User’s Manual

of Terca○R Electromagnetic Retarder

深圳市特尔佳运输科技有限公司
SHENZHEN TERCA TRANSPORTATION TECHNOLOGY CO.,LTD .
Dear Sir or Madam:
In order to provide you with rapider, better
after-service, please fill in the maintenance
card and mail it to TERCA after sale
service department without fail in two
weeks after you purchase the Terca
Electromagnetic Retarder.
Please read this guide carefully before
installation!

Cultivating habit of maintenance will help to

make full use of the retarder!

一．Brief Introduction

Served as an assistant of braking system installed

in automotive, the retarder has been used for tens of
year in oversea market. Accounting on its advantages
like, low speed with powerful torque 、 easy
maintenance、 high accountability, it is widely used in
automotive industry.
Key features:
1.1、Considerably improves braking efficiency; Extends
the life span of braking system; be cost saving;
1.2、Avoid braking system failure and tire bursting

caused by the high temperature of brake blocks;

Safety capacity has been greatly enhanced;

1.3、Pollution free: Environmentally friendliness by
greatly reducing the dust and noise generated by
braking vane;
1.4 、 Alleviates vehicle’s slant-slipping caused by
improper adjustment of braking clearance or
uneven wear abrasion;

Based on the abovementioned advantages, TERCA

retarder will play a more important role in the
automotive industry to meet the increasing demand
for safer 、 more comfortable 、 more
environmentally friendly automotive.
As the initiative electromagnetic retarder promoter,
specialized in retarder R&D 、manufacturing and
marketing, Terca has accumulated a lot of
experience in this industry. By integrating the
advanced technology from foreign countries with
the innovation of its own, TERCA secures custom
confidence through its excellent quality guarantee
 and after sale service network. Terca has built wide
cooperation relationship with bus manufacturers,
relevant components manufacturers, based on
which terca has become the most professional
manufacturer with the wide scope of products 、
whole ranges of products specification. Now
another new R&D manufacturing center is in the
process of establishment, and terca is striving to
top itself on the auto electromagnetic retarder
industry.
二、working principle：
The retarder works by the magnetic field generated

by the rotator and the rotor, which are the main

components of the whole retarder. Separated by a

narrow air gap, the stator is connected to the vehicle

chassis (gear box、rear axle、vehicle bracket ),while the

rotor runs together with the drive shaft connected by

flange. Coils embedded in the rotator produces huge

torque by which the running speed is decelerated

Assembly’s wiring diagram

电气原理图
 Electrical wiring diagram

Switch controlling wiring harness

Indicator
(to ACC)

Indicator
Brake lamp wiring harness
relay Brake signal
wiring harness

Brake Brake lamp

lamp switch

Driving
wiring
Master power switch harness

Manual switch 24V Storage

Batteries －12 3 4

Brake pressure
inducting switch
 R series B series M series
Function
components components components
Stator: coils inside; main component;
connected to the chassis by fixed bracket;
Stator of M series connected to the chassis by
fixed bracket 、 spring washer and bearing
bracket;
Rotor: rotor of R series(single dial) and B
series (symmetrical fore-and-aft dial ) runs
together with the drive shaft connected by
flange or rotor connecting tach;
Flange of Rotor of M series runs together
with the drive shaft ;
Speed sensor: fixed on the stator magnetism
producing board, the head of the speed sensor
produces impulse signal when the rotor runs.
So comes out the speed signal of the vehicle;
Controller: core components; adopting
electronic power module to control;

Pressure sensor: installed together with air

valve pedal on the vehicle frame and connected
to braking air channel by air pipe, the pressure
sensor served as the controller when foot pedal
is employed;
Installed in the cab, the hand controller is
employed to brake the vehicle through
appropriate gear;
Power: usually installed in the electric cab and
be connected between the anode of the
accumulator and the controller of the retarder;
Working indicator: installed in the cab to
provide with information of operation and
failure evidence;
三、operation

3.1、operation steps：

POWER PRE-WORK WORK

INDICATOR INDICATOR INDICATOR

3.1.1、Switching on the vehicle power, the red power

indicator lamp is on (the power of the retarder must be

off) which shows that the power supply is in normal

state. Under such circumstance the retarder does not

work whenever stepping down the foot pedal or

pressing the hand controller;

3.1.2、When accelerate the speed,(speed differs from 2

to 10 km/h depending on the parameter of
specification、drive axle decelerated ratio、tire radius
etc.),the pre-work indicator lamp is on which shows the
retarder is ready to work;

3.1.3、Step down the foot pedal or press the hand

controller. The retarder works and speed slows down in
accordance to signal produced by employing foot pedal
or choosing different gear which are demonstrated by
working indicator lamp;
3.1.4、When the speed is decelerated to the critical
point (about 2-10km/h), the pre-work indictor lamp is
off and the retarder stops working (the hand controller
must be in state of 0 gear );
：Attention:
3.2、
3.2.1、Hand controller or slowly stepping down the foot
pedal is strongly recommended, for by doing that, the
conventional braking load can be deduced, so too much
attrition or high temperature can be effectively avoided.
Thus the conventional braking system can be kept in a
good state to meet safety capacity demand even in
emergency;
3.2.2、When applying to foot pedal to control, step it
down slowly because Retarder works before the
conventional braking system does; Try to avoid instant
application for braking system unless under panic stop
conditions. Thus retarder function can be brought into
full display;
3.2.3、In case of foreseeable braking, for example
vehicle is been pulling in station at highway or toll
station , the retarder should be employed in advance to
decelerate and finally the vehicle will be completely
stopped by using braking vane. By doing that vane
attrition can be effectively avoided for the braking vane
will be seriously damaged when vehicle is running at
full speed;

3.2.4、When vehicles of load-free or running on icy or

muddy surface, do not use the hand controller to
change gear too fast because under such circumstance
the aft wheel are easy to skid if the braking torque
reaches its full scope;
3.2.5、When vehicle runs in mountain area, especially
running in long slope, do not apply to retarder in a
continuously long time, for long time heating will
greatly affect the life span of the coils. When retarder
used for a certain time, do not stop the vehicle
suddenly so as to avoid uneven heating emanation.
(Drive another 1km will be appreciated);
3.2.6、Do turn off the general power supply when not
use it for a long time;
3.2.7、The gear indicator may glint even when the
vehicle is still, which may caused by the pulsatile
current generated by instant power off of the relay (for
example by stepping down the foot pedal). Such
phenomenon is technically normal. Under such
circumstance, the retarder actually does not work.
四、maintenance

4.1、purpose
Keep the retarder in good operation condition;
reduce fault rate and abnormal damage of its
components;
4.2、clearing

A、Periodically wash out the sediment on the rotor by

high-pressure water after the vehicle runs on the dusty,

muddy or salt-scattered road.

B、Clearing ensures heat emanation effectiveness. The

stator especially stator connecting pole should be

cleaned by low-pressure water.

Attention: Before clearing, the general power supply

must be turned off and the temperature must be cooled

down to normal state; volatile or corrosive solution

must be avoided.

Warning: clear the smears oozed by the gear box

or rear axle and fix them in time
4.3、periodical check
A routine check of the items attached ※ must be
carried out when vehicle runs every 5000km and a
whole check must be carried out over every 20 000km.
Items show as following:
4.3.1、mechanical part

items to be checked requirement measures to be taken

Check the clearance B series: 1.3－1.7mm Add or reduce the adjusting
between the rotor and the shim between the fixed bracket
stator. (1.5±0.2mm)※ and the rotator
R series: 0.8－1.2mm Overhaul、 replace components

M series: 1.05－1.45mm add or reduce rotor adjusting

shim between flange and
bearing bush
Check the clearance 4－6mm Loosen nuts fixed on the head
between the speed sensor of the sensor and readjust the
and the rotor dial clearance.
Stiffness coefficient of No loose; drive shaft Tighten bolts in accordance to
bolts connecting the drive must be oiled stiffness coefficient
shaft and flange; Oiling standards
the drive shaft
 items to be checked requirement measures to be taken
rotor※ the drive shaft Flange、fastening bolts of Gear
amplitude of B series box (rear axle)must be checked
must be kept less than when B or R series to be
0.1 mm; installed.
that of R series must Axletree of retarder must be
be kept less than 0.3 checked when M series to be
mm; installed
That of M series must
be kept no larger than
0.1mm.
rotor lamina 、 stator No damage of the stator Replace the rotator assembly、
shell 、 bolts ; 、 rotor shell and rotor rotor assembly; fasten the
fastening bolts lamina; no loose bolts bolts
 items to be checked requirement measures to be taken
Connecting bolts of No distortion of Fasten bolts; replace buffer
auxiliary bracket auxiliary bracket、no shim
assembly or hanging loose bolts; no
bracket 、 buffering distortion or damage
shim(B and M series) of spring washer
Oil leaking of gear box No loose bolts on shell Check the connector between
or rear axle(B 、 R No oil leakage shell and
series)
Check weather the bolts No loose bolts; no Replace the bolt(nut) 、 in
on flange fixed on gear abrasion of spline /out shaft、spline
box or rear axle is inside the flange
loose or not(B 、 R
series)
4.3.2、electronic part (check every 5000km)

measures to be
components items to be checked
taken
1、check whether the bolts be tightened tighten bolts
controller 2 、 check whether the wiring harness are well rereel and fix the
connected wiring harness、
1、whether wiring harness well fixed stator repair
stator
2、whether nuts being well fixed tighten nuts
1、whether clearance normal readjust
speed sensor 2、 check whether the bolts fixed on bracket is
tighten bolts
tightened
1、disassemble and check whether it was water
pressure sensor dry it
contained
1、Whether wiring harness be well fastened and Clear up the wiring
wiring harness
connecting available harness connecting
Rereel , rep
2、Check whether the driving loops be well reeled
components
3、check the wiring harness be well fixed by the tighten the bolt
 measures to be
components items to be checked
taken
4、Check whether the remaining distance from the fix
rereel
point of driving wiring harness to crossbeam is enough
5、Whether the coils be well tightened rereel
other vehicle
components
1、Whether the liquid surface be in a normal state supply distilled water
accumulator 2 、 Check whether battery connecting pole be clear up oxides by sand
oxidized、well connected paper and tighten nuts
Power wiring 1、Check whether the negative pole of battery be Clear interface、tighten
harness well connected to the vehicle crossbeam. bolts
1、Check the connecting condition of the wiring
Clear interface、tighten
generator harness, make sure accumulator charge function in
bolts
good state
air storage periodically discharge
1、Discharge water
canister water
4.4、dismantlement and installation
The whole body is heavy; take necessary protecting measures to avoid being hurt when dismantling.

4.4.1、Exploded View of Retarder

6 Rear gearbox flange

Drive shaft

1 2 3 4
5

1— rear rotor； 2— stator assembly； 3— speed sensor assembly； 4— fore rotor； 5

— assistant bracket assembly； 6— bearing bracket
B series retarder exploded view
 Rear
后桥axle
5
4
3
2
Drive shaft
传动轴 1

1—rotor 2—rotor connector 3－stator 4－speed sensor 5－stator connector

R series retarder exploded view
to rear axle
connectting to
crossbeam (two
sides)
Drive shaft

5
4
Drive shaft
to gear-box

－speed sensor assembly 2－bearing bracket 3－rubber

cushion 4－assistant 5－retarder mechanical assembly
M series retarder exploded view
4.4.2、dismantle step of the mechanical part;
1) cut off retarder power supply;
2) Dismantle speed sensor installed on the stator assembly;
B series retarder: pull out the plug, do not need to dismantle;
3) dismantle the connecting pole of drive wiring harness fixed
on the stator(pay attention to the marks);
4) mark out the balance sign of the drive shaft and dismantle
the head part of the drive shaft;
5) B series: dismantle the rear part of the rotor assembly; R
series: dismantle the rotor assembly; M series: dismantle the
whole body part after breaking down the connecting body of
the bearing bracket and the vehicle bracket;
6) dismantle the stator assembly(attention: make sure the
adjusting shim being kept as original installation state to
confirm dedicate clearance between rotor assembly and rotator
assembly);
7) break down the rear axletree of the drive shaft;
8) B series: dismantle rear dial of the rotor assembly;
9) dismantle the flange or connecting annulus;
10) dismantle the fixed bracket or connecting ring connecting
the gear box or rear axle to retarder;
 Referring to the dismantle step, apply to the contrary step to
reinstall, but attention must be paid to:
1) The clearance between the head of the sensor and the
rotor dial must be kept to 4-6mm (standard );
2) make sure the clearance between the stator assembly and
the rotor assembly (standard: B series:1.4-1.6mm; R series:
0.8-1.2mm; M series: 1.05-1.45mm);
3) enough distance must be remained between the drive
wiring harness fixed on the stator and the
crossbeam(transmission: 800 mm ; real axle:150 mm );
4) Check whether components be damaged, if they are,
replace them; all the fastener must be reinforced by worm glue
and tighten in accordance to the standard torque requirement;

4.5、electronic failure and analysis

Failure
analysis measures to be taken
symptom
The power 1 、 The 1、turn on the power switch(in
indicator does indicator a clockwise direction)
not work switch is 2、Check whether there 24V
turned off voltage input through the
2 、 Power connecting pin when the key
default of key switch is turned on
 Failure
analysis measures to be taken
symptom
controlling 3、Check whether there is
3 、 Wiring broken wiring harness
harness 4、Check the controller by test
broken instrument
4、Controller 5、Replace the indicator
been broken assembly
5 、 indicator
faults

The pre 1、The 1、Clearance between the speed

-work clearance sensor and the rotor dial is
indicator lamp of speed kept at 4-6mm.
is not on and sensor is 2、sensor resistance is kept
retarder does not between 1.1-1.4KΩ
not work accurate 3、Check whether wiring harness
2、Speed connecting the sensor and
sensor is controller is broken
damaged 4、Check the whether the
3、Wiring controller works by test
harness is instrument
broken 5、Replace the indicator
4、Controller assembly
faults
5、Indicator
faults
Retarder does 1、Pressure 1、Check the channel of the
not work even sensor is braking throttle. dismantle
foot pedal is jammed the pressure sensor ;step
 Failure
analysis measures to be taken
symptom
stepped down 2、Pressure down foot pedal to check
sensor is whether there is air
damaged pressure
3、Connecting 2、Check whether the wiring
wiring harness are well connected
harness is to the speed sensor;
broken 3、Check the two signal
4、Controller transmission wiring
faults harness, whether it is
5、Indicator broken or insufficiently
faults connected
4、Check whether the controller
is in normal state
5、Replace the indicator
assembly
The working 1、Air 1、Check the Pressure channel
indicator pressure connecting that of the
remains on even is leaked vehicle, make sure no
the foot out from braking no pressure out;
braking be not the 2、Check the two pressure
stepped down. braking sensor wiring harness, if
the vehicle bump. there pressure exist, they
brakes without 2、pressure are connected if no ,they
starting switch is disconnected; check whether
braking system damaged there is water contained;
3、Wiring 3、 Check whether the pressure
harness is switch and the controller
short are short circuited;
circuited 4、Check whether the controller
 Failure
analysis measures to be taken
symptom
4、controller by test instrument is in
faults normal state;
The pre-work 1、Controller Check whether the controller is
indicator lamp faults in normal state
keeps on even
vehicle be
stopped
Working 1、Controller Check whether the controller is
indictor keeps faults in normal state
on even vehicle
be stopped
The working 1、Drive 1、Check the drive wiring
indicator lamp wiring harness
twinkles(once harness is 2、Check whether the wiring
a second) short harness reeled on stator is
circuited short circuited or exterior
2、Coils on is damaged
stator are 3、Check whether the sensor
short wiring harness and the rotor
circuited are broken or insufficiently
3、Output connected
broken 4、Check the controller
4、Controller
faults
The working 1、 the coils 1 、 check whether the rotor
indicator lamp are short resistance is in a small side or
twinkles(twice circuited short circuited
a second) 2、controller 2、check whether the controller
 Failure
analysis measures to be taken
symptom
faults is in normal state

The working 1、controller 1、check the passableness of the

indicator lamp faults 、 positive pole and gear
twinkles(four braking even
times a second) without
starting the
braking
system

Attachment 1 ： Torque requirement on installation and maintenance

 M12（10.9 degree） torque：100～110N.m
flange tightening
Other torque ：480～560N.m

M10（8.8 degree）torque：45～50N.m
Fixed bracket or M12（8.8 degree）torque：80～85N.m
connecting tach
installing M14（8.8 degree）torque：120～125N.m

M22（8.8 degree）torque：210～230N.m

M12×1.5（10 degree） torque：110～115N.m

Installation drive M12×1.5（12 degree） torque：140～145N.m

shaft M14×1.5（10 degree） torque：200～205N.m

M16×1.5（10 degree） torque：235～240N.m

M12×1.5（10 degree） torque：110～115N.m

installation of head
M14×1.5（10 degree） torque：200～205N.m
rotor assembly
M16×1.5（10 degree） torque：235～240N.m

installation of M12×1.5（8.8 degree）torque：80～85N.m

stator assembly M14×1.5（8.8）degree) torque：120～125N.m

installation of rear M10（9.8 degree） torque：60～65N.m

rotor dial M12（9.8 degree） torque：80～85N.m
 Warning:

1、If welding needed to operate in vehicle, the positive and

negative pole of the accumulator must be dismantled or it

will possibly cause damage of electronic components of the

vehicle as well as the circuit board of drive controller and

other electronic components of the retarder.

2、As to M series, special attention should be paid

to lubricant, for the continuous high temperature

caused by working retarder will greatly affect the

lubricant in the axletree. Special high temperature

proof lubricant other than any ordinary one must be

reinforced periodically, for two kinds of lubricant

being mixed may possibly cause chemic reaction which

may shorten the life span of the retarder. 300-400g

lubricant of CAM2 brand must be added every

5000-10000km
★ Custom should take the responsibility of
the retarder damage which caused by
adding different brand of lubricant other
than appointed one. Purchase the
appointed lubricant otherwise contact
us.

Suggestion:

Exchange the rotator wiring harness link after two

years, so as to balance the wiring coil working time,

further to avoid wiring coils aging.

Two ways to exchange the wiring harness link:

一：

1． Dismantle connecting washer of the No 1 and No 2 ,and

connecting it to No 3 and No 4;

2． connect the No 1＋2 drive wiring harness to No 3 or No

4 ;drive wiring harness No 3 to No 2 ,drive wiring

harness No 4 to No 1, as the following graph shows ;

Stator junction box

＃ ＃ 1＋2＃
wiring wiring wiring
二:

1. Dismantle the connecting tach between No 1 and No

2 of controller, and connect it to No 3 and No 4

2. No 1＋2 drive wiring harness be connected to No 3

or No 4 stator connecting pole; No 3 drive wiring

harness is connected to No 2 stator connecting pole; No

4 drive wiring be connected to No 1 stator connecting

pole.

＃ ＃ 1＋2＃
wiring wiring wiring
Attachment 二：

Tools in common use（Next page）

Name Specifications Amount
1 Controller Test 1
2 Digital Display 1
3 Plug Guage 1
4 Hemicycle File 1
5 Slip Joint Pliers 1
6 Diagonal Cutting Pliers
7 Sharp Nose Pliers 1
8 Cross Head Driver Middle 1
9 Flat Heat Driver 1
10 Little Bolt Sleeve 1 Set
11 Large Bolt Sleeve 46 pieces per set 1 Set
12 Transforming From large to small 1
13 Monkey Wrench 8” 1
14 Monkey Wrench 10” 1
15 Quincunx Open Wrench 10-10mm 2
16 Quincunx Open Wrench 13-13mm 1
17 Quincunx Open Wrench 14-14mm 1
18 Quincunx Open Wrench 16-16mm 1
19 Quincunx Open Wrench 17-17mm 1
20 Quincunx Open Wrench 18-18mm 1
21 Quincunx Open Wrench 19-19mm 1
22 Quincunx Open Wrench 21-21mm 1
23 Quincunx Open Wrench 22-22mm 1
24 Quincunx Open Wrench 24-24mm 1
25 Open Wrench 12-14mm 1
26 Open Wrench 22-24mm 1
27 Flashlight 1
28 Crowbar 600mm 1
 Terca Electromagnetic Retarder
Guarantee Card

Vehicle License No.:

User Name:
User Address:
Retarder Model:
※Controller Serial No./ Assembly No.
★Stator Serial No./ Assembly No.
Installation Position: Gearbox □ Rear Axle □ Crossbeam □
Model:
Installation Date: Using Date:
Vehicle Serial No.
Vehicle Manufacturer and Model:

Note:
1. ‘※’ Please find out from the nameplate of the controller.
2. ‘★’ Please find out from the nameplate of the stator.
3. There is a duplicate copy of this guarantee card. The original one is
kept by the user. Please fill in the duplicate one, and mail it to our
service department in two weeks in order that we can serve you.
4. Please show this card when repairing and maintaining freely.

Address: A9 guigudongli Qinghu Park, bulan road, Longhua

Baoan district Shenzhen China

Service Tel: 86-0755-2651345 26513588-819 13827404959
Fax: 86-0755-26519166 Post Code: 518109
Shenzhen Terca Transportation Technology Co,.Ltd
 Quality Guarantee kept as the precondition for free maintenance;
Dear our custom: 2) The guarantee starts on the day when the retarder is
installed;
Thanks for choosing Terca Electromagnetic Retarder!
3) The retarder faults caused by spare parts quality on the
Holing the concept of ‘all for the user’, TERCA condition that the retarder is normally used and
promises that Retarder purchased from Shenzhen Terca maintained.
Transportation Technology Co., Ltd or its authorized 2. Cases excluded in the range of free maintenance:
companies and installed by or under the instruction of 1) The retarder faults caused by vehicle parts;
2) The retarder faults caused by user’s improper
Shenzhen Terca Transportation Technology Co., Ltd or its
maintenance ;
authorized companies are included in this guarantee range 3) Unauthorized operation of installing or dismantling
as the following table shows: and unoriginal or unauthorized spare parts used in
Guarantee parts included: retarder;
Guarantee range Maintenance
Name
charge Remark:
Mechanical One year or Any operation of installing and dismantling of Terca
Assembly Free
100,000 km Electromagnetic Retarder must be carried out by mechanics
One year or authorized by Terca Company.
Electric
Free
Assembly 100,000 km
Shenzhen Terca Transportation Technology Co,.Ltd.
1. Free maintenance service:
1) Any of the two guarantee range satisfied first will be
 Maintaining Record

Vehicle License No:

Date Note Operator Guarantee Bill User’s
No. Signature
1
2
3
4
5
6
7
8
9
10
 User’s Data
User Name: Vehicle Model:
User Address: Vehicle Manufacturer:
Tel: Installation Position:
Fax: Gearbox □ Model:
Retarder Model: Rear Axle □ Model:
※Controller Serial No.: Crossbeam □ Model:
※Controller Assembly No.: Note:
★Rotor Serial No.: 1. ‘※’ Please find out from the nameplate of the controller.
★Rotor Assembly No.: 2. ‘★’ Please find out from the nameplate of the stator.
★Stator Serial No.: Remark:
★Stator Assembly No.:
Installation Date:
Using Date:
Vehicle Serial No.:
 Shenzhen Terca Transportation Technology Co., Ltd reserves

explaining right of this handbook.

This handbook is subject to change without prior notice

ELECTROMAGNETIC RETARDER

SHENZHEN TERCA TRANSPORTATION

TECHNOLOGY CO., LTD.

Address: A9 guigudongli Qinghu Park, bulan road, Longhua

Baoan district Shenzhen China.

Tel: 86-0755-26513588
Fax: 86-0755-26519166 Post Code: 518109
Http://www.terca.cn
Email: terca@21cn.com terca@terca.cn