Technical Info 02 2008b AD Hub Replacement

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More details at TELMA Customer Service Engineering (CSE) department

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TECHNICAL INFORMATIONn 02/2008bHUB REPLACEMENT FOR TELMA RETARDER - AD RANGE

St-Ouen-LAumne, February 2008

CAUTION !

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 orientationduring the re-assembly. It is important to maintain proper

balance.

There is also a balancing mark

can be used if necessary.


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More details at TELMA Customer Service Engineering (CSE) department.

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1. REMOVAL OF ROTOR ON AXLE SIDE (opposite from connecting blockside)

1-A

Remove the tab washer. Relieve the stressin the tab by tapping on one side and by

removing on the other.

1-B

Remove the end shaft screws (use 17 or 19mm sockets, according to the retarder size).

1-C

Remove the end shaft plate. 1-D Remove the rotor with its coupling flange.


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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 connectingblock 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 upor down).


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3-C

On the gearbox side remove the 6 hubretaining screws around the shaft.

3-D

Put the stator in a horizontal position (sideof the hub screw removed down) on wood

shims in order to protect the shaft.

3-E

On the other side remove the 6 hubretaining 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.


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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.


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5. CLEANING OF THE STATOR AND HUB

5-A

Clean the poles and the stator especially thesurface 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 ofthe new complete hub.

5-D

Before cleaning


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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 hubscrews (see Annex for cross clamping) to

the correct torque and mark them with paint.


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6-EPut 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 thestator. The comparator is positioned on the hub and we take reference on one pole shoe (0mm).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.


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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 newshims (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.


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ANNEX / ADDITIONAL INFORMATION

TORQUES:

Remark: Always perform cross clamping. See the example under (order: 1-2-38).

End shaft screw torque:

AD5 and AD6 range:

AD50-55 / AD50-90

AD61-30 / AD61-55

AD7 range:

AD72-00 / AD72-45 / AD72-60

30 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 107 980 VB 107 979 VB 107 978

1

8 2

3

4

5

6

7


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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 lifestyle.

Warning

Warning indicates an unsafe practice that could result in personal injury. Personal injury means that the injuryis 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 !

Technical Info 02 2008b AD Hub Replacement

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