Retrofit permanent magnet retarder

AN43.40-W-1001PR

Retrofit permanent magnet retarder

22.3.12

16.3.12

Screw threaded pin (14) into flange adapter (7) and tighten, added.

Operation step 14

AN43.40-W-1001-01PR

Tighten bolts (13), added.

Step 15

AN43.40-W-1001-01PR



To achieve a swift installation of the permanent magnet retarder or to keep the idle time of the vehicle as low as possible for the customer, the following points must be clarified in advance; they are available in the Service Information bulletin.

SI43.40-W-0001A

 Danger!

Risk of death caused by working on permanent magnet retarder for groups of persons with implants. Risk of injury caused by burns that may occur due to contact with the hot rotor.

For persons with implants, a minimum distance of 30 cm between the permanent magnet retarder and the body parts of the affected person is to be maintained as a safe distance from the permanent magnet retarder.

Do not touch hot or rotating parts.

AS43.40-Z-0001-01A

 Danger!

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut.

AS60.80-Z-0001-01A



Notes on tilting the cab

AH60.80-N-0003-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Switch off ignition

2

Disconnect ground lead from battery

AR54.10-W-0003A

3

Remove propeller shaft

 The drive shaft may only be shortened and balanced by an authorized specialist workshop (GKN Service). Otherwise damage could occur to the drive shaft and the vehicle.

AR41.10-W-0050A

4

Remove paneling at top for instrument panel on the passenger side

AR68.10-W-3435A

5

Remove bottom paneling for dashboard on passenger side

AR68.10-W-1502A

6

Remove stowage compartment from center module

Vehicles with code (FN1) Distributor vehicle cockpit

AR68.10-W-1624A

Vehicles with code (FN2) Comfort cockpit

AR68.10-W-1624B

Vehicles with code (FN3) Long-distance haulage vehicle cockpit

AR68.10-W-1624C

7

Remove Instrument paneling

AR68.10-W-3513A

8

Remove operating lever for engine control and continuous brake

 The removed operating lever for the engine control and permanent brake is no longer required.

AR54.25-W-2805C

9

Remove center module

Vehicles with code (FN1) Distributor vehicle cockpit

AR68.10-W-1004A

Vehicles with code (FN2) Comfort cockpit

AR68.10-W-1004B

Vehicles with code (FN3) Long-distance haulage vehicle cockpit

AR68.10-W-1004C

10

Remove center air vent

AR83.10-W-4503AX

11

Retrofit parameterizable special module (PSM)

 Only for vehicles that have not yet been installed with a parameterizable special module (PSM).

AN54.21-W-0002G

12

Install electrical wiring harness for permanent magnet retarder into cab

AN43.40-W-1001-02PR

 Assembly wedge

*110589035900

13

Install center air vent

AR83.10-W-4503AX

14

Install center module

Vehicles with code (FN1) Distributor vehicle cockpit

AR68.10-W-1004A

Vehicles with code (FN2) Comfort cockpit

AR68.10-W-1004B

Vehicles with code (FN3) Long-distance haulage vehicle cockpit

AR68.10-W-1004C

15

Install new operating lever for engine control and permanent brake

AR54.25-W-2805C

16

Install Instrument paneling

AR68.10-W-3513A

17

Install stowage compartment onto center module

Vehicles with code (FN1) Distributor vehicle cockpit

AR68.10-W-1624A

Vehicles with code (FN2) Comfort cockpit

AR68.10-W-1624B

Vehicles with code (FN3) Long-distance haulage vehicle cockpit

AR68.10-W-1624C

18

Remove soundproofing part under the transmission

 If present.

19

Drain transmission oil

 Use clean oil collection pan, because the drained off automatic transmission fluid is to be used again.

AP26.00-W-2601A

20

Remove transmission output flange

 The removed transmission output flange is no longer required.

 Puller

*000589893300

 Retainer wrench

*717589003100

21

Remove exhaust tailpipe

 Only for vehicles with code (KH0) Muffler, inward tailpipe.

22

Remove transmission end cover

AN26.30-W-0001-01PR

23

Remove battery cable bracket

AN54.18-W-1001-01PR

24

Remove compressed air line

The removed compressed air line is no longer required.

AN13.30-W-0001-01PR

25

Prepare transmission housing rear section

AN26.40-W-0001-03PR



*BA43.40-N-1001-01D



*BA43.40-N-1002-01D

*BR00.45-Z-1001-02A

26

Install transmission end cover

AN26.30-W-0001-02PR



*BA26.40-N-1002-01B

*BR00.45-Z-1001-02A

*BR00.45-Z-1015-01A

27

Install battery cable bracket

AN54.18-W-1001-02PR

28

Mount permanent magnet retarder to transmission housing rear section

AN43.40-W-1001-01PR



*BA26.50-N-1001-01A



*BA43.40-N-1003-01D



*BA43.40-N-1004-01D



*BA43.40-N-1005-01D



*BA43.40-N-1006-01D



*BA43.40-N-1008-01D

*BR00.45-Z-1001-02A

29

Install compressor air line

AN13.30-W-0001-02PR



*BA13.30-N-1010-01A

30

Install pneumatic line of permanent magnet retarder

AN43.40-W-1001-04PR



*BA43.40-N-1007-01D

31

Install electrical wiring harness for permanent magnet retarder into vehicle

AN43.40-W-1001-03PR

*BR00.45-Z-1025-01A

32

Install exhaust tailpipe

 Only for vehicles with code (KH0) Muffler, inward tailpipe.

33

Fill with transmission oil

AP26.00-W-2601A

34

Install propeller shaft

AR41.10-W-0050A

35

Mount soundproofing part below the transmission

 If present.

36

Attach adhesive label to heat shield, transmission and interior trim

AN43.40-W-1001-05PR

37

Install bottom paneling for dashboard on passenger side

AR68.10-W-1502A

38

Install paneling at top for instrument panel on the passenger side

AR68.10-W-3435A

39

Enable permanent magnet retarder

AR43.40-W-1005PR

40

Update data card for vehicle in VeDoc

 For this purpose:

 Enter code BA2 Permanent magnet retarder

 Enter SAA number to match installed parts kit

Z599 430/01

Z599.430/02

Z599.430/03

Z599.430/04

 Enter SAA number to match installed operating lever for engine control and permanent brake

Z533.517/25

Z533.517/26

 Enter SAA number to match installed compressed air line

Z509.230/82

Z509.230/83

 Enter SAA numbers for shortened / new drive shaft or bracket

 Delete SAA number for transmission housing rear section

Z504.144/XX

The new SAA number for the transmission housing rear section is filed in the SAA number for the installed parts kit

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

Engine
924.9, 925.9, 926.9

BA13.30-N-1010-01A

Union nut, air line to fitting

M221.5

Nm

65

65

M261.5

Nm

75

75

Number

Designation

Transmis-sion
712.62
715.050

Transmis-sion
712.63,
715.060/
068

BA26.40-N-1002-01B

Bolt, end cover to
rear section of transmission housing

Nm

60

60

Number

Designation

Transmission
712.62/63
715.050/051/
060/068

BA26.50-N-1001-01A

Bolt, output flange to main shaft

Nm

275

Number

Designation

Model
970.0, 970.2,
974.2 with code BA2

BA43.40-N-1001-01D

Bolts of drilling template to transmission housing rear section

Nm

45

BA43.40-N-1002-01D

Threaded pin to transmission housing rear section

Nm

120

BA43.40-N-1003-01D

Adapter plate to transmission housing rear section

Nm

190

BA43.40-N-1004-01D

Bolt, stator to adapter plate

Nm

78

BA43.40-N-1005-01D

Bolt, propeller shaft flange to flange adapter

Nm

24

BA43.40-N-1006-01D

Bolt, rotor to flange adapter

Nm

140

BA43.40-N-1007-01D

Bolt, heat shield to stator

Nm

20

BA43.40-N-1008-01D

Threaded pin on flange adapter

Nm

25

Number

Designation

Order number

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10

BR00.45-Z-1025-01A

Sealing adhesive Union Zement

A 003 989 01 71

BR00.45-Z-1001-02A

Thread locking adhesive, Loctite 241

A 002 989 94 71

Part no.

Designation

Quantity

A 000 430 52 90

Parts kit for permanent magnet retarder (SAA Z599.430/01), for vehicles with transmission output flange Ø 150 mm and without parameterizable special module (PSM)

1

A 000 430 53 90

Parts kit for permanent magnet retarder (SAA Z599.430/02), for vehicles with transmission output flange Ø 120 mm and without parameterizable special module (PSM)

1

A 000 430 54 90

Retrofit for permanent magnet retarder (SAA Z599.430/03), for vehicles with transmission output flange Ø 150 mm and with parameterizable special module (PSM)

1

A 000 430 55 90

Retrofit for permanent magnet retarder (SAA Z599.430/04), for vehicles with transmission output flange Ø 120 mm and with parameterizable special module (PSM)

1

A 009 545 28 24 7C45

Operating lever for engine control and permanent brake (SAA Z533.517/25), for vehicles with code (MD9) Cruise control

1

A 009 545 29 24 7C45

Operating lever for engine control and permanent brake (SAA Z533.517/26), for vehicles without code (MD9) Cruise control

1

A 970 430 97 72

Compressor air line (SAA Z509.230/82), for vehicles without code (F04) Cab L (long) and without code (Y19) Stowage box, on frame

1

A 970 430 98 72

Compressor air line (SAA Z509.230/83), for vehicles with code (F04) Cab L (long)
and without code (Y19) Stowage box, on frame

1