Working instruction for TN 873/19

Installation of the switches see drawing 8E217, modification of the wiring see wiring plan 8E218
1.	Switch off the main switch.
2.	remove the cover from the relay compartment.
3.	Remove the red cover plate from the change-over switch by lifting the plate until the switch toggle breaks off. Screw off  both switches and pull them out of the relay compartment.
4.	Pull off wires “37” and “59” from the old auto/man switch. Cut off the socket terminal including the wire which runs to the diode from wire “37”. Crimp a flat pin terminal to wire “37”. Remove the wire marking number “59” and plug both wires together, cover with heat shrink tubing.
5.	Pull off wires “40” and “41” from the old auto/man switch. Cut off the socket terminal including the wire which runs to the diode from wire “40”. Crimp a flat pin terminal to wire “40”. Remove the wire marking number “41” and plug both wires together, cover with heat shrink tubing.
6.	Remove the old auto/man switch together with the old wires “60” and “90”.
7.	Pull off wires “18” and “005” from the old ext./retr. switch. Plug wire “18” to the new ext./retr. switch. Insulate the terminal of wire “005”, it’s no longer required. Remove the old ext./retr. switch.
8.	Insert the new auto/man switch into the hole of the old ext./retr. switch and insert the new ext./retr. switch into the hole of the old auto/man switch, take care for correctly position the notches. The operation directions are the same as with the old switches. Secure the nuts with Loctite 243. Lay the wiring towards the control unit.
9.	Remove the connector plug from the control unit and open the plug casing. Don’t loosen the strain relief shackle of the wiring set which runs into the plug.
10.	Insert the new wires through the lower one of the holes located in the side of the plug casing.
11.	Unsolder wire 55 (grey) from pin 28 of the plug. Solder wire 55 to the new wire “15” and secure with heat shrink tubing. Solder the new wire “60” to pin 28 and cover with heat shrink tubing. Solder wire “59” to pin 7 and wire “41” to pin 26 and cover with heat shrink tubing. 
12.	Secure the new wiring with the supplied strain relief shackle in the region already covered with heat shrink tubing to the plug casing.
13.	Close and secure the  plug casing. Install the plug to the control unit and secure with a ty-rap 4.8 x 360mm.
14.	Switch on the main switch and the engine master switch and execute a functioning check. Check that the switches work in the right sense. If this is not the case rotate the wrongly installed switch 180°.
15.	
1 mm

Roughen the toggle of the auto/man switch  and apply scratches with a file to the toggle. Glue on the red cover plate with a suitable metal adhesive e.g. Stabilit Express onto the toggle of the auto/man switch. Make sure that the cover plate is positioned correctly and that the notch in the plate is large enough to ensure the 1mm gap see sketch. If not, enlarge the notch with a file (prior to gluing on).
16.	Reassemble the cover to close the relay compartment.

Issued: May 24.2000