INSTALLATION MANUAL FOR TELMA AF50-55 ON CHEVROLET G4500 CUTAWAY 6.0L GASOLINE WITH ROTARY FOOT SWITCH 6nov15jh
1 Preparation of the Chassis 1.1 Driveline 1.2 Exhaust 1.3 Fuel Tank 2 Telma Installation 2.1 Installation Kit TIK10314 2.2 Install the Chassis Brackets 2.3 Assemble the Telma Brackets and mounts 2.4 Install the Telma in the Chassis 2.5 Drive Shaft Modification and Installation 2.6 Axle Shim Installation 2.7 Exhaust Modification 3 Control Components 3.1 Relay Box Installation 3.2 Light Bar Installation 3.3 Telma Control Module Installation 3.4 Rotary Foot Switch Installation 4 Wiring Harness Installation 4.1 Harness Assembly Layout 4.2 Power Harness Installation 4.3 Control Harness Installation 4.4 Wiring Diagram 5 Recommended Tools 6 Post Install Checklist TL113021 TABLE OF CONTENTS 7 Appendix 4500 Express 159 WB Installation Drawing with 6.0L Gasoline Engine 4500 Express 177 WB Installation Drawing with 6.0L Gasoline Engine 4500 Express 159to177 WB Installation Drawing with 6.0L Gasoline Engine (stretch in front) 4500 Express 159to182 WB Installation Drawing with 6.0L Gasoline Engine (stretch in front) 4500 Express 159to187 WB Installation Drawing with 6.0L Gasoline Engine (stretch in front) 4500 Express 159to191 WB Installation Drawing with 6.0L Gasoline Engine (stretch in front) Page 2 of 23 6nov15jh
SECTION 1 PREPARATION OF THE CHASSIS 1.1 DRIVELINE Remove the complete drive-shaft assembly after measurements have been taken. 1.2 EXHAUST An exhaust modification is needed for all wheelbases to route the exhaust between the Telma side plate bracket and the frame. Keep all components at least ¼ away from the side plate bracket to prevent vibrations through the exhaust. 1.3 FUEL TANK An aft-of-axle fuel tank and no mid ship tank is required for Telma installation Page 3 of 23 6nov15jh
SECTION 2 RETARDER INSTALLATION 2.1 INSTALLATION KIT TIK10314 P/N DESCRIPTION QTY LFA101156 AF50-55 / 12v with 156 index 1 JZ1007XX-45 Telma Shock Mount Set - 45 Shore 1 TIB01017 CONTROL/RELAY BOX BRACKET 2 TIB01035 Pedal Bracket Ford & GM 1 TIB01036 Rotary Foot Switch Bracket 1 TIB01038 Pedal Clamp GM4500 1 TIB05048 2009 Chevy GMT TRCM Bracket 1 TIB07000 Chevy / Ford LVR5 Chassis Bracket 2 TIB07005 AF50-55 Driver Side Plate Brkt Chevy Express Gas 4.5 Degrees 1 TIB07006 Pass Side Plate Bkt Chevy Express Chassis Gas 4.5 Degrees 1 TID17000 Relay box harness assembly AF50-55 for rotary switch 1 TIF01064 HCS 1/4-28 x 1.25 grade 8 yellow zinc 2 TIF01065 Hex Head Bolt ZP GR8 partial thread 1/4-28 UNF x 2 1 TIF01066 Nylon Insert Locknut ZP 1/4-28 UNF 6 TIF01067 M4-0.7 x 20mm DIN 933 Class 8.8 Zinc Cap Screw 1 TIF01068 M4 DIN 137 Zinc Wave Washer 1 TIF05004 NUT 1/4-28UNF G8 (USED FOR PEDAL CLAMP) 1 TIF05005 BOLT 1/4-28UNF x 3/4 HEX HEAD G8 3 TIF05010 LOCKWASHER 5/16 SPLIT 4 TIF05011 NUT 5/16 4 TIF05012 BOLT 5/16-18UNC x 1-1/2 HEX HEAD G5 4 TIF05013 BOLT 1/2-13UNC x 1-1/2 HEX HEAD G5 2 TIF05014 LOCKWASHER 1/2 MED SPLIT 2 TIF07000 12pt Head Bolt M12 x 1.75 x 25 8 TIF07001 M12 x 1.75 x 35 Grade 10.9 DIN 933 Black Phosphate 200+ Salt 6 TIF07002 7/16-14 x 1.75 Hex Flange Bolt Full Thread Grade 8 12 TIF07003 7/16-14 Hex Flanged Locknut Grade 8 12 TIG11010 TELMA LIGHT BAR DISPLAY 1 TIG31064 Telma Control Module GM CAN 1 TIG31066 Rotary Foot Switch 1 VF201400 STATOR TREP WHR F170-2400 6 Page 4 of 23 6nov15jh
2.2 INSTALLATION OF THE CHASSIS BRACKETS Remove any bolts such as battery box and/or exhaust hanger mounts that will interfere with the chassis bracket mounting Mark the reference hole T1 from the top of the frame down to the reference hole. Mark the reference hole CC1 from the center of the transmission u-joint or X1 from the body mount hole. Drill a single 7/16 hole in the frame and bolt the chassis bracket (TIB07000) against the outside of the frame using the reference hole in the center of the bracket and 4.25 down from the top of the bracket. Rotate the bracket to the angle specified on the installation drawing. NOTE: Use electronic anglemeter with 0.1 accuracy (e.g. SPI Pro360 digital protractor). All angles indicated are with frame reference of 0. Drill four additional 7/16 holes in each frame rail using the chassis bracket as a template and secure chassis bracket to frame with the flanged head bolts 7/16-14UNC x 1.75" (TIF07002) and flanged lock nuts (TIF07003) included in the kit. Tighten the 7/16 bolts to 70 lb-ft (±10%). Drill through the chassis bracket any holes needed for battery box and/or exhaust hanger mounts and reinstall the original bolts that were previously removed. It may be necessary to make a 5/16 spacer to keep the accessory brackets flush on the outside of the frame rail. Brackets are slotted so that they can be installed in the stretch area. Page 5 of 23 6nov15jh
2.3 ASSEMBLE THE TELMA BRACKETS AND MOUNTS Identify the driver s side of the Telma from the passenger side. The power connection block is on the passenger side top corner and the ground is on the driver side top corner. Identify the Telma brackets. The longer bracket TIB07005 is for the driver s side. The shorter passenger side bracket is TIB07006. Use medium strength thread locking adhesive (e.g. Loctite 243) on all fasteners and mark with paint after tightening to proper torque. Use three hex head bolts M12x1.75x35mm (TIF07001) and Trep washers (VF201400) provided in the kit to attach each Telma bracket onto the unit. Tighten bolts to 30 lb.-ft (±10%) CAUTION: DO NOT OVERTIGHTEN! Install the rubber mounts into the retarder brackets as shown below. Insert the male parts of the rubber mounts into the 1 5/8 holes in the brackets from the bottom and the other half of the rubber mount on top. Place one 2 ¾ diameter 5/8 flat washer on the top and bottom of each mount and another on the bottom between the chassis bracket and nut. 2.4 INSTALL THE TELMA IN THE CHASSIS Lower the Telma, equipped with its brackets and mounts, into place on top of the chassis brackets. Install the M16x1.5x100mm (4 ) bolts and spring washers down through the holes in the mounts and brackets at each mount. Install 2 ¾ diameter flat washers, spring washers and M16 locknuts at each mount as shown below and tighten to 150 lb.-ft (±10%). Page 6 of 23 6nov15jh
2.5 DRIVE SHAFT MODIFICATION AND INSTALLATION A slip assembly is required on each side of the Telma. The slip position should be at center of slip travel when the shaft is installed. Refer to GM Upfitters guidelines for proper drive shaft manufacture, balance, straightness, and critical speed limits. Refer to the appendix for Telma guidelines. Refer to the installation drawings in the appendix for shaft length guidelines. Shaft lengths over 50 should use 4 tubing. Always verify proper shaft lengths before modification. Connect the Telma flange yoke of each drive shaft to the Telma coupling flange using the M12x1.75x25mm 12 point head bolts (TIF07000) supplied in the kit. Tighten to 80 lb-ft (±10%). Use medium strength thread locking adhesive (e.g. Loctite 243) and mark with paint after tightening to proper torque. Page 7 of 23 6nov15jh
2.6 AXLE SHIM INSTALLATION Some installation configurations require the addition of steels shims to adjust the axle angle. Refer to GM guidelines for proper shim type and procedure Below are some guidelines - Loosen the spring u-bolt nuts - Lift the chassis by the frame rail until the shim can be slid over the centering pin. - To reduce the axle angle (as shown in the example), the thicker part of the shim should be toward the front of the vehicle. The nose of the axle will go down. - Lower the chassis and tighten the u-bolts. In some cases a new spring pack bolt will need to be installed to make sure the centering pin extends far enough into the spring pad hole. 2.7 EXHAUST MODIFICATION Modify the exhaust as shown below to clear brackets. Page 8 of 23 6nov15jh
SECTION 3 CONTROL SYSTEM COMPONENTS INSTALLATION 3.1 RELAY BOX MOUNTING Install the relay box on the inside of the driver side frame rail as high as possible using the relay box mounting brackets TIB01017 x 2 and fasteners supplied in the kit. Tighten the four 5/16 bolts to 17 lb-ft (±10%) and the two ½ bolts to 75 lb-ft (±10%). 3.2 LIGHT BAR INSTALLATION The Light Bar should be mounted so that it is easily visible to the driver. Make a rectangular hole, 7/8 wide x 1 ¾ tall in the lower dash to the right of the steering column or install the Light Bar in an existing console receptacle. Feed the harness through the hole and connect to the Light Bar. Plug the light bar into the hole. PANEL OPENING LIGHT BAR DISPLAY Page 9 of 23 6nov15jh
3.3 TELMA CONTROL MODULE INSTALLATION Bracket TIB05048 is used to mount the Telma Control Module as shown below. Page 10 of 23 6nov15jh
3.4 ROTARY FOOT SWITCH INSTALLATION Install the rotary switch in the rear upper holes of the bracket farthest from the firewall as shown below using the M4x0.7x20mm bolt (TIF01067) and washer (TIF01068) supplied in the kit. Tighten to 12 lb-in ±10%. Install the rotary foot switch bracket TIB01036 to the lower left pedal cluster mounting stud as shown below. Install the pedal clamp TIB01038 and pedal bracket TIB01035 to the brake pedal as shown below. Use one ¼ x.75 long bolt (TIF05004) and one ¼ x 2 long bolt (TIF01065). Slide the pedal clamp up so that the bolt is near the center of travel in the actuator arm or slightly lower. The 2 long bolt will be installed closest to the firewall and is used to actuate the foot switch. Nylon insert nuts (TIF01066) and one standard nut (TIF05004) are included in the kit. Use the standard nut and one nylon insert nut on the long bolt. Use another nylon insert nut on the short bolt for the pedal clamp and bracket assembly. Tighten the ¼ nuts to 12 lb-ft ±10%. Page 11 of 23 6nov15jh
SECTION 4 WIRING HARNESS INSTALLATION 4.1 HARNESS ASSEMBLY LAYOUT Control Module Telma PN: Date Code: Page 12 of 23 6nov15jh
4.2 POWER HARNESS INSTALLATION From the relay box, route the Telma power connection and ground harness along the inside of the left frame rail and up over the top along the middle of the Telma. Connect the 10G orange, blue, yellow, and brown wires to the connecting block at the top right corner. Connect the 10G relay box ground cable and the 4G Telma main ground cable to the insulated ground terminal at the Telma top left corner. Coat the terminals with anti-corrosion paint or body undercoat after the connections are made. Secure the harness to the center of the Telma brackets with rubber coated cable clamps. The harness should be secured along the centerline of the Telma and as far away as possible from either rotor to avoid heat damage to the harness. No cables should cross the heat outlets in the periphery of the rotors. Continue across with the black 4G ground cable and connect to negative terminal of the battery pack on the passenger side. Route the red power positive cable along the cross member in front of the Telma and connect to the positive terminal of the battery pack on the passenger side. Secure the cable to the cross member with rubber coated cable clamps. GROUND CONNECTION AT TOP LEFT CORNER SECURE HARNESS TO RETARDER USING RUBBER COATED CABLE CLAMPS POWER CONNECTIONS AT TOP RIGHT CORNER Page 13 of 23 6nov15jh
4.3 CONTROL HARNESS INSTALLATION AND TRCM CONFIGURATION Route the control harness into the cab through the rubber grommet in the floor under the driver s seat. Follow the OEM harness under the carpet to the dashboard. Connect the main harness to the subharness at the connector labeled TO RELAY BOX. Find the Telma Control Module cab harness and plug the two plugs into the Telma Control Module. Plug the foot switch connector onto the rotary foot switch. Remove the OEM OBD2 diagnostics connector from its attachment points under the dash and plug the mating OBD2 connector of the Telma harness into the OEM OBD2 connector. Secure together with a wire tie. Attach the OBD2 connector of the Telma harness to the OEM attaching points where the OEM OBD2 diagnostics connector was installed. Attach the mating connector to the four wires (org, blu, yel, brn) found in the relay box control harness and plug into the cab harness receptacle labeled to relay box. After final installation of the wiring, connect the PC to configure the Telma Control Module (TRCM) and check proper function. Unplug the gray connector from the module and reconnect in order to power cycle after a configuration change has been made. Configuration Settings Chevrolet G4500 with rotary foot switch Low/High Low CAN GM 4500 Exp. Speed 1.0mph Transducer Stage 1 2.3 Transducer Stage 2 2.4 Transducer Stage 3 2.5 Transducer Stage 4 2.6 Page 14 of 23 6nov15jh
4.4 WIRING DIAGRAM SECTION 5 RECOMMENDED TOOLS Transmission Jack Heavy duty drill motor Standard assortment of mechanics hand tools Vehicle hoist, pit, or floor jack with stands Electrical connector crimping pliers for use with non-insulated connectors Electronic angle meter with 0.1 accuracy (e.g. SPI Pro360 digital protractor) Laptop or desktop Windows computer with DB9 serial port or USB-to-serial port adapter TIG01027. Straight through DB9 serial cable (male/female) Page 15 of 23 6nov15jh
SECTION 6 POST INSTALL CHECKLIST TL133010 Revised 19may15 INSTALLATION FOLLOWUP CHECKLIST Retain a copy of this checklist in the chassis VIN record Record Telma serial number in electronic VIN record harness properly routed along center of Telma away from rotors and secured with cable clamps to retarder bracket CHASSIS #: CHASSIS MAKE/MODEL: Telma part number: Telma Serial number: End Customer: INSTALLER: INSPECTION DATE: INSPECTED BY: X COMMENTS minimum 1/4" clearance between chassis bracket and retarder bracket harnesses routed on inside of frame rail away from heat sources, sharp edges, etc. and secured with rubber coated metal cable clamps ELECTRICAL MECHANICAL correct cable eyelet size at battery / disconnect switch relay box mounted vertical with wiring exiting from the bottom and can be easily accessed Telma battery power cable connected to battery switch or to battery "+" terminal and is protected with corrosion inhibitor Telma battery ground cable connected to frame rail bare metal surface where battery pack is grounded or directly to battery ground post and protected with corrosion inhibitor relay box ground connected to retarder ground post electrical connections (weatherproof connectors, no quick splice, avoid butt connectors) Light Bar Display installed correctly, visible to driver, and operates properly Telma Control Module accessible and secured with screws Telma foot control shuts off automatically at 1mph Telma activates when moving and brakes are applied Connect PC to TRCM to check proper configuration and function Telma hydraulic brake foot switch brackets installed correctly cables, hoses and air lines are at least 4" from rotors or heat shield installed drive shaft weld quality, slip installed on each side of Telma at center of travel, balance, u-joints same quality as OEM Transmission angle measurement Telma angle measurement First shaft angle and installed length measurement Second shaft angle and installed length measurement Third shaft angle and installed length measurement Fourth shaft angle and installed length measurement Axle angle measurement drive shaft lengths/angles, Telma angle conforms to drawing Flange yokes are in same plane Page 16 of 23 6nov15jh
APPENDIX Page 17 of 23 6nov15jh
VEHICLE TECHNICAL DATA CHASSIS MAKE / MODEL CHEVROLET 4500 EXPRESS CUSTOMER: WHEELBASE 159.0" VEHICLE NUMBER ENGINE MAKE / MODEL CHEVROLET 6.0L GASOLINE SPEED SWITCH / INTERFACE TRCM TRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16 AXLE MAKE / MODEL AAM GVW / GCW 14200 lbs DRIVE TYPE 4X2 BRAKES HYD RETARDER MODEL AF50-55 ABS RETARDER PART NUMBER LFA101156 AXLE RATIO 4.10 RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485 RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479 MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRING HOURS AT TIME OF INSTALL VOCATION SHUTTLE Note: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT. Dc loaded: 11 11/16 Dv unloaded: 13 3/16 D chassis only: 14 11/16 L2 CHASSIS ONLY (±1.0 ) = 11.9 TRANSMISSION= 3.0 CHASSIS BRACKET= 1.5 L2 UNLOADED WITH BODY (±1.0 ) = 9.1 L1= 4.5 RETARDER= 6.0 L2 LOADED (±1.0 ) = 6.2 AXLE= 6.0 A B1 C1 T1 X1 CC L1 L2 3 7 8 3/8 5 5/16-1 3/4 57 3/8 SHAFT LENGTH 51 30 1/2 S1 S2 S4 SR R1 SHAFT MINIMUM TUBE DIAMETER 3.50 3.00 20 1/4 21 3/4 21 3/4 21 3/4 13 1/16 SHAFT MINIMUM TUBE THICKNESS 0.083 0.083 NOTE 1: Drive shaft lengths are measured from center of U-joint and are installed lengths. angle tolerance=±0.2 NOTE 2: All drive shafts must be dynamically balanced after modification. NOTE 3: Always verify proper shaft lengths before modification NOTE 4: When not specified, the front & the rear drive shafts, on each retarder side, must have at least the same slip as the original drive shaft NOTE 5: When not specified, the flange yoke on each retarder side must have the maximum working angle capacity available in the driveline series concerned. NOTE 6: adjust retarder to angle indicated by rotating chassis bracket NOTE 7: After installation is completed, measure drive shaft angles and compare to the angles on the installation drawing. Contact TELMA Customer Support Engineering if the angles measured do not conform to the drawing NOTE 8: USE BRACKETS TIB07000, TIB07005, TIB07006 NOTE 9: adjust axle angle to 6.0 with frame reference of 0 NOTE 10: vehicle speed electronically limited to 70mph dimension tolerance=±1/16" Page 18 of 23 6nov15jh
VEHICLE TECHNICAL DATA CHASSIS MAKE / MODEL CHEVROLET 4500 EXPRESS CUSTOMER: WHEELBASE 177.0" VEHICLE NUMBER ENGINE MAKE / MODEL CHEVROLET 6.0L GASOLINE SPEED SWITCH / INTERFACE TRCM TRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16 AXLE MAKE / MODEL AAM GVW / GCW 14200 lbs DRIVE TYPE 4X2 BRAKES HYD RETARDER MODEL AF50-55 ABS RETARDER PART NUMBER LFA101156 AXLE RATIO 4.10 RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485 RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479 MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRING HOURS AT TIME OF INSTALL VOCATION SHUTTLE Note: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT. Dc loaded: 11 11/16 Dv unloaded: 13 3/16 D chassis only: 14 11/16 L2 CHASSIS ONLY (±1.0 ) = 9.2 TRANSMISSION= 3.0 CHASSIS BRACKET= 0.0 L2 UNLOADED WITH BODY (±1.0 ) = 7.2 L1= 3.8 RETARDER= 4.5 L2 LOADED (±1.0 ) = 5.1 AXLE= 4.5 A B1 C1 T1 X1 CC L1 L2 3 6 7/8 7 7/8 5 8 1/4 65 3/8 SHAFT LENGTH 59 42 3/8 S1 S2 S4 SR R1 SHAFT MINIMUM TUBE DIAMETER 3.50 3.00 20 1/4 21 3/4 21 3/4 21 3/4 13 1/16 SHAFT MINIMUM TUBE THICKNESS 0.083 0.083 NOTE 1: Drive shaft lengths are measured from center of U-joint and are installed lengths. angle tolerance=±0.2 NOTE 2: All drive shafts must be dynamically balanced after modification. NOTE 3: Always verify proper shaft lengths before modification NOTE 4: When not specified, the front & the rear drive shafts, on each retarder side, must have at least the same slip as the original drive shaft NOTE 5: When not specified, the flange yoke on each retarder side must have the maximum working angle capacity available in the driveline series concerned. NOTE 6: adjust retarder to angle indicated by rotating chassis bracket NOTE 7: After installation is completed, measure drive shaft angles and compare to the angles on the installation drawing. Contact TELMA Customer Support Engineering if the angles measured do not conform to the drawing NOTE 8: USE BRACKETS TIB07000, TIB07005, TIB07006 NOTE 9: Check axle angle after body is installed and if necessary adjust to 4.5 with frame reference of 0 NOTE 10: vehicle speed electronically limited to 70mph dimension tolerance=±1/16" Page 19 of 23 6nov15jh
VEHICLE TECHNICAL DATA CHASSIS MAKE / MODEL CHEVROLET 4500 EXPRESS CUSTOMER: WHEELBASE 177.0" stretch from 159 VEHICLE NUMBER ENGINE MAKE / MODEL CHEVROLET 6.0L GASOLINE SPEED SWITCH / INTERFACE TRCM TRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16 AXLE MAKE / MODEL AAM GVW / GCW 14200 lbs DRIVE TYPE 4X2 BRAKES HYD RETARDER MODEL AF50-55 ABS RETARDER PART NUMBER LFA101156 AXLE RATIO 4.10 RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485 RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479 MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRING HOURS AT TIME OF INSTALL VOCATION SHUTTLE Note: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT. Dc loaded: 11 11/16 Dv unloaded: 13 3/16 D chassis only: 14 11/16 L2 CHASSIS ONLY (±1.0 ) = 8.7 TRANSMISSION= 3.0 CHASSIS BRACKET= 0.0 L2 UNLOADED WITH BODY (±1.0 ) = 6.9 L1= 3.8 RETARDER= 4.5 L2 LOADED (±1.0 ) = 5.1 AXLE= 4.5 A B1 C1 T1 X1 CC L1 L2 3 6 5/16 7 3/8 4 1/2 16 1/4 57 3/8 SHAFT LENGTH 50 15/16 48 9/16 S1 S2 S4 SR R1 SHAFT MINIMUM TUBE DIAMETER 3.50 3.50 20 1/4 21 3/4 21 3/4 21 3/4 13 1/16 SHAFT MINIMUM TUBE THICKNESS 0.083 0.083 NOTE 1: Drive shaft lengths are measured from center of U-joint and are installed lengths. angle tolerance=±0.2 NOTE 2: All drive shafts must be dynamically balanced after modification. NOTE 3: Always verify proper shaft lengths before modification NOTE 4: When not specified, the front & the rear drive shafts, on each retarder side, must have at least the same slip as the original drive shaft NOTE 5: When not specified, the flange yoke on each retarder side must have the maximum working angle capacity available in the driveline series concerned. NOTE 6: adjust retarder to angle indicated by rotating chassis bracket NOTE 7: After installation is completed, measure drive shaft angles and compare to the angles on the installation drawing. Contact TELMA Customer Support Engineering if the angles measured do not conform to the drawing NOTE 8: USE BRACKETS TIB07000, TIB07005, TIB07006 NOTE 9: Check axle angle after body is installed and if necessary adjust to 4.5 with frame reference of 0 NOTE 10: vehicle speed electronically limited to 70mph dimension tolerance=±1/16" Page 20 of 23 6nov15jh
VEHICLE TECHNICAL DATA CHASSIS MAKE / MODEL CHEVROLET 4500 EXPRESS CUSTOMER: WHEELBASE 182.0" stretch from 159 VEHICLE NUMBER ENGINE MAKE / MODEL CHEVROLET 6.0L GASOLINE SPEED SWITCH / INTERFACE TRCM TRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16 AXLE MAKE / MODEL AAM GVW / GCW 14200 lbs DRIVE TYPE 4X2 BRAKES HYD RETARDER MODEL AF50-55 ABS RETARDER PART NUMBER LFA101156 AXLE RATIO 4.10 RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485 RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479 MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRING HOURS AT TIME OF INSTALL VOCATION SHUTTLE Note: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT. Dc loaded: 11 11/16 Dv unloaded: 13 3/16 D chassis only: 14 11/16 L2 CHASSIS ONLY (±1.0 ) = 7.9 TRANSMISSION= 3.0 CHASSIS BRACKET= 0.0 L2 UNLOADED WITH BODY (±1.0 ) = 6.2 L1= 3.8 RETARDER= 4.5 L2 LOADED (±1.0 ) = 4.6 AXLE= 4.5 A B1 C1 T1 X1 CC L1 L2 3 6 3/8 7 3/8 4 1/2 21 1/4 57 3/8 SHAFT LENGTH 50 15/16 53 9/16 S1 S2 S4 SR R1 SHAFT MINIMUM TUBE DIAMETER 3.50 3.50 20 1/4 21 3/4 21 3/4 21 3/4 13 1/16 SHAFT MINIMUM TUBE THICKNESS 0.083 0.083 NOTE 1: Drive shaft lengths are measured from center of U-joint and are installed lengths. angle tolerance=±0.2 NOTE 2: All drive shafts must be dynamically balanced after modification. NOTE 3: Always verify proper shaft lengths before modification NOTE 4: When not specified, the front & the rear drive shafts, on each retarder side, must have at least the same slip as the original drive shaft NOTE 5: When not specified, the flange yoke on each retarder side must have the maximum working angle capacity available in the driveline series concerned. NOTE 6: adjust retarder to angle indicated by rotating chassis bracket NOTE 7: After installation is completed, measure drive shaft angles and compare to the angles on the installation drawing. Contact TELMA Customer Support Engineering if the angles measured do not conform to the drawing NOTE 8: USE BRACKETS TIB07000, TIB07005, TIB07006 NOTE 9: Check axle angle after body is installed and if necessary adjust to 4.5 with frame reference of 0 NOTE 10: vehicle speed electronically limited to 70mph dimension tolerance=±1/16" Page 21 of 23 6nov15jh
VEHICLE TECHNICAL DATA CHASSIS MAKE / MODEL CHEVROLET 4500 EXPRESS CUSTOMER: WHEELBASE 187.0" stretch from 159 VEHICLE NUMBER ENGINE MAKE / MODEL CHEVROLET 6.0L GASOLINE SPEED SWITCH / INTERFACE TRCM TRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16 AXLE MAKE / MODEL AAM GVW / GCW 14200 lbs DRIVE TYPE 4X2 BRAKES HYD RETARDER MODEL AF50-55 ABS RETARDER PART NUMBER LFA101156 AXLE RATIO 4.10 RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485 RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479 MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRING HOURS AT TIME OF INSTALL VOCATION SHUTTLE Note: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT. Dc loaded: 11 11/16 Dv unloaded: 13 3/16 D chassis only: 14 11/16 L2 CHASSIS ONLY (±1.0 ) = 7.2 TRANSMISSION= 3.0 CHASSIS BRACKET= 0.0 L2 UNLOADED WITH BODY (±1.0 ) = 5.7 L1= 3.8 RETARDER= 4.5 L2 LOADED (±1.0 ) = 4.2 AXLE= 4.5 A B1 C1 T1 X1 CC L1 L2 3 6 3/8 7 3/8 4 1/2 26 1/4 57 3/8 SHAFT LENGTH 50 15/16 58 9/16 S1 S2 S4 SR R1 SHAFT MINIMUM TUBE DIAMETER 3.50 3.50 20 1/4 21 3/4 21 3/4 21 3/4 13 1/16 SHAFT MINIMUM TUBE THICKNESS 0.083 0.083 NOTE 1: Drive shaft lengths are measured from center of U-joint and are installed lengths. angle tolerance=±0.2 NOTE 2: All drive shafts must be dynamically balanced after modification. NOTE 3: Always verify proper shaft lengths before modification NOTE 4: When not specified, the front & the rear drive shafts, on each retarder side, must have at least the same slip as the original drive shaft NOTE 5: When not specified, the flange yoke on each retarder side must have the maximum working angle capacity available in the driveline series concerned. NOTE 6: adjust retarder to angle indicated by rotating chassis bracket NOTE 7: After installation is completed, measure drive shaft angles and compare to the angles on the installation drawing. Contact TELMA Customer Support Engineering if the angles measured do not conform to the drawing NOTE 8: USE BRACKETS TIB07000, TIB07005, TIB07006 NOTE 9: adjust axle angle to 4.5 with frame reference of 0 NOTE 10: vehicle speed electronically limited to 70mph dimension tolerance=±1/16" Page 22 of 23 6nov15jh
VEHICLE TECHNICAL DATA CHASSIS MAKE / MODEL CHEVROLET 4500 EXPRESS CUSTOMER: WHEELBASE 191.0" stretch from 159 VEHICLE NUMBER ENGINE MAKE / MODEL CHEVROLET 6.0L GASOLINE SPEED SWITCH / INTERFACE TRCM TRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16 AXLE MAKE / MODEL AAM GVW / GCW 14200 lbs DRIVE TYPE 4X2 BRAKES HYD RETARDER MODEL AF50-55 ABS RETARDER PART NUMBER LFA101156 AXLE RATIO 4.10 RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485 RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479 MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRING HOURS AT TIME OF INSTALL VOCATION SHUTTLE Note: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT. Dc loaded: 11 11/16 Dv unloaded: 13 3/16 D chassis only: 14 11/16 L2 CHASSIS ONLY (±1.0 ) = 6.9 TRANSMISSION= 3.0 CHASSIS BRACKET= 0.0 L2 UNLOADED WITH BODY (±1.0 ) = 5.4 L1= 3.8 RETARDER= 4.5 L2 LOADED (±1.0 ) = 4.0 AXLE= 4.5 A B1 C1 T1 X1 CC L1 L2 3 6 5/8 7 5/8 4 3/4 22 1/4 61 3/8 SHAFT LENGTH 54 15/16 58 9/16 S1 S2 S4 SR R1 SHAFT MINIMUM TUBE DIAMETER 3.50 3.50 20 1/4 21 3/4 21 3/4 21 3/4 13 1/16 SHAFT MINIMUM TUBE THICKNESS 0.083 0.083 NOTE 1: Drive shaft lengths are measured from center of U-joint and are installed lengths. angle tolerance=±0.2 NOTE 2: All drive shafts must be dynamically balanced after modification. NOTE 3: Always verify proper shaft lengths before modification NOTE 4: When not specified, the front & the rear drive shafts, on each retarder side, must have at least the same slip as the original drive shaft NOTE 5: When not specified, the flange yoke on each retarder side must have the maximum working angle capacity available in the driveline series concerned. NOTE 6: adjust retarder to angle indicated by rotating chassis bracket NOTE 7: After installation is completed, measure drive shaft angles and compare to the angles on the installation drawing. Contact TELMA Customer Support Engineering if the angles measured do not conform to the drawing NOTE 8: USE BRACKETS TIB07000, TIB07005, TIB07006 dimension tolerance=±1/16" Page 23 of 23 6nov15jh