020-001 Manual Exc 2-500L

MANUAL INDEX
2-500L ANFO CHARGER

KOL (ARAMINE)
S/N 020-001
6/1/2010
1. INTRODUCTION /GENERAL INFORMATION
F1008 PARTS ORDER INSTRUCTIONS

F1000 GETMAN WARRANTY
F1009 COMPONENT LIST
M1040 A-64 OPERATION MANUAL
M1006 ANFO CHARGER OPERATION MANUAL
M1004 BOOM INSPECTION
S1000 BOLTS TORQUE & SIZE SAE
F1003 LUBRICANTS CROSS REFERENCE
F1001 STORAGE PROCEDURES
F1002 TROUBLESHOOTING CHECK LIST
F1004 PREVENTIVE MAINTENANCE SCHEDULE FORMS
F1005 SERVICE REPORT FORM
F1006 SHIFT CHANGE CHECK LIST
2. CHASSIS
10368 SIGHT GAUGE

10376 FILL CAP (FUEL OIL)
10398 FILL CAP (HYDRAULIC OIL)
10448 HOLD DOWN FASTENERS
13524 SEAT ASSEMBLY (DRIVER)
13936 SEAT ASSEMBLY (PASSENGER)
13942 STEERING (PINS, BEARINGS, BUSHINGS)
12043 ARTICULATION INSTALLATION
3. ELECTRICAL SYSTEM AND INSTRUMENTS
30343 WIRING DIAGRAM

17143 INSTRUMENT PANEL
13747 ENGINE FUNCTION DISPLAY
S1100 MURPHY POWERVIEW OPERATION MANUAL
13663 ALTERNATOR
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
4. ENGINE AND ACCESSORIES
F1007 DETROIT DIESEL WARRANTY

S1034 ENGINE OPERATION MANUAL
S1078 ENGINE MAINTENANCE MANUAL
S1035 ENGINE PARTS MANUAL
13807 ENGINE FILTERS
13661 RADIATOR INSTALLATION
13660 CHARGE AIR INSTALLATION
13713 AIR INTAKE SYSTEM
11637 AIR CLEANER
13676 EXHAUST SYSTEM
17309 EXHAUST INSULATION INSTALLATION
S1020 EXHAUST INFORMATION
5. DRIVE TRAIN
17193 TRANSMISSION
13436 TRANSMISSION MOUNTS
17331 TRANSMISSION DIPSTICK
S1005 TRANSMISSION MAINTENANCE & SERVICE MANUAL
13675 DRIVELINE INSTALLATION
6. AXLE
10829 AXLE ORIENTATION

13335 AXLE ASSEMBLY
13332 CRADLE INSTALLATION
S1037 AXLE SERVICE & REPAIR MANUAL
13158 BRAKE ACTUATOR
S1023 BRAKE ACTUATOR INSTALLATION
13938 TIRE & RIM
S1007 TIRE SERVICE
7. BRAKE SYSTEM
13378 BRAKE VALVE

S1008 BRAKE VALVE SERVICE
16483 DUAL CHARGE VALVE
S1009 DUAL CHARGE VALVE SERVICE
12976 ACCUMULATOR
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
8. HYDRAULIC SYSTEM
310-020-001 HYDRAULIC SCHEMATIC

S1077 HYDRAULIC SYMBOLS
17132 SERVICEJUNIOR DIGITAL PRESSURE GAUGE
13259 FILTER (HYDRAULIC)
12860 STEERING ORBITROL
S1024 STEERING ORBITROL SERVICE
16384 BOOM ROTATION MOTOR
S1010 PUMP SERVICE
17172 REMOTE CONTORL BOOM VALVE (IN BASKET)
12508 BOOM CONTROL VALVE (ON BOOM)
13282 JACK CONTROL VALVE
13970 BOOM LEVELING CYLINDER
13629 BOOM LIFT CYLINDER
13827 BOOM EXTENSION CYLINDER (LOWER)
13828 BOOM EXTENSION CYLINDER (UPPER)
13628 BASKET LEVELING CYLINDER
13627 STABILIZER CYLINDER
13943 STEERING CYLINDER
9. CONTROLS
13905 ELECTRIC SHIFTER

10827 STEERING WHEEL & COLUMN
13655 THROTTLE (ELECTRONIC)
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
10. MOUNTED EQUIPMENT
S1011 FIRE EXTINGUISHER #10

S1012 FIRE PROTECTION INFORMATION MANUAL
S1013 FIRE SUPPRESSION MAINTENANCE MANUAL
7334-00015 FIRE SUPPRESSION INSTALLATION – MAIN
7334-00025 FIRE SUPPRESSION INSTALLATION –
BASKET/PLATFORM
7334-00024 FIRE SUPPRESSION INSTALLATION – AIR
COMPRESSOR
17344 FIRE SUPPRESSION SYSTEMS
13597 BASKET DOOR INSTALLATION
S1026 DOOR SPRING PIVOT ADJUSTMENT
17069 BOOM INSTALLATION
16572 TURRET TABLE INSTALLATION
16256 ROTATION GEAR BOX
M1005 ROTATION GEAR REMOVAL & INSTALLATION
15174 ANFO PIPING SCHEMATIC (WITH AIR BOOST CLEAN
OUT)
15175 ANFO PIPING SCHEMATIC (POT)
17194 ANFO POT
13712 ANFO ACTUATOR
S1027 ACTUATOR SERVICE MANUAL
S1101 EXTERNAL PNEUMATIC VIBRATOR
14053 BASKET ROTATOR
S1033 ROTARY ACTUATOR MAINTENANCE MANUAL
13651 STABILIZER INSTALLATION
17070 125 CFM COMPRESSOR
S1028 COMPRESSOR OPERATION MANUAL
17165 AUTO LUBE SYSTEM INSTALLATION
S1094 LINCOLN AUTO LUBE MANUAL
17341 CHASSIS LUBE ELECTRONIC GREASE PUMP
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
1. INTRODUCTION /GENERAL INFORMATION
F1008 PARTS ORDER INSTRUCTIONS

F1000 GETMAN WARRANTY
F1009 COMPONENT LIST
M1040 A-64 OPERATION MANUAL
M1006 ANFO CHARGER OPERATION MANUAL
M1004 BOOM INSPECTION
S1000 BOLTS TORQUE & SIZE SAE
F1003 LUBRICANTS CROSS REFERENCE
F1001 STORAGE PROCEDURES
F1002 TROUBLESHOOTING CHECK LIST
F1004 PREVENTIVE MAINTENANCE SCHEDULE FORMS
F1005 SERVICE REPORT FORM
F1006 SHIFT CHANGE CHECK LIST
INSTRUCTIONS FOR ORDERING F1008
REPAIR PARTS Page 1 of 1
TO AVOID DELAYS AND ASSURE THE MOST EFFICIENT HANDLING, PLEASE

SPECIFY THE FOLLOWING ON ALL ORDERS.
• MODEL TYPE AND FACTORY SERIAL NUMBER OF YOUR MACHINE.
• NAME, MODEL NUMBER, AND SERIAL NUMBER OF THE ASSEMBLY (SUCH

AS A TRANSMISSION) FOR WHICH THE PART REQUIRED.
• PART NUMBER (REFER TO THE CORRECT REPAIR PART NUMBER).
• GIVE COMPLETE PART DESCRIPTION.
• EXACT QUANTITY OF PART REQUIRED. (DO NOT ORDER BY SET UNLESS

SET IS SPECIFICALLY CALLED OUT IN PARTS MANUAL. IN THOSE
INSTANCES, SPECIFY ONE (1) SET OF ___________ MATCHES PIECES.)
• SHIPPING INSTRUCTIONS (INCLUDE ROUTING WHEN POSSIBLE).
• BILLING INSTRUCTIONS.
PLEASE PLACE ALL ORDERS WITH YOUR LOCAL GETMAN DISTRIBUTOR OR

CALL 1-800-533-1110 OR 269-427-5611 ext. 305 or 330.
BANGOR, MICHIGAN U.S.A
MODEL SERIAL NO.

2-500L ANFO CHARGER 020-001
Updated:
04/16/10
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 Getman’s 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 Getman’s
judgment, as to affect the product adversely;
3. Any vehicle or component which has, in Getman’s 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 GETMAN’S
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
BUYER’S 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
COMPONENT LIST
Page 1 of 1
Model: 2-500L ANFO CHARGER Serial No.: 020-001
Customer: ARAMINE (KOL)

COMPONENT MANUFACTURER MODEL SPECIFICATION SERIAL NUMBER
ENGINE DETROIT DIESEL OM904LA 465399 904-971-00-799339
EXHAUST
(PURIFIER) ECS A20 594995 B123377
EXHAUST
(SILENCER ECS A42 594372 B122790
TRANSMISSION DANA 32000 465563 2145010
FRONT AXLE NEW HOLLAND D-45I 464872 86578601 9K22
REAR AXLE NEW HOLLAND D-45I 464872 86578601 9K22
MAIN HYD PUMP COMMERCIAL P-31 494169 N0309-4040
MAIN HYD PUMP AM-DYN P-30 494054 N/A
CANOPY GETMAN N/A N/A 0309-G-00196
(ROPS/FOPS)
OPTIONS:
ROTATION GEAR GEAR PRODUCTS 010-00008-1 594869 554302-002
BOX
ROTATION GEAR EATON N/A 534214 101-1083-009
B0X MOTOR
MAN BASKET GETMAN N/A 12275-01 N/A
COMPRESSOR VIPER 125CFM 465139 30-76628
ANFO POT (D.S) BAYCAR 1060LBS 465562 D-136-51-3240-01
ANFO POT (P.S) BAYCAR 1060LBS 465562 D-136-10-2663-01
BASKET ROTATOR HELAC HP15 594634 N/A
ROTATION GEAR PRODUCTS 449 594868 552852-002
BEARING
SAFETY VALVE DEPATIE FLUID V120 605582 C10 K4285
(ANFOR TREE D.S)
SAFETY VALVE DEPATIE FLUID V120 605582 C10 K4284
(ANFO TREE P.S)
SAFETY VALVE DEPATIE FLUID V150 605586 V10 DD9 19667
(AIR TANK)
SAFETY VALVE DEPATIE FLUID V175 605640 J659
(COMPRESSOR)
†COMMON MAINTENANCE ITEMS
AIR FILTER ELEMENT (PRIMARY) P/N: 604711
AIR FILTER ELEMENT (SECONDARY) P/N: 604709
ENGINE OIL FILTER P/N: 146000
FUEL FILTER P/N: 146001
FUEL WATER SEPERATOR P/N: 146022
TRANSMISIÓN FILTER P/N: 24069
HYDRAULIC FILTER ELEMENT P/N: 534691
FAN/ALT BELT P/N: 9041-10013
*WHEN ORDERING PARTS, ALWAYS GIVE MODEL AND SERIAL NUMBER OF UNIT. Updated:
†SEE MAINTENANCE SECTION IN MANUAL FOR SERVICE INTERVAL ON THESE ITEMS 06/15/10
OPERATING AND MAINTENANCE M1040
MANUAL FOR MODEL A-64 CHASSIS Page 1 of 33
GETMAN CORPORATION
OPERATING AND MAINTENANCE

MANUAL
FOR
MODEL A-64 CHASSIS
EQUIPPED WITH
465313-100-OV DASH PANEL
MERCEDES or CUMMINS ENGINE
Read thoroughly before operating vehicle
TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS. Updated:
02/26/10
TABLE OF CONTENTS PAGE INTRODUCTION
Introduction 2
Related Manuals 2 This manual is a guide to proper, safe operation, maintenance,
General Description 3 and minor adjustment of the Getman A-64 Chassis. Each
General Safety Precautions 3-5 operator assigned to this vehicle should study this manual
Safety Alert Symbol 3 carefully before starting or operating the vehicle in order to
Rules 4 become familiar with all the controls and procedures.
Parking Procedure 5
Service Positions 5 Getman A-64 Chassis are purchased with the expectation that
Fuel Shut Off 5 it will provide long and faithful service. In its construction,
Canopy 5 we have taken every precaution to see that you receive an
Name, Warning, and Caution Plates 6 efficient, long-lived, satisfactory vehicle. However, to realize
Caution Statement 7-8 the full measure of value and utility that Getman has designed
Electrical System Safety 8 into this unit, a small amount of time and expense must be
Safety w/ Fuel, Oils, & invested in the performance of regular inspections and service
Coolant 8 as recommended in this manual. The small investment will
Instrument Panel Descriptions 9-10 pay off in low operating costs, minimal service expenses, and
Instrument Warning Panel 11 most importantly in personal safety.
Electronic Engine Data Display 12-13
Gauge Descriptions 14-15 RELATED MANUALS
Other Controls 15
Checks Before Startup 16 Engine operation manual is included with the Parts and
Starting Procedure 17 Service Manuals supplied with this vehicle. You should
Park Brake Test Procedure 18 become familiar with these manuals.
Service Brake Test 18
After Engine Starts 19 NOTE: For Cummins engine parts and service manuals not
Operating Vehicle 20 supplied, please see Section 4 of your truck Parts & Service
Towing Procedures 21-22 Manual for instructions.
Preparing a Vehicle 21
Transmission 21 Getman has increased the frequency of many recommended
Brake Release 22 maintenance procedures due to the vehicles demanding
Maintenance Schedule – As Required 23 application. These changes are noted at each maintenance
Maintenance Schedule – Daily 24-25 section end.
Maintenance Schedule – 50 Hours 26-27
ECS Catalytic Air Purifier or A complete parts listing of engine train components,
Diesel Particulate Filter 27 applicable Electric/Air/Hydraulic systems, and mounted
Maintenance Schedule – 250 Hours 28-29 equipment is included in the Parts and Service Manual. This
Maintenance Schedule – 500 Hours 30 manual also contains service and repair information useful to
Maintenance Schedule – 1000 Hours 31 maintenance department personnel.
Specifications 32
Fuel 32 If you have any questions about operating or servicing this
Tires 32 unit, contact your local Getman dealer or Getman Corporation
Pressures 32 direct, immediately.
Fluid Capacity Quick Reference Guide 33
02/26/10
GENERAL DESCRIPTION
Getman Model A-64 Chassis is a four wheel drive, articulating parking brakes, are manually set and released by utilizing the
frame steering vehicle powered by a diesel engine. The power dash mounted push/pull control button. The front and rear
of the engine is transmitted through the torque converter to a service brakes are also used as secondary brake which
powershift transmission. From the transmission, drive shafts automatically apply in the event of loss of hydraulic or
with universal joints transmit the power to the deep reduction, transmission pressure. This brake can also be manually
inboard planetary drive axles. applied in the event of complete hydraulic system failure.
Steering is full hydraulic power type, utilizing a flange This vehicle is equipped with two red Brake Warning lights
mounted direct drive hydraulic gear pump which provides located in the instrument panel. One light for the front and
hydraulic fluid to an orbitrol valve operated by the steering one for the rear brake circuits. These warning lights will
wheel. This operates the two steer cylinders located in the illuminate if hydraulic pressure in either brake circuit drops
articulation joint. below the preset 1100 PSI (76 BAR) level. The front and rear
service brakes will automatically apply if the hydraulic
Every effort has been made to ensure that you can stop this pressure in the brake circuit drops below 1100 PSI (76 BAR).
vehicle. The service brakes (axle brakes) are fully enclosed Trucks with Brake Impending option, auto brake application
wet disc type, with a dual system, permitting separate circuitry occurs when hydraulic pressure in either front or rear brake
for front and rear brakes. Should a failure occur in either circuit falls below 1200 PSI. All the instruments required to
circuit, the other circuit remains functional. The spring set, operate the vehicle are located in the operator’s area. Become
hydraulically released, service brakes which also serve as familiar with the position and function of each.
GENERAL SAFETY PRECAUTIONS

Before operating or performing any maintenance on the SAFETY ALERT SYMBOL
vehicle, review the following safety precautions. These are
included for your protection and safety. This symbol will appear at various points
throughout the manual in conjunction with
Always observe the following general safety rules during warning statements. Its appearance means:
operation of the vehicle. Also observe the safety rules set ATTENTION! BECOME ALERT!
forth in the work place. The need for additional rules for safe YOUR SAFETY IS INVOLVED!
operation may arise due to particular mine applications. This
should only be used as guidance. This manual also uses the following messages:
Safety depends on well maintained, properly operated NOTICE: Used for special information or instructions,
equipment. Following service and maintenance relating to procedures, equipment, tools, and other special
recommendations set forth in this manual will result in a data.
reliable vehicle. Observing operating procedures can help you
avoid accidents. Listed in the following pages are some basic IMPORTANT: Used when special precautions should be
safety precautions which should be read, understood and taken to ensure correct action or to avoid damage to or
practiced. It is, however, impossible to cover every condition. malfunction of equipment.
Always be alert, think SAFETY at all times, and use common
sense. 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.
02/26/10
GENERAL SAFETY PRECAUTIONS (CONTINUED)
RULES
• Do not re-fuel the vehicle with engine running.
• Read and carefully follow all instructions as outlined in
the vehicle manuals. • Do not drive the vehicle over electrical cables.
• Always be aware of location of nearest fire extinguisher. • Do not pump the brake pedal.
• Always ensure that excess grease, oil, etc., are cleaned up • Place transmission gear selector in neutral (N) when not
immediately to prevent a potential fire hazard. in use.
• Avoid smoking or open flame around fuel. • Engage the parking brake when not in use.
• Recognize and avoid potential hazard areas, such as the • Park vehicle on level surface, if possible, and always
articulation area. lower ground engaging implements and utilize wheel
chocks. If parking on a grade is unavoidable, point the
• Perform all recommended checks and report all vehicle vehicle towards the rib.
defects.
• Use proper tools for service.
• Check the area around entire vehicle prior to entering the
operator’s compartment. • Avoid wearing loose or baggy clothing when working
around engines or other rotating or moving equipment.
• Never allow riders in vehicles not designated to carry
passengers. Operator and passengers must be seated in • Do not arc weld on vehicle without first turning master
proper seats with seat belts fastened. switch to off position.
• Enter and exit operator’s compartment carefully. Never IMPORTANT

utilize operating controls as hand holds to assist entering When welding on all Cummins engines,
or exiting a vehicle. disconnect the 50-pin OEM connector and 4-
pin power connector from the engine ECM,
• Do not operate while under the influence of alcohol or as well as disconnect battery positive and
drugs. negative terminals. Failure to follow this
procedure could result in damage to ECM and voiding of
• Do not operate a vehicle with a defective exhaust system. warranty. It is a good practice to always disconnect OEM
connector from engine ECM in addition to disconnecting the
• Sound horn before starting engine. batteries regardless of engine manufacturer.
• Ensure that all instruments, indicators, and operating • Never utilize a vehicle for an application other than it was
controls are functioning. originally designed for.
• Check operation of brake circuit prior to beginning of • Operate vehicle with caution. Be aware of your
each shift. surroundings.
• Do not allow pedestrians near vehicle when engine is in • Watch out for others. They may not be watching out for
operation. you!
• Never stand when operating a vehicle in motion.
• Never dismount from a vehicle unless brakes are set. Do

not enter or exit a vehicle when in motion.
• Never remove any elements of the engine’s exhaust

system or any safety guards when vehicle is in operation.
02/26/10
GENERAL SAFETY PRECAUTIONS (CONTINUED)
PARKING PROCEDURE
1. Park vehicle away from traffic, and turn into the rib. IMPORTANT
Any modification not supplied by Getman
2. Apply the parking brake and place transmission in neutral Corporation or by OEM should be approved
(N). prior to change by Getman.
3. If the vehicle has been operating in a working condition WARNING

just prior to parking, allow engine to cool. Park and run The seat belt is an important part of the
at idle for 1 to 2 minutes. MSHA canopy safety system. Failure to
wear a seat belt can cause extreme injury
4. Stop engine. or death.
5. Block wheels.
SERVICE POSITION CAUTION

Steering is not functional when engine is not
Throughout this manual, you will be told to “place vehicle in running.
service position”.
1. Park vehicle on level area and block wheels.
2. Apply parking brake.
3. Lock frame articulation joint by installing safety bar.

(articulating vehicle only)
4. Stop engine.
NOTE: Complete procedure before servicing vehicle.
FUEL SHUT OFF

Close fuel line valves at tank ports
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 operator’s 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.
02/26/10
NAME, WARNING AND CAUTION PLATES
Locate and understand all name plates and decals, including the Getman Model/Serial Number Plate and two types of Warning Plates.
These are placed there for your safety and protection. Should any of these labels require replacement, please notify your local Getman
Distributor to order the appropriate label. Please be sure to provide the correct vehicle serial number with your order.
02/26/10
CAUTION STATEMENT
Use this equipment under the following conditions: RPM should not exceed engine manufacture’s recommended
value. The QSB4.5 and QSB6.7 Cummins diesel engines
1. GENERAL SAFETY should not exceed (25) inches of water (dirty filter). The
This diesel-powered vehicle may only be designed for use in OM904LA and OM906LA diesel engine should not exceed
non-coal mines. Such mines are those in which material being (22) inches of water (dirty filter). A restriction indicator will
mined is incombustible or contains at least 65% by weight of provide warning indication by turning red when twenty (20)
incombustible material, and in which underground atmosphere inches of water is achieved. Inspect the intake air cleaner at
in any open workings contain less than 0.25% by volume of regular intervals and clean or replace as necessary.
flammable gas. Tunneling operations in which underground
conditions confirm with the foregoing are in the same category 8. EXHAUST SYSTEM
as non-coal mines. Any questions pertaining to the design of Keep exhaust piping tight at all times. Do not allow piping to
this vehicle, please contact your local distributor. Make become blocked. The maximum back pressure (positive) in
frequent inspections to see all engine intake and exhaust parts, exhaust system at full throttle, no load, 2500 RPM must not
all electrical components, including wiring and all other exceed the engine manufacturer’s recommended value. The
equipment, are in safe operating condition. There must be no QSB4.5 and QSB6.7 Cummins diesel engine’s maximum
openings in any part of the engine exhaust system except one exhaust back pressure measured at the turbocharger outlet
exhaust outlet originally provided. should not exceed 1.5 PSI without an exhaust catalyst or 2.2
PSI with an exhaust catalyst.
All circuit breakers for overload protection in electrical
circuits must be kept in good condition. 9. EXHAUST PURIFIER
Purifier can lose efficiency when used on engines producing
2. FASTENERS excessive amounts of blue and/or black smoke. Other engine
Keep all bolts, nuts, screws and other fasteners for electrical malfunctions such as stuck or leaking injectors will also cause
enclosures in place. Properly tighten and secure them. loss of efficiency. Compression loss will lead to lower
Similarly, keep fasteners for the engine cylinder head, intake exhaust temperature and loss of purifier efficiency.
and exhaust systems in place, properly tightened and secured.
10. FUEL
3. REPAIRS AND RENEWALS Use only diesel fuel recommended by the engine manufacturer
Take special care when making repairs and renewals. Use for satisfactory engine operation. The flash point must not be
new parts exactly like those furnished by original less than 140°F or sulfur content greater than 0.5% by weight.
manufacturer. Use gaskets from the manufacturer only. Have When filling fuel tanks underground, transport fuel in secure
all mating surfaces clean and in proper condition. metal containers. Store fuel containers in closed,
incombustible compartments while awaiting transfer to the
4. BATTERY AND CABLES fuel tank of the diesel vehicle. Keep fuel in ventilated area.
Before working on or around batteries, turn the battery
disconnect switches off. 11. FIRE EXTINGUISHER
Each diesel vehicle must carry at least one dry type or CO²
5. VENTILATION type pressurized fire extinguisher at all times.
The amount of fresh moving air for ventilation at any place
underground where the vehicle is working must meet the 12. VEHICLE OUT OF SERVICE
engine manufacturer’s minimum requirements. This Each out of service vehicle must have an “OUT OF
ventilation must be supplied in addition to that required for SERVICE” tag displayed.
other diesel powered vehicles and other requirements. Shut
off the engine whenever underground ventilation stops for any
reason. It is recommended the engine be shut off any time the
vehicle is not in use. Do not idle engine for excessively long WARNING
periods. Improper operation of this vehicle can
cause severe injury or death!!!
6. ENGINE
Replace any faulty part with manufacturer’s parts.
7. INTAKE SYSTEM
Air must flow freely into intake system. Maximum pressure
(vacuum) through intake system at full throttle, no load, 2500
02/26/10
CAUTION STATEMENT (CONTINUED)
• Prior to performing service on a vehicle, place a “DO ELECTRICAL SYSTEM SAFETY
NOT OPERATE” tag on the steering wheel (if
equipped) or engine start switch. If applicable, remove • Turn the on/off and master disconnect switches both to
engine start key. the off position.
• Steering is NOT functional when engine is not running. • Disconnect the negative (-) battery cable first and when
reconnecting, connect the negative (-) cable last.
• Always wear proper protective items such as safety
glasses, safety boots, etc… • Do not grind, weld or have open flame near batteries.
Sparks can cause explosion.
• Always ensure the vehicle is parked on level ground away
from vehicle traffic with the parking brake applied and • Do not weld on truck without turning off master
wheel chocks in place. disconnect switches and disconnecting battery.
• Never enter into the articulation area unless the • Do not short across battery terminals. Sparks can cause
articulation-locking bar is in place. an explosion.
• Never stand under an unsupported structure (boom, • Always remove caps and have adequate ventilation when
basket, scissor deck, etc…). charging batteries.
• Always consult the correct manual and/or drawing for the • Batteries are maintenance free and do not need to be
specific vehicle. opened.
• Always use the specific parts book when ordering parts SAFETY WITH FUEL, OILS AND ENGINE
for a vehicle.
COOLANTS
• Always depressurize the hydraulic system (hydraulic tank
and vehicle accumulators) “before” removing any • When working on vehicles equipped with water cooled
hydraulic components, hoses or fittings. Failure to do so engines, exercise extreme caution when removing radiator
could result in serious injury or death. caps. Always allow radiator to cool prior to removing
cap. When removing cap, turn cap to first notch to allow
• Always ensure components such as boom, baskets, scaler any residual pressure in the cooling system to escape.
picks, scissor decks, etc… are retracted against their stops Remove cap fully only after pressure is released.
before removing any components from their specific
circuits. This will avoid unexpected movement of the • All fuels and most oils are flammable. Handle with care.
vehicle, which could cause injury or death.
• Ensure all oil and/or fuel soaked rags are stored in an
• Always proceed with extreme caution when working appropriate container.
around hydraulic systems. Hydraulic fluid injected into
the skin can cause severe injury or death. • Use non-flammable cleaning solvent to clean parts.
• Maintain a fully charged fire extinguisher on vehicle at all

times. If extinguisher is used, have it serviced.
02/26/10
INSTRUMENT PANEL DESCRIPTIONS
1. Engine Function Display: This instrument will display either shutdown or go into limp home mode. Also the stop
all available engine functions (engine oil pressure, temp, engine light will be illuminated.
rpm, engine hours, etc...), and it also displays check
engine and stop engine warning codes. See Murphy 2. Engine Warning Alarm: This gauge provides an
Operating Manual in Section 3 for more information. audio/visual warning in conjunction with the Murphy
Engine Function Display.
Note: On Cummins engines, the engine oil pressure reading is
similar to an on/off switch. If the oil pressure is good as
determined by Cummins electronics, then the gauge will read
a value between 60 to 75 psi. If the oil pressure drops below
normal operating parameters, as determined by Cummins
electronics, then the gauge will read 0 psi and the engine will
02/26/10
INSTRUMENT PANEL DESCRIPTIONS (CONTINUED)
3. Transmission Pressure Gauge: Transmission pressure 17. Beacon/Strobe Light (Optional): Turn to on position to
gauge indicates pressure being regulated and provided to operate Beacon or strobe light.
the transmission clutches. If the gauge fails to register
pressure after engine start up, shut down engine 18. Canopy Light (Optional): Turn to on position to operate
immediately and contact maintenance. Normal operating Canopy light.
pressure is approximately 300 PSI. See Transmission
Service Manual in Section 5 for more information. 19. Warning Panel: This panel provides a visual warning for
various events. See “Instrument Warning Panel” for more
4. Converter Oil Temperature Gauge: Normal information.
transmission/Converter operating temperature 160°-220°F
(71°-104°C). If gauge indicates higher temperature, stop
vehicle, shift transmission into neutral, apply parking
brake and run engine at 1000 0 1200 RPM until oil
temperature returns to normal. See Transmission Service
Manual in Section 5 for more information.
5. Parking/Secondary Brake Button: Push to apply, pull to

release.
6. Voltmeter: Indicates battery charging or discharging.
7. Work Light Switch (Optional): If equipped, switch on

for work light application.
8. Horn Button: Push to sound horn.
9. Circuit Breakers: Consists of 10, 20, and 30 AMP

breakers used for gauges, lights, horns, etc…
10. Spare Space: Available for additional usage, contact

Getman Corporation if space is needed.
11. PLC Reset Switch (Optional): Used to reset engine

controls. Pull out for 30 seconds, fuse will reset. Push
back in and restart engine.
12. Remote Throttle Enable Switch (Optional): Enables a

remote throttle to be used to control engine RPM’s.
13. Park Brake Test Button: For vehicles equipped with a

“Park Brake Test” button, depressing and holding this
button allows the operator to engage the transmission for
testing of the park brake. See “Park Brake Test
Procedure” for instructions on performing this test.
14. Low Fuel Light (Optional): For vehicles equipped with

this light when illuminated vehicle is low on fuel.
15. Start Switch: Turn switch to position 1 for preheat, and

momentary turn to position 2 to start engine.
16. Light Switch: Toggle switches for front and rear lights.
02/26/10
INSTRUMENT WARNING PANEL
PARK BRAKE: This light illuminates when the driveline system. This is considered to be a major fault which will
parking brake is engaged. When the parking brake is released require immediate attention. Shut down the engine as soon as
to set the vehicle in motion, this light will not be illuminated. possible and notify maintenance.
FRONT AND REAR BRAKES: Two individual lights are BRAKE IMPENDING (OPTIONAL): This light
in the display to provide the operator with information illuminates when transmission/ converter pressure drops to
regarding possible auto brake application. These lights are an 75PSI. Auto brake application occurs when transmission/
indication that less than 1100 PSI exists in either the forward converter pressure drops to 60 PSI.
or rear brake circuit. Auto brake application occurs when
brake system pressure falls below 1100 PSI. Trucks equipped DECLUTCH: This light illuminates when the transmission
with Brake Impending option, auto brake application occurs selector is disabled. Depending on options chosen, the
when hydraulic pressure in either front or rear brake circuit following can activate the declutch option.
falls below 1200 PSI. 1. Parking Brake is “ON”.
2. Diverter valve is in Accessories mode.
POWER ON LIGHT: The power light is an indication that 3. Stabilizer Jacks are not fully retracted.
the ignition switch has been turned to the “ON” position. It 4. Man basket is not stowed level on deck.
will remain illuminated until the ignition is turned off. 5. Scissor deck is in elevated position.
CHECK ENGINE: This light illuminates in the event of an TRANSMISSION: This light illuminates in the event of low
engine fault being detected by the engine electronic control hydraulic oil pressure or high transmission temperature.
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
02/26/10
ELECTRONIC ENGINE DATA DISPLAY
02/26/10
ELECTRONIC ENGINE DATA DISPLAY (CONTINUED)
NOTE: For more information on electronic engine data display, see section 3 (Engine Function Display Operating Manual).
02/26/10
GAUGE DESCRIPTIONS
Fuel gauges can be inside or outside of the cab. The gauge

Normal transmission/converter temperatures are between indicates the existing fuel level in the fuel reservoir.
180°F-220°F (82°C-104°C). Should temperatures rise above
the 220°F 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.
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.
02/26/10
GAUGE DESCRIPTIONS (CONTINUED)
Pressure gauges are used to measure the hydraulic pressure OPTIONAL

system. They could be used to measure brake pressure, total Exhaust back pressure is measured in inches of water (H20).
system pressure, etc. Exhaust back pressure is pressure that develops in the exhaust
system while a vehicle’s engine is running. High exhaust back
pressure is undesirable, as it reduces engine power. It’s
important to 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 manufacturer’s
recommended valve. The OM904LA diesel engine maximum
recommended valve is 40” H2O.
OTHER CONTROLS
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.
WARNING
Never free wheel vehicle. Free wheeling
will cause serious injury and damage
vehicle.
Direction Selector Lever - Move selector lever to “F” for

forward. Move selector lever to “R” for reverse direct. “N” is
for neutral.
Gear Selector Lever - Move lever to position “1” for low

gear, position “2” for second gear and position “3” for third
gear.
02/26/10
CHECKS BEFORE STARTUP
Check all the engine belt(s) for tension and condition. Worn
or gouged belt(s) should be replaced immediately.
Check area around vehicle for obstacles that might be

damaged by, or cause damage to, vehicle when it is driven.
Check Fire Extinguisher and replace as needed.
Check engine oil level. Fill as required with recommended

lubricant.
Make sure frame joint safety bar is not connected.
Check air cleaner sight gauge. If indicator is in the red zone,

clean or replace filter element(s). Visually inspect rubber
connectors and clamps.
Check hydraulic oil reservoir level with engine shut off. Oil
level should not be above the top sight gauge or below the Check lights and horn to ensure all are operational.
lower sight gauge. Fill as required.
Check seat belt to make certain fastener works and belt is not
worn or cut. Adjust operator’s seat to a comfortable operating
Check tire pressure, 95 PSI (6.55 BAR) is recommended. position. Some seats have height adjustments.
Check wheel nuts. Do not operate with loose or missing
wheel nuts.
02/26/10
STARTING PROCEDURE
IMPORTANT
Before you enter operators compartment, all
personnel must be a safe distance from
vehicle.
Frame safety bar must not be connected.
4. Move Directional Lever to neutral position.
1. Turn Battery and ECM Disconnects to “ON” position.

This switch could be located on the side of the vehicle, in
the cab, or both.
5. Turn Start Switch to “ON” position. (a)

2. Adjust and fasten Seat Belt to a comfortable operating
position. 6. Wait for Powerview Warning Lights to go out. (b)
Approximately 3 seconds.
7. Push Horn Button to sound horn. (c)
8. Turn Start Switch to start position to engage starter motor

and hold until engine starts. NOTE: Do not hold for
periods longer than 15 seconds.
9. If engine, transmission, and hydraulic pressure gauges do

not show pressure shortly after stat-up, stop engine and
determine cause.
NOTICE
3. Push down Park Brake Button. Do not crank engine for more than 15
seconds. Allow starter to cool for two
minutes before cranking again.
Turbocharger (if equipped) damage can
CAUTION result, if the engine rpm is not kept low until
Transmission must be in neutral and park the engine oil pressure gauge indicates pressure is sufficient.
brake must be applied to start engine.
02/26/10
PARK BRAKE TEST PROCEDURE – PERFORM DAILY
NOTICE
Depressing the Park Brake Button located in
the switch panel overrides the transmission
declutch feature.
To test the Park Brake only:
3. Place shifter in 3rd Gear. Forward.
4. Fully depress Throttle.
5. Vehicle Should Not move.
1. Set Park Brake. (a)
2. Depress & hold Park Brake Test Button. (b)
SERVICE BRAKE TEST – PERFORM DAILY

Test the service brake by fully depressing the service brake pedal. Placing the transmission in forward, 2nd gear, release the parking
brake and increase engine RPM to maximum for 3-5 seconds. Vehicle should not move. If vehicle moves, park and apply wheel
chocks and contact maintenance.
02/26/10
AFTER ENGINE STARTS
1. Engine Oil Pressure Electronic Engine Display – Oil 6. Park Brake Test – This system is designed to hold a
pressure should read 25-50 PSI at idle with engine at fully load vehicle on a 35% grade. For safety reasons, a
operating temperature. At full engine load, pressure parking brake test should be performed at the beginning
should read between 45-60 PSI. If gauge fails to show of each shift. See Park Brake Test Procedures for
pressure after engine start up, stop engine immediately instructions on how to conduct this test.
and find cause.
2. Voltmeter – With engine running, voltage should read

12-16 volts for 12 volt vehicle systems and 24-30 volts CAUTION
for 24 volt vehicle systems. Stop engine immediately if any gauge is not
in its set range.
3. Transmission Temperature Gauge – During work
cycles, if Trans/Converter Gauge indicates temperature WARNING
above 220°F, bring vehicle to a stop, place transmission Do not operate any vehicle with a faulty
in Neutral with park brake applied and increase engine parking/service brake system. Serious
RPM to approximately 1000-1200 RPM. Maintain this personal injury or damage to vehicle may
RPM until Transmission temperature returns to normal result.
levels.
4. Transmission Pressure Gauge – 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.
5. 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).
02/26/10
OPERATING VEHICLE
1. Once all gauges have been checked and are within
normal operating ranges, vehicle is ready to
operate.
2. Turn Light Switches to the “ON” position (a).
3. Depress Service Brake and hold Park Brake
Button (b).
4. Check Brake Accumulator Pressure Gauges and
check Instrument Panel Warning Display for Low
Pressure Warning Lights in Warning Panel (c).
5. Ensure all hydraulic stabilizers are in the top
position (if applicable).
6. 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.
7. Pull Park Brake Button (b) to release the driveline
disc brake.
8. Depress horn button (d) on instrument panel to
sound horn.
9. Release Foot Brake Pedal, test steering for proper
operation and move vehicle slowly by gently depressing Accelerator Pedal with foot.
Acquaint yourself with the “FEEL” of the steering by driving NOTE: When traveling up a grade, select lower gear if torque
the pattern shown above. Do this several times until you converter oil temperature approaches 200°F (93 °C).
become familiar with vehicle steering and feel you would be
comfortable driving the vehicle in traffic areas. To familiarize CAUTION
yourself with vehicle response to an automatic application of When proceeding down grades, use 1st gear.
the driveline brake, drive straight, remove foot from Use of 2nd or 3rd gear could cause engine
accelerator pedal and push Park Brake Button while still over speeds and possible safety hazards to
rolling. operator.
Park brake should set and vehicle should come to a stop. If

this does not occur, have brake circuit and adjustment checked
by authorized personnel.
When satisfied that you can safely and comfortably operate

the vehicle, find a long straight open stretch of roadway and
accelerate. Start in 1st gear, shift to 2nd gear, and then to 3rd,
etc. (if conditions permit). Make certain area chosen is free of
obstacles and/or other personnel. At higher speeds slight turns
should be tried as long as there is no danger of hooking the rib
or another vehicle. Stop vehicle and return transmission gear
selector to neutral (N). Apply Park Brake. Check all gauges
again to be certain they are within normal operating range.
02/26/10
TOWING PROCEDURES FOR A DISABLE VEHICLE
If your Getman vehicle is equipped with the auxiliary brake PREPARING A VEHICLE TO BE TOWED
release hand pump, you will be able to release the brakes to
facilitate towing of a disabled vehicle. In a mining environment, inclines and declines are a fact of
life. Before any effort to release the brakes is taken, the
There are several operations outlined below that are vehicle to be towed should first be secured from moving. This
recommended for the protection of all personnel involved in can be done by placing wheel chocks in front and rear of as
the use of this machine and to protect vehicle components many wheels as possible.
from costly damage.
Approach the vehicle to be towed with the tow vehicle. The
Read and follow these instructions carefully. use of a rigid steel tow bar is highly recommended. Using a
rigid tow bar, connect the two vehicles together by inserting
If you do not understand these instructions, please contact the bar into the tow eye and secure the tow pins on both
your Supervisor or Getman Corporation for further vehicles. Verify that the brakes of both vehicles are set.
clarification.
NOTE: The use of a rigid tow bar is recommended to prevent
DANGER the vehicle being towed from uncontrolled forward or
The towing of any vehicle in an rearward motion towards or away from the tow vehicle. Such
underground environment can be an unexpected motion can often lead to loss of control.
extremely hazardous operation. Caution
must be taken to ensure the safety of all
personnel involved in this task. CAUTION
Precautions should be taken to ensure any
unnecessary personnel are clear of the
working area.
IMPORTANT
The tow vehicle must have adequate weight,
power, traction and braking capabilities to
safely perform the function of controlling
and stopping both vehicles on maximum
grades that may be encountered during the
entire towing procedure.
TRANSMISSION
IMPORTANT
The Getman A64 is equipped with a
pressure lubricated transmission. Towing
the vehicle without the engine running and
the drivetrain connected may cause clutch
and/or bearing damage due to lack of
lubrication. When the vehicle is to be towed, the drive lines
connecting the transmission to both the front and rear axles
should be disconnected at the axles. Once disconnected from
the axles, the drivelines should be removed or secured to avoid
damage.
02/26/10
TOWING PROCEDURES FOR A DISABLED VEHICLE (CONTINUED)
BRAKE RELEASE
If your A-64 is equipped with a Brake Release option, you have the ability to manually release the
brakes without engine powered hydraulics. This is done with the optional hand pump, diverter valve and
relief valve normally located on the floor of the operator’s compartment, to the right hand side of the
operator’s seat.
1. Before an attempt to release the brakes is made, ensure all unnecessary personnel are clear of the
work area.
2. Close the ON/OFF valve of the Manual Pump located near the floor on the right hand side of the
operator’s seat. This is done by completely screwing in the control valve “clockwise”.
3. Pull the handle of the Diverter Valve to the “UP” position.
4. If your vehicle is equipped with a quick connect fitting located at the relief valve beside the
diverter, attach a 0-3000 PSI hydraulic gauge and commence pumping the hydraulic pump using the
supplied handle. Continue to pump until the gauge reaches the 2000 PSI range. The brakes will now
be released and the vehicle will be ready to be towed.
5. To resume normal operation once towing is completed, you should push the handle of the Diverter
Valve to the “DOWN” position and open the ON/OFF valve by screwing the valve
“counterclockwise”.
NOTE: In the event of an emergency or need to stop the vehicle being towed, the brakes can be fully
applied by pushing the handle of the Diverter Valve to the “DOWN” position. To resume towing, it is
then necessary to pull the handle of the Diverter Valve back to the “UP” position and pump the
hydraulic pressure to the 2000 PSI range.
NOTE: If your vehicle is not equipped with the brake release option and towing is the only option,
contract Getman Service for further information.
02/26/10
MAINTENANCE SCHEDULE – AS REQUIRED
Place vehicle in service position.
NOTE: Depending on dust conditions, air cleaner may require daily service.
This vehicle is equipped with a Donaldson dry type air cleaner.
NOTE: Lack of engine power and/or excessive exhaust smoke is signs the air filter elements may require service.
Check service indicator. Clear dust collector discharge slot daily. Service air cleaner only when indicator locks in red position.
Proceed as follows:
Loosen cover clamp by unscrewing support clamp and remove cover. Unscrew filter support thumbscrew and remove and discard
primary filter element. Clean inside housing. Install new element.
Check cover gasket to ensure a good seal. Reposition cover and thumbscrew. Reset service indicator.
Replace safety filter element every 5th primary filter change. Safety filter element is replaced in same manner as primary element
change.
02/26/10
MAINTENANCE SCHEDULE – DAILY OR EVERY SHIFT CHANGE
• Perform Maintenance – As Required

• Perform Daily Maintenance Schedule
ITEM COMPONENT FLUID*

1. Tires ____
2. Hydraulic System HO
3. Engine EO
4. Air Pre-cleaner ____
5. Fuel System D2
6. Belts ____
7. Oscillating Axle Trunnions EPG
8. Transmission & Torque
Converter TF
9. Upper & Lower Pivot Pin Check hydraulic reservoir sight gauges and fill as required.
Bearings EPG Fluid level should not be above top sight gauge or below
10. Steering Cylinder bottom sight gauge.
Bushings EPG
*See Fluid Specifications.
Check engine oil level. Fill as required.
Check tire condition and pressure. Do not operate vehicle

with low tire pressure. Do not operate vehicle with badly
worn and/or gouged tires. Verify all wheel retention bolts are
present and secure.
02/26/10
MAINTENANCE SCHEDULE – DAILY OR EVERY SHIFT CHANGE (CONTINUED)
Empty and clean pre-cleaner dust bowl .

Check fuel level. Fill as required.
Check transmission fluid level. Fluid should be checked at

normal operating temperature with engine running at idle and
transmission in neutral. For detailed information, see section 5
(Transmission Service and Maintenance Manual). Fill as
required.
Check all engine belts for tension and condition. Worn or

gouged belts should be replaced immediately. CAUTION
Avoid any moving belts, components, or
Push the belt at center between pulleys with finger. Belt high temperature areas. Serious personal
movement should be 3/8” to 5/8” (10-15mm). injury can result from carelessness.
Visually inspect machine:
WARNING Check – With Engine Running:

Engine MUST be shut off to check belt 1. Hydraulic system for leaks.
tension. 2. Fuel system for leaks.
3. Instruments for proper function.
Check – With Engine Off:

1. All controls for free movement.
2. Mounting bolts.
NOTE: Perform engine maintenance as indicated in the

engine operator’s manual or by contacting Getman
Corporation for the latest information.
Grease axle trunnions.
02/26/10
MAINTENANCE SCHEDULE – EVERY 50 OPERATING HOURS

• Perform 50 Hour Maintenance Schedule

1. Wheels ____
2. Battery H2O
3. Air Cleaner EO
4. Air Cooling System ____
5. Catalytic Exhaust Purifiers ____
Check wheel nuts. Nuts should be tightened to 300 LBS-FT

(406.7 Nm).
Release and lift battery access plate. Clean battery off and
inspect cables.
WARNING
Check all air intake connections. Tighten as required.
Be aware of hydrogen gas build up under
battery access plate. Keep open flame
and sparks away from battery.
IMPORTANT
Do not get battery acid on skin. Keep all
open flame out of area. Add grease to both steering cylinder ends.
02/26/10
MAINTENANCE SCHEDULE – EVERY 50 OPERATING HOURS (CONTINUED)
Add grease to both upper and lower pivot pin bearings. (See Remove air cowl on injector side of engine by releasing
specifications) retainer snaps. Clean cooling fins, oil cooler, transmission
cooler, and radiator if applicable with compressed air.
ECS CATALYTIC AIR PURIFIER OR DIESEL PARTICULATE FILTER – COMBIFILTER

If vehicle is operated under heavy load with engine rpm at Cleaning Procedure:
least 70% of operating time, a minimum amount of 1. Remove center section of purifier.
maintenance will be required. If engine does not work hard 2. Dry brush inlet face of catalyst.
and is allowed to idle for excessive periods of time, the 3. Air clean through outlet face of catalyst.
catalyst may become “carboned up” and exhaust will start to 4. Continue steps 2 & 3 until inlet face is clean.
smoke after a few hours, indicating regeneration is necessary. 5. Completely soak catalyst in Stoddard, S.C. solution for
one hour.
NOTE: DO NOT allow engine to idle more than five (5) 6. Solvent-air clean through outlet face of catalyst for 10
minutes at a time, or purifier will loose efficiency. minutes.
7. Air clean through outlet face.
Before vehicle is put into service, and during every 50 Hour 8. Repeat steps 5, 6, and 7 until purifier is clean.
Maintenance, check exhaust back pressure at full throttle by 9. High pressure water wash purifier through outlet face and
connecting a back pressure or water gauge to the 1/8” NPT air dry.
test port between purifier and exhaust manifold. If back 10. Replace purifier.
pressure exceeds 40” (1016 mm) H2O or has risen 5” 11. Record back pressure at full throttle, remove gauge and
(127mm) or more since last regeneration, purifier must be tighten test plug.
regenerated.
NOTE: If high pressure steam is available, it may be
NOTE: If exhaust system is set up with a Combifilter that substituted for solvent solution. Steam clean through outlet
requires a regeneration station, follow the Engine Control face, keeping nozzle 2” (51mm) away from catalyst face.
System’s Regeneration Procedures instead of the following
listed steps. NOTE: If purifier has been regenerated but engine continues
to smoke, engine must be serviced to maintain safe exhaust
Required Equipment: conditions.
• Nylon, hard-bristle parts cleaning brush.
• Solvent-air, parts cleaning gun.
• Super concentrate degreasing solution.
• Stoddard solvent or high grade kerosene (sulfur free) – 5
parts Stoddard to 1 part S.C.
• High pressure air source (30PSI).
• Wrench.
WARNING
Flammable Solution. Use in accordance
with manufacturers recommendations.
Use in a properly ventilated area.
02/26/10


1. Driveline, Universal
Joints, Slip Joints EPG
2. Transmission TF
4. Axle Differential Housing MBO
5. Axle Breather ____
6. Engine ____
7. Parking Brake ____
Add grease to driveline slip yokes, one fitting each.
Add grease to all driveline universal joints, and center bearing.
NOTE: Some universal joints may not be shown.
Drain transmission oil by removing the drain plug. Clean plug

in solvent, dry, and replace in transmission.
02/26/10
MAINTENANCE SCHEDULE – EVERY 250 OPERATING HOURS (CONTINUED)
Remove return line filter. Replace filter element and install

return line filter. Install drain plug. Fill hydraulic reservoir
Remove transmission filter. Replace with new filter. Before
with fluid.
installing filter, coat gasket with light film of oil. See Section
5 (Transmission Service & Maintenance Manual) for detailed
information.
Fill and check transmission as follows:

1. Fill transmission to low mark on dipstick.
2. Run engine at idle 500-600 RPM to prime converter and
hydraulic hoses.
3. Re-check oil level with engine at idle and transmission in
neutral. Bring oil level to low mark on dipstick. When
oil reached normal operating temperature of 158° to Check hydraulic reservoir sight gauge. Add fluid as required.
248°F (70°-120°C) make a final check and bring to the Fluid level should not be above top sight gauge or below
full mark of the dipstick. lower sight gauge.
4. Check for oil leaks.
Check lubricant level in both differential housings. Remove

fill plug. Gear oil should be level with full plug bottom. Add
lubricant as required. Replace fill plug. Refer to specification
page for proper fluid.
Remove reservoir fill cap and empty main hydraulic reservoir

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

servicing.
Remove axle breather, clean in solvent and dry with
compressed air. Re-install in axle. Do for both axles.
02/26/10

ITEM COMPONENT FLUID* Clean reservoirs inside with steam or solvent.

*See Fluid Specifications. Clean or replace sump strainer and re-install inside reservoir.
Remove return line filter. Replace filter element. Install

return line filter.
Remove reservoir fill cap. Empty main hydraulic reservoir by Install reservoir access plate, install drain plug, and fill
removing drain plug. hydraulic reservoir with fluid. Check specifications.
NOTE: To avoid contamination, replace cap and clean

reservoir top before proceeding.
Check hydraulic reservoir sight gauges. Add fluid as required.

Level should not be above upper sight gauge or below lower
sight gauge.
Remove hydraulic reservoir access plate. Disconnect sump

strainer located inside reservoir.
NOTE: Strainer suction port must be closed off with a 1 1/2”

NPT cap to prevent circuit contamination and possible damage
to hydraulic components.
02/26/10


1. Axle Differential Housing MBO
2. Axle Breather ____
Remove front and rear axle differential drain plugs. When

axle is empty of all fluid, clean and re-install drain plugs.
Remove differential fill plugs (one per axle). Add specified

lubricant until fluid level reaches bottom of oil fill plug port.
Clean and re-install differential fill plugs.
02/26/10
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 cetane number. For complete details see Engine Operation and Maintenance Manual or contact your
local Getman Distributor.
TIRES
SIZE PLY RATING TYPE PSI BAR
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 PSI BAR
Engine Oil Pressure at 1000 RPM 45-60 3.1-4.1
Steering Hydraulic System at low idle with 1500-2000 103-138
vehicle turned and against stops.
Hydraulic brake charging pressure.
John Deere Axles 1650-2200 114-151
Ford/New Holland D45 & D65 1650-2200 114-151
Pressure from brake treadle valve.
John Deere Axles 1000 69.0
Ford/New Holland D45 & D65 1500 130.5
NOTE: Checks made at 150°F (65°C) oil temperature.
02/26/10
FLUID CAPACITY QUICK REFERENCE GUIDE
ENGINES
MANUFACTURER MODEL GALLONS LITERS
MERCEDES 904 W/ FILTER (OIL) 4.5 W/ FILTER (OIL) 17
MERCEDES 906 W/ FILTER (OIL) 6.75 W/ FILTER (OIL) 25.6
CUMMINS QSB SERIES W/ FILTER: W/ FILTER:
STANDARD OIL PAN 4.3 STANDARD OIL PAN 16.1
DEEP SUMP OIL PAN 5 DEEP SUMP OIL PAN 18.9
DEUTZ F3L912 W/O FILTER (OIL) 2.4 W/O FILTER (OIL) 9
W/ FILTER (OIL) 2.8 W/ FILTER (OIL) 10.4
DEUTZ F5L912 W/O FILTER (OIL) 3.6 W/O FILTER (OIL) 13.5
DEUTZ BF4M1012 & (E) & W/O FILTER (OIL) 2.3 W/O FILTER (OIL) 8.5
(C) & (EC) W/ FILTER (OIL) 2.7 W/ FILTER (OIL) 10
DEUTZ BF6M1012 & (E) & W/O FILTER (OIL) 3.3 W/O FILTER (OIL) 12.5
(C) * (EC) W/ FILTER (OIL) 3.5 W/ FILTER (OIL) 13.2
DEUTZ BF4M2012 & (C) W/O FILTER (OIL) 2.3 W/O FILTER (OIL) 8.5
DEUTZ BF8M2012C W/O FILTER (OIL) 3.3 W/O FILTER (OIL) 12.5
W/ FILTER (OIL) 3.7 W/ FILTER (OIL) 14
TRANSMISSION
CLARK/ DANA 32000 5 18.9
CLARK/ DANA 28000 REPLACED BY 32000 TRANSMISSION
CLARK/ DANA 20000 4.1 15.5
CLARK/ DANA 18000 REPLACED BY 20000 TRANSMISSION
JOHN DEERE 2000 SHORT DROP 4 15
AXLE
NEW HOLLAND D65 7.3 27.4
NEW HOLLAND D45 5.8 21.8
JOHN DEERE TMII 1200 5 18.9
NAF BOGIE GTM 01 3.2 12
NOTE: This should only be used as a reference, fluid requirements may very. Refer to component page in manual to determine
which components are equipped with your truck. For further information, see operation/ service manuals for each component or
contact Getman Corp direct.
02/26/10
A-64 ANFO CHARGER OPERATING AND M1006
INSPECTION MANUAL Page 1 of 17
GETMAN CORPORATION
OPERATING AND MAINTENANCE

MANUAL
FOR
A-64 ANFO CHARGER
Read thoroughly before operating vehicle

*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS. Updated:
02/22/10
TABLE OF CONTENTS PAGE INTRODUCTION
Introduction 2
Related Manuals 2 Operators should carefully read and understand all vehicle
General Safety Precautions 4 manuals. You must become familiar with all controls and
Safety Alert Symbol 4 procedures. Getman’s A-64 Series ANFO Truck manual is a
Rules 4 guide to safe, proper operation, and maintenance. Always
Safety Instructions 4 keep manual on vehicle at all times.
Boom Man Lift General Descriptions 5
Boom and Outrigger Operation 6-7 This Getman A-64 Series ANFO Truck has been purchased
Daily and Pre-Op Inspection 8 with expectations that it will provide long and reliable service.
Daily Inspection 8 During it’s design and construction, we have taken every
Anfo Loading System 9-10 precaution to ensure we meet those expectations. To realize
Loading Material Into the Anfo Pots 11 the full valve Getman has designed into this vehicle, a small
Control of the Anfo System 12-13 amount of time and expense must be invested in the inspection
Misconceptions 12 and maintenance procedures outlined in this manual. This
Basket Controls 13 small investment will ensure low operating cost, minimal
Basic System Adjustments and service expenses and most importantly, personal safety.
Operation 14-16
Key Items to Remember 17 RELATED MANUALS
This manual covers operation and maintenance of the ANFO
loading system and boom mounted on the Getman A-64
chassis. An Operators manual for the primary A-64 chassis is
also incorporated in your Parts and Service Manual for your
specific vehicle. Please read and become familiar with all
these manuals. A complete listing of engine, drive train
components, applicable Electrical, Hydraulic and Air Systems
can also be found in their respective system schematics and
Parts and Service Manuals. We have also provided Parts and
Service Manuals for major components such as axles,
transmissions, and engines. These will be located in the
Getman Parts and Service Manuals for your vehicle, or by
other means.
Getman has increased the frequency for some component

manufacturer’s recommended maintenance procedures. This
is due to the demanding environment and applications in
which these vehicles must operate.
If you have any questions in regards to operating or servicing

this vehicle, immediately contact your local Getman Dealer or
Getman Corporation direct.
02/22/10
DESIGN FEATURES
Getman Corporation has always had one main goal in the past 50 years. This has been to provide our customers with the safest, most
reliable product possible to positively impact your production cycle and cost per ton.
That’s why, in 1963, Getman Corporation pioneered and produced the first complete self contained anfo hauling/loading package.
While making this the fastest way to speed up your production cycle time, this was secondary to making it the safest method possible.
Here are just a few of the design features that make your Getman A-64 Anfo Charger the vehicle you can count on day in and day out:
• The large man basket (available in several sizes) is self leveling and rotates in each direction to always allow it to be square
with the face to ensure maximum operator comfort and reach.
• A full set of boom/basket controls are located in the basket as well as at the base of the boom.
• All cylinders are equipped with counterbalance valves to prevent uncontrolled decent in the event of system damage.
• The boom, basket, and outriggers have undergone complete finite element analysis and are fabricated by certified welders to
ensure maximum strength and safety.
• The basket-mounted boom controls are pilot operated and can be overridden by the base mounted controls at the base of the
boom in the event of an emergency.
• Basket-mounted anfo loading controls are fully protected from accidental activation.
• All anfo delivery fittings are made of SS304 material for maximum life and reliability.
• All the pressure vessels (anfo pots) are certified AS 1210, ASME Code Section VIII Div I UW 12. Designed working
pressure is 100PSI (6.9 BAR).
• The vehicle is equipped with detonator storage compartments which conform to MSHA regulations.
• Getman offers a selection of onboard compressors in a variety of makes and CFM rages and also offers a mine air hyd/elec
package.
These are just a few of the design features that make your Getman Anfo Charge the #1 self contained anfo charger in the market place
today.
Please not that there are numerous other available options from fully enclosed operators compartments, boom lengths, interlocking
safety systems, etc….
The following pages are provided to allow a new operator to have an understanding of the anfo delivery system and how to best make
adjustments and settings to suit your specific application.
02/22/10
GENERAL SAFETY PRECAUTIONS
SAFETY ALERT SYMBOL • Always lower ground engaging implements and
utilize wheel chocks when vehicle is parked.
This symbol will appear at various points • If parking on a grade is unavoidable, point the
throughout the manual in conjunction with vehicle towards the rib, engage the parking brake,
warning statements. Its appearance means: lower all ground engaging implements and utilize
ATTENTION! BECOME ALERT! wheel chocks.
YOUR SAFETY IS INVOLVED! • Avoid smoking or open flame around fuel.
• Always be aware of location of nearest fire
This manual also uses the following messages: extinguisher.
• Check operation of brake circuit prior to beginning of
NOTICE: Used for special information or instructions, each shift.
relating to procedures, equipment, tools, and other special • Never utilize a vehicle for an application other than it
data. was originally designed for.
• Watch out for others. They may not be watching out
IMPORTANT: Used when special precautions should be for you!
taken to ensure correct action or to avoid damage to or
malfunction of equipment. SAFETY INSTRUCTION
CAUTION: Used as a reminder of safety hazards which can WARNING
result in personal injury if proper precautions are not taken. ANFO IS A HIGHLY EXPLOSIVE
MATERIAL!
WARNING: Used when a hazard exists which can result in All safety regulations must be followed
injury or death if proper precautions are not taken. during it’s use. The Operating Procedures
in this manual are intended for general
DANGER: Used when an extreme hazard exists which can information only! Obtain approval safety procedures and
result in serious injury or death if proper precautions are not practices from your safety inspector and material supplier.
taken.
Always wear safety glasses and gloves when operating or
RULES working near compressed air and anfo products.
Before performing any maintenance on the vehicle, review the Never disconnect any compressed air hoses or fittings when
following safety precautions. These are included for your under pressure
protection and safety.
WARNING
Always observe the following general safety rules during HAZARDS OF STATIC
operation of the vehicle. Also observe the safety rules set ELECTRICITY
forth in the work place. The need for additional rules for safe USE ONLY APPROVED
operation may arise due to particular mine applications. This PROCEDURES FOR GROUNDING
should ONLY be used as guidance. PNEUMATIC LOADING VESSEL
AND USE ONLY APPROVED SEMI-CONDUCTIVE
• Read and carefully follow all instructions as outlined (ANTI-STATIC) ANFO PLACEMENT TUBING.
in the vehicle manuals.
• Ensure that all instruments, indicators, and operating
controls are functioning.
• Never utilize operating controls as hand holds to
assist entering or exiting a vehicle.
• Never stand when operating a vehicle in motion.
• Avoid wearing loose or baggy clothing when
working around engines or other rotating or moving
equipment.
• Never allow riders in vehicles not designated to carry
passengers.
• Never dismount from a vehicle unless brakes are set.
02/22/10
BOOM MAN-LIFT GENERAL DESCRIPTION

The boom and turret arrangement with a man basket attached at the end is attached to the truck rear frame. This is a three piece boom
consisting of outer, middle, and inner sections. The boom can generally be swung 50° to either the left or right of the vehicle. The
basket itself can also be swiveled 45° right or left of the boom. As the boom is raised, interconnecting hydraulic cylinders keep the
basket level. The hydraulic power necessary to move the boom and basket are provided by an engine driven pump. Air powered
hydraulics is an available option. The ANFO vessel and air control are frame mounted. A grounding reel is also mounted on the
chassis.
1. Parking Brake Control: Push to apply, pull to 7. Boom: Outer, middle, and inner tubes. Used to
release. extend and retract platform during positioning of
basket.
2. Accessory Control: Pull to activate, push to
deactivate. 8. Interconnecting Cylinders: Used to keep basket
level as boom raises and lowers.
3. Stabilizers: Used to level truck. Not to be used to
gain additional basket height. 9. Air Compressor and Controls: Used to move
ANFO material.
4. Stabilizer Controls: Used to extend and retract
stabilizers. 10. ANFO Vessel: Carries ANFO material.
5. Basket: Operator’s work platform. Raises and 11. Grounding Reel: Grounds frame to earth.
lowers.
12. Engine Start/Stop: Used to shut down or start
6. Controls: Hydraulic controls used to perform all engine from basket (Optional).
boom basket functions. Including, raise, lower,
extend, retract, swing, and tilt.
02/22/10
BOOM AND OUTRIGGER OPERATION

Park vehicle on as flat and level surface as possible.
Apply park brake. Pull tee handle to accessory mode to

activate boom/outrigger hydraulic circuit.
NOTICE
STEERING IS DISABLED!
To operate boom and basket from the ground, use truck

mounted controls located at base of boom. To operate from
basket, use controls located in basket.
LEVER FUNCTIONS
1. Boom Swing left or right.

2. Boom extension in or out.
Extend all stabilizer jacks to a solid footing prior to raising 3. Boom lift up or down.
boom off of deck. 4. Basket tilt up or down.
5. Basket rotate left or right. (Optional)
Connect ground cable to earth. Use approved grounding
procedures when connecting cable.
WARNING
OVERHEAD OBSTRUCTIONS
Be sure to have enough overhead clearance.
Failure to follow this rule could cause
serious injury or death.
Connect truck to mine air. If truck is using engine powered

hydraulics, set engine R.P.M.
02/22/10
BOOM AND OUTRIGGER OPERATION CONTINUED
Always use boom and basket controls to position yourself in a

desired position rather than reaching extensively.
WARNING
DO NOT SIT OR STAND ON BASKET
Booms operating using mine air to run hydraulics may operate RAILING OR ALLOW PASSENGERS
boom basket functions from the basket by activating the TO DO SO.
basket mounted air valve to start and stop the air driven
hydraulic pump.
Booms operating using diesel engine power to run hydraulics

may operate boom basket functions from the basket by
activating the basket mounting engine start/stop button to start When work has been completed, put vehicle in Travel Position
and stop the diesel engine from the basket. by performing the following:
1. Retract boom.
2. Lower basket to position on deck.
3. Place stabilizers to fully retracted position.
4. Retract and stow grounding cable.
5. Disconnect mine air.
6. Release air from ANFO pots.
Vehicle is now ready for tramming.
When moving boom, make certain all hoses are in a position

where they will not be damaged.
02/22/10
DAILY AND PRE-OP INSPECTION
WARNING
VESSEL AIR PRESSURE
Prior to working on the vessel or leaving
vehicle unattended, vent all existing air
pressure from pots. Failure to do so could
cause serious injury.
IMPORTANT
Always make certain vehicle is in “Service
Position” before performing maintenance or
service.
DAILY INSPECTION
1. Thoroughly inspect the complete vessel(s) and
accessories for wear due to corrosive nature of
ANFO material. If vessel(s) are in need of repair or
displays signs of damage to vessel structure, retire
unit from service immediately.
2. Inspect the interior of vessel(s) for foreign material

such as paper, wood, or wire which may have entered
into the pot.
3. Inspect basket floor. It must be in good repair and

free of debris.
4. Inspect basket railing and entrance. It must be in

place and in good repair.
5. Lower stabilizers. They should all extend and retract

smoothly and have foot pads attached.
6. Using controls at base of boom raise boom to full

height and lower. Carefully observe for kinks or
sharp bends.
NOTICE
7. Observe as hoses fold and unfold and ensure there are REPORT ANY UNUSUAL OR
no kinks or sharp bends. FAULTY CONDITIONS TO YOUR
MAINTENANCE DEPARTMENT.
8. Check hose pathways and fittings to ensure there are TAG VEHICLE OUT OF SERVICE
no indications of leaking, chaffing or cutting.
9. Raise and lower and rotate basket throughout its full

range of motion. Ensure hoses are clear and
movement is smooth.
10. Remove all debris from truck, wash truck with water
and blow dry.
02/22/10
ANFO LOADING SYSTEM
1. VIRBRATOR: Keeps anfo moving. Turns on “only” when supply and boost are engaged.
2. ANFO SUPPLY VALVE: When air is applied to “open”, anfo is allowed to flow through to basket.
3. BOOST AIR VALVE: Opens when anfo supply valve is opened. Directs air in elbow in base of tank to create venturi
effect and push material to basket. Vibrator applies at same time.
4. HOSE CLEAN OUT VALVE: When utilized with supply valve closed, this allows supply hose to be emptied. When
used with anfo supply valve open, may add additional air for up holes.
5. REGULATED AIR: This air is main anfo pot air that is normally regulated to approx. 60PSI by an air regulating valve.
This air pushes down on top of material to ensure constant flow downward. Can be adjusted to suit operator’s
requirements.
6. PILOT AIR: This air is regulated to approx. 70PSI. It provides supply air for the relay valves, vibrators, control valves
in basket, and anfo supply valve. (Jamesbury)
7. STAINLESS STEEL DELIVERY ELBOW: This elbow is flange mounted using stainless steel bolts and can quickly
be removed if needed to remove plugging or debris.
02/22/10
ANFO LOADING SYSTEM CONTINUED
• BOOST AIR BALL VALVE (2): This ball valve can be used to increase, reduce, or stop the “volume” of air being
used for pushing material to the basket.
• CLEAN OUT BALL VALVE (2): This ball valve can be used to increase, reduce or stop the “volume” of air
being used to blow material out of the hose or clean out the hole.
• SAFETY RELIEF VALVE (2): This relief valve (set @120PSI) is used as a safety in the event air pressure to the
pots increases above 120PSI.
• ANFO POT BALL VALE (2): This ball valve can be used to increase, reduce, or stop the “volume” or air being
supplied to the tanks.
• ANFO POT PRESSURE REGULATING VALVE (2): This adjustable regulating valve can be used to increase
or decrease the “pressure” of air being supplied to the tanks.
• PILOT AIR REGULATING & LUBE (70PSI): This adjusting regulating valve can be used to increase or
decrease the “pressure” of air being supplied to the controls and relay valves and lubricate as well.
• AIR PRESSURE GAUGES(4): You will find a total of four air pressure gauges in the anfo loading system. As
shown above, there is one for main air supply, either from onboard compressor or mine air. Two others are for
regulated air pressure for each of the individual pots and one for pilot control regulated pressure.
02/22/10
LOADING MATERIAL INTO THE ANFO POTS
• The stainless steel ANFO pot or pots on your Getman vehicle are equipped with a lid over the top opening to keep water
and/or debris out of the pot. This lid should only be opened when the pot is completely de-pressurized by opening the tank
drain ball valve and venting the air to atmosphere. Once the vessel is filled, the lid should be closed and latched before the
vessel is again pressurized.
• Located under the lid, is a stainless steel screen. The screen is utilized to screen out any debris that may be inadvertently
directed towards the pot. This will also help break up any larger lumps of anfo and maintain conformity in material size. Do
not remove this screen. It will provide added assurance against material plugging and added security for personnel while
loading the vessel with material.
• There is a rubber sealing cap inside the pot below the screen. The cap automatically rises and seals the pot when air pressure
is applied to the pot. The pot should never be filled to a point above the base of the cap as this may prohibit the cap from
properly sealing. The normal fill capacity would be approximately ¾ to ⅞ full.
• A “grounding reel” is provided on every ANFO vehicle Getman manufactures. The cable of the reel should be run to earth
whenever filling the ANFO pots and/or when charging holes.
02/22/10
CONTROL OF THE ANFO SYSTEM
The operating controls for the anfo system are completely air powered. The main air manifold or “tree” is located between the pots on
a dual pot system in the center of the deck behind the boom. It is also located in the same general area on a single pot delivery system.
This location was chosen to provide maximum protection from falling debris while still providing easy access for operator
adjustments.
This Getman Anfo Charger has been carefully designed to create a delivery system which will function properly in almost any
application with material from various suppliers. Many updates and improvements have been made throughout the years to ensure
proper loading can always be achieved for maximum productivity. The key to successful loading will be for the operator to determine
the correct settings necessary to properly place the material in your specific application.
This manual may “not” be able to provide each and every operator with the precise settings which may be required for the best
material delivery in each application. By following the simple instructions listed in this manual, you should be able to have the
delivery system fine tuned to your particular operation in a matter of hours.
Universally, there are several suppliers of anfo material. This allows for many differences in texture, weight and conformity. Some
materials manufacturer’s provide a very dry, light product and others are heavier and stickier. This is why finding the correct air
pressure and volume settings for each application is so important.
Once the operator has utilized this system for some time and has determined what settings best fit his needs and application, further
adjustments are seldom required.
MISCONCEPTIONS
Here are some of the misconceptions that often make finding the perfect settings difficult:
If I use the maximum air volume, I’ll get the maximum amount of anfo-
While this sounds logical, we all know the goal when loading is to place the material into the hole quickly and well compacted.
Sometimes when too much boost air volume is used, the air/material ratio is too high. This means more air and less anfo travels down
the lines to the delivery hose. This means longer fill times and less productivity.
I’ll keep maximum air pressure going into the top of the anfo pot to push more material-
Again, very sound logic, but not always practical. The pot is cone shaped with a 4” outlet at the bottom. The real purpose for the air
pressure on the top of the pot is to assist the material to travel to the outlet in the bottom of the pot. Depending on the humidity factor
of the material in the pot, too high an air pressure will lead to packing the material too tight into the outlet and lead to plugging. The
boost air venturi located at the elbow at the pot outlet is truly “the mover” of the material to the basket. The pressure in the pot is
there to ensure the material can get to the outlet in a consistent manner.
02/22/10
CONTROL OF THE ANFO SYSTEM CONTINUED
BASKET CONTROLS
There are two hand operated 2 position control valves in the basket which allow the operator to control the anfo delivery system.
These come conveniently hard mounted on the basket railing. There is an optional belt attachment available which allows the operator
to have the ability to have the controls mounted remotely with them.
• CLEAN OUT CONTROL VALVE: This control valve when actuated (ON) sends pilot air to open the relay valve located
downstream from the anfo supply valve (Jamesbury). Once the relay valve is actuated, maximum air pressure will be sent
through the delivery hose at a rate dictated by the adjustment of the “clean out ball valve.” This can be utilized to purge
remaining material from the delivery hose and/or to blow out water or rock dust from the drill hole prior to loading.
• ANFO SUPPLY CONTROL VALVE: This control valve when actuated (ON) sends pilot air to perform three separate but
related functions. #1 Opens the “anfo supply valve” located between the elbow at the outlet of the anfo pot and the
adapter/reducer where the delivery hose to the basket commences. This allows the material to move into the delivery hose.
#2 Opens the “boost air relay valve” which can then allow regulated air flow to push material down the delivery hose to the
basket. #3 Turns on the tank mounted “vibrator” to create tank vibration to assist the material in the pot in moving freely into
the outlet elbow. Returning the control valve to the “OFF” position will close the anfo supply valve, stop boost air from
entering the outlet elbow and stop the vibrator.
02/22/10
BASIC SYSTEM ADJUSTMENTS AND OPERATION
Once you have placed the vehicle in it’s work position, apply the parking brake. At this time the operator should then pull out the tee
handle of the diverter valve located to the right side of the operator’s seat. This valve will be labeled “Steering/Accessories”. This
valve disables the steering, prohibits the release of the parking brake and directs oil to the rear of the vehicle to provide for the
hydraulic jacks, boom functions, and hydraulic air compressor. Now the operator should proceed to the rear passenger side of the
vehicle and with the correct diverter valve placed in the “JACKS” position, the stabilizer jacks can be lowered until the vehicle is
supported and is level as possible. Depending on the vehicle configuration listed below, the engine can be shut off. Do not utilize
stabilizers to obtain extra height. Try and park the vehicle with the front and rear frames aligned as straight as possible.
If vehicle was purchased equipped to operate the ANFO delivery system utilizing mine air, there should be a mine air connection
located on each side of the vehicle. You can now connect the mine air to whichever side is most convenient. Please note the mine air
supply house should be blown out prior to connecting to the vehicle to ensure the supply hose is free of water or debris. Once the
mine air valve is opened, you can open the ball valve located immediately after the mine air connection. This will provide air to the
“tree” for feeding the pots and controls, the air powered hydraulic pump for the boom and outrigger functions, and the air driven
alternator which will allow operation of all work lights. The light control switches are located in the instrument panel in the operator’s
compartment. The ball valve located just prior to the air driven alternator should be “opened” to operate the alternator.
02/22/10
BASIC SYSTEM ADJUSTMENTS AND OPERATION CONTINUED

Each loading situation is different. Therefore, the system control settings are different as well. With this system, you can control both
the volume of material being delivered and the speed or force in which that material is being delivered. The key things to keep in
mind are:
NOTICE
To change the “amount” of ANFO being delivered, changes must be made to the regulated pot pressure.
NOTICE
To change the “speed or force” or the material being delivered, changes must be made to the boost air ball
valve. (Increase or Decrease Volume)
The two system adjustments mentioned above are the most important ones the operator can make to be able to fine tune the system to
his satisfaction. The key is achieving the correct balance of the two. Too much boost volume may cause jerkiness of the delivery tube
and sporadic spurts of air. Too much pot pressure may cause intermittent plugging of material. The correct balance must be found for
the application. Once this balance is found, any further adjustments will be minor and quickly done. A lot of this will depend on the
material used, the application, and the conditions and the operator preferences. Basically, it will be whatever works best for you.
To determine what is right for you, you must approach this system with an open mind. You should not assume that the same settings
as on an older vehicle with a different system will be right for this one. Many of the older systems had very few adjustments available
to them.
Getman has worked closely for several years with many customers in various countries to develop a delivery system that was
adjustable enough to adapt to material differences and various applications. During these years, we have found that the best and
quickest method to determine what setting are best for your application is to start slowly with minimum pressures then grow from
there. Generally within the first hour of use, you will be near your desired settings.
PLEASE TRY THE FOLLOWING METHOD ON THE NEXT PAGE.
02/22/10
BASIC SYSTEM ADJUSTMENTS AND OPERATIONS CONTINUED

As per previous pages, this vehicle can be manufactured with a mine air ANFO system, an onboard air compressor ANFO system, or a
combination of both. Regardless of the system you have chosen, once you have an air supply for your system, the system settings
become the most critical component to successful operation. Once you have placed the vehicle in the required position, lowered the
stabilizers, and connected the grounding reel cable to earth, Getman suggests you start with the following settings:
• Adjust the ANFO pot pressure regulating valve until the ANFO pot pressure gauge indicates approximately 25PSI.
• Adjust your clean out air ball valve to approximately the half (1/2) open position.
• Adjust your boost air ball valve to approximately the half (1/2) open position.
Because there will always be a short delay after the ANFO delivery valve is closed after loading a hole, we recommend you place a
piece of tape on the delivery wand approximately 10-12” from the place you want the flow of material to stop in that particular hole.
This is done so you can feel and see when the tape exits the hole and turn off the delivery system and yet fill the hole to the desired
depth.
• Now insert the loading wand into the hole to be filled and pull open the “clean out” valve control in the basket. This will
open the “clean out relay valve” and send only air through the wand to blow any water and/or debris from the hole. Be
certain to position your face and body to the side of the hole to avoid being sprayed. If the blow back is too strong, close
your clean out air ball valve slightly to reduce the volume of air being delivered.
• Once the hole has been cleaned out, it’s time to fill the hole with ANFO material. Pull open the “ANFO delivery control
valve” in the basket. This will open the material delivery valve, apply the tank vibrator and open the boost air. Because the
pot air pressure is set low and the boost air ball valve is at ½ open and should easily be controlled. This will be slow, but
will allow you to “get the feel” or the system. You will notice that when you start loading, the wand (delivery hose) will start
to push itself out of the hole. You should keep your hands gripped loosely around the hose so it can continue to come in time
with the material going in to the system.
• Once your comfortable with the feel, you can increase the material flow being delivered by increasing the pot pressure
regulator up to approximately 35PSI. Since you are delivering more material, you should now feel the wand being pushed
back out quicker than before and the hole will be filled quicker. Once you see your tape, shut off the ANFO delivery control
valve.
Now we will increase the speed by opening the Boost air ball valve. Now you may find the delivery hose (wand) is a little harder to
hold because it has more recoil. Again, the hole will be filling faster. Depending on the material type being used and the required
fragmentation, an adequate speed (force) may be critical to properly pack the material in the hole.
Continue to adjust the pressure and volumes until the system is performing to your satisfaction.
The methods mentioned above will basically be the same for loading any type of holes. The key is always going to be “getting the
settings to where they work best for you!!”
02/22/10
KEY ITEMS TO REMEMBER
• MORE ANFO POT PRESSURE NORMALLY CREATES MORE MATERIAL VOLUME FLOW.
•
NOTICE
TOO MUCH ANFO POT PRESSURE CAN LEAD TO PLUGGING. CUSTOMER EXPERIENCE HAS
INDICATED 60PSI IS GENERALLY THE OPTIMUM SETTING FOR ANFO POT REGULATED
PRESSURE.
• INCREASE BOOST AIR (BALL VALVE) CREATES INCREASED MATERIAL DELIVERY SPEED.
• INCREASED CLEAN OUT AIR (BALL VALVE) CREATES INCREASED AIR VOLUME.
NOTICE
NEVER LEAVE MATERIAL IN THE ANFO POTS OVERNIGHT. THE CONDENSATION AND
HUMIDITY MAY LEAD TO PLUGGING PROBLEMS.
NOTICE
NEVER LEAVE THE POTS PRESSURIZED BETWEEN LOADING CYCLES. DOING SO MAY LEAD
TO POSSIBLE PLUGGING PROBLEMS
• WHENEVER ANY HOSING, FITTINGS, OR CONNECTIONS OF SMALLER SIZES ARE USED, THIS WILL
LIKELY NECESSITATE THE RE-ADJUSTMENT OF THE AIR SETTINGS. THIS IS DUE TO THE POSSIBLE
RESTRICTION CREATED BY THE SMALLER DIAMETER.
• ALWAYS EMPTY ANY MATERIAL FROM POTS PRIOR TO ENTERING MAINTENANCE SHOP FOR
WELDING OR REPAIRS.
IMPORTANT
NEVER MOVE THE BOOM FROM THE DECK WITHOUT THE STABILIZERS LOWERED AND THE
FRAM AS LEVEL AS POSSIBLE.
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 1 of 12
SUGGESTIONS AND PROCEDURE FOR THE INSPECTION OF A GETMAN BOOM
The following procedure should be used when inspecting a boom/ basket for reliability and safety after a period
of 4000 hours or 5 year of use. This procedure involves the complete removal of the boom and basket and
disassembly of the boom, in order to properly evaluate its condition. This inspection is highly detailed.
Regular 50 hour maintenance checks should still be performed on the boom/ basket, and parts will have to be
replaced before this check. This inspection is highly detailed and should be performed on booms/ baskets that
have been used extensively in the field.
The information and suggestions found here are presented in a general matter. In order to find information
specific to the truck, consult the truck manual, or contact Getman Service.
HYDRAULIC SYSTEM
Before completely breaking down the boom assembly, it is important to evaluate the current working condition
of the boom/ basket before the replacement of parts or other components. Therefore the following information
should be recorded.
_____ BASKET WEIGHT TESTED AT 150% OF RATED CAPACITY __________LBS

_____ BOOM CONTROLS (OPERATE BOOM TO FULL RANGE)
AT 100% RATED CAPACITY _______ LBS
_____ RECORD PRESSURES WITH 100% RATED CAPACITY IN BASKET
Boom Up Pressure __________ Boom Down Pressure __________
Boom Up Time __________ Boom Down Time __________
Boom Ext. Pressure __________ Boom Ret. Pressure __________
Boom Ext. Time __________ Boom Ret. Time __________
Boom Rotate CW Pressure __________ Boom Rotate CCW Pressure __________
Boom Rotate CW Time __________ Boom Rotate CCW Time __________
Basket Rotate CW Pressure __________ Basket Rotate CCW Pressure __________
Basket Rotate CW Time __________ Basket Rotate CCW Time __________
Basket Up Pressure __________ Basket Down Pressure __________
Basket Up Time __________ Basket Down Time __________
Updated:
02/22/10
HYDRAULIC SYSTEM (CONTINUED)
If any of the functions seem excessively slow, or have a lack of power, some of the hydraulic components may
need to be replaced.
During operation and after break down the hydraulic system must be evaluated for the following points.
1. Cylinders
a. Check for leaks.
b. Check for proper extension and retraction speeds.
c. Check for damage or excessive corrosion to the component itself.
d. Check for slop or excessive movement in the rod.
2. Control Valves
a. Check for leaks.
b. Check for proper operation.
c. Check correspondence between tags and operation.
d. Check for damage or excessive corrosion to the component itself.
3. Other Components and Hoses

a. Check for leaks.
b. Check for proper operation.
c. Check routing of hoses.
d. Check for damage or excessive corrosion to the component itself.
Depending on the condition of the components and hoses, it may be wise or necessary to replace some of the
components and all of the hoses. It may also be a good opportunity to rebuild the cylinders.
PINS AND BUSHINGS
Throughout a Getman boom there are many different Pins and Bushings, it is imperative that all of them are
inspected properly in order to insure the safety and correct operation of the boom. See Figure 1 for general
location of boom pins.
1. Pins
a. Check pins for steps, grooves, or excessive wear. The pin should not be able to move up or
down in the bushing.
b. Have the pins tested for cracks using a Magnetic Particle test, or other nondestructive testing
method.
c. Replace bolts that hold pins in position.
d. Check bolt holes for worn threads or excessive slop.
2. Bushings
a. Replace all Removable Bushings.
b. Check welded bushings for excessive pin movement. The pin should not be able to move in
any direction perpendicular to the bore.
Updated:
02/22/10
WEAR PADS
When performing a detailed inspection of the Getman boom, involving the complete tear down of the assembly,
it is recommended that all the boom wear pads and their mounting bolts be replaced. The parts are relatively
inexpensive, and it is easy to do with the boom disassembled. See Figure 1 for general location of the wear
pads. See Figure 2 for Wear Pad Replacement Procedure.
Replacement of these wear pads should remove any excessive sag or movement in the boom, and will help
return it to proper working condition. If the wear pads are worn excessively to the point where the mounting
screws are contacting the boom, they must be replaced. This excessive wear can cause extreme damage to the
boom, and will result in failure.
WELDMENTS
A typical Getman Boom is composed of a turret, outer boom weldment, middle boom weldment, inner boom
weldment and basket. (See Figure 1) These weldments should all be inspected in depth for cracks, corrosion,
wear, and damage. Any components exhibiting these characteristics should be replaced, or properly repaired.
CORROSION
The affect of corrosion on a boom/ basket can dangerously fatigue the boom/ basket beyond repair. While
corrosion in some areas of the boom/ basket maybe less serious as others, it’s important that the boom/ basket
be relatively free of heavy corrosion if still in use. Getman suggests that the depth of corrosion, within 12
inches of the boom ends and on all pivoting components, be less then .01”. In the middle sections of the boom
where the stress on the sections is less, the corrosion can be as deep as .03”. However, with excessive
corrosion, the amount of material worn away maybe enough so that the depth of the corrosion maybe
inaccurately measured. A combination of excessive wear and corrosion can lead to failure. Getman
recommends that corrosion and wear be looked at carefully. Refer to the pictures in Figure 3 for examples of
excessive corrosion of the boom.
BASKET
The basket should be inspected regularly for bent supports, welds, corrosion, deformation, etc. See Figure 4 for
an example of a basket that is unsafe and needing replacement. If a basket has been deformed, it would be
recommended to inspect all pins, cylinders, and links on the boom for indications of damage.
FINAL INSPECTION
After the boom has been properly serviced and reassembled the boom / basket should be inspected again for
proper operation of hydraulic components. The boom/ basket should be tested with 150% of rated weight, for
proper range of motion and operation. With proper care and attention to these guidelines the Getman boom/
basket should be ready for safe use once again, however in some instances a boom/ basket may be beyond
economical repair, and should be removed from further use. If any questions or concerns arise during the
inspection please feel free to contact Getman Service for further assistance.
Updated:
02/22/10
FIGURE 1
Updated:
02/22/10
ANFO LOADER BOOM WEAR PAD REPLACEMENT PROCEDURE
The wear pads on an Anfo Loader boom will eventually wear thin.
If these pads are not replaced damage to the boom can occur,
resulting in costly repair. Like the brake pads on an automobile
once the pads have worn down to the level of the screws holding it
on, its time for replacement. In order to reduce the risk of damage,
the pads should be inspected every 200 hrs.
This step by step procedure will allow you to disassemble the

boom, and replace all of the wear pads. The numbers used to
describe the different parts of the boom can be referenced to the
assembly drawing of the boom at the end of this manual.
Depending on the exact type of Getman boom being serviced,
there may be small differences in parts or service procedure. The
owner manual for the truck will have specific Getman part
numbers for the boom being serviced. This procedure has been
written for a wide range of Getman booms.
PREPARATION
9 Insure that the truck is parked on a level surface
9 Disconnect power at main battery disconnect switch
9 Properly place wheel chocks so that the truck won’t roll
OUTER SLIDE PADS AND WEAR PADS
See Figure 3 for the following location points. Both the outer
boom (#10) and the middle boom (#25) have a slide pad (#22) on
the bottom end, and a set of side wear pads (#24). The slide pad is
attached to the bottom of the boom using a pin that is bolted in
place (#20 & #28). By putting the weight of the boom on the
basket, pressure will be relieved from the bottom slide pads and
they can be removed and serviced. The slide pads have wear pads
(#21) that can be replaced when needed. The side wear pads (#23)
can also be replaced as needed. Two bolts hold on the side wear
pads, when removed, the wear pads can be unbolted from the plate
and replaced. The replacement of the wear pads on the outside of
the boom is fairly simple, and will extend the life of the boom.
Failure to replace these pads before they are over worn can result
in extreme damage to the main boom assembly. The screws that
hold on the wear pads can cut deep grooves in the boom
components causing the boom to weaken.
FIGURE 2
Updated:
02/22/10
ANFO LOADER BOOM WEAR PAD REPLACEMENT PROCEDURE (CONTINUED)
WEAR PAD SHIMS
When removing wear pads, shims will be present. These shims

are installed in the factory assembly process. The purpose of
these shims is to center the middle boom in the outer boom, or to
center the inner boom in the middle boom. They also keep the
boom from slopping around in the wrong direction. If the factory
shims are in good shape they should be marked for their location
and put back in the same position with the new wear pad. If the
shims are badly damaged, then the boom will have to be shimmed
again with the new wear pads in order to center the boom. The
boom must be checked for free movement. If the wear pads are
too tight it will result in slow or no movement of the boom. Wear
pads and wear pad bolts should be coated with seize proof coating
before being reassembled.
INNER WEAR PAD REPLACEMENT
Both the middle boom and the inner boom have four wear pads
on the end of them. The wear pads on the middle boom run on
the inside of the outer boom, and the wear pads on the inner boom
run on the inside of the middle boom. In order to replace these
pads the boom must be taken apart. Depending on the shop
environment, this can be an easy or fairly difficult task. The use
of an overhead crane can make the job simple.
To change out the wear pads, the inner boom and the middle
boom have to be removed from the outer boom. The outer boom
can be left attached to the truck, and the other booms can just be
pulled out of it. The basket on the end of the boom does not
necessarily have to be removed from the inner boom, but it may
make the job easier.
To start, all the hydraulic pilot control hoses connected to

bulkhead plates on the inner boom or the middle boom must be
removed, capped and tagged. This will insure that the lines stay
free of debris, and are put back together correctly. Any hangers
or other wires connected to the inner or middle booms must be
removed. Use care when disconnecting the hydraulic pilot lines,
the boom may have a tendency to slowly move out.
At this point the basket can be disconnected if needed by

removing the pin connecting the basket to the boom, and the pin
connecting the hydraulic cylinder to the boom.
FIGURE 2
Updated:
02/22/10
ANFO LOADER BOOM WEAR PAD REPLACEMENT PROCEDRUE (CONTINUED)
The hydraulic cylinders that extend and retract the boom are bolted
to the inside of the middle boom. The ends of the cylinders are
connected to the front of the outer boom, and the end of the inner
boom. The pins that connect the cylinder ends to the boom must
be unbolted and removed in order to pull out the inner and middle
boom.
Once the cylinders have been freed from the boom assembly, the
inner and middle booms can be removed from the outer boom
together. In order to do this the slider pad and the side wear pads
on the outer boom must first be removed. Using a crane or
whatever is available, the basket end of the inner boom should be
supported and pulled out, along with the middle boom, from the
outer boom. It maybe necessary to tie the middle boom and the
inner boom together in order to pull them out together. At this
time the wear pads on the middle boom should be visible.
Placing the boom on a set of horses, or a table makes it easy to

work on the two halves and replace the wear pads. In order to
separate the inner boom from the middle boom, the bottom slider
pad, and the side wear pads must be removed from the middle
boom. This will allow the inner boom to be removed from the
middle boom, and the wear pads on the inner boom become
accessible.
Once the pads have been replaced on both the inner boom, and the
middle boom, the booms can be carefully put back together.
Sometimes the crane may have to be used in order to pull the two
booms together, especially with new wear pads. The boom will fit
tightly at first, but will eventually wear and return to normal
smooth operation.
SIGNS LEADING TO WEAR PAD REPLACEMENT
9 Excessive boom sag at full extension
9 Excessive bounce when moving boom
9 Unusual scraping sounds when extending or retracting

boom
FIGURE 2
Updated:
02/22/10
Extra Pictures
Updated:
02/22/10
FIGURE 2
Updated:
02/22/10
ITEM DESCRIPTION QTY.
BOOM ASSEMBLY 1
1 PIN (LEVELING CYLINDER) 2
2 CYLINDER (LEVELING) 1
3 TURRET 1
4 PIN (LIFT CYLINDER) 1
5 BUSHING (TURRET) 2
6 BOLT 8
7 BOLT 20
8 COVER 1
9 KEEPER 1
10 OUTER BOOM 1
11 LIFT CYLINDER 1
12 PIN (TURRET) 1
13 PIN (EXTENSION CYLINDER) 1
14 TRUNNION 2
15 ALLEN HEAD 2
16 PIN RETAINER 1
17 ALLEN HEAD (FLAT) 24
NUT 24
18 EXTENSION CYLINDER ASSEMBLY 1
19 PIN (LIFT CYLINDER) 1
20 PIN (SLIDE PAD) 1
21 WEAR PAD 12
SHIM A/R
22 SLIDE PAD 2
23 WEAR PAD 4
SHIM A/R
24 PAD ASSEMBLY 4
25 MIDDLE BOOM 1
26 INNER BOOM 1
27 ALLEN HEAD (FLAT) 8
NUT 8
28 PIN (SLIDE PAD) 1
Updated:
02/22/10
ITEM DESCRIPTION QTY.
29 PIN (LEVELING CYLINDER) 1
30 PIN (EXTENSION CYLINDER) 1
31 PIN (BASKET) (REF.) 1
32 BUSHING 2
33 ROTATOR 1
34 BOLT 3
35 WASHER 3
36 CYLINDER (LEVELING) 1
37 PIN (LEVELING) 3
38 LEVELING LINK 1
39 LEVELING LINK 1
40 BASKET 1
FIGURE 3
Updated:
02/22/10
FIGURE 4
Updated:
02/22/10
S1000
BOLTS TORQUE AND SIZE SAE.

Thread Size Socket Size Torque Ft lbs... Lubed Torque N-m Grade
1/4" C 7/16 79 in 9 5
1/4" F 7/16 91 in 10 5
5/16" C 1/2 14 19 5
5/16" F 1/2 15 20 5
3/8" C 9/16 24 33 5
3/8" F 9/16 27 37 5
7/16" C 5/8 38 52 5
7/16" F 5/8 43 58 5
1/2" C 3/4 83 113 8
1/2" F 3/4 94 127 8
9/16" C 13/16 120 163 8
9/16" F 13/16 134 182 8
5/8" C 15/16 166 225 8
5/8" F 15/16 189 256 8
3/4" C 1 1/8 295 400 8
3/4" F 1 1/8 330 447 8
7/8" C 1 5/16 477 647 8
7/8" F 1 5/16 526 713 8
1" C 1 1/2 715 969 8
1" F 1 1/2 783 1062 8
1 1/8" C 1 11/16 1013 1373 8
1 1/8" F 1 11/16 1137 1542 8
1 1/4" C 1 7/8 1430 1939 8
1 1/4" F 1 7/8 1584 2148 8
1 3/8" C 2 1/16 1875 2542 8
1 3/8" F 2 1/16 2135 2895 8
1 1/2" C 2 1/4 2489 3375 8
1 1/2" F 2 1/4 2799 3795 8
1 3/4" C 2 5/8 3740 5071 8
1 3/4" F 2 5/8 4300 5830 8
2" C 3
2" F 3
2 1/4" C 3 3/8
2 1/4" F 3 3/8
2 1/2" C 3 3/4
2 1/2" F 3 3/4
2 3/4" C 4 1/8
2 3/4" F 4 1/8
3" C 4 1/2
3" F 4 1/2
(C) Course Threads

(F) Fine Threads
LUBRICANT CROSS F1003
REFERENCE Page 1 of 2
ENGINE OIL VISCOSITY RECOMMENDATIONS
IMPORTANT:
Whenever performing service on this vehicle, make certain it has first been placed in service
position. Basic service and maintenance procedures are illustrated in the maintenance manuals.
These are to be performed at regular intervals based on hours of operation. For further details
on service and necessary major component adjustments (i.e. engine, transmission, axles, etc.)
see respective sections in this manual. Read and become familiar with them. Any further questions, contact
your local Getman Distributor or Getman Service direct.
The viscosity of the oil is greatly influenced by the

ambient temperature, the choice of SAE-grade
should be governed by the ambient temperature of
the engine site (see diagram). If temperatures
temporarily fall below the limit of the SAE grade
selected, engine will not be damaged. However,
starting performance will be affected. During winter
operation viscosity grade should be governed by
ambient temperature when starting engine.
Synthetics maybe of choice.
FLUID SPECIFICATIONS
COMPONENT SYMBOL FLUID
Hydraulic Transmission Fluid, Type TO-4, J20 C, D, MIL-L-2104C,
Transmission & Torque Converter TF C-4
Examples: Citgo Transgard Torque Converter 250, Shell Donax T,
Mobil Trans HD, Texaco Texamatic 4291
Hydraulic system (Steering and optional Use only an “MS” API (MS-DG) oil, MIL-L244459
cylinders) HO Examples: Citgo AW 68 Hydraulic Oil, Shell Tellus 68, Mobil DTE
26, Texaco Rando HD 68
Mineral Base Oil.
Drive Axle Differential Examples: Citgo Transgard Tractor Hydraulic Fluid, Shell Donax TD,
(Front and Rear) Mobil Mobil Fluid 424, Texaco Super Universal Tractor Oil.
All Grease Fittings including Upper & Grade 2 Lithium Base Extreme Pressure Grease, MIL-G-10924A
Lower Hinge Pins, Bearings, & Oscillating EPG Examples: Citgo Overdrive HD, Shell Super Duty Lithium MDS,
Trunnion Mobil Mobilegrease Special, Texaco Multifak All-Purpose EP-2
All Linkage EO Hand Oil As Required
Fuel System D2 #2 Diesel Fuel, Centane 40 Minimum
SEE COMPLETE CROSS REFERENCE LIST ON NEXT PAGE

NOTE: THIS SHOULD ONLY BE USED AS REFERENCE, FOR SPECIFIC COMPONENT LUBRICATE
SEE THAT COMPONENT’S OPERATION MANUAL AND IF ANY QUESTION CONTACT GETMAN
SERVICE BEFORE CHANGING/ADDING FLUID.
NOTE: THIS SHOULD ONLY BE USED AS REFERENCE, FOR SPECIFIC COMPONENT LUBRICATE SEE THAT COMPONENT’S OPERATION Updated:
MANUAL AND IF ANY QUESTION CONTACT GETMAN SERVICE BEFORE CHANGING/ADDING FLUID.
03/22/10
LUBRICANT CROSS F1003
REFERENCE Page 2 of 2
ENGINE & AIR CLEANER (OIL BATH) AXLES - FORD, JOHN DEERE, NAF, KESSLER
(Engine Manufacturers Specifications.)
Shell Rotella Shell Donax TD

Gear Oil 90 LS
BP Vanellus C-Extra Citgo Transgard Tractor
Citgo C-500 Motor Oil Hydraulic Fluid
Citgo – Kessler Axle/Hub Gear Lube 85W-140
Conoco HD Fleet Conoco Power Trans. 11 Fluid
Gulf Super Duty Gulf Universal Tractor Fluid
Mobil Delvac 1300 Mobil Mobil Fluid 424
Mobillube SHC-LS
Sunoco Super-C Sunoco TH Tractor Fluid
Texaco Ursa Super Premium Texaco Super Universal
Exxon XD-3 Tractor Oil
Exxon Hydraul 560
BP Energear LS 90
POWERSHIFT TRANSMISSION OIL HYDRAULIC OIL

CLARK, JOHN DEERE (TYPE C-3, TO -4)
Shell Donax T Shell Tellus 68

BP Autran C-4/TO-4 BP AW 68
Citgo Transgard Torque Citgo AW 68 Hydraulic Oil
Converter 250 Conoco Hydroclear AW 68
Conoco Powerdrive Fluid Gulf Harmony 68 AW
Gulf HT C-3 Fluid Mobil DTE 26
Mobil Trans HD Sunoco Sunvis 800
Sunoco TO-4 Transmission Texaco Rando HD 68
Texaco Texamatic 4291 Exxon Nuto H68
Torque converter/transmission lubricant must be

qualified by one of the following specifications.
ORDER OF PREFERENCE PER SPICER OFF CHASSIS GREASE

HIGHWAY:
1. Caterpillar TO-4 Shell Super Duty

2. John Deere/Funk J20 C, D Lithium MDS
3. Military MIL-PRF-2104G BP Energrease LC
4. Allison C-4 Citgo Overdrive HD
5. Dexron II Equivalent unless using Graphite Conoco Super Lube
Gulf Crown LC3
Mobil Mobilegrease Special
LUBRICANTS NOT RECOMMENDED: Sunoco Ultra Prestige
DEXRON III, ENGINE OIL, ANY GL-5 OILS Texaco Multifak All-Purpose
EP-2
Exxon Ronex Extra Duty
COOLANT/ ANTIFREEZE (Ethylene- Glycol Base) Moly 2
Mobile Devac (50/50) CAT EC-1
NOTE: THIS SHOULD ONLY BE USED AS REFERENCE, FOR SPECIFIC COMPONENT LUBRICATE SEE THAT COMPONENT’S OPERATION Updated:
MANUAL AND IF ANY QUESTION CONTACT GETMAN SERVICE BEFORE CHANGING/ADDING FLUID.
03/22/10
GETMAN EQUIPMENT F1001
STORAGE PROCEDURES Page 1 of 1
The following storage instructions are intended to help ensure

optimum performance from Getman equipment that will not be
utilized for a period of three months to one year.
IMPORTANT
The following instructions be followed as described in order to
keep your warranty valid.
ENGINE
Change oil using an oil with corrosion preventing TRANSMISSION & HYDRAULICS
properties of a least a HD-S1 oil. Listed are some No special care is required except exposed cylinder
of the oils that have been approved: Esso rods should be covered with grease.
MZ20X20V7N; Texaco EKM 162; Shell V6828.
AXLE
Change oil and fuel filters. Axle housings should be filled completely to
eliminate the change of moisture condensation.
Fill fuel tank completely with a mixture of diesel
fuel and 10% corrosion inhibiting motor oil. BRAKE SYSTEM
Drain all air reservoirs of moisture.
Run engine for at least 10 minutes to fill fuel lines
and filters, injection pump and nozzles with BATTERY
preservative mixture. Remove battery; clean off top, and store in a well-
ventilated battery storage area. Do not store on
If engine is to be stored over six months, seal intake concrete or metal.
and exhaust system to keep moisture out.
EQUIPMENT STORAGE FOR LESS THAN
THREE MONTHS
When storing equipment for less than three months,
vehicles should be started and driven for a
minimum of two minutes every two weeks.
Any further questions please contact your local

Getman Distributor or the contact information
below.
Getman Corporation, 59750 34th Avenue, Bangor, Michigan 49013, U.S.A. Updated:
Telephone: (269) 427-5611/ Facsimile: (269) 427-8781/ E-mail: info@getman.com. 01/19/09
TROUBLESHOOTING CHECK F1002
LIST Page 1 of 2
CAUSE REMEDY
ENGINE WON’T CRANK
1. SHIFT LEVER IN WRONG POSITION 1. APPLY TO NEUTRAL

2. PARK BRAKE NOT APPLIED 2. APPLY PARK BRAKE
3. MAIN FUSE IN BATTERY BOX 3. REPLACE FUSE
BLOWN
4. DEAD BATTERY 4. CHARGE OF REPLACE
5. LOOSE OR CORRODED CABLES 5. CLEAN AND TIGHTEN
6. NEUTRAL START SWITCH FAULTY 6. REPLACE SWITCH
7. START SWITCH FAULTY 7. REPLACE SWITCH
8. STARTER FAULTY 8. REPLACE STARTER
ENGINE CRANKS BUT WON’T START
1. OUT OF FUEL 1. FILL TANK

2. SHUT OFF VALVES CLOSED 2. OPEN VALVES
3. FUEL FILTER PLUGGED 3. REPLACE FILTER
4. FUEL LINES LEAKING 4. TIGHTEN ALL LINES
5. PREHEAT FAILS 5. TIGHTEN TERMINALS, REPLACE IF
NEEDED
ENGINE OVERHEATS
1. BROKEN FAN BELT 1. REPLACE BELT

2. AIR INLET OBSTRUCTED 2. REMOVE OBSTRUCTION
3. LOW COOLANT LEVEL 3. FILL SYSTEM. CHECK FOR LEAKS
4. RADIATOR BLOCKED 4. CLEAN WITH COMPRESSED AIR OR
HIGH PRESSURE WATER
LOW OIL PRESSURE
1. LOW OIL LEVEL 1. FILL TO PROPER LEVEL. CHECK

FOR LEAKS.
2. PRESSURE GAUGE FAULTY 2. REPLACE GAUGE
3. RELIEF VALVE FAULTY 3. CLEAN OR REPLACE
4. OIL PUMP WORN 4. REPLACE PUMP
5. EXCESSIVE WEAR IN BEARINGS 5. REBUILD OR REPLACE ENGINE
TRANSMISSION NOT FUNCTIONING PROPERLY
1. LOW OR ERRATIC TRANSMISSION 1. ADD TRANSMISSION OIL. CHECK

CHARGE PRESSURE. FOR LEAKS.
2. TRANSMISSION PRESSURE DROPS 2. VERIFY CLUTCH FOR LEAKAGE.
ONLY IN CERTAIN GEARS. REPAIR.
Updated:
04/26/07
TROUBLESHOOTING CHECK F1002
LIST Page 2 of 2
3. PRESSURE OK BUT NOT ENGAGING 3. VERIFY CONTROL VALVE
CERTAIN GEARS ELECTRICAL SOLENOIDS
CONNECTIONS.
SEE “CONVERTER AND TRANSMISSION – SECTION 5” OF SPARE PARTS AND
MAINTENANCE MANUAL.
PARKING BRAKE NOT HOLDING PROPERLY
1. BRAKE OUT OF ADJUSTMENT 1. READJUST

2. BRAKE PADS WORN OUT 2. REPLACE PADS
PARKING BRAKE WON’T RELEASE
1. HYDRAULIC PRESSURE LOW 1. CHECK OIL LEVEL AND RELIEF

VALVE SETTING.
2. LOOSE OR BROKEN LINES 2. TIGHTEN OR REPLACE
STEERING SYSTEM NOT FUNCTIONING PROPERLY
1. HYDRAULIC OIL LEVEL TOO LOW 1. FILL TO PROPER LEVEL

2. RELIEF VALVE IN FLOW DIVIDER 2. CLEAN OR REPLACE AND CHECK
TOO LOW RELIEF SETTING
3. HYDRAULIC PUMP WORN 3. REPLACE PUMP
4. STEERING VALVE FAULTY 4. REPLACE VALVE
5. STEER CYLINDER LEAKING 5. REPAIR OR REPLACE
HYDRAULIC SYSTEM NOT FUNCTIONING PROPERLY
1. LOW FLUID LEVEL 1. FILL TO PROPER LEVEL

2. SUCTION STRAINER BLOCKED 2. CLEAN OR REPLACE
3. HYDRAULIC FILTERS PLUGGED 3. REPLACE FILTERS
4. LOOSE CONNECTIONS OR 4. TIGHTEN OR REPLACE
DAMAGED HOSE
5. RELIEF VALVE STICKING 5. CLEAN OR REPLACE
6. RELIEF VALVE SET TOO LOW 6. ADJUST TO PROPER SETTING
7. WORN PUMP 7. REPLACE PUMP
Updated:
04/26/07
PREVENTIVE MAINTENANCE F1004
SCHEDULE FORMS Page 1 of 5
S/N________ HOURS________ DATE_________
SIGNATURE______________________________
DAILY SERVICES
OK PARTS UNIT PERFORM THE FOLLOWING CHECKS

ORDERED DOWN
Tire pressure and condition
Hydraulic fluid level
Engine oil level
Clean intake precleaner dust bowl
Fuel level
Engine belt wear
Grease axle trunnions
Transmission fluid level
Grease top and bottom articulation pins
Grease steer cylinder pins
Hydraulic system leaks
Fuel system leaks
Instrument operation
All controls for movement and adjustment
Park brake performance
Service brake performance
Updated:
01/29/10
S/N________ HOURS________ DATE_________
SIGNATURE______________________________
50 HOUR SERVICE

ORDERED DOWN
Check wheel nut torque
Check battery and clean posts
Check air cleaner service indicator
Check air intake clamps and connections
Clean radiator fins
Check exhaust back pressure
Check for corrosion or deformation on all major
components
Daily services
Updated:
01/29/10
S/N________ HOURS________ DATE_________
SIGNATURE______________________________
250 HOUR SERVICE

ORDERED DOWN
Grease driveline and universal joints
Change transmission fluid
Change transmission filter
Check hydraulic fluid, change if needed.
Change hydraulic filter element
Change differential fluid
Clean axle breather vents
Change engine oil
Change engine oil filter
Change fuel filter
Change fuel water separator
Check park brake adjustment
Check radiator and if equipped exhaust heat
exchanger coolant, change if needed
50 hour services
Daily services
Updated:
01/29/10
S/N________ HOURS________ DATE_________
SIGNATURE______________________________
500 HOUR SERVICES

ORDERED DOWN
Remove internal strainer from hydraulic reservoir
and clean
250 hour services
50 hour services
Daily services
Updated:
01/29/10
S/N________ HOURS________ DATE_________
SIGNATURE______________________________
1000 HOUR SERVICES

ORDERED DOWN
Change differential fluid
500 hour services
250 hour services
50 hour services
Daily services
Updated:
01/29/10
F1005
SERVICE REPORT FORM
Page 1 of 1
MAKE COMMENTS ON FAULTS FOUND – FACT OF YOUR OPINION:
FAULTS FOUND IF ANY:
ACTION TAKEN IF ANY:
PARTS USED:
NOTE: SAFETY FIRST
MAINTENANCE
PERSON’S SIGNATURE:________________________________________ DATE:___________________
SUPERVISOR’S
SIGNATURE:__________________________________________________ DATE:___________________
Updated:
04/26/07
F1006
SHIFT CHANGE CHECK LIST
Page 1 of 1
OK
1 CHECK FUEL OIL LEVEL
2 CHECK ENGINE OIL LEVEL
3 CHECK V-BELT CONDITION
4 CHECK HYDRAULIC OIL LEVEL
5 CHECK COMPRESSOR OIL LEVEL
6 CHECK CYLINDER PINS AND KEEPERS
7 CHECK ALL HYDRAULIC HOSES FOR LEAKS OR
WEAR
8 CHECK HORN AND LIGHTS
9 SECURE BIN DOOR
10 CHECK WHEEL LUG NUTS
11 CHECK FOR MISSING OR LOOSE NUTS, BOLTS OR
SCREWS
12 TEST PARKING BRAKE
Updated:
04/26/07
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
2. CHASSIS
10368 SIGHT GAUGE

10376 FILL CAP (FUEL OIL)
10398 FILL CAP (HYDRAULIC OIL)
10448 HOLD DOWN FASTENERS
13524 SEAT ASSEMBLY (DRIVER)
13936 SEAT ASSEMBLY (PASSENGER)
13942 STEERING (PINS, BEARINGS, BUSHINGS)
12043 ARTICULATION INSTALLATION
10368
SIGHT GAUGE
Page 1 of 1
ITEM PART # DESCRIPTION QTY.

1 53011 WINDOW SIGHT GAUGE 1
Updated:
12/11/06
FILL CAP 10376
Page 1 of 1

392012 CAP & SCREEN ASSEMBLY (INCLUDES ITEMS 1, 2) 1
1 NSS CAP 1
2 NSS SCREEN 1
Updated:
03/08/07
10398
FILL CAP (HYDRAULIC OIL)
Page 1 of 1

52500 CAP & SCREEN ASSEMBLY 1
1 54048 CAP 1
2 54003 SCREEN 1
Updated:
12/11/06
10448
HOLD DOWN FASTENERS
Page 1 of 1

1 132130 HOLD DOWN ASSEMBLY (INCLUDES ITEMS 5, 6) 1
2 594535 CLIP (USE AS REQUIRED) 1
3 01GE04 WASHER 4
4 01GC04008 BOLT 4
5* NSS STRAP 1
6* NSS CLIP (90 DEGREE MOUNT) 1
*ITEMS NOT SHOWN Updated:

12/11/06
13524
SEAT (DRIVER)
Page 1 of 1

424370 SEAT ASSEMBLY 1
1 424384 COVER (BACK) 1
2 424385 BOTTOM CUSHION 1
3 424386 KNOB (BACK ADJUSTMENT) 1
4 424375 SHOCK ABSORBER 1
5 424388 TRACK SET (SOLD IN SETS) 1
6 424389 KNOB (HEIGHT CONTROL) 1
7* 424364 SEAT BELT RETRACTABLE 1
8* 424381 ARMREST (OPTIONAL) (SOLD IN SETS) 1

11/06/08
13936
SEAT ASSEMBLY
Page 1 of 1

424371 SEAT ASSEMBLY 1
1 424392 CUSHION (BACK) 1
2 595327 ARMREST (OPTIONAL) (SET) 1
3 424391 CUSHION (BOTTOM) 1
4 424390 TRACK SET (SET) 1
5* 424381 SUSPENSION (SEAT) (OPTIONAL) 1
6* 424364 SEAT BELT 1

05/25/07
STEERING (PINS, BEARINGS, 13942
BUSHINGS) Page 1 of 1

1 26409-01 BEARING (IN CYLINDER TUBE END) 2
2 524202 BUSHING (STEERING EAR) 8
3 13796-01 PIN (STEERING CYLINDER) 4
4 SEE SECTION 8 STEERING CYLINDER 2
5 524203 BUSHING (STEERING CYLINDER) 2
Updated:
10/17/07
12043
ARTICULATION JOINT
Page 1 of 3
Updated:
04/24/09
12043
ARTICULATION JOINT
Page 2 of 3

464332 ARTICULATION JOINT KIT (LRD 220) 1
(INCLUDES ITEMS 1-14)
464469 ARTICULATION JOINT KIT (A-64 WIDE) 1
464579 ARTICULATION JOINT KIT (A-64 STANDARD) 1
464739 ARTICULATION JOINT KIT (LRD 220) 1
1 NSS JOINT PLATE 2
2 10697-01 CAP PIN 1
3 16369-02 BUSHING - CAP SIDE 2
4 594572 SHIM CAP (.005 IN.) (.13MM) A/R
594573 SHIM CAP (.007 IN.) (.18MM) A/R
594574 SHIM CAP (.020 IN.) (.51MM) A/R
5 16367-03 BEARING INSERT ASSEMBLY (INCLUDES ITEM 8) 2
6 594575 SHIM INSERT (.005 IN.) (.13MM) A/R
594576 SHIM INSERT (.007 IN.) (.18MM) A/R
594577 SHIM INSERT (.020 IN.) (.51MM) A/R
7 NSS JOINT PLATE 2
8 264032 BEARING 2
9 16369-03 BUSHING PIN SIDE 2
10 13796-03 PIN 2
11 NSS JOINT PLATE 2
12 73GC08024 CAP SCREW (SCKT HD) 12
13 17GC08024 CAP SCREW (HEX HD) 12
14 464420 CAP SCREW (HEX HD) 6
15 10697-01 CAP PIN 1
Updated:
04/24/09
12043
ARTICULATION JOINT
Page 3 of 3
1. MALE ASSEMBLY: INSTALL BEARING – INSERT (ITEM 5) WITH 3 SOCKET HEAD

CAPSCREWS (ITEM 12) EQUALLY SPACED WITH NO SHIMS. TORQUE SOCKET HEAD
CAPSCREWS TO (65 LB. FT.) (88N-M) AND MEASURE THE SPACE FOR THE NUMBER
OF (7” DIA.) (178MM) B.C. SHIMS REQUIRED (APPROX. .060). DISASSEMBLE AND
INSERT REQUIRED NUMBER OF SHIMS, REASSEMBLE AND INSTALL 6 SOCKET
HEAD CAPSCREWS (ITEM 12) WITH LOCKTITE AND TORQUE TO (100 LB. FT.) (135 N-
M). REPEAT PROCESS FOR BOTH TOP AND BOTTOM OF JOINT.
2. JOINT ASSEMBLY: INSTALL BUSHINGS (TOP ITEM 3, BOTTOM ITEM 9) WITH PIN
(ITEM 10) AND CAP (ITEM 2) AND CAPSCREW (ITEM 14) TORQUE TO (100 LB. FT.) (135
N-M) AND MEASURE THE SPACE FOR THE NUMBER OF (5 ¾”) (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:
04/24/09
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
3. ELECTRICAL SYSTEM AND INSTRUMENTS
30343 WIRING DIAGRAM

17143 INSTRUMENT PANEL
13747 ENGINE FUNCTION DISPLAY
S1100 MURPHY POWERVIEW OPERATION MANUAL
13663 ALTERNATOR
17143
INSTRUMENT PANEL
Page 1 of 2
465313-100-OV

1 124454 ENGINE POWERVIEW GAUGE 1
2 124455 ENGINE WARNING ALARM 1
3 124421 CONVERTER PRESSURE GAUGE 1
* 124278 CONVERTER PRESSURE SENDER 1
4 124403 TRANSMISSION TEMPERATURE GAUGE 1
* 124406 TRANSMISSION TEMPERATURE SENDER 1
5 134019 PARK BRAKE SWITCH 1
* 134020 PARK BRAKE BUTTON 1
6 124396 VOLTMETER 1
7† 124148 WORK LIGHT SWITCH (OPTIONAL) 1
124461
8 122100 HORN BUTTON 1

†CONFIRM WHICH PART NUMBER IS USED ON YOUR TRUCK 03/11/08
17143
INSTRUMENT PANEL
Page 2 of 2
9 134117 (10 AMP)CIRCUIT BREAKER A/R
134009 (20 AMP)CIRCUIT BREAKER A/R
134118 (30 AMP)CIRCUIT BREAKER A/R
10 N/A SPARE SPACE N/A
11 124498 PLC RESET SWITCH 1
12† 124148 PTO FAST IDLE SWITCH (OPTIONAL) 1
124461
13 122100 PARK BRAKE TEST BUTTON 1
124433 GREY CAP 1
14 124195 LOW FUEL LIGHT (OPTIONAL) 1
15 124380 START SWITCH 1
16 124501 TOGGLE LIGHT SWITCH 2
17† 124148 BEACON LIGHT SWITCH (OPTIONAL) 1
124461
18 124148 CANOPY LIGHT SWITCH (OPTIONAL) 1
124461
19 SEE GETMAN WARNING PANEL 1
20* 464670 RESISTOR PACK 1

†CONFIRM WHICH PART NUMBER IS USED ON YOUR TRUCK 03/11/08
ENGINE FUNCTION DISPLAY 13747
PANEL Page 1 of 1

1 124454 MURPHY POWERVIEW DISPLAY 1
2 124457 MURPHY AUDIO ENGINE ALARM 1
Updated:
12/14/06
S1100
PowerView™
Model PV-101
User’s Guide
Rev 09-10-08 00-02-0605
Catalog Section 78
S1100
In order to consistently bring you the highest quality, full
featured products, we reserve the right to change our
specifications and designs at any time. The latest version of
this manual can be found at www.fwmurphy.com.
Warranty - A limited warranty on materials and

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

MURPHY PRODUCT:
• Disconnect all electrical power to the machine.
• Make sure the machine cannot operate during
installation.
• Follow all safety warnings of the machine
manufacturer.
• Read and follow all installation instructions.
S1100
Table of Contents
Introduction............................................................................. 1
Engine and Transmission Parameters 2
Faceplate Features 3
Navigation and Keypad Functions 4
Operation ................................................................................. 9
PowerView Menus (First Time Start Up) 9
Setting Up the Display 12
Main Menu Options 18
Faults and Warnings 20
Utilities Menu 23
Modbus® Setup 25
Selecting Engine ECU 26
Troubleshooting ................................................................... 27
S1100
Introduction
Congratulations on purchasing your PowerView display, a
multifunction tool that provides a window into the many
parameters and service codes of modern electronic engines
and transmissions.
This guide is intended to help you set up your PowerView

display and identify navigation basics and product features.
The display’s simple navigation and intuitive yet powerful
features allow you to master the product in no time.
Additional information can be found on our website at

www.fwmurphy.com/powerview.
00-02-0605 -1- Rev 09-10-08

S1100
Engine and Transmission Parameters
The following are some of the engine and transmission
parameters which may be displayed in standard or metric
units as well as in English, Spanish, French, Italian, or
German languages (when applicable, consult engine or
transmission manufacturer for SAE J1939 supported
parameters):
• Engine RPM • Transmission oil

• Engine hours pressure
• System voltage • Transmission oil
• Percent engine load at the temperature
current RPM • Transmission gear
• Coolant temperature position
• Oil pressure • Engine configuration
• Fuel economy parameters
• Throttle position • Active fault codes
• Engine manifold air • Stored fault codes
temperature
• Current fuel consumption
00-02-0605 -2- Rev 09-10-08

S1100
Faceplate Features
00-02-0605 -3- Rev 09-10-08

S1100
Navigation and Keypad Functions
The keypad on the PowerView display is a capacitive touch
sensing system. There are no mechanical switches to wear
or stick. When a key is touched, feedback is provided by the
screen flashing. The keys on the keypad perform the
following functions:
Menu – Enter or exit menu screens.
Left Arrow – Scroll the screen or move the

parameter selection to the left or upward.
Right Arrow – Scroll the screen and move
the parameter selection to the right or
downward.
Enter Key – Select a menu or parameter or

hide/view an active fault code.
00-02-0605 -4- Rev 09-10-08

S1100
Basic Navigation
1. When Menu is pressed, the main menu items are
displayed.
00-02-0605 -5- Rev 09-10-08

S1100
2. Touching the Arrow Keys will move the selection bar to
other menu items.
00-02-0605 -6- Rev 09-10-08

S1100
3. Certain menus have multiple pages of items. Scrolling
past the top item or bottom item on the current page will
reveal other menu items on additional pages.
00-02-0605 -7- Rev 09-10-08

S1100
4. When the desired item is highlighted by the cursor,
pressing Enter will select that item and display the
corresponding screen.
5. Anytime the word MORE appears above the Arrow

Keys there are more screens that may be viewed. Use
the Arrow Keys to scroll to the next screen of
information.
00-02-0605 -8- Rev 09-10-08

S1100
Operation
PowerView Menus (First Time Start Up)
1. When power is first applied to the display, the Murphy
logo appears.
00-02-0605 -9- Rev 09-10-08

S1100
2. If the Engine ECU is broadcasting a 'Wait To Start'
message, this screen will be shown. Engine
manufacturers typically recommend against starting the
engine while this message is broadcasted from the
ECU. Once the ECU stops broadcasting this message,
this screen will no longer be displayed.
00-02-0605 - 10 - Rev 09-10-08

S1100
3. Once the engine has started, the single engine
parameter appears with the engine RPM displayed.
Pressing the Right Arrow Key will display the coolant
temperature. The screen can be changed to other
parameters by pressing Menu.
00-02-0605 - 11 - Rev 09-10-08

S1100
Setting Up the Display
The screen may be configured to display a single engine
parameter (1-up display), or four parameters at once (4-up
display). Default options are provided or you may customize
the display by selecting the parameters you want.
1-Up Display
Three options are available for modification of the 1-Up
display.
Use Defaults – This option contains a set of engine

parameters: Engine Hours, Engine RPM, System Voltage,
Battery Voltage, % Engine Load at Current RPM, Coolant
Temperature, and Oil Pressure.
Custom Setup – This option allows for the modification of
which parameter, the number of parameters, and the order
in which the parameters are being displayed.
Automatic Scan – Selecting the scan function will cause
the 1-Up Display to scroll through the selected set of
parameters one at a time, momentarily pausing at each.
00-02-0605 - 12 - Rev 09-10-08

S1100
1-Up Display Settings
1. Touch Menu and use the Arrow Keys to highlight
SETUP 1-UP DISPLAY, then press Enter.
2. To select USE DEFAULTS, highlight the option and

press Enter. A message indicating “RESTORED TO
DEFAULTS” is displayed.
3. To select CUSTOM SETUP, highlight the option and

press Enter. A list of engine parameters is displayed.
4. To select a parameter, use the Arrow Keys to scroll

and highlight the parameter, then touch Enter.
Selected parameters are indicated by a # symbol to the

right of it and represent the order in which the
parameter will be displayed.
5. To deselect a selected parameter and remove it from

the list of displayed parameters, highlight the parameter
and touch Enter.
00-02-0605 - 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.
7. Selecting the AUTOMATIC SCAN ON function will

cause the 1-up display to scroll through the selected set
of parameters one at a time.
8. Once the USE DEFAULTS, CUSTOM SETUP and

AUTOMATIC SCAN functions have been set, touch
Menu once to return to the main menu, or twice to
display the 1-up display screen.
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.
1 = upper left quadrant

2 = lower left quadrant
3 = upper right quadrant
4 = lower right quadrant
6. Use the Arrow Keys to highlight the new parameter to

be placed in the quadrant that was selected in step 4
and touch Enter.
7. Touch Menu to return to the 4-UP CUSTOM SETUP

screen.
00-02-0605 - 16 - Rev 09-10-08

S1100
8. The parameter in the selected quadrant has changed to
the parameter selected in the previous screen.
9. Repeat the parameter selection process until all spaces

are filled.
00-02-0605 - 17 - Rev 09-10-08

S1100
Main Menu Options
This section describes the features listed on the main menu
of the PowerView. These menu options are displayed
whenever you touch Menu. The Arrow Keys allow you to
scroll the items, and Enter selects the highlighted option.
Selecting a Language
From LANGUAGES, you may select ENGLISH, ESPANOL,
FRANCAIS, ITALIANO, or DEUTSCH. The currently
selected language is indicated by an asterisk.
Stored Fault Codes*

Request stored fault code information.
Engine Configuration Data*

ENGINE CONFG allows you to scroll through engine
configuration data.
* This function may not be supported by all manufacturers.

00-02-0605 - 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
Faults and Warnings
The PowerView provides two means for detecting faults and
warnings: visual LEDs on the casing (See “Faceplate
Features”) and fault indicators on the display.
Visual Indication
• Amber LED (Warning)
• Red LED (Derate / Shutdown)
Fault Indicators
00-02-0605 - 20 - Rev 09-10-08

S1100
Auxiliary Gage Fault
Murphy’s PVA Gages can be attached to the PowerView. If
an auxiliary gage should fail, the 1-up or 4-up display will be
replaced with the fault message “GAGE NOT
RESPONDING”.
NOTE: The fault can only be cleared by correcting the

cause of the fault condition.
Active Fault Codes

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

When the PowerView receives a severe fault code from an
engine control unit the 1-up or 4-up display will be replaced
with the SHUTDOWN message.
00-02-0605 - 21 - Rev 09-10-08
S1100
Acknowledging Fault Codes
1. To acknowledge and hide the fault and return to the
1-up or 4-up display, touch Enter. The display will
return to the 1-up or 4-up display, but the display will
contain the shutdown icon.
2. Touch Enter to redisplay the hidden fault. Touch Enter

once again will hide the fault and return the screen to
the 1-up or 4-up display.
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 ECU’s use Version 4,
therefore in most cases adjustment of this menu option
will not be required.
Upon receiving an unrecognizable fault, change to a

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

accept an optional backlighting dimmer.
• FUEL LEVEL accepts an optional Murphy fuel

sender (model ES2F recommended) for fuel level
information.
7. SELECT ENGINE ECU – listens to all ECUs or scrolls

to a specific engine ECU.
00-02-0605 - 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
Selecting Engine ECU
1. From the UTILITIES menu, choose SELECT ENGINE
ECU.
2. The message “LISTEN TO ECU: ALL” is displayed as
the default setting, and indicates the PV101 is listening
to all devices on the network.
3. To change the setting to a specific address, press the
Arrow Keys to scroll through the numbers (0-253).
4. Once the target address is displayed, press Enter.
5. A confirmation screen displays. Selecting “NO” (shown
above Menu key) returns to the SELECT ENGINE ECU
screen. Selecting “YES” (shown above Enter key)
stores the selected address and returns to the
UTILITIES menu.
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
“NO STORED CODES” is displayed
The PowerView sent a request to the ECU for Stored Fault
Code (DM2) information, and the ECU responded. There
are zero stored codes.
“NO GAGE DATA” is displayed

The PowerView has no record of gages connected to the
RS485 bus.
“NO DATA” is displayed in place of a parameter value

The PowerView has not received data for the selected
parameter for at least 5 seconds.
“NOT SUPPORTED” is displayed in place of a parameter

value
The ECU is sending a message that it does not support this
parameter.
00-02-0605 - 28 - Rev 09-10-08

S1100
“DATA ERROR” is displayed in place of a parameter value
The ECU is sending a message that there is a data error
with this parameter. Or (PV101 only) FUEL LEVEL has
been selected for display, ANALOG INPUT has been set to
FUEL LEVEL, but no Murphy Fuel Sender has been
connected to the analog input.
One of the 4-UP quadrants is empty

No parameter has been selected for display in this
quadrant.
Display is not readable, either very dim or very dark

The LCD contrast may have been over or under adjusted.
Press and hold the MENU key for approximately 5
seconds. This will reset the LCD contrast setting to factory
default.
00-02-0605 - 29 - Rev 09-10-08

S1100
0710172
02-13-07
Section 78
PowerView™ - Model PV101 – Troubleshooting

Message Translation
“WAIT TO START PREHEATING” is The ECU is broadcasting a 'Wait To Start'
displayed 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
PV100/PV101 Implementation of SAE J1939 Parameters*

Source: SAEJ1939-71 Surface Vehicle Recommended Practice
Description PGN Parameter Display Value
Elec Eng Cont #2 - EEC2 61443 Accelerator Pedal Position THROTTLE

Percent Load at Current RPM LOAD@RPM
Elec Eng Cont #1 - EEC1 61444 Actual engine % torque ENG TORQ
Engine Speed ENG RPM
Engine hours, Revolutions 65253 Total Engine Hours ENG HRS
Fuel Consumption 65257 Trip Fuel TRIP FUEL
Total Fuel Used FUEL USED
Engine Temperature 65262 Engine Coolant Temp COOL TEMP
Fuel Temperature FUEL TEMP
Engine Oil Temperature OIL TEMP
Engine Intercooler Temperature INTC TEMP
Engine Fluid Level/Pressure 65263 Fuel Delivery Pressure FUEL PRES
Engine Oil Level OIL LVL
Engine Oil Pressure OIL PRES
Coolant Pressure COOL PRES
Coolant Level COOL LVL
Fuel Economy 65266 Fuel Rate FUEL RATE
Instantaneous Fuel Economy FUEL ECON
Average Fuel Economy AVG ECON
Ambient Conditions 65269 Barometric Pressure BARO PRES
Air Inlet Temperature AIR IN TP
Inlet/Exhaust Conditions 65270 Boost Pressure BST PRES
Intake Manifold Temp MANI TEMP
Air Filter Differential Pressure AIR DIF PR
Exhaust Gas Temperature EXH TEMP
Engine Fluid Level/Pressure #2 65243 Injector Metering Rail 1 Pres INJ PRES1
Injector Metering Rail 2 Pres INJ PRES2
Fan Drive-FD 65213 Estimated Percent Fan Speed FAN SPD
65226 DM1 - Active Diagnostic SRVCCODE
Diagnostic Messages 65227 DM2 - Previously Act Diag Codes STORCODE
65228 DM3 - Diagnostic Clear
Machine Hours (PowerView Calculated) N/A Machine Hours MACH HRS
Engine Conf. 65251 Engine Configuration ENG CONF
Hydraulic Pressure Governor Info-HPG 61448 Hydraulic Oil Pressure HYD PRES
Electronic Transmission Controller #1 61442 Output Shaft Speed OUT SFT SP
Electronic Transmission Controller #1 61442 Input Shaft Speed IN SFT SPD
Electronic Transmission Controller #1 61442 Torque Converter Lockup Engaged TORQ LOCK
Electronic Transmission Controller #2 61445 Selected Gear SLECT GEAR
61445 Current Gear CURNT GEAR
Transmission Fluids 65272 Transmission Oil Pressure TRAN PRES
Transmission Oil Temperature TRAN TEMP
Transmission Control 1-TC1 256 Requested Gear REQ GEAR
Auxiliary Pressures & Temperatures 65164 Auxiliary Temperature AUX TEMP
Auxiliary Pressure AUX PRES
Auxiliary Input/Output Status 65241 Auxiliary I/O #1 AUX 10 1
Cruise Control /Vehicle Speed 65265 Wheel Based Vehicle Speed VEH SPD
Alternator Voltage ALT VOLT
Vehicle Electrical Power 65271 Electrical Potential (Voltage) SYS VOLT
Battery Pot. Voltage (Switched) BAT VOLT
Vehicle Distance 65248 Trip Distance TRIP DIST
Total Vehicle Distance VEH DIST
Vehicle Fluids-VF 65128 Hydraulic Oil Temperature HYD TEMP
Dash Display-DD 65276 Fuel Level FUEL LEVEL
Rudder 127245 Rudder Angle RUD ANG
Speed 128259 Water Referenced H20 REF.SP
Small Craft Status, Port Trim 130576 Port Trim Tab P TRIM TAB
Small Craft Status, Starboard Trim 130576 Starboard Trim Tab S TRIM TAB
Support Allison DTCs Retarded Temperature Above Normal RETARDED OIL TEMPERATURE ABOVE NORMAL
(SPN=120, FMI=15)
Transmission Oil Temperature Above TRANSMISSION OIL TEMPERATURE ABOVE NORMAL
Normal (SPN=177, FMI=15)
Unknown General Transmission Fault GENERAL TRANSMISSION FAULT UNKNOWN
(SPN=2003, FMI=31)
*PV100-A, software version Murphy 2.09

PV101-A, software version Murphy 1.00.06
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.
13663
ALTERNATOR
Page 1 of 1

146009 ALTERNATOR (DETROIT OM904 24V) A/R
146010 ALTERNATOR (DETROIT OM906 24V) A/R
1* 146015 ALTERNATOR BELT 56.5” LONG (DETROIT OM904) A/R
USED WITH LARGE DIA ALT PULLEYS, NO AIR
CONDITION. USED APPROX BEFORE 2006.
FIRST USED ON S/N 6758, WITH AIR CONDITION, NO
SPACERS USED WITH A/C COMPRESSOR TO ENGINE
USED WITH LARGE DIA ALT PULLEY
NO AIR CONDITION, USED APPROX 2006-NOV 2008
4* 146074 ALTERNATOR BELT 76” LONG (DETROIT OM904) A/R
WITH AIR CONDITION, USED APPROX 2006-NOV 2008
WITH AIR CONDITION, STARTING DEC 2008
6* 9041-10013 ALTERNATOR BELT 55” LONG (DETROIT OM904) A/R
NO AIR CONDITION, STARTING DEC 2008
7* 146041 ALTERNATOR BELT 58” LONG (DETROIT OM906) A/R

05/27/10
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
4. ENGINE AND ACCESSORIES
F1007 DETROIT DIESEL WARRANTY

S1034 ENGINE OPERATION MANUAL
S1078 ENGINE MAINTENANCE MANUAL
S1035 ENGINE PARTS MANUAL
13807 ENGINE FILTERS
13661 RADIATOR INSTALLATION
13660 CHARGE AIR INSTALLATION
13713 AIR INTAKE SYSTEM
11637 AIR CLEANER
13676 EXHAUST SYSTEM
17309 EXHAUST INSULATION INSTALLATION
S1020 EXHAUST INFORMATION
Limited Warranty on New Detroit Diesel F1007
Series 900 Engines Used In Agricultural,

Construction and Industrial Applications
Terms of Coverage: This Warranty Does Not Cover:

Uses Repairs Due To Accidents, Misuse, Storage Damage,
This warranty applies to the first retail purchaser and subsequent Negligence or Certain Modifications
owners during the WARRANTY PERIOD of new Detroit Diesel Series Repairs due to an accident, misuse, misapplication, storage dam-
900 engines (referred to as Engine) manufactured or supplied by age, negligence or modification exceeding DDC specifications, are
Detroit Diesel Corporation (referred to as DDC) which are used in not covered by this warranty.
construction and industrial applications operated in the United
States, Canada or Mexico. Non-DDC Supplied/Manufactured
Components
Defects DDC is not responsible for repair of components and/or assemblies
This warranty covers Engine REPAIRS to correct any malfunction which are supplied by another manufacturer, such as power take-
occurring during the WARRANTY PERIOD resulting from defects in offs, intake and exhaust system. Such items may be covered by the
material or workmanship. manufacturer or supplier.
Repairs Maintenance
To obtain warranty repairs, you must request the needed repairs DDC is not responsible for the cost of maintenance or repairs due to
within the WARRANTY PERIOD from an authorized Detroit Diesel lack of performance of required maintenance service or the failure to
Corporation (referred to as DDC)* service outlet. Only new genuine use fuel, oil, lubricants and coolant meeting DDC-recommended
parts or remanufactured parts or components supplied or approved specifications. Performance of required maintenance and use of
by DDC will be used. DDC may, at its discretion, replace rather than proper fuel, oil, lubricants and coolant are the responsibility of the
repair components. A reasonable time must be allowed to perform owner. See the Operating Manual for details.
the warranty repair. Repairs will be performed during normal busi-
ness hours. Incidental or Consequential Damages
DDC is not responsible for incidental or consequential costs or
Warranty Period expenses which the owner may incur as a result of a malfunction or
The WARRANTY PERIOD begins on the date the Engine is delivered failure covered by this warranty, such as communication expenses,
to the first retail purchaser or put in use prior to sale at retail, which- meals, lodging, overtime, towing, loss of use of the Engine or equip-
ever date occurs first, and ends at the time limits shown below: ment (“downtime”), loss of time, inconvenience, cargo loss or dam-
age, and other similar costs and expenses.
WARRANTY PERIOD Other Limitations
Warranty Limitations Repair Charge To Be
(Whichever Occurs First) Paid By Owner
The performance of REPAIRS is the exclusive Owner’s remedy under
Item this warranty. DDC does not authorize any person to assume or cre-
MONTHS ENGINE HOURS PARTS LABOR ate for it any other obligation or liability in connection with the Engine.
Engine 0-24 3,000 No Charge No Charge THIS LIMITED WARRANTY IS THE ONLY WARRANTY APPLICABLE
TO THIS ENGINE AS USED IN AGRICULTURAL, CONSTRUCTION
AND INDUSTRIAL APPLICATIONS. DETROIT DIESEL CORPORA-
Service Supplies TION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED,
INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FIT-
The cost of service supplies such as coolant, oil and filters, which are
NESS FOR A PARTICULAR PURPOSE. DETROIT DIESEL CORPO-
not reusable due to needed repairs is covered by this warranty.
RATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CON-
SEQUENTIAL DAMAGES AS DESCRIBED ABOVE.
Like Replacement Engine
Engine(s) supplied by DDC as a replacement for an Engine still Some states do not allow the limitation of how long this warranty may
under warranty will assume the identity of the Engine being replaced last or the limitation or exclusion of incidental or consequential
and be entitled to the remaining warranty coverage. damages, so the above may not apply to you. This warranty gives
you specific legal rights, and you may also have other rights which
Mechanic’s Travel Expenses may vary from state to state.
Mercedes-Benz will pay reasonable travel expenses for the repairing
mechanic to travel to and from the repair site.
Engine Removal And Reinstallation

Reasonable labor costs for engine removal and reinstallation, when
necessary to make a warranty repair, are covered by this warranty.
*In Canada, the reference is to Detroit Diesel of Canada Limited, in

Mexico, the reference is to Detroit Diesel Allison de Mexico.
17SE702 0202 Conditions of this offer are subject to change without notice. Printed in U.S.A.
S1034
OM 904 LA - OM 906 LA - OM 924 LA - OM 926 LA Operating Instructions
Mercedes-Benz
S1034
Thank you for choosing this the art. You cannot, therefore, base any
Mercedes-Benz engine. claims on the data, illustrations or descrip-
tions in these Operating Instructions.
Please get to know your new Mercedes-
Benz engine first. Make sure you read the For further information contact a
Operating Instructions in particular before Mercedes-Benz Service Centre.
using the engine for the first time. In this
The Operating Instructions and Mainte-
way you can ensure successful and safe
nance Booklet belong with the engine. You
use. At the same time you will avoid endan-
should therefore always keep them with
gering yourself and others when operating
the engine and pass them on to the new
the engine.
owner if you sell it.
Items of special equipment are marked
The technical documentation team at
with an asterisk *. The equipment in your
DaimlerChrysler AG wishes you every suc-
Mercedes-Benz engine may vary, depend-
cess.
ing on the version. Mercedes-Benz is con-
stantly updating its engines to the state of
S1034
introduction 4 Safety Cleaning/protective treatment 55

Cleaning the engine 55
The aim of these Operating Safety precautions 36 Cleaning the cooling system 56
Instructions 5 Personnel qualifications 37 Protective treatment. 58
Symbols 6 Conversion parts and Service products 59
Protection of the environment 7 modifications 38 Diesel fuels 60
Operating safety 8 Safety / emergency running Engine oils 62
Correct use 9 programs 39 Coolant 63
Genuine Mercedes-Benz parts 40
2 At a glance Maintenance
5 Operation
OM 904 LA/OM 924 LA 12 Maintenance instructions 66
OM 906 LA/OM 926 LA 16 Commissioning 42 Overview of work plans 67
Location of sensors 20 Preparation 42 Maintenance service 67
Engine plate 22 Starting the engine for the first Additional work 67
time 44 Additional work during every
3 Before commissioning
Starting the engine 47 3rd maintenance service 67
General 24 Monitoring engine operation 49 Work plans 68
Type designation 24 Charge current 49 Engine: Checking for leaks and
Engine data card 24 Telligent@ engine system 50 general condition 68
Description of the engine 25 Flame-start system* 50 Lines and hoses on the engine:
Flame-start system* 26 Grid heater* 51 Checking for leaks and general
Grid heater* 27 Stopping the engine 52 condition 68
Exhaust brake / constantly-open Winter operation 53 Engine: Oil change and filter
throttle valve* 28 replacement 69
Telligent@ engine system 29 Adjusting the valve clearance 73
Transport and installation 33
S1034
Fuel prefilter: Cleaning the filter 7 Practical advice

element. 77
Fuel prefilter with heated water Malfunctions, causes and
separator*: Replacing the filter solutions 98
element. 78 Jump-starting 106
Replacing the fuel filter element. .. 80
8 Technical data
Intake pipe between air cleaner
and engine: Checking for leaks Engine data 108
and general condition 82 Test values and adjustment
Poly-V-belt: Checking values 112
the condition 83 Tightening torques 113
Engine brake: Checking the
Glossary and index
condition and setting 88
Engine cooling system: Checking Technical terms 115
and correcting the fluid level Index 117
and the antifreeze / corrosion
inhibitor 90
Cooling and heating system:
Checking for leaks and general
condition 91
Renewing coolant 94
S1034
The aim of these Operating Instructions

~ The aim of these Operating Instructions
These Operating Instructions are intended 5 Operation The engine documentation comprises the
to assist you in all situations with your new following:
engine. Each section has a list of contents Here you will find all the information you o these Operating Instructions
to help you find the information you re- will need when you are operating the en-
quire quickly: .. the Maintenance Booklet
gine.
2 At a glance .. Specifications for Service Products
6 Maintenance
You may receive additional supplements
This section gives you an overview of the This is where you will find more detailed in- depending on the equipment.
layout of important components in the en- formation about maintenance work.
gine.
7 Practical advice
3 Before commissioning
Here you will find practical help for possi-
This contains the basic information you re- ble problems.
quire for initial operation. If this is your first
Mercedes-Benz engine, you should read 8 Technical data
this section first.
All the important technical data for the en-
Safety gine is listed here.
9 Glossary and index
This section contains important aspects
with regard to safety when handling
Mercedes-Benz 900 series engines. The glossary of technical terms explains
the most important technical concepts.
The index is intended to help you find infor-
mation quickly.
S1034
Symbols
T Symbols
You will find the following symbols used in ~ This symbol means that you have to do
1
....... these Operating Instructions: Environmental note something.
* This asterisk indicates special ~ A number of these symbols one after

An environmental note givesyou tips on the
equipment. Since not all models the other indicates a sequence of ac-
protection of the environment.
have the same standard equip- tions.
ment, the layout of your engine may
differ from certain descriptions and
illustrations. :I."This note draws your attention to possi-
ble hazards to your engine.
[>
[>[>
page This symbol indicates the page
on which you will find further in-
formation on the subject.
This continuation symbol indi-
Warning cates an interrupted sequence
A warning draws your attention to possible I e of actions that will be continued
I
This tip contains advice or further infor- on the next page.
risks of accident and injury to yourself and mation you may find useful.
others. -> This symbol in the glossary of
technical terms means that the
You should therefore always read and ob-
term following the arrow is also
serve all warning notices.
explained.
S1034
..... Protection of the environment
Fuel consumption and engine wear depend 1

Environmental note
on the operating conditions.
DaimlerChrysler's declared policy is one of Therefore you should:

integrated environmental protection. This " not warm up the engine at idle
policy starts at the root causes and encom-
" switch off the engine during waiting pe-
passes in its management decisions all the
riods imposed by operations
consequences for the environment which
could arise from production processes or .. monitor fuel consumption
the products themselves. .. carry out the specified maintenance
work regularly
The objectives are for the natural resources
which form the basis of our existence on this
planet to be used sparingly and in a manner
which takes the requirements of both nature
and humanity into account.
Operate the engine in an environmentally-

responsible manner, and you will help to
protect the environment.
S1034
Operating safety
T Operating safety
1 The operating safety of an engine firstly de-
...... pends on its proper installation into the Risk of accident Risk of accident
complete system (e.g. vehicle, machine,
etc.). Secondly, as operator or service per- Improper operation of the engine, e.g. ex- Faulty maintenance work or failure to carry
sonnel, you also have a direct influence on ceeding the permitted maximum engine out maintenance work, e.g. not changing the
the safe operation of the engine. speed in overrun mode or operating the en- oil filter or not observing the correct mainte-
gine with too little oil, can cause engine nance interval, can cause engine damage.
Some of the requirements for operating
damage. Engine damage can lead to an in- Engine damage can lead to an increase in
the engine safely can be achieved by ad-
crease in the risk of accident. the risk of accident.
hering to the specified maintenance inter-
vals and ensuring that the required Therefore, observe the notes on operating Therefore, observe the notes on engine
maintenance work is carried out correctly. the engine in these Operating Instructions. maintenance in these Operating Instruc-
tions.
However, safe engine operation also de-
pends on correct servicing, such as check-
ing the engine oil level at regular intervals.
S1034
Correct use
Risk of accident
The engine is only designed for installation
in accordance with the specifications de-
Work incorrectly carried out on electronic
termined in the contract.
components and its software could impair
the functioning of these components. Since The manufacturer of the end product is
the electronic systems are networked, this personally responsible for the complete
might also affect systems that have not system of the end product, and in particu-
been modified. lar for the correct installation and compat-
Always have work on or modifications to ibility of this engine with the complete
electronic components carried out at a qual- system.
ified specialist workshop which hasthe nec- The engine must not be modified.
essary specialist knowledge and tools to DaimlerChrysler accepts no responsibility
carry out the work required. for damage caused as the result of modifi-
Mercedes-Benz recommends that you use a cations.
Mercedes-Benz Service Centre for this pur- Correct use of the engine includes adher-
pose. ing to these Operating Instructions, adher-
ing to the maintenance intervals and
performing maintenance work correctly in
accordance with these Operating Instruc-
tions.
S1034
S1034
iocatron of sensors
Engine plate
S1034
OM 904 LAIOM 924 LA

TOM 904 LA/OM 924 LA
7 )-------------..,..,..,.....-,
6 )------...."....~-----;,.:,;.
2
......
5)------~
41----------'
3)--------'
2 } - - -__-....::..,,-
CDl------......,.....~~
G01.00-3123-31
S1034
CD Fan
® Poly-V-belt tensioning pulley
o Coolant pump
@ Charge pressure pipe (with flame-start 2
system *) from intercooler
® Charge pressure pipe to intercooler
@ Crankcase ventilation system
(}) Heating delivery line* coolant line
® Oil filler neck
® Fuel filter
® Fuel prefilter
® Dipstick
@ Air compressor (with power-steering
pump*)
@ Engine control unit
S1034
®l----------==-~
2 }---------------=~ ___
0-----4--
G01.0D-3124-31
S1034
CD Flywheel housing
CD Charge-air housing
® Oil filler neck
8) Charge pressure pipe to intercooler
® Charge pressure pipe (with flame-start
system*) from intercooler
@ Exhaust manifold
o Oil filter
® Exhaust gas turbocharger
® Alternator
@ Starter motor
S1034
OM 906 LA/ OM 926 LA

'If OM 906 LA/OM 926 LA
®r----------------. ':::::::==""'""-----~10
®r-------------F.~___::'
..... 01--------~ -----~11
"------....{12
::!.----~13
GOl.OO-3121-31
S1034
CD Fan
(3) Poly-v-belt tensioning pulley
@ Coolant pump
o Heating forward line* coolant line
® Charge pressure pipe from intercooler
@ Oil filter
o Charge pressure pipe to intercooler
® Oil filler neck
® Charge-air housing
® Cylinder head cover
® Fuel filter
@ Fuel prefilter
@ Engine control unit
@ Air compressor*
@ Dipstick
@ Power-steering pump
S1034
2
......
G01.00-3122-31
S1034
CD Starter motor
CD Flywheel housing
o Exhaust gas turbocharger
o Exhaust manifold
CD Charge-air housing
@ Cylinder head cover
CD Oil filler neck
® Charge pressure pipe to intercooler
® Charge pressure pipe from intercooler
@ Crankcase ventilation system
® Alternator
S1034
.., Location of sensors

OM 904 LA/OM 924 LA (comparable to OM 906 LA/OM 926 LA)
G01.0D-3127-31
S1034
CD Oil pressure sensor

CD Coolant temperature sensor
o Fuel temperature sensor
G) TOCsensor (on the camshaft sprocket)
® Crankshaft position sensor (on the fly-
wheel)
-- 2
@ Combined charge-air / charge-air pres-

sure sensor
S1034
Engine plate
T Engine plate
Location
The engine plate is located on the right-
hand side of the engine at the rear under-
-
2 neath the exhaust manifold (arrow).
Location of engine plate

S1034
S1034
T General
Type designation
OM 9XX L A
OM Oil engine (diesel en-

gine)
--
3
9XX
L
Engine type
Intercooler
A Exhaust gas turbo-
charger
Engine data card

N01.00-2388-31
The engine data card (DIN A4 sheet) forms
Engine data card
an integral part of the documents belong-
ing to the engine and should always be
kept with the Maintenance Booklet. It con-
e
The engine data card describes the
tains details about the engine's construc- scope of delivery from the factory from
tion, including special equipment features. which the engine was shipped; later
The engine data card must be produced for changes to the scope of delivery are
the procurement of genuine parts. not included on the data card.
Always keep the engine data card with
the Maintenance Booklet.
S1034
Description of the engine The control system comprises an engine-

resident control module, an engine control
The OM 904 LA/OM 924 LA (4-cylinder)
(MR) and an application-related vehicle
and OM 906 LA/OM 926 LA (6-cylinder)
control unit (FR) or an adaptation module
engines are water-cooled four-stroke die-
(ADM), all interconnected via the Control-
sel injection engines.
ler Area Network (CAN).
The cylinders are arranged in-line and have 3
separate fuel-injection pumps (unit
...........
pumps) with a short high-pressure fuel-
injection line to the multi-hole nozzle locat-
ed centrally in relation to the combustion
chamber. The unit pumps are mounted di-
rectly on the crankcase. They are driven by
the camshaft roller tappets. Each cylinder
has two inlet valves and one exhaust valve.
The engines are equipped with an exhaust
gas turbocharger (sometimes with charge-
pressure limiting) and intercooler as stand-
ard. The engine can be optionally equipped
with an engine brake* (throttle and con-
stantly-open throttle valves).
Thanks to its fully electronic control sys-
tem for controlling the injection quantity
and injection timing via solenoid valves,
this is a particularly low-emission engine.
S1034
Flame-start system *
The flame-start system is a cold-start aid
for starting at low outside temperatures. It
reduces the white smoke emission after
the engine is started. In addition, it reduc-
3 es the strain on the starter motor and bat-
..... teries by shortening the startup time.
Fuel can be ignited by a flame glow plug in-
tegrated in the charge-air pipe from the in-
tercooler. The fuel is supplied to the flame
glow plug via a solenoid valve with a dosing
jet.
854.30-3770-31
Flame-start system Flame-start system indicator lamp
The flame-start system is primed after a The flame-start system is only operational
preglow time (maximum 20 seconds) if the engine is started within 30 seconds
which is dependent on the outside temper- of the flame-start system indicator lamp
ature. After this time the flame-start sys- going out.
tem indicator lamp goes out.
Once the engine has started, the flame-
start system is supplied with fuel by the en-
gine's fuel delivery pump.
S1034
Grid heater*
If the flame-start system indicator lamp The grid heater is a cold-start aid for start-
does not go out after more than 20 sec- ing at low outside temperatures. The
onds there is a malfunction in the charge-air is preheated by a heater strip in-
flame-start system. tegrated in the charge-air pipe from the in-
tercooler. In addition, it reduces the strain
See also the "Diesel fuels" section on the starter motor and battery by short-
(I> see page 60) and "Coolant" section ening the startup time.
(I> see page 63) for operation of the en-
The white smoke limit is reduced by a run-
gine at low outside temperatures.
on heating time of up to 180 seconds after
starting the engine.
S1034
When the engine brake* is applied, the

Exhaust brake / constantly-open
constantly-open throttle valves are pneu-
throttle valve*
matically pressurised on the 4-cylinder en-
To increase braking power, the engine can gine and hydraulically pressurised on the
be equipped with an engine brake valve on 6-cylinder engine. This opens the valves.
the exhaust gas turbocharger in conjunc- At the same time, the engine brake valve
3 tion with constantly-open throttle valves on the exhaust gas turbocharger is closed .
...... on the cylinders.
The constantly-open throttle valves are not
While the exhaust gas back pressure from controlled at lower engine speeds (900/
the engine brake valve is used to increase 1,300 rpm) or at temperatures below
the braking power, the constantly-open 40 "C. When the power unit is being used,
throttle valves cause a pressure reduction these limitations must be taken into ac-
in the working cycle (3rd cycle), while com- count under braking conditions.
pression (2nd cycle) is practically unaffect-
ed.
Constantly-open throttle valves on a 4-cylin-
The constantly-open throttle valves are der engine
small valves in the cylinder head and locat-
ed on the side opposite the exhaust valve.
When open, they form a connection from
the combustion chamber to the exhaust
port.
S1034
The engine brake* is controlled by the Telligent@ engine system

drive control unit (I> page 31) or the ADM.
The engine has a fully electronic control
The engine brake* is always disabled be- system, which, in addition to the engine
low 900 rpm to prevent the engine from and related sensors, also comprises:
stalling. The engine brake* is also auto-
l1li an engine control unit, and
matically deactivated if the position sensor
is triggered (e.g. if the accelerator pedal is l1li a drive control unit and / or other vehi-
depressed). cle-specific control units or ADM.
Both are interconnected via a CAN (Con-

troller Area Network) line which exchanges
In emergency running mode (constant
all the necessary data / information.
engine speed), the engine brake* can
only be activated in overrun mode at The engine control monitors itself as well
a higher engine speed. The engine as the engine. A safety and emergency run-
brake* is automatically disabled again ning program is selected automatically de-
once the constant engine speed has pending on the malfunctions/failures
< been reached. occurring (I> page 39).
S1034
Engine control unit (engine-resident) This data is evaluated along with data from
the sensors on the engine, such as those
The engine control unit is located on the DaimlerChrysler
for:
left-hand side of the engine. Elect. Control Unit
It charge-air pressure and temperature Calibration Nr. ZGS
G)----H6 I 0011
It coolant temperature ,,; I ,certification Nr.
2
It fuel temperature Unit Identif.
Engine Number
oil pressure
~;-:n7,"it-;:c'"o-;d~e------l
8
These parameters are compared with the 4

characteristic maps and graphs stored in
the engine control unit.
Start, duration and amount of injection are
calculated from the graphs and the unit N07.15-2071-31
pumps are controlled accordingly via the

Control unit type plate
solenoid valves.
CD Data record
CD Certification no.
Engine control unit All the information on the control unit ® Engine plate
type plate is required to obtain a re- 8) Equipment code
The engine control unit processes data placement engine control unit.
coming from the drive control unit or the
ADM, such as the position of the setpoint The type plate is located on the engine
value sensor (accelerator pedal), the en- control unit in the upper right-hand cor-
gine brake* or engine start/stop, etc. ner.
S1034
FR (drive control) unit or ADM The FR (drive control) unit and the ADM re-
(appliance-resident) ceive data from the
The engine can be adapted to meet the • operator (position of setpoint value
various application-specific requirements sensor, engine start/ stop)
by means of the FR (drive control) unit or
• engine brake switch"
adaptation module (ADM).
3
• other systems (e.g. traction control) .......
IJI engine control unit (e.g. oil pressure
and coolant temperature)
From this data, the instructions for the MR
(engine control) unit are computed and
transmitted to it via the CAN line.
The drive control unit and the ADM control
various displays, e.g. the electronics warn-
N15.00-2089-31
ing lamp, the engine brake * and the con-
stantly-open throttle valves*.
Drive control unit
The FR (drive control) unit or the ADM unit

stores data for specific applications, such
as idling speed, maximum working speed
and speed limitation.
S1034
If the Telligent'" engine system detects a The Operating Instructions and Mainte-
fault, this is stored as a fault code in the nance Booklet must be given to the per-
control units and can be read using the ap- sonnel responsible for operating the
propriate diagnostic equipment (STAR engine or carrying out work on the engine,
DIAGNOSIS or Minidiag 2). and should be kept in an easily accessible
place where the engine is used.
3 In addition, the electronics warning lamp is
_ switched on. Personnel must be instructed in how to
work on the engine using these Operating
Instructions. In particular, the safety notes
N54.22-2015-31
The DaimlerChrysler diagnostic testers must be explained. This is especially im-
can be connected to the equipment- Diagnostic socket
portant for personnel who only work on the
resident, 14-pin diagnostic socket. engine occasionally.
Both the malfunction memory and the Organisational measures
In addition to these Operating Instructions,
stored engine data can be read with
the country-specific legal and all other
this equipment. Risk of accident and injury .&. binding regulations for accident prevention
and protection of the environment must be
Before operatingthe engine, please read
observed.
these Operating Instructionsand other rele-
vant documentation, such as the operating
instructions for the vehicleor the machine
the engine is installed in.
You could otherwise fail to recognise dan-
gers and could injure yourself or others.
S1034
T Transport and installation

Transport
Risk of accident and injury Lt.

The engine can tear loose and cause injury
to persons by overturning or falling.
.. Only lift the engine by the appropriate
lifting points on the engine.
.. Only use transport equipment which has
been approved for use by
DaimlerChrysler.
.. Only lift and transport the engine in its
installation position.
G22.00-3101-31
Lifting point, flywheel end Lifting point, timing end

S1034
Installation
The engine is only designed for installation
in accordance with the specifications de-
termined in the contract.
The manufacturer of the end product is
3 personally responsible for the complete
..... system of the end product, and in particu-
lar for the correct installation and compat-
ibility of this engine with the complete
system.
Observe the "Correct use" (I> page 9) and
"Conversion parts and modifications to the
engine" (l> page 38) sections.
These Operating Instructions contain in-
stallation data in the "Technical data" sec-
tion.
Should you have any questions, please
contact a Mercedes-Benz Service Centre.
The engine is filled with engine oil at

the factory.
S1034
·ul"ming program
'i: "
~~~~-!3~n~ pints
-~1' .~' - -, ;
S1034
Safety precautions
"if' Safety precautions
Make sure that the following safety pre-
cautions are observed to prevent injury to
Note that for electric welding work, • Only use suitable test leads (e.g.
persons as well as damage to the engine,
the batteries must be disconnected DaimlerChrysler connection set) for
components and cable harness.
and both connector leads ("+" and measuring connectors.
"_") securely connected to each
• Telephones and two-way radios
other.
• Only start the engine with securely which are not connected to an ex-
connected batteries. III The control unit connectors must ternal aerial can cause malfunc-
only be removed or inserted when tions to the vehicle's electronics
• Do not disconnect the batteries
the electrical system has been and could therefore endanger the
with the engine running.
switched off. engine's operating safety.
• Only start the engine with the rota-
• Incorrect polarity of the control unit
tional speed sensor connected.
supply voltage (e.g. through incor-
',,' III Do not use a rapid charger to start rect battery polarity) can cause ir-
the engine. reparable damage to the control
• Only perform jump-starting with units.
separate batteries. • Tighten the connections to the fuel-
Please note that the battery termi- injection system to the specified
nals must be removed for rapid bat- tightening torque.
tery charging. Observe the rapid • The control units must be removed
charger operating instructions. if temperatures over 80°C (e.g. in
the drying oven) are expected.
S1034
" Personnel qualifications

Engines may only be operated, maintained
Risk of accident and injury and repaired by trained personnel instruct-
ed and authorised by the operator.
Maintenance and repair work to the engine
Responsibility for operation, maintenance
incorrectly performed can cause engine
and repairs must be determined by the op-
damage and may lead to personal injury as
erator.
a consequence.
The legal minimum age for carrying out the
Maintenance and repair work on the engine
work listed above must be observed.
may only be carried out by personnel who
have undergone the appropriate training.
4
Always have work on or modifications to the
engine carried out at a qualified specialist
workshop which has the necessary special-
ist knowledge and tools to carry out the
work required.
Mercedes-Benz recommends that you use a
Mercedes-Benz Service Centre for this pur-
pose.
S1034
Conversion parts and modifications

." Conversion parts and modifications
Risk of accident
Tampering with the fuel-injection sys-
tem and engine electronics can affect
Tampering with the engine with the inten-
the engine's performance and emis-
tion to produce modifications to it can im-
sions characteristics. Compliance with
pair both its correct operation and its safety,
the factory settings and legal environ-
leading to personal injury as a consequence.
mental protection conditions can then
Always have work on or modifications to the no longer be guaranteed.
engine carried out at a qualified specialist
4
...... workshop which has the necessary special-
work required.
Mercedes-Benz recommends that you use a

pose.
The warranty does not cover damage aris-

ing from tampering with the engine.
S1034
Safety/emergency running programs

T Safety / emergency running programs
The engine is equipped with an electronic
control system which monitors both the Risk of accident
engine and itself (self-diagnostic system).
Incorrectly performed maintenanceand re-
As soon as the electronic control system
pair work on the engine can impair both its
has detected and assessed a malfunction,
correct operation and safety, leading to ac-
one of the following measures is automati-
cidents and personal injury as a conse-
cally implemented:
quence.
CD When the engine is in operation, the
Alwayshavework on or modifications to the
electronic system warning lamp lights
engine carried out at a qualified specialist N54.30-8279-31 4
up, indicating a malfunction. Electronic system warning lamp
S The fault codes may be shown on a dis- ist knowledge and tools to carry out the
play which is part of the Telligent'" work required.
engine system (vehicle diagnostic sys-
Mercedes-Benz recommendsthat you use a
tem).
CD The engine switches to the appropriate pose.
back-up function for continued (but re-
stricted) operation (e.g. constant emer-
gency running speed).
o
The fault codes can be read from the
DaimlerChrysler diagnostic testers
(STAR DIAGNOSIS or Minidiag 2 test-
er), connected to the 14-pin diagnostic
socket (equipment-resident).
S1034
Genuine Mercedes-Benz parts

" Genuine Mercedes-Benz parts
Make sure that the replacement parts are Additional information about recommend-
suitable for your vehicle. Parts which lead ed conversion parts and accessories and
to a vehicle modification, e.g.: permissible technical modifications is
available from any Mercedes-Benz Service
• a change in the type of vehicle ap-
Centre. Always quote the engine plate and
proved in the General Operating Permit
type designation when ordering genuine
• which could pose a threat to road us- parts. You will find the numbers on the en-
ers, or gine (I> page 22) and on the engine data
card (I> page 24).
-
• cause a deterioration in exhaust gas
emission levels or noise levels,
will result in the invalidation of the General
Operating Permit (in many countries). The
use of non-approved parts can impair safe-
ty.
Environmental note
To combine cost-effective repairs with recy-

cling, Mercedes-Benz also offers recondi-
tioned engines and parts. These are of the
same quality andhavethe samewarranty as
new parts.
S1034
S1034
Commissioning
'If Commissioning
Preparation Topping up with coolant
When it leaves the factory, the engine is o Coolant composition (I> see page 63)
filled with engine oil in accordance with It Filling the cooling system
Sheet 228.5 ofthe Mercedes-Benz Service (I> see page 94).
Product Guidelines.
These high-quality engine oils assist the
running-in process, enabling the first oil
change to take place at the usual oil
change intervals for normal operation. This
eliminates the need for special initial oper-
ation oils and the oil change otherwise re-
~ quired.
The extended maintenance intervals can
be observed if engine oils in accordance
Oil filler neck
with Sheet 228.5 of the Mercedes-Benz
Specifications for Service Products are ~ Check the oil level and add engine oil if
used. necessary via the filler neck (arrow) up
to the maximum mark on the dipstick
(I> see page 71).
S1034
Refuelling Checking the batteries

Use summer or winter fuel depending on Risk of explosion
the season. See also "Diesel fuels" Risk of burning
Gases escaping from batteries can explode
([> page 60).
The acid contained in batteries burns skin and injure people.
and eyes on contact. Therefore, do not allow fire, naked flames,
Make sure that utmost cleanliness is .. Do not allow acid to come into contact smoking or the creation of sparks in the vi-
observed while refuelling and that no with your skin, eyes or clothing. cinity of batteries.
water is allowed to enter the tank. .. Wear suitable protective clothing, as
battery acid can burn through normal Only use batteries which are completely
Bleeding the fuel system clothing. In addition, protective gloves filled and have been perfectly maintained.
and safety goggles should be worn. Grease the battery terminals with acid-
The fuel system is bled when the engine is 5
started after refuelling if the fuel system .. Rinse acid splashes off immediately with proof grease (terminal grease).
was previously allowed to run dry. Contin- clean water and consult a doctor if nec-
uous bleeding takes place automatically in
the filter.
essary. f
fa
0
The cable cross-sections are depend-
\, ent on the distance between the bat-
o I tery and the starter motor.
To ensure that the fuel system can be
bled, the battery must have enough
charge when the engine is started.
S1034
Starting the engine for the first time o

Carry out the work listed under "Prepara- As a safety feature, the Telligent@ en-
tion for commissioning" (I> page 42) be- gine system is equipped with a function
fore operating the engine for the first time. that only allows the engine to be start-
ed with the transmission in neutral.
~ Switch on the operating current.
~ Start the engine with the setpoint value
sensor at idling position (e.g. accelera- Risk of burns
tor pedal), for instance by operating the
starter switch on the equipment or The engine becomes very hot while it is run-
Start button CD on the engine, ning and remains so for some time after it
(I> see page 47). has stopped. It will cause burns if you touch
it.
Before starting any work on the engine, al-
Start-Stop buttons low all engine parts to cool down or else
wear suitable gloves and items of clothing to
CD Stop button protect yourself against hot engine compo-
(3) Start button nents.
S1034
Risk of injury Risk of scalding Risk of poisoning
There is a danger of limbs being caught, en- The cooling system is pressurised. Hot cool- There is a risk of poisoning if coolant is swal-
trapped, crushed or torn off by rotating en- ant can spray out when the cooling system lowed.
gine parts. Therefore you should: is opened and scald your skin and eyes. It Never swallow coolant.
.. Keep a safe distance between yourself .. Only open the cooling system at coolant It Never put coolant into container nor-
and rotating engine parts, including temperatures below 90 °G. mally used for beverages.
when the engine is being started. .. Unscrew the sealing cap slowly and re- • Store coolant out of the reach of chil-
.. Wait until all engine parts have come to lease any excess pressure completely dren.
a standstill before carrying out any work before opening the cap fully.
on the engine. .. Wear suitable protective gloves, protec- ~ To check the coolant level: 5
.. Wear work clothing which is fastened tive clothing and safety goggles when .........
and close-fitting. Wear a hair net if nec- handling coolant. Leave the engine running at moderate
essary. Remove jewellery such as speeds for approximately 5 minutes.
watches and necklaces.
~ If the coolant temperature is below
50 C, check the coolant level again
0
and add coolant if necessary. 1>1>

S1034
~ Check the engine oil level approximate-

ly 5 minutes after stopping the engine
If a heating system is connected to the
and add oil up to the maximum mark on
cooling system, all heating system
the dipstick if necessary.
valves must be opened while the cool-
ing system is being topped up. ~ Check for firm seating of mountings on
the engine.
:.~ Otherwise there might be too little
coolant in the cooling system after fill- ~ Check the securing bolts on the ex-
'~!f
ing. haust manifold, engine mountings,
coolant pump, starter motor and air
Only close the heating system valves once compressor for firm seating.
the engine has been running for a brief pe-
5 riod. Top up with coolant if necessary.
......
~ Check the engine for leaks.
~ Check the hose fittings, hose clamps
and pipe connections on the engine as
well as the oil feed and return lines on
the exhaust gas turbocharger for leaks
and firm seating, and tighten if neces-
sary.
S1034
Starting the engine ~ 0

~ At outside temperature~ below -30°C
Risk of injury ;1!j we recommend preheating the coolant
If not properly secured, a vehicle might acci-

dentally be set in motion when the engine is
started, knocking people down or trapping
1
I."
~?
(~.g. using an electric preheating de-
vice)
Starting procedure
them. Before starting the engine:
In the case of vehicle engines, secure the
• Prevent the vehicle from rolling away by vehicle to prevent it from rolling away acci-
applying the parking brake and, if neces- dentally:
sary, by placing chocks under the
wheels. ~ Apply the parking brake.
• Shift the transmission into neutral. ~ Shift the transmission into neutral.
G54.3G-3771-31
~ Place wheel chocks in front of or be-
, 0 hind the wheels. CD Charge current indicator lamp
® Electronic system warning lamp
f.j Starting the engine for the first time ~ Insert the key into the ignition and turn ® Flame-start system indicator lamp or
m~ ([> see page 44). it to the driving position. grid heater
~ Carry out special measures before The following indicator and warning
If!.: starting the engine when it has been lamps light up: Start the engine within 30 seconds of the
flame-start indicator lamp going out. c-r-
stopped for a long period, see the
I
~I
~
~~
~
"Cleaning/protective treatment" sec-
tion (I> page 55).
S1034
o
Keep the engine running at idling speed The indicator lamp for the flame-start
until an oil pressure reading is dis- system lights up for approximately
played. If no oil pressure is displayed 2 seconds (function check, flame-start
after approximately 10 seconds, system not in operation) to approximate-
switch off the engine. Determine the ly 20 seconds (maximum preglow time)
cause; see the "Oil pressure" section depending on the outside temperature.
(I> page 51). If the indicator lamp for the flame-start
system does not go out after approxi-
I
~
0
If necessary, break off the starting
mately 20 seconds, there is a fault; see
the "Telligent@ engine system" section
j
.... • procedure after a maximum of 20 sec-
(I> page 50).
Start-Stop buttons
!i~
I
\~
onds, and then repeat after approxi-
mately 1 minute.
The charge current indicator lamp and
Ii ~ grid heat" ;, controlled by the drive
control unit or the ADM control unit. The
CD Stop button electronic system warning lamp must I preglow time lasts for approximately
CD Start button
~ using the starter switch on the equip-
ment
11 go out after the engine has started. If
they remain on, there are malfunctions;
i~ (I> see page 49) and (I> page 50).
~~
~ 30 seconds and depends on the temper-
ature of the coolant and the charge air.
During the preglow time, the indicator
lamp lights up and then goes out once the
~ using Start button CD on the engine. preglow time has finished.
~ Monitor the oil pressure gauge immedi-
At extremely cold temperatures, do not
ately after starting the engine.
place the cold engine under a full load im-
mediately after starting.
S1034
.. Monitoring engine operation
Charge current
I
It.l
The charge current indicator lamp must go Th, poly-v-belt contact surfaces must
out after the engine has been started. ; ;~~~~.damaged (e.g. torn), oily or
Do not run the engine without a poly-V-

belt since the alternator and coolant
iI
~ pump will not be driven. This will result
in engine damage.
Charge current indicator lamp

N54.30-8281-31
- 5
If the indicator lamp does not go out or

lights up when the engine is running, stop
the engine and check the poly-V-belt.
S1034
Telligent@ engine system The fault codes may be shown on a display Flame-start system*
which is part of the Telligent@ engine sys-
The electronic system warning lamp must
tem (vehicle diagnostic system).
go out after the engine has been started.
Fault codes can be read using
DaimlerChrysler diagnostic equipment
(STAR DIAGNOSIS or Minidiag 2-Tester),
(I> see page 31). If the electronic system
warning lamp lights up while the engine is
running, read or determine the fault code.
Flame-start system indicator lamp

.....
N54.30-8279-31 There is a fault in the flame-start system, if:
Electronic system warning lamp
• the flame-start system indicator lamp
If the warning lamp does not go out or lights up when the engine is running
lights up while the engine is running, there
CD the flame-start system indicator lamp
is a fault in the Telligent@ engine system.
does not go out after more than ap-
Each fault is stored in the system with a proximately 20 seconds when the en-
special fault code. Even temporary faults gine is started
are stored.
S1034
Have the flame-start system checked at a Grid heater* Oil pressure

specialist workshop. DaimlerChrysler rec-
ommends that you visit a Mercedes-Benz
Service Centre for this purpose as it has Once the operating temper ature has
the necessary specialist knowledge and been reached, the engine oil pressure
, tools to carry out the work required.
~j 0
~1 The flame-start system switches off au-
must not fall below:
•
lit
2.5 bar at rated speed
0.5 bar at idling speed
~ tomatically, if: If the pressure falls below these values,
III'~·-: .
the engine is not started within stop the engine and determine the
30 seconds of the flame-start sys- cause.
tem indicator lamp going out
"I
f"'"
lID the engine is started while the

~~~I~;start system indicator lamp is
I~ e the charge current indicator lamp

fi does not go out when the engine is
t
II.~t:.~
running
• the engine reaches a temperature
at which the flame-start system is
- no longer needed
S1034
Stopping the engine

"f' Stopping the engine
~ After driving at full power output or at a ~ Press Stop button CD on the engine or
high coolant temperature, allow the en- on the equipment-resident stopping fa-
gine to idle without load for one or two cility.
minutes.
Stop the engine immediately if you ob-

serve any of the following signs:
CD oil pressure drops or fluctuates
considerably
CD power and speed drop while the po-
sition sensor (accelerator pedal po-
sition sensor) stays in the same
position
e large amounts of exhaust smoke
are emitted from the exhaust
CD coolant and oil temperature in-
crease very quickly
Start-Stop buttons CD unusual noises suddenly occur in

the engine or exhaust gas turbo-
CD Stop button charger
CD Start button
S1034
Y Winter operation
The following notes should be observed at Coolant
the start of the cold season: Risk of poisoning
Risk of scalding
Fuel There is a risk of poisoning if cool ant is swal-
lowed.
The cooling system is pressurised. Hot cool-
Risk of fire ant can spray out when the cooling system .. Never swallow coolant.
is opened and scald your skin and eyes. • Never put coolant into container nor-
There is an increased risk of fire when han- " Only open the cooling system at coolant mally used for beverages.
dling fuels as they are highly flammable. temperatures below 90 "C. .. Store coolant out of the reac h of chil-
Avoid fire, naked flames, and sparks and re- " Unscrew the sealing cap slowly and re- dren.
frain from smoking when handling fuels. lease any excess pressure completely
5
Use cold-resistant diesel fuel
before opening the cap fully. Check the coolant's antifreeze protection
in good time and increase the antifreeze/
........
" Wear suitable protective gloves, protec-
(I> see page 60). tive clothing and safety goggles when corrosion inhibitor concentration if neces-
handling coolant. sary (I> see page 63).
Engine oil
When changing the engine oil, select an

engine oil that is compatible with the SAE
class and the ambient temperatures ex-
pected during the period of use
(I> see page 62).
S1034
Batteries
Risk of explosion
Have the batteries serviced and recharged
more frequently during the cold months of
the year.
and injure people.
Therefore, do not allow fire, naked flames,
Risk of acid burns and the creation of sparks and do not smoke
in the vicinity of batteries.
The acid contained in batteries burns skin
and eyes on contact.
Careful maintenance and low power con-
.. Do not allow acid to come into contact sumption will help maintain the full battery
with your skin, eyes or clothing.
charge. Starting capacity is greatly re-
5
..... .. Wear suitable protective clothing, as duced in cold weather; for example, at
battery acid can burn through normal -10 DC it is only about 60% of normal ca-
clothing. In addition, protective gloves pacity. If the engine is not used for a long
and safety goggles should be worn.
period of time, store the batteries in a
.. Rinse acid splashesoff immediately with heated place if possible. Ensure good ven-
clean water and consult a doctor if nec- tilation when recharging.
essary.
S1034
V Cleaning/protective treatment
Cleaning the engine
Risk of fire and injury
Make sure that water does not enter
Risk of poisoning the intake, ventilation or bleed ducts.
Fuels are highly flammable and can injure
your health. If they are used as cleaning Protect the engine after cleaning. Be
Care and cleaning agents can be toxic and
agents, they can cause fires or skin irritation careful to protect the belt drive against
lead to severe poisoning if swallowed.
and poisoning. preservative agents.
• Always keep care and cleaning agent
Never use fuels for cleaning.
containers closed and out of the reach
~I 0
I:~:~~~~e;;:~:~:;_~~~~~:~;~:b~e," --
of children.
f:" Information about suitable cleaning
• Never store care or cleaning products in
Environmental note
foodstuff containers such as bottles so
as to avoid confusion with foodstuffs. 5
Observe the regulations for environmental
• Observe the instructions for using care protection.
and cleaning products.
Only clean the engine in a washing area de-
signed for this purpose. Dispose of empty
packaging and used cleaning materials in an
environmentally-responsible manner.
S1034
High-pressure cleaners Cleaning the cooling system

Observe the manufacturer's operating in- Risk of scalding
structions. Environmental note The cooling system is pressurised. Hot cool-
ant can spray out when the cooling system
Collect used coolant, cleaning solutions and
Maintain the minimum distance be- is opened and scald your skin and eyes.
detergents and dispose of them in accord-
tween the high-pressure cleaner nozzle e Only open the cooling system at coolant
ancewith current local regulations and in an
and the object to be cleaned: temperatures below 90°C.
environmentally-responsible manner.
• approximately 70 cm for round- e Unscrew the sealing cap slowly and re-
spray jets ~ Blowout any foreign objects (dust, in- lease any excess pressure completely
sects, etc.) from the radiator fins using before opening the cap fully.
.~ .. approximately 30 cm for 25 a flat-
spray jets and concentrated-power compressed air or remove by spraying e Wear suitable protective gloves, protec-
jets water on the rear side of the radiator tive clothing and safety goggles when
(against the direction of the cooling air handling coolant.
Keep the water jet constantly moving
.I·
flow).
while cleaning. To avoid damage, do
I::::~::::~,:ompo"e"ts
if
I 1>1>
~.: ~ppl~mOdtehrated~retssuf:e
not aim the water jet directly at:
°lnly when
c earnng since e ra ra or ms cou ld
• otherwise be damaged.
illJ
I. hoses
Information about suitable cleaning and

preservative agents is available from any
Mercedes-Benz Service Centre.
S1034
C>C>~ Drain off coolant when the engine is Degreasing

cold (I> page 95).
~ Fill the cooling system with a 5% solu-
~ If a heater is attached to the cooling tion of water and a mild alkaline clean-
system, open the regulating valves ful- er, e.g. "P3 Croni" (50 g cleaning agent
ly. per litre of water).
~ Warm up the engine at moderate en-
Risk of poisoning gine speed up to approximately 80 DC
(coolant thermostat starts to open) and
There is a risk of poisoningif coolant is swal- allow to run for approximately 5 min-
lowed. utes longer.
.. Neverswallow coolant. ~ Switch off the engine and allow to cool
.. Neverput coolant into container nor-
mally used for beverages.
~
to approximately 50 DC.
Drain off the cleaning solution com-
- 5
II Store coolant out of the reach of chil- pletely.

dren.
~ Immediately afterwards, fill the cooling
system with clean water, warm up the
engine, and drain off the water after
5 more minutes. Then repeat the pro-
cedure a second time.
~ Fill the cooling system with new cool-
ant (l> page 96) and follow the instruc-
tions in the "Coolant" section
(f> page 63).
S1034
Protective treatment Information is available from any

Mercedes-Benz Service Centre. We strong-
The special protection required will de-
ly recommend asking for information.
pend on the length of time the engine is to
be out of use as well as the climate of the
place where the engine is to be located or
stored.
After cleaning the engine, store it in a dry,
well-ventilated place as far as possible. If
this is not possible, the intervals for carry-
ing out regular protective measures must
be halved.
5
- It is essential that the engine be protected
from direct contact with water (rain/spray
water).
If the engine is to be out of use for less
than 12 months and the above conditions
are met, no corrosion-protection measures
need to be taken.
If the engine is to be out of use for more
than 12 months and there are excep-
tional storage and transport condi-
tions, special protective treatment
measures are required.
S1034
" Service products

Special lubricant additives are not neces-
Risk of poisoning/injury .& • If service products do come into contact
with your eyes, rinse off thoroughly with
sary. The warranty entitlement may be re-
stricted if special lubricant additives are
clean water and consult a doctor if nec-
Service products can cause injury or poison- used.
essary.
ing if they come into contact with skin or are
swallowed.
• Consult a doctor immediately if a serv-
ice product is swallowed.
e
Information is available from any
Observe the prevailing regulations when
e Keep service products out of the reach Mercedes-Benz Service Centre.
handling service products and storing and
of children.
disposing of them. Service products could
otherwise endanger people and the environ-
Environmental note
ment.
Risk of fire
e Always wear appropriate protective
clothing and a breathing mask when
handling service products. If possible,
There is an increased risk of fire when han-
dling fuels and lubricants as they are highly
Dispose of service products as well as parts
which come into contact with service prod-
ucts, e.g. the filter, in an environmentally-
- 5
avoid inhaling vapours.

flammable. responsible manner.
e Do not allow service products to come
Avoid fire, naked flames, and sparks and re- Observe the legal requirements.
into contact with your skin, eyes or
frain from smoking when handling service
clothing. Clean affected areas of skin
with soap and water. products.
Greases and lubricants must be compati-

ble with engine components. For this rea-
son, only brands that have been tested and
approved by DaimlerChrysler should be
used. These are listed in the Mercedes-
Benz Specifications for Service Products.
S1034
Diesel fuels The 900 series engines are suitable for use
with FAME fuels in accordance with
Only use commercially available vehicle
DIN E 51606. If you do so, you must con-
diesel fuels (EN 590). Grades such as ma-
sult a Mercedes-Benz Service Centre to
rine diesel fuel, heating oils, etc. are not
have the exact operating procedures (e.g.
permitted.
maintenance intervals) explained.
Fuel additives are not necessary. The war-
ranty entitlement may be restricted if fuel Diesel fuels in extremely cold weather
additives are used.
At low outside temperatures, paraffin sep-
If diesel fuels with a sulphur content above aration may affect the flow characteristics
0.3% by weight are used, carry out an oil of diesel fuel.
5 change at shorter intervals. Observe the To prevent operating problems (e.g. as a
....... information provided in the Maintenance
result of blocked filters), diesel fuel with
Booklet.
improved cold flow properties is available
Filling the vehicle's fuel tank from drums or on the market in the winter months. Devia-
canisters may introduce impurities into the tions may be possible in the transition be-
fuel system. This can lead to fuel system tween the cold and the warm seasons, and
malfunctions. Therefore, filter the fuel in other countries. In Germany, special
when filling the tank. cold-resistant winter-grade diesel fuels are
sold. They ensure reliable operation down
to approximately -20°C. Winter-grade die-
sel fuel can normally be used without risk
of malfunctioning at the outside tempera-
tures expected in the country of sale.
S1034
If summer diesel fuel or winter diesel fuel Flow improvers

with less resistance to low temperatures is
If petrol is added, there is a risk of seri- The effectiveness offlow improvers cannot
used, only add a specific quantity of flow
ous engine damage. be guaranteed with all fuels. Comply with
improver or kerosene, depending on the
the manufacturer's recommendations. In-
outside temperatures. Therefore, never add petrol to diesel
formation about approved flow improvers
fuel.
is available from any Mercedes-Benz Serv-
Risk of fire and explosion it. Add the flow-improver additive to the die-
ice Centre.
sel fuel in good time, before paraffin sepa-

Adding petrol reduces the flash point for the Kerosene
ration affects the diesel's flow properties.
dieselfuel and increases the risk of fire and
Malfunctions caused by paraffin separa- Add as little as possible, depending on out-
explosion.
tion can only be remedied by warming up side temperatures. The addition of 5% by
.. Therefore, neveradd petrol to diesel
..
fuel.
For this reason, you must avoid fire, na-
the entire fuel system.
Do not add additives to especially cold-
resistant winter diesel fuels, as the fuel's
volume of kerosene improves the cold-
resistance of diesel fuel by approximately
1°C. Do not exceed the maximum mixing
-
5
ked flames andsparks and refrain from ratio of 50% kerosene.

cold-flow properties could deteriorate.
smokingwhen handling these service
products.
.. Observe the relevant safety regulations.
S1034
For safety reasons, only mix kerosene with Engine oils

diesel fuel in the fuel tank. Add the kero-
sene first, then the diesel fuel. Run the en-
gine for a while to ensure that the additive +;;'t+·~o .................................
+77 .. +25
reaches all parts of the fuel system. +66 ',+20

+ 59 ' + 15
1
.&. :::1:
:~~::"·l:~~
.-l~l:
+32 .+ 0
:
Risk of fire and explosion
Adding kerosene reduces the flash point of - 13 ~ 25
the diesel fuel and increases the risk of fire ! )
and explosion.
s
.... .. For this reason, you must avoid fire, na- Engine oil SAE classes
ked flames and sparks and refrain from
Engine oils are specially tested for suitabil-
smoking when handling these service
products. ity in our engines. Therefore, only use en-
gine oil brands approved by Mercedes-
.. Observe the relevant safety regulations.
Benz. These are listed in the Mercedes-
Benz Specifications for Service Products.
Observe the information provided in the
Maintenance Booklet.
8h
II
l'~ T e use 0 f non-approve d enzine
engme oil
01
brands can restrict the warranty enti-
I tlement.
S1034
engine oils of a different grade are used, Water

Coolant
Ie oil change intervals will alter. Informa-
Water without additives is not permitted as
In is available from any Mercedes-Benz
Risk of poisoning a coolant, even if antifreeze properties are
ervice Centre. Select the SAE class of en-
not necessary.
ne oil in accordance with the outside
There is a risk of poisoningif coolant is swal-
.rnperatures. The coolant water must satisfy certain re-
lowed.
quirements which are not always fulfilled
fter maintenance work, the engine oil
II Never swallow coolant. by drinking water.
lange is entered in the Maintenance
ooklet along with the engine oil brand, .. Never put coolant into container nor- If the water is not of sufficient quality, it
"ade and SAE class. mally used for beverages. must be treated.
.. Store coolant out of the reach of chil-
0
I
nly use engine oils of the same grade and
dren. ~··
!\E class when topping up.
~.;.~ Information is available from any .!...
o The coolant is a mixture of water and anti-
freeze/corrosion inhibitor. The coolant
~ Mercedes-Benz Service Centre.
If engine oil of a lower grade is used to

must remain in the cooling system all year
top up, the properties of the engine oil
round to ensure anti-corrosion protection
are impaired and the engine oil and fil-
and to increase the boiling point.
ter changes must therefore be carried
out at shorter intervals.
o
Renew the coolant every three years,
since the level of corrosion protection
~ gradually decreases.
S1034
Antifreeze/corrosion inhibitor Coolant mixing ratio: Disposal

To prevent damage to the cooling system:
Antifreeze -37 DC approxi-
e Only use approved antifreeze/corro- Environmental note
protection mately
sion inhibitor. Information is available down to -45 DC
The coolants mentioned are biodegradable
from any Mercedes-Benz Service Cen-
Water % by vol. 50 45 substances. When disposing of used cool-
tre.
Antifreeze/ cor- 50 maximum ants, observe the legal requirements and
e When topping up (after coolant loss), rosion inhibitor waste water regulations in the country con-
55
make sure that the antifreeze/corro- % by vol. cerned.
sion inhibitor concentration is 50% by
We recommend that you ask the relevant
volume (this ensures antifreeze protec-
In exceptional cases, when no antifreeze/ water authority for advice on the disposal of
tion down to -37 DC).
corrosion inhibitor is available and/ or no
.... antifreeze protection is required (in tropi-
coolant.
Due to the complex tasks which a modern

cal regions), use an approved coolant
If the concentration is too low, there is coolant must perform, improper "recycling"
additive without antifreeze properties in
a risk of engine damage as a result of consisting simply of a mechanical pre-clean-
accordance with Sheet 312.0 of the
corrosion/cavitation. ing must be emphatically rejected.
Mercedes-Benz Specifications for Service
Products (e.g. MB corrosion inhibitor
e Do not use an antifreeze/corrosion in-
A 000 98913 2510 by DaimlerChrysler AG
hibitor concentration of over 55% by
or an approved additive from another man-
volume (maximum antifreeze protec-
ufacturer).
tion). Above this concentration, anti-
freeze protection deteriorates and heat
dissipation is less effective.
In this case, the coolant must be re-
newed every year.
S1034
Work plans
S1034
.. Maintenance instructions
This section describes all maintenance The scope of maintenance and frequency
work which concerns the engine. Risk of accident of maintenance work depend on the differ-
ent operating conditions and are listed in
Faulty maintenance work or failure to carry the Maintenance Booklet.
Risk of accident
out maintenance work, e.g., not changing
Have the work which is carried out con-
the oil filter or not observing the correct
Before any maintenance work or repairs are firmed in the Maintenance Booklet. This
maintenance interval, can cause engine
carried out, please make sure that you read proof of regular maintenance is always re-
damage. Enginedamage can lead to an in-
the relevant sections of the technical docu- quired for any warranty claims.
creased risk of accident.
mentation concerned with servicing and re-
Also observe the maintenance regulations
pairs, for example: For this reason, please observe the instruc-
for special accessories.
tions on servicing the engine given in these
.. Operating Instructions and workshop in-
Operating Instructions.
II
~"
formation
Youshould alsofamiliarise yourselffirstwith The engine oil filled at the factory in
the legal requirements, for example: ., accordance with Sheet 228.5 of the
All maintenance intervals and mainte- ":' Mercedes-Benz Specifications for Serv-
.. work safety and accident prevention
regulations nance work refer to genuine Mercedes- i! ice Products must be changed if more
Benz parts and accessories specifically ".~ than 12 months elapse before the en-
You could otherwise fail to recognise dan- ,:' gine is operated for the first time.
approved for the engine by
gers and could injure yourself or others.
DaimlerChrysler.
S1034
Y Overview of work plans
Maintenance service Checking and correcting the fluid level

Additional work during every
Engine: If more fluid is lost than can be accounted 3rd maintenance service
Oil change and filter replacement for by normal consumption, trace the Fuel prefilter: Clean filter element
cause and rectify.
Fuel filter: Replace filter
Engine cooling system:
Change the engine oil and replace the Fuel prefilter with water separator:
oil filter at least once a year. Check and correct fluid level and Replace filter element
antifreeze / corrosion inhibitor concen-
tration Engine brake*: Check condition and
Poly-V-belt: Check condition
setting
Additional work Renew coolant
Checking for leaks and general condi-
tion Check and adjust valve clearance
Check for points of abrasion and incorrect Renewal interval depends on the cool-
positioning:
Engine
Lines and hoses on the engine
The valve clearance must be adjusted
during the first maintenance service
and then during the 3rd, 5th, 7th main-
tenance services and so on.
ant additive used (see Mercedes-Benz
Specifications for Service Products).
--
Intake pipe between air cleaner and en-
gine
Cooling and heating system
S1034
Engine: Checking for leaks and lines and hoses on the engine:
general condition Checking for leaks and general Risk of injury
~ Visual inspection of the engine for condition
There is a danger of limbs being caught, en-
signs of leakage. ~ Make a visual inspection of lines and
trapped, crushed or torn off by rotating en-
hoses. Also make a listening check for:
Sealing points which are slightly damp are gine parts. Therefore you should:
harmless. • leaks .. Keep a safe distance between yourself
I ~emedy • check for undamaged condition and rotating engine parts, including
more .signifi~antle~ks
involv-
ling constant ali loss Immediately.
• chafe-free routing and
..
when the engine is being started.
Wait until all engine parts have come to
• correct mounting a standstill before carrying out any work
on the engine.
Risk of burns .. Wear work clothing which is fastened

and close-fitting. Wear a hair net if nec-
- The engine is very hot when it is running and

also for some time after it has been swit-
ched off. It may cause burns if you touch it.
essary. Removejewellery such as
watches and necklaces.
Before starting any work on the engine, al-

low all engine parts to cool down or else
wear suitable gloves and items of clothing to
protect yourself against hot engine compo-
nents.
S1034
Engine: Oil change and filter

replacement
.. a
~~
j
,ill
'U'
Only change engine oil when the engine
It~~ is at normal operating temperature.
Risk of scalding
Hot engine oil spraying out can scald your

skin and eyes.
Wear suitable protective gloves, protective
clothing and eye protection.
G1B.20-3113-31
Oil filter cap 6

~ Remove the oil filter cap using the
socket spanner insert (WAF 36). Allow
oil to drain from the filter housing. Make sure that no foreign objects enter
~ Unscrew cap CD and oil filter element the filter housing. Never wipe the filter
@ and remove element @ from the housing out.
cap by pressing the lower edge on the
sides.
S1034
~ Screw the cap on the oil filter housing

and tighten it
Tightening torque: 25 Nm.
Extracting and draining the engine oil
Extraction:
~ Extract the engine oil through the dip-
stick guide pipe. To do this, pull out the
dipstick and insert the scavenging de-
vice sealed with an a-ring into the
guide pipe.
N18.20-2045-31
6
...... Cap with oil filter element Dipstick guide pipe
CD Cap
o Sealing ring
(}) Oil filter element
I
[I
Observe 'he operating ;""'UC';o", for
the engine oil scavenging device.
~ Replace the sealing ring on cap 0.
~ Insert new filter element in the cap and
clip it into place by pressing on it.
S1034
Draining:
~ Place a suitable collecting receptacle Environmental note

under the drain plug on the underside
Dispose of engine oil and filters in accord-
of the oil sump.
ance with the regulations in force at the
~ Unscrew the drain plug carefully and al- place of use of the engine.
low the oil to drain out.
Renewing:
~ Screw the drain plug back in with a new

sealing ring and tighten.
Tightening torque:
M20 x 1.5 - 60 Nm
M26 x 1.5 - 85 Nm
~ Add new engine oil into the engine via

the oil filler neck up to the maximum Oil filler neck
mark on the dipstick. 1>1>
G18.00-3114-31
Oil drain plug

S1034
>1> ~ Start the engine with the setpoint value

sensor in the idling position. Monitor
the oil pressure gauge.
I·~:.'~.,:• ~~~i:~:~":;~::uu,~";~:d~~~:~"~i:~eed
i
I
played. If no oil pressure is displayed
•. after approximately 10 seconds, switch
• off the engine and establish the cause.
~ Check the filter and drain plug for

leaks.
~ Stop the engine. Check the oil level af-
6 ter approximately 5 minutes. Top up oil
...... to the maximum mark on the dipstick if
necessary.
S1034
Adjusting the valve clearance Special tools

Risk of injury
Rotation device: 904 589 04 63 00
Valve clearance: If not properly secured, a vehicle might acci-
dentally be set in motion, knocking people
Inlet valves = 0.40 mm down or trapping them and otherwise caus-
Exhaust valve = 0.60 mm ing an accident and injuring you or others.
• Always secure the vehicle against rolling

away by applying the parking brake and,
if necessary, by placing chocks under
Adjust the valve clearance when the
the wheels.
engine is cold (at least 30 minutes after
the engine was stopped, even if it was • Shift the transmission into neutral.
only operated for a brief period). • Only turn the engine over using the rota-
~.
tion device provided for this purpose.
Clean very dirty cylinder head covers
G01.00-3128-31
before removing.
Layout of cylinders and valves
¢ = inlet valve
.. = exhaust valve
X = flywheel end
S1034
Removing and fitting the cylinder head Removing:

cover
~ Remove engine breather hose @ from
the cylinder head cover.
~ Unscrew Allen bolt ® from the cylin-
der head cover together with sealing
washers @.
~ Remove cylinder head cover 0.
Fitting:
~ Clean the cylinder head and the cylin-
der head cover sealing surfaces.
~ Check the gasket between the cylinder
head cover and charge-air manifold CD
and replace if necessary. Flywheel housing inspection hole
G01.20-3100-31
~ Always replace the gasket between the ~ Fit rotation device (904 589 04 63 00)
CD Charge-air manifold cylinder head cover and the cylinder on the flywheel housing inspection
o Cylinder head cover head. hole.
® Allen bolt
~ Position the cylinder head cover.
@ Sealing washer
® Cover seal ~ Fit Allen bolts ® with new sealing
@ Engine breather hose washers @ and tighten
S1034
Adjusting the valve clearance
Engine Crankshaft position Cylinder /valves to be adjusted

2 3 4 5 6
OM 904/924 LA 4th cylinder valve overlap liE I E
1st cylinder valve overlap E I liE
OM 906/926 LA 6th cylinder valve overlap liE I E I E
1st cylinder valve overlap E I E I liE
I - inlet valve
E - exhaust valve
Adjust all valve clearances in 2 crankshaft

positions.
6
~ Use the rotation device to turn the
crankshaft until no. 4 or 6 cylinder is at
overlap TDG (no. 1 cylinder at ignition
TDG). Then turn no. 1 cylinder to over-
lap TOG (no. 4 or 6 cylinder at ignition
TOG).
~ Check the valves in accordance with
the above table and adjust.
S1034
Checking and adjusting the valve ~ Measure the valve clearance between Concluding work
clearance the rocker arm and valve stem (exhaust
~ Refit the cylinder head cover
valve) or valve bridge (inlet valve) with
(I> see page 74).
a feeler gauge (arrow).
It must be possible to pull the feeler ~ Remove the rotation device from the
gauge through with only light resist- flywheel housing inspection hole.
ance.
~ Slacken counternut CD to adjust the
valve clearance. Adjust the valve clear-
ance by turning adjustment screw CD.
~ Retighten the counternut.
~ Check the valve clearance again and
readjust if necessary.
CD Adjustment screw
CD Counternut
S1034
Fuel prefilter: Cleaning the filter

element Risk of fire Environmental note
There is an increased risk of fire when han- Dispose of used filter elements and fuel res-
dling fuels as they are highly flammable. idue in accordance with current local regula-
Avoid fire, naked flames and sparks and re- tions.
frain from smoking when handlingfuels.
® ~ Check sealing ring ® for the cap and
~ Open the tank cap to remove excess replace if necessary.
,,--,~-0
pressure in the fuel tank. ~ Insert the filter element in the cap and
~ Clean the outside of the fuel prefilter screw the cap onto the filter housing.
and cover any hoses / lines under the Tightening torque: 25 Nm.
prefilter.
~ Unscrew cap CD and pull it out of the 6

filter housing together with filter
G07.57-31 00-31 element 0.
Fuel prefilter ~ Clean cap CD and filter element 0.
CD Cap Replace the filter element if it is very dirty
o Filter element or damaged.
® Sealing ring
S1034
Fuel prefilter with heated water

separator*: Replacing the filter Risk of fire Environmental note
element
There is an increased risk of fire when han- Dispose of used filter elements and fuel res-
dling fuels as they are highly flammable. idue in accordancewith current local regula-
Avoid fire, naked flames and sparks and re- tions.
frain from smoking when handling fuels.
~ Remove the separator vessel from the
~ Open the drain valve and loosen the filter element and clean or replace as
vent screw. Collect the fuel/water necessary.
mixture from the filter element in a ~ Refit in the reverse order. Use new
suitable receptacle. sealing rings when fitting.
~ Remove the heater connector. 1>1>
~ Unscrew the filter element.
N07.0Q-Z096-31
Fuel prefilter with heated water separator*
CD Hand pump
CD Filter housing
CD Water separator (heated)
@ Water drain valve
S1034
>
Screw the filter element onto the filter

head tightly by hand.
~ Close the drain valve and fill the pre-

filter using the fuel hand pump. Then
close the vent screw.
~ Start the engine and bleed the fuel sys-
tem.
Leave the engine running for approxi-

mately 1 minute. The fuel system
bleeds automatically.
~ Check the pre-filter for leaks.

S1034
Replacing the fuel filter element

Risk of fire &
There is an increased risk of fire when han- CD
dling fuels as they are highly flammable. 0
Avoidfire, nakedflames and the creation of
sparks refrain from smoking when handling
fuels.
0-<::::>
®
~ Open the tank cap to prevent excess
pressure in the fuel tank.
®
~ Unscrew fuel filter cap CD
with the
socket spanner insert (WAF 36).
G47.20-3119-31
6 ~ Pull cap CD and filter element slightly
out of filter housing 0. Allow fuel to CD Cap
flowout.
o Sealing ring
Fuel filter
o Filter element
CD Cap 8) Dirt trap
o Filter housing ® Filter housing
C>C>
S1034
> ~ Remove the cap and filter element. Un-

clip filter element 0 by pressing the
o
If the level of the diesel fuel in the tank Leave the engine running for approxi-
lower edge of the filter element on the
is higher than the level of the engine, mately 1 minute. The fuel system
sides.
the feed line must be closed when re- bleeds automatically.
~ Pull dirt trap @ out of the filter housing placing the filter.
by the tabs. ~ Check the fuel filter for leaks with the
The diesel fuel could flow out.
engine running.
Neither dirt nor water should enter the ~ Lightly grease sealing ring 0 and the
filter element seals.
filter housing; do not empty dirt trap @ To ensure the fuel system can be bled,
into the filter housing. ~ Insert dirt trap @ into filter housing the battery must have enough charge
0; observe the correct installation po- when the engine is started, since the
~ Clean cap CD and dirt trap @. sition. fuel system must fill up with fuel first.
~ Replace sealing ring 0. ~ Screw on cap and filter element and
tighten.
~ Clip new filter element 0 into cap CD.
~ Start the engine and bleed the fuel sys-
tem.
S1034
Intake pipe between air cleaner and

engine: Checking for leaks and
general condition
~ Check the rubber sleeves, intake pipe
and connection hoses for damage and
leaks.
~ Check the hose clamps, flanged joints
and intake manifold for firm seating.
S1034
Poly-V-belt: Checking the condition
Risk of injury
I! ~Place the poly-V-belt if one of the
damage patterns shown on the next
~ page is detected. For information on in-
~
Faulty poly-V-belts may tear and parts or all I stalling and removing the poly-V-belt
of the belt may be thrown off, thereby caus- lii! (I> see page 86).
~
ing injury to persons.
~ Remove the rotation device.
CII Always observe the specified mainte-
nance intervals for poly-V-belts.
CII If damage is detected, replace the poly-
V-belt concerned immediately.
Special tools
Rotation device: 904 589 04 63 00 Flywheel housing inspection hole 6
..-
~ Fit the rotation device to the flywheel ~ rotate further using the rotation device
housing inspection hole. until the chalk mark is reached again.
~ Make a chalk mark on the poly-V-belt.
Check the poly-V-belt for damage in sec-
tions; rotate the engine and poly-V-belt a
little at a time
S1034
N13.20-2075-31
S1034
Damage patterns
CD Condition as new (as reference: trape-

zoidal ribs)
@ One-sided wear: wedge-shaped ribs
® Cord visible in the base of the ribs
@ Ribs split
® Transverse cracks in several ribs
@ Rubber lumps in the base of the belt
o Deposits of dirt or stones
® Rib detached from the base of the belt
® Cord torn out to the side
@ Outer cord frayed
@ Transverse cracks on the back of the
belt
@ Transverse cracks in several ribs
--
6
S1034
Removing and installing the poly-V-belt ~ Swing back the tensioning device.
Risk of injury ~ Check that the tensioning device and
belt pulley are in perfect condition (e.g.
The tensioning device is spring-tensioned.
check for worn bearings on the ten-
When it is loosened or tightened, there is a
sioning device, tensioning pulley and
risk of injury from hands or fingers being
deflection pulleys as well as wear on
crushed or trapped in pretensioned parts.
belt pulleys); replace parts if
co Make sure that the tool is handled cor- necessary.
rectly.
~ Lay the poly-V-belt (new) on all belt pul-
co Keep your fingers out of the area be-
leys, except for the tensioning pulley
tween the belt pulley and the poly-V-belt
(see illustrations for poly-V-belt rout-
when fitting or dismantling the poly-V-
ing).
belt.
co Wear work gloves when working on the ~ Swing the tensioning pulley upwards
....6 tensioner. using the lever, insert the poly-V-belt

and swing back the tensioning pulley .
Spanner with extension in the tensioning ~ Attach spanner CD with the 17 mm ~ Remove the spanner and check for cor-
device socket to the hexagon bolt of tension- rect seating of the poly-V-belt on the
CD Tensioning pulley ing pulley CD. belt pulley.
CD Spanner ~ Swing the tensioning pulley upwards
and remove the poly-V-belt.
S1034
Routing of the poly-V-belt (engine Routing of the poly-V-belt (engine with

without refrigerant compressor) refrigerant compressor)
G13.20-3110-31 G13.20-3111-31
CD Alternator CD Alternator
CD Coolant pump CD Coolant pump
® Tensioning pulley ® Tensioning pulley
@ Crankshaft @ Refrigerant compressor
® Deflection and guide pulley
@ Crankshaft
S1034
Engine brake: Checking the Checking the condition

condition and setting ~ Remove the wire circlip from the ball
cup on the engine cylinder.
~ Force the ball cup off the ball neck of
throttle valve lever CD.
~ Check the engine brake cylinder, ball
neck and ball cup, and the throttle
valve shaft for wear.
~ Check the firm seating of the throttle
valve lever on the throttle valve shaft.
Tighten screws if necessary.
~ Grease the ball cup with the grease
-
6 Throttle valve lever in working position
CD Throttle valve lever

(3) Retainer
~
specified.
Push the ball cup back onto the ball
neck.
Throttle valve lever in rest position
~ Fit the wire circlip.
CD Throttle valve lever
@ Retainer
S1034
Checking the adjustment
o
Throttle valve lever CD must lie against
bracket @ in the operating position
(cylinder extended) when the engine
brake is operated.
When the engine brake cylinder (with
the cylinder retracted) is in the rest po-
sition, the throttle valve lever must also
lie against the bracket; the pre-tension
of the engine brake cylinder return
spring is then sufficient.
Check the position of the throttle valve
shaft: the notches must be horizontal
when the engine brake is in the rest po-
/
sition (I> page 88, illustration on the
, left-hand side). The notches must be
vertical in the working position
1
:.~.'
:1
(I> page 88, illustration on the right-
hand side).
S1034
Engine cooling system: Checking

and correcting the fluid level and the Risk of poisoning
Only check and correct the coolant lev-
antifreeze / corrosion inhibitor el when the coolant temperature is
Thereis a risk of poisoning if coolant is swal-
below 50 "C. Check the antifreeze /
lowed.
Risk of scalding corrosion inhibitor before correcting
.. Never swallow coolant. the coolant level. Only use prepared
The cooling system is pressurised. Hot cool- .. Never put coolant into containers nor- coolant with 50% by volume anti-
ant can spray out when the cooling system mally used for beverages. freeze/ corrosion inhibitor for topping
is opened and scald your skin and eyes. .. Store coolant out of the reach of chil- up.
.. Only open the cooling system at coolant dren.
temperatures below 90 "C. .. Open the engine cooling system radia-
tor cap slowly. Relieve excess pres-
.. Unscrew the sealing cap slowly and re-
sure.
lease any excess pressure completely Only use service products approved by
before opening the cap fully. ... Check the antifreeze / corrosion inhibi-
6 DaimlerChrysler, (I> see page 63).
.- .. Wear suitable protective gloves, protec- tor using testing device. The correct
tive clothing and safety goggles when concentration of 50% by volume
handling coolant. antifreeze / corrosion inhibitor in the
coolant is indicated when there is anti-
freeze protection down to -37 DC. If
less antifreeze protection is displayed,
correct the mixing ratio.
S1034
Cooling and heating system:

If the concentration is too low, there is Checking for leaks and general
a risk of engine damage as a result of condition
corrosion / cavitation in the cooling The "Engine cooling system: Checking and
system. correcting the fluid level and antifreeze /
corrosion inhibitor" work item must have
already been carried out.
Avoid concentrations of more than 55% Il>- Carry out a visual inspection of the ra-
by volume antifreeze / corrosion inhibi- diator for leaks and undamaged condi-
tor, otherwise maximum antifreeze pro- tion.
tection down to -45 DC will not be
achieved. If the concentration is higher,
heat dissipation and antifreeze protec- If damage /faults are found, repair the
tion deteriorate. radiator or replace it.
Il>- Check the coolant level.

The cooling system is correctly filled if the
Il>- Check the radiator fer external dirt. The
fins must not be dirty.
-
coolant reaches the mark in the filler neck. Il>- Check that all lines and hoses are un-
damaged, that they are routed to avoid
chafing and that they are secured in ac-
cordance with the regulations.
S1034
Special tool:
Pressure tester 001 589 83 21 00 Risk of poisoning
There is a risk of poisoning if coolant is swal-

Risk of scalding lowed.
• Never swallow coolant.

The cooling system is pressurised. Hot cool-
ant can spray out when the cooling system • Never put coolant into containers nor-
is opened and scald your skin and eyes. mally used for beverages.
• Store coolant out of the reach of chil-
II Only open the cooling system at coolant
dren.
temperatures below 90 "C.
• Unscrew the sealing cap slowly and re-
lease any excess pressure completely ~ On heating systems: Open the regulat-
before opening the cap fully. ing valves and shutoff valves.
6 II Wear suitable protective gloves, protec-
~ Remove the coolant expansion tank Pressure tester special tool
- tive clothing and safety goggles when 1>1>
cap.
handling coolant.
~ Fit the testing equipment.
S1034
1>1> ~ Connect the compressed-air hose with

the tyre inflator connection to the valve
and build up a test pressure equal to
the cooling system opening pressure.
The cooling system opening pressure can
be seen on the code on the cap or pressure
relief valve.
Example: Code 70 = 0.7 bar pressure.
~!i1· " 1
~
e
A pressure relief valve is integrated in
the testing equipment so that a pres-
I¥J!\l
sure of 1.2 bar cannot be exceeded.
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Renewing coolant
Risk of poisoning I «)
~_.' I l ~he
g
Risk of scalding '...."•'.'·
...• Befol·re
coo ingrenedWhin
an coolant,for
eating system check the
leaks
There is a risk of poisoning if coolant is swal-
and condition. Have the coolant renew-
lowed.
The cooling system is pressurised. Hot cool- al confirmed in the Maintenance Book-
1:
ant can spray out when the cooling system .. Never swallow coolant. .• let.
is opened and scald your skin and eyes. .. Never put coolant into containers nor-
mally used for beverages.
.. Only open the cooling system at coolant
temperatures below 90 DC. .. Store coolant out of the reach of chil-
dren.
.. Unscrew the sealing cap slowly and re-
lease any excess pressure completely
before opening the cap fully.
.. Wear suitable protective gloves, protec- Only use antifreeze / corrosion inhibitor
tive clothing and safety goggles when approved by Mercedes-Benz
handling coolant. ([> see page 59).
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Draining coolant
Risk of scalding
,I.'~ere
"'~
are additional drain plugs on the
radiator.
Hot coolant will scald your skin and eyes.
I~
.. Only carry out work on the cooling sys-
First cover the lines, etc. beneath the
tem at coolant temperatures below
.• drain plugs and place a receptacle suit-
50 DC.
able for the volume of coolant.
• Wear suitable protective gloves, protec-
tive clothing and safety goggles when
handling coolant.
~ Open the engine cooling system radia-

tor cap slowly. Let off excess pressure
and remove the radiator cap. Coolant drain plug
~ On heating systems: Open the heating ~ Place the drain hose on the coolant
temperature selector (regulating drain plug on the engine (arrow).
valve).
~ Loosen the drain plug (1 to 2 turns)
The coolant flows out.
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Adding coolant
Environmental note
II> Start the engine and allow it to run at
different speeds for approximately
Dispose of used coolant in accordance with
1 minute.
prevailing local regulations
(I> see page 64). II> Add coolant in the specified ratio until
it reaches the lower edge of the filler
II> Clear blocked drain openings from de- neck.
posits. II> Switch off the engine and close the
II> Retighten the coolant drain plug on the cooling system again.
engine.
II> Pull off the drain hose.
II> Fit additional drain plugs (without hose
connections) with new seals and screw
·I.~r
further ;nforrnation se, the vehicle
• manufacturer's operating instructions.
tight.
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Malfunctions, causes and solutions

V Malfunctions, causes and solutions
Besides careful operation and mainte-
nance of the engine, it is important that Risk of accident and injury .&
malfunctions are remedied in good time.
Further information on the measures listed Incorrect maintenance and repair work to
under "Solution" can be found in the "Main- the engine can cause engine damage and
tenance" or "Tests and other work for rem- may cause personal injury as a conse-
edying problems" section. quence.
You can rectify certain faults yourself Maintenance and repair work on the engine
(l> page 99). may only be carried out by personnel who
have undergone the appropriate training.
Always have faults that you cannot remedy
yourself rectified at a qualified specialist Always have work on or modifications to the
workshop. engine carried out at a qualified technical
DaimlerChrysler recommends that you vis-
it a Mercedes-Benz Service Centre for this
work required.
purpose as it has the necessary specialist
knowledge and tools to carry out the work Mercedes-Benz recommends that you use a
required. In particular, work relevant to Mercedes-Benz Service Centre for this pur-
safety or on safety-related systems must pose.
be carried out at a qualified specialist
workshop.
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General troubleshooting
Malfunction Cause Solution

Starter pinion does not turn or turns too Battery is not sufficiently charged ~ Charge the battery
slowly
Connecting cable to the starter motor is ~ Tightenthe cable on the terminal. If
loose necessary, solder on a new terminal.
Starter motor solenoid switch malfunction ~ Have it checked by specialists
Enginedoes not start Ar c t-rvrvc imrne- Fuel tank empty ~ Refuel
diately
Fuel filter blocked ~ Clean orreplacethe filter element
(t>page80)
Fuel line, pre-cleaner or screen in the fuel ~ Clean and bleed.thesystem
tank blocked
Fuel system or filter leaking ~ Seal
Fuel not resistant to cold ~ Clean the pre-filter (I> page 78)
~ Replace fuel filter
~ Use winter fuel [I> page 60)

Outside temperature too low ~ Observe measures for winter operation
(t> page 53)
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Engine starts badly Fuel temperature too high or sensor mal- ~ Replace fuel temperature sensor; con-
function sult a qualified specialist workshop
Engine control unit malfunction ~ Read engine control unit malfunction

memory, consult a qualified specialist
workshop
Leakages or pressure too low in the low- ~ Testforleaks (visual inspection); have
pressure fuel circuit pressure tested at a qualified specialist
workshop
Engine control unit malfunction (total fail- ~ Consult a qualified specialist workshop
ure)
Electrical system interrupted; short circuit ~ -Consulta qualified specialist workshop

in cabling or in Stop button; engine control
unit malfunction
Leakages or pressure too low in the low- ~ Test for leaks (visual inspection); have
pressure fuel circuit or fuel delivery pump pressure tested at a qualified specialist
drive defective workshop
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Engine in emergency running mode: Engine control unit or drive control unit ~ Read malfunction memory in control
Constant speed 1,300 rpm malfunction units; consult a qualified specialist
workshop
lIiror",jr"" or.runs irregularly Crankshaft position sensor or TOC sensor ~ Remove each sensor; sensor polarity is
(camshaft angle sensor) polarity reversed reversed if engine runs better (emer-
gency running engine speed) - reverse
polarity
~ Consult a qualified specialist workshop
Charge-air pressure sensor malfunction Check with OaimlerChrysler diagnostic
tester; replace if necessary; consult a
qualified specialist workshop
Charge-air temperature too high or Check temperature sensor; replace if
temperature sensor malfunction necessary; consult a qualified specialist
workshop
Fuel temperature too low ~ Check temperature sensor; replace if
necessary, check fan speed cut-in
point; consult a qualified specialist
workshop
Coolant temperature too high ~ Check temperature sensor; replace if
necessary; check fan speed cut-in
point; consult a qualified specialist
workshop
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Poor engine output (lack of power) Engine brake valve* defective ~ Carry out function or visual inspection
Fault in the fuel system (blocked, leaking) ~ Carry out visual inspection for leaks;
consult a qualified specialist workshop
Engine control or drive control module ~ Read control unit malfunction memory;
malfunction consult a qualified specialist workshop
Tractive force interruption Loose contacts in the electrical supply ~ Check battery terminal clamps and
connector on engine control unit for
firm seating and corrosion
Leakages or pressure too low in the low- ~ Test for leaks (visual inspection); have
pressure fuel circuit pressure tested at a qualified specialist
workshop
Poor engine braking power Drive control unit malfunction ~ Read drive control unit malfunction
memory; consult a qualified specialist
workshop
-
7 Constantly-open throttle valve* defective
Engine brake flap* defective

~
~
Check control; consult a qualified spe-
cialist workshop
Carry out a function /visual inspection;
consult a qualified specialist workshop
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Fuel consumption too high Fuel temperature too high or sensor mal- ~ Replace fuel temperature sensor; con-
function sult a qualified specialist workshop
Turbocharger leaking on pressure (deliv- ~ Carry out a test for leaks; consult a
ery) side qualified specialist workshop
Connection points (unit pump - line and in- ~ Set pumps using STAR DIAGNOSIS or
jectors) defective or leaking Minidiag 2; consult a qualified special-
ist workshop
Engine cut-off too early (maximum revs Drive control unit or ADM control unit de- ~ Consult a qualified specialist workshop
cannot be reached) fective or incorrectly programmed
Engine gets too hot (according to coolant Coolant temperature sensor malfunction ~ Replace sensor
temperature gauge)
Insufficient coolant or cooling system not ~ Top up, bleed (I> page 96)
fully bled
Poly-V-belt damaged ~ see Replacing the poly-V-belt
(I> page 86)
Fan does not switch on correctly ~ Consult a qualified specialist workshop
Radiator dirty on inside or choked with ~ Clean or remove limescale
limescale; radiator very dirty on outside
Thermostat malfunction ~ Check, replace if necessary; consult a
qualified specialist workshop
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Charge current indicator lamp does not Bulb malfunction or supply line broken ~ Replace bulb or repair break
light up while the vehicle is stationary
Charge current indicator lamp lights up Poly-V-belt too slack ~ Check belt tension; replace tensioning
when the engine is running pulley if necessary
Poly-V-belt torn ~ Replace the poly-V-belt (I> page 86)
Alternator or regulator malfunction ~ Check; consult a qualified specialist

workshop
Engine emits black smoke Charge-air sensor, coolant sensor or fuel ~ Check with DaimlerChrysler diagnostic
temperature sensor defective tester; consult a qualified specialist
workshop
Injector defective ~ Consult a qualified specialist workshop
Exhaust gas turbocharger or charge-air ~ Carry out visual inspection; consult a

pipe defective, air cleaner dirty qualified specialist workshop
7 Constantly-open throttle valve defective ~ Consult a qualified specialist workshop

...... Exhaust fumes are blue Oil level in the engine too high; engine oil ~ Correct oil level; have it checked at a
entering combustion chamber qualified specialist workshop
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Exhaust fumes are white Cylinder head or cylinder head gasket ~ Locate damaged cylinder using pres-
leaking; coolant entering the combustion sure loss test; consult a qualified spe-
chamber cialist workshop
Engine "knocks" Combustion malfunction ~ Consult a qualified specialist workshop
Knocking noise from the bearings Damage to bearings ~ Consult a qualified specialist workshop
Abnormal noises Leakage in intake pipe and exhaust pipe ~ Remedy leakage; replace seals if nec-
causes whistling noise essary
Turbine or compressor wheel scrapes on ~ Have the exhaust gas turbocharger re-
the housing; foreign object in the compres- placed at a qualified specialist work-
sor or turbine; seized bearing in rotating shop
parts
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Jump-starting
V Jump-starting
If the battery is discharged, the engine can
be started using jump leads and a donor Risk of explosion
When jump-starting the engine, the
battery.
maximum on-board voltage of 28 V
must not be exceeded (as this would
Risk of burning and injure people.
cause electronic damage to the control
Therefore, avoid fire, naked flames and part).
The acid contained in batteries burns skin sparks and refrain from smoking in the vicin-
and eyes on contact. ity of batteries. ~ Connect the positive terminals first and
• Avoid contact of acid with your skin, then the negative battery terminals.
eyes or clothing.
~~~ ~ Start the engine (I> see page 47) and
• Wear suitable protective clothing, as
battery acid can burn through normal
I Make sure that the donor battery and allow to run for a short while.
clothing, and also wear protective
III the starter battery have the same nom- ~ Remove the jump leads in the reverse
gloves and safety goggles. I.:.. inal voltage. Otherwise a battery could
order.
• Rinse acid splashes off immediately with
I be irreparably damaged.
clean water and consult a doctor if nec- ~ Do not place any metal parts on the
essary. batteries. There is a risk of short cir-
cuit.
Only use insulated jump leads (cable
cross section approximately 70 mm 2 )
and insulated terminal clamps. There is
a risk of short circuit.
A discharged battery can freeze at
about -10°C; it must have thawed out
before jump-starting.
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adjustment values
Tightening torques
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Dimensions in mm:
(Standard version, other versions on re-
quest)
OM 904 LA
OM 924 LA
c
A = Engine length 830 mm
B = Engine width 645 mm
C = Engine height 925 mm
OM 906 LA
f----B---~
OM 926 LA G01.00-3129-31 G01.00-3130-31
A = Engine length 1,078 mm Illustrated: OM 904/924 LA Illustrated: OM 904/924 LA
B = Engine width 645 mm

C = Engine height 940 mm
8
.......
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Weights
OM 904 LA OM 906 LA
OM 924 LA OM 926 LA
Engine, dry 395 kg 530 kg
Engine, wet 420 kg 573 kg
General data
Type In-line engine with exhaust gas turbocharger and intercooler

Type ofcooling system Forced circulation cooling
Combustion principle 4-stroke diesel direct injection
Number of cylinders
OM 904 LA/OM 924 LA: 4
OM 906 LA/OM 926 LA: 6
Cylinder bore
OM 904 LA/OM 906 LA 102 mm
OM 924 LA/OM 926 LA 106 mm
Piston stroke
OM 904 LA/OM 906 LA 130mm
OM 924 LA/OM 926 LA 136 mm
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General data continued
Displacement
OM 904 LA/OM 924 LA: 4,250 cm 3 / 4,800 cm 3
OM 906 LA/OM 926 LA: 6,370 cm 3 / 7,200 cm 3
Direction of rotation of engine viewed from flywheel Anti-clockwise
Type of starting Electric
Coolant capacity of engine without intercooler
OM 904 LA/OM 924 LA: 8.5 I
OM 906 LA/OM 926 LA: 12.51
Engine oil capacity including oil filter
OM 904 LA/OM 924 LA: min. 13 I; max. 16 I
OM 906 LA/OM 926 LA: min. 24 I; max. 29 I
8
.......
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Data: Starter motor, battery and alter-

nator (standard)
Starter motor
Voltage 24 V
Output 4.0 kW
Battery (not in scope of delivery)
Voltage 24 V
Cold test current in accordance with DIN 72311 max. 450 A
Cold start ability without jump-starting and 75% battery charge
down to max. -20 DC
Alternator
Voltage 28 V
Current rating 80 A
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Test values and adjustment values

T Test values and adjustment values
Engine oil pressure (min)
at idling speed ~ 0.5 bar
at rated speed ~ 2.5 bar
Valve clearance
Inlet valve 0.4 mm

Exhaust valve 0.6 mm
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'!If Tightening torques
I~ 0
All threads on mechanical parts and re-
.'I
~ lated contact sUrfac~s must ~e clea.n
I and smooth and lubncated with engine
~.~.;. . oil; other lu bricants require significant-
I Iy different tightening torques.
Designation Nm
Engine block
Cylinder head cover to cylinder head bolt 30
Oil sump bolt to cylinder crankcase 25
Poly-V-belt tensioning device to cylinder r.r;:lnkr.r1~;p support 50
Fuel/injection system
Injection line to unitpurnppressure pipe connection 35
Banjo bolts forfuellines 40
Cap to fuel filter housing 25
Starter motor/ alternator
Starter motor to tirningcase 50
Alternator support to cylinder crankcase 100
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Designation Nm
Alternator to support 50
Alternator to retainer 65
Oil circuit
Oil drain plug in oil sump
M20 x 1.5 thread 65
M26 x 1.5 thread 85
Alternator retainer to oil filter 40
Oil filter housing tocylindercrankcase 25
Oil filter housing support to cylinder crankcase 25
Oil filter cap to oil filter housing 25
Pressure sensor to oil filter housing 25
Valve adjustment
Counternut on rocker arm set screw 25
Cooling circuit
Coolant line with thermostat valve to coolant pump 25
Coolant pump to cylinder crankcase 25
Belt pulley to coolant pump hub 25
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ADM Control unit FAME fuels

Control module as interface between Part of the electronic system which (Fatty Acid Methyl Ester) FAME fuels
the engine and the vehicle electronics. controls the engine or transmission are bio-diesel fuels based on fatty acid
functions, for example. methyl esters.
Belt drive
Drive connection from the engine to Emergency running program Flame-start system
the engine assemblies, such as the al- Special program in the Telligent@ en- This is a cold-start aid for the engine. It
ternator, coolant pump or refrigerant gine system which allows limited can be used to preheat the charge air
compressor. engine operation if electronic compo- using fuel combustion.
nents have failed.
CAN (Controller Area Network) FR
Serial data transfer system which net- Engine oil viscosity (Drive control) control unit. The drive
works the vehicle's electronic systems Measurement of the internal friction control is a monitored electronic sys-
and allows an organised mutual data (viscosity) of an oil at a defined temper- tem and is connected to the engine
exchange. At the same time the ature. The viscosity is better the higher control via the CAN bus. The FR is per-
number of components required is low- the temperature the oil can withstand manently installed in the driver's cab. It
er. This reduction of potential malfunc- without becoming too thin, or the lower controls vehicle-relevant functions and
tion sources improves reliability and the temperature the oil can withstand switches on the engine control via CAN
maintenance friendliness. without becoming too thicl<. bus commands, e.g. engine torque re-
quest via accelerator pedal position.
Constantly-open throttle valve Engine plate
Valve fitted in the cylinder head in con- Number specified by the manufacturer Grid heater
junction with throttle valve brake or and marked on the cylinder head to This is a cold-start aid for the engine. It
Turbobrake *. When the engine brake is clearly identify each engine. can be used to preheat the charge air
operated, the constantly-open throttle using a heater coil.
Exhaust brake
valve causes a reduction in the cylinder
also throttle valve brake. Works by
pressure during the working stroke.
closing the exhaust pipe.
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Minidiag 2 TDC
DaimlerChrysler AG electronic diag- Top dead centre; term for the upper po-
nostic tool for reading faults and pa- sition of the piston in the cylinder.
rameters on commercial vehicles.
Telligent@ engine system
MR Mercedes-Benz electronic engine con-
(Engine control) control unit. Engine trol. Controls fuel injection period and
control is a monitored electronic sys- quantity depending on the current op-
tem which forms part of the Telligent@ erating conditions and driver's re-
engine system. It controls the engine quests.
functions, such as the engine idling
Tightening torque (Nm)
speed and exchanges data with the
Product of force and lever arm length
drive control.
with which bolted connections, e.g.
OM cylinder head bolts, are tightened.
Engine name, abbreviation for oil en- (Nm = Newton metres)
gine = diesel engine.
Sensor
Electronic component which converts
certain parameters (e.g. oil tempera-
ture, engine speed and others) into
electrical values for use in the engine
control unit.
STAR DIAGNOSIS
DaimlerChrysler AG electronic diag-
nostic system
S1034
Engine control unit 30

Adaptation module 31 Diagnostic socket 32 Engine data 108
Adjusting the valve clearance . . 73, 75 Diagnostic testers 32 Engine data card 24
ADM 31 Diesel fuels Engine oil
Alternator. . . . . . . . . . . . . . . . . . . . . 111 In extremely cold weather. 60 Extracting, draining 70
Antifreeze/corrosion inhibitor . . . . . 64 Sulphur content 60 Engine plate 22
Dimensions. . . . . . . . . . . . . . . . . . .. 108 Environmental note 7
Disposal of service products 64 Exhaust brake 28
Battery 43, 106, 111 Drive control unit 31
Flame-start system 26
Charge current 49 Emergency running program 29 Flow improvers 61
Commissioning 42 Engine Fuel 53
Constantly-open throttle valve 28 Checking for leaks and general Filling the tank 43
Conversion parts and condition 68 Filter element 80
modifications 38 Cleaning 55 Prefilter 77
Coolant Oil change and filter replacement 69 Fuel additives 60
Mixing ratio 64 Starting 47 Fuel system
Renewing 94 Stopping 52 Bleeding 80
Coolant level. 90 Engine brake
Cooling system Checking the adjustment 89
Cleaning 56 Genuine Mercedes-Benz parts 40
Checking the condition 88
Degreasing 57 Grid heater 27, 51
Cylinder head cover
Removing and fitting 74
S1034
High-pressure cleaners 56 Personnel 32 Telligent® engine system 32, 50

Poly-V-belt Test values and adjustment
Checking the condition 83 values 112
Indicator lamp 47 Removing and installing 86 Tightening torques 113
Intake pipe Routing 87 Transport and installation 33
Checking for leaks ., 82 Tensioning pulley 86 Type designation 24
Protection of the
environment 7,32,38
Jump-starting 36, 106 Valve clearance 112
Protective treatment 58
Adjusting 73
Adjustment 75
Kerosene 61
Safety and emergency running pro- Checking 76
gram 29
Location of sensors 20 Safety precautions 36
Service products 64 Warning lamp 47
Special lubricant additives 59 Warranty entitlement 59
Maintenance instructions 66 Starter motor 111 Water 63
Maintenance intervals 42 Starting the engine for the first Weights 109
Maintenance service 67 time 44 Winter operation 53
Work plans 67
Oil pressure 51
(} Operating safety 8
- Overview
OM 904 LA/OM 924 LA 12
S1034
Contact Editorial office

Mercedes-Benz will be happy to answer You are welcome to forward any queries
any queries you may have: or suggestions you may have regarding
these Operating Instructions to the
Mercedes-Benz Contact
technical documentation team at
Telephone: 00800 1 777 7777
the following address:
International: +49 69 95 30 72 77
DaimlerChrysler AG, HPC: R822,
Internet 70546 Stuttgart, Germany
Further information about As at: 25.05.2003
Mercedes-Benz and
Title illustration number NOO.O 1-2194-31
DaimlerChrysler can be found on
the following websites: Not to be reprinted, translated
or otherwise reproduced,
www.mercedes-benz.com
in whole or in part,
www.daimlerchrysler.com
without written permission.
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S1035
® Mercedes-Benz
Motor / Engine / Moteur OM 904/907/924 LA

OM 906/909/926 LA/RLA
DaimlerChrysler AG . Global Service & Parts· GSPITIO • D-70546 Stuttgart

S1035
Vorbemerlmngen
Dieser Bildkatalog soIl Ihnen die Ermittlung und BesteIlung von Teilen fur die Wartung bzw. Reparatur Ihres MERCEDES-BENZ
erleichtern. Er enthalt die Bildtafeln der Grundausfuhrung.
Die auf den Bildtafeln abgebildeten Teile entsprechen nicht in jedem Fall der neuesten Ausfuhrung.
Ihr MERCEDES-BENZ-Produkt kann mit Sonderausfuhrungen (SA) ausgerustet sein, die in diesem Katalog nicht aufgefuhrt sind.
Fur die Errnittlung der richtigen Teile ist die Vorlage der Fahrzeug- bzw. Motoren-Datenkarte bei den MERCEDES-BENZ-Service-
organen 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 Seite Katalog
Motor 904.904-911, 914-917, 921-923, 927-931,936, 942, 944, 21 - 82 06T

946, 947-953, 955, 959, 961, 964
90~910, 920, 930, 940, 941, 960, 970, 980, 990 06T
Motor 906.910,911,915,916,919-923,925-928,930,931,935, 85 - 161 06V

937-941,949-952,954-956,960-965,976,982
909.900, 901, 910, 911, 920, 921, 960, 970, 971 06V
924.911,915,916,920 06T
926.911-915,917,924,929 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 Fahrzeug-
Datenkarte):
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 Ausgabe A
Seite 23, Gruppe 01, Bild 21 1 Stuck
Seite 32, Gruppe 07, Bild 260 3 Stuck
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.
4
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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 Page Catalog
Engine 904.904-911,914-917, 921-923,927-931,936,942,944, 21 - 82 06T

946,947-953,955,959,961,964
90l910, 920, 930, 940, 941, 960, 970, 980, 990 06T
Engine 906.910,911,915,916,919-923,925-928,930,931,935, 85 - 161 06V

937-941, 949-952, 954-956, 960-965, 976, 982
909.900,901,910,911,920,921,960,970,971 06V
924.911,915,916,920 06T
926.911-915,917,924,929 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 Edition A
Page 23, Group 01, Fig. 21 1 piece
Page 32, Group 07, Fig. 260 3 pieces
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.
6
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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 chas-
sis), de moteur, de cabine, de carrosserie (autocars/autobus). Voir a cet effet la fiche signaletique du vehicule, II faut abso-
lument tenir compte des 6 premiers chiffres de ces numeros correspondant a ce que nous appelons Ie modele.
Designation Modele Page Catalogue
Moteur 904.904-911,914-917,921-923,927-931,936,942,944, 21 - 82 06T

946,947-953,955,959,961,964
90Z910, 920, 930, 940,941,960, 970, 980, 990 06T
Moteur 906.910,911,915,916,919-923,925-928,930,931,935, 85 - 161 06V

937-941, 949-952, 954-956, 960-965, 976, 982
909.900,901,910,911, 920,921,960,970,971 06V
924.911,915,916,920 06T
926.911-915,917,924,929 06V
En cas de commandes de pieces, vous devez absolument indiquer la page sur laquelle figurent les pieces en question.
7
S1035
En cas de comrnande de pieces, il faut - en fonction des besoins - absolument indiquer les donnees suivantes (voir fiche
signaletique du vehicule):
1. Numeros d'identification du vehicule (nO de chassis), de moteur, de carrosserie, de cabine.

Pour les organes mecaniques, indiquer Ie numero complet de la hoite de vitesses, des essieux AV/AR ou de la direction (voir
fiche signaletlque).
2. Numero d'impression et edition de ce catalogue.
3. Numero de la planche illustree (en haut it droit) et numero de la figure.
4. Ouantite souhaitee,
C'est Ie reseau de service apres-vente de la Mercedes-Benz AG qui est seul responsable pour la livraison de pieces.
Exemple d'une commande

Pour moteur 314.910-10-096127, n" d'impression 6450 000180 Edition A
Page 23, planche illustree 01, figure 21 1 unite
Page 32, planche illustree 07, figure 260 3 unites
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.
8
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 Pagina Catalogo
Motor 904.904-911,914-917,921-923,927-931,936,942,944, 21 - 82 06T

946, 947-953, 955, 959, 961, 964
90Z910, 920, 930, 940, 941, 960, 970, 980, 990 06T
Motor 906.910, 911, 915, 916, 919-923, 925-928, 930, 931, 935, 85 - 161 06V
937-941,949-952,954-956,960-965,976,982
909.900,901,910,911,920,921,960,970,971 06V
924.911, 915, 916, 920 06T

926.911-915,917,924,929 06V
Es muy importante que, al efectuar pedidos de piezas, se indique tambien la pagina en la que se eligieron las piezas reque-
ridas.
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 0 cabina. En caso de
grupos: mimero completo del cambio, eje delantero 0 eje trasero, 0 de la direcci6n (vease ficha de datos).
2. Ntimero de impresi6n y edici6n del presente catalogo,
3. Ntimero de lamina (arriba, a la derecha) y de ilustraci6n.
4. Cantidad deseada.
Unicamente la organizaci6n del servicio postventa es la encargada del suministro de piezas de la Mercedes-Benz AG.
Ejemplo para la formulacion de un pedido

para motor 314.910-10-096127, N° de impresi6n 6450 000180 Edici6n A
pagina 23, grupo 01, ilustraci6n 21 1 unidad
pagina 32, grupo 07, ilustraci6n 260 3 unidades
Las piezas para motor, chasis y, en vehiculos industriales, tarnbien para superestructura ° cabina se encuentran en catalogos
aparte.
Las tablas graficas de grupos se encuentran en el apendice del catalogo de chasis.
10
S1035
Considerazioni preliminari
Questo catalogo illustrato vi servira a determinare ed ordinare i pezzi necessari per la manutenzione risp. riparazione della
vostra MERCEDES-BENZ. Esso contiene le tavole illustrate dell'Equipaggiamento di Base.
Talvolta i pezzi raffigurati nelle tavole illustrate non corrispondono pili all'ultima versione.
II vostro prodotto MERCEDES-BENZ pub essere dotato di equipaggiamenti speciali (SA) che non sono elencati in questa
catalogo. Per stabilire gli esatti pezzi e assolutamente necessario presentare agli organi di servizio MERCEDES-BENZ la
cartolina del veicolo ovvero dei dati del motore.
Le tavole illustrate valide per la vostra MERCEDES-BENZ dipendono generalmente dai numeri d'identificazione del veicolo
(del telaio), del motore, della cabina e, per gli autobus, della carrozzeria. (Vedi scheda dei dati del veicolo). Si prega di tener
conto delle prime 6 cifre di questa numero riferentesi al cosiddetto modello di costruzione.
Denominazione Modello costruzione Pagina Catalogo
Motore 904.904-911,914-917,921-923,927-931,936,942,944, 21 - 82 06T

946,947-953,955,959,961,964
90~910, 920, 930, 940, 941, 960, 970, 980, 990 06T
Motore 906.910,911,915,916,919-923,925-928,930,931,935, 85 - 161 06V

937-941,949-952,954-956,960-965,976,982
909.900,901,910,911,920,921,960,970,971 06V
924.911,915,916,920 06T
926.911-915,917,924,929 06V
Per le ordinazioni dei pezzi e importante che indichiate anche la pagina dalla quale sono stati scelti i pezzi necessari.
11
S1035
Per l'ordinazione di pezzi e strettamente necessario, a seconda del fabbisogno, fornire i seguenti dati (vedi scheda dei dati del
veicolo):
1. W d'identificazione del veicolo (N° di telaio), numeri del motore, della carrozzeria e della cabina. Per gli aggregati l'intero
numero del cambio, dell'assale anteriore 0 posteriore 0 dello sterzo (vedi scheda dei dati).
2. Numero di stampa ed edizione di questa catalogo.
3. Numero della tavola illustrata (in alto a destra) e della figura.
4. Ouantita desiderata.
Per la consegna dei pezzi il solo responsabile e l'organizzazione assistenza clienti della Mercedes-Benz AG.
Esempio ill ordinazione

Per il motore 314.910-10-096127, N° di stampa 6450000180 Edizione A
Pagina 23, Tavola illustrata 01, Figura 21 N° di pezzi 1
Pagina 32, Tavola illustrata 07, Figura 260 N° di pezzi 3
I pezzi per motore, telaio e, per i veicoli industriali, anche per la carrozzeria e la cabina si trovano in cataloghi separati.
Le tavole illustrate per gli aggregati sono contenute nell'appendice del catalogo illustrato del telaio.
12
S1035
Advertencias preliminares
Este catalogo ilustrado tern por fim facilitar a V. Sa. a identificacao e a encomenda de pecas para a manutencao e a reparacao
do seu MERCEDES-BENZ. Ele contem os quadros ilustrados da versao basica.
As Ilustracoes nos quadros nao correspondem, em todos os cas os, a versao mais recente das pecas.
E possfvel que 0 seu vefculo MERCEDES-BENZ disponha de equipamentos especiais (SA) nao mencionados neste catalogo,
Para a determinacao das pecas adequadas, e absolutamente indispensavel a apresentacao do cartao de dados do veiculo ou
do cartao de dados do motor nos postos de service MERCEDES-BENZ.
Os quadros validos para 0 seu produto MERCEDES-BENZ dependem do respectivo mimero de identificacan do veiculo (nu-
mero 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 Pagina Catalogo
Motor 904.904-911,914-917,921-923,927-931,936,942,944, 21 - 82 06T

946,947-953,955,959,961,964
90Z910, 920,93~940,94L960,970, 980,990 06T
Motor 906.910,911,915,916,919-923,925-928,930,931,935, 85 - 161 06V

937-941,949-952,954-956,960-965,976,982
909.900,901,910,911,920,921,960,970,971 06V
924.911,915,916,920 06T
926.911-915,917,924,929 06V
Para a encomenda de pecas, e de suma importancia que V. Sa. mencione tambem a pagina da qual selecionou as pecas
necessitadas.
13
S1035
Na encomenda de pecas, sao absolutamente necessaries as seguintes dados, em dependencia cia necessiclacle de pecas (vide
cartao cle daclos cia veiculo):
1. Numero cle identificacao cia veiculo (numero do chassi), niimero cia motor, da carrocaria au da cabina, resp.
Em se tratanclo de grupos de maquinas, fornecer a mimero completo cia caixa cle mundancas, cia eixo clianteiro au traseiro,
ou da direcao (vicle cartao cle dados).
2. Ntimero cle impressao edicao cleste catalogo.
3. Niimero cia quaclro ilustrado (no alto aclireita) eo mirnero da Ilustracao.
4. Quantidacle clesejacla.
A entrega cle pecas compete exclusivamente ao service de atenclimento aos clientes da Mercedes-Benz AG.
Exemplo para uma encomenda

Para motor 314.910-10-096127, mimero cle impressao 6450 000180
Pagina 23, grupo 01, ilustracao 21 1 peca
Pagina 32, grupo 07, ilustracao 260 3 pecas
As pecas para 0 motor, a chassi e, para veiculos utilitarios, tambern para a carrocaria e a cabina clo motorista, foram agrupadas
em catalogos em separaclo.
As ilustracoes para os grupos cle maquinas constam cia anexo do catalogo ilustrado para a chassi.
14
S1035
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937-941,949-952,954-956,960-965,976,982
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924.911, 915, 916, 920 06T

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15
S1035
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16
S1035
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Motor / Engine / Moteur 904.904-911,914-917, 921-923, 927-931, 936, 942, 06T

944,946,947-953,955,959,961,964
90~910,920,930,940,941,960,970,980, 990
924.911, 915, 916, 920

S1035
S1035
Motorgehause ICarter do motor Gruppe Grupo
Engme Housmg
Carter du moteur
Carter del motor
uaprep ASliraTenA
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Grupo
rpynna
01 005 00027
Basamento motore )J~ rl ..JS-..o
i Gruppo :<...>- J-....=I.I
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18 Turbochargeur
Sobreahmentaclon
15 Eleklrische Ausriistung
Electrical Equipment
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14 Saugrohr und AuspUffkrummer

/. ;::::~~'~~~~~~~~t,,__-.007 Einspritzung
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22 Motoraufhanqunq
20 Motorkiihlunq Engine Suspension
Engine Cooling System Suspension du moteur
Refroidissement du moteur Suspension del motor
Refrigeracion del motor
23 Lenkhelfpumpe
Power Steering Pump
03 Triebwerkleile Pompe pour servo-direction
Moving Parts Bomba de la servodirecci6n
Organes moteurs
Piezas motrices 09 Kraltstoff-Fllter
Fuel Filter
Flltre a combustible
Filtro carburants
21
S1035
Motorqehsuse
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I
Carter do motor
Carter del motor
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15
22
S1035
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23
S1035
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24
S1035
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S1035
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26
S1035
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27
S1035
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410
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28
S1035
Zylinderkopf I Culata
Culatra Gruppe Grupo
Cylinder Head
Culasse ronoaaa ono.Ha u~mlHl1pOB
Group
Groupe ~;~~~a . 01 075 00235
Testata )..c..:.LJi ....)) Gruppo I ~J........"d.\
<j 240
@245
220
~ 235 230
W@({@ZJ)
215
210
~225
29
S1035
Zylinderkopf ICulatra
ulata 08 Gruppe
Group I Grupo
Grupo 0 1 07 5
Cylinder Head C OSKa onoKa UI1l1l1HAP
~pyn'::'J.i
00288
Culasse
Testata r~\
_ ~).J Groupe
Gruppo ~_ .
140
~
165 165
~
~
30
S1035
Zylinderko f
I
Cylinder H~ d Culalra Gruppe
Group
I GGrupo
Culasse a Culata
_ _ _ -'--.:)~'~.I
Testata ronoaua Ii
6niOKa UI1nJ-IHAPOB
.r~
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01 075 00289
_
350 33~ 350
330 ~@
~~~~ \D340
~
3BOl Il 350 1345
375~ ~ 345
(j)
3~ ~?55 355
325
31
S1035
Zylinderkopf I
Culatra
Cylinder Head Culata
Gruppe
Group
I
Grupo
Grupo
Culasse ronoBH,a6npHa 1.1I1J1I1HAPOB Groupe rpynna , 0 1 105 00061
Testata j..L.i..J1 ,..r.J) Gruppo ......~I
50
60
120
115~
Q9; 125
125 t2>
~
16 ~~~ 105
~@ ~, 14 55
~ ~0J
12 18 20
32
S1035
g;~~pe I Grupo
---~
~ ~G~r~o~uP~~ I ~';:.ti
Grup~~ 00208
Grupo
03 015
90
45
V 15
35 ~@65 80
@P
52 40
48
33
S1035
Iriebwerkteile , Orgaos molores Gruppe Grupo
Moving Paris Prezas rnotnces
Organes moleurs nerana I1Bl1raTenR
Group
Groupe ~;~~~a . 03 045 00159
Manovellismo c::-h'
•.;10)'\ ""L.,,:s:.. Gruppo I :w:.~..l\
34
S1035
Steuerung I Dlstnbuicao Gruppe Grupo
Trrnmq
Drstributron
Dlstribucion
pynesoe vnpaanenue
Group
Groupe ~;~~~a . 05 015 00146
Distnbuzione ~ ~....::Ji Gruppo I ;u. ~....,.:;d.1
25
10
35
S1035
Kraftsloffpum
Fuel Pump
d' ali pe I
Bomba
Bomba d e combustivel
Gruppe IG
Grup
com~~~:~~,on TonmIB~~I~mbustible
Pompe . Group
Grup~~ ':P"-'-J~l
vn na . 0 7 030
0
Grou rupo
j--,~--,-J\ ~oc
Pompa
ue __ 00269
36~-------------
S1035
Kraftstoffpumpe IBomba
Bomba de combustivel Gruppe I Grupo
Fuel Pump
Pompe d' alimentation
de combustible
TOnnl1BHbli'l Hacoc
Group
Groupe
Grupo
rpynna .
07 090 00144
Pompa combuslJbile o~...j ~...J\ ~ Gruppo ....... ~......;dl
30 25
ij)~
37
S1035
Kraflstoff-Filter
Fuel Filter
Filtro de combustivel
Filtro de combustible
Gruppe
Group
I Grupo
Grupo
Filtre a combustible TonmlBHblH cPl1nbTp Groupe rpynna . 09 030 00111
Filtro carburante ~~.,..Ji ;;L.La.., Gruppo ;w:.."""".1\
23 c:=:J
23
45
15
S ®
t78
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55
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25
80 83
89f~
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75 @ l--.o~_-\~) 35
75@ ~65 70@ ~~65 \30
70@
38
S1035
Kraflstoff-Riler mbustivel
Filtro de co bustible Gruppe
Group
I Grupo
Grupo
Fuel Filter
Filtre a combus I
fble Filtro de co.m<pl-1nbTp
TonnHBHblH Groupe rp
- ynna
.......,d\.
09 03000151
Filtro carburante -.,t·\-~
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119 113 TI 112
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119
(]§lQ:u
116
95 98
107
110
~104
39
S1035
Kraftstoff-Rlter
Fuel Filter
Flltro de combustivel
Rltre de combustible
Gruppe
Group
IGrupo
Grupo
Rltre a combustible TOnm-lBHblH ¢J11DbTP Groupe rpynna . 09 060 00029
Filtro carburante J;:>rli ;~ Gruppo ....... ~~\
~
40
1
125 130
35~V
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5~W 45® ~
65 10
35~~
105~~~75
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55 ~ 113
~~
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110
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113
111
56 57 15
40
S1035
1~rbOChargeUr ISobreahm
Aufladung
Turbocharger
SObreahm:~i:~~o GruppeI GGrupo
~ . \ 0 9 075
Group
vrahmentazione HaMye
~\ jL,-""
n Grup~~ ~n~.
Grou rupo
00129
270
365
~
355 ~
~
~ 80
41
S1035
~~~~~ 09 07 5
Sobreahmenta9a.o
Aufladung
Turbocharger
Sobreahmenta cion
HaMYs Gruppe
Group
I rpynna. 00149
Turbochargeu~ ne ...... ~\
sovrahmentazto
I
.,..=.:.Ii jLr.
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95
'V 320
65
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310
@ ~ 155 185
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300
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280 ~210
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.>: 85
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rf1 275
L;W
230
42
S1035
Aufladung
Turbocharger I Sobreahmen
SObreahmenia<;:~.o- g;~~peI Grupo
Grup~~ Grupo
~n~.
TSurbochargeur
~ . \ 09 075
Group
ovrahmentazione Ha,Q,lWB acton 00158
_ _ _ 1:':'...,...=..::.1\ jL,-o-
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330 345 375 I .. 140
J
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235 230 ~ ~227
265
355~ ~ 383@~282
280@"W
___ 220
43
S1035
Aufladung
Turbocharger
ISDbreahmenta<;~_~
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HaAQya Gruppe
Group
Ig~~~~
rpynna_
09 075 00185
TurbOChargte~~one
Sovrahmen a
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134
~
136
14~~
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@ 116
{If 148
146 ~390
1200
150~
44
S1035
Aufladung I Sobrealirnentacao Gruppe I Grupo
Grupo
Turbocharger
Turbochargeur
Sobreallrnentacion
HaWlYB
Group
Groupe rpynna •
09 07 5 00191
Sovralimentazione ~,..=..::.Ii jL,-"," Gruppo :w:. J.......,d\
138
142
146 ~
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120~
395 150
01 o
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280 187
@JD
45
S1035
Luftpresser
I Compressor de I Grupo
g~~~;~~eur ;~=y~or~e a~~
Air Compressor Gruppe
Group G
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ore ana d'air
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blH HOMn
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13 060 00079
77~
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~75 Q)G95 100
70~
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&>60 ~ 80
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15 45
55
~~ 25 20
46
S1035
Luflpresser
Air Compressor
I Compressor de ar
Cornpresor de aire
Gruppe Grupo
~~~~a
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Compresseur d'air B03AYWHblH HOMnpeccop Groupe . 13 075 00126
Compressore aria ,\ y-;Ji.!a..i.L." Gruppo I :\...<;. ~....=,J.\
35
70 ~
65 ~
80
90@
150~
140
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145 \] \'L.Jo!~---'"
47
S1035
Luftpresser I Compressor de ar Gruppe Grupo
Air Compressor Cornpresor de aire
Compresseur d'air B03,QYWHbIH HOMnpeccop
Group
Groupe ~;~~~a . 13 075 00142
Compressore ana 'I.hJi .h..i.L..:. Gruppo I ~ .,.-J.\
130
48
Saugrohr und AuspuffkrUmmer Tuba de adrnissao e calector de escape S1035
Intake and Exhaust Manifolds
Collecteurs d'admissian et
Tuba de admision y calectar de escape
BnycHHaR Tpy6a '" uoneuo
Gruppe
Group
I Grupo
Grupa
d'echappernent BblnycHHora Tpy6onpoBaAa Groupe rpynna " 14 0 1 5 00194
Condollo aspirazione e callellare scarico ~i ~,U\.J LI""~i ""'.r'i Gruppa ;u: ~\
49
S1035
Auspuffkrummer
Exhaust Manifold
IColector de escape
Colector de escape
Gruppe
Group
I Grupo
Grupo
Collecteur d'echappernent KoneKOBblnycKKoro Tpy6onpoBoila Groupe rpynna . 14030 00267
Collettore scarico ~i t,Ui Gruppo W. ~~\
180 165~
@175
@ 155 ~ 170
210 ~ ,\:,220 195 185 190 ~ 175 155 C?0 @ 180
215 @O -\) ®=J ® ~@ ~160
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205
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120
50
Saugrohr und AuspuffkrOmmer Tubo de adrnissao e colector de escape S1035
Intake and Exhaust Manifolds Tubo de admislon y colector de escape Gruppe Grupo
Collecteurs d'admission et Group Grupo
d'echappement
BnycHHaA Tpyoa " HoneHO
BblnycHHoro TpyoonpoBoAa Groupe rpynna . 14030 00339
Condotto aspirazione e collettore scarico ~i ~'l,J\.J ..r"~i ..,..,y-,'i Gruppo I :Ls.~~1
~ 15
51
S1035
Gruppe
Group
I Grupo
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Groupe rpynna 15 010 00007
Gruppo ;w;.~....-.J.i
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@
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7
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52
S1035
Elektrische Ausrustung
Electricai Equipment
IEquipamenlo electrico
Equipo electrico
Gruppe Grupo
~;~~~a
Group
Equipement electrique 3neHTpoo6oPYAoBaHHe Groupe 15 010 00008
Impianto elettrico <""';~J~i dJ~i Gruppo .....J~i
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II"
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41
I o
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53
S1035
Elektrische AusrUstung I
Equipamento electrico Gruppe I Grupo
g;~~~e ~;~~~B.
Electrical Equipment Equipo electrico
Equipernent electrique 3J1eHTpoo6oPYAosBHHe 15 01 0 00052
Impianto elellrico :c..,,;~~-..(Ji d~~i Gruppo U.~......;;--..ll
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165
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157 263 278
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318
395
54
S1035
Eleklrische Ausrustung I Equipamento electrico Gruppe Grupo
Equipo electrico
3I1eKTpoo6oPYAos8HHe
Group
Groupe %~~~8 . 15 010 00053
Impianto eleltrico :c..".;l:~.....;5Ji ",,\~~i Gruppo I :w.J.....q-..l.1
55
Elektrische Ausrilstunq
I
Equipamenlo electrico
Equipo etectrlco
Gruppe
Group
I Grupe
Grupo S1035
Equipement electrique anexrpoodopvnoaauae Groupe rpynna . 15 0 1 5 00173
Implanlo elettrico ~~~-.;s:Ji d~i Gruppe ....... ~~I
30
6570~
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15
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10
90 85~'
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55 75
56
S1035
Elektrische A "
IEquipament' g~~~pe I Grupo
I~~!~~r::~nltttelectriq~e ;~eUiPoelect~i~~ectrico
Electr'
E usrustung
,leal Equipmen Grupo
~G:rup~~ ~n~.
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Group
e nco ~~~.
HTPoo6oPy~oBaH~e
15 030 00196
.. ,~ \d~~i ____________
12
9
~ 135
t?J
57
S1035
~uiPeme~i~'I~~~~~ IE' I grupo
Elektrische ..
E~~:~~~~~o. electrico
Electrical Ausrustung Gruppe
Group
pianto elettrico e
_-__v_"""'-_'_C>'::"\J~::_~'~~-li~
wL. .s;)' PYAosaHHe
:>neHTpoo6;'co
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_ _ _ _ _ _ _ _ _ ~G~ro~u:~
Grup~~ I ~t':".J·1
_
rupo 1 5 030
00230
----
60 45
~
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55
(1J
58
S1035
Elektrische A ..
1~U1pement
E . ca I Equipment
Electri I
usrustung Equipament' Gruppe
Group
I GGrupo
Grup~~ ~n~:.t'
electriq Equipo eleCr electrico
~~ ~.oPYAOBaHHe
pianto eleltrico ue 3I1eK1;looD nco
Grou
~ . \ 1 5 03 0
rupo
00257
____.~-T \ ",,\~i
59
S1035
Elektrische A
E . leal Equipme
Electrl
..
usrustun 9
I quipernent elect nt
I Equipo
Equipamen .
el .Jo, electrico
Gruppe
Group
I GGrup 0
mpianto eletlriconque 3neKTpO~6;ICO

~~~. PYAosaHKe
_.~ Id~i
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G pe
_ _ ruppo
rupo
rpynna
u~i
15 030 00284
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143
G @,~ 142
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130
67 68 46 j
92
60
S1035
Elektrische Ausrllstunq IEquipamenlo alectrlco Gruppe Grupo
Equipo electrico
anearpootiopvnoeaaae
Group
Groupe %~~~a . 15 045 00172
Impianto elellrico :L,..:l;~,sJi d j...~i Gruppo I :Lc .....
~J.\
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155 145 ®
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160 1°50
205 @)~ 165
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230(j}p~' c
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115 ~'\3tio
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5 40
61
S1035
Elektnsche Ausrtistung
Electncal Equipment
I
Equipamento electrico
Equipo electnco
Gruppe
Group
I Grupo
Grupo
15 045
Equipement electnque 3neHTPOo6opY,QosaHHe Groupe rpynna . 00202
lrnpranto eJettnco ~~~....,s:Ji ,::..I.j-".p.c:Ji Gruppo :L.>.~~\
255 ~ o~
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215
140
210 220
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50 135
185
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75
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240 @p
190
62
S1035
Elektrische AusrUstung IEquipamento electrlco Gruppe Grupo
%~~~a
Electrical Equipment Equipo electrico Group
Equipement electrlque snearpootiopvnoaauae Groupe 15150 00001
Implanto eletlrico ~l.:~.,sJ\ d~~\ Gruppo :u:. ~.....,;;d\
63
S1035
~~~iS~ag~
~~t?rSChmierung
glne Lubricar ILubrifica -
du ~~~ur Lubricaci: d~~ motor
o Gruppe
Group
I
Grupo
G
18 0 15
'"-"-J~i
Groupe rupo
yn na
_ _ _-=o"re~ I,'
n cazione mot CMa3Ha AS" motor _ Grupp 0 :P 00165
---:.-::....=-----
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J.r>..::-'
"raTenA
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60 c
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80~
6
90
64
S1035
Motorschmierung I Lubricaci6n
Lubrificacao do motor Gruppe Grupo
Engine Lubrication
Graissage du moteur
del motor
CMa3Ka flBl-1raTeJ1A
Group
Groupe
Grupo
rpynna
. 18 045 00270
Lubrificazione motore .J;:;.rl\ ~ Gruppo I ..... ~......,.J.i
~20
145
~
15~@
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160 @
155
165 00°
o
q 0 °
0
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140
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30
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85
65
S1035
Lubrificacao do motor Gruppe I Grupo
Grupo
Engine Lubrication del motor Group
Groupe rpynna .
18 060 00142
Graissage du moteur CMa3Ka ABHfaTeJ1R
Lubrificazione motore .J~~.....ll ~ Gruppo ;w;.~~\
~60
8 @75
5
~85
~
~~
70 55
15
60~o@
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105 IJ @~15
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@
66
S1035
Grup~
- do molar
Rejrigera~~.o
RefrigeraCI~~
MolorkUhlun.g S stem
Engine Cooling I Ju moleur oxna-anen
del motor
ABl-!raTenA
..
Gruppe
Group I rpynna
Grup
•
20 0 1 5 00 294
Refroidissemen tore . .;;...J.I -'-7. .,T"7'
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283 ~ 275 215
282 160
139
@ 0 160 0 220
@~157
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-------~67
S1035
Molorkilhlung
Engine Cooling System
IRefriqeracao do molar
Refrigeraci6n del motor
Gruppe Grupo
Relroidissemenl du moteur oxnamAeHHe ABHraTe.nA

Group
Groupe ~;~~~a . 20015 00347
Rallreddamento molore J J';; JJi -'-7._~ Gruppo I ......._--"..1\
24
(9JJ1l
68
S1035
Mot?rkuhlun.g
IRefriqeracao do motor
Gruppe
Group
I Grupo
Grupe
Refroidissement du moteur oxnal-H,QeHl-ie ,QBl-iraTenA Groupe rpynna 20 0 15 00366
Raffreddamento motore ) y ~.Ji _'-'.~ Gruppo :i....<:.~1
~
385
~ 415
405 350
69
S1035
I
MotorkOhlung
Refroidissemenl du moleur
Raffreddamenlo motore
Refrigera<;:ao do molor
Refrigeraci6n del molor
oxnaHil1eHHe.QBHraTenR
.JJ".:-li ~~~
Gruppe
Group
Groupe
Gruppo I
Grupo
*~~~a
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, 2 a a1 5 00399
106~
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8
106~ '~M~1l8
o lffi
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109 ~
70
S1035
MotorkOhlung
IRetriqeracao do motor
Gruppe Grupo
Refroidissement du moteur OXJ1a/t{AeHHe ABHraTenA
Group
Groupe ~;~~~a . 20 030 00125
Raffreddamento motore . ,,;;...J.i _'-'--'-:;
J..;..,I •• ~ •
Gruppo I ....... ~....-..ll
18
20
30
® ~' ~
,40~f
® ~ 55
25 50
15
52
71
S1035
MotorkGhlung I
Refngerac;iio do motor Gruppe Grupo
Refroldissement du moteur
oxnafH/1eHfie /1BfiraTenR
Group
Groupe
Grupo
rpynna
20 100 00007
Raffreddamento motore JY~...J\ ~_~--7 Gruppo I ~~~i
72
S1035
Motoraufhanqunq
Engine Suspension
ISuspension
Suspensao do motor
del motor
Gruppe Grupo
Suspension du moteur
Sospensione del motore
nOABeCHa ABHraTeJlR
rl
.; ~...;; i "",:>'L..r
Group
Groupe ~;~~~a . 22 015 00100
Gruppo I :<....<..~\
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75
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80
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cc
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10 30
65
55 30
73
S1035
SonderausfUhrungen IVers6es especiais Gruppe Grupo
Special Versions
Versions speciales
Ejecuciones especiales
cneu-ransuea KOMnl1eHTaL\HR
Group
Groupe
Grupo
rpynna
23 010 00001
Versioni speciali :<..-.ui dj~':Ii -,i djly-laJi Gruppo I ,--,-~i
55
@ 53
W
52
[):~
22
40
() 35
74
S1035
Sonderausfilhrungen I Versoes especiais Gruppe
Special Versions Ejecuciones especiales Group
Versions speclales cneuaansaas HOMnneHTalll1R Groupe 00122
Versioni speciali .........u.i dj~...;~i -,i djl.."....wi Gruppo
20 25
75
S1035
Nebenantrieb
P. T. O. ITomad Gruppe
Group I Grupo
G
Grup~o ~=~i
Prise de fore .. Toma a de forca
Presa di f orzae auxillaire aTe>LOP de fuerza u Grou e rupo 00024
_
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cs-""'L;;,..'
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cr'L,''':11, J-:,.i..:.::Ji 23 045
n~"c%lC
Q; ~ ~ 165 155
160
70 112
50
766-------
S1035
Gruppe
Grou I GGrupo
rupo
Grup~~ ~pvnna
Group
~~~\. 23 045 00031
206
L"
~~:u~
\J ~
~~ 202
,,/
205
201
25
77
S1035
~ebenantrieb
. T. O. I Tomad a de forca Gruppe
Grou I GGrupo
rupo
Grup~~ ~:~i
Prise de fore "" lorna Group
Presa di f orza
e auxilialre oro opde fuerza 00032
~L..;:.,.:
_
MOUUHOCT
_ ) \". ) 1. ", .••
Hcr'-"':I\ ~\
23 045
106
oo~
135 140 145
trPQ45
78
S1035
ITomad
cr_.~_I. : J: : :_;~.-J~i_ _ ~ruppe
Nebenantrieb
P. T. O.
~~-""\ Gru~~~ I
Prise de fore Toma a de forca G~~up Grupe
~\
~L,.:.>)ti__
Presa di f orzae auxiliaire oT6 opde fuerza
MOl1.\HOCT cs:
Grupo 00035
__ ."i Jo1 'w," ,?ynna . 23 045
400
~
220
265
2~ () [J ;lil392 375 380 385

370 • Jii& o&ll
~~~~IQ~ Jo&ll
390" 'f;J' 365 330
~ ~
I ~~~@ ~Q~q!5~0
395'@
245
!Q \l! 310 315 320 325
~. '\11,
~
305
295' 300
\i) 275
290
79
S1035
Kaltekompressor
Refrigerant Compressor
Compressor do produto refngerante
Compresor de refrigeraci6n Gruppe
Group
I Grupo
Grupo
Compresseur pour installation d'air OXJ1aAHTeJ1b
conditio nne -'--:!~\ .;,-=.:.. -'i crW
Groupe rpynna . 23 07 5 00010
Compressore irnpianto refrigeratore Gruppo t i _~\
45 20
~
55
80
Kaltekompressor Compressor do produto refrigerante S1035
Gruppe Grupo
Refrigerant Compressor Compresor de refrigeraci6n
Group Grupo
Compresseur pour installation d'air oxnaAHTeJlb
Groupe rpynna 23 075 00018
conditionne ..l-;~\ ~ "i ..,.L.,5 Gruppo :t....c..~~i
Compressore impianto refrigeratore
60 ' l - - - - - - - - - - - - - - - - - - - ,
81
S1035
SonderausfUhrungen I
Vers6es especiais Gruppe Grupe
Special Versions
Versions speciales
cneuaansaas KOMnneKTaLjYlA
Group
Groupe %~~~a . 23 1 0 0 00001
Versioni speciali ~L3-i dj~,:!i Ji d)\."..Jdi Gruppe I ~_~..l.\
82
S1035
Baumuster/Modef/Modele Katalog
Motor / Engine / Moteur 906.910, 911, 915, 916, 919-923, 925-928, 930, 06V
931,935,937-941,949-952,954-956,
960-965,976,982
909.900,901,910,911,920,921,960,970,971
926.911-915,917,924,929
83
S1035
S1035
~oll:,rgehiiuse
ngme Housin
Carter d
Carter d~1 motor Gruppe
G roup
I Grup 0
Carter d u moteur
B 9 aaprep motor
) ....:; ...J.o!'1BHraTeJ1R
Grou
G pe
Grupo
rpynna 01005 00039
AJ;. ~......;JI
asamento motore
I ~ ~ I J>.-.:,.o ruppo
07 ~inspritzung
ruection
Injection
Inyeccion
13
L~ftpresser
~Ir Compressor
C~mpresseur d'air
mpressore aria
Lenkhelfpum
Power Steerl pe
Pompe po ng Pump
Bomba de~~ servo-~irectlon
Elektrische A ,. servodirecclon
Electrical E usrustunq
EqUiPemeni~\~m,:nt
Equipo elect' ctnque
20 Motorkiihl
Engine Co~7? ?_2 Motoraufh" nco
Refroidissemng System Engine su:ngun~
Refrigeracione;tldu moteur
e motor suspensiO:~nslon
Suspension du
el moteur
motor
03 Triebwerkt 'I 09
Moving pa~' e
}(raftstoff-Filt
Fuel Filter er
Or s
P' ganesmoteurs Filtre ca~~mbustiblE'
a
iezas motrices Filtro
urante
85
S1035
Motorgehause , Carter do motor Gruppe Grupo
Engine Housing Carter del motor Group Grupo
Carter du moteur aapren /jBl-fraTeJlR Groupe rpynna 01 010 00035
Basamento motore ) y:;•..J.i w~ Gruppo I w-•......:;Ji
86
S1035
Motorgehause ICarter do motor Gruppe I Grupo
Engine Housing
Carter du moteur
Carter del motor
xaprep ~B",raTenA
Group
Groupe
Grupo
rpynna .
01 015 00250
Basamento motore ) ~ J...J.\ J>--=", Gruppo A...>:. J....-l\
314
83
((, ~
89
(]
278~
23 ~ l' "0 o @
248~
@320
@326
29 206 Bfl 5
236
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218@ 248~ 250 at"~ ~
59 cCJ. A 242
@~
248 .. '<, ~ 246 179 1jU191
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212[/ 244
87
S1035
~~~~~
~ngine Housing
Motorgehause
Ig~rter do motor gruppe
roup
I Grupo
Grupo
;w:.~i 01 045
arter du moteur arter del motor Groupe rpynna
Basamento motore Kap~ep IClBHraTeJ1A Gruppo 00207
Jr'rl\ JL,..
23
'00~ ,
")))~
\)' 140
,
C)
,
130 120
ij)
128
15
88
S1035
Motorgehause
Engine Housing
I
Carter do motor
Carter del motor
Gruppe
Group
I Grupo
Grupo
Carter du moteur HapTep ABVlraTeIlR Groupe rpynna • 01 060 00149
Basamento motore ).,...:;rl
i J5.....:;o Gruppo ~~......".J.I
92
380
@
'7
.-, Jfl 263
275
260\j
~
208
0
()325
<§l330
255~
~235
344
@~42
'I\l(Q ~350
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~ @J 21 8
365 ®
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85 i 390
80 [j385
© 25
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r@ 21
'@395
89
S1035
IHapTep
Carter del moto~R g~~~~ 01 060
Carter do motor
Motorgehiius.e
Engine Housln~r i;lBV1raT
Gruppe
Group
I rpynna. 00157
~
)~..-'...J.\
C rter du mote Groupe ;w:. .......:;d \
s:samento motore ... Gruppo ~
LJ325
C@ 268
@330
300 152~ 265

r1 ta
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280 ~130
~133
180 @ 155
240 ~
235 ~ 50 ~
110, ~
60 ~f4
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105 290
!/ib@4~~
63
220 •
0 0
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69 76
@~77
7~~ '~c",i:)
c
95
75
90
S1035
Gruppe
Group I GGrupe
Greu
G pe
rupo
rpynna 01 060 00177
ruppo ~~~i
195
30(i') @
35
~
166
16
91
S1035
Motorgehause
Engine Housing
I
Carter do motor
Carter del motor
Gruppe 1 Grupo
Group Grupo
Carter du moteur saorep J;\Bl-lraTeJ1A Groupe rpynna , 01 060 00265
Basamento motore ).,...:;.,...t\ J5....".o Gruppo :w:. ~......:;d \
105
92
S1035
Cylmder H~ad
Zyhnderko f I
gUlatra
Culasse
Testata
ulata
)..Li.Ji 6noHa
ronoaxa . UHm.,HAPOB
00228
J))
300~ 275© i 305

~ 130
275©
260 ; 250
~ ® 310
~ 300 390 @ 125
~ ~ 120
r;;f~ 282 I:iJ 115
85
298 280@
50 ©
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U '8
g
~ 110
55 g 0 45
~ 105
1~
00
e 90
9 I:iJ 80
10 0 : ® 75
~ 70
172~
~ <§>
65
93
Zylmderkopf
Cylinder Head
ICulatra
Culata
Gruppe
Group
I Grupo
Grupo S1035
Culasse ronoaaa 6noHa I.\HnHH.QpoB Groupe rpynna 0 1 075 00229
Testata .)..t...:LJi ,ri.) Gruppo U. ~~i
i 240
@245
196
CD@ 198
v 195 190
, @~ ~
~_1L.-!.'i~
220
~ 235 230
([) @«riJ[)
200
~215
210
"<,
1 a
;225
94
S1035
CylinderH~ad ICulatra
Zylmderko f Gruppe
Group
I
Grupo
G
Gruppo ~:~i
JG~ro~~u:~p~e
Culasse Culata
6nt
00230
Testata
r- -'-JJ~1
ronoaua
·1 Ii
Ka
l.lWlHHApOB _ _ _ _ _ _ _ _ _ _ _ _ rupo 01 075
I ,-""'.J _
320
o
325
95
S1035
H~ad I Culatra
Zylinderko f
Cylinder g~~~pe I
Grupo
~Gr~upp;pP;;~ ~=~i 01
Culasse Culata Group Grupo 00291
Testata J..L:.l.Ji
ronoaaa 6niOHa 1l",m1HAP08
_________ 075
..rJ
165
gj
160 \J)1J
96
S1035
Zylinderkopf ICulatra
Gruppe
Group
I Grupo
Grupo
Culasse ronoaaa onoKa !.1l1nHHAPOB Groupe rpynna 0 1 105 00069
Testata .)..L-i...J i J"' i.) Gruppo '-<. ~......:;Ji
68
~
' ~160
o
150 ~
o
5
~41
115
47
97
S1035
Zylinderkopf I
Culatra
Gruppe
Group
Culasse ronoBH,a6npHa UWlI1HAPOB Groupe 00080
Testata ..>..e-:U1 ~,..,I..> Gruppo
S)
50
o
59
77
e
8
98
S1035
Triebwerkterle
Moving Parts
I
Org30s motores
Piezas motnces
Gruppe
Group
Grupo
Grupo 03 015
Organes moteurs AeT8nH ABHraTeJ1R Groupe rpynnB . 00195
Manoveilismo ;.J\,~\ <.:JL...,,:s:.. ~ Gruppo I ;w.J~\
40
46
[PD
75
70
~
Q)O 65
73
99
S1035
Triebwerkteile
Moving Parts
I
Orqaos motores
Prezas motnces
Gruppe
Group
Organes moteurs nerana .QSHraTenR Groupe 00159
Manovelilsmo o.;b:;,rl ""~ e:---W Gruppo
100
S1035
Steuerung
Timing
I
Distnburcao
Dlstrlbucron
Gruppe
Group
Distribution pynesoe vnpaane-u-e Groupe 00147
Drstnbuzione "--="'" ~...:.:Ji Gruppo
25
10
to
15
101
S1035
Kraftstoffpumpe
Fuel Pump
I Bomba de combustivel
Bomba de combustible Gruppe
Group
I Grupe
Grupo 07 030 00290
Pompe d' alimentation Tonm'BHblH Hacoc Groupe rpynna
Pompa combustibile 0 ~...j~..J\ ~ Gruppo :L.>. ~...-.J.i
17
~ 70
102
S1035
Kraflstoffpumpe
Fuel Pump
I Bomba de combustivel
Bomba de combustible
Gruppe I Grupo
Group Grupo
Pompe d' alimentation Tonm,sHblH Hacoc Groupe rpynna 07 090 00157
Pompa combustJbile .)"..:i"..J\ ~ Gruppo ti~i
30 25
ij)~
103
S1035
Kraftsloff-Filter Filtro de combustivel Gruppe Grupo
Fuel Riler Rilro de combustible
Fillre a combustible TonmlBHblH cjJl1nbTp
Group
Groupe %~~~a . 09 030 00116
Fillro carburanle J r'~..Ji ;l....i...... Gruppo I ...... ~.....-..l\
c=::J
S~
c
fe 23
23 25
45
45
15 80 85
10
9°f~
___ @Cl
~~
60
1 35 40
60
1 75@
0
t~@35
75@ ~65 70~ ~65 \30
70~
104
S1035
Kraftstoff-Filler
Fuel Riter
Filtro de combustivel
Fillro de combusllble
Gruppe
Group
I Grupo
Grupo
Fillre a combustible TonmlBHblH epHObTp Groupe rpvnna _ 09 030 00125
Fillro carburanle 0.r'rli;L.i...a.., Gruppo u.~\
lS0f! ,@i ® 145

135~1851
~130
145@
@140
155@
o
~ e130
®145
175 120
165 ([®@ 165~~ 170
r@ 160
175 ~ ~
~180
~ij).
ij)~ 200 195
200 190
105
S1035
Kraftstoff-Filter Filtro de combustivel Gruppe Grupo
Fuel Filter Filtro de combustible Group Grupo
Filtre a combustible TonIll1BHbll1 cPl1JlbTP Groupe rpynna 0903000150
Filtro carburante ".r" ~..Ji ,L.i...a.. Gruppo I ~~.....:;d\
115 110
f\)\.
\2!J c®.
115
CP~
113
95
97
105 105
106
S1035
Kraflstoff-Filter
Fuel Filter
Flltro de combustivel
Filtro de combustible
Gruppe
Group
I Grupo
Grupo
Rltre a combustibie TOnm-lBHblH ¢WlbTP Groupe rpynna . 09 060 00032
Rltro carburante ,~....;~..Ji ,L...i..a.. Gruppo "--<:.~~I
~
140 ~~
145
160 150
~130 @~
20 25 ~~155
165
(J;;J B 110
'\5-Qo 1f 12 0
_ ~15 ~ ®@ 100
40 ~~®II(
@D ~
" 30 S ~ 105
~~
115
5
90 95
107
S1035
Aufladung
Turbocharger
, Sobreahrnentacao
Sobreailmentaci6n
Gruppe
Group
I Grupo
Grupo
Turbochargeur HaMYS Groupe rpynna . 09 075 00148
Sovrailmentazione ~i jLr.- Gruppo :i..c~~1
~315
25
65
~94
~
160 220 eu 152
diJ"
251
f'~
190
~& ~
@P
280
®
IJ75 ~
~~"(\J)
55
108
S1035
Aufladung
Turbocharger
, Sobrealimentacao
Sobrealimentaci6n
Gruppe
Group
I Gnupo
Grupo
Turbochargeur HaMYs Groupe rpynna . 09 0 7 5 00155
Sovralimentazione ..r=-0i )L;~ Gnuppo u~~\
@
175 ~
170
160
185~
~
280
G:
Q
()
Q
0
2 00
109
S1035
Aufladung
Turbocharger
Turbochargeur
ISobreailmenta
SObreailmenta~f·o
-
Sovrailmentaz',one HaAQYB
_ ,." jl.-.-"'" on
~\
235 295
~~
~~
«
«
f'
«
~380
~375
110
S1035
Aufladung
Turbocharger ISObreahment:~~·o
Sobreahrnent - Gruppe
Group
I Grupo
G
Grup~~ ~:~i 09 075
1urbOChargeUr Grou rupo
ovrahmentazione Ha,Qiwe IOn
00172
.:,-=:J\ jLr.-
~
312
152
o
O~
94
136
~
J~205
290 ~(@
310
102 165
~
))
111
S1035
Aufladung
Turbocharger
Turbochargeur
I Sobreahmentacao
Sobreahrnentaclon
Sovralimentazione HaMYS
,:,-=-:J' jL~
I'
~l1C
~
252 240
~~
1~43
~
B
253 D
~J 0 242'0
114
108
0Q330 335
~
,7
"
\
\ oJ . .
0 0
~
289 ~,O
340
~
~248 'c~
112
S1035
Luflpresser
Air Compressor I Compressor de ar
gompresseur d'air Compresor de arre
ompressore ana '\r)\
803.QYWHbli:i HOMnpeccop
L...i.L.:.
~77
~40
~75
70~
65
@>60 ~ 80
IJG
15 45
~
55
~~ 25 20
113
S1035
Luftpresser I Compressor de ar Gruppe Grupo
Air Compressor Compresor de aire
Compresseur d'air B03AYWHblH HOMnpeccop
Group
Groupe %~~~a . 13 075 00123
Compressore aria '\~~.Ji ,h..i.L.;. Gruppo I :i....l:.~~\
10
184
0
~
~ 66
~<\:: ~75
255~
185 ~190
@195 Qfi375
Q68
@70
114
S1035
Luflpresser
Air Compressor
ICompresor
Compressor de ar
de aire
Gruppe
Group
I Grupo
Grupo
Compresseur d'air B03AYWHblH HOMnpeccop Groupe rpynna , 13 075 00143
Compressore aria '\~~.Ji .h.i.~ Gruppo ~~\
~85
~80
175
G ~150 i 170
~
160. 145
6 0
0
-----------~> ('~ 155
~'::;. 140 ~~ 0 160 105 ~---:l ~
125 e. ~ <, = Q<:1 165
eJ9
\f=~?
~~ 110 ~
125
~ 130;;:~.
100 ~r~~
130 ~
105
115
S1035
Luflpresser I Compressor de ar Gruppe Grupo
~;~~~a .13075
Air Compressor Compresor de aire Group
Compresseur d'air B03AYWHblH HOMnpeccop Groupe 00144
Compressore aria .\ Ji.k-<.L..:,.
n Gruppo I ........ ~~\
~60
75~ 182
~187
116
S1035
Luftpresser I Compressor de ar Gruppe I Grupo
Air Compressor Compresor de atre
Compresseur d'air B03AYWHbll1 HOMnpeccop
Compressore ana ,I,r)i ~L.;"
g;~~~e %~~~a
Gruppo ~J~\
, 13 075 0 0 1 56
235
~
168
117
Saugrohr und AuspuffkrUmmer Tubo de adrrussao e colector de escape S1035
Intake and Exhaust Manifolds Tubo de adrrnslon y colector de escape Gruppe Grupo
Collecteurs d'admission et
d'echappernent
snycKHaR Tpy6a '" xoneno
8b,nycKHoro Tpy6onpo8oAa
Group
Groupe %~~~a . 14 015 00202
Condollo aspirazione e collellore scarico ~i r,L.JI J U"'~i Y..r:'i Gruppo I ti~.-d\
55 40
~5
~
~~~
~ c5illW-'
60 45
~11
80
25
118
S1035
Saugrohr und Auspuffkrilrnmer Tubo de adrrussao e cclector de escape
Intake and Exhaust Manifolds Tubo de adrrusion y colector de escape Gruppe Grupo
Collecteurs d'admission et
d'echappernent
BnycHHaR Tpy6a " aoneao
BblnyCHHOro Tpy6onpoBoAB
Group
Groupe %~~~a . 14015 00207
Condotto aspirazione e collettore scaricc ~i ~Ol.Jl3 J"'L4:..i ,-:,~i Gruppo I U:.~.-d\
80
t[]J
65~1
52
30
75
119
AuspuffkrOmmer
Exhaust Manifold
I
Colector de escape
Colector de escape
Gruppe Grupo
S1035
Collecteur d'echappernent aoneno BblnyCHHOro TPy6onpoBoAa

Group
Groupe ~;~~~a . 14 030 00233
Collettore scarico ~i ~,Ui Gruppo I W:~I
.s-,
QQ
55
60
120
S1035
AuspuffkrUmmer , Colector de escape Gruppe Grupo
Exhaust Manifold Colector de escape Group
Collecteur d'echappernent HoneHOBbtnycHHoro TPy60npoBot\a Groupe ~~~~~a . 14 030 00249
Collettore scarico
. '---"-':J.i ,Ui
~
Gruppo I u.~.....-l\
~ 25
~
60
~20
121
S1035
AuspuffkrUmmer IColector de escape Gruppe Grupo
~~~~~a
Exhaust Manifold Colector de escape Group
Collecteur d'echappernent xoneao BblnycKHoro TPyoonpoBoAa Groupe 14 030 00250
Collettore scarico ~i r,Ui Gruppo u~i
25
65@
122
S1035
Auspuffk ..
COII:~tuMa~~fold I~~~ector esca~: ~ruppe I
COllett~r:~~~happement
Exh rummer Grupo
Col ector de esca roup G
nco ~i ,..,LJi
de
eHOBblnycH Horo lpy6onpoBoAa ~roupe r~~~~a 14030 00264
_ _ _ _ _ _ _ _~nruJpp~PO ~ ~i
245
~
215
G
210 ~205
195 190
© (@ct®n190 195
170 (@ ©
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1~ 1/;f %J ~145 240 235
~
I
0
©
200 90
C@
185
123
S1035
Eleklrische Ausrlistung , Equipamento electrico
Electrical Equipment Equipo electrlco
Gruppe
Group
I Grupo
Grupo
Equipement electrique aneurpoooopvnoaauae Groupe rpynna . 1 5 0 10 00009
Impianto eletlrico ~~~-;5:J\ d~\ Gruppo ~ ~~.J.\
f1]23 580
17 ~
@
7
~~74
::to
9 ~406
~382
448(]'p
riO
~ c I 514
400 454@W~O\rQJ
442
~466
y472
: III Mer~edes-B!!n2 AG
520 526 ~ ~
532
538
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I
II
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"
H ~ ffi1
.e: 1ID ·~ ~6 1J
::
" 502
r"":
496 (ij ~ • 562
478 490 508 550
484 544
124
S1035
Elektrische Ausriistung
I
Equipo electrico
Gruppe
Group
Grupo
Grupo
Equipement electrique 3J1eHTpoo6oPY.QosaH",e Groupe rpynna 15010 00010
Impianto elettrico ....;l;~.......<.Ji d~i Gruppo ~~.......,di
II
41 II
II
II
II
II
~
"IIII
II
II
""
II
II
II
II
II
~] 47
125
Elektrische AusrUslung IEquipamento electrico Gruppe I Grupo S1035
~~~~~e ~;~~~a.
Eiectrical Equipment Equipo electrlco
Equipement electrique 3J1eKTpoo6oPY.'lOSaHHe 15 010 00050
Implanto elettrico ;;..",;~~-+()\ d~1 Gruppo u~.......::J\
06
~06 ~ Y49 (~)] ~516
~L1CQ)
08 B12 ,--,
010
o
p;:'= 08 510 0 000 I 22
Zl ~===;=""'" 517
Q
~
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53 516 Bll 516 / III
517 B15 517

IL..-1J
~ B16
85
6
616 ~
610 ~604
~ 115
70 100 130
Z4 Z4 / ? 220 N3 02
e I
KlO K16 418 ~03
Kll K17
~~ K12 K18 ~©~

~424
175
~
!:> Q
~
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K21
I)
@ 190
160
tn lCJ 2 5 0 ' (\)
235
m
~~~ 205 280
~295
145
B15 510
B16
l 310
412
~ 345
360
375
126
S1035
Elektrische Ausriistunq I
Equipamento eleclrico Gruppe Grupo
Equipo electrlco
sneurpoooopvnoaaaae
Group
Groupe ~;~~~a . 15 010 00051
Impianto elettrico <""';~~-;5Ji d~i Gruppo I u.~~1
586
127
Elektrische Ausrtistung , Equipamento electrico Gruppe Grupo S1035
Electrical Equipment Equipo electrlco
Equipement etectrique 3IleHTPOo6oPY,QosaH",e
Group
Groupe %~~~a . 15 015 00173
Impianto elettrico ~~~....,.sJ\ d~~i Gruppo I w.~~\
30
6570~
®®~
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15
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S1035
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S1035
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S1035
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S1035
Elektrische A -,
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S1035
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S1035
Elektrische AusrUstung IEquipo
Equipamento electrico Gruppe Grupo
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S1035
Elektnsche AusrUstung
Electncal Equipment
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Equipo electnco
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135
S1035
Elektrische AusrUstung
I
Equipo electrico
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Equipement electrlque aneHTpoo6oPY,QosaHHe Groupe rpynna 00190
Impianto eJettrico :c...,,;~~....,.sJi d~i Gruppo 1 ;w:.~~i
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136
S1035
Elektrische Ausnlstunq
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Equipement electrlque anearpootiopvnoaauae Groupe rpynna
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137
S1035
Molorschmierung
Engine Lubrication
I
Lubrificacao do molor
Lubricaci6n del motor
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S1035
Mot,?rsctu~~T~~~n
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S1035
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S1035
Engine Lubrication
Graissage du moteur
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CMB3Ha ABl1raT€llR
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18 060 00143
Lubrificazione motore .J~":;~....li ~ Gruppo I u_~i
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15
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S1035
Motorschmierung I Lubrificacao do motor Gruppe
Group
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Engine Lubrication Lubricaci6n del motor
Graissage du moteur CMa3Ha ABHraTeJ1R Groupe 00144
Lubrificazione motore .;Y:;.rll ~ Gruppo I u.~1
27
d2
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142
S1035
- do motor
.
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S1035
Motorklihlung
IRefrigerac;ao do molor
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144
S1035
MotorkOhlung
I
Refriqeracao do motor
Gruppe Grupo
%~~~a. 20015
Group
Refroidissement du moteur oxnaltlgeHl1e gBl1raTenA Groupe 00387
Raffreddamento motore , .;;,.Ji -,--,-:;
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Gruppo I :\..s.~1
24
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145
S1035
Molorkuhlullg
IRefrigeraci6n
Refriqeracao do molor
del molar
Gruppe
Group
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Refroldlssement du moleur oxnaH<l1eHHe I1BHraTenA Groupe %~~~a. 20015 00400
Raffreddamenlo molore J~':;~....l\ _'--.~-:; Gruppo I w.....I~.l\
106~
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146
S1035
Molorkiihlung , Refriqeracao do motor Gruppe
Engine Cooling System Refrigeraci6n del motor Group
Refroidissemenl du moleur oxna>HAeHHe ABHraTeJlR Groupe 00133
Raffreddamenlo molore . .:; ..J. i -'-' -:; Gruppo
-'.J' -' .......
20
, ~
® 45 55
50
15
10
147
S1035
MotorkGhlung IRefrigeraci6n
Refriqeracao do motor Gruppe Grupo
RefrOidissement du moteur
del motor
oxnalH/leHl1e /lBl1raTenA
Group Grupo
rpynna
20 100 00007
Raffreddamento motore JY.ri' -'-'_~-:-'
Groupe
Gruppo I
...... ~~i
148
S1035
Gruppe
Group I Grupo
Grupo 22 0 15
00110
Groupe ~ynna i
Sospensrone del motore .J~ Gruppo "-'-~~
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~5 75
om@;
88
86
~
65
149
I S1035
Motoraufhangung
Engine Suspension
Suspension du moteur
Sospensicne del motore
Suspensao do motor
Suspension del motor
nonaecxa ASHraTeJ1R
.;..,...:; y-ti c:/:IL?-
Gruppe
Group
Groupe
Gruppo
Grupo
I*~~~a .22 015

.......J......qdl
00121
30(~
80
85 ~
150
S1035
Special Ver~orungen
speci~f
Sonderausfiih
I
Versoes I
~;~~~e ~rupo 2
G_rUrP.pPJ~~ ~~i
Versions EjeCuciO:peCiais
Versioni Special"es
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45
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151
S1035
SonderausfOhrungen , Vers6es especiais Gruppe Grupo
Special Versions
Versions speciales
cneuaanenaa HOMnneHTaL\HR
Group
Groupe
Grupo
rpynna
23 015 00118
Versioni speciali ........LJ.i dj~~i."i djlJ...bJi Gruppo I u.J~i
20 25
152
S1035
Nebenantrieb
P. T. O. I Tomad Gruppe
Group I Grupo
G
~G~ro~~u:~~
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Presa di f orzae auxiliaire oT6opde fuerza
MOl11Hoe _ _ _ _ _ _ _ ~~~\ 2 3 045
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153
Nebenantrieb
P. T. O. I Tomad a de forca
Gruppe
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S1035
.Pp,.~. ~:~i
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Presa di f orzaauxiliaire oT6 de fuerza Grou rupo 00029
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op MOl11HOC,TH
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S1035
Gruppe
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Grou
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225
205
155
S1035
Nebenantrieb
P. T. O. , Tomad Gruppe
G roup
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e auxiliaire oT6op
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103
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135 140 145
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156
S1035
~ebenantrieb
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157
Kaltekompressor Compressor do produto refrigerante
Gruppe Grupo S1035
Refrigerant Compressor Compresor de refriqeracion
%~~~a, 23 075
Group
Compresseur pour installation d'air oxnaA>1Tenb
Groupe 00007
conditlonne
Compressore impianto refrigeratore
.L.;.~\ .:r-=.:... "i U"L,5 Gruppo I w.~\
70
4125
45
(:)
158
I S1035
SonderausfOhrungen Vers5es especiais
Special Versions
Versions speclales
Versioni speciali
cneuaansaas HOMnneHTal1HA
:\.-,Ui djL..;..;~'i .)i dj\...-kli
Gruppe
Group
Groupe
Gruppo
Grupo
I*~~a
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159
S1035
SonderausfDhrungen
Special Versions
IVers6es especiais
Gruppe
Group
I Grupo
Grupo
Versions speciales cneuaansaaa KOMnneHTaL111R Groupe rpynna . 23 980 00003
Version! special! :i.-.Ui ",-,Ij~','i -,i djly-l-Ji Gruppo ;w:.~I
l-.
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8
160
S1035
SonderausfUhrungen
Special Versions
IVers6es especiais
Gruppe Grupo
~;~~~a
Group
Versions speciales cneuaansaaa HOMnneHTal.\HR Groupe , 23 980 00004
Versioni speciali ~Lll Q\jL;..;'/I)i djl.rlJi Gruppo I ;;....~I
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47 c8)J ~ <,
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56
41
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161
13807
ENGINE FILTERS
Page 1 of 1

1 146001 FUEL FILTER ELEMENT KIT (OM 904 & 906) 1
2 146018 FUEL PRE FILTER KIT - SCREEN (OM 904 & 906) 1
3 146040 FUEL/WATER SEPARATOR ASSEMBLY (OM 904 & 906) 1
4 146022 FUEL/WATER SEPARATOR ELEMENT (OM 904 & 906) 1
5 146000 OIL FILTER ELEMENT (OM 904 ONLY) 1
146017 OIL FILTER ELEMENT (OM 906 ONLY) 1
6 146101 FUEL/WATER SEPARATOR BOWL 1
7 146093 OIL FILTER HOUSING GASKET 1
Updated:
03/04/10
13661
RADIATOR INSTALLATION
Page 1 of 1

465216 RADIATOR/CHARGE AIR COOLER ASSEMBLY 1
1 605726 RADIATOR HOSE (2”) A/R
2 20611-03 TUBE WELDMENT (RADIATOR) 1
3 12326-06 RADIATOR HOSE (ELBOW) 1
4 12922-04 TUBE WELDMENT (RADIATOR) 1
5* 465303 OVERFLOW SURGE TANK 1
6* 605961 OVERFLOW HOSE FOR SURGE TANK 1
7 465480 RADIATOR CAP #15 DOUBLE SEAL USED WITH 1
OVERFLOW

11/13/08
13660
CHARGE AIR INSTALLATION
Page 1 of 2
Updated:
03/02/10
13660
CHARGE AIR INSTALLATION
Page 2 of 2
1 465216 RADIATOR ASSEMBLY (DDC 904) 1
2 12567-05 SILICONE HOSE 4” 1
3 7043-00024 TUBE WELDMENT LOWER (CHARGE AIR) 1
(NOTE: OLD NUMBER WAS 12964-01)
4 605663 SILICONE HUMP HOSE (3 ½” ID) 1
5 12929-01 CHARGE AIR TUBE 1
6 N/A CHARGE AIR TUBE (SEE DETROIT DIESEL) 1
7 595320 SILICONE CONNECTOR (3 ½” ID) 1
8 12964-03 TUBE WELDMENT UPPER (CHARGE AIR) 1
9 12567-05 SILICONE HOSE 4” 1
10 146043 CHARGE AIR COOLER CLAMP BOLT 1
11 146042 CHARGE AIR COOLER CLAMP 1
12 146105 CHARGE AIR COOLER NUT 1
13 146044 CHARGE AIR COOLER SEAL 1
Updated:
03/02/10
13713
AIR INTAKE SYSTEM
Page 1 of 1

1 604686 AIR CLEANER 1
2 604691 AIR CLEANER BANDS 2
3 604921 AIR INLET HOOD 1
4 604692 RUBBER REDUCER (5” – 4”) 1
5 12350-09 ELBOW WELDMENT 1
6 605693 HUMP HOSE (2 ¾”) 2
7 6498-43 ELBOW (2 ¾”) 1
8* 604464 INDICATOR 20” 1
ITEM NOT SHOWN Updated:

06/17/08
11637
AIR CLEANER 12”
Page 1 of 1

604686 AIR CLEANER ASSEMBLY (INCLUDES ITEMS 1-8) 1
1 604707 CUP ASSEMBLY 1
2 604710 CLAMP ASSEMBLY 1
3 604711 PRIMARY ELEMENT 1
4 604709 SAFETY ELEMENT 1
5 604264 VACUATOR VALVE 1
6 604706 BAFFLE ASSEMBLY 1
7 604708 NUT ASSEMBLY 1
8 604704 O-RING 1
9* 604921 INLET HOOD 1
10* 604691 MOUNTING BAND 2

05/03/10
13676
EXHAUST SYSTEM
Page 1 of 1

1 12964-07 EXHAUST ADAPTER WELDMENT 1
2 12964-08 EXHAUST TUBE WELDMENT (FLEX) 1
3 604922 EXHAUST ELBOW 1
4 594995 EXHAUST PURIFIER 1
5 594372 EXHAUST SILENCER 1
6 15951-01 EXHAUST DISSFUSER 1
7 595469 CLAMP 3
8* 19188-11 FLAME ARRESTOR (OPTIONAL) 1
9* 605537 ALUMINIZED HEAT BARRIER WRAP A/R

11/19/08
EXHAUST INSULATION 17309
INSTALLATION Page 1 of 1

465546 INSULATION KIT (INCLUDES ITEMS 1 & 2) 1
1 465499-02 INSULATION , 90° ELBOW 1
2 465546-01 INSULATION, EXHAUST PIPING 1
Updated:
12/30/09
S1020
S1020
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
5. DRIVE TRAIN
17193 TRANSMISSION
13436 TRANSMISSION MOUNTS
17331 TRANSMISSION DIPSTICK
S1005 TRANSMISSION MAINTENANCE & SERVICE
MANUAL
13675 DRIVELINE INSTALLATION
TRANSMISSION ASSEMBLY 17193
465563 Page 1 of 38
Updated:
10/28/08
465563 Page 2 of 38

465563 TRANSMISSION ASSEMBLY 1
32000 CONVERTER HOUSING GROUP
1 N/A NOT USED ON THIS MODEL 1
2 23033 PIPE PLUG 1
3 244390 CONVERTER HOUSING & TUBE ASSEMBLY 1
(INCLUDES ITEMS 6-15, 19, 24-44)
4-5 N/A NOT USED ON THIS MODEL 1
6 24913 TUBE SLEEVE 1
8 24594 CONVERTER HOUSING SLEEVE 1
9 244457 CONVERTER HOUSING SLEEVE LOCK 1
10 24473 CONVERTER HOUSING SLEEVE SCREW LOCKWASHER 1
11 24474 CONVERTER HOUSING SLEEVE SCREW 1
12 24474 CONVERTER HOUSING SLEEVE SCREW 1
13 24473 CONVERTER HOUSING SLEEVE SCREW LOCKWASHER 1
14 244457 CONVERTER HOUSING SLEEVE LOCK 1
15 24594 CONVERTER HOUSING SLEEVE 1
16 24240 BREATHER 1
17 244160 STREET ELBOW 1
18 244157 BREATHER REDUCING BUSHING 1
20 24435 CONVERTER HOUSING TO TRANSMISSION HOUSING 4
SCREW LOCKWASHER
SCREW
LOCKWASHER
SCREW
24 24473 LUBE TUBE RETAINING SCREW 1
25 24474 LUBE TUBE RETAINING SCREW 1
26 24952 SUCTION TUBE O-RING 1
27 244057 SUCTION TUBE SPACER RING 1
Updated:
10/28/08
465563 Page 3 of 38
28 24933 SUCTION TUBE ASSEMBLY 1
29 04GE06 SUCTION TUBE RETAINER SCREW/LOCKWASHER 1
(PART OF ITEM 30)
30 24191 SUCTION TUBE RETAINER SCREW & LOCKWASHER 1
31 24474 TUBE CLIP SCREW 1
32 24473 TUBE CLIP SCREW LOCKWASHER 1
33 24592 TUBE CLIP 1
34 24921 REVERSE TUBE ASSEMBLY 1
35 24684 REVERSE TUBE O-RING 1
36 24474 LUBE TUBE RETAINER SCREW 1
37 24473 LUBE TUBE RETAINER SCREW LOCKWASHER 1
38 24920 LUBE TUBE ASSEMBLY 1
39 24474 TUBE CLIP SCREW 1
40 24473 TUBE CLIP SCREW LOCKWASHER 1
41 24592 TUBE CLIP 1
42 24922 3RD SPEED TUBE ASSEMBLY 1
43 24684 3RD SPEED TUBE O-RING 1
44 24924 VALVE OIL SUPPLY TUBE 1
45 24686 TRANSMISSION CASE TO CONVERTER HOUSING 10
SCREW
46 24435 TRANSMISSION CASE TO CONVERTER HOUSING 10
SCREW LOCKWASHER
47 24047 CONVERTER HOUSING TO TRANSMISSION CASE 1
GASKET
48 24338 CONVERTER HOUSING TO TRANSMISSION CASE 2
DOWEL PIN
57 244384 SPEED SENSOR ADJUSTER BUSHING 1
58 244387 SPEED SENSOR ADJUSTER SHIM A/R
59 244388 SPEED SENSOR HOLE PLUG 1
60 244389 SPEED SENSOR O-RING 1
Updated:
10/28/08
465563 Page 4 of 38
Updated:
10/28/08
465563 Page 5 of 38

TRANSMISSION CASE GROUP
1 244741 TRANSMISSION CASE ASSEMBLY 1
(INCLUDES ITEMS: 2-24)
2 24601 SUCTION TUBE ASSEMBLY 1
3 24692 SUCTION TUBE CLIP 1
4 N/A NOT USED ON THIS MODEL
5 24337 PRESSURE TUBE SLEEVE 1
6 24598 LOW SPEED CLUTCH PRESSURE TUBE 1
7 24337 PRESSURE TUBE SLEEVE 1
8 244391 SUCTION TUBE CLIP RIVET 1
9 24693 RETAINING WASHER SCREW 2
10 ZG-230921 RETAINING WASHER 1
11 244232 SUCTION TUBE O-RING 1
12 244391 RIVET 2
13 244256 OIL BAFFLE 1
15 244391 RIVET 2
16-24 N/A NOT USED ON THIS MODEL
25 24566 CASE TO COVER GASKET 2
26 24467 PRESSURE TUBE O-RING 1
29 24339 MAGNETIC DRAIN PLUG 1
30 24689 OIL LEVEL PLUG 1
30A 24689 OIL LEVEL PLUG 1
31 24689 OIL LEVEL PLUG 1
32 24244 SCREEN ASSEMBLY
33 24203 SCREEN ASSEMBLY GASKET 1
34 24690 PLUG 1
Updated:
10/28/08
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REAR COVER GROUP
1 244726 REAR COVER 1
2 24046 CASE TO COVER GASKET 1
3 24686 REAR COVER TO TRANSMISSION CASE SCREW 21
4 24435 REAR COVER TO TRANSMISSION CASE SCREW 23
LOCKWASHER
5 24389 REAR COVER TO TRANSMISSION CASE STUD NUT 2
6 24654 REAR COVER TO TRANSMISSION CASE STUD 2
7 244453 PLUG 1
Updated:
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Updated:
10/28/08
465563 Page 8 of 38

TURBINE SHAFT GROUP
1 24670 STATOR SUPPORT SCREW 6
2 24680 STATOR SUPPORT SCREW LOCKWASHER 6
3 24936 STATOR SUPPORT & SLEEVE ASSEMBLY 1
4 244728 TURBINE SHAFT 1
5 244365 TURBINE SHAFT PISTON RING 1
6 24306 TURBINE SHAFT BEARING 1
7 24219 TURBINE SHAFT GEAR SNAP RING 1
8 244364 PISTON RING 1
11 24022 OIL BAFFLE OIL SEAL 1
12 24929 OIL BAFFLE SEAL RING 1
13 244128 OIL BAFFLE RETAINER RING 1
14 24910 IMPELLER HUB GEAR 1
15 24576 IMPELLER HUB GEAR SNAP RING 1
16 244265 TURBINE SHAFT GEAR 1
Updated:
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Updated:
10/28/08
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WHEEL GROUP
1 244729 TURBINE HUB 1
2 244123 REACTION MEMBER SNAP RING 1
3 244281 REACTION MEMBER 1
4 24577 REACTION MEMBER SPACER 1
5 244280 BEARING SNAP RING 1
6 244279 IMPELLER HUB BEARING 1
7 244278 IMPELLER HUB 1
8 244557 IMPELLER HUB O-RING 1
9 244745 IMPELLER 1
10 244275 IMPELLER HUB SCREW BACKING RING 1
11 NOT USED ON THIS MODEL
12 244274 HUB TO IMPELLOR SCREW 12
13 24559 TURBINE 1
14 244185 TURBINE HUB SCREW BACKING RING 1
15 24054 IMPELLER TO COVER O-RING 1
16 244187 IMPELLER COVER 1
17 04GE06 IMPELLER TO COVER SCREW LOCKWASHER 24
18 24673 IMPELLER TO COVER SCREW 24
19 ZZ240234 IMPELLER COVER BEARING 1
20 244664 BEARING CAP TO IMPELLOR COVER O-RING 1
21 244570 BEARING WASHER 1
22 244569 BEARING SNAP RING 1
23 244731 IMPELLER COVER BEARING CAP 1
24 24476 TURBINE HUB SCREW BACKING RING 8
Updated:
10/28/08
465563 Page 11 of 38

DRIVE PLATE GROUP
1 464914 FLEXPLATE KIT (INCLUDES ITEMS 2-5) 1
2 NSS DRIVE PLATE (INCLUDES ITEM 1) 4
3 244062 DRIVE PLATE BACKING RING 1
4 244393 DRIVE PLATE MOUNTING SCREW 10
5 24505 WASHER 10
Updated:
10/28/08
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Updated:
10/28/08
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DRIVE PUMP GROUP HIGH CAPACITY
1 244321 LOCKWASHER 2
3 24947 CAPSCREW 2
4 465563-01 DRIVE PUMP GEAR 1
5 465563-02 SUPPORT DRIVE PUMP BEARING 2
6 24909 BEARING BALL 2
7 465563-03 SNAP RING 2
8 ZG-224009 SNAP RING 1
9 465563-04 IMPELLER HUB GEAR 1
10 465563-05 DRIVE PUMP IDLER GEAR 1
11 465563-06 SUPPORT DRIVE PUMP IDLER 1
12 465563-07 BEARING BALL 6309 1
14 24947 CAPSCREW 2
15 465563-08 INTERNAL SNAP RING 1
18 24947 CAPSCREW 2
19 465563-01 DRIVE PUMP GEAR 1
20 465563-02 SUPPORT DRIVE PUMP GEAR 1
21 24909 BEARING BALL 1
22 465563-03 SNAP RING 1
Updated:
10/28/08
465563 Page 14 of 38

FORWARD AND REVERSE SHAFT GROUP
1 465563-09 CLUTCH DRIVEN GEAR 25T 2
2 24612 HIGH RANGE GEAR 52T 1
3 465563-10 LOW & 4TH DRIVE GEAR 1
4 465563-11 2ND GEAR 30T 1
Updated:
10/28/08
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Updated:
10/28/08
465563 Page 16 of 38

RD
REVERSE AND 3 CLUTCH SHAFT GROUP WITH
STEP SEALED PISTON
1 24347 REVERSE & 3RD CLUTCH SHAFT PISTON RING 3
2 244190 FRONT BEARING RETAINER RING 1
3 244572 WASHER 1
4 244573 BALL END PLATE 1
5 244006 REVERSE & 3RD SHAFT FRONT BEARING 1
7 24291 CLUTCH DRIVEN GEAR BEARING – SHIELD IN 1
8 244652 CLUTCH DRIVEN GEAR BEARING SNAP RING 1
9 N/A NOT USED IN THIS MODEL
10 24568 END PLATE RETAINER RING 1
11 244574 END PLATE - 3RD CLUTCH 1
12 24058 CLUTCH OUTER DRIVE DISC – 3RD CLUTCH 7
13 244546 CLUTCH INNER DISC – 3RD CLUTCH 7
14 244691 CLUTCH PISTON ASSEMBLY - 3RD CLUTCH 1
15 24526 CLUTCH PISTON OUTER SEAL 1
16 24529 CLUTCH PISTON INNER SEAL 1
17 244692 CLUTCH PISTON METERING SEAL 1
18 244693 REVERSE & 3RD CLUTCH DRUM & PLUG ASSEMBLY 1
19 244692 CLUTCH PISTON METERING SEAL 1
22 244694 CLUTCH PISTON ASSEMBLY- REVERSE CLUTCH 1
(INCLUDES ITEMS 20 & 21)
23 244546 CLUTCH INNER DISC – REVERSE CLUTCH 6
24 24058 CLUTCH OUTER DISC – REVERSE CLUTCH 6
25 24583 END PLATE – REVERSE CLUTCH 1
27 24610 SPRING RETAINER 1
28 24609 PISTON RETURN SPRING 1
Updated:
10/28/08
465563 Page 17 of 38
30 24962 SPRING RETAINER SNAP RING RETAINER 1
31 24298 SPRING RETAINER SNAP RING 1
32 24293 CLUTCH DRIVEN GEAR BEARING 1
38 24962 SPRING RETAINER SNAP RING RETAINER 1
40 24611 3RD GEAR BEARING 1
41 24579 3RD GEAR BEARING SNAP RING 1
43 24613 3RD GEAR BEARING SPACER 1
44 24579 3RD GEAR BEARING SNAP RING 1
45 24614 3RD GEAR BEARING – SHIELD OUT 1
46 244559 REVERSE & 3RD SHAFT REAR BEARING 1
47 24581 GEAR RETAINING RING 1
48 244695 LOW CLUTCH DRIVE GEAR 1
49 24612 3RD GEAR 1
50 244266 CLUTCH DRIVEN GEAR 1
Updated:
10/28/08
465563 Page 18 of 38
Updated:
10/28/08
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ND
FORWARD & 2 CLUTCH SHAFT GROUP WITH STEP
SEALED PISTON
1 24347 FORWARD & 2ND SHAFT PISTON RING 3
3 244572 WASHER 1
4 244573 FORWARD & 2ND SHAFT FRONT END BALL RETAINER 1
5 244006 FORWARD & 2ND SHAFT FRONT BEARING 1
6 24290 FRONT BEARING LOCATING RING 1
8 24291 CLUTCH DRIVEN GEAR BEARING – SHIELD IN 1
12 24293 CLUTCH DRIVEN GEAR BEARING 1
15 24962 SPRING RETAINER - SNAP RING RETAINER 1
20 24298 2ND GEAR RETAINING RING 1
21 244580 2ND GEAR LOCATING RING RETAINER 1
22 244224 2ND GEAR LOCATING RING RETAINER SNAP RING 1
24 24962 SPRING RETAINER - SNAP RING RETAINER 1
29 244574 END PLATE – 2ND CLUTCH 1
Updated:
10/28/08
465563 Page 20 of 38
30 24058 CLUTCH OUTER DISC – 2ND CLUTCH 7
31 244546 CLUTCH INNER DISC – 2ND CLUTCH 7
32 244691 CLUTCH PISTON ASSEMBLY – 2ND CLUTCH 1
35 244692 CLUTCH PISTON METERING RING 1
36 244696 FORWARD & 2ND SHAFT, CLUTCH DRUM & PLUG 1
ASSEMBLY
37 244692 CLUTCH PISTON METERING RING 1
40 244694 CLUTCH PISTON ASSEMBLY – FORWARD CLUTCH 1
(INCLUDES ITEMS 38 & 39)
41 24058 CLUTCH OUTER DISC. – FORWARD CLUTCH 6
42 244546 CLUTCH INNER DISC. – FORWARD CLUTCH 6
43 24583 END PLATE – FORWARD CLUTCH 1
45 244266 FORWARD CLUTCH DRIVEN GEAR 1
46 244235 2ND GEAR 1
Updated:
10/28/08
465563 Page 21 of 38
Updated:
10/28/08
465563 Page 22 of 38

LOW SHAFT GROUP
1 24915 FORWARD & 2ND SHAFT PILOT BEARING 1
3 244703 LOW SHAFT FRONT BEARING CUP 1
4 244704 LOW SHAFT FRONT BEARING CONE 1
5 244732 LOW SPEED GEAR BEARING ASSEMBLY 1
6 244701 LOW SPEED GEAR 1
7 244702 WASHER – BEARING SPACER 1
8 244699 SPRING RETAINING RING RETAINER 1
9 24219 SPRING RETAINING RING 1
10 244698 SPRING RETAINING 1
11 244697 SPRING - WAVE 1
12 244119 RETAINER – WAVE SPRING 1
14 24583 END PLATE 1
15 24057 CLUTCH INNER DISC 9
16 24058 CLUTCH OUTER DISC 9
17 244694 CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 18 & 19) 1
20 244692 SEAL – CLUTCH PISTON METERING 1
21 244394 LOW CLUTCH HUB RETAINING RING 1
22 244705 LOW CLUTCH HUB & DRUM ASSEMBLY 1
23 244706 LOW DRUM & SHAFT O-RING 1
24 244709 LOW SHAFT & DRUM ASSEMBLY 1
25 244707 LOW SHAFT 1
26 244708 LOW SHAFT PLUG 1
27 244601 LOW SHAFT REAR BEARING CONE 1
28 24667 LOW SHAFT REAR BEARING CUP 1
29 244523 LOW SHAFT PRESSURE PISTON RING 1
Updated:
10/28/08
465563 Page 23 of 38
30 244715 REAR BEARING CAP O-RING 1
31 244710 BEARING CAP SHIM - .004 A/R
31A 244711 BEARING CAP SHIM - .007 A/R
31B 244712 BEARING CAP SHIM - .010 A/R
31C 244713 BEARING CAP SHIM - .020 A/R
32 244716 O-RING PRESSURE TUBE 1
33 244453 REAR BEARING CAP PLUG 1
34 244714 REAR BEARING CAP 1
35 04GE06 REAR BEARING CAP LOCKWASHER 5
36 24673 REAR BEARING CAP CAPSCREW 5
Updated:
10/28/08
465563 Page 24 of 38
Updated:
10/28/08
465563 Page 25 of 38

IDLER SHAFT GROUP
1 244190 BEARING RETAINER RING 1
2 24575 BEARING LOCATING RING 1
3 24100 IDLER SHAFT FRONT BEARING 1
4 465563-12 IDLER SHAFT AND GEAR 45T 1
(NOT AS SHOWN: SHAFT INCLUDES ITEMS 4, 5, 6 AND
IS A ONE PIECE CONTRUSTION)
7 24997 IDLER SHAFT GEAR BEARING 1
8 24697 IDLER SHAFT REAR BEARING LOCK BALL 1
9 24627 REAR BEARING LOCATING RING 1
10 244596 IDLER SHAFT NUT 1
11 24628 IDLER SHAFT BEARING CAP GASKET 1
12 SEE ITEM # 21 1
13-16 NOT USED ON THIS MODEL
17 244536 IDLER SHAFT BEARING CAP SCREW LOCKWASHER 2
18 244597 IDLE SHAFT BEARING CAP SCREW 2
19 244597 IDLE SHAFT BEARING CAP SCREW 2
20 244536 IDLER SHAFT BEARING CAP SCREW LOCKWASHER 2
21 465563-13 IDLE SHAFT BEARING CAP ROTATED 90 DEGREES 1
(C.C.W.)
22 244734 SPACER – IDLER BEARING 1
24 244735 PLUG – IDLER CAP SPEEDO 1
Updated:
10/28/08
465563 Page 26 of 38
Updated:
10/28/08
465563 Page 27 of 38

SHORT DROP OUTPUT SHAFT GROUP
1 244562 FRONT BEARING CAP OIL SEAL 1
2 24636 FRONT BEARING CAP 1
3 24632 BEARING CAP SHIM (.004) A/R
3A 24633 BEARING CAP SHIM (.007) A/R
3B 24634 BEARING CAP SHIM (.010) A/R
3C 24635 BEARING CAP SHIM (.013) A/R
4 24699 FRONT BEARING CAP O-RING 1
5 244600 FRONT BEARING CUP 1
6 244601 FRONT BEARING CONE 1
7 244602 OUTPUT SHAFT GEAR SPACER 1
8 244603 OUTPUT SHAFT 1
9 244601 REAR BEARING CONE 1
10 24667 REAR BEARING CUP 1
13 244536 REAR BEARING CAPSCREW LOCKWASHER 4
14 24675 REAR BEARING CAPSCREW 4
15 244562 REAR BEARING CAP OIL SEAL 1
16 244536 FRONT BEARING CAPSCREW LOCKWASHER 4
17 24674 FRONT BEARING CAPSCREW 4
27 244605 REAR BEARING CAP 1
28 244606 OUTPUT SHAFT GEAR 1
Updated:
10/28/08
465563 Page 28 of 38

1 244565 FRONT OUTPUT END YOKE 1
2 244556 O-RING 1
3 244564 WASHER 1
4 24567 NUT 1
5 244565 REAR OUTPUT END YOKE 1
6 244556 O-RING 1
7 244564 WASHER 1
8 24567 NUT 1
Updated:
10/28/08
465563 Page 29 of 38
Updated:
10/28/08
465563 Page 30 of 38

PRESSURE REGULATOR VALVE & CHARGING PUMP
GROUP
3 244111 VALVE TO HOUSING GASKET 1
4 24950 VALVE BODY O-RING 1
7 244079 VALVE TO CONVERTER HOUSING STUD 4
8 244078 VALVE BODY TO PUMP GASKET 1
9 24435 VALVE TO HOUSING STUD LOCKWASHER 4
10 24464 VALVE TO HOUSING STUD NUT 4
Updated:
10/28/08
465563 Page 31 of 38
Updated:
10/28/08
465563 Page 32 of 38

PRESSURE REGULATING VALVE ASSEMBLY
1 244076 PRESSURE REGULATOR VALVE ASSEMBLY 1
2 24689 PIPE PLUG 1
3 244091 SAFETY VALVE SEAT 1
4 244092 SAFETY VALVE SPACER 1
5 24534 SAFETY VALVE PLUNGER 1
6 24533 SAFETY VALVE SPRING 1
7 24490 VALVE STOP O-RING 1
8 244070 VALVE STOP SPRING 1
9 244286 VALVE STOP ROLL PIN 1
10 244286 VALVE STOP ROLL PIN 1
11 24570 VALVE STOP 1
12 24080 VALVE STOP O-RING 1
13 244736 VALVE PISTON 1
14 24572 VALVE SPRING – INNER 1
15 244109 VALVE SPRING – OUTER 1
16 24982 PUMP DRIVE SHAFT OIL SEAL 1
17 244093 VALVE BODY ROLL PIN 3
Updated:
10/28/08
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Updated:
10/28/08
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CHARGING PUMP AND FILTER
1 465563-14 20 GPM CHARGING PUMP ASSEMBLY 1
2 244192 PUMP TO FILTER ADAPTOR SCREW LOCKWASHER 4
3 244287 PUMP TO FILTER ADAPTOR SCREW 4
4 244080 PUMP TO FILTER GASKET 1
5 465563-15 FILTER ADAPTER 1
6 465563-16 OIL FILTER ELEMENT ASSEMBLY 1
7 244075 FILTER HOUSING 1
8 244074 OIL FILTER ELEMENT SPRING 1
9 244165 FILTER HOUSING O-RING 1
10 244071 BY-PASS FILTER DISC SPRING 1
11 244072 BY-PASS FILTER DISC 1
12 244073 BY-PASS FILTER DISC SEAT 1
13 24043 FILTER SEAT RETAINING RING 1
14 24462 FILTER ADAPTOR PLUG 1
15 24462 FILTER ADAPTOR PLUG 1
16 NSS PART OF ITEM 1 1
Updated:
10/28/08
465563 Page 35 of 38
Updated:
10/28/08
465563 Page 36 of 38
ELECTRIC CONTROL VALVE ASSEMBLY
1 244641 CONTROL VALVE COVER ASSEMBLY 1
(INCLUDES ITEM 2)
2 244639 CLUTCH PRESSURE PORT PLUG 6
3 244638 CONTROL VALVE COVER TO HOUSING GASKET 1
4 244640 CONTROL VALVE ASSEMBLY – TO CONVERTER 2
HOUSING SCREW
5 244154 CONTROL VALVE ASSEMBLY SCREW WASHER 2
15 244628 CONTROL VALVE ASSEMBLY TO CONVERTER 1
HOUSING GASKET
Updated:
10/28/08
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Updated:
10/28/08
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ELECTRIC CONTROL VALVE ASSEMBLY CONT
1 244628 CONTROL VALVE HOUSING ASSEMLBY 1
(INCLUDES ITEMS 2 – 21)
2 244405 CARTRIDGE O-RING 4
6 NSS VALVE CARTRIDGE – PART OF ITEM 12 4
8 NSS SOLENOID COIL – 24V PART OF ITEM 12 4
10 NSS SOLENOID COIL NUT – PART OF ITEM 12 4
12 244637 SPOOL TYPE SOLENOID CARTRIDGE ASSEMBLY 1
(SOLD AS AN ASSEMBLY ONLY)
13 244167 MODULATOR PRESSURE REGULATOR BORE PLUG 1
13A 244159 O-RING (PART OF ITEM 13) 1
Updated:
10/28/08
13436
TRANSMISSION MOUNTS
Page 1 of 1

1 13256-02 TRANSMISSION MOUNT (R.H. SIDE) 1
2 13256-01 TRANSMISSION MOUNT (L.H. SIDE) 1
3 17GC12072 BOLT 2
4 32290 RUBBER MOUNT 2
5 17503-01 WASHER 2
6 59GD12 NUT 2
7 02GE12 WASHER 8
8 17GC12030 BOLT 8
Updated:
12/11/06
17331
TRANSMISSION DIPSTICK
Page 1 of 1
TOTAL LENGTH, REF PART NUMBER
ITEM PART # DESCRIPTION QTY./

VEHICLE
-- 10469-01 USED ON TOW TRACTORS 200/220 (17.88 INCHES) 1
-- 12352-03 USED ON A-64 WITH 32K TRANSMISSION (49.5 INCHES) 1
-- 26362-06 USED ON A-64 WITH 20K TRANSMISSION (49.5 INCHES) 1
-- 26362-07 USED ON RDG1504 ROAD BUILDER 1
WITH FUNK TRANSMISSION (49.19 INCHES)
-- 16443 USED ON 1248 REMIXERS, SCALERS, 1
AND OLD A-64 WITH 28K TRANSMISSION (24.5 INCHES)
Updated:
04/01/10
S1005
Specifications
Model 32000 Series Transmission
SPICER OFF-HIGHWAY PRODUCTS

S1005
S1005
TOWING OR'PUSH STARTING
Before towing the vehicle, be sure to lift the rear wheels off the NOTE: If the transmission has 4 wheel drive, disconnect both
ground or disconnect the driveline to avoid damage to the trans- front and rear drivelineSl Because of the design otthe hydraulic
mission during towing. system, the engine cannot be started by pushing or towing.
CCopyrightSpicer Off-Highway Products Division 1997

Unpublished material • All rights reserved • Limiteddistribution
No part of the work may be reproduced in any form under any means
without direct written permission of Spicer Off-Highway Products Division
/j
S1005
FORWARD
This manual has been prepared to provide the customer and the
maintenance personnel with information and instructions on the
maintenance and repair of the SPICER OFF-HIGHWAY COMPONENTS
DIVISION product.
Extreme care has been exercised in the design, selection of materials and
manufacturing of these units. The slight outlay in personal attention and
cost required to provide regular and proper lubrication, inspection at
stated intervals, and such adjustments as may be indicated with be
reimbursed many times in low cost operation and trouble free service.
In order to become familiar with the various parts of the product, its
principle of operation, trouble shooting and adjustments, it is urged that
the mechanic study the instructions in this manual carefully and use it as
a reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only

Spicer Off-Highway Components Division-approved parts as listed in
the applicable parts manual should be used. Use of "will-fit" or non-
approved parts may endanger proper operation and performance of the
equipment. Spicer Off-Highway Components Divison does not warrant
repair or replacement parts, nor failures resulting form the use of parts
which are not supplied by or approved by Spicer Off-Highway
Components Division. IMPORTANT: Always furnish the Distributor
with the serial and model number when ordering parts.
S1005
TABLE OF CONTENTS
HOW THE UNITS OPERATE
SECTIONAL VIEWS AND PARTS IDENTIFICATION
Basic Design Silhouette Fig. A
Converter Group Fig. B
Converter and Transmission Case Group Fig. C
Reverse and 3rd and Forward and 2nd Clutch Group Fig. D
Low (1st Clutch) and Output Group Fig. E
Regulating Valve, Charging Pump and Filter Group Fig. F
Control Valve Assembly Fig. G
Axle Disconnect and Mechanical Parking Brake Fig. H
Assembly Instruction Illustration Fig. I
HR32000 3 Speed Typical Cross Section Fig J
DISASSEMBLY OF TRANSMISSION 1
REASSEMBLY OF TRANSMiSSiON 38
SERVICING MACHINE AFTER TRANSMISSION OVERHAUL. 56
SPECIFICATIONS AND SERVICE DATA 57
LUBRiCATION 57
TROUBLE SHOOTING GUIDE. 58
16 SCREW RING GEAR INSTALLATION 60-61
TYPICAL THREE SPEED POWER FLOW 62-63
HR EXTERNAL PLUMBING DIAGRAM 65
CLEANING AND INSPECTION 66
SPEED SENSOR BUSHING INSTALLATION 67
32 SCREW RING GEAR INSTALLATION 68-69
R-MODEL SECTION 70
6 & 8 SPEED SECTION 80
8 SPEED SECTION 92
DRIVE PLATE INSTALLATION 98
ELECTRIC CONTROLS 100
NOTE: Metric Dimensions Shown in Brackets [ ].

S1005
TRANSMISSION ASSEMBLY
The transmission and hydraulic torque portion of the power train enacts an important role in transmitting
engine power to the driving wheels. In order to properly maintain and service these units it is important
to first understand their function and how they operate.
The transmission and torque converter function together and operate through a common hydraulic system.
It is necessary to consider both units in the study of their function and operation.
To supplement the text below, and for reference use therewith, the following illustrations are provided:
Basic Design Silhouette

Converter Group
Converter and Transmission Case Group
Reverse and 3rd, Forward and 2nd Clutch Group
Low (1 st) Clutch and Output Group
Regulating Valve, Charging Pump and Filter Group
Control Valve Assembly
Axle Disconnect and Mechanical Parking Brake
Assembly Instruction
Ring Gear Installation
Clutch and Gear Arrangement
Three Speed Power Flow
External Plumbing
The R, HR, and MHR Model Transmissions are of three basic designs.
The R Model consists of a separate torque converter, mounted to the engine with the powershift trans-
mission 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 assem-
blies are mounted inside the transmission case and are connected to the output shaft of the converter either
by direct gearing or drive shaft. The purpose of the speed or directional clutches is to direct the power
flow through the gear train to provide the desired speed range and direction.
An axle disconnect is optional and is located on the output shaft. The drive to the front or rear axle can
be disconnected or connected by manual shifting.
S1005
HOW THE UNITS OPERATE
With the engine running, the converter charging pump draws oil from the transmission sump through the
removable oil suction screen and directs it through the pressure regulating valve and oil filter.
The pressure regulating valve maintains pressure to the transmission control cover for actuating the direc-
tion and speed clutches. This requires a small portion of the total volume of oil used in the system. The
remaining volume of oil is directed through the torque converter circuit to the oil cooler and returns to
the transmission for positive lubrication. This regulator valve consists of a hardened valve spool operating
in a closely fitted bore. The valve spool is spring loaded to hold the valve in a closed position. When a
specific pressure is achieved, the valve spool works against the spring until a port is exposed along the
side of the bore. This sequence of events provides the proper system pressure.
After entering the converter housing the oil is directed through the stator support to the converter blade
cavity and exits in the passage between the turbine shaft and converter support. The oil then flows out of
the converter to the oil cooler. After leaving the cooler, the oil is directed to a fitting on the transmission.
Then through a series of tubes and passages lubricates the transmission bearings and clutches. The oil then
gravity drains to the transmission sump.
The hydraulic torque converter consists basically of three elements and their related parts to multiply engine
torque. The engine power is transmitted from the engine flywheel to the impeller element through the
impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary com-
ponent which starts the oil flowing to the other components which results in torque multiplication. This el-
ement can be compared to a centrifugal pump in that it picks up fluid at its center and discharges at its outer
diameter.
The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the
torque converter. This element receives fluid at its outer diameter and discharges at its center. Fluid directed
by the impeller out into the particular design of blading in the turbine and reaction member is the means
by which the hydraulic torque converter multiplies torque.
The reaction member of the torque converter is located between and at the center or inner diameters of the
impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion
of the turbine and change its direction to allow correct entry for recirculation into the impeller element.
The torque converter will multiply engine torque to its designed maximum multiplication ratio when the out-
put shaft is at zero RPM. Therefore, we can say that as the output shaft is decreasing in speed the torque
multiplication is increasing.
The shift control valve assembly consists of a valve body with selector valve spools. A detent ball and spring
in the selector spool provides one position for each speed range. A detent ball and spring in the direction
spool provides three positions, one each for forward, neutral and reverse.
With the engine running and the directional control lever in neutral position, oil pressure from the regulat-
ing valve is blocked at the control valve, and the transmission is in neutral. Movement of the forward and
reverse spool will direct oil, under pressure to either the forward or reverse direction clutch as desired.
S1005
When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through
the direction selector spool. The same procedure is used in the speed selector.
The direction or speed clutch assembly consists of a drum with internal splines and a bore to receive a hy-
draulically 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 direc-
tion 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 MHR·32000
FIG. A
S1005
"
~"
\
57
58
Figure B
S1005
HR32000 CONVERTER GROUP
ITEM DESCRIPTION OTY. ITEM DESCRIPTION OTY.

1 Bearing Support Screw. . . . . . . . . . . .. 6 30 Hub to Impeller Screw. . . . . . . . . . . . .. 12
2 Bearing Support Screw Lockwasher. .. 6 31 Impeller Hub Screw Backing Ring .
3 Drive Gear Snap Ring . . . . . . . . . . . . . . 3 32 Impeller .
4 Pump Drive Gear Bearing . . . . . . . . . .. 3 33 Impeller Hub "0" Ring .
5 Pump Drive Bearing Support. . . . . . . .. 3 34 Impeller Hub .
6 Pump Drive Gear . . . . . . . . . . . . . . . . .. 3 35 Impeller Hub Bearing .
7 Turbine Shaft Gear . 36 Bearing Snap Ring .
8 Turbine Shaft Gear Snap Ring . 37 Reaction Member Spacer .
9 Charging Pump Drive Sleeve . 38 Reaction Member .
10 Pump Sleeve Snap Ring . 39 Reaction Member Snap Ring .
11 Valve to Housing Gasket. . 40 Turbine Hub .
12 Valve Body "0" Ring . 41 Turbine .
13 Valve Body "0" Ring . 42 Turbine Hub Backing Ring .
14 Charging Pump& Oil Filter Assembly . 43 Turbine Hub Screw . . . . . . . . . . . . . . .. 8
15 Valve Body "0" Ring . 44 Impeller to Cover "0" Ring .
16 Turbine Shaft Bearing . 45 Impeller Cover .
17 Turbine Shaft Piston Ring . 46 Impeller Cover Bearing .
18 Turbine Shaft . 47 Bearing Cap to Impeller Cover "0" Ring
19 Stator Support . 48 Bearing Washer .
20 Stator Support Screw Lockwasher. . .. 6 49 Bearing Snap Ring .
21 Stator Support Screw. . . . . . . . . . . . . .. 6 50 Impeller Cover Bearing Cap .
22 Piston Ring . 51 Impeller Cover Sleeve .
23 Piston Ring Expander Spring . 52 Ring Gear Screw . . . . . . . . . . . . . . . . .. 16
24 Impeller Hub Gear Snap Ring . 53 Plain Washer. . . . . . . . . . . . . . . . . . . . .. 16
25 Impeller Hub Gear . 54 Flywheel Ring Gear .
26 Oil Baffle Oil Seal. . . . . . . . . . . . . . . . .. 1 55 Bearing Cap to Impeller Cover Screw. .. 10
27 Oil Baffle Seal Ring . 56 Bearing Cap to Impeller Cover
28 Oil Baffle . Screw Lockwasher. . . . . . . . . . . . . . . .. 10
29 Oil Baffle Retainer Ring . 57 Impeller to Cover Screw 24

58 Impellerto Cover Screw Lockwasher . .. 24
S1005
4
3~
2 (
I
MHR OPTION
73
CONVERTER HOUSING TO TRANSMISSION

CASE SPACER USED ONLY WITH 12
PLATE CLUTCH PACK ASSEMBLY.
Figure C
S1005
HR32000 CONVERTER & TRANSMISSION CASE GROUP
ITEM DESCRIPTION QTY , ITEM DESCRIPTION QTY

1 Pipe Plug . 45 Clutch Pressure Tube "0" Ring. . . . . . . . . . . . . . . . . .. 1
2 Converter Housing Assembly. . . . . . . . . . . . . . . . . . .. 1 46 Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
3 Converter Housing to 47 Low Speed Clutch Pressure Tube. . . . . . . . . . . . . . . .. 1
Front Cover Screw Lockwasher 12 48 Transmission Case to Converter
4 Converter Housing to Front Cover Screw 12 Housing Screw Lockwasher 10
5 Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 49 Transmission Case to Converter
6 Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 Housing Screw 10
7 Converter Housing Sleeve. . .. . . . . . . . . . . . . . . . . . .. 1 50 Rear Cover Dowel Pin. . . . . . . . . . . . . . . . . . . . . . . . .. 2
8 Converter Housing Sleeve Lock. . . . . . . . . . . . . . . . .. 1 51 Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 Converter Housing Sleeve Screw Lockwasher. . . . . .. 1 52 Rear Cover to Transmission Case
Screw Lockwasher 13
10 Converter Housing Sleeve Screw. . . . . . . . . . . . . . . .. 1
53 Rear Cover to Transmission Case Screw 13
11 Converter Housing Sleeve Screw. . . . . . . . . . . . . . . .. 1
54 Rear Cover Pipe Plug. . . . . . . . . .. . . . . . . . . . . . . . . .. 1
12 Converter Housing Sleeve Screw Lockwasher. . . . . .. 1
55 Rear Cover to CaseStud Nut. . . . . . . . . . . . . . . . . . . .. 2
13 Converter Housing Sleeve Lock. . . . . . . . . . . . . . . . .. 1
56 Rear Cover to Case Stud Lockwasher. . . . . . . . . . . . .. 2
14 Converter Housing Sleeve. . . . . . . . . . . . . . . . . . . . . .. 1
57 Clutch Pressure Tube "0" Ring. . . . . . . . . . . . . . . . . .. 1
15 Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
58 Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
16 Street Ell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
59 Rear Cover to Transmission Case Gasket. . . . . . . . . .. 1
17 Breather Reducing Bushing. . . . . . . . . . . . . . . . . . . . .. 1
60 Rear Cover to Case Stud. . . . . . . . . . . . . . . . . . . . . . .. 2
18 Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3
61 Magnetic Drain Plug. . . . . . . . . . . . . . . . . . . . . . . . . .. 1
19 Pipe Plug.................................... 1
62 Oil Level Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
20 Converter Housing to Transmission
Housing Screw Lockwasher. . . . . . . . . . . . . . . . . . . .. 4 63 Oil Level Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
21 Converter Housing to Transmission 64 Transmission Case Assembly. . . . . . . . . . . . . . . . . . .. 1
Housing Screw............................... 4 65 Screen Assembly Gasket. . . . . . . . . . . . . . . . . . . . . . .. 1
22 Converter Housing to Transmission 66 Screen Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Housing Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . .. 4 67 Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
23 Converter Housing to Transmission 68 Suction Tube Clip Washer. . . . . . . . . . . . . . . . . . . . . .. 1
Housing Screw............................... 4
69 Suction Tube Clip 1
24 Lube Tube Retaining Screw Lockwasher. . . . . . . . . .. 1
70 Suction Line Screw. . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
25 Lube Tube Retaining Screw. . . . . . . . . . . . . . . . . . . .. 1
71 Suction Line Washer. . . . . . . . . . . . . . . . . . . . . . . . . .. 1
26 Suction Tube "0" Ring. . . . . . . . . . . . . . . . . . . . . . . .. 1
72 Suction Line "0" Ring. . . . . . . . . . . . . . . . . . . . . . . . .. 1
27 Suction Tube Spacer Ring. . . . . . . . . . . . . . . . . . . . . .. 1
73 Suction Tube Clip Rivet. . . . . . . . . . . . . . . . . . . . . . . .. 1
28 Suction Tube Assembly. . . . . . . . . . . . . . . . . . . . . . .. 1
74 Converter Housing to Transmission
29 Suction Tube Retainer Screw Lockwasher. . . . . . . . .. 1 Case Gasket .
30 Suction Tube Retainer Screw. . . . . . . . . . . . . . . . . . .. 1 75 Oil Baffle .
31 Tube Clip Screw , . . . . . . . . . . . . . . . . . . .. 1 76 Converter Housing Adaptor Ring .
32 Tube Clip Screw Lockwasher. . . . . . . . . . . . . . . . . . .. 1 77 4th Speed Pressure Tube "0" Ring .
33 Tube Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 78 Low Speed Pressure Tube "0" Ring .
34 Reverse Tube Assembly. . . . . . . . . . . . . . . . . . . . . . .. 1 79 Converter Housing to Transmission
35 Reverse Tube "0" Ring. . . . . . . . . . . . . . . . . . . . . . . .. 1 Case Gasket .
36 Lube Tube Retainer Screw. . . . . . . . . . . . . . . . . . . . .. 1 80 Converter Housing to Transmission
37 Lube Tube Retainer Screw Lockwasher. . . . . . . . . . .. 1 Case Spacer (12 plate clutch pack only) .
38 Lube Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . .. 1 81 Front Cover Oil Seal .
39 Tube Clip Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 82 Converter Housing Front Cover .
40 Tube Clip Screw Lockwasher. . . . . . . . . . . . . . . . . . .. 1 83 Converter Housing Front Cover Gasket .
41 Tube Clip 1 84 Hose Fitting .
42 3rd Speed Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 85 Hose Assembly .
43 3rd Speed Tube "0" Ring. . . . . . . . . . . . . . . . . . . . . .. 1 86 Hose Fitting .
44 Valve Oil Supply Tube. . . . . . . . . . . . . . . . . . . . . . . . .. 1 ITEMS 81 THRU 86 FOR MHR ONLY.
S1005
Figure D
S1005
R OR HR32000
REVERSE & 3RD & FORWARD & 2ND CLUTCH GROUP
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY

1 Reverse & 3rd Clutch Shaft Piston Ring 3 47 Low Clutch Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . .. 1
1A Piston Ring ExpanderSprings . . . . . . . . . . . . . . . . . . .. 3 48 GearRetaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
2 Front Bearing Retainer Ring. . . . . . . . . . . . . . . . . . . . .. 1 49 2nd Gear 1
3 Reverse & 3rd Shaft Front Bearing End Plate 1 50 Clutch Hub Oil Baffle Ring. . . . . . . . . . . . . . . . . . . . . .. 1
4 Reverse & 3rd Shaft Bearing End PlateBall. . . . . . . . .. 1 51 2nd GearRetainer Ring 1
5 Reverse & 3rd Shaft Front Bearing 1 52 2nd GearRetainer Ring Retainer . . . . . . . . . . . . . . . . .. 1
6 Front Bearing Retainer Ring. . . . . . . . . . . . . . . . . . . . .. 1 53 2nd GearRetainer Ring Retainer Snap Ring 1
7 Clutch Driven Gear Bearing - Shield In 1 54 Spring Retainer Snap Ring 1
8 Clutch Driven Gear Bearing Snap Ring . . . . . . . . . . . .. 1 55 Spring Retainer Snap Ring Retainer 1
9 Clutch Driven Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 56 Spring Retainer 1
10 Clutch Hub Oil Baffle Ring. . . . . . . . . . . . . . . . . . . . . .. 1 57 Piston Return Spring .. . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 Spring Retainer Snap Ring 1 58 Spring Retainer 1
12 Clutch Driven GearBearing Snap Ring . . . . . . . . . . . .. 1 59 End PlateRetainer Ring . . . . . . . . . . . . . . . . . . . . . . . .. 1
13 Clutch Driven Gear Bearing . . . . . . . . . . . . . . . . . . . . .. 1 60 End Plate- 2nd Clutch ... . . . . . . . . . . . . . . . . . . . . . .. 1
14 Spring RetainerSnap Ring 1 61 Clutch Outer Disc - 2nd Clutch 6
15 Spring RetainerSnap Ring Retainer 1 62 Clutch Inner Disc - 2nd Clutch . . . . . . . . . . . . . . . . . . .. 6
16 Spring Retainer 1 63 Clutch PistonAssembly - 2nd Clutch. . . . . . . . . . . . . .. 1
17 Piston Return Spring ; . . . . . . . . . .. 1 64 Clutch Piston Outer Seal 1
18 Spring Retainer 1 65 Clutch Piston Inner Seal. . . . . . . . . . . . . . . . . . . . . . . .. 1
19 End Plate Retainer Ring . . . . . . . . . . . . . . . . . . . . . . . .. 1 66 Forward & 2nd Clutch Drum . . . . . . . . . . . . . . . . . . . .. 1
20 End Plate- Reverse Clutch. . . . . . . . . . . . . . . . . . . . . .. 1 67 Clutch Piston Inner Seal. . . . . . . . . . . . . . . . . . . . . . . .. 1
21 Clutch Outer Disc - Reverse Clutch . . . . . . . . . . . . . . .. 6 68 Clutch Piston Outer Seal 1
22 Clutch Inner Disc - Reverse Clutch. . . . . . . . . . . . . . . .. 6 69 Clutch Piston Assembly - Forward Clutch . . . . . . . . . .. 1
23 Clutch Piston Assembly - Reverse Clutch . . . . . . . . . .. 1 70 Clutch Outer Disc - Forward Clutch . . . . . . . . . . . . . . .. 6
24 Clutch Piston Outer Seal 1 71 Clutch Inner Disc - Forward Clutch 6
25 Clutch Piston Inner Seal. . . . . . . . . . . . . . . . . . . . . . . .. 1 72 End Plate- Forward Clutch. . . . . . . . . . . . . . . . . . . . . .. 1
26 Reverse & 3rd Clutch Drum. . . . . . . . . . . . . . . . . . . . .. 1 73 End PlateRetainer Ring . . . . . . . . . . . . . . . . . . . . . . . .. 1
27 Clutch Piston Inner Seal. . . . . . . . . . . . . . . . . . . . . . . .. 1 74 Spring Retainer Snap Ring 1
28 Clutch Piston Outer Seal 1 75 Spring Retainer 1
29 Clutch Piston - 3rd Clutch 1 76 Piston Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
30 Clutch Inner Disc - 3rd Clutch 6 77 Spring Retainer 1
31 Clutch Outer Disc - 3rd Clutch . . . . . . . . . . . . . . . . . . .. 6 78 Spring Retainer Snap Ring Retainer 1
32 End Plate- 3rd Clutch. . . . . . . . . . . . . . . . . . . . . . . . . .. 1 79 Spring Retainer Snap Ring 1
33 End PlateRetainer Ring . . . . . . . . . . . . . . . . . . . . . . . .. 1 80 Clutch Driven Gear Bearing . . . . . . . . . . . . . . . . . . . . .. 1
34 Spring Retainer 1 81 Clutch Driven Gear BearingSnap Ring . . . . . . . . . . . .. 1
35 Piston Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 82 Clutch Hub Oil Baffle Ring . . . . . . . . . . . . . . . . . . . . . .. 1
36 Spring Retainer 1 83 Forward Clutch Driven Gear 1
37 Spring Retainer Snap Ring Retainer 1 84 Clutch Driven Gear BearingSnap Ring . . . . . . . . . . . .. 1
38 Spring RetainerSnap Ring 1 85 Clutch Driven Gear Bearing- Shield In 1
39 3rd GearBearing 1 86 Front Bearing Retainer Ring. . . . . . . . . . . . . . . . . . . . .. 1
40 3rd Gear Bearing Snap Ring 1 87 Front Bearing Locating Ring : 1
41 Clutch Hub Oil Baffle Ring 1 88 Forward & 2nd Shaft Front Bearing. . . . . . . . . . . . . . .. 1
42 3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 89 Forward & 2nd Shaft BearingEnd PlateBall . . . . . . . .. 1
43 3rd GearBearingSpacer . . . . . . . . . . . . . . . . . . . . . . .. 1 90 Forward & 2nd Shaft Front BearingEnd Plate. . . . . . .. 1
44 3rd GearBearing Snap Ring 1 91 Front Bearing Retainer Ring. . . . . . . . . . . . . . . . . . . . .. 1
45 3rd Gear Bearing - Shield Out 1 92 Forward & 2nd Shaft Piston Ring 3
46 Reverse & 3rd Shaft Rear Bearing . . . . . . . . . . . . . . . .. 1 92A Piston Ring ExpanderSprings . . . . . . . . . . . . . . . . . . .. 3
S1005
52
53 \ .>:
55 54
56 \ \
~GY
58 57\ \ .'~'
~~\\)
-;"
59 \ rr"~
r~i·~
\~~~
~"'"
\
60
61
74 77 78 79 80
72 73 \ \ ~\ \
71~\ ~~
76
\~. ~\,l)
75 \~~~
~~.~
70
\
~ 82 81
Figure E
S1005
R OR HR32000 LOW f1ST) CLUTCH & OUTPUT GROUP
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY.

1 Low Speed Clutch Shaft Pilot Bearing 1 42 Idler Shaft Rear Bearing. . . . . . . . . . . . . . . . . . . . . . . .. 1
2 2nd Gear Bearing End Plate. . . . . . . . . . . . . . . . . . . . .. 1 43 RearBearing Cap Oil Seal 1
3 2nd Gear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 44 RearBearing Cap Screw . . . . . . . . . . . . . . . . . . . . . . .. 4
4 Bearing Retaining Ring Retainer . . . . . . . . . . . . . . . . .. 1 45 Rear Bearing Cap Screw Lockwasher . . . . . . . . . . . . .. 4
5 Low Speed Gear Bearing Retainer Ring 1 46 Rear Bearing Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
6 Low Speed Gear Bearing Assembly 1 47 Rear Bearing Cap "0" Ring. . . . . . . . . . . . . . . . . . . . .. 1
7 Low Speed Gear 1 48 RearBearing Cap "0" Ring . . . . . . . . . . . . . . . . . . . . .. 1
8 Clutch Hub Oil Baffle Ring . . . . . . . . . . . . . . . . . . . . . .. 1 49 RearBearing Cup. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
9 Spring Retaining Ring Retainer . . . . . . . . . . . . . . . . . .. 1 50 Rear Bearing Cone. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
10 Spring Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . .. 1 51 Output Shaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
11 Piston Return Disc Springs . . . . . . . . . . . . . . . . . . . . .. 5 52 Output Shaft GearSpacer . . . . . . . . . . . . . . . . . . . . . .. 1
12 Piston to Piston Return Disc Springs Spacer. . . . . . . .. 1 53 Output Shaft 1
13 End Plate Retainer Ring . . . . . . . . . . . . . . . . . . . . . . . .. 1 54 Front Bearing Cone . . . . . . . . . . . . . . . . . . . .. 1
14 End Plate 1 55 Front Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
15 Clutch Inner Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 56 Front Bearing Cap "0" Ring 1
16 Clutch Outer Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 57 Bearing Cap Shim. . . . . . . . . . . . . . . . . . . . . . . . . . .. AR
17 Clutch Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 58 Front Bearing Cap 1
18 Clutch Piston Outer Seal 1 59 Front Bearing Cap Oil Seal. . . . . . . . . . . . . . . . . . . . . .. 1
19 Clutch Piston Inner Seal. . . . . . . . . . . . . . . . . . . . . . . .. 1 60 Front Bearing Cap Screw. . . . . . . . . . . . . . . . . . . . . . .. 4
20 Low Speed Clutch Drum . . . . . . . . . . . . . . . . . . . . . . .. 1 61 Front Bearing Cap Screw Lockwasher 4
21 Low Speed Shaft RearBearing . . . . . . . . . . . . . . . . . .. 1 62 Bearing RetainerRing 1
22 Bearing Lockball 1 63 Bearing Locating Ring . . . . . . . . . . . . . . . . . . . . . . . . .. 1
23 Rear Bearing RetainerPlate . . . . . . . . . . . . . . . . . . . . .. 1 64 Idler Shaft Front Bearing . . . . . . . . . . . . . . . . . . .. 1
24 RearBearing RetainerPlate Screw 3 65 Idler Shaft 1
25 Rear Bearing Cap Gasket. . . . . . . . . . . . . . . . . . . . . . .. 1 66 Idler Shaft Gear Key. . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
26 Rear Bearing Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 67 Idler Shaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
27 Rear Bearing Cap Screw Lockwasher . . . . . . . . . . . . .. 5 68 Bore Plug (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
28 RearBearing Cap Screw . . . . . . . . . . . . . . . . . . . . . . .. 5 69 Disconnect Assembly (optional) 1
29 RearBearing Cap Plug. . . . . . . . . . . . . . . . . . . . . . . . .. 1 70 Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
30 RearBearing Cap "0" Ring . . . . . . . . . . . . . . . . . . . . .. 1 71 Output Flange 1
31 Clutch Shaft Piston Plug 1 72 Output Flange "0" Ring 1
32 Low Speed Shaft RearBearing Locating Ring 1 73 Output FlangeWasher. . . . . . . . . . . . . . . . . . . . . . . . .. 1
33 Bearing Cap Screw Lockwasher . . . . . . . . . . . . . . . . .. 2 74 Output Flange Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
34 Bearing Cap Screw 2 75 Speedo Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
35 Bearing Cap Screw 2 76 Rear Bearing Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
36 Bearing Cap Screw Lockwasher . . . . . . . . . . . . . . . . .. 2 77 Rear Bearing Cap Screw Lockwasher . . . . . . . . . . . . .. 3
37 Idler Shaft Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . .. 1 78 Rear Bearing Cap Screw . . . . . . . . . . . . . . . . . . . . . . .. 3
38 Idler Shaft Bearing Cap Gasket . . . . . . . . . . . . . . . . . .. 1 79 Speedo Driven Gear. . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
39 Idler Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 80 Speedo Tube Nut 1
40 Rear Bearing Locating Ring . . . . . . . . . . . . . . . . . . . . .. 1 81 Rear Bearing Cap Screw . . . . . . . . . . . . . . . . . . . . . . .. 1
41 Idler Shaft Rear Bearing Lockball . . . . . . . . . . . . . . . . .. 1 82 Rear Bearing Cap Screw Lockwasher . . . . . . . . . . . . .. 1
S1005
_ PRESSURE 34
REGULATOR SlOE
Figure F
S1005
PRESSURE REGULATOR VALVE, CHARGING PUMP & OIL FILTER GROUP
ITEM DESCRIPTION QTV. ITEM DESCRIPTION QTV.

1 Charging Pump Drive Sleeve. . . . . . . .. 1 26 Valve to Housing Stud Lockwasher . .. 4
2 Pump Sleeve Snap Ring. . . . . . . . . . . . 1 27 Valve to Housing Stud Nut. . . . . . . . .. 4
3 Valve to Housing Gasket . 28 Thrust Plate & Bearing Assembly. . . .. 2
4 Valve Body "0" Ring . 29 Wave Spring. . . . . . . . . . . . . . . . . . . . .. 2
5 Valve Body "0" Ring . 30 Pump Shaft Seal. . . . . . . . . . . . . . . . . .. 2
6 Pipe Plug . 31 Pump to Filter Adaptor

Screw Lockwasher................. 4
7 Safety Valve Seat .
32 Pump to Filter Adaptor Screw. . . . . . .. 4
8 Safety Valve Spacer .
33 Pump Drive Shaft Assembly .
9 Safety Valve Plunger .
34 Pump Drive Shaft Oil Seal. .
10 Safety Valve Spring .
35 Pressure Regulator Valve .
11 Valve Stop "0" Ring .
36 Valve Body Roll Pin. . . . . . . . . . . . . . .. 3
12 Valve Stop .
37 Valve Body "0" Ring. . . . . . . . . . . . . .. 1
13 Valve Stop Roll Pin .
38 Pump to Filter Gasket .
14 Valve Stop Roll Pin .
39 Filter Adaptor .
15 Valve Stop . 1
40 Filter Adaptor Plug .
16 Valve Stop "0" Ring .
41 By-Pass Filter Disc Spring .
17 Valve Piston .
42 By-Pass Filter Disc .
18 Valve Spring - Inner .
43 By-Pass Filter Disc Seat .
19 Valve Spring - Outer . . . . . . . . . . . . . . . 1
44 Filter Seat Retainer Ring .
20 Valve to Converter Housing Stud. . . .. 4
45 Filter Housing "0" Ring .
21 Valve Body to Pump Gasket .
46 Oil Filter Element Assembly .
22 Pump Body Snap Ring .
47 Oil Filter Element Spring .
23 Thrust Plate & Bearing Assembly. . . .. 2
48 Filter Housing .
24 Pump Driven Shaft Assembly .
49 Pipe Plug .
25 Charging Pump Housing .
50 Optional Adaptor for Remote Filter ...
S1005
kli
28--~
29-1Q)
30-~
26 31-~
32_a
33~~
34'--. ~
35~§
~
r---------------T-----~-----T--------------~
I DEC.lUTCH I DEClUTCH I DEClUTCH INCHING I
FORWARD & REVERSE ONLY FORWARD ONLY
REVERSE
~-36
t" "11
37
t I
L
3J
FIG. A
_
FIG. B
38-1
t 3J
FIG.C
---l
38__ 1
39__
I 40_®
e
I 41 __ ~
I
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48 I
I
F1G:{J I
L J
VALVE ROTATED 90'
8 - 20
/
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 ~o
declutch valve, spool and spring needed. NOTE:
Some valves will require no spacers, some valves will
7 I
require 1 spacer and some will require 2 spacers. 8
CONTROL VALVE ASSEMBLY

(AIR OECLUTCH)
FigureG
S1005
CONTROL VALVE ASSEMBLY
ITEM DESCRIPTION QTY. ITEM DESCRIPTION QTY.
Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . 1 22 Overshift Spacer (Not on all models) .
2 Oil Seal Retainer Ring. . . . . . . . . . . . . . 1 23 Oil Seal Retainer Washer .
3 Oil Seal Retainer Washer . 24 Oil Seal Retainer Ring. . . . . . . . . . . . . . 1
4 Forward & Reverse Valve Spool . 25 Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 Control Valve Gasket. . 26 Piston Housing Assembly .
6 Detent Spring . 27 Stop Plug .... . . . . . . . . . . . . . . . . . . . . 1
7 Detent Spring . 28 Plug "0" Ring. . . . . . . . . . . . . . . . . . . . . 1
8 Detent Ball. . . . . . . . . . . . . . . . . . . . . .. 3 29 Piston "0" Ring. . . . . . . . . . . . . . . . . . . 1
9 Neutral Switch . . . . . . . . . . . . . . . . . . .. 1 30 Glyd Ring . . . . . . . . . . . . . . . . . . . . . . . . 1
10 Detent Ball . . . . . . . . . . . . . . . . . . . . . . . 1 31 Piston........................... 1
11 Valve Housing Plug . 32 Piston Housing .
12 Valve Housing Plug "0" Ring . 33 Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 Overshift Spacer (Not on all models) . 34 Band Seal .
14 Control Valve Housing. . . . . . . . . . . . . . 1 35 "0" Ring. . . . . . . . . . . . . . . . . . . . . . . . . 1
15 Detent Spring Plug . Figures A-B-C & D are various declutch options.
16 Detent Spring Plug Washer . 44 Adaptor Screw . . . . . . . . . . . . . . . . . . .. 4
17 Detent Spring. . . . . . . . . . . . . . . . . . . . . 1 45 Adaptor Screw Lockwasher. . . . . . . . .. 4
18 Valve to Adaptor Housing Screw. . . .. 9 46 Valve Adaptor .
19 Valve to Adaptor Housing Screw 47 Valve Adaptor Gasket .

Lockwasher. . . . . . . . . . . . . . . . . . . . . .. 9
48 Adaptor Screw . . . . . . . . . . . . . . . . . . .. 5
20 Speed Selector Spool Plug .
49 Adaptor to Plate Gasket .
21 Speed Selector Spool .
50 Valve Adaptor Plate .
S1005
AXLE DISCONNECT
MECHANICAL PARKING BRAKE
Figure H
S1005
AXLE DISCONNECT
ITEM DESCRIPTION QTV ITEM DESCRIPTION QTV
Disconnect Housing Capscrew. . . . . . . . . . . . .. 4 9 Detent Ball .
2 Disconnect Housing Capscrew

10 Detent Spring .
Lockwasher " 4
11 Shift Rail .
3 Disconnect Housing .
12 Shift Rail Oil Seal .
4 Disconnect Housing Plug .
13 Bearing Retainer Ring .
5 Shift Hub .
14 Bearing .
6 Shift Fork .
15 Bearing Retainer Ring .
7 Shift Fork Lockscrew .
8 Disconnect Shaft .
PARKING BRAKE GROUP

10 X 3 BRAKE
ITEM DESCRIPTION QTV ITEM DESCRIPTION QTV
Lock Nut .
9 Brake Flange .
2 Washer .
10 Brake Drum .
3 Operating Lever o' • • • • • • • • • • • • • • • •

11 Brake Drum Screw Lockwasher. . . . . . . . . . . . .. 6
4 Backing Plate .
12 Brake Drum Screw. . . . . . . . . . . . . . . . . . . . . . .. 6
5 Cam Shaft .
13 Brake Lining .
6 Strut Assembly .
14 Rivet Kit 24
7 Return Spring .
15 Backing Plate Screw. . . . . . . . . . . . . . . . . . . . .. 4
8 Brake Shoe, Lining & Rivet .

16 Backing Plate Screw Lockwasher . . . . . . . . . . .. 4
S1005
View"Q"
1.
HOUSln9th
spacer
used WI 12 plate
modulation only.
Figure I
S1005
Impeller Hub and Turbine Hub Assembly with & Heat nose bushing to 2000 FO (930C) before ass'y. of
Backing Ring and Special Self Locking Screws. bushing to cover.
1. Clean hub mounting surface and tapped holes
with solvent. Dry thoroughly being certain tapped Bearing shield OUT on 3rd speed clutch. Bearing shield
holes are dry & clean. IN on Fwd. & Rev. clutch.
2. Install backing ring and special self locking Must be loose internal fit bearings, No. "3" etched on
screws. bearing.
Tighten screws 40 to 45 Lbs. Ft. [54,3-61,0 N'm]
Note: Assembly of hub must be complete within a
fifteen minute period from start of screw installa-
&. (12 Plate Modulation)Two clutches, 12-outersteel plates,
12-inner friction plates. Assemble alternately, starting
tion. The special screw is to be used for one in- with outer steel plate.
stallation only. If the screw is removed for any
reason it must be replaced. The epoxy left in the Notes
hub holes must be removed with the proper tap A.. Use Permatex & Crane Sealer only where
and cleaned with solvent. Dry hole thoroughly and specified.
use a new screw for reinstallation. B. - All lead in chamfers for oil seals, piston rings &
"0" rings must be smooth & free from burrs.
Gear to be assembled with long hub length to this Inspect at ass'y.
side. C.. Lubricate all piston ring grooves & "0" rings
with oil before ass'y.
&. Three c1utches,6-outer steel plates,6-inner friction D. - Apply very light coat of Permatex NO.2 to 0.0.
of all oil seals before ass'y.
plates.Assemble alternately, starting with outer
steel plate. E.. After assembly of parts using Permatex or
Crane sealer, there must not be any free or
& See Elastic Stop Nut Torque Chart excess material that could enter the oil circuit.
F. - Apply light coat of Crane Sealer to all pipe
&, Low clutch,9-outer steel plates,9-inner friction plugs.
plates. Assemble alternately, starting with outer G. - Apply a thin coating of grease between seal
steel plate. lips on lip type seals prior to ass'y.
H. - Apply light coat of Permatex NO.2 to all thru
& See Elastic Stop Nut Torque Chart hole stud threads.
!J::, Shim output shaft bearings to produce 6 to 8 Lbs.-

NOTE:The friction discs in the low clutch has
In. [0,68,-0,90 N'm] preload.
a higher co-efficient rating than the friction
& Tighten oil screen ass'y. 10 to 15 Lbs. Ft. discs in the other clutches, therefore the
discs must not be mixed. The low clutch in-
[13,6-20,0 Nrn]
ner disc can be identified by an "X" stamped
on one side of the inner teeth. The low clutch
View "Q" 2 Places inner disc also has a strip of non-soluble
yellow paint sprayed on the outer edge of
~
the disc.
Low Clutch Return Springs.
Concave side of first spring to be placed
against clutch piston. Remaining four springs
to be stacked alternately reversed as shown.
Forward & Reverse Clutch Return Springs.

against clutch piston. Remaining six springs Enlarged view of Piston Ring & Expander
of each clutch to be stacked alternately Note: Expander gap to be approx. 180 0 from ring
reversed as shown. See note on page 77. hook joint to aid ring assembly.
ELASTIC STOP NUT TORQUE

THREAD SIZE LB.-FT. [N'm]
NOTE: Metric dimensions shown 1" - 20 150 - 200 [203,4 - 271,1]
in brackets [ ]. 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]
Grade 5 ED Torque Specification for Lubricated

or Plated Screw Threads Grade 8 M
'\!Sl
NOM. FINE THREAD COARSE THREAD FINE THREAD COARSE THREAD
SIZE LB-FT [NM] LB-FT [NM] LB-FT [NM] LB-FT [NM]
L-,~~+
5000 ,
91 - 100
64 - 70
1123,4 -
I 86,8-
135.51
94,91
82 -
57 -
90 1111,2 -
I 77,3-
122,01
85,41
128 -
141 1-173,6 -
[122,1 -
191,11
134,21
115 - 127 1156,0-172,2
63 90 -
99 80 - 88 1108,5 - 119.3
4375 41 - 45 1 55,6- 61,01 -- 37 -
41 r 50,2- 55,51 58 -
64 I 78,7- 86,71 52 - 57 r 70,6- 77,2
3750 26 - 29· I 35,3- 39,3J 23 - 25 r 31,2- 33,8\ 37 -
41 r 50,2- 55,51 33 - 36 r 44,8- 48,8
3125 16 - 20 i 21.7- 27,11 12 - 16 [ 16,3- 21,61 28 - 32 I 38,0- 43,31 26 - 30 r 35,3- 40,6
2500 9 - 11 I 12.3- 14.91 8- 10 [ 10,9- 13,5] i1- 13 [ 15,0- 17,61 9 - 11 I 12,3- 14,9]
Figure I
S1005
Figure J
S1005
MAINTENANCE AND SERVICE
The instructions contained herein cover the disassembly and shafts with and without disconnect assemblies may vary on
reassembly of the transmission in a sequence that would nor- specific models. The units are very similar to trouble shoot,
mally be followed after the unit has been removed from the
disassemble, repair, and reassemble. Drain as much oil as
machine and is to be completely overhauled. It must also be possible before disassembly. See page 70 for R-Model
understood that this is a basic HR32000 3 speed long drop
(remote mounted) transmission front cover section. See page
transmission with many options. Companion flanges and output 85 for 6 & 8 speed maintenance information.
DISASSEMBLY
Figure 1 Figure 3
Side view of 3 speed HR32000 long drop transmission. Removefilter element housing and element. NOTE: It is recom-
mended a small pan be used to catch remaining oil in element
housing.
Figure 2
Remove two valve to converter housing capscrews. Install two
aligning studs as shown. Remove remaining capscrews. Figure 4
Remove control valve and gasket.
Remove charging pump to pressure regulating valve stud nuts.
-1-
S1005
Figure 5 Figure 8
Remove charging pump and filter adaptor assembly. Remove pump adaptor bolts, adaptor and gasket.
Figure 9
Remove impeller cover bearing cap bolts. NOTE: Some
Figure 6 units will have drive plates instead of ring gear. Remove
Remove pressure regulating valve assembly and "0" rings. drive plates.
Figure 7 Figure 10
Remove pump drive sleeve and gasket. Remove bearing cap and "0" ring.
-2-
S1005
Figure 14
Remove reaction member.
Figure 11
Remove impeller cover to impeller bolts.
Figure 15
Remove reaction member spacer.
Figure 12
Remove impeller cover and turbine as an assembly.
Figure 16
Remove oil baffle retainer ring. Using pry slots in converter
housing, pry oil baffle and impeller from housing. NOTE:
Figure 13 Impeller, oil baffle and impeller hub gear are removed as an
Remove reaction member retainer ring. assembly.
-3-
S1005
Figure 20
Figure 17 Remove pump drive gear support bolts.
Remove impeller assembly.
Figure 21
Figure 18 Remove pump drive gear and bearing assemblies.
Remove stator support to housing bolts.
Figure 22
Support converter housing with a chain fall. Remove converter
Figure 19 housing to transmission housing bolts. NOTE: For converter
Remove stator support. NOTE: Support must be turned to clear housing removal on the 8 speed transmission, see Figure
pump drive gear. 1 In the 8 speed section, page 93.
-4-
S1005
Figure 23
Separate the converter housing from the transmission
housing. Remove gasket. NOTE: Forward and 2nd clutch will Figure 26
remain in converter housing. Remove turbine shaft gear.
Figure 24
Use a spreading type snap ring pliers to spread the ears on for- Figure 27
ward clutch front bearing retainer ring. Remove forward clutch Tap turbine shaft and bearing from converter housing.
with pry bar.
Figure 25 Figure 28
Remove turbine shaft gear retainer ring. Remove bearing from turbine shaft.
-5-
S1005
Figure 29 Figure 32
Remove 2nd clutch disc hub retainer ring retainer. Remove disc hub.
Figure 30 Figure 33
Remove disc hub ring retainer. Remove bearing end plate.
Figure 34
Figure 31 Remove brake drum stud nuts (used only to hold drum in place
Remove disc hub retainer ring. after drive shaft was removed).
-6-
S1005
Figure 35 Figure 38
Remove brake drum. Pry brake strut from brake bands.
Figure 36 Figure 39
Remove output flange nut, washer and "0" ring. Remove brake backing plate bolts.
Figure 37 Figure 40
Remove output flange. Remove backing plate and brake band assembly.
-7-
S1005
Figure 41 Figure 44
Remove idler shaft rear bearing cap bolts and washers. Remove rear bearing locating ring.
Figure 45
Figure 42 Remove 1st speed clutch (low) rear bearing cap bolts and
Remove bearing cap and gasket. washers.
Figure 43 Figure 46
Remove idler shaft rear bearing retainer nut and spacer. 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
Figure 48 removed without shaft binding. NOTE: The use of alignment
Remove retainer plate. studs will facilitate cover removal.
Figure 52
Figure 49 Remove 1st speed clutch double bearing cup, outer taper
Remove bearing locating ring. bearing and spacer.
-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 trans-
mission 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 Figure 56
rollers may be pulled from the bearing inner race and the inner Remove 1st speed clutch drive gear retainer ring.
race can be removed after the low clutch assembly has been
removed from the transmission. See caution in Figure 53.
1-5/32
1/8
49164 CUTWITH 1/16 RUBBER
5/32 - 1/16 R.CENT. WHEELAFTERHON.
Irr
+~I~" ifr
"'
ltL~~'~~-LI
+><
4-17164
"O"RING OIA.
Figure 54-A
A timken bearing cup, No. 29520 must be used with the above Figure 57
bearing puller. Remove drive gear.
-10-
S1005
Figure 58 Figure 61
Remove 1st speed clutch assembly. Remove front output flange nut, washer, "0" ring and flange. see
6 & 8 Speed Section for RangeShiftOutputShaft Removal.
Figure 59 Figure 62
Remove 1st speed front bearing. Remove output shaft front bearing cap bolts and washers.
Figure 60 Figure 63
Remove reverse and 3rd clutch assembly. Remove bearing cap, "0" ring and shims.
-11-
S1005
Figure 64 Figure 67
Remove output shaft rear bearing cap bolts and washers. Remove rear taper bearing.
Figure 65 Figure 68
Remove bearing cap and "0" rings. Remove output shaft, gear spacer and front taper bearing.
Figure 66
Block output gear. Push or drive output shaft through taper Figure 69
bearing and output gear. Remove output gear.
-12-
S1005
Figure 70
Remove front bearing.
Figure 73
Remove taper bearing retainer ring retainer.
Figure 71
If idler shaft, idler gear or rear bearing are to be replaced,
remove bearing and gear. Turn shaft over and remove the front
bearing retainer ring and bearing.
Figure 74
1ST SPEED CLUTCH (LOW) Remove bearing retainer ring.
DISASSEMBLY AND REASSEMBLY
See 8 Speed Section for 4th Speed Clutch Repair
DISASSEMBLY
See Note In Figure 83
Figure 72 Figure 75
Remove clutch assembly front bearing inner race. Remove 1st speed gear and outer taper bearing.
-13-
S1005
Figure 76 Figure 79
Remove taper bearing spacer. Remove inner and outer clutch discs.
Figure 77 Figure 80
Remove clutch end plate retainer ring. Remove inner taper bearing.
Figure 81
Figure 78 Remove piston return disc spring retainer ring retainer washer.
Remove end plate.
-14-
S1005
NOTE: Each disc spring assembly is made up of selected

springs to precisely match each part within this assembly.
Failure to replace all piston return springs can result in
unequal deflection within the spring pack. The result of
this imbalance may adversely affect overall life of springs.
The disc spring packs are to be used as complete
assemblies and care should be taken not to intermix the
individual disc springs with disc springs in another clutch
or disc spring pack.
1ST SPEED CLUTCH REASSEMBLY
Figure 82
Remove return disc spring retainer ring.
Figure 85
Figure 83
Install clutch piston outer seal ring.
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 for-
ward 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' Figure 86
clutch shaft on a block of wood to remove clutch piston. Install clutch piston inner seal ring. Install piston into clutch
drum. Use caution as not to damage seal rings.
See cleaning and inspection page.
-15-
S1005
Figure 90
Figure 87 Position ring retainer over retainer ring.
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
Figure 89 paint sprayed on the outer edge of the disc. Alternate steel
Position return spring retainer ring on clutch shaft. Compress and friction discs until the proper amount of discs are installed.
disc springs and install retainer ring. First disc next to the piston is steel, last disc installed is friction.
-16-
S1005
Figure 96
Figure 93 Position taper bearing spacer on shaft.
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
Figure 94
force this operation. Gear splines must be in full position with
Install end plate retainer ring.
internal teeth of all friction discs.
Figure 95 Figure 98
Install inner clutch gear taper bearing. Install outer taper bearing.
-17-
S1005
Figure 99
Install low clutch taper bearing retainer ring.
Figure 102
NOTE: Retainer ring is selected at assembly for proper Position front bearing on clutch shaft inner race. NOTE: Bearing
thickness. A snap ring kit is available. Select the thickest could be installed in transmission case before installing clutch.
of the three rings in the kit that can be fitted into the snap
ring groove to assure a proper taper bearing tightness.
Check ring as shown for tight ring to bearing fit.
REVERSE AND 3RD CLUTCH
DISASSEMBY AND REASSEMBLY
DISASSEMBLY
(Reverse being disassembled)
Figure 100
Position ring retainer over retainer ring.
Figure 103
Remove clutch shaft piston rings. NOTE: Some units will
have Telfon piston rings and expander springs. these
Figure 101 rings are to be replaced with a new style ring and does
Install clutch shaft front bearing inner race with large diameter NOT use an expander spring. See page 79 for proper
of race down. piston ring Installation.
-18-
S1005
Figure 104 Figure 107

Remove front bearing retainer ring. Remove front bearing.
Figure 108
Figure 105 Pry front bearing inner race up far enough to use a bearing
Remove front bearing end plate. puller.

Remove end plate lock ball. Remove bearing inner race.
-19-
S1005
Figure 1,10 Figure 113

Remove clutch driven gear outer bearing retainer ring. Remove end plate.

Remove clutch gear and outer bearing. Remove inner and outer clutch discs.

Remove clutch disc end plate retainer ring. Remove inner bearing.
-20-
S1005
Figure 119
Remove clutch piston.
Figure 116
Compress piston return spring. Remove spring retainer ring.
3RD SPEED CLUTCH DISASSEMBLY

Remove retainer ring retaining washer. 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 Figure 121
springs. (See note on page 15. Figure 83.1 Remove 3rd speed gear and outer bearing.
-21-
S1005

Remove clutch gear outer and inner bearing spacer. Remove clutch disc end plate retainer ring.

Pry inner bearing up far enough to use a bearing puller. Remove end plate.

Remove inner bearing. Remove inner and outer clutch discs.
-22-
S1005
Figure 131
Figure 128
Compress piston return spring. Remove return spring retainer
ring.
3RD SPEED CLUTCH REASSEMBLY
Figure 132
Figure 129
Install clutch piston inner and outer seal rings. Install clutch
Remove retainer ring retaining washer.
piston in clutch drum, use caution as not to damage seal rings.
Figure 133
Figure 130 Position the inner return spring retainer, the return spring and
Remove return spring retainers and spring. the outer spring retainer on clutch shaft.
-23-
S1005

Position return spring retainer ring retaining washer on clutch Install one friction disc. Alternate steel and friction discs until
shaft. 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 Figure 138
ring is in full position in retaining washer and ring groove. Install clutch disc end plate.

Install one steel disc. Install end plate retainer ring.
-24-
S1005
Figure 143
Install clutch gear outer bearing. NOTE: Outer bearing has a
Figure 140 shield in it, this shield must be up.
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
Figure 141 diameter locating ring must be down.
Install clutch gear inner and outer bearing spacer.
REVERSE CLUTCH REASSEMBLY
Figure 142
Install clutch gear into clutch drum. Align splines on clutch gear
with internal teeth of friction discs. Tap gear into position. Do Figure 145
not force this operation. Gear splines must be in full position Install clutch piston inner and outer oil seal rings. Install clutch
with internal teeth of all friction discs. 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 Figure 149
the outer spring retainer. NOTE: If reverse and forward Install one steel disc.
clutches are modulated, assemble disc springs as shown
in Figure A on page 59.
Figure 150
Figure 147 Install one friction disc. Alternate steel and friction discs until
Position return spring retainer ring retaining washer on clutch the proper amount of discs are installed. First disc next to the
shaft. piston is steel, last disc installed is friction.
Figure 148
Compress return spring and install retainer ring being certain Figure 151
-26-
S1005
Figure 152
Figure 155
Install end plate retainer ring.
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 Figure 157
operation. Gear splines must be in full position with internal Install clutch shaft front bearing inner race with large diameter
teeth of all friction discs. 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 DISASSEMBLY AND REASSEMBLY

Position end plate lock ball in clutch shaft. OF THE FORWARD AND 2ND CLUTCH
(Forward being disassembled)

Install bearing end plate, aligning notch in plate with lock ball. Remove clutch shaft piston rings. (See note in Figure 103.)
-28-
S1005

Remove front bearing end plate retainer ring. Remove bearing end plate lock ball.

Remove end plate. Remove front bearing inner race.

Remove front bearing. Remove clutch gear outer bearing retainer ring.
-29-
S1005

Remove clutch gear and outer bearing. Remove end plate.

Remove inner bearing. Remove inner and outer clutch discs.
Figure 175
Figure 172 Compress piston return spring. Remove return spring retainer
Remove clutch disc end plate retainer ring. ring.
-30-
S1005
2ND CLUTCH DISASSEMBLY
Figure 176
Remove retainer ring retaining ring. Figure 179
Remove clutch disc end plate retainer ring.
Figure 177
Remove piston return spring and retainers. See note in Figure
118. Figure 180
Remove end plate.

Remove clutch piston. Remove inner and outer clutch discs.
-31-
S1005
Figure 185
Figure 182 Remove clutch piston.
Compress piston return spring. Remove return spring retainer
ring.
2ND CLUTCH REASSEMBLY
Figure 183
Remove retainer ring retaining washer. Figure 186
Install clutch piston inner and outer seal rings. Install clutch
piston in clutch drum, use caution as not to damage seal rings.
Figure 187
Figure 184 Position the inner return spring retainer, the return spring and
Remove return spring retainers and spring. outer spring retainer on clutch shaft.
-32-
S1005
Figure 191
Figure 189
Compress return spring and install retainer ring, being certain Figure 192

Install one steel disc. Install end plate retainer ring.
-33-
S1005
FORWARD CLUTCH REASSEMBLY
Figure 197
Compress return spring and install retainer ring, being certain
Figure 194 ring is in full position in retaining washer and ring groove.
Install clutch piston inner and outer seal rings. Install piston in
clutch drum, use caution as not to damage seal rings.

Position the inner return spring retainer, the return spring and Install one steel disc.
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
-34-
S1005
Figure 203
Install clutch gear into clutch drum. Align splines on clutch gear
Figure 200 with internal teeth of friction discs. Tap gear into position. Do
Install clutch disc end plate. not force this operation. Gear splines must be in full position
with internal teeth of all friction discs.

Install end plate retainer ring. Install clutch gear outer bearing. NOTE: Outer bearing has a
shield in it. this shield must be down.
Figure 202
Install clutch gear inner bearing. NOTE: This bearing does not Figure 205
have a shield in it. Install bearing retainer ring.
-35-
S1005
Figure 206
Install clutch shaft front bearing inner race with large diameter Figure 209
of race down. Install bearing end plate, aligning notch in plate with lock ball.

Position end plate lock ball in clutch shaft. Install bearing retainer ring.
Figure 211
Figure 208 Install clutch shaft piston rings. See note in Figure 103.
Position front bearing over bearing race.
-36-
S1005
OIL SEALING RING SLEEVE REMOVAL

NOTE: The following photos are not of the HR Converter
Housing but the sleeve removal procedure is identical.
Figure 215
Use a sleeve puller like the one shown.
Figure 212
Remove clutch front bearing locating ring.
Figure 216
Sleeve being removed.

NOTE: When installing a new sleeve it is recommended a press
or a driver be used to prevent damage to the sleeve and be sure
the notch in the sleeve is aligned with sleeve lock notch. Install
Figure 213 sleeve lock and capscrew. Tighten screw to specified torque.
Remove oil sealing ring sleeve retainer screw. (See torque chart.)
Figure 217
Figure 214 Position new oil sealing ring on turbine shaft. Install turbine
Remove screw and sleeve lock. shaft bearing on shaft with bearing outer locating ring down.
-37-
S1005
Figure 220
Install drive gear retainer ring.
Figure 218 TRANSMISSION REASSEMBLY

Install turbine shaft and bearing in converter housing.
SEE 6 & 8 SPEED SECTION FOR RANGE SHIFT OUTPUT
SHAFT INSTALLATION.
Figure 221
View of output shaft as it would be positioned in transmission
case. NOTE: Front cone bearing shouldered on shaft with large
diameter of bearing in, and long hub of gear toward gear spacer.
Figure 219
Install turbine shaft drive gear as shown in Figure 219-A.
DRIVE GEAR
NOTE: LONG HUB OF

DRIVE GEAR TOWARD Figure 222
RETAINER RING 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 in-
Figure 219·A stall rear taper bearing with large diameter in.
-38-
S1005

Coat outer diameter of oil seal with Permatex No.2 and press Install front bearing cap and shims. Tighten bolts to specified
seal in bearing cap with lip of seal in. See assembly instruction torque. Tap output shaft front and rear to seat taper bearings.
sheet for seal depth. Using new "0" rings install rear output Loosen front bearing cap bolts.
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 227
Using a inch lb. torque wrench, determine the rolling torque of
the output shaft and record. Tighten front bearing cap bolts to
Figure 224 specified torque. Check rolling torque with bolts tight. Torque
Tighten bearing cap bolts to specified torque. (See torque must be 6 to 8 inch Ibs. [0,7-0,09 N.m] more than when bearing
chart.) cap bolts were loose. Add or omit shims on the front bearing
cap to achieve the proper preload.
Figure 225
. Coat outer diameter of front output oil seal with Permatex No.2. Figure 228
Install seal in bearing cap with lip of seal in. Position reverse and 3rd clutch in transmission housing.
-39-
S1005
Figure 232
Figure 229 If idler shaft was disassembled, install front bearing. Install idler
From the rear of the transmission case, install the low (1 st) gear on shaft with long hub of gear up. (6 & 8 speed will have
clutch. 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.
NOTE: Double taper bearing must be replaced as an
assembly as the bearing spacer Is pre-selected at factory.
Figure 230
Install low (1 stl speed drive gear on clutch shaft.
Figure 233
Install idler shaft assembly. NOTE: Lock ball in bearing cup.
Figure 234
Figure 231 Install low (1 stl clutch outer double taper bearing. NOTE:
Install drive gear retainer ring. Locating ring groove in bearing cup to be out (to the rear).
-40-
S1005
Figure 235
Use caution as not to lose low (1 st) and idler bearing lock balls. Figure 238
A light coat of grease will hold lock balls in place. Tap cover in place.

The use of aligning studs will facilitate rear cover installation. Install rear cover bolts and washers, tighten to specified torque.
Position a new gasket and "0" ring on rear of case. A light coat (See torque chart).
of grease will hold gasket in place.
Figure 240
From the front, tap the low (1 stl clutch and idler shaft to the rear
Figure 237 to expose the rear bearing locating ring groove. Install locating
Align lock balls in bearing with notches in rear cover. ring.
-41-
S1005

Install low (1 stl clutch rear bearing retainer plate. NOTE: Inner Position bearing cap over bearing and install bearing cap bolts.
diameter hole chamfer to go toward bearing. Tighten to specified torque. (See torque chart).
Figure 242
Install retainer plate bolts and tighten to specified torque (see Figure 245
torque chart). Lock wire bolts together to prevent loosening. Install idler shaft rear bearing locating ring.
Figure 243
Install new "0" ring and gasket on low (1 stl clutch shaft rear Figure 246
bearing cap. Install idler shaft rear bearing spacer.
-42-
S1005

Install idler shaft rear bearing retainer nut. Tighten to specified Install brake backing plate and brake band assembly on output
torque. (See elastic stop nut torque chart). bearing cap.

Position a new gasket on the idler shaft rear bearing cap, install Install backing plate capscrews and tighten to specified torque.
bearing cap. (See torque chart).
Figure 249
Install capscrews and tighten to specified torque. (See torque Figure 252
chart). Install brake strut to brake bands.
-43-
S1005
Figure 256
Position brake drum on output flange studs. Install stud nut
Figure 253 washers and stud nuts. Tighten stud nuts enough to hold drum
Install rear output flange. in place until drive shaft is installed.

Install flange "0" ring, washer and lock nut. Install front output flange.
Figure 255
Tighten lock nut to specified torque. (See elastic stop nut torque Figure 258
chart). Install new output flange "0" ring, washer and flange nut.
-44-
S1005
Figure 259
Tighten flange nut to proper specifications. (See elastic stop nut Figure 262
torque chart). Install disc hub retainer ring.

Position 2nd clutch bearing end plate on low (1 st) clutch shaft. Install disc hub retainer ring retainer.

Position 2nd clutch disc hub on clutch shaft. Install disc hub ring retainer retaining ring.
-45-
S1005

Position 2nd speed clutch shaft pilot bearing on clutch shaft. A Spread forward clutch front bearing locating ring. Position
light coat of grease will hold bearing in place. Install forward converter housing to transmission housing. Tap housing into
and 2nd clutch in clutch disc hub being certain clutch disc hub place using caution as not to damage clutch shaft oil sealing
is in full position in clutch discs. See 8 speed section for 4th rings. Do not force this operation.
speed clutch Installation.

Position new gasket and "0" rings on housing. A light coat of Install bolts and washers,tighten to specified torque (see torque
grease will hold gasket and "0" rings in place. chart).

Install alignment studs in transmission housing to facilitate con- Using a hammer puller as shown, pull forward clutch until front
verter housing to transmission housing assembly. bearing locating ring is in full position in ring groove.
-46-
S1005

Install pump drive gears. Install support bolts and tighten to specified torque. (See torque
chart).
DISASSEMBLY AND REASSEMBLY

OF IMPELLER AND BAFFLE
DISASSEMBLY
Figure 272
Tighten pump drive gear support bolts to specified torque. (See
torque chart).
Figure 275
Remove pump drive gear retainer ring.
Figure 273
Install new sealing ring expander spring and oil sealing ring on
support. NOTE: Expander spring gap to be 1800 from sealing
ring hook joint. Position support on turbine shaft, turn support
to clear pump drive gear. Align support holes with converter Figure 276
housing. Remove pump drive gear.
-47-
S1005
Figure 280
Remove hub bearing retainer ring.
Figure 277
Remove impeller hub bolts.
Figure 281
Remove hub bearing.
Figure 278
Remove backing ring. See cleaning and inspection page.
REASSEMBLY

Tap impeller hub from impeller. 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
Figure 285 proper tap and cleaned with solvent. Dry hole thoroughly and
Align holes in impeller with holes in impeller hub. use a new screw for reinstallation.
-49-
S1005
Figure 291
Install pump drive gear retainer ring.
Figure 288
Apply a light coat of Permatex No. 2 on the outer diameter of
the oil baffle seal. Press seal in oil baffle with lip of seal down. DISASSEMBLY AND REASSEMBLY
OF TURBINE AND IMPELLER COVER
DISASSEMBLY
Figure 289
Install new oil baffle seal ring. Position oil baffle on impeller and
hub assembly. Figure 292
Remove turbine hub to impeller cover bearing retainer ring.

Install pump drive gear on impeller hub. Remove retainer ring to bearing washer.
-50-
S1005
If turbine and hub was disassembled, use the following instruc-

tions 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.
REASSEMBLY

Install impeller cover bearing. Position bearing washer over turbine hub.
-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 Figure 303
in converter housing. Install reaction member with thick part of blades out.
Figure 301
Position oil baffle in housing. Secure with oil baffle retainer ring, Figure 304
being sure ring is in full position in ring groove. Install reaction member retainer ring.
-52-
S1005

Position a new "0" ring on impeller cover. Position new "0" ring on impeller cover bearing cap.
Figure 306
Position turbine and impeller cover on turbine shaft. NOTE: Figure 309
Some units will have drive plates instead of impeller cover Install bearing cap, bolts and washers, tighten to specified
& ring gear. See drive plate installation section. torque. (See torque chart).

Install impeller cover to impeller bolts and washers. Tighten to Install aligning studs to facilitate control valve assembly. Install
specified torque (see torque chart). new control valve gasket.
-53-
S1005

Position control valve assembly on aligning studs. Install charging pump drive sleeve.
Figure 312
Install control valve bolts and washers and tighten to specified Figure 315
torque. (See torque chart). Install new pressure regulating valve gasket.

Install pump adaptor, bolts and washers. Tighten to specified Install new "0" rings on pressure regulating valve. Position
torque. (See torque chart). valve on studs.
-54-
S1005

Position new valve to pump gasket on studs. Install charging Install bolts and washers. Tighten to specified torque. (See
pump and filter adaptor on studs. torque chart).
Figure 318
Install washers and nuts, tighten to specified torque. (See Figure 321
torque chart). Install new filter element and filter housing.
Figure 319
Install new auxiliary pump adaptor gasket and adaptor.
-55-
S1005
SERVICING MACHINE AFTER TRANSMISSION OVERHAUL
The transmission, torque converter, and its allied 5. On remote mounted torque converters remove
hydraulic system are important links in the drive line drain plug from torque converter and. inspect
between the engine and the wheels. The proper oper- interior of converter housing, gears, etc. If
ation of either unit depends greatly on the condition presence of considerable foreign material is
and operation of the other; therefore, whenever repair noted, it will be necessary that converter be re-
or overhaul of one unit is performed, the balance of moved, disassembled and cleaned thoroughly.
the system must be considered before the job can be It is realized this entails extra labor; however,
considered completed. such labor is a minor cost compared to cost of
difficulties which can result from presence of
After the overhauled or repaired transmission has such foreign material in the system.
been installed in the machine, the oil cooler, and con-
necting hydraulic system must be thoroughly cleaned.
This can be accomplished in several manners and a de- 6. Reassemble all components and use only type
gree of judgment must be exercised as to the method oil recommended in lubrication section. Fill
employed. transmission through filler opening until fluid
comes up to LOW mark on transmission dipstick.
The following are considered the minimum steps to NOTE: If the dipstick is not accessible oil level
be taken: check plugs are provided.
Remove LOWER check plug, fill until oil runs
1. Drain entire system thoroughly. from LOWER oil hole. Replace filler and level
plug.
2. Disconnect and clean all hydraulic lines. Where
feasible, hydraulic lines should be removed from Run engine two minutes at 500-600 RPM to
machine for cleaning. prime torque converter and hydraulic lines. Re-
check level of fluid in transmission with engine
3. Replace oil filter elements, cleaning out filter running at idle (500-600 RPM).
cases thoroughly.
Add quantity necessary to bring fluid level
4. The oil cooler must be thoroughly cleaned. The to LOW mark on dipstick or runs freely from
cooler should be "back flushed" with oil and LOWER oil level check plug hole. Install oil
compressed air until all foreign material has been level plug or dipstick. Recheck with hot oil
removed. Flushing in direction of normal oil flow (180-200° F.) [82,2-93,3° C].
will not adequately clean the cooler. If neces- Bring oil level to FULL mark on dipstick or
sary, cooler assembly should be removed from runs freely from UPPER oil level plug.
machine for cleaning, using oil, compressed air
and steam cleaner for that purpose. DO NOT 7. Recheck all drain plugs, lines, connections, etc.,
use flushing compounds for cleaning purposes. for leaks and tighten where necessary.
TORQUE IN (LBS.-FT.)
BOLTS, CAPSCREWS, STUDS AND NUTS
Grade 5 Identification, 3 Radial Grade B Identification, 6 Radial
0
Dashes 120 Apart on Head of Bolt 0
Dashes 60 Apart on Head of Bolt
LUBRICATED OR PLATED
Grade 5 Grade 8
Nominal Fine Thread Course Thread Fine Thread Course Thread
Size Torque Lbs. Ft./N.m. Torque Lbs. Ft./N.m. Torque Lbs. Ft./N.m. 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 [35,3·40.7]
.3750 26-29 [35,3·39,3] 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] 37·41 [50,2-55,6] 58-64 [78.6-86,8] 52·57 [70.5-77.3]
.5000 64-70 [86.8-94,9] 57·63 [77,3-85.4] 90-99 [122.0-134.2] 80-88 [108,5-119,3]
.5625 91-100 [123.4-135,6] 82-90 [111,2-122,0] 128-141 [173.5-191.2] 115·127 [156,0·172,2]
-56-
SPECIFICATIONS AND SERVICE DATA - POWER SHIFT TRANSMISSION
S1005
AND TORQUE CONVERTER
CONVERTER OUT Converter outlet oil temp. 180· - 200· F. OIL FILTRATION Full flow oil filter safety by-pass, also strainer
PRESSURE [82,3" - 93,3" C]. screen in sump at bottom of transmission case.
Transmission in NEUTRAL.
CLUTCH PRESSURE 240 - 300 psi [1654,8 - 2068, 4 kPa]- With parking
Operating specifications: brake set (see note), oil temperature 180" - 200" F.
25 PS.1. [172,4 kPa] minimum pressure at 2000 [82,2" - 93,3" C], engine at idle (400 to 600 RPM),
R.PM. engine speed AND a maximum of 70 shift thru direction and speed clutches. All clutch
PS.1. [482,6 kPa] outlet pressure with engine
operating at no-load governed speed. pressure must be equal within 5 psi. [34,5 kPaj. If
clutch pressure variers in anyone clutch more than
CONTROLS Forward and Reverse - Manual 5 psi [34,5 kPa] repair clutch.
Speed Selection - Manual NOTE: Never use service brakes while making
clutch pressure checks. Units having brake
CLUTCH TYPE Multiple discs, hydraulically actuated, spring actuated declutching in forward and/or reverse
released, automatic wear compensation and no
adjustment. All clutches oil cooled and lubricated. will not give a true reading.
ALWAYS USE PARKING BRAKE WHEN
CLUTCH INNER DISC Friction. MAKING CLUTCH PRESSURE CHECKS.
CLUTCH OUTER DISC Steel.
LUBRICATION
RECOMMENDED LUBRICANTS FOR TORQUE CONVERTERS AND POWERSHIFT TRANSMISSIONS
TYPE OFOIL See Lube Chart. (a) Drain transmission and remove sump
CAPACITY Consult Operators Manual on applicable screen. Clean screen thoroughly and
machine model for system capacity. Torque replace, using new gaskets.
Converter, Transmission and allied hydraulic (b) Drain oil filters, remove and discard filter
system must be considered as a whole to elements. Clean filter shells and install new
determine capacity. elements.
CHECK PERIOD Check oil level DAILY with engine running at
(c) Refill transmission to LOW mark.
500-600 RPM and oil at 180" to 200" F. [82,2 -
93,3" C]. Maintain oil level to FULL mark. (d) Run engine at 500 - 600 RPM to prime
NORMAL Every 500 hours, change oil filter element. converter and lines.
DRAIN PERIOD Every 1000 hours, drain and refill system as
(e) Recheck level with engine running at
follows: Drain with oil at 150" to 200" F. [65,6 -
500 • 600 RPM and add oil to bring level to
93.3" C].
LOW mark. When oil temperature is hot (180
NOTE: It is recommended that filter elements • 200" F.) [82.2 - 93,3° C] make final oil level
i:le changed after 50 and 100 hours of opera- check. BRING OIL LEVEL TO FULL MARK.
tion on new and rebuilt or repaired units.
Torque converter/transmission lubricant must be qualified by one of the following
specifications.
ORDER OF PREFERENCE: RECOMMENDED SAE J300 VISCOSITY GRADE
1. Caterpillar TO • 4 4. Allison C-4
2. John Deere J20 C , D 5. Dexron II Equivalent - See note below. BASED ON PREVAILING AMBIENT TEMPERATURE
3. Military MIL-PRF-2104G
SAE OW20
IMPORTANT: Dexron* II equivalent is acceptable: however it is not compatible with torque
converters or transmissions equipped with graphitic friction material clutch plates.
Dexron* II or equivalent I
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 multi-
grades 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 SAE30
monograde is used. If a C·4 multigrade is used in place of J20 lubricant it is recommended
that the viscosity span no more than 10 points, i.e. 10W20. SAE40
SYNTHETIC LUBRICANTS ARE APPROVED IF QUALIFIED BY ONE OFTHE ABOVE CELSIUS ·40 -30 -20 -10 0 10 20 30 40 50
SPECIFICATIONS. OIL VISCOSITY GUIDELINES APPLY, BUT SYNTHETIC
MULTIGRADES MAY SPAN MORE THAN 10 POINTS. FAHRENHEIT -40 -22 -4 14 32 50 68 88 104 122
FOR FIRE RESISTANT FLUID RECOMMENDATIONS PLEASE CONTACT SPICER POWER SHIFT TRANSMISSION AND TORQUE
OFF-HIGHWAY PRODUCTS. CONVERTER HYDRAULIC FLUID ANALYSIS
SUMP pREHEATERS - preheat the transmission fluid to the minimum temperature Spicer Off-Highway Components Division recommends that when
for the oil viscosity used before engine start up.
chemical sampling of a power shift transmission lubrication circuit fluid
NORMAL OIL CHANGE INTERVAL - drain and refill system every 1000 hours for average is being taken that several samples be analyzed over a period of time
environmental and duty cycle conditions. Severe or sustained high operating temperature or to establish its normal base. Large changes in particle quantity from the
very dusty atmospheric conditions will result in accelerated deterioration or contamination. normal level may indicate an abnormal condition within the transmis-
Judgement must be used to determine the required change intervals for extreme
conditions. sion or its lubrication fluid. Any conclusion made of the transmission
actual condition, or action taken by the transmission user when
EXTENPEP OIL CHANGE INTERVAL - Extended oil service life may result when using interpreting the sample results, is the full responsibility of the user.
synthetic fluids. Appropriate change intervals should be determined fur each transmission
by measuring oil oxidation and wear metals, over time, to determine a baseline. Wear metal The following part per million (PPM) values represent general guide-
analysis can provide useful information, but a transmission should not be removed from
service based solely on this analysis. lines which may be used for references as a normal limit:
Iron Fe 125 PPM
.EJ..LIE.B.S. - Service oil filter element every 500 hours under normal environmental and duty Copper Cu 350 PPM
cycle conditions. Service the high performance extended life filter element every 1000 hours
or upon warning indication from the filter back pressure sensor. Silicon Si 20 PPM
Aluminum AI 15 PPM
This recommended lubricant section does not apply'to transmissions with electronic Lead Pb 50 PPM
modulation where separate approved oils are identified.
Chromium Cr 5 PPM
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 -
S1005
TROUBLE SHOOTING GUIDE

For The
Rand H R Model, 32000 Transmission
The following data is presented as an aid to locating the others. By studying the principles of operation
the source of difficulty in a malfunctioning unit. It is together with data in this section, it may be possible
necessary to consider the torque converter charging to correct any malfunction which may occur in the
pump, transmission, oil cooler, and connecting lines system.
as a complete system when running down the source TROUBLE SHOOTING PROCEDURE BASICALLY CON-
of trouble since the proper operation of any unit there- SISTS OF TWO CLASSIFICATIONS: MECHANICAL AND
in depends greatly on the condition and operations of HYDRAULIC.
MECHANICAL CHECKS
Prior to checking any part of the system from a 2. Check shift levers and rods for binding or restric-
hydraulic 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 engage-
1. 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, transmis- the converter. Where the former means is impractical,
sion, and allied hydraulic system for pressures and the latter means should be employed as follows:
rate of oil flow, it is essential that the following pre- Engage shift levers in forward and high speed and
liminary checks be made: apply brakes. Accelerate engine half to three-quarter
Check oil level in transmission. This should be done throttle.
with oil temperatures of 180 to 200 0 F. [82,2-93,3 0 C]. Hold stall until desired converter outlet temperature
DO NOT ATTEMPT THESE CHECKS WITH COLD OIl. is reached. CAUTION: FULL THROTTLE STALL SPEEDS
To bring the oil temperature to this specification it FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT
is necessary to either work the machine or "stall" out THE CONVERTER.
LOW CLUTCH PRESSURE

Cause Remedy
1. Low oil level. 1. Fill to proper level.
2. Clutch pressure regulating valve spool stuck open. 2. Clean valve spool and housing.
3. Faulty charging pump. 3. Replace pump.
4. Broken or worn clutch shaft or piston sealing rings. 4. Replace sealing rings.
5. Clutch piston bleed valve stuck open. 5. Clean bleed valves thoroughly.
LOW CONVERTER CHARGING PUMP OUTPUT

2. Suction screen plugged. 2. Clean suction screen.
3. Air leaks at pump intake hose and connections or 3. Tighten all connections or replace hose if necessary.
collapsed hose. (R-32000 only)
4. Defective oil pump. 4. Replace pump.
OVERHEATING
1. Worn oil sealing rings. 1. Remove, disassemble, and rebuild converter assem-
bly.
2. Worn oil pump. 2. Replace.
4. Pump suction line taking air. (R-32000 only) 4. Check oil line connections and tighten securely.
NOISY CONVERTER
1. Worn coupling gears. 1. Replace.
2. Worn oil pump. 2. Replace.
3. Worn or damaged bearings. 3. A complete disassembly will be necessary to deter-
mine what bearing is faulty.
LACK OF POWER
1. Low engine RPM at converter stall. 1. Tune engine check governor.
2. See "Overheating" and make same checks. 2. Make corrections as explained in "Overheating."
-58-
S1005
FIG.A
I I
III REV. & FWD.
~!~!
-------l:! -! + - - - - - - - -
_ _~t ~ - - - - - -
\\ .063 - .064
-4\--[1.600 - 1.626]
MODULATED FWD.
& REV. CLUTCHES
2nd & 3rd & NON-

FIG.S
{ MODULATED FORWARD &
REVERSE CLUTCHES
FIG.C
\\ .048 - .049
-4\---[1.219 - 1.245]
LOW (1st)
CLUTCH
FIG.D
(4 SPEED ONLY)
4TH
-59-
S1005
<, .... BACKING RING
~--
RING GEAR SCREW
RING GEAR SCREW ENGINE FLYWHEEL

(16) 236288 1.500 [38,1)
---~
SEE PAGE 61
FOR INSTALLATION
PROCEDURE AND
BOLT TORQUE
l
"'l (
",..,~'--\~~ BACKING RING
243767
--,.j TORQUE CONVERTER

RING GEAR 249341
-60-
S1005
16 SCREW RING GEAR INSTALLATION PROCEDURE

(Non-Asbestos Ring Gear)
1. Remove all burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface
and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean.
2. Check engine flywheel and housing or housing adaptor for conformance to standard SAE. No.3 - SAE J927 and Jl033
tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine
crankshaft end play.
3. Install torque converter ring gear as shown.
NOTE: Assembly of the ring gear must be completed within a fifteen minute
period from start of screw installation. The screws are prepared with an epoxy
coating which begins to harden after installation in the flywheel mounting holes. If not
tightened to proper torque within the fifteen minute period insufficient screw clamping
tension will result.
4. Install backing ring and sixteen (16) special screws to approximately .06 inch 11,5 mm I of seated position. It is permissible to use
a power wrench for this installation phase. With a calibrated torque wrench tighten screws 30 to 33 pounds feet of torque 140,7-
44,7 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 802554 - 1.5 INCH 138.1116 SCREW RING GEAR KIT
1 249341 Torque Converter Ring Gear 1 249341 Torque Converter Ring Gear
16 236288 Ring Gear Screw 1.5 Inch 138.11 16 236288 Ring Gear Screw 1.5 Inch 138,11
1 802555 Installation Instruction Sheet 1 243767 Backing Ring
1 802555 Installation Instruction Sheet
243767 Backing Ring not included in 802553 Ring Gear Kit. Must be Ordered Separately
Dimensions are in inches - Dimensions in 1 I are mm.
SEE PAGE 60 FOR INSTALLATION ILLUSTRATIONS

SEE PAGE 69 FOR 32 BOLT INSTALLATION
-61-
S1005
FORWARD
1ST (LOW)
-- - ---2ND
- - - - - 3RD
-62-
S1005
REVERSE
1ST (LOW)
_ _ _ _ _ _ 2ND
_ - _ - -3RD
-63-
S1005
TURBINE HUB SCREW
IMPELLER HUB & TURBINE HUB ASSEMBLY WITH BACKING

RING AND SPECIAL SELF LOCKING SCREWS.
1. CLEAN HUB MOUNTING SURFACE AND TAPPED HOLES WITH SOLVENT. DRY THOROUGHLY
BEING CERTAIN TAPPED HOLES ARE DRY AND CLEAN.
2. INSTALL BACKING RING AND SPECIAL SCREWS TO APPROXIMATELY .06 INCH [1.5] OF SEATED
POSITION. WITH A CALIBRATED TORQUE WRENCH, TIGHTEN SCREWS 40 TO 45 LBS. FT. TORQUE
[54,3-61,0 N.m]. NOTE: ASSEMBLY OF IMPELLER OR TURBINE HUB MUST BE COMPLETED WITHIN
A FIFTEEN MINUTE PERIOD FROM START OF SCREW INSTALLATION. THE SCREWS ARE PREPARED
WITH A COATING WHICH BEGINS TO HARDEN AFTER INSTALLATION IN THE HUB HOLES. IF NOT
TIGHTENED TO PROPER TORQUE WITHIN THE FIFTEEN MINUTE PERIOD, INSUFFICIENT SCREW
CLAMPING TENSION WILL RESULT. THE SPECIAL SCREW IS TO BE USED FOR ONE INSTALLATION
ONLY. IF THE SCREW IS REMOVED FOR ANY REASON IT MUST BE REPLACED.
THE COMPOUND LEFT IN THE HUB HOLES MUST BE REMOVED WITH THE PROPER TAP AND
CLEANED WITH SOLVENT. DRY HOLE THOROUGHLY AND USE A NEW SCREW FOR
REINSTALLATION.
-64-
S1005
Cooler inletrCOOler
pressure outlet pressure
~ ",~._-o._..... r = I y;~t~~~rtemperature
Filter type "A"---"""",\
Use replacement element
215502
Cooler DO NOT SUBSTITUTE
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
Port "R"
pressure
Modulated reverse
clutch check port
From cooler
to transmission
lube distributor
Port "A"
Port "J" Converter outlet temperature

Port "R" Converter outlet pressure
Port "T" Checkpoint transmission forward clutch pressure
Port "S" Checkpoint transmission reverse clutch pressure
Ports "J", "R", and "DO" Used for field trouble shooting
PLUMBING DIAGRAM FOR HR 32000

W/12 PLATE MODULATION AND
AUXILIARY LUBE
-65-
S1005
CLEANING AND INSPECTION Oil Seals. Gaskets and Retaining Rings

Replacement of spring load oil seals, "0" rings, metal
CLEANING
sealing rings, gaskets and snap rings is more economical
Clean all parts thoroughly using solvent type cleaning when unit is disassembled than premature overhaul to
fluid. It is recommended that parts be immersed in cleaning replace these parts at a future time. Further loss of lubricant
fluid and moved up and down slowly until all old lubricant through a worn seal may result in failure of other more
and foreign material is dissolved and parts are thoroughly expensive parts of the assembly. Sealing members should
cleaned. be handled carefully, particularly when being installed.
CAUTION: Care should be exercised to avoid skin Cutting, scratching, or curling under of lip of seal seriously
rashes, fire hazards and inhalation of vapors when using impairs its efficiency. Apply a thin coat of Permatex No.2 on
solvent type cleaners. the outer diameter of the oil seal to assure an oil tight fit into
the retainer. When assembling new metal type sealing
Bearings
rings, same should be lubricated with coat of chassis
Remove bearings from cleaning fluid and strike larger grease to stabilize rings in their grooves for ease of
side of cone flat against a block of wood to dislodge assembly of mating members. Lubricate all "0" rings and
solidified particles of lubricant. Immerse again in cleaning seals with recommended type Automatic Transmission
fluid to flush out particles. Repeat above operation until Fluid before assembly.
bearings are thoroughly clean. Dry bearings using moisture
free compressed air. Be careful to direct air stream across Gears and Shafts
bearing to avoid spinning. Do not spin bearings when If magna-flux process is available, use process to check
drying. Bearings may be rotated slowly by hand to facilitate parts. Examine teeth on all gears carefully for wear, pitting,
drying process. chipping, nicks, cracks or scores. If gear teeth show spots
where case hardening is worn through or cracked, replace
Housings
with new gear. Small nicks may be removed with suitable
Clean interior and exterior of housings, bearing caps, hone. Inspect shafts and quills to make certain they are not
etc., thoroughly. Cast parts may be cleaned in hot solution sprung, bent. or splines twisted, and that shafts are true.
tanks with mild alkali solutions providing these parts do not
have ground or polished surfaces. Parts should remain in Housing. Covers. etc.
solution long enough to be thoroughly cleaned and heated. Inspect housings, covers and bearing caps to be certain
This will aid the evaporation of the cleaning solution and they are thoroughly cleaned and that mating surfaces,
rinse water. Parts cleaned in solution tanks must be bearing bores, etc., are free from nicks or burrs. Check all
thoroughly rinsed with clean water to remove all traces of parts carefully for evidence of cracks or condition which
alkali. Cast parts may also be cleaned with steam cleaner. would cause subsequent oil leaks or failures.
CAUTION: Care should be exercised to avoid skin rashes
and inhalation of vapors when using alkali cleaners.
All parts cleaned must be thoroughly dried immediately
by using moisture-free compressed air or soft, lintless
absorbent wiping rags free of abrasive materials such as
metal filings, contaminated oil or lapping compound.
INSPECTION
The importance of careful and thorough inspection of all
parts cannot be overstressed. Replacement of all parts
showing indication of wear or stress will eliminate costly
and avoidable failures at a later date.
Bearings
Carefully inspect all rollers, cages and cups for wear,
chipping or nicks to determine fitness of bearings for
further use. Do not replace a bearing cone or cup individ-
ually without replacing the mating cup or cone at the same
time. After inspection, dip bearings in clean light oil and
wrap in clean lintless cloth or paper to protect them until
installed.
-66-
S1005
1.060± .007 [26.9 ± .17]
Stake 3 places approx,

equally spaced.
After curing of Loctite,

speed sensor bushing
must be secure with 40
Ft. Lb. [54.2 N·m] torque.
1.390 ± .007 [35.3 ± .17)

ASsemble.Speed Sensor Bushing··in housing to specified
REAR VIEW dimension with Loctite 262 and stake (3) three places.
SPEED SENSOR BUSHING INSTALLATION
-67-
S1005
BACKING RING
TORQUE CONVERTER
RING GEAR
RING GEAR SCREW
ENGINE FLYWHEEL
RING GEAR SCREW

(32) 243970 1.500 [38,11
(32) 244903 1.750 [44.4J
(32) 240318 2.000 [50.8J
_ l_- _ , S- __ --.J
(32) 237153 2.500 [63,5J SEE PAGE 69
(32) 236938 3.000 [76,2J FOR INSTALLATION
(32) 4200097 [M8 x 1.25J
PROCEDURE AND
BOLT TORQUE
BACKING RING
236937
TORQUE CONVERTER RING GEAR 249265

S1005
32 SCREW RING GEAR INSTALLATION PROCEDURE

(Non-Asbestos Ring Gear)
1. Remove all burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface
and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean.
2. Check engine flywheel and housing or housing adaptor for conformance to standard SAE. No.3 - SAE J927 and J1033
tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine
crankshaft end play.
3. Install torque converter ring gear as shown.
NOTE: Assembly of the ring gear must be completed within a fifteen minute
period from start of screw installation. The screws are prepared with an epoxy
coating which begins to harden after installation in the flywheel mounting holes. If not
tightened to proper torque within the fifteen minute period insufficient screw clamping
tension will result.
4. Install backing ring and thirty-two (32) special screws to approximately .06 inch [1,5 rnrnl of seated position. It is permissible to
use a power wrench for this installation phase. With a calibrated torque wrench tighten screws 23 to 25 pounds feet of torque
[31,2 - 33,8 N.m].
To obtain maximum effectiveness of the special screw's locking feature, a minimum time period after screw installation of
twelve (12) hours is suggested before engine start-up.
The special screw is to be used for ONE installation only. If the screw is removed for any reason it MUST BE REPLACED. It is
recommended that the epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent. Dry hole
thoroughly and use a NEW screw for re-installation.
5. Assemble torque converter to engine flywheel by sliding converter into position by hand before fastening housing attachment
screws. This may require more than one trial to match the drive gear teeth. Pulling the converter into position with housing
attachment bolts is not recommended.
6. Measure engine crankshaft end play after assembly of torque converter. This value must be within one thousandth (,001l of an
inch [0,0254mm) of end play recorded (in Paragraph #2) before assembly of torque converter.
802544 - 1.5 INCH [38,1] 32 SCREW RING GEAR KIT 802547 - 2.5 INCH [63,5] 32 SCREW RING GEAR KIT
32 243970 Ring Gear Screw 1.5 Inch 138,11 32 237153 Ring Gear Screw 2.5 Inch 163,51
1 802550 Installation Instruction Sheet 1 802550 Installation Instruction Sheet
802545 - 1.75 INCH [44,4) 32 SCREW RING GEAR KIT 802548 - 3.0 INCH [76,2) 32 SCREW RING GEAR KIT
32 244903 Ring Gear Screw 1.75 Inch 144,4) 32 236938 Ring Gear Screw 3.0 Inch 176,21
802546 - 2.0 INCH [50,8) 32 SCREW RING GEAR KIT 802549 - M8-32 SCREW RING GEAR KIT
32 240318 Ring Gear Screw 2.0 Inch [50,8] 32 4200097 Ring Gear Screw [M8 x 1.251
236937 Backing Ring Not Included in Ring Gear Kit. Must be Ordered Separately.
NOTE: The initial installation drive gear mounting kit includes a converter air breather. This breather is used on C & CL 270/C &
CL 320 converters only and is not required for the HR & LHR 28000/HR & LHR 32000 applications.
SEE PAGE 68 FOR INSTALLATION ILLUSTRATIONS
-69-
S1005
R-MODEL SECTION
-70-
S1005
R32000 FRONT COVER GROUP
ITEM DESCRIPTION OTY ITEM DESCRIPTION OTY

1 Flange Nut Cotter 1 23 Input Shaft 1
2 Flange Nut . 24 Input Shaft Rear Bearing .
3 Flange Nut Washer . 25 Input Shaft Gear 1
4 Flange "0" Ring . 26 Input Shaft Gear Retaining Ring . . . . . . . . . . . .. 1
5 Input Flange . 27 Tube Sleeve .
6 Input Flange Oil Seal . . . . . . . . . . . . . . . . . . . . .. 1 28 Tube Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
7 Input Shaft Front Bearing Retaining Ring . . . . .. 1 29 Detent Spring .
8 Input Shaft Front Bearing 1 30 Detent Spring .
9 Input Shaft Front Bearing Retaining Ring . . . . .. 1 31 Valve to Converter Housing Screw. . . . . . . . . .. 9
10 Pipe Plug . 32 Valve to Converter Housing Screw Lockwasher 9
11 Front Cover & Tube Assembly . . . . . . . . . . . . .. 1 33 Control Valve Assembly 1
12 "0" Ring 2 34 Control Valve Gasket. . . . . . . . . . . . . . . . . . . . .. 1
13 3rd Speed Tube Assembly .. . . . . . . . . . . . . . .. 1 35 Detent Ball 1
14 Tube Clip 2 36 Detent Ball .
15 Tube Clip Screw Lockwasher . . . . . . . . . . . . . .. 2 37 Pipe Plug .
16 Tube Clip Screw 2 38 Cover to Case Screw . . . . . . . . . . . . . . . . . . . . .. 4
17 Reverse Tube Assembly 1 39 Cover to Case Screw Lockwasher 4
18 Breather . 40 Front Cover Plug .. 1
19 Front Cover Sleeve 2 41 Front Cover Plug Gasket . . . . . . . . . . . . . . . . . .. 1
20 Front Cover Sleeve Lock . . . . . . . . . . . . . . . . . .. 2 42 Cover to Case Screw . . . . . . . . . . . . . . . . . . . . .. 4
21 Sleeve Lockscrew Lockwasher . . . . . . . . . . . . .. 2 43 Cover to Case Screw Lockwasher 4
22 Sleeve Lockscrew . . . . . . . . . . . . . . . . . . . . . . .. 2
-71-
S1005
R·32000
ASSEMBLY INSTRUCTION ILLUST~ATION
Spacer used with

12 plate modulation only.
-72-
S1005
Apply very light coat of Permatex No.2 to 0.0.

of all oil seals before ass'y.
Gear to be assembled with long hub length to this

side.
Three clutches,6-outer steel plates,6-inner friction Lockwire to prevent loosening

plates.Assemble alternately, starting with outer
steel plate.
Bearing shield out
See Elastic Stop Nut Torque Chart
~ onMustbearing.
be loose internal fit bearings. No. "3" etched
Low clutch,9-outer steel plates,9-inner friction
~ (12
plates. Assemble alternately. starting with outer
steel plate. Plate Modulation) Two clutches,12-outer steel
plates,12-inner friction plates.Assemble alternately.
starting with outer steel plate.
& Bearing shield in.
Notes
A. - Use Permatex & Crane Sealer only where E. - After assembly of parts using Permatex or
specified. Crane sealer, there must not be any free or
B. - All lead in chamfers for oil seals, piston rings & excess material that could enter the oil circuit.
"0" rings must be smooth & free from burrs. F. - Apply light coat of Crane Sealer to all pipe
Inspect at ass'y. plugs.
C. - Lubricate all piston ring grooves & "0" rings G. - Apply a thin coating of grease between seal
with oil before ass'y. lips on lip type seals prior to ass'y.
O. - Apply very light coat of Permatex NO.2 to 0.0. H. - Apply light coat of Permatex NO.2 to all thru
of all oil seals before ass'y. hole stud threads.
NOTE: Metric dimensions shown

in brackets [ ].
View"Q"
2 Places
Low Clutch Return Springs. ELASTIC STOP NUT TORQUE
Concave side of first spring to be placed THREAO SIZE LB.-FT. [N'rn]
against clutch piston. Remaining four washers
1" - 20 150 - 200 [203,4 - 271.1]
1V4" - 18 200 - 250 (271.2 - 338.9]
1'12" - 18 300 - 350 (406.8 - 474,5]
1'/4" - 12 400 - 450 (542,4 - 610,11

against clutch piston. Remaining six washers of
each clutch to be stacked alternately reversed
as shown.

or Plated Screw Threads Grade 8 M
\!57
NOM FINE THREAD COARSE THREAD FINE THREAD COARSE THREAD
SIZE LB-FT (NM) LB-FT [N·M) LB-FT (NM) LB-FT (NM)
5625. 91 - 100 (123,4 - 135.5] 82 - 90 [111,2 - 122.01 128 - 141 [173.6 - 191.1] 115 - 127 [156.0 - 172.2
5000 64- 70 [ 86.8- 94.91 57 - 63 [ 77,3- 85.4] 90 - 99 [122.1 - 134.2] 80 - 88 (108,5 - 119.3
.4375 41 - 45 [ 55,6- 61.01 37 - 41 [ 50,2- 55.5) 58 - 64 [ 78.7- 86.71 52 - 57 [ 70.6- 77,2
-
3750' 26 - 29 [ 35.3- 39.31 23 - 25 [ 31.2 - 33,8] 37 - 41 [ 50.2- 55.51 33- 36 [ 44,8- 48,8
3125 16- 20 [ 21.7· 27.11 12 - 16 [ 16.3- 21,6] 28 - 32 [ 38.0- 43.3] 26 - 30 [ 35.3 - 40.6]
2500 9- 11 ( 12.3· 14.9) 8- 10 ( 10.9- 13.5) 11- 13 ( 15.0- 17.6) 9- 11 ( 12.3- 14.9)
-73 -
S1005
MAINTENANCE AND SERVICE
The instructions contained herein cover the dis- assemblies may vary on specific models. The units are very
assembly and reassembly ofthe transmission in a sequence similar to trouble shoot. disassemble, repair and re-
that would normally be followed after the unit has been assemble.
removed from the machine and is to be completely CAUTION: Cleanliness is of extreme importance and
overhauled. It must also be understood that this is a basic an absolute must in the repair and overhaul of this unit.
32000 transmission with many options. Companion Before attempting any repairs, the exterior of the unit must
flanges and output shafts with and without disconnect be thoroughly cleaned to prevent the possibility of dirt and
foreign matter entering the mechanism.
DISASSEMBLY
Figure 1 Figure 3
Removecontrol valve bolts and washers. Removecontrol valve. Remove front cover plug.
Use caution as not to lose detent springs and balls.
Figure 2 Figure 4
Remove companion flange nut, washer and "0" ring. Remove bolts securing front cover to transmission housing.
-74-
S1005
INSTALL INPUT SHAFT OIL SEAL IN FRONT
COVER AS SHOWN ON PAGE 72.
DRIVE GEAR
-J------'---INPUT SHAFT
NOTE: LONG HUB OF

DRIVE GEAR TOWARD
RETAINER RING
Figure 5
Remove front cover and forward and 2nd clutch. Figure 8
Input shaft, rear bearing, drive gear and snap ring.
Figure 6
Figure 9
Use a spreading type snap ring pliers to spread the ears on for-
Install input shaft into front bearing.
ward clutch front bearing retainer ring. Remove forward clutch
with pry bar.
Figure 7 Figure 10
If input shaft is to be removed, tap on threaded end of shaft, Support converter housing with chain fall. Spread forward
remove input shaft, gear and bearing. clutch front bearing retainer ring and tap forward and 2nd clutch
assembly into transmission case assembly. Be certain snap ring
See cleaning and inspection page. is in full position in ring groove.
-75-
S1005
Figure 11 Figure 14
Install 2nd speed clutch pilot bearing. 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 12
Install transmission case gasket and "0" ring seals.
Figure 15
Install front cover plug.
Figure 13 Figure 16
Install housing spacer, gasket and "0" ring seals. NOTE: Hous- Install companion flange, flange "0" ring, washer and nut. Tor-
ing spacer is used with 12 plate clutch modulation only. que nut to specified torque. (See elastic stop nut torque chart).
-76-
S1005
NOTE: The disc spring packs are to be used as

complete assemblies and care should be taken
not to intermix the individual disc springs with
disc springs in another clutch or disc spring
pack.
Each disc spring assembly is made up of

selected springs to precisely match each part
within this assembly. Failure to replace all
piston return springs can resut in unequal
deflection within the spring pack. The result of
this imbalance may adversely affect overall life
of springs.
Figure 17 Service replacement assemblies are banded

Locate detent balls and springs in control valve. Position new
gasket. Secure valve with bolts and washers. Tighten to
together and must be replaced as assembly.
specified torque.
BEARING SHIELD
MUST FACEIN
BEARING SHIELD
MUST FACE OUT
REAR
BEARING SHIELD
SHIELDED BEARING INSTALLATION
-77-
S1005
R32000 - C270/C320 EXTERNAL PLUMBING DIAGRAM
Check point "E"

Filter Assembly (see chart)
Cooler inlet pressure.
Note: Check point "F"

Line from pump must be connected Cooler outlet pressure.
to "ln" side of filter.
Check point "G"
Cooler outlet temperature.
Line from pump to filter and
from filter to reg. valve.
Oil filler opening
Check point "S"

converter inlet pressure.
Check point ''/lI'

clutch pressure
240-280 PSI [1655.0-1931,0 kPa]
Install breather and

adapter in highest
converter drain location.
Select lowest connection

for gravity drain to trans.
Check point "0"

Converter oil temperature
Suction line from transmission
(Red line 250°F. [121OC])
sump to pump.
Check point "C" converter
outlet pressure. Converter Gravity drain-must have
outlet oil temp. 180°-200°F. continuous slope from
[82,3 °-93,3 0c) converter to transmission.
Transmission in neutral.
Operating specifications: Notes:
25 PSI [172,0 kPal minimum Hose line operating requirements.
pressure at 2000 RPM engine 1. Pressure Lines-Suitable for operation from
Metric dimensions shown speed and a maximum of 70 PSI ambient to 250°F. [121,1OC] continuous operatina
in brackets [ ]. [483,0 kPal outlet pressure temperature. Must withstand 300 PSI [2068 kPal
with engine operating at continuous pressure with 600 PSI [4137 kPal
Note: Do not deviate any line size. no-load governed speed. intermittent surges. Ref. SAE. Spec. No.
J517,100R1 Hydraulic Hose Specification.
2. Suction Line-To be protected from collapse
by interwoven steel wire. Ref. S.A.E. Spec. No.
J517,100R4 Hydraulic Hose Specification.
FILTER ASSEMBLY CHART Suitable for operation from ambient to
250°F. [121,1OC]. Continuous operating temperature.
Spin-on Type 3. Grevlty Drain Line-Suitable for operation
Filter Type Assembly No. Cartridge No. Assembly No. Element from ambient to 250°F. [121,1OCj continuous
1533614 247055 operating temperature. Ref. SAE. Spec. No. J517,100R1
A 215502 247052
Single Can Single Element Hydraulic Hose Specification.
S 234m 215502 246787 4. All Hose Lines used must conform to S.A.E.
Dual Can Dual Element 243622
Spec. No. J1019 Test Procedure for High
Temp. Transmission Oil Hose.
5. See Lubrication Specifications.
-78-
INSTALLATION INSTRUCTIONS OF NEW NON-METALLIC SEALING RINGS
S1005
Proper oil sealing ring (piston ring) installation procedures. Refer to the appropriate transmission
maintenance and service manual for disassembly, cleaning, inspection and reassembly.
1. Fill the oil sealing ring grooves with a good grade of grease, this will help stabilize the sealing ring
in the ring groove for installation.
2. Carefully position the piston ring on the shaft in the inner most ring groove. Hook the piston ring
joint.
3. Repeat steps 1, and 2 for the remaining ring or rings making certain all hook joints are fastened
securely.
4. Apply a heavy coat of grease to the outer diameter of the rings and shaft. Center the piston rings
in the ring groove.
5. When installing the clutch assembly in the transmission case it is recommended a piston ring
sleeve PIN's 241309, 237576, 234265, 235314 or 248694 be used to center all of the piston rings
in their respective ring grooves. Use extreme caution to not damage piston ring when installing
the clutch shaft in the transmission case, or when installing the converter housing or front cover
on the clutch shafts.
PISTON RING
SLEEVE
USED FOR POSITIONING 234265
OF PISTON RINGS
BEARING
PISTON RINGS
18000 SERIES
PISTON RING USED FOR POSITIONING PISTON RING USED FOR POSITIONING
SLEEVE OF PISTON RINGS SLEEVE OF PISTON RINGS
241309 OR 237576 23531- 4 OR 248694
BEARING
PISTON RINGS
Be aunt that lead in charnf8r and
Intersectionof lead in ~r 10 pilton
ring bore is free of burrs end nicka.
2420,24000,28000,32000,33000 28000, 32000 SERIES

34000,36000 SERIES -79- 4TH CLUTCH SHAFT
S1005
-80-
S1005
32000 6 & 8 SPEED OUTPUT GROUP

WITH RANGE SHIFT
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY

1 Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . .. 1 38 Output Flange Nut 1
2 Idler Shaft Rear Bearing Lock Ball. . . . . . . .. 1 39 Output Flange Nut 1
3 Idler Shaft Rear Bearing 1 40 Output Flange Washer .. . . . . . . . . . . . . . .. 1
4 Idler Shaft Bearing Cap Screw . . . . . . . . . .. 3 41 Output Flange "0" Ring . . . . . . . . . . . . . . .. 1
5 Speedometer Driven Gear 1 42 Output Flange . . . . . . . . . . . . . . . . . . . . . . .. 1
6 Speedometer Tube Nut 1 43 Output Shaft Front Bearing Cap Oil Seal ... 1
7 Idler Shaft Bearing Capscrew . . . . . . . . . . .. 1 44 Output Shaft Front Bearing Cap Screw . . .. 4
8 Idler Shaft Bearing Capscrew Lockwasher .. 4 45 Output Shaft Front Bearing Cap Lockwasher 4
9 Idler Shaft Bearing Cap . . . . . . . . . . . . . . . .. 1 46 Output Shaft Front Bearing Cap 1
10 Idler Shaft Bearing Cap Gasket. . . . . . . . . .. 1 47 Front Bearing Cap Shim AR
11 Idler Shaft Nut. . . . . . . . . . . . . . . . . . . . . . .. 1 48 Front Bearing Cap "0" Ring . . . . . . . . . . . .. 1
12 Speedometer Drive Gear or Bearing Spacer. 1 49 Bushing (Used with Disconnect Only) ..... 1
13 Idler Shaft Rear Bearing Locating Ring " 1 50 Output Shaft (Used with Disconnect Only) . 1
14 Idler Shaft Gear " 1 51 Output Shaft. . . . . . . . . . . . . . . . . . . . . . . .. 1
15 Idler Shaft Gear Spacer. . . . . . . . . . . . . . . .. 1 52 Output Shaft Front Bearing Cup. . . . . . . . .. 1
16 Idler Shaft Low Range Gear .. . . . . . . . . . .. 1 53 Output Shaft Front Bearing Cone . . . . . . . .. 1
17 Low Range Gear . . . . . . . . . . . . . . . . . . . . .. 1 54 Output Gear Thrust Washer . . . . . . . . . . . .. 1
18 High Low Shift Hub. . . . . . . . . . . . . . . . . . .. 1 55 Output Gear Bearing . . . . . . . . . . . . . . . . . .. 1
19 Shift Hub Sleeve. . . . . . . . . . . . . . . . . . . . .. 1 56 Output Gear Bearing . . . . . . . . . . . . . . . . . .. 1
20 High Range Gear. . . . . . . . . . . . . . . . . . . . .. 1 57 Output Gear Bearing Inner Race. . . . . . . . .. 1
21 Output Gear Inner Race 1 58 Idler Shaft Front Bearinq Retainer Ring .... 1
22 Output Gear Bearing . . . . . . . . . . . . . . . . . .. 1 59 Idler Shaft Front Bearing. . . . . . . . . . . . . . .. 1
23 Output Gear Bearing . . . . . . . . . . . . . . . . . .. 1 60 Idler Shaft Gear Locating Ring 1
24 Output Gear Thrust Washer . . . . . . . . . . . .. 1 61 Idler Shaft . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
25 Output Shaft Rear Bearing Cone 1 62 Transmission Case Assembly. . . . . . . . . . .. 1
26 Output Shaft Rear Bearing Cup 1 63 Range Shift Rail Support "0" Ring 1
27 Output Shaft Rear Bearing Cap "0" Ring .. 1 64 Range Shift Rail Support. . . . . . . . . . . . . . .. 1
28 Output Shaft Rear Bearing Cap "0" Ring .. 1 65 Range Shift Rail Support Screw
29 Output Shaft Rear Bearing Cap Screw. . . .. 4 Lockwasher 2
30 Output Shaft Rear Bearing Cap Screw 66 Range Shift Rail Support Screw. . . . . . . . .. 2
Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . .. 4 67 Range Shift Rail Oil Seal . . . . . . . . . . . . . . .. 1
31 Output Shaft Rear Bearing Cap 1 68 Range Shift Rail. . . . . . . . . . . . . . . . . . . . . .. 1
32 High and Low Range Shift Fork 1 69 Range Shift Rail Detent Plug. . . . . . . . . . . .. 1
33 Shift Fork Lock Screw. . . . . . . . . . . . . . . . .. 1 70 Range Shift Rail Detent Ball . . . . . . . . . . . .. 1
34 Rear Bearing Cap Oil Seal . . . . . . . . . . . . . .. 1 71 Range Shiftr Rail Detend Spring. . . . . . . . .. 1
35 Rear Output Flange . . . . . . . . . . . . . . . . . . .. 1 72 Disconnect (Optional) . . . . . . . . . . . . . . . . .. 1
36 Output Flange"0" Ring . . . . . . . . . . . . . . .. 1 73 Bearing Cap Bore Plug (Optional) . . . . . . . .. 1
37 Output Flange Washer . . . . . . . . . . . . . . . .. 1
-81-
S1005
View"Q"
Housing spacer
used with 12 plate
modulation only.
6 SPEED TRANSMISSION
NON-MODULATED
-82-
S1005
Impeller Hub and Turbine Hub Assembly with &. Heat nose bushing to 200 0 FO (93OC) before ass'y. of
Backing Ring and Special Self Locking Screws. bushing to cover.
1. Clean hub mounting surface and tapped holes
with solvent. Dry thoroughly being certain tapped Bearing shield OUT on 3rd speed clutch. Bearing shield
holes are dry & clean. IN on Fwd. & Rev. clutch.
2. Install backing ring and special self locking Must be loose internal fit bearings, No. "3" etched on
screws. bearing.
Tighten screws 40 to 45 Lbs. Ft. [54,3-61,0 N'm)
Note: Assembly of hub must be complete within a
fifteen minute period from start of screw installa-
&. (12 Plate Modulation) Two clutches, 12-outer steel plates,
12-inner friction plates. Assemble alternately, starting
tion. The special screw is to be used for one in- wit,h outer steel plate.
stallation only. If the screw is removed for any
reason it must be replaced. The epoxy left in the Notes
hub holes must be removed with the proper tap A. - Use Permatex & Crane Sealer only where
and cleaned with solvent. Dry hole thoroughly and specified.
use a new screw for reinstallation. B. - All lead in chamfers for oil seals, piston rings &
"0" rings must be smooth & free from burrs.
Gear to be assembled with long hub length to this Inspect at ass'y.
side. C. - Lubricate all piston ring grooves & "0" rings
with oil before ass'y.
Three clutches,6-outer steel plates,6-inner friction D.• Apply very light coat of Permatex NO.2 to 0.0.
plates. Assemble alternately, starting with outer of all oil seals before ass'y.
steel plate. E.. After assembly of parts using Permatex or
Crane sealer, there must not be any free or
&. See Elastic Stop Nut Torque Chart excess material that could enter the oil circuit.
F. - Apply light coat of Crane Sealer to all pipe
& Low clutch,9-outer steel plates.s-lnner friction plugs.
plates. Assemble alternately, starting with outer G. - Apply a thin coating of grease between seal
steel plate. lips on lip type seals prior to ass'y.
H. - Apply light coat of Permatex NO.2 to all thru
ill See Elastic Stop Nut Torque Chart hole stud threads.
& Shim output shaft bearings to produce 6 to 8 Lbs.-

NOTE: The friction discs in the low clutch has
In, [0,68,-0,90 N'm) preload.
a higher co-efficient rating than the friction
ill Tighten oil screen ass'y. 10 to 15 Lbs. Ft. discs in the other clutches, therefore the
discs must not be mixed. The low clutch in-
[13,6-20.0 N'm] (Not shown) ner disc can be identified by an "X" stamped
on one side of the inner teeth. The low clutch
View"Q" 2 Places inner disc also has a strip of non-soluble
yellow paint sprayed on the outer edge of
~
the disc.
Low Clutch Return Springs.
against clutch piston. Remainin9 four springs
~i'W'S'
against clutch piston. Remaining six springs Enlarged view of Piston Ring & Expander
of each clutch to be stacked alternately Note: Expander gap to be approx. 180 0 from ring
reversed as shown. See note on page 77. hook joint to aid ring assembly.
ELASTIC STOP NUT TORQUE

THREAD SIZE LB.-FT. [N'm]
NOTE: Metric dimensions shown 1" - 20 150 - 200 [203,4 - 271,1]
in brackets [ ]. lV." - 18 200 - 250 [271,2 - 338,9]
1'12" 18 300 - 350 [406,8 - 474,5]
1314" - 12 400 - 450 [542,4 - 610,1]

or Plated Screw Threads Grade aM
\!Sl
NOM, FINE THREAD COARSE THREAD FINE THREAD COARSE THREAD
SIZE LB·FT [NM] LB-FT [N·M) LB-FT [N·M] LB-FT [NM]
-~~+ 91·100 1123,4 - 135,51 82 - 90 1111.2 -122.01 128 - 141 1-173.6 - 191.11 115 - 127 1156.0 - 172.2]
5000 , 64 - 70 1 86.8- 94.91 57 - 63 r 77,3- 85,41 90 - 99 1122.1 - 134,21 80 - 88 1108.5 - 119.3]
4375 41 - 45 I 55,6- 61.01 -- 37 -
41 [ 50.2· 55,5J 58 - 64 I 78,7- 86.71 52 - 57 r 70.6- 77,21
3750 26 - 29 [ 35.3- 39.31 23 - 25 1 31.2- 33.81 37 - 41 r 50.2- 55.51 33 - 36 T 44.8- 48.81
3125 16 - 20 1 21.7- 27,'-1 12 - 16 1 16.3· 21,61 28 - 32 1 38.0· 43.31 26· 30 1 35,3- 40.61
,2500 , 9 - 11 I 12.3- 14,9) 8 - 10 I 10.9- 13,5] 11- 13 I 15.0- 17.61 9 - 11 [ 12,3- 14,9]
-83
S1005
~-
- -.::.,..
-84-
S1005
R & HR MODEL 6 & 8 SPEED
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 out-
put 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 The 8-speed transmission has 8 forward speeds and 8 reverse
travel range shifts. speeds.
Gear ratio determines working and travel ranges. They are as The 8-speed transmission has 4 working range shifts and 4 travel
follows: range shifts.
1st- 2nd and 4th working range. 3rd - 5th and 6th travel range. Gear ratio determines working and travel ranges. They are as follows:
NOTE: Range shift from low to high must be made with 1st - 2nd - 3rd and 5th working ranges 4th - 6th - 7th and 8th travel
machine stopped. range.
NOTE: Range shift from low to high must be made with machine
stopped.
DISASSEMBLY
Figure 55 shows the idler shaft with one gear. The 6-speed unit
will have two gears and a heavier front bearing. See Figure 55A
below:
Figure 2
Remove range shift rail support bolts. Remove rail support, rail
and range shift fork.
Flgure55A
6 & 8 speed idler shaft, gear and bearing assembly. NOTE:
Do not lose rear bearing lock ball.
6 & 8 SPEED OUTPUT DISASSEMBLY
Figure 1
With all clutches and shafts removed, cut lockwire on range Figure 3
shift fork lockscrew. Remove fork lockscrew. 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
Figure 4 gear needle bearings.
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 Figure 8
shouldered on shaft with large diameter of bearing in. 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 Figure 13
specified torque. Check rolling torque with bolts tight. Torque Locate lockscrew hole in shift rail with hole in shift fork. Install
must be 6 to 8 inch Ibs. [0.68 - 0.90 N'rnl more than when bear- lockscrew, tighten securely and lockwire to prevent loosening.
ing cap bolts were loose. Add or omit shims on the front bearing
cap to achieve the proper preload. Proceed with Figure 228 in the R & HR 32000 3-Speed Section.
-87-
S1005
KEY
1ST (LOW)
_ _ 2ND
• • • • 3RD (HIGH)
~~~~F~3- - RANGE SHIFT
6 SPEED TRANSMISSION LOW RANGE
-88-
S1005
KEY
4TH
- _ 5TH
• • • • 6TH
-tB~~~~~3- - RANGE SHIFT
6 SPEED TRANSMISSION HI RANGE
-89-
S1005
LOW RANGE
1ST (LOW)
- - - - - - 2ND
- - 3RD
• • • • • • • • • • 4TH (HI)
~~.~~~~~)$.
~ - ......LOW
...... RANGE
8 SPEED TRANSMISSION LOW RANGE
-90-
S1005
HIGH RANGE
1ST (LOW)
- - - - - - 2ND
- - 3RD
• • • • • • • • • • 4TH (HI)
8 SPEED TRANSMISSION HIGH RANGE
-91-
S1005
8 SPEED CLUTCH SECTION
4TH SPEED CLUTCH GROUP 8 SPEED TRANSMISSION
ITEM DESCRIPTION QTY ITEM DESCRIPTION Ql
Piston Return Spring . 10 Clutch Piston Assembly................ 1

2 Spring Retainer . 11 Clutch Piston Seal - Outer................................... 1
3 Spring Retainer Snap Ring.. 1 12 Clutch Piston Seal - Inner.................................... 1
4 Clutch Hub Snap Ring .. 13 4th Sped Shaft Piston Ring.................................. 2
5 4th Speed Clutch Hub.................................. 1 14 Front Bearing Retainer Ring................................ 1
6 Backing Plate Snap Ring............................ 1 15 4th Speed Shaft Front Bearing............................. 1
7 Clutch Disc Backing Plate............................ 1 16 Front Bearing Snap Ring..................................... 1
8 Clutch Outer Disc......................................... 7 17 4th Speed Shaft & Plug Assembly......................... 1
9 Clutch Inner Disc.. 8
-92-
8 SPEED SECTION S1005
rhe difference between the 6 speed transmission and the 8

speed is that the 8 speed has an added 4th speed clutch. This
section will describe the converter housing removal and the
nh speed clutch repair.
DISASSEMBLY
Figure 3
Remove fourth speed clutch disc hub retainer ring.
Figure
Figure 1
Remove bolts securing converter housing to transmission
housing. Support converter housing with a chain fall. Using
spreading type snap ring pliers, spread ears on the fourth
speed clutch front bearing retaining ring. Holding snap ring
open, tap converter housing from transmission housing. The
fourth clutch will remain in the transmission housing. Figure 4
Remove fourth speed clutch disc hub.
4TH SPEED CLUTCH

DISASSEMBLY
(8 speed transmission only)
Figure 2
Remove fourth speed clutch assembly from transmission Figure 5
housing Remove end plate retainer.
-93-
S1005
Figure 6
Remove end plate. Figure 9
Figure 7
Figure 10
Remove inner and outer clutch discs.
Remove clutch shaft piston rings and expander springs. See
note In Figure 103.
Figure 8 Figure 11
Compress spring retainer washer. Remove spring retainer snap Remove clutch shaft bearing retainer ring. Remove shaft bearing.
ring. Release tension on spring retainer. Remove snap ring,
spring retainer and return spring. See cleaning and inspection page.
-94-
4TH SPEED CLUTCH S1005
REASSEMBLY
(8 speed transmission only)
Figure 15
Install new clutch piston inner and outer sealing rings. Insert
clutch piston in clutch drum. Use caution as not to damage
sealing rings.
Figure 12
Install clutch shaft bearing. NOTE: Bearing snap ring groove
must be down.
Figure 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
Figure 13 next to piston is friction, last disc installed is friction. (8 friction -
Install bearing retainer ring. 7 steel).
Figure 14 Figure 17
Install piston rings as explained on page 79. Install end plate.
-95-
S1005
Figure 21
Position pilot bearing on fourth speed clutch shaft. Install fourth
Figure 18
clutch on disc hub. Use caution as not to damage the pilot
Install end plate retainer ring. See transmission reassembly
bearing.
on page 38.
CONVERTER HOUSING INSTALLATION
4TH SPEED CLUTCH INSTALLATION
(8 speed only)
Figure 22
Support converter housing with a chain fall. Spread fourth
clutch front bearing retainer ring. Position converter housing to
transmission case assembly. Tap housing into place using
Figure 19
caution as not to damage any of the clutch shaft piston rings.
Position 4th speed clutch disc hub on idler shaft.
Figure 23
Figure 20 Spread forward clutch front bearing retainer ring to allow the
Install disc hub retainer ring. converter housing to position properly.
-96-
S1005
Figure 25
Figure 24 Use the same procedure for the forward clutch as explained in
A hammer puller was used to pull the fourth clutch bearing Figure 24. Be certain both snap rings are fully seated in the
forward to engage the front bearing snap ring in the bearing bearing snap ring grooves. Install converter housing to
groove. transmission housing cap screws, tighten to specified torque.
REFER TO PAGE 46 FOR COMPLETE TRANSMISSION REASSEMBLY.
-97-
S1005
DRIVE PLATE INSTALLATION
SUBJECT: 28000/32000 Series Transmission and C-270/C-320 Series Converter Drive Plate Kits.
REASON FOR BULLETIN: Proper Identification by Bolt Circle Diameter.
Measure the "A" dimension (Bolt Circle diameter) and order Drive Plate Kit listed below.
ALIGNMENT HOLES
(1) DRIVE PLATE AND
WELD NUT ASSEMBLY
BOLT CIRCLE DIA (4) INTERMEDIATE

DRIVE PLATES
BACKING RING
"A" Dimension (Bolt Circle Diameter)

13.125" [333,375 mml Diameter
Kit No. 802335
13.50" [342,900 mml Diameter
Kit No. 802333
17.00" [431,800 mrnl Diameter
Kit No. 802454
Each kit will include the following parts:
4 Intermediate Drive Plates
1 Drive Plate and Weld Nut Assembly.
1 Backing Ring.
10 Screw and Lockwasher Assembly.
1 Instruction Sheet.
TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES - SEE ILLUSTRATION ABOVE.
Position drive plate and weld nut assembly on impeller cover with weld nuts toward cover. Align intermediate drive plate and
backing ring with holes in impeller cover. NOTE: Two dimples 180 0 apart in backing ring must be out (toward engine flywheel).
Install capscrews and washers. Tighten 23 to 25 ft. Ibs. torque [31,2 - 33,8 N.m].
SEE PAGE 99 FOR TRANSMISSION TO ENGINE

INSTALLATION PROCEDURE
Instruction SheeUlO2334
TSB-7.&~ev. 11-93
-98-
S1005
TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
1. Remove all burrs from flywheel mounting face and

FLYWHEEL
nose pilot bore. Clean drive plate surface with solvent. HOUSING
2. Check engine flywheel and housing for conformance

to standard S.A.E. #3 - SAE. J-927 tolerance
specifications for pilot bore size, pilot bore runout and ENGINE
mounting face flatness. Measure and record engine

crankshaft end play. FLYWHEEL
PILOT BORE
3. Install two 3.50 [88,90 mml long transmission to
flywheel housing. guide studs in the engine flywheel
housing as shown. Rotate the engine flywheel to align
a drive plate mounting screw hole with the flywheel
housing access hole. FLYWHEEL
4. Install a 4.00 [101,60 mml long drive plate locating

stud .3750-24 fine thread in a drive plate nut. Align the FIG 1
locating stud in the drive plate with the flywheel-drive
plate mounting screw hole positioned in step No.3.
5. Locate transmission on flywheel housing aligning
drive plate to flywheel and transmission to flywheel
housing.
Install transmission to flywheel housing screws.
Tighten screws to specified torque. Remove trans- 31'.1" ALIGNING
STUDS
mission to engine guide studs. Install remaining
screws and tighten to specified torque.
6. Remove drive plate locating stud. DRIVE
PLATE
7. Install drive plate attaching screw and washer. Snug
screw but do not tighten. Some engine flywheel
housings have a hole located on the flywheel housing SPECIAL STUD, WASHER AND
FIG 2 SELF LOCK NUT FURNISHED
circumference in line with the drive plate screw access BY MACHINE MANUFACTURER.
hole. A screwdriver-er.orv bar used to hold the drive
plate against the flywheel will facilitate installation of
FLYWHEEL
the drive plate screws. Rotate the engine flywheel and HOUSING
install the remaining seven (7) flywheel to drive plate

attaching screws. Snug screws but do not tighten. FLYWHEEL
After all eight (8) screws are installed torque each one
25 to 30 ft. Ibs. torque [33,9 - 40,6 Nrn.l, This will re-
quire torquing each screw and rotating the engine
flywheel until the full amount of eight (8) screws have IMPELLER
COVER
been tightened.
(3) INTERMEDIATE _
8. Measure engine crankshaft end play after trans- DRIVE PLATES
mission 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 FIG 4
-99-
Control valve function of 28000 / 32000 - 4 speed: forward 1st
'I 1
S1005
F 1 F 1
2nd
SUPPLY
o
I
D 1st
I
c o
o
..-
I
3rd
~ REVER
4th
[gJ
~
"'" ,
~
R 2 3
R 2 3
It 1
OFF-HIGHWAY COMPONENTS
Control valve function of 28000 / 32000 - 4 speed: forward 2nd
It
F 1 F 1
IT]
2nd
SUPPLY
1st
I D
-'
~
I o
3rd
~ 4th
[Q]
'i 7
R 2 3
R 2 3
't 1
S1005
<$> OFF-HIGHWAYCOMPONENTS
Control valve function of 28000 / 32000 - 4 speed: forward 3rd
'I
S1005
F 1 F 1
[OJ
2nd
SUPPLY
Q
D
r 1st
o
I
C\I
....0
I
3rd
O'~ 4th
~[QJ
R 2 3
R 2 3
1
<$:> OFF-HIGHWAY COMPONENTS
Control valve function of 28000 / 32000 - 4 speed: forward 4th
'I
F 1 F 1
[Q]
2nd
SUPPLY
I
(0
~ 1st
0
(,) r
I
~
0 3rd
~J 4th
~[Q][QJ R 2 3
R 2 3
S1005
Control valve function of 28000 / 32000 - 4 speed: neutral 4th
S1005
F 1 F 1
[OJ [OJ
~ ~ ----'1111
'* . ~,ili Mtli
2nd
. .. ---=- SUPPLY
Q"
~_~"'-M'''' .'''",,'-,".,
_~",',','--
I tst I
D "'"
0
.....
I
0 A>.J ~
, . ·.~:.:x:''I!!III::''F:''<:1
e-JI'· ... f::i. ·1l;11111,!lw11i&
-- . ~'M!:~'- L ~~~_
""_ _ _ ":,:,:,:,:cr~",,_::;:::m:»"'~
3rd
o1)~
"-
~ (©'i ".llll]lliltl~lltllR-~:::;!:]:(~ 4th
II II II
[Q] [Q] [Q]
s:»
R 2 3 R 2 3
Control valve function of 28000 / 32000 - 4 speed: reverse 1st
1
F 1 F 1
[OJ
d
Q
I
....I
D
8:
I o
R 2 3
R 2 3
't I; '1
S1005
~ OFF-HIGHWAYCOMPONENTS
S1005
NOTES
-106-
OPERATOR COMPARTMENT
28000 I 32000transmission· hydraulic diagram t)('\ PRESSURE
PRESSURE TBIIPUATURB Total neutral \.2) CRBCK-PORT
3 speed • with total neutral GAUGB GAUGH baT
TBIIPBRATURE
x
O CRBCK-PORT
'C
Safetyva1¥e
11,6 - 13,8 bar
cl'Il:kq pressure _ r..n'l L ubril:ation
-=- .@ .@
" " .. 'u ~ 'C
.8
• 'C
'VI
t
Hose
----- Cooler Hose
Torque
converter
- ""
Pressure
repIator
valve
16,5 - 20,7 bar
I
.....
0 total neutral 2nd
"'-J I 1st I FORWARD I REVJ!RSJ!
I I I I solenoid I solenoid solenoid SOLE.OID SOLE. OlD
...
PlJIIP
@
onSUIIP • baT baT
:¢::I ¢::I
1
3rd 2nd 1st fOlWard reverse
( 1 bar =14,504 PSI) clutch
~clutch
J!
clutch
~clutch
~ clutch
S1005
<$> OFF-HIGHWAY COMPONENTS

28000 / 32000 transmlsslon- hydraulic diagram
3 speed· with total neutral
PRBSSURB
GAUGE
TBMPBRATURB
GAUGE
Forward and 1st clutch engaged O
bn
PRBSSURB
CHBCK-PORT
O TBMPBRATURB
S1005
CHBCK-PORT
·C
Safety valve
9,6 - 13,8 bar
cracking pressure
Q ~ .8.8
E ' 14'--01 • U--I_J
'0
.@.@
,.'.... J.o
Hose
~
Cooler
\:.
~
Hose
h, E
L_tiD.
L....-y--' Torque
!, converter
Pressure
regulator
valve
16,5 - 20,7 bar
I
~
1st REVBRSB
solenoid SOLB.OID
By-pass ~~
. :~. - - Y-IL;E~- -:
valve ~•• _. __ • __ ~
1,7 - 4,3 bar
~
PUMP
AIR
BREATHER
»r:»,
~ IJ k~ ~
OIL SUMP •
B bn
:¢:I ,¢;:I
1 I I I I
3rd 2nd 1st forward reverse
( 1 bar = 14,504 PSI) dutch dutch dutch clutch dutch
.~ OFF-HIGHWAY COMPONENTS
~
28000 I 32000 transmission . hydraulic diagram fi{\ PRESSURE
PRESSURE TEMPERATURE Forward and 2nd clutch engaged v CRBCK-PORT
3 speed • with total neutral GAUGE GAUGE hn
(j{'l TEMPERATURE
\.:) CHECK-PORT
·C
Safety valve
9,6 -13,8 bar
cracking pressure Lubrication
J@ J@
har ·C
• ' 1+=11 • II --. J ~! JS
\:.,J
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
1st REVERSE
solenoid SOLE. OlD
~
I
PUMP
...
/
§
OIL SUMP • har
:¢:I ~¢:I ~¢:I
1 I =1
3rd 2nd 1st
~~
forward reverse
J2
( 1 bar =14,504 PSI ) clutch
~clutch
.u
dutch dutch clutch
S1005
<EJ> OFF-HIGHWAY COMPONENTS

28000 I 32000 transmission - hydraulic diagram
3 speed - with total neutral
PRI!SSURI!
GAUGE
TI!IlIPI!RATURI!
GAUGE
Forward and 3rd clutch engaged O
baT
PRI!S5URI!
CHI!CK-PORT
O TI!IlIPI!RATURK
S1005
CBI!CK-PORT
'C
Safety valve
9,6 - 13,8 bar
cracking pressure
J@ LubricatJon
• • 1+-'11 • II I
bu
. . . .J.J@ 'C
t! ~
I@
~
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
I
o
,....
2nd 1st ,....
REVERSJ!
solenoid solenoid SOLI!ROID
~<.)-F-IL;I!~- -;
.....
PUIlIP
)
~ ~ L~ ~
§
~~
OIL SUIlIP
/¢:I
I I I I
Jrd 2nd 1st fnrward reverse
( 1 bar = 14,504 PSI) clutch clutch clutch clutch clutch
28000 I 32000 transmission· hydraulic diagram PRI!SSURI!
PRI!SSURI! TI!MPI!RATURI! Reverse and 1st clutch engaged O CBI!CK-PORT
3 speed • with total neutral GAUGE GAUGI! liar
TI!IIPI!RATURI!
O CBI!CK-PORT
'C
Safety valve
9,ll - 13,8 bar
cl'III:killg pressure L ulIic:ation
.@
bar
.@ 'C
• ' 1+-'1 • II I .... .J ~! I@
~ J
Hose Cooler Hose

Torque
converter
Pressure
regulator
valve
Ill,! - 20,7 bar. 'V'
FORWARD
SOLI!.OID
......
......
......
§
OIL SUMP • liar liar liar
:¢I ~ ~
~@
1
3rd 2nd 1st fOlWlIrd reverse
J£
clutch clutch clutch clutch
S1005
28000 / 32000 transmission • hydraulic diagram
3 speed· without total neutral PRBSSURH
GAUGH
THIIPHRATURH
GAUGH
I Neutral and 3rd clutch engaged ®
hT
~'=~RT
O TIlIIPI!RATURIl
S1005
CIJBCK-PORT
'C
Safety valve
9,6 -1:3,8 bar
cracking pressure
.... .J.@
J@ LUBRICATION
• • Ihl • II I
lIu 'C
:t! ~
I@
~
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
2nd 1st I
FORWARD RIlTIlRSl! C\l
solenoid solenoid SOLDOID SOLBJrOm .....
.....
By-pass
valve
1.7 - 4.:3 bar
PUMP
.
OIL SUMP
@
• lIu
I¢=I
~
,1@ bu
I¢=I
J! bu
I¢=I
,1@ lIaT
I¢=I
1
3rd 2nd 1st fOlWard reverse
( 1 bar = 14,504 PSI) clutch clutch clutch clutch clutch
28000 J 32000 transmission • hydraulic diagram PRESSURE
PRESSURE TEIIPf!RATURE Forward and 1st clutch engaged CHECK-PORT
3 speed· without total neutral GAUGE GAUGl! I 0'ar
Tl!IlIPERATURf!
O CHECK-PORT
'C
Safety valve
9,6 - 13,8 bar
crackq pressure
LUBRICATION
.@ .@ 'C
• • 1"""1 • II I
'ar .....J .8 ~
::p! ~
Hose Cooler Hose
Torque
T co:nverter
Pressure
re&U1ator
VCI1ve
16,5 - 20,7 bar
..... 2nd 1st FORWARD RI!VERSI!

..... solenoid solenoid
I
(.,) SOLE.OID S OLBI OlD
I 1. Fl r». 1II0DULATIO.
7 fl:::l I<: IVALVl!
By-pass
valve
1.7 - ".3 bar
AIR
&REATeR
,.............
B §
OIL SUMP
3rd 2nd 1st forward reverse

( 1 bar
S1005
=14,504 PSI) clutch clutch clutch clutch clutch

28000 I 32000 transmlssion- hydraulic diagram
3 speed- without total neutral PRBSSU.RB
GAUGB
TBMPBRATURB
GAUGl! I Forward and 2nd clutch engaged 0
lIu
PRESSURE
CHBCK-PORT
O
S1005
TBMPERATURE
CHECK-PORT
'C
Safety valve
9,6 - 13,8 bar
cracking pressure
.@ .@
~.@
LUBRICATION
,
~
liar 'C
• • 1'-'1 • II I ! ~
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
I
......"'"
2nd 1st REVERSl!
solenoid solenoid SOU.OID
By-pass
valve
1,7 - ".3 bar
@
OIL SUMP
lrd 1st
2nd
clutch dutch
fOlWard
r.lutm
reverse
dutch
~
PRESSURE
28000 / 32000 transmission • hydraulic diagram Forward and 3rd clutch engaged CHECK-PORT
PRESSURB TEMPBRATURE O
3 speed. without total neutral GAUGB GAUGE lIu
TEMPERATURE
O CHECK-PORT
'C
Safety valve
9,6 -13,1 bar
craddna pressure LUBRICATION
·C
>J t t! .J
Hose Cooler Hose

Torque
! comerter
Pnnsure
relPJlator
valve
16,S - 20,7 bar
...... 2nd 1st RETERSE

...... SOLB.OlD
01 solenoid solenoid
I
By-pus
n1¥e
1.7 - 43 bar
B lIu liar
OILSUIIP L
~¢:I :=
I
L@ ~¢:I
I
I]
"1 1st reverse
3rd 2nd forward
S1005
(1 bar =14,504 PSI) clutch

~clutch
.u
clutch clutch clutch
<E:;> OFF-HIGHWAYCOMPONENTS
28000 J 32000 transmission • hydraulic diagram
3 speed- without total neutral PRBSSURB
GAUGH
TBIIPHRATORB
GAUGH I Reverse and 1st cl utch engaged 0hT PRI!SSU'RE
COCK-PORT
S1005
O·C
TI!IiIPI!RATORI!
COCK-PORT
Safety valve
9,6 - 13,8 bar
cracking pressure
.@ ______ .@
_'C ~ .@J
LUBRICATION
~
ltaT
, , I+--'I ,II I
Hose
\:. ~ ~
Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
I
FORWARD CD
SOLDOID
.-
-e-
By-pass ;.(..>-
," -;-
FILTn '
I
valve
1.7 - 4.3 bar
PUMP
•
1~ J! J!
@
( 1 bar
OIL SUMP
=14,504 PSI)
~~
3rd
clutch
2nd
clutch
1st
clutch
ltaT
!¢:I
forward
clutch
ltaT
!¢:I
J! hT
revel'Se
clutch
!¢:I
28000 I 32000 transmlsslon- hydraulic diagram (X'" PRI!SSURI!
PRI!SSURI! TI!MPI!RATURI! Total neutral ~) CHI!CK-PORT
4 speed· with total neutral GAUGI! GAUGI! liar
TI!MPI!RATURI!
O CHI!CK-PORT
·C
Safety valve
9,6 - 13,8 bar
cracking pressure II .-=., II Lubrication
-(,.~
J@ J@ J§
j lIa. • ·C
hl II - I f
~
Hose Cooler Hose
Torque
.. converter
Pressure -
regulator
valve
16,5 - 20,7 bar
1-1. I
total neutral 3rd 2nd 1st
...... I TORWARD I RI!VI!RSI!
...... I I I solenoid solenoid solenoid solenoid SOLI!lIOID SOLI!. OlD
.....
I
• • :A--
I •••
----,
TILTI!R :
...
PUMP
@
OIL SUMP liar liar lIa. liar liar liar
• ~ ¢:I ¢:I ¢:I ¢:I ¢:I
1
4th 3rd 2nd 1st forward reverse
~
clutch
If J! J£
lr
clutch
S1005
<€3> OFF-HIGHWAY COMPONENTS

28000 I 32000 transmission· hydraulic diagram
4 speed· with total neutral PRI!SSURJ!
GAUGH
TEMPERATURE
GAUGE
I Neutral and 4th clutch engaged Ox
liar
PRESSURE
CBHCK-PORT
S1005
O'C
THIiIPERATURE
CBHCK-PORT
Safety VlI1vll
!1,6 - 13,1 bar
crackiD& pressure
I@
liar
I@
~ 'C
IS
::a:
'C
Luhrleatkm
• ' 1+-'1 • II 1
Hose Cooler Hose
Torque
convener
Pressure
replatDr !t
VlI1vll
16,5 - 20,7 bar
3rd 2nd 1st FORWARD RJ!VERSE
solenoid solenoid solenoid SOLE. OlD SOLE. OlD I
«Xl
.....
.....
~
@
( 1 bar
OIL SUMP
=14,504 PSI)
•
4th
clutch
liar
:¢:I
1 1f3rd
clutch
liar
¢:I
2nd
clutch
J! J1
1st
clutch
liar
¢:I
forward
clutch
liar
¢:I
l¥
reverse
clutch
~¢:I
28000 132000 transmission· hydraulic diagram r)('I PRESSURI!
PRI!SSURB TI!IIPI!RATURI! Forward and 1st clutch engaged \.:J COCK-PORT
4 speed • with total neutral GAUGI! GAUGI tin
Tl!llPI!RATURB
Ox COCK-PORT
'C
Safety'nI1ve
!I,lS - 13,8bar
Cl'lKkh1I pressure Lubricatlon
,@ ,@
"p '0
Hose Cooler }iJse
----r--' Torque
.!, colMll1e1'
Pressure
reauJator
'nI1ve
16,5 - 20.7 bar
Jtn1lRSB
..... • • SUIt:nUIU • aula_lulU • _'U""'". • _._••_-- • ::lItu..... u&U • SOLDOID
--"
CO
I
@
OIL S1JIIP • "p "p
-~ ~
fth
, ~3rd
~ 2nd 1l1t
1£ ~fulWlrd rev.....
~~
( 1 bar =14,504 PSI) dutch dutch dutch dutch clutch dutch
S1005
28000 132000 transmission· hydraulic diagram
I Forward and 2nd clutch engaged v r;{I PRESSURB
S1005
PRBSSlJRE TEMPERATURE CHECK-PORT

4 speed· with total neutral GAUGB GAUGB !Jar
O'C
TBMPERATURE
CHECK-PORT
Safety wire
11,6 -13,8 bar
Cl'lll:kiD& pressure
.@ !Jar
.s
'C
Lmril:atlon
Pressure
,..... Torque
converter
Hose Cooler lWlse

reKUJator
wire
Hi,! - 20,7 bar
2nd 1st RI!VERSH I
solenoid solenoid SOLH.OID o
C\l
By-pass
va1vI!
1,7 - 4,3 bar
OIL SUMP
•
@
har
:~
1 Jf bar
¢:I
r=-=J
l@ bar
(¢:I
~ 1st
J1 !Jar
(¢:I
1:~
( 1 bar =14.504 PSI) 4th
clutch
3rd
clutch
2nd
clutch clutch
forward
clutch
reverse
clutch
28000 f 32000 transmission- hydraulic diagram PRESSURI!
PRI!SSURI! TI!MPI!RATURI! Forward and 3rd clutch engaged O CBBCK-PORT
4 speed· with total neutral GAUGI! GAUGI! lou
TI!JIIIPI!RATURI!
0) CBBCK-PORT
'C
Safety valve
9.6 -13.SbaJ:'
r rae king pl'essul'e
Lubril:atlon
J@ J@
lIa. "C
i ' I+--.I • II I
Hose Cooler IiJse
Torque
converter
Pressure
regulator
vah"
16,5 - 20, i bar
2nd 1. FORWARD I RBVI!RSI!

solenoid solenoid SOLD OlD SOLD om
~ L Fl 0'\ MODULATIOR
1n I<:IVALVI!
@
OIL SUMP lIa. n. n. D,
• ~
1
~ ~ ~
'a~T
4th 3rd 2nd 1. forward reverse
( 1 bar = 14,504 PSI) c1utcil
Jffi
clutch
~clutch
J! J!
c1utcil clutcil
JJclutch
S1005
28000 132000 transmission· hydraulic diagram
4 speed • with total neutral PRI!SSURI! Tl!llPIlllATURI! I Forward and 4th clutch engaged 0 :=r-~~RT
S1005
GAUGH GAUGH 1Ia~

M Tl!llPBRATURB
\V CBBCK-PORT
'C
Safety valve
11,6 -13,8 bar
cracking pressure Lubrkatlon
J@
lIat
Hose Cooler Hose
~ Torque
.!. C:OlM!rter
Pressure
rqulator
valve
16,5 - 20.7 bar
3rd 2nd 1st I
solenoid solenoid solenoid
FORWARD
16
SOLaom
($):~~no.
I U"fl!RSI!
SOLD om
C\I
C\I
....
PUMP
J=@ 1~ J:;@
~ ~
@
• \at \at \al'
OIL SUMP
~ ~ ~
1
4th 3rd 2nd 1st forward rev81'S8
( 1 bar = 14,504 PSI) dutch dutch dutch dutch clutch dutch
28000 I 32000 transmission· hydraulic diagram r)(\ PIlESSURII
PRI!SSURI! Tl!llPI!RATURI! Reverse and 1st clutch engaged I...:J CBIICK-PORT
4 speed • with total neutral GAUGII GADGII liar
(;1 TI!IIIPIlRA TURII
~ CBIlCK-PORT
'C
Safety valve
l',6 -13,8 bar
cracking pressure Lmrkatlon
J@ .@
\at -c
• 'I+-'I • II I .... .J <t! ,@
\:. #
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20.7 bar
2nd 1st FORWARD

... solenoid solenoid SOLIIIOID
~
I
By-pass
valve
1,7 - 4,3 bar
@
OIL SUMP lIat \at J=@ lIat liar liar
• ~ ¢I ¢I ¢I ¢I
1 I I
( 1 bar =14,504 PSI) 4th
clutch
~ 3rd
clutch
J!2nd
clutch
1st
clutch
forward
lfclutch
I!
reverse
clutch
S1005

28000 I 32000 transmission • hydraulic diagram ~ PRHSSURH
4 speed· without total neutral PRRSSURR
OAUOR
TBllPBRATURI!:
GAUOl! I Neutral and 4th clutch engaged ~
liar
CRECK-PORT
O TBIIPBRATURB
S1005
CRBCK-PORT
·C
Safety valve
9,6 -13,8 bar
Cl'lIl:kq pressure
.@
liar
.@ ·C
LUBRICATION
Hose Cooler Hose
Torque
cOllVerter
Pressure
reauJator
vain!
lCi,5 - 20,7 bar
3rd 2nd 1st FORWARD RBVBRSB
solenoid solenoid solenoid SOLBROID SOLBROID
I
~
~ Jr 1° Jr
@
OILSUIIP
I
t-:$. i
br
~
br
~
hr
~
( 1 bar =14,504 PSI) 411I
clutch
3rd
clutch
2nd
clutch
1st
clutch
forward
clutch
reverse
dutch
~
28000 I 32000 transmtsslon- hydraulic diagram 0(\ PRIISSURB
PRJ!SSURJ! THMPJ!RATURH Forward and 18t clutch engaged \..:.J CHECK-PORT
4 speed· without total neutral GAUGJ! GAUGH
1II.r
TDlPIlRATU'RII
x
O CBIlCK-PORT
·C
Safety valve
9,6 -13,8 bar
cracking pressure
J@ J@
liar 'C
" J <t! 18
1(----
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5- 20,7 bar
2nd 1st
RIlVIlRSI!
.... solenoid solenoid SOLO om
~
I
By-pass ;<:.)-r~L;J!~--;
valve
1.7 - 4.3 bar
PUMP
...
OIL SUMP liar •

Bliar liar liar liar
• I¢:I I¢:I :¢:I i¢:I i¢:I
4th 3rd
1
2nd
---=]
1@ 1st
I
L8 I
reverse
forwllrd
( 1 bar =14,504 PSI) clutch clutch
~
J!
clutch
S1005
<eSi> OFF-HIGHWAY COMPONENTS

28000 I 32000 transmlsslon- hydraulic diagram
4 speed· without total neutral PRI!SSURI!
GAUGI!
TI!MPI!RATURI!
GAUGI!
Forward and 2nd clutch engaged O
liar
PRI!SSURI!
CHI!CK-PORT
O TI!MPI!RATURI!
S1005
CHI!CK-PORT
·C
Safety valve
9,6 - 13,8 bar
cratking pressure
.... ~
J@ J@ lUIRICATION
, , 1+=11 ,II I
liar ·C
t! .s
\:~
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
2nd 1st RI!VI!RSI!
solenoid solenoid I
SOLI!IfOID
co
C\l
By-pass ;'(0) -F~L;~--;
valve
1,7 - 4,3 bar
PUMP
...
OIL SUMP
•
@
liar
~
1 Jf Jf 1 liar
~
liar
~
8 liar
~
~s liar
~
1;8 liar
~
( 1 bar =14,504 PSI) 4th
clutch
3rd
clutch
2nd
clutch
1st
clutch
forward
clutch
reverse
clutch
~
28000 I 32000 transmission • hydraulic diagram PRRSSORR
PRRSSORI! TEMPERATURE Forward and 3rd clutch engaged O CHECK-PORT
4 speed· without total neutral GAUGE GAUGE liar
TRMPERATORR
O CHRCK-PORT
'C
Safety valve
9,6 - 13,8 bar
crackiJIi pressure
LUBRICATION
,@ 'C
. q: •
""'"-,; ! '-.m '"
Hose Cooler Hose
Torque
! converter
Pressure
regulator
valve
16,5 - 20,7bar. ~
2nd 1st RR'iERSE

I\)
solenoid solenoid SOLI!IOID
-..j
I
By-pass ~~'~-~L;~--;
valve
1.7 - 4.3bar
....
PUIIP
@ 8
OIL SUMP liar liar liar 1lar
• ~ ~ ~ ¢2
1
~8
4th 3rd 2nd 1st forward reverse
( 1 bar = 14,504 PSI) clutch
~
clutch
J1 1
S1005

28000 I 32000 transmission· hydraulic diagram t')('\ PR1!SSURl!
4 speed· without total neutral PRBSSURII TBIIPIlRATURII Forward and 4th clutch engaged V CHECK-PORT
OAUOH OAUOH
'u
S1005
O
x
·C
TllIIPI!RATURE
CHECK-PORT
Safety valve
96 -13,8bar
~klDa pressure II
" ~
I
@
liar
I@ LlJIRICATIIII
...,)-l
Hose Cooler Hose
- --
T
0.=.1
TOI1lUB
amvel1er
Pressure
regulator
valve
16,5 - 20,7 bar
J-l. I 3rd
solenoid G solenoid
I 11t
solenoid
FOllWARD
S OLEII om
..t fl
7a
r». IIODULATIO.
I?IULVE
I RI!VERs]!
SOLEIIOID
re
I
,....
( 1 bar
OIL SUIIP
=14,504 PSI)
•
4th
clutch
@
liar
, ~
~ 3rd
clutch
Jr 1@ JJ
2nd
dutch
liar
~
1st
clutch
lIa,.
~
forward
clutch
J£ liar
reverse
dutch
~
~
OPERATORCOMPARTMENT
28000 / 32000 transmission • hydraulic diagram PRl!SSURl!
PRBSSURB TEMPBRATURB Reverse and 1st clutch engaged O CHECK-PORT
4 speed· without total neutral GAUGH GAUGH 1II.r
Tl!MPl!RATURl!
O CHl!CK-PORT
·C
Safety valve
9,6 -13,8 bar
craekhll pressure
LUBRICATION
.@
1I&r
.@ ·C
.s
:) '-c
l
Hose c... lIMe
Torque
1 comlerter
Pressure
regulator
valve
16,5 - 20,7......
FORWARD Rl!Vl!RSl!
SOLDom SOLE. 010
~ .l. Fl 17\. MODULATIO.
I 7n I?-IVALVH
@
OIL SUMP 11&.. 11&.. 11&..
• ~
1
~ ~
4th Jrd 2nd 1st forward reverse

~clutch
J! J!
S1005
S1005
S1005
13675
DRIVELINE INSTALLATION
Page 1 of 1

1 SEE AXLE END YOKE (STD.) 1
PARTS PAGE
2 SEE TRANSMISSION OUTPUT FLANGE/ END YOKE BRAKE (REAR) 1
PARTS PAGE
3 SEE TRANSMISSION OUTPUT FLANGE/ END YOKE (FRONT) 1
PARTS PAGE
4 SEE AXLE END YOKE 1
PARTS PAGE
5 364024 CROSS AND BEARING KIT 5
6 19201-39 DRIVELINE ASSEMBLY 2
7 362120 CENTER BEARING 2
8 364023 CROSS AND BEARING KIT 1
9 464640 SLIP ASSEMBLY 1
10 19200-14 DRIVELINE ASSEMBLY 1
Updated:
11/03/08
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
6. AXLE
10829 AXLE ORIENTATION

13335 AXLE ASSEMBLY
13332 CRADLE INSTALLATION
S1037 AXLE SERVICE & REPAIR MANUAL
13158 BRAKE ACTUATOR
S1023 BRAKE ACTUATOR INSTALLATION
13938 TIRE & RIM
S1007 TIRE SERVICE
10829
FORD AXLE ORIENTATION
Page 1 of 1
Updated:
12/11/06
13335
AXLE ASSEMBLY 464872
Page 1 of 9
Updated:
03/12/07
13335
Page 2 of 9
Updated:
03/12/07
13335
Page 3 of 9

464872 AXLE ASSEMBLY 1
1 444144 HOUSING - BRAKE OUTER 2
2 444196 HOUSING - INNER, R.H. 1
3 444193 HOUSING - INNER, L.H. 1
4 442010 DISC ASSEMBLY 8
5 442020 DISC 4
6 444707 DISC ASSEMBLY (INCLUDES ITEMS 7-10) 2
7 444428 LINK 4
8 444859 BALL 12
9 442050 SPRING RETURN 8
10 444708 PIN 2
11 444860 NUT 4
12 444861 BOLT 12
13 442090 STUD SCREW 4
14 444862 NUT 4
15 442110 PIN 2
16 11828-04 ROD CONTROL 2
17 01GF02048 PIN - COTTER 2
18 442130 PIN 2
19 444837 SEAL 2
---- ------------ BRAKE ACTUATOR (SEE SECTION 6) ----
Updated:
03/12/07
13335
Page 4 of 9
Updated:
03/12/07
13335
Page 5 of 9

1 444863 HOUSING ASSEMBLY, FRONT AXLE R.H. (DIFF. LOCK) 1
444864 HOUSING ASSEMBLY, REAR AXLE R.H. 1
444864 HOUSING ASSEMBLY, FRONT AXLE L.H. 1
444863 HOUSING ASSEMBLY, REAR AXLE L.H. (DIFF. LOCK) 1
(INCLUDES ITEMS 3, 6, 20A)
2 444865 PLUG LESS BRAKES 2
3 444115 GEAR-PLANET RING 2
4 ------------ SEE PAGE 3 OF 9
5 ------------ SEE PAGE 3 OF 9
6 442150 CUP - SHAFT BEARING 2
7 444841 O-RING 2
8 444191 BOLT 21
444866 BOLT, HEX HEAD 1
9 444867 STUD SCREW 4
10 444243 NUT, HEX 4
11 444801 SHIFT AND BOLT ASSEMBLY (INCLUDES ITEM 12) 2
12 444631 BOLT 16
13 272410 LUG NUT A/R
15 442180 CONE AND ROLLER ASSEMBLY (OUTER) 2
17 444800 SEAL (CASSETTE) 2
18 444868 CARRIER ASSEMBLY (INCLUDES ITEMS 20-25) 2
19 444245 RETAINER 2
20 442200 CONE AND ROLLER ASSEMBLY 2
20A 442140 CUP 2
21 444246 SHAFT 6
22 444869 GEAR, PLANET 6
23 444102 WASHER, THRUST 12
24 444248 KIT, PLANET GEAR (INCLUDES ITEM 32) A/R
25 444104 SPACER 6
26 444064 GEAR 2
Updated:
03/12/07
13335
Page 6 of 9
27 444205 SPACER, (.049/.050) A/R
444105 SPACER, (.053/.054) A/R
444118 SPACER, (.057/.058) A/R
444119 SPACER, (.061/.062) A/R
444120 SPACER, (.065/.066) A/R
444106 SPACER, (.069/.070) A/R
444122 SPACER, (.073/.074) A/R
444123 SPACER, (.077/.078) A/R
444145 SPACER, (.081/.082) A/R
444237 SPACER, (.085/.086) A/R
444097 SPACER, (.089/.090) A/R
28 444142 WASHER, RETAINING 2
29 444033 LOCK BOLT 2
30 444143 BOLT, HEX HEAD 2
31 ------------ BRAKE ASSEMBLY 2
32 444144 HOUSING, REAR BRAKE OUTER 2
33 444196 HOUSING, BRAKE INNER R.H. 1
444193 HOUSING, BRAKE INNER L.H. 1
34 444125 SHIM (.038/.040) A/R
444098 SHIM (.044/.046) A/R
444126 SHIM (.050/.052) A/R
444127 SHIM (.056/.058) A/R
444099 SHIM (.062/.064) A/R
444108 SHIM (.068/.070) A/R
444100 SHIM (.074/.076) A/R
444109 SHIM (.080/.082) A/R
35 444164 CUP BEARING 1
36 444177 CUP BEARING, R.H 1
37 444008 CONE AND ROLLER ASSEMBLY L.H. 1
38 444176 CONE AND ROLLER ASSEMBLY R.H. 1
39 444249 CASE ASSEMBLY 1
40 444250 SCREW, HEX 8
41 444251 GEAR SET-MATCHED 1
42 442210 BOLT 12
43 444110 NUT-HEX LOCK 12
44 444170 GEAR-SIDE 1
45 444171 GEAR-SIDE 1
46 444178 WASHER-THRUST 2
Updated:
03/12/07
13335
Page 7 of 9
47 444169 SPIDER-DIFFERENTIAL 1
48 444172 PINION ASSEMBLY-DIFFERENTIAL 4
49 444175 WASHER-THRUST 4
50 444173 BUSHING 2
51 444854 ADAPTER 1
52 444855 SPRING 1
53 444856 COUPLING 1
54 444252 WASHER 1
55 444092 RING-LOCKING 1
56 442220 BEARING ASSEMBLY 1
57 444850 LOCK RING 1
59 442250 RETAINER ASSEMBLY 1
60 442260 CUP-BEARING 1
61 442270 CUP-BEARING 1
62 444253 WASHER-LOCK 1
63 444782 BOLT-HEX HEAD 1
64 444111 SPACER (1.254/1.2545) A/R
444093 SPACER (1.256/1.2565) A/R
444255 SPACER (1.258/1.2585) A/R
444112 SPACER (1.260/1.2605) A/R
444114 SPACER (1.262/1.2625) A/R
444094 SPACER (1.264/1.2645) A/R
444128 SPACER (1.266/1.2665) A/R
444129 SPACER (1.268/1.2685) A/R
444130 SPACER (1.270/1.2705) A/R
444095 SPACER (1.272/1.2725) A/R
444131 SPACER (1.274/1.2745) A/R
444132 SPACER (1.276/1.2765) A/R
444133 SPACER (1.278/1.2785) A/R
444096 SPACER (1.280/1.2805) A/R
444134 SPACER (1.282/1.2825) A/R
65 442280 SEAL, O-RING 1
66 442290 SEAL, RETAINER 1
69 444852 SEAL, ASSEMBLY 1
Updated:
03/12/07
13335
Page 8 of 9
70 11827-01 FLANGE (STANDARD) 1
19495-01 FLANGE (DISC BRAKE) 1
71 442310 SEAL, SALINE 1
72 442320 WASHER, RETAINER 1
73 442330 NUT, HEX SLOTTED 1
74 01GF03032 PIN, COTTER 1
76 442350 BLOCK, THRUST 1
77 04GE07 WASHER, LOCK 2
78 444258 BOLT, HEX HEAD 2
Updated:
03/12/07
13335
Page 9 of 9

1 444165 LEVER 1
2 444260 PIN 1
3 444168 SHAFT 1
4 444174 SEAL 1
5 444167 FORK 1
6 444261 SCREW 1
7 444197 HOUSING-CENTER 1
8 223185 PLUG BREATHER 1
9 444844 PLUG-PIPE 1
10 444844 PLUG-PIPE 1
11 444844 PLUG-PIPE 1
12* 11293-01 GUARD ASSEMBLY 1
Updated:
03/12/07
13332
AXLE CRADLE
Page 1 of 1

1 10574-01 CRADLE ASSEMBLY 1
2 17GD10 NUT 8
3 27GE10 WASHER 8
4 ------------ LONG GREASE HOSE 1
5 ------------ SHORT GREASE HOSE 1
6 17GC10136 BOLT 8
7 464693 BUSHING 2
8 04GE10 WASHER 4
9 19204-88 PIN ASSEMBLY 2
10 01GC10024 BOLT 4
Updated:
01/30/07
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
13158
BRAKE ACTUATOR
Page 1 of 2
Updated:
01/30/07
13158
BRAKE ACTUATOR
Page 2 of 2

595172 ACTUATOR ASSEMBLY 1
534372 REPAIR KIT (INCLUDES ITEMS 2, 5, 7, 8, 10, 11, 17-21, 24) 1
1 253172 BLEEDER SCREW 2
2 NSS O-RING 1
3 534377 BLEEDER PLUG 1
4 534387 BLEEDER SCREW 1
5 NSS O-RING 1
6 534378 HOUSING 1
7 NSS BACK-UP RING 1
8 NSS O-RING 1
9 534374 PISTON 1
10 NSS O-RING 1
12 534646 SPRING 1
13 534373 PISTON 1
14 534380 STOP 1
16 534384 LOCK NUT 1
19 NSS CUP 1
20 NSS O-RING 1
21 NSS O-RING 1
22 534383 SPRING 1
23 534376 END PLUG 1
24 NSS GASKET 1
25 534375 END PLUG 1
26 534128 MOUNTING BRACKET 1
Updated:
01/30/07
S1023
S1023
13938
TIRE & RIM
Page 1 of 1

465417 TIRE & RIM 1
1 25818-01 RIM ASSEMBLY (INCLUDES ITEMS 2 & 3) 1
2 NSS LOCK RING 1
3 NSS SIDE RING 1
4 484085 TIRE 1
5* 272410 LUG NUT 8
*ITEM NOT SHOWN Updated:

11/07/07
S1007
S1007
S1007
S1007
S1007
S1007
S1007
S1007
S1007
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
7. BRAKE SYSTEM
13378 BRAKE VALVE

S1008 BRAKE VALVE SERVICE
16483 DUAL CHARGE VALVE
S1009 DUAL CHARGE VALVE SERVICE
12976 ACCUMULATOR
13378
PEDAL BRAKE VALVE
Page 1 of 4
Updated:
12/11/06
13378
PEDAL BRAKE VALVE
Page 2 of 4
Updated:
12/11/06
13378
PEDAL BRAKE VALVE
Page 3 of 4

464952 BRAKE VALVE ASSEMBLY 1
534288 PEDAL & BASE ASSEMBLY 1
(INCLUDES ITEMS 2, 23, 24, 28-32, 35, 36)
595149 VALVE ASSEMBLY (INCLUDES ITEMS 1, 3-22, 33, 34) 1
595145 REPAIR KIT (INCLUDES ITEMS 2, 3, 8, 12, 18, 21) 1
1 NSS PISTON 1
2 NSS BOOT 1
3 NSS QUAD RING 1
4 NSS RETAINER 1
5 NSS BALL 1
6 NSS SPOOL 1
7 NSS HOUSING 1
8 NSS O-RING 1
9 NSS SPRING 1
10 NSS END PLUG 1
11 NSS SPRING 1
12 NSS CUP 1
13 NSS SPRING 1
14 NSS SPRING 1
15 NSS SHIM 1
16 NSS RETAINER RING 1
17 NSS SPACER 1
18 NSS O-RING 1
19 NSS SPOOL 1
20 NSS HOUSING 1
21 NSS O-RING 1
22 NSS RETAINER 1
23 NSS PEDAL 1
24 NSS CAM 1
25 15248-02 PIN 1
Updated:
12/11/06
13378
PEDAL BRAKE VALVE
Page 4 of 4
26 67GD06 NUT 2
01GF01016 COTTER PIN 2
27 15248-01 PIN 1
28 NSS CAP SCREW 2
29 NSS WASHER 2
30 NSS BASE 1
31 NSS LABEL 1
32 NSS DRIVE SCREW 2
33 NSS WASHER 2
34 NSS CAP SCREW 2
35 NSS CAP SCREW 1
36 NSS NUT 1
Updated:
12/11/06
S1008
S1008
S1008
S1008
16483
CHARGING VALVE
Page 1 of 4
Updated:
12/11/06
16483
CHARGING VALVE
Page 2 of 4
Updated:
12/11/06
16483
CHARGING VALVE
Page 3 of 4

594922 VALVE ASSEMBLY 1
534293 REPAIR KIT 1
(INCLUDES ITEMS 3, 6, 10, 12, 14, 17, 19, 26, 28, 32-34, 36)
1 NSS HOUSING 1
2 NSS SPOOL 1
3 NSS SEAL 1
4 NSS SPRING 1
5 NSS ROD 1
6 NSS O-RING 2
7 NSS PLUG 2
8 NSS SCREW 1
9 NSS WASHER 1
10 NSS O-RING 1
11 NSS SPRING 3
12 NSS POPPET 1
13 NSS SEAT 1
14 NSS O-RING 2
15 NSS WASHER 1
16 NSS WASHER 1
17 NSS FILTER 1
18 NSS RETAINER 1
19 NSS PLUG 1
20 NSS SCREW 1
21 NSS NUT 1
22 NSS PLUG 1
23 NSS SPRING 1
24 NSS STOP 1
25 NSS BALL 2
26 NSS O-RING 1
27 NSS SPOOL 1
28 NSS O-RING 1
Updated:
12/11/06
16483
CHARGING VALVE
Page 4 of 4
29 NSS INSEAT 1
30 NSS SPRING 1
31 NSS END PLUG 1
32 NSS O-RING 1
33 NSS POPPET 2
34 NSS O-RING 1
35 NSS SLEEVE 1
36 NSS O-RING 1
Updated:
12/11/06
S1009
S1009
S1009
S1009
12976
ACCUMULATOR
Page 1 of 1

1 534607 ACCUMULATOR ASSEMBLY 1
2* 534608 MOUNTING BRACKET 1

12/11/06
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
8. HYDRAULIC SYSTEM
310-020-001 HYDRAULIC SCHEMATIC

S1077 HYDRAULIC SYMBOLS
17132 SERVICEJUNIOR DIGITAL PRESSURE GAUGE
13259 FILTER (HYDRAULIC)
12860 STEERING ORBITROL
S1024 STEERING ORBITROL SERVICE
16384 BOOM ROTATION MOTOR
S1010 PUMP SERVICE
17172 REMOTE CONTORL BOOM VALVE (IN BASKET)
12508 BOOM CONTROL VALVE (ON BOOM)
13282 JACK CONTROL VALVE
13970 BOOM LEVELING CYLINDER
13629 BOOM LIFT CYLINDER
13827 BOOM EXTENSION CYLINDER (LOWER)
13828 BOOM EXTENSION CYLINDER (UPPER)
13628 BASKET LEVELING CYLINDER
13627 STABILIZER CYLINDER
13943 STEERING CYLINDER
HYDRAULIC SYMBOLS
S1077
Lines Hydraulic Pumps Miscellaneous Units
Line, Working (Main)

Fixed Displacement Cooler
Line, Pilot or Drain
Flow Direction Variable Displacement Temperature Controller

Hydraulic
Pneumatic
Filter, Strainer
Motors and Cylinders

Lines Crossing
Pressure Switch
Hydraulic
Fixed Displacement Pressure Indicator

Lines Joining
Variable Displacement Temperature Indicator

Lines With Fixed
Restriction
Cylinder, Single-Acting Component Enclosure

Line, Flexible
Cylinder, Double-Acting Direction of Shaft
Station, Testing, Rotation (assume arrow
Measurement or Power on near side of shaft)
Single End Rod
Take-Off
Variable Component (run

arrow through symbol Double End Rod Methods of Operation
at 45°)
Adjustable Cushion
Spring
Advance Only
Pressure Compensated
Units (Arrow parallel to
short side of symbol) Differential Piston Manual
Temperature Cause or Push Button

Effect
Miscellaneous Units
Reservoir Push-Pull Lever
Electric Motor
Vented
Pedal or Treadle
Accumulator,
Pressurized Spring Loaded
Mechanical
Line, To Reservoir Accumulator,
Gas Charged
Detent
Above Fluid Level
Heater
Below Fluid Level
Pressure Compensated
Vented Manifold
Industrial Supplies and Expertise 1093
CH12_1069-1114.indd 1093 4/9/07 2:34:47 PM

HYDRAULIC SYMBOLS
S1077
Color Code for Fluid

Methods of Operation Valves
Power Schematic Drawings
Black Intensified Pressure
Solenoid, Single Winding Check
Red Supply
Servo Control On-Off (manual shut-off) Intermittent Red Charging Pressure
Intermittent Red Reduced Pressure

Pilot Pressure
Pressure Relief
Intermittent Red Pilot Pressure
Remote Supply
Yellow Metered Flow
Pressure Reducing
Internal Supply Blue Exhaust
Flow Control, Adjustable Green Intake

- Non-Compensated
Green Drain
Flow Control, Adjustable
(Temperature and Blank Inactive
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 Infinite

Positioning (Horizontal
bars indicate infinite
positioning ability)
1094 Call your local Applied® service center to order at 1-866-351-3464 or visit us online at Applied.com
CH12_1069-1114.indd 1094 4/9/07 2:34:48 PM

17132
Getman Corporation
ServiceJunior
Getman P/N 468005
The NEWServiceJunior
Digital Pressure Gauge
• 50 Times Faster than Previous Model
• 10 msec Scanning Rate
• Measure PSI, bar, mPa, and
kPa with One Gauge
• +1- 0.5% Full Scale Accuracy
• Simple Operation
• Peak and Hold Function with
Bar Graph Display
17132
Getman’s 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 • Accuracy +/- 0.5% of full scale
using Parker Diagnostic test port couplings • Three pressure ranges
• Robust, dirt resistant housing • Operating temperature 14° to 122° F
• Simple to operate, four key menu • Fluid temperature -4° to 176° F
• Four digit backlit display with easy to read • Storage temperature -4° to 140° F
large 0.60" characters • Auto power off after 15 minutes or
• Minimum and maximum graphic display constant on" at the touch of a button
shows pressure peak • Zero adjustment function
• Power status displayed continuously • 10 msec scanning rate
• Can be used with most hydraulic and • Ratings:
pneumatic media Environmental Protection: EN60529 (IP 65)
• Measure PSI, bar, mPa, kPa with one gauge Vibration: IFC 60068-2-6/10 — 500Hz: 20g
Shock: IEC 60068-2-29/50g 11 msec
Measuring Overload
Resolution
Range Pressure
0 to 5800 PSI
(0 to 400 bar) 11,600 PSI 1 PSI
NOTES: 1. PD Couplers rated to 6,000 PSI max. 2. EMA3 Couplers rated to 9,000 PSI max.
Getman Corporation provides the

most complete line of mining
equipment available. For more
information please contact:
sales@getman.com
Getman Corporation
59750 34 t h A ve n u e
Bangor, MI 49013
PH: (269) 427-5611 FAX: (269) 427-8781
www.getman.com
13259
HYDRAULIC FILTER
Page 1 of 1

1 534690 FILTER ASSEMBLY 1
2 534691 REPLACEMENT FILTER 1
3 534712 SERVICE INDICATOR 1
Updated:
12/11/06
12860
STEERING ORBITROL
Page 1 of 2

174110 STEERING VALVE 1
174116 SEAL KIT (INCLUDES ITEMS 3, 8, 9, 15, 16, 17, 24, 25) 1
174112 SERVICE KIT (INCLUDES ITEMS 1, 4, 5) 1
1 NSS SCREW, CAP (6 POINT) 7
2 NSS CAP, END 1
3 NSS SEAL 3
4 NSS GEROTOR 1
5 NSS SPACERS A/R
6 174113 PLATE, SPACER 1
7 173172 DRIVE 1
8 NSS HOUSING 1
Updated:
12/11/06
12860
STEERING ORBITROL
Page 2 of 2
9 NSS SLEEVE, CONTROL 1

NSS SPOOL, CONTROL
10 174033 PIN, CENTERING 1
11 174115 SPRING, CENTERING 6
13 174039 RACE, BEARING 2
14 174034 BEARING, NEEDLE THRUST 1
15 NSS SEAL 1
16 NSS SEAL 1
17 NSS SEAL, QUAD RING 1
18 174036 BUSHING, SEAL GLAND 1
19 174044 RING, RETAINING 1
20 174046 NEEDLE BEARING KIT 1
21 174035 RETAINER, CHECK BALL 1
22 174045 BALL CHECK 1
23 174038 SEAT, CHECK BALL 1
24 NSS SEAL 1
25 NSS SEAL 1
26 174067 SCREW, SET 1
Updated:
12/11/06
S1024
S1024
S1024
S1024
16384
HYDRAULIC MOTOR
Page 1 of 2
Updated:
12/18/06
16384
HYDRAULIC MOTOR
Page 2 of 2

534214 MOTOR ASSEMBLY 1
54041 SEAL KIT (INCLUDES ITEMS 2, 4-6, 11, 13, 18) 1
1 54021 CAP SCREW 4
2 NSS EXCLUSION SEAL 1
3 54033 FLANGE (2 BOLT) 1
4 NSS SHAFT PRESSURE SEAL 1
5 NSS RING BACK-UP 1
6 NSS SEAL 1
7 54028 BEARING RACE 1
8 54029 BEARING THRUST NEEDLE 1
9 54024 SHAFT OUTPUT 1
10 54037 HOUSING 1
11 NSS O-RING 1
12 54036 PLUG 1
13 NSS SEAL 3
14 54044 DRIVE 1
15 54022 SPACER PLATE 1
16 54045 GEROTOR SET 1
17 54027 END, CAP 1
18 NSS SEAL WASHER 7
19 174029 CAP SCREW 7
Updated:
12/18/06
S1010
S1010
S1010
S1010
BASKET VALVE 5 SECTION 17172
(IN BASKET) Page 1 of 3

465484 VALVE 5 SECTION ASSEMBLY 1
Updated:
07/09/08
Updated:
07/09/08

1 465484-01 MOUNTING BRACKET 1
2 465484-02 90 DURO O-RING 8
3 465484-03 THREADED ROD 2
4 465484-04 LOCK WASHER 4
5 465484-05 SPRING CENTERED HYDRAULIC JOYSTICK CONTROL 5
6 465484-06 VALVE BODY 4
7 465484-07 90 DURO 8
8 465484-08 UNC HEX NUT 4
10 465484-09 HEX HEAD CAPSCREW 4
11 465484-10 LOCK WASHER 4
12 465484-11 HEX NUT 4
Updated:
07/09/08
BOOM CONTROL VALVE 12508
ORIENTATION (56476) Page 1 of 7
MAIN
HANDLE END RELIEF
PILOT SECTION
VALVE HANDLES VALVE INLET

PORT RELIEF SECTION
1500 2500 1000 2500
A A A A A
B B B B B
1500 1000 1000 1000
PORT RELIEF
PILOT SECTION
BOOM SWING BOOM LIFT
SECTION SECTION BASKET ROTATION
SECTION
OUTLET END BOOM BASKET
COVER EXTENSION LEVELING
SECTION SECTION
NOTE: THE “B” PORTS ON THE BOOM LIFT AND EXTENSION ARE EQUIPPED WITH MOTOR SPOOLS
BASKET BASKET BOOM BOOM BOOM

ROTATE LEVEL LIFT EXTEND SWING
IN OUT
Updated:
03/17/10

56476 BOOM CONTROL VALVE (5 SECTION) (INCLUDES 1
ITEMS 1-9)
534490 SEAL KIT (INCLUDES ITEMS 5, 6) 1
1 REFER TO 12508 (6 OF 7) 1
2 REFER TO 12508 (4 OF 7) 1
2A REFER TO 12508 (5 OF 7) 1
3 REFER TO 12508 (7 OF 7) 1
4 NSS RETAINER 2
5 NSS WASHER (BACK-UP) 2
6 NSS SEAL (O-RING) 2
7 NSS HOUSING 1
8 NSS SPOOL 1
9 REFER TO 12508 (3 OF 7) 1
10 595112 STUD KIT 1
Updated:
03/17/10

534135 MAIN RELIEF
534494 SEAL KIT (INCLUDES ITEMS 1-5) 1
2 NSS RING (BACK-UP) 1
6 NSS PISTON 1
7 NSS CAP 1
8 NSS NUT 1
9 NSS STEM 1
10 NSS NUT 1
11 NSS POPPET 1
12 NSS SPRING 1
13 NSS BODY 1
Updated:
03/17/10

CYLINDER PORT RELIEF
534700 PORT RELIEF (1000 PSI) (INCLUDES ITEMS 1-14) 1
534500 SERVICE KIT (INCLUDES ITEMS 10, 11) 1
1 NSS SHIM A/R
2 NSS SPRING A/R
8 NSS CAP 1
9 NSS BODY 1
10 NSS POPPET 1
11 NSS RING 1
12 NSS CHECK 1
13 NSS SPRING 1
14 NSS SLEEVE 1
Updated:
03/17/10

LOAD CHECK PLUG
534495 SERVICE KIT (INCLUDES ITEMS 1-8) 1
534496 SEAL KIT (INCLUDES ITEMS 2-6 1
1 NSS PLUG 1
7 NSS POPPET 1
8 NSS SPRING 1
Updated:
03/17/10

SPOOL POSITIONER END
1 NSS WASHER (LOCK) 4
2 NSS SPRING 1
3 NSS SPRING 1
4 NSS BONNET 1
5 534503 SEAL (SQUARE – CUT) 1
6 NSS COLLAR 1
7 NSS SLEEVE 1
8 NSS PLATE 4
9 NSS SCREW (HSHC) 4
10 NSS WASHER 1
11 NSS SPUD 1
Updated:
03/17/10

SPOOL CLEVIS END WITH HANDLE OVERRIDE
1 534410 KNOB 1
2 534413 ROD 1
3 NSS NUT 1
4 NSS ADAPTOR 1
5 534417 PIN (DOWEL) 1
8 534414 RETAINER (SEAL) 1
9 534420 GUIDE 1
10 NSS WASHER 4
12 534800 BONNET 1
13 534419 BOOT 1
14 NSS SEAL (SQUARE-CUT) 1
Updated:
03/17/10
CONTROL VALVE 13282
Updated:
03/17/10
CONTROL VALVE 13282

534731 BOOM CONTROL VALVE (3 SECTION) 1
534490 SEAL KIT (INCLUDES ITEMS 5, 6) 1
1 SPOOL POSITIONER END (REFER TO PAGE 5) 1
2 LOAD CHECK PLUG (REFER TO PAGE 4) 1
3 SPOOL CLEVIS END WITH HANDLE OVERRIDE 1
(REFER TO PAGE 6)
4 NSS RETAINER 2
7 NSS HOUSING 1
8 NSS SPOOL 1
9 MAIN RELIEF (REFER TO PAGE 3) 1
10 595154 STUD KIT 1
Updated:
03/17/10
CONTROL VALVE 13282

534135 RELIEF VALVE 1
2 NSS RING (BACK-UP) 1
6 NSS PISTON 1
7 NSS CAP 1
8 NSS NUT 1
9 NSS STEM 1
10 NSS NUT 1
11 NSS POPPET 1
12 NSS SPRING 1
13 NSS BODY 1
Updated:
03/17/10
CONTROL VALVE 13282

LOAD CHECK PLUG
1 NSS PLUG 1
7 NSS POPPET 1
8 NSS SPRING 1
Updated:
03/17/10
CONTROL VALVE 13282

SPOOL POSITIONER END
2 NSS SPRING 1
3 NSS SPRING 1
4 NSS BONNET 1
5 534503 SEAL (SQUARE - CUT) 1
6 NSS COLLAR 1
7 NSS SLEEVE 1
8 NSS PLATE 4
10 NSS WASHER 1
11 NSS SPUD 1
Updated:
03/17/10
CONTROL VALVE 13282

1 534410 KNOB 1
2 534413 ROD 1
3 NSS NUT 1
4 NSS ADAPTOR 1
5 534417 PIN (DOWEL) 1
8 534414 RETAINER (SEAL) 1
9 534420 GUIDE 1
10 NSS WASHER 4
12 NSS BONNET 1
13 534419 BOOT 1
14 NSS SEAL (SQUARE-CUT) 1
17 NSS SEAL (SPECIAL) 1
Updated:
03/17/10
13970
HYDRAULIC CYLINDER
Page 1 of 1

465407 CYLINDER ASSEMBLY 1
465121-08 SEAL KIT 1
1 465407-01 BARREL ASSEMBLY 1
2 465121-02 ROD ASSEMBLY 1
3 465407-03 PISTON ASSEMBLY 1
4 465407-04 ROD BEARING ASSEMBLY 1
5 465407-05 NUT 1
6 465407-06 CAP SCREW 1
7 465407-07 GREASE FITTING 2
8 465407-08 BUSHING 2
Updated:
01/08/09
13629
HOIST CYLINDER
Page 1 of 1

2 465134-02 ROD 1
5 465134-05 NUT 1
6 465134-06 SELF TAPPING SCREW (LOCK) 1
7 465134-07 LOAD CHECK VALVE 1
8 465134-08 SEAL KIT 1
Updated:
10/07/09
13827
EXTENSION CYLINDER
Page 1 of 1

5 465174-05 STROKE LIMITER ASSEMBLY 1
6 465174-06 TRANSFER TUBE ASSEMBLY 1
7 465174-07 O-RING 1
8 465174-08 BACK-UP RING 2
9 465174-09 O-RING 1
10 465174-10 BACK-UP RING 2
11 465174-11 SELF-TAPPING SCREW 1
12 465174-12 SET SCREW 1
13 465174-13 NYLON PLUG 1
14 465174-14 SHIPPING PLUG 1
Updated:
06/01/07
13828
EXTENSION CYLINDER
Page 1 of 1

5 465175-05 NUT 1
6 465175-06 SELF-TAPPING SCREW 1
7 465175-07 STROKE LIMITER ASSEMBLY 1
8 465175-08 SHIPPING PLUG 1
Updated:
06/01/07
13628
BASKET LEVELING CYLINDER
Page 1 of 1

2 465121-02 ROD 1
5 465121-05 NUT 1
7 465121-07 COUNTER BALANCE VALVE 2
8 465121-08 SEAL KIT 1
10 465121-10 BASE END BUSHING 1
11 465121-11 ROD END BUSHING 1
Updated:
08/19/09
13627
STABILIZER CYLINDER
Page 1 of 1

2 465143-02 ROD 1
5 465143-05 NUT 1
7 465143-07 CHECK VALVE 1
8 465143-08 SEAL KIT 1
Updated:
12/18/06
13943
STEER CYLINDER
Page 1 of 1

465411-07 SEAL KIT 1
5 465411-05 NUT 1
6 465411-06 CAP SCREW 1
Updated:
12/11/06
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
9. CONTROLS
13905 ELECTRIC SHIFTER

10827 STEERING WHEEL & COLUMN
13655 THROTTLE (ELECTRONIC)
13905
ELECTRIC SHIFTER
Page 1 of 2
* ITEM NOT SHOWN Updated:

01/08/10
13905
ELECTRIC SHIFTER
Page 2 of 2

534772 ELECTRIC SHIFTER 1
534772-20 SWITCH AND HARNESS ASSEMBLY 1
(INCLUDES ITEMS 7, 12, 18, 19)
1 534772-01 ALUMINUM CASTING 1
2 534772-02 SWITCH MOUNTING PLATE 1
3 534772-03 RIGHT SIDE DECAL 1
4 534772-04 LEFT SIDE DECAL 1
5 534772-05 SCREW 4
6 534772-06 NUT 4
7 534772-07 ROTARY SWITCH 1
(NOT SOLD SEPARATELY AS OF 1-8-10, SEE ITEM 20)
8 534772-08 SWITCH DRIVE BEARING 2
10 534772-09 SPRING LEVER ASSEMBLY (LEFT) 1
534772-10 SPRING LEVER ASSEMBLY (RIGHT) 1
11 534776-01 MOLDED HANDLE 2
(OLD P/N WAS 534772-11)
12 534772-12 WIRE HARNESS 1
14 534772-13 SCREW 4
15 534772-14 SCREW 4
16 534772-15 SCREW 4
17 534772-16 NUT 1
534772-17 PRESS IN NUT 3
18 534772-18 HEAT SHRINK END CAP SEAL 2
19 534772-19 ROTARY SWITCH 1
(NOT SOLD SEPARATELY AS OF 1-8-10, SEE ITEM 20)
20* 534772-20 ROTARY SWITCH KIT (INCLUDES ITEMS 7 & 19) 1
* ITEM NOT SHOWN Updated:

01/08/10
10827
STEERING WHEEL & COLUMN
Page 1 of 1

1 492191 WHEEL, STEERING 1
2 171002 COLUMN 1
3 173132 NUT, ORBITROL 1
4 173175 CAPSCREW 2
5* 494081 KNOB (STEERING) (OPTIONAL) 1

12/11/06
ELECTRONIC THROTTLE 13655
PEDAL Page 1 of 1

1 595395 ELECTRONIC THROTTLE PEDAL (INCLUDES BRACKET) 1
2 595395-01 SENSOR 1
Updated:
02/17/10
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
10. MOUNTED EQUIPMENT
S1011 FIRE EXTINGUISHER #10

S1012 FIRE PROTECTION INFORMATION MANUAL
S1013 FIRE SUPPRESSION MAINTENANCE MANUAL
7334-00015 FIRE SUPPRESSION INSTALLATION – MAIN
7334-00025 FIRE SUPPRESSION INSTALLATION –
BASKET/PLATFORM
7334-00024 FIRE SUPPRESSION INSTALLATION – AIR
COMPRESSOR
17344 FIRE SUPPRESSION SYSTEMS
13597 BASKET DOOR INSTALLATION
S1026 DOOR SPRING PIVOT ADJUSTMENT
17069 BOOM INSTALLATION
16572 TURRET TABLE INSTALLATION
16256 ROTATION GEAR BOX
M1005 ROTATION GEAR REMOVAL & INSTALLATION
15174 ANFO PIPING SCHEMATIC (WITH AIR BOOST CLEAN
OUT)
15175 ANFO PIPING SCHEMATIC (POT)
17194 ANFO POT
13712 ANFO ACTUATOR
S1027 ACTUATOR SERVICE MANUAL
S1101 EXTERNAL PNEUMATIC VIBRATOR
14053 BASKET ROTATOR
S1033 ROTARY ACTUATOR MAINTENANCE MANUAL
13651 STABILIZER INSTALLATION
17070 125 CFM COMPRESSOR
S1028 COMPRESSOR OPERATION MANUAL
17165 AUTO LUBE SYSTEM INSTALLATION
S1094 LINCOLN AUTO LUBE MANUAL
17341 CHASSIS LUBE ELECTRONIC GREASE PUMP
S1011
S1012
Vehicle Fire Protection

An Owner’s Manual for Ansul
Fire Suppression/Detection Systems
002792
S1012
Off-road vehicles do have fires

Statistics show that on-road vehicles burn.......with Insurance companies are well aware of these facts.
alarming frequency. These vehicles are susceptible to That's why insurance rates are skyrocketing.
fire for several reasons. They often operate steady for
several hours at a time (sometimes around the clock). As the owner of a vehicle equipped with an Ansul Fire
They use flammable liquids – lubricating oil, gasoline, Detection/Suppression System, you've taken an
diesel oil, greases and hydraulic fluids – in their nor- important step in facing the fire problem. You are dra-
mal operation. They also generate heat – from engine matically reducing your potential fire loss and helping
blocks, manifolds, turbochargers and brake systems – to ensure personnel safety.
which can ignite these flammable liquids and debris.
This owner's guide has been provided to help
Since the passage of the federal and state clean air you understand how your Ansul Fire
acts, many vehicles, including most busses operated Detection/Suppression System works, your
by mass transit authorities and state agencies, have responsibilities for fire prevention and mainte-
been converting to cleaner burning fuels such as nance, and what to do in case of fire. In no way is
LPG, LNG, and CNG instead of gasoline or diesel this guide intended to provide detailed installation
fuel. Use of these fuels is an essential component of instructions. A copy of the complete Installation,
improving our environment, but their use raises the Recharge, Inspection, and Maintenance Manual
possibility of dangerous gas leaks. for the Ansul Fire Detection and Suppression
System is available upon request from Ansul.
When fire breaks out, it can result in expensive repair Should you have any questions, contact Ansul or
or replacement of valuable equipment, costly down- your nearest authorized Ansul products
time or loss of business continuity. Worse yet, it can distributor.
mean serious personal injury to vehicle operators or
passengers.
Transmission &
Turbocharger Disc Brake
Exhaust Battery Box

Manifold
Hydraulic
Pump Hose
Area
Engine
Block
Typical Vehicle
Fire Hazard Areas 002776
S1012
SAFETY Your role in

protecting your
PRECAUTIONS vehicle from fire
The fire system described in these materials is a sup- Your Ansul Fire Suppression System is custom-
pression system only and is not designed or intended designed to protect specific hazard areas on your
to extinguish all fires, particularly when unusual vehicle. It’s been carefully engineered for reliability
amounts of combustible materials and an ample oxy- and built to the highest quality standards. Every com-
gen supply are present. It is extremely important that ponent has been tested to ensure long life and
alternative firefighting equipment be available in case dependable performance.
the system does not totally extinguish a fire.
With proper maintenance, your Ansul Fire
Use extreme care to prevent the accumulation of Suppression System should give you years of fire
debris, combustible materials and fluids which could protection.
intensify the fire or cause it to spread to areas where
there was no previous potential for fire. The main purpose of the manual, however, is to
explain the most basic form of fire protection – fire
If modifications are made to the equipment being pro- prevention. It outlines steps you can take to prevent a
tected or if the fire detection and/or suppression sys- disastrous fire. Precautions which can greatly reduce
tem is disconnected for any reason, make certain the the risk of serious fire damage.
fire equipment is immediately inspected and tested by
an Ansul-authorized vehicle systems distributor. Fire prevention on vehicles relies upon two basic
factors:
If an automatic fire detection and actuation system
has not been supplied or has been disconnected,
system actuation and discharge will not occur unless
1. Inspection and preventative maintenance at
points where fires are most likely to start –
the fire suppression system is manually actuated. engine blocks, electrical systems, turbo-
Reliance on a manual release system usually results chargers, exhaust manifolds and brake
in a slower reaction to fire. systems.
2. Regular cleaning of all areas where flam-

mable materials such as fuel, oil, grease,
hydraulic fluid and combustible debris may
collect.
S1012
Vehicle Fire Prevention Maintenance

The following is a suggested daily maintenance outline which can help reduce the risk of fire on your vehicle.
CAUTION: Take care during vehicle maintenance, cleaning, or welding. To avoid unintentionally setting off the system
and the discharge of agent, do not cut, pinch, or apply heat exceeding 200 °F (93 °C) to the detection lines of
the system.
1. Check all oil, hydraulic fluid and gas lines for cuts,
abrasions or undue wear. Replace as needed.
000620
2. Inspect all oil, hydraulic and gas line fittings for

tightness. Clean off all residue and tighten.
000621
3. Inspect and clean engine area. Depending upon the

operation of the vehicle, use water or steam to clean it.
Schedule cleaning for the end of the work shift
when heat buildup may occur after the engine is shut
down.
000622
4. Check braking system for proper adjustment –

especially if brakes overheat when not engaged.
000623
5. Check all possible ignition points (engine block,

exhaust manifolds, turbochargers, etc.). Make sure
oil, hydraulic fluid and gas lines are not in contact
with these ignition points.
000624
6. Clean vehicle of all combustible debris – dry

vegetation, grain particles, coal dust, etc. Also,
remove any oil and fuel drippings.
000625
7. Check all electrical lines and connections for tight fit,

wear or abrasion. Replace any defective electrical
equipment or wiring.
000626
S1012
How your Ansul Fire Suppression System

works . . . manually
1. A fire starts in the protected area.
002777
2. Equipment operator pulls the ring pin

and strikes the plunger on the manual
actuators. Pressure from the actuator
causes the Ansul Fire Suppression
System to actuate.
002778
3. Expellant gas pressure ‘‘fluidizes’’ the

dry chemical extinguishing agent and
propels it through distribution hose.
002779
4. Dry chemical extinguishing agent is

discharged through fixed nozzles into
protected areas, suppressing the fire.
002780
And you can have automatic 24 hour protection with

Ansul CHECKFIRE Detection and Actuation Systems . . .
S1012
How the system works with optional

CHECKFIRE Electric Detection and Actuation
1. A fire starts in the protected area.
002781
2. Linear or spot detectors signal the

system control module indicating that a
fire has started in the protected area.
002782
3. The Control Module actuates the fire

suppression system. The module will
also provide time delay, shut down
functions and activation of auxiliary
vehicle components in accordance with
your installation.
002783
S1012
4. Expellant gas pressure ‘‘fluidizes’’ the

dry chemical extinguishing agent and
propels it through the distribution hose.
002784
5. Dry chemical extinguishing agent is

discharged through fixed nozzles into
protected areas, to suppress the fire.
002785
Optional LVS (Twin Agent) Fire Suppression System

Along with dry chemical fire suppression system protection, some vehicles, because of their size, require an additional type of system.
This type of system is called a twin agent system. An Ansul LVS, Liquid Agent System, is designed to discharge wet chemical into
the protected hazard areas after the dry chemical discharge has ended. The addition of the wet chemical produces a cooling effect
onto the flammable fuel and the surrounding surface areas. The wet chemical can flow into hard to reach areas where fuels may
have flowed into.
S1012
Make sure your Ansul Fire Suppression System is

The Ansul Fire Suppression System is your second line of fire defense in case your fire prevention efforts are not enough.
However, in order to perform properly, your Ansul System requires periodic inspection and maintenance.
Nozzles System Hydraulic Hose

NO CUTS
BLOW-0FF CAPS IN NOZZLES NOT CLOGGED NOZZLES TIGHT
PLACE (IF SUPPLIED) OR COVERED WITH DEBRIS IN BRACKETS
ALL FITTINGS
TIGHT NO KINKS
IN HOSE
NO ABRASIONS
ALL HOSE MOUNTS SECURELY

WELDED OR BOLTED
002797 002798 002799 002786
Agent Tank AUTHORIZED ANSUL Agent Tank LVS Hand Portable Fire
DISTRIBUTOR VISUAL SEAL
A-101 CERTIFICATION TAG or LT-A-101-125/250 Extinguisher IN PLACE
ATTACHED FIRMLY
MOUNTED
DISTRIBUTOR
CERTIFICATION
TAG ATTACHED
NO
EXCESSIVE
NO
WEAR
ABRASIONS
NO EXCESSIVE FIRMLY
WEAR MOUNTED NO
EXCESSIVE
NO WEAR
NO CORROSION FIRMLY
CORROSION MOUNTED
NO
CORROSION
NO
CORROSION
002794 002788
FIRMLY MOUNTED 004320
S1012
kept in good working order.

CHECKFIRE Electric Series I Inspection Detection Wire, Power Wire
ALL NYLON
TIES SECURE
RING PIN IN LIGHT MUST
PLACE AND SEALED NO CUTS
GO ON WHEN
TEST BUTTON IS BATTERY NO KINKS
BRACKET CONNECTIONS
PUSHED
SECURELY SECURE
WELDED OR NO ABRASIONS
BOLTED
ALL RUBBER SLEEVES IN PLACE
002790
FUSE IN
FUSEHOLDER
CONNECTION
SECURE CONNECTION
CARTRIDGE SECURE
INSTALLED
002789
DETECTION LINE AND/OR DETECTOR

SECURE AND NOT DAMAGED
CHECKFIRE MP Inspection CHECKFIRE SC-N Inspection
RING PIN IN
BRACKET PLACE AND
SECURELY SEALED
WELDED OR
BOLTED
CHECK THE SYSTEM
BRACKET
DAILY BY VISUALLY
RING PIN IN SECURELY
SEALED VERIFYING THAT THE
PLACE AND WELDED OR CHECK THE SYSTEM
CARTRIDGE GREEN POWER LED
SEALED BOLTED DAILY BY VISUALLY
INSTALLED IS FLASHING ONCE
VERIFYING THAT THE EVERY THREE
GREEN BATTERY LED SECONDS AND NO
IS FLASHING ONCE OTHER LED IS FLASH-
EVERY THREE SEC- ING
ONDS AND NO
OTHER LED IS
FLASHING
BRACKET
CARTRIDGE
SECURELY
INSTALLED
WELDED OR
BOLTED
CARTRIDGE
INSTALLED
DETECTION LINE
AND/OR DETECTION LINE
DETECTORS AND/OR
SECURE AND NOT DETECTORS
DAMAGED SECURE AND NOT
DAMAGED
002791 002775
S1012
Provide for vehicle modification
Your Ansul Fire Suppression System was custom When such modifications are made, contact your
designed and installed on your vehicle to protect spe- Ansul distributor. He can reevaluate your Ansul
cific hazard areas from fire. Should you add accesso- System to ensure it protects all hazard areas from
ry equipment to your vehicle at a later date, or make fire.
major mechanical modifications, you may be reducing
the capabilities of the Ansul Fire Suppression System.
Provide for periodic maintenance

Periodic maintenance is essential to ensure that your
Ansul Fire Suppression System is operational.
Contact your Ansul distributor for periodic follow-up,
in-depth inspection and maintenance.
Protect against fires outside of

the hazard area
Hand portable fire extinguishers are an effective way
to suppress fires which may occur away from the
vehicle, or in areas not protected by the Ansul Fire
1. Shut off the vehicle’s engine and set
brakes.
Suppression System. Your Ansul distributor can rec-
ommend the proper size, type and placement of hand
portable extinguishers and train your personnel in
2. Evacuate the vehicle and secure a hand
portable fire extinguisher.
their operation, inspection and maintenance.
Should fire occur in an area not protected by the

3. Approach the fire from the upwind side.
Ansul Fire Suppression System, a hand portable fire 4. Actuate the hand portable fire extinguisher per
instructions printed on the extinguisher’s name-
extinguisher should be employed as follows:
plate.
5. Once the fire is extinguished, stand by in case

the fire reflashes.
S1012
In the event of a fire on your vehicle
To manually operate system:
1. Shut off the vehicle
2. Set the brakes
3. Pull the ring pin on

manual actuator and
strike the red button
000627
4. Evacuate the vehicle
5. Stand by with a fire extinguisher

S1012
Inspection and Maintenance Record

Date Authorized Ansul Distributor Recharge Inspection Action Taken
ANSUL and CHECKFIRE are registered trademarks.
Your Authorized Ansul Distributor

Litho in U.S.A.
©1999 Ansul Incorporated
Part No. 53081-08
ANSUL INCORPORATED, ONE STANTON STREET, MARINETTE, WI 54143-2542

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 one’s
responsibilities.
Design, installation, recharge, and maintenance of the system
must conform to the limitations detailed in this manual and per-
formed 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 oper-
ate effectively and safely. Inspection frequency shall be per-
formed monthly, or sooner, depending on operating and/or envi-
ronmental conditions. Maintenance shall be performed semi-
annually or sooner, depending on operating and/or environmental
conditions.
This ANSUL systems manual is limited to uses herein described.
For other applications, contact your local ANSUL distributor,
Domestic District Manager, International Area Manager, or Ansul
Incorporated – Technical Services Department, Marinette,
Wisconsin 54143-2542.
ANSUL and CHECKFIRE are trademarks of Ansul Incorporated or its affiliates.
NOTICE: Some sections have been removed by Getman as they do not

apply to your application needs. Any questions please call Getman
Corporation directly.
S1013
TABLE OF CONTENTS
6-30-05
REV. 3
SECTION PAGES SECTION PAGES

I. GENERAL INFORMATION 1-1 – 1-2 VII. INSPECTION 7-1 – 7-2
INTRODUCTION 1-1
VIII. MAINTENANCE 8-1 – 8-2
TWIN AGENT SYSTEM 1-1
SEMI-ANNUAL 8-1 – 8-2
FM APPROVAL 1-1
12-YEAR 8-2
HOW THE SYSTEM OPERATES 1-2
IN CASE OF FIRE 1-2 IX. RECHARGE 9-1 – 9-2
II. SYSTEM DESCRIPTION 2-1 – 2-2 X. SYSTEM APPLICATION OPTIONS 10-1 – 10-6
APPLICATION METHOD 2-1 XI. APPENDIX 11-1 – 11-10
Local Application – Vehicle 2-1
Total Flooding 2-1 SYSTEM COMPONENT INDEX 11-1 – 11-2
PIPING ARRANGEMENT 2-1
Two Nozzle 2-1
Four Nozzle 2-1
Six Nozzle 2-1
DETECTION 2-1
III. SYSTEM COMPONENTS 3-1 – 3-6

TANK ASSEMBLY 3-1
TANK BRACKET 3-1
DRY CHEMICAL 3-2
CARTRIDGE – EXPELLANT GAS 3-2
CARTRIDGE – ACTUATION GAS 3-2
CARTRIDGE BRACKET 3-2
PNEUMATIC ACTUATOR 3-3
MANUAL ACTUATORS 3-3
1/4 IN. CHECK VALVE 3-3
DISTRIBUTION TEE 3-3
REDUCING TEE 3-4
TRIPLE TEE 3-4
SAFETY RELIEF VALVE 3-4
AIR CYLINDER (OPTIONAL) 3-4
PRESSURE SWITCH – WEATHERPROOF 3-4
PRESSURE SWITCH – 3-5
NON-WEATHERPROOF
PRESSURE SWITCH – EXPLOSION PROOF 3-5
NOZZLES 3-5
NOZZLE BRACKET 3-6
HOSE (SUPPLIED BY OTHERS) 3-6
SEALED BURST DISC ASSEMBLY 3-6
ENGINE SHUTDOWN DEVICE 3-6
CHECKFIRE ELECTRIC DETECTION 3-6
AND ACTUATION SYSTEM
S1013
SECTION I – GENERAL INFORMATION
6-30-05 Page 1-1
REV. 2
INTRODUCTION FM APPROVAL
The ANSUL A-101/LT-A-101 fire suppression system is a pre- The ANSUL A-101/LT-A-101 fire suppression system has been
engineered, fixed nozzle system for protection of off-highway tested and is FM approved. These tests require extinguishment of
vehicles, commercial vehicles, or industrial type applications. fire initiated in open vessels and within enclosures fueled with
Typical applications include surface mining equipment, under- flammable liquid. In each case, these fires are allowed to
ground mining machines, forest harvesting equipment, construc- progress to maximum intensity before the system is actuated.
tion equipment, farming machinery, and transportation vehicles The time of actuation in these tests is well beyond the time that a
such as municipal busses. detector would take to detect the fire and actuate the system.
The A-101/LT-A-101 system consists of three major components: Other tests required by FMRC are as follows:
a container to store the dry chemical extinguisher agent; an actu- 1. Fuel in depth splash tests under a minimum hose length,
ation system operated manually or automatically, and an agent maximum temperature, and minimum clearance condition to
distribution system which delivers the agent from the tank through ensure that the nozzle does not cause splashing of fuel.
hydraulic hose and fixed nozzles to the hazard areas. 2. Operational flow rate tests at the minimum, average, and the
The fire system described is a suppression system only and is not maximum temperatures, with maximum and minimum hose
designed or intended to extinguish all fires, particularly when lengths.
unusual amounts of combustible materials and an ample oxygen 3. Cycle tests on all mechanical and electrical devices to deter-
supply are present. It is extremely important that supplement fire mine their structural integrity.
fighting equipment be available in case the system does not total-
ly extinguish a fire. The A-101 systems which utilize carbon dioxide as the expellant
gas are approved for temperature ranges of +32 °F to +120 °F
If an automatic fire detection and actuation system has not been (0 °C to 49 °C).
supplied or has been disconnected, system actuation and dis-
charge will not occur unless the fire suppression system is manu- The LT-A-101 systems which utilize nitrogen as the expellant gas
ally actuated. (Use of manual system only must be approved by are approved for temperature ranges of –65 °F to +210 °F
authority having jurisdiction.) Reliance on a manual release sys- (–54 °C to 99 °C).
tem usually results in a slower reaction to fire. Means to shut
down the vehicle must be added to a manual or disconnected TWIN AGENT SYSTEM (LVS PORTION NOT FM APPROVED)
automatic system. The system consists of both dry chemical and liquid agent. The
The basic agent storage container is a tank filled with ANSUL dry chemical portion of the system is the ANSUL A-101/LT-A-101,
FORAY (monoammonium phosphate base) dry chemical which is 50, 125, or 250 system (either standard discharge or extended
effective on Class A, B, and C fires. A gas expellant cartridge, discharge) and the liquid agent portion of the system consists of
either carbon dioxide or nitrogen, provides pressurization of the an agent storage tank containing a premixed solution of LVS wet
dry chemical upon actuation. chemical.
Automatic detection, either electric or pneumatic, and actuation, The LVS-30 (30 gallon) system is designed to discharge for
is recommended. The A-101/LT-A-101 system is actuated manu- approximately 2 minutes when two agent discharge nozzles are
ally by a pneumatic actuator located on the dashboard or on the used.
exterior of the vehicle. The LVS Fire Suppression System is designed to operate within a
The dry chemical extinguishing agent is delivered from the tank temperature range of –40 °F to +120 °F (–40 °C to 49 °C).
through hydraulic hose and pre-set nozzles into the fire hazard The dry chemical system used in conjunction with the LVS sys-
areas or onto the fire prone surfaces. tem is the ANSUL A-101/LT-A-101, 50, 125 or 250. The dry chem-
Along with the fire suppression system, the total system design ical system is connected to the ANSUL CHECKFIRE Detection
must include a hand portable fire extinguisher(s) located on board and Control System. the dry chemical system can be designed as
the vehicle that can be used to manually suppress a fire that may a standard discharge or as an extended discharge system per the
be burning in an unprotected area. Refer to NFPA 10, “Standard requirements of the A-101/LT-A-101 Vehicle Fire suppression
For Portable Fire Extinguisher,” for additional information. Installation, Recharge, Inspection, and Maintenance Manual.
Both systems are designed to discharge simultaneously
when actuated either manually or automatically.
For detailed instructions, refer to manual Part No. 427865 regard-
ing the LT-A-101-50/125/250 system. For detailed instructions,
refer to manual Part No. 427109 regarding the LVS system.
S1013
SECTION I – GENERAL INFORMATION
5-15-02 Page 1-2
REV. 2
FROM AUTOMATIC
DETECTION SYSTEM
2
1
TO OPTIONAL
PRESSURE SWITCH
3
FIGURE 1
002581
HOW THE SYSTEM OPERATES IN CASE OF FIRE
Discharge of the A-101/LT-A-101 system manually is initiated When a fire starts, the way the operator reacts is very important.
from a remote actuator (1). Depressing the actuator plunger As soon as the operator is aware of a fire, he should do the fol-
punctures the seal on the cartridge. The released pressure is lowing four things:
transmitted to the pneumatic actuator/cartridge receiver (2). A 1. Turn the machine off and set the brake.
safety relief valve (3) at this point prevents too high an actuation
pressure build-up. The pressure drives a puncture pin through 2. Quickly actuate the system by pulling the safety ring pin on
the seal in the expellant gas cartridge (4). This releases the the manual actuator and strike the red button.
expellant gas which is then transmitted to the dry chemical tank 3. Evacuate the vehicle.
(5) where it fluidizes the dry chemical before carrying it to the fire
hazard. A sealed burst disc assembly (6) prevents the flow of dry 4. Stand by with a fire extinguisher.
chemical until sufficient pressure is built up within the dry chemi-
cal tank. When the proper pressure is reached, the disc breaks
allowing the gas/dry chemical mixture to flow to the nozzle(s) (7) ! CAUTION
and discharge onto the hazard. The fire system described in this manual is a suppression sys-
Refer to appropriate CHECKFIRE design, installation and main- tem only and is not designed or intended to extinguish all fires,
tenance manual for information on the operation of the automatic particularly when unusual amounts of combustible materials
detection system. and an ample oxygen supply are present. It is extremely
important that supplemental firefighting equipment be available
NOTE: Mechanical or electrical means must be provided to shut
in case the system does not totally extinguish a fire.
down vehicle upon system actuation.
S1013
SECTION III – SYSTEM COMPONENTS
6-30-05 Page 3-1
REV. 1
TANK ASSEMBLY TANK BRACKET

The tank assemblies, nominal 10, 20, and 30 lb. size, are factory The tank mounting bracket assemblies consist of heavy gauge
filled with 8.5, 17, and 25 lb. respectively of FORAY dry chemical. steel back plates and clamp arms. Each style bracket is con-
Each tank is finished in red enamel paint. A nameplate is affixed structed to properly retain the agent tank from movement or dam-
to the exterior and contains information on recharge and mainte- age in the rugged environment that these systems are normally
nance. Two style of tanks are available: a tank containing a car- used. Each tank bracket contains rubber pads to minimize the
tridge receiver and pneumatic actuator and a tank with 1/4 in. shock and vibration effect on the tank. The brackets are finished
adapter for a pressure line from a remote cartridge. See Figure 1. with red, air dry enamel paint. See Figure 2.
A-101 MODEL 10 LT-A-101 MODEL 10 A-101 MODEL 10 / LT-A-101 MODEL 10
PART NO. 24855 PART NO. 24966 PART NO. 24854
12 IN. (30.5 cm) MIN.
2 7/8 IN. OPENING WIDTH
7 IN. 6 3/4 IN. (7.3 cm)
(17.8 cm) (17.1 cm)
11 3/8 IN.
(28.9 cm)
10 1/4 IN. 10 1/4 IN.
(26 cm) (26 cm) 3/4 IN.
16 1/8 IN. 16 1/8 IN. (1.9 cm)
(41 cm) (41 cm)
2 1/32 IN.
(5.2 cm)
000459 000459 3 5/8 IN.

(9.2 cm) 3 3/8 IN.
1 13/16 IN. (8.6 cm)
(4.6 cm) 003464
A-101 MODEL 20 LT-A-101 MODEL 20 A-101 MODEL 20 LT-A-101 MODEL 20

PART NO. 24970 PART NO. 24894 PART NO. 24971 PART NO. 24895
12 IN. (30.5 cm) MIN.

OPENING WIDTH
7 5/8 IN. 3 1/2 IN. 2 IN.
8 1/4 IN. (19.4 cm) (8.9 cm) 8 5/8 IN.
(5.1 cm)
(21 cm) (21.9 cm)
6 1/2 IN.
(16.5 cm)
8 5/8 IN. 8 1/2 IN.
3 9/16 IN.
11 IN. (21.9 cm) 19 15/16 IN. (21.6 cm)
(9 cm)
(27.9 cm) (50.6 cm)
1 3/16 IN.
19 1/2 IN. 4 3/8 IN.
(4.6 cm)
(49.5 cm) 3 3/4 IN. (11 cm)
(9.5 cm)
4 1/2 IN.
(11.4 cm) 2 3/4 IN. 003468
10 1/8 IN.
000459 (7 cm)
(25.7 cm) 003461
003465
A-101 MODEL 30 LT-A-101 MODEL 30 A-101 MODEL 30 LT-A-101 MODEL 30

PART NO. 53000 PART NO. 29375 PART NO. 14098 PART NO. 30494
14 IN. MIN. (35.6 cm)
9 IN. OPENING WIDTH
3.5 IN.
9 3/4 IN. (22.9 cm) (8.9 cm) 2 1/2 IN. 9 7/8 IN.
(24.8 cm) (6.3 cm) (25 cm)
8 5/8 IN. 7 1/2 IN.

9 7/8 IN. (21.9 cm) (19 cm)
11 7/8 IN. (25 cm) 22 1/2 IN. 4 IN.
(30.1 cm) (57 cm) 4 9/32 IN. (10 cm)
22 1/2 IN. 1 3/16 IN.
(10.9 cm) (4.6 cm) 4 7/8 IN.
(57 cm) 3 IN. (12 cm)
(7.6 cm) 4 IN.
(10.1 cm) 5 IN.
10 1/4 IN. 3 IN.
(12.7 cm) 003468
000459
(26 cm) 003461
6 IN. (7.6 cm)
5 9/16 IN.
(15.2 cm) (14.1 cm)
003466
LP-A-101 MODEL 20B / LT-LP-A-101 MODEL 20

LP-A-101 MODEL 20-B LT-LP-A-101 MODEL 20-B PART NO. 31171
PART NO. 24427 PART NO. 24425
9 IN. 9 IN. 2 1/2 IN. 9 7/8 IN.
(22.9 cm) (22.9 cm) (6.3 cm) (25 cm)
4 IN.
(10.2 cm)
4 IN.
9 7/8 IN. 16 IN. 9 7/8 IN. 16 IN. (10 cm)
(25 cm) (40.6 cm) (25 cm) (40.6 cm) 1 3/16 IN.
(4.6 cm) 4 7/8 IN.
(12 cm)
003463 10 1/4 IN. 003463 5 IN. 3 IN.

(26 cm) (12.7 cm) (7.6 cm) 003467
FIGURE 2
FIGURE 1
S1013
6-30-05 Page 3-2
REV. 2
DRY CHEMICAL CARTRIDGE – ACTUATION GAS

FORAY is a monoammonium phosphate based dry chemical The actuation gas cartridge used on the A-101/LT-A-101 system
which is effective on Class A,B, C related fires. FORAY agent is contains nitrogen as the actuation gas. The cartridge is a sealed
color coded yellow for easy identification. FORAY dry chemical is pressure vessel containing gas under pressure. When the car-
shipped in 45 lb. pails, Part No. 53080. See Figure 3. tridge seal is punctured by the pin in the remote manual or pneu-
matic actuator, the gas flows to the actuator on the expellant gas
cartridge, causing that actuator to puncture the seal in the expel-
lant gas cartridge. The actuation gas cartridges meet the require-
ments of DOT 3E-1800. See Figure 5.
B
FIGURE 3
000417 A
CARTRIDGE – EXPELLANT GAS

The expellant gas cartridges used on the A-101/LT-A-101 system RIGHT-HAND LEFT-HAND
contain either carbon dioxide or nitrogen as their expellant gas. A B THREAD THREAD
LT-10 2 IN. 6 13/16 IN. PART NO. 13193 (DOT) PART NO. 13177 (DOT)
The cartridge is a sealed pressure vessel containing gas under (5.1 cm) (17.3 cm) PART NO. 423423 (TC/DOT) PART NO. 423425 (TC/DOT)
pressure. When the cartridge seal is punctured by the pneumatic
FIGURE 5
actuator pin, the gas flows into the dry chemical tank, fluidizes the 000439
dry chemical, and carries it through the distribution piping network
and out the nozzles. CARTRIDGE BRACKET
The expellant gas cartridges meet the requirements of DOT The cartridge brackets for the expellant gas cartridges are con-
3A-2100 or 3AA-1800. See Figure 4. structed of heavy gauge steel and formed to protect and secure
Several cartridge Part No.’s have been added to comply with the the cartridge. The cartridge brackets are painted with red, air dry
requirements of Transport Canada (TC). These cartridges have enamel paint. See Figure 6.
been approved for both DOT and TC.
CARBON DIOXIDE CARTRIDGES LT-A-101-20 / LT-LP-A-101-20-B LT-A-101-30
PART NO. 24325 PART NO. 29193
7 7/8 IN. 3 1/2 IN.

9 IN. (8.9 cm) 18 IN.
(20 cm) (45.7 cm)
(22.9 cm) 11 5/8 IN.
(29.5 cm)
3 IN. 4 IN.
(7.6 cm) (10.2 cm)
000150
2 1/2 IN. 12 5/8 IN. 11 IN.
000149 2 IN. (32 cm) (28 cm) 5 1/2 IN.
(6.4 cm)
(5.1 cm) 003470 (14 cm)
FOR A-101-10 SYSTEMS FOR A-101-20 AND
LP-A-101-20 000151
USE PART NO. 15850 2 1/2 IN.
SYSTEMS USE PART 003472
(DOT) (6.4 cm) 3/8 IN.
PART NO. 423439 (TC/DOT) NO. 423441 FOR A-101-30 SYSTEMS USE (.95 cm)
2 7/8 IN.
(TC/DOT) PART NO. 423443 (TC/DOT) (7.3 cm)
9/16 IN.
NITROGEN CARTRIDGES (1.4 cm)
LP-A-101-20-B
PART NO. 31177
3 1/2 IN.
(8.9 cm)
7 7/8 IN. 2 5/16 IN.

(20 cm) (5.9 cm)
11 5/8 IN.
(29.5 cm)
16 1/2 IN.
(42 cm) 10 1/4 IN.
(26 cm)
000145 003470
2 1/2 IN.
(6.4 cm)
FIGURE 6
FOR LT-A-101-10
SYSTEMS USE PART 000146
NO. 423429 (TC/DOT) 2 1/2 IN.
(6.4 cm)
FOR LT-A-101-20,
3 9/16 IN.
LT-LP-A-101-20 000148
(9 cm)
SYSTEMS USE PART
NO. 423435 (TC/DOT) FOR LT-A-101-30 SYSTEMS
USE PART NO. 423491 (TC/DOT)
FIGURE 4
S1013
5-15-02 Page 3-3
REV. 1
PNEUMATIC ACTUATOR 1/4 IN. CHECK VALVE

The pneumatic actuator, Part No. 430221, is constructed of brass The 1/4 in. actuation line check valve, Part No. 25627, is used at
and mounts on top of the expellant gas cartridge(s). When actuat- the branch lines to each actuation device (whether manual or
ed, the actuator punctures a seal in the cartridge head, allowing automatic). The check valve blocks the flow of actuation gas from
the expellant gas to flow into the agent tank. See Figure 6a. the actuator that was actuated to the actuator(s) that was not
actuated. This prevents actuation gas from escaping from an
1/4 IN. ACTUATION open actuator which may have had the cartridge removed. The
LINE INLET (TYP. 2) check valve also keeps the gas from pressurizing all branch actu-
ation lines thus allowing the main line to be of maximum length.
See Figure 8.
CHECK VALVE PART NO. 25627
VENT HOLE
1/4 IN. EXPELLANT

GAS LINE OUTLET (1)
1/4 IN. NPT

FIGURE 6a (0.6 cm)
006433
MANUAL ACTUATORS
The manual actuator is available for use with either right or left
FIGURE 8
hand cartridges. Manual actuators should be mounted near the 000899
vehicle operator and/or at a point on the vehicle that can be
reached from ground level. Two styles of manual actuators are DISTRIBUTION TEE
available: the standard actuator with either the “S” type bracket or
the “L” type bracket, and the cartridge guard type actuator. See When six nozzles are to be fed from one dry chemical tank, the
Figure 7. distribution supply line must enter the inlet of a distribution tee,
Part No. 25031, and each branch line must exit from one of three
CARTRIDGE GUARD ACTUATOR FOR RIGHT HAND CARTRIDGES PART NO. 19330 outlets of the distribution tee. This is required to assure equal dis-
CARTRIDGE GUARD ACTUATOR FOR LEFT HAND CARTRIDGES PART NO. 16186
5 IN. tribution of dry chemical to each nozzle. See Figure 9.
(12.7 cm) DISTRIBUTION TEE, 1/2 IN. X 1/2 IN. X 1/2 IN. X 3/4 IN. – PART NO. 25031
3 IN. “L” BRACKET PART NO. 70580
(7.6 cm) 1/8 IN.
(.32 cm)
3 IN. 3 IN.
(7.6 cm) (7.6 cm)
3/4 IN. NPT

2 1/4 IN. INLET
5 IN. (5.7 cm)
(12.7 cm) 1/2 IN. NPT
12 1/4 IN. OUTLET –
(31.1 cm) 3 PLACES 2 1/16 IN.
003473b (5.2 cm)
003473a 2 1/8 IN.
(5.4 cm)
7/8 IN.
1 3/4 IN. (2.2 cm) “S” BRACKET PART NO. 57661
(4.4 cm)
1 13/16 IN.
REMOTE ACTUATOR FOR RIGHT HAND 3 IN. (8.7 cm) 1 1/2 IN. 31/32 IN. (2.5 cm)
CARTRIDGES PART NO. 57452 (7.6 cm) (3.8 cm) 2 1/4 IN. DIA.
REMOTE ACTUATOR FOR LEFT HAND (5.7 cm)
2 3/8 IN.
CARTRIDGES PART NO. 70581 (6 cm)
FIGURE 9
002583
1/2 IN.
4 IN. (1.3 cm)
5 5/8 IN. 2 IN.
(10.2 cm)
(14.3 cm) (5.1 cm) 1/2 IN.
(1.3 cm)
2 IN.
(5.1 cm)
9 IN.
(22.9 cm)
3 3/8 IN.
(8.6 cm) 3/4 IN.
(1.9 cm)
003473c 3 IN.
1 1/2 IN. (7.6 cm) 3 7/16 IN.
(3.8 cm) (8.7 cm)
003460
FIGURE 7
S1013
5-15-02 Page 3-4
REV. 1
REDUCING TEE AIR CYLINDER (OPTIONAL)

When two or four nozzles are to be fed from a single dry chemical The air cylinder, Part No. 15733, is a system accessory whose
tank, a 1/2 x 1/2 x 3/4 in. reducing tee, Part No. 4655, is used to function is to shut off the fuel supply to the engine when the fire
properly distribute the dry chemical from the supply line to two suppression system is actuated. It is a piston operated by gas
branch lines. See Figure 10. pressure from the actuation line. See Figure 13.
AIR CYLINDER PART NO. 15733
REDUCING TEE, 1/2 IN. X 1/2 IN. X 3/4 IN. – PART NO. 4655
2 1/4 IN.
(5.7 cm)
1 1/2 IN. 2 IN.
(3.8 cm) 3/4 IN. NPT (5.1 cm)
INLET
5 IN.
(12.7 cm) 1/8 IN. NPT
FIGURE 13
1 7/8 IN. 003459
(4.8 cm)
1/2 IN. NPT
OUTLET
(TYP. 2 PLACES) PRESSURE SWITCH – WEATHERPROOF
FIGURE 10 The pressure switch, Part No. 46250, is a DPST (Double-Pole,
003456 Single Throw) pneumatically operated, resettable switch used to
open or close electrical circuits to either shut down equipment or
TRIPLE TEE turn on lights or alarms. The pressure switch is constructed of
When four nozzles are to fed from a single dry chemical tank, a malleable iron, painted red. A 1/4 in. NPT pressure inlet is used to
triple tee, Part No. 16424, can be used to properly distribute the dry connect the 1/4 in. hose from the actuation line. The switch rating
chemical from the supply line to two branch lines. See Figure 11. is 2 HP-240 VAC/480 VAC, 2 HP-250 VDC, 30A-250 VAC/DC,
5A-480 VAC/DC. See Figure 14.
TRIPLE TEE, 1/2 IN. X 1/2 IN. X 1/2 IN. X 3/4 IN. – PART NO. 16424 PRESSURE SWITCH PART – NO. 46250
MALLEABLE 3 5/8 IN.

IRON FINISH – (9.2 cm)
6 IN. RED PAINT BRASS RESET
(15.2 cm) TO ELECTRICAL PLUNGER
EQUIPMENT TO MOISTURE
BE CONTROLLED PROOF JOINT
GASKET NUT
1/2 IN. NPT “O” RING GASKET

1 7/8 IN.
(4.8 cm) OUTLET NAMEPLATE
(TYP. 4
PLACES) DOUBLE POLE – HEAVY
DUTY TOGGLE SWITCH
WITH FULLY ENCLOSED
BAKELITE BASE
BRASS PISTON
3/4 IN. NPT 2 1/4 IN.
INLET (5.7 cm) PISTON “O”
TO RING GASKET
POWER
3/4 IN.
ELECTRICAL
CONDUIT OUTLETS
FIGURE 11 1/4 IN. UNION
1/4 IN. ACTUATION
003462
HOSE
SAFETY RELIEF VALVE 2 7/8 IN.

(7.3 cm)
A spring-loaded pressure relief valve, Part No. 15677, is used to
prevent excessive pressure from building up in the actuation line.
The valve is set to relieve at 265 psi (18.3 bar). After system dis-
charge, all pressure in the actuation line can be relieved by
pulling the ring on the safety relief valve. See Figure 12.
SAFETY RELIEF VALVE PART – NO. 15677
4 9/16 IN.
(11.5 cm)
1/4 IN. NPT
FIGURE 12 FIGURE 14
000437 000716
S1013
5-15-02 Page 3-5
REV. 1
PRESSURE SWITCH – NON-WEATHERPROOF NOZZLES

The Electric Pressure Switch, Part No. 8372, is a SPDT (Single Three types of nozzles are approved for use with the A-101/
Pole-Double Throw) pneumatically operated, resettable switch to LT-A-101 system. One type is the F-1/2 nozzle. This nozzle gives
be used for turning off pump motors, exhaust fans, conveyors and a 180° fan shape pattern and can be used for either total flooding
similar devices; or turning on alarms or electric door closures. The or local application. The second type of nozzle is the C-1/2. This
switch contacts are rated at 15 amp, 125, 250, or 480 VAC, 1/4 nozzle gives a cone pattern and is used for direct application to a
hp at 125 VAC, 1/2 hp at 250 VAC or 1/2 amp at 125 VDC, 1/4 vehicle component or burning surface. The third type of nozzle is
amp at 250 VDC. See Figure 15. the V-1/2. This nozzle produces a 160° fan shape pattern and is
generally used for screening engine compartments, torque con-
1/2 IN. verters and all other hazard areas. All nozzles are constructed of
1 3/4 IN.
COMPRESSION (4.4 cm) brass and require protective blow-off caps. Exception: The F-1/2
FITTING
nozzle can utilize either a blow-off cap or the opening can be
1/8 NPT
packed with a good grade of extreme temperature silicone
grease, such as Dow Corning No. 4. See Figure 17.
F-1/2 NOZZLE EFFECTIVE DISCHARGE PATTERN PART NO. 16449
33 IN.
(83.8 cm)
1 13/16 IN.
(4.6 cm)
33 IN.
4 3/4 IN. (83.8 cm)
(12.1 cm)
1 IN.
003469 HEX
1/2 IN. NPT
15 IN. PART NO. 16449
(38.1 cm)
5 1/4 IN.
(13.3 cm)
V-1/2 NOZZLE EFFECTIVE DISCHARGE PATTERN PART NO. 56748
6 FT.
FIGURE 15 (1.83 m)
000453
Explosion-Proof Pressure Switch – DPDT 1 13/16 IN.

160° 4 FT. (4.6 cm)
(1.22 m)
The Explosion-Proof Pressure Switch, Part No. 43241, is a DPDT
(Double-Pole, Double-Throw) pneumatically operated, resettable
switch to be used for turning off pump motors, exhaust fans, con- 15 IN. 003471
1 IN.
(38.1 cm) HEX 1/2 IN. NPT
veyors, and similar devices; or turning on alarms or electric door PART NO. 56748
closures. The switch contacts are rated at 10 amp at 125 VAC or
5 amp at 250 VAC. The pressure switch is constructed with an C-1/2 NOZZLE EFFECTIVE DISCHARGE PATTERN PART NO. 53791
explosion-proof housing suitable for hazardous environments.
The switch operates off the nitrogen pressure from the ANSUL
6 FT.
AUTOMAN release or remote pneumatic actuator. (1.83 m)
1/4 IN. UNION 3/4 IN.

CONDUIT
OUTLET
3/8 IN. X 1/4 IN.
BUSHING
1 13/16 IN.
(4.6 cm)
1 IN.
7 7/8 IN. 3 FT.
003724 HEX 1/2 IN. NPT
(20 cm) (0.9 m)
PART NO. 53791
NAMEPLATE
FIGURE 17
2 11/32 IN.
- (5.9 cm) 5 5/8 IN.
3 9/16 IN. MOUNTING (14.2 cm)
(9 cm) HOLES
3/4 IN. CONDUIT
OUTLET
FIGURE 16
000454
S1013
SECTION IV – SYSTEM DESIGN – VEHICLE
5-15-02 Page 4-1
REV. 1
HAZARD ANALYSIS High Pressure Hoses – Hot fluid spraying from a ruptured high
Individuals responsible for the design of an A-101/LT-A-101 system pressure hose, or leaking from a loose flange or fitting could find
must be trained and hold a current ANSUL certificate in an A- its way to a source of ignition.
101/LT-A-101 training program. Knowledge of the fire hazards that Belly Pan – The belly pan can accumulate not only leaking fuel
exist in the equipment to be protected is also required. Finally, a from the vehicle, but external debris, and because of its unique
good understanding of federal and local fire protection codes and location, a fire starting in the belly pan could quickly engulf the
standards is necessary. No one should begin designing without entire vehicle.
previously becoming familiar with the applicable codes. Hydraulic/Fuel Pumps – Because of the high pressures involved
Having read about the A-101/LT-A-101 system and the basic ter- with these pumps, fluid spraying from a leaking pump could find
minology and operation of the system, you should now begin to its way to a heat source and cause ignition.
identity the fire hazards in the equipment to be protected. Every After completing the hazard analysis, determine nozzle cover-
foreseeable hazard must be identified now while you have design ages.
flexibility; once the system is installed, adding protection for
another hazard becomes more difficult. Note that the A-101/LT-A- NOZZLE COVERAGE AND LOCATION
101 system is designed only for the protection of specified equip-
The first step is to determine which nozzles are needed and
ment for the foreseeable hazards that exist due to that equipment
where they should be placed to best protect the hazard.
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 Nozzle selection can be made by first determining the size of the
remove the need for a hand portable fire extinguisher on the hazard and then comparing that to the nozzle’s effective dis-
equipment. Fuel spills, welding (repair) heat or other unforesee- charge pattern.
able causes may result in fires not having A-101/LT-A-101 protec- C-1/2 Nozzle Part No. 53791 – The cone-shape discharge pat-
tion. The A-101/LT-A-101 system protects the areas with high like- tern of the C-1/2 nozzle will widen to a 3 ft. (.9 m) diameter at the
lihood of fire and potential for high damage; seldom would an maximum effective discharge range of 6 ft. (1.8 m). See Figure 1.
A-101/LT-A-101 system be designed to protect every square inch V-1/2 Nozzle Part No. 56748 – The V-1/2 nozzle creates a fan-
of the equipment to be protected. shaped discharge pattern of 160° and has a maximum effective
An effective system design is based on a through hazard analy- discharge range of 4 ft. (1219 mm) in length by 15 in. (38.1 cm) in
sis. Fire is made up of heat, fuel, and oxygen. A fire hazard is any height with a maximum width of 6 ft. (1.8 m). See Figure 1.
place that these three elements could be brought together.
F-1/2 Nozzle Part No. 16449 – The F-1/2 nozzle also produces a
Because oxygen is always present, identifying fuel and heat
fan-shaped discharge pattern, but with a 180° pattern at a maxi-
sources is most critical.
mum effective range of 33 in. (83.8 cm) in length by 15 in.
Large excavators must be considered special type hazards. See (38.1 cm) in height with a maximum width of 5 ft. 6 in. (1.7 m) See
the Appendix Section for design information or contact ANSUL Figure 1.
Application Engineering Department.
C-1/2 NOZZLE
Operator safety is also a concern when designing a fire suppres- 6 FT.
sion system. The operator must have enough time to safely exit (1.83 m)
the vehicle. In some situations, an extended discharge dry chemi-
cal system (not FM Approved) may offer the operator the addition-
al 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 informa-
tion.
Some common fuel sources in vehicles include flammable liquids
and greases, rubber, plastics, upholstery, and environmental
debris such as wood chips or coal dust. 3 FT.
(0.9 m)
Common vehicle heat sources are engine blocks, exhaust sys-
V-1/2 NOZZLE
tems, pumps, and turbochargers, as well as bearings, gears, 003724a
brakes, and electrical equipment. A potential hazard exists when

6 FT.
a fuel comes in contact with any heat source. (1.83 m)
Where there is dripping or leaking fuel, the hazard can become
even more dangerous than initially considered. Consulting with
4 FT.
experienced operators or owners of similar equipment can help to 160° (1.22 m)
identify locations of previous fires and special hazards not nor-
mally considered as common hazards. 15 IN.
The following are typical vehicle fire hazards that require consid- (38.1 cm)
eration: 003471a
Engine Compartment – The engine compartment contains an F-1/2 NOZZLE
assortment of fluids, fuels, oils, and greases, as well as congest- 33 IN.

(83.8 cm)
ed wires, hoses, and accumulated debris, all very near high heat
33 IN.
sources. (83.8 cm)
33 IN.
Battery Compartments – Battery compartments are a potential (83.8 cm)
180°
fire hazard when combustible materials build up on the top of the
battery. These materials, in the presents of moisture, can cause a 15 IN.
short circuit. (38.1 cm) 003476
Transmissions, Torque Converters, and Parking Brakes – All

these components are a possible high heat source that could FIGURE 1
cause ignition to combustible material.
S1013
SECTION VII – INSPECTION
6-30-05 Page 7-1
REV. 3
Inspection is a “quick check” that the system is operable. It is

intended to give reasonable assurance that the system is fully
charged and will operate. This is done by seeing that the system
has not been tampered with and there is no obvious physical
damage, or condition, to prevent operation. The value of an
inspection lies in the frequency, and thoroughness with which it is
conducted.
Inspection frequency shall be performed monthly, or sooner,
depending on operating and/or environmental conditions.
To provide reasonable assurance that your ANSUL A-101/LT-A-
101 system is charged and operable:
1. Note general appearance of system components for mechan-
ical damage or corrosion.
2. Check all hose to make certain it is securely fastened and not
cut or show signs of abrasion.
3. Make certain all hose fittings are tight.
4. Make certain the nozzles are correctly aimed, openings are
clean and not obstructed and the blow off caps are properly
installed. NOTE: Blow off caps must be replaced annually.
5. Check nameplate(s) for readability and make certain they are
properly attached.
6. The automatic detection system should be inspected as fol-
lows: If system is equipped with a CHECKFIRE SC-N or
MP-N electric automatic detection system, make certain
green “Power” LED is blinking. If system is equipped with a
CHECKFIRE Series I, push button on top of module and note
illumination of indicator light. If the system is equipped with a
CHECKFIRE Series II, push and hold the test/control button
momentarily. The internal alarm will sound and the two out-
side LED’s will flash. If system is equipped with a CHECK-
FIRE pneumatic detection system, make certain yellow “Low
Pressure” indicator light is not on.
7. Check to make certain hazard size or components being pro-
tected have not changed since original installation.
8. If there are any broken or missing lead and wire seals, or any
other deficiency is noted, immediately contact the authorized
ANSUL Distributor.
9. Keep a permanent record of each inspection.
S1013
SECTION VIII – MAINTENANCE
6-30-05 Page 8-1
REV. 3
Maintenance is a ”thorough check” of the system. It is intended to – Using a wooden dowel, push pin assembly and spring out
give maximum assurance that the system will operate effectively of the actuator body.
and safely. It includes a thorough examination and any necessary – Remove the gasket from inside the cartridge thread port.
repair or replacement. It will normally reveal if there is a need for Inspect, clean, apply a good grade of low temperature
hydrostatic testing of the tank. grease, such as Dow Corning No. 4, and reinstall the gas-
Maintenance shall be performed semi-annually or sooner, ket. Replace if necessary.
depending on operating and/or environmental conditions. The fire – Remove the O-Rings from the pin assembly and swivel
suppression system including alarms, shutdown and associated adaptor. Inspect, clean, apply a good grade of low temper-
equipment shall be thoroughly examined and checked for proper ature grease, such as Dow Corning No. 4, and reinstall the
operation by the fire protection manufacturer, authorized distribu- O-Rings. Replace if necessary.
tor or their designee in accordance with this manual.
– Apply a small amount of grease to the puncture pin shaft.
SEMI-ANNUAL MAINTENANCE There is a U-Cup guide inside the actuator body and when
the pin is reinstalled into the body, the grease on the shaft
To provide maximum assurance that your ANSUL A-101/LT-A-101 will lubricate the U-Cup.
system will operate effectively and safely:
– Clean the inner surface of the actuator body and, using a
1. Check to see that the hazard has not changed. small diameter wire, clean the vent hole. Make certain not
2. Remove all cartridges, install safety shipping caps, and put in to scratch the inner surface.
a safe place for future reinstalling. – To minimize the potential of moisture or dirt entering the
3. Note the general appearance of the system components actuator, apply a thin coat of a good grade of extreme
checking for mechanical damage or corrosion, and check that temperature silicone grease, such as Dow corning No. 4
the components are securely fastened and all hose fittings or equal, over the vent hole.
are tight. – Reinstall spring onto puncture pin shaft and insert into
4. Check nameplates to make certain they are clean, readable, actuator body. Push pin down several times to allow
and properly attached. grease to coat U-Cup. When positioned back in body,
5. Remove tank fill cap(s) and check that the agent tank is filled make certain the tip of the pin is above the gasket in the
to approximately 3 in. (76 mm) from the bottom of the fill bottom of the actuator.
opening with ANSUL FORAY dry chemical. Check the dry – Reinstall the actuator unto the cartridge. Hand tighten.
chemical for lumps.If lumps are present, drop one from a – Reinstall swivel adaptor in the correct position for the actu-
height of 4 in. (102 mm) onto a hard surface. If the lump does ation lines and wrench tighten the swivel nut. Make certain
not break up completely, the dry chemical must be replaced. all actuation and expellant lines are properly tightened into
6. Inspect threads on fill cap and on tank fill opening for nicks, the actuator.
burrs, or cross-threading. – Secure the assembly into the bracket.
7. Check fill cap gasket and quad ring for elasticity, cuts, or
checking, and lightly coat them with an extreme temperature SWIVEL NUT,
PART NO. 430210
silicone grease, such as Dow Corning No. 4 or equal.
8. Disconnect sealed bursting disc assembly.
9. Examine the disc to ensure that it is not wrinkled, kinked,
dented, or deformed in any way and then apply a thin coat of
O-RING #119, SWIVEL ADAPTOR,
a good grade of extreme temperature silicone grease, such PART NO. 24899 PART NO. 430209
as Dow Corning No. 4 or equal, to the male threads and
reconnect the sealed burst disc assembly. NOTE: Before SLAVE PISTON,
reconnecting, if needed, blow all lines clear with dry air or O-RING #210, PART NO. 56749
PART NO. 5151
nitrogen.
10. Check that the nozzle openings are not obstructed and that PUNCTURE PIN,
PART NO. 56104
the nozzles are properly aimed and have not rotated out of
position.
11. Make certain each nozzle has a blow-off cap (the opening of SPRING,
an F-1/2 nozzle can be packed with an extreme temperature PART NO. 56105
silicone grease, such as Dow Corning No. 4 or equal, to
avoid build-up of foreign material) and check that the caps
are pliable and free of cuts and checks. NOTE: Blow off caps BODY,
PART NO. 430215
must be replaced annually.
12. Unscrew the pneumatic actuator(s) from the cartridge receiv-
er(s) and inspect all threaded areas for nicks, burrs, and VENT HOLE
cross threads.
13. Clean actuator(s) (Part No. 430221) as follows: (see Figure1)
– Using two wrenches, one positioned on the swivel nut, and GASKET,
one positioned on the bottom portion of the actuator, PART NO. 181
loosen the swivel nut and remove the top portion of the
actuator. FIGURE 1
006195
S1013
SECTION VIII – MAINTENANCE
6-30-05 Page 8-2
REV. 2
SEMI-ANNUAL MAINTENANCE (Continued)

14. Weigh the gas cartridge which was removed earlier. It must
be +/– 1/2 oz. from the weight stamped on the cartridge.
Weigh cartridge with shipping cap removed.
15. Hand tighten the cartridge into the actuator.
16. Next, remove the gaskets from the manual remote actuators.
Examine them for elasticity, cuts, and checking and lubricate
them with a light coat of extreme temperature silicone grease,
such as Dow Corning No. 4 or equal.
17. Inspect the threaded areas for nicks, burrs, or cross threading
and clean them with a stiff bristle brush.
18. Make certain cartridge is removed. Pull the ring pin and oper-
ate the manual actuator to test the puncture lever for free
movement.
19. Next, remove the puncture pin by disassembling the actuator
and examine the pin to ensure it is sharp, straight, free of cor-
rosion.
20. Lubricate the puncture pin O-ring and reassemble the actua-
tor.
21. Insert ring pin and install visual seal, Part No. 197, to each
actuator stem.
22. Weigh each actuator cartridge. Weight must be +/– 1/4 oz.
from weight stamped on cartridge. Weight cartridge with ship-
ping cap removed.
23. Install cartridge into each remote actuator. Hand tighten.
24. Refer to appropriate manual for detailed maintenance instruc-
tions if the system contains an automatic CHECKFIRE
Detection System.
25. After all actuation devices are re-armed, record date of main-
tenance and inform personnel that the system is back in
operation.
12-YEAR MAINTENANCE EXAMINATION

At the 12-year maintenance examination, along with completing
the semi-annual maintenance requirements, some A-101 compo-
nents require hydrostatic testing.
The components requiring hydrostatic testing are:
– Tank – 600 psi (40.8 bar) hydro pressure.
– Actuation hose – 1000 psi (69 bar) hydro pressure
– Cartridges – After properly discharging cartridge, return to
ANSUL for hydrotesting
See appropriate hydrotest requirements in NFPA 17, “Standard
For Dry Chemical Extinguishing Systems,” and Ansul Technical
Bulletin No. 50, “Hydrostatic Retest Requirements for Ansul porta-
bles, Wheeled Units, and Pre-Engineered Vessels,” Form No.
F-81301.
S1013
SECTION IX – RECHARGE
6-30-05 Page 9-1
REV. 3
The first concern in Recharge is to determine the cause of the 6. Remove the tank fill cap, discard any remaining dry chemical,
system discharge and to have the problem corrected before re- and fill each tank to its rated capacity with ANSUL FORAY dry
arming the fire suppression system. chemical as specified on the nameplate.
In the event of system discharge, the vehicle must not be 7. Check inside of tank for any signs of corrosion. Check for any
returned to service until the system has been recharged. signs of moisture and/or chemical caking. Make certain gas
The system must be recharged immediately after use. A fire con- tube and rubber check are securely in place.
dition could cause damage to the hose and nozzles and possibly 8. Before securing the fill cap, brush the dry chemical from the
support members. Check all hose supports, hose, and all fitting threads on the fill cap and tank, and clean the gasket seating
connections. Take the nozzles off, inspect for damage, corrosion, surface on the tank opening. Coat the gasket lightly with a
or obstructions, clean and re-install, making certain they are good grade of extreme temperature silicone grease, such as
aimed correctly. Blow-off caps must also be replaced. Dow Corning No. 4 or equal.
See Figure 1 when following the recharge steps. 9. Secure the fill cap, hand tighten.
10. Loosen the bolts on the expellant gas cartridge bracket or
15 17 remove the cartridge guard on the tank.
2 11 18 11. Unscrew and remove the empty expellant gas cartridge.
15 17
12. Disassemble and clean the cartridge actuator by following the
instructions stated in Step No. 13, Section VIII –
Maintenance.
16
13. Install new cartridge per the following chart. Before installing,
1 16 weigh cartridge to determine if it is within specifications
8 7 stamped on the cartridge. Weigh cartridge with shipping cap
removed.
Type of System Cartridge Part No.
A-101-10 15850 (DOT) 423439 (TC/DOT)
LT-A-101-10 423429 (TC/DOT)
A-101-20 423441 (TC/DOT)
9 10 12 13 LT-A-101-20 423435 (TC/DOT)
6 LT-LP-A-101-20 423435 (TC/DOT)
A-101-30 423443 (TC/DOT)
LT-A-101-30 423491 (TC/DOT)
3 14. Re-install cartridge guard or retaining bolts on cartridge
bracket.
15. Return tank(s) to its bracket, reconnect sealed burst disc
assembly to distribution hose, and tighten securely.
16. Depending on the type of manual actuator, either pull up the
red button or pull up the puncture lever.
14 5 4 17. Remove spent cartridge. Weigh fully charged LT-10 cartridge.
Make certain cartridge is within +/– 1/4 oz. (7.1 g) from weight
stamped on cartridge. Install cartridge.
NOTICE
If automatic detection system was used, refer
to appropriate Installation, Recharge Manual for
detailed recharge instructions.
FIGURE 1 18. Insert ring pin in actuator stem and seal with visual seal, Part
003519
No. 197.
1. Pull ring on safety relief valve to relieve actuation pressure. 19. Reconnect actuation and, if necessary, expellant gas hose.
2. Disconnect actuation system hose at cartridge receiver/actu- Wrench tighten.
ation assembly. 20. Notify operating personnel that the suppression system is
3. Open sealed burst disc assembly. back in service and record date of recharge.
4. Remove dry chemical tank from its bracket.
5. Replace ruptured sealed burst disc assembly. Remove used
sealed disc assembly from tank outlet. Clean tank threads.
Apply a non-permanent thread sealant or Teflon tape to male
threads on new sealed burst disc assembly. Install to tank out-
let. Wrench tighten. NOTE: Before reconnecting, if needed,
blow all lines clear with dry air or nitrogen.
S1013
SECTION XI – APPENDIX
5-15-02 Page 11-2
REV. 2
SYSTEM COMPONENT INDEX (Continued) SYSTEM CARTRIDGES

15850 A-101-10 Cartridge (DOT)
SYSTEM TANKS
423439 A-101-10 Cartridge (TC/DOT)
24855 A-101-10 Includes: Charged Agent Tank with Cartridge
423441 A-101-20, LP-A-101-20-B Cartridge (TC/DOT)
423443 A-101-30 Cartridge (TC/DOT)
423429 LT-A-101-10 Cartridge (TC/DOT)
24966 LT-A-101-10 Includes: Charged Agent Tank with
Cartridge 423435 LT-A-101-20 and LT-LP-A-101-20-B Cartridge
(TC/DOT)
24894 LT-A-101-20 Includes: Charged Agent Tank without
Cartridge 423491 LT-A-101-30 Cartridge (TC/DOT)
29375 LT-A-101-30 Includes: Charged Agent Tank without 13193 LT-10-R Cartridge (DOT)
Cartridge 423423 LT-10-R Cartridge (TC/DOT)
24427 LP-A-101-20-B Includes: Charged Agent Tank without 13177 LT-10-L Cartridge (DOT)
Cartridge
423425 LT-10-L Cartridge (TC/DOT)
24425 LT-LP-A-101-20-B Includes: Charged Agent Tank
without Cartridge FOR SYSTEM COMPONENT INDEX FOR THE CHECKFIRE
AUTOMATIC DETECTION AND ACTUATION SYSTEMS, SEE
SYSTEM BRACKETS THE FOLLOWING INSTALLATION MANUALS:
24854 A-101-10, LT-A-101-10 Tank Mounting Bracket (1) • CHECKFIRE MP-N ELECTRIC SYSTEM – Manual Part No.
24971 A-101-20 Tank Mounting Bracket (1) 427310
14098 A-101-30 Tank Mounting Bracket (1) • CHECKFIRE SC-N ELECTRIC SYSTEM – Manual Part No.
423522
24910 A-101-30 Tank Mounting Bracket (1) (Extra Heavy)
• CHECKFIRE ELECTRIC SERIES I SYSTEM – Manual Part
24895 LT-A-101-20 Tank Mounting Bracket (1) No. 54894
30494 LT-A-101-30 Tank Mounting Bracket (1)
31171 LP-A-101-20-B, LT-LP-A-101-20-B Tank Mounting
Bracket (1)
31177 Cartridge Bracket Assembly for LP-A-101-20-B
24325 Cartridge Bracket Assembly for LT-A-101-20 or
LT-LP-A-101-20-B
29193 Cartridge Bracket Assembly for LT-A-101-30
RECHARGE EQUIPMENT AND MATERIAL

53080 FORAY Multi-Purpose Dry Chemical 45 lb. Pail
16511 Fill Cap Spanner Wrench (Low Profile)
428363 Bursting Disc Package (Includes: 15 Bursting Disc
Assemblies, Part No. 428271)
75382 Cartridge Scale and Hook Assembly (LT-A-101-30)
3923 Cartridge Scale and Hook Assembly
197 Lead Wire Seal
15496 Bursting Disc Union Assembly
24327 A-101 Installation, Recharge, Inspection and
Maintenance Manual
53081 Owner’s Manual
ITEM PART NUMBER DESCRIPTION QTY.
NO.
8 12 1 134167 PRESSURE SWITCH 1
10
404 2 332042 VENT, SAFETY 1
3 332043 TRIPLE TEE 1
NON-LINEAR DETECTION
INSTALLATION 4 334005 NOZZLE PKG, FIRE SUPPRESSION 4
5 334124 TANK & BRKT, AGENT LT-A-101-30 1
12 6 334125 CARTRIDGE & ACTUATOR KIT 1
4
409 7 334126 CHECK VALVE,1/4",FIRE SUPP 2
402 8 7334-00001 BRACKET, FIRE SUPPRESSION 2
NOTE: ITEM 7 SUPPLIED 9 7334-00004 MOUNTING BRACKET, FS TEE 1
403 405 W/ ACTUATOR KIT 10 7334-00006 FS NOZZLE MOUNT, 90 DEG 1
11 (#) NOZZLE MOUNT, A64 2
12 9334-00003 ACTUATOR, DASHBOARD 1(2)
13 9334-00004 DETECTION,SYS. AUTO SC-N 1(0)
AS
15 334010 SLEEVE, RUBBER REQ'D
16 334011 WIRE, LINEAR DETECTION 1(0)
2 17 464870 RESISTOR ASSY, DETECTION LOOP 1(0)
NOT
SHOWN - 334146 BATTERY, MODULE CHECKFIRE 1(0)
(#) ITEM 11 - P/N VARIES DUE TO ( )=QTY FOR
13 HOOD DIMENSION CENTER/CENTER: NON-LINEAR
46 3/8" - 7334-00014 DETECTION
52 3/4" - 7334-00002 SYSTEMS
61" - 7334-00012
408 5 45 1/2" - 7334-00029 (QTY 1)
3
HOSE# I.D. LENGTH ENDS ADAPTERS FROM TO
407 3/4" 125"(+) 94734 84GF1212
6 401 94875 94734 89GF1212 30# TANK TRIPLE TEE
1
1/2" 94725 - RIGHT ENG
402 48" TRIPLE TEE
94874 94733 89GF0808 NOZZLE
1/2" 94725 - LEFT ENG
403 110 TRIPLE TEE
94874 94733 89GF0808 NOZZLE
1/2" 94725 - REAR ENG
406 404 40" TRIPLE TEE
94874 94733 89GF0808 NOZZLE
1/2" 94725 - HYD PUMP
LEFT ENG NOZZLE 405 48" TRIPLE TEE
94874 94733 89GF0808 NOZZLE
7 1/4" 94751 89GF0404 MAIN
406 10" 30# TANK
RIGHT ENG NOZZLE REAR ENG NOZZLE NOTE: FOR TRUCKS W/ 3 ACTUATORS
94878 94731 89GF0404 ACTUATOR
11 (EX. SCISSOR BOOMS) SEE REAR FRAME 1/4" 94731 89GF0404 ACTUATOR CAB
9 407 94878 100" 94731 89GF0404 TEE ACTUATOR
INSTALLATION FOR CHECK VALVE LOCATIONS
1/4" 175"(+) 94731 89GF0404 ACTUATOR
408 BULKHEAD
94878 94731 45GK0404 TEE
1/4" 94731 45GK0404 BULKHEAD REAR
409 (*)
REAR FENDER 94878 94731 89GF0404 ACTUATOR(S)
401
HY D PUMP
NOZZLE (*) LENGTH VARIES DEPENDING ON WHEEL BASE
(+) ADD 10" FOR LONG FRAME (EX. FRAME W/ 6.7L CUMMINS)
(STANDARD SHOWN - FOR 3
ACTUATOR SYSTEMS SEE REAR
FRAME INSTALLATION PAGE)
ZIP-TIE TO NOTES:
SUCTION 1. THIS INSTALLATION IS TO BE MADE IN ACCORDANCE WITH THE
LINE LT-A-101-30 INSTALLATION MANUAL
2. ALL HOSES MUST MEET (AS A MINIMUM) SAE 100R5 OR 100R1
HOSE SPECIFICATIONS
3. FOR ALL UNDERGROUND MINING, ALL HOSES MUST COMPLY
WITH USBM SPECIFIED FLAME RESISTANCE ACCEPTANCE
DESIGNATION "MSHA 2G-11C"
4. FOR ALL HOSE FITTINGS USE ONLY STAINLESS STEEL OR PLATED
16 METAL. USE OF STREET ELBOWS IS NOT ACCEPTABLE
15
17
NO. DESCRIPTION CN# BY DATE
STD. TOLERANCES UNLESS OTHERWISE NOTED.

QTY FRACTIONS ±1/16" DEC. ±.010 ANGLES ±1°
MATERIAL
TITLE
CONFIDENTIAL NOTICE
THIS DRAWING IS THE PROPERTY OF GETMAN CORPORATION
FS LAYOUT,A64,30# 4N
WHICH RESERVES ALL RIGHTS IN THIS DRAWING ITS
SUBJECT MATTER AND THE INVENTIONS DISCLOSED
THEREIN. THIS DRAWING IS LOANED SUBJECT TO THE
AGREEMENT AND UNDERSTANDING THAT ITS SUBJECT
MATTER IS NOT TO BE DISCLOSED, IN WHOLE OR IN
PART, TO ANY OTHER PARTY, AND THAT IT SHALL NOT
BE COPIED IN ANY MANNER WITHOUT THE EXPRESS DRAWN DATE SCALE SIZE DRW. NO.
PERMISSION OF GETMAN CORPORATION. ACCEPTANCE
OF THIS COPY WILL BE CONSTRUED AS AN ACCEPTANCE
OF THE FOREGOING CONDITION.
BL 10/19/2009 1:8 D 7334-00015
(PARTS IN ADDITION TO THOSE SHOWN ON MAIN LAYOUT)
ITEM NO. PART NUMBER DESCRIPTION QTY.
NOTE: ACTUATORS NOT TO BE
1 9334-00003 ACTUATOR, DASHBOARD 1 INSTALLED IN JOINT AREA
2 16070-01 BULKHEAD WELDMENT, 1/4" 1
3* 334126 CHECK VALVE,1/4",FIRE SUPP 1
*NOTE: ITEM 3 SUPPLIED W/ ACTUATOR KIT NOTE: FOR STAINLESS STEEL OPTION, BOTH LOCATED IN
REAR FRAME ACTUATORS AND CHECK BASKET/PLATFORM
VALVES WILL BE REPLACED BY:
9334-00009 - CHECK VALVE,1/4", SS
9334-00010 - ACTUATOR, DASHBOARD, SS 1
9334-00012 - S-BRACKET, ACTUATOR
9334-00013 - CARTRIDGE, ACTUATOR
A
TO
AC
TO TU
BU AT
LK OR
HE
AD IN C
AB
TANK & BOTTLE FROM ENGINE END FRAME
REF DWG 7334-00015
DETAIL A
SCALE 1 : 2
2

FRACTIONS ±1/16" DEC. ±.010 ANGLES ±1°
3 QTY
MATERIAL
TITLE
CONFIDENTIAL NOTICE
FS LAYOUT,A64,BSKT/PLTFRM OPT.
BL 1/21/2010 NONE C 7334-00025
ITEM NO. PART NUMBER DESCRIPTION QTY.
3 1 11049-02 TEE WELDMENT,3/4" 1

401 2
4 2 334058 FIRE SUPP SYS,20#,LOW PROFILE 1
402 5 3 7334-00001 BRACKET, FIRE SUPPRESSION 2
8 4 9334-00005 FILL CAP ASSEMBLY, SS 1

5 9334-00006 NOZZLE, V-1/2, SS 2
6
ATTACH TEE TO
COMPRESSOR 6 9334-00007 VENT, SAFETY VALVE RELIEF, SS 1
404 MOUNT PLATE
1 403 7 9334-00008 BURST DISC ASSEMBLY, SS 1
8 9334-00011 ACTUATOR ASSY, PNEUMATIC, SS 1
7
HOSE# I.D. LENGTH ENDS ADAPTERS FROM TO
3/4" 94734 89GF1212 20# TANK
401 * DIST TEE
94875 94734 89GF1212
405
1/2" 94733 89GF1208 DIST TEE REAR COMP
402 30"
94874 94733 89GF0808 NOZZLE
1/2" 94733 89GF1208 DIST TEE FRONT COMP
403 45"
94874 94733 89GF0808 NOZZLE
1/4" 94751 89GF0404 20# TANK MAIN
404 *
94878 94731 89GF0404 ACTUATOR
NOTE: CUT HOLE IN 1/4" 94731 89GF0404 MAIN
405 * 89GF0404 ACTUATOR RR FRAME TEE
VENTED SIDE COVER
TO ROUTE 3/4" HOSE 94878 94731
16070-03 REF
TEE WELDMENT * - HOSE LENGTH VARIES DUE TO DIFFERENT
9334-00009 REF REAR FRAME CONFIGURATIONS
SS CHECK VALVE
TO BULKHEAD
(REFERENCE DRAWING
7334-00025
BASKET/PLATFORM
OPTION)
TO REMOTE
ACTUATORS

FRACTIONS ±1/16" DEC. ±.010 ANGLES ±1°
QTY
MATERIAL
TITLE
CONFIDENTIAL NOTICE
FS LAYOUT, AIR COMP, 2 NOZ, SS

BL 5/19/2010 1:8 C 7334-00024
17344
FIRE SUPPRESSION SYSTEMS
Page 1 of 10

06/03/10
17344
Page 2 of 10

334058 FIRE SUPPRESSION 20 LBS SYSTEM LOW PROFILE 1
(IF EQUIPPED W/STAINLESS STEEL OPTION, NO KIT
AVAILABLE, MUST BUY COMPONENTS SEPARATELY
1 334058-01 TANK ASSEMBLY 1
2 334057 BURSTING DISC ASSEMBLY (INCLUDES ITEMS 3-5) 1
9334-00008 BURSTING DISC ASSEMBLY, SS (AVAIL KIT ONLY) 1
3 334058-02 UNION RING & TAIL PIECE (EXCLUDES SS) 1
4 334058-03 BURSTING DISC (EXCLUDES SS) 1
5 334058-04 ADAPTER 1
6 334118 FILL CAP ASSEMBLY (INCLUDES ITEMS 7-8) 1
9334-00005 FILL CAP ASSEMBLY, SS (AVAIL ONLY AS KIT) 1
7 334058-05 QUAD RING (EXCLUDES SS) 1
8 334058-06 GASKET (EXCLUDES SS) 1
9 NSS NAME PLATE 1
10 334117 ADAPTER 1
11 334120 PNEUMATIC ACTUATOR ASSEMBLY 1
9334-00011 PNEUMATIC ACTUATOR ASSEMBLY, SS 1
(AVAIL ONLY AS KIT)
12 334058-07 ACTUATOR BODY (EXCLUDES SS) 1
13 334058-08 PISTON (EXCLUDES SS) 1
14 334058-09 O-RING (EXCLUDES SS) 2
15 334058-10 PUNCTURE PIN (EXCLUDES SS) 1
16 334058-11 SPRING (EXCLUDES SS) 1
17 334058-12 BODY ADAPTOR (EXCLUDES SS) 1
18 334058-13 PIN GUIDE (EXCLUDES SS) 1
19 334058-14 U-CUP (EXCLUDES SS) 1
20 334058-15 RETAINING RING (EXCLUDES SS) 1
21 334058-16 GASKET (EXCLUDES SS) 1
22 334115 CARTRIDGE ASSEMBLY 1
25 334058-17 CARTRIDGE BRACKET ASSEMBLY 1
26 334058-18 FRAME ASSEMBLY 1
27 334058-19 CLAMP BAND 1

06/03/10
17344
Page 3 of 10

28 334058-20 CAPSCREW 4
29 334058-21 LOCK NUT 4
30 332042 SAFETY RELIEF VALVE 1
9334-00007 SAFETY RELIEF VALVE, SS 1
31 334126 CHECK VALVE ¼” 1
9334-00009 CHECK VALVE ¼”, SS 1
50 334116 BRACKET ASSEMBLY (INCLUDES ITEMS 51-55) 1
51 334058-22 FRAME ASSEMBLY 1
52 334058-23 CLAMP BAND 1
53 334058-24 BOLT 2
54 334058-25 WASHER 2
55 334058-26 LOCK NUT 2

06/03/10
17344
Page 4 of 10
NOTE: FOR ITEM 38

(CARTRIDGE & ACTUATOR ASSEMBLY KIT)
USED IN BOTH 30 & 50LBS SYSTEMS

06/03/10
17344
Page 5 of 10

334124 FIRE SUPPRESSION 30 LBS SYSTEM 1
1 324014 BRACKET ASSEMBLY (INCLUDES ITEMS 2-9) 1
2 334124-01 CLAMP ARM PAD 1
3 334124-02 BOLT 2
4 334058-25 WASHER 2
5 334058-26 LOCK NUT 2
6 334124-03 BUMPER PAD 1
7 334124-04 BASE PAD 1
8 334058-23 CLAMP BAND 1
9 334124-05 CLAMP BAND PAD 1
10 334118 FILL CAP ASSEMBLY (INCLUDES ITEMS 11-12) 1
11 334058-05 QUAD RING 1
12 334058-06 GASKET 1
13 NSS NAMEPLATE 1
14 334117 ADAPTER 1
15 334057 BURSTING DISC UNION ASSEMBLY (INCLUDES ITEM 1
16)
16 334058-02 UNION RING & TAIL PIECE 1
18 334119 CARTRIDGE BRACKET ASSEMBLY 1
19 334124-06 CARRIAGE BOLT 2
20 334124-07 LOCK NUT 2
21 334124-08 CLAMP ARM 1
22 334124-09 CLAMP ARM PAD 1
23 334123 CARTRIDGE ASSEMBLY 1
25 334124-10 PNEUMATIC ACTUATOR ASSEMBLY 1
26 334124-11 SWIVEL NUT 1
27 334124-12 SWIVEL ADAPTOR 1
28 334124-13 SWIVEL ADAPTOR O-RING 1
29 334124-14 PNEUMATIC PISTON 1
30 334124-15 PUNCTURE PIN 1

06/03/10
17344
Page 6 of 10

31 334124-16 PNEUMATIC PISTON O-RING 1
32 334124-17 COMPRESSION SPRING 1
33 334124-18 BODY 1
34 334124-19 BODY U-CUP 1
35 334124-20 BODY GUIDE 1
36 334124-21 BODY RETAINING RING 1
37 334124-22 BODY GASKET 1
38 334125 CARTRIDGE & ACTUATOR KIT 1
(INCLUDES ITEMS 18-23, 25-37)

06/03/10
17344
Page 7 of 10

06/03/10
17344
Page 8 of 10

---------- FIRE SUPPRESSION 50 LBS SYSTEM
1 9334-00001-001 TANK ASSEMBLY 1
2 334118 FILL CAP ASSEMBLY W/ GASKET & QUAD RING 1
* 334058-05 QUAD RING 1
* 334058-06 GASKET 1
3 9334-00001-002 GAS TUBE ADAPTOR 1
4 9334-00001-003 1” (2.54cm) PIPE PLUG 1
5 9334-00001-004 ORIFICE UNION-HALF 1
6 9334-00001-005 BURST DISC ASSEMBLY 1
7 9334-00001-006 BACK BRACKET FRAME 1
8 9334-00001-007 STRAP – SHORT 1
9 9334-00001-008 STRAP – LONG 1
10 9334-00001-009 10” (25.4cm) NEOPRENE PADDING 1
11 9334-00001-010 12” (30.5cm) NEOPRENE PADDING 1
12 9334-00001-011 3¼” (8.3cm) NEOPRENE PADDING 1
13 9334-00001-012 HEX CAPSCREW 1
14 9334-00001-013 FLAT WASHER 1
15 9334-00001-014 LOCKNUT 1
16 9334-00001-015 BRACKET ASSEMBLY (INCLUDES ITEMS 7-15) 1
17 9334-00001 TANK AND BRACKET ASSEMBLY 1
NOTE: SEE PAGE 4, ITEM 38 FOR CARTRIDGE & ACTUATOR KIT, USED ON BOTH 30 & 50 LBS
SYSTEMS

06/03/10
17344
Page 9 of 10

06/03/10
17344
Page 10 of 10

332044 DASHBOARD ACTUATOR & CARTRIDGE ASSEMBLY 1
KIT (LEFT HAND THREAD)
9334-00003 DASHBOARD ACTUATOR & CARTRIDGE ASSEMBLY 1
KIT (RIGHT HAND THREAD)
1 9334-00003-001 KNOB 1
2 9334-00003-002 BOOT 1
3 9334-00003-003 JAM NUT 1
4 332044-01 ACTUATOR BODY (LEFT HAND THREADS) 1
9334-00003-008 ACTUATOR BODY (RIGHT HAND THREADS) 1
9334-00010 ACTUATOR BODY, SS (RIGHT HANDED THREADS) 1
(NOTE: 9334-00010 INCLUDES ITEMS: 1-5, 9-11)
5 334125-13 GASKET 1
6 9334-00003-009 PUNCTURE PIN ASSEMBLY 1
7 9334-00003-010 O-RING 1
8 9334-00003-004 LEAD-WIRE SEAL 1
9 9334-00003-005 RING PIN 1
10 9334-00003-006 CHAIN 1
11 9334-00003-007 DRIVE SCREW 1
16 9334-00012 BRACKET (S-SHAPED) 1
18 334013 CARTRIDGE (LEFT HANDED) 1
9334-00013 CARTRIDGE (RIGHT HANDED) 1

06/03/10
13597
BASKET DOOR INSTALLATION
Page 1 of 1

1 102080 KNOB 1
2 19217-173 ROD 1
3 68GD06 NUT (NYLOCK) 2
4 27GE12 WASHER (FLAT) 1
5 11075-02 BRACKET (LATCH) 1
6 284160 SPRING 2
7 11075-03 ROD (LATCH) 1
8 20085-01 DOOR 1
9 605443 HINGE (DOOR) 1
Updated:
12/18/06
S1026
17069
BOOM INSTALLATION
Page 1 of 3
Updated:
05/25/10
17069
BOOM INSTALLATION
Page 2 of 3

465130 BOOM ASSEMBLY A/R
(USES HARNESS P/N 35511-01)
465555 BOOM ASSEMBLY A/R
(USES HARNESS P/N 35511-107
DEDICATED CONDUCTOR)
1 27158-03 PIN (LEVELING CYLINDER) 2
2 SEE CYL. PAGE CYLINDER (LEVELING) 1
3 SEE TURRET PAGE TURRET 1
4 19204-78 PIN (LIFT CYLINDER) 1
5 464698 BUSHING (TURRET) 2
6 01GC06016 BOLT 8
7 17GC08024 BOLT 20
8 27587-01 COVER 1
9 22893-03 KEEPER 1
10 12850-01 OUTER BOOM 1
11 465134 LIFT CYLINDER 1
12 27158-01 PIN (TURRET) 1
13 10817-04 PIN (EXTENSION CYLINDER) 1
14 27722-01 TRUNNION 2
15 73GC12016 ALLEN HEAD 2
16 22893-03 PIN RETAINER 2
17 09GG06016 ALLEN HEAD (FLAT) 24
17GD06 NUT 24
18 SEE CYL. PAGE EXTENSION CYLINDER ASSEMBLY 1
19 19204-90 PIN (LIFT CYLINDER) 1
20 19204-91 PIN (SLIDE PAD) 1
21 16408 WEAR PAD 8
14594-03 SHIM A/R
22 27269-01 SLIDE PAD 1
23 16406 WEAR PAD 8
14594-02 SHIM A/R
24 25644-01 PAD ASSEMBLY 4
25 27519-01 MIDDLE BOOM 1
26 12799-01 INNER BOOM 1
Updated:
05/25/10
17069
BOOM INSTALLATION
Page 3 of 3

27 09GG06024 ALLEN HEAD (FLAT) 8
17GD06 NUT 8
28 19204-92 PIN (SLIDE PAD) 1
29 19204-99 PIN (LEVELING CYLINDER) 1
30 10817-03 PIN (EXTENSION CYLINDER) 1
31 10898-01 PIN (BASKET) (REF.) 1
32 464696 BUSHING 2
33 22891-01 ROTATOR 1
34 17GC08040 BOLT 3
35 22893-03 WASHER 3
36 SEE CYL. PAGE BASKET CYLINDER (LEVELING) 1
37 10898-01 PIN (LEVELING) 3
38 14488-01 LEVELING LINK 1
39 14488-02 LEVELING LINK 1
40 SEE COMPONENT BASKET 1
PAGE
41 25645-01 SLIDE PAD 1
42 464019 WEAR PAD 1
25672-01 SHIM A/R
43 605583 LIP SEAL 2
Updated:
05/25/10
16572
TURRET INSTALLATION
Page 1 of 2

12/19/06
16572
TURRET INSTALLATION
Page 2 of 2

1 01GC06016 CAP SCREW 4
2 534214 ORBIT MOTOR 1
3 594869 ROTATION GEAR BOX 1
4 10GH02 GREASE ZERK 2
5 27965-01 TURRET ASSEMBLY 1
6 18GC12040 HHCS 23
7 27GE12 WASHER 23
8 594868 ROTATION GEAR & BEARING ASSEMBLY 1
9 27GE12 WASHER 18
10 18GC12064 HHCS 18
11 17GC12052 HHCS 4
12 02GE12 WASHER 4
13 17GD12 NUT 4
16 594134 O-RING 1
17 16535-07 BUSHING 2
18* 25284-12 ORIFICE, BOOM ROTATION MOTOR 2
19* 15GH02 GREASE ZERK 1

12/19/06
ROTATION GEAR BOX PARTS
16256
BREAKDOWN &
ASSEMBLY PROCEDURE Page 1 of 4

05/05/09
16256
BREAKDOWN &

594869 GEAR BOX ASSEMBLY 1
1 604205 GASKET (1/64) 1
2 604206 GASKET (1/32 HVF) 2
3 604994 GASKET (1/32 MTR) 1
4 604348 SEAL 1
6 604935 CAPSCREW 10
7 604996 BEARING CONTAINER 1
8 604354 BEARING CUP 2
9 604353 BEARING CONE 2
10 604999 WORM 1
11 605011 PLUG 1
12 604995 BEARING RETAINER 1
13 604931 PLUG, VENT 1
14 605103 PLUG 2
15 605012 ZERK 1
16 605007 BUSHING BRONZE 1
17 605000 COVER 1
18 604252 O-RING 1
19 605003 LOCKNUT 1
20 605016 CAPSCREW 1
21 605014 KEY 2
22 604998 WORM GEAR 1
23 604997 HOUSING 1
24 605005 BEARING CONE 2
25 605006 BEARING CUP 2
26 605009 O-RING 1
27 605008 SEAL 1
28 605001 SPACER 1
29 605002 OUTPUT SHAFT 1

05/05/09
16256
BREAKDOWN &
30* 605010 PLUG 1
31* 605015 CAPSCREW 4
ASSEMBLY PROCEDURE
1. Press two bearing cones (Item #9) onto worm (Item #10).
2. Press two bearing cups (Item #25) into housing (Item #23).
3. Press bushing (Item #16) into cover (Item#17).
4. With housing (Item #23) large opening down, install bearing cone (Item #24).
5. Install seal (Item #27) into housing).

NOTE: Install seal with loctite sealant on outer diameter of seal; lubricate seal with loctite anti-seize
lubricant.
6. Install o-ring (Item #26) onto output shaft into groove.

NOTE: If worm, output shaft (Item #29), spacer (Item #28), and o-ring (Item #26) are to be purchased pre-
assembled.
7. Press output shaft (Item #29) into housing (Item #23).
8. Turn housing over; install bearing cone (Item #24). PRESS COMPLETELY ONTO SHAFT.
9. Install two keys (Item #21) into output shaft.
10. Lay worm (Item #10) with bearing cones installed into housing.
NOTE: Do not install bearing cups (Item #8) at this time.
11. Press worm gear (Item #22) onto output shaft with gear hub facing up.
CAUTION
When pressing worm gear onto shaft, position worm so not to damage bronze worm gear.
12. After pressing gear, tap gear box with hammer to loosen bearings.
13. Install nut (Item #19). Torque to approximately 5 FT. LBS. to set load on bearings.
14. Install bolt (Item #20); torque to 15 FT. LBS.
15. Install o-ring (Item #18) onto cover (Item #17).

05/05/09
16256
BREAKDOWN &
PROCEDURE (CONTINUED)
16. Install cover to housing using six bolts and lockwashers (Item #’s 6, and 5); torque cover bolts to 58 FT.
LBS.
17. Install two bearing cups (Item #8) onto housing.
18. Install bearing retainer (Item #12) using one 1/32 gasket (Item #2) and one 1/64 gasket (Item #1).
19. Install four bolts (Item # 31) and fasten bearing retainer to housing. Torque bolts to 58 FT. LBS.
20. Install seal (Item #4) into bearing container (Item #7).
NOTE: Install seal with loctite sealant on outer diameter of seal; lubricate seal with loctite anti-seize
lubricate.
21. Install bearing container with seal in place 1/64 and 1/32 gaskets (Item #’s 1 and 2) required to remove
end play, but allow worm to rotate freely by hand.
22. Torque four bolts and lockwashers (Item # 6 and 5) used to fasten bearing container (Item #7) to housing
to 58 FT. LBS.
23. Install plugs, vents, and zerks (Item #’s 13, 15, and 14).
24. Lubrication:
A. Fill with 80W90 worm gear oil (3 quarts) or until oil runs out of fill and level hole. Install fill and level
plug (Item #30).
B. Grease bearings thru zerk (Item #15) located under pinion gear in housing.

05/05/09
BOOM ROTATION GEAR M1005
Boom Rotation Gear and Bearing Assembly

Removal and Installation Instructions
(Reference Gear Box parts page in Section 10 of Service Manual)
Removal:
1. Secure articulation safety lock bar and block wheels.
2. Properly support boom with over head lifting device. (The boom and turret assembly can be removed
together as a single unit. Care must be taken to properly support the boom from both ends in order to lift
the boom straight up from the chassis.
3. Disconnect all hoses and wiring running from the chassis to the boom.
4. Remove the ¾” capscrews, items #6 and flat washer item #7, from the turret and rotation gear and
bearing assembly.
5. Lift the boom and turret assembly from the rotation gear and bearing.
6. Remove the ¾” capscrews, item #10 and flat washer item #9, from the bottom side of the rotation gear
and bearing mounting plate.
7. Lift the rotation gear and bearing assembly from the mounting plate.
Updated:
05/03/07
Installation:
1. Remove all paint, grease or dirt from all mating surfaces.
2. Place the rotation gear and bearing assembly on to the chassis mounting plate. Install the ¾” capscrews,
item #10, with the hardened flat washer, item #9, using a medium strength lock tight on the bolt threads.
Note: When installation the rotation gear and bearing it’s recommended to only use new grade 8
capscrews. Do not reuse old capscrews.
3. Tighten capscrews using an alternating sequence.
Example:
1
6 11
10 7
4 3
8 9
12 5
2
First torque capscrews to 100 LB/FT. (135.6 Nm)

Final torque capscrews to 300 LB/FT. (406.7 Nm)
4. Inspect the o-ring seal, item #16, located in the groove at the bottom edge of the turret base, item #5. Be
sure it’s free of cuts and wear. Replace if necessary.
5. Thoroughly grease the o-ring and outer surface of the rotation gear and bearing mounting plate to ease
installation of the turret assembly onto the mounting plate.
6. Lower the boom and turret assembly down onto the rotation gear and bearing assembly.
7. Install the ¾” capscrews, item #6, with hardened flat washer, item #7, into the turret and rotation gear
and bearing assemblies. Use a medium strength lock tight on bolt threads.
8. Tighten capscrews using a similar alternating sequence as described in #3. Again first torque all
capscrews to 100 LB/FT. (135.6 Nm) Then final torque to 300 LB/FT. (406.7 Nm)
9. Reconnect all hoses and wiring taking care to route them the same as prior to removal.
Updated:
05/03/07
INSTALLATION AND CARE OF ROTATION BEARINGS
1. To insure the best possible performance of Rotation Bearings, we recommend the following procedures:
A. Machined, flat, rigid mounting surfaces must be provided to minimize localized internal loading
which will reduce bearing life.
B. Bearings have been mounted on unmachined surfaces by means of shimming. Gear Products,
Inc. recommends that all mounting structures to be machined. However, if shimming is used,
first remove noticeable high spots of other convex material by hand grinding. After placing
bearing on mounting surface install shims to reduce clearance on approximately .003”.
C. When bolts are used to fasten the bearing to the mounting surfaces, use SAE Grade 8 bolts. Bolts
should mount freely into holes. Bolts should be torqued to 70% of yield strength. Hardened steel
flat washers should be used under bolt heads or nuts to assure uniform bolt tension.
D. If Allen head bolts are used then a nut must be used on the opposite end because of the inability
to torque sufficiently this type of bolt into a threaded hole.
E. On all Gear Products rotation bearings the balls are plug loaded. It is preferred at installation of
the bearing on the crane that the plug be located 90 degrees from the direction of maximum
moment. This insures that the plug area will be as lightly loaded as possible.
Updated:
05/03/07
2. After installation the following suggestion will assure longer life and service:
A. Bolts should be checked periodically and retightened to proper torque. The possibility exists that
due to the stresses applied to the rotation system, the bolts could work loose.
B. Regular periodic lubrication is the most effective way to increase the life and serviceability of
rotation bearings. Most large diameter bearings are used out-of-doors and under conditions likely
to produce internal condensation. Also, when bearings are heavily loaded, extreme lubrication is
helpful.
Below are several lubricants which are acceptable for both rust inhibiting and extreme pressure
characteristics. There are several others on the market that may also be used.
i. Lubricate the bearing daily if the unit is used daily.

ii. Lubricate the bearing every 30 days if it is used intermittently.
iii. Rotate the bearing through two or more rotations during the lubrication process.
C. Gear – The chart below shows several lubricants for the gear. It is recommended that the teeth be
lubricated with a small amount of grease every 8 hours if the unit is used daily. The grease is
purged from the teeth by the very nature of this type gear drive being exposed to the elements;
therefore, close attention to the gear lubricant will provide a longer tooth life. Grease the gear at
the location of the pinion.
D. If the bearing has been stored for a long period of time before installation, it should be lubricated
before installation.
MOBILE TEXACO SUNOCO PURE SOHIO
RACE Mobilplex EP Marfak MP #2 Prestige 742EP Poco Ht EP #2 Sohitran EP #1

#2
GEAR Mobilcote-S Crater 407 Compound Poco Gearshield Sohitac #1
Compound B
Updated:
05/03/07
17194
ANFO POT
Page 1 of 2

* 464874 ANFO POT 636Lbs. (288.5KG) 100psi A/R
* 9126-0002 ANFO POT 2600Lbs. (1179KG) 128psi A/R
1 595366 FUNNEL WELDMENT BOLT SET 1
2 595267 ANFO POT LID 1
3 595268 ANFO POT WELDMENT (OLD P/N WAS 525268) 1
*PARTS ARE NOT INTERCHANGEABLE, BUT FIT/ FUNCTION ARE THE SAME Updated:
06/03/10
17194
ANFO POT
Page 2 of 2

4 595240 ANFO POT SCREEN 1
5 595463 CLOSURE INSTALLATION BOLT SET (100psi) 1
595464 CLOSURE INSTALLATION BOLT SET (125 & 128psi) 1
(NOTE: 12 PER SET)
6 595365 FUNNEL/ POT GASKET 1
7 595228 CAP (PNEUMATIC CLOSURE) (100psi) 1
CAP (PNEUMATIC CLOSURE) (125 & 128psi) 1
8 595465 CLOSURE CAP BOLT (100psi) 1
595466 CLOSURE CAP BOLT (125 & 128psi) 1
9 CALL COMPLETE CLOSURE ASSEMBLY 1
(LENGTHS VERY PER POT SIZE, CALL WITH POT P/N
FOR CORRECT ASSEMBLY)
10 595467 BOLT ASSEMBLY 1
11 604240 DISCHARGE O-RING 1
12 604295 DISCHARGE HOUSING 1
*PARTS ARE NOT INTERCHANGEABLE, BUT FIT/ FUNCTION ARE THE SAME Updated:
06/03/10
13712
ACTUATOR
Page 1 of 2

465162 ACTUATOR ASSEMBLY 1
465162-71 SEAL KIT 1
1 465162-01 OCTI-CAM (STOP ARRANGEMENT) 1
2 465162-02 STOP CAP SCREW 2
3 465162-03 WASHER (STOP CAP SCREW) 2
4 465162-04 NUT (STOP CAP SCREW) 2
5 465162-05 BEARING (PISTON BACK) 2
6 465162-06 BEARING (PINION TOP) 1
Updated:
04/19/07
13712
ACTUATOR
Page 2 of 2
7 465162-07 BEARING (PINION BOTTOM) 1
8 465162-08 THRUST BEARING (PINION) 2
9 465162-09 PLUG (TRANSFER PORT) 2
10 465162-10 THRUST WASHER (PINION) 1
11 465162-11 O-RING (STOP CAP SCREW SEAL) 2
12 465162-12 PISTON GUIDE 2
13 465162-13 CAP SCREW (END CAP) 8
(FOR MODELS VPVL-050 THROUGH 600)
465162-13 CAP SCREW (END CAP) 12
(FOR MODELS VPVL-700 THROUGH 800)
14 465162-14 O-RING (END CAP) 2
15 465162-15 BEARING (PISTON HEAD) 2
16 465162-16 O-RING (PISTON) 2
17 465162-17 SPRING (CARTRIDGE) 4-12
18 465162-18 SPRING CLIP (PINION) 1
19 465162-19 POSITION INDICATOR 1
20 465162-20 O-RING (PINION BOTTOM) 1
21 465162-21 O-RING (PINION TOP) 1
30 465162-30 RIGHT END CAP 1
31 465162-31 LEFT END CAP 1
39 465162-39 CAP SCREW (INDICATOR) 1
40 465162-40 PISTONS 2
41 465162-41 ACTUATOR IDENTIFICATION LABEL 1
42 465162-42 END CAP LABEL 2
50 465162-50 BODY 1
60 465162-60 DRIVE SHAFT 1
Updated:
04/19/07
S1027
IMO - 528EN Issue Date: 5/04
INSTALLATION, MAINTENANCE, AND

OPERATING INSTRUCTIONS
VALV-POWR® VPVL
MOD C VALUE-LINE®
DOUBLE-OPPOSED
PISTON ACTUATORS
Read entire instructions carefully before installation or servicing
TABLE OF CONTENTS
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.1 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
4.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
4.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
5 SAFETY LOCKOUT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
6 ACTUATOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
7 REPAIR KITS/SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
8 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
S1027
2
1 GENERAL
6. OPERATING THE ACTUATOR OVER TEMPERATURE LIMITS MAY
This instruction manual contains important information DAMAGE INTERNAL AND EXTERNAL COMPONENTS (DISASSEMBLY
regarding the installation, operation, and troubleshooting OF SPRING RETURN ACTUATORS MAY BE DANGEROUS).
of the Jamesbury® Valv-Powr VPVL Mod C Value-Line
7. OPERATING OVER PRESSURE LIMITS MAY RESULT IN PREMATURE
Double-Opposed Piston Actuators. Please read these
FAILURE AS WELL AS DAMAGE TO THE HOUSING.
instructions carefully and save them for further reference.
1.1 WARNING 2 TECHNICAL DATA

1. KEEP HANDS AND CLOTHING AWAY FROM THE VALVE PORTS 1. Operating Media: Dry or lubricated air, non-corrosive
AND ACTUATOR PINION AT ALL TIMES. and inert gas, or light hydraulic oil.
2. DO NOT ATTEMPT TO DISASSEMBLE INDIVIDUAL SPRING
2. Air Supply: 116 psi (8 bar) Maximum.
CARTRIDGES. DISASSEMBLY OF THE CARTRIDGE MAY RESULT IN
SERIOUS PERSONAL INJURY. IF MAINTENANCE OF THE CARTRIDGE
IS NECESSARY, IT MUST BE RETURNED TO METSO AUTOMATION. 3. Temperature:
3. SHUT OFF AND BLEED ALL SUPPLY LINES BEFORE INSTALLATION Standard – NBR; -4˚ to 175˚F (-20˚ to 80˚C)
OR SERVICING. DO NOT REMOVE END CAPS WHILE THE ACTUATOR
IS PRESSURIZED. HT – Viton O-rings: -4˚ to 300˚F (-20˚ to 150˚C)
4. BEFORE INSTALLING THE VALVE AND ACTUATOR, BE SURE THAT LT – Silicon O-rings: -40˚ to 175˚F (-40˚ to 80˚C)
THE INDICATOR ON TOP OF THE ACTUATOR CORRECTLY SHOWS
THE VALVE POSITION. FAILURE TO ASSEMBLE THESE PRODUCTS LX – Silicon O-rings + Low Temp. Grease:
TO INDICATE THE CORRECT VALVE POSITION COULD RESULT IN -60˚ to 175˚F (-50˚ to 80˚C)
PERSONAL INJURY.
4. Lubrication: Factory lubricated for the life of the
5. AN ACTUATOR MUST BE SIZED ACCURATELY FOR PROPER actuator under normal operating conditions.
OPERATION. REFER TO INFORMATION ON ACTUATOR OUTPUT
TORQUES IN THIS BULLETIN AND VALVE TORQUE REQUIREMENTS
5. Construction: Suitable for indoor and outdoor use.
IN THE APPROPRIATE VALVE BULLETIN.
6. External Travel Stops: ±4 degree adjustment on 90

degree stroke.
Double-Acting (Top View)
Port 2 Port 4 Port 2 Port 4
Air supplied to Port 2 forces pistons apart and toward end posi- Air supplied to Port 4 forces pistons toward center with exhaust
tions with exhaust air exiting at Port 4 (a counterclockwise rota- air exiting at Port 2 (a clockwise rotation is obtained).
tion is obtained).
Figure 1
Spring-Return (Top View) Spring-to-Close
Port 2 Port 4 Port 2 Port 4
Air supplied to Port 2 forces pistons apart and toward end posi- Loss of air pressure allows springs to force pistons toward center
tion, compressing springs. Exhaust air exits at Port 4 (a counter- position with exhaust air exiting at Port 2 (a clockwise rotation is
clockwise rotation is obtained). obtained).
Figure 2
S1027
3
3 INSTALLATION 4.2 Disassembly

3.1 General When disassembly of the actuator is required for maintenance,
remove the actuator from the valve. Ensure proper lifting
1. Check to see that the desired failure mode is correct procedures are followed when moving or carrying actuators.
(Figures 1 & 2).In the spring-to-close mode,the actuator (Table 4) lists the approximate weights of the VPVL actuators
will cycle clockwise to close upon loss of pressure. If the and provides outline dimensions for the double acting and
spring-return actuator is not set up in the configuration spring return actuators. CAUTION: Do not use the M5
desired, follow the disassembly procedure section 4.2. VDE/ VDI mounting holes or the M6 hole in the pinion
Reverse the orientation of the pistons, then reassemble for lifting the actuator.
following the assembly procedure, section 4.3.
When disassembling VPVL actuators, use caution and be
2. Mount the actuator to the valve, following the direction certain that the actuator is free from accessories and the
in the linkage AMI or valve IMO. air supply is disconnected. When the actuator is a spring-
return unit, make sure that the actuator is in the failed
3. Connect a regulated air supply to the NPT fitting in the position before disassembling.
actuator housing. CAUTION: The maximum operat-
ing pressure is 116 psi (8 bar). 1. Removal of Position Indicator (19,20), (Figure 3):
4. Adjust the stop screws following ASSEMBLY Section

4.3.5. Stops can be adjusted by up to ±4 degrees.
3.2 Operation
19 39
1. The actuator series, size, operating pressure, output
torque,spring directions,and drive type is determined by
the actuator designation.
2. The label lists the actuator series, size, operating pres-

sure, maximum pressure, and serial number. Actuator
designation example, VPVL300 SR6 B F07-N-L-19, is a
spring-return series, VPVL300 double-opposed piston
actuator that has 80-psi (5.5-bar) springs, a Teflon® -
coated anodized housing (protection B), an end-of-
stroke output torque of 41.1 FT•LBS (55.7 N•m), mounts Figure 3
via an F07 pattern, and uses a 19-mm female parallel
square to drive the valve.
A. Remove cap screw if fitted (39).
4 MAINTENANCE
B. Lift position indicator (19) off shaft; it may be
4.1 General necessary to pry gently with a screwdriver.
NOTE: All VPVL actuator fasteners are metric. Under normal 2. Removal of Stop Cap Screws (02), (Figure 4):
operating conditions the actuator requires only periodic
observation to ensure proper adjustment. Service kits are
available to replace seals and bearings (soft parts). These
parts are identified in (Figure 23) and listed in (Table 3).
Table 1 below lists kit part numbers.
TABLE 1
Actuator Service Kit Actuator Service Kit
VPVL01/011 RKP-152 VPVL-450 RKP-160
VPVL050/051 RKP-153 VPVL-500 RKP-161 02, 04, 03, 11
VPVL100 RKP-154 VPVL-550 RKP-162
VPVL200 RKP-155 VPVL-600 RPK-163
VPVL400 RKP-159
Figure 4
4 S1027
A. Remove both stop cap screws (02) together with A. Holding the body (50) in a vice (or similar device),
nut (04) and washer (03). rotate the drive shaft (60) until the pistons (40)
are released. CAUTION: Air Pressure should not
B. Remove stop screw o-rings (11) and discard if be used to remove the pistons from the body.
replacing all soft parts. Clean and inspect the piston teeth for signs of
wear. Replace piston if wear seems excessive.
3. End Cap (30, 31) Disassembly, (Figure 5):
B. Remove piston o-ring seal (16) using a screwdriver.
Remove the piston head (15) and piston back (5)
bearings. Discard bearings if replacing all soft
parts.
3 5. Drive Shaft (60) and Bearing (6, 7) Disassembly,
(Figure 7):
13
1
18
10
2 8 50
30, 31
4
Figure 5
8
A. Remove the end cap bolts (13) in the sequence
shown in (Figure 5). CAUTION: When disassem-
bling a spring return actuator, the end cap 1
(30, 31) should be loose after unscrewing end 60
cap bolts (13) 4-5 turns. If there is still force on
the end cap (30, 31) after 4-5 turns of the end Figure 7
cap bolt (13), this may indicate a damaged
spring cartridge and any further disassembly A. Remove spring clip (18) carefully, using snap-ring
should be discontinued. Further disassembly pliers. Remove external thrust bearing (8) and
of the end-caps may result in serious personal thrust washer (10).
injury. Return actuator to Metso Automation
for further maintenance. B. Apply downward force to top of drive shaft (60)
until it is partially out of the bottom of the body
B. For spring return actuators, remove spring (50) and the octi-cam (1) and internal thrust
cartridges (17). bearing (8) can be removed. Remove the octi-cam
C. Remove end-cap o-rings (14) and discard if (1) and internal thrust bearing (8). Push the drive
replacing all soft parts. shaft (60) completely out of the bottom of the
body (50). If the shaft (60) does not move freely,
4. Piston (40) Disassembly, (Figure 6): gently tap with a plastic mallet.
C. Remove the top and bottom shaft bearings (6, 7)
40 and top and bottom shaft o-rings (21, 22).
Discard if replacing all soft parts.
60
6. Cleaning and Inspection.
A. When all components are disassembled, those
not being replaced should be properly cleaned
and inspected for wear prior to re-assembly.
4.3 Assembly
50 Prior to assembly, ensure that all components are clean
40 and undamaged.
Figure 6 NOTE: (Table 2) lists the recommended Valv-Powr lubri-

cants.
S1027 5
TABLE 2 1. Drive Shaft (60) Assembly, (Figures 8 & 9):

Recommended VPVL Lubricants A. Install the top and bottom shaft bearings (6, 7)
Kluber UniGear LA 02 Grease and o-rings (21, 22) onto the shaft (60).
Esso (Exxon) Beacon EP2
B. Apply grease to the shaft bearings (6, 7), using a
Fina Marson EP L2 general purpose grease listed in (Table 2). Apply
Shell Alvania EP2
silicone grease to the shaft o-rings (21,22) using
General Use the recommended o-ring-area grease listed in
Mobilux EP2 (Table 2).
Dyrdene Pyroplex EP2
C. Partially Insert the shaft (60) into the body (50).
Oilsum Multiplex
Install the octi-cam (1) onto the shaft in the
Dow Corning 33, Light Grade (2x” for -60˚F/-50˚C) orientation shown in (Figure 9). The edges of the
octi-cam (1) should align with the edges of the
Dow-Corning Silicone 111
O-Ring Areas square in the bottom of the shaft (60). Insert the
Dow Corning 33, Light Grade (2x” for -60˚F/-50˚C) internal thrust bearing (8) over the octi-cam (1).
Fully insert the shaft into the body (50).
D. Install the external thrust bearing (8), thrust

washer (10), and the spring clip (18).
2. Piston (40) Assembly, (Figures 10 through 13):

60
21
A. Install the piston o-ring seal (16) and the piston
6 head (15) and piston back (5) bearings.
B. Apply silicone grease to the internal bore of the

body (50) using a recommended o-ring area
grease listed in (Table 2). Apply grease to the
piston (40) rack teeth using a recommended
general-purpose grease listed in (Table 2).
7 C. Hold the body (50) in a horizontal position by

inserting the top of the shaft in a vice, or inserting
20
the bottom of the shaft connection into a male
drive fitted into a vice as shown by (Figure 10).
Figure 8
18 60
1
10
8
50 50
60
1 Driver Square (60) –

OCTI Cam (1)
Alignment
Figure 9 Figure 10
6 S1027
D. Ensure that the octi-cam (1) is in the correct H. Temporarily install the position indicator (19)
position as shown by (Figure 11). onto the shaft (60) to determine whether the
correct stroke is obtained, Verify that the slot in
the top of the position indicator (19) will rotate a
minimum of 4˚ beyond the 90˚ vertical centerline
60
of the actuator body (50) and a minimum of 4˚
1
beyond the 0˚ horizontal centerline of the actuator
45˚ body as shown in (Figure 13). If the proper
stroke is not obtained, remove the pistons and
repeat from step 2d. Once the proper stroke is
verified, remove the position indicator (19).
90˚
19 4˚ Min
Figure 11 0˚
E. For standard-rotation assembly (clockwise to close)

rotate the body (50) 40 – 45˚ counterclockwise (if Closed Position –
viewing the bottom of the actuator),or clockwise (if CW to Close Orientation
viewing the top of the actuator) as shown in 90˚
(Figure 12).
F. Press the two pistons (40) simultaneously into 0˚

the body (50) until the piston racks are engaged 4˚ Min
and rotate the body clockwise (if viewing the 19
bottom of the actuator), or counter-clockwise (if Open Position –
viewing the top of the actuator), until the stroke CCW to Open Orientation
is completed.
Figure 13
G. To ensure that the piston (40) teeth are evenly
engaged, fully compress both pistons (40) inward 3. End Cap (30, 31) and Spring Cartridge (17)
and measure the distance from the edge of the Assembly, (Figures 14 through 16):
body to the piston (40) face on each side, shown
as dimension “A” in (Figure 12). If a different value NOTE: In Models VPVP550 through 800 the end caps are
is obtained on each side, remove the pistons and symmetrical and use two item (30)s.
repeat from step 2d.
A. For spring-return actuators, insert the proper
quantity of spring cartridges (17) according to the
pattern shown in (Figure 14) (referring to the
total number of springs). Insert spring cartridges
40˚- 45˚
(17) as shown in (Figure 15).
A A
SR2 SR2/3 SR3 SR3/4 SR4 SR4/5 SR5 SR5/6 SR6
Figure 12 Figure 14
S1027 7
5. External Travel Stop Adjustment, (Figure 17):
17
50
60
2, 3, 4, 11
Figure 15
Figure 17
B. Apply silicone grease to the end-cap o-ring seals,
using the recommended o-ring-area grease listed
in (Table 2). Fit the end-cap o-ring seals (14) into The stop adjustment screw (2) to the right controls the
the groove in each end cap (30, 31). clockwise end of travel. The stop adjustment screw (2) to
the left controls the counter-clockwise end of travel.
C. Fit the end caps (30, 31) onto the body (50), A. Cycle the actuator/valve to the clockwise end of
verifying that the o-ring seals (14) remain in the travel and measure to determine if the valve is in
grooves. the proper position. (In most applications this
will be fully closed.)
D. Insert all end-cap screws (13) and hand tighten.
Complete tightening by following the sequence B. If the valve is not in the correct clockwise position,
indicated in (Figure 16). turn the right stop adjustment screw (2) IN to
reduce actuator travel, or OUT to increase actuator
travel.
C. When the correct clockwise position is obtained,

hold the adjusting screw (2) stationary while
tightening the lock nut (4).
3
D. Cycle the actuator/valve to the counter-clockwise
end of travel and measure to determine if the valve
13 is in the proper position. (In most applications
1
this will be fully opened.)
E. If the valve is not in the correct counter-clockwise

2
position, turn the left stop adjustment screw (2)
30, 31 IN to reduce actuator travel, or OUT to increase
4 actuator travel.
F. When the correct counter-clockwise position is

Figure 16 obtained, hold the adjusting screw (2) stationary
while tightening the lock nut (4).
4. Assembly of Stop Screws (2) and Stroke 6. Position Indicator (19, 39) Assembly. (Figure 18):
Adjustment. (Figure 17):
A. Fit position indicator (19) on the shaft (60),
A. Insert the nut (4), washer (3), and o-ring (11) onto verifying that it indicates the correct actuator
the stop screws (2). position.
B. Screw the stop screws (2) into the body (50). B. Tighten cap screw (39) to secure the position
indicator.
8 S1027
Double Acting Actuators:
A. Back off one travel stop screw, leaving it partially

threaded in the end cap. Entirely remove the
19 39 other stop screw from the other end cap.
B. Open valve using air pressure.NOTE: Actuator will

leak due to removed travel stop.
C. Use the indicator pointer on top of actuator to

determine if valve is open to desired position. If
not, repeat steps 1-3, backing off or screwing in
stop screw to attain proper open position of valve.
D. Make sure O-ring is in proper position in coun-

Figure 18
tersunk area on end cap and the washer is in
place.Tighten down nut to set stop position.
7. Setting 100% Adjustable Stop (If applicable).
(Figure 19): E. Thread in the other travel stop, making sure the
O-ring and washer are in the correct place.
To limit the rotation on the stroke beyond the standard ±4˚ of
When the travel stop will not thread any further,
a VPVL actuator, a stainless steel 100% adjustable travel
tighten nut to set stop position.
stop option can be added.The stops, located in the end caps,
allow the valve position to be set anywhere between full
F. The previous steps set the open travel stop. See
closed and full open. This option limits travel of only the
section 4.3.5 for instructions on setting the close
couter-clockwise stroke for standard double-acting and
position stop.
spring-closed units.
Follow the proceeding steps in order to set the 100%

adjustable travel stops.
O-ring
Washer
Nut
Travel Stop
Screw
Stop Screw
Type A
VPVL 051-300
L Min. Approx
Stop Screw L Max. Approx

Type B
VPVL 350-800
Figure 19
S1027 9
Spring Return Actuators: 2. Assembly of stop cap screws:
A. Back off one travel stop screw, leaving it partially A. Before inserting the special longer screw (226) or
threaded in the end cap. Entirely remove the the standard screw (02) into the actuator body,
other stop screw from the other end cap. check what stop position is required? If the stop
position is fully close (0˚) or fully open (90˚), see
B. Open valve using air pressure. Note actuator will (Figure 21). Note, when the stop screws are
leak due to removed travel stop. inserted into the actuator body, the actuator
must be at the desired position.
C. Keeping air pressure applied to actuator, use the
indicator pointer on top of actuator to determine Top View
Special longer screw
if valve is open to desired position. If not, remove
position to lock in 0˚
air pressure and repeat steps 1-3, backing off or
(Close) position
screwing in stop screw to attain proper open
position of valve.
D. Make sure O-ring is in proper position in coun- Special Longer Screw (226)
tersunk area on end cap and the washer is in Standard Stop Cap Screw (02)
place.Tighten down nut to set stop position.
E. Thread in the other travel stop, making sure the O- Special longer screw
Top View
ring and washer are in the correct place. When the position to lock in 90˚
travel stop will not thread any further, tighten nut (Open) position
to set stop position.
F. The previous steps set the open travel stop. See

section 4.3.5 for instructions on setting the close
position stop. Standard Stop Cap Screw (02)
Special Longer Screw (226)
5 SAFETY LOCKOUT DEVICE Figure 21
1. Removal of stop cap screws: B. Insert the special longer screw (226) and the
standard screw (02) into the actuator body until
A. Remove from the body both existing standard
the desired lock position is achieved then tighten
stop cap screws (02) together with the nut (04),
the special nut (228).
washer (03) and O-ring (11) shown in (Figure 4).
3. Assembly of safety cover and padlock:
B. Insert on the special longer screw (226) and
standard stop cap screws (02) the special nut A. Slide the safety cover (229) between the special
(228), the washer (03) and the O-ring (11) shown nut (226) and washer (03) on both the special
in (Figure 20). longer screw (226) and the standard screw (02)
as shown in (Figure 22).
Standard
Screw
Special
Longer Screw (226)
Washer (03)
Standard Special
Stop Cap Screw
Screw (02)**
O-Ring (11)
Special Nut (228) Safety Cover

(229)
** For model AT051 the Screw (02) is not standard and is included in the kit.
Figure 20 Figure 22
10 S1027
B. Insert the padlock into the hole of the safety 7 REPAIR KITS/SPARE PARTS
cover (229) and lock it. For safety, keep the pad-
lock key in a safe place. For further information on spare parts and service or
assistance visit our web-site at www.jamesbury.com.
6 ACTUATOR STORAGE
If the actuators are not for immediate use, the following
precautions must be taken for storage:
A. Store in a dry environment
B. It is recommended that the actuator be stored in

its original box.
C. Do not remove the plastic plugs on the air supply

ports.
8 EXPLODED VIEW
5* 50 41 10 18 39 19 8* 30
11*
3
2
8*
17 4
1
21*
13
6*
42
31
* Suggested Spare Parts
60 for Maintenance
7*
20*
14* 15* 16* 40 12 9*
Figure 23
S1027 11
TABLE 3 - PARTS LIST FOR (FIGURE 23)

Corrosion
No. Unit Qty Part Description Material Specifications Protection
1 1 Octi-Cam (Stop Arrangement) Stainless Steel1 EN 10088-3/ISO 10831
2 2 Stop Cap Screw Stainless Steel ASTM A193
3 2 Washer (Stop Cap Screw) Stainless Steel ISO 3506
4 2 Nut (Stop Cap Screw) Stainless Steel ISO 3506
5* 2 Bearing (Piston Back) Polyphthalamide Amodel ET1001HS
6* 1 Bearing (Pinion Top) Polyetherimide Stanyl TW300
7* 1 Bearing (Pinion Bottom) Polyetherimide Stanyl TW300
8* 2 Thrust Bearing (Pinion) Polyphthalamide Amodel ET1001HS
9* 2 Plug (Transfer Port) Nitrile Rubber NBR 70Shore A
10 1 Thrust Washer (Pinion) Stainless Steel EN 10088-3
11* 2 O-ring (Stop Cap Screw Seal) Nitrile Rubber NBR 70Shore A
12 2 Piston Guide Polyphthalamide GF Amodel AS1145
13 8/12/ 2 Cap Screw (End Cap) Stainless Steel ISO 3506
14* 2 O-ring (End Cap) Nitrile Rubber NBR 70Shore A
15* 2 Bearing (Piston Head) Polyphthalamide Amodel ET1001HS
16* 2 O-ring (Piston) Nitrile Rubber NBR 70Shore A
17 min. 4/ max.12 Spring (Cartridge) Alloy Steel DIN 17223 Part2 Epoxy Coated
18 1 Spring Clip (Pinion) Carbon Steel DIN 17222 ENP
19 1 Position Indicator Polypropylene GF Hostalen PPN
20* 1 O-ring (Pinion Bottom) Nitrile Rubber NBR 70Shore A
21* 1 O-ring (Pinion Top) Nitrile Rubber NBR 70Shore A
30 1 3
Right End Cap 3
Aluminum UNI 5075 Polyester-Coated
31 13 Left End Cap3 Aluminum UNI 5075 Polyester-Coated
39 1 Cap Screw (Indicator) Stainless Steel ISO 3506
40 2 Pistons Aluminum UNI 5075 Anodized
41 1 Actuator Identification Label Polyester Aluminum
42 2 End Cap Label Polyester Aluminum
Anodized
50 1 Body Aluminum ASTM B221
PTFE-Coated
60 1 Drive Shaft Carbon Steel Plated ASTM A105 ENP
* Suggested spare parts for maintenance
Notes: (1) AISI 420 for models VPVL-051 through 300; GS400-15 for models VPVL-350 through 800
(2) Qty 8 pieces for models VPVL-051 through 600; Qty 12 pieces for model VPVL-700
(3) For models VPVL500 through VPVL700, right and left end-caps are symmetric
12 S1027
Metso Automation, Field Systems Division

Europe, Levytie 6, P.O.Box 310, 00811 Helsinki, Finland. Tel. int. +358 20 483 150. Fax int. +358 20 483 151
Europe (UK), 2 Lindenwood, Crockford Lane, Chineham Business Park, Basingstoke, RG24 8QY UK.Tel. int. +44 (0) 8706 061478. Fax int. +44 (0) 1256 707661
North America, 44 Bowditch Drive, P.O.Box 8044, Shrewsbury, Massachusetts, 01545-8044 USA. Tel. int. +1 508 852 0200. Fax int. +1 508 852 8172
Latin America, Av. Central, 181- Cháracas Reunidas, 12238-430, São Jose dos Campos. SP BRAZIL. Tel. int. +55 12 3935 3500. Fax int. +55 12 3935 3535
Asia Pacific, 501 Orchard Road, #05-09 Wheelock Place, 238880 Singapore. Tel. int. +65 735 5200. Fax int. +65 735 4566
www.jamesbury.com
IMO-528EN-5/04 © 2004 Metso Automation Printed in U.S.A.-R-J

S1101
OT
OR
• EXTERNAL PNEUMATIC VIBRATORS
• DRUCKLUFTAUSSENVIBRATOREN
• VIBRATEURS EXTERNES PNEUMATIQUES
• VIBRATORI PNEUMATICI ESTERNI

All rights reserved © WAMGROUP
CATALOGUE No. OL.2000 EX CREATION DATE
ISSUE CIRCULATION DATE OF LATEST UPDATE 06 - 2004

A 100
06.04
- DESCRIPTION S1101
S - BESCHREIBUNG
OT
- DESCRIPTION 2
OR
- DESCRIZIONE OL.2000 EX M. 3
GENERAL NOTES ALLGEMEINES REMARQUES GÉNÉRALES NOTE GENERALI

The vibrators are made in ac- Die Vibratoren der Serie S, OR Les vibrateurs S, OT et OR cor- I vibratori sono costruiti in con-
cordance with the EC machine und OT entsprechen der EU-Ma- respondent à la directive Machi- formità alla norma 89/392/CE sui
regulation 89/392/E1EC. The schinenrichtlinie 89/392/EWG nes 89/392/C.E.E. Il a été tenu macchinari. Si è in particolare
standards EN 292, part 1 and part und insbesondere den Normen compte des normes EN 292, l’ et tenuto conto di quanto stabilito
2 have been particularly ob- EN 292, Teil 1 und 2. 1-2 parties. Ces vibrateurs gé- dalle norme EN 292, parte 1 e
served. Dieser Vibratortyp erzeugt un- nèrent des vibrations multidirec- parte 2.
The vibrators produce non-di- gerichtete Schwingungen. tionnelles. Ils sont utilisés pour I vibratori producono vibrazioni
rected vibrations. They are used Sie werden zur Behälterentlee- le vidage de silos, l’entraînement multidirezionali. Sono impiegati
to keep a constant flow in hop- rung, als Antriebe für Rinnen, de goulottes l’activation de cou- per mantenere un flusso co-
pers and silo’s, to drive chutes Siebe und Vibrationstische ein- loirs vibrants, de tamis et de ta- stante nelle tramogge e nei sili,
and are also used in screens gesetzt und im allgemeinen zum bles vibrantes et, d’une façcon per attivare dosatori, vagli e ta-
and vibrating tables. Generally Lösen, Fördern, Verdichten und generale en général, pour ,dé- vole vibranti e in generale per
for loosening, conveying and Trennen von Schüttgütern und colmater, transporter, compac- distaccare, trasportare, compat-
separating of bulk materials and zur Reduzierung von Reibung. ter, et séparer les matières en tare e separare materiale sfuso
for the reduction of friction. Unter Beachtung der Bedie- vrac et réduire les frictions. Si e per ridurre l’attrito.
The vibrators are ideal for use in nungsvorschriften des Betrei- les prescriptions d’emploi élabo- I vibratori sono perfettamente
the food industry, explosive at- bers können diese Vibratoren rées par l’utilisateur sont respec- indicati per l’impiego nell’industria
mosphere’s, wet environment’s auch für die Nahrungsmittelher- tées, ils peuvent être mis en alimentare, in atmosfera esplo-
and outside. The frequency and stellung sowie in EX- und Naß- oeuvre pour la fabrication de siva, in ambienti umidi e all’ester-
the centrifugal force are deter- bereichen eingesetzt werden. denrées alimentaires ainsi qu’en no. La frequenza delle vibrazio-
mined by the operating pressure. Ein Einsatz der Vibratoren im milieu explosif ou humide. Les ni e la forza centrifuga sono de-
Freien ist möglich. vibrateurs peuvent aussi fonc- terminati dalla pressione d’eser-
Frequenz und die davon abhän- tionner à l’extérieur. La fréquen- cizio.
gige Zentrifugalkraft werden ce et la force centrifuge sont dé-
durch den Betriebsdruck be- terminées par la pression de
stimmt. service.
NOTE HINWEIS REMARQUE NOTA

For extraordinary maintenance, Für etwaige außerordentliche Pour les entretiens extraordinai- Per eventuali manutenzioni stra-
if necessary, contact: Wartungsarbeiten wenden Sie res s’adresser exclusivement à ordinarie rivlgersi esclusivamen-
sich bitte ausschließlich an: : te a:
OLI SRL
Via Canalazzo, 35
41036 Medolla (MO)
ITALY
Tel.: + 39.0535 - 46400

Fax: + 39.0535 - 46350
- PNEUMATIC BALL VIBRATORS “S” S110106.04
S - DRUCKLUFT - KUGELVIBRATOREN “S”
OT
- VIBRATEURS PNEUMATIQUES A BILLE “S” 2
OR
- VIBRATORI PNEUMATICI A SFERA TIPO “S” OL.2000 EX M. 4
General indications Allgemeine Angaben Indications générales Indicazioni generali

- Ball vibrators “S” consist of an - Die Kugelvibratoren Serie „S” - Les vibrateurs à bille de la sé- - I vibratori a sfera serie “S”
anodized aluminium body in- bestehen aus einem Gehäuse rie “S” sont constitués d’un sono costituiti da un corpo in
side which a tempered steel ball aus eloxiertem Aluminium, in- corps en aluminium anodisé alluminio anodizzato all’interno
rotates on an anti-wear tem- nerhalb dessen sich eine Ku- dans lequel tourne une bille en del quale ruota una sfera in ac-
pered steel seating. Vibrator gel aus gehärtetem Stahl in ei- acier trempé sur un siège en ciaio temprato su una sede di
“S” generates vibrations of nem Sitz aus gehärtetem ver- acier trempé anti-usure. Le vi- acciaio temprato antiusura. Il vi-
small amplitudes. schleißfestem Stahl dreht. Der brateur “S” produit des vibra- bratore “S” genera vibrazioni
Examples of application Vibrator „S” erzeugt Schwin- tions de petite amplitude. di piccola ampiezza di sposta-
- Separation, transport, com- gungen kleinern Ausmaßes. Exemples d’application mento.
pacting of materials. Anwendungsbeispiele - Séparation, transport, com- Esempi di applicazione
- Gushing of material from of si- - Materialien abscheiden, beför- pactage de produits - Separazione, trasporto, com-
los, hoppers, screens, etc. dern, verdichten. - Débourrage de silos, trémie, ta- pattazione materiali.
- Cleaning filters. - Silos, Trichtern, Sieben, etc. mis, etc. - Sgorgo di sili, tramogge, vagli,
- On conveyor chains (for ex- freimachen. - Nettoyage des filtres. ecc.
amples cans, bottles, etc.) they - Filter reinigen. - Sur les chaînes de transport - Pulizia filtri.
facilitate the flow and eliminate - Auf Förderketten (z.B. Dosen, (par ex. boîtes, bouteilles, etc.) - Su catene di trasporto (per es.
problems of blockage. Flaschen, etc.) vereinfachen ils facilitent l’écoulement et éli- barattoli, bottiglie, ecc.) facili-
Maximum operating temper- sie den Materialfluss und be- minent les problèmes de blo- tano il deflusso ed eliminano i
ature: seitigen Probleme mit etwaigen cage. problemi di bloccaggio.
- 20°C / +200°C Blockierungen. Température maximum de Temperatura
Max. Betriebstemperatur service massima d’esercizio
-20°C / +200°C -20°C / +200°C - 20°C / +200°C
DIMENSIONS - ABMESSUNGEN - DIMENSIONS - DIMENSIONI

Weights - Gewichte
A B C D E F G
Type H Poids - Pesi
mm in mm in mm in mm in mm in mm in mm in kg lbs
S8
50 1.97 86 3.38 20 0.79 68 2.68 4 1.57 12 0.47 7 0.27 1/4" 0.13 0.29
S 10
S 13 24 1.91 0.26 0.57
65 2.56 113 4.45 90 3.54 50 1.97 16 0.63 9 0.35 1/4"
S 16 27 1.06 0.30 0.66
S 20 33 1.30 0.53 1.17
80 3.15 128 5.04 104 4.09 60 2.36 16 0.63 9 0.35 1/4"
S 25 38 1.50 0.63 1.39
S 30 44 1.73 1.13 2.49
100 3.94 160 6.30 130 5.12 80 3.15 20 0.79 11 0.43 3/8"
S 36 50 1.97 1.34 2.95
PERFORMANCE DATA - LEISTUNGSDATEN- PERFORMANCE - PRESTAZIONI
Vibrations - Schwingungen Air consumption - Lufterverbrauch
Vibrations - Vibrazioni Fc max. kg Consommation d'air - Consumo d'aria
min -1 l/min
Type
2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi 2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi
2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi
kg lbs kg lbs kg lbs dm3 cf dm3 cf dm3 cf
S8 25,500 31,000 35,000 13 29 26 58 36 81 83 2.6 145 5.1 195 6.9
S 10 22,500 28,000 34,000 25 56 47 106 71 160 92 3.2 150 5.3 200 7.1
S 13 15,000 18,500 22,500 32 72 55 124 87 196 94 3.3 158 5.6 225 7.9
S 16 13,000 17,000 19,500 45 101 80 180 110 248 122 4.3 200 7.1 280 9.9
S 20 10,500 14,500 16,500 72 162 122 275 172 387 130 4.6 230 8.1 340 12.0
S 25 9,200 12,200 14,000 93 209 157 353 205 461 160 5.6 290 10.2 425 15.0
S 30 7,800 9,700 12,500 151 340 247 556 321 722 215 7.6 375 13.2 570 20.0
S 36 7,300 9,000 10,000 206 464 315 709 405 911 260 9.2 475 16.8 675 24.0
06.04
- PNEUMATIC TURBINE VIBRATORS “T” S1101
S - PNEUMATISCHE DRUCKLUFT - TURBINEN-VIBRATOREN “T”
OT
- VIBRATEURS PNEUMATIQUES A TURBINE “T” 2
OR
- VIBRATORI PNEUMATICI A TURBINA “T” OL.2000 EX M. 5
General indications Allgemeines Indications générales Indicazioni generali

- Vibration is generated by a - Die Vibration wird durch eine - la vibration est engendrée par - La vibrazione è generata da
strongly unbalanced turbine exzentrisch angeordnete Tur- une turbine déséquilibrée mon- una turbina sbilanciata che gira
which rotates on two high- bine erzeugt, die sich mit ho- tée sur 2 roulements à bille à su 2 cuscinetti a sfera ad alta
speed ball bearings. her Geschwindigkeit auf 2 Ku- haute vitesse. velocità.
- OT vibrators develop a high gellagern dreht. - Les vibrateur à turbine OT en- - I vibratori a turbina OT genera-
work moment and a high vibra- - Zwei überdimensionierte, für gendrent un couple élevé et une no un elevato momento di lavo-
tion frequency. den Dauereinsatz bei hohen haute fréquence de vibration. ro ed una alta frequenza di vi-
- Vibrations present a large am- Drehzahlen geeignete Lager - Les vibrations ont une amplitu- brazione.
litude even with low operating garantieren einen hohen Wir- de considérable même à bas- - Le vibrazioni hanno una note-
pressure. kungsgrad und ermöglichen se pression d’exercice. vole ampiezza anche a basse
Examples of application den Einsatz ungeölter Druck- Exemple d’application pressioni di esercizio.
- Food and Pharmacentical indu- luft. - Industries alimentaire et phar- Esempi di applicazione
stries. - OT Vibratoren sind vollkommen maceutique - Industria alimentare e farma-
- Bins and hoppers. wartungsfrei und zeichnen - Trémies et d’autres récipients. ceutica.
- Goreens. sich aus durch hohe Drehzah- - Tamis. - Sili e tramogge.
Maximum operating len bei gleichzeitig geringem Température maximum de - Vagli.
temperature: Luftverbrauch. service Temperatura
- 20°C / +120°C Anwendungsbeispiele -20°C / +120°C massima d’esercizio
- Nahrungsmittel und Pharmain- - 20°C / +120°C
dustrie.
- Trichter und Behälterbau.
- Siebanlagen.
Max. Betriebstemperatur
-20°C / +120°C

A B C D E F Weights - Gewichte - Poids - Pesi
Type x-y
mm in mm in mm in mm in mm in mm in kg lbs
OT 8 .250 .55
OT 10 50 1.97 86 3.38 68 2.68 12 0.47 33 1.30 7 0.27 1/8" .255 .56
OT 10-S .263 .58
OT 13 .565 1.24
OT 16 65 2.56 113 4.45 90 3.54 16 0.63 42 1.65 9 0.53 1/4" .580 1.28
OT 16-S .614 1.35
OT 20 1.090 2.40
OT 25 80 3.15 128 5.04 104 4.09 16 0.63 56 2.20 9 0.35 1/4" 1.120 2.46
OT 25-S 1.200 2.64
OT 30 2.200 4.85
OT 36 100 3.94 160 6.30 130 5.12 20 0.79 73 2.87 11 0.43 3/8" 2.300 5.10
OT 36-S 2.530 5.57
06.04
- PNEUMATIC ROLL VIBRATORS “R” S1101
S - DRUCKLUFT - ROLLEN VIBRATOREN “R”
OT
- VIBRATEURS PNEUMATIQUES A ROULEX “R” 2
OR
- VIBRATORI PNEUMATICI A RULLI “R” OL.2000 EX M. 7
General indications Allgemeines Indications générales Indicazioni generali

- The roller vibrators series “R” are - Die Rollen „R“ Rüttler bestehen aus - Les vibrateurs à rouleaux, série “R”, - I vibratori a rulli serie “R” sono co-
formed by an anodized aluminium einemm Körper aus eloxiertem Alu- comprennent un corps en aluminium stituiti da un corpo in alluminio ano-
body inside which a hardened steel minium, innerhalb mit einer Rolle anodisé avec un rouleau en acier dizzato all’interno del quale ruota un
roller wheels an a cast iron race. aus gehärtetem Stahl, die auf Guss- trempé sur piste en fonte roulant à rullo in acciaio temprato su pista in
- Vibration is generated by a rotor eisen Laufbahn rotiert. l’interieur. ghisa.
which describes an epicycloidal - Die Vibration wird durch eine Rolle - La vibration est engendrée par un - La vibrazione è generata da un ro-
movement inside a steel race. erzeugt, die innerhalb eines speziell rouleau qui accomplit un mouve- tore che compie un movimento epi-
- The OR vibrators generate a very gehärteten Stahlringes eine epizyk- ment épicycloïdal à l’intérieur d’une cicloidale all’interno di una pista di
high frequency with low consump- lische Bewegung beschreibt. piste en acier. acciaio.
tion as compared to the force giv- - OR Vibratoren entwickeln hohe - Les vibrateurs à rouleau OR, en- - I vibratori a rullo OR generano una
en. Fliehkräfte und laufen in jeder Ein- gendrent une fréquence trés éle- frequenza molto elevata con un
Examples of application baulage sicher an. vée avec une consommation d’air consumo ridotto, in relazione alla
- Bins and hoppers Anwendungsbeispiele réduite par rapport à la force déve- forza resa.
- Moulding dies - Trichter und Behälter loppée. Esempi di applicazione
- Compacting - Gussformen Exemple d’application - Sili e tramogge
- Separation - Verdichter - Trémies et d’autres récipients - Forme
Maximum operating - Klassierer - Moules - Compattazione
temperature Max. Betriebstemperatur - Compactage - Separazione
0°C / +200°C 0°C / +200°C - Séparation Temperatura
Température maximum de service massima d’esercizio
0°C / +200°C 0°C / +200°C

A B C D E F Weights - Gewichte - Poids - Pesi
Type H
mm in mm in mm in mm in mm in mm in kg lbs
OR 50 50 1.97 86 3.38 68 2.68 12 0.47 30 1.18 7 0.27 1/8" 0.370 0.82
OR 65 65 2.56 113 4.45 90 3.54 16 0.63 36 1.42 9 0.35 1/4" 0.760 1.68
OR 80 80 3.15 128 5.04 104 4.09 16 0.63 40 1.57 9 0.35 1/4" 1.270 2.80
OR 100 100 3.94 160 6.30 130 5.12 20 0.79 52 2.05 11 0.43 3/8" 2.600 5.73
PERFORMANCE DATA - LEISTUNGSDATEN- PERFORMANCE - PRESTAZIONI
Vibrations - Schwingungen
Air consumption - Lufterverbrauch
Vibrations - Vibrazioni Fc max.
Consommation d'air - Consumo d'aria
vpm
Type
2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi 2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi
2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi
kg lbs kg lbs kg lbs dm3 cf dm3 cf dm3 cf
OR 50 21000 25000 29500 1840 413 2760 620 3480 782 78 2.7 144 5.0 204 7.2
OR 65 19000 22000 26000 2303 518 4306 968 5420 1218 100 3.5 198 6.9 296 10.4
OR 80 14000 16000 21500 3354 754 5762 1295 6124 1377 122 4.3 255 9.0 378 13.3
OR 100 6750 9750 11000 2839 638 5924 1332 7678 1726 132 4.6 284 10.0 412 14.5
N.B.: data abtained from a vibrating
N.B.: daten wurden auf einem gefe- N.B.: les données ont été relevées N.B.: dati rilevati utilizzando un ban-
table supported by springs that per-
derten Rütteltisch ermittelt, aud dem sur un banc vibrant à ressorts, de co vibrante a molle, in modo da simu-
fectly simulates the major part of the
die Mehrzahl der möglichen Anwen- manière à simuler parfaitement la plu- lare perfettamente la maggior parte
applications possible. Frequency and
dungen perfekt simuliert wurde. Fre- part des applications possibles. La delle possibili applicazioni. Frequenza
centrifugla force increase when thequenz und Zentrifugalkraft nehmen frequence et la force centrifuge se- e forza centriga saranno maggiori ap-
vibrator is applied to more rigid struc-
bei einer Befestigung des Vibrators ront plus grandes où le vibrateur est plicando il vibratore su strutture più
tures. auf weniger elastischen Unterlagen appliqué sur une structure plus rigide. rigide.
zu.
For activation a 2/2 way electrov- Zur Betätigung ist ein 2/2 Wege- Pour l’actionnement on a besoin Per l’azionamento occorrono una
alve and filtered compressed air Ventil und gefilter Druckluft erfor- d’une èlectrovanne à 2/2 voies et elettrovalvola a 2/2 vie ed aria fil-
are required. derlich d’air filtré trata.
- MANUFACTURING DATA S110106.04
S - KONSTRUKTIONSDATEN
OT
- DONNÉES CONSTRUCTIVES 2
OR
- DATI COSTRUZIONE OL.2000 EX M. 8
Rating plate for S or OR vibrator - Schild für Vibrator S oder OR

Plaque pour vibrateur S ou OR - Targhetta per vibratore S e OR
B) IDENTIFICATION B) IDENTIFIKATION IDENTIFICATION IDENTIFICAZIONE

OF COMPONENT DES BAUTEILS DU COMPOSANT DELCOMPONENTE
For correct identification of the Zur korrekten Identifikation des Pour identifier correctement le Per una corretta identificazione
component, refer to the code on Bauteils Bezug auf den Code composant, faire référence au del componente, bisogna fare
the rating plate. nehmen, der auf dem Schild code qui se trouve sur la plaque riferimento al codice che si tro-
steht. signalétique. va sulla targhetta.
NOTE: The pneumatic vibra- Anm.: Der pneumatische Vi- N.B. : En tant que composant N.B.: il vibratore pneumatico
tor must not be CE marked brator darf nicht mit der CE- le vibrateur pneumatique ne non deve essere marcato
since it is a component. Kennzeichnung versehen porte pas le marquage CE. CE in quanto componente.
werden, da es sich um ein
Bauteil handelt.
e x
≤ ≤
1) Machine code 1) Maschinencode 1) Code machine 1) Codice macchina

2) Machine serial number 2) Serien-Nr. Maschine 2) Matricule de la machine 2) Numero matricola
3) Assembly operator code 3) Monteur-Code 3) Code opérateur assembleur 3) Codice operatore assembla-
4) Year of construction 4) Baujahr der Maschine 4) Année de fabrication machi- tore
5) Group and category 5) Gruppe und Kategorie ne 4) Anno di costruzione macchi-
6) Surface Tmax 6) Tmax Oberfläche 5) Groupe et catégorie na
with T amb. -20 °C / +180°C mit T amb. -20 °C / +180°C 6) Tmax superficiel 5) Gruppo e categoria
avec T amb. -20 °C / +180°C 6) Tmax superficiale
con T amb. -20 °C / +180°C
Rating plate for OT vibrator- Schild für Vibrator OT

Plaque pour vibrateur OT - Targhetta per vibratore OT
e x
≤ ≤
1) Machine code 1) Maschinencode 1) Code machine 1) Codice macchina

2) Machine serial number 2) Serien-Nr. Maschine 2) Matricule de la machine 2) Numero matricola
3) Assembly operator code 3) Monteur-Code 3) Code opérateur assembleur 3) Codice operatore assembla-
4) Year of construction 4) Baujahr der Maschine 4) Année de fabrication machi- tore
5) Group and category 5) Gruppe und Kategorie ne 4) Anno di costruzione macchi-
6) Surface Tmax 6) Tmax Oberfläche 5) Groupe et catégorie na
with T amb. -20 °C / +120°C mit T amb. -20 °C / +120°C 6) Tmax superficiel 5) Gruppo e categoria
avec T amb. -20 °C / +120°C 6) Tmax superficiale
con T amb. -20 °C / +120°C
06.04
- SCOPE AND IMPORTANCE OF THE MANUAL S1101
S - ZWECK UND BEDEUTUNG DES HANDBUCHS
OT
- BUT ET IMPORTANCE DU MANUEL 2
OR
- SCOPO E IMPORTANZA DEL MANUALE OL.2000 EX M. 9
This manual, prepared by the manu- Dieses Handbuch, das vom Herstel- Le présent Manuel, rédigé par le cons- Il presente manuale, redatto dal co-
facturer, forms an integral part of ler erstellt wurde, ist integrierender tructeur, fait partie intégrante de la struttore, è parte integrante del vi-
the pneumatic vibrator S/OR/OT sup- Teil des Druckluft Vibrator S/OR/OT. fourniture du vibrateur pneumatique bratore pneumatico S/OR/OT; come
ply. It must therefore accompany the Daher muss es unbedingt dem Filter S/OR/OT; comme tel il doit absolu- tale deve assolutamente seguire il
filter right up to its final scrapping,folgen, bis er demontiert wird, und ment suivre le filtre jusqu’à son dé- filtro fino al suo smantellamento ed
and must be available ready at hand leicht zu finden sein, wenn der Bedie- mantèlement et être à portée de la essere facilmente reperibile per una
for quick consultation by the opera- ner oder die Baustellenleitung in ihm main pour une consultation rapide de rapida consultazione da parte degli
tors concerned and those in charge nachschlagen wollen. Bei einem Be- la part des opérateurs concernés et operatori interessati e della direzione
of operations at the work site. If the sitzerwechsel des Gerätes muss das par la direction des travaux du chan- lavori del cantiere. In caso di cambio
machine changes hands, this manu- Handbuch dem neuen Besitzer aus- tier. En cas de changement de pro- di proprietà della macchina il manuale
al must be handed over to the new gehändigt wer-den. Bevor das Be- priété de la machine, le manuel doit deve essere consegnato alla nuova
owner. Before carrying out any oper- triebspersonal irgendwelche Arbeiten être remis au nouveau propriétaire. proprietà. Prima di eseguire qualsiasi
ation on or using the pneumatic vi- an oder mit Druckluft Vibrator aus- Avant d’effectuer une quelconque operazione con, o sul vibratore pneu-
brator, the personnel concerned must führt, muss es dieses Handbuch un- opération avec ou sur le vibrateur matico ; il personale interessato deve
have read this manual carefully and bedingt mit großer Aufmerksamkeit pneumatique, le personnel concerné assolutamente ed obbligatoriamente
completely. If the manual is lost, or durchgelesen haben. Falls das Hand- doit absolument et obligatoirement aver letto con la massima attenzione
in such a condition as to make it il- buch verloren geht oder unleserlich avoir lu très attentivement le présent il presente manuale. Qualora il ma-
legible, download a new copy from wird, kann man sich eine neue Kopie manuel. Si le manuel est égaré ou nuale venga smarrito, sgualcito e tale
the OLI s.r.l internet site, and check von den Internetseiten des Herstel- abîmé de manière à ne plus être lisi- da non essere completamente leggi-
the date of the last revision. This lers OLI s.r.l herunterladen, um dann ble, une copie doit être téléchargée à bile, si deve scaricare una nuova
manual provides warnings and indi- das Datum der letzten Aktualisierung partir du site internet de OLI s.r.l en copia dal sito internet della OLI s.r.l e
cations concerning the safety regu- des Handbuchs zu prüfen. Dieses vérifiant la date de la dernière mise à verificarne la data dell’ultimo aggior-
lations for preventing accidents at Handbuch liefert Hinweise und Anga- jour. Le présent manuel fournit les namento. Il presente manuale forni-
the work site. However, the opera- ben zu den Sicherheits- und Unfall- recommandations et les indications sce avvertenze ed indicazioni relati-
tors MUST scrupulously follow the verhütungsbestimmungen am Ar- concernant les consignes de sécurité ve alle norme di sicurezza per la pre-
safety regulations meant for them beitsplatz. Die Sicherheitsbestimmun- pour la prévention contre les acci- venzione degli infortuni sul lavoro.
according to the existing legislation. gen, die laut der geltenden Bestim- dents du travail. Dans tous les cas Vanno comunque, ed in ogni caso,
Modifications to the safety regula- mungen vom Bedienungspersonal zu les consignes de sécurité conformé- osservate con il massimo scrupolo
tions made over time must be inte- beachten sind, müssen auf jeden Fall ment aux normes en vigueur doivent da parte dei vari operatori le norme di
grated and implemented. immer beachtet werden. être observées avec la plus grande sicurezza poste a loro carico dalle vi-
Etwaige Änderungen der Sicherheits- attention par les différents opérateurs. genti normative.
With the basic features of the ma- bestimmungen, die im Laufe der Zeit Les modifications éventuelles des Eventuali modifiche delle norme di
chines as described, the Manufac- vorgenommen werden, sind immer zu consignes de sécurité devront être sicurezza che nel tempo dovessero
turer reserves every right to make erfassen und umzusetzen. adoptées et mises en oeuvre. aver luogo dovranno essere recepite
modifications to parts, details and ed attuate.
accessories considered to be neces- Der Hersteller behält sich das Recht Les caractéristiques essen tielles des
sary for improving the product for vor, unter Beibehaltung der wesentli- machines décrites étant entendues, Ferme restando le caratteristiche es-
design or commercial reasons, at any chen Eigenschaften der beschriebe- le constru cteur se réserve le droit senziali delle macchine descritte, il
time without any obligation to update nen Geräte etwaige Änderungen an d’ap porter à tout moment et sans costruttore si riserva il diritto di ap-
the publication imme-diately. Organen, Teilen und Zubehör vorzu- engagement de mettre à jour en temps portare le eventuali modifiche di or-
The latest version of the present cat- nehmen, die im Zuge der Produktver- utile cette publication, des modifica- gani, dettagli ed accessori che riterrà
alogue is available under besserung erforderlich sind oder aus tions aux organes, pièces et acces- convenienti per il miglioramento del
www.olivibra.it konstruktiven oder kommerziellen soires qu’il retiendra avantageuses prodotto, o per esigenze di carattere
Erfordernissen heraus ausgeführt pour l’amélioration du produit ou pour costruttivo o commerciale, in qualun-
werden. Solche Änderungen können des exigences de fabrication ou de que momento e senza impegnarsi ad
jederzeit vorgenommen werden und commer cialisation. aggiornare tempestivamente questa
verpflichten den Hersteller nicht, die- La version toujours mise à jour de ce pubblicazione.
se Veröffentlichung gleichzeitig auf catalogue est dis-ponible sul le site La versione sempre aggiornata del
den neuesten Stand zu bringen. internet www.olivibra.it presente catalogo è reperibile sul sito
Die letzte Version dieses Katalogs internet www.olivibra.it
steht im Internet unter
www.olivibra.it
CERTIFICATE OF CONFORMITY KONFORMITÄTSERKLÄRUNG CERTIFICAT DE CONFORMITÉ ATTESTATO DI CONFORMITA’
The equipment is accompanied by a Das Gerät wird von einer den gelten- L'appareillage est accompagné d’une L'apparecchiatura è accompagnata da
declaration of conformity to existing den Richtlinien entsprechenden Kon- déclaration de conformité aux directi- una dichiarazione di conformità alle
regulations, but, since it is a compo- formitäts-erklärung begleitet, aber als ves en vigueur, mais en tant que direttive vigenti, ma, in quanto com-
nent to be integrated into a system Bestandteil einer kompletten Anlage composant devant s’intégrer dans ponente da integrarsi in un impianto
or plant, its safety is connected to ist seine Betriebs-sicherheit mit der une installation complète, sa sécurité completo, la sua sicurezza è legata al
compliance with all the directives Beachtung aller Richtlinien verbun- est étro itement lié au respect de tou- rispetto di tutte le direttive applicabili
applicable in final assembly of the den, die nach dem Einbau in die Anla- tes les directives applicables dans nell'assemblamento della macchina
machine. ge oder Maschine anwendbar sind. l’assemblage de la machine finale. finale.
Improper use of the pneumatic vi- Jede bestimmungswidrige Benutzung Toute utilisation impropre du vibra- Ogni utilizzo improprio del vibratore
brator without following the instruc- des Druckluft Vibrator ohne Befol- teur pneumatique sans suivre les in- pneumatico senza seguire le indica-
tions in this manual frees the Manu- gung der Angaben dieses Handbuchs dications du présent manuel dégage zioni del presente manuale solleverà
facturer of all responsibility for poor entbindet den Hersteller von jeglicher le constructeur de toutes responsabi- il costruttore da ogni responsabilità
working of the pneumatic vibrator. Haftung hinsichtlich der fehlerhaften lités ayant trait à un mauvais fonc- inerenti ad un cattivo funzionamento
As this is a subject in the process of Funktion des Druckluft Vibrator. tionnement du vibrateur pneumatique del vibratore pneumatico stesso.
significant technical and normative Da es sich um Produkte handelt, die lui-même. Trattandosi di materia in forte evolu-
evolution, the Manufacturer reserves einer schnellen technischen Entwick- Etant donnée qu’il s’agit d’une matiè- zione tecnica e normativa, il costrut-
the right to upgrade its products as lung unterliegen, behält es sich der re en forte évolution technique et ré- tore si riserva di adeguare con la
fast as possible with all the techno- Hersteller vor, die eigenen Erzeug- glementaire, le constructeur se ré- massima celerità i propri manufatti a
logical know-how and official stand- nisse so schnell wie möglich an alle serve d’adapter avec rapidité ses pro- tutte le conoscenze tecnologiche e le
ards applicable (EN, UNI) which are technologischen Erkenntnisse und die pres produits manufacturés à toutes norme ufficiali applicabili (EN, UNI)
available at the time. anwendbaren offiziellen Normen (EN, les connaissances techno logiques che di volta in volta si rendessero
UNI) anzupassen, die von Fall zu Fall et les normes of ficielles applicables disponibili.
erforderlich sind. (EN, UNI) au fur et à mesure de leur
parution.
- CERTIFICATE OF CONFORMITY S110106.04
S - KONFORMITÄTSBESCHEINIGUNG
OT
- CERTIFICAT DE CONFORMITÉ 2
OR
- ATTESTATO DI CONFORMITA’ OL.2000 EX M. 10
OLI S.r.l.
Via Canalazzo, 35 – I - Medolla (MO)
ITALY
CERTIFICATE OF CONFORMITY
with the Directives of the European Union
The OLI percussion guns model
S/OR/OT....ATEX (Code: SX....)
are manufactured in conformity with the following directives:
- Directive “Machines” 98/37/CE of 22nd June, 1998

- Directive “ATEX” 94/9/CE of 23rd March, 1994
The conformity has been verified according to the conditions included in the
following standard documents:
• EN 1127-1 • EN 292-1-2
• EN 13463-1 • EN 1050
Serie S, OR, OT II 3 D 85°C (T6) X

Serie S, OR, X Tmax.=200°C (T3) Tamb. -20°C +180°C
Serie OT, X Tmax.=135°C (T4) Tamb. -20°C +120°C
This equipment must never be put into operation before the machine or plant
into which it has been integrated has been declared in conformity with the
Directives in force.
Medolla, 1st November, 2003

OLI S.r.l.
Adriano Marchesini
(General Manager)
- WARNING S110106.04
S - HINWEISE
OT
- RECOMMANDATIONS 2
OR
- AVVERTENZE OL.2000 EX M. 14
SAFETY SICHERHEIT SÉCURITÉ SICUREZZA

Whilst carrying out any work on
Sicherstellen, daß während des Assurez-vous, lors du montage Durante l’installazione o in caso
the S, OT or OR Pneumatic Vi- Einbaus oder bei Arbeiten am Vi- ou de tous autres travaux ef- di interventi ai vibratori pneuma-
brators Make sure that the com-
brator und an den Zuleitungen, fectués sur le vibrateur ou les tici S, OR o OT, assicurarsi di
pressed air is shut off on anydie Druckluft abgestellt ist. Die conduites d’amenée, que l’ali- avere interrotto l’alimentazione
supply lines. All pipes must be
Schlauchleitungen müssen fest mentation en air comprimé est in- d’aria compressa su tutte le li-
tightly connected. verbunden sein. terrompue. Les flexibles doivent nee. Tutti i tubi devono essere
A pipe coming loose under pres-
Ein unter Druck stehender, sich être solidement raccordés. Un saldamente collegati.
sure may cause injury. Vibrations
lösender Schlauch, kann Verlet- flexible sous pression qui se Il distacco di un tubo sotto pres-
can cause loosening of bolted zungen verursachen. Des wei- détache peut provoquer des sione può provocare lesioni. Le
connections and equipment. This
teren können Vibrationen ein Lö- blessures. Les raccords vissés vibrazioni possono allentare i
may cause damage to persons sen der Schraubverbindungen et les appareils peuvent se des- raccordi a vite e gli apparecchi,
and machines. und Geräte verursachen. Perso- serrer sous l’effet des vibra- con rischio di danni a persone e
Take note of the enclosed nen- und Materialschäden kön- tions, ce qui risque de provo- macchinari.
drawings. nen die Folge sein. quer des dommages corporels Prendere visione dei dise-
Die beiliegenden Zeichnun- et matériels. gni inclusi.
Alterations to the unit may gen sind zu beachten. Tenez compte des croquis,
change the characteristics of ci-joint. Eventuali modifiche apporta-
the vibrator or even damage Veränderungen am Gerät te all’unità possono variare
the unit and will cause the können dessen Eigenschaf- Toute modification du vibra- le caratteristiche del vibra-
rejection of any warranty ten verändern bzw. dassel- teur est susceptible d’en al- tore, se non addirittura dan-
claims. be beschädigen, was zum térer les propriétés ou de le neggiare l’unità stessa, con
Erlöschen aller Garantiean- détruire et rend caduque conseguente annullamento
sprüche führen kann. tous recours en garantie di qualsiasi diritto di garan-
entraîne l’extinction des zia.
droits de garantie.
Air Compressor Antriebsmittel Fluide d’entraînement Compressore pneumatico

The Air Compressor needs to be Saubere, gefilterte (Filter < Le fluide d’entraînement est l’air Il compressore pneumatico va
kept clean and filtered (filter 50µm) Druckluft oder Stickstoff comprimé exempt d’impuretés et tenuto pulito e l’aria filtrata (filtro
<50pm). Compressed air or ni- (2 bis 6 bar). Die Verwendung filtré (filtre < 50 µm), ou l’azote, < 60 mm). Si richiede azoto o aria
trogen of 2 to 6 bar (30 to 90 nicht gefilterter Luft führt sous une pression de 2 à 6 bars compressa alla pressione com-
PSI) is required. The vibrators zum Ausfall der Vibratoren. (30 à 90 PSI). Les vibrateurs presa tra 2 e 6 bar (da 30 a 90
are designed for lubrication- Alle Vibratoren können öl- sont conçus pour fonction- PSI). I vibratori sono proget-
free operation. The life time frei betrieben werden, ein ner sans huile, un graisseur tati per l’uso esente da lu-
of the S and OR vibrator will Nebelöler verlängert die Le- prolongera la durée de vie brificante. La lubrificazione
be extended with lubrica- bensdauer von S und OR. des S et OR. prolunga la durata dei vibra-
tion. Non-filtered air will L’utilisation d’air non filtré tori S e OR. L’impiego di aria
damage the vibrators. entraîne la défaillance des non filtrata danneggia il vi-
vibrateurs. bratore.
Maximum operating pres- Max. Betriebsdruck Pression maximale de ser- Pressione massima d’eser-
sure vice cizio
The maximum operating pres- Der max. Betriebsdruck darf 6 La pression maximale de servi- La pressione massima d’eserci-
sure must not exceed 6 bar (90 bar (90PSI) nicht überschreiten. ce ne doit pas dépasser 6 bars zio non deve superare i 6 bar
PSI). (90 PSI). (90 PSI).
06.04
- INDICATIONS FOR THE USE S1101
S - ANGABEN ZUM GEBRAUCH
OT
- MODES D’EMPLOI 2
OR
- INDICAZIONI PER L’USO OL.2000 EX M. 15
The pneumatic vibrators de- Die pneumatischen Vibrato- Les vibrateurs pneumati- I vibratori pneumatici descritti
scribed in this Manual are deren, die in diesem Handbuch be- ques décrits dans ce manuel ont in questo manuale sono stati pro-
signed and tested for use in po- schrieben werden, sind für den été conçus et testés pour être gettati e testati per un utilizzo in
tentially explosive areas classi- Einsatz in explosionsgefährde- utilisé dans les environnement zone potenzialmente esplosive
fied as zone 22 cat. II 3 D ac- ter Bereichen ausgelegt und explosibles classés comme zone classificate come zona 22 cat. II
cording to directive 94/9/CE. konstruiert worden, die als Zone 22 cat. II 3 D d’après la directive 3 D secondo la direttiva 94/9/CE.
The powders handled must have 22 Kat. II 3 D gemäß der Richtli- 94/9/CE. Les poussières traitées Le polveri trattate dovranno ave-
explosiveness index St1 or St2 nie 94/9/EG klassifiziert worden doivent avoir des indices d’ex- re indici di esplosività St1 o St2 e
and this must be notified to OLI sind. Die aufbereiteten Stäube plosivité St1 ou St2 ; pour un devono essere comunicate alla
s.r.l. at the time of placing the müssen Staubexplosionsklasse choix correct du composant cel- OLI s.r.l. al momento dell’ordine
order to allow correct selection St1 oder St2 haben und müssen les-ci doivent être indiquées à per una scelta corretta del com-
of the component. der Firma OLI s.r.l. bei der Be- OLI s.r.l. au moment de la componente.
stellung angegeben werden, um mande.
The user must make sure the eine korrekte Auslegung des L’utilizzatore dovrà assicurarsi
plant in which the pneumatic Bauteils zu ermöglichen. L’utilisateur doit contrôler, avant che l’impianto all’interno del qua-
vibrator is installed has been la mise en marche, que l’installa- le verrà installato il vibratore
set in safety condition from the Der Anwender muss sicherstel- tion dans laquelle est monté le pneumatico sia stato adegua-
point of view of explosion risk len, dass die Anlage, in welcher vibrateur pneumatique a été tamente messo in sicurezza da
before being started up, and that der pneumatische Vibrator mise en sécurité en ce qui con- un punto di vista di rischio esplo-
the “document on protection installiert werden soll, hinsicht- cerne le risque d’explosion. Il faut sione prima di essere avviato e
against explosions” has also lich der Explosionsgefahr auf aussi que le “document sur la che inoltre sia stato redatto il
been prepared as specified by ausreichende Weise in einen si- protection contre les explosions” “documento sulla protezione
Directive ATEX 99/92/CE. (This cheren Zustand gebracht wor- ait été rédigé conformément à la contro le esplosioni” come pre-
only applies to the European den ist, bevor sie in Betrieb ge- Directive ATEX 99/92/CE (Ceci visto dalla Direttiva ATEX 99/92/
market). nommen wird, und dass zudem n’est valable que pour le marché CE. (Questo vale unicamente per
das „Explosionsschutzdoku- européen). il mercato europeo).
ment” verfasst worden ist, so
wie es die ATEX-Richtlinie 99/92/
EG vorsieht (Dies gilt nur für den
europäischen Markt).
06.04
- INDICATIONS FOR THE USE S1101
S - ANGABEN ZUM GEBRAUCH
OT
- MODES D’EMPLOI 2
OR
- INDICAZIONI PER L’USO OL.2000 EX M. 17
In accordance with the Directive ATEX Im Sinne der ATEX-Richtlinie 94/9/EG Le constructeur, aux termes de la Il costruttore, ai sensi della direttiva
94/9/CE, the manufacturer defines definiert der Hersteller die Außenum- directive ATEX 94/9/CE, définit l’ex- ATEX 94/9/CE, definisce l’esterno del
the outside of the pneumatic vibrator gebung des pneumatischen Klopfers térieur du vibrateur pneumatique com- vibratore pneumatico come:
as: als: me:
CAT. II 3 D KAT. II 3 D CAT. II 3 D CAT. II 3 D
IMPORTANT: specify that the non WICHTIG: Die Versionen, die nicht IMPORTANT: Spécifier que les ver- IMPORTANTE: Specificare che le
ATEX versions must not be used in ATEX sind, dürfen nicht in explosi- sions non ATEX ne doivent pas tra- versioni non ATEX non devono
potentially explosive environ- onsgefährdeten Bereichen arbei- vailler dans des atmosphères ex- operare in atmosfere potenzialmen-
ments. ten. plosibles. te esplosive.
The pneumatic vibrators are de- Die pneumatischen Vibratoren sind
signed and constructed in such a so entwickelt und konstruiert worden, Les vibrateurs pneumatiques ont I vibratori pneumatici sono stati
manner as to avoid unusual over- dass es während ihres Betriebs nicht été conçus et construits de manière progettati e costruiti in modo tale da
heating during operation. To operate zu Überhitzungen kommt. Um unter à ne pas provoquer d’échauffements non provocare surriscaldamenti ano-
in safe conditions, check to make sicheren Voraussetzungen arbeiten zu anormaux pendant le fonctionnement. mali durante il funzionamento. Per
sure the powders handled have a können, ist sicherzustellen, dass Pour travailler en condition de sécuri- poter operare in condizioni di sicurez-
minimum ignition temperature die aufbereiteten Stäube eine Min- té il faut vérifier que les poussiè- za occorre verificare che le polve-
higher than the temperature value destzündtemperatur haben, die res traitées on une température ri trattate abbiano una minima tem-
indicated on the code plate. unterhalb des Temperaturwerts d’inflammation minimale supé- peratura di ignizione superiore al
- The pneumatic vibrators must be liegt, der auf dem Typenschild rieure à la valeur de température valore di temperatura indicato sul-
installed with sufficient clearance steht. indiqué sur la plaque signaléti- la targhetta.
around to allow assembly/disas- - Die pneumatischen Vibratoren que. - I vibratori pneumatici dovranno
sembly operations, cleaning and müssen so installiert werden, dass - Les vibrateurs pneumatiques doi- essere installati con uno spazio cir-
maintenance. ringsum genügend Raum zur Ver- vent être installés avec autour un costante sufficiente per effettuare
fügung steht, um die normalen Ar- espace suffisant pour effectuer les le normali operazioni di montaggio/
Before carrying out any operation beiten für Ein- und Ausbau, Reini- opérations ordinaires de montage/ smontaggio, pulitura e manutenzio-
on the component, make sure it is gung und Wartung vornehmen zu démontage, nettoyage et mainte- ne.
in safe condition. können. nance.
Bevor man irgendeinen Eingriff an Prima di effettuare un qualsiasi
IMPORTANT: In this Manual “setting dem Bauteil vornimmt, ist sicher- Avant d’effectuer toute intervention intervento sul componente assi-
the component in safety condi- zustellen, dass es sich in einem sur le composant vérifier que ce- curarsi che questa sia messa in
tion” will include the following opera- sicheren Zustand befindet. lui-ci a été mis en sécurité. sicurezza.
tions: WICHTIG: Auf den weiteren Seiten
- Make sure the component is dis- dieses Handbuchs werden wir die IMPORTANT: Dans le présent manuel IMPORTANTE: In seguito nel presen-
connected from all electric sup- Ausdrucksweise „den Bauteil in ei- nous indiquons par “mettre en sécu- te manuale indicheremo con la dicitu-
ply sources. nen sicheren Zustand versetzen” rité le composant” les opérations ra “mettere in sicurezza il compo-
- Make sure the component is dis- benutzen, um folgende Vorgänge an- suivantes: nente” le seguenti operazioni:
connected from all compressed zugeben: - Contrôler si le composant est dé- - Accertarsi che il componente sia
air supply sources. - Sicherstellen, dass der Bauteil branché de toutes les alimenta- scollegata da tutte le alimenta-
- The area around the component von allen elektrischen Versor- tions électriques. zioni elettriche.
must be suitably lighted (opera- gungsquellen abgetrennt ist. - Contrôler si le composant est dé- - Accertarsi che il componente sia
tors can be provided with elec- - Sicherstellen, dass der Bauteil branché de toutes les alimenta- scollegata da tutte le alimenta-
tric lights suitable for zone 22 von allen pneumatischen Ver- tions pneumatiques. zioni pneumatiche.
cat. II 3 D). sorgungsquellen abgetrennt ist. - Eclairer correctement la zone qui - Provvedere a illuminare corret-
For carrying out operations on the - Dafür sorgen, dass der Bereich entoure le composant (en dotant tamente la zona circostante al
components (maintenance and clean- rings um den Bauteil korrekt aus- éventuellement les opérateurs de componente (eventualmente do-
ing), the operators must use suitable geleuchtet wird (indem die Arbeit- lampes électriques appropriées tando gli operatori di lampade
personal protection devices (PPD): nehmer eventuell mit elektri- pour zone 22 cat. II 3 D). elettriche idonee per zona 22 cat.
- Antistatic safety footwear (certi- schen Lampen ausgestattet wer- II 3 D.
fied) den, die für die Zone 22 Kat. II 3 Pour toute opération à effectuer sur
- Antistatic protective clothing (certi- D geeignet sind). le composant (entretien et nettoya- Per qualsiasi operazione da effettuarsi
fied) Für jeden Eingriff, der auf dem Baut- ge), les opérateurs doivent être mu- sul componente (manutenzioni e puli-
- Helmet eil vorzunehmen ist (Wartungen und nis des équipements de protection zia), gli operatori dovranno essere
- Antistatic cut proof gloves Reinigungen), müssen die Arbeitneh- individuelle (EPI): muniti degli appositi dispositivi di pro-
- Protective masks mer mit angemessenen persönlichen tezione individuale (DPI):
It is also necessary to use all the Schutzausrüstungen (PSA) versehen - Chaussures de protection antis-
safety devices specified in the safe- sein: tatiques (certifiées) - Scarpe antinfortunistiche anti-
ty sheet of the product handled. - antistatisches unfallsicheres - Vêtements de protection antista- statiche (certificate)
Schuhwerk (zertifiziert) tiques (certifiés) - Indumenti protettivi antistatici
NOTE: All the electrical equipment - antistatische Schutzkleidung (zer- - Casque (certificati)
used for maintenance or cleaning tifiziert) - Gants anti-coupure antistatiques - Casco
operations on the outside of the - Schutzhelm - Masques de protection - Guanti antitaglio antistatici
component must be ATEX certified - antistatische Schnittschutzhand- Il faut aussi utiliser tous les disposi- - Mascherine protettive
for zone 22 cat. II 3 D. schuhe tifs de protection prévus par la fiche Inoltre occorre utilizzare tutti i dispo-
- Schutzmasken de sécurité du produit traité. sitivi di protezione previsti dalla sche-
Außerdem sind alle Schutzvorrichtun- da di sicurezza del prodotto trattato.
gen zu verwenden, die von dem Si- N.B.: Tous les appareillages élec-
cherheitsdatenblatt des behandelten triques, utilisés pour les interven- N.B. Tutte le apparecchiature elet-
Produkts vorgesehen sind. tions de maintenance et de net- triche eventualmente utilizzate per
Anm.: Alle elektrische Ausrüstun- toyage réalisées à l’extérieur du interventi manutentivi o di pulizia
gen, die eventuell für die War- composant doivent être certifiés eseguiti all’esterno componente
tungseingriffe und die Reinigung ATEX pour zone 22 cat. II 3 D. devono essere certificate ATEX per
außerhalb des Bauteils benutzt zona 22 cat. II 3 D.
werden, müssen für Zone 22 Kat. II
3 D nach ATEX zertifiziert sein.
zona 22
- OPERATING CONDITIONS S110106.04
S - EINSATZEINSCHRÄNKUNGEN
OT
- LIMITES D’EMPLOI 2
OR
- LIMITI DI IMPIEGO OL.2000 EX M. 18
Noise level Betriebsgeräusche Niveau de bruit Rumorosità

Depending on the type of vibrator Je nach Typ (mit Schalldämpfer) und En fonction du type de vibrateur (avec A seconda del tipo di vibratore e della
and air pressure the noise level is 75- 6 bar Luftdruck bei 75 - 85 dB(A), bei silencieux) et pour une pression de 6 pressione dell’aria, il livello di rumo-
85 dB(A) (with silencer). If the air pres- geringerem Luftdruck weniger. Ein bars,( 90 PSI) le niveau de bruit est rosità sarà pari a 75-85 dB(A) (con
sure is lower, the noise level is also Betrieb ohne Schalldämpfer ist nicht compris entre 75 et 85 dB(A). Il est silenziatore). In caso di pressione
lower. We recommend in order to empfehlenswert, um die Lärm-Um- plus faible quand la pression est moin- dell’aria inferiore, anche la rumorosi-
avoid unnecessary noise for the en- weltbelastung so gering wie möglich dre. Ne pas faire fonctionner le vi- tà risulterà ridotta. Al fine di evitare
vironment, the vibrators should not zu halten. brateur sans silencieux pour ne pas rumori inutili nell’ambiente, si racco-
be operated without a silencer. provoquer des nuisances sonores manda di azionare sempre il vibratore
inutiles. provvisto di silenziatore.
NOTE ANM.: REMARQUE: NOTA

- The employer must take the neces- - Der Arbeitgeber muss im Betrieb - L’employeur doit mettre en oeuvre, - Il datore di lavoro dorà attuare, nel-
sary measures in the work area to alle technischen Maßnahmen dans le milieu de travail, les mesu- l’ambiente di lavoro, le misure tec-
reduce to the minimum the risk de- durchführen, um Gefahren, die sich res techniques appropriées pour li- niche adeguate per ridurre al mini-
riving from daily exposure to noise. aus der täglichen Lärmexposition miter au minimum les risques déri- mo i rischi derivanti dall’esposizio-
ergeben, auf ein Minimum zu vants de l’exposition journalière au ne giornaliera al rumore.
reduzieren. bruit.
Permissible operating conditions Zulässige Betriebsbedingungen Conditions de service admissibles Condizioni d’esercizio ammesse
Permissible temperature range: Betriebstemperaturen Températures admissibles: Range di temperatura ammesso:
S/OR -20°C to +200°C S / OR -20°C bis 200°C S/OR -20° C à 200° C S/OR da -20°C a +200°C
OT -20°C to +120°C OT -20°C bis 120°C. OT -20° C à 120° C OT da -20°C a +120°C
S and OR require heat resistant hose S-und OR-Vibratoren Betriebstempe- Pendant le fonctionnement la plage In caso di temperature superiori a
nipples and silencers for temperatures raturen über 120°C erfordern den Ein- de température admissible de -20°C 120°C (272°F), i vibratori S e OR do-
above 120°C (272°F) satz von Anschlußtüllen und Schall- à +120°C ne doit pas être dépassé. vranno essere dotati di silenziatori e
OT Vibrators may be operated in- dämpfern in temperaturbeständiger Des températures d’utilisation entre raccordi per flessibili resistenti al ca-
side liquids if the exhaust air is Ausführung. Sofern vorhanden, den 120°C et 200°C nécessitent des rac- lore.
piped into the atmosphere. Nebelöler einstellen (2-5 Tropfen/h). cords et des silencieux appropriés. I vibratori OT possono essere azio-
OT-Vibratoren Pour l’utilisation des OT sous l’eau nati all’interno di liquidi purché
Der Betrieb in Flüssigkeiten erfor- l’échappement doit se faire a l’air l’aria di scarico sia convogliata
dert die Abführung der Druckluft libre nell’atmosfera.
an die Atmosphäre.
Type S / OR
0 °C - 200°C
32 F° -390F°
Pressure - Betriebsdruk
Pression - Pressione
Type OT
0 °C - 120°C 6 bar / 90 PSI
32 F° - 250F° MAX.
Features of powders - Eigenschaften der stäube- Caracteristiques des poussières - Caratteristiche delle polveri
Powders - Staub Powders - Staub

Poussières - Polveri Poussières - Polveri
St 1 St 2
MINIMUM IGNITION ENERGY (mj) WITHOUT INDUCTANCE
ZÜNDENERGIE (mj) OHNE INDUKTANZ
> 3 > 3
ENERGIE D’INFLAMMATION MINIMUM (mj) SANS INDUCTANCE
MINIMA ENERGIA DI IGNIZIONE (mj) SENZA INDUTTANZA
MINIMUM IGNITION TEMPERATURE (°C) MIT
TIEFSTE ZÜNDTEMPERATUR (°C) MIT
≥ 200 ≥ 200
TEMPERATURE MINIMUM D’INFLAMMABILITE' (°C) MIT
MINIMA TEMPERATURA DI IGNIZIONE (°C) MIT
IGNITION TEMPERATURE OF POWDER LAYER DEPOSITED (°C) L.I.T.
ZÜNDTEMPERATUR DER ABGELAGERTEN STAUBSCHICHT (°C) L.I.T.
≥ 200 ≥ 200
TEMP. D’INFLAMMATION DE LA COUCHE DE POUSSIÈRE DÉPOSÉE (°C) L.I.T.
TEMPERAURA DI IGNIZIONE DELLO STRATO D POLVERE DEPOSITATO (°C) L.I.T.
MAXIMUM EXPLOSION PRESSURE (bar)
HÖCHSTER EXPLOSIONSDRUCK (bar)
≤9 ≤9
PRESSION MAXIMUM D’EXPLOSION (bar)
MASSIMA PRESSIONE DI ESPLOSIONE (bar)
REACTIVITY PARAMETER KST (bar m/s)
REAKTIVITÄTSPARAMETER KST (bar m/s)
< 300 < 300
PARAMÉTRE DE RÉACTIVITÉ KST (bar m/s)
PARAMETRO DI REATTIVITA' KST (bar m/s)
SURFACE RESISTIVITY (Ω m)
OBERFLÄCHENWIDERSTAND (Ω m)
< 1 x 1012 < 1 x 10 12
RÉSISTIVITÉ SUPERFICIELLE (Ω m)
RESISTIVITA' SUPERFICIALE (Ω m)
06.04
- WARRANTY CONDITIONS S1101
S - GARANTIEBEDINGUNGEN
OT
- CONDITIONS DE GARANTIE 2
OR
- CONDIZIONI DI GARANZIA OL.2000 EX M. 19
OLI S.r.l provides a 12-month OLI S.r.l. gewährt auf ihre Er- La Société OLI S.r.l reconnaît La OLI S.r.l riconosce un perio-
warranty on their products. This zeugnisse eine Garantie von une période de 12 mois de ga- do di 12 mesi di garanzia sui pro-
period starts from the date of the 12 Monaten. Die Garantiezeit rantie sur les produits de sa fa- dotti di propria costruzione. Il
consignment note. beginnt mit dem Datum des Lie- brication. La période prend ef- periodo decorre dalla data della
The warranty is not applicable ferscheins. fet à compter de la date indiquée bolla di consegna.
for breakage and/or defects Die Garantie ist nicht anwend- sur le bon de livraison. La garanzia non è applicabile a
caused by incorrect installation bar, wenn es sich um Schäden La garantie ne s’applique pas à seguito di rotture e/o difetti cau-
or use, or incorrect maintenan- und/oder Defekte handelt, die la suite de ruptures et/ou de dé- sati da errata installazione o uti-
ce, or modifications not authori- auf falschem Einbau oder Ge- fauts provoqués par un monta- lizzo, oppure da manutenzioni
zed by the Manufacturer. brauch, nicht korrekter Wartung ge et une utilisation impropre, non corrette o modifiche appor-
The warranty does not extend oder Änderungen beruhen, die des entretiens qui ne sont réali- tate senza autorizzazione del
to parts that wear out following ohne die Genehmigung des Her- sés correctement ou des modi- costruttore.
normal use and electrical com- stellers ausgeführt wurden. fications apportées sans autori- La garanzia non si estende alle
ponents. Die Garantie deckt keine Teile ab, sation du constructeur. parti che si logorano in seguito
The warranty elapses if the die infolge des normalen Ge- La garantie s’étend aux pièces al normale uso e alle parti elettri-
pneumatic vibrator: brauchs verschleißen, und auch qui s’usent à la suite d’une utili- che.
- has been tampered with or mo- keine elektrischen Teile. sation normale et aux parties A miglior precisazione la garan-
dified, Genauer geagt verfällt die Ga- électriques. zia decade nei casi in cui il vi-
- has not been used correctly, rantie in folgenden Fällen: Plus précisément la garantie est bratore pneumatico:
- has been used without res- - Das Druckluft Vibratoren wur- sans effet si le vibrateurs pneu- - sia stato manomesso o modifi-
pecting the limits indicated in de manipuliert oder abgeändert; matique : cato,
this manual and/or has been - wurde nicht angewandt; - a été manipulé ou modifié, - sia stato utilizzato non corret-
subjected to excessive mecha - bei seinem Gebrauch wurden - a été utilisé de manière incor tamente,
nical stress, die in diesem Handbuch ge- recte, - sia stato utilizzato non rispet-
- has not been subjected to the nannten Einsatzbeschränkun- - a été utilisé sans respecter les tando i limiti indicati nel presen-
necessary maintenance or the- gen nicht beachtet und/oder es limites indiquées dans la pré- te manuale e/o sia stato sotto-
se operations have been car- wurde zu starken mechani- sen te notice et/ou qu’il a été posto ad eccessive sollecita-
ried out partly and/or incorrect- schen Belastun gen ausge- soumis à des contraintes mé- zioni meccaniche,
ly, setzt; caniques excessives - non sia stato sottoposto alle
- has been damaged due to ca- - er wurde nicht der erforder- - il n’a pas été soumis aux en- necessarie manutenzioni o
relessness during transport, lichen Wartung unterzogen tretiens nécessaires ou que queste siano state eseguite
installation and use, oder diese wurde nur teilweise ces opérations ont été effec- solo in parte e/o non corretta-
- has been fitted with spare und/oder nicht korrekt ausge- tuées partiellement, de maniè- mente,
parts that are not original. führt; re incom plète ou incorrecte - abbia subito danni per incuria
On receiving the product, the - es wurde beschädigt, weil - a subit des dommages par né- durante il trasporto, l’installa-
user must check these for de- Transport, Einbau oder Ge- gligence pendant le transport, zione e l’utilizzo,
fects deriving from transport brauch ohne die erforderliche la mise en place et l’utilisation, - siano state inserite parti di ri-
and/or incomplete supply. Sorgfalt vorgenommen wur- - a été réparé avec des pièces cambio non originali.
Defects, damage or incom plete- den; qui ne sont pas d’origine. Al ricevimento del prodotto, il
ness of the supply must be im- - es wurden keine Original-Er- Dès réception de la marchan destinatario deve verificare che
mediately communicated to the satzteile verwendet. dise, le destinataire doit vérifier lo stesso non presenti difetti o
Manufacturer in writing and Beim Empfang der Ware hat der que celle-ci n’a pas de défauts danni derivanti dal trasporto e/o
countersigned by the haulage Empfänger sicherzustellen, ou subit de dégâts dus au tran incompletezza della fornitura.
transporter. dass die Ware keine durch den sport et que la fourniture n’est Eventuali difetti, danni o incom-
Transport verursachten Schä- pas incomplète. pletezza vanno immediatamente
den oder Defekte aufweist, und/ Tout défaut, dommage ou four segnalati al costruttore median-
oder dass der Lieferumfang voll- niture incomplète doit immédia te comunicazione scritta e con-
stän-dig ist. tement être signalée au constru trofirmata dal vettore.
Etwaige Defekte, Schäden oder cteur par communication écrite
Fehlmengen sind mittels schrift- et contresignée par le tran spor-
licher und vom Frachtführer ge- teur.
gengezeichneter Mitteilung
sofort dem Hersteller zu melden.
- TRANSPORT AND PACKING S110106.04
S - TRANSPORT UND PACKUNG
OT
- TRANSPORT ET EMBALLAGE 2
OR
- TRASPORTO E IMBALLO OL.2000 EX M. 20
TRANSPORT TRANSPORT TRANSPORT TRASPORTO

When the filter is delivered, make Bei Erhalt der Ware sicherstel- Au moment où vous recevez la Al ricevimento della merce con-
sure that the type and quantity len, ob Typ und Menge mit den machine, vérifiez si la typologie trollare se la tipologia e la quan-
of the materials consigned com- Daten auf der Bestellung über- et la quantité correspondent bien tità corrispondono con i dati del-
ply with the information on the einstimmen. aux données qui se trouvent sur la conferma d’ordine.
order confirmation. Etwaige Transportschäden sind la confirmation de la commande. Eventuali danni devono essere
Immediately inform the haulage sofort auf dem Schriftwege zu Si vous constatez des domma- fatti presenti immediatamente per
contractor in writing if damage melden, und zwar durch Eintra- ges, vous devez immédiatement iscritto nell’apposito spazio della
is discovered, using the relative gen auf dem Lieferschein. le déclarer en l’écrivant dans l’em- lettera di vettura.
space on the consignment form. Der Fahrer ist verpflichtet, diese placement réservé à cet effet L’autista è obbligato ad accetta-
The driver is obliged to accept Reklamation anzunehmen und Ih- sur la lettre de voiture. re un tale reclamo e lasciarne
the complaint and to issue you nen eine Kopie davon auszuhän- Le chauffeur est obligé d’accep- una copia a Voi. Se la fornitura è
with a copy. If the filter has been digen. Wenn die Lieferung frei ter votre réclamation et de vous franco destino, inviate il vs. re-
supplied carriage forward, either Haus erfolgt, senden Sie Ihre Re- en laisser une copie. Si la four- clamo e noi, altrimenti direttamen-
sent your complaint to us or klamation an uns, andernfalls di- niture a été livrée franco desti- te allo spedizioniere. Il risarcimen-
straight to the haulage contrac- rekt an den Frachtführer. Die Ent- nation, envoyez-nous votre ré- to avviene soltanto se avete fat-
tor. Damages will only be reim- schädigung erfolgt nur, wenn der clamation, sinon envoyez-la di- to presente il danno all’atto del
bursed if you have notified the Schaden gleich bei Empfang der rectement au transporteur. ricevimento.
matter on receipt of the goods. Ware gemeldet wird. Vous ne pourrez être rembour- Evitate ogni tipo di danneggia-
Prevent all type of damage dur- Vermeiden Sie jede Art der Be- sé des dommages et intérêts que mento durante lo scarico e le mo-
ing the unloading and handling schädigung beim Abladen und si vous avez déclaré le domma- vimentazioni.
operations. Bewegen. ge au moment où vous avez reçu Tenete conto che si tratta di ma-
Always bear in mind you are Immer berücksichtigen, daß es la machine. Faites bien attention teriale meccanico che deve es-
dealing with mechanical equip- sich um mechanische Elemente à ne pas abîmer la machine du- sere movimentato con cura.
ment which must be treated with handelt, die mit Vorsicht zu be- rant son déchargement et sa
care. handeln sind. manutention.
Rappelez-vous qu’il s’agit de ma-
tériel mécanique qui doit être dé-
placé avec le plus grand soin.
PACKING PACKUNG EMBALLAGE IMBALLO

NOTE: N.B.: N.B.: N.B.:
It is the installer’s responsibility Der Anlagenaufsteller ist dafür L’installateur doit, à ses frais, éli- è a cura dell’installatore smaltire
to dispose off the packaging in a verantwortlich, das Verpa- miner les emballages de manière gli imballi in modo adeguato e
suitable manner, in compliance ckungsmaterial auf angemesse- adéquate et conformément aux secondo le leggi vigenti in mate-
with existing legislation. ne Art und in Übereinstimmung lois en vigueur en la matière. ria.
mit den einschlägigen, geltenden
Gesetzen zu entsorgen.
06.04
- STORAGE S1101
S - LAGERHALTUNG
OT
- EMMAGASINAGE 2
OR
- IMMAGAZZINAGGIO OL.2000 EX M. 21
1)STORAGE PRIOR TO IN- 1) EINLAGERUNG VOR DEM 1) EMMAGASINAGE AVANT LA 1) IMMAGAZZINAGGIO PRIMA
STALLATION EINBAU MISE EN PLACE DELL’INSTALLAZIONE
- Avoid damp, salty environ- - Feuchte und salzhaltige Luft - Si possible éviter les locaux - Evitare possibilmente ambienti
ments, if possible. für die Einlagerung vermeiden. humides et les saumâtres umidi e salmastri.
- Place the component on wood- - Den Bauteil auf einer Holzpa- - Placer le composant sur des - Sistemare il componente su
en platforms and store it pro- lette setzen und vor Witterung palettes en bois et les ranger à pedane di legno e locarle al ri-
tected from unfavourable schützen. l’abri des intempéries. paro dalle intemperie.
weather conditions.
2)PROLONGED MACHINE 2) LÄNGERE BETRIEBSRUHE 2) ARRÊT MACHINE PROLON- 2) FERMO COMPONENTE PRO-
SHUTDOWNS AFTER AS- NACH DEM EINBAU GÉ APRÈS LE MONTAGE LUNGATO DOPO IL MON-
SEMBLY - Vor der Inbetriebnahme ist der - Avant la mise en service met- TAGGIO
- Before starting up the compo- Bauteil in einen sicheren Zu- tre le composant en sécurité. - Prima della messa in servizio
nent, set it in safety status. stand zu bringen. - Avant la mise en service du mettere in sicurezza il compo-
- Before starting up the compo- - Vor der Inbetriebnahme des composant contrôler l’intégrité nente.
nent, check the condition of the Bauteils die elektrische und de l’équipement électrique et de - Prima della messa in servizio
electric and pneumatic system pneumatische Anlage und alle toutes les parties pour lesquel- del componente controllare l’in-
and all parts for which long Teile, deren Funktionstüchtig- les un arrêt prolongé pourrait tegrità dell’impianto elettrico,
shutdowns may affect work- keit die bei einem längeren Still- compromettre le fonctionne- pneumatico, e di tutte le parti
ing. stand in Frage gestellt werden ment. per le quali un prolungato arre-
könnte, prüfen. sto potrebbe compromettere la
funzionalità.
3) POSSIBLE REUSE AFTER PE- 3) MÖGLICHE WIEDERVER- 3) RÉ-UTILISATION APRÈS UNE 3)POSSIBILE REIMPIEGO
RIODS OF INACTIVITY WENDUNG NACH EINEM LÄN- PÉRIODE D’INACTIVITÉ DOPO PERIODO DI INATTIVI-
- During component halts, avoid- GEREN STILLSTAND - Pendant la période d’inactivité TA’
damp, salty environments. - Während des Stillstands des du composant éviter les locaux - Durante il fermo componente
- Place the component on wood- Bauteils Räume mit feuchter humides et saumâtres evitare ambienti umidi e salma-
en platforms and store it pro- und salzhaltiger Luft vermei- - Placer le composant sur des stri.
tected from unfavourable den. palettes en bois et les ranger à - Sistemare il componente su
weather conditions. - Den Bauteil auf eine Holzpalet- l’abri des intempéries. pedane di legno e locarle al ri-
- Set the component in safety te setzen und vor Witterung - Avant la mise en service met- paro dalle intemperie.
status before starting it up. schützen. tre le composant en sécurité - Prima della messa in servizio
- Before starting up the compo- - Vor der Inbetriebnahme ist der - Avant la mise en service du mettere in sicurezza il compo-
nent, check the condition of the Bauteil in einen sicheren Zu- composant contrôler l’intégrité nente.
electric and pneumatic sys- stand zu bringen. de l’équipement électrique et de - Prima della messa in servizio
tems and all parts for which - Vor der Inbetriebnahme des toutes les parties pour lesquel- del componente controllare l’in-
long shutdowns may affect Bauteils die elektrische und les un arrêt prolongé pourrait tegrità dell’impianto elettrico,
working. pneumatische Anlage und alle compromettre le fonctionne- pneumatico, e delle parti per le
- Before starting up the compo- Teile, deren Funktionstüchtig- ment. quali un prolungato arresto po-
nent, clean it thoroughly by fol- keit die bei einem längeren Still- - Avant la mise en service du trebbe compromettere la fun-
lowing the indications on the stand in Frage gestellt werden composant effectuer un cycle zionalità.
powder safety sheet. könnte, prüfen. complet de nettoyage en res- - Prima della messa in servizio
- If the component operates in - Vor der Inbetriebnahme des pectant ce qui est indiqué sur del componente eseguire un
conditions and with materials Bauteils ist ein vollständiger la fiche de sécurité de la pous- ciclo completo di pulizia rispet-
different from the previous ap- Abreinigungszyklus vorzuneh- sière. tando quanto riportato sulla
plication, check the compatibil- men, wobei das zu beachten - Si le composant travaille dans scheda di sicurezza della pol-
ity of this use according to the ist, was auf dem Sicherheits- des conditions et avec des ma- vere.
indications in the INDICATIONS Datenblatt des entsprechenden tières différentes de l’applica- - Se il componente opera in con-
FOR USE section. Erzeugnisses steht. tion précédente, vérifier la dizioni e con materiali diversi
- Wenn der Bauteil unter Bedin- compatibilité de cette utilisation dall’applicazione precedente,
gungen oder mit Material betrie- d’après ce qui est indiqué dans verificare la compatibilità di tale
ben wird, das vom vorherigen la section MODE D’EMPLOI. utilizzo secondo quanto ripor-
Einsatz abweicht, ist die Ver- tato nel sezione INDICAZIONE
träglichkeit für den neuen Ein- PER L’USO.
satz mit den BEDIENSUNGSAN-
LEITUNG zu vergleichen.
- MAINTENANCE S110106.04
S - WARTUNG
OT
- ENTRETIEN 2
OR
- MANUTENZIONE OL.2000 EX M. 26
Set the component in safety Vor der Ausführung jeder Avant toute opération met- Prima di qualsiasi interven-
status before carrying out beliebiger Arbeit ist der Baut- tre le composant en condi- to mettere il componente in
any operation. eil in einen Zustand verset- tion de sécurité. sicurezza.
zen.
- If work is to be carried out on - Wo sich Teile des pneuma- - Pour atteindre des parties du - Là dove si debbano raggiun-
parts at the top of the pneu- tischen Vibrators in größerer vibrateur pneumatique en hau- gere parti del vibratore pneu-
matic vibrator, use a work area Höhe befinden, eine Arbeits- teur, utiliser une plate-forme matico in quota utilizzare una
platform which must be select- plattform zu benutzen, die so aérienne de travail qui devra piattaforma aerea di lavoro che
ed in such a manner as to avoid zu wählen ist, dass eine être choisie de manière à évi- dovrà essere scelta in modo
risk of slipping, tripping or fall- Gefährdung des Personals in ter tout danger de glissement da evitare pericoli di scivola-
ing of operators. Form von Ausrutschen, Hän- ou de chute des opérateurs. mento, inciampo o caduta per
genbleiben oder Absturz ver- gli operatori.
mieden wird.
S and OR-vibrators are mainte- S-und OR- Vibratoren sind war- Les S et OR ne réclament pas I vibratori S e OR sono esenti da
nance-free. From outside they tungsfrei. Sie können von außen d’entretien. Ils peuvent être net- manutenzione. Possono essere
can be cleaned with a water jet. mit einem Wasserstrahl gereinigt toyés extérieurement à l’eau puliti esternamente mediante get-
Operate the vibrator for a short werden. Nach der Reiningung sous pression. Après le nettoya- to d’acqua. Dopo avere eseguito
while after. den Vibrator kurz betätigen. ge, faire brièvement fonctionner questa operazione, farli funzio-
le vibrateur. nare per un breve intervallo di
tempo.
WARNING ACHTUNG ATTENTION ATTENZIONE

Dirty compressed air caus- Schmutzige Druckluft führt L’air chargé d’impuretés L’aria compressa contenen-
es clogging of filter and si- zur Verschmutzung von Fil- provoque l’encrassement te impurità provoca l’insudi-
lencer. ter und Schalldämpfer. du filtre et du silencieux. ciamento del filtro e del si-
If necessary empty the fil- Filter ggfls. leeren, den Fil- En cas de nécessité, purger lenziatore. Se necessario,
ter, clean filter element and tereinsatz und den Schall- le filtre, nettoyer la garnitu- svuotare il filtro, pulire la car-
silencer (wash out). dämpfer reinigen bzw. aus- re du filtre et le silencieux tuccia e il silenziatore (ri-
waschen. (en les lavant). sciacquo).
REPLACING “OT” ERSETZEN DER LAGER REMPLACEMENT DES SOSTITUZIONE

SERIES BEARINGS SERIEN „OT” ROULEMENTS SERIE “OT” CUSCINETTI SERIE “OT”
06.04
- MAINTENANCE S1101
S - WARTUNG
OT
- ENTRETIEN 2
OR
REPLACING “OT” AUSTAUSCH DER LAGER REMPLACEMENT DES SOSTITUZIONE

SERIES BEARINGS SERIE „OT” ROULEMENTS SERIE “OT” CUSCINETTI SERIE “OT”
3 4
Use exclusively bearings of the Ausschließlich Lager des folgen- Remplacer exclusivement avec Sostituire esclusivamente con
following type for replacement: den Typs verwenden: des roulements type: cuscinetti tipo:
OT type SKF bearing type

OT 8
OT 10 607 ZTN9/C3
OT 10 S
OT 13
OT 16 6000 ZTN9/C3
OT 16 S
OT 20
OT 25 6203 ZTN9/C3
OT 25 S
OT 30
OT 36 6303 ZTN9/C3
OT 36 S
- MAINTENANCE S110106.04
S - WARTUNG
OT
- ENTRETIEN 2
OR
PERIODIC CHECKS REGELMÄSSIGE KONTROLLEN CONTROLES PERIODIQUES CONTROLLI PERIODICI
Set the component in safety Vor der Ausführung belie- Avant toute operation met- Prima di qualsiasi interven-
status before carrying out biger Arbeiten das Bauteil in tre le composant en condi- to mettere il componente in
any operation. einen sicheren Zustand ver- tion de sécurité. sicurezza.
setzen.
- Clean dust deposits on a week- - Etwaige Staubansammlungen - Chaque semaine éliminer les - Settimanalmente rimuovere
ly basis. einmal pro Woche entfernen. dépôts de poussière qui se eventuali cumuli di polvere di
- Check the tightening of the - Die Schraubanschlüsse einmal sont accumulés. deposito.
screw connectors on a month- pro Monat auf festen Sitz prü- - Tous les mois vérifier le serra- - Verificare mensilmente, il ser-
ly basis. fen. ge des raccords à vis. raggio dei raccordi a vite.
- Check tightening torque of the - Einmal pro Monat das Anzugs- - Tous les mois vérifier le couple - Verificare mensilmente, la cop-
fixing screws on a monthly moment der Befestigungs- de serrage des vis de fixation. pia di serraggio delle viti di fis-
basis. schrauben prüfen. - Tous les mois vérifier l’équipo- saggio.
- Check the equipotential with - Einmal pro Monat die Struktur, tentialité avec la structure sur - Verificare mensilmente, l’equi-
the structure on which the vi- an der der Vibrator befestigt laquelle est fixé le vibrateur. potenzialità con la struttura su
brator is mounted, on a month- ist, auf Potentialausgleich prü- - Tous les 3000 heures rempla- cui viene fissato il vibratore.
ly basis. fen. cer les roulements à bille sur le - Sostituire ogni 3000 ore sul mo-
- Change the ball bearings on the - Alle 3000 Betriebsstunden bei modèle OT. dello OT i cuscinetti a sfera.
OT model every 3000 hours. Modell OT die Kugellager prü-
fen.
CLEANING REINIGUNG NETTOYAGE PULIZIA

Set the component in safety Vor der Ausführung belie- Avant toute operation met- Prima di qualsiasi interven-
status before carrying out biger Arbeiten das Bauteil in tre le composant en condi- to mettere il componente in
any operation. einen sicheren Zustand tion de sécurité. sicurezza.
versetzen.
While cleaning the dust deposit- En éliminant la poussière présen- Nella rimozione della polve-
ed on the component, avoid Beim Entfernen von Staub, der te sur le composant faire atten- re eventualmente presente
throwing up dust into the sur- sich eventuell auf dem Bauteil tion à ne pas la disperser dans nel componente, aver cura
roundings and avoid dust depos- gebildet hat, dafür sorgen, dass le milieu environnant et éviter tou- di non disperdere la polvere
its. der Staub nicht in die Umgebung te accumulation. stessa nell’ambiente circo-
verteilt wird, und vermeiden, stante e avere cura di evita-
- The user must choose suitable dass sich zu viel Staub ansam- - L’utilisateur doit utiliser des pro- re cumuli.
cleaning products depending melt. duits appropriés pour le net-
on the type of plant and the toyage en fonction du type - L’utilizzatore dovrà provvede-
product handled, taking care to - Der Anwender muss Reini- d’installation et du produit trai- re alla scelta dei prodotti idonei
avoid toxic and inflammable gungsmittel verwenden, die té, en faisant attention à ne pas alle fasi di pulizia in base alla
products. zum Typ der Anlage und zum employer de produits toxique tipologia di impianto ed al pro-
- If the pneumatic vibrator is to behandelten Produkt passen. ou inflammables. dotto trattato facendo comun-
be used with food products, Er muss auf jeden Fall dafür - Si le vibrateur pneumatique tra- que attenzione a non usare
use non toxic detergents suit- sorgen, dass keine giftigen vaille avec des produits alimen- prodotti tossici o infiammabili.
able for the type of application. oder feuergefährlichen Pro- taires il est obligatoire d’utiliser - Nel caso che il vibratore pneu-
- The cleaning frequency de- dukte verwendet werden. des détergents non toxiques, matico operi con prodotti ali-
pends on the type of product - Falls der pneumatische Vibra- mais appropriés au type d’ap- mentari è obbligatorio usare
handled and the plant. tor zum Verarbeiten von Le- plication. detergenti non tossici, ma ido-
- In case of harmful, toxic prod- bensmitteln benutzt wird, ist es - La fréquence des opérations nei al tipo di applicazione.
ucts, cleaning wastes must be vorgeschrieben, ungiftige Rei- de nettoyage dépend de la na- - La frequenza delle operazioni
conveyed into closed tanks and nigungsmittel zu verwenden, ture du produit traité et de l’équi- di pulizia dipendono dalla natu-
disposed off according to the die zur Anwendung passen. pement. ra del prodotto trattato e del-
indications in the products - Die Häufigkeit der Reinigung - En cas de produits nocifs ou l’impianto.
safety sheet. hängt von der Beschaffenheit toxiques, les eaux usées du - Nel caso di prodotti nocivi, tos-
des zu behandelnden Produkts nettoyage doivent être con- sici, i reflui della pulitura do-
und der Anlage ab. voyées dans une cuve fermée vranno essere convogliati in
- Falls man schädliche oder gif- adéquate et éliminées confor- idonea vasca chiusa e smaltiti
tige Erzeugnisse verarbeitet, mément à ce qui est prévu par secondo quanto previsto dalla
müssen die Reinigungsabwäs- la fiche de sécurité du produit. scheda di sicurezza del pro-
ser in einer geeigneten, ge- dotto.
schlossenen Wanne gesam-
melt und gemäß den Angaben
auf dem Sicherheits-Datenblatt
entsorgt werden.
06.04
- RESIDUAL RISKS S1101
S - RESTRISIKEN
OT
- RISQUES RESIDUELS 2
OR
- RISCHI RESIDUI OL.2000 EX M. 29
On the basis of the use of the Je nach Verwendung des Druck- L'installateur, en fonction de l’utili- L'installatore, in base all'utilizzo
pneumatic vibrator, the installer luft Vibratoren muss der Installa- sation du vibrateur pneumatiques, del vibratore pneumatico, deve
must inform the operator by means teur das Personal durch besonde- doit informer les opérateurs, au informare gli operatori, tramite
of specific signals, regarding the re Hinweisschilder auf folgende moyen d’indications et de signali- appositi segnali, in merito ai se-
residual risks: Restrisiken hinweisen: sations prévues à cet effet, sur les guenti rischi residui :
risques résiduels suivants :
1. Mechanical risk 1.Gefahren mechanischer Art 1. Pericoli di natura meccanica
For maintenance operations, it Für die Wartungsarbeiten muss 1. Dangers de nature mécanique Per le attività di manutenzione
is compulsory for the operator das Personal immer seine per- Pour les activités d’entretien è fatto obbligo all'operatore di
to always use personal protec- sönlichen Schutzausrüstungen l’opérateur a l’obligation d’utili- impiegare sempre i dispositivi
tion equipment. benutzen. ser toujours les dispositifs de di protezione individuale.
Special warning notices on each Besondere Warnschilder an den protection individuelle. Apposite targhe monitorie nel-
section of the machine indicate einzelnen Abschnitten des Ge- Des plaques d’avertissements le singole sezioni di macchina
the obligatory personal protec- räts geben an, welche persönli- apposées dans chaque section indicano quali dispositivi di pro-
tion equipment: chen Schutzausrüstungen de la machine indiquent quels tezione individuale si rendono
jeweils erforderlich sind: sont les dispositifs de protection obbligatori:
individuelle qui sont obligatoi-
GLOVE ARE
COMPULSORY DIE BENUTZUNG res :
VON
HANDSCHUHEN
E’ OBBLIGATORIO
IST VORGESCHRIEBEN
PORT DE USARE I GUANTI
GANTS
SAFETY
OBLIGATOIRE
FOOTWEAR ARE DIE BENUTZUNG
COMPULSORY VON SICHERHEITS E’ OBBLIGATORIO
SCHUHWERK USARE LE
IST CHASSURES DE CALZATURE
VORGESCHRIEBEN SÉCURITÉ DI SICUREZZA
2. Presence of possible residu- OBLIGATOIRES
al high temperature after percus- 2. Vorliegen möglicher hoher 2. Presenza di possibili alte tem-
sion gun stop Temperaturen nach dem Still- 2. Présence de hautes tempéra- perature residue dopo l'arresto
During the course of mainte- stand der Klopfer
nance and cleaning operations tures résiduelles après l’arrêt del percussore
Im Laufe einiger Wartungs- und du percuteur Nel corso di interventi manu-
and in certain operating sec- Reinigungsarbeiten und in ei- tentivi e di pulizia e in alcune
tions, the operator may enter Au cours des interventions d’en-
nigen Arbeitsabschnitten kann tretien et de nettoyage et dans sezioni di lavoro, l'operatore può
into contact with very hot parts das Personal bei stehendem entrare in contatto, a macchina
of the percussion gun, with the certaines sections de travail,
Gerät in Kontakt mit Teilen der l’opérateur peut entrer en conferma, con parti del percussore
machine stopped. Klopfer geraten, die eine hohe pneumatico con superfici ad ele-
Special warning notices, locat- tact, quand la machine est arrê-
Temperatur aufweisen. tée, avec des parties du filtre vata temperatura.
ed at strategic points indicate Besondere Warnschilder, die an Apposite targhe monitorie, col-
the risk due to the presence of dont les surfaces sont à des tem-
den strategischen Stellen ange- pératures élevées. locate nei punti strategici indi-
very hot surfaces and the obli- bracht sind, weisen auf die Ge- cano il pericolo dovuto alla pre-
gation for the operator to wear Des plaques d’avertissement,
fahren hin, die sich durch die apposées dans les endroits stra- senza di superfici ad elevata
personal protection equipment, hohe Temperatur der Oberflä- temperatura e l'obbligo per
especially protective gloves. tégiques, signalent le danger
chen ergeben und weisen das dû à la présence de surfaces à l'operatore di utilizzare disposi-
Personal darauf hin, dass es zur des températures élevées et tivi di protezione individuale, in
Verwendung der persönlichen l’obligation de l’opérateur d’uti- particolare guanti protettivi.
GLOVES ARE Schutzausrüstungen verpflichtet
COMPULSORY liser les dispositifs de protection
ist, insbesondere zum Tragen individuelle, en particulier des E’ OBBLIGATORIO
von Schutzhandschuhen.. gants de protection. USARE I GUANTI
WARNING
DANGEROUS DIE BENUTZUNG PORT DE
TEMPERATURE VON GANTS
HANDSCHUHEN ATTENZIONE
OBLIGATOIRE TEMPERATURE
IST VORGESCHRIEBEN
PERICOLOSE
3. Presence of potentially haz-
ardous dusts ATTENTION
ACHTUNG TEMPERATURES
In the event of both routine and GEFÄHRLICHE 3. Presenza di polveri potenzial-
DANGEREUSES
extraordinary maintenance, the TEMPERATUREN mente pericolose
operator must wear suitable per- Nel caso di interventi sia ordi-
sonal protection equipment, 3. Vorhandensein potentiell ge- 3. Présence de poussières po- nari che straordinari di manu-
and in particular, use a safety fährlicher Stäube tentiellement dangereuses
tenzione l'operatore deve dotar-
mask for the respiratory tract Bei regelmäßiger und außeror- Aussi bien dans le cas d’inter-
si di idonei dispositivi di prote-
depending on the type of dust dentlicher Wartung muss das ventions d’entretien ordinaires
zione individuale ed in partico-
daalt as well as gloves and Personal geeignete pers önli- ou extraordinaires, l’opérateur
lare deve utilizzare maschere a
clothing. che Schutzausrüstungen ver- doit se doter des dispositifs de
protezione delle vie respirato-
For more details, refer to the wenden und insbesondere Mas- protection individuelle et en
rie di classe idonea in base al
safety chart of the product han- ken zum Schutz der Atemwege particulier il doit utiliser des
tipo di polvere trattata nonché
dled. mit geeigneter Klasse für den masques de classe appropriée
di guanti o indumenti.
aufbereiteten Staub, wie auch pour protéger les voies respira-
Per maggiori dettagli si deve far
Schutzhandschuhe und Schutz- toires en fonction du type de
riferimento alla scheda di sicu-
MASK IS kleidung tragen. poussière traitée ainsi que de
rezza del prodotto utilizzato.
COMPULSORY Für nähere Angaben ist Bezug gants ou de vêtements adé-
auf das Sicherheitsdatenblatt quats.
des verwendeten Produkts zu Pour plus de détails consulter E’ OBBLIGATORIO
la fiche de sécurité du produit USARE LA
nehmen. MASCHERA
utilisé.
DIE BENUTZUNG
DER MASKE IST MASQUE
VORGESCHRIEBEN OBLIGATOIRE
- RESIDUAL RISKS S110106.04
S - RESTRISIKEN
OT
- RISQUES RESIDUELS 2
OR
- RISCHI RESIDUI OL.2000 EX M. 30
- In certain handling of dusts, - Bei bestimmten Staubbehand- - Dans des traitements détermi- - In determinati trattamenti di pol-
where hazardous substanc- lungen, wo schädliche Substan- nés de poussières où il y a la veri dove vi è la presenza di
es are present, the operator zen auftreten, muss das Perso- présence de substances no- sostanze nocive, l'operatore
concerned who has to access nal, falls es im Laufe der regel- cives, l’opérateur qui doit y che dovesse accedere, nel
the machine for routine and mäßigen oder außerordentli- avoir accès, dans le cours des corso di interventi ordinari o
extraordinary maintenance chen Wartung damit in Kontakt interventions ordinaires ou ex- straordinari, deve indossare gli
operations must wear suitable kommt, persönliche Schutzaus- traordinaires, doit porter les dis- idonei dispositivi di protezione
protective devices as indicat- rüstungen tragen, so wie auf den positifs de protection appro- come indicato dalla cartelloni-
vorhandenen Schildern ange-
ed on the notice signs provid- priés comme signalé par les stica ivi presente.
geben.
ed. panneaux indicateurs qui s’y
DIE BENUTZUNG trouvent. E’ OBBLIGATORIO
DER MASKE IST USARE LA
MASK IS MASCHERA
VORGESCHRIEBEN
COMPULSORY MASQUE
OBLIGATOIRE
ATTENZIONE
VORSICHT: SOSTANZE
WARNING SCHADSTOFFE
HURTFUL ATTENTION NOCIVE
SUBSTANCE SUBSTANCES
DANGEREUSES
DIE BENUTZUNG
VON
HANDSCHUHE E’ OBBLIGATORIO
GLOVES ARE IST VORGESCHRIEBEN USARE I GUANTI
PORT DE
COMPULSORY
GANTS
Bei der Ausführung von erhit- OBLIGATOIRE
zenden Arbeiten (Schweißen, Tutte le manutenzioni all'inter-
In case of operations involving no del vibratore pneumatico
Schneiden) ist es erforderlich, Tous les entretiens à l’intérieur
heating (welding, cutting) it is DEVONO essere effettuate ad
die Oberfläche des pneumati- du vibrateur pnumatique DOI-
necessary to clean the sur- schen Vibrators vorbeugend zu VENT être effectués quand l’ins- impianto fermo e in assenza di
face of the pneumatic vibrator behandeln, um alle Staubab- tallation est arrêtée et en ab- polvere aerodispersa. In caso
first, removing all dust depos- lagerungen und in Abwesenheit sence de poussière dispersée di lavori a caldo (saldatura, ta-
its (the layers, the deposits atembarer Stäube durchgeführt dans l’air. Dans le cas de tra- glio) è necessario bonificare
and accumulated combustible werden. Bei der Ausführung von vaux à chaud (soudure, décou- preventivamente le superfici
powder MUST be considered erhitzenden Arbeiten (Schwei- pe) il faut préalablement net- del vibratore pneumatico, ri-
like any other source which can ßen, Schneiden) ist es erforder- toyer les surfaces du vibrateur muovendo tutti i depositi di pol-
result in an explosive atmos- lich, den Vibrator so vorzube- pneumatique,, en éliminant tous vere (gli strati, i depositi ed i
phere). reiten, dass alle Staubablage- les dépôts de poussière (les cou- cumuli di polvere combustibile
Authorization for operations in- rungen entfernt werden (Schich- ches, les dépôts et les tas de DEVONO essere considerati
volving heating MUST be given ten, Ablagerungen und An- poussière combustible DOI- come qualsiasi altra sorgente
by technical personnel special- sammlungen von brennbarem VENT être considérés comme
che può dare origine ad un'at-
iz-ed and trained in the risk of Staub MÜSSEN wie jede une autre source pouvant don-
mosfera esplosiva).
andere Staubquelle betrachtet ner lieu à une atmosphère ex-
explosion from dusts (capable L'autorizzazione all'esecuzio-
werden, die zur Entstehung ei- plosive).
of checking residual risk, suit- ne dei lavori a caldo DEVE es-
ner explosiven Atmosphäre bei- L'autorisation à l’exécution des
ability of tools and a knowledge tragen kann). sere data da personale tecni-
of the procedures). travaux à chaud DOIT être don-
Die Genehmigung zur Ausfüh- née par du personnel technique co specializzato e formato sul
(The person responsible for rung von Arbeiten im erwärm- rischio esplosione da polveri
spécialisé et formé sur le risque
safety must issue a “Fire Per- ten Zustand DARF NUR durch (in grado di verificare il rischio
d’explosion des poussières (en
mit” to the operator). spezialisiertes technisches Per- mesure4 de vérifier le risque ré- residuo, l'idoneità degli utensili
4. Hazards deriving from sonal erteilt werden, das über siduel, l’aptitude des outils et e la conoscenza delle proce-
pressurized circuits (hydrau die Explosionsgefahr durch la connaissance des procédu- dure). Il responsabile della si-
lic, pneumatic) Staub unterrichtet ist (das in der res). curezza dovrà rilisciare un
During maintenance and/or Lage ist, das Restrisiko festzu- Le responsable de la sécurité “permesso di lavoro fuoco” al-
repair operations pressure stellen, das die geeigneten devra délivrer un “permis de l’operatore.
must be discharged from the Werkzeuge und auch die Pro- feu” à l’opérateur. 4. Pericoli derivanti da circuiti
plants and accumulators (if zeduren kennt). Der Werkschutz- 4. Dangers dérivant des circuits in pressione (idraulici, pneu-
present), according to the in- verantwortliche muss dem Per- sous pression (hydrauliques, matici)
sonal eine „Genehmigung zur
structions given along-side the pneumatiques) Durante le operazioni di manu-
Feuerarbeit” ausstellen.
components and in the respec- Pendant les opérations d’entre- tenzione e/o riparazione occor-
4. Gefahren durch unter Druck
tive user manuals. tien et/ou de réparation il faut
stehende Leitungen (hydrau- re porre in scarico gli impianti e
5. Hazard generated by noise lisch, pneumatisch) décharger les installations et les
gli eventuali accumulatori, se-
The user and employer are Während der Wartungsarbeiten éventuels accumulateurs, con-
formément aux instructions qui
condo le istruzioni riportate in
obliged to respect the legal und/oder Reparaturen sind die prossimità dei componenti e nei
standards as regards protec- Anlagen und die etwaigen Ak- se trouvent à proximité des com-
posants et dans les notices d’ins- rispettivi manuali d'uso.
tion from daily personal expo- kumulatoren zu entleeren, so 5. Pericoli generati da rumo-
tructions correspondantes.
sure of operators to noise (in wie es in den Anweisungen an re
5. Dangers provoqués par le
Italy L.D.277/91). de jeweiligen Komponenten
bruit E' fatto obbligo all'utilizzatore e
oder in den entsprechenden
L’utilisateur ainsi que l’em- al datore di lavoro di rispettare
Handbüchern steht.
ployeur ont l’obligation de faire le norme di legge in termine di
5. Gefährdung der Arbeitnehmer
respecter les normes de loi en protezione contro l'esposizio-
durch Lärm
matière de protection contre l’ex- ne personale quotidiana degli
Der Anwender und der Arbeit-
position personnelle quotidien- operatori al rumore (in Italia
geber sind zur Einhaltung der
ne des opérateurs au bruit (en D.Lgs.277/91).
gesetzlichen Bestimmungen in
Italie D.Lgs.277/91).
Sachen Schutz gegen tägliche
persönliche Lärmexposition der
Arbeitnehmer verpflichtet (in
Italien D.Lgs.277/91).
06.04
- FAULT FINDING S1101
S - BETRIEBSSTÖRUNGEN UND ABHILFE
OT
- INCONVENIENTS ET SOLUTIONS 2
OR
- INCONVENIENTI E SOLUZIONI OL.2000 EX M. 31
FAULT ACTION
Check the presence of compressed-air
The vibrator does not start
Check the presence of foreign elements in the piping or in the vibrator
The vibrator increase in Check the fastening of the fixing screws and in case, make the supporting plate stiff
noisiness Lubrificate the pneumatic line
Check the feed pressure (MAX 6 BAR)
The vibrator loose its vibrating
Check the fastening of the fixing screws and in case, make the supporting plate stiff
effect
Lubrificate the pneumatic line
STÖRUNG ABHILFE
Die Druckluft kontrollieren
Der Rüttler starts nicht
Eventuelle Fremdkörper in der Leitung oder in den Rüttler kontrollieren
Den Spanndruck der Befestigungsschrauben kontrollieren und die Stutzplatte eventuell verstärken
Mehr Rüttlergeräusch
Die pneumatische Vorrichtung schmieren
Den Einlassdruck (MAX 6 BAR) kontrollieren
Verlust an Vibrierwirkung Den Spanndruck der Befestigungsschrauben kontrollieren und die Stutzplatte eventuell verstärken
Die pneumatische Vorrichtung schmieren
PROBLÈME SOLUTION
Vérifier la présence d'air comprimé
Le vibrateur ne démarre pas
Vérifier la présence d'éléments étrangers dans la tubuluru ou le vibrateur
Vérifier le serrage des vis et éventuellement raidir la plaque d'appui
Il rumore del vibratore aumenta
Lubrifier la ligne pneumatique
Vérifier la pression d'alimentation (MAX 6 BAR)
Il vibratore cala l'effetto vibrante Vérifier le serrage des vis et éventuellement raidir la plaque d'appui
Lubrifier la ligne pneumatique
PROBLEMA SOLUZIONE
Controllare presenza aria compressa
Il vibratore non parte
Controllare presenza elementi estranei nella tubazione o nel vibratore
Controllare il serraggio delle viti di fissaggio ed eventualmente irrigidire la piastra di supporto
Il rumore del vibratore aumenta
Lubrificare la linea pneumatica
Controllare la pressione di alimentazione (MAX 6 BAR)
Il vibratore cala l'effetto vibrante Controllare il serraggio delle viti di fissaggio ed eventualmente irrigidire la piastra di supporto
Lubrificare la linea pneumatica
- SCRAPPING COMPONENT / RETURNING COMPONENT S110106.04
S - VERSCHROTTUNG DES BAUTEILS / RÜCKGABE DES BAUTEILS
OT
- DEMANTELEMENT DU COMPOSANT / RESTITUTION DU COMPOSANT 2
OR
- ROTTAMAZIONE COMPONENTE / RESO COMPONENTE OL.2000 EX M. 32
SCRAPPING VERSCHROTTUNG DES DEMANTELEMENT DU ROTTAMAZIONE

COMPONENT BAUTEILS COMPOSANT COMPONENTE
- Before proceeding with dis- - Bevor das Druckluft Vibrator - Avant mettre le vibrateur pneu- - Prima di procedere allo smalti-
posal of the pneumatic vibra- entsorgt wird, dieses vollkom- matique à la décharge le net- mento del vibratore pneumati-
tor, clean it thoroughly and dis- men reinigen und den enthalte- toyer complètement et éliminer co provvedere alla sua com-
pose off the residual dust in nen Reststaub in Übereinstim- les poussières restantes con- pleta pulizia ed allo smaltimen-
accordance with the indica- mung mit dem Sicherheitsda- formément aux indications to delle polveri residue in ac-
tions in the safety chart. tenblatt entsorgen. fournies par la fiche de sécuri- cordo con le indicazioni della
- The operators in charge of dis- - Die Arbeitnehmer, die sich um té. scheda di sicurezza.
posal must use suitable per- die Entsorgung kümmern, müs- - Les personnes préposées à la - Gli operatori addetti allo smalti-
sonal protection equipment. sen angemessene persönliche mise à la décharge doivent por- mento devono indossare di-
- For scrapping or demolition of Schutzausrüstungen verwen- ter des dispositifs personnels spositivi di protezione perso-
the component, separate the den. de protection appropriés. nale adeguati.
plastic parts (seals and com- - Wenn der Bauteil verschrottet - - En cas de mise à la décharge - In caso di rottamazione o de-
ponents) and send these to werden soll, sind die kunst- ou de démantèlement du com- molizione a fine vita del com-
special collection centres. stoffhaltigen Teile (Dichtungen posan, il faut démonter les piè- ponente, avere cura di smon-
- The other parts must be sent und Komponenten) auszubau- ces en matière plastique (joints tare le parti in materiale plasti-
for recycling ferrous materials. en und über die entsprechen- et composants) et les mettre à co (guarnizioni e componenti)
den Sammelstellen dem Recy- la décharge dans des déchet- e destinarle agli appositi centri
cling zuzuleiten. teries spécialisées. di raccolta.
- Die restlichen Teile sind als Ei- - Les pièces restantes sont à - Le restanti parti sono da desti-
senschrott zu behandeln. destiner à la récupération des nare al recupero dei materiali
matériaux ferreux. ferrosi.
RETURNING THE MACHINE RÜCKGABE DES GERÄTES RESTITUTION MACHINE RESO MACCHINA
When returning the component, Falls der Bauteil zurückgegeben En cas de restitution du compo- In caso di reso del componente
use the original packaging if it werden soll und man die Origi- sant, si l’emballage a été conse si è conservato l’imballo rein-
has been preserved, otherwise nalverpackung aufbewahrt hat, servé, le remettre dans celui-ci, serirla nello stesso, altrimenti in-
place it in a box and cover it with ist er darin einzupacken. sinon le mettre dans une caisse serirlo in una scatola e proteg-
nylon shrink-wrap, to protect it Andernfalls ist er in einen Kar- et le protéger avec du nylon ther- gerlo con del nylon termoretrai-
as best as possible from impact ton zu packen und mit Schrumpf- morétractable, en essayant de bile, cercando di proteggerlo al
during transport. In any event, folie zu schützen, wobei man la protéger le plus possible con- meglio da eventuali urti derivanti
make sure there is no residue versucht, sie so gut wie möglich tre les chocs provoqués par le dal trasporto. In ogni caso assi-
material inside the component. vor etwaigen Stößen beim transport. Dans tous les cas s’as- curarsi che il componente non
Transport zu schützen. Auf je- surer que la machine ne contient abbia residui di materiale.
den Fall sicherstellen, dass sich pas de résidus de matière.
keine Materialreste mehr in der
Bauteil befinden.
14053
BASKET ROTATOR ASSEMBLY
Page 1 of 2
Updated:
12/19/06
14053
BASKET ROTATOR ASSEMBLY
Page 2 of 2

22891-01 BASKET ROTATOR 1
524382 SEAL KIT (INCLUDES ITEM 8-14) 1
524381 BEARING KIT (INCLUDES ITEMS 15, 16) 1
1 524378 SHAFT WELDMENT 1
2 524380 SLEEVE 1
3 524383 PISTON 1
4 524379 NUT 1
5 524375 LOCKNUT 1
6 524376 CAP SCREW 4
7 524377 SET SCREW 2
8 NSS END CAP SEAL 1
9 NSS END CAP B/U RING 1
10 NSS EXCLUDER SEAL 2
11 NSS ROD PACKING 2
12 NSS PISTON PACKING 2
13 NSS SHAFT AND CAP PACKING 2
14 NSS PISTON SEAL 1
15 NSS BEARING 2
16 NSS THRUST BEARING 2
Updated:
12/19/06
S1033
MAINTENANCE
MANUAL FOR
HP SERIES PIVOT
ROTARY ACTUATORS
TABLE OF CONTENTS
PAGE 2 THEORY OF OPERATION
PAGE 3 DISASSEMBLY AND INSPECTION
PAGE 3 ASSEMBLY AND TESTING
PAGE 3 TESTING AND STORAGE
PAGE 4 HYDRAULIC LINE ATTACHMENT
PAGE 4 SEAL AND BEARING KIT ORDERING INSTRUCTIONS
PAGE 4 WARRANTY
® HP-0293
S1033
THEORY OF OPERATION The shaft (2A) is integral with the shaft flange (2B)
In reference to Figure I, fluid entering Port P2 under and bearing tube (2C). The shaft is supported
pressure will bear on the piston (4) and force the radially by the large upper radial bearing (19) and
piston sleeve (3) upwards. The left-handed spline the lower radial bearing (18). Axially, the shaft is
of the piston sleeve (3) will combine with the right- separated from the housing by the upper and
handed spline of the shaft (2A) and cause rapid lower thrust rings (20). The end cap (5) is adjusted
counter-clockwise rotation of the shaft and flange for axial clearance and locked in position by cap
(2B) (looking down). Fluid entering Port P1 will screws (7).
reverse this rotation.
Displacement and torque are identical for clockwise
and counter-clockwise rotation.
FIGURE I
Flange Mounted Pivot Actuator
20
2B
16
15
19
2C 3
21 P1
14
17
1
9
2A 11
22 4
18 P2
15 20
5 16
6 7
2
S1033
DISASSEMBLY AND INSPECTION actuator in a vertical position.
Place on a clean workbench with room to place the The end cap (5) is torqued to 60-400 FT-LB depend-
internal parts as they are removed. Remove all ing on the actuator size, such that the actuator begins
hydraulic fittings. Loosen cap screws (7) and unscrew rotation at approximately 100 PSI pressure. The shaft
locknut (6) and end cap (5). The shaft is now free to flang cannot be rotated by hand; the combined
move up and out of engagement with the piston sleeve backdrive efficiency and friction prevent manual rota-
(3). Note the orientation between the spline teeth (see tion. If the end cap is torqued too high, the actuator
Figure II), as this will greatly simplify actuator timing may require as much as 300 PSI to rotate. If the end
upon reassembly. cap is not torqued high enough, shaft axial motion and
After removing the shaft, the piston sleeve and the radial backlash will result. The end cap must be
secured against the shaft by tightening cap screws
piston assembly can now be moved down and out of
(7), or by installing axial set screws, depending on the
the housing. Remove all seals and bearings from their
grooves, except static piston seals (9) and (11).
These seals generally do not require replacement. FIGURE II
Clean all parts thoroughly and inspect for wear. A
MATCHED TIMING MATCHED TIMING
small amount of wear in the spline teeth will have little MARKS ON PISTON MARKS ON SHAFT
effect on the actuator strength. New spline sets are SLEEVE AND RING GEAR AND PISTON SLEEVE
manufactured with a backlash of about .005" per
mating set. After long service, a backlash of about
.015" per set may still be acceptable in most cases,
depending on the required accuracy of the applica-
tion.
Item (1) is the integral housing and ring gear. Check
the ring gear for wear and weld damage to the pins.
Inspect the cylinder bore for wear and scratches. The
surface finish should be 32 RMS or better; rehone if
necessary. The radial bearings (18) and (19) and the
piston bearings (17) should have a maximum radial
clearance of.006". A clearance in excess of .008"
requires replacement of the bearings. Rough and
grooved shaft journals require shaft replacement.
ASSEMBLY AND TESTING

Wash all parts thoroughly in cleaning solvent and
blow dry. Coat all sealing and working surfaces with
a good grade hydraulic oil. Install seals and bearings 1 2 3
in the piston sleeve, piston, shaft, and end cap. The
lips of the exclusion seals (16) face outward, and the
lips of the high pressure seals face inward. model. Apply hydraulic pressure and check for
Place the actuator in a vertical position, install the breakaway pressure and shaft axial motion.
piston sleeve (3) in timed relation to the housing, To test for leakage, pressurize Port P2 to 3000 PSI.
applying firm pressure as the new seals and bearings No oil should seep from Port P1 or from around end
enter the housing and become compressed by the cap (5). Repeat test by pressurizing Port P1 and
housing chamber. (CAUTION: Do not misalign the check for leakage out of Port P2, around shaft flange
sleeve too much any one way, as it will mar the cylinder (2B), and from ring gear pin welds.
bore). The timing marks (the small punch marks on
the face of each gear), must be aligned for proper shaft TESTING AND STORAGE
orientation (see Figure II). All standard Helac Corporation actuators have been
If the actuator is not equipped with grease fittings, the tested and operated through at least twenty-five (25)
thrust bearings (20) are coated with good grease full cycles at 3000 PSI. Additionally, all actuators are
before sliding on the shaft and end cap. The shaft is tested at 4500 PSI for structural integrity.
installed by again aligning the proper punched timing Helac Corporation actuators are normally shipped
marks (see Figure II). Temporarily taping the threaded filled with petroleum base hydraulic oil, and the ports
portion of the shaft will help installation past the shaft are plugged with the proper high strength steel plugs
seals (masking tape works well). Apply antiseize to to prevent leakage during shipment.
threaded and surrounding areas of the end caps.
Also, depending on the size of the actuator (60K and
larger), the end cap may need to be installed with the
3
S1033
HYDRAULIC LINE ATTACHMENT
The hydraulic lines from the control valve to the the oil is cycled back and forth, and not allowed to
actuator should be as short as possible. If the lines flow to tank for filtering and cooling, resulting in
hold more oil than the actuator displaces, some of premature actuator wear.
SEAL AND BEARING KIT ORDERING INSTRUCTIONS

Helac recommends that all seals be replaced whenever the actuator is reassembled.
Complete Seal and Bearing Kits for rebuilding the actuator can be
123456
ordered by referring to the ID Tag and specifying the Serial Number,
Model Number, and Control Number followed by "S" or "B". 4-102B
SERIAL NUMBER 123456 1-2-93

MODEL NUMBER HP-28K-FL-180-0-3000-H 3000 PSI H
SEAL KIT 4-102B-S
HP-28K-FL-180-0-3000-H
BEARING KIT 4-102B-B
WARRANTY INFORMATION
Helac Corporation warrants products manufactured by it to be free from defective material and factory workmanship. Helac Corporation shall replace
or repair such products, which under normal use and service disclose such defects, and return the repaired or replacement products to the purchaser
prepaid. Claims under this warranty will be satisfied only by repair or replacement of the unit or any defective part thereof. No cash payment or credit
will be made for defective materials or workmanship. Products under warranty shall be returned to Helac Corporation's manufacturing facility at 225
Battersby Avenue, Enumclaw, Washington 98022 USA, transportation prepaid by the purchaser, for inspection by Helac Corporation, whose opinion as
to defects shall be conclusive.
The warranty period shall be one year from the date of shipment from Helac Corporation's manufacturing facility for Helac Corporation approved
applications. This warranty shall be voided as to any products which have been repaired, worked upon, or altered by persons not authorized by Helac
Corporation, or which have been subject to misuse, negligence, accident, or overload. In no event shall Helac Corporation be liable for any incidental
or consequential damages.
Helac Corporation reserves the right to make changes in the design or construction of any of its products at any time without incurring any obligations
to make changes or alterations to products previously sold.
This warranty is in lieu of all other and/or prior warranties, expressed or implied, and no other company or person is authorized to represent or assume
for Helac Corporation any liability in connection with the sale of Helac Corporation products other than set forth herein.
HELAC CORPORATION
® 225 BATTERSBY AVE • ENUMCLAW, WA 98022 USA
PHONE 360/825-1601 • FAX 360/825-1603
13651
STABILIZER INSTALLATION
Page 1 of 2
4 1
2
5

03/02/09
13651
STABILIZER INSTALLATION
Page 2 of 2

465171 24” OUTRIGGER REPAIR KIT 1
1 465143 CYLINDER 1
2 10305-03 TUBE 1
3 10305-01 PAD 1
4 10305-04 PIN, (TOP) 1
5 10305-05 PIN, (BOTTOM) 1
6* 01GC05016 BOLT 2
7* 04GE05 LOCK WASHER 2
8* 22736-02 GUARD (1 PER JACK ASSEMBLY) 1
9* 27352-03 HOSE COVER (OPTIONAL) 1

03/02/09
17070
125 CFM COMPRESSOR
Page 1 of 14

02/17/10
17070
125 CFM COMPRESSOR
Page 2 of 14

DISCHARGE SYSTEM
465139 COMPRESSOR ASSEMBLY 1
1 465139-01 85 CFM ORIFICE 1
1 465139-02 125/160 CFM ORIFICE 1
2* 465139-03 185 CFM ORIFICE 1
3 465139-04 RECEIVER, AIR/FLUID 1
7 465139-05 MUFFLER, BLOWDOWN 1
8 465139-06 ELBOW, 90E PUSH ON 1/4T X 1/8P 1
9 465139-07 ELBOW, 90E PUSH ON 1/4T X 1/4P 2
12 465139-08 VALVE, SERVICE ¾ 2
18 465139-09 VALVE, REGULATOR 1
20 465139-10 VALVE, PNEU. BLOWDOWN 1
21 465139-11 ORIFICE, HEX .047 DIA. 1
22 465139-12 TUBE, DRAIN SEPARATOR 1
23 465139-13 TEE, MALE PIPE ¼ 1
25 465139-14 TEE, PIPE REDUCING 1 X ¾ X ¾ 1
26 465139-15 TEE, PIPE REDUCING 1 X 1 X ¼ 1
32 465139-16 TEE, ELBOW, 1/4JIC X ¼ 1
34 465139-17 NIPPLE, PIPE 1 X 2 ½ LG. 1
47 465139-18 PLUG, PIPE ¼ 1
49 465139-19 ELBOW, 90E ORIFICE/CHECK VALVE 1
50 465139-20 TUBING, NYLON ¼ PUSH-ON FT
51 465139-21 HOSE, MED. PRESSURE FT
52 465139-22 END, HOSE CRIMP SWIVEL ¼ 2
59 465139-23 NIPPLE, ¾ CLOSE 2

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125 CFM COMPRESSOR
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02/17/10
17070
125 CFM COMPRESSOR
Page 4 of 14
DISCHARGE SYSTEM
2 465139-24 ADAPTOR, SWIVEL 1 1/2 , 45° 1
3 465139-25 RECEIVER, TANK AIR/FLUID 1
4 465139-26 ADAPTOR, ELBOW 90E X ¾ 2
5 524583 ELEMENT, AIR/FLUID SEPARATOR 1
(WAS P/N 465139-27)
10 465139-28 ADAPTOR, FILL 1
11 465139-29 PLUG, O-RING 1 ¼ 1
13 465139-30 GLASS, SIGHT OIL LEVEL 1 ½ 1
14 465139-31 HEAD, FLUID FILTER 1
15 465139-32 ELEMENT, FLUID FILTER 1
16 465139-33 PLUG, PIPE ½ MAGNETIC 1
17 465139-34 VALVE, RELIEF 1
19 465139-35 BAND, MOUNTING 12” 2
24 465139-36 ELBOW, PIPE 90E STREET X ½ 1
27 465139-37 TEE, PIPE REDUCING 1 ½ X ½ X 1 ½ 2
27A 465139-38 ELBOW, 1 ½ (FRONT COOLED) (FRONT COOLED – USED 2
WITH #57A)
28 465139-39 BUSHING, REDUCING 1 ½ X ½ 1
29 465139-40 TEE, PIPE 1 ½ 1
30 465139-41 PLUG, PIPE ½ 1
33 465139-42 NIPPLE, PIPE 1 ½ X CLOSE 1
35 465139-43 NIPPLE, PIPE 1 ½ X 3 (STANDARD) 1
35A 465139-44 NIPPLE, PIPE 1 ½ X 6 (SPLIT SHAFT) 1
37 465139-45 END, HOSE 1 ½ 2
38 465139-46 HOSE, MED. PRESSURE 1 ½ FT
40 465139-47 WASHER, FLAT 3/8 4
42 465139-48 CAPSCREW, HEX HD 3/8 X 16 X 1 ½ 4
43 465139-49 END, HOSE CRIMP ¾ 2
44 465139-50 HOSE, MED. PRESSURE ¾ FT
45 465139-51 NUT, LOCKING HEX 3/8 – 16 6
46 465139-52 CAPSCREW, HEX HD 3/8 – 16 X 2 2
57 524671 SWITCH, TEMPERATURE 1
58 465139-54 O-RING, 1 1/4” DIA 1
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125 CFM COMPRESSOR
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02/17/10
17070
125 CFM COMPRESSOR
Page 6 of 14
ENCLOSURE
1 465139-55 WASHER, FLAT NYLON ¼ 1
2 465139-56 WASHER, FLAT NYLON 5/16 14
3 465139-57 SCREW, TRUSS HD 5/16 – 18 X ¾ 14
4 465139-58 SCREW, TRUSS HD ¼ X ¾ 1
5 465139-59 FRAME, ASSEMBLY ADHD-EC 1
6 465139-60 PANEL, END 1
7 465139-61 PANEL, SIDE R.H. 1
8 465139-62 PANEL, SIDE L.H. 1
9 465139-63 PANEL, ROOF 1
10 465139-64 ANGLE, RECEIVER TANK MTG. 2
11 465139-65 CAPSCREW, HEX HD ¼ -20 X ¾ 2
12 465139-66 CAPSCREW, HEX HD 5/16 – 18 X ¾ 6
13 465139-67 WASHER, FLAT ¼ 5
14 465139-68 WASHER, FLAT ½ 8
15 465139-69 NUT, LOCKING HEX ¼ -20 3
16 465139-70 CAPSCREW, HEX HD ½ - 13 X 2 4
17 465139-71 NUT, LOCKING HEX ½ - 13 4

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125 CFM COMPRESSOR
Page 7 of 14

02/17/10
17070
125 CFM COMPRESSOR
Page 8 of 14

INSTRUMENT PANEL
1 605709 GAUGE, TEMPERATURE 1
(OLD# 465139-72)
2 524794 GAUGE, HOUR METER 1
(OLD# 465139-73)
3 524798 GAUGE, PRESSURE 1
(OLD# 465139-74)
4 465139-76 COUPLING, PIPE 1/8 1
5 465139-77 ELBOW, 1/4T X 1/8P PUSH-ON 1
7 ------------- FUSE, 14 AMP 1
8 524777 SWITCH, HIGH TEMP. SHUTDOWN 1
(OLD# 465139-78)
9 465139-79 PANEL, GAUGE 1
10 465139-80 DECAL, PANEL OVERLAY 1
10A 465139-81 DECAL, PANEL OVERLAY INVERTED 1
11* 465139-82 RELAY, NO/NC 1

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02/17/10
17070
125 CFM COMPRESSOR
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INLET VALVE ASSEMBLY
465139-83 INLET VALVE ASSEMBLY 1
1 465139-84 SEAL, INLET VALVE 1
2 465139-85 PISTON, INLET VALVE 1
3 465139-86 SPRING, PISTON INLET VALVE 1
5 465139-87 SCREW, SOCKET HEAD M6 X 50 2
6 465139-88 SPRING, INLET VALVE 1
7 465139-89 STEM, INLET CHECK 1
8 465139-90 VALVE, INLET CHECK 1
9 465139-91 SCREW, SOCKET HEAD M6 X 16 5
10 465139-92 O-RING, VITON 3 ¼ X 3/32 1
11 465139-93 ADAPTER, INLET VALVE 1
12* 465139-94 TUBE, GASKET CEMENT 1
13* 465139-95 TUBE, THREADLOCK 1
14* 465139-96 KIT, INLET REPAIR (INCLUDES ITEMS 1,3,5,6,10,12, & 13) 1

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125 CFM COMPRESSOR
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02/17/10
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125 CFM COMPRESSOR
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OIL COOLING SYSTEM
1 465139-97 MOTOR, FAN 16” PLASTIC ASSEMBLY 1
2 465139-98 CAPSCREW, HEX GR5 ¼ - 20 X ¾ 6
3 465139-99 FAN AND MOTOR ASSEMBLY 1
4 465139-100 CLIPS, FAN & MOTOR MOUNTING 6
5 465139-101 NUT, RETAINER 8
6 465139-102 GUARD, COOLER 1
7 465139-103 SHROUD, COOLER 1
8 465139-104 COOLER, OIL 125-185 CFM 1
9 465139-105 SCREW, SERRATED WASHER 5/16-18 X ¾ 8
10 465139-106 HARNESS, FAN 15’ 1
11 465139-107 ELBOW, ADAPTOR 90° ¾ 1

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ABOVE DECK – HYDRAULIC DRIVE
465139-108 COMPRESSOR UNIT & AIR FILTER ASSEMBLY 1
1 465139-109 FILTER, AIR COMPLETE 1
1A 465139-110 ELEMENT, AIR FILTER 1
1B 465139-111 CAP, AIR FILTER END 1
1C 465139-112 BAND, AIR FILTER 1
1D 465139-113 CAP, AIR FILTER 1
2 465139-114 INDICATOR, AIR FILTER (OPTIONAL) 1
3 465139-115 CLAMP, HOSE 3” KANAFLEX 2
4 465139-116 TUBING, 3” INTAKE 8.3FT
5 465139-141 COMPRESSOR UNIT 1
5A 465139-117 SEAL, INPUT SHAFT 1
6 465139-118 PLUG, PIPE ¼ 1
7 465139-119 ELBOW, 1/8P X 1/4T 1
7A 465139-120 TEE, 1/8P X 1/4T (ALTERNATE) 1
8 465139-121 ADAPTER, ¾ PIPE X ¾ O-RING 1
9 465139-122 TEE, PIPE 1 ½ X ½ X 1 ½ 1
10 465139-123 ADAPTER, SWIVEL 1 ½ 1
11 465139-124 TEE, ¼ O-RING X ¼ PIPE 1
12 465139-125 TEE, 1/4P X 1/4T 1
13 465139-126 ELBOW, 1/8P X 1/4J W/ CHECK & ORIFICE 1
15 465139-127 ELBOW, ¾ SAE X ¾ P SWIVEL 1
16 465139-128 SUPPORT, COMPR./ HYD. MOTOR 1
17 465139-129 WASHER, LOCK 3/8 5
18 465139-130 CAPSCREW, GR8 3/8 – 16 X 1 ¼ 5
19 465139-131 BUSHING, TAPER BORE 1 ½ BORE 1
20 465139-132 BUSHING, TAPER BORE 1 BORE 1
21 465139-133 HUB, TAPERLOCK 1
22 465139-134 ELEMENT, COUPLING 1
23 465139-135 MOTOR, HYDRAULIC 60-85 CFM 1
465139-136 MOTOR, HYDRAULIC 125-185 CFM 1
24 465139-137 CAPSCREW, GR8 ½ -13 X 1 ½ 2
25 465139-138 WASHER, LOCK ½ 2
26 465139-139 WASHER, FLAT ½ 2
30 465139-140 BUSHING, 1/4P X 1/8P EXTENDED 1

02/17/10
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Vanair ADHD Powertech

125 to 185 CFM
Rotary Screw Air Compressor
Installation, Operating,
and Maintenance Manual
19015 US Hwy 12
New Buffalo, MI 49117
(800) 526-8817 10-06
Fax: 269-469-0497 POO280-2
www.vanair.com
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DEFINITION OF TERMS
AD Abovedeck
ADBD Abovedeck Belt Drive
ADHD Abovedeck Hydraulic Drive
ASME American Society of Mechanical Engineers
BD Belt Drive
CA Cab to axle Length
CFM Cubic Feet per Minute
EC Electric Cooled
FC Front Cooled
GAWR Gross Axle Weight Rating
GPM Gallons per Minute
GVWR Gross Vehicle Weight Rating
HC Hydraulic Cooled
HD Hydraulic Drive
ICFM Inlet Cubic Feet per Minute
PSI Pounds per Square Inch
PSIG Pounds per Square Inch Gauge
PTO Power Take Off
RPM Revolutions per Minute
SCFM Standard Cubic Feet per Minute
SM Side Mount
TM Tractor Mount
TMBD Tractor Mount Belt Drive
UD Underdeck
UDHD Underdeck Hydraulic Drive
UDISS Underdeck Integral Split-Shaft
UDSM Underdeck Side Mount
WB Wheel Base
Vanair 19015 US Hwy 12 New Buffalo, MI 49117 (800) 526-8817

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WARRANTY (Applies to following models: UDSM, UDISS, UDHD, ADHD, GENAIR, TMBD, ADBD)
The rotary screw compressor unit air end is warranted for life when adhering to the prescribed
maintenance schedule. The unit will be replaced or repaired at VANAIR’S option. The hydraulic motor
on the UDHD and ADHD is warranted for two (2) years. All other parts including the compressor unit
shaft seal and generator are warranted for twelve (12) months. This warranty does not cover damage
caused by accident, misuse or negligence. If a compressor unit is disassembled the warranty is void.
Any disassembly of major components must be approved by Vanair to avoid voiding of warranty. Any
and all such claims for warranty consideration must be coordinated through the Warranty-Service
Department at the address below. Do not return parts without prior authorization.
Warranty is limited to the supply of replacement parts failing within the warranty period. Credit for
labor required to refit replacement parts is NOT included. All warranted parts are to be shipped
PREPAID to VANAIR. Replacement parts will be shipped back to the customer by VANAIR via
ground shipment. Cost to expedite delivery of replacement parts will be incurred by customer. Factory
installed units will also include warranty on the installation for one year.
This statement of warranty is expressly in lieu of and disclaims all other express warranties, implied
warranties of merchantability and fitness for a particular purchase and all other implied warranties
which extend beyond the description on the face hereof. The warranty does not include incidental or
consequential damages.
This warranty shall be void and VANAIR shall have no responsibility to repair, replace or repay the
purchase price of defective or damaged parts resulting from the use of or repair of replacement parts
or fluids not of VANAIR’S manufacture or from buyer’s failure to store, install, maintain and operate the
compressor according to the recommendations contained in the Manual.
All claims under the Warranty shall be made by contacting VANAIR Warranty-Service Department.
19015 US Hwy 12
New Buffalo, MI 49117
TEL: (800) 526-8817 FAX: (269) 469-0497 PARTS FAX: (269) 469-4013
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SAFETY Section 1 - Pg 01
1.1 GENERAL
Vanair Manufacturing designs and manufactures all of its products so they can be
operated safely. However, the responsibility for safe operation rests with those who use
and maintain these products. The following safety precautions are offered as a guide
which, if conscientiously followed, will minimize the possibility of accidents through the
useful life of this equipment.
The air compressor should be operated only by those who have been trained and
delegated to do so, and who have read and understood this Operator’s Manual. Failure to
follow the instructions, procedures and safety precautions in this manual can result in
accidents and injuries.
NEVER start the air compressor unless it is safe to do so DO NOT attempt to operate the
air compressor with a known unsafe condition. Tag the air compressor and render it
inoperative by disconnecting the battery so others who may not know of the unsafe
condition will not attempt to operate it until the condition is corrected.
Use and operate the air compressor only in full compliance with all pertinent OSHA
requirements and/or all pertinent Federal, State and Local codes or requirements.
DO NOT modify the compressor except with written factory approval.
Each day walk around the air compressor and inspect for leaks, loose or missing parts,
damaged parts or parts out of adjustment. Perform all recommended daily maintenance.
Inspect for torn, frayed, blistered or otherwise deteriorated and degraded hoses. Replace
as required.
NOTE: Estimated hose life based on a 5-day 8-hour work week is 3 years. These
conditions exist on an 8-hour shift only. Any other operation of the equipment
other than 8-hour shifts would deteriorate the hose life based on hours of
operation.
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1.2 PARKING OR LOCATING COMPRESSOR

1. Park or locate compressor on a level surface, if possible. If not, park or locate
compressor across grade so the compressor does not tend to roll downhill. DO NOT
park or locate compressor on grades exceeding 15Ε (27%).
2. Make sure compressor is parked or located on a firm surface that can support its
weight.
3. Park or locate compressor so the wind, if any, tends to carry the exhaust fumes and
radiator heat away from the compressor air inlet openings, and also where the
compressor will not be exposed to excessive dust from the work site.
4. Block or chock both sides of wheels.
1.3 PRESSURE RELEASE
A. Open the pressure relief valve at least weekly to make sure it is not blocked, closed,
obstructed or otherwise disabled.
B. Install an appropriate flow-limiting valve between the compressor service air outlet
and the shutoff (throttle) valve, when an air hose exceeding 1/2" (13mm) inside
diameter is to be connected to shut-off (throttle) valve, to reduce pressure in case of
failure, per OSHA Standard 20 CFR 1926.302 (b) (7) or any applicable
Federal, State and local codes, standards and regulations.
C. When the hose is to be used to supply a manifold, install an additional appropriate

flow-limiting valve between the manifold and each air hose exceeding 1/2" (13mm)
inside diameter that is to be connected to the manifold to reduce pressure in case of
hose failure.
D. Provide an appropriate flow-limiting valve for each additional 75 feet (23 meters) of
hose in runs of air hose exceeding 1/2" (13mm) inside diameter to reduce pressure in
case of hose failure.
E. Flow-limiting valves are listed by pipe size and rated CFM. Select appropriate valve
accordingly.
F. DO NOT use tools that are rated below the maximum rating of this compressor.
Select tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT
exceed manufacturer’s rated safe operating pressures for these items.
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G. Secure all hose connections by wire, chain or other suitable retaining device to
prevent tools or hose ends from being accidentally disconnected and expelled.
H. Open fluid filler cap only when compressor is not running and is not pressurized.
Shut down the compressor and bleed the sump (receiver) to zero internal pressure
before removing the cap.
I. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug,
connection or other component, such as filters and line oilers, and before attempting
to refill optional air line anti-icer systems with antifreeze compound.
J. Keep personnel out of line with and away from the discharge opening of hoses, tools
or other points of compressed air discharge.
K. DO NOT use air at pressures higher than 30 psig (2.1 bar) for cleaning purposes, and
then only with effective chip guarding and personal protective equipment per OSHA
Standard 29 CFR 1910.242 (b) or any applicable Federal, State and Local codes,
standards and regulations.
L. DO NOT engage in horseplay with air hoses as death or serious injury may result.
M. This equipment is supplied with an ASME designed pressure vessel protected by an

ASME rated relief valve. Lift the handle once a week to make sure the valve is
functional. DO NOT lift the handle while machine is under pressure.
N. If the machine is installed in an enclosed area it is necessary to vent the relief valve to
the outside of the structure or to an area of non-exposure.
O. If a manual blowdown valve is provided on the receiver, open the valve to insure all
internal pressure has been vented prior to servicing any pressurized component of the
compressor air/fluid system.
1.4 FIRE AND EXPLOSION
A. Refuel at a service station or from a fuel tank designed for its intended purpose. If
this is not possible, ground the compressor to the dispenser prior to refueling.
B. Clean up spills of fuel, fluid, battery electrolyte or coolant immediately if such spills
occur.
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C. Shut off air compressor and allow it to cool. Then keep sparks, flames and other
sources of ignition away and DO NOT permit smoking in the vicinity when adding
fuel, or when checking or adding electrolyte to batteries, or when checking or adding
fluid, or when checking diesel engine ether starting aid systems or replacing cylinders,
or when refilling air line anti-icer systems antifreeze compound.
D. DO NOT permit liquids, including air line anti-icer system antifreeze compound or
fluid film to accumulate on bottom covers or on any external or internal surfaces of
the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as
required. DO NOT use flammable solvents for cleaning purposes.
E. Disconnect the grounded (negative) battery connection prior to attempting any repairs
or cleaning inside the enclosure. Tag the battery connections so others will not
unexpectedly reconnect it.
F. Keep electrical wiring, including the battery terminals and other terminals, in good
condition. Replace any wiring that has cracked, cut abraded or otherwise degraded
insulation or terminals that are worn, discolored or corroded. Keep all terminals clean
and tight.
G. Turn off battery charger before making or breaking connections to the battery.
H. Keep grounded conductive objects such as tools away from exposed live electrical
parts such as terminals to avoid arcing which might serve as a source of ignition.
I. Keep a suitable fully charged class BC or ABC fire extinguisher or extinguishers

nearby when servicing and operating the compressor.
J. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the
compressor.
K. DO NOT operate compressor under low overhanging leaves or permit such leaves to
contact hot exhaust system surfaces when operating the compressor in forested areas.
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L. DO NOT spray ether into compressor air filter or into an air filter that serves the
compressor as serious damage to the compressor or personal injury may result.
M. Antifreeze compound used in air line anti-icer systems contains methanol which is
flammable. Use systems and refill with compound only in well-ventilated areas away
from heat, open flames or sparks. DO NOT expose any part of these systems or
antifreeze compound to temperatures above 150ΕF (66ΕC). Vapors from the
antifreeze compound are heavier than air. DO NOT store compound or discharge
treated air in confined or unventilated areas. DO NOT store containers or antifreeze
compound in direct sunlight.
N. Store flammable fluids and materials away from your work area. Know where fire
extinguishers are and how to use them, and for what type of fire they are intended.
Check readiness of fire suppression systems and detectors if so equipped.
1.5 MOVING PARTS
A. Keep hands, arms and other parts of the body and also clothing away from belts,
pulleys and other moving parts.
B. DO NOT attempt to operate the compressor with the fan or other guards removed.
C. Wear snug-fitting clothing and confine long hair when working around this
compressor, especially when exposed to hot or moving parts inside the enclosure.
D. Make sure all personnel are out of and clear of the compressor prior to attempting to
start or operate it.
E. Disconnect the grounded negative battery connection to prevent accidental engine

operation prior to attempting repairs or adjustments. Tag the battery connection so
others will not unexpectedly reconnect it.
F. When adjusting the controls, it may require operation of the equipment during
adjustment. DO NOT come in contact with any moving parts while adjusting the
control regulator and setting the engine RPM. Make all other adjustments with the
engine shut off. When necessary, make adjustment, other than setting control
regulator and engine RPM, with the engine shut off. If necessary, start the engine and
check adjustment. If adjustment is incorrect, shut engine off, readjust, then restart the
engine to recheck adjustment.
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G. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water,
antifreeze or other liquids to minimize possibility of slips and falls.
1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and
corners.
B. Keep all parts of the body away from all points of air discharge and away from hot
exhaust gases.
C. Wear personal protective equipment including gloves and head covering when
working in, on or around the compressor.
D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury.
DO NOT ignore small cuts and burns as they may lead to infection.
1.7 TOXIC AND IRRITATING SUBSTANCES
A. DO NOT use air from this compressor for respiration (breathing) except in full
compliance with OSHA Standards 29 CFR 1920 and any other Federal, State or Local
codes or regulations.
DANGER: Death or serious injury may occur from inhaling compressed air
without using proper safety equipment. See OSHA standards, and/or
any Federal, State or local codes or regulations on safety equipment.
B. DO NOT use air line anti-icer systems in air lines supplying respirators or other
breathing air utilization equipment and DO NOT discharge air from these systems
into unventilated or other confined areas.
C. Operate the compressor only in open or well-ventilated areas.
D. If the compressor is operated indoors, discharge engine exhaust fumes outdoors.
E. Locate the compressor so that exhaust fumes are not apt to be carried towards
personnel, air intakes servicing personnel areas or towards the air intake of any
portable or stationary compressor.
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F. Fuels, fluids, coolants, lubricants and battery electrolyte used in the compressor are
typical of the industry. Care should be taken to avoid accidental ingestion and/or skin
contact. In the event of ingestion seek medical treatment promptly. DO NOT induce
vomiting if fuel is ingested. Wash with soap and water in the event of skin contact.
G. If ethyl ether or air line anti-icer system anti-freeze compound enters the eyes or if
fumes irritate the eyes, they should be washed with large quantities of clean water for
15 minutes. A physician, preferably any eye specialist, should be contacted
immediately.
H. DO NOT store ether cylinders or air line anti-icer system antifreeze compound in
operator’s cabs or in other similar confined areas.
I. The antifreeze compound used in air line anti-icer systems contains methanol and is
toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid
breathing the fumes. If swallowed, induce vomiting by administering a tablespoon of
salt in each glass of clean warm water until vomit is clear, then administer two
tablespoons of baking soda in a glass of clean water. Have patient lay down and cover
eyes to exclude light. Call a physician immediately.
1.8 ELECTRICAL SHOCK
A. Keep the vehicle or equipment carrier, compressor hoses, tools and all personnel at
least 10 feet (3 meters) from power lines and buried cables.
B. Keep all parts of the body and any hand-held tools or other conductive objects away
from exposed live parts of electrical system. Maintain dry footing, stand on insulating
surfaces and DO NOT contact any other portion of the compressor when making
adjustments or repairs to exposed live parts of the electrical system.
C. Attempt repairs only in clean, dry and well-lighted and ventilated areas.
D. Stay clear of the compressor during electrical storms! It can attract lightning.
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DESCRIPTION Section 2 - Pg 01
2.1 INTRODUCTION
The Vanair 85 thru 185 hydraulic driven Air Compressors offer superior performance and
reliability while requiring very minimal maintenance.
Your compressor is equipped with a Sullair rotary screw compressor unit. Compared to other
compressors, the Sullair is unique for its mechanical reliability, performance and durability.
The compressor never needs any inspection of the internal parts.
As you continue reading this manual and learn how the compressor operates and is maintained,
you will see how surprisingly easy it is to keep a Vanair air compressor in top operating
condition.
Read Section 6 (Maintenance) to keep your compressor in top operating condition.

Should any problem or question arise which cannot be answered in this text, contact your
nearest Vanair representative or the Vanair Manufacturing Service Department.
2.2 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION

Vanair compressors feature the Sullair compressor unit, a single-stage, positive displacement,
fluid lubricated-type compressor. This unit provides continuous pulse-free compression to meet
your needs. With a Sullair compressor, no maintenance or inspection of the internal parts of
the compressor unit is permitted in accordance with the warranty.
Fluid is injected into the compressor unit and mixes directly with the air as the rotors turn
compressing the air. The fluid has three functions:
1. As coolant, it controls the rise of air temperature normally associated with the heat of
compression.
2. Seals the leakage paths between the rotors and the stator and also between the rotors
themselves.
3. Acts as a lubricating film between the rotors allowing one rotor to directly drive the
other, which is an idler.
After the air/fluid mixture is discharged from the compressor unit, the fluid is separated from
the air. At this time, the air flows to your service line and the fluid is cooled in preparation for
re-injection.
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2.3 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL

DESCRIPTION
Refer to Figures 2-2. The compressor cooling and lubrication system is designed to provide
adequate lubrication as well as maintain the proper operating temperature of the compressor. In
addition to the cooler and fan, the system consists of a oil filter, electric fan switch.
The fluid in the system is used as both coolant and lubricant. It is housed in the receiver/sump
or sump (which will be referred to as the SUMP from hereon).
The cooler is a radiator-type that works in conjunction with an electric driven fan and electric
fan switch. The fan draws air across the cooler core removing the heat of compression from the
fluid. The fluid flows from the sump thru the oil filter, thru the cooler core, and then is injected
into the compressor chamber and bearings of the compressor. Once the oil reaches
approximately 165°F the fan switch will turn on the fan to cool the oil.
The oil filter has a replaceable spin-on element and a built-in bypass valve which allows the
fluid to flow even when the filter element becomes plugged and requires changing or when the
viscosity of the fluid is too high for adequate flow. After the fluid is properly filtered, it then
flows on to the compressor unit where it lubricates, seals and cools the compression chamber as
well as lubricates the bearings and gears.
2.4 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figures 2-2. The Sullair compressor unit discharges compressed air/fluid
mixture. The air fluid mixture is directed to the combination sump. The sump has three
functions:
1. It acts as a primary fluid separation system.
2. Serves as the compressor fluid sump.
3. Houses the air/fluid separator.
The compressed air/fluid mixture enters the sump and is directed off the bottom of the separator
element. By change of direction and reduction of velocity, larger droplets of fluid separate and
fall to the bottom of the sump. The fractional percentage of fluid remaining in the compressed
air collects on the surface of the final separator element as the compressed air flows through the
separator. As more and more fluid collects the element’s surface, the fluid descends to the
bottom of the separator. A return line (or scavenge tube) leads from the bottom of the separator
element to the inlet region of the compressor unit. Fluid collecting on the bottom of the
separator element is returned to the compressor by the pressure difference between the area
surrounding the separator element and the compressor inlet. An orifice is included on this
return line to help assure proper flow.
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The sump is ASME code rated at 175 psig working pressure. A minimum pressure/orifice
valve, located downstream from the separator, helps assure a minimum receiver pressure of 65
psig during all conditions. This pressure is necessary for proper air/fluid separation and proper
fluid circulation.
An optional check valve at the outlet of the receiver can be installed to prevent compressed air
in the service line from bleeding back into the receiver on shutdown when the compressor
is being run in parallel with other compressors tied to a large air system.
A pressure relief valve (located on the wet side of the separator) is set to open if the sump
pressure exceeds 175 psig. A temperature switch will shut down the compressor if the
discharge temperature reaches 240°F.
Fluid is added to the sump via a capped fluid filter. A glass fluid level gauge enables the
operator to visually monitor the sump fluid level.
WARNING: DO NOT remove caps, plugs, and/or other components when compressor is
running or pressurized. Stop compressor and relieve all internal pressure before doing so.
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Figure 2 - 2 Compressor Discharge and Cooling and Lubrication System:
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2.5 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
Refer to Figure 2-2. The purpose of the control system is to regulate the amount of air intake in
accordance with the amount of compressed air demand. The Control System consists of an air
inlet valve, a control regulator, blowdown valve, and tubing connecting the various
components together.
The functional descriptions of the Control System are given below in two distinct phases of
operation. These descriptions will apply to all control systems.
START - 0 TO 40 PSIG
The sump pressure will quickly rise from 0 to 40 PSIG. During this period the compressor inlet
valve control chamber has received no air signal from the pressure regulator. The spring
attached to the control plunger holds it in a wide open position allowing the compressor to work
at full-rated capacity. As the compressor operates at full-rated capacity, the engine speed
control remains fully open enabling the trucks engine to run at full speed. The rising sump
pressure begins to pass air through the minimum pressure orifice.
MODULATION - 100 TO 115 PSIG

Should less than the rated capacity of air be used, the service line pressure will rise above
100 psi . The control pressure regulator gradually opens, applying pressure to the spring side of
the inlet valve piston. This causes the inlet valve to partially close. With the service line closed
and no air demand, the control pressure regulator opens fully, closing the inlet valve.
When air demand then increases, the sump pressure will fall below 115 psig (7.9 bar). The
control pressure regulator valve will close, and the inlet valve to open. The compressor will
then be operating at full load condition.
SHUTDOWN
The blowdown valve is normally closed. When the compressor is shutdown, system pressure
backs up to the inlet valve causing the check spring in the inlet valve to close the air inlet valve.
This sends a pressure signal to the blowdown valve causing it to open and vent the pressure in
the system. After the pressure is vented, the blowdown valve spring returns the blowdown
valve to the closed position.
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2.6 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-3. The compressor inlet system consists of one air filter, a compressor
air inlet valve and interconnecting piping.
The air filter is a 2-stage dry element-type filter. This filter is capable of cleaning extremely
dirty air. However, in such cases, frequent checks of the air filter will be required. See
Section 6 for Air Filter Maintenance Procedures.
The compressor air inlet valve controls the amount of air intake of the compressor in
response to the air demand.
Figure 2 - 3 Air Inlet System:

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2.7 INSTRUMENT PANEL, FUNCTIONAL DESCRIPTION

Refer to Figure 2-4. The instrument panel group consists of a receiver pressure gauge, a
compressor discharge temperature gauge, hour meter.
• The air pressure gauge continually monitors the sump pressure at various load and\or
unload conditions.
• The compressor discharge temperature gauge monitors the temperature of the

air/fluid mixture leaving the compressor unit. The normal reading should be
approximately 180° F to 210° F.
• The hour meter indicates the cumulative hours of compressor operation which is useful
for planning and logging service operations.
NOTE: When re-starting the compressor, make sure receiver tank pressure has blown
down to 10 psig can put extra load on the hydraulic system.
Figure 2-4 Instrument Panel Group

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2.8 HYDRAULIC MOTOR, FUNCTIONAL DESCRIPTION

The hydraulic motor is used to power the compressor unit. If the proper flow and pressure is
supplied to the motor there should be many hours of trouble free use in
conjunction with the compressor.
Vanair doesn’t supply or recommend any other hydraulic system component information.
It is recommended that the person installing a Vanair hydraulic driven compressor seek in their
area a reputable hydraulic supplier for the hydraulic components (i.e: pump, relief valve, oil
cooler, flow control, hosing, reservoir).
Following is a list of flows and pressures for the appropriate compressor model.
C.F.M. Air Pressure Compressor Speed H.P. Min. Recom. Oil Flow
Nominal psig R.P.M. System Pressure G.P.M.
85 100 1460 23.3 2300 20.5
85 150 1460 29.4 2700 20.5
125 100 1330 30.2 2200 26.4
125 150 1330 37.8 2700 26.4
160 100 1675 39.2 2300 33.5
160 150 1675 48.7 2700 33.5
185 100 1920 45.6 2400 38.5
185 150 1920 57.1 2900 38.5
2.9 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION

The electrical system is comprised of not only the necessary equipment required to
operate the compressor, but also a system to shut it down in the event of a malfunction. The
components of the electrical system are a compressor discharge temperature switch
(which will shut down the compressor should the compressor temperature exceed
240ΕF).
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SPECIFICATIONS Section 3 - Pg 01
COMPRESSOR:
Type: Rotary Screw

Delivery @Operating Pressure: 85 Free CFM @ 100 psig
85 Free CFM @ 150 psig
Cooling: Pressurized Compressor Fluid

Lubricating Compressor Fluid: Vanguard Rotary Screw Compressor Oil
Sump Capacity: 3 U.S. Gallons (sump)
3 1/2 U.S. Gallons (total system)
LUBRICATION GUIDE – COMPRESSOR
WARNING- It is important that the compressor oil be of a recommended type and that t is inspected
and replace together with the oil and air filters, in accordance with this manual.
The result of poorly maintained lubricant and/or filters may produce hazardous conditions resulting in
ignition, which could cause a fire in the sump. Damage to equipment and serious bodily harm may
result.
PRIME LUBRICANT CHARACTERISTICS:
1. Viscosity: 180 SUS AT 100 ° F

2. Flashpoint: 385 ° F Minimum
3. Pour Point: Must be at least 20 ° F lower that the lowest
expected ambient operating temperature.
4. Contain: Rust and Oxidation Inhibitors
5. Contain: Foam Suppressors
CAUTION – DO NOT MIX OILS OF DIFFERENT TYPES
FACTORY FILL: Vanguard High Performance Rotary Screw Compressor Oil

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APPLICATION GUIDE
Water must be drained from the receiver periodically. In high ambient temperature and high humidity
conditions, condensed moisture may emulsify with the oil forming a “milky” color. The fluid should
be changed if this condition develops.
DO NOT mix different types of fluids. Combinations of different fluids may lead to
operational problems such as foaming, filter plugging, orifice or line plugging.
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OPERATION Section 4 - Pg 01
4.1 GENERAL
While Vanair has built into this compressor a comprehensive array of controls and
indicators to assure you that it is operating properly, you will want to recognize and
interpret the readings which will call for service or indicate the beginning of a malfunction.
Before starting your Vanair compressor, read this section thoroughly and familiarize yourself
with the controls and indicators - their purpose, location and use.
4.2 PURPOSE OF CONTROLS
CONTROL OR INDICATOR PURPOSE
AIR PRESSURE GAUGE Continually monitors the pressure inside

The receiver tank at various load and
Unload conditions.
HOUR METER Indicates the cumulated hours of operation.

Useful for planning and logging service
schedules.
COMPRESSOR DISCHARGE Monitors the temperature of the air/fluid

TEMPERATURE GAUGE mixture leaving the compressor unit. The
normal reading should be approximate
180°F to 210° F.
FLUID LEVEL SIGHT GLASS Monitors the fluid level in the sump. Proper
Level is always visible in the sight glass.
Check the level when the compressor is shut
down.
COMPRESSOR DISCHARGE Opens the electrical circuit to shut down the

TEMPERATURE SWITCH compressor when the discharge temperature
Reaches 240° F.
INLET VALVE Regulates the amount of air allowed to enter

the air end. This regulation is determined by
the amount of air being used at the service
line.
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OPERATION Section 4 - Pg 02
MINIMUM PRESSURE ORIFICE Maintains the minimum of 65 psig in the

compressor sump. This valve restricts
receiver air discharge from receiver/sump
when pressure falls to 65 psig, however, full
flow is allowed at normal operating
pressures.
PRESSURE RELIEF VALVE Opens sump pressure to the atmosphere

Should pressure inside the sump exceed
175 psig.
PRESSURE REGULATOR Opens a pressure line between the sump and

inlet valve allowing the inlet valve to
regulate air delivery according to air
demand.
SYSTEM BLOWDOWN VALVE Vents sump pressure to the atmosphere at

shutdown.
4.3 INITIAL START-UP PROCEDURE

The following procedure should be used to make the initial start-up of your compressor:
1. Position the compressor on a level surface so that proper amounts of liquid can be
added if necessary.
2. Fill compressor fluid sump with fluid as recommended in Section 3, Specification.

System capacity is 3 1/2 gallons.
3. Check engine oil level and add if necessary.
4. Start truck engine (let engine warm up)
5. Engage hydraulic system.
6. Bring up engine speed to proper RPM.
7. After the initial run, shut the compressor down and refill compressor with oil
and tighten any loose fittings.
For starting compressor for daily use repeat steps #3 through #6.
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INSTALLATION Section 5 - Pg 01
INSTALLATION
5.1 A location on the truck is the first thing that needs to be found. Some of the concerns are that
there has to be enough room around the compressor package to insure proper cooling. Also,
access will be needed to service the air cleaner, separator element, and oil filter. Lastly, the
instrument panel should be able to be seen for daily operations. Once a location is found, the
compressor package should be mounted down with a minimum of (4) 1/2-13 capscrews.
5.2 The hydraulic hoses must be ran into the package to the hydraulic motor. Insure the hoses
are hooked up properly to insure proper rotation. Also, insure that the hoses are run thru an area
so that no chafing of the hoses are possible.
5.3 The hydraulic compressor package should be wired per wire diagram 5.1. There are a total of
(4) wires to be run inside of the package.
S1028
Wire Diagram 5.1
S1028
RECEIVER TANK INSTALLATION:
S1028
MAINTENANCE Section 6 - Pg 01
6.1 GENERAL
A good maintenance program is the key to long compressor life. Below is a program that
when adhered to, should keep the compressor in top operating condition. See Section 6.7, Parts
Replacement and Adjustment Procedures for a detailed description of specific compressor
system components. Units that have not yet been installed should be stored in a dry, temperature
controlled environment. Unit should be recharged with oil if it has been in extensive storage.
WARNING: DO NOT remove caps, plugs and/or other components when compressor
is running or pressurized.
Stop compressor and relieve all internal pressure before doing so.
6.2 DAILY OPERATION

Prior to starting the compressor, it is necessary to check the fluid level in the sump. Should the
level be low, simply add the necessary amount. If the addition of fluid becomes too frequent, a
simple problem has developed which is causing this excessive loss. See the Troubleshooting
Section (6.8) under Excessive Fluid Consumption for a probable cause and remedy.
After a routine start has been made, observe the instrument panel gauge and be sure it
monitors the correct reading for that particular phase of operation. After the compressor has
warmed up, it is recommended that a general check on the overall compressor and
instrument panel be made to assure that the compressor is running properly. Also check the air
filter maintenance indicators (if provided).
6.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION

After the initial 50 hours of operation, a few maintenance requirements are needed to rid the
system of any foreign materials. Perform the following maintenance operations to
prevent unnecessary future problems.
1. Change the oil filter element.

2. Drain and refill air/oil receiver sump.
3. Inspect intake air filter (change if necessary)
6.4 MAINTENANCE EVERY 500 HOURS OR ANNUALLY.

IMPORTANT – It may be necessary to change at earlier intervals if oil has water
contamination or if compressor is operated in poor/dirty environment.
1. Change the oil filter element.

2. Drain and refill air/oil receiver sump.
3. Replace intake air filter.
4. Annually replace separator element (located in air-oil sump).
5. Inspect exterior of front mounted oil cooler, clean if necessary.
S1028
6.5 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
COMPRESSOR FLUID CHANGE PROCEDURE

Warm-up compressor for 5 to 10 minutes to warm the fluid. Shut the compressor off and
relieve all internal pressure before proceeding. Drain the fluid sump by removing the plug
at the bottom of the sump tank. Change the compressor fluid and replace the fluid filter
element. For element replacement see procedure for servicing the fluid filter in this
section. Fill the sump with fluid according to specifications in Section 3.
COMPRESSOR FLUID FILTER ELEMENT REPLACEMENT

Refer to Figure 6-3.
1. Using a strap wrench, remove the old element and gasket.

2. Clean the gasket seating surface.
3. Apply a light film of fluid to the new gasket.
4. Hand tighten the new element until the new gasket is seated in the gasket groove.
5. Continue tightening the element by hand an additional 1/2 to 3/4" turn.
6. Restart the compressor and check for leaks.
CAUTION: To minimize the possibility of filter element rupture, it is important that

only replacement elements identified with the Vanair name, logo and
appropriate part number be used. DO NOT use substitute elements.
This is due to the fact that such substitution may have inadequate or
questionable working pressure ratings.
S1028
Replacement Element P/N: 261991

6.5 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES (CONT’D.)
AIR FILTER MAINTENANCE

Refer to Figure 6-4. The air filter supplied with your compressor is a two-stage system which
offers more than adequate filtration. The air filter should be inspected periodically to
maintain maximum compressor protection and filter service life. These inspections should be
made:
1. Inspect the air transfer duct work between the air filter and compressor unit to be sure
all clamps and joints are tight and there are no cracks in the ducting.
2. The air filter mounting clamps and bolts must be tight to hold the air cleaner securely.
3. Check the rain cap to make sure it is sealing 360Ε around the air cleaner body.
4. Inspect for dents and damage to the air filter. The end cap (dust cap) of the filter is
removable and should be emptied of dirt particles every 100 hours.
5. Check the filter more frequently if used under extreme conditions. The air filter
element is a cleanable type and should be serviced in accordance with the following
instructions.
S1028
Replacement Element P/N: 262092
ELEMENT REPLACEMENT
1. Loosen the clamp which secures the rain cap to the body and remove the cap.
2. Remove the rubber baffle from inside the dust cap and empty all dirt particles.
3. Unscrew the wingnut from the center post to loosen the element and remove.
4. Clean the body and dust cap with a clean damp cloth inside and out. DO NOT
BLOW DIRT OUT WITH COMPRESSED AIR!
5. At this time clean or replace the element (Part No. 262092). Cleaning instructions
follow.
6. Install the element back into the body and replace the wingnut. Tighten securely.
7. Replace the rubber baffle into the dust cap and attach the cap to the body.
8. Retighten the clamp to secure the filter.
AIR FILTER ELEMENT CLEANING
The air filter element is cleanable by using compressed air. The maximum amount of times that
an element should be cleaned is six (6) times: however, the element should be used no longer
than a period of one (1) year without changing.
S1028
Prior to cleaning an element, check the element for damage. Damaged elements must be
replaced.
When cleaning an element, never exceed the maximum allowable pressures for compressed
air (30 PSI).
Do not strike the element against any hard surface to dislodge dust. This will damage the
sealing surfaces and possibly rupture the element. Never “blow” dirt out of the interior of
the filter housing. This may introduce dust downstream of the filter. Instead, use a clean
damp cloth. Do not oil the elements.
CLEANING THE ELEMENT WITH COMPRESSED AIR

When cleaning the element with compressed air, never let the air pressure exceed 30 PSI.
Reverse flush the element by directing the compressed air up and down the pleats in the
filter media from the “clean side” of the element. Continue reverse flushing until all
dust is removed. Should any oil or greasy dirt remain on the filter surface the element
should then be replaced. When the element is satisfactorily cleaned, inspect thoroughly prior
to installation. (See Element Inspection)
ELEMENT INSPECTION
1. Place a bright light inside the element to inspect for damage or leak holes.
Concentrated light will shine through the element and disclose any holes.
2. Inspect all gaskets and gasket contact surfaces of the housing. Should faulty gaskets
be evident, correct the condition immediately.
3. If the clean element is to be stored for later use, it must be stored in a clean container.
4. After the element has been installed, inspect and tighten, if necessary, all air inlet
connections prior to resuming operation.
SEPARATION ELEMENT REPLACEMENT

Refer to Figure 5-6. When fluid carry-over is evident after the fluid return line orifice as well
as the blowdown valve diaphragm have been inspected and found to be in satisfactory
condition, separator element replacement (P/N 260017-001) is necessary. Follow the procedure
explained below.
1. Remove all piping connected to the sump cover to allow removal (return line, service
line, etc.).
2. Remove the fluid return line from the fitting in the cover.
3. Remove the eight (8) 1/2 - 13 cover bolts and lock washers and lift the cover from the sump.
4. Remove the separator element.
5. Scrape the old gasket material from the cover and the flange on the sump. Be sure to
keep all scrapings from falling inside tank.
S1028
SEPARATOR ELEMENT REPLACEMENT (CONT’D.)
6. Install the element with bonded gaskets, making sure the staples in the gaskets come in
contact with the metal surface of the bolt ring and cover. DO NOT use gasket sealer
as it can insulate the staples causing the element not to be properly grounded for
operation.
7. Replace the sump cover and bolts . Run the cover bolts in finger tight, then gradually
tighten in a crisscross pattern in 4 to 5 steps. ALWAYS tighten the bolts alternately at
Opposite sides of the cover. NEVER tighten bolts adjacent to each other. Torque
bolts to 55 to 75 Ft. lbs.
8. Reconnect all piping.
9. Clean the fluid return line and clear the orifice prior to restarting the compressor.
Figure 5-6 Separator Element (P/N 260017-001)

S1028
6.6 TROUBLESHOOTING
The information contained in the Troubleshooting chart has been compiled from field report
data and factory experience. It contains symptoms and usual causes for the described problems.
However, DO NOT, assume that these are the only problems that may occur. All available data
concerning the trouble should be systematically analyzed before undertaking any repairs or
component replacement procedures.
A detailed visual inspection is worth performing for almost all problems. Doing so may
prevent damage to the compressor. Always remember to:
1. Check for loose wiring.

2. Check for damaged piping.
3. Check for parts damaged by heat or an electrical short circuit, usually noticeable by
discoloration or a burnt odor.
Should your problem persist after making the recommended check, consult your nearest
Vanair representative or Vanair Manufacturing, Inc.
SYMPTOM PROBABLE CAUSE REMEDY
COMPRESSOR SHUTS DOWN Compressor Discharge Temperature Cooling air flow is insufficient; clean WITH
AIR DEMAND PRESENT Switch is Open. cooler and check for proper ventilation.
Low fluid sump level; add fluid.
Dirty compressor fluid filter; change

element.
Electric fan is not functioning.
Defective discharge temperature

switch; check for a short or open circuit
to the engine fuel solenoid. Should this
check out normal, it could be possible
that the temperature switch itself is
defective.
Circuit Breaker Tripped on Reset circuit breaker and check for

Instrument Panel cause of overload.
S1028
6.6 TROUBLESHOOTING (CONT’D)
COMPRESSOR WILL NOT Air demand is Too Great Check service lines for leaks or open
valves.
BUILD UP FULL DISCHARGE
PRESSURE
Dirty Air Filter Check the filter and change
element if required.
Pressure Regulator Out of Adjustment Adjust regulator according to control

adjustment instructions in the
Maintenance section.
Defective Pressure Regulator Check diaphragm and replace if

necessary.
Incorrect Compressor Speed Check & adjust to proper speed.
IMPROPER UNLOADING WITH

AN EXCESSIVE PRESSURE
BUILD-UP CAUSING PRESSURE
RELIEF VALVE TO OPEN Pressure Regulating Valve is Set
Too High Readjust.
Leak in Control System Causing

Loss of Pressure Signal Check control lines.
Defective pressure regulating valve.

Repair valve.
Inlet Valve Jammed Free or replace valve.
Defective Pressure Relief Valve Replace pressure relief valve.
INSUFFICIENT AIR DELIVERY Plugged Air Filter Replace
Plugged Air/Fluid Separator Replace separator element and also

change compressor fluid and fluid filter
at this time.
Defective Pressure Regulator Adjust or repair.
Engine Speed Too Low Readjust engine speed.

S1028
6.6 TROUBLESHOOTING (CONT’D)
EXCESSIVE COMPRESSOR FLUID

CONSUMPTION Clogged Return Line Clear orifice.
Defective Shutdown Blowdown

Valve Diaphragm Replace diaphragm.
Leak in the Lubrication System Check all pipes, connections and

components.
Separator Element Damaged or

Not Functioning Properly Change separator element.
Fluid Sump Overfilled Drain to proper level.
COMPRESSOR OVERHEATING Dirty Fluid Cooler Core Clean core thoroughly.
Plugged Fluid Cooler Tube

(Internal) Clean tube thoroughly.
Low Sump Fluid Level Fill.
Plugged Compressor Fluid Filter Change element.
Electric Fan is Not Functioning Check Wires, Fan Motor,

& Fan Switch for Fault
& Replace Faulty Part.
S1028
ILLUSTRATIONS AND PARTS LIST Section 7 - Pg 01
7.1 PROCEDURE FOR ORDERING PARTS

Parts should be ordered from the nearest Vanair Representative or the Representative from
whom the compressor was purchased. If for any reason parts cannot be obtained in this
manner, contact the factory directly at the address or phone numbers below.
When ordering parts always indicate the Serial Number of the compressor. This can be
obtained from the Bill of Lading for the compressor or from the Serial Number Plate
located on the compressor.
VANAIR MANUFACTURING, INC.

19015 U S 12
New Buffalo MI 49117
Telephone: 269-469-4461
FAX: 269-469-0497
S1028
VanAir Manufacturing, Inc.

269-469-4461
INSTALLATION/TEST RECORD
Distributor_____________________ End User__________________

_____________________
_____________________
Receiver S/N___________________ Serial Number______________
Air End S/N___________________ Vin Number________________
Split Shaft S/N_________________
Locations:
Split Shaft Location (inches from cab) _______________________________________
Air End/PTO: Left/Right/Extension Bracket Notes ____________________
Receiver Tank: Left/Right Notes ____________________
Instrument Panel: Ship Loose/Inside Cab/Under Hood/Other______________________
Air Cleaner: Ship Loose/Under Hood/Inside Body
Notes: ____________________________________________________________
Cooler: Ship Loose/Front of Body/Van Wall/None Electric/
Notes:_____________________________________________________________
Generator Panel: N/A Location: ________________________________________
Service Valve Locations: _____________________________________________
Muffler Modifications: _______________________________________________
Notes: ____________________________________________________________
Auxiliary Equipment: Hose Reels/Tool Lifter/Generator/Other________________
__________________________________________________________________
Truck Date: Make ________________Model ______________Year ___________
GVW ________________Engine _____________Trans ___________
Wheel Base ___________C.A. _______________________________
Compressor Data: Size________________ Mounting: Above/Below
PTO Data: Make____________ Model _____________ Control Type __________
Drivelines _____________________ U-Joints_____________________
Speeds: _________________ Idle _______________ Full Load________________
Engine: _______________ RPM ___________ RPM________________________
Compressor: ___________ RPM ___________ RPM ______ CFM_____ Pressure
Tested_________________________ Date_______________________
ANFO TRUCK LINCOLN LUBE 17165
SYSTEM INSTALLATION Page 1 of 2

1 595135 LINCOLN QUICK LUBE, OUTLET 2
595140 LINCOLN QUICK LUBE, FERRULE 2
(ENGINE END STEERING CYL PINS GREASE POINTS)
2 595141 LINCOLN QUICK LUBE, CLOSURE PLUG 12
595142 LINCOLN QUICK LUBE, GASKET 12
(CRADLE PINS GREASE POINTS)
(REAR FRAME STEERING CYL PINS GREASE POINTS)
(ARTICULATION PINS GREASE POINTS)
(BOOM LEVEL CYL PINS ROD END GREASE POINTS)
(BOOM LEVEL CYL PINS PISTON END GREASE POINTS)

06/06/08
ANFO TRUCK LINCOLN LUBE 17165
SYSTEM INSTALLATION Page 2 of 2
(BOOM LIFT CYL PINS)
(BOOM TURRET ROTATION PIN)
(BASKET ROTATION PIN)
11 595131 LINCOLN QUICK LUBE, 12V PUMP A/R
595132 LINCOLN QUICK LUBE, 12V TIMER A/R
595255 LINCOLN QUICK LUBE, 24V PUMP (INCLUDES TIMER) A/R
NOTE: ON TIME SETTING: 1 FOR 2 MINUTES

OFF TIME SETTING: 1 FOR 1 HOUR

06/06/08
S1094
S1094
CHASSIS LUBE ELECTRIC 17341
GREASE PUMP Page 1 of 3
Updated:
05/14/10

595255 LINCOLN QUICK LUBE, 24V PUMP ASSEMBLY 1
595359 RESERVOIR KIT – INCLUDES ITEMS 1 & 7 1
595255-01 PADDLE KIT – INCLUDES ITEMS 2, 3, & 4 1
595255-02 BEARING & SEAL KIT – INCLUDES ITEMS 4-6, & 9-11 1
595255-03 24V MOTOR KIT – INCLUDES ITEMS 13-15, 26-28, & 35 1
595255-04 HOUSING SEAL KIT – INCLUDES ITEMS 15 & 27 1
595255-05 PUMP ELEMENT KIT – INCLUDES ITEMS 31-33 1
1 NSS RESERVOIR 1
(INCLUDED IN RESERVOIR KIT 595359)
2 NSS HOSE 1
(INCLUDED IN PADDLE KIT 595255-01)
3 NSS STIRRING PADDLE 1
(INCLUDED IN PADDLE KIT 595255-01)
4 NSS WASHER 1
(INCLUDED IN PADDLE KIT 595255-01 & BEARING &
SEAL KIT 595255-02)
5 NSS BEARING RING 2
(INCLUDED IN BEARING & SEAL KIT 595255-02)
6 NSS BEARING 1
7 595255-06 O-RING 2
8 595255-07 INTERMEDIATE PLATE 1
9 NSS SHIM 1
10 NSS SNAP RING 2
11 NSS INNER RING 1
12 595255-08 ECCENTRIC CAM 1
13 NSS CAPSCREW 3
(INCLUDED IN 24V MOTOR KIT 595255-03)
14 NSS WASHER 3
15 NSS O-RING 3
(INCLUDED IN 24V MOTOR KIT 595255-03 & HOUSING
SEAL KIT 595255-04)
16 595255-09 PUMP HOUSING 1
17 595255-10 CLOSURE PLUG
Updated:
05/14/10

18 595255-11 3 WIRE POWER CORD/PLUG 1
21 595255-12 SEALING PLUG 1
22 595255-13 NIPPLE 1
23 595255-14 CAPSCREW 10
25 595255-16 PRINTED CIRCUIT BOARD 1
26 NSS WOODRUFF KET 1
27 NSS RADIAL SEAL 1
(INCLUDED IN 24V MOTOR KIT 595255-02 & HOUSING
SEAL KIT 595255-04)
28 NSS 24 VDC MOTOR 1
29 595255-17 HOUSING COVER 1
31 NSS CHECK VALVE 1
(INCLUDED IN PUMP ELEMENT KIT 595255-05)
32 NSS PUMP ELEMENT 1
33 NSS GASKET 1
34 595255-18 PRESSURE RELIEF ASSEMBLY 1
35 NSS PLUG FOR MOTOR 1
36 595255-19 GREASE CAP 1
37 NSS ADAPTER FOR RELIEF ASSEMBLY 1
38 NSS INNER RING 1
Updated:
05/14/10

020-001 Manual Exc 2-500L

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MANUAL INDEX

2-500L ANFO CHARGER

1. INTRODUCTION /GENERAL INFORMATION

F1008 PARTS ORDER INSTRUCTIONS

10368 SIGHT GAUGE

3. ELECTRICAL SYSTEM AND INSTRUMENTS

30343 WIRING DIAGRAM

4. ENGINE AND ACCESSORIES

F1007 DETROIT DIESEL WARRANTY

10829 AXLE ORIENTATION

13378 BRAKE VALVE

310-020-001 HYDRAULIC SCHEMATIC

13905 ELECTRIC SHIFTER

10. MOUNTED EQUIPMENT

S1011 FIRE EXTINGUISHER #10

1. INTRODUCTION /GENERAL INFORMATION

F1008 PARTS ORDER INSTRUCTIONS

TO AVOID DELAYS AND ASSURE THE MOST EFFICIENT HANDLING, PLEASE

• MODEL TYPE AND FACTORY SERIAL NUMBER OF YOUR MACHINE.

• NAME, MODEL NUMBER, AND SERIAL NUMBER OF THE ASSEMBLY (SUCH

• PART NUMBER (REFER TO THE CORRECT REPAIR PART NUMBER).

• GIVE COMPLETE PART DESCRIPTION.

• EXACT QUANTITY OF PART REQUIRED. (DO NOT ORDER BY SET UNLESS

• SHIPPING INSTRUCTIONS (INCLUDE ROUTING WHEN POSSIBLE).

PLEASE PLACE ALL ORDERS WITH YOUR LOCAL GETMAN DISTRIBUTOR OR

BANGOR, MICHIGAN U.S.A

MODEL SERIAL NO.

Customer: ARAMINE (KOL)

OPERATING AND MAINTENANCE

Read thoroughly before operating vehicle

GENERAL SAFETY PRECAUTIONS

WARNING: Used when a hazard exists which can result in

DANGER: Used when an extreme hazard exists which can

• Enter and exit operator’s compartment carefully. Never IMPORTANT

• Never stand when operating a vehicle in motion.

• Never dismount from a vehicle unless brakes are set. Do

• Never remove any elements of the engine’s exhaust

3. If the vehicle has been operating in a working condition WARNING

SERVICE POSITION CAUTION

1. Park vehicle on level area and block wheels.

2. Apply parking brake.

3. Lock frame articulation joint by installing safety bar.

NOTE: Complete procedure before servicing vehicle.

FUEL SHUT OFF

Modifications such as adding attachments to the cab/canopy,

• Maintain a fully charged fire extinguisher on vehicle at all

5. Parking/Secondary Brake Button: Push to apply, pull to

6. Voltmeter: Indicates battery charging or discharging.

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

8. Horn Button: Push to sound horn.

9. Circuit Breakers: Consists of 10, 20, and 30 AMP

10. Spare Space: Available for additional usage, contact

11. PLC Reset Switch (Optional): Used to reset engine

12. Remote Throttle Enable Switch (Optional): Enables a

13. Park Brake Test Button: For vehicles equipped with a

14. Low Fuel Light (Optional): For vehicles equipped with

15. Start Switch: Turn switch to position 1 for preheat, and

STOP ENGINE: This light illuminates in the event of an

Fuel gauges can be inside or outside of the cab. The gauge

Transmission pressure gauge indicates pressure being

Voltmeter indicates current battery voltage level, charging or

Pressure gauges are used to measure the hydraulic pressure OPTIONAL

Brake Pedal (Not Shown) - Push to activate service brakes.