300
6150 O-ring 25 x 2.5; replace
6200 Hex.-head screw M 10 x 40;
hexagon insert bit, w.a.f. 15; 46 Nm 6150 2100
1000 4800
6100
6300 Hex.-head screw M 10 x 70;
Voith Turbo I 153.00018210 I arrtd I 2008-07

hexagon insert bit, w.a.f. 15; 46 Nm

NOTE
Ö Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free and non-
corrosive grease before installation.
© 2008

32028

Page 67
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Oil cooler

Checking
Special tools
CAUTION
Hot parts!
Hands could be burned. 50/65
Ö Work carefully.
Ö Wear protective gloves or use cloths if necessary.

Removing
153.000769xx 6000
1. Unscrew the hex.-head screws (3600, 4800, 6200
and 6300).
Pressure test
32094
equipment 2. Remove the cover (2000) using suitable lifting
equipment.
50/65 1. Attach the pressure test device (50/65) with
3. Remove the O-rings (1000 and 2100) O-rings to the oil cooler (6000) and connect the
Requirements compressed-air line.
4. Remove the oil cooler (6000).
• Retarder switched off 2. Place the oil cooler (6000) with the pressure test
device (50/65) in a water bath (approx. 60°C).
• Ignition switched off
3. Slowly pressurize the oil cooler (6000) with
• Supply-air pressure drained
compressed air from 0–max. 10 bar.
Voith Turbo I 153.00018210 I arrtd I 2008-07

• Oil drained (see Page 25)

• Coolant drained (see Page 29)

© 2008

Page 68
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Oil cooler

CAUTION 6100 6150 NOTE

Leaky oil cooler! 6000 Ö When inserting the oil cooler (6000), pay
Malfunction of the retarder. attention to the installation orientation (see
arrow in the diagram).
Ö If air bubbles occur in the water or if an external
leak is found: Replace the oil cooler. Ö Do not damage sealing surfaces.

4. If air bubbles form in the water: Replace the oil 3. Insert the oil cooler (6000).
cooler (6000). 4. Lubricate the new O-ring (2100) with silicone-free
1000 6100
6150 and non-corrosive grease and pull it on.
5. Release the compressed air and detach the 32095
compressed-air line.
3 7
6. Remove the oil cooler (6000) from the pressure
CAUTION 3600
4800 4800
test device (50/65). 3600
Leaks (internal/external)! 2000
6200 1 6
Installing Malfunction of the retarder.
4800
Ö Use only O-rings 25 x 2.5, Voith item no. 6300
NOTE 190.00230210.
4800 4800
The water and oil section of new oil coolers are
coated with anti-corrosion oil.
1. Lubricate the new O-rings (6100) and (6150) with 2
silicone-free and non-corrosive grease and pull 5 4
Voith Turbo I 153.00018210 I arrtd I 2008-07

Ö Before installation drain any anti-corrosion oil 32064

them onto the oil cooler (6000).
and rinse the water section with hot water.
2. Lubricate the new O-ring (1000) with silicone-free 5. Screw on the cover (2000) with the hex.-head
and non-corrosive grease and pull it on. screws (3600, 4800).
© 2008

Page 69
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Oil cooler

CAUTION CAUTION
Incorrect sequence when tightening the hex.- In case of water in the retarder!
head screws! Oil emission through retarder ventilation.
Cover can buckle. Malfunction of the retarder
Ö Tighten the hex.-head screws in the prescribed Ö Fill the retarder with 6.0 l of oil (as per the Voith
sequence (see diagram). Retarder oil change intervals/Oil selection list).
Ö Flush the retarder system by braking several
6. Tighten the hex.-head screws (3600, 4800) in the times lightly.
prescribed sequence (see diagram) to 17 Nm. Ö Drain the oil.
Ö Repeat the process 2 or 3 times.
7. Tighten the hex.-head screws (3600, 4800) in the
Ö De-oil the cooling and heating system (see
prescribed sequence (see diagram) to 30 Nm.
specifications of vehicle manufacturer).
8. Screw in the hex.-head screws (6200 and 6300)
and tighten to 46 Nm. 11.Fill in the oil (see "Oil change" on Page 24).

9. Complete the retarder.

CAUTION
Wrong coolant type!
Damage to the vehicle and retarder cooling circuit.
Voith Turbo I 153.00018210 I arrtd I 2008-07

Ö Observe the specifications of the vehicle

manufacturer or those of Voith Turbo coolant
quality list.

10.Fill the vehicle and retarder cooling circuit (see

specifications of vehicle manufacturer)
© 2008

Page 70
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Water neck

7.7 Water neck

NOTE
Depending on the vehicle manufacturer, the design
of the water neck can differ (see specifications of
vehicle manufacturer).

Item No. Name

20000 Water neck inlet
20100 Water neck outlet
20200 Screw plug M 14 x 1.5;
hexagon socket head, w.a.f. 6; 25 Nm
20300 Sealing ring A 14 x 18; replace
20400 Hex.-head screw M 8 x 45;
hexagon insert bit, w.a.f. 13; 30 Nm
3
R 12
TYP
.Nr.

20500 O-ring 55.56 x 3.53; replace

FABR
hr
Bauja 0
1.0
T=
iRE r.
ach-N
Kd.-S h-N
r.
-Sac
Voith

20600 Coolant temperature sensor;

M 14 x 1.5; hexagon insert bit, 20000
w.a.f. 27; 28 Nm
Voith Turbo I 153.00018210 I arrtd I 2008-07

20500
20700 Sealing ring A 14 x 20; replace
20500
20700
NOTE 20400

Ö Lubricate sealing rings, O-rings and shaft 20600 20400

sealing rings with silicone-free and non- 20100
20200 20400
corrosive grease before installation.
© 2008

20300 20400
32029

Page 71
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Water neck

Requirements

• Retarder switched off

• Ignition switched off

• Coolant drained (see Page 29)

CAUTION
Hot parts!
Hands could be burned.
Ö Work carefully.
Ö Wear protective gloves or use cloths if necessary.
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 72
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Return valve

7.8 Return valve

2600

Item No. Name

2700
2600 Valve piece M 24 x 1.5;
hexagon socket head, w.a.f. 12; 46 Nm
glue in with Loctite 572
2700 Washer

Special tools

H53.6820xx H53.1403xx

Adapter plate Pressure gauge

0–6 bar

50/66 99/7
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

32101

Page 73
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Return valve

Requirements Checking
5100 50/66
3
• Retarder switched off 2600
A
• Ignition switched off 2700 4
100
• Proportional valve and damping plate removed A
(see Page 81)

• Top cover removed (see Page 57)

CAUTION 2
99/7 32110
Hot parts!
32109
Hands could be burned. 3. Attach the top cover (3000) (see Page 57).
Ö Work carefully.
4. Attach the damping plate (5100) with new O-rings
Ö Wear protective gloves or use cloths if necessary.
CAUTION (5200) (see Page 81).
Retarder housing open!
5. Attach the adapter plate (50/66) with hex.-head
The test specimen (A) can fall into the retarder
nuts M 8, tightening torque 18 Nm, to the damping
housing.
plate (5100).
Ö Hold the test specimen (A) securely.
6. Connect the pressure gauge (99/7) and pressure
1. Check whether the washer (2700) is located under reducer (3) to the compressed-air line (4).
Voith Turbo I 153.00018210 I arrtd I 2008-07

the valve piece (2600):

7. Connect the compressed-air line (4) to the
- insert a suitable test specimen (A) (e.g. drill bit
adapter plate (50/66) at connection "A".
smaller than 6 mm) into the bore in the valve
piece (2600) 8. Set a max. overpressure of 3 bar at the pressure
reducer.
2. Install the missing washer if necessary.
9. Open the stop cock (2) and pressurize the
© 2008

retarder with a max. of 3 bar at connection "A".

Page 74
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Return valve

10.Close the stop cock (2).

Depending on the design, the pressure
immediately drops and must be at least 2.5 bar
after 30 seconds.

11.Remove the pressure reducer (3).

12.Slowly open the stop cock (2) so that the

compressed air can escape slowly.

13.Remove the pressure gauge (99/7) and

compressed-air line (4).

14.Remove the adapter plate (50/66).

15.Complete the retarder.

Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 75
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Oil temperature sensor

7.9 Oil temperature sensor

Item No. Name

8000 Temperature sensor M 14 x 1.5;
hexagon insert bit, w.a.f. 27; 28 Nm
8100 Sealing ring A 14 x 20; replace

NOTE
Ö Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free and non-
corrosive grease before installation. 8100

Requirements

• Retarder switched off

• Ignition switched off

TYP R 123
FABR.Nr.

• Electrical connecting leads disconnected Baujahr

iRET = 1.00
Kd.-Sach-Nr.

Voith-Sach-Nr.

CAUTION 8000
Voith Turbo I 153.00018210 I arrtd I 2008-07

Hot parts!
Hands could be burned.
Ö Work carefully.
Ö Wear protective gloves or use cloths if necessary.
© 2008

32032

Page 76
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Oil temperature sensor

NOTE
Measuring in one temperature range is usually
sufficient.
Polarity irrelevant.

Temperature Resistance
20°C ± 10°C 1039–1117 Ω
60°C ± 10°C 1194–1271 Ω
80°C ± 10°C 1271–1347 Ω
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 77
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Coolant temperature sensor

7.10 Coolant temperature sensor

Item No. Name

20600 Temperature sensor M 14 x 1.5:
hexagon insert bit, w.a.f. 27; 28 Nm
20700 Sealing ring A 14 x 20; replace

NOTE
Ö Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free and non-
corrosive grease before installation.

Requirements

• Retarder switched off

20700
• Ignition switched off
TYP R 123

• Coolant drained (see Page 29)

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

Voith-Sach-Nr.

• Electrical connecting lead disconnected

Voith Turbo I 153.00018210 I arrtd I 2008-07

CAUTION
Hot parts! 20600
Hands could be burned.
Ö Work carefully.
Ö Wear protective gloves or use cloths if necessary.
© 2008

32033

Page 78
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Coolant temperature sensor

NOTE
Ö Regarding the coolant quality, observe the
specifications of the vehicle manufacturer or
those of the Voith Turbo coolant quality list.

NOTE
Measuring in one temperature range is usually
sufficient.
Polarity irrelevant.

Temperature Resistance
20°C ± 10°C 1039–1117 Ω
60°C ± 10°C 1194–1271 Ω
80°C ± 10°C 1271–1347 Ω
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 79
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Pressure sensor

7.11 Pressure sensor

7000

Item No. Name

7000 Pressure sensor M 16 x 1.5
with integrated FPM ring;
hexagon insert bit, w.a.f. 27; 30 Nm

NOTE
Ö Lubricate the FPM sealing ring on both sides
with silicone-free and non-corrosive grease
before installation.

Requirements

• Retarder switched off

• Ignition switched off

• Electrical connecting lead disconnected

CAUTION
Voith Turbo I 153.00018210 I arrtd I 2008-07

Hot parts!
Hands could be burned.
Ö Work carefully.
Ö Wear protective gloves or use cloths if necessary.

Measurement values can be found on Page 42

"Supply and signal voltage of the pressure sensor".
© 2008

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Page 80
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Proportional valve and damping plate

7.12 Proportional valve and damping

plate

Item No. Name

5000 Proportional valve
5100 Damping plate, replace if damaged
5200 5100
5200 O-ring 16 x 3; replace 5200 5000 5400
5300 Hex.-head screw M 8 x 20, replace
hexagon insert bit, w.a.f. 13; 30 Nm
5400 Hex.-head nut M 8; replace
hexagon insert bit, w.a.f. 13; 18 Nm
5300
5400
NOTE
Ö Lubricate sealing rings, O-rings and shaft
sealing rings with silicone-free and non-
corrosive grease before installation.

NOTE
Voith Turbo I 153.00018210 I arrtd I 2008-07

Ö For vehicles used mainly in city traffic: Replace

the proportional valve every 120,000 km.
© 2008

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Page 81
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Repair Proportional valve and damping plate

Requirements
CAUTION
• Retarder switched off
Incorrect sequence when tightening the hex.-
• Ignition switched off head nuts!
• Supply-air pressure drained Proportional valve can be damaged.
Ö Tighten the hex.-head nuts in the prescribed
• Compressed-air line disconnected sequence to 18 Nm.

• Electrical connecting lead disconnected from

proportional valve. Male and female connector
checked for damage or wear (notch scratches)
4

NOTE 1
2
Ö Check damping plate (5100) for mechanical and
aging damage and replace if necessary. 3

32112
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 82
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Overview of the tools

8. Overview of the tools

8.1 Diagnosis 84
8.2 Repair 86

CAUTION
False special tools!
Damage to components.
Ö Only use special tools from the specified version
onward.
Ö Take the last two digits of the Voith item no. into
account in the graphics of the special tools.
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 83
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Overview of the tools Diagnosis

8.1 Diagnosis

Activity Special tools Tools for self-fabrication

Checking the constant- –
air pressure control
loop

153.001085xx 153.000776xx H53.1403xx

Retarder tester, Test software Pressure gauge

complete in a "DIANA Lite" 0–6 bar
case
50/56 50/56i 99/7
Checking the dynamic –
pressure (pdyn)
Voith Turbo I 153.00018210 I arrtd I 2008-07

153.001085xx 153.000776xx

Retarder tester, Test software

complete in a "DIANA Lite"
case
© 2008

50/56 50/56i

Page 84
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Overview of the tools Diagnosis

Activity Special tools Tools for self-fabrication

Checking the –
proportional valve
current

H53.8198xx

Measuring
adapter
99/3
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 85
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Overview of the tools Repair

8.2 Repair

Activity Special tools Tools for self-fabrication

Casing ventilation

Ø 40.5 mm

7 mm
Ø 60 mm

H53.7712xx H53.942811 H67.2757xx

Impact puller Adapter Test ring

99/5 98/9 99/4
Oil cooler –

153.000769xx
Voith Turbo I 153.00018210 I arrtd I 2008-07

Pressure test
equipment
50/65
© 2008

Page 86
 Voith Turbo I Aftersales Service Manual Voith Retarder VR 123 - 153.00018210 I Overview of the tools Repair

Activity Special tools Tools for self-fabrication

Return valve –

H53.6820xx H53.1403xx

Adapter plate Pressure gauge

0–6 bar
50/66 99/7
Voith Turbo I 153.00018210 I arrtd I 2008-07
© 2008

Page 87
Voith Turbo
Produktgruppe Retarder
Postfach 1555
D-74555 Crailsheim, Germany
Tel. +49 79 51 32-0
Fax +49 79 51 32-756
[email protected]
www.voith.com

Engineered reliability.