Telma OC441665 User manual

OC441665
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MAINTENANCE MANUAL
Hub replacement on retarders AF5 and LVRS600
These instructions define how to replace the hub on:
Axial retarders LB-LE-LF-LJxxxxxxx (AF5 and LVRS600)

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Table of contents
1.TELMA ORIGINAL SPARE PART NEEDED...........................................................................................................................3
2.SAFETY PRECAUTIONS.............................................................................................................................................................4
3.NECESSARY TOOLS...................................................................................................................................................................5
4.PARTS TO BE REPLACED SYSTEMATICALLY...................................................................................................................5
5.NOTES .............................................................................................................................................................................................5
6.DISMANTLING...............................................................................................................................................................................6
a.REMOVAL OF ROTORS.........................................................................................................................................................6
b.RETARDER STATOR OPENING...........................................................................................................................................9
c.REMOVAL OF THE DEFECTIVE HUB...............................................................................................................................12
7.RE ASSEMBLING .......................................................................................................................................................................14
a.INSTALLATION OF THE NEW COMPLETE HUB...........................................................................................................14
8.INSTALLATION OF THE ROTORS.........................................................................................................................................20

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1. TELMA ORIGINAL 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, its serial number, and
the model.
You will find the necessary information on spare parts for this equipment in the spare parts catalogue:
« SPARE PART CATALOG FOR AF / LVRS TELMA RETARDERS » OC443040
For more information about your TELMA SA product, please contact your TELMA dealer.

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2. SAFETY PRECAUTIONS
Before operating your retarder you must have read this maintenance manual thoroughly.
All operations and interventions for fixing this retarder will be carried 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 various 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.
Safety warning symbol for 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 cases 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 weighs 101 kg (223 lb), a rotor weighs 14 kg (31 lb), and a hub weighs 5.5
kg (11 lb),
-Put the retarder on a solid table, with the handling safety tool.
-Be-careful of the heavy parts of the retarder which can cause serious personal injury.

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3. NECESSARY TOOLS
-Protective glasses and gloves
-Handling safety tools for retarder
-Flat screwdriver
-Torx® TX40 wrench
-Click-type wrench
-10 mm long socket and 17 mm socket
-Tab washer driver
-Hammer
-A feeler gauge
-Magnetic dial gauge and its sensor
-Ink marker
-Torque wrench (torque values : 5.25 and 30 Nm)
-Abrasive cloth (120 grade)
4. PARTS TO BE REPLACED SYSTEMATICALLY
When they have been removed the following parts need to be changed.
-End shaft screws, washers, shims and lock tabs
-Screws used to secure hub
-Screws used to secure retarder fixation pads
-Screws used to secure pole shoes plate
-Air gap adjusting shims
-Line shaft dust shields
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 (power unit and retarder brackets)
removed from the retarder.
To remove power unit or retarder brackets, please refer to the appropriate procedures.
The different pictures on this procedure are generic views and are not contractual.

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6. DISMANTLING
a. REMOVAL OF ROTORS
Identify all parts before dismantling in order to find their initial orientations during the re-
assembly.
1-A 1-B
1-C 1-D
Draw a mark with an ink marker on a rotor. Draw a same mark on the other rotor, the 2
marks must be aligned.
AF5 retarder with retarder brackets
removed. LVRS600 retarder with retarder brackets removed.
Retarder axle side.
Retarder harness on left
Retarder axle side. Main connecting block on right

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1-E 1-F
1-G 1-H
On a retarder side, remove the lock tab by
using a flat screwdriver and a hammer.
Caution: In order to avoid the springiness,
suppress the stress in the tab by tapping on one
side and by removing on the other).
Remove the lock tab.
Unscrew the 2 end shaft screws.
Use a 17 mm socket and a bar to lock the
rotation of the rotor.
Remove the 2 end shaft screws with the end
shaft plate.

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1-I 1-J
1-K 1-L
Remove the rotor with its coupling flange.
Remove the dust shield from the shaft line.
Remove air gap adjusting shims and the
black shim, from the shaft line.
Black shimShims used to adjust air gap
Do the same steps from 1-E to 1-K for the
other rotor (gearbox side).

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b. RETARDER STATOR OPENING
If you replace the hub on retarder LVRS600, please go directly to the picture 2-C.
Specific operations in case of hub replacement on AF5 retarder.
2-A 2-B
2-C 2-D
Unscrew and remove the 3 screws securing
the hub on gearbox side.
Use a Torx® TX40 wrench.

Install two wood bars for toggling the
retarder on them (axle side up).
The wood pieces must be thick enough in
order that the shaft line doesn’t touch the table
and for hand access for further operations.
Vent cap
Gearbox side
Unscrew the 2 nuts + 2 washers securing
the cover to the connecting block, and remove
them (use a 10 mm long socket).
Remove the cover.
Unscrew the nut securing the connecting
block to the stator frame. It isn’t necessary to
remove nut completely. (Use a 10 mm long
socket
)
.
2 nuts + 2 washers

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2-E 2-F
2-G 2-H
Remove the 15 screws (4 + 8 + 3) securing
the pole shoes plate to fixation pads, poles, and
hub.
Use a Torx® TX40 wrench to unscrew the
15 screws.
View of the retarder toggled on the 2 wood
bars (axle side up).
The wood pieces must be thick enough in
order that the shaft line doesn’t touch the table
and for hand access for further operations.
Axle side

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If you replace the hub on retarder LVRS600, please go directly to the picture 2-K.
Specific operations in case of hub replacement on AF5 retarder.
2-I 2-J
2-K 2-L
Lift and remove completely the pole shoes
plate.
Don’t remove the spring washer on top of
each coil.
View of the retarder with the pole shoes
plate removed.
Spring washers on top of the coils
During pole shoes plate lifting, lift slightly
the pole shoes plate nearest the screw, which
secures the connecting block to the pole shoes
plate.
Lift the pole shoes plate.

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c. REMOVAL OF THE DEFECTIVE HUB
3-A 3-B
3-C 3-D
Screw by hand a screw in the shaft line in
order to facilitate hub removal.
Pull on the screw by hand to help removing the
hub.
When removing hub, be careful not to
damage the coils and internal wiring.
Internal view of retarder without its hub. Clean the stator in order to remove dust
which could cause bad hub fitting.
Use abrasive cloth (120 grade).
Indexing location for hub vent cap (gearbox side).

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3-E 3-F
Clean poles with abrasive cloth.
Use abrasive cloth (120 grade).
On pole shoes plate, clean the pole shoes
and surfaces where hub is in contact.
Use abrasive cloth (120 grade).

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7. RE ASSEMBLING
a. INSTALLATION OF THE NEW COMPLETE HUB
4-A 4-B
4-C 4-D
Take the new complete hub. Screw by hand a screw in the shaft line (axle
side) in order to facilitate hub installation.
Orient 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 screw after hub installation.
Check that wires are not stuck.
Vent cap (gearbox side) Axle side

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4-E 4-F
4-G 4-H
On gearbox side by going under the stator,
screw by hand completely 3 new screws in
order to secure the hub.
View of the 3 screws under stator (gearbox
side).
Check that all output coils (black and red)
of the 8 coils, are in front of the notch
locations.
Check that all the spring washers are well
located on the top of the coils.

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If you replace the hub on retarder LVRS600, please go directly to the picture 4-L.
Specific operations in case of hub replacement on AF5 retarder.
4-I 4-J
4-K
Check that the Vistop® lock washer steel is
at 8 to 10 mm of the head screw. On axle side, toggle the pole shoes plate to
the poles.
Take care not to wedge the spring washers
with the poles during toggling.
8 to 10 mm
Take care to slide the screw correctly in the
pole shoes plate slot.

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4-L 4-M
4-N 4-O
On axle side, toggle completely the pole
shoes plate to the poles.
Take care not to wedge the spring washers with
the poles during toggling.
Put in place by hand, 15 new screws:
-Put the 4 screws to the fixation pads 1st
-Put the 3 screws to the hub
-Put the 8 screws to the pole shoes.
Tighten screws at the nominal torque (25
Nm +/- 20%) (18 lb-ft±20%) following specific
order, described on point 4-O.
Use a Torx® TX40 wrench.
Tighten screws, starting by:
-The 8 screws of the pole shoes.
-The 3 screws to the hub.
-The 4 screws to the fixation pads.
1
2
3
4 5
6
9 10
11
12
15
14
13
8
7

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4-P 4-Q
4-R 4-S
Put the retarder in a vertical position.
Turn the retarder in order to have the
gearbox side in front of you (vent cap in front
of you).
Tighten the 3 screws of the hub at the
nominal torque (25 Nm +/- 20%)
(18 lb-ft±20%).
Use the Torx® TX40 wrench.
Vent cap
Specific operation for AF5 retarder only
Tight the nut (used to secure the connecting
block to the stator) at nominal torque (5 Nm
+/- 20%) (44 lb-in±20%).
Use a 10 mm long socket.

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4-T 4-U
4-V 4-W
Toggle the retarder and put it in a vertical
position. Retarder in a vertical position
Axle side
Axle side
Toggle again the retarder (axle side up) to
the wood bars in order to check the stator run
out.
Check the run out of the stator by using a
magnetic dial gauge and a sensor.
Maximum value allowed is 0.40 mm.
Nota: In case the maximum value is up to
0.40mm, contact technical department at
TELMA SA.

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8. INSTALLATION OF THE ROTORS
6-A 6-B
6-C 6-D
On the both sides of the shaft line, put in
place a new black shim and new air gap
adjusting shims with a thickness similar to the
shims removed on operation 1-K.
NB: The black shim has to be first installed
and its presence is mandatory in any case.
Put new dust shields on the both shaft line
sides.
Re-install the 2 rotors on the shaft line,
ensuring that the 2 ink marks are aligned.
Ensure that the 2 marks (1) are aligned.
Black shim in first.
1
Air gap adjusting shims.