Awm R133 PDF

$IWHUVDOHV:RUNVKRS0DQXDO
92,7+5HWDUGHU/RJRSURS
cbtd 00-03
67.1405.20
Content 7DEOHRI&RQWHQWV
1. Preface.................................................................................................... 1/1
2. General ................................................................................................... 2/1

2.1 Retarder Data ..................................................................................................2.1/1
2.2 Assembly Overview .........................................................................................2.2/1
With Stainless-Steel Heat Exchanger ..............................................................2.2/1
With Aluminium Heat Exchanger .....................................................................2.2/3
2.3 Function and Operation Scheme .....................................................................2.3/1
3. Maintenance............................................................................................ 3/1
3.1 Maintenance Work / Oil Change Intervals .......................................................3.1/1
3.2 Checking Oil Level...........................................................................................3.2/1
With Oil Filler / Check Plug ..............................................................................3.2/1
With Oil Filling Plug..........................................................................................3.2/5
3.3 Oil Change .......................................................................................................3.3/1
With Stainless-Steel Heat Exchanger ..............................................................3.3/1
With Aluminium Heat Exchanger .....................................................................3.3/5
3.4 Cleaning Line Filter (optional extra) .................................................................3.4/1
cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

67.1405.20 Page IHV / 1
(Continue)
4. Diagnosis / Troubleshooting.................................................................... 4/1
4.1 Troubleshooting Diagram A to D ...................................................................4.1/1
Electrical Connections Diagram.....................................................................4.1/6
4.2 Troubleshooting and Remedies.....................................................................4.2/1
4.3 Illustration Control System.............................................................................4.3/1
4.4 Checking Supply-Air Pressure.......................................................................4.4/1
4.5 Checking Constant-Air Pressure ...................................................................4.5/1
4.6 Checking Control Current of Proportional......................................................4.6/1
4.7 Checking Temperature Limit..........................................................................4.7/1
4.8 Checking Control Unit....................................................................................4.8/1
4.9 Checking Housing Pressure ..........................................................................4.9/1
4.10 Table of Measurements ...............................................................................4.10/1
4.11 Operational Check .......................................................................................4.11/1
5. Removing, Installing Retarder................................................................. 5/1

5.1 Removing, Installing Retarder (Free Mount Installation)..................................5.1/1
5.2 Removing, Installing Retarder (Gearbox Attachment) .....................................5.2/1

67.1405.20 Page IHV / 2
(Continue)
6. Repair (Gearbox Attachment) ................................................................. 6/1
6.1 Overall Illustration of Main Components........................................................6.1/1
6.2 Checking, Removing and Installing Casing Ventilation .................................6.2/1
6.3 Checking, Removing and Installing Sump Check Valve................................6.3/1
6.4 Removing, Cleaning and Installing Silencer ..................................................6.4/1
6.5 Removing and Installing Prop Shaft Flanges.................................................6.5/1
6.6 Removing and Installing Labyrinth Cover (Output Side),
Renewing Radial Shaft Sealing Ring.............................................................6.6/1
6.7 Removing and Installing Centering Cover (Input Side),
6.8 Removing and Installing Housing Cover........................................................6.8/1
6.9 Removing and Installing Sump Flap Valve ....................................................6.9/1
6.10 Removing and Installing Stator and Rotor,
Renewing Cylinder Roller Bearing...............................................................6.10/1
6.11 Removing and Installing Stator Pins............................................................6.11/1
6.12 Renewing Rectangular-Section Rings (Polypenco-Rings) ..........................6.12/1
6.13 Parameterizing Control Unit.........................................................................6.13/1

67.1405.20 Page IHV / 3
(Continue)
7. Repair (Free Mount Installation).............................................................. 7/1
7.1 Overall Illustration of Main Components........................................................7.1/1
7.2 Checking, Removing and Installing Casing Ventilation .................................7.2/1
7.3 Checking, Removing and Installing Sump Check Valve................................7.3/1
7.4 Removing, Cleaning and Installing Silencer ..................................................7.4/1
7.5 Removing and Installing Prop Shaft Flanges.................................................7.5/1
7.7 Removing and Installing Labyrinth Cover (Input Side),
7.8 Removing and Installing Housing Cover,
Renewing Deep-Groove Ball Bearing............................................................7.8/1
7.9 Removing and Installing Sump Flap Valve ....................................................7.9/1
7.10 Removing and Installing Rotor ....................................................................7.10/1
7.11 Removing and Installing Stator
Renewing Cylinder Roller Bearing...............................................................7.11/1
7.12 Removing and Installing Stator Pins............................................................7.12/1
7.13 Renewing Rectangular-Section Rings (Polypenco-Rings) ..........................7.13/1
7.14 Parameterizing Control Unit.........................................................................7.14/1

67.1405.20 Page IHV / 4
(Continue)
8. Removing, Checking and Installing Heat Exchanger ............................. 8/1
8.1 Removing, Checking and Installing Stainless-Steel Heat Exchanger............8.1/1
8.2 Removing, Checking and Installing Aluminium Heat Exchanger ..................8.2/1
9. Control Parts Digiprop............................................................................. 9/1

9.1 Removing and Installing Valve Block.............................................................9.1/1
9.2 Removing and Installing Cooling-Water Temperature Pick-Up ....................9.2/1
10. Annex .................................................................................................... 10/1

Data Sheet
Conversion Table

67.1405.20 Page IHV / 5
Preface 3UHIDFH
The present workshop manual serves as training material for the training of VOITH sales- and
service-partner. The information and instructions which are given to you furthermore provide the basis for
appropriate and professional maintenance and repair at the VOITH Retarder VOITH Retarder 133 with
Logoprop control system.
In some footers, you will find a symbolic book in yellow colour.

On the so marked pages you will find continuing information in comparison to the service manual
„VOITH Retarder 133-2“ (53.2641.10). These information have been implemented additionally into the
present workshop manual, or were supplemented in the detail.
The labeling of the pages shall illustrate you in simple manner the demarcation (interfaces/information-flow)
to the service manual.

67.1405.20 Page 1 / 1
Preface 3UHIDFH
(Continue)
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.
Notice
is associated for general notices for a better handling during maintenance of the retarder.

67.1405.20 Page 1 / 2
Preface 3UHIDFH
(Continue)
Caution!
The switched-on retarder will not secure the parked vehicle.
At a failure of the retarder, or while the temperature limitation is effective the vehicle speed must be settled
with the service brake.
Notice
Only genuine spare parts may be used for repairs. For inquiries and orders, please provide the following
information (see also section 2.1 „Retarder Data“):
• Brake number 6-digit number and letters

• Basic group-number 8-digit number

67.1405.20 Page 1 / 3
Preface 3UHIDFH
(Continue)
Notice
The used three- or four-digit item numbers in these instructions are corresponding to the item numbers in
the spare parts lists in the annex.
Items or components shown with an oblique-number are not available.
Items or components with two-digit item numbers are no spare parts and therefore not available in the spare
parts lists.
Caution!
Pay attention to absolute cleanliness in maintenance work. Dirt on bearing and sealing surfaces and
electrical contacts may cause considerable damage or operational malfunctions.
Notice
To observe environmental protection you should dispose of drained fuels, coolants and lubricants
professionally.

67.1405.20 Page 1 / 4
Preface 3UHIDFH
(Continue)
Notice
In troubleshooting you must not replace parts on suspicion. Warranty work or goodwill work can only be
offered, if the parts involved are demonstrably defective.
To exclude injuries and to avoid impairment of the operational reliability of the retarder or damage to the
retarder as a result of inexpert workmanship, the information and instructions must be read carefully and
complied with in their entirety.
Notice
It is not allowed from safety-related reasons to open and or dismantle the valve block.

67.1405.20 Page 1 / 5
Preface 3UHIDFH
(Continue)
Inevitably, it is impossible for VOITH TURBO GmbH & Co. KG in the last analysis 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 VOITH retarders 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.
It is therefore expressly pointed out that all working procedures described must be carried out only in
compliance with the valid general directions and regulations of the locally responsible authorities, of the
health protection, accident prevention and environmental protection organisations.
The technical status of the present instructions can be seen from the date (see footer on left). There may
be discrepancies between the actual technical status of the retarders and the descriptions owing to
continuous development and improvement of the retarders.
VOITH TURBO GmbH & Co. KG reserves the right to make modifications at any time and without
prior notification.

67.1405.20 Page 1 / 6
Preface 3UHIDFH
(Continue)
Should you have any queries about the descriptions, please contact the responsible person in the
appropriate organisation of the country involved or:
VOITH TURBO GmbH & Co. KG

Department cb; Voithstraße 1
PO box 15 55
D-74564 Crailsheim
Telephone xx49 - (0)7951 32-0

Telefax xx49 - (0)7951 32-756
Telex 74 338
e-mail: retarder@voith.de
Extensions:
Customer telephone and Spare Parts Service
32-401 / 32-422

67.1405.20 Page 1 / 7
General *HQHUDO
2.1 Retarder Data............................................................................................. 2.1/1
2.2 Assembly Overview.................................................................................... 2.2/1

With Stainless-Steel Heat Exchanger ............................................................................2.2/1
With Aluminium Heat Exchanger ...................................................................................2.2/3
2.3 Function and Operation Scheme ............................................................... 2.3/1

67.1405.20 Page 2 / 1
General 5HWDUGHU'DWD
The data (arrow) of the retarder 133-2 is punched on the output side of the retarder housing on the left.
The retarder data plate provides the following information:
1. Number of the brake (Br.Nr.):
5/91
Six-digit number.
The retarder 133-S is is marked at the end of the brake number with a „S“.
Retarder 133
F = fixed bearing BrNr
GrNr
L = moveable bearing M = 4000 Nm
n =
No data = free mount installation
2. Basic group number (Gr.Nr.):

0503
Eight-digit number
3. Max. possible braking torque on prop shaft (M):

M = 4000 Nm (must not correspond to the setting)

67.1405.20 Page 2.1 / 1
General 5HWDUGHU'DWD
(Continue)
Notice
Max. braking torque is set for the specific vehicle.

Observe the vehicle manufacturer´s data.
4. Max. retarder r.p.m. (max. prop shaft r.p.m.):
4.1 R 133: vps = 2000 r.p.m.

4.2 R 133-S: vps = 2500 r.p.m.
Notice
Please, always quote the No. of the brake and No. of basic group when submitting queries or ordering spare
parts.

67.1405.20 Page 2.1 / 2
General $VVHPEO\2YHUYLHZ
Illustration VOITH Retarder R 133-2

basic group with stainless-steel heat exchanger
1000 Heat exchanger

1010/1 Retarder data 1030
1010/3 Connection ventilation
1030 Check connection housing pressure pG 2260
M 12 x 1,5
1040 Oil level plug M 24 x 1,5
1060 Oil filler/check plug M 24 x 1,5
2260 Oil filling plug M 24 x 1,5,
alternative M 18 x 1,5
1010/1
1010/3
1060
1040
1000
0502

67.1405.20 Page 2.2/1
(Continue)
basic group with stainless-steel heat exchanger
(Continue)
1000 Heat exchanger

1001 Cooling-water drain plug 2105
M 18 x 1,5 1070
1070 Retarder oil drain plug
M 30 x 1,5
1440 Silencer (ventilation)
2105 Sump check valve plug
M 22 x 1,5
1440
1001
1000
0002

67.1405.20 Page 2.2/2
(Continue)
basic group with aluminium heat exchanger
1000 Heat exchanger

1002 Heat exchanger oil-drain plug
M 12 x 1,5 1030
1010/1 Retarder data
1010/2 Connection constant-air pressure line py 2260
1010/3 Connection ventilation line
1030 Test connection, housing pressure pG
M 12 x 1,5
2260 Oil filling plug M 24 x 1,5
1010/1
1010/3
1010/2
1060
1040
1000
1002
0501

67.1405.20 Page 2.2/3
(Continue)
basic group with aluminium heat exchanger
(Continue)
2105
1000 Heat exchanger 1070
1001 Cooling-water drain plug
M 12 x 1,5
1002 Heat exchanger oil drain plug
M 12 x 1,5
1070 Retarder oil drain plug
M 30 x 1,5 1440
1440 Silencer (ventilation)
2105 Sump check valve plug
M 22 x 1,5
1001
1000
1002
0004

67.1405.20 Page 2.2/4
General )XQFWLRQDQG2SHUDWLRQ6FKHPH
(Continue)
Illustration VOITH Retarder R 133
25 Oil sump
Supply-air pressure p V
P Constant-air pressure p y
Coolant (water)
A 26 Housing pressure p H
46 10 36 R
21
23
49
14 6 3
44
56
51
1 2 16
45
19
22
17
47
58
54 68 59 43 53 18
0500
Notice
The reference numbers indicated in section 2.3 are not identical with the reference numbers of the spare parts lists.
1 Heat exchanger 36 Ventilation line

2 Control unit 43 Oil sump
3 Connection vehicle battery supply 24 V 44 Stator
6 Fuses (8 A) 45 Stator pin
8 Connection ground 46 Rotor
10 Test connection housing pressure pG 47 Speedometer signal
14 ABS switch-off relay 49 Output restrictor p1
16 Retarder stage switch 51 Filling restrictor p2
17 Retarder pilot light 53 Filling duct
18 Stop light relay 54 Duct
19 Cooling-water temperature pick-up 56 Leakage oil return line
21 Valve block 58 Sump check valve
22 Ventilation 59 Sump flap valve
23 Casing ventilation 68 Auxiliary chambers
25 Constant-air pressure line py
26 Supply-air pressure line pv
(to valve block)

67.1405.20 Page 2.3/1
General )XQFWLRQDQGRSHUDWLRQ6FKHPH
(Continue)
Description of the function
The VOITH retarder 133 is a powerful, hydrodynamic, continues brake of compact design for buses and
commercial vehicles in the heavy range.
The VOITH retarder 133 is located in a vehicle drive train between gearbox and rear axle.
In this way, the retarder braking torque is sustained even when gear changes are made.
The switched-on retarder will not secure a parked vehicle.
A retarder stage switch (16) with a maximum of 5 switching stages is used to control the
VOITH retarder 133. A special version combines the retarder stage switch (16), in use with ABS, with a
3- or 4-stage pedal operated brake valve.

67.1405.20 Page 2.3/2
(Continue)
The following versions of the retarder stage switch are made:
a) Control system with function ,,Constant Speed"

The retarder is operated by a 5-stage retarder stage switch.
When the retarder stage switch is shifted to position 1, the momentary speed is transferred to memory and
the retarder holds the vehicle speed downhill constant within the limits of the maximum braking torque.
If after activation of „constant speed“ operation the retarder is switched off (position 0), or switched to
braking stage (position 2 to 5), „constant speed“ is deleted from the memory. Another transfer to memory
of the „constant speed“ operation holds the new, momentary speed.
When the retarder stage switch is shifted to position 2 to 5, braking stage 1 to 4 is energized.
Maximum braking torque is obtained when the retarder stage switch is in the maximum position.
b) Control system without function ,,Constant Speed"

The retarder is operated by a 5-stage retarder stage switch.
When the retarder stage switch is shifted to stage 1 to 5, the retarder brakes through braking stage 1 to 5.
Maximum braking torque is obtained in braking stage 5.

67.1405.20 Page 2.3/3
(Continue)
Description of operation of retarder R 133 with Logoprop control system
c
The control medium for the Voith Retarder 133 is compressed air, which is taken from the air tank for
auxiliary equipment on the vehicle.
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 flows to the valve block (21).
a b
The valve block (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).
0006
The rotor (46) is connected with the prop shaft to the vehicle rear axle, the stator (44) is connected via the
retarder housing with the vehicle frame. The hydrodynamic principle
a Rotor (46)
The rotation of the rotor sets the oil in motion and circulates it in a closed flow between the rotor (46) and b Stator (44)
stator (44). c Oil flow
The reduction of the velocity of the oil flow in the working chambers of the stator (44) leads the deceleration
of the rotor (46) and consequently to braking of the vehicle.
During braking, the kinetic energy of a deceleration is transformed into heat. To dissipate this heat, part of
the circulating oil is pumped continuously by the rotor (46) through the heat exchanger (1) and via
filling ducts to join the circulating flow 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.

67.1405.20 Page 2.3/4
(Continue)
Temperature pick-up water (19)
The temperature pick-up is installed in the cooling-water return pipe from the retarder to the heat exchanger
and transmit signals on cooling-water temperature to the control unit (2).
This temperature pick-up guarantees that the mximum permissible cooling-water temperatures are not
exceeded.
If the cooling water in the return pipe heats up to a preselected value, the constant-air pressure py
decreases linearly over a range of approx. 10°C at the highest braking stage.
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 limit range of approx. 10°C is exceeded while braking, braking torque output is stopped to protect the
vehicle cooling system.
While the temperature limit is effective or if there is a retarder failure, the service brake must be used to
control the vehicle speed.

67.1405.20 Page 2.3/5
(Continue)
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) into the open air.
If the working circuit has been vented, a float rises and closes off the casing ventilation.
Sump check valve (58)

Any small amounts of leakage oil present on the shaft sealing rings are collected by the labyrinth seals and
returned via the leakage oil return line (56), the sump check valve and the duct (54) into the auxiliary
chambers (68), and thus to the oil sump (43).
When the retarder is switched off, the compressed-air escapes via the auxiliary chambers (68) and the
silencer (22) into the open air and simultaneously acts on the sump check valve via the duct (54).
The aluminium disc is pushed upwards by the compressed-air and closes the leakage oil return line (56).
Oil is thus prevented from escaping via the labyrinth seals when the retarder is switched off.

67.1405.20 Page 2.3/6
(Continue)
Sump flap valve (59)
When the retarder is switched on, the oil sump (43) is pressurized with compressed air.
This closes the sump flap valve. The oil sump (43) is seperated from the auxiliary chambers (68).
After the retarder has been switched off, the sump flap valve opens again and the oil can level out
between the oil sump (43) and the auxiliary chambers (68).
Stator pins (45)

The pin plates steer the accelerated airflow past the stator blades and prevent the build-up of an effective
flow. When the working chamber is full of oil, the oil presses the plates back on their seats against the force
of the spring and the full space between the blades is available.

67.1405.20 Page 2.3/7
Maintenance 0DLQWHQDQFH
3.1 Maintenance Work / Oil Change Intervals.................................................. 3.1/1
3.2 Checking Oil Level ..................................................................................... 3.2/1

With Oil Filler/Check Plug ..............................................................................................3.2/1
With Oil Filling Plug........................................................................................................3.2/5
3.3 Oil Change ................................................................................................. 3.3/1

With Stainless-Steel Heat Exchanger ............................................................................3.3/1
With Aluminium Heat Exchanger ...................................................................................3.3/5
3.4 Cleaning Line Filter (optional extra) ........................................................... 3.4/1

67.1405.20 Page 3/1
Maintenance 0DLQWHQDQFH:RUN2LO&KDQJH,QWHUYDOV
Overview of maintenance work

Carry out the following maintenance work at each oil change:
• Clean line filter (optional extra)

• Carry out visual inspection on leaks at the complete retarder
• Tighten all screw plugs of the heat exchanger and retarder basic groups with the appropriate torque
(see annex)
Except all fastening nuts of the heat exchanger (see arrows in illustration and chapter 8)!
• Check hex.-head screws of prop shaft and correct fitment, or tighten if necessary.
Observe guidelines and instructions!
Notice
The illustration shows a retarder 133 with stainless-steel heat exchanger.

0565
The maintenance work for retarder with aluminium heat exchanger are identical.

67.1405.20 Page 3.1/1
(Continue)
Caution!
Tighten fastening nuts and screws only in case of leakage between heat exchanger and retarder.
Tightening torque 46 Nm
Do not tighten with impact tool!
Do not tighten studs (Dilavar) too high. This causes damage of the studs and they may crack at once or
during the driving session.
Single-grade Multi-grade Synthetic /

mineral oil 1) mineral oil 1) part synthetic oil
1)
HGV 90.000 km 2) - 135.000 km 2)

Normal duty
HGV 45.000 km 2) - 90.000 km 2)
Heavy duty
BUS 135.000 km 2) 90.000 km 2) 180.000 km 2)

Normal duty
BUS 60.000 km 2) 45.000 km 2)

90.000 km 2)
Heavy duty
1) Operating specifications, see annex

2) Change oil at latest after 2 years, if fewer kilometres are travelled.

67.1405.20 Page 3.1/2
(Continue)
1. „Normal duty“
Example:
- Long distance traffic
2. „Heavy duty“
Subject to more than normal stress.
Examples:
- Use in regions with high ambient temperatures
- Vehicles at construction sites and timber lorries
- High max. permissible weight with low rated engine power (< 6 kW/metric ton)
- Stretches 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 (TransmaxZ or SEA 5W-40)
must be used.

67.1405.20 Page 3.1/3
Maintenance &KHFNLQJ2LO/HYHO
Illustration checking oil level
Notice
2260
The oil change intervals and operating specifications
have to be taken from the annex.
2270

Hex.-head, w.a.f. 22, 80 Nm 1060
1050 Sealing ring A 24 x 29, Copper, renew
Inhex.-head, w.a.f. 22, 80 Nm
Hex.-head, w.a.f. 22, 80 Nm,
alternative M 18 x 1,5 1050
Hex.-head, w.a.f. 17, 50 Nm
2270 Sealing ring A 24 x 29, A 18 x 24, Copper,
renew
1050
1040
0508

67.1405.20 Page 3.2/1
(Continue)
Notice
For satisfactory retarder operation, it is important to adhere to the specified service filling and to use only
oils specified in the operating specifications (see annex) for operating the retarder in the relevant
application.
The illustration on page 3.2/1 shows a retarder 133 with stainless-steel heat exchanger.
Checking oil level at aluminium heat exchanger is identical.
The oil level check can be carried out either with oil filler/check plug (1060) or with the oil filling plug (1040)
from page 3.2/5, depending on access on the vehicle.
Service filling
The service filling for the complete retarder system depends on the version of the mounted heat exchanger,
see also table on page 3.3/3 and 3.3/7.
For relevant application approved oils

Use only approved oils specified in the operating specifications (see annex).
Notice
The temperature of the retarder oil must be higher than 60°C (operating temperature) for checking the oil
level.
The oil level check must be carried out with the vehicle in horizontal position.
The difference between min. and max. mark on oil filler/check plug is approx. 1,0 litre oil.

67.1405.20 Page 3.2/2
(Continue)
Job scope
Preconditions for checking
• Ignition ON
• Operating pressure
Oil level check with oil filler/check plug

1. Operate the retarder at the highest stage (highest braking stage) with vehicle stationary and switch
it off after approx. 5 sec.
Repeat this procedure twice.
2. Switch off retarder and wait 5 minutes (control function).
Caution! Risk of injury!
The oil filler/check plug is hot! Oil temperature!
3. Screw out the oil filler/check plug (1060) and remove sealing ring (1050).
Wipe the oil off the dipstick.
4. Position oil filler/check plug (1060) plane at the thread. Do not screw in!

67.1405.20 Page 3.2/3
(Continue)
Oil level check with oil filler/check plug (Continue)
5. Pull out the oil filler/check plug (1060) again.
If the oil filling is correct, the oil level must be between the min. and max. marks of the dipstick. 1060
6. Top up slowly any lacking oil through the hole for the oil filler/check plug.
Max
Min
Notice
If the oil is filled in too quickly at the housing cover, there is an oil backflow and the oil may emerge through
the ventilation system (silencer).
0129
7. Screw the oil filler/check plug (1060) tight with new sealing ring (1050) or, as the case may be,
the oil filling plug (2260) tight with new sealing ring (2270).
Tightening torque
Oil filler/check plug = 80 Nm
Oil filling plug M 24 x 1,5 = 80 Nm

67.1405.20 Page 3.2/4
(Continue)
Checking oil level with oil level plug
2. Switch off retarder and wait 5 minutes (control function).

1050
The oil level plug is hot! Oil temperature! 1040
0509
3. Screw out the oil level plug (1040) and remove sealing ring (1050).
Wipe the oil off the wire hook. The oil level is satisfactory, when it reaches the lower edge of the
threaded bore (arrow).
4. Insert the oil level plug (1040) with wire hook into the threaded bore.
5. Pull the oil level plug (1040) out again.

The minimum oil level is reached when the tip of the wire hook (arrow) is wetted with oil.
6. Top up slowly any lacking oil through the hole for the oil filling plug (2260) in the housing cover.
1040
0510

67.1405.20 Page 3.2/5
(Continue)
Checking oil level with oil level plug (Continue)
7. Screw the oil level plug (1040) and the oil filling plug (2260) tight with a new sealing ring.
Tightening torques 2260

Oil level plug = 80 Nm
The oil change intervals have to be taken from chapter 3.1 and the operating specifications have to 1040
be taken from the annex!
0511

67.1405.20 Page 3.2/6
Maintenance 2LO&KDQJH
Illustration oil change R 133 with

stainless-steel heat exchanger

1070 Retarder oil drain plug M 30 x 1,5 2260
1080 Sealing ring A 30 x 26, Copper, renew 2270
2105 Screw plug sump check valve M 22 x 1,5
alternative M 18 x 1,5 1060
alternative A 18 x 24, Copper, renew 1080
2090 2105
1050
0507

67.1405.20 Page 3.3/1
(Continue)
Caution
For satisfactory retarder operation, it is important to adhere to the specified service filling
(see table next page) and to use only oils specified in the operating specifications (see annex) for
operating the retarder in the relevant application. The retarder oil temperature must be higher than 60 oC
(operating temperature) for the oil to be drained.
While the oil is being changed, make sure that no constant-air pressure is acting on the retarder.
The retarder and the vehicle ignition system must have been switched off!
Notice
If it is necessary to drain the cooling water during a service, remove end empty retarder on oil side
completely (see following table service filling). This process also must be enforced with strongly spent oil.
Then install heat exchanger with new sealing rings.

67.1405.20 Page 3.3/2
(Continue)
Stainless-steel Stainless-steel
heat exchanger heat exchanger
small large
VOITH item number 67.0481.11 67.0567.11
Service filling 6,0 litre 6,0 litre
After exchange of heat exchanger 7,5 litre 8,2 litre
After complete taking apart and cleaning, as

well as emptied heat exchanger 8,5 litre 9,5 litre
(corresponds new filling)

67.1405.20 Page 3.3/3
(Continue)
Job scope
The retarder oil drain plug and screw plug are hot! Oil temperature!
If the retarder is still switched on during working step 3 and the oil drain plug (1070),
oil filler/check plug (1060) or oil filling plug (2260) are unscrewed, high risk of injury excist by hot leaving oil
(increased pressure)!
2. Push an oil collecting pan under retarder.
3. Screw out the retarder oil check plug (1070) and remove sealing ring (1800).
Drain any leakage oil which has collected professionally.
4. Provide retarder oil check plug (1070) with new sealing ring (1080) and screw it tight in its hole.
5. Screw out screw plug of sump check valve (2105) at the lower side of the housing cover and remove
sealing ring (2090).
Drain any leakage oil which has collected.

67.1405.20 Page 3.3/4
(Continue)
6. Provide screw plug of sump check valve (2105) with new sealing ring (2090) and screw it tight.
7. Fill in slowly in a time range > 3 min. specified quantity of oil (see page 3.3/3) in accordance with
operating specifications (see annex) through the hole for the oil filler/check plug (1060) or for the
oil filling plug (2260).
Notice
8. Screw oil filling plug (2260) tight with new sealing ring (2270).
Tightening torque
The oil change intervals have to be taken from chapter 3.1 and the operating specifications have to

67.1405.20 Page 3.3/5
(Continue)
Illustration oil change R 133 with
aluminium heat exchanger
1002 Heat exchanger oil drain plug M 12 x 1,5

Hex.-head, w.a.f. 13, 25 Nm 1002
1060 Oil filler/check plug M 24 x 1,5 2260
1070 Retarder oil drain plug M 30 x 1,5
1060
2105 Screw plug sump check valve M 22 x 1,5
1070
alternative M 18 x 1,5, 1080
Hex.-head, w.a.f. 17, 50 Nm 1050
2270 Sealing ring A 22 x 29, Copper, renew 2090 2105
alternative A 18 x 24, Copper, renew
0504

67.1405.20 Page 3.3/6
(Continue)
Caution
For satisfactory 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. The retarder oil temperature
must be higher than 60 oC (operating temperature) for the oil to be drained.
While the oil is being changed, make sure that no constant-air pressure is acting in the retarder.
The retarder and the ignition must have been switched off!
Notice
The service filling for the complete retarder system depends on the mounted version of heat exchanger.
If another version of heat exchanger is mounted, the quantity of the service filling will change as well.
The AKG- item number can be found on the type plate on the upper side of the heat exchanger.
Aluminium Aluminium Aluminium

heat exchanger heat exchanger heat exchanger
standard displaced on the slim
right
AKG item number 0591 033 0591 045 0591 126

0591 039 0591 133
0591 069
Service filling 9,0 litre 9,0 litre 8,8 litre

67.1405.20 Page 3.3/7
(Continue)
The oil-drain plug and the screw plug is hot! Oil temperature!
Job scope
1. Push an oil collecting pan under retarder.
2. Screw out the oil-drain plug (1070) at the retarder and the oil-drain plug (1000/1) at the
heat exchanger and remove sealing rings (1003, 1080). Drain any leakage oil which has collected
professionally.
3. Provide oil drain plugs (1002, 1070) with new sealing rings (1003, 1080) and screw them tight in their
holes.
Tightening torque
Retarder oil drain plug (1070) 150 Nm
Heat exchanger oil drain plug (1002) 25 Nm 1002
1003
1080
1070
0505

67.1405.20 Page 3.3/8
(Continue)
4. Screw out screw plug of sump check valve (2105) at the lower side of the housing cover and remove
sealing ring (2090).
Drain any leakage oil which has collected.
5. Provide screw plug of sump check valve (2105) with new sealing ring (2090) and screw it tight.
6. Fill in through the hole for the oil level plug (1060) or through the bore for the oil filling plug (2260) the
specified quantity of oil (see page 3.3/7 and annex) in accordance with the Operating Specifications
(see annex).
2090
2105
Notice 0506
7. Screw oil filling plug (2260) tight with new sealing ring (2270).
Tightening torques
The oil change intervals have to be taken from chapter 3.1 and the operating specifications have to

67.1405.20 Page 3.3/9
Maintenance &OHDQLQJ/LQH)LOWHURSWLRQDOH[WUD
Illustration line filter
12000 Complete line filter

12000/1 Pressure spring
12000/2 Intermediate plate 12000/1
(mind mounting position)
12000/3 Cover
12000/4 Holding plate 12000/6
12000/5 Pressure spring
12111
12000/6 Filter housing
12111 Filter insert
12112 O-ring (36,2 x 3), renew,
coat with silicone-free and non-corossive 12000/2
12000
grease for installation
12000/5
Lubricants
O-ring Silicone-free and

non-corossive grease
12112
12000/3
Notice
The inner bridges of the intermediate plate must face

in direction of pressure spring (12000/5).
12000/4
0015

67.1405.20 Page 3.4/1
(Continue)
Notice
Vehicle specific can be installed a line filter within the constant-air pressure line between air tank
for auxiliary equipment and the proportional valve of the retarder control system.
The line filter is designed and in the way installed, to ensure an optimum air flow to the proportional valve
also when filter insert is badly soiled. In this case the compressed air will not be cleaned anymore.
Job scope
Observe fall in pressure in the compressed air circuit for auxiliary equipment (e.g. air springs)!
1. Disconnect constant-air pressure line at the line filter for air tank of auxiliary equipment .
2. Press in the cover (12000/3) and pull out the holding plate (12000/4).
3. Pull out of the filter housing (12000/6) the cover (12000/3) with O-ring (12112),
the pressure spring (12000/5), the intermediate plate (12000/2), the filter insert (12111)
and the pressure spring (12000/1) .

67.1405.20 Page 3.4/2
(Continue)
4. Blow out the filter insert (12111) with compressed air from inside out. Check filter insert for
damages and renew if necessary.
Notice
The inner bridges of the intermediate plate must face in direction of pressure spring (12000/5).
5. Insert the pressure spring (12000/1), the filter insert (12111), the intermediate plate (12000/2) and
the pressure spring (12000/5) in filter housing (12000/6).
6. Coat new O-ring (12112) with silicone-free and non-corossive grease. Pull the new O-ring on to the
cover (12000/3).
7. Press in the cover (12000/3) into the filter housing (12000/6) and put in the holding plate (12000/4).
Notice
If complete filter (12000) has to be removed, observe the correct installing position.

67.1405.20 Page 3.4/3
Diagnosis / 'LDJQRVLV7URXEOHVKRRWLQJ
Troubleshooting
4.1 Troubleshooting Diagram............................................................................ 4.1/1

Troubleshooting Diagram A to D...................................................................................... 4.1/1
Electrical Connections Diagram....................................................................................... 4.1/6
4.2 Troubleshooting and Remedies .................................................................. 4.2/1
4.3 Illustration Control System .......................................................................... 4.3/1
4.4 Checking Supply-Air Pressure .................................................................... 4.4/1
4.5 Checking Constant-Air Pressure................................................................. 4.5/1
4.6 Checking Control Current of Proportional Valve ......................................... 4.6/1
4.7 Checking Temperature Limit ....................................................................... 4.7/1
4.8 Checking Control System............................................................................ 4.8/1
4.9 Checking Housing Pressure........................................................................ 4.9/1
4.10 Table of Measurements ............................................................................ 4.10/1
4.11 Operational Check .................................................................................... 4.11/1

67.1405.20 Page 4/1
Diagnosis/ 7URXEOHVKRRWLQJ'LDJUDP
Troubleshooting
Illustration troubleshooting diagram main groups
Notice
Before starting troubleshooting the oil level of the retarder must be checked and corrected, if necessary (see chapter 3.3 „Checking Oil Level“).
It is important that the specific service filling is kept for a trouble-free operation of the retarder (see chapter 3.2 „Oil Change“ and annex).
A
Oil loss
through
ventilation
Oil loss
B
Complaint
Retarder
pilot light R 133
Logoprop
input / output
side C
No respectively
insufficient
retarder braking
effect
D 0514

67.1405.20
Page 4.1/1
Troubleshooting (Continue)
Illustration troubleshooting diagram group A
Oil loss
through
ventilation
Check
retarder oil level
Water in oil OK NOK Water in oil

(emulsion) (emulsion)
Check
casing ventilation
NO YES Check YES NO
heat exchanger
(chapter 6.2, 7.2)
Correct
oil level *
see chapter 8
OK NOK
Replace
casing ventilation
(chapter 6.2, 7.2)
Check
sump flap valve
(chapter 6.9)
Replace
OK NOK sump flap valve
(chapter 6.9 and 7.9)
Check screw plugs M30 x 1,5

in filling duct according to
Aftersales Service Information
11/97 and 15/96
(see annex) Repair
screw plugs
OK NOK (see Aftersales
Service Information
11/97 and 15/96)
Check valve block

for correct
installation according to
Aftersales Service
Information 14/93
* Do you get oil loss again after a trail run:

Dismantle retarder and appraise, continue at "Checking Casing Ventilation".
replace wear and tear parts,
if necessary
seal new and assemble,
check again 0130

67.1405.20
Page 4.1/2
Illustration troubleshooting diagram group B
B
Retarder
pilot light
no
function flashes
Temperature
Check retarder pilot light limit!
and its electrical lead
OK NOK
Check operation
(during braking with
retarder nominal engine
Check control unit Replace retarder pilot speed, if possible)
according to chapter 4.8 light or its electrical
and replace, if necessary lead OK NOK
Check temperature
pick-up (water) Driver instruction!
and its electrical lead
(see chapter 4.9)
OK NOK
Check Replace temperature

control unit pick-up or its
(chapter 4.8) electrical lead
(see chapter 9)
NOK OK
Replace Check vehicle

control unit cooling system:
- coolant level
- thermostat
- coolant pump
- radiator fan
- radiator grill for
dirtiness
0516

67.1405.20 Page 4.1/3
Illustration troubleshooting diagram group C
C
Oil loss
input / output
side
Water in oil
(emulsion)
YES NO
Replace
heat exchanger
(siehe Kapitel 8)
Oil loss at Oil loss when
switching on switching off
retarder retarder
Check radial shaft sealing ring

input or output side and Check sump check valve
renew, if necessary and replace, if necessary
(chapter 6.6, 6.7, 7.7, and 7.8) (chapter 6.3)
If problem occours again after test trail,

check or replace rectangular-section
rings, if necessary
(see chapter 6.12 and 7.13)
0020

67.1405.20 Page 4.1/4
Illustration troubleshooting diagram group D
No respectively
too insufficient
retarder braking
effect
Check oil level

of retarder
Water in oil OK NOK Water in oil

(emulsion) (emulsion)
NO YES Check YES NO

heat exchanger
Correct
retarder oil level
see chapter 8
Check
py (static)
(chapter 4.4)
OK NOK
Check
p (dynamic) Check current of
(chapter 4.5) proportional valve
(chapter 4.6)
NOK OK
OK NOK
Check outlet throttle Is the static and dynamic pressure Check temperature
assign to heat exchanger ok, it is not possible to get the pick-up (water)
variant above mentioned complaint. and its electrical
(Kapitel 8) Please, clarify this complaint with lead
your customer again, as well as to (chapter 4.9)
carry out the checks again.
OK NOK
OK NOK
Check
control system Replace temperature
Retarder inside (mechanically) Install correct Check supply-air renew, if necessary pick-up (water)
defect, dismantle retarder and outlet throttle pressure (see chapter 4.8) and electrical lead
appraise, replace if necessary (chapter 8) (chapter 4.4) (chapter 9.2)
(chapter 8)
OK NOK
Check vehicle
compressed-air
pressure system
OK NOK
Proportional valve
mechanically defect.
Compressed-air line Contact vehicle
to proportional valve manufacturer
interrupted or leaking.
0549

67.1405.20 Page 4.1/5
Diagnosis / 7URXEOHVKRRWLQJ'LDJUDP
Illustration electrical connections diagram
4
6 16 19
2 Control unit
4 Terminal 15
6 Fuse (8 A)
14 ABS switch-off relay 1 2 3 4 5
16 Retarder stage switch
17 Retarder pilot light
18 Stop light relay
87 87a
19 Cooling-water temperature pick-up
21 Proportional valve
30
47 Speedometer signal
ye/gn
pi
vio
wh
(only with control system with the function
bu
bu
rd
gr
bl
„Constant Speed“) 14 U U
U U U U U U
2 10 9 8 7 6 5 11 12
1 3 4 13 14
2 U U I
ye/gn
br
bl
br
or
30
87 87a
47
18 17
21 0518

67.1405.20 Page 4.1/6
Diagnosis / 7URXEOHVKRRWLQJDQG5HPHGLHV
Troubleshooting
Troubleshooting and remedies
Requirements for check

• Battery voltage 18 - 32 V
• Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found
satisfactory.
• Fuse for retarder control unit checked and found satisfactory.
• Compressed-air pressure 6 - 11 bar
Notice
Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary
(see chapter 3.2 „Checking Oil Level“).
For trouble-free retarder operation, it is important that the filling quantity specified is adhered to
(see tables chapter 3.3 „Oil Change“).

67.1405.20 Page 4.2/1
Diagnosis/ ,OOXVWUDWLRQ&RQWURO6\VWHP
Troubleshooting
Illustration checking control system
Notice
The reference numbers indicated in Section 4.3 are

11
not identical with the reference numbers of the
spare parts lists. 71 33
26 32 61
1 Heat exchanger
2 Control unit P
11 Connection valve block cuurent
19 Temperatur pick-up cooling water
21 Valve block
25 Constant-air pressure line py „A“ A
26 Supply-air pressure line pv
31
R
31 Compressed air line 21
(pressure regulator - four-circuit 34
protection valve) 25 35
36
32 Compressed-air pressure line
(four-circuit protection valve -
air tank for auxiliary equipment
with test connection 38
33 Compressed-air line
(brake circuit No. 1) 19
34 Compressed-air line 2
(brake circuit No. 2)
35 Compressed-air line
(parking brake)
36 Ventilation line „R“
38 Electrical lead (cooling-water
temperature pick-up to control unit,
2 wires)
47
47 Speedometer signal 1
(only at operation with function
„Constant Speed“) 0517
61 Four-circuit protection valve
71 Air tank for auxiliary equipment

67.1405.20 Page 4.3/1
Diagnosis / &KHFNLQJ6XSSO\$LU3UHVVXUH
Troubleshooting
Special tool
23
53.4788.10
Oil pressure gauge

0 to 25 bar 32
0037
99/1
Checking supply-air pressure pv

1. Connect test pressure gauge (99/1) 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 6 bar
Maximum pressure 11 bar
Notice
If the pressure is not within the specified range, the service brake must be checked to the manufacturer´s
data.

67.1405.20 Page 4.4/1
Diagnosis / &KHFNLQJ&RQVWDQW$LU3UHVVXUH
Troubleshooting

l Retarder stage switch in position 0
l Vehicle ignition system OFF
Special tool
53.1403.10
Compressed-air gauge
0 to 6 bar
99/9

67.1405.20 Page 4.5/1

1060
The oil filler/check plug is hot! Oil temperature!
1. Screw out oil filler/check plug (1060) with sealing ring (1050). 1050
0520
2. Connect pressure gauge (99/9) to hole.
0521
99/9 Pressure gauge 53.1403.10

67.1405.20 Page 4.5/2
3. Shift the retarder stage switch to the highest braking stage, with the vehicle in parking position,
and read-off the constant-air pressure py from the pressure gauge (99/9).
4. Compare read-off pressure with the values of the constant-air pressure py on table
(see page 4.10/1 „Table of Measurements“).
Caution!
If the measured constant-air pressure py falls short of the pressure specified for each case, either the
retarder has a leak or the control system is defective (see troubleshooting diagram).
The constant-air pressure py may not change during driving.

67.1405.20 Page 4.5/3
Diagnosis / &KHFNLQJ&RQWURO&XUUHQWRI3URSRUWLRQDO9DOYH
Troubleshooting

• Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found
satisfactory.
• Fuse for retarder control unit checked and found satisfactory.
• Check plug at proportional valve and socket for damage as well as wear (notch scratches).
Special tool
100 mA ~ 100 mV
I U
53.8179.10
Measuring adapter
99/3
Commercially available tool
Multimeter recommended: Fluke 87

67.1405.20 Page 4.6/1
Diagnosis / &KHFNLQJ&RQWURO&XUUHQWRI3URSRUWLRQDO9DOYH
Job scope
1. Disconnect plug at proportional valve (21000) and connect with measuring adapter (99/3).
21000
98/8
2. Connect plug of measuring adapter (99/3) with the proportional valve (21000).
3. Connect the Multimeter (98/8). Switch position: mA or A
4. Turn switch „Propvalve“ at measuring adapter (99/3) in position „I“.

100 mA ~ 100 mV
5. Shift the retarder stage switch in position 5 and compare the read-off value with the given values of I U
the control current of the proportional valve in accordance with the tables (see page 4.10/1 to 4.10/2).
99/3
0890
99/3 Measuring adapter „Propstrom“ 53.8198.10

Notice 98/8 Multimeter
If the control current is reached but the constant-air pressure py is not, there are either outer leakyness,
or the proportional valve is defective and must be renewed.
If both values are not reached, please read chapter 4.2 „Troubleshooting and Remedies“.

67.1405.20 Page 4.6/2
Diagnosis / &KHFNLQJ7HPSHUDWXUH/LPLW
Troubleshooting

l Battery voltage 18 - 32 V
l Vehicle ignition system OFF
l Pressure gauge constant-air pressure (99/9) connected
l Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found
satisfactory.
l Fuse for retarder control unit checked and found satisfactory.
Special tool
101103105
99 107
97 111
95 113
93 115
o o
120 C 200 C
53.4377.10
Temperature
simulator
99/4

67.1405.20 Page 4.7/1
Job scope test set-up
38
1. Unplug electrical connection lead (38) at temperature pick-up (19) and connect with
temperature simulator (99/4).
Adjust temperature range at temperature simulator to 120°C. 99/4
101103105
99 107
97 111
19 95
93
113
115
Notice
o
120 C 200oC
The temperature simulator (99/4) is delivered with flat plugs.
If the electrical connection lead (38) is delivered with round plugs make a plug converter in local fabrication.
0519
99/4 Temperature simulator 53.4377.10

67.1405.20 Page 4.7/2
Job scope test
Prior jobs 38
• Vehicle ignition system ON
• Retarder stage switch in maximum position
99/4
1. Set rotary switch of temperature simulator (99/4) approx. 3° C below the determind start of 99
101103105
107
97 111
temperature limitation (e.g. to 99 °C at determined start of temperature limitation 96 °C) and operate 19 95
93
113
115
the retarder at the highest braking stage.
The constant-air pressure p y must now drop of approx. 0,6 bar below the setted maximum value. o
120 C 200oC
No more constant-air pressure py should be operated, if the temperature limit of approx. 10°C is
overstepped.
0519
99/4 Temperature simulator 53.4377.10
Notice
If the values are not reached, the electrical system must be checked as follows.
2. Disconnect pressure gauge.
3. Screw oil filler plug (1900) tight with new sealing ring (1800).
4. Connect the electrical connection lead (38) with temperature pick-up (19).

67.1405.20 Page 4.7/3
Diagnosis / &KHFNLQJ&RQWURO8QLW
Troubleshooting
Prior jobs
• Vehicle ignition system OFF
• Disconnect plug at control unit (2)
Special tool
53.8167.10
Socket box
99/8
2
1. Connect up socket box (99/8).

• Connect wiring harness to appropriate connector of socket box (99/8). 99/8
• Connect appropriate plug of socket box (99/8) to control unit (2).
0522
99/8 Socket box 53.8167.10

67.1405.20 Page 4.7/4
Notice
All checks have to be made with the socket box.

In the column „Measuring equipment/test connection“ measuring is done as follows:
Pin - multimeter - measuring mode V or Ω - Pin.
Test step Scope of check Measuring equipment / Requirement Result / Cause / Remedy
test connection Action Set point
1 Voltage 1-V- 2 Ignition: ON ≥ 20 V - End of check
< 20 V - Test step 1.2
1.2 1-V- 2 Ignition: OFF ≥ 20 V - Renew control unit

- Disconnect plug from
control unit
Ignition: ON < 20 V - Lead discontinuity
- Lead short circuit
2.1 Retarder pilot 1-V- 4 Ignition: ON <1V - Test step 2.2

light - Retarder stage switch in
stage position 0 - Lead short circuit
≥1V - Retarder stage switch
defect
- Control unit defect

67.1405.20 Page 4.8/1
2.2 1-V- 4 Ignition: ON ≥ 20 V - End of check

- Retarder stage switch in
stage position 1 to 5 - Lead discontinuity
< 20 V - Lead short circuit
- Retarder stage switch
defect
3.1 Stop light relay 1-V- 3 Ignition: ON <1V - Test step 3.2
- Retarder stage switch in
stage position 0 ≥1V - Lead short circuit
defect
3.2 1-V- 3 - Retarder stage switch in ≥ 20 V - End of check

stage position 1 to 5
< 20 V - Lead discontinuity

defect

67.1405.20 Page 4.8/2
4.1 Input 1-V- 5 Ignition: ON ≥ 7,7 V - Test step 4.2

Retarder stage switch - Retarder stage switch in
stage position 5
< 7,7 V - Lead discontinuity
defect
4.2 1-V- 5 ≤ 8,3 V - End of check
- Lead discontinuity
> 8,3 V - Lead short circuit
defect
5.1 Output 1-V- 6 Ignition: ON ≥ 14,7 V - Test step 5.2

Retarder stage switch 1-V- 7 - Retarder stage switch in
1-V- 8 stage position 0
1-V- 9 < 14,7 V - Lead discontinuity
1 - V - 10 - Lead short circuit
defect

67.1405.20 Page 4.8/3
5.2 1-V- 6 ≤ 15,3 V - End of check

1-V- 7
1-V- 8
1-V- 9 > 15,3 V - Lead discontinuity
1 - V- 10 - Lead short circuit
defect
6.1 Temperature pick-up 11 - Ω - 12 Ignition: OFF - Check electrical lead

- Disconnect plug from and temperature pick-up
control unit
Temperature of cooling wa-

ter
Notice:
The measuring in one
temperature range normally
is sufficient. 500 ... 700 Ω
+ 20°C 134 ± 13 Ω
+ 60°C 52 ± 4 Ω
+ 90°C 38,5 ± 3,5 Ω
+ 100°C

67.1405.20 Page 4.8/4
6.2 11 - Ω - 12 ≥ 54 Ω - Lead discontinuity

< 54 Ω - End of check
If fault is still existing,

renew temperature pick-
up.

67.1405.20 Page 4.8/5
Diagnosis/ &KHFNLQJ+RXVLQJ3UHVVXUH
Troubleshooting
Illustration checking housing pressure

Prior jobs
• Retarder stage switch in stage 0
• Vehicle ignition system OFF
Notice
The housing pressure check provides information

1030
on internal leaks and on the correct operation of the
1040
retarder.
1030 Screw plug M 12 x 1,5,

Special tool
53.4788.10
Oil pressure gauge

0 to 25 bar
99/1
0524

67.1405.20 Page 4.9/1
Diagnosis / &KHFNLQJ+RXVLQJ3UHVVXUH
The screw plug is hot!
Job scope
1. Screw out screw plug at retarder (1030) with sealing ring (1040).
2. Connect up pressure gauge (99/1) (see arrow) to retarder housing.

0525
Job scope dynamic 99/1 Pressure gauge 53.4788.10

1. Drive the vehicle with a prop shaft speed of vps = 1000 r.p.m.
Put in direct gear (gear ratio 1:1), and drive with an engine speed of 1000 r.p.m.
2. Shift the retarder stage switch to position 5 while on the move and read pump pressure off at
appropriate prop shaft speed at pressure gauge (99/1).

67.1405.20 Page 4.9/2
Diagnosis / &KHFNLQJ+RXVLQJ3UHVVXUH
3. Compare read-off pump pressure with the value of dynamic pump pressure according to the table
(see page 4.10/1).
Caution!
If the setpoint is obtained in the test at a standstill but the minimum value is not reached in the dynamic test,
the retarder as well as the control system is defect.
The screwings of the pressure gauge and retarder are hot!
4. Disconnect the pressure gauge (99/1). Screw in screw plug (101) with new sealing ring (102).

67.1405.20 Page 4.9/3
Diagnosis / 7DEOHRI0HDVXUHPHQWV
Troubleshooting
Control current of proportional valve without v-const.
Setting Control current mA 1) Constant-air pressure py 1) 2) Housing pressure dynamic 1)

[Nm ] [bar] vps = 1000 r.p.m.
correspnds housing pressure minimum value [bar]
static
2400 241 - 254 1,48 - 1,88 2,8
2620 250 - 262 1,73 - 2,03 3,2
2780 258 - 270 1,62 - 2,02 3,6
3000 267 - 279 1,87 - 2,27 4,0
3250 278 - 290 2,04 - 2,44 4,5
3500 288 - 300 2,20 - 2,60 5,0
3750 300 - 310 2,36 - 2,76 5,5
4000 315 - 319 2,52 - 2,92 6,5
1)
Retarder stage switch in highest position
2)
Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
Notice
• If a commercially available multimeter is used for measurements (without real effective measuring)
exact readings cannot be made (indication jumps!).
• The working-range of the control current is declared in the pressure-regulating circuit.

67.1405.20 Page 4.10/1
Diagnosis / 7DEOHRI0HDVXUHPHQWV
Control current of proportional valve with v-const.
Setting Control current mA 1) Constant-air pressure py 1) 2) Housing pressure dynamic 1)

[Nm ] [bar] vps = 1000 r.p.m.
correspnds housing pressure minimum value [bar]
static
2400 241 - 254 1,48 - 1,88 2,8
3000 266 - 280 1,87 - 2,27 4,0
3250 277 - 291 2,04 - 2,44 4,5
3500 288 - 300 2,18 - 2,58 5,0
3750 299 - 311 2,35 - 2,75 5,5
4000 311 - 323 2,52 - 2,92 6,5
1)
Retarder stage switch in highest position
2)
Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
Notice
• If a commercially available multimeter is used for measurements (without real effective measuring)
exact readings cannot be made (indication jumps!).
• The working-range of the control current is declared in the pressure-regulating circuit.

67.1405.20 Page 4.10/2
Diagnosis / 2SHUDWLRQDO&KHFN
Troubleshooting

• Electrical system checked in accordance with the Owner´s 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 off

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 five possible retarder braking stages has been selected
with the retarder stage switch.
• Retarder pilot light flashes
1 On moving off
This flashing function comes on at low ambient temperatures in braking stages 1 to 4 or 1 to 5 and
goes off as soon as the vehicle engine has reached operating temperature.
The retarder, however, is fully operational.
2 During braking with the retarder
• The temperature limit is effective - the retarder cuts its braking torque back.
• The control unit detects a discontinuity to the temperature pick-up.

67.1405.20 Page 4.11/1
Diagnosis / 2SHUDWLRQDO&KHFN
Test step Scope of check Requirement / Result / Set point Note, Cause / Remedy
Operation
1 Retarder pilot light Ignition: ON Retarder pilot light comes on and Retarder pilot light trouble-free
goes off after approx. 5 sec.
Retarder pilot light does not

come on, or does not go off. Troubleshooting as on page 4.1/1

67.1405.20 Page 4.11/2
Retarder Remo- 5HPRYLQJ,QVWDOOLQJ5HWDUGHU
ving, Installing
5.1 Removing, Installing Retarder (Free Mount Installation)............................ 5.1/1
5.2 Removing, Installing Retarder (Gearbox Attachment) ............................... 5.2/1

67.1405.20 Page 5/1
ving, Installing )UHH0RXQW,QVWDOODWLRQ
Illustration removing, installing retarder (free mount installation)
6000
6000 92
7000
3200 2000/1 6000
3100
7000
6000 2000/1
7000
7000
2000/1
2000/1
2000/1 36
25
7000 97
8000 96
4000 2000/1
1004 2000/1 1000 7000
7000
1001 8000
92 8000 0528
Prior jobs
• Measureing gradient of retarder before removing. After installing the retarder the gradient must be the same as before (see also Installation Instructions).
• Ignition OFF
• Retarder stage switch in switch stage 0
• Drain cooling water
• Drain oil from retarder (see chapter 3.3)
Notice
When using stainless-steel heat exhanger the oil cannot be drained from the heat exchanger.
25 Constant-air pressure line py 2000/1 Washer

36 Ventilation line 3100 Hex.-head nut
92 Prop shaft 3200 Spring washer, renew
96 Hose clamp 4000 Hex.-head screw
97 Hose connection 6000 Hex.-head screw M 16 x 90
1000 Heat exchanger Hex.-head, w.a.f. 24
1001 Drain plug cooling-water M 12 x 1,5 7000 Washer B16
Hex.-head, w.a.f. 17, 25 Nm 8000 Hex.-head nut M 16 self-locking, renew,
1004 Sealing ring A 12 x 15,5, Copper, renew Hex.-head, w.a.f. 24, 110 Nm
2000 Megi-pads with washer,
check, renew if necessary

67.1405.20 Page 5.1/1
ving, Installing )UHH0RXQW,QVWDOODWLRQ(Continue)
Special Tool
0 0
53.9142.10
Gradient- and slope

spirit level
Note for installation
The universal joints for both prop-shafts (92) must be installed aligned with one another.
Max. permissible offset 5° .
Tightening torques, see manufacturer´s data.
Renew spring washers (if installed).
Caution!
Observe VOITH-Installation instructions. These have to be requested from VOITH TURBO.

Should these installation instructions be disregarded, the retarder may be completely wrecked!

67.1405.20 Page 5.1/2
ving, Installing *HDUER[$WWDFKPHQW
To install the retarder 133 according to regulations to the gearbox or to remove from the gearbox, specific
working steps requiring special tools have to be carried out!
Caution!
Observe VOITH-Installation instructions and gear-box specific installation instructions.

These have to be requested from VOITH TURBO.
Should these installation instructions be disregarded, the retarder may be completely wrecked!

67.1405.20 Page 5.2/1
Repair Gearbox 5HSDLU
Attachment
6.1 Overall Illustration of Main Components ............................................................ 6.1/1
6.2 Checking, Removing and Installing Casing Ventilation...................................... 6.2/1
6.3 Checking, Removing and Installing Sump Check Valve .................................... 6.3/1
6.4 Removing, Cleaning and Installing Silencer....................................................... 6.4/1
6.5 Removing and Installing Prop Shaft Flanges ..................................................... 6.5/1

Renewing Radial Shaft Sealing Ring ................................................................. 6.6/1

67.1405.20 Page 6/1
Repair Gearbox 5HSDLU
Attachment (Continue)
6.7 Removing and Installing Centering Cover (Input Side),
6.8 Removing and Installing Housing Cover ............................................................ 6.8/1
6.9 Checking, Removing and Installing Sump Flap Valve ....................................... 6.9/1
6.10 Removing and Installing Stator and Rotor,

Renewing Cylinder Roller Bearing ................................................................... 6.10/1
6.11 Removing and Installing Stator Pins ................................................................ 6.11/1
6.12 Renewing Rectangular-Section Rings (Polypenco-Rings)............................... 6.12/1
6.13 Parameterizing Control Unit ............................................................................. 6.13/1

67.1405.20 Page 6/2
Repair Gearbox 2YHUDOO,OOXVWUDWLRQRI0DLQ*URXSV
Attachment *HDUER[$WWDFKPHQW
Illustration main components (retarder basic group)
4080 2120 2260

4090
2270 1250
1260
2010
1200
2250
2110 1210
2130
3020 1220/1
3010 2301
2160 1220/2
4030 1220
1220/3 1060
4010
2080
4030 1030 1050
2100 4020 1110
2140 1020
2090
2105 2060
2050 4070
2040
2020 1020
1030
1150
1040
1050
1120 2230 1160 3030

1370
1170
1420
1010 3000
1440
1080 1190
1450
1070 2000 1180
3000 1190
1195
0551
1010 Retarder housing 1370 O-ring 196,52 x 2,62 2250 O-ring 297 x 4
1020 Sealing ring A 12 x 18 1420 Silencer 2260 Oil filling plug M 24 x 1,5
1030 Screw plug M 12 x 1,5 1440 Cover plate alternative M 18 x 1,5
1040 Screw plug M 24 x 1,5 1450 Cap screw M 6 x 16 2270 Sealing ring A 24 x 29
1050 Sealing ring A 24 x 29 1500 2/2-way valve (Herion 4021338) alternative A 18 x 24
1060 Oil filler/check plug M 24 x 1,5 / DIN908 1510 O-ring 10 x 2,2 2301 O-ring 55 x 3
1070 Retarder oil drain plug M 30 x 1,5 1520 O-ring 28,24 x 2,62 3000 O-ring 36 x 4
1080 Sealing ring A 30 x 36 2000 Throttle disc D 35 / 11 x 3 3010 Rotor
1110 Stator 2010 Housing cover 3020 Cap screw CV 84, M 10 x 18
1120 Stator pin 2020 Cap screw M 6 x 25 3030 Racer
1150 Radial shaft sealing ring 2040 Retainer 4010 Hollow shaft
115 x 140 x 10 2050 Valve flap, vulkanized 4020 O-ring 95 x 4,5
1160 Back-up ring 2060 Valve seat 4030 Rectangular-section ring
1170 Labyrinth cover 2080 Sealing disc D 15 x 2 4070 Cylinder roller bearing
1180 Cap screw CV 84, M 10 x 35 2090 Sealing ring A 22 x 29 4080 Centering cover
1190 Washer 10,5 2100 Retainer 4090 Hex.-head screw M 8 x 16
1195 Cap screw CV 84, M10 x 25 2105 Screw plug M 22 x 1,5 alternative M 8 x 20
1200 Cover casing ventilation 2110 Radial shaft sealing ring
1210 Gasket casing ventilation 115 x 140 x 10
1220 Casing ventilation 2120 Back-up ring
1220/1 Valve insert 2130 Cover
1220/2 Float 2140 Cap screw M 6 x 16
1220/3 Float cage 2160 Cap screw M 10 x 55
1250 Hex.-head screw M 8 x 25 alternative M 10 x 65
1260 Washer B 8,4 2230 O-ring 10 x 3
Notice
At gearbox installation ZF 8 S 180 reinforced, the centering cover (4080) and the hex.-head screws (4090) are integrated in the housing cover (2010).

67.1405.20 Page 6.1/1
Repair Gearbox &KHFNLQJ5HPRYLQJDQG,QVWDOOLQJ
Attachment &DVLQJ9HQWLODWLRQ
Illustration casing ventilation
1250
1260
Notice
1200
This step can be performed with the retarder
removed or installed.
1210

1030 Screw plug M 12 x 1,5
1200 Cover casing ventilation, 1220/1
coat sealing surface thin with Hylomar
sealant 2301
1210 Gasket, renew 1220
1220 Casing ventilation
1220/1 Valve insert 1220/2
1220/2 Float checking, renew if necessary,
specified weight: 11g ± 1 g 1220/3
1220/3 Float cage
1250 Hex.-head screw M 8 x 25,
1260 Washer B 8,4
2301 O-ring 55 x 3, renew,
1020
coat of silicone-free and non-corrosive 1030
0048

67.1405.20 Page 6.2/1
Attachment &DVLQJ9HQWLODWLRQ (Continue)
Sealants, lubricants and cleaning agents
O-ring Silicone-free and non-corrosive grease
Float Methylated Spirit
Housing sealing surfaces Hylomar
Special tools
53.7712.10 53.9428.10
Impact puller Adapter

99/5 98/7

67.1405.20 Page 6.2/2
Tool for local fabrication
40,5 mm
7 mm
60 mm
Werkstoff: St 37
Gewicht: 0,085 kg 0491
Test ring
99/7
Notice
The test ring (99/7) can also be ordered from VOITH TURBO - VOITH code number 67.2757.10.

67.1405.20 Page 6.2/3
To check in installed condition
1. Screw out screw plug (1030) and remove sealing ring (1020).
1020
1030
0049
2. Place a measuring beaker at the bore and operate retarder in highest braking stage.
Specified leakage oil

Leakage oil quantity each full stop: 25 -50 cm3
Duration of leakage oil escape: 2 -3 sec.
0
100
If the specified quantity is exceeded, the casing ventilation must be check after removal (page 6.2/6).
750
500
3. Provide the screw plug (1030) with new sealing ring (1020) and screw it tight.
250
Anziehdrehmoment 25 Nm
0
0050

67.1405.20 Page 6.2/4
To remove
1. Screw out hex.-head screws (1250). 99/5
2. Remove washers (1260).
3. Remove casing ventilation cover (1200) with gasket (1210) from retarder housing.
Clean the sealing surface. 98/7
4. Use impact tool (99/5) and adapter (98/7) to extract casing ventilation (1220).
Notice 0051
Alternative are valve insert versions with three bridges possible. 98/7 Adapter 53.9428.10
99/5 Impact tool 53.7712.10
5. Remove the valve insert (1200/1) from the float cage (1220/3).
6. Lever O-ring (2301) out of the groove in the valve insert (1220/1) and remove it.
7. Remove float (1220/2) and float cage (1220/3) from the retarder housing.
1220/1
2301
0052

67.1405.20 Page 6.2/5
To check
1. Check the float (1220/2) for damage to the surface and to the sealing surface (arrow).
2. Weigh the float (1220/2).

Specified weight 11 ± 1 Gramm. If the actual weight is above the specified weight, the float must be
renewed.
1220/2
Notice
Oil has penetrated into the float, the retarder is impaired in its operation. 0053
Notice
The test ring is only allowed being put on with the design in aluminium (four bridges).
99/7
3. Check sealing edge of shaft sealing ring (arrow) in the valve insert (1220/1). 1220/2
Put down the valve insert (1220/1) on the float (1220/2) than weigh down the valve insert with the
test ring (99/7).
1220/1
Caution!
Use only this test ring, since deviant weight can enable no correct test of this ring.
0429

67.1405.20 Page 6.2/6
4. 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.
5. Before installing the casing ventilation check O-ring (2301) for damages.
Renew O-ring, if necessary.

67.1405.20 Page 6.2/7
Installing
1. Pull new O-ring (2301) on to the valve insert (1220/1) and coat it with silicone-free and non-corrosive
grease.
2. Fit the float (1220/2) and the float cage (1220/3) into the valve insert (1220/1).
3. Fit the casing ventilation (1220) into the retarder housing.

1200
4. Knock in the casing ventilation (1220) with impact tool (99/5) and adapter (98/7) carefully in as far
as it will go.
5. Coat sealing surface on retarder housing and on cover (1200) with thin coat of Hylomar sealant.
0055
6. Place a new gasket on the retarder housing with the graphite side facing downwards.
7. Place the cover (1200) on the retarder haousing, insert hex.-head screws (1250) with
washers (1260) and screw them tight.

67.1405.20 Page 6.2/8
Attachment 6XPS&KHFN9DOYH
Illustration sump check valve
Prior job
• Drained retarder oil (see chapter 3.3)
2080 Sealing disc, check, renew if necessary

2100 Retainer
Inhex.-head, w.a.f. 10, 25 Nm,
check, renew if necessary,
install with Loctite 242 locking agent
Locking agent
Thread on retainer Loctite 242
To check sump check valve

Operate retarder at highest stage and switch it off 2080
after approx. 5 seconds .
If oi emerges at the labyrinth covers on the output or 2100
input side, the sump check valve is defective.
2090
Notice
2105
0529
Install only in vertical position!

Do not use impact tool!
Install in reverse sequence.

67.1405.20 Page 6.3/1
Repair Gearbox 5HPRYLQJ&OHDQLQJDQG,QVWDOOLQJ6LOHQFHU
Attachment
Illustration silencer
Notice

1420 Silencer,
clean with Benzine and blow out with
compressed-air
1440 Cover plate
1450 Cap screw M 6 x 16,
Cleaning agent 1420

Silencer Benzine
1440 1450
1450
Notice
Check silencer on damages and wear, renew if

necessary.
0057

67.1405.20 Page 6.4/1
Repair Gearbox 5HPRYLQJDQG,QVWDOLQJ3URS6KDIW)ODQJHV
Attachment
Notice
Because of the great numbers of possibilities to install the prop shaft flanges it is impossible to give here
special descriptions of removing and installing the prop shaft flanges.
Observe specific installation instructions.

These have to be requested from VOITH TURBO.
Notice
Generally the prop shaft screws and O-rings must be renewed.

67.1405.20 Page 6.5/1
Repair Gearbox 5HPRYLQJDQG,QVWDOOLQJ/DE\ULQWK&RYHU
Attachment (Output Side)5HQHZLQJ5DGLDO6KDIW6HDOLQJ5LQJ
Illustration labyrinth cover
Prior jobs
• Prop shafts removed from flanges
(see vehicle manufacturer´s instruction)
• Prop shaft flanges removed
(see VOITH Installing Instructions)
4010
Notice
This step can be performed with retarder removed 4020

or installed.
1150
1160
1150 Radial shaft sealing ring 115 x 140 x 10
renew, 3030
1160 Back-up ring
1170 Labyrinth cover, 1170
apply thin coat of Hylomar sealant to
sealing surface
1180 Cap screw CV 84, M10 x 35
screw with internal serrations
self-locking, renew, 46 Nm
1190 Washer 10,5
1370 O-ring 196,52 x 2,62, renew,
coat of silicone-free and non-corrosive
1190
grease for installation 1180
3030 Racer, check, renew if necessary 0531
4010 Hollow shaft
4020 O-ring 95 x 4,5 , renew,

67.1405.20 Page 6.6/1
Repair Gearbox 5HPRYLQJ,QVWDOOLQJ/DE\ULQWK&RYHU (Output
Attachment Side)5HQHZLQJ5DGLDO6KDIW6HDOLQJ5LQJ(Cont.)
Notice
This step can be performed with the retarder removed or installed.

Observe the possibility of two retrader versions:
- with standard labyrinth: race (3030) = 31 mm long

- with short labyrinth: race (3030) = 27 mm long
Observe therefore the installing sequence.

67.1405.20 Page 6.6/2
Sealants and lubricants

non-corrosive grease
Special tools
53.1180.10 53.1373.10 53.1372.10
Socket wrench Bearing race puller Press-in equipment

95/1 94/4 97/1

67.1405.20 Page 6.6/3
Job scope
1. Screw out cylinder screws (1180) with the socket wrench (95/1) and remove together 1170
with washers (1190).
2. Press off the labyrinth cover (1170) with two hex.-head screws M 10 x 65 (see arrows) from the
retarder housing. 1180
3. Use the three inner hex.-head screws to clamp the bearing race puller (94/4) evenly in the
bearing race (3030), making sure that the bearing race does not become out of round. 1190
0534
4. Use the bearing race puller (94/4) to pull the bearing race (3030) off the hollow shaft (97/4).
Remove the back-up ring.
5. Remove the shaft sealing ring (1150) without damaging the sealing surface of the retarder housing.
3030
94/4
4010
0535
94/4 Bearing race puller 53.1373.10

67.1405.20 Page 6.6/4
6. Remove the O-ring (4020) for the hollow shaft (4010).
4010 4010
4020
Notice 4020
Check running surface of radial shaft sealing ring (3030) at the hollow shaft for scores and uneven surface.
Notice 1150
If running surface of the radial shaft sealing ring is uneven the axial und radial gap of the retarder has to be 0536
checked according to the table, see annex.
Recommendation:
Change radial shaft sealing ring and race together.
1150
7. Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (1150).
8. Knock in the radial shaft sealing ring (1150) with the press-in equipment (97/1) flush with
4020 4010
the retarder housing.
Notice
97/1
Retarder version with short labyrinth (bearing race Pos. 3030 = 27 mm long):
Set back-up ring (1160) together with radial shaft sealing ring (1150) onto the press-in equipment (97/1) and 0537
knock in flush with the retarder housing.
97/1 Press-in equipment 53.1372.10

67.1405.20 Page 6.6/5
9. Pull new O-ring (4020) on to the hollow shaft (4010) and apply coat thin with silicone-free and
non-corrosive grease.
4010
10. Use a suitable drift to press the back-up ring (1160) and the bearing race (3030) on to the hollow shaft
(4010) as far as they will go. 1160
3030
Notice
Retarder version with short labyrinth (bearing race Pos. 3030 = 27 mm long):
In this case the back-up ring is already installed.
0538
11. Fit new O-ring (1370) in labyrinth cover (1170) and apply a thin coat of silicone-free and
12. Apply a thin coat of Hylomar sealant to the sealing surface of the labyrinth cover (1170) around the
holes illustrated and install it in such a way that the groove in the retarder housing and the duct in the
labyrinth cover (arrow) for the leakage oil return face each other.
13. Tighten new cap screws (1180) with washers (1190).

Tightening torque 46 Nm 1370
1170
0065

67.1405.20 Page 6.6/6
Repair Gearbox 5HPRYLQJ,QVWDOOLQJ&HQWHULQJ&RYHU (Input Side)
Attachment 5HQHZLQJ5DGLDO6KDIW6HDOLQJ5LQJ
Illustration centering cover
Prior job
• Retarder removed (see Section 5)

renew, coat of silicone-free and non-cor-
rosive grease for installation
2120 Back-up ring
2110
4080 Centering cover, 2120
apply thin coat of Hylomar sealant to 4080
sealing surface
hex.-head, w.a.f. 13,
alternative M 8 x 20, self-locking,
renew, hex.-head, w.a.f. 13, 23 Nm
O-rings and Silicone-free and

radial shaft sealing rings non-corrosive grease
Notice
At gearbox installation ZF 8 S 180 reinforced, the cen-

tering cover (4080) and the hex.-head screws (4090)
are integrated in the housing cover (2010). 4090
0070

67.1405.20 Page 6.7/1
Job scope
1. Screw out hex.-head screws (4090).
2. Press centering cover (4080) off housing cover.
3. Remove back-up ring (2120).
4. Remove radial shaft sealing ring (2110) without damaging the sealing surface of the housing cover.
Notice
Check race of radial shaft sealing ring (2110) at the hollow shaft for scores and uneven surface.
If a sealing function is no longer guaranteed, renew hollow shaft (see chapter 6.13).
Notice
If running surface of the radial shaft sealing ring is uneven the axial und radial gap of the retarder has to be

67.1405.20 Page 6.7/2
6. Join new radial shaft sealing ring (2110) to hollow shaft.
7. Join back-up ring (2120) to radial shaft sealing ring. 4090

4080
8. Apply a thin coat of Hylomar sealant to the sealant surface of the centering cover (4080) and install
it in such a way that the groove faces the leakage oil return hole in the housing cover (arrow)
downwards.
9. Use a plastic hammer to knock the centering cover carefully in the housing cover .
10. Screw the housing cover with the new self-locking hex.-head screws (4090) tight.

67.1405.20 Page 6.7/3
Repair Gearbox 5HPRYLQJDQG,QVWDOOLQJ+RXVLQJ&RYHU
Attachment
Illustration housing cover
Prior job
• Retarder removed (see chapter 5)
2230
2010 Housing cover
2110 Radial shaft sealing ring 115 x 140 x 10,
renew, 2140
2120 Back-up ring
2130 Cover, check, renew if necessary,
sealing surface 4080
2140 Cap screw M 6 x 16, 2120
Inhex.-head, w.a.f. 4
2160 Collar screw M 10 x 65 or
M 10 x 40 or M 10 x 50 or M 10 x 55,
Hex.-head, w.a.f. 15, 60 Nm 2130
• new screws with coating thread install
without Loctite
2250
• used screws (disassemled)
after degrease and installed with 4090
Loctite 242 locking agent
2230 O-ring 10 x 3, renew
2250 O-ring 297 x4, renew 2010 2160
0072
4080 Centering cover,
sealing surface
alternative M 8 x 20,
Hex.-head, w.a.f. 13,
Notice
During this work the following parts can also be

checked:
• Sump flap valve (see chapter 6.9)

• Rectangular-section rings (see chapter 6.12)
• Race of radial shaft sealing ring
• Screw plug filling duct

(see Aftersales Service Information
11/97 and 15/96)
• At gearbox installation ZF 8 S 180 reinforced,

the centering cover (4080) and the hex.-head
screws (4090) are integrated in the housing
cover (2010).

67.1405.20 Page 6.8/1
Sealants, lubricants and locking agents
O-rings and radial shaft sealing rings Silicon-free and non-corrosive grease
Collar screws Loctite 242
Special tool Tool for local fabrication
15
M10
200
0073
53.1372.10
Press-in equipment Threaded pin M10

90/1 Material: St 37-2 DIN 17100 (1.80)

67.1405.20 Page 6.8/2
To remove
1. Screw out collar screws (2160) and hex.-head screws (4090). 1010
2. Use two hex.-head screws (M10 x 65) (see arrows) to press the housing cover (2010) off the 4090
retarder housing.
2010
0539
3. Screw out the cap screws (2140). 2140

2010
4. Remove O-ring (2250) from the housing cover (2010) or the retarder housing (2230).
2250
0075

67.1405.20 Page 6.8/3
5. Press the centering cover (4080) off the housing cover (2010) and take out the back-up ring (2120).
4080
2120
Notice
2010
Alternative, the back-up ring (2120) can be pressed out together with the radial shaft sealing (2110) and
the inner cover (2130).
0076
6. Place the housing cover (2010) on a piece of pipe and press out the radial shaft sealing ring (2110)
with the inner cover (2130) with a suitable drift (arrow).
2010
0077

67.1405.20 Page 6.8/4
To install
2230
1. Apply thin coat of silicone-free and non-corrosive grease to a new O-ring (2230) and fit it into
the retarder housing (1010).
1010
0078
2. Apply thin coat of Hylomar sealant to the sealing surface of the centering cover (4080) and install it 4090
in such a way that the bore for the leakage oil return (arrow) is at the bottom.
Screw centering cover (4080) with new self-locking hex.-head screws (4090) tight. 4080
4080 0079

67.1405.20 Page 6.8/5
2120
Notice
2010
Mind installation position! The ramp must face the radial shaft sealing ring.
3. Place back-up ring (2120) in housing cover (2010).
0080
4. Apply thin coat of silicone-free and non-corrosive grease to radial shaft sealing ring (2110) and press
in carefully with press-in equipment (90/1) as far as it will go. 90/1
90/1
2110 2110
2010 2250 0081

67.1405.20 Page 6.8/6
2140
Notice 2130
Check cover (2130) for damages (race, rectangular-section rings etc.) ad renew, if necessary.
5. Apply thin coat of Hylomar sealant to the sealing surface of the cover (2130) and install it such way
that groove faces the leakage oil return bore in the housing cover (arrow).
Than screw new self-locking cap screws (2140) tight.
6. Fit new O-ring (2250) to housing cover (2010) and apply a thin coat of silicone-free and non-corrosive
grease. 0082
7. Apply a thin coat of Hylomar sealant to the sealing face of the retarder housing.
1010
Notice
Do not forget the sealing surfaces (lands) to coat also thin with Hylomar sealant.
8. Screw two threaded pins (arrows) into the retarder housing.
0083

67.1405.20 Page 6.8/7
Caution!
Take care that the rectangular-section rings do not jut out of the groove and the ends are assembled
gap-free - danger of cut-off.
For fixing use silicone-free and non-corrosive grease.
9. Place the housing cover (2010) on the retarder housing (1010) in such a way the lip of the
radial shaft sealing ring will not be damaged.
Caution!
Do not install collar screws with Loctite 242 locking agent coated thread!
10. Screw new collar screws (2160) with coated thread without locking agent, or used (disassembled)
collar screws after degrease and coating with Loctite 242 locking agent, in by hand into the
appropriate bore at the retarder housing (1010).
Notice
Pay attention to differing length of collar screws.

67.1405.20 Page 6.8/8
Screw the collar screws tight in two stages:
11. Tighten first all collar screws (2160) in the specified sequence 1 to 44. 1010 21
20 18 17 1 16 15
44
Tightening torque 50 Nm +10 Nm 22
19 14
43
3 13
2010
23 42
12. Tighten all collar screws (2160) after approx. 15 minutes time to settle in the specified sequence 4
5
1 to 44. 24 41
Tightening torque 50 Nm +10 Nm 25 6

12
40 2160
26 11 39
7 10
8 2 9
38
27
37
28 36
34 35
31 32 33
29 30 0540

67.1405.20 Page 6.8/9
Attachment 6XPS)ODS9DOYH
Prior jobs
• Removed prop shaft flanges (see chapter 6.6)
• Removed retarder (see chapter 5)
2020
• Removed housing cover (see chapter 6.9)
2010 Housing cover

2040 2010
alternative Inhex.-head, w.a.f. 4, 9 Nm
2040 Retainer
2050 Valve flap, 2050
2060 Valve seat
Inhex.-head, w.a.f. 19, 50 Nm 2060
Remove valve seat only,if sealing surface
is damaged!
Locking agent
Valve seat Loctite 242
0085

67.1405.20 Page 6.9/1
Attachment 6XPS)ODS9DOYH (Continue)
To check
Hot oil may escape!
Lay out ready lightning appliance.
For this examining method two persons are needed!
1. Screw out valve seat (2260) at housing cover (2010) and remove sealing ring (2270).
2. Shine with the lightning appliance into the oil filling duct.
At improper action hot oil can escape!

67.1405.20 Page 6.9/2
3. Now, the second person must operate the retarder in the highest braking stage.
4. If you now notice that oil rises in the oil filling duct, the sump check valve must be checked on
dirt or damages.
Hot oil can escape!
5. Screw in quickly valve seat (2260) into oil filling duct.
6. Switch off retarder.
7. Screw valve seat (2260) tight with new sealing ring (2270).
Tightening torque
Valve seat M 24 x 1,5 = 80 Nm
Valve seat M 18 x 1,5 = 50 Nm

67.1405.20 Page 6.9/3
To remove, install
2020
1. Screw out cap screws (2020) and remove retainer (2040) and valve flap (2050).
2. Check valve flap (2050) and valve seat (2060) for damages and foreign matter 2040
and renew, if necessary.
2050
0086

67.1405.20 Page 6.9/4
To renew valve seat
Caution!
For renewal, only the illustrated kit (with O-ring-flap) may be used for installation.
Caution!
Before removing the area around the valve seat must be heated up to approx. 80 °C.
The valve seat is hot!

2060
3. Screw out valve seat (2060).
Caution!
Do not use impact tool!
4. Screw in tight new valve seat (2060) with Loctite 242 locking agent.

67.1405.20 Page 6.9/5
To check valve flap
1. The rubber coating of the valve flap (2050) must not be cracked or have other damage.
Renew valve flap, if necessary.
2. Place valve flap (2050) on the valve seat. 2050

2050
Caution!
Mind installation position! 2040

2020
0088
3. Position the retainer (2040) and screw it tight with the cap screws (2020).

67.1405.20 Page 6.9/6
Repair Gearbox 5HPRYLQJDQG,QVWDOOLQJ6WDWRUDQG5RWRU
Attachment 5HQHZLQJ&\OLQGHU5ROOHU%HDULQJ
Illustration stator
Prior jobs
• Labyrinth cover (output side) removed
(see chapter 6.7)
• Housing cover removed (see chapter 6.9)
1010
1195
1010 Retarder housing
1110 Stator 4070 1110
Apply thin coat of Hylomar sealant to
sealing surface
1190 Washer 10,5 4070/1
1195 Cap screw CV 84, M 10 x 25, self-locking, 1190
renew, 46 Nm
3010 Rotor
3020 Cap screw CV 84, M 10 x 18,
renew, 46 Nm
4010 Hollow shaft
4030 Rectangular-section ring
4070 Roller bearing, check, renew if necessary
4070/1 Inner ring (roller bearing),
check, renew if necessary 4010 3010
3020
4030
4030
0541

67.1405.20 Page 6.10/1
Attachment 5HQHZLQJ&\OLQGHU5ROOHU%HDULQJ (Continue)
Housing sealing surface Hylomar
Commercially available tools
Hot-air gun 2000 Watt
Gas welding equipment
15
M10
200
0073
53.1180.10
Socket wrench Threaded pin M10

95/1 Material: St37-2, DIN 17100 (1.80)

67.1405.20 Page 6.10/2
To remove
3010
1. Screw out cap screws (3020) with socket wrench (95/1).
3020
2. Use two M 10 x 65 screws threaded along their entire length (arrows) to press the rotor (3010) off
the hollow shaft (4010).
4010
0542
3. Use two M 10 x 65 screws threaded along their entire length (arrows) to press the hollow shaft (4010)
off the stator (1110). 1110
4. Remove the rectangular-section rings (4030) according to chapter 6.13. 4010
0543

67.1405.20 Page 6.10/3
5. Screw out the two cap screws (1195) with the socket wrench (95/1) on the output side of the retarder
and remove them together with the washers (1190).
6. Screw three hex.-head screws M 10 x 65 (arrows) into the stator (1110).
1195
Notice
Place the retarder housing on a even and soft pad tto ensure the stator is not damaged while being driven
out.
0092
7. Tap the screw heads to drive the stator (1110) out of the retarder housing. Then remove the
O-ring (1100) out of the retarder housing.
8. Check the roller bearing (4070) on damages and renew, if necessary.
1110
0544

67.1405.20 Page 6.10/4
To renew roller bearing
4070
1. Use suitable drift to press out the roller bearing (4070).
Press in flush a new roller bearing (4070) with a suitable drift.
Notice
If roller bearing has to be renewed the inner ring must be renewed as well.
Recommendation:
If one part is damaged, always renew both parts. 0094
The inner ring and parts of the hollow shaft are hot!
4070/1
2. Heat the inner ring (4070/1) uniformly and use a suitable drift to drive it off the hollow shaft (4010).
3. Heat the inner ring (4070/1) to max. 80 to 100 °C and push it on to the hollow shaft (4010).
4010
0095

67.1405.20 Page 6.10/5
To install
1. Clean the cleaning surfaces on the stator (1110) and on the rotor housing (1010).
2. Apply a thin coat of Hylomar sealant to the sealing surface of the stator (1110).
Screw two threaded pins (arrows) into the stator (1110).
Caution! Risk of injury! 1110

0096
The inner area of the retarder housing is hot!
3. Use a hot-air gun or a welding flame to heat the retarder housing (1010) in the zone marked (arrow)
to max. 80 to 100 °C.
1010
0097

67.1405.20 Page 6.10/6
1110
Notice
Align the stator holes with the holes in the retarder housing.
4. Fit the stator (1110) into the retarder housing (1010) with the slotted stator blades at the top.
0099
5. Screw the stator (1110) on output side tight with two new cap screws (1195) and washers (1190).
1195
6. Screw out the threaded pins.
0100

67.1405.20 Page 6.10/7
7. Place the rotor (3010) on the hollow shaft (4010) and screw tight with new cap screws (3020).
8. Install new rectangular-section rings (4030) according to chapter 6.13. 3010 3020
9. Install rotor (3010) with hollow shaft (4010) into retarder housing (1010).
0101

67.1405.20 Page 6.10/8
Repair Gearbox 5HPRYLQJDQG,QVWDOOLQJ6WDWRU3LQV
Attachment
Illustration stator pins
Prior job
• Stator and rotor removed (see chapter 6.11)

1120
1110 Stator
1120 Stator pin, 45 Nm
Notice
Check stator pins for free movement of tappets and

for external damage.
The threads of the stator pins and of the stator must
be free of grease when the pins are installed.
Locking agent
Thread on stator pin Loctite 640
1110
0102

67.1405.20 Page 6.11/1
Repair Gearbox 5HQHZLQJ5HFWDQJXODU6HFWLRQ5LQJV
Attachment 3RO\SHQFR5LQJV
Illustration rectangular-section ring
Prior job
4010 Hollow shaft

The rectangular-section rings may not jut
out of their groove and their ends are
mounted gap-free- danger fo shear off.
Apply coat of non-corrosive and
silicone-free grease to grooves in
proximity of ring links.
4030 Rectangular section-rings, renew
Lubricants
Hollow shaft grooves Silicone-free and 4030

4010
4030
0103

67.1405.20 Page 6.12/1
Repair Gearbox 3DUDPHWHUL]LQJ&RQWURO8QLW
Attachment
Illustration control unit
21 Dual-In-Line-Switch (DIL)
Check setting, correct if necessary
31 Circuit board
Notice
As a general rule, the maximum permissible constant-

air pressure (determines maximum braking torque)
are settings made in the control unit at the factory for
the specific vehicle prior to delivery to the customer.
5
4
3
Caution !
4
ON
1
It is not permitted to change these settings!
3
2
31
ON
1
21
0744

67.1405.20 Page 6.13/1
The control unit has a data plate to identify it.
The following data are marked on the data plate:
- Logoprop-operating voltage
VOITH RETARDER
- Article number of the control unit Logoprop. 24V
- Maximum braking torque (Nm)
- Start of temperature limit (°C) Art. Nr.: 53.1366.30
- Serial No. of the control unit
- Date of manufacture M: 3000 Nm Temp.: 98 C
S. Nr.: 007141 Datum: 21. 01. 1999
0513
Notice
Control units obtained as spare parts must be set for the vehicle in which they are to be installed on the
basis of the information on the data plate of the old control unit prior to the retarder being operated again!
The settings made must be marked on the data plate of the new control unit.
Notice
The settings must only be performed by personnel qualified to carry out this work.

67.1405.20 Page 6.13/2
Setting constant-air pressure
Job scope
1. Remove the cover of the control unit to make the necessary settings.
2. Max. constant-air pressure is set at the Dual-In-Line-switch (DIL) (21) on the circuit board (31) on the
control unit pursuant to table see page 6.13/4.
Notice
The data represent the state of the art at the time of going to print. Control units to which other data apply
are still in use. The manufacturer reserves the right to make further modifications.

67.1405.20 Page 6.13/3
Table constant-air pressure settings
Make settings of maximum constant-air pressure with DIL-switches 3, 4 and 5.
Dual-In-Line-switch
Switch position Constant-air pressure py in Retarder braking torque at

retarder braking stage 5 retarder braking stage 5
1 2 3 4 5 [Bar] [Nm]
- - ON ON ON 1,48 - 1,88 2400
- - OFF OFF ON 1,87 - 2,27 3000
- - ON ON OFF 2,04 - 2,44 3250
- - OFF ON OFF 2,20 - 2,60 3500
- - ON OFF OFF 2,36 - 2,76 3750
- - OFF OFF OFF 2,52 - 2,92 4000
Example for 2400 Nm: Dil 3, 4, 5 ON
ON
1 2 3 4 5
0870

67.1405.20 Page 6.13/4
Setting temperature limit
Job scope
1. Remove the cover of the control unit to make the necessary settings.
2. Temperature limit is set at the Dual-In-Line-switch (DIL) (21) on the circuit board (31) on the
control unit pursuant to table see page 6.13/6.
Notice
The data represent the state of the art at the time of going to print. Control units to which other data apply
are still in use. The manufacturer reserves the right to make further modifications.

67.1405.20 Page 6.13/5
Table temperature limit
DIL-switches 1 and 2 are used to set the temperature limit.
Dual-In-Line-switch
Switch position Start of End of temperature limit

temperature limit (py = 0 bar)
1 2 3 4 5
OFF OFF - - - 96 °C 106 °C
ON OFF - - - 98 °C 108 °C
OFF ON - - - 100 °C 110 °C
ON ON - - - 102 °C 112 °C
Example for 96°C: Dil 1, 2, OFF
ON
1 2 3 4 5
0870

67.1405.20 Page 6.13/6
Repair Free 5HSDLU
Mount Installation
7.1 Overall Illustration of Main Components .........................................................7.1/1
7.2 Checking, Removing and Installing Casing Ventilation...................................7.2/1
7.3 Checking, Removing and Installing Sump Check Valve .................................7.3/1
7.4 Removing, Cleaning and Installing Silencer....................................................7.4/1
7.5 Removing and Installing Prop Shaft Flanges ..................................................7.5/1

Renewing Radial Shaft Sealing Ring ..............................................................7.6/1

67.1405.20 Page 7/1
Repair Free 5HSDLU
Mount Installation (Continue)
7.7 Removing and Installing Labyrinth Cover (Input Side),
7.8 Removing and Installing Housing Cover

Renewing Deep-Groove Ball Bearing ................................................................ 7.8/1
7.9 Checking, Removing and Installing Sump Flap Valve ....................................... 7.9/1
7.10 Removing and Installing Rotor ......................................................................... 7.10/1
7.11 Removing and Installing Stator

Renewing Cylinder Roller Bearing ................................................................... 7.11/1
7.12 Removing and Installing Stator Pins ................................................................ 7.12/1
7.13 Renewing Rectangular-Section Rings (Polypenco-Rings)............................... 7.13/1
7.14 Parameterizing Control Unit ............................................................................. 7.14/1

67.1405.20 Page 7/2
Repair Free 2YHUDOO,OOXVWUDWLRQRI0DLQ*URXSV
Mount Installation )UHH0RXQW,QVWDOODWLRQ
Illustration main components (retarder basic group)
2220
2210 2200
2260
2135 2270
4110
2120 2010 1250
2110 1260
2250
1200
4150
1210
2135
2225 2130
2220 3020 1220/1
3010
1220 2301
2160 1220/2
4020
1220/3
4030
4010 1030
2080 1060
1020
2100 4030 1110
4020 1050
2090 2060
2105 2050
4070
2040
2020 1020
1030
1150
1040
1050
2230
1160
1120 3030
1370
1420 1010 1170
3000
1440
1450 1190
1080 1180
1190 2000
1070
3000 1195
0552
1010 Retarder housing 1260 Washer B 8,4 2220 Washer 10,5

1020 Sealing ring A 12 x 18 1370 O-ring 196,52 x 2,62 2225 Cap screw CV 84, M 10 x 25
1030 Screw plug M 12 x 1,5 1420 Silencer 2230 O-ring 10 x 3
1040 Screw plug M 24 x 1,5 1440 Cover plate 2250 O-ring 297 x 4
1050 Sealing ring A 24 x 29 1450 Cap screw M 6 x 16 2260 Oil filling plug M 24 x 1,5
1060 Oil filler/check plug M 24 x 1,5 / DIN908 1510 O-ring 10 x 2,2 alternative M 18 x 1,5
1070 Retarder oil drain plug M 30 x 1,5 1520 O-ring 28,24 x 2,62 2270 Sealing ring A 24 x 29
1080 Sealing ring A 30 x 36 2000 Throttle disc, pressed in alternative A 18 x 24
1110 Stator 2010 Housing cover 2301 O-ring 55 x 3
1120 Stator pin 2020 Cap screw M 6 x 25 3000 O-ring 36 x 4
1150 Radial shaft sealing ring 2040 Retainer 3010 Rotor
115 x 140 x 10 2050 Valve flap, vulkanized 3020 Cap screw CV 84, M 10 x 18
1160 Back-up ring 2060 Valve seat 3030 Racer
1170 Labyrinth cover 2080 Sealing disc D 15 x 2 4010 Hollow shaft
1180 Cap screw CV 84, M 10 x 35 2090 Sealing ring A 22 x 29 4020 O-ring 95 x 4,5
1190 Washer 10,5 2100 Retainer 4030 Rectangular-section ring
1195 Cap screw CV 84, M10 x 25 2105 Screw plug M 22 x 1,5 D 120 / 112,4 x 4,2
1200 Cover casing ventilation 2110 Radial shaft sealing ring 115 x 140 x 10 4070 Cylinder roller bearing
1210 Gasket casing ventilation 2120 Back-up ring 4080 Centering cover
1220 Casing ventilation 2130 Racer 4090 Hex.-head screw M 8 x 16
1220/1 Valve insert 2135 O-ring 196,52 x 2,62 alternative M 8 x 20
1220/2 Float 2160 Collar screw M 10 x 65 4110 Racer
1220/3 Float cage 2200 Labyrinth cover 4150 Deep-groove ball bearing
1250 Hex.-head screw M 8 x 25 2210 Cap screw CV 84, M 10 x 35
Notice
The cylinder roller bearing (4070) and deep-groove ball bearing (4150) may be installed in opposite position.

67.1405.20 Page 7.1/1
Repair Free &KHFNLQJ5HPRYLQJDQG,QVWDOOLQJ
Mount Installation &DVLQJ9HQWLODWLRQ
Illustration casing ventilation

1030 Screw plug M 12 x 1,5 1260
1200 Cover casing ventilation,
coat sealing surface thin with Hylomar 1200
sealant
1210 Gasket, renew 1210
1220 Casing ventilation
1220/1 Valve insert
1220/2 Float checking, renew if necessary,
specified weight: 11g ± 1 g
1220/3 Float cage 1220/1
1260 Washer B 8,4 2301
2301 O-ring 55 x 3, renew, 1220
coat of silicone-free and non-corrosive 1220/2
1220/3
Notice
1020
The checking and working steps are described in
chapter 6.2.
1030
0048

67.1405.20 Page 7.2/1
Mount Installation 6XPS&KHFN9DOYH
Prior job
• Drained retarder oil (see chapter 3.3)
2080 Sealing disc, check, renew if necessary

2100 Retainer
Inhex.-head, w.a.f. 10, 25 Nm,
Locking agent
Thread on retainer Loctite 242
To check sump check valve

Operate retarder at highest stage and switch it off
after approx. 5 seconds .
If oi emerges at the labyrinth covers on the output or
input side, the sump check valve is defective.
2080
2100
Notice
2090
Install only in vertical position!
Do not use impact tool! 2105
0529
Install in reverse sequence.

67.1405.20 Page 7.3/1
Repair Free 5HPRYLQJ&OHDQLQJDQG,QVWDOOLQJ6LOHQFHU
Mount Installation
Illustration silencer
Notice

1420 Silencer,
clean with Benzine and blow out with
compressed-air
1440 Cover plate
Cleaning agent 1420

Silencer Benzine
1440 1450
1450
Notice
Check silencer on damages and wear, renew if

necessary.
0057

67.1405.20 Page 7.4/1
Repair Free 5HPRYLQJDQG,QVWDOOLQJ3URS6KDIW)ODQJHV
Mount Installation
Illustration prop shaft flanges
Prior job
1000 Prop shaft flange

1001 Prop shaft flange
5000 Guard ring
7000 Flange fastening screw 1001 8000
M 24 x 200, renew,
(use only phosphated version), 5000
Initial torque: 50 Nm
Final torque: 90° turning angle
8000 Prop shaft screw, renew
Notice
This step can be performed with the retarder 5000

1000
Commercially available tool 8000
Tightening angel measuring tool 3/4
E.g. Messrs. Richard Abr. Herder KG
Postbox 10 08 67 7000
D - 42569 Solingen
Tel. (xx49) 212/888-0 / Ordering-No. 8200-02
0530

67.1405.20 Page 7.5/1
To remove, install
1. Unscrew flange fastening screw (7000) on output side prop shaft flange (1000).
1000
Initial torque: 50 Nm
Final torque: 90° turnig angle
7000
0532
2. Pull the prop shaft flanges (1000) out of the retarder housing.
1000 1000
0533

67.1405.20 Page 7.5/2
3. Remove guard rings (5000).
8000 5000
Note for installation
Renew prop shaft screws (8000). Align hole patterns of both prop shaft flanges prior to installation.
Maximum permissible offset 5°.
4. Install in reverse sequence.
0069

67.1405.20 Page 7.5/3
Repair Free 5HPRYLQJDQG,QVWDOOLQJ/DE\ULQWK&RYHU
Mount Installation (Output Side)5HQHZLQJ5DGLDO6KDIW6HDOLQJ5LQJ
Prior jobs
• Prop shafts removed from flanges
(see vehicle manufacturer´s instruction)
(see VOITH Installing Instructions)
4010
Notice
This step can be performed with retarder removed 4020

or installed.
1150
1160
renew, 3030
1160 Back-up ring
1170 Labyrinth cover, 1170
sealing surface
1180 Cap screw CV 84, M10 x 35
screw with internal serrations
1190 Washer 10,5
1370 O-ring 196,52 x 2,62, renew,
1190
grease for installation 1180
3030 Racer, check, renew if necessary 0531
4010 Hollow shaft
4020 O-ring 95 x 4,5 , renew,

67.1405.20 Page 7.6/1
Repair Free 5HPRYLQJ,QVWDOOLQJ/DE\ULQWK&RYHU(Output
Mount Installation Side),5HQHZLQJ5DGLDO6KDIW6HDOLQJ5LQJ(Cont.)

Special tools
53.1180.10 53.1373.10 53.1372.10

95/1 94/4 97/1

67.1405.20 Page 7.6/2
Job scope
1. Screw out cylinder screws (1180) with the socket wrench (95/1) and remove together 1170
with washers (1190).
2. Press off the labyrinth cover (1170) with two hex.-head screws M 10 x 65 (see arrows) from the
retarder housing. 1180
3. Use the three inner hex.-head screws to clamp the bearing race puller (94/4) evenly in the
bearing race (3030), making sure that the bearing race does not become out of round. 1190
0534
4. Use the bearing race puller (94/4) to pull the bearing race (3030) off the hollow shaft (97/4).
Remove the back-up ring.
3030
5. Remove the shaft sealing ring (1150) without damaging the sealing surface of the retarder housing.
94/4
4010
0535

67.1405.20 Page 7.6/3
6. Remove the O-ring (4020) for the hollow shaft (4010).
4010 4010
Notice 4020
4020
Check the running surface of the race (3030) for scores and uneven surface of the radial shaft sealing ring
and renew race, if necessary.
Notice 1150
If running surface of the radial shaft sealing ring is uneven the axial und radial gap of the retarder has to be 0536
Recommendation:
1150
4020 4010
97/1
0537

67.1405.20 Page 7.6/4
9. Pull new O-ring (4020) on to the hollow shaft (4010) and apply coat thin with silicone-free and
4010
10. Fit back-up ring (1160) to radial shaft sealing ring. Use a suitable drift to press the bearing race (3030)
on to the hollow shaft (4010) as far as they will go. 1160
3030
0538
11. Fit new O-ring (1370) in labyrinth cover (1170) and apply a thin coat of silicone-free and
holes illustrated and install it in such a way that the groove in the retarder housing and the duct in the

1170
0065

67.1405.20 Page 7.6/5
Repair Free 5HPRYLQJDQG,QVWDOOLQJ/DE\ULQWK&RYHU
Mount Installation (Input Side)5HQHZLQJ5DGLDO6KDIW6HDOLQJ5LQJ
Prior job
(see chapter 7.6)
4010
2110 Radial shaft sealing ring
115 x 140 x 10,renew, 4020
2120 Back-up ring 2120 4110
2135 O-ring 196,52 x 2,62 2135
2200
2200 Labyrinth cover,
sealing surface
2210 Cap screw CV 84, M 10 x 35,
2220 Washer 10,5
4010 Hollow shaft
4020 O-ring 95 x 4,5 2220
2210
4110 Racer
0120

67.1405.20 Page 7.7/1
Repair Free 5HPRYLQJ,QVWDOOLQJ/DE\ULQWK&RYHU(Input Side),
Mount Installation 5HQHZLQJ5DGLDO6KDIW6HDOLQJ5LQJ (Continue)
Housing sealing rsurface Hylomar

Special tools
53.1180.10 53.1373.10 53.1372.10

95/1 94/4 97/1

67.1405.20 Page 7.7/2
Job scop
1. Screw out cap screws (2210) with socket wrench (95/1) and remove them with washers (2220). 2220
2210
0121
2. Press off labyrinth cover (2200) with two hex.-head screws M 10 x 65 threaded along their entire
length (see arrows) from housing cover.
2200
0122

67.1405.20 Page 7.7/3
3. Use the three inner hex.-head screws to clamp the bearing race puller (94/4) in the
bearing race (4110). Make sure that the bearing race does not become out of round. 4110
94/4
4. Use bearing race puller (94/4) to pull the bearing race (4110) off the hollow shaft (4010).
Then remove the back-up ring.
0123
5. Remove radial shaft sealing ring (2110), without damaging the sealing surface of the 4020
retarder housing.
4010
6. Remove the O-ring (4020) for the hollow shaft (4010). 2110
4020
4010
0124

67.1405.20 Page 7.7/4
Notice
2110 97/1
Check the running surface of the race for scores and uneven surface of the radial shaft sealing ring
and renew race, if necessary. 4020
4010
Notice
If running surface of the radial shaft sealing ring is uneven the axial und radial gap of the retarder has to be
0125
Recommendation: 97/1 Press-in tool 53.1372.10

9. Pull new O-ring (4020) on to hollow shaft (4010) and apply thin coat of silicone-free and non-corrosive
grease.

67.1405.20 Page 7.7/5
10. Use suitable drift to press back-up ring (2120) and bearing race (4110) on to the hollow shaft (4010)
as far as they will go. 4010
2120
4110
0126
11. Fit new O-ring (2135) into labyrinth cover (2200) and apply thin coat of silicone-free and
2135
holes illustrated and install it in such a way that the groove in the retarder housing and the duct in the 2200

0127

67.1405.20 Page 7.7/6
Repair Free 5HPRYLQJDQG,QVWDOOLQJ+RXVLQJ&RYHU
Mount Installation 5HQHZLQJ'HHS*URRYH%DOO%HDULQJ
Illustration housing cover
Prior jobs
• Retarder removed (see chapter 5)
• Labyrinth cover and radial shaft sealing ring
input side removed (see chapter 7.7)
1010 Retarder housing 1010 2230

2135 O-ring 196,52 x 2,62, renew,
2010 Housing cover
2010
2130 Bearing ring, check, renew if necessary,
sealing surface 2220
2160 Collar screw M 10 x 65,
• new screws with coating thread install
without Loctite
• used screws (disassemled)
after degrease and installed with
Loctite 242 locking agent 3010
2220 Washer B 10,5 2250 2225
2135
2225 Cap screw CV 84, M 10 x 25 4010
2130
self-locking, renew, 46 Nm 4150
2230 O-ring 10 x 3, renew
2250 O-ring 297 x4, renew
3010 Rotor
4010 Hollow shaft
4150 Deep-groove ball bearing, 0553
alternative can also be installed the
cylinder roller bearing (4070) and the
deep-groove ball bearing (4150)
in swapped position.
Notice
During this work the following parts can also be

checked:
• Sump flap valve (see chapter 7.9)

• Race of radial shaft sealing ring
• Screw plug filling duct

(see Aftersales Service Information
11/97 and 15/96)

67.1405.20 Page 7.8/1
Mount Installation 5HQHZLQJ'HHS*URRYH%DOO%HDULQJ (Continue)
Sealants, lubricants and locking agents
O-rings and radial shaft sealing rings Silicon-free and non-corrosive grease
Collar screws Loctite 242
Commercially available tool
Claw puller
Tool for local fabrication

Threaded pin M10
Material: St 37-2 DIN 17100 (1.80)
15
M10
200
0073

67.1405.20 Page 7.8/2
To remove
1. Screw out collar screws (2160). 1010
2. Use two hex.-head screws M10 x 65 (see arrows) to press the housing cover (1010) together with the
hollow shaft (4010) and rotor (3010) off the retarder housing (1010).
3. Use a suitable drift to press the hollow shaft (4010) and the rotor (3010) off the housing cover (2010).
4. Remove rectangular-section rings (4030) according to chapter 7.12. 2010
0554
Notice
Alternative a cylinder ball bearing is installed in the housing cover.
5. Remove O-ring (2250) from housing cover (2010) or retarder housing (2230).
2010
2250
0871

67.1405.20 Page 7.8/3
6. Remove O-ring (2230) from retarder housing (1010).
2230
7. Check deep-groove ball bearing or alternative the cylinder roller bearing and replace with a
deep-groove ball bearing, if necessary.
Notice 1010
If a cylinder roller bearing was installed in the housing cover the bearings on input side and output side must
be changed. The cylinder roller bearing must be installed in the stator (output side) and the deep-groove
ball bearing in the housing cover (input side).
0555
To renew cylinder roller bearing:

2220
1. Screw out cap screws (2225) and remove them together with washers (2220).
2225
0556

67.1405.20 Page 7.8/4
2. Screw three hex.-head screws M 10 x 65 (arrows) into the bearing ring (2130).
3. Tap on the screw heads to drive the bearing ring (2130) out of the housing cover. 2130
0557
4. Remove the O-ring (1370) from the bearing ring (2130).

1370 2130
0558

67.1405.20 Page 7.8/5
5. Use a suitable drift to press the cylinder roller bearing (4070), alternative the deep-groove ball
bearing (4070) out of the bearing ring.
4070
0559
6. Use a suitable drift to press the new deep-groove ball bearing (4070) into the bearing ring 4070
as far as it will go.
0560

67.1405.20 Page 7.8/6
7. Fit new O-ring (2135) into the bearing ring (2130) and apply thin coat of silicone-free and
8. Screw the two threaded pins (arrows) into the bearing ring (2130). 2130
9. Apply thin coat of Hylomar sealant to the sealing surface of the bearing ring (2130).
2135
0561
10. Fit bearing ring (2130) into the housing cover.
11. Screw new cap screws (2225) with washers (2220) tight. 2130
0562

67.1405.20 Page 7.8/7
4010 4070/1
Notice 4070/1
If the cylinder roller bearing was replaced by a deep-groove ball bearing, the following working steps must
be carried out:
12. Fit a suitable pressure plate (arrow) into the hollow shaft.
13. Apply the claw puller to the recesses in the hollow shaft and pull the inner ring of the
cylinder roller bearing (4070/1) off.
4010
0563
To install
1. Fit new O-ring (2230) into the retarder housing (1010) and apply thin coat of silicone-free and 2230
1010
0555

67.1405.20 Page 7.8/8
2. Apply a thin coat of Hylomar sealant to the sealing surface of the retarder housing (1010).
1010
Notice
Do not forget to apply thin coat of Hylomar sealant to the lands.
3. Screw two threaded pins (arrows) into the retarder housing (1010).
0083
4. Pull new O-ring (2250) on to the housing cover (2010) and apply thin coat of silicone-free and
non-corrosive grease. 2010
5. Install the rectangular-section rings (4030) according to chapter 7.13.
6. Press hollow shaft (4010) with rotor and rectangular-section rings into the housing cover (2010).
7. Place the housing cover (2010) on the retarder housing (1010).
2250
0564

67.1405.20 Page 7.8/9
Caution!
Do not install collar screws with Loctite 242 locking agent coated thread!
8. Screw new collar screws (2160) with coated thread without locking agent, or used (disassembled)
collar screws after degrease and coating with Loctite 242 locking agent, in by hand into the
appropriate bore at the retarder housing (1010).
Screw the collar screws tight in two stages:
9. Tighten first all collar screws (2160) in the specified sequence 1 to 44. 1010 20 18 17 1 16 15
21 44
22 43
3 13
2010
10. Tighten all collar screws (2160) after approx. 15 minutes time to settle in the specified sequence 23 42
4
1 to 44. 24
5
41
12
40 2160
26 11 39
7 10
8 2 9
38
27
37
28 36
34 35
31 32 33
29 30 0540

67.1405.20 Page 7.8/10
Mount Installation 6XPS)ODS9DOYH
Prior jobs
• Removed retarder (see chapter 5)
• Removed housing cover (see chapter 6.9)
2020
2010 Housing cover
alternative Inhex.-head, w.a.f. 4, 9 Nm 2040 2010
2040 Retainer
2050 Valve flap,
check, renew if necessary 2050
2060 Valve seat
install with Loctite 242 locking agent 2060
Remove valve seat only,if sealing surface
is damaged!
Locking agent
Valve seat Loctite 242
Notice
The checking and working steps are described in

chapter 6.10.
0085

67.1405.20 Page 7.9/1
Repair Free 5HPRYLQJDQG,QVWDOOLQJ5RWRU
Mount Installation
Prior job
4010
• Housing cover removed (see chapter 7.9) working steps 1. to 3.
3010 3020
1. Screw out cap screws (3020).
2. Remove rotor (3010) from hollow shaft (4010).
Notice
It is also possible to check the following parts during this working steps: 0101
• Running surface of the radial shaft sealing rings (see chapter 7.6 and 7.7)
3. Install the parts in reverse sequence.

Tightening torque 50 Nm +10 Nm

67.1405.20 Page 7.10/1
Repair Free 5HPRYLQJDQG,QVWDOOLQJ6WDWRU
Mount Installation 5HQHZLQJ&\OLQGHU5ROOHU%HDULQJ
Illustration stator removing and installing
Prior job
• Housing cover removed (see chapter 7.9)
1010 Retarder housing

1010
1195
1110 Stator,
4070
sealing surface
1190 Washer 10,5
1195 Cap screw CV 84, M 10 x 25, 4070/1
self-locking, renew, 46 Nm 1190
3010 Rotor
3020 Cap screw CV 84, M 10 x 18,
renew, 46 Nm
4010 Hollow shaft
4030 Rectangular-section ring
4070 Cylinder roller bearing, check,
renew if necessary
4070/1 Inner ring (cylinder roller bearing),
4010 3010
3020
Notice
Alternative the deep-groove ball bearing (4150) and

the cylinder roller bearing (4070) may be installed in
swapped position. 4030
4030
0541

67.1405.20 Page 7.11/1
Mount Installation 5HQHZLQJ&\OLQGHU5ROOHU%HDULQJ (Continue)
Housing sealing surface Hylomar
Commercially available tools
Hot-air gun 2000 Watt
Gas welding equipment
15
M10
200
0073
53.1180.10
Socket wrench Threaded pin M10

95/1 Material: St37-2, DIN 17100 (1.80)

67.1405.20 Page 7.11/2
To remove
3010
3020
Notice
Is a deep-groove ball bearing installed in the stator (output side) the following prior jobs have to be made:
4010
1. Screw out cap screws (3020).
2. Use two M 10 x 65 screws threaded along their entire length (arrows) to press the rotor (3010) off the
hollow shaft (4010).
0542
3. Use two M 10 x 65 screws threaded along their entire length (arrows) to press the hollow shaft (4010)
off the stator (1110). 1110
4. Screw out the two cap screws (1195) at the output side of the retrader and remove the
4010
washers (1190).
0543

67.1405.20 Page 7.11/3
5. Screw three hex.-head screws M 10 x 65 (arrows) into the stator (1110).
Notice
Place the retarder housing on an even and soft pad to ensure the stator is not damaged while being driven
1195
out.
0092
6. Tap the screw heads to drive the stator (1110) out of the retarder housing.
1110
0544

67.1405.20 Page 7.11/4
7. Check the cylinder roller bearing (4070)alternative the deep-groove ball bearing on damages and
renew, if necessary. 4070
Notice
If a cylinder roller bearing was installed in the stator the bearings on input side and output side must be
changed. The cylinder roller bearing must be installed in the stator (output side) and the deep-groove ball
bearing in the housing cover (input side).
0094
To renew cylinder roller bearing:
1. Use a suitable drift to press the cylinder roller bearing (4070), alternative the deep-groove ball
bearing (4070) out of the bearing ring.
Use a suitable drift to press the new cylinder roller bearing (4070) into the bearing ring
as far as it will go.
Notice
If the cylinder roller bearing was replaced, then the inner ring also must be replaced.
Recommendation:
If one part shows damages, replace always both parts.

67.1405.20 Page 7.11/5
Notice 4070/1
Working step 2. must not be made, if a deep-groove-ball bearing was installed.

4010
The inner ring and areas of the hollow shaft are hot!
0095
2. Heat inner ring (4070/1) uniformly and use a suitable drift to drive it off the hollow shaft (4010).
3. Heat the new inner ring (4070/1) to max. 80 to 100 °C and push it on to the hollow shaft (4010).

67.1405.20 Page 7.11/6
To install
1. Clean the cleaning surfaces on the stator (1110) and on the rotor housing (1010).
2. Apply a thin coat of Hylomar sealant to the sealing surface of the stator (1110).
Screw two threaded pins (arrows) into the stator (1110).
1110
The inner area of the retarder housing is hot!
3. Use a hot-air gun or a welding flame to heat the retarder housing (1010) in the zone marked (arrow)
to max. 80 to 100 °C.
1010
0097

67.1405.20 Page 7.11/7
1110
Notice
Align the stator holes with the holes in the retarder housing.
4. Fit the stator (1110) into the retarder housing (1010) with the slotted stator blades at the top.
0099
5. Screw the stator (1110) on output side tight with two new cap screws (1195) and washers (1190).
1195
6. Screw out the threaded pins.
0100

67.1405.20 Page 7.11/8
Repair Free 5HPRYLQJDQG,QVWDOOLQJ6WDWRU3LQV
Mount Installation
Illustration stator pins
Prior job
• Stator and rotor removed (see chapter 7.11) 1120

1110 Stator
1120 Stator pin, 45 Nm
Notice
Check stator pins for free movement of tappets and

for external damage.
The threads of the stator pins and of the stator must
be free of grease when the pins are installed.
Locking agent
Thread on stator pin Loctite 640
1110
0102

67.1405.20 Page 7.12/1
Repair Free 5HQHZLQJ5HFWDQJXODU6HFWLRQ5LQJV
Mount Installation 3RO\SHQFR5LQJV
Illustration rectangular-section ring
Prior job
4010 Hollow shaft

The rectangular-section rings may not jut
out of their groove and their ends are
mounted gap-free- danger fo shear off.
Apply coat of non-corrosive and
silicone-free grease to grooves in
proximity of ring links.
4030 Rectangular section-rings, renew
Lubricants
Hollow shaft grooves Silicone-free and

non-corrosive grease 4030
4010
4030
0103

67.1405.20 Page 7.13/1
Repair Free 3DUDPHWHUL]LQJ&RQWURO8QLW
Mount Installation
Illustration control unit
21 Dual-In-Line-Switch (DIL)
Check setting, correct if necessary
31 Circuit board
Notice
As a general rule, the maximum permissible constant-

air pressure (determines maximum braking torque)
are settings made in the control unit at the factory for
the specific vehicle prior to delivery to the customer.
5
4
Caution !
3
2
4
ON
1
It is not permitted to change these settings!
3
Notice
2
The checking and working steps are described in 31
ON
1
chapter 6.13.
21
0744

67.1405.20 Page 7.14/1
Repair 5HPRYLQJ&KHFNLQJDQG,QVWDOOLQJ
Heat Exchanger +HDW([FKDQJHU
8.1 Removing, Checking and Installing Stainless-Steel Heat Exchanger ........ 8.1/1
8.2 Removing, Checking and Installing Aluminium Heat Exchanger ............... 8.2/1

67.1405.20 Page 8/1
Heat Exchanger 6WDLQOHVV6WHHO+HDW([FKDQJHU
Illustration stainless-steel heat exchanger
1004
2000 1001
1000
3000
4000 6000
5000 1080
1070 3000
9000
10000
10000
9000
97 5000
96
4000
6000
4000
7000 0545
Notice
In case of a mechanical damage or a leakage, the heat exchanger may be sealed new or some parts may be changed
(see Aftersales Service Instruction 11/96 in the annex).
Prior job
• This job can also be performed, if retarder is installed.
Caution!
If another version of heat exchanger is built on to the retarder, the appropriate throttle disc must be fitted.
96 Hose clamp 4000 Washer 10,5

97 Hose connection 5000 Collar nut M10,
1000 Heat exchanger Hex.-head, w.a.f. 17, self-locking, renew 46 Nm
1001 Cooling-water drain plug M 18 x 1,5 Washers and hex.-head nuts are replaced by collar nuts
Hex.-head, w.a.f. 17, 50 Nm (see Aftersales Service Instruction 7/98)
1004 Sealing ring A 18 x 22, Copper, renew 7000 Hex.-head screw M 10 x 40,
1070 Retarder oil-drain plug M 30 x 1,5 Hex.-head, w.a.f. 17, 46 Nm
Hex.-head, w.a.f. 22, 150 Nm 8000 Stud M 10 x 50, hand tight, max. 10 Nm
1080 Sealing ring A 30 x 36, Copper, renew 9000 Connecting piece
2000 Throttle disc, pressed-in 10000 Gasket
3000 O-ring 36 x 4, renew,
coat with silicone-free and non-corrosive grease
for installation

67.1405.20 Page 8.1/1
Heat Exchanger 6WDLQOHVV6WHHO+HDW([FKDQJHU(Continue)
Lubricants
O-rings, Throttle disc (alternative) Silicone-free and

Data
Pressure for pressure test in oil section: max. 10 bar
Special tool
53.1369.10
Pressure test equipment

97/3

67.1405.20 Page 8.1/2
To remove
Notice
If this job sequence is performed with the retarder installed, the following jobs must first be performed:
The cooling-water drain plug and the cooling-water are hot!
1. Screw out cooling-water drain plug (1001) and drain cooling-water of heat exchanger (1000).
1001
1000 1004
0105

67.1405.20 Page 8.1/3
2. Loosen hose clamps (96) on the left and on the right side and remove hose connection (97) from the
heat exchanger (1000).
3. Screw in cooling water drain plug (1001) again with new sealing ring (1004) tight. 96
4. Place oil pan underneath the retarder.

97

The oil drain plug is hot! Oil temperature! 1070 0106
5. Screw out oil drain plug (1070) on the retarder and drain the oil.
6. Screw the oil drain plug (1070) together with a new sealing ring (1080) into its hole.
Tighten the oil drain plug (1070).

67.1405.20 Page 8.1/4
7. Unscrew the four hex. nuts (5000) with washers (4000) or collar nuts (5000)
and the hex.-head screws (7000) with washers (4000).
Notice
If the heat exchanger is the version „stainless-steel large“ unscrew 6 hex. nuts.
If DILAVAR studs have been used, the studs may be screwed out together with the hex. nuts.
Remedy: 5000 4000

4000 5000
Clamp the stud in a vice (taking care not to damage the thread) and unscrew the hex. nut. Screw the stud
4000 7000 0872
handtight (max. 10 Nm) without using a locking agent into the retarder housing again.
Caution!
Damaged studs must be renewed!
Notice
A small amount of oil remains only in the stainless-steel heat exchanger, which can be drained by the two
ducts.Before mounting, the heat exchanger must be emptied by shifting.
8. Remove heat exchanger (1000).

67.1405.20 Page 8.1/5
9. Remove the two O-rings (3000) from the heat exchanger.
Notice
Do not remove throttle-disc (2000), if pressed in!
2000
Notice 3000
0107
If another version of the heat exchanger is built on to the retarder, the appropriate throttle disc must be fitted!
10. Nehmen Sie die Drosselscheibe (2000) ab, wenn lose verbaut.

67.1405.20 Page 8.1/6
To check
1. Fit the pressure-test equipment (97/3) to the heat exchanger (1000). Connect up the compressed-air
line with pressure-regulator.
1000
2. Fill the heat exchanger (1000) (water section) with hot water (approx. 70°C).
3. Pressurize the heat exchanger (1000) slowly to max. 10 bar overpressure (oil section).
Notice
97/3 0546
If air bubbles form in the hot water, the oil-cooler inserts or gaskets are defect on oil section.
97/3 Pressure-test equipment 53.1369.10
4. Remove the pressure-test equipment (97/3).

67.1405.20 Page 8.1/7
To install
Notice
New heat exchangers are wetted with preserving oil in the oil section.
Prior to installation of a new heat exchanger, drain any preserving oil which has collected.
1. Apply thin coat of silicone-free and non-corrosive grease to the new O-rings (3000) and fit them in
the bores of the retarder housing.
Caution!
At necessary repair work, changes of the heat exchanger etc., where the hex.-head nuts with washers have
to be unscrewed, the hex.-head nuts have to be replaced by collar nuts
(see Aftersales Service Information 7/98).
Do not tighten the collar nuts with an impact tool!

67.1405.20 Page 8.1/8
2. Install the heat exchanger (1000) on the retarder housing and use new self-locking collar nuts (5000),
hex.-head screws (7000) and washers (4000) to screw it tight on the retarder housing.
3. Install hose connection (97) on the heat exchanger (1000) and screw the hose clamps (96) tight.
4. Install retarder, if necessary (see chapter 5 „Removing and Installing Retarder“).
5. Fill in cooling-water and bleed cooling-water circuit according the vehicle manufacturer´s instructions.
5000 5000
Notice
4000 7000 0873
Heed the statements of the vehicle manufacturer respecting the cooling-water quality, as well as the
VOITH cooling-water list in the annex.
6. If the heat exchanger had been leaking on oil section, flush the retarder.

67.1405.20 Page 8.1/9
The oil-drain plug is hot! Oil temperature!
Fill retarder with 9 litres of engine oil or flushing oil to flush it out. Flush the retarder system by braking
lightly several times and drain the oil at the oil-drain plug (1070).
Repeat this procedure two- or three times until no more oil is visible inthe water.
Provide the oil-drain plug (1070) with new sealing ring (1080) and screw them tight.
Tightening torque
Retarder oil-drain plug (1070) 150 Nm
Notice
If the retarder oil has entered the cooling water-system, the vehicle cooling-system must be cleaned in ac-
cordance with the vehicle manufacturer´s instruction.

67.1405.20 Page 8.1/10
Notice
Brake lightly several times to prevent the retarder oil overheating.
Oil and cooling-water are hot!
The oil-water mixture in the retarder may cause the oil in the retarder to foam and escape through the
casing ventilation to the open air.
7. Unscrew the screw plug of the sump check valve (2105) and drain any leakage oil and cooling-water
which has collected.
8. Fill the retarder with the specified oil (see chapter 3.3 „Oil Change“).

67.1405.20 Page 8.1/11
Heat Exchanger $OXPLQLXP+HDW([FKDQJHU
Illustration aluminium heat exchanger
1002
1003
1000
1004
1001
3000 1000
2000
3000
1080
7000 1070
4000
5000
97
96
0109
Prior job
• This job can also be performed, if retarder is installed.
Caution!
If another version of heat exchanger is built on to the retarder, the appropriate throttle disc must be fitted.
96 Hose clamp 2000 Throttle disc, pressed in

97 Hose connection 3000 O-ring 36 x 4, renew,
1000 Heat exchanger coat with silicone-free and non-corrosive grease
1002 Oil-drain plug heat exchanger M 12 x 1,5 for installation
Hex.-head, w.a.f. 13, 25 Nm 4000 Washer 10,5
1003 Sealing ring A 12 x 15,5,Copper, renew 5000 Collar nut M10,
1001 Cooling-water drain plug M 12 x 1,5 Hex.-head, w.a.f. 17, self-locking, renew 46 Nm
Hex.-head, w.a.f. 13, 25 Nm Washers and hex.-head nuts are replaced by collar nuts (see Af-
1004 Sealing ring A 12 x 15,5, Copper, renew tersales Service Instruction 7/98)
1070 Retarder oil-drain plug M 30 x 1,5 7000 Hex.-head screw M 10 x 35,
Hex.-head, w.a.f. 22, 150 Nm Hex.-head, w.a.f. 17, 46 Nm

67.1405.20 Page 8.2/1
Heat Exchanger $OXPLQLXP+HDW([FKDQJHU(Continue)
Lubricants
O-rings, Throttle disc (alternative) Silicone-free and

Data
Pressure for pressure test in oil section: max. 10 bar
Special tool
53.1369.10
Pressure test equipment

97/3

67.1405.20 Page 8.2/2
To remove
Notice
If this job sequence is performed with the retarder installed, the following jobs must first be performed:
96
1004
97 1000
1001
The cooling-water drain plug and the cooling-water are hot! 0110
1. Screw out cooling-water drain plug (1001) and drain cooling-water of heat exchanger (1000).
2. Loosen hose clamps (96) on the left and on the right side and remove hose connection (97) from the
heat exchanger (1000).
3. Screw in cooling water drain plug (1001) again with new sealing ring (1004) tight.

67.1405.20 Page 8.2/3
4. Place oil pan underneath the retarder.
1002
The oil drain plugs are hot! Oil temperature!
5. Screw the oil-drain plug (1070) with sealing ring (1080) out of the retarder and drain oil.
1080
6. Screw also the oil-drain plug (1002) with sealing ring (1003) out of the heat exchanger and drain oil. 1070
0111
7. Screw the oil drain plug (1070) of the retarder together with a new sealing ring (1080) into its hole.
Tighten the oil drain plug (1070).
8. Screw the oil drain plug (1002) of the heat exchanger together with a new sealing ring (1003) into its
hole. Tighten the oil drain plug (1002).

67.1405.20 Page 8.2/4
9. Unscrew the four collar nuts (5000), or hex. nuts (5000) with washers (4000) and the hex.-head
screws (7000) with washers (4000).
Notice
If the heat exchanger is the version „HGV1“ unscrew 6 collar nuts.

If DILAVAR studs have been used, the studs may be screwed out together with the collar nuts.
4000
5000 0112
Remedy:
Clamp the stud in a vice (taking care not to damage the thread) and unscrew the collar nut. Screw the stud
handtight (max. 10 Nm) without using a locking agent into the retarder housing again.
Caution!
Damaged studs must be renewed!

67.1405.20 Page 8.2/5
10. Remove the heat exchanger (1000).
11. Remove the two sealing rings (3000) from the retarder housing.
12. Remove throttle disc (2000), if installed loose.
Caution!
2000
If another version of the heat exchanger is built on to the retarder, the appropriate throttle disc must be fitted! 3000
0107

67.1405.20 Page 8.2/6
To check
1. Fit the pressure-test equipment (97/3) to the heat exchanger (1000). Connect up the compressed-air
line with pressure-regulator.
1000
2. Fill the heat exchanger (1000) (water section) with hot water (approx. 70°C).
3. Pressurize the heat exchanger (1000) slowly to max. 10 bar overpressure (oil section).
Notice
97/3 0114
If air bubbles form in the hot water, the oil-cooler inserts or gaskets are defect on oil section.
97/3 Pressure-test equipment 53.1369.10
4. Remove the pressure-test equipment (97/3).

67.1405.20 Page 8.2/7
To install
Notice
New heat exchangers are wetted with preserving oil in the oil section.
Prior to installation of a new heat exchanger, drain any preserving oil which has collected.
1. Apply thin coat of silicone-free and non-corrosive grease to the new O-rings (3000) and fit them in
the bores of the retarder housing.
2. Apply thin coat of silicone-free and non-corrosive grease to throttle disc (2000) and fit into the bore
on the right.

67.1405.20 Page 8.2/8
Caution!
At necessary repair work, changes of the heat exchanger etc., where the hex.-head nuts with washers have
to be unscrewed, the hex.-head nuts have to be replaced by collar nuts
(see Aftersales Service Information 7/98).
Do not tighten the collar nuts with an impact tool!
3. Install the heat exchanger (1000) on the retarder housing. Screw it with new collar nuts (5000),
hex.-head screws (7000) and washers (4000) tight at the retarder housing.
4. Install hose connection (97) on the heat exchanger (1000) and screw the hose clamps (96) tight.

67.1405.20 Page 8.2/9
5. Install retarder, if necessary (see chapter 5 „Removing and Installing Retarder“).
6. Fill in cooling-water and bleed cooling-water circuit according the vehicle manufacturer´s instructions.
Notice
Heed the statements of the vehicle manufacturer respecting the cooling-water quality, as well as the
VOITH cooling-water list in the annex.
7. If heat exchanger had been leaking on oil section, flush the retarder.

67.1405.20 Page 8.2/10
The oil-drain plugs are hot! Oil temperature!
8. Fill retarder with prescribed quantity of engine oil or flushing oil to flush it out. Flush the retarder sy-
stem by braking lightly several times and drain the oil at the oil-drain plug (1070, 1002).
Repeat this procedure two- or three times until no more oil is visible inthe water.
Provide the oil-drain plugs (1070, 1002) with new sealing rings (1080, 1003) and screw them tight.
Tightening torques
Retarder oil-drain plug (1070): 150 Nm
Heat exchanger oil-drain plug (1002): 25 Nm
Notice
Brake lightly several times to prevent the retarder oil overheating.

The oil-water mixture in the retarder may cause the oil in the retarder to foam and escape through the casing
ventilation to the open air.

67.1405.20 Page 8.2/11
The screw plug is hot! Oil temperature!
9. Unscrew the screw plug of the sump check valve (2105) and drain any leakage oil and cooling-water
which has collected.
10. Fill the retarder with the specified oil (see chapter 3.3 „Oil Change“).

67.1405.20 Page 8.2/12
Control Parts &RQWURO3DUWV/RJRSURS
9.1 Removing and Installing Valve Block ......................................................... 9.1/1
9.2 Removing and Installing Cooling-Water Temperature Pick-up .................. 9.2/1

67.1405.20 Page 9/1
Control Parts 5HPRYLQJDQG,QVWDOOLQJ9DOYH%ORFN
Illustration valve block
Prior job
26
• Supply-air pressure discharged or switched-off 21000
Escaping compressed-air! 23000
25 Supply-air pressure line py

26 Constant-air pressure line pv
36 Ventilation line
5000/1 Plug valve block
21000 Valve block
23000 Hex.-head nut
5000/1 25
36
0547

67.1405.20 Page 9.1/1
Control Parts 5HPRYLQJ,QVWDOOLQJ&RROLQJ:DWHU
7HPSHUDWXUH3LFN8S
Illustration cooling-water temperature pick-up
with aluminium heat exchanger
The temperature pick-up is hot! Water temperature!

38
Job scope
1. Remove electrical lead (38) to cooling-water
temperature pick-up (19).
2. Screw out the temperature pick-up (19) and 19

close the opening immediately with a plug.
3. Install the temperature pick-up (19) in reverse

sequence.
0550

67.1405.20 Seite 9.2/1
Annex $QQH[
Data Sheet
Conversion Table
Operating Specifications
Spare Parts Lists
Other Information

67.1405.20 Page 10/1
Annex 'DWD6KHHW
Data Sheet VOITH Retarder 133, 133 S
Max. braking torque at prop shaft M(Br) max 4000 Nm
Max. retarder speed R 133(= max. prop shaft speed) v(max.) 2000 r.p.m.
Max. retarder speed R 133S (= max. prop shaft speed) v(max.) 2500 r.p.m.
Working medium Oil grade given in Operating Specification
Service filling: With aluminium heat exchanger With stainless-steel heat exchanger
- service filling (oil change, checking oil level) 9,0 litre (standard) 7,5 litre (small)
9,0 litre (HGV 1) 7,5 litre (large)
8,8 litre (HGV 2)
- after changing heat exchanger 7,5 litre (small)

8,2 litre (large)
- after complete taking apart and cleaning 9,0 litre (small) **

(corresponds new filling) 9,7 litre (large) **
Overall weight (with flange and heat exchanger, without oil) approx. 85 kg *
* Overall weight will depend on the retarder version
** Heat exchanger is empty

67.1405.20
Annex &RQYHUVLRQ7DEOH
D GB USA D GB USA
10 oC 50 oF 50 oF 80 Nm 59 lbf-ft 59 lbf-ft
120 oC 248 oF 248 oF 11 g ± 1 g 0,38 ± 0,035 oz 0,38 ± 0,035 oz
25 Nm 18 lbf-ft 18 lbf-ft 0 - 25 bar 0 - 369 psi 0 - 369 psi
46 Nm 34 lbf-ft 34 lbf-ft 0,6 bar 9 psi 9 psi
50 Nm 37 lbf-ft 37 lbf-ft 2,8 bar 41 psi 41 psi
66 Nm 49 lbf-ft 49 lbf-ft 4 bar 58 psi 58 psi

67.1405.20
Annex &RQYHUVLRQ7DEOH
(Continue)
D GB USA D GB USA
4,5 bar 65 psi 65 psi 9l 1,980 UK gal 2,376 US gal
5 bar 72 psi 72 psi 9,5 l 2,090 UK gal 2,508 US gal
5,5 bar 80 psi 80 psi 9,7 l 2,134 UK gal 2,561 US gal
6,5 bar 94 psi 94 psi 10,5 l 2,310 UK gal 2,772 US gal
1,48 - 1,88 bar 22 - 27 psi 22 - 27 psi 27 mm 1,063 inch 1,063 inch
1,87 - 2,27 bar 27 - 33 psi 27 - 33 psi 31 mm 1,221 inch 1,221 inch
2,04 - 2,44 bar 30 - 35 psi 30 - 35 psi 10 cm3 0,61 cubic inch 0,61 cubic inch
2,20 - 2,60 bar 32 - 38 psi 32 - 38 psi 25 - 50 cm3 1,525 - 3,050 cubic inch 1,525 - 3,050 cubic inch
2,36 - 2,76 bar 34 - 40 psi 34 - 40 psi
2,52 - 2,92 bar 37 - 42 psi 37 - 42 psi
1,0 l 0,22 UK gal 0,264 US gal
7,5 l 1,650 UK gal 1,980 US gal

67.1405.20

Awm R133 PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Awm R133 PDF

Hochgeladen von

Copyright:

Verfügbare Formate

$IWHUVDOHV:RUNVKRS0DQXDO

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

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

5. Removing, Installing Retarder................................................................. 5/1

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

9. Control Parts Digiprop............................................................................. 9/1

10. Annex .................................................................................................... 10/1

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

In some footers, you will find a symbolic book in yellow colour.

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

The switched-on retarder will not secure the parked vehicle.

• Brake number 6-digit number and letters

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

Items or components shown with an oblique-number are not available.

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

VOITH TURBO GmbH & Co. KG

Telephone xx49 - (0)7951 32-0

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

2.1 Retarder Data............................................................................................. 2.1/1

2.2 Assembly Overview.................................................................................... 2.2/1

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

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

2. Basic group number (Gr.Nr.):

3. Max. possible braking torque on prop shaft (M):

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

Max. braking torque is set for the specific vehicle.

4. Max. retarder r.p.m. (max. prop shaft r.p.m.):

4.1 R 133: vps = 2000 r.p.m.

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

Illustration VOITH Retarder R 133-2

1000 Heat exchanger

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

1000 Heat exchanger

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

1000 Heat exchanger

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

1 Heat exchanger 36 Ventilation line

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

a) Control system with function ,,Constant Speed"

b) Control system without function ,,Constant Speed"

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

Sump check valve (58)

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

Stator pins (45)

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

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

3.2 Checking Oil Level ..................................................................................... 3.2/1

3.3 Oil Change ................................................................................................. 3.3/1

3.4 Cleaning Line Filter (optional extra) ........................................................... 3.4/1

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop

Overview of maintenance work

• Clean line filter (optional extra)

The illustration shows a retarder 133 with stainless-steel heat exchanger.

cbtd 00-03 Aftersales Workshop Manual VOITH Retarder R 133 Logoprop