CAPÍTULO 4. APLICACIÓN DE LAS HERRAMIENTAS LEAN
4.4 Aplicación de SMED
Illustration prop shafts flanges Prior jobs
• Prop shafts flanges removed
(see vehicle manufacturer instructions)
Notice
The jobs in this section can be performed with the retarder removed or installed.
93/1 Hex.-head screw (M 20 x 180) 95/2 Hex.-head nut (M 20), 375 Nm 97/6 Prop shaft flange
(output side)
97/7 Prop shaft screw, renew 97/8 Guard ring (output side) 97/9 Guard ring (input side)
98 Prop shaft flange (input side)
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.7/1 93/1 97/6 97/8 97/9 98 97/7 95/2 16060 93/1 97/6 97/8 97/9 98 97/7 95/2 16060
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Installation
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7.7 Removing and Installing Prop Shafts Flanges
(Continue)
Removing and installing
1. Screw out hex.-head screw (95/2).
Note for installation
Screw hex.-head nut (95/2) tight. Tightening torque 375 Nm 2. Pull out hex.-head screw (93/1) on output side.
3. Pull both prop shaft flanges (97/6, 98) out of the retarder housing. 4. Remove guard rings (97/8, 97/9).
Note for installation
Renew prop shaft screws (97/7).
Align hole patterns of both prop shaft flanges prior to installation. Maximum permissible offset 5°.
5. Install the prop shafts in accordance to the vehicle manufacturer instructions.
97/9 97/8
16061 97/7
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7.8 Checking, Removing and Installing Closing
Cover of Retarder Housing
Special tool
To check
1. Check closing cover (1000) for leaks, renew O-ring (1100) if necessary.
To remove
1. Drive out closing cover (1000) with impact tool (99/5) and remove O-rings (1100).
To install
1. Coat new O-rings (1100) with thin coat of silicone-free and non-corossive grease and install together with closing covers (1000).
53.7712.10
1000 1100
99/5
1000
16062
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Installation
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7.9 Removing and Installing Labyrinth Cover
(Output
Side), Renewing Radial Shaft Sealing Ring
Illustration labyrinth cover Prior jobs
• Prop shaft removed from flange (see vehicle manufacturer instructions) • Prop shaft flange removed
(see VOITH-installation schemes) • Retarder stage switch in position 0 • Ignition OFF
Notice
This job can be performed with the retarder removed or installed.
700 Radial shaft sealing ring
(80 x 100 x 10), renew, coat with silicone-free and non-corossive grease for installation
800 Labyrinth cover, coat with Hylomar sealant around leakage oil return bore
850 O-ring (125 x 2,5), renew, coat with silicone-free and non-corossive grease for installation
900 Hex.-head screw (M 8 x 25) self-locking, renew, 23 Nm 5400 Race
5500 O-ring (80 x 3), renew, coat with silicone-free and non-corossive grease for installation
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.9/1 800 700 5400 5500 850 900 16063
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Installation
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7.9 Removing and Installing Labyrinth Cover
(Output
Side), Renewing Radial Shaft Sealing Ring (Cont.)
Special tool
Job scope
1. Screw out hex.-head screw (900).
2. Use two hex.-head screws (M 8 x 25) (arrows) to press the labyrinth cover (800) off the rotor housing.
Sealants and locking agents
Housing sealing surfaces Hylomar
O-ring Silicone-free and
non-corossive grease 53.0742.10 900 16064 800 16065
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7.9 Removing and Installing Labyrinth Cover
(Output
Side), Renewing Radial Shaft Sealing Ring (Cont.)
3. Place the labyrinth cover (800) on a piece of pipe.
4. Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes (arrows) out of the labyrinth cover (800).
5. Use an appropriate puller (do-it-yourself) to pull off evenly the race (5400) of the hollow shaft. 6. Remove O-ring (5500) of hollow shaft.
7. Check race for scores and radial shaft sealing ring for uneven surface and renew race if necessary.
Notice
If a sealing function is no longer guaranteed, please contact VOITH TURBO. Recommendation:
Always change radial shaft sealing ring and race together.
8. Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (5500) and pull-on to the hollow shaft.
9. Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it will go.
10. Apply thin coat of silicone-free and non-corossive grease to new radial shaft ring (700).
16049
800 700
5400
16066
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7.9 Removing and Installing Labyrinth Cover (Output
Side), Renewing Radial Shaft Sealing Ring (Cont.)
11. Use a press-in equipment (94/4) to press the radial shaft sealing ring (700) as far as it will go into the labyrinth cover (800).
Position for installation: Sealing lip at top.
12. Apply thin coat of silicone-free and non-corossive grease to new O-ring (850) and fit in the labyrinth cover.
13. Apply thin coat of Hylomar sealant around leakage-oil return bore in labyrinth cover (800). Install so that the leakage-oil return bores in the rotor housing and in the labyrinth cover (arrow) are in alignment.
14. Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm
94/4 800 700 94/4 Press-in equipment 53.0742.10 800 850 16051
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Installation
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7.10 Removing and Installing Labyrinth Cover
(Input
Side), Renewing Radial Shaft Sealing Ring
Illustration labyrinth cover Prior jobs
• Prop shaft removed from flange (see vehicle manufacturer instructions) • Prop shaft flange removed
(see Section 7.7)
Notice
This job can be performed with the retarder removed or installed.
700 Radial shaft sealing ring
(95 x 115 x 10), renew, coat with silicone-free and non-corossive grease for installation
800 Labyrinth cover, coat with Hylomar sealant around leakage oil return bore
850 O-ring (125 x 2,5), renew, coat with silicone-free and non-corossive grease for installation
4700 Hex.-head screw (M 8 x 30) self-locking, renew, 25 Nm 5400 Race
5500 O-ring (80 x 3), renew, coat with si- licone-free and non-corossive grea- se for installation
Aftersales Service Manual VOITH Retarder 120 Digiprop Page 7.10/1 4700 800 850 700 5400 5500 16067
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Installation
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7.10 Removing and Installing Labyrinth Cover (Input
Side), Renewing Radial Shaft Sealing Ring (Cont.)
Special tool
Job scope
1. Screw out hex.-head screws (4700).
2. Use two hex.-head screws (M 8 x 40) (arrows) to press labyrinth cover (4400) off retarder housing.
3. Place the labyrinth cover (800) on a piece of pipe.
Sealants and locking agents
Housing sealing surfaces Hylomar
O-ring Silicone-free and
non-corossive grease
53.0742.10
800
16068
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Installation
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7.10 Removing and Installing Labyrinth Cover (Input
Side), Renewing Radial Shaft Sealing Ring (Cont.)
4. Use an appropriate punch to knock the radial shaft sealing ring (700) through the two holes (arrows) out of the labyrinth cover (800).
5. Use an appropriate puller (do-it-yourself) to pull off evenly the race (5400) of the hollow shaft. 6. Remove O-ring (5500) of hollow shaft.
7. Check race for scores and radial shaft sealing ring for uneven surface and renew race if necessary.
Notice
If a sealing function is no longer guaranteed, please contact VOITH TURBO. Recommendation:
Always change radial shaft sealing ring and race together.
8. Apply thin coat of silicone-free and non-corossive grease to a new radial shaft sealing ring (5500) and pull-on to the hollow shaft.
9. Fix race (5400) at the hollow shaft and use an appropriate punch to knock in the race as far as it will go.
10. Apply thin coat of silicone-free and non-corossive grease to new radial shaft ring (700).
16049
800 700
16069
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7.10 Removing and Installing Labyrinth Cover (Input
Side), Renewing Radial Shaft Sealing Ring (Cont.)
11. Use a press-in equipment (94/4) to press the radial shaft sealing ring (700) as far as it will go into the labyrinth cover (800).
Position for installation: Sealing lip at top.
12. Apply thin coat of silicone-free and non-corossive grease to new O-ring (850) and fit in the labyrinth cover.
13. Apply thin coat of Hylomar sealant around leakage-oil return bore in labyrinth cover (800). Install so that the leakage-oil return bores in the rotor housing and in the labyrinth cover (arrow) are in alignment.
14. Fit new self-locking hex.-head screws and screw them tight. Tightening torque 25 Nm
94/4 800 700 16050 94/4 Press-in equipment 53.0742.10 800 850 16051
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