Remove/install retarder

AR43.30-T-0002EL

Remove/install retarder

12.10.11



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

Remove transmission (9)

Transmission 714.120/690 in model 613.365

Transmission 714.120 in model 613.368

Transmission 714.120 in models 671.015/020/030/042/332

Transmission 714.140 in models 671.015/020/021/030/042/332

AR26.10-T-0020AA

Transmission 714.668 in model 613.355

Transmission 714.690 in model 613.355/455/485

Transmission 714.691 in models 613.355/455/485

AR26.10-T-0020B

Transmission 714.120/140 in model 613.358/388 with engine 457.944

AR26.10-T-0020BA

Transmission 714.120 in model 613.367

AR26.10-T-0020CB

Transmission 714.120 in model 613.364

Transmission 714.692 in model 613.365

AR26.10-T-0020C

2

Drain retarder oil

Transmission 714.120 in model 613.364

Transmission 714.120/690/692 in model 613.365

Transmission 714.120/140 in model 613.358/388 with engine 457.944

Transmission 714.140 in models 671.015/020/021/030/042/332

Transmission 714.691 in models 613.355/455/485

Transmission 714.668 in model 613.355

AP43.30-T-4301EL

Transmission 714.120 in model 613.367

Transmission 714.120 in model 613.368

AP43.30-T-4310EL

3

Detach clutch housing from transmission (11)

Only on transmission (11) without integral clutch housing.

Transmission 714.120/140

AR26.30-T-0330AA

Transmission 714.668/690/ 691/692

AR26.30-T-0330B

4

Attach transmission (11) to assembly device

Universal assembly stand GS

"GSA SKN" adapter for transmission with integrated clutch housing.

"GSA SKN 2" adapter for transmission without integrated clutch housing.

5

Remove output flange from transmission (11)

AR26.50-T-2000B

6

Detach coolant connection (1) from retarder (10)

7

Remove TCO vehicle speed sensor (B17)

8

Remove bolts (3, 4)

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

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

9

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 must not make contact with the retarder (10) or transmission (11) here and it must be protected against mechanical damage.

 No tools for levering may be applied to the retarder sealing surface (8) or the transmission sealing surface (9).

10

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

11

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.

 Countersupport

*000589353300

 Internal extractor

*000589313300

Hot-air gun

gotis://K_60-65_11.0

12

Remove shim (7)

 If step 10 has been carried out.

13

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-T-0002-02EL

Retarder measuring device

 Order tool from
Voith Turbo GmbH & Co. KG

D-74564 Crailsheim

www.voith.com

Order number H67.3224xx

14

Insert shim (7)

 Perform only if the shim (7) was removed in operation step 12.

15

Press bearing outer race (6) into transmission housing

 Perform only if the bearing outer race (6) was removed in operation step 11.

 Use a suitable drift.

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

16

Clean retarder sealing surface (8) and transmission sealing surface (9)

 The retarder sealing surface (8) and the transmission sealing surface (9) must be clean, dry and free of grease.

17

Apply sealant to transmission sealing surface (9)

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

*BR00.45-Z-1015-01A

18

Insert O-rings (5) into transmission (9)

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

*BR00.45-Z-1015-06A

19

Position retarder (10) on transmission (11)

 To enable the retarder sealing surface (8) and the transmission sealing surface (9) to be placed on each other congruently, two threaded pins 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

Transmissions 714.120/140/6

WF58.50-N-4330-03B

20

Screw in bolts (3, 4)

 Observe identification on the
bolts (3, 4).



*BA43.30-N-1006-01G

 Torque wrench

*001589672100

21

Move transmission (9) into the horizontal position

22

Install TCO speed sensor



*BA26.19-N-1003-01F

 Torque wrench

*000589642100

23

Install coolant connection (1) on retarder (10)



*BA43.30-N-1001-01G

 Torque wrench

*000589642100

24

Install output flange on transmission (11)

AR26.50-T-2000B

25

Install transmission (11).

Transmission 714.120/690 in model 613.365

Transmission 714.120 in model 613.368

Transmission 714.120 in models 671.015/020/030/042/332

Transmission 714.140 in models 671.015/020/021/030/042/332

AR26.10-T-0020AA

Transmission 714.668 in model 613.355

Transmission 714.690 in model 613.355/455/485

Transmission 714.691 in models 613.355/455/485

AR26.10-T-0020B

Transmission 714.120/140 in model 613.358/388 with engine 457.944

AR26.10-T-0020BA

Transmission 714.120 in model 613.367

AR26.10-T-0020CB

Transmission 714.120 in model 613.364

Transmission 714.692 in model 613.365

AR26.10-T-0020C

26

Fill transmission with oil

Transmission 714.6 in model 613, 671

AP26.00-T-2601A

Transmission 714.690/692 in model 613.364/365

AP26.00-T-2601B

Transmission 714.120/140 in model 613, 671

AP26.00-T-2601BA

27

Fill retarder with oil

AP43.30-T-4301EL

28

Conduct a road test

 Bleed retarder:

- If present and possible:

Switch off retarder foot control.

-Drive vehicle at 50 km/h.

- Switch on retarder in first brake
stage 5

times in succession for approx. 5 s each time.

Number

Designation

Model
613 with transmission 714.66/69
with code B10

Models 613.358/388 with transmission 714.140
with code B10

Model 613.3
with transmission 714.120
with code B10

BE43.30-N-1001-01B

End play of retarder drive shaft

mm

0.02

0.02

0.02

Number

Designation

Model
671 with transmission 714.120/140
with code B10

BE43.30-N-1001-01B

End play of retarder drive shaft

mm

0.02

Number

Designation

Transmission 714.100/668/
690/691/692
in model 613

Trans-mission
714.120
in model 613

Transmission
714.140
in model 613.358/388

BA26.19-N-1003-01F

Speedometer sensor to rear transmission cover

M12

Nm

19

19

19

M18

Nm

30

30

30

M20

Nm

57

57

57

Number

Designation

Trans-mission
714.120
in model 671

Trans-mission
714.140
in model 671

BA26.19-N-1003-01F

Speedometer sensor to rear transmission cover

M12

Nm

19

19

M18

Nm

30

30

M20

Nm

57

57

Number

Designation

Model 613
with code B10

BA43.30-N-1001-01G

Bolt, coolant connection to heat exchanger of retarder

M8

Nm

30

BA43.30-N-1006-01G

Bolt, retarder to transmission

M10

Nm

58

Number

Designation

Model 671 with code B10

BA43.30-N-1001-01G

Bolt, coolant connection to heat exchanger of retarder

M8

Nm

30

BA43.30-N-1006-01G

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