Manual for the fitting of the TELMA Axial AF30-35 retarder on the MERCEDES-BENZ Sprinter type 906 with BR9 preparation

Transcription

1 Manual for the fitting of the TELMA Axial AF30-35 retarder on the MERCEDES-BENZ Sprinter type 906 with BR9 preparation (TELMA delivery set n GA000601) 1) Preliminary operations: - if possible, a road test should be made prior fitting the retarder in order to check the general condition of the vehicle as well as the vibratory behaviour. 2) Disconnection of the battery (batteries): Fig. 1 - disconnect the battery (batteries). There are 2 possible configurations: a) the vehicle is equipped with only one battery located under the floor: depending on the vehicle equipment, the disconnection might be done easily from the special terminal (option code E30) located near the throttle pedal. Pull down the red lock and remove the cable. b) the vehicle is equipped with 2 batteries: disconnect the main battery located under the floor and the extra battery located inside the engine compartment. Fig. 2 - main battery located under the floor. Fig. 3 - extra battery located inside the engine compartment. ind.: page 1

2 3) Installation of handlever and indicating lamp: 3.1) 1 st possibility: on right hand side of steering wheel Opening of dashboard: Fig. 4 - pull off the bottom of the central part of the dashboard and remove this part. Fig. 5 - remove the fasteners which hold the cover of the air outlet located near the ignition key. Fig. 6 - pull out the combined instrument unit with the finger nails. Disconnect the connector and remove the instrument. - remove the upper screw from the dashboard panel. Fig. 7 - unscrew the fasteners of both bottom grey panels and remove these parts. ind.: page 2

3 Fig. 8 - remove the screws from the right hand side of the dashboard panel in order to pull it slightly off. - remove the fasteners and the air outlet located near the ignition key. hole Ø 22mm ± 0.1 for the indicating light Fig. 9 - stick some adhesive paper tape over the right hand side area of the dashboard panel above the ignition key. - on the paper tape, mark the dimensions of the rectangular and circular apertures as shown below. One is for the handlever and the other one corresponds to the indicating light. rectangular aperture for the handlever groove panel edge Ignition key Fig drill, cut and finish with a file the rectangular aperture 60mm x 26mm - drill hole Ø 22mm ± through aperture 26 x 60mm, mark the part of the plastic reinforcement which is located behind this aperture. Cut the reinforcement. ind.: page 3

4 S191 S191 / 1 S191 E16/11 Fig glide both wires of the indicating light through the hole Ø 22mm and secure it with the nut. - insert the blue wire in the hole marked in blue on the supplied connector and the red wire in the hole marked in red. - connect the light to the 2 pin connector n E16/11 located under the steering column. - connect the handlever to the 4 wires on stand-by under the steering column and fitted with the 8 pin connector n S191 / 1. Fig install the handlever in the rectangular aperture with the off position (0) towards the top. - secure the wirings under the dashboard. - re-install the dashboard and the plastic panels. 3.2) 2 nd possibility: on left hand side of steering wheel Should equipment such as the telephone already be fitted on the right hand side of the dashboard, the handlever and the indicating lamp can also be installed on the left hand side. Fig remove plastic cover of A pillar. - remove left part of dashboard. - mark the locations and cut out the apertures for the handlever and the indicating light. ind.: page 4

5 4) Installation of the foot control insulation switch: A Fig remove the cover of the fuse compartment located near the clutch pedal (LHD variant). Diagnosis plug OBD Clutch pedal (LHD) - put the "TELMA On / Off" sticker under the flat face (item A) of the fuse box housing. Refer to the dimensions 23mm and 14mm on figure existing wires Fig drill a hole Ø12mm through the hole of the sticker. - screw first the metal nut on the switch to approx. 5mm. Then install the on / off switch from the top through the hole and secure from the bottom with the black plastic nut. 23 mm Fig turn the on / off switch (normally open) so that the lever points down towards the left and that the black markings on the switch are oriented towards the front of the vehicle. 14 mm Fig connect both pre-installed wires (blue and brown) from the top. 28, rue Paul Painlevé- P.M.E. Z.A. du Vert- Galant ind. : page 5

6 5) Preparation of the retarder installation: Fig remove both midship and rear drive shafts. Fig scrape off the underfloor protection at the 4 locations to which the retarder brackets will be secured to the 2 crossmembers behind the second centre bearing. - repaint the 4 locations with anti-corrosion paint. - by means of a M8 tap, clean the thread of the 10 nuts welded to the crossmembers. Fig cut the insulation padding to the width of 300mm instead of 400mm. - on one side, do not remove the protection film on a strip of approx. 100mm under the parking brake cable in order for the padding to protect the cable without sticking. - drill about 10 holes through the floor of the van in order to secure the insulation padding with rivets and washers. ind. : page 6

7 6) Retarder handling: Fig open the box and place textile lifting ropes between the chassis brackets and the side plates for lifting the retarder assembly. Fig place the retarder assembly on a hydraulic lifting table and move it under the vehicle. - align the holes of the châssis brackets with the 10 M8 threaded holes of the vehicle cross-members. 7) Retarder installation: Fig install by hand the 10 M8 screws. Fig tighten the 10 M8 screws with a torque wrench: tightening torque: 18Nm ± 20% 28, rue Paul Painlevé- P.M.E. Z.A. du Vert- Galant ind.: page 7

8 8) Installation of the drive shafts: Fig install both drive shafts - install the 8 M10 nuts: tightening torque: 1) with the torque wrench do a preliminary tightening to 15Nm 2) then turn by 1/4 a turn (90 ). (This corresponds to about 70Nm ± 20%) 9) Connection of the control cable to the relaybox: Fig should for any reason the side plates, the rubber mounts or the side plates have been removed, it is requested to check that the longitudinal centreline of the retarder is parallele to the chassis centreline. In the same way, it is necessary to verify that the retarder slope is identical to the drive axle slope. Note: the tightening torque of the 3 M12x1.75 screws which secure the side plate to the retarder is limited to 40Nm ± 20% Fig take the 5 core cable on stand-by in the left hand side frame longmember and connect it to the 7 pin plug on the left hand side (front) of the relaybox. 10) Connection of the supply cable to the relaybox: Fig crimp the supplied terminal (Ø8mm / 25mm²) at the end of the 25mm² cable also on stand-by in the left chassis longmember. - glide this cable through the empty conduit at the bottom in the middle of the relaybox and connect it to terminal "+". tightening torque: 14Nm ± 20% 28, rue Paul Painlevé- P.M.E. Z.A. du Vert- Galant ind.: page 8

9 11) Cable securing: Fig fit the supplied cable tie in the last notch of the rubber grommet for securing the supply cable. - group and secure as high as possible with cable ties the relaybox cables so that there is no loop under the retarder lowest point. Fig. 30 Fig clean the M6 negative return terminal located left in the chassis frame behind the retarder. - connect to this terminal the 25mm² cable coming from the negative termimal (M) of the relaybox. 12) Installation of the 100A fuse and programming: rebrancher la (les) batterie(s). Fig in the electrical compartment located under the driver's seat, install the 100A fuse supplied in the TELMA kit. Unscrew the existing nuts and mount them together with the contact washers above the fuse. - re-connect the battery (batteries). - at a MERCEDES-BENZ dealer, proceed with the coding of the PSM and ESP modules by means of the "Xentry kit" testing unit. 28, rue Paul Painlevé- P.M.E. Z.A. du Vert- Galant ind.: page 9