TL113001 Chevy C4500/5500 Installation Manual for

TL113001 Chevy C4500/5500 Installation Manual for

TL113001
TL113001
INSTALLATION MANUAL FOR
TELMA AC51-00
ON CHEVROLET
C4500 (C4V042) / C5500 (C5V042)
CHASSIS
FROM MODEL YEAR 2004-2007
13may05
JCH
REVISED: 17-MAY-04
TIK10304 INSTALLATION KIT CHEV 5500 AC51-00 1480 (SPL55) WITH HYDRAULIC BRAKES
ENC SALINA DURAMAX 6.6L ALLISON 1000/2000 WITH SPEED SWITCH
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
PART
NUMBER
CM231158
JC120102
JC251100
JZ100110
JZ100280
JZ100723
TIB01019b
TIB01025c
TIB03105
TIB03106
TIB03108c
TIB03109a
TIB05002
TID13019a
TIF01063
TIF01086
TIF03001
TIF03003
TIF03005
TIF03011
TIF03012
TIF03013
TIF04001
TIF05000
TIF05002
TIF05003
TIF05004
TIF05010
TIF05011
TIF05012
TIF05019
TIF05021
TIG11010
DESCRIPTION
QTY
AC51-00 (CC 100) 12V 1480/1550/1610/SPL90/SPL100
FOOT CONTROL SWITCH
SPEED SWITCH (3.3V)
VENT TUBE EXTENSION
SIDE PLATE FASTENERS
MOUNT KIT
PEDAL BRACKET
CHEVY C5500 FOOT SWITCH BRACKET
LEFT RETARDER BRACKET
RIGHT RETARDER BRACKET
INSIDE MOUNT CHASSIS BRACKET
RELAY BOX BRACKET
PEDAL CLAMP
WIRING HARNESS C5500 HYD AC51-00 ALLISON LCT PIN26
HEX BOLT 1/4"-28UNF X 1"
1480/SPL55 FLANGE YOKE INDEX 158 (3-2-499)
3/8-24UNF ALL METAL LOCK NUT
9/16-12UNC NUT
9/16" LOCK WASHER
HEX BOLT 3/4-10UNC X 2 1/2"
3/4" LOCK WASHER
3/4-10UNC NUT
HEX BOLT 9/16-12UNC X 1 1/2"
LOCK WASHER 1/4"
NUT 3/8 - 16 UNC HEX G5
LOCKWASHER 3/8 G5
NUT 1/4-28UNF
LOCKWASHER 5/16" RELAY BOX MOUNTING
NUT 5/16" RELAY BOX MOUNTING
BOLT 5/16"-18UNC X 1 1/4" RELAY BOX MOUNTING
BOLT 3/8 - 16 UNC x 2 ELEVATOR BOLT G5
RETURN SPRING
TELMA LIGHT BAR DISPLAY
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
2
16
10
10
2
2
2
10
2
2
1
2
4
4
4
1
1
1
C5500 2-1 183.5 MAY-11-05 .xls
TELMA RETARDER, INC
This document is the exclusive property of TELMA RETARDER, INC. It cannot be copied, modified, forwarded, or given to
any third party without prior agreement from TELMA RETARDER, INC. Any infringement will immediately involve legal
1521 Morse Avenue, Elk Grove Village, IL 60007
Tel: (847) 593-1098 Fax: (847) 593-3592
CUSTOMER:
VEHICLE TECHNICAL DATA
CHASSIS MAKE / MODEL
CHEVROLET
C5500 VIN EXAMPLE:
WHEELBASE
183.5"
VEHICLE NUMBER
JC251100
ENGINE MAKE / MODEL
GM
6.6L / 8.1L SPEED SWITCH
TRANSMISSION MAKE / MODEL
ALLISON
1000 / 2200 TIRE SIZE
245/70R-19.5
AXLE MAKE / MODEL
DANA
S150 GVW / GCW
19500 / 22000 LBS
DRIVE TYPE
4X2
BRAKES
HYDRAULIC
RETARDER MODEL
AC51-00
ABS
CONTINENTAL-TEVES
RETARDER PART NUMBER
CM231158
AXLE RATIO
4.78
/ 5.13
RETARDER SERIAL NUMBER
DRIVE LINE SERIES
SPL55 / SPL70
RETARDER CONTROL SYSTEM
FOOT
FLANGE YOKE
3-2-499 / 4-2-689
MILEAGE AT TIME OF INSTALL
SUSPENSION TYPE
SPRING / AIR
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: 16 13/16
Dv unloaded: 17 5/16
TRANSMISSION: 5.0°
L1: 4.3°
L2: 3.5°
L3 LOADED:
L3 UNLOADED:
REAR AXLE LOADED:
REAR AXLE UNLOADED:
CHASSIS BRACKET: 0.0°
RETARDER: 4.0°
16 1/2
16 1/2
16 1/2
16 1/2
16 1/2
16 1/2
A
6 1/2
CC
65 7/16
B
10 5/8
T
8 3/8
C
11 1/2
DD INSIDE
33
P1
9
KLI
7 3/4
P2
N/A
KRI
7 3/4
M
2
G
2
R
12 3/4
6.4°
7.1°
4.0°
4.0°
17 1/2
L1
33
L2
24 1/4
L3
46
L4
N/A
X
70 3/4
CAUTION:
NOTE 1: L1, L2 and L3 are measured from center of U-joint and are installed lengths.
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 driveshaft.
NOTE 4: When not specified, the flange yoke on each retarder side must have the maximum working angle
capacity available in the driveline series concerned.
NOTE 5: USE MOUNTING BRACKETS TIB03108, TIB03105, TIB03106
NOTE 6: USE BRACKET POSITION 3
TEMPLATE LAST REVISED 4-FEB-03
PAGE 1
C5500 2-1 195.5 MAY-11-05 .xls
TELMA RETARDER, INC
This document is the exclusive property of TELMA RETARDER, INC. It cannot be copied, modified, forwarded, or given to
any third party without prior agreement from TELMA RETARDER, INC. Any infringement will immediately involve legal
1521 Morse Avenue, Elk Grove Village, IL 60007
Tel: (847) 593-1098 Fax: (847) 593-3592
CUSTOMER:
VEHICLE TECHNICAL DATA
CHASSIS MAKE / MODEL
CHEVROLET
C5500 VIN EXAMPLE:
WHEELBASE
195.5"
VEHICLE NUMBER
JC251100
ENGINE MAKE / MODEL
GM
6.6L / 8.1L SPEED SWITCH
TRANSMISSION MAKE / MODEL
ALLISON
1000 / 2200 TIRE SIZE
245/70R-19.5
AXLE MAKE / MODEL
DANA
S150 GVW / GCW
19500 / 22000 LBS
DRIVE TYPE
4X2
BRAKES
HYDRAULIC
RETARDER MODEL
AC51-00
ABS
CONTINENTAL-TEVES
RETARDER PART NUMBER
CM231158
AXLE RATIO
4.78
/ 5.13
RETARDER SERIAL NUMBER
DRIVE LINE SERIES
SPL55 / SPL70
RETARDER CONTROL SYSTEM
FOOT
FLANGE YOKE
3-2-499 / 4-2-689
MILEAGE AT TIME OF INSTALL
SUSPENSION TYPE
SPRING / AIR
HOURS AT TIME OF INSTALL
VOCATION
SHUTTLE
Note: If any of the above mentioned factors vary with your application, please call our TECHNICAL DEPARTMENT.
CC1
REFERENCE HOLE
Dc loaded: 16 13/16
T1
Dv unloaded: 17 5/16
TRANSMISSION: 5.0°
L1: 4.3°
L2: 5.1°
L3 LOADED:
L3 UNLOADED:
REAR AXLE LOADED:
REAR AXLE UNLOADED:
CHASSIS BRACKET: 0.0°
RETARDER: 4.0°
16 1/2
16 1/2
16 1/2
16 1/2
16 1/2
16 1/2
A
6 1/2
CC
77 7/16
B
12 3/8
T
6 3/8
C
13 1/4
DD INSIDE
33
P1
9
KLI
7 3/4
P2
N/A
KRI
7 3/4
M
2
G
2
R
12 3/4
4.3°
4.9°
4.0°
4.0°
17 1/2
L1
33
L2
36 1/4
L3
46
L4
N/A
X
70 3/4
CAUTION:
NOTE 1: L1, L2 and L3 are measured from center of U-joint and are installed lengths.
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 driveshaft.
NOTE 4: When not specified, the flange yoke on each retarder side must have the maximum working angle
capacity available in the driveline series concerned.
NOTE 5: USE MOUNTING BRACKETS TIB03108, TIB03105, TIB03106
NOTE 6: USE BRACKET POSITION 4
TEMPLATE LAST REVISED 4-FEB-03
PAGE 1
C5500 2-1 213.5 MAY-11-05 .xls
TELMA RETARDER, INC
This document is the exclusive property of TELMA RETARDER, INC. It cannot be copied, modified, forwarded, or given to
any third party without prior agreement from TELMA RETARDER, INC. Any infringement will immediately involve legal
1521 Morse Avenue, Elk Grove Village, IL 60007
Tel: (847) 593-1098 Fax: (847) 593-3592
CUSTOMER:
VEHICLE TECHNICAL DATA
CHASSIS MAKE / MODEL
CHEVROLET
C5500 VIN EXAMPLE:
WHEELBASE
213.5"
VEHICLE NUMBER
JC251100
ENGINE MAKE / MODEL
GM
6.6L / 8.1L SPEED SWITCH
TRANSMISSION MAKE / MODEL
ALLISON
1000 / 2200 TIRE SIZE
245/70R-19.5
AXLE MAKE / MODEL
DANA
S150 GVW / GCW
19500 / 22000 LBS
DRIVE TYPE
4X2
BRAKES
HYDRAULIC
RETARDER MODEL
AC51-00
ABS
CONTINENTAL-TEVES
RETARDER PART NUMBER
CM231158
AXLE RATIO
4.78
/ 5.13
RETARDER SERIAL NUMBER
DRIVE LINE SERIES
SPL55 / SPL70
RETARDER CONTROL SYSTEM
FOOT
FLANGE YOKE
3-2-499 / 4-2-689
MILEAGE AT TIME OF INSTALL
SUSPENSION TYPE
SPRING / AIR
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: 16 13/16
Dv unloaded: 17 5/16
TRANSMISSION: 5.0°
L1: 5.2°
L2: 5.0°
L3 LOADED:
L3 UNLOADED:
REAR AXLE LOADED:
REAR AXLE UNLOADED:
CHASSIS BRACKET: 0.0°
RETARDER: 4.0°
16 1/2
16 1/2
16 1/2
16 1/2
16 1/2
16 1/2
A
6 1/2
CC
95 7/16
B
14 3/8
T
8 3/8
C
15 1/4
DD INSIDE
33
P1
9 1/2
KLI
7 3/4
P2
N/A
KRI
7 3/4
M
2
G
2
R
12 3/4
1.8°
2.4°
4.0°
4.0°
17 1/2
L1
33
L2
54 3/8
L3
45 7/8
L4
N/A
X
70 3/4
CAUTION:
NOTE 1: L1, L2 and L3 are measured from center of U-joint and are installed lengths.
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 driveshaft.
NOTE 4: When not specified, the flange yoke on each retarder side must have the maximum working angle
capacity available in the driveline series concerned.
NOTE 5: USE MOUNTING BRACKETS TIB03108, TIB03105, TIB03106
NOTE 6: USE BRACKET POSITION 4
TEMPLATE LAST REVISED 4-FEB-03
PAGE 1
C5500 2-1 233 MAY-11-05 .xls
TELMA RETARDER, INC
This document is the exclusive property of TELMA RETARDER, INC. It cannot be copied, modified, forwarded, or given to
any third party without prior agreement from TELMA RETARDER, INC. Any infringement will immediately involve legal
1521 Morse Avenue, Elk Grove Village, IL 60007
Tel: (847) 593-1098 Fax: (847) 593-3592
CUSTOMER:
VEHICLE TECHNICAL DATA
CHASSIS MAKE / MODEL
CHEVROLET
C5500 VIN EXAMPLE:
WHEELBASE
233.0"
VEHICLE NUMBER
JC251100
ENGINE MAKE / MODEL
GM
6.6L / 8.1L SPEED SWITCH
TRANSMISSION MAKE / MODEL
ALLISON
1000 / 2200 TIRE SIZE
245/70R-19.5
AXLE MAKE / MODEL
DANA
S150 GVW / GCW
19500 / 22000 LBS
DRIVE TYPE
4X2
BRAKES
HYDRAULIC
RETARDER MODEL
AC51-00
ABS
CONTINENTAL-TEVES
RETARDER PART NUMBER
CM231158
AXLE RATIO
4.78
/ 5.13
RETARDER SERIAL NUMBER
DRIVE LINE SERIES
SPL55 / SPL70
RETARDER CONTROL SYSTEM
FOOT
FLANGE YOKE
3-2-499 / 4-2-689
MILEAGE AT TIME OF INSTALL
SUSPENSION TYPE
SPRING / AIR
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: 16 13/16
Dv unloaded: 17 5/16
TRANSMISSION: 5.0°
L1: 4.2°
L2: 4.1°
L3 LOADED:
L3 UNLOADED:
REAR AXLE LOADED:
REAR AXLE UNLOADED:
CHASSIS BRACKET: 0.0°
RETARDER: 4.0°
16 1/2
16 1/2
16 1/2
16 1/2
16 1/2
16 1/2
A
6 1/2
CC
B
14 3/8
T
114 15/16 8 3/8
C
15 1/4
DD INSIDE
33
P1
10 1/2
KLI
7 3/4
P2
N/A
KRI
7 3/4
M
2
G
2
R
12 3/4
1.8°
2.4°
4.0°
4.0°
17 1/2
L1
55
L2
51 7/8
L3
45 7/8
L4
N/A
X
70 3/4
CAUTION:
NOTE 1: L1, L2 and L3 are measured from center of U-joint and are installed lengths.
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 driveshaft.
NOTE 4: When not specified, the flange yoke on each retarder side must have the maximum working angle
capacity available in the driveline series concerned.
NOTE 5: USE MOUNTING BRACKETS TIB03108, TIB03105, TIB03106
NOTE 6: USE BRACKET POSITION 4
TEMPLATE LAST REVISED 4-FEB-03
PAGE 1
ABS CONNECTION
CHEVROLET C5500 CHASSIS
WITH 6.6L DIESEL ENGINE
CONNECT WHITE WIRE
FROM TELMA HARNESS TO
BLK 18G WIRE AT POSITION
D OF 6-WAY PACKARD
CONNECTOR BELOW UNDERHOOD ELECTRICAL
DISTIBUTION BOX BEHIND
RIGHT INNER FENDER WELL
(CIRCUIT 2657 FROM PIN 36
OF EBCM)
CONNECT RED WIRE FROM
TELMA HARNESS TO PINK
WIRE IN POSITION B OF
PACKARD 6-WAY
CONNECTOR
ABS CONNECTION
CHEVROLET C5500 CHASSIS
WITH 8.1L GASOLINE ENGINE
CONNECT WHITE WIRE
FROM TELMA HARNESS TO
BLK 18G WIRE IN HARNESS
ON RIGHT FRONT FRAME
RAIL (CIRCUIT 2657 FROM
PIN 36 OF EBCM)
SPEED SIGNAL
CONNECT TAN WIRE OF
TELMA HARNESS TO PIN
26 OF ALLISON TCM
GRAY CONNECTOR
USE TERMINAL
PACKARD # 12084912
NAVISTAR # 3517243C1
FEMALE FOR 18G WIRE
CHEVROLET C5500
FOOT SWITCH
INSTALLED