Remove/install diaphragms

AR43.30-B-0029THV

Remove/install diaphragms

12.02.16



Remove

Danger!

Risk of injuries by touching the hot retarder and burns with oil from the hot retarder

Carry out the jobs only with the retarder disconnected. When working on a too hot retarder utilize gloves, clothes and protection glasses.

AS43.30-B-0001-01A

Replacement of the diaphragms with the retarder removed from the vehicle

1.1

Remove the retarder (1)

AR43.30-B-0002THV

1.2

Place the retarder (1) on a workbench and secure it adequately

1.3

Remove the proportional valve (Y114)

1.4

Remove the 2/2 way valve (5)

AR43.30-B-0025THV

1.5

Remove the diaphragm housing cover (9)

AR43.30-B-0029-01THV

1.6

Remove the top diaphragm (10)

1.7

Remove the intermediate ring (11)

retarder with Voith code: 153.00177411, 153.00184511, 153.00184811 or 153.00184911

AR43.30-B-0029-02THV

 Pulling device

*715589073300

retarder with Voith code: 153.00177412, 153.00184512, 153.00184812 or 153.00184912

AR43.30-B-0029-02HVB



Intermediate ring on the modified diaphragm housing

retarder with Voith code 153.00177412, 153.00184512, 153.00184812 or 153.00184912

BT43.30-B-0005-01A

1.8

Remove the bottom diaphragm (12)



Install

1.9

Clean the retarder housing (13), the top diaphragm (10), the bottom diaphragm (12) and the intermediate ring (11)

Lubricate lightly.

1.10

Lubricate the retarder housing (13) in the support area of the bottom diaphragm (C).

*BR00.45-B-1006-06A

Install the bottom diaphragm (12)

 The protrusion of the diaphragm (B) must point to the intermediate ring (11). Lubricate the protrusion of the diaphragm (B) after its installation.

*BR00.45-B-1006-06A

1.11

Install the intermediate ring (11)

retarder with Voith code: 153.00177411, 153.00184511, 153.00184811 or 153.00184911.

AR43.30-B-0029-02THV

retarder with Voith code: 153.00177412, 153.00184512, 153.00184812 or 153.00184912.

AR43.30-B-0029-02HVB

*BR00.45-B-1006-06A



Intermediate ring in the modified diaphragm housing

retarder with Voith code 153.00177412, 153.00184512, 153.00184812 or 153.00184912.

BT43.30-B-0005-01A

1.12

Install the top diaphragm (10)

 Lubricate the intermediate ring (11) in the supporting area of the top diaphragm (10).

The protrusion of the diaphragm (A) has to be installed perfectly in the groove of the intermediate ring (11).

*BR00.45-B-1006-06A

After installing the top diaphragm (10), lubricate the supporting area of the diaphragm (9) housing cover.

*BR00.45-B-1006-06A

1.13

Reverse the process for the correct assembly

Diaphragm replacement with the retarder installed on the vehicle



Remove

2.1

Remove the transmission shaft

 Support the transmission shaft on a bracket.

AR41.10-B-0050TA

2.2

Check the oil level in the retarder

Drain the retarder oil, should it be necessary.

AR43.30-B-0024THV

2.3

Remove the 2/2 way valve (5)

AR43.30-B-0025THV

2.4

Remove the diaphragm housing cover ()

AR43.30-B-0029-01THV

2.5

Remove the top diaphragm (10)

2.6

Remove the intermediate ring ()

Valid for retarder with Voith code: 153.00177411, 153.00184511, 153.00184811, 153.00184911.

AR43.30-B-0029-02THV

Remove the intermediate ring

Valid for retarder with Voith code: 153.00177412, 153.00184512, 153.00184812, 153.00184912.

AR43.30-B-0029-02HVB

Intermediate ring in the modified diaphragm housing

BT43.30-B-0005-01A



Install

2.7

Apply six spots of liquid adhesive (17) distributed uniformly on the sealing surfaces of the intermediate ring (11)

Clean the intermediate ring (11), it must be free of oil, grease or residue.

*BR00.45-B-1014-02A

2.8

Position the new bottom diaphragm (12) centered on the intermediate ring (11), press lightly the sealing ball uniformly during 10 to 20 seconds

Important! After this stage, corrections are no longer permitted, if necessary, remove and discard the bottom diaphragm (12), eliminate any residue on the intermediate ring and repeat the process with a new diaphragm.

2.9

Lubricate the entire edge of the sealing ball of the top diaphragm (10) with grease

 The grease must be silicone free and non corrosive.

2.10

Apply six spots of liquid adhesive (16) distributed uniformly on the sealing surfaces of the intermediate ring

2.11

Position the new top diaphragm (10) centered on the intermediate ring (11), press lightly the sealing ball uniformly during 10 to 20 seconds

Important! After this stage, corrections are no longer permitted, if necessary, remove and discard the top diaphragm (10), eliminate any residue on the intermediate ring and repeat the process with a new diaphragm.

2.12

Lubricate the entire edge of the bottom diaphragm (12) with grease

The grease must be silicone free and not corrosive.

2.13

Lubricate the sealing O-ring (14) and assemble on the intermediate ring (11)

2.14

Insert the assembled assembly(18) in the retarder housing (13)

 Observe the position and assembly order (18).

2.15

Utilize two M10 screws for the correct positioning (19) of the sealing plate (15) and of the diaphragm housing cover (9)

2.16

Reverse the process for the correct assembly

Número

Denominação

Chassis 958 with CODE BA1

BA43.30-B-1009-01E

Membrane in the retarder housing

Pre-tightening

Nm

17

Final tightening

50

BA43.30-B-1017-01E

Valve block

Nm

22

Número

Denominação

Número de pedido

BR00.45-B-1014-02A

Loctite 435

-

Número

Denominação

Número de pedido

BR00.45-B-1006-06A

Grease - DBL 6804.60 (Olista Longtime 3 EP - Castrol)

A 001 989 36 51