TECHNICAL INFORMATION n 02/2008b

Transcription

1 TECHNICAL INFORMATION n 02/2008b HUB REPLACEMENT FOR TELMA RETARDER - AD RANGE CAUTION! St-Ouen-L Aumône, February 2008 Do an entire wash of the retarder before its disassembly. Do this operation on a cold retarder. The use of a high pressure washer is permissible whenever the jet is not directly oriented on the stator / coil harness (25 bars max). Do the replacement and job in a clean working environment. Store new parts in their original packing until they are used. During disassembly, always mark the parts from the axle side and/or gearbox side separately. Be careful of the heavy parts of the retarder which can cause serious personal injury. Before the removal of the rotors, draw a reference mark on each rotor external edge in order to find its initial orientation during the re-assembly. It is important to maintain proper balance. There is also a balancing mark can be used if necessary. 1/11

2 1. REMOVAL OF ROTOR ON AXLE SIDE (opposite from connecting block side) 1-A Remove the tab washer. Relieve the stress in the tab by tapping on one side and by removing on the other. 1-B Remove the end shaft screws (use 17 or 19 mm sockets, according to the retarder size). 1-C Remove the end shaft plate. 1-D Remove the rotor with its coupling flange.. 2/11

3 2. REMOVAL OF ROTOR ON GEARBOX SIDE (connector side) Make the same step from 1A to 1D 3. REMOVAL OF AXLE SIDE STATOR FRAME (opposite from connecting block side) 3-A Note the dust cover position (direction). Remove the dust cover and the shims. 3-B Note the position of the hub (vent tube up or down). 3/11

4 3-C On the gearbox side remove the 6 hub retaining screws around the shaft. 3-D Put the stator in a horizontal position (side of the hub screw removed down) on wood shims in order to protect the shaft. 3-E On the other side remove the 6 hub retaining screws around the shaft and the 8 pole shoe screws. 3-F Remove the stator frame. 3-G Remove the coil pressure washers. Clean them. 4/11

5 4. REMOVAL OF THE COMPLETE HUB 4-A Note again the position of the vent tube. Remove the hub. Caution! When removing the hub be careful not to damage the coils and internal wiring. 5/11

6 5. CLEANING OF THE STATOR AND HUB 5-A Clean the poles and the stator especially the surface between hub and stator. Remove old grease. A small layer of grease can be added for rust protection. 5-B Do the same on the other stator frame. 5-C Clean also carefully the machined surface of the new complete hub. 5-D Before cleaning 6/11

7 6. INSTALLATION OF THE NEW COMPLETE HUB 6-A Orient the new hub at the correct position for the vent tube ( 3B and 4A). 6-B Then put all the pressure washers on the coils. 6-C Put the stator frame on the coils. 6-D Tighten the pole shoe screws and hub screws (see Annex for cross clamping) to the correct torque and mark them with paint. 7/11

8 6-E Put the retarder in a vertical position. Install and tighten the 6 front hub screws to the correct torque. 7. CONTROL OF THE FLATNESS OF THE STATOR 7-A Clean well the pole shoes. Be sure also that the shoulder of the hub is in total contact with the stator. The comparator is positioned on the hub and we take reference on one pole shoe (0 mm).the measure should be made on each pole shoe. The flatness of the pole shoes must not exceed 0.3 mm. Make this operation on both sides of the stator. 8/11

9 8. INSTALLATION OF THE ROTORS 8-A Refer to the IT 05/2006a and IT 07/2006 for the air gap measure and adjustment. Put the new shims (black one first), the new dust covers (direction noted in 3A) and the rotors in place (use the balancing mark done). Do the same for the new end shaft screws and tab washer. Check and adjust the air gap. 9/11

10 ANNEX / ADDITIONAL INFORMATION TORQUES: Remark: Always perform cross clamping. See the example under (order: ) End shaft screw torque: 8 2 AD5 and AD6 range: AD50-55 / AD50-90 AD61-30 / AD61-55 AD7 range: AD72-00 / AD72-45 / AD N.m (+/- 20%) 60 N.m (+/- 20%) Hub screw torque: 68 N.m (+/- 20%) Pole shoe screw torque: 45 N.m (+/- 10%) TELMA Original Spare Parts: TELMA AD5 AD6 AD7 Complete hub VB VB VB /11

11 Danger Danger indicates an unsafe practice that could result in death or serious personal injury. Serious personal injury is considered to be permanent injury from which full recovery is NOT expected, resulting in a change in life style. Warning Warning indicates an unsafe practice that could result in personal injury. Personal injury means that the injury is of a temporary nature and that full recovery is expected. Caution Caution indicates an unsafe practice that could lead to damage of the product. Note Note indicates a procedure, practice, or condition that must be followed in order for the vehicle or component to function in the manner intended. Remember, Safety..is no accident! 11/11