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Gearbox-Retarder-System GO170 - GO210 with R 115 E

Aftersales Service Manual Gearbox-Retarder-System cbtd 2000-01 53.2687.10

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1 Preface ...1/1

2 General...2/1

2.1 Illustration Gearbox-Retarder-System ... 2.1/1

2.2 Function and Operation Scheme Gearbox ... 2.2/1

2.3 Function and Operation Scheme Retarder ... 2.3/1

2.4 Gearbox Identification... 2.4/1

2.5 Retarder Identification... 2.5/1

2.6 Retarder Control-Unit Identification ... 2.6/1

3 Maintenance...3/1

3.1 Maintenance Work / Oil Change Intervals ... 3.1/1

3.2 Checking Oil Level of Gearbox ... 3.2/1

3.3 Checking Oil Level of Retarder... 3.3/1

3.4 Oil Change of Gearbox ... 3.4/1

3.5 Oil Change of Retarder... 3.5/1

4 Diagnosis / Troubleshooting Gearbox ...4/1

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Aftersales Service Manual Gearbox-Retarder-System

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5 Diagnosis / Troubleshooting Retarder...5/1

5.1 Troubleshooting Diagram A to C ... 5.1/1

Electrical Connectrions Diagram ... 5.1/6

5.2 Troubleshooting and Remedies... 5.2/1

5.3 Illustration Control System... 5.3/1

5.4 Checking Supply-Air Pressure... 5.4/1

5.5 Checking Constant-Air Pressure (p

_y

)... 5.5/1

5.6 Checking Control Current of Proportional Valve... 5.6/1

5.7 Checking Temperature Adaption ... 5.7/1

5.8 Checking Pressure Sensor ... 5.8/1

5.9 Checking Pump Pressure ... 5.9/1

5.10 Table of Measurements ... 5.10/1

5.11 Operational Check ... 5.11/1

6 Removing, Installing Gearbox ...6/1

6.1 Removing, Installing Gearbox... 6.1/1

7 Removing, Installing Retarder ...7/1

7.1 Removing, Installing Retarder ... 7.1/1

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8 Repair Gearbox ...8/1

8.1 Overall Illustration of Main Components... 8.1/1

8.2 Removing, Installing Front Housing Cover, Cover Countershaft and

Closing Cover 5./6.-Gear ... 8.2/1

8.3 Removing, Installing Shift ... 8.3/1

8.4 Removing, Installing Breather... 8.4/1

8.5 Removing, Installing Sensor/Switch at Gearbox... 8.5/1

8.6 Removing, Installing Clutch Servo

and Adjusting Wear Indicator ... 8.6/1

8.7 Removing, Installing Output Flange

Renewing Radial Shaft Sealing Ring... 8.7/1

9 Repair Retarder...9/1

9.1 Overall Illustration of Main Components... 9.1/1

9.2 Removing, Checking and Installing Casing Ventlation ... 9.2/1

9.3 Removing, Cleaning and Installing Silencer ... 9.3/1

9.4 Removing, Installing Water Neck... 9.4/1

9.5 Removing, Checking, Installing Heat Exchanger... 9.5/1

9.6 Removing, Installing Oil Tank Cover ... 9.6/1

A Top Oil Tank Cover ... 9.6/1

B Bottom Oil Tank Cover ... 9.6/2

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Aftersales Service Manual Gearbox-Retarder-System

cbtd 2000-01 53.2687.10

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10 Control Parts Retarder ...10/1

10.1 Removing, Installing Proportional Valve ... 10.1/1

10.2 Removing, Installing Oil Temperature Pick-Up... 10.2/1

10.3 Removing, Installing Cooling-Water Temperature Pick-up... 10.3/1

10.4 Removing, Installing Pressure Sensor... 10.4/1

11 Annex ...11/1

Data Sheet

Conversion Table

Operating Specifications: - Oil Specifications Gearbox

- Oil Specifications Retarder

- Cooling Water Quality

Spare Parts Lists

Other Information

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The present service manual serves as training material for the training. The information and instructions which are given to you furthermore provide the basis for appropriate and professional maintenance and repair at the gearbox-retarder-system.

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 situation for persons, at reduc-tion of quality of workmanship and the possibility of damage to property.

Note

is associated for general notices for a better handling during maintenance of the gearbox-retarder-system.

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Caution!

• The switched-on retarder will not secure the parked vehicle!

• During a failure of the Retarders, or while the temperature-adaptation is effective, the vehicle-speed must be settled by using the service-brake and the lowest possible gear is in use (increase of the engine-speed). This vehicle condition must be held as long as the retarder again is available with its full performance.

• Unauthorized changes at the gearbox-retarder-system as well as the use of spare parts, accessories, attachments and special-productions, not tested and released from Voith, can influence the security of the entire vehicle negatively. No liability takes place for damages resulting from it

• The gearbox-retarder-system is built after the state-of -the-art technology and the recognized safety-related rules. Nevertheless dangers and damages can originate during improper use, maintenance and repair.

• We will take on no liability for injuries and/or damages, that originate through non-observance of the security-hints of the service manual or through injuries of the diligence-duty with the handling, at the service, with the care and maintenance or repair of the gearbox-retarder-system.

• Repair and maintenance work may only be enforced by qualified specialist-staff.

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Note

• The used position numbers used in this manual corresponds to the position numbers in the spare parts lists in chapter 9 „Annex“.

Exception:

Items or parts with one -, as well as two-digit position-numbers are no spare parts and not listed in the spare parts lists.

Items and parts from the retarder sector shown with an oblique number are no spare parts and therefore not listed in the spare parts lists.

• The terms of the parts for the gearbox correspond to the DaimlerChrysler-EPC-documentation. Example: 26 / 100 / 35

• Inevitably, it is impossible for us to warn at each position in these service manual 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 the gearbox-retarder-system uses his pro-fessional knowledge to make sure that his own safety is not endangered and that the retarder suf-fers no negative effects, in particular safety-wise, through the chosen working procedure. For these reasons, no liability can be assumed for damage incurred.

• The pertinent accident-prevention-regulation, other broadly rules of the security-technology and

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• With the contact with oils, greases and other chemical substances, the current safety regulations for these products are to be heeded!

•

Caution with the contact with hot fuels! Danger of burn and scald!

• Please read the hints in the operation manual to the safe, proper and economic operation of the retarder gearbox-retarder-system.

• Should you have any queries and queries about the working steps not described in this manual, please contact the responsible person in the appropriate organisation of the country involved or:

DaimlerChrysler AG Voith Turbo GmbH & Co. KG

Business unit gearbox Production group retarder

Sales Voithstraße 1

Hauptstraße 107 Post box 15 55

D-76568 Gaggenau D-74555 Crailsheim

Telephone 07225 / 61-65 56 Telephone 07951 / 32-401, -422

Fax 07225 / 61-65 51 Fax 07951 / 32-756

e-mail: e-mail:

[email protected] [email protected]

Copyright October 1999 - Voith Turbo / DaimlerChrysler

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2.1 Illustration Gearbox-Retarder-System...2.1/1

2.2 Function and Operation Scheme Gearbox...2.2/1

2.3 Function and Operation Scheme Retarder...2.3/1

2.4 Gearbox Identification ...2.4/1

2.5 Retarder Identification ...2.5/1

2.6 Retarder Control-Unit Identification ...2.6/1

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3URGXFWXQLWUHWDUGHU Illustration gearbox-retarder-system

26/100/116 Screw plug oil sieve M38x1,5

Inhex.-head, w.a.f. 17 (removing height 120 mm) 26/100/122 Oil filler plug gearbox

M24x1,5

Inhex.-head, w.a.f. 14 26/100/125 Oil drain plug gearbox

M24x1,5

Inhex.-head, w.a.f. 14 (bottom)

26/100/206 Speedometer sensor 26/250/047 Switch for starter lock *

26/250/068 Inductive sensor for overspeed protection *

26/400/083 Oil temperature pick-up gearbox *

26/400/089 Switch reversing light * 3500 Screw plug with sieve

M30x1,5 Inhex.-head, w.a.f. 17 3700 Proportional valve retarder control * = optional

3700

26/250/068

26/400/089

26/400/083

26/100/125

26/100/122

26/100/125

26/100/116

3500

26/100/206

26/250/047

M+P-07A-1708

3700

26/250/068

26/400/089

26/400/083

26/100/125

26/100/122

26/100/125

26/100/116

3500

26/100/206

26/250/047

M+P-07A-1708

Page 2.1/1

Remark:

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Illustration gearbox-retarder-system

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25/250/068 Clutch servo * 26/150/ Drive shaft

26/250/ Clutch wear indicator * 26/250/047 Switch for starter lock *

26/250/068 Inductive sensor for overspeed protection *

26/350/ Shift

26/400/089 Switch reversing light * 3700 Proportional valve retarder

control

4100 Oil filler screw retarder M30x1,5

Inhex.-head, w.a.f. 17 6400 Heat exchanger retarder * = option

3700

6400

4100

26/350/

26/400/089

26/250/068

26/250/

25/250/068

26/250/047

26/150/

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Illustration gearbox-retarder-system (Continue)

100/1 Retarder data plate 103 Screw plug

Measure point pump pressure M12x1,5

Inhex.-head, w.a.f. 6 107 Oil drain plug retarder

M24x1,5

Inhex.-head, w.a.f. 12 3500 Screw plug with sieve

M30x1,5

Inhex.-head, w.a.f. 17 3700 Proportional valve 4200 Oil drain plug oil tank

M24x1,5 Inhex.-head, w.a.f. 12 6400 Heat exchanger M+P-07A-1484

107 4200

3500

100/1

103 3700

6400

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Illustration gearbox-longitudinal section

1 1. Gear wheel 2 2. Gear wheel 3 3. Gear wheel 4 4. Gear wheel 5 5. Gear wheel 6 Reverse gear wheel 7 Countershaft 8 Oil pump 9 Drive shaft 10 Pilot bearing 11 Switch lever 12 Switch rails 13 Sliding sleeve 14 Synchromesh ring 15 Synchromesh body 16 Synchromesh cone 17 Mainshaft 18 Actuating lever 19 Fly wheel 19 18 17 16 18 15 14 18 13 12 18 11 10 9 5 7 4 3 2 1 6 8

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Illustration gearbox-longitudinal section 1 1. Gear wheel 2 2. Gear wheel 3 3. Gear wheel 4 4. Gear wheel 5 5. Gear wheel 6 Reverse gear wheel 7 Countershaft 8 Oil pump 9 Drive shaft 10 Pilot bearing 11 Switch lever 12 Switch rails 13 Sliding sleeve 14 Synchromesh ring 15 Synchromesh body 16 Synchromesh cone 17 Mainshaft 18 Actuating lever 19 Fly wheel 19 18 17 16 18 15 14 18 13 12 18 11 10 9 5 7 4 3 2 1 6 8

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Illustration gearbox-sectional view

7 Countershaft 11 Switch lever 12 Switch rails 17 Mainshaft 18 Actuating lever 20 Cross shift 21 Reverse gear lock 22 Actuating lever bolt 23 Gearbox housing 24 Loose wheel bearing 25 Shift link (option) 26 Shift ramifications 27 Cam follower 28 Reverse idler gear

11 12 20 21 22 23 18 17 24 25 26 27 7 28

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Illustration retarder

Note

The reference numbers indicated in section 2.3 are not identical with the reference numbers of the spare parts lists. 1 Heat exchanger complete

1/1 Retarder oil-cooling circuit 1/2 Gearbox oil-cooling circuit

2 Control unit

4 Connection Terminal 15 6 Fuse (8A)

8 Connection Ground 15 ABS-signal

16 Retarder stage switch 17 Retarder pilot light 18 Stop light relay

19 Cooling-water temperature pick-up 20 Oil temperature pick-up

21 Proportional valve 22 Ventilation 23 Casing ventilation

25 Air pressure line “A” constant-air pressure (p_y) 26 Air pressure line supply-air pressure (p_v) 36 Ventilation line “R” 41 Oil duct 42 Oil tank 43 Oil sump 44 Stator 46 Rotor 47 Speedometer signal 55 Oil-drain plugs

62 Pressure regulating valve 63 Check valve (inlet)

70 15 17 18 2 69 8 4 16 6 25 26 23 36 1 19 63 20 43 46 22 44 62 55 64 A R 21 42 4 Oil sump Supply-air pressure p_V Constant-air pressure py Coolant (water) FD914be Pump pressure p P 41 1/1 1/2 72 47

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Description of the function

The Voith retarder 115 E is a powerful, hydrodynamic continous brake of compact design. The retarder is driven and braking torque is transmitted by pinions in the gearbox.

The transmission ratio enables the retarder to achieve high braking torques right down to low r.p.m. ranges with the compactest configuration (small rotor/stator).

Retarder braking torque is sustained even when gear changes are made. The switched-on retarder will not secure the parked vehicle.

In the event of a retarder failure or when the temperature adaption is effective, the service brake must be used to regulate the vehicle speed.

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Action of the retarder R 115 E with Digiprop control system

A retarder stage switch (16) with 5 switch stages is used to operate the Voith retarder 115 E. In a special version, the retarder stage switch (16) in conjunction with ABS can be combined with a 3-stage treadle brake valve or a pressure switch unit for the service brake.

When the retarder stage switch (16) is shifted to position 1, the function „Constant Speed“ is activated. The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limit of the maximum possible braking torque.

If the retarder is switched-off (position 0), or if a braking stage is engaged (position 2 to 5), the memorized „Constant Speed“ is deleted. If the function „Constant Speed“ is re-activated the new present speed is memorized.

When shifting the retarder stage switch (16) into position 2 to 5, the retarder brakes in braking stage 1 to 4.

In the maximum position of the retarder stage switch (16) the braking torque of the Voith retarder is at maximum.

The control medium for the Voith retarder 115 E is compressed air, which is taken from the vehicle air-tank for auxiliary equipment.

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 is passed on to the proportional valve (21).

The proportional valve (21), depending on the magnitude of the control current, provides a constant-air

c

a

b

FD299

The hydrodynamic principle a Rotor (46)

b Stator (44) c Oil flow

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The rotation of the retarder 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 deceleration energy is transformed into heat. To dissipate this heat, part of the oil in the working circuit is pumped continuously by the rotor (46) through the heat exchanger (1) and filling ducts and returned to the circuit again.

In the heat exchanger (1), 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.

The gearbox- and retarder oil reservoires are seperated from each other at the gearbox-retarder-system. Both oil circuits are cooled down independently in a 3-chamber steel heat exchanger of the retarder - without limited compromizes.

Temperature 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 adapted to protect the vehicle cooling system and the retarder.

The braking torque and consequently the heat generated are reduced until a balance is obtained bet-ween the braking energy of the retarder and the amount of heat which can be dissipated by the vehicle cooling system.

If the cooling water temperature rises into the temperature adaption range, the consequence is an ad-aption of the retarder braking torque to protect the vehicle cooling system. If the temperature rises above the temperature adaption range, there is no more braking torque output.

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While the temperature adaption is effective or if there is a retarder failure, the service brake must be used to control the vehicle.

Additionally the control unit cuts back braking torque if oil temperature rises too rapidly - irrespective of actual oil temperature.

Pressure regulating valve (62)

The pressure regulating valve (62) adjusts the lubrication in the no-load operation of the retarder.

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.

Non-return valve (63) inlet

When the retarder is switched on, the oil sump is pressurized, causing the check valve (63) to open and the oil to enter the working space.

Non-return valve (64) outlet

The oil pressure in the working space opens the check valve (64), causing the oil to enter the heat exchanger (1), to be cooled and to be returned to the working circuit.

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3RZHUWUDLQ%XVLQHVV8QLW 7UDQVPLVVLRQV Indic. Code Serial No M-Code Version No M+P-07A-1705e

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Illustration 2 Illustration 1 Indic. GO 170-6/8,2 Code G 714.100 L Serial No M-Code Variant No

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Ratio 1. gear Number of gears Input torque (x 10) Gearbox-Bus 71 4. 692 L GO 170 - 6 / 8,2 Gearbox number Gearbox part-No M+P-07A-1704e The gearbox identification (data plate) s located

at the side of the retarder-gearbox-system on the right in direction of travel

(see illustration 2 – example).

Note

For queries or when ordering spare parts we need the data of the gearbox.

Only with this data a fast and effective run time is possible.

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The retarder identification (data plate) is located at the gearbox-retarder-system on the right in direction of travel (see Illustration 2).

Note

For queries or when ordering spare parts we need the data of the retarder.

Only with this data a fast and effective run time is possible. CW/Year Serial-No M+P-07A-1707 000000 45/1999 CW/Year Serial-No Voith Item-Number 8-digit number Date of production Serial-Number (Brake-Number) 6-digit number DaimlerChrysler part-number Retarder ratio (i Ret) M+P-07A-1706e Illustration 2 Illustration 1

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The Digiprop-control unit identification (data plate) is located at the control unit and provides the following information:

1. Voith-number 8-digit number

The software version can be identified by the last two numbers.

Example: .12 = version 1.2 2. Code-number

3-digit number

(Adjustment of the control unit) 3. Serial-number

5-digit number with date of coding 4. Client-number

(DaimlerChrysler part-number)

Note

For queries or when ordering spare parts we need the data of the control unit.

Only with this data a fast and effective run time is possible. Vo_ith-Nr .: 53.xxxx.1 2 Code-Nr .: xxx Se rie_n-Nr .: xxxx/ Datum Kunde n-Nr .:

Voith no.:

Code no.:

Serial no.:

Date:

Client no.:

M+P07A-1617a

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3.1 Maintenance Work / Oil Change Intervals...3.1/1

3.2 Checking Oil Level at Gearbox...3.2/1

3.3 Checking Oil Level at Retarder ...3.3/1

3.4 Oil Change at Gearbox...3.4/1

3.5 Oil Change at Retarder ...3.5/1

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3URGXFWXQLWUHWDUGHU Maintenance work

The following maintenance work has to be carried out at each oil change (gearbox and retarder):

- Clean the oil sieve (gearbox)

- Clean the sieve for the pressure regulating valve (retarder) - Check fastening screws of the retarder heat exchanger - Check all screw plugs on leak and correct fitment - Carry out visual inspection on leak and existing damages

Please note the following data into the service overview of the Operation Manual „Gearbox-Retarder-System / GO170 - GO210 with R 115 E”: - maintenance work been carried out

- the oil grade used for the oil change

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1) according to Operating Specifications, page 11/4 - 11/7 2) according to Operating Specifications, page 11/8 - 11/12 3) according to Operating Specifications, page 11/13

4) change oil at the latest after 1 year, if fewer kilometres are travelled 5) change oil at the latest after 2 years, if fewer kilometres are travelled

6) The oil change intervals for the retarder oils (see note 2) may adapted to the oil change intervals of the single-grade mineral oils for the gearbox

–

Single-grade mineral oil 1)

Synthetic oil 1) Single-grade mineral oil 2)

Synthetic oil 2) Synthetic oil 3)

Normal duty _{100 000 km}4) _{300 000 km}5) _{135 000 km}4) _{180 000 km}5) _{300 000 km}5)

Heavy duty _{50 000 km}4) _{300 000 km}5) _{60 000 km}4) _{90 000 km}5) _{300 000 km}5)

Retarder 6) Gearbox

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1. „Normal duty“ Example:

– Long distance traffic

2. „Heavy duty“

Subject to more than normal stress. Example:

– Use in regions with high ambient temperature (e.g. Saudi-Arabia)

– High max. permissible weight with low rated engine power (< 5,9 kW/metric ton) – Streches with lots of hills and valleys

– Extreme short-distance traffic with lots of gradients

The given maximum specified figures can be lowered, if overall maintenance cycles for the vehicle are improved.

With a total-life of the retarder of more than 10%, covered on the vehicle-performance, as well as other factors not mentioned here also affect the ageing of the oil, it may be necessary to shorten the intervals between oil changes in individual cases.

For use in extremely cold zones, oils in an appropriately lower viscosity class must be used. In doubts please contact the service departement.

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Illustration checking oil level

26/100/122 Oil filler plug M24x1,5 Inhex.-head, w.a.f. 14, 47 Nm 26/100/128 Sealing ring A24x29

renew

26/100/128

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Note

For satisfactory gearbox operation, it is important to adhere to the specified service filling (see annex) for operating the retarder in the relevant application.

For the oil level check, the temperature of the gearbox oil must have reached the operating temperature. The oil level check must be carried out with the vehicle in a horizontal position.

Caution! Risk of injury!

The oil filler plug is hot! Oil temperature!

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Job scope

The oil filler plug is hot! Oil temperature!

1. Screw out oil filler plug (26/100/122) and remove sealing ring (26/100/128).

The oil level is correct, if the oil level is at the lower edge of the oil check hole (see illustration right). 2. Top up slowly any lacking oil through the hole for the oil filler plug according to the

Operation Specifications.

Note

If there is any lacking oil, the gearbox must be checked for outer leaks.

3. Screw in oil filler plug with new sealing ring and screw them tight. Tightening torque oil filler plug (26/100/122) 47 Nm

26/100/128 26/100/122

Remark:

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Illustration checking oil level A Oil drain and measure method

107 Oil drin plug M24x1,5 Inhex.-head, w.a.f. 12 65 Nm (80 Nm) 4200 Oil drin plug M24x1,5

Inhex.-head, w.a.f. 12 65 Nm (80 Nm)

4200

107

M+P-07A-1712

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Illustration checking oil level B With oil check plug

109 Oil check plug M24x1,5 Inhex.-head, w.a.f. 12 65 Nm (80 Nm)

4100 Oil filling plug M30x1,5 Inhex.-head, w.a.f. 17 100 Nm (150 Nm)

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Note

Two methods are available for checking the oil level: A Oil drain and measure method

B With oil check plug

For satisfactory retarder operation it is important to adhere to the specified service filling of 7,0 litres and to use only oils specified in the operating Specifications (see annex) for operating the retarder in the relevant application.

For the oil level check, the temperature of the gearbox oil must have reached the operating temperature. The oil level check must be carried out with the vehicle in a horizontal position.

Caution!

Two version of the screw plugs (107, 4100, 4200) are possible: A) Version with integrated FPM-sealing ring;

these corresponds the standard version at the time going to print.

The integrated sealing rings must be checked during the oil level check for possible damages; replace completely if necessary.

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B) Version with loose inserted copper-sealing ring.

In this Aftersales Service Manual is excluding the variant A (series version) described.

If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in brackets are valid. The copper-sealing rings are generel to renew.

A Oil drain and measure method

Job scope

1. Push a clean vessel under retarder.

The oil drain plugs (107, 4200) and oil filler plug (4100) are hot! Oil temperature! During the oil level check the retarder mustbe switched-off!

If the retarder is switched-on during working step 2 and screwed out oil drain plugs and/or oil filler plug, high risk of injury exist by hot leaving oil (increased pressure)!

2. Screw out oil drain plugs and drain oil in clean vessel. ₄₂₀₀

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5. Measure drained oil.

6. Top up any lacking oil according to the Operating Specifications, chapter 3.1: „Oil Change Intervals“ and chapter 11: „Annex“.

7. Fill in slowly, over a time period longer than 3 minutes, the quantity of oil specified in the bore of the oil filler plug (4100).

Caution!

The retarder must only be filled with oil via the bore of the oil filler plug (4100)!

Note

With determined lacking oil quantity check retarder for possible outer leak.

8. Check sealing ring of oil filler plug for possible damages, renew oil filler plug if necessary. 9. Screw in oil filler plug and screw it tight.

Tightening torque oil filler plug (4100): 100 Nm (150 Nm)

Caution!

Operate the retarder, after checking oil level, first time during a trail run at a speed of minimum 50 km/h 5 times for approx. 5 seconds each time in position 2 at the retarder stage switch

(corresponds braking stage 1).

(38)

B With oil check plug

Job scope

1. Switch vehicle ignition system „OFF“ and then „ON“ again (reset).

2. Operate the retarder in stand-still in switch position 2 at the retarder stage switch (corresponds braking stage 1) and switch it off after approx. 5 seconds.

Repeat this procedure twice.

3. Switch off the retarder and wait 5 minutes.

The oil check plug (109) and oil filler plug (4100) are hot! Oil temperature! While the oil level is being checked, the retarder must be switched off!

If the retarder is switched-on during working step 4 and screwed out oil drain plugs and/or oil filler plug, high risk of injury exist by hot leaving oil (increased pressure)!

4. Screw out oil check plug (109).

The oil level is correct, if it is at the lower edge of the oil check hole (see illustration).

(39)

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5. Fill in slowly the quantity of oil, via the bore of the oil filler plug, specified in accordance to the Operating Specifications.

Note

With determined lacking oil quantity check retarder for possible outer leak.

6. Check sealing ring of oil check plug for possible damages, renew oil check plug if necessary. 7. Screw in oil check plug and screw it tight.

Tightening torque oil check plug (109): 65 Nm (80 Nm)

8. Check sealing ring of oil filler plug (4100) for possible damages, renew oil filler plug if necessary. 9. Screw in oil filler plug and screw it tight.

(40)

Illustration oil change

26/100/107 Oil sieve

clean sieve with appropriate cleaning agent (Benzine) 26/100/113 Spring

26/100/116 Screw plug (oil sieve) M38x1,5

Inhex.-head, w.a.f. 17, 60 Nm 26/100/119 Sealing ring A38x46

renew

26/100/122 Oil filler plug M24x1,5

Inhex.-head, w.a.f. 14, 47 Nm 26/100/125 Oil drain plug M24x1,5

Inhex.-head, w.a.f. 14, 47 Nm 26/100/128 Sealing ring A24x29

renew

Lubricants and cleaning agents

Sieve in screw plug Benzine

26/100/116

26/100/107

26/100/119

26/100/122

26/100/128

26/100/125

M+P-07A-1715

26/100/113

26/100/128

26/100/125

(41)

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Note

The gearbox- and retarder oil reservoires are seperated from each other at the gearbox-retarder-system. Both oil circuits are cooled down independently in a 3-chamber steel heat exchanger of the retarder - without limited compromizes.

For satisfacory 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.

For draining the oil the temperature of the gearbox oil must have reached the operating temperature.

The oil drain plugs are hot! Oil temperature!

Oil filling

Service filling (oil change) 12,5 litre

New filling 13,0 litre

(42)

Job scope

1. Push an oil pan under the gearbox.

The oil drain plugs (26/100/125) are hot! Oil temperature!

2. Screw out oil drain plugs (26/100/125), remove sealing rings (26/100/128) and drain oil. 3. Screw the oil drain plugs (26/100/125) with new sealing rings tight.

Tightening torque oil drain plugs (26/100/125): 47 Nm

4. Screw out screw plugs (26/100/116) and remove sealing rings (26/100/119).

5. Clean oil sieve (26/100/107) with appropriate cleaning agent (Benzine) and blow it out with compressed-air. Check cleaned sieve for possible damages, renew if necessary.

6. Fix spring (26/100/113) with oil sieve (100/107) in bore of screw plug (26/100/116). 7. Screw the screw plug (26/100/116) with new sealing ring tight.

Tightening torque screw plug oil sieve (26/100/116): 60 Nm

8. Screw out oil filler plug (26/100/122) and remove sealing ring (26/100/128).

9. Fill in slowly oil via the bore of the oil filler plug according to the Operating Specifications.

26/100/116 26/100/125 26/100/107 26/100/119 26/100/122 26/100/128 26/100/128 26/100/125 M+P-07A-1715b 26/100/113 26/100/128 Remark:

(43)

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Illustration oil change retarder

107 Oil drain plug M24x1,5 Inhex.-head, w.a.f. 12 65 Nm (80 Nm)

3500 Screw plug with sieve M30x1,5 Inhex.-head, w.a.f. 17

100 Nm (150 Nm),

Clean sieve with appropriate cleaning agent and blow out with compressed-air

4100 Oil filler plug M30x1,5 Inhex.-head, w.a.f. 17 100 Nm (150 Nm)

4200 Oil drain plug oil tank M24x1,5 Inhex.-head, w.a.f. 12

65 Nm (80 Nm)

Lubricants and cleaning agents

O-rings Silicone- free and non-corrosive grease Sieve in screw plug Benzine

3500

4100

4200

107

M+P-07A-1488

(44)

Note

The gearbox- and retarder oil reservoires are seperated from each other at the gearbox-retarder-system. Both oil circuits are cooled down independently in a 3chamber steel heat exchanger of the retarder -without limited compromizes.

For satisfacory retarder operation, it is important to adhere to the specified service filling (see table on next page) and to use only oils specified in the Operating Specifications, chapter 3.1 „Oil Change Inter-vals“ and chapter 11: „Annex“ for operating the retarder in the relevant application.

For draining the oil the temperature of the retarder oil must have reached the operating temperature. Ensure that during the entire oil change no constant-air pressure acts on the retarder, that means the retarder must be switched off!

Caution!

Two versions of screw plugs (107, 3500, 4100, 4200) are possible: A) Version with integrated FPM-sealing ring;

(45)

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B) Version with loose inserted copper-sealing ring.

In this Aftersales Service Manual is excluding the variant A (series version) described.

If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in brackets are valid. The copper-sealing rings are generel to renew.

Job scope

1. Push an oil collecting pan under the retarder.

The oil drain plugs (107, 4200) are hot! Oil temperature!

2. Screw out the oil drain plugs (107 and 4200) and drain the oil.

3. Check sealing rings of oil drain plugs on possible damages, renew oil drain plugs if necessary. 4. Screw the oil drain plugs tight.

Tightening torque oil drain plugs (107, 4200): 65 Nm (80 Nm)

Oil filling with heat exchanger

Service filling (oil change, oil level check) 7,0 litre After complete taking apart and cleaning as well as

emptied heat exchanger (corresponds new filling) 7,8 litre

4200

107 4200

M+P-07A-1489

(46)

5. Screw screw plug with sieve (3500) out of the retarder.

6. Clean sieve in screw plug with appropriate cleaning agent (Benzine) and blow it out with compressed-air.

7. Check sealing ring of screw plug with sieve on possible damages, renew screw plug if necessary. 8. Fit screw plug with sieve and screw it tight.

Tightening torque screw plug (3500): 100 Nm (150 Nm) 9. Screw out oil filler plug (4100).

Achtung!

The retarder must only be filled with oil via the bore of the oil filler plug (4100)!

10. Fill in slowly in the bore of the oil filler plug, over a time period longer than 3 minutes, the quantity of oil specified (see table page 3.5/3 in this chapter) according the Operation Specifications, chapter 3.1: „Oil Change Intervals“ and chapter 11: „Annex“.

This working step is necessary for the correct bleeding of the retarder system.

3500

(47)

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11. Check sealing ring of oil filler plug on possible damages, renew oil filler plug if necessary. 12. Fit oil filler plug and screw it tight.

Caution!

Operate the retarder after the oil change first during the trial run 5 times with a speed of minimum 50 km/h each time for approx. 5 seconds in position 2 at the retarder stage switch (corresponds braking stage 1).

(48)

4.1 Troubleshooting Diagram ...4.1/1

Troubleshooting Master System ... 4.1/1

Troubleshooting Diagram A to E... 4.1/2

(49)

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Troubleshooting

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Illustration troubleshooting master-system

Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10 Page 4.1/1

Complaint

_retarder?

at

see

troubleshooting

diagram

at page 5.1/2

at the

gearbox-retarder-system,

but I am not sure

at

gearbox?

see

troubleshooting

diagram

at page 4.1/2

Please contact

DaimlerChrysler

(50)

leaks elektrical function shiftability no traction Complaint Gearbox noices

A1

A3*

*Begin of troubleshooting at A1

E

B

(51)

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(Continue)

Illustration troubleshooting diagram A1

YES NO

at O-ring?

YES NO

use new micro encapsulated screws

leaks

YES NO at the drive shaft? YES NO at radial shaft sealing ring?

A1

Renew radial shaft sealing ring (chapter 8.2)

YES NO

at O-rings?

Check residual oil quantity. Contact product unit gearbox

if residual oil quantity smaller 50%. YES NO at surface / surface sealant? Renew O-rings (chapter 8.2) Contact product unit gearbox YES NO at countershaft cover?

A2

NO YES at cover 5./6.-gear? (only GO 210) seal new with

released surface sealant (chapter 8.2) Renew O-rings (chapter 8.2) Renew O-rings (chapter 8.2) Contact product unit gearbox at the micro capsulated screws?

(52)

leaks

YES NO at cover oil pump? YES NO am Gehäuseteil?

A2

seal new with surface sealant

(chapter 8.3)

YES NO

at cover of gearbox selecting fork right and left?

NO YES

Threaded compo-nents / shift rocker

arm bearing ?

NO YES

Filler cap?

Seal parts new, renew if necessary NO YES Sensor / switch? leaky sealed Check sensor / switch for leak

Renew parts

and seal them Seal parts new

A3

YES NO Radial shaft sealing rings of cross shift? YES NO Radial shaft sealing ring left side?

renew radial shaft sealing ring (chapter 8.3) YES NO at parting surface of housing? YES NO Renew cross shift complete (chapter 8.3) Contact product unit gearbox Contact product unit gearbox Contact product unit gearbox Contact product unit gearbox Radial shaft sealing ring right side?

(53)

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leaks

YES NO at breather? Cover / flanges leak?

A3

Check oil level and correct if necessary (chapter 3.2) _YES _NO Cover / flanges damaged? YES NO Breather correct mounted? Renew breather (chapter 8.4) YES NO Seal new cover / flanges (chapter 8.2) Replace cover / flanges (chapter 8.2) YES NO Contact product unit gearbox Paper gasket damaged YES NO Renew cross shift complete (chapter 8.3) Paper gasket at cross shift leaks between inner and outer

cover?

Seal new with released liquid sealant

(54)

Illustration troubleshooting diagram B Renew cross shift complete (chapter 8.3)

Shiftability

YES NO Selectability? NO YES outer shift smooth? NO YES Smooth shifting of gear? NO YES Shift at still stand heavy handling? YES NO Reverse gear heavy handling? YES NO Clutch servo in function? Contact product unit gearbox

B

NO YES Does clutch disconnect? Change clutch servo (chapter 8.6) Contact product unit gearbox Contact product unit gearbox Contact product unit gearbox Contact product unit gearbox Adjust clutch according to vehicle manufacturer instructions

(55)

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Illustration troubleshooting diagram C

Noices

YES NO noices when shifting? YES NO in reverse gear? NO YES Noices during stress cycle? YES NO Noices during operation in retarder operation?

C

YES NO

Check oil level (chapter 3.2), if OK, contact product unit gearbox YES NO scratching when shifting? COLD WARM Ambient temperature? YES NO Rattleing in idle speed? Contact product unit gearbox Contact product unit gearbox Contact product unit gearbox Contact product unit gearbox Noices during operation in pulling action?

Check for clutch disconnect according to vehicle manufacturer

instructions

Check and adjust according to the vehicle manufacturer instructions: - Idle speed of engine - torsional absorption of clutch

does not appear at operation temperature

Check outer shift for easy handling

(56)

Illustration troubleshooting diagram D

no

traction

YES NO

D

Contact product unit gearbox Gear shifted at gearbox? (check at gearbox) Adjust again outer shift according to the vehicle manufacturer instructions

(57)

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Troubleshooting

Illustration troubleshooting diagram E

electrical

function

YES NO OK NOK YES NO functioning? OK NOK Check contacts of components YES NO functioning?

E

YES NO Sensors available? Renew components Does switch exist (switch for reverse

gear position or neutral position) Contact product unit gearbox Renew components Renew components Contact product unit gearbox Contact product unit gearbox Renew components Check contacts of components

(Continue)

(58)

5.1 Troubleshooting Diagram ...5.1/1

Troubleshooting Master System

...5.1/1

Troubleshooting Diagram A to C

...5.1/2

Electrical Connections Diagram

...5.1/6

5.2 Troubleshooting and Remedies ...5.2/1

5.3 Illustration Control System ...5.3/1

5.4 Checking Supply-Air Pressure ...5.4/1

5.5 Checking Constant-Air Pressure (p

_y

) ...5.5/1

5.6 Checking Control Current of Proportional Valve ...5.6/1

5.7 Checking Temperature Adaption...5.7/1

5.8 Checking Pressure Sensor...5.8/1

5.9 Checking Pump Pressure...5.9/1

5.10 Table of Measurements...5.10/1

5.11 Operational Check...5.11/1

(59)

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Complaint

_retarder?

at

see

troubleshooting

diagram

at page 5.1/2

at the

gearbox-retarder-system,

but I am not sure

at

gearbox?

see

troubleshooting

diagram

at page 4.1/2

Please contact

DaimlerChrysler

Illustration troubleshooting master system

(60)

Oil loss through ventilation Retarder pilot light Complaint Retarder R 115 E No respectively insufficient retarder braking effect

B

A

(61)

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Illustration troubleshooting diagram group

Note

It is important that the specific service filling is kept for a trouble-free operation of the retarder (see chapter 3.5 „Oil Change“ and chapter 11 „Annex“).

Oil loss

through

ventilation

OK NOK

Check retarder oil level

YES NO Water in oil? (emulsion)

A

OK NOK Check casing ventilation (chapter 9.2) Replace casing ventilation Check control unit (chapter 5.4 - 5.9) too high too low Check retarder oil level

NOK OK

Check gearbox oil level

Correct retarder oil level

NO YES Water in oil? (emulsion) OK NOK Correct retarder- and gearbox oil level

Correct retarder- and gearbox oil level Check heat exchanger (chapter 9.5) Contact Voith service partner Contact Voith service partner Contact Voith service partner Check gearbox oil level

Check gearbox oil level Check

gearbox oil level too high too high too low too low M+P-07A-1763 ae

(62)

Activate blinking code

and read out fault code (chapter 5.2)

Retarder

pilot light

B

Permanent light in position 0 after light test?

Rectify fault and delete fault memory (chapter 5.2)

no function?

Check retarder pilot light

and renew, if necessary Contact Voith service partner flashes? Temperature adaption OK NOK Check operation (during braking with retarder nominal engine speed, if possible) Driver instruction! OK NOK Check temperature pick-up oil / water

(chapter 5.7) Replace temperature pick-ups (chapter 10.2, 10.3) Check vehicle cooling system: -coolant level -thermostat -coolant pump -radiator fan -radiator grill for dirtiness

(63)

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Troubleshooting

No respectively

too insufficient

retarder braking

effect

OK NOK Check retarder oil level

YES NO Water in oil? (emulsion)

C

OK NOK Check constant-air pressure (py) (chapter 5.5) too high too low Check retarder oil level

Correct retarder oil level

NO YES Water in oil? (emulsion) (chapter 9.5) Check heat exchanger OK NOK Check gearbox oil level

too high

too low Check gearbox oil level

Contact Voith service partner

Correct retarder- and gearbox oil level Contact Voith service partner OK NOK Check current of proportinal valve (chapter 5.6) OK NOK Check pump pressure (chapter 5.9) OK NOK Check temperature adaption/ pressure sensor (chapter 5.7 / 5.8) OK NOK Check supply-air pressure (chapter 5.4) OK NOK Check vehicle compressed-air pressure system Contact vehicle manufacturer Proportional valve or damping plate mechanically defect Contact Voith service partner Contact Voith service partner Contact Voith service partner Contact Voith service partner Contact Voith service partner

(Continue)

(64)

Electrical connections diagram R 115 E (Voith-wiring harness)

2 Control unit

4 Connection Terminal 15 15 ABS-signal

16 Retarder stage switch 17 Retarder pilot light 18 Stop light relais

19 Cooling-water temperature pick-up 20 Oil temperature pick-up

21 Proportional valve 47 Speedometer signal 69 Plug ISO-Interface 70 Plug optional functions 72 Pressure sensor 18 70 47 15 21 - + + - + -19 20 17 4 69 4 2 X1 X2 X3 8 9 4 5 6 1 3 2 3 2 1 6 5 4 9 7 12 10 11 8 14 87 87a 30 13 11 12 10 1 9 5 8 4 3 2 7 6 2 1 18 17 16 6 5 4 9 810 11 12 13 14 157 4 3 2 1 4 8 3 2 5 6 7 3 2 1 7 1 2 4

.

P _U ₇₂

(65)

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Troubleshooting and remedies

Requirements for check

l Battery voltage 18 - 32 V

l Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found satisfactory.

l Fuse for retarder control unit checked and found satisfactory.

l 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) and pin 13 (plug X1) must be connected terminal 15

Note

Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary (see table, chapter 3.5, page 3.5/3).

(66)

Note

The retarder pilot light additionally has the function of a fault code:

- slight fault

Permanent light in position 0 - 5 of retarder stage switch, braking is still possible to limited extent.

- serious fault

Permanent light in position 0 - 5 of retarder stage switch,, braking is no longer possible - the retarder is switched off.

Note

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.

(67)

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Connector arrangement and pin assignment

Note

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 2 5 Retarder stage switch, Position 1 6 Retarder stage switch, Position 1 7 Terminal 15

8 Retarder stage switch, Position 4 9 Retarder stage switch, Position 3 10 Retarder stage switch +

11 ISO-interface, L-lead 12 ISO-interface, K-lead 13 connected with terminal 15 14 Not in use

15 Terminal 31

16 Output / high side 2 „HS2“ 17 Not in use

18 Output / high side 1 „HS1“ FD846

1 4 7 10 13 16 2 5 8 11 14 17 3 6 9 12 15 18

(68)

1 Not operational 2 Proportional valve - 3 Proportional valve +

4 Cooling-water temperature pick-up - 5 Cooling-water temperature pick-up + 6 Not operational

7 Not in use

8 Oil temperature pickup -9 Oil temperature pick-up +

1 Input / pull up „DIU 1“ 2 Speedometer signal 3 ABS-signal

4 Input / pull down „DID 2“ 5 Input / pull down „DID 1“ 6 Pressure sensor ground 7 Pressure sensor signal voltage 8 Retarder pilot light

1 4 7 10 2 5 8 11 3 6 9 12 FD848 1 4 7 2 5 8 3 6 9

(69)

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Plug optional functions

1 Retarder stage switch + 2 Input / pull down „DID 1“ 3 Input / pull down „DID 2“ 4 Input / pull down „DID 3“

5 Input / pull down / PWM -in „DID 4“ 6 Input / pull up „DIU 1“

7 Pressure sensor ground 8 Pressure sensor signal voltage 9 Pressure sensor supply voltage 10 Output / high side „HS1“

11 Output / high side 2 „HS2“ 12 No function 13 Terminal 15 14 Terminal 31 Plug ISO-interface 1 K-lead 2 L-lead 3 Terminal 15 4 Terminal 31 2 1 4 3 FD854 2 1 4 3 6 5 8 7 10 9 12 11 14 13 FD849

(70)

Plug cooling-water temperature pick-up Plug oil temperature pick-up

Plug proportional valve

1 Proportional valve + 2 Proportional valve – 3 No function 4 No function 1 2 3 4 FD851

(71)

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Plug retarder stage switch

1 Not operational 2 Position 5 3 Position 4

4 Retarder stage switch + 5 Position 3 6 Position 2 7 Position 1 8 Bridge to pin 4 FD853 1 2 3 4 5 6 7 8

(72)

A. With fault code

Special tool

Commercially available tool

Note

The blinking code of the retarder pilot light with service-cable can be used to obtain a read-out from the fault memory.

Multimeter recommended: Fluke 87

(73)

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Fault memory readout via retarder pilot light blinking code

Note

If sveral faults have been stored in the memory, they are output in the sequence of their occurence, but always only one fault per triggering.

Exception:

The fault „Coding Fault“ is not held in the memory but is output via the blinking code. The blinking code can be read of the control unit service cable or retarder stage switch.

Fault memory readout with service cable

Requirements

l Retarder stage switch in position O.

l Vehicle at standstill, ignition ON

1. Service interface L-lead connected to ground ≥ 2s. For this pupose, press „L - pushbutton“ at service cable

2. First fault as blinking code output.

3. Item 2 and 3 repeated for more blinking code outputs.

Meaning

l Long blinking signals (2 sec.) tens unit.

l Short blinking signals (0,5 sec.) single unit.

(74)

Fault memory read out with retarder stage switch

The blinking code can be triggered with the retarder stage switch during the service function (vehicle ignition system ON and v = 0):

1. Retarder stage switch in position 0

2. Retarder stage switch in position 1 (≥ 2 seconds) 3. Retarder stage switch in position 0

4. First fault as blinking code

5. Items from ...3 for more blinking code outputs

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 units first indicated as long ON time: each 2 seconds The number of single unit then is indicated as short ON time: each 0,5 seconds

Breaks between each ON time: each 1 second

If an actual fault is available (before triggering the blinking code the retarder pilot light is switched ON) the retarder pilot light switches to permanent light again after the blinking code.

Is only one stored fault available, the retarder pilot light is OFF after the output.

Display example for fault code 23 E Retarder pilot light ON A Retarder pilot light OFF t Time

2 sec 1 sec _{2 sec} 1 sec _{0,5 sec} 1 sec _{0,5 sec} 1 sec _{0,5 sec}

(75)

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Delete fault memory

No marginal notes in accordance with fault memory read out. 1. Vehicle ignition system: OFF

2. Servcie interface L-lead connected to ground. For this purpose, press „L-pushbutton“ of service cable.

3. Vehicle ignition system: ON

4. Release L-lead from ground after ≥ 2 sec.

(76)

Note

Meaning of entries in „Measurement/test connection“ column: X 1/15 Ω X3/11

Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3

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 Test step

01 Stop light relay/

Short circuit to ground

slight 1 s - Ignition: OFF - Pull plug X3 out of

control unit

X 3/11 Ω X 1/15 Relay is installed: 250-350 Ω

Check lead, plugs and relay or consumers

(77)

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Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code Test step

03 HS 1 output

Short circuit

control unit

Check lead, plugs and relay

or consumers

04 HS 2 output

Short circuit

control unit

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)

(78)

* Fault is in serious class, if temperature pick-up for oil and water are defect at the same time.

Trigger time Requirement / Operation Measure-ment/ Test connec-tion Result/ Set point Cause/ Remedy

Code Test step 08 09 Cooling-water temperature pick-up Discontinuity / Short circuit to battery serious/ slight * 1 s - Ignition: OFF - Pull plug X2 out of

control unit X 2/5 Ω X 2/4 20°C ± 10°C = 1039 - 1117Ω 60°C ± 10°C = 1099 - 1271Ω 80°C ± 10°C = 1271 - 1347Ω Notice: The measuring in one tempera-ture range normally is sufficient.

Check lead and sensor

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Troubleshooting

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* Fault is in serious class, if temperature pick-up for oil and water are defect at the same time.

Trigger time Requirement / Operation Measurement/ Test connec-tion Result/ Set point Cause/ Remedy

Code Test step 11 12 Oil temperature pick-up Discontinuity / Short circuit to battery serious/ slight * 1 s - Ignition: OFF - Pull plug X2 out of

control unit X 2/9 Ω X 2/8 20°C ± 10°C = 1039 - 1117Ω 60°C ± 10°C = 1099 - 1271Ω 80°C ± 10°C = 1271 - 1347Ω Notice: The measuring in one tempera-ture range normally is sufficient.

Check lead and sensor

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Trigger time Requirement / Operation Measurement/ Test connection Result/ Set point Cause/ Remedy Code Test step

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

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 ≥ 17,5 V ≥ 17,5 V ≥ 17,5 V

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Gearbox-Retarder-System GO170 - GO210 with R 115 E

1 Preface ...1/1

2 General...2/1

2.1 Illustration Gearbox-Retarder-System ... 2.1/1

2.2 Function and Operation Scheme Gearbox ... 2.2/1

2.3 Function and Operation Scheme Retarder ... 2.3/1

2.4 Gearbox Identification... 2.4/1

2.5 Retarder Identification... 2.5/1

2.6 Retarder Control-Unit Identification ... 2.6/1

3 Maintenance...3/1

3.1 Maintenance Work / Oil Change Intervals ... 3.1/1

3.2 Checking Oil Level of Gearbox ... 3.2/1

3.3 Checking Oil Level of Retarder... 3.3/1

3.4 Oil Change of Gearbox ... 3.4/1

3.5 Oil Change of Retarder... 3.5/1

4 Diagnosis / Troubleshooting Gearbox ...4/1

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5 Diagnosis / Troubleshooting Retarder...5/1

5.1 Troubleshooting Diagram A to C ... 5.1/1

Electrical Connectrions Diagram ... 5.1/6

5.2 Troubleshooting and Remedies... 5.2/1

5.3 Illustration Control System... 5.3/1

5.4 Checking Supply-Air Pressure... 5.4/1

5.5 Checking Constant-Air Pressure (p

)... 5.5/1

5.6 Checking Control Current of Proportional Valve... 5.6/1

5.7 Checking Temperature Adaption ... 5.7/1

5.8 Checking Pressure Sensor ... 5.8/1

5.9 Checking Pump Pressure ... 5.9/1

5.10 Table of Measurements ... 5.10/1

5.11 Operational Check ... 5.11/1

6 Removing, Installing Gearbox ...6/1

6.1 Removing, Installing Gearbox... 6.1/1

7 Removing, Installing Retarder ...7/1

7.1 Removing, Installing Retarder ... 7.1/1

8 Repair Gearbox ...8/1

8.1 Overall Illustration of Main Components... 8.1/1

8.2 Removing, Installing Front Housing Cover, Cover Countershaft and

Closing Cover 5./6.-Gear ... 8.2/1

8.3 Removing, Installing Shift ... 8.3/1

8.4 Removing, Installing Breather... 8.4/1

8.5 Removing, Installing Sensor/Switch at Gearbox... 8.5/1

8.6 Removing, Installing Clutch Servo

and Adjusting Wear Indicator ... 8.6/1

8.7 Removing, Installing Output Flange

Renewing Radial Shaft Sealing Ring... 8.7/1

9 Repair Retarder...9/1

9.1 Overall Illustration of Main Components... 9.1/1

9.2 Removing, Checking and Installing Casing Ventlation ... 9.2/1

9.3 Removing, Cleaning and Installing Silencer ... 9.3/1

9.4 Removing, Installing Water Neck... 9.4/1

9.5 Removing, Checking, Installing Heat Exchanger... 9.5/1

9.6 Removing, Installing Oil Tank Cover ... 9.6/1

A Top Oil Tank Cover ... 9.6/1

B Bottom Oil Tank Cover ... 9.6/2

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10 Control Parts Retarder ...10/1

10.1 Removing, Installing Proportional Valve ... 10.1/1

10.2 Removing, Installing Oil Temperature Pick-Up... 10.2/1

10.3 Removing, Installing Cooling-Water Temperature Pick-up... 10.3/1

10.4 Removing, Installing Pressure Sensor... 10.4/1

11 Annex ...11/1

Data Sheet

Conversion Table

Operating Specifications: - Oil Specifications Gearbox

- Oil Specifications Retarder

- Cooling Water Quality

Spare Parts Lists

Other Information

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