Telma TL113005 Manuel utilisateur

17feb12jh

TL113005

INSTALLATION MANUAL

FOR

TELMA AC50-55

ON FORD E-350/450 CUTAWAY

WITH TELMA CONTROL MODULE

TL113005

Ford E-350/450 Cutaway Installation Manual with Telma Control Module (TRCM)

Page 2 of 30__________________________________________________________________________17feb12jh

TABLE OF CONTENTS

1 Preparation of the Chassis

1.1 Driveline

1.2 Exhaust

2 Telma Installation

2.1 Installation Kit TIK10677

2.2 Install the Chassis Brackets

2.3 Install vent tube extension

2.4 Assemble the Telma Brackets and mounts

2.5 Install the Telma in the Chassis

2.6 Drive Shaft Modification and Installation

2.7 Axle Shim Installation

3 Control Components

3.1 Relay Box Installation

3.2 Light Bar Installation

3.3 Telma Control module and Foot Control Switch Installation

3.4 Foot Switch Adjustment

4 Wiring Harness Installation

4.1 Power Harness Installation

4.2 Control Harness Installation

4.3 Wiring Diagram

5 Recommended Tools

6 Post Install Checklist

Appendix

(1.1) E350 138” WB with 5.4L engine

(1.2) E350 138” WB with 6.0L/6.8L engine

(1.3) E350/450 158” WB with 5.4L engine

(1.3.1)E350/450 158” WB with 6.0L/6.8L engine

(1.4) E350/450 176” WB with 6.0L/6.8L engine (X1=24)

(1.4.1) E350/450 176” WB with 6.0L/6.8L engine (X1=22.5 / L1= original)

(1.4.2) E350/450 176” WB with 6.0L/6.8L engine (X1=10)

(1.4.3) E350/450 158 to 176” WB with 6.0L/6.8L engine (stretch in front of x-member)

(1.5) E350/450 186” WB with 6.0L/6.8L engine (stretched chassis)

(1.5.1) E350/450 158 to 186” WB with 6.0L/6.8L engine (stretch in front of x-member)

(1.6) E350/450 190” WB with 6.0L/6.8L engine (stretched chassis)

(1.6.1) E350/450 158 to 190” WB with 6.0L/6.8L engine (stretch in front of x-member)

(1.7) E350/450 208” WB with 6.0L/6.8L engine (stretched chassis)

(1.7.1) E350/450 158 to 208” WB with 6.0L/6.8L engine (stretch in front of x-member)

TL113005

Ford E-350/450 Cutaway Installation Manual with Telma Control Module (TRCM)

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SECTION 1 PREPARATION OF THE CHASSIS

1.1 DRIVELINE

Remove the complete drive-line assembly from the transmission flange yoke to the rear axle flange yoke.

1.2 EXHAUST

There should be no exhaust modification necessary for any wheelbase other than 138. A shorter replacement muffler

is necessary for E350 138” wheelbase.

SECTION 2 RETARDER INSTALLATION

2.1 INSTALLATION KIT TIK10677

P/N DESCRIPTION QTY

CN201155 AC50-55 / 12V (1410-1550) 1

TIB03123 LEFT SIDE RETARDER BRACKET (4.5 DEGREE) 1

TIB03124 RIGHT SIDE RETARDER BRACKET (4.5 DEGREE) 1

TIB03127 FORD E350-450 CHASSIS BRACKET 2

JZ100280 SIDE PLATE FASTENERS 1

JZ1007XX-30 TELMA SHOCK MOUNT SET (30 SHORE) 1

VF120340 ALL METAL LOCKNUT ½-20UNF G8 8

TIF03003 NUT 9/16 - 12 UNC G8 6

TIF03005 LOCKWASHER 9/16 G8 6

TIF04001 BOLT 9/16 - 12 UNC X 2 HEX HEAD G8 6

TID11050 HARNESS W/ JD331121 1

TIB01017 CONTROL / RELAY BOX BRACKET 2

TIG31063 TELMA CONTROL MODULE FORD CAN 1

TIB05002 FORD E350-450 PEDAL CLAMP 1

TIB05046 FORD E350-450 FOOT SWITCH BRACKET 1

TIB05047 FORD E350-450 PEDAL BRACKET 1

JC120102 FOOT SWITCH 1

TIG11010 TELMA LIGHT BAR DISPLAY 1

TIF05021 MUSIC WIRE / RETURN SPRING 1

TIF05000 LOCKWASHER 1/4 SPLIT 6

TIF05002 NUT 3/8 - 16 UNC G5 2

TIF05003 LOCKWASHER 3/8 G5 SPLIT 1

TIF05004 NUT 1/4 - 28 UNF G8 6

TIF05005 BOLT 1/4 - 28 UNF X ¾ HEX HEAD G8 6

TIF05010 LOCKWASHER 5/16 SPLIT 4

TIF05011 NUT 5/16 4

TIF05012 BOLT 5/16 - 18 UNC X 1-3/4 HEX HEAD G5 4

TIF05013 BOLT 1/2 - 13 UNC X 1-1/2 HEX HEAD G5 2

TIF05014 LOCKWASHER ½ MED SPLIT 2

TIF05019 ELEVATOR BOLT 3/8 - 16 UNC 2-1/2 1

TIF05034 FENDER WASHER ¼ X 1 1

JZ100110 DISCHARGE ASSEMBLY 1

Note: 1410 Flange yokes 2 x Telma part number TIF01080 / Spicer part number 3-2-429 must be ordered separately.

TL113005

Ford E-350/450 Cutaway Installation Manual with Telma Control Module (TRCM)

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2.2 INSTALL THE CHASSIS BRACKETS

•Remove any bolts such as battery box and/or exhaust hanger mounts or other components that may interfere with

the chassis bracket mounting.

•Clamp the chassis bracket (TIB03127) against the frame rail at dimension X1 from the body mount hole and

dimension T1 from the outside top of the frame. If T1 is 4.5”, the chassis bracket will be against the inside bottom

lip of the frame rail.

•Drill three 9/16” holes in each frame rail using the chassis bracket as a template and secure with bolts (TIF03001),

nuts (TIF03003), and lock washers (TIF03005) included in the kit.

•Tighten the 9/16” bolts to 150 lb-ft (±10%).

•Drill through the chassis bracket any holes needed for battery box and/or exhaust hanger mounts and reinstall the

original bolts and components that were removed previously.

•Refer to the figure below for details.

TL113005

Ford E-350/450 Cutaway Installation Manual with Telma Control Module (TRCM)

Page 5 of 30__________________________________________________________________________17feb12jh

2.3 INSTALL VENT TUBE EXTENSION

•At the time of installation the plastic vent tube extension kit should be attached to the grease chamber vent tube

according to the instructions supplied. Install the vent tube before the retarder bracket is installed to avoid the

possibility of crimping the nylon tube and restricting the outlet. The vent tube is located at the upper passenger

side corner of the Telma. Cut off the vent tube at the bottom of the Telma using a knife or cable cutter. Do not use

diagonal cutters which may crimp and restrict the outlet. Do not wrap the vent tube under the retarder.

TL113005

Ford E-350/450 Cutaway Installation Manual with Telma Control Module (TRCM)

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2.4 ASSEMBLE THE TELMA BRACKETS AND MOUNTS

•Identify the driver’s side of the Telma from the passenger side. To do so, orient the arrow of the red plate on the

Telma towards the axle with the red plate on the driver’s side.

•Identify the Telma brackets. The longer bracket TIB03123 is for the driver’s side. The shorter passenger side

bracket is TIB03124.

•Use four M14 bolts flat washers and Trep washers provided with the set of fasteners (JZ100280) to fasten the

Telma bracket onto each side of the unit. Tighten bolts to 65 lb.-ft (±10%).

•Install the rubber mounts into the retarder brackets. 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 top of each mount.

•Refer to the figure below for details.

2.5 INSTALL THE TELMA IN THE CHASSIS

•Lift the Telma, equipped with its brackets and mounts, into place against the bottom of the chassis brackets.

•Install the M16x1.5x100mm (4”) bolts and spring washers down through the holes in the chassis brackets, mounts

and Telma brackets at each mount. Install a 2 ¾” diameter flat washer, a spring washer and M16 locknut at each

mount and tighten to 150 lb.-ft (±10%).

TL113005

Ford E-350/450 Cutaway Installation Manual with Telma Control Module (TRCM)

Page 7 of 30__________________________________________________________________________17feb12jh

2.6 DRIVE SHAFT MODIFICATION and INSTALLATION

•A slip assembly is required on each side of the Telma. Slip position should be at center of slip travel when shaft is

installed

•Refer to FORD QVM guidelines and SPICER recommendations for proper drive shaft manufacture, balance,

straightness, and critical speed limits.

•Refer to the appendix for Telma guidelines

•Use u-joint SPICER part number SPL36-1X (1410)

•Refer to 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.

CN201155: Tighten the 1/2”-20UNF all metal lock nuts to 97-116 lb-ft.

TL113005

Ford E-350/450 Cutaway Installation Manual with Telma Control Module (TRCM)

Page 8 of 30__________________________________________________________________________17feb12jh

2.7 AXLE SHIM INSTALLATION

TL113005

Ford E-350/450 Cutaway Installation Manual with Telma Control Module (TRCM)

Page 9 of 30__________________________________________________________________________17feb12jh

SECTION 3 CONTROL SYSTEM COMPONENTS INSTALLATION

3.1 RELAY BOX MOUNTING

•Install the relay box on the inside driver side frame rail using an existing hole approximately 40” forward from the

center of the Telma and down 1 1/2“ from the top of the frame rail 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.

•Install the mating connector onto the five wires (org/wht, blu/wht, yel,grn, brn/wht, blk) found in the relay box

control harness.

•Feed the harness through the hole and connect to the Light Bar

•Plug the light bar into the hole

LIGHT BAR

DISPLAY

PANEL OPENING

TL113005

Ford E-350/450 Cutaway Installation Manual with Telma Control Module (TRCM)

Page 10 of 30__________________________________________________________________________17feb12jh

3.3 TELMA CONTROL MODULE & FOOT CONTROL SWITCH INSTALLATION

Bracket TIB05046 is used to mount the Telma Control Module and foot switch to the dash as shown.

Attach pedal clamp TIB05002 and pedal bracket TIB05047 to the brake pedal using the ¼” bolts, nuts and lock

washers supplied in the kit.

The return spring TIB05021 attaches using the 1/8” holes in the pedal bracket and foot switch bracket.

The special 3/8’ adjustment bolt, nuts and lock washers are assembled as shown.

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