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...
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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...
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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...
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...
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.
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.
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...
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.
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.
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...
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...
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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...
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;...
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.)
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.:)
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)
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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...
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,...
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...
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...
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,...
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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! •...
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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.
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...
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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.
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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.
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...
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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.
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...
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...
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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,...
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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...
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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...
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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...
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)
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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. •...
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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"...
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...
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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.
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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...
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 •...
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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...
Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Removing and Installing the Retarder Removing and Installing the Retarder Page 44...
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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.
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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,...
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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...
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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.
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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.
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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.
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...
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.
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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.
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.
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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. •...
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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.
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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.
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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.
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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).
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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.
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.
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...
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...
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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 •...
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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.
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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...
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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).
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,...
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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.
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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).
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...
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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.
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...
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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...
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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.
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...
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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...
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...
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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...
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...
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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.
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