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Training

Aftersales Service Manual Gearbox-Retarder-System GO170 - GO210 with R 115 E

Content

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1 2

Preface ....................................................................................................1/1 General....................................................................................................2/1


2.1 2.2 2.3 2.4 2.5 2.6 Illustration Gearbox-Retarder-System ............................................................. 2.1/1 Function and Operation Scheme Gearbox ...................................................... 2.2/1 Function and Operation Scheme Retarder ...................................................... 2.3/1 Gearbox Identification...................................................................................... 2.4/1 Retarder Identification...................................................................................... 2.5/1 Retarder Control-Unit Identification ................................................................. 2.6/1

Maintenance............................................................................................3/1
3.1 3.2 3.3 3.4 3.5 Maintenance Work / Oil Change Intervals ....................................................... 3.1/1 Checking Oil Level of Gearbox ........................................................................ 3.2/1 Checking Oil Level of Retarder........................................................................ 3.3/1 Oil Change of Gearbox .................................................................................... 3.4/1 Oil Change of Retarder.................................................................................... 3.5/1

Diagnosis / Troubleshooting Gearbox .....................................................4/1


4.1 Troubleshooting Diagram A to E...................................................................... 4.1/1

Content

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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 (py)............................................................... 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

Removing, Installing Gearbox .................................................................6/1


6.1 Removing, Installing Gearbox.......................................................................... 6.1/1

Removing, Installing Retarder .................................................................7/1


7.1 Removing, Installing Retarder ......................................................................... 7.1/1

Content

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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

Repair Retarder.......................................................................................9/1
9.1 9.2 9.3 9.4 9.5 9.6 Overall Illustration of Main Components.......................................................... 9.1/1 Removing, Checking and Installing Casing Ventlation .................................... 9.2/1 Removing, Cleaning and Installing Silencer .................................................... 9.3/1 Removing, Installing Water Neck..................................................................... 9.4/1 Removing, Checking, Installing Heat Exchanger............................................. 9.5/1 Removing, Installing Oil Tank Cover ............................................................... 9.6/1 A Top Oil Tank Cover ..................................................................................... 9.6/1 B Bottom Oil Tank Cover ................................................................................ 9.6/2

Content

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10

Control Parts Retarder ..........................................................................10/1


10.1 10.2 10.3 10.4 Removing, Installing Proportional Valve ........................................................ 10.1/1 Removing, Installing Oil Temperature Pick-Up.............................................. 10.2/1 Removing, Installing Cooling-Water Temperature Pick-up............................ 10.3/1 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

Preface

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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 reduction 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.

Preface

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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 vehiclespeed 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.

Preface

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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
image board

35
part in drawing

gearbox-design-group

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 professional knowledge to make sure that his own safety is not endangered and that the retarder suffers no negative effects, in particular safety-wise, through the chosen working procedure. For these reasons, no liability can be assumed for damage incurred. The pertinent accident-prevention-regulation, other broadly rules of the security-technology and working-medicine and the traffic admission law are to be kept. We are not liable for damages, that originate through contempt of these rugulations.

Preface

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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 Business unit gearbox Sales Hauptstrae 107 D-76568 Gaggenau Telephone 07225 / 61-65 56 Fax 07225 / 61-65 51 e-mail: sales.transmissions@daimlerchrysler.com Voith Turbo GmbH & Co. KG Production group retarder Voithstrae 1 Post box 15 55 D-74555 Crailsheim Telephone 07951 / 32-401, -422 Fax 07951 / 32-756 e-mail: retarder@voith.de

Copyright October 1999 - Voith Turbo / DaimlerChrysler

General

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2.1 2.2 2.3 2.4 2.5 2.6

Illustration Gearbox-Retarder-System........................................................2.1/1 Function and Operation Scheme Gearbox.................................................2.2/1 Function and Operation Scheme Retarder.................................................2.3/1 Gearbox Identification ................................................................................2.4/1 Retarder Identification ................................................................................2.5/1 Retarder Control-Unit Identification ............................................................2.6/1

General



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Illustration gearbox-retarder-system

26/250/047
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

26/400/089

26/250/068

3700

26/100/125 26/400/083

26/100/122

26/100/125

3500 26/100/206
M+P-07A-1708 M+P-07A-1708

26/100/116

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

General



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Illustration gearbox-retarder-system (Continue) 25/250/068 26/150/ 26/250/ 26/250/047 26/250/068 26/350/ 26/400/089 3700 4100 Clutch servo * Drive shaft Clutch wear indicator * Switch for starter lock * Inductive sensor for overspeed protection * Shift Switch reversing light * Proportional valve retarder control Oil filler screw retarder M30x1,5 Inhex.-head, w.a.f. 17 Heat exchanger retarder

26/350/

4100

6400

3700

6400 * = option

26/150/

25/250/068

26/250/068 26/400/089

26/250/047

26/250/

M+P-07A-1710

Remark: Terms for items from DaimlerChrysler-EPC-documentation

General



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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

3700 100/1

3500

103 6400

107 4200
M+P-07A-1484

General



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Illustration gearbox force diagram

General



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Illustration gearbox-longitudinal section

10

11 18

12

13

18

14

15

18

16

17

18

19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1. Gear wheel 2. Gear wheel 3. Gear wheel 4. Gear wheel 5. Gear wheel Reverse gear wheel Countershaft Oil pump Drive shaft Pilot bearing Switch lever Switch rails Sliding sleeve Synchromesh ring Synchromesh body Synchromesh cone Mainshaft Actuating lever Fly wheel

General



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Illustration gearbox-longitudinal section

10

11 18

12

13

18

14

15

18

16

17

18

19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1. Gear wheel 2. Gear wheel 3. Gear wheel 4. Gear wheel 5. Gear wheel Reverse gear wheel Countershaft Oil pump Drive shaft Pilot bearing Switch lever Switch rails Sliding sleeve Synchromesh ring Synchromesh body Synchromesh cone Mainshaft Actuating lever Fly wheel

General



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Illustration gearbox-sectional view

11

12

20

25 21

26

27

22

23

18

17

24

28

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

Countershaft Switch lever Switch rails Mainshaft Actuating lever Cross shift Reverse gear lock Actuating lever bolt Gearbox housing Loose wheel bearing Shift link (option) Shift ramifications Cam follower Reverse idler gear

General



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Illustration retarder

70

47

15

17

18 23

42

26 72 21

A R

25 20 2 63 1/1 1 1/2

36

19

46 22 6 8 4 44 64 16 62 43 55 Oil sump Supply-air pressure p V Constant-air pressure p y 41 Coolant (water) Pump pressure p P

69

FD914be

Note The reference numbers indicated in section 2.3 are not identical with the reference numbers of the spare parts lists. 1 1/1 1/2 2 4 6 8 15 16 17 18 19 20 21 22 23 25 26 36 41 42 43 44 46 47 55 62 63 64 69 70 72 Heat exchanger complete Retarder oil-cooling circuit Gearbox oil-cooling circuit Control unit Connection Terminal 15 Fuse (8A) Connection Ground ABS-signal Retarder stage switch Retarder pilot light Stop light relay Cooling-water temperature pick-up Oil temperature pick-up Proportional valve Ventilation Casing ventilation Air pressure line A constant-air pressure (py) Air pressure line supply-air pressure (pv) Ventilation line R Oil duct Oil tank Oil sump Stator Rotor Speedometer signal Oil-drain plugs Pressure regulating valve Check valve (inlet) Check valve (outlet) Plug ISO-interface Plug additional functions Pressure sensor

General



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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.

General



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c

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 pressure (py) on the oil sump (43). The constant-air pressure (py) in the oil sump (43), depending on the operating conditions (prop-shaft speed), forces a certain quantity of oil into the working chamber between rotor (46) and stator (44). The rotor (46) is connected with the drive shaft of the retarder, the stator (44) is fixed to the retarder housing.

FD299

The hydrodynamic principle a Rotor (46) b Stator (44) c Oil flow

General



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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 between the braking energy of the retarder and the amount of heat which can be dissipated by the vehicle cooling system. If the cooling water temperature rises into the temperature adaption range, the consequence is an adaption 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.

General



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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.

Note If the check valve (outlet) must be renewed during a repair operation, please contact Voith Turbo or a responsible contract party.

General



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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.

DAIMLERCHRYSLER
Indic. Code Serial No
71 4. 692 L

Unit Series Version Left hand drive

Ratio 1. gear Number of gears Input torque (x 10) Gearbox-Bus

GO 170 - 6 / 8,2

DAIMLERCHRYSLER
Indic. GO 170-6/8,2 G 714.100 L Serial No

Gearbox number Gearbox part-No

M-Code Version No

Code

M-Code Variant No

M+P-07A-1705e

M+P-07A-1704e

Illustration 1

Illustration 2

General



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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.
Retarder ratio (i Ret) Serial-Number (Brake-Number) 6-digit number

Serial-No

000000 45/1999

CW/Year

Date of production
Serial-No
CW/Year

Voith Item-Number 8-digit number


M+P-07A-1707

DaimlerChrysler part-number
M+P-07A-1706e

Illustration 1

Illustration 2

General



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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)

Vo it Co h-N r.: Se de-N Kurien- r.: nd Nr. en : -N r.:

53 . xx xxxx x .12 xx xx /D atu m

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.

Voith no.: Code no.: Serial no.: Client no.:

Date:

M+P07A-1617a

Maintenance

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3.1 3.2 3.3 3.4 3.5

Maintenance Work / Oil Change Intervals..................................................3.1/1 Checking Oil Level at Gearbox...................................................................3.2/1 Checking Oil Level at Retarder ..................................................................3.3/1 Oil Change at Gearbox...............................................................................3.4/1 Oil Change at Retarder ..............................................................................3.5/1

Maintenance



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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

Maintenance



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Gearbox Single-grade mineral oil 1) Normal duty Heavy duty 100 000 km 4) 50 000 km 4) Synthetic oil 1) 300 000 km 5) 300 000 km 5) Single-grade mineral oil 2) 135 000 km 4) 60 000 km 4)

Retarder 6) Synthetic oil 2) 180 000 km 5) 90 000 km 5) Synthetic oil 3) 300 000 km 5) 300 000 km 5)

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

Maintenance



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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.

Maintenance



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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

26/100/122 26/100/128

M+P-07A-1716a

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Maintenance



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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!

Maintenance



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Job scope

Caution! Risk of injury! The oil filler plug is hot! Oil temperature!

26/100/122 26/100/128

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.
Remark: Terms for items from DaimlerChrysler-EPC-documentation

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

Maintenance



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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

Maintenance



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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)

4100

109
M+P-07A-1713

Maintenance



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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.

Maintenance



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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.

Caution! Risk of injury! 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 107

3. Check sealing rings of oil drain plugs for damages, renew oil drain plugs if necessary. 4. Screw in oil drain plugs and screw them tight. Tightening torque oil drain plugs (107, 4200) 65 Nm (80 Nm)

Maintenance



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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).

Maintenance



&KHFNLQJ 2LO /HYHO DW 5HWDUGHU (Continue)

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.

Caution! Risk of injury! 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).
4100

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

109
M+P-07A-1713

Maintenance



&KHFNLQJ 2LO /HYHO DW 5HWDUGHU (Continue)

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

Maintenance



2LO &KDQJH DW *HDUER[

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

26/100/122 26/100/116 26/100/119

26/100/128

26/100/107 26/100/113

26/100/128 26/100/125

Lubricants and cleaning agents Sieve in screw plug Benzine

26/100/128 26/100/125
M+P-07A-1715

Remark: Terms for items from DaimlerChrysler-EPC-documentation

Maintenance



2LO &KDQJH DW *HDUER[ (Continue)

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.

Caution! Risk of injury! The oil drain plugs are hot! Oil temperature!

Oil filling Service filling (oil change) New filling 12,5 litre 13,0 litre

Maintenance



2LO &KDQJH DW *HDUER[ (Continue)


26/100/122 26/100/128

Job scope 1. Push an oil pan under the gearbox.

Caution! Risk of injury! 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. 10. Screw the oil filler plug (26/100/122) with new sealing ring tight. Tightening torque oil filler plug (100/122): 47 Nm

26/100/116 26/100/119 26/100/107 26/100/113

26/100/128 26/100/125 26/100/128 26/100/125

M+P-07A-1715b

Remark: Terms of items from DaimlerChrysler-EPC-documentation

Maintenance



2LO &KDQJH DW 5HWDUGHU

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)

4100

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

107 3500 4200 4200


M+P-07A-1488

Maintenance



2LO &KDQJH DW 5HWDUGHU (Continue)

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 on next page) and to use only oils specified in the Operating Specifications, chapter 3.1 Oil Change Intervals 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; 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.

Maintenance



2LO &KDQJH DW 5HWDUGHU (Continue)

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.

Oil filling with heat exchanger Service filling (oil change, oil level check) After complete taking apart and cleaning as well as emptied heat exchanger (corresponds new filling) 7,0 litre 7,8 litre

Job scope 1. Push an oil collecting pan under the retarder.

Caution! Risk of injury! 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)

107

4200

4200
M+P-07A-1489

Maintenance



2LO &KDQJH DW 5HWDUGHU (Continue)

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).

3500

M+P-07A-1490

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.

Maintenance



2LO &KDQJH DW 5HWDUGHU (Continue)

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

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).

Diagnosis / Troubleshooting 4.1

'LDJQRVLV  7URXEOHVKRRWLQJ *HDUER[

Troubleshooting Diagram ...........................................................................4.1/1


Troubleshooting Master System .................................................................................... 4.1/1 Troubleshooting Diagram A to E.................................................................................... 4.1/2

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP

Illustration troubleshooting master-system

see troubleshooting diagram at page 4.1/2

at gearbox?

Complaint

at retarder?

see troubleshooting diagram at page 5.1/2

Please contact DaimlerChrysler

at the gearbox-retardersystem, but I am not sure

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

A1 A2* A3*

*Begin of troubleshooting at A1

E
elektrical function

leaks

B
shiftability

Complaint Gearbox

no traction

noices

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

Illustration troubleshooting diagram A1

A1
leaks

Check residual oil quantity. Contact product unit gearbox if residual oil quantity smaller 50%.

at the drive shaft? YES NO

at radial shaft sealing ring? YES NO

at countershaft cover? YES NO

Renew radial shaft sealing ring (chapter 8.2)

seal new with released surface sealant (chapter 8.2)

at cover 5./6.gear? (only GO 210) NO YES

at O-rings? YES NO

A2

at O-ring? YES NO

Renew O-rings (chapter 8.2)

at surface / surface sealant? YES NO Renew O-rings (chapter 8.2)

at the micro capsulated screws? YES NO

Renew O-rings (chapter 8.2)

Contact product unit gearbox

use new micro encapsulated screws

Contact product unit gearbox

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

Illustration troubleshooting diagram A2

A2
leaks

at cover oil pump? Contact product unit gearbox YES NO at parting surface of housing? YES NO

Contact product unit gearbox

am Gehuseteil? YES NO

at cover of gearbox selecting fork right and left? YES NO

seal new with surface sealant (chapter 8.3)

Threaded components / shift rocker arm bearing ? NO YES

Filler cap?

Contact product unit gearbox

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

YES

Seal parts new, renew if necessary

NO

YES

A3
renew radial shaft sealing ring (chapter 8.3) Radial shaft sealing ring right side? YES NO Check sensor / switch for leak leaky sealed

Renew cross shift complete (chapter 8.3)

Contact product unit gearbox

Renew parts and seal them

Seal parts new

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

Illustration troubleshooting diagram A3

A3
leaks

at breather? Breather correct mounted? YES NO YES NO Cover / flanges leak? YES NO

Check oil level and correct if necessary (chapter 3.2)

Renew breather (chapter 8.4)

Cover / flanges damaged? YES NO

Paper gasket at cross shift leaks between inner and outer cover? YES NO

Replace cover / flanges (chapter 8.2)

Seal new cover / flanges (chapter 8.2)

Paper gasket damaged

Contact product unit gearbox

YES

NO

Renew cross shift complete (chapter 8.3)

Seal new with released liquid sealant

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

Illustration troubleshooting diagram B

Shiftability

Selectability?

YES

NO

outer shift smooth? NO YES

Shift at still stand heavy handling? NO YES

Smooth shifting of gear? NO YES

Contact product unit gearbox

Reverse gear heavy handling? YES NO

Does clutch disconnect? NO YES

Renew cross shift complete (chapter 8.3)

Contact product unit gearbox

Contact product unit gearbox

Contact product unit gearbox

Adjust clutch according to vehicle manufacturer instructions

Clutch servo in function? YES NO

Contact product unit gearbox

Change clutch servo (chapter 8.6)

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

Illustration troubleshooting diagram C

Noices

noices when shifting? YES NO

in reverse gear?

Noices during operation in pulling action? YES NO

YES

NO

Check for clutch disconnect according to vehicle manufacturer instructions

scratching when shifting? YES NO

Check oil level (chapter 3.2), if OK, contact product unit gearbox

Noices during stress cycle? NO YES

Ambient temperature? COLD WARM

Contact product unit gearbox

Noices during operation in retarder operation? YES NO

Contact product unit gearbox

does not appear at operation temperature

Check outer shift for easy handling

Contact product unit gearbox

Rattleing in idle speed? YES NO

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

Contact product unit gearbox

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

Illustration troubleshooting diagram D

D
no traction

Gear shifted at gearbox? (check at gearbox) YES NO

Contact product unit gearbox

Adjust again outer shift according to the vehicle manufacturer instructions

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

Illustration troubleshooting diagram E

E
electrical function

Does switch exist (switch for reverse gear position or neutral position) YES NO

Check contacts of components OK NOK

Sensors available? YES NO

functioning?

Renew components

Check contacts of components OK NOK

Contact product unit gearbox

YES

NO

Contact product unit gearbox

Renew components

functioning?

Renew components

YES

NO

Contact product unit gearbox

Renew components

Diagnosis / Troubleshooting 5.1

'LDJQRVLV  7URXEOHVKRRWLQJ 5HWDUGHU

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 Troubleshooting and Remedies .................................................................5.2/1 Illustration Control System .........................................................................5.3/1 Checking Supply-Air Pressure ...................................................................5.4/1 Checking Constant-Air Pressure (py) .........................................................5.5/1 Checking Control Current of Proportional Valve ........................................5.6/1 Checking Temperature Adaption................................................................5.7/1 Checking Pressure Sensor.........................................................................5.8/1 Checking Pump Pressure...........................................................................5.9/1 Table of Measurements..............................................................................5.10/1 Operational Check......................................................................................5.11/1

5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP

Illustration troubleshooting master system

see troubleshooting diagram at page 4.1/2

at gearbox?

Complaint

at retarder?

see troubleshooting diagram at page 5.1/2

Please contact DaimlerChrysler

at the gearbox-retardersystem, but I am not sure

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

A
Oil loss through ventilation

Complaint Retarder R 115 E

Retarder pilot light

No respectively insufficient retarder braking effect

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

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).

A
Oil loss through ventilation

Check retarder oil level Water in oil? (emulsion) NO YES OK NOK Water in oil? (emulsion) YES NO

Check heat exchanger (chapter 9.5)

Contact Voith service partner

Check retarder oil level too high too low

Check gearbox oil level NOK OK

Check gearbox oil level OK NOK

Check gearbox oil level too high too low

Correct retarder oil level

Check casing ventilation (chapter 9.2) OK NOK

Check gearbox oil level too high too low

Correct retarder- and gearbox oil level

Contact Voith service partner

Check control unit (chapter 5.4 - 5.9)

Replace casing ventilation

Correct retarder- and gearbox oil level

Contact Voith service partner

M+P-07A-1763 ae

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

B
Retarder pilot light

Permanent light in position 0 after light test?

no function?

flashes?

Activate blinking code and read out fault code (chapter 5.2)

Check retarder pilot light and renew, if necessary

Temperature adaption

Rectify fault and delete fault memory (chapter 5.2)

Contact Voith service partner

Check operation (during braking with retarder nominal engine speed, if possible) OK NOK

Check temperature pick-up oil / water (chapter 5.7) OK NOK

Driver instruction!

Check vehicle cooling system: -coolant level -thermostat -coolant pump -radiator fan -radiator grill for dirtiness

Replace temperature pick-ups (chapter 10.2, 10.3)

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

C
No respectively too insufficient retarder braking effect

Check retarder oil level Water in oil? (emulsion) NO YES OK NOK Water in oil? (emulsion) YES NO

Check heat exchanger (chapter 9.5)

Check constantair pressure (py) (chapter 5.5) OK NOK

Check retarder oil level too high too low

Check pump pressure (chapter 5.9) OK NOK

Contact Voith service partner

Check gearbox oil level OK NOK

Contact Voith service partner

Contact Voith service partner

Check current of proportinal valve (chapter 5.6) OK NOK

Correct retarder oil level

Check gearbox oil level too high too low

Check supply-air pressure (chapter 5.4) OK NOK

Check temperature adaption/ pressure sensor (chapter 5.7 / 5.8) OK NOK

Contact Voith service partner

Correct retarder- and gearbox oil level

Proportional valve or damping plate mechanically defect

Check vehicle compressed-air pressure system OK NOK

Contact Voith service partner

Contact Voith service partner

Contact Voith service partner

Contact vehicle manufacturer

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ 'LDJUDP (Continue)

Electrical connections diagram R 115 E (Voith-wiring harness) 2 4 15 16 17 18 19 20 21 47 69 70 72 Control unit Connection Terminal 15 ABS-signal Retarder stage switch Retarder pilot light Stop light relais Cooling-water temperature pick-up Oil temperature pick-up Proportional valve Speedometer signal Plug ISO-Interface Plug optional functions Pressure sensor
P
1 2

U
4

72
14 13 11 12 10 1

70
9 5 8 4 3 2 7 6

47 15

21

19

20

18
87 87a 30

. . .

2 1

17

X3

X2
2 3 1 6 5 4 9 8 7

. 4

8 11 10 12 7

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

X1

4 3 2 1 4

4 69

16

FD983a

Diagnosis / Troubleshooting
Troubleshooting and remedies Requirements for check



7URXEOHVKRRWLQJ DQG 5HPHGLHV

l l l l l

Battery voltage 18 - 32 V Vehicle electrical system checked in accordance with the Owners Manual for the vehicle and found satisfactory. Fuse for retarder control unit checked and found satisfactory. Compressed-air pressure 6 - 11 bar 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).

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

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.

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Connector arrangement and pin assignment

Note All plugs illustrated from plug-in side (i.e. leads at back).

Plug X1 control unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Not in use Not in use Not in use Retarder stage switch, Position 2 Retarder stage switch, Position 1 Retarder stage switch, Position 1 Terminal 15 Retarder stage switch, Position 4 Retarder stage switch, Position 3 Retarder stage switch + ISO-interface, L-lead ISO-interface, K-lead connected with terminal 15 Not in use Terminal 31 Output / high side 2 HS2 Not in use Output / high side 1 HS1

16 17 18

13 14 15

10 11 12

7 8 9

4 5 6

1 2 3

FD846

Diagnosis / Troubleshooting
Plug X2 control unit 1 2 3 4 5 6 7 8 9



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Not operational Proportional valve Proportional valve + Cooling-water temperature pick-up Cooling-water temperature pick-up + Not operational Not in use Oil temperature pick-up Oil temperature pick-up +

7 8 9

4 5 6

1 2 3

FD848

Plug X3 control unit 1 2 3 4 5 6 7 8 9 10 11 12 Input / pull up DIU 1 Speedometer signal ABS-signal Input / pull down DID 2 Input / pull down DID 1 Pressure sensor ground Pressure sensor signal voltage Retarder pilot light Input / pull down DID 3 Pressure sensor supply voltage Stop light relais Input / pull down / PWM-in DID4

10 11 12

7 8 9

4 5 6

1 2 3

FD847

Diagnosis / Troubleshooting
Plug optional functions 1 2 3 4 5 6 7 8 9 10 11 12 13 14



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Retarder stage switch + Input / pull down DID 1 Input / pull down DID 2 Input / pull down DID 3 Input / pull down / PWM -in DID 4 Input / pull up DIU 1 Pressure sensor ground Pressure sensor signal voltage Pressure sensor supply voltage Output / high side HS1 Output / high side 2 HS2 No function Terminal 15 Terminal 31

10

12

14

11

13

FD849

Plug ISO-interface 1 2 3 4 K-lead L-lead Terminal 15 Terminal 31

4 2

3 1

FD854

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

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

FD851

Plug proportional valve 1 2 3 4 Proportional valve + Proportional valve No function No function

4 1

2 3

FD850

Diagnosis / Troubleshooting
Plug retarder stage switch 1 2 3 4 5 6 7 8



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Not operational Position 5 Position 4 Retarder stage switch + Position 3 Position 2 Position 1 Bridge to pin 4

5 1

6 2

7 3

8 4

FD853

Diagnosis / Troubleshooting A. With fault code


Special tool



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

53.8224.10

Commercially available tool Multimeter recommended: Fluke 87

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

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

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 l
1. 2. 3.

Retarder stage switch in position O. Vehicle at standstill, ignition ON Service interface L-lead connected to ground 2s. For this pupose, press L - pushbutton at service cable First fault as blinking code output. Item 2 and 3 repeated for more blinking code outputs. Long blinking signals (2 sec.) tens unit. Short blinking signals (0,5 sec.) single unit.

Meaning

l l

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

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. 2. 3. 4. 5. Retarder stage switch in position 0 Retarder stage switch in position 1 ( 2 seconds) Retarder stage switch in position 0 First fault as blinking code Items from ...3 for more blinking code outputs

0,5 sec

0,5 sec

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: The number of single unit then is indicated as short ON time: Breaks between each ON time: each 2 seconds each 0,5 seconds each 1 second
Display example for fault code 23 E Retarder pilot light ON A Retarder pilot light OFF t Time

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.

0,5 sec
99-03-fd1620

2 sec

2 sec

1 sec

1 sec

1 sec

1 sec

Diagnosis / Troubleshooting
Delete fault memory



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

No marginal notes in accordance with fault memory read out. 1. 2. Vehicle ignition system: OFF Servcie interface L-lead connected to ground. For this purpose, press L-pushbutton of service cable. Vehicle ignition system: ON Release L-lead from ground after 2 sec.

3. 4.

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Note Meaning of entries in Measurement/test connection column: X 1/15 X3/11 Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3

Fault

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection1)

Result/ Set point

Cause/ Remedy 2)

Code 01

Test step Stop light relay/ Short circuit to ground slight 1s - Ignition: OFF - Pull plug X3 out of control unit X 3/11 X 1/15 Relay is installed: 250-350 Check lead, plugs and relay or consumers

1) 2)

X 1/15 = ground control unit Only, if no fault is recognizable after a complete check of the periphery: change control unit.

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Fault Code 03 Test step

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection

Result/ Set point

Cause/ Remedy

HS 1 output Short circuit

slight

1s

- Ignition: OFF - Pull plug X1 out of control unit - Ignition: OFF - Pull plug X1 out of control unit - Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON - Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON - Start engine (idle speed)

X 1/18 X 1/15

Relay is installed: 250-350 Relay is installed: 250-350 17,5 V

Check lead, plugs and relay or consumers Check lead, plugs and relay or consumers Check lead, plugs and fuses

04

HS 2 output Short circuit Terminal 15 Undervoltage

slight

1s

X 1/16 X 1/15

05

serious

60 s

X 1/7 V X 1/15

06

Terminal 15 Overvoltage

serious

10 s

X 1/7 V X 1/15

32,5 V

Checking electrical installation of vehicle (see manufacturer instructions)

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Fault

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection

Result/ Set point

Cause/ Remedy

Code 08 09

Test step Cooling-water temperature pick-up Discontinuity / Short circuit to battery 1s serious/ slight * - Ignition: OFF - Pull plug X2 out of control unit X 2/5 X 2/4 20C 10C = 1039 - 1117 60C 10C = 1099 - 1271 80C 10C = 1271 - 1347 Notice: The measuring in one temperature range normally is sufficient. Check lead and sensor

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

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Fault

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection

Result/ Set point

Cause/ Remedy

Code 11 12

Test step Oil temperature pick-up Discontinuity / Short circuit to battery 1s serious/ slight * - Ignition: OFF - Pull plug X2 out of control unit X 2/9 X 2/8 20C 10C = 1039 - 1117 60C 10C = 1099 - 1271 80C 10C = 1271 - 1347 Notice: The measuring in one temperature range normally is sufficient. Check lead and sensor

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

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Fault Code 13 Test step 1

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection

Result/ Set point

Cause/ Remedy

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 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 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 0V 0V 0V 0V 0V 17,5 V 17,5 V 0V 0V 0V 0V 17,5 V 17,5 V 17,5 V 0V 0V 0V

Check lead, plug and retarder stage switch

13

- Ignition: ON - Retarder stage switch: Position 1

Check lead, plug and retarder stage switch

13

- Ignition: ON - Retarder stage switch: Position 2

Check lead, plug and retarder stage switch

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Fault Code 13 Test step 4

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection

Result/ Set point

Cause/ Remedy

- Ignition: ON - Retarder stage switch: Position 3

X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15

17,5 V 17,5 V 17,5 V 17,5 V 0V 0V 17,5 V 17,5 V 17,5 V 17,5 V 17,5 V 0V 17,5 V 17,5 V 17,5 V 17,5 V 17,5 V 17,5 V

Check lead, plug and retarder stage switch

13

- Ignition: ON - Retarder stage switch: Position 4

X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15

Check lead, plug and retarder stage switch

13

- Ignition: ON - Retarder stage switch: Position 5

X 1/10 V X 1/15 X 1/6 V X 1/15 X 1/5 V X 1/15 X 1/4 V X 1/15 X 1/9 V X 1/15 X 1/8 V X 1/15

Check lead, plug and retarder stage switch

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Fault

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection

Result/ Set point

Cause/ Remedy

Code 14

Test step Retarder stage switch Short circuit to battery serious 10 s - Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON - Retarder stage switch: Position 0 - Ignition: OFF - Pull plug X1 out of control unit - Retarder stage switch: Position 5 - Ignition: ON X 1/10 V X 1/15 0V Check lead and plug

15

Retarder stage switch Short circuit to battery Speedometer signal Discontinuity

serious

1s

X 1/10 X 1/15

Resistor infinite

Single check of stages for short circuit

16

serious

2s

X 3/2 V X 1/15

1V

Check lead and speedometer

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Fault

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection

Result/ Set point

Cause/ Remedy

Code 18

Test step Speedometer signal Short circuit to battery undefined signal ABS Short circuit to ground ABS-Signal undefined serious 2s - Ignition: OFF - Pull plug X3 out of control unit - Ignition: ON - Ignition: ON X 3/2 V X 1/15 9V Check lead and speedometer

19

serious

60 s

X 3/3 V X 1/15

3,5 V

Check lead, relay and ABS-control unit Check lead, relay and ABS-control unit Replace control unit Check lead

21

serious

60 s

- Ignition: ON

X 3/3 V X 1/15

16,5 V

22 23

Internal fault ABS-current path Proportional valve Fault No. 1: Short circuit to battery

serious serious

1s 1s

- Ignition: OFF - Pull plug X2 out of control unit - Ignition: ON

X 2/3 V X 1/15

10 V

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Fault

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection

Result/ Set point

Cause/ Remedy

Code 24

Test step 1 Proportional valve Fault No. 2: - Short circuit proportional valve magnetic - Short circuit connection lead proportional valve - Discontinuity proportional valve magnetic Valve magnetic - Discontinuity connection lead proportional valve - Short circuit to ground at proportional valve - Prop.- and shift valve interchanged serious 1s - Ignition: ON - Pull plug X2 out of control unit X 2/2 X 2/3 18-25 Check lead and proportional valve (valve block)

24

- Ignition: OFF - Pull plug X2 out of control unit

X 2/3 X 1/15

Resistor infinite

Check lead and proportional valve (valve block)

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Fault

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection

Result/ Set point

Cause/ Remedy

Code 24

Test step 3 - Ignition: OFF - Pull plug X2 out of control unit Valve block Fault No. 3: defective control unit Valve block Fault No. 5: defective control unit Terminal 30 Undervoltage serious 10 s X 2/2 X 1/15 Resistor infinite Check lead and valve block Replace control unit

25

27

serious

2s

Replace control unit

28

serious

60 s

- Ignition: OFF - Pull plug X1 out of control unit - Ignition: ON

X 1/13 V X 1/15

17,5 V

Check lead, plug and fuse

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Fault

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection

Result/ Set point

Cause/ Remedy

Code 29 31

Test step Fault control unit Control unit: Coding fault Retarder pilot light: Discontinuity / Short circuit to ground Retarder pilot light: Short circuit to battery serious serious 180 ms 100 ms Replace control unit Provide new parameters for control unit - Ignition: OFF - Pull plug X3 out of control unit - Ignition: ON - Ignition: ON - Retarder stage switch: Position 1 X 3/8 V X 1/15 17,5 V Check lead, retarder pilot light and fuse Check lead and retarder pilot light Replace control unit

32

serious

3s

33

serious

3s

X 3/8 V X 1/15

2V

35

Fault control unit

serious

500 ms / 123 s

Diagnosis / Troubleshooting



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Fault

Fault text

Fault class

Trigger time

Requirement / Operation

Measurement/ Test connection

Result/ Set point

Cause/ Remedy

Code 37

Test step Fault foot operation slight 100 ms / 1 s Check installation in accordance with OEM - as well as Voith requirements Ignition: ON Position 0 X 3/7 V X 1/15 and X 3/10 V X 1/15 0,3-0,7 V 4,75-5,25 V If deviation: step 2 2 Troubleshooting in wiring harness, pressure sensor, proportional valve, supply-air pressure, ECU (Contact Voith) Pressure sensor wiring harness

38

Fault constant-air pressure

slight

1 s to 10 s

Diagnosis / Troubleshooting B. Without fault code



7URXEOHVKRRWLQJ DQG 5HPHGLHV (Continue)

Note Retarder faults without fault code are not recognized electronically.

Diagnosis / Troubleshooting
Illustration control system



,OOXVWUDWLRQ &RQWURO 6\VWHP

11 33 71

Note The reference numbers indicated in section 5.3 are not identical with the reference numbers of the spare parts lists.

25 A P R 36 21 26

32

61

1 2 11 19 20 21 25 26 31

32

33 34 35 36 39

40 61 71

Heat exchanger Control unit Connection proportional valve current Cooling-water temperature pick-up Oil temperature pick-up Proportional valve Constant-air pressure line py (connection A) Supply-air pressure line pv (connection P) Compressed-air line (pressure regulator-four circuit protection valve) Compressed-air line (four circuit protection valve air tank for auxiliary equipment) with test connection Compressed-air line (Brake circuit 1) Compressed-air line (Brake circuit 2) Compressed-air line (Parking brake) Ventilation line (Connection R) Electrical lead (cooling-water temperature pick-up to control unit, 2-wires) Electrical lead (oil temperature pick-up to control unit, 2-wires) Four-circuit protection valve Air tank for auxiliary equipment

31 35 40 2 39 29 20 34

FD919

Diagnosis / Troubleshooting
Job scope test 1.



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Connect suitable test pressure gauge to test connection of compressed-air line (32) (four circuit protection valve - air tank for auxiliary equipment) and check supply-air pressure pv.. Minimum pressure: Maximum pressure: 6 bar 11 bar

Note If the pressure is not within the specified range, the compressed-air pressure installation must be checked to the manufacturers data.
32
FD122

Diagnosis / Troubleshooting
Requirements for check



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Retarder stage switch in position 0 Vehicle ignition system OFF

Special tool

53.1403.10

Compressed-air gauge 0-6 bar

Diagnosis / Troubleshooting



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Caution! Two versions of screw plugs (103) 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. 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.

Diagnosis / Troubleshooting
Job scope test



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4100

1. Screw out oil filler plug (4100).

M+P-07A-1488c

2. Connect pressure gauge (99/1) to bore of oil filler plug (4100).

99/1
3. operate retarder in braking stage 5 and compare read-off value with the values of the constant-air pressure (py) according to table see page 5.10/1. 4. Check sealing ring of screw plug for damages; replace if necessary. 5. Disconnect pressure gauge (99/1). Fit oil filler plug (4100) and screw it tight. Tightening torque oil filler plug (4100): 100 Nm (150 Nm)

M+P-07A-1488b

99/1 Pressure gauge 53.1403.10

Diagnosis / Troubleshooting
Requirements for check



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Battery voltage 18 - 32 V Vehicle electrical system checked in accordance with the Owners Manual for the vehicle and found satisfactory. Fuse for retarder control unit checked and found satisfactory. Plug at valve block and socket checked for damage as well as wear (notch scratches).

Special tool

53.8198.10

Measuring adapter

Commercially available tool Multimeter recommended: Fluke 87

Diagnosis / Troubleshooting
Job scope test 1. 2. 3. 4. 5.



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21 98/8

Disconnect plug at proportional valve (21) and connect with measuring adapter (99/3). Connect plug of measuring adapter (99/3) with the proportional valve (21). Connect the Multimeter (98/8) to the measuring socket 1. Switch position: mA or A Turn switch Propvalve at measuring adapter (99/3) in position I. Shift the retarder stage switch in position 5 and compare the read-off value with the given values of the control current of the proportional valve in accordance with the tables see page 5.10/1.

99/3
FD923

99/3 Measuring adapter Prop current 53.8198.10 99/8 Multimeter

Diagnosis / Troubleshooting
Requirements for check



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l l l l l

Battery voltage 18 - 32 V Vehicle ignition system OFF Pressure gauge constant-air pressure (99/9) connected Vehicle electrical system checked in accordance with the Owners Manual for the vehicle and found satisfactory. Fuse for retarder control unit checked and found satisfactory.

Special tool

Wasser

53.8207.10

53.8279.10

Temperature simulator

Adapter cable

Diagnosis / Troubleshooting



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98/5 57

Arbeitsumfang Prfung 1. Connect temperature simulator (99/2) with adapter cable (98/5) to plug temperature simulator (57).

Note Mind the correct connection of the plugs for cooling-water and oil! 2. Set the rotary switch of the temperature simulator (99/2) to 95C cooling water temperature and 165C oil temperature. Operate the retarder at the highest braking stage. 3. Set the rotary switch of the temperature simulator (99/2) to 105oC cooling water temperature. The constant-air pressure py must drop temporary below the set maximum pressure. Set rotary switch of the temperature simulator (99/2) to 125oC cooling water temperature. There must be no more output of constant-air pressure py. Set rotary switch of temperature simulator (99/2) again to 95oC cooling water temperature. 4. Set the rotary switch of the temperature simulator (99/2) to 185oC oil temperature.rThe constant-air pressure must drop temporary below the set maximum pressure. Set the rotary switch of the temperature simulator (99/2) to 225oC oil temperature. There must be no more output of constant-air pressure py. 5. Reconnect electrical lead (57) to temperature pick-up cooling-water and oil.

99/2

FD1455

99/2 Temperature simulator 53.8207.10 98/5 Adapter cable 53.8279.10

Diagnosis / Troubleshooting
Requirements for check



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Ignition ON Pressure gauge constant-air pressure connected Retarder stage switch in position 0

Special tool

53.8198.10

Measuring adapter

Commercially available tool Multimeter recommended: Fluke 87

Diagnosis / Troubleshooting
Job scope test



&KHFNLQJ 3UHVVXUH 6HQVRU (Continue)

1. Disconnect plug of pressure sensor (38) and connect with measuring adapter (99/3). 2. Connect plug of measuring adapter to pressure sensor (38). 3. Connect electrical lead Ground of Multimeter (98/8) to measuring socket 4 of adapter. 4. Turn switch Propvalve at measuring adapter (99/3) downwards (not in position I). 5. Connect electrical lead Positive of Multimeter to measuring socket 1.

98/8

38

99/3

6. The measured voltage must be between 4,75 and 5,25 V. 7. Connect electrical lead Positive of Multimeter to measuring socket 2. 8. Compare measured voltage in conjunction of constant-air pressure with the following values: 0 bar = 0,3 - 0,7 V 2,5 bar = 2,8 - 3,2 V 9. After disconnecting the measuring adapter connect electrical lead again to pressure sensor.

99-03-923a

98/8

38

99/3
99-03-923b

Diagnosis / Troubleshooting
Prior jobs



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Retarder stage switch in braking stage 0 Ignition OFF 103 Screw plug (measuring point pump pressure) M12x1,5 Inhex.-head, w.a.f. 6 13 Nm (20 Nm)

103

Note The pump pressure check provides information on internal leaks and on the correct operation of the retarder. Special tool

53.4788.10

Oil pressure gauge 0-25 bar

M+P-07A-1491

Diagnosis / Troubleshooting
Requirements for check



&KHFNLQJ 3XPS 3UHVVXUH (Continue)

l l l l l l

Battery voltage 18 - 32 V Vehicle electrical system checked in accordance with the Operating Manual for the vehicle and found satisfactory. Fuse for retarder control unit checked and found satisfactory. Compressed-air pressure 6 - 11 bar No external leaks at the retarder Retarder stage switch in braking stage 0

Caution! Two versions of screw plugs (103) 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. 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.

Diagnosis / Troubleshooting



&KHFNLQJ 3XPS 3UHVVXUH (Continue)

Caution! Risk of injury! The screw plug (103) and the oil is hot!

103 103

Caution! Easy oil-exit is caused constructively, but has no effect on the function of the retarder, however.

Job scope test 1. Screw out screw plug (103). 2. Connect up pressure gauge (99/1) to the retarder housing.

99/1

M+P-07A-1493

Diagnosis / Troubleshooting



&KHFNLQJ 3XPS 3UHVVXUH (Continue)

3. Drive the vehicle with a prop shaft speed of v ps = 1000 r.p.m. Put in direct gear (gear ratio 1:1), and drive with an engine speed of 1000 r.p.m. 4. Shift the retarder stage switch to position 5 while on the move and read pump pressure off test pressure gauge (99/1) at prop shaft speed vps = 1000 r.p.m. 5. Compare read-off pump pressure with the value of dynamic pump pressure according to the table see page 5.10/1.

Caution! If the constant-air pressure (py) is obtained in the test at stillstand (see chapter 5.5), but the minimum value of the dynamic pump pressure is not reached, please contact your Voith service partner.

Caution! Risk of injury! Hot oil can leave when disconnecting the presure gauge!

6. Check sealing ring of screw plug for damages; renew if necessary. 7. Disconnect pressure gauge. Screw in screw plug tight. Tightening torque screw plug (103): 13 Nm (20 Nm).

Diagnosis / Troubleshooting

 7DEOH RI 0HDVXUHPHQWV

Code number 2)

Control current mA1) 3) 5)

Constant-air pressure (py) (static) 4) 1) set value [bar] 2,10 - 2,30 2,30 - 2,50 2,75 - 2,95

Pump pressure (dynamic) 1) vps = 1000 r.p.m. minimum value [bar] 17 19 23

055 056 - 058 059, 079, 080 1) 2) 3) 4) 5)

396 - 596 409 - 609 440 - 640

Retarder stage switch in highest braking stage! The code number is to be found on the control unit If a commercially available multimeter is used for measurements (without real effective measuring) exact readings cannot be made (indication jumps!). Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure). The values are not steadily because of continuous control in the closed loop (however within the stated range).

Note These values represent the state of the art at the time going to print. The manufacturer reserves the right to make further modifications.

Diagnosis / Troubleshooting
Requirements for check

 2SHUDWLRQDO &KHFN

Battery voltage 18 - 32 V Electrical system checked in accordance with the Operating Manual for the vehicle and found satisfactory. Constant-air pressure 6 -11 bar Retarder oil level satisfactory

The following operational states are indicated by the retarder pilot light: Retarder pilot light without indication The retarder is switched off. There is no fault in the memory. Retarder pilot light permanently on The retarder is switched on, i.e., one of the four possible retarder braking stages or Constant Speed operation has been selected with the retarder stage switch. The retarder pilot light additionally has the function of a fault indicator. slight fault Continous light in position 0 - 5 of the retarder stage switch, braking operations are possible (partly with reduced braking torque). serious fault The retarder pilot light shows permanent light in position 0 - 5 of the retarder stage switch. There are no more braking operations possible - the retarder is switched off.

Diagnosis / Troubleshooting

 2SHUDWLRQDO &KHFN (Continue)

Note If the ignition is switched off and on again, the retarder is in operation and the retarder pilot light is going off. If the fault occurs again, the retarder switches off again and the retarder pilot light is permanently on in position 0 to 5 of the retarder stage switch.

Retarder pilot light flashes during retarder braking The temperature adaption is effective - the retarder regulates back its braking torque. These flash function however, is only realized at defined regulation variants!

Diagnosis / Troubleshooting

 2SHUDWLRQDO &KHFN (Continue)

Test step 1

Scope of check Retarder pilot light

Requirement / Operation Ignition: ON

Result / Set point Retarder pilot light comes on and goes off after approx. 5 sec. Retarder pilot light does not come on, or does not go off.

Note, Cause / Remedy Retarder pilot light trouble-free

Troubleshooting as on page 5.1/2 Retarder operates trouble-free.

Retarder

Vehicle on move - Shift retarder stage switch to stage 1 to 5.

Retarder pilot light comes on, retarder brakes in stages 1 to 5. Retarder pilot light does not come on, or retarder does not brake properly.

Troubleshooting as on page 5.1/2

Gearbox Removing, Installing 6.1

5HPRYLQJ ,QVWDOOLQJ *HDUER[

Removing, Installing Gearbox ....................................................................6.1/1

Gearbox, Removing, Installing



5HPRYLQJ ,QVWDOOLQJ *HDUER[ (Continue)

Illustration removing, installing gearbox Prior jobs Ignition OFF Shift linkage removed Clutch output cylinder removed Engine bonnet removed, if necessary Engine compartment enclosed casing removed, if necessary Clutch servo removed, if necessary (chapter 8.6) Weight in kg: approx.195 kg without clutch housing

21 19 7 3 3 26

Achtung Verletzungsgefahr! Secure vehicle, engine and gearbox propper!

20 4 1 25/250/119
M+P-07A-1773

1 3 4 5 6 7 19 20 21 26 25/250/119

Plug switch reversing light Connecting piece Plug speedometer sensor Hex.-head nut, renew Propeller shaft Plug switch for starter lock Plug cooling-water temperature pick-up Plug oil temperature pick-up Plug proportional valve Compressed-air line supply-air pressure Hex.-head screw M10x45, 45 Nm

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Gearbox Removing, Installing


Workshop equipment Gearbox lifter Nr. 554



5HPRYLQJ ,QVWDOOLQJ *HDUER[ (Continue)

Manufacturer: e. g. Fa. Kirner Obersteinstrae 139 D-55602 Kirn Tel. 06752 / 93110 Fax 06752 / 71751

M+P-07A-1775

Gearbox Removing, Installing



5HPRYLQJ ,QVWDOOLQJ *HDUER[ (Continue)

Adapter for gearbox lifter Nr. WBM 0079.06 Manufacturer: e. g. Fa. Wagner Dieselstrae 9-11 D-70829 Gerlingen Tel. 07156 / 22013 Fax 07156 / 22014

M+P-07A-1776

Commercially available equipments Wheel gripper tool RG 5/2HD2 z. B. Fa. Hywema

Gearbox Removing, Installing


Removing, installing



5HPRYLQJ ,QVWDOOLQJ *HDUER[ (Continue)

1. Lift the vehicle with 4 wheel gripper to the wished working height. 2. Drain coolant (heed the statements of the vehicle-manufacturer). 3. Drain oil of gearbox and retarder (chapter 3.4 and 3.5). 4. Prop up engine with suitable device, (heed the statements of the vehicle-manufacturer). 5. Remove eventually existing cross bars, which are in the way with the removal of the gearbox. Note for installation Tightening torque: 55-65 Nm 6. Remove connecting pieces (3) from heat exchanger. 7. Pull the plug (19) from cooling-water temperature pick-up. 8. Pull the plug (20) from the oil temperature pick-up. 9. Remove compressed-air line (26) from proportional valve. 10. Pull the plug (21) from proportional valve. 11. Pull the plug (1) from switch reversing light. 12. Pull the plug (4) from speedometer sensor. 13. Pull the plug (7) from switch for starter lock.

Gearbox Removing, Installing



5HPRYLQJ ,QVWDOOLQJ *HDUER[ (Continue)

14. Remove propeller shaft (6) from retarder. Note for installation: Use new self-locking hex.-head nuts. Tightening torque according to vehicle manufacturer instructions. 15. Screw out hex.-head screws from bracket / engine bearing right and left. Note for installation: Tightening torque: 180-210 Nm 16. Screw out top hex.-head screw from clutch housing / engine. Note for installation: Tightening torque: 39-46 Nm 17. Remove both rear engine bearing brackets. Note for installation: Tightening torque: 165-195 Nm 18. Drive gearbox lifter with adapter below the gearbox, adjust gearbox lifter and secure with safety chain. Slightly lift the gearbox. 19. Screw out bottom hex.-head screw from clutch housing / engine. Note for installation: Tightening torque: 39-46 Nm 20. Lift the gearbox higher and drive out it to the rear.

Gearbox Removing, Installing



5HPRYLQJ ,QVWDOOLQJ *HDUER[ (Continue)

21. Clean all parts, check for wear, and renew parts if necessary. 22. Install in reverse sequence. 23. Top up coolant according to the vehicle manufacturer instructions. Heed the cooling water-quality in chapter 11. 24. Top up oil of gearbox and retarder. Therefore heed chapter 3.4 and 3.5. 25. Enforce a visual examination on leaks after taken place test drive.

Note Connections as hoses, hose ties, screws and nuts, plugs and terminals must be in propper conditions. Defective parts must be renewed. Clean the drive shaft and grease it wafer-thin. Therefore see Operating Specifications of vehicle manufacturer. Engage retaining ring before installation of the clutch output cylinder by pulling at the clutch release fork. Check the function by pushing. Check gearbox oil level: See chapters 3.2: Checking Oil Level of Gearbox and 3.3: Checking Oil Level of Retarder. Top up coolant: See statements of the vehicle-manufacturer.

Retarder Removing, Installing 7.1

5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU

Removing, Installing Retarder ....................................................................7.1/1

Retarder Removing, Installing



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU

Illustration removing, installing retarder Prior jobs Gearbox (with retarder) removed (see chapter 6.1) Connecting pieces removed (see chapter 9.4) Speedometer sensor removed (see chapter 8.5) Output flange removed (see chapter 8.7) 850 Outer race Remove only, if taper roller bearing is renewed or a new balance washer is added (DC-tool) 850/001 Taper roller bearing 4100 Screw plug M30x1,5 Inhex.-head, w.a.f. 17 100 Nm (150 Nm) 25000 Balance washer 25100 O-ring, renew coat with silicone-free and noncorrosive grease for installation 25200 Hex.-head screw M10x70 Hex.-head, w.a.f. 15 58 Nm 25300 Hex.-head screw M10x60 Hex.-head, w.a.f. 15, 58 Nm
850 25000 (26/860/020*) 25300 25300

25200

4100

25100 (26/860/023*)

25200

850/001
M+P-07A-1497

* DaimlerChrysler position number

Retarder Removing, Installing


Special tools



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue)

67.2713.10

67.3056.10

on inquiry
Puller for outer race

on inquiry
Impact tool for outer race

Control device

Measuring device

Tool for local fabrication

M10

15

80
0073ae

Material: St37-2, DIN 17100 (1.80)

Threaded bolt M10x80

Retarder Removing, Installing



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue)

Lubricants and locking agents O-rings Retarder housing Silicone-free and non-corrosive grease Omnifit FD10-1042

Caution! The measuring device 67.3056.10 has to be calibrated annually! The workshop using this device is responsible for calibration and the propper condition of the device. Two versions of screw plugs (4100) 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. 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 generelly to be renew.

Service-

Retarder Removing, Installing



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue)


25200

Caution! Risk of injury! Secure retarder before working step 1 (prop up)!

25300

Caution! Remove speedometer sensor before working step 1 (see chapter 8.5)! Removing, installing 1. Screw out the 5 hex.-head screws (25200) and 17 hex.-head screws (25300) and remove retarder with suitable lifter device from gearbox. 2. Remove O-rings (25100) from gearbox.

25200
M+P-07A-1498

25000 850

Note You must execute the following working-step only, if: - a new retarder is installed - the taper roller bearing (850/001) is renewed or - the gearbox is renewed 3. Dismantle outer race (850) with puller for outer race (DaimlerChrysler tool F3 6280 0 486 285) and remove balance washer (25000).

850/1

25100

M+P-07A-1499

Retarder Removing, Installing


Installing 1.



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue)

Determine the thickness of the balance washer like follows:

Note Determine the thickness of the balance washer only, if: - one or both taper roller bearings of the retarder was renewed - the retarder was dismantled or changed or - the gearbox was dismantled or changed

M+P-07A-1444

The following described measurements may only being carried out at room temperature! 1.1 Take measuremnets of the spacing a between the surface of the gearbox housing (320) on retarder side and the surface of the balance washer. Note down the measured value as dimension a. Place measuring device (98/1) on supporting plate (60). Push vernier caliper (61) at measuring plate (62) and set to zero by using the reset key (63).

61 62 63

1.2 1.3

60

M+P-07A-1976

98/1 Measuring device 67.3056.10

Retarder Removing, Installing


1.4 1.5



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue)


62

Place outer race (850) on taper roller bearing (850/1). Place measuring plate (62) on outer race (850) and check correct and gap-free seat by rotation. Then press with one hand powerful onto the measuring plate (62) and turn the driving wheel (arrow) 2 turns clockwise and 2 turns counter-clockwise.

850 850/1

M+P-07A-1977

1.6

Place the measuring device (98/1) in the way on the retarder housing, that both plastic bolts mesh in the flat surface. Place vernier caliper (61) at measuring plate (62) and read-off value.

1.7

61
Note The measured value must be between +0,86 mm and -0,28 mm, contact Voith if necessary. 1.8 Calculate dimension b. Dimension b plus or minus the read-off value from working step 1.7 (heed sign at scale). Note down the calculated value as dimension b. 98/1 Measuring device 67.3056.10
M+P-07A-1978

62 98/1

Retarder Removing, Installing


1.9



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue)

Place again the measuring device at the supporting plate (60).

1.10 Push vernier caliper (61) at measuring plate (60) and check, if zero position still is set.

61 62
Note The measuring device must display zero, if necessary press reset key to repeat measuring procedure.

63

60

1.11 Calculate thickness of balance washer.


M+P-07A-1976

Thickness of balance washer = dimension a minus dimension b minus 0,02 mm 2. Place balance washer (25000) into gearbox housing (if dismantled).

Note

25000 850

If taper roller bearing was renewed, renew also outer race (850).

3.

Place outer race (850 - if removed) into the gearbox housing and knock it in with the impact tool for the outer race (DaimlerChrysler tool) as far as it will go.
M+P-07A-1446

Retarder Removing, Installing


4.



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue)


1

Clean sealing surface of retarder housing (1).

M+P-07A-1501

5. 6. 7. 8.

Turn the gearbox until the sealing surface does show upwards (gearbox is in vertically position). Clean sealing surface of gearbox housing and coat it with locking agent Omnifit FD10-1042. Coat O-rings (25100) with silicone-free and non-corrosive grease and place into the gearbox. Screw in two threaded bolts M10x80 (see arrows) into the gearbox housing. The threaded bolts are required so that the sealing surfaces (gearbox/retarder) can be installed congruent.

25100

M+P-07A-1448

Retarder Removing, Installing


9.



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue)


25200 25200 25200

Place retarder at gearbox and screw it tight with 5 hex.-head screws (25200). Tightening torque hex.-head screws 58 Nm Unscrew the two threaded bolts M10x80 again. Screw in the 17 hex.-head screws (25300) and screw them tight. Tightening torque hex.-head screws 58 Nm

10. 11.

25300
M+P-07A-1502a

12. 13.

Turn gearbox with fixed retarder in the horizontally position again. Screw out screw plugs (4100) out of retarder housing.

4100

M+P-07A-1497a

Retarder Removing, Installing


14.



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue)


98/2 4100

Press threaded spindle of control device (98/2) into direction of arrow as far as it will go.

M+P-07A-1997 M+P-07A-1503

98/2 Control device 67.2713.10

15. 16.

Screw control device (98/2) via A hand tight into the retarder housing. Screw control device (98/2) via B into the drive shaft until it is turning too.

A 98/2

Note Over the threaded bore of the speedometer sensor (arrow) can be determined, if the impulse ring itself and so the drive shaft turns.

M+P-07A-1979

98/2 Control device 67.2713.10

Retarder Removing, Installing


17. 18.



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue)

Fix the holder (99/8) with dial gauge at retarder housing. Place test prod with initial tension at surface (arrow) of control device (98/2) and set scale of dial gauge to zero.

4100

99/8

98/2
98/2 Control device 67.2713.10 19. Check gap of taper roller bearings as following:

M+P-07A-1980 M+P-07A-1503

0HDVXUHPHQW  19.1 Connect filling connection (arrow) with compressed-air and charge control device (98/2) with compressed-air (approx. 6 to 8 bar). 19.2 Turn shaft of the control device (64) three times about its own axis. 19.3 Read-off the values of the dial gauge while turning shaft of the control device (64) again one time about 360. Make marking at surface of control device at the point you can read-off the lowest value of the dial gauge. 19.4 Place test prod with initial tension at the marked position and set scale of dial gauge to zero. Seite 4/1Service-Handbuch VOITH Retarder 115 E

98/2

64
98/2 Control device 67.2713.10

M+P-07A-1981

Retarder Removing, Installing


0HDVXUHPHQW 



5HPRYLQJ ,QVWDOOLQJ 5HWDUGHU (Continue)

19.5 Connect filling connection (arrow) with compressed-air and charge control device (98/2) with compressed-air (approx. 6 to 8 bar). 19.6 Turn shaft of the control device (64) three times about its own axis. 19.7 Read-off the values of the dial gauge while turning shaft of the control device (64) again one time about 360. The smallest value corresponds the bearing gap. Set value: 0,02 to 0,12 mm, contact Voith if necessary.

4100

98/2

64
98/2 Control device 67.2713.10 Caution!

M+P-07A-1982 M+P-07A-1503

If the set value is not reached, the retarder must be removed and be installed again with another corresponding balance washer. To this all working steps described in this chapter must be carried out once again.

4100
20. 21. 22. Remove control device again. Check sealing ring of screw plug (4100) on damages; renew if necessary. Screw in screw plug (4100) again and screw it tight. Tightening torque: 100 Nm (150 Nm)

M+P-07A-1497a

Repair Gearbox 8.1 8.2 8.3 8.4 8.5 8.6 8.7

5HSDLU *HDUER[

Overall Illustration of Main Components ....................................................8.1/1 Removing, Installing Front Housing Cover, Cover Countershaft and Closing Cover 5./6.- Gear...........................................................................8.2/1 Removing, Installing Shift...........................................................................8.3/1 Removing, Installing Breather ....................................................................8.4/1 Removing, Installing Sensor/Switch at Gearbox ........................................8.5/1 Removing, Installing Clutch Servo and Adjusting Wear Indicator .....................................................................8.6/1 Removing, Installing Output Flange Renewing Radial Shaft Sealing Ring .........................................................8.7/1

Repair Gearbox



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Illustration main components gearbox GO170 - GO210

26/350/083 26/100/056 26/100/053 26/100/059 26/350/101 26/100/032 25/250/020 26/100/038 26/100/014 26/100/008

26/350/080

26/250/047 26/100/206 26/860/026 26/860/017 26/860/014 26/860/026 26/100/197 26/100/203 26/100/200 26/100/194 26/400/083 26/100/128 26/100/125 26/100/128 26/400/089 26/100/122

26/100/023 26/100/029 26/100/128 26/100/125

25/250/008

25/250/113 26/350/ 25/250/068

26/350/071

26/250/068

26/100/113 26/100/116 26/100/107 26/100/119

26/350/065 25/250/110

25/250/008 25/250/020 25/250/068 25/250/110 25/250/113 26/100/008 26/100/014 26/100/023 26/100/029 26/100/032 26/100/038 26/100/053 26/100/056 26/100/059 26/100/107 26/100/113 26/100/116 26/100/119

Clutch housing Hex.-head screw Clutch servo Cover metal sheet Hex.-head screw Front housing cover O-ring Radial shaft sealing ring Hex.-head screw Countershaft cover Hex.-head screw Closing cover 5./6.-gear O-ring Hex.-head screw Oil sieve Spring Screw plug Sealing ring

* = option

26/100/122 26/100/125 26/100/128 26/100/194 26/100/197 26/100/200 26/100/203 26/100/206 26/250/047 26/250/068 26/350/065 26/350/071 26/350/080 26/350/083 26/350/101 26/350/ 26/400/083 26/400/089 26/860/014 26/860/017 26/860/026

Oil filler plug Oil drain plug Sealing ring Sealing ring Anti-fatigue screw O-ring O-ring Speedometer sensor Switch starter lock * Inductive sensor for overspeed protection * Hex.-head screw Breather complete Cover bearing reverse gear end stop Radial shaft sealing ring Hex.-head screw Shift Oil temperature pick-up gearbox * Switch reversing light * Radial shaft sealing ring Radial shaft sealing ring Hex.-head screw

Repair Gearbox
Prior jobs



5HPRYLQJ ,QVWDOOLQJ )URQW +RXVLQJ &RYHU &RYHU &RXQWHUVKDIW DQG &ORVLQJ &RYHU  *HDU (Cont.)

Gearbox removed (chapter 6.1) Gearbox housing removed Clutch servo removed (chapter 8.6) Clutch release removed 26/100/008 Housing cover front, coat with sealant Omnifit FD10-1042 26/100/014 O-ring, renew coat with silicone-free and noncorrosive grease for installation 26/100/023 Radial shaft sealing ring, renew 26/100/029 Hex.-head screw 30 Nm 26/100/032 Cover countershaft, coat with sealant Omnifit FD10-1042 26/100/038 Hex.-head screw M10x35 30 Nm 26/100/053 Closing cover 5./6.- gear 26/100/056 O-ring, renew coat with silicone-free and noncorrosive grease for installation 26/100/059 Hex.-head screw 30 Nm

26/100/056 26/100/053 26/100/059 26/100/023 26/100/008 26/100/014 26/100/032 26/100/038 26/100/029


M+P-07A-1774

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Repair Gearbox



5HPRYLQJ ,QVWDOOLQJ )URQW +RXVLQJ &RYHU &RYHU &RXQWHUVKDIW DQG &ORVLQJ &RYHU  *HDU (Cont.)

Sealants and Lubricants Runddichtringe Gehusedeckel Vorgelegewellendeckel Verschludeckel 5./6.-Gang Silicon- und surefreies Fett Omnifit FD10-1042

To remove, to install 1. Only with gearbox G0210: 1.1 Screw out hex.-head screws (26/100/059). 1.2 Remove closing cover 5./6.-gear (26/100/053) with O-ring (26/100/056) ab. Clean sealing surface. Note for installation Coat new O-ring (26/100/56) with silicone-free and non-corrosive grease. Tightening torque: 30 Nm

26/100/056 26/100/053 26/100/059

M+P-07A-1779

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Repair Gearbox



5HPRYLQJ ,QVWDOOLQJ )URQW +RXVLQJ &RYHU &RYHU &RXQWHUVKDIW DQG &ORVLQJ &RYHU  *HDU (Cont.)

Note Do not damage oil spin disk in front housing cover (26/100/008)! Therefore perform working step 2 to 5 only with gearbox in vertical positioned gearbox (drive shaft up). 2. 3. Screw out hex.-head screw (26/100/029). Remove front housing cover (26/100/008). Clean sealing surface.

26/100/008

26/100/029
M+P-07A-1781

4.

Remove O-ring (26/100/014).

5.

Remove radial shaft sealing ring (26/100/023). Note for installation Install new radial shaft sealing ring (26/100/023) pin drift, thus the sealing lip shows upwards Coat new O-ring (26/100/014) with silicone-free and non-corrosive grease. Coat sealing surfaces of housing cover with sealant Omnifit FD10-1042. Tightening torque: 30 Nm

26/100/023 26/100/014
M+P-07A-1778

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Repair Gearbox
6. 7.



5HPRYLQJ ,QVWDOOLQJ )URQW +RXVLQJ &RYHU &RYHU &RXQWHUVKDIW DQG &ORVLQJ &RYHU  *HDU (Cont.)

Screw out hex.-head screws (26/100/038). Remove countershaft cover (26/100/032). Clean sealing surface. Note for installation Coat sealing surfaces of housing cover with sealant Omnifit FD10-1042. Tightening torque: 30 Nm

26/100/032 26/100/038

8.

Install in reverse sequence.

M+P-07A-1780

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Repair Gearbox
Prior jobs



5HPRYLQJ ,QVWDOOLQJ 6KLIW

Gearbox selector rod removed Switch for starter lock removed (if available)

26/350/065 Hex.-head screw M8x60 16-21 Nm 26/350/080 Bearing cover of reverse gear end stop, coat with sealant Omnifit FD10-1040 26/350/083 Radial shaft sealing ring, renew 26/350/101 Hex.-head screw 16-21 Nm 26/350/x Shift, coat with sealant Omnifit FD10-1040

26/350/083

26/350/080

26/350/101

Sealant Cover bearing of reverse gear end stop, shift Omnifit FD10-1042

26/350/x 26/350/65

M+P-07A-1777

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Repair Gearbox
To remove, to install 1. 2. 3. 4.



5HPRYLQJ ,QVWDOOLQJ 6KLIW (Continue)

Switch gearbox in neutral position. Screw out hex.-head screws (26/350/101). Remove bearing cover reverse gear end stop (26/350/080). Remove radial shaft sealing ring (26/350/083). Note for installation Knock in new radial shaft sealing ring with suitable pin drift. Coat sealing surface of bearing cover reverse gear end stop with sealant Omnifit FD10-1042. Tightening torque: 16-21 Nm

5. 6.

Screw out hex.-head screws (26/350/65). Remove shift (26/350/X). Note for installation Coat sealing surface of shift with sealant Omnifit FD10-1042. Tightening torque: 16-21 Nm

7.

Install in reverse sequence.

Repair Gearbox
Prior jobs



5HPRYLQJ ,QVWDOOLQJ %UHDWKHU

Engine bonnet removed, if necessary Engine compartment enclosed casing removed, if necessary 26/350/071 1 2 3 4 5 Breather complete Hex.-head screw 20 Nm Spring washer Bush Oil sieve Neck

1 2 26/350/071 3 4 5

M+P-07A-1782

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Repair Gearbox
Prior jobs



5HPRYLQJ ,QVWDOOLQJ 6HQVRU6ZLWFK DW *HDUER[

Engine bonnet removed, if necessary Engine compartment enclosed casing removed, if necessary 26/100/89 Switch reverse gear * 40-52 Nm 26/100/206 Speedometer sensor 32-42 Nm 26/250/47 Switch for starter lock * 26/250/68 Induktive sensor for overspeed protection * 26/400/83 Oil temperature pick-up gearbox * 40Nm

26/250/047

* = option

26/100/206 26/100/089 26/250/068

26/400/083
M+P-07A-1772

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Repair Gearbox
Prior jobs



5HPRYLQJ,QVWDOOLQJ &OXWFK 6HUYR DQG $GMXVWLQJ :HDU ,QGLFDWRU

Engine bonnet removed, if necessary Engine compartment enclosed casing removed, if necessary 25/250/068 25/250/113 35 25/250/110 38 39 40 41 42 43 44 45 Clutch servo Hex.-head screw, 40 Nm Tappet Cover metal sheet Spacer Neck Sealing rings, renew Compressed-air pressure line Hydraulic pipe Banjo bolt Closing cover Banjo bolt

25/250/113 38 39 45 40 41 25/250/068 35 25/250/110


M+P-07A-1798

42

44 40 43

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Repair Gearbox
To remove 1.



5HPRYLQJ,QVWDOOLQJ &OXWFK 6HUYR DQG $GMXVWLQJ :HDU ,QGLFDWRU (Continue)

Remove compressed-air pressure line (41) and hydraulic pipe (42) from clutch servo.

42

41
M+P-07A-1799

2.

Screw out hex.-head screws (25/250/113) and remove clutch servo (25/250/068) with the cover metal sheet (25/250/110).

25/250/068

25/250/113

M+P-07A-1800

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Repair Gearbox
To install



5HPRYLQJ,QVWDOOLQJ &OXWFK 6HUYR DQG $GMXVWLQJ :HDU ,QGLFDWRU (Continue)

1. Snap in by hand the clutch release bearing, with the help of the clutch release fork (arrow), through the opening of the clutch housing into the stress ring of the clutch.

M+P-07A-1801

2. Align clutch servo (25/250/068) with cover metal sheet (25/250/110) at clutch dome. 3. Screw the hex.-head screws (25/250/113) tight. Tightening torque: 40 Nm.

25/250/068

25/250/113

M+P-07A-1800

Remark: Terms of parts from DaimlerChrysler-EPC-documentation

Repair Gearbox
4.



5HPRYLQJ,QVWDOOLQJ &OXWFK 6HUYR DQG $GMXVWLQJ :HDU ,QGLFDWRU (Continue)

Install compressed-air pressure line (41) with banjo bvolt (43) and new sealing ring (40) to clutch servo (25/250/71). Install hydraulic pipe (42) with spacer (38), neck (39), banjo bolt (45) and closing cover (44) to clutch servo (37). Bleed hydraulically clutch actuation.

5.

42 44 45 39 43 40 25/250/71

38

6.

41
M+P-07A-1803

Remark: Terms of parts from DaimlerChrysler-EPC-documentation



Adjust mechanical wear indicator:

7.1 Pull cover cap (54) off.

51
7.2 Release hex.-head nut (52). 7.3 Screw in wear indicator (53) as far as the indicator (51) is flush with the wear indicator (arrow). 7.4 Fit cover cap (54).

52 53

54

M+P-07A-1804

Repair Gearbox
8. Wear control:



5HPRYLQJ,QVWDOOLQJ &OXWFK 6HUYR DQG $GMXVWLQJ :HDU ,QGLFDWRU (Continue)

8.1 Pull cover cap (54) off.

54
8.2 Check wear of clutch disk.

Note The clutch disk is wear out, if the back edge of the indicator (51) is flush with the back edge of the wear indicator (arrow).

51
M+P-07A-1805

8.3 Fit cover cap (54).

Repair Gearbox
Prior jobs



5HPRYLQJ ,QVWDOOLQJ 2XWSXW )ODQJH 5HQHZLQJ 5DGLDO 6KDIW 6HDOLQJ 5LQJ


31 26/100/197 32 26/100/200 26/100/194 26/100/203 26/860/017 26/860/014

Engine bonnet removed, if necessary Engine compartment enclosed casing removed, if necessary 26/860/014 Radial shaft sealing ring, renew 26/860/017 Radial shaft sealing ring, renew 26/100/194 O-ring, renew coat with silicone-free and noncorrosive grease for installation 26/100/197 Anti-fatigue screw, renew 450 Nm 26/100/200 O-ring, renew coat with silicone-free and noncorrosive grease for installation 26/100/203 O-ring, renew coat with silicone-free and noncorrosive grease for installation 31 Hex.-head nut, renew 32 Propeller shaft

Lubricants O-ring Silicone-free and non-corrosive grease


Remark: Terms of parts from DaimlerChrysler-EPC-documentation

M+P-07A-1797

Repair Gearbox
To remove, to install



5HPRYLQJ ,QVWDOOLQJ 2XWSXW )ODQJH 5HQHZLQJ 5DGLDO 6KDIW 6HDOLQJ 5LQJ (Continue)

1. Remove propeller shaft from output flange. Note for installation Use new self-locking hex.-head nut (31). Tightening torque according to vehicle manufacturer instructions. 2. Screw out anti-fatigue screw (26/100/197) and remove O-rings (26/100/194), (26/100/200) and 100/203). Note for installation Coat new O-rings (26/100/200 und 26/100/203) with silicone-free and non-corrosive grease and use new anti-fatigue screw. Tightening torque: 396 - 484 Nm. 3. Pull off output flange. 4. Remove radial shaft sealing rings (26/860/014 and 26/860/017). Note for installation Install new radial shaft sealing rings (26/860/014 and 26/860/017) with suitable pin drift. 5. Install in reverse sequence.

Repair Retarder 9.1 9.2 9.3 9.4 9.5 9.6

5HSDLU 5HWDUGHU

Overall Illustration of Main Components ....................................................9.1/1 Removing, Checking and Installing Casing Ventilation ..............................9.2/1 Removing, Cleaning and Installing Silencer...............................................9.3/1 Removing, Installing Water Neck ...............................................................9.4/1 Removing, Checking and Installing Heat Exchanger .................................9.5/1 Removing, Installing Oil Tank Cover ..........................................................9.6/1 A Top Oil Tank Cover ......................................................................................9.6/1 B Bottom Oil Tank Cover .................................................................................9.6/2

Repair Retarder



2YHUDOO ,OOXVWUDWLRQ RI 0DLQ &RPSRQHQWV

Illustration main components R 115 E

6101 3300 6100 6101 9000 3850 3850 3800 3900 8000 6600 6700 3700 2900 2300 4000 5400 5500 5600 7500 109 850 6400 7300 5200 5300 7500 2600 2500/1 3100 4200 4200 107 4100 6700 6600 20300
M+P-07A-1504b

4100 3100 2000/1

3300 2800/1

25000

2301

7600

20100 20000 20300 20200 20300 5200 5300 6700 6600 20000 20200

103 3500

7300

20100

103 107 109 850 2000/1 2300 2301 2500/1 2600 2800/1 2900 3100 3300 3500 3700 3800 3850 3900 4000 4100 4200 5200

Screw plug M12x1,5, Inhex.-head, w.a.f. 6 Screw plug M24x1,5, Inhex.-head, w.a.f. 12 Screw plug M24x1,5, Inhex.-head, w.a.f. 12 Outer race Top cover Casing ventilation Bgr. D30x38, die casting O-ring 55x3 Bottom cover Bottom gasket Cover casing ventilation Bgr. Gasket Combined hex.-head screw M8x30, w.a.f. 13 Combined hex.-head screw M8x30, w.a.f. 13 Screw plug with sieve, M30x1,5, Inhex.-head, w.a.f. 17 Proportional valve Damping plate O-ring 16x3 Combined hex.-head screw M8x20, w.a.f. 13 Hex.-head nut M8 Screw plug M30x1,5, Inhex.-head, w.a.f. 17 Screw plug M24x1,5, Inhex.-head, w.a.f. 12 Temperature pick-up

5300 5400 5500 5600 6100 6101 6400 6600 6700 7200 7300 7400 7500 7600 7800 8000 9000 20000 20200 20300 25000

Sealing ring A14x20 Corrugated spring Disc (silencer) D30x4 Circlip Pipe O-ring 15,3x2,4 Heat exchanger Hex.-head screw M14x40, w.a.f. 19 alternative: hex.-head screw with flange M14x40 Washer Throttle disc 39/15x3 O-ring 15x4 O-ring 40x2 O-ring 45x5 O-ring 25x4 O-ring 34x3 Intermediate plate 196x144x2 Pressure sensor 0-4 bar Water neck Combined hex.-head screw M8x80, w.a.f. 13 Hex.-head screw M14x1,5, w.a.f. 6 Shim (selection row)

Repair Retarder
Illustration casing ventilation



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ &DVLQJ 9HQWLODWLRQ

Note This step can be performed with the retarder removed or installed.

Prior jobs Ignition OFF Retarder OFF Proportional valve and damping plate removed (chapter 10.1)

Caution! Risk of injury! The retarder housing is hot!

Repair Retarder
2300 2300/1 2300/2 2300/3 2301



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue)

2800/1 2900 3300

6100 6101

Casing ventilation D30x38 Valve insert Float specified weight 11g 1 g Float cage O-ring 55x3, renew, coat with silicone-free and noncorrosive grease for installation Cover casing ventilation Gasket casing ventilation, renew Hex.-head screw M8x80 Hex.-head, w.a.f. 13 renew, 25 Nm Pipe O-ring 15,2x2,4, renew coat with silicone-free and noncorrosive grease for installation

3300 6101 2800/1 6101 2900 2300/1 2300 2301 2300/2 2300/3 6100

Lubricants and sealing agents O-ring Float silicone-free and non-corrosive grease Methylated Spirit

M+P-07A-1505

Repair Retarder
Special tools



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue)


Tool for local fabrication

40,5 mm 60 mm 7 mm
M+P-07A-1758 a

53.7712.10

53.9428.10

Material: St 37 Weight 0,085 kg

Note The test ring can also be ordered from Voith Turbo - Voith code number 67.2757.10.

Repair Retarder



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue)

To remove 1. Screw out hex.-head screws (3300).

3300

M+P-07A-1506

2. Remove cover (2800/1) with gasket (2900) from retarder housing. Clean sealing surface.

2800/1

2900

M+P-07A-1507

Repair Retarder



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue)


6101 6100 6101

3. Remove pipe (6100) and O-rings (6101).

M+P-07A-1508

4. Use the impact tool (99/5) and adapter (98/9) to extract the valve insert of the retarder housing (1).

99/5

98/9

M+P-07A-1509

99/5 Impact tool 53.7712.10

Repair Retarder



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ &DVLQJ 9HQWLODWLRQ (Continue)


2300/2 1

5. Take float (2300/2) and float cage (2300/3) out of the retarder housing (1).

2300/3

M+P-07A-1510

6. Lever O-ring (2301) out of the groove of valve isert (2300/1) and pull it off.

2300/1

2301
M+P-07A-1020

Repair Retarder
To check



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1. Check the float (2300/2) for damages to the surface and sealing surface (arrow). 2. Weight the float (2300/2). Specified weight 11 g 1 g. If the weight is more than the specified weight renew complete casing ventilation.
2300/2

2300/2

Note Oil has penetrated into the float, the retarder is impaired in its operation.
FD194 FD194

3. Check sealing edge of shaft sealing ring (arrow) in the valve insert (2300/1). Put down the valve insert (2300/1) on the float (2300/2) than weigh down the valve insert with the test ring (99/7). Fill up the hollow space between float and upper edge of valve insert with methylated spirit. If the sealing edge is not damaged, the fluid level must not alter in the course of 1 minute. If necessary, renew the complete casing ventilation.

99/7 2300/2

2300/1

M+P-07A-1730

Repair Retarder
To install



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1. Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on to the valve insert (2300/1). 2. Insert the float (2300/2) and float cage (2300/3) into the valve seat. 3. Insert the casing ventilation into the retarder housing. 4. Use the impact puller (99/5) and adapter (98/9) to knock in the casing ventilation (2300).

99/5

98/9

M+P-07A-1509

99/5 Impact tool 53.7712.10 98/9 Adapter 53.9428.10 5. Put pipe (6100) with new O-rings in cover (2000).

2000 6100

M+P-07A-1511

Repair Retarder
6.



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Place cover (2800/1) with new gasket into air-pipe (6100) on the retarder housing and screw the hex.-head screws (3300) tight. Tightening torque hex.-head screws: 25 Nm.

6100 3300 2800/1

M+P-07A-1512

Repair Retarder
Illustration Silencer



5HPRYLQJ &OHDQLQJ DQG ,QVWDOOLQJ 6LOHQFHU

Note This step can be performed with the retarder removed or in situ.

5400 5500 5600

5400 5500

5600

Corrugated spring Disc (Silencer) D30x4, clean with suitable cleaning agent (Benzine) and blast out with compressed-air Circlip JL30x1,2 konvex side must face the silencer

Cleaning agents Silencer Benzine

M+P-07A-1456

Repair Retarder
Prior jobs Ignition OFF Retarder OFF Cooling-water drained



5HPRYLQJ DQG ,QVWDOOLQJ :DWHU 1HFN

20000 20100 20200

20300

Water neck Gasket, renew Hex.-head screw M8x80 Hex.-head, w.a.f. 13 28 Nm Hex.-head screw M14x1,5 Inhex head, w.a.f. 6 28 Nm

20100 20000 20200

20100 20000 20200

M+P-07A-1568

Repair Retarder
Illustration heat exchanger



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ +HDW ([FKDQJHU

6700 7500

6600

7300 7600 6400 7500 7300 4200 107


M+P-07A-1513

6700 6600

4200

Note The heat exchanger can also be removed with installed retarder. Prior jobs Ignition OFF Retarder removed (see chapter 7.1)

With retarder installed: Proportional valve and damping plate removed (see chapter 10.1) Oil drained from retarder (see chapter 3.4) Cooling-water drained Water neck removed (see chapter 9.4)

107 4200 6400 6600

Oil-drain plug retarder M24x1,5, Inhex.-head, w.a.f. 12, 65 Nm (80 Nm) Oil-drain plug oil tank M24x1,5, Inhex.-head, w.a.f. 12, 65 Nm (80 Nm) Heat exchanger Hex.-head screw M14x40, w.a.f. 19, renew Initial torque: 35 Nm Final turn: 30 turn alternative: hex.-head screw M14x40 with flange, w.a.f. 19, renew

6700 7300 7500 7600

Washer, renew O-ring 15x4, renew coat with silicone-free and non-corrosive grease for installation O-ring 45x5, renew coat with silicone-free and non-corrosive grease for installation O-ring 25x4, renew coat with silicone-free and non-corrosive grease for installation

Lubricant O-ring Silicone-free and non-corrosive grease

Repair Retarder



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ +HDW ([FKDQJHU (Continue)

Caution! Two versions of screw plugs (107, 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 for possible damages during the installation of the heat exchanger; replace complete screw plug if necessary. 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 generally to be renew.

Repair Retarder
Special tool



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67.1948.10

Pressure-test equipment

Commercially available tool Turning angle measuring tool 3/4 e.g. Messrs Richard Abr. Herder Post box 10 08 67 D-42659 Solingen Tel. 0212/ 888-0 Ordering No. 8200-02

Repair Retarder



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ +HDW ([FKDQJHU (Continue)

Note If this job sequence is performed with the retarder in situ, the following prior jobs must be performed:

1. Screw out oil-drain plugs (107 and 4200) as well as the oil filler plug (for quicker drain) and drain oil. 2. Pull cooling-water hoses off the heat exchanger.

107

4200

4200
M+P-07A-1489

Repair Retarder



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ +HDW ([FKDQJHU (Continue)

To remove 1. Screw out the four hex.-head screws (6600). 2. Remove heat exchanger (6400).

6400

6600

6600 6600
3. Remove O-rings (7300, 7500 and 7600).
M+P-07A-1514

7500 7300 7300 7600 7500 7300


M+P-07A-1515

Repair Retarder
To check



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ +HDW ([FKDQJHU (Continue)


99/6 6400

1. Fit pressure-test equipment (99/6) together with O-rings to heat exchanger (6400) and connect compressed-air line to bottom connection (arrow). 2. Fill heat exchanger (6400) on water side with hot water (approx. 70 oC). 3. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the heat exchanger).

Note
M+P-07A-1580

If air bubbles form in the hot water or has outer leaks, the heat exchanger must be renewed. 99/6 Pressure-test equipment 67.1948.10 4. Connect compressed-air line to top connection (arrow). 5. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the heat exchanger).

99/6

6400

Note If air bubbles form in the hot water, the heat exchanger leaks and must be renewed. New heat exchanger are wetted with corrosion-inhibiting oil in the water- and oil section of the heat exchanger. Prior to installing a new heat exchanger, drain any corrosion-inhibiting oil which may have collected and flush it out with hot water in the water section of the heat exchanger.

M+P-07A-1581

99/6 Pressure-test equipment 67.1498.10

Repair Retarder
Einbauen



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7600 7500

1. Fit new O-rings (7300, 7500 and 7600) in the bores. 2. Align heat exchanger (6400) with retarder housing and screw the hex.-head screws (6600) tight. Initial torque: 35 Nm Final turn: 30 turn

7300 7300

7500 7300
M+P-07A-1516

6600 2400

6600

6600

6600
M+P-07A-1517

Repair Retarder



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ +HDW ([FKDQJHU (Continue)

3. Install the retarder, if necessary (see chapter 7: Removing, Installing Retarder). 4. If available, open the check valves in the flow and return pipe of the cooling-water section. Fill in cooling-water and bleed cooling-water circuit.

Caution! If the heat exchanger leaks, there is water present in the retarder. If the retarder is filled up, a mixture of oil and water is created, causing the oil in the retarder to foam and escape through the casing ventilation system to the atmosphere. For this reason, it is indispensible to flush out the retarder after repair! While flushing, apply the brake gently several times to prevent the retarder oil warming up excessively. 5. Flush the retarder, if the heat exchanger has leaked: To flush the retarder, fill it with 7,0 litres of engine- or flushing oil. Apply the brakes gently several times to flush out the retarder system and drain the oil through the oil drain plugs (107 and 4200). Repeat the procedure 2 or 3 times. Check sealing rings of oil-drain plugs for possible damages; renew oil-drain plug if necessary.

107

4200

4200
M+P-07A-1489

Repair Retarder
-



5HPRYLQJ &KHFNLQJ DQG ,QVWDOOLQJ +HDW ([FKDQJHU (Continue)

Screw oil-drain plug tight Tightening torque oil-drain plug (107, 4200): 65 Nm (80) Fill in retarder oil (chapter 3.5)

6. If heat exchanger had been leaking, deoil cooling- and heating system of vehicle according to the vehicle manufacturer instructions.

Repair Retarder
A Top oil tank cover Prior jobs Ignition OFF Retarder OFF



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6101 6100 6101 3300 9000

Note

3100
This job sequence can also be performed with the retarder installed.

2000/1
Caution! Risk of injury! The retarder housing is hot! 2000/1 3100 Top cover Hex.-head screw M8x30 Hex.-head, w.a.f. 13 renew, 25 Nm Hex.-head screw M8x80 Hex.-head, w.a.f. 13 renew, 25 Nm Pipe O-ring 15,2x2,4, renew coat with silicone-free and noncorrosive grease for installation Intermediate plate Pressure sensor

8000

3300

6100 6101

M+P-07A-1518

8000 9000

Repair Retarder
Illustration oil tank cover B Bottom oil tank cover Prior jobs



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Ignition OFF Retarder OFF Retarder oil drained (see chapter 3.4) 2500/1 2600 3100 Bottom cover Bottom gasket, renew Hex.-head screw M8x30 Hex.-head, w.a.f. 13 renew, heed tightening sequence! 25 Nm Oil drain plug oil tank M24x1,5 Inhex.-head, w.a.f. 12 65 Nm (80 Nm)

4200

2600

2500/1 3100 4200


M+P-07A-1519

Repair Retarder



5HPRYLQJ DQG ,QVWDOOLQJ 2LO 7DQN &RYHU (Continue)

Caution! Two versions of screw plugs (4200) are possible: A) Version with integrated FPM-sealing ring; these corresponds the standard version at the time going to print. The integrated sealing ring must be checked during for possible damages during the installation of the oil tank cover; replace complete screw plug if necessary. 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 generally to be renew.

Repair Retarder
Note for installation



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Heed the mounting position of the gasket and the cover. Tighten all hex.-head screws in defined sequence from 1 to 17 initially with 14 - 19 Nm torque. Then tighten in the same sequence with 25 Nm torque.
4 17 16 15

6 5 3 2 1 7 8 9 10 11 14 13
M+P-07A-1368

12

Control Parts Retarder 10.1 10.2 10.3 10.4



&RQWURO 3DUWV 5HWDUGHU

Removing, Installing Proportional Valve...................................................10.1 Removing, Installing Oil Temperature Pick-Up ........................................10.2 Removing, Installing Cooling-Water Temperatur Pick-Up........................10.3 Removing, Installing Pressure Sensor .....................................................10.4

Control Parts Retarder


Illustration proportional valve

 5HPRYLQJ ,QVWDOOLQJ 3URSRUWLRQDO 9DOYH

Removing, installing proportional valve Prior jobs Ignition OFF Retarder OFF Supply-air discharged Plug at proportional valve and socket checked for damages as well as wear (notch scratches)

3850

3800 3850 3900 4000 39 3900 3700 26 4000

26 39 3700 3800 3850 3900

4000

Constant-air pressure line pv Electrical lead Proportional valve Damping plate, renew if necessary O-ring 16x3, renew Hex.-head screw M8x20 Hex.-head, w.a.f. 13 renew, 30 Nm Hex.-head nut M8, renew, 18 Nm

Caution! If, during repair work the hex.-head nuts (4000) or the hex.-head screws (3900) have to be unscrewed the antivibration plate also has to be checked on mechanical and aging damages and to be renewed, if necessary.

Control Parts Retarder

 5HPRYLQJ DQG ,QVWDOOLQJ &RROLQJ:DWHU 7HPSHUDWXUH 3LFN8S

Removing, installing cooling-water temperature pick-up Prior jobs Ignition OFF Retarder OFF Cooling-water drained

5200 5300

Cooling-water temperature pick-up, 28 Nm Sealing ring A14x20, renew

5200 5300

Caution! Risk of injury! The coolant is hot!

Note Please, bear in mind to the instructions regarding the quality of coolant given from the vehicle manufacturer or Voith Turbo.
M+P-07A-1569

Control Parts Retarder


Prior jobs Ignition OFF Retarder OFF

 5HPRYLQJ DQG ,QVWDOOLQJ 2LO 7HPSHUDWXUH 3LFN8S

32 5200 5300

Electrical lead Oil temperature pick-up, 28 Nm Sealing ring A14x20, renew

5300 5200 32

M+P-07A-1495

Control Parts Retarder


Prior jobs Ignition OFF Retarder OFF

 5HPRYLQJ DQG ,QVWDOOLQJ 3UHVVXUH 6HQVRU

9000

9000

Pressure sensor, 30 Nm

M+P-07A-1496

Annex



$QQH[

Data Sheet: Conversion Tables

- Gearbox / Retarder

Operating Specifications: - Oil Specifications Gearbox - Oil Specifications Retarder - Cooling Water Quality Spare Parts Lists Other Information

Annex



'DWD 6KHHW

GO170-6 R 115 E Gearbox input power up to [kW] max. input torque [Nm] (Standard value depending on respective use)

GO190-6 R 115 E

GO210-6 R 115 E

320

1750

1900

2100

Ratio range / expanded scale

8,17 - 1,00 8,17

6,53 - 0,80 8,16

Braking torque up to [Nm] / Braking power up to [kW] Permissible vehicle cross weight [t]

3750 / 700

 W

 W

Annex



'DWD 6KHHW (Continue)

Ratio 1. gear 2. gear 3. gear 4. gear 5. gear 6. gear Reverse-gear

GO170-6 R 115 E 8,170 4,650 2,790 1,810 1,250 1,000 7,683

GO190-6 R 115 E 8,170 4,650 2,790 1,810 1,250 1,000 7,683

GO210-6 R 115 E 6,528 3,711 2,231 1,443 1,000 0,799 6,136

Annex



&RQYHUVLRQ 7DEOHV

D
-37 C -45 C 10 oC 20 oC 60 oC 80 oC 95 oC 105 oC 125 oC 165 C 185 oC 225 oC 13 Nm 14 Nm 16 Nm

GB
- 34,6 F -49 F 50 oF 68 oF 140 oF 176 oF 203 oF 221 oF 257 oF 329 F 365 oF 437 oF 9.1 lbf-ft 9.8 lbf-ft 11.2 lbf-ft

USA
-34,6 F -49 F 50 oF 68 oF 140 oF 176 oF 203 oF 221 oF 257 oF 329 F 365 oF 437 oF 9.1 lbf-ft 9.8 lbf-ft 11.2 lbf-ft

D
18 Nm 19 Nm 20 Nm 21 Nm 25 Nm 28 Nm 30 Nm 32 Nm 35 Nm 39 Nm 40 Nm 42 Nm 45 Nm 46 Nm 47 Nm

GB
12.6 lbf-ft 13.3 lbf-ft 14 lbf-ft 14.7 lbf-ft 18 lbf-ft 19.6 lbf-ft 21 lbf-ft 22.4 lbf-ft 24.5 lbf-ft 27.3 lbf-ft 28 lbf-ft 29.4 lbf-ft 31.5 lbf-ft 32.2 lbf-ft 32.9 lbf-ft

USA
12.6 lbf-ft 13.3 lbf-ft 14 lbf-ft 14.7 lbf-ft 18 lbf-ft 19.6 lbf-ft 21 lbf-ft 22.4 lbf-ft 24.5 lbf-ft 27.3 lbf-ft 28 lbf-ft 29.4 lbf-ft 31.5 lbf-ft 32.2 lbf-ft 32.9 lbf-ft

Annex



&RQYHUVLRQ 7DEOHV (Continue)

D
52 Nm 55 Nm 58 Nm 60 Nm 65 Nm 80 Nm 100 Nm 150 Nm 165 Nm 180 Nm 195 Nm 210 Nm 450 Nm 1750 Nm 1900 Nm

GB
36.4 lbf-ft 38.5 lbf-ft 40.6 lbf-ft 42 lbf-ft 45.5 lbf-ft 56 lbf-ft 70 lbf-ft 105 lbf-ft 115.5 lbf-ft 126 lbf-ft 136.5 lbf-ft 147 lbf-ft 315 lbf-ft 1,225 lbf-ft 1,330 lbf-ft

USA
36.4 lbf-ft 38.5 lbf-ft 40.6 lbf-ft 42 lbf-ft 45.5 lbf-ft 56 lbf-ft 70 lbf-ft 105 lbf-ft 115.5 lbf-ft 126 lbf-ft 136.5 lbf-ft 147 lbf-ft 315 lbf-ft 1,225 lbf-ft 1,330 lbf-ft

D
2100 Nm 3750 Nm 2,10 bar 2,30 bar 2,50 bar 2,75 bar 2,95 bar 4 bar 6 bar 8 bar 11 bar 17 bar 19 bar 23 bar 25 bar

GB
1,470 lbf-ft 2,625 lbf-ft 30.45 psi 33.35 psi 36.25 psi 39.88 psi 42.78 psi 58 psi 87 psi 116 psi 159.5 psi 246.5 psi 275.5 psi 333.5 psi 362.5 psi

USA
1,470 lbf-ft 2,625 lbf-ft 30.45 psi 33.35 psi 36.25 psi 39.88 psi 42.78 psi 58 psi 87 psi 116 psi 159.5 psi 246.5 psi 275.5 psi 333.5 psi 362.5 psi

Annex



&RQYHUVLRQ 7DEOHV (Continue)

D
7 litre 7,8 litre 12,5 litre 13 litre

GB
1.54 gal 1.72 gal 2.75 gal 2.86 gal

USA
1.85 gal 2.06 gal 3.30 gal 3.43 gal

D
50.000 km 60.000 km 90.000 km 100.000 km 135.000 km

GB
31,070 miles 37,284 miles 55,926 miles 62,140 miles 83,889 miles 111,852 miles 186,420 miles

USA
31,070 miles 37,284 miles 55,926 miles 62,140 miles 83,889 miles 111,852 miles 186,420 miles

1g 11 g

15.4 grains 169.4 grains

15.4 grains 169.4 grains

180.000 km 300.000 km

195 Kg

430 pounds

430 pounds

50 Km/h

31 miles/h

31 miles/h

0,02 mm 0,12 mm 0,28 mm 0,86 mm 131,31 mm

0.0008 inch 0.0048 inch 0.0112 inch 0.0344 inch 5.2524 inch

0.0008 inch 0.0048 inch 0.0112 inch 0.0344 inch 5.2524 inch

Annex



2SHUDWLQJ 6SHFLILFDWLRQV

Operating specification

Mineral oil for use in gearbox: SAE 80, 80W, 80W/85W Type of oil
Addinol Gear Oil GS Agip Rotra Hy DB Antar EP Aral-Gear Oil EP Armorine BM Aseol Gepress 11-508 Autol Gear Oil D8 Avia Gear Oil MZ Aviaricon Gold MZ

Caution! Risk of poisoning! Fuels are harmful to health! If a fuel was swallowed, visit immediately a doctor! Keep fuels away of children!

Supplier
Addinol Minerall, Krumpa Agip Petroli, Rom/Italien Elf Lubrifiants, Paris/Frankreich Aral Lubricants, Bochum Armorine, Lanester Cedex/ Frankreich Shell Aseal, Bern/Schweiz Agip Schmiertechnik, Wrzburg Avia Minerall, Mnchen Emil Finke Minerallwerk, Bremen

BayWa Multi Purpose Gear BayWa, Mnchen Oil BP Energear EP BP Energear FE GL4 BP Gear Oil EP Calpam Multi Purpose Gear Oil BP Oil International, London/England BP Oil International, London/England BP Oil International, London/England Calpam Minerall-Gesellschaft, Aschaffenburg

Annex



2SHUDWLQJ 6SHFLILFDWLRQV (Continue)

Mineral oil for use in gearbox: SAE 80, 80W, 80W/85W Type of oil Type of oil
Caltez Universal Gear Oil HD Carrier Hykomol Castrol EP Condat Gear A CS 80 M-EP Deagear EP-A Dearon EP-A Deutz l GO-MP Divinal Multi Purpose Gear Oil Dragon Gear TM Ellmo-Multi Purpose Gear Oil Engen Gearlube HP Ertoil Transmissiones F Esso Gear Oil GP-D

Supplier
Fina Europe, Brssel/Belgien BP Schmierstoff, Hamburg Fuchs Minerallwerke, Mannheim Petroleos de Portugal, Petrogal, Lissabon/Portugal Texaco Services (Europe), Brssel/Belgien SAEL, Madrid/Spanien Gulf Oil (GB), Cheltenham/ England H. o.B. Burrenkopf, Kln Hafa, Paris/Frankreich J. & A. Homberg, Wuppertal Hyperol Minerall-Vertrieb, Stuttgart Igol France, Paris/Frankreich INA Rafinerija Zagreb, Zagreb/Kroatien Italiana Petroli, Genua/Italien Kompressol-l, Kln

Supplier
Caltez (UK) Limited, London/England MOL Hungarian Oil and Gas Co., Kornrom/Ungarn Castrol, Swindon/England Condat, Chasse-sur Rhne/Frankreich Repso Distribucin, Madrid/ Spanien DEA Minerall, Hamburg DEA Minerall, Hamburg Klckner Energiehandel, Kln Zeller+Gmelin, Eislingen Ssang Yong Oil Refining, Seoul/Rep. Korea Eller-Montan-Comp., Duisburg Engen Petroleum, Kapstadt/Sdafrika Ertoil, Madrid/Spanien Esso, Hamburg

Fina Pontonic N Frontol Gear Oil MZ M Fuchs Titan Gear MP Galp Transoil Geartex EP-A Gulf Gear Lubricant (EP) Gulf Ultragear 4000 (GB) H.o.B.- Gear Oil ML Hafa MPB Homberg Gear Oil MZ Hyperol Multi Purpose Gear Oil Igol Trans EPA Ina Transmol DB IP Pontiax DB Kompressol Multi Purpose Gear Oil

Annex



2SHUDWLQJ 6SHFLILFDWLRQV (Continue)

Mineral oil for use in gearbox: SAE 80, 80W, 80W/85W Type of oil Type of oil
Leprinzol SP Mac MP-Gear Oil megol Multi Purpose Gear Oil GL4 MHG-Manual-Gear Oil EP Mobilube GX-A Motorex Gear Oil EP Neste Gear EP Oest Multi Purpose Gear Oil OMV Gear Oil MP Optimol Multi Purpose Gear Oil Orly XP Luna P. O. Keban EP MB Panolin EP Gear GL4 Parnas Parnalube GP

Supplier
Minerall-Raffinerie Dollbergen Petrol d. d., Ljubljana/Slowenien Petramin Lubricating Oil, Jeddah/Saudi-Arabien Kuwait Petroleum, Hoogvliet RT/Niederlande Raloy Lubricantes, Santiago Tianguistenco/Mexico Ryazan Oil Refinery, Ryazan/Ruland Pertamina, Jakarta/Indonesien Kppler, Stuttgart Shell International, London/ England Sonol Israel, Haifa/Israel Bharat Petroleum Carpn., Bombay/Indien De Oliebron, Zwijndrecht/Niederlande Total Deutschland, Dsseldorf

Supplier
Leprince & Siveke, Herford Deutsche Shell, Hamburg Meguin, Saarlouis MHG, Sulzbach-Rosenberg Mobil Schmierstoff, Hamburg Bucher, Langenthal/Schweiz Neste Oy Lubrication, Espoo/Finnland Oest Minerallwerke, Freudenstadt OMV, Wien/sterreich Optimol lwerke Industrie GmbH, Mnchen Orly International, Vieux-Thann/Frankreich Petrol Ofisi, Bakanlikar-Ankara/Trkei Panolin, Madetswill/Schweiz Parnas/Saksan, Athen/Griechenland

Pennasol Multi Purpose Gear Oil GL4 Petrol Transol GL4 Petramin Gear Oil MB Q8 T 35 Raloy Transmission EP Rexol MBG Rored EPA Selectol Multi Purpose Gear Oil Shell Spirax MA Sonolgear DBM Spirol XEP Tor Multi Purpose Gear Oil Total EP

Annex



2SHUDWLQJ 6SHFLILFDWLRQV (Continue)

Mineral oil for use in gearbox: SAE 80, 80W, 80W/85W Type of oil
Tranself EP Triathlon Gear Unil EP Unil Opal Gear EP Valvoline X-18 Veba Movara EP-Gear Oil Veedol Multigear Westfalen Grado Gear Oil Wintershall Wiolin Multi Purpose Gear Oil Westfalen Grado Gear Oil Wisura GL WLZ-Raiffeisen Multi Purpose Gear Oil

Type of oil Supplier


York 791 Zenex Gear Oil ZP

Supplier
Ginouves Georges La Farlde/Frankreich Zenex Oil, Rivonia/Sdafrika

Elf Lubrifiants, Paris/Frankreich Wrth, Knzelsau Unil Deutschland, Bremen Unil-Opal, Rueil-Malmaison/ Frankreich Valvoline International Europe, Dardrecht/Niederlande Veba l, Gelsenkirchen Veedol International, Swindon/England Westfalen AG, Mnster Schmierstoffraffinerie Salzbergen Westfalen AG, Mnster Wisura Minerallwerk, Bremen WLZ-Raiffeisen, Stuttgart

Synthetic oil for use in gearbox: Type of oil Supplier

MB 235.11 Manual Gear Oil DaimlerChrysler AG, Stuttgart A 001 989 2803 Veedol Synmesh-AT Castrol Syntrans-AT Deagear Synth Burmah Oil Technology Burmah Oil Technology DEA Minerall GmbH

Annex



2SHUDWLQJ 6SHFLILFDWLRQV (Continue)

The type of oil admitted for the retarder operation must meet the following specifications: Classification group Identification letters to DIN 51502 Single-grademineral oil 1) Synthetic oil/ part-synthetic oil 1) HD Viskosity class to DIN 51511 SAE 10W SAE 20W 20 SAE 30 SAE 0W40 SAE 5W30 SAE 5W40 SAE 5W50 SAE10W30 SAE10W40 SAE 75W-80W Performance class API - CC/SF and higher API - CC/SF and higher

HC

Synthetic oil 2)

HC

see page 11/13

1)

The statements of the vehicle-manufacturer are valid respecting the choice of oil types. If no statements are available, the oils documented on the following pages are to be used. Here is only allowed to use the synthetic oil documented on page 11/13.

2)

Annex



2SHUDWLQJ 6SHFLILFDWLRQV (Continue)

Mineral oil for use in retarder: SAE 10W, 20W 20, 30 Type of oil Type of oil
Agip Diesel Sigma S Agip Engine oil HD Aral Basic Turboral Avia Special HDC Avia Engine Oil HD BP Vanellus C3 Castrol CRD-DB DEA Cronus Super DEA Rigis Elf Performance XC Elf Performance XR Elf Performance 3D Elf Performance Super D Essolube X 301 Essolube X 201 Agip Agip Aral Avia Avia BP Burmah Oil DEA DEA Elf Elf Elf Elf Esso Esso

Supplier
Fina Fina Krafft Mobil Oil Motorex Motorex Multimiles Repsol Repsol

Supplier

Fina Kappa Super Fina Kappa TC SAE 30 Serie III Mobil Delvac 1300-Serie Extra Cobra Multimiles R/5 mono Repsol Serie 3 SAE 10W Repsol Serie 3 SAE 30

CS Mizar Serie 3 SAE 10W Repsol CS Mizar Serie 3 SAE30 CS Mizar HD SAE 20W Repsol Repsol

Shell Rimula X Monograde Shell Shell Rotella MX Glap Diesel Glap Orion Wintershall Rekord 10W Shell Sofomil Sofomil SRS

Annex



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Synth./part-synth. oil for use in retarder: SAE 0W40, 5W30, 5W40, 5W50, 10W30, 10W40

Mineral oil for use in retarder: SAE 10W, 20W 20, 30 Type of oil
Wintershall Rekord 20W-20 SRS Wintershall Rekord 30 Havoline Motor Oil Ursa Super LA Total rubia S Unocal Firebird HD Motor Oil SRS Texaco Texaco Total Unocal

Supplier

Type of oil
Agip Diesel Sigma TFE Agip Sigma Super TFE Agip Sigma Ultra TFE Amsoil 10W30 Antar Maxolia 10W40 Aral Extra Turboral SAE 10W40 Aral High Turboral SAE 10W40 Aral Super Turboral SAE 5W30 Aral Mega Turboral SAE 10W40 Avia Synth 5W40 Avia Multi CFE 10W40 Agip Agip Agip Amsoil Antar Aral Aral Aral Aral Avia Avia

Supplier

Avia Multi CFE Plus 10W40 Avia Avia Turbosynth CFE 10W40 Avia Turbosynth HT-E 10W40 BP Vanellus FE 10W40 Avia Avia BP Oil

Annex



2SHUDWLQJ 6SHFLILFDWLRQV (Continue)


Elf Performance Experty 10W40 Elf Performance Experty FE 5W40 Esso Ultra Elf

Synth./part-synth. oil for use in retarder: SAE 0W40, 5W30, 5W40, 5W50, 10W30, 10W40 Type of oil
BP Vanellus FE Extra 10W40 BP Vanellus HT 10W40 BP Vanellus HT Extra 10W40 Castrol Syntruck SAE 5W40 Castrol Dynamax SAE 10W40 Castrol Transmax Z DEA Cronos Synth SAE 5W40 DEA Cronos Premium HC SAE 10W40 DEA Cronos Premium XL SAE 10W40 DEA Cronos Premium FX SAE 10W40 DEA Cronos Premium LD 10W40 Elf Ecomax FE 10W40 BP Oil BP Oil BP Oil Castrol Commercial Castrol Commercial Castrol Commercial DEA DEA DEA DEA DEA Elf

Supplier

Elf Esso Esso Esso Esso Esso Fina Fina Fina

Esso Ultron Esso Ultra Diesel Essolube XTS 301 Essolube XTS 501 Fina Kappa First SAE 15W40 Fina Kappa Ultra SAE 10W40 Fina First 5W40

Titan Unic MC SAE 10W40 Fuchs Titan Unic Plus MC SAE 10W40 Titan Cargo MC SAE 10W40 Emgard MTF 4200 HRD Maxima LD 10W40 Klbersynth GEM 4-68 Mogul Diesel DTT Plus 10W40 Fuchs Fuchs Henkel Huiles Renault Diesel Klber Koramo

Elf Ecomax FE plus 10W40 Elf

Annex



2SHUDWLQJ 6SHFLILFDWLRQV (Continue)


Oest gigant Turbo FE 10W40 Trysk Top Tir - Fe 10W40 Oest Paramo

Synth./part-synth. oil for use in retarder: SAE 0W40, 5W30, 5W40, 5W50, 10W30, 10W40 Type of oil
Sintetic 10W40 Gasolina Sintetic 10W40 Diesel Mobil Delvac XHP 10W40 Mobil Delvac XHP Extra 10W40 Krafft Krafft Mobil Oil Mobil Oil

Supplier

Repsol Competicion 5W40 Repsol Repsol Sintetico Gasolina 10W40 Repsol Sintetico Diesel 10W40 Shell Myrina TX 5W30 Shell Myrina TX 10W40 Glap Synth D 1040 Wintershall TFX Wintershall TFE Wintershall TFG Ursa Super TDX 10W40 Total rubia TIR 8600 Repsol

Repsol Shell Shell Sofomil SRS SRS SRS Texaco Total Wameco Wameco

Mobil Delvac 1 SHC 5W40 Mobil Oil Carrier Diesel Sint 10W40 MC Power 3 SAE 10W40 MC plus SAE 10W40 Star-Synt SAE 5W50 Multimiles MM-1 Bioil chem. 0W30/40 Multimiles Fut. 3 MM-23 D-2 10W40 Multimiles Fut. 2 MM-23 F-H 10W40 Multimiles Fut. 2 MM-23 F-HP 10W40 Multimiles Fut. 2 MM-23 F-P 5W50 Mol Motorex Motorex Motorex Multimiles Multimiles Multimiles Multimiles Multimiles

Wameco Green Rallenter Fluid N Wameco Red Rallenter Fluid N

Annex



2SHUDWLQJ 6SHFLILFDWLRQV (Continue)

Synthetic oil for use in retarder: SAE 75W-80W Type of oil


Emgard MTF Henkel

Supplier

Annex



2SHUDWLQJ 6SHFLILFDWLRQV (Continue)

Cooling water quality

Caution! Risk of poisoning! Fuels are harmful to health! If a fuel was swallowed, visit immediately a doctor! Keep fuels away of children! The coolant may not be discharged into the sewage system. It must be brought to the recycling as well as to the waste disposal. The legal regulations as well as regulations for sewage can deviate country-specific and are to be heeded with the waste disposal of used coolants. Before use of the coolants, the safety-data-sheets and product-information of the respective manufacturer are to be heeded and to keep. The coolant is a mixture of water and corrosion-/anti-freeze agent.From reasons of the corrosion-protection and to the increase of the boiling point, the coolant must remain non-seasonal in the cooling system. Coolants have to be renewed after three years, because the corrosion-protection will reduce itself. Water Water itself is not allowable as coolant, even if anti-freeze-qualities are not necessary. The water of the coolant must fulfil defined requests, that frequently, however not always meet the drinking water quality. If the water-quality is not sufficient, the water must be purified. Information about this can be ordered from us.

Annex



2SHUDWLQJ 6SHFLILFDWLRQV (Continue)

Corrosion-/anti-freeze agent To avoid damages in the retarder cooling-system: Use only a released corrosion-/antifreeze agent, that is released expressly for aluminium by the manufacturer. The use of purely glycol is not allowed. With refills (after coolant-loss) a proportion of corrosion-/antifreeze agent of 50 vol.-% in the coolant (antifreeze to -37 C) must be secured. Do not use more than 55 vol. -% (= maximum antifreeze) corrosion-/antifreeze agent. The feature of antifreeze will be reduced and the heat rejection poor.

Ratio for coolant Antifreeze to C -37 approx. -45 Water Vol.-% 50 45 Corrosion-/ antifreeze agent vol.-% 50 max. 55

In exceptions, if no corrosion-/antifreeze agent is available and no antifreeze is required (for example tropics), 1 vol. -% = 10 cm3/litre refining agent must be used. In this case, the coolant is to be renewed annually. Continuing information can be taken from the Voith cooling-water list. This can be ordered from Voith Turbo with the Voith item-number 67.2224.10.

Annex



6SDUH 3DUWV /LVWV

Gearbox spare part recommendation list


26/350/083 26/100/056 26/100/053 26/100/059 26/350/101 26/100/032 25/250/020 26/100/038 26/100/014 26/100/008 26/350/080

Remark: Terms of items from DaimlerChrysler-EPC-documentation

26/250/047 26/100/206 26/860/026 26/860/017 26/860/014 26/860/026 26/100/197 26/100/203 26/100/200 26/100/194 26/400/083 26/100/128 26/100/125 26/100/128 26/400/089 26/100/122

26/100/023 26/100/029 26/100/128 26/100/125

25/250/008

25/250/113 26/350/ 25/250/068

26/350/071

26/250/068

26/100/113 26/100/116 26/100/107 26/100/119

26/350/065 25/250/110

Annex



6SDUH 3DUWV /LVWV (Continue)


6101 3300 6100 6101 9000 3850 3850 3800 3900 8000 6600 6700 3700 2900 2300 4000 5400 5500 5600 7500 109 850 6400 7300 5200 5300 7500 7600 20100 20000 20300 20200 20300 5200 5300 4100 4200 107 6700 6600 20300
M+P-07A-1504b

Retarder spare part recommendation list

4100 3100 2000/1

3300 2800/1

25000

2301

2600 2500/1 3100 4200

103 3500

7300

6700 6600 20000 20200

20100

Annex



6SDUH 3DUWV /LVWV (Continue)

Digiprop Control Unit

Vo it Co h-N r. Se de-N : ri r.: Ku en-N nd en r.: -N r.:

53 .x xx xxx x .12 xx xx /D atu m

M+P-07A-1617a

Retarder stage switch

Ersatzteil-Katalog - Stand: 2000-04-13


Gruppe Group Katalog Identification No Benennung Designation Typ Type Zeichnung-/ET-Katalog-Nr. Drawing-/SP-Catalog-No. Blatt Nr. Sheet No.

01 53.2654.90
ZPOSNR Draw.it.No Sachnummer Identification No

ET-VORSCHLAGSLISTE
Benennung Designation

RET. 115 E
Abmessung Dimensions Norm-Nr. Standard No. GR BTA ET-KZ

1
Menge Quantity

Revisions-Nr.: Bemerkung.: AZ-Nummer: Typ: Kennwort: Betriebsanl.Nr.: Werkstatthandb.: Kunden-Nr.: Kunden-Code: 53.2993.00 RETARDER 115
SP.PARTS CATALOGUE 01

ET - Vorschlagsliste Retarder 115 E Schulungsmappe

137975

103

01 . 0907 . 86

VERSCHLUSSSCHRAUBE
SCREW PLUG Kunden-Sachnr.: A 000 997 68 32

VS M12X1,5

VN 1638

107

91 . 2769 . 10

VERSCHLUSSSCHRAUBE
SCREW PLUG Kunden-Sachnr.: A 000 997 69 32

M24X1,5

OHNE ZCHN

109

91 . 2769 . 10

VERSCHLUSSSCHRAUBE
SCREW PLUG Kunden-Sachnr.: A 000 997 69 32

M24X1,5

OHNE ZCHN

850

91 . 2493 . 10

AUSSENRING
OUTER RING Kunden-Sachnr.: A 000 438 01 12

M802011AP

OHNE ZCHN

2300

53 . 1332 . 11

PROFILENTLUEFT.BGR.
HOUSING VENTILATION Kunden-Sachnr.: A 003 430 58 81 beinhaltet Pos. 2301 INCLUDES POS. 2301

D30X38 DRUCKG.

53.1332.11

2301

01 . 0647 . 56

RUNDDICHTRING
O-RING Kunden-Sachnr.: A 006 997 56 48

55X3

VN 3014

2600

67 . 1491 . 10

DICHTUNG UNTEN
SEAL Kunden-Sachnr.: A 000 438 13 80

67.1491.10

2900

67 . 1497 . 10

DICHTUNG
SEAL Kunden-Sachnr.: A 000 438 14 80

PE-DECKEL

67.1497.10

3100

53 . 9454 . 20

KOMBI-6KT.SCHRAUBE
HEXAGON BOLT Kunden-Sachnr.: A 000 438 27 71

M 8 X 30

53.9451.20

22

3300

53 . 9457 . 20

KOMBI-6KT.SCHRAUBE
HEXAGON BOLT Kunden-Sachnr.: A 000 438 28 71

M 8 X 80

53.9451.20

11

3500

67 . 2418 . 10

VERSCHLUSSCHRAUBE
SCREW PLUG

MIT SIEB

67.2418.10

Ersatzteil-Katalog - Stand: 2000-04-13


Gruppe Group Katalog Identification No Benennung Designation Typ Type Zeichnung-/ET-Katalog-Nr. Drawing-/SP-Catalog-No. Blatt Nr. Sheet No.

01 53.2654.90
ZPOSNR Draw.it.No Sachnummer Identification No

ET-VORSCHLAGSLISTE
Benennung Designation

RET. 115 E
Abmessung Dimensions Norm-Nr. Standard No. GR BTA ET-KZ

2
Menge Quantity

3700

53 . 9490 . 22

PROPORTIONAL-VENTIL
PROPORTIONAL VALVE Kunden-Sachnr.: A 000 438 17 81

DIGIPROP

67.1098.22

3800

67 . 1703 . 10

DAEMPFUNGSPLATTE
DAMPING PLATE

160X70X22

67.1703.10

Bei Sandgussventil 67.1091.10 ist der Reparatursatz 53.2672.10 zuverwenden.

3850

01 . 0041 . 83

RUNDDICHTRING
O-RING Kunden-Sachnr.: A 027 997 72 48

16X3

VN 3014

3900

53 . 9452 . 11

KOMBI-6KT.SCHRAUBE
HEXAGON BOLT

M 8 X 20

53.9451.11

nur noch fuer Befestigung der Dmpfungsplatte fuer andere Anwendungen ==> Ersatz 53.9452.20 ONLY FOR MOUNTING OF DAMPING PLATE, FOR OTHER USES REPLACED BY 53.9452.20

4000

01 . 0837 . 09

SECHSKANTMUTTER
HEXAGON NUT

M8

DIN 6927

4100

91 . 2770 . 10

VERSCHLUSSSCHRAUBE
SCREW PLUG Kunden-Sachnr.: A 000 997 71 32

M30X1,5

OHNE ZCHN

4200

91 . 2769 . 10

VERSCHLUSSSCHRAUBE
SCREW PLUG Kunden-Sachnr.: A 000 997 69 32

M24X1,5

OHNE ZCHN

5200

67 . 0150 . 22

TEMPERATURGEBER
THERMOCOUPLE Kunden-Sachnr.: A 001 540 52 17

M14X1,5/SW21

67.0150.22

5300

01 . 0044 . 47

DICHTRING
SEAL RING Kunden-Sachnr.: N 007603 014106

A14X20

DIN 7603

5400

91 . 2474 . 10

WELLENFEDER
UNDULATED WASHER Kunden-Sachnr.: A 000 438 00 93

SSB-0118

OHNE ZCHN

5500

53 . 3467 . 10

SCHEIBE (DAEMPFER)
WASHER Kunden-Sachnr.: A 000 438 04 67

D30X4

53.3467.10

5600

90 . 9270 . 10

SICHERUNGSRING
CIRCLIP Kunden-Sachnr.: A 000 438 06 73

JL 30X1,2

90.9270.10

6100

67 . 1947 . 10

ROHR
PIPE Kunden-Sachnr.: A 000 438 02 29 beinhaltet Pos. 6101 INCLUDES POS. 6101

M. RDR / LUFT

67.1947.10

6101

01 . 0041 . 78

RUNDDICHTRING
O-RING

15,3X2,4

VN 3014

Ersatzteil-Katalog - Stand: 2000-04-13


Gruppe Group Katalog Identification No Benennung Designation Typ Type Zeichnung-/ET-Katalog-Nr. Drawing-/SP-Catalog-No. Blatt Nr. Sheet No.

01 53.2654.90
ZPOSNR Draw.it.No Sachnummer Identification No

ET-VORSCHLAGSLISTE
Benennung Designation

RET. 115 E
Abmessung Dimensions Norm-Nr. Standard No. GR BTA ET-KZ

3
Menge Quantity

6400

67 . 2378 . 13

WAERMETAUSCHER
HEAT EXCHANGER

67.2378.13

6600

53 . 9461 . 10

6KT.SCHRAUBE M.FL.
HEXAGON BOLT Kunden-Sachnr.: A 000 438 22 71

M14 X 40

53.9458.11

7300

01 . 0759 . 56

RUNDDICHTRING
O-RING Kunden-Sachnr.: A 020 997 62 48

15X4

VN 3014

7500

01 . 0759 . 32

RUNDDICHTRING
O-RING Kunden-Sachnr.: A 024 997 37 48

45X5

VN 3014

7600

01 . 0759 . 63

RUNDDICHTRING
O-RING Kunden-Sachnr.: A 027 997 31 48

25X4

VN 3014

8000

67 . 2043 . 10

ZWISCHENPLATTE
INTERMEDIATE PLATE Kunden-Sachnr.: A 000 438 01 84

196X144X2

67.2043.10

9000

53 . 8258 . 10

DRUCKSENSOR
PRESSURE SENSOR Kunden-Sachnr.: A 002 542 64 18

0-4 BAR

53.8258.10

20000

67 . 2069 . 20

WASSERSTUTZEN
WATER SOCKET Kunden-Sachnr.: A 656 997 00 72

AD 52

67.2069.20

20100

67 . 2178 . 10

DICHTUNG
SEAL Kunden-Sachnr.: A 656 997 00 49

WASSERSTUTZEN 67.2178.10

20200

53 . 9457 . 20

KOMBI-6KT.SCHRAUBE
HEXAGON BOLT Kunden-Sachnr.: A 000 438 28 71

M 8 X 80

53.9451.20

25000

67 . 2674 . 10

AUSGLEICHSCH.(AUSW)
SET OF SHIMS

R115 AN GO4

O.Z.

bestehend aus A 629 261 01 52 bis A 629 261 33 52

25100

67 . 2683 . 10

O-RING
O RING Kunden-Sachnr.: A 019 997 83 48

D 14 X 4

O.Z.

25200

67 . 2676 . 10

SCHRAUBE
BOLT Kunden-Sachnr.: A 914 26 01 00 37

M10X70

O.Z.

25300

67 . 2675 . 10

SCHRAUBE
BOLT

M10X60

O.Z.

17

Kunden-Sachnr.: A 914 126 01 00 51

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