Remove/install retarder

AR43.30-B-0002RO

Remove/install retarder

19.06.2020

Model

963 with transmission 712.820/830

1

Heat exchanger

7

Clamp

2

Hose

8

Hose

3

Coolant outlet piping

9

Clamp

4

Clamp

15

Retarder

5

Electrical connector

B65

Coolant temperature sensor

6

Coolant inlet piping

10

Electrical connector

14

Supporting plate

11

Holder

15

Retarder

12

Compressed-air line connector

B66

Retarder oil temperature sensor

13

Electrical connector

Y114

Actuation valve

15

Retarder

16

Screw

17

Nut

18

O-ring

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Park the vehicle on a flat road, apply the parking brake and shim the wheels

2

Turn off ignition

 Make sure that the retarder drive (15) is in the "0" position.

 Carry out the work only when retarder (15) is off. Wear protective clothing and goggles.

3

Remover the step plate from over the transmission

4

Drain the retarder oil (15)

AR43.30-B-0024RO


Be careful when working on the hot retarder (15).
Since the contact with hot oil and under pressure can cause serious accidents, such as burns and eye injuries. Wear protective clothing and goggles.

 Collect the oil in an appropriated recipient and dispose of it in Eco-friendly manner.

5

Fit the output flange with the flat side facing the retarder (15)

6

Drain the retarder coolant (15)

AR20.00-B-1142TB


Be careful when handling the coolant.
Since the contact with hot and pressurized coolants may cause serious accidents.

 Drain only in the heat exchanger (1) of the retarder (15).

 Installation: Fill the cooling system of the vehicle.

7

Drain the transmission oil



AP26.00-B-2601MB

 Partially drain the oil from the transmission.

 Installation: Fill up transmission with recommended oil.

8

Remove the propeller shaft from the transmission

 Tie the propeller shaft to the vehicle chassis.
Mark the position of the propeller shaft with the output flange.

  Coupling flanges

*BA41.10-B-1003-01H

9

Remove the connector (5) in the coolant temperature sensor (B65)

10

Remove the coolant (3) outlet piping hose (2) from the retarder (15)

  Coolant outlet hose clamp

*BA43.30-B-1003-01RO

11

Remove the coolant (6) inlet piping hose (8) from the retarder (15)

  Coolant inlet hose clamp

*BA43.30-B-1002-01RO

12

Remove the connector (10) in the actuation valve (Y114)

13

Remove the holder (11) from compressed-air line (15) in the retarder

14

Remove the compressed-air line connector (12) in the actuation valve (Y114)

15

Remove the connector (13) in the retarder oil temperature sensor (B66)

16

Place a supporting plate (14) with a jack under the retarder (15)

 Tie the retarder (15) with a strap and place in a suitable lifting device.

17

Remove the retarder (15) from the transmission

 Installation: Use new screws (16) and nuts (17) to fasten the retarder (15) to the transmission.
Apply sealant to the screws (16).

 Installation: Apply chemical lock to the threaded pin.

Sealing compound Dirko S Profi Press HT

*BR00.45-Z-1075-01A

Quick-acting adhesive, Loctite 270

*BR00.45-Z-1008-02A

  Transmission threaded pin

*BA43.30-B-1008-01RO

  Retarder nut/screw

*BA43.30-B-1001-01RO

18

Install in reverse order

 Installation: Replace the O-Ring (18) with a new one. Apply lubricating grease to O-Ring (18).

Olista Longtime lubricating grease, DB supply specification 6804.60, 100 g

*BR00.45-Z-1062-06A

 Propeller shaft

Number

Designation

Type 963.4

BA41.10-B-1003-01H

Coupling flanges

M8

Nm

-

M10

Nm

-

M12

Nm

100

M14

Nm

154

M14(with collar)

Nm

-

M16

Nm

233

M20

Nm

467

 Voith secondary retarder VR 115 HV

Number

Designation

Vehicle 963 with transmission 712.820/830

BA43.30-B-1001-01RO

Retarder nut/screw

Nm

172

 Voith secondary retarder VR 115 HV

Number

Designation

Vehicle 963 with transmission 712.820/830

BA43.30-B-1002-01RO

Coolant inlet hose clamp

Nm

5

 Voith secondary retarder VR 115 HV

Number

Designation

Vehicle 963 with transmission 712.820/830

BA43.30-B-1003-01RO

Coolant outlet hose clamp

Nm

5

 Voith secondary retarder VR 115 HV

Number

Designation

Vehicle 963 with transmission 712.820/830

BA43.30-B-1008-01RO

Transmission threaded pin

Nm

60

Repair materials

Number

Designation

Order number

BR00.45-Z-1008-02A

Quick-acting adhesive, Loctite 270

A 002 989 93 71

BR00.45-Z-1062-06A

Olista Longtime lubricating grease, DB supply specification 6804.60, 100 g

A 001 989 36 51 10

BR00.45-Z-1075-01A

Sealing compound Dirko S Profi Press HT

A 004 989 65 20