Transmissao Voith Gearbox Retarder System GO170 GO210 With R115E 60 Pag PDF
Transmissao Voith Gearbox Retarder System GO170 GO210 With R115E 60 Pag PDF
Transmissao Voith Gearbox Retarder System GO170 GO210 With R115E 60 Pag PDF
Operating Instructions
Gearbox Retarder System / GO170 - GO210 with R115E
R 1 3 5
2 4 6
MBR
20t/24t
State: October 1999
67.2964.10
2 Betriebsanleitung Getriebe-Retarder-System
Preface 1
1. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. System Identification
3.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Retarder control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Illustrations Gearbox Retarder System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. Operation
6.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2 Retarder
6.2.1 Temperature limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.2 Functions and indications of retarder stage switch, retarder pilot light . . . . . . . . . . . . 22
6.2.3 "Constant speed" function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.4 Pedal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7. Maintenance
7.1 Maintenance works / Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2 Gearbox oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3 Retarder oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.4 Gearbox oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.5 Retarder oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8. Fuel Specification
8.1 Gearbox oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.2 Retarder oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.3 Retarder cooling water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9. Service Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10. Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
To guarantee sound operation of the gearbox retard- The safety symbols are explained below:
er system and to exclude any risks due to improper
handling, please read and follow the safety informa-
tion mentioned on this and the next page as well as
Warning!
in each chapter!
Precautions and safety rules protecting persons from in-
juries or danger to their life.
Caution!
Special information and precautions preventing damage
to the gearbox retarder system or vehicle.
Non-observance leads to exclusion of warranty.
Note
Special information for better handling when operating
the gearbox retarder system and for maintenance work.
The gearbox retarder system is manufactured to the mode of operation and that it has no negative effect on
latest design standards and approved safety regulations. the gearbox retarder system, in particular, with regard to
Nevertheless, hazards and damage to property may oc- the safety.
cur in case of improper use. We are not liable for personal injury and/or damage to
property caused by improper and unprofessional opera-
The user/owner has the obligation to always operate tion.
the system in sound condition.
Together with the vehicle instruction manual, the in-
In case of malfunctions, observe the relevant informa- struction manual must always be available at the site
tion. where the vehicle is in service. An incomplete or illegible
instruction manual should to be replaced immediately.
We will not assume liability for injuries and/or damage
to property, resulting from non-observance of the safety The relevant regulations for the prevention of acci-
information, instruction manual or violation of the duty of dents, the other safety engineering and industrial medi-
care in handling, operation, maintenance and repair of cine rules generally approved as well as the Road Traffic
the retarder. Act are to be observed. We are not liable for damages
originating from disregarding these regulations.
We are not in the position to give explicit warnings ev-
erywhere in this instruction manual, in case of any think-
able situation, which may lead to a risk of injury for the
operator and/or damage to the system described. It is
therefore absolutely necessary that everyone in charge
of operation and maintenance of the gearbox retarder
system does not put its own safety at risk by the selected
DAIMLERCHRYSLER
Bez. GO 170-6/8,2 Fortl. Nr. gearbox number
Code G 714.100 L
Code
000000
KW/Jahr 45/1999
Year of manufacture
M+P-07A-1706a
M+P-07A-1707
1. Voith number
8-digit number
It is possible to derive the software version from the
Vo
it
Co h-N
ri
r.
Se de-N :
r.:
last two digits.
Ku en-N 53
2. Code number
3-digit number
(adjustment of control unit)
3. Serial number
Voith-Nr.: 5-digit number
Code-Nr.: also indicating the coding date
Serien-Nr.: Datum:
Kunden-Nr.: 4. Client number
(DaimlerChrysler part number)
M+P-07A-1617
Please enter the identification data, indicated on your
control unit, on the left-hand side nameplate. Please let
us know these data in the event of any queries or spare
parts orders.
* = optional
M+P-07A-1708
Side view
* = optional
26/150/
25/250/068 26/250/068
26/250/047 26/250/ 26/400/089
M+P-07A-1710
Top view
6400/2
4200
107
26/100/125
26/100/125 M+P-07A-1709
Note
The retarder braking torque is sustained even when gear
changes are made!
Warning!
Prior to starting the vehicle engine, push the gearshift le-
ver into idle position (L)!
R 1 3 5
Caution!
L For correct operation of the gearbox it is necessary to
push the clutch pedal all the way down. Hence there
must be no obstacles in the floor area below the foot con-
2 4 6 trols. Observe that any additional floor mats have a good
contact to the floor and are not getting in contact with the
pedals.
How?
– On retarder braking shift the gearbox down to reach
engine rated speed!
Thus:
– High delivery rate of water pump
15 20
– High fan speed
10
25
Result:
30
– It is possible to make optimum use of the vehicle cool-
u/pm
ing system performance!
For vehicles with zero gas switch the “constant speed“ Caution!
function or the active brake stage is cleared on applica-
Only qualified staff is allowed to activate the flash code
tion of the gas pedal. After releasing the pedal, the new
and to perform any repair work which might be neces-
momentary „constant speed“ is stored or the previously
sary.
applied brake stage is reactivated.
0
1 OFF (symbol for retarder pilot 0
1 Steady light position 0 to 5
2
3 light may differ from vehicle to 2
3 Minor fault:
4 4
5 vehicle) 5 Retarder brakings partly pos-
sible with reduced braking
torque.
Light test: Consult a specialized work-
Ignition ON Retarder pilot light shop!
5 sec. steady light
0
1 Flash light:
2
3
Temperature limit
4
5
M+P-07A-1591
Caution!
The activation of the flash code as well as maintenance
works must be carried out only by qualified and
specialized personnel.
Mineral oil 1) Synthetic oil 1) Mineral oil 2) Synthetic oil 2) Synthetic oil 3)
Normal duty 100 000 km 4) 300 000 km 5) 100 000 km 4) 300 000 km 5) 300 000 km 5)
Heavy duty 50 000 km 4) 300 000 km 5) 50 000 km 4) 300 000 km 5) 300 000 km 5)
26/100/122
26/100/128
M+P-07A-1716
Note
Check the oil with the vehicle in horizontal position. Note
In the event of any lacking oil, check the gearbox for a
For oil level check, the gearbox oil must have working possible external leak.
temperature.
3. Screw in the oil filler plug with a new sealing ring and
Warning! tighten it.
Oil filler plug (26/100/122): 47 Nm
Oil filler plug (26/100/122) is hot (oil temperature)!
4100
4200
107
109
M+P-07A-1713 M+P-07A-1712
Caution! Caution!
For sound retarder operation it is important to adhere the There are two possible variants of the screw plugs (107,
specified oil level of 7.0 liters and to only use oils re- 4100, 4200):
leased by the fuel specification, chapter 7.1: „Oil change
intervals” and chapter 8.2: „Fuel specification – retarder A) with integrated FPM-sealing ring;
oil specification”. corresponding standard design on printing
Two variants are available for selection of oil level check: 2. Remove the oil drain plugs (107, 4200) and drain the
oil into the oil collecting pan.
A. Volumetric measuring method
3. Check the integrated sealing rings of the oil drain
1. Put a clean oil collecting pan under the retarder. plugs (107, 4200) for any damage; replace the oil
drain plugs, if necessary.
While the oil level is being checked, make sure that no 6. Add the lacking oil which you might determine during
constant-air pressure is acting in the retarder. The re- volumetric measurement according to the fuel speci-
tarder and the ignition must have been switched off! fication, chapter 7.1: „Oil change intervals” and chap-
ter 8.2: „Fuel specification – retarder oil specification”.
Note Caution!
Should you detect a lack of oil fill, check the retarder for After the oil level check engage the retarder during driv-
a possible external leak. ing with min. 50 km/h at least briefly 5 times for approx.
5 secs. each time in stage position 2 (corresponds to
braking stage 1).
Warning!
The retarder may only be filled through the hole for the
oil filler plug (4100)!
7. Refill oil slowly through the hole for the oil filler plug
(4100) over a duration of more than 3 minutes.
This working step is necessary for correct ventilation
of the retarder system.
B. Using the oil check plug 4. Unscrew the oil check plug (109).
The oil level is correct when it reached the lower edge
1. Vehicle ignition „OFF”, then rest to „ON”. of the oil check hole (see illustration page 35).
Caution!
Warning! The retarder may only be filled through the hole for the
oil filler plug (4100)!
The oil check plug (109) and oil filler plug (4100) are hot
(oil temperature)!
5. Fill in any lacking oil slowly through the hole for the
While the oil level is being checked, make sure that no oil filler plug (4100) according to fuel specification,
constant-air pressure is acting in the retarder. The re- chapter 7.1: „Oil change intervals” and chapter 8.2:
tarder and the ignition must have been switched off! „Fuel specification – retarder oil specification”.
26/100/128
26/100/125
26/100/128
26/100/125
M+P-07A-1715a
Caution!
2. Unscrew the oil drain plugs (26/100/125), remove the
For sound gearbox function it is important to observe the sealing rings (26/100/128) and drain the oil.
specified oil fill and to only use oils released by the fuel
specification, chapter 7.1: „Oil change intervals“ and 3. Screw the oil drain plugs tight with new sealing rings.
chapter 8.1: „Fuel specification – gearbox oil specifica- Oil drain plugs (26/100/125): 47 Nm
tion”.
4. Unscrew the screw plug (26/100/116) and remove
the sealing ring (26/100/119).
Note
For draining the gearbox oil must have operating tem-
perature.
Oil fill
– Service fill (oil change) ................................ 12.5 liters
– Initial fill .......................................................13.0 liters
9. Fill in slowly oil through the hole for the oil filler plug,
according to the fuel specification, chapter 7.1: „Oil
change intervals“ and chapter 8.1: „Fuel specification
- gearbox oil specification“ and oil fill, page 42.
10.Screw the oil filler plug tight with new sealing ring.
Oil filler plug (26/100/122): 47 Nm
4100
4200
107
Warning! Caution!
Dispose of drained oil in a professional manner! There are two possible variants of the screw plugs (107,
Observe the statutory provisions! 3500, 4100, 4200):
For sound retarder operation it is necessary to adhere Performing the oil level check, the integrated sealing
the specified oil fill, see below. It is only allowed to use rings have to be checked for any damage; replace the
oils released by the fuel specification, chapter 7.1: „Oil complete screw plug, if necessary.
change intervals” and chapter 8.2: „Fuel specification –
retarder oil specification”! B) variant with copper sealing ring attached as loose
part.
While the oil is being drained, make sure that no con- 7. Check the integrated sealing ring of the screw plug
stant-air pressure is acting in the retarder. The retarder with screen for any damage; replace the screw plug,
and the ignition must have been switched off! if necessary.
Caution! Caution!
The retarder may be only filled through the hole of the oil After the oil lchange engage the retarder during driving
filler plug (4100)! with min. 50 km/h at least briefly 5 times for approx. 5
secs. each time in stage position 2 (corresponds to brak-
ing stage 1).
10.Fill in oil slowly through the hole for the oil filler plug,
according to fuel specification, chapter 7.1: „Oil
change intervals“ and chapter 8.2: „Fuel specification
- retarder oil specification“ and oil fill, page 45, over a
duration of more than 3 minutes.
This working step is necessary for correct ventilation
of the retarder system.
Armorine,
Armorine BM
Lanester Cedex/ France
BayWa Multipurpose
BayWa, Munich
Gearbox Oil
Engen Petroleum,
Engen Gearlube HP
Cape Town/South Africa
Mac MP Gearbox Oil Deutsche Shell, Hamburg Petrol Transol GL4 Petrol d. d., Ljubljana/Slovenia
De Oliebron,
Tor Multi Purpose Gearbox Oil
Zwijndrecht/Netherlands
Veba Movara EP-Gearbox Oil Veba Öl, Gelsenkirchen Castrol Syntrans-AT Burrmah Oil Technology
Veedol Multigear Veedol International, Swindon/GB Deagear Synth DEA Mineralöl GmbH
1)
Respecting the oil type selection, the statements of the vehicle manufacturer are valid.
If no statements are available, the oil types documentated on the following pages are to be used.
2)
Only the synthetic oil documentated on page 54 may be used.
BP Vanellus C3 BP
Prevent that the coolant is lead into the sewerage sys- Water
tem. Reuse or dispose it. Water alone is not permitted as coolant, even when an-
tifreeze qualities are not required. However, the water of
The statutory or waste water disposal regulations may coolant should meet specific requirements, which fre-
vary from country to country and need to be observed on quently, but not always, are fulfilled by drinking water. If
disposal of used coolants. the water quality is not sufficient, the water needs treat-
ment.
Prior to using the coolant observe the safety data sheets
and product information of the relevant suppliers. Please contact us if you should need any information.
Gearbox input
up to [kW] 320