Read 050785_r.pdf text version

DaimlerChrysler AG

Powertrain Business Unit Transmissions

VOITH TURBO

A NT R I E B ST E C H N I K

Operating Instructions Gearbox Retarder System / GO170 - GO210 with R115E

R

1 2

3 4

5 6

MBR

n

State: October 1999 67.2964.10

20t/24t

2

Betriebsanleitung Getriebe-Retarder-System

Preface 1

A future-oriented concept for your benefit Everyone travelling with the bus expects safety and comfortable driving. And the person who is driving a bus expects optimal driving performance and optimal and comfortable shifting. And who operates a bus expect a long lifetime and maximum economic efficiency. Our gearbox retarder system contributes a substantial part to the realization of these requirements in the daily bus traffic. Gearbox and retarder form a precise matching system. Safety and comfort are combined with the economical benefit. We always wish you GOOD TRIP! DaimlerChrysler AG Drive Train Division Gearbox Product Group Sales Hauptstraße 107 D-76568 Gaggenau Telephone 07225 / 61-65 56 Fax 07225 / 61-65 51 e-mail: [email protected]

Voith Turbo GmbH & Co. KG Retarder Product Group Voithstraße 1 P. O. Box 15 55 D-74555 Crailsheim Telephone 07951 / 32-401, -422, -694 Fax 07951 / 32-756 e-mail: [email protected]

October 1999 Printed in Germany

Operating Instructions Gearbox Retarder System

5

1 Preface

The Operating Instructions submitted contains important information for a safe, proper and economical operation of the gearbox retarder system. The use of the gearbox retarder system as six-speed synchronizer gearbox with integrated hydrodynamic continuous service brake (retarder) is considered as proper use for buses. The directives for proper use of the gearbox retarder system are to be observed strictly by the persons in charge, in particular, by the staff in charge of operation and repair. The user is liable for any hazardous situation and damages resulting from improper use. Observe the information ­ in particular, the safety information, for operation and perform the specified service work in regular intervals and in time using the specified fuels. Only qualified staff is allowed to do the repair and maintenance work. Enter the work performed in the service table provided for this purpose enabling you to claim full warranty. Use only original spare parts in the event of a repair, cause only this guarantees that your gearbox retarder system meets the traffic safety and the design standard on shipment. For the purpose of technical development of our products and to maintain the progress, we reserve the right for modification of the system illustrated in this instruction manual and for the applicable technical information and form.

October 1999 - VOITH TURBO / DaimlerChrysler

6

Operating Instructions Gearbox Retarder System

Table of Contents 1. 2. 3. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 System Identification

3.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.2 Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.3 Retarder control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4. 5. 6.

Illustrations Gearbox Retarder System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 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

Operating Instructions Gearbox Retarder System

3

Table of Contents 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. 10.

Service Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4

Operating Instructions Gearbox Retarder System

Safety Information 2

To guarantee sound operation of the gearbox retarder system and to exclude any risks due to improper handling, please read and follow the safety information mentioned on this and the next page as well as in each chapter! The safety symbols are explained below:

Warning! Precautions and safety rules protecting persons from injuries 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.

Operating Instructions Gearbox Retarder System

7

2 Safety Information

Warning! Unauthorized modifications on the gearbox retarder system and the use of spare parts, accessories, attachments and special equipment not tested and released by us, may have a negative effect on the safety of the complete vehicle, for which liability is excluded for any resulting damages. When in contact with oils, greases and other chemical substances, e.g. retarder oil, observe the safety regulations applicable to these products. Be cautious when you are in contact with hot operating fluids! Danger of burning or scald! In case of unsafe road conditions (slick ice, snow, gravel etc.) or risk of aquaplaning operate the retarder carefully and gradually only. In an extreme case, leave the retarder switched off! Observe these precautions, in particular, for vehicles without ABS system! Switch off the retarder main switch (if available - see vehicle manual) for vehicles without ABS system. For empty running vehicles or vehicles without body (e.g. transfer) operate the retarder carefully! The switched-on retarder will not lock or secure the parked vehicle! In the event of retarder failure or when the temperature control is effective (see page 20), use the service brake to adapt the vehicle speed.

8

Operating Instructions Gearbox Retarder System

Safety Information 2

The gearbox retarder system is manufactured to the latest design standards and approved safety regulations. Nevertheless, hazards and damage to property may occur in case of improper use. The user/owner has the obligation to always operate the system in sound condition. In case of malfunctions, observe the relevant information. We will not assume liability for injuries and/or damage to property, resulting from non-observance of the safety information, instruction manual or violation of the duty of care in handling, operation, maintenance and repair of the retarder. We are not in the position to give explicit warnings everywhere in this instruction manual, in case of any thinkable 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 mode of operation and that it has no negative effect on the gearbox retarder system, in particular, with regard to the safety. We are not liable for personal injury and/or damage to property caused by improper and unprofessional operation. Together with the vehicle instruction manual, the instruction manual must always be available at the site where the vehicle is in service. An incomplete or illegible instruction manual should to be replaced immediately. The relevant regulations for the prevention of accidents, the other safety engineering and industrial medicine rules generally approved as well as the Road Traffic Act are to be observed. We are not liable for damages originating from disregarding these regulations.

Operating Instructions Gearbox Retarder System

9

2 Safety Information

Do not start the vehicle without oil in gearbox and/or retarder. In the event of a gearbox failure it is necessary to remove the cardan shaft or the two axle stub shafts prior to towing the vehicle. The openings then need to be covered according to the vehicle manufacturer's specifications.

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Operating Instructions Gearbox Retarder System

System identification: gearbox 3.1

The gearbox identification (nameplate) is located on the side of gearbox retarder system, i.e. on the right-hand side in driving direction, with the following data (example):

unit series design LHD vehicle 71 4. 692 L

gear ratio 1st gear number of gears input torque (x 10) gearbox bus

GO 170 - 6 / 8,2

DAIMLERCHRYSLER

Bez. Code GO 170-6/8,2 G 714.100 L Fortl. Nr.

gearbox number gearbox part number

DAIMLERCHRYSLER

Bez. Code Fortl. Nr.

M-Code Variante Nr.

M+P-07A-1704a

M-Code Variante Nr.

Please enter the gearbox data, indicated on your gearbox retarder system, on the left-hand side nameplate. Please let us know these data in the event of any queries or spare parts orders.

M+P-07A-1705

Operating Instructions Gearbox Retarder System

11

3.2 System identification: retarder

The retarder identification (nameplate) is located on the gearbox retarder system, on the bottom right-hand side (front) in driving direction, with the following data:

Retarder transmission(i Ret)

Series number (brake number) 6-digit number

000000

KW/Jahr

45/1999

Year of manufacture

Voith part number 8-digit number

DaimlerChrysler part number

M+P-07A-1706a

Serial-No

CW/Year

Please enter the retarder data, indicated on your gearbox retarder system, on the left-hand side nameplate. Please let us know these data in the event of any queries or spare parts orders.

M+P-07A-1707

12

Operating Instructions Gearbox Retarder System

System identification: retarder control unit 3.3

The Digiprop control unit identification (nameplate) is located on the control unit, with the following data: 1. Voith number 8-digit number It is possible to derive the software version from the last two digits. Example: .12 = version 1.2 2. Code number 3-digit number (adjustment of control unit) 3. Serial number 5-digit number also indicating the coding date

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

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

Voith-Nr.: Code-Nr.: Serien-Nr.: Kunden-Nr.:

Datum:

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.

Operating Instructions Gearbox Retarder System

13

4 Illustrations Gearbox Retarder System

26/250/047 26/400/089 26/250/068 3700

26/100/116 Screw plug oil screen (demounting height 120 mm) 26/100/122 Oil filler plug gearbox 26/100/125 Oil drain plug gearbox (bottom side) 26/100/206 Tacho signal 26/250/047 Starter interlock switch * 26/250/068 Inductive pickup for overspeed protection * 26/400/083 Oil temperature sensor gearbox * 26/400/089 Backup lamp switch * 3500 Screw plug with screen 3700 Proportional valve retarder control

* = optional

26/100/125

26/100/122

26/100/125

3500

26/400/083

26/100/116

26/100/206

M+P-07A-1708

Side view

14

Operating Instructions Gearbox Retarder System

Illustrations Gearbox Retarder System 4

25/250/068 26/150/ 26/250/ 26/250/047 26/250/068 26/350/ 26/400/089 3700 4100 6400 Clutch booster Input shaft Clutch wear indicator * Starter interlock switch * Inductive pickup for overspeed protection * Gearshift shaft Backup lamp switch * Proportional valve retarder control Oil filler plug retarder Heat exchanger retarder

26/350/

4100

6400

3700

* = optional

26/150/ 25/250/068 26/250/047 26/250/068 26/400/089

M+P-07A-1710

26/250/

Top view

Operating Instructions Gearbox Retarder System

15

4 Illustrations Gearbox Retarder System

100/1 3500 5500 6400 6400/1

100/1 26/100/125 107 3500 4200 5500 6400 6400/1 6400/2 Nameplate Oil drain plugs gearbox Oil drain plug retarder (system) Screw plug with screen Oil drain plugs retarder Retarder ventilation Heat exchanger retarder Water return connection (example) Water supply connection (example)

6400/2 4200 107 26/100/125 26/100/125

M+P-07A-1709

16

Operating Instructions Gearbox Retarder System

General description 5

As special version, the retarder stage switch may additionally combined in connection with ABS-system, with a 3- or 4-stage pedal-actuation via the brake valve or a pressure switch unit of the vehicle service brake.

Warning! The switched-on retarder will not secure the parked vehicle!

Note The retarder braking torque is sustained even when gear changes are made! The gearbox retarder system is a six-speed synchromesh gearbox, with a hydrodynamic continuous service brake (retarder), integrated in the gearbox housing, for buses with a permissible total weight up to 24 tons. The connection from gearshift lever to gearbox is made through linkage or Bowden cables. The retarder stage switch can be used for control of 5 brake stages - from position 2 to 5 with increasing brake force. The function of position 1 is ,,constant speed" (control to constant speed).

Operating Instructions Gearbox Retarder System

17

6.1 Operation: gearbox

Warning! Prior to starting the vehicle engine, push the gearshift lever into idle position (L)!

R

1

3 L

5

Caution! 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 controls. Observe that any additional floor mats have a good contact to the floor and are not getting in contact with the pedals. Shift without using any force.

M+P-07A-1711

2

4

6

Shift to reverse gear (R) only at engine idle speed and parking vehicle. It is possible to use a vehicle-specific warning buzzer and/or a warning lamp, if a too low gear was used for downshift. Danger of engine overspeed! Shift to a higher gear!

18

Operating Instructions Gearbox Retarder System

Operation: gearbox 6.1

Operate the clutch pedal to change gears and move the gearshift lever to a position as illustrated in the scheme on page 18. Shift the lever from idle position (L) to the left front to change to reverse gear.

Note When driving observe the tachometer and the economical range. Drive in the highest gear (before downgrades shift in due time to reverse gear). Prior to retarder braking shift to the lowest possible gear to reach engine rated speed (see chapter 6.2.1: "Retarder operation ­ temperature limit"). Skip the gears, if possible, and change gears only, if required.

Operating Instructions Gearbox Retarder System

19

6.2.1 Operation retarder: temperature limit

During braking with the retarder integrated in the gearbox, deceleration is converted into heat. To dissipate this heat, part of the oil in the working chamber is pumped continuously by the rotor through a heat exchanger and fed back into the retarder circuit. In the heat exchanger the heat of oil is transferred to the vehicle cooling water and dissipated through the vehicle cooling system. The cooling water and oil temperature are monitored by one temperature sensor each transmitting this information to the retarder control unit. This guarantees that the maximum permissible temperatures for cooling water and oil are not exceeded. The control unit includes vehicle-specific cooling water oil temperature limit settings. To prevent that these temperature limits are exceeded during retarder operation, the retarder braking torque is adapted optimally for protection and effective utilization of vehicle cooling system and retarder. With already significantly reduced braking torque the retarder pilot light starts flashing. Caution! Observe the following when the retarder pilot light is flashing or the temperature limit is effective: Adjust the vehicle speed using the service brake and change to the lowest possible gear (increase the engine speed). Keep this driving condition until the retarder regained its full power.

20

Operating Instructions Gearbox Retarder System

Operation retarder: temperature limit 6.2.1

By driving or operating the retarder properly you can increase and/or secure the vehicle cooling capacity and thus the availability of the retarder. How? ­ On retarder braking shift the gearbox down to reach engine rated speed! Thus: ­ High delivery rate of water pump ­ High fan speed

25 30 u/pm

M+P-07A-1624

15 10

20

Result: ­ It is possible to make optimum use of the vehicle cooling system performance! Fuel consumption is not affected by the high engine speed, as the throttle of the fuel injection system is closed when the engine is in overrun.

1 2 3 4 5

M+P-07A-1624

Operating Instructions Gearbox Retarder System

21

6.2.2 Operation retarder:

functions and indications of retarder stage switch, retarder pilot light

M+P-07A-1590

A Retarder pilot light (vehicle-specific installation site) B Retarder stage switch (vehicle-specific installation site) 0 Retarder OFF 1 Constant speed 2 Brake stage 1 3 Brake stage 2 4 Brake stage 3 5 Brake stage 4

A

B 0 1 2 3 4 5

Caution! Operate the retarder stage switch only step-by-step to reach the required braking torque (do not ,,force through")! In an emergency situation a ,,force through" of the retarder stage switch is permitted. To reduce the actual braking torque, several stages can be left out at once with the retarder stage switch.

M+P-07A-1590

22

Operating Instructions Gearbox Retarder System

Operation retarder: functions and indications of retarder stage switch, retarder pilot light 6.2.2

The retarder pilot light has the additional function of fault indication to be able, in the event of a fault, to also find the fault in the electronic system without service unit. Display of a fault, which may exist, is possible by a flash code.

Note In case of very low outside temperatures the braking action on first retarder braking starts with a response delay after starting to drive. For vehicles with zero gas switch the "constant speed" function or the active brake stage is cleared on application of the gas pedal. After releasing the pedal, the new momentary ,,constant speed" is stored or the previously applied brake stage is reactivated. For vehicles with cruise control it is possible to clear cruise control automatically, dependent on the equipment, by operating the ,,constant speed" function".

Caution! Only qualified staff is allowed to activate the flash code and to perform any repair work which might be necessary.

Operating Instructions Gearbox Retarder System

23

6.2.2 Operation retarder:

functions and indications of retarder stage switch, retarder pilot light

0 1 2 3 4 5

OFF (symbol for retarder pilot

light may differ from vehicle to vehicle)

0 1 2 3 4 5

Ignition ON

Light test: Retarder pilot light 5 sec. steady light

0

Steady light position 0 to 5 Minor fault: Retarder brakings partly possible with reduced braking torque. Consult a specialized workshop!

0 1 2 3 4 5

Steady light: ,,constant speed"

5

1 2 3 4

0 1 2 3 4 5

Steady light: Brake stages 1 to 4

Steady light position 0 to 5 Major fault: Retarder braking no longer possible ­ the retarder is switched off. Only continue driving with considerably reduced speed - consult immediately a specialized workshop!

0 1 2 3 4 5

Flash light: Temperature limit

24

Operating Instructions Gearbox Retarder System

Operation retarder: ,,constant speed" function 6.2.3

M+P-07A-1618

0 1 2 3 4 5

1 Adjust the speed.

1

0

2

5

1 2 3 4

6%

2 At the desired speed switch on ,,constant speed". The retarder keeps this vehicle speed constant within maximum braking torque. Should the vehicle accelerate in spite of ,,constant speed", it is necessary to apply the service brake in addition. Continued shifting to gear stage 5 does not increase the braking action. When leaving the ,,constant speed" lever position, the automatic control is cleared immediately.

10 km

3 Switch off the retarder or adjust to the traffic situation using a brake stage.

0 1 2 3 4 5

M+P-07A-1618

3

Operating Instructions Gearbox Retarder System

25

6.2.4 Pedal Operation

M+P-07A-1591

3 B

2 1 A

A B 1 2 3

Retarder Retarder and Service Brake Brake Stage 1 * Brake Stage 2 * Brake Stage 3 *

* The operated brake stages via the pedal operation normally are identical with the brake stages operated via the hand operation.

M+P-07A-1591

26

Operating Instructions Gearbox Retarder System

Pedal Operation 6.2.4

The retarder is operated via a 3-stage or 4-stage pedal operation of the service brake. The maximum braking torque will be reached in the maximum position. Pedal plate in position 0: The retarder is switched off­ the retarder pilot light is without indication. Pedal plate in position 1 to 3 or 1 to 4 The brake stages 1 to 3 or 1 to 4 are tuned accordingly ­ the light of the retarder pilot light comes on continuously.

Note The graphic shows the 3-stage variant, a 4-stage variant also is possible. The main switch ,,Pedal Operation ON-OFF" is located at the dashboard. ON: The retarder is ready to operate OFF: i.e. at unsafe road conditions The higher braking torque is valid with combined handor pedal-operation in each case. In case of low temperatures outdoors, the braking effect starts late when braking the first time after starting the vehicle. The function ,,Constant Speed" can not be selected via the pedal plate.

Operating Instructions Gearbox Retarder System

27

6.2.4 Pedal Operation

Special functions at combined Hand-, pedal operation (without pushbutton for function ,,Constant Speed") Retarder stage switch in position 1 ­ ,,Constant Speed", Pedal plate in position 1: The function ,,constant speed" will be cancelled, if first selected in position 1 with the retarder stage switch and than operated to the retarder via the pedal plate. After releasing the pedal plate the new momentary speed will be memorized, assumed that the retarder stage switch stays unchanged in position 1 ­ the light of the retarder pilot light comes on continuously. The following operation conditions can be indicated additionally by the retarder pilot light: Without Indication: The retarder is switched off, no fault. Retarder Pilot Light flashing - when retarder is operated: The temperature limitation is effective ­ the retarder reduces its braking torque. Therefore read the notes on pages 20 to 21! Retarder Pilot Light on continuously - at testing the light: When vehicle ignition is switched on for approx. 5 secs. - in Position 0 to 3 or 0 to 4 (minor fault): Retarder brakings partly possible with reduced braking torque. Contact specialized work shop!

28

Operating Instructions Gearbox Retarder System

Pedal Operation 6.2.4

- in Position 0 to 3 or 0 to 4 (serious fault): Retarder brakings are not possible any longer ­ the retarder is switched off. Continue driving only with clear reduced speed ­ contact immediately specialized work shop! The retarder pilot light has the additional function of error indication. The retarder pilot light enables a troubleshooting in the electronic system without using the service unit. The indication of an error can be realized by the flash code of the retarder pilot light.

Caution! The activation of the flash code as well as maintenance works must be carried out only by qualified and specialized personnel.

Operating Instructions Gearbox Retarder System

29

7.1 Maintenance: maintenance works / oil change intervals

Maintenance works The following works are to be performed on each oil change (gearbox and retarder): ­ ­ ­ ­ ­ clean oil screen (gearbox) Clean screen for pressure control valve (retarder) check fastening screws on retarder heat exchanger check all screw plugs for leaks and proper seat visual inspection for any damages and leaks which might exist

Please enter the following data in the service overview of these operating instructions: ­ performed maintenance works ­ used oil type for oil change

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Operating Instructions Gearbox Retarder System

Maintenance: maintenance works / oil change intervals

Gearbox Mineral oil 1) Normal duty Heavy duty 100 000 km 4) 50 000 km 4) Synthetic oil 1) 300 000 km 5) 300 000 km 5) Mineral oil 2) 100 000 km 4) 50 000 km 4) Retarder 6) Synthetic oil 2) 300 000 km 5) 300 000 km 5)

7.1

Synthetic oil 3) 300 000 km 5) 300 000 km 5)

1) 2) 3) 4)

according to fuel specification, page 48-51 according to fuel specification, page 52-54 according to fuel speciflication, page 54 If the specified operating performance is not achieved within 1 year, it is necessary to change the oil. 5) If the specified operating performance is not achieved within 2 years, it is necessary to change the oil. 6) The oil change intervals of the retarder oils, listed under 2), may be adjusted to the oil change intervals of the gearbox mineral oils.

Operating Instructions Gearbox Retarder System

31

7.1 Maintenance: maintenance works / oil change intervals

1. ,,Normal duty" Example: ­ long-distance traffic 2. ,,Heavy duty" Duties exceeding the normal limit. Examples: ­ Applications in regions with high outside temperatures (e.g. Saudi Arabia) ­ High permissible total weight at low rated engine power (< 8 PS/ton) ­ Frequent uphill/downhill roads ­ Extremely short distances with many road downgrades It is possible to fall below the specified maximum values, if this results in an improvement of operating sequences relative to the overall maintenance of vehicle. In case of a total service life of retarder of more than 10 %, relative to the vehicle operating performance as well as other factors, not mentioned in here, also affecting the aging of retarder oil, it is necessary to shorten the specified oil-changing intervals individually. In case of application in extremely cold zones, use oils of corresponding low viscosity. In case of doubt, please consult our Service Department.

32

Operating Instructions Gearbox Retarder System

Maintenance: gearbox oil level check 7.2

26/100/122 26/100/128

M+P-07A-1716

26/100/122 Oil filler plug Inbus, w.a.f. 14 ............................. TA = 47 N 26/100/128 Sealing ring A24x29 ...................... renew

Operating Instructions Gearbox Retarder System

33

7.2 Maintenance: gearbox oil level check

Note Four sound function of gearbox it is important to adhere the specified oil service filling and that only oils are used released by the fuel specification, chapter 7.1: ,,Oil change intervals" and chapter 8.1: ,,Fuel specification ­ gearbox oil specification". 1. Screw out the oil filler plug (26/100/122) and remove the sealing ring (26/100/128). The oil level is correct when it reached the bottom edge of taphole (see illustration page 32). 2. Fill in slowly any lacking oil through the hole of oil filler plug according to fuel specification, chapter 7.1: ,,Oil change intervals" and chapter 8.1: ,,Fuel specification ­ gearbox oil specification".

Note Check the oil with the vehicle in horizontal position. For oil level check, the gearbox oil must have working temperature.

Note In the event of any lacking oil, check the gearbox for a possible external leak. 3. Screw in the oil filler plug with a new sealing ring and tighten it. Oil filler plug (26/100/122): 47 Nm

Warning! Oil filler plug (26/100/122) is hot (oil temperature)!

34

Operating Instructions Gearbox Retarder System

Maintenance: retarder oil level check 7.3

4100

4200 107

109

M+P-07A-1713

M+P-07A-1712

109 Oil check plug Inbus, w. a. f. 12 ............. TA = 65 Nm (80 Nm) 4100 Oil filler plug Inbus, w. a. f. 17 ............. TA = 100 Nm (150 Nm)

107 Oil drain plug Inbus, w. a. f. 12 ............. TA = 65 Nm (80 Nm) 4200 Oil drain plugs Inbus, w. a. f. 12 ............. TA = 65 Nm (80 Nm)

Operating Instructions Gearbox Retarder System

35

7.3 Maintenance: retarder oil level check

Caution! For sound retarder operation it is important to adhere the specified oil level of 7.0 liters and to only use oils released by the fuel specification, chapter 7.1: ,,Oil change intervals" and chapter 8.2: ,,Fuel specification ­ retarder oil specification". Caution! There are two possible variants of the screw plugs (107, 4100, 4200): A) with integrated FPM-sealing ring; corresponding standard design on printing Performing the oil level check, the integrated sealing rings have to be checked for any damage; replace the complete screw plug, if necessary. B) variant with copper sealing ring attached as loose part. In these operating instructions exclusively the variant A (standard design) is described. For screw plugs with copper sealing rings attached as loose part (variant B) the tightening torques given in brackets are valid. The copper sealing rings are to be replaced generally.

Note Check the oil level with the vehicle in horizontal position. For oil level check, the retarder oil must have operating temperature.

36

Operating Instructions Gearbox Retarder System

Maintenance: retarder oil level check 7.3

Two variants are available for selection of oil level check: A. Volumetric measuring method 1. Put a clean oil collecting pan under the retarder. 3. Check the integrated sealing rings of the oil drain plugs (107, 4200) for any damage; replace the oil drain plugs, if necessary. 4. Screw the oil drain plugs tight. Oil drain plugs (107, 4200): 65 Nm (80 Nm) 5. Measure the volume of drained oil. 6. Add the lacking oil which you might determine during volumetric measurement according to the fuel specification, chapter 7.1: ,,Oil change intervals" and chapter 8.2: ,,Fuel specification ­ retarder oil specification". 2. Remove the oil drain plugs (107, 4200) and drain the oil into the oil collecting pan.

Warning! The oil drain plugs (107, 4200) and oil filler plug (4100) are hot (oil temperature)! While the oil level is being checked, make sure that no constant-air pressure is acting in the retarder. The retarder and the ignition must have been switched off!

Operating Instructions Gearbox Retarder System

37

7.3 Maintenance: retarder oil level check

Note Should you detect a lack of oil fill, check the retarder for a possible external leak. Caution! After the oil level check engage the retarder during driving 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. 8. Check the integrated sealing ring of the oil filler plug (4100) for any damage; replace the oil filler plug, if necessary. 9. Screw the oil filler plug tight. Oil filler plug (4100): 100 Nm (150 Nm)

38

Operating Instructions Gearbox Retarder System

Maintenance: retarder oil level check 7.3

B. Using the oil check plug 1. Vehicle ignition ,,OFF", then rest to ,,ON". 2. Operate the retarder at standstill in braking stage 2 (corresponds to braking stage 1) and switch it off after approx. 5 secs. Repeat this procedure twice. 3. Switch off the retarder and wait for 5 minutes. Caution! Warning! The oil check plug (109) and oil filler plug (4100) are hot (oil temperature)! While the oil level is being checked, make sure that no constant-air pressure is acting in the retarder. The retarder and the ignition must have been switched off! The retarder may only be filled through the hole for the oil filler plug (4100)! 5. Fill in any lacking oil slowly through the hole for the oil filler plug (4100) according to fuel specification, chapter 7.1: ,,Oil change intervals" and chapter 8.2: ,,Fuel specification ­ retarder oil specification". 4. Unscrew the oil check plug (109). The oil level is correct when it reached the lower edge of the oil check hole (see illustration page 35).

Note In the event of any lacking oil, check the retarder for a possible external leak.

Operating Instructions Gearbox Retarder System

39

7.3 Maintenance: retarder oil level check

6. Check the integrated sealing ring of the oil level check plug for any damage; replace the oil level check plug, if necessary. 7. Screw the oil check plug tight. Oil check plug (109): 65 Nm (80 Nm) 8. Check the integrated sealing ring of the oil filler plug for any damage; replace the oil filler plug, if necessary. 9. Screw the oil filler plug tight. Oil filler plug (4100): 100 Nm (150 Nm)

40

Operating Instructions Gearbox Retarder System

Maintenance: gearbox oil change 7.4

26/100/128 26/100/122 26/100/116 26/100/119 26/100/107 26/100/113

26/100/107 Oil screen.......................................clean 26/100/113 Spring 26/100/116 Screw plug oil screen.....................TA = 60 Nm Inbus, w.a.f. 17 26/100/119 Sealing ring A38x46.......................replace 26/100/122 Oil filler plug ..................................TA = 47 Nm Inbus, w.a.f. 14 26/100/125 Oil drain plugs ...............................TA = 47 Nm Inbus, w.a.f. 14 26/100/128 Sealing ring A24x29.......................replace

26/100/128 26/100/125

26/100/128 26/100/125

M+P-07A-1715a

Operating Instructions Gearbox Retarder System

41

7.4 Maintenance: gearbox oil change

1. Put a clean oil collecting pan under the gearbox. Warning! Dispose of drained oil in a professional manner! Observe the statutory provisions!

Warning! Oil drain plugs (26/100/125) are hot (oil temperature)! 2. Unscrew the oil drain plugs (26/100/125), remove the sealing rings (26/100/128) and drain the oil. 3. Screw the oil drain plugs tight with new sealing rings. Oil drain plugs (26/100/125): 47 Nm 4. Unscrew the screw plug (26/100/116) and remove the sealing ring (26/100/119).

Caution! For sound gearbox function it is important to observe the specified oil fill and to only use oils released by the fuel specification, chapter 7.1: ,,Oil change intervals" and chapter 8.1: ,,Fuel specification ­ gearbox oil specification".

Note For draining the gearbox oil must have operating temperature. Oil fill ­ Service fill (oil change) ................................ 12.5 liters ­ Initial fill .......................................................13.0 liters

42

Operating Instructions Gearbox Retarder System

Maintenance: gearbox oil change 7.4

5. Clean oil screen (26/100/107) using a corresponding cleaning agent (benzine) and blow out using compressed air. Check the cleaned oil screen for damage and replace it, if necessary. 6. Screw oil screen (26/100/107) with spring (26/100/ 113) in the hole of the screw plug (26/100/116). 7. Screw the screw plug (26/100/116) with new sealing ring (26/100/119) tight. Screw plug with oil screen (26/100/116): 60 Nm 8. Unscrew oil filler plug (26/100/122) and remove the sealing ring (26/100/128). 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

Operating Instructions Gearbox Retarder System

43

7.5 Maintenance: oil change of retarder

4100

4200 107

3500

M+P-07A-1714a

M+P-07A-1712a

3500 Screw plug with screen Inbus, w.a.f. 17.................. TA = 100 Nm (150 Nm) 4100 Oil filler plug Inbus, w.a.f. 17.................. TA = 100 Nm (150 Nm)

107 Oil drain plug Inbus, w.a.f. 12 ..................TA = 65 Nm (80 Nm) 4200 Oil drain plugs Inbus, w.a.f. 12 ..................TA = 65 Nm (80 Nm)

44

Operating Instructions Gearbox Retarder System

Maintenance: retarder oil change 7.5

Warning! Dispose of drained oil in a professional manner! Observe the statutory provisions!

Caution! There are two possible variants of the screw plugs (107, 3500, 4100, 4200): A) with integrated FPM-sealing ring; corresponding standard design on printing Performing the oil level check, the integrated sealing rings have to be checked for any damage; replace the complete screw plug, if necessary. B) variant with copper sealing ring attached as loose part. In these operating instructions exclusively the variant A (standard design) is described. For screw plugs with copper sealing rings attached as loose part (variant B) the tightening torques given in brackets are valid. The copper sealing rings are to be replaced generally.

Caution! For sound retarder operation it is necessary to adhere the specified oil fill, see below. It is only allowed to use oils released by the fuel specification, chapter 7.1: ,,Oil change intervals" and chapter 8.2: ,,Fuel specification ­ retarder oil specification"!

Note For draining the retarder oil must have operating temperature! Oil fill ­ Service fill (oil change) ................................. 7.0 liters ­ Initial fill ....................................................... 7.8 liters

Operating Instructions Gearbox Retarder System

45

7.5 Maintenance: oil change of retarder

1. Put a clean oil collecting pan under the retarder. 5. Unscrew the screw plug with screen (3500) out of the retarder housing. 6. Clean the screen in the screw plug using a corresponding cleaning agent (benzine) and blow it out using compressed air. 7. Check the integrated sealing ring of the screw plug with screen for any damage; replace the screw plug, if necessary. 8. Screw the screw plug with screen tight. Screw plug with screen (3500): 100 Nm (150 Nm) 9. Unscrew the oil filler plug (4100).

Warning! The oil drain plugs (107, 4200) are hot (oil temperature)! While the oil is being drained, make sure that no constant-air pressure is acting in the retarder. The retarder and the ignition must have been switched off! 2. Remove the oil drain plugs (107, 4200) and drain the oil. 3. Check the integrated sealing rings of the oil drain plugs for any damage; replace the oil drain plugs, if necessary. 4. Screw the oil drain plugs tight. Oil drain plugs (107, 4200): 65 Nm (80 Nm)

46

Operating Instructions Gearbox Retarder System

Maintenance: retarder oil change 7.5

Caution! The retarder may be only filled through the hole of the oil filler plug (4100)! 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. 11.Check the integrated sealing ring of the oil filler plug (4100) for any damage; replace the oil filler plug, if necessary. 12.Screw the oil filler plug tight. Oil filler plug (4100): 100 Nm (150 Nm)

Caution! After the oil lchange engage the retarder during driving 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).

Operating Instructions Gearbox Retarder System

47

8.1 Fuel specification: gearbox oil specification

Warning! Hazard of intoxication! Fuels are harmful to the health! Consult a physician immediately after swallowing fuel! Keep fuels away from children! Mineral oil for gearbox application SAE 80, 80W, 80W/85W

Oil type

Addinol Gearbox Oil GS Agip Rotra Hy DB Antar EP Aral Gearbox Oil EP Armorine BM Aseol Gepress 11-508 Autol Gearbox Oil D8 Avia Gear Oil MZ Aviaricon Gold MZ BayWa Multipurpose Gearbox Oil BP Energear EP BP Energear FE GL4 BP Gear Oil EP

Supplier

Addinol Mineral Oil, Krumpa Agip Petroli, Rom/Italy Elf Lubrifiants, Paris/France Aral Lubricants, Bochum Armorine, Lanester Cedex/ France Shell Aseal, Bern/Switzerland Agip Schmiertechnik, Würzburg Avia Mineralöl, Munich Emil Finke Mineralölwerk, Bremen BayWa, Munich BP Oil International, London/GB BP Oil International, London/GB BP Oil International, London/GB

48

Operating Instructions Gearbox Retarder System

Fuel specification: gearbox oil specification 8.1

Mineral oil for gearbox application SAE 80, 80W, 80W/85W

Oil type Supplier Oil type

Ertoil Transmissiones F Esso Gear Oil GP-D Fina Pontonic N Frontol Gearbox Oil MZ M Fuchs Titan Gear MP Galp Transoil Geartex EP-A Gulf Gear Lubricant (EP) Gulf Ultragear 4000 (GB) H.o.B. Gearbox Oil ML Hafa MPB Homberg Gearbox Oil MZ

Supplier

Ertoil, Madrid/Spain Esso, Hamburg Fina Europe, Brussels/Belgium BP Schmierstoff, Hamburg Fuchs Mineralölwerke, Mannheim Petroleos de Portugal, Petrogal, Lisbon/Portugal Texaco Services (Europe), Brussels/Belgium SAEL, Madrid/Spain Gulf Oil (GB), Cheltenham/GB H. o.. Burrenkopf, Cologne Hafa, Paris/France J. & A. Homberg, Wuppertal

Calpam Mineralöl-Gesellschaft, Calpam Multipurpose Gear Oil Aschaffenburg Caltez Universal Gear Oil HD Carrier Hykomol Castrol EP Condat Gear A CS 80 M-EP Deagear EP-A Dearon EP-A Deutz Oil GO-MP Divinal Multipurpose Gearbox Oil Dragon Gear TM Ellmo-Multipurpose Gearbox Oil Engen Gearlube HP Caltez (UK) Limited, London/GB MOL Hungarian Oil and Gas Co., Kornárom/Hungary Castrol, Swindon/GB Condat, Chasse-sur Rhône/France Repso Distribución, Madrid/Spain DEA Mineralöl, Hamburg DEA Mineralöl, Hamburg Klöckner Energiehandel, Cologne Zeller+Gmelin, Eislingen Ssang Yong Oil Refining, Seoul/Rep. of Korea Eller-Montan-Comp., Duisburg Engen Petroleum, Cape Town/South Africa

Hyperol Multipurpose Gearbox Hyperol Mineralöl-Vertrieb, Stuttgart Oil Igol Trans EPA Igol France, Paris/France

Operating Instructions Gearbox Retarder System

49

8.1 Fuel specification: gearbox oil specification

Mineral oil for gearbox application SAE 80, 80W, 80W/85W

Oil type

Ina Transmol DB IP Pontiax DB Kompressol Multipurpose Gearbox Oil Leprinzol SP Mac MP Gearbox Oil megol Multipurpose Gearbox Oil GL4 MHG Manual Gearbox Oil EP Mobilube GX-A Motorex Gear Oil EP Neste Gear EP

Oil type

Orly XP Luna P. O. Keban EP MB Panolin EP Gear GL4 Parnas Parnalube GP Pennasol Multipurpose Gearbox Oil GL4 Petrol Transol GL4 Petramin Gear Oil MB Q8 T 35 Raloy Transmission EP Rexol MBG Rored EPA

Supplier

Orly International, Vieux-Thann/France Petrol Ofisi, Bakanlikar-Ankara/Turkey Panolin, Madetswill/Switzerland Parnas/Saksan, Athens/Greece Mineralöl-Raffinerie Dollbergen Petrol d. d., Ljubljana/Slovenia Petramin Lubricating Oil, Jeddah/Saudi Arabia Kuwait Petroleum, Hoogvliet RT/Netherlands Raloy Lubricantes, Santiago Tianguistenco/Mexico Ryazan Oil Refinery, Ryazan/Russia Pertamina, Jakarta/Indonesia

Supplier

INA Rafinerija Zagreb, Zagreb/Croatia Italiana Petroli, Genova/Italy Kompressol-Öl, Cologne Leprince & Siveke, Herford Deutsche Shell, Hamburg Meguin, Saarlouis MHG, Sulzbach-Rosenberg Mobil Schmierstoff, Hamburg Bucher, Langenthal/Switzerland Neste Oy Lubrication, Espoo/Finland

Oest Multipurpose Gearbox Oil Oest Mineralölwerke, Freudenstadt OMV Gear Oil MP Optimol Multipurpose Gearbox Oil OMV, Vienna/Austria Optimol Ölwerke Industrie GmbH, Munich

50

Operating Instructions Gearbox Retarder System

Fuel specification: gearbox oil specification 8.1

Mineral oil for gearbox application SAE 80, 80W, 80W/85W

Oil type

Selectol Multipurpose Gearbox Oil Shell Spirax MA Sonolgear DBM Spirol XEP Tor Multi Purpose Gearbox Oil Total EP Tranself EP Triathlon Gear Unil EP Unil Opal Gear EP Valvoline X-18 Veba Movara EP-Gearbox Oil Veedol Multigear Westfalen Grado Gearbox Oil

Oil type

Wintershall Wiolin Multipurpose Gearbox Oil Wisura GL WLZ-Raiffeisen Multipurpose Gearbox Oil York 791 Zenex Gear Oil ZP

Supplier

Schmierstoffraffinerie Salzbergen Wisura Mineralölwerk, Bremen WLZ-Raiffeisen, Stuttgart Ginouves Georges La Farlède/France Zenex Oil, Rivonia/South Africa

Supplier

Käppler, Stuttgart Shell International, London/GB Sonol Israel, Haifa/Israel Bharat Petroleum Corpn., Bombay/India De Oliebron, Zwijndrecht/Netherlands Total Deutschland, Düsseldorf Elf Lubrifiants, Paris/France Würth, Künzelsau Unil Deutschland, Bremen Unil-Opal, Rueil-Malmaison/France Valvoline International Europe, Dardrecht/Netherlands Veba Öl, Gelsenkirchen Veedol International, Swindon/GB Westfalen AG, Münster

Synthetic oil for gearbox application

Oil type

MB 235.11 Manual Gearbox Oil A 001 989 2803 Veedol Synmesh-AT Castrol Syntrans-AT Deagear Synth

Supplier

Daimler-Chrysler AG, Stuttgart Burrmah Oil Technology Burrmah Oil Technology DEA Mineralöl GmbH

Operating Instructions Gearbox Retarder System

51

8.2 Fuel specification: retarder oil specification

For the retarder application authorized oil types must meet the following specification: Classification Single-grade mineral oil 1) Synthetic oil / part-synthetic oil 1) Code as per DIN 51502 HD Viscosity class as per DIN 51511 SAE 10W SAE 20W 20 SAE 30 SAE 0W40 SAE 5W30 SAE 5W40 SAE 5W50 SAE 10W30 SAE 10W40 SAE 75W-80W Performance class API - CC/SF and higher API - CC/SF and higher

HD

Synthetic oil 2)

1)

HC

see page 54

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. Only the synthetic oil documentated on page 54 may be used.

2)

52

Operating Instructions Gearbox Retarder System

Fuel specification: retarder oil specification 8.2

Mineral oil for retarder application SAE 10W, 20W20, 30

Oil type

Agip Diesel Sigma S Agip Motoroil HD Aral Basic Turboral Avia Special HDC Avia Motor Oil HD BP Vanellus C3 Castrol CRD-DB DEA Cronus Super DEA Rigis Elf Performance XC Elf Performance XR Elf Performance 3D Elf Performance Super D Essolube X 301 Essolube X 201 Agip Agip Aral Avia Avia BP Burmah Oil DEA DEA Elf Elf Elf Elf Esso Esso

Warning! Hazard of intoxication! Fuels are harmful to the health! Consult a physician immediately after swallowing fuel! Keep fuels away from children!

Supplier

Operating Instructions Gearbox Retarder System

53

8.2 Fuel specification: retarder oil specification

Mineral oil for retarder application SAE 10W, 20W20, 30

Oil type

Fina Kappa Super Fina Kappa TC SAE 30 Series III Mobil Delvac 1300-Series Extra Cobra Multimiles R/5 mono Rapsol Series 3 SAE 10W Rapsol Series 3 SAE 30 CS Mizar Series 3 SAE 10W CS Mizar Series 3 SAE30 CS Mizar HD SAE 20W Shell Rimula X Monograde Shell Rotella MX Glap Diesel Glap Orion Fina Fina Krafft Mobil Oil Motorex Motorex Multimiles Rapsol Rapsol Rapsol Rapsol Rapsol Shell Shell Sofomil Sofomil

Oil type

Wintershall Rekord 10W SRS SRS SRS Texaco Texaco Total Unocal

Supplier

Supplier

Wintershall Rekord 20W-20 Wintershall Rekord 30 Havoline Motor Oil Ursa Super LA Total rubia S Unocal Firebird HD Motor Oil

Synthetic oil for retarder application SAE 75W-80W

Oil type

Emgard MTF Henkel

Supplier

54

Operating Instructions Gearbox Retarder System

Fuel specification: cooling water quality 8.3

The coolant is a mixture of water and corrosion preventive/antifreeze. For reasons of protection against corrosion and to increase the boiling point it is necessary to keep the coolant the whole year in the cooling system. Change the coolant every three years, as the corrosion protection is deteriorating. Water Water alone is not permitted as coolant, even when antifreeze qualities are not required. However, the water of coolant should meet specific requirements, which frequently, but not always, are fulfilled by drinking water. If the water quality is not sufficient, the water needs treatment. Please contact us if you should need any information.

Warning! Hazard of intoxication! Fuels are harmful to the health! Consult a physician immediately after swallowing fuel! Keep fuels away from children! Prevent that the coolant is lead into the sewerage system. Reuse or dispose it. The statutory or waste water disposal regulations may vary from country to country and need to be observed on disposal of used coolants. Prior to using the coolant observe the safety data sheets and product information of the relevant suppliers.

Operating Instructions Gearbox Retarder System

55

8.3 Fuel specification: cooling water quality

Corrosion preventive/antifreeze To avoid any damage in the retarder cooling system: ­ Use only a corrosion preventive/antifreeze, specifically released by the supplier for aluminium. It is not allowed to use pure glycols. ­ On refill (after loss of coolant) a corrosion preventive/ antifreeze of 50 vol.-% (antifreeze up to -37 °C) must be guaranteed. ­ Do not use more than 55 vol.-% (= max. antifreeze) corrosion preventive/antifreeze. This reduces the antifreeze quality and results in a poor heat dissipation. Mixture ratio of coolant Antifreeze up to °C -37 approx. -45 Water vol.-% 50 45 Corrosion preventive / antifreeze vol.-% 50 max. 55 In exceptional cases, when a corrosion preventive/antifreeze is not available and an antifreeze is not required (for example in tropical climate), it is necessary to use 1 vol.-% = 10 cm3/liters treatment agent. In this case it is necessary to change the coolant every year. Regarding any further information please refer to the Voith cooling water list, which you can obtain from Voith Turbo under Voith Art. No. 67.2224.10.

56

Operating Instructions Gearbox Retarder System

Service Overview 9

kilometer reading.............................. Oil change Gearbox (oil type): Mineral oil Synthetic oil Retarder (oil type): Mineral oil Synthetic oil Oil screen(gearbox) cleaned Screen pressure control valve (retarder) checked Fastening screws on retarder heat exchanger checked Screw plugs checked Visual inspection performed kilometer reading.............................. Oil change Gearbox (oil type): Mineral oil Synthetic oil Retarder (oil type): Mineral oil Synthetic oil Oil screen(gearbox) cleaned Screen pressure control valve (retarder) checked Fastening screws on retarder heat exchanger checked Screw plugs checked Visual inspection performed

Company stamp / Signature Date: ........................................ kilometer reading.............................. Oil change Gearbox (oil type): Mineral oil Synthetic oil Retarder (oil type): Mineral oil Synthetic oil Oil screen(gearbox) cleaned Screen pressure control valve (retarder) checked Fastening screws on retarder heat exchanger checked Screw plugs checked Visual inspection performed

Company stamp / Signature Date: ........................................ kilometer reading.............................. Oil change Gearbox (oil type): Mineral oil Synthetic oil Retarder (oil type): Mineral oil Synthetic oil Oil screen(gearbox) cleaned Screen pressure control valve (retarder) checked Fastening screws on retarder heat exchanger checked Screw plugs checked Visual inspection performed

Company stamp / Signature Date: ........................................

Company stamp / Signature Date: ........................................

Operating Instructions Gearbox Retarder System

57

9 Service Overview

kilometer reading.............................. Oil change Gearbox (oil type): Mineral oil Synthetic oil Retarder (oil type): Mineral oil Synthetic oil Oil screen(gearbox) cleaned Screen pressure control valve (retarder) checked Fastening screws on retarder heat exchanger checked Screw plugs checked Visual inspection performed kilometer reading.............................. Oil change Gearbox (oil type): Mineral oil Synthetic oil Retarder (oil type): Mineral oil Synthetic oil Oil screen(gearbox) cleaned Screen pressure control valve (retarder) checked Fastening screws on retarder heat exchanger checked Screw plugs checked Visual inspection performed

Company stamp / Signature Date: ........................................ kilometer reading.............................. Oil change Gearbox (oil type): Mineral oil Synthetic oil Retarder (oil type): Mineral oil Synthetic oil Oil screen(gearbox) cleaned Screen pressure control valve (retarder) checked Fastening screws on retarder heat exchanger checked Screw plugs checked Visual inspection performed

Company stamp / Signature Date: ........................................ kilometer reading.............................. Oil change Gearbox (oil type): Mineral oil Synthetic oil Retarder (oil type): Mineral oil Synthetic oil Oil screen(gearbox) cleaned Screen pressure control valve (retarder) checked Fastening screws on retarder heat exchanger checked Screw plugs checked Visual inspection performed

Company stamp / Signature Date: ........................................

Company stamp / Signature Date: ........................................

58

Operating Instructions Gearbox Retarder System

Technical Data 10

GO170-6 ­ R 115 E Gearbox input up to [kW] Max. input torque [Nm] (determining factor dependent on application) GO190-6 ­ R 115 E GO210-6 ­ R 115 E

320

1750

1900

2100

Range of gearbox ratio 1. speed 2. speed 3. speed 4. speed 5. speed 6. speed Reverse speed Braking torque to [Nm] / Brake power [kW] Permissible vehicle weight [t]

8,170 4,650 2,790 1,810 1,250 1,000 7,683 3750 / 700

6,528 3,711 2,231 1,443 1,000 0,799 6,136

20 t

24 t

Operating Instructions Gearbox Retarder System

59

10 Technical Data

Gear ratio 1. gear 2. gear 3. gear 4. gear 5. gear 6. gear Reverse gear

GO170-6 ­ R 115 E

8,170 4,650 2,790 1,810 1,250 1,000 7,683

GO190-6 ­ R 115 E

8,170 4,650 2,790 1,810 1,250 1,000 7,683

GO210-6 ­ R 115 E

6,528 3,711 2,231 1,443 1,000 0,799 6,136

60

Operating Instructions Gearbox Retarder System

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