2.
CHASSIS
10368
10376
10398
10448
13758
13942
12043
3.
SIGHT GAUGE
FILL CAP (FUEL OIL)
FILL CAP (HYDRAULIC OIL)
HOLD DOWN FASTENERS
SEAT ASSEMBLY
STEERING (PINS, BEARINGS, BUSHINGS)
ARTICULATION INSTALLATION
WIRING DIAGRAM
INSTRUMENT PANEL
MURPHY POWERVIEW INSTRUCTIONS
ALTERNATOR
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.
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
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
F1008
Page 1 of 1
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:
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
*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
M1040
Page 1 of 32
GETMAN CORPORATION
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
Updated:
05/29/08
M1040
Page 2 of 32
INTRODUCTION
RELATED MANUALS
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:
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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.
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:
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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.
Always ensure that excess grease, oil, etc., are cleaned up immediately to prevent a potential fire hazard.
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
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*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
Updated:
05/29/08
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.
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Page 6 of 32
SERVICE POSITION
4. Stop engine.
DO NOT
Do not operate while under the influence of alcohol or
drugs.
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.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
Updated:
05/29/08
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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
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.
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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:
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465313-100
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
Updated:
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Updated:
05/29/08
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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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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
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:
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*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
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STOP
ENGINE
CHECK
ENGINE
Updated:
05/29/08
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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.
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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.
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Check all the engine belt(s) for tension and condition. Worn or
gouged belt(s) should be replaced immediately.
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 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:
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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.
4.
9.
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:
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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.
2.
3.
4.
5.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
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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:
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4
3
Once all gauges have been checked and are within normal operating ranges, vehicle is ready to
operate.
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.
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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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:
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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.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
Updated:
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WARNING
Engine MUST be shut of to check belt tension.
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.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
Updated:
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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:
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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.
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.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
Updated:
05/29/08
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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.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
Updated:
05/29/08
M1040
Page 29 of 32
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
Updated:
05/29/08
M1040
Page 30 of 32
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.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
Updated:
05/29/08
M1040
Page 31 of 32
ITEM
1.
2.
COMPONENT
Axle Differential Housing
Axle Breather
FLUID*
MBO
____
Remove front and rear axle differential drain plugs. When axle
is empty of all fluid, clean and re-install drain plugs.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS.
Updated:
05/29/08
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
*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
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 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:
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MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
M1040
Pag. 4 de 32
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.
Siempre asegrese que los excesos de grasa, son limpiados inmediatamente para prevenir un riesgo potencial de
incendio.
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.
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:
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MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
M1040
Pag. 5 de 32
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
M1040
Pag. 6 de 32
CIERRE EL COMBUSTIBLE
Cierre las vlvulas de la lnea de combustible en las salidas del
tanque.
NO LO HAGA
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.
2.
3.
4.
Apague el motor.
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
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
*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. 9 de 32
465313-100
*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. 10 de 32
*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. 11 de 32
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)
*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. 12 de 32
OTROS CONTROLES
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
*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. 13 de 32
47
BATERIA
PRESION DE
ACEITE
*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS
INSTRUCCIONES EN LAS PLACAS.
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MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
M1040
Pag. 14 de 32
CODIGOS ACTIVOS
DE FALLA
ADVERTENCIA!
SPN100 FM18 BAJA
PRESION DE ACEITE
CODIGOS ACTIVOS
DE FALLA
ADVERTENCIA!
SPN100 FM10 ALTA
TEMP. DE ENFRIADOR
VOLTIOS
PARAR EL
MOTOR
PRESION
DE ACEITE
CHECAR EL
MOTOR
*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. 15 de 32
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.
Actualizado:
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MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
M1040
Pag. 16 de 32
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.
Actualizado:
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MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
M1040
Pag. 17 de 32
*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. 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!
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.
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:
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MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
M1040
Pag. 19 de 32
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)
*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
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:
10/30/08
MANUAL DE OPERACION Y
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.
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.
Actualizado:
10/30/08
MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
M1040
Pag. 22 de 32
CONDUCIENDO EL CAMION
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.
Actualizado:
10/30/08
MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
M1040
Pag. 23 de 32
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.
Actualizado:
10/30/08
MANUAL DE OPERACION Y
MANTENIMIENTO PARA EL CAMION
GETMAN A-64
M1040
Pag. 24 de 32
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
EPG
*Realice el Programa de Mantenimiento como se requiere
*Observe las Especificaciones del Fluido.
*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
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:
*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
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.
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.
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
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.
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
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.
*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
*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
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.
*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
PARTIDA
1.
2.
COMPONENTE
Caja del Eje Diferencial
Respirador del Eje
FLUIDO*
MBO
____
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
45-60
3.1-4.1
1500-2000
103-138
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
S1092
S1092
S1092
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S1000
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 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
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.
FLUID SPECIFICATIONS
COMPONENT
SYMBOL
TF
HO
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
Updated:
01/17/08
LUBRICANT CROSS
REFERENCE
F1003
Page 2 of 2
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
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
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
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
GETMAN EQUIPMENT
STORAGE PROCEDURES
F1001
Page 1 of 1
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.
AXLE
Axle housings should be filled completely to
eliminate the change of moisture condensation.
BRAKE SYSTEM
Drain all air reservoirs of moisture.
BATTERY
Remove battery; clean off top, and store in a wellventilated battery storage area. Do not store on
concrete or metal.
Updated:
04/26/07
TROUBLESHOOTING CHECK
LIST
CAUSE
F1002
Page 1 of 2
REMEDY
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
OUT OF FUEL
SHUT OFF VALVES CLOSED
FUEL FILTER PLUGGED
FUEL LINES LEAKING
PREHEAT FAILS
ENGINE OVERHEATS
1.
2.
3.
4.
TROUBLESHOOTING CHECK
LIST
F1002
Page 2 of 2
1. READJUST
2. REPLACE PADS
1.
2.
3.
4.
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
DAILY SERVICES
OK
PARTS
ORDERED
UNIT
DOWN
Updated:
04/26/07
PREVENTIVE MAINTENANCE
SCHEDULE FORMS
F1004
Page 2 of 5
50 HOUR SERVICE
OK
PARTS
ORDERED
UNIT
DOWN
Updated:
04/26/07
PREVENTIVE MAINTENANCE
SCHEDULE FORMS
F1004
Page 3 of 5
OK
PARTS
ORDERED
UNIT
DOWN
Updated:
04/26/07
PREVENTIVE MAINTENANCE
SCHEDULE FORMS
F1004
Page 4 of 5
OK
PARTS
ORDERED
UNIT
DOWN
Updated:
04/26/07
PREVENTIVE MAINTENANCE
SCHEDULE FORMS
F1004
Page 5 of 5
OK
PARTS
ORDERED
UNIT
DOWN
Updated:
04/26/07
F1005
Page 1 of 1
PARTS USED:
MAINTENANCE
PERSONS SIGNATURE:________________________________________
DATE:___________________
SUPERVISORS
SIGNATURE:__________________________________________________
DATE:___________________
Updated:
04/26/07
F1006
Page 1 of 1
OK
1
7
8
Updated:
04/26/07
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.
53011
Updated:
12/11/06
FILL CAP
ITEM PART #
10376
Page 1 of 1
DESCRIPTION
QTY.
392012
NSS
CAP
NSS
SCREEN
Updated:
03/08/07
ITEM PART #
10398
Page 1 of 1
DESCRIPTION
QTY.
52500
54048
CAP
54003
SCREEN
Updated:
12/11/06
10448
Page 1 of 1
ITEM PART #
DESCRIPTION
QTY.
132130
594535
01GE04
WASHER
01GC04008
BOLT
5*
NSS
STRAP
6*
NSS
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
424396-02
424396-03
424396-04
424396-05
FRAME
424396-06
424396-07
DAMPER KIT
424396-08
424396-09
SUSPENSION
10
424396-10
SEATBELT BRACKET
11
424396-11
12
424396-12
SUSPENSION COVER
13
424396-13
SLIDERAIL KIT
Updated:
12/11/06
13942
Page 1 of 1
ITEM PART #
DESCRIPTION
QTY.
26409-01
524202
13796-01
SEE SECTION 8
STEERING CYLINDER
524203
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
10697-01
CAP PIN
16369-02
594572
594573
594574
16367-03
A/R
A/R
A/R
2
594575
594576
594577
NSS
A/R
A/R
A/R
2
264032
BEARING
16369-03
10
13796-03
PIN
11
NSS
JOINT PLATE
12
73GC08016
12
13
17GC08024
12
14
464420
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.
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
WIRING DIAGRAM
INSTRUMENT PANEL
MURPHY POWERVIEW INSTRUCTIONS
ALTERNATOR
17143
Page 1 of 2
INSTRUMENT PANEL
465313-100-OV
ITEM PART #
DESCRIPTION
QTY.
124454
124455
3
*
4
*
5
*
6
124421
124278
124403
124406
134019
134020
124396
1
1
1
1
1
1
1
124148
124461
122100
HORN BUTTON
Updated:
03/11/08
INSTRUMENT PANEL
9
17143
Page 2 of 2
10
134117
134009
134118
N/A
A/R
A/R
A/R
N/A
11
124498
12
14
124148
124461
122100
124433
124195
1
1
1
15
124380
START SWITCH
16
124501
17
19
124148
124461
124148
124461
SEE GETMAN
WARNING PANEL
20*
464670
RESISTOR PACK
13
18
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.
S1100
Table of Contents
Introduction............................................................................. 1
Engine and Transmission Parameters
Faceplate Features
Operation ................................................................................. 9
PowerView Menus (First Time Start Up)
12
18
20
Utilities Menu
23
Modbus Setup
25
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 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
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
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
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.
00-02-0605
- 12 -
Rev 09-10-08
S1100
- 13 -
Rev 09-10-08
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.
00-02-0605
- 14 -
Rev 09-10-08
S1100
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.
00-02-0605
- 15 -
Rev 09-10-08
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.
- 16 -
Rev 09-10-08
S1100
8. The parameter in the selected quadrant has changed to
the parameter selected in the previous screen.
00-02-0605
- 17 -
Rev 09-10-08
S1100
Selecting a Language
From LANGUAGES, you may select ENGLISH, ESPANOL,
FRANCAIS, ITALIANO, or DEUTSCH. The currently
selected language is indicated by an asterisk.
- 18 -
Rev 09-10-08
S1100
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)
00-02-0605
- 19 -
Rev 09-10-08
S1100
Visual Indication
Fault Indicators
00-02-0605
- 20 -
Rev 09-10-08
S1100
- 21 -
Rev 09-10-08
S1100
00-02-0605
- 22 -
Rev 09-10-08
S1100
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
00-02-0605
- 23 -
Rev 09-10-08
S1100
being used. Most engine ECUs use Version 4,
therefore in most cases adjustment of this menu option
will not be required.
- 24 -
Rev 09-10-08
S1100
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.
00-02-0605
- 25 -
Rev 09-10-08
S1100
00-02-0605
- 26 -
Rev 09-10-08
S1100
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.
00-02-0605
- 27 -
Rev 09-10-08
S1100
00-02-0605
- 28 -
Rev 09-10-08
S1100
DATA ERROR is displayed in place of a parameter value
00-02-0605
- 29 -
Rev 09-10-08
S1100
0710172
02-13-07
Section 78
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
00-02-0605
- 30 -
Rev 09-10-08
0710174 S1100
02-14-07
Section 78
PGN
Parameter
Display Value
61443
THROTTLE
LOAD@RPM
61444
ENG TORQ
ENG RPM
65253
ENG HRS
Fuel Consumption
65257
Trip Fuel
Total Fuel Used
TRIP FUEL
FUEL USED
Engine Temperature
65262
COOL TEMP
FUEL TEMP
OIL TEMP
INTC TEMP
65263
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
65243
INJ PRES1
INJ PRES2
Fan Drive-FD
65213
FAN SPD
Diagnostic Messages
65226
65227
65228
SRVCCODE
STORCODE
N/A
Machine Hours
MACH HRS
Engine Conf.
65251
Engine Configuration
ENG CONF
61448
HYD PRES
61442
61442
61442
OUT SFT SP
IN SFT SPD
TORQ LOCK
61445
61445
Selected Gear
Current Gear
SLECT GEAR
CURNT GEAR
Transmission Fluids
65272
TRAN PRES
TRAN TEMP
256
Requested Gear
REQ GEAR
65164
Auxiliary Temperature
Auxiliary Pressure
AUX TEMP
AUX PRES
65241
Auxiliary I/O #1
AUX 10 1
65265
VEH SPD
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
HYD TEMP
Dash Display-DD
65276
Fuel Level
FUEL LEVEL
Rudder
127245
Rudder Angle
RUD ANG
Speed
128259
Water Referenced
H20 REF.SP
130576
P TRIM TAB
130576
S TRIM TAB
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
2*
146015
A/R
3*
146014
4*
146031
5*
146073
6*
146074
A/R
A/R
A/R
A/R
Updated:
11/30/07
F1007
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.
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.
S1034
Mercedes-Benz
S1034
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
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
Practical advice
98
106
Technical data
Engine data
Test values and adjustment
values
Tightening torques
108
112
113
115
117
S1034
At a glance
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.
Technical data
All the important technical data for the engine is listed here.
9
S1034
Symbols
T Symbols
1
.......
Environmental note
An environmental note givesyou tips on the
protection of the environment.
Warning
:I."
You should therefore always read and observe all warning notices.
[>
page
->
I e
This tip contains advice or further information you may find useful.
S1034
"
"
..
..
policy starts at the root causes and encompasses in its management decisions all the
consequences for the environment which
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.
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.
S1034
S1034
iocatron of sensors
Engine plate
S1034
2
......
6 )------...."....~-----;,.:,;.
5)------~
41----------'
3)--------'
2 } - - -__-....::..,,-
CDl------......,.....~~
G01.00-3123-31
S1034
CD Fan
o Coolant pump
S1034
l----------==-~
2
}---------------=~
___
0-----4--
G01.0D-3124-31
S1034
CD Flywheel housing
CD Charge-air housing
@ Exhaust manifold
o Oil filter
S1034
OM 906
LA/ OM 926 LA
r----------------.
.....
r-------------F.~___::'
01--------~
':::::::==""'""-----~10
-----~11
"------....{12
::!.----~13
GOl.OO-3121-31
S1034
CD
Fan
@ Oil filter
@
@
@
@
@
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
G01.0D-3127-31
S1034
-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).
S1034
S1034
T General
Type designation
OM
9XX
L A
OM
-3
Engine type
9XX
L
Intercooler
A Exhaust gas turbocharger
N01.00-2388-31
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
3
...........
S1034
Flame-start system *
Flame-start system
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
der engine
S1034
<
l1li
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
It
coolant temperature
It
fuel temperature
oil pressure
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
CD Data record
CD Certification no.
Engine plate
8) Equipment code
S1034
The FR (drive control) unit and the ADM receive data from the
IJI
N15.00-2089-31
3
.......
S1034
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.
N54.22-2015-31
Diagnostic socket
Organisational measures
Risk of accident and injury
.&.
S1034
Lt.
..
..
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.
S1034
ul"ming program
'i:
"
~~~~-!3~n~ pints
-~1'
.~'
- -,
S1034
Safety precautions
',,'
Only start the engine with the rotational speed sensor connected.
III
S1034
S1034
4
......
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
Risk of accident
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
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
S1034
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.
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.
It
S1034
Refuelling
Use summer or winter fuel depending on
the season. See also "Diesel fuels"
([> page 60).
..
..
o
To ensure that the fuel system can be
bled, the battery must have enough
charge when the engine is started.
..
fa
The cable cross-sections are depend\, ent on the distance between the battery and the starter motor.
S1034
Carry out the work listed under "Preparation for commissioning" (I> page 42) before operating the engine for the first time.
~
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
CD Stop button
S1034
Risk of injury
Risk of scalding
Risk of poisoning
trapped, crushed or torn off by rotating engine parts. Therefore you should:
lowed.
..
..
..
..
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.
It
It
5
.........
1>1>
S1034
5
......
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.
S1034
;1!j
Starting procedure
~?
, 0
f.j
m~
I
~I
~
~~
temperature~
At outside
below -30C
we recommend preheating the coolant
(~.g. using an electric preheating device)
I."
If!.:
G54.3G-3771-31
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
~
CD on the engine.
Monitor the oil pressure gauge immediately after starting the engine.
11
Ii ~
S1034
It.l
;
iI
~
N54.30-8281-31
S1034
Flame-start system*
.....
N54.30-8279-31
CD
S1034
,
~j
tomatically, if:
III'~-: .
"I
f"'"
lID
I~
fi
II.~t:.~
Grid heater*
Oil pressure
lit
S1034
CD on the engine or
on the equipment-resident stopping facility.
Stop the engine immediately if you observe any of the following signs:
Start-Stop buttons
CD Stop button
CD Start button
CD
CD
power and speed drop while the position sensor (accelerator pedal position sensor) stays in the same
position
CD
CD
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.
..
5
........
S1034
Batteries
Have the batteries serviced and recharged
more frequently during the cold months of
the year.
5
.....
..
..
..
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.
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.
S1034
High-pressure cleaners
Environmental note
Collect used coolant, cleaning solutions and
detergents and dispose of them in accordancewith current local regulations and in an
environmentally-responsible manner.
.~
..
I::::~::::~,:ompo"e"ts
if
I.
hoses
.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
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
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).
Risk of poisoning
There is a risk of poisoningif coolant is swallowed.
..
Neverswallow coolant.
to approximately 50 DC.
~
system
engine,
5 more
cedure
~
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.
S1034
.&
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
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
flammable.
responsible manner.
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.
S1034
it.
For this reason, you must avoid fire, naked flames andsparks and refrain from
smokingwhen handling these service
products.
..
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.
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
.&.
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 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
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
The coolant water must satisfy certain requirements which are not always fulfilled
by drinking water.
..
..
II
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
....
Disposal
-37 DC
approximately
-45 DC
Water % by vol.
50
45
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
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:
..
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.
You could otherwise fail to recognise dangers and could injure yourself or others.
~"
II
All maintenance intervals and maintenance work refer to genuine MercedesBenz parts and accessories specifically
approved for the engine by
DaimlerChrysler.
i!
S1034
Additional work
--
S1034
signs of leakage.
Sealing points which are slightly damp are
harmless.
I ~emedy
.signifi~antle~ks
more
involvling constant ali loss Immediately.
leaks
correct mounting
Risk of burns
Risk of injury
There is a danger of limbs being caught, entrapped, crushed or torn off by rotating engine parts. Therefore you should:
..
..
..
S1034
.. a
~~
j
,ill
It~~
'U'
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
S1034
and tighten it
Tightening torque: 25 Nm.
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
......
CD Cap
o Sealing ring
(}) Oil filter element
~ Replace the sealing ring on cap
~
[I
0.
S1034
Draining:
~
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
G18.00-3114-31
1>1>
S1034
I~:.'~.,: ~~~i:~:~":;~::uu,~";~:d~~~:~"~i:~eed
I
i
6
......
Stop the engine. Check the oil level after approximately 5 minutes. Top up oil
to the maximum mark on the dipstick if
necessary.
S1034
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
Exhaust valve
0.60 mm
G01.00-3128-31
inlet valve
..
exhaust valve
flywheel end
Only turn the engine over using the rotation device provided for this purpose.
S1034
Removing:
~ Remove engine breather hose
@ from
0.
Fitting:
~
Clean the cylinder head and the cylinder head cover sealing surfaces.
CD
G01.20-3100-31
CD Charge-air manifold
@ Sealing washer
Cover seal
@ Engine breather hose
S1034
OM 904/924 LA
Crankshaft position
liE
liE
liE
liE
I - inlet valve
E - exhaust valve
S1034
CD to adjust the
valve clearance. Adjust the valve clearance by turning adjustment screw CD.
~ Slacken counternut
readjust if necessary.
CD Adjustment screw
CD Counternut
Concluding work
~
S1034
,,--,~-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.
~ Clean cap
replace if necessary.
~
S1034
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.
~
N07.0Q-Z096-31
CD Hand pump
CD Filter housing
1>1>
S1034
>
Close the drain valve and fill the prefilter using the fuel hand pump. Then
close the vent screw.
Leave the engine running for approximately 1 minute. The fuel system
bleeds automatically.
~
S1034
&
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
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.
and the
~ Clean cap
~
Leave the engine running for approximately 1 minute. The fuel system
bleeds automatically.
S1034
S1034
Risk of injury
I! ~Place
CII
Special tools
Check the poly-V-belt for damage in sections; rotate the engine and poly-V-belt a
little at a time
6
..-
S1034
N13.20-2075-31
S1034
Damage patterns
CD Condition
@
@
@
@
-6
S1034
Lay the poly-V-belt (new) on all belt pulleys, except for the tensioning pulley
(see illustrations for poly-V-belt routing).
Remove the spanner and check for correct seating of the poly-V-belt on the
belt pulley.
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
....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
S1034
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
S1034
CD Throttle
@ Retainer
valve lever
(3) Retainer
S1034
/
1
,
:.~.'
:1
S1034
6
.-
..
Risk of poisoning
Thereis a risk of poisoning if coolant is swallowed.
..
..
..
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.
... 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
Il>- Carry out a visual inspection of the radiator for leaks and undamaged condition.
S1034
Special tool:
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
6
-
II
cap.
~
1>1>
S1034
~!i1 " 1
~
J!\l
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.
..
..
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.
..
..
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
"'~
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).
S1034
Adding coolant
Environmental note
Dispose of used coolant in accordance with
prevailing local regulations
(I> see page 64).
I.~r
S1034
S1034
quence.
.&
S1034
General troubleshooting
Malfunction
Cause
Solution
~ Refuel
~ Seal
S1034
Malfunction
Cause
Solution
Leakages or pressure too low in the lowpressure fuel circuit or fuel delivery pump
drive defective
S1034
Malfunction
Cause
Solution
S1034
Malfunction
Cause
Solution
S1034
Malfunction
Cause
Solution
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)
Replace sensor
Poly-V-belt damaged
Thermostat malfunction
S1034
Malfunction
Cause
Solution
pulley if necessary
Poly-V-belt torn
workshop
Engine emits black smoke
7
......
Injector defective
S1034
Malfunction
Cause
Solution
Locate damaged cylinder using pressure loss test; consult a qualified specialist workshop
Engine "knocks"
Combustion malfunction
Damage to bearings
Abnormal noises
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
Risk of burning
ity of batteries.
eyes or clothing.
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
Combustion principle
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
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
Anti-clockwise
Type of starting
Electric
8.5 I
12.51
min. 13 I; max. 16 I
min. 24 I; max. 29 I
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24 V
Output
4.0 kW
24 V
max. 450 A
max. -20 DC
Alternator
Voltage
28 V
Current rating
80 A
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~ 0.5 bar
at rated speed
~ 2.5 bar
Valve clearance
Inlet valve
0.4 mm
Exhaust valve
0.6 mm
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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
25
support
50
Fuel/injection system
Injection line to unitpurnppressure pipe connection
35
40
25
50
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
40
25
25
25
25
Valve adjustment
Counternut on rocker arm set screw
25
Cooling circuit
Coolant line with thermostat valve to coolant pump
25
25
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.
Flame-start system
This is a cold-start aid for the engine. It
can be used to preheat the charge air
using fuel combustion.
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.
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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
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)
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Adaptation module
31
Adjusting the valve clearance . . 73, 75
ADM
31
Alternator. . . . . . . . . . . . . . . . . . . . . 111
Antifreeze/corrosion inhibitor . . . . . 64
Battery
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
29
68
55
69
47
52
89
88
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
24
70
22
7
28
80
40
27, 51
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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
32, 50
112
113
33
24
7,32,38
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
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Contact
Editorial office
Mercedes-Benz Contact
Telephone: 00800 1 777 7777
International: +49 69 95 30 72 77
Internet
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Mercedes-Benz
OM 904/907/924 LA
OM 906/909/926 LA/RLA
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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
Motor
Seite
Katalog
21 - 82
06T
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
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.
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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
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.
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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
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
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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.
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
06T
85 - 161
06V
909.900,901,910,911,920,921,960,970,971
06V
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
eje trasero,
0 cabina. En caso de
de la direcci6n (vease ficha de datos).
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
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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
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
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.
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
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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
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
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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).
aclireita) eo mirnero
da Ilustracao.
4. Quantidacle clesejacla.
A entrega cle pecas compete exclusivamente ao service de atenclimento aos clientes da Mercedes-Benz AG.
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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946,947-953,955,959,961,964
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21 - 82
06T
06T
85 - 161
06V
909.900,901,910,911,920,921,960,970,971
06V
06T
06V
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15
S1035
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16
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S1035
Aufladung
Turbocharger
Turbochargeur
Sovrailmentaz',one
ISobreailmenta
SObreailmenta~fo
HaAQYB
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235
295
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110
Aufladung
Turbocharger
1urbOChargeUr
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S1035
ISObreahment:~~o
Sobreahrnent
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Group
Grou
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00172
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312
152
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94
136
J~205
290
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310
102
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111
S1035
Aufladung
Turbocharger
Turbochargeur
Sovralimentazione
I Sobreahmentacao
Sobreahrnentaclon
HaMYS
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252
240
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253
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114
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112
242'0
0Q330
108
335
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Luflpresser
Air Compressor
Compressor de ar
gompresseur d'air Compresor de arre
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803.QYWHbli:i
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70~
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80
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15
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45
20
113
S1035
Gruppe
Group
Groupe
Gruppo
Luftpresser
Compressor de ar
Air Compressor
Compresor de aire
Compresseur d'air B03AYWHblH HOMnpeccop
Compressore aria '\~~.Ji ,h..i.L.;.
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. 13 075
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10
184
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@195
114
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255~
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Luflpresser
Air Compressor
Compresseur d'air
Compressore aria
ICompresor
Compressor de ar
de aire
Gruppe
Group
Groupe
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B03AYWHblH HOMnpeccop
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S1035
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110
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165
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115
S1035
Luflpresser
Compressor de ar
Air Compressor
Compresor de aire
Compresseur d'air B03AYWHblH HOMnpeccop
Compressore aria .\ Ji.k-<.L..:,.
Gruppe
Group
Groupe
Gruppo
Grupo
~;~~~a .13075
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00144
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75~
182
~187
116
S1035
Luftpresser
Compressor de ar
Air Compressor
Compresor de atre
Compresseur d'air B03AYWHbll1 HOMnpeccop
Compressore ana ,I,r)i ~L.;"
Gruppe
I Grupo
g;~~~e %~~~a
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0 0 1 56
235
168
117
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Group
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55
40
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Grupo
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ti~.-d\
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45
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80
25
118
00202
S1035
Gruppe
Group
Groupe
Gruppo
Grupo
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. 14015
00207
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80
t[]J
65~1
52
30
75
119
AuspuffkrOmmer
Exhaust Manifold
Collecteur d'echappernent
Collettore scarico
Colector de escape
Colector de escape
aoneno BblnyCHHOro TPy6onpoBoAa
~i ~,Ui
60
S1035
Grupo
~;~~~a
. 14 030
W:~I
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55
120
Gruppe
Group
Groupe
Gruppo
00233
S1035
Gruppe
Group
Groupe
Gruppo
AuspuffkrUmmer
, Colector de escape
Exhaust Manifold
Colector de escape
Collecteur d'echappernent HoneHOBbtnycHHoro TPy60npoBot\a
Collettore scarico
'---"-':J.i ,Ui
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14 030
00249
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25
60
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121
AuspuffkrUmmer
Exhaust Manifold
Collecteur d'echappernent
Collettore scarico
IColector
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S1035
Gruppe
Group
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122
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S1035
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200
235
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123
S1035
Eleklrische Ausrlistung , Equipamento electrico
Electrical Equipment
Equipo electrlco
Equipement electrique aneurpoooopvnoaauae
Impianto eletlrico
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124
1 5 0 10
490
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496
508
568
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562
544
532
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550
Elektrische Ausriistung
Electrical Equipment
Equipement electrique
Impianto elettrico
S1035
Gruppe
Group
Groupe
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Equipo electrico
3J1eHTpoo6oPY.QosaH",e
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125
Elektrische AusrUslung
Eiectrical Equipment
Equipement electrique
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Equipamento electrico
Equipo electrlco
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517
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B16
85
616
610 ~604
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190
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310
412
126
510
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B16
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360
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115
100
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516
517
S1035
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280
418
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Elektrische Ausriistunq
Electrical Equipment
Equipement electrique
Impianto elettrico
S1035
Equipamento eleclrico
Equipo electrlco
sneurpoooopvnoaaaae
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Gruppe
Group
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127
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Elektrische A
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Electri
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electrlq
Equipo elect. electnco
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200
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175
125
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260
235
131
Elektrische A -,
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Electrical
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132
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S1035
00258
Gruppe
Group
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144
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140
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S1035
15 045
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70
146
145
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157
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148
154
52
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133
Elektrische AusrUstung
Electrical Equipment
Equipement electnque
lrnpranto elettnco
S1035
IEquipo
Equipamento electrico
electnco
Gruppe
Group
Groupe
Gruppo
anesrrpootiopvnoeauae
~~~-;-Qi d~i
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185
160
50
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70
134
Grupo
Grupo
rpynna
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15 045
00171
Elektnsche AusrUstung
Electncal Equipment
Equrpernent electnque
lrnpianto elettnco
Gruppe
Group
Groupe
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Equipo electnco
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50
190
175
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135
Elektrische AusrUstung
Electrical Equipment
Equipement electrlque
Impianto eJettrico
S1035
Gruppe
Grupe
Group
Grupe
rpynna
Groupe
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Equipamento electrico
Equipo electrico
aneHTpoo6oPY,QosaHHe
:c...,,;~~....,.sJi d~i
25
136
15 045
00190
Elektrische Ausnlstunq
Electrical Equipment
Equipement electrlque
Impianto elettrico
Equipamento electrlco
Equipo electrico
anearpootiopvnoaauae
:i....,,-:~~-oSJi d~i
Gruppe
Group
Groupe
Gruppo
Grupo
Grupo
rpynna
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S1035
15 150 00002
137
Molorschmierung
Engine Lubrication
Graissage du moteur
Lubrificazione molore
Lubrificacao do molor
Lubricaci6n del motor
Gruppe
Group
Groupe
Gruppo
CMa3Ka I1BHraTenA
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138
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S1035
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18 0 15
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Mot,?rsctu~~T~~~n
Engine
d moteur
Graissag~ Ue motore
Lubrificazlon
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18 045
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139
Motorschmierung
Engine Lubrication
Graissage du moteur
Lubrificazione motore
S1035
Gruppe
Group
Groupe
Gruppo
Lubrificacao do motor
Lubricaci6n del motor
CM83Ha ABHr8TenR
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132
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100
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125
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110
105
140
Grupo
00283
S1035
Motorschmierung
Engine Lubrication
Graissage du moteur
Lubrificazione motore
I Lubricaci6n
Lubrificacao do motor
del motor
Gruppe
Group
Groupe
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CMB3Ha ABl1raTllR
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u_~i
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125
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20
125
10
141
Motorschmierung
Engine Lubrication
Graissage du moteur
Lubrificazione motore
I Lubrificacao
do motor
Lubricaci6n del motor
Gruppe
Group
Groupe
Gruppo
CMa3Ha ABHraTeJ1R
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S1035
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27
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102 @
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135
142
00144
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Motorkilhlung
S stem
Engine .Coohn~t au moteur
RefrOldlssem~tomotore
Raffreddame
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Refngera9~.o
del motor
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Group
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160
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200
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143
Motorklihlung
Engine Cooling System
Refroidissemenl du moleur
Raffreddamento molore
IRefrigerac;ao
do molor
Refrigeraci6n del molor
Gruppe
Group
Groupe
Gruppo
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430
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365
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300
310
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315
350
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144
325
S1035
I Grupe
Grupo
rpynna
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20 0 15
00327
MotorkOhlung
Engine Cooling System
Refroidissement du moteur
Raffreddamento motore
S1035
Refriqeracao do motor
Refrigeraci6n del motor
oxnaltlgeHl1e gBl1raTenA
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Group
Groupe
Gruppo
Grupo
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00387
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24
145
Molorkuhlullg
Engine Cooling System
Refroldlssement du moleur
Raffreddamenlo molore
S1035
IRefrigeraci6n
Refriqeracao do molor
del molar
Gruppe
Group
Groupe
Gruppo
oxnaH<l1eHHe I1BHraTenA
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115
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Molorkiihlung
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Engine Cooling System
Refrigeraci6n del motor
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Raffreddamenlo molore
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Group
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20
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55
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15
10
147
MotorkGhlung
Engine Cooling System
RefrOidissement du moteur
Raffreddamento motore
148
IRefrigeraci6n
Refriqeracao do motor
del motor
oxnalH/leHl1e /lBl1raTenA
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Group
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149
Motoraufhangung
Engine Suspension
Suspension du moteur
Sospensicne del motore
Suspensao do motor
Suspension del motor
nonaecxa ASHraTeJ1R
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Group
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S1035
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Special Ver~orungen
Versions
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23 015
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305
290
Q[J
285
325
i~ 3; ~~ ~ ~~.,Jij) ~@.,Jij)
395
400
~
405 410 415 420
""'"
~~
365
~ Q)~~~ ~~ ~~~80J85
430
(i)
" 425
~ ~o
\d
335 340
15
157
Kaltekompressor
Refrigerant Compressor
Compresseur pour installation d'air
conditlonne
Compressore impianto refrigeratore
70
4125
45
(:)
158
.L.;.~\
.:r-=.:...
"i U"L,5
Gruppe
Group
Groupe
Gruppo
Grupo
%~~~a, 23 075
I w.~\
S1035
00007
Gruppe
Group
Groupe
Gruppo
Grupo
.......
I*~~a
, 23 100
S1035
00001
~~\
159
SonderausfDhrungen
Special Versions
Versions speciales
Version! special!
IVers6es
especiais
Ejecuciones especiales
Gruppe
Group
Groupe
Gruppo
cneuaansaaa KOMnneHTaL111R
:i.-.Ui
",-,Ij~','i
-,i djly-l-Ji
l-.
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I~
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32
8
160
I Grupo
Grupo
rpynna .
;w:.~I
S1035
23 980
00003
SonderausfUhrungen
Special Versions
Versions speciales
Versioni speciali
S1035
IVers6es
especiais
Ejecuciones especiales
Gruppe
Group
Groupe
Gruppo
cneuaansaaa HOMnneHTal.\HR
~Lll Q\jL;..;'/I)i djl.rlJi
Grupo
~;~~~a
, 23 980
;;....~I
00004
50
.r">;
47 c8)J ~
<,
CO
53 ----
~<. rI. -.
r
.;.\
I'~
\~LJ
UP
56
41
~v
~
17
161
ENGINE FILTERS
13807
Page 1 of 1
ITEM PART #
DESCRIPTION
QTY.
146001
146018
146040
146022
146000
146017
146101
1
1
1
Updated:
09/18/07
RADIATOR INSTALLATION
ITEM PART #
13661
Page 1 of 1
DESCRIPTION
QTY.
465216
605726
A/R
20611-03
12326-06
12922-04
Updated:
11/19/07
13660
Page 1 of 2
Updated:
09/27/07
13660
Page 2 of 2
ITEM PART #
DESCRIPTION
QTY.
465216
12567-05
SILICONE HOSE 4
12964-01
605663
N/A
N/A
595320
12964-03
12567-05
SILICONE HOSE 4
10
146043
11
146042
12
146105
13
146044
Updated:
09/27/07
13713
Page 1 of 1
ITEM PART #
DESCRIPTION
QTY.
604686
AIR CLEANER
604691
604921
604692
RUBBER REDUCER (5 4)
12350-09
ELBOW WELDMENT
605693
HUMP HOSE (2 )
6498-43
ELBOW (2 )
8*
604464
INDICATOR 20
Updated:
06/17/08
AIR CLEANER
ITEM PART #
11637
Page 1 of 1
DESCRIPTION
QTY.
604686
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
Updated:
11/06/07
EXHAUST SYSTEM
13676
Page 1 of 1
ITEM PART #
DESCRIPTION
QTY.
12964-07
12964-08
604922
EXHAUST ELBOW
594995
EXHAUST PURIFIER
594372
EXHAUST SILENCER
15951-01
EXHAUST DISSFUSER
7*
19188-11
8*
605537
A/R
Updated:
11/19/07
S1020
S1020
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
N/A
23033
PIPE PLUG
244390
4-5
N/A
24913
TUBE SLEEVE
24337
TUBE SLEEVE
24594
244457
10
24473
11
24474
12
24474
13
24473
14
244457
15
24594
16
24240
BREATHER
17
244160
STREET ELBOW
18
244157
19
24337
TUBE SLEEVE
20
24435
21
244195
22
24435
23
244196
24
24473
25
24474
26
24952
27
244057
4
4
4
1
Updated:
10/28/08
TRANSMISSION ASSEMBLY
465563
17193
Page 3 of 38
28
24933
29
04GE06
30
24191
31
24474
32
24473
33
24592
TUBE CLIP
34
24921
35
24684
36
24474
37
24473
38
24920
39
24474
40
24473
41
24592
TUBE CLIP
42
24922
43
24684
44
24924
45
24686
10
46
24435
47
24047
48
24338
57
244384
58
244387
A/R
59
244388
60
244389
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.
244741
24601
2
3
24692
N/A
24337
24598
24337
244391
24693
10
ZG-230921
RETAINING WASHER
11
244232
12
244391
RIVET
13
244256
OIL BAFFLE
14
244257
OIL BAFFLE
15
244391
RIVET
16-24
N/A
25
24566
26
24467
27
24467
28
24467
29
24339
30
24689
30A
24689
31
24689
32
24244
SCREEN ASSEMBLY
33
24203
34
24690
PLUG
35-55
N/A
Updated:
10/28/08
TRANSMISSION ASSEMBLY
465563
ITEM PART #
17193
Page 6 of 38
DESCRIPTION
QTY.
244726
REAR COVER
24046
24686
21
24435
23
24389
24654
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.
24670
24680
24936
244728
TURBINE SHAFT
244365
24306
24219
244364
PISTON RING
N/A
10
24911
OIL BAFFLE
11
24022
12
24929
13
244128
14
24910
15
24576
16
244265
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
244281
REACTION MEMBER
24577
244280
244279
244278
IMPELLER HUB
244557
244745
IMPELLER
10
244275
11
12
244274
12
13
24559
TURBINE
14
244185
15
24054
16
244187
IMPELLER COVER
17
04GE06
24
18
24673
24
19
ZZ240234
20
244664
21
244570
BEARING WASHER
22
244569
23
244731
24
24476
25
N/A
Updated:
10/28/08
TRANSMISSION ASSEMBLY
465563
ITEM PART #
DESCRIPTION
17193
Page 11 of 38
QTY.
464914
NSS
244062
244393
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.
244321
LOCKWASHER
N/A
24947
CAPSCREW
465563-01
465563-02
24909
BEARING BALL
465563-03
SNAP RING
ZG-224009
SNAP RING
465563-04
10
465563-05
11
465563-06
12
465563-07
13
244321
LOCKWASHER
14
24947
CAPSCREW
15
465563-08
16
244321
LOCKWASHER
17
N/A
18
24947
CAPSCREW
19
465563-01
20
465563-02
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.
465563-09
24612
465563-10
465563-11
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
244190
244572
WASHER
244573
244006
244190
24291
244652
N/A
10
24568
11
244574
12
24058
13
244546
14
244691
15
24526
16
24529
17
244692
18
244693
19
244692
20
24529
21
24526
22
244694
23
244546
24
24058
25
24583
26
24568
27
24610
SPRING RETAINER
28
24609
29
24607
SPRING RETAINER
Updated:
10/28/08
TRANSMISSION ASSEMBLY
465563
17193
Page 17 of 38
30
24962
31
24298
32
24293
33
244652
34
35
24610
SPRING RETAINER
36
24609
37
24607
SPRING RETAINER
38
24962
39
24298
40
24611
41
24579
42
N/A
43
24613
44
24579
45
24614
46
244559
47
24581
48
244695
49
24612
3RD GEAR
50
244266
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
244190
244572
WASHER
244573
244006
24290
244190
24291
244652
10
N/A
11
244652
12
24293
13
24298
14
15
24962
16
24607
SPRING RETAINER
17
24609
18
24610
SPRING RETAINER
19
N/A
20
24298
21
244580
22
244224
23
24298
24
24962
25
24607
SPRING RETAINER
26
24609
27
24610
SPRING RETAINER
28
24568
29
244574
1
Updated:
10/28/08
TRANSMISSION ASSEMBLY
465563
17193
Page 20 of 38
30
24058
31
244546
32
244691
33
24526
34
24529
35
244692
36
244696
37
244692
38
24529
39
24526
40
244694
41
24058
42
244546
43
24583
44
24568
45
244266
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.
24915
N/A
244703
244704
244732
244701
244702
244699
24219
10
244698
SPRING RETAINING
11
244697
SPRING - WAVE
12
244119
13
24568
14
24583
END PLATE
15
24057
16
24058
17
244694
18
24526
19
24529
20
244692
21
244394
22
244705
23
244706
24
244709
25
244707
26
244708
27
244601
28
24667
29
244523
Updated:
10/28/08
TRANSMISSION ASSEMBLY
465563
17193
Page 23 of 38
30
244715
31
244710
A/R
31A
244711
A/R
31B
244712
A/R
31C
244713
A/R
32
244716
33
244453
34
244714
35
04GE06
36
24673
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.
244190
24575
24100
465563-12
N/A
N/A
24997
24697
24627
10
244596
11
24628
12
SEE ITEM # 21
13-16
17
244536
18
244597
19
244597
20
244536
21
465563-13
22
244734
23
N/A
24
244735
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.
244562
24636
24632
A/R
3A
24633
A/R
3B
24634
A/R
3C
24635
A/R
24699
244600
244601
244602
244603
OUTPUT SHAFT
244601
10
24667
11
24953
12
24698
13
244536
14
24675
15
244562
16
244536
17
24674
18-26
N/A
27
244605
28
244606
Updated:
10/28/08
TRANSMISSION ASSEMBLY
465563
17193
Page 28 of 38
ITEM PART #
DESCRIPTION
QTY.
1
2
3
4
5
6
7
8
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
N/A
244111
24950
24467
24951
244079
244078
24435
10
24464
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.
244076
24689
2
3
244091
244092
24534
24533
24490
244070
244286
10
244286
11
24570
VALVE STOP
12
24080
13
244736
VALVE PISTON
14
24572
15
244109
16
24982
17
244093
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.
465563-14
244192
244287
244080
465563-15
FILTER ADAPTER
465563-16
244075
FILTER HOUSING
244074
244165
10
244071
11
244072
12
244073
13
24043
14
24462
15
24462
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.
244641
244639
1
6
244638
244640
244154
N/A
N/A
N/A
N/A
10
N/A
11
N/A
12
N/A
13
N/A
14
N/A
15
244628
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.
244628
244405
2
3
244171
CARTRIDGE O-RING
244630
CARTRIDGE O-RING
244631
CARTRIDGE O-RING
NSS
N/A
NSS
N/A
10
NSS
11
N/A
12
244637
13
244167
13A
244159
14
N/A
15
N/A
16
N/A
17
N/A
18
N/A
19
N/A
20
N/A
21
N/A
4
4
1
Updated:
10/28/08
TRANSMISSION MOUNTS
13436
Page 1 of 1
ITEM PART #
DESCRIPTION
QTY.
13256-02
13256-01
17GC12072
BOLT
32290
RUBBER MOUNT
17503-01
WASHER
59GD12
NUT
02GE12
WASHER
17GC12030
BOLT
Updated:
12/11/06
S1005
Specifications
Model 32000 Series Transmission
S1005
S1005
/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
Fig. A
Converter Group
Fig. B
Fig. C
Fig. D
Fig. E
Fig. F
Fig. G
Fig. H
Fig. I
Fig J
DISASSEMBLY OF TRANSMISSION
REASSEMBLY OF TRANSMiSSiON
38
56
57
LUBRiCATION
57
58
60-61
62-63
65
66
67
68-69
R-MODEL SECTION
70
80
8 SPEED SECTION
92
98
ELECTRIC CONTROLS
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:
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
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
ITEM
DESCRIPTION
OTY.
ITEM
DESCRIPTION
OTY.
30
31
32
Impeller
33
34
Impeller Hub
35
36
37
38
Reaction Member
10
39
11
40
Turbine Hub
12
41
Turbine
13
42
14
43
15
44
16
45
Impeller Cover
17
46
18
Turbine Shaft
47
19
Stator Support
48
Bearing Washer
20
49
21
50
22
Piston Ring
51
23
52
24
53
Plain Washer. . . . . . . . . . . . . . . . . . . . .. 16
25
54
26
55
27
56
28
Oil Baffle
29
57
58
24
S1005
3~
(
I
MHR OPTION
73
Figure C
S1005
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
49
50
45
46
47
48
10
10
51
Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
52
10
11
12
13
14
15
16
Street Ell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
17
18
Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3
19
Pipe Plug.................................... 1
20
21
22
23
53
54
55
56
57
58
Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
59
60
61
62
63
64
65
66
67
13
13
68
69
70
71
72
73
24
25
26
27
28
29
30
31
76
77
32
33
Tube Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
78
34
79
35
36
80
37
.
.
74
75
38
81
39
82
40
41
83
84
42
85
Hose Fitting
Hose Assembly
.
.
43
44
86
Hose Fitting
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
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
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
DESCRIPTION
QTY
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.
S1005
Figure F
PRESSURE
REGULATOR SlOE
34
S1005
ITEM
DESCRIPTION
QTV.
ITEM
DESCRIPTION
QTV.
26
27
28
29
Wave Spring. . . . . . . . . . . . . . . . . . . . ..
30
Pipe Plug
31
.
32
.
33
.
34
10
.
35
11
.
36
12
Valve Stop
.
37
13
.
38
14
.
39
Filter Adaptor
15
Valve Stop
40
16
.
41
17
Valve Piston
.
42
18
.
43
19
1
44
20
4
45
21
.
46
22
.
47
23
48
Filter Housing
24
.
49
Pipe Plug
25
.
50
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
FigureG
40_
41 __ ~
u--ll
F1G:{J
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
ITEM
DESCRIPTION
QTY.
ITEM
DESCRIPTION
QTY.
Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . .
22
23
24
25
Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . .
26
Detent Spring
27
Detent Spring
28
Detent Ball. . . . . . . . . . . . . . . . . . . . . ..
29
Neutral Switch . . . . . . . . . . . . . . . . . . ..
30
Glyd Ring . . . . . . . . . . . . . . . . . . . . . . . .
10
Detent Ball . . . . . . . . . . . . . . . . . . . . . . .
31
Piston...........................
11
32
Piston Housing
12
33
Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . .
13
34
Band Seal
14
35
"0" Ring. . . . . . . . . . . . . . . . . . . . . . . . .
15
16
44
Adaptor Screw . . . . . . . . . . . . . . . . . . ..
17
Detent Spring. . . . . . . . . . . . . . . . . . . . .
45
18
46
Valve Adaptor
19
47
48
Adaptor Screw . . . . . . . . . . . . . . . . . . ..
49
50
20
21
.
1
.
1
S1005
AXLE DISCONNECT
Figure H
S1005
AXLE DISCONNECT
ITEM
DESCRIPTION
QTV
ITEM
"
DESCRIPTION
QTV
Detent Ball
10
Detent Spring
11
Shift Rail
12
13
14
Bearing
15
Disconnect Housing
Shift Hub
Shift Fork
Disconnect Shaft
ITEM
DESCRIPTION
QTV
Lock Nut
Washer
Operating Lever
Backing Plate
Cam Shaft
Strut Assembly
Return Spring
o'
ITEM
DESCRIPTION
QTV
Brake Flange
10
Brake Drum
11
12
13
Brake Lining
14
Rivet Kit
15
16
.
24
S1005
View"Q"
1.
spacer
HOUSln9th
used WI 12 plate
modulation only.
Figure I
S1005
&
&.
&,
&
!J::,
&
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.
&
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
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]
COARSE THREAD
LB-FT
[NM]
82 57 -- 37 23 12 8-
THREAD SIZE
90
63
41
25
16
10
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
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
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
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.
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
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.
-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.
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.
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
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.
Figure 69
-12-
S1005
Figure 70
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.
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
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.
-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
-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.
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.
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.
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.
Figure 113
Figure 115
-20-
S1005
Figure 119
Remove clutch piston.
Figure 116
Compress piston return spring. Remove spring retainer ring.
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.
Figure 126
Figure 124
Figure 127
Remove inner and outer clutch discs.
-22-
S1005
Figure 131
Figure 128
Compress piston return spring. Remove return spring retainer
ring.
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
-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.
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.
Figure 159
Position end plate lock ball in clutch shaft.
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.
-29-
S1005
Figure 170
Remove clutch gear and outer bearing.
Figure 173
Figure 171
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
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
Figure 178
Figure 181
Remove inner and outer clutch discs.
-31-
S1005
Figure 185
Figure 182
Compress piston return spring. Remove return spring retainer
ring.
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.
-33-
S1005
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.
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.
Figure 211
-36-
S1005
Figure 215
Use a sleeve puller like the one shown.
Figure 212
Remove clutch front bearing locating ring.
Figure 216
Sleeve being removed.
Figure 213
Remove oil sealing ring sleeve retainer screw.
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.
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
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.
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
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
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.
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).
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
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.
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.
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
TORQUE IN (LBS.-FT.)
BOLTS, CAPSCREWS, STUDS AND NUTS
Grade 5 Identification, 3 Radial
0
Dashes 120 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]
CONTROLS
OIL FILTRATION
CLUTCH PRESSURE
CLUTCH TYPE
Friction.
Steel.
LUBRICATION
RECOMMENDED LUBRICANTS FOR TORQUE CONVERTERS AND POWERSHIFT TRANSMISSIONS
TYPE OFOIL
(a)
CAPACITY
(b)
(c)
(d)
(e)
CHECK PERIOD
NORMAL
DRAIN PERIOD
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.
.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
S1005
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
Remedy
Fill to proper level.
2. Clean valve spool and housing.
3. Replace pump.
4. Replace sealing rings.
5. Clean bleed valves thoroughly.
1.
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.
NOISY CONVERTER
1. Replace.
2. Replace.
3. A complete disassembly will be necessary to determine what bearing is faulty.
LACK OF POWER
1. Tune engine check governor.
2. Make corrections as explained in "Overheating."
-58-
S1005
FIG.A
I
III
\\
.063 - .064
-4\--[1.600 - 1.626]
MODULATED FWD.
& REV. CLUTCHES
FIG.S
FIG.C
\\
.048 - .049
-4\---[1.219 - 1.245]
LOW (1st)
CLUTCH
FIG.D
(4 SPEED ONLY)
4TH
-59-
S1005
<, ....
BACKING RING
~--
---~
ENGINE FLYWHEEL
SEE PAGE 61
FOR INSTALLATION
PROCEDURE AND
BOLT TORQUE
"'l
",..,~'--\~~
--,.j
BACKING RING
243767
TORQUE CONVERTER
RING GEAR 249341
-60-
S1005
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.
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
1
16
1
1
249341
236288
243767
802555
243767 Backing Ring not included in 802553 Ring Gear Kit. Must be Ordered Separately
-61-
S1005
FORWARD
-- - -
1ST (LOW)
---2ND
- - 3RD
-62-
S1005
REVERSE
1ST (LOW)
_ _ _ _ _ _ 2ND
_ -
_ -
-3RD
-63-
S1005
-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"
-65-
S1005
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.
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.
-66-
S1005
-67-
S1005
BACKING RING
TORQUE CONVERTER
RING GEAR
ENGINE FLYWHEEL
_ l_- _ ,
S- __ --.J
SEE PAGE 69
FOR INSTALLATION
PROCEDURE AND
BOLT TORQUE
BACKING RING
236937
TORQUE CONVERTER RING GEAR 249265
S1005
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.
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
1
32
1
32
249265
244903
802550
1
1
249265
240318
802550
1
32
1
32
249265
237153
802550
249265
236938
802550
1
32
1
249265
4200097
802550
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.
-69-
S1005
R-MODEL SECTION
-70-
S1005
ITEM
DESCRIPTION
OTY
ITEM
DESCRIPTION
OTY
23
Input Shaft
24
25
26
Input Flange
27
Tube Sleeve
28
Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
29
Detent Spring
30
Detent Spring
31
10
Pipe Plug
32
11
33
12
"0" Ring
34
13
35
Detent Ball
14
Tube Clip
36
Detent Ball
15
37
Pipe Plug
16
38
17
39
18
Breather
40
19
41
20
42
21
43
22
Sleeve Lockscrew . . . . . . . . . . . . . . . . . . . . . . .. 2
Flange Nut
-71-
1
.
1
4
.. 1
S1005
R32000
ASSEMBLY INSTRUCTION
-72-
ILLUST~ATION
S1005
~ onMustbearing.
be loose internal fit bearings. No. "3" etched
~ (12
Plate Modulation) Two clutches,12-outer steel
plates,12-inner friction plates.Assemble alternately.
&
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.
in brackets [ ].
View"Q"
2 Places
ELASTIC STOP NUT TORQUE
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
Grade 5
ED
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
135.5]
94.91
61.01
39.31
27.11
14.9)
90
63
41
25
16
10
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
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
DRIVE GEAR
-J------'---INPUT SHAFT
Figure 8
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.
Figure 7
Figure 10
-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
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
BEARING SHIELD
MUST FACEIN
BEARING SHIELD
MUST FACE OUT
REAR
BEARING SHIELD
-77-
S1005
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-
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
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-
S1005
-80-
S1005
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
S1005
View"Q"
Housing spacer
used with 12 plate
modulation only.
6 SPEED TRANSMISSION
NON-MODULATED
-82-
S1005
&.
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.
&
ill
&
ill
&.
bushing to cover.
~i'W'S'
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
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-
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.
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:
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-
RANGE SHIFT
S1005
KEY
4TH
- _ 5TH
6TH
-tB~~~~~3-
-89-
RANGE SHIFT
S1005
LOW RANGE
1ST (LOW)
- - - - - 2ND
3RD
4TH (HI)
~~.~~~~~)$.
~
- ......LOW
...... RANGE
-90-
S1005
HIGH RANGE
1ST (LOW)
- - - - - - 2ND
3RD
4TH (HI)
-91-
S1005
ITEM DESCRIPTION
QTY
ITEM DESCRIPTION
Ql
10
Spring Retainer
11
12
13
14
15
16
17
1
..
-92-
8 SPEED SECTION
S1005
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.
Figure 2
Remove fourth speed clutch assembly from transmission
housing
Figure 5
Remove end plate retainer.
-93-
S1005
Figure 6
Figure 9
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.
S1005
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.
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.
(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.
-97-
S1005
ALIGNMENT HOLES
(1) DRIVE PLATE AND
(4) INTERMEDIATE
DRIVE PLATES
BACKING RING
Backing Ring.
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
1.
2.
3.
4.
5.
FLYWHEEL
HOUSING
ENGINE
FLYWHEEL
PILOT BORE
FLYWHEEL
FIG 1
6.
7.
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-
FIG 2
FIG 4
S1005
'I
REVER
4th
3rd
1st
SUPPLY
2nd
[gJ
"'"
It 1
OFF-HIGHWAY COMPONENTS
o
o
..-
-'
<$>
'i
't 1
IT]
OFF-HIGHWAYCOMPONENTS
[Q]
It
4th
3rd
1st
SUPPLY
2nd
S1005
'I
F
[OJ
4th
3rd
1st
SUPPLY
2nd
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
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!:~'-
'*
('i
A>.J
-- .
Q"
II
o1)~
"-
[OJ
II
[OJ
II
s:
R
OFF-HIGHWAYCOMPONENTS
<$>
S1005
0
"'"
.....
....I
8:
I;
't
'1
OFF-HIGHWAYCOMPONENTS
[OJ
S1005
S1005
NOTES
-106-
.....
0
"'-J
PlJIIP
...
""
"
Torque
converter
"
total neutral
solenoid
-=-
Hose
-----
@
3rd
clutch
:::I
2nd
clutch
1st
solenoid
~ 'C
.@
TBIIPUATURB
GAUGH
2nd
solenoid
baT
.@
.. 'u
PRESSURE
GAUGB
OPERATOR COMPARTMENT
OFF-HIGHWAY COMPONENTS
=14,504 PSI)
onSUIIP
<$>
( 1 bar
repIator
valve
16,5 - 20,7 bar
Pressure
Safetyva1e
11,6 - 13,8 bar
cl'Il:kq pressure
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
14'--01
Safety valve
9,6 - 13,8 bar
cracking pressure
'
_. __ __
U--I_J
'0
~
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
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.
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
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
S1005
Safety valve
9,6 - 13,8 bar
cracking pressure
1+-'11
II
Torque
converter
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
<$>
S1005
I@
Hose
/:I
fnrward
clutch
L~
O
baT
TI!IlIPI!RATURK
CBI!CK-PORT
PRI!S5URI!
CHI!CK-PORT
'C
reverse
clutch
REVERSJ!
SOLI!ROID
LubricatJon
t!
Cooler
~
1st
clutch
o
,....
,....
......
......
......
I
Torque
converter
2nd
clutch
J
~
:I
1
liar
liar
Hose
'C
.@
TI!MPI!RATURI!
GAUGI!
.... .J
3rd
clutch
bar
.@
PRI!SSURI!
GAUGE
OPERATOR COMPARTMENT
OFF-HIGHWAYCOMPONENTS
=14,504 PSI)
OIL SUMP
'V'
II
valve
Ill,! - 20,7 bar.
regulator
Pressure
' 1+-'1
( 1 bar
Safety valve
9,ll - 13,8 bar
cl'III:killg pressure
Cooler
~!
1st
clutch
liar
~@
fOlWlIrd
clutch
FORWARD
SOLI!.OID
Hose
I@
~
'C
liar
L ulIic:ation
reverse
clutch
TI!IIPI!RATURI!
CBI!CK-PORT
PRI!SSURI!
CBI!CK-PORT
S1005
S1005
Safety valve
9,6 -1:3,8 bar
cracking pressure
Ihl
II
3rd
clutch
I=I
lIu
2nd
solenoid
converter
Torque
Pressure
regulator
PUMP
valve
16,5 - 20,7 bar
By-pass
valve
1.7 - 4.:3 bar
OIL SUMP
I=I
:t!
Cooler
FORWARD
SOLDOID
I@
bu
I=I
J!
fOlWard
clutch
Hose
I=I
TIlIIPI!RATURIl
CIJBCK-PORT
~'=~RT
hT
'C
LUBRICATION
lIaT
reverse
clutch
,1@
RIlTIlRSl!
SOLBJrOm
bu
THIIPHRATURH
GAUGH
OPERATOR COMPARTMENT
PRBSSURH
GAUGH
lIu
J@
'C
clutch
1st
,1@
.... .J.@
Hose
1st
solenoid
~
2nd
clutch
OFF-HIGHWAY COMPONENTS
C\l
.....
.....
.....
.....
(.,)
By-pass
Pressure
re&U1ator
VCI1ve
1"""1
II
<$>
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
valve
( 1 bar
crackq pressure
Safety valve
9,6 - 13,8 bar
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
S1005
Safety valve
9,6 - 13,8 bar
cracking pressure
1'-'1
II
@
clutch
lrd
2nd
solenoid
Torque
converter
Pressure
regulator
valve
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
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
Safety valve
Cooler
forward
clutch
~:I
L@
t!
Hose
.J
reverse
clutch
I]
RETERSE
SOLB.OlD
'C
lIu
O
O
LUBRICATION
TEMPERATURE
CHECK-PORT
PRESSURE
CHECK-PORT
S1005
Safety valve
9,6 - 13,8 bar
cracking pressure
, I+--'I
FILTn
,II
-;-
'
I
Torque
converter
Pressure
regulator
valve
,"
;.(..>-
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
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 bar
<$>
S1005
.....
......
......
..
total neutral
solenoid
Torque
converter
II
.-=.,
4th
clutch
liar
3rd
solenoid
lIa.
J@
PRI!SSURI!
GAUGI!
Hose
3rd
clutch
:I
liar
2nd
solenoid
1st
clutch
Hose
liar
-(,.~
TORWARD
SOLI!lIOID
liar
Lubrication
:I
:I
forward
clutch
:I
TI!MPI!RATURI!
CHI!CK-PORT
~) CHI!CK-PORT
liar
(X'" PRI!SSURI!
If J! J
lIa.
1st
solenoid
2nd
clutch
Cooler
Total neutral
J@
TI!MPI!RATURI!
GAUGI!
OPERATOR COMPARTMENT
OFF-HIGHWAY COMPONENTS
=14,504 PSI)
PUMP
...
----,
TILTI!R :
1-1.
II
II
:A--
OIL SUMP
<3>
( 1 bar
Pressure
regulator
valve
16,5 - 20,7 bar
hl
Safety valve
9,6 - 13,8 bar
cracking pressure
liar
clutch
reverse
:I
lr
RI!VI!RSI!
SOLI!. OlD
S1005
S1005
II
!t
crackiD& pressure
Safety VlI1vll
!1,6 - 13,1 bar
' 1+-'1
Pressure
replatDr
VlI1vll
16,5 - 20,7 bar
OIL SUMP
=14,504 PSI)
1
Hose
'C
:I
liar
1f
3rd
clutch
2nd
solenoid
I@
TEMPERATURE
GAUGE
OPERATOR COMPARTMENT
PRI!SSURJ!
GAUGH
liar
I@
::I
1
liar
3rd
solenoid
4th
clutch
OFF-HIGHWAY COMPONENTS
Torque
convener
( 1 bar
<$>
'C
IS
::a:
Hose
'C
liar
Ox
O
Luhrleatkm
FORWARD
SOLE. OlD
liar
:I
forward
clutch
J! J1
1st
clutch
liar
:I
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
.....
'nI1ve
reauJator
Pressure
Cl'lKkh1I pressure
!I,lS - 13,8bar
Safety'nI1ve
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
Jtn1lRSB
dutch
rev.....
~~
SOLDOID
S1005
S1005
,.....
Torque
converter
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
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
'
<$>
( 1 bar
Safety valve
9.6 -13.SbaJ:'
r rae king pl'essul'e
1.
solenoid
2nd
clutch
n.
Cooler
"C
n.
'C
1n
c1utcil
forward
clutcil
D,
0'\ MODULATIOR
I<:IVALVI!
Lubril:atlon
FORWARD
SOLD OlD
L Fl
PRESSURI!
CBBCK-PORT
TI!JIIIPI!RATURI!
0) CBBCK-PORT
lou
J! J!
1.
IiJse
J@
'a~T
reverse
clutch
JJ
RBVI!RSI!
SOLD om
S1005
S1005
.!.
C:OlM!rter
~ Torque
Safety valve
11,6 -13,8 bar
cracking pressure
Pressure
rqulator
....
PUMP
valve
16,5 - 20.7 bar
OIL SUMP
Hose
~
dutch
3rd
2nd
solenoid
Tl!llPIlllATURI!
GAUGH
OPERATOR COMPARTMENT
PRI!SSURI!
GAUGH
lIat
\at
3rd
solenoid
J@
4th
dutch
OFF-HIGHWAY COMPONENTS
Hose
\at
1st
1Ia~
'C
:=r-~~RT
U"fl!RSI!
SOLD om
dutch
rev81'S8
Tl!llPBRATURB
\V CBBCK-PORT
($):~~no.
FORWARD
SOLaom
\al'
J:;@
clutch
forward
1~
16
Lubrkatlon
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
=14,504 PSI)
OIL SUMP
By-pass
valve
1,7 - 4,3 bar
( 1 bar
Safety valve
l',6 -13,8 bar
cracking pressure
1st
2nd
clutch
\at
solenoid
J!
Cooler
<t!
1st
clutch
J=@
lIat
Hose
\:.
,@
'C
forward
clutch
lf
liar
Lmrkatlon
FORWARD
SOLIIIOID
PIlESSURII
CBIlCK-PORT
liar
r)(\
reverse
clutch
I
I
liar
I!
S1005
411I
clutch
t-:$.
solenoid
3rd
cOllVerter
Torque
=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
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
::I
clutch
1st
---=]
1@
Cooler
<t!
liar
i:I
I
L8
forwllrd
clutch
Hose
18
1(----
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
;'(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
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
<$>
PUIIP
....
~~'~-~L;~--;
clutch
4th
liar
converter
Torque
3rd
clutch
2nd
solenoid
Hose
2nd
clutch
Cooler
q:
!
1st
clutch
liar
liar
'"
1lar
forward
clutch
~8
Hose
'-.m
'C
liar
O
TRMPERATORR
CHRCK-PORT
PRRSSORR
CHECK-PORT
reverse
clutch
RR'iERSE
SOLI!IOID
LUBRICATION
J1 1
1st
solenoid
'C
,@
TEMPERATURE
GAUGE
.
""'"-,;
PRRSSORI!
GAUGE
OPERATOR COMPARTMENT
OFF-HIGHWAY COMPONENTS
OIL SUMP
1.7 - 4.3bar
valve
By-pass
Pressure
regulator
valve
16,5 - 20,7bar.
Safety valve
S1005
--
"
0.=.1
3rd
solenoid
liar
~
@
4th
clutch
TOI1lUB
amvel1er
II
Safety valve
96 -13,8bar
J-l.
=14,504 PSI)
OIL SUIIP
Pressure
regulator
valve
16,5 - 20,7 bar
~klDa pressure
( 1 bar
liar
PRBSSURII
OAUOH
Hose
11t
I@
liar
lIa,.
clutch
2nd
dutch
forward
clutch
'u
TllIIPI!RATURE
CHECK-PORT
t')('\ PR1!SSURl!
V CHECK-PORT
x
O
liar
reverse
dutch
RI!VERs]!
SOLEIIOID
LlJIRICATIIII
r. IIODULATIO.
I?IULVE
FOllWARD
S OLEII om
7a
..t fl
Hose
Cooler
1st
Jr 1@ JJ
solenoid
...,)-l
TBIIPIlRATURII
OAUOH
OPERATOR COMPARTMENT
solenoid
~
3rd
clutch
.~ OFF-HIGHWAY COMPONENTS
S1005
re
,....
4th
clutch
~
1
11&..
comlerter
Torque
Jrd
clutch
.@
1I&r
PRBSSURB
GAUGH
Hose
11&..
c...
:)
1st
clutch
2nd
clutch
11&..
'-c
forward
clutch
FORWARD
SOLDom
lIMe
.s
l
1II.r
7n
.l. Fl
Tl!MPl!RATURl!
CHl!CK-PORT
PRl!SSURl!
CHECK-PORT
reverse
clutch
I?-IVALVH
17\. MODULATIO.
Rl!Vl!RSl!
SOLE. 010
LUBRICATION
J! J!
.@
TEMPBRATURB
GAUGH
OPERATORCOMPARTMENT
OFF-HIGHWAYCOMPONENTS
=14,504 PSI)
<$>
( 1 bar
OIL SUMP
16,5 - 20,7......
valve
regulator
Pressure
craekhll pressure
Safety valve
9,6 -13,8 bar
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
END YOKE
364024
19201-29
362120
CENTER BEARING
464640
19200-14
DRIVELINE ASSEMBLY
10
364023
1
2
3
4
Updated:
10/30/08
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
10829
Page 1 of 1
Updated:
12/11/06
13320
Page 1 of 8
Updated:
10/30/08
13320
Page 2 of 8
Updated:
10/30/08
13320
Page 3 of 8
DESCRIPTION
QTY.
464891
AXLE ASSEMBLY
444285
444286
444262
1
1
2
444268
PIN
444829
DISC ASSEMBLY
444625
444830
12
444831
13
444235
14
15
444858
444832
444156
1
1
1
16
444835
17
444836
STUD
18
444157
19
444570
BOLT
20
444231
21
444060
22
444425
23
444151
24
444150
WASHER, THRUST
25
444152
SPACER
26
444159
GEAR, PLANETARY
27
444158
RETAINER
28
444160
WASHER, RETAINER
Updated:
10/30/08
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
36
444838
39
01GF02016
PIN, COTTER
40
442130
PIN, CLEVIS
41
444191
BOLT
11
42
444839
SHAFT
43
442480
BOLT
14
44
444751
SEAL
45
444752
46
444841
SEAL
47
444424
BOLT
48
444217
BLOCK, THRUST
49
444842
WASHER, LOCK
50
444269
BOLT
51
444843
SLEEVE
Updated:
10/30/08
13320
Page 5 of 8
Updated:
10/30/08
13320
Page 6 of 8
ITEM PART #
DESCRIPTION
QTY.
444712
444844
444272
223185
444845
444177
444008
444176
444274
CASE ASSEMBLY
10
442210
BOLT
12
11
444110
12
12
444250
BOLT
13
444275
14
444846
14B
444847
15
444848
16
444173
17
444172
PINION DIFF.
18
444715
19
444849
SPIDER DIFF.
20
442220
21
444850
22
444780
CONE BEARING
23
444147
24
444781
25
442270
Updated:
10/30/08
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
29
442290
30
444851
RETAINER ASSEMBLY
31
444852
SEAL ASSEMBLY
32
11827-01
FLANGE U-JOINT
33
442310
34
442320
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
47
444252
WASHER DIFF.
48
444092
RING, LOCK
49
444788
FORK DIFF.
50
444857
NUT JAM
51
444264
SCREW
Updated:
10/30/08
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
60
444125
444098
444126
444127
444108
444100
444109
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
S1021
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.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
S1021
TORQUE TRANSFER
S1021
2
Differential Lock Assembly
1.
2.
3.
4.
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.
10.
11.
12.
13.
14.
15.
16.
17.
18.
BRAKE OPERATION
S1021
Left Axle
Right Axle
Brake Overhaul
Planetary Overhaul
Pinion Assembly
4
Rear View of Housing Assembly Removal
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
1.
2.
3.
Actuating Discs
Actuating Link
Axle Housing
S1021
6
Axle Shaft Rolling Torque Measurement
7
Axle Shaft End Play Measurement
S1021
8
Planet Gear Carrier Assembly
1.
2.
3.
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
--
--
11
Installing Planetary Ring Gear
1.
2.
10
S1021
12
Axle Shaft Cone and Roller Assembly Removal
1.
2.
3.
4.
5.
6.
7.
13
Removing Outer Bearing Cup from Axle Housing
1.
2.
3.
11
S1021
14
Axle Shaft with Seal and Bearing Installed
1.
2.
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
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.
17
Removing Drive Pinion Rear Bearing
1.
2.
3.
4.
14
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.
19
Measuring Pinion Bearing Rolling Torque
1.
2.
15
Torque Wrench
1-3/4 Socket
S1021
20
Differential Assembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Retaining Ring
Washer
Spring
Adaptor
Retaining Bolt
Thrust Washer
Pinion Gear and Washer
Thrust Washer
DISASSEMBLY
16
S1021
21
Removing Differential Bearing
REASSEMBLY
Reassembly of the differential and differential lock
follows the disassembly procedure in reverse. On
reassembly, observe the following requirements:
17
1.
2.
3.
4.
S1021
2
1
22
Differential Bearing Preload Check
1.
2.
3.
18
S1021
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.
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
Spring Apply--Mico
20
S1021
50 -- 150 in-lb.
Thickness
C5NN-4374-AB
81803491
C5NN-4374-L
81803502
C5NN-4374-M
81803503
C5NN-4374-N
81803504
C5NN-4374-R
81803505
C5NN-4374-S
81803506
C5NN-4374-T
81803507
C5NN-4374-U
81803508
C5NN-4374-V
81803509
C5NN-4374-Y
81803510
C5NN-4374-Z
81803511
Differential bearing rolling torque using a spring pull gauge: 7--34kgf (15--75 lb).
Thickness
C5NN-4548-A
81803515
C5NN-4548-B
81803516
C5NN-4548-C
81803517
C5NN-4548-D
81803518
C5NN-4548-E
81803519
C5NN-4548-F
81803520
C5NN-4548-G
81803521
C5NN-4548-H
81803522
21
S1021
Thickness
D8NN-4662-FA
R, R, R
83914106
D8NN-4662-GA
R, R, B
83914107
D8NN-4662-HA
R, R, Y
83914108
D8NN-4662-JA
R, R, W
83914109
D8NN-4662-KA
B, B, B
83914110
D8NN-4662-LA
B, B, Y
83914111
D8NN-4662-MA
B, B, W
83914112
D8NN-4662-NA
Y, Y, R
83914113
D8NN-4662-PA
Y, Y, B
83914114
D8NN-4662-SA
Y, Y, Y
83914115
D8NN-4662-TA
W, W, R
83914116
D8NN-4662-UA
W, W, B
83914117
D8NN-4662-VA
W, W, Y
83914119
D8NN-4662-XA
W, W, W
83914120
TIGHTENING TORQUE
Components
ft-lb
Nm
140--170
190--230
300--350
407--475
85
115
68--92
92--125
24--30
32--41
80--95
108--129
80--95
108--129
100--125
135--170
200--600
271--813
27--37
37--50
22
S1021
SPECIAL TOOLS
Description
Tool No.
Ref. Section
FNH09507
E, D
FNH09567
E, D
FNH09526
E, D, G
FNH09506
FNH09521
OTC7366
FNH09212
Puller Tool
FNH09516
F, G, D
FNH09190
FNH02123
FNH09210
23
S1021
26
Axle Shaft Torque Tool
27
24
BRAKE ACTUATOR
ITEM PART #
13321
Page 1 of 2
DESCRIPTION
QTY.
595248
ACTUATOR ASSEMBLY
534372
NSS
O-RING PLUG
NSS
O-RING
534377
BLEEDER PLUG
534387
BLEEDER SCREW
NSS
HOUSING
NSS
BACK-UP RING
NSS
O-RING
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
Updated:
12/11/06
S1023
S1023
13322
Page 1 of 1
ITEM PART #
DESCRIPTION
QTY.
15996
284002
LOCK RING
284003
SIDE RING
484085
TIRE
5*
442480
BOLT
14
6*
56405
Updated:
01/22/07
S1007
S1007
S1007
S1007
S1007
S1007
S1007
S1007
S1007
BRAKE SYSTEM
31547
13378
S1008
16483
S1009
12976
HYDRAULIC SCHEMATIC
BRAKE VALVE
BRAKE VALVE SERVICE
DUAL CHARGE VALVE
DUAL CHARGE VALVE SERVICE
ACCUMULATOR
13378
Page 1 of 4
Updated:
12/11/06
13378
Page 2 of 4
Updated:
12/11/06
13378
Page 3 of 4
DESCRIPTION
QTY.
464952
534288
595149
595145
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
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
Updated:
12/11/06
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
Filter, Strainer
Pressure Switch
Hydraulic
Fixed Displacement
Pressure Indicator
Variable Displacement
Temperature Indicator
Cylinder, Single-Acting
Component Enclosure
Lines Joining
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
Adjustable Cushion
Advance Only
Spring
Differential Piston
Manual
Push Button
Miscellaneous Units
Reservoir
Vented
Methods of Operation
Push-Pull Lever
Electric Motor
Pedal or Treadle
Pressurized
Accumulator,
Spring Loaded
Mechanical
Line, To Reservoir
Accumulator,
Gas Charged
Detent
Heater
Pressure Compensated
Vented Manifold
CH12_1069-1114.indd 1093
1093
4/9/07 2:34:47 PM
HYDRAULIC SYMBOLS
Methods of Operation
Solenoid, Single Winding
Servo Control
S1077
Valves
Check
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
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
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
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
174112
NSS
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
15
NSS
SEAL
16
NSS
SEAL
17
NSS
18
174036
19
174044
RING, RETAINING
20
174046
21
174035
22
174045
BALL CHECK
23
174038
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
465411-05
NUT
465411-06
CAP SCREW
Updated:
12/11/06
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
534772-02
534772-03
534772-04
534772-05
SCREW
534772-06
NUT
534772-07
ROTARY SWITCH
534772-08
10
11
534772-09
534772-10
534772-11
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
10827
Page 1 of 1
ITEM PART #
DESCRIPTION
QTY.
492191
WHEEL, STEERING
171002
COLUMN
173132
NUT, ORBITROL
173175
CAPSCREW
5*
494081
Updated:
12/11/06
ELECTRONIC THROTTLE
PEDAL
13655
Page 1 of 1
ITEM PART #
DESCRIPTION
QTY.
595395
Updated:
09/05/07
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
Litho in U.S.A.
S1012
002792
S1012
Turbocharger
Exhaust
Manifold
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.
2.
Regular cleaning of all areas where flammable materials such as fuel, oil, grease,
hydraulic fluid and combustible debris may
collect.
S1012
1.
Check all oil, hydraulic fluid and gas lines for cuts,
abrasions or undue wear. Replace as needed.
000620
2.
000621
3.
4.
000623
5.
000624
6.
000625
7.
000626
S1012
002777
2.
002778
3.
002779
4.
002780
S1012
002781
2.
002782
3.
002783
S1012
4.
002784
5.
002785
S1012
BLOW-0FF CAPS IN
PLACE (IF SUPPLIED)
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
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
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
CHECKFIRE MP Inspection
BRACKET
SECURELY
WELDED OR
BOLTED
SEALED
CARTRIDGE
INSTALLED
RING PIN IN
PLACE AND
SEALED
BRACKET
SECURELY
WELDED OR
BOLTED
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
1.
2.
3.
4.
5.
S1012
000627
S1012
Recharge
Inspection
Litho in U.S.A.
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.
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
SECTION
SEMI-ANNUAL
8-1 8-2
12-YEAR
8-2
IX. RECHARGE
9-1 9-2
2-1 2-2
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
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
3-4
3-4
3-4
PRESSURE SWITCH
NON-WEATHERPROOF
3-5
3-5
NOZZLE BRACKET
3-6
3-6
3-6
3-6
3-6
11-1 11-10
11-1 11-2
S1013
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.
S1013
FROM AUTOMATIC
DETECTION SYSTEM
1
2
1
TO OPTIONAL
PRESSURE SWITCH
4
5
7
FIGURE 1
002581
IN CASE OF FIRE
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.
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
APPLICATION METHOD
DETECTION
S1013
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.
A-101 MODEL 10
PART NO. 24855
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)
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
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)
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
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
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.
FIGURE 3
A
000417
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.
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
000149
LT-10
11 IN.
(28 cm)
5 1/2 IN.
(14 cm)
003470
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
PNEUMATIC ACTUATOR
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.
FIGURE 6a
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)
2 1/4 IN.
(5.7 cm)
5 IN.
(12.7 cm)
12 1/4 IN.
(31.1 cm)
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)
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)
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
REDUCING TEE
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.
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)
5 IN.
(12.7 cm)
FIGURE 13
1 7/8 IN.
(4.8 cm)
003459
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
6 IN.
(15.2 cm)
1 7/8 IN.
(4.8 cm)
3 5/8 IN.
(9.2 cm)
BRASS RESET
PLUNGER
MOISTURE
PROOF JOINT
GASKET NUT
O RING GASKET
NAMEPLATE
DOUBLE POLE HEAVY
DUTY TOGGLE SWITCH
WITH FULLY ENCLOSED
BAKELITE BASE
BRASS PISTON
2 1/4 IN.
(5.7 cm)
PISTON O
RING GASKET
TO
POWER
3/4 IN.
ELECTRICAL
CONDUIT OUTLETS
FIGURE 11
003462
2 7/8 IN.
(7.3 cm)
FIGURE 12
FIGURE 14
000437
000716
S1013
NOZZLES
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
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)
6 FT.
(1.83 m)
FIGURE 15
000453
1 13/16 IN.
(4.6 cm)
4 FT.
(1.22 m)
160
15 IN.
(38.1 cm)
003471
1 IN.
HEX
6 FT.
(1.83 m)
3/4 IN.
CONDUIT
OUTLET
1 13/16 IN.
(4.6 cm)
3 FT.
(0.9 m)
7 7/8 IN.
(20 cm)
003724
1 IN.
HEX
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
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).
2 IN.
(51 mm)
FIGURE 20
004793
5 IN.
(127 mm)
7/8 IN.
(2.2 cm)
1 3/32 IN.
(28 mm) HOLE
2 IN.
(51 mm)
1/4 IN.
(0.6 cm)
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 Series I:
Manual Part No. 54894
40 F to +140 F
(40 C to +60 C)
40 F to +140 F
(40 C to +60 C)
+32 F to +120 F
(0 C to +49 C)
S1013
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.
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
S1013
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
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
GASKET,
PART NO. 181
FIGURE 1
006195
S1013
S1013
SECTION IX RECHARGE
6-30-05
Page 9-1
REV. 3
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.
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
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
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 5
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
16430
16131
31581
24306
53003
24883
31344
24307
ACTUATION DEVICE
70584
71699
57484
71804
70581
57452
57661
70580
32747
32739
16033
16459
DISTRIBUTION TEES
53036
25031
Distribution Tee
53038
16424
Triple Tee
53040
4655
419695
Y Lateral
NOZZLES
57046
57044
53042
53791
56748
16449
415192
73870
73871
427149
427228
73872
53050
53051
57488
16408
31579
8372
46250
427425
S1013
SECTION XI APPENDIX
5-15-02
Page 11-2
REV. 2
24970
53000
24966
24894
SYSTEM CARTRIDGES
15850
423439
423441
423443
423429
423435
423491
29375
13193
423423
24427
13177
24425
423425
SYSTEM BRACKETS
24854
24971
14098
24910
24895
30494
31171
31177
24325
29193
16511
428363
75382
3923
197
15496
24327
53081
Owners Manual
S1014
006052
S1014
S1014
SECTION
PAGES
SECTION
SAFETY PRECAUTIONS
IN CASE OF FIRE
26
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
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
WARNING
CAUTION
CAUTION
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
CAUTION
S1014
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
4
6
5
002998
S1014
SYSTEM COMPONENTS
8-1-02
Page 3
REV. 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
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
S1014
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
INSULATED
SPRING STEEL
CONDUCTORS
FIGURE 6
000855
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
S1014
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
SWIVEL BRACKET,
PART NO. 432300
FIGURE 9
006829
RESPONDER
CONNECTION TO
CONTROL MODULE
FIGURE 8
000857
FIGURE 10
006830
S1014
SYSTEM COMPONENTS
6-30-05
Page 6
REV. 2
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.
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
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
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.
FIGURE 19
003015
1 5/8 IN.
(4.1 cm)
FIGURE 17
000899
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
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.
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
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
CAUTION
2
STRIKE
BUTTON
PULL RING
PIN
3.
!
WARNING
FIGURE 50
002773
S1014
RECHARGE
6-30-05
Page 27
REV. 2
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
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
DAILY INSPECTIONS
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
CAUTION
DETECTION
CIRCUIT
WIRING
CAUTION
FIGURE 52
002770
S1014
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.
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
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
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
LED Code
_________
Trouble
_______
Soft Reset
Indicates that the external power input voltage has dropped below a Normal threshold
level and is in need of servicing.
Detection TD1
Detection TD2
Manual TD
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
Manual Fault
Squib Fault
Squib Release
Unknown
All Clear
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
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
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
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
Yellow
Power
Fault
_____
Red
Alarm
_____
Yellow
Detection
Fault
________
Yellow
Release
Fault
_______
off
pulsing
once every
10 seconds
off
off
off
pulsing
normal
once every
10 seconds
normal
transferred off
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
________
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)
423538
10
(4.5)
427308
54919
426461
426520
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
1/4
1/4
1/4
1/4
1/4
(.1)
(.1)
(.1)
(.1)
(.1)
416762
1/4
(.1)
1/4
(.1)
416214
416215
416784
416113
416216
416378
417055
(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
Shipping
Assembly
Nylon Cable Tie (Package of 20)
Rubber Sleeve (Package of 20)
Weight
lb.
(kg)
1
(.5)
2
(.9)
422747
(.5)
419780
(.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
Rating
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
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
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
17183
Page 1 of 2
Updated:
08/26/08
ITEM PART #
17183
Page 2 of 2
DESCRIPTION
QTY.
334145
NSS
MOUNTING BRACKET
NSS
MANUAL/AUTOMATIC ACTUATOR
334133
SQUIB
NSS
CONTROL MODULE
334146
MODULE BATTERY
334122
CARTRIDGE
334011
DETECTION WIRE
464870
334145-01
10*
334010
RUBBER SLEEVE
A/R
Updated:
08/26/08
16721
Page 1 of 4
Updated:
10/10/07
16721
Page 2 of 4
DESCRIPTION
QTY.
1
334005
324014
NSS
NSS
BOLT
NSS
WASHER
NSS
NUT, LOCK
NSS
BUMPER PAD
NSS
PAD, BASE
NSS
BAND, CLAMP
NSS
10
334118
11
NSS
GASKET
12
NSS
QUAD RING
13
NSS
TAG, INSTRUCTION
14
334117
ADAPTER
15
334057
16
NSS
17
NSS
BURSTING DISC
18
NSS
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
A/R
24
NSS
A/R
25
334119
26
NSS
334124
334125
1
6
2
Updated:
10/10/07
16721
Page 3 of 4
27
NSS
NUT, LOCK
28
NSS
ARM, CLAMP
29
NSS
30
334123
31
NSS
CARTRIDGE
32
NSS
CAP, SHIPPING
33
334126
VALVE, CHECK
34
332042
35
NSS
36
NSS
37
NSS
O-RING
38
NSS
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
47
NSS
CARTRIDGE
48
NSS
CAP, SHIPPING
49
332044
50
NSS
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
16721
Page 4 of 4
58
NSS
SEAL, LEAD-WIRE
59
NSS
SCREW, DRIVE
60
NSS
CHAIN
61
NSS
RING PIN
62
334003
A/R
Updated:
10/10/07
S1081
Ersatzteilkatalog
Spare parts list
Catalogue de pieces
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
R0
R1
R2
R3
R4
SR..
X
STZS
STZY
OS
OE
OM
OB
OFB
OSE
OFS
OSK
OSK(M)
SBM
SHB
SES
>........
........>
(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
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
Pipes-Lube system
Pipes-Control F,H
Pipes-Control F,H
010.0600 Pipes-Control RC
010.0700 Extension box-R1
Pipes-Control RC
Extension box-R1
Brazo de extensin-R1
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
Extension box-R2X
Brazo de extensin-R2X
Extension box-R3X
Brazo de extensin-R3X
Extension cylinder-R2X,R3X
Cilindro de extens.-R2X,R3X
010.1300 Pipes-R2X,R3X
Pipes-R2X,R3X
Entubado-R2X,R3X
Stabilizer ram-STZS
Cilindro de apoyo-STZS
Pipes-Support STZS
Pipes-Support STZS
Stabilizer ram-STZY
Cilindro de estab.-STZY
Pipes-Support STZY
Pipes-Support STZY
Oil tank,cpl.(70l)
Depsito,cpl.(70l)
Oil tank,cpl.(140l)
Depsito,cpl.(140l)
Oil tank,cpl.(200l)
Depsito,cpl.(200l)
CONTROL
Control valve-Support
Control valve-Details
Vlvula de control
Control valve-F
Vlvula de control-F
Control valve-F,H
Vlvula de control-F,H
Control valve-Details
Vlvula de control
Control valve-Details
Vlvula de control
Control valve-Details RC
Detalles de distribuidor RC
Control valve-Details RC
Detalles de distribuidor RC
Control valve-RC001
Vlvula de control-RC001
020.1100 Control
Control
OVERLOAD PROTECTION
PROTECCIN SOBRECARGA
Overload protection-OSK-F
Proteccin de sobr.-OSK-F
Overload protection-OSK-H
Proteccin de sobr.-OSK-H
Overload protection-OSK-RC
Proteccin de sobr.-OSK-RC
Limit. of rotation
Lmite de rotacin
osicion de tran
Support control
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
Crane column
Columna
Lifting cylinder
Cilindro elevacin
Pipes-Lifting cylinder
Top seat
Asiento alto
MAIN BOOM
BRAZO PRINCIPAL
OUTER bOOM
BRAZO ACODADO
Outer boom
Brazo acodado
BOMM EXTENSIONS
BRAZOS DE EMPUJE
Boom extension I
Brazo de empuje I
Boom extension II
Brazo de empuje II
Boom extension IV
Brazo de empuje IV
Boom Extension V
Brazo de empuje V
Pipes-Boom extens.ram
Pipes-Boom extens.ram
Pipes-Boom extens.ram
Hose guide
Gua de manguera
Pipes-Hose guide
EXTENSIONS
EXTENSIONS
Prolongas
Prolongas
ROPE WINCH
TORNO DE CABLE
Rope winch-S
Torno de cable-S
Pipes-Rope winch S
Entubado-Torno de cable S
Rope winch-SES
Torno de cable-SES
DIVERSES
Diversos
100.0100 Diverses
Diverses
Diversos
100.0200 Shields
Shields
Placa
040
050
060
CRANE COLUME
MAIN BOOM
OUTER bOOM
070
080
BOMM EXTENSIONS
090
100
ROPE WINCH
DIVERSES
S1081
Tafel
Figure
Planche
Table of contents
Index
ENCLOSURE
ENCLOSURE
VASE APNDICE
A1
Cover
Cover
Capa
A2
Abbreviation
Abbreviation
Abreviatura
A3
Preface
Preface
Prefacio Prologo
A4
Spareparts order
Spareparts order
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
M 10 DIN 934
RC400
M 8 DIN 985
RC
M 8x12 DIN 912
PALTRONIC
D 20,5x1,5x115
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.
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
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
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
D 62 mm
8 mm
M 8x20 DIN 7984
M 6 DIN 985
D 12 DIN 471
D 47 mm
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
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
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
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
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
M 12 DIN 985
M 12x35 DIN 933
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
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
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
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
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
M5
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
Vlvula de sobrepr.
sin anticavitacin
... bar
EV 049
EO 025
ED 055
EO 026
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
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
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
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
020.1000
09/2004
PK 7501,9501
Control valve-RC001
Control valve-RC001
Distribuidor-RC001
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
D 4 DIN 6799
M 6 DIN 985
D 6,4 DIN 134
M 6x35 DIN 6912
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
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.
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
HH 454
HH 455
10
EK 901
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
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
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
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)
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
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
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
030.0500
01/2004
PK 7501,9501
Base
Base
Base
S1081
S1081
PALFINGER
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
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
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
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
NW 10x4200
NW 10x4050
D 12
D 12
Vsti R 1/8"-Ed
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
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)
M 16x25 DIN7984
75x70x15
050.0200
03/2001
PK 9501
PK 7501,9501
Base
Base
Base
S1081
S1081
PALFINGER
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)
M 16x25 DIN7984
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
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
060.0100
05/2002
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
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
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
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
070.0100
11/2000
PK 7501,9501
PK 7501 (>0621435)
PK 9501 (>0621728)
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
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
070.0200
11/2000
PK 7501,9501
PK 7501 (>0621435)
PK 9501 (>0621728)
Base
Base
Base
S1081
PK 7501 (0621436>)
PK 9501 (0621729>)
PK 7501 (>0621435)
PK 9501 (>0621728)
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
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
070.0300
11/2000
PK 7501,9501
PK 7501 (>0621435)
PK 9501 (>0621728)
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
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
Description
zu Tafel
to figure
a' planche
070.0300
Denominacin de repuestos
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
070.0400
09/1999
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
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
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
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
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
8,0 t
070.0600
11/2000
PK 7501,9501
Base
Base
Base
S1081
S1081
PALFINGER
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
(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
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
Abmessung
Dimension
Dimension
070.0700
11/2004
Base
Base
Base
PK 7501,9501
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
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
D 16
D 12
D 12
070.0800
11/2004
Base
Base
Base
PK 7501,9501
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
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
D 16
D 12
D 12
070.0900
11/2004
Base
Base
Base
PK 7501,9501
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
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
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
D 10 DIN 125
M 10x20 DIN 912
D 5x50 DIN 94
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
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)
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
S1092
S1092
S1092
S1094
S1094
S1094
S1094
S1094