Upload
others
View
25
Download
0
Embed Size (px)
Citation preview
(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.
F-95310 SAINT-OUEN-L'AUMONE
page 1 Tel: (+33)(0)1 34 48 54 00 - Telefax: (+33)(0)1 30 37 63 69
28, rue Paul Painlevé - P.M.E. Z.A. du Vert-Galant
Ce document est la propriété exclusive de TELMA. Il ne peut être copié, ni transmis, ni communiqué à une tierce personne, sous peine de poursuites pénales.
This document is the property of TELMA. It cannot be copied, forwarded nor given to any third party without prior agreement from TELMA. Any infringement will immediately involve legal action.
ind.: M.G. 11/09/2015
Manual for the fitting of the TELMA Axial AF30-35 retarder on
the MERCEDES-BENZ Sprinter type 906 with BR9 preparation
B.P. 80692 F- 95004 CERGY-PONTOISE Cedex (France)
ATTENTION: les constructeurs de véhicules se réservant le droit d'apporter à tout moment des améliorations à leur fabrication, bien vérifier la conformité du plan avec le véhicule à traiter.
CAUTION: vehicle manufacturers reserve the right to change their vehicles at any time. Therefore it is essential to check that the specifications listed above conform to the vehicle to be fitted.
OC441673
3) Installation of handlever and indicating lamp:
3.1) 1st
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.
F-95310 SAINT-OUEN-L'AUMONE
28, rue Paul Painlevé - P.M.E. Z.A. du Vert-Galant
B.P. 80692 F- 95004 CERGY-PONTOISE Cedex (France)
Ce document est la propriété exclusive de TELMA. Il ne peut être copié, ni transmis, ni communiqué à une tierce personne, sous peine de poursuites pénales.
This document is the property of TELMA. It cannot be copied, forwarded nor given to any third party without prior agreement from TELMA. Any infringement will immediately involve legal action.
ATTENTION: les constructeurs de véhicules se réservant le droit d'apporter à tout moment des améliorations à leur fabrication, bien vérifier la conformité du plan avec le véhicule à traiter.
CAUTION: vehicle manufacturers reserve the right to change their vehicles at any time. Therefore it is essential to check that the specifications listed above conform to the vehicle to be fitted.
OC441673ind.: M.G. 11/09/2015
page 2 Tel: (+33)(0)1 34 48 54 00 - Telefax: (+33)(0)1 30 37 63 69
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.
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.
hole Ø 22mm ± 0.1for the indicating light
rectangular aperture
for the handlever
60
18 12
20 26 5
23
Ignition key
Fig. 10
- drill, cut and finish with a file the
rectangular aperture 60mm x 26mm
- drill hole Ø 22mm ± 0.1
- through aperture 26 x 60mm, mark the part
of the plastic reinforcement which is located
behind this aperture. Cut the reinforcement.
F-95310 SAINT-OUEN-L'AUMONE
28, rue Paul Painlevé - P.M.E. Z.A. du Vert-Galant
B.P. 80692 F- 95004 CERGY-PONTOISE Cedex (France)
Ce document est la propriété exclusive de TELMA. Il ne peut être copié, ni transmis, ni communiqué à une tierce personne, sous peine de poursuites pénales.
This document is the property of TELMA. It cannot be copied, forwarded nor given to any third party without prior agreement from TELMA. Any infringement will immediately involve legal action.
ATTENTION: les constructeurs de véhicules se réservant le droit d'apporter à tout moment des améliorations à leur fabrication, bien vérifier la conformité du plan avec le véhicule à traiter.
CAUTION: vehicle manufacturers reserve the right to change their vehicles at any time. Therefore it is essential to check that the specifications listed above conform to the vehicle to be fitted.
OC441673ind.: M.G. 11/09/2015
page 3 Tel: (+33)(0)1 34 48 54 00 - Telefax: (+33)(0)1 30 37 63 69
panel edge
groove
Fig. 11
- 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. 12
- 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) 2nd
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. 13
- 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.
F-95310 SAINT-OUEN-L'AUMONE
B.P. 80692 F- 95004 CERGY-PONTOISE Cedex (France)
Ce document est la propriété exclusive de TELMA. Il ne peut être copié, ni transmis, ni communiqué à une tierce personne, sous peine de poursuites pénales.
This document is the property of TELMA. It cannot be copied, forwarded nor given to any third party without prior agreement from TELMA. Any infringement will immediately involve legal action.
ATTENTION: les constructeurs de véhicules se réservant le droit d'apporter à tout moment des améliorations à leur fabrication, bien vérifier la conformité du plan avec le véhicule à traiter.
CAUTION: vehicle manufacturers reserve the right to change their vehicles at any time. Therefore it is essential to check that the specifications listed above conform to the vehicle to be fitted.
OC441673ind.: M.G. 11/09/2015
page 4 Tel: (+33)(0)1 34 48 54 00 - Telefax: (+33)(0)1 30 37 63 69
28, rue Paul Painlevé - P.M.E. Z.A. du Vert-Galant
S191
S191 / 1
E16/11
S191
4) Installation of the foot control insulation switch:
Fig. 14
- remove the cover of the fuse compartment
located near the clutch pedal (LHD variant).
- 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 16.
Fig. 15
- 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.
Fig. 16
- 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.
Fig. 17
- connect both pre-installed wires (blue and
brown) from the top.
F-95310 SAINT-OUEN-L'AUMONE
Ce document est la propriété exclusive de TELMA. Il ne peut être copié, ni transmis, ni communiqué à une tierce personne, sous peine de poursuites pénales.
This document is the property of TELMA. It cannot be copied, forwarded nor given to any third party without prior agreement from TELMA. Any infringement will immediately involve legal action.
ATTENTION: les constructeurs de véhicules se réservant le droit d'apporter à tout moment des améliorations à leur fabrication, bien vérifier la conformité du plan avec le véhicule à traiter.
CAUTION: vehicle manufacturers reserve the right to change their vehicles at any time. Therefore it is essential to check that the specifications listed above conform to the vehicle to be fitted.
OC441673ind. : M.G. 11/09/2015
page 5 Tel: (+33)(0)1 34 48 54 00 - Telefax: (+33)(0)1 30 37 63 69
28, rue Paul Painlevé- P.M.E. Z.A. du Vert- Galant
B.P. 80692 F- 95004 CERGY-PONTOISE Cedex (France)
Diagnosis plug OBD
A
Clutch pedal (LHD)
2 existing wires
23 mm
14 mm
5) Preparation of the retarder installation:
Fig. 18
- remove both midship and rear drive shafts.
Fig. 19
- 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. 20
- 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.
F-95310 SAINT-OUEN-L'AUMONE
B.P. 80692 F- 95004 CERGY-PONTOISE Cedex (France)
Ce document est la propriété exclusive de TELMA. Il ne peut être copié, ni transmis, ni communiqué à une tierce personne, sous peine de poursuites pénales.
This document is the property of TELMA. It cannot be copied, forwarded nor given to any third party without prior agreement from TELMA. Any infringement will immediately involve legal action.
Ce document est la propriété exclusive de TELMA. Il ne peut être copié, ni transmis, ni communiqué à une tierce personne, sous peine de poursuites pénales.
This document is the property of TELMA. It cannot be copied, forwarded nor given to any third party without prior agreement from TELMA. Any infringement will immediately involve legal action.
OC441673ind. : M.G. 11/09/2015
page 6 Tel: (+33)(0)1 34 48 54 00 - Telefax: (+33)(0)1 30 37 63 69
28, rue Paul Painlevé - P.M.E. Z.A. du Vert-Galant
6) Retarder handling:
Fig. 21
- open the box and place textile lifting ropes
between the chassis brackets and the side
plates for lifting the retarder assembly.
Fig. 22
- 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. 23
- install by hand the 10 M8 screws.
Fig. 24
- tighten the 10 M8 screws with a torque
wrench:
tightening torque: 18Nm ± 20%
F-95310 SAINT-OUEN-L'AUMONE M.G. 11/09/2015 Tel: (+33)(0)1 34 48 54 00 - Telefax: (+33)(0)1 30 37 63 69 page 7
Ce document est la propriété exclusive de TELMA. Il ne peut être copié, ni transmis, ni communiqué à une tierce personne, sous peine de poursuites pénales.
This document is the property of TELMA. It cannot be copied, forwarded nor given to any third party without prior agreement from TELMA. Any infringement will immediately involve legal action.
ATTENTION: les constructeurs de véhicules se réservant le droit d'apporter à tout moment des améliorations à leur fabrication, bien vérifier la conformité du plan avec le véhicule à traiter.
CAUTION: vehicle manufacturers reserve the right to change their vehicles at any time. Therefore it is essential to check that the specifications listed above conform to the vehicle to be fitted.
B.P. 80692 F- 95004 CERGY-PONTOISE Cedex (France) OC441673 28, rue Paul Painlevé- P.M.E. Z.A. du Vert- Galant ind.:
8) Installation of the drive shafts:
Fig. 25
- 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%)
Fig. 26
- 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%
9) Connection of the control cable to the relaybox:
Fig. 27
- 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. 28
- 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%
F-95310 SAINT-OUEN-L'AUMONE M.G. 11/09/2015 Tel: (+33)(0)1 34 48 54 00 - Telefax: (+33)(0)1 30 37 63 69 page 8
Ce document est la propriété exclusive de TELMA. Il ne peut être copié, ni transmis, ni communiqué à une tierce personne, sous peine de poursuites pénales.
This document is the property of TELMA. It cannot be copied, forwarded nor given to any third party without prior agreement from TELMA. Any infringement will immediately involve legal action.
ATTENTION: les constructeurs de véhicules se réservant le droit d'apporter à tout moment des améliorations à leur fabrication, bien vérifier la conformité du plan avec le véhicule à traiter.
CAUTION: vehicle manufacturers reserve the right to change their vehicles at any time. Therefore it is essential to check that the specifications listed above conform to the vehicle to be fitted.
B.P. 80692 F- 95004 CERGY-PONTOISE Cedex (France) OC441673 28, rue Paul Painlevé- P.M.E. Z.A. du Vert- Galant ind.:
11) Cable securing:
Fig. 29
- 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. 31
- 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:
Fig. 32
- 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
rebrancher la (les) batterie(s). 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.
F-95310 SAINT-OUEN-L'AUMONE M.G. 11/09/2015 Tel: (+33)(0)1 34 48 54 00 - Telefax: (+33)(0)1 30 37 63 69 page 9
Ce document est la propriété exclusive de TELMA. Il ne peut être copié, ni transmis, ni communiqué à une tierce personne, sous peine de poursuites pénales.
This document is the property of TELMA. It cannot be copied, forwarded nor given to any third party without prior agreement from TELMA. Any infringement will immediately involve legal action.
ATTENTION: les constructeurs de véhicules se réservant le droit d'apporter à tout moment des améliorations à leur fabrication, bien vérifier la conformité du plan avec le véhicule à traiter.
CAUTION: vehicle manufacturers reserve the right to change their vehicles at any time. Therefore it is essential to check that the specifications listed above conform to the vehicle to be fitted.
B.P. 80692 F- 95004 CERGY-PONTOISE Cedex (France) OC441673 28, rue Paul Painlevé- P.M.E. Z.A. du Vert- Galant ind.: