Voith VR 115 E Manuale utente

Voith Turbo

Aftersales Service Manual Voith Retarder VR 115 E

153.00009710 I 2005-11

Page 2

Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents

Voith Turbo I 153.00009710 I arrtd I 2005-11

Table of Contents

1 About this Document 5

1.1 Purpose of this Document 6

1.2 Target Groups 6

1.3 Other Applicable Documents 6

1.4 Symbols and Identifications 7

1.5 Item Numbers 7

1.6 Legal/Contact Information 7

2 Basic Safety Information 8

2.1 Product Safety 9

2.2 Staff Qualification 9

2.3 Safety-Conscious Working 9

2.4 Environmental Protection 9

2.5 Troubleshooting 9

2.6 Maintenance and Repair 9

2.7 Driving Mode 9

2.8 Warranty 10

3 Design and Function 11

3.1 Overview of the Modules 12

3.2 Retarder Identification 14

3.3 Controller Identification (VERATM) 15

3.4 Controller Identification (Digiprop) 16

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents

Voith Turbo I 153.00009710 I arrtd I 2005-11

3.5 Function and Control Scheme 17

3.6 Function Description 19

4 Maintenance and Service 20

4.1 Maintenance Intervals 21

4.2 Oil Change 22

4.3 Checking the Oil Level 25

4.4 Draining the Coolant 28

5 Diagnosis and Troubleshooting 30

5.1 Troubleshooting Chart 31

5.2 Constant-Air Pressure Control Loop 36

5.3 Pump Pressure (pdyn) 39

5.4 Proportional Valve Current 42

6 Removing and Installing the Retarder 44

7 Repair 51

7.1 Components Overview 52

7.2 Top Oil Tank Cover 59

7.3 Bottom Oil Tank Cover 61

7.4 Casing Ventilation 63

7.5 Retarder Ventilation 69

7.6 Water Neck 70

7.7 Heat Exchanger 71

7.8 Pressure Control Valve 76

7.9 Non-Return Valve Inlet 79

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Table of Contents

Voith Turbo I 153.00009710 I arrtd I 2005-11

7.10 Non-Return Valve Outlet 81

7.11 Oil Temperature Sensor 84

7.12 Coolant Temperature Sensor 86

7.13 Pressure Sensor 88

7.14 Proportional Valve and Damping Plate 89

8 Appendix 91

8.1 Tightening Torques 92

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document

Voith Turbo I 153.00009710 I arrtd I 2005-11

1. About this Document

1.1 Purpose of this Document 6

1.2 Target Groups 6

1.3 Other Applicable Documents 6

1.4 Symbols and Identifications 7

1.5 Item Numbers 7

1.6 Legal/Contact Information 7

Page 6

Purpose of this DocumentVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document

Voith Turbo I 153.00009710 I arrtd I 2005-11

1.1 Purpose of this Document

This Aftersales Service Manual provides information

and instructions on maintenance and repair of the

Voith Retarder VR 115 E.

1.2 Target Groups

This Aftersales Service Manual is intended for service

people for service and diagnoses only and may not be

reproduced or given to third parties.

1.3 Other Applicable Documents

Documents Information Item number

Voith retarder oil change intervals/oil specification list Oil change intervals and approved oil types 153.000831xx

Operating instructions for Voith Retarder VR 115 E Information on the safe, professional and economical operation of the

Voith Retarder VR 115 E H67.2964xx

Cooling water quality list Approved coolants H67.2224xx

Operating instructions for retarder tester Measured values for constant-air pressure and pump pressure Included in scope of delivery of

the retarder tester(153.001085xx)

Operating instructions for Diana-Lite test software Information on the testing of:

• Constant-Air Pressure Control Loop

• pump pressure (pdyn)

Included in the scope of delivery

of the Diana-Lite test software

(153.000776xx)

Operating instructions for the WinDia diagnostic

software Instructions on PC diagnosis for the Digiprop and VERATM controllers 3623-020900

Gearbox-specific documents on the retarder Information on safe, professional installation and removal of the retarder On request

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Symbols and IdentificationsVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I About this Document

Voith Turbo I 153.00009710 I arrtd I 2005-11

1.4 Symbols and Identifications

Structure of warnings

Levels of danger

The warnings are categorized into four levels of

danger:

Notes

Distinctions

ÖOne-step action instruction.

1. First step of an action instruction. Other steps

follow and are numbered in sequence.

1.5 Item Numbers

The item numbers used are usually found in the spare

parts lists.

Exceptions:

• One- or two-digit item numbers

• Item numbers with a slash

1.6 Legal/Contact Information

For questions and work procedures not described in

these documents, contact the respective organisation

for your area.

Voith Turbo

Produktgruppe Retarder

Postfach 1555

74555 Crailsheim

Deutschland

Phone: 00 49 79 51 / 32-401, 32-422, 32-1860

Fax: 00 49 79 51 / 32-756

[email protected]

www.voith.com

Type and source of danger!

Possible consequences if not observed.

ÖMeasures for the prevention of danger and its

consequences.

Potentiallyhazardous situation which, ifnotavoided,

may result in property damage.

Potentiallyhazardous situation which, ifnotavoided,

may result in minor or moderate injury.

LEVEL OF DANGER

CAUTION

Potentially hazardous situationwhich,ifnotavoided,

could result in death or serious injury.

Imminently hazardous situation which, if not

avoided, will result in death or serious injury.

Information on easier and safer work with the

retarder.

ÖMeasures for easier and safer work with the

retarder.

WARNING

DANGER

NOTE

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Voith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information

Voith Turbo I 153.00009710 I arrtd I 2005-11

2. Basic Safety Information

2.1 Product Safety 9

2.2 Staff Qualification 9

2.3 Safety-Conscious Working 9

2.4 Environmental Protection 9

2.5 Troubleshooting 9

2.6 Maintenance and Repair 9

2.7 Driving Mode 9

2.8 Warranty 10

Page 9

Product SafetyVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information

Voith Turbo I 153.00009710 I arrtd I 2005-11

2.1 Product Safety

The retarder is constructed according to state of the

art technology and acknowledged safety regulations.

Nevertheless, hazardous situations and property

damage may occur as a result of improper usage,

maintenance and repair.

ÖObserve safety and warning information.

2.2 Staff Qualification

ÖAllow only qualified professionals to carry out repair

and maintenance work.

2.3 Safety-Conscious Working

Voith does not assume any liability for personal injury

and/or property damage caused by improper and

unprofessional work.

ÖObserve the following regulations:

- Accident-prevention regulations

- Other generally acknowledged safety

regulations and occupational health

- Motor vehicle regulations

- Safety regulations for handling chemical

substances such as oils and greases

2.4 Environmental Protection

ÖDrainedfuelsandfluids,consumablesandoldparts

must be disposed of properly.

2.5 Troubleshooting

Voith provides a warranty/goodwill service for

defective parts only.

ÖDo not replace parts on mere speculation.

2.6 Maintenance and Repair

Danger of burning and scalding via squirting oil!

The oil in the retarder may be hot.

ÖWork carefully.

Danger of burning and scalding via hot coolant!

The coolant may be hot.

ÖWork carefully.

Danger of burns via hot parts!

Parts of the retarder may be hot.

ÖWork carefully.

ÖWear protective gloves or use cloths if necessary.

Damage to property via soiled parts!

Considerable damage or malfunctions may occur due

to soiling.

ÖEnsure cleanliness.

Damage to property via improper cleaning!

ÖDo not aim the jet of a high-pressure cleaner

(steam-jet device) at valves, pressure sensors or

ventilators of the retarder.

2.7 Driving Mode

ÖEnsure that the retarder is fully functional for all

vehicle maneuvers, i.e.:

- Retarder properly filled with oil

- Retarder electronics connected and functional

- Pneumatic control connected and functional

Page 10

WarrantyVoith Turbo I Aftersales Service Manual Voith Retarder VR 115 E I Basic Safety Information

Voith Turbo I 153.00009710 I arrtd I 2005-11

Driving after repair/oil change

Oil ejection!

De-aeration not performed.

ÖDe-aerate retarder.

- Switch off retarder foot control if present and

possible

- Move vehicle at 50 km/h

- Activate retarder at brake stage one five times

for approx. 5 sec. each time

Towing

ÖTow vehicle with retarder max. 100 km at max.

40 km/h.

Parking

ÖDo not use retarder as a parking brake, as it does

not act as a brake when the vehicle is standing still.

Failure while driving

During failure of the retarder, or while temperature

adaptation is active, only the service brake is

functional.

ÖAdjust the speed of the vehicle with the service

brake.

ÖEngage the lowest possible gear to achieve a high

engine speed.

ÖContinue driving in this way until the retarder is

available at full capacity again.

2.8 Warranty

Voith accepts no liability for damage caused by

changes to the retarder or the use of spare parts,

accessories, attachments and special features not

tested and approved by Voith.

ÖUse only parts approved by Voith to ensure the

safety of the vehicle.

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