洛阳凯迈电涡流缓速器培训资料(中英文)

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
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
名称数量QTY
★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.
●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
●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.
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.
二．安装流程图Installation flow sheet
注：用户可以根据实际情况，错误!未找到引用源。

～错误!未找到引用源。

的安装顺序可以做相应的调整，
错误!未找到引用源。

～错误!未找到引用源。

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
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 mm2)
b. 主机与传感器线束总成(62
mm)
Operating wiring harness of retarder (6mm2)
c缓速器主机接地线(352
mm)
Earth cable of retarder (35 mm2)
d. 缓速器电源总线(352
mm)
Power wiring harness of retarder (35 mm2)
e.控制电源开关接地线(62
mm)
mm) (其余线束为0.752
Earth cable of control power switch (6 mm2)
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
错误!未找到引用源。

．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 ：
错误!未找到引用源。

. 缓速器电源开关安装尺寸图
I nstallation 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
错误!未找到引用源。

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.
错误!未找到引用源。

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.
错误!未找到引用源。

．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）
错误!未找到引用源。

.安装手动开关和气压开关总成
The hand-lever switch and pressure switch assembly
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.
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 switch seat is fastened to fixed mount with M6x50 bolts.
b.将气压开关支架焊接到靠近前轮刹车分配气源的车大梁之上
（应使气压开关朝上）；
Weld the fixed mount on the vehicle chassis which is close to brake distribution air supply of front-wheel. (The pressure switch should be mounted upward).
c.用气管连接刹车气源，并固定好连接气管。

Connect brake air supply via air tube, and then fix the air tube.
2.注意事项：气阀座安装好后用压缩空气清理内部杂物，防止堵塞气
压开关；连接气管的安装应避开高温、锐边、易腐蚀和油污场所。

Important instructions：The compressed air is needed to clear up interior impurity after the completion of the pressure switch seat installation in case of blocking the pressure switches. The installation of the braking pipe should be kept away from the high-temperature, sharp edge, corrosion and oil stain sites.
错误!未找到引用源。

．安装各控制线束和搭铁线Control wiring harnesses and earthed cable:
1.缓速器控制线束总成的连接：按照缓速器接线原理图和线束标识连
接缓速器控制线束总成，线束用线夹固定于车体，如用扎带固定，
每隔1m至少要固定一根，剪后扎带长度留5～10mm.
Connection of control wiring harness(code “a” in Diagram2)：Install
and connect the wiring harness in accordance with the electric connection diagram(Diagram 2) and wiring harness’s label. The control wiring harness
need be fixed to the vehicle body via cable clips. If fastened by tape, at
least one point need to be fixed with the tape every 1m, and 5~10mm of the
tape length is left after snipping.
2.缓速器驱动线的连接：按照缓速器接线原理图和线束标识连接缓速
器驱动线，一端接于缓速器接线盒内的端子“1”、“2”、“3”和“4”，
另一端分别对应地接于控制电源开关盒子内的接线柱“错误!未找到
引用源。

”、“错误!未找到引用源。

”、“错误!未找到引用源。

”和“错
误!未找到引用源。

”上。

线束用线夹固定于车体，如用扎带固定，
每隔500mm至少要固定一根，剪后扎带长度留5～10mm.
Connection of the operating wiring harness of retarder (code “b” in Diagram2)
One end is attached to the “1”, “2”, “3”and “4”terminal posts in the junction box of the retarder and the other end is connected to the “Ⅰ”, “Ⅱ”,
“Ⅲ” and “Ⅳ”terminal posts in the control power switch correspondently in
line with the electric connection diagram(Diagram 2) and wire harness’
label. The wire harness need be fixed to the vehicle body via cable clips. If fastened by tape, at least one point need to be fixed with the tape every
500mm, and 5~10mm of the tape length must be left after snipping.
3.各个接地的连接：按照缓速器接线原理图和线束标识连接缓速器主
机接地线、控制电源开关接地线，线束用线夹固定于车体，如用扎
带固定，每隔300mm内至少要固定一根，剪后扎带长度留5～10mm. Connection of earthed cables:
Connect the earthed cables of the retarder and control power switch(code
“c、e”in Diagram2)in accordance with the electric connection diagram(Diagram 2) and wiring harness’s label. The earthed cable should
be fixed to the vehicle body via cable clips. If fastened by tape, at least one
point need to be fixed with the tape every 300mm, and 5~10mm of the tape
length must be left after snipping.
警告：搭铁线束接触不良将导致系统不能正常工作，引发控制器
故障！搭铁接线柱导通性能必须良好，禁止安装在车身以点焊方式连
接的薄钢板上！
Warning:Imperfect contacts of earth cables will result in abnormal operation of system and malfunction of controller! Electrical conductivity
of earth terminal terminals must be well, and the earth terminal terminals
are prohibited from mounting to sheet steel of vehicle body which is joined
up via dot welding!
注意事项Important notice:
a. 线束穿过铁板孔、横跨大梁、横梁等折角锐边处时，应加装保护措
施，防止线束受损。

The protective measures must be taken while the cables cross over the through hole, break corner and sharp edge of the cross and side members in case of
damaging them.
b. 线束应避开高温、油污位置；尤其是缓速器主机周围的线束，一定要采取隔热措施。

The cables should be kept away from the high temperature and oily stain sites.
c.线束在跨越有相对位移的两个部件之间时，应在此处留有一定余量，防止车辆在行驶时产生相对位移而造成扯断。

If the cables cross over two components which have relative displacement, some margin must be left in case that the relative displacement produced by vehicle riding leads to pull apart the cable.
错误!未找到引用源。

．安装缓速器电源总线Power wiring harness of retarder (code “d” in Diagram2)
1.安装位置
Installation site
连接于原车+24V蓄电池和缓速器电源总开关、和控制电源开关之间。

The power wiring harness is is connected among the vehicle battery, main switch of retarder and control power switch of retarder。

2.安装
Installation
a.将第一根电源线束一端接缓速器控制电源开关“+”极，另一端接
于缓速器电源总开关上；将第二根电源线束一端接缓速器电源总开关，另一端接原车24V蓄电池正极。

One end of the first power wire harness is attached to “+”pole of control power switch, the other end is connected to the retarder main switch; One end of the second power wire harness is attached to the retarder main switch, the other end is connected to “+” pole of battery.
b.固定线束。

如用扎带固定，剪后扎带长度留5～10 mm。

线束穿过
铁板处应采取有效保护措施，以防止线束受损。

If fastened by tape, 5-10mm of the tape length must be left after snipping. The protective measures must be taken while the wire harnesses
cross over the mental plate in case of damaging them.
3.注意事项Important instructions ：
a. 接线牢固，接触良好。

搭铁接线表面清洁，去除油漆，确保接触良好。

b. 连接电源线束时，原车蓄电池必须保持断开的状态。

Make sure that the vehicle battery is off while connecting the power wiring harness of retarder.
错误!未找到引用源。

.检查Inspection
1.检查机械部件是否安装调整完毕
Check if the installation and debugging of the mechanic parts are completed.
2.电气安装各连接部分是否正确，固定牢固。

Check if the connecting terminalions of the electric assembling are correct and fixed firmly.
注意：以上检查正确无误后，连接原车电源线！
Cautions: Turning on the main vehicle switch after the inspection items mentioned above are checked out!
错误!未找到引用源。

．通电测试Testing procedure for the hand-lever switch
注意以下的测试是在车辆静止的状态下检测，此时应将车速信号屏蔽：用短接线将缓速器控制单元端口4与3短接。

Make sure that the following test must be carried out when vehicle is stopping, and connect the port “3”with port “4”of control unit of retarder via a jumper cable─screen vehicle speed sig
1.手动开关的检测（需将车速信号屏蔽）Testing procedure for the hand-lever switch
step1:启动发动机，手动开关至0档，用试灯（用一只24V的汽车小灯泡做成，以下的试灯同此）检测手动开关各输出端（试灯的另一端接
地），如试灯点亮，则更换手动开关；如试灯不亮，则进入step2。

Start up engine, push the hand-lever switch to step 0 and check up all output ports of the hand-lever switch via a test lamp (i.e. a 24V lamp). If the test lamp is illuminated, replace the hand-lever switch; otherwise enter the procedure 9.1.2.
Step2：保持通电状态，手动开关至1档，用试灯检测各档位对应的输出端，此时1档端口应能使试灯点亮。

2、3、4档的输出端应不亮。

如检测1档的输出端时试灯不亮，则检测手动开关的电流输入端是否有电以及5A保险丝是否烧断。

若一切正常，则是手动开关1档接触片烧断，则需更换手动开关。

若在2、3、4档任意输出端口试灯亮，则更换手动开关；如上述检测没有问题则进如step3。

Keeping energized state, change over the hand-lever switch to step1. Output port 1 should make test lamp illuminating and output ports 2, 3, 4 make it put off after checking up all correspondent output ports via a test lamp; if any of the output ports 2, 3, 4 makes test lamp illuminating, and then replace the hand-lever switch. In the event output port make the test lamp put off when changing over the hand-lever switch to step 1, checking whether the current input of the hand-lever switch is charged or 5A safety fuse is burned out; if the current input of the hand-lever switch is charged and 5A safety fuse can work, maybe the port 1 of hand-lever is burned off, and replace a good hand-lever switch. If the checking items mentioned above are up to par, enter the procedure 9.1.3.
Step3：保持通电状态，手动开关至2档，用试灯检测各档位对应的输出端，此时输出端口1和2应能使试灯点亮；输出端口3和4不应点亮试灯。

如果检测输出端口1或2时试灯不亮，或者检测输出端口3或4时试灯可以点亮，则更换手动开关；如果上述检测没问题则进入Step4。

Keeping energized state, change over the hand-lever switch to step 2. Output ports 1, 2 should make test lamp illuminating and ports 3, 4 make it put off after checking up all correspondent output ports via a test lamp. Replace the hand-lever switch in case that Output ports 1, 2 make test lamp put off, or port 3 or 4 makes it illuminating. If the checking items mentioned above are up to par, enter 9.1.4
Step4：保持通电状态，手动开关至3档，用试灯检测各档位对应的输出端，此时输出端口1、2和3应能使试灯点亮；输出端口4不应点亮试灯。

如果检测输出端口1、2或3时试灯不亮，或者检测输出端口4时试灯可以点亮，则更换手动开关；如果上述检测没问题则进入Step5。

Keeping energized state, change over the hand-lever switch to step 3. Output ports 1, 2, 3 should make test lamp illuminating and port 4 makes it put off after checking up all correspondent output ports via a test lamp. Replace the hand-lever switch in case that Output port 1 or 2 or 3 makes test lamp put off, or port 4 makes it illuminating. If the checking items mentioned above are up to par, enter the procedure 9.1.5.
Step5：保持通电状态，手动开关至4档，用试灯检测各档位对应的输出端，此时输出端口1、2、3和4应都能使试灯点亮。

如果检测各输出端口时有任意一个不能点亮试灯，则更换手动开关；如果上述检测没问题则进入Step6。

Keeping energized state, change over the hand-lever switch to step 4. Output ports 1, 2, 3, 4 should make test lamp illuminating after checking up all correspondent output ports via a test lamp. Replace the hand-lever switch in case that any of output ports 1, 2, 3, 4 makes test lamp put off. If the checking items mentioned above are up to par, enter the procedure 9.1.6.
Step6：当确认手动开关没有问题后，逐档搬动手柄，同时检查缓速器控制电源开关盒内各接线端口是否按如下规律动作：
After ensuring the hand-lever switch is in going order, check whether the
control power switch acts in conformity with the following patterns while pushing the hand-lever switch step by step:
错误!未找到引用源。

手柄置0档，控制电源开关盒内端口1、2、3、4无+24V电压；
After the hand-lever switch is positioned at step 0, there is 0V on output terminalsⅠ,Ⅱ, Ⅲ, Ⅳ, S, V of the control power switch.
错误!未找到引用源。

手柄置1档，控制电源开关盒内端口1有+24V 电压；
After change over the hand-lever switch to step 1, there is +24V on output terminalsⅠ, S, V ;
错误!未找到引用源。

手柄置2档，控制电源开关盒内端口1、2有+24V 电压；
After change over the hand-lever switch to step 2, there is +24V on output terminalsⅠ,Ⅱ, S, V;
错误!未找到引用源。

手柄置3档，控制电源开关盒内端口1、2、3有+24V电压；
After change over the hand-lever switch to step 3, there is +24V on output terminalsⅠ,Ⅱ, Ⅲ, Ⅳ, S, V;
错误!未找到引用源。

手柄置4档，控制电源开关盒内端口1、2、3、4有+24V电压。

After change over the hand-lever switch to step 4, there is +24V on output terminalsⅠ,Ⅱ, Ⅲ, Ⅳ, S, V;
如果检查结果与上述规律不符，则应检查手动开关与缓速器控制电源开关之间的线束是否有断路、搭铁与线束之间因绝缘损坏相互连通的故障；若检查结果正常，则进一步检查缓速器控制电源开关内部的故障，具体请阅读后面的介绍。

If the check results can not to be in compliance with the patterns mentioned above, check the cables between the hand-lever switch and
control power switch of retarder; If the control results are normal, should check the interior of the control power switch further and details is referred to in the following chapter.
2 缓速器控制电源开关的检测Testing control power switch of retarder
step1:检查缓速器的电源线以及各接地线的连接状况，确认其完整无损、接触良好。

手动开关置0档，用试灯一端接地，另一端分别检测缓速器控制电源开关的输出端口Ⅰ、Ⅱ、Ⅲ和Ⅳ，试灯不应点亮。

如果某端口使试灯亮，则更换该控制电源开关。

如正常，则进入step2。

Make sure the power cable of retarder and the earth cable are correctly connected. Change over the hand-lever switch to step 0, then one end of the test lamp is attached to earth and the other end is connected to the output terminal Ⅰ,Ⅱ,Ⅲor Ⅳrespectively; replace the control power switch in case of illuminating the test lamp; If not, enter the procedure 9.2.2.
step2：用跨接导线一端接“＋”极，另一端分别与接线柱1、2、3和4进行碰触，同时试灯一端接地，另一端检测端口Ⅰ、Ⅱ、Ⅲ和Ⅳ。

正常情况下，跨接导线接触到某一接线柱，对应的接线端口有+24V输出，对应输出端口就能使试灯点亮。

如果对应的接线端口没有+24V输出，或相应端口不能使试灯点亮，则更换该控制电源开关。

如正常，则进入step3。

One end of the jumper cable is attached to “+” pole and the other end is touched to the terminals 1, 2, 3 or 4 respectively. Then one end of the test lamp is attached to earth and the other end is connected to the output terminal Ⅰ,Ⅱ,Ⅲor Ⅳrespectively;the corresponding output terminals Ⅰ,Ⅱ, Ⅲ, or Ⅳwill make the test lamp illuminating, and then enter the procedure 9.2.3. Or else, replace the control power switch.
Step3：在电源开关盒的“＋”极和接线柱1之间接上跨接导线，用试灯一端接地，分别检测接线柱V和S，试灯应点亮；如果不亮，则更
换控制电源开关。

如试灯可以点亮，但是车辆上相应的仪表指示灯或刹车灯不亮，则应检修车辆相关线路或更换相关灯泡。

After connect the “+”terminal of the control power switch box with terminal 1 via jumper cable, one end of the test lamp is attached to earth and the other end is touched to terminals V and S respectively, the test lamp should be illuminating; If not, replace the control power switch. If the test lamp is illuminating but the corresponding retarder operating tell-tale or braking tell-tale of vehicle is gone out, check correlative circuits or replace the tel-tale.
3.气压开关的检测Testing pressure switch
注意：在进行本检测之前，必须确认车辆的刹车气路工作正常。

Notice: It must be ensured that the braking pneumatic circuit works normally before carrying out the pressure switch test.
step1：启动发动机，用试灯对四个气压开关分别进行检测。

试灯一端接地，另一端分别接在四个气压开关的输出端。

试灯应不亮。

如果试灯被点亮，则更换相应的气压开关，如果检查正常，则进入step2。

Start-up engine and then test 4 pressure switches respectively via a test lamp. After one end of the test lamp is attached to earth and the other end is connected to the common terminal (i.e. common positive pole) of 4 pressure switches, the lamp should be gone out and then enter the next procedure; if not, replace the pressure switches.
Step2：启动发动机，确认气制动系统压力正常后，踩下刹车踏板，用试灯分别检测四个气压开关的输出端，试灯应被点亮，同时控制电源开关内端口V、S、Ⅰ、Ⅱ、Ⅲ和Ⅳ有+24V输出；如试灯不亮，或控制电源开关内端口内相应端口V、S、Ⅰ、Ⅱ、Ⅲ和Ⅳ没有+24V输出，则更换相应的气压开关，或检查气压开关到控制电源开关的连接导线；如果检查正常，则结束本次检测。

After start up engine, ensure that the pressure for air braking system is normal and step on the braking pedal, test 4 pressure switches respectively。