Remove/install stator

AR43.40-Y-1300A

Remove/install stator

02.04.2020

Model

831.247

Retarder stator frame and retarder hub removal

1

Axle side dust cover

2

Axle side shims

3

Gearbox side dust cover

4

Gearbox side shims

5

Retarder hub vent tube

6

Gearbox side retarder hub mounting bolts

7

Retarder stator

8

Wooden block

9

Axle side retarder hub mounting bolts

10

Axle side pole shoe mounting bolts

12

Stator coil pressure washers

11

Stator frame

13

Retarder hub

14

Vent tube

Stator and retarder hub assembly cleaning

11

Stator frame

12

Stator coil pressure washers

15

Stator pole face

16

Retarder hub and rotor frame area

17

Retarder hub assembly machined surfaces

Retarder stator frame and retarder hub installation

5

Vent tube

14

Position marking

13

Retarder hub

11

Stator frame

12

Stator coil pressure washers

A-B, C-D, E-F, G-H

Cross clamping method

9

Axle side retarder hub mounting bolts

6

Gearbox side retarder hub mounting bolts

10

Axle side pole shoe mounting bolts

Stator pole shoe flatness checking

10

Axle side pole shoe mounting bolts

13

Retarder hub shaft

18

Dial gauge

19

Gearbox side pole shoe mounting bolts



Remove

 Danger

Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC.

No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

1

Remove retarder rotor from the retarder assembly.

AR43.40-Y-1600A

2

Remove the axle side dust cover (1) from retarder hub shaft.

3

Remove axle side shims (2) from the retarder hub shaft.

4

Remove the gearbox side dust cover (3) from retarder hub shaft.

5

Remove gearbox side shims (4) from the retarder hub shaft.

6

Mark the position of retarder hub vent tube (5).

7

Remove gearbox side retarder hub mounting bolts (6).

8

Place the retarder stator (7) horizontally on the wooden blocks (8) to protect the shaft.

 Ensure the gearbox side facing down.

9

Remove axle side retarder hub mounting bolts (9).

10

Remove axle side pole shoe mounting bolts (10).

11

Remove stator frame (11) from the stator coils.

12

Remove stator coil pressure washers (12).

13

Remove the retarder hub (13) from stator coil frame.

 Ensure that vent tube position is marked (14).



Clean

14

Clean the stator frame (11).

15

Clean pole faces (15) of the stator and area between the retarder hub and rotor frame (16).

 Remove traces of old grease and add new grease for easier mounting.

16

Clean stator coil pressure washers (12).

17

Clean the retarder hub assembly machined surfaces (17) carefully.



Install

18

Before installing hub assembly on stator frame ensuring the vent tube (5) placed on the position of marked side (14).

19

Install and align the retarder hub (13) on the stator coil frame.

 Check and ensure the retarder hub (13) is properly placed on the stator coil frame.

20

Install stator coils pressure washers (12).

21

Install stator frame (11) on stator coils.

22

Install and tighten axle side pole shoe mounting bolts (10).

 Use cross clamping method (A-B, C-D, E-F, G-H) for axle side pole shoe mounting bolts tightening.

 Tighten axle side pole shoe mounting bolts.

*BA43.40-Y-1012-01A

23

Install and tighten axle side retarder hub mounting bolts (9).

 Tighten axle side retarder hub mounting bolts.

*BA43.40-Y-1013-01A

24

Position the stator vertically and install gearbox side retarder hub mounting bolts (6).

 Tighten gearbox side retarder hub mounting bolts.

*BA43.40-Y-1014-01A



Check

25

Clean the pole shoes and hub shaft surface, before placing the dial gauge.

26

Place the magnetic base of the dial gauge (18) on the retarder hub shaft (13).

27

Set the dial gauge (18) to 0 mm taking one pole shoe (10) as a reference.

28

The measurement of the stator flatness will made on each pole shoe (10).

 Measurement value not exceed 0.3 mm.

29

Follow the same procedure for gearbox side (19).

30

Install retarder rotor to the retarder assembly.

AR43.40-Y-1600A

 Retarder electronic control unit (ECU) assembly

Number

Designation

Model 831.247

BA43.40-Y-1012-01A

Tighten axle side pole shoe mounting bolts.

Nm

45

 Retarder electronic control unit (ECU) assembly

Number

Designation

Model 831.247

BA43.40-Y-1013-01A

Tighten axle side retarder hub mounting bolts.

Nm

68

 Retarder electronic control unit (ECU) assembly

Number

Designation

Model 831.247

BA43.40-Y-1014-01A

Tighten gearbox side retarder hub mounting bolts.

Nm

68