telma parts

SPARE PARTS CATALOGUE

AC – SERIES AXIAL RETARDER

INSULATED EARTH RETURN

OC443013/aEdition 06/2001

TABLE OF CONTENTS

Technical specifications of the AC series retarders ................................................................ 2

Identification of the retarders by their dimensions (mm) ........................................................ 3

Indexes, designation and dimensions for identification of the coupling flanges............... 4-5

Stator assembly................................................................................................................ ........ 6-8

Coil assembly .................................................................................................................. ............ 9

Retarder shaft assembly ...................................................................................................... 10 -12

SAE coupling flanges with metric fasteners...................................................................... 13-14

SAE coupling flanges with anglo-american ............................................................................ 15

70° cross–serrated coupling flanges and SCANIA yokes ..................................................... 16

DIN flat coupling flanges ..................................................................................................... 1 7-18

12 V and 24 V wiring diagrams – Insulated earth return ................................................... 19-22

Junction block assembly – VD 407 390 ................................................................................... 23

Connecting block and earth terminal – VD 408 573 ............................................................... 24

Greasing ....................................................................................................................... .............. 25

Crimping tool .................................................................................................................. ........... 25

Wiring repair kit .............................................................................................................. ........... 25

Protection of terminals against corrosion .............................................................................. 25

Replacement of a coil .......................................................................................................... ..... 26

– 1 –

Technical specifications of the AC series retarders

– 2 –

LEDOMREDRATER 55–05CA 56–05CA 08–05CA 00–15CA 52–16CA 52–16CA 53–16CA 06–16CA 00–27CA 07–28CA 00–38CA 13–38CA

EDOCREDRATER 02NC 32NC 32PC 32MC 63EC 73EC 32EC 32FC 32HC 32UC 32TC 32LC

GNIKARBMUMIXAMEUQROT

mNtf-bl

005863

056974

008985

0001737

0521129

0521129

0531599

00619711

00024741

00720991

00031122

00332342

SSAMLATOT kgbl

401922

431592

431592

351733

271973

291324

922505

922505

872316

333437

083838

593178

ssamrotatS kgbl

27851

001022

001022

911262

221962

241313

261753

261753

491824

742445

492746

903086

ssamsrotoR)segnalfhtiw(

kgbl

2307

4357

4357

4357

05011

05011

76841

76841

48581

68091

68091

68091

PAG–RIA mmhcni

8.0130.

5.1950.

8.0130.

8.0130.

1930.

1930.

9.1570.

2.1740.

2.1740.

2.1740.

5.1950.

5.1950.

ECNATSISEREGATSREP

F°86(C°02ta%5± )

V21 ΩΩΩΩΩ 56.0 3.0 3.0 72.0 42.0 4.0 91.0 91.0 91.0 81.0 51.0

V42 ΩΩΩΩΩ 6.2 2.1 2.1 80.1 79.0 6.1 57.0 57.0 57.0 7.0 6.0 75.0

ECNATSISERLIOCREP

F°86(C°02ta%5± )ΩΩΩΩΩ 56.0 2.1 2.1 80.1 79.0 6.1 57.0 57.0 57.0 7.0 6.0 75.0

EGAREPMAEGATSREP

)F°86(C°02ta%5±

V21 A 2.81 04 04 6.54 8.84 03 36 36 6.36 5.76 08

V42 A 1.9 02 02 8.22 4.42 51 5.13 5.13 8.13 8.33 04 24

ECNATSISERNOITALUSNI)yrdredrateR( MΩΩΩΩΩ ≥ 1 ≥ 1 ≥ 1 ≥ 1 ≥ 1 ≥ 1 ≥ 1 ≥ 1 ≥ 1 ≥ 1 ≥ 1 ≥ 1

0- 0.15 mm /

0- .006 inch

noisnemiDREDRATER

55–05CA....02NC

56–05CA....32NC

08–05CA....32PC

00–15CA....32MC

52–16CA....63EC

52–16CA....73EC

53–16CA....32EC

06–16CA....32FC

00–27CA....32HC

07–28CA....32UC

00–38CA....32TC

13–38CA....32LC

A 363 363 363 363 074 074 074 074 594 035 035 035

B 383 383 383 383 694 694 694 694 915 455 455 455

C 022 123 123 123 662 662 853 853 383 814 814 814

D 421 5.912 5.912 5.912 451 451 022 022 932 2.082 2.082 2.082

E 8.0 5.1 8.0 8.0 1 1 9.1 2.1 2.1 2.1 5.1 5.1

∅F 253 253 253 253 424 424 644 644 084 005 005 005

Identification of the retarders by their dimensions (mm)

Note : all the dimensions are given in millimeters 1mm = .039 inch.

– 3 –

air escape tube

connecting block

earth terminal M8 x 1.25

grease point

A Ø F

180

± 0.

4

E : airgap

90 ± 0.4

B DE

C

earth terminal M8 x 1.25

180

± 0.

4

42 ± 0.4

DE

C

(AC50–55 only)

Ø F

E: airgap

Figure I Figure II Figure III

Figure IV Figure V

Indexes, designation and dimensions for identification of the coupling flanges

.dnI noitpircseD .giF B C D E F

301 srenetsafcirtem,0031EAS I 151 23.06 73.97 4 01



601 srenetsafcirtem,0061EAS II 2.302/6.471 22.861 25.551 8 01

701 srenetsafcirtem,0071EAS III 2.302 58.691 21.481 8 01

801 srenetsafcirtem,0081EAS III 2.302 58.691 21.481 21 11

*011 srenetsafcirtem,0081EAS III 2.302 58.691 21.481 21 11

711 051ØNID V/VI 051 09 031 8 21

021 081ØNID VI 081 011 5.551 8 41

321 021ØzneB-sedecreM IV 051 5.28 6.101 6 01

421 031ØzneB-sedecreM I 031 65.28 211 8 01

431 021ØNID VI 031 57 5.101 8 01

931 081ØNID VI 081 011 5.551 8 61

041 081ØNID VI 081 011 5.551 01 61

141 561ØNID VI 561 59 041 8 61

541 decrofnierR0071EAS III 2.302 58.691 21.481 21 01

251 0171EAS III 2.302 58.691 21.481 8 25.9

451 0141/0531EAS I 151 58.96 52.59 4 1.11

551 0551/0841EAS I 151 52.59 76.021 4 7.21

751 0181/0671EAS III 2.302 58.691 21.481 21 1.11

851 0161/0551EAS II 2.302/6.471 52.861 25.551 8 25.9

* Index 110 :Similar to index 108, but rear propshaft securing is offset by 45°, anti-clockwise, inrelation to front propshaft.

Dimensions (mm)

B external diameter of the retarder coupling flangeC centering diameterD drilling diameter (P.C.D.) or distance between fastenersE number of securing screws or holesF diameter of securing screws or studsFigure VI

– 4 –

Figure VII Figure VIII

Indexes, designation and dimensions for identification of the coupling flanges

Figure IX

.dnI noitpircseD .giF B C D E F

821 021Ønoitarres–ssorC IIV )00-15CAot56-05CA(051)06-16CA/53-16CA(561 001 4 01

921 051Ønoitarres–ssorC IIV)00-15CAot56-05CA(051)06-16CAot52-16CA(561)00-38CAot00-27CA(081

031 4 21

531 561ØleseidnassiN IIIV 561 09 611x08 4 61

631 004P/04PAINACS XI 58x9.131 4 21

731 005P/05PAINACS XI 59x7.521 4 21

831 081Ønoitarres–ssorC IIV 081 051 4 41

Dimensions (mm)

B external diameter of the retarder coupling flangeC centering diameterD drilling diameter (P.C.D.) or distance between fastenersE number of securing screws or holesF diameter of securing screws or studs

– 5 –

Stator assembly

metI noitpircseD ytQ

REDRATEREDOC

55–05CA....02NC

56–05CA08–05CA....32NC....32PC

00–15CA.....32MC

01stloV21ylbmessarotatSstloV42

1417701BV517701BV

617701BV717701BV

817701BV917701BV

51 ebutepacseriA 1 023005BV 023005BV 023005BV

61 hsubdedaerhT 1 051105BV 051105BV 051105BV

a61 noisnetxeebutepacseriateS 1 011001ZJ 011001ZJ 011001ZJ

71 ebutgnitacirbuL 1 022005BV 022005BV 022005BV

81 rehsawtalF 1 001002FV 001002FV 001002FV

91 elppinesaerG 1 001005FV 001005FV 001005FV

02 ylbmessaliocrolioC)9egapnosliatedees( 61 495013DV 021012DV 083012DV

12 rehsawerusserP 61 034105BV 034105BV 034105BV

22 lewodgnitacoL 61 056012FV 056012FV 056012FV

32 wercstekcospacknusretnuoc°09)wercsdaehlanogaxehlanretni( 61 001901FV 001901FV 001901FV

42 eohseloP 61 687415BV 099605BV 099605BV

ylbmessagniriW 1 segapees22dna12

segapees02dna91

segapees02dna91

lanimrethtraednakcolbgnitcennoC 1 egapees42

egapees42

egapees42

ylbmessakcolbnoitcnuJ 3 egapees32

egapees32

egapees32

– 6 –

(50 Nm37 lb–ft)

Stator assembly


REDRATEREDOC

52–16CA....63EC

52–16CA....73EC

53–16CA06–16CA....32EC....32FC


1027701BV127701BV 327701BV

427701BV527701BV

51 ebutepacseriA 1 033005BV 033005BV 033005BV

61 hsubdedaerhT 1 051105BV 051105BV 051105BV

a61 noisnetxeebutepacseriateS 1 011001ZJ 011001ZJ 011001ZJ

71 ebutgnitacirbuL 1 062005BV 062005BV 062005BV

81 rehsawtalF 1 001002FV 001002FV 001002FV

91 elppinesaerG 1 001005FV 001005FV 001005FV

02 ylbmessaliocrolioC)9egapnosliatedees( 61 594013DV 584013DV 031012DV

12 rehsawerusserP 61 074105BV 074105BV 074105BV

22 lewodgnitacoL 61 056012FV 056012FV 056012FV

32 wercstekcospacknusretnuoc°09)wercsdaehlanogaxehlanretni( 61 001901FV 001901FV 001901FV

42 eohseloP 61 670515BV 670515BV 025005BV


segapees02dna91

segapees02dna91


egapees42

egapees42


egapees32

egapees32

(AC61–25 only)

– 7 –

(50 Nm37 lb–ft)

Stator assembly


REDRATEREDOC

00–27CA....32HC

07–28CA....32UC

00–38CA....32TC

13–38CA....32LC


1627701BV727701BV

827701BV927701BV

037701BV137701BV 337701BV

51 ebutepacseriA 1 043005BV 025215BV 025215BV 025215BV

61 hsubdedaerhT 1 051105BV 051105BV 051105BV 051105BV

a61 noisnetxeebutepacseriateS 1 011001ZJ 011001ZJ 011001ZJ 011001ZJ

71 ebutgnitacirbuL 1 052005BV 015215BV 015215BV 015215BV

81 rehsawtalF 1 001002FV 001002FV 001002FV 001002FV

91 elppinesaerG 1 001005FV 001005FV 001005FV 001005FV

02 ylbmessaliocrolioC)9egapnosliatedees( 61 041012DV 484013DV 534013DV 695013DV

12 rehsawerusserP 61 044105BV 077905BV 077905BV 077905BV

22 lewodgnitacoL 61 056012FV 056012FV 056012FV 056012FV

32 wercstekcospacknusretnuoc°09)wercsdaehlanogaxehlanretni( 61 001901FV 001901FV 001901FV 001901FV

42 eohseloP 61 035005BV 045005BV

edisxobraeg 8 113515BV 113515BV

ediselxa 8 213515BV 213515BV


segapees02dna91

segapees02dna91

segapees02dna91


egapees42

egapees42

egapees42


egapees32

egapees32

egapees32

– 8 –

(AC82–70 and AC83 –31 only)

gearbox side axle side (50 Nm37 lb–ft)

Coil assembly

Figure I

Figure II

REDRATER .giF lioCylbmessagnidulcni

smetia02 ot h02

dnelioCevitcetorp

revocmetia02

lioCdne

rotalusnimetie02

evitcetorPnorehsawedisgnisuoh

metif02

lanretxEevitcetorp

eveelsmetig02

teS61fo

slanimretmetih02

55–05CA I 495013DV 285305DV 996305DV *630202BV 278704DV

56–05CA08–05CA I 021012DV 285305DV 996305DV *630202BV 278704DV

00–15CA I 083012DV 285305DV 996305DV *630202BV 278704DV

63epyT52–16CA I 594013DV 985305DV 116305DV *630202BV 278704DV

73epyT52–16CA I 584013DV 985305DV 116305DV *630202BV 278704DV

53–16CA06–16CA I 031012DV 985305DV 116305DV *630202BV 278704DV

00–27CA I 041012DV 063005DV 367305DV *630202BV 278704DV

07–28CA I 484013DV 316305DV 545305DV *630202BV 278704DV

00–38CA II 534013DV 955305DV 416305DV 545305DV *630202BV 278704DV

13–38CA II 695013DV 357305DV 316305DV 545305DV *630202BV 278704DV

* set of 8 pieces, to be cut to the dimensions of the coils.

– 9 –

Retarder shaft assembly


REDRATER

55–05CA56–05CA08–05CA00–15CA

13 ,ylbmessatfahS :gnidulcni 1 003701BV 103701BV

a13 selohknusretnuochtiwtfahs 1rednudeilppus

ylbmessaehtrebmuntrap

rednudeilppusylbmessaehtrebmuntrap

b13 rehsawbat 2 061515BV 061515BV

c13 wercsdnetfahs 4 083001FV 083001FV

d13 etalp 2 751515BV 751515BV

23 smihsgnitsujdapag–riafoteS 1 051001BV 051001BV

53 erobrofgnirpanS 2 011022FV 011022FV

73 laespilelbuoD 2 033004FV 033004FV

83 gnirrecapS 2 808415BV 001705BV


REDRATER

55–05CA56–05CA08–05CA00–15CA

93 gniraebrellorderepaT 2 051013FV 051013FV

0414

smihsgnitsujdagniraebfoteSgnirrecapS

1 029102BV 029102BV

54 tsuD 2 761515BV 761515BV

05 rotoresiwkcolC 1 887415BV 018105BV

15 rotoresiwkcolc–itnA 1 987415BV 028105BV

45 rotorotwercsgnirucesegnalfgnilpuoC 8 045001FV 005001FV

55 wercsgnirucesegnalfrofrehsawgnirpS 8 006002FV 006002FV

65 egnalfgnilpuoC 2 segapees81ot31

segapees81ot31

)52egapees(esaerG 1 043002JV 043002JV

– 10 –

(30 Nm 22 lb–ft)

(100 Nm 74 lb–ft)

(100 Nm 74 lb–ft)

(30 Nm 22 lb–ft)



REDRATER

52–16CA 53–16CA06–16CA

13 ,ylbmessatfahS :gnidulcni 1 303701BV 403701BV






d13 etalp 2 851515BV 851515BV



73 laespilelbuoD 2 023004FV 023004FV



metI noitpircseD ytQREDRATER

52–16CA 53–16CA06–16CA

0414

smihsgnitsujdagniraebfoteSgnirrecapS 1 039102BV 039102BV

54 tsuD 2 099415BV 099415BV




45 rotorotwercsgnirucesegnalfgnilpuoCrofylno 631dna431sexedni 8 033801FV 033801FV


55 wercsgnirucesegnalfrofrehsawgnirpSrofylno 431xedni 8 018002FV 018002FV


segapees81ot31


– 11 –

(30 Nm 22 lb–ft)

(180 Nm 132 lb–ft)

(180 Nm 132 lb–ft)

(30 Nm 22 lb–ft)


REDRATER

00–27CA07–28CA00–38CA13–38CA

13 nidulcni,ylbmessatfahS :g 1 603701BV 703701BV






d13 etalp 2 951515BV 951515BV



73 )epytNOTIVEI(laespiL 2 023004FV 043004FV





REDRATER

00–27CA07–28CA00–38CA13–38CA

0414

smihsgnitsujdagniraebfoteSgnirrecapS 1 049102BV 059102BV

54 tsuD 2 462515BV 457305DV




45 rotorotwercsgnirucesegnalfgnilpuoCrofylno 731dna631sexedni

44

062801FV023801FV

062801FV023801FV



segapees81ot31


– 12 –

(60 Nm 44 lb–ft)

(250 Nm 184 lb–ft)

(250 Nm 184 lb–ft)

(60 Nm 44 lb–ft)

SAE coupling flanges with metric fasteners

XEDNI REDRATER .giF*srenetsaFylbmessa

wercS)Bmeti(

dutS)Cmeti(

tuN)Dmeti(

301 55–05CA I 580701BV 051131FV4:ytQ

041021FV4:ytQ

401

55–05CA I 680701BV 003131FV4:ytQ

061021FV4:ytQ

56–05CA08–05CA00–15CA

I 049001BV 003131FV4:ytQ

061021FV4:ytQ

501

56–05CA00–15CA I 059001BV 024131FV

4:ytQ071021FV

4:ytQ

53–16CA06–16CA I 089001BV 024131FV

4:ytQ071021FV

4:ytQ

CAUTION : After degreasing the parts, the studs must be fitted to the coupling flange with LOCTITE 270.

Figure I

– 13 –

* including the items C and D.

SAE coupling flanges with metric fasteners

xednI REDRATER .giF

ebotderedro

yletarapes

*srenetsaFylbmessa

wercS)Bmeti(

dutS)Cmeti(

tuN)Dmeti(

etalpgniniateR)Gmeti(

601

56–05CA08–05CA00–15CA

II 029201BV 012911FV8:ytQ

041021FV8:ytQ

130515BV1:ytQ

52–16CA VI 991701BV 032911FV8:ytQ

041021FV8:ytQ

030515BV1:ytQ

53–16CA06–16CA VI 091701BV 032911FV

8:ytQ041021FV

8:ytQ130515BV

1:ytQ

00–27CA07–28CA VI 371701BV 001131FV

8:ytQ041021FV

8:ytQ

70106–16CA III 191701BV 032911FV

8:ytQ041021FV

8:ytQ130515BV

8:ytQ

00–27CA III 471701BV 032911FV8:ytQ

041021FV8:ytQ

038205BV1:ytQ

801

52–16CA III 102701BV 021911FV21:ytQ

051021FV21:ytQ

030515BV1:ytQ

53–16CA06–16CA III 291701BV 021911FV

21:ytQ051021FV

21:ytQ130515BV

1:ytQ

00–27CA07–28CA00–38CA13–38CA

III 671701BV 021911FV21:ytQ

051021FV21:ytQ

038205BV1:ytQ

011

00–27CA07–28CA00–38CA13–38CA

III 671701BV 021911FV21:ytQ

051021FV21:ytQ

038205BV1:ytQ

541

53–16CA06–16CA III 391701BV 032911FV

21:ytQ041021FV

21:ytQ130515BV

1:ytQ

00–27CA07–28CA00–38CA

III 571701BV 032911FV21:ytQ

041021FV21:ytQ

038205BV1:ytQ


Figure II

Figure III

Figure IV

– 14 –

* including the items B, C and D.

SAE coupling flanges with anglo american fasteners

xednI REDRATER .giF

ebotderedro

yletarapes

*srenetsaFylbmessa

wercS)Bmeti(

dutS)Cmeti(

tuN)Derèper(

etalpgniniateR)Gmeti(

251

52–16CA IIIV 004701BV 072911FV8:ytQ

030515BV1:ytQ

53–16CA06–16CA IIIV 491701BV 072911FV

8:ytQ130515BV

1:ytQ

00–27CA IIIV 081701BV 072911FV8:ytQ

038205BV1:ytQ

451

55–05CA V 512701BV 021031FV4:ytQ

073021FV4:ytQ

56–05CA08–05CA00–15CA

V 112701BV 021031FV4:ytQ

073021FV4:ytQ

551

56–05CA08–05CA00–15CA

V 212701BV 031031FV4:ytQ

043021FV4:ytQ

52–16CA V 302701BV 031031FV4:ytQ

043021FV4:ytQ

53–16CA06–16CA V 762701BV 031031FV

4:ytQ043021FV

4:ytQ

751

06–16CA IIIV 893701BV 081401FV21:ytQ

073021FV21:ytQ

130515BV1:ytQ

00–27CA07–28CA00–38CA13–38CA

IIIV 281701BV 081401FV21:ytQ

073021FV21:ytQ

038205BV1:ytQ

851

08–05CA00–15CA IV 312701BV 062911FV

8:ytQ

52–16CA IV 702701BV 072911FV8:ytQ

030515BV1:ytQ

53–16CA06–16CA IV 591701BV 072911FV

8:ytQ130515BV

1:ytQ

00–27CA IIV 971701BV 011031FV8:ytQ


Figure V

Figure VI

Figure VII

Figure VIII

– 15 –


70° cross–serrated coupling flanges and SCANIA yokes

XEDNI REDRATER .giF*renetsaFylbmessa

wercS)Bmeti(

dutS)Cmeti(

tuN)Dmeti(

821

56–05CA08–05CA00–15CA

XI 499601BV 011131FV4:ytQ

041021FV4:ytQ

52–16CA XI 505701BV 011131FV4:ytQ

041021FV4:ytQ

53–16CA06–16CA XI 602701BV 011131FV

4:ytQ041021FV

4:ytQ

921

08–05CA00–15CA XI 599601BV 063131FV

4:ytQ061021FV

4:ytQ

52–16CA XI 913701BV 063131FV4:ytQ

083021FV4:ytQ

53–16CA06–16CA XI 691701BV 063131FV

4:ytQ083021FV

4:ytQ

00–27CA07–28CA00–38CA

XI 381701BV 063131FV4:ytQ

083021FV4:ytQ

631

06–16CA X 036701BV

00–27CA07–28CA00–38CA

X 100701BV

73100–27CA07–28CA00–38CA

X 200701BV

831

52–16CA XI 616701BV 005131FV4:ytQ

093021FV4:ytQ

53–16CA06–16CA XI 254701BV 005131FV

4:ytQ093021FV

4:ytQ

00–27CA07–28CA00–38CA13–38CA

XI 581701BV 005131FV4:ytQ

093021FV4:ytQ


Figure IX

Figure X

– 16 –

* including the items C and D.

DIN flat coupling flanges

Figure XI

Figure XII



rotpadA)Ameti(

wercS)Bmeti(

dutS)Cmeti(

tuN)Dmeti(

wercS)Emeti(

rehsaW)Hmeti(

711

08–05CA00–15CA IIIX 021501BV 062131FV

8:ytQ061021FV

8:ytQ

52–16CA IIX 902701BV 015001FV8:ytQ

53–16CA06–16CA IIX 001101BV 015001FV

8:ytQ

00–27CA07–28CA IX 048001BV 019205BV

1:ytQ015001FV

4:ytQ025031FV

4:ytQ003901FV

4:ytQ038002FV

4:ytQ

02106–16CA IIX 021101BV 028001FV

8:ytQ

00–27CA IIX 871701BV 034101FV8:ytQ

321

55–05CA VIX 931701BV 098305BV1:ytQ

051131FV6:ytQ

041021FV6:ytQ

058001FV4:ytQ

018002FV4:ytQ

56–05CA08–05CA00–15CA

VIX 039201BV 098305BV1:ytQ

051131FV6:ytQ

041021FV6:ytQ

058001FV4:ytQ

018002FV4:ytQ

421

55–05CA IIIX 980701BV 081131FV8:ytQ

041021FV8:ytQ

56–05CA08–05CA00–15CA

IIIX 069001BV 081131FV8:ytQ

041021FV8:ytQ

52–16CA IIIX 437701BV 081131FV8:ytQ

041021FV8:ytQ

53–16CA IIIX 623701BV 081131FV8:ytQ

041021FV8:ytQ

Figure XIII

Figure XIV– 17 –

* including the items A, B, C, D, E and H.

DIN flat coupling flanges

Figure XV

Figure XVI

Figure XVII

Figure XVIII CAUTION : After degreasing the parts, the studs must be fitted to the coupling flange with LOCTITE 270.


wercS)Bmeti(

dutS)Cmeti(

tuN)Dmeti(

431

55–05CA VX 090701BV 081131FV8:ytQ

041021FV8:ytQ

56–05CA08–05CA00–15CA

VX 079001BV 081131FV8:ytQ

041021FV8:ytQ

53–16CA06–16CA VX 032301BV 061131FV

8:ytQ031021FV

8:ytQ

531 52–16CA IVX 537701BV 021101FV4:ytQ

081021FV4:ytQ

93100–27CA07–28CA00–38CA

IIVX 681701BV 021101FV8:ytQ

04100–27CA07–28CA00–38CA

IIIVX 009001BV 032101FV01:ytQ

14106–16CA IIVX 031101BV 021101FV

8:ytQ

00–27CA07–28CA IIVX 098001BV 021101FV

8:ytQ

– 18 –


12 V wiring diagram – Insulated earth return

metI ytQ noitpircseD

REDRATER

56–05CA08–05CA00–15CA

52–16CA53–16CA06–16CA

00–27CA 07–28CA00–38CA

1 1 srenetsafhtiwylbmessakcolbgnitcennoC lanimrethtraedetalusnidna )42egapnosliatedees( 375804DV 375804DV 375804DV 375804DV

2 3 srenetsafhtiwylbmessakcolbnoitcnuJ )32egapnosliatedees( 093704DV 093704DV 093704DV 093704DV

4 1 ,tesgniriwlanretniV42dnaV21 gnidulcni : 575804DV 675804DV 775804DV 875804DV

V21

a4 2 )trohs(eriwgnitcennoc

b4 2 )muidem(eriwgnitcennoc

c4 4 )gnol(eriwgnitcennoc

d4 4 tnuhshtrae

e4 4 eriwhtrae

f4 2 eriwhtraeelbuod

1S

4N

2N

3S

3'S

2'N

1'S

4'N

4c

4e

4d4f

4d

1

4d

4e

2 2

2FRONT SIDE REAR SIDE

1

1'

N

N

2'S

2S

3'N

3N

4'S

4S

4d

4e

4a

4b

4c

4a 4b

4e

4f2

2 2

1

12

34

red sleeve

blue sleeve

– 19 –


metI ytQ noitpircseD

REDRATER

56–05CA08–05CA00–15CA

52–16CA53–16CA06–16CA

00–27CA07–28CA00–38CA13–38CA

1 1 slanimrethtraedetalusnidnasrenetsafhtiwylbmessakcolbgnitcennoC )42egapnosliatedees( 375804DV 375804DV 375804DV 375804DV

2 3 srenetsafhtiwylbmessakcolbnoitcnuJ )32egapnosliatedees( 093704DV 093704DV 093704DV 093704DV

4 1 ,tesgniriwlanretniV42dnaV21 :gnidulcni 575804DV 675804DV 775804DV 875804DV

V42




d4 3 tnuhshtrae

e4 1 eriwhtrae


FRONT SIDE REAR SIDE

red sleeve

blue sleeve

– 20 –

4N

4'N

2N

2'N

1S

1'S

3'S

3S

4f

4e

4d

4f

1

2 2

2

4d 4d

1N

1'N

3'N

3N

2S

2'S

4S

4'S

4a

4b4c

4a 4b2

2 2

1

12

34


metI ytQnoitpircseD REDRATER

55–05CA

1 1 lanimrethtraedetalusnidnasrenetsafhtiwylbmessakcolbgnitcennoC )42egapnosliatedees( 375804DV

2 3 srenetsafhtiwylbmessakcolbnoitcnuJ )32egapsliatedees( 093704DV

4 1 ,tesgniriwlanretniV42dnaV21 :gnidulcni 575804DV

V21




d4 3 tnuhshtrae

e4 1 eriwhtrae



red sleeve

blue sleeve

– 21 –

4N

4'N

2N

2'N

1S

1'S

3'S

3S

4f

4e

4d

1

2 2

2

4f4d 4d

1N

1'N

3'N

3N

2S

2'S

4S

4'S

4a

4b4c

4a 4b2

2 2

1

12

34


metI ytQ noitpircseDREDRATER

55–05CA

1 1 slanimrethtraedetalusnidnasrenetsafhtiwylbmessakcolbgnitcennoC )42egapnosliatedees( 375804DV

2 3 srenetsafhtiwylbmessakcolbnoitcnuJ )32egapsliatedees( 093704DV

4 1 ,tesgniriwlanretniV42dnaV21 :gnidulcni 575804DV

V42




d4 2 tnuhshtrae

e4 1 eriwhtrae

f4 / eriwhtraeelbuod


red sleeve

blue sleeve

– 22 –

2

2 2

2

4N

3'S

3S

4'N

2'N

1'S

2N

1'S4c

4c4c

4c

4d

4e

4d

4a4b

2

22

1

1

234

2'S

1'N

1N

2S

4'N

3N

3'N

4S

Junction block assembly – VD 407 390

metI noitpircseD ytQ ecnerefeR

ylbmessakcolbnoitcnuJ:gnidulcni

093704DV

2 ylbmessakcolbnoitcnujllamS )slanimretdetalusni2(:gnidulcni

2

a2 )slanimretdetalusni2(kcolbnoitcnujllams1

b2 stun6M2

c2 6Øsrehsawtcatnoc2

4 srenetsafhtiwylbmessarevocllamS:gnidulcni

2 032704DV

a4 revocllams1

b4 wercsgnirucesdil1

c4 etalpgnikcol1

d4 tun5M1

5 srenetsafhtiwslanimrethguorhtdeeffoteS:gnidulcni

1

a5 slanimrethguorhtdeef2

b5 sgnir–pans2


d5 stun6M4

e5 stun6M2

f5 srehsaw6NM2

– 23 –

Connecting block and insulated earth terminal – VD 408 573

metI noitpircseD ytQ ecnerefeR

,lanimrethtraedetalusnidnakcolbgnitcennoC :gnidulcni 375804DV

1 egraL ylbmessakcolbgnitcennoc )slanimretdetalusni4(dulcni :gni

1

a1 )slanimretdetalusni4(kcolbgnitcennocegral1

b1 stun00.1x6M4


3 ,srenetsafhtiwylbmessarevocegraL :gnidulcni 1 022704DVa3 revocegral1


c3 etalpgnikcol1

d3 tun5M1

5 ,srenetsafhtiwslanimretelbuodfoteS :gnidulcni 1a5 slanimrethguorhtdeef2

b5 sgnir-pans2


d5 stun6M4

e5 stun6M2

f5 srehsaw6NM2

6 ,slanimrethtraehtiwylbmessakcolbgnitcennocegraL:gnidulcni

1

a6 )slanimretdetalusni4(kcolbgnitcennocegral1

b6 stun00.1x6M2


d6 ffumhtraelanogaxeh1

e6 8Ørehsawtcatnoc1

f6 wercs52.1x8M1

7 ylbmessarevocegraL ,htiw :gnidulcni 1 975804DVa7 revocegral1


c7 etalpgnikcol1

d7 tun5M1

– 24 –

5a

5b5c5d

5f

5e5c

5d

3d

3c

3a

3b

3

5

6

6a6c6b

6d6e

6f

7

7a

7c

7d

7b

5 Nm 3.7 lb-ft

5 Nm 3.7 lb-ft

AC61-25 toAC83-31AC50-55 toAC51-00

5 Nm 3.7 lb-ft

4 Nm 3 lb-ft

4 Nm 3 lb-ft

Greasing Crimping tool

Using a manual grease gun, fill the retarder hub with «SUPERTELMACO 3» grease untilit starts to appear at the air escape pipe aperture.

IMPORTANT :

In order to guarantee proper operation of the retarder and maintain warranty conditions,it is necessary that only «SUPERTELMACO 3» grease or another TELMA approvedgrease is used exclusively.

RECOMMENDED GREASING INTERVAL

Greasing must be carried out every 60 000 km (40 000 miles), ensuring there isno mixing with other kinds of greases.

MISCIBILITY

Any mixing of this high performance grease with other kinds of grease is notaccepted .

PACKAGING

«SUPERTELMACO 3» grease is available in the following packs:

GNIGAKCAP °nAMLET

egdirtrac–g714mm25Ø–mm042=L

043002JV

gk52 – lerrab 031002JV

In certain cases, it is necessary to replace coil eyelet terminals.

Only genuine TELMA parts (see below repair kit VD 407 872) and a suitable crimping tool,RKG n° 69003 or TELMA n° JZ 800 380 , should be used.

IMPORTANT : Do not remove the insulation varnish of the wire before crimping.

Crimp the «COPALUM» eyelet terminal usingthe last notch of the crimping tool.

The kit VD 407 872 includes:

Wiring repair kit

noitpircseD ytQ

.................................lanimretteleye 61

...........................eveelsknirhstaehder 8

eveelsknirhstaeheulb .......................... 8

Protection of terminals against corrosion

To protect the connecting and junction terminals, use Body –Coating – n° VH 520 100(1 liter – can).

coil wirered or blue heat

shrink sleeve

– 25 –

Replacement of a coil

1 – REMOVAL OF A DAMAGED COIL

– Remove the cover of the junction block which corresponds to the faulty coil .

– Disconnect the faulty coil after having carefully marked the position of each wire(red and blue sleeves ).

– Remove the pole shoe securing screw (item 23).

– Remove the pole shoe (item 24), the pressure washer (item 21) and the faultycoil or coil assembly (item 20).

2 – CLEANING OF THE STATOR

– Remove all traces of varnish, insulation material, Araldite and corrosion from thepole, the pole shoe and the stator.

3 – PREPARATION OF THE MIXTURE OF ARALDITE AND HARDENER

In the following text, the mixture will be designated by Araldite.

IMPORTANT: for hygiene and health reason it is recommended not to breathAraldite vapour. Contact of Araldite with the skin must also be avoided.Therefore use gloves and keep the tools and the work bench clean.

– As mentioned on the page 9, there are 2 types of coils for AC retarders. The coilsare bonded on the poles with an Araldite/hardener mixture, to be prepared with:

a 1 kg (2.2 lb) can of Araldite n° VH 510 160a 0.4 kg (0.8 lb) can of hardener n° VH 510 310

Take a very clean metal container and just before use, mix 4 parts of hardenerwith 10 parts of Araldite for each coil to be bonded.

The required quantity of mixture depends on the number of coils to be bonded.Approximately 60 to 80 grams (2 to 3 oz) of mixture are required per coil.Polymerization time at ambient temperature of 20 °C ( 68 °F): approx. 12 hours .

IMPORTANT :Before bonding the coil with Araldite, make a preliminary test installation to checkthat the set consisting in the coil itself, the insulating washers, the protectivecover and the pressure washer fits properly on the pole. The mating face for thepressure washer on the coil must be below the face of the pole shoe. Should thecoil be much lower than the pole, then the gap must be filled by additional insulationwashers (item 20e).

4 – FITTING OF THE NEW COIL

Non moulded coil (details on page 9)– If the coil assembly includes the following components, coat with Araldite and

install on the pole:• the stainless protective washer (item 20f),• the coil end insulation washer(s) (item 20e).

– Before installing the coil on the pole, coat the inside of the new coil (item 20d). Ifthe following items are included in the concerned coil assembly, install:• the stainless protective washer (item 20a),• the pressure washer (item 21).

– Secure the pole shoe (item 24) by means of the screw (item 23).Tightening torque 50 Nm (37 lb–ft).

– Reconnect the coil wires to the terminals marked during disassembly (red andblue sleeves, see wiring diagrams).

– Install the contact washers Ø 6 mm and tighten the M6 nuts.Tightening torque 5 Nm (3.7 lb–ft).

– To protect the connecting and junction block terminals against corrosion, sprayor brush liberally these connections with Body–Coating n° VH 520 100.

– Refit the cover of the junction block, the locking tab and the nut.Tightening torque 4 Nm (3 lb–ft).

– Deform the locking tab to avoid the rotation of the nut.

Tightening torques

50 Nm – 37 lb–ft

– 26 –

28, rue Paul Painlevé – Z.A. du Vert GalantF–95310 SAINT OUEN L’AUMONE – FRANCEB.P. 692 F–95004 CERGY Cedex – FRANCE

Tel. (+33) (0) 1 34 48 54 00 – Fax : (+33) (0) 1 30 37 63 69

TELMA S.A. au capital de 163 603 000 FSiège Social : 28, rue Paul Painlevé – F95310 Saint Ouen l’Aumône410 163 125 – R.C.S. Pontoise

This technical data is supplied for your guidance in the use of the product and may be modified at anymoment without prior notice.Any reproduction, duplication or translation of this publication, also in the form of an abstract, issubject to the previous written permission of TELMA, Cergy.

Printed in France

telma parts

Documents

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crossserrated coupling

din flat coupling flanges

coil assembly

ac series retarders

stator assembly

junction block assembly

earth terminal vd