manual for the fitting of the telma axial af30-35 retarder on ...manual for the fitting of the telma...

(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.








OC441673ind.: M.G. 11/09/2015

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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.








OC441673ind.: M.G. 11/09/2015

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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.







OC441673ind.: M.G. 11/09/2015

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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.






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


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.







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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





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%







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.







manual for the fitting of the telma axial af30-35 retarder on ...manual for the fitting of the telma...

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