Voith VR 115 E Service Manual
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Voith VR 115 E Service Manual

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

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  • Page 1 Voith Turbo Aftersales Service Manual Voith Retarder VR 115 E 153.00009710 I 2005-11...

  • Page 2: Table Of Contents

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents Table of Contents About this Document Purpose of this Document Target Groups Other Applicable Documents Symbols and Identifications Item Numbers Legal/Contact Information Basic Safety Information...
  • Page 3 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents Function and Control Scheme Function Description Maintenance and Service Maintenance Intervals Oil Change Checking the Oil Level Draining the Coolant Diagnosis and Troubleshooting Troubleshooting Chart...
  • Page 4 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents 7.10 Non-Return Valve Outlet 7.11 Oil Temperature Sensor 7.12 Coolant Temperature Sensor 7.13 Pressure Sensor 7.14 Proportional Valve and Damping Plate Appendix Tightening Torques Page 4...

  • Page 5: About This Document

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document About this Document Purpose of this Document Target Groups Other Applicable Documents Symbols and Identifications Item Numbers Legal/Contact Information Page 5...

  • Page 6: Purpose Of This Document

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document Purpose of this Document Purpose of this Document This Aftersales Service Manual provides information and instructions on maintenance and repair of the Voith Retarder VR 115 E.

  • Page 7: Symbols And Identifications

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document Symbols and Identifications Symbols and Identifications Item Numbers WARNING The item numbers used are usually found in the spare Structure of warnings Potentially hazardous situation which, if not avoided, parts lists.

  • Page 8: Basic Safety Information

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information Basic Safety Information Product Safety Staff Qualification Safety-Conscious Working Environmental Protection Troubleshooting Maintenance and Repair Driving Mode Warranty Page 8...

  • Page 9: Product Safety

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information Product Safety Product Safety Environmental Protection Damage to property via soiled parts! Considerable damage or malfunctions may occur due Drained fuels and fluids, consumables and old parts The retarder is constructed according to state of the to soiling.

  • Page 10: Warranty

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information Warranty Driving after repair/oil change Failure while driving Oil ejection! During failure of the retarder, or while temperature adaptation is active, only the service brake is De-aeration not performed.

  • Page 11: Design And Function

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Design and Function Overview of the Modules Retarder Identification Controller Identification (VERA Controller Identification (Digiprop) Function and Control Scheme Function Description Page 11...

  • Page 12: Overview Of The Modules

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Overview of the Modules Overview of the Modules 2810 Item No. Designation 3700 100 Retarder housing 4100 1600 Valve cover (non-return valve outlet) 1900 Non-return valve inlet...
  • Page 13 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Overview of the Modules Item No. Designation 103 Screw plug M12x1.5 107 Screw plug M24x1.5 (oil drain plug) 3500 Screw plug M30x1.5 4200 Screw plug M24x1.5 (oil drain plug) 5200/2 Coolant temperature sensor M14x1.5...

  • Page 14: Retarder Identification

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Retarder Identification Retarder Identification NOTE Specify the following data in case you have questions or are ordering spare parts: Serial number (Serien-Nr.) Voith item number (Voith-Sach-Nr.) Typ VR115E;...

  • Page 15: Controller Identification (Vera Tm )

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Controller Identification (VERA Controller Identification (VERA Example: NOTE Specify the following data in case you have questions or are ordering spare parts: Serial number (Serial-No.) Part number (Part No.)

  • Page 16: Controller Identification (Digiprop)

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Controller Identification (Digiprop) Controller Identification (Digiprop) Example: NOTE Specify the following data in case you have questions or are ordering spare parts: Basic number (Basis-Nr.:) Serial number (Serien-Nr.:)

  • Page 17: Function And Control Scheme

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Function and Control Scheme Function and Control Scheme Item No. Designation A Compressed-air line (pressure controller) B Four-circuit protection valve 2810 2300 9000 3700 C Compressed-air line (brake circuit 2)
  • Page 18 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Function and Control Scheme Item No. Designation 2300 Casing ventilation 2810 Ventilation filter 3700 Proportional valve 4200 Oil drain plug 2810 2300 9000 3700 5200/1 Oil temperature sensor...

  • Page 19: Function Description

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Design and Function Function Description Function Description Proportional valve (3700) If the critical temperature threshold has been exceeded, the braking torque is no longer active. Depending on the intensity of the electric input signal,...

  • Page 20: Maintenance And Service

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Maintenance and Service Maintenance Intervals Oil Change Checking the Oil Level Draining the Coolant Page 20...

  • Page 21: Maintenance Intervals

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Maintenance Intervals Maintenance Intervals The maintenance intervals depend on the stress put on the retarder. Activity Interval Change oil See document: Oil Page 22 change intervals/ oil specification list 153.000831xx...

  • Page 22: Oil Change

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Oil Change Oil Change 4100 Item No. Designation 107 Screw plug M24x1.5, 4150 hexagon socket head, w.a.f. 12, with copper sealing ring: 80 Nm with integrated sealing ring: 47 Nm 108 Sealing ring A24x29, replace 3500 Screw plug M30x1.5,...
  • Page 23 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Oil Change • Tighten screw plugs of retarder basic module to NOTE CAUTION the specified tightening torque (see page 91). Observe the reduced tightening torque with the Hot screw plugs! •...
  • Page 24 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Oil Change Pressure control valve 2. Lubricate the new sealing ring (4150) with silicone-free, non-corrosive grease. NOTE 3. Screw in the screw plug (4100) with sealing ring There are two variants of the pressure control (4150) and tighten to 130 Nm.

  • Page 25: Checking The Oil Level

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Checking the Oil Level Checking the Oil Level 4100 Item No. Designation 107 Screw plug M24x1.5, 4150 hexagon socket head, w.a.f. 12, with copper sealing ring: 80 Nm...
  • Page 26 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Checking the Oil Level NOTE CAUTION CAUTION Observe the reduced tightening torque with the Hot screw plugs! Wrong oil type! integrated sealing ring. Hands could be burned.
  • Page 27 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Checking the Oil Level De-aerating the retarder CAUTION Oil ejection! De-aeration not performed. De-aerate retarder. 1. Switch off the retarder foot control if present and possible.

  • Page 28: Draining The Coolant

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Draining the Coolant Draining the Coolant Item No. Designation 20000 Water neck 20300 Screw plug M14x1.5, hexagon insert bit, w.a.f. 13, 32 Nm 20400 Sealing ring A14x20, replace...
  • Page 29 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Maintenance and Service Draining the Coolant CAUTION Incorrect coolant! Damage to vehicle and retarder cooling circuits. Observe the specifications of the vehicle manufacturer or those of Voith Turbo cooling water quality list.

  • Page 30: Diagnosis And Troubleshooting

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Diagnosis and Troubleshooting Troubleshooting Chart Constant-Air Pressure Control Loop Pump Pressure (p Proportional Valve Current Page 30...

  • Page 31: Troubleshooting Chart

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Troubleshooting Chart Troubleshooting Chart Retarder pilot light (standard type)* Oil loss via Complaint Other external ventilation (5500) Retarder leak** or vent and air VR 115 E...
  • Page 32 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Troubleshooting Chart Instruct the driver! Check the Retarder operation (for Replace pilot light Temperature retarder braking, temperature FLASHING? adaptation (standard nominal speed sensor of the engine,...
  • Page 33 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Troubleshooting Chart Replace casing O il loss via Replace casing ventilation 2810 ventilation ventilation (5500) Oil loss (see page 63 onw.) or vent and air...
  • Page 34 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Troubleshooting Chart N o or Y es Repair retarder External leak insufficient (except for retarder ventilation) brake efficiency Check the prop. Water in the current as well...
  • Page 35 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Troubleshooting Chart Leaky near the top oil tank cover (2000) (see page 59 onw.) Leaky near Leaky near Leaky near non-return the heat the casing...

  • Page 36: Constant-Air Pressure Control Loop

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Constant-Air Pressure Control Loop Constant-Air Pressure Control Loop Item No. Designation 99/32 9000 3700 Proportional valve 9000 Pressure sensor 99/30 Retarder tester 3700 99/31 Cable 1 (to the proportional valve)
  • Page 37 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Constant-Air Pressure Control Loop Requirements Test scope Special tools • Ignition switched off CAUTION • Retarder switched off Hot parts! Hands could be burned. •...
  • Page 38 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Constant-Air Pressure Control Loop 5. With the multimeter (measuring type: volts), 8. After approx. 20 seconds, the value "Act.setting measure the voltage at the retarder tester socket pressure"...

  • Page 39: Pump Pressure (P Dyn )

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Pump Pressure (p Pump Pressure (p Item No. Designation 100 Retarder housing 99/32 9000 3700 Proportional valve 9000 Pressure sensor 50/36 Pressure sensor: 0–30 bar...
  • Page 40 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Pump Pressure (p Requirements Test scope Special tools • Ignition switched off CAUTION • Retarder switched off Hot parts and oil! Hands can be burned and scalded.
  • Page 41 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Pump Pressure (p 3. Connect the retarder tester (99/30) (see Test set- NOTE up diagram Page 39 and operating instructions of the retarder tester): If the setpoint of the constant-air pressure (p...

  • Page 42: Proportional Valve Current

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Proportional Valve Current Proportional Valve Current Requirements Test scope • Ignition switched off 3700 Special tools • Retarder switched off 98/8 • Battery voltage 24–28 V •...
  • Page 43 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Diagnosis and Troubleshooting Proportional Valve Current NOTE Controller Item number/ Measured Code number value Due to continuous readjustment in the control loop, VERA H67.2763.xx 440–640 mA the measured values may not be constant, but are H67.2866.xx...

  • Page 44: Removing And Installing The Retarder

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder Removing and Installing the Retarder Page 44...
  • Page 45 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder DANGER Retarder can fall! Your body can be crushed severely. Secure retarder against falling. Use a suitabe device for hanging it up. CAUTION Improper removal/installation! Damage to/failure of the retarder.
  • Page 46 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder Item No. Designation 800 Inside part 850 Outer ring 25300 Remove only if the taper roller bearing 25000 is replaced or a new shim is fitted 25300 4100 Screw plug M30x1.5,...
  • Page 47 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder Removal NOTE Special tools 25200 The shim must always be redetermined if 25300 the inside part (800) is replaced the retarder is attached to the gearbox...
  • Page 48 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder Determining the shim NOTE Carry out measurements at the retarder and 25000 gearbox in the vertical position at room temperature. The retarder and gearbox must have cooled 98/4 down.
  • Page 49 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder 4. Move lever from position 1 to position 2. A defined Installation pre-stress is applied to the drive shaft. NOTE 5. Turn the pinion clockwise 15 times by hand and anticlockwise 15 times.
  • Page 50 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder NOTE 25200 25200 25100 For easier mounting, heat the housing near the 25200 bearing outer ring to approx. 80 °C. 2. Fit bearing outer ring (850) into the gearbox housing and drive it in with the drive-in tool (98/3) until it stops.

  • Page 51: Repair

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Repair Components Overview Top Oil Tank Cover Bottom Oil Tank Cover Casing Ventilation Retarder Ventilation Water Neck Heat Exchanger Pressure Control Valve Non-Return Valve Inlet 7.10 Non-Return Valve Outlet 7.11...

  • Page 52: Components Overview

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview Components Overview 4100 4150 5901 Item No. Designation 3300 5900 3100 100 Retarder housing 9000 107 Screw plug M24x1.5, hexagon socket head, w.a.f. 12, 6101...
  • Page 53 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview Item No. Designation 4100 4150 5901 1950 Sealing ring A48x55, replace 3300 5900 3100 2000 Top oil tank cover 9000 2100 Non-return valve "outlet" 6101...
  • Page 54 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview Item No. Designation 4100 4150 5901 2800 Cover of casing ventilation 3300 5900 3100 2801 Cover 9000 2810 Vent and air filter M12x1.5, hexagon insert bit, w.a.f. 17, 10 Nm...
  • Page 55 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview Item No. Designation 4100 4150 5901 3550 Sealing ring A30x36, replace 3300 5900 3100 3700 Proportional valve 9000 3800 Damping plate 6101 3850 O-ring 16x3, replace...
  • Page 56 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview Item No. Designation 4100 4150 5901 4200 Screw plug M24x1.5, 3300 5900 hexagon socket head, w.a.f. 12, 3100 with copper sealing ring: 80 Nm 9000...
  • Page 57 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview Item No. Designation 4100 4150 5901 5900 Pipe 3300 5900 3100 5901 O-ring 15.3x2.4, replace 9000 6100 Pipe 6101 6101 O-ring 15.3x2.4, replace 2000 6100...
  • Page 58 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Components Overview Item No. Designation 4100 4150 5901 9000 Pressure sensor M16x1.5, 3300 5900 hexagon insert bit, w.a.f. 27, 32 Nm 3100 9000 20000 Water neck 20100 Gasket, replace...

  • Page 59: Top Oil Tank Cover

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Top Oil Tank Cover Top Oil Tank Cover 6101 3300 Item No. Designation 9000 6100 2000 Top oil tank cover 3100 Combined hex head screw M8x30, 6101 hexagon insert bit, w.a.f.
  • Page 60 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Top Oil Tank Cover 4. Lubricate the new O-rings (6101) with silicone- CAUTION free, non-corrosive grease and pull them on the pipe (6100). Hot parts! NOTE Hands could be burned.

  • Page 61: Bottom Oil Tank Cover

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Bottom Oil Tank Cover Bottom Oil Tank Cover Item No. Designation 2500 Bottom oil tank cover 2600 Cover gasket bottom, replace 3100 Combined hex head screw M8x30, hexagon insert bit, w.a.f.
  • Page 62 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Bottom Oil Tank Cover Requirements CAUTION • Retarder switched off Incorrect sequence when tightening the • Ignition switched off combined hex head screws! Cover can buckle. •...

  • Page 63: Casing Ventilation

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation Casing Ventilation 3300 Item No. Designation 2300 Casing ventilation 2301 O-ring 55x3, replace 2300/1 Valve insert 2800 6101 2810 2300/2 Float, specified weight max. 12 g...
  • Page 64 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation CAUTION CAUTION Tools for self-fabrication Incorrect adapter! Hot parts! Damage to casing ventilation. Hands could be burned. Use only the adapter (98/9) as from item number Work carefully.
  • Page 65 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation 2800 99/5 2300/1 98/9 2900 2301 28051 28053 28055 2. Remove cover of casing ventilation (2800). 5. Knock valve insert (2300/1) with the impact puller 7.
  • Page 66 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation Checking Installation 1. Check the casing ventilation (2300) for dirt/sludge CAUTION 99/7 and clean it. 2300/2 Lubrication of the radial shaft sealing ring! Retarder fault.
  • Page 67 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation 8. Lubricate the new O-rings (6101) with silicone- free, non-corrosive grease and pull them on the 99/5 pipe (6100). 2300/1 NOTE 98/9 2300/2 Ensure proper installation position of the pipe (6100) in the top oil tank cover (2000).
  • Page 68 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Casing Ventilation 6100 3300 2800 28061 13.Screw on cover of casing ventilation (2800) with the combined hex head screws (3300). 14.Tighten combined hex head screws (3300) crosswise to 30 Nm.

  • Page 69: Retarder Ventilation

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Retarder Ventilation Retarder Ventilation DANGER Heavily soiled or painted-over retarder Item No. Designation ventilation! 5400 Corrugated spring Retarder reduces braking power after a delay. 5500 Check, clean and blow out disc Replace retarder ventilation.

  • Page 70: Water Neck

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Water Neck Water Neck Item No. Designation 20000 Water neck 20100 Gasket, replace 20200 Combined hex head screw M8x80, hexagon insert bit, w.a.f. 13, 30 Nm NOTE...

  • Page 71: Heat Exchanger

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Heat Exchanger Heat Exchanger Item No. Designation 107 Screw plug M24x1.5, hexagon socket head, w.a.f. 12, with copper sealing ring: 80 Nm with integrated sealing ring: 47 Nm...
  • Page 72 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Heat Exchanger Requirements Removal NOTE • Retarder switched off Observe the reduced tightening torque with the 6400 • Ignition switched off integrated sealing ring. The copper sealing ring variant is described in the •...
  • Page 73 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Heat Exchanger Checking 4. Repeat Steps 1 through 3 at connections "B" and "C". 50/22 6400 28068 CAUTION Heat exchanger leaky! Retarder fault. If air bubbles appear in the water or an external leak is detected, replace the heat exchanger.
  • Page 74 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Heat Exchanger Installation 2. Apply sealing agent (arrow) to the retarder housing (100) near the heat exchanger (6400) (see dashed NOTE line/figure). The water and oil section of new heat exchangers...
  • Page 75 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Heat Exchanger 6400 28175 6. With housing models up to retarder serial number 963 690, the gap at the top between the heat exchanger (6400) and the retarder housing (100) must be sealed with sealing agent (arrow) (see dashed line/figure).

  • Page 76: Pressure Control Valve

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Pressure Control Valve Pressure Control Valve Item No. Designation 2200 Complete pressure control valve 2206 O-ring 21.5x2.5, replace 3500 Screw plug M30x1.5, hexagon socket head, w.a.f. 17,...
  • Page 77 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Pressure Control Valve Requirements Special tool • Retarder switched off • Ignition switched off • Retarder oil discharged (see page 22) N r. N r. K d.
  • Page 78 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Pressure Control Valve Installation h -N .- S h -N it h 2206 2200 28078 1. Lubricate the new O-ring (2206) with silicone-free, non-corrosive grease and pull it onto the pressure control valve (2200).

  • Page 79: Non-Return Valve Inlet

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Inlet Non-Return Valve Inlet Item No. Designation 1900 Non-return valve inlet, complete 1900/1 Guide M48x1.5, hexagon insert bit, w.a.f. 55, with copper sealing ring: 280 Nm...
  • Page 80 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Inlet Installation CAUTION NOTE Hot parts! Hands could be burned. Use sealing agent Loctite 572 with retarders starting with Voith item No. H67.1500.30. Work carefully.

  • Page 81: Non-Return Valve Outlet

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Outlet 7.10 Non-Return Valve Outlet Item No. Designation 1600 Valve cover, mind mounting position 1700 O-ring 60x3, replace 2100 Non-return valve outlet, complete. Mind mounting position...
  • Page 82 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Outlet Removal Checking Special tool 1. Unscrew the combined hex head screws (3100). 2100 2105 2. Remove the valve cover (1600). 153.000052xx Puller for non-return...
  • Page 83 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Non-Return Valve Outlet Installation 1. Apply silicone-free and non-corrosive grease to the new O-rings (2105 and 2106) and pull them onto the non-return valve outlet (2100). 2100 28178 2.

  • Page 84: Oil Temperature Sensor

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Oil Temperature Sensor 7.11 Oil Temperature Sensor Item No. Designation 5200/1 Oil temperature sensor M14x1.5, hexagon insert bit, w.a.f. 21, with copper sealing ring: 32 Nm 5300 Sealing ring A14x20, replace...
  • Page 85 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Oil Temperature Sensor Checking the internal resistance NOTE Measuring in one temperature range is usually sufficient. Polarity is irrelevant. Temperature Resistance 1039–1117 Ω 20 °C ± 10 °C 1194–1271 Ω...

  • Page 86: Coolant Temperature Sensor

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Coolant Temperature Sensor 7.12 Coolant Temperature Sensor Item No. Designation 5200/2 Coolant temperature sensor M14x1.5, hexagon insert bit, w.a.f. 21, with copper sealing ring: 32 Nm 5300 Sealing ring A14x20, replace...
  • Page 87 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Coolant Temperature Sensor Checking the internal resistance NOTE Measuring in one temperature range is usually sufficient. Polarity is irrelevant. Temperature Resistance 1039–1117 Ω 20 °C ± 10 °C 1194–1271 Ω...

  • Page 88: Pressure Sensor

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Pressure Sensor 7.13 Pressure Sensor Item No. Designation 9000 Pressure sensor M16x1.5, hexagon insert bit, w.a.f. 27, with integrated sealing ring: 32 Nm NOTE 9000 Lubricate sealing rings, O-rings and shaft sealing rings with silicone-free, non-corrosive grease before installation.

  • Page 89: Proportional Valve And Damping Plate

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Proportional Valve and Damping Plate 7.14 Proportional Valve and Damping Plate Item No. Designation 3850 G Supply-air pressure (p L Electrical connecting lead 3700 Proportional valve 3800...
  • Page 90 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Repair Proportional Valve and Damping Plate Requirements • Retarder switched off • Ignition switched off • Supply-air pressure discharged • Compressed-air line disconnected • Electrical connection lead disconnected from proportional valve.

  • Page 91: Appendix

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Appendix Appendix Tightening Torques Page 91...

  • Page 92: Tightening Torques

    Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Appendix Tightening Torques Tightening Torques Item No. Designation Dimensions Tightening torque Throttle M14x1.5 – Screw plug M12x1.5, hexagon socket head, w.a.f. 6 With copper sealing ring: 20 Nm...
  • Page 93 Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Appendix Tightening Torques Item No. Designation Dimensions Tightening torque 4100 Screw plug M30x1.5, hexagon socket head, w.a.f. 17 With copper sealing ring: 130 Nm With integrated sealing ring: 100 Nm...
  • Page 94 Voith Turbo Produktgruppe Retarder Postfach 1555 74555 Crailsheim Deutschland Phone: 00 49 79 51 / 32-0 Fax: 00 49 79 51 / 32-756 service-retarder@voith.com www.voith.com Engineered reliability.

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