tl113036 installation manual for telma af50-55 on ... · tl113036 installation manual for telma...

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TL113036

INSTALLATION MANUAL

FOR TELMA AF50-55

ON CHEVROLET G4500 CUTAWAY

6.0L GASOLINE and 6.6L DIESEL ENGINE

TL113036

Chevrolet G4500 Installation Manual for AF50-55 for Gasoline and Diesel

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TABLE OF CONTENTS

1 Preparation of the Chassis 1.1 Driveline 1.2 Exhaust 1.3 Fuel Tank

2 Telma Installation 2.1 Installation Kit TIK10317 for Gasoline 6.0L (TIK10316 for Diesel 6.6L) 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 (TRCM) 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

7 Appendix 7.1.1 G4500 159” WB Installation Drawing with 6.6L Diesel Engine 1-1 7.1.2 G4500 159” WB Installation Drawing with 6.0L Gasoline Engine 1-1 7.2.1 G4500 177” WB Installation Drawing with 6.6L Diesel Engine 1-1 7.2.2 G4500 177” WB Installation Drawing with 6.0L Gasoline Engine 1-1 7.2.3 G4500 159to177” WB Installation Drawing with 6.6L Diesel Engine 1-1 7.2.4 G4500 159to177” WB Installation Drawing with 6.0L Gasoline Engine 1-1 7.3.1 G4500 159to182” WB Installation Drawing with 6.6L Diesel Engine 1-1 7.3.2 G4500 159to182” WB Installation Drawing with 6.0L Gasoline Engine 1-1 7.4.1 G4500 159to187” WB Installation Drawing with 6.6L Diesel Engine 1-1 7.4.2 G4500 159to187” WB Installation Drawing with 6.0L Gasoline Engine 1-1 7.5.1 G4500 159to191” WB Installation Drawing with 6.6L Diesel Engine 1-1 7.5.2 G4500 159to191” WB Installation Drawing with 6.0L Gasoline Engine 1-1 7.5.3 G4500 159to191” WB Installation Drawing with 6.0L Gasoline Engine 1-2

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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

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SECTION 2 RETARDER INSTALLATION

2.1 INSTALLATION KIT TIK10317 (TIK10316 diesel 6.6L) P/N DESCRIPTION QTYLFA101156 AF50-55 / 12v with 156 index 1JZ1007XX-45 Telma Shock Mount Set - 45 Shore 1TIB01017 CONTROL/RELAY BOX BRACKET 2TIB05048 2009 Chevy GMT TRCM Bracket 1TIB07000 Chevy / Ford LVR5 Chassis Bracket 2TIB07005 (TIB07003 diesel) AF Driver (left) Side Retarder Bracket 1TIB07006 (TIB07004 diesel) AF Passenger (right) Side Retarder Bracket 1TID17002 OBD2 HARNESS for AF55 1

TIF01064 hex head bolt 1/4 - 28 x 1.25 for TRCM mounting 2TIF05005 hex head bolt 1/4 - 28 x 0.75 for TRCM bracket mounting 2TIF01066 Nylon Insert Locknut ZP 1/4 - 28 UNF 4TIF05005 BOLT 1/4-28UNF x 3/4 HEX HEAD G8 2TIF05010 LOCKWASHER 5/16 SPLIT 4TIF05011 NUT 5/16 4TIF05012 BOLT 5/16-18UNC x 1-1/2 HEX HEAD G5 4TIF05013 BOLT 1/2-13UNC x 1-1/2 HEX HEAD G5 2TIF05014 LOCKWASHER 1/2 MED SPLIT 2TIF07000 12pt Head Bolt M12 x 1.75 x 25 8TIF07001 M12 x 1.75 x 35 Grade 10.9 Black Phosphate 6TIF07002 7/16-14 x 1.75 Hex Flange Bolt Full Thread Grade 8 12TIF07003 7/16-14 Hex Flanged Locknut Grade 8 12TIG11010 TELMA LIGHT BAR DISPLAY 1TIG31064 Telma Control Module GM CAN 1VF201400 Trep washer M12 for retarder bracket 6

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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 on the left and right of the chassis rail at dimension T1 down from the outside top of the frame and dimension CC back from the center of the transmission u-joint.

Drill a single 7/16” hole in the frame at the dimension of CC and T1 and bolt the chassis bracket (TIB07000) against the outside of the frame using the reference hole in the bracket.

Attach the chassis brackets to the frame rail using the flanged head bolts 7/16-14UNC x 1.75" (TIF07002) and flanged lock nuts (TIF07003) included in the kit.

Rotate the bracket to the angle specified on the installation drawing and tighten the bolts to 70 lb-ft (±10%). NOTE: Use electronic anglemeter with 0.1° accuracy (e.g. SPI Pro360 digital protractor). All angles indicated are with frame reference of 0°.

Drill five additional 7/16” holes in each frame rail evenly spaced across the chassis bracket and the rest of 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.

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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 left (driver) side bracket is TIB07005 for gasoline or TIB07003 for diesel. The

shorter right (passenger) side bracket is TIB07006 for gasoline or TIB07004 for diesel. 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 35 lb.-ft (±5 lb-ft) Mark all fasteners with paint after tightening to proper torque. 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%).

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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 installation drawings in the appendix for shaft length guidelines. Always verify proper shaft lengths before modification after Telma is installed. Connect the Telma flange yoke of each drive shaft to the Telma coupling flange using the M12x1.75x25mm 12 point

head bolts with patch-lock (TIF07000) supplied in the kit. Tighten to 85 lb-ft (±5 lb-ft). Mark with paint after tightening to proper torque.

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2.6 AXLE SHIM INSTALLATION Some installation configurations require the addition of steel 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.

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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.

LIGHT BAR DISPLAY

PANEL

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3.3 TELMA CONTROL MODULE INSTALLATION Bracket TIB05048 is used to mount the Telma Control Module as shown below.

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SECTION 4 WIRING HARNESS INSTALLATION 4.1 HARNESS ASSEMBLY LAYOUT

Control ModuleTelma PN: Date Code:

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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.

POWER CONNECTIONS AT

TOP RIGHT CORNER

GROUND CONNECTION AT

TOP LEFT CORNER

SECURE HARNESS TO RETARDER USING RUBBER

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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 sub-harness 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 installation is complete, connect the PC to check TRCM configuration and test the system as an end-line-line quality check. Set speed to 0 mph temporarily to test the system when stopped to ensure proper function. Do not forget to change speed cutoff back to 2.0 mph after testing. After changes are made press the send all config button to update the current vales. It may be necessary to unplug the gray connector from the module and reconnect in order to power cycle after a configuration change has been made for the current values to update. The configuration settings are in the table below. Make sure to check telmausa.com to download and install the latest Telma Desktop Client to use (03.02.07 and later) and the check that firmware revision is 03.02.07 or above.

Configuration Settings Ford F550 shuttle Low/High Low CAN G4500 2012- Speed 2.0mph Set point Stage 1 3% Set point Stage 2 5% Set point Stage 3 7% Set point Stage 4 10%

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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. DB9 serial extension cable (male/female)

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SECTION 6 POST INSTALL CHECKLIST

TL133010 Revised 19may15 INSTALLATION FOLLOWUP CHECKLIST

CHASSIS #:

CHASSIS MAKE/MODEL: Telma part number: Telma Serial number: End Customer: Retain a copy of this checklist in the chassis VIN record INSTALLER: Record Telma serial number in electronic VIN record INSPECTION DATE:

INSPECTED BY:

√ X COMMENTS

ELE

CT

RIC

AL

harness properly routed along center of Telma away from rotors and secured with cable clamps to retarder bracket

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

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

ME

CH

AN

ICA

L

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

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APPENDIX

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VEHICLE TECHNICAL DATACHASSIS MAKE / MODEL CHEVROLET G4500 CUSTOMER:WHEELBASE 159.0" VEHICLE NUMBERENGINE MAKE / MODEL CHEVROLET 6.6L DIESEL SPEED SWITCH / INTERFACE TRCMTRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16AXLE MAKE / MODEL AAM GVW / GCW 14200 lbsDRIVE TYPE 4X2 BRAKES HYDRETARDER MODEL AF50-55 ABSRETARDER PART NUMBER LFA101156 AXLE RATIO 4.10RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRINGHOURS AT TIME OF INSTALL VOCATION SHUTTLENote: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT.

Dc loaded: 10 1/4Dv unloaded: 11 3/4

D chassis only: 13 1/4

L2 CHASSIS ONLY (±1.0°) = 9.9°TRANSMISSION= 3.0° CHASSIS BRACKET= 0.0° L2 UNLOADED WITH BODY (±1.0°) = 7.0°

L1= 4.5° RETARDER= 4.5° L2 LOADED (±1.0°) = 4.2° AXLE= 4.5°

A B1 C1 T1 CC L1 L23 7 8 4 5/8 57 3/8 SHAFT LENGTH 51 30 1/2S1 S2 S4 SR R1 SHAFT MINIMUM TUBE DIAMETER 3.50 3.00

18 3/4 23 1/4 21 3/4 23 1/4 13 1/16 SHAFT MINIMUM TUBE THICKNESS 0.083 0.083NOTE 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. dimension tolerance=±1/16"NOTE 3: Always verify proper shaft lengths before modificationNOTE 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 bracketNOTE 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 drawingNOTE 8: USE BRACKETS TIB07000e, TIB07003, TIB07004NOTE 9: Check axle angle after body is installed and if necessary adjust to 4.5° with frame reference of 0°

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VEHICLE TECHNICAL DATACHASSIS MAKE / MODEL CHEVROLET G4500 CUSTOMER:WHEELBASE 159.0" VEHICLE NUMBERENGINE MAKE / MODEL CHEVROLET 6.0L GASOLINE SPEED SWITCH / INTERFACE TRCMTRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16AXLE MAKE / MODEL AAM GVW / GCW 14200 lbsDRIVE TYPE 4X2 BRAKES HYDRETARDER MODEL AF50-55 ABSRETARDER PART NUMBER LFA101156 AXLE RATIO 4.10RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRINGHOURS AT TIME OF INSTALL VOCATION SHUTTLENote: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT.



L2 CHASSIS ONLY (±1.0°) = 10.1°TRANSMISSION= 4.5° CHASSIS BRACKET= -0.5° L2 UNLOADED WITH BODY (±1.0°) = 7.2°


A B1 C1 T1 CC L1 L22 9/16 7 8 4 5/8 57 3/8 SHAFT LENGTH 51 1/16 30 7/16

S1 S2 S4 SR R1 SHAFT MINIMUM TUBE DIAMETER 3.50 3.0020 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. dimension tolerance=±1/16"NOTE 3: Always verify proper shaft lengths before modificationNOTE 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




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VEHICLE TECHNICAL DATACHASSIS MAKE / MODEL CHEVROLET G4500 CUSTOMER:WHEELBASE 177.0" VEHICLE NUMBERENGINE MAKE / MODEL CHEVROLET 6.6L DIESEL SPEED SWITCH / INTERFACE TRCMTRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16AXLE MAKE / MODEL AAM GVW / GCW 14200 lbsDRIVE TYPE 4X2 BRAKES HYDRETARDER MODEL AF50-55 ABSRETARDER PART NUMBER LFA101156 AXLE RATIO 4.10RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRINGHOURS AT TIME OF INSTALL VOCATION SHUTTLENote: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT.





A B1 C1 T1 CC L1 L23 6 3/8 7 3/8 4 65 3/8 SHAFT LENGTH 58 15/16 42 3/8S1 S2 S4 SR R1 SHAFT MINIMUM TUBE DIAMETER 3.50 3.00





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VEHICLE TECHNICAL DATACHASSIS MAKE / MODEL CHEVROLET G4500 CUSTOMER:WHEELBASE 177.0" VEHICLE NUMBERENGINE MAKE / MODEL CHEVROLET 6.0L GASOLINE SPEED SWITCH / INTERFACE TRCMTRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16AXLE MAKE / MODEL AAM GVW / GCW 14200 lbsDRIVE TYPE 4X2 BRAKES HYDRETARDER MODEL AF50-55 ABSRETARDER PART NUMBER LFA101156 AXLE RATIO 4.10RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRINGHOURS AT TIME OF INSTALL VOCATION SHUTTLENote: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT.





A B1 C1 T1 CC L1 L22 9/16 6 1/8 7 1/16 3 3/4 65 3/8 SHAFT LENGTH 58 15/16 42 3/8






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VEHICLE TECHNICAL DATACHASSIS MAKE / MODEL CHEVROLET G4500 CUSTOMER:WHEELBASE 177.0" stretch from 159 VEHICLE NUMBERENGINE MAKE / MODEL CHEVROLET 6.6L DIESEL SPEED SWITCH / INTERFACE TRCMTRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16AXLE MAKE / MODEL AAM GVW / GCW 14200 lbsDRIVE TYPE 4X2 BRAKES HYDRETARDER MODEL AF50-55 ABSRETARDER PART NUMBER LFA101156 AXLE RATIO 4.10RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRINGHOURS AT TIME OF INSTALL VOCATION SHUTTLENote: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT.










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VEHICLE TECHNICAL DATACHASSIS MAKE / MODEL CHEVROLET G4500 CUSTOMER:WHEELBASE 177.0" stretch from 159 VEHICLE NUMBERENGINE MAKE / MODEL CHEVROLET 6.0L GASOLINE SPEED SWITCH / INTERFACE TRCMTRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16AXLE MAKE / MODEL AAM GVW / GCW 14200 lbsDRIVE TYPE 4X2 BRAKES HYDRETARDER MODEL AF50-55 ABSRETARDER PART NUMBER LFA101156 AXLE RATIO 4.10RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRINGHOURS AT TIME OF INSTALL VOCATION SHUTTLENote: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT.











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A B1 C1 T1 CC L1 L23 6 1/8 7 1/8 3 3/4 57 3/8 SHAFT LENGTH 50 15/16 53 9/16S1 S2 S4 SR R1 SHAFT MINIMUM TUBE DIAMETER 3.50 3.50





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Contact TELMA Customer Support Engineering if the angles measured do not conform to the drawingNOTE 8: USE BRACKETS TIB07000, TIB07003, TIB07004NOTE 9: Check axle angle after body is installed and if necessary adjust to 4.5° with frame reference of 0°

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VEHICLE TECHNICAL DATA CUSTOMER:CHASSIS MAKE / MODEL CHEVROLET G4500 CHASSIS VIN:WHEELBASE 191.0" 159 stretch after x-member VEHICLE NUMBERENGINE MAKE / MODEL CHEVROLET 6.0L GASOLINE CONTROL MODULE TRCMTRANSMISSION MAKE / MODEL CHEVROLET 6L90 TIRE SIZE 225/75R-16AXLE MAKE / MODEL AAM GVW / GCW 14200 lbsDRIVE TYPE 4X2 BRAKES HYDRETARDER MODEL AF50-55 ABSRETARDER PART NUMBER LFA101156 AXLE RATIO 4.10RETARDER SERIAL NUMBER DRIVE LINE SERIES 1485RETARDER CONTROL SYSTEM FOOT FLANGE YOKE 3-2-479MILEAGE AT TIME OF INSTALL SUSPENSION TYPE SPRINGHOURS AT TIME OF INSTALL VOCATION REFUSENote: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT.


CHASSIS BRACKET= 0.0° L3 CHASSIS ONLY (±1.0°) = 6.3°TRANSMISSION= 4.5° RETARDER= 4.5° L3 UNLOADED WITH BODY (±1.0°) = 4.2°

L1= 4.0° L2= 4.0° L3 LOADED (±1.0°) = 2.1°AXLE= 4.0°

A B1 C1 P T1 CC L1 L2 L32 9/16 4 5/8 5 11/16 8 11/16 2 5/16 36 3/8 SHAFT LENGTH 29 7/8 43 1/4 41 13/16S1 S2 SR S6 S4 R1 SHAFT MINIMUM TUBE DIAMETER 2.50 3.00 3.00

20 1/4 21 3/4 21 3/4 21 3/4 21 3/4 13 1/16 SHAFT MINIMUM TUBE THICKNESS 0.095 0.095 0.095CAUTION: angle tolerance=±0.2°NOTE 1: L1, L2 and L3 are measured from center of U-joint and are installed lengths. dimension tolerance=±1/16"NOTE 2: All drive shafts must be dynamically balanced after modification.NOTE 3: 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: 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 6: USE BRACKETS TIB07000, TIB07005, TIB07006NOTE 7: adjust retarder to angle indicated by rotating chassis bracketNOTE 8: ADJUST CARRIER BEARING SO THAT SECOND SHAFT SHAFT (L2) IS 4.0°NOTE 9: ADJUST CARRIER BEARING SO THAT OFFSET MATCHES TELMA OFFSETNOTE 10: Check axle angle after body is installed and if necessary adjust to 4.0° with frame reference of 0°

tl113036 installation manual for telma af50-55 on ... · tl113036 installation manual for telma...

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