洛阳凯迈电涡流缓速器培训教程.docx

洛阳凯迈电涡流缓速器培训资料
CAMA Electromagnetic retarder
Training Material

凯迈（洛阳）机电有限公司
CAMA（luoyang） Electromechanic Equipment Co.,Ltd

目 录
DIRECTORY
电涡流缓速器原理…………………………2
Electromagnetic retarder principle
主机总成及安装……………………………5
The retarder assembly part
电器总成及安装……………………………11
The Electric System
维护与保养…………………………………33
Maintenance
故障与排除…………………………………38
Troubleshooting

电涡流缓速器原理
Electromagnetic retarder principle
缓速器基本原理是电磁感应现象
1855年，法国物理学家Leon FOUCAULT先生发现了电磁感应现象.
The working principle of electromagnetic retarder is electromagnetism induction, which is found by physical scientist Leon FOUCAULT in 1855.

电源断开时铁锤急速下降
Hammer dropped quickly when power is off.
电源接通时铁锤缓速下降
Hammer dropped slowly when power is on.

定子固定安装在汽车底盘大梁上
线圈装在定子上

电磁场在转子产生电涡流
转子叶片通过风冷散发制动能量

主机总成部分
The retarder assembly part
目前我公司能提供与进口ZF S 5-80/S6-90变速箱、綦江S6-90、QJ1506、S5-80变速箱、铁马变速箱、大同变速箱、一汽解放系列变速箱和陕齿富勒系列变速箱等相匹配的电涡流缓速器。下面以DHB20A缓速器在綦江S6-90变速箱后端盖上安装为例，介绍缓速器的安装过程。（在其它变速箱上的安装，除了定子支架稍有不同之外，其他过程基本相同）
An electromagnetic retarder which is a frictionless braking system used in vehicle can be attached to the rear part of the gear box, the rear drive axle, or in between the driving shafts. Up to now Nanfeng company can provide the electromagnetic retarders which are matched with imterminaled ZFS5-80/S6-90, QiJiang S6-90/S6-85/S5-80, TieMa, DaTong, FAW series, DongFeng series of gear boxes and etc In order to introduce operator to the retarder installation, the process of mounting the DHB20A retarder to the rear part of QiJiang S6-90 gear box is taken as an example. (Except for the stator brackets, the installing processes of the other components which are attached to gear boxes are similar to the DHB20A)

●安装示意图：Scheme of Installation:

4 5 6 7 8 9 10 11 12

3

2

1

图（1）
Diagram(1)

●零组件汇总表PART LIST

序号 ITEM
名称
DESCRIPTION
数量QTY
1
六角螺母M12、弹簧垫圈12 Nut M12, Spring Washer 12
4
2
后转子 Rear Rotor
1
3
六角螺栓M12×90、双头螺柱M12×80、螺母M12、弹簧垫圈12、平垫12
Hexagon Bolt M12x90, Spring Washer 12
8
4
定子总成 Stator Assembly
1
5
双头螺柱M16×1.5，螺母M16×1.5、弹簧垫圈16
Stud Bolt M16x1.5, Nut M16x1.5, Spring Washer 16
8
6
传动轴法兰 Driving Shaft Flange
1
7
六角螺栓M16×1.5×30、轻型弹簧垫圈16
Hexagon Bolt M16x1.5x30, Spring Washer 16
8
8
前转子总成 Front Rotor Assembly
1
9
六角螺栓M22×1.5×55、弹簧垫圈22 Hexagon Bolt M22x1.5x55, Spring Washer 22
4
10
M形调整垫片 M-shape Spacer Spool
按需
a set
11
支架 Bracket
1
12
变速箱端盖和输出法兰
The special rear unit of gear box and output flange
1

★注意：在缓速器安装前应确保车前后轮不能移动，断开原车电源，并用高度尺测量变速箱箱体端面与变速箱输出法兰端面之间的距离，应为193mm；用百分表测量变速箱输出法兰的轴向窜动量应小于0.3mm；径向和轴向跳动量均应小于0.05mm；变速箱输出法兰端面的平面度应小于0.1mm。如不符合则换装符合要求的变速箱。
●IMTERMINALANT NOTICE: It must be ensured that the fore and rear wheels of the vehicle are not moved before installing the retarder, and the main switch of battery is off; the distance between the end surface and output flange of gear box housing, measured by height gauge, should be 193.5mm; the axial play of the gear box output flange measured by dial indicator should be less than 0.3mm; the radial play should be less than 0.05mm; the planeness of the output flange end surface of the gear box should be less than 0.1mm. If the conditions mentioned above can not be met, substitute with the qualified gear box.

★电涡流缓速器安装步骤
Assembly of electromagnetic retarder:
注意！！！缓速器上的所有螺栓、螺母、螺杆处必须涂抹乐泰270或相同强度螺纹锁固剂！
IMTERMINALANT NOTICE: It must be ensured that all bolts, nuts and threaded rods are daubed with LETAI 270 or the same step thread locker！
1.安装支架(序号11)：Installation of Bracket (Item 11)
用4个六角螺栓M22×1.5×50、弹簧垫圈22、 (序号10)，将支架(序号11)固定在变速箱后端盖(序号12)上，螺栓紧固力矩为230～250Nm。（注意：操作时不能损坏原车体）
The bracket (Item 11) should be fixed to the rear unit of gear box (Item 12) by 4 hexagon bolts M22x1.5x55, spring Washers 22with fastening moment of 230N.m ~250N.m. (Note: The vehicle body can not be damaged while operating)
2.安装缓速器主机总成 Installation of Retarder Assembly
安装缓速器之前应将S6-90变速箱置于空挡。把缓速器主机总成整体吊起，注意应使用定子总成上φ12通孔作为起吊受力点，切不可使接线盒或线圈承受机械外力！用8个六角螺栓M16×1.5、弹簧垫圈16 (序号7)将缓速器主机总成固定在变速箱输出法兰(序号12)上，紧固力矩 220～240Nm。
The S6-90 gear box should be set to neutral position before mounting the retarder. Hoist the retarder assembly by φ12 throughholes at the stator part, the junction box and coil can not stand any external mechanical force! The retarder assembly should be fixed to the output flange (Item 12) by 8 hexagon bolts M16x1.5, spring Washers 16 (Item 7) with fastening moment of 220 N.m ~240N.m.
3.初选支架四支角M形调整垫片厚度，为1mm。
The initially selected thickness of M-shape space spool (Item 10) fixed to the 4 outsoles of the bracket should be 1mm.
4.固定定子总成(序号4) Installation of Stator assembly (Item 4)：
首先拆掉转子总成上4个L形定位片及薄螺母。缓速器定子总成(序号4)的接线盒的方向朝上，对准支架(序号11)上的安装螺纹孔，用8个六角螺栓M12X90（紧固扭矩为90Nm）、弹簧垫圈12和平垫12(序号3)、M形调整垫片(序号10)将定子总成固定在支架(序号11)上。通过增减M形调整垫片数量和厚度调整转子内侧与定子端面之间的间隙为总气隙的1/2。（总气隙在出厂时已调好）
The stator part of the retarder (Item 4) whose junction box face up side should be connected to bracket (Item 11) by 8 hexagon bolts M12, spring Washers 12 (Item 3) and M-shape spacer spool (Item 10) which is positioned between the outsoles of the bracket and the backup block of the stator with fastening moment of 90N.m, the clearance between the rotor and the stator which is adjusted through increasing or decreasing the number of the different M-shape spacer spool must be half of the total clearance which has been adjusted before retarder is sold.
5. 安装传动轴前半轴(序号6) Installation of fore semi-axle of driving shaft (Item 6)：
用双头螺柱M16×1.5、螺母M16×1.5、弹簧垫圈16（序号5）将传动轴前半轴（序号6）和前转子总成（序号8）连接，预紧力矩220～240Nm。
The fore semi-axle of driving shaft (Item 6) should be mounted to the front rotor (Item 8) via stud bolts M16x1.5, spring washer 16 (Item 5) and nuts M16x1.5 fastened with 220 N.m ~ 240N.m moment.
6.安装后转子（序号2）Installation of rear rotor (Item2)
将后转子（序号2）用4个螺母M12、弹簧垫圈12（序号1）固定在前转子总成（序号8）上，紧固力矩为120Nm，并保证后转子内侧与定子总成端面间隙为总气隙的1/2。（总气隙在出厂时已调好）
The rear rotor (Item 2) should be attached to the front rotor (Item 8) via 4 nuts M12 and spring washer 12 (Item 1) with fastening moment of 120Nm; It must be ensured that the gap between the rotor inside and the end surface of the stator is be half of the total clearance which has been adjusted before retarder is sold..
7.安装传动轴后半轴Installation of rear semiaxle of driving shaft：
对准传动轴标记，将传动轴后半轴插入前半轴，再将传动轴后半轴安装到后桥输出法兰上，并按厂家规定扭矩紧固螺母。
After targeting the alignment mark of the driving shaft, insert the rear semiaxle into the fore semiaxle (Item 6) and then mount the rear semiaxle of the driving shaft to the output flange of the rear axle by fastening the nuts with specified moment.
8.辅助吊架（或托架）的安装 Installation of auxiliary hanging bracket
缓速器主机安装在变速箱之后，用辅助吊架（或托架将缓速器吊起来（或托起来），辅助吊架（或托架）固定到大梁上（辅助吊架或托架一般由用户自备。）
After attaching the retarder to the gear box and then hoisting (or propping) the retarder with auxiliary hanging bracket (or poppet), mount the auxiliary hanging bracket ( or poppet) to the vehicle chassis (the auxiliary hanging bracket should be provided by clients).

电气总成部分 The Electric System

一．安装条件 Installation condition
安装前请详细阅读本说明书、车辆安装条件、安装前注意事项。如不符合车辆安装条件，可能会造成缓速器工作不正常，或原车其他设备工作不正常，引发其他故障。
The installation manual, vehicle installation condition and important notices should always be read through carefully before installation. If the vehicle installation condition can not be met, may lead to abnormal operation of retarder or other vehicle equipments.
如不遵守安装前注意事项，可能会造成人车安全事故！
If the important notices is not observed, may involve danger to life and limb and the risk of damage to vehicle.

l 车辆安装条件：
1.蓄电池： 24V ≥150AH
Battery: 24V ≥150AH
2.发电机(选装)： 28V ≥150A
Generator: 28V ≥150A
l 安装前注意事项 Important notice
1. 安装前断开安装车辆总电源，确保车内所有电设备断开电源。
Before carrying out working on the unit, the main switch of battery should be off in order to ensure all electric equipments in the vehicle shut down.

2. 确保驻车安全，车轮用枕木塞固牢靠。
The vehicle wheels must be locked by wooden sleeper to ensure the safety of halting the vehicle.
l 安装前准备 Preparation before installation:
请准备以下工具：螺丝刀、剥线钳、电钻、活动扳手、开口扳手、梅花扳手、照明灯具、电焊机等。
Required tools: screw driver, cable stripper, electric drill, adjustable spanner, open end wrench, plum blossom-shape wrench, lighting fixtures, electrical welder and etc.
警告WARNING:
安装缓速器电气系统或车辆维修时，如进行焊接，必须关闭整车电源，拆除总电源正负极连线。如带电源安装或进行焊接可能会损坏电气部件。
If the welding is necessary while installing the electrical system of the retarder or maintaining the vehicle, the system must be disconnected from the electrical power supply of the vehicle and dismantle the connecting line between the cathode and anode of the battery. The electrical components may be damaged in case of installing or welding while electrifying.

1. 安装缓速器控制单元Installing the control unit of retarder;

二．安装流程图 Installation flow sheet

2.安装缓速器控制电源开关
Installing the control power switch of retarder

3.安装缓速器电源总开关Installing the main switch of retarder (JK451Z)

4. 安装手动开关和气压开关
Installing the hand control(Jk594) and pressure switch assembly(JK612C);
总成

5. 安装各控制线束和接地线
Installing all the control wiring harnesses and earth cables

6. 安装缓速器电源总线
Installing power wiring harness of retarder;

7. 检 查
Checkup

8. 通电测试
Energized test

9. 试车检验
Commission test

注：用户可以根据实际情况，⑴～⑸的安装顺序可以做相应的调整，
⑹～⑼的安装顺序必须严格遵守本流程。
Note: The installing sequence of the procedure 1~5 can be adjusted in accordance with the actual condition by customer, but the sequence of the procedure 6~9 must be observed strictly.
三．缓速器接线原理图 Eletric connection diagram

Connector Plug DJ7061-6.3-21 and DJ7011-6.3-21 must be connected to signal of vehicle. Definition is as below.

注：①如果ABS作用时输出低有效信号，如：0V），则接ABSL，缓速器将停止工作，；反之，如果输出高有效信号，则接ABSH。
若车辆无ABS系统，可将ABSL和ABSH悬空。
Note: If ABS outputs low effective signal ,connect it with ABSL(pin7). In other words, if pin7 received low signal, pin4 has no output 24V ; on the contrary connect it with ABSH (pin8) if ABS outputs high effective signal
If there is no ABS system on the vehicle, keep ABSL and ABSH impending.
②打开点火钥匙，NF标志灯亮；
当车速达到5Km/h以上，绿色圆型灯点亮；
当手柄分别拨至1、2、3、4档，红色梯形灯逐个点亮；
当超温报警器检测到缓速器主机温度超过110℃，绿色圆型灯闪烁，此时请关断缓速器检查。
Start up engine and ignition switch, the “NF” lamp of working
indicator light is illuminated;
When the speed of vehicle is above 5Km/h, the round
lamp(greenlight) is illuminated;
push the hand-lever switch to step 1,2,3,4 respectively and the
scalariform lamp is illuminated one by one;
If the temperature annunciator of retarder test the temp of retarder
coil is above 110℃,the the round lamp(greenlight) will flicker
continueously. You must power off the main swich of retarder
and check it up.
缓速器线束如下：
Wiring harness of retarder is as below:

a.缓速器控制线束总成
Control wiring harness assembly of retarder ( 0.75 mm)
b. 主机与传感器线束总成(6)
Operating wiring harness of retarder (6mm)
c缓速器主机接地线(35)
Earth cable of retarder (35 mm)
d. 缓速器电源总线(35)
Power wiring harness of retarder (35 mm)
e.控制电源开关接地线 (6) (其余线束为0.75)
Earth cable of control power switch (6 mm)
注意：在进行缓速器检修完毕时，必须核对各接地线是否正确连接。
Notice: Must check if all earth cables connections are correct after completing the retarder inspection.

四．部分电气元件的管脚定义和安装尺寸图
Pin Assignment and Installation Diagram
㈠．缓速器控制单元（VD-HKD201A）的管脚定义和安装尺寸图
Pin assignment and installation diagram of the control unit (VD-HKD201A)of retarder ：

㈡. 缓速器电源开关安装尺寸图
Installation diagram of the control power switch(VD-HDK202) of retarder

五．电气部件的安装和线束的连接
Electrical units Installation and wiring harnesses Connection
㈠ 安装缓速器控制单元 Control unit(VD-HKD201) of retarder
1．安装位置 Installation site
a.安装位置要求防水、防尘，远离高温环境，周围要有足够散热空间,建议安装在驾驶室或副电气箱内部；安装表面平整、坚固；安装位置周围应留有足够拆装余地，并便于以后检修、保养。
The installation site need to be water-proof, dust-proof, kept away from high-temperature environment, guaranteed enough radiating space. Control unit is advised to be installed in the cab or auxiliary electrical box; Installing surface should be flattening and firm; Enough disassembly and assembly space must be left to examine, repair and maintain conveniently.

b.缓速器控制单元应平放安装或侧面安装，避免倒置安装。The control unit of retarder must be mounted flatwise or sideface, ensure against bottom-up installation.

2.安装 Installation
a.根据控制单元安装尺寸（如图(3)所示），在安装面钻两个Φ7通孔。The 2-φ7 through holes need to be drilled out at the installing surface according to the installation dimension (i.e. diagram 3) of the control unit .
b.用M6螺栓将控制器单元固定牢固。
The control unit is fastened with M6 bolts.
3.注意事项 Warning：
安装前需将蓄电池电源电线拆下，拆卸时应先拆负极，后拆正极。
The main switch of battery should be shut down before installation.
㈡ 安装缓速器控制电源开关
Control power switch(VD-HDK202) of retarder
1. 安装位置 Installation site
a.防水、防尘且靠缓速器主机附近的位置；
The installation site needs to be water-proof, dust-proof, and keep it near battery and retarder. It is advised to be installed in the installing cabin of vehicle battery.
b. 安装表面平整、坚固
Installing surface should be flattening and firm.
2.安装 Installation
a.在安装面钻四个Φ9通孔，尺寸如图（4）所示
The 4 –φ9 through holes need to be drilled out at the installing surface in line with diagram 4。
b.用M8螺栓将控制电源开关固定。
The control power switch is fastened with M8 bolts.

㈢．安装缓速器电源总开关
Main switch(JK451Z) of retarder
1.安装位置 Installation site
建议安装在汽车蓄电池附近。
It is recommended to mount it near the vehicle battery in the installing cabin of vehicle battery.
2.安装 Installation：
a. 在安装面上钻4个Φ7的通孔。尺寸如下图（5）所示
The 4 –φ7 through holes need to be drilled out at the installing surface in line with diagram 5.
b. 用M6螺栓将电源总开关固定。
The mains switch is fastened with M6 bolts.

图（5）
㈣.安装手动开关和气压开关总成
The hand-lever switch and pressure switch assembly

l 手动开关的安装 Installation of hand-lever switch

建议手动开关安装在方向盘的下方或仪表板上，便于司机操作。
We recommend that the hand-lever switch should be installed under the steering wheel or on the dash board in order to make the driver operate conveniently.
l 气压开关总成的安装 Installation of the pressure switch assembly
1. 安装位置 Installation site
气压开关作用是采集刹车信号，为避免连接气管过长，安装位置应靠近气源附近。建议取前轮刹车气源。分配阀如无接口，则需要在分配阀前管路上加装三通接头连接。
The installation site needs to be close to air source in case that the braking pipe is overlong. It is recommended to distribute the air source at the front-wheel air brake valve. A three way control valve need to be installed in the front pipeline of the front-wheel air brake valve.
2.安装Installation
a.用M6X50螺栓将气压开关座体安装到气压开关支架上。
The pressure