Remove/install retarder

AR43.30-G-0002G

Remove/install retarder

8.6.11



Remove

 Danger!

Risk of injury caused by touching hot retarder and by scalding from hot retarder oil. Risk of injury to skin or eyes caused by retarder oil escaping under high pressure

Do not carry out any work unless retarder is switched off. Wear suitable protective clothing and safety glasses when working on the hot retarder.

AS43.30-Z-0001-01A

1

Drain oil from transmission

AP26.00-G-2601E

2

Drain oil from retarder

AP43.30-G-4301G

3

Remove transmission (11)

 See vehicle operator's manual or repair instructions.

4

Detach clutch housing from transmission (11)

Only on transmission (11) without integral clutch housing.

AR26.30-G-0330G

5

Attach transmission (11) to assembly device

Universal assembly stand GS

Adapter "GSA SKN" for transmission with integral clutch housing

Adapter "GSA SKN 2" for transmission without integral clutch housing

Universal assembly stand GS and adapter, see:

gotis://A_25/35/49_06.0

6

Remove output flange from transmission (11)

AR26.50-G-2000G

7

Detach coolant connection (1) from retarder (10)

8

Remove travel and speed sensor (14)

9

Remove bolts (3, 4)

 Secure the retarder (10) against tilting and support.

Due to the different length identify the bolts (3, 4) in order to avoid mixing up.

10

Remove retarder (10)

 The retarder (10) may only be transported and stored in the position as given by the transport frame ex plant. The retarder drive shaft which is hanging down must not make contact and must be protected against mechanical damage otherwise the retarder (10) or transmission (11) may be damaged

 No tools for levering may be applied to the sealing surfaces of the retarder (10) or transmission (11).

11

Detach O-rings (5) from the transmission (11)

12

Remove bearing outer race (6)

Only carry out if:

 the retarder (10) is replaced,

 the tapered roller bearing (12) is replaced,

 the transmission (11) is replaced.

 Use internal extractor and heat gun.



*000589353300



*000589313300

13

Remove shim (7)

If step 10 has been carried out.

14

Remove gear wheel (13)

 Mark installed position.



Install

15

Install gear wheel (13)

 Observe identification for determining the installation position.

16

Determine thickness of shim (7)

Only carry out if:

 the tapered roller bearing (12) is replaced,

 the retarder (10) is disassembled or replaced,

 the transmission (11) is disassembled or replaced,

 the axial play of the retarder drive shaft has to be adjusted.

 Before installing the retarder (10).

AR43.30-G-0002-02G

*BE43.30-N-1001-01B

Retarder measuring device (H67.322421):

Voith Turbo GmbH & Co. KG,

D-74564 Crailsheim, Germany

17

Insert shim (7)

Only carry out if the shim (7) was removed during work step 13.

18

Press bearing outer race (6) into transmission housing

Only carry out if the bearing outer race (6) was removed during work step 12.

 Use a suitable drift.

If the tapered roller bearing (12) was replaced, the bearing outer race (6) must also be replaced.

19

Clean the sealing surface (8) of the retarder housing and sealing surface (9) of the transmission housing

 The sealing surfaces (8, 9) must be clean, dry and free from grease.

20

Apply sealant to sealing surface (9) of transmission housing

 To apply the sealant, turn the transmission (11) until the sealing surface (9) faces upwards.

*BR00.45-Z-1015-01A

21

Insert O-rings (5) in the transmission (11)

 Replace the O-rings (5) and coat with vaseline.

*BR00.45-Z-1015-06A

22

Position retarder (10) on transmission (11)

 So that the sealing surface (8) of the retarder housing and sealing surface (9) of the transmission housing can be placed on each other congruently two threaded studs must be screwed into the thread shown (arrows). Remove the threaded studs again after attaching the retarder (10).



Threaded studs for mounting the retarder housing

WF58.50-N-4330-03B

23

Screw in screws (3)

 Observe identification on the bolts (3).



*BA43.30-N-1006-01D

24

Screw in screws (4)

 Observe identification on the bolts (4).



*BA43.30-N-1006-01D

25

Move transmission (11) into the horizontal position

26

Install travel and speed sensor (14)



*BA26.19-N-1007-01F

27

Install coolant connection (1) on retarder (10)



*BA43.30-N-1001-01D

28

Install output flange on transmission (11)

AR26.50-G-2000G

29

Install transmission (11).

 See vehicle operator's manual or repair instructions.

30

Fill transmission with oil

AP26.00-G-2601E

31

Fill retarder with oil

AP43.30-G-4301G

32

Conduct a road test

 At the start of a trip switch on the retarder (10) at least three times in order to guarantee internal lubrication.

Number

Designation

Model 000.001
with transmission 714.100/120/140/143/160/161
with Voith retarder R115E

BE43.30-N-1001-01B

End play of retarder drive shaft

mm

0.02

Number

Designation

Transmission 714.100/120/140/143/160/161
in model 000.001

BA26.19-N-1007-01F

Travel and speed sensor on rear transmission cover

M12

Nm

19

M18

Nm

30

M20

Nm

57

Number

Designation

Transmission
714.100/120/140/143/160/161
in model 000.001 with Voith retarder R115E

BA43.30-N-1001-01D

Bolt, coolant connection to heat exchanger of retarder

M8

Nm

30

BA43.30-N-1006-01D

Bolt, retarder to transmission

M10

Nm

58

Number

Designation

Order number

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10

BR00.45-Z-1015-06A

Vaseline

Karl Käppler GmbH & Co. KG, Liebknechtstr. 48,
D-70565 Stuttgart
Tel. +49 711 7868-481
Fax +49 711 7868-489
www.karl-kaeppler.de