Training
cbtd 98-01 53.2659.10
Aftersales Service Manual
Content
cbtd 98-01 53.2659.10Table of Contents
1.
Preface ...1/1
2.
General...2/1
2.1 Assembly Overview
...2.1/1
2.2 Function and Operation Scheme
...2.2/1
2.3 Retarder Data
...2.3/1
3.
Maintenance...3/1
3.1 Maintenance Work
...3.1/1
3.2 Oil
Change
...3.2/1
With Stainless-Steel Heat Exchanger
...3.2/1
With Aluminium Heat Exchanger
...3.2/5
3.3 Checking Oil Level
...3.3/1
3.4 Cleaning Line Filter (Optional extra)
...3.4/1
4. Diagnosis/Troubleshooting...4/1
4.1 Troubleshooting Diagram
...4.1/1
Elektrical Connections Diagram
...4.1/2
4.2 Troubleshooting and Remedies...4.2/1
4.3 Checking Pump Pressure
...4.3/1
4.4 Checking Control System
...4.4/1
4.5 Operational Check
...4.5/1
5.
Removing, Installing Retarder ...5/1
5.1 Removing, Installing Retarder (Free Mount Installation)...5.1/1
5.2 Removing, Installing Retarder (Gearbox Attachment)
...5.2/1
Aftersales Service Manual VOITH Retarder 120 Digiprop Page IHV/1
Content
cbtd 98-01 53.2659.10
Table of Contents
(Continue)
6.
Retarder Basic Group Repair (Gearbox Attachment)...6/1
6.1 Assembly Overview
...6.1/1
6.2 Removing, Checking and Installing Casing Ventilation
...6.2/1
6.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation)
...6.3/1
6.4 Removing, Checking and Installing Non-Return Valve
(Stainless-Steel Heat Exchanger)
...6.4/1
6.5 Removing, Cleaning and Installing Silencer...6.5/1
6.6 Removing and Installing Bottom Cover
...6.6/1
6.7 Checking, Removing and Installing Closing Cover of Retarder Housing
...6.7/1
6.8 Removing and Installing Labyrinth Ring (Output Side),
Renewing Radial Shaft Sealing Ring
...6.8/1
6.9 Removing and Installing Centering Cover (Input Side),
Renewing Radial Shaft Sealing Ring
...6.9/1
7.
Retarder Basic Group Repair (Free Mount Installation) ...7/1
7.1 Assembly Overview
...7.1/1
7.2 Removing, Checking and Installing Casing Ventilation
...7.2/1
7.3 Removing and Installing Non-Return Valve (Cover Casing Ventilation)
...7.3/1
7.4 Removing, Checking and Installing Non-Return Valve
(Stainless-Steel Heat Exchanger)
...7.4/1
Aftersales Service Manual VOITH Retarder 120 Digiprop Page IHV/2
Content
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Table of Contents
(Continue)
7.5 Removing, Cleaning and Installing Silencer...7.5/1
7.6 Removing and Installing Bottom Cover
...7.6/1
7.7 Removing and Installing Prop Shaft Flanges
...7.7/1
7.8 Checking, Removing and Installing Closing Cover of Retarder Housing
...7.8/1
7.9 Removing and Installing Labyrinth Ring (Output Side),
Renewing Radial Shaft Sealing Ring
...7.9/1
7.10 Removing and Installing Centering Cover (Input Side),
Renewing Radial Shaft Sealing Ring
...7.10/1
8.
Removing, Checking and Installing Heat Exchanger ...8/1
8.1 Stainless-steel Heat Exchanger
...8.1/1
8.2 Aluminium Heat Exchanger
...8.2/1
9.
Control Parts ...9/1
10.
Annex ...10/1
Data Sheet
Miscellaneous Conversions
Aftersales Service Manual VOITH Retarder 120 Digiprop Page IHV/3
Preface
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1
Preface
The present service manual serves as training material of the basics course.
The information and instructions which is given to you furthermore provide the basis for
appropriate and professional maintenance and repair at the VOITH Retarder 120 with Digiprop control. We ask you firmly to notice the safety and warning notes which you will find in these instructions.
Caution!
is associated for safety instructions and for warning notes at dangerous situations for persons, at reduction of quality of workmanship and the possibility of damage to property.
Notice
is associated for general notices for a better handling during maintenance of the retarder.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 1/1
Preface
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Preface
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Caution!The switched-on retarder will not secure the parked vehicle.
At a failure of the retarder, or while the temperature limitation is effective the vehicle speed must be settled with the service brake.
Notice
Only genuine spare parts may be used for repairs. For inquiries and orders, please provide the following information (see also Section 2.3):
• Serial-Number • Code-Number
Notice
The used three- or four-digit item numbers in these instructions are corresponding to the item numbers in the spare part lists in the annex. Items or components shown with an oblique-number are not available. Items or components with two-digit item numbers are no spare parts and therefore not available in the spare part lists.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 1/2
Preface
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Preface
(Continue)
Caution!Pay attention to absolute cleanliness in maintenance work. Dirt on bearing and sealing surfaces and electrical contacts may cause considerable damage or operational malfunctions.
Notice
To observe environmental protection you should dispose of drained fuels, coolants and lubricants professionally.
Notice
Shield retarder proportional valve from direct jet of high-pressure cleaner (steam jet cleaner)!
Notice
In troubleshooting you must not replace parts on suspicion. Warranty work or goodwill work can only be offered, if the parts involved are demonstrably defective.
To exclude injuries and to avoid impairment of the operational reliability of the retarder or damage to the retarder as a result of inexpert workmanship, the information and instructions must be read carefully and complied with in their entirety.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 1/3
Preface
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1
Preface
(Continue)
Inevitably, it is impossible for VOITH TURBO GmbH & Co. KG in the last analysis to assess all situations which might entail the risk of injury for the person carrying out the work. It is therefore imperative that any person carrying out repair work on VOITH retarders uses his professional knowledge to make sure that his own safety is not endangered and that the retarder suffers no negative effects, in particular safety-wise, through the chosen working procedure. For these reasons, no liability can be assumed for damage incurred.
It is therefore expressly pointed out that all working procedures described must be carried out only in compliance with the valid general directions and regulations of the locally responsible authorities, of the health protection, accident prevention and environmental protection organisations.
The technical status of the present instructions can be seen from the updating index. There may be discrepancies between the actual technical status of the retarders and the descriptions owing to continuous development and improvement of the retarders.
VOITH TURBO GmbH & Co. KG reserves the right to make modifications at any time and without prior notification.
Should you have queries about the descriptions, please contact the responsible person in the appropriate organisation of the country involved or:
VOITH TURBO GmbH & Co. KG D-74564 Crailsheim
Department cb; Voithstraße 1 Telephone (07951) 32-0 Telefax (07951) 32-756 Extensions:
Customer telephone and Spare Parts Service 32-401 / 32-422
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 1/4
General
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2
General
2.1
Assembly Overview ...2.1/1
With Stainless-Steel Heat Exchanger
...2.1/1
With Aluminium Heat Exchanger
...2.1/3
2.2
Function and Operation Scheme...2.2/1
2.3
Retarder Data...2.3/1
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2/1
General
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2.1 Assembly Overview
Illustration VOITH Retarder R 120 with Digiprop control system basic group with stainless-steel heat exchanger 100/1 Retarder data 100/2 Constant-air pressure connection py „A“ 100/3 Ventilation connection „R“ 1000 Heat exchanger
1900 Oil filler/check plug (M 30 x 1,5)
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.1/1 1900 100/1 1000 100/2 100/3 16001
General
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2.1 Assembly Overview
(Continue)
Illustration VOITH Retarder R 120 with Digiprop control system basic group with stainless-steel heat exchanger
(Continue)
1000 Heat exchanger 1000/1 Leakage oil drain plug
(M 14 x 1,5)
1000/5 Cooling water drain plug (M 18 x 1,5)
1700 Retarder oil drain plug (M 22 x 1,5)
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.1/2 1000/1 1700 1000/5 1000 16002
General
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2.1 Assembly Overview
(Continue)
Illustration VOITH Retarder R 120 with Digiprop control system
basic group with aluminium heat exchanger
100/1 Retarder data
100/2 Constant-air pressure connection py „A“
100/3 Ventilation connection „R“ 1000 Heat exchanger
1000/5 Cooling water drain plug (M 12 x 1,5)
1900 Oil filler/check plug (M 30 x 1,5)
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.1/3 1900 100/1 1000/5 1000 100/2 100/3 16003
General
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2.1 Assembly Overview
(Continue)
Illustration VOITH Retarder R 120 with Digiprop control system
basic group with aluminium heat exchanger
(Continue)
1000 Heat exchanger 1000/1 Leakage oil drain plug
(M 10 x 1)
1000/3 Heat exchanger oil drain plug (M 12 x 1,5)
1000/5 Cooling water drain plug (M 12 x 1,5)
1700 Retarder oil drain plug (M 22 x 1,5)
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.1/4 16004 1000/1 1700 1000/5 1000 1000/3
General
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2.2 Function and Operation Scheme
Illustration of VOITH Retarder 120 with Digiprop control system
Notice
The reference numbers indicated in Section 2.2 are not identical with the reference numbers of the spare parts lists.
1 Heat exchanger 2 Control unit 4 Connection terminal 15 5 Connection terminal 30 7 Fuses (5A) 8 Connection ground
12 Pump pressure test connection
15 ABS-Signal
16 Retarder stage switch 17 Retarder pilot light 18 Stop light relay
19 Temperature pick-up cooling water 20 Oil temperature pick-up
21 Proportional valve 23 Casing ventilation
25 Constant-air pressure line py „A“
26 Supply-air pressure line pv „P“
37 Ventilation line „ R“ 43 Oil sump 44 Stator 45 Stator pin 46 Rotor 47 Speedometer signal 50 Output restrictor D1 52 Filling restrictor D2 53 Filling duct
56 Leakage oil return line
66 Check valve
(stainless-steel heat exchanger)
67 Check valve
(casing ventilation cover) 69 ISO interface plug 70 Extra operations plug
R P A 46 44 12 50 25 52 45 23 53 19 37 67 20 26 21 7 4 16 5 8 2 70 15 47 17 7 4 18 69 43 56 66 1 Oil sump Supply-air pressure p V Constant-air pressure py Coolant (water) Pump pressure pP 16005e
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.2/1
General
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2.2 Function and Control System
(Continue)
Description of the function
The VOITH Retarder 120 is a powerful hydrodynamic continous brake of compact design for buses and commercial vehicles of the medium range. The VOITH Retarder 120 is mounted between the gearbox and the rear axle of the vehicle.
The retarder braking torque is sustained even when gear changes are made. The switched-on retarder will not secure a parked vehicle.
In the event of a retarder failure or when the temperature limit is effective, the service brake must be used to regulate the vehicle speed.
A retarder stage switch (16) with a maximum of 5 switching stages is used to control the VOITH Retarders 120. A special version combines the retarder stage switch (16) with ABS, a 3-stage pedal-operated brake valve or a service-brake pressure switch.
The following variaties in operation are available:
Operation with function ,,Constant speed"
The retarder is operated by a 5-stage retarder stage switch.
When the retarder stage switch (16) is shifted to position 1, the „Constant Speed“ function is activated. The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limit of the maximum braking torque.
If the retarder is switched off (0 position), or switched to braking stage (position 2 to 5), the memorized constant speed is deleted. If the constant speed function is re-activated, the new present speed is memorized.
When the retarder stage switch is shifted to position 2 to 5, braking stage 1 to 4 is energized. Maximum braking torque is obtained when the retarder stage switch is in the maximum position.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.2/2
General
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2.2 Function and Control System
(Continue)
Description of operation of retarder R 120 with digiprop control system
As a special version, the control system is available with push button operation for constant speed. The retarder is operated in this case by a 4-stage retarder stage switch.
When the push button is pushed in any position of the retarder stage switch, the momentary speed is transferred to memory. In the 0 braking stage, this transfer to memory takes effect and the retarder holds the vehicle speed downhill constant within the limits of the maximum braking torque. Another push on the push button in any switch position will delete the speed data.
On a downhill run with „constant speed“ operation, the vehicle can be slowed down within the limits of the maximum braking torque and the temperature limit, for an obstacle ahead (e.g. bend) by shifting to braking positions 1 to 4. If the retarder stage switch is then shifted to position 0, the vehicle accelerates to the speed previously transferred to memory.
The control medium for the Voith Retarder 120 is compressed air, which is taken from the air tank for auxiliary equipment on the vehicle.
When the retarder stage switch (16) is operated, an input signal is fed to the control unit (2). From this input signal, the control unit (2) provides a control current which flows to the proportional valve (21).
The proportional valve (21), depending on the magnitude of the control current, provides a constant-air pressure py on the oil sump (43).
The constant-air pressure py in the oil sump (43), depending on the operating conditions (prop shaft speed), forces a certain quantity of oil into the working chamber between rotor (46) and stator (44).
c
a
b
16006
The hydrodynamic principle a Rotor (46)
b Stator (44) c Oil flow
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.2/3
General
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2.2 Function and Control System
(Continue)
The rotor (46) is connected with the retarder drive shaft, the stator (44) is stationary with the retarder housing.
The rotation of the rotor sets the oil in motion and circulates it in a closed circuit between the rotor (46) and stator (44).
The reduction of the velocity of the oil flow in the chambers of the stator (44) leads to braking of the rotor (46) and consequently to braking of the vehicle.
During braking, the kinetic energy of a deceleration is transformed into heat. To dissipate this heat, part of the circulating oil is pumped continuously by the rotor (46) through the heat exchanger (3300) and via filling ducts to join the circulating flow again.
In the heat exchanger (3300), the heat energy of the oil is transferred to the cooling water of the vehicle and dissipated via the vehicle radiator to the ambient air.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.2/4
General
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2.2 Function and Control System
(Continue)
Temperatur pick-ups, water (19), oil (20)
The temperature pick-ups are installed in the cooling system of the vehicle (cooling return circle from the retarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water and oil temperature to the control unit (2).
To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarder braking torque is limited to protect the vehicle cooling system and the retarder.
The constant-air pressure py is limited.
The braking torque and consequently the heat generated are reduced until a balance is obtained between the braking energy of the retarder and the amount of heat which can be dissipated by the vehicle cooling system.
If the cooling water temperature rises into the temperature limit range, the consequence is a limitation of the retarder braking torque to protect the vehicle cooling system. If the temperature rises above the temperature limit range, there is no more braking torque output.
While the temperature limit is effective or if there is a retarder failure, the service brake must be used to control the vehicle.
The control unit (2) also cuts back braking torque if oil temperature rises too rapidly, irrespective of actual oil temperature.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.2/5
General
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2.2 Function and Control System
(Continue)
Casing ventilation (23)
During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) and the ventilation system (22) out of the retarder.
Once the working circuit is free of air, a float rises and closes the casing ventilation.
Stator pins (45)
When the working chamber is empty, the rotor (46) sets up in it an air flow, which is retarded by the stator (44). To minimize this loss, automatically operating stator pins have been installed in the outer zone of the stator blades. The pin plates steer the accelerated airflow past the stator blades and prevent the build-up of an effective flow. When the working chamber is full of oil, the oil presses the plates back on their seats against the force of the spring and the full space between the blades is available.
Check valve (66) stainless-steel heat exchanger
The check valve (66) prevents the airflow emptying the heat exchanger insert of oil when idling.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.2/6
General
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2.3 Retarder Data
The retarder data (arrow) are punched on the left side on the retarder housing. The retarder data plate (2) provides the following information:
1. Serial number: Six-digit number 2. Code number:
Eight-digit number
Notice
Please, always quote the retarder serial-No. and code-No. when submitting queries or ordering spare parts.
16007
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 2.3/1
Maintenance
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Maintenance
3.1
Maintenance Work ...3.1/1
3.2
Oil Change ...3.2/1
Stainless-steel Heat Exchanger
...3.2/1
Aluminium Heat Exchanger
...3.2/5
3.3
Checking Oil Level ...3.3/1
3.4
Cleaning Line Filter (Optional Extra) ...3.4/1
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3/1
Maintenance
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3.1 Maintenance Work
Overview of maintenance work
Carry out the following maintenance work at each oil change:
l Clean the cleaning line filter (optional extra)
l Carry out visual inspection on leaks at the complete retarder
l Check hex.-head screws of prop shaft on correct fitment, or tighten.
Observe guidelines and instructions!
l Tighten all screw plugs of the retarder basic groups and the heat exchanger with the appropriate
torque (see Annex) except all fastening nuts of the heat exchanger (see Annex).
Caution!
Tighten fastening nuts of heat exchanger only in case of leakage. Tightening torque: 23 Nm
The oil change intervals and operating specifications have to be taken from the annex!
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.1/1
Maintenance
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3.2 Oil Change
Illustration oil change R 120
with stainless-steel heat exchanger
1000/1 Leakage oil drain plug (M 10 x 1), 13 Nm
1000/2 Sealing ring (A 10 x 13,5), renew 1000/5 Cooling water drain plug
(M12 x 1,5), 25 Nm
1000/6 Sealing ring (A12 x 18), renew 1600 Sealing ring (A 22 x 29), renew 1700 Retarder oil drain plug
(M 22 x 1,5), 66 Nm
1800 Sealing ring (A 30 x 36), renew 1900 Oil filler/check plug
(M 30 x 1,5), 150 Nm
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.2/1 1900 1800 1000/2 1000/6 1000/5 1000/1 1700 1600 16008
Maintenance
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(Continue)
NoticeFor satisfactory retarder operation, it is important to adhere to the specified service filling (see table below) and to use only oils specified in the operating specifications (see Annex) for operating the retarder in the relevant application.
The retarder oil temperature must be higher than 60 oC (operating temperature) for the oil to be drained.
Caution!
While the oil is being changed, make sure that no constant-air pressure is acting in the retarder. The retarder and the ignition must have been switched off!
Heat exchanger
Service filling
After complete
taking apart and
cle-aning, as well as
emptied heat
exchanger
After exchange of
heat exchanger
Stainless-steel
heat exchanger
(L+R)
4,5 l
5,8 l
6,5 l
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.2/2
Maintenance
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(Continue)
Job scope1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and switch it off after approx. 5 sec.
Repeat this procedure twice.
Switch off the retarder and ignition and wait 5 minutes (control function).
Caution! Risk of injury!
The oil filler/check plug is heated up (oil temperature)! 2. Push an oil collecting pan under retarder.
3. Screw out the oil check plug (1900) and remove sealing ring (1800).
Caution! Risk of injury!
The retarder oil drain plug is heated up (oil temperature)!
4. Screw out the retarder oil drain plug (1700) and remove sealing ring (1600) and drain oil.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.2/3
Maintenance
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(Continue)
5. Screw out the leakage oil drain plug (1000/1) and remove sealing ring (1000/2) and drain the accumulated oil.
Notice
If a higher quantity of oil (from approx. 0,2 l) is flowing out after opening the
leakage oil drain plug (1000/1), you must enforce a control of the oil level again after driving with the vehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the two radial shaft sealing rings at the Retarder and renew those, if necessary
(see Section 6.8, 6.9, 7.9, 7.10).
If it is necessary to drain the cooling water during the service, remove and empty the retarder on oil side completely (see Section 8.1, 8.2).
This process also must be enforced with strongly spent oil.
6. Screw the oil drain plugs (1700 and 1000/1) tight with new sealing rings (1600 and 1000/2). Retarder oil drain plug (1700): Tightening torque 66 Nm
Leakage oil drain plug (1000/1): Tightening torque 13 Nm
7. Fill in slowly,in the hole of the oil filler/check plug (1900), the quantity of oil specified (see page 3.2/2) in accordance with the operating specifications (see Annex).
8. Screw the oil filler/check plug (1900) tight with a new sealing ring (1800). Tightening torque: 150 Nm 9. Check the oil level (see Section 3.3).
The oil change intervals and operating specifications have to be taken from the annex!
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.2/4
Maintenance
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3.2 Oil Change
(Continue)
Illustration oil change R 120 with aluminium heat exchanger
1000/1 Leakage oil drain plug (M 10 x 1), 13 Nm
1000/2 Sealing ring (A 10 x 13,5), renew 1000/3 Heat exchanger oil drain plug
(M 12 x 1,5), 25 Nm
1000/4 Sealing ring (A 12 x 15,5), renew 1600 Sealing ring (A 22 x 29), renew 1700 Retarder oil drain plug
(M 22 x 1,5), 66 Nm
1800 Sealing ring (A 30 x 36), renew 1900 Oil filler/check plug
(M 30 x 1,5), 150 Nm
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.2/5 1000/3 1000/4 1000/2 1000/1 1700 1600 1900 1800 16009
Maintenance
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(Continue)
NoticeFor satisfactory retarder operation, it is important to adhere to the specified service filling (see table below) and to use only oils specified in the operating specifications (see Annex) for operating the retarder in the relevant application.
The retarder oil temperature must be higher than 60 oC (operating temperature) for the oil to be drained.
Caution!
While the oil is being changed, make sure that no constant-air pressure is acting in the retarder. The retarder and the ignition must have been switched off!
Heat exchanger
Service filling
New filling
Aluminium heat exchanger (AKG)
5,5 l
6,0 l
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.2/6
Maintenance
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(Continue)
Job scope1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and switch it off after approx. 5 sec.
Repeat this procedure twice.
Switch off the retarder and ignition and wait 5 minutes (control function).
Caution! Risk of injury!
The oil filler/check plug is heated up (oil temperature)! 2. Push an oil collecting pan under retarder.
3. Screw out the oil filler/check plug (1900) and remove sealing ring (1800).
Caution! Risk of injury!
The retarder oil drain plug is heated up (oil temperature)!
4. Screw out the retarder oil drain plug (1700) and the heat exchanger oil drain plug (1000/3) and remove the sealing rings (1600 and 1000/4) and drain oil.
5. Screw out the leakage oil drain plug (1000/1) and drain the accumulated oil.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.2/7
Maintenance
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(Continue)
NoticeIf a higher quantity of oil (from approx. 0,2 l) is flowing out after opening the
leakage oil drain plug (1000/1), you must enforce a control of the oil level again after driving with the vehicle of approx. 1000km. If with this control a higher quantity of oil is existing again, check the two radial shaft sealing rings at the Retarder and renew those, if necessary
(see Section 6.8, 6.9, 7.9, 7.10).
6. Screw the oil drain plugs (1700, 1000/3 and 1000/1) tight with new sealing rings (1600, 1000/2 and 1000/4).
Retarder oil drain plug (1700): Tightening torque 66 Nm Heat exchanger oil drain plug (1000/3): Tightening torque 25 Nm Leakage oil drain plug (1000/1): Tightening torque 13 Nm
7. Fill in slowly,in the hole of the oil filler/check plug (1900), the quantity of oil specified (see page 3.2/2) in accordance with the operating specifications (see Annex).
8. Screw the oil filler/check plug (1900) tight with a new sealing ring (1800). Tightening torque: 150 Nm 9. Check the oil level (see Section 3.3).
The oil change intervals and operating specifications have to be taken from the annex!
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.2/8
Maintenance
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3.3 Checking Oil Level
Illustration checking oil level
Notice
The oil change intervals and operating specifications have to be taken from the annex.
1800 Sealing ring (A 30 x 36), renew 1900 Oil filler/check plug (M 30 x 1,5),
150 Nm
Notice
The illustration shows a retarder 120 with stainless-steel heat exchanger. A version with aluminium heat exchanger is possible.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.3/1
1900
1800
Maintenance
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3.3 Checking Oil Level
(Continue)
Notice
For satisfactory retarder operation, it is important to use only oils specified in the operating specifications (see Annex) for operating the retarder in the relevant application.
Service filling
The service filling for the complete retarder system depends on the version of the mounted heat exchanger.
For relevant application approved oils
Use only approved oils specified in the operating specifications (see Annex).
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.3/2
Maintenance
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3.3 Checking Oil Level
(Continue)
Notice
For the oil level check, the temperature of the retarder oil must be higher than 60°C (operating temperature).
The oil level check must be carried out with the vehicle in a horizontal position. Difference between min. and max. mark on oil filler/check plug is approx. 0,5 l.
Job scope
1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and switch it off after approx. 5 sec.
Repeat this procedure twice.
Caution!
While the oil level is being checked, make sure that retarder and ignition system must have been switched off!
Risk of injury exists at nonobservance, by hot leaving oil when screw out oil filler/check plug!
2. Switch off the retarder and wait 5 minutes (control function).
Caution! Risk of injury!
The oil filler/check plug (1900) is heated up (oil temperature)!
3. Screw out the oil filler/check plug (1900) and remove sealing ring (1800). Wipe off oil of the oil filler/check plug.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.3/3
Maintenance
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3.3 Checking Oil Level
(Continue)
4. Position oil filler/check plug (1900) plane at the thread.
Do not screw in the oil filler/check plug!
5. Pull out again the oil filler/check plug (1900).
Oil level is correct bewteen min. and max. mark of the oil filler/check plug. 6. Top up slowly any lacking oil through the hole for the oil filler/check plug.
7. Screw the oil filler/check plug (1900) tight with new sealing ring (1800). Tightening torque 150 Nm
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.3/4
Max Min 1900
Maintenance
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3.4 Cleaning Line Filter
(Optional Extra)
Illustration line filter
12000 Complete line filter 12000/1 Pressure spring 12000/2 Intermediate plate 12000/3 Cover 12000/4 Holding plate 12000/5 Pressure spring 12000/6 Filter housing 12111 Filter insert 12112 O-ring (36,2 x 3), renew, coat with silicone-free and non-corossive grease for installation
Lubricants
O-ring Silicone-free and non-corossive grease 12000/1 12111 12000/2 12000/5 12112 12000/3 12000/4 12000/6 12000 16012
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.4/1
Maintenance
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3.4 Cleaning Line Filter
(Continue)
Notice
Vehicle specific can be installed a line filter within the constant-air pressure line between air tank for auxiliary equipment and the proportional valve of the retarder control system.
The line filter is designed and in the way installed, to ensure an optimum air flow to the proportional valve also when filter insert is badly soiled. In this case the compressed air will not be cleaned anymore.
Job scope
Caution! Risk of injury!
Observe fall in pressure in the compressed air circuit for auxiliary equipment (e.g. air springs)! 1. Disconnect constant-air pressure line at the line filter for air tank of auxiliary equipment . 2. Press in the cover (12000/3) and pull out the holding plate (12000/4).
3. Pull out of the filter housing (12000/6) the cover (12000/3) with O-ring (12112),
the pressure spring (12000/5), the intermediate plate (12000/2), the filter insert (12111) and the pressure spring (12000/1) .
4. Blow out the filter insert (12111) with compressed air from inside out. Check filter insert for damages and renew if necessary.
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Maintenance
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3.4 Cleaning Line Filter
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5. Insert the pressure spring (12000/1), the filter insert (12111), the intermediate plate (12000/2) and the pressure spring (12000/5) in filter housing (12000/6).
6. Coat new O-ring (12112) with silicone-free and non-corossive grease. Pull the new O-ring on to the cover (12000/3).
7. Press in the cover (12000/3) into the filter housing (12000/6) and put in the holding plate (12000/4).
Notice
If complete filter (12000) has to be removed, observe the correct installing position.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 3.4/3
Diagnosis /
Troubleshooting
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Diagnosis / Troubleshooting
4.1
Troubleshooting Diagram ...4.1/1
Electrical Connections Diagram
...4.1/2
4.2
Troubleshooting and Remedies ...4.2/1
4.3
Checking Pump Pressure...4.3/1
4.4
Checking Control System ...4.4/1
4.5
Operational Check...4.5/1
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Diagnosis /
Troubleshooting
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4.1 Troubleshooting Diagram
Illustration troubleshooting diagram
Notice
Before starting troubleshooting the oil level of the retarder must be checked and corrected (see chapter 3.3 ‘‘Checking oil level‘‘).
It is important that the specific service filling is kept for a trouble-free operation of the retarder (see chapter 3.2 ‘‘Oil change‘‘ and annex).
Renew casing ventilation
Check oil level of retarder OK NOK YES
NO
Water in the oil? (emulsion) Check casing ventilation (Chapter 6.2) NOK OK YES NO Water in the oil?
(emulsion)
OK NOK Check oil level of
retarder
YES NO Water in the oil?
(emulsion) NO YES
Water in the oil? (emulsion) OK NOK Check py (static) (Chapterl 4.4) OK NOK Check voltage of proportional valve (Chapter 4.4) OK NOK Check compressed--air supply (Chapter 4.4) Mechanical fault of proportional valve Complaint R 120 Digiprop Check p (dynamic) (Kapitel 4.3) Contact VOITH
Activate flash code and read out trouble code (Chapter 4.2) Temperature limit! Permanent lighting flashes OK NOK Check operation
(by braking with retarder nominal engine speed,
if possible Check cooling system: -coolant level -thermostat -coolant pump -radiator fan -radiator grill for dirtiness Retarder: Check Temp.-Sens. (oil/water)
Driver instruction!
Clear faults and delete fault memory
(Chapter 4.2) OK NOK Contact VOITH OK NOK Check vehicle compressed-air supply Contact vehicle manufacturer Contact VOITH OK NOK Check control unit
(Chapter 4.4) Check heat exchanger see chapter 6.4 Check heat exchanger see chapter 6.4 Contact VOITH Contact VOITH Retarder pilot light No respectively too insufficient retarder braking effect Oil leak by ventilation
Oil leak input side or output side
Empty chamber of return of leakage oil (at heat exchanger)
(Chapter 3.3) If the retarder is
still leaking, or the chamber of leakage oil is filled again with oil after
1000 km, renew radial shaft
seal
Correct oil level of retarder (*)
Correct oil level of retarder Check non-return valve in cover of casing ventilation (Chapter 6.3) NOK OK Contact VOITH Renew non-return valve FD 1601
If you get oil leakage after a trail run again: continue at ´´Checking casing ventilation´´
*
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Diagnosis /
Troubleshooting
cbtd 98-01 53.2659.104.1 Troubleshooting Diagram
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Electrical Diagram Version 1
Electrical Diagram Version 2
Input / (0...20mA ) `INA-I ´
Stop light relay Stop light relay
Speedometer signal Speedometer signal
Prop valve `+` Output / low side 1 `LS 1`
Output / high side `HS 2` Output / high side 1 `HS 1`
Prop valve `-`
T 30 (Battery) T 30 (Battery)
T 31 (Ground)
T 31 (Ground) Retarder Stage Switch`+`
ISO L ISO K Position 5 Position 4 Position 3 Position 2 Position 1 Position 5 Position 4 Position 3 Position 2 Position 1 CAN-low CAN-Ground CAN-high T 15 (Ignition lock) T 15 (Ignition lock) Changeover valve `-` Changeover valve `+` Water temp.`-` Water temp.`+` Oil temp.`+` Oil temp.`-` Prop valve `+` Prop valve `-` Changeover valve `-` Changeover valve `+` Water temp.`-` Water temp.`+` Oil temp.`+` Oil temp.`-` ABS ABS blue white white weiß white black pink pink blue/white blue/white brown/white orange/white orange/white orange orange orange orange yellow/green yellow/green grey/black red/white grey blue purple 3 2 3 12 11 10 15 14 13 18 17 16 2 1 6 5 4 9 8 7 7 3 2 1 6 5 4 9 8 1 6 5 4 9 8 7 12 12pins X3. 9pins X2. 18pins X1. Digiprop 11 10 grey brown brown beige beige red red grey grey pink blue black/white black/white yellow/green
Input / p.-down / PWM-in `DID 4 ` Input / (m 0...5V ) `INA-U ` Input / pull-down `DID 3 ` Input / pull-up `DIU 1` Input / pull-up `DIU 2` Input / pull-down `DID 1` Input / pull-down `DID 2`
Retarder pilot light Retarder pilot light
purple purple
9 584 3 2 7 61112101314 1
Connecting plug 14 ins "Additional Functions" "ISO Interface"
Connecting plug 4 pins
7 6 5 3 2 8 4 3124
Retarder Stage Switch`+` "Retarder Stage Switch" Connecting plug 8 pins
+ + + Lead Retarder Lead E-Box 3 4 2 1 Pin 16014e
Input / (0...20mA ) `INA-I ´
Stop light relay Stop light relay
Speedometer signal Speedometer signal
Prop valve `+` Output / low side 1 `LS 1`
Output / high side `HS 2` Output / high side 1 `HS 1`
Prop valve `-`
T 30 (Battery) T 30 (Battery)
T 31 (Ground)
T 31 (Ground) Retarder Stage Switch`+`
ISO L ISO K Position 5 Position 4 Position 3 Position 2 Position 1 Position 5 Position 4 Position 3 Position 2 Position 1 CAN-low CAN-Ground CAN-high T 15 (Ignition lock) T 15 (Ignition lock) Changeover valve `-` Changeover valve `+` Water temp.`-` Water temp.`+` Oil temp.`+` Oil temp.`-` Prop valve `+` Prop valve `-` Changeover valve `-` Changeover valve `+` Water temp.`-` Water temp.`+` Oil temp.`+` Oil temp.`-` ABS ABS blue white white weiß white black pink pink blue/white blue/white brown/white orange/white orange/white orange orange orange orange yellow/green yellow/green grey/black red/white grey blue purple 3 2 3 12 11 10 15 14 13 18 17 16 2 1 6 5 4 9 8 7 7 3 2 1 6 5 4 9 8 1 6 5 4 9 8 7 12 12pins X3. 9pins X2. 18pins X1. Digiprop 11 10 grey brown brown beige beige red red grey grey pink blue black/white black/white yellow/green
Input / p.-down / PWM-in `DID 4 ` Input / (m 0...5V ) `INA-U ` Input / pull-down `DID 3 ` Input / pull-up `DIU 1` Input / pull-up `DIU 2` Input / pull-down `DID 1` Input / pull-down `DID 2`
Retarder pilot light Retarder pilot light
purple purple
9 5 84 3 2 7 61112101314 1
Connecting plug 14 pins "Additional Functions" "ISO Interface" 7 6 5 3 2 8 4 3124
Retarder Stage Switch`+` "Retarder Stage Switch" Connecting plug 8 pins
+ + + Lead Retarder Lead E-Box 3 4 2 1 Pin 3 4 2 1 Pin 16015e
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
Troubleshooting and remedies Check requirements
• Battery voltage 18 - 32 V
• Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found satisfactory.
• Fuse for retarder control unit checked and found satisfactory. • Compressed-air pressure 6 - 11 bar
l For check with the multimeter, pin 15 (plug X1) on the control unit (2)
must be connected to pin 15 ground (terminal 31), at pin 7 (plug X1) must be connected terminal 15 and at pin 13 (terminal X1) terminal 30.
Notice
Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary (see Section 3.3 „Checking Oil Level“).
For trouble-free retarder operation, it is important that the filling quantity specified is adhered to (see table, Section 3.2, page 3.2/2).
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Notice
The retarder pilot light (arrow) has additionally the function of a fault code:
- slight fault
Permanent lighting in position 0 - 5 of retarder stage switch, braking is still possible to limited extent.
- serious fault
Permanent lighting in position 0 - 5 of retarder stage switch, braking no longer possible - retarder is switched off.
Notice
If the ignition is switched off and on, the retarder is in operation again and the retarder pilot light goes off. If a serious fault remains present or reoccurs, the retarder switches off again and the retarder pilot light comes on permanently in position 0 to 5 of the retarder stage switch.
R
16016
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Diagnosis /
Troubleshooting
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Connector arrangement and pin assignment
Notice: All plugs illustrated from plug-in side (i.e. leads at back).
Plug X1 Control unit
1 Not in use 2 Not in use 3 Not in use
4 Retarder stage switch, position 3 -(or) 5 Retarder stage switch, position 2 -(bl) 6 Retarder stage switch, position 1 -(pi) 7 Terminal 15 (rd)
8 Retarder stage switch, position 5 -(gr) 9 Retarder stage switch, position 4 -(wh) 10 Retarder stage switch + (vi)
11 ISO-interface, L-lead (or/wh) 12 ISO-interface, K-lead (bl/wh) 13 Terminal 30 (bl)
14 Not in use 15 Terminal 31 (br)
16 Output / high side 2 „HS2“ (bl/wh) 17 Output / low side 1 „LS1“ (ye/gr) 18 Output / high side 1 „HS1“ (be)
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
(Continue)
Plug X2 Control unit
1 Not operational/usable for applications (or) 2 Proportional valve - (gr)
3 Proportional valve + (pi)
4 Cooling water temperature pick-up - (bl) 5 Cooling water temperature pick-up + (ye/gr) 6 Not operational/ground (be)
7 Not in use
8 Oil temperature pick-up - (wh) 9 Oil temperature pick-up + (vi)
Plug X3 Control unit
1 Input / pull up „DIU 1“ (wh) 2 Speedometer signal (bl) 3 ABS-Signal (bl/wh)
4 Input / pull down „DID 2“ (br/wh) 5 Input / pull down „DID 1“ (bl/wh) 6 Input / pull up „DIU 2“ (pi) 7 Input / (0...5V) „INA-U“ (gr/bl) 8 Retarder pilot light (ye/gr) 9 Input / pull down „DID 3“ (or/wh) 10 Input / (0...20 mA) „INA-I“ (rd/wh) 11 Stop light relay (or)
12 Input / pull down / PWM-in „DID4“ (gr) / engine-speed signal
16018 1 4 7 2 5 8 3 6 9 16019 1 4 7 10 2 5 8 11 3 6 9 12
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
(Continue)
Extra operations plug
1 Retarder stage switch + (vi) 2 Input / pull down „DID 1“ (bl/wh) 3 Input / pull down „DID 2“ (br/wh) 4 Input / pull down „DID 3“ (or/wh) 5 Input / pull down / PWM -in „DID 4“ (gr) 6 Input / pull up „DIU 1“ (wh)
7 Input / pull up „DIU 2“ (pi) 8 Input / (0...5V) „INA-U“ (gr/bl) 9 Input / (0...20 mA) „INA-I“ (rd/wh) 10 Output / high side 1 „HS1“ (be) 11 Output / high side 2 „HS2“ (bl/wh) 12 Output / low side 1 „LS1“ (ye/gr) 13 Terminal 15 (rd) 14 Terminal 31 (br) ISO-Interface plug 1 K-lead (bl/wh) 2 K-lead (or/wh) 3 Terminal 15 (rd) 4 Terminal 31 (br) 2 1 4 3 6 5 8 7 10 9 12 11 14 13 16020 2 1 4 3 16021
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Cooling water temperature pick-up plug Oil temperature pick-up plug
Proportional valve plug
1 Proportional valve + (pi) 2 Proportional valve + (gr) 3 Not operational (or) 4 Not operational (be)
16022
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Retarder stage switch plug
1 Not in use 2 Position 5 - (gr) 3 Position 4 - (wh)
4 Retarder stage switch + (vi) 5 Position 3 - (or) 6 Position 2 - (bl) 7 Position 1 - (pi) 8 Bridge to pin 4 16024 1 2 3 4 5 6 7 8
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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A. With fault code
Special tool
Commercially available tool
Notice
The blinking code of the retarder pilot light (as of Digiprop-Version 1.0) can be used to obtain a read-out from the fault memory.
Furthermore a diagnosis with the PC „DigiDia“ software is possible. In this case please contact VOITH TURBO or a responsible contracting party.
Multimeter recommended: Fluke 87 53.8224.10
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Fault memory read-out via retarder pilot light blinking code
Notice
If several faults have been stored in the memory, they are indicated in the sequence of their occurance, but always only one fault per triggering.
Exception:
The fault „Coding fault“ is not held in the memory but is indicated via the blinking code.
The blinking code can be read-out of the control unit with service cable or retarder stage switch.
Fault memory read-out with service cable (Digiprop-Version 0.2)
Requirements
- Retarder stage switch in position 0 - Vehicle in parking position, Ignition ON
1. Service interface L-lead connected to ground for ≥ 2 s. For this purpose, press push-button of service cable switch.
2. First fault as blinking code output.
3. Repeat from step 2 and 3 for more blinking code outputs.
Meaning
- long blinking signals (2 sec.) tens unit. - short blinking signals (0,5 sec.) single unit.
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R
Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Digiprop-Version 1.0
The blinking code can be triggered analogous to V 0.2, the conditions are the same. Additionally the blinking code can be triggered with the help of the retarder stage switch during the service function: 1. Shift RSS-Position 0
2. Shift RSS-Position 1 ( ≥ 2 Seconds) 3. Shift RSS-Position 0
4. Blinking code of first fault is indicated
5. Repeat from step 2 to 3 for more blinking code outputs
Addition for versions as of V 1.1
There is a break of 3 seconds before and after each blinking code output, during this time the retarder pilot light is switched off.
Display example for fault code 23:
The number of tens will be indicated first as long ON-time: each 2 seconds The number of singles afterwards will be indicated as short ON-time: each 0,5 seconds Breaks between each ON-time: each 1 second
If a relevant fault is indicated, the retarder pilot light is ON before triggering of the blinking code, the retarder pilot light switches to permanent lighting again after the blinking code.
If there is only one fault in the memory, the retarder pilot light stays OFF after the output.
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/10
16025
Display example: Fault code 23 E Retarder stage swit ch on A Retarder stage swit ch off
Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Delete fault memory
No marginal conditions in accordance with read-out of fault memory. 1. Ignition: OFF
2. Service interface L-lead connected to ground. For this purpose, press push-button of service cable switch.
3. Ignition: ON
4. Disconnect after ≥ 2 seconds the L-lead of ground.
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Notice
Meaning of entries in „Measurement/test connection“ column: X 1/15 W X 3/11 Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3
Table 1:
1) X 1/15 = ground control unit
2) Only, if no fault is recognizable after a complete check of the periphery: change control unit.
Fault Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connection1 ) Result/ Set point Cause/ Remedy 2) Code (Check)
01 Stop light relay/ Short circuit to ground
slight 1 s - Ignition: OFF - Pull plug X3 out of
control unit
X 3/11 W X 1/15 Relay is installed: 250 - 350 W
Check lead, plugs and relay
or consumers
02 LS 1 output Short circuit to battery
slight 400 ms - Ignition: OFF - Pull plug X1 out of
control unit - Disconnect plug for extra operation
(e.g. lamp or relay) - Ignition: ON
X 1/17 V X 1/15 0 V Check lead, plugs and relay
or consumers
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Table 2:
Fault
Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connection Result/ Set point Cause/ Remedy Code (Check) 03 HS 1 output Short circuit
slight 1 s - Ignition: OFF - Pull plug X1 out of
control unit X 1/18 W X 1/ 15 With relay installed: 250 - 350 W
Check lead, plugs and relay
or consumers
04 HS 2 output
Short circuit
slight 1 s - Ignition: OFF - Pull plug X1 out of
control unit
X 1/16 W X 1/15 With relay installed: 250 - 350 W
Check lead, plugs and relay
or consumers
05 Terminal 15
Undervoltage
serious 60 s - Ignition: OFF - Pull plug X1 out of
control unit - Ignition: ON
X 1/7 V X 1/15 ≥ 17,5 V Check lead, plugs and fuses
06 Terminal 15
Overvoltage
serious 10 s - Ignition: OFF - Pull plug X1 out of
control unit - Ignition: ON - Start engine (idle speed) X 1/7 V X 1/15 ≤ 32,5 V Checking electrical installation of vehicle (see manufacturer instructions)
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Table 3:
* Fault is in serious class, if temperature sensor for oil and water are defective at the same time.
Fault
Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connec-tion Result/ Set point Cause/ Remedy Code (Check) 08 09 Water tempera-ture sensor Discontinuity / Short circuit to battery serious/ slight * 1 s - Ignition: OFF - Pull plug X2 out of
control unit X 2/5 W X 2/4 20°C ± 10 °C = 1039 - 1117W 60°C ± 10 °C = 1099 - 1271W 80°C ± 10 °C = 1271 - 1347W Notice: The measuring in one temperature range normally is sufficient.
Check lead and sensor
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Diagnosis /
Troubleshooting
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Table 4:
* Fault is in serious class, if temperature sensor for oil and water are defective at the same time.
Fault
Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connec-tion Result/ Set point Cause/ Remedy Code (Check) 11 12 Oil temperature sensor Discontinuity / Short circuit to battery serious/ slight * 1 s - Ignition: OFF - Pull plug X2 out of
control unit X 2/9 W X 2/8 20°C ± 10 °C = 1039 - 1117W 60°C ± 10 °C = 1099 - 1271W 80°C ± 10 °C = 1271 - 1347W Notice: The measuring in one temperature range normally is sufficient.
Check lead and sensor
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Table 5:
Fault
Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connection Result/ Set point Cause/ Remedy Code (Check) 13 1 Retarder stage switch Undefined switch state serious 100 ms - Ignition: ON - Retarder stage switch: Position 0 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 ≥ 17,5 V 0 V 0 V 0 V 0 V 0 V
Check lead, plug and retarder stage switch
13 2 - Ignition: ON - Retarder stage switch: Position 1 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 ≥ 17,5 V ≥ 17,5 V 0 V 0 V 0 V 0 V
Check lead, plug and retarder stage switch
13 3 - Ignition: ON - Retarder stage switch: Position 2 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V 0 V 0 V 0 V
Check lead, plug and retarder stage switch
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Table 6:
Fault
Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connection Result/ Set point Cause/ Remedy Code (Check) 13 4 - Ignition: ON - Retarder stage switch: Position 3 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V 0 V 0 V
Check lead, plug and retarder stage switch
13 5 - Ignition: ON - Retarder stage switch: Position 4 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V 0 V
Check lead, plug and retarder stage switch
13 6 - Ignition: ON - Retarder stage switch: Position 5 X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15 ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V
Check lead, plug and retarder stage switch
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Diagnosis /
Troubleshooting
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Table 7:
Fault
Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connection Result/ Set point Cause/ Remedy Code (Check) 14 Retarder stage switch Short circuit to battery
serious 10 s - Ignition: OFF - Pull plug X1 out of
control unit - Ignition: ON - Retarder stage switch:
Position 0
X 1/10 V X 1/15 0 V Check lead and plug
15 Retarder stage switch
Short circuit to battery
serious 1 s - Ignition: OFF - Pull plug X1 out of
control unit - Retarder stage switch: Position 5 X 1/10 W X 1/15 Resistor infinite Single check of stages for short circuit
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Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Table 8:
Fault
Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connec-tion Result/ Set point Cause/ Remedy Code (Check) 16 Speedometer signal Discontinuity
serious 2 s - Ignition: ON X 3/2 V X 1/15 ≤==1 V Check lead and speedometer
18 Speedometer si-gnal
Short circuit to battery
serious 2 s - Ignition: OFF - Pull plug X3 out of
control unit - Ignition: ON
X 3/2 V X 1/15 ≤==9 V Check lead and speedometer
19 ABS
Short circuit to ground
serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ 3,5 V Check lead, relay and ABS-con-trol unit
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/19
Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Table 9:
Fault
Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connec-tion Result/ Set point Cause/ Remedy Code (Check)
21 ABS-Signal undefined serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ 16,5 V Check lead, relay and ABS-control unit
22 Internal fault ABS-current path
serious 1 s - - − Replace control
unit
23 Proportional valve Fault No. 1:
Short circuit to battery
serious 1 s - Ignition: OFF - Pull plug X2 out of
control unit - Ignition: ON
X 2/3 V X 1/15 ≤==10 V Check lead
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/20
Diagnosis /
Troubleshooting
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Table 10:
Fault
Fault text Fault
class
Trigger time Requirement / Operation Measurement/ test connec-tion Result/ Set point Cause/ Remedy Code (Check) 24 1 Proportional valve Fault No. 2:
- Short circuit proportional valve magnetic
- Short circuit connection lead proportional valve - Discontinuity nal valve magnetic
Valve magnetic - Discontinuity tion lead proportional valve
- Short circuit to ground at proportional valve - Prop.- and shift valve
interchanged
serious 1 s - Ignition: ON - Pull plug X2 out of control unit
X 2/2 W X 2/3 18-25 W Check lead and proportional valve (valve block)
24 2 - Ignition: OFF
- Pull plug X2 out of control unit
X 2/3 W X 1/15 Resistor infinite
Check lead and proportional valve (valve block)
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/21
Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Table 11:
Fault
Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connec-tion Result/ Set point Cause/ Remedy Code (Check) 24 3 - Ignition: OFF
- Pull plug X2 out of control unit
X 2/2 W X 1/15 Resistor infinite
Check lead and proportional valve (valve block)
25 Proportional valve Fault No. 3:
defective control unit
serious 10 s Replace
control unit
27 Proportional valve Fault No. 5:
defective control unit
serious 2 s Replace
control unit
28 Terminal 30
Undervoltage
serious 60 s - Ignition: OFF - Pull plug X1 out of
control unit - Ignition: ON
X 1/13 V X 1/15 ≥ 17,5 V Check lead, plug and fuse
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/22
Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
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Table 12:
Fault
Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connec-tion Result/ Set point Cause/ Remedy Code (Check)
29 Fault control unit serious 180 ms Replace
control unit
31 Control unit: Coding fault
serious 100 ms Provide new
parameters for control unit
32 Retarder pilot light: Discontinuity /
Short circuit to ground
serious 3 s - Ignition: OFF - Pull plug X3 out of
control unit - Ignition: ON
X 3/8 V X 1/15 ≥ 17,5 V Check lead, retarder pilot light and fuse
33 Retarder pilot light: Short circuit to battery
serious 3 s - Ignition: ON - Retarder stage
switch: Position 1
X 3/8 V X 1/15 ≤==2 V Check lead and retarder pilot light
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/23
Diagnosis /
Troubleshooting
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4.2 Troubleshooting and Remedies
(Continue)
Table 13:
Fault
Fault text Fault class
Trigger time Requirement / Operation Measurement/ test connec-tion Result/ Set point Cause/ Remedy Code (Check)
35 Fault control unit serious 500 ms / 123 s Replace
control unit
37 Fault pedal operation slight 100 ms / 1 s Check installati-on relating to OEM- respectively VOITH-instructions
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 4.2/24
