Telma Af8 User manual

MAINTENANCE MANUAL

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The following instructions define how to replace the hub on

Axial retarders LM/LN/LP/LR/LTxxxxxx

Hub replacement on AF8

retarder range

MAINTENANCE MANUAL

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1. TELMA GENUINE SPARE PART NEEDED...............................................................................................3

2. SAFETY PRECAUTIONS........................................................................................................................3

3. REQUIRED TOOLS................................................................................................................................4

4. PARTS TO BE REPLACED SYSTEMATICALLY ........................................................................................ 5

5. NOTES .................................................................................................................................................5

6. DISMANTLING STEPS...........................................................................................................................6

A. REMOVAL OF ROTORS....................................................................................................................6

B. RETARDER STATOR OPENING.......................................................................................................... 8

C. REMOVAL OF THE DEFECTIVE HUB .................................................................................................9

7. RE ASSEMBLING STEPS......................................................................................................................11

A. INSTALLATION OF THE NEW COMPLETE HUB................................................................................11

B. INSTALLATION OF THE ROTORS ....................................................................................................15

8. ANNEX.............................................................................................................................................. 18

B. TAB WASHER DRIVER ....................................................................................................................18

MAINTENANCE MANUAL

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1. TELMA GENUINE SPARE PART NEEDED

Hub assembly >> See spare parts catalogue for reference.

For any spare parts orders, it is necessary to specify the part number of the retarder

the model, engraved on the front stator housing, in the upper left corner.

You will find the necessary information on spare parts for this equipment in the spare parts

catalogue:

OC443068 Spare Parts AF8 Telma Retarder

For more information about your TELMA product, please contact your TELMA dealer or the TELMA

technical department.

2. SAFETY PRECAUTIONS

Before repairing your retarder, you must have read this maintenance manual thoroughly.

All operations and interventions for repairing this retarder will be carried out by qualified

personnel.

Our technical support is available for all the information you may need.

The various operations described in this manual are accompanied by recommendations or

symbols to alert the user to the risk of accidents. You must understand and respect the following

warnings below.

Using and safety warning symbol, for an operation capable of damaging or destroying

the retarder or surrounding equipment. The no respect of these warnings can cause

injuries from mild to severe.

Safety warning symbol for an immediate danger to personnel. The no respect of this

warning can cause serious injuries.

MAINTENANCE MANUAL

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Safety warning symbol for an electrical danger to personnel. The no respect of this

warning can cause serious injuries.

The repair methods described by TELMA SA, in this document, are based on the technical

specifications in effect at the date of this writing. They are subject to modifications in case of

changes done by TELMA SA to manufacture the various component units and accessories brand

(?) products.

The company TELMA SA reserves the right to modify the characteristics of its products at any time

in order to incorporate the latest technological developments. The information contained in this

document are subject to change without notice.

-We would like to draw your attention to the contents of this maintenance manual.

Indeed, following the respect of important points during installation, use and maintenance

of your retarder will ensure trouble-free operation for many years.

-When using lifting equipment, do not walk or stand under suspended loads.

-For information, a complete retarder weights around 330 kg (728 lb), a rotor with coupling

flange weights about 63kg (139 lb), and a hub weights 5.5 kg (12 lb).

-Put the retarder on a solid table, with the handling safety tool.

-Pay attention to the heavy parts of the retarder which can cause serious personal injury.

3. REQUIRED TOOLS

-Protective glasses and gloves

-Handling safety tools for retarder

-Flat screwdriver

-Torx® TX40 socket

-Click-type wrench

-10 mm long socket and 19mm socket

-Tab washer driver (See Annexe 1)

-Hammer

-Feeler gauge

-Dial gauge with magnetic base

-Ink marker

-Torque wrench (torque values: 45Nm, 60Nm and 68Nm)

-Abrasive cloth (120 grade)

MAINTENANCE MANUAL

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4. PARTS TO BE REPLACED SYSTEMATICALLY

When removed, the following parts need to be replaced by the new ones which are supplied

with the spare hub assembly:

-Shaft end screws, washers, air gap adjusting shims and lock tabs

-Screws used to secure hub

-Screws used to secure pole shoes plate

-Dust protection washers

5. NOTES

Some parts handled during the maintenance operations are covered with a special product

against corrosion. Take precautions when handling to prevent damage to these protections.

For ease and given the diversity of installations on vehicles, this procedure has been done with the

retarder removed from the vehicle and its accessories (retarder brackets) removed from the

retarder.

To remove the retarder brackets, please refer to the appropriate procedures.

The different pictures on this procedure are generic views and are not contractual.

MAINTENANCE MANUAL

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6. DISMANTLING STEPS

A. REMOVAL OF ROTORS

IMPORTANT: identify all parts before dismantling in order to find their initial orientations and

location during the re-assembly.

6A-1

6A-2

Draw a mark on each rotor outer edge with an ink

marker, the two marks must be aligned to find

again the initial angular orientation during re-

assembly. This is essential to maintain proper

balancing.

On the first retarder side (for instance here the

gearbox side, with the engraved part and serial

numbers), remove the lock tab by using a flat

screwdriver and a hammer. Caution: in order to

reduce the spring effect, suppress the stress in the

tab by hitting on one side and by removing the

other).

6A-3

6A-4

Unscrew the 2 shaft end screws to remove them.

Use a 19mm socket and a bar to lock the rotation

of the rotor.

Draw a mark on both shaft and coupling flange

with an ink marker, to find again the initial position.

MAINTENANCE MANUAL

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6A-5

6A-6

Insert a lifting hook between 2 cooling fins on the

frontal face of the rotor to facilitate pull off of the

rotor and coupling flange assembly.

Remove the dust shield from the shaft.

6A-7

6A-8

Remove from the shaft the air gap adjusting shims

and the 0.70mm black shim with Nuflon coating.

Do the same steps from 6A-2 to 6A-7 for the other

rotor (drive axle side).

Dust shim

Black shim

Shims used

to set air

gap

MAINTENANCE MANUAL

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B. RETARDER STATOR OPENING

6B-1

6B-2

Unscrew and remove the 6 screws securing the

hub on gearbox side. Use a 19mm socket.

Put the stator in horizontal position (gearbox side

with the removed hub screws down) on wooden

blocks to protect the shaft. The wood beams must

be thick enough in order that the shaft does not

touch the table and for providing hand access for

further operations.

6B-3

6B-4

On the upper side, unscrew and remove the 6

screws securing the hub on axle side. Use a 19mm

socket.

On the upper side, remove the 10 screws securing

the pole shoes plate, using a Torx® TX40 socket.

Zone for

hand access

MAINTENANCE MANUAL

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6B-5

6B-6

Lift and remove completely the pole shoes plate.

Put aside the 10 pressure washers from the top of the

coils in order not to lose or damage these parts.

C. REMOVAL OF THE DEFECTIVE HUB

6C-1

6C-2

View of the stator with the hub assembly ready to

be removed.

Pull on the screw by hand to help removing the hub

Fit 2 hooks or 2 screws either in the shaft end or in the

hub shoulder and pull out the hub assembly with

care in order not to damage the internal wiring nor

the coil insulators.

Spring

washers

MAINTENANCE MANUAL

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6C-3

6C-4

After having removed the hub assembly, please

note the location of the cut out in the gearbox side

stator frame, towards the top, corresponding to the

location of the hub vent cap.

On the mating face for the hub, remove traces of

dirt using if necessary abrasive cloth.

6C-5

6C-6

Clean core mating faces using abrasive cloth (120

grade).

Clean as well the core mating faces on the pole

shoes on the removed “drive axle side“ stator

housing.

Indexing

location for hub

vent cap

(gearbox side)

MAINTENANCE MANUAL

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7. RE ASSEMBLING STEPS

A. INSTALLATION OF THE NEW COMPLETE HUB ASSEMBLY

7A-1

7A-2

Unpack the new hub assembly.

The “drive axle side”is shown below on the right

hand side.

On the drive axle side, fit 2 hooks or 2 screws either

in the shaft end or in the hub shoulder in order to

lift the hub assembly in the vertical position.

7A-3

7A-4

Before hub fitment, if a coil has also been

replaced, ensure that the coil wires are well placed

in the notch of the coil protective washer.

Orientate the hub at the correct position for the

vent cap, inside its indexing location.

Lower the hub in stator, taking care to coils and

internal wiring.

Remove hooks or screws after hub positioning.

MAINTENANCE MANUAL

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7A-5

7A-6

From underneath, place by hand the 6 new screws

with spring washers for securing the hub assembly.

View of the 6 screws under stator (gearbox side).

7A-7

7A-8

Check again that all output coils (black and red) of

the 10 coils, are well located in the notches.

Place again the pressure washers on top of the

coils and check that they are well located.

Pressure

washers

MAINTENANCE MANUAL

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7A-9

7A-10

On axle side, relocate the pole shoes plate over

the cores.

Take care that the spring washers remain well in

place around the cores and do not get clamped.

Put in place,by hand, 16 new screws:

-6 screws with spring washers for the hub

-10 screws for the pole shoes.

7A-11

7A-12

Using the order shown below, tighten:

-first the 10 pole shoe securing screws with a

Torx® TX40 socket:

Tightening torque: 68 Nm ± 20% (50 lb.ft ± 20%)

-afterwards the 6 hub securing screws:

Tightening torque: 45 Nm ± 20% (33 lb.ft ± 20%)

Put the retarder in vertical position.

MAINTENANCE MANUAL

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7A-13

7A-14

Turn the retarder in order to have the gearbox side

in front of you (view on vent cap).

Tighten the 6 hub securing screws:

Tightening torque: 68 Nm ± 20% (50 lb.ft ± 20%)

7A-15

7A-16

Toggle again the stator onto the wood blocks in

order to check the stator flatness.

Check the axial run out of the stator by using a dial

gauge with magnetic base.

Maximum allowed value: 0.40 mm

Note: in case that the measured value is above

this limit, check that no coil pressure washer is

clamped between a core and a pole shoe or

consult the TELMA technical department.

Vent

cap

MAINTENANCE MANUAL

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B. INSTALLATION OF THE ROTORS

7B-1

7B-2

Lift up the stator in vertical position. On both ends

of the shaft, put in place a new black shim and

new air gap adjusting shims with a thickness to the

one removed in step 6A-7.

Note: the black “Nuflon” coated shim must be

installed first; its presence is mandatory in any case.

Put new dust shields on both shaft ends.

7B-3

7B-4

Re-install both rotor with coupling flange assemblies

on the shaft, ensuring that the marks painted on

the shaft splines and on the coupling flange splines

(refer to picture 6A-4) are aligned.

When fitting the second rotor, ensure that both

marks painted on the outer edges of the rotors are

aligned.

MAINTENANCE MANUAL

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7B-5

7B-6

Re-install both removed shaft end screws with the

removed pressure plates, on both retarder sides.

Do not install lock tabs yet.

With a manual torque wrench apply a tightening

torque value of 60 Nm ± 20% (44 lb.ft ± 20%)

alternately on these 2 screws.

Use a 19mm socket and a locking bar to be

inserted inside a rotor cooling canal for preventing

rotor rotation.

7B-7

7B-8

Check the axial run out of the rotors by using a dial

gauge with magnetic base.

Maximum allowed value: 0.28mm

Note: should the measured value be higher than

0,28mm, please contact the technical department

at TELMA SA.

Measure the air gaps by using a feeler gauge.

Do not turn the rotors and measure the air gap

between the rotor and each pole shoe.

The average of these 10 values must be conform

with values mentioned in retarder technical

specifications: 1.30mm 0 -0.20 . Proceed on the

same way for both retarder side). Adjust air gap by

adding or removing air gap adjusting shims if the

value is not correct (operations 7B-1 to 7B-7).

Get closer to your TELMA agent for retarder

specifications.

For additional information related to air gap

measurement, please refer to technical

information 2006/05.

MAINTENANCE MANUAL

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7B-9

7B-10

After having adjusted the air gaps, on each

retarder side, unscrew the removed shaft end

screws and the removed pressure plate.

Install 2 new shaft end screws and a new pressure

plate supplied with the replacement hub assembly.

With a manual torque wrench, apply a tightening

torque value of 60 Nm ± 20% (44 lb.ft ± 20%)

alternately on these 2 screws.

Use a locking bar to be inserted inside a rotor

cooling canal for preventing the rotation of the

rotor.

7B-11

7B-12

Insert a new lock tab in the retaining tab driver

On each retarder side, put in place the lock tab

over the screw heads and hit with a hammer.

Check that the lock tabs are well bottomed over

the shaft end screw heads.

Pressure

plate

Shaft

endnd

screws

MAINTENANCE MANUAL

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