Removing, Installing Retarder /

Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10

Illustration removing, installing retarder Prior jobs

• Gearbox (with retarder) removed (see chapter 6.1)

• Connecting pieces removed (see chapter 9.4)

• Speedometer sensor removed (see chapter 8.5)

• Output flange removed (see chapter 8.7)

850 Outer race

Remove only, if taper roller bearing is renewed or a new balance washer is added (DC-tool)

850/001 Taper roller bearing 4100 Screw plug M30x1,5

Inhex.-head, w.a.f. 17 100 Nm (150 Nm) 25000 Balance washer 25100 O-ring, renew

coat with silicone-free and non- corrosive grease for installation 25200 Hex.-head screw M10x70 25100 (26/860/023*) 25000 (26/860/020*) 850 25300 25300 4100 25200 25200

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Special tools

Control device Measuring device Puller for Impact tool outer race for outer race

Tool for local fabrication

Threaded bolt M10x80

67.2713.10 _67.3056.10 on inquiry on inquiry

Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10 Page 7.1/2

15

80

M10

0073ae Material: St37-2, DIN 17100 (1.80)

Caution!

The measuring device 67.3056.10 has to be calibrated annually! The workshop using this device is responsible for calibration and the propper condition of the device.

Two versions of screw plugs (4100) are possible:

A) Version with integrated FPM-sealing ring;

these corresponds the standard version at the time going to print.

The integrated sealing rings must be checked during the oil level check for possible damages; replace completely if necessary.

B) Version with loose inserted copper-sealing ring.

Lubricants and locking agents

O-rings Silicone-free and

non-corrosive grease Retarder housing Omnifit FD10-1042

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Retarder Remo-

ving, Installing

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Caution! Risk of injury!

Secure retarder before working step 1 (prop up)!

Caution!

Remove speedometer sensor before working step 1 (see chapter 8.5)!

Removing, installing

1. Screw out the 5 hex.-head screws (25200) and 17 hex.-head screws (25300) and remove retarder with suitable lifter device from gearbox.

2. Remove O-rings (25100) from gearbox.

Note

You must execute the following working-step only, if: - a new retarder is installed

- the taper roller bearing (850/001) is renewed or - the gearbox is renewed

3. Dismantle outer race (850) with puller for outer race (DaimlerChrysler tool F3 6280 0 486 285) and remove balance washer (25000).

M+P-07A-1499

850

25100

25000

850/1

25300

M+P-07A-1498

25200

25200

Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10

Installing

1. Determine the thickness of the balance washer like follows:

Note

Determine the thickness of the balance washer only, if:

- one or both taper roller bearings of the retarder was renewed - the retarder was dismantled or changed or

- the gearbox was dismantled or changed

The following described measurements may only being carried out at room temperature!

1.1 Take measuremnets of the spacing „a” between the surface of the gearbox housing (320) on retarder side and the surface of the balance washer. Note down the measured value as

dimension „a“.

1.2 Place measuring device (98/1) on supporting plate (60).

1.3 Push vernier caliper (61) at measuring plate (62) and set to zero by using the reset key (63).

M+P-07A-1444

a

M+P-07A-1444

a

61

62

63

60

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1.4 Place outer race (850) on taper roller bearing (850/1).

1.5 Place measuring plate (62) on outer race (850) and check correct and gap-free seat by rotation. Then press with one hand powerful onto the measuring plate (62) and turn the driving wheel (ar- row) 2 turns clockwise and 2 turns counter-clockwise.

1.6 Place the measuring device (98/1) in the way on the retarder housing, that both plastic bolts mesh in the flat surface.

1.7 Place vernier caliper (61) at measuring plate (62) and read-off value.

Note

The measured value must be between +0,86 mm and -0,28 mm, contact Voith if necessary. 1.8 Calculate dimension „b“.

Dimension „b“ plus or minus the read-off value from working step 1.7 (heed sign at scale). Note down the calculated value as dimension b.

62

850

850/1

M+P-07A-1977

98/1

61

62

M+P-07A-1978

Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10

Page 7.1/6

1.9 Place again the measuring device at the supporting plate (60).

1.10 Push vernier caliper (61) at measuring plate (60) and check, if zero position still is set.

Note

The measuring device must display zero, if necessary press reset key to repeat measuring procedure.

1.11 Calculate thickness of balance washer.

Thickness of balance washer = dimension „a“ minus dimension „b“ minus 0,02 mm

2. Place balance washer (25000) into gearbox housing (if dismantled).

Note

If taper roller bearing was renewed, renew also outer race (850).

3. Place outer race (850 - if removed) into the gearbox housing and knock it in with the impact tool

61

62

63

60

M+P-07A-1976

850

25000

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4. Clean sealing surface of retarder housing (1).

5. Turn the gearbox until the sealing surface does show upwards (gearbox is in vertically position). 6. Clean sealing surface of gearbox housing and coat it with locking agent Omnifit FD10-1042. 7. Coat O-rings (25100) with silicone-free and non-corrosive grease and place into the gearbox. 8. Screw in two threaded bolts M10x80 (see arrows) into the gearbox housing.

The threaded bolts are required so that the sealing surfaces (gearbox/retarder) can be installed congruent.

M+P-07A-1448

25100

M+P-07A-1501

1

Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10

9. Place retarder at gearbox and screw it tight with 5 hex.-head screws (25200). Tightening torque hex.-head screws 58 Nm

10. Unscrew the two threaded bolts M10x80 again.

11. Screw in the 17 hex.-head screws (25300) and screw them tight. Tightening torque hex.-head screws 58 Nm

12. Turn gearbox with fixed retarder in the horizontally position again. 13. Screw out screw plugs (4100) out of retarder housing.

25300

M+P-07A-1502a

25200

25200

25200

4100

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14. Press threaded spindle of control device (98/2) into direction of arrow as far as it will go.

15. Screw control device (98/2) via „A“ hand tight into the retarder housing.

16. Screw control device (98/2) via „B“ into the drive shaft until it is turning too.

Note

Over the threaded bore of the speedometer sensor (arrow) can be determined, if the impulse ring itself and so the drive shaft turns.

M+P-07A-1503

4100

M+P-07A-1997

98/2

A

98/2

B

M+P-07A-1979

Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10

Page 7.1/10

98/2 Control device 67.2713.10

17. Fix the holder (99/8) with dial gauge at retarder housing.

18. Place test prod with initial tension at surface (arrow) of control device (98/2) and set scale of dial gauge to zero.

19. Check gap of taper roller bearings as following:

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19.1 Connect filling connection (arrow) with compressed-air and charge control device (98/2) with compressed-air (approx. 6 to 8 bar).

19.2 Turn shaft of the control device (64) three times about its own axis.

19.3 Read-off the values of the dial gauge while turning shaft of the control device (64) again one time

98/2

M+P-07A-1503

4100

99/8

98/2

M+P-07A-1980 98/2 Control device 67.2713.10

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19.5 Connect filling connection (arrow) with compressed-air and charge control device (98/2) with compressed-air (approx. 6 to 8 bar).

19.6 Turn shaft of the control device (64) three times about its own axis.

19.7 Read-off the values of the dial gauge while turning shaft of the control device (64) again one time about 360°.

The smallest value corresponds the bearing gap. Set value: 0,02 to 0,12 mm, contact Voith if necessary.

Caution!

If the set value is not reached, the retarder must be removed and be installed again with another corresponding balance washer. To this all working steps described in this chapter must be carried out once again.

20. Remove control device again.

21. Check sealing ring of screw plug (4100) on damages; renew if necessary. 22. Screw in screw plug (4100) again and screw it tight.

Tightening torque: 100 Nm (150 Nm) M+P-07A-1503

4100

98/2

64

M+P-07A-1982 4100 M+P-07A-1497a 98/2 Control device 67.2713.10

Aftersales Service Manual Gearbox-Retarder-System cbtd 00-01 53.2687.10

8.1

Overall Illustration of Main Components ...8.1/1

In document 050399_r (Page 115-128)