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PARTS LIST INDEX

A-64 CRANE TRUCK


AGNICO PINOS ALTOS
S/N 7056
10/31/08
1.

INTRODUCTION /GENERAL INFORMATION


F1008
F1000
F1009
M1040
S1092
S1000
F1003
F1001
F1002
F1004
F1005
F1006

2.

CHASSIS
10368
10376
10398
10448
13758
13942
12043

3.

PARTS ORDER INSTRUCTIONS


GETMAN WARRANTY
COMPONENT LIST
A-64 OPERATING MANUAL
CRANE OPERATION MANUAL
BOLTS TORQUE & SIZE SAE
LUBRICANTS CROSS REFERENCE
STORAGE PROCEDURES
TROUBLESHOOTING CHECK LIST
PREVENTIVE MAINTENANCE SCHEDULE FORMS
SERVICE REPORT FORM
SHIFT CHANGE CHECK LIST

SIGHT GAUGE
FILL CAP (FUEL OIL)
FILL CAP (HYDRAULIC OIL)
HOLD DOWN FASTENERS
SEAT ASSEMBLY
STEERING (PINS, BEARINGS, BUSHINGS)
ARTICULATION INSTALLATION

ELECTRICAL SYSTEM AND INSTRUMENTS


30318
17143
S1100
13663

WIRING DIAGRAM
INSTRUMENT PANEL
MURPHY POWERVIEW INSTRUCTIONS
ALTERNATOR

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
4.

ENGINE AND ACCESSORIES


F1007
S1034
S1078
S1035
13807
13661
13660
13713
11637
13676
S1020

5.

DRIVE TRAIN
17193
13436
S1005
12408

6.

TRANSMISSION ASSEMBLY
TRANSMISSION MOUNTS
TRANSMISSION MAINTENANCE & SERVICE
MANUAL
DRIVELINE INSTALLATION

AXLE
10829
13320
13319
S1021
13321
S1023
13954
S1007

7.

DETROIT DIESEL WARRANTY


ENGINE OPERATION MANUAL
ENGINE MAINTENANCE MANUAL
ENGINE PARTS MANUAL
ENGINE FILTERS
RADIATOR INSTALLATION
CHARGE AIR INSTALLATION
AIR INTAKE SYSTEM
AIR CLEANER
EXHAUST SYSTEM
EXHAUST INFORMATION

AXLE ORIENTATION
AXLE ASSEMBLY
AXLE CRADLE INSTALLATION
AXLE SERVICE & REPAIR MANUAL
BRAKE ACTUATOR
ACTUATOR INSTALLATION
TIRE & RIM
TIRE SERVICE

BRAKE SYSTEM
31547
13378
S1008
16483
S1009
12976

HYDRAULIC SCHEMATIC
BRAKE VALVE
BRAKE VALVE SERVICE
DUAL CHARGE VALVE
DUAL CHARGE VALVE SERVICE
ACCUMULATOR

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
8.

HYDRAULIC SYSTEM
31547
S1077
17132
13259
12860
S1024
S1010
13943

9.

CONTROLS
13905
10827
13655

10.

HYDRAULIC SCHEMATIC
HYDRAULIC SYMBOLS
SERVICEJUNIOR DIGITAL PRESSURE GAUGE
FILTER (HYDRAULIC)
STEERING ORBITROL
STEERING ORBITROL SERVICE
PUMP SERVICE
STEERING CYLINDER

ELECTRIC SHIFTER
STEERING WHEEL & COLUMN
THROTTLE (ELECTRONIC)

MOUNTED EQUIPMENT
S1025
S1012
S1013
S1014
23276
17183
16721
S1081
S1092
S1094

FIRE EXTINGUISHER
FIRE PROTECTION INFORMATION MANUAL
FIRE SUPPRESSION MAINTENANCE MANUAL
AUTO FIRE SUPPRESSION SERVICE MANUAL
FIRE SUPPRESSION INSTALLATION
FIRE SUPPRESSION AUTO DETECTION SYSTEM
FIRE SUPPRESSION SYSTEM
CRANE PARTS MANUAL
CRANE SERVICE MANUAL
LINCOLN AUTO GREASE LUBE MANUAL

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
1.

INTRODUCTION /GENERAL INFORMATION


F1008
F1000
F1009
M1040
S1092
S1000
F1003
F1001
F1002
F1004
F1005
F1006

PARTS ORDER INSTRUCTIONS


GETMAN WARRANTY
COMPONENT LIST
A-64 OPERATING MANUAL
CRANE OPERATION MANUAL
BOLTS TORQUE & SIZE SAE
LUBRICANTS CROSS REFERENCE
STORAGE PROCEDURES
TROUBLESHOOTING CHECK LIST
PREVENTIVE MAINTENANCE SCHEDULE FORMS
SERVICE REPORT FORM
SHIFT CHANGE CHECK LIST

INSTRUCTIONS FOR ORDERING


REPAIR PARTS

F1008
Page 1 of 1

TO AVOID DELAYS AND ASSURE THE MOST EFFICIENT HANDLING, PLEASE


SPECIFY THE FOLLOWING ON ALL ORDERS.
MODEL TYPE AND FACTORY SERIAL NUMBER OF YOUR MACHINE.
NAME, MODEL NUMBER, AND SERIAL NUMBER OF THE ASSEMBLY (SUCH
AS A TRANSMISSION) FOR WHICH THE PART REQUIRED.
PART NUMBER (REFER TO THE CORRECT REPAIR PART NUMBER).
GIVE COMPLETE PART DESCRIPTION.
EXACT QUANTITY OF PART REQUIRED. (DO NOT ORDER BY SET UNLESS
SET IS SPECIFICALLY CALLED OUT IN PARTS MANUAL. IN THOSE
INSTANCES, SPECIFY ONE (1) SET OF ___________ MATCHES PIECES.)
SHIPPING INSTRUCTIONS (INCLUDE ROUTING WHEN POSSIBLE).
BILLING INSTRUCTIONS.
PLEASE PLACE ALL ORDERS WITH YOUR LOCAL GETMAN DISTRIBUTOR OR
CALL 1-800-533-1110 OR 269-427-5611.

MODEL

A-64

TYPE

CRANE TRUCK

SPEC.

3508

SERIAL NO.

7053

Updated:
10/28/08

F1000

Limited Warranty
Getman Corporation warrants each new vehicle manufactured by it to be free from defects in materials and
workmanship for one (1) year or two thousand (2,000) hours of operation (whichever occurs first) from the
date of delivery to the first user, excepting the vehicle mainframe which is warranted to be free from defects
in materials and workmanship for five (5) years or ten thousand (10,000) hours of operation (whichever
occurs first).
This warranty is limited to the replacement or repair, at Getmans factory or at a point designated by Getman,
of such part which is found by Getman, after inspection, to be defective in materials or workmanship. Repair
parts provided under this warranty are warranted for the remainder of the warranty period of the vehicle to the
same extent as if such parts were original components thereof.
This warranty does not apply to:
1. Engines, tires, batteries, or other components which are warranted directly to the user by the
respective manufacturers thereof;
2. Any vehicle or component which has been repaired or altered in such a way, and in Getmans
judgment, as to affect the product adversely;
3. Any vehicle or component which has, in Getmans judgment, been subject to negligence, accident or
improper storage or usage;
4. Any vehicle which has not been operated and maintained in accordance with normal practices and
within the recommendations of Getman; and
5. Any vehicle or component or accessory manufactured by others and supplied by Getman on special
order by the first user.
This warranty does not obligate Getman to bear the costs of labor or transportation charges in connection with
the replacement or repair of defective vehicles or parts.
ALL WARRANTIES IN THIS AGREEMENT ARE IN LIEU OF ANY OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SAID WARRANTIES BEING
EXPRESSLY DISCLAIMED.
GETMAN WILL NOT BE LIABLE FOR ANY LOSS, DAMAGE OR INJURY RESULTING FROM
DELAY IN DELIVERY OR INSTALLATION OF THE GOODS OR FOR ANY FAILURE TO PERFORM
WHICH IS DUE TO CIRCUMSTANCES BEYOND ITS CONTROL. THE MAXIMUM LIABILITY, IF
ANY, OF GETMAN FOR ALL DAMAGES, INCLUDING WITHOUT LIMITATIONS CONTRACT
DAMAGES FOR INJURIES TO PERSONS OR PROPERTY, WHETHER ARISING FROM GETMANS
BREACH OF THIS AGREEMENT, BREACH OF WARRANTY, NEGLIGENCE, STRICT LIABILITY,
OR OTHER TORT WITH RESPECT TO THE GOODS, IS LIMITED AS OTHERWISE PROVIDED
HEREIN. IN NO EVENT SHALL GETMAN BE LIABLE TO BUYER FOR ANY INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES, INCLUDING WITHOUT LIMITATION LOST
REVENUES AND PROFITS, EVEN IF IT HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH
DAMAGES. THE RIGHT TO RECOVER DAMAGES WITHIN THE LIMITATION SPECIFIED IS
BUYERS EXCLUSIVE ALTERNATIVE REMEDY IN THE EVENT THAT ANY OTHER
CONTRACTUAL REMEDY FAILS OF ITS ESSENTIAL PURPOSE.
Any dispute arising out of or relating to an alleged breach of this warranty shall be submitted for resolution to
arbitration. Such arbitration shall be conducted according to the rules of the American Arbitration
Association, and any reward shall, if deemed necessary by either party, be submitted to the appropriate
judicial body for confirmation as a judgment to such judicial body.

Getman Corporation, 59750 34th Avenue, Bangor, Michigan 49013, U.S.A./ Telephone: (269) 427-5611/ Facsimile: (269) 427-8781/ E-mail: info@getman.com.
Registered Trademark of Getman Corporation

F1009
Page 1 of 1

COMPONENT LIST

Model:

CRANE TRUCK

Type:

Shop No.:

3530

Serial No.:

Customer:

AGNICO PINOS ALTOS

7056

A-64

Truck No.:

N/A

COMPONENT
ENGINE
TRANSMISSION
CRADLE AXLE
RIGID AXLE
MAIN HYD PUMP

MANUFACTURER
DETROIT DIESEL
CLARK
NEW HOLLAND
NEW HOLLAND
COMMERCIAL

MODEL
OM904LA
32000
D65
D65
P25

SPECIFICATION
465198
465563
464891
464891
494217

SERIAL NUMBER
904.971-00-736305
KBEA328988
86559438 8G15
86559438 8G15
HD79317G5

OPTIONS:
DECK CRANE

PALFINGER

PK7501

465527

100090477

COMMON MAINTENANCE ITEMS


ENGINE OIL FILTER
146000
FUEL FILTER
146001
FUEL WATER SEPARATOR
146022
TRANSMISSION FILTER
24069
HYDRAULIC FILTER ELEMENT
534691
FAN/ALT BELT
146073

*WHEN ORDERING PARTS, ALWAYS GIVE MODEL AND SERIAL NUMBER OF UNIT.
SEE MAINTENANCE SECTION IN MANUAL FOR SERVICE INTERVAL ON THESE ITEMS.

Updated:
11/07/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 1 of 32

GETMAN CORPORATION

OPERATING AND MAINTENANCE


MANUAL
FOR
MODEL A-64 CHASSIS

Read thoroughly before


operating vehicle

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 2 of 32

INTRODUCTION

RELATED MANUALS

This manual is a guide to proper, safe operation,


lubrication, and minor adjustment of the Getman A-64
Chassis. Each operator assigned to this vehicle should
study this manual carefully before starting or operating
the vehicle in order to become familiar with all the
controls and procedures.

Engine operation manual is included with the Parts and


Service Manuals supplied with this vehicle. You should
become familiar with these manuals.

Getman A-64 Chassis are purchased with the expectation


that it will provide long and faithful service. In its
construction, we have taken every precaution to see that
you receive an efficient, long-lived, satisfactory vehicle.
However, to realize the full measure of value and utility
that Getman has designed into this unit, a small amount of
time and expense must be invested in the performance of
regular inspections and service as recommended in this
manual. The small investment will pay off in low
operating costs, minimal service expenses, and most
importantly in personal safety.

Getman has increased the frequency of many recommended


maintenance procedures due to the vehicles demanding
application. These changes are noted at each maintenance
section end.

A complete parts listing of engine train components,


applicable Electric/Air/Hydraulic systems, and mounted
equipment is included in the Parts and Service Manual. This
manual also contains service and repair information useful to
maintenance department personnel.
If you have any questions about operating or servicing this
unit, contact your local Getman dealer or Getman Corporation
direct, immediately.

TABLE OF CONTENTSPAGE 2
Introduction.2
Related Manuals..2
General Safety Precautions..3-4
Name, Warning and Caution Plates5
Safety Notice......6
Fuel Shut-Off..6
Service Position..6
Parking Procedure..6
Caution Statement..7
General Description........8
Instrument Panel Descriptions...9-10
Instrument Warning Panel...11-12
Electronic Engine Data Display...13-14
Gauge Descriptions..15-16
Checks Before Start Up.17
Starting Procedure.....18
Park Brake Test Procedure........19
Service Brake Test Procedure...19
After Engine Starts20
Operating Vehicle21-22
Maintenance Schedule.....23-31
Specifications....32

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 3 of 32

SAFETY ALERT SYMBOL

This symbol will appear at various points throughout the manual in


conjunction with warning statements. Its appearance means:
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

This manual also uses the following messages:


NOTICE: Used for special information or instructions, relating to procedures, equipment, tools, and other special data.

IMPORTANT: Used when special precautions should be taken to ensure correct action or to avoid damage to or malfunction of
equipment.

CAUTION: Used as a reminder of safety hazards which can result in personal injury if proper precautions are not taken.

WARNING: Used when a hazard exists which can result in injury or death if proper precautions are not taken.

DANGER: Used when an extreme hazard exists which can result in serious injury or death if proper precautions are not taken.

RULES
Before performing any maintenance on the vehicle, review the following safety precautions. These are included for your
protection and safety.
Always observe the following general safety rules during operation of the vehicle. Also observe the safety rules set forth in the
work place. The need for additional rules for safe operation may arise due to particular mine applications. This should ONLY
be used as guidance.

Read and carefully follow all instructions as outlined in the vehicle manuals.

Ensure that all instruments, indicators, and operating controls are functioning.

Never utilize operating controls as hand holds to assist entering or exiting a vehicle.

Never stand when operating a vehicle in motion.

Avoid wearing loose or baggy clothing when working around engines or other rotating or moving equipment.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 4 of 32

Never allow riders in vehicles not designated to carry passengers.

Never dismount from a vehicle unless brakes are set.

Always lower ground engaging implements and utilize wheel chocks when vehicle is parked.

If parking on a grade is unavoidable, point the vehicle towards the rib, engage the parking brake, lower all ground engaging
implements and utilize wheel chocks.

Avoid smoking or open flame around fuel.

Always be aware of location of nearest fire extinguisher.

Always ensure that excess grease, oil, etc., are cleaned up immediately to prevent a potential fire hazard.

Check operation of brake circuit prior to beginning of each shift.

Never remove any elements of the engines exhaust system or any safety guards when vehicle is in operation.

Never utilize a vehicle for an application other than it was originally designed for.

Watch out for others. They may not be watching out for you!

CANOPY
Your GETMAN vehicle could be equipped with a MSHA canopy or cab option. These are designed to provide protection to
the operator in the event of a rollover of the vehicle or from foreign objects falling on the operators area. There will be a label
attached to the structure which will include the structure serial number, vehicle weights, and vehicle model numbers.
Modifications such as adding attachments to the cab/canopy, welding, cutting, and/or drilling holes can weaken the structure,
lessen operator protection, and void certification. Should your vehicle sustain damage to the structure, contact your local
distributor prior to performing repairs.

IMPORTANT: Any modification not supplied by Getman Corporation or by OEM should be approved prior to change
by Getman.

WARNING: The seat belt is an important part of the MSHA canopy safety system. Failure to wear a seat belt can
cause extreme injury or death.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 5 of 32

NAME, WARNING AND CAUTION PLATES


Locate and understand all name plates and decals, including the Getman Model/Serial Number Plate and two types of Warning
Plates. These are placed there for your safety and protection. Should any of these labels require replacement, please notify your
local Getman Distributor to order the appropriate label. Please be sure to provide the correct vehicle serial number with your
order.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

from engine ECM in addition to disconnecting the


batteries regardless of engine manufacturer.

SAFETY NOTICE
Safety depends on well maintained, properly operated
equipment. Following service and maintenance
recommendations set forth in this manual will result in a reliable
vehicle. Observing operating procedures can help you avoid
accidents. Listed below are some basic safety precautions which
should be read, understood and practiced. It is, however,
impossible to cover every condition. Always be alert, think
SAFETY at all times, and use common sense.

DO
Do read this manual thoroughly before operating vehicle.

M1040
Page 6 of 32

Do not allow riders. Passengers must be seated in proper


seats with seat belts fastened.

Do not enter or exit a vehicle when in motion.

Do not pump the brake pedal.

Do not drive the vehicle over electrical cables.

Do not operate a vehicle with a defective exhaust system.

Do not re-fuel the vehicle with engine running.

Do learn to recognize and avoid potential hazard areas,


such as the articulation area.

Do perform all recommended checks.

Do report all vehicle defects.

FUEL SHUT OFF

Do check the area around entire vehicle prior to entering


the operators compartment.

SERVICE POSITION

Do carefully inspect and fasten seat belt.

Throughout this manual, you will be told to place the vehicle in


SERVICE POSITION.

Do sound horn before starting engine.

1. Park vehicle on level area and block wheels.

Do operate vehicle with caution.

2. Apply parking brake.

Do park vehicle on level surface, if possible, and block


wheels.

3. Lock frame articulation joint by installing safety bar. (articulating


vehicle only)

Do use parking brake.

4. Stop engine.

Do place transmission gear selector in neutral (N) when not


in use.

Complete procedure before servicing vehicle.

Do enter and exit operators compartment carefully.

Do use proper tools for service.

DO NOT
Do not operate while under the influence of alcohol or
drugs.

Do not allow pedestrians near vehicle when engine is in


operation.

Do not arc weld on vehicle without first turning master


switch to off position.

Close fuel line valves at tank ports.

PARKING PROCEDURE
1. Park vehicle away from traffic, and turn into the rib.
2. Apply the parking brake and place transmission in neutral (N).
3. If the vehicle has been operating in a working condition just prior
to parking, allow engine to cool. Park and run at idle for 1 to 2
minutes.
4. Stop engine.

IMPORTANT
When welding on all Cummins engines, disconnect the 50pin OEM connector and 4-pin power connector from the
engine ECM, as well as disconnect battery positive and
negative terminals. Failure to follow this procedure could
result in damage to ECM and voiding of warranty. It is a

5. Block wheels.

good practice to always disconnect OEM connector

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS
CAUTION STATEMENT
Use this equipment under the following conditions.
1. GENERAL SAFETY
This diesel-powered vehicle may only be designed for use in
non-coal mines. Such mines are those in which material being
mined is incombustible or contains at least 65% by weight of
incombustible material, and in which underground atmosphere
in any open workings contain less than 0.25% by volume of
flammable gas. Tunneling operations in which underground
conditions confirm with the foregoing are in the same category
as non-coal mines. Any questions pertaining to the design of
this vehicle, please contact your local distributor. Make
frequent inspections to see all engine intake and exhaust parts,
all electrical components, including wiring and all other
equipment, are in safe operating condition. There must be no
openings in any part of the engine exhaust system except one
exhaust outlet originally provided.
All circuit breakers for overload protection in electrical circuits
must be kept in good condition.
2. FASTENERS
Keep all bolts, nuts, screws and other fasteners for electrical
enclosures in place. Properly tighten and secure them.
Similarly, keep fasteners for the engine cylinder head, intake
and exhaust systems in place, properly tightened and secured.
3. REPAIRS AND RENEWALS
Take special care when making repairs and renewals. Use new
parts exactly like those furnished by original manufacturer. Use
gaskets from the manufacturer only. Have all mating surfaces
clean and in proper condition.
4. BATTERY AND CABLES
Before working on or around batteries, turn the battery
disconnect switches off.
5. VENTILATION
The amount of fresh moving air for ventilation at any place
underground where the vehicle is working must meet the engine
manufacturers minimum requirements. This ventilation must
be supplied in addition to that required for other diesel powered
vehicles and other requirements. Shut off the engine whenever
underground ventilation stops for any reason. It is
recommended the engine be shut off any time the vehicle is not
in use. Do not idle engine for excessively long periods.

M1040
Page 7 of 32

8. EXHAUST SYSTEM
Keep exhaust piping tight at all times. Do not allow piping to
become blocked. The maximum back pressure (positive) in exhaust
system at full throttle, no load, 2500 RPM must not exceed the engine
manufacturers recommended value.
9. EXHAUST PURIFIER
Purifier can lose efficiency when used on engines producing
excessive amounts of blue and/or black smoke. Other engine
malfunctions such as stuck or leaking injectors will also cause loss of
efficiency. Compression loss will lead to lower exhaust temperature
and loss of purifier efficiency.
10. FUEL
Use only diesel fuel recommended by the engine manufacturer for
satisfactory engine operation. The flash point must not be less than
140F or sulfur content greater than 0.5% by weight. When filling
fuel tanks underground, transport fuel in secure metal containers.
Store fuel containers in closed, incombustible compartments while
awaiting transfer to the fuel tank of the diesel vehicle. Keep fuel in
ventilated area.
11. FIRE EXTINGUISHER
Each diesel vehicle must carry at least one dry type or CO type
pressurized fire extinguisher at all times.
12. VEHICLE OUT OF SERVICE
Each out of service vehicle must have an OUT OF SERVICE tag
displayed.

WARNING!
Improper operation of this vehicle can cause severe injury or
death!!!

6. ENGINE
Replace any faulty part with manufacturers parts.
7. INTAKE SYSTEM
Air must flow freely into intake system. Maximum pressure
(vacuum) through intake system at full throttle, no load, 2500
RPM should not exceed engine manufactures recommended
value. The OM904LA and OM906LA diesel engine should not
exceed (22) inches of water (dirty filter). A restriction indicator
will provide warning indication by turning red when twenty (20)
inches of water is achieved. Inspect the intake air cleaner at
regular intervals and clean or replace as necessary.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS
GENERAL DESCRIPTION
Getman Model A-64 Chassis is a four wheel drive,
articulating frame steering vehicle powered by a diesel
engine. The power of the engine is transmitted through
the torque converter to a powershift transmission. From
the transmission, drive shafts with universal joints
transmit the power to the deep reduction, inboard
planetary drive axles.

CAUTION
Steering is not functional when engine is not running.
Steering is full hydraulic power type, utilizing a flange
mounted direct drive hydraulic gear pump which provides
hydraulic fluid to an orbitrol valve operated by the
steering wheel. This operates the two steer cylinders
located in the articulation joint.

M1040
Page 8 of 32

Every effort has been made to ensure that you can stop this
vehicle. The service brakes (axle brakes) are fully enclosed
wet disk type, with a dual system, permitting separate circuitry
for front and rear brakes. Should a failure occur in either
circuit, the other circuit remains functional. The spring set,
hydraulically released, service brakes which also serve as
parking brakes, are manually set and released by utilizing the
dash mounted push/pull control button. The front and rear
service brakes are also used as secondary brake which
automatically apply in the event of loss of hydraulic or
transmission pressure. This brake can also be manually
applied in the event of complete hydraulic system failure.
This vehicle is equipped with two red Brake Warning lights
located in the instrument panel. These are for each the front
and rear brake circuits. These warning lights will illuminate if
hydraulic pressure in either brake circuit drops below the
preset 1100 PSI (76 BAR) level. The front and rear service
brakes will automatically apply if the hydraulic pressure in the
brake circuit drops below 1100 PSI (76 BAR). The Brake
Impending light in the Warning Panel will illuminate when
hydraulic pressure drops below 1200 PSI. All the instruments
require to operate the vehicle are located in the operators
area. Become familiar with the position and function of each.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 9 of 32

INSTRUMENT PANEL DESCRIPTIONS

465313-100

1. Engine Function Display: This instrument


will display all available engine functions
(engine oil pressure, temp, rpm, engine hours,
etc..), and it also displays check engine and stop
engine warning codes. See Murphy Operating
Manual in Section 3 for more information.
2. Engine Warning Alarm: This gauge
provides an audio/visual warning in conjunction
with the Murphy Engine Function Display.

3. Transmission Pressure Gauge: Transmission


pressure gauge indicates pressure being regulated
and provided to the transmission clutches. If the
gauge fails to register pressure after engine start
up, shut down engine immediately and contact
maintenance. Normal operating pressure is
approximately 300 PSI. See Transmission
Service Manual in Section 5 for more
information.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 10 of 32

4. Converter Oil Temperature Gauge: Normal


transmission/Converter operating temperature
160-220F (71-104C). If gauge indicates
higher temperature, stop vehicle, shift
transmission into neutral, apply parking brake and
run engine at 1000-1200 RPM until oil
temperature returns to normal. See Transmission
Service Manual in Section 5 for more
information.

15. Start Switch: Turn switch to position 1 for


preheat, and momentary turn to position 2 to start
engine.

5. Parking/Secondary Brake Button: Push to


apply, pull to release.

18. Canopy Light (Optional): Turn to on


position to operate Canopy light.

6. Voltmeter: Indicates battery charging or


discharging.

19. Warning Panel: This panel provides a


visual warning for various events. See Instrument
Warning Panel for more information.

16. Light Switch: Toggle switches for front and


rear lights.
17. Beacon/Strobe (Optional): Turn to on
position to operate Beacon or strobe light.

7. Work Light Switch (Optional): If equipped,


switch on for work light application.
8. Horn Button: Push to sound horn.
9. Circuit Breakers: Consists of 10, 20 and 30
AMP breakers used for gauges, lights, horns,
etc
10. Spare Space: Available for additional usage,
contact Getman Corporation if space is needed.
11. PLC Reset Switch (Optional): Used to reset
engine controls. Pull out for 30 seconds, fuse will
reset. Push back in and restart engine.
12. Remote Throttle Enable Switch (Optional):
Enables a remote throttle to be used to control
engine RPMs.
13. Park Brake Test Button: For vehicles
equipped with a Park Brake Test button,
depressing and holding this button allows the
operator to engage the transmission for testing of
the park brake. See Procedures in Section 1 for
instructions on performing this test.
14. Low Fuel Light (Optional): For vehicles
equipped with this light when illuminated unit is
low on fuel.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 11 of 32

INSTRUMENT WARNING PANEL

PARK BRAKE
(RED)

ACCUMULATOR
PRESSURE LOW
FRONT BRAKES
(RED)

ACCUMULATOR
PRESSURE LOW
REAR BRAKES
(RED)

STOP ENGINE
(RED)

CHECK ENGINE
(YELLOW)
POWER ON
(GREEN)
TRANSMISSION
FAULT
(RED)

IMPENDING
AUTO BRAKE
APPLICATION
(YELLOW)

DECLUTCH
(RED)

PARK BRAKE: This light illuminates when the driveline parking brake is engaged.
When the parking brake is released to set the vehicle in motion, this light will not be
illuminated.
FRONT AND REAR BRAKES: Two individual lights are in the display to provide
the operator with information regarging possible auto brake application. These lights
are an indication that less than 1100 PSI exists in either the forward or rear brake
circuit. Auto brake application occurs when brake system pressure falls below 1100
PSI.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
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OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 12 of 32

POWER ON LIGHT: The power light is an indication that the ignition switch has
been turned to the ON position. It will remain illuminated until the ignition is
turned off.
CHECK ENGINE: This light illuminates in the event of an engine fault being
detected by the engine electronic control system. This is normally considered to be a
minor fault where attention should be attended whenever possible.
STOP ENGINE: This light illuminates in the event of an engine fault being detected
by the engine electronic control system. This is considered to be a major fault which
will require immediate attention. Shut down the engine as soon as possible and notify
maintenance.
BRAKE IMPENDING: This light illuminates when hydraulic pressure in either the
front or rear brake circuit falls below the 1200 PSI range. This is a warning to the
operator of a possible impending auto brake application which occurs below 1100
PSI.
DECLUTCH: This light illuminates when the transmission selector is disabled.
Depending on options chosen, the following can activate the declutch option.
1. Parking Brake is ON.
2. Diverter valve is in Accessories mode.
3. Stabilizer Jacks are not fully retracted.
4. Man basket is not stowed level on deck.
5. Scissor deck is in elevated position.
TRANSMISSION: This light illuminates in the event of low hydraulic oil pressure
or high transmission temperature.

OTHER CONTROLS

Gear Selector Lever- Move lever to position 1 for low


gear, position 2 for second and position 3 for third gear.

WARNING
Never free wheel vehicle. Free wheeling will cause serious
injury and damage vehicle.
Accelerator Pedal (Not Shown)- Push to increase engine
RPM.
Brake Pedal (Not Shown)- Push to activate service brakes.
Seat Adjustment (Not Shown)- Adjust for operator comfort.
Direction Selector Lever- Move selector lever to F for
forward. Move selector lever to R for reverse direct. N is
for neutral

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 13 of 32

ELECTRONIC ENGINE DATA DISPLAY

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
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OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 14 of 32

ELECTRONIC ENGINE DATA DISPLAY CONTINUED

STOP
ENGINE

CHECK
ENGINE

NOTE: FOR MORE INFORMATION ON ELECTRONIC ENGINE DATA DISPLAY, SEE


SECTION 3 (ENGINE FUNCTION DISPLAY OPERATING MANUAL)
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 15 of 32

GAUGE DESCRIPTIONS

Normal transmission/converter temperatures are between 180F-220F (82C-104C). Should temperatures rise
above the 220F range, apply parking brake, place transmission in neutral and increase engine speed to approximately
1000 RPM until temperatures return to normal range.

Transmission pressure gauge indicates pressure being regulated and provided to the transmission clutches. If the
gauge fails to register pressure after engine start up, shut down engine immediately and contact maintenance. Normal
operating pressure is approximately 300 PSI.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 16 of 32

GAUGE DESCRIPTION CONTINUED

Fuel gauges can be inside or outside of the cab. The gauge indicates the existing fuel level in the fuel reservoir.

Voltmeter indicates current battery voltage level, charging or discharging. There will either be a 16V gauge used for a
12V charging system or a 32V gauge used for a 24V charging system. With engine running a 12V charging system
should read 12-16 volts and 24 30 volts for a 24V charging system.

Pressure gauges are used to measure the hydraulic pressure system. They could be used to measure brake pressure, total
system pressure, etc.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 17 of 32

CHECKS BEFORE START UP

Check all the engine belt(s) for tension and condition. Worn or
gouged belt(s) should be replaced immediately.

Check area around vehicle for obstacles that might be damaged


by, or cause damage to, vehicle when it is driven.

Check Fire Extinguisher and replace as needed.

Check engine oil level. Fill as required with recommended


lubricant.

Make sure frame joint safety bar is not connected.


Check air cleaner sight gauge. If indicator is in the red zone,
clean or replace filter element(s). Visually inspect rubber
connectors and clamps.

Check hydraulic oil reservoir level with engine shut off. Oil
level should not be above the top sight gauge or below the lower
sight gauge. Fill as required.

Check tire pressure, 95 PSI (6.55 BAR) is recommended.


Check wheel nuts. Do not operate with loose or missing wheel
nuts.

Check lights and horn to ensure all are operational.

Check seat belt to make certain fastener works and belt is not
worn or cut. Adjust operators seat to a comfortable operating
position. Some seats have height adjustments.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 18 of 32

STARTING PROCEDURE

IMPORTANT
Before you enter operators compartment, all personnel must be a
safe distance from vehicle.

CAUTION
Transmission must be in neutral and park brake must be applied
to start engine.

Frame safety bar must not be connected.

1. Turn Battery and ECM Disconnects to ON position.


NOTE: This switch could be located on the side of the vehicle,
in the cab, or both.

4.

Move Directional Lever to neutral position.

2. Adjust and fasten Seat Belt to a comfortable operating


position.
5.

Turn Start Switch to ON position. (a)

6. Wait for Powerview Warning Lights to go out. (b)


Approximately 3 seconds.
7.

Push Horn Button to sound horn. (c)

8. Turn Start Switch to start position to engage starter motor


and hold until engine starts. NOTE: Do not hold for periods
longer than 15 seconds.
3.

Push down Park Brake Button.

9.

If engine, transmission, and hydraulic pressure gauges do


not show pressure shortly after stat-up, stop engine and
determine cause.

NOTICE
DO NOT CRANK ENGINE FOR MORE THAN 30 SECONDS. ALLOW STARTER TO COOL FOR TWO MINUTES BEFORE
CRANKING AGAIN. TURBOCHARGER (IF EQUIPPED) DAMAGE CAN RESULT, IF THE ENGINE RPM IS NOT KEPT LOW
UNTIL THE ENGINE OIL PRESSURE GAUGE INDICATES PRESSURE IS SUFFICIENT.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 19 of 32

PARK BRAKE TEST PROCEDURE (PERFORM DAILY)

NOTICE
Depressing the Park Brake Button located in the switch panel overrides the transmission declutch feature.
To test the Park Brake Only:
a

b
1.

Set Park Brake. (a)

2.

Depress & hold Park Brake Test Button. (b)

3.

Place shifter in 3rd Gear. Forward.

4.

Fully depress Throttle.

5.

Vehicle Should Not move.

SERVICE BRAKE TEST (PERFORM DAILY)


Test the service brake by fully depressing the service brake pedal. Placing the transmission in forward, 2nd gear, release the
parking brake and increase engine RPM to maximum for 3-5 seconds. Vehicle should not move. If vehicle moves, park and
apply wheel chocks and contact maintenance.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

M1040
Page 20 of 32

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS
AFTER ENGINE STARTS
3
1

Engine Oil Pressure #1 Electronic Engine Display- Oil pressure should read 25-50 PSI at idle with engine at operating
temperature. At full engine load, pressure should read between 45-60 PSI. If gauge fails to show pressure after engine start up,
stop engine immediately and find cause.
Voltmeter #2- With engine running, voltage should read 12-16 volts for 12 volt vehicle systems and 24-30 volts for 24 volt
vehicle systems.
Transmission Temperature Gauge #3 & Transmission Pressure Gauge #4- During work cycles, if Trans/Converter Gauge
indicates temperature above 220F, bring vehicle to a stop, place transmission in Neutral with park brake applied and increase
engine RPM to approximately 1000-1200 RPM. Maintain this RPM until Transmission temperature returns to normal levels.
Normal transmission operating pressure is approximately 250 PSI (17.2 BAR). Should transmission pressure fail to register upon
starting of vehicle, stop engine and contact maintenance.
Brake Pressure Gauges- There are two brake accumulator pressure gauges located on the side of the dash on the engine panel .
These display the individual hydraulic pressures existing in the front and rear brake accumulators. Normal operating pressure in
these gauges is between 1500 and 2200 PSI (103.5-151.5 BAR).

CAUTION
Stop engine immediately if any gauge is not in its set range.
Park Brake Test- This system is designed to hold a fully load vehicle on a 35% grade. For safety reasons, a parking brake test
should be performed at the beginning of each shift. See Park Brake Test Procedures for instructions on how to conduct this test.

WARNING
Do not operate any vehicle with a faulty parking/service brake system. Serious personal injury or damage to vehicle may result.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

M1040
Page 21 of 32

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS
OPERATING VEHICLE

4
3

Once all gauges have been checked and are within normal operating ranges, vehicle is ready to
operate.

Turn Light Switchs to the on position #1.

Depress Service Brake and hold #2.

Check Brake Accumulator Pressure Gauges and check Instrument Panel Warning Display for Low
Pressure Warning Lights in Warning Panel #3.

Ensure all hydraulic stabilizers are in the top position (if applicable)

Check to be sure area is clear of all personnel and obstacles. Select forward by pushing the gear
selector lever to F position and select 1st gear pulling gear selector lever to 1 position.

Pull Park Brake Button #2 to release the driveline disk brake.

Depress horn button #4 on instrument panel to sound horn.

Release Foot Brake Pedal, test steering for proper operation and move vehicle slowly by gently
depressing Accelerator Pedal with foot.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
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OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 22 of 32

OPERATING VEHICLE (CONTD)

Acquaint yourself with the FEEL of the steering


by driving the pattern shown above. Do this several
times until you become familiar with vehicle
steering and feel you would be comfortable driving
the vehicle in traffic areas. To familiarize yourself
with vehicle response to an automatic application of
the driveline brake, drive straight, remove foot from
accelerator pedal and push Park Brake Button while
still rolling.
Park brake should set and vehicle should come to a
stop. If this does not occur, have brake circuit and
adjustment checked by authorized personnel.

When satisfied that you can safely and comfortably


operate the vehicle, find a long straight open stretch of
roadway and accelerate. Start in 1st gear, shift to 2nd
gear, and then to 3rd, etc. (if conditions permit). Make
certain area chosen is free of obstacles and/or other
personnel. At higher speeds slight turns should be tried
as long as there is no danger of hooking the rib or
another vehicle. Stop vehicle and return transmission
gear selector to neutral (N). Apply Park Brake. Check
all gauges again to be certain they are within normal
operating range.
NOTE: When traveling up a grade, select lower gear if
torque converter oil temperature approaches 200F (93
C).

CAUTION!
When proceeding down grades, use 1st gear. Use of 2nd
or 3rd gear could cause engine over speeds and possible
safety hazards to operator.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 23 of 32

MAINTENANCE SCHEDULE AS REQUIRED


Place vehicle in service position.
NOTE:
Depending on dust conditions, air cleaner may require
daily service.
The vehicle will be equipped with one of the following air
filtration options. Determine which system your vehicle
is equipped with and refer to the proper section for service
instructions.
AIR CLEANER SERVICE PROCEDURE
NOTE: Lack of engine power and/or excessive exhaust
smoke is signs the air filter elements may require service.

Check service indicator. Clear dust collector discharge slot


daily. Service air cleaner ONLY when indicator locks in red
position. Proceed as follows:

Check service indicator. Clear dust collector discharge


slot daily. Service air cleaner ONLY when indicator locks
in red position. Proceed as follows:

Loosen nuts on air cleaner housing and remove pre-cleaner


panel. Remove and discard dirty filter cartridge. Clean inside
filter housing and install new filter cartridge.
Clean pre-cleaner panel. Replace panel and tighten nuts.
Reset service indicator.

Loosen thumbscrew holding cover and remove cover.


Remove and discard primary filter element. Clean inside
housing. Install new element.
Check cover gasket to ensure a good seal. Reposition
cover and thumbscrew. Reset service indicator.
Replace safety filter element every 5th primary filter
change. Safety filter element is replaced in same manner
as primary element change.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 24 of 32

MAINTENANCE SCHEDULE DAILY OR EVERY SHIFT CHANGE


Place vehicle in service position.

9
8

4
3
2

1
7
10
5
1
COMPONENT
FLUID*
Tires
____
Hydraulic System
HO
Engine
EO
Air Pre-cleaner
____
Fuel System
D2
Belts
____
Oscillating Axle
Trunnions
EPG
8. Transmission & Torque
Converter
TF
9. Upper & Lower Pivot Pin
Bearings
EPG
10. Steering Cylinder
Bushings
EPG
*Perform maintenance schedule as required.
*See Fluid Specifications.

ITEM
1.
2.
3.
4.
5.
6.
7.

Check tire condition and pressure. Do not operate vehicle


with low tire pressure. Do not operate vehicle with badly
worn and/or gouged tires.

Check hydraulic reservoir sight gauges and fill as required.


Fluid level should not be above top sight gauge or below
bottom sight gauge.

Check engine oil level. Fill as required.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 25 of 32

DAILY MAINTENANCE OR EVERY SHIFT CHANGE (CONTD)

Empty and clean pre-cleaner dust bowl .

Check fuel level. Fill as required.

Check all engine belts for tension and condition. Worn or


gouged belts should be replaced immediately. Check belt
tension as follows:

WARNING
Engine MUST be shut of to check belt tension.

Check transmission fluid level. Fluid should be checked at


normal operating temperature with engine running at idle and
transmission in neutral. For detailed information, see section 5
(Transmission Service and Maintenance Manual). Fill as
required.

1. Push the belt at


center between pulleys
with finger.
2. Belt movement
should be 3/8 to 5/8
(10-15mm).

CAUTION
Avoid any moving belts, components, or high temperature
areas. Serious personal injury can result from
carelessness.
Visually inspect machine:
With Engine Running Check:
1. Hydraulic system for leaks.
2. Fuel system for leaks.
3. Instruments for proper function.
With Engine Off Check:
1. All controls for free movement.
2. Mounting bolts.

Grease axle trunnions.

NOTE: Perform engine maintenance as indicated in the


engine operators manual or by contacting Getman
Corporation for the latest information.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 26 of 32

MAINTENANCE SCHEDULE EVERY 50 OPERATING HOURS


Place vehicle in service position.

2
1

ITEM
1.
2.
3.
4.
5.

COMPONENT
FLUID*
Wheels
____
Battery
H2O
Air Cleaner
EO
Air Cooling System
____
Catalytic Exhaust
Purifiers
____
*Perform Maintenance Schedule As Required.
*Perform Maintenance Schedule Daily Or Every Shift.
*See Fluid Specifications.
Release and lift battery access plate. Clean battery off and
inspect cables.

WARNING
Be aware of hydrogen gas build up under battery access
plate. Keep open flame and sparks away from battery.

Check wheel nuts. Nuts should be tightened to 300 LBSFT (406.7 Nm).

IMPORTANT
Do not get battery acid on skin. Keep all open flame out
of area.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 27 of 32

MAINTENANCE SCHEDULE EVERY 50 OPERATING HOURS (CONTD.)


DO NOT allow engine to idle more than five (5) minutes at a time, or
purifier will loose efficiency.
2. Before vehicle is put into service, and during every 50 hour check,
check exhaust back pressure at full throttle by connecting a back
pressure or water gauge to the 1/8 NPT test port between purifier
and exhaust manifold. If back pressure exceeds 40 (1016 mm) H2O
or has risen 5 (127mm) or more since last regeneration, purifier
must be regenerated.
Add grease to both upper and lower pivot pin bearings. (See
specifications)

ECS REGENERATION
Required Equipment:
1. Nylon, hard bristle parts cleaning brush.
2. Solvent-air, parts cleaning gun.
3. Super concentrate degreasing solution.
4. Stoddard solvent or high grade kerosene (sulphur free) - - 5 parts
Stoddard to 1 part S.C.
5. High pressure air source (30PSI).
6. Wrench.

Add grease to both steering cylinder ends.


WARNING
Flammable Solution. Use in accordance with manufacturers
recommendations. Use in a properly ventilated area. Failure to
follow these instructions could result in serous injury.

Check ALL air intake connections. Tighten as required.

Remove air cowl on injector side of engine by releasing retainer


snaps. Clean cooling fins, oil cooler, transmission cooler, and
radiator if applicable with compressed air.
Vehicles equipped with ECS catalytic air purifier:

Cleaning Procedure:
1. Remove center section of purifier.
2. Dry brush inlet face of catalyst.
3. Air clean through outlet face of catalyst.
4. Continue steps 1 & 2 until inlet face is clean.
5. Completely soak catalyst in Stoddard, S.C. solution for one hour.
6. Solvent-air clean through outlet face of catalyst for 10 minutes.
7. Air clean through outlet face.
8. Repeat steps 4, 5, and 6 until purifier is clean.
9. High pressure water wash purifier through outlet face and air dry.
10. Replace purifier.
11. Record back pressure at full throttle, remove gauge and tighten
test plug.
NOTE: If high pressure steam is available, it may be substituted for
solvent solution. Steam clean through outlet face, keeping nozzle 2
(51mm) away from catalyst face.
NOTE: If purifier has been regenerated but engine continues to
smoke, engine must be serviced to maintain safe exhaust conditions.

1. If vehicle is operated under heavy load with engine rpm at


least 70% of operating time, a maximum amount of maintenance
will be required. If engine does not work hard and is allowed to
idle for excessive periods of time, the catalyst may become
carboned up and exhaust will start to smoke after a few hours,
indicating regeneration is necessary.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 28 of 32

MAINTENANCE SCHEDULE EVERY 250 OPERATING HOURS


Place vehicle in service position.

2
6

ITEM
1.

COMPONENT
FLUID*
Driveline, Universal
Joints, Slip Joints
EPG
2. Transmission
TF
3. Hydraulic System
HO
4. Axle Differential Housing MBO
5. Axle Breather
____
6. Engine
____
7. Parking Brake
____
*Perform Maintenance Schedule as Required.
*Perform Maintenance Schedule Daily or Every Shift.
*Perform 50 Hour Maintenance.
*See Fluid Specifications.

Add grease to all driveline universal joints, and center


bearing.

Add grease to driveline slip yokes, one fitting each.

Drain transmission oil by removing the drain plug. Clean plug


in solvent, dry, and replace in transmission.

NOTE: Some universal joints may not be shown.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 29 of 32

MAINTENANCE SCHEDULE EVERY 250 OPERATING HOURS (CONTD)

Remove transmission filter. Replace with new filter.


Before installing filter, coat gasket with light film of oil.
See Section 5 (Transmission Service & Maintenance
Manual) for detailed information.
Fill and check transmission as follows:
1. Fill transmission to low mark on dipstick.
2. Run engine at idle 500-600 RPM to prime converter
and hydraulic hoses.
3. Re-check oil level with engine at idle and transmission
in neutral. Bring oil level to low mark on dipstick. When
oil reached normal operating temperature of 158 to
248F (70-120C) make a final check and bring to the
full mark of the dipstick.
4. Check for oil leaks.

Remove return line filter. Replace filter element and install


return line filter. Install drain plug. Fill hydraulic reservoir
with fluid.

Check hydraulic reservoir sight gauge. Add fluid as required.


Fluid level should not be above top sight gauge or below
lower sight gauge.

Check lubricant level in both differential housings. Remove


fill plug. Gear oil should be level with full plug bottom. Add
lubricant as required. Replace fill plug. Refer to specification
page for proper fluid.

Remove reservoir fill cap and empty main hydraulic


reservoir by removing drain plug.
NOTE: To avoid contamination, clean reservoir top
before servicing.

Remove axle breather, clean in solvent and dry with


compressed air. Re-install in axle. Do for both axles.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 30 of 32

MAINTENANCE SCHEDULE EVERY 500 OPERATING HOURS


Place vehicle in service position.
Clean or replace sump strainer and re-install inside reservoir.

ITEM COMPONENT
FLUID*
1. Hydraulic System
HO
*Perform Maintenance Schedule as required.
*Perform Maintenance Schedule Daily or Every Shift.
*Perform 50 Hour Maintenance.
*Perform 250 Hour Maintenance.
*See Fluid Specifications.

Remove return line filter. Replace filter element. Install


return line filter.
Install reservoir access plate, install drain plug, and fill
hydraulic reservoir with fluid. Check specifications.

Check hydraulic reservoir sight gauges. Add fluid as required.


Level should not be above upper sight gauge or below lower
sight gauge.

Remove reservoir fill cap. Empty main hydraulic


reservoir by removing drain plug.
NOTE: To avoid contamination, replace cap and clean
reservoir top before proceeding.

Remove hydraulic reservoir access plate. Disconnect sump


strainer located inside reservoir.
NOTE: Strainer suction port must be closed off with a 1 1/2
NPT cap to prevent circuit contamination and possible damage
to hydraulic components.
Clean reservoirs inside with steam or solvent.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 31 of 32

MAINTENANCE SCHEDULE EVERY 1000 OPERATING HOURS


Place vehicle in service position.

ITEM
1.
2.

COMPONENT
Axle Differential Housing
Axle Breather

FLUID*
MBO
____

*Perform Maintenance Schedule as required.


*Perform Maintenance Schedule Daily or
Every Shift.
*Perform 50 Hour Maintenance.
*Perform 250 Hour Maintenance.
*Perform 500 Hour Maintenance.
*See Fluid Specifications

Remove front and rear axle differential drain plugs. When axle
is empty of all fluid, clean and re-install drain plugs.

Remove differential fill plugs (one per axle). Add specified


lubricant until fluid level reaches bottom of oil fill plug port.
Clean and re-install differential fill plugs.

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

OPERATING AND MAINTENANCE


MANUAL FOR MODEL A-64 CHASSIS

M1040
Page 32 of 32

SPECIFICATIONS
FUEL
Use No. 2 Diesel Fuel, Cetane 40 Minimum
Use a dependable brand of diesel fuel with a sulfur content of less than 0.5%. Use care when re-fueling to avoid
fuel system contamination. Use a winter grade fuel when operating vehicle in low temperatures. NOTE: To avoid
drawing air into the fuel system, do not allow vehicle to run out of fuel as this can cause extreme hard starting.

NOTICE
Using diesel fuel with lower than recommended cetane number can cause hard starting, instability, and excessive
white smoke. To maintain satisfactory operation at low ambient temperatures, it is important to specify diesel fuel of
the correct centane number. For complete details see Engine Operation and Maintenance Manual or contact your
local Getman Distributor.

TIRES
SIZE

PLY
TYPE
PSI
BAR
RATING
14.00X24
28
____
120
8.3
10.00X20
14
LCM
95
6.5
12.00X20
16
SMC
95
6.5
9.00X20
12
LCM
90
6.1
NOTE: This chart indicates tire pressure specifications ONLY. The sizes are not interchangeable. Always
replace with tires of same size, type, and ply rating originally supplied with vehicle
PRESSURES
TYPE
Engine Oil Pressure at 1000 RPM
Steering Hydraulic System at low idle with vehicle turned
and against stops.
NOTE: Checks made at 150F (65C) oil temperature
Hydraulic brake charging pressure.
John Deere Axles
Ford/New Holland D45 & D65
Pressure from brake treadle valve.
John Deere Axles
Ford/New Holland D45 & D65

PSI
45-60

BAR
3.1-4.1

1500-2000

103-138

1650-2200
1650-2200

114-151
114-151

1000
1500

69.0
130.5

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.

Updated:
05/29/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 1 de 32

CORPORACION GETMAN

MANUAL DE OPERACION Y
MANTENIMIENTO
PARA
EL CAMION GETMAN A-64

Lea cuidadosamente este manual


antes de operar el vehculo

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
INTRODUCCIN
Este manual es una gua para una apropiada y segura
operacin, lubricacin y ajustes menores del Camin
Getman A-64. Cada operador asignado a este vehculo
deber estudiar este manual cuidadosamente antes de
arrancar u operar el camin de tal forma que se familiarice
con todos los controles y procedimientos.
Los Camiones Getman A-64 son comprados con la
expectativa de que proveer un servicio prolongado y
confiable. En su construccin, hemos tomado todas las
precauciones para asegurar que usted reciba un vehculo
eficiente y duradero. Sin embargo, para llevar a cabo la
medida completa de valuacin y utilidad que Getman ha
designado a esta unidad, una pequea cantidad de tiempo y
costo debe ser invertido en el cumplimiento de
inspecciones y servicio tal y como se recomienda en este
manual . Esta pequea inversin se retribuir en bajos
costos de operacin, mnimos costos de servicio y, lo ms
importante, en seguridad del personal.

M1040
Pag. 2 de 32

RELACION DE MANUALES.
Los manuales de operacin est incluidos con los manuales de
partes y servicios suministrados con este vehculo. Usted se
debe familiarizar con estos manuales.
Getman ha incrementado la frecuencia de muchos
procedimientos de mantenimiento recomendados debido a la
aplicacin de demanda. Estos cambios son sealados en cada
seccin de mantenimiento y en el manual de refacciones y
servicio.
Se incluye una lista completa de componentes del motor y
transmisin, sistemas aplicables elctricas/aire/hidrulicas,
este manual tambin contiene informacin del servicio y
reparacin til para el personal del departamento de
mantenimiento.
Si usted tiene algunas preguntas acerca del servicio y
operacin de esta unidad, contacte al representante local de
Getman o directamente a la Corporacin Getman,
inmediatamente.

TABLA DE CONTENIDOS......PAGINA 2
Introduccin......................................................2
Relacin de manuales.......................................2
Precauciones generales de seguridad............3-4
Nombres, placas de advertencia y precaucin..5
Aviso de seguridad...........6
Cierre de combustible..........6
Posicin de servicio.....................6
Procedimiento de estacionamiento.......6
Declaracin de advertencia..................7
Descripcin general..................9
Descripcin de los instrumentos del
Tablero..10-11
Instrumentos de advertencia en el tablero.12-13
Exposicin de Datos del Control Electrnico13
Descripcin de los manmetros14-15
Inspecciones antes del arranque.16
Procedimiento de arranque.17
Procedimiento de prueba del freno de
Estacionamiento.18
Despus de que el motor se arranca.......19
Operacin del camin...20-21
Programa de mantenimiento.22-31
Especificaciones.....32

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 3 de 32

SIMBOLO DE ALERTA DE SEGURIDAD

Este smbolo aparecer en varios puntos a travs de este manual como


declaracin de advertencia. Su aparicin significa:
ATENCION! MANTENGASE ALERTA! SU SEGURIDAD ESTA DE POR MEDIO!

Este manual tambin usa los siguientes mensajes:


NOTICE (ATENCIN): Este mensaje es usado para informacin o instrucciones especiales, relacionadas con
procedimientos, equipo, herramientas y otros datos especiales.
IMPORTANT (IMPORTANTE): Este mensaje se utiliza cuando se deben tomar precauciones especiales para
asegurar la accin correcta y evitar dao o anomalas al equipo.
CAUTION (PRECAUCION): Este mensaje se utiliza como recordatorio de riesgo de seguridad el cual puede
resultar con dao o lesin al personal si no se toman las precauciones apropiadas.
WARNING (ADVERTENCIA): Este mensaje se utiliza cuando existe el riesgo que puede causar lesiones o muerte
si no se toman las precauciones necesarias.
DANGER (PELIGRO): Este mensaje se usa cuando existe un alto riesgo en el cual causar la muerte o lesiones
graves si no se toman las precauciones adecuadas.
REGLAS
Antes de realizar cualquier mantenimiento en el camin, revise las siguientes precauciones de seguridad. Estas son
incluidas para su proteccin y seguridad.
Siempre observe las siguientes reglas de seguridad durante la operacin del camin. Siempre observe las reglas de
seguridad impuestas en el lugar de trabajo. La necesidad de reglas de seguridad adicionales para una operacin
segura pueden presentarse debido a particulares aplicaciones de la mina. Las siguientes reglas son solamente usadas
como una gua.

Lea y siga cuidadosamente todas las instrucciones descritas en los manuales del camin.

Asegrese que todos los instrumentos, indicadores y controles de operacin estn funcionando.

Nunca utilice los controles de operacin como agarraderas para ayudarse a subir o salir del camin.

Nunca se ponga de pie cuando el camin est en movimiento.

Nunca use ropa suelta u holgada cuando est trabajando cerca de mquinas o equipo en movimiento.

Nunca permita personal en los camiones que no estn designados para transportar personal pasajeros.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 4 de 32

Nunca se baje de un camin a menos que los frenos estn activados.

Siempre baje los implementos de tierra y utilice los tacones de soporte en las llantas cuando el camin est
estacionado.

Si se estaciona inevitablemente en una pendiente, coloque el camin dirigido hacia la tabla del cerro, aplique el
freno de estacionamiento, baje los implementos de tierra y utilice los soportes de tacones en las llantas.

Evite fumar o prender fuego cerca de combustible.

Siempre recuerde la localizacin del extintor de fuego ms cercano.

Siempre asegrese que los excesos de grasa, son limpiados inmediatamente para prevenir un riesgo potencial de
incendio.

Compruebe la operacin del circuito de frenos antes de iniciar cada turno.

Nunca quite algn elemento del escape del motor o algunas guardas de seguridad cuando el camin est en
operacin.

Nunca utilice un camin para realizar una actividad o aplicacin para la cual no fue diseado originalmente.

Cuide de otras personas. Ellas pueden no estar cuidando de usted.

CUBIERTA DE LA CABINA

Su camin podra ser equipado con una cubierta o cabina MSHA opcional. Estas son diseadas para proporcionar
proteccin al operador en caso de una volcadura del camin o de objetos que estn cayendo en el rea del
operador. Deber estar una etiqueta pegada a la estructura, la cual incluye el nmero de serie, pesos del camin y
nmeros del modelo del camin.

Modificaciones tales como agregar instrumentos a la cabina/cubierta, soldadura, cortes y/o perforaciones pueden
debilitar la estructura, reducir la proteccin del operador, e invalidar la certificacin. Si su camin sufriera un
dao en la estructura, contacte a su distribuidor antes de realizarle reparaciones.

IMPORTANTE: Cualquier modificacin que no sea suministrada por la Corporacin Getman o por OEM
deber ser aprobada antes del cambio por Getman.

ADVERTENCIA: El cinturn del asiento es una parte importante del sistema de seguridad de la cubierta
o cabina del MSHA. Omitir el uso del cinturn puede causar lesiones graves o la muerte.
*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 5 de 32

PLACAS CON NOMBRE, ADVERTENCIA Y PRECAUCION


Localice y comprenda todas las placas de nombre, advertencia y precaucin, incluyendo una placa con el
Modelo/Nmero de Serie y dos Placas de Advertencia. Estas estn colocadas en la posicin mostrada abajo
para su seguridad y proteccin. Si alguna de estas placas requiere ser reemplazada, por favor notifquelo a
su distribuidor Getman para ordenar la placa adecuada. Por favor asegrese de proporcionar el nmero de
serie con su orden.

PRECAUCION
NO HAY ESPACIO PARA UNA
PERSONA EN ESTA AREA CUANDO
LA MAQUINA ESTA EN MARCHA.
ASEGURE LAS BARRAS DE
SEGURIDAD CUANDO ESTE EN
SERVICIO..

ADVERTENCIA
NO ES ESPACIO PARA UNA PERSO
NA EN ESTA AREA CUANDO LA
MAQUINA ES GIRADA.

PARA EVITAR
LESIONES O DAO
A LA MAQUINA:

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

CUANDO SE PROPORCIONE
SERVICIO A LA MAQUINA
UTILICE LA HERRAMIENTA
Y EQUIPO ADECUADO.
CONSULTE EN EL MANUAL
DE OPERACIN PARA
INSTRUCCIONES.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
AVISO DE SEGURIDAD
La seguridad depende de un buen mantenimiento y operacin
adecuada del vehculo. Siguiendo las recomendaciones de
servicio y mantenimiento dadas a conocer en este manual tendr
como resultado un vehculo confiable. Observando los
procedimientos de operacin le puede ayudar a evitar accidentes.
El listado que se describe abajo son algunas precauciones
bsicas de seguridad las cuales debern ser ledas, entendidas y
practicadas. Sin embargo es imposible cubrir cada condicin.
Siempre est alerta, piense en SEGURIDAD todo el tiempo,
utilice el sentido comn.
HAGALO

Lea completamente este manual antes de operar el camin.

Aprenda a reconocer y evitar las reas de riesgo potencial,


tales como las uniones de articulacin.

M1040
Pag. 6 de 32

Omitir seguir este procedimiento puede resultar en dao al


motor ECM e invalida la garanta. Es una buena prctica
siempre desconectar el conector OEM
del motor ECM adems de desconectar las bateras sin importar
el fabricante del motor.

No permita personal de ms en el vehculo, los pasajeros


debern estar sentados en los asientos asignados y abrocharse el
cinturn de seguridad.

No suba o baje del camin si est en movimiento.

No bombe el pedal del freno.

No conduzca el camin sobre cables elctricos.

No opere el camin con un problema en el sistema de escape.


No recargue combustible u otro fluido con el motor trabajando.

Realice todas las inspecciones recomendadas.

Reporte todas las anomalas o daos.

CIERRE EL COMBUSTIBLE
Cierre las vlvulas de la lnea de combustible en las salidas del
tanque.

Revise el rea alrededor del vehculo antes de subir a la


cabina del operador.

Revise cuidadosamente y abrchese el cinturn de


seguridad.

Accione el clxon antes de encender el motor.

Opere el vehculo con precaucin.

Si es posible estacione el camin en un terreno plano y


bloquee las llantas.

Utilice el freno de estacionamiento.

Coloque la palanca selectora de engrane de la transmisin


en neutral (N) cuando no est en uso.

Entre y salga con precaucin a la cabina del operador.

Utilice la herramienta adecuada para el servicio.

NO LO HAGA

No opere el vehculo bajo la influencia del alcohol o


drogas.

No permita personal (peatones) cerca del camin cuando el


motor est funcionando.

No utilice el arco de soldadura en el camin sin antes no


haber girado el interruptor principal en la posicin (off).

IMPORTANTE
Cuando solde en todos los motores Cummins, desconecte la
terminal OEM No. 50 y el conector 4 del motor ECM, tambin
desconecte las terminales positivo y negativo de la batera.

POSICIN DE SERVICIO
A travs de este manual, se le pedir que coloque el camin en
Posicin de Servicio. Realice esto de la siguiente forma:
1.

Estacione el camin en un rea plana y despejada, bloquee


las llantas.

2.

Aplique el freno de estacionamiento.

3.

Asegure la estructura del camin conectando las barras de


seguridad (slo en camiones con articulacin).

4.

Apague el motor.

Realice los procedimientos indicados antes de realizar el servicio.

PROCEDIMIENTO DE ESTACIONAMIENTO.
1. Estacione el vehculo fuera o lejos del rea de trfico, y gire el
camin, hacia la tabla del cerro.
2. Aplique el freno de estacionamiento y, coloque la transmisin en
posicin neutral (N).
3. Si el camin ha estado en operacin en algn lugar de trabajo antes
de estacionarlo, permita que se enfre el motor. Estacinese y deje el
motor trabajar en vaco por 1-2 minutos.
4. Apague el motor.
5. Bloque las llantas.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
RELACION DE ADVERTENCIAS
Utilice este equipo solamente bajo las siguientes
condiciones.
1. SEGURIDAD GENERAL
Este vehculo accionado con diesel es solamente para
utilizarlo en minas que no sean de carbn. Tales minas
son aquellas en que el material que est siendo minado o
explotado es incombustible o contiene por lo menos 65%
de peso de material incombustible, y en las cuales la
atmsfera subterrnea o de la mina y en cualesquier
trabajo abierto contenga menos del 0.25% por volumen de
gas flamable. En operaciones de cruceros y tneles en los
cuales las condiciones subterrneas son similares a las
anteriores, estn en la misma categora como las minas
que no son de carbn. Cualquier pregunta relacionada con
el diseo de este camin contacte a su distribuidor local
Getman
Realice frecuentes inspecciones para observar todos los
componentes del sistema de admisin y escape, todos los
componentes elctricos, incluyendo alambrado y todo el
equipo, que estn en condiciones seguras de operacin.
No debe haber cuarteaduras en ninguna parte del sistema
de escape del motor excepto una salida de escape provista
originalmente.
Todos los interruptores del circuito o fusibles para
proteccin de sobrecarga en los circuitos elctricos deben
mantenerse en buenas condiciones.
2. SUJETADORES
Mantenga todos los pernos, tuercas, tornillos y otros
sujetadores para cajas y partes elctricas en su lugar.
Apriete y asegrelos adecuadamente. De igual forma,
asegure y apriete los pernos, tornillos y tuercas de la
cabeza del cilindro del motor, sistemas de admisin y
escape en su lugar, adecuadamente apretados y
asegurados.
3. REPARACIONES Y RECONSTRUCCIONES
Tome especial cuidado cuando realice reparaciones y
reconstrucciones. Utilice refacciones nuevas exactamente
como las surtidas por el fabricante. Utilice empaques o
juntas del fabricante nicamente. Mantenga todas las
superficies de contacto limpias y en condiciones
adecuadas.
4. BATERIA Y CABLES
Antes de trabajar cerca o con la batera, coloque el
interruptor de batera en (off).
5. VENTILACIN
La cantidad de aire fresco en movimiento para ventilacin
en cualquier lugar subterrneo donde el vehculo est
trabajando debe tener los requerimientos mnimos del
fabricante del motor. Esta ventilacin debe ser
suministrada adems de la requerida por otros vehculos
con motores diesel y otros
requerimientos. Pare el motor siempre que la ventilacin
en la mina subterrnea se suspenda por alguna razn. Se
recomienda que se pare el motor cuando el vehculo no se

M1040
Pag. 7 de 32

utilice. No arranque el motor en vaco por perodos


excesivamente largos.
6. MOTOR
Reemplace cualquier parte de la inyeccin de combustible con
repuestos del fabricante.
7. SISTEMA DE ADMISIN
El aire debe fluir libremente en el sistema de admisin.
Mxima presin (vaco) a travs del sistema de admisin con
el acelerador al mximo, sin carga, a 2500 RPM el motor no
debe exceder el valor recomendado por el fabricante. El motor
diesel OM904LA y OM906LA no debe exceder (22) pulgadas
de agua. Un indicador de restriccin le proporcionar una
indicacin de advertencia en rojo cuando llega a 20 de agua.
Verifique el purificador de aire de admisin en perodos
regulares y limpie o reemplcelo si es necesario.
8. SISTEMA DE ESCAPE
Mantenga siempre ajustados los tubos de escape, no permita
que los tubos de escape se lleguen a bloquear. La mxima
presin de retorno (positivo) en el sistema de escape con la
aceleracin total, sin carga, a 2500 RPM no debe pasar el
valor recomendado por el fabricante del motor.
9. PURIFICADOR DE ESCAPE
El purificador puede perder eficiencia cuando se utiliza en
motores que producen cantidades excesivas de humo azul y/o
negro. Otras anomalas en el motor tales como atascamiento o
fugas en los inyectores tambin causar prdida de eficiencia.
La prdida de compresin permitir la baja de temperatura en
el escape y prdida de eficiencia en el purificador.
10. COMBUSTIBLE
Utilice solamente el combustible diesel recomendado por el
fabricante del motor para mantener una operacin
satisfactoria. El punto de encendido no debe ser menor a 140
F, o con contenido de azufre mayor a 0.5% del peso. Cuando
llene los tanques en la mina, transporte el combustible en
contenedores metlicos seguros. Almacene los contenedores
de combustible en compartimentos cerrados e incombustibles
mientras se espera transferirlo al tanque de combustible del
vehculo diesel. Mantenga los contenedores en un rea
ventilada.
11. EXTINGUIDORES DE INCENDIO
Cada vehculo diesel debe cargar por lo menos un extinguidor
de incendio tipo CO2 o tipo seco presurizado. Siempre debe
tener este implemento.
12. VEHCULO FUERA DE SERVICIO
Cada vehculo que est fuera de servicio debe tener una
etiqueta a la vista que indique FUERA DE SERVICIO.

ADVERTENCIA!
La operacin inapropiada de este camin puede causar
serias lesiones o la muerte!

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
DESCRIPCIN GENERAL
El Camin Getman modelo A-64 es un camin de cuatro
llantas, consta de una estructura con direccin articulada y
accionado por un motor diesel. La potencia del motor es
transmitida del convertidor de torque a una transmisin de
cambios de potencia. A travs de la transmisin flechas de
conduccin con uniones universales transmiten la
potencia al sistema de reduccin y los ejes planetarios
de conduccin.

PRECAUCION
La direccin no funciona cuando el camin no est
trabajando.
La direccin es totalmente de tipo hidrulico, utilizando
una bomba de engranes con empuje directo la cual provee
el flujo hidrulico a una vlvula (orbitrol) accionada por
el volante de direccin. Esta acciona los dos cilindros de
direccin localizados en la unin articulada.

M1040
Pag. 8 de 32

Cada esfuerzo y empeo ha sido hecho para asegurar que


usted pueda parar este camin. El servicio de frenos (frenado
de ejes) es total mente cerrado y es del tipo de disco hmedo,
con un sistema dual, permitiendo por separado el frenado del
circuito trasero y delantero. Si ocurriera una falla en
cualesquier circuito el otro circuito se mantiene funcionando.
El juego de frenos de disco con resorte, liberado
hidrulicamente los frenos de servicio, los cuales tambin
sirven como un frenos de estacionamiento, son aplicados
manualmente ajustado utilizando el botn de control push/pull
(empuje/jale) colocado en el tablero. Este sistema de frenado
de disco, los frenos de servicio frontal y trasero, tambin es
utilizado como un freno secundario, el cual se acciona
automticamente en el momento de prdida de potencia en la
transmisin o hidrulica del freno frontal o trasero.
Este freno tambin se puede accionar manual- mente en el
caso de una falla total del sistema hidrulico.
Este camin est equipado con dos luces rojas de advertencia
en el sistema de frenos localizadas en el tablero de
instrumentos.
Cada uno es para el circuito de frenos delantero y trasero.
Estas luces de advertencia se iluminaran si la presin
hidrulica de cualquiera de los frenos trasero o delantero cae
por debajo del nivel previamente ajustado 1100 PSI (76 BAR).
Los frenos delantero y trasero de servicio se aplican
automticamente si la presin hidrulica cae por debajo de
1100 PSI (76 BAR). La luz independiente del freno localizada
en el tablero de advertencia se iluminar cuando la presin cae
por debajo de 1200 PSI. Todos los instrumentos requeridos
para operar el camin se localizan en el rea del operador.
Familiarcese con la posicin y funcin de cada uno.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 9 de 32

DESCRIPCION DEL TABLERO DE INSTRUMENTOS

465313-100

1. Engine Function Display (Exposicin de la Funcin


del Motor): Este instrumento mostrar todas las
funciones disponibles en el motor. Presin de aceite del
motor, temperatura, rpm, horas de operacin del motor,
etc.), y tambin muestra cdigos de advertencia de
revisin y paro del motor. Ver el Manual de Operacin
(Murphy) en la Seccin 3 para ms informacin.
2. Engine Warning Alarm (Alarma de Advertencia del
Motor): Este indicador proporciona una advertencia
audio/visual en conjuncin con la Funcin Murphy del
Motor.

3. Transmission Pressure Gauge (Manmetro de Presin


de la Transmisin): El manmetro de presin de la
transmisin indica la presin que va a ser regulada y enviada a
los embragues de la transmisin. Si el manmetro no registra
presin despus de que se arranca el
motor pare el motor inmediatamente y avise el departamento
de mantenimiento.
La presin normal de operacin es aproximadamente 300 PSI.
Vea el Manual de Servicio para la Transmisin en la seccin 5
para ms informacin.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 10 de 32

4. Converter Oil Temperatura Gauge (Manmetro de


la Temperatura de Aceite del Convertidor): La
temperatura normal de operacin de
transmisin/convertidor es entre 160-220F (71-104C)
si el manmetro indica una temperatura ms alta, pare el
camin, cambie la transmisin a neutral, aplique el freno
de estacionamiento y acelere el motor a 1000-1200 RPM
hasta que la temperatura regrese a normal. Ver el Manual
de Servicio de la Transmisin en la Seccin 5 para ms
informacin.

13. Park Brake Test Buttom (Botn de Prueba del Freno


de Estacionamiento): Para camiones equipados con un botn
de Prueba del Freno para Estacionamiento, manteniendo
presionado este botn le permitir al operador embragar la
transmisin para prueba. Ver procedimientos en Seccin 1 de
instrucciones para realizar esta prueba.

5. Parking/Secondary Brake Button (Botn de Freno


de Estacionamiento Secundario): Empuje para
aplicarlo, jale para liberarlo.

15. Start Switch (Interruptor de Arranque): Gire el


interruptor a la posicin 1 para precalentamiento, y gire
momentneamente a la posicin 2 para arrancar el motor.

6. Voltmeter (Voltmetro): Indica batera cargando o


descargando.

16. Light Switch (Interruptor de Luces): Interruptores de


palanca para luces delanteras y traseras.

7. Work Light Switch (Interruptor de Luces de


Trabajo (Opcional): Si est equipado encienda el
interruptor aplicacin de las luces de trabajo.

17. Beacon (Interruptor de la Farola Opcional): Gire a la


posicin de encendido para encender la luz de la farola.

8. Horn Button (Botn del Clxon): Presione para


accionarlo.
9. Circuit Breakers (Interruptor Automtico): Consiste
en interruptores de 10, 20 y 30 amperios, usados para
manmetros , luces, clxons, etc.

14. Low Fuel Light (Luz Indicadora de Combustible Bajo


Opcional): Para camiones equipados con esta luz cuando se
ilumina indica que la unidad est baja en combustible.

18. Canopy Light (Luz de la Cubierta de la Cabina


Opcional): Gire a la posicin de encendido para encender la
Luz de la Cubierta.
19. Warning Panel (Tablero de Advertencia): Este tablero
proporciona una advertencia visual para varios eventos. Ver
tablero de Instrumentos de Advertencia para ms
informacin).

10. Spare Space (Espacio de Reserva): Disponible para


uso adicional, contacte a la Corporacin Getman si el
espacio es necesario.
11. PLC Reset Switch (Interruptor Restablecedor PLC
Opcional): Utilizado para restablecer los controles del
motor. Jale por 30 segundos, el fusible se restablecer.
Empuje y arranque de nuevo el motor.
12. Remote Throttle Enable Switch (Interruptor
Remoto de la Vlvula de Restriccin de Activacin
Opcional): Activa una vlvula de restriccin para ser
usada para controlar las RPMs del motor.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

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MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 11 de 32

TABLERO DE INSTRUMENTOS DE ADVERTENCIA

PARK BRAKE
(RED)

ACCUMULATOR
PRESSURE LOW
FRONT BRAKES
(RED)

ACCUMULATOR
PRESSURE LOW
REAR BRAKES
(RED)

STOP ENGINE
(RED)

CHECK ENGINE
(YELLOW)
POWER ON
(GREEN)
TRANSMISSION
FAULT
(RED)

IMPENDING
AUTO BRAKE
APPLICATION
(YELLOW)

DECLUTCH
(RED)

PARK BRAKE (FRENO DE ESTACIONAMIENTO): Esta luz se iluminar cuando la lnea de


accionamiento del freno de estacionamiento est activada. Cuando el freno de estacionamiento es
liberado para poner el camin en movimiento, esta luz no se ilumina.
FRONT AND REAR BRAKES (FRENOS TRASERO Y DELANTERO): Hay dos luces
independientes en el tablero para proporcionar al operador informacin con respecto a una posible auto
aplicacin de los frenos. Estas luces son una indicacin de que hay menos de 1100 PSI aplicadas ya sea
en el freno de servicio delantero o izquierdo. La aplicacin de autofrenado sucede cuando la presin del
sistema de frenos cae por debajo de 1100 PSI.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 12 de 32

POWER ON LIGHT (LUZ DE ENCENDIDO): La luz de arranque es una indicacin de que el


interruptor de arranque ha sido girado a la posicin ON encendido. Esta luz permanecer iluminada
hasta que el interruptor de encendido se gire a la posicin off apagado.
CHECK ENGINE (CHECAR MOTOR): Esta luz se ilumina en caso de que una falla ha sido
detectada por el sistema de control electrnico del motor. Esto es normalmente considerado ser una falla
menor, la cual deber ser atendida lo ms pronto posible.
STOP ENGINE (PARAR EL MOTOR): Esta luz se ilumina en caso de que una falla en el motor sea
detectada por el sistema de control electrnico del motor. Esto es considerado ser una falla importante,
la cual requiere atencin inmediata. Pare el motor tan pronto como sea posible y avise al departamento
de mantenimiento.
BRAKE IMPENDING (FRENADO INMINENTE): Esta luz se iluminar cuando la presin
hidrulica cae por debajo de 1200 PSI en cualquiera del circuito de frenado, ya sea delantero o trasero.
Esto es una advertencia para el operador de la posible aplicacin de autofrenado la cual ocurre con una
presin debajo de 1100 PSI.
DECLUTCH (DESEMBRAGUE): Esta luz se ilumina cuando el selector de la transmisin est
desembragado.
Dependiendo de las opciones seleccionadas, lo siguiente puede activar la opcin de desembrague.
1. El freno de estacionamiento est activado ON.
2. La vlvula selectora est en modo de accesorios.
3. Los gatos estabilizadores no estn totalmente retrados.
4. La canastilla no est asentada a nivel sobre la cubierta o plataforma.
5. La plataforma de tijera est en la posicin elevada.
TRANSMISSION (TRANSMISION): Esta luz se iluminar en el momento que baje la presin de
aceite hidrulico o se eleve la temperatura de la transmisin.

OTROS CONTROLES

Gear Selector Lever (Palanca Selectora de Cambios) (De


Engranes): Mueva la palanca a la posicin 1 para cambio
en baja velocidad, posicin 2 para la segunda velocidad y
posicin 3 para la tercera velocidad.

ADVERTENCIA
Nunca deje el camin en neutral. Esto le causar serias
lesiones y dao al camin.
Accelerator Pedal (Pedal de Aceleracin) (No se muestra):
Empuje para incrementar las RPM del motor

Direction Selector Lever (Palanca Selectora de


Direccin): Mueva la palanca a la posicin F para
mover el camin hacia delante. Mueva la palanca
selectora a la posicin R para reversa directa. La
posicin N es para neutral.

Brake Pedal (Pedal del Freno) (No se muestra): Empuje


para activar el servicio de frenos.
Seat Adjustment (Ajuste del Asiento) (No se muestra): Se
ajusta para comodidad del operador.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 13 de 32

EXPOSICION DE DATOS DEL MOTOR ELECTRONICO

47
BATERIA

PRESION DE
ACEITE

MENU KEY (LLAVE DEL MENU): Esta llave es presionada ya


sea para entrar o salir del modo MENU.

LEFT ARROW (FLECHA IZQUIERDA): Esta llave es usada


para navegar a travs de la pantalla, ya sea para mover el parmetro
a la izquierda o hacia abajo.

RIGHT ARROW (FLECHA DERECHA): Esta llave es usada


para navegar a travs de la pantalla, ya sea para mover el parmetro
a la derecha o hacia abajo.
ENTER KEY (LLAVE DE ACCESO): Esta llave es presionada
para seleccionar el parmetro que es sealado en la pantalla.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 14 de 32

EXPOSICION DE DATOS DEL MOTOR ELECTRONICO. CONT.

CODIGOS ACTIVOS
DE FALLA

ADVERTENCIA!
SPN100 FM18 BAJA
PRESION DE ACEITE

SPN100 FM118 BAJA


PRESION DE ACEITE

CODIGOS ACTIVOS
DE FALLA

ADVERTENCIA!
SPN100 FM10 ALTA
TEMP. DE ENFRIADOR

SPN110 FM10 ALTA


TEMP. DE ENFRIADOR

VOLTIOS

PARAR EL
MOTOR

PRESION
DE ACEITE

CHECAR EL
MOTOR

NOTA: PARA MAS INFORMACION DE EXPOSICION DE DATOS SOBRE EL MOTOR ELECTRONICO ,


VER SECCION 3 (MANUAL DE EXPOSICION DE LA FUNCION Y OPERACIN DEL MOTOR).

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

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MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 15 de 32

DESCRIPCION DE LOS MANOMETROS

Las temperaturas normales del convertidor/transmisin estn entre 180F-220F (82C.104C). Si las
temperaturas subieran arriba de la escala de 220F, aplique el freno de estacionamiento, ponga la
transmisin en neutral e incremente la velocidad del motor aproximadamente 1000R.P.M. hasta que la
temperatura regrese a la escala normal.

El manmetro de presin de la transmisin indica la presin que est siendo regulada y aplicada a los
embragues de la transmisin. Si el manmetro deja de registrar la presin despus de que el motor se
arranca, pare el motor inmediatamente y avise al departamento de mantenimiento. La presin normal de
operacin es aproximadamente 300 PSI.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

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MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 16 de 32

DESCRIPCION DE LOS MANOMETROS CONT.

Los indicadores de combustible pueden estar fuera o dentro de la cabina. El manmetro indica el nivel del
combustible existente en el depsito de combustible.

El voltmetro indica el nivel de voltaje, carga o descarga. Puede haber voltmetros de 16V usados para un
sistema de carga de 12V o un voltmetro usado para un sistema de carga de 24V. Con un camin trabajando
un sistema de cargado de 12V debera tener una lectura de 12-16 voltios y 24-30 voltios para un sistema de
cargado de 24V.

Los manmetros de presin son usados para medir la presin del sistema hidrulico. Pueden ser usados para medir presin de
freno, la presin total del sistema, etc.
*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

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MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 17 de 32

INSPECCIONES ANTES DE ARRANCAR

Inspeccione la condicin y tensin de todas las bandas, las que


tengan desgaste o cuarteaduras remplcelas de inmediato.

Inspeccione el rea en torno del camin por la existencia


de algunos obstculos que puedan daar o causar daos al
camin cuando sea conducido.
Inspeccione el extinguidor de incendios y reemplcelo si es
necesario

Inspeccione el nivel de aceite, llnese si se requiere con el


lubricante recomendado.

Asegrese que la barra de seguridad en la articulacin no est


conectada.

Inspeccione el indicador de mirilla. Si el indicador est en


la zona roja, limpie y reemplace el elemento del filtro/s.
Visualmente inspeccione los conectores y abrazaderas
ahulados.

Inspeccione las luces y clxon para asegurarse que estn en


condiciones de funcionar.
Inspeccione el nivel del aceite hidrulico en el tanque con
el motor apagado. El nivel de aceite no debe estar en la
parte alta del indicador de mirilla o en la parte baja de la
misma. Llnese segn requiera.

Inspeccione el cinturn del asiento para realizar algunos


ajustes y si no est daado o roto. Ajuste el asiento en una
posicin confortable para el operador. Algunos asientos tienen
ajustes superiores.
Inspeccione la presin de las llantas, 95 PSI (6.55 BAR)
es lo recomendado. Inspeccione las tuercas de las llantas.
No conduzca el camin con tuercas flojas o faltantes.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 18 de 32

PROCEDIMIENTO DE ARRANQUE
PRECAUCION
La transmisin debe estar en neutral y el freno de
estacionamiento debe estar aplicado para arrancar el
motor.

IMPORTANTE
Todo el personal deber estar a una distancia segura del
camin antes que usted entre a la cabina del operador!
La barra de seguridad de articulacin no debe estar
conectada!

1. Gire los interruptores de la batera y ECM a la posicin


ON.
NOTA: Este interruptor puede estar localizado en un lado del
camin, en la cabina o en ambos.

Mueva la palanca de direccin a la posicin neutral.


a

a
2. Ajuste y abroche el cinturn a una posicin confortable de
operacin.
5. Gire el botn de arranque a la posicin ON (a)
6. Espere a que las luces de advertencia visuales de
fuerza se apaguen (b) Aproximadamente 3 segundos.
7. Presione el botn del clxon para que ste suene ( c ).
8. Gire el interruptor de encendido a la posicin de
arranque (Start) para embragar el motor de arranque y
sostngalo hasta que el motor arranque. NOTA: No lo
sostenga por periodos mayores de 15 segundos.
3. Empuje hacia abajo el botn de estacionamiento.

9. Si los manmetros de presin del motor, transmisin e


hidrulicos no indican presin poco despus del
arranque, pare el motor y determine la ca

ATENCION
NO ARRANQUE EL MOTOR POR MAS DE 30 SEGUNDOS. PERMITA QUE EL MOTOR DE ARRANQUE SE ENFRIE POR DOS MINUTOS
ANTES DE ARRANCAR DE NUEVO. EL TURBO CARGADOR (SI ESTA EQUIPADO) PUEDE RESULTAR DAADO SI NO SE MANTIENEN
BAJAS LAS R.P.M. HASTA QUE EL MANOMETRO DE PRESION DE ACEITE DEL MOTOR INDIQUE QUE LA PRESION ES SUFICIENTE.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 19 de 32

PROCEDIMIENTO DE PRUEBA DEL FRENO DE ESTACIONAMIENTO.

ATENCION
Empujando el botn del freno de estacionamiento localizado en el tablero anula el desembrague de la transmisin.
Para probar el Freno de Estacionamiento solamente:
a

b
1. Aplique el freno de estacionamiento(a).
2. Empuje y sostenga el botn del freno de estacionamiento (b)

3. Coloque la palanca de velocidades en 3 y la palanca selectora de direccin en F


4. Acelere totalmente
5. El camin no se deber mover.

PRUEBA DEL FRENO DE SERVICIO (REALIZARSE DIARIAMENTE)


Pruebe el freno de servicio presionando el pedal del mismo. Colocar la transmisin en el 2 engrane hacia delante, libere el freno
de estacionamiento e incremente las RPM del motor al mximo por 3 o 5 segundos. El camin no se deber mover. Si el camin
se mueve, estacinelo y colquele la retenida a las llantas y contacte a mantenimiento.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
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MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 20 de 32

DESPUES DE ARRANCAR EL MOTOR


3
1

Engine Oil Pressure (1) Electronic Engine Display (Presin de Aceite del Motor) (1) (Exposicin del Motor Electrnico): La presin de
aceite deber leer 25-50 PSI en vaco con el motor a una temperatura de operacin. En condiciones de carga completa del motor, la presin
deber leer entre 45-60 PSI. Si el manmetro no muestra presin despus de que se arranca el motor, pare el motor inmediatamente y localice la
causa.
Voltmeter (Voltmetro) (2): Con el motor trabajando, el voltaje deber leer 12-16 voltios para camiones con sistema de 12 voltios y 24-30
voltios para camiones con sistema de 24 voltios.
Transmissin Temperature Gauge y Transmissin Pressure Gauge (Manmetro de Temperatura de la Transmisin (3) y Manmetro de
Presin de la Transmisin (4): Durante los ciclos de trabajo, si el manmetro de la transmisin/convertidor indica temperatura arriba de 220F,
estacione el camin y coloque la transmisin en neutral con el freno de estacionamiento aplicado e incremente las R.P.M. del motor
aproximadamente 1000-1200 R.P.M. mantenga estas revoluciones por minuto hasta que la temperatura del motor retorne a niveles normales.
La presin normal de la transmisin operando es aproximadamente 250 PSI (17.2 BAR). Si la presin de la transmisin dejara de registrarse
despus de arrancar el camin, pare el motor y avise al departamento de mantenimiento.
Brake Pressure Gauges (Manmetros de Presin de Frenos): Hay dos manmetros de presin del acumulador de frenos localizados en el
lado del tablero en el panel del motor. Estos muestran la presin hidrulica independiente existente en los acumuladores de los frenos delantero
y trasero. La presin normal en estos manmetros es entre 1500 y 2200 PSI (103.5-151.5 BAR).

PRECAUCION
Pare el motor inmediatamente si alguno de los manmetros no est colocado en su escala.
Park Brake Test (Prueba del Freno de Estacionamiento): Este sistema est diseado para sostener un camin cargado totalmente en una
pendiente de 35%. Por razones de seguridad una prueba del freno de estacionamiento debera realizarse al inicio de cada turno. Vea los
procedimientos para prueba del freno de estacionamiento para instrucciones de cmo realizar esta. prueba.

ADVERTENCIA
No opere ningn camin con falla en el sistema de frenos de estacionamiento/servicio. Puede resultar en serias lesiones al personal o dao al
camin si lo hace.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
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MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 21 de 32

OPERANDO EL CAMION

4
3

Una vez que todos los manmetros han sido verificados y estn dentro de los lmites de operacin
normal, el camin est listo para operar.

Gire el Interruptor de Luces (1) a la posicin ON (encendido).

Empuje el Botn de Freno de Servicio y sostngalo (2).

Verifique la presin de los acumuladores de los frenos y verifique el tablero de instrumentos por si hay
seales de advertencia o por baja presin en las luces de advertencia en el tablero de advertencia (3).

Asegrese que todos los estabilizadores hidrulicos estn retrados totalmente (si aplica).

Verifique para estar seguro que el rea est libre de personal y obstculos. Seleccione hacia adelante
moviendo la palanca selectora de engranes a la posicin F y seleccione el 1er cambio moviendo la
palanca selectora de cambios a la posicin 1.

Jale el botn del freno de estacionamiento (2) para liberar la lnea de mando del freno de disco.

Presione el botn del clxon (4) en el tablero de instrumentos para que suene.

Quite el pie del pedal del freno, pruebe el volante de direccin para asegurarse de su ptima operacin y
mueva el camin suavemente empujando el pedal de aceleracin con el pie.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

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MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 22 de 32

CONDUCIENDO EL CAMION

Por si mismo acostmbrese a la forma de conducir


moviendo el camin tomando la gua arriba mostrada.
Realice esta actividad varias veces hasta que se
familiarice con la conduccin del camin y se sienta
capaz de conducir el camin en reas de trfico.
Para familiarizarse con la respuesta a la aplicacin
automtica de la lnea de frenos, conduzca en lnea recta,
y quite el pie del pedal de aceleracin y empuje el botn
de estacionamiento (#1) mientras est el camin todava
movindose.
El freno de estacionamiento se activar y el camin
llegar a pararse. Si esto no sucede, realice una inspeccin
y ajuste del freno con el personal autorizado.

Cuando confe que puede operar el camin seguro y


satisfactoriamente, localice un lugar o camino recto y
acelrelo. Comience con el 1er. Engrane, cambie a 2 y luego
a 3. (si las condiciones lo permiten). Asegrese que el rea
elegida est libre de obstculos y/o personal. A velocidades
ms altas deber de tratar de dar giros muy ligeros mientras no
exista el peligro de daar el camin u otro vehculo. Detenga
el vehculo y regrese el selector de cambios de la transmisin a
neutral (N). Aplique el freno de estacionamiento. Revise de
nuevo todos los manmetros para estar seguro que estn
operando dentro del lmite normal.
NOTA: Cuando est conduciendo el camin hacia arriba en
camino inclinado (rampa), seleccione el engrane ms bajo si la
temperatura del convertidor de torque alcanza 200 F (93 C).

ADVERTENCIA!
Cuando est conduciendo el camin en caminos con
inclinacin negativa (hacia abajo) utilice el 1er. Engrane
(primera). El uso del 2 y 3er engrane (segunda y tercera)
podra causar que el motor se desgobierne y agarre altas
velocidades y posible riesgo en la seguridad del operador.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

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MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 23 de 32

PROGRAMA DE MANTENIMIENTO SEGUN REQUIERA


Coloque el camin en posicin para servicio.

PURIFICADOR DE AIRE FARR TIPO SECO

NOTA:
Dependiendo de las condiciones, de la cantidad de polvo
existente, el filtro de aire debe de requerir de servicio
diariamente.
Este camin estar equipado con alguna de las opciones
siguientes de filtracin de aire. Determine con cual
sistema est equipado su camin y consulte en la seccin
correspondiente para las instrucciones de servicio.
PROCEDIMIENTO PARA EL SERVICIO DEL
PURIFICADOR DE AIRE
NOTA: La prdida de potencia del motor y/o excesiva
cantidad de humo en el escape son seales de que los
elementos del filtro de aire pueden requerir de servicio.

Revise el indicador de servicio. Limpie diariamente los


canales de descarga del colector de polvo. Realice el servicio
al purificador de aire SOLAMENTE cuando el indicador se
observa en la posicin roja y proceda como sigue:

PURIFICADOR DE AIRE TIPO SECO DONALDSON

Verifique el indicador de servicio. Limpie diariamente los


canales de descarga del colector de polvo. Realice el
servicio al purificador de aire solamente cuando el
indicador se pone en la posicin roja y proceda como
sigue:
Afloje las tuercas en la caja del purificador de aire y quite la
rejilla prelimpiadora. Quite y elimine o deseche el cartucho de
filtro de polvo. Limpie la parte interna de la caja e instale un
cartucho de filtro nuevo.
Limpie la rejilla de filtracin primaria. Coloque de nuevo la
rejilla. Reajuste el indicador de servicio.

Afloje el tornillo de oreja que sostiene la tapa y seprela,


saque y elimine el elemento de filtrado primario. Limpie
la parte interna de la caja del filtro (housing), instale un
elemento nuevo.
Cheque el empaque de la tapa para asegurar un buen
sello. Al volver a instalar el tornillo y la tapa reajuste
(reset) el indicador de servicio.
Reemplace el elemento del filtro de seguridad cada 5
cambios realizados del filtro primario. El cambio de filtro
de seguridad se realiza de la misma manera que el cambio
del filtro primario.
*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
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MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 24 de 32

PROGRAMA DE MANTENIMIENTO DIARIO O CADA CAMBIO DE TURNO

Coloque el vehculo en posicin de servicio

9
8

4
3
2

1
7
10
5
6
1
PARTIDA
1.
2.
3.
4.
5.
6.
7.

COMPONENTE
Llantas
Sistema Hidrulico
Motor
Limpiador de Aire Primario
Sistema de Combustible
Bandas
Muones de Oscilacin

8.

Transmisin y Convertidor
de Torque
Baleros y Pernos Superior e
Inferior
Bujes del Cilindro de
Direccin

FLUIDO*
____
HO
EO
____
D2
____
EPG

9.
10.

TF
EPG

Cheque los indicadores de mirilla del depsito hidrulico y llnese


segn requiera. El nivel del aceite no debe estar ni por encima o por
debajo del indicador de mirilla.

EPG
*Realice el Programa de Mantenimiento como se requiere
*Observe las Especificaciones del Fluido.

Cheque la presin de aire y condiciones de las llantas. No


conduzca el camin con baja presin en las llantas. No conduzca
el camin con llantas malas o desgastadas y/o llantas cortadas o
con muescas.

Cheque el nivel de aceite. Agregue si lo requiere.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 25 de 32

MANTENIMIENTO DIARIO O CADA CAMBIO DE TURNO (CONT.)

Vaciar y limpiar el recipiente del prelimpiador de polvo.


Cheque la condicin y tensin de todas las bandas
tensin y condicin. Bandas desgasta das con
quebradura o muesca deben ser reemplazadas
inmediatamente.
Cheque la tensin como sigue:

Cheque el nivel de combustible agregue si se requiere.

ADVERTENCIA
El motor DEBE estar apagado para checar la tensin de la
banda.
Verifique el nivel de aceite de transmisin. El aceite deber
ser verificado con temperatura de operacin normal con el
motor trabajando en vaco y la transmisin en neutral.
Agregue aceite si es necesario.
1. Empuje la banda
hacia el centro con los
dedos entre las poleas.
2. El movimiento de la
polea debe ser 3/8 a
5/8 (10-15mm).

ADVERTENCIA
Evite cualquier banda en movimiento, componentes o
reas con alta temperatura. Serias lesiones pueden
resultar por descuidos o negligencia.
Visualmente inspeccione el camin:
Con el motor trabajando cheque:

1. Fugas en el sistema hidrulico.


2. El sistema de combustible por posibles fugas.
3. Instrumentos para una operacin apropiada.
Con el motor apagado cheque:
1. Que todos los controles se muevan libremente.
2. Que los pernos estn colocados en su lugar.
NOTA: Realice el mantenimiento del motor como est
indicado en el Manual del Operador o contacte a la
Corporacin Getman por la informacin actualizada.
Engrase los muones del eje.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 26 de 32

PROGRAMA DE MANTENIMIENTO CADA 50 HORAS DE OPERACION


Coloque el vehculo en posicin de servicio

2
1

COMPONENTE
FLUIDO*
Llantas
____
Batera
H2O
Purificador de Aire
EO
Sistema de Enfriamiento
____
de Aire
5. Purificadores Catalticos
del Escape
____
*Realice el Programa de Mantenimiento como es
requerido.
*Realice el programa de mantenimiento diariamente o
cada turno.
*Vea las especificaciones de fluido.

PARTIDA
1.
2.
3.
4.

Afloje y levante la tapa de acceso a la batera. Limpie la


batera. Cheque el nivel de fluido. Aada agua destilada segn
se requiera.

ADVERTENCIA
Vigile la posible acumulacin de gas hidrgeno debajo de
la tapa de acceso a la batera. Mantenga la batera alejada
de chispas o flama.

Cheque las tuercas de las llantas. Deben estar apretadas a


300 LBS-FT (406.7 Nm).

IMPORTANTE
Cuide que no le caiga cido de la batera sobre los ojos o la
piel. Mantenga la batera alejada del fuego o flama.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
MANTENIMIENTO DE 50 HORAS
(CONT.)

M1040
Pag. 27 de 32

NO deje trabajar en vaco el motor por ms de cinco (5) minutos a la


vez, o el purificador perder eficiencia.
2. Antes de poner el camin en servicio, y durante el chequeo de cada
50 horas, cheque la presin de escape con la aceleracin total,
conectando un manmetro de retorno de presin o manmetro de
agua a la conexin de prueba de 1/8 NPT que se encuentra entre el
purificador y el mltiple de escape. Si la presin de retorno excede
29 (737 mm) H2O o ha aumentado 5(127 mm) o ms desde la
ltima regeneracin, el purificador debe ser limpiado o regenerado.

Aplique grasa a los baleros de los pernos superior e inferior.


(Vea especificaciones)

Agregue grasa a las dos terminales de los cilindros de la


direccin.

Verifique todas las conexiones de la admisin de aire. Apritelas


si se requiere.

Quite la cubierta que est del lado del motor aflojando los
broches de retencin. Limpie las aletas de enfriamiento, el
enfriador de aceite, enfriador de la transmisin y el radiador si
existe para limpiar aplique aire comprimido.
Camiones equipados con purificador de aire cataltico ECS:
1. Si el camin est operando bajo carga pesada con el motor en
altas RPM por lo menos al 70% del tiempo de operacin
requiere de mnima cantidad de mantenimiento. Si el camin no
trabaja bajo carga y es operado en vaco por periodos de tiempo
excesivos, el catalizador puede llegar a carbonizarse y
empezar a generar humo por el escape despus de pocas horas,
indicando que es necesario limpiarlo o regenerarlo.

REGENERACIN DEL PURIFICADOR ECS


Equipo requerido:
1. Cepillo de nailon, de cerda dura para limpiar.
2. Solvente con aire, y partes para pistola o soplete de aire.
3. Una solucin desengrasante concentrada.
4. Solvente stoddard, solvente con alto grado de keroseno (libre de
azufre) 5 partes stoddard con 1 parte de S.C.
5. Disponibilidad de aire comprimido (30 PSI)
6. Llave cresent.

ADVERTENCIA
Solucin Inflamable. Utilcese de acuerdo a las recomendaciones
de los fabricantes, una equivocacin en el seguimiento de estas
instrucciones pueden causar serias lesiones.
Procedimiento de limpieza:
1. Remueva la seccin central del purificador.
2. Seque con cepillo la entrada del catalizador.
3. Limpie con aire a travs de la salida del catalizador.
4. Contine con los pasos 1 y 2 hasta que la parte de entrada est
limpia.
5. Sumerja completamente el catalizador en la solucin S.C.
stoddard por una hora.
6. Aplique solvente con aire para limpiar la cara de salida del
catalizador por 10 minutos.
7. Limpie a travs de la salida con aire.
8. Repita los pasos 4, 5 y 6 hasta que el purificador est limpio.
9. Aplique agua a presin y limpie el purificador a travs de la salida
y seque con aire.
10. Reemplace el purificador.
11. Anote la presin de escape con aceleracin total, quite el
manmetro y apriete el tapn de prueba.
NOTA: Si se dispone de vapor a alta presin, puede ser sustituido
por la solucin solvente. Limpie con el vapor a travs de la cara de
salida del catalizador. Manteniendo la conexin de salida del vapor
retirada 2 (51 mm) del frente del catalizador.
NOTA: Si el purificador ha sido regenerado, pero el motor sigue
despidiendo humo, se le deber dar servicio al motor para mantener
seguras las condiciones de escape.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 28 de 32

PROGRAMA DE MANTENIMIENTO CADA 250 HORAS DE OPERACIN


Coloque el camin en posicin de servicio

2
6

PARTIDA
1.

COMPONENTE
FLUIDO*
Lnea de Mando, Crucetas
y Uniones Articuladas
EPG
2. Transmisin
TF
3. Sistema Hidrulico
HO
4. Caja del Eje Oscilante
MBO
5. Respiradero del Eje
____
6. Motor
____
7. Freno de Estacionamiento _ _ _ _
*Realice el Programa de Mantenimiento como se requiere
*Realice el Programa de Mantenimiento Diario o cada
turno.
*Realice el Programa de Mantenimiento de 50 horas.
*Vea las especificaciones de fluido.

Agregue grasa a las cinco graseras de las uniones o


crucetas de la flecha de conduccin universal y los
baleros de alineacin.

Agregue grasa a los yugos deslizantes, cada uno con una


grasera.

Drene el aceite de transmisin quitando el tapn de drenado.


Limpie el tapn en solvente, squelo y colquelo de nuevo en
la transmisin.

NOTA: Algunas uniones universales pueden no verse.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 29 de 32

MANTENIMIENTO DE 250 HORAS (CONT.)

Quite el filtro de transmisin. Reemplcelo con uno


nuevo. Antes de instalar el filtro, cubra el empaque con
una capa ligera de aceite. Vea la Seccin 5 (Servicio y
Mantenimiento de la Transmisin) para informacin ms
detallada.
Llene y cheque la transmisin de la siguiente manera:
1. Llene la transmisin hasta la marca inferior de la varilla
de nivel.
2. Arranque el motor en vaco 500-600 RPM para llenar
el convertidor y mangueras hidrulicas.
3. Cheque de nuevo el nivel de aceite con el motor en
vaco y la transmisin neutral. Llegue el nivel de aceite
hasta la marca inferior de la varilla de nivel. Cuando el
aceite alcance la temperatura normal de operacin (158 a
248 F) (70 a 120 C) haga una verificacin final del
nivel de aceite y llegue el nivel de aceite hasta la marca
full de la varilla de nivel.
4. Verifique si no hay fugas.

Remueva el filtro de la lnea de retorno. Reemplace el


elemento del filtro e instale el filtro de la lnea de retorno.
Instale el tapn de drenado. Llene el depsito con aceite
hidrulico.

Cheque los indicadores de mirilla. Agregue aceite si requiere.


El nivel no debe estar ni por encima ni por debajo de los
indicadores de mirilla.

Verifique el nivel de lubricacin de las dos cajas del


diferencial. Remueva el tapn de llenado. El aceite de
transmisin debe estar a nivel del tapn de llenado. Agregue
lubricante si requiere. Coloque de nuevo el tapn de llenado.
Consulte la pgina especfica para el fluido apropiado

Remueva la tapa de llenado del depsito de aceite


hidrulico y vace el depsito hidrulico quitando el tapn
de drene.
NOTA: Para evitar contaminacin, limpie la parte
superior del depsito antes del servicio.

Remueva el respiradero del eje, lmpielo con solvente y


squelo con aire comprimido. Colquelo de nuevo en el eje.
Realice esta operacin a los dos ejes.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 30 de 32

PROGRAMA DE MANTENIMIENTO CADA 500 HORAS DE OPERACION


Coloque el camin en posicin de servicio
Remueva la placa de acceso al depsito hidrulico.
Desconecte el cedazo que est localizado en el interior del
depsito.
NOTA: La rosca de succin del cedazo debe ser cerrada o
tapada con un tapn hembra de 1 NPT para prevenir
contaminacin y posible dao a los componentes hidrulicos.
1

PARTIDA COMPONENTE
FLUIDO*
1. Sistema Hidrulico
HO
*Realice el Programa de Mantenimiento como es
requerido.
*Realice el Programa de Mantenimiento Diario o Cada
Turno.
*Realice el Mantenimiento de 50 horas.
*Realice el Mantenimiento de 250 horas.
*Vea las Especificaciones de Fluido.

Limpie el interior de los depsitos con vapor o solvente.


Limpie o reemplace el cedazo y reinstlelo en el interior del
depsito.

Quite el filtro de la lnea de retorno. Reemplace el elemento


del filtro. Instale el filtro a la lnea de retorno.
Instale la placa de acceso al depsito, coloque el tapn de
drenado, y llene el depsito con aceite hidrulico. Verifique
las especificaciones.

Remueva el capuchn de llenado del depsito. Vace el


depsito principal de aceite hidrulico quitando el tapn
de drenado.
NOTA: Para evitar contaminacin, coloque de nuevo el
capuchn y limpie la parte superior del depsito antes de
proceder al servicio.

Cheque los indicadores de mirilla del depsito de aceite


hidrulico, agregue aceite si se requiere. El nivel no debe estar
arriba de la parte superior de la mirilla o por debajo de la parte
inferior de la misma.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 31 de 32

PROGRAMA DE MANTENIMIENTO CADA 1000 HORAS DE OPERACION


Coloque el camin en posicin de Servicio

PARTIDA
1.
2.

COMPONENTE
Caja del Eje Diferencial
Respirador del Eje

FLUIDO*
MBO
____

*Realice el Programa de Mantenimiento como es requerido.


*Realice el Programa de Mantenimiento Diario o Cada Turno.
*Realice el Mantenimiento de 50 horas.
*Realice el Mantenimiento de 250 horas.
*Realice el Mantenimiento de 500 horas.
*Vea las Especificaciones de Fluido.

Remueva los tapones de drenado del eje diferencial, frontal y trasero. Cuando el eje est
totalmente vaco de aceite, limpie el tapn de drenado e instlelo de nuevo.

Quite los tapones de llenado del diferencial (uno por eje). Agregue
lubricante como se especifica hasta que el nivel de aceite llegue a
la parte baja de la entrada del tapn de llenado. Limpie y reinstale
los tapones de llenado del diferencial.

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

Actualizado:
10/30/08

MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64

M1040
Pag. 32 de 32

ESPECIFICACIONES
COMBUSTIBLE
Use combustible Diesel No. 2, Cetane 40 Mnimo
Utilice la marca de diesel en la cual confa que contiene menos del 0.5% de azufre. Tenga cuidado al llenar o rellenar el depsito
para evitar la contaminacin del combustible (diesel). Utilice un combustible con graduacin para invierno cuando est operando
el camin en bajas temperaturas. NOTA: Para evitar que el sistema agarre aire, no permita que el camin trabaje hasta terminarse
el combustible esto puede ocasionar un arranque difcil.

ATENCION
Utilizar combustible diesel ms bajo del nmero recomendado de cetane puede causar un arranque difcil, inestabilidad y
humo blanco excesivo. Para mantener una operacin satisfactoria en bajas temperaturas, es importante especificar el
nmero correcto de cetane del combustible diesel. Para detalles ms completos consulte el Manual de Operacin y
Mantenimiento del Motor o contacte a su distribuidor local Getman.
LLANTAS
TAMAO

CANTIDAD
DE CAPAS

TIPO

PSI

BAR

14.00 X 24
28
___
120
8.3
10.00 X 20
14
LCM
95
6.5
12.00 X 20
16
SMC
95
6.5
9.00 X 20
12
LCM
90
6.1
NOTA: Esta grfica solamente indica las especificaciones de presin de la llanta. Las medidas de la llanta no son
intercambiables. Siempre reemplace llantas de la misma medida, tipo y cantidad de capas como las originales suministradas con
el camin.
PRESIONES
TIPO

PSI

Presin de aceite en el motor a 1000 RPM

45-60

3.1-4.1

1500-2000

103-138

Sistema de direccin hidrulica en vaco y el camin


girado y apoyado contra las retenidas.
NOTA: Inspecciones hechas a 150 F (65 C) de temperatura
en el aceite hidrulico en la presin de carga de frenado.
Presin de carga hidrulica en el freno.
Ejes John Deere
Ford/New Holland D45 y D65
Presin del freno en la vlvula del pedal.
Ejes John Deere
Ford/New Holland D45 y D65

1650-2200
1650-2200
1000
1500

*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.

BAR

114-151
114-151
69.0
103.5

Actualizado:
10/30/08

S1092

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APPLICATIONS.

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S1000

BOLTS TORQUE AND SIZE SAE.


Thread Size

Socket Size

1/4" C
1/4" F
5/16" C
5/16" F
3/8" C
3/8" F
7/16" C
7/16" F
1/2" C
1/2" F
9/16" C
9/16" F
5/8" C
5/8" F
3/4" C
3/4" F
7/8" C
7/8" F
1" C
1" F
1 1/8" C
1 1/8" F
1 1/4" C
1 1/4" F
1 3/8" C
1 3/8" F
1 1/2" C
1 1/2" F
1 3/4" C
1 3/4" F
2" C
2" F
2 1/4" C
2 1/4" F
2 1/2" C
2 1/2" F
2 3/4" C
2 3/4" F
3" C
3" F
(C) Course Threads
(F) Fine Threads

7/16
7/16
1/2
1/2
9/16
9/16
5/8
5/8
3/4
3/4
13/16
13/16
15/16
15/16
1 1/8
1 1/8
1 5/16
1 5/16
1 1/2
1 1/2
1 11/16
1 11/16
1 7/8
1 7/8
2 1/16
2 1/16
2 1/4
2 1/4
2 5/8
2 5/8
3
3
3 3/8
3 3/8
3 3/4
3 3/4
4 1/8
4 1/8
4 1/2
4 1/2

Torque Ft lbs... Lubed


79 in
91 in
14
15
24
27
38
43
83
94
120
134
166
189
295
330
477
526
715
783
1013
1137
1430
1584
1875
2135
2489
2799
3740
4300

Torque N-m

Grade

9
10
19
20
33
37
52
58
113
127
163
182
225
256
400
447
647
713
969
1062
1373
1542
1939
2148
2542
2895
3375
3795
5071
5830

5
5
5
5
5
5
5
5
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8

LUBRICANT CROSS
REFERENCE

F1003
Page 1 of 2

ENGINE OIL VISCOSITY RECOMMENDATIONS

IMPORTANT:
Whenever performing service on this vehicle, make certain it has first been placed in service position.
Basic service and maintenance procedures are illustrated in the maintenance manuals. These are to be
performed at regular intervals based on hours of operation. For further details on service and necessary major
component adjustments (i.e. engine, transmission, axles, etc.) see respective sections in this manual. Read and
become familiar with them. Any further questions, contact your local Getman Distributor.

The viscosity of the oil is greatly influenced by the


ambient temperature, the choice of SAE-grade
should be governed by the ambient temperature of
the engine site (see diagram). If temperatures
temporarily fall below the limit of the SAE grade
selected, engine will not be damaged. However,
starting performance will be affected. During winter
operation viscosity grade should be governed by
ambient temperature when starting engine.
Synthetics maybe of choice.

FLUID SPECIFICATIONS
COMPONENT

SYMBOL

Transmission & Torque Converter

TF

Hydraulic system (Steering and optional


cylinders)

HO

Drive Axle Differential


(Front and Rear)
All Grease Fittings including Upper &
Lower Hinge Pins, Bearings, & Oscillating
Trunnion
All Linkage
Fuel System

EPG
EO
D2

FLUID
Hydraulic Transmission Fluid, Type TO-4, J20 C, D, MIL-L-2104C,
C-4
Examples: Citgo Transgard Torque Converter 250, Shell Donax T,
Mobil Trans HD, Texaco Texamatic 4291
Use only an MS API (MS-DG) oil, MIL-L244459
Examples: Citgo AW 68 Hydraulic Oil, Shell Tellus 68, Mobil DTE
26, Texaco Rando HD 68
Mineral Base Oil.
Examples: Citgo Transgard Tractor Hydraulic Fluid, Shell Donax TD,
Mobil Mobil Fluid 424, Texaco Super Universal Tractor Oil.
Grade 2 Lithium Base Extreme Pressure Grease, MIL-G-10924A
Examples: Citgo Overdrive HD, Shell Super Duty Lithium MDS,
Mobil Mobilegrease Special, Texaco Multifak All-Purpose EP-2
Hand Oil As Required
#2 Diesel Fuel, Centane 40 Minimum

SEE COMPLETE CROSS REFERENCE LIST ON NEXT PAGE

Updated:
01/17/08

LUBRICANT CROSS
REFERENCE

F1003
Page 2 of 2

ENGINE & AIR CLEANER (OIL BATH)


(Engine Manufacturers Specifications.)

AXLES - FORD, JOHN DEERE, NAF

Shell

Rotella

Shell

BP
Citgo
Conoco
Gulf
Mobil

Vanellus C-Extra
C-500 Motor Oil
HD Fleet
Super Duty
Delvac 1300

Citgo

Sunoco
Texaco
Exxon

Super-C
Ursa Super Premium
XD-3

Conoco
Gulf
Mobil
Sunoco
Texaco
Exxon
BP

POWERSHIFT TRANSMISSION OIL


CLARK, JOHN DEERE (TYPE C-3, TO -4)

HYDRAULIC OIL

Shell
BP
Citgo

Shell
BP
Citgo
Conoco
Gulf
Mobil
Sunoco
Texaco
Exxon

Conoco
Gulf
Mobil
Sunoco
Texaco

Donax T
Autran C-4/TO-4
Transgard Torque
Converter 250
Powerdrive Fluid
HT C-3 Fluid
Trans HD
TO-4 Transmission
Texamatic 4291

Donax TD
Gear Oil 90 LS
Transgard Tractor
Hydraulic Fluid
Power Trans. 11 Fluid
Universal Tractor Fluid
Mobil Fluid 424
Mobillube SHC-LS
TH Tractor Fluid
Super Universal
Tractor Oil
Hydraul 560
Energear LS 90

Tellus 68
AW 68
AW 68 Hydraulic Oil
Hydroclear AW 68
Harmony 68 AW
DTE 26
Sunvis 800
Rando HD 68
Nuto H68

Torque converter/transmission lubricant must be


qualified by one of the following specifications.
ORDER OF PREFERENCE PER SPICER OFF
HIGHWAY:

CHASSIS GREASE

1. Caterpillar
2. John Deere/Funk
3. Military
4. Allison
5. Dexron II Equivalent

Shell

TO-4
J20 C, D
MIL-PRF-2104G
C-4
unless using Graphite

LUBRICANTS NOT RECOMMENDED:


DEXRON III, ENGINE OIL, ANY GL-5 OILS

BP
Citgo
Conoco
Gulf
Mobil
Sunoco
Texaco
Exxon

Super Duty
Lithium MDS
Energrease LC
Overdrive HD
Super Lube
Crown LC3
Mobilegrease Special
Ultra Prestige
Multifak All-Purpose
EP-2
Ronex Extra Duty
Moly 2

COOLANT/ ANTIFREEZE (Ethylene- Glycol Base)


Mobile Delvac (50/50)
CAT EC-1
Updated:
01/17/08

GETMAN EQUIPMENT
STORAGE PROCEDURES

F1001
Page 1 of 1

The following storage instructions are intended to help ensure


optimum performance from Getman equipment that will not be
utilized for a period of three months to one year.

IMPORTANT
The following instructions be followed as described in order to
keep your warranty valid.

ENGINE
Change oil using an oil with corrosion preventing
properties of a least a HD-S1 oil. Listed are some
of the oils that have been approved: Esso
MZ20X20V7N; Texaco EKM 162; Shell V6828.

TRANSMISSION & HYDRAULICS


No special care is required except exposed cylinder
rods should be covered with grease.

Change oil and fuel filters.

AXLE
Axle housings should be filled completely to
eliminate the change of moisture condensation.

Fill fuel tank completely with a mixture of diesel


fuel and 10% corrosion inhibiting motor oil.

BRAKE SYSTEM
Drain all air reservoirs of moisture.

Run engine for at least 10 minutes to fill fuel lines


and filters, injection pump and nozzles with
preservative mixture.

BATTERY
Remove battery; clean off top, and store in a wellventilated battery storage area. Do not store on
concrete or metal.

If engine is to be stored over six months, seal intake


and exhaust system to keep moisture out.

EQUIPMENT STORAGE FOR LESS THAN


THREE MONTHS
When storing equipment for less than three months,
vehicles should be started and driven for a
minimum of two minutes every two weeks.

Any further questions please contact your local


Getman Distributor or the contact information
below.

Getman Corporation, 59750 34th Avenue, Bangor, Michigan 49013, U.S.A.


Telephone: (269) 427-5611/ Facsimile: (269) 427-8781/ E-mail: info@getman.com.

Updated:
04/26/07

TROUBLESHOOTING CHECK
LIST
CAUSE

F1002
Page 1 of 2

REMEDY

ENGINE WONT CRANK


1. SHIFT LEVER IN WRONG POSITION
2. PARK BRAKE NOT APPLIED
3. MAIN FUSE IN BATTERY BOX
BLOWN
4. DEAD BATTERY
5. LOOSE OR CORRODED CABLES
6. NEUTRAL START SWITCH FAULTY
7. START SWITCH FAULTY
8. STARTER FAULTY

1. APPLY TO NEUTRAL
2. APPLY PARK BRAKE
3. REPLACE FUSE
4.
5.
6.
7.
8.

CHARGE OF REPLACE
CLEAN AND TIGHTEN
REPLACE SWITCH
REPLACE SWITCH
REPLACE STARTER

1.
2.
3.
4.
5.

FILL TANK
OPEN VALVES
REPLACE FILTER
TIGHTEN ALL LINES
TIGHTEN TERMINALS, REPLACE IF
NEEDED

1.
2.
3.
4.

REPLACE BELT
REMOVE OBSTRUCTION
FILL SYSTEM. CHECK FOR LEAKS
CLEAN WITH COMPRESSED AIR OR
HIGH PRESSURE WATER

ENGINE CRANKS BUT WONT START


1.
2.
3.
4.
5.

OUT OF FUEL
SHUT OFF VALVES CLOSED
FUEL FILTER PLUGGED
FUEL LINES LEAKING
PREHEAT FAILS

ENGINE OVERHEATS
1.
2.
3.
4.

BROKEN FAN BELT


AIR INLET OBSTRUCTED
LOW COOLANT LEVEL
RADIATOR BLOCKED

LOW OIL PRESSURE


1. LOW OIL LEVEL
2.
3.
4.
5.

PRESSURE GAUGE FAULTY


RELIEF VALVE FAULTY
OIL PUMP WORN
EXCESSIVE WEAR IN BEARINGS

1. FILL TO PROPER LEVEL. CHECK


FOR LEAKS.
2. REPLACE GAUGE
3. CLEAN OR REPLACE
4. REPLACE PUMP
5. REBUILD OR REPLACE ENGINE

TRANSMISSION NOT FUNCTIONING PROPERLY


1. LOW OR ERRATIC TRANSMISSION
CHARGE PRESSURE.
2. TRANSMISSION PRESSURE DROPS
ONLY IN CERTAIN GEARS.

1. ADD TRANSMISSION OIL. CHECK


FOR LEAKS.
2. VERIFY CLUTCH FOR LEAKAGE.
REPAIR.
Updated:
04/26/07

TROUBLESHOOTING CHECK
LIST

F1002
Page 2 of 2

3. PRESSURE OK BUT NOT ENGAGING


CERTAIN GEARS

3. VERIFY CONTROL VALVE


ELECTRICAL SOLENOIDS
CONNECTIONS.
SEE CONVERTER AND TRANSMISSION SECTION 5 OF SPARE PARTS AND
MAINTENANCE MANUAL.
PARKING BRAKE NOT HOLDING PROPERLY
1. BRAKE OUT OF ADJUSTMENT
2. BRAKE PADS WORN OUT

1. READJUST
2. REPLACE PADS

PARKING BRAKE WONT RELEASE


1. HYDRAULIC PRESSURE LOW
2. LOOSE OR BROKEN LINES

1. CHECK OIL LEVEL AND RELIEF


VALVE SETTING.
2. TIGHTEN OR REPLACE

STEERING SYSTEM NOT FUNCTIONING PROPERLY


1. HYDRAULIC OIL LEVEL TOO LOW
2. RELIEF VALVE IN FLOW DIVIDER
TOO LOW
3. HYDRAULIC PUMP WORN
4. STEERING VALVE FAULTY
5. STEER CYLINDER LEAKING

1. FILL TO PROPER LEVEL


2. CLEAN OR REPLACE AND CHECK
RELIEF SETTING
3. REPLACE PUMP
4. REPLACE VALVE
5. REPAIR OR REPLACE

HYDRAULIC SYSTEM NOT FUNCTIONING PROPERLY


1.
2.
3.
4.

LOW FLUID LEVEL


SUCTION STRAINER BLOCKED
HYDRAULIC FILTERS PLUGGED
LOOSE CONNECTIONS OR
DAMAGED HOSE
5. RELIEF VALVE STICKING
6. RELIEF VALVE SET TOO LOW
7. WORN PUMP

1.
2.
3.
4.

FILL TO PROPER LEVEL


CLEAN OR REPLACE
REPLACE FILTERS
TIGHTEN OR REPLACE

5. CLEAN OR REPLACE
6. ADJUST TO PROPER SETTING
7. REPLACE PUMP

Updated:
04/26/07

PREVENTIVE MAINTENANCE
SCHEDULE FORMS

F1004
Page 1 of 5

S/N________ HOURS________ DATE_________


SIGNATURE______________________________

DAILY SERVICES

OK

PARTS
ORDERED

UNIT
DOWN

PERFORM THE FOLLOWING CHECKS


Tire pressure and condition
Hydraulic fluid level
Engine oil level
Clean intake precleaner dust bowl
Fuel level
Engine belt wear
Grease axle trunnions
Transmission fluid level
Grease top and bottom articulation pins
Grease steer cylinder pins
Hydraulic system leaks
Fuel system leaks
Instrument operation
All controls for movement and adjustment
Park brake performance
Service brake performance

Updated:
04/26/07

PREVENTIVE MAINTENANCE
SCHEDULE FORMS

F1004
Page 2 of 5

S/N________ HOURS________ DATE_________


SIGNATURE______________________________

50 HOUR SERVICE

OK

PARTS
ORDERED

UNIT
DOWN

PERFORM THE FOLLOWING CHECKS


Check wheel nut torque
Check battery and clean posts
Check air cleaner service indicator
Check air intake clamps and connections
Clean radiator fins
Check exhaust back pressure
Daily services

Updated:
04/26/07

PREVENTIVE MAINTENANCE
SCHEDULE FORMS

F1004
Page 3 of 5

S/N________ HOURS________ DATE_________


SIGNATURE______________________________

250 HOUR SERVICE

OK

PARTS
ORDERED

UNIT
DOWN

PERFORM THE FOLLOWING CHECKS


Grease driveline and universal joints
Change transmission fluid
Change transmission filter
Check hydraulic fluid, change if needed.
Change hydraulic filter element
Change differential fluid
Clean axle breather vents
Change engine oil
Change engine oil filter
Change fuel filter
Change fuel water separator
Check park brake adjustment
Check radiator and if equipped exhaust heat
exchanger coolant, change if needed
50 hour services
Daily services

Updated:
04/26/07

PREVENTIVE MAINTENANCE
SCHEDULE FORMS

F1004
Page 4 of 5

S/N________ HOURS________ DATE_________


SIGNATURE______________________________

500 HOUR SERVICES

OK

PARTS
ORDERED

UNIT
DOWN

PERFORM THE FOLLOWING CHECKS


Remove internal strainer from hydraulic reservoir
and clean
250 hour services
50 hour services
Daily services

Updated:
04/26/07

PREVENTIVE MAINTENANCE
SCHEDULE FORMS

F1004
Page 5 of 5

S/N________ HOURS________ DATE_________


SIGNATURE______________________________

1000 HOUR SERVICES

OK

PARTS
ORDERED

UNIT
DOWN

PERFORM THE FOLLOWING CHECKS


Change differential fluid
500 hour services
250 hour services
50 hour services
Daily services

Updated:
04/26/07

SERVICE REPORT FORM

F1005
Page 1 of 1

MAKE COMMENTS ON FAULTS FOUND FACT OF YOUR OPINION:

FAULTS FOUND IF ANY:

ACTION TAKEN IF ANY:

PARTS USED:

NOTE: SAFETY FIRST

MAINTENANCE
PERSONS SIGNATURE:________________________________________

DATE:___________________

SUPERVISORS
SIGNATURE:__________________________________________________

DATE:___________________

Updated:
04/26/07

SHIFT CHANGE CHECK LIST

F1006
Page 1 of 1

OK
1

CHECK FUEL OIL LEVEL

CHECK ENGINE OIL LEVEL

CHECK V-BELT CONDITION

CHECK HYDRAULIC OIL LEVEL

CHECK COMPRESSOR OIL LEVEL

CHECK CYLINDER PINS AND KEEPERS

7
8

CHECK ALL HYDRAULIC HOSES FOR LEAKS OR


WEAR
CHECK HORN AND LIGHTS

SECURE BIN DOOR

10 CHECK WHEEL LUG NUTS


11 CHECK FOR MISSING OR LOOSE NUTS, BOLTS OR
SCREWS
12 TEST PARKING BRAKE

Updated:
04/26/07

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
2.

CHASSIS
10368
10376
10398
10448
13758
13942
12043

SIGHT GAUGE
FILL CAP (FUEL OIL)
FILL CAP (HYDRAULIC OIL)
HOLD DOWN FASTENERS
SEAT ASSEMBLY
STEERING (PINS, BEARINGS, BUSHINGS)
ARTICULATION INSTALLATION

SIGHT GAUGE

10368
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

WINDOW SIGHT GAUGE

53011

Updated:
12/11/06

FILL CAP

ITEM PART #

10376
Page 1 of 1

DESCRIPTION

QTY.

392012

CAP & SCREEN ASSEMBLY (INCLUDES ITEMS 1, 2)

NSS

CAP

NSS

SCREEN

Updated:
03/08/07

FILL CAP (HYDRAULIC OIL)

ITEM PART #

10398
Page 1 of 1

DESCRIPTION

QTY.

52500

CAP & SCREEN ASSEMBLY

54048

CAP

54003

SCREEN

Updated:
12/11/06

HOLD DOWN FASTENERS

10448
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

132130

HOLD DOWN ASSEMBLY (INCLUDES ITEMS 5, 6)

594535

CLIP (USE AS REQUIRED)

01GE04

WASHER

01GC04008

BOLT

5*

NSS

STRAP

6*

NSS

CLIP (90 DEGREE MOUNT)

*ITEMS NOT SHOWN

Updated:
12/11/06

SEAT ASSEMBLY

13758
Page 1 of 2

Updated:
12/11/06

SEAT ASSEMBLY
ITEM PART #

13758
Page 2 of 2

DESCRIPTION

QTY.

424396

SEAT ASSEMBLY

424396-01

SEAT BACK COVER

424396-02

SEAT BACK FOAM

424396-03

SEAT BOTTOM COVER

424396-04

SEAT BOTTOM FOAM

424396-05

FRAME

424396-06

SEAT MOUNTING CHANNELS

424396-07

DAMPER KIT

424396-08

WEIGHT ADJUSTER KIT

424396-09

SUSPENSION

10

424396-10

SEATBELT BRACKET

11

424396-11

SLIDERAILD MOUNTING PLATE

12

424396-12

SUSPENSION COVER

13

424396-13

SLIDERAIL KIT

Updated:
12/11/06

STEERING (PINS, BEARINGS,


BUSHINGS)

13942
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

26409-01

BEARING (IN CYLINDER TUBE END)

524202

BUSHING (STEERING EAR)

13796-01

PIN (STEERING CYLINDER)

SEE SECTION 8

STEERING CYLINDER

524203

BUSHING (STEERING CYLINDER)

Updated:
10/17/07

ARTICULATION JOINT

12043
Page 1 of 3

Updated:
12/11/06

ARTICULATION JOINT
ITEM PART #
464332

12043
Page 2 of 3

DESCRIPTION

QTY.
1

NSS

ARTICULATION JOINT KIT (LRD 220)


(INCLUDES ITEMS 1-14)
ARTICULATION JOINT KIT (A-64 WIDE)
(INCLUDES ITEMS 1-14)
ARTICULATION JOINT KIT (A-64 STANDARD)
(INCLUDES ITEMS 1-14)
ARTICULATION JOINT KIT (LRD 220)
(INCLUDES ITEMS 1-14)
JOINT PLATE

10697-01

CAP PIN

16369-02

BUSHING - CAP SIDE

594572
594573
594574
16367-03

SHIM CAP (.005 IN.) (.13MM)


SHIM CAP (.007 IN.) (.18MM)
SHIM CAP (.020 IN.) (.51MM)
BEARING INSERT ASSEMBLY (INCLUDES ITEM 8)

A/R
A/R
A/R
2

594575
594576
594577
NSS

SHIM INSERT (.005 IN.) (.13MM)


SHIM INSERT (.007 IN.) (.18MM)
SHIM INSERT (.020 IN.) (.51MM)
JOINT PLATE

A/R
A/R
A/R
2

264032

BEARING

16369-03

BUSHING PIN SIDE

10

13796-03

PIN

11

NSS

JOINT PLATE

12

73GC08016

CAP SCREW (SCKT HD)

12

13

17GC08024

CAP SCREW (HEX HD)

12

14

464420

CAP SCREW (HEX HD)

15

10697-01

CAP PIN

464469
464579
464739

5
6

1
1
1
2

Updated:
12/11/06

ARTICULATION JOINT

12043
Page 3 of 3

1.

MALE ASSEMBLY: INSTALL BEARING INSERT (ITEM 5) WITH 3 SOCKET HEAD


CAPSCREWS (ITEM 12) EQUALLY SPACED WITH NO SHIMS. TORQUE SOCKET HEAD
CAPSCREWS TO (65 LB. FT.) (88N-M) AND MEASURE THE SPACE FOR THE NUMBER
OF (7 DIA.) (178MM) B.C. SHIMS REQUIRED (APPROX. .060). DISASSEMBLE AND
INSERT REQUIRED NUMBER OF SHIMS, REASSEMBLE AND INSTALL 6 SOCKET
HEAD CAPSCREWS (ITEM 12) WITH LOCKTITE AND TORQUE TO (100 LB. FT.) (135 NM). REPEAT PROCESS FOR BOTH TOP AND BOTTOM OF JOINT.

2.

JOINT ASSEMBLY: INSTALL BUSHINGS (TOP ITEM 3, BOTTOM ITEM 9) WITH PIN
(ITEM 10) AND CAP (ITEM 2) AND CAPSCREW (ITEM 14) TORQUE TO (100 LB. FT.) (135
N-M) AND MEASURE THE SPACE FOR THE NUMBER OF (5 ) (145MM) B.C. SHIMS
REQUIRED. DISASSEMBLE AND INSERT THE REQUIRED SHIMS (LESS .010) (.25MM)
REASSEMBLE AND TORQUE THE (ITEM 14) CAPSCREW TO (175 LB. FT.) (235 N-M),
AND LOCKWIRE THE BOLTS TOGETHER. INSTALL THE 6 CAPSCREWS (ITEM 13)
WITH LOCKTITE AND TORQUE TO (1OO LB. FT.) (135 LB. FT.). REPEAT PROCESS FOR
BOTH TOP AND BOTTOM OF JOINT.

Updated:
12/11/06

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
3.

ELECTRICAL SYSTEM AND INSTRUMENTS


30318
17143
S1100
13663

WIRING DIAGRAM
INSTRUMENT PANEL
MURPHY POWERVIEW INSTRUCTIONS
ALTERNATOR

17143
Page 1 of 2

INSTRUMENT PANEL

465313-100-OV

ITEM PART #

DESCRIPTION

QTY.

124454

ENGINE POWERVIEW GAUGE

124455

ENGINE WARNING ALARM

3
*
4
*
5
*
6

124421
124278
124403
124406
134019
134020
124396

CONVERTER PRESSURE GAUGE


CONVERTER PRESSURE SENDER
TRANSMISSION TEMPERATURE GAUGE
TRANSMISSION TEMPERATURE SENDER
PARK BRAKE SWITCH
PARK BRAKE BUTTON
VOLTMETER

1
1
1
1
1
1
1

124148
124461
122100

WORK LIGHT SWITCH (OPTIONAL)

HORN BUTTON

*ITEMS NOT SHOWN


CONFIRM WHICH PART NUMBER IS USED ON YOUR TRUCK

Updated:
03/11/08

INSTRUMENT PANEL
9

17143
Page 2 of 2

10

134117
134009
134118
N/A

(10 AMP)CIRCUIT BREAKER


(20 AMP)CIRCUIT BREAKER
(30 AMP)CIRCUIT BREAKER
SPARE SPACE

A/R
A/R
A/R
N/A

11

124498

PLC RESET SWITCH

12

PTO FAST IDLE SWITCH (OPTIONAL)

14

124148
124461
122100
124433
124195

PARK BRAKE TEST BUTTON


GREY CAP
LOW FUEL LIGHT (OPTIONAL)

1
1
1

15

124380

START SWITCH

16

124501

TOGGLE LIGHT SWITCH

17

BEACON LIGHT SWITCH (OPTIONAL)

CANOPY LIGHT SWITCH (OPTIONAL)

19

124148
124461
124148
124461
SEE GETMAN

WARNING PANEL

20*

464670

RESISTOR PACK

13

18

*ITEMS NOT SHOWN


CONFIRM WHICH PART NUMBER IS USED ON YOUR TRUCK

Updated:
03/11/08

S1100

PowerView

Model PV-101
Users Guide
Rev 09-10-08

00-02-0605
Catalog Section 78

S1100
In order to consistently bring you the highest quality, full
featured products, we reserve the right to change our
specifications and designs at any time. The latest version of
this manual can be found at www.fwmurphy.com.

Warranty - A limited warranty on materials and


workmanship is given with this FW Murphy product. A copy
of the warranty may be viewed or printed by going to
www.fwmurphy.com/support/warranty.htm

BEFORE BEGINNING INSTALLATION OF THIS


MURPHY PRODUCT:
Disconnect all electrical power to the machine.
Make sure the machine cannot operate during
installation.
Follow all safety warnings of the machine
manufacturer.
Read and follow all installation instructions.

S1100

Table of Contents
Introduction............................................................................. 1
Engine and Transmission Parameters

Faceplate Features

Navigation and Keypad Functions

Operation ................................................................................. 9
PowerView Menus (First Time Start Up)

Setting Up the Display

12

Main Menu Options

18

Faults and Warnings

20

Utilities Menu

23

Modbus Setup

25

Selecting Engine ECU

26

Troubleshooting ................................................................... 27

S1100

Introduction
Congratulations on purchasing your PowerView display, a
multifunction tool that provides a window into the many
parameters and service codes of modern electronic engines
and transmissions.
This guide is intended to help you set up your PowerView
display and identify navigation basics and product features.
The displays simple navigation and intuitive yet powerful
features allow you to master the product in no time.
Additional information can be found on our website at
www.fwmurphy.com/powerview.

00-02-0605

-1-

Rev 09-10-08

S1100

Engine and Transmission Parameters


The following are some of the engine and transmission
parameters which may be displayed in standard or metric
units as well as in English, Spanish, French, Italian, or
German languages (when applicable, consult engine or
transmission manufacturer for SAE J1939 supported
parameters):

Engine RPM
Engine hours
System voltage
Percent engine load at the
current RPM
Coolant temperature
Oil pressure
Fuel economy
Throttle position
Engine manifold air
temperature
Current fuel consumption

00-02-0605

-2-

Transmission oil
pressure
Transmission oil
temperature
Transmission gear
position
Engine configuration
parameters
Active fault codes
Stored fault codes

Rev 09-10-08

S1100

Faceplate Features

00-02-0605

-3-

Rev 09-10-08

S1100

Navigation and Keypad Functions


The keypad on the PowerView display is a capacitive touch
sensing system. There are no mechanical switches to wear
or stick. When a key is touched, feedback is provided by the
screen flashing. The keys on the keypad perform the
following functions:

Menu Enter or exit menu screens.


Left Arrow Scroll the screen or move the
parameter selection to the left or upward.
Right Arrow Scroll the screen and move
the parameter selection to the right or
downward.
Enter Key Select a menu or parameter or
hide/view an active fault code.

00-02-0605

-4-

Rev 09-10-08

S1100

Basic Navigation
1. When Menu is pressed, the main menu items are
displayed.

00-02-0605

-5-

Rev 09-10-08

S1100
2. Touching the Arrow Keys will move the selection bar to
other menu items.

00-02-0605

-6-

Rev 09-10-08

S1100
3. Certain menus have multiple pages of items. Scrolling
past the top item or bottom item on the current page will
reveal other menu items on additional pages.

00-02-0605

-7-

Rev 09-10-08

S1100

4. When the desired item is highlighted by the cursor,


pressing Enter will select that item and display the
corresponding screen.

5. Anytime the word MORE appears above the Arrow


Keys there are more screens that may be viewed. Use
the Arrow Keys to scroll to the next screen of
information.

00-02-0605

-8-

Rev 09-10-08

S1100

Operation
PowerView Menus (First Time Start Up)
1. When power is first applied to the display, the Murphy
logo appears.

00-02-0605

-9-

Rev 09-10-08

S1100
2. If the Engine ECU is broadcasting a 'Wait To Start'
message, this screen will be shown. Engine
manufacturers typically recommend against starting the
engine while this message is broadcasted from the
ECU. Once the ECU stops broadcasting this message,
this screen will no longer be displayed.

00-02-0605

- 10 -

Rev 09-10-08

S1100
3. Once the engine has started, the single engine
parameter appears with the engine RPM displayed.
Pressing the Right Arrow Key will display the coolant
temperature. The screen can be changed to other
parameters by pressing Menu.

00-02-0605

- 11 -

Rev 09-10-08

S1100

Setting Up the Display


The screen may be configured to display a single engine
parameter (1-up display), or four parameters at once (4-up
display). Default options are provided or you may customize
the display by selecting the parameters you want.

1-Up Display
Three options are available for modification of the 1-Up
display.
Use Defaults This option contains a set of engine
parameters: Engine Hours, Engine RPM, System Voltage,
Battery Voltage, % Engine Load at Current RPM, Coolant
Temperature, and Oil Pressure.
Custom Setup This option allows for the modification of
which parameter, the number of parameters, and the order
in which the parameters are being displayed.
Automatic Scan Selecting the scan function will cause
the 1-Up Display to scroll through the selected set of
parameters one at a time, momentarily pausing at each.
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1-Up Display Settings


1. Touch Menu and use the Arrow Keys to highlight
SETUP 1-UP DISPLAY, then press Enter.
2. To select USE DEFAULTS, highlight the option and
press Enter. A message indicating RESTORED TO
DEFAULTS is displayed.
3. To select CUSTOM SETUP, highlight the option and
press Enter. A list of engine parameters is displayed.
4. To select a parameter, use the Arrow Keys to scroll
and highlight the parameter, then touch Enter.
Selected parameters are indicated by a # symbol to the
right of it and represent the order in which the
parameter will be displayed.
5. To deselect a selected parameter and remove it from
the list of displayed parameters, highlight the parameter
and touch Enter.
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S1100
6. Continue to scroll and select additional parameters for
the CUSTOM 1-UP DISPLAY. Touch Menu at any time
to return to the CUSTOM SETUP menu.

7. Selecting the AUTOMATIC SCAN ON function will


cause the 1-up display to scroll through the selected set
of parameters one at a time.
8. Once the USE DEFAULTS, CUSTOM SETUP and
AUTOMATIC SCAN functions have been set, touch
Menu once to return to the main menu, or twice to
display the 1-up display screen.

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4-Up Display
The 4-up display places the parameter data into four areas
of the screen known as quadrants. Factory defaults for the
4-up display include coolant temperature, engine speed, oil
pressure, and battery voltage. You may customize the 4-up
display with parameters you define for each quadrant.
1. Touch Menu and use the Arrow Keys to highlight
SETUP 4-UP DISPLAY, then press Enter.
2. To select USE DEFAULTS, highlight the option and
press Enter. A message indicating RESTORED TO
DEFAULTS is displayed.
3. To select CUSTOM SETUP, highlight the option and
press Enter. The 4-up display appears.
4. The quadrant with the backlit parameter value is the
currently selected parameter. Use the Arrow Keys to
select which quadrant you wish to edit.

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S1100
5. Touch Enter and a list of parameters will appear.
The parameter that is highlighted is the selected
parameter for the screen. The number to the right of the
parameter indicates the quadrant in which it is
displayed.

1 = upper left quadrant


2 = lower left quadrant
3 = upper right quadrant
4 = lower right quadrant
6. Use the Arrow Keys to highlight the new parameter to
be placed in the quadrant that was selected in step 4
and touch Enter.
7. Touch Menu to return to the 4-UP CUSTOM SETUP
screen.
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8. The parameter in the selected quadrant has changed to
the parameter selected in the previous screen.

9. Repeat the parameter selection process until all spaces


are filled.

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S1100

Main Menu Options


This section describes the features listed on the main menu
of the PowerView. These menu options are displayed
whenever you touch Menu. The Arrow Keys allow you to
scroll the items, and Enter selects the highlighted option.

Selecting a Language
From LANGUAGES, you may select ENGLISH, ESPANOL,
FRANCAIS, ITALIANO, or DEUTSCH. The currently
selected language is indicated by an asterisk.

Stored Fault Codes*


Request stored fault code information.

Engine Configuration Data*


ENGINE CONFG allows you to scroll through engine
configuration data.
* This function may not be supported by all manufacturers.
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Backlight Adjustment
ADJUST BACKLIGHT allows you to select the desired
backlight intensity.

Contrast Adjustment
From ADJUST CONTRAST, you may select the desired
contrast intensity.

Select Units
From SELECT UNITS, you may select how information is
displayed. ENGLISH for Imperial units, i.e., PSI, F or
METRIC KPA, METRIC BAR for IS units, i.e., kPa, Bar, C.

Utilities
UTILITIES provide troubleshooting features and displays
information about the PowerView configuration. (See
Utilities Menu)
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Faults and Warnings


The PowerView provides two means for detecting faults and
warnings: visual LEDs on the casing (See Faceplate
Features) and fault indicators on the display.

Visual Indication

Amber LED (Warning)

Red LED (Derate / Shutdown)

Fault Indicators

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Auxiliary Gage Fault


Murphys PVA Gages can be attached to the PowerView. If
an auxiliary gage should fail, the 1-up or 4-up display will be
replaced with the fault message GAGE NOT
RESPONDING.
NOTE: The fault can only be cleared by correcting the
cause of the fault condition.

Active Fault Codes


When the PowerView receives a fault code from an engine,
the 1-up or 4-up display will be replaced with the active fault
codes message.

Derate / Shutdown Codes


When the PowerView receives a severe fault code from an
engine control unit the 1-up or 4-up display will be replaced
with the SHUTDOWN message.
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Acknowledging Fault Codes


1. To acknowledge and hide the fault and return to the
1-up or 4-up display, touch Enter. The display will
return to the 1-up or 4-up display, but the display will
contain the shutdown icon.
2. Touch Enter to redisplay the hidden fault. Touch Enter
once again will hide the fault and return the screen to
the 1-up or 4-up display.

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Utilities Menu
The following steps take place starting at the UTILITIES
menu option.
1. GAGE DATA - View information for optional connected
PVA gages.
2. REMOVE ALL GAGES - Reset the PowerView's gage
memory.
3. SOFTWARE VERSION - View the PowerView's
software version.
4. MODBUS SETUP refer to Modbus Setup section.
5. FAULT CODE CONVERSION - View/edit the J1939
fault code conversion method.
NOTE: There are four (4) different methods for
converting fault codes. The PowerView always looks for
J1939 Version 4 and can be set to read the code as
one of three (3) other J1939 versions if Version 4 is not
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S1100
being used. Most engine ECUs use Version 4,
therefore in most cases adjustment of this menu option
will not be required.

Upon receiving an unrecognizable fault, change to a


different J1939 Version. If the fault SPN does not
change when the version is changed, the ECU
generating the fault is using Fault Conversion method 4.
If the SPN number does change but is still
unrecognizable, try changing to another J1939 Version
not yet used and continue to check the SPN number.
6. ANALOG INPUT provides two setting options:

BACKLIGHT DIMMER, the default setting, will


accept an optional backlighting dimmer.

FUEL LEVEL accepts an optional Murphy fuel


sender (model ES2F recommended) for fuel level
information.

7. SELECT ENGINE ECU listens to all ECUs or scrolls


to a specific engine ECU.
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Modbus Setup
1. From the UTILITIES menu, select MODBUS SETUP.
2. Select either the SLAVE ACTIVE (SCADA or remote
Modbus master) or MASTER ACTIVE (auxiliary gages)
modes. Touch Enter to toggle between master and
slave.
3. Select SERIAL PORT SETUP (slave mode only), then
touch Enter.
4. Continue to scroll each selection (BAUD RATE,
PARITY, DATA BITS, STOP BITS) to configure the
serial port parameters for your Modbus slave
application.

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Selecting Engine ECU


1. From the UTILITIES menu, choose SELECT ENGINE
ECU.
2. The message LISTEN TO ECU: ALL is displayed as
the default setting, and indicates the PV101 is listening
to all devices on the network.
3. To change the setting to a specific address, press the
Arrow Keys to scroll through the numbers (0-253).
4. Once the target address is displayed, press Enter.
5. A confirmation screen displays. Selecting NO (shown
above Menu key) returns to the SELECT ENGINE ECU
screen. Selecting YES (shown above Enter key)
stores the selected address and returns to the
UTILITIES menu.

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Troubleshooting
WAIT TO START PREHEATING is displayed
The ECU is broadcasting a 'Wait To Start' message. Engine
manufacturers typically recommend against starting the
engine while the ECU is broadcasting this message. Once
the ECU stops broadcasting this message, this screen will
no longer be displayed on the PowerView.
CANBUS FAILURE is displayed
The PowerView has not received any valid J1939 CAN
messages for at least 30 seconds.
TIMEOUT ECU NOT RESPONDING is displayed
The PowerView sent a request to the ECU for Stored Fault
Code (DM2) information, and the ECU did not respond to
the request. This message on the PowerView indicates the
ECU may not support Stored Fault Code (DM2) functionality
over J1939.

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NO STORED CODES is displayed


The PowerView sent a request to the ECU for Stored Fault
Code (DM2) information, and the ECU responded. There
are zero stored codes.
NO GAGE DATA is displayed
The PowerView has no record of gages connected to the
RS485 bus.
NO DATA is displayed in place of a parameter value
The PowerView has not received data for the selected
parameter for at least 5 seconds.
NOT SUPPORTED is displayed in place of a parameter
value
The ECU is sending a message that it does not support this
parameter.

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S1100
DATA ERROR is displayed in place of a parameter value

The ECU is sending a message that there is a data error


with this parameter. Or (PV101 only) FUEL LEVEL has
been selected for display, ANALOG INPUT has been set to
FUEL LEVEL, but no Murphy Fuel Sender has been
connected to the analog input.
One of the 4-UP quadrants is empty
No parameter has been selected for display in this
quadrant.
Display is not readable, either very dim or very dark
The LCD contrast may have been over or under adjusted.
Press and hold the MENU key for approximately 5
seconds. This will reset the LCD contrast setting to factory
default.

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0710172
02-13-07
Section 78

PowerView - Model PV101 Troubleshooting


Message
WAIT TO START PREHEATING is
displayed

Translation
The ECU is broadcasting a 'Wait To Start'
message. Engine manufacturers typically
recommend against starting the engine while the
ECU is broadcasting this message. Once the
ECU stops broadcasting this message,
this screen will no longer be displayed on the
PowerView.
CANBUS FAILURE is displayed
The PowerView has not received any valid
J1939 CAN messages for at least 30 seconds
TIMEOUT ECU NOT RESPONDING The PowerView sent a request to the ECU for
is displayed
Stored Fault Code (DM2) information, and the
ECU did not respond to the request. This
message on the PowerView indicates the ECU
may not support Stored Fault Code (DM2)
functionality over J1939.
NO STORED CODES is displayed
The PowerView sent a request to the ECU for
Stored Fault Code (DM2) information, and the
ECU responded. There are zero stored codes.
NO GAGE DATA is displayed
The PowerView has no record of gages
connected to the RS485 bus.
NO DATA is displayed in place of a
The PowerView has not received data for the
parameter value
selected parameter for at least 5 seconds
NOT SUPPORTED is displayed in
The ECU is sending a message that it does not
place of a parameter value
support this parameter
DATA ERROR is displayed in place The ECU is sending a message that there is a
of a parameter value
data error with this parameter. Or (PV101 only)
FUEL LEVEL has been selected for display,
ANALOG INPUT has been set to FUEL LEVEL,
but no Murphy Fuel Sender has been connected
to the analog input.
One of the 4-UP quadrants is empty
No parameter has been selected for display in
this quadrant.
Display is not readable, either very
The LCD contrast may have been over or under
dim or very dark
adjusted. Press and hold the MENU key for
approximately 5 seconds. This will reset the
LCD contrast setting to factory default.

(1)

S1100

NOTES

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0710174 S1100
02-14-07
Section 78

PV100/PV101 Implementation of SAE J1939 Parameters*


Source: SAEJ1939-71 Surface Vehicle Recommended Practice
Description

PGN

Parameter

Display Value

Elec Eng Cont #2 - EEC2

61443

Accelerator Pedal Position


Percent Load at Current RPM

THROTTLE
LOAD@RPM

Elec Eng Cont #1 - EEC1

61444

Actual engine % torque


Engine Speed

ENG TORQ
ENG RPM

Engine hours, Revolutions

65253

Total Engine Hours

ENG HRS

Fuel Consumption

65257

Trip Fuel
Total Fuel Used

TRIP FUEL
FUEL USED

Engine Temperature

65262

Engine Coolant Temp


Fuel Temperature
Engine Oil Temperature
Engine Intercooler Temperature

COOL TEMP
FUEL TEMP
OIL TEMP
INTC TEMP

Engine Fluid Level/Pressure

65263

Fuel Delivery Pressure


Engine Oil Level
Engine Oil Pressure
Coolant Pressure
Coolant Level

FUEL PRES
OIL LVL
OIL PRES
COOL PRES
COOL LVL

Fuel Economy

65266

Fuel Rate
Instantaneous Fuel Economy
Average Fuel Economy

FUEL RATE
FUEL ECON
AVG ECON

Ambient Conditions

65269

Barometric Pressure
Air Inlet Temperature

BARO PRES
AIR IN TP

Inlet/Exhaust Conditions

65270

Boost Pressure
Intake Manifold Temp
Air Filter Differential Pressure
Exhaust Gas Temperature

BST PRES
MANI TEMP
AIR DIF PR
EXH TEMP

Engine Fluid Level/Pressure #2

65243

Injector Metering Rail 1 Pres


Injector Metering Rail 2 Pres

INJ PRES1
INJ PRES2

Fan Drive-FD

65213

Estimated Percent Fan Speed

FAN SPD

Diagnostic Messages

65226
65227
65228

DM1 - Active Diagnostic


DM2 - Previously Act Diag Codes
DM3 - Diagnostic Clear

SRVCCODE
STORCODE

Machine Hours (PowerView Calculated)

N/A

Machine Hours

MACH HRS

Engine Conf.

65251

Engine Configuration

ENG CONF

Hydraulic Pressure Governor Info-HPG

61448

Hydraulic Oil Pressure

HYD PRES

Electronic Transmission Controller #1


Electronic Transmission Controller #1
Electronic Transmission Controller #1

61442
61442
61442

Output Shaft Speed


Input Shaft Speed
Torque Converter Lockup Engaged

OUT SFT SP
IN SFT SPD
TORQ LOCK

Electronic Transmission Controller #2

61445
61445

Selected Gear
Current Gear

SLECT GEAR
CURNT GEAR

Transmission Fluids

65272

Transmission Oil Pressure


Transmission Oil Temperature

TRAN PRES
TRAN TEMP

Transmission Control 1-TC1

256

Requested Gear

REQ GEAR

Auxiliary Pressures & Temperatures

65164

Auxiliary Temperature
Auxiliary Pressure

AUX TEMP
AUX PRES

Auxiliary Input/Output Status

65241

Auxiliary I/O #1

AUX 10 1

Cruise Control /Vehicle Speed

65265

Wheel Based Vehicle Speed

VEH SPD

Vehicle Electrical Power

65271

Alternator Voltage
Electrical Potential (Voltage)
Battery Pot. Voltage (Switched)

ALT VOLT
SYS VOLT
BAT VOLT

Vehicle Distance

65248

Trip Distance
Total Vehicle Distance

TRIP DIST
VEH DIST

Vehicle Fluids-VF

65128

Hydraulic Oil Temperature

HYD TEMP

Dash Display-DD

65276

Fuel Level

FUEL LEVEL

Rudder

127245

Rudder Angle

RUD ANG

Speed

128259

Water Referenced

H20 REF.SP

Small Craft Status, Port Trim

130576

Port Trim Tab

P TRIM TAB

Small Craft Status, Starboard Trim

130576

Starboard Trim Tab

S TRIM TAB

Retarded Temperature Above Normal


(SPN=120, FMI=15)
Transmission Oil Temperature Above
Normal (SPN=177, FMI=15)
Unknown General Transmission Fault
(SPN=2003, FMI=31)

RETARDED OIL TEMPERATURE ABOVE NORMAL

Support Allison DTCs

*PV100-A, software version Murphy 2.09


PV101-A, software version Murphy 1.00.06

TRANSMISSION OIL TEMPERATURE ABOVE NORMAL


GENERAL TRANSMISSION FAULT UNKNOWN

S1100
Murphy, the Murphy logo, and PowerView are registered and/or
common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by
Murphy Industries, Inc., with all rights reserved. (c) 2008 Murphy
Industries, Inc. Other third party product or trade names
referenced herein are the property of their respective owners and
are used for identification purposes only.

ALTERNATOR

13663
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

146009

ALTERNATOR (DETROIT OM904 24V)

2*

146015

A/R

3*

146014

4*

146031

5*

146073

6*

146074

ALTERNATOR BELT 56.5 LONG (DETROIT OM904)


VEHICLE WITH NO AIR CONDITION
ALTERNATOR BELT 81 LONG (DETROIT OM904)
VEHICLE WITH AIR CONDITION AND SPACERS
ALTERNATOR BELT 79.7 LONG (DETROIT OM904)
VEHICLE WITH AIR CONDITION
ALTERNATOR BELT 54.5 LONG (DETROIT OM904)
VEHICLE WITH NO AIR CONDITION
ALTERNATOR BELT 77.5 LONG (DETROIT OM904)
VEHICLE WITH AIR CONDITION

*ITEMS NOT SHOWN

A/R
A/R
A/R
A/R

Updated:
11/30/07

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
4.

ENGINE AND ACCESSORIES


F1007
S1034
S1078
S1035
13807
13661
13660
13713
11637
13676
S1020

DETROIT DIESEL WARRANTY


ENGINE OPERATION MANUAL
ENGINE MAINTENANCE MANUAL
ENGINE PARTS MANUAL
ENGINE FILTERS
RADIATOR INSTALLATION
CHARGE AIR INSTALLATION
AIR INTAKE SYSTEM
AIR CLEANER
EXHAUST SYSTEM
EXHAUST INFORMATION

Limited Warranty on New Detroit Diesel

F1007

Series 900 Engines Used In Agricultural,


Construction and Industrial Applications
Terms of Coverage:

This Warranty Does Not Cover:

Uses
This warranty applies to the first retail purchaser and subsequent
owners during the WARRANTY PERIOD of new Detroit Diesel Series
900 engines (referred to as Engine) manufactured or supplied by
Detroit Diesel Corporation (referred to as DDC) which are used in
construction and industrial applications operated in the United
States, Canada or Mexico.

Repairs Due To Accidents, Misuse, Storage Damage,


Negligence or Certain Modifications
Repairs due to an accident, misuse, misapplication, storage damage, negligence or modification exceeding DDC specifications, are
not covered by this warranty.

Defects
This warranty covers Engine REPAIRS to correct any malfunction
occurring during the WARRANTY PERIOD resulting from defects in
material or workmanship.
Repairs
To obtain warranty repairs, you must request the needed repairs
within the WARRANTY PERIOD from an authorized Detroit Diesel
Corporation (referred to as DDC)* service outlet. Only new genuine
parts or remanufactured parts or components supplied or approved
by DDC will be used. DDC may, at its discretion, replace rather than
repair components. A reasonable time must be allowed to perform
the warranty repair. Repairs will be performed during normal business hours.
Warranty Period
The WARRANTY PERIOD begins on the date the Engine is delivered
to the first retail purchaser or put in use prior to sale at retail, whichever date occurs first, and ends at the time limits shown below:
WARRANTY PERIOD
Item

Engine

Warranty Limitations
(Whichever Occurs First)

Non-DDC Supplied/Manufactured
Components
DDC is not responsible for repair of components and/or assemblies
which are supplied by another manufacturer, such as power takeoffs, intake and exhaust system. Such items may be covered by the
manufacturer or supplier.
Maintenance
DDC is not responsible for the cost of maintenance or repairs due to
lack of performance of required maintenance service or the failure to
use fuel, oil, lubricants and coolant meeting DDC-recommended
specifications. Performance of required maintenance and use of
proper fuel, oil, lubricants and coolant are the responsibility of the
owner. See the Operating Manual for details.
Incidental or Consequential Damages
DDC is not responsible for incidental or consequential costs or
expenses which the owner may incur as a result of a malfunction or
failure covered by this warranty, such as communication expenses,
meals, lodging, overtime, towing, loss of use of the Engine or equipment (downtime), loss of time, inconvenience, cargo loss or damage, and other similar costs and expenses.

Other Limitations
Repair Charge To Be
Paid By Owner

MONTHS

ENGINE HOURS

PARTS

LABOR

0-24

3,000

No Charge

No Charge

Service Supplies
The cost of service supplies such as coolant, oil and filters, which are
not reusable due to needed repairs is covered by this warranty.
Like Replacement Engine
Engine(s) supplied by DDC as a replacement for an Engine still
under warranty will assume the identity of the Engine being replaced
and be entitled to the remaining warranty coverage.
Mechanics Travel Expenses
Mercedes-Benz will pay reasonable travel expenses for the repairing
mechanic to travel to and from the repair site.

The performance of REPAIRS is the exclusive Owners remedy under


this warranty. DDC does not authorize any person to assume or create for it any other obligation or liability in connection with the Engine.
THIS LIMITED WARRANTY IS THE ONLY WARRANTY APPLICABLE
TO THIS ENGINE AS USED IN AGRICULTURAL, CONSTRUCTION
AND INDUSTRIAL APPLICATIONS. DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED,
INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE.
Some states do not allow the limitation of how long this warranty may
last or the limitation or exclusion of incidental or consequential
damages, so the above may not apply to you. This warranty gives
you specific legal rights, and you may also have other rights which
may vary from state to state.

Engine Removal And Reinstallation


Reasonable labor costs for engine removal and reinstallation, when
necessary to make a warranty repair, are covered by this warranty.
*In Canada, the reference is to Detroit Diesel of Canada Limited, in
Mexico, the reference is to Detroit Diesel Allison de Mexico.
17SE702 0202 Conditions of this offer are subject to change without notice. Printed in U.S.A.

S1034

OM 904 LA - OM 906 LA - OM 924 LA - OM 926 LA Operating Instructions

Mercedes-Benz

S1034

Thank you for choosing this


Mercedes-Benz engine.
Please get to know your new MercedesBenz engine first. Make sure you read the
Operating Instructions in particular before
using the engine for the first time. In this
way you can ensure successful and safe
use. At the same time you will avoid endangering yourself and others when operating
the engine.
Items of special equipment are marked
with an asterisk *. The equipment in your
Mercedes-Benz engine may vary, depending on the version. Mercedes-Benz is constantly updating its engines to the state of

the art. You cannot, therefore, base any


claims on the data, illustrations or descriptions in these Operating Instructions.
For further information contact a
Mercedes-Benz Service Centre.
The Operating Instructions and Maintenance Booklet belong with the engine. You
should therefore always keep them with
the engine and pass them on to the new
owner if you sell it.
The technical documentation team at
DaimlerChrysler AG wishes you every success.

S1034

introduction
The aim of these Operating
Instructions
Symbols
Protection of the environment
Operating safety
Correct use
2

5
6

7
8
9

At a glance

OM 904 LA/OM 924 LA


OM 906 LA/OM 926 LA
Location of sensors
Engine plate
3

12
16
20
22

Before commissioning

General
Type designation
Engine data card
Description of the engine
Flame-start system*
Grid heater*
Exhaust brake / constantly-open
throttle valve*
Telligent@ engine system
Transport and installation

24
24
24
25
26
27
28
29
33

Safety

Safety precautions
Personnel qualifications
Conversion parts and
modifications
Safety / emergency running
programs
Genuine Mercedes-Benz parts
5

36
37
38
39
40

Cleaning/protective treatment
Cleaning the engine
Cleaning the cooling system
Protective treatment.
Service products
Diesel fuels
Engine oils
Coolant

55
55
56
58
59
60
62
63

Maintenance

Operation

Commissioning
Preparation
Starting the engine for the first
time
Starting the engine
Monitoring engine operation
Charge current
Telligent@ engine system
Flame-start system*
Grid heater*
Stopping the engine
Winter operation

42
42
44
47
49
49
50
50
51
52
53

Maintenance instructions
Overview of work plans
Maintenance service
Additional work
Additional work during every
3rd maintenance service
Work plans
Engine: Checking for leaks and
general condition
Lines and hoses on the engine:
Checking for leaks and general
condition
Engine: Oil change and filter
replacement
Adjusting the valve clearance

66
67
67
67

67
68
68

68
69
73

S1034

Fuel prefilter: Cleaning the filter


element.
77
Fuel prefilter with heated water
separator*: Replacing the filter
element.
78
Replacing the fuel filter element. .. 80
Intake pipe between air cleaner
and engine: Checking for leaks
and general condition
82
Poly-V-belt: Checking
the condition
83
Engine brake: Checking the
condition and setting
88
Engine cooling system: Checking
and correcting the fluid level
and the antifreeze / corrosion
inhibitor
90
Cooling and heating system:
Checking for leaks and general
condition
91
Renewing coolant
94

Practical advice

Malfunctions, causes and


solutions
Jump-starting

98
106

Technical data

Engine data
Test values and adjustment
values
Tightening torques

108
112
113

Glossary and index


Technical terms
Index

115
117

S1034

The aim of these Operating Instructions


~

The aim of these Operating Instructions

These Operating Instructions are intended


to assist you in all situations with your new
engine. Each section has a list of contents
to help you find the information you require quickly:

At a glance

This section gives you an overview of the


layout of important components in the engine.

Here you will find all the information you


will need when you are operating the engine.

Maintenance

This is where you will find more detailed information about maintenance work.

7
3

Operation

Practical advice

Before commissioning

This contains the basic information you require for initial operation. If this is your first
Mercedes-Benz engine, you should read
this section first.
Safety
This section contains important aspects
with regard to safety when handling
Mercedes-Benz 900 series engines.

Here you will find practical help for possible problems.

Technical data

All the important technical data for the engine is listed here.
9

Glossary and index

The glossary of technical terms explains


the most important technical concepts.
The index is intended to help you find information quickly.

The engine documentation comprises the


following:
o

these Operating Instructions

.. the Maintenance Booklet


.. Specifications for Service Products
You may receive additional supplements
depending on the equipment.

S1034

Symbols

T Symbols
1
.......

You will find the following symbols used in


these Operating Instructions:

This asterisk indicates special


equipment. Since not all models
have the same standard equipment, the layout of your engine may
differ from certain descriptions and
illustrations.

This symbol means that you have to do


something.

A number of these symbols one after


the other indicates a sequence of actions.

Environmental note
An environmental note givesyou tips on the
protection of the environment.

Warning

:I."

A warning draws your attention to possible


risks of accident and injury to yourself and
others.

You should therefore always read and observe all warning notices.

[>

page

This note draws your attention to possible hazards to your engine.


[>[>

This continuation symbol indicates an interrupted sequence


of actions that will be continued
on the next page.

->

This symbol in the glossary of


technical terms means that the
term following the arrow is also
explained.

I e

This tip contains advice or further information you may find useful.

This symbol indicates the page


on which you will find further information on the subject.

S1034

..... Protection of the environment


Environmental note

Fuel consumption and engine wear depend


on the operating conditions.

DaimlerChrysler's declared policy is one of

Therefore you should:

integrated environmental protection. This

"

not warm up the engine at idle

"

switch off the engine during waiting periods imposed by operations

could arise from production processes or

..

monitor fuel consumption

the products themselves.

..

carry out the specified maintenance


work regularly

policy starts at the root causes and encompasses in its management decisions all the
consequences for the environment which

The objectives are for the natural resources


which form the basis of our existence on this
planet to be used sparingly and in a manner
which takes the requirements of both nature
and humanity into account.
Operate the engine in an environmentallyresponsible manner, and you will help to
protect the environment.

S1034

Operating safety

T Operating safety

1 The operating safety of an engine firstly de...... pends on its proper installation into the
complete system (e.g. vehicle, machine,
etc.). Secondly, as operator or service personnel, you also have a direct influence on
the safe operation of the engine.
Some of the requirements for operating
the engine safely can be achieved by adhering to the specified maintenance intervals and ensuring that the required
maintenance work is carried out correctly.
However, safe engine operation also depends on correct servicing, such as checking the engine oil level at regular intervals.

Risk of accident

Risk of accident

Improper operation of the engine, e.g. exceeding the permitted maximum engine
speed in overrun mode or operating the engine with too little oil, can cause engine
damage. Engine damage can lead to an increase in the risk of accident.

Faulty maintenance work or failure to carry


out maintenance work, e.g. not changing the
oil filter or not observing the correct maintenance interval, can cause engine damage.
Engine damage can lead to an increase in
the risk of accident.

Therefore, observe the notes on operating


the engine in these Operating Instructions.

Therefore, observe the notes on engine


maintenance in these Operating Instructions.

S1034

Correct use
Risk of accident
Work incorrectly carried out on electronic
components and its software could impair
the functioning of these components. Since
the electronic systems are networked, this
might also affect systems that have not
been modified.
Always have work on or modifications to
electronic components carried out at a qualified specialist workshop which hasthe necessary specialist knowledge and tools to
carry out the work required.
Mercedes-Benz recommends that you use a
Mercedes-Benz Service Centre for this purpose.

The engine is only designed for installation


in accordance with the specifications determined in the contract.
The manufacturer of the end product is
personally responsible for the complete
system of the end product, and in particular for the correct installation and compatibility of this engine with the complete
system.
The engine must not be modified.
DaimlerChrysler accepts no responsibility
for damage caused as the result of modifications.
Correct use of the engine includes adhering to these Operating Instructions, adhering to the maintenance intervals and
performing maintenance work correctly in
accordance with these Operating Instructions.

S1034

S1034

iocatron of sensors
Engine plate

S1034

OM 904 LAIOM 924 LA

TOM 904 LA/OM 924 LA


7 )-------------..,..,..,.....-,

2
......

6 )------...."....~-----;,.:,;.
5)------~

41----------'

3)--------'
2 } - - -__-....::..,,-

CDl------......,.....~~

G01.00-3123-31

S1034

CD Fan

Poly-V-belt tensioning pulley

o Coolant pump

@ Charge pressure pipe (with flame-start


system *) from intercooler
Charge pressure pipe to intercooler
@ Crankcase ventilation system
(}) Heating delivery line* coolant line
Oil filler neck
Fuel filter
Fuel prefilter
Dipstick
@ Air compressor (with power-steering
pump*)
@ Engine control unit

S1034

l----------==-~
2

}---------------=~

___

0-----4--

G01.0D-3124-31

S1034

CD Flywheel housing
CD Charge-air housing

Oil filler neck

8) Charge pressure pipe to intercooler

Charge pressure pipe (with flame-start


system*) from intercooler

@ Exhaust manifold

o Oil filter

Exhaust gas turbocharger


Alternator
@ Starter motor

S1034

OM 906

LA/ OM 926 LA

'If OM 906 LA/OM 926 LA

r----------------.
.....

r-------------F.~___::'
01--------~

':::::::==""'""-----~10

-----~11

"------....{12
::!.----~13

GOl.OO-3121-31

S1034

CD

Fan

(3) Poly-v-belt tensioning pulley


@ Coolant pump

o Heating forward line* coolant line

Charge pressure pipe from intercooler

@ Oil filter

o Charge pressure pipe to intercooler

Oil filler neck


Charge-air housing
Cylinder head cover

@
@
@
@
@

Fuel filter
Fuel prefilter
Engine control unit
Air compressor*
Dipstick
Power-steering pump

S1034

2
......

G01.00-3122-31

S1034

CD
CD

o
o

CD

CD

Starter motor
Flywheel housing
Exhaust gas turbocharger
Exhaust manifold
Charge-air housing
Cylinder head cover
Oil filler neck
Charge pressure pipe to intercooler
Charge pressure pipe from intercooler
Crankcase ventilation system
Alternator

S1034

.., Location of sensors


OM 904 LA/OM 924 LA (comparable to OM 906 LA/OM 926 LA)

G01.0D-3127-31

S1034

CD Oil pressure sensor


CD Coolant temperature sensor

o Fuel temperature sensor

G) TOCsensor (on the camshaft sprocket)

Crankshaft position sensor (on the flywheel)

@ Combined charge-air / charge-air pressure sensor

-2

S1034

Engine plate

T Engine plate
Location

The engine plate is located on the righthand side of the engine at the rear underneath the exhaust manifold (arrow).

Location of engine plate

S1034

S1034

T General
Type designation
OM

9XX

L A

Oil engine (diesel engine)

OM

-3

Engine type

9XX
L

Intercooler
A Exhaust gas turbocharger

Engine data card


The engine data card (DIN A4 sheet) forms
an integral part of the documents belonging to the engine and should always be
kept with the Maintenance Booklet. It contains details about the engine's construction, including special equipment features.
The engine data card must be produced for
the procurement of genuine parts.

N01.00-2388-31

Engine data card

e
The engine data card describes the
scope of delivery from the factory from
which the engine was shipped; later
changes to the scope of delivery are
not included on the data card.
Always keep the engine data card with
the Maintenance Booklet.

S1034

Description of the engine


The OM 904 LA/OM 924 LA (4-cylinder)
and OM 906 LA/OM 926 LA (6-cylinder)
engines are water-cooled four-stroke diesel injection engines.
The cylinders are arranged in-line and have
separate fuel-injection pumps (unit
pumps) with a short high-pressure fuelinjection line to the multi-hole nozzle located centrally in relation to the combustion
chamber. The unit pumps are mounted directly on the crankcase. They are driven by
the camshaft roller tappets. Each cylinder
has two inlet valves and one exhaust valve.
The engines are equipped with an exhaust
gas turbocharger (sometimes with chargepressure limiting) and intercooler as standard. The engine can be optionally equipped
with an engine brake* (throttle and constantly-open throttle valves).
Thanks to its fully electronic control system for controlling the injection quantity
and injection timing via solenoid valves,
this is a particularly low-emission engine.

The control system comprises an engineresident control module, an engine control


(MR) and an application-related vehicle
control unit (FR) or an adaptation module
(ADM), all interconnected via the Controller Area Network (CAN).

3
...........

S1034

Flame-start system *

The flame-start system is a cold-start aid


for starting at low outside temperatures. It
reduces the white smoke emission after
the engine is started. In addition, it reduc3 es the strain on the starter motor and bat..... teries by shortening the startup time.
Fuel can be ignited by a flame glow plug integrated in the charge-air pipe from the intercooler. The fuel is supplied to the flame
glow plug via a solenoid valve with a dosing
jet.
854.30-3770-31

Flame-start system

Flame-start system indicator lamp

The flame-start system is primed after a


preglow time (maximum 20 seconds)
which is dependent on the outside temperature. After this time the flame-start system indicator lamp goes out.

The flame-start system is only operational


if the engine is started within 30 seconds
of the flame-start system indicator lamp
going out.

Once the engine has started, the flamestart system is supplied with fuel by the engine's fuel delivery pump.

S1034

Grid heater*
If the flame-start system indicator lamp
does not go out after more than 20 seconds there is a malfunction in the
flame-start system.
See also the "Diesel fuels" section
(I> see page 60) and "Coolant" section
(I> see page 63) for operation of the engine at low outside temperatures.

The grid heater is a cold-start aid for starting at low outside temperatures. The
charge-air is preheated by a heater strip integrated in the charge-air pipe from the intercooler. In addition, it reduces the strain
on the starter motor and battery by shortening the startup time.
The white smoke limit is reduced by a runon heating time of up to 180 seconds after
starting the engine.

S1034

When the engine brake* is applied, the


constantly-open throttle valves are pneumatically pressurised on the 4-cylinder engine and hydraulically pressurised on the
6-cylinder engine. This opens the valves.
At the same time, the engine brake valve
on the exhaust gas turbocharger is closed .

Exhaust brake / constantly-open


throttle valve*
To increase braking power, the engine can
be equipped with an engine brake valve on
the exhaust gas turbocharger in conjunc3 tion with constantly-open throttle valves
...... on the cylinders.

The constantly-open throttle valves are not


controlled at lower engine speeds (900/
1,300 rpm) or at temperatures below
40 "C. When the power unit is being used,
these limitations must be taken into account under braking conditions.

While the exhaust gas back pressure from


the engine brake valve is used to increase
the braking power, the constantly-open
throttle valves cause a pressure reduction
in the working cycle (3rd cycle), while compression (2nd cycle) is practically unaffected.
Constantly-open throttle valves on a 4-cylin-

The constantly-open throttle valves are


small valves in the cylinder head and located on the side opposite the exhaust valve.
When open, they form a connection from
the combustion chamber to the exhaust
port.

der engine

S1034

The engine brake* is controlled by the


drive control unit (I> page 31) or the ADM.
The engine brake* is always disabled below 900 rpm to prevent the engine from
stalling. The engine brake* is also automatically deactivated if the position sensor
is triggered (e.g. if the accelerator pedal is
depressed).

<

In emergency running mode (constant


engine speed), the engine brake* can
only be activated in overrun mode at
a higher engine speed. The engine
brake* is automatically disabled again
once the constant engine speed has
been reached.

Telligent@ engine system


The engine has a fully electronic control
system, which, in addition to the engine
and related sensors, also comprises:
l1li

an engine control unit, and

l1li

a drive control unit and / or other vehicle-specific control units or ADM.

Both are interconnected via a CAN (Controller Area Network) line which exchanges
all the necessary data / information.
The engine control monitors itself as well
as the engine. A safety and emergency running program is selected automatically depending on the malfunctions/failures
occurring (I> page 39).

S1034

Engine control unit (engine-resident)

The engine control unit is located on the


left-hand side of the engine.

This data is evaluated along with data from


the sensors on the engine, such as those
for:
It

charge-air pressure and temperature

It

coolant temperature

It

fuel temperature

oil pressure

These parameters are compared with the


characteristic maps and graphs stored in
the engine control unit.
Start, duration and amount of injection are
calculated from the graphs and the unit
pumps are controlled accordingly via the
solenoid valves.

DaimlerChrysler
Elect. Control Unit
Calibration Nr. ZGS
G)----H6
I 0011
,certification Nr.

,,; I
2

Unit Identif.
Engine Number

~;-:n7,"it-;:c'"o-;d~e------l
4

N07.15-2071-31

Control unit type plate

CD Data record
CD Certification no.

Engine control unit

The engine control unit processes data


coming from the drive control unit or the
ADM, such as the position of the setpoint
value sensor (accelerator pedal), the engine brake* or engine start/stop, etc.

All the information on the control unit


type plate is required to obtain a replacement engine control unit.
The type plate is located on the engine
control unit in the upper right-hand corner.

Engine plate

8) Equipment code

S1034

FR (drive control) unit or ADM


(appliance-resident)

The FR (drive control) unit and the ADM receive data from the

The engine can be adapted to meet the


various application-specific requirements
by means of the FR (drive control) unit or
adaptation module (ADM).

operator (position of setpoint value


sensor, engine start/ stop)

engine brake switch"

other systems (e.g. traction control)

IJI

engine control unit (e.g. oil pressure


and coolant temperature)

From this data, the instructions for the MR


(engine control) unit are computed and
transmitted to it via the CAN line.

N15.00-2089-31

Drive control unit

The FR (drive control) unit or the ADM unit


stores data for specific applications, such
as idling speed, maximum working speed
and speed limitation.

The drive control unit and the ADM control


various displays, e.g. the electronics warning lamp, the engine brake * and the constantly-open throttle valves*.

3
.......

S1034

If the Telligent'" engine system detects a


fault, this is stored as a fault code in the
control units and can be read using the appropriate diagnostic equipment (STAR
DIAGNOSIS or Minidiag 2).

3
_

The Operating Instructions and Maintenance Booklet must be given to the personnel responsible for operating the
engine or carrying out work on the engine,
and should be kept in an easily accessible
place where the engine is used.

In addition, the electronics warning lamp is


switched on.

The DaimlerChrysler diagnostic testers


can be connected to the equipmentresident, 14-pin diagnostic socket.
Both the malfunction memory and the
stored engine data can be read with
this equipment.

N54.22-2015-31

Diagnostic socket

Personnel must be instructed in how to


work on the engine using these Operating
Instructions. In particular, the safety notes
must be explained. This is especially important for personnel who only work on the
engine occasionally.

Organisational measures
Risk of accident and injury

.&.

Before operatingthe engine, please read


these Operating Instructionsand other relevant documentation, such as the operating
instructions for the vehicleor the machine
the engine is installed in.
You could otherwise fail to recognise dangers and could injure yourself or others.

In addition to these Operating Instructions,


the country-specific legal and all other
binding regulations for accident prevention
and protection of the environment must be
observed.

S1034

T Transport and installation


Transport
Risk of accident and injury

Lt.

The engine can tear loose and cause injury


to persons by overturning or falling.
..

Only lift the engine by the appropriate


lifting points on the engine.

..

Only use transport equipment which has


been approved for use by
DaimlerChrysler.

..

Only lift and transport the engine in its


installation position.
G22.00-3101-31

Lifting point, flywheel end

Lifting point, timing end

S1034

Installation
The engine is only designed for installation
in accordance with the specifications determined in the contract.
The manufacturer of the end product is
personally responsible for the complete
..... system of the end product, and in particular for the correct installation and compatibility of this engine with the complete
system.

Observe the "Correct use" (I> page 9) and


"Conversion parts and modifications to the
engine" (l> page 38) sections.
These Operating Instructions contain installation data in the "Technical data" section.
Should you have any questions, please
contact a Mercedes-Benz Service Centre.

The engine is filled with engine oil at


the factory.

S1034

ul"ming program
'i:

"

~~~~-!3~n~ pints
-~1'

.~'

- -,

S1034

Safety precautions

"if' Safety precautions


Make sure that the following safety precautions are observed to prevent injury to
persons as well as damage to the engine,
components and cable harness.

',,'

Only start the engine with securely


connected batteries.

Do not disconnect the batteries


with the engine running.

Only start the engine with the rotational speed sensor connected.

III

Note that for electric welding work,


the batteries must be disconnected
and both connector leads ("+" and
"_") securely connected to each
other.
III

Incorrect polarity of the control unit


supply voltage (e.g. through incorrect battery polarity) can cause irreparable damage to the control
units.

Tighten the connections to the fuelinjection system to the specified


tightening torque.

The control units must be removed


if temperatures over 80C (e.g. in
the drying oven) are expected.

Do not use a rapid charger to start


the engine.
Only perform jump-starting with
separate batteries.
Please note that the battery terminals must be removed for rapid battery charging. Observe the rapid
charger operating instructions.

The control unit connectors must


only be removed or inserted when
the electrical system has been
switched off.

Only use suitable test leads (e.g.


DaimlerChrysler connection set) for
measuring connectors.

Telephones and two-way radios


which are not connected to an external aerial can cause malfunctions to the vehicle's electronics
and could therefore endanger the
engine's operating safety.

S1034

" Personnel qualifications


Engines may only be operated, maintained

Risk of accident and injury


Maintenance and repair work to the engine
incorrectly performed can cause engine
damage and may lead to personal injury as
a consequence.
Maintenance and repair work on the engine
may only be carried out by personnel who
have undergone the appropriate training.
Always have work on or modifications to the
engine carried out at a qualified specialist
workshop which has the necessary specialist knowledge and tools to carry out the
work required.
Mercedes-Benz recommends that you use a
Mercedes-Benz Service Centre for this purpose.

and repaired by trained personnel instructed and authorised by the operator.


Responsibility for operation, maintenance
and repairs must be determined by the operator.
The legal minimum age for carrying out the
work listed above must be observed.

S1034

Conversion parts and modifications


." Conversion parts and modifications
Risk of accident
Tampering with the engine with the intention to produce modifications to it can impair both its correct operation and its safety,
leading to personal injury as a consequence.
Always have work on or modifications to the

4
......

engine carried out at a qualified specialist


workshop which has the necessary specialist knowledge and tools to carry out the
work required.
Mercedes-Benz recommends that you use a
Mercedes-Benz Service Centre for this purpose.

The warranty does not cover damage arising from tampering with the engine.

Tampering with the fuel-injection system and engine electronics can affect
the engine's performance and emissions characteristics. Compliance with
the factory settings and legal environmental protection conditions can then
no longer be guaranteed.

S1034

Safety/emergency running programs

T Safety / emergency running programs


The engine is equipped with an electronic
control system which monitors both the
engine and itself (self-diagnostic system).

Risk of accident

As soon as the electronic control system


has detected and assessed a malfunction,
one of the following measures is automatically implemented:

Incorrectly performed maintenanceand repair work on the engine can impair both its
correct operation and safety, leading to accidents and personal injury as a consequence.

CD

CD

When the engine is in operation, the


electronic system warning lamp lights
up, indicating a malfunction.
The fault codes may be shown on a display which is part of the Telligent'"
engine system (vehicle diagnostic system).
The engine switches to the appropriate
back-up function for continued (but restricted) operation (e.g. constant emergency running speed).

Alwayshavework on or modifications to the


engine carried out at a qualified specialist
workshop which has the necessary specialist knowledge and tools to carry out the
work required.
Mercedes-Benz recommendsthat you use a
Mercedes-Benz Service Centre for this purpose.

o
The fault codes can be read from the
DaimlerChrysler diagnostic testers
(STAR DIAGNOSIS or Minidiag 2 tester), connected to the 14-pin diagnostic
socket (equipment-resident).

N54.30-8279-31

Electronic system warning lamp

S1034

Genuine Mercedes-Benz parts


" Genuine Mercedes-Benz parts
Make sure that the replacement parts are
suitable for your vehicle. Parts which lead
to a vehicle modification, e.g.:

a change in the type of vehicle approved in the General Operating Permit

which could pose a threat to road users, or

cause a deterioration in exhaust gas


emission levels or noise levels,

will result in the invalidation of the General


Operating Permit (in many countries). The
use of non-approved parts can impair safety.

Environmental note
To combine cost-effective repairs with recycling, Mercedes-Benz also offers reconditioned engines and parts. These are of the
same quality andhavethe samewarranty as
new parts.

Additional information about recommended conversion parts and accessories and


permissible technical modifications is
available from any Mercedes-Benz Service
Centre. Always quote the engine plate and
type designation when ordering genuine
parts. You will find the numbers on the engine (I> page 22) and on the engine data
card (I> page 24).

S1034

S1034

Commissioning

'If Commissioning
Topping up with coolant

Preparation
When it leaves the factory, the engine is
filled with engine oil in accordance with
Sheet 228.5 ofthe Mercedes-Benz Service
Product Guidelines.

These high-quality engine oils assist the


running-in process, enabling the first oil
change to take place at the usual oil
change intervals for normal operation. This
eliminates the need for special initial operation oils and the oil change otherwise required.
The extended maintenance intervals can
be observed if engine oils in accordance
with Sheet 228.5 of the Mercedes-Benz
Specifications for Service Products are
used.

Oil filler neck


~

Check the oil level and add engine oil if


necessary via the filler neck (arrow) up
to the maximum mark on the dipstick
(I> see page 71).

Coolant composition (I> see page 63)

It

Filling the cooling system


(I> see page 94).

S1034

Refuelling
Use summer or winter fuel depending on
the season. See also "Diesel fuels"
([> page 60).

Make sure that utmost cleanliness is


observed while refuelling and that no
water is allowed to enter the tank.

Checking the batteries


Risk of explosion
Risk of burning

..

Do not allow acid to come into contact


with your skin, eyes or clothing.

..

Wear suitable protective clothing, as


battery acid can burn through normal
clothing. In addition, protective gloves
and safety goggles should be worn.

Bleeding the fuel system


The fuel system is bled when the engine is
started after refuelling if the fuel system
was previously allowed to run dry. Continuous bleeding takes place automatically in
the filter.

o
To ensure that the fuel system can be
bled, the battery must have enough
charge when the engine is started.

Gases escaping from batteries can explode


and injure people.

The acid contained in batteries burns skin


and eyes on contact.

..

Rinse acid splashes off immediately with


clean water and consult a doctor if necessary.

Therefore, do not allow fire, naked flames,


smoking or the creation of sparks in the vicinity of batteries.

Only use batteries which are completely


filled and have been perfectly maintained.
Grease the battery terminals with acidproof grease (terminal grease).

fa

The cable cross-sections are depend\, ent on the distance between the battery and the starter motor.

S1034

Starting the engine for the first time

As a safety feature, the Telligent@ engine system is equipped with a function


that only allows the engine to be started with the transmission in neutral.

Carry out the work listed under "Preparation for commissioning" (I> page 42) before operating the engine for the first time.
~

Switch on the operating current.

Start the engine with the setpoint value


sensor at idling position (e.g. accelerator pedal), for instance by operating the
starter switch on the equipment or
Start button CD on the engine,
(I> see page 47).

Risk of burns
The engine becomes very hot while it is running and remains so for some time after it
has stopped. It will cause burns if you touch

it.
Before starting any work on the engine, al-

Start-Stop buttons

low all engine parts to cool down or else

CD Stop button

wear suitable gloves and items of clothing to

(3) Start button

protect yourself against hot engine components.

S1034

Risk of injury

Risk of scalding

Risk of poisoning

There is a danger of limbs being caught, en-

The cooling system is pressurised. Hot cool-

There is a risk of poisoning if coolant is swal-

trapped, crushed or torn off by rotating engine parts. Therefore you should:

ant can spray out when the cooling system

lowed.

is opened and scald your skin and eyes.

..

Keep a safe distance between yourself


and rotating engine parts, including
when the engine is being started.

..

Only open the cooling system at coolant


temperatures below 90 G.

..

..

Wait until all engine parts have come to


a standstill before carrying out any work
on the engine.

Unscrew the sealing cap slowly and release any excess pressure completely
before opening the cap fully.

..

..

Wear work clothing which is fastened


and close-fitting. Wear a hair net if necessary. Remove jewellery such as
watches and necklaces.

Wear suitable protective gloves, protective clothing and safety goggles when
handling coolant.

It
It

Never swallow coolant.


Never put coolant into container normally used for beverages.
Store coolant out of the reach of children.

~ To check the coolant level:

5
.........

Leave the engine running at moderate


speeds for approximately 5 minutes.
~

If the coolant temperature is below


50 C, check the coolant level again
and add coolant if necessary.
0

1>1>

S1034

If a heating system is connected to the


cooling system, all heating system
valves must be opened while the cooling system is being topped up.
:.~
'~!f

5
......

Otherwise there might be too little


coolant in the cooling system after filling.

Only close the heating system valves once


the engine has been running for a brief period. Top up with coolant if necessary.
~

Check the engine for leaks.

Check the hose fittings, hose clamps


and pipe connections on the engine as
well as the oil feed and return lines on
the exhaust gas turbocharger for leaks
and firm seating, and tighten if necessary.

Check the engine oil level approximately 5 minutes after stopping the engine
and add oil up to the maximum mark on
the dipstick if necessary.

Check for firm seating of mountings on


the engine.

Check the securing bolts on the exhaust manifold, engine mountings,


coolant pump, starter motor and air
compressor for firm seating.

S1034

Starting the engine


Risk of injury

;1!j

started, knocking people down or trapping

Starting procedure

them. Before starting the engine:

Prevent the vehicle from rolling away by


applying the parking brake and, if necessary, by placing chocks under the
wheels.
Shift the transmission into neutral.

~?

In the case of vehicle engines, secure the


vehicle to prevent it from rolling away accidentally:
~

Apply the parking brake.

Shift the transmission into neutral.

Place wheel chocks in front of or behind the wheels.

Insert the key into the ignition and turn


it to the driving position.
The following indicator and warning
lamps light up:

, 0

f.j

m~

I
~I

~
~~

temperature~

At outside
below -30C
we recommend preheating the coolant
(~.g. using an electric preheating device)

dentally be set in motion when the engine is

I."

If not properly secured, a vehicle might acci-

If!.:

Starting the engine for the first time


([> see page 44).
Carry out special measures before
starting the engine when it has been
stopped for a long period, see the
"Cleaning/protective treatment" section (I> page 55).

G54.3G-3771-31

CD Charge current indicator lamp


Electronic system warning lamp
Flame-start system indicator lamp or
grid heater
Start the engine within 30 seconds of the
flame-start indicator lamp going out.

c-r-

S1034

o
Keep the engine running at idling speed
until an oil pressure reading is displayed. If no oil pressure is displayed
after approximately 10 seconds,
switch off the engine. Determine the
cause; see the "Oil pressure" section
(I> page 51).

....

!i~

\~

Start-Stop buttons

CD Stop button
CD Start button
~

using the starter switch on the equipment

~ using Start button


~

CD on the engine.

Monitor the oil pressure gauge immediately after starting the engine.

The indicator lamp for the flame-start


system lights up for approximately
2 seconds (function check, flame-start
system not in operation) to approximately 20 seconds (maximum preglow time)
depending on the outside temperature.
If the indicator lamp for the flame-start
system does not go out after approximately 20 seconds, there is a fault; see
the "Telligent@ engine system" section
(I> page 50).

If necessary, break off the starting


procedure after a maximum of 20 seconds, and then repeat after approximately 1 minute.

The charge current indicator lamp and


electronic system warning lamp must
go out after the engine has started. If
they remain on, there are malfunctions;
i~ (I> see page 49) and (I> page 50).
~~

11

Ii ~

grid heat" ;, controlled by the drive


control unit or the ADM control unit. The
preglow time lasts for approximately
~ 30 seconds and depends on the temperature of the coolant and the charge air.
During the preglow time, the indicator
lamp lights up and then goes out once the
preglow time has finished.

At extremely cold temperatures, do not


place the cold engine under a full load immediately after starting.

S1034

.. Monitoring engine operation


Charge current
The charge current indicator lamp must go
out after the engine has been started.

It.l
;

iI
~

Th, poly-v-belt contact surfaces must

;~~~~.damaged (e.g. torn), oily or


Do not run the engine without a poly-Vbelt since the alternator and coolant
pump will not be driven. This will result
in engine damage.

N54.30-8281-31

Charge current indicator lamp

If the indicator lamp does not go out or


lights up when the engine is running, stop
the engine and check the poly-V-belt.

S1034

Telligent@ engine system


The electronic system warning lamp must
go out after the engine has been started.

The fault codes may be shown on a display


which is part of the Telligent@ engine system (vehicle diagnostic system).

Flame-start system*

Fault codes can be read using


DaimlerChrysler diagnostic equipment
(STAR DIAGNOSIS or Minidiag 2-Tester),
(I> see page 31). If the electronic system
warning lamp lights up while the engine is
running, read or determine the fault code.

Flame-start system indicator lamp

.....
N54.30-8279-31

Electronic system warning lamp

If the warning lamp does not go out or


lights up while the engine is running, there
is a fault in the Telligent@ engine system.
Each fault is stored in the system with a
special fault code. Even temporary faults
are stored.

There is a fault in the flame-start system, if:

the flame-start system indicator lamp


lights up when the engine is running

CD

the flame-start system indicator lamp


does not go out after more than approximately 20 seconds when the engine is started

S1034

Have the flame-start system checked at a


specialist workshop. DaimlerChrysler recommends that you visit a Mercedes-Benz
Service Centre for this purpose as it has
the necessary specialist knowledge and
tools to carry out the work required.

,
~j

~1 The flame-start system switches off au-

tomatically, if:

III'~-: .
"I

the engine is not started within


30 seconds of the flame-start system indicator lamp going out

f"'"

lID

I~

fi

the charge current indicator lamp


does not go out when the engine is
running

the engine reaches a temperature


at which the flame-start system is
no longer needed

II.~t:.~

the engine is started while the

~~~I~;start system indicator lamp is

Grid heater*

Oil pressure

Once the operating temper ature has


been reached, the engine oil pressure
must not fall below:

2.5 bar at rated speed

lit

0.5 bar at idling speed

If the pressure falls below these values,


stop the engine and determine the
cause.

S1034

Stopping the engine

"f' Stopping the engine


~

After driving at full power output or at a


high coolant temperature, allow the engine to idle without load for one or two
minutes.

CD on the engine or
on the equipment-resident stopping facility.

~ Press Stop button

Stop the engine immediately if you observe any of the following signs:

Start-Stop buttons

CD Stop button
CD Start button

CD

oil pressure drops or fluctuates


considerably

CD

power and speed drop while the position sensor (accelerator pedal position sensor) stays in the same
position

large amounts of exhaust smoke


are emitted from the exhaust

CD

coolant and oil temperature increase very quickly

CD

unusual noises suddenly occur in


the engine or exhaust gas turbocharger

S1034

Y Winter operation
The following notes should be observed at
the start of the cold season:

Fuel

Risk of fire

Coolant
Risk of poisoning
Risk of scalding
The cooling system is pressurised. Hot coolant can spray out when the cooling system
is opened and scald your skin and eyes.

There is an increased risk of fire when handling fuels as they are highly flammable.

"

Avoid fire, naked flames, and sparks and refrain from smoking when handling fuels.

"

Unscrew the sealing cap slowly and release any excess pressure completely
before opening the cap fully.

"

Wear suitable protective gloves, protective clothing and safety goggles when
handling coolant.

Use cold-resistant diesel fuel


(I> see page 60).
Engine oil
When changing the engine oil, select an
engine oil that is compatible with the SAE
class and the ambient temperatures expected during the period of use
(I> see page 62).

Only open the cooling system at coolant


temperatures below 90 "C.

There is a risk of poisoning if cool ant is swallowed.


..

Never swallow coolant.

Never put coolant into container normally used for beverages.

..

Store coolant out of the reac h of children.

Check the coolant's antifreeze protection


in good time and increase the antifreeze/
corrosion inhibitor concentration if necessary (I> see page 63).

5
........

S1034

Batteries
Have the batteries serviced and recharged
more frequently during the cold months of
the year.

Risk of acid burns


The acid contained in batteries burns skin
and eyes on contact.

5
.....

..

Do not allow acid to come into contact


with your skin, eyes or clothing.

..

Wear suitable protective clothing, as


battery acid can burn through normal
clothing. In addition, protective gloves
and safety goggles should be worn.

..

Rinse acid splashesoff immediately with


clean water and consult a doctor if necessary.

Risk of explosion
Gases escaping from batteries can explode
and injure people.
Therefore, do not allow fire, naked flames,
and the creation of sparks and do not smoke
in the vicinity of batteries.
Careful maintenance and low power consumption will help maintain the full battery
charge. Starting capacity is greatly reduced in cold weather; for example, at
-10 DC it is only about 60% of normal capacity. If the engine is not used for a long
period of time, store the batteries in a
heated place if possible. Ensure good ventilation when recharging.

S1034

V Cleaning/protective treatment
Cleaning the engine
Risk of fire and injury

Risk of poisoning
Care and cleaning agents can be toxic and
lead to severe poisoning if swallowed.

Always keep care and cleaning agent


containers closed and out of the reach
of children.
Never store care or cleaning products in
foodstuff containers such as bottles so
as to avoid confusion with foodstuffs.
Observe the instructions for using care
and cleaning products.

Make sure that water does not enter


the intake, ventilation or bleed ducts.

Fuels are highly flammable and can injure


your health. If they are used as cleaning
agents, they can cause fires or skin irritation

Protect the engine after cleaning. Be


careful to protect the belt drive against
preservative agents.

and poisoning.
Never use fuels for cleaning.

~I 0

I:~:~~~~e;;:~:~:;_~~~~~:~;~:b~e," -f:"

Environmental note
Observe the regulations for environmental
protection.
Only clean the engine in a washing area designed for this purpose. Dispose of empty
packaging and used cleaning materials in an
environmentally-responsible manner.

Information about suitable cleaning

S1034

High-pressure cleaners

Cleaning the cooling system


Risk of scalding

Observe the manufacturer's operating instructions.

Environmental note
Collect used coolant, cleaning solutions and
detergents and dispose of them in accordancewith current local regulations and in an
environmentally-responsible manner.

Maintain the minimum distance between the high-pressure cleaner nozzle


and the object to be cleaned:

.~

..

approximately 70 cm for roundspray jets


approximately 30 cm for 25 a flatspray jets and concentrated-power
jets

Keep the water jet constantly moving


while cleaning. To avoid damage, do
not aim the water jet directly at:

I::::~::::~,:ompo"e"ts
if

I.

hoses

Information about suitable cleaning and


preservative agents is available from any
Mercedes-Benz Service Centre.

.I
~.:

illJ

Blowout any foreign objects (dust, insects, etc.) from the radiator fins using
compressed air or remove by spraying
water on the rear side of the radiator
(against the direction of the cooling air
flow).

The cooling system is pressurised. Hot coolant can spray out when the cooling system
is opened and scald your skin and eyes.
e

Only open the cooling system at coolant


temperatures below 90C.

Unscrew the sealing cap slowly and release any excess pressure completely
before opening the cap fully.

Wear suitable protective gloves, protective clothing and safety goggles when
handling coolant.
1>1>

~ppl~mOdtehrated~retssuf:e

lnly
when
c earnng since e ra ra or ms cou ld
otherwise be damaged.

S1034

C>C>~ Drain off coolant when the engine is

cold (I> page 95).


~

Degreasing
~

Fill the cooling system with a 5% solution of water and a mild alkaline cleaner, e.g. "P3 Croni" (50 g cleaning agent
per litre of water).

Warm up the engine at moderate engine speed up to approximately 80 DC


(coolant thermostat starts to open) and
allow to run for approximately 5 minutes longer.

If a heater is attached to the cooling


system, open the regulating valves fully.

Risk of poisoning
There is a risk of poisoningif coolant is swallowed.
..

Neverswallow coolant.

.. Neverput coolant into container normally used for beverages.


II

Store coolant out of the reach of children.

~ Switch off the engine and allow to cool

to approximately 50 DC.
~

Drain off the cleaning solution completely.

~ Immediately afterwards, fill the cooling

system
engine,
5 more
cedure
~

with clean water, warm up the


and drain off the water after
minutes. Then repeat the proa second time.

Fill the cooling system with new coolant (l> page 96) and follow the instructions in the "Coolant" section
(f> page 63).

S1034

Protective treatment
The special protection required will depend on the length of time the engine is to
be out of use as well as the climate of the
place where the engine is to be located or
stored.

After cleaning the engine, store it in a dry,


well-ventilated place as far as possible. If
this is not possible, the intervals for carrying out regular protective measures must
be halved.
It is essential that the engine be protected
from direct contact with water (rain/spray
water).
If the engine is to be out of use for less
than 12 months and the above conditions
are met, no corrosion-protection measures
need to be taken.
If the engine is to be out of use for more
than 12 months and there are exceptional storage and transport conditions, special protective treatment
measures are required.

Information is available from any


Mercedes-Benz Service Centre. We strongly recommend asking for information.

S1034

" Service products


Risk of poisoning/injury

.&

Service products can cause injury or poisoning if they come into contact with skin or are
swallowed.
Observe the prevailing regulations when
handling service products and storing and
disposing of them. Service products could
otherwise endanger people and the environment.
e

Always wear appropriate protective


clothing and a breathing mask when
handling service products. If possible,
avoid inhaling vapours.
Do not allow service products to come
into contact with your skin, eyes or
clothing. Clean affected areas of skin
with soap and water.

If service products do come into contact


with your eyes, rinse off thoroughly with
clean water and consult a doctor if necessary.
Consult a doctor immediately if a service product is swallowed.
Keep service products out of the reach
of children.

Special lubricant additives are not necessary. The warranty entitlement may be restricted if special lubricant additives are
used.

e
Information is available from any
Mercedes-Benz Service Centre.

Environmental note
Risk of fire
There is an increased risk of fire when handling fuels and lubricants as they are highly

Dispose of service products as well as parts


which come into contact with service products, e.g. the filter, in an environmentally-

flammable.

responsible manner.

Avoid fire, naked flames, and sparks and re-

Observe the legal requirements.

frain from smoking when handling service


products.
Greases and lubricants must be compatible with engine components. For this reason, only brands that have been tested and
approved by DaimlerChrysler should be
used. These are listed in the MercedesBenz Specifications for Service Products.

S1034

Diesel fuels
Only use commercially available vehicle
diesel fuels (EN 590). Grades such as marine diesel fuel, heating oils, etc. are not
permitted.
Fuel additives are not necessary. The warranty entitlement may be restricted if fuel
additives are used.
If diesel fuels with a sulphur content above
0.3% by weight are used, carry out an oil
5 change at shorter intervals. Observe the
....... information provided in the Maintenance
Booklet.
Filling the vehicle's fuel tank from drums or
canisters may introduce impurities into the
fuel system. This can lead to fuel system
malfunctions. Therefore, filter the fuel
when filling the tank.

The 900 series engines are suitable for use


with FAME fuels in accordance with
DIN E 51606. If you do so, you must consult a Mercedes-Benz Service Centre to
have the exact operating procedures (e.g.
maintenance intervals) explained.

Diesel fuels in extremely cold weather


At low outside temperatures, paraffin sep-

aration may affect the flow characteristics


of diesel fuel.
To prevent operating problems (e.g. as a
result of blocked filters), diesel fuel with
improved cold flow properties is available
on the market in the winter months. Deviations may be possible in the transition between the cold and the warm seasons, and
in other countries. In Germany, special
cold-resistant winter-grade diesel fuels are
sold. They ensure reliable operation down
to approximately -20C. Winter-grade diesel fuel can normally be used without risk
of malfunctioning at the outside temperatures expected in the country of sale.

S1034

If summer diesel fuel or winter diesel fuel


with less resistance to low temperatures is
used, only add a specific quantity of flow
improver or kerosene, depending on the
outside temperatures.

Risk of fire and explosion

it.

Adding petrol reduces the flash point for the


dieselfuel and increases the risk of fire and
explosion.
.. Therefore, neveradd petrol to diesel
fuel.
..

For this reason, you must avoid fire, naked flames andsparks and refrain from
smokingwhen handling these service
products.

..

Observe the relevant safety regulations.

Flow improvers
If petrol is added, there is a risk of serious engine damage.
Therefore, never add petrol to diesel
fuel.
Add the flow-improver additive to the diesel fuel in good time, before paraffin separation affects the diesel's flow properties.
Malfunctions caused by paraffin separation can only be remedied by warming up
the entire fuel system.
Do not add additives to especially coldresistant winter diesel fuels, as the fuel's
cold-flow properties could deteriorate.

The effectiveness offlow improvers cannot


be guaranteed with all fuels. Comply with
the manufacturer's recommendations. Information about approved flow improvers
is available from any Mercedes-Benz Service Centre.

Kerosene
Add as little as possible, depending on outside temperatures. The addition of 5% by
volume of kerosene improves the coldresistance of diesel fuel by approximately
1C. Do not exceed the maximum mixing
ratio of 50% kerosene.

S1034

For safety reasons, only mix kerosene with


diesel fuel in the fuel tank. Add the kerosene first, then the diesel fuel. Run the engine for a while to ensure that the additive
reaches all parts of the fuel system.

Risk of fire and explosion

.&.

Adding kerosene reduces the flash point of


the diesel fuel and increases the risk of fire
and explosion.

s
....

..

..

For this reason, you must avoid fire, naked flames and sparks and refrain from
smoking when handling these service
products.
Observe the relevant safety regulations.

Engine oils

+;;'t+~o
+77

.................................

.. +25

+66 ',+20

+ 59

' + 15

:::1:

+32

.+

- 13

25

:~~::"l:~~
.-l~l:
!

Engine oil SAE classes

Engine oils are specially tested for suitability in our engines. Therefore, only use engine oil brands approved by MercedesBenz. These are listed in the MercedesBenz Specifications for Service Products.
Observe the information provided in the
Maintenance Booklet.

II
l'~

8h
T e use 0 f non-approve d enzine
engme oil
01
brands can restrict the warranty entitlement.

S1034

engine oils of a different grade are used,


Ie oil change intervals will alter. InformaIn is available from any Mercedes-Benz
ervice Centre. Select the SAE class of enne oil in accordance with the outside
.rnperatures.
fter maintenance work, the engine oil
lange is entered in the Maintenance
ooklet along with the engine oil brand,
"ade and SAE class.
nly use engine oils of the same grade and
!\E class when topping up.

o
If engine oil of a lower grade is used to
top up, the properties of the engine oil
are impaired and the engine oil and filter changes must therefore be carried
out at shorter intervals.

Coolant

Water

Risk of poisoning

Water without additives is not permitted as


a coolant, even if antifreeze properties are
not necessary.

There is a risk of poisoningif coolant is swallowed.


Never swallow coolant.

The coolant water must satisfy certain requirements which are not always fulfilled
by drinking water.

..

Never put coolant into container normally used for beverages.

If the water is not of sufficient quality, it


must be treated.

..

Store coolant out of the reach of children.

Information is available from any


Mercedes-Benz Service Centre.

II

The coolant is a mixture of water and antifreeze/corrosion inhibitor. The coolant


must remain in the cooling system all year
round to ensure anti-corrosion protection
and to increase the boiling point.

o
Renew the coolant every three years,
since the level of corrosion protection
~ gradually decreases.

I
~.;.~

.!...

S1034

Antifreeze/corrosion inhibitor
To prevent damage to the cooling system:
e

....

Only use approved antifreeze/corrosion inhibitor. Information is available


from any Mercedes-Benz Service Centre.
When topping up (after coolant loss),
make sure that the antifreeze/corrosion inhibitor concentration is 50% by
volume (this ensures antifreeze protection down to -37 DC).

If the concentration is too low, there is


a risk of engine damage as a result of
corrosion/cavitation.
e

Do not use an antifreeze/corrosion inhibitor concentration of over 55% by


volume (maximum antifreeze protection). Above this concentration, antifreeze protection deteriorates and heat
dissipation is less effective.

Coolant mixing ratio:


Antifreeze
protection
down to

Disposal

-37 DC

approximately
-45 DC

Water % by vol.

50

45

Antifreeze/ corrosion inhibitor


% by vol.

50

maximum
55

Environmental note
The coolants mentioned are biodegradable
substances. When disposing of used coolants, observe the legal requirements and
waste water regulations in the country concerned.
We recommend that you ask the relevant

In exceptional cases, when no antifreeze/


corrosion inhibitor is available and/ or no
antifreeze protection is required (in tropical regions), use an approved coolant
additive without antifreeze properties in
accordance with Sheet 312.0 of the
Mercedes-Benz Specifications for Service
Products (e.g. MB corrosion inhibitor
A 000 98913 2510 by DaimlerChrysler AG
or an approved additive from another manufacturer).

In this case, the coolant must be renewed every year.

water authority for advice on the disposal of


coolant.
Due to the complex tasks which a modern
coolant must perform, improper "recycling"
consisting simply of a mechanical pre-cleaning must be emphatically rejected.

S1034

Work plans

S1034

.. Maintenance instructions
This section describes all maintenance
work which concerns the engine.

Risk of accident
Before any maintenance work or repairs are
carried out, please make sure that you read
the relevant sections of the technical documentation concerned with servicing and repairs, for example:
..

Operating Instructions and workshop information

Risk of accident
Faulty maintenance work or failure to carry
out maintenance work, e.g., not changing
the oil filter or not observing the correct
maintenance interval, can cause engine
damage. Enginedamage can lead to an increased risk of accident.
For this reason, please observe the instructions on servicing the engine given in these
Operating Instructions.

Youshould alsofamiliarise yourselffirstwith


the legal requirements, for example:
..

work safety and accident prevention


regulations

You could otherwise fail to recognise dangers and could injure yourself or others.

The scope of maintenance and frequency


of maintenance work depend on the different operating conditions and are listed in
the Maintenance Booklet.
Have the work which is carried out confirmed in the Maintenance Booklet. This
proof of regular maintenance is always required for any warranty claims.
Also observe the maintenance regulations
for special accessories.

~"

II

The engine oil filled at the factory in

., accordance with Sheet 228.5 of the

All maintenance intervals and maintenance work refer to genuine MercedesBenz parts and accessories specifically
approved for the engine by
DaimlerChrysler.

":' Mercedes-Benz Specifications for Service Products must be changed if more


".~ than 12 months elapse before the en,:' gine is operated for the first time.

i!

S1034

Y Overview of work plans


Maintenance service
Engine:
Oil change and filter replacement

Change the engine oil and replace the


oil filter at least once a year.
Poly-V-belt: Check condition

Checking for leaks and general condition


Check for points of abrasion and incorrect
positioning:
Engine
Lines and hoses on the engine
Intake pipe between air cleaner and engine
Cooling and heating system

Checking and correcting the fluid level


If more fluid is lost than can be accounted
for by normal consumption, trace the
cause and rectify.
Engine cooling system:
Check and correct fluid level and
antifreeze / corrosion inhibitor concentration

Additional work

Additional work during every


3rd maintenance service
Fuel prefilter: Clean filter element
Fuel filter: Replace filter
Fuel prefilter with water separator:
Replace filter element
Engine brake*: Check condition and
setting
Renew coolant

Check and adjust valve clearance

The valve clearance must be adjusted


during the first maintenance service
and then during the 3rd, 5th, 7th maintenance services and so on.

Renewal interval depends on the coolant additive used (see Mercedes-Benz


Specifications for Service Products).

--

S1034

Engine: Checking for leaks and


general condition
~ Visual inspection of the engine for

signs of leakage.
Sealing points which are slightly damp are
harmless.

I ~emedy

.signifi~antle~ks

more
involvling constant ali loss Immediately.

lines and hoses on the engine:


Checking for leaks and general
condition
~ Make a visual inspection of lines and

hoses. Also make a listening check for:

leaks

check for undamaged condition

chafe-free routing and

correct mounting

Risk of burns

The engine is very hot when it is running and


also for some time after it has been switched off. It may cause burns if you touch it.
Before starting any work on the engine, allow all engine parts to cool down or else
wear suitable gloves and items of clothing to
protect yourself against hot engine components.

Risk of injury
There is a danger of limbs being caught, entrapped, crushed or torn off by rotating engine parts. Therefore you should:
..

Keep a safe distance between yourself


and rotating engine parts, including
when the engine is being started.

..

Wait until all engine parts have come to


a standstill before carrying out any work
on the engine.

..

Wear work clothing which is fastened


and close-fitting. Wear a hair net if necessary. Removejewellery such as
watches and necklaces.

S1034

Engine: Oil change and filter


replacement

.. a

~~
j

,ill

It~~

'U'

Only change engine oil when the engine


is at normal operating temperature.

Risk of scalding
Hot engine oil spraying out can scald your
skin and eyes.
Wear suitable protective gloves, protective
clothing and eye protection.
~

G1B.20-3113-31

Oil filter cap


Remove the oil filter cap using the
socket spanner insert (WAF 36). Allow
oil to drain from the filter housing.
Unscrew cap

CD and oil filter element

@ and remove element @ from the


cap by pressing the lower edge on the
sides.

Make sure that no foreign objects enter


the filter housing. Never wipe the filter
housing out.

S1034

~ Screw the cap on the oil filter housing

and tighten it
Tightening torque: 25 Nm.

Extracting and draining the engine oil

Extraction:
~

Extract the engine oil through the dipstick guide pipe. To do this, pull out the
dipstick and insert the scavenging device sealed with an a-ring into the
guide pipe.

N18.20-2045-31

......

Cap with oil filter element

Dipstick guide pipe

CD Cap

o Sealing ring
(}) Oil filter element
~ Replace the sealing ring on cap
~

[I

0.

Insert new filter element in the cap and


clip it into place by pressing on it.

Observe 'he operating ;""'UC';o", for


the engine oil scavenging device.

S1034

Draining:
~

Place a suitable collecting receptacle


under the drain plug on the underside
of the oil sump.
Unscrew the drain plug carefully and allow the oil to drain out.

Environmental note
Dispose of engine oil and filters in accordance with the regulations in force at the
place of use of the engine.

Renewing:
~ Screw the drain plug back in with a new

sealing ring and tighten.


Tightening torque:
M20 x 1.5 - 60 Nm
M26 x 1.5 - 85 Nm
~ Add new engine oil into the engine via

the oil filler neck up to the maximum


mark on the dipstick.

G18.00-3114-31

Oil drain plug

Oil filler neck

1>1>

S1034

>1> ~ Start the engine with the setpoint value


sensor in the idling position. Monitor
the oil pressure gauge.

I~:.'~.,: ~~~i:~:~":;~::uu,~";~:d~~~:~"~i:~eed
I
i

played. If no oil pressure is displayed


. after approximately 10 seconds, switch
off the engine and establish the cause.

6
......

Check the filter and drain plug for


leaks.

Stop the engine. Check the oil level after approximately 5 minutes. Top up oil
to the maximum mark on the dipstick if
necessary.

S1034

Adjusting the valve clearance

Special tools
Rotation device: 904 589 04 63 00
Valve clearance:

Risk of injury
If not properly secured, a vehicle might accidentally be set in motion, knocking people

Inlet valves

0.40 mm

down or trapping them and otherwise caus-

Exhaust valve

0.60 mm

ing an accident and injuring you or others.

Adjust the valve clearance when the


engine is cold (at least 30 minutes after
the engine was stopped, even if it was
only operated for a brief period).
~.

G01.00-3128-31

Layout of cylinders and valves

inlet valve

..

exhaust valve

flywheel end

Clean very dirty cylinder head covers


before removing.

Always secure the vehicle against rolling


away by applying the parking brake and,
if necessary, by placing chocks under
the wheels.

Shift the transmission into neutral.

Only turn the engine over using the rotation device provided for this purpose.

S1034

Removing and fitting the cylinder head


cover

Removing:
~ Remove engine breather hose

@ from

the cylinder head cover.

from the cylinder head cover together with sealing


washers @.

~ Unscrew Allen bolt

~ Remove cylinder head cover

0.

Fitting:
~

Clean the cylinder head and the cylinder head cover sealing surfaces.

Check the gasket between the cylinder


head cover and charge-air manifold
and replace if necessary.

CD

G01.20-3100-31

CD Charge-air manifold

Always replace the gasket between the


cylinder head cover and the cylinder
head.

Position the cylinder head cover.

o Cylinder head cover


Allen bolt

@ Sealing washer

Cover seal
@ Engine breather hose

with new sealing


washers @ and tighten
Tightening torque: 30 Nm.

~ Fit Allen bolts

Flywheel housing inspection hole


~

Fit rotation device (904 589 04 63 00)


on the flywheel housing inspection
hole.

S1034

Adjusting the valve clearance


Engine

OM 904/924 LA

Crankshaft position

4th cylinder valve overlap

Cylinder /valves to be adjusted

liE

1st cylinder valve overlap


OM 906/926 LA

6th cylinder valve overlap


1st cylinder valve overlap

liE

liE
liE

I - inlet valve
E - exhaust valve

Adjust all valve clearances in 2 crankshaft


positions.
~

Use the rotation device to turn the


crankshaft until no. 4 or 6 cylinder is at
overlap TDG (no. 1 cylinder at ignition
TDG). Then turn no. 1 cylinder to overlap TOG (no. 4 or 6 cylinder at ignition
TOG).

Check the valves in accordance with


the above table and adjust.

S1034

Checking and adjusting the valve


clearance

Measure the valve clearance between


the rocker arm and valve stem (exhaust
valve) or valve bridge (inlet valve) with
a feeler gauge (arrow).
It must be possible to pull the feeler
gauge through with only light resistance.

CD to adjust the
valve clearance. Adjust the valve clearance by turning adjustment screw CD.

~ Slacken counternut

~ Retighten the counternut.

Tightening torque: 25 Nm.


~ Check the valve clearance again and

readjust if necessary.

CD Adjustment screw
CD Counternut

Concluding work
~

Refit the cylinder head cover


(I> see page 74).

Remove the rotation device from the


flywheel housing inspection hole.

S1034

Fuel prefilter: Cleaning the filter


element

,,--,~-0

G07.57-31 00-31

Fuel prefilter

CD Cap

o Filter element
Sealing ring

Risk of fire

Environmental note

There is an increased risk of fire when handling fuels as they are highly flammable.

Dispose of used filter elements and fuel residue in accordance with current local regulations.

Avoid fire, naked flames and sparks and refrain from smoking when handlingfuels.

~ Check sealing ring


~

Open the tank cap to remove excess


pressure in the fuel tank.

Clean the outside of the fuel prefilter


and cover any hoses / lines under the
prefilter.

Unscrew cap CD and pull it out of the


filter housing together with filter
element 0.

~ Clean cap

CD and filter element 0.

Replace the filter element if it is very dirty


or damaged.

for the cap and

replace if necessary.
~

Insert the filter element in the cap and


screw the cap onto the filter housing.
Tightening torque: 25 Nm.

S1034

Fuel prefilter with heated water


separator*: Replacing the filter
element

Risk of fire

Environmental note

There is an increased risk of fire when handling fuels as they are highly flammable.

Dispose of used filter elements and fuel residue in accordancewith current local regulations.

Avoid fire, naked flames and sparks and refrain from smoking when handling fuels.
~

Open the drain valve and loosen the


vent screw. Collect the fuel/water
mixture from the filter element in a
suitable receptacle.
Remove the heater connector.

~ Unscrew the filter element.

N07.0Q-Z096-31

Fuel prefilter with heated water separator*

CD Hand pump
CD Filter housing

CD Water separator (heated)


@

Water drain valve

Remove the separator vessel from the


filter element and clean or replace as
necessary.

Refit in the reverse order. Use new


sealing rings when fitting.

1>1>

S1034

>

Screw the filter element onto the filter


head tightly by hand.
~

Close the drain valve and fill the prefilter using the fuel hand pump. Then
close the vent screw.

Start the engine and bleed the fuel system.

Leave the engine running for approximately 1 minute. The fuel system
bleeds automatically.
~

Check the pre-filter for leaks.

S1034

Replacing the fuel filter element

&

Risk of fire

There is an increased risk of fire when handling fuels as they are highly flammable.
Avoidfire, nakedflames and the creation of
sparks refrain from smoking when handling
fuels.
~ Open the tank cap to prevent excess

pressure in the fuel tank.


~ Unscrew fuel filter cap

CD

0-<::::>

CD

with the
socket spanner insert (WAF 36).

6
Fuel filter

CD Cap

o Filter housing

CD

Pull cap
and filter element slightly
out of filter housing 0. Allow fuel to
flowout.

G47.20-3119-31

CD Cap

o Sealing ring

o Filter element
8) Dirt trap

Filter housing
C>C>

S1034

>

Remove the cap and filter element. Unclip filter element 0 by pressing the
lower edge of the filter element on the
sides.

If the level of the diesel fuel in the tank


is higher than the level of the engine,
the feed line must be closed when replacing the filter.

Pull dirt trap @ out of the filter housing


by the tabs.

Neither dirt nor water should enter the


filter housing; do not empty dirt trap @
into the filter housing.

CD and dirt trap @.


Replace sealing ring 0.
Clip new filter element 0 into cap CD.

~ Insert dirt trap

Check the fuel filter for leaks with the


engine running.

and the

filter element seals.

@ into filter housing

0; observe the correct installation position.

~ Clean cap
~

The diesel fuel could flow out.


~ Lightly grease sealing ring

Leave the engine running for approximately 1 minute. The fuel system
bleeds automatically.

Screw on cap and filter element and


tighten.
Tightening torque: 25 Nm.

Start the engine and bleed the fuel system.

To ensure the fuel system can be bled,


the battery must have enough charge
when the engine is started, since the
fuel system must fill up with fuel first.

S1034

Intake pipe between air cleaner and


engine: Checking for leaks and
general condition
~

Check the rubber sleeves, intake pipe


and connection hoses for damage and
leaks.

Check the hose clamps, flanged joints


and intake manifold for firm seating.

S1034

Risk of injury

I! ~Place

Faulty poly-V-belts may tear and parts or all

Poly-V-belt: Checking the condition

the poly-V-belt if one of the


damage patterns shown on the next
~ page is detected. For information on in~
stalling and removing the poly-V-belt
lii! (I> see page 86).

of the belt may be thrown off, thereby caus-

ing injury to persons.


CII

Always observe the specified maintenance intervals for poly-V-belts.

CII

If damage is detected, replace the polyV-belt concerned immediately.

Remove the rotation device.

Special tools

Rotation device: 904 589 04 63 00


~

Fit the rotation device to the flywheel


housing inspection hole.

Make a chalk mark on the poly-V-belt.

Check the poly-V-belt for damage in sections; rotate the engine and poly-V-belt a
little at a time

Flywheel housing inspection hole


~

rotate further using the rotation device


until the chalk mark is reached again.

6
..-

S1034

N13.20-2075-31

S1034

Damage patterns

CD Condition
@

@
@
@

as new (as reference: trapezoidal ribs)


One-sided wear: wedge-shaped ribs
Cord visible in the base of the ribs
Ribs split
Transverse cracks in several ribs
Rubber lumps in the base of the belt
Deposits of dirt or stones
Rib detached from the base of the belt
Cord torn out to the side
Outer cord frayed
Transverse cracks on the back of the
belt
Transverse cracks in several ribs

-6

S1034

Removing and installing the poly-V-belt


Risk of injury

Swing back the tensioning device.

Check that the tensioning device and


belt pulley are in perfect condition (e.g.
check for worn bearings on the tensioning device, tensioning pulley and
deflection pulleys as well as wear on
belt pulleys); replace parts if
necessary.

Lay the poly-V-belt (new) on all belt pulleys, except for the tensioning pulley
(see illustrations for poly-V-belt routing).

Swing the tensioning pulley upwards


using the lever, insert the poly-V-belt
and swing back the tensioning pulley .

Remove the spanner and check for correct seating of the poly-V-belt on the
belt pulley.

The tensioning device is spring-tensioned.


When it is loosened or tightened, there is a
risk of injury from hands or fingers being
crushed or trapped in pretensioned parts.
co

Make sure that the tool is handled correctly.

co

Keep your fingers out of the area between the belt pulley and the poly-V-belt
when fitting or dismantling the poly-Vbelt.

co

Wear work gloves when working on the


tensioner.

....6
Spanner with extension in the tensioning

device

CD Tensioning pulley
CD Spanner

CD with the 17 mm
socket to the hexagon bolt of tensioning pulley CD.

~ Attach spanner

Swing the tensioning pulley upwards


and remove the poly-V-belt.

S1034

Routing of the poly-V-belt (engine


without refrigerant compressor)

Routing of the poly-V-belt (engine with


refrigerant compressor)

G13.20-3110-31

G13.20-3111-31

CD Alternator
CD Coolant pump
Tensioning pulley

CD Alternator
CD Coolant pump

@ Crankshaft

@ Refrigerant compressor

Tensioning pulley

Deflection and guide pulley


@ Crankshaft

S1034

Checking the condition

Engine brake: Checking the


condition and setting

Remove the wire circlip from the ball


cup on the engine cylinder.

Force the ball cup off the ball neck of


throttle valve lever CD.

~ Check the engine brake cylinder, ball

neck and ball cup, and the throttle


valve shaft for wear.
~ Check the firm seating of the throttle

valve lever on the throttle valve shaft.


Tighten screws if necessary.

Grease the ball cup with the grease


specified.

Push the ball cup back onto the ball


neck.

Fit the wire circlip.

Throttle valve lever in working position

CD Throttle valve lever


Throttle valve lever in rest position

CD Throttle
@ Retainer

valve lever

(3) Retainer

S1034

Checking the adjustment

Throttle valve lever CD must lie against


bracket @ in the operating position
(cylinder extended) when the engine
brake is operated.
When the engine brake cylinder (with
the cylinder retracted) is in the rest position, the throttle valve lever must also
lie against the bracket; the pre-tension
of the engine brake cylinder return
spring is then sufficient.
Check the position of the throttle valve
shaft: the notches must be horizontal
when the engine brake is in the rest position (I> page 88, illustration on the
left-hand side). The notches must be
vertical in the working position

/
1
,

:.~.'

:1

(I> page 88, illustration on the righthand side).

S1034

Engine cooling system: Checking


and correcting the fluid level and the
antifreeze / corrosion inhibitor
Risk of scalding
The cooling system is pressurised. Hot coolant can spray out when the cooling system
is opened and scald your skin and eyes.
..
..

6
.-

..

Only open the cooling system at coolant


temperatures below 90 "C.
Unscrew the sealing cap slowly and release any excess pressure completely
before opening the cap fully.
Wear suitable protective gloves, protective clothing and safety goggles when
handling coolant.

Risk of poisoning
Thereis a risk of poisoning if coolant is swallowed.
..

Never swallow coolant.

..

Never put coolant into containers normally used for beverages.

..

Store coolant out of the reach of children.

Only check and correct the coolant level when the coolant temperature is
below 50 "C. Check the antifreeze /
corrosion inhibitor before correcting
the coolant level. Only use prepared
coolant with 50% by volume antifreeze/ corrosion inhibitor for topping
up.
.. Open the engine cooling system radiator cap slowly. Relieve excess pressure.

Only use service products approved by


DaimlerChrysler, (I> see page 63).

... Check the antifreeze / corrosion inhibitor using testing device. The correct
concentration of 50% by volume
antifreeze / corrosion inhibitor in the
coolant is indicated when there is antifreeze protection down to -37 DC. If
less antifreeze protection is displayed,
correct the mixing ratio.

S1034

If the concentration is too low, there is


a risk of engine damage as a result of
corrosion / cavitation in the cooling
system.

Avoid concentrations of more than 55%


by volume antifreeze / corrosion inhibitor, otherwise maximum antifreeze protection down to -45 DC will not be
achieved. If the concentration is higher,
heat dissipation and antifreeze protection deteriorate.
Il>- Check the coolant level.
The cooling system is correctly filled if the
coolant reaches the mark in the filler neck.

Cooling and heating system:


Checking for leaks and general
condition
The "Engine cooling system: Checking and
correcting the fluid level and antifreeze /
corrosion inhibitor" work item must have
already been carried out.

Il>- Carry out a visual inspection of the radiator for leaks and undamaged condition.

If damage /faults are found, repair the


radiator or replace it.

Il>- Check the radiator fer external dirt. The


fins must not be dirty.
Il>- Check that all lines and hoses are undamaged, that they are routed to avoid
chafing and that they are secured in accordance with the regulations.

S1034

Special tool:

Pressure tester 001 589 83 21 00


Risk of scalding

Risk of poisoning
There is a risk of poisoning if coolant is swallowed.

The cooling system is pressurised. Hot coolant can spray out when the cooling system

Never swallow coolant.

Never put coolant into containers normally used for beverages.

Store coolant out of the reach of children.

is opened and scald your skin and eyes.


II

6
-

II

Only open the cooling system at coolant


temperatures below 90 "C.
Unscrew the sealing cap slowly and release any excess pressure completely
before opening the cap fully.
Wear suitable protective gloves, protective clothing and safety goggles when
handling coolant.

~ On heating systems: Open the regulat-

ing valves and shutoff valves.


~ Remove the coolant expansion tank

cap.
~

Fit the testing equipment.

Pressure tester special tool

1>1>

S1034

1>1> ~ Connect the compressed-air hose with

the tyre inflator connection to the valve


and build up a test pressure equal to
the cooling system opening pressure.
The cooling system opening pressure can
be seen on the code on the cap or pressure
relief valve.
Example: Code 70

~!i1 " 1
~

J!\l

0.7 bar pressure.

A pressure relief valve is integrated in


the testing equipment so that a pressure of 1.2 bar cannot be exceeded.

S1034

Renewing coolant

Risk of poisoning
Risk of scalding
The cooling system is pressurised. Hot coolant can spray out when the cooling system
is opened and scald your skin and eyes.
..

Only open the cooling system at coolant


temperatures below 90 DC.

..

Unscrew the sealing cap slowly and release any excess pressure completely
before opening the cap fully.

..

Wear suitable protective gloves, protective clothing and safety goggles when
handling coolant.

There is a risk of poisoning if coolant is swallowed.


..

Never swallow coolant.

..

Never put coolant into containers normally used for beverages.

..

Store coolant out of the reach of children.

Only use antifreeze / corrosion inhibitor


approved by Mercedes-Benz

([> see page 59).

I
~_.' I l

~he

g
...
Befolre
coolant,for
check
the
'...."'.'
coo
ingrenedWhin
an
eating system
leaks
and condition. Have the coolant renewal confirmed in the Maintenance Book1:
. let.

S1034

,I.'~ere

Draining coolant

Risk of scalding

"'~

Hot coolant will scald your skin and eyes.


..

I~

Only carry out work on the cooling system at coolant temperatures below
50 DC.

Wear suitable protective gloves, protective clothing and safety goggles when
handling coolant.

Open the engine cooling system radiator cap slowly. Let off excess pressure
and remove the radiator cap.
On heating systems: Open the heating
temperature selector (regulating
valve).

Coolant drain plug


~

Place the drain hose on the coolant


drain plug on the engine (arrow).

Loosen the drain plug (1 to 2 turns)


The coolant flows out.

are additional drain plugs on the


radiator.

First cover the lines, etc. beneath the


drain plugs and place a receptacle suitable for the volume of coolant.

S1034

Adding coolant
Environmental note
Dispose of used coolant in accordance with
prevailing local regulations
(I> see page 64).

II> Clear blocked drain openings from deposits.

II> Retighten the coolant drain plug on the


engine.

II> Pull off the drain hose.


II> Fit additional drain plugs (without hose
connections) with new seals and screw
tight.

II> Start the engine and allow it to run at


different speeds for approximately
1 minute.

II> Add coolant in the specified ratio until


it reaches the lower edge of the filler
neck.

II> Switch off the engine and close the


cooling system again.

I.~r

further ;nforrnation se, the vehicle


manufacturer's operating instructions.

S1034

S1034

Malfunctions, causes and solutions

V Malfunctions, causes and solutions


Besides careful operation and maintenance of the engine, it is important that
malfunctions are remedied in good time.
Further information on the measures listed
under "Solution" can be found in the "Maintenance" or "Tests and other work for remedying problems" section.

quence.

You can rectify certain faults yourself


(l> page 99).

may only be carried out by personnel who

Always have faults that you cannot remedy


yourself rectified at a qualified specialist
workshop.
DaimlerChrysler recommends that you visit a Mercedes-Benz Service Centre for this
purpose as it has the necessary specialist
knowledge and tools to carry out the work
required. In particular, work relevant to
safety or on safety-related systems must
be carried out at a qualified specialist
workshop.

Risk of accident and injury

.&

Incorrect maintenance and repair work to


the engine can cause engine damage and
may cause personal injury as a conse-

Maintenance and repair work on the engine


have undergone the appropriate training.
Always have work on or modifications to the
engine carried out at a qualified technical
workshop which has the necessary specialist knowledge and tools to carry out the
work required.
Mercedes-Benz recommends that you use a
Mercedes-Benz Service Centre for this purpose.

S1034

General troubleshooting
Malfunction

Cause

Solution

Starter pinion does not turn or turns too


slowly

Battery is not sufficiently charged

~ Charge the battery

Connecting cable to the starter motor is


loose

Tightenthe cable on the terminal. If


necessary, solder on a new terminal.

Starter motor solenoid switch malfunction

Have it checked by specialists

Enginedoes not start Ar c t-rvrvc


diately

imrne- Fuel tank empty

~ Refuel

Fuel filter blocked

Fuel line, pre-cleaner or screen in the fuel


tank blocked

~ Clean and bleed.thesystem

Fuel system or filter leaking

~ Seal

Fuel not resistant to cold

~ Clean the pre-filter (I> page 78)

Clean orreplacethe filter element


(t>page80)

~ Replace fuel filter


~ Use winter fuel

Outside temperature too low

[I> page 60)

Observe measures for winter operation


(t> page 53)

S1034

Malfunction

Cause

Solution

Engine starts badly

Fuel temperature too high or sensor malfunction

Engine control unit malfunction

~ Read engine control unit malfunction

Replace fuel temperature sensor; consult a qualified specialist workshop

memory, consult a qualified specialist


workshop
Leakages or pressure too low in the lowpressure fuel circuit

~ Testforleaks (visual inspection); have

Engine control unit malfunction (total failure)

Electrical system interrupted; short circuit


in cabling or in Stop button; engine control
unit malfunction

~ -Consulta qualified specialist workshop

Leakages or pressure too low in the lowpressure fuel circuit or fuel delivery pump
drive defective

~ Test for leaks (visual inspection); have

pressure tested at a qualified specialist


workshop
Consult a qualified specialist workshop

pressure tested at a qualified specialist


workshop

S1034

Malfunction

Cause

Solution

Engine in emergency running mode:


Constant speed 1,300 rpm

Engine control unit or drive control unit


malfunction

Crankshaft position sensor or TOC sensor


(camshaft angle sensor) polarity reversed

~ Remove each sensor; sensor polarity is

lIiror",jr"" or.runs irregularly

Read malfunction memory in control


units; consult a qualified specialist
workshop
reversed if engine runs better (emergency running engine speed) - reverse
polarity

Consult a qualified specialist workshop

Charge-air pressure sensor malfunction

Check with OaimlerChrysler diagnostic


tester; replace if necessary; consult a
qualified specialist workshop

Charge-air temperature too high or


temperature sensor malfunction

Check temperature sensor; replace if


necessary; consult a qualified specialist
workshop

Fuel temperature too low

~ Check temperature sensor; replace if

necessary, check fan speed cut-in


point; consult a qualified specialist
workshop
Coolant temperature too high

~ Check temperature sensor; replace if

necessary; check fan speed cut-in


point; consult a qualified specialist
workshop

S1034

Malfunction

Cause

Solution

Poor engine output (lack of power)

Engine brake valve* defective

Carry out function or visual inspection

Fault in the fuel system (blocked, leaking)

Carry out visual inspection for leaks;


consult a qualified specialist workshop

Engine control or drive control module


malfunction

Read control unit malfunction memory;


consult a qualified specialist workshop

Loose contacts in the electrical supply

Check battery terminal clamps and


connector on engine control unit for
firm seating and corrosion

Leakages or pressure too low in the lowpressure fuel circuit

Test for leaks (visual inspection); have


pressure tested at a qualified specialist
workshop

Drive control unit malfunction

Read drive control unit malfunction


memory; consult a qualified specialist
workshop

Constantly-open throttle valve* defective

Check control; consult a qualified specialist workshop

Engine brake flap* defective

Carry out a function /visual inspection;


consult a qualified specialist workshop

Tractive force interruption

Poor engine braking power

S1034

Malfunction

Cause

Solution

Fuel consumption too high

Fuel temperature too high or sensor malfunction

~ Replace fuel temperature sensor; con-

Turbocharger leaking on pressure (delivery) side

sult a qualified specialist workshop


Carry out a test for leaks; consult a
qualified specialist workshop

Connection points (unit pump - line and in- ~ Set pumps using STAR DIAGNOSIS or
Minidiag 2; consult a qualified specialjectors) defective or leaking
ist workshop
Engine cut-off too early (maximum revs
cannot be reached)

Drive control unit or ADM control unit defective or incorrectly programmed

Consult a qualified specialist workshop

Engine gets too hot (according to coolant


temperature gauge)

Coolant temperature sensor malfunction

Replace sensor

Insufficient coolant or cooling system not


fully bled

Top up, bleed (I> page 96)

Poly-V-belt damaged

see Replacing the poly-V-belt


(I> page 86)

Fan does not switch on correctly

Consult a qualified specialist workshop

Radiator dirty on inside or choked with


limescale; radiator very dirty on outside

Clean or remove limescale

Thermostat malfunction

Check, replace if necessary; consult a


qualified specialist workshop

S1034

Malfunction

Cause

Solution

Charge current indicator lamp does not


light up while the vehicle is stationary

Bulb malfunction or supply line broken

~ Replace bulb or repair break

Charge current indicator lamp lights up


when the engine is running

Poly-V-belt too slack

~ Check belt tension; replace tensioning

pulley if necessary
Poly-V-belt torn

~ Replace the poly-V-belt (I> page 86)

Alternator or regulator malfunction

~ Check; consult a qualified specialist

workshop
Engine emits black smoke

7
......

Exhaust fumes are blue

Charge-air sensor, coolant sensor or fuel


temperature sensor defective

~ Check with DaimlerChrysler diagnostic

Injector defective

~ Consult a qualified specialist workshop

Exhaust gas turbocharger or charge-air


pipe defective, air cleaner dirty

~ Carry out visual inspection; consult a

Constantly-open throttle valve defective

~ Consult a qualified specialist workshop

Oil level in the engine too high; engine oil


entering combustion chamber

~ Correct oil level; have it checked at a

tester; consult a qualified specialist


workshop

qualified specialist workshop

qualified specialist workshop

S1034

Malfunction

Cause

Solution

Exhaust fumes are white

Cylinder head or cylinder head gasket


leaking; coolant entering the combustion
chamber

Locate damaged cylinder using pressure loss test; consult a qualified specialist workshop

Engine "knocks"

Combustion malfunction

Consult a qualified specialist workshop

Knocking noise from the bearings

Damage to bearings

Consult a qualified specialist workshop

Abnormal noises

Leakage in intake pipe and exhaust pipe


causes whistling noise

Remedy leakage; replace seals if necessary

Turbine or compressor wheel scrapes on


~ Have the exhaust gas turbocharger rethe housing; foreign object in the compresplaced at a qualified specialist worksor or turbine; seized bearing in rotating
shop
parts

S1034

Jump-starting
V Jump-starting
If the battery is discharged, the engine can
be started using jump leads and a donor
battery.

Risk of explosion

When jump-starting the engine, the


maximum on-board voltage of 28 V
must not be exceeded (as this would
cause electronic damage to the control
part).

Gases escaping from batteries can explode


and injure people.

Risk of burning

Therefore, avoid fire, naked flames and


The acid contained in batteries burns skin

sparks and refrain from smoking in the vicin-

and eyes on contact.

ity of batteries.

eyes or clothing.

~ Connect the positive terminals first and

Avoid contact of acid with your skin,

then the negative battery terminals.


~~~

Wear suitable protective clothing, as


battery acid can burn through normal
clothing, and also wear protective
gloves and safety goggles.

Rinse acid splashes off immediately with


clean water and consult a doctor if necessary.

~ Start the engine (I> see page 47) and

Make sure that the donor battery and


III the starter battery have the same nomI.:.. inal voltage. Otherwise a battery could
be irreparably damaged.

Do not place any metal parts on the


batteries. There is a risk of short circuit.
Only use insulated jump leads (cable
cross section approximately 70 mm 2 )
and insulated terminal clamps. There is
a risk of short circuit.
A discharged battery can freeze at
about -10C; it must have thawed out
before jump-starting.

allow to run for a short while.


~

Remove the jump leads in the reverse


order.

S1034

adjustment values
Tightening torques

S1034

Dimensions in mm:
(Standard version, other versions on request)

OM 904 LA
OM 924 LA
A = Engine length

830 mm

B = Engine width

645 mm

C = Engine height

925 mm

OM 906 LA

f----B---~

OM 926 LA
A = Engine length

8
.......

1,078 mm

B = Engine width

645 mm

C = Engine height

940 mm

G01.00-3130-31

G01.00-3129-31

Illustrated: OM 904/924 LA

Illustrated: OM 904/924 LA

S1034

Weights
OM 904 LA

OM 906 LA

OM 924 LA

OM 926 LA

Engine, dry

395 kg

530 kg

Engine, wet

420 kg

573 kg

General data
Type

In-line engine with exhaust gas turbocharger and intercooler

Type ofcooling system

Forced circulation cooling

Combustion principle

4-stroke diesel direct injection

Number of cylinders
OM 904 LA/OM 924 LA:
OM 906 LA/OM 926 LA:

4
6

Cylinder bore
OM 904 LA/OM 906 LA
OM 924 LA/OM 926 LA

102 mm
106 mm

Piston stroke
OM 904 LA/OM 906 LA
OM 924 LA/OM 926 LA

130mm
136 mm

S1034

General data continued

8
.......

Displacement
OM 904 LA/OM 924 LA:
OM 906 LA/OM 926 LA:

4,250 cm 3 / 4,800 cm 3
6,370 cm 3 / 7,200 cm 3

Direction of rotation of engine viewed from flywheel

Anti-clockwise

Type of starting

Electric

Coolant capacity of engine without intercooler


OM 904 LA/OM 924 LA:
OM 906 LA/OM 926 LA:

8.5 I
12.51

Engine oil capacity including oil filter


OM 904 LA/OM 924 LA:
OM 906 LA/OM 926 LA:

min. 13 I; max. 16 I
min. 24 I; max. 29 I

S1034

Data: Starter motor, battery and alternator (standard)


Starter motor
Voltage

24 V

Output

4.0 kW

Battery (not in scope of delivery)


Voltage

24 V

Cold test current in accordance with DIN 72311

max. 450 A

Cold start ability without jump-starting and 75% battery charge


down to

max. -20 DC

Alternator
Voltage

28 V

Current rating

80 A

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Test values and adjustment values

T Test values and adjustment values


Engine oil pressure (min)
at idling speed

~ 0.5 bar

at rated speed

~ 2.5 bar

Valve clearance
Inlet valve

0.4 mm

Exhaust valve

0.6 mm

S1034

'!If Tightening torques

I~

All threads on mechanical parts and re~ lated contact sUrfac~s must ~e clea.n
and smooth and lubncated with engine
~.~.;. . oil; other lu bricants require significantIy different tightening torques.

.'I
I

Nm

Designation
Engine block
Cylinder head cover to cylinder head bolt

30

Oil sump bolt to cylinder crankcase

25

Poly-V-belt tensioning device to cylinder r.r;:lnkr.r1~;p

support

50

Fuel/injection system
Injection line to unitpurnppressure pipe connection

35

Banjo bolts forfuellines

40

Cap to fuel filter housing

25

Starter motor/ alternator


Starter motor to tirningcase

50

Alternator support to cylinder crankcase

100

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Designation

Nm

Alternator to support

50

Alternator to retainer

65

Oil circuit
Oil drain plug in oil sump
M20 x 1.5 thread
M26 x 1.5 thread

65
85

Alternator retainer to oil filter

40

Oil filter housing tocylindercrankcase

25

Oil filter housing support to cylinder crankcase

25

Oil filter cap to oil filter housing

25

Pressure sensor to oil filter housing

25

Valve adjustment
Counternut on rocker arm set screw

25

Cooling circuit
Coolant line with thermostat valve to coolant pump

25

Coolant pump to cylinder crankcase

25

Belt pulley to coolant pump hub

25

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ADM
Control module as interface between
the engine and the vehicle electronics.
Belt drive
Drive connection from the engine to
the engine assemblies, such as the alternator, coolant pump or refrigerant
compressor.
CAN (Controller Area Network)
Serial data transfer system which networks the vehicle's electronic systems
and allows an organised mutual data
exchange. At the same time the
number of components required is lower. This reduction of potential malfunction sources improves reliability and
maintenance friendliness.
Constantly-open throttle valve
Valve fitted in the cylinder head in conjunction with throttle valve brake or
Turbobrake *. When the engine brake is
operated, the constantly-open throttle
valve causes a reduction in the cylinder
pressure during the working stroke.

Control unit
Part of the electronic system which
controls the engine or transmission
functions, for example.

FAME fuels
(Fatty Acid Methyl Ester) FAME fuels
are bio-diesel fuels based on fatty acid
methyl esters.

Emergency running program


Special program in the Telligent@ engine system which allows limited
engine operation if electronic components have failed.

Flame-start system
This is a cold-start aid for the engine. It
can be used to preheat the charge air
using fuel combustion.

Engine oil viscosity


Measurement of the internal friction
(viscosity) of an oil at a defined temperature. The viscosity is better the higher
the temperature the oil can withstand
without becoming too thin, or the lower
the temperature the oil can withstand
without becoming too thicl<.
Engine plate
Number specified by the manufacturer
and marked on the cylinder head to
clearly identify each engine.
Exhaust brake
also throttle valve brake. Works by
closing the exhaust pipe.

FR
(Drive control) control unit. The drive
control is a monitored electronic system and is connected to the engine
control via the CAN bus. The FR is permanently installed in the driver's cab. It
controls vehicle-relevant functions and
switches on the engine control via CAN
bus commands, e.g. engine torque request via accelerator pedal position.
Grid heater
This is a cold-start aid for the engine. It
can be used to preheat the charge air
using a heater coil.

S1034

Minidiag 2
DaimlerChrysler AG electronic diagnostic tool for reading faults and parameters on commercial vehicles.

MR
(Engine control) control unit. Engine
control is a monitored electronic system which forms part of the Telligent@
engine system. It controls the engine
functions, such as the engine idling
speed and exchanges data with the
drive control.
OM

Engine name, abbreviation for oil engine = diesel engine.


Sensor
Electronic component which converts
certain parameters (e.g. oil temperature, engine speed and others) into
electrical values for use in the engine
control unit.

STAR DIAGNOSIS
DaimlerChrysler AG electronic diagnostic system

TDC
Top dead centre; term for the upper position of the piston in the cylinder.
Telligent@ engine system
Mercedes-Benz electronic engine control. Controls fuel injection period and
quantity depending on the current operating conditions and driver's requests.
Tightening torque (Nm)
Product of force and lever arm length
with which bolted connections, e.g.
cylinder head bolts, are tightened.
(Nm = Newton metres)

S1034

Adaptation module
31
Adjusting the valve clearance . . 73, 75
ADM
31
Alternator. . . . . . . . . . . . . . . . . . . . . 111
Antifreeze/corrosion inhibitor . . . . . 64

Battery

43, 106, 111

Charge current
Commissioning
Constantly-open throttle valve
Conversion parts and
modifications
Coolant
Mixing ratio
Renewing
Coolant level.
Cooling system
Cleaning
Degreasing
Cylinder head cover
Removing and fitting

49

42
28

38
64
94

90
56
57
74

Diagnostic socket
32
Diagnostic testers
32
Diesel fuels
In extremely cold weather.
60
Sulphur content
60
Dimensions. . . . . . . . . . . . . . . . . . .. 108
Disposal of service products
64
Drive control unit
31

Emergency running program


Engine
Checking for leaks and general
condition
Cleaning
Oil change and filter replacement
Starting
Stopping
Engine brake
Checking the adjustment
Checking the condition

29

68
55
69
47
52
89
88

Engine control unit


Engine data
Engine data card
Engine oil
Extracting, draining
Engine plate
Environmental note
Exhaust brake

30
108

Flame-start system
Flow improvers
Fuel
Filling the tank
Filter element
Prefilter
Fuel additives
Fuel system
Bleeding

26
61
53
43
80
77
60

Genuine Mercedes-Benz parts


Grid heater

24
70
22
7
28

80

40
27, 51

S1034

High-pressure cleaners

56

Indicator lamp
Intake pipe
Checking for leaks .,

47

Jump-starting

(}
-

82

36, 106

Kerosene

61

Location of sensors

20

Maintenance instructions
Maintenance intervals
Maintenance service

66

Oil pressure
Operating safety
Overview
OM 904 LA/OM 924 LA

42
67

51
8
12

Personnel
Poly-V-belt
Checking the condition
Removing and installing
Routing
Tensioning pulley
Protection of the
environment
Protective treatment

32
83
86
87
86

Telligent engine system


Test values and adjustment
values
Tightening torques
Transport and installation
Type designation

32, 50
112
113

33
24

7,32,38

Safety and emergency running program


Safety precautions
Service products
Special lubricant additives
Starter motor
Starting the engine for the first
time

58

29
36
64
59
111

44

Valve clearance
Adjusting
Adjustment
Checking

Warning lamp
Warranty entitlement
Water
Weights
Winter operation
Work plans

112
73
75
76

47
59
63
109

53
67

S1034

Contact

Editorial office

Mercedes-Benz will be happy to answer


any queries you may have:

You are welcome to forward any queries


or suggestions you may have regarding
these Operating Instructions to the
technical documentation team at
the following address:

Mercedes-Benz Contact
Telephone: 00800 1 777 7777
International: +49 69 95 30 72 77
Internet

Further information about


Mercedes-Benz and
DaimlerChrysler can be found on
the following websites:
www.mercedes-benz.com
www.daimlerchrysler.com

DaimlerChrysler AG, HPC: R822,


70546 Stuttgart, Germany
As at: 25.05.2003
Title illustration number NOO.O 1-2194-31
Not to be reprinted, translated
or otherwise reproduced,
in whole or in part,
without written permission.

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S1035

Motor / Engine / Moteur

Mercedes-Benz

OM 904/907/924 LA
OM 906/909/926 LA/RLA

DaimlerChrysler AG . Global Service & Parts GSPITIO D-70546 Stuttgart

S1035

Vorbemerlmngen
Dieser Bildkatalog soIl Ihnen die Ermittlung und BesteIlung von Teilen fur die Wartung bzw. Reparatur Ihres MERCEDES-BENZ
erleichtern. Er enthalt die Bildtafeln der Grundausfuhrung.
Die auf den Bildtafeln abgebildeten Teile entsprechen nicht in jedem Fall der neuesten Ausfuhrung.
Ihr MERCEDES-BENZ-Produkt kann mit Sonderausfuhrungen (SA) ausgerustet sein, die in diesem Katalog nicht aufgefuhrt sind.
Fur die Errnittlung der richtigen Teile ist die Vorlage der Fahrzeug- bzw. Motoren-Datenkarte bei den MERCEDES-BENZ-Serviceorganen eine zwingende Notwendigkeit.
Die fur Ihr MERCEDES-BENZ-Produkt giiJtigen Bildtafeln sind jeweils von der Fahrzeug-ldent-No. (Fahrgestell-No.),
Motornurnmer, Fahrerhausnumrner, Aufbaunurnrner (bei Ornnibussen) abhangig (siehe Fahrzeug-Datenkarte). Beachten Sie bitte
die ersten 6 Zahlen dieser Nummer, wobei es sich um das sogenannte Baurnuster handelt.
Benennung

Baurnuster

Motor

904.904-911, 914-917, 921-923, 927-931,936, 942, 944,


946, 947-953, 955, 959, 961, 964
90~910,

Motor

Seite

Katalog

21 - 82

06T

920, 930, 940, 941, 960, 970, 980, 990

906.910,911,915,916,919-923,925-928,930,931,935,
937-941,949-952,954-956,960-965,976,982

06T
85 - 161

06V

909.900, 901, 910, 911, 920, 921, 960, 970, 971

06V

924.911,915,916,920
926.911-915,917,924,929

06T
06V

Fur Teile-Bestellungen ist sehr wichtig, dass Sie auch angeben, auf welcher Seite die benotigten Teile ausgewahlt wurden.
3

S1035

Bei der Bestellung von Teilen sind, in Abhangigkeit von Teile-Bedarf, folgende Angaben unbedingt erforderlich (siehe FahrzeugDatenkarte):
1. Fahrzeug-Ident-No. (FahrgestelI-No.), Motor-, Aufbau- bzw. Fahrerhausnummer.

Bei Aggregaten die vollstandige Nummer des Getriebes, der Vorder- oder Hinterachse oder der Lenkung (siehe Datenkarte),
2. Druck-Nurnmer und Ausgabe dieses Kataloges.
3. Nummer der Bildtafel (rechts oben) und die Bildnummer.
4. Gewiinschte Menge.
Fur die Lieferung von Teilen ist ausschlieBlich die Kundendienstorganisation der Mercedes-Benz AG zustiindig.
Beispiel fiir eine Bestellung
Fur Motor 314.910-10-096127, Druck-Nr, 6450 000180
Seite 23, Gruppe 01, Bild 21 1 Stuck
Seite 32, Gruppe 07, Bild 260 3 Stuck

Ausgabe A

Die Teile fur Motor, Fahrgestell und bei Nutzfahrzeugen auch AufbaujFahrerhaus sind in getrennten Katalogen erfasst.
Die Bildtafeln fur die Aggregate sind im Anhang des Fahrgestell-Blldkatalogs enthalten.

S1035

Preliminary Remarks
This Catalog of Illustrations has been compiled to help you finding out and ordering the parts required for the maintenance and
repair of your MERCEDES-BENZ.
It comprises the illustrations of the Standard Equipment.
The parts illustrated do not in any case conform to the latest version.
Your MERCEDES-BENZ product may be equipped with Special Versions (SA's) which have not been listed in this catalog.
In order to identify the appropriate parts, it is mandatory to submit your vehicle data card, or engine data card, to the
MERCEDES-BENZ services.
The illustrations applicable to your MERCEDES-BENZ product are relative to the respective vehicle ident. No. (chassis No.),
engine number, cab number, or (in the case of buses) body number - see vehicle data card. Please mind the first six
digits of this number representing the so-called model.
Designation

Model

Engine

904.904-911,914-917, 921-923,927-931,936,942,944,
946,947-953,955,959,961,964

Page

Catalog

21 - 82

06T

90l910, 920, 930, 940, 941, 960, 970, 980, 990


Engine

906.910,911,915,916,919-923,925-928,930,931,935,
937-941, 949-952, 954-956, 960-965, 976, 982

06T
85 - 161

06V

909.900,901,910,911,920,921,960,970,971

06V

924.911,915,916,920
926.911-915,917,924,929

06T
06V

When ordering parts, be sure to indicate the page from which you have selected the spare parts required.
5

S1035

When placing orders for parts, it is a must to specify - depending on parts requirements -. the following points (see vehicle
data card):
1. Vehicle Ident No (Chassis No), Engine No, Body/Cab No.

In the case of Units, the complete number of transmission, or front axle, or rear axle, or steering (see data card).
2. Print No and Edition of this Catalog.
3. Illustration No (right top) and Fig. No.
4. Quantity required.
Only our Mercedes-Benz AG Dealer Organizations are competent for delivery of parts.
Example for Ordering Parts
For engine 314.910-10-096127, Print No 6450 000180
Page 23, Group 01, Fig. 21 1 piece
Page 32, Group 07, Fig. 260 3 pieces

Edition A

The parts for engine, chassis, and with commercial vehicles also for body/cab, have been compiled in separate catalogs.
The illustrations of units will be found in the annex of the chassis catalog of illustrations.

S1035

Prelimlnaires
Ce catalogue illustre doit vous faciliter la recherche et la commande de pieces pour la maintenance et la reparation de
votre MERCEDES-BENZ. II contient les planches illustrees de la version de base.
Les pieces figurant sur les planches illustrees ne sont pas toujours conformes a la version la plus recente,
Votre vehicule MERCEDES-BENZ peut etre equipe de versions speciales (SA) ne figurant pas dans ce catalogue. La
presentation de la fiche signaletique du vehicule ou du moteur aupres du service apres-vente MERCEDES-BENZ est
indispensable pour la recherche des pieces exactes.
Les planches lllustrees valables pour votre MERCEDES-BENZ sont fonction des nurneros d'identification du vehicule (n? de chassis), de moteur, de cabine, de carrosserie (autocars/autobus). Voir a cet effet la fiche signaletique du vehicule, II faut absolument tenir compte des 6 premiers chiffres de ces numeros correspondant a ce que nous appelons Ie modele.
Designation

Modele

Moteur

904.904-911,914-917,921-923,927-931,936,942,944,
946,947-953,955,959,961,964

Page

Catalogue

21 - 82

06T

90Z910, 920, 930, 940,941,960, 970, 980, 990


Moteur

906.910,911,915,916,919-923,925-928,930,931,935,
937-941, 949-952, 954-956, 960-965, 976, 982

06T
85 - 161

06V

909.900,901,910,911, 920,921,960,970,971

06V

924.911,915,916,920
926.911-915,917,924,929

06T
06V

En cas de commandes de pieces, vous devez absolument indiquer la page sur laquelle figurent les pieces en question.
7

S1035

En cas de comrnande de pieces, il faut - en fonction des besoins - absolument indiquer les donnees suivantes (voir fiche
signaletique du vehicule):
1. Numeros d'identification du vehicule (nO de chassis), de moteur, de carrosserie, de cabine.

Pour les organes mecaniques, indiquer Ie numero complet de la hoite de vitesses, des essieux AV/AR ou de la direction (voir
fiche signaletlque).
2. Numero d'impression et edition de ce catalogue.
3. Numero de la planche illustree (en haut it droit) et numero de la figure.
4. Ouantite souhaitee,
C'est Ie reseau de service apres-vente de la Mercedes-Benz AG qui est seul responsable pour la livraison de pieces.

Exemple d'une commande


Pour moteur 314.910-10-096127, n" d'impression 6450 000180
Page 23, planche illustree 01, figure 21 1 unite
Page 32, planche illustree 07, figure 260 3 unites

Edition A

Les pieces pour moteur et chassis et - lorsqu'i] s'agit de vehicules utilitaires - egalement pour carrosserie/cabine figurent dans
des catalogues separes.
Les planches illustrees pour les organes mecaniques se trouvent a l'annexe du catalogue illustre des chassis.

S1035

Advertencias preliminares
El presente catalogo ilustrado tiene por objeto facilitar la biisqueda y el pedido de piezas para el mantenimiento 0 reparaclon
de su MERCEDES-BENZ. Contiene las laminas i1ustradas de la ejecucion basica.
Las piezas reproducidas en las laminas no corresponden siempre a la ultima ejecucion.
Su producto MERCEDES-BENZ puede ir equipado con ejecuciones especiales (SA) que no esten incluidas en el presente
catalogo. Para la localizacion de las piezas correctas es imprescindible presentar la documentacion del vehfculo 0 la tarjeta de
los datos del motor a los organism os de servicio postventa MERCEDES-BENZ.
Las laminas validas para su producto MERCEDES-BENZ pueden reconocerse siempre por el mimero de identiflcacion
del vehfculo (rnirn. de chasis), asf como por los mimeros del motor, cabina y superestructura (en autobuses); vease la ficha de
datos del vehfculo. Sfrvase fijarse en las seis primeras cifras de dicho mimero, que corresponde al de la ejecucidn,

Denominacion

Modelo

Motor

904.904-911,914-917,921-923,927-931,936,942,944,
946, 947-953, 955, 959, 961, 964

Pagina

Catalogo

21 - 82

06T

90Z910, 920, 930, 940, 941, 960, 970, 980, 990


Motor

906.910, 911, 915, 916, 919-923, 925-928, 930, 931, 935,


937-941,949-952,954-956,960-965,976,982

06T
85 - 161

06V

909.900,901,910,911,920,921,960,970,971

06V

924.911, 915, 916, 920


926.911-915,917,924,929

06T
06V

Es muy importante que, al efectuar pedidos de piezas, se indique tambien la pagina en la que se eligieron las piezas requeridas.
9

S1035

Para la formulaci6n del pedido de piezas, segun la demanda, son indispensables los siguientes datos (vease ficha de datos del
vehiculo):
1. Ntimero de identificaci6n del vehiculo [rnim. de chasis), asf como mimeros de motor, superestructura

grupos: mimero completo del cambio, eje delantero

eje trasero,

0 cabina. En caso de
de la direcci6n (vease ficha de datos).

2. Ntimero de impresi6n y edici6n del presente catalogo,


3. Ntimero de lamina (arriba, a la derecha) y de ilustraci6n.
4. Cantidad deseada.
Unicamente la organizaci6n del servicio postventa es la encargada del suministro de piezas de la Mercedes-Benz AG.
Ejemplo para la formulacion de un pedido
para motor 314.910-10-096127, N de impresi6n 6450 000180
pagina 23, grupo 01, ilustraci6n 21 1 unidad
pagina 32, grupo 07, ilustraci6n 260 3 unidades

Edici6n A

Las piezas para motor, chasis y, en vehiculos industriales, tarnbien para superestructura
aparte.
Las tablas graficas de grupos se encuentran en el apendice del catalogo de chasis.

10

cabina se encuentran en catalogos

S1035

Considerazioni preliminari
Questo catalogo illustrato vi servira a determinare ed ordinare i pezzi necessari per la manutenzione risp. riparazione della
vostra MERCEDES-BENZ. Esso contiene le tavole illustrate dell'Equipaggiamento di Base.
Talvolta i pezzi raffigurati nelle tavole illustrate non corrispondono pili all'ultima versione.
II vostro prodotto MERCEDES-BENZ pub essere dotato di equipaggiamenti speciali (SA) che non sono elencati in questa
catalogo. Per stabilire gli esatti pezzi e assolutamente necessario presentare agli organi di servizio MERCEDES-BENZ la
cartolina del veicolo ovvero dei dati del motore.
Le tavole illustrate valide per la vostra MERCEDES-BENZ dipendono generalmente dai numeri d'identificazione del veicolo
(del telaio), del motore, della cabina e, per gli autobus, della carrozzeria. (Vedi scheda dei dati del veicolo). Si prega di tener
conto delle prime 6 cifre di questa numero riferentesi al cosiddetto modello di costruzione.

Denominazione

Modello costruzione

Pagina

Catalogo

Motore

904.904-911,914-917,921-923,927-931,936,942,944,
946,947-953,955,959,961,964

21 - 82

06T

90~910,

Motore

Per le ordinazioni dei pezzi

920, 930, 940, 941, 960, 970, 980, 990

906.910,911,915,916,919-923,925-928,930,931,935,
937-941,949-952,954-956,960-965,976,982

06T
85 - 161

06V

909.900,901,910,911,920,921,960,970,971

06V

924.911,915,916,920
926.911-915,917,924,929

06T
06V

e importante che indichiate anche la pagina dalla quale sono stati scelti i pezzi

necessari.
11

S1035

Per l'ordinazione di pezzi


veicolo):

e strettamente necessario, a seconda del fabbisogno, fornire i seguenti dati (vedi scheda dei dati del

1. W d'identificazione del veicolo (N di telaio), numeri del motore, della carrozzeria e della cabina. Per gli aggregati l'intero
numero del cambio, dell'assale anteriore 0 posteriore 0 dello sterzo (vedi scheda dei dati).
2. Numero di stampa ed edizione di questa catalogo.

3. Numero della tavola illustrata (in alto a destra) e della figura.

4. Ouantita desiderata.
Per la consegna dei pezzi il solo responsabile e l'organizzazione assistenza clienti della Mercedes-Benz AG.
Esempio ill ordinazione
Per il motore 314.910-10-096127, N di stampa 6450000180
Pagina 23, Tavola illustrata 01, Figura 21 N di pezzi 1
Pagina 32, Tavola illustrata 07, Figura 260 N di pezzi 3

Edizione A

I pezzi per motore, telaio e, per i veicoli industriali, anche per la carrozzeria e la cabina si trovano in cataloghi separati.
Le tavole illustrate per gli aggregati sono contenute nell'appendice del catalogo illustrato del telaio.

12

S1035

Advertencias preliminares
Este catalogo ilustrado tern por fim facilitar a V. Sa. a identificacao e a encomenda de pecas para a manutencao e a reparacao
do seu MERCEDES-BENZ. Ele contem os quadros ilustrados da versao basica.
As Ilustracoes nos quadros nao correspondem, em todos os cas os, a versao mais recente das pecas.
E possfvel que 0 seu vefculo MERCEDES-BENZ disponha de equipamentos especiais (SA) nao mencionados neste catalogo,
Para a determinacao das pecas adequadas, e absolutamente indispensavel a apresentacao do cartao de dados do veiculo ou
do cartao de dados do motor nos postos de service MERCEDES-BENZ.
Os quadros validos para 0 seu produto MERCEDES-BENZ dependem do respectivo mimero de identificacan do veiculo (numero do chassi), do mimero do motor, do mimero da cabina, do mimero da carrocaria (em se tratando de autocarros/onibus)
- (vide cartao de dados do veiculo). Queira observar as primeiros 6 algarismos desse mimero, pois trata-se da identificacao
do respectivo modelo.

Denominacao

Modelo

Motor

904.904-911,914-917,921-923,927-931,936,942,944,
946,947-953,955,959,961,964

Pagina

Catalogo

21 - 82

06T

90Z910, 920,93~940,94L960,970, 980,990


Motor

Para a encomenda de pecas,


necessitadas.

906.910,911,915,916,919-923,925-928,930,931,935,
937-941,949-952,954-956,960-965,976,982

06T
85 - 161

06V

909.900,901,910,911,920,921,960,970,971

06V

924.911,915,916,920
926.911-915,917,924,929

06T
06V

e de suma importancia que V. Sa. mencione tambem a pagina da qual selecionou as pecas
13

S1035

Na encomenda de pecas, sao absolutamente necessaries as seguintes dados, em dependencia cia necessiclacle de pecas (vide
cartao cle daclos cia veiculo):
1. Numero cle identificacao cia veiculo (numero do chassi), niimero cia motor, da carrocaria au da cabina, resp.
Em se tratanclo de grupos de maquinas, fornecer a mimero completo cia caixa cle mundancas, cia eixo clianteiro au traseiro,
ou da direcao (vicle cartao cle dados).

2. Ntimero cle impressao edicao cleste catalogo.


3. Niimero cia quaclro ilustrado (no alto

aclireita) eo mirnero

da Ilustracao.

4. Quantidacle clesejacla.
A entrega cle pecas compete exclusivamente ao service de atenclimento aos clientes da Mercedes-Benz AG.

Exemplo para uma encomenda


Para motor 314.910-10-096127, mimero cle impressao 6450 000180
Pagina 23, grupo 01, ilustracao 21 1 peca
Pagina 32, grupo 07, ilustracao 260 3 pecas

As pecas para 0 motor, a chassi e, para veiculos utilitarios, tambern para a carrocaria e a cabina clo motorista, foram agrupadas
em catalogos em separaclo.
As ilustracoes para os grupos cle maquinas constam cia anexo do catalogo ilustrado para a chassi.

14

S1035

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85 - 161

06V

909.900,901,910,911,920,921,960,970,971

06V

924.911, 915, 916, 920


926.911-915,917,924,929

06T
06V

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15

S1035

npH saaaae aansacrea 06AaaTenbHO vsaaare CtletlYIOLUl1e tlaHHble:

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16

S1035

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S1035

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S1035
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S1035
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S1035

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S1035

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S1035

Distnburcao
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S1035
Kraftstoffpumpe
Fuel Pump
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I Bomba de combustivel

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S1035

I Bomba
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S1035
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Kraftstoff-Filler
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S1035
Kraftstoff-Filter
Fuel Filter
Filtre a combustible
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Luflpresser
Air Compressor
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Luftpresser
Compressor de ar
Air Compressor
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Air Compressor
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Saugrohr und AuspuffkrUmmer


Tubo de adrrussao e colector de escape
Intake and Exhaust Manifolds
Tubo de adrrnslon y colector de escape
Collecteurs d'admission et
snycKHaR Tpy6a '" xoneno
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Tubo de adrrussao e cclector de escape


Saugrohr und Auspuffkrilrnmer
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Intake and Exhaust Manifolds
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d'echappernent
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119

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Collecteur d'echappernent
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Colector de escape
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60

S1035

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S1035
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AuspuffkrUmmer
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Collecteur d'echappernent
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Eleklrische Ausrlistung , Equipamento electrico
Electrical Equipment
Equipo electrlco
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Elektrische Ausriistung
Electrical Equipment
Equipement electrique
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S1035

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Elektrische AusrUslung
Eiectrical Equipment
Equipement electrique
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Elektrische Ausriistunq
Electrical Equipment
Equipement electrique
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S1035

Equipamento eleclrico
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Elektrische Ausrtistung , Equipamento electrico


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Elektrische A
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Elektrische AusrUstung
Electrical Equipment
Equipement electnque
lrnpranto elettnco

S1035

IEquipo
Equipamento electrico
electnco

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Electncal Equipment
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lrnpianto elettnco

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Equipo electnco
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Elektrische AusrUstung
Electrical Equipment
Equipement electrlque
Impianto eJettrico

S1035

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Electrical Equipment
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Molorschmierung
Engine Lubrication
Graissage du moteur
Lubrificazione molore

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Lubricaci6n del motor

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Engine Lubrication
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S1035

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Engine Lubrication
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Engine .Coohn~t au moteur
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Motorklihlung
Engine Cooling System
Refroidissemenl du moleur
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IRefrigerac;ao
do molor
Refrigeraci6n del molor

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oxnal-HAeHHe ABHraTenA
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Engine Cooling System
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S1035

Refriqeracao do motor
Refrigeraci6n del motor
oxnaltlgeHl1e gBl1raTenA
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Molorkuhlullg
Engine Cooling System
Refroldlssement du moleur
Raffreddamenlo molore

S1035

IRefrigeraci6n
Refriqeracao do molor
del molar

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Engine Cooling System
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147

MotorkGhlung
Engine Cooling System
RefrOidissement du moteur
Raffreddamento motore

148

IRefrigeraci6n
Refriqeracao do motor
del motor
oxnalH/leHl1e /lBl1raTenA

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Motoraufhangung
Engine Suspension
Suspension du moteur
Sospensicne del motore

Suspensao do motor
Suspension del motor
nonaecxa ASHraTeJ1R
.;..,...:; y-ti c:/:IL?-

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Ejecuciones especiales
Versions speciales
cneuaanenaa HOMnneHTaL\HR
Versioni speciali
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25

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335 340

15

157

Kaltekompressor
Refrigerant Compressor
Compresseur pour installation d'air
conditlonne
Compressore impianto refrigeratore

70

4125

45

(:)

158

Compressor do produto refrigerante


Compresor de refriqeracion
oxnaA>1Tenb

.L.;.~\

.:r-=.:...

"i U"L,5

Gruppe
Group
Groupe
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Grupo

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Group
Groupe
Gruppo

SonderausfOhrungen Vers5es especiais


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Ejecuciones especiales
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cneuaansaas HOMnneHTal1HA
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SonderausfDhrungen
Special Versions
Versions speciales
Version! special!

IVers6es
especiais
Ejecuciones especiales

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cneuaansaaa KOMnneHTaL111R

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Special Versions
Versions speciales
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S1035

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especiais
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161

ENGINE FILTERS

13807
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

146001

FUEL FILTER ELEMENT KIT (OM 904 & 906)

146018

FUEL PRE FILTER KIT - SCREEN (OM 904 & 906)

146040

FUEL/WATER SEPARATOR ASSEMBLY (OM 904 & 906)

146022

FUEL/WATER SEPARATOR ELEMENT (OM 904 & 906)

146000
146017
146101

OIL FILTER ELEMENT (OM 904 ONLY)


OIL FILTER ELEMENT (OM 906 ONLY)
FUEL/WATER SEPARATOR BOWL

1
1
1

Updated:
09/18/07

RADIATOR INSTALLATION

ITEM PART #

13661
Page 1 of 1

DESCRIPTION

QTY.

465216

RADIATOR/CHARGE AIR COOLER ASSEMBLY

605726

RADIATOR HOSE (2)

A/R

20611-03

TUBE WELDMENT (RADIATOR)

12326-06

RADIATOR HOSE (ELBOW)

12922-04

TUBE WELDMENT (RADIATOR)

Updated:
11/19/07

CHARGE AIR INSTALLATION

13660
Page 1 of 2

Updated:
09/27/07

CHARGE AIR INSTALLATION

13660
Page 2 of 2

ITEM PART #

DESCRIPTION

QTY.

465216

RADIATOR ASSEMBLY (DDC 904)

12567-05

SILICONE HOSE 4

12964-01

TUBE WELDMENT LOWER (CHARGE AIR)

605663

SILICONE HUMP HOSE (3 ID)

N/A

CHARGE AIR TUBE (SEE DETROIT DIESEL)

N/A

CHARGE AIR TUBE (SEE DETROIT DIESEL)

595320

SILICONE CONNECTOR (3 ID)

12964-03

TUBE WELDMENT UPPER (CHARGE AIR)

12567-05

SILICONE HOSE 4

10

146043

CHARGE AIR COOLER CLAMP BOLT

11

146042

CHARGE AIR COOLER CLAMP

12

146105

CHARGE AIR COOLER NUT

13

146044

CHARGE AIR COOLER SEAL

Updated:
09/27/07

AIR INTAKE SYSTEM

13713
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

604686

AIR CLEANER

604691

AIR CLEANER BANDS

604921

AIR INLET HOOD

604692

RUBBER REDUCER (5 4)

12350-09

ELBOW WELDMENT

605693

HUMP HOSE (2 )

6498-43

ELBOW (2 )

8*

604464

INDICATOR 20

ITEM NOT SHOWN

Updated:
06/17/08

AIR CLEANER

ITEM PART #

11637
Page 1 of 1

DESCRIPTION

QTY.

604686

AIR CLEANER ASSEMBLY (INCLUDES ITEMS 1-8)

604707

CUP ASSEMBLY

604710

CLAMP ASSEMBLY

604711

PRIMARY ELEMENT

604709

SAFETY ELEMENT

604264

VACUATOR VALVE

604706

BAFFLE ASSEMBLY

604708

NUT ASSEMBLY

604704

O-RING

10*

604921

INLET HOOD

11*

604687

PRECLEANER

12*

604691

MOUNTING BAND

*ITEMS NOT SHOWN

Updated:
11/06/07

EXHAUST SYSTEM

13676
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

12964-07

EXHAUST ADAPTER WELDMENT

12964-08

EXHAUST TUBE WELDMENT (FLEX)

604922

EXHAUST ELBOW

594995

EXHAUST PURIFIER

594372

EXHAUST SILENCER

15951-01

EXHAUST DISSFUSER

7*

19188-11

FLAME ARRESTOR (OPTIONAL)

8*

605537

ALUMINIZED HEAT BARRIER WRAP

A/R

*ITEMS NOT SHOWN

Updated:
11/19/07

S1020

S1020

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
5.

DRIVE TRAIN
17193
13436
S1005
12408

TRANSMISSION ASSEMBLY
TRANSMISSION MOUNTS
TRANSMISSION MAINTENANCE & SERVICE
MANUAL
DRIVELINE INSTALLATION

TRANSMISSION ASSEMBLY
465563

17193
Page 1 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #
465563

17193
Page 2 of 38

DESCRIPTION

QTY.

TRANSMISSION ASSEMBLY

32000 CONVERTER HOUSING GROUP


1

N/A

NOT USED ON THIS MODEL

23033

PIPE PLUG

244390

4-5

N/A

CONVERTER HOUSING & TUBE ASSEMBLY


(INCLUDES ITEMS 6-15, 19, 24-44)
NOT USED ON THIS MODEL

24913

TUBE SLEEVE

24337

TUBE SLEEVE

24594

CONVERTER HOUSING SLEEVE

244457

CONVERTER HOUSING SLEEVE LOCK

10

24473

CONVERTER HOUSING SLEEVE SCREW LOCKWASHER

11

24474

CONVERTER HOUSING SLEEVE SCREW

12

24474

CONVERTER HOUSING SLEEVE SCREW

13

24473

CONVERTER HOUSING SLEEVE SCREW LOCKWASHER

14

244457

CONVERTER HOUSING SLEEVE LOCK

15

24594

CONVERTER HOUSING SLEEVE

16

24240

BREATHER

17

244160

STREET ELBOW

18

244157

BREATHER REDUCING BUSHING

19

24337

TUBE SLEEVE

20

24435

21

244195

22

24435

23

244196

24

24473

CONVERTER HOUSING TO TRANSMISSION HOUSING


SCREW LOCKWASHER
CONVERTER HOUSING TO TRANSMISSION HOUSING
SCREW
CONVERTER HOUSING TO TRANSMISSION HOUSING
LOCKWASHER
CONVERTER HOUSING TO TRANSMISSION HOUSING
SCREW
LUBE TUBE RETAINING SCREW

25

24474

LUBE TUBE RETAINING SCREW

26

24952

SUCTION TUBE O-RING

27

244057

SUCTION TUBE SPACER RING

4
4
4
1

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 3 of 38

28

24933

SUCTION TUBE ASSEMBLY

29

04GE06

30

24191

SUCTION TUBE RETAINER SCREW/LOCKWASHER


(PART OF ITEM 30)
SUCTION TUBE RETAINER SCREW & LOCKWASHER

31

24474

TUBE CLIP SCREW

32

24473

TUBE CLIP SCREW LOCKWASHER

33

24592

TUBE CLIP

34

24921

REVERSE TUBE ASSEMBLY

35

24684

REVERSE TUBE O-RING

36

24474

LUBE TUBE RETAINER SCREW

37

24473

LUBE TUBE RETAINER SCREW LOCKWASHER

38

24920

LUBE TUBE ASSEMBLY

39

24474

TUBE CLIP SCREW

40

24473

TUBE CLIP SCREW LOCKWASHER

41

24592

TUBE CLIP

42

24922

3RD SPEED TUBE ASSEMBLY

43

24684

3RD SPEED TUBE O-RING

44

24924

VALVE OIL SUPPLY TUBE

45

24686

10

46

24435

47

24047

48

24338

57

244384

TRANSMISSION CASE TO CONVERTER HOUSING


SCREW
TRANSMISSION CASE TO CONVERTER HOUSING
SCREW LOCKWASHER
CONVERTER HOUSING TO TRANSMISSION CASE
GASKET
CONVERTER HOUSING TO TRANSMISSION CASE
DOWEL PIN
SPEED SENSOR ADJUSTER BUSHING

58

244387

SPEED SENSOR ADJUSTER SHIM

A/R

59

244388

SPEED SENSOR HOLE PLUG

60

244389

SPEED SENSOR O-RING

10
1
2
1

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 4 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

DESCRIPTION

17193
Page 5 of 38
QTY.

TRANSMISSION CASE GROUP


1

244741

24601

TRANSMISSION CASE ASSEMBLY


(INCLUDES ITEMS: 2-24)
SUCTION TUBE ASSEMBLY

2
3

24692

SUCTION TUBE CLIP

N/A

NOT USED ON THIS MODEL

24337

PRESSURE TUBE SLEEVE

24598

LOW SPEED CLUTCH PRESSURE TUBE

24337

PRESSURE TUBE SLEEVE

244391

SUCTION TUBE CLIP RIVET

24693

RETAINING WASHER SCREW

10

ZG-230921

RETAINING WASHER

11

244232

SUCTION TUBE O-RING

12

244391

RIVET

13

244256

OIL BAFFLE

14

244257

OIL BAFFLE

15

244391

RIVET

16-24

N/A

NOT USED ON THIS MODEL

25

24566

CASE TO COVER GASKET

26

24467

PRESSURE TUBE O-RING

27

24467

PRESSURE TUBE O-RING

28

24467

PRESSURE TUBE O-RING

29

24339

MAGNETIC DRAIN PLUG

30

24689

OIL LEVEL PLUG

30A

24689

OIL LEVEL PLUG

31

24689

OIL LEVEL PLUG

32

24244

SCREEN ASSEMBLY

33

24203

SCREEN ASSEMBLY GASKET

34

24690

PLUG

35-55

N/A

NOT USED ON THIS MODEL

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

ITEM PART #

17193
Page 6 of 38

DESCRIPTION

QTY.

REAR COVER GROUP


1

244726

REAR COVER

24046

CASE TO COVER GASKET

24686

REAR COVER TO TRANSMISSION CASE SCREW

21

24435

23

24389

REAR COVER TO TRANSMISSION CASE SCREW


LOCKWASHER
REAR COVER TO TRANSMISSION CASE STUD NUT

24654

REAR COVER TO TRANSMISSION CASE STUD

244453

PLUG

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 7 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

DESCRIPTION

17193
Page 8 of 38
QTY.

TURBINE SHAFT GROUP


1

24670

STATOR SUPPORT SCREW

24680

STATOR SUPPORT SCREW LOCKWASHER

24936

STATOR SUPPORT & SLEEVE ASSEMBLY

244728

TURBINE SHAFT

244365

TURBINE SHAFT PISTON RING

24306

TURBINE SHAFT BEARING

24219

TURBINE SHAFT GEAR SNAP RING

244364

PISTON RING

N/A

NOT USED ON THIS MODEL

10

24911

OIL BAFFLE

11

24022

OIL BAFFLE OIL SEAL

12

24929

OIL BAFFLE SEAL RING

13

244128

OIL BAFFLE RETAINER RING

14

24910

IMPELLER HUB GEAR

15

24576

IMPELLER HUB GEAR SNAP RING

16

244265

TURBINE SHAFT GEAR

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 9 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

DESCRIPTION

17193
Page 10 of 38
QTY.

WHEEL GROUP
1

244729

TURBINE HUB

244123

REACTION MEMBER SNAP RING

244281

REACTION MEMBER

24577

REACTION MEMBER SPACER

244280

BEARING SNAP RING

244279

IMPELLER HUB BEARING

244278

IMPELLER HUB

244557

IMPELLER HUB O-RING

244745

IMPELLER

10

244275

IMPELLER HUB SCREW BACKING RING

11

NOT USED ON THIS MODEL

12

244274

HUB TO IMPELLOR SCREW

12

13

24559

TURBINE

14

244185

TURBINE HUB SCREW BACKING RING

15

24054

IMPELLER TO COVER O-RING

16

244187

IMPELLER COVER

17

04GE06

IMPELLER TO COVER SCREW LOCKWASHER

24

18

24673

IMPELLER TO COVER SCREW

24

19

ZZ240234

IMPELLER COVER BEARING

20

244664

BEARING CAP TO IMPELLOR COVER O-RING

21

244570

BEARING WASHER

22

244569

BEARING SNAP RING

23

244731

IMPELLER COVER BEARING CAP

24

24476

TURBINE HUB SCREW BACKING RING

25

N/A

NOT USED ON THIS MODEL

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

ITEM PART #

DESCRIPTION

17193
Page 11 of 38

QTY.

DRIVE PLATE GROUP


1

464914

FLEXPLATE KIT (INCLUDES ITEMS 2-5)

NSS

DRIVE PLATE (INCLUDES ITEM 1)

244062

DRIVE PLATE BACKING RING

244393

DRIVE PLATE MOUNTING SCREW

10

24505

WASHER

10

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 12 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

DESCRIPTION

17193
Page 13 of 38
QTY.

DRIVE PUMP GROUP HIGH CAPACITY


1

244321

LOCKWASHER

N/A

NOT USED ON THIS MODEL

24947

CAPSCREW

465563-01

DRIVE PUMP GEAR

465563-02

SUPPORT DRIVE PUMP BEARING

24909

BEARING BALL

465563-03

SNAP RING

ZG-224009

SNAP RING

465563-04

IMPELLER HUB GEAR

10

465563-05

DRIVE PUMP IDLER GEAR

11

465563-06

SUPPORT DRIVE PUMP IDLER

12

465563-07

BEARING BALL 6309

13

244321

LOCKWASHER

14

24947

CAPSCREW

15

465563-08

INTERNAL SNAP RING

16

244321

LOCKWASHER

17

N/A

NOT USED ON THIS MODEL

18

24947

CAPSCREW

19

465563-01

DRIVE PUMP GEAR

20

465563-02

SUPPORT DRIVE PUMP GEAR

21

24909

BEARING BALL

22

465563-03

SNAP RING

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

ITEM PART #

DESCRIPTION

17193
Page 14 of 38

QTY.

FORWARD AND REVERSE SHAFT GROUP


1

465563-09

CLUTCH DRIVEN GEAR 25T

24612

HIGH RANGE GEAR 52T

465563-10

LOW & 4TH DRIVE GEAR

465563-11

2ND GEAR 30T

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 15 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

17193
Page 16 of 38

DESCRIPTION

QTY.
RD

24347

REVERSE AND 3 CLUTCH SHAFT GROUP WITH


STEP SEALED PISTON
REVERSE & 3RD CLUTCH SHAFT PISTON RING

244190

FRONT BEARING RETAINER RING

244572

WASHER

244573

BALL END PLATE

244006

REVERSE & 3RD SHAFT FRONT BEARING

244190

FRONT BEARING RETAINER RING

24291

CLUTCH DRIVEN GEAR BEARING SHIELD IN

244652

CLUTCH DRIVEN GEAR BEARING SNAP RING

N/A

NOT USED IN THIS MODEL

10

24568

END PLATE RETAINER RING

11

244574

END PLATE - 3RD CLUTCH

12

24058

CLUTCH OUTER DRIVE DISC 3RD CLUTCH

13

244546

CLUTCH INNER DISC 3RD CLUTCH

14

244691

CLUTCH PISTON ASSEMBLY - 3RD CLUTCH

15

24526

CLUTCH PISTON OUTER SEAL

16

24529

CLUTCH PISTON INNER SEAL

17

244692

CLUTCH PISTON METERING SEAL

18

244693

REVERSE & 3RD CLUTCH DRUM & PLUG ASSEMBLY

19

244692

CLUTCH PISTON METERING SEAL

20

24529

CLUTCH PISTON INNER SEAL

21

24526

CLUTCH PISTON OUTER SEAL

22

244694

23

244546

CLUTCH PISTON ASSEMBLY- REVERSE CLUTCH


(INCLUDES ITEMS 20 & 21)
CLUTCH INNER DISC REVERSE CLUTCH

24

24058

CLUTCH OUTER DISC REVERSE CLUTCH

25

24583

END PLATE REVERSE CLUTCH

26

24568

END PLATE RETAINER RING

27

24610

SPRING RETAINER

28

24609

PISTON RETURN SPRING

29

24607

SPRING RETAINER

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 17 of 38

30

24962

SPRING RETAINER SNAP RING RETAINER

31

24298

SPRING RETAINER SNAP RING

32

24293

CLUTCH DRIVEN GEAR BEARING

33

244652

CLUTCH DRIVEN GEAR BEARING SNAP RING

34

NOT USED ON THIS MODEL

35

24610

SPRING RETAINER

36

24609

PISTON RETURN SPRING

37

24607

SPRING RETAINER

38

24962

SPRING RETAINER SNAP RING RETAINER

39

24298

SPRING RETAINER SNAP RING

40

24611

3RD GEAR BEARING

41

24579

3RD GEAR BEARING SNAP RING

42

N/A

NOT USED ON THIS MODEL

43

24613

3RD GEAR BEARING SPACER

44

24579

3RD GEAR BEARING SNAP RING

45

24614

3RD GEAR BEARING SHIELD OUT

46

244559

REVERSE & 3RD SHAFT REAR BEARING

47

24581

GEAR RETAINING RING

48

244695

LOW CLUTCH DRIVE GEAR

49

24612

3RD GEAR

50

244266

CLUTCH DRIVEN GEAR

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 18 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

17193
Page 19 of 38

DESCRIPTION

QTY.
ND

24347

FORWARD & 2 CLUTCH SHAFT GROUP WITH STEP


SEALED PISTON
FORWARD & 2ND SHAFT PISTON RING

244190

FRONT BEARING RETAINER RING

244572

WASHER

244573

FORWARD & 2ND SHAFT FRONT END BALL RETAINER

244006

FORWARD & 2ND SHAFT FRONT BEARING

24290

FRONT BEARING LOCATING RING

244190

FRONT BEARING RETAINER RING

24291

CLUTCH DRIVEN GEAR BEARING SHIELD IN

244652

CLUTCH DRIVEN GEAR BEARING SNAP RING

10

N/A

NOT USED IN THIS MODEL

11

244652

CLUTCH DRIVEN GEAR BEARING SNAP RING

12

24293

CLUTCH DRIVEN GEAR BEARING

13

24298

SPRING RETAINER SNAP RING

14

NOT USED ON THIS MODEL

15

24962

SPRING RETAINER - SNAP RING RETAINER

16

24607

SPRING RETAINER

17

24609

PISTON RETURN SPRING

18

24610

SPRING RETAINER

19

N/A

NOT USED IN THIS MODEL

20

24298

2ND GEAR RETAINING RING

21

244580

2ND GEAR LOCATING RING RETAINER

22

244224

2ND GEAR LOCATING RING RETAINER SNAP RING

23

24298

SPRING RETAINER SNAP RING

24

24962

SPRING RETAINER - SNAP RING RETAINER

25

24607

SPRING RETAINER

26

24609

PISTON RETURN SPRING

27

24610

SPRING RETAINER

28

24568

END PLATE RETAINER RING

29

244574

END PLATE 2ND CLUTCH

1
Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 20 of 38

30

24058

CLUTCH OUTER DISC 2ND CLUTCH

31

244546

CLUTCH INNER DISC 2ND CLUTCH

32

244691

CLUTCH PISTON ASSEMBLY 2ND CLUTCH

33

24526

CLUTCH PISTON OUTER SEAL

34

24529

CLUTCH PISTON INNER SEAL

35

244692

CLUTCH PISTON METERING RING

36

244696

37

244692

FORWARD & 2ND SHAFT, CLUTCH DRUM & PLUG


ASSEMBLY
CLUTCH PISTON METERING RING

38

24529

CLUTCH PISTON INNER SEAL

39

24526

CLUTCH PISTON OUTER SEAL

40

244694

41

24058

CLUTCH PISTON ASSEMBLY FORWARD CLUTCH


(INCLUDES ITEMS 38 & 39)
CLUTCH OUTER DISC. FORWARD CLUTCH

42

244546

CLUTCH INNER DISC. FORWARD CLUTCH

43

24583

END PLATE FORWARD CLUTCH

44

24568

END PLATE RETAINER RING

45

244266

FORWARD CLUTCH DRIVEN GEAR

46

244235

2ND GEAR

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 21 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

17193
Page 22 of 38

DESCRIPTION

QTY.

LOW SHAFT GROUP


1

24915

FORWARD & 2ND SHAFT PILOT BEARING

N/A

NOT USED ON THIS MODEL

244703

LOW SHAFT FRONT BEARING CUP

244704

LOW SHAFT FRONT BEARING CONE

244732

LOW SPEED GEAR BEARING ASSEMBLY

244701

LOW SPEED GEAR

244702

WASHER BEARING SPACER

244699

SPRING RETAINING RING RETAINER

24219

SPRING RETAINING RING

10

244698

SPRING RETAINING

11

244697

SPRING - WAVE

12

244119

RETAINER WAVE SPRING

13

24568

END PLATE RETAINER RING

14

24583

END PLATE

15

24057

CLUTCH INNER DISC

16

24058

CLUTCH OUTER DISC

17

244694

CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 18 & 19)

18

24526

CLUTCH PISTON OUTER SEAL

19

24529

CLUTCH PISTON INNER SEAL

20

244692

SEAL CLUTCH PISTON METERING

21

244394

LOW CLUTCH HUB RETAINING RING

22

244705

LOW CLUTCH HUB & DRUM ASSEMBLY

23

244706

LOW DRUM & SHAFT O-RING

24

244709

25

244707

LOW SHAFT & DRUM ASSEMBLY


(INCLUDES ITEMS 21-26)
LOW SHAFT

26

244708

LOW SHAFT PLUG

27

244601

LOW SHAFT REAR BEARING CONE

28

24667

LOW SHAFT REAR BEARING CUP

29

244523

LOW SHAFT PRESSURE PISTON RING

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 23 of 38

30

244715

REAR BEARING CAP O-RING

31

244710

BEARING CAP SHIM - .004

A/R

31A

244711

BEARING CAP SHIM - .007

A/R

31B

244712

BEARING CAP SHIM - .010

A/R

31C

244713

BEARING CAP SHIM - .020

A/R

32

244716

O-RING PRESSURE TUBE

33

244453

REAR BEARING CAP PLUG

34

244714

REAR BEARING CAP

35

04GE06

REAR BEARING CAP LOCKWASHER

36

24673

REAR BEARING CAP CAPSCREW

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 24 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

17193
Page 25 of 38

DESCRIPTION

QTY.

IDLER SHAFT GROUP


1

244190

BEARING RETAINER RING

24575

BEARING LOCATING RING

24100

IDLER SHAFT FRONT BEARING

465563-12

N/A

IDLER SHAFT AND GEAR 45T


(NOT AS SHOWN: SHAFT INCLUDES ITEMS 4, 5, 6 AND
IS A ONE PIECE CONTRUSTION)
NOT USED ON THIS MODEL

N/A

NOT USED ON THIS MODEL

24997

IDLER SHAFT GEAR BEARING

24697

IDLER SHAFT REAR BEARING LOCK BALL

24627

REAR BEARING LOCATING RING

10

244596

IDLER SHAFT NUT

11

24628

IDLER SHAFT BEARING CAP GASKET

12

SEE ITEM # 21

13-16

NOT USED ON THIS MODEL

17

244536

IDLER SHAFT BEARING CAP SCREW LOCKWASHER

18

244597

IDLE SHAFT BEARING CAP SCREW

19

244597

IDLE SHAFT BEARING CAP SCREW

20

244536

IDLER SHAFT BEARING CAP SCREW LOCKWASHER

21

465563-13

22

244734

IDLE SHAFT BEARING CAP ROTATED 90 DEGREES


(C.C.W.)
SPACER IDLER BEARING

23

N/A

NOT USED ON THIS MODEL

24

244735

PLUG IDLER CAP SPEEDO

1
1

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 26 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

DESCRIPTION

17193
Page 27 of 38
QTY.

SHORT DROP OUTPUT SHAFT GROUP


1

244562

FRONT BEARING CAP OIL SEAL

24636

FRONT BEARING CAP

24632

BEARING CAP SHIM (.004)

A/R

3A

24633

BEARING CAP SHIM (.007)

A/R

3B

24634

BEARING CAP SHIM (.010)

A/R

3C

24635

BEARING CAP SHIM (.013)

A/R

24699

FRONT BEARING CAP O-RING

244600

FRONT BEARING CUP

244601

FRONT BEARING CONE

244602

OUTPUT SHAFT GEAR SPACER

244603

OUTPUT SHAFT

244601

REAR BEARING CONE

10

24667

REAR BEARING CUP

11

24953

REAR BEARING CAP O-RING

12

24698

REAR BEARING CAP O-RING

13

244536

REAR BEARING CAPSCREW LOCKWASHER

14

24675

REAR BEARING CAPSCREW

15

244562

REAR BEARING CAP OIL SEAL

16

244536

FRONT BEARING CAPSCREW LOCKWASHER

17

24674

FRONT BEARING CAPSCREW

18-26

N/A

NOT USED ON THIS MODEL

27

244605

REAR BEARING CAP

28

244606

OUTPUT SHAFT GEAR

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 28 of 38

ITEM PART #

DESCRIPTION

QTY.

1
2
3
4
5
6
7
8

FRONT OUTPUT END YOKE


O-RING
WASHER
NUT
REAR OUTPUT END YOKE
O-RING
WASHER
NUT

1
1
1
1
1
1
1
1

244565
244556
244564
24567
244565
244556
244564
24567

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 29 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 30 of 38

ITEM PART #

DESCRIPTION

QTY.

N/A

PRESSURE REGULATOR VALVE & CHARGING PUMP


GROUP
NOT USED ON THIS MODEL

N/A

NOT USED ON THIS MODEL

244111

VALVE TO HOUSING GASKET

24950

VALVE BODY O-RING

24467

VALVE BODY O-RING

24951

VALVE BODY O-RING

244079

VALVE TO CONVERTER HOUSING STUD

244078

VALVE BODY TO PUMP GASKET

24435

VALVE TO HOUSING STUD LOCKWASHER

10

24464

VALVE TO HOUSING STUD NUT

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 31 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

17193
Page 32 of 38

DESCRIPTION

QTY.

PRESSURE REGULATING VALVE ASSEMBLY


1

244076

24689

PRESSURE REGULATOR VALVE ASSEMBLY


(INCLUDES ITEMS 2-17)
PIPE PLUG

2
3

244091

SAFETY VALVE SEAT

244092

SAFETY VALVE SPACER

24534

SAFETY VALVE PLUNGER

24533

SAFETY VALVE SPRING

24490

VALVE STOP O-RING

244070

VALVE STOP SPRING

244286

VALVE STOP ROLL PIN

10

244286

VALVE STOP ROLL PIN

11

24570

VALVE STOP

12

24080

VALVE STOP O-RING

13

244736

VALVE PISTON

14

24572

VALVE SPRING INNER

15

244109

VALVE SPRING OUTER

16

24982

PUMP DRIVE SHAFT OIL SEAL

17

244093

VALVE BODY ROLL PIN

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 33 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

17193
Page 34 of 38

DESCRIPTION

QTY.

CHARGING PUMP AND FILTER


1

465563-14

20 GPM CHARGING PUMP ASSEMBLY

244192

PUMP TO FILTER ADAPTOR SCREW LOCKWASHER

244287

PUMP TO FILTER ADAPTOR SCREW

244080

PUMP TO FILTER GASKET

465563-15

FILTER ADAPTER

465563-16

OIL FILTER ELEMENT ASSEMBLY

244075

FILTER HOUSING

244074

OIL FILTER ELEMENT SPRING

244165

FILTER HOUSING O-RING

10

244071

BY-PASS FILTER DISC SPRING

11

244072

BY-PASS FILTER DISC

12

244073

BY-PASS FILTER DISC SEAT

13

24043

FILTER SEAT RETAINING RING

14

24462

FILTER ADAPTOR PLUG

15

24462

FILTER ADAPTOR PLUG

16

NSS

PART OF ITEM 1

17

NSS

PART OF ITEM 1

18

NSS

PART OF ITEM 1

19

NSS

PART OF ITEM 1

20

NSS

PART OF ITEM 1

21

NSS

PART OF ITEM 1

22

NSS

PART OF ITEM 1

23

NSS

PART OF ITEM 1

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 35 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

17193
Page 36 of 38

DESCRIPTION

QTY.

ELECTRIC CONTROL VALVE ASSEMBLY


1

244641
244639

CONTROL VALVE COVER ASSEMBLY


(INCLUDES ITEM 2)
CLUTCH PRESSURE PORT PLUG

1
6

244638

CONTROL VALVE COVER TO HOUSING GASKET

244640

244154

CONTROL VALVE ASSEMBLY TO CONVERTER


HOUSING SCREW
CONTROL VALVE ASSEMBLY SCREW WASHER

N/A

NOT USED ON THIS MODEL

N/A

NOT USED ON THIS MODEL

N/A

NOT USED ON THIS MODEL

N/A

NOT USED ON THIS MODEL

10

N/A

NOT USED ON THIS MODEL

11

N/A

NOT USED ON THIS MODEL

12

N/A

NOT USED ON THIS MODEL

13

N/A

NOT USED ON THIS MODEL

14

N/A

NOT USED ON THIS MODEL

15

244628

CONTROL VALVE ASSEMBLY TO CONVERTER


HOUSING GASKET

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563

17193
Page 37 of 38

Updated:
10/28/08

TRANSMISSION ASSEMBLY
465563
ITEM PART #

17193
Page 38 of 38

DESCRIPTION

QTY.

ELECTRIC CONTROL VALVE ASSEMBLY CONT


1

244628

244405

CONTROL VALVE HOUSING ASSEMLBY


(INCLUDES ITEMS 2 21)
CARTRIDGE O-RING

2
3

244171

CARTRIDGE O-RING

244630

CARTRIDGE O-RING

244631

CARTRIDGE O-RING

NSS

VALVE CARTRIDGE PART OF ITEM 12

N/A

NOT USED ON THIS MODEL

NSS

SOLENOID COIL 24V PART OF ITEM 12

N/A

NOT USED ON THIS MODEL

10

NSS

SOLENOID COIL NUT PART OF ITEM 12

11

N/A

NOT USED ON THIS MODEL

12

244637

13

244167

SPOOL TYPE SOLENOID CARTRIDGE ASSEMBLY


(SOLD AS AN ASSEMBLY ONLY)
MODULATOR PRESSURE REGULATOR BORE PLUG

13A

244159

O-RING (PART OF ITEM 13)

14

N/A

NOT USED ON THIS MODEL

15

N/A

NOT USED ON THIS MODEL

16

N/A

NOT USED ON THIS MODEL

17

N/A

NOT USED ON THIS MODEL

18

N/A

NOT USED ON THIS MODEL

19

N/A

NOT USED ON THIS MODEL

20

N/A

NOT USED ON THIS MODEL

21

N/A

NOT USED ON THIS MODEL

4
4
1

Updated:
10/28/08

TRANSMISSION MOUNTS

13436
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

13256-02

TRANSMISSION MOUNT (R.H. SIDE)

13256-01

TRANSMISSION MOUNT (L.H. SIDE)

17GC12072

BOLT

32290

RUBBER MOUNT

17503-01

WASHER

59GD12

NUT

02GE12

WASHER

17GC12030

BOLT

Updated:
12/11/06

S1005

Specifications
Model 32000 Series Transmission

SPICER OFF-HIGHWAY PRODUCTS

S1005

S1005

TOWING OR'PUSH STARTING


Before towing the vehicle, be sure to lift the rear wheels off the
ground or disconnect the driveline to avoid damage to the transmission during towing.

NOTE: If the transmission has 4 wheel drive, disconnect both


front and rear drivelineSl Because of the design otthe hydraulic
system, the engine cannot be started by pushing or towing.

CCopyrightSpicer Off-Highway Products Division 1997


Unpublished material All rights reserved Limiteddistribution
No part of the work may be reproduced in any form under any means
without direct written permission of Spicer Off-Highway Products Division

/j

S1005

FORWARD
This manual has been prepared to provide the customer and the
maintenance personnel with information and instructions on the
maintenance and repair of the SPICER OFF-HIGHWAY COMPONENTS
DIVISION product.
Extreme care has been exercised in the design, selection of materials and
manufacturing of these units. The slight outlay in personal attention and
cost required to provide regular and proper lubrication, inspection at
stated intervals, and such adjustments as may be indicated with be
reimbursed many times in low cost operation and trouble free service.
In order to become familiar with the various parts of the product, its
principle of operation, trouble shooting and adjustments, it is urged that
the mechanic study the instructions in this manual carefully and use it as
a reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only
Spicer Off-Highway Components Division-approved parts as listed in
the applicable parts manual should be used. Use of "will-fit" or nonapproved parts may endanger proper operation and performance of the
equipment. Spicer Off-Highway Components Divison does not warrant
repair or replacement parts, nor failures resulting form the use of parts
which are not supplied by or approved by Spicer Off-Highway
Components Division. IMPORTANT: Always furnish the Distributor
with the serial and model number when ordering parts.

S1005

TABLE OF CONTENTS

HOW THE UNITS OPERATE


SECTIONAL VIEWS AND PARTS IDENTIFICATION
Basic Design Silhouette

Fig. A

Converter Group

Fig. B

Converter and Transmission Case Group

Fig. C

Reverse and 3rd and Forward and 2nd Clutch Group

Fig. D

Low (1st Clutch) and Output Group

Fig. E

Regulating Valve, Charging Pump and Filter Group

Fig. F

Control Valve Assembly

Fig. G

Axle Disconnect and Mechanical Parking Brake

Fig. H

Assembly Instruction Illustration

Fig. I

HR32000 3 Speed Typical Cross Section

Fig J

DISASSEMBLY OF TRANSMISSION

REASSEMBLY OF TRANSMiSSiON

38

SERVICING MACHINE AFTER TRANSMISSION OVERHAUL.

56

SPECIFICATIONS AND SERVICE DATA

57

LUBRiCATION

57

TROUBLE SHOOTING GUIDE.

58

16 SCREW RING GEAR INSTALLATION

60-61

TYPICAL THREE SPEED POWER FLOW

62-63

HR EXTERNAL PLUMBING DIAGRAM

65

CLEANING AND INSPECTION

66

SPEED SENSOR BUSHING INSTALLATION

67

32 SCREW RING GEAR INSTALLATION

68-69

R-MODEL SECTION

70

6 & 8 SPEED SECTION

80

8 SPEED SECTION

92

DRIVE PLATE INSTALLATION

98

ELECTRIC CONTROLS

NOTE: Metric Dimensions Shown in Brackets [ ].

100

S1005

TRANSMISSION ASSEMBLY
The transmission and hydraulic torque portion of the power train enacts an important role in transmitting
engine power to the driving wheels. In order to properly maintain and service these units it is important
to first understand their function and how they operate.
The transmission and torque converter function together and operate through a common hydraulic system.
It is necessary to consider both units in the study of their function and operation.
To supplement the text below, and for reference use therewith, the following illustrations are provided:

Basic Design Silhouette


Converter Group
Converter and Transmission Case Group
Reverse and 3rd, Forward and 2nd Clutch Group
Low (1 st) Clutch and Output Group
Regulating Valve, Charging Pump and Filter Group
Control Valve Assembly
Axle Disconnect and Mechanical Parking Brake
Assembly Instruction
Ring Gear Installation
Clutch and Gear Arrangement
Three Speed Power Flow
External Plumbing

The R, HR, and MHR Model Transmissions are of three basic designs.
The R Model consists of a separate torque converter, mounted to the engine with the powershift transmission remotely mounted and connected to the torque converter with a drive shaft.
The HR Model consists of a torque converter and powershifted transmission in one package mounted directly
to the engine.
The MHR version is a mid-mount torque converter and transmission assembly connected to the engine by
means of a drive shaft. (See Fig. A for basic design silhouette.)
The shift control valve assembly may be mounted directly on the side of the converter housing or front
transmission cover, or remote mounted and connected to the transmission by means of flexible hoses. The
function of the control valve assembly is to direct oil under pressure to the desired directional and speed
clutch. A provision is made on certain models to neutralize the transmission when the brakes are applied.
This is accomplished through use of a brake actuated shutoff valve. The speed and direction clutch assemblies are mounted inside the transmission case and are connected to the output shaft of the converter either
by direct gearing or drive shaft. The purpose of the speed or directional clutches is to direct the power
flow through the gear train to provide the desired speed range and direction.
An axle disconnect is optional and is located on the output shaft. The drive to the front or rear axle can
be disconnected or connected by manual shifting.

S1005

HOW THE UNITS OPERATE


With the engine running, the converter charging pump draws oil from the transmission sump through the
removable oil suction screen and directs it through the pressure regulating valve and oil filter.
The pressure regulating valve maintains pressure to the transmission control cover for actuating the direction and speed clutches. This requires a small portion of the total volume of oil used in the system. The
remaining volume of oil is directed through the torque converter circuit to the oil cooler and returns to
the transmission for positive lubrication. This regulator valve consists of a hardened valve spool operating
in a closely fitted bore. The valve spool is spring loaded to hold the valve in a closed position. When a
specific pressure is achieved, the valve spool works against the spring until a port is exposed along the
side of the bore. This sequence of events provides the proper system pressure.
After entering the converter housing the oil is directed through the stator support to the converter blade
cavity and exits in the passage between the turbine shaft and converter support. The oil then flows out of
the converter to the oil cooler. After leaving the cooler, the oil is directed to a fitting on the transmission.
Then through a series of tubes and passages lubricates the transmission bearings and clutches. The oil then
gravity drains to the transmission sump.
The hydraulic torque converter consists basically of three elements and their related parts to multiply engine
torque. The engine power is transmitted from the engine flywheel to the impeller element through the
impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication. This element can be compared to a centrifugal pump in that it picks up fluid at its center and discharges at its outer
diameter.
The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the
torque converter. This element receives fluid at its outer diameter and discharges at its center. Fluid directed
by the impeller out into the particular design of blading in the turbine and reaction member is the means
by which the hydraulic torque converter multiplies torque.
The reaction member of the torque converter is located between and at the center or inner diameters of the
impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion
of the turbine and change its direction to allow correct entry for recirculation into the impeller element.
The torque converter will multiply engine torque to its designed maximum multiplication ratio when the output shaft is at zero RPM. Therefore, we can say that as the output shaft is decreasing in speed the torque
multiplication is increasing.
The shift control valve assembly consists of a valve body with selector valve spools. A detent ball and spring
in the selector spool provides one position for each speed range. A detent ball and spring in the direction
spool provides three positions, one each for forward, neutral and reverse.
With the engine running and the directional control lever in neutral position, oil pressure from the regulating valve is blocked at the control valve, and the transmission is in neutral. Movement of the forward and
reverse spool will direct oil, under pressure to either the forward or reverse direction clutch as desired.

S1005

When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through
the direction selector spool. The same procedure is used in the speed selector.
The direction or speed clutch assembly consists of a drum with internal splines and a bore to receive a hydraulically actuated piston. The piston is "oil tight" by the use of sealing rings. A steel disc with external
splines is inserted into the drum and rests against the piston. Next, a friction disc with splines at the inner
diameter is inserted. Discs are alternated until the req uired total is achieved. A heavy back-up plate is then
inserted and secured with a snap ring. A Hub with 0.0. splines is inserted into the splines of discs with
teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch.
To engage the clutch, as previously stated, the control valve is placed in the desired position. This allows
oil under pressure to flow from the control valve, through a tube, to a chosen clutch shaft. This shaft has
a drilled passageway for oil under pressure to enter the shaft. Oil pressure sealing rings are located on the
clutch shaft. These rings direct oil under pressure to a desired clutch. Pressure of the oil forces the piston
and discs against the heavy back-up plate. The discs, with teeth on the outer diameter, clamping against
discs with teeth on the inner diameter, enables the hub and clutch shaft to be locked together and allows
them to drive as a unit.
There are bleed balls in the clutch piston which allow quick escape for oil when the pressure to the piston
is released.

R-32000

HR-32000

FIG. A

MHR32000

S1005

"

~"
\

57

58

Figure B

S1005

HR32000 CONVERTER GROUP

ITEM

DESCRIPTION

OTY.

ITEM

DESCRIPTION

OTY.

Bearing Support Screw. . . . . . . . . . . ..

30

Hub to Impeller Screw. . . . . . . . . . . . .. 12

Bearing Support Screw Lockwasher. ..

31

Impeller Hub Screw Backing Ring

Drive Gear Snap Ring . . . . . . . . . . . . . .

32

Impeller

Pump Drive Gear Bearing . . . . . . . . . ..

33

Impeller Hub "0" Ring

Pump Drive Bearing Support. . . . . . . ..

34

Impeller Hub

Pump Drive Gear . . . . . . . . . . . . . . . . ..

35

Impeller Hub Bearing

Turbine Shaft Gear

36

Bearing Snap Ring

Turbine Shaft Gear Snap Ring

37

Reaction Member Spacer

Charging Pump Drive Sleeve

38

Reaction Member

10

Pump Sleeve Snap Ring

39

Reaction Member Snap Ring

11

Valve to Housing Gasket.

40

Turbine Hub

12

Valve Body "0" Ring

41

Turbine

13

Valve Body "0" Ring

42

Turbine Hub Backing Ring

14

Charging Pump& Oil Filter Assembly

43

Turbine Hub Screw . . . . . . . . . . . . . . ..

15

Valve Body "0" Ring

44

Impeller to Cover "0" Ring

16

Turbine Shaft Bearing

45

Impeller Cover

17

Turbine Shaft Piston Ring

46

Impeller Cover Bearing

18

Turbine Shaft

47

Bearing Cap to Impeller Cover "0" Ring

19

Stator Support

48

Bearing Washer

20

Stator Support Screw Lockwasher. . ..

49

Bearing Snap Ring

21

Stator Support Screw. . . . . . . . . . . . . ..

50

Impeller Cover Bearing Cap

22

Piston Ring

51

Impeller Cover Sleeve

23

Piston Ring Expander Spring

52

Ring Gear Screw . . . . . . . . . . . . . . . . .. 16

24

Impeller Hub Gear Snap Ring

53

Plain Washer. . . . . . . . . . . . . . . . . . . . .. 16

25

Impeller Hub Gear

54

Flywheel Ring Gear

26

Oil Baffle Oil Seal. . . . . . . . . . . . . . . . ..

55

Bearing Cap to Impeller Cover Screw. .. 10

27

Oil Baffle Seal Ring

56

28

Oil Baffle

Bearing Cap to Impeller Cover


Screw Lockwasher. . . . . . . . . . . . . . . .. 10

29

Oil Baffle Retainer Ring

57

Impeller to Cover Screw

58

Impellerto Cover Screw Lockwasher . .. 24

24

S1005

3~
(
I

MHR OPTION

73

CONVERTER HOUSING TO TRANSMISSION


CASE SPACER USED ONLY WITH 12
PLATE CLUTCH PACK ASSEMBLY.

Figure C

S1005

HR32000 CONVERTER & TRANSMISSION CASE GROUP


ITEM

DESCRIPTION

QTY ,

DESCRIPTION

ITEM

QTY

1
2
3

Pipe Plug
.
Converter Housing Assembly. . . . . . . . . . . . . . . . . . .. 1
Converter Housing to
Front Cover Screw Lockwasher
12

4
5
6

Converter Housing to Front Cover Screw


12
Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

49

Converter Housing Sleeve. . .. . . . . . . . . . . . . . . . . . .. 1

50

Rear Cover Dowel Pin. . . . . . . . . . . . . . . . . . . . . . . . .. 2

45
46
47
48

Clutch Pressure Tube "0" Ring. . . . . . . . . . . . . . . . . .. 1


Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Low Speed Clutch Pressure Tube. . . . . . . . . . . . . . . .. 1
Transmission Case to Converter
Housing Screw Lockwasher
Transmission Case to Converter
Housing Screw

10
10

Converter Housing Sleeve Lock. . . . . . . . . . . . . . . . .. 1

51

Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

Converter Housing Sleeve Screw Lockwasher. . . . . .. 1

52

10

Converter Housing Sleeve Screw. . . . . . . . . . . . . . . .. 1

11
12

Converter Housing Sleeve Screw. . . . . . . . . . . . . . . .. 1


Converter Housing Sleeve Screw Lockwasher. . . . . .. 1

Rear Cover to Transmission Case


Screw Lockwasher
Rear Cover to Transmission Case Screw

13

Converter Housing Sleeve Lock. . . . . . . . . . . . . . . . .. 1

14
15

Converter Housing Sleeve. . . . . . . . . . . . . . . . . . . . . .. 1


Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

16

Street Ell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

17

Breather Reducing Bushing. . . . . . . . . . . . . . . . . . . . .. 1

18

Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3

19

Pipe Plug.................................... 1

20

Converter Housing to Transmission


Housing Screw Lockwasher. . . . . . . . . . . . . . . . . . . ..
Converter Housing to Transmission
Housing Screw...............................
Converter Housing to Transmission
Housing Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . ..
Converter Housing to Transmission
Housing Screw...............................

21
22
23

53
54

Rear Cover Pipe Plug. . . . . . . . . .. . . . . . . . . . . . . . . .. 1

55

Rear Cover to CaseStud Nut. . . . . . . . . . . . . . . . . . . .. 2

56
57

Rear Cover to Case Stud Lockwasher. . . . . . . . . . . . .. 2


Clutch Pressure Tube "0" Ring. . . . . . . . . . . . . . . . . .. 1

58

Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

59

Rear Cover to Transmission Case Gasket. . . . . . . . . .. 1

60

Rear Cover to Case Stud. . . . . . . . . . . . . . . . . . . . . . .. 2

61

Magnetic Drain Plug. . . . . . . . . . . . . . . . . . . . . . . . . .. 1

62

Oil Level Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1


Oil Level Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

63

64
65

66
67

13
13

68

Transmission Case Assembly. . . . . . . . . . . . . . . . . . .. 1


Screen Assembly Gasket. . . . . . . . . . . . . . . . . . . . . . .. 1
Screen Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Suction Tube Clip Washer. . . . . . . . . . . . . . . . . . . . . .. 1

69
70

Suction Tube Clip

71

Suction Line Washer. . . . . . . . . . . . . . . . . . . . . . . . . .. 1

72

Suction Line "0" Ring. . . . . . . . . . . . . . . . . . . . . . . . .. 1

73

Suction Tube Clip Rivet. . . . . . . . . . . . . . . . . . . . . . . .. 1


Converter Housing to Transmission
Case Gasket
.
Oil Baffle
.

24

Lube Tube Retaining Screw Lockwasher. . . . . . . . . .. 1

25

Lube Tube Retaining Screw. . . . . . . . . . . . . . . . . . . .. 1

26

Suction Tube "0" Ring. . . . . . . . . . . . . . . . . . . . . . . .. 1

27
28

Suction Tube Spacer Ring. . . . . . . . . . . . . . . . . . . . . .. 1


Suction Tube Assembly. . . . . . . . . . . . . . . . . . . . . . .. 1

29

Suction Tube Retainer Screw Lockwasher. . . . . . . . .. 1

30
31

Suction Tube Retainer Screw. . . . . . . . . . . . . . . . . . .. 1


Tube Clip Screw
, . . . . . . . . . . . . . . . . . . .. 1

Tube Clip Screw Lockwasher. . . . . . . . . . . . . . . . . . .. 1

76
77

Converter Housing Adaptor Ring

32

4th Speed Pressure Tube "0" Ring

33

Tube Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

78

Low Speed Pressure Tube "0" Ring

34

Reverse Tube Assembly. . . . . . . . . . . . . . . . . . . . . . .. 1

79

35

Reverse Tube "0" Ring. . . . . . . . . . . . . . . . . . . . . . . .. 1

Converter Housing to Transmission


Case Gasket

36

Lube Tube Retainer Screw. . . . . . . . . . . . . . . . . . . . .. 1

80

37

Lube Tube Retainer Screw Lockwasher. . . . . . . . . . .. 1

.
.

74
75

Suction Line Screw. . . . . . . . . . . . . . . . . . . . . . . . . . .. 2

38

Lube Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . .. 1

81

Converter Housing to Transmission


Case Spacer (12 plate clutch pack only)
Front Cover Oil Seal

39

Tube Clip Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

82

Converter Housing Front Cover

40
41

Tube Clip Screw Lockwasher. . . . . . . . . . . . . . . . . . .. 1


Tube Clip
1

83

Converter Housing Front Cover Gasket

84

42

3rd Speed Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

85

Hose Fitting
Hose Assembly

.
.

43
44

3rd Speed Tube "0" Ring. . . . . . . . . . . . . . . . . . . . . .. 1


Valve Oil Supply Tube. . . . . . . . . . . . . . . . . . . . . . . . .. 1

86

Hose Fitting

ITEMS 81 THRU 86 FOR MHR ONLY.

S1005

Figure D

S1005

R OR HR32000
REVERSE & 3RD & FORWARD & 2ND CLUTCH GROUP

ITEM
1
1A
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
34
35
36
37
38
39
40
41
42
43
44
45
46

DESCRIPTION

QTY

Reverse & 3rd Clutch Shaft Piston Ring


Piston Ring ExpanderSprings . . . . . . . . . . . . . . . . . . ..
Front Bearing Retainer Ring. . . . . . . . . . . . . . . . . . . . ..
Reverse & 3rd Shaft Front Bearing End Plate
Reverse & 3rd Shaft Bearing End PlateBall. . . . . . . . ..
Reverse & 3rd Shaft Front Bearing
Front Bearing Retainer Ring. . . . . . . . . . . . . . . . . . . . ..
Clutch Driven Gear Bearing - Shield In
Clutch Driven Gear Bearing Snap Ring . . . . . . . . . . . ..
Clutch Driven Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Clutch Hub Oil Baffle Ring. . . . . . . . . . . . . . . . . . . . . ..
Spring Retainer Snap Ring
Clutch Driven GearBearing Snap Ring . . . . . . . . . . . ..
Clutch Driven Gear Bearing . . . . . . . . . . . . . . . . . . . . ..
Spring RetainerSnap Ring
Spring RetainerSnap Ring Retainer
Spring Retainer
; . . . . . . . . . ..
Piston Return Spring
Spring Retainer
End Plate Retainer Ring . . . . . . . . . . . . . . . . . . . . . . . ..
End Plate- Reverse Clutch. . . . . . . . . . . . . . . . . . . . . ..
Clutch Outer Disc - Reverse Clutch . . . . . . . . . . . . . . ..
Clutch Inner Disc - Reverse Clutch. . . . . . . . . . . . . . . ..
Clutch Piston Assembly - Reverse Clutch . . . . . . . . . ..
Clutch Piston Outer Seal
Clutch Piston Inner Seal. . . . . . . . . . . . . . . . . . . . . . . ..
Reverse & 3rd Clutch Drum. . . . . . . . . . . . . . . . . . . . ..
Clutch Piston Inner Seal. . . . . . . . . . . . . . . . . . . . . . . ..
Clutch Piston Outer Seal
Clutch Piston - 3rd Clutch
Clutch Inner Disc - 3rd Clutch
Clutch Outer Disc - 3rd Clutch . . . . . . . . . . . . . . . . . . ..
End Plate- 3rd Clutch. . . . . . . . . . . . . . . . . . . . . . . . . ..
End PlateRetainer Ring . . . . . . . . . . . . . . . . . . . . . . . ..
Spring Retainer
Piston Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . ..
Spring Retainer
Spring Retainer Snap Ring Retainer
Spring RetainerSnap Ring
3rd GearBearing
3rd Gear Bearing Snap Ring
Clutch Hub Oil Baffle Ring
3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
3rd GearBearingSpacer . . . . . . . . . . . . . . . . . . . . . . ..
3rd GearBearing Snap Ring
3rd Gear Bearing - Shield Out
Reverse & 3rd Shaft Rear Bearing . . . . . . . . . . . . . . . ..

3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
6
1
1
1
1
1
1
1
6
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

ITEM
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
92A

DESCRIPTION

QTY

Low Clutch Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . ..


GearRetaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . ..
2nd Gear
Clutch Hub Oil Baffle Ring. . . . . . . . . . . . . . . . . . . . . ..
2nd GearRetainer Ring
2nd GearRetainer Ring Retainer . . . . . . . . . . . . . . . . ..
2nd GearRetainer Ring Retainer Snap Ring
Spring Retainer Snap Ring
Spring Retainer Snap Ring Retainer
Spring Retainer
Piston Return Spring .. . . . . . . . . . . . . . . . . . . . . . . . ..
Spring Retainer
End PlateRetainer Ring . . . . . . . . . . . . . . . . . . . . . . . ..
End Plate- 2nd Clutch ... . . . . . . . . . . . . . . . . . . . . . ..
Clutch Outer Disc - 2nd Clutch
Clutch Inner Disc - 2nd Clutch . . . . . . . . . . . . . . . . . . ..
Clutch PistonAssembly - 2nd Clutch. . . . . . . . . . . . . ..
Clutch Piston Outer Seal
Clutch Piston Inner Seal. . . . . . . . . . . . . . . . . . . . . . . ..
Forward & 2nd Clutch Drum . . . . . . . . . . . . . . . . . . . ..
Clutch Piston Inner Seal. . . . . . . . . . . . . . . . . . . . . . . ..
Clutch Piston Outer Seal
Clutch Piston Assembly - Forward Clutch . . . . . . . . . ..
Clutch Outer Disc - Forward Clutch . . . . . . . . . . . . . . ..
Clutch Inner Disc - Forward Clutch
End Plate- Forward Clutch. . . . . . . . . . . . . . . . . . . . . ..
End PlateRetainer Ring . . . . . . . . . . . . . . . . . . . . . . . ..
Spring Retainer Snap Ring
Spring Retainer
Piston Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . ..
Spring Retainer
Spring Retainer Snap Ring Retainer
Spring Retainer Snap Ring
Clutch Driven Gear Bearing . . . . . . . . . . . . . . . . . . . . ..
Clutch Driven Gear BearingSnap Ring . . . . . . . . . . . ..
Clutch Hub Oil Baffle Ring . . . . . . . . . . . . . . . . . . . . . ..
Forward Clutch Driven Gear
Clutch Driven Gear BearingSnap Ring . . . . . . . . . . . ..
Clutch Driven Gear Bearing- Shield In
Front Bearing Retainer Ring. . . . . . . . . . . . . . . . . . . . ..
Front Bearing Locating Ring
:
Forward & 2nd Shaft Front Bearing. . . . . . . . . . . . . . ..
Forward & 2nd Shaft BearingEnd PlateBall . . . . . . . ..
Forward & 2nd Shaft Front BearingEnd Plate. . . . . . ..
Front Bearing Retainer Ring. . . . . . . . . . . . . . . . . . . . ..
Forward & 2nd Shaft Piston Ring
Piston Ring ExpanderSprings . . . . . . . . . . . . . . . . . . ..

1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
6
1
1
1
1
1
1
1
6
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3

S1005

52

53

55 54
56 \ \
59

58
\

57\

~GY

.>:

.'~'

~~\\)
-;"

rr"~

\~~~
r~i~
\
61
~"'"
60

74
72 73 \

70

71~\
~~
\~. ~\,l)

Figure E

76

75

77 78 79 80
\ ~\ \

\~~~

~~.~

82 81

S1005

R OR HR32000 LOW f1ST) CLUTCH & OUTPUT GROUP


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
34
35
36
37
38
39
40
41

DESCRIPTION

QTY

Low Speed Clutch Shaft Pilot Bearing


2nd Gear Bearing End Plate. . . . . . . . . . . . . . . . . . . . ..
2nd Gear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Bearing Retaining Ring Retainer . . . . . . . . . . . . . . . . ..
Low Speed Gear Bearing Retainer Ring
Low Speed Gear Bearing Assembly
Low Speed Gear
Clutch Hub Oil Baffle Ring . . . . . . . . . . . . . . . . . . . . . ..
Spring Retaining Ring Retainer . . . . . . . . . . . . . . . . . ..
Spring Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . ..
Piston Return Disc Springs . . . . . . . . . . . . . . . . . . . . ..
Piston to Piston Return Disc Springs Spacer. . . . . . . ..
End Plate Retainer Ring . . . . . . . . . . . . . . . . . . . . . . . ..
End Plate
Clutch Inner Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Clutch Outer Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Clutch Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Clutch Piston Outer Seal
Clutch Piston Inner Seal. . . . . . . . . . . . . . . . . . . . . . . ..
Low Speed Clutch Drum . . . . . . . . . . . . . . . . . . . . . . ..
Low Speed Shaft RearBearing . . . . . . . . . . . . . . . . . ..
Bearing Lockball
Rear Bearing RetainerPlate . . . . . . . . . . . . . . . . . . . . ..
RearBearing RetainerPlate Screw
Rear Bearing Cap Gasket. . . . . . . . . . . . . . . . . . . . . . ..
Rear Bearing Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Rear Bearing Cap Screw Lockwasher . . . . . . . . . . . . ..
RearBearing Cap Screw . . . . . . . . . . . . . . . . . . . . . . ..
RearBearing Cap Plug. . . . . . . . . . . . . . . . . . . . . . . . ..
RearBearing Cap "0" Ring . . . . . . . . . . . . . . . . . . . . ..
Clutch Shaft Piston Plug
Low Speed Shaft RearBearing Locating Ring
Bearing Cap Screw Lockwasher . . . . . . . . . . . . . . . . ..
Bearing Cap Screw
Bearing Cap Screw
Bearing Cap Screw Lockwasher . . . . . . . . . . . . . . . . ..
Idler Shaft Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . ..
Idler Shaft Bearing Cap Gasket . . . . . . . . . . . . . . . . . ..
Idler Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Rear Bearing Locating Ring . . . . . . . . . . . . . . . . . . . . ..
Idler Shaft Rear Bearing Lockball . . . . . . . . . . . . . . . . ..

1
1
1
1
1
1
1
1
1
1
5
1
1
1
9
9
1
1
1
1
1
1
1
3
1
1
5
5
1
1
1
1
2
2
2
2
1
1
1
1
1

ITEM
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82

DESCRIPTION

QTY.

Idler Shaft Rear Bearing. . . . . . . . . . . . . . . . . . . . . . . .. 1


RearBearing Cap Oil Seal
1
RearBearing Cap Screw . . . . . . . . . . . . . . . . . . . . . . .. 4
Rear Bearing Cap Screw Lockwasher . . . . . . . . . . . . .. 4
Rear Bearing Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Rear Bearing Cap "0" Ring. . . . . . . . . . . . . . . . . . . . .. 1
RearBearing Cap "0" Ring . . . . . . . . . . . . . . . . . . . . .. 1
RearBearing Cup. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Rear Bearing Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Output Shaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Output Shaft GearSpacer . . . . . . . . . . . . . . . . . . . . . .. 1
Output Shaft
1
Front Bearing Cone
. . . . . . . . . . . . . . . . . . . .. 1
Front Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
1
Front Bearing Cap "0" Ring
Bearing Cap Shim. . . . . . . . . . . . . . . . . . . . . . . . . . .. AR
Front Bearing Cap
1
Front Bearing Cap Oil Seal. . . . . . . . . . . . . . . . . . . . . .. 1
Front Bearing Cap Screw. . . . . . . . . . . . . . . . . . . . . . .. 4
Front Bearing Cap Screw Lockwasher
4
Bearing RetainerRing
1
Bearing Locating Ring . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Idler Shaft Front Bearing
. . . . . . . . . . . . . . . . . . .. 1
Idler Shaft
1
Idler Shaft Gear Key. . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Idler Shaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Bore Plug (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Disconnect Assembly (optional)
1
Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Output Flange
1
1
Output Flange "0" Ring
Output FlangeWasher. . . . . . . . . . . . . . . . . . . . . . . . .. 1
Output Flange Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Speedo Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Rear Bearing Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Rear Bearing Cap Screw Lockwasher . . . . . . . . . . . . .. 3
Rear Bearing Cap Screw . . . . . . . . . . . . . . . . . . . . . . .. 3
Speedo Driven Gear. . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Speedo Tube Nut
1
Rear Bearing Cap Screw . . . . . . . . . . . . . . . . . . . . . . .. 1
Rear Bearing Cap Screw Lockwasher . . . . . . . . . . . . .. 1

S1005

Figure F

PRESSURE
REGULATOR SlOE

34

S1005

PRESSURE REGULATOR VALVE, CHARGING PUMP & OIL FILTER GROUP

ITEM

DESCRIPTION

QTV.

ITEM

DESCRIPTION

QTV.

Charging Pump Drive Sleeve. . . . . . . ..

26

Valve to Housing Stud Lockwasher . ..

Pump Sleeve Snap Ring. . . . . . . . . . . .

27

Valve to Housing Stud Nut. . . . . . . . ..

Valve to Housing Gasket

28

Thrust Plate & Bearing Assembly. . . ..

Valve Body "0" Ring

29

Wave Spring. . . . . . . . . . . . . . . . . . . . ..

Valve Body "0" Ring

30

Pump Shaft Seal. . . . . . . . . . . . . . . . . ..

Pipe Plug

31

Pump to Filter Adaptor


Screw Lockwasher.................

Safety Valve Seat

.
32

Pump to Filter Adaptor Screw. . . . . . ..

Safety Valve Spacer

.
33

Pump Drive Shaft Assembly

Safety Valve Plunger

.
34

Pump Drive Shaft Oil Seal.

10

Safety Valve Spring

.
35

Pressure Regulator Valve

11

Valve Stop "0" Ring

.
36

Valve Body Roll Pin. . . . . . . . . . . . . . ..

12

Valve Stop

.
37

Valve Body "0" Ring. . . . . . . . . . . . . ..

13

Valve Stop Roll Pin

.
38

Pump to Filter Gasket

14

Valve Stop Roll Pin

.
39

Filter Adaptor

15

Valve Stop

40

Filter Adaptor Plug

16

Valve Stop "0" Ring

.
41

By-Pass Filter Disc Spring

17

Valve Piston

.
42

By-Pass Filter Disc

18

Valve Spring - Inner

.
43

By-Pass Filter Disc Seat

19

Valve Spring - Outer . . . . . . . . . . . . . . .

1
44

Filter Seat Retainer Ring

20

Valve to Converter Housing Stud. . . ..

4
45

Filter Housing "0" Ring

21

Valve Body to Pump Gasket

.
46

Oil Filter Element Assembly

22

Pump Body Snap Ring

.
47

Oil Filter Element Spring

23

Thrust Plate & Bearing Assembly. . . ..

48

Filter Housing

24

Pump Driven Shaft Assembly

.
49

Pipe Plug

25

Charging Pump Housing

.
50

Optional Adaptor for Remote Filter ...

S1005

kli
28--~
29-1Q)

30-~

31-~

26

32_a
33~~

34'--. ~

35~
~

r---------------T-----~-----T--------------~

t"
t
I

DEC.lUTCH
FORWARD &
REVERSE

DEClUTCH
REVERSE ONLY

37

38-1

FIG. B

FIG. A
_

3J
FIG.C

---l
I
I
I

~>
48

8 - 20

~o
I

CONTROL VALVE ASSEMBLY


(AIR OECLUTCH)

FigureG

40_
41 __ ~

u--ll

F1G:{J

VALVE ROTATED 90'

38__
39__

NOTE:
Speed selector spacers (items 13 and 22) and the
declutch valve (item 26) are not included when the
control valve housing assembly (item 14) is ordered.
When ordering the control valve housing assembly
(Item 14) from the service Parts List also order the
spacer or spacers listed as Items 13 and 22 and the
declutch valve, spool and spring needed. NOTE:
Some valves will require no spacers, some valves will
require 1 spacer and some will require 2 spacers.

INCHING I

~-36

"11

3J

DEClUTCH
FORWARD ONLY

S1005

CONTROL VALVE ASSEMBLY

ITEM

DESCRIPTION

QTY.

ITEM

DESCRIPTION

QTY.

Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . .

22

Overshift Spacer (Not on all models)

Oil Seal Retainer Ring. . . . . . . . . . . . . .

23

Oil Seal Retainer Washer

Oil Seal Retainer Washer

24

Oil Seal Retainer Ring. . . . . . . . . . . . . .

Forward & Reverse Valve Spool

25

Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . .

Control Valve Gasket.

26

Piston Housing Assembly

Detent Spring

27

Stop Plug .... . . . . . . . . . . . . . . . . . . . .

Detent Spring

28

Plug "0" Ring. . . . . . . . . . . . . . . . . . . . .

Detent Ball. . . . . . . . . . . . . . . . . . . . . ..

29

Piston "0" Ring. . . . . . . . . . . . . . . . . . .

Neutral Switch . . . . . . . . . . . . . . . . . . ..

30

Glyd Ring . . . . . . . . . . . . . . . . . . . . . . . .

10

Detent Ball . . . . . . . . . . . . . . . . . . . . . . .

31

Piston...........................

11

Valve Housing Plug

32

Piston Housing

12

Valve Housing Plug "0" Ring

33

Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . .

13

Overshift Spacer (Not on all models)

34

Band Seal

14

Control Valve Housing. . . . . . . . . . . . . .

35

"0" Ring. . . . . . . . . . . . . . . . . . . . . . . . .

15

Detent Spring Plug

Figures A-B-C & D are various declutch options.

16

Detent Spring Plug Washer

44

Adaptor Screw . . . . . . . . . . . . . . . . . . ..

17

Detent Spring. . . . . . . . . . . . . . . . . . . . .

45

Adaptor Screw Lockwasher. . . . . . . . ..

18

Valve to Adaptor Housing Screw. . . ..

46

Valve Adaptor

19

Valve to Adaptor Housing Screw


Lockwasher. . . . . . . . . . . . . . . . . . . . . ..

47

Valve Adaptor Gasket

48

Adaptor Screw . . . . . . . . . . . . . . . . . . ..

49

Adaptor to Plate Gasket

50

Valve Adaptor Plate

20

Speed Selector Spool Plug

21

Speed Selector Spool

.
1

.
1

S1005

AXLE DISCONNECT

MECHANICAL PARKING BRAKE

Figure H

S1005

AXLE DISCONNECT
ITEM

DESCRIPTION

QTV

ITEM

Disconnect Housing Capscrew. . . . . . . . . . . . .. 4


2

Disconnect Housing Capscrew


Lockwasher

"

DESCRIPTION

QTV

Detent Ball

10

Detent Spring

11

Shift Rail

12

Shift Rail Oil Seal

13

Bearing Retainer Ring

14

Bearing

15

Bearing Retainer Ring

Disconnect Housing

Disconnect Housing Plug

Shift Hub

Shift Fork

Shift Fork Lockscrew

Disconnect Shaft

PARKING BRAKE GROUP


10 X 3 BRAKE

ITEM

DESCRIPTION

QTV

Lock Nut

Washer

Operating Lever

Backing Plate

Cam Shaft

Strut Assembly

Return Spring

Brake Shoe, Lining & Rivet

o'

ITEM

DESCRIPTION

QTV

Brake Flange

10

Brake Drum

11

Brake Drum Screw Lockwasher. . . . . . . . . . . . .. 6

12

Brake Drum Screw. . . . . . . . . . . . . . . . . . . . . . .. 6

13

Brake Lining

14

Rivet Kit

15

Backing Plate Screw. . . . . . . . . . . . . . . . . . . . .. 4

16

Backing Plate Screw Lockwasher . . . . . . . . . . .. 4

.
24

S1005

View"Q"

1.

spacer
HOUSln9th
used WI 12 plate

modulation only.

Figure I

S1005

&

Impeller Hub and Turbine Hub Assembly with


Backing Ring and Special Self Locking Screws.
1. Clean hub mounting surface and tapped holes
with solvent. Dry thoroughly being certain tapped
holes are dry & clean.
2. Install backing ring and special self locking
screws.
Tighten screws 40 to 45 Lbs. Ft. [54,3-61,0 N'm]
Note: Assembly of hub must be complete within a
fifteen minute period from start of screw installation. The special screw is to be used for one installation only. If the screw is removed for any
reason it must be replaced. The epoxy left in the
hub holes must be removed with the proper tap
and cleaned with solvent. Dry hole thoroughly and
use a new screw for reinstallation.

Bearing shield OUT on 3rd speed clutch. Bearing shield


IN on Fwd. & Rev. clutch.
Must be loose internal fit bearings, No. "3" etched on
bearing.

&.

&. Three c1utches,6-outer steel plates,6-inner friction


plates.Assemble alternately, starting with outer
steel plate.

&,

&
!J::,

&

(12 Plate Modulation)Two clutches, 12-outersteel plates,


12-inner friction plates. Assemble alternately, starting
with outer steel plate.

Notes
A.. Use Permatex & Crane Sealer only where
specified.
B. - All lead in chamfers for oil seals, piston rings &
"0" rings must be smooth & free from burrs.
Inspect at ass'y.
C.. Lubricate all piston ring grooves & "0" rings
with oil before ass'y.
D. - Apply very light coat of Permatex NO.2 to 0.0.
of all oil seals before ass'y.
E.. After assembly of parts using Permatex or
Crane sealer, there must not be any free or
excess material that could enter the oil circuit.
F. - Apply light coat of Crane Sealer to all pipe
plugs.
G. - Apply a thin coating of grease between seal
lips on lip type seals prior to ass'y.
H. - Apply light coat of Permatex NO.2 to all thru
hole stud threads.

Gear to be assembled with long hub length to this


side.

&

Heat nose bushing to 2000 FO (930C) before ass'y. of


bushing to cover.

See Elastic Stop Nut Torque Chart


Low clutch,9-outer steel plates,9-inner friction
plates. Assemble alternately, starting with outer
steel plate.
See Elastic Stop Nut Torque Chart
Shim output shaft bearings to produce 6 to 8 Lbs.In. [0,68,-0,90 N'm] preload.

NOTE:The friction discs in the low clutch has


a higher co-efficient rating than the friction
discs in the other clutches, therefore the
discs must not be mixed. The low clutch inner disc can be identified by an "X" stamped
on one side of the inner teeth. The low clutch
inner disc also has a strip of non-soluble
yellow paint sprayed on the outer edge of
the disc.

Tighten oil screen ass'y. 10 to 15 Lbs. Ft.


[13,6-20,0 Nrn]

View "Q" 2 Places

Low Clutch Return Springs.


Concave side of first spring to be placed
against clutch piston. Remaining four springs
to be stacked alternately reversed as shown.

Forward & Reverse Clutch Return Springs.


Concave side of first spring to be placed
against clutch piston. Remaining six springs
of each clutch to be stacked alternately
reversed as shown. See note on page 77.

Enlarged view of Piston Ring & Expander


Note: Expander gap to be approx. 180 0 from ring
hook joint to aid ring assembly.
ELASTIC STOP NUT TORQUE

NOTE: Metric dimensions shown


in brackets [ ].

Grade 5
NOM.
SIZE

L-,~~+
5000 ,
4375
3750
3125
2500

FINE THREAD
LB-FT
[NM]
91 - 100
64 - 70
41 - 45
26 - 29
16 - 20
9 - 11

1123,4 I 86,81 55,6I 35,3i 21.7I 12.3-

135.51
94,91
61,01
39,3J
27,11
14.91

ED

LB.-FT.

[N'm]

1" - 20

150 - 200

[203,4 - 271,1]

1V." - 18

200 - 250

[271,2 - 338,9]

1'12" - 18

300 350

[406,8 474,5]

13/4" - 12

400 450

[542,4 - 610,1]

Torque Specification for Lubricated


or Plated Screw Threads

COARSE THREAD
LB-FT
[NM]
82 57 -- 37 23 12 8-

THREAD SIZE

90
63
41
25
16
10

1111,2 I 77,3r 50,2r 31,2[ 16,3[ 10,9-

122,01
85,41
55,51
33,8\
21,61
13,5]

Figure I

Grade 8

FINE THREAD
LB-FT
[NM]
128
90
58
37

141
99
64
41
28 - 32
i1- 13

1-173,6 [122,1 I 78,7r 50,2I 38,0[ 15,0-

191,11
134,21
86,71
55,51
43,31
17,61

'\!Sl
COARSE THREAD
LB-FT
[NM]
115
80
52
33
26
9

127
88
57
36
30
11

1156,0-172,2
1108,5 - 119.3
r 70,6- 77,2
r 44,8- 48,8
r 35,3- 40,6
I 12,3- 14,9]

S1005

Figure J

S1005

MAINTENANCE AND SERVICE

The instructions contained herein cover the disassembly and


reassembly of the transmission in a sequence that would normally be followed after the unit has been removed from the
machine and is to be completely overhauled. It must also be
understood that this is a basic HR32000 3 speed long drop
transmission with many options. Companion flanges and output

shafts with and without disconnect assemblies may vary on


specific models. The units are very similar to trouble shoot,
disassemble, repair, and reassemble. Drain as much oil as
possible before disassembly. See page 70 for R-Model
(remote mounted) transmission front cover section. See page
85 for 6 & 8 speed maintenance information.

DISASSEMBLY

Figure 3
Removefilter element housing and element. NOTE: It is recommended a small pan be used to catch remaining oil in element
housing.

Figure 1
Side view of 3 speed HR32000 long drop transmission.

Figure 2
Remove two valve to converter housing capscrews. Install two
aligning studs as shown. Remove remaining capscrews.
Remove control valve and gasket.

Figure 4
Remove charging pump to pressure regulating valve stud nuts.

-1-

S1005

Figure 5
Remove charging pump and filter adaptor assembly.

Figure 8
Remove pump adaptor bolts, adaptor and gasket.

Figure 6
Remove pressure regulating valve assembly and "0" rings.

Figure 9
Remove impeller cover bearing cap bolts. NOTE: Some
units will have drive plates instead of ring gear. Remove
drive plates.

Figure 7
Remove pump drive sleeve and gasket.

Figure 10
Remove bearing cap and "0" ring.

-2-

S1005

Figure 14

Remove reaction member.

Figure 11
Remove impeller cover to impeller bolts.

Figure 15
Remove reaction member spacer.
Figure 12
Remove impeller cover and turbine as an assembly.

Figure 16
Remove oil baffle retainer ring. Using pry slots in converter
housing, pry oil baffle and impeller from housing. NOTE:
Impeller, oil baffle and impeller hub gear are removed as an
assembly.

Figure 13
Remove reaction member retainer ring.

-3-

S1005

Figure 20
Remove pump drive gear support bolts.

Figure 17
Remove impeller assembly.

Figure 21
Remove pump drive gear and bearing assemblies.

Figure 18
Remove stator support to housing bolts.

Figure 22
Support converter housing with a chain fall. Remove converter
housing to transmission housing bolts. NOTE: For converter
housing removal on the 8 speed transmission, see Figure
1 In the 8 speed section, page 93.

Figure 19
Remove stator support. NOTE: Support must be turned to clear
pump drive gear.

-4-

S1005

Figure 23
Separate the converter housing from the transmission
housing. Remove gasket. NOTE: Forward and 2nd clutch will
remain in converter housing.

Figure 26
Remove turbine shaft gear.

Figure 24
Use a spreading type snap ring pliers to spread the ears on forward clutch front bearing retainer ring. Remove forward clutch
with pry bar.

Figure 27
Tap turbine shaft and bearing from converter housing.

Figure 25
Remove turbine shaft gear retainer ring.

Figure 28
Remove bearing from turbine shaft.

-5-

S1005

Figure 29
Remove 2nd clutch disc hub retainer ring retainer.

Remove disc hub.

Figure 30
Remove disc hub ring retainer.

Figure 33
Remove bearing end plate.

Figure 31
Remove disc hub retainer ring.

Figure 34
Remove brake drum stud nuts (used only to hold drum in place
after drive shaft was removed).

Figure 32

-6-

S1005

Figure 35

Remove brake drum.

Figure 38
Pry brake strut from brake bands.

Figure 36
Remove output flange nut, washer and "0" ring.

Figure 39
Remove brake backing plate bolts.

Figure 37

Figure 40
Remove backing plate and brake band assembly.

Remove output flange.

-7-

S1005

Figure 41
Remove idler shaft rear bearing cap bolts and washers.

Figure 44
Remove rear bearing locating ring.

Figure 42
Remove bearing cap and gasket.

Figure 45
Remove 1st speed clutch (low) rear bearing cap bolts and
washers.

Figure 43
Remove idler shaft rear bearing retainer nut and spacer.

Figure 46
Remove bearing cap and gasket.

-8-

S1005

Figure 50
Remove rear cover bolts and washers.

Figure 47
Remove rear bearing retainer plate bolts.

Remove retainer plate.

Figure 51
Using pry slots provided, pry cover from transmission housing
tapping on 1st speed clutch and idler shaft to allow cover to be
removed without shaft binding. NOTE: The use of alignment
studs will facilitate cover removal.

Figure 49
Remove bearing locating ring.

Figure 52
Remove 1st speed clutch double bearing cup, outer taper
bearing and spacer.

Figure 48

-9-

S1005

Figure 53
CAUTION: Outer cone, double bearing cup, spacer and inner
bearing cone are replaced as a set.

Figure 55
Remove idler shaft assembly. NOTE: The 6 & 8 speed transmission will have two gears and a heavier front bearing.

Figure 54
Remove low clutch inner bearing cone. NOTE: To remove the
inner cone bearing without damage, a special bearing puller
must be made (see diagram Fig. 54-A) or the outer cage and
rollers may be pulled from the bearing inner race and the inner
race can be removed after the low clutch assembly has been
removed from the transmission. See caution in Figure 53.

Figure 56
Remove 1st speed clutch drive gear retainer ring.

1-5/32
1/8

5/32

Irr
+~I~"

49164

- 1/16 R.CENT.

CUTWITH 1/16 RUBBER


WHEELAFTERHON.

ifr
"'

ltL~~'~~-LI
"O"RING

+><

4-17164
OIA.

Figure 54-A
A timken bearing cup, No. 29520 must be used with the above
bearing puller.

Figure 57
Remove drive gear.

-10-

S1005

Figure 61

Figure 58
Remove 1st speed clutch assembly.

Remove front output flange nut, washer, "0" ring and flange. see

6 & 8 Speed Section for RangeShiftOutputShaft Removal.

Figure 59
Remove 1st speed front bearing.

Figure 62
Remove output shaft front bearing cap bolts and washers.

Figure 60
Remove reverse and 3rd clutch assembly.

Figure 63
Remove bearing cap, "0" ring and shims.

-11-

S1005

Figure 64
Remove output shaft rear bearing cap bolts and washers.

Figure 67
Remove rear taper bearing.

Figure 65
Remove bearing cap and "0" rings.

Figure 68
Remove output shaft, gear spacer and front taper bearing.

Figure 66
Block output gear. Push or drive output shaft through taper
bearing and output gear.

Remove output gear.

Figure 69

-12-

S1005

Figure 70

Remove front bearing.


Figure 73
Remove taper bearing retainer ring retainer.

Figure 71
If idler shaft, idler gear or rear bearing are to be replaced,
remove bearing and gear. Turn shaft over and remove the front
bearing retainer ring and bearing.
Figure 74
Remove bearing retainer ring.

1ST SPEED CLUTCH (LOW)


DISASSEMBLY AND REASSEMBLY
See 8 Speed Section for 4th Speed Clutch Repair

DISASSEMBLY
See Note In Figure 83

Figure 72
Remove clutch assembly front bearing inner race.

Figure 75
Remove 1st speed gear and outer taper bearing.

-13-

S1005

Figure 76
Remove taper bearing spacer.

Figure 79
Remove inner and outer clutch discs.

Figure 77
Remove clutch end plate retainer ring.

Figure 80
Remove inner taper bearing.

Figure 81
Remove piston return disc spring retainer ring retainer washer.

Figure 78
Remove end plate.

-14-

S1005

NOTE: Each disc spring assembly is made up of selected


springs to precisely match each part within this assembly.
Failure to replace all piston return springs can result in
unequal deflection within the spring pack. The result of
this imbalance may adversely affect overall life of springs.
The disc spring packs are to be used as complete
assemblies and care should be taken not to intermix the
individual disc springs with disc springs in another clutch
or disc spring pack.

1ST SPEED CLUTCH REASSEMBLY

Figure 82
Remove return disc spring retainer ring.

Figure 85
Install clutch piston outer seal ring.

Figure 83
Remove piston return disc spring. NOTE: Disc springs in the
low clutch are different than springs in the forward and
reverse clutch. Do not mix low clutch springs with forward and reverse springs (see note at top of page). Non
modulated units will have return springs in forward &
reverse clutches.

Figure 84
Remove return spring to piston spacer. Turn clutch over and tap'
clutch shaft on a block of wood to remove clutch piston.

Figure 86
Install clutch piston inner seal ring. Install piston into clutch
drum. Use caution as not to damage seal rings.

See cleaning and inspection page.

-15-

S1005

Figure 90
Position ring retainer over retainer ring.

Figure 87
Install piston spacer.

Figure 91
Install one steel disc.
Figure 88
See NOTE in figure 83. Install disc springs. First spring with
large diameter toward spacer. Alternate (5) five washers. See
page 59, Figure C.

Figure 92
Install one friction disc. NOTE: The friction discs in the low
clutch has a higher co-efficient rating than the friction
discs in the other clutches, therefore the discs must not
be mixed. The low clutch inner disc can be identified by
an "X" stamped on one side of the inner teeth. The low
clutch inner disc also has a strip of non-soluble yellow
paint sprayed on the outer edge of the disc. Alternate steel
and friction discs until the proper amount of discs are installed.
First disc next to the piston is steel, last disc installed is friction.

Figure 89
Position return spring retainer ring on clutch shaft. Compress
disc springs and install retainer ring.

-16-

S1005

Figure 96
Position taper bearing spacer on shaft.

Figure 93
Install clutch disc end plate.

Figure 97
Install 1st gear into clutch drum. Align splines on 1st gear with
internal teeth of friction discs. Tap gear into position. Do not
force this operation. Gear splines must be in full position with
internal teeth of all friction discs.

Figure 94
Install end plate retainer ring.

Figure 95
Install inner clutch gear taper bearing.

Figure 98

Install outer taper bearing.

-17-

S1005

Figure 99
Install low clutch taper bearing retainer ring.
Figure 102
Position front bearing on clutch shaft inner race. NOTE: Bearing
could be installed in transmission case before installing clutch.

NOTE: Retainer ring is selected at assembly for proper


thickness. A snap ring kit is available. Select the thickest
of the three rings in the kit that can be fitted into the snap
ring groove to assure a proper taper bearing tightness.
Check ring as shown for tight ring to bearing fit.

REVERSE AND 3RD CLUTCH


DISASSEMBY AND REASSEMBLY
DISASSEMBLY
(Reverse being disassembled)

Figure 100
Position ring retainer over retainer ring.

Figure 103
Remove clutch shaft piston rings. NOTE: Some units will
have Telfon piston rings and expander springs. these
rings are to be replaced with a new style ring and does
NOT use an expander spring. See page 79 for proper
piston ring Installation.

Figure 101
Install clutch shaft front bearing inner race with large diameter
of race down.

-18-

S1005

Figure 104
Remove front bearing retainer ring.

Remove front bearing.

Figure 105
Remove front bearing end plate.

Figure 108
Pry front bearing inner race up far enough to use a bearing
puller.

Figure 106
Remove end plate lock ball.

Figure 109
Remove bearing inner race.

Figure 107

-19-

S1005

Figure 1,10
Remove clutch driven gear outer bearing retainer ring.

Remove end plate.

Figure 111
Remove clutch gear and outer bearing.

Figure 114
Remove inner and outer clutch discs.

Figure 112
Remove clutch disc end plate retainer ring.

Remove inner bearing.

Figure 113

Figure 115

-20-

S1005

Figure 119
Remove clutch piston.

Figure 116
Compress piston return spring. Remove spring retainer ring.

3RD SPEED CLUTCH DISASSEMBLY

Figure 117
Remove retainer ring retaining washer.

Figure 120
Remove 3rd speed clutch shaft bearing.

Figure 118
Remove piston return spring and retainers. NOTE: Modulated
forward and reverse clutches will have piston return disc
springs. (See note on page 15. Figure 83.1

Figure 121
Remove 3rd speed gear and outer bearing.

-21-

S1005

Figure 122
Remove clutch gear outer and inner bearing spacer.

Figure 125
Remove clutch disc end plate retainer ring.

Figure 123
Pry inner bearing up far enough to use a bearing puller.

Remove end plate.

Figure 126

Figure 124

Figure 127
Remove inner and outer clutch discs.

Remove inner bearing.

-22-

S1005

Figure 131

Remove clutch piston.

Figure 128
Compress piston return spring. Remove return spring retainer
ring.

See cleaning and inspection page.


3RD SPEED CLUTCH REASSEMBLY

Figure 132
Install clutch piston inner and outer seal rings. Install clutch
piston in clutch drum, use caution as not to damage seal rings.

Figure 129
Remove retainer ring retaining washer.

Figure 133
Position the inner return spring retainer, the return spring and
the outer spring retainer on clutch shaft.

Figure 130
Remove return spring retainers and spring.

-23-

S1005

Figure 134
Position return spring retainer ring retaining washer on clutch
shaft.

Figure 137
Install one friction disc. Alternate steel and friction discs until
the proper amount of discs are installed. First disc next to the
piston is steel, last disc installed in friction.

Figure 135
Compress return spring and install retainer ring being certain
ring is in full position in retaining washer and ring groove.

Figure 138
Install clutch disc end plate.

Figure 139
Install end plate retainer ring.

Figure 136

Install one steel disc.

-24-

S1005

Figure 143
Install clutch gear outer bearing. NOTE: Outer bearing has a
shield in it, this shield must be up.

Figure 140
Install clutch gear inner bearing. NOTE: The inner bearing does
not have a bearing shield.

Figure 144
Install 3rd speed clutch shaft rear bearing. NOTE: Bearing outer
diameter locating ring must be down.

Figure 141
Install clutch gear inner and outer bearing spacer.

REVERSE CLUTCH REASSEMBLY

Figure 142
Install clutch gear into clutch drum. Align splines on clutch gear
with internal teeth of friction discs. Tap gear into position. Do
not force this operation. Gear splines must be in full position
with internal teeth of all friction discs.

Figure 145
Install clutch piston inner and outer oil seal rings. Install clutch
piston in clutch drum, use caution as not to damage seal rings.

-25-

S1005

Figure 146
Position the inner return spring retainer, the return spring and
the outer spring retainer. NOTE: If reverse and forward
clutches are modulated, assemble disc springs as shown
in Figure A on page 59.

Figure 149
Install one steel disc.

Figure 147
Position return spring retainer ring retaining washer on clutch
shaft.

Figure 150
Install one friction disc. Alternate steel and friction discs until
the proper amount of discs are installed. First disc next to the
piston is steel, last disc installed is friction.

Figure 148
Compress return spring and install retainer ring being certain
ring is in full position in retaining washer and ring groove.

Figure 151
Install clutch disc end plate.

-26-

S1005

Figure 152
Install end plate retainer ring.

Figure 155
Install clutch gear outer bearing. NOTE: Outer bearing has a
shield in it, this shield must be down.

Figure 153
Install clutch gear inner bearing. NOTE: This bearing does not
have a shield in it.

Figure 156
Install clutch gear outer bearing retainer ring.

Figure 154
Install clutch gear into clutch drum. Align splines on reverse
gear with internal teeth of friction discs. Do not force this
operation. Gear splines must be in full position with internal
teeth of all friction discs.

Figure 157
Install clutch shaft front bearing inner race with large diameter
of race down.

-27-

S1005

Figure 161
Install bearing retainer ring.
Figure 158
Position front bearing over bearing race.

Figure 162
Install clutch shaft piston rings. See note in Figure 103.

DISASSEMBLY AND REASSEMBLY


OF THE FORWARD AND 2ND CLUTCH

Figure 159
Position end plate lock ball in clutch shaft.

(Forward being disassembled)

Figure 160
Install bearing end plate, aligning notch in plate with lock ball.

Figure 163
Remove clutch shaft piston rings. (See note in Figure 103.)

-28-

S1005

Figure 164
Remove front bearing end plate retainer ring.

Figure 167
Remove bearing end plate lock ball.

Figure 165

Figure 168
Remove front bearing inner race.

Figure 166

Figure 169
Remove clutch gear outer bearing retainer ring.

Remove end plate.

Remove front bearing.

-29-

S1005

Figure 170
Remove clutch gear and outer bearing.

Figure 173

Remove end plate.

Figure 171

Remove inner bearing.

Figure 174
Remove inner and outer clutch discs.

Figure 172
Remove clutch disc end plate retainer ring.

Figure 175
Compress piston return spring. Remove return spring retainer
ring.

-30-

S1005

2ND CLUTCH DISASSEMBLY

Figure 176
Remove retainer ring retaining ring.

Figure 179
Remove clutch disc end plate retainer ring.

Figure 177
Remove piston return spring and retainers. See note in Figure
118.

Figure 180

Remove end plate.

Figure 178

Figure 181
Remove inner and outer clutch discs.

Remove clutch piston.

-31-

S1005

Figure 185

Figure 182
Compress piston return spring. Remove return spring retainer
ring.

Remove clutch piston.

See cleaning and inspection page.


2ND CLUTCH REASSEMBLY

Figure 183
Remove retainer ring retaining washer.

Figure 186
Install clutch piston inner and outer seal rings. Install clutch
piston in clutch drum, use caution as not to damage seal rings.

Figure 187
Position the inner return spring retainer, the return spring and
outer spring retainer on clutch shaft.

Figure 184
Remove return spring retainers and spring.

-32-

S1005

Figure 188
Position return spring retainer ring retaining washer on clutch
shaft.

Figure 191
Install one friction disc. Alternate steel and friction discs until
the proper amount of discs are installed. First disc next to the
piston is steel, last disc installed is friction.

Figure 189
Compress return spring and install retainer ring, being certain
ring is in full position in retaining washer and ring groove.

Figure 192
Install clutch disc end plate.

Figure 190

Figure 193
Install end plate retainer ring.

Install one steel disc.

-33-

S1005

FORWARD CLUTCH REASSEMBLY

Figure 197
Compress return spring and install retainer ring, being certain
ring is in full position in retaining washer and ring groove.

Figure 194
Install clutch piston inner and outer seal rings. Install piston in
clutch drum, use caution as not to damage seal rings.

Figure 198

Figure 195
Position the inner return spring retainer, the return spring and
outer spring retainer. NOTE: If forward and reverse clutches
are modulated, assemble piston return disc springs as
shown in Figure A on page 59.

Install one steel disc.

Figure 199
Install one friction disc. Alternate steel and friction discs until
the proper amount of discs are installed. First disc next to the
piston is steel, last disc installed is friction.

Figure 196
Position return spring retainer ring retaining washer on clutch
shaft.

-34-

S1005

Figure 203
Install clutch gear into clutch drum. Align splines on clutch gear
with internal teeth of friction discs. Tap gear into position. Do
not force this operation. Gear splines must be in full position
with internal teeth of all friction discs.

Figure 200
Install clutch disc end plate.

Figure 204
Install clutch gear outer bearing. NOTE: Outer bearing has a
shield in it. this shield must be down.

Figure 201
Install end plate retainer ring.

Figure 202
Install clutch gear inner bearing. NOTE: This bearing does not
have a shield in it.

Figure 205
Install bearing retainer ring.

-35-

S1005

Figure 206
Install clutch shaft front bearing inner race with large diameter
of race down.

Figure 209
Install bearing end plate, aligning notch in plate with lock ball.

Figure 207
Position end plate lock ball in clutch shaft.

Figure 210
Install bearing retainer ring.

Figure 208
Position front bearing over bearing race.

Install clutch shaft piston rings. See note in Figure 103.

Figure 211

-36-

S1005

OIL SEALING RING SLEEVE REMOVAL


NOTE: The following photos are not of the HR Converter
Housing but the sleeve removal procedure is identical.

Figure 215
Use a sleeve puller like the one shown.

Figure 212
Remove clutch front bearing locating ring.

Figure 216
Sleeve being removed.

See cleaning and inspection page.

Figure 213
Remove oil sealing ring sleeve retainer screw.

NOTE: When installing a new sleeve it is recommended a press


or a driver be used to prevent damage to the sleeve and be sure
the notch in the sleeve is aligned with sleeve lock notch. Install
sleeve lock and capscrew. Tighten screw to specified torque.
(See torque chart.)

Figure 214
Remove screw and sleeve lock.

Figure 217
Position new oil sealing ring on turbine shaft. Install turbine
shaft bearing on shaft with bearing outer locating ring down.

-37-

S1005

Figure 220
Install drive gear retainer ring.

TRANSMISSION REASSEMBLY

Figure 218
Install turbine shaft and bearing in converter housing.

SEE 6 & 8 SPEED SECTION FOR RANGE SHIFT OUTPUT


SHAFT INSTALLATION.

Figure 221
View of output shaft as it would be positioned in transmission
case. NOTE: Front cone bearing shouldered on shaft with large
diameter of bearing in, and long hub of gear toward gear spacer.
Figure 219
Install turbine shaft drive gear as shown in Figure 219-A.

DRIVE GEAR

NOTE: LONG HUB OF


DRIVE GEAR TOWARD
RETAINER RING

Figure 222
Position output gear in transmission case with protruding hub
toward front of case. See Figure 221. Insert output shaft, gear
spacer and taper bearing from front of case and through output
gear. Install front taper bearing cup. Block output shaft and install rear taper bearing with large diameter in.

Figure 219A

-38-

S1005

Figure 223
Coat outer diameter of oil seal with Permatex No.2 and press
seal in bearing cap with lip of seal in. See assembly instruction
sheet for seal depth. Using new "0" rings install rear output
bearing cap, oil seal and taper bearing cup on transmission
case. Lube opening in bearing cap must be aligned with lube
opening in case.

Figure 226
Install front bearing cap and shims. Tighten bolts to specified
torque. Tap output shaft front and rear to seat taper bearings.
Loosen front bearing cap bolts.

Figure 227
Using a inch lb. torque wrench, determine the rolling torque of
the output shaft and record. Tighten front bearing cap bolts to
specified torque. Check rolling torque with bolts tight. Torque
must be 6 to 8 inch Ibs. [0,7-0,09 N.m] more than when bearing
cap bolts were loose. Add or omit shims on the front bearing
cap to achieve the proper preload.

Figure 224
Tighten bearing cap bolts to specified torque. (See torque
chart.)

Figure 225
. Coat outer diameter of front output oil seal with Permatex No.2.
Install seal in bearing cap with lip of seal in.

Figure 228
Position reverse and 3rd clutch in transmission housing.

-39-

S1005

Figure 232
If idler shaft was disassembled, install front bearing. Install idler
gear on shaft with long hub of gear up. (6 & 8 speed will have
two gears on the idler shaft). Install rear inner taper bearing
with large diameter of taper down. Install bearing spacer and
double bearing cup with outer diameter locating ring groove
up. Install outer taper bearing with large diameter of taper up.

Figure 229
From the rear of the transmission case, install the low (1 st)
clutch.

NOTE: Double taper bearing must be replaced as an


assembly as the bearing spacer Is pre-selected at factory.

Figure 230
Install low (1 stl speed drive gear on clutch shaft.
Figure 233
Install idler shaft assembly. NOTE: Lock ball in bearing cup.

Figure 234
Install low (1 stl clutch outer double taper bearing. NOTE:
Locating ring groove in bearing cup to be out (to the rear).

Figure 231
Install drive gear retainer ring.

-40-

S1005

Figure 235
Use caution as not to lose low (1 st) and idler bearing lock balls.
A light coat of grease will hold lock balls in place.

Figure 238

Tap cover in place.

Figure 236
The use of aligning studs will facilitate rear cover installation.
Position a new gasket and "0" ring on rear of case. A light coat
of grease will hold gasket in place.

Figure 239
Install rear cover bolts and washers, tighten to specified torque.
(See torque chart).

Figure 240
From the front, tap the low (1 stl clutch and idler shaft to the rear
to expose the rear bearing locating ring groove. Install locating
ring.

Figure 237
Align lock balls in bearing with notches in rear cover.

-41-

S1005

Figure 241
Install low (1 stl clutch rear bearing retainer plate. NOTE: Inner
diameter hole chamfer to go toward bearing.

Figure 244
Position bearing cap over bearing and install bearing cap bolts.
Tighten to specified torque. (See torque chart).

Figure 242
Install retainer plate bolts and tighten to specified torque (see
torque chart). Lock wire bolts together to prevent loosening.

Figure 245
Install idler shaft rear bearing locating ring.

Figure 243
Install new "0" ring and gasket on low (1 stl clutch shaft rear
bearing cap.

Figure 246
Install idler shaft rear bearing spacer.

-42-

S1005

Figure 247
Install idler shaft rear bearing retainer nut. Tighten to specified
torque. (See elastic stop nut torque chart).

Figure 250
Install brake backing plate and brake band assembly on output
bearing cap.

Figure 248
Position a new gasket on the idler shaft rear bearing cap, install
bearing cap.

Figure 251
Install backing plate capscrews and tighten to specified torque.
(See torque chart).

Figure 249
Install capscrews and tighten to specified torque. (See torque
chart).

Figure 252
Install brake strut to brake bands.

-43-

S1005

Install rear output flange.

Figure 256
Position brake drum on output flange studs. Install stud nut
washers and stud nuts. Tighten stud nuts enough to hold drum
in place until drive shaft is installed.

Figure 254
Install flange "0" ring, washer and lock nut.

Figure 257
Install front output flange.

Figure 255
Tighten lock nut to specified torque. (See elastic stop nut torque
chart).

Figure 258
Install new output flange "0" ring, washer and flange nut.

Figure 253

-44-

S1005

Figure 259
Tighten flange nut to proper specifications. (See elastic stop nut
torque chart).

Figure 262
Install disc hub retainer ring.

Figure 260
Position 2nd clutch bearing end plate on low (1 st) clutch shaft.

Figure 263
Install disc hub retainer ring retainer.

Figure 261
Position 2nd clutch disc hub on clutch shaft.

Figure 264
Install disc hub ring retainer retaining ring.

-45-

S1005

Figure 265
Position 2nd speed clutch shaft pilot bearing on clutch shaft. A
light coat of grease will hold bearing in place. Install forward
and 2nd clutch in clutch disc hub being certain clutch disc hub
is in full position in clutch discs. See 8 speed section for 4th

Figure 268
Spread forward clutch front bearing locating ring. Position
converter housing to transmission housing. Tap housing into
place using caution as not to damage clutch shaft oil sealing
rings. Do not force this operation.

speed clutch Installation.

Figure 266
Position new gasket and "0" rings on housing. A light coat of
grease will hold gasket and "0" rings in place.

Figure 269
Install bolts and washers,tighten to specified torque (see torque
chart).

Figure 267
Install alignment studs in transmission housing to facilitate converter housing to transmission housing assembly.

Figure 270
Using a hammer puller as shown, pull forward clutch until front
bearing locating ring is in full position in ring groove.

-46-

S1005

Figure 271

Figure 274
Install support bolts and tighten to specified torque. (See torque
chart).

Install pump drive gears.

DISASSEMBLY AND REASSEMBLY


OF IMPELLER AND BAFFLE
DISASSEMBLY

Figure 272
Tighten pump drive gear support bolts to specified torque. (See
torque chart).
Figure 275
Remove pump drive gear retainer ring.

Figure 273
Install new sealing ring expander spring and oil sealing ring on
support. NOTE: Expander spring gap to be 1800 from sealing
ring hook joint. Position support on turbine shaft, turn support
to clear pump drive gear. Align support holes with converter
housing.

Figure 276
Remove pump drive gear.

-47-

S1005

Figure 280
Remove hub bearing retainer ring.
Figure 277
Remove impeller hub bolts.

Figure 281

Remove hub bearing.


Figure 278

See cleaning and inspection page.

Remove backing ring.

REASSEMBLY

Figure 279
Tap impeller hub from impeller.

Figure 282
Install impeller hub bearing in hub.

-48-

S1005

Figure 283
Install bearing retainer ring.
Figure 286
Position backing ring on impeller.

Figure 284
Position new "0" ring on impeller hub.

Figure 287
Install (12) impeller hub special screws to approximately .06
inch [1,5] of seated position. With a calibrated torque wrench,
tighten screws to 40-45 Ibs. ft. [54,3-61,0 N.m.] torque. NOTE:
Assembly of impeller to impeller hub must be completed within
a fifteen minute period from start of screw installation. The
screws are prepared with a coating which begins to harden after
installation in the impeller hub holes. If not tightened to proper
torque within the fifteen minute period, insufficient screw
clamping tension will result. The special screw is to be used for
one installation only. If the screw is removed for any reason it
must be replaced.

The compound left in the hub holes must be removed with the
proper tap and cleaned with solvent. Dry hole thoroughly and
use a new screw for reinstallation.

Figure 285
Align holes in impeller with holes in impeller hub.

-49-

S1005

Figure 291
Install pump drive gear retainer ring.
Figure 288
Apply a light coat of Permatex No. 2 on the outer diameter of
the oil baffle seal. Press seal in oil baffle with lip of seal down.

DISASSEMBLY AND REASSEMBLY


OF TURBINE AND IMPELLER COVER
DISASSEMBLY

Figure 289
Install new oil baffle seal ring. Position oil baffle on impeller and
hub assembly.

Figure 292
Remove turbine hub to impeller cover bearing retainer ring.

Figure 293
Remove retainer ring to bearing washer.

Figure 290
Install pump drive gear on impeller hub.

-50-

S1005

If turbine and hub was disassembled, use the following instructions for reassembly.
1. Clean hub mounting surface and tapped holes with solvent.
Dry thoroughly being certain tapped holes are dry and clean.
2. Install backing ring and special self locking screws.
Tighten screws 40 to 45 Ibs. ft. [54,3-61,0 N.m.]. NOTE:
Assembly of hub must be complete within a fifteen minute
period from start of screw installation. The special screw is to be
used for one installation only. If the screw is removed for any
reason it must be replaced. The epoxy left in the hub.holes must
be removed with the proper tap and cleaned with solvent. Dry!
hole thoroughly and use a new screw for reinstallation.

Figure 294
Separate turbine from impeller cover.

Figure 297
Position turbine and hub assembly in impeller cover assembly.

Figure 295
Remove impeller cover bearing.

See cleaning and inspection page.


REASSEMBLY

Figure 298
Position bearing washer over turbine hub.

Figure 296
Install impeller cover bearing.

-51-

S1005

Figure 299
Install turbine hub to impeller cover retainer ring.

Figure 302
Install reaction member spacer with tang facing out.

Figure 300
Greasestator support piston ring, oil baffle oil seal and seal ring
to facilitate reassembly. Install impeller and oil baffle assembly
in converter housing.

Figure 303
Install reaction member with thick part of blades out.

Figure 301
Position oil baffle in housing. Secure with oil baffle retainer ring,
being sure ring is in full position in ring groove.

Figure 304
Install reaction member retainer ring.

-52-

S1005

Figure 305
Position a new "0" ring on impeller cover.

Figure 308
Position new "0" ring on impeller cover bearing cap.

Figure 306
Position turbine and impeller cover on turbine shaft. NOTE:
Some units will have drive plates instead of impeller cover
& ring gear. See drive plate installation section.

Figure 309
Install bearing cap, bolts and washers, tighten to specified
torque. (See torque chart).

Figure 307
Install impeller cover to impeller bolts and washers. Tighten to
specified torque (see torque chart).

Figure 310
Install aligning studs to facilitate control valve assembly. Install
new control valve gasket.

-53-

S1005

Figure 311
Position control valve assembly on aligning studs.

Figure 314
Install charging pump drive sleeve.

Figure 312
Install control valve bolts and washers and tighten to specified
torque. (See torque chart).

Figure 315
Install new pressure regulating valve gasket.

Figure 313
Install pump adaptor, bolts and washers. Tighten to specified
torque. (See torque chart).

Figure 316
Install new "0" rings on pressure regulating valve. Position
valve on studs.

-54-

S1005

Figure 317
Position new valve to pump gasket on studs. Install charging
pump and filter adaptor on studs.

Figure 320
Install bolts and washers. Tighten to specified torque. (See
torque chart).

Figure 318
Install washers and nuts, tighten to specified torque. (See
torque chart).

Figure 321
Install new filter element and filter housing.

Figure 319
Install new auxiliary pump adaptor gasket and adaptor.

-55-

S1005

SERVICING MACHINE AFTER TRANSMISSION OVERHAUL


The transmission, torque converter, and its allied
hydraulic system are important links in the drive line
between the engine and the wheels. The proper operation of either unit depends greatly on the condition
and operation of the other; therefore, whenever repair
or overhaul of one unit is performed, the balance of
the system must be considered before the job can be
considered completed.

5. On remote mounted torque converters remove


drain plug from torque converter and. inspect
interior of converter housing, gears, etc. If
presence of considerable foreign material is
noted, it will be necessary that converter be removed, disassembled and cleaned thoroughly.
It is realized this entails extra labor; however,
such labor is a minor cost compared to cost of
difficulties which can result from presence of
such foreign material in the system.

After the overhauled or repaired transmission has


been installed in the machine, the oil cooler, and connecting hydraulic system must be thoroughly cleaned.
This can be accomplished in several manners and a degree of judgment must be exercised as to the method
employed.

6. Reassemble all components and use only type


oil recommended in lubrication section.
Fill
transmission through filler opening until fluid
comes up to LOW mark on transmission dipstick.
NOTE: If the dipstick is not accessible oil level
check plugs are provided.

The following are considered the minimum steps to


be taken:

Remove LOWER check plug, fill until oil runs


from LOWER oil hole. Replace filler and level
plug.

1. Drain entire system thoroughly.


2. Disconnect and clean all hydraulic lines. Where
feasible, hydraulic lines should be removed from
machine for cleaning.

Run engine two minutes at 500-600 RPM to


prime torque converter and hydraulic lines. Recheck level of fluid in transmission with engine
running at idle (500-600 RPM).

3. Replace oil filter elements, cleaning out filter


cases thoroughly.

Add quantity necessary to bring fluid level


to LOW mark on dipstick or runs freely from
LOWER oil level check plug hole. Install oil
level plug or dipstick. Recheck with hot oil
(180-200 F.) [82,2-93,3 C].

4. The oil cooler must be thoroughly cleaned. The


cooler should be "back flushed" with oil and
compressed air until all foreign material has been
removed. Flushing in direction of normal oil flow
will not adequately clean the cooler. If necessary, cooler assembly should be removed from
machine for cleaning, using oil, compressed air
and steam cleaner for that purpose. DO NOT
use flushing compounds for cleaning purposes.

Bring oil level to FULL mark on dipstick or


runs freely from UPPER oil level plug.
7. Recheck all drain plugs, lines, connections, etc.,
for leaks and tighten where necessary.

TORQUE IN (LBS.-FT.)
BOLTS, CAPSCREWS, STUDS AND NUTS
Grade 5 Identification, 3 Radial
0
Dashes 120 Apart on Head of Bolt

Grade B Identification, 6 Radial


0
Dashes 60 Apart on Head of Bolt

LUBRICATED OR PLATED

Grade 5

Grade 8

Nominal
Size

Fine Thread
Torque Lbs. Ft./N.m.

Course Thread
Torque Lbs. Ft./N.m.

Fine Thread
Torque Lbs. Ft./N.m.

Course Thread
Torque Lbs. Ft./N.m.

.3125

16-20 [21,7-27,1]

12-16 [16,3-21,7]

28-32 [38,0-43.4]

26-30 [35,340.7]

.3750

26-29 [35,339,3]

23-25 [31,2-33.9]

37-41 [50,2-55,6]

33-36 [44,7-48,8]

.4375

41-45 [55,6-61,0]

3741 [50,2-55,6]

58-64 [78.6-86,8]

5257 [70.5-77.3]

.5000
.5625

64-70 [86.8-94,9]
91-100 [123.4-135,6]

5763 [77,3-85.4]
82-90 [111,2-122,0]

-56-

90-99 [122.0-134.2]

80-88 [108,5-119,3]

128-141 [173.5-191.2]

115127 [156,0172,2]

SPECIFICATIONS AND SERVICE DATA - POWER SHIFT TRANSMISSION


S1005
AND TORQUE CONVERTER
CONVERTER OUT
PRESSURE

CONTROLS

Converter outlet oil temp. 180 - 200 F.


[82,3" - 93,3" C].
Transmission in NEUTRAL.
Operating specifications:
25 PS.1. [172,4 kPa] minimum pressure at 2000
R.PM. engine speed AND a maximum of 70
PS.1. [482,6 kPa] outlet pressure with engine
operating at no-load governed speed.

OIL FILTRATION

Full flow oil filter safety by-pass, also strainer


screen in sump at bottom of transmission case.

CLUTCH PRESSURE

240 - 300 psi [1654,8 - 2068, 4 kPa]- With parking


brake set (see note), oil temperature 180" - 200" F.
[82,2" - 93,3" C], engine at idle (400 to 600 RPM),
shift thru direction and speed clutches. All clutch
pressure must be equal within 5 psi. [34,5 kPaj. If
clutch pressure variers in anyone clutch more than
5 psi [34,5 kPa] repair clutch.
NOTE: Never use service brakes while making
clutch pressure checks. Units having brake
actuated declutching in forward and/or reverse
will not give a true reading.
ALWAYS USE PARKING BRAKE WHEN
MAKING CLUTCH PRESSURE CHECKS.

Forward and Reverse - Manual


Speed Selection - Manual

CLUTCH TYPE

Multiple discs, hydraulically actuated, spring


released, automatic wear compensation and no
adjustment. All clutches oil cooled and lubricated.

CLUTCH INNER DISC

Friction.

CLUTCH OUTER DISC

Steel.

LUBRICATION
RECOMMENDED LUBRICANTS FOR TORQUE CONVERTERS AND POWERSHIFT TRANSMISSIONS
TYPE OFOIL

See Lube Chart.

(a)

CAPACITY

Consult Operators Manual on applicable


machine model for system capacity. Torque
Converter, Transmission and allied hydraulic
system must be considered as a whole to
determine capacity.

Drain transmission and remove sump


screen. Clean screen thoroughly and
replace, using new gaskets.

(b)

Drain oil filters, remove and discard filter


elements. Clean filter shells and install new
elements.

(c)

Refill transmission to LOW mark.

(d)

Run engine at 500 - 600 RPM to prime


converter and lines.

(e)

Recheck level with engine running at


500 600 RPM and add oil to bring level to
LOW mark. When oil temperature is hot (180
200" F.) [82.2 - 93,3 C] make final oil level
check. BRING OIL LEVEL TO FULL MARK.

CHECK PERIOD

Check oil level DAILY with engine running at


500-600 RPM and oil at 180" to 200" F. [82,2 93,3" C]. Maintain oil level to FULL mark.

NORMAL
DRAIN PERIOD

Every 500 hours, change oil filter element.


Every 1000 hours, drain and refill system as
follows: Drain with oil at 150" to 200" F. [65,6 93.3" C].
NOTE: It is recommended that filter elements
i:le changed after 50 and 100 hours of operation on new and rebuilt or repaired units.

Torque converter/transmission lubricant must be qualified by one of the following


specifications.
ORDER OF PREFERENCE:
1. Caterpillar
TO 4
C-4
4. Allison
2. John Deere J20 C , D
5. Dexron II Equivalent - See note below.
3. Military
MIL-PRF-2104G

RECOMMENDED SAE J300 VISCOSITY GRADE


BASED ON PREVAILING AMBIENT TEMPERATURE
SAE OW20

IMPORTANT: Dexron* II equivalent is acceptable: however it is not compatible with torque


converters or transmissions equipped with graphitic friction material clutch plates.

Dexron* II or equivalent

LUBRICANTS NOT RECOMMENDED: DEXRON III, ENGINE OIL, ANY GL-5 OILS.
SAE lOW

OIL VISCOSITY -lt is recommended that the highest viscosity monograde lubricant
available be used for the anticipated ambient temperature. Typically this will be a CAT TO-4
qualified luoricant, When large swings in ambient temperature are probable, J20 C. 0 multigrades are recommended. Multigrade lubricants should be applied at the lower viscosity
rating for the prevailing ambient temperature, i.e. a 10W20 should be used where a lOW
monograde is used. If a C4 multigrade is used in place of J20 lubricant it is recommended
that the viscosity span no more than 10 points, i.e. 10W20.
SYNTHETIC LUBRICANTS ARE APPROVED IF QUALIFIED BY ONE OFTHE ABOVE
SPECIFICATIONS. OIL VISCOSITY GUIDELINES APPLY, BUT SYNTHETIC
MULTIGRADES MAY SPAN MORE THAN 10 POINTS.
FOR FIRE RESISTANT FLUID RECOMMENDATIONS PLEASE CONTACT SPICER
OFF-HIGHWAY PRODUCTS.

SUMP pREHEATERS - preheat the transmission fluid to the minimum temperature


for the oil viscosity used before engine start up.
NORMAL OIL CHANGE INTERVAL - drain and refill system every 1000 hours for average
environmental and duty cycle conditions. Severe or sustained high operating temperature or
very dusty atmospheric conditions will result in accelerated deterioration or contamination.
Judgement must be used to determine the required change intervals for extreme
conditions.
EXTENPEP OIL CHANGE INTERVAL - Extended oil service life may result when using
synthetic fluids. Appropriate change intervals should be determined fur each transmission
by measuring oil oxidation and wear metals, over time, to determine a baseline. Wear metal
analysis can provide useful information, but a transmission should not be removed from
service based solely on this analysis.

.EJ..LIE.B.S. - Service oil filter element every 500 hours under normal environmental and duty

cycle conditions. Service the high performance extended life filter element every 1000 hours
or upon warning indication from the filter back pressure sensor.
This recommended lubricant section does not apply'to transmissions with electronic
modulation where separate approved oils are identified.
Any deviation from this recommendation must have written approval from the
application engineering department of Spicer Off-Highway Products.
*Dexron is a registered trademark of General Motors Corp.

57 -

SAE30
SAE40
CELSIUS
FAHRENHEIT

40 -30
-40 -22

-20
-4

-10
14

0
32

10
50

20
68

30
88

40
104

50
122

POWER SHIFT TRANSMISSION AND TORQUE


CONVERTER HYDRAULIC FLUID ANALYSIS
Spicer Off-Highway Components Division recommends that when
chemical sampling of a power shift transmission lubrication circuit fluid
is being taken that several samples be analyzed over a period of time
to establish its normal base. Large changes in particle quantity from the
normal level may indicate an abnormal condition within the transmission or its lubrication fluid. Any conclusion made of the transmission
actual condition, or action taken by the transmission user when
interpreting the sample results, is the full responsibility of the user.
The following part per million (PPM) values represent general guidelines which may be used for references as a normal limit:
Iron
Fe
125 PPM
Copper
Cu
350 PPM
Silicon
Si
20 PPM
Aluminum
AI
15 PPM
Lead
Pb
50 PPM
Chromium
Cr
5 PPM

S1005

TROUBLE SHOOTING GUIDE


For The

Rand H R Model, 32000 Transmission


The following data is presented as an aid to locating
the source of difficulty in a malfunctioning unit. It is
necessary to consider the torque converter charging
pump, transmission, oil cooler, and connecting lines
as a complete system when running down the source
of trouble since the proper operation of any unit therein depends greatly on the condition and operations of

the others. By studying the principles of operation


together with data in this section, it may be possible
to correct any malfunction which may occur in the
system.
TROUBLE SHOOTING PROCEDURE BASICALLY CONSISTS OF TWO CLASSIFICATIONS: MECHANICAL AND
HYDRAULIC.

MECHANICAL CHECKS
Prior to checking any part of the system from a
2. Check shift levers and rods for binding or restrichydraulic standpoint, the following mechanical checks
tions in travel that would prevent full engagement.
should be made:
Shift levers by hand at controi valve, if full engage1. A check should be made to be sure all control
ment cannot be obtained, difficulty may be in control
lever linkage is properly connected and adjusted at all
cover and valve assembly.
connecting points.
HYDRAULIC CHECKS
Before checking on the torque converter, transmission, and allied hydraulic system for pressures and
rate of oil flow, it is essential that the following preliminary checks be made:
Check oil level in transmission. This should be done
with oil temperatures of 180 to 200 0 F. [82,2-93,3 0 C].
DO NOT ATTEMPT THESE CHECKS WITH COLD OIl.
To bring the oil temperature to this specification it
is necessary to either work the machine or "stall" out

the converter. Where the former means is impractical,


the latter means should be employed as follows:
Engage shift levers in forward and high speed and
apply brakes. Accelerate engine half to three-quarter
throttle.
Hold stall until desired converter outlet temperature
is reached. CAUTION: FULL THROTTLE STALL SPEEDS
FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT
THE CONVERTER.

LOW CLUTCH PRESSURE


Cause
1.
2.
3.
4.
5.

Low oil level.


Clutch pressure regulating valve spool stuck open.
Faulty charging pump.
Broken or worn clutch shaft or piston sealing rings.
Clutch piston bleed valve stuck open.

Remedy
Fill to proper level.
2. Clean valve spool and housing.
3. Replace pump.
4. Replace sealing rings.
5. Clean bleed valves thoroughly.
1.

LOW CONVERTER CHARGING PUMP OUTPUT


1. Low oil level.

2. Suction screen plugged.


3. Air leaks at pump intake hose and connections or
collapsed hose. (R-32000 only)
4. Defective oil pump.

1. Fill to proper level.


2. Clean suction screen.
3. Tighten all connections or replace hose if necessary.

4.

Replace pump.

OVERHEATING
Remove, disassemble, and rebuild converter assembly.
2. Replace.
3. Fill to proper level.
4. Check oil line connections and tighten securely.
1.

1. Worn oil sealing rings.


2. Worn oil pump.
3. Low oil level.
4. Pump suction line taking air. (R-32000 only)

NOISY CONVERTER
1. Replace.
2. Replace.
3. A complete disassembly will be necessary to determine what bearing is faulty.

1. Worn coupling gears.


2. Worn oil pump.
3. Worn or damaged bearings.

LACK OF POWER
1. Tune engine check governor.
2. Make corrections as explained in "Overheating."

1. Low engine RPM at converter stall.


2. See "Overheating" and make same checks.

-58-

S1005

FIG.A
I
III

REV. & FWD.


~!~!
-------l:! -! + - - - - - - - _ _~t ~ - - - - - -

\\
.063 - .064
-4\--[1.600 - 1.626]

MODULATED FWD.
& REV. CLUTCHES

FIG.S

2nd & 3rd & NON{ MODULATED FORWARD &


REVERSE CLUTCHES

FIG.C

\\
.048 - .049
-4\---[1.219 - 1.245]

LOW (1st)
CLUTCH

FIG.D
(4 SPEED ONLY)

4TH

-59-

S1005

<, ....

BACKING RING

~--

RING GEAR SCREW

RING GEAR SCREW


(16) 236288 1.500 [38,1)

---~

ENGINE FLYWHEEL

SEE PAGE 61
FOR INSTALLATION
PROCEDURE AND
BOLT TORQUE

"'l

",..,~'--\~~

--,.j

BACKING RING
243767

TORQUE CONVERTER
RING GEAR 249341

-60-

S1005

16 SCREW RING GEAR INSTALLATION PROCEDURE


(Non-Asbestos Ring Gear)
1.

Remove all burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface
and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean.

2.

Check engine flywheel and housing or housing adaptor for conformance to standard SAE. No.3 - SAE J927 and Jl033
tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine
crankshaft end play.

3.

Install torque converter ring gear as shown.


NOTE: Assembly of the ring gear must be completed within a fifteen minute
period from start of screw installation. The screws are prepared with an epoxy
coating which begins to harden after installation in the flywheel mounting holes. If not
tightened to proper torque within the fifteen minute period insufficient screw clamping
tension will result.

4.

Install backing ring and sixteen (16) special screws to approximately .06 inch 11,5 mm I of seated position. It is permissible to use
a power wrench for this installation phase. With a calibrated torque wrench tighten screws 30 to 33 pounds feet of torque 140,744,7 N.m].
To obtain maximum effectiveness of the special screw's locking feature, a minimum time period after screw installation of
twelve (12) hours is suggested before engine start-up.
The special screw is to be used for ONE installation only. If the screw is removed for any reason it MUST BE REPLACED. It is
recommended that the epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent. Dry hole
thoroughly and use a NEW screw for re-installation.

5.

Assemble torque converter to engine flywheel by sliding converter into position by hand before fastening housing attachment
screws. This may require more than one trial to match the drive gear teeth. Pulling the converter into position with housing
attachment bolts is not recommended.

6.

Measure engine crankshaft end play after assembly of torque converter. This value must be within one thousandth (001) of an
inch [0,0254mm] of end play recorded (in Paragraph #2) before assembly of torque converter.
802553 - 1.5 INCH [38,1] 16 SCREW RING GEAR KIT

1
16
1

249341
236288
802555

802554 - 1.5 INCH 138.1116 SCREW RING GEAR KIT

Torque Converter Ring Gear


Ring Gear Screw 1.5 Inch 138.11
Installation Instruction Sheet

1
16

1
1

249341
236288
243767
802555

Torque Converter Ring Gear


Ring Gear Screw 1.5 Inch 138,11
Backing Ring
Installation Instruction Sheet

243767 Backing Ring not included in 802553 Ring Gear Kit. Must be Ordered Separately

Dimensions are in inches -

Dimensions in 1 I are mm.

SEE PAGE 60 FOR INSTALLATION ILLUSTRATIONS


SEE PAGE 69 FOR 32 BOLT INSTALLATION

-61-

S1005

FORWARD

-- - -

1ST (LOW)
---2ND
- - 3RD

-62-

S1005

REVERSE

1ST (LOW)
_ _ _ _ _ _ 2ND
_ -

_ -

-3RD

-63-

S1005

TURBINE HUB SCREW

IMPELLER HUB & TURBINE HUB ASSEMBLY WITH BACKING


RING AND SPECIAL SELF LOCKING SCREWS.
1. CLEAN HUB MOUNTING SURFACE AND TAPPED HOLES WITH SOLVENT. DRY THOROUGHLY
BEING CERTAIN TAPPED HOLES ARE DRY AND CLEAN.
2. INSTALL BACKING RING AND SPECIAL SCREWS TO APPROXIMATELY .06 INCH [1.5] OF SEATED
POSITION. WITH A CALIBRATED TORQUE WRENCH, TIGHTEN SCREWS 40 TO 45 LBS. FT. TORQUE
[54,3-61,0 N.m]. NOTE: ASSEMBLY OF IMPELLER OR TURBINE HUB MUST BE COMPLETED WITHIN
A FIFTEEN MINUTE PERIOD FROM START OF SCREW INSTALLATION. THE SCREWS ARE PREPARED
WITH A COATING WHICH BEGINS TO HARDEN AFTER INSTALLATION IN THE HUB HOLES. IF NOT
TIGHTENED TO PROPER TORQUE WITHIN THE FIFTEEN MINUTE PERIOD, INSUFFICIENT SCREW
CLAMPING TENSION WILL RESULT. THE SPECIAL SCREW IS TO BE USED FOR ONE INSTALLATION
ONLY. IF THE SCREW IS REMOVED FOR ANY REASON IT MUST BE REPLACED.
THE COMPOUND LEFT IN THE HUB HOLES MUST BE REMOVED WITH THE PROPER TAP AND
CLEANED WITH SOLVENT. DRY HOLE THOROUGHLY AND USE A NEW SCREW FOR
REINSTALLATION.

-64-

Port "R"
pressure

S1005

Cooler inletrCOOler
pressure
outlet pressure

",~._-o._.....

y;~t~~~rtemperature
Filter type "A"---"""",\
Use replacement element
215502
DO NOT SUBSTITUTE

Cooler
Port "AP"
Ports "R" and "J" are permanent requirements
and their installation is required in this area.

Checkpoint
Port "DO"
Clutch pressure

Modulated forward
clutch check port

Modulated reverse
clutch check port
From cooler
to transmission
lube distributor
Port "A"

Port "J" Converter outlet temperature


Port "R" Converter outlet pressure
Port "T" Checkpoint transmission forward clutch pressure
Port "S" Checkpoint transmission reverse clutch pressure
Ports "J", "R", and "DO" Used for field trouble shooting

PLUMBING DIAGRAM FOR HR 32000


W/12 PLATE MODULATION AND
AUXILIARY LUBE

-65-

S1005

CLEANING AND INSPECTION

Oil Seals. Gaskets and Retaining Rings


Replacement of spring load oil seals, "0" rings, metal
sealing rings, gaskets and snap rings is more economical
when unit is disassembled than premature overhaul to
replace these parts at a future time. Further loss of lubricant
through a worn seal may result in failure of other more
expensive parts of the assembly. Sealing members should
be handled carefully, particularly when being installed.
Cutting, scratching, or curling under of lip of seal seriously
impairs its efficiency. Apply a thin coat of Permatex No.2 on
the outer diameter of the oil seal to assure an oil tight fit into
the retainer. When assembling new metal type sealing
rings, same should be lubricated with coat of chassis
grease to stabilize rings in their grooves for ease of
assembly of mating members. Lubricate all "0" rings and
seals with recommended type Automatic Transmission
Fluid before assembly.

CLEANING
Clean all parts thoroughly using solvent type cleaning
fluid. It is recommended that parts be immersed in cleaning
fluid and moved up and down slowly until all old lubricant
and foreign material is dissolved and parts are thoroughly
cleaned.
CAUTION: Care should be exercised to avoid skin
rashes, fire hazards and inhalation of vapors when using
solvent type cleaners.
Bearings
Remove bearings from cleaning fluid and strike larger
side of cone flat against a block of wood to dislodge
solidified particles of lubricant. Immerse again in cleaning
fluid to flush out particles. Repeat above operation until
bearings are thoroughly clean. Dry bearings using moisture
free compressed air. Be careful to direct air stream across
bearing to avoid spinning. Do not spin bearings when
drying. Bearings may be rotated slowly by hand to facilitate
drying process.

Gears and Shafts


If magna-flux process is available, use process to check
parts. Examine teeth on all gears carefully for wear, pitting,
chipping, nicks, cracks or scores. If gear teeth show spots
where case hardening is worn through or cracked, replace
with new gear. Small nicks may be removed with suitable
hone. Inspect shafts and quills to make certain they are not
sprung, bent. or splines twisted, and that shafts are true.

Housings
Clean interior and exterior of housings, bearing caps,
etc., thoroughly. Cast parts may be cleaned in hot solution
tanks with mild alkali solutions providing these parts do not
have ground or polished surfaces. Parts should remain in
solution long enough to be thoroughly cleaned and heated.
This will aid the evaporation of the cleaning solution and
rinse water. Parts cleaned in solution tanks must be
thoroughly rinsed with clean water to remove all traces of
alkali. Cast parts may also be cleaned with steam cleaner.

Housing. Covers. etc.


Inspect housings, covers and bearing caps to be certain
they are thoroughly cleaned and that mating surfaces,
bearing bores, etc., are free from nicks or burrs. Check all
parts carefully for evidence of cracks or condition which
would cause subsequent oil leaks or failures.

CAUTION: Care should be exercised to avoid skin rashes


and inhalation of vapors when using alkali cleaners.
All parts cleaned must be thoroughly dried immediately
by using moisture-free compressed air or soft, lintless
absorbent wiping rags free of abrasive materials such as
metal filings, contaminated oil or lapping compound.
INSPECTION
The importance of careful and thorough inspection of all
parts cannot be overstressed. Replacement of all parts
showing indication of wear or stress will eliminate costly
and avoidable failures at a later date.
Bearings
Carefully inspect all rollers, cages and cups for wear,
chipping or nicks to determine fitness of bearings for
further use. Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same
time. After inspection, dip bearings in clean light oil and
wrap in clean lintless cloth or paper to protect them until
installed.

-66-

S1005

1.060 .007 [26.9 .17]

Stake 3 places approx,


equally spaced.

After curing of Loctite,


speed sensor bushing
must be secure with 40
Ft. Lb. [54.2 Nm] torque.

1.390 .007 [35.3 .17)


REAR VIEW

ASsemble.Speed Sensor Bushingin housing to specified


dimension with Loctite 262 and stake (3) three places.

SPEED SENSOR BUSHING INSTALLATION

-67-

S1005

BACKING RING

TORQUE CONVERTER
RING GEAR

RING GEAR SCREW

ENGINE FLYWHEEL

RING GEAR SCREW


(32) 243970 1.500 [38,11
(32) 244903 1.750 [44.4J
(32) 240318 2.000 [50.8J
(32) 237153 2.500 [63,5J
(32) 236938 3.000 [76,2J
(32) 4200097 [M8 x 1.25J

_ l_- _ ,

S- __ --.J
SEE PAGE 69
FOR INSTALLATION
PROCEDURE AND
BOLT TORQUE

BACKING RING
236937
TORQUE CONVERTER RING GEAR 249265

S1005

32 SCREW RING GEAR INSTALLATION PROCEDURE


(Non-Asbestos Ring Gear)
1.

Remove all burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface
and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean.

2.

Check engine flywheel and housing or housing adaptor for conformance to standard SAE. No.3 - SAE J927 and J1033
tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine
crankshaft end play.

3.

Install torque converter ring gear as shown.


NOTE: Assembly of the ring gear must be completed within a fifteen minute
period from start of screw installation. The screws are prepared with an epoxy
coating which begins to harden after installation in the flywheel mounting holes. If not
tightened to proper torque within the fifteen minute period insufficient screw clamping
tension will result.

4.

Install backing ring and thirty-two (32) special screws to approximately .06 inch [1,5 rnrnl of seated position. It is permissible to
use a power wrench for this installation phase. With a calibrated torque wrench tighten screws 23 to 25 pounds feet of torque
[31,2 - 33,8 N.m].
To obtain maximum effectiveness of the special screw's locking feature, a minimum time period after screw installation of
twelve (12) hours is suggested before engine start-up.
The special screw is to be used for ONE installation only. If the screw is removed for any reason it MUST BE REPLACED. It is
recommended that the epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent. Dry hole
thoroughly and use a NEW screw for re-installation.

5.

Assemble torque converter to engine flywheel by sliding converter into position by hand before fastening housing attachment
screws. This may require more than one trial to match the drive gear teeth. Pulling the converter into position with housing
attachment bolts is not recommended.

6.

Measure engine crankshaft end play after assembly of torque converter. This value must be within one thousandth (,001l of an
inch [0,0254mm) of end play recorded (in Paragraph #2) before assembly of torque converter.
802544 - 1.5 INCH [38,1] 32 SCREW RING GEAR KIT

1
32

249265
243970
802550

802547 - 2.5 INCH [63,5] 32 SCREW RING GEAR KIT

Torque Converter Ring Gear


Ring Gear Screw 1.5 Inch 138,11
Installation Instruction Sheet

1
32

802545 - 1.75 INCH [44,4) 32 SCREW RING GEAR KIT

1
32

249265
244903
802550

1
1

249265
240318
802550

Torque Converter Ring Gear


Ring Gear Screw 2.5 Inch 163,51
Installation Instruction Sheet

802548 - 3.0 INCH [76,2) 32 SCREW RING GEAR KIT

Torque Converter Ring Gear


Ring Gear Screw 1.75 Inch 144,4)
Installation Instruction Sheet

1
32
1

802546 - 2.0 INCH [50,8) 32 SCREW RING GEAR KIT

32

249265
237153
802550

249265
236938
802550

Torque Converter Ring Gear


Ring Gear Screw 3.0 Inch 176,21
Installation Instruction Sheet

802549 - M8-32 SCREW RING GEAR KIT

Torque Converter Ring Gear


Ring Gear Screw 2.0 Inch [50,8]
Installation Instruction Sheet

1
32
1

249265
4200097
802550

Torque Converter Ring Gear


Ring Gear Screw [M8 x 1.251
Installation Instruction Sheet

236937 Backing Ring Not Included in Ring Gear Kit. Must be Ordered Separately.

NOTE:

The initial installation drive gear mounting kit includes a converter air breather. This breather is used on C & CL 270/C &
CL 320 converters only and is not required for the HR & LHR 28000/HR & LHR 32000 applications.

SEE PAGE 68 FOR INSTALLATION ILLUSTRATIONS

-69-

S1005

R-MODEL SECTION

-70-

S1005

R32000 FRONT COVER GROUP

ITEM

DESCRIPTION

OTY

ITEM

DESCRIPTION

OTY

23

Input Shaft

24

Input Shaft Rear Bearing

Flange Nut Washer

25

Input Shaft Gear

Flange "0" Ring

26

Input Shaft Gear Retaining Ring . . . . . . . . . . . .. 1

Input Flange

27

Tube Sleeve

Input Flange Oil Seal . . . . . . . . . . . . . . . . . . . . .. 1

28

Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1

Input Shaft Front Bearing Retaining Ring . . . . .. 1

29

Detent Spring

Input Shaft Front Bearing

30

Detent Spring

Input Shaft Front Bearing Retaining Ring . . . . .. 1

31

Valve to Converter Housing Screw. . . . . . . . . .. 9

10

Pipe Plug

32

Valve to Converter Housing Screw Lockwasher 9

11

Front Cover & Tube Assembly . . . . . . . . . . . . .. 1

33

Control Valve Assembly

12

"0" Ring

34

Control Valve Gasket. . . . . . . . . . . . . . . . . . . . .. 1

13

3rd Speed Tube Assembly .. . . . . . . . . . . . . . .. 1

35

Detent Ball

14

Tube Clip

36

Detent Ball

15

Tube Clip Screw Lockwasher . . . . . . . . . . . . . .. 2

37

Pipe Plug

16

Tube Clip Screw

38

Cover to Case Screw . . . . . . . . . . . . . . . . . . . . .. 4

17

Reverse Tube Assembly

39

Cover to Case Screw Lockwasher

18

Breather

40

Front Cover Plug

19

Front Cover Sleeve

41

Front Cover Plug Gasket . . . . . . . . . . . . . . . . . .. 1

20

Front Cover Sleeve Lock . . . . . . . . . . . . . . . . . .. 2

42

Cover to Case Screw . . . . . . . . . . . . . . . . . . . . .. 4

21

Sleeve Lockscrew Lockwasher . . . . . . . . . . . . .. 2

43

Cover to Case Screw Lockwasher

22

Sleeve Lockscrew . . . . . . . . . . . . . . . . . . . . . . .. 2

Flange Nut Cotter

Flange Nut

-71-

1
.
1

4
.. 1

S1005

R32000

ASSEMBLY INSTRUCTION

Spacer used with


12 plate modulation only.

-72-

ILLUST~ATION

S1005

Apply very light coat of Permatex No.2 to 0.0.


of all oil seals before ass'y.
Gear to be assembled with long hub length to this
side.
Lockwire to prevent loosening

Three clutches,6-outer steel plates,6-inner friction


plates.Assemble alternately, starting with outer
steel plate.

Bearing shield out


See Elastic Stop Nut Torque Chart

~ onMustbearing.
be loose internal fit bearings. No. "3" etched

Low clutch,9-outer steel plates,9-inner friction


plates. Assemble alternately. starting with outer
steel plate.

~ (12
Plate Modulation) Two clutches,12-outer steel
plates,12-inner friction plates.Assemble alternately.

&

starting with outer steel plate.


Bearing shield in.

Notes
E. - After assembly of parts using Permatex or
Crane sealer, there must not be any free or
excess material that could enter the oil circuit.
F. - Apply light coat of Crane Sealer to all pipe
plugs.
G. - Apply a thin coating of grease between seal
lips on lip type seals prior to ass'y.
H. - Apply light coat of Permatex NO.2 to all thru
hole stud threads.

A. - Use Permatex & Crane Sealer only where


specified.
B. - All lead in chamfers for oil seals, piston rings &
"0" rings must be smooth & free from burrs.
Inspect at ass'y.
C. - Lubricate all piston ring grooves & "0" rings
with oil before ass'y.
O. - Apply very light coat of Permatex NO.2 to 0.0.
of all oil seals before ass'y.

NOTE: Metric dimensions shown

in brackets [ ].
View"Q"
2 Places
ELASTIC STOP NUT TORQUE

Low Clutch Return Springs.


Concave side of first spring to be placed
against clutch piston. Remaining four washers
to be stacked alternately reversed as shown.

THREAO SIZE

LB.-FT.

1" - 20
1V4" - 18

150
200
300
400

1'12" - 18
1'/4" - 12

200
250
350
450

[N'rn]
[203,4 - 271.1]
(271.2 - 338.9]
(406.8 - 474,5]
(542,4 - 610,11

Forward & Reverse Clutch Return Springs.


Concave side of first spring to be placed
against clutch piston. Remaining six washers of
each clutch to be stacked alternately reversed
as shown.

Grade 5

ED

Torque Specification for Lubricated


or Plated Screw Threads

NOM
SIZE

FINE THREAD
(NM)
LB-FT

COARSE THREAD
[NM)
LB-FT

5625.
5000
.4375
3750'
3125
2500

91 6441 26 169-

82 57 37 23 12 8-

100
70
45
29
20
11

(123,4 [ 86.8[ 55,6[ 35.3[ 21.7


( 12.3

135.5]
94.91
61.01
39.31
27.11
14.9)

90
63
41
25
16
10

[111,2 [ 77,3[ 50,2[ 31.2 [ 16.3( 10.9-

Grade 8 M

\!57

FINE THREAD
LB-FT
(NM)

122.01
85.4]
55.5)
33,8]
21,6]
13.5)

128 90 58 37 28 11-

-73 -

141
99
64
41
32
13

[173.6 - 191.1]
[122.1 - 134.2]
[ 78.7- 86.71
[ 50.2- 55.51
[ 38.0- 43.3]
( 15.0- 17.6)

COARSE THREAD
LB-FT
(NM)

115 80 52 3326 9-

127
88
57
36
30
11

[156.0 - 172.2
(108,5 - 119.3
[ 70.6- 77,2
[ 44,8- 48,8
[ 35.3 - 40.6]
( 12.3- 14.9)

S1005

MAINTENANCE AND SERVICE


The instructions contained herein cover the disassembly and reassembly ofthe transmission in a sequence
that would normally be followed after the unit has been
removed from the machine and is to be completely
overhauled. It must also be understood that this is a basic
32000 transmission with many options. Companion
flanges and output shafts with and without disconnect

assemblies may vary on specific models. The units are very


similar to trouble shoot. disassemble, repair and reassemble.
CAUTION: Cleanliness is of extreme importance and
an absolute must in the repair and overhaul of this unit.
Before attempting any repairs, the exterior of the unit must
be thoroughly cleaned to prevent the possibility of dirt and
foreign matter entering the mechanism.

DISASSEMBLY

Figure 1
Removecontrol valve bolts and washers. Removecontrol valve.
Use caution as not to lose detent springs and balls.

Figure 3
Remove front cover plug.

Figure 4
Remove bolts securing front cover to transmission housing.

Figure 2
Remove companion flange nut, washer and "0" ring.

-74-

S1005

INSTALL INPUT SHAFT OIL SEAL IN FRONT


COVER AS SHOWN ON PAGE 72.

DRIVE GEAR

-J------'---INPUT SHAFT

NOTE: LONG HUB OF


DRIVE GEAR TOWARD
RETAINER RING
Figure 5

Figure 8

Remove front cover and forward and 2nd clutch.

Input shaft, rear bearing, drive gear and snap ring.

Figure 6

Figure 9

Use a spreading type snap ring pliers to spread the ears on forward clutch front bearing retainer ring. Remove forward clutch
with pry bar.

Install input shaft into front bearing.

Figure 7

Figure 10

If input shaft is to be removed, tap on threaded end of shaft,


remove input shaft, gear and bearing.

Support converter housing with chain fall. Spread forward


clutch front bearing retainer ring and tap forward and 2nd clutch
assembly into transmission case assembly. Be certain snap ring
is in full position in ring groove.

See cleaning and inspection page.

-75-

S1005

Figure 14
Support front cover with a chain fall. Install alignment studs in
transmission case. Position front cover assembly on aligning
studs. Turn output flange to align clutch disc hub in clutch. Do
not force this operation. With front cover in position against the
transmission case install cover to case bolts. Tighten to
specified torque.

Figure 11
Install 2nd speed clutch pilot bearing.

Figure 12
Install transmission case gasket and "0" ring seals.

Figure 15

Install front cover plug.

Figure 13
Install housing spacer, gasket and "0" ring seals. NOTE: Housing spacer is used with 12 plate clutch modulation only.

Figure 16
Install companion flange, flange "0" ring, washer and nut. Torque nut to specified torque. (See elastic stop nut torque chart).

-76-

S1005

NOTE: The disc spring packs are to be used as


complete assemblies and care should be taken
not to intermix the individual disc springs with
disc springs in another clutch or disc spring
pack.
Each disc spring assembly is made up of
selected springs to precisely match each part
within this assembly. Failure to replace all
piston return springs can resut in unequal
deflection within the spring pack. The result of
this imbalance may adversely affect overall life
of springs.
Figure 17
Locate detent balls and springs in control valve. Position new
gasket. Secure valve with bolts and washers. Tighten to
specified torque.

Service replacement assemblies are banded


together and must be replaced as assembly.

BEARING SHIELD
MUST FACEIN
BEARING SHIELD
MUST FACE OUT

REAR

BEARING SHIELD

SHIELDED BEARING INSTALLATION

-77-

S1005

R32000 - C270/C320 EXTERNAL PLUMBING DIAGRAM


Check point "E"
Cooler inlet pressure.

Filter Assembly (see chart)


Note:
Line from pump must be connected
to "ln" side of filter.

Check point "F"


Cooler outlet pressure.
Check point "G"
Cooler outlet temperature.

Line from pump to filter and


from filter to reg. valve.

Oil filler opening


Check point "S"
converter inlet pressure.

Check point ''/lI'


clutch pressure
240-280 PSI [1655.0-1931,0 kPa]

Install breather and


adapter in highest
converter drain location.

Select lowest connection


for gravity drain to trans.

Check point "0"


Converter oil temperature
(Red line 250F. [121OC])

Metric dimensions shown


in brackets [ ].
Note: Do not deviate any line size.

Check point "C" converter


outlet pressure. Converter
outlet oil temp. 180-200F.
[82,3 -93,3 0c)
Transmission in neutral.
Operating specifications:
25 PSI [172,0 kPal minimum
pressure at 2000 RPM engine
speed and a maximum of 70 PSI
[483,0 kPal outlet pressure
with engine operating at
no-load governed speed.

FILTER ASSEMBLY CHART


Filter Type
A

Assembly No.
1533614
Single Can

234m
Dual Can

Cartridge No.
215502
215502

Spin-on Type
Assembly No.
Element
247055
247052
Single Element
246787
243622
Dual Element

-78-

Suction line from transmission


sump to pump.
Gravity drain-must have
continuous slope from
converter to transmission.
Notes:
Hose line operating requirements.
1. Pressure Lines-Suitable for operation from
ambient to 250F. [121,1OC] continuous operatina
temperature. Must withstand 300 PSI [2068 kPal
continuous pressure with 600 PSI [4137 kPal
intermittent surges. Ref. SAE. Spec. No.
J517,100R1 Hydraulic Hose Specification.
2. Suction Line-To be protected from collapse
by interwoven steel wire. Ref. S.A.E. Spec. No.
J517,100R4 Hydraulic Hose Specification.
Suitable for operation from ambient to
250F. [121,1OC]. Continuous operating temperature.
3. Grevlty Drain Line-Suitable for operation
from ambient to 250F. [121,1OCj continuous
operating temperature. Ref. SAE. Spec. No. J517,100R1
Hydraulic Hose Specification.
4. All Hose Lines used must conform to S.A.E.
Spec. No. J1019 Test Procedure for High
Temp. Transmission Oil Hose.
5. See Lubrication Specifications.

INSTALLATION INSTRUCTIONS OF NEW NON-METALLIC SEALING RINGS


S1005
Proper oil sealing ring (piston ring) installation procedures. Refer to the appropriate transmission
maintenance and service manual for disassembly, cleaning, inspection and reassembly.
1. Fill the oil sealing ring grooves with a good grade of grease, this will help stabilize the sealing ring
in the ring groove for installation.
2. Carefully position the piston ring on the shaft in the inner most ring groove. Hook the piston ring
joint.
3. Repeat steps 1, and 2 for the remaining ring or rings making certain all hook joints are fastened
securely.
4. Apply a heavy coat of grease to the outer diameter of the rings and shaft. Center the piston rings
in the ring groove.
5. When installing the clutch assembly in the transmission case it is recommended a piston ring
sleeve PIN's 241309, 237576, 234265, 235314 or 248694 be used to center all of the piston rings
in their respective ring grooves. Use extreme caution to not damage piston ring when installing
the clutch shaft in the transmission case, or when installing the converter housing or front cover
on the clutch shafts.
PISTON RING
SLEEVE

USED FOR POSITIONING


OF PISTON RINGS

234265

BEARING
PISTON RINGS

18000 SERIES

PISTON RING
USED FOR POSITIONING
SLEEVE
OF PISTON RINGS
241309 OR 237576

PISTON RING
SLEEVE

23531- 4 OR 248694

USED FOR POSITIONING


OF PISTON RINGS
BEARING

PISTON RINGS
Be aunt that lead in charnf8r and
Intersectionof lead in ~r 10 pilton
ring bore is free of burrs end nicka.

2420,24000,28000,32000,33000
34000,36000 SERIES

-79-

28000, 32000 SERIES


4TH CLUTCH SHAFT

S1005

-80-

S1005

32000 6 & 8 SPEED OUTPUT GROUP


WITH RANGE SHIFT

ITEM
DESCRIPTION
QTY
1 Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . .. 1
2 Idler Shaft Rear Bearing Lock Ball. . . . . . . .. 1
3 Idler Shaft Rear Bearing
1
4 Idler Shaft Bearing Cap Screw . . . . . . . . . .. 3
5 Speedometer Driven Gear
1
6 Speedometer Tube Nut
1
7 Idler Shaft Bearing Capscrew . . . . . . . . . . .. 1
8 Idler Shaft Bearing Capscrew Lockwasher .. 4
9 Idler Shaft Bearing Cap . . . . . . . . . . . . . . . .. 1
10 Idler Shaft Bearing Cap Gasket. . . . . . . . . .. 1
11 Idler Shaft Nut. . . . . . . . . . . . . . . . . . . . . . .. 1
12 Speedometer Drive Gear or Bearing Spacer. 1
13 Idler Shaft Rear Bearing Locating Ring
" 1
14 Idler Shaft Gear
" 1
15 Idler Shaft Gear Spacer. . . . . . . . . . . . . . . .. 1
16 Idler Shaft Low Range Gear .. . . . . . . . . . .. 1
17 Low Range Gear . . . . . . . . . . . . . . . . . . . . .. 1
18 High Low Shift Hub. . . . . . . . . . . . . . . . . . .. 1
19 Shift Hub Sleeve. . . . . . . . . . . . . . . . . . . . .. 1
20 High Range Gear. . . . . . . . . . . . . . . . . . . . .. 1
21 Output Gear Inner Race
1
22 Output Gear Bearing . . . . . . . . . . . . . . . . . .. 1
23 Output Gear Bearing . . . . . . . . . . . . . . . . . .. 1
24 Output Gear Thrust Washer . . . . . . . . . . . .. 1
1
25 Output Shaft Rear Bearing Cone
26 Output Shaft Rear Bearing Cup
1
27 Output Shaft Rear Bearing Cap "0" Ring .. 1
28 Output Shaft Rear Bearing Cap "0" Ring .. 1
29 Output Shaft Rear Bearing Cap Screw. . . .. 4
30 Output Shaft Rear Bearing Cap Screw
Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . .. 4
31 Output Shaft Rear Bearing Cap
1
32 High and Low Range Shift Fork
1
33 Shift Fork Lock Screw. . . . . . . . . . . . . . . . .. 1
34 Rear Bearing Cap Oil Seal . . . . . . . . . . . . . .. 1
35 Rear Output Flange . . . . . . . . . . . . . . . . . . .. 1
36 Output Flange"0" Ring . . . . . . . . . . . . . . .. 1
37 Output Flange Washer . . . . . . . . . . . . . . . .. 1

ITEM
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73

-81-

DESCRIPTION

QTY

Output Flange Nut


1
Output Flange Nut
1
Output Flange Washer .. . . . . . . . . . . . . . .. 1
Output Flange "0" Ring . . . . . . . . . . . . . . .. 1
Output Flange . . . . . . . . . . . . . . . . . . . . . . .. 1
Output Shaft Front Bearing Cap Oil Seal ... 1
Output Shaft Front Bearing Cap Screw . . .. 4
Output Shaft Front Bearing Cap Lockwasher 4
Output Shaft Front Bearing Cap
1
Front Bearing Cap Shim
AR
Front Bearing Cap "0" Ring . . . . . . . . . . . .. 1
Bushing (Used with Disconnect Only) ..... 1
Output Shaft (Used with Disconnect Only) . 1
Output Shaft. . . . . . . . . . . . . . . . . . . . . . . .. 1
Output Shaft Front Bearing Cup. . . . . . . . .. 1
Output Shaft Front Bearing Cone . . . . . . . .. 1
Output Gear Thrust Washer . . . . . . . . . . . .. 1
Output Gear Bearing . . . . . . . . . . . . . . . . . .. 1
Output Gear Bearing . . . . . . . . . . . . . . . . . .. 1
Output Gear Bearing Inner Race. . . . . . . . .. 1
Idler Shaft Front Bearinq Retainer Ring .... 1
Idler Shaft Front Bearing. . . . . . . . . . . . . . .. 1
Idler Shaft Gear Locating Ring
1
Idler Shaft . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Transmission Case Assembly. . . . . . . . . . .. 1
1
Range Shift Rail Support "0" Ring
Range Shift Rail Support. . . . . . . . . . . . . . .. 1
Range Shift Rail Support Screw
Lockwasher
2
Range Shift Rail Support Screw. . . . . . . . .. 2
Range Shift Rail Oil Seal . . . . . . . . . . . . . . .. 1
Range Shift Rail. . . . . . . . . . . . . . . . . . . . . .. 1
Range Shift Rail Detent Plug. . . . . . . . . . . .. 1
Range Shift Rail Detent Ball . . . . . . . . . . . .. 1
Range Shiftr Rail Detend Spring. . . . . . . . .. 1
Disconnect (Optional) . . . . . . . . . . . . . . . . .. 1
Bearing Cap Bore Plug (Optional) . . . . . . . .. 1

S1005

View"Q"

Housing spacer
used with 12 plate
modulation only.

6 SPEED TRANSMISSION

NON-MODULATED
-82-

S1005

&. Heat nose bushing to 200

Impeller Hub and Turbine Hub Assembly with


Backing Ring and Special Self Locking Screws.
1. Clean hub mounting surface and tapped holes
with solvent. Dry thoroughly being certain tapped
holes are dry & clean.
2. Install backing ring and special self locking
screws.
Tighten screws 40 to 45 Lbs. Ft. [54,3-61,0 N'm)
Note: Assembly of hub must be complete within a
fifteen minute period from start of screw installation. The special screw is to be used for one installation only. If the screw is removed for any
reason it must be replaced. The epoxy left in the
hub holes must be removed with the proper tap
and cleaned with solvent. Dry hole thoroughly and
use a new screw for reinstallation.

Bearing shield OUT on 3rd speed clutch. Bearing shield


IN on Fwd. & Rev. clutch.
Must be loose internal fit bearings, No. "3" etched on
bearing.

&.

Notes
specified.
B. - All lead in chamfers for oil seals, piston rings &
"0" rings must be smooth & free from burrs.
Inspect at ass'y.
C. - Lubricate all piston ring grooves & "0" rings
with oil before ass'y.
D. Apply very light coat of Permatex NO.2 to 0.0.
of all oil seals before ass'y.
E.. After assembly of parts using Permatex or
Crane sealer, there must not be any free or
excess material that could enter the oil circuit.
F. - Apply light coat of Crane Sealer to all pipe
plugs.
G. - Apply a thin coating of grease between seal
lips on lip type seals prior to ass'y.
H. - Apply light coat of Permatex NO.2 to all thru
hole stud threads.

Three clutches,6-outer steel plates,6-inner friction


plates. Assemble alternately, starting with outer
steel plate.

&

ill
&
ill

See Elastic Stop Nut Torque Chart


Low clutch,9-outer steel plates.s-lnner friction
plates. Assemble alternately, starting with outer
steel plate.
See Elastic Stop Nut Torque Chart
Shim output shaft bearings to produce 6 to 8 Lbs.In, [0,68,-0,90 N'm) preload.

NOTE: The friction discs in the low clutch has


a higher co-efficient rating than the friction
discs in the other clutches, therefore the
discs must not be mixed. The low clutch inner disc can be identified by an "X" stamped
on one side of the inner teeth. The low clutch
inner disc also has a strip of non-soluble
yellow paint sprayed on the outer edge of
the disc.

Tighten oil screen ass'y. 10 to 15 Lbs. Ft.


[13,6-20.0 N'm] (Not shown)
View"Q" 2 Places

(12 Plate Modulation) Two clutches, 12-outer steel plates,


12-inner friction plates. Assemble alternately, starting
wit,h outer steel plate.

A. - Use Permatex & Crane Sealer only where

Gear to be assembled with long hub length to this


side.

&.

FO (93OC) before ass'y. of

bushing to cover.

Low Clutch Return Springs.


Concave side of first spring to be placed
against clutch piston. Remainin9 four springs
to be stacked alternately reversed as shown.

~i'W'S'

Forward & Reverse Clutch Return Springs.


Concave side of first spring to be placed
against clutch piston. Remaining six springs
of each clutch to be stacked alternately
reversed as shown. See note on page 77.

Enlarged view of Piston Ring & Expander


Note: Expander gap to be approx. 180 0 from ring
hook joint to aid ring assembly.
ELASTIC STOP NUT TORQUE

NOTE: Metric dimensions shown


in brackets [ ].

THREAD SIZE

LB.-FT.

1" - 20
lV." - 18

150 - 200
200 - 250

18

300 - 350

1314" - 12

400 - 450

1'12"

Grade
NOM,
SIZE

-~~+
5000 ,
4375
3750
3125
,2500

FINE THREAD
[NM]
LBFT
1123,4 - 135,51
91100
1 86.8- 94.91
64 - 70
41 - 45
I 55,6- 61.01
26 - 29
[ 35.3- 39.31
1 21.7- 27,'-1
16 - 20
9 - 11
I 12.3- 14,9)

ED

Torque Specification for Lubricated


or Plated Screw Threads

COARSE THREAD
[NM)
LB-FT
1111.2 -122.01
82 - 90
57 - 63
r 77,3- 85,41
41
[ 50.2 55,5J
-- 37 1 31.2- 33.81
23 - 25
12 - 16
1 16.3 21,61
8 - 10
I 10.9- 13,5]

-83

Grade

FINE THREAD
LB-FT
[NM]
128 - 141
1-173.6 - 191.11
1122.1 - 134,21
90 - 99
58 - 64
I 78,7- 86.71
37 - 41
r 50.2- 55.51
28 - 32
1 38.0 43.31
11- 13
I 15.0- 17.61

[N'm]
[203,4 - 271,1]
[271,2 - 338,9]
[406,8 - 474,5]
[542,4 - 610,1]

aM
\!Sl
COARSE THREAD
LB-FT
[NM]
115 - 127
1156.0 - 172.2]
80 - 88
1108.5 - 119.3]
52 - 57
r 70.6- 77,21
33 - 36
T 44.8- 48.81
1 35,3- 40.61
26 30
9 - 11
[ 12,3- 14,9]

S1005

~-

- -.::.,..

-84-

R & HR MODEL 6 & 8 SPEED

S1005

The R & HR 32000 6 speed transmission is the same as the 3 speed R & HR 32000 except the difference being in the idler and output shafts. The 6-speed unit has a gear added to the idler shaft and the output shaft has a high and low range shift.
The 32000 8 speed transmission is the same as the 6 speed except the 8 speed has a 4th speed clutch.
The 6-speed transmission has 3 working range shifts and 3
travel range shifts.

The 8-speed transmission has 8 forward speeds and 8 reverse


speeds.

Gear ratio determines working and travel ranges. They are as


follows:

The 8-speed transmission has 4 working range shifts and 4 travel


range shifts.

1st

- 2nd and 4th working range. 3rd - 5th and 6th travel range.
NOTE: Range shift from low to high must be made with
machine stopped.

DISASSEMBLY

Gear ratio determines working and travel ranges. They are as follows:
1st - 2nd - 3rd and 5th working ranges 4th - 6th - 7th and 8th travel
range.
NOTE: Range shift from low to high must be made with machine
stopped.

Figure 55 shows the idler shaft with one gear. The 6-speed unit
will have two gears and a heavier front bearing. See Figure 55A
below:

Figure 2
Remove range shift rail support bolts. Remove rail support, rail
and range shift fork.

Flgure55A
6 & 8 speed idler shaft, gear and bearing assembly. NOTE:

Do not lose rear bearing lock ball.

6 & 8 SPEED OUTPUT DISASSEMBLY

Figure 1
With all clutches and shafts removed, cut lockwire on range
shift fork lockscrew. Remove fork lockscrew.

Figure 3
Remove output shaft rear bearing cap bolts and bearing cap.

-85-

S1005

Figure 6
Position high and low range gears, shift hub, hub sleeve and
needle bearings in transmission case as shown in Figure 5.
Insert output shaft, front bearing and thrust washer through
output gears. Use caution as not to damage high and low range
gear needle bearings.

Figure 4
Remove front output flange nut, washer, "0" ring, flange and
bearing cap from housing. Block output gears. Push output
shaft from rear through gears and taper bearing.
Proceedwith Figure 72 through 216 in the R & HR 32000 Series
3-Speed Maintenance Section then refer to Figure 5 below.

REASSEMBLY
(See cleaning and inspection page.)

Figure 7
Position output gear thrust washer and rear taper bearing on
output shaft.

Figure 5
View of output shaft as it would be positioned in transmission
case. NOTE: Front bearing cone and output gear thrust washer
shouldered on shaft with large diameter of bearing in.

Figure 8
Block output shaft from the front and install rear taper bearing.

-86-

S1005

Figure 11
Locate high-low range shift fork in shift hub with offset of fork
toward gear, Insert rail support and rail into bore in transmission
housing and into shift fork.
Figure 9
Using new "0" rings install rear output bearing cap and taper
bearng. cup on transmission case. Lube opening in bearing cap
must be aligned with lube opening in case. Tighten bearing cap
bolts to specified torque. (See torque chart.)
Install front bearing cap and shims. Tighten bolts to specified
torque. Tap output shaft front and rear to seat taper bearings.
Loosen front bearing cap bolts.

Figure 12
Tighten support bolts to specified torque. (See torque chart).

Figure 10
Using a inch lb. torque wrench, determine the rolling torque of
the output shaft and record. Tighten front bearing cap bolts to
specified torque. Check rolling torque with bolts tight. Torque
must be 6 to 8 inch Ibs. [0.68 - 0.90 N'rnl more than when bearing cap bolts were loose. Add or omit shims on the front bearing
cap to achieve the proper preload.

Figure 13
Locate lockscrew hole in shift rail with hole in shift fork. Install
lockscrew, tighten securely and lockwire to prevent loosening.
Proceed with Figure 228 in the R & HR 32000 3-Speed Section.

-87-

S1005

KEY
1ST (LOW)
_ _ 2ND
3RD (HIGH)

~~~~F~3-

6 SPEED TRANSMISSION LOW RANGE


-88-

RANGE SHIFT

S1005

KEY
4TH
- _ 5TH
6TH

-tB~~~~~3-

6 SPEED TRANSMISSION HI RANGE

-89-

RANGE SHIFT

S1005

LOW RANGE
1ST (LOW)
- - - - - 2ND
3RD
4TH (HI)

~~.~~~~~)$.
~
- ......LOW
...... RANGE

8 SPEED TRANSMISSION LOW RANGE

-90-

S1005

HIGH RANGE

1ST (LOW)
- - - - - - 2ND
3RD
4TH (HI)

8 SPEED TRANSMISSION HIGH RANGE

-91-

8 SPEED CLUTCH SECTION

S1005

4TH SPEED CLUTCH GROUP 8 SPEED TRANSMISSION

ITEM DESCRIPTION

QTY

ITEM DESCRIPTION

Ql

Piston Return Spring

10

Clutch Piston Assembly................

Spring Retainer

11

Clutch Piston Seal - Outer...................................

Spring Retainer Snap Ring..

12

Clutch Piston Seal - Inner....................................

Clutch Hub Snap Ring

13

4th Sped Shaft Piston Ring..................................

4th Speed Clutch Hub..................................

14

Front Bearing Retainer Ring................................

Backing Plate Snap Ring............................

15

4th Speed Shaft Front Bearing.............................

Clutch Disc Backing Plate............................

16

Front Bearing Snap Ring.....................................

Clutch Outer Disc.........................................

17

4th Speed Shaft & Plug Assembly.........................

Clutch Inner Disc..

1
..

-92-

8 SPEED SECTION

S1005

rhe difference between the 6 speed transmission and the 8


speed is that the 8 speed has an added 4th speed clutch. This
section will describe the converter housing removal and the
nh speed clutch repair.

DISASSEMBLY

Figure 3
Remove fourth speed clutch disc hub retainer ring.
Figure

Figure 1
Remove bolts securing converter housing to transmission
housing. Support converter housing with a chain fall. Using
spreading type snap ring pliers, spread ears on the fourth
speed clutch front bearing retaining ring. Holding snap ring
open, tap converter housing from transmission housing. The
fourth clutch will remain in the transmission housing.

Figure 4
Remove fourth speed clutch disc hub.

4TH SPEED CLUTCH


DISASSEMBLY
(8 speed transmission only)

Figure 2
Remove fourth speed clutch assembly from transmission
housing

Figure 5
Remove end plate retainer.

-93-

S1005

Figure 6
Figure 9

Remove end plate.


Remove clutch piston.

Figure 7
Remove inner and outer clutch discs.

Figure 10
Remove clutch shaft piston rings and expander springs. See
note In Figure 103.

Figure 8
Compress spring retainer washer. Remove spring retainer snap
ring. Release tension on spring retainer. Remove snap ring,
spring retainer and return spring.

Figure 11
Remove clutch shaft bearing retainer ring. Remove shaft bearing.

See cleaning and inspection page.


-94-

S1005

4TH SPEED CLUTCH


REASSEMBLY
(8 speed transmission only)

Figure 15
Install new clutch piston inner and outer sealing rings. Insert
clutch piston in clutch drum. Use caution as not to damage
sealing rings.
Figure 12
Install clutch shaft bearing. NOTE: Bearing snap ring groove
must be down.

Figure 13
Install bearing retainer ring.

Figure 16
Install clutch piston return spring, spring retainer and retainer
snap ring. Install one friction disc. Alternate steel and friction
discs until the proper amount of discs are installed. First disc
next to piston is friction, last disc installed is friction. (8 friction 7 steel).

Figure 14
Install piston rings as explained on page 79.

Install end plate.

Figure 17

-95-

S1005

Figure 21
Position pilot bearing on fourth speed clutch shaft. Install fourth
clutch on disc hub. Use caution as not to damage the pilot
bearing.

Figure 18
Install end plate retainer ring. See transmission reassembly
on page 38.

CONVERTER HOUSING INSTALLATION


4TH SPEED CLUTCH INSTALLATION

(8 speed only)

Figure 22
Support converter housing with a chain fall. Spread fourth
clutch front bearing retainer ring. Position converter housing to
transmission case assembly. Tap housing into place using
caution as not to damage any of the clutch shaft piston rings.

Figure 19
Position 4th speed clutch disc hub on idler shaft.

Figure 23
Spread forward clutch front bearing retainer ring to allow the
converter housing to position properly.

Figure 20
Install disc hub retainer ring.

-96-

S1005

Figure 25
Use the same procedure for the forward clutch as explained in
Figure 24. Be certain both snap rings are fully seated in the
bearing snap ring grooves. Install converter housing to
transmission housing cap screws, tighten to specified torque.

Figure 24
A hammer puller was used to pull the fourth clutch bearing
forward to engage the front bearing snap ring in the bearing
groove.

REFER TO PAGE 46 FOR COMPLETE TRANSMISSION REASSEMBLY.

-97-

S1005

DRIVE PLATE INSTALLATION


SUBJECT: 28000/32000 Series Transmission and C-270/C-320 Series Converter Drive Plate Kits.
REASON FOR BULLETIN: Proper Identification by Bolt Circle Diameter.
Measure the "A" dimension (Bolt Circle diameter) and order Drive Plate Kit listed below.

ALIGNMENT HOLES
(1) DRIVE PLATE AND

WELD NUT ASSEMBLY

BOLT CIRCLE DIA

(4) INTERMEDIATE
DRIVE PLATES

BACKING RING

"A" Dimension (Bolt Circle Diameter)


13.125" [333,375 mml Diameter
Kit No. 802335
13.50" [342,900 mml Diameter
Kit No. 802333
17.00" [431,800 mrnl Diameter
Kit No. 802454
Each kit will include the following parts:
4

Intermediate Drive Plates

Drive Plate and Weld Nut Assembly.

Backing Ring.

10 Screw and Lockwasher Assembly.


1 Instruction Sheet.
TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES - SEE ILLUSTRATION ABOVE.

Position drive plate and weld nut assembly on impeller cover with weld nuts toward cover. Align intermediate drive plate and
backing ring with holes in impeller cover. NOTE: Two dimples 180 0 apart in backing ring must be out (toward engine flywheel).
Install capscrews and washers. Tighten 23 to 25 ft. Ibs. torque [31,2 - 33,8 N.m].
SEE PAGE 99 FOR TRANSMISSION TO ENGINE
INSTALLATION PROCEDURE
Instruction SheeUlO2334
TSB-7.&~ev. 11-93

-98-

S1005

TRANSMISSION TO ENGINE INSTALLATION PROCEDURE

1.

Remove all burrs from flywheel mounting face and


nose pilot bore. Clean drive plate surface with solvent.

2.

Check engine flywheel and housing for conformance


to standard S.A.E. #3 - SAE. J-927 tolerance
specifications for pilot bore size, pilot bore runout and
mounting face flatness. Measure and record engine
crankshaft end play.

3.

4.

5.

FLYWHEEL
HOUSING

ENGINE

FLYWHEEL
PILOT BORE

Install two 3.50 [88,90 mml long transmission to


flywheel housing. guide studs in the engine flywheel
housing as shown. Rotate the engine flywheel to align
a drive plate mounting screw hole with the flywheel
housing access hole.

FLYWHEEL

Install a 4.00 [101,60 mml long drive plate locating


stud .3750-24 fine thread in a drive plate nut. Align the
locating stud in the drive plate with the flywheel-drive
plate mounting screw hole positioned in step No.3.

FIG 1

Locate transmission on flywheel housing aligning


drive plate to flywheel and transmission to flywheel
housing.
Install transmission to flywheel housing screws.
Tighten screws to specified torque. Remove transmission to engine guide studs. Install remaining
screws and tighten to specified torque.

6.

Remove drive plate locating stud.

7.

Install drive plate attaching screw and washer. Snug


screw but do not tighten. Some engine flywheel
housings have a hole located on the flywheel housing
circumference in line with the drive plate screw access
hole. A screwdriver-er.orv bar used to hold the drive
plate against the flywheel will facilitate installation of
the drive plate screws. Rotate the engine flywheel and
install the remaining seven (7) flywheel to drive plate
attaching screws. Snug screws but do not tighten.
After all eight (8) screws are installed torque each one
25 to 30 ft. Ibs. torque [33,9 - 40,6 Nrn.l, This will require torquing each screw and rotating the engine
flywheel until the full amount of eight (8) screws have
been tightened.

8.

31'.1" ALIGNING
STUDS

DRIVE
PLATE

FLYWHEEL
HOUSING

FLYWHEEL

IMPELLER
COVER
(3) INTERMEDIATE _
DRIVE PLATES

Measure engine crankshaft end play after transmission has been completely installed on engine
flywheel. This value must be within .001 [0,025 rnrnl
of the end play recorded in step No.2.
FIG 3

-99-

SPECIAL STUD, WASHER AND


SELF LOCK NUT FURNISHED
BY MACHINE MANUFACTURER.

FIG 2

FIG 4

S1005

'I

REVER

4th

3rd

1st

SUPPLY

2nd

Control valve function of 28000 / 32000 - 4 speed: forward 1st

[gJ
"'"

It 1
OFF-HIGHWAY COMPONENTS

o
o
..-

-'

<$>

'i

't 1

IT]

OFF-HIGHWAYCOMPONENTS

[Q]

It

4th

3rd

1st

SUPPLY

2nd

Control valve function of 28000 / 32000 - 4 speed: forward 2nd

S1005

'I
F

[OJ

4th

3rd

1st

SUPPLY

2nd

Control valve function of 28000 / 32000 - 4 speed: forward 3rd

o
O'~
2

1
OFF-HIGHWAY COMPONENTS

~[QJ

<$:>

S1005

C\I

....0

(,)

(0

[Q]

<$>

OFF-HIGHWAYCOMPONENTS

~[Q][QJ

~J

'I

4th

3rd

1st

SUPPLY

2nd

Control valve function of 28000 / 32000 - 4 speed: forward 4th

S1005

~,ili

..

Mtli

_~",',','--

---=-

----'1111

.'''",,'-,".,

""_ _ _

":,:,:,:,:cr~",,_::;:::m:"'~

2nd

SUPPLY

tst

3rd
~~~_

4th

".llll]lliltl~lltllR-~:::;!:]:(~

~
, . .~:.:x:''I!!III::''F:''<:1
e-JI' ... f::i.
1l;11111,!lw11i&

~
~_~"'-M''''

~'M!:~'-

'*

Control valve function of 28000 / 32000 - 4 speed: neutral 4th

('i

A>.J

-- .

Q"

II

o1)~

"-

[OJ

II

[OJ

II

s:
R

OFF-HIGHWAYCOMPONENTS

[Q] [Q] [Q]

<$>

S1005

0
"'"
.....

....I
8:

I;

't

'1

OFF-HIGHWAYCOMPONENTS

[OJ

Control valve function of 28000 / 32000 - 4 speed: reverse 1st

S1005

S1005

NOTES

-106-

.....

0
"'-J

PlJIIP

...

""

"

Torque
converter

"

total neutral
solenoid

-=-

Hose

-----

@
3rd
clutch

:::I

2nd
clutch

1st
solenoid

~ 'C

.@

TBIIPUATURB
GAUGH

2nd
solenoid

baT

.@
.. 'u

PRESSURE
GAUGB

OPERATOR COMPARTMENT

OFF-HIGHWAY COMPONENTS

=14,504 PSI)

onSUIIP

<$>

( 1 bar

repIator
valve
16,5 - 20,7 bar

Pressure

Safetyva1e
11,6 - 13,8 bar
cl'Il:kq pressure

28000 I 32000transmission hydraulic diagram


3 speed with total neutral

Cooler

'VI

clutch

1st

::I

J!

baT

'C

_ r..n'l

fOlWard
clutch

FORWARD
SOLE.OID

Hose

.8

Total neutral

TBIIPBRATURE
CRBCK-PORT

reverse
clutch

REVJ!RSJ!
SOLE. OlD

L ubril:ation

'C

x
O

baT

\.2) CRBCK-PORT

t)('\ PRESSURE

S1005

!,
converter

L....-y--' Torque

3 speed with total neutral

14'--01

Safety valve
9,6 - 13,8 bar
cracking pressure

'

_. __ __

U--I_J
'0

28000 / 32000 transmlsslon- hydraulic diagram

~
PUMP

~~
. :~. - - Y-IL;E~- -:

Pressure
regulator
valve
16,5 - 20,7 bar

By-pass
1,7 - 4,3 bar

valve

r:,

AIR
BREATHER

OIL SUMP

( 1 bar = 14,504 PSI)

TBMPBRATURB
GAUGE

OPERATOR COMPARTMENT
PRBSSURB
GAUGE

Hose

1st

~
Cooler

,;:I
I

IJ
dutch

1st

h,

k~

forward
clutch

.8.8
~
Hose

\:.

bn

O
O

PRBSSURB
CHBCK-PORT

TBMPBRATURB
CHBCK-PORT

reverse
dutch

REVBRSB
SOLB.OID

L_tiD.

Forward and 1st clutch engaged

solenoid

.@.@

bn

::I
1

2nd
dutch

,.'.... J.o

3rd
dutch

.~ OFF-HIGHWAY COMPONENTS

S1005

II
Torque
converter

::I

har

Hose

1st

2nd
clutch

~:I

Cooler

~!

dutch

1st

~:I

.u

Hose

=1

~~
forward
dutch

\:.,J

JS

CRBCK-PORT

\.:) CHECK-PORT

(j{'l TEMPERATURE

hn

fi{\ PRESSURE

reverse
clutch

J2

REVERSE
SOLE. OlD

Lubrication

Forward and 2nd clutch engaged

solenoid

J@

TEMPERATURE
GAUGE

--. J

3rd
clutch

har

J@

PRESSURE
GAUGE

OPERATOR COMPARTMENT

OFF-HIGHWAY COMPONENTS

=14,504 PSI )

OIL SUMP

...

PUMP

Pressure
regulator
valve
16,5 - 20,7 bar

' 1+=11

<EJ>

( 1 bar

Safety valve
9,6 -13,8 bar
cracking pressure

28000 I 32000 transmission . hydraulic diagram


3 speed with total neutral

S1005

Safety valve
9,6 - 13,8 bar
cracking pressure

1+-'11

II

Torque
converter

28000 I 32000 transmission - hydraulic diagram


3 speed - with total neutral

PUIlIP

.....

~<.)-F-IL;I!~- -;

Pressure
regulator
valve
16,5 - 20,7 bar

OIL SUIlIP

TI!IlIPI!RATURI!
GAUGE

'C

1st

OPERATOR COMPARTMENT
PRI!SSURI!
GAUGE

bu

2nd
clutch

solenoid

. . . .J.J@
Hose

2nd
solenoid

~~
I

J@

Jrd
clutch

OFF-HIGHWAYCOMPONENTS

( 1 bar = 14,504 PSI)

<$>

S1005

I@
Hose

/:I

fnrward
clutch

L~

O
baT

TI!IlIPI!RATURK
CBI!CK-PORT

PRI!S5URI!
CHI!CK-PORT

'C

reverse
clutch

REVERSJ!
SOLI!ROID

LubricatJon

Forward and 3rd clutch engaged

t!
Cooler

~
1st

clutch

o
,....
,....

......
......
......

I
Torque
converter

2nd
clutch

J
~

:I
1

liar
liar

Hose

'C

.@

TI!MPI!RATURI!
GAUGI!

.... .J

3rd
clutch

bar

.@

PRI!SSURI!
GAUGE

OPERATOR COMPARTMENT

OFF-HIGHWAYCOMPONENTS

=14,504 PSI)

OIL SUMP

'V'

II

valve
Ill,! - 20,7 bar.

regulator

Pressure

' 1+-'1

( 1 bar

Safety valve
9,ll - 13,8 bar
cl'III:killg pressure

3 speed with total neutral

28000 I 32000 transmission hydraulic diagram

Cooler

~!

1st
clutch

liar

~@

fOlWlIrd
clutch

FORWARD
SOLI!.OID

Hose

I@
~

'C

liar

L ulIic:ation

Reverse and 1st clutch engaged

reverse
clutch

TI!IIPI!RATURI!
CBI!CK-PORT

PRI!SSURI!
CBI!CK-PORT

S1005

S1005

Safety valve
9,6 -1:3,8 bar

cracking pressure

Ihl

II

3rd
clutch

I=I

lIu

2nd
solenoid

converter

Torque

28000 / 32000 transmission hydraulic diagram


3 speed without total neutral

Pressure
regulator

PUMP

valve
16,5 - 20,7 bar

By-pass
valve
1.7 - 4.:3 bar

OIL SUMP

( 1 bar = 14,504 PSI)

I=I

:t!
Cooler

FORWARD
SOLDOID

I@

bu

I=I

J!
fOlWard
clutch

Hose

I=I

TIlIIPI!RATURIl
CIJBCK-PORT

~'=~RT
hT

'C

LUBRICATION

lIaT

reverse
clutch

,1@

RIlTIlRSl!
SOLBJrOm

I Neutral and 3rd clutch engaged

bu

THIIPHRATURH
GAUGH

OPERATOR COMPARTMENT
PRBSSURH
GAUGH

lIu

J@
'C

clutch

1st

,1@

.... .J.@
Hose

1st
solenoid

~
2nd
clutch

OFF-HIGHWAY COMPONENTS

C\l
.....
.....

.....
.....

(.,)

By-pass

16,5 - 20,7 bar

Pressure
re&U1ator
VCI1ve

1"""1

II

<$>

3rd
clutch

2nd
solenoid

Torque
co:nverter

1st
clutch

'C

2nd

1st
solenoid

Hose

.....J

.@

TEIIPf!RATURE
GAUGl!

clutch

'ar

.@

PRESSURE
GAUGE

OPERATOR COMPARTMENT

OFF-HIGHWAY COMPONENTS

=14,504 PSI)

OIL SUMP

,.............

AIR
&REATeR

1.7 - ".3 bar

valve

( 1 bar

crackq pressure

Safety valve
9,6 - 13,8 bar

28000 J 32000 transmission hydraulic diagram


3 speed without total neutral

Hose

.8
~

forward
clutch

I<: IVALVl!

r. 1II0DULATIO.

FORWARD
SOLE.OID

1. Fl
7 fl:::l

Cooler

::p!

clutch

reverse

RI!VERSI!
S OLBI OlD

Tl!IlIPERATURf!
CHECK-PORT

O
'C

PRESSURE
CHECK-PORT

0'ar

LUBRICATION

Forward and 1st clutch engaged

S1005

Safety valve
9,6 - 13,8 bar
cracking pressure

1'-'1

II

@
clutch

lrd

2nd
solenoid

Torque
converter

28000 I 32000 transmlssion- hydraulic diagram


3 speed- without total neutral

Pressure
regulator
valve

16,5 - 20,7 bar

By-pass
1,7 - ".3 bar

valve

OIL SUMP

=14,504 PSI)

'C

1st
dutch

.@

TBMPBRATURB
GAUGl!

OPERATOR COMPARTMENT
PRBSSU.RB
GAUGB

liar

.@
,
Hose

1st
solenoid

2nd
clutch

.~ OFF-HIGHWAY COMPONENTS

( 1 bar

S1005

Hose

'C

lIu

0
O

LUBRICATION

I Forward and 2nd clutch engaged


~.@
!
~
Cooler

dutch

reverse

REVERSl!
SOU.OID

r.lutm

fOlWard

PRESSURE
CHBCK-PORT

TBMPERATURE
CHECK-PORT

......"'"

01

......
......

=14,504 PSI)

"1

~:I

lIu

B
3rd
clutch

2nd
clutch

1st

solenoid

2nd

solenoid

Torque
comerter

Hose

1st
clutch

:=

liar

.u

TEMPBRATURE
GAUGE

>J

PRESSURB
GAUGB

OPERATOR COMPARTMENT

<E:;> OFF-HIGHWAYCOMPONENTS

(1 bar

OILSUIIP

By-pus
n1e
1.7 - 43 bar

valve
16,S - 20,7 bar

relPJlator

Pnnsure

9,6 -13,1 bar


craddna pressure

Safety valve

28000 / 32000 transmission hydraulic diagram


3 speed. without total neutral

Cooler

forward
clutch

~:I

L@

t!
Hose

.J

reverse
clutch

I]

RETERSE
SOLB.OlD

'C

lIu

O
O

LUBRICATION

Forward and 3rd clutch engaged

TEMPERATURE
CHECK-PORT

PRESSURE
CHECK-PORT

S1005

Safety valve
9,6 - 13,8 bar
cracking pressure

, I+--'I

FILTn

,II

-;-

'

I
Torque
converter

28000 J 32000 transmission hydraulic diagram


3 speed- without total neutral

Pressure
regulator
valve

,"

;.(..>-

16,5 - 20,7 bar

By-pass
valve

PUMP

~~
3rd

clutch

Hose

.@J

\:.
Hose

0hT

TI!IiIPI!RATORI!
COCK-PORT

PRI!SSU'RE
COCK-PORT

LUBRICATION

.-

CD

clutch

revel'Se

!:I

-e-

hT

J!

FORWARD

ltaT
!:I

SOLDOID

Cooler

I Reverse and 1st cl utch engaged

ltaT
!:I

clutch

forward

J! J!
1st
clutch

______ .@
_'C

TBIIPHRATORB
GAUGH

OPERATOR COMPARTMENT
PRBSSURB
GAUGH

ltaT

.@

1~
2nd

clutch

OFF-HIGHWAYCOMPONENTS

=14,504 PSI)

OIL SUMP

1.7 - 4.3 bar

( 1 bar

<$>

S1005

.....

......
......

..

total neutral
solenoid

Torque
converter

II

.-=.,

4th
clutch

liar

3rd
solenoid

lIa.

J@

PRI!SSURI!
GAUGI!

Hose

3rd
clutch

:I

liar

2nd
solenoid

1st
clutch

Hose

liar

-(,.~

TORWARD
SOLI!lIOID

liar

Lubrication

:I

:I

forward
clutch

:I

TI!MPI!RATURI!
CHI!CK-PORT

~) CHI!CK-PORT
liar

(X'" PRI!SSURI!

If J! J
lIa.

1st
solenoid

2nd
clutch

Cooler

Total neutral

J@

TI!MPI!RATURI!
GAUGI!

OPERATOR COMPARTMENT

OFF-HIGHWAY COMPONENTS

=14,504 PSI)

PUMP

...

----,

TILTI!R :

1-1.

II

II

:A--

OIL SUMP

<3>

( 1 bar

Pressure
regulator
valve
16,5 - 20,7 bar

hl

Safety valve
9,6 - 13,8 bar
cracking pressure

4 speed with total neutral

28000 I 32000 transmlsslon- hydraulic diagram

liar

clutch

reverse

:I

lr

RI!VI!RSI!
SOLI!. OlD

S1005

S1005

II

!t

crackiD& pressure

Safety VlI1vll
!1,6 - 13,1 bar

' 1+-'1

Pressure
replatDr
VlI1vll
16,5 - 20,7 bar

OIL SUMP

=14,504 PSI)

1
Hose

'C

:I

liar

1f
3rd
clutch

2nd
solenoid

I@

TEMPERATURE
GAUGE

OPERATOR COMPARTMENT
PRI!SSURJ!
GAUGH

liar

I@

::I
1

liar

3rd
solenoid

4th
clutch

OFF-HIGHWAY COMPONENTS

Torque
convener

28000 I 32000 transmission hydraulic diagram


4 speed with total neutral

( 1 bar

<$>

'C

IS
::a:
Hose

'C

liar

Ox
O

Luhrleatkm

FORWARD
SOLE. OlD

liar
:I

forward
clutch

J! J1
1st
clutch

liar
:I

Neutral and 4th clutch engaged

Cooler

1st
solenoid

~
2nd
clutch

PRESSURE
CBHCK-PORT

THIiIPERATURE
CBHCK-PORT

RJ!VERSE
SOLE. OlD

clutch

~:I

reverse

Xl
.....
.....

CO

--"

SUIt:nUIU

----r--' Torque
.!,
colMll1e1'

fth
dutch

-~

"p

aula_lulU

,@
"p

PRI!SSURB
GAUGI!

Hose

dutch

3rd

_'U""'".

'0

,@

TI!IIPI!RATURI!
GAUGI

OPERATOR COMPARTMENT

OFF-HIGHWAYCOMPONENTS

=14,504 PSI)

OIL S1JIIP

( 1 bar

.....

16,5 - 20.7 bar

'nI1ve

reauJator

Pressure

Cl'lKkh1I pressure

!I,lS - 13,8bar

Safety'nI1ve

28000 132000 transmission hydraulic diagram


4 speed with total neutral

dutch

2nd

_.__--

Cooler

1l1t
dutch

"p

}iJse

'C

Ox

tin

clutch

fulWlrd

::lItu..... u&U

Tl!llPI!RATURB
COCK-PORT

r)('I PRESSURI!
\.:J COCK-PORT

Lubricatlon

Forward and 1st clutch engaged

Jtn1lRSB

dutch

rev.....

~~

SOLDOID

S1005

S1005

,.....
Torque
converter

28000 132000 transmission hydraulic diagram


4 speed with total neutral

Safety wire
11,6 -13,8 bar
Cl'lll:kiD& pressure

reKUJator

Pressure
wire
Hi,! - 20,7 bar

=14.504 PSI)

OIL SUMP

By-pass
va1vI!
1,7 - 4,3 bar

( 1 bar

Hose

3rd
clutch

:I

bar

Jf

2nd
solenoid

TEMPERATURE
GAUGB

OPERATOR COMPARTMENT
PRBSSlJRE
GAUGB

!Jar

:~

har

.@

4th
clutch

OFF-HIGHWAY COMPONENTS

'C

1st

clutch

lWlse

.s

forward
clutch

(:I

!Jar

J1

Lmril:atlon

'C

!Jar

r;{I

I Forward and 2nd clutch engaged v

Cooler

1st
solenoid

(:I

bar

l@
r=-=J

2nd
clutch

PRESSURB
CHECK-PORT

TBMPERATURE
CHECK-PORT

RI!VERSH
SOLH.OID

1:~

clutch

reverse

C\l

I+--.I

II

converter

Torque

lIa.

4th
c1utcil

lIa.

J@

PRI!SSURI!
GAUGI!

Hose

3rd
clutch

Jffi

2nd
solenoid

TI!MPI!RATURI!
GAUGI!

OPERATOR COMPARTMENT

OFF-HIGHWAYCOMPONENTS

= 14,504 PSI)

OIL SUMP

Pressure
regulator
vah"
16,5 - 20, i bar

'

<$>

( 1 bar

Safety valve
9.6 -13.SbaJ:'
r rae king pl'essul'e

4 speed with total neutral

28000 f 32000 transmission- hydraulic diagram

1.
solenoid

2nd
clutch

n.

Cooler

"C

n.

'C

1n

c1utcil

forward
clutcil

D,

0'\ MODULATIOR
I<:IVALVI!

Lubril:atlon

FORWARD
SOLD OlD

L Fl

PRESSURI!
CBBCK-PORT

TI!JIIIPI!RATURI!
0) CBBCK-PORT

lou

J! J!
1.

IiJse

J@

Forward and 3rd clutch engaged

'a~T

reverse
clutch

JJ

RBVI!RSI!
SOLD om

S1005

S1005

.!.

C:OlM!rter

~ Torque

28000 132000 transmission hydraulic diagram


4 speed with total neutral

Safety valve
11,6 -13,8 bar
cracking pressure

Pressure
rqulator

....
PUMP

valve
16,5 - 20.7 bar

OIL SUMP

( 1 bar = 14,504 PSI)

Hose

~
dutch

3rd

2nd
solenoid

Tl!llPIlllATURI!
GAUGH

OPERATOR COMPARTMENT
PRI!SSURI!
GAUGH

lIat

\at

3rd
solenoid

J@

4th

dutch

OFF-HIGHWAY COMPONENTS

Hose

\at

1st

1Ia~

'C

:=r-~~RT

U"fl!RSI!
SOLD om

dutch

rev81'S8

Tl!llPBRATURB

\V CBBCK-PORT

($):~~no.

FORWARD
SOLaom

\al'

J:;@

clutch

forward

1~

16

Lubrkatlon

I Forward and 4th clutch engaged

Cooler

1st
solenoid

dutch

J=@
2nd

~
dutch

C\I
C\I

...

Pressure
regulator
valve
16,5 - 20.7 bar

'I+-'I

II

I
Torque
converter

4th
clutch

lIat

\at

J@
Hose

3rd
clutch

2nd
solenoid

-c

.@

Tl!llPI!RATURI!
GADGII

.... .J

PRI!SSURI!
GAUGII

OPERATOR COMPARTMENT

<$> OFF-HIGHWAY COMPONENTS

=14,504 PSI)

OIL SUMP

By-pass
valve
1,7 - 4,3 bar

( 1 bar

Safety valve
l',6 -13,8 bar
cracking pressure

4 speed with total neutral

28000 I 32000 transmission hydraulic diagram

1st

2nd
clutch

\at

solenoid

J!

Cooler

<t!

1st
clutch

J=@
lIat

Hose

\:.

,@

'C

forward
clutch

lf
liar

Lmrkatlon

FORWARD
SOLIIIOID

PIlESSURII

CBIlCK-PORT

(;1 TI!IIIPIlRA TURII

liar

r)(\

Reverse and 1st clutch engaged I...:J CBIICK-PORT

reverse
clutch

I
I

liar

I!
S1005

411I
clutch

t-:$.

solenoid

3rd

cOllVerter

Torque

28000 I 32000 transmission hydraulic diagram


4 speed without total neutral

=14,504 PSI)

OILSUIIP

vain!
lCi,5 - 20,7 bar

reauJator

Pressure

Safety valve
9,6 -13,8 bar
Cl'lIl:kq pressure

( 1 bar

Hose

br
~

FORWARD
SOLBROID

Hose

br

hr

forward
clutch

TBIIPBRATURB
CRBCK-PORT

CRECK-PORT

~ PRHSSURH

liar

reverse
dutch

RBVBRSB
SOLBROID

LUBRICATION

I Neutral and 4th clutch engaged

Cooler

1st
clutch

Jr 1 Jr
2nd
clutch

1st
solenoid

.@

TBllPBRATURI!:
GAUOl!

OPERATOR COMPARTMENT
PRRSSURR
OAUOR

liar

.@

2nd
solenoid

~
3rd
clutch

.~ OFF-HIGHWAY COMPONENTS

S1005

....

PUMP

...

;<:.)-r~L;J!~--;

4th
clutch

liar

Torque
converter

I:I
1

liar

3rd
clutch

Hose

1st

2nd
clutch

I:I

liar

solenoid

'C

J@

THMPJ!RATURH
GAUGH

" J

2nd
solenoid

liar

J@

PRJ!SSURJ!
GAUGJ!

OPERATOR COMPARTMENT

OFF-HIGHWAY COMPONENTS

=14,504 PSI)

<eSi>

( 1 bar

OIL SUMP

By-pass
valve
1.7 - 4.3 bar

Pressure
regulator
valve
16,5- 20,7 bar

Safety valve
9,6 -13,8 bar
cracking pressure

28000 I 32000 transmtsslon- hydraulic diagram


4 speed without total neutral

::I

clutch

1st

---=]

1@

Cooler

<t!

liar

i:I
I

L8
forwllrd
clutch

Hose

18
1(----

Forward and 18t clutch engaged

reverse
clutch

i:I

J!

SOLO om

liar

TDlPIlRATU'RII
CBIlCK-PORT

RIlVIlRSI!

x
O

1II.r

0(\ PRIISSURB
\..:.J CHECK-PORT

S1005

S1005

Safety valve
9,6 - 13,8 bar
cratking pressure

, 1+=11

,II

liar

@
4th
clutch

converter

Torque

28000 I 32000 transmlsslon- hydraulic diagram


4 speed without total neutral

;'(0) -F~L;~--;

Pressure
regulator
valve
16,5 - 20,7 bar

By-pass

...
PUMP

=14,504 PSI)

OIL SUMP

valve
1,7 - 4,3 bar

( 1 bar

J@

TI!MPI!RATURI!
GAUGI!

OPERATOR COMPARTMENT
PRI!SSURI!
GAUGI!

liar

J@

.... ~

1st
clutch

.s
\:~
Hose

forward
clutch

~s

liar

O
liar

TI!MPI!RATURI!
CHI!CK-PORT

PRI!SSURI!
CHI!CK-PORT

liar

reverse
clutch

1;8

RI!VI!RSI!
SOLI!IfOID

lUIRICATION

Forward and 2nd clutch engaged

t!
Cooler

1st
solenoid

liar

Hose

2nd
solenoid

liar

8
~

liar

2nd
clutch

Jf Jf 1
3rd
clutch

.~ OFF-HIGHWAY COMPONENTS
~

co

C\l

I\)
-..j

<$>

PUIIP

....

~~'~-~L;~--;

clutch

4th

liar

converter

Torque

3rd
clutch

2nd
solenoid

Hose

2nd
clutch

Cooler

q:
!

1st
clutch

liar

liar

'"

1lar

forward
clutch

~8

Hose

'-.m

'C

liar

O
TRMPERATORR
CHRCK-PORT

PRRSSORR
CHECK-PORT

reverse
clutch

RR'iERSE
SOLI!IOID

LUBRICATION

Forward and 3rd clutch engaged

J1 1

1st
solenoid

'C

,@

TEMPERATURE
GAUGE

.
""'"-,;

PRRSSORI!
GAUGE

OPERATOR COMPARTMENT

OFF-HIGHWAY COMPONENTS

( 1 bar = 14,504 PSI)

OIL SUMP

1.7 - 4.3bar

valve

By-pass

Pressure
regulator
valve
16,5 - 20,7bar.

9,6 - 13,8 bar


crackiJIi pressure

Safety valve

4 speed without total neutral

28000 I 32000 transmission hydraulic diagram

S1005

--

"
0.=.1

3rd
solenoid

liar
~

@
4th
clutch

TOI1lUB
amvel1er

II

28000 I 32000 transmission hydraulic diagram


4 speed without total neutral

Safety valve
96 -13,8bar

J-l.

=14,504 PSI)

OIL SUIIP

Pressure
regulator
valve
16,5 - 20,7 bar

~klDa pressure

( 1 bar

liar

PRBSSURII
OAUOH

Hose

11t

I@

liar

lIa,.

clutch

2nd
dutch

forward
clutch

'u

TllIIPI!RATURE
CHECK-PORT

t')('\ PR1!SSURl!
V CHECK-PORT

x
O

liar

reverse
dutch

RI!VERs]!
SOLEIIOID

LlJIRICATIIII

r. IIODULATIO.

I?IULVE

FOllWARD
S OLEII om

7a

..t fl

Hose

Forward and 4th clutch engaged

Cooler

1st

Jr 1@ JJ

solenoid

...,)-l

TBIIPIlRATURII
OAUOH

OPERATOR COMPARTMENT

solenoid

~
3rd
clutch

.~ OFF-HIGHWAY COMPONENTS

S1005

re

,....

4th
clutch

~
1

11&..

comlerter

Torque

Jrd
clutch

.@
1I&r

PRBSSURB
GAUGH

Hose

11&..

c...

:)

1st

clutch

2nd

clutch

11&..

'-c

forward
clutch

FORWARD
SOLDom

lIMe

.s
l

1II.r

7n

.l. Fl

Tl!MPl!RATURl!
CHl!CK-PORT

PRl!SSURl!
CHECK-PORT

reverse
clutch

I?-IVALVH

17\. MODULATIO.

Rl!Vl!RSl!
SOLE. 010

LUBRICATION

Reverse and 1st clutch engaged

J! J!

.@

TEMPBRATURB
GAUGH

OPERATORCOMPARTMENT

OFF-HIGHWAYCOMPONENTS

=14,504 PSI)

<$>

( 1 bar

OIL SUMP

16,5 - 20,7......

valve

regulator

Pressure

craekhll pressure

Safety valve
9,6 -13,8 bar

28000 / 32000 transmission hydraulic diagram


4 speed without total neutral

S1005

S1005

S1005

DRIVELINE INSTALLATION

ITEM PART #

12408
Page 1 of 1

DESCRIPTION

QTY.

SEE AXLE
PARTS PAGE
SEE TRANSMISSION
PARTS PAGE
SEE TRANSMISSION
PARTS PAGE
SEE AXLE
PARTS PAGE

END YOKE

OUTPUT FLANGE/ END YOKE BRAKE (REAR)

OUTPUT FLANGE/ END YOKE (FRONT)

END YOKE

364024

CROSS AND BEARING KIT

19201-29

DRIVELINE ASSEMBLY (INCLUDES ITEM 7)

362120

CENTER BEARING

464640

SLIP ASSEMBLY (INCLUDES 2X OF ITEM 5)

19200-14

DRIVELINE ASSEMBLY

10

364023

CROSS AND BEARING KIT

1
2
3
4

Updated:
10/30/08

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
6.

AXLE
10829
13320
13319
S1021
13321
S1023
13954
S1007

AXLE ORIENTATION
AXLE ASSEMBLY
AXLE CRADLE INSTALLATION
AXLE SERVICE & REPAIR MANUAL
BRAKE ACTUATOR
ACTUATOR INSTALLATION
TIRE & RIM
TIRE SERVICE

FORD AXLE ORIENTATION

10829
Page 1 of 1

Updated:
12/11/06

AXLE ASSEMBLY 464891

13320
Page 1 of 8

Updated:
10/30/08

AXLE ASSEMBLY 464891

13320
Page 2 of 8

Updated:
10/30/08

AXLE ASSEMBLY 464891


ITEM PART #

13320
Page 3 of 8

DESCRIPTION

QTY.

464891

AXLE ASSEMBLY

444285
444286
444262

INNER BRAKE HOUSING (RH)


INNER BRAKE HOUSING (LH)
NUT

1
1
2

444268

PIN

444829

DISC ASSEMBLY

444625

DISC ASSEMBLY (INTERMEDIATE)

444830

DISC ASSEMBLY (ACTUATING)

12

444831

OUTER BRAKE HOUSING

13

444235

GEAR, PLANETARY (SUN)

14
15

444858
444832
444156

HOUSING ASSEMBLY (RH)


HOUSING ASSEMBLY (LH)
GEAR, PLANETARY (OUTER)

1
1
1

16

444835

CUP, ROLLER BEARING (OUTER)

17

444836

STUD

18

444157

CUP, ROLLER BEARING (INNER)

19

444570

BOLT

20

444231

CARRIER (INCLUDES ITEMS 21-27)

21

444060

CONE BEARING INNER

22

444425

SHAFT PLANETARY GEAR

23

444151

KIT, NEEDLE BEARING

24

444150

WASHER, THRUST

25

444152

SPACER

26

444159

GEAR, PLANETARY

27

444158

RETAINER

28

444160

WASHER, RETAINER

Updated:
10/30/08

AXLE ASSEMBLY 464891


29

13320
Page 4 of 8

30

444205
444105
444118
444119
444120
444106
444122
444123
444145
444237
444097
444149

SPACER(1.245/1.321mm)
SPACER(1.346/1.422mm)
SPACER(1.448/1.524mm)
SPACER(1.549/1.626mm)
SPACER(1.651/1.727mm)
SPACER(1.753/1.829mm)
SPACER(1.854/1.930mm)
SPACER(1.956/2.032mm)
SPACER(2.057/2.134mm)
SPACER(2.159/2.235mm)
SPACER(2.262/2.337mm)
BOLT, LOCK

A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
1

35

444837

SEAL ASSEMBLY BOOT

36

444838

ROD, BRAKE CONTROL

39

01GF02016

PIN, COTTER

40

442130

PIN, CLEVIS

41

444191

BOLT

11

42

444839

SHAFT

43

442480

BOLT

14

44

444751

SEAL

45

444752

CONE, ROLLER BEARING (OUTER)

46

444841

SEAL

47

444424

BOLT

48

444217

BLOCK, THRUST

49

444842

WASHER, LOCK

50

444269

BOLT

51

444843

SLEEVE

Updated:
10/30/08

AXLE ASSEMBLY 464891

13320
Page 5 of 8

Updated:
10/30/08

AXLE ASSEMBLY 464891

13320
Page 6 of 8

ITEM PART #

DESCRIPTION

QTY.

444712

HOUSING ASSEMBLY DIFF. (INCLUDES ITEMS 2-6)

444844

PLUG DRAIN (MAG.)

444272

PLUG DRAIN (STD.)

223185

PLUG DIFF. HOUSING VENT

444845

PLUG CENTER HOUSING

444177

CUP DIFF. (RH)

444008

CONE & ROLLER ASSEMBLY (RH)

444176

CONE & ROLLER ASSEMBLY (LH)

444274

CASE ASSEMBLY

10

442210

BOLT

12

11

444110

NUT, LOCK, HEX

12

12

444250

BOLT

13

444275

GEAR SET (MATCHED)

14

444846

GEAR DIFF. SIDE

14B

444847

GEAR DIFF. SIDE (DIFF. LOCK)

15

444848

WASHER, THRUST (AXLE PINION DIFF. RH)

16

444173

BUSHING GEAR CASE (DIFF. RH)

17

444172

PINION DIFF.

18

444715

WASHER, THRUST (AXLE PINION DIFF. RH)

19

444849

SPIDER DIFF.

20

442220

BEARING ASSEMBLY, PINION PILOT

21

444850

RING DRIVE, PINION PILOT

22

444780

CONE BEARING

23

444147

RETAINER ASSEMBLY (INCLUDES ITEMS 24, 25)

24

444781

CUP DRIVE PINION (REAR)

25

442270

CUP DRIVE PINION (FRONT)

Updated:
10/30/08

AXLE ASSEMBLY 464891


26

13320
Page 7 of 8

27

444219
444220
444221
444222
444223
444239
444224
444225
444240
444226
444227
444228
444229
444230
442280

SPACER(1.3281/1.3286)
SPACER(1.3289/1.3294)
SPACER(1.3297/1.3302)
SPACER(1.3305/1.3310)
SPACER(1.3313/1.3318)
SPACER(1.3321/1.3326)
SPACER(1.3329/1.3340)
SPACER(1.3337/1.3342)
SPACER(1.3345/1.3350)
SPACER(1.3353/1.3358)
SPACER(1.3361/1.3366)
SPACER(1.3369/1.3374)
SPACER(1.3377/1.3382)
SPACER(1.3385/1.3390)
SEAL

A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
1

28

442340

CONE & ROLLER ASSEMBLY

29

442290

SEAL, PINION RETANER BEARING

30

444851

RETAINER ASSEMBLY

31

444852

SEAL ASSEMBLY

32

11827-01

FLANGE U-JOINT

33

442310

SEAL, PINION DRIVE

34

442320

WASHER, PINION FLANGE

35

444853

NUT, HEX

36

01GF03016

PIN, COTTER

37

444782

BOLT

38

444253

WASHER, LOCK

44

444854

ADAPTOR, DIFF.

45

444855

SPRING, DIFF.

46

444856

COUPLING DIFF. LOCK

47

444252

WASHER DIFF.

48

444092

RING, LOCK

49

444788

FORK DIFF.

50

444857

NUT JAM

51

444264

SCREW

Updated:
10/30/08

AXLE ASSEMBLY 464891

13320
Page 8 of 8

52

444790

WASHER, FLAT

53

444791

SHAFT, DIFF.

54

444792

SEAL ASSEMBLY

55

444793

SHIELD DIFF.

56

444794

RING

57

444260

PIN, SHACKLE

58

444165

LEVER, DIFF.

59

444164

CUP BEARING DIFF.

60

444125
444098
444126
444127
444108
444100
444109

SHIM DIFF. 0.038(1.016mm)


SHIM DIFF. 0.044(1.118mm)
SHIM DIFF. 0.050(1.270mm)
SHIM DIFF. 0.056(1.422mm)
SHIM DIFF. 0.068(1.727mm)
SHIM DIFF. 0.074(1.880mm)
SHIM DIFF. 0.080(2.032mm)

A/R
A/R
A/R
A/R
A/R
A/R
A/R

Updated:
10/30/08

CRADLE INSTALLATION

13319
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

15261-01

CRADLE ASSEMBLY

464693

BUSHING

19204-88

PIVOT PIN

04GE10

WASHER

17GD10136

BOLT

27GE10

FLAT WASHER

17GD10

LOCKNUT

10

01GC10024

BOLT

11

15262-03

AXLE PAD

Updated:
03/16/07

S1021

D65

REPAIR
MANUAL

5/00

S1021

CONTENTS
Description

Page

Rear Axle Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


A. Teardown Guideline and Removal of Axle Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Brake Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. Axle Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
D. Planetary Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
E. Axle Bearing and Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F. Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
G. Differential & Mechanical Differential Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
H. Differential Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
I. No-Spin Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
J. Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
K. Specifications, Tightening Torque, and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

S1021

REAR AXLE DESCRIPTION AND OPERATION

22

21

20

23

24

3
4
5

19

18

7
17

16

15

14

13

12 11 10

1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Rear Axle Center Housing


Yoke
Drive Pinion Bearing Retainer
Differential Lock Operating Shaft
Planet Gear
Sun Gear and Shaft
Ring Gear
Differential Bearing
Differential Ring Gear
Differential Assembly
Differential Bearing
Differential Lock Assembly

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

The rear axle contains the differential, brakes, final


reduction gears, axle shaft, and the differential lock
(Figure 1).

Brake Inner Housing


Brake Actuating Discs
Planet Gear Carrier
Rear Axle Shaft
Axle Shaft Outer Bearing
Sleeve
Rear Wheel Flange
Axle Shaft Oil Seal
Axle Shaft Housing
Axle Shaft Inner Bearing
Brake Discs
Brake Actuating Rod

S1021

TORQUE TRANSFER

differential action allows virtually all the drive to be


applied to this wheel and a little to the opposite rear
wheel, which may be on firm ground. The result is
that the unit is either brought to a complete halt or
slowed down considerably.

The spiral bevel pinion is held by preloaded opposed


tapered roller bearings. The differential ring gear is
bolted to the differential case, and the drive from the
case is transmitted through a conventional four
pinion differential to two side gears of the differential.

When the differential lock is engaged, improved


traction is possible because the lock enables traction
to be obtained from the wheel, which is on firm
ground, thus enabling the unit to pull through the soft
ground conditions.

In each axle housing assembly, a shaft terminates in


a spur gear, which is the sun gear of the planetary
reduction gear system. The planetary ring gear is
pressed into the rear axle housing. The three planet
gears are mounted in a carrier and positioned around
the sun gear and within the planetary ring gear.

Basically, the locking device consists of a dog-type


coupling, which is splined to, but free to slide on, the
differential side gear to the differential case. The
connection side is made through the differential lick
adaptor, which has dog teeth on both side faces. The
teeth on the inside engage with teeth on the outside,
with the differential lock coupling.

The planet gears are mounted to the carrier by shafts


and rotate on uncaged needle bearings. The carrier
has internal splines that engage splines on the inner
end of the axle shaft.
As the sun gear is driven by the differential, the planet
gears are forced to revolve inside the stationary
planetary ring gear and force the carrier to revolve at
a lower speed than the sun gear.

In operation, pressing of the foot pedal first moves


the coupling into contact with the adaptor and then
compresses the spring in the operating rod assembly
(Figure 2). As the teeth of the coupling come into
alignment with the teeth spaced in the fixed adaptor,
the spring tension will move the coupling into
engagement with the adaptor. The fact that the
spring supplies the final operating force prevents the
possibility of damage if excessive force is applied to
the foot pedal.

The rear shaft is held in opposed tapered roller


bearings, and the play is adjusted by means of
selective spacers held under the retaining bolt. The
shaft terminates in a flange to which the rear wheel
is bolted.
A common supply of oil is used for lubricating the rear
axle and differential assemblies. The differential ring
gear and differential assembly are partly immersed
in oil, which provides adequate lubrication for
bearing and bushings.

When full engagement has taken place (noticeable


by the reduced pedal pressure), the foot pedal
should be released. The coupling and adaptor teeth
side forces, resulting from the transfer of power from
one wheel to another, will keep the coupling and
adapter teeth in mesh. As the drive becomes more
equally distributed, the compressed operating spring
overcomes the reduced teeth side forces and
automatically disengages the differential lock.

DIFFERENTIAL LOCK OPERATION


When one rear wheel of a unit encounters a soft
patch of ground and spins, the normal-type

S1021

2
Differential Lock Assembly
1.
2.
3.
4.

Differential Lock Fork


Coupling
Adaptor
Differential Side Gear

5.
6.
7.

Differential Housing
Spring
Fork Retaining Bolt

S1021

18

3
Axle Housing Assembly--Exploded View
1.
2.
3.
4.
5.
6.
7.
8.
9.

Axle Shaft Outer Bearing


Axle Shaft
Spacer
Bearing
Planet Gear Carrier
Retaining Washer
Retaining Bolt
Lock Plate
Sun Gear and Shaft

10.
11.
12.
13.
14.
15.
16.
17.
18.

BRAKE OPERATION

Brake Actuating Rod


Brake Actuating Discs
Inner Brake Housing
Rotating Brake Discs
Fixed Brake Discs
Outer Brake Housing
Ring Gear
Axle Housing
Seal

Operation of the foot brake pedal causes the rear


brake actuating discs to rotate and the balls to rotate
up the ramped pockets. This rotation expands the
actuating discs, which force the rear brake disc
assemblies into contact with the intermediate disc,
the actuating discs, and the inner and outer
housings. Rotation of the stationary components of
the brake unit is prevented by a large-diameter
torque pin held in the outer brake housing.

The disc brakes consist of two sets of stationary and


revolving discs. The revolving discs are splined to the
shaft of the sun gear, located on either side of an
actuator assembly (Figure 3).
The actuator assembly consists of two thrust plates
with ramped pockets in which steel balls are
located. The actuating discs are held in contact with
the balls by four coil springs and connected by
suitable linkage with the appropriate foot brake
pedal.

S1021

A. TEARDOWN GUIDELINE AND REMOVAL


OF AXLE HOUSING ASSEMBLY
Operations or repairs the can be performed on
counterclockwise (CCW) D65 axle components with
the left and/or right housing assembly removed.
Component

Left Axle

Right Axle

Brake Overhaul

Planetary Overhaul

Axle Shaft Bearing/Seals

Differential Operating Fork

Pinion Assembly

Differential Gears &


Differential Lock Assembly

1. Drain oil from axle.


2. Place axle in a low stand, and place a jack under
the housing not being removed.
3. Remove brake cylinders, if installed.
4. Install half of the wheel bolts in wheel flange.
5. Remove the right housing assembly first so that
the differential gear set is supported by the left
sun gear when the right housing is removed.
Place a strap around the square section of the
housing next to the bell end (Figure 4).
6. Remove the housing attaching bolts, leaving the
top bolt until last. Use an overhead hoist to
remove the housing assembly, and then stand
the assembly vertically on the wheel disc.

4
Rear View of Housing Assembly Removal

7. Remove the left housing in a similar manner after


the differential assembly is removed.

S1021

B. BRAKE OVERHAUL
1. Right-Hand Axle Housings--Remove the two
bolts securing the differential ring gear thrust
block to the brake housing, and remove the thrust
block.
2. Remove the two nuts and six bolts that retain the
inner disc brake housing assembly in the axle
housing. Lift the brake housing out of the axle
housing.
3. Remove the brake actuator (Figure 5). Remove
the brake rod seal if damaged. To remove the
seal, place a sharp tool between the seal flange
and the rear axle housing, and pry the seal out.
Remove the brake disc assemblies intermediate
discs, and actuating disc assembly.

5
Removing and Installing Brake Actuating Mechanism

4. Lift the sun gear out of the planet gear carrier.

1.
2.
3.

5. Remove the outer brake housing from the axle


housing.
NOTE: Replace friction plates and separator plates
if they are overheated or worn more than 0.5 mm
(0.020 ) per friction plate. New thickness is 4.8 mm
(0.0190 ).
6. Reassemble the brake components in the
reverse order. Be sure the spring is in the groove
on the pullrod boot and the boot is in the groove
on the pullrod.

Actuating Discs
Actuating Link
Axle Housing

S1021

C. AXLE BEARING PRELOAD


1. If the planetary gears or the axle bearings or
seals are to be serviced, first check the axle shaft
rolling torque and end play to see if they are
correctly shimmed.
2. Install axle shaft torque tool (see Special Tools,
Section K) as shown in Figure 6. Rolling torque
should be as follows:

50 -- 150 in. lb.

3. Check axle shaft end play. If any end play is


detected, use a dial indicator as shown in Figure
7 to determine the amount.
4. If torque is too high, use the next thicker spacer
after the planetary or axle system repair.

6
Axle Shaft Rolling Torque Measurement

5. If 0.003 or more end play is detected, install a


spacer one size smaller for every 0.004 or
portion of 0.004 measured (e.g., if 0.018 end
play is measure, change to a spacer five sizes
smaller).
6. If this check is not possible before the repair,
install a 0.081 thick spacer. Position the
selected spacer and shaft retaining washer, and
tighten the axle shaft bolt to 407 Nm (300 ft. lb.)
torque. Then, proceed with steps 2 through 5
until bearing preload is okay.
7. To position, the bolt lock may require that the bolt
be tightened more, up to 350 ft. lb. so that the lock
notches will fit the bolt head corners.

7
Axle Shaft End Play Measurement

It may be necessary to turn the bolt lock over.


Apply adhesive or grease to the bottom of the bolt
lock to hold it in position while the side housing
is attached to the center housing.

S1021

D. PLANETARY GEAR ASSEMBLY


1. Remove the axle shaft bolt lock, axle shaft
retaining bolt, axle shaft retaining washer, and
selective spacer
2. Lift the carrier assembly out of the axle housing.
3. If the planetary carrier assembly must be
serviced, bend up one end of the planet gear
shaft retaining ring, and withdraw the ring. Pull
the planet gear shafts from the carrier, and
remove the planet gears, complete with needle
bearings and thrust washers (Figures 8 and 9).
Rebuild the carrier using new components as
required. Pack the needle bearings in the planet
gears with grease, and be sure to bend the ends
of the retainer ring downward.

8
Planet Gear Carrier Assembly
1.
2.
3.

Planet Gear Shaft


Planet Gear
Planet Gear Shaft Retainer

4. If the bearing on the planet gear carrier requires


replacing, removing it by using pulling attachment tool FNH0926 and puller tool FNH09516.
Install a step plate adapter into the end of the
carrier. Install a new cone and roller assembly.
5. If necessary, remove the inner bearing cup from
the housing by using puller FNH09507 and
FNH09567. Install a new cup.

9
Planet Gear Carrier Assembly
1.
2.
3.
4.
5.
6.
7.
8.

Retaining Ring
Thrust Washer
Planet Gear
Rollers
Thrust Washers
Cone and Roller Assembly
Carrier
Planet Gear Shaft

S1021

6. Inspect the planetary ring gear located in the axle


housing. If damaged or worn. replace as follows:
---

--

Remove the axle shaft from the axle.


Position Tool No. FNH021223 behind the
ring gear and tighten the retaining nuts
(Figure 10).
Place the axle housing on a press beam with
the large end down. Insert a bar of suitable
length into the small end of the housing
against Tool No. FNH02123. Position the
other end of the bar under the press ram, and
press out the ring gear.
10
Removing Planetary Ring Gear
1.
2.

Clean the new ring gear and the housing


shoulder, and position the ring gear in the
axle housing, ensuring that the studs in the
housing are aligned with the holes in the ring
gear.
-- Place the axle housing on a press beam with
the large end up. Position Tool No.
FNH02123 on the ring gear (Figure 11), and
press the ring gear into the housing. Be sure
the ring gear is pressed squarely into the
housing.
-- To check that the ring gear is seated correctly, use a feeler gauge to ascertain if there is
a gap between the ring gear and housing
shoulder.
NOTE: If a new planetary ring gear has been
installed in the right-hand axle housing, the
differential bearing preload must be checked as
described in the Differential Bearing Preload section.

Tool No. FNH02123


Ring Gear

--

11
Installing Planetary Ring Gear
1.
2.

10

Tool No. FNH02123


Ring Gear

S1021

E. AXLE BEARING AND SEAL REPLACEMENT


1. Starting with the axle in vertical position and the
planetary carrier removed, attach a chain at two
of the bolt holes on the flange of the trumpet
housing.
2. Lift the housing assembly upward approximately
1, and then place a block of wood on top of the
axle shaft and drive the shaft out of the housing.
3. When removing the axle shaft outer cone and
roller assembly and shaft seal, use tools listed
below Figure 12.

12
Axle Shaft Cone and Roller Assembly Removal
1.
2.
3.
4.
5.
6.
7.

Ratchet, Tool No. OTC7366


Legs, Tool No. FNH09521
Pulling Attachment, Tool No. FNH09526
Axle Shaft
Cone and Roller Assembly
Puller, Tool No. FNH09506
Shaft Protector, Tool No. FNH09212

4. Use slide hammer, Tool No. FNH09567, and


puller Tool No. FNH09507, to remove the bearing
cup from the outer end of the axle housing
(Figure 13). To replace the cup, use a suitable
stepped plate and a mallet; install cup until fully
seated in housing.

13
Removing Outer Bearing Cup from Axle Housing
1.
2.
3.

11

Tool No. FNH09567


Tool No. FNH09507
Bearing Cup

S1021

5. Install a new cassette seal by using a metal


sleeve to press on the OD of the seal (Figure 14)

6. Install a new bearing by using a suitable sized


sleeve, which can be used as a slide hammer.
7. Using a chain attached to the housing flange,
lower the axle housing over the shaft assembly,
taking care to maintain alignment. Do not change
direction after the seal starts to enter the bore in
the end of the housing or the seal will be
damaged.
8. Measure the removed spacer thickness, and
then use the results obtained in Section C, Axle
Bearing Preload to determine the required
spacer thickness. See Specifications in Section
K for the available spacers.

14
Axle Shaft with Seal and Bearing Installed
1.
2.

9. Assemble the axle shaft retaining bolt and check


rolling torque and axle shaft end play as
described in Section C, Axle Bearing Preload.

12

Cassette Seal
Bearing Assembly

S1021

F. PINION ASSEMBLY
15
16

20004159

15
Pinion Shaft Layout
1.
2.
3.
4.
5.
6.
7.
8.

Retainer Assembly
Seal
Retainer
Castellated Nut
Cotter Pin
Washer
Seal
Yoke

9.
10.
11.
12.
13.
14.
15.
16.

13

Bearing
Spacer
Bearing
Pinion Shaft
Bearing
Lock Ring
Seal
Seal Assembly

S1021

Prior to disassembling the drive pinion assembly,


remove the differential from the rear axle center
housing.

3
4

DISASSEMBLY
1. Remove the six bolts and lockwashers securing
the drive pinion assembly to the rear axle center
housing, and using two 9/16 National Course
(NC) bolts as jacking screws, remove the drive
pinion assembly.
2. Place the drive pinion assembly in a vise.
Remove the cotter pin and the nut by using the
yoke holding tool (See Special Tools in Section
K) as shown in Figure 16.

16
1.
2.
3.
4.

3. Slide off the yoke, and remove the oil seal


assembly and O-ring.
4. Remove the drive pinion assembly, the bearing
spacer, and the front cone and roller assembly
from the bearing retainer assembly.

Yoke Holding Tool


Retainer
Pinion
Wrench

INSPECTION AND REPAIR


1. Thoroughly clean and inspect all parts, and if
worn or damaged, install new parts.
2. If it is necessary to install a new rear pinion cone
and roller assembly, the assembly may be
removed as shown in Figure 17. The new cone
and roller are installed by using the tools and a
suitable sleeve shown in Figure 18 to enable the
tool to press on the inner bearing race.
3. It it is necessary to install new retainer bearing
cups, the cups may be removed from the housing
by using Tool No. FNH09507 and FNH09567 or
equivalent.

17
Removing Drive Pinion Rear Bearing

4. If it is necessary to replace the pilot bearing,


remove the lock ring from the rear end of the
pinion gear, and pull the pilot bearing off the
pinion gear and replace it by using appropriate
tools.

1.
2.
3.
4.

NOTE: If a new drive pinion is to be installed, a new


differential ring gear must also be fitted. This
installation should be carried out as outlined in
Section G, Differential and Mechanical Differential
Lock Assembly.

14

Tool No. FNH09516


Drive Pinion Shaft
Bearing Assembly
Tool No. FNH09190

S1021

ASSEMBLY
1. Install the pilot bearing on the pinion by using a
suitable hollow sleeve, and fit a new lock ring.
2. Position the pinion shaft assembly in the retainer
assembly.
3. Install the pinion bearing spacer and the front
cone and roller assembly.
4. Place the oil seal O-ring in the groove, and
position the oil seal assembly on the retainer
assembly.
5. Lubricate the outside of splined end of the flange,
and slide the splined end carefully on the pinion
shaft splines and through the oil seal assembly
until the splined end is stopped by the inner race
of the front bearing cone and roller.
6. Install the shaft seal, the washer, and the
retaining nut. TIghten the nut to 200--600 ft. lb.
(271--813 Nm). At the same time, align the
notches in the nut with the cotter pin hole in the
pinion shaft.

18
Installing Drive Pinion Rear Bearing
1.
2.
3.
4.
5.

Tool No. FNH09516


Drive Pinion Shaft
Sleeve
Rear Bearing Assembly
Tool No. FNH09516

7. Check the bearing preload with an in-lb torque


wrench as shown in Figure 19. Preload should be
10--40 in. lb. (1.1--4.5 Nm). If the rolling torque
check is done in the center housing, leave the
bolts loose.
8. Insert the cotter pin, and bend each half of the pin
over. If the yoke prevents insertion of the cotter
pin in the hold, which aligns with the notches,
remove the yoke and reposition it on the spline.
NOTE: When it is necessary to replace the bearing
retainer, it may be necessary to replace the bearing
spacer to obtain correct preload. In that case, repeat
steps 3 through 7 until the correct preload is
obtained.

19
Measuring Pinion Bearing Rolling Torque
1.
2.

15

Torque Wrench
1-3/4 Socket

S1021

G. DIFFERENTIAL & MECHANICAL DIFFERENTIAL LOCK ASSEMBLY

20
Differential Assembly
1.
2.
3.
4.
5.
6.
7.
8.

Cone and Roller Assembly


Ring Gear and Housing Assembly
Side Gear
Pinion Gear Assembly
Side Gear
Housing
Cone and Roller Assembly
Coupling

9.
10.
11.
12.
13.
14.
15.
16.

Retaining Ring
Washer
Spring
Adaptor
Retaining Bolt
Thrust Washer
Pinion Gear and Washer
Thrust Washer

With the right axle shaft housing removed, withdraw


the differential assembly from the center housing.

1. Remove the differential lock ring from the end of


the side gear. WIthdraw the stop washer,
coupling, spring, and adaptor.

DISASSEMBLY

2. Mark the two halves of the differential case to


facilitate correct installation on reassembly.

With reference to Figure 20.

16

S1021

3. Remove the differential cone and roller assembly


from the small half of the case using tools shown
in Figure 21.
4. Extract the differential case retaining bolts.
5. Separate the differential case.
6. Withdraw the thrust washer and side gear, the
spider and pinion assembly, and the second side
gear and washer from the case.
7. Remove the cone and roller assembly in the ring
gear half of the housing by using puller, Tool No.
FNH09516; pulling attachment, Tool No.
FNH09526; and step place adaptor, Tool No.
FNH09210.

21
Removing Differential Bearing

8. Separate the pinion gears from the spider.

INSPECTION AND REPAIR


1. Clean and inspect all components for damage or
excessive wear. Install new components where
necessary.
2. If a new differential ring gear is required, drill out
the rivets installed during production, and
replace them with nuts and bolts available from
the Parts department. The bolts should be
tightened to a torque value of 115 Nm (85 ft. lb.).
NOTE: If the ring gear is replaced, a new matching
drive pinion must also be installed. Refer to Section
F. Pinion Assembly.

REASSEMBLY
Reassembly of the differential and differential lock
follows the disassembly procedure in reverse. On
reassembly, observe the following requirements:

Coat all bearing with a suitable wheel bearing


grease prior to installation.
Tighten the differential case retaining bolts to a
torque of 92--125 Nm (68--92 ft. lb.).

17

1.
2.
3.
4.

Tool No. FNH09516


Tool No. FNH09526
Bearing Assembly
Tool No. FNH09210

S1021

H. DIFFERENTIAL BEARING PRELOAD


Adjust the bearing preload by installing thinner or
thicker shim between the differential cup and the
inner brake housing. Proceed, as follows, to
measure and adjust the differential bearing preload:
1. Install the differential assembly on the inner end
of the left sun gear shaft in the center housing. Do
not install the pinion assembly.
2. Install the right axle housing assembly without
sun gear with four bolts.

3. Remove the left axle housing assembly.


4. Push the differential coupling inward to engage
it, and place 1/4 square stock under the washer
at two locations.
5. Install a sun gear into the differential assembly.
6. Wrap a length of string or electrical wire on
evenly, without overlapping around the sun gear
shaft, and using a pull scale, measure the force
required to rotate the shaft and differential
assembly. Read the scale during rotation of the
shaft. Do not read the scale at the point where
rotation starts. The pull should be 7--34 kg
(15--75 lbs.). See Figure 22.

2
1

7. If necessary, remove the shim from the inner


brake housing in the right axle housing assembly
and install a thicker shim to increase the rolling
torque or a thinner shim to reduce the rolling
torque.

22
Differential Bearing Preload Check

8. See Section K, Specifications, for available


shims.

1.
2.
3.

9. After the rolling torque check, reinstall the left


axle housing assembly, and remove the right
axle housing assembly.

18

Differential Lock Engaged with Spacers


Sun Gear Installed
Pull Scale

S1021

I. NO-SPIN DIFFERENTIAL ASSEMBLY


1. Install a retaining bolt, washers, and wing nut to
restrain the springs in the no-spin differential
during disassembly (Figure 23).
2. Remove the eight bolts holding the two halves of
the differential case together.
3. Compress the springs on the no-spin assembly,
and remove the wing nut and bolt.
4. Inspect the parts for wear, especially the teeth on
the left-hand and right-hand clutch assemblies
and the spider/cam assembly (Figure 24).

CAUTION
Failure to use a retaining bolt or some other
restraining means when separating the differential case halves can cause injury because
no-spin differentials have compressed springs.

23

24
No-spin differential spider assembly, clutch assembly, springs, retainers, and side gears.

5. Replace any badly worn parts


6. ALign the gaps in the holdout rings on the left and
right coupling assemblies with the keys on the
sides of the spider assembly.
7. Assemble the springs, retainers, and side gears
to the no-spins center section. Compress the
springs, and assemble the bolt, washers, and
wing nut through the center of the no-spin
assembly.
8. Place the differential case assembly, and install
the eight retaining bolts.
9. Remove the center bolt washers and wing nut.

19

S1021

J. BRAKE ADJUSTMENT
SPRING APPLY CYLINDER (FAIL SAFE
BRAKE)
1. Assemble cylinder over pullrod.
2. Install bracket and U-bolt assembly with bolts
and tighten.
3. Apply 300 psi hydraulic pressure to pressure port
to compress the spring.
4. Install the conical nut, and tighten to approximately 1.7 Nm (15 in-lb) so that the brake has
locked.
5. Back nut off eight flats.
25

If the brakes must be adjusted without turning the


axle shafts, tighten the conical nut to 5.6 Nm (50
in-lb) and then back off the nut 2 turns (twelve
flats).

Spring Apply--Mico

6. Release hydraulic pressure.


7. Install prevailing torque nut, and tighten until it
contacts the conical nut.
8. Apply pressure to port again, and confirm that
axle shaft rotates freely. Install spring and nut
with square head in end of cylinder.
NOTE: Brake cylinders should be filled with mineral
brake fluid (e.g., NH ESN-M6C59-A).

20

S1021

K. SPECIFICATIONS, TIGHTENING TORQUE, AND SPECIAL TOOLS


AXLE SHAFT PRELOAD
Axle shaft rolling torque using a torque wrench:

50 -- 150 in-lb.

AXLE SHAFT PRELOAD


North American Part Number

European Part Number

Thickness

C5NN-4374-AB

81803491

0.049 (1.24 mm)

C5NN-4374-L

81803502

0.053 (1.35 mm)

C5NN-4374-M

81803503

0.057 (1.45 mm)

C5NN-4374-N

81803504

0.061 (1.55 mm)

C5NN-4374-R

81803505

0.065 (1.65 mm)

C5NN-4374-S

81803506

0.069 (1.75 mm)

C5NN-4374-T

81803507

0.073 (1.85 mm)

C5NN-4374-U

81803508

0.077 (1.96 mm)

C5NN-4374-V

81803509

0.081 (2.06 mm)

C5NN-4374-Y

81803510

0.085 (2.16 mm)

C5NN-4374-Z

81803511

0.089 (2.26 mm)

DIFFERENTIAL BEARING PRELOAD

Differential bearing rolling torque using a spring pull gauge: 7--34kgf (15--75 lb).

DIFFERENTIAL BEARING SHIM TABLE


North American Part Number

European Part Number

Thickness

C5NN-4548-A

81803515

0.038--0.040 (0.965--1.018 mm)

C5NN-4548-B

81803516

0.044--0.046 (1.118--1.168 mm)

C5NN-4548-C

81803517

0.050--0.052 (1.270--1.321 mm)

C5NN-4548-D

81803518

0.056--0.058 (1.422--1.473 mm)

C5NN-4548-E

81803519

0.062--0.064 (1.575--1.626 mm)

C5NN-4548-F

81803520

0.068--0.070 (1.727--1.778 mm)

C5NN-4548-G

81803521

0.074--0.076 (1.880--1.930 mm)

C5NN-4548-H

81803522

0.080--0.082 (2.032--2.083 mm)

21

S1021

DRIVE PINION PRELOAD


Drive pinion torque using in-lb torque wrench: 1.1--4.6 Nm (10--40 in-lb).

DRIVE PINION SPACER TABLE


North American Part Number

European Part Number

Thickness

D8NN-4662-FA

R, R, R

83914106

1.3281--1.3286 (33.734--33.746 mm)

D8NN-4662-GA

R, R, B

83914107

1.3289--1.3294 (33.754--33.767 mm)

D8NN-4662-HA

R, R, Y

83914108

1.3297--1.3302 (33.774--33.787 mm)

D8NN-4662-JA

R, R, W

83914109

1.3305--1.3310 (33.795--33.807 mm)

D8NN-4662-KA

B, B, B

83914110

1.3313--1.3318 (33.815--33.828 mm)

D8NN-4662-LA

B, B, Y

83914111

1.3321--1.3326 (33.835--33.848 mm)

D8NN-4662-MA

B, B, W

83914112

1.3329--1.3334 (33.856--33.868 mm)

D8NN-4662-NA

Y, Y, R

83914113

1.3337--1.3342 (33.876--33.889 mm)

D8NN-4662-PA

Y, Y, B

83914114

1.3345--1.3350 (33.896--33.909 mm)

D8NN-4662-SA

Y, Y, Y

83914115

1.3353--1.3358 (33.917--33.929 mm)

D8NN-4662-TA

W, W, R

83914116

1.3361--1.3366 (33.937--33.950 mm)

D8NN-4662-UA

W, W, B

83914117

1.3369--1.3374 (33.957--33.970 mm)

D8NN-4662-VA

W, W, Y

83914119

1.3377--1.3382 (33.978--33.990 mm)

D8NN-4662-XA

W, W, W

83914120

1.3385--1.3390 (33.998--33.011 mm)

Color Code: R--Red, B--Blue, Y--Yellow, W--White

TIGHTENING TORQUE
Components

ft-lb

Nm

Axle shaft housing retaining bolts

140--170

190--230

Axle shaft retaining bolt

300--350

407--475

Differential ring gear retaining nuts

85

115

Differential case retaining bolts

68--92

92--125

Differential lock fork pivot shaft retaining bolt

24--30

32--41

Inner brake housing retaining bolts

80--95

108--129

Inner brake housing retaining nuts

80--95

108--129

Drive pinion bearing retaining bolts

100--125

135--170

Drive pinion nut

200--600

271--813

Ring gear thrust block

27--37

37--50

22

S1021

SPECIAL TOOLS
Description

Tool No.

Ref. Section

Axle shaft torque tool

Pusher-puller bearing cup pulling attachment

FNH09507

E, D

Puller bearing tool (slide hammer)

FNH09567

E, D

Pusher-puller bearing pulling attachment (large)

FNH09526

E, D, G

17-1/2 ton capacity pusher-puller tool

FNH09506

Pusher-puller legs attachment

FNH09521

Pusher-puller ratchet attachment

OTC7366

Pusher-pull shaft protectors (set of 6)

FNH09212

Yoke holding tool

Puller Tool

FNH09516

F, G, D

Pusher-puller bearing pulling attachment (small)

FNH09190

Pusher-puller tool to remove--install ring gear

FNH02123

Step plates (set of 11)

FNH09210

*See specifications for making tools on page 24.

23

S1021

26
Axle Shaft Torque Tool

Make a yoke holding tool (1410 flange) according to


the following dimensions:
1. 1.65 (42 mm)
2. 2.559 (65 mm)
3. 0.394 (10 mm)
4. 1.575 (40 mm)
5. 8.66 (220 mm)
6. 5.51 (140 mm)
7. 3.74 (95 mm)
8. 0.394 (10 mm)

27

9. 4.33 (110 mm)

Yoke Holding Tool

24

BRAKE ACTUATOR

ITEM PART #

13321
Page 1 of 2

DESCRIPTION

QTY.

595248

ACTUATOR ASSEMBLY

534372

REPAIR KIT (INCLUDES ITEMS 2, 6, 7, 9, 10, 15-19, 22)

NSS

O-RING PLUG

NSS

O-RING

534377

BLEEDER PLUG

534387

BLEEDER SCREW

NSS

HOUSING

NSS

BACK-UP RING

NSS

O-RING

*ITEMS NOT SHOWN

Updated:
12/11/06

BRAKE ACTUATOR

13321
Page 2 of 2

534374

PISTON

NSS

O-RING

10

NSS

BACK-UP RING

11

534646

SPRING

12

534373

PISTON

13

534380

STOP

14

534379

RETAINER

15

NSS

BACK-UP RING

16

NSS

BACK-UP RING

17

NSS

CUP

18

NSS

O-RING

19

NSS

O-RING

20

534383

SPRING

21

534376

END PLUG

22

NSS

GASKET

23

534375

END PLUG

24*

253172

BLEEDER SCREW

25

444807

LOCKNUT

*ITEMS NOT SHOWN

Updated:
12/11/06

S1023

S1023

TIRE & RIM

13322
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

15996

RIM ASSEMBLY (INCLUDES ITEMS 2, 3)

284002

LOCK RING

284003

SIDE RING

484085

TIRE

5*

442480

BOLT

14

6*

56405

URETHANE FILL (OPTIONAL)

*ITEMS NOT SHOWN

Updated:
01/22/07

S1007

S1007

S1007

S1007

S1007

S1007

S1007

S1007

S1007

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
7.

BRAKE SYSTEM
31547
13378
S1008
16483
S1009
12976

HYDRAULIC SCHEMATIC
BRAKE VALVE
BRAKE VALVE SERVICE
DUAL CHARGE VALVE
DUAL CHARGE VALVE SERVICE
ACCUMULATOR

PEDAL BRAKE VALVE

13378
Page 1 of 4

Updated:
12/11/06

PEDAL BRAKE VALVE

13378
Page 2 of 4

Updated:
12/11/06

PEDAL BRAKE VALVE


ITEM PART #

13378
Page 3 of 4

DESCRIPTION

QTY.

464952

BRAKE VALVE ASSEMBLY

534288

595149

PEDAL & BASE ASSEMBLY


(INCLUDES ITEMS 2, 23, 24, 28-32, 35, 36)
VALVE ASSEMBLY (INCLUDES ITEMS 1, 3-22, 33, 34)

595145

REPAIR KIT (INCLUDES ITEMS 2, 3, 8, 12, 18, 21)

NSS

PISTON

NSS

BOOT

NSS

QUAD RING

NSS

RETAINER

NSS

BALL

NSS

SPOOL

NSS

HOUSING

NSS

O-RING

NSS

SPRING

10

NSS

END PLUG

11

NSS

SPRING

12

NSS

CUP

13

NSS

SPRING

14

NSS

SPRING

15

NSS

SHIM

16

NSS

RETAINER RING

17

NSS

SPACER

18

NSS

O-RING

19

NSS

SPOOL

20

NSS

HOUSING

21

NSS

O-RING

22

NSS

RETAINER

23

NSS

PEDAL

24

NSS

CAM

25

15248-02

PIN

Updated:
12/11/06

PEDAL BRAKE VALVE


26

13378
Page 4 of 4

27

67GD06
01GF01016
15248-01

NUT
COTTER PIN
PIN

2
2
1

28

NSS

CAP SCREW

29

NSS

WASHER

30

NSS

BASE

31

NSS

LABEL

32

NSS

DRIVE SCREW

33

NSS

WASHER

34

NSS

CAP SCREW

35

NSS

CAP SCREW

36

NSS

NUT

Updated:
12/11/06

S1008

S1008

S1008

S1008

CHARGING VALVE

16483
Page 1 of 4

Updated:
12/11/06

CHARGING VALVE

16483
Page 2 of 4

Updated:
12/11/06

CHARGING VALVE
ITEM PART #

16483
Page 3 of 4

DESCRIPTION

QTY.

594922

VALVE ASSEMBLY

534293

NSS

REPAIR KIT
(INCLUDES ITEMS 3, 6, 10, 12, 14, 17, 19, 26, 28, 32-34, 36)
HOUSING

NSS

SPOOL

NSS

SEAL

NSS

SPRING

NSS

ROD

NSS

O-RING

NSS

PLUG

NSS

SCREW

NSS

WASHER

10

NSS

O-RING

11

NSS

SPRING

12

NSS

POPPET

13

NSS

SEAT

14

NSS

O-RING

15

NSS

WASHER

16

NSS

WASHER

17

NSS

FILTER

18

NSS

RETAINER

19

NSS

PLUG

20

NSS

SCREW

21

NSS

NUT

22

NSS

PLUG

23

NSS

SPRING

24

NSS

STOP

25

NSS

BALL

26

NSS

O-RING

27

NSS

SPOOL

28

NSS

O-RING

Updated:
12/11/06

CHARGING VALVE

16483
Page 4 of 4

29

NSS

INSEAT

30

NSS

SPRING

31

NSS

END PLUG

32

NSS

O-RING

33

NSS

POPPET

34

NSS

O-RING

35

NSS

SLEEVE

36

NSS

O-RING

Updated:
12/11/06

S1009

S1009

S1009

S1009

ACCUMULATOR

12976
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

534607

ACCUMULATOR ASSEMBLY

2*

534608

MOUNTING BRACKET

*ITEMS NOT SHOWN

Updated:
12/11/06

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
8.

HYDRAULIC SYSTEM
31547
S1077
17132
13259
12860
S1024
S1010
13943

HYDRAULIC SCHEMATIC
HYDRAULIC SYMBOLS
SERVICEJUNIOR DIGITAL PRESSURE GAUGE
FILTER (HYDRAULIC)
STEERING ORBITROL
STEERING ORBITROL SERVICE
PUMP SERVICE
STEERING CYLINDER

HYDRAULIC SYMBOLS
S1077

Lines

Hydraulic Pumps
Line, Working (Main)

Miscellaneous Units

Fixed Displacement

Cooler

Variable Displacement

Temperature Controller

Line, Pilot or Drain


Flow Direction
Hydraulic
Pneumatic

Filter, Strainer

Motors and Cylinders


Lines Crossing

Pressure Switch

Hydraulic
Fixed Displacement

Pressure Indicator

Variable Displacement

Temperature Indicator

Cylinder, Single-Acting

Component Enclosure

Lines Joining

Lines With Fixed


Restriction

Line, Flexible
Direction of Shaft
Rotation (assume arrow
on near side of shaft)

Cylinder, Double-Acting
Station, Testing,
Measurement or Power
Take-Off
Variable Component (run
arrow through symbol
at 45)

Pressure Compensated
Units (Arrow parallel to
short side of symbol)

Temperature Cause or
Effect

Single End Rod

Adjustable Cushion
Advance Only

Spring

Differential Piston

Manual

Push Button

Miscellaneous Units

Reservoir

Vented

Methods of Operation

Double End Rod

Push-Pull Lever
Electric Motor
Pedal or Treadle

Pressurized

Accumulator,
Spring Loaded
Mechanical

Line, To Reservoir

Accumulator,
Gas Charged
Detent

Above Fluid Level


Below Fluid Level

Heater
Pressure Compensated

Vented Manifold

Industrial Supplies and Expertise

CH12_1069-1114.indd 1093

1093

4/9/07 2:34:47 PM

HYDRAULIC SYMBOLS

Methods of Operation
Solenoid, Single Winding

Servo Control

S1077

Color Code for Fluid


Power Schematic Drawings

Valves
Check

On-Off (manual shut-off)

Pilot Pressure
Pressure Relief

Black

Intensied Pressure

Red

Supply

Intermittent Red

Charging Pressure

Intermittent Red

Reduced Pressure

Intermittent Red

Pilot Pressure

Yellow

Metered Flow

Blue

Exhaust

Green

Intake

Green

Drain

Blank

Inactive

Remote Supply
Pressure Reducing
Internal Supply
Flow Control, Adjustable
- Non-Compensated
Flow Control, Adjustable
(Temperature and
pressure compensated)
Two-Position
Two Connection
Two-Position
Three Connection
Two-Position
Four Connection
Three-Position
Four Connection
Two-Position
In Transition
Valves Capable of Innite
Positioning (Horizontal
bars indicate innite
positioning ability)

1094

CH12_1069-1114.indd 1094

Call your local Applied service center to order at 1-866-351-3464 or visit us online at Applied.com

4/9/07 2:34:48 PM

17132

Getman Corporation
ServiceJunior
Getman P/N 468005

The NEWServiceJunior
Digital Pressure Gauge

50 Times Faster than Previous Model


10 msec Scanning Rate
Measure PSI, bar, mPa, and
kPa with One Gauge
+1- 0.5% Full Scale Accuracy
Simple Operation
Peak and Hold Function with
Bar Graph Display

17132

Getmans ServiceJunior
The new Getman Service Junior captures
momentary pressure spikes that are
"invisible" to normal liquid-filled gauges.
That means the maximum pressure
reading it delivers can be trusted
as a much truer reflection of the
system's actual condition; so you
can identify potential problems
better and diagnose their causes
faster. All readings are accurate
to within +/-0.5%.

ServiceJunior Features
Easy to connect and test system pressure
using Parker Diagnostic test port couplings
Robust, dirt resistant housing
Simple to operate, four key menu
Four digit backlit display with easy to read
large 0.60" characters
Minimum and maximum graphic display
shows pressure peak
Power status displayed continuously
Can be used with most hydraulic and
pneumatic media
Measure PSI, bar, mPa, kPa with one gauge

Accuracy +/- 0.5% of full scale


Three pressure ranges
Operating temperature 14 to 122 F
Fluid temperature -4 to 176 F
Storage temperature -4 to 140 F
Auto power off after 15 minutes or
constant on" at the touch of a button
Zero adjustment function
10 msec scanning rate
Ratings:
Environmental Protection: EN60529 (IP 65)
Vibration: IFC 60068-2-6/10 500Hz: 20g
Shock: IEC 60068-2-29/50g 11 msec

Measuring
Range

0 to 5800 PSI
(0 to 400 bar)

Overload
Pressure

Resolution

11,600 PSI

1 PSI

NOTES: 1. PD Couplers rated to 6,000 PSI max. 2. EMA3 Couplers rated to 9,000 PSI max.

Getman Corporation provides the


most complete line of mining
equipment available. For more
information please contact:
sales@getman.com

Getman Corporation
59750 34 t h A ve n u e
Bangor, MI 49013
PH: (269) 427-5611 FAX: (269) 427-8781
www.getman.com

HYDRAULIC FILTER

13259
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

534690

FILTER ASSEMBLY

534691

REPLACEMENT FILTER

534712

SERVICE INDICATOR

Updated:
12/11/06

STEERING ORBITROL

ITEM PART #

12860
Page 1 of 2

DESCRIPTION

QTY.

174110

STEERING VALVE

174116

SEAL KIT (INCLUDES ITEMS 3, 8, 9, 15, 16, 17, 24, 25)

174112

SERVICE KIT (INCLUDES ITEMS 1, 4, 5)

NSS

SCREW, CAP (6 POINT)

NSS

CAP, END

NSS

SEAL

NSS

GEROTOR

NSS

SPACERS

A/R

174113

PLATE, SPACER

173172

DRIVE

NSS

HOUSING

Updated:
12/11/06

STEERING ORBITROL
9

12860
Page 2 of 2

10

NSS
NSS
174033

SLEEVE, CONTROL
SPOOL, CONTROL
PIN, CENTERING

1
1

11

174115

SPRING, CENTERING

13

174039

RACE, BEARING

14

174034

BEARING, NEEDLE THRUST

15

NSS

SEAL

16

NSS

SEAL

17

NSS

SEAL, QUAD RING

18

174036

BUSHING, SEAL GLAND

19

174044

RING, RETAINING

20

174046

NEEDLE BEARING KIT

21

174035

RETAINER, CHECK BALL

22

174045

BALL CHECK

23

174038

SEAT, CHECK BALL

24

NSS

SEAL

25

NSS

SEAL

26

174067

SCREW, SET

Updated:
12/11/06

S1024

S1024

S1024

S1024

S1010

S1010

S1010

S1010

STEER CYLINDER

ITEM PART #

13943
Page 1 of 1

DESCRIPTION

QTY.

465411

CYLINDER ASSEMBLY

465411-07

SEAL KIT

465411-01

BARREL ASSEMBLY

465411-02

ROD ASSEMBLY

465411-03

PISTON ASSEMBLY

465411-04

ROD BEARING ASSEMBLY

465411-05

NUT

465411-06

CAP SCREW

Updated:
12/11/06

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
9.

CONTROLS
13905
10827
13655

ELECTRIC SHIFTER
STEERING WHEEL & COLUMN
THROTTLE (ELECTRONIC)

ELECTRIC SHIFTER

13905
Page 1 of 2

Updated:
06/20/07

ELECTRIC SHIFTER
ITEM PART #

13905
Page 2 of 2

DESCRIPTION

QTY.

534772

ELECTRIC SHIFTER

534772-20

534772-01

SWITCH AND HARNESS ASSEMBLY


(INCLUDES ITEMS 7, 12, 18, 19)
ALUMINUM CASTING

534772-02

SWITCH MOUNTING PLATE

534772-03

RIGHT SIDE DECAL

534772-04

LEFT SIDE DECAL

534772-05

SCREW

534772-06

NUT

534772-07

ROTARY SWITCH

534772-08

SWITCH DRIVE BEARING

10
11

534772-09
534772-10
534772-11

SPRING LEVER ASSEMBLY (LEFT)


SPRING LEVER ASSEMBLY (RIGHT)
MOLDED HANDLE

1
1
2

12

534772-12

WIRE HARNESS

14

534772-13

SCREW

15

534772-14

SCREW

16

534772-15

SCREW

17
18

534772-16
534772-17
534772-18

NUT
PRESS IN NUT
HEAT SHRINK END CAP SEAL

1
3
2

19

534772-19

ROTARY SWITCH

Updated:
06/20/07

STEERING WHEEL & COLUMN

10827
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

492191

WHEEL, STEERING

171002

COLUMN

173132

NUT, ORBITROL

173175

CAPSCREW

5*

494081

KNOB (STEERING) (OPTIONAL)

*ITEMS NOT SHOWN

Updated:
12/11/06

ELECTRONIC THROTTLE
PEDAL

13655
Page 1 of 1

ITEM PART #

DESCRIPTION

QTY.

ELECTRONIC THROTTLE PEDAL (INCLUDES BRACKET)

595395

Updated:
09/05/07

PARTS LIST INDEX


A-64 CRANE TRUCK
AGNICO PINOS ALTOS
S/N 7056
10/31/08
10.

MOUNTED EQUIPMENT
S1025
S1012
S1013
S1014
23276
17183
16721
S1081
S1092
S1094

FIRE EXTINGUISHER
FIRE PROTECTION INFORMATION MANUAL
FIRE SUPPRESSION MAINTENANCE MANUAL
AUTO FIRE SUPPRESSION SERVICE MANUAL
FIRE SUPPRESSION INSTALLATION
FIRE SUPPRESSION AUTO DETECTION SYSTEM
FIRE SUPPRESSION SYSTEM
CRANE PARTS MANUAL
CRANE SERVICE MANUAL
LINCOLN AUTO GREASE LUBE MANUAL

ANSUL

S1025

SENTRY
FIRE
EXTINGUISHERS
PARTS LIST

MODELS
A05, AA05,
A05VB, AA05VB,
PK05, C05

10

1
16

11
12
8
7

5
13

4
6

3
18
15
14

19

20
21

006004

FIG.
NO.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

DESCRIPTION
Valve Assembly
Valve Body, Machined
Tube, Pick-Up
O-Ring (Pick-up Tube)
Valve Stem Assembly (Includes O-Ring)
O-Ring
Spring
O-Ring
Gauge, Pressure
Lever, Operating
Handle, Carrying
Rivet, Operating Lever
Rivet, Carrying Handle
Pull Pin (Ring Pin)
Seal, Visual Inspection
Hose Assembly
Hanger Hook
Bracket Assembly (Not Shown)
One-Piece Nameplate, Replacement
(Maintenance, w/o UL/ULC Approval)
Adaptor Assembly, Recharge
O-Ring
Hose Retainer

PART NUMBER
PK05
A05

AA05

AA05VB

429084
428062
428796
76076
429099
11873
415565
428327
428280
429096
429097
428130
428130
16235
419790
428729
54405

430854

429084
428062
428796
76076
429099
11873
415565
428327
428280
429096
429097
428130
428130
16235
419790
428729

429146
430854

429084
428062
428796
76076
429099
11873
415565
428327
428280
429096
429097
428130
428130
16235
419790
428730
54405

429642
57744
427995

429642
57744
427995

429642
57744
427995

A05VB

429084
429084
428062
428062
428796
428796
76076
76076
429099
429099
11873
11873
415565
415565
428327
428327
428280
428280
429096
429096
429097
429097
428130
428130
428130
428130
16235
16235
419790
419790
428728
429728
54405

429146

(431049-ULC) (431049-ULC)
429642
429642
57744
57744
427995
427995

C05
429084
428062
428796
76076
429099
11873
415565
428327
428280
429096
429097
428130
428130
16235
419790
428731
54405

429642
57744
427995

Indicates revision
ANSUL and SENTRY are trademarks of Ansul Incorporated or its affiliates.
ANSUL INCORPORATED, ONE STANTON STREET, MARINETTE, WI 54143-2542

715-735-7411

Form No. F-2001047-1

2002 Ansul Incorporated

Litho in U.S.A.

S1012

Vehicle Fire Protection


An Owners Manual for Ansul
Fire Suppression/Detection Systems

002792

S1012

Off-road vehicles do have fires


Statistics show that on-road vehicles burn.......with
alarming frequency. These vehicles are susceptible to
fire for several reasons. They often operate steady for
several hours at a time (sometimes around the clock).
They use flammable liquids lubricating oil, gasoline,
diesel oil, greases and hydraulic fluids in their normal operation. They also generate heat from engine
blocks, manifolds, turbochargers and brake systems
which can ignite these flammable liquids and debris.
Since the passage of the federal and state clean air
acts, many vehicles, including most busses operated
by mass transit authorities and state agencies, have
been converting to cleaner burning fuels such as
LPG, LNG, and CNG instead of gasoline or diesel
fuel. Use of these fuels is an essential component of
improving our environment, but their use raises the
possibility of dangerous gas leaks.
When fire breaks out, it can result in expensive repair
or replacement of valuable equipment, costly downtime or loss of business continuity. Worse yet, it can
mean serious personal injury to vehicle operators or
passengers.

Turbocharger
Exhaust
Manifold

Insurance companies are well aware of these facts.


That's why insurance rates are skyrocketing.
As the owner of a vehicle equipped with an Ansul Fire
Detection/Suppression System, you've taken an
important step in facing the fire problem. You are dramatically reducing your potential fire loss and helping
to ensure personnel safety.
This owner's guide has been provided to help
you understand how your Ansul Fire
Detection/Suppression System works, your
responsibilities for fire prevention and maintenance, and what to do in case of fire. In no way is
this guide intended to provide detailed installation
instructions. A copy of the complete Installation,
Recharge, Inspection, and Maintenance Manual
for the Ansul Fire Detection and Suppression
System is available upon request from Ansul.
Should you have any questions, contact Ansul or
your nearest authorized Ansul products
distributor.

Transmission &
Disc Brake
Battery Box
Hydraulic
Pump Hose
Area

Engine
Block

Typical Vehicle
Fire Hazard Areas

002776

S1012

SAFETY
PRECAUTIONS
The fire system described in these materials is a suppression system only and is not designed or intended
to extinguish all fires, particularly when unusual
amounts of combustible materials and an ample oxygen supply are present. It is extremely important that
alternative firefighting equipment be available in case
the system does not totally extinguish a fire.
Use extreme care to prevent the accumulation of
debris, combustible materials and fluids which could
intensify the fire or cause it to spread to areas where
there was no previous potential for fire.
If modifications are made to the equipment being protected or if the fire detection and/or suppression system is disconnected for any reason, make certain the
fire equipment is immediately inspected and tested by
an Ansul-authorized vehicle systems distributor.
If an automatic fire detection and actuation system
has not been supplied or has been disconnected,
system actuation and discharge will not occur unless
the fire suppression system is manually actuated.
Reliance on a manual release system usually results
in a slower reaction to fire.

Your role in
protecting your
vehicle from fire
Your Ansul Fire Suppression System is customdesigned to protect specific hazard areas on your
vehicle. Its been carefully engineered for reliability
and built to the highest quality standards. Every component has been tested to ensure long life and
dependable performance.
With proper maintenance, your Ansul Fire
Suppression System should give you years of fire
protection.
The main purpose of the manual, however, is to
explain the most basic form of fire protection fire
prevention. It outlines steps you can take to prevent a
disastrous fire. Precautions which can greatly reduce
the risk of serious fire damage.
Fire prevention on vehicles relies upon two basic
factors:

1.

Inspection and preventative maintenance at


points where fires are most likely to start
engine blocks, electrical systems, turbochargers, exhaust manifolds and brake
systems.

2.

Regular cleaning of all areas where flammable materials such as fuel, oil, grease,
hydraulic fluid and combustible debris may
collect.

S1012

Vehicle Fire Prevention Maintenance


The following is a suggested daily maintenance outline which can help reduce the risk of fire on your vehicle.
CAUTION: Take care during vehicle maintenance, cleaning, or welding. To avoid unintentionally setting off the system
and the discharge of agent, do not cut, pinch, or apply heat exceeding 200 F (93 C) to the detection lines of
the system.

1.

Check all oil, hydraulic fluid and gas lines for cuts,
abrasions or undue wear. Replace as needed.
000620

2.

Inspect all oil, hydraulic and gas line fittings for


tightness. Clean off all residue and tighten.

000621

3.

Inspect and clean engine area. Depending upon the


operation of the vehicle, use water or steam to clean it.
Schedule cleaning for the end of the work shift
when heat buildup may occur after the engine is shut
down.
000622

4.

Check braking system for proper adjustment


especially if brakes overheat when not engaged.

000623

5.

Check all possible ignition points (engine block,


exhaust manifolds, turbochargers, etc.). Make sure
oil, hydraulic fluid and gas lines are not in contact
with these ignition points.

000624

6.

Clean vehicle of all combustible debris dry


vegetation, grain particles, coal dust, etc. Also,
remove any oil and fuel drippings.

000625

7.

Check all electrical lines and connections for tight fit,


wear or abrasion. Replace any defective electrical
equipment or wiring.

000626

S1012

How your Ansul Fire Suppression System


works . . . manually
1.

A fire starts in the protected area.

002777

2.

Equipment operator pulls the ring pin


and strikes the plunger on the manual
actuators. Pressure from the actuator
causes the Ansul Fire Suppression
System to actuate.

002778

3.

Expellant gas pressure fluidizes the


dry chemical extinguishing agent and
propels it through distribution hose.

002779

4.

Dry chemical extinguishing agent is


discharged through fixed nozzles into
protected areas, suppressing the fire.

002780

And you can have automatic 24 hour protection with


Ansul CHECKFIRE Detection and Actuation Systems . . .

S1012

How the system works with optional


CHECKFIRE Electric Detection and Actuation
1.

A fire starts in the protected area.

002781

2.

Linear or spot detectors signal the


system control module indicating that a
fire has started in the protected area.

002782

3.

The Control Module actuates the fire


suppression system. The module will
also provide time delay, shut down
functions and activation of auxiliary
vehicle components in accordance with
your installation.

002783

S1012

4.

Expellant gas pressure fluidizes the


dry chemical extinguishing agent and
propels it through the distribution hose.

002784

5.

Dry chemical extinguishing agent is


discharged through fixed nozzles into
protected areas, to suppress the fire.

002785

Optional LVS (Twin Agent) Fire Suppression System


Along with dry chemical fire suppression system protection, some vehicles, because of their size, require an additional type of system.
This type of system is called a twin agent system. An Ansul LVS, Liquid Agent System, is designed to discharge wet chemical into
the protected hazard areas after the dry chemical discharge has ended. The addition of the wet chemical produces a cooling effect
onto the flammable fuel and the surrounding surface areas. The wet chemical can flow into hard to reach areas where fuels may
have flowed into.

S1012

Make sure your Ansul Fire Suppression System is


The Ansul Fire Suppression System is your second line of fire defense in case your fire prevention efforts are not enough.
However, in order to perform properly, your Ansul System requires periodic inspection and maintenance.
Nozzles

System Hydraulic Hose

BLOW-0FF CAPS IN
PLACE (IF SUPPLIED)

NOZZLES NOT CLOGGED


OR COVERED WITH DEBRIS

NO CUTS

NOZZLES TIGHT
IN BRACKETS
ALL FITTINGS
TIGHT

NO KINKS
IN HOSE
NO ABRASIONS
ALL HOSE MOUNTS SECURELY
WELDED OR BOLTED

002798

002797

Agent Tank
A-101

AUTHORIZED ANSUL
DISTRIBUTOR
CERTIFICATION TAG
ATTACHED

002786

002799

Agent Tank LVS


or LT-A-101-125/250

Hand Portable Fire


Extinguisher

VISUAL SEAL
IN PLACE

FIRMLY
MOUNTED

DISTRIBUTOR
CERTIFICATION
TAG ATTACHED
NO
EXCESSIVE
WEAR
NO EXCESSIVE
WEAR

NO
ABRASIONS

FIRMLY
MOUNTED
NO
CORROSION

NO
CORROSION

NO
EXCESSIVE
WEAR
FIRMLY
MOUNTED

NO
CORROSION
NO
CORROSION
002794

FIRMLY MOUNTED

004320

002788

S1012

kept in good working order.


CHECKFIRE Electric Series I Inspection

Detection Wire, Power Wire


ALL NYLON
TIES SECURE

RING PIN IN
PLACE AND SEALED
BRACKET
SECURELY
WELDED OR
BOLTED

LIGHT MUST
GO ON WHEN
TEST BUTTON IS
PUSHED

NO CUTS
BATTERY
CONNECTIONS
SECURE

NO KINKS
NO ABRASIONS
ALL RUBBER SLEEVES IN PLACE
002790

FUSE IN
FUSEHOLDER
CONNECTION
SECURE

CONNECTION
SECURE

CARTRIDGE
INSTALLED

002789

DETECTION LINE AND/OR DETECTOR


SECURE AND NOT DAMAGED

CHECKFIRE MP Inspection

CHECKFIRE SC-N Inspection

BRACKET
SECURELY
WELDED OR
BOLTED

SEALED
CARTRIDGE
INSTALLED

RING PIN IN
PLACE AND
SEALED

BRACKET
SECURELY
WELDED OR
BOLTED

CHECK THE SYSTEM


DAILY BY VISUALLY
VERIFYING THAT THE
GREEN POWER LED
IS FLASHING ONCE
EVERY THREE
SECONDS AND NO
OTHER LED IS FLASHING

CHECK THE SYSTEM


DAILY BY VISUALLY
VERIFYING THAT THE
GREEN BATTERY LED
IS FLASHING ONCE
EVERY THREE SECONDS AND NO
OTHER LED IS
FLASHING

BRACKET
SECURELY
WELDED OR
BOLTED

RING PIN IN
PLACE AND
SEALED

CARTRIDGE
INSTALLED

CARTRIDGE
INSTALLED
DETECTION LINE
AND/OR
DETECTORS
SECURE AND NOT
DAMAGED

DETECTION LINE
AND/OR
DETECTORS
SECURE AND NOT
DAMAGED

002791

002775

S1012

Provide for vehicle modification


Your Ansul Fire Suppression System was custom
designed and installed on your vehicle to protect specific hazard areas from fire. Should you add accessory equipment to your vehicle at a later date, or make
major mechanical modifications, you may be reducing
the capabilities of the Ansul Fire Suppression System.

When such modifications are made, contact your


Ansul distributor. He can reevaluate your Ansul
System to ensure it protects all hazard areas from
fire.

Provide for periodic maintenance


Periodic maintenance is essential to ensure that your
Ansul Fire Suppression System is operational.
Contact your Ansul distributor for periodic follow-up,
in-depth inspection and maintenance.

Protect against fires outside of


the hazard area
Hand portable fire extinguishers are an effective way
to suppress fires which may occur away from the
vehicle, or in areas not protected by the Ansul Fire
Suppression System. Your Ansul distributor can recommend the proper size, type and placement of hand
portable extinguishers and train your personnel in
their operation, inspection and maintenance.
Should fire occur in an area not protected by the
Ansul Fire Suppression System, a hand portable fire
extinguisher should be employed as follows:

1.

Shut off the vehicles engine and set


brakes.

2.

Evacuate the vehicle and secure a hand


portable fire extinguisher.

3.
4.

Approach the fire from the upwind side.

5.

Once the fire is extinguished, stand by in case


the fire reflashes.

Actuate the hand portable fire extinguisher per


instructions printed on the extinguishers nameplate.

S1012

In the event of a fire on your vehicle


To manually operate system:
1. Shut off the vehicle
2. Set the brakes
3. Pull the ring pin on
manual actuator and
strike the red button

000627

4. Evacuate the vehicle


5. Stand by with a fire extinguisher

S1012

Inspection and Maintenance Record


Date

Authorized Ansul Distributor

Recharge

Inspection

ANSUL and CHECKFIRE are registered trademarks.

Part No. 53081-08

1999 Ansul Incorporated

Litho in U.S.A.

Your Authorized Ansul Distributor

ANSUL INCORPORATED, ONE STANTON STREET, MARINETTE, WI 54143-2542

Action Taken

S1013

A-101-10/20/30, LT-A-101-10/20/30
VEHICLE SYSTEMS
Installation, Recharge, Inspection, and Maintenance Manual

003898

S1013

This manual is intended for use with the ANSUL A-101 Vehicle
Fire Suppression System.
Those who install, operate, recharge, inspect, or maintain these
fire suppression systems should read this entire manual. Specific
sections will be of particular interest depending upon ones
responsibilities.
Design, installation, recharge, and maintenance of the system
must conform to the limitations detailed in this manual and performed by an individual who attended an ANSUL training program
and became trained to design, install, recharge, and maintain the
ANSUL system(s).
Fire suppression systems are mechanical devices. They need
periodic care to provide maximum assurance that they will operate effectively and safely. Inspection frequency shall be performed monthly, or sooner, depending on operating and/or environmental conditions. Maintenance shall be performed semiannually or sooner, depending on operating and/or environmental
conditions.
This ANSUL systems manual is limited to uses herein described.
For other applications, contact your local ANSUL distributor,
Domestic District Manager, International Area Manager, or Ansul
Incorporated Technical Services Department, Marinette,
Wisconsin 54143-2542.

ANSUL and CHECKFIRE are trademarks of Ansul Incorporated or its affiliates.

NOTICE: Some sections have been removed by Getman as they do not


apply to your application needs. Any questions please call Getman
Corporation directly.

S1013

TABLE OF CONTENTS
6-30-05
REV. 3

PAGES

PAGES

SECTION

I. GENERAL INFORMATION
INTRODUCTION
TWIN AGENT SYSTEM
FM APPROVAL
HOW THE SYSTEM OPERATES
IN CASE OF FIRE

1-1 1-2
1-1
1-1
1-1
1-2
1-2

VII. INSPECTION

7-1 7-2

VIII. MAINTENANCE

8-1 8-2

II. SYSTEM DESCRIPTION

SECTION

SEMI-ANNUAL

8-1 8-2

12-YEAR

8-2

IX. RECHARGE

9-1 9-2

2-1 2-2

X. SYSTEM APPLICATION OPTIONS

10-1 10-6

APPLICATION METHOD
Local Application Vehicle
Total Flooding

2-1
2-1
2-1

XI. APPENDIX

PIPING ARRANGEMENT
Two Nozzle
Four Nozzle
Six Nozzle

2-1
2-1
2-1
2-1

DETECTION

2-1

III. SYSTEM COMPONENTS


TANK ASSEMBLY
TANK BRACKET
DRY CHEMICAL
CARTRIDGE EXPELLANT GAS
CARTRIDGE ACTUATION GAS
CARTRIDGE BRACKET
PNEUMATIC ACTUATOR
MANUAL ACTUATORS
1/4 IN. CHECK VALVE
DISTRIBUTION TEE

3-1 3-6
3-1
3-1
3-2
3-2
3-2
3-2
3-3
3-3
3-3
3-3

REDUCING TEE

3-4

TRIPLE TEE

3-4

SAFETY RELIEF VALVE

3-4

AIR CYLINDER (OPTIONAL)

3-4

PRESSURE SWITCH WEATHERPROOF

3-4

PRESSURE SWITCH
NON-WEATHERPROOF

3-5

PRESSURE SWITCH EXPLOSION PROOF 3-5


NOZZLES

3-5

NOZZLE BRACKET

3-6

HOSE (SUPPLIED BY OTHERS)

3-6

SEALED BURST DISC ASSEMBLY

3-6

ENGINE SHUTDOWN DEVICE

3-6

CHECKFIRE ELECTRIC DETECTION


AND ACTUATION SYSTEM

3-6

SYSTEM COMPONENT INDEX

11-1 11-10
11-1 11-2

S1013

SECTION I GENERAL INFORMATION


6-30-05
Page 1-1
REV. 2

INTRODUCTION

FM APPROVAL

The ANSUL A-101/LT-A-101 fire suppression system is a preengineered, fixed nozzle system for protection of off-highway
vehicles, commercial vehicles, or industrial type applications.
Typical applications include surface mining equipment, underground mining machines, forest harvesting equipment, construction equipment, farming machinery, and transportation vehicles
such as municipal busses.

The ANSUL A-101/LT-A-101 fire suppression system has been


tested and is FM approved. These tests require extinguishment of
fire initiated in open vessels and within enclosures fueled with
flammable liquid. In each case, these fires are allowed to
progress to maximum intensity before the system is actuated.
The time of actuation in these tests is well beyond the time that a
detector would take to detect the fire and actuate the system.
Other tests required by FMRC are as follows:

The A-101/LT-A-101 system consists of three major components:


a container to store the dry chemical extinguisher agent; an actuation system operated manually or automatically, and an agent
distribution system which delivers the agent from the tank through
hydraulic hose and fixed nozzles to the hazard areas.
The fire system described is a suppression system only and is not
designed or intended to extinguish all fires, particularly when
unusual amounts of combustible materials and an ample oxygen
supply are present. It is extremely important that supplement fire
fighting equipment be available in case the system does not totally extinguish a fire.
If an automatic fire detection and actuation system has not been
supplied or has been disconnected, system actuation and discharge will not occur unless the fire suppression system is manually actuated. (Use of manual system only must be approved by
authority having jurisdiction.) Reliance on a manual release system usually results in a slower reaction to fire. Means to shut
down the vehicle must be added to a manual or disconnected
automatic system.
The basic agent storage container is a tank filled with ANSUL
FORAY (monoammonium phosphate base) dry chemical which is
effective on Class A, B, and C fires. A gas expellant cartridge,
either carbon dioxide or nitrogen, provides pressurization of the
dry chemical upon actuation.
Automatic detection, either electric or pneumatic, and actuation,
is recommended. The A-101/LT-A-101 system is actuated manually by a pneumatic actuator located on the dashboard or on the
exterior of the vehicle.
The dry chemical extinguishing agent is delivered from the tank
through hydraulic hose and pre-set nozzles into the fire hazard
areas or onto the fire prone surfaces.
Along with the fire suppression system, the total system design
must include a hand portable fire extinguisher(s) located on board
the vehicle that can be used to manually suppress a fire that may
be burning in an unprotected area. Refer to NFPA 10, Standard
For Portable Fire Extinguisher, for additional information.

1. Fuel in depth splash tests under a minimum hose length,


maximum temperature, and minimum clearance condition to
ensure that the nozzle does not cause splashing of fuel.
2. Operational flow rate tests at the minimum, average, and the
maximum temperatures, with maximum and minimum hose
lengths.
3. Cycle tests on all mechanical and electrical devices to determine their structural integrity.
The A-101 systems which utilize carbon dioxide as the expellant
gas are approved for temperature ranges of +32 F to +120 F
(0 C to 49 C).
The LT-A-101 systems which utilize nitrogen as the expellant gas
are approved for temperature ranges of 65 F to +210 F
(54 C to 99 C).
TWIN AGENT SYSTEM (LVS PORTION NOT FM APPROVED)
The system consists of both dry chemical and liquid agent. The
dry chemical portion of the system is the ANSUL A-101/LT-A-101,
50, 125, or 250 system (either standard discharge or extended
discharge) and the liquid agent portion of the system consists of
an agent storage tank containing a premixed solution of LVS wet
chemical.
The LVS-30 (30 gallon) system is designed to discharge for
approximately 2 minutes when two agent discharge nozzles are
used.
The LVS Fire Suppression System is designed to operate within a
temperature range of 40 F to +120 F (40 C to 49 C).
The dry chemical system used in conjunction with the LVS system is the ANSUL A-101/LT-A-101, 50, 125 or 250. The dry chemical system is connected to the ANSUL CHECKFIRE Detection
and Control System. the dry chemical system can be designed as
a standard discharge or as an extended discharge system per the
requirements of the A-101/LT-A-101 Vehicle Fire suppression
Installation, Recharge, Inspection, and Maintenance Manual.
Both systems are designed to discharge simultaneously
when actuated either manually or automatically.
For detailed instructions, refer to manual Part No. 427865 regarding the LT-A-101-50/125/250 system. For detailed instructions,
refer to manual Part No. 427109 regarding the LVS system.

S1013

SECTION I GENERAL INFORMATION


5-15-02
Page 1-2
REV. 2

FROM AUTOMATIC
DETECTION SYSTEM

1
2
1

TO OPTIONAL
PRESSURE SWITCH

4
5

7
FIGURE 1
002581

HOW THE SYSTEM OPERATES

IN CASE OF FIRE

Discharge of the A-101/LT-A-101 system manually is initiated


from a remote actuator (1). Depressing the actuator plunger
punctures the seal on the cartridge. The released pressure is
transmitted to the pneumatic actuator/cartridge receiver (2). A
safety relief valve (3) at this point prevents too high an actuation
pressure build-up. The pressure drives a puncture pin through
the seal in the expellant gas cartridge (4). This releases the
expellant gas which is then transmitted to the dry chemical tank
(5) where it fluidizes the dry chemical before carrying it to the fire
hazard. A sealed burst disc assembly (6) prevents the flow of dry
chemical until sufficient pressure is built up within the dry chemical tank. When the proper pressure is reached, the disc breaks
allowing the gas/dry chemical mixture to flow to the nozzle(s) (7)
and discharge onto the hazard.

When a fire starts, the way the operator reacts is very important.
As soon as the operator is aware of a fire, he should do the following four things:

Refer to appropriate CHECKFIRE design, installation and maintenance manual for information on the operation of the automatic
detection system.
NOTE: Mechanical or electrical means must be provided to shut
down vehicle upon system actuation.

1. Turn the machine off and set the brake.


2. Quickly actuate the system by pulling the safety ring pin on
the manual actuator and strike the red button.
3. Evacuate the vehicle.
4. Stand by with a fire extinguisher.

CAUTION

The fire system described in this manual is a suppression system only and is not designed or intended to extinguish all fires,
particularly when unusual amounts of combustible materials
and an ample oxygen supply are present. It is extremely
important that supplemental firefighting equipment be available
in case the system does not totally extinguish a fire.

S1013

SECTION II SYSTEM DESCRIPTION


5-15-02
Page 2-1
REV. 2

APPLICATION METHOD

DETECTION

The A-101/LT-A-101 system provides fire protection using total


flooding and local application methods. These methods are
described below.

Automatic electric detection is available for the A-101/LT-A-101


system.

Local Application Vehicle


When designing a local application system for vehicle protection,
each individual hazard area must be surveyed and the correct
type nozzle must be chosen to give the proper coverage. It must
also be determined if certain local application hazard areas
require screening to adequately protect them.
Total Flooding
Total flooding is described as volume protection and it is applied
only when a hazard is located in an enclosure. Openings such as
doors, windows, and grating shall not be more than 15% of the
enclosures total surface area (ceiling, floors, and all walls).
Openings of 5% or less of the total surface area are acceptable
and do not require screening. Hazards with openings greater than
5% but not over 15% can be protected by screening.
Total flooding application is accomplished by introducing a sufficient quantity of FORAY dry chemical through fixed nozzles
throughout the volume of the enclosure.
To enhance the effectiveness of the total flooding system in industrial applications, all fan air movements should be shut down
and/or dampered at discharge of the dry chemical system. Refer
to NFPA 17, Standard For Dry Chemical Extinguishing Systems,
for additional information.
PIPING ARRANGEMENT
The A-101/LT-A-101 system utilizes three methods of splitting the
dry chemical flow from the tank to the nozzles. Each method is
approved for use on vehicle or industrial type applications.
Two Nozzle System
The two nozzle system can be used in either vehicle or industrial
hazard protection. It can be used in total flooding, or as a local
application system on off-road vehicles. The supply line is split
into two branch lines by the use of a 3/4 x 1/2 x 1/2 in. reducing
tee. Two nozzles systems can be used with nominal 10, 20, and
30 lb. tank sizes.
Four Nozzle System
The four nozzle system can be used in either vehicle or industrial
hazard protection. It can be used in total flooding, or as a local
application system on off-road vehicles. The supply line is divided
into four branch lines by the use of a triple tee or a split tee. Four
nozzle systems can only be used with nominal 20, and 30 lb.
tanks. Four nozzle 30 lb. systems are preferred for all systems
protecting hazards in environments which are extremely rugged,
and very prone to Class A and Class B fuel build up in hard to
protect areas, providing more agent per nozzle and longer discharge times.
Six Nozzle System
The six nozzle system can be used in vehicle or industrial hazard
protection. It can only be used in local application systems on offroad vehicles, when minimal discharge time and agent discharge
per nozzle is acceptable. The supply line is divided into six branch
lines by the use of a distribution tee and three 1/2 in. tees. Six
nozzle systems can only be used with nominal 20, and 30 lb.
tanks.

Electric detection systems (CHECKFIRE MP-N*, Series I, and


SC-N) are available to provide rugged, automatic detection for
vehicle protection. These systems are either powered by the vehicle battery or by the internal module battery.
The electric detection systems can use either linear heat detection or spot thermal detectors, or pneumatic linear detectors.
* Not FM Approved

S1013

SECTION III SYSTEM COMPONENTS


6-30-05
Page 3-1
REV. 1

TANK ASSEMBLY

TANK BRACKET

The tank assemblies, nominal 10, 20, and 30 lb. size, are factory
filled with 8.5, 17, and 25 lb. respectively of FORAY dry chemical.
Each tank is finished in red enamel paint. A nameplate is affixed
to the exterior and contains information on recharge and maintenance. Two style of tanks are available: a tank containing a cartridge receiver and pneumatic actuator and a tank with 1/4 in.
adapter for a pressure line from a remote cartridge. See Figure 1.

The tank mounting bracket assemblies consist of heavy gauge


steel back plates and clamp arms. Each style bracket is constructed to properly retain the agent tank from movement or damage in the rugged environment that these systems are normally
used. Each tank bracket contains rubber pads to minimize the
shock and vibration effect on the tank. The brackets are finished
with red, air dry enamel paint. See Figure 2.

A-101 MODEL 10
PART NO. 24855

A-101 MODEL 10 / LT-A-101 MODEL 10


PART NO. 24854

LT-A-101 MODEL 10
PART NO. 24966

7 IN.
(17.8 cm)

2 7/8 IN.
(7.3 cm)

6 3/4 IN.
(17.1 cm)

12 IN. (30.5 cm) MIN.


OPENING WIDTH

11 3/8 IN.
(28.9 cm)
10 1/4 IN.
(26 cm)

10 1/4 IN.
(26 cm)
16 1/8 IN.
(41 cm)

16 1/8 IN.
(41 cm)

3/4 IN.
(1.9 cm)
2 1/32 IN.
(5.2 cm)

000459

000459

3 5/8 IN.
(9.2 cm)
1 13/16 IN.
(4.6 cm)

A-101 MODEL 20
PART NO. 24970

7 5/8 IN.
(19.4 cm)

19 15/16 IN.
(50.6 cm)

19 1/2 IN.
(49.5 cm)

A-101 MODEL 30
PART NO. 53000

2 1/2 IN.
(6.3 cm)

8 5/8 IN.
(21.9 cm)

10 1/4 IN.
(26 cm)

003461

2 3/4 IN.
(7 cm)

003468

LT-A-101 MODEL 30
PART NO. 30494

14 IN. MIN. (35.6 cm)


OPENING WIDTH
3.5 IN.
(8.9 cm)

22 1/2 IN.
(57 cm)

4 3/8 IN.
(11 cm)

003465

A-101 MODEL 30
PART NO. 14098

22 1/2 IN.
(57 cm)

000459

3 9/16 IN.
(9 cm)
1 3/16 IN.
(4.6 cm)

003461

9 7/8 IN.
(25 cm)

8 5/8 IN.
(21.9 cm)

6 1/2 IN.
(16.5 cm)

8 1/2 IN.
(21.6 cm)

9 IN.
(22.9 cm)

11 7/8 IN.
(30.1 cm)

2 IN.
(5.1 cm)

4 1/2 IN.
(11.4 cm)

LT-A-101 MODEL 30
PART NO. 29375

9 3/4 IN.
(24.8 cm)

12 IN. (30.5 cm) MIN.


OPENING WIDTH

3 3/4 IN.
(9.5 cm)
10 1/8 IN.
(25.7 cm)

000459

LT-A-101 MODEL 20
PART NO. 24895

3 1/2 IN.
(8.9 cm)

8 5/8 IN.
(21.9 cm)

11 IN.
(27.9 cm)

003464

A-101 MODEL 20
PART NO. 24971

LT-A-101 MODEL 20
PART NO. 24894

8 1/4 IN.
(21 cm)

3 3/8 IN.
(8.6 cm)

9 7/8 IN.
(25 cm)

7 1/2 IN.
(19 cm)

4 9/32 IN.
(10.9 cm)
3 IN.
(7.6 cm)

4 IN.
(10 cm)

1 3/16 IN.
(4.6 cm)
4 IN.
(10.1 cm)

6 IN.
(15.2 cm)

5 9/16 IN.
(14.1 cm)

5 IN.
(12.7 cm)

4 7/8 IN.
(12 cm)
3 IN.
(7.6 cm)

003468

003466

LP-A-101 MODEL 20-B


PART NO. 24427

LP-A-101 MODEL 20B / LT-LP-A-101 MODEL 20


PART NO. 31171

LT-LP-A-101 MODEL 20-B


PART NO. 24425

9 IN.
(22.9 cm)

2 1/2 IN.
(6.3 cm)

9 IN.
(22.9 cm)

9 7/8 IN.
(25 cm)

4 IN.
(10.2 cm)
9 7/8 IN.
(25 cm)

16 IN.
(40.6 cm)

003463

9 7/8 IN.
(25 cm)

10 1/4 IN.
(26 cm)

16 IN.
(40.6 cm)

003463

FIGURE 1

4 IN.
(10 cm)

1 3/16 IN.
(4.6 cm)

5 IN.
(12.7 cm)

4 7/8 IN.
(12 cm)
3 IN.
(7.6 cm)

003467

FIGURE 2

S1013

SECTION III SYSTEM COMPONENTS


6-30-05
Page 3-2
REV. 2

DRY CHEMICAL
FORAY is a monoammonium phosphate based dry chemical
which is effective on Class A,B, C related fires. FORAY agent is
color coded yellow for easy identification. FORAY dry chemical is
shipped in 45 lb. pails, Part No. 53080. See Figure 3.

CARTRIDGE ACTUATION GAS


The actuation gas cartridge used on the A-101/LT-A-101 system
contains nitrogen as the actuation gas. The cartridge is a sealed
pressure vessel containing gas under pressure. When the cartridge seal is punctured by the pin in the remote manual or pneumatic actuator, the gas flows to the actuator on the expellant gas
cartridge, causing that actuator to puncture the seal in the expellant gas cartridge. The actuation gas cartridges meet the requirements of DOT 3E-1800. See Figure 5.
B

FIGURE 3
A

000417

CARTRIDGE EXPELLANT GAS


The expellant gas cartridges used on the A-101/LT-A-101 system
contain either carbon dioxide or nitrogen as their expellant gas.
The cartridge is a sealed pressure vessel containing gas under
pressure. When the cartridge seal is punctured by the pneumatic
actuator pin, the gas flows into the dry chemical tank, fluidizes the
dry chemical, and carries it through the distribution piping network
and out the nozzles.
The expellant gas cartridges meet the requirements of DOT
3A-2100 or 3AA-1800. See Figure 4.
Several cartridge Part No.s have been added to comply with the
requirements of Transport Canada (TC). These cartridges have
been approved for both DOT and TC.

A
2 IN.
(5.1 cm)

B
6 13/16 IN.
(17.3 cm)

000439

CARTRIDGE BRACKET
The cartridge brackets for the expellant gas cartridges are constructed of heavy gauge steel and formed to protect and secure
the cartridge. The cartridge brackets are painted with red, air dry
enamel paint. See Figure 6.

FOR A-101-10 SYSTEMS


USE PART NO. 15850
(DOT)
PART NO. 423439 (TC/DOT)

18 IN.
(45.7 cm)

3 IN.
(7.6 cm)

000150

4 IN.
(10.2 cm)

12 5/8 IN.
(32 cm)

2 1/2 IN.
(6.4 cm)

2 IN.
(5.1 cm)

LT-A-101-30
PART NO. 29193

3 1/2 IN.
(8.9 cm)
11 5/8 IN.
(29.5 cm)

LEFT-HAND
THREAD
PART NO. 13177 (DOT)
PART NO. 423425 (TC/DOT)

FIGURE 5

7 7/8 IN.
(20 cm)

9 IN.
(22.9 cm)

RIGHT-HAND
THREAD
PART NO. 13193 (DOT)
PART NO. 423423 (TC/DOT)

LT-A-101-20 / LT-LP-A-101-20-B
PART NO. 24325

CARBON DIOXIDE CARTRIDGES

000149

LT-10

11 IN.
(28 cm)

5 1/2 IN.
(14 cm)

003470

FOR A-101-20 AND


LP-A-101-20
SYSTEMS USE PART
NO. 423441
(TC/DOT)

000151

2 1/2 IN.
(6.4 cm)
FOR A-101-30 SYSTEMS USE
PART NO. 423443 (TC/DOT)

3/8 IN.
(.95 cm)
9/16 IN.
(1.4 cm)

NITROGEN CARTRIDGES

003472

2 7/8 IN.
(7.3 cm)

LP-A-101-20-B
PART NO. 31177
3 1/2 IN.
(8.9 cm)

7 7/8 IN.
(20 cm)

2 5/16 IN.
(5.9 cm)

11 5/8 IN.
(29.5 cm)
16 1/2 IN.
(42 cm)

10 1/4 IN.
(26 cm)
003470

000145

2 1/2 IN.
(6.4 cm)
FOR LT-A-101-10
SYSTEMS USE PART
NO. 423429 (TC/DOT)

FIGURE 6
000146

2 1/2 IN.
(6.4 cm)

FOR LT-A-101-20,
LT-LP-A-101-20
SYSTEMS USE PART
NO. 423435 (TC/DOT)

3 9/16 IN.
000148
(9 cm)
FOR LT-A-101-30 SYSTEMS
USE PART NO. 423491 (TC/DOT)

FIGURE 4

S1013

SECTION III SYSTEM COMPONENTS


5-15-02
Page 3-3
REV. 1

PNEUMATIC ACTUATOR

1/4 IN. CHECK VALVE

The pneumatic actuator, Part No. 430221, is constructed of brass


and mounts on top of the expellant gas cartridge(s). When actuated, the actuator punctures a seal in the cartridge head, allowing
the expellant gas to flow into the agent tank. See Figure 6a.

The 1/4 in. actuation line check valve, Part No. 25627, is used at
the branch lines to each actuation device (whether manual or
automatic). The check valve blocks the flow of actuation gas from
the actuator that was actuated to the actuator(s) that was not
actuated. This prevents actuation gas from escaping from an
open actuator which may have had the cartridge removed. The
check valve also keeps the gas from pressurizing all branch actuation lines thus allowing the main line to be of maximum length.
See Figure 8.

1/4 IN. ACTUATION


LINE INLET (TYP. 2)

CHECK VALVE PART NO. 25627


VENT HOLE

1/4 IN. EXPELLANT


GAS LINE OUTLET (1)

FIGURE 6a

1/4 IN. NPT


(0.6 cm)

006433

MANUAL ACTUATORS
The manual actuator is available for use with either right or left
hand cartridges. Manual actuators should be mounted near the
vehicle operator and/or at a point on the vehicle that can be
reached from ground level. Two styles of manual actuators are
available: the standard actuator with either the S type bracket or
the L type bracket, and the cartridge guard type actuator. See
Figure 7.
CARTRIDGE GUARD ACTUATOR FOR RIGHT HAND CARTRIDGES PART NO. 19330
CARTRIDGE GUARD ACTUATOR FOR LEFT HAND CARTRIDGES PART NO. 16186
5 IN.
(12.7 cm)
L BRACKET PART NO. 70580
3 IN.
(7.6 cm)

FIGURE 8
000899

DISTRIBUTION TEE
When six nozzles are to be fed from one dry chemical tank, the
distribution supply line must enter the inlet of a distribution tee,
Part No. 25031, and each branch line must exit from one of three
outlets of the distribution tee. This is required to assure equal distribution of dry chemical to each nozzle. See Figure 9.
DISTRIBUTION TEE, 1/2 IN. X 1/2 IN. X 1/2 IN. X 3/4 IN. PART NO. 25031
1/8 IN.
(.32 cm)

3 IN.
(7.6 cm)

3 IN.
(7.6 cm)

3/4 IN. NPT


INLET

2 1/4 IN.
(5.7 cm)

5 IN.
(12.7 cm)
12 1/4 IN.
(31.1 cm)

1/2 IN. NPT


OUTLET
3 PLACES

2 1/16 IN.
(5.2 cm)

003473b

2 1/8 IN.
(5.4 cm)

003473a

1 3/4 IN.
(4.4 cm)

7/8 IN.
(2.2 cm)

S BRACKET PART NO. 57661

REMOTE ACTUATOR FOR RIGHT HAND


CARTRIDGES PART NO. 57452
REMOTE ACTUATOR FOR LEFT HAND
CARTRIDGES PART NO. 70581

1 13/16 IN.
(8.7 cm)

3 IN.
(7.6 cm)

1 1/2 IN.
(3.8 cm)
2 3/8 IN.
(6 cm)

31/32 IN. (2.5 cm)


2 1/4 IN. DIA.
(5.7 cm)

FIGURE 9
002583

1/2 IN.
(1.3 cm)

4 IN.
(10.2 cm)

5 5/8 IN.
(14.3 cm)

2 IN.
(5.1 cm)

2 IN.
(5.1 cm) 1/2 IN.
(1.3 cm)
9 IN.
(22.9 cm)

3 3/8 IN.
(8.6 cm)

003473c

1 1/2 IN.
(3.8 cm)

3/4 IN.
(1.9 cm)

3 IN.
(7.6 cm)

3 7/16 IN.
(8.7 cm)
003460

FIGURE 7

S1013

SECTION III SYSTEM COMPONENTS


5-15-02
Page 3-4
REV. 1

REDUCING TEE

AIR CYLINDER (OPTIONAL)

When two or four nozzles are to be fed from a single dry chemical
tank, a 1/2 x 1/2 x 3/4 in. reducing tee, Part No. 4655, is used to
properly distribute the dry chemical from the supply line to two
branch lines. See Figure 10.

The air cylinder, Part No. 15733, is a system accessory whose


function is to shut off the fuel supply to the engine when the fire
suppression system is actuated. It is a piston operated by gas
pressure from the actuation line. See Figure 13.
AIR CYLINDER PART NO. 15733

REDUCING TEE, 1/2 IN. X 1/2 IN. X 3/4 IN. PART NO. 4655

2 1/4 IN.
(5.7 cm)
1 1/2 IN.
(3.8 cm)

2 IN.
(5.1 cm)

3/4 IN. NPT


INLET

5 IN.
(12.7 cm)

1/2 IN. NPT


OUTLET
(TYP. 2 PLACES)

FIGURE 13

1 7/8 IN.
(4.8 cm)

003459

PRESSURE SWITCH WEATHERPROOF


FIGURE 10
003456

TRIPLE TEE
When four nozzles are to fed from a single dry chemical tank, a
triple tee, Part No. 16424, can be used to properly distribute the dry
chemical from the supply line to two branch lines. See Figure 11.
TRIPLE TEE, 1/2 IN. X 1/2 IN. X 1/2 IN. X 3/4 IN. PART NO. 16424

The pressure switch, Part No. 46250, is a DPST (Double-Pole,


Single Throw) pneumatically operated, resettable switch used to
open or close electrical circuits to either shut down equipment or
turn on lights or alarms. The pressure switch is constructed of
malleable iron, painted red. A 1/4 in. NPT pressure inlet is used to
connect the 1/4 in. hose from the actuation line. The switch rating
is 2 HP-240 VAC/480 VAC, 2 HP-250 VDC, 30A-250 VAC/DC,
5A-480 VAC/DC. See Figure 14.
PRESSURE SWITCH PART NO. 46250
MALLEABLE
IRON FINISH
RED PAINT
TO ELECTRICAL
EQUIPMENT TO
BE CONTROLLED

6 IN.
(15.2 cm)

1 7/8 IN.
(4.8 cm)

1/8 IN. NPT

3 5/8 IN.
(9.2 cm)

BRASS RESET
PLUNGER
MOISTURE
PROOF JOINT
GASKET NUT
O RING GASKET

1/2 IN. NPT


OUTLET
(TYP. 4
PLACES)

NAMEPLATE
DOUBLE POLE HEAVY
DUTY TOGGLE SWITCH
WITH FULLY ENCLOSED
BAKELITE BASE
BRASS PISTON

3/4 IN. NPT


INLET

2 1/4 IN.
(5.7 cm)

PISTON O
RING GASKET

TO
POWER
3/4 IN.
ELECTRICAL
CONDUIT OUTLETS

FIGURE 11

1/4 IN. UNION

003462

SAFETY RELIEF VALVE

1/4 IN. ACTUATION


HOSE

2 7/8 IN.
(7.3 cm)

A spring-loaded pressure relief valve, Part No. 15677, is used to


prevent excessive pressure from building up in the actuation line.
The valve is set to relieve at 265 psi (18.3 bar). After system discharge, all pressure in the actuation line can be relieved by
pulling the ring on the safety relief valve. See Figure 12.
SAFETY RELIEF VALVE PART NO. 15677
4 9/16 IN.
(11.5 cm)

1/4 IN. NPT

FIGURE 12

FIGURE 14

000437

000716

S1013

SECTION III SYSTEM COMPONENTS


5-15-02
Page 3-5
REV. 1

PRESSURE SWITCH NON-WEATHERPROOF

NOZZLES

The Electric Pressure Switch, Part No. 8372, is a SPDT (Single


Pole-Double Throw) pneumatically operated, resettable switch to
be used for turning off pump motors, exhaust fans, conveyors and
similar devices; or turning on alarms or electric door closures. The
switch contacts are rated at 15 amp, 125, 250, or 480 VAC, 1/4
hp at 125 VAC, 1/2 hp at 250 VAC or 1/2 amp at 125 VDC, 1/4
amp at 250 VDC. See Figure 15.

Three types of nozzles are approved for use with the A-101/
LT-A-101 system. One type is the F-1/2 nozzle. This nozzle gives
a 180 fan shape pattern and can be used for either total flooding
or local application. The second type of nozzle is the C-1/2. This
nozzle gives a cone pattern and is used for direct application to a
vehicle component or burning surface. The third type of nozzle is
the V-1/2. This nozzle produces a 160 fan shape pattern and is
generally used for screening engine compartments, torque converters and all other hazard areas. All nozzles are constructed of
brass and require protective blow-off caps. Exception: The F-1/2
nozzle can utilize either a blow-off cap or the opening can be
packed with a good grade of extreme temperature silicone
grease, such as Dow Corning No. 4. See Figure 17.

1/2 IN.
COMPRESSION
FITTING

1 3/4 IN.
(4.4 cm)

1/8 NPT

F-1/2 NOZZLE EFFECTIVE DISCHARGE PATTERN PART NO. 16449


33 IN.
(83.8 cm)

1 13/16 IN.
(4.6 cm)

33 IN.
(83.8 cm)

4 3/4 IN.
(12.1 cm)

003469

1 IN.
HEX

15 IN.
(38.1 cm)

5 1/4 IN.
(13.3 cm)

1/2 IN. NPT


PART NO. 16449

V-1/2 NOZZLE EFFECTIVE DISCHARGE PATTERN PART NO. 56748

6 FT.
(1.83 m)

FIGURE 15
000453

Explosion-Proof Pressure Switch DPDT


The Explosion-Proof Pressure Switch, Part No. 43241, is a DPDT
(Double-Pole, Double-Throw) pneumatically operated, resettable
switch to be used for turning off pump motors, exhaust fans, conveyors, and similar devices; or turning on alarms or electric door
closures. The switch contacts are rated at 10 amp at 125 VAC or
5 amp at 250 VAC. The pressure switch is constructed with an
explosion-proof housing suitable for hazardous environments.
The switch operates off the nitrogen pressure from the ANSUL
AUTOMAN release or remote pneumatic actuator.

1 13/16 IN.
(4.6 cm)

4 FT.
(1.22 m)

160

15 IN.
(38.1 cm)

003471

1 IN.
HEX

1/2 IN. NPT


PART NO. 56748

C-1/2 NOZZLE EFFECTIVE DISCHARGE PATTERN PART NO. 53791

6 FT.
(1.83 m)

3/4 IN.
CONDUIT
OUTLET

1/4 IN. UNION


3/8 IN. X 1/4 IN.
BUSHING

1 13/16 IN.
(4.6 cm)

3 FT.
(0.9 m)

7 7/8 IN.
(20 cm)

003724

1 IN.
HEX

1/2 IN. NPT


PART NO. 53791

NAMEPLATE

FIGURE 17

3 9/16 IN.
(9 cm)

2 11/32 IN.
(5.9 cm)
MOUNTING
HOLES

5 5/8 IN.
(14.2 cm)
3/4 IN. CONDUIT
OUTLET

FIGURE 16
000454

S1013

SECTION III SYSTEM COMPONENTS


5-15-02
Page 3-6
REV. 2

NOZZLE BRACKETS
Two styles of nozzle brackets are available for the A-101/LT-A101 system. Each style of bracket is constructed of unpainted
1/4 in. (6.4 mm) steel. They contain pre-punched mounting holes
for the nozzle.
An individual L-shaped bracket-shipping assembly, Part No.
427149, is available. This bracket is 2 in. x 3 in. (51 mm x 76
mm). A second L-shaped bracket (in packs of 12), Part No.
73871, is also available. This L shaped bracket is 2 in. x 2 in.
(51 mm x 51 mm).

SEALED BURST DISC ASSEMBLY


The Sealed Burst Disc Assembly, Part No. 428271, is a machined
brass component containing a stainless steel burst disc inside.
The disc assembly is designed to rupture when the proper expellant gas pressure is built up within the tank. The disc assembly is
part of the agent tank shipping assembly. After tank discharge,
the complete burst disc assembly must be removed, discarded,
and replaced with a new assembly. Replacement assemblies are
available in a 15 pack, Part No. 428363.

A straight bracket (in packs of 4), Part No. 427228, is available.


this bracket is 5 in. x 2 in. (127 mm x 51 mm). See Figure 18.
PART NO. 427228
1 3/32 IN.
(28 mm)
HOLE

2 IN.
(51 mm)

7/8 IN. (22 mm)


HOLE

FIGURE 20
004793

5 IN.
(127 mm)

PART NO. 427149


2 IN.
(51 mm)

PART NO. 73871


1 IN.
(2.5 cm)
7/8 IN. DIA.
(2.2 cm)

7/8 IN.
(2.2 cm)

1 3/32 IN.
(28 mm) HOLE

2 IN.
(51 mm)

1/4 IN.
(0.6 cm)

ENGINE SHUTDOWN DEVICE


The ANSUL Engine Shutdown Device, Part No. 427425, can be
used to pneumatically shut down the vehicle fuel rack by venting
the hydraulic pressure through the safety system. This can be
accomplished by installing the shutdown device in the actuation
line. When the fire suppression system is actuated, the actuation
pressure opens the check valve located in the shutdown device,
allowing the safety system pressure to bleed into the holding
tank. The drop in pressure causes the valves in the fuel rack to
close, thus shutting down the engine. See Figure 21.

2 IN.
(5.1 cm)

2 IN.
(5.1 cm)

2 IN.
(5.1 cm)

3 IN.
(76 mm)
004334

003474

FIGURE 18
HOSE (SUPPLIED BY OTHERS)
To assure proper performance of an A-101/LT-A-101 system, the
hose used must meet SAE 100 R5 or 100 R1 (minimum) hose
specification. For underground mining applications, the hose must
also be accepted by MSHA as flame resistant and marked as follows Flame-Resistant, USMSHA No. _____* at intervals not
exceeding 3 ft. (.9 m). Letters and numbers must be at least 1/4
in. (.6 cm) high and comply all other SAE requirements including
an operating temperature of 65 F to +250 F (54 C to 121
C). (*This number is assigned to the manufacturer after samples
have passed the required tests. The number will be different for
each manufacturer.) See Figure 19.

FIGURE 21
004474

CHECKFIRE ELECTRIC DETECTION AND


ACTUATION SYSTEM
Three styles of electric detection and actuation systems are available: CHECKFIRE Electric Series I, CHECKFIRE Electric SC-N,
and CHECKFIRE Electric MP-N*. Each electric/pneumatic system
consists of detection wiring, control module, actuator with nitrogen
cartridge, mounting bracket, and squib (Series I and SC-N) or gas
motor (MP-N). The CHECKFIRE Electric Series I requires power
from the vehicle battery where as the CHECKFIRE SC-N and
MP-N contains its own internal Lithium batteries as the power
source. All styles of CHECKFIRE electric* are FM Approved when
consisting of all basic components.
* CHECKFIRE MP-N is not FM Approved

The temperature ratings of the system are as follows:


FIGURE 19
003475

CHECKFIRE Series I:
Manual Part No. 54894

40 F to +140 F
(40 C to +60 C)

CHECKFIRE Series SC-N:


Manual Part No. 79061

40 F to +140 F
(40 C to +60 C)

CHECKFIRE Series MP-N:


Manual Part No. 427310

+32 F to +120 F
(0 C to +49 C)

S1013

SECTION IV SYSTEM DESIGN VEHICLE


5-15-02
Page 4-1
REV. 1

HAZARD ANALYSIS
Individuals responsible for the design of an A-101/LT-A-101 system
must be trained and hold a current ANSUL certificate in an A101/LT-A-101 training program. Knowledge of the fire hazards that
exist in the equipment to be protected is also required. Finally, a
good understanding of federal and local fire protection codes and
standards is necessary. No one should begin designing without
previously becoming familiar with the applicable codes.
Having read about the A-101/LT-A-101 system and the basic terminology and operation of the system, you should now begin to
identity the fire hazards in the equipment to be protected. Every
foreseeable hazard must be identified now while you have design
flexibility; once the system is installed, adding protection for
another hazard becomes more difficult. Note that the A-101/LT-A101 system is designed only for the protection of specified equipment for the foreseeable hazards that exist due to that equipment
and its operation. The areas of protection are fixed at installation
and are limited in number. An A-101/LT-A-101 system does not
remove the need for a hand portable fire extinguisher on the
equipment. Fuel spills, welding (repair) heat or other unforeseeable causes may result in fires not having A-101/LT-A-101 protection. The A-101/LT-A-101 system protects the areas with high likelihood of fire and potential for high damage; seldom would an
A-101/LT-A-101 system be designed to protect every square inch
of the equipment to be protected.
An effective system design is based on a through hazard analysis. Fire is made up of heat, fuel, and oxygen. A fire hazard is any
place that these three elements could be brought together.
Because oxygen is always present, identifying fuel and heat
sources is most critical.
Large excavators must be considered special type hazards. See
the Appendix Section for design information or contact ANSUL
Application Engineering Department.
Operator safety is also a concern when designing a fire suppression system. The operator must have enough time to safely exit
the vehicle. In some situations, an extended discharge dry chemical system (not FM Approved) may offer the operator the additional time he needs to get away from the burning vehicle. Consider
egress time when designing the final system. See Appendix
Section for extended discharge and twin agent design information.
Some common fuel sources in vehicles include flammable liquids
and greases, rubber, plastics, upholstery, and environmental
debris such as wood chips or coal dust.
Common vehicle heat sources are engine blocks, exhaust systems, pumps, and turbochargers, as well as bearings, gears,
brakes, and electrical equipment. A potential hazard exists when
a fuel comes in contact with any heat source.
Where there is dripping or leaking fuel, the hazard can become
even more dangerous than initially considered. Consulting with
experienced operators or owners of similar equipment can help to
identify locations of previous fires and special hazards not normally considered as common hazards.
The following are typical vehicle fire hazards that require consideration:
Engine Compartment The engine compartment contains an
assortment of fluids, fuels, oils, and greases, as well as congested wires, hoses, and accumulated debris, all very near high heat
sources.
Battery Compartments Battery compartments are a potential
fire hazard when combustible materials build up on the top of the
battery. These materials, in the presents of moisture, can cause a
short circuit.
Transmissions, Torque Converters, and Parking Brakes All
these components are a possible high heat source that could
cause ignition to combustible material.

High Pressure Hoses Hot fluid spraying from a ruptured high


pressure hose, or leaking from a loose flange or fitting could find
its way to a source of ignition.
Belly Pan The belly pan can accumulate not only leaking fuel
from the vehicle, but external debris, and because of its unique
location, a fire starting in the belly pan could quickly engulf the
entire vehicle.
Hydraulic/Fuel Pumps Because of the high pressures involved
with these pumps, fluid spraying from a leaking pump could find
its way to a heat source and cause ignition.
After completing the hazard analysis, determine nozzle coverages.
NOZZLE COVERAGE AND LOCATION
The first step is to determine which nozzles are needed and
where they should be placed to best protect the hazard.
Nozzle selection can be made by first determining the size of the
hazard and then comparing that to the nozzles effective discharge pattern.
C-1/2 Nozzle Part No. 53791 The cone-shape discharge pattern of the C-1/2 nozzle will widen to a 3 ft. (.9 m) diameter at the
maximum effective discharge range of 6 ft. (1.8 m). See Figure 1.
V-1/2 Nozzle Part No. 56748 The V-1/2 nozzle creates a fanshaped discharge pattern of 160 and has a maximum effective
discharge range of 4 ft. (1219 mm) in length by 15 in. (38.1 cm) in
height with a maximum width of 6 ft. (1.8 m). See Figure 1.
F-1/2 Nozzle Part No. 16449 The F-1/2 nozzle also produces a
fan-shaped discharge pattern, but with a 180 pattern at a maximum effective range of 33 in. (83.8 cm) in length by 15 in.
(38.1 cm) in height with a maximum width of 5 ft. 6 in. (1.7 m) See
Figure 1.
C-1/2 NOZZLE
6 FT.
(1.83 m)

3 FT.
(0.9 m)
V-1/2 NOZZLE

003724a

6 FT.
(1.83 m)

160

4 FT.
(1.22 m)

15 IN.
(38.1 cm)
003471a

F-1/2 NOZZLE
33 IN.
(83.8 cm)
33 IN.
(83.8 cm)
180
15 IN.
(38.1 cm)

33 IN.
(83.8 cm)

003476

FIGURE 1

S1013

SECTION VII INSPECTION


6-30-05
Page 7-1
REV. 3

Inspection is a quick check that the system is operable. It is


intended to give reasonable assurance that the system is fully
charged and will operate. This is done by seeing that the system
has not been tampered with and there is no obvious physical
damage, or condition, to prevent operation. The value of an
inspection lies in the frequency, and thoroughness with which it is
conducted.
Inspection frequency shall be performed monthly, or sooner,
depending on operating and/or environmental conditions.
To provide reasonable assurance that your ANSUL A-101/LT-A101 system is charged and operable:
1. Note general appearance of system components for mechanical damage or corrosion.
2. Check all hose to make certain it is securely fastened and not
cut or show signs of abrasion.
3. Make certain all hose fittings are tight.
4. Make certain the nozzles are correctly aimed, openings are
clean and not obstructed and the blow off caps are properly
installed. NOTE: Blow off caps must be replaced annually.
5. Check nameplate(s) for readability and make certain they are
properly attached.
6. The automatic detection system should be inspected as follows: If system is equipped with a CHECKFIRE SC-N or
MP-N electric automatic detection system, make certain
green Power LED is blinking. If system is equipped with a
CHECKFIRE Series I, push button on top of module and note
illumination of indicator light. If the system is equipped with a
CHECKFIRE Series II, push and hold the test/control button
momentarily. The internal alarm will sound and the two outside LEDs will flash. If system is equipped with a CHECKFIRE pneumatic detection system, make certain yellow Low
Pressure indicator light is not on.
7. Check to make certain hazard size or components being protected have not changed since original installation.
8. If there are any broken or missing lead and wire seals, or any
other deficiency is noted, immediately contact the authorized
ANSUL Distributor.
9. Keep a permanent record of each inspection.

S1013

SECTION VIII MAINTENANCE


6-30-05
Page 8-1
REV. 3

Maintenance is a thorough check of the system. It is intended to


give maximum assurance that the system will operate effectively
and safely. It includes a thorough examination and any necessary
repair or replacement. It will normally reveal if there is a need for
hydrostatic testing of the tank.
Maintenance shall be performed semi-annually or sooner,
depending on operating and/or environmental conditions. The fire
suppression system including alarms, shutdown and associated
equipment shall be thoroughly examined and checked for proper
operation by the fire protection manufacturer, authorized distributor or their designee in accordance with this manual.
SEMI-ANNUAL MAINTENANCE
To provide maximum assurance that your ANSUL A-101/LT-A-101
system will operate effectively and safely:
1. Check to see that the hazard has not changed.
2. Remove all cartridges, install safety shipping caps, and put in
a safe place for future reinstalling.
3. Note the general appearance of the system components
checking for mechanical damage or corrosion, and check that
the components are securely fastened and all hose fittings
are tight.
4. Check nameplates to make certain they are clean, readable,
and properly attached.
5. Remove tank fill cap(s) and check that the agent tank is filled
to approximately 3 in. (76 mm) from the bottom of the fill
opening with ANSUL FORAY dry chemical. Check the dry
chemical for lumps.If lumps are present, drop one from a
height of 4 in. (102 mm) onto a hard surface. If the lump does
not break up completely, the dry chemical must be replaced.
6. Inspect threads on fill cap and on tank fill opening for nicks,
burrs, or cross-threading.

Using a wooden dowel, push pin assembly and spring out


of the actuator body.
Remove the gasket from inside the cartridge thread port.
Inspect, clean, apply a good grade of low temperature
grease, such as Dow Corning No. 4, and reinstall the gasket. Replace if necessary.
Remove the O-Rings from the pin assembly and swivel
adaptor. Inspect, clean, apply a good grade of low temperature grease, such as Dow Corning No. 4, and reinstall the
O-Rings. Replace if necessary.
Apply a small amount of grease to the puncture pin shaft.
There is a U-Cup guide inside the actuator body and when
the pin is reinstalled into the body, the grease on the shaft
will lubricate the U-Cup.
Clean the inner surface of the actuator body and, using a
small diameter wire, clean the vent hole. Make certain not
to scratch the inner surface.
To minimize the potential of moisture or dirt entering the
actuator, apply a thin coat of a good grade of extreme
temperature silicone grease, such as Dow corning No. 4
or equal, over the vent hole.
Reinstall spring onto puncture pin shaft and insert into
actuator body. Push pin down several times to allow
grease to coat U-Cup. When positioned back in body,
make certain the tip of the pin is above the gasket in the
bottom of the actuator.
Reinstall the actuator unto the cartridge. Hand tighten.
Reinstall swivel adaptor in the correct position for the actuation lines and wrench tighten the swivel nut. Make certain
all actuation and expellant lines are properly tightened into
the actuator.
Secure the assembly into the bracket.

7. Check fill cap gasket and quad ring for elasticity, cuts, or
checking, and lightly coat them with an extreme temperature
silicone grease, such as Dow Corning No. 4 or equal.

SWIVEL NUT,
PART NO. 430210

8. Disconnect sealed bursting disc assembly.


9. Examine the disc to ensure that it is not wrinkled, kinked,
dented, or deformed in any way and then apply a thin coat of
a good grade of extreme temperature silicone grease, such
as Dow Corning No. 4 or equal, to the male threads and
reconnect the sealed burst disc assembly. NOTE: Before
reconnecting, if needed, blow all lines clear with dry air or
nitrogen.
10. Check that the nozzle openings are not obstructed and that
the nozzles are properly aimed and have not rotated out of
position.
11. Make certain each nozzle has a blow-off cap (the opening of
an F-1/2 nozzle can be packed with an extreme temperature
silicone grease, such as Dow Corning No. 4 or equal, to
avoid build-up of foreign material) and check that the caps
are pliable and free of cuts and checks. NOTE: Blow off caps
must be replaced annually.
12. Unscrew the pneumatic actuator(s) from the cartridge receiver(s) and inspect all threaded areas for nicks, burrs, and
cross threads.

SWIVEL ADAPTOR,
PART NO. 430209

O-RING #119,
PART NO. 24899

SLAVE PISTON,
PART NO. 56749

O-RING #210,
PART NO. 5151

PUNCTURE PIN,
PART NO. 56104

SPRING,
PART NO. 56105

BODY,
PART NO. 430215

VENT HOLE

13. Clean actuator(s) (Part No. 430221) as follows: (see Figure1)


Using two wrenches, one positioned on the swivel nut, and
one positioned on the bottom portion of the actuator,
loosen the swivel nut and remove the top portion of the
actuator.

GASKET,
PART NO. 181

FIGURE 1
006195

S1013

SECTION VIII MAINTENANCE


6-30-05
Page 8-2
REV. 2

SEMI-ANNUAL MAINTENANCE (Continued)


14. Weigh the gas cartridge which was removed earlier. It must
be +/ 1/2 oz. from the weight stamped on the cartridge.
Weigh cartridge with shipping cap removed.
15. Hand tighten the cartridge into the actuator.
16. Next, remove the gaskets from the manual remote actuators.
Examine them for elasticity, cuts, and checking and lubricate
them with a light coat of extreme temperature silicone grease,
such as Dow Corning No. 4 or equal.
17. Inspect the threaded areas for nicks, burrs, or cross threading
and clean them with a stiff bristle brush.
18. Make certain cartridge is removed. Pull the ring pin and operate the manual actuator to test the puncture lever for free
movement.
19. Next, remove the puncture pin by disassembling the actuator
and examine the pin to ensure it is sharp, straight, free of corrosion.
20. Lubricate the puncture pin O-ring and reassemble the actuator.
21. Insert ring pin and install visual seal, Part No. 197, to each
actuator stem.
22. Weigh each actuator cartridge. Weight must be +/ 1/4 oz.
from weight stamped on cartridge. Weight cartridge with shipping cap removed.
23. Install cartridge into each remote actuator. Hand tighten.
24. Refer to appropriate manual for detailed maintenance instructions if the system contains an automatic CHECKFIRE
Detection System.
25. After all actuation devices are re-armed, record date of maintenance and inform personnel that the system is back in
operation.
12-YEAR MAINTENANCE EXAMINATION
At the 12-year maintenance examination, along with completing
the semi-annual maintenance requirements, some A-101 components require hydrostatic testing.
The components requiring hydrostatic testing are:
Tank 600 psi (40.8 bar) hydro pressure.
Actuation hose 1000 psi (69 bar) hydro pressure
Cartridges After properly discharging cartridge, return to
ANSUL for hydrotesting
See appropriate hydrotest requirements in NFPA 17, Standard
For Dry Chemical Extinguishing Systems, and Ansul Technical
Bulletin No. 50, Hydrostatic Retest Requirements for Ansul portables, Wheeled Units, and Pre-Engineered Vessels, Form No.
F-81301.

S1013

SECTION IX RECHARGE
6-30-05
Page 9-1
REV. 3

The first concern in Recharge is to determine the cause of the


system discharge and to have the problem corrected before rearming the fire suppression system.

6. Remove the tank fill cap, discard any remaining dry chemical,
and fill each tank to its rated capacity with ANSUL FORAY dry
chemical as specified on the nameplate.

In the event of system discharge, the vehicle must not be


returned to service until the system has been recharged.

7. Check inside of tank for any signs of corrosion. Check for any
signs of moisture and/or chemical caking. Make certain gas
tube and rubber check are securely in place.

The system must be recharged immediately after use. A fire condition could cause damage to the hose and nozzles and possibly
support members. Check all hose supports, hose, and all fitting
connections. Take the nozzles off, inspect for damage, corrosion,
or obstructions, clean and re-install, making certain they are
aimed correctly. Blow-off caps must also be replaced.
See Figure 1 when following the recharge steps.

8. Before securing the fill cap, brush the dry chemical from the
threads on the fill cap and tank, and clean the gasket seating
surface on the tank opening. Coat the gasket lightly with a
good grade of extreme temperature silicone grease, such as
Dow Corning No. 4 or equal.
9. Secure the fill cap, hand tighten.
10. Loosen the bolts on the expellant gas cartridge bracket or
remove the cartridge guard on the tank.

15 17
2 11 18

15 17

11. Unscrew and remove the empty expellant gas cartridge.


12. Disassemble and clean the cartridge actuator by following the
instructions stated in Step No. 13, Section VIII
Maintenance.

16
8

16

9 10 12 13
6
3

13. Install new cartridge per the following chart. Before installing,
weigh cartridge to determine if it is within specifications
stamped on the cartridge. Weigh cartridge with shipping cap
removed.
Type of System

Cartridge Part No.

A-101-10
LT-A-101-10
A-101-20
LT-A-101-20
LT-LP-A-101-20
A-101-30
LT-A-101-30

15850 (DOT)
423439 (TC/DOT)
423429 (TC/DOT)
423441 (TC/DOT)
423435 (TC/DOT)
423435 (TC/DOT)
423443 (TC/DOT)
423491 (TC/DOT)

14. Re-install cartridge guard or retaining bolts on cartridge


bracket.
15. Return tank(s) to its bracket, reconnect sealed burst disc
assembly to distribution hose, and tighten securely.
16. Depending on the type of manual actuator, either pull up the
red button or pull up the puncture lever.

14 5

17. Remove spent cartridge. Weigh fully charged LT-10 cartridge.


Make certain cartridge is within +/ 1/4 oz. (7.1 g) from weight
stamped on cartridge. Install cartridge.
NOTICE
If automatic detection system was used, refer
to appropriate Installation, Recharge Manual for
detailed recharge instructions.
FIGURE 1
003519

1. Pull ring on safety relief valve to relieve actuation pressure.


2. Disconnect actuation system hose at cartridge receiver/actuation assembly.
3. Open sealed burst disc assembly.
4. Remove dry chemical tank from its bracket.
5. Replace ruptured sealed burst disc assembly. Remove used
sealed disc assembly from tank outlet. Clean tank threads.
Apply a non-permanent thread sealant or Teflon tape to male
threads on new sealed burst disc assembly. Install to tank outlet. Wrench tighten. NOTE: Before reconnecting, if needed,
blow all lines clear with dry air or nitrogen.

18. Insert ring pin in actuator stem and seal with visual seal, Part
No. 197.
19. Reconnect actuation and, if necessary, expellant gas hose.
Wrench tighten.
20. Notify operating personnel that the suppression system is
back in service and record date of recharge.

S1013

SECTION XI APPENDIX
5-15-02
Page 11-1
REV. 1

SYSTEM COMPONENT INDEX


BASIC UNIT
16559

A-101-10 Includes: Agent Tank, Tank Mounting


Bracket, 101-10 Cartridge

16430

A-101-20 Includes: Agent Tank, Tank Mounting


Bracket, 101-20 Cartridge

16131

A-101-30 Includes: Agent Tank, Tank Mounting


Bracket, 101-30 Cartridge

31581

LT-A-101-10 Includes: Agent Tank, Tank Mounting


Bracket, LT-20-R Cartridge

24306

LT-A-101-20 Includes: Agent Tank, Tank Mounting


Bracket, LT-30-R Cartridge, Cartridge Bracket, and
Pneumatic Actuator

53003

LT-A-101-30 Includes: Agent Tank, Tank Mounting


Bracket, (Does Not Include Cartridge, Cartridge
Bracket or Pneumatic Actuator)

24883

LT-A-101-30 Cartridge, Cartridge Bracket, and


Pneumatic Actuator for LT-A-101-30 Unit

31344

LP-A-101-20-B Includes: Agent Tank, Tank Mounting


Bracket, 101-20 Cartridge, Cartridge Bracket, and
Pneumatic Actuator

24307

LT-LP-A-101-20-B Includes: Agent Tank, Tank


Mounting Bracket, LT-30-R Cartridge, Cartridge
Bracket, and Pneumatic Actuator

ACTUATION DEVICE
70584

Remote Manual Actuator Package Includes: LT-10-L


(Left Hand) Cartridge, S Bracket, Elbow, Check
Valve, Seal, Operating Instruction Labels and
Installation Instructions

71699

Remote Manual Actuator Package Includes: LT-10-L


(Left Hand) Cartridge L Bracket, Elbow Check Valve,
Seal, Operating Instruction Labels and Installation
Instructions

57484

Remote Manual Actuator Package Includes: LT-10-R


(Right Hand) Cartridge, S Bracket, Elbow, Check
Valve, Seal, Operating Instruction Labels and
Installation Instructions

71804

Remote Manual Actuator Package Includes: LT-10-R


(Right Hand) Cartridge, L Bracket, Elbow, Check
Valve, Seal, Operating Instruction Labels and
Installation Instructions

70581

Remote Manual Actuator for LT-10-L (Left Hand)


Cartridge Only

57452

Remote Manual Actuator for LT-10-R (Right Hand)


Cartridge Only

57661

S Type Mounting Bracket for Dashboard Actuator,


Part No. 70581 and 57452

70580

L Type Mounting Bracket for Remote Manual


Actuator, Part No. 70581 and 57452

32747

Remote Actuator Package, Cartridge Guard Type (Left


Hand) Includes: Actuator, LT-10-L Cartridge, Check
Valve, Operating Instruction Labels, Lead Wire Seal

32739

Remote Actuator Package, Cartridge Guard Type


(Right Hand) Includes: Actuator, LT-10-R Cartridge,
Check Valve, Operating Instruction Labels, Lead Wire
Seal

16033

Operating Instruction Labels for Manual Actuator


Includes: Nameplate IN CASE OF FIRE 1. SHUT
OFF ENGINE 2. PULL RING PIN 3. PUSH LEVER

16459

Operating Instruction Labels for Manual Actuator


Includes: Nameplate IN CASE OF FIRE 1. SHUT
OFF POWER 2. PULL RING PIN 3. STRIKE BUTTON

DISTRIBUTION TEES
53036

Distribution Tee Package Includes: 4 Distribution Tees

25031

Distribution Tee

53038

Triple Tee Package Includes: 2 Triple Tees

16424

Triple Tee

53040

Reducing Tee Package Includes: 2 Reducing Tees


(1/2 in. x 1/2 in. x 3/4 in.)

4655

Reducing Tee (1/2 in. x 1/2 in. x 3/4 in.)

419695

Y Lateral

NOZZLES
57046

C-1/2 Nozzle Package Includes: 4 Nozzles, 4 Nozzle


Brackets, 4 Blow-Off Caps and 8 Lockwashers

57044

V-1/2 Nozzle Package Includes: 4 Nozzles, 4 Nozzle


Brackets, 4 Blow-Off Caps and 8 Lockwashers

53042

F-1/2 Nozzle Package Includes: 4 Nozzles, 4 Nozzle


Brackets, 4 Blow-Off Caps and 8 Lockwashers

53791

Nozzle C-1/2 Includes: Nozzle, Blow-Off Cap

56748

Nozzle V-1/2 Includes: Nozzle, Blow-Off Cap

16449

Nozzle F-1/2 Includes: Nozzle Only

415192

Blow-Off Cap With Retaining Strap Package Includes:


50 Blow-Off Caps (Part No. 415108) For V-1/2 and
C-1/2 Nozzle Only

73870

Blow-Off Cap Package: Includes: 50 Blow-Off Caps,


Part No. 4120, For F-1/2 Nozzle

73871

Nozzle Bracket Package: Includes: 12 Brackets,


2 in. x 2 in. Angle

427149

Nozzle Bracket, 2 in. x 3 in. Angle

427228

Nozzle Bracket, Straight 5 in. x 2 in., 4 Brackets

73872

Nozzle Lockwasher Package: Includes: 50 Lock


washers, Part No. 25581

ACTUATION LINE DEVICES


15677

Safety Vent Relief Valve

53050

Safety Vent Relief Valve Package Includes: 2 Safety


Vent Relief Valves

53051

1/4 in. Check Valve (Package of 2)

57488

LT and LP Model Pneumatic Actuator Assembly

16408

A-101 Pneumatic Actuator with Cartridge Receiver


Assembly

31579

LT-A-101-10 Pneumatic Actuator Assembly

8372

Pressure Switch (Shutdown)

46250

Pressure Switch, Weather Proof, DPST (shutdown)

427425

Engine Shutdown Device

S1013

SECTION XI APPENDIX
5-15-02
Page 11-2
REV. 2

SYSTEM COMPONENT INDEX (Continued)


SYSTEM TANKS
24855

A-101-10 Includes: Charged Agent Tank with Cartridge

24970

A-101-20 Includes: Charged Agent Tank with Cartridge

53000

A-101-30 Includes: Charged Agent Tank with Cartridge

24966

LT-A-101-10 Includes: Charged Agent Tank with


Cartridge

24894

LT-A-101-20 Includes: Charged Agent Tank without


Cartridge

SYSTEM CARTRIDGES
15850

A-101-10 Cartridge (DOT)

423439

A-101-10 Cartridge (TC/DOT)

423441

A-101-20, LP-A-101-20-B Cartridge (TC/DOT)

423443

A-101-30 Cartridge (TC/DOT)

423429

LT-A-101-10 Cartridge (TC/DOT)

423435

LT-A-101-20 and LT-LP-A-101-20-B Cartridge


(TC/DOT)

423491

LT-A-101-30 Cartridge (TC/DOT)


LT-10-R Cartridge (DOT)

29375

LT-A-101-30 Includes: Charged Agent Tank without


Cartridge

13193
423423

LT-10-R Cartridge (TC/DOT)

24427

LP-A-101-20-B Includes: Charged Agent Tank without


Cartridge

13177

LT-10-L Cartridge (DOT)

24425

LT-LP-A-101-20-B Includes: Charged Agent Tank


without Cartridge

423425

LT-10-L Cartridge (TC/DOT)

SYSTEM BRACKETS
24854

A-101-10, LT-A-101-10 Tank Mounting Bracket (1)

24971

A-101-20 Tank Mounting Bracket (1)

14098

A-101-30 Tank Mounting Bracket (1)

24910

A-101-30 Tank Mounting Bracket (1) (Extra Heavy)

24895

LT-A-101-20 Tank Mounting Bracket (1)

30494

LT-A-101-30 Tank Mounting Bracket (1)

31171

LP-A-101-20-B, LT-LP-A-101-20-B Tank Mounting


Bracket (1)

31177

Cartridge Bracket Assembly for LP-A-101-20-B

24325

Cartridge Bracket Assembly for LT-A-101-20 or


LT-LP-A-101-20-B

29193

Cartridge Bracket Assembly for LT-A-101-30

RECHARGE EQUIPMENT AND MATERIAL


53080

FORAY Multi-Purpose Dry Chemical 45 lb. Pail

16511

Fill Cap Spanner Wrench (Low Profile)

428363

Bursting Disc Package (Includes: 15 Bursting Disc


Assemblies, Part No. 428271)

75382

Cartridge Scale and Hook Assembly (LT-A-101-30)

3923

Cartridge Scale and Hook Assembly

197

Lead Wire Seal

15496

Bursting Disc Union Assembly

24327

A-101 Installation, Recharge, Inspection and


Maintenance Manual

53081

Owners Manual

FOR SYSTEM COMPONENT INDEX FOR THE CHECKFIRE


AUTOMATIC DETECTION AND ACTUATION SYSTEMS, SEE
THE FOLLOWING INSTALLATION MANUALS:
CHECKFIRE MP-N ELECTRIC SYSTEM Manual Part No.
427310
CHECKFIRE SC-N ELECTRIC SYSTEM Manual Part No.
423522
CHECKFIRE ELECTRIC SERIES I SYSTEM Manual Part
No. 54894

S1014

006052

CHECKFIRE SC-N ELECTRIC


DETECTION & ACTUATION SYSTEM

Installation, Recharge, Inspection, and Maintenance Manual

S1014

This manual is intended for use with the CHECKFIRE SC-N


Electric Detection and Actuation System.
Those who install, operate, inspect, or maintain this system
should read this entire manual. Specific sections will be of particular interest depending upon ones responsibilities.
As with all electro-mechanical equipment, the electric detection
and actuation system needs periodic care to provide maximum
assurance that it will operate effectively and safely. Inspection frequency shall be performed monthly, or sooner, depending on
operating and/or environmental conditions. Maintenance shall be
performed semi-annually, or sooner, depending on operating
and/or environmental conditions.
The application and use of the CHECKFIRE SC-N system is limited to the application and uses described in this manual. For
other applications, contact your local ANSUL distributor or the
ANSUL technical representative in your area.

ANSUL and CHECKFIRE are trademarks of Ansul Incorporated or its affiliates.

NOTICE: Some sections have been removed by Getman as they do not


apply to your application needs. Any questions please call Getman
Corporation directly.

S1014

SECTION

PAGES

SECTION

SAFETY PRECAUTIONS

IN CASE OF FIRE

26

TOTAL SYSTEM DESCRIPTION

23

RECHARGE

27

SYSTEM COMPONENTS
Control Module
Manual/Automatic Actuator
LT-10-R Cartridge
Mounting Brackets
Splicing Device
Linear Detection Wire
Thermal Spot Detector
Pneumatic/Linear Detector
Triple IR (IR3) Flame Detector
Squib
Squib Cable
Battery
End of Line Resistor
Check Valve
Remote High Level Alarm
Release Circuit Test Module

37
3
3
3
4
4
4
4
5
56
6
6
6
6
7
7
7

INSPECTION AND MAINTENANCE


Daily Inspections
Maintenance

28 29
28
28 29

USER INTERFACE
Field Terminations
Front Panel Indicators
Power Connections
Front Panel Buttons
Battery Replacement
Enclosure
Cover Removal
Strain Relief Installation
Mounting

8 10
8
9
10
10
10
10
10
10
10

PAGES

TROUBLESHOOTING
Diagnostics
History Buffer
Troubleshooting Table

30 33
30
30
31 33

APPENDIX
Component Index
Detection Wire Fluid Resistance Capability

39 41
39 40
41

S1014

SAFETY PRECAUTIONS
9-1-98
Page 1

SAFETY PRECAUTIONS
For the protection of personnel and equipment being installed, this
manual contains WARNING and CAUTION statements which are
listed in the steps which they apply. These warnings and cautions
are also listed here so that the manual user can become familiar
with them before performing any procedures.

WARNING

In case of fire, evacuate area to lessen the risk of injury from


flames, heat, hazardous vapors, explosions, or other hazards
that may be created.

WARNING

The squib is an explosive device. Do not attach connector until


squib is installed in actuator body. If the squib is actuated outside of the actuator body, possible personal injury could result.

CAUTION

Manual pneumatic actuation will result in immediate system


discharge which may obscure vision. Make certain vehicle is
stopped safely before manually actuating the system. Manual
actuation will bypass all auxiliary shutdown and alarm
functions.

CAUTION

The fire suppression system could be accidentally actuated


causing the release of agent if the squib or nitrogen cartridge
is installed before the appropriate installation step is reached.

CAUTION

The control module could be damaged and the fire suppression system may not operate if the squib spring (shunt) is not
removed before installing the squib connector.

CAUTION

The fire suppression system will discharge dry chemical if the


cartridge is installed when operating the strike button. Do not
install cartridge unless puncture pin is fully retracted with ring
pin inserted and visual inspection seal installed.

CAUTION

Discharged lithium batteries may contain significant amounts


of unused energy and should be handled with care. Do not
compact for disposal. Before disposal, each battery must be
fully discharged and electrically isolated by enclosing in a plastic bag and sealing the bag. Do not dispose of in fire. Check
applicable solid waste disposal regulations for proper disposal
of more than one battery.

S1014

TOTAL SYSTEM DESCRIPTION


7-1-03
Page 2
REV. 2

TOTAL SYSTEM DESCRIPTION


The complete CHECKFIRE SC-N system is composed of components which are combined to provide automatic fire detection and
actuation for equipment hazard areas. The electric detection and
actuation system is designed for use only with ANSUL fire suppression systems requiring pneumatic input as a means of actuation. In addition to the mechanical pneumatic means of operating
the suppression system, the CHECKFIRE SC-N also provides an
automatic and manual electric means to perform the same
function.
The CHECKFIRE SC-N system is typically used with an ANSUL
A-101 Vehicle Fire Suppression system for 24-hour protection of
equipment. The system is particularly suited for the protection of
equipment that is subjected to extreme environmental and physical conditions such as vehicles used in forestry, mining, agriculture, construction, public transportation, public utilities, land fill,
and waste disposal.
Some of its features include linear (wire) and/or spot (thermal),
flame detection, supervised circuitry, internally powered,
adjustable shutdown and discharge time delays, auxiliary relays,
and one-button operation.
CHECKFIRE SC-N Electric Detection and Actuation System consists of the following components:
1. Control Module
2. Manual/Automatic Actuator
3. Mounting Bracket
4. Detection Wire
5. Thermal Detectors
6. Pneumatic/Linear Detection
7. Triple IR (IR3) Flame Detector
8. Squib (not shown)
9. LT-10-R Cartridge
10. Check Valve (not shown)
11. Remote High Level Alarm (not shown)
12. Squib Circuit Test Module (not shown)
2

The control module can be used as a self contained system, powered by its own internal lithium battery. This allows the detection
system to operate around-the-clock without use of external power.
Optionally, external power can be connected to the control module
with the internal power also connected, which results in a system
with battery back-up. When connected to an external 12/24 VDC
supply with the internal battery also connected, the external power
source becomes the primary supply, while the internal power
source is maintained in a stand-by mode of operation.
The control module may be installed where the ambient temperature is between 40 F to 140 F (40 C to 60 C).
The CHECKFIRE SC-N Detection and Actuation System is listed
by FM Approvals.
Circuits
The first initiating circuit is the supervised detection circuit
designed to be connected to linear (wire) and/or spot type thermal
detectors that provide a contact closure input to initiate a fire
detected condition. The second initiating circuit is designed to
accept a contact closure type of actuating device such as an electric manual pull station or a pressure switch. The initiating circuits
are low impedance and designed to eliminate nuisance alarms
associated with contact bounce.
Two field programmable time delays provide timing of shutdown
and release functions associated with the operation of the detection and electric manual pull/ pressure switch initiation circuits.
1) DETECTION INITIATING CIRCUIT
The detection circuit consists of two time delays:
The first time delay is field programmed to assign the time
between alarm (initiation of the detection circuit) and the operation of the shutdown relay. The first time delay is field programmable for 5, 10, 20, or 30 seconds.
The second time delay is field programmed to assign the time
between the completion of the first time delay (when the shutdown relay operates) and the operation of the release circuit.
The second time delay is field programmable for 0, 10, 20, or
30 seconds.
2) ELECTRIC MANUAL PULL/PRESSURE SWITCH FEEDBACK INITIATING CIRCUIT

The second initiating circuit is field programmable to be used


as either an electric manual pull or pressure switch feedback
circuit. If selected as an electric manual pull circuit, its operation will override the first time delay function and initiate a second time delay condition, causing the shutdown relay to
immediately operate and system release to occur upon completion of the second time delay. Additionally, the control module can be field programmed to shorten the second time delay
when a manual actuation occurs. The time delay options
available with the electric manual actuation are 0, 10, 20, and
30 seconds, with the condition that it can only be less than or
equal to the programmed time delay of the detection circuit.

4
6

5
002998

Selection of the second initiating circuit as a pressure switch


feedback circuit will result in the operation of the alarm relay
and shutdown relay immediately upon receiving the signal.
The release circuit will not be initiated from this feedback circuit because the system will already have been pneumatically actuated from the manual pneumatic actuator.
When this initiating circuit has operated, the Alarm and
Release LEDs, along with the audio sounder, will pulse until
the pressure switch is reset and then the control panel is reset.

S1014

SYSTEM COMPONENTS
8-1-02
Page 3
REV. 1

TOTAL SYSTEM DESCRIPTION (Continued)


Circuits (Continued)
3) A DELAY button is available for the operators use. Operation
of the DELAY button will restart the first time delay cycle if
initiated while the first time delay is active. Once the second
time delay has started, operation of the DELAY button has
no affect. The DELAY button also serves the dual function of
silencing the auxiliary alarm relay. The silence function is only
effective 30 seconds or more after release or pressure switch
feedback operation has occurred.
CONTROL MODULE
The Control Module, Part No. 423504, is the basis of the
CHECKFIRE SC-N detection system. The module cover and back
box is made of durable Noryl SE1gfN3 material with a flammability rating of UL94 V-1. The back box contains the field interface terminal block, battery, and field wiring entrance ports. The cover
assembly contains the control PC board assembly, sounder, operator interface panel, and environmental seal. The enclosure meets
International Standard IEC 529 requirements for dust and water
spray in all directions. Mounting pads allow mounting to any suitable flat surfaces. Steel mounting brackets are also available.
All circuitry, relays, switches, and LEDs are contained on a single
PC board. A board mounted receptacle mates with the plug-in terminal block mounted in the back box. A high pitch sounder is
threaded into the cover and plugged into the PC board. The PC
board is encapsulated to provide added protection against moisture and dust. An RS232 interface cable connector is provided for
field programming from a PC and for data retrieval from a trouble
and alarm history buffer. The PC board assembly contains a DIP
switch for optional manual programming functions without the use
of a PC. See Figure 1.

MANUAL/AUTOMATIC ACTUATOR
The manual/automatic actuator, Part No. 24479, provides a manual and automatic means of fire suppression system actuation. By
pulling the ring pin and striking the red button, manual system actuation can be accomplished. The system is automatically actuated
by use of a squib. When the detection circuit is activated, the control module will direct the electrical current to the squib, causing it
to actuate. The pressure generated from the squib actuation forces
the puncture pin down automatically.
A 1/4 in. NPT street elbow is supplied with the actuator for convenient connection of the 1/4 in. actuation line to the fire suppression
system. See Figure 2.
STRIKE
BUTTON
RING
PIN

1/4 IN. NPT TO


ACTUATION
LINE

SQUIB
PORT

FIGURE 2
000850

LT-10-R CARTRIDGE
The LT-10-R cartridge is a pressure vessel that is factory-filled with
nitrogen to 1800 psi at 70 F (124 bar at 21 C). The cartridge is
installed in the manual/automatic actuator and provides the pressure required to actuate the connected fire suppression system.
Cartridges requiring DOT (Department of Transportation) approval
only can be ordered as Part No. 13193. Cartridges requiring DOT
and TC (Transport Canada) approval can be ordered as Part No.
423423. Following operation, the cartridge must be replaced. See
Figure 3.
SAFETY
SHIPPING CAP

CARTRIDGE

FIGURE 1
002755

FIGURE 3
000851

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SYSTEM COMPONENTS
6-30-05
Page 4
REV. 2
MOUNTING BRACKETS
The CHECKFIRE SC-N Detection and Actuation System offers
three types of steel mounting brackets.
The first type, Part No. 423525, is a combined bracket for mounting the control module and the pneumatic actuator together. See
Figure 4.
The second type, Part No. 423528, is an individual bracket for
mounting the control module separate from the pneumatic actuator. Note: When ordering this bracket, it is also necessary to order
the pneumatic actuator bracket, Part No. 419772. See Figure 4.
The third type, Part No. 423531, is a retrofit bracket for mounting
a SC-N module to any existing CHECKFIRE bracket except
CT/CT + G. See Figure 4.
All brackets can be fastened by either bolting or welding. Brackets
are painted with red enamel paint.

COMBINED BRACKET
PART NO. 423525

RETROFIT BRACKET
PART NO. 423531

002756

002757

STRAIN RELIEF,
PART NO. 423546
LINEAR
DETECTION
WIRE

3/8 IN.
(1 cm)

LINEAR
DETECTION
WIRE

SPLICE BODY,
PART NO. 426783

SPLICE
BLOCK,
PART NO.
433284

STRAIN RELIEF,
PART NO. 423546
LINEAR
DETECTION
WIRE

LINEAR
DETECTION
WIRE

OVERLAP
CONDUCTORS
UNDER SCREW
TERMINALS

3/4 IN.
(2 cm)

FIGURE 5
000854

LINEAR DETECTION WIRE


The linear detection wire consists of two spring steel conductors
which are separated by a heat-sensitive insulator. At the temperature rating of the wire, 356 F (180 C), the insulator melts, allowing the two conductors to make contact. This contact provides
electrical continuity between the two conductors. The linear detection wire is supplied in lengths of 100 ft. (30.5 m), Part No. 71230,
or 500 ft. (152.4 m), Part No. 71231, and must be ordered separately. See Figure 6.

INSULATED
SPRING STEEL
CONDUCTORS

FIGURE 6
000855

THERMAL SPOT DETECTOR


Thermal detectors are normally open, contact closure devices.
The fixed temperature design of these detectors will cause the
contacts to close when the temperature of the surrounding air
reaches the set point temperature of the detector. See Figure 7.

MODULE BRACKET
PART NO. 423528

ACTUATOR BRACKET
PART NO. 419772

002758

000852

FIGURE 4
SPLICING DEVICE
The In-Line Splice Kit, Part No. 428375, is required for detection
wire connection between the control module and the linear detection wire or between separate pieces of linear detection cable.
When the splicing device is used in the system, special sealing
compound is required to make a proper seal. The kit consists of
the necessary number of components to assemble 10 complete
assemblies. See Figure 5.

MOUNTING
BRACKET,
PART NO.
416221

CABLE CLAMP
WITHOUT PROTECTIVE
TUBING, PART NO.
416762
CABLE CLAMP WITH
PROTECTIVE TUBING,
PART NO. 416214

SPOT
DETECTOR

FIGURE 7
000856

Thermal detectors are available in three preset temperatures as


shown below. Each temperature rating is stamped on the detector.
Rated
Maximum
Operating
Continuous
Temperature
Use Temperature
Detector
(C)
F
(C)
Color
Part No.
F
270 (132)
234 (112)
Blue
416218
325 (163)
280 (137)
Red
416219
360 (182)
312 (155)
Red
416220

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SYSTEM COMPONENTS
7-1-03
Page 5
REV. 1

PNEUMATIC/LINEAR DETECTOR
The pneumatic/linear detector, Part No. 416113, consists of 35 ft.
(10.7 m) of gas filled stainless steel tubing connected to a small
pressure responder. When the gas in the tubing heats up, the
increase in pressure operates the responder, thus closing the
detection circuit of the control module. The pneumatic/linear detector will operate at a temperature of 900 F (482 C) over 12 in.
(31 cm) or 300 F (149 C) over the total length. The detector
assembly connects to the control module by means of a special
wire assembly which is supplied with the detector assembly. See
Figure 8.

DETECTOR
TUBE

TRIPLE IR (IR3) FLAME


DETECTOR, PART NO. 432035

SWIVEL BRACKET,
PART NO. 432300

FIGURE 9
006829

STARTER JUNCTION/CABLE ASSEMBLY (TRIPLE IR (IR3))


The Starter Junction/Cable Assembly, Part No. 432477, is used
with the first (or only) detector in the system. This assembly allows
the interface between the first detector, the next detector (if necessary), the input power source, and the CHECKFIRE SC-N
Control Module. See Figure 10.

RESPONDER

CONNECTION TO
CONTROL MODULE

FIGURE 8
000857

TRIPLE IR (IR3) FLAME DETECTOR


Note: Triple IR Flame Detection is to be used as an optional
add-on to standard linear detection or thermal detection.
Important: Triple IR detection can only be used with 18-24
VDC power source.
Triple IR (IR3) Flame Detector Shipping Assembly, Part No.
432480, consists of a Spectrex Model 20/20MI-32-A-F Triple IR
(IR3) flame detector and swivel detector bracket assembly. See
Figure 9.
The Model 20/20MI-32-A-N flame detector uses innovative technology of advanced digital signal processing to analyze the
dynamic characteristics of fire. Three sensitive IR channels
process the signals. Detection performance is controlled by a
microprocessor and easily adapted to all environments, applications, and requirements. The result is a unique and superior flame
detector, which provides excellent detection sensitivity with
extreme immunity to false alarm.

FIGURE 10
006830

FOLLOWING JUNCTION/CABLE ASSEMBLY (TRIPLE IR (IR3))


The Following Junction/Cable Assembly, Part No. 432478, is used
with all detectors in the system except for the first one. This
assembly allows the interface between the detector and the detectors following in the total system. See Figure 11.

The swivel bracket allows the detector to be easily pointed in the


correct direction for optimum cone of vision viewing.
The swivel bracket can be welded or bolted to the vehicle, for rigid
support.
Mounting bolts, nuts and washers are included for assembling the
detector to the bracket. Hardware is not provided for mounting the
bracket to the vehicle.
Individual components are available also.
Part No. 432035 Spectrex Model 20/20MI-32-A-F Triple IR (IR3)
Flame Detector
Part No. 432300 Swivel Bracket
FIGURE 11
006831

S1014

SYSTEM COMPONENTS
6-30-05
Page 6
REV. 2

CABLE ASSEMBLIES (TRIPLE IR)

BATTERY

Cable assemblies are required to wire from one detector to another. Cable assemblies plug into the junction boxes mounted to each
detector mounting plate. Plug-plug cable assemblies are available
in three different lengths with an additional receptacle-receptacle
assembly available to attach one to another to make longer
lengths. See Figure 12.

The CHECKFIRE SC-N control module uses one 3.6 VDC lithium
battery, Part No. 427308. All power required to run the detection
system can be provided from this battery. The battery is supplied
with two separate plug-in connectors. One connector is used for
plugging into SC-N modules and the other connector is used for
plugging into MP-N modules. CAUTION: Do not cut off unused
connector assembly. It must remain on battery module even
though it is not used. Simply tuck the extra connector assembly
along side the battery module when installing the cover. The battery must be replaced annually, after discharge, or when the YELLOW Battery LED and the Audio Alarm are pulsing. See Figure 15.

Part No. 432319 10 ft. (3.1 m) Plug-Plug Cable Assembly


Part No. 432320 20 ft. (6.1 m) Plug-Plug Cable Assembly
Part No. 432324 30 ft. (9.1 m) Plug-Plug Cable Assembly
Part No. 432321 1 ft. (.3 m) Receptacle-Receptacle Assembly

FIGURE 12
006832

SC-N
CONNECTOR

SQUIB
The squib assembly, Part No. 54919, is an electrically-actuated
component containing a small charge of powder. When the circuit
is closed to the squib, a small internal wiring bridge heats up,
causing ignition of the squib. This generates pressure, which
forces the puncture pin of the actuator through the seal in the
nitrogen cartridge. See Figure 13.

MP-N
CONNECTOR

NOTE: DO NOT CUT OFF


UNUSED WIRE
ASSEMBLY

FIGURE 15

WARNING
DEVICE CONTAINS EXPLOSIVE
CHARGE.
DO NOT REMOVE SHUNT
UNTIL READY TO CONNECT
INTO ELECTRICAL SYSTEM.

004877

END-OF-LINE RESISTOR

FIGURE 13
000858

SQUIB CABLE OPTIONAL 15 FT. (4.6 m)


The standard cable, Part No. 79062, is 20 in. (51 cm) and is
included with the control module shipping assembly. The optional
squib cable, Part No. 422747, is required to supply an electrical
signal from a remote module to the squib located in the actuator
body. The squib cable is 15 ft. (4.6 m) and can be cut to whatever
length is required. See Figure 14. The maximum allowable cable
length from controller to actuator is 15 ft. (4.6 m).

The End-Of-Line Resistor Assembly, Part No. 426520, is required


for supervision of the external input circuits. The end-of-line resistor assembly is available in a package of 10, Part No. 426461.
Each package consists of 10 of the required components to
assemble 10 of the resistor assemblies. See Figure 16. The package contains an instruction sheet, Part No. 423542, detailing the
assembly requirements.

LOCK
NUT

STRAIN RELIEF
CONNECTOR
TERMINAL BLOCK
WITH 4.7 K OHM
RESISTOR
CAP

FIGURE 16
FIGURE 14
001058

003050

S1014

SYSTEM COMPONENTS
7-1-03
Page 7
REV. 1

CHECK VALVE
The 1/4 in. check valve, Part No. 25627, is installed in the actuation line between the manual/automatic actuator and the pneumatic actuator on the connected fire suppression system. This
check valve allows actuation pressure to flow to the fire suppression system, but does not allow pressure from other actuation
devices to back up into the manual/automatic actuator of the
CHECKFIRE SC-N system. See Figure 17.
Other actuation devices in the fire suppression system also
require check valves to be installed in the same fashion. This prevents pressure from escaping through an actuator whose cartridge was inadvertently removed.

RELEASE CIRCUIT TEST MODULE


The release circuit test module, Part No. 423541, is used in place of
the squib during test procedures to simulate squib actuation or gas
motor actuation on CHECKFIRE MP systems (indicator lamp on). It
is also used when verifying time delay durations. See Figure 19.

1/4 IN. NPT


(BOTH ENDS)

FIGURE 19
003015

1 5/8 IN.
(4.1 cm)

FIGURE 17
000899

REMOTE HIGH LEVEL ALARM


The remote high level alarm, Part No. 79559, is intended for those
installations where the noise level or operating conditions may
prevent the operator from recognizing the control module alarm
condition. This device is connected through the alarm relay of the
control module to a separately fused power source. It is capable
of 102 decibels at 6 to 30 volts, 0.3 amp maximum at a temperature range of 40 F to 170 F (40 C to 76.7 C). See Figure 18.

FIGURE 18
000861

S1014

USER INTERFACE
7-1-03
Page 8
REV. 1

USER INTERFACE
This section is designed to give the user overall information on all
features and components pertaining to the CHECKFIRE SC-N
Control Module itself.
FIELD TERMINATIONS
External Power Circuit (Terminals No. 1 and No. 2)
12 to 24 VDC
Polarity must be considered Terminal No. 1 (+), Terminal No.
2 ()
3 amp inline fuse must be used in the positive side
Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25
in., suitable for the intended usage
Detection Circuit (Terminal No. 3 and No. 4)
Cable from splicing device must be round jacketed, with an O.D.
of 0.13 in. to 0.25 in., suitable for the intended usage
Polarity need not be considered
Manual Pull/Pressure Switch Circuit (Terminals No. 5 and
No. 6)
Can be set up for either manual pull input or pressure switch
feedback input
When set up for pressure switch feedback input, operation does
not discharge system
Polarity need not be considered
Cable from splicing device must be round jacketed, with an O.D.
of 0.13 to 0.25 in., suitable for the intended usage
Release Circuit (Terminals No. 7 and No. 8)
Polarity must be considered Terminal No. 7 (+), Terminal No.
8 ()
15 ft. maximum cable length between control module and pneumatic actuator
Cable from splicing device must be round jacketed, with an O.D.
of 0.13 to 0.25 in., suitable for the intended usage
Trouble Relay Circuit (Terminals No. 9 and No. 10)
Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25
in., suitable for the intended usage
3 amp maximum load
Contacts are normally open in the powered, non-trouble condition. Contacts close upon trouble
Relay specification: 4A 250VAC, 3A 30VDC resistive
Alarm Relay Circuit (Terminals No. 11, No. 12, and No. 13)
Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25
in., suitable for the intended usage
3 amp maximum load
Relay specification: 4A 250VAC, 3A 30VDC resistive
Normally open, normally closed set of contacts
Form C contact arrangement
Contacts shown in non-alarm condition No. 11 (N.O.), No. 12
(Common), No. 13 (N.C.)

Shut Down Relay Circuit (Terminals No. 14, No. 15, and No. 16)
Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25
in., suitable for the intended usage
3 amp maximum load
Relay specification: 4A 250VAC, 3A 30VDC resistive
Normally open, normally closed set of contacts
Form C contact arrangement
Contacts shown in normal condition No. 14 (N.O.), No. 15
(Common), No. 16 (N.C.)
Terminal Block
Terminal connections are sized for 12 - 24 AWG
Terminal is labeled from left to right, No. 1 through No. 16
The terminals are designed as follows:
1. + Ext. 12/24 VDC Battery
2. Ext. 12/24 VDC Battery
3. + Detection Input
4. Detection Input
5. + Manual Input
6. Manual Input
7. + Release Output
8. Release Output
9. Trouble Common
10. Trouble N.O.
11.Alarm N.O.
12. Alarm Common
13. Alarm N.C.
14. Shutdown N.O.
15. Shutdown Common
16. Shutdown N.C.

S1014

USER INTERFACE
7-1-03
Page 9
REV. 1

FRONT PANEL INDICATORS (See Figure 21)

Release Trouble (Yellow)

Battery Trouble (Yellow)

The Yellow Release LED and the audio will pulse at a rate of once
every 10 seconds when a trouble condition is detected in the
release circuit. The control module will return to normal when the
trouble condition is cleared.

LED pulses once every 10 seconds when indicating battery


trouble
The yellow battery trouble LED will pulse when a low power condition is detected in either of the connected supplies (internal or
external). If only one power source is used, the control module
will automatically ignore the unconnected circuit upon resetting
the control module. If a power source is once connected and
recognized, a subsequent loss of that power source will be recognized as a Battery Trouble condition. If a power source is
once connected, recognized, and then disconnected, the disconnected supply can be ignored by operating the RESET button.
Power Normal (Green)
LED pulses once every 3 seconds when indicating normal
power
The green Power Normal LED pulses on once every 3 seconds indicating power is normal from both sources of input
power. If the power drops below an acceptable level from either
the internal or external source of input power, the green Power
LED will be extinguished. If only one source of power is used,
the green Power LED will extinguish when the voltage level
drops below an acceptable level.
Alarm (Red)
The alarm LED will flash if an alarm condition exists. An alarm
condition is caused by operation of the detection circuit or operation of the manual pull/pressure switch input circuit. The alarm
condition will continue until the source of the alarm is removed
and the control module is reset.
DETECTION CIRCUIT ACTIVATION MODE Upon receipt of
an input to the detection circuit, the Alarm LED and the sounder
will pulse at a rate of 2 times per second and will continue at this
rate until the first time delay period has expired.

The Release Trouble will also pulse after the system has completed a discharge cycle or a pressure switch feed back signal has
been received. The trouble signal in this condition is used to indicate a recharge of the fire suppression system is necessary. A
Release Trouble under either of these conditions can only be
cleared by resetting the control module.
Detection Trouble (Yellow)
The Yellow Detection Trouble LED and the audio pulse once every
10 seconds when the control module detects a trouble in the
detection circuit. The control module will automatically return to
normal when the trouble is cleared.
Sounder (Audio)
The sounder gives the audio indication for all alarm and trouble
outputs. The sounder will pulse at the same rate as the visual corresponding LED.
The sounder gives the audio indications of the various outputs.
The sounder is rated at 85 Db at 10 feet.
The pulse rates are as follows:
Alarm Time Delay 1 = 2 pulses per second
Time Delay 2 = 4 pulses per second
Trouble 1 pulse per 10 seconds
Loss of Power 1 pulse per 10 seconds
Release Circuit Fired 4 pulses per second for 30 seconds, then
1 pulse per 10 seconds
Low Battery 1 pulse per 10 seconds

After the first time delay, a second time delay mode is initiated.
This causes the LED and sounder to pulse at a rate of 4 times
per second.
After discharge, the LED and sounder will continue to pulse at
a rate of 4 times per second for 30 seconds. After that, it will
switch to the trouble mode and pulse once every 10 seconds.
ELECTRIC MANUAL RELEASE MODE The first time delay
mode will be by-passed and the LED will pulse at a rate of 4
pulses per second. After the time delay setting is reached, it will
pulse another 30 seconds at the same rate. After that, the control module will go into the post-discharge mode, at which time
the Alarm LED and Release LED will pulse at a rate of one
pulse per 10 seconds.
PRESSURE SWITCH CIRCUIT (FEED BACK) ACTIVATED
MODE When this mode is actuated, the Alarm LED will pulse
a minimum of 30 seconds at 4 pulses per second. The control
module will then go into the post-discharge mode and the Alarm
and Release LED will pulse at a rate of one pulse per 10 seconds.

SOUNDER

GREEN
YELLOW
RED
YELLOW

FIGURE 21
002760

S1014

USER INTERFACE
7-1-03
Page 10
REV. 2

POWER CONNECTIONS
Internal
The 3.6 VDC internal lithium battery is connected to the control
module by a removable type plug. The battery must be replaced
annually or when the Yellow Battery LED and sounder are pulsing.
A label is attached near the battery mounting location for recording the installation date.
!

CAUTION

Discharged lithium batteries may contain significant amounts


of unused energy and should be handled with care. Do not
compact for disposal. Before disposal, each battery must be
fully discharged and electrically isolated by enclosing in a plastic bag and sealing the bag. Do not dispose of in fire. Check
applicable solid waste disposal regulations for proper disposal
of more than one battery.

DELAY
BUTTON

DELAY

RESET

RESET
BUTTON

FIGURE 22
External
The external power circuit can be between 12 to 24 VDC. The circuit must be fused at the source on the positive line. The external
power source is connected to the module terminal block on terminals No. 1 (+) and No. 2 ().
Both power sources, internal and external, should be utilized
whenever possible. This will always give the fire suppression system a battery back-up when one of the sources are removed for
whatever reason.
FRONT PANEL BUTTONS (See Figure 22)
Delay
Pushing the DELAY button during the first time delay cycle will
restart the time delay cycle. If the second time delay cycle has
already started, the DELAY button will have no effect.
The DELAY button can also be used to check the diagnostics
function. By depressing the delay button when the system is in
the trouble condition, the LEDs will flash a pattern code. Each
pattern code indicates a certain type of trouble. The code pattern is prioritized. The first trouble must be fixed before addressing the next one. Once the first trouble is taken care of, depressing the DELAY button will cause the LEDs to indicate the code
for the next trouble, if there is one. When the DELAY button is
pressed, three short audio and visual indications will acknowledge the switch has been depressed properly.
In a post discharge condition, pressing the DELAY button will
silence the alarm relay if the alarm relay has been programmed
to silence.
Reset
The RESET button is used to re-initialize the control panel.
When depressed, it provides an indication that all LEDs and the
sounder are functional.
It is used to upload the manual programming into the control
module.
If trouble(s) has not been cleared, the trouble indication will
reappear after the RESET button is pressed.
When the RESET button is pressed, three short audio and
visual indications will acknowledge the switch has been
depressed properly.

0002760

BATTERY REPLACEMENT
While in use, the battery requires replacement every year or
when the Yellow Battery LED and sounder are pulsing.
The shelf life of the battery is 8 years.
Control Module contains a label for recording battery replacement date.
Make certain used battery is disposed of properly.
ENCLOSURE
The enclosure is watertight. It meets the requirements of
International Standard IEC 529, Degrees of Protection
Provided by Enclosures for an IP 66 rating.
COVER REMOVAL
The cover is attached with 4, captive, slotted screws.
When removing and installing cover, make certain seal is always
correctly in place and not twisted.
Seal should always be kept clean.
A small amount of silicone lubricant will improve the seals effectiveness.
STRAIN RELIEF INSTALLATION
Always use Dow Corning 737 RTV Sealant or equal on all strain
relief and plug male threads.
MOUNTING
There are four types of mounting options available for the
CHECKFIRE SC-N Control Module:
Control Module can be mounted without a bracket. It has molded-in mounting tabs on the back box. Note: Surface must be
suitable.
Control Module can be mounted on a combined bracket which
will allow both the module and the actuator to be mounted
together.
Control Module can be mounted on its own bracket and the
actuator can be also mounted on its own bracket, with a maximum release cable length of 15 ft.
Control Module can be mounted to an existing CHECKFIRE SC
bracket by the use of a retrofit bracket.
The Control Module should never be mounted in an area which is
subject to pressure washing or steam cleaning.

S1014

IN CASE OF FIRE
7-1-03
Page 26
REV. 2

Read these precautions carefully until they are clearly understood.


All equipment operators or anyone who has any responsibility for
the equipment should fully understand how the CHECKFIRE
SC-N Detection and Actuation System operates. Every operator
should be fully trained in these procedures.
1. When the system alarm sounds, bring the equipment to a safe
controlled stop, shut off the engine, and exit. (Equipment left
running may add fuel to the fire or reignite the fire with heat or
sparks.)
Automatic Equipment Shutdown The CHECKFIRE SC-N
system is equipped with a shutdown relay and time delay. If a
shutdown device is connected to the system, all responsible
personnel should understand shutdown device operation and
the length of the time delay (in seconds). If the DELAY button
(on the control module cover) is pushed and released before
the end of the shutdown time delay period, the time delay will
automatically repeat itself. This delay can be repeated (using
the DELAY button) as many times as is necessary to stop the
vehicle safely before it shuts down. (The DELAY button can
also be held in indefinitely to delay shutdown the shutdown
delay will then restart after the button is released.)
2. Move away from the equipment taking a hand portable extinguisher along if possible.

Manual System Actuation


The system can be actuated manually by pulling the ring pin and
striking the red button on the manual/automatic actuator as shown
in Figure 50. Again, bring the equipment to a safe stop, shut off the
engine, manually actuate the system, move a safe distance from
the vehicle, and stand by with a hand portable extinguisher.
!

CAUTION

Manual actuation will result in immediate system discharge


which may obscure vision. Make certain vehicle is stopped
safely before manually actuating the system. Manual actuation
will bypass all auxiliary shutdown and alarm functions.

2
STRIKE
BUTTON

PULL RING
PIN

3.
!

WARNING

In case of fire, evacuate area to lessen risk of injury from


flames, heat, hazardous vapors, explosions, or other
hazards that may be created.
Stand by with a hand portable extinguisher to guard against
any fire that may reignite after the fire suppression system has
been discharged. Remain alert until the equipment cools and
the possibility of reignition is no longer a threat.

FIGURE 50
002773

S1014

RECHARGE
6-30-05
Page 27
REV. 2

For continued protection, the CHECKFIRE SC-N Detection and


Actuation System and the fire suppression system must be
recharged immediately after operation.
Before performing the recharge steps, determine the cause of the
system discharge.

UPPER PORTION
OF BODY

1. Remove the 4 screws holding the cover to the back box and
remove the cover.
BASE
OF STEM

2. Remove the battery from the back box and properly discard.
Battery must be replaced after each discharge. If system contains optional vehicle power, also disconnect the wire leads at
the vehicle battery.

LUBRICATE O-RING
WITH SILICONE GREASE
PUNCTURE PIN

3. Remove the empty LT-10-R cartridge from the manual/automatic actuator.


4. If the system was manually actuated Skip steps 5, 6, and
proceed to step 7.
5. If the system was automatically actuated Unscrew the
squib lead connector. Remove the squib from the
manual/automatic actuator.
6. Clean and lubricate the manual/automatic actuator by completing the following steps. See Figure 51.
NOTICE
If the system was actuated manually and the
squib was not actuated, cleaning is not necessary.
a. Remove jam nut and slide actuator out of mounting bracket.
b. Unscrew upper portion of actuator body.
c. Using a pencil eraser, apply pressure to the bottom of the
puncture pin. This will force the puncture pin and spring out
of the actuator body.
d. Thoroughly clean carbon deposits from base of stem,
puncture pin, spring, and inside surface of actuator body.
e. After all components are clean and dry, liberally lubricate
O-rings with a good grade of extreme temperature silicone
grease.
f. Reassemble actuator, reinstall into bracket, and securely
tighten jam nut.
g. Pull ring pin and push strike button several times to spread
grease and ensure free movement of puncture pin.
h. With strike button in the up position, insert ring pin through
actuator body into puncture pin shaft. Install visual inspection seal, Part No. 197.

SPRING
RESET
POSITION
APPROXIMATELY
1/16 IN. (1.6 mm)
1/16 (1.6 mm)

ACTUATOR
BODY

FIGURE 51
000888

NOTICE
When puncture pin is fully reset, cutting point of
pin will be located approximately 1/16 in.
(1.6 mm) below threads in lower actuator body.
7. In the case of a fire, replace all linear detection wire and spot
detector cable. See Section III, Installation, for instructions.
a. Inspect all spot thermal detectors, if used, for damage, and
verify that each one has reset to its normal operational
mode. (With the detection wiring disconnected from the
detector, using a multimeter, check to verify that there is no
continuity between any of the detector pin connections.)
b. If Spectrex Model 20/20MI-32-A-F Triple IR (IR3) flame
detection is utilized, inspect detectors and verify they have
not been damaged. Make certain all detectors have been
reset to their normal operating condition. Refer to User and
Maintenance Manual (Ansul Part No. 432485) and follow
the detector maintenance instructions outlined on Page 18
in the manual to verify detector operation.
NOTE: The functional operation of the IR3 flame detectors
should result in an alarm condition in the CHECKFIRE SC-N
module.
8. Install new battery, Part No. 427308, in module. Record date
of installation.
9. Recharge the fire suppression system in accordance with the
corresponding manual.
10. Test the system and place into service by completing the
steps listed under FUNCTIONAL TEST.
11. Record date of recharge on a tag or in permanent record file.
Notify operating personnel that the system is back in service.

S1014

INSPECTION AND MAINTENANCE


6-30-05
Page 28
REV. 2

To ensure the CHECKFIRE SC-N Electric Detection and Actuation


System will operate as intended, proper inspection and maintenance procedures must be performed at the specified intervals.

d. Disconnect the detection wiring and check the resistance


across the field wiring circuit to verify detection circuit continuity and the proper end of line resistance. The end of line
resistance should read 4.7k ohms.

DAILY INSPECTIONS

e. After the detection circuit has been tested, reconnect the


detection wiring to terminals TB-3 and TB-4.

The vehicle operator must check the system daily by visually verifying that the GREEN power LED is flashing and no other LED is
illuminated. Also, no audio alarm should be sounding. If any other
conditions exist, contact the local authorized ANSUL distributor or
whoever has been trained and authorized by ANSUL to perform
inspection and maintenance checks.
MAINTENANCE
To give maximum assurance that the system will operate as
intended, maintenance shall be performed semi-annually or sooner, depending on the operating and/or environment conditions.
Maintenance should be performed by an authorized ANSUL distributor or someone who has been trained and authorized by
ANSUL to perform maintenance checks.
1. Check all mounting bolts for tightness or corrosion.
2. Remove the LT-10-R cartridge from the manual/automatic
actuator, install shipping cap, and set aside in a safe location.
!

CAUTION

Cartridge must be removed before continuing with the


following steps or accidental system actuation will take
place when squib is actuated.

CAUTION

Do not actuate squib unless it is installed in actuator


body. If the squib is actuated outside of actuator body, it
will detonate causing possible personal injury.
3. Five Year Squib Replacement The squib must be replaced
after being in service for five years. (The month and year of
manufacture is stamped on the squib hex surface.) Proper
disposal of the squib is accomplished by actuating the squib
within the actuator body. If this is required, skip Steps 4 and 5
which deal with installing the test module in place of the squib.
By skipping steps 4 and 5, the squib will be actuated during
the following test procedures.
!

7. If IR3 flame detection is utilized, refer to User and


Maintenance Manual (Ansul Part No. 432485) for detector
maintenance instructions. Follow the maintenance steps outlined on Page 18 in the manual.
NOTE: The functional operation of the IR3 flame detectors
should result in an alarm condition in the CHECKFIRE
SC-N module.
8. If thermal detectors are used, check that they are securely
mounted and have not corroded or been damaged.
NOTICE
If a vehicle shutdown device is installed, the
vehicle should be running at this time to verify
that the device is functioning properly.
9. If external power is used, measure the voltage at terminals
1 and 2 to ensure that the 12/24 VDC is present. Check monitoring of the external power by removing the in-line fuse and
checking to see that a power trouble condition is present.
Replace fuse and depress the RESET button on the control
module.
10. Check first time delay Alarm to Shutdown Using a short
length of insulated wire stripped at both ends, hold one end of
the wire to Terminal 3 and the other end to Terminal 4 on the
control module. See Figure 52.
DETECTION CIRCUIT
TERMINALS 3 AND 4
JUMPER
3

DETECTION
CIRCUIT
WIRING

CAUTION

Make certain the cartridge is removed from the actuator.


Failure to do so will cause system discharge when squib
is actuated.
4. Remove the squib lead connector from the squib.
5. Hand tighten the squib lead connector onto the test module,
Part No. 423541.
6. Inspect the detection and interconnecting wiring as follows:
a. Check for wear due to vibration at penetrations, around
corners, etc.
b. Check for damage from direct impact or other abuse.
c. Check for tightness at points of securement. Make certain
fasteners have not come loose which would allow the wire
to sag or shift.

FIGURE 52
002770

Using a jumper wire, temporarily short Terminals 3 and 4,


removing the jumper before the end of the first time delay
cycle. This will test the non-latching function of the first time
delay. While the wire is being held in place, the RED Alarm
LED will pulse and the sounder will operate.
Remove the jumper wire. At this point, both the RED Alarm
LED and the sounder will stop pulsing and the first time delay
will recycle back to zero. The control module will return to normal with only the GREEN Power LED on.

S1014

INSPECTION AND MAINTENANCE


6-30-05
Page 29
REV. 2

MAINTENANCE (Continued)
11. Check second time delay Shutdown to Discharge
Once again, hold the wire on Terminals 3 and 4. The RED
Alarm LED and the Audio Alarm will pulse. Hold the wire on
the terminals for a period longer than what the first time delay
is set up for. While holding the wire on the terminals, time the
length of the first time delay to verify that it is the same as
what it was set for.
At the end of the first time delay cycle, the pulse rate of the
Audio Alarm will change. This will start the cycle of the second
time delay. At this point, the timing cycle is latched, and the
wire jumper need not be held on the terminals. Also at this
point, the shutdown relay will operate, causing the vehicle to
shutdown.
Time the length of the second time delay to confirm that it is
the same as what has been set.
When the second time delay cycle is completed, the release
circuit will activate causing the GREEN LED on the test module to illuminate or in the case of the five year squib replacement, the squib will fire.
12. (If used) Reset test module by pressing the reset button on
the tester.
13. Disconnect the squib lead from the squib test module lead
adaptor and verify that the module is indicating both a RED
alarm LED and a YELLOW release fault LED. Reconnect the
squib lead to the squib test module lead adaptor.
14. Complete the following steps only if the squib has been actuated. Otherwise, go to Step No. 15.
a. Unscrew the squib lead connector from the squib and
remove the squib from the actuator body.
b. Clean manual/automatic actuator by referring to Step 6 on
Page 26 in Recharge Section.
c. Screw replacement squib into the upper-right hole in the
actuator body and wrench tighten.
d.
!

CAUTION

The control module could be damaged and the fire suppression system may not operate if the squib spring
(shunt) is not removed. Always remove cap and spring
(shunt) before installing squib connector.
Unscrew protective cap from replacement squib and
remove spring (shunt). Retain these components for possible future use.
e. Line up index slot in squib lead connector with index tab on
squib. Then, hand tighten squib lead connector onto squib.
15. Unscrew the squib lead connector from the test module.
NOTICE
When squib lead connector is removed from test
module, the YELLOW Release LED and the
audio alarm on the control module will
temporarily pulse. This will stop when squib is
connected.
16. Line up index slot in squib lead connector with index tab on
squib. Then, hand tighten squib connector onto squib.

17. Push RESET button on CHECKFIRE SC-N Control Module


to reset system.
CAUTION

The fire suppression system will discharge dry chemical if


the cartridge is installed when operating the strike button.
Do not install cartridge at this time.
18. Pull ring pin and push strike button on manual/automatic actuator several times to ensure smooth movement.
NOTICE
If lever does not operate smoothly, clean and
lubricate internal components by completing
Step No. 6 on Page 27 in Recharge Section.
19. Yearly Remove control module cover screws and replace
internal 3.6 VDC lithium battery, Part No. 427308. Record
date of new battery installation on label located near battery.
Reinstall control module cover and depress RESET button.
!

CAUTION

Contact your local waste management company for information concerning the correct disposal of lithium batteries.
20. Reinstall LT-10-R cartridge by completing the following steps:
a. Make certain puncture pin is fully retracted and insert ring
pin through actuator body into puncture pin shaft. Attach
visual inspection seal, Part No. 197.
b. Remove shipping cap and weigh cartridge before installing.
Replace if weight is 1/4 ounce (7.1 g) or more below weight
stamped on LT-10-R cartridge.
c. Screw cartridge into actuator body and hand tighten.
21. Reset any auxiliary shutdown and alarm equipment in accordance with manufacturers instructions.
22. Record date of maintenance on an affixed tag or in a permanent record file.

S1014

TROUBLESHOOTING
7-1-03
Page 30
REV. 1

DIAGNOSTICS

Below is a listing and explanation of each type of recorded fault:

The diagnostics feature offers a means to pinpoint various trouble


symptoms by displaying a flashing code on the control module
status LEDs.

Programmed

This indicates any time the unit is programmed or a programming change has been
made.

If there is more than one trouble at a time, the system will display
them in a pre-set priority.

Switch Enabled

This indicates that the manual programming


switch is enabled and the program settings
are being taken from the program switch settings.

Init Bad Log

With the system in the trouble mode, depress the DELAY button.
With the DELAY button depressed, the trouble codes will be indicated on the LEDs.

This indicates that an error has been detected in the datalog. If this occurs, the datalog is
automatically cleared and reset.

Bad Checksum

Indicates that an error has been detected in


the E-Prom. If this occurs, the factory default
program settings are restored.

LED Code
_________

Trouble
_______

Soft Reset

Yellow Battery LED flashing

Internal battery disconnected

Indicates that the Reset button has been


depressed. The clock is not reset during a soft
reset.

Yellow Battery LED flashing


Red Alarm LED flashing

External battery disconnected

+12 (24V) Low

Yellow Release LED flashing

Release circuit is open

Indicates that the external power input voltage has dropped below a Normal threshold
level and is in need of servicing.

+12 (24V) Fault

Yellow Release LED flashing


Red Alarm LED flashing

Release circuit has operated

Indicates external power input voltage has


dropped below the minimum operating
threshold or the external power has been disconnected.

Yellow Detection LED flashing

Detection circuit is open

Int Batt Low

Yellow Detection LED flashing


Red Alarm LED flashing

Electric manual pull station


circuit is open

Indicates the internal battery voltage has


dropped below a Normal threshold level and
requires servicing.

Int Batt Fault


The CHECKFIRE SC-N control module is programmed to record
faults, alarms, and programming changes in a numerical
sequence. The module will store approximately 50 recorded
events. If the number of events exceeds 50, the earlier events will
be erased to make room for the later ones.

Indicates that the internal battery voltage has


dropped below the minimum operating
threshold or the battery has been
disconnected.

Detection TD1

Indicates that the Time Delay 1 sequence has


been initiated. This occurs as a result of operation of the detection circuit.

A sample History Buffer screen appears as follows:

Detection TD2

Indicates the start of the Time Delay 2


sequence as a result of a detection input.

Manual TD

Indicates the start of the time delay as a result


of the manual input circuit being initiated.

In multiple trouble situations, the first trouble must be cleared


before the system will display the next one.
The system must be in the trouble mode in order to display the
diagnostics codes.

HISTORY BUFFER

Event Number

Event

0
1
2
3
4
5
6
7
8
9

Programmed
Detection TD1
Delay Engaged
Delay Released
Detection TD2
Squib Release
Soft Reset
All Clear
Int Batt Low
Int Batt Fault

Time (dddd:hh:mm:ss)
0000:00:01:46
0000:00:01:52
0000:00:02:15
0000:00:02:25
0000:00:02:35
0000:00:05:10
0000:00:05:13
385:12:24:32
405:20:32:07

The recorded event indicates which circuit had a fault or an alarm


recorded. Along with the type of fault or alarm, the history buffer
also records the time, relative to the first event which is the powering of the unit or restoration of power. New events are recorded
by days: hours: minutes: seconds that have transpired from the
last restoration of power. If power is removed and then restored,
the counter starts over at 0000:00:00:00, however, previous history will be retained in the buffer.

Pressure Switch Indicates activation of the pressure switch


input circuit.
Delay Engaged

Indicates the delay button has been


depressed during TD1 of an alarm condition.

Delay Released Indicates the time the Delay button was


released after initiating.
Detection Fault

Indicates an open circuit in the detection


circuit.

Manual Fault

Indicates an open in the manual pull or pressure switch circuit.

Squib Fault

Indicates an open in the squib circuit or that


the squib has fired.

Squib Release

Indicates that the control module has fired the


squib.

Unknown

Indicates an unexplainable event in the control module circuitry.

All Clear

Indicates alarm condition has been reset. This


indication occurs after TD2 clears.

S1014

TROUBLESHOOTING
7-1-03
Page 31
REV. 1

TROUBLESHOOTING TABLE
The following table designates normal operating and trouble conditions for the CHECKFIRE SC-N Detection and Actuation System.
Green
Power
Normal
______

Yellow
Power
Fault
_____

Red
Alarm
_____

Yellow
Detection
Fault
________

Yellow
Release
Fault
_______

Audio
Alarm
_____

Alarm
Relay
_____

Shutdown Trouble
Relay
_________ Relay
_______

Agent
Release
_______

battery normal
module normal
external power
not used

pulsing
once every
3

off

off

off

off

off

normal

normal

off

battery normal
detection fault
external power
not used

pulsing
once every
3 seconds

off

battery normal
release fault
external power
not used

pulsing

off

battery normal
detection fault
release fault
external power
not used

pulsing

Condition
________

normal

seconds

off

off

pulsing
once every
10 seconds

off

pulsing
normal
once every
10

normal

off

pulsing
once every
10 seconds

pulsing
normal
once every
10

normal

transferred off
seconds

transferred off
seconds

off

off

pulsing
once every
10 seconds

pulsing
once every
10 seconds

pulsing
normal
once every
10 seconds

normal

transferred off

battery fault
off
external power normal
module normal

pulsing
once every
10 seconds

off

off

off

pulsing
normal
once every
10 seconds

normal

transferred off

battery fault
off
external power normal
detection fault

pulsing
once every
10 seconds

off

pulsing
once every
10 seconds

off

pulsing
normal
once every
10 seconds

normal

transferred off

battery fault
off
release fault
external power normal

pulsing
once every
10 seconds

off

off

pulsing
once every
10 seconds

pulsing
normal
once every
10 seconds

normal

transferred off

battery fault
off
detection fault
release fault
external power normal

pulsing
once every
10 seconds

off

pulsing
once every
10 seconds

pulsing
once every
10 seconds

pulsing
normal
once every
10 seconds

normal

transferred off

alarm detected
alarm to shutdown
period TD1

off

pulsing
twice
every

off

off

pulsing
transferred normal
twice every
second

pulsing
once every
3 seconds

normal

off

second

external power fault


off
detection fault
manual pull circuit fault
release fault
battery normal

pulsing
once every
10 seconds

off

pulsing
once every
10 seconds

pulsing
once every
10 seconds

pulsing
normal
once every
10 seconds

normal

transferred off

battery fault
external power fault

off

pulsing
once every
10 seconds

off

off

off

pulsing
normal
once every
10 seconds

normal

transferred off

battery fault
external power fault
detection fault

off

pulsing
once every
10 seconds

off

pulsing
once every
10 seconds

off

pulsing
normal
once every
10 seconds

normal

transferred off

S1014

TROUBLESHOOTING
7-1-03
Page 32
REV. 1

TROUBLESHOOTING TABLE (Continued)

Condition
________

Green
Power
Normal
______

Yellow
Power
Fault
_____

Red
Alarm
_____

Yellow
Detection
Fault
________

Yellow
Release
Fault
_______

Audio
Alarm
_____

Alarm
Relay
_____

Shutdown Trouble
Relay
_________ Relay
_______

Agent
Release
_______

battery fault
off
external power fault
detection fault
manual pull circuit fault

pulsing
once every
10 seconds

off

pulsing
once every
10 seconds

off

pulsing
normal
once every
10 seconds

normal

transferred off

battery fault
external power fault
detection fault
manual pull circuit
fault
release fault

off

pulsing
once every
10 seconds

off

pulsing
once every
10 seconds

pulsing
once every
10 seconds

pulsing
normal
once every
10 seconds

normal

transferred off

manual pull circuit


activated
pre release period
(manual release
time delay)

pulsing
once every
3 seconds

off

pulsing
off
4 times
per second

off

pulsing
transferred transferred
4 times
per second

normal

off

pressure switch
activated (0 to 30
seconds
after activated)

pulsing
once every
3 seconds

off

pulsing
off
4 times
per second

off

pulsing
transferred transferred
4 times
per second

normal

off

pressure switch
activated
(post 30+ seconds
period)

pulsing
once every
3 seconds

off

pulsing
off
once every
10 seconds

pulsing
once every
10 seconds

pulsing
transferred transferred
once every
10 seconds

transferred off

shutdown to release
period
(2nd time delay)

pulsing
once every
3 seconds

off

pulsing
off
4 times
per second

off

pulsing
transferred transferred
4 times
per second

normal

0 - 30 seconds
after release

pulsing
once every
3 seconds

off

pulsing
off
4 times
per second

off*

pulsing
transferred transferred
4 times
per second

transferred fired

30+ seconds
after release

pulsing
once every
3 seconds

off

pulsing
off
once every
10 seconds

pulsing
once every
10 seconds

pulsing
transferred** transferred
once every
10 seconds

transferred fired

manual pull
pulsing
circuit fault
once every
battery normal
3 seconds
external power normal

off

off

pulsing
once every
10 seconds

off

pulsing
normal
once every
10 seconds

normal

transferred off

manual pull
pulsing
circuit fault
once every
detection fault
3 seconds
battery normal
external power normal

off

off

pulsing
once every
10 seconds

off

pulsing
normal
once every
10 seconds

normal

transferred off

manual pull
circuit fault
detection fault
release fault
battery normal

off

off

pulsing
once every
10 seconds

pulsing
once every
10 seconds

pulsing
normal
once every
10 seconds

normal

transferred off

pulsing
once every
3 seconds

off

S1014

TROUBLESHOOTING
7-1-03
Page 33
REV. 1

TROUBLESHOOTING TABLE (Continued)


Green
Power
Normal
______

Yellow
Power
Fault
_____

Red
Alarm
_____

Yellow
Detection
Fault
________

Yellow
Release
Fault
_______

external power fault


battery normal

off

pulsing
once every
10 seconds

off

off

off

pulsing
normal
once every
10 seconds

normal

transferred off

external power fault


detection fault
battery normal

off

pulsing
once every
10 seconds

off

pulsing
once every
10 seconds

off

pulsing
normal
once every
10 seconds

normal

transferred off

battery fault
no external power
module normal

off

pulsing
once every
30 seconds

off

off

off

pulsing
normal
once every
30 seconds

normal

transferred off

battery fault
detection fault
external power
not used

off

pulsing
once every
10 seconds

off

pulsing
once every
10 seconds

off

pulsing
normal
once every
10 seconds

normal

transferred off

manual pull
circuit activated
(0-30 seconds after
system activation)

pulsing
once every
3 seconds

off

pulsing
off
4 times
per second

off*

pulsing
transferred transferred
4 times
per second

transferred fired

pressure switch
activated detection
fault (30+ seconds
after system
activation)

pulsing
once every
3 seconds

off

pulsing
pulsing
once every once every
10 seconds 10 seconds

pulsing
once every
10 seconds

pulsing
transferred transferred
once every
10 seconds

transferred off

Condition
________

* Will pulse if circuit opens as a result from release


** Can be silenced at this time

Audio
Alarm
_____

Alarm
Relay
_____

Shutdown Trouble
Relay
_________ Relay
_______

Agent
Release
_______

S1014

6-30-05

COMPONENT INDEX
Part
No.

Shipping
Assembly

Weight
lb.
(kg)

Main Assemblies
423500
CHECKFIRE SC-N Electric Detection and Actuation
System includes:
423504
24479
423525
79062
13193
25627
79064
53081

10

(4.5)

Control Module (module contains nuts and


washers for mounting to bracket)
Manual/Automatic Actuator
Combined Mounting Bracket
Squib Cable with Connector
Nitrogen Cartridge, LT-10-R
1/4 in. Check Valve
Label Package
Owners Manual

423538

(Transport Canada) CHECKFIRE SC-N Electric Detection


and Actuation System includes:
(All of the standard shipping assembly components
except Nitrogen Cartridge, Part No. 13193, is replaced
with Nitrogen Cartridge, Part No. 423423)

10

(4.5)

427308
54919
426461
426520

Battery Shipping Assembly (3.6 VDC)


Squib
End-of-Line Resistor Assembly (Package of 10)
End-of-Line Resistor Assembly (Single)

1/4
1/4
1/4
1/4

(.1)
(.1)
(.1)
(.1)

1
1

(.5)
(.5)

(.5)

(.5)

(.5)

Accessory Equipment
423541
Release Circuit Test Module
423525
Combined Bracket Shipping Assembly
For mounting control module and actuator together
423528
Control Module Mounting Bracket
For mounting control module separately
419772
Actuator Mounting Bracket
For mounting actuator separately
423531
Control Module Retrofit Mounting Bracket
For mounting control module to existing
CHECKFIRE SC mounting bracket
79559
Remote High Level Alarm
71820
Splicing Device
71230
356 F (180 C) Linear Detection Wire, 100 Ft. (30.4 m)
71231
356 F (180 C) Linear Detection Wire, 500 Ft. (152.4 m)

2
1/4
5
10

(.9)
(.1)
(2.3)
(4.5)

416218
416219
416220
416213
416221

270 F (132 C) Spot Detector


325 F (163 C) Spot Detector
360 F (182 C) Spot Detector
Spot Detector Connector Package
Spot Detector Bracket

1/4
1/4
1/4
1/4
1/4

(.1)
(.1)
(.1)
(.1)
(.1)

416762

Spot Detector Cable Clamp Package (For Use


Without Protective Tubing)
Spot Detector Cable Clamp Package (For Use
With Protective Tubing)
Flex Non-Metallic Tubing 100 Ft. (30.4 m)
(For Spot Detectors)
Crimp Tool (For Spot Detector)

1/4

(.1)

1/4

(.1)

416214
416215
416784
416113
416216
416378
417055

Pneumatic/Linear Detector, 35 Ft. (10.7 m)


(Model 808-DRV)
Cable Assembly, 15 ft. (4.6 m) (For Pneumatic/
Linear Detector)
Mounting Clips Package For Pneumatic/Linear
Detector Sensing Element (Includes 100 Clips)
Wire, 392 F (200 C), 18 AWG-2 W/Shield and Drain Wire
500 ft. (152 m)

(1.8)

(.5)

(.5)

1/4

(.1)

1/4

(.1)

10

(4.5)

APPENDIX
Page 39
REV. 2

S1014

APPENDIX
6-30-05
Page 40
REV. 1

COMPONENT INDEX (Continued)


Accessory Equipment (Continued)
Part
No.
56691
56692

Shipping
Assembly
Nylon Cable Tie (Package of 20)
Rubber Sleeve (Package of 20)

Weight
lb.
(kg)
1
(.5)
2
(.9)

422747

Squib Cable with Connector 15 ft. (4.6 m)

(.5)

419780

Power Wiring Assembly 15 ft. (4.6 m)


(Connector on one end)
Power Wiring Assembly 15 ft. (4.6 m)
(Connector on both ends)
Power Wiring Assembly 10 ft. (3.1 m)
(Connector on both ends)
Battery Connection (Fused at 5 amp)
RS-232 PC Interface Cable Kit
Extender Cable Assembly
Battery Extender Cable Assembly
Triple IR (IR3) Flame Detector Shipping Assembly
(includes Spectrex Model 20/20MI-32-A-F Triple IR (IR3)
Flame Detector, Part No. 432035;
Swivel Bracket with Mounting Plate, Part No. 432300)
Starter Junction/Cable Assembly (Triple IR)
Following Junction/Cable Assembly (Triple IR)
10 ft. (3.1 m) Plug-Plug Cable Assembly (Triple IR)
20 ft. (6.1 m) Plug-Plug Cable Assembly (Triple IR)
30 ft. (9.1 m) Plug-Plug Cable Assembly (Triple IR)
1 ft. (.3 m) Receptacle-Receptacle Cable Assembly
(Triple IR)
Supervision End Plug (Triple IR)
Triple IR Flame Detector User and Maintenance Manual
WinHost Programming Manual (Triple IR)

(.5)

(.5)

(.5)

419781
419782
419783
423524
426601
426604
432480

432477
432478
432319
432320
432324
432321
432481
432485
432484

RECHARGE EQUIPMENT
54919
Squib
13193
LT-10-R Cartridge (DOT)
423423
LT-10-R Cartridge (DOT/TC)
427308
Battery Shipping Assembly (3.6 VDC)
423522
Installation, Maintenance, Recharge Manual

1
1/4
1/4
1/4
5

(.5)
(.1)
(.1)
(.1)
(2.3)

2
2
2
4
6
.5

(.9)
(.9)
(.9)
(1.8)
(2.7)
(.2)

1/4
1/4
1/4

(.1)
(.1)
(.1)

1/4
2
2
1/4
1/4

(.1)
(.9)
(.9)
(.1)
(.1)

S1014

7-1-03

APPENDIX
Page 41

DETECTION WIRE FLUID RESISTANCE CAPABILITY


Resistance Rating Key:
G = GOOD
L = LIMITED
C = CONDITIONAL

(Service conditions must be outlined to


ANSUL for approval of wire suitability for
applications.)

U = UNACCEPTABLE (Not to be used)


Agent

Rating

Acetate Solvents, Crude


Acetate Solvents, Pure
Acetic Acid, Dilute (20%)
Acetic Acid, Glacial
Acetone
Air
Alcohols
Aluminum Chloride
Aluminum Fluoride
Aluminum Sulfate
Ammonia Liquid (Anhydrous)
Ammonia, Chloride
Ammonium Hydroxide
Ammonium Nitrate
Ammonium Phosphate
Ammonium Sulfate
Amyl Acetate
Amyl Alcohol
Asphalt

U
U
U
U
U
G
C
G
G
G
U
G
L
G
G
G
U
L
C

Barium Chloride
Barium Hydroxide
Barium Sulfide
Benzene, Benzol
Benzene (Petroleum Ether)
Benzene (Petroleum Naphtha)
Borax
Boric Acid
Bromine
Butyl Acetate
Butyl Alcohol, Butanol

G
G
G
C
C
C
L
L
U
U
L

Calcium Bisulfite
Calcium Chloride
Calcium Hydroxide
Calcium Hypochlorite
Carbolic Acid Phenol
Carbon Dioxide
Carbon Disulfide
Carbon Monoxide, Hot
Carbon Tetrachloride
Carbonic Acid
Castor Oil
Chlorinated Solvents
Chlorine, Dry
Chlorine, Wet
Chloroacetic Acid
Chloroform
Chlorosulphonic Acid
Chromic Acid
Citric Acid
Copper Chloride
Copper (II) Sulfate
Creosote

L
G
G
L
C
G
U
U
L
G
C
C
U
U
U
U
U
U
L
G
G
U

Agent

Rating

Diesel Oil, Light

Ethers
Ethyl Acetate
Ethyl Alcohol
Ethyl Chloride
Ethylene Dichloride
Ethylene Glycol

U
U
C
U
U
L

Ferric Chloride
Ferric Sulfate
Ferrous Salt Solutions
Formaldehyde
Formic Acid
Fuel Oil
Furfural

G
G
G
L
L
L
U

Gasoline
Glycerine, Glycerol
Grease, Petro

C
L
L

Heptane
Hexane
Hydraulic Fluids & Lubricating Oils,
Straight Petroleum Base
Water and Petroleum Oil
Emulsion (FR)
Water and Glycol Solution
Straight PhosphateEster (FR)
Silicone Oils
Hydrobromic Acid
Hydrochloric Acid, Cold
Hydrochloric Acid, Hot
Hydrocyanic Acid
Hydrofluoric Acid, Cold
Hydrofluoric Acid, Hot
Hydrogen Peroxide (Dilute)
Hydrogen Peroxide (Concentrated)
Hydrogen Sulfide

C
L
L
L
L
L
L
U
C
U
C
C
C
G
C
C

Kerosene

Lacquer Solvents
Lactic Acid
Linseed Oil

U
C
L

Magnesium Chloride
Magnesium Hydroxide
Magnesium Sulfate
Mercuric Chloride
Mercury
Methyl Alcohol, Methanol
Methyl Chloride
Methyl Ethyl Ketone
Methyl Isopropyl-Keytone
Mineral Oil

G
G
G
U
L
L
U
U
U
L

Agent

Rating

Naphtha
Naphthalene
Nickel Chloride
Nickel Sulfate
Nitric Acid, 10%
Nitric Acid, 70%
Nitrobenzene

C
U
G
G
L
U
U

Oleic Acid
Oleum Spirits

C
U

Perchlorethylene
Picric Acid, Molten
Picric Acid, Solution
Potassium Chloride
Potassium Cyanide
Potassium Hydroxide
Potassium Sulfate

C
U
U
G
G
C
G

Soda Ash Sodium Carbonate


Sodium Bisulfate
Sodium Chloride
Sodium Cyanide
Sodium Hydroxide
Sodium Hypochorite
Sodium Nitrate
Sodium Peroxide
Sodium Phosphate
Sodium Silicate
Sodium Sulfate
Sodium Sulfide
Sodium Thiosulfate, Hypo
Soybean Oil
Stannic Chloride
Stearic Acid
Sulfur Dioxide
Sulfur Trioxide
Sulfuric Acid, 10%, Cold
Sulfuric Acid, 10%, Hot
Sulfuric Acid, 75%, Cold
Sulfuric Acid, 75%, Hot
Sulfuric Acid, 95%, Cold
Sulfuric Acid, 95%, Hot
Sulfuric Acid, Fuming
Sulfurous Acid

G
G
G
G
C
C
G
C
G
G
G
C
G
L
G
L
C
C
L
L
L
L
U
U
U
L

Tannic Acid
Tartaric Acid
Toluene
Trichloroethylene
Turpentine

G
G
U
U
L

Varnish

Xylene

Zinc Chloride
Zinc Sulfate

L
G

AUTO DETECTION SYSTEM

*ITEMS NOT SHOWN

17183
Page 1 of 2

Updated:
08/26/08

AUTO DETECTION SYSTEM

ITEM PART #

17183
Page 2 of 2

DESCRIPTION

QTY.

334145

AUTO DETECTION SYSTEM (INCLUDES ITEMS 1, 2, 4, 6, 7)

NSS

MOUNTING BRACKET

NSS

MANUAL/AUTOMATIC ACTUATOR

334133

SQUIB

NSS

CONTROL MODULE

334146

MODULE BATTERY

334122

CARTRIDGE

334011

DETECTION WIRE

464870

RESISTOR ASSEMBLY (DETECTION LOOP)

334145-01

REMOTE HIGH LEVEL ALARM (OPTIONAL)

10*

334010

RUBBER SLEEVE

A/R

*ITEMS NOT SHOWN

Updated:
08/26/08

FIRE SUPPRESSION SYSTEM

16721
Page 1 of 4

Updated:
10/10/07

FIRE SUPPRESSION SYSTEM


ITEM PART #

16721
Page 2 of 4

DESCRIPTION

QTY.
1

334005

FIRE SUPPRESSION SYSTEM ASSEMBLY


(INCLUDES ITEMS 1-18)
FIRE SUPPRESSION SYSTEM ASSEMBLY
(INCLUDES ITEMS 25-33)
NOZZLE PACKAGE (INCLUDES ITEMS 21-24)

324014

BRACKET ASSEMBLY (INCLUDES ITEMS 2-9)

NSS

PAD, CLAMP ARM

NSS

BOLT

NSS

WASHER

NSS

NUT, LOCK

NSS

BUMPER PAD

NSS

PAD, BASE

NSS

BAND, CLAMP

NSS

PAD, CLAMP BAND

10

334118

FILL CAP ASSEMBLY (INCLUDES ITEMS 11, 12)

11

NSS

GASKET

12

NSS

QUAD RING

13

NSS

TAG, INSTRUCTION

14

334117

ADAPTER

15

334057

16

NSS

BURSTING DISC UNION ASSEMBLY


(INCLUDES ITEMS 16, 18)
ADAPTER

17

NSS

BURSTING DISC

18

NSS

UNION RING AND TAIL PIECE

19

332043

TEE, TRIPLE

A/R

20

332046

TEE, TRIPLE

A/R

21

332049

LOCKWASHER, NOZZLE

A/R

22

332047

NOZZLE

A/R

23

334121

CAP, BLOW OFF

A/R

24

NSS

BRACKET, NOZZLE MOUNTING

A/R

25

334119

26

NSS

BRACKET ASSEMBLY, CARTRIDGE


(INCLUDES ITEMS 26-29)
BOLT, CARRIAGE

334124
334125

1
6

2
Updated:
10/10/07

FIRE SUPPRESSION SYSTEM

16721
Page 3 of 4

27

NSS

NUT, LOCK

28

NSS

ARM, CLAMP

29

NSS

PAD, CLAMP ARM

30

334123

CARTRIDGE ASSEMBLY (INCLUDES ITEMS 31, 32)

31

NSS

CARTRIDGE

32

NSS

CAP, SHIPPING

33

334126

VALVE, CHECK

34

332042

VALVE, SAFETY RELIEF

35

NSS

36

NSS

ACTUATOR ASSEMBLY, PNEUMATIC


(INCLUDES ITEMS 36-45)
BODY, ACTUATOR

37

NSS

O-RING

38

NSS

PISTON, PNEUMATIC SLAVE

39

NSS

PIN, PUNCTURE

40

NSS

SPRING

41

NSS

O-RING

42

NSS

ADAPTER, BODY

43

NSS

WASHER

44

NSS

RING, RETAINING

45

NSS

GASKET

46

334013

CARTRIDGE ASSEMBLY (INCLUDES ITEMS 47, 48)

47

NSS

CARTRIDGE

48

NSS

CAP, SHIPPING

49

332044

50

NSS

ACTUATOR ASSEMBLY, MANUAL


(INCLUDES ITEMS 46-48, 50-61)
KNOB

51

NSS

BOOT

52

NSS

NUT, JAM

53

NSS

BRACKET

54

NSS

BODY, ACTUATOR

55

NSS

O-RING

56

NSS

PIN, PUNCTURE

57

NSS

ELBOW, STREET

Updated:
10/10/07

FIRE SUPPRESSION SYSTEM

16721
Page 4 of 4

58

NSS

SEAL, LEAD-WIRE

59

NSS

SCREW, DRIVE

60

NSS

CHAIN

61

NSS

RING PIN

62

334003

REMOTE ACTUATOR CARTRIDGE

A/R

Updated:
10/10/07

S1081

Ersatzteilkatalog
Spare parts list
Catalogue de pieces

Dok Nr.: s106sga

Hydraulischer Ladekran
Hydraulic crane
Grue hydraulique

Hydraulischer Ladekran
Hydraulic crane
Grue hydraulique

PK 7501

PK 9501

Gltig ab Krannummer
Valid from crane number
Valable a patir du nr. de grue

Gltig ab Krannummer
Valid from crane number
Valable a patir du nr. de grue

0522109

0522114

DE 727

DE 727

Ausgabe
Edition
Edition

Ausgabe
Edition
Edition

09/99

09/99

S1081

ABKRZUNGEN UND SYMBOLE


>........ = bis Krannummer
........> = ab Krannummer
(116) = bestehend aus Position 116
(+20) = mit Position 20
ASeite = Steuerschieberseite
BSeite = Gegenschaltseite
F = Steuerung Flur
H = Steuerung Hochsitz
KL0 = Linearsteuerung Hochsitz
KK1 = Kreuzhebelsteuerung Hochsitz
HF = Steuerung HochsitzFlur
2K = Zweikreisanlage
J = Steuerung Kabine
I = Steuerung Hochstand
RC = Fernsteuerung
NK = NotsteuerungKransule
l = Lnge in mm
s = Strke in mm
LS = LoadSensing
S = Seilwinde ohne Endlagenschalter und Schubstop
TOQU = Totpunkt ber Querholm
TOWI = Totpunkt ber Wippe
CC = Verstellpumpe
OC = Konstantpumpe

R0
R1
R2
R3
R4
SR..
X
STZS
STZY
OS
OE
OM
OB
OFB
OSE
OFS
OSK
OSK(M)
SBM
SHB
SES

= Ausleger einseitig ausziehbar


= Ausleger beidseitig ausziehbar
= Verlngerte beidseitig ausziehbare Ausleger
= Teleskopausleger
= Verlngerte Teleskopausleger
= Absttzung vom Hochsitz steuerbar
= Beidseitig hydraulisch ausfahrbare Ausleger
= Absttzzylinder starr
= Absttzzylinder schwenkbar
= berlastsicherung hydraulisch
= berlastsicherung akustisch oder optisch
= berlastsicherung mit Manometer
= berlastsicherung elektrohydraulisch ohne Pendel
= berlastsicherung elektrohydraulisch mit Pendel
= berlastsicherung elektrohydraulisch ohne Pendel
= berlastsicherung elektrohydraulisch mit Pendel
= berlastsicherung hydraulisch
= berlastsicherung hydraulisch mit Manometer
= Schwenkbegrenzung mit Manometer
= schwenkwinkelabhngige Hubkraftbegrenzung
= Seilwinde mit Endlagenschalter und Schubstop

ABBREVATIONS AND SYMBOLS


>........ = to crane number
R0
........> = from crane number
R1
(116) = consists out of position 116
R2
(+20) = with position 20
R3
ASeite = Control valve side
R4
BSeite = Counter control side
SR..
F = Control base
X
H = Control top seat
STZS
KL0 = Top seat linear control
STZY
KK1 = Top seat joystick control
OS
HF = Control top seat, base
OE
2K = Double circuit system
OM
J = Control cabin
OB
I = Control high stand
OFB
RC = Remote control
OSE
NK = Emergency controlcrane column
OFS
l = lenght in mm
OSK
s = thickness in mm
OSK(M)
LS = LoadSensing
SBM
S = Cable winch without final layer switch and extension stop SHB
TOQU = Death center over transverse spar
SES
TOWI = Death center over balance
CC = variable displacement pump
OC = fixed displacement pump

= One side extension box


= Both side extension box
= Both side extension box extended
= Extension box telescopic
= Extension box telescopic extended
= Support controllable from top seat
= Both side extension box hydraulic
= Stabilizer ram rigid
= Stabilizer ram slewable
= Overload protection hydraulic
= Overload protection acoustical or optical
= Overload protection with manometer
= Overload protection electrohydraulic without pendulum
= Overload protection electrohydraulic with pendulum
= Overload protection electrohydraulic without pendulum
= Overload protection electrohydraulic with pendulum
= Overload protection hydraulic
= Overload protection hydraulic with manometer
= Limitation of rotation with manometer
= slew angle dependent lifting capacity limitation
= Cable winch with final layer switch and extension stop

ABBREVATIONS AVEC SYMBOLES


= jusquau grue no.
= a partier du grue no.
= compse de position 116
= avec position 20
= Cote de bloc de commande
= Cote oppose
= Commande socle
= Commande siege haute
= Commande lineaire sur siege sur colonne
= Commande avec leviers en croix
= Commande siege haute, socle
= Systeme circuit double
= Commande cabine
= Commande poste de commande debout
= Inst de telecommde
= Commande de secourscolonne
= lonqueur en mm
= a paisseur en mm
= LoadSensing
= Treuil a cable sans interrupteur de couche finale
et arret d extension
TOQU = Point mort sur cadre transversale
TOWI = Point mort sur balancier
CC = pompe a cylindre variable
OC = pompe a cylindre constante

>........
........>
(116)
(+20)
ASeite
BSeite
F
H
KL0
KK1
HF
2K
J
I
RC
NK
l
s
LS
S

R0
R1
R2
R3
R4
SR..
X
STZS
STZY
OS
OE
OM
OB
OFB
OSE
OFS
OSK
OSK(M)
SBM
SHB
SES

= Extension unilateral
= Extension bilateral
= Extension bilateral rallongement
= Extension telescopique
= Extension telescopique rallongement
= Support gouvernable de siege haute
= Extension bilateral hydraulique
= Verin de stabilisateur rigide
= Verin de stabilisateur basculant
= Soupape de surcharge hydraulique
= Soupape de surcharge acoustique ou optique
= Soupape de surcharge avec manometre
= Soupape de surcharge electrohydraulique sans pendule
= Soupape de surcharge electrohydraulique avec pendule
= Soupape de surcharge electrohydraulique sans pendule
= Soupape de surcharge electrohydraulique avec pendule
= Soupape de surcharge hydraulique
= Soupape de surcharge hydraulique avec manometre
= Limitation de rotation avec manometre
= Limitation de rotation suivant capacite
= Treuil a cable avec interrupteur de couche finale
et arret d extension

S1081

HINWEISE ZUR ERSATZTEILBESTELLUNG


Bei Bestellungen bitte unbedingt angeben:
Krantype, Code und Fabrikationsnummer (siehe Typenschild)
Ersatzteilnummer
gewnschte Anzahl der Ersatzteile
Ersatzteilnummern fr Druckleitungen bzw. Druckschluche bei
Kranen mit Brdelverschraubungen 37 enden mit JI

INFORMATION ON THE ORDERING OF SPARE PARTS


To supply you with the correct parts in the shortest possible
time it is necessary to inform us about following details:
Loader type, code and serial number (look identification plate)
Spare parts number
Required quantity of spare parts
For cranes with flangecouplings 37 , spare parts numbers
for pipes and hoses end with JI

CONSIGNES RELATIVES A LA COMMANDE DES PIECES DE RECHANGE


Pour toute commande nous indiquer necessairement:
Le type de la grue, code et no de fabrication (voir plaque signaletique)
La reference de piece
La quantite de pieces
Les pieces tuyau et flexible pour les grues raccords de bordel 37
se terminent par JI

Code
Code
Code

Krantype
Loader type
Type de la grue
Fabrikationsnummer
Serial number
No de fabrication

Type:
Code:
Nr.:

A5101 Salzburg

S1081

1999/09

PK 7501,9501
Tafel
Figure
Planche

010

Index

ndice

BASE

SOPORTE BASE

010.0100 Base
010.0200 Slewing system

Base

Base

Slewing system

Sistema de giro

010.0300 Pipes-Lube system

Pipes-Lube system

Tubos del sistema de lubric.

010.0400 Pipes-Control F,H


010.0500 Pipes-Control F,H

Pipes-Control F,H

Tubos del mando F, H

Pipes-Control F,H

Tubos del mando F, H

010.0600 Pipes-Control RC
010.0700 Extension box-R1

Pipes-Control RC

Tubos del mando RC

Extension box-R1

Brazo de extensin-R1

010.0800 Extension box-R2

Extension box-R2

Brazo de extensin-R2

010.0900 Pipes-R1,R2

Pipes-R1,R2

Entubado-R1,R2

010.0901 Pipes-R1,R2

Pipes-R1,R2

Entubado-R1,R2

010.1000 Extension box-R2X

Extension box-R2X

Brazo de extensin-R2X

010.1100 Extension box-R3X

Extension box-R3X

Brazo de extensin-R3X

010.1200 Extension cylinder-R2X,R3X

Extension cylinder-R2X,R3X

Cilindro de extens.-R2X,R3X

010.1300 Pipes-R2X,R3X

Pipes-R2X,R3X

Entubado-R2X,R3X

010.1400 Stabilizer ram-STZS

Stabilizer ram-STZS

Cilindro de apoyo-STZS

010.1500 Pipes-Support STZS

Pipes-Support STZS

Tubos del soporte STZS

010.1600 Pipes-Support STZS

Pipes-Support STZS

Tubos del soporte STZS

010.1700 Stabilizer ram-STZY

Stabilizer ram-STZY

Cilindro de estab.-STZY

010.1800 Pipes-Support STZY

Pipes-Support STZY

Tubos del soporte STZY

010.1900 Pipes-Support STZY

Pipes-Support STZY

Tubos del soporte STZY

010.2000 Oil tank,cpl.(70l)

Oil tank,cpl.(70l)

Depsito,cpl.(70l)

010.2100 Oil tank,cpl.(140l)

Oil tank,cpl.(140l)

Depsito,cpl.(140l)

010.2200 Oil tank,cpl.(200l)

Oil tank,cpl.(200l)

Depsito,cpl.(200l)

CONTROL

Control del mando

020.0100 Control valve-Support

Control valve-Support

Mando de los estabilizadores

020.0200 Control valve-Details

Control valve-Details

Vlvula de control

020.0300 Control valve-F

Control valve-F

Vlvula de control-F

020.0400 Control valve-F,H

Control valve-F,H

Vlvula de control-F,H

020.0500 Control valve-Details

Control valve-Details

Vlvula de control

020.0600 Control valve-Details

Control valve-Details

Vlvula de control

020.0700 Control valve RSQ 240 RC

Control valve RSQ 240 RC

Distribuidor RSQ 240 RC

020.0800 Control valve-Details RC

Control valve-Details RC

Detalles de distribuidor RC

020.0900 Control valve-Details RC

Control valve-Details RC

Detalles de distribuidor RC

020.1000 Control valve-RC001

Control valve-RC001

Vlvula de control-RC001

020.1100 Control

Control

Control del mando

020.1200 Control (reverse acting)

Control (reverse acting)

Control del mano

OVERLOAD PROTECTION

PROTECCIN SOBRECARGA

030.0100 Overload protection-OSK-F

Overload protection-OSK-F

Proteccin de sobr.-OSK-F

030.0200 Overload protection-OSK-H

Overload protection-OSK-H

Proteccin de sobr.-OSK-H

030.0300 Overload protection-OSK-RC

Overload protection-OSK-RC

Proteccin de sobr.-OSK-RC

030.0400 Limit. of rotation

Limit. of rotation

Lmite de rotacin

030.0500 Transport position control

Transport position control

osicion de tran

030.0600 Support control

Support control

Cuidados con el punto de apoyo

020

030

BASE

Index

CONTROL

OVERLOAD PROTECTION

S1081

1999/09

PK 7501,9501
Tafel
Figure
Planche

031

Index

PALTRONIC

Index

ndice

PALTRONIC

PALTRONIC

Elektrical parts

Partes electricas

CRANE COLUME

Columna

040.0100 Crane column

Crane column

Columna

040.0200 Lifting cylinder


040.0300 Pipes-Lifting cylinder

Lifting cylinder

Cilindro elevacin

Pipes-Lifting cylinder

Tubos del cilindro de elevaci

040.0400 Top seat

Top seat

Asiento alto

MAIN BOOM

BRAZO PRINCIPAL

050.0100 Main boom PK 7501

Main boom PK 7501

Brazo principal PK 7501

050.0200 Main boom PK 9501

Main boom PK 9501

Brazo principal PK 9501

050.0300 Pipes-Outer boom ram

Pipes-Outer boom ram

Tubos del cilindro del mstil

OUTER bOOM

BRAZO ACODADO

Outer boom

Brazo acodado

BOMM EXTENSIONS

BRAZOS DE EMPUJE

070.0100 Boom extension I

Boom extension I

Brazo de empuje I

070.0200 Boom extension II

Boom extension II

Brazo de empuje II

070.0300 Boom extension III

Boom extension III

Brazo de empuje III

070.0400 Boom extension IV

Boom extension IV

Brazo de empuje IV

070.0500 Boom Extension V

Boom Extension V

Brazo de empuje V

070.0600 Boom extensions ram I-V

Boom extensions ram I-V

Cilindro de empuje I-V

070.0700 Pipes-Boom extens.ram

Pipes-Boom extens.ram

Tubos de los cilindros de ext.

070.0800 Pipes-Boom extens.ram

Pipes-Boom extens.ram

Tubos de los cilindros de ext.

070.0900 Pipes-Boom extens.ram

Pipes-Boom extens.ram

Tubos de los cilindros de ext.

070.1000 Hose guide

Hose guide

Gua de manguera

070.1100 Pipes-Hose guide

Pipes-Hose guide

Tubos de la gua de las mangue

EXTENSIONS

EXTENSIONS

Prolongas

Man. boom extensions

Prolongas

ROPE WINCH

TORNO DE CABLE

090.0100 Rope winch-S

Rope winch-S

Torno de cable-S

090.0200 Pipes-Rope winch S

Pipes-Rope winch S

Entubado-Torno de cable S

090.0300 Rope winch-SES

Rope winch-SES

Torno de cable-SES

090.0400 Pipes-Rope winch SES

Pipes-Rope winch SES

Entubado-Torno de cable SES

090.0500 Guide pulley,trolley head

Guide pulley,trolley head

Polea inversin,aparato halar

DIVERSES

Diversos

100.0100 Diverses

Diverses

Diversos

100.0200 Shields

Shields

Placa

031.0100 Elektrical parts

040

050

060

CRANE COLUME

MAIN BOOM

OUTER bOOM

060.0100 Outer boom

070

080

BOMM EXTENSIONS

080.0100 Man. boom extensions

090

100

ROPE WINCH

DIVERSES

S1081

Tafel
Figure
Planche

Table of contents

Index

Table des matieres

ENCLOSURE

ENCLOSURE

VASE APNDICE

A1

Cover

Cover

Capa

A2

Abbreviation

Abbreviation

Abreviatura

A3

Preface

Preface

Prefacio Prologo

A4

Spareparts order

Spareparts order

Piezas de recambio pedidos

A5

O-seal

O-seal

Anillo en O

A6

Hose armatures

Hose armatures

Manguera armatures

A7

Ausgabenbersicht

editions overvu

apercu d'editions

A8

nderungshistorie

history of modifications

histoire de modification

010.0100
03/2004

PK 7501,9501

Base
Base
Base

S1081

RC

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

zu Tafel
to figure
a' planche

Base
Base
Base

Stk.
Qty.
Nbre.

1
2
3
3
3
3
4
4
4
4
5
6
7
8

S106G01-A
EQ 189
HT6218
HT6749
HT6750
HT6751
HT6217
HT6758
HT6759
HT6760
HBK 129
ES 264
ES 265
HXL 020

1
1
1
1
1
1
1
1
1
1
1
3
5
1

HXV 407

10

EA1391
TD 513

11
12
13
14

HXE1863
ES1082
ES1172
HXE2022

1
2
4
1

15
16

EM 006
HXE...

4
1

17

HXE...

18
19

S106G04-A
KMG00...A

1
2

20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

HA5934
EM 026
HXE1860
ES 374
HXE1796
HXV 398
HX 463
HBA 096
EF 081
HI 916
EZ 253
HA2210
EQ 299
EA 412
HXS 021
EA1392
BZ204S

1
4
1
4
1
1
1
1
1
1
1
1
1
1
1
1

Description

Base
Circlip
Bearing
Bearing
Bearing
Bearing
Bearing
Bearing
Bearing
Bearing
Bearing ring
Screw
Screw
Hose ring
[H]
Lever cpl.
[R1,R2]
High press. filter
Seal kit
[fr EA1391]
Bracket
Screw
Screw
Armrest
[fr S105S02SA]
Nut
Bracket
[siehe KSC0000]
[Seite 100.0200]
Bracket
[siehe KSC0000]
[Seite 100.0200]
Base
Housing cpl.
[siehe KMG00303A]
[Seite 020.0200]
Bracket
Nut
Bracket
Screw
Bracket
Housing cpl.
Bush
Bush
Pressure spring
Pin
Handle,black
Pin
Adapter sleeve
Grease nipple
Safety chain
Filter element
Filter element,
cpl.

Description

Base
Circlip
Bearing
Bearing
Bearing
Bearing
Bearing
Bearing
Bearing
Bearing
Bearing ring
Screw
Screw
Hose ring
[H]
Lever cpl.
[R1,R2]
High press. filter
Seal kit
[for EA1391]
Bracket
Screw
Screw
Armrest
[for S105S02SA]
Nut
Bracket
[look KSC0000]
[page 100.0200]
Bracket
[look KSC0000]
[page 100.0200]
Base
Housing cpl.
[look KMG00303A]
[page 020.0200]
Bracket
Nut
Bracket
Screw
Bracket
Housing cpl.
Bush
Bush
Pressure spring
Pin
Handle,black
Pin
Adapter sleeve
Grease nipple
Safety chain
Filter element
Filter element,
cpl.

010.0100

Denominacin de repuestos

Base
Circlip exterior
Soporte
Soporte
Soporte
Soporte
Soporte
Soporte
Soporte
Soporte
Anillo de cojinete
Tornillo
Tornillo
Anillo de manguera
[H]
Palanca de trinquete
[R1,R2]
Filtro de alta pres.
Juego de juntas
[pour EA1391]
Consola
Tornillo
Tornillo
Apoyo de brazo
[pour S105S02SA]
Tuerca
Consola distribuidor
[voir KSC0000]
[page 100.0200]
Consola distribuidor
[voir KSC0000]
[page 100.0200]
Base
Carcasa de trinquete
[voir KMG00303A]
[page 020.0200]
Consola
Tuerca
Consola
Tornillo
Consola
Carcasa de trinquete
Casquillo trinquete
Casquillo trinquete
Resorte de compres.
Clavija
Maneta negra
Pasador
Casquillo de apriete
Racor de engrase
Cadena de seguridad
Filtro
Cartucho filtro
cplto.

Abmessung
Dimension
Dimension

D 140 DIN 471


3,0 mm
3,1 mm
3,2 mm
3,3 mm
3,0 mm
3,1 mm
3,2 mm
3,3 mm
M 8x16 DIN 912
M 8x20 DIN 912

M 8x12 DIN 7984


M 10x40 DIN 912

M 10 DIN 934

RC400
M 8 DIN 985
RC
M 8x12 DIN 912
PALTRONIC

D 20,5x1,5x115

D 4x18 DIN 1481


M 6x1 H1 71412

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

36

EA2168

Stk.
Qty.
Nbre.

TD1553
37

EA2169

zu Tafel
to figure
a' planche

Base
Base
Base

Description

[Seite 100.0100]
High press. filter
[100015264-->]
Seal kit
[fr EA2168]
Filter element

Description

[page 100.0100]
High press. filter
[100015264-->]
Seal kit
[for EA2168]
Filter element

010.0100

Denominacin de repuestos

[page 100.0100]
Filtro de alta pres.
[100015264-->]
Juego de juntas
[pour EA2168]
Filtro

Abmessung
Dimension
Dimension

ab BJ 09/2004

ab BJ 09/2004

010.0200
11/2004

PK 7501,9501

Base
Base
Base

(>1010212)

(1010213>)

F,RC

S1081

S1081

PALFINGER

Slewing system
Slewing system
Sistema de giro

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2

EA 039
HLR 8769

1
1

HLR12400

HLR 8866

HLR 8768

HLR12401

HLR 8865

4
5

EA1749
HLR 8791

1
1

6
7

EA 183
EV5037-160

4
1

TD1001
7

EV5037-210

TD1001

Description

Description

zu Tafel
to figure
a' planche

010.0200

Denominacin de repuestos

Abmessung
Dimension
Dimension

Adaptor
Pipe
(F)
Pipe
(RSQ 240 RC)
Pipe
(RC001)
Pipe
(F)
Pipe
(RSQ 240 RC)
Pipe
(RC001)
Banjo
Pipe

Adaptor
Pipe
(F)
Pipe
(RSQ 240 RC)
Pipe
(RC001)
Pipe
(F)
Pipe
(RSQ 240 RC)
Pipe
(RC001)
Banjo
Pipe

Racor
Tubo
(F)
Tubo
(RSQ 240 RC)
Tubo
(RC001)
Tubo
(F)
Tubo
(RSQ 240 RC)
Tubo
(RC001)
Engranaje
Tubo

GE 12 SR 3/8"ED
D 12

Adaptor
Load holding valve
(PK 7501)
Seal kit
(for EV5037)
Load holding valve
(PK 9501)
Seal kit
(for EV5037)
Pipe
Hose
(PK 9501)
Hose
(PK 7501)
Screw

Adaptor
Load holding valve
(PK 7501)
Seal kit
(for EV5037)
Load holding valve
(PK 9501)
Seal kit
(for EV5037)
Pipe
Hose
(PK 9501)
Hose
(PK 7501)
Screw

Racor
Vlvula retencin
(PK 7501)
Juego de juntas
(para EV5037)
Vlvula retencin
(PK 9501)
Juego de juntas
(para EV5037)
Tubo
Manguera
(PK 9501)
Manguera
(PK 7501)
Tornillo

GE 12 SR 1/2"ED
160 bar

Nut
Bracket
O-seal
Piston
Limit. of rotation
(190 degree)
Limit. of rotation
(210 degree)
Seal ring

Tuerca
Consola
Anillo en O
Pistn
Lmite de rotacin

M 8 DIN 985

Lmite de rotacin
(210 grados)
Anillo obturador

l=139 mm

8
9

HLR 8792
EH 321

1
2

EH4902

10

ES 432

11
12
13
14
14

EM 026
HXE 509
EO 035
HK 652
HK 670

2
1
2
2
2

14

HK 671

15

ED1228

Nut
Bracket
O-seal
Piston
Limit. of rotation
(190 degree)
Limit. of rotation
(210 degree)
Seal ring

16
17
18
19
20

HK 653
EG 111
EQ 132
EK 007
ES1444

2
2
2
2
2

Piston
Guide ring
Circlip
Washer
Screw

Piston
Guide ring
Circlip
Washer
Screw

Pistn
Anillo-gua
Circlip exterior
Arandela
Tornillo

21
22
23
23

HY1392A+00001
ED 064
HK 064
HXE1918

2
2
2
2

23

SK458-4002

Cylinder tube
Piston seal
Piston
Limit. of rotation
(200 degree)
Limit. of rotation

Cylinder tube
Piston seal
Piston
Limit. of rotation
(200 degree)
Limit. of rotation

Cilindro
Junta de pistn
Pistn
Lmite de rotacin
(200 grados)
Lmite de rotacin

D 12
D 12
D 12
D 12
D 12
WH 12S 3/8-O
D 12

210 bar

D 12
NW 8x3100
NW 8x2950
M 8x50 DIN 912

D 24,2x3
l=154 mm

100x80x12.5 mm

100x95x14.8 mm
D 65 DIN 471
D 10 DIN 125
M10x1x25 DIN961

l=147.5 mm
l=110.5 mm

S1081

PALFINGER

Slewing system
Slewing system
Sistema de giro

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

010.0200

Denominacin de repuestos

24
25

HZS 089
HIG 228

1
1

(250 degree)
Rack
Grease tube

(250 degree)
Rack
Grease tube

Cremallera
Tubo de lubricacin

26
27
28

EO 130
EO 027
EZ1208

1
1
1

O-seal
O-seal
Guide block

O-seal
O-seal
Guide block

Anillo en O
Anillo en O
Pieza deslizante

Abmessung
Dimension
Dimension

D 11x3,5
D 11,3x2,4

010.0300
04/2003

alte Ausfhrung
Type old
Version vieux

PK 7501,9501

Base
Base
Base

neue Ausfhrung
Type new
Version nouveau

S1081

S1081

PALFINGER

Pipes-Lube system
Pipes-Lube system
Tubos del sistema de lubric.

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

010.0300

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
2
3
4
5

EA 002
EA 005
EA 001
EA 623
HLA1098

5
4
1
2
1

Adaptor
Grease nipple
Banjo
Adaptor
Grease tube

Adaptor
Grease nipple
Banjo
Adaptor
Grease tube

Racor
Racor de engrase
Engranaje
Racor
Tubo de lubricacin

GE 6L M10x1-ED
M 10x1 DIN71412
WH 06L M 10x1
WE 06-LM

6
7
8
9
10

EO 547
ED 391
EA1079
EA 265
EA 641

1
1
8
8
8

O-seal
Sealing ring
Bush
Cutting ring
Nut

O-seal
Sealing ring
Bush
Cutting ring
Nut

Anillo en O
Arista obturadora
Casquillo
Anillo cortante
Tuerca de racor

D 9,3x1,5
KD M10
E 6/3
D6S
M6L

11

EH1434

Grease tube
(sold by the meter)

Grease tube
(sold by the meter)

Tubo de lubricacin
(en metros)

010.0400
09/1999

PK 7501,9501

Base
Base
Base
Steuerventil
Directional control valve
Distributeur de commande

H
ltank
Oil tank
Reservoir a huile

Hochdruckfilter
High press. filter
Filtre haute press.

F
ltank
Oil tank
Reservoir a huile

Steuerventil
Directional control valve
Distributeur de commande

Hochdruckfilter
High press. filter
Filtre haute press.

S1081

S1081

PALFINGER

Pipes-Control F,H
Pipes-Control F,H
Tubos del mando F, H

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

010.0400

Denominacin de repuestos

1
2
3
4
5

EA 045
EA 343
EA 033
EH1175
EH1565

1
1
3
1
1

Nut
Locking bolt
Adaptor
Hose
Hose

Nut
Locking bolt
Adaptor
Hose
Hose

Tuerca de racor
Tapn
Racor
Manguera
Manguera

6
7
8
9
10

HA2673
EM 026
ES 265
HG 167
ES 059

1
4
2
1
2

Bearer
Nut
Screw
Housing
Screw

Bearer
Nut
Screw
Housing
Screw

Soporte
Tuerca
Tornillo
Carcasa
Tornillo

11
12
13

EA 243
ES 111
EH 736

2
1
1

13

EH1973

14

EH3472

14

EH4894

15

EH4872

15

EH4901

Adaptor
Locking screw
Hose
(PK 9501)
Hose
(PK 7501)
Hose
(PK 9501)
Hose
(PK 7501)
Hose
(PK 9501)
Hose
(PK 7501)

Adaptor
Locking screw
Hose
(PK 9501)
Hose
(PK 7501)
Hose
(PK 9501)
Hose
(PK 7501)
Hose
(PK 9501)
Hose
(PK 7501)

Racor
Tapn roscado
Manguera
(PK 9501)
Manguera
(PK 7501)
Manguera
(PK 9501)
Manguera
(PK 7501)
Manguera
(PK 9501)
Manguera
(PK 7501)

Abmessung
Dimension
Dimension
M 16 S
BUZ 16 S
GE 16 SR 3/4"ED
NW 16x1100
NW 12x700

M 8 DIN 985
M 8x20 DIN 912
M 8x70 DIN 912
GE 18 LRed
vsti 3/4"
NW 12x3160
NW 12x3000
NW 12x3200
NW 12x3050
NW 16x3150
NW 16x3000

010.0500
09/1999

PK 7501,9501

S1081

Base
Base
Base

Anschlublock
Connection block
Bloc de connexion

SteuerventilAbsttzung
Directional control valveSupport
Distributeur de commandeSupport

SteuerventilAbsttzung
Directional control valveSupport
Distributeur de commandeSupport

SteuerventilAbsttzung
Directional control valveSupport
Distributeur de commandeSupport

Steuerventil
Directional control valve
Distributeur de commande

Steuerventil
Directional control valve
Distributeur de commande

Steuerventil
Directional control valve
Distributeur de commande

S1081

PALFINGER

Pipes-Control F,H
Pipes-Control F,H
Tubos del mando F, H

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange
1
2
3
4
5
6
7
8
9

EA 019
EA 237
HLR 8778
HLR 8779
HLR 8789
HLR 8800
HLR 8790
EA 033
EA 243

Stk.
Qty.
Nbre.
1
1
1
1
1
1
1
1
1

Description

Angle coupling
Angle coupling
Pipe
Pipe
Pipe
Pipe
Pipe
Adaptor
Adaptor

Description

Angle coupling
Angle coupling
Pipe
Pipe
Pipe
Pipe
Pipe
Adaptor
Adaptor

zu Tafel
to figure
a' planche

010.0500

Denominacin de repuestos

Acoplamiento acodado
Acoplamiento acodado
Tubo
Tubo
Tubo
Tubo
Tubo
Racor
Racor

Abmessung
Dimension
Dimension
EVW 16 S
evW 18 L
D 16
D 18
D 16
D 18
D 18
GE 16 SR 3/4"ED
GE 18 LRed

010.0600
03/2004

PK 7501,9501

Base
Base
Base

S1081

RC001
Steuerventil
Directional control valve
Distributeur de commande

SteuerventilAbsttzung
Directional control valveSupport
Distributeur de commandeSupport

Hochdruckfilter
High press. filter
Filtre haute press.

RSQ 240 RC
ltank
Oil tank
Reservoir a huile

Steuerventil
Directional control valve
Distributeur de commande

SteuerventilAbsttzung
Directional control valveSupport
Distributeur de commandeSupport
Hochdruckfilter
High press. filter
Filtre haute press.

S1081

PALFINGER

Pipes-Control RC
Pipes-Control RC
Tubos del mando RC

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

010.0600

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
2
3
4
5

EH4921
EA 238
EA 344
EA 511
EA 106

1
1
1
1
1

Hose
Nut
Locking bolt
L-coupling
Nut

Hose
Nut
Locking bolt
L-coupling
Nut

Manguera
Tuerca de racor
Tapn
Racor en L
Tuerca de racor

NW 16x1700
M 18 L
BUZ 18 L
EVL 18 L
M 20 S

6
7
7
8
9
10

EA 345
EA 097
EA 754
EH1873
EH1036
EH5038

1
2
2
1
1
1

Locking bolt
Adaptor
Adaptor
Hose
Hose
Hose

Locking bolt
Adaptor
Adaptor
Hose
Hose
Hose

Tapn
Racor
Racor
Manguera
Manguera
Manguera

BUZ 20 S
GE 20 SR 3/4"ED
GE 20S R1/1-ED
NW 16x700
NW 12x2000
NW 10x1900

11
12
13
14
15

EA 237
EH4891
EA 190
EA 045
EA 343

1
1
1
1
1

Angle coupling
Hose
Adaptor
Nut
Locking bolt

Angle coupling
Hose
Adaptor
Nut
Locking bolt

Acoplamiento acodado
Manguera
Racor
Tuerca de racor
Tapn

evW 18 L
NW 6x1550
GE 10-L 3/8-ED
M 16 S
BUZ 16 S

16
17

EA 033
EA 226

2
2

EH1565
EA 039
EH1175

1
1
1

Adaptor
Reduction
(for EA2168)
Hose
Adaptor
Hose

Racor
Tubuladura reduccin
(para EA2168)
Manguera
Racor
Manguera

GE 16 SR 3/4"ED
RI 1"-3/4"

18
19
20

Adaptor
Reduction
(for EA2168)
Hose
Adaptor
Hose

NW 12x700
GE 12 SR 3/8"ED
NW 16x1100

010.0700
04/2003

R1

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Extension box-R1
Extension box-R1
Brazo de extensin-R1

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

010.0700

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
2
3
4
5

ES1089
HTR1529
HTR1427
HF 050
HXE1716

16
2
2
7
4

Screw
Shim plate
Shim plate
Guide
Tread roller,
cpl.

Screw
Shim plate
Shim plate
Guide
Tread roller,
cpl.

Tornillo
Placa intermedia
Placa intermedia
Rodillo
Rodillo portante,
cpl.

M 8x10 DIN 7984


1 mm
5 mm
3 mm

6
7
8
9
10

ES1082
HA3499
EM 180
HIG 653
HTR3550

4
1
8
4
2

Screw
Hose guide
Nut
Guide
Guide piece

Screw
Hose guide
Nut
Guide
Guide piece

Tornillo
Gua de manguera
Tuerca
Rodillo
Pieza gua

M 8x12 DIN 7984

11
12
13
14
15

EK 340
ES 006
EM 021
EK 202
HA6238

4
4
1
1
1

Washer
Screw
Nut
Washer
Cover plate

Washer
Screw
Nut
Washer
Cover plate

Arandela
Tornillo
Tuerca
Arandela
Place de cubierta

D 8 DIN 125
M 8x25 DIN 912
M 10 DIN 985
D 10,5 DIN 134

16
17
18
19
20

HA6237
HR 226
HR 224
ES 308
HXE1764

1
1
1
4
2

Bearer
Eccentric bolt
Tread roller
Screw
Stirrup

Bearer
Eccentric bolt
Tread roller
Screw
Stirrup

Soporte
Buln excntrico
Rodillo portante
Tornillo
Estribo

21

S105A11-A

Extension box-R1

Extension box-R1

21

S106A11-A

(PK 7501)
Extension box-R1

(PK 7501)
Extension box-R1

22
23

HF 796
S106A10-A

2
1

(PK 9501)
Guide
Extension box-R1

(PK 9501)
Guide
Extension box-R1

24

S106A10-B

Extension box-R1

Extension box-R1

25

S105A11-B

Extension box-R1

Extension box-R1

25

S106A11-B

(PK 7501)
Extension box-R1

(PK 7501)
Extension box-R1

(PK 9501)

(PK 9501)

Brazo de
extensin-R1
(PK 7501)
Brazo de
extensin-R1
(PK 9501)
Rodillo
Brazo de
extensin-R1
Brazo de
extensin-R1
Brazo de
extensin-R1
(PK 7501)
Brazo de
extensin-R1
(PK 9501)

M 24x1.5
l=28 mm
10 mm

D 62 mm
M 8x20 DIN 7984

8 mm

010.0800
04/2003

R2

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Extension box-R2
Extension box-R2
Brazo de extensin-R2

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2
3
4
5

ES1089
HTR1529
HTR1427
HF 050
HXE1716

14

HXE1718

7
8
9

ES1082
HA3499
HXE1717

4
1
2

10

ES 265

11
12
13
14
15

Description

Description

zu Tafel
to figure
a' planche

010.0800

Denominacin de repuestos

Abmessung
Dimension
Dimension

Screw
Shim plate
Shim plate
Guide
Tread roller,
cpl.

Screw
Shim plate
Shim plate
Guide
Tread roller,
cpl.

Tornillo
Placa intermedia
Placa intermedia
Rodillo
Rodillo portante,
cpl.

Tread roller,
cpl.
Screw
Hose guide
Tread roller,
cpl.
Screw

Tread roller,
cpl.
Screw
Hose guide
Tread roller,
cpl.
Screw

Rodillo portante,
cpl.
Tornillo
Gua de manguera
Rodillo portante,
cpl.
Tornillo

EK 340
HTR3595
HF 281
EM 180
HIG 428

6
1
3
10
3

Washer
Shim plate
Guide
Nut
Guide

Washer
Shim plate
Guide
Nut
Guide

Arandela
Placa intermedia
Rodillo
Tuerca
Rodillo

D 8 DIN 125
15 mm
13.5 mm
M 24x1.5
l=40 mm

16
17
18
19
20

HTR3551
ES 006
HTR3550
HIG 653
EM 021

1
4
1
2
3

Guide piece
Screw
Guide piece
Guide
Nut

Guide piece
Screw
Guide piece
Guide
Nut

Pieza gua
Tornillo
Pieza gua
Rodillo
Tuerca

10 mm
M 8x25 DIN 912
10 mm
l=28 mm
M 10 DIN 985

21
22
23
24
25

EK 202
HA6238
HA6237
HR 226
HR 224

3
3
2
3
1

Washer
Cover plate
Bearer
Eccentric bolt
Tread roller

Washer
Cover plate
Bearer
Eccentric bolt
Tread roller

Arandela
Place de cubierta
Soporte
Buln excntrico
Rodillo portante

D 10,5 DIN 134

26
27
28
29
30

HR 225
HA6236
HF 796
ES 308
HXE1764

2
1
1
4
2

Tread roller
Bearer
Guide
Screw
Stirrup

Tread roller
Bearer
Guide
Screw
Stirrup

Rodillo portante
Soporte
Rodillo
Tornillo
Estribo

D 70 mm

31

S106A21-A

Extension box-R2

Extension box-R2

32

S106A20-A

Extension box-R2

Extension box-R2

33
34
35

EM 014
EQ 043
HR 124

2
2
1

Nut
Circlip
Tread roller

Nut
Circlip
Tread roller

Brazo de
extensin-R2
Brazo de
extensin-R2
Tuerca
Circlip exterior
Rodillo portante

36
37
38
39

HI 521
EF 024
ES 100
S106A20-B

1
2
2
1

Pin
Pressure spring
Screw
Extension box-R2

Pin
Pressure spring
Screw
Extension box-R2

40

S106A21-B

Extension box-R2

Extension box-R2

1
3
1

Pasador
Resorte de compres.
Tornillo
Brazo de
extensin-R2
Brazo de
extensin-R2

M 8x10 DIN 7984


1 mm
5 mm
3 mm

M 8x12 DIN 7984

M 8x20 DIN 912

D 62 mm

8 mm
M 8x20 DIN 7984

M 6 DIN 985
D 12 DIN 471
D 47 mm

M 6x60 DIN 6912

010.1200
09/1999

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Extension cylinder-R2X,R3X
Extension cylinder-R2X,R3X
Cilindro de extens.-R2X,R3X

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

010.1200

Denominacin de repuestos

1
2
3
4
5

UP1409
UP1408
UP1406
HY1280
HSK1166

1
1
1
2
2

Extension ram
Extension ram
Extension ram
Cylinder tube
Piston rod

Extension ram
Extension ram
Extension ram
Cylinder tube
Piston rod

Cilindro de extens.
Cilindro de extens.
Cilindro de extens.
Cilindro
Vstago del mbolo

6
7
8
9
10

HY1278
HSK1162
EO 108
HBS2662
TD 526

1
1
1
1
3

Cylinder tube
Piston rod
O-seal
Distance washer
Seal kit

Cylinder tube
Piston rod
O-seal
Distance washer
Seal kit

Cilindro
Vstago del mbolo
Anillo en O
Faja espaciadora
Juego de juntas

11

HV 437

Cylinder nut

Cylinder nut

Tuerca del cilindro

Abmessung
Dimension
Dimension

D 25x2

010.1300
09/2003

PK 7501,9501

S1081

Base
Base
Base

SteuerventilAbsttzung
Directional control valveSupport
Distributeur de commandeSupport

ASeite
SideA
CoteA
Ausfahrzylinder
Extension cylinder
Verin de extension

Ausfahrzylinder
Extension cylinder
Verin de extension
BSeite
SideB
CoteB

S1081

PALFINGER

Pipes-R2X,R3X
Pipes-R2X,R3X
Entubado-R2X,R3X

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2
3
4

HLR 8775
HLR 8776
HLR 8773
EH 322

1
1
1
2

EH 337

EH6149

EH6160

HLR 8777

6
7

EA 195
EH 344

2
2

EH3632

EH6159

EH 680

8
9

HLR 8774
UV423

1
2

10

EH3094

11

EA 280

12
13
14
15

HLR 8771
EA 204
HLR 8772
EA 280

1
1
1
2

16
17

HLR 8770
EH1876

1
2

17

EH1877

17

EH2201

17

EH2202

18
19

EA 039
EV4107/040

1
1

Description

Description

zu Tafel
to figure
a' planche

010.1300

Denominacin de repuestos

Abmessung
Dimension
Dimension

Pipe
Pipe
Pipe
Hose
(STZY,R3X)
Hose
(STZY,R2X)
Hose
(STZS,R2X)
Hose
(STZS,R3X)
Pipe

Pipe
Pipe
Pipe
Hose
(STZY,R3X)
Hose
(STZY,R2X)
Hose
(STZS,R2X)
Hose
(STZS,R3X)
Pipe

Tubo
Tubo
Tubo
Manguera
(STZY,R3X)
Manguera
(STZY,R2X)
Manguera
(STZS,R2X)
Manguera
(STZS,R3X)
Tubo

D 12
D 12
D 12
NW 8x2900

T-coupling
Hose
(STZY,R2X)
Hose
(STZY,R3X)
Hose
(STZS,R3X)
Hose
(STZS,R2X)
Pipe
Pretension valve,
cpl.
Hose

T-coupling
Hose
(STZY,R2X)
Hose
(STZY,R3X)
Hose
(STZS,R3X)
Hose
(STZS,R2X)
Pipe
Pretension valve,
cpl.
Hose

Racor en T
Manguera
(STZY,R2X)
Manguera
(STZY,R3X)
Manguera
(STZS,R3X)
Manguera
(STZS,R2X)
Tubo
Vlvula pretensin
cplta.
Manguera

T 12 S
NW 8x2700

Angle coupling
(R3X)
Pipe
Adaptor
Pipe
Angle coupling

Angle coupling
(R3X)
Pipe
Adaptor
Pipe
Angle coupling

Acoplamiento acodado
(R3X)
Tubo
Racor
Tubo
Acoplamiento acodado

EVW 12 S

Pipe
Protection hose
(STZS,R2X)
Protection hose
(STZS,R3X)
Protection hose
(STZY,R2X)
Protection hose
(STZY,R3X)
Adaptor
Pretension valve

Pipe
Protection hose
(STZS,R2X)
Protection hose
(STZS,R3X)
Protection hose
(STZY,R2X)
Protection hose
(STZY,R3X)
Adaptor
Pretension valve

Tubo
Manga protectora
(STZS,R2X)
Manga protectora
(STZS,R3X)
Manga protectora
(STZY,R2X)
Manga protectora
(STZY,R3X)
Racor
Vlvula de pretens.

D 12
D 50x1900

NW 8x2500
NW 8x2100
NW 8x2350
D 12

NW 8x3000
NW 8x2500
NW 8x2200
D 12
40 bar
NW 8x480

D 12
G 12 S
D 12
EVW 12 S

D 50x2150
D 50x2700
D 50x3100
GE 12 SR 3/8"ED

010.1400
08/2000

PK 7501,9501

Sttzteller nicht im Lieferumfang enthalten,


diese mssen als Zubehr gesondert bestellt werden

The support plates are not included in the delivery,


they mast be ordered separatly as accessoires.
Les pieds de bequille ne font pas partie de la fournituro,
ils doivent etre commandes separement
comme accessoires.

Base
Base
Base

S1081

S1081

PALFINGER

Stabilizer ram-STZS
Stabilizer ram-STZS
Cilindro de apoyo-STZS

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2
3

UP1489
HY1370
TD 596

1
1
1

4
5

HSK 083A
HV 371

6
7
8
8
9
10
11
12
13
14

Description

Description

zu Tafel
to figure
a' planche

010.1400

Denominacin de repuestos

Abmessung
Dimension
Dimension

Stabilizer ram
Cylinder tube
Seal kit
(+6)
Piston rod
Cylinder nut

Cilindro de apoyo
Cilindro
Juego de juntas
(+6)
Vstago del mbolo
Tuerca del cilindro

l=961 mm

1
1

Stabilizer ram
Cylinder tube
Seal kit
(+6)
Piston rod
Cylinder nut

EG 051
ES1161
HD 008
HD 063
EM 026
EZ 872

2
1
1
1
1
1

Guide ring
Screw
Stabilizer plate
Adapter
Nut
Distance plate

Guide ring
Screw
Stabilizer plate
Adapter
Nut
Distance plate

Anillo-gua
Tornillo
Plato de soporte
Prolonga
Tuerca
Chapa separadora

75x70x15
M 8x100 DIN 912
Standard
250 mm
M 8 DIN 985
D 400

ES 157
EM 023
ES 173
HAU 197

8
10
2
1

Screw
Nut
Screw
Stirrup

Screw
Nut
Screw
Stirrup

Tornillo
Tuerca
Tornillo
Estribo extrable

M 12x35 DIN 912


M 12 DIN 985
M 12x45 DIN 912

010.1500
09/1999

Side-A
Side-A
Lado A

Stabilizer ram
Stabilizer ram
Cilindr. gatos

PK 7501,9501

S1081

Base
Base
Base

Side-B
Side-B
Lado B

Stabilizer ram
Stabilizer ram
Cilindr. gatos

S1081

PALFINGER

Pipes-Support STZS
Pipes-Support STZS
Tubos del soporte STZS

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2
3

HLR 8509
EA1749
EV4109A
TD 264

1
2
2

4
5

EA 039
HLR 8788

6
7

EA1449
ED 620

Description

Description

zu Tafel
to figure
a' planche

010.1500

Denominacin de repuestos

4
1

Pipe
Banjo
Check valve
Seal kit
(for EV4109A)
Adaptor
Pipe

Pipe
Banjo
Check valve
Seal kit
(for EV4109A)
Adaptor
Pipe

Tubo
Engranaje
Vlvula de ret.
Juego de juntas
(para EV4109A)
Racor
Tubo

1
1

Female screw
Sealing ring

Female screw
Sealing ring

Tornillo racor
Arista obturadora

Abmessung
Dimension
Dimension
D 12
WH 12S 3/8-O

GE 12 SR 3/8"ED
D 12

KD 3/8"

010.1600
09/1999

ASeite
SideA
CoteA

Absttzzylinder
Stabilizer ram
Verin de stabilisateur

PK 7501,9501

S1081

Base
Base
Base

BSeite
SideB
CoteB

Absttzzylinder
Stabilizer ram
Verin de stabilisateur

S1081

PALFINGER

Pipes-Support STZS
Pipes-Support STZS
Tubos del soporte STZS

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2
3

HLR 8509
EA1749
EV4418
TD 848

1
2
1

4
5

EA 039
EV4110
TD 848

4
1

6
7
8

HLR 8788
EA1449
ED 620

1
2
2

Description

Description

zu Tafel
to figure
a' planche

010.1600

Denominacin de repuestos

Abmessung
Dimension
Dimension

Pipe
Banjo
Check valve
Seal kit
(for EV4418)
Adaptor
Check valve
Seal kit
(for EV4110)

Pipe
Banjo
Check valve
Seal kit
(for EV4418)
Adaptor
Check valve
Seal kit
(for EV4110)

Tubo
Engranaje
Vlvula de ret.
Juego de juntas
(para EV4418)
Racor
Vlvula de ret.
Juego de juntas
(para EV4110)

D 12
WH 12S 3/8-O

Pipe
Female screw
Sealing ring

Pipe
Female screw
Sealing ring

Tubo
Tornillo racor
Arista obturadora

D 12

GE 12 SR 3/8"ED

KD 3/8"

010.1700
08/2000

PK 7501,9501

Sttzteller nicht im Lieferumfang enthalten,


diese mssen als Zubehr gesondert bestellt werden

The support plates are not included in the delivery,


they mast be ordered separatly as accessoires.
Les pieds de bequille ne font pas partie de la fournituro,
ils doivent etre commandes separement
comme accessoires.

Base
Base
Base

S1081

S1081

PALFINGER

Stabilizer ram-STZY
Stabilizer ram-STZY
Cilindro de estab.-STZY

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2

UP1511
TD 596

1
1

3
4
5

EG 051
HV 371
HSK 084A

6
7
8
9
10

Description

Description

zu Tafel
to figure
a' planche

010.1700

Denominacin de repuestos

2
1
1

Stabilizer ram
Seal kit
(+3)
Guide ring
Cylinder nut
Piston rod

Stabilizer ram
Seal kit
(+3)
Guide ring
Cylinder nut
Piston rod

Cilindro de apoyo
Juego de juntas
(+3)
Anillo-gua
Tuerca del cilindro
Vstago del mbolo

HY1387
EA 005
HI2738
EF 061
HX 463

1
3
1
1
1

Cylinder tube
Grease nipple
Pin
Pressure spring
Bush

Cylinder tube
Grease nipple
Pin
Pressure spring
Bush

Cilindro
Racor de engrase
Pasador
Resorte de compres.
Casquillo trinquete

11
11
12
13
14
15

EQ 275
EQ 299
HA6490
EZ 253
EM 023
ES 022

1
1
1
1
10
10

Roll pin
Adapter sleeve
Pin
Handle,black
Nut
Screw

Roll pin
Adapter sleeve
Pin
Handle,black
Nut
Screw

Pasador de sujecin
Casquillo de apriete
Pasador
Maneta negra
Tuerca
Tornillo

16
17
18
19
20

HXE1711
ES1181
HA6446
ES 275
HXE1875

1
2
1
1
1

Cylinder support
Screw
Stirrup
Screw
Hose guide

Cylinder support
Screw
Stirrup
Screw
Hose guide

Soporte de apoyo
Tornillo
Estribo extrable
Tornillo
Gua de manguera

21
22
23
23
24

EM 026
ES1161
HD 008
HD 063
EZ 872

1
1
1
1
1

Nut
Screw
Stabilizer plate
Adapter
Distance plate

Nut
Screw
Stabilizer plate
Adapter
Distance plate

Tuerca
Tornillo
Plato de soporte
Prolonga
Chapa separadora

Abmessung
Dimension
Dimension
l=954 mm

75x70x15

M 10x1 DIN71412
D 24,2,5x60

D 2x20 DIN 1481


D 4x18 DIN 1481

M 12 DIN 985
M 12x35 DIN 933

M 12x40 DIN 912


M 8x30 DIN 7984

M 8 DIN 985
M 8x100 DIN 912
Standard
250 mm
D 400

010.1800
09/2002

Side-B
Side-B
Lado B

Stabilizer ram
Stabilizer ram
Cilindr. gatos

PK 7501,9501

S1081

Base
Base
Base

Side-A
Side-A
Lado A

Stabilizer ram
Stabilizer ram
Cilindr. gatos

S1081

PALFINGER

Pipes-Support STZY
Pipes-Support STZY
Tubos del soporte STZY

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2
3

HLR 8510
EA 039
EV4109A
TD 264

2
2
2

4
5

EA1749
EA1449

6
7

ED 620
EH1487

Description

Description

zu Tafel
to figure
a' planche

010.1800

Denominacin de repuestos

Abmessung
Dimension
Dimension

Pipe
Adaptor
Check valve
Seal kit
(for EV4109A)
Banjo
Female screw

Tubo
Racor
Vlvula de ret.
Juego de juntas
(para EV4109A)
Engranaje
Tornillo racor

D 12
GE 12 SR 3/8"ED

4
1

Pipe
Adaptor
Check valve
Seal kit
(for EV4109A)
Banjo
Female screw

1
2

Sealing ring
Protection hose

Sealing ring
Protection hose

Arista obturadora
Manga protectora

KD 3/8"
D 50x750

WH 12S 3/8-O

010.1900
09/2002

BSeite
SideB
CoteB

Absttzzylinder
Stabilizer ram
Verin de stabilisateur

PK 7501,9501

S1081

Base
Base
Base

ASeite
SideA
CoteA

Absttzzylinder
Stabilizer ram
Verin de stabilisateur

S1081

PALFINGER

Pipes-Support STZY
Pipes-Support STZY
Tubos del soporte STZY

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

010.1900

Denominacin de repuestos

1
2
3
4
5

HLR 8805
EA 039
EA1749
EA 280
EV4418
TD 848

2
4
2
2
1

Pipe
Adaptor
Banjo
Angle coupling
Check valve
Seal kit
(for EV4418)

Pipe
Adaptor
Banjo
Angle coupling
Check valve
Seal kit
(for EV4418)

Tubo
Racor
Engranaje
Acoplamiento acodado
Vlvula de ret.
Juego de juntas
(para EV4418)

EV4110
TD 848

7
8
9

EA1449
ED 620
EH1487

2
2
2

Check valve
Seal kit
(for EV4110)
Female screw
Sealing ring
Protection hose

Check valve
Seal kit
(for EV4110)
Female screw
Sealing ring
Protection hose

Vlvula de ret.
Juego de juntas
(para EV4110)
Tornillo racor
Arista obturadora
Manga protectora

Abmessung
Dimension
Dimension
D 12
GE 12 SR 3/8"ED
WH 12S 3/8-O
EVW 12 S

KD 3/8"
D 50x750

020.0100
05/2002

PK 7501,9501

Base
Base
Base

R1,R2
RSQ 240 RC

R2X,R3X
RSQ 240 RC

R1,R2(RSQ 240 RC)

R2X,R3X(RSQ 240 RC)

R1,R2

R2X,R3X

S1081

S1081

PALFINGER

Control valve-Support
Control valve-Support
Mando de los estabilizadores

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange
1

KSC00012A

KSC00234A

KSC00013A

KSC00235A

Stk.
Qty.
Nbre.

Description

Description

Control valve

Control valve

cpl.(2-sections)
(R1,R2)
(page 020.0200)
Control valve

cpl.(2-sections)
(R1,R2)
(page 020.0200)
Control valve

cpl.(2-sections)
(RSQ 240 RC)
(page 020.0200)
Control valve

cpl.(2-sections)
(RSQ 240 RC)
(page 020.0200)
Control valve

cpl.(4-sections)
(R3X)
(page 020.0200)
Control valve

cpl.(4-sections)
(R3X)
(page 020.0200)
Control valve

cpl.(4-sections)
(RSQ 240 RC)
(page 020.0200)

cpl.(4-sections)
(RSQ 240 RC)
(page 020.0200)

zu Tafel
to figure
a' planche

020.0100

Denominacin de repuestos

Bloque vlvula de
control
cpl.(2 secciones)
(R1,R2)
(Pgina 020.0200)
Bloque vlvula de
control
cpl.(2 secciones)
(RSQ 240 RC)
(Pgina 020.0200)
Bloque vlvula de
control
cpl.(4 secciones)
(R3X)
(Pgina 020.0200)
Bloque vlvula de
control
cpl.(4 secciones)
(RSQ 240 RC)
(Pgina 020.0200)

Abmessung
Dimension
Dimension

020.0200
10/2002

PK 7501,9501

Schalthebel nicht im Lieferumfang enthalten,


diese mssen als Zubehr gesondert bestellt werden

The control levers are not included in the delivery,


they mast be ordered separatly as accessoires.
Les levier de commande ne font pas partie de la fournituro,
ils doivent etre commandes separement
comme accessoires.

Base
Base
Base

S1081

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

EV 990

2
3
4
5

EK 279
EF 077
EK 278
EV 989

6
7

EK 715A
EZ2147

EZ2148

zu Tafel
to figure
a' planche

Control valve-Details
Control valve-Details
Vlvula de control
Description

Description

020.0200

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
1
1
1

Main relief valve,


cpl.
Bush
Pressure spring
Washer
Valve housing

Main relief valve,


cpl.
Bush
Pressure spring
Washer
Valve housing

Vlv. de
sobrepresin pral,cp
Casquillo
Resorte de compres.
Arandela
Asiento de vlvula

1
4

Cape
Spring housing cpl.

Cape
Spring housing cpl.

Capuchn de precinto
Tapa de resorte,
cpl.

(without counter
switch)
Spring housing cpl.

(without counter
switch)
Spring housing cpl.
(with counter
switch)
Screw
Washer

Tornillo
Arandela

M 8x16 DIN 912


D 8 DIN 125

Tapa de resorte,
cpl.

8
9

ES 264
EK 003

1
3

(with counter
switch)
Screw
Washer

10
10

EA 039
EA 769

1
1

Adaptor
Adaptor

Adaptor
Adaptor

Racor
Racor

GE 12 SR 3/8"ED
GE 16 SR 3/8-ed

11
12
13
14
15

EA 039
EA 746
HLA 376
ES1154
EM 026

6
2
1
2
2

Adaptor
Locking screw
Adaptor
Screw
Nut

Adaptor
Locking screw
Adaptor
Screw
Nut

Racor
Tapn roscado
Racor
Tornillo
Tuerca

GE 12 SR 3/8"ED
vsti M 18x1.5
GE 18 L 3/8-ed
M 8x60 DIN 912
M 8 DIN 985

16
17

EZ2146
HH 420

4
4

Lever support,cpl.
Control lever,cpl.

Lever support,cpl.
Control lever,cpl.

18
19
20

ES 051
EK 871
HH 419

4
1
1

Screw
Handle
Control lever

Screw
Handle
Control lever

Palanca, cpl.
Palanca de mando,
cpl.
Tornillo
Empuadura
Palanca de mando

21
22
23
24
25

HI1543
EM 234
EK 866
EK 867
ES1381

1
1
1
1
1

Pin
Nut
Cotter
Cotter
Screw

Pin
Nut
Cotter
Cotter
Screw

Pasador
Tuerca
Chaveta
Chaveta
Tornillo

M 8x16 DIN 7984

M5

M 5x80 DIN 931

020.0300
08/2000

Base
Base
Base

PK 7501,9501

1A > PK 7501
1B > PK 9501

1A > PK 7501
1B > PK 9501

S1081

S1081

PALFINGER

Control valve-F
Control valve-F
Vlvula de control-F

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange
1

KSC00008A

KSC00009A

Stk.
Qty.
Nbre.

Description

Description

Control valve

Control valve

cpl.(5-sections)
(page 020.0500)
Control valve

cpl.(5-sections)
(page 020.0500)
Control valve

cpl.(7-sections)
(page 020.0500)

cpl.(7-sections)
(page 020.0500)

zu Tafel
to figure
a' planche

020.0300
Abmessung
Dimension
Dimension

Denominacin de repuestos

Bloque vlvula de
control
cpl.(5 secciones)
(Pgina 020.0500)
Bloque vlvula de
control
cpl.(7 secciones)
(Pgina 020.0500)

020.0400
10/2001

PK 7501,9501

Base
Base
Base

H
PK 7501
HH433 (>0722793)
HH433A (0722794>)
PK 9501
HH433 (>0722816)
HH433A (0722817>)

1A > PK 7501
1B > PK 9501

6A > PK 7501
6B > PK 9501

S1081

S1081

PALFINGER

Control valve-F,H
Control valve-F,H
Vlvula de control-F,H

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange
1

KSC00010A

KSC00011A

Stk.
Qty.
Nbre.

Description

Description

Control valve

Control valve

cpl.(4-sections)
(page 020.0500)
Control valve

cpl.(4-sections)
(page 020.0500)
Control valve

cpl.(6-sections)
(page 020.0500)

cpl.(6-sections)
(page 020.0500)

zu Tafel
to figure
a' planche

020.0400
Abmessung
Dimension
Dimension

Denominacin de repuestos

Bloque vlvula de
control
cpl.(4 secciones)
(Pgina 020.0500)
Bloque vlvula de
control
cpl.(6 secciones)
(Pgina 020.0500)

020.0500
05/2002

PK 7501,9501

alte Ausfhrung
Type old
Version vieux

neue Ausfhrung
Type new
Version nouveau

alte Ausfhrung
Type old
Version vieux

Base
Base
Base

neue Ausfhrung
Type new
Version nouveau

S1081

S1081

PALFINGER

Control valve-Details
Control valve-Details
Vlvula de control

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange
1
2
3
4
5

EA 261
EA 240
EA 074
EV 784
EV 472

6
7
8
9
9
10

EM 021
EA 590
EF 008
HD 108
HD 376
HLA 372

11
12
13
14
15

ED 170
EA 183
EA1645
EA1646
EV 043/...

16

EV 044/...

17
18
19
20

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

020.0500

Denominacin de repuestos

Abmessung
Dimension
Dimension

Locking screw
Adaptor
Adaptor
Screw in nipple
End cover

Locking screw
Adaptor
Adaptor
Screw in nipple
End cover

Tapn roscado
Racor
Racor
Racor para enroscar
Tapa final

vsti R1/2"-ed
GE 18 LRed
GE 16 SR 1/2"ED

Nut
Adaptor
Pressure spring
Restrictor
Restrictor
Adaptor

Nut
Adaptor
Pressure spring
Restrictor
Restrictor
Adaptor

Tuerca
Racor
Resorte de compres.
Estrangulador
Estrangulador
Racor

M 10 DIN 985
GE 12 SR 1/2"ED
D 11x0.8x22
D 1,0 mm
D 1,5 mm

Seal ring
Adaptor
Circlip
Adaptor
Relief press. valve
with anti cavication
cation valve, cpl.

Seal ring
Adaptor
Circlip
Adaptor
Relief press. valve
with anti cavication
cation valve, cpl.

Anillo obturador
Racor
Circlip exterior
Racor
Vlvula de sobrepr.
con anticavitacin
cpl.

R 1/2"
GE 12 SR 1/2"ED
WEO 1/2"
GE 12K R1/2" ED
... bar

Relief press. valve


without anti
cavication valve
cation valve, cpl.
Plug
O-seal
Back up ring
O-seal

Vlvula de sobrepr.
sin anticavitacin

... bar

EV 049
EO 025
ED 055
EO 026

Relief press. valve


without anti
cavication valve
cation valve, cpl.
Plug
O-seal
Back up ring
O-seal

cpl.
Tornillo ciego
Anillo en O
Anillo de apoyo
Anillo en O

D 17,3x2,4

21
22

EB 925
EV5027

Seal
Control valve

Seal
Control valve

Precinto
Bloque vlvula de
control

1KH

22

EV5028

(Standard)
Control valve

(Standard)
Control valve

22

EV5029

(slewing)
Control valve

(slewing)
Control valve

22

EV5031

(Main boom)
(Outer boom)
Control valve

(Main boom)
(Outer boom)
Control valve

22

EV5032

(Boom extension)
Control valve

(Boom extension)
Control valve

22

EV5033

(slewing)
Control valve

(slewing)
Control valve

EV5034

(F,Main boom)
(F,Outer boom)
Control valve

(F,Main boom)
(F,Outer boom)
Control valve

(H,Main boom)

(H,Main boom)

22

1
2
1
1
6

D 12,3x2,4

Bloque vlvula de
control
(bascular)
Bloque vlvula de
control
(Brazo pral.)
(Brazo acodado)
Bloque vlvula de
control

14SAH

Bloque vlvula de
control
(bascular)
Bloque vlvula de
control
(F,brazo pral.)
(F,brazo acodado)
Bloque vlvula de
control
(H,brazo pral.)

124SAH

14XAH

14ZAH

124XAH

124YAH

S1081

PALFINGER

Control valve-Details
Control valve-Details
Vlvula de control

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

020.0500

Denominacin de repuestos

22

EV5035

(H,Outer boom)
Control valve

(H,Outer boom)
Control valve

22

EV5036

(F,Boom extension)
Control valve

(F,Boom extension)
Control valve

23

ES 065

23

ES 067

23

ES 068

24

EV4615
TD 239

25
25

EV2811
EV2812

1
1

(H,Boom extension)
Tension rod
(4-elements)
Tension rod
(6-elements)
Tension rod
(7-elements)
Magnet valve
Seal kit
(for EV4615)
Magnet coil
Magnet coil

(H,Boom extension)
Tension rod
(4-elements)
Tension rod
(6-elements)
Tension rod
(7-elements)
Magnet valve
Seal kit
(for EV4615)
Magnet coil
Magnet coil

(H,brazo acodado)
Bloque vlvula de
control
(F,brazo de empuje)
Bloque vlvula de
control
(H,brazo de empuje)
Varilla (4
elementos)
Varilla (6
elementos)
Tirante
(7-elementos)
Vlvula magntica
Juego de juntas
(para EV4615)
Bobina de imn
Bobina de imn

26
27
28

HLA1123
EK 883
EV2349
TD 239

1
1
1

29
30

EV 821
EV2552

1
1

Protecting cap
Protecting cap
Magnet valve
Seal kit
(for EV2349)
(+27)
Plug
Pressure balance

Protecting cap
Protecting cap
Magnet valve
Seal kit
(for EV2349)
(+27)
Plug
Pressure balance

Sombrerete protec.
Sombrerete protec.
Vlvula magntica
Juego de juntas
(para EV2349)
(+27)
Tornillo ciego
Balanza de presin

31
32
33
34

EV2718
EA 243
EA 716
EV2085A
TD 636

1
1
1
1

35

ES 310

Main relief valve


Adaptor
Pressure gauge conn.
Inlet cover
Seal kit
(for EV2085A)
Tension rod
(5-elements)

Main relief valve


Adaptor
Pressure gauge conn.
Inlet cover
Seal kit
(for EV2085A)
Tension rod
(5-elements)

Vlvula de sobrepr.
Racor
Racor de presin
Tapa de entrada
Juego de juntas
(para EV2085A)
Varilla (5
elementos)

36
37

EV2723
EV5118

1
1

Inlet cover
Main relief valve

Inlet cover
Main relief valve

Tapa de entrada
Vlvula de sobrepr.

Abmessung
Dimension
Dimension

124ZAH

124ZBH

12 V
26 V

35-350 bar
GE 18 LRed
EMA3 R1/4"

35-350 bar

020.0600

PK 7501,9501

05/2002

Kennzeichnung der Schieberstange


Indication of piston rod
Caracterisation de tige de piston
1 = Standard Schieberstange
2 = Schieberstange mit offener Nullstellung
3 = Schieberstange fr Schwenkelement
4 = Schieberstange mit beidseitiger Leckagenut
5 = Schieberstange mit Leckagenut SeiteA
6 = Schieberstange mit Leckagenut SeiteB

1 = Standard piston rod


2 = Piston rod with open 0position
3 = Piston rod for slewing system
4 = Piston rod with drain groove both sided
5 = Piston rod with drain groove sideA
6 = Piston rod with drain groove sideB
1 = Tige de piston standard
2 = Tige de piston avec position ouvert
3 = Tige de piston pour element de rotation
4 = Tige de piston avec mise a vide deux cotes
5 = Tige de piston avec mise a vide coteA
6 = Tige de piston avec mise a vide coteB
Max. Durchflumenge
Quantity of flow max.
Quantite de passage max.

1
2
3
4
5
6

2030l
1DH
4DH
12SAH
12ZAH
12ZBH
12XAH
12YAH

3550l
1KH
4KH
14SAH
14ZAH
14ZBH
14XAH
14YAH

Druckwaage
Pressure compensator
Balance de pression

3550l
1KH
4KH
124SAH
124ZAH
124ZBH
124XAH
124YAH

F
H

Base
Base
Base

S1081

S1081

PALFINGER

Control valve-Details
Control valve-Details
Vlvula de control

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

ED 076

2
3
4
5

EK 120
EK 122
EF 036
EK 724

1
1
1
1

EK 746

7
8
9
10

EK 121
ES 176
EV 982
ES 497

1
1
1
2

11
12

EV 164
EV4462

2
1

13
14
15

ER 009
ES 172
TD 774

1
6

16
17
18

EV1121
ES 316
EV1093

3
4
1

19

EV1094

20

EV2788

21

EV1122

22

EV1123

23

EV2758

24

EV1573

25

EV1572

26
27

ES 498
EV2759

1
1

28
29
30

ES1055
ES1054
EV3614

1
2
1

31

EV5090

Description

Description

zu Tafel
to figure
a' planche

020.0600

Denominacin de repuestos

O-seal with back up


ring
Washer
Spring cap
Pressure spring
Washer
(slewing)

O-seal with back up


ring
Washer
Spring cap
Pressure spring
Washer
(slewing)

Anillo en O con
anillo apoyo
Arandela
Platillo de resorte
Resorte de compres.
Arandela
(bascular)

Washer
(slewing)
Spring cap
Screw
Spring housing
Screw

Washer
(slewing)
Spring cap
Screw
Spring housing
Screw

Arandela
(bascular)
Platillo de resorte
Tornillo
Tapa de resorte
Tornillo

Check valve
Lever support
(+13)
Seal ring
Screw
Seal kit

Check valve
Lever support
(+13)
Seal ring
Screw
Seal kit

Vlvula de ret.
Soporte de palanca
(+13)
Anillo obturador
Tornillo
Juego de juntas

Spring housing
Screw
Block cylinder,cpl.
(push)
Block cylinder,cpl.
(pull)
Block cylinder,cpl.
(double-acting)

Spring housing
Screw
Block cylinder,cpl.
(push)
Block cylinder,cpl.
(pull)
Block cylinder,cpl.
(double-acting)

Tapa de resorte
Tornillo
Vlvula de bloqueo
(apretando)
Vlvula de bloqueo
(estirando)
Vlvula de bloqueo
(doble efecto)

Bloc-cylinder
(push)
Bloc-cylinder
(pull)
Bloc-cylinder
(double-acting)
Piston
(push)
Piston
(pull)

Bloc-cylinder
(push)
Bloc-cylinder
(pull)
Bloc-cylinder
(double-acting)
Piston
(push)
Piston
(pull)

Vlvula de bloqueo
(apretando)
Vlvula de bloqueo
(estirando)
Vlvula de bloqueo
(doble efecto)
Pistn
(apretando)
Pistn
(estirando)

Traction screw
Piston
(double-acting)
Traction screw
Screw
Spool position
control
cation valve, cpl.
(PALTRONIC)
Spool position
control
(PALTRONIC)

Traction screw
Piston
(double-acting)
Traction screw
Screw
Spool position
control
cation valve, cpl.
(PALTRONIC)
Spool position
control
(PALTRONIC)

Tornillo tensor
Pistn
(doble efecto)
Tornillo tensor
Tornillo
Control vara del=
distribuidor
cpl.
(PALTRONIC)
Control vara del=
distribuidor
(PALTRONIC)

Abmessung
Dimension
Dimension

s=0.5 mm

s=0.3 mm

M 5x6 DIN 912

M 5x16 DIN 912

M 5x55 DIN 7984

M 5x80 DIN 912

020.1000
09/2004

PK 7501,9501

Spare parts look PVG32


Spare parts look PVG32
Pieza de recambio ver PVG32

Control valve-RC001
Control valve-RC001
Distribuidor-RC001

A2,B2 > PK 9501


A1,B1 > PK 7501

S1081

S1081

PALFINGER

Control valve-RC001
Control valve-RC001
Vlvula de control-RC001

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange
1

KSC00045B
EA 033
EA 089
EA 097
EA 243
EA 261
EA 590
EA 716
EA1646
HD 376

Stk.
Qty.
Nbre.
1

Description

Description

Control valve

Control valve

Adaptor
Adaptor
Adaptor
Adaptor
Locking screw
Adaptor
Pressure gauge conn.
Adaptor
Restrictor

Adaptor
Adaptor
Adaptor
Adaptor
Locking screw
Adaptor
Pressure gauge conn.
Adaptor
Restrictor

zu Tafel
to figure
a' planche

020.1000

Denominacin de repuestos

Bloque vlvula de
control
Racor
Racor
Racor
Racor
Tapn roscado
Racor
Racor de presin
Racor
Estrangulador

Abmessung
Dimension
Dimension
RC001
GE 16 SR 3/4"ED
GE 8 SRed
GE 20 SR 3/4"ED
GE 18 LRed
vsti R1/2"-ed
GE 12 SR 1/2"ED
EMA3 R1/4"
GE 12K R1/2" ED
D 1,5 mm

020.1100
10/2000

PK 7501,9501

Base
Base
Base

S1081

ASeite
SideA
CoteA

BSeite
SideB
CoteB

S1081

PALFINGER

Control
Control
Control del mando

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2
3

ES 265
EK 003
HH 431

2
2
1

HH 409

HH 429

HI 827

6
7

EK 884
HH 430

8
9
10

EM 234
HI1543
EK 866

11
12
13

EK 867
ES1381
HH 408

13

HH 428

14
15

HSV 206
HI2603

16
17

EQ 116
HH 411

17

HH 425

18

HH 427

19
20

HI2907
EK 868

21

HH 410

21

HH 424

22

HH 426

23
24
25

HSV 205
EM 014
EK 043

3
3

26
27
28
29
30

ES 080
HI2735
HH 423
ES 105
EM 014

3
1

31

HA6509

Description

Description

zu Tafel
to figure
a' planche

020.1100

Denominacin de repuestos

Screw
Washer
Control lever
(stabilisation)
Control lever,cpl.

Screw
Washer
Control lever
(stabilisation)
Control lever,cpl.

(black)
Control lever
(blue)
Control axle

(black)
Control lever
(blue)
Control axle

Tornillo
Arandela
Palanca de mando
(Apoyo)
Palanca de mando,
cpl.
(negro)
Palanca de mando
(azul)
Eje de cambio

Cover
Control lever
(stabilisation)
Nut
Pin
Cotter

Cover
Control lever
(stabilisation)
Nut
Pin
Cotter

Tapa
Palanca de mando
(Apoyo)
Tuerca
Pasador
Chaveta

Cotter
Screw
Control lever
(black)
Control lever
(blue)
Control rod
Pin

Cotter
Screw
Control lever
(black)
Control lever
(blue)
Control rod
Pin

Chaveta
Tornillo
Palanca de mando
(negro)
Palanca de mando
(azul)
Varilla
Pasador

Locking washer
Control lever
(black)
Control lever
(blue)
Control lever
(stabilisation)
Pin
Pin locking

Locking washer
Control lever
(black)
Control lever
(blue)
Control lever
(stabilisation)
Pin
Pin locking

Arandela seguridad
Palanca de mando
(negro)
Palanca de mando
(azul)
Palanca de mando
(Apoyo)
Pasador
Seguro de perno

Control lever
(black)
Control lever
(blue)
Control lever
(stabilisation)
Control rod
Nut
Washer

Control lever
(black)
Control lever
(blue)
Control lever
(stabilisation)
Control rod
Nut
Washer

Palanca de mando
(negro)
Palanca de mando
(azul)
Palanca de mando
(Apoyo)
Varilla
Tuerca
Arandela

1
1

Screw
Control axle
Control lever
Screw
Nut

Screw
Control axle
Control lever
Screw
Nut

Tornillo
Eje de cambio
Palanca de mando
Tornillo
Tuerca

Bearer

Bearer

Soporte

Abmessung
Dimension
Dimension
M 8x20 DIN 912
D 8 DIN 125

M5

M 5x80 DIN 931

D 4 DIN 6799

M 6 DIN 985
D 6,4 DIN 134
M 6x35 DIN 6912

M 6x40 DIN 912


M 6 DIN 985

S1081

PALFINGER

Control
Control
Control del mando

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

32
33
34

HH 422
EK 871
HIB 248

Stk.
Qty.
Nbre.

1
1

Description

(R2X,RC)
Control lever
Handle
Pin

Description

(R2X,RC)
Control lever
Handle
Pin

zu Tafel
to figure
a' planche

020.1100

Denominacin de repuestos

(R2X,RC)
Palanca de mando
Empuadura
Pasador

Abmessung
Dimension
Dimension

020.1200
09/2001

BSeite
SideB
CoteB

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Control (reverse acting)


Control (reverse acting)
Control del mano

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2
3

ES 265
EK 003
HH 450

2
2
1

HH 451

HH 452

Description

Description

Screw
Washer
Control lever
cation valve, cpl.
Control lever
cation valve, cpl.
Control lever,cpl.

Screw
Washer
Control lever
cation valve, cpl.
Control lever
cation valve, cpl.
Control lever,cpl.

cation valve, cpl.

cation valve, cpl.

zu Tafel
to figure
a' planche

020.1200

Denominacin de repuestos

Tornillo
Arandela
Palanca de mando
cpl.
Palanca de mando
cpl.
Palanca de mando,
cpl.
cpl.

HH 409

Control lever,cpl.

Control lever,cpl.

HH 453

cation valve, cpl.


Control lever,cpl.

cation valve, cpl.


Control lever,cpl.

HH 454

cation valve, cpl.


Control lever,cpl.

cation valve, cpl.


Control lever,cpl.

HH 455

10

EK 901

cation valve, cpl.


Control lever
cation valve, cpl.
Handle,black
(stabilisation)

cation valve, cpl.


Control lever
cation valve, cpl.
Handle,black
(stabilisation)

Palanca de mando,
cpl.
cpl.
Palanca de mando,
cpl.
cpl.
Palanca de mando,
cpl.
cpl.
Palanca de mando
cpl.
Maneta negra
(Apoyo)

11
12
13

HI 827
EK 884
HH 408

14
15

EM 234
HI1543

Control axle
Cover
Control lever
(black)
Nut
Pin

Control axle
Cover
Control lever
(black)
Nut
Pin

Eje de cambio
Tapa
Palanca de mando
(negro)
Tuerca
Pasador

16
17
18
19
20

EK 866
EK 867
ES1381
EK 900
HXE1923

1
1

Cotter
Cotter
Screw
Handle,blue
Control lever

Cotter
Cotter
Screw
Handle,blue
Control lever

Chaveta
Chaveta
Tornillo
Maneta azul
Palanca de mando

21
22
23
24
25

EK 899
HXE1924
HXE1925
HXE1926
HXE1927

1
1
1
1

Handle,black
Control lever
Control lever
Control lever
Control lever

Handle,black
Control lever
Control lever
Control lever
Control lever

Maneta negra
Palanca de mando
Palanca de mando
Palanca de mando
Palanca de mando

26

HXE1928

Control lever

Control lever

Palanca de mando

Abmessung
Dimension
Dimension
M 8x20 DIN 912
D 8 DIN 125

M5

M 5x80 DIN 931

030.0100

PK 7501,9501

01/2004

S1081

Base
Base
Base

OSKF

EN12999

Lifting cylinder
Lifting cylinder
Cilindro elevacin

Control valve
Control valve
Distribuidor

Oil tank
Oil tank
Depsito

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

zu Tafel
to figure
a' planche

Overload protection-OSK-F
Overload protection-OSK-F
Proteccin de sobr.-OSK-F

Stk.
Qty.
Nbre.

EV4452
TD 947

2
3
4
5

EA 236
EV4500
EV4453
UV431-330

6
7
8
9
10

Description

Description

030.0100

Denominacin de repuestos

Abmessung
Dimension
Dimension

3
1
2
1

Overload block
Seal kit
(for EV4452)
Locking screw
Adapter
Adapter
Load holding valve

Overload block
Seal kit
(for EV4452)
Locking screw
Adapter
Adapter
Load holding valve

Bloque de sobrecarga
Juego de juntas
(para EV4452)
Tapn roscado
vsti R 1/4"
Pieza prolongacin
RS 210
Pieza prolongacin
RS 210
Vlvula retencin

HG 171
EA 423
EV 330
EA 089
EA 039

1
6
1
5
3

Housing
Locking screw
Lock valve
Adaptor
Adaptor

Housing
Locking screw
Lock valve
Adaptor
Adaptor

Carcasa
Tapn roscado
Vlvula de seguridad
Racor
Racor

11
12

EA 201
EV 612
TD 204

1
1

13
14
15

ES1036
EM 199
EV2151

1
1
1

Adaptor
Valve insert
Seal kit
(for EV 612)
Winding pin
Sealing nut
Valve insert

Adaptor
Valve insert
Seal kit
(for EV 612)
Winding pin
Sealing nut
Valve insert

Racor
Asiento de vlvula
Juego de juntas
(para EV 612)
Pasador roscado
Tuerca obturadora
Asiento de vlvula

16
17
18
19
20

EV2152
HLR 9841
EA 091
EA 263
UV097A

1
1
1
1
1

Piston
Pipe
L-coupling
Angle coupling
Pressure switch

Piston
Pipe
L-coupling
Angle coupling
Pressure switch

Pistn
Tubo
D8
Racor en L
EVL 8 S
Acoplamiento acodado evW 8 S
Monocontacto

21
22
23
24
25

EA 151
EH4445
EA 190
EH5162
EA1655

1
1
1
1
1

Adaptor
Hose
Adaptor
Hose
Adaptor

Adaptor
Hose
Adaptor
Hose
Adaptor

Racor
Manguera
Racor
Manguera
Racor

evGE 8 S
NW 6x4400
GE 10-L 3/8-ED
NW 6x750
STE 10K R 3/8"

26
27

EA1052
HLR 8827

1
1

Adaptor
Pipe

Adaptor
Pipe

Racor
Tubo

GE 8 SR 3/8-ed
D8

Vsti R 1/8"-Ed
GE 8 SRed
GE 12 SR 3/8"ED
GE 12 SRed

M 8x20 DIN 916


M 8x1.5

030.0200
01/2004

PK 7501,9501

S1081

Base
Base
Base

OSKH

EN12999

Lifting cylinder
Lifting cylinder
Cilindro elevacin

Control valve
Control valve
Distribuidor

Oil tank
Oil tank
Depsito

S1081

PALFINGER

Overload protection-OSK-H
Overload protection-OSK-H
Proteccin de sobr.-OSK-H

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange
1
2

HTR3533
EV 174

Stk.
Qty.
Nbre.
1
1

TD 845
EZ1277

Description

Description

zu Tafel
to figure
a' planche

030.0200

Denominacin de repuestos

Soporte
Pulsador de pico de
presin
Juego de juntas
Sombrerete protec.
cpl. para EV 174
Tornillo
Arandela
Vlvula sobrecarga

Abmessung
Dimension
Dimension

Bearer
Pressure peak button

Bearer
Pressure peak button

Seal kit
Protecting cap
cpl. for EV 174
Screw
Washer
Overload valve
(+7,8)

Seal kit
Protecting cap
cpl. for EV 174
Screw
Washer
Overload valve
(+7,8)
Nut
Sealing nut
Sealing nut
Female screw
(with O-ring)
Connection block

Tuerca
Tuerca obturadora
Tuerca obturadora
Tornillo racor
(con anillo en O)
Bloque de conexin

M 6 DIN 985
M 8x1.5
M 12x1.5

3
4
5

ES 106
EK 043
EV3263

2
2
1

M 6x55 DIN 7984


D 6,4 DIN 134

6
7
8
9

EM 014
EM 199
EM 200
EA1057

2
1
1
3

10

HLA 875

Nut
Sealing nut
Sealing nut
Female screw
(with O-ring)
Connection block

11
12
13
14
15

ED 619
EA 236
HLR 9841
EA 091
EA 263

3
3
1
2
1

Sealing ring
Locking screw
Pipe
L-coupling
Angle coupling

Sealing ring
Locking screw
Pipe
L-coupling
Angle coupling

Arista obturadora
Tapn roscado
Tubo
Racor en L
Acoplamiento acodado

KD 1/4"
vsti R 1/4"
D8
EVL 8 S
evW 8 S

16
17
18
19

EA 089
UV097A
EA 151
UV431-330

9
1
2
1

HLR 8799

Adaptor
Pressure switch
Adaptor
Load holding valve
(page 030.0100)
Pipe

Racor
Monocontacto
Racor
Vlvula retencin
(Pgina 030.0100)
Tubo

GE 8 SRed

20

Adaptor
Pressure switch
Adaptor
Load holding valve
(page 030.0100)
Pipe

21
22
23
24
25

EA 192
HLR 8797
EA1655
EA1052
HLR 8798

1
1
1
2
1

T-coupling
Pipe
Adaptor
Adaptor
Pipe

T-coupling
Pipe
Adaptor
Adaptor
Pipe

Racor en T
Tubo
Racor
Racor
Tubo

T8S
D8
STE 10K R 3/8"
GE 8 SR 3/8-ed
D8

26
27
28
29

HLR 7219
EH1148
HLR 8796
EH3213

1
1
1
1

Pipe
Hose
Pipe
Hose

Pipe
Hose
Pipe
Hose

Tubo
Manguera
Tubo
Manguera

D8
NW 6x3200
D8
NW 6x3500

evGE 8 S

D8

030.0300
01/2004

PK 7501,9501

S1081

Base
Base
Base

OSKRC

Lifting cylinder
Lifting cylinder
Cilindro elevacin

EN12999

Control valve
Control valve
Distribuidor

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

zu Tafel
to figure
a' planche

Overload protection-OSK-RC
Overload protection-OSK-RC
Proteccin de sobr.-OSK-RC

Stk.
Qty.
Nbre.

EV4452
TD 947

2
3
4
5

EA 236
EV4501
EV4454
ED 619

6
7
8
9
10

Description

Description

030.0300

Denominacin de repuestos

Abmessung
Dimension
Dimension

2
1
2
2

Overload block
Seal kit
(for EV4452)
Locking screw
Adapter
Adapter
Sealing ring

Overload block
Seal kit
(for EV4452)
Locking screw
Adapter
Adapter
Sealing ring

Bloque de sobrecarga
Juego de juntas
(para EV4452)
Tapn roscado
Pieza prolongacin
Pieza prolongacin
Arista obturadora

vsti R 1/4"
RSQ 240
RSQ 240
KD 1/4"

EO 906
EA 282
EEA1194
HLR 9841
EA 091

1
2
1
1
2

O-seal
Banjo
Pressure switch
Pipe
L-coupling

O-seal
Banjo
Pressure switch
Pipe
L-coupling

Anillo en O
Engranaje
Monocontacto
Tubo
Racor en L

D 12,5x1,5
WHO 8 SR
30-400 bar
D8
EVL 8 S

11
12
13
14
15

EA 263
EA 089
UV097A
EA 151
UV431-330

1
4
1
2
1

Angle coupling
Adaptor
Pressure switch
Adaptor
Load holding valve
(page 030.0100)

Angle coupling
Adaptor
Pressure switch
Adaptor
Load holding valve
(page 030.0100)

Acoplamiento acodado evW 8 S


Racor
GE 8 SRed
Monocontacto
Racor
evGE 8 S
Vlvula retencin
(Pgina 030.0100)

16
17
18
19
20

EH4445
EA1023
EH1924
EH5162
HLR 8437

1
1
1
1
1

Hose
Blanking part
Hose
Hose
Pipe

Hose
Blanking part
Hose
Hose
Pipe

Manguera
Obturador
Manguera
Manguera
Tubo

NW 6x4400
ROV-10L
NW 6x400
NW 6x750
D8

21
22
23

EA1655
EA1052
HLR 8846

1
1
1

Adaptor
Adaptor
Pipe

Adaptor
Adaptor
Pipe

Racor
Racor
Tubo

STE 10K R 3/8"


GE 8 SR 3/8-ed
D8

030.0400
01/2004

PK 7501,9501

SHB

Kransockel
Base
Socle

Base
Base
Base

S1081

S1081

PALFINGER

Limit. of rotation
Limit. of rotation
Lmite de rotacin

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

HLR 8802

HLR 8892

HLR 8801

HLR 8893

EV5037-160

Description

Description

zu Tafel
to figure
a' planche

030.0400

Denominacin de repuestos

Abmessung
Dimension
Dimension

4
5

EA 183
HLR 8791

4
1

Pipe
(F)
Pipe
(RC001)
Pipe
(F)
Pipe
(RC001)
Load holding valve
(PK 7501)
Seal kit
(for EV5037)
Load holding valve
(PK 9501)
Seal kit
(for EV5037)
Adaptor
Pipe

6
7
8
9
10

EA1749
EA 039
HLR 8792
ES 432
EM 026

1
1
1
2
2

Banjo
Adaptor
Pipe
Screw
Nut

Banjo
Adaptor
Pipe
Screw
Nut

Engranaje
Racor
Tubo
Tornillo
Tuerca

11
12
13
14
15

HXE 509
ES1330
HT6323
HBS2884
HA6551

1
2
1
2
1

Bracket
Screw
Plate
Distance washer
Bearer

Bracket
Screw
Plate
Distance washer
Bearer

Consola
Tornillo
Placa
Faja espaciadora
Soporte

16
17
18
19
20

EM 004
EK 043
HA6550
ES 019
EM 154

2
4
1
2
4

Nut
Washer
Bearer
Screw
Nut

Nut
Washer
Bearer
Screw
Nut

Tuerca
Arandela
Soporte
Tornillo
Tuerca

M 6 DIN 934
D 6,4 DIN 134

21
22

EK 124
EEA...

4
2

HIG 459

Washer
Limit switch
(look ELEKTRIK)
(page 030.0400)
Fixing stirrup

Arandela
Interruptor
(Vase ELEKTRIK)
(Pgina 030.0400)
Estribo de fijacin

D 4,3 DIN 433

23

Washer
Limit switch
(look ELEKTRIK)
(page 030.0400)
Fixing stirrup

TD1001
3

EV5037-210

TD1001

Pipe
(F)
Pipe
(RC001)
Pipe
(F)
Pipe
(RC001)
Load holding valve
(PK 7501)
Seal kit
(for EV5037)
Load holding valve
(PK 9501)
Seal kit
(for EV5037)
Adaptor
Pipe

Tubo
(F)
Tubo
(RC001)
Tubo
(F)
Tubo
(RC001)
Vlvula retencin
(PK 7501)
Juego de juntas
(para EV5037)
Vlvula retencin
(PK 9501)
Juego de juntas
(para EV5037)
Racor
Tubo

D 12

WH 12S 3/8-O
GE 12 SR 3/8"ED
D 12
M 8x50 DIN 912
M 8 DIN 985

D 12
D 12
D 12
160 bar

210 bar

GE 12 SR 1/2"ED
D 12

M 6x25 DIN 7991


l=15 mm

M 6x20 DIN 912


M 4 DIN 985

030.0500
01/2004

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Transport position control


Transport position control
osicion de tran

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2
3
4

HT6978
ES 175
ES 450
EEA...

1
2
2
1

ES 061

6
7
8

HT7003
HTR3901
HB 334

Description

Description

zu Tafel
to figure
a' planche

030.0500

Denominacin de repuestos

Guide slot/gate
Screw
Screw
Limit switch
(look ELEKTRIK)
(page 030.0400)
Screw

Guide slot/gate
Screw
Screw
Limit switch
(look ELEKTRIK)
(page 030.0400)
Screw

Rodillo
Tornillo
Tornillo
Interruptor
(Vase ELEKTRIK)
(Pgina 030.0400)
Tornillo

1
1
1

Guide slot/gate
Spacing piece
Cover

Guide slot/gate
Spacing piece
Cover

Rodillo
Distanciador
Tapa

Abmessung
Dimension
Dimension

M 6x16 DIN 912


M 4x50 DIN 84

M 5x12 DIN 912

030.0600
01/2004

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Support control
Support control
Cuidados con el punto de apoyo

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

030.0600

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
2
3
4
5

HT3449
EM 154
EK 124
EK 044
ES 308

2
4
4
4
4

Bearer
Nut
Washer
Washer
Screw

Bearer
Nut
Washer
Washer
Screw

Soporte
Tuerca
Arandela
Arandela
Tornillo

EEA...

7
8
9
10

ES 791
EM 023
HA4795
ES 173

4
4
1
4

Limit switch
(look ELEKTRIK)
(page 030.0400)
Screw
Nut
Stop buffer
Screw

Limit switch
(look ELEKTRIK)
(page 030.0400)
Screw
Nut
Stop buffer
Screw

Interruptor
(Vase ELEKTRIK)
(Pgina 030.0400)
Tornillo
Tuerca
Tope
Tornillo

11
12
13
14
15

HA4794
EZ2058
HA7143
ES 853
EM 026

1
2
2
4
2

Stop buffer
Hose clip
Bearer
Screw
Nut

Stop buffer
Hose clip
Bearer
Screw
Nut

Tope
Abrazadera p.mangas
Soporte
Tornillo
M 4x16 DIN 912
Tuerca
M 8 DIN 985

16
17

HXE2227
ES1161

2
2

Stop buffer
Screw

Stop buffer
Screw

Tope
Tornillo

M 4 DIN 985
D 4,3 DIN 433
D 8 DIN 7349
M 8x20 DIN 7984

M 4x25 DIN 912


M 12 DIN 985
M 12x45 DIN 912

M 8x100 DIN 912

040.0100
06/2001

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Krans ule
Crane colume
Colonne

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

S105S01-A

S105S02-A

S106S01-A

S106S02-A

2
3
4
5

HT3568
ES 264
HXL 020
HI2771

1
1
1
1

6
7
8
9
10

ELG 011
EA 005
HBS 874
EQ 086
UP1515

2
1
1
1
1

10

UP1517

11

EH 963

11

EH 808

11

EH1567

11

EH2251

Description

Description

zu Tafel
to figure
a' planche

040.0100

Denominacin de repuestos

Abmessung
Dimension
Dimension

Crane column
(PK 7501)
Crane column
(PK 7501)
Crane column
(PK 9501)
Crane column
(PK 9501)
Plate
Screw
Hose ring
Pin

Crane column
(PK 7501)
Crane column
(PK 7501)
Crane column
(PK 9501)
Crane column
(PK 9501)
Plate
Screw
Hose ring
Pin

Columna
(PK 7501)
Columna
(PK 7501)
Columna
(PK 9501)
Columna
(PK 9501)
Placa soldada
Tornillo
Anillo de manguera
Pasador

h=1382 mm

Bearing bush
Grease nipple
Distance washe
Circlip
Inner boom ram
(PK 9501)
(page 040.0200)
Inner boom ram
(PK 7501)
(page 040.0200)

Bearing bush
Grease nipple
Distance washe
Circlip
Inner boom ram
(PK 9501)
(page 040.0200)
Inner boom ram
(PK 7501)
(page 040.0200)

Casquillo
Racor de engrase
M 10x1 DIN71412
Arandela espaciadora 2 mm
Circlip exterior
D 50 DIN 471
Cilindro elevacion
(PK 9501)
(Pgina 040.0200)
Cilindro elevacion
(PK 7501)
(Pgina 040.0200)

Protection hose
(H)
Protection hose
(F)
Protection hose
(H)
Protection hose
(Main boom)

Protection hose
(H)
Protection hose
(F)
Protection hose
(H)
Protection hose
(Main boom)

Manga protectora
(H)
Manga protectora
(F)
Manga protectora
(H)
Manga protectora
(Brazo pral.)

h=1160 mm
h=1482 mm
h=1282 mm
H
M 8x16 DIN 912

D 102x1500
D 102x2300
D 102x2600
D 102x800

040.0200
09/1999

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Lifting cylinder
Lifting cylinder
Cilindro elevacin

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

UP1515

UP1517

2
3
4

ELG 002
HBS 381
HSK1251

4
1
1

HSK1255

TD 525

6
7
8
9

EG 037
HV 363
HK 362A
HY1393

2
1
1
1

HY1397

10

EA 005

Description

Description

zu Tafel
to figure
a' planche

040.0200

Denominacin de repuestos

Inner boom ram


(PK 9501)
Inner boom ram
(PK 7501)
Bearing bush
Distance washer
Piston rod
(PK 9501)
Piston rod
(PK 7501)
Seal kit
(+6)

Inner boom ram


(PK 9501)
Inner boom ram
(PK 7501)
Bearing bush
Distance washer
Piston rod
(PK 9501)
Piston rod
(PK 7501)
Seal kit
(+6)

Cilindro elevacion
(PK 9501)
Cilindro elevacion
(PK 7501)
Casquillo
Faja espaciadora
Vstago del mbolo
(PK 9501)
Vstago del mbolo
(PK 7501)
Juego de juntas
(+6)

Guide ring
Cylinder nut
Piston
Cylinder tube
(PK 9501)
Cylinder tube
(PK 7501)
Grease nipple

Guide ring
Cylinder nut
Piston
Cylinder tube
(PK 9501)
Cylinder tube
(PK 7501)
Grease nipple

Anillo-gua
Tuerca del cilindro
Pistn
Cilindro
(PK 9501)
Cilindro
(PK 7501)
Racor de engrase

Abmessung
Dimension
Dimension

95 x 90 x 15

M 10x1 DIN71412

040.0300
06/2000

PK 7501,9501

Base
Base
Base

Hubzylinder
Lifting cylinder
Verin de levage

PALTRONIC
Hubzylinder
Lifting cylinder
Verin de levage

Notabsenkung
Emergency lowering device
Dipositife d abaissement d urgence
Hubzylinder
Lifting cylinder
Verin de levage

S1081

S1081

PALFINGER

Pipes-Lifting cylinder
Pipes-Lifting cylinder
Tubos del cilindro de elevaci

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

EH4876

EH4877

EH4887

2
3

UV439-330
HLR 8835

1
1

HLR 8836

4
5

HG 171
EA 423

1
6

6
7
8
9

EA 236
EA 039
EA 201
EV 612
TD 204

2
3
2
1

10

ES1036

11
12
13
14
15

Description

Description

zu Tafel
to figure
a' planche

040.0300

Denominacin de repuestos

Abmessung
Dimension
Dimension

Hose
(H)
Hose
F(PK 9501)
Hose
F(PK 7501)
Load holding valve
Pipe
(PK 7501)
Pipe
(PK 9501)
Housing
Locking screw

Hose
(H)
Hose
F(PK 9501)
Hose
F(PK 7501)
Load holding valve
Pipe
(PK 7501)
Pipe
(PK 9501)
Housing
Locking screw

Manguera
(H)
Manguera
F(PK 9501)
Manguera
F(PK 7501)
Vlvula retencin
Tubo
(PK 7501)
Tubo
(PK 9501)
Carcasa
Tapn roscado

NW 10x3200

Locking screw
Adaptor
Adaptor
Valve insert
Seal kit
(for EV 612)
Winding pin

Tapn roscado
Racor
Racor
Asiento de vlvula
Juego de juntas
(para EV 612)
Pasador roscado

vsti R 1/4"
GE 12 SR 3/8"ED
GE 12 SRed

Locking screw
Adaptor
Adaptor
Valve insert
Seal kit
(for EV 612)
Winding pin

EM 199
EV2151
EV2152
UV438-330
EV 661

1
1
1
1
1

Sealing nut
Valve insert
Piston
Load holding valve
Shut-off cock

Sealing nut
Valve insert
Piston
Load holding valve
Shut-off cock

Tuerca obturadora
Asiento de vlvula
Pistn
Vlvula retencin
Llave esfrica cierr

M 8x1.5

16

HLR 9300

HLR 9302

17
18
19

EA1334
EA 089
HLR 9301

2
1
1

19

HLR 9303

20

EA 784

Pipe
(PK 9501)
Pipe
(PK 7501)
Adaptor
Adaptor
Pipe
(PK 9501)
Pipe
(PK 7501)
Adaptor

Tubo
(PK 9501)
Tubo
(PK 7501)
Racor
Racor
Tubo
(PK 9501)
Tubo
(PK 7501)
Racor

D8

16

Pipe
(PK 9501)
Pipe
(PK 7501)
Adaptor
Adaptor
Pipe
(PK 9501)
Pipe
(PK 7501)
Adaptor

21
22

EA 263
EA 151

1
1

Angle coupling
Adaptor

Angle coupling
Adaptor

Acoplamiento acodado evW 8 S


Racor
evGE 8 S

NW 10x4200
NW 10x4050

D 12
D 12

Vsti R 1/8"-Ed

M 8x20 DIN 916

D8
TR 12/08/12S
GE 8 SRed
D 12
D 12
GZ 12 S

050.0100
03/2001

PK 7501

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Main boom PK 7501


Main boom PK 7501
Brazo principal PK 7501

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

050.0100

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
2
3
4
5

S105H01-A
ES 979
HB 130
HIG 507
HI2772

1
1
1
1
1

Main boom
Screw
Washer
Pin
Pin

Main boom
Screw
Washer
Pin
Pin

Brazo principal
Tornillo
Arandela
Pasador
Pasador

6
7
8
9
10

HBS 874
EQ 086
ELG 009
EA 005
HXE2010

1
1
2
2
1

Distance washe
Circlip
Bearing bush
Grease nipple
Hose clip

Distance washe
Circlip
Bearing bush
Grease nipple
Hose clip

Arandela espaciadora 2 mm
Circlip exterior
D 50 DIN 471
Casquillo
Racor de engrase
M 10x1 DIN71412
Abrazadera p.mangas

11
12

ES 353
UP1518

2
1

Screw
Outer boom ram

Screw
Outer boom ram

13
14
15

ELG 002
HBD 020
EA 023

2
1
1

Bearing bush
Distance washer
Grease nipple

Bearing bush
Distance washer
Grease nipple

Tornillo
Cilindro de
articulacin
Casquillo
Faja espaciadora
Racor de engrase

16
17

HY1396
TD 577

1
1

18
19
20

HK 291
EG 051
HV 384

1
2
1

Cylinder tube
Seal kit
(+19)
Piston
Guide ring
Cylinder nut

Cylinder tube
Seal kit
(+19)
Piston
Guide ring
Cylinder nut

Cilindro
Juego de juntas
(+19)
Pistn
Anillo-gua
Tuerca del cilindro

21
22
23
24

HSK1254
ELG 020
HBD 177
EZ 578

1
2
1

Piston rod
Bearing bush
Distance washer
Edge protection
(sold by the meter)

Piston rod
Bearing bush
Distance washer
Edge protection
(sold by the meter)

Vstago del mbolo


Casquillo
Faja espaciadora
Proteccin de arista
(en metros)

M 16x25 DIN7984

M 5x40 DIN 7984

M 10x1 DIN 7141

75x70x15

050.0200
03/2001

PK 9501

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Main boom PK 9501


Main boom PK 9501
Brazo principal PK 9501

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

050.0200

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
2
3
4
5

S106H01-A
ES 979
HB 130
HIG 507
HI2772

1
1
1
1
1

Main boom
Screw
Washer
Pin
Pin

Main boom
Screw
Washer
Pin
Pin

Brazo principal
Tornillo
Arandela
Pasador
Pasador

6
7
8
9
10

HBS 874
EQ 086
ELG 009
EA 005
HXE2010

1
1
2
2
1

Distance washe
Circlip
Bearing bush
Grease nipple
Hose clip

Distance washe
Circlip
Bearing bush
Grease nipple
Hose clip

Arandela espaciadora 2 mm
Circlip exterior
D 50 DIN 471
Casquillo
Racor de engrase
M 10x1 DIN71412
Abrazadera p.mangas

11
12

ES 353
UP1516

2
1

Screw
Outer boom ram

Screw
Outer boom ram

13
14
15

ELG 002
HBS2836
EA 558

2
1
1

Bearing bush
Distance washer
Grease nipple

Bearing bush
Distance washer
Grease nipple

Tornillo
Cilindro de
articulacin
Casquillo
Faja espaciadora
Racor de engrase

16
17

HY1394
TD 525

1
1

18
19
20

HK 362A
EG 037
HV 363

1
2
1

Cylinder tube
Seal kit
(+19)
Piston
Guide ring
Cylinder nut

Cylinder tube
Seal kit
(+19)
Piston
Guide ring
Cylinder nut

Cilindro
Juego de juntas
(+19)
Pistn
Anillo-gua
Tuerca del cilindro

21
22
23
24

HSK1252
ELG 020
HBS2837
EZ 578

1
2
1

Piston rod
Bearing bush
Distance washer
Edge protection
(sold by the meter)

Piston rod
Bearing bush
Distance washer
Edge protection
(sold by the meter)

Vstago del mbolo


Casquillo
Faja espaciadora
Proteccin de arista
(en metros)

M 16x25 DIN7984

M 5x40 DIN 7984

M 10x1 DIN71412

95 x 90 x 15

050.0300
06/2000

Knickzylinder
Outer boom ram
Verin deuxieme bras

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Pipes-Outer boom ram


Pipes-Outer boom ram
Tubos del cilindro del mstil

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

EH4881

EH4886

EH4875

2
3
4
5

HLR 8837
UV432-340
HG 172
EA 423

1
1
1
3

6
7
8

EA 039
EA 201
EV2151
TD 204

3
1
1

9
10

ES1036
EM 199

1
1

Description

Description

zu Tafel
to figure
a' planche

050.0300

Denominacin de repuestos

Abmessung
Dimension
Dimension

Hose
(H)
Hose
F(PK 7501)
Hose
F(PK 9501)
Pipe
Load holding valve
Housing
Locking screw

Hose
(H)
Hose
F(PK 7501)
Hose
F(PK 9501)
Pipe
Load holding valve
Housing
Locking screw

Manguera
(H)
Manguera
F(PK 7501)
Manguera
F(PK 9501)
Tubo
Vlvula retencin
Carcasa
Tapn roscado

NW 10x3600

Adaptor
Adaptor
Valve insert
Seal kit
(for EV2151)
Winding pin
Sealing nut

Adaptor
Adaptor
Valve insert
Seal kit
(for EV2151)
Winding pin
Sealing nut

Racor
Racor
Asiento de vlvula
Juego de juntas
(para EV2151)
Pasador roscado
Tuerca obturadora

GE 12 SR 3/8"ED
GE 12 SRed

NW 10x4350
NW 10x4550
D 12

Vsti R 1/8"-Ed

M 8x20 DIN 916


M 8x1.5

060.0100
05/2002

PK 7501,9501

PK 7501 (>0621435) PK 7501 (0621436>)


PK 9501 (>0621728) PK 9501 (0621729>)

Base
Base
Base

S1081

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

zu Tafel
to figure
a' planche

Outer boom
Outer boom
Brazo acodado

Stk.
Qty.
Nbre.

S105K01-A

S106K01-A

2
3
4
5
5
5

ES 979
HB 130
ELG 011
HTR 659
HTR 837
HTR1024

6
7
8
9
9
9
9
9
9
9
9
9

Description

Description

060.0100

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
1
2
2
2
2

Outer boom
(PK 7501)
Outer boom
(PK 9501)
Screw
Washer
Bearing bush
Guide block
Guide block
Guide block

Outer boom
(PK 7501)
Outer boom
(PK 9501)
Screw
Washer
Bearing bush
Guide block
Guide block
Guide block

Brazo acodado
(PK 7501)
Brazo acodado
(PK 9501)
Tornillo
Arandela
Casquillo
Guia
Guia
Guia

EA 005
HBD 314
HIG 599
HTR3920
HTR3921
HTR3922
HTR3923
HTR3924
HTR3956
HTR3957
HTR3958
HTR3959

4
1
1
1
1
1
1
1
1
1
1
1

Grease nipple
Distance washer
Pin
Stop buffer
Stop buffer
Stop buffer
Stop buffer
Stop buffer
Stop buffer
Stop buffer
Stop buffer
Stop buffer

Grease nipple
Distance washer
Pin
Stop buffer
Stop buffer
Stop buffer
Stop buffer
Stop buffer
Stop buffer
Stop buffer
Stop buffer
Stop buffer

Racor de engrase
Faja espaciadora
Pasador
Tope
Tope
Tope
Tope
Tope
Tope
Tope
Tope
Tope

M 10x1 DIN71412

10
10

ES 109
ES 297

2
2

Screw
Screw

Screw
Screw

Tornillo
Tornillo

M 8x20 DIN 7991


M 8x25 DIN 7991

11
12
13
13
13
13

EF 144
HT5746
HTR2951
HTR2952
HTR2953
HTR2982

2
2
2
2
2
2

Feather
Bearer
Guide block
Guide block
Guide block
Guide block

Feather
Bearer
Guide block
Guide block
Guide block
Guide block

Resorte
Soporte
Guia
Guia
Guia
Guia

6 mm
8 mm
10 mm
1 mm

14
14
14
14
14
14

HF 846
HF 847
HF 848
HF 849
HF 850
HF 851

4
4
4
4
4
4

Guide block
Guide block
Guide block
Guide block
Guide block
Guide block

Guide block
Guide block
Guide block
Guide block
Guide block
Guide block

Guia
Guia
Guia
Guia
Guia
Guia

8 mm l=85 mm
9 mm l=85 mm
10 mm l=85 mm
11 mm l=85 mm
12 mm l=85 mm
13 mm l=85 mm

15
15
15
15
15
15

HF 846A
HF 847A
HF 848A
HF 849A
HF 850A
HF 851A

4
4
4
4
4
4

Guide block
Guide block
Guide block
Guide block
Guide block
Guide block

Guide block
Guide block
Guide block
Guide block
Guide block
Guide block

Guia
Guia
Guia
Guia
Guia
Guia

8 mm l=130 mm
9 mm l=130 mm
10 mm l=130 mm
11 mm l=130 mm
12 mm l=130 mm
13 mm l=130 mm

16
17
18
19
20

HI2774
HI2773
HHK 317
ES 264
HI2771

1
1
1
1
1

Pin
Pin
Lever
Screw
Pin

Pin
Pin
Lever
Screw
Pin

Pasador
Pasador
Palanca articulada
Tornillo
Pasador

M 16x25 DIN7984

8 mm
6 mm
10 mm

10 mm
12 mm
13 mm
14 mm
8 mm
15 mm
16 mm
18 mm
20 mm

M 8x16 DIN 912

S1081

PALFINGER

Outer boom
Outer boom
Brazo acodado

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

21
22
23

HBK 089
ELG 002
HHK 318

2
2
1

24
25
26
27
28
28
29
30

HHK 316
EQ 086
HBS 874
EQ 062
HBS 760
HBS 888
ES1089
EK 003

31
32
33
34
34

ES1082
HA3737
HA3737A
ES1082
ES1089

Description

Description

zu Tafel
to figure
a' planche

060.0100

Denominacin de repuestos

1
1
1
1
1
1
4
4

Bearing bush
Bearing bush
Lever
(+21,22)
Lever
Circlip
Distance washe
Circlip
Distance washe
Distance washe
Screw
Washer

Bearing bush
Bearing bush
Lever
(+21,22)
Lever
Circlip
Distance washe
Circlip
Distance washe
Distance washe
Screw
Washer

Casquillo
Casquillo
Palanca articulada
(+21,22)
Palanca articulada
Circlip exterior
Arandela espaciadora
Circlip exterior
Arandela espaciadora
Arandela espaciadora
Tornillo
Arandela

4
1
1
4
4

Screw
Bearer
Bearer
Screw
Screw

Screw
Bearer
Bearer
Screw
Screw

Tornillo
Soporte
Soporte
Tornillo
Tornillo

Abmessung
Dimension
Dimension

D 50 DIN 471
2 mm
D 70 DIN 471
1,5 mm
2,0 mm
M 8x10 DIN 7984
D 8 DIN 125
M 8x12 DIN 7984

M 8x12 DIN 7984


M 8x10 DIN 7984

070.0100
11/2000

PK 7501,9501
PK 7501 (>0621435)
PK 9501 (>0621728)

Ausfhrung mit mehr als einem hydraulischen Ausschub


Crane with more than one hydraulic boom extension
Modele plus d une extension hydraulique

Ausfhrung mit einem hydraulischen AusschubStd.


Crane with one hydraulic boom extensionStd.
Modele a une extension hydrauliqueStd.

Base
Base
Base

PK 7501 (0621436>)
PK 9501 (0621729>)

S1081

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

zu Tafel
to figure
a' planche

Boom extension I
Boom extension I
Brazo de empuje I

Stk.
Qty.
Nbre.

1
2

S106T01-A
UP1535

1
1

3
4
5

EM 021
EK 007
ES 276

6
7
8
9
10
10
10
10
10
10

Description

Description

070.0100

Denominacin de repuestos

Abmessung
Dimension
Dimension

Boom extension I
Boom extens. ram I
(page 070.0600)
Nut
Washer
Screw

Brazo de empuje I
Cilindro de prolonga
(Pgina 070.0600)
Tuerca
Arandela
Tornillo

260x140 mm

2
2
2

Boom extension I
Boom extens. ram I
(page 070.0600)
Nut
Washer
Screw

EA 005
EQ 218
HI 704
EK 176
HF 840
HF 841
HF 842
HF 843
HF 844
HF 845

2
1
1
2
2
2
2
2
2
2

Grease nipple
Roll pin
Pin
Washer
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block

Grease nipple
Roll pin
Pin
Washer
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block

Racor de engrase
Pasador de sujecin
Pasador
Arandela
Guia
Guia
Guia
Guia
Guia
Guia

M 10x1 DIN71412
D 6x30 DIN 1481

11
11
11
11
11
11

HF 840A
HF 841A
HF 842A
HF 843A
HF 844A
HF 845A

2
2
2
2
2
2

Guide block
Guide block
Guide block
Guide block
Guide block
Guide block

Guide block
Guide block
Guide block
Guide block
Guide block
Guide block

Guia
Guia
Guia
Guia
Guia
Guia

8 mm l=105 mm
9 mm l=105 mm
10 mm l=105 mm
11 mm l=105 mm
12 mm l=105 mm
13 mm l=105 mm

12
13
14
14
14
14

HT5746
EF 144
HTR2951
HTR2952
HTR2953
HTR2982

2
2
2
2
2
2

Bearer
Feather
Guide block
Guide block
Guide block
Guide block

Bearer
Feather
Guide block
Guide block
Guide block
Guide block

Soporte
Resorte
Guia
Guia
Guia
Guia

6 mm
8 mm
10 mm
1 mm

15

UP1452

Boom extens. ram I


(page 070.0600)

Boom extens. ram I


(page 070.0600)

Cilindro de prolonga
(Pgina 070.0600)

16
16
17
18
19
20

ES1082
ES1089
HIS 008
EQ 042
HXL 010
EZ1422

4
4
1
1
1
1

20

EZ1600

Screw
Screw
Pin
Split pin
Shackle
Crane hook
(+21)
Crane hook
(+21)

Screw
Screw
Pin
Split pin
Shackle
Crane hook
(+21)
Crane hook
(+21)

Tornillo
Tornillo
Bulon anchufe
Pasador abatible
Grillete
Gancho de carga
(+21)
Gancho de carga
(+21)

21

EZ1423

21

EZ1599

Safety latch
(for EZ1422)
Safety latch
(for EZ1600)

Safety latch
(for EZ1422)
Safety latch
(for EZ1600)

Cierre de seguridad
(para EZ1422)
Cierre de seguridad
(para EZ1600)

M 10 DIN 985
D 10 DIN 125
M 10x30 DIN 912

D 20 DIN 125
8 mm l=70 mm
9 mm l=70 mm
10 mm l=70 mm
11 mm l=70 mm
12 mm l=70 mm
13 mm l=70 mm

M 8x12 DIN 7984


M 8x10 DIN 7984
l=135 mm
D 4,5 DIN 11023
10 t
4,5 t
8,0 t

070.0200
11/2000

PK 7501,9501
PK 7501 (>0621435)
PK 9501 (>0621728)

Base
Base
Base

S1081

PK 7501 (0621436>)
PK 9501 (0621729>)

Ausfhrung mit mehr als zwei hydraulischen Ausschben


Crane with more than two hydraulic boom extensions
Modele plus d deux extensions hydrauliques

PK 7501 (>0621435)
PK 9501 (>0621728)

Ausfhrung mit zwei hydraulischen AusschbenA


Crane with two hydraulic boom extensionsA
Modele a deux extensions hydrauliquesA

PK 7501 (0621436>)
PK 9501 (0621729>)

S1081

PALFINGER

Boom extension II
Boom extension II
Brazo de empuje II

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2

1160-711
UP1535

1
1

3
3
3
3
3
3
4
4
4
4
4
4
5
6
7
8
9
10
11
12
13

HF 840
HF 841
HF 842
HF 843
HF 844
HF 845
HF 840A
HF 841A
HF 842A
HF 843A
HF 844A
HF 845A
ES 050
HXE1679
EA 005
EQ 218
HI 704
HIS 008
EQ 042
HXL 010
EZ1422

2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1

13

EZ1600

14

EZ1423

14

EZ1599

15
15
15
15
15
15
16
16
16
16
16
16
17
17
17
17
18
19
20

HF 834
HF 835
HF 836
HF 837
HF 838
HF 839
HF 834A
HF 835A
HF 836A
HF 837A
HF 838A
HF 839A
HTR2951
HTR2952
HTR2953
HTR2982
EF 144
HT5746
UP1452

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1

21
21

ES1082
ES1089

4
4

Description

Boom extension II
Boom extens. ram II
[Seite 070.0600]
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Screw
Cylinder guide
Grease nipple
Roll pin
Pin
Pin
Split pin
Shackle
Crane hook
[+14]
Crane hook
[+14]
Safety latch
[fr EZ1422]
Safety latch
[fr EZ1600]
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Feather
Bearer
Boom extens. ram II
[Seite 070.0600]
Screw
Screw

Description

Boom extension II
Boom extens. ram II
[page 070.0600]
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Screw
Cylinder guide
Grease nipple
Roll pin
Pin
Pin
Split pin
Shackle
Crane hook
[+14]
Crane hook
[+14]
Safety latch
[for EZ1422]
Safety latch
[for EZ1600]
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Feather
Bearer
Boom extens. ram II
[page 070.0600]
Screw
Screw

zu Tafel
to figure
a' planche

070.0200

Denominacin de repuestos

Brazo de empuje II
Cilindro de prolonga
[page 070.0600]
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Tornillo
Gua de cilindro
Racor de engrase
Pasador de sujecin
Pasador
Bulon anchufe
Pasador abatible
Grillete
Gancho de carga
[+14]
Gancho de carga
[+14]
Cierre de seguridad
[pour EZ1422]
Cierre de seguridad
[pour EZ1600]
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Resorte
Soporte
Cilindro de prolonga
[page 070.0600]
Tornillo
Tornillo

Abmessung
Dimension
Dimension
224x120 mm

8 mm l=70 mm
9 mm l=70 mm
10 mm l=70 mm
11 mm l=70 mm
12 mm l=70 mm
13 mm l=70 mm
8 mm l=105 mm
9 mm l=105 mm
10 mm l=105 mm
11 mm l=105 mm
12 mm l=105 mm
13 mm l=105 mm
M 10x20 DIN 912
M 10x1 DIN71412
D 6x30 DIN 1481

D 4,5 DIN 11023


10 t
4,5 t
8,0 t

8 mm l=55 mm
9 mm l=55 mm
10 mm l=55 mm
11 mm l=55 mm
12 mm l=55 mm
13 mm l=55 mm
8 mm l=80 mm
9 mm l=80 mm
10 mm l=80 mm
11 mm l=80 mm
12 mm l=80 mm
13 mm l=80 mm
6 mm
8 mm
10 mm
1 mm

M 8x12 DIN 7984


M 8x10 DIN 7984

070.0300
11/2000

PK 7501,9501
PK 7501 (>0621435)
PK 9501 (>0621728)

Ausfhrung mit mehr als drei hydraulischen Ausschben


Crane with more than three hydraulic boom extensions
Modele plus d trois extensions hydrauliques

Ausfhrung mit drei hydraulischen AusschbenB


Crane with three hydraulic boom extensionsB
Modele a trois extensions hydrauliquesB

Base
Base
Base
PK 7501 (0621436>)
PK 9501 (0621729>)

S1081

S1081

PALFINGER

Boom extension III


Boom extension III
Brazo de empuje III

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

1
2

1160-712
UP1454

1
1

3
3
3
3
3
3
4
4
4
4
4
4
5
6
7
8
9
10
11
12
13
14

HF 834
HF 835
HF 836
HF 837
HF 838
HF 839
HF 834A
HF 835A
HF 836A
HF 837A
HF 838A
HF 839A
HXE1624
ES 050
EA 005
EQ 218
HI 704
EK 176
HIS 008
EQ 042
HXL 010
EZ1422

2
2
2
2
2
2
2
2
2
2
2
2
1
3
1
1
1
2
1
1
1
1

14

EZ1600

15

EZ1423

15

EZ1599

16
16
16
16
16
17
17
17
17
18
19
20

HF 829
HF 830
HF 831
HF 832
HF 833
HTR2951
HTR2952
HTR2953
HTR2982
HT5746
EF 144
UP1453

2
2
2
2
2
2
2
2
2
2
2
1

21
21

ES1082
ES1089

4
4

Description

Boom extension III


Boom extens. ram III
[Seite 070.0600]
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Cylinder guide
Screw
Grease nipple
Roll pin
Pin
Washer
Pin
Split pin
Shackle
Crane hook
[+15]
Crane hook
[+15]
Safety latch
[fr EZ1422]
Safety latch
[fr EZ1600]
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Bearer
Feather
Boom extens. ram III
[Seite 070.0600]
Screw
Screw

Description

Boom extension III


Boom extens. ram III
[page 070.0600]
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Cylinder guide
Screw
Grease nipple
Roll pin
Pin
Washer
Pin
Split pin
Shackle
Crane hook
[+15]
Crane hook
[+15]
Safety latch
[for EZ1422]
Safety latch
[for EZ1600]
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Bearer
Feather
Boom extens. ram III
[page 070.0600]
Screw
Screw

zu Tafel
to figure
a' planche

070.0300

Denominacin de repuestos

Brazo de empuje III


Cilindro de prolonga
[page 070.0600]
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Gua de cilindro
Tornillo
Racor de engrase
Pasador de sujecin
Pasador
Arandela
Bulon anchufe
Pasador abatible
Grillete
Gancho de carga
[+15]
Gancho de carga
[+15]
Cierre de seguridad
[pour EZ1422]
Cierre de seguridad
[pour EZ1600]
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia
Soporte
Resorte
Cilindro de prolonga
[page 070.0600]
Tornillo
Tornillo

Abmessung
Dimension
Dimension
188x98 mm

8 mm l=55 mm
9 mm l=55 mm
10 mm l=55 mm
11 mm l=55 mm
12 mm l=55 mm
13 mm l=55 mm
8 mm l=80 mm
9 mm l=80 mm
10 mm l=80 mm
11 mm l=80 mm
12 mm l=80 mm
13 mm l=80 mm
M 10x20 DIN 912
M 10x1 DIN71412
D 6x30 DIN 1481
D 20
D 4,5 DIN 11023
10 t
4,5 t
8,0 t

8 mm
9 mm
10 mm
11 mm
12 mm
6 mm
8 mm
10 mm
1 mm

M 8x12 DIN 7984


M 8x10 DIN 7984

070.0400
09/1999

PK 7501,9501

Ausfhrung mit mehr als vier hydraulischen Ausschben


Crane with more than four hydraulic boom extensions
Modele plus d quatre extensions hydrauliques

Ausfhrung mit vier hydraulischen AusschbenC


Crane with four hydraulic boom extensionsC
Modele a quatre extensions hydrauliquesC

Base
Base
Base

S1081

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

zu Tafel
to figure
a' planche

Boom extension IV
Boom extension IV
Brazo de empuje IV

Stk.
Qty.
Nbre.

Description

Description

070.0400

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
2

1160-713
UP1454

1
1

Boom extension IV
Boom extens. ram IV

Boom extension IV
Boom extens. ram IV

3
3
3
3
3

HF 829
HF 830
HF 831
HF 832
HF 833

2
2
2
2
2

(page 070.0600)
Guide block
Guide block
Guide block
Guide block
Guide block

(page 070.0600)
Guide block
Guide block
Guide block
Guide block
Guide block

Brazo de empuje IV
Cilindro de
prolonga IV
(Pgina 070.0600)
Guia
Guia
Guia
Guia
Guia

155x79 mm

4
5

HXE1679
ES 050

1
2

Cylinder guide
Screw

Cylinder guide
Screw

Gua de cilindro
Tornillo

6
7
8
9
10

EA 005
EQ 218
HI 704
HIS 008
EQ 042

1
1
1
1
1

Grease nipple
Roll pin
Pin
Pin
Split pin

Grease nipple
Roll pin
Pin
Pin
Split pin

Racor de engrase
Pasador de sujecin
Pasador
Bulon anchufe
Pasador abatible

M 10x1 DIN71412
D 6x30 DIN 1481

11
12

HXL 010
EZ1422

1
1

EZ1600

13

EZ1423

13

EZ1599

14
14
14
14
14

HF 824
HF 825
HF 826
HF 827
HF 828

2
2
2
2
2

Shackle
Crane hook
(+13)
Crane hook
(+13)
Safety latch
(for EZ1422)
Safety latch
(for EZ1600)
Guide block
Guide block
Guide block
Guide block
Guide block

Grillete
Gancho de carga
(+13)
Gancho de carga
(+13)
Cierre de seguridad
(para EZ1422)
Cierre de seguridad
(para EZ1600)
Guia
Guia
Guia
Guia
Guia

10 t
4,5 t

12

Shackle
Crane hook
(+13)
Crane hook
(+13)
Safety latch
(for EZ1422)
Safety latch
(for EZ1600)
Guide block
Guide block
Guide block
Guide block
Guide block

15
15
15
15

HTR2951
HTR2952
HTR2953
HTR2982

2
2
2
2

Guide block
Guide block
Guide block
Guide block

Guide block
Guide block
Guide block
Guide block

Guia
Guia
Guia
Guia

6 mm
8 mm
10 mm
1 mm

16
17
18

EF 144
HT5746
UP1453

1
1
1

Feather
Bearer
Boom extens. ram IV

Feather
Bearer
Boom extens. ram IV

19
19

ES1082
ES1089

4
4

(page 070.0600)
Screw
Screw

(page 070.0600)
Screw
Screw

Resorte
Soporte
Cilindro de
prolonga IV
(Pgina 070.0600)
Tornillo
Tornillo

M 8x12 DIN 7984


M 8x10 DIN 7984

8 mm l=40 mm
9 mm l=40 mm
10 mm l=40 mm
11 mm l=40 mm
12 mm l=40 mm

M 10x20 DIN 912

l=135 mm
D 4,5 DIN 11023

8,0 t

8 mm l=40mm
9 mm l=40mm
10 mm l=40mm
11 mm l=40mm
12 mm l=40mm

070.0500
09/1999

PK 7501,9501

Ausfhrung mit fnf hydraulischen AusschbenD


Crane with five hydraulic boom extensionsD
Modele a cinq extensions hydrauliquesD

Base
Base
Base

S1081

S1081

PALFINGER

Boom Extension V
Boom Extension V
Brazo de empuje V

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

070.0500

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
2

1160-714
UP1454

1
1

Boom Extension V
Boom extens. ram V

Boom Extension V
Boom extens. ram V

3
3
3
3
3

HF 824
HF 825
HF 826
HF 827
HF 828

2
2
2
2
2

(page 070.0600)
Guide block
Guide block
Guide block
Guide block
Guide block

(page 070.0600)
Guide block
Guide block
Guide block
Guide block
Guide block

Brazo de empuje V
Cilindro de
prolonga V
(Pgina 070.0600)
Guia
Guia
Guia
Guia
Guia

123x62 mm

4
5

HXE1623
ES 050

1
2

Cylinder guide
Screw

Cylinder guide
Screw

Gua de cilindro
Tornillo

6
7
8
9
10

EA 005
HI 704
EQ 218
HIS 008
EQ 042

1
1
1
1
1

Grease nipple
Pin
Roll pin
Pin
Split pin

Grease nipple
Pin
Roll pin
Pin
Split pin

Racor de engrase
Pasador
Pasador de sujecin
Bulon anchufe
Pasador abatible

M 10x1 DIN71412

11
12

HXL 010
EZ1422

1
1

EZ1600

13

EZ1423

13

EZ1599

Shackle
Crane hook
(+13)
Crane hook
(+13)
Safety latch
(for EZ1422)
Safety latch
(for EZ1600)

Grillete
Gancho de carga
(+13)
Gancho de carga
(+13)
Cierre de seguridad
(para EZ1422)
Cierre de seguridad
(para EZ1600)

10 t
4,5 t

12

Shackle
Crane hook
(+13)
Crane hook
(+13)
Safety latch
(for EZ1422)
Safety latch
(for EZ1600)

8 mm l=40mm
9 mm l=40mm
10 mm l=40mm
11 mm l=40mm
12 mm l=40mm

M 10x20 DIN 912

D 6x30 DIN 1481


l=135 mm
D 4,5 DIN 11023

8,0 t

070.0600
11/2000

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Boom extensions ram I-V


Boom extensions ram I-V
Cilindro de empuje I-V

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

UP1452

UP1452

UP1453

UP1453

UP1454

UP1454

Description

Description

zu Tafel
to figure
a' planche

070.0600

Denominacin de repuestos

Boom extens. ram I


(Type A)
Boom extens. ram II
(Type B)
Boom extens. ram III
(Type C)
Boom extens. ram IV

Boom extens. ram I


(Type A)
Boom extens. ram II
(Type B)
Boom extens. ram III
(Type C)
Boom extens. ram IV

(Type D)
Boom extens. ram III
(Type B)
Boom extens. ram IV

(Type D)
Boom extens. ram III
(Type B)
Boom extens. ram IV

UP1454

(Type C)
Boom extens. ram V

(Type C)
Boom extens. ram V

UP1535

UP1535

HY1353

(Type D)
Boom extens. ram I
(Type standard)
Boom extens. ram II
(Type A)
Cylinder tube

(Type D)
Boom extens. ram I
(Type standard)
Boom extens. ram II
(Type A)
Cylinder tube

Cilindro de prolonga
(Version A)
Cilindro de prolonga
(Version B)
Cilindro de prolonga
(Version C)
Cilindro de
prolonga IV
(Version D)
Cilindro de prolonga
(Version B)
Cilindro de
prolonga IV
(Version C)
Cilindro de
prolonga V
(Version D)
Cilindro de prolonga
(Vers. estndar)
Cilindro de prolonga
(Version A)
Cilindro

6
7
8
9
10

HSK1219
HY1354
HSK1220
HY1355
HSK1221

1
1
1
1
1

Piston rod
Cylinder tube
Piston rod
Cylinder tube
Piston rod

Piston rod
Cylinder tube
Piston rod
Cylinder tube
Piston rod

Vstago del mbolo


Cilindro
Vstago del mbolo
Cilindro
Vstago del mbolo

11
12
13
14
15

HSK1266
TD 528
HK 300
HV 370
ES 228

1
4
2
4
2

Piston rod
Seal kit
Piston
Cylinder nut
Winding pin

Piston rod
Seal kit
Piston
Cylinder nut
Winding pin

Vstago del mbolo


Juego de juntas
Pistn
Tuerca del cilindro
Pasador roscado

Abmessung
Dimension
Dimension

M 6x6 DIN 913

070.0700
11/2004

Base
Base
Base

PK 7501,9501

Ausfhrung mit drei hydraulischen AusschbenBe


Crane with three hydraulic boom extensionsB
Modele a trois extensions hydrauliquesB

Schubzylinder III
Boom extension ram III
Verin de extension III

Schubzylinder II
Boom extension ram II
Verin de extension II

Schubzylinder I
Boom extension ram I
Verin de extension I

Knickarm
Outer boom
Deuxieme bras

S1081

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

zu Tafel
to figure
a' planche

Pipes-Boom extens.ram
Pipes-Boom extens.ram
Tubos de los cilindros de ext.

Stk.
Qty.
Nbre.

1
2
3
4

EV5144
ES1157
HBS1020
EH4874

1
2
2
2

EH4878

EH4888

EA 183

6
7
8
9

EA 074
EA 496
HLR 8838
HLR 8803

3
1
1
1

HLR 8833

10

HLR 8804

10

HLR 8834

11
12
13
14

HLR 8275
HLR 8276
HLR 8467
HLR 8278

1
1
1
1

Description

Description

070.0700

Denominacin de repuestos

Abmessung
Dimension
Dimension

Load holding valve


Screw
Distance washer
Hose
(H)
Hose
F(PK 9501)
Hose
F(PK 7501)
Adaptor

Load holding valve


Screw
Distance washer
Hose
(H)
Hose
F(PK 9501)
Hose
F(PK 7501)
Adaptor

Vlvula retencin
Tornillo
Faja espaciadora
Manguera
(H)
Manguera
F(PK 9501)
Manguera
F(PK 7501)
Racor

Adaptor
Adaptor
Pipe
Pipe
(PK 9501)
Pipe
(PK 7501)
Pipe
(PK 9501)
Pipe
(PK 7501)

Adaptor
Adaptor
Pipe
Pipe
(PK 9501)
Pipe
(PK 7501)
Pipe
(PK 9501)
Pipe
(PK 7501)

Racor
Racor
Tubo
Tubo
(PK 9501)
Tubo
(PK 7501)
Tubo
(PK 9501)
Tubo
(PK 7501)

GE 16 SR 1/2"ED
G 16 S
D 16
D 16

Pipe
Pipe
Pipe
Pipe

Pipe
Pipe
Pipe
Pipe

Tubo
Tubo
Tubo
Tubo

D 16
D 12
D 16
D 12

M 8x70 DIN 912


20 mm
NW 10x4800
NW 10x5850
NW 10x5650
GE 12 SR 1/2"ED

D 16
D 12
D 12

070.0800
11/2004

Base
Base
Base

PK 7501,9501

Ausfhrung mit vier hydraulischen AusschbenCe


Crane with four hydraulic boom extensionsC
Modele a quatre extensions hydrauliquesC

Schubzylinder IV
Boom extension ram IV
Verin de extension IV

Schubzylinder III
Boom extension ram III
Verin de extension III

Schubzylinder II
Boom extension ram II
Verin de extension II

Schubzylinder I
Boom extension ram I
Verin de extension I

Knickarm
Outer boom
Deuxieme bras

S1081

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

zu Tafel
to figure
a' planche

Pipes-Boom extens.ram
Pipes-Boom extens.ram
Tubos de los cilindros de ext.

Stk.
Qty.
Nbre.

1
2
3
4

EV5144
ES1157
HBS1020
EH4874

1
2
2
2

EH4878

EH4888

EA 183

6
7
8
9

EA 074
EA 496
HLR 8838
HLR 8803

4
1
1
1

HLR 8833

10

HLR 8804

10

HLR 8834

11
12
13
14
15

HLR 8275
HLR 8276
HLR 8277
HLR 8468
HLR 8469

16

HLR 8466

Description

Description

070.0800

Denominacin de repuestos

Abmessung
Dimension
Dimension

Load holding valve


Screw
Distance washer
Hose
(H)
Hose
F(PK 9501)
Hose
F(PK 7501)
Adaptor

Load holding valve


Screw
Distance washer
Hose
(H)
Hose
F(PK 9501)
Hose
F(PK 7501)
Adaptor

Vlvula retencin
Tornillo
Faja espaciadora
Manguera
(H)
Manguera
F(PK 9501)
Manguera
F(PK 7501)
Racor

Adaptor
Adaptor
Pipe
Pipe
(PK 9501)
Pipe
(PK 7501)
Pipe
(PK 9501)
Pipe
(PK 7501)

Adaptor
Adaptor
Pipe
Pipe
(PK 9501)
Pipe
(PK 7501)
Pipe
(PK 9501)
Pipe
(PK 7501)

Racor
Racor
Tubo
Tubo
(PK 9501)
Tubo
(PK 7501)
Tubo
(PK 9501)
Tubo
(PK 7501)

GE 16 SR 1/2"ED
G 16 S
D 16
D 16

1
1
1
1
1

Pipe
Pipe
Pipe
Pipe
Pipe

Pipe
Pipe
Pipe
Pipe
Pipe

Tubo
Tubo
Tubo
Tubo
Tubo

D 16
D 12
D 16
D 12
D 16

Pipe

Pipe

Tubo

D 12

M 8x70 DIN 912


20 mm
NW 10x4800
NW 10x5850
NW 10x5650
GE 12 SR 1/2"ED

D 16
D 12
D 12

070.0900
11/2004

Base
Base
Base

PK 7501,9501

Ausfhrung mit fnf hydraulischen AusschbenD8b


Crane with five hydraulic boom extensionsD
Modele a cinq extensions hydrauliquesD

Schubzylinder V
Boom extension ram V
Verin de extension V

Schubzylinder IV
Boom extension ram IV
Verin de extension IV

Schubzylinder III
Boom extension ram III
Verin de extension III

Schubzylinder II
Boom extension ram II
Verin de extension II

Schubzylinder I
Boom extension ram I
Verin de extension I

Knickarm
Outer boom
Deuxieme bras

S1081

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

zu Tafel
to figure
a' planche

Pipes-Boom extens.ram
Pipes-Boom extens.ram
Tubos de los cilindros de ext.

Stk.
Qty.
Nbre.

Description

Description

070.0900

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
2
3
4
5

EV5144
ES1157
HBS1020
EA 181
EV 363/040

1
2
2
1
1

Load holding valve


Screw
Distance washer
Adaptor
Pretension valve

Load holding valve


Screw
Distance washer
Adaptor
Pretension valve

Vlvula retencin
Tornillo
Faja espaciadora
Racor
Vlvula de pretens.

6
7

EA 074
EH4874

6
2

EH4878

EH4888

8
9
10

EA 183
EA 496
HLR 8838

7
1
1

Adaptor
Hose
(H)
Hose
F(PK 9501)
Hose
F(PK 7501)
Adaptor
Adaptor
Pipe

Racor
Manguera
(H)
Manguera
F(PK 9501)
Manguera
F(PK 7501)
Racor
Racor
Tubo

GE 16 SR 1/2"ED
NW 10x4800

Adaptor
Hose
(H)
Hose
F(PK 9501)
Hose
F(PK 7501)
Adaptor
Adaptor
Pipe

11

HLR 8803

HLR 8833

12

HLR 8804

12

HLR 8834

13
14
15

HLR 8275
HLR 8276
HLR 8277

1
1
1

Pipe
(PK 9501)
Pipe
(PK 7501)
Pipe
(PK 9501)
Pipe
(PK 7501)
Pipe
Pipe
Pipe

Tubo
(PK 9501)
Tubo
(PK 7501)
Tubo
(PK 9501)
Tubo
(PK 7501)
Tubo
Tubo
Tubo

D 16

11

Pipe
(PK 9501)
Pipe
(PK 7501)
Pipe
(PK 9501)
Pipe
(PK 7501)
Pipe
Pipe
Pipe

16
17
18
19

HLR 8468
HLR 8463
HLR 8466
HLR 8465

1
1
2
1

Pipe
Pipe
Pipe
Pipe

Pipe
Pipe
Pipe
Pipe

Tubo
Tubo
Tubo
Tubo

D 12
D 16
D 12
D 16

M 8x70 DIN 912


20 mm
EGE 16S 1/2"-ed
40 bar

NW 10x5850
NW 10x5650
GE 12 SR 1/2"ED
G 16 S
D 16

D 16
D 12
D 12
D 16
D 12
D 16

070.1000
09/1999

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Hose guide
Hose guide
Gua de manguera

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

zu Tafel
to figure
a' planche

070.1000

Denominacin de repuestos

1
2
3
4
5

HA3559
ES 374
EK 003
EM 026
HBS2126

1
6
6
5
5

Hose guide
Screw
Washer
Nut
Spacer tube

Hose guide
Screw
Washer
Nut
Spacer tube

Gua de manguera
Tornillo
Arandela
Tuerca
Lamina

6
7
8
9
10

ES1163
HXE1154
EQ 044
EK 007
ES 050

5
5
10
10
10

Screw
Hose guide
Adapter sleeve
Washer
Screw

Screw
Hose guide
Adapter sleeve
Washer
Screw

Tornillo
Gua de manguera
Casquillo de apriete
Arandela
Tornillo

11
12
13
14
15

HI2453
EQ 021
HXS 032
HA4298
EK 043

1
1
1
4
4

Pin
Split pin
Safety chain
Bearer
Washer

Pin
Split pin
Safety chain
Bearer
Washer

Pasador
Pasador aletas
Cadena de seguridad
Soporte
Arandela

16

ES 414

Screw

Screw

Tornillo

Abmessung
Dimension
Dimension

M 8x12 DIN 912


D 8 DIN 125
M 8 DIN 985
l=92 mm
M 8x110 DIN 912

D 10 DIN 125
M 10x20 DIN 912

D 5x50 DIN 94

D 6,4 DIN 134


M 6x10 DIN 912

070.1100
09/1999

Schlauchwanne
Hose guide
Guide de flexible

Schlauchwanne
Hose guide
Guide de flexible

Schlauchwanne
Hose guide
Guide de flexible

Schlauchwanne
Hose guide
Guide de flexible

Schlauchwanne
Hose guide
Guide de flexible

Schlauchwanne
Hose guide
Guide de flexible

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER

Pipes-Hose guide
Pipes-Hose guide
Tubos de la gua de las mangue

PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

Stk.
Qty.
Nbre.

Description

Description

1
2

EA1113
TD 045

2
1

Quick coupling,cpl.
Seal kit cpl.

Quick coupling,cpl.
Seal kit cpl.

EK 112

EK 143

4
5

EA1266
EK 113

1
1

EK 144

Dust cover
(Red)
Dust cover
(Black)
Plug box
Dust cover
(Red)
Dust cover
(Black)

Dust cover
(Red)
Dust cover
(Black)
Plug box
Dust cover
(Red)
Dust cover
(Black)

6
7
7
7
8
9

EA1267
EH 617
EH 619
EH 768
EA1646
EH4882

EH4879

EH4889

10

EH2283

16

Plug
Protection hose
Protection hose
Protection hose
Adaptor
Hose
(H)
Hose
F(PK 9501)
Hose
F(PK 7501)
Hose

11

EH4786

Hose

4
4

zu Tafel
to figure
a' planche

070.1100

Denominacin de repuestos

Abmessung
Dimension
Dimension

Acoplamiento rpido
Juego de juntas
cplto.
Tapa guardapolvo
(Rojo)
Tapa guardapolvo

12-S DIN 2353

Caja de enchufe
Tapa guardapolvo
(Rojo)
Tapa guardapolvo

12 S
Rot

Plug
Protection hose
Protection hose
Protection hose
Adaptor
Hose
(H)
Hose
F(PK 9501)
Hose
F(PK 7501)
Hose

Enchufe
Manga protectora
Manga protectora
Manga protectora
Racor
Manguera
(H)
Manguera
F(PK 9501)
Manguera
F(PK 7501)
Manguera

12 S
D 50x1400
D 50x1500
D 70x1500
GE 12K R1/2" ED
NW 10x5700

Hose

Manguera

NW 10x3350

Rot
Schwarz

Schwarz

NW 10x6750
NW 10x6550
NW 10x2700

080.0100
07/2004

PK 7501,9501

Base
Base
Base

S1081

S1081

PALFINGER
PK 7501,9501
Nr. Ersatzteil Nr.
No. Sparepart no.
No. No Piece de
rechange

zu Tafel
to figure
a' planche

Verl ngerungen
Man. boom extensions
Rallonges

Stk.
Qty.
Nbre.

Description

Description

080.0100

Denominacin de repuestos

Abmessung
Dimension
Dimension

1
2
3
4
5

KMT006ASA
KMT007ASA
KMT008ASA
KMT006A-A
KMT007A-A

1
1
1
1
1

Extension I,cpl.
Extension cpl.
Extension cpl.
Extension
Extension

Extension I,cpl.
Extension cpl.
Extension cpl.
Extension
Extension

I prolonga cplta.
Prolonga cplta.
Prolonga cplta.
prolonga
prolonga

155x81 mm
123x64 mm

6
7
7
8
9
10
10
10
10
10

KMT008A-A
HT2220
HT2221
HIS 061
EQ 042
HF 829
HF 830
HF 831
HF 832
HF 833

1
2
2
2
3
2
2
2
2
2

Extension
Guide block
Guide block
Pin
Split pin
Guide block
Guide block
Guide block
Guide block
Guide block

Extension
Guide block
Guide block
Pin
Split pin
Guide block
Guide block
Guide block
Guide block
Guide block

prolonga
Guia
Guia
Bulon anchufe
Pasador abatible
Guia
Guia
Guia
Guia
Guia

93x47 mm
8 mm
10 mm
l=128 mm
D 4,5 DIN 11023
8 mm l=40 mm
9 mm l=40 mm
10 mm l=40 mm
11 mm l=40 mm
12 mm l=40 mm

11
11
11
11

HTR2951
HTR2952
HTR2953
HTR2982

6
6
6
6

Guide block
Guide block
Guide block
Guide block

Guide block
Guide block
Guide block
Guide block

Guia
Guia
Guia
Guia

6 mm
8 mm
10 mm
1 mm

12
12
12
13
13
13
13
13

HT6723
HT2218
HT2219
HF 824
HF 825
HF 826
HF 827
HF 828

4
4
4
2
2
2
2
2

Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block

Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block
Guide block

Guia
Guia
Guia
Guia
Guia
Guia
Guia
Guia

7 mm
8 mm
10 mm
8 mm l=40mm
9 mm l=40mm
10 mm l=40mm
11 mm l=40mm
12 mm l=40mm

14
15

HIS 040
EA 005

1
3

Pin
Grease nipple

Pin
Grease nipple

Bulon anchufe
Racor de engrase

M 10x1 DIN71412

16
16
16
17

ES1082
ES1088
ES1089
KLG001A-A

Screw
Screw
Screw
Pressure balance
(look KMG00303A)
(page 030.0100)

Screw
Screw
Screw
Pressure balance
(look KMG00303A)
(page 030.0100)

Tornillo
Tornillo
Tornillo
Balanza de presin
(Vase KMG00303A)
(Pgina 030.0100)

M 8x12 DIN 7984


M 8x6 DIN 7984
M 8x10 DIN 7984

Schlaucharmaturen
Hose fittings
Les goulottes

EA1645

Druckschlauch
Hose
Flexible

Abmessungen
Dimension
Dimension

EH 838

NW 10

EH 839

NW 12

Presshlse
Hose sleeve
Douille a flexible

Abmessungen
Dimension
Dimension

EA 312

NW 10

EA 313

NW 12

Pressarmatur
Hose clip
Collier a flexible

Abmessungen
Dimension
Dimension

EA1648

NW 10

EA1649

NW 12

Steuerventil
Directional control valve
Distributeur de commande

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1081

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

S1092

NOTE: SOME SECTIONS ARE REMOVED AS


THEY DO NOT APPLY TO GETMAN
APPLICATIONS.

S1092

S1092

Does not apply to Getman applications.

S1092

S1094

S1094

S1094

S1094

S1094

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