Voith VR 115 E User manual

Voith Turbo
Aftersales Service Manual Voith Retarder VR 115 E
153.00009710 I 2005-11

Page 2
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
Table of Contents
1 About this Document 5
1.1 Purpose of this Document 6
1.2 Target Groups 6
1.3 Other Applicable Documents 6
1.4 Symbols and Identifications 7
1.5 Item Numbers 7
1.6 Legal/Contact Information 7
2 Basic Safety Information 8
2.1 Product Safety 9
2.2 Staff Qualification 9
2.3 Safety-Conscious Working 9
2.4 Environmental Protection 9
2.5 Troubleshooting 9
2.6 Maintenance and Repair 9
2.7 Driving Mode 9
2.8 Warranty 10
3 Design and Function 11
3.1 Overview of the Modules 12
3.2 Retarder Identification 14
3.3 Controller Identification (VERATM) 15
3.4 Controller Identification (Digiprop) 16

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
3.5 Function and Control Scheme 17
3.6 Function Description 19
4 Maintenance and Service 20
4.1 Maintenance Intervals 21
4.2 Oil Change 22
4.3 Checking the Oil Level 25
4.4 Draining the Coolant 28
5 Diagnosis and Troubleshooting 30
5.1 Troubleshooting Chart 31
5.2 Constant-Air Pressure Control Loop 36
5.3 Pump Pressure (pdyn) 39
5.4 Proportional Valve Current 42
6 Removing and Installing the Retarder 44
7 Repair 51
7.1 Components Overview 52
7.2 Top Oil Tank Cover 59
7.3 Bottom Oil Tank Cover 61
7.4 Casing Ventilation 63
7.5 Retarder Ventilation 69
7.6 Water Neck 70
7.7 Heat Exchanger 71
7.8 Pressure Control Valve 76
7.9 Non-Return Valve Inlet 79

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
7.10 Non-Return Valve Outlet 81
7.11 Oil Temperature Sensor 84
7.12 Coolant Temperature Sensor 86
7.13 Pressure Sensor 88
7.14 Proportional Valve and Damping Plate 89
8 Appendix 91
8.1 Tightening Torques 92

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
1. About this Document
1.1 Purpose of this Document 6
1.2 Target Groups 6
1.3 Other Applicable Documents 6
1.4 Symbols and Identifications 7
1.5 Item Numbers 7
1.6 Legal/Contact Information 7

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Purpose of this DocumentVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
1.1 Purpose of this Document
This Aftersales Service Manual provides information
and instructions on maintenance and repair of the
Voith Retarder VR 115 E.
1.2 Target Groups
This Aftersales Service Manual is intended for service
people for service and diagnoses only and may not be
reproduced or given to third parties.
1.3 Other Applicable Documents
Documents Information Item number
Voith retarder oil change intervals/oil specification list Oil change intervals and approved oil types 153.000831xx
Operating instructions for Voith Retarder VR 115 E Information on the safe, professional and economical operation of the
Voith Retarder VR 115 E H67.2964xx
Cooling water quality list Approved coolants H67.2224xx
Operating instructions for retarder tester Measured values for constant-air pressure and pump pressure Included in scope of delivery of
the retarder tester(153.001085xx)
Operating instructions for Diana-Lite test software Information on the testing of:
• Constant-Air Pressure Control Loop
• pump pressure (pdyn)
Included in the scope of delivery
of the Diana-Lite test software
(153.000776xx)
Operating instructions for the WinDia diagnostic
software Instructions on PC diagnosis for the Digiprop and VERATM controllers 3623-020900
Gearbox-specific documents on the retarder Information on safe, professional installation and removal of the retarder On request

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Symbols and IdentificationsVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
1.4 Symbols and Identifications
Structure of warnings
Levels of danger
The warnings are categorized into four levels of
danger:
Notes
Distinctions
ÖOne-step action instruction.
1. First step of an action instruction. Other steps
follow and are numbered in sequence.
1.5 Item Numbers
The item numbers used are usually found in the spare
parts lists.
Exceptions:
• One- or two-digit item numbers
• Item numbers with a slash
1.6 Legal/Contact Information
For questions and work procedures not described in
these documents, contact the respective organisation
for your area.
Voith Turbo
Produktgruppe Retarder
Postfach 1555
74555 Crailsheim
Deutschland
Phone: [phone] / 32-401, 32-422, 32-1860
Fax: [phone] / 32-756
[email protected]
www.voith.com
Type and source of danger!
Possible consequences if not observed.
ÖMeasures for the prevention of danger and its
consequences.
Potentiallyhazardous situation which, ifnotavoided,
may result in property damage.
Potentiallyhazardous situation which, ifnotavoided,
may result in minor or moderate injury.
LEVEL OF DANGER
CAUTION
CAUTION
Potentially hazardous situationwhich,ifnotavoided,
could result in death or serious injury.
Imminently hazardous situation which, if not
avoided, will result in death or serious injury.
Information on easier and safer work with the
retarder.
ÖMeasures for easier and safer work with the
retarder.
WARNING
DANGER
NOTE

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
2. Basic Safety Information
2.1 Product Safety 9
2.2 Staff Qualification 9
2.3 Safety-Conscious Working 9
2.4 Environmental Protection 9
2.5 Troubleshooting 9
2.6 Maintenance and Repair 9
2.7 Driving Mode 9
2.8 Warranty 10

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Product SafetyVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
2.1 Product Safety
The retarder is constructed according to state of the
art technology and acknowledged safety regulations.
Nevertheless, hazardous situations and property
damage may occur as a result of improper usage,
maintenance and repair.
ÖObserve safety and warning information.
2.2 Staff Qualification
ÖAllow only qualified professionals to carry out repair
and maintenance work.
2.3 Safety-Conscious Working
Voith does not assume any liability for personal injury
and/or property damage caused by improper and
unprofessional work.
ÖObserve the following regulations:
- Accident-prevention regulations
- Other generally acknowledged safety
regulations and occupational health
- Motor vehicle regulations
- Safety regulations for handling chemical
substances such as oils and greases
2.4 Environmental Protection
ÖDrainedfuelsandfluids,consumablesandoldparts
must be disposed of properly.
2.5 Troubleshooting
Voith provides a warranty/goodwill service for
defective parts only.
ÖDo not replace parts on mere speculation.
2.6 Maintenance and Repair
Danger of burning and scalding via squirting oil!
The oil in the retarder may be hot.
ÖWork carefully.
Danger of burning and scalding via hot coolant!
The coolant may be hot.
ÖWork carefully.
Danger of burns via hot parts!
Parts of the retarder may be hot.
ÖWork carefully.
ÖWear protective gloves or use cloths if necessary.
Damage to property via soiled parts!
Considerable damage or malfunctions may occur due
to soiling.
ÖEnsure cleanliness.
Damage to property via improper cleaning!
ÖDo not aim the jet of a high-pressure cleaner
(steam-jet device) at valves, pressure sensors or
ventilators of the retarder.
2.7 Driving Mode
ÖEnsure that the retarder is fully functional for all
vehicle maneuvers, i.e.:
- Retarder properly filled with oil
- Retarder electronics connected and functional
- Pneumatic control connected and functional

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WarrantyVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
Driving after repair/oil change
Oil ejection!
De-aeration not performed.
ÖDe-aerate retarder.
- Switch off retarder foot control if present and
possible
- Move vehicle at 50 km/h
- Activate retarder at brake stage one five times
for approx. 5 sec. each time
Towing
ÖTow vehicle with retarder max. 100 km at max.
40 km/h.
Parking
ÖDo not use retarder as a parking brake, as it does
not act as a brake when the vehicle is standing still.
Failure while driving
During failure of the retarder, or while temperature
adaptation is active, only the service brake is
functional.
ÖAdjust the speed of the vehicle with the service
brake.
ÖEngage the lowest possible gear to achieve a high
engine speed.
ÖContinue driving in this way until the retarder is
available at full capacity again.
2.8 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.
ÖUse only parts approved by Voith to ensure the
safety of the vehicle.

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
3. Design and Function
3.1 Overview of the Modules 12
3.2 Retarder Identification 14
3.3 Controller Identification (VERATM) 15
3.4 Controller Identification (Digiprop) 16
3.5 Function and Control Scheme 17
3.6 Function Description 19

Page 12
Overview of the ModulesVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
3.1 Overview of the Modules
Item No. Designation
100 Retarder housing
1600 Valve cover (non-return valve outlet)
1900 Non-return valve inlet
2810 Vent and air filter
3700 Proportional valve
4100 Screw plug M30x1.5 (oil filler plug)
4100
100
1600
3700
1900
2810
28003

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Overview of the ModulesVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
Item No. Designation
103 Screw plug M12x1.5
107 Screw plug M24x1.5 (oil drain plug)
3500 Screw plug M30x1.5
4200 Screw plug M24x1.5 (oil drain plug)
5200/2 Coolant temperature sensor M14x1.5
5500/1 Ventilation
6400 Heat exchanger
20000 Water neck
103
107
4200
20000
6400
3500
5500/1
20000
5200/2
28004

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Retarder IdentificationVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
3.2 Retarder Identification
ÖSpecify the following data in case you have
questions or are ordering spare parts:
- Serial number (Serien-Nr.)
- Voith item number (Voith-Sach-Nr.)
Kd.-Sach-Nr.
Voith-Sach-Nr.
Typ VR115E; Serien-Nr.
KW/Jahri Ret. = 2.03
Kd.-Sach-Nr.
Voith-Sach-Nr.
i Ret =2.03KW/Jahr
Serien-Nr.
T
ypVR115E;
28001
NOTE

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Controller Identification (VERATM)Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
3.3 Controller Identification (VERATM)
Example:
ÖSpecify the following data in case you have
questions or are ordering spare parts:
- Serial number (Serial-No.)
- Part number (Part No.)
ÖSpecify the following data of the retarder (see
page 14):
- Serial number (Serien-Nr.)
- Voith item number (Voith-Sach-Nr.)
Retarder Control Unit VERA
Serial-No. XXXXXX / JJJJ-MM-TT
Part-No. VERA.D.H-E02.10-H67.2866.20
OEM-No. 0004463315 / EvoBus
VOITH Voith Turbo
X1 X2 X3
e1 022084
TM
Retarder Control Unit VERA
Serial-No. XXXXXX / JJJJ-MM-TT
Part-No. VERA.D.H-E02.10-H67.2866.20
OEM-No. 0004463315 / EvoBus
VOITH
Voith Turbo
X1 X2 X3
e1 022084
TM
28138
NOTE

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Controller Identification (Digiprop)Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
3.4 Controller Identification (Digiprop)
Example:
ÖSpecify the following data in case you have
questions or are ordering spare parts:
- Basic number (Basis-Nr.:)
- Serial number (Serien-Nr.:)
ÖSpecify the following data of the retarder (see
page 14):
- Serial number (Serien-Nr.)
- Voith item number (Voith-Sach-Nr.)
Basis-Nr.: 53.xxxx.12
Code-Nr.: xxx
Serien-Nr.: xxxx/
VOITH
Basis-Nr.:
Code-Nr.:
Serien-Nr.:
VOITH
28002
NOTE

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Function and Control SchemeVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
3.5 Function and Control Scheme
Item No. Designation
A Compressed-air line (pressure
controller)
B Four-circuit protection valve
C Compressed-air line (brake circuit 2)
D Compressed-air line (brake circuit 1)
E Compressed-air line (parking brake)
F Air tank for auxiliary equipment
G Supply-air pressure (pv) "P"
HConstant-air pressure (py) "A"
I Ventilation line "R"
J Oil tank
K Rising duct
107 Oil drain plug
200 Stator
300 Rotor
1900 Non-return valve (inlet)
2100 Non-return valve (outlet)
2200 Pressure control valve
AR
P
H
G
2300
I
6400
5200/2
1900
5200/1
300
5500
200
2200
4200
107
2100
2810 3700
J
K
9000
ABC
D
EF
28005
Vehicle
electronics
Oil sump
Supply-air pressure pv
Constant-air pressure py
Coolant
Pump pressure pdyn

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Function and Control SchemeVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
Item No. Designation
2300 Casing ventilation
2810 Ventilation filter
3700 Proportional valve
4200 Oil drain plug
5200/1 Oil temperature sensor
5200/2 Coolant temperature sensor
5500 Ventilation
6400 Heat exchanger
9000 Pressure sensor
AR
P
H
G
2300
I
6400
5200/2
1900
5200/1
300
5500
200
2200
4200
107
2100
2810 3700
J
K
9000
ABC
D
EF
28005
Vehicle
electronics
Oil sump
Supply-air pressure pv
Constant-air pressure py
Coolant
Pump pressure pdyn

Page 19
Function DescriptionVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
3.6 Function Description
Non-return valve (inlet) (1900)
When the retarder is switched on, the oil sump is
pressurized. This opens the non-return valve (inlet)
(1900) and allows oil into the working space.
Non-return valve (outlet) (2100)
In braking mode, the oil reaches the heat exchanger
from the working space via the non-return valve
(outlet) (2100), is cooled down and is fed back into the
system circuit.
Pressure control valve (2200)
In no-load operation of the retarder, the pressure
control valve (2200) regulates the lubrication.
Casing ventilation (2300)
At the beginning of the braking process, the oil expels
the air located in the system circuit from the retarder
via the casing ventilation (2300) and a de-aeration
filter (2810).
Once the system circuit is free of air, a float will rise
and seal the casing ventilation.
Proportional valve (3700)
Depending on the intensity of the electric input signal,
the proportional valve (3700) issues a pneumatic
constant-air pressure which acts on the oil tank of the
retarder.
Oil temperature sensor (5200/1) and
coolant (5200/2)
Thetemperature sensors are screwed into the cooling
systemofthevehicle(returnpipefromretardertoheat
exchanger) and in the oil duct of the retarder. The
temperature sensors pass on information on the
temperature of the coolant and oil to the controller.
Maximum values for the temperature of coolant and
oil are set in the controller for protection of the cooling
system and the retarder. To prevent the values being
exceeded, the controller adapts the braking torque of
the retarder accordingly via the constant-air
pressure py.
The braking torque and the heat produced regulate
themselves until an equilibrium has been reached
between the braking force and the heat dissipated via
the vehicle cooling system.
If the temperature limit is exceeded during braking,
the braking torque is adapted to protect the cooling
system and retarder.
If the critical temperature threshold has been
exceeded, the braking torque is no longer active.
The controller also adjusts the braking torque if the
temperature of the oil increases rapidly, regardless of
the actual temperature of the oil.
During temperature adaptation or failure of the
retarder, you must use the service brake to slow down
the vehicle.
Pressure sensor (9000)
The pressure sensor (9000) measures the pneumatic
constant-air pressure. A deviation from the allowed
pressure tolerance is recognized as a fault and
displayed by the controller.

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service
Voith Turbo I 153.00009710 I arrtd I 2005-11 © 2005
4. Maintenance and Service
4.1 Maintenance Intervals 21
4.2 Oil Change 22
4.3 Checking the Oil Level 25
4.4 Draining the Coolant 28