6975 Manual (3414)

MANUAL INDEX
A-64N CABLE STRINGER TRUCK

FRESNILLO
S/N 6975
12/27/07
1. INTRODUCTION /GENERAL INFORMATION
F1008 PARTS ORDER INSTRUCTIONS

F1000 GETMAN WARRANTY
F1009 COMPONENT LIST
M1027 A-64 OPERATING MANUAL
S1000 BOLTS TORQUE & SIZE SAE
S1077 HYDRAULIC SYMBOLS
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
13533 SEAT ASSEMBLY
13942 STEERING (PINS, BEARINGS, BUSHINGS)
12043 ARTICULATION INSTALLATION
3. ELECTRICAL SYSTEM AND INSTRUMENTS
30304 WIRING DIAGRAM

17092 INSTRUMENT PANEL
13918 ALTERNATOR
MANUAL INDEX
FRESNILLO
S/N 6975
12/27/07
4. ENGINE AND ACCESSORIES
F1011 DEUTZ WARRANTY POLICY

S1056 ENGINE OPERATION & MAINTENANCE MANUAL
S1057 ENGINE PARTS MANUAL
F1012 EMISSION CONTROL INFORMATION
13715 ENGINE FILTERS
17096 RADIATOR INSTALLATION
13753 AIR INTAKE & EXHAUST SYSTEMS
11968 AIR CLEANER
S1020 EXHAUST INFORMATION
5. DRIVE TRAIN
17055 TRANSMISSION
16922 TRANSMISSION MOUNTS
S1036 TRANSMISSION MAINTENANCE & SERVICE
MANUAL
13731 DRIVELINE INSTALLATION
6. AXLE
10829 AXLE ORIENTATION

13335 AXLE ASSEMBLY
13332 AXLE CRADLE INSTALLATION
S1037 AXLE SERVICE & REPAIR MANUAL
13158 BRAKE ACTUATOR
S1023 BRAKE ACTUATOR INSTALLATION
17095 TIRE & RIM
S1007 TIRE SERVICE
7. BRAKE SYSTEM
31516 HYDRAULIC SCHEMATIC

13378 BRAKE VALVE
S1008 BRAKE VALVE SERVICE
16483 DUAL CHARGE VALVE
S1009 DUAL CHARGE VALVE SERVICE
12976 ACCUMULATOR
MANUAL INDEX
FRESNILLO
S/N 6975
12/27/07
8. HYDRAULIC SYSTEM

13259 FILTER (HYDRAULIC)
12860 STEERING ORBITROL
S1024 STEERING ORBITROL SERVICE
S1010 PUMP SERVICE
13943 STEERING CYLINDER
9. CONTROLS
13905 ELECTRIC SHIFTER

10827 STEERING WHEEL & COLUMN
13025 THROTTLE (HYDRAULIC)
13305 HAND THROTTLE LINKAGE
16976 RESERVOIR (HYDRAULIC)
10. MOUNTED EQUIPMENT
S1025 FIRE EXTINGUISHER

S1012 FIRE PROTECTION INFORMATION MANUAL
S1013 FIRE SUPPRESSION MAINTENANCE MANUAL
23276 FIRE SUPPRESSION INSTALLATION
16721 FIRE SUPPRESSION SYSTEM
17124 CABLE STRINGER ASSEMBLY
S1076 SOUTHWORTH LS SERIES LIFT TABLES MANUAL
MANUAL INDEX
FRESNILLO
S/N 6975
12/27/07
1. INTRODUCTION /GENERAL INFORMATION
F1008 PARTS ORDER INSTRUCTIONS

F1000 GETMAN WARRANTY
F1009 COMPONENT LIST
M1027 A-64 OPERATING MANUAL
S1000 BOLTS TORQUE & SIZE SAE
S1077 HYDRAULIC SYMBOLS
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.
MODEL A-64N TYPE CABLE STRINGER
SPEC. 3414 SERIAL NO. 6975
Updated:
11/06/07
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: CABLE STRINGER Type: A-64N
Shop No.: 3414 Serial No.: 6975 Truck No.: N/A
Customer: FRESNILLO
COMPONENT MANUFACTURER MODEL SPECIFICATION SERIAL NUMBER

ENGINE DEUTZ BF4M2012C 465231 10439184
TRANSMISSION DANA 20000 465425 JBEA280830
FRONT AXLE NEW HOLLAND D-45 464872 86578601 7J27
REAR AXLE NEW HOLLAND D-45 464872 86578601 7J27
MAIN HYD PUMP COMMERCIAL P-30 494054 N/A
MAIN HYD PUMP COMMERCIAL P-31 494029 N/A
FAN/ALT BELT GATES A-46 284017 GETMAN
OPTIONS:
LIFT SOUTHWORTH LS4-48 464573 42324-01/M042324-100-01
*WHEN ORDERING PARTS, ALWAYS GIVE MODEL AND SERIAL NUMBER OF UNIT. Updated:
12/18/07
OPERATING AND MAINTENANCE M1027
MANUAL FOR MODEL A-64 CHASSIS Page 1 of 30
GETMAN CORPORATION
OPERATING AND MAINTENANCE

MANUAL
FOR
MODEL A-64 CHASSIS
Read thoroughly before

operating vehicle
Updated:
08/22/07
INTRODUCTION RELATED MANUALS
This manual is a guide to proper, safe operation, Engine operation manual is included with the Parts and
lubrication, and minor adjustment of the Getman A-64 Service Manuals supplied with this vehicle. You should
Chassis. Each operator assigned to this vehicle should become familiar with these manuals.
study this manual carefully before starting or operating
the vehicle in order to become familiar with all the Getman has increased the frequency of many recommended
controls and procedures. maintenance procedures due to the vehicles demanding
application. These changes are noted at each maintenance
Getman A-64 Chassis are purchased with the expectation section end.
that it will provide long and faithful service. In its
construction, we have taken every precaution to see that
you receive an efficient, long-lived, satisfactory vehicle. A complete parts listing of engine train components,
However, to realize the full measure of value and utility applicable Electric/Air/Hydraulic systems, and mounted
that Getman has designed into this unit, a small amount of equipment is included in the Parts and Service Manual. This
time and expense must be invested in the performance of manual also contains service and repair information useful to
regular inspections and service as recommended in this maintenance department personnel.
manual. The small investment will pay off in low
operating costs, minimal service expenses, and most If you have any questions about operating or servicing this
importantly in personal safety. unit, contact your local Getman dealer or Getman Corporation
direct, immediately.
TABLE OF CONTENTS……………PAGE 2
Introduction…………………………………….2
Related Manuals………………………………..2
General Safety Precautions..…………………3-4
Name, Warning and Caution Plates……………5
Safety Notice……………………...…………...6
Fuel Shut-Off…………………………………..6
Service Position………………………………..6
Parking Procedure..……………………………6
Caution Statement….………………………….7
General Description………………………........8
Instrument Panel Descriptions……………...9-10
Instrument Warning Panel………………...11-12
Other Controls…………...................................12
Gauge Descriptions….…………………….13-14
Checks Before Start Up……………………….15
Starting Procedure…………………….……....16
Park Brake Test Procedure………………........17
After Engine Starts……………………………18
Operating Vehicle…………………………19-20
Maintenance Schedule……..……………...21-29
Specifications…………...…………………….30
Updated:
08/22/07
SAFETY ALERT SYMBOL
This symbol will appear at various points throughout the manual in

conjunction with warning statements. Its appearance means:
! ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
This manual also uses the following messages:
NOTICE: Used for special information or instructions, relating to procedures, equipment, tools, and other special data.
IMPORTANT: Used when special precautions should be taken to ensure correct action or to avoid damage to or malfunction of
equipment.
CAUTION: Used as a reminder of safety hazards which can result in personal injury if proper precautions are not taken.
WARNING: Used when a hazard exists which can result in injury or death if proper precautions are not taken.
DANGER: Used when an extreme hazard exists which can result in serious injury or death if proper precautions are not taken.
RULES
Before performing any maintenance on the vehicle, review the following safety precautions. These are included for your
protection and safety.
Always observe the following general safety rules during operation of the vehicle. Also observe the safety rules set forth in the
work place. The need for additional rules for safe operation may arise due to particular mine applications. This should ONLY
be used as guidance.
• Read and carefully follow all instructions as outlined in the vehicle manuals.
• Ensure that all instruments, indicators, and operating controls are functioning.
• Never utilize operating controls as hand holds to assist entering or exiting a vehicle.
• Never stand when operating a vehicle in motion.
• Avoid wearing loose or baggy clothing when working around engines or other rotating or moving equipment.
Updated:
08/22/07
• Never allow riders in vehicles not designated to carry passengers.
• Never dismount from a vehicle unless brakes are set.
• Always lower ground engaging implements and utilize wheel chocks when vehicle is parked.
• If parking on a grade is unavoidable, point the vehicle towards the rib, engage the parking brake, lower all ground engaging
implements and utilize wheel chocks.
• Avoid smoking or open flame around fuel.
• Always be aware of location of nearest fire extinguisher.
• Always ensure that excess grease, oil, etc., are cleaned up immediately to prevent a potential fire hazard.
• Check operation of brake circuit prior to beginning of each shift.
• Never remove any elements of the engine’s exhaust system or any safety guards when vehicle is in operation.
• Never utilize a vehicle for an application other than it was originally designed for.
• Watch out for others. They may not be watching out for you!
CANOPY
• Your GETMAN vehicle could be equipped with a MSHA canopy or cab option. These are designed to provide protection to
the operator in the event of a rollover of the vehicle or from foreign objects falling on the 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.
IMPORTANT: Any modification not supplied by Getman Corporation or by OEM should be approved prior to change
by Getman.
WARNING: The seat belt is an important part of the MSHA canopy safety system. Failure to wear a seat belt can
cause extreme injury or death.
Updated:
08/22/07
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.
Updated:
08/22/07
SAFETY NOTICE • Do not allow riders. Passengers must be seated in proper

Safety depends on well maintained, properly operated seats with seat belts fastened.
equipment. Following service and maintenance
recommendations set forth in this manual will result in a reliable • Do not enter or exit a vehicle when in motion.
vehicle. Observing operating procedures can help you avoid
accidents. Listed below are some basic safety precautions which • Do not pump the brake pedal.
should be read, understood and practiced. It is, however,
impossible to cover every condition. Always be alert, think • Do not drive the vehicle over electrical cables.
SAFETY at all times, and use common sense.
• Do not operate a vehicle with a defective exhaust system.
DO
• Do read this manual thoroughly before operating vehicle. • Do not re-fuel the vehicle with engine running.
• Do learn to recognize and avoid potential hazard areas, FUEL SHUT OFF
such as the articulation area. Close fuel line valves at tank ports.
• Do perform all recommended checks. SERVICE POSITION

Throughout this manual, you will be told to place the vehicle in
• Do report all vehicle defects. SERVICE POSITION.
• Do check the area around entire vehicle prior to entering 1. Park vehicle on level area and block wheels.
the operator’s compartment.
2. Apply parking brake.
• Do carefully inspect and fasten seat belt.
3. Lock frame articulation joint by installing safety bar. (articulating
• Do sound horn before starting engine. vehicle only)
• Do operate vehicle with caution. 4. Stop engine.
• Do park vehicle on level surface, if possible, and block Complete procedure before servicing vehicle.
wheels.
• Do use parking brake.
• Do place transmission gear selector in neutral (N) when not

in use.
• Do enter and exit operator’s compartment carefully. PARKING PROCEDURE

1. Park vehicle away from traffic, and turn into the rib.
• Do use proper tools for service.
2. Apply the parking brake and place transmission in neutral (N).
DO NOT
• Do not operate while under the influence of alcohol or
3. If the vehicle has been operating in a working condition just prior
drugs.
to parking, allow engine to cool. Park and run at idle for 1 to 2
minutes.
• Do not allow pedestrians near vehicle when engine is in
operation.
4. Stop engine.
• Do not arc weld on vehicle without first turning master
5. Block wheels.
switch to off position.
Updated:
08/22/07
CAUTION STATEMENT 8. EXHAUST SYSTEM

Use this equipment under the following conditions. Keep exhaust piping tight at all times. Do not allow piping to
become blocked. The maximum back pressure (positive) in exhaust
1. GENERAL SAFETY system at full throttle, no load, 2500 RPM must not exceed the engine
This diesel-powered vehicle may only be designed for use in manufacturer’s recommended value.
non-coal mines. Such mines are those in which material being
mined is incombustible or contains at least 65% by weight of 9. EXHAUST PURIFIER
incombustible material, and in which underground atmosphere Purifier can lose efficiency when used on engines producing
in any open workings contain less than 0.25% by volume of excessive amounts of blue and/or black smoke. Other engine
flammable gas. Tunneling operations in which underground malfunctions such as stuck or leaking injectors will also cause loss of
conditions confirm with the foregoing are in the same category efficiency. Compression loss will lead to lower exhaust temperature
as non-coal mines. Any questions pertaining to the design of and loss of purifier efficiency.
this vehicle, please contact your local distributor. Make
frequent inspections to see all engine intake and exhaust parts, 10. FUEL
all electrical components, including wiring and all other Use only diesel fuel recommended by the engine manufacturer for
equipment, are in safe operating condition. There must be no satisfactory engine operation. The flash point must not be less than
openings in any part of the engine exhaust system except one 140°F or sulfur content greater than 0.5% by weight. When filling
exhaust outlet originally provided. fuel tanks underground, transport fuel in secure metal containers.
Store fuel containers in closed, incombustible compartments while
All circuit breakers for overload protection in electrical circuits awaiting transfer to the fuel tank of the diesel vehicle. Keep fuel in
must be kept in good condition. ventilated area.
2. FASTENERS 11. FIRE EXTINGUISHER

Keep all bolts, nuts, screws and other fasteners for electrical Each diesel vehicle must carry at least one dry type or CO² type
enclosures in place. Properly tighten and secure them. pressurized fire extinguisher at all times.
Similarly, keep fasteners for the engine cylinder head, intake
and exhaust systems in place, properly tightened and secured. 12. VEHICLE OUT OF SERVICE
Each out of service vehicle must have an “OUT OF SERVICE” tag
3. REPAIRS AND RENEWALS displayed.
Take special care when making repairs and renewals. Use new
parts exactly like those furnished by original manufacturer. Use
gaskets from the manufacturer only. Have all mating surfaces
clean and in proper condition.
4. BATTERY AND CABLES

WARNING!
Before working on or around batteries, turn the battery
disconnect switches off.
Improper operation of this vehicle can cause severe injury or
5. VENTILATION death!!!
The amount of fresh moving air for ventilation at any place
underground where the vehicle is working must meet the engine
manufacturer’s minimum requirements. This ventilation must
be supplied in addition to that required for other diesel powered
vehicles and other requirements. Shut off the engine whenever
underground ventilation stops for any reason. It is
recommended the engine be shut off any time the vehicle is not
in use. Do not idle engine for excessively long periods.
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
RPM should not exceed engine manufacture’s recommended
value. This diesel engine should not exceed (25) inches of water
(dirty filter). A restriction indicator will provide warning
indication by turning red when twenty (20) inches of water is
achieved. Inspect the intake air cleaner at regular intervals and
clean or replace as necessary.
Updated:
08/22/07
GENERAL DESCRIPTION Every effort has been made to ensure that you can stop this
vehicle. The service brakes (axle brakes) are fully enclosed
Getman Model A-64 Chassis is a four wheel drive, wet disk type, with a dual system, permitting separate circuitry
articulating frame steering vehicle powered by a diesel for front and rear brakes. Should a failure occur in either
engine. The power of the engine is transmitted through circuit, the other circuit remains functional. The spring set,
the torque converter to a powershift transmission. From hydraulically released, service brakes which also serve as
the transmission, drive shafts with universal joints parking brakes, are manually set and released by utilizing the
transmit the power to the deep reduction, inboard dash mounted push/pull control button. The front and rear
planetary drive axles. service brakes are also used as secondary brake which
automatically apply in the event of loss of hydraulic or
transmission pressure. This brake can also be manually
applied in the event of complete hydraulic system failure.
This vehicle is equipped with two red Brake Warning lights

CAUTION located in the instrument panel. These are for each the front
Steering is not functional when engine is not running. and rear brake circuits. These warning lights will illuminate if
hydraulic pressure in either brake circuit drops below the
Steering is full hydraulic power type, utilizing a flange preset 1100 PSI (76 BAR) level. The front and rear service
mounted direct drive hydraulic gear pump which provides brakes will automatically apply if the hydraulic pressure in the
hydraulic fluid to an orbitrol valve operated by the brake circuit drops below 1100 PSI (76 BAR). The Brake
steering wheel. This operates the two steer cylinders Impending light in the Warning Panel will illuminate when
located in the articulation joint. hydraulic pressure drops below 1200 PSI. All the instruments
require to operate the vehicle are located in the operator’s
area. Become familiar with the position and function of each.
Updated:
08/22/07
INSTRUMENT PANEL DESCRIPTIONS
465313-200
1. Engine Oil PSI Gauge: This gauge indicates engine 5. Tachometer Gauge: Indicates engine RPM’s
oil pressure. Normal operating pressure is 45-60 PSI.
6. Converter Oil Temperature Gauge: Normal
2. Engine Temperature Gauge: This gauge indicates transmission/Converter operating temperature 160°-
engine temperature. 220°F (71°-104°C). If gauge indicates higher
temperature, stop vehicle, shift transmission into
3. Voltmeter: Indicates battery charging or neutral, apply parking brake and run engine at 1000-
discharging. 1200 RPM until oil temperature returns to normal.
See Transmission Service Manual in Section 5 for
4. Hourmeter: Indicates truck hours when start switch more information.
is turned to the on position.
Updated:
08/22/07
7. Transmission Pressure Gauge: Transmission 18. Light Switch: Four position switch turn as follows:
pressure gauge indicates pressure being regulated and Position 1- Off
provided to the transmission clutches. If the gauge Position 2- Front lights and rear red
fails to register pressure after engine start up, shut Position 3- All lights on.
down engine immediately and contact maintenance. Position 4- Rear lights and rear red.
Normal operating pressure is approximately 300 PSI.
See Transmission Service Manual in Section 5 for 19. Beacon Light Switch (Optional): Toggle switch to
more information. turn Beacon Light on if equipped.
8. Parking/Secondary Brake Button: Push to apply, 20. Warning Panel: See Instrument Warning Panel for
pull to release. detailed description.
9. Park Brake Test Button: For vehicles equipped 21. Canopy Light Switch (Optional): Toggle switch to
with a “Park Brake Test” button, depressing and turn Canopy Light on if equipped.
holding this button allows the operator to engage the
transmission for testing of the park brake.
Follow the instruction tag as follows:
1. Apply parking brake.
2. Place transmission in 3rd gear F.
3. Increase engine RPM to maximum.
4. Vehicle should not move.
If vehicle moves, park vehicle in a safe area, apply wheel
chocks and notify maintenance for brake inspection
and/or adjustment. If vehicle is equipped with Ford/New
Holland axles, the service brakes act as the parking brake
and are tested with this procedure.
10. Boom Light Switch (Optional): Toggle switch to

turn Boom Lights on if equipped.
11. Horn Button: Push to sound horn.
12. Circuit Breakers: Consists of 10, 20 and 30 AMP

breakers used for gauges, lights, horns, etc…
13. PLC Reset Switch (Optional): Used to reset engine

controls. Pull out for 30 seconds, fuse will reset.
Push back in and restart engine.
14. Glowplug Override Button: Used when engine

does not need the aid of glowplugs for starting.
15. Glowplug Preheat Indicator: Informs operator

when Glowplugs are preheated.
16. Warning Buzzer: Used to alert operator when

transmission temperature exceeds 250°F or when
transmission pressure falls below 60 PSI. Buzzer
will also briefly sound on start up.
17. Start Switch: Turn switch to position 1 for preheat,

and momentary turn to position 2 to start engine.
Updated:
08/22/07
INSTRUMENT WARNING PANEL
HYDRAULIC
PRESSURE LOW STOP ENGINE PARK BRAKE
(RED) (RED) (RED)
ACCUMULATOR
PRESSURE LOW
FRONT BRAKES
(RED)
POWER ON
(GREEN)
TRANSMISSION
FAULT
(RED)
ACCUMULATOR
PRESSURE LOW
REAR BRAKES
(RED)
DECLUTCH
IMPENDING (RED)
AUTO BRAKE
APPLICATION
(YELLOW)
• HYDRAULIC PRESSURE LOW: This light illuminates when the hydraulic

system detects a sudden drop in pressure.
• STOP ENGINE: This light illuminates in the event of an engine fault being detected
by the engine electronic control system. This is considered to be a major fault which
will require immediate attention. Shut down the engine as soon as possible and notify
maintenance.
• PARK BRAKE: This light illuminates when the driveline parking brake is engaged.
When the parking brake is released to set the vehicle in motion, this light will not be
illuminated.
Updated:
08/22/07
• TRANSMISSION: This light illuminates in the event of low hydraulic oil pressure
or high transmission temperature.
• POWER ON LIGHT: The power light is an indication that the ignition switch has
been turned to the “ON” position. It will remain illuminated until the ignition is
turned off.
• FRONT AND REAR BRAKES: Two individual lights are in the display to provide
the operator with information regarging possible auto brake application. These lights
are an indication that less than 1100 PSI exists in either the forward or rear brake
circuit. Auto brake application occurs when brake system pressure falls below 1100
PSI.
• BRAKE IMPENDING: This light illuminates when hydraulic pressure in either the
front or rear brake circuit falls below the 1200 PSI range. This is a warning to the
operator of a possible impending auto brake application which occurs below 1100
PSI.
• DECLUTCH: This light illuminates when the transmission selector is disabled.
Depending on options chosen, the following can activate the declutch option.
1. Parking Brake is “ON”.
2. Diverter valve is in Accessories mode.
3. Stabilizer Jacks are not fully retracted.
4. Man basket is not stowed level on deck.
5. Scissor deck is in elevated position.
OTHER CONTROLS Gear Selector Lever- Move lever to position “1” for low
gear, position “2” for second and position “3” for third gear.
WARNING
Never free wheel vehicle. Free wheeling will cause serious
injury and damage vehicle.
Accelerator Pedal (Not Shown)- Push to increase engine

RPM.
Brake Pedal (Not Shown)- Push to activate service brakes.
Seat Adjustment (Not Shown)- Adjust for operator comfort.

Direction Selector Lever- Move selector lever to “F” for
forward. Move selector lever to “R” for reverse direct. “N” is
for neutral
Updated:
08/22/07
GAUGE DESCRIPTIONS
Normal transmission/converter temperatures are between 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.
Updated:
08/22/07
GAUGE DESCRIPTION CONTINUED
Fuel gauges can be inside or outside of the cab. The gauge indicates the existing fuel level in the fuel reservoir.
Voltmeter indicates current battery voltage level, charging or discharging. There will either be a 16V gauge used for a
12V charging system or a 32V gauge used for a 24V charging system. With engine running a 12V charging system
should read 12-16 volts and 24 – 30 volts for a 24V charging system.
Pressure gauges are used to measure the hydraulic pressure system. They could be used to measure brake pressure, total
system pressure, etc.
Updated:
08/22/07
CHECKS BEFORE START UP
Check all the engine belt(s) for tension and condition. Worn or
gouged belt(s) should be replaced immediately.
Check area around vehicle for obstacles that might be damaged

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

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

clean or replace filter element(s). Visually inspect rubber
connectors and clamps.
Check lights and horn to ensure all are operational.

Check hydraulic oil reservoir level with engine shut off. Oil
level should not be above the top sight gauge or below the lower
sight gauge. Fill as required.
Check seat belt to make certain fastener works and belt is not
worn or cut. Adjust operator’s seat to a comfortable operating
position. Some seats have height adjustments.
Check tire pressure, 95 PSI (6.55 BAR) is recommended.

Check wheel nuts. Do not operate with loose or missing wheel
nuts.
Updated:
08/22/07
STARTING PROCEDURE
CAUTION
Transmission must be in neutral and park brake must be applied
to start engine.
IMPORTANT
Before you enter operators compartment, all personnel must be a
safe distance from vehicle.
Frame safety bar must not be connected.
1. Turn Battery and ECM Disconnects to “ON” position. 4. Move Directional Lever to neutral position.
NOTE: This switch could be located on the side of the vehicle,
in the cab, or both.
b
a
2. Adjust and fasten Seat Belt to a comfortable operating
position.
5. Turn Start Switch to “ON” position. (a)
6. Check all gauges and make sure they are functioning

properly. (b)
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

3. Push down Park Brake Button. not show pressure shortly after stat-up, stop engine and
determine cause.
NOTICE
DO NOT CRANK ENGINE FOR MORE THAN 30 SECONDS. ALLOW STARTER TO COOL FOR TWO MINUTES BEFORE
CRANKING AGAIN. TURBOCHARGER (IF EQUIPPED) DAMAGE CAN RESULT, IF THE ENGINE RPM IS NOT KEPT LOW
UNTIL THE ENGINE OIL PRESSURE GAUGE INDICATES PRESSURE IS SUFFICIENT.
Updated:
08/22/07
PARK BRAKE TEST PROCEDURE
NOTICE
Depressing the Park Brake Button located in the switch panel overrides the transmission declutch feature.
To test the Park Brake Only:

a
1. Set Park Brake. (a)
2. Depress & hold Park Brake Test Button. (b)
3. Place shifter in 3rd Gear. Forward.
4. Fully depress Throttle.
5. Vehicle Should Not move.
Updated:
08/22/07
3
AFTER ENGINE STARTS
4
2
Engine Oil Pressure #1 - Oil pressure should read 25-50 PSI at idle with engine at operating temperature. At full engine load,
pressure should read between 45-60 PSI. If gauge fails to show pressure after engine start up, stop engine immediately and find
cause.
Voltmeter #2- With engine running, voltage should read 12-16 volts for 12 volt vehicle systems and 24-30 volts for 24 volt
vehicle systems.
Transmission Temperature Gauge #3 & Transmission Pressure Gauge #4- During work cycles, if Trans/Converter Gauge
indicates temperature above 220°F, bring vehicle to a stop, place transmission in Neutral with park brake applied and increase
engine RPM to approximately 1000-1200 RPM. Maintain this RPM until Transmission temperature returns to normal levels.
Normal transmission operating pressure is approximately 250 PSI (17.2 BAR). Should transmission pressure fail to register upon
starting of vehicle, stop engine and contact maintenance.
Brake Pressure Gauges- There are two brake accumulator pressure gauges located on the side of the dash on the engine panel .
These display the individual hydraulic pressures existing in the front and rear brake accumulators. Normal operating pressure in
these gauges is between 1500 and 2200 PSI (103.5-151.5 BAR).
CAUTION
Stop engine immediately if any gauge is not in its set range.
Park Brake Test- This system is designed to hold a fully load vehicle on a 35% grade. For safety reasons, a parking brake test
should be performed at the beginning of each shift. See Park Brake Test Procedures for instructions on how to conduct this test.
WARNING
Do not operate any vehicle with a faulty parking/service brake system. Serious personal injury or damage to vehicle may result.
Updated:
08/22/07
OPERATING VEHICLE
1 4
• Once all gauges have been checked and are within normal operating ranges, vehicle is ready to
operate.
• Turn Light Switch #1 to the ON position.
• Depress Service Brake and hold #2.
• Check Brake Accumulator Pressure Gauges and check Instrument Panel Warning Display for Low
Pressure Warning Lights in Warning Panel #3.
• Ensure all hydraulic stabilizers are in the top position (if applicable)
• Check to be sure area is clear of all personnel and obstacles. Select forward by pushing the gear
selector lever to “F” position and select 1st gear pulling gear selector lever to “1” position.
• Pull Park Brake Button #2 to release the driveline disk brake.
• Depress horn button #4 on instrument panel to sound horn.
• Release Foot Brake Pedal, test steering for proper operation and move vehicle slowly by gently
depressing Accelerator Pedal with foot.
Updated:
08/22/07
OPERATING VEHICLE (CONT’D)
Acquaint yourself with the “FEEL” of the steering When satisfied that you can safely and comfortably
by driving the pattern shown above. Do this several operate the vehicle, find a long straight open stretch of
times until you become familiar with vehicle roadway and accelerate. Start in 1st gear, shift to 2nd
steering and feel you would be comfortable driving gear, and then to 3rd, etc. (if conditions permit). Make
the vehicle in traffic areas. To familiarize yourself certain area chosen is free of obstacles and/or other
with vehicle response to an automatic application of personnel. At higher speeds slight turns should be tried
the driveline brake, drive straight, remove foot from as long as there is no danger of hooking the rib or
accelerator pedal and push Park Brake Button while another vehicle. Stop vehicle and return transmission
still rolling. gear selector to neutral (N). Apply Park Brake. Check
all gauges again to be certain they are within normal
Park brake should set and vehicle should come to a operating range.
stop. If this does not occur, have brake circuit and
adjustment checked by authorized personnel. NOTE: When traveling up a grade, select lower gear if
torque converter oil temperature approaches 200°F (93
°C).
CAUTION!
When proceeding down grades, use 1st gear. Use of 2nd
or 3rd gear could cause engine over speeds and possible
safety hazards to operator.
Updated:
08/22/07
MAINTENANCE SCHEDULE AS REQUIRED

Place vehicle in service position.
NOTE:
Depending on dust conditions, air cleaner may require
daily service.
The vehicle will be equipped with one of the following air

filtration options. Determine which system your vehicle
is equipped with and refer to the proper section for service
instructions.
Check service indicator. Clear dust collector discharge slot
AIR CLEANER SERVICE PROCEDURE daily. Service air cleaner ONLY when indicator locks in red
NOTE: Lack of engine power and/or excessive exhaust position. Proceed as follows:
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 nuts on air cleaner housing and remove pre-cleaner

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

Reset service indicator.
Loosen thumbscrew holding cover and remove cover.

Remove and discard primary filter element. Clean inside
housing. Install new element.
Check cover gasket to ensure a good seal. Reposition

cover and thumbscrew. Reset service indicator.
Replace safety filter element every 5th primary filter

change. Safety filter element is replaced in same manner
as primary element change.
Updated:
08/22/07
MAINTENANCE SCHEDULE DAILY OR EVERY SHIFT CHANGE

9
8 4
3
2
1
7
10
5
6
1
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
*Perform maintenance schedule as required.
*See Fluid Specifications.
Check tire condition and pressure. Do not operate vehicle

Check engine oil level. Fill as required.
with low tire pressure. Do not operate vehicle with badly
worn and/or gouged tires.
Updated:
08/22/07
DAILY MAINTENANCE OR EVERY SHIFT CHANGE (CONT’D)
Empty and clean pre-cleaner dust bowl .

Check fuel level. Fill as required.
Check all engine belts for tension and condition. Worn or

gouged belts should be replaced immediately. Check belt
tension as follows:
WARNING Check transmission fluid level. Fluid should be checked at

Engine MUST be shut of to check belt tension.
normal operating temperature with engine running at idle and
transmission in neutral. For detailed information, see section 5
(Transmission Service and Maintenance Manual). Fill as
required.
1. Push the belt at

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

1. Hydraulic system for leaks.
2. Fuel system for leaks.
3. Instruments for proper function.
With Engine Off Check:

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

engine operator’s manual or by contacting Getman
Grease axle trunnions. Corporation for the latest information.
Updated:
08/22/07
MAINTENANCE SCHEDULE EVERY 50 OPERATING HOURS

3 5
1 4

1. Wheels ____
2. Battery H2O
3. Air Cleaner EO
4. Air Cooling System ____
5. Catalytic Exhaust
Purifiers ____
*Perform Maintenance Schedule As Required.
*Perform Maintenance Schedule Daily Or Every Shift.
Release and lift battery access plate. Clean battery off and
inspect cables.
WARNING
Be aware of hydrogen gas build up under battery access
plate. Keep open flame and sparks away from battery.
IMPORTANT
Check wheel nuts. Nuts should be tightened to 300 LBS- Do not get battery acid on skin. Keep all open flame out
FT (406.7 Nm). of area.
Updated:
08/22/07
MAINTENANCE SCHEDULE EVERY 50 OPERATING HOURS (CONT’D.)
DO NOT allow engine to idle more than five (5) minutes at a time, or
purifier will loose efficiency.
2. Before vehicle is put into service, and during every 50 hour check,
check exhaust back pressure at full throttle by connecting a back
pressure or water gauge to the 1/8” NPT test port between purifier
and exhaust manifold. If back pressure exceeds 40” (1016 mm) H2O
or has risen 5” (127mm) or more since last regeneration, purifier
must be regenerated.
Add grease to both upper and lower pivot pin bearings. (See ECS REGENERATION
specifications) Required Equipment:
1. Nylon, hard –bristle parts cleaning brush.
2. Solvent-air, parts cleaning gun.
3. Super concentrate degreasing solution.
4. Stoddard solvent or high grade kerosene (sulphur free) - - 5 parts
Stoddard to 1 part S.C.
5. High pressure air source (30PSI).
6. Wrench.
Add grease to both steering cylinder ends.

WARNING
Flammable Solution. Use in accordance with manufacturers
recommendations. Use in a properly ventilated area. Failure to
follow these instructions could result in serous injury.
Cleaning Procedure:
1. Remove center section of purifier.
2. Dry brush inlet face of catalyst.
3. Air clean through outlet face of catalyst.
Check ALL air intake connections. Tighten as required. 4. Continue steps 1 & 2 until inlet face is clean.
5. Completely soak catalyst in Stoddard, S.C. solution for one hour.
6. Solvent-air clean through outlet face of catalyst for 10 minutes.
7. Air clean through outlet face.
8. Repeat steps 4, 5, and 6 until purifier is clean.
9. High pressure water wash purifier through outlet face and air dry.
10. Replace purifier.
11. Record back pressure at full throttle, remove gauge and tighten
test plug.
NOTE: If high pressure steam is available, it may be substituted for

Remove air cowl on injector side of engine by releasing retainer solvent solution. Steam clean through outlet face, keeping nozzle 2”
snaps. Clean cooling fins, oil cooler, transmission cooler, and (51mm) away from catalyst face.
radiator if applicable with compressed air.
NOTE: If purifier has been regenerated but engine continues to
Vehicles equipped with ECS catalytic air purifier: smoke, engine must be serviced to maintain safe exhaust conditions.
1. If vehicle is operated under heavy load with engine rpm at
least 70% of operating time, a maximum amount of maintenance
will be required. If engine does not work hard and is allowed to
idle for excessive periods of time, the catalyst may become
“carboned up” and exhaust will start to smoke after a few hours,
indicating regeneration is necessary.
Updated:
08/22/07

4
5
3
7 2
6

1. Driveline, Universal
Joints, Slip Joints EPG
2. Transmission TF
4. Axle Differential Housing MBO
5. Axle Breather ____
6. Engine ____
7. Parking Brake ____
*Perform Maintenance Schedule as Required.
*Perform Maintenance Schedule Daily or Every Shift. Add grease to driveline slip yokes, one fitting each.
*Perform 50 Hour Maintenance.
Drain transmission oil by removing the drain plug. Clean plug

Add grease to all driveline universal joints, and center in solvent, dry, and replace in transmission.
bearing.
NOTE: Some universal joints may not be shown.
Updated:
08/22/07
MAINTENANCE SCHEDULE EVERY 250 OPERATING HOURS (CONT’D)
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.
with fluid.
Before installing filter, coat gasket with light film of oil.
See Section 5 (Transmission Service & Maintenance
Manual) for detailed information.
Fill and check transmission as follows:

1. Fill transmission to low mark on dipstick.
2. Run engine at idle 500-600 RPM to prime converter
and hydraulic hoses.
3. Re-check oil level with engine at idle and transmission
in neutral. Bring oil level to low mark on dipstick. When Check hydraulic reservoir sight gauge. Add fluid as required.
oil reached normal operating temperature of 158° to Fluid level should not be above top sight gauge or below
248°F (70°-120°C) make a final check and bring to the lower sight gauge.
full mark of the dipstick.
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.
Updated:
08/22/07
Clean or replace sump strainer and re-install inside reservoir.
Remove return line filter. Replace filter element. Install

return line filter.
1
Install reservoir access plate, install drain plug, and fill
hydraulic reservoir with fluid. Check specifications.
*Perform Maintenance Schedule as required.
*Perform Maintenance Schedule Daily or Every Shift.
Check hydraulic reservoir sight gauges. Add fluid as required.

Level should not be above upper sight gauge or below lower
sight gauge.
Remove reservoir fill cap. Empty main hydraulic

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

reservoir top before proceeding.
Remove hydraulic reservoir access plate. Disconnect sump

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

NPT cap to prevent circuit contamination and possible damage
to hydraulic components.
Clean reservoirs inside with steam or solvent.
Updated:
08/22/07
2
1

1. Axle Differential Housing MBO
2. Axle Breather ____
*Perform Maintenance Schedule as required.
*Perform Maintenance Schedule Daily or
Every Shift.
*See Fluid Specifications
Remove front and rear axle differential drain plugs. When axle
is empty of all fluid, clean and re-install drain plugs.
Remove differential fill plugs (one per axle). Add specified

lubricant until fluid level reaches bottom of oil fill plug port.
Clean and re-install differential fill plugs.
Updated:
08/22/07
SPECIFICATIONS
FUEL
Use No. 2 Diesel Fuel, Cetane 40 Minimum
Use a dependable brand of diesel fuel with a sulfur content of less than 0.5%. Use care when re-fueling to avoid
fuel system contamination. Use a winter grade fuel when operating vehicle in low temperatures. NOTE: To avoid
drawing air into the fuel system, do not allow vehicle to run out of fuel as this can cause extreme hard starting.
NOTICE
Using diesel fuel with lower than recommended cetane number can cause hard starting, instability, and excessive
white smoke. To maintain satisfactory operation at low ambient temperatures, it is important to specify diesel fuel of
the correct centane number. For complete details see Engine Operation and Maintenance Manual or contact your
local Getman Distributor.
TIRES
SIZE PLY TYPE PSI BAR

RATING
14.00X24 28 ____ 120 8.3
10.00X20 14 LCM 95 6.5
12.00X20 16 SMC 95 6.5
9.00X20 12 LCM 90 6.1
NOTE: This chart indicates tire pressure specifications ONLY. The sizes are not interchangeable. Always
replace with tires of same size, type, and ply rating originally supplied with vehicle
PRESSURES
TYPE PSI BAR

Engine Oil Pressure at 1000 RPM 45-60 3.1-4.1
Steering Hydraulic System at low idle with vehicle turned
and against stops. 1500-2000 103-138
NOTE: Checks made at 150°F (65°C) oil temperature
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
Updated:
08/22/07
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
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

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.
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
Updated:
04/26/07
LUBRICANT CROSS F1003
REFERENCE Page 2 of 2
ENGINE & AIR CLEANER (OIL BATH) AXLES - FORD, JOHN DEERE, NAF
(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
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
Moly 2
Updated:
04/26/07
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 TRANSMISSION & HYDRAULICS

Change oil using an oil with corrosion preventing No special care is required except exposed cylinder
properties of a least a HD-S1 oil. Listed are some rods should be covered with grease.
of the oils that have been approved: Esso
MZ20X20V7N; Texaco EKM 162; Shell V6828. AXLE
Axle housings should be filled completely to
Change oil and fuel filters. eliminate the change of moisture condensation.
Fill fuel tank completely with a mixture of diesel BRAKE SYSTEM

fuel and 10% corrosion inhibiting motor oil. Drain all air reservoirs of moisture.
Run engine for at least 10 minutes to fill fuel lines BATTERY

and filters, injection pump and nozzles with Remove battery; clean off top, and store in a well-
preservative mixture. ventilated battery storage area. Do not store on
concrete or metal.
If engine is to be stored over six months, seal intake
and exhaust system to keep moisture out. EQUIPMENT STORAGE FOR LESS THAN
THREE MONTHS
When storing equipment for less than three months,
vehicles should be started and driven for a
minimum of two minutes every two weeks.
Any further questions please contact your local

Getman Distributor or the contact information
below.
Getman Corporation, 59750 34th Avenue, Bangor, Michigan 49013, U.S.A. Updated:
Telephone: (269) 427-5611/ Facsimile: (269) 427-8781/ E-mail: info@getman.com. 04/26/07
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:
04/26/07
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
Daily services
Updated:
04/26/07
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:
04/26/07
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:
04/26/07
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:
04/26/07
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
FRESNILLO
S/N 6975
12/27/07
2. CHASSIS
10368 SIGHT GAUGE

10376 FILL CAP (FUEL OIL)
10398 FILL CAP (HYDRAULIC OIL)
10448 HOLD DOWN FASTENERS
13533 SEAT ASSEMBLY
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
13533
SEAT
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* 424279 SEAT BELTS (SET) 1*

01/30/07
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 465411 STEERING CYLINDER 2
5 524203 BUSHING (STEERING CYLINDER) 2
Updated:
12/11/06
12043
ARTICULATION JOINT
Page 1 of 3
Updated:
12/11/06
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 73GC08016 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:
12/11/06
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:
12/11/06
MANUAL INDEX
FRESNILLO
S/N 6975
12/27/07
3. ELECTRICAL SYSTEM AND INSTRUMENTS
30304 WIRING DIAGRAM

17092 INSTRUMENT PANEL
13918 ALTERNATOR
17092
INSTRUMENT PANEL
Page 1 of 2
465313-200

08/14/07
17092
INSTRUMENT PANEL
Page 2 of 2
1 124401 ENGINE OIL PSI GAUGE (3304/3056/F6L-912) 1
* 124255 ENGINE OIL PSI SENDER (3304/3056/F6L-912) 1
1 124400 ENGINE OIL PSI GAUGE (DEUTZ 1013) 1
* 44140 ENGINE OIL SENDER (DEUTZ 1013) 1
2 124399 ENGINE TEMP GAUGE (CAT 3056/3304) 1
* 124253 ENGINE TEMP SENDER (CAT 3056/3304) 1
2 124402 ENGINE HEAD TEMP GAUGE (DEUTZ F6L-912W) 1
* 124299 ENGINE HEAD TEMP SENDER (DEUTZ F6L-912W) 1
2 124403 ENGINE TEMP GAUGE (DEUTZ 1013) 1
* 44167 ENGINE TEMP SENDER (DEUTZ 1013) 1
3 124396 VOLTMETER GAUGE 24V 1
4 124441 HOURMETER GAUGE 1
5 465085 TACHOMETER GAUGE 1
* 124426 RESISTOR (5 WATT) TACHOMETER 1
* 124258 INSTRUMENT BULB TACHOMETER 1
6 124403 TRANSMISSION TEMPERATURE GAUGE 1
* 124406 TRANSMISSION TEMPERATURE SENDER 1
7 124421 CONVERTER PRESSURE GAUGE 1
* 124278 CONVERTER PRESSURE SENDER 1
8 134019 PARK BRAKE SWITCH 1
* 134020 PARK BRAKE BUTTON 1
9 122100 PARK BRAKE TEST BUTTON 1
* 124433 GRAY DUST CAP 1
10 124148 BOOM LIGHT SWITCH (OPTIONAL) 1
11 122100 HORN SWITCH 1
12 134117 CIRCUIT BREAKER (10AMP) A/R
134009 CIRCUIT BREAKER (20AMP) A/R
134118 CIRCUIT BREAKER (30AMP) A/R
13 124121 PLC RESET SWITCH 1
14 122100 GLOWPLUG OVERRIDE BUTTON 1
15 44119 GLOWPLUG PREHEAT INDICATOR 1
16 124313 WARNING BUZZER 1
17 124380 START SWITCH 1
18 124462 LIGHT SWITCH 1
19 124148 BEACON LIGHT SWITCH OPTIONAL 1
20 SEE GETMAN WARNING PANEL (SEE INSTRUMENT WARNING PANEL 1
PAGE FOR DESCRIPTION)
21 124148 CANOPY LIGHT SWITCH OPTIONAL 1

08/14/07
13918
ALTERNATOR
Page 1 of 1

1 44260 ALTERNATOR (DEUTZ 2012 12V/140A) 1
2* 284017 ALTERNATOR BELT 1

03/29/07
MANUAL INDEX
FRESNILLO
S/N 6975
12/27/07
4. ENGINE AND ACCESSORIES
F1011 DEUTZ WARRANTY POLICY

S1056 ENGINE OPERATION & MAINTENANCE MANUAL
S1057 ENGINE PARTS MANUAL
F1012 EMISSION CONTROL INFORMATION
13715 ENGINE FILTERS
17096 RADIATOR INSTALLATION
13753 AIR INTAKE & EXHAUST SYSTEMS
11968 AIR CLEANER
S1020 EXHAUST INFORMATION
F1011
DEUTZ Warranty Statement

1. DEUTZ Corporation (“ DC” ) warrants to the original retail 5. This warranty does not cover any components supplied
customer that each new DEUTZ diesel engine (“ Engine” ) or by DC manufactured by someone other than DEUTZ AG,
genuine new DEUTZ spare or replacement part (“ Part” ) such as components obtained by DC from its suppliers
supplied by DC or an authorized distributor of DC, (other than DEUTZ AG), and DC makes no warranty
purchased by the original retail customer and properly whatsoever with respect to such components. Such
installed in an application, will be free from defects in components will be covered only by the warranties, if any,
material and workmanship under normal use and service. as may be issued by such suppliers themselves, which
If, during the warranty period following the delivery of the warranties will be made available to customer upon
Engine or Part, it is shown there is a defect in material or request.
workmanship caused solely by failure of DC’ s manufacturer
(DEUTZ AG) to meet such standards, and customer has 6. The warranties, obligations, liabilities and remedies of
notified DC in writing of such defect within that period, DC the parties, as provided herein, are exclusive and in lieu of
shall repair or replace, at DC’ s cost and option, such any others available at law or in equity. DC’ s total
defective Engine or Part. Such repair or replacement will aggregate liability with respect to any defective Engine or
be made without charge to the customer at customer’ s Part shall not exceed the amount paid by the customer for
premises or, at the option of DC, at such other location as such Engine or Part and customer agrees to release,
DC may designate. Any Engine or Part that is replaced defend, indemnify and hold DC harmless from and against
shall become the property of DC. Any repaired or replaced any and all further liability arising in any manner from any
Engine or Part shall be warranted until the expiration of the alleged defective Engine or Part. To the fullest extent
original warranty period. DC’ s warranty obligation is allowed by law, releases from, and limitations of liability
expressly conditioned upon the customer fulfilling all shall apply notwithstanding breach of contract, tort
obligations pursuant to customer’ s purchase order, (including negligence), strict liability or other theory of legal
including, without limitation, all payment obligations. liability of the party released or whose liability is limited.
The laws of the State of Georgia shall govern this warranty.
2. ENGINES: Warranty coverage is provided
for the DEUTZ diesel engine series listed below: 7. UNDER NO CIRCUMSTANCES WILL THE CUSTOMER
Warranty Warranty BE ENTITLED TO RECISSION OR TO A REDUCTION IN
Period Operating Hours Coverage THE PURCHASE PRICE. CUSTOMER WAIVES ANY
AND ALL CLAIM FOR LOSS OF TIME, REPLACEMENT
12 months Unlimited All Components
POWER, INCREASED COST, INCONVENIENCE, LOSS
OF USE OR PROFIT, LOSS OF GOODWILL, COST OF
1008, 1008F 1000h CAPITAL, COST OF RENTALS OR ANY OTHER DIRECT,
909, 1011, 2010, 2011 2000h INDIRECT, PUNITIVE, SPECIAL, EXEMPLARY,
24 months 2008, 2009 2000h All Components INCIDENTAL OR CONSEQUENTIAL DAMAGES
1012, 2012, 1013, 2013 3000h WHATSOEVER.
910, 912, 913, 914 3000h
1015, 2015 5000h 8. THIS WARRANTY AND THE DC LIMITED WARRANTY
FOR EPA-APPROVED DEUTZ DIESEL ENGINES AND
1008, 1008F 1500h Main Components, NEW GENUINE DEUTZ DIESEL ENGINE PARTS
909, 1011, 2010, 2011 3000h Crankcase,
Crankshaft,
INSTALLED IN SUCH ENGINES ARE IN LIEU OF ALL
36 months 2008, 2009 3000h OTHER EXPRESS OR IMPLIED WARRANTIES OF DC
Camshaft,
1012, 2012, 1013, 2013 4500h Connecting Rods, AND DEUTZ AG WITH RESPECT TO DEUTZ DIESEL
910, 912, 913, 914 4500h Cylinder Head Casting ENGINES AND GENUINE DEUTZ DIESEL ENGINE
1015, 2015 7500h PARTS, INCLUDING, WITHOUT LIMITATION, ANY
The Engine warranty will commence at the date of sale to IMPLIED WARRANTY OF MERCHANTABILITY OR
the original retail customer, or one year from the date of FITNESS FOR ANY PARTICULAR PURPOSE. NEITHER
manufacture, whichever occurs first. DC NOR DEUTZ AG ASSUME, NOR AUTHORIZE ANY
DISTRIBUTOR OR OTHER PERSON TO ASSUME, ON
3. PARTS: Warranty coverage is provided for each new THEIR BEHALF, ANY OTHER OBLIGATION OR
genuine DEUTZ Part for a period of 12 months from the LIABILITY.
date of sale to the original retail customer.
9. For details of the DEUTZ warranty contact:
4. This warranty does not cover the following: (i) wear and DEUTZ Corporation
tear or contaminants; (ii) exposure, corrosion or prolonged Warranty Department
or improper storage; (iii) normal maintenance service or the 3883 Steve Reynolds Blvd
replacement or repair of parts required to be replaced or Norcross GA 30093 USA
repaired in the course of normal maintenance service; (iv) Phone: 770-564-7100
improper installation, use, fuels, lubricants, operation, www.deutzusa.com
maintenance, transportation or packing; (v) misuse,
alteration, negligence and accidents; (vi) chemical or
electrical action; and (vii) unauthorized repairs.
Limited Warranty for DEUTZ Engine or DEUTZ Part Rev. August, 2006
S1056
Operation Manual
2012
C 2000
1 Gerade BA 2012 9912en
S1056
Safety guidelines / Accident prevention
● Please read and observe the information

given in this Operation Manual. This will ● Unauthorized engine modifications will in-
enable you to avoid accidents, preserve the validate any liability claims against the manu-
manufacturer’s warranty and maintain the facturer for resultant damage.
engine in peak operating condition. Manipulations of the injection and regulating
system may also influence the performance
● This engine has been built exclusively for of the engine, and its emissions. Adherence
the application specified in the scope of to legislation on pollution cannot be guaran-
supply, as described by the equipment manu- teed under such conditions.
facturer and is to be used only for the
intended purpose. Any use exceeding that ● Do not change, convert or adjust the cooling
scope is considered to be contrary to the air intake area to the blower.
intended purpose. The manufacturer will The manufacturer shall not be held respon-
not assume responsibility for any damage sible for any damage which results from
resulting therefrom. The risks involved are such work.
to be borne solely by the user.
● When carrying out maintenance/repair op-
● Use in accordance with the intended pur- erations on the engine, the use of DEUTZ
pose also implies compliance with the con- original parts is prescribed. These are spe-
ditions laid down by the manufacturer for cially designed for your engine and guaran-
operation, maintenance and servicing. The tee perfect operation.
engine should only be operated by person- Non-compliance results in the expiry of the
nel trained in its use and the hazards in- warranty!
volved.
● Maintenance and cleaning of the engine
● The relevant accident prevention guidelines should only be carried out when the engine
and other generally accepted safety and is switched off and has cooled down.
industrial hygiene regulations must be ob- You must ensure that the electrical systems
served. have been switched off and the ignition key
has been removed.
● When the engine is running, there is a risk of Accident prevention guidelines concerning
injury through: electrical systems (e.g. VDE-0100/-0101/-
- turning/hot components 0104/-0105 Electrical protective measures
- engines with positive ignition against dangerous touch voltage) are to be
- ignition systems (high electrical voltage) observed.
You must avoid contact at all times! When cleaning with fluids, all electrical com-
ponents are to be covered impermeably.
00_GB.p65 2 04.02.2002, 14:23

S1056
Operation Manual
2012
0297 9912 en
Engine Serial
Number:
Please enter the engine serial number here. This

number should be quoted when inquiring about
Customer Service, Repairs or Spare Parts (see
Section 2.1).
Technical modifications required to improve our

engines are reserved with regard to specification
data and other technical information contained in
this Operation Manual. No parts of this Manual
© 2003
may be reproduced in any form or by any means
without our written approval.
S1056
Foreword
Dear Customer,
Liquid-cooled DEUTZ engines are designed

for a large number of applications. Conse-
quently, a wide range of variants are offered to
meet the requirements of specific cases.
Your engine is appropriately equipped for the

installation concerned, which means that not
all of the components described in this Opera-
tion Manual are necessarily mounted to your
engine.
We have endeavored to highlight any differ-

ences so that you will be able to locate the
operating and maintenance instructions rel-
evant to your engine quickly and easily.
Please read this Manual before starting your

engine, and always observe the operating
and maintenance instructions.
We are available to help with any additional
inquiries
Sincerely,
DEUTZ AG
© 31 493 0
© 2003
S1056
Index
1. General 3.2.1 Electric Starting 6.1.1 Oil Change Intervals

3.3 Monitoring Operation 6.1.2 Check Oil Level, Change Engine Oil
3.3.1 Engine Oil Pressure 6.1.3 Replace Oil Filter
2. Engine Description 3.3.2 Coolant Temperature 6.1.4 Clean/Replace Oil Filter (Cup)
2.1 Model 3.4 Shutting off 6.2 Fuel System
2.1.1 Rating Plate
3.4.1 Mech. Stopping 6.2.1 Replace Fuel Filter
2.1.2 Position of the Rating Plate
3.4.2 Electr. Stopping 6.2.2 Fuel Pre-filter, Clean Filter Element /
2.1.3 Engine Serial Number 3.5 Operating Conditions Replace if Necessary
2.1.4 Cylinder Enumeration
3.5.1 Winter Operation 6.2.3 Bleed Fuel System
2.2 Engine Illustrations
3.5.2 High Ambient Temperature, High Alt- with Fuel Pre-filter
2.2.1 Operating Side 2012 itude 6.2.4 Bleed Fuel System
Ribbed V-belt Drive
without Fuel Pre-filter
2.2.2 Starter Side 2012
Ribbed V-belt Drive
4. Operating Media 6.3 Cooling System
4.1 Lube Oil 6.3.1 Cleaning Intervals
2.2.3 Operating Side 2012
4.1.1 Quality 6.3.2 Clean Cooling System
4.1.2 Viscosity 6.3.3 Drain Cooling System
2.3 Lube Oil Circuit Schematic 6.3.4 Fill / Bleed Cooling System
2.3.1 Lube Oil Plan 4.2 Fuel
4.2.1 Quality 6.4 Combustion Air Filter
2.4 Fuel System
4.2.2 Winter Fuel 6.4.1 Cleaning Intervals
2.4.1 Fuel System Plan 6.4.2 Emptying Cyclone Type Precleaner
2.5 Coolant System 4.3 Coolant
4.3.1 Water Quality for Coolant 6.4.3 Clean Oil Bath Air Filter
2.5.1 Coolant Plan 2012
4.3.2 Coolant Treatment 6.4.4 Dry Type Air Cleaner
4.3.3 Cooling System Protectants 6.5 Belt Drives
3. Engine Operation 6.5.1 Check V-belts
3.1 Commissioning – 2012 Standard
3.1.1 Pour in Engine Oil
5. Routine Maintenance
– 2012 with Ribbed V-belt
5.1 Maintenance Plan
3.1.2 Filling Oil Bath Air Filter with Engine
Oil 5.2 Maintenance Diagram
5.3 Maintenance Work Completed
3.1.3 Pour in Fuel
3.1.4 Fill / Bleed Cooling System
3.1.5 Other Preparations 6. Service and Maintenance
© 2003
3.2 Starting 6.1 Lubrication System
S1056
Index
6.5.2 Tension V-belts 7. Faults, Causes and Remedies

Coolant / Fuel Pump 7.1 Fault Table
6.5.3 Replace V-belts
Coolant / Fuel Pump 8. Engine Preservation
6.5.4 Replace V-belts
8.1 Preservation
Ribbed V-belts
6.5.5 Tension Alternator V-belts
6.5.6 Replace Alternator V-belts
9. Technical Specification
6.5.7 Wedge rib V-belts wear limit examine
6.6 Adjustments 9.1 Engine Specifications and Settings
6.6.1 Check Valve Clearance (Adjust if Neces- 9.2 Screw Tightening Torques
sary) 9.3 Tools
6.6.1.1 Valve Clearance Adjustment Plan
6.7 Accessories 10. Service
6.7.1 Battery
6.7.2 Rotary Current Alternator
6.7.3 Transportation Shackles
© 2003
S1056
General
DEUTZ Diesel Engines Care and Maintenance Service

1
are the product of many years of research and Sound care and maintenance practices will ensure Please contact one of our authorized service
development. The resulting know-how, coupled that the engine continues to meet the requirements representatives in the event of breakdowns or for
with stringent quality standards, guarantee their placed on it. Recommended service intervals must spare parts inquiries. Our trained specialists will
long service life, high reliability and low fuel be observed and service and maintenance work carry out repairs quickly and professionally, using
consumption. carried out conscientiously. only genuine spare parts.
It goes without saying that DEUTZ Diesel Engines Special care should be taken under abnormally Original parts from DEUTZ AG are always produced
meet the highest standards for environmental demanding operating conditions. in accordance with state-of-the-art technology.
protection. Please turn to the end of this manual for further
service information.
Beware of Running Engine Safety

California
Proposition 65 Warning
Shut the engine down before carrying out mainte- This symbol is used for all safety
nance or repair work. Ensure that the engine cannot warnings. Please follow them Diesel engine exhaust and some of its consti-
be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any
! carefully. The attention of operating
personnel should be drawn to these
tuents are known to the State of California to
cause cancer, birth defects, and other repro-
ductive harm.
panels and guards that may have been removed. safety instructions. General safety
Never fill the fuel tank while the engine is running. and accident prevention regulations laid down by
Observe industrial safety regulations when running law must also be observed.
the engine in an enclosed space or underground.
Asbestos
DEUTZ original parts are asbestos-

free.
S1056
1
S1056
Engine Description
2
2.1 Model
2.2 Engine Illustrations
2.3 Lube Oil Circuit Schematic
2.4 Fuel System
2.5 Coolant System
© 2003
S1056
Engine Description 2.1 Model
2.1.1 Rating Plate 2.1.3 Engine Serial Number

2 2.1.2 Position of the Rating Plate
A B
C
© 26 332 3 © 31 488 0 © 31 823 0
The model A , the engine serial number B and The rating plate C is attached to the crankcase. The engine serial number is stamped on the
the performance data are stamped on the arrow
crankcase (arrow
arrow) as well as the rating plate.
rating plate.The model and engine serial
number must be given when ordering parts.
© 2003
S1056
2.1 Model Engine Description
2.1.4 Cylinder Enumeration

2
1 2 3 4
© 31 813 0
Cylinders are numbered consecutively, be-

ginning at the flywheel.
© 2003
S1056
Engine Description 2.2 Engine Illustration

2 Ribbed V-belt drive
1 Alternator
2 Oil filler
1 2 3 3 Coolant connection compensation line
4 Fan pulley
17 5 Fuel pump
6 Coolant pump
7 Ribbed V-belt pulley on crankshaft
4 8 Tension roller
9 Feet
16 10 Oil pan
11 Oil filler neck
12 Oil filter housing with engine oil cooler
13 Oil dipstick
5 14 Optional attachment of:
15 Compressor or hydraulic pump
15 Fuel filter cartridge
16 Oil filter cartridge
17 Tractive electromagnet
14 6
13 7
12 11 10 9 8
© 2003
© 31 482 0
S1056
2.2 Engine Illustration Engine Description

Ribbed V-belt drive
2
18 Turbocharger
19 Engine suspension
20 Speed regulator
18 19 21 Flywheel
22 SAE housing
27 23 Starter
24 Exhaust manifold
25 Coolant inlet
26 Heater flange not shown
27 Thermostat housing coolant outlet
26
20
25
24
21
23 22
© 2003
© 31 483 0
S1056
Engine Description 2.2 Engine Illustration

2
1 Turbocharger
2 Heater flange
3 Fan
14 1 4 Alternator
5 V-belt pulley on crankshaft
6 Coolant pump
7 Fuel pump
8 Oil filler
13 9 Oil filter housing with engine oil cooler
10 Oil filter housing with oil filter cartridge
2 11 Oil dipstick
12 Fuel filter
13 Tractive electromagnet
14 Oil filler neck
12
3
11
4
10
9
© 2003
8 7 6 5
© 31 484 0
S1056
2.2 Engine Illustration Engine Description

2
15 Engine suspension
16 Speed regulator
17 Flywheel
15 18 SAE housing
25 19 Oil pan
20 Starter
21 Feet
22 Alternator
23 Coolant inlet
24 Exhaust manifold
24 25 Coolant outlet
16
23
22
21
17
20 19 18
© 2003
© 31 485 0
S1056
Engine Description 2.3 Lube Oil Circuit Schematic
2 2.3.1 Lube Oil Plan
1 Oil pan
2 Intake line
3 Lube oil pump
4 Lube oil cooler
4.1 Heat exchanger bypass valve
4.2 Shut-off valve
4.3 Lube oil replacement filter
4.4 Oil pressure sensor
5 Main oil pipe
6 Crankshaft bearing
7 Con-rod bearing
8 Camshaft bearing
9 Line to spray nozzle
10 Spray nozzle for piston cooling
11 Valve lifter with rocker arm impulse lubrica-
tion
12 Stop rod, oil supply for rocker arm lubrication
13 Rocker arm
14 Return line to oil pan
15 Oil line to turbocharger
16 Turbocharger
17 Oil line to compressor or hydraulic pump
18 Compressor
19 Hydraulic pump
20 Return line from compressor or hydraulic
pump
21 Line to the differential (2x)
22 Balancer shafts
23 Turbocharger return to crankcase
© 2003
© 31 808 0
S1056
2.4 Fuel System Engine Description
2.4.1 Fuel System Plan

2
1 Fuel tank
8 9 7 2 Line to fuel pump
3 Fuel pump
4 Line to fuel filter
10 5 Fuel filter
6 Line to the injection pumps
7 Injection pump
5 8 Line to injection valve
9 Injection valve
11 10 Banjo bolt with pressure maintenance valve
11 Return line to fuel filter housing from
pressure maintenance valve
12 (with cup filter installation only)
12 Return line to fuel tank
13 13 Maintain maximum possible distance
© 2003
1 2 4 3 6
© 31 809 1
S1056
Engine Description 2.5 Coolant System
2.5.1 Coolant block diagram 2012

2 Example: With cup filter
1. Thermostat housing
2. Outlet neck cover
3. Coolant pump
12 4. Lube oil cooler
5. Cylinder cooling
6. Cylinder head cooling
13 10 11 7. Line from engine to heat exchanger
8. Heat exchanger
9. Line from heat exchanger to thermostat
6 10. Ventilation line to the compensation tank
11. Compensation tank
12. Coolant compensation line
13. Coolant return from heater
8 14. Coolant supply to heating at V-belts
15. Coolant supply to heating at ribbed
5 7
V-belts
15 9
3
© 2003
4 14
© 31 810 1
S1056
Engine Operation
3
3.1 Commissioning
3.2 Starting
3.3 Monitoring Operation
3.4 Shutting off
3.5 Operating Conditions
© 2003
S1056
Engine Operation 3.1 Commissioning
3.1.1 Pour in Engine Oil 3.1.2 Oil Bath Air Filter with
3 Engine Oil
OIL
FUEL
© 31 491 0 © 26 398 0
As a rule, engines are delivered without oil. Fill oil cup 1 of the oil bath air cleaner (if
Pour lube oil into the oil filler neck (arrow). installed) with oil up to the arrow.
Oil capacity, see 9.1. For oil grade and viscosity, see 4.1.
For oil grade and viscosity, see 4.1.
Never fill the fuel tank while the

© 2003
engine is running. Ensure clean-

! liness! Do not spill fuel!
S1056
3.1 Commissioning Engine Operation
3.1.3 Fill / Bleed Cooling System 3.1.4 Other Preparations

3
● 2012: In accordance with the radiator suppli- ● Check battery and cable connections, see
er’s specifications 6.7.1.
● Unit engine: In accordance with the radiator
supplier’s specifications ● Trial run
- After the engine has been prepared, carry out
a brief trial run for approx. 10 minutes, without
load if possible.
During and after the trial run

- Check the engine for leaks.
After the engine has been turned off

- Check oil level and top up if necessary,
see 6.1.2.
- Retension V-belts, see 6.5.
● Breaking in
During the break-in phase - about 200 operat-
ing hours - check the oil level twice a day.
After the engine is broken in, checking once a
day will be sufficient.
● In the event of commissioning engines

which have been preserved
Carry out removal of preservation in accord-
ance with Chapter 8.1.
© 2003
S1056
Engine Operation 3.2 Starting
3.2.1 Electric Starting

3 without cold start assistance
Before starting, make sure that

nobody is standing in the im-
! mediate vicinity of the engine
or driven machine.
After repair work:
2
Check that all guards have
been replaced and that all tools have been
removed from the engine.
When starting with glow plugs, do not use any
other starter substance (e.g. injection with
start pilot). Risk of accident! 1
Caution: If the speed regulator has been
removed, the engine must not be started
under any circumstances.
Disconnect the battery!
© 31 824 0 © 25 745 0
● Disengage the clutch to separate the en- ● Insert key

gine from any driven parts. - Position 0 = no operating voltage.
● Bring speed adjustment lever 1 into at least ● Turn key clockwise

the middle speed position in the direction of - Position 1 = operating voltage
the arrow. - Pilot lights 1 and 2 illuminate.
● Move cut-out handle 2 into operating posi- ● Push key in and turn further clockwise
tion counter to the direction of the arrow. against spring pressure.
- Position 2 = no function
Do not actuate the starter for more than 20 - Position 3 = start
seconds. If the engine does not catch, wait for one
minute then try again. ● Release key as soon as engine fires
© 2003
If the engine does not catch after two attempts, - The pilot lights will go out.
refer to the Fault Table (see 7.1).
S1056
3.2 Starting
with cold start assistance

3
Heater flange
© 25 746 2
● Insert key
- Position 0 = no operating voltage.
● Turn key clockwise

- Position 1 = operating voltage.
- Pilot lights illuminate, pre-glowing until
glow indicator is extinguished.
● Push key in and turn further clockwise

against spring pressure.
- Position 2 = no function
- Position 3 = start
● Release key as soon as engine fires.
© 2003
- The pilot lights will go out.
S1056
Engine Operation 3.3 Monitoring Operation
3.3.1 Engine Oil Pressure

3
Oil pressure lamp Oil Pressure Indicator Oil Pressure Gauge
© 25 752 1 © 25 753 0 © 25 754 0
● The oil pressure pilot light comes on with ● The pointer must remain in the green sector ● The pointer of the oil pressure gauge must
operating voltage on and engine off. over the entire operating range. display the minimum oil pressure (see 9.1)
● The oil pressure pilot light must be extin-

guished when the engine is running.
© 2003
S1056
3.3 Monitoring Operation Engine Operation
3.3.2 Coolant temperature

3
© 26 246 0
● The engine temperature gauge pointer

should always remain in the green sector. It
should rarely enter the yellow-green sector.
If the pointer enters the orange sector, the
engine is overheating.
Turn off and establish the cause from the
Fault Table (see 7.1).
© 2003
S1056
Engine Operation 3.4 Shutting Off
3.4.1 Mechanical Stopping 3.4.2 Electrical Stopping

3
© 31 825 0 © 25 746 2
● Move speed adjustment lever 1 to low idle. ● Turn key counterclockwise (to position 0)
and remove. The pilot lights will go out.
● Move shut-off lever 2 until the engine comes
to a stop. The charge pilot light and the oil
pressure pilot light illuminate when the en-
gine stops.
● Turn key counterclockwise (to position 0)

and remove. The pilot lights will go out.
© 2003
If possible, do not switch off the engine when

under full load. Subsequently allow the en-
gine to idle for approx. 2 mins.
S1056
3.5 Operating Conditions Engine Operation
3.5.1 Winter Operation

3
● Lube Oil Viscosity ● Battery
- Select the oil viscosity (SAE grade) according - Efficient cold starting necessitates that
to the ambient temperature before starting the battery is well-charged, see 6.7.1.
the engine, see 4.1.2. -The starting limit temperatures can be low-
- Increase oil change frequency when operat- ered by 4-5 °C by heating the bat-
ing below -10 °C, see 6.1.1. tery up to about 20 °C. (To do so, remove the
battery and store in a warm place).
● Diesel Fuel
- Use winter-grade diesel fuel for operation
below 0 °C, see 4.2.2.
● Coolant
- Mixture ratio of anti-freeze / water for mini-
mum temperature (max. -35 °C),
see 4.3.1.
● Additional Maintenance Work © 26 248 0

- Drain the sludge from the fuel tank once a
week (undo the sludge drain screw).
- If necessary, adjust oilbath filter oil level,
like the engine oil, to the ambient temperture.
- Below -20 °C, after removing the starter if
necessary, smear the ring gear on the fly-
wheel via the pinion bore from time to time
with cold-resistant grease. (e.g. Bosch
grease FT 1 V 31).
● Cold Start Assistance

- The heater flange is automatically initialised at
temperatures < -25 °C.
© 2003
S1056
Engine Operation 3.5 Operating Conditions
3.5.2 High Ambient Temperature

3 High Altitude
● Air density decreases as altitude or ambi-

ent temperature increase.
As a result of this, the engine’s maximum
output, the quality of the exhaust gas, the
C F
temperature level and, in extreme cases,
starting behaviour, are impeded.
In the event of non-stationary operation,
use up to altitudes of 1000 m and tempera-
tures of 30 °C is permissible.
If the engine is to operate under unfavour- 0 32
able conditions (at higher altitudes or tem-
peratures), it will be necessary to reduce
the injected fuel quantity and thus, engine
power.
● If you have any doubts about engine opera-

© 25 901 1
tion under these or similar conditions, ask
your engine or equipment supplier whether
the engine has been derated in the inter-
ests of reliability, service life and exhaust
gas quality (smoke!). Otherwise contact
your service representative.
© 2003
S1056
Operating Media
4
4.1 Lube Oil
4.2 Fuel
4.3 Coolant
© 2003
S1056
Operating Media 4.1 Lube Oil
4.1.1 Quality Grade 4.1.2 Viscosity

4
Lube oils are differentiated by Deutz according Generally, multi-grade oils shall be used. In
to their performance and quality class. Oils of closed heated rooms at temperatures >5°C,
other, comparable specifications can be used. also single-grade oils can be used.
As the viscosity of lube oil is dependent on

temperature, the choice of SAE grade should
be governed by the ambient temperature
Approved oils: prevailing at the engine operating site.
Optimum operating behaviour will be attained
if you take the accompanying oil viscosity
Deutz DQC I DQC II DQC III diagram as a guide.
Should the temperature fall temporarily below
ACEA E2-96 E3/96/E5-02 E4-99 the limits of the SAE grade selected, cold
API CF/CF-4 CH-4/CG-4 - starting may be affected but the engine will
not be damaged.
DHD - DHD-1 - In order to keep wear to a minimum, do not
exceed application limits for extended periods
of time.
The precise assignment of the admissible
oil qualities to the engines is indicated in Synthetic lube oils feature an improved
chapter 6.1.1. temperature and oxidation stability.
If in doubt, contact your service represen-
tative.
© 2003
Only with preheating

30 298 1
S1056
4.1 Lube Oil Operating Media
4.1.2.1 Specific lube oil

definitions
Lube oils for engines with uprated power and engines with high loading
Producer Type of lube oil SAE class Availability
4
DEUTZ TXL-10W40 FE 10W-40
AGIP Agip Sigma Ultra TFE 10W-40 worldwide
Turbocharged engines with uprated power and AGIP Autol Valve Ultra FE 10W-40 Germany
engines with high loading ARAL GmbH Aral MegaTurboral 10W-40 worldwide
The oils listed in enclosure 1 are to be used ARAL GmbH Aral SuperTurboral 5W-30 worldwide
for the following engines and applications:
BAYWA BayWa Super Truck 1040 MC 10W-40 South Gemany
COM/EPA II version and increased output
BAYWA BayWa Turbo 4000 10W-40 South Gemany
BF4M 2012/C > 95 kW
BF6M 2012/C > 143 kW (bore 101 + 98-MVS) Castrol GmbH Castrol SYNTRUCK 5W-40 Europe, North America, Brazil
BF6M 2012/C > 135 kW (bore 98 mech. FIE) Argentina, Australia, South Africa
all engines in CHP plants Castrol GmbH Castrol DYNAMAX 7,5W-40 Europe, North America, Brazil
all engines in gensets operating in parallel with Argentina, Australia, South Africa
the mains/with each other CHEVRON Chevron Delo 400 Synthtic 5W-40 North America
engines in combines with: ESSO Essolube XTS 501 10W-40 Europe
These are high-grade oils according to ACEA or FINA FINA KAPPA FIRST 5W-30 Europe
API. In addition most of these oils are partly FINA FINA KAPPA ULTRA 10W-40 Europe
synthetic, some even fully synthetic (5W-40) and FUCHS DEA DEA Cronos Synth 5W-40 Germany, Europe
thus achieve the thermal stability required for the FUCHS DEA DEA Cronos Premium LD 10W-40 Germany, Europe
relevant application and are distinguished by a FUCHS DEA Fuchs Titan Cargo MC 10W-40 worldwide
low tendency to cause deposits in the turbocharger FUCHS DEA Deutz Oel TLL 10W-40 MB 10W-40 Germany
and in the charge air pipes with closed-circuit FUCHS DEA DEA Cronos Premium FX 10W-40 Europe
crankcase breather FUCHS DEA Fuchs Titan Unic Plus MC 10W-40 worldwide
MOBIL OIL Mobil Delvac 1 SHC 5W-40 Europe, SE Asia, Africa
MOBIL OIL Mobil Delvac 1 5W-40 worldwide
MOBIL OIL Mobil Delvac XHP Extra 10W-40 Europe, SE Asia
BP OIL International BP Vanellus HT Extra 10W-40 Europe
Shell International Shell Myrina TX / 5W-30 Europe, different
Shell Rimula Ultra description in some countries
Shell International Shell Myrina TX / 10W-40 Europe, different
Shell Rimula Ultra description in some countries
TOTAL TOTAL RUBIA TIR 86000 10W-40 worldwide
Schmierölraffinerie Wintershall TFG 10W-40 Europe
Salzbergen GmbH
© 2003
The table will be extended as and when required.
S1056
Operating Media 4.2 Fuel
4.2.1 Quality 4.2.2 Winter Fuel

4
Use commercially available diesel fuel with Waxing may occur at low temperatures, +32 0
less than 0.5 % sulphur content. If the sulphur clogging the fuel system and reducing engine I
content is higher, oil change intervals should efficiency. Use winter-grade diesel fuel (up to +23 -5
be reduced (see 6.1.1). -20 °C) for operation below 0 °C. This is made
available within good time by filling stations +14 - 10
The following fuel specifications / standards prior to the start of the winter season.
are approved: + 5 - 15
Kerosene must be added at temperatures
DIN EN 590 below -20 °C. The relevant percentages - 4 - 20
are given in the adjacent diagram.
BS 2869: A1 and A2 Special diesel fuels may be used in arctic - 13 - 25
(with A2, take note of the sulphur content!) climatic zones up to -44 °C. II
- 22 - 30
ASTM D 975-88; 1-D and 2-D If summer-grade diesel fuel must be used at
temperatures below 0 °C, up to 60% kerosene 0 10 20 30 40 50 60 %
°F °C
NATO Code F-54 and F-75 can be added (see diagram). A
B
© 26 441 1
Exhaust emission values which may be In most cases, adequate resistance to cold
determined in the case of type approval tests can be obtained by adding a flow improver Legend:
always refer to the reference fuel prescribed (additive). Please ask your DEUTZ partner.
by the authorities for the type approval test. I Summer-grade diesel fuel
II Winter-grade diesel fuel
A Ambient temperature
B Percentage of kerosen added
Diesel fuels must never be Mix in tank only! Fill with the
mixed with gasoline appropriate amount of kerosene
! !
© 2003
(Normal and Super grades)! first, then add the diesel fuel.
S1056
4.3 Coolant Operating Media
4.3.1 Quality of Water for

Coolant
4.3.2 Coolant Treatment 4.3.3 Cooling System
Protectants
4
The values listed below must not be exceeded. In the case of liquid-cooled engines, special DEUTZ cooling system protectant must be pur-
In order to examine the quality of your water, a test attention must be paid to the treatment and chased in drums under Order No. 01011490 (5
case can be ordered from DEUTZ under Order control of the coolant, as the engine may litres) or 1221 1500 (210 litres). These are nitrite,
No. 12130382. otherwise become damaged as a result of amine and phosphate-free, and provide effective
corrosion, cavitation and freezing. protection against corrosion, cavitation and freez-
The treatment of the coolant is carried out by ing.
Water quality min. max. adding a cooling system protectant to the If the above mentioned cooling system protectant
cooling water. is unavailable, the following products may be
pH value at 20 °C 6.5 8.5 The cooling system must be continuously moni- used in exceptional cases.
3
tored, see 5.1. In addition to checking the Manufacturer Product designation
Chloride ion content [mg / dm ] - 100 coolant level, this also involves checking the
concentration of the cooling system protectant. AVIA AVIA Antifreeze Extra
Sulphate ion content [mg / dm3] - 100
The cooling system protectant concentration ARAL Antifreeze Extra
Total hardness [°dGH] 3 20 can be checked with commercially available BASF Glysantin G 48
testers (example: gefo glycomat ®).
DEA DEA Radiator Antifreeze
SHELL SHELLGlycoShell
The cooling system protectant in the coolant should
not fall below or exceed the following concentration:
Cooling system protectant Water
max. 45 Vol.% 55%
min. 35 Vol.% 65%
Filling volume, see chart over page in combina-
tion with specifications in Chapter 9.1.
The use of other cooling system protectants, e.g.
chemical anti-corrosion agents, is possible in
exceptional cases. Consult DEUTZ Service.
If nitrite-based cooling system
protectants are mixed with
! Cooling system protectants must
© 2003
amine-based agents, danger-
ous nitrosamines are formed. ! be disposed of in an environmen-
tally-friendly manner.
S1056
Operating Media 4.3 Coolant
4 Cooling system protection

content of coolant system *)
Cooling Frost [Litres]
system
protection
protection 18 20 22 25 27 30 32 35
in
in
[ °C] Cooling system protectant
35 –22 6,3 7,0 7,7 8,75 9,5 10,5 11,2 12,3
40 –28 7,2 8,0 8,8 10 10,8 12 12,8 14
45 –35 8,1 9,0 9,9 11,3 12,2 13,5 14,4 15,8
50 –45 9,0 10 11 12,5 13,5 15 16 17,5
*) For coolant content of your engine, see Operation Manual Chapter 9.1.
Note: Grey sector only after consulting head office
© 2003
S1056
Routine Maintenance
5
5.1 Maintenance Schedule
5.2 Maintenance Chart
5.3 Maintenance Work Completed
© 2003
S1056
Routine Maintenance 5.1 Maintenance Schedule
check= ● adjust= ❍ clean= ▲ replace= ■

5 ⇓ prior to or during 1st trial run, check 2x daily during the breaking in phase or Industrial engines
when commissioning new and overhauled engines The specified engine maintenance values are
Section
permissible recommended maximums.
⇓ every 10 hours of operation or daily
Depending on usage, reduced maintenance
Operating hours (OP) every intervals may be necessary, comply with the
unit manufacturer’s operating instructions.
Years # Maintenance must only be carried out by
250 500 1000 1 5 0 0 12000 1 2 Operation authorised service personnel
● ● Top lube oil up if necessary 6.1.2/3.3.4
■ Lube oil (oil change intervals depending on engine use), see TR 0199-99-3002 6.1.1/ 6.1.2
■ Oil filter cartridge (at each lube oil change) 6.1.3
■ Fuel filter cartridge 6.2.1
● ■ Flexible fuel leak oil lines (replace completely)
■ Injection valve #
● ▲ ■ Fuel pre-cleaner/ filter element (cleaning or replace if necessary) 4.2/ 5.2
● ● ■ Coolant (additive concentration) 4.3.1/ 2/ 3
■ Coolant pump #
● ● Coolant level –
● ● ■ Intake air cleaner (If available, maintain according to maintenance indicator) 6.4.3 /6.4.4
● ● ▲ Intercooler (drain lube oil/condensation)
● Battery and cable connectors 6.7.1
● ● Engine monitoring system, warning system 3.3 #
❍ Valve clearance 6.6.1#
● ● ■ V-belts (retension or replace if necessary) 6.5.1
* When the warning system responds (lamp/horn), the fuel pre-filter must be emptied immediately
© 2003
S1056
5.1 Maintenance Schedule Routine Maintenance
check= ● adjust= ❍ clean= ▲ replace= ■

prior to or during 1st trial run, check 2x daily during the breaking in phase or when
Industrial engines 5
The specified engine maintenance values
commissioning new and overhauled engines
are permissible recommended maximums.
every 10 hours of operation or daily Depending on usage, reduced maintenance
In hours of operation (HO) every intervals may be necessary, comply with the
Years unit manufacturer’s operating instructions.
# Maintenance must only be carried out by
250 500 1000 1500 12000 1 2 authorised service personnel
Operation Section
● ● Check engine for leaks (visual inspection) –
● ● Engine suspension (replace if damaged) 9.2
● ● Fastenings, hose connections / clamps –
■ Basic overhaul #
Page 2 of 2
check= ● adjust= ❍ clean= ▲ replace= ■ Additions and modifications

Max. permissible reference times in operating hours (HO) every for engines with EPA approval
prior to or during 1st trial run, check 2x daily during the breaking in The specified engine maintenance values arepermissible
phase or when commissioning new and overhauled engines recommended maximums. Depending on usage, reduced
maintenance intervals may be necessary, comply with the
every 10 hours of operation or daily unit manufacturer’s operating instructions.
In hours of operation (HO) every Years # Maintenance must only be carried out by authorised
service personnel Section
250 500 1000 3000 6000 12000 1 2 Operation
■ Injection valve #
© 2003
S1056
Routine Maintenance 5.2 Maintenance Chart
The maintenance chart shown on this page is

5 supplied as a self-adhesive label with each
engine. It should be affixed where it can be AIR
h
125- Std.
seen clearly on the engine or driven 2000 10 500
OIL
equipment.
Check that this is the case.

a
If necessary, ask your engine or equipment in.
1500
supplier for a fresh supply of labels. ex.
Routine work should be carried out according

to the schedule in 5.1.
OIL
500
FU
EL 1000
10 10
ER
WAT
OIL
max.
2012
0297 9901 1
Stop the engine before carry-

© 2003
ing out any maintenance work.

!
S1056
5.2 Maintenance Chart Routine Maintenance
The maintenance chart shown on this page is supplied as a self-adhesive label with each engine. It should be affixed where it can be seen
clearly on the engine or driven equipment.
Check that this is the case.
5
If necessary, ask your engine or equipment supplier for a fresh supply of labels.
Routine work should be carried out according to the schedule in 5.1.
max
.
min.
min.
0297 9902 0
2012
© 2003
9912EN_K05-1.P65 37 17.02.2003, 12:05 Uhr
S1056
Routine Maintenance 5.3 Maintenance Work Completed
5 Op. hours
*
Date Signature/stamp Op. hours Date Signature/stamp
50-150 -
125 250
375 500
625 750
875 1000
1125 1250
1375 1500
1625 1750
1875 2000
2115 2250
2375 2500
2625 2750
* following commissioning of new and overhauled engines.
Duly completed maintenance jobs can be recorded and signed off in the above chart.
© 2003
S1056
5.3 Maintenance Work Completed Routine Maintenance
Op. hours Date Signature/stamp Op. hours Date Signature/stamp

5
2875 3000
3125 3250
3375 3500
3625 3750
3875 4000
4125 4250
4375 4500
4625 4750
4875 5000
5125 5250
5375 5500
5625 5750
© 2003
S1056
5 Op. hours Date Signature/stamp Op. hours Date Signature/stamp

5875 6000
6125 6250
6375 6500
6625 6750
6875 7000
7125 7250
7375 7500
7625 7750
7825 8000
8125 8250
8375 8500
8625 8750
© 2003
S1056
5.3 Maintenance Work Completed Routine Maintenance
Op. hours Date Signature/stamp Op. hours Date Signature/stamp

5
8875 9000
9125 9250
9375 9500
9625 9750
9875 10000
10125 10250
10375 10500
10625 10750
10825 11000
11125 11250
11375 11500
11625 11750
© 2003
S1056
5 Op. hours Date Signature/stamp Op. hours Date Signature/stamp

© 2003
S1056
Service and Maintenance
6.1 Lubrication System

6.2 Fuel System
6.3 Cooling System
6.4 Combustion Air Filter
6.5 Belt Drives
6.6 Adjustments
6.7 Accessories
© 2003
S1056
Service and Maintenance 6.1 Lubrication System
6 6.1.1 Oil Change Intervals
● The oil change intervals are dependent on ● If, for vehicle engines, lube oil change
the engine application and the quality of intervals are determined by operating hours,
the lube oil. the lube oil change intervals indicated in table
6.1.1.1. equipment engines.
● If the engine runs fewer hours during the
year than stated in the table, the oil should
be changed at least once a year.
● The table refers to the following condi-

tions:
– For diesel fuel: sulfur content max. 0.5
% by weight.
– Continuous ambient temperatures down
to -10 °C / +14°F
● For fuels
– with sulfur content is > 0.5 to 1 %
or
– continuous ambient temperature below
-10 °C/+14°F
or
– with bio-diesel fuels in accordance with
DIN 51606-FAME the intervals between
oil changes should be halved.
● In the case of fuels containing more than

1 % sulfur, contact your service repre-
sentative.
© 2002
Change the oil with the engine off but still

warm (lube oil temperature approx. 80 °C).
ENGLISCH • Kapitel 6 • Seite 52

9682en_K06.p65 52 30.07.2003, 10:13
S1056
6.1 Lubrication System Service and Maintenance
6.1.1.2 Lube oil change intervals for industrial and marine engines 6
Lube oil grade
Deutz lube oil quality class DQC I DQC II DQC III
ACEA-specfication E2-96 E3-96/E5-02 E4-99
API-specification CF/CF-4 CG-4/CH-4 -
Worldwide specification - DHD-1 -
special DEUTZ release list - - Enclosure 1
Standard lube oil code for building EO... EO...C -
equipment and nonraod vehicles EO...A, EO...B
Engine Engine version Lube oil change intervals in op. hours

series Oil use Oil use Oil use
normal high normal high normal high
2012 All engines except for: 250 500 500

BF4M2012C P > 95 kW - - 500
BF6M2012C P > 143 kW, from nonroad stage II - - 500
at cylinder bore 101 mm or 98 mm with MV system
BF6M2012C P > 135 kW, from nonroad stage II - - 500
at cylinder bore 98 mm with mech. injection system
Other engines from nonroad stage II - 500 500
eng. in harv. machines, block-typethermal power stat., gensets** - - 500
*Gensets as referred to here are units operating in parallel with the mains / with each other.
© 2003
Emergency power units are dealt with in TR 0199-99-1126.
S1056
6.1.1.2 Oil change intervals for vehicle engines

6 Schmieröl-Qualität
Deutz lube oil quality class DQC I DQC II DQC III
ACEA specification E2-96 E3-96/E5-02 E4-99
API specification CF/CF-4 CG-4/CH-4 -
worldwide specification - DHD-1 -
special DEUTZ release - - Enclosure 1
Application Engine version Lube oil change intervals in km
Site 25 2012 Euro I 10 000 15 000 20 000
vehicles/ Euro II and Euro III, except for: - 15 000 20 000
busses BF4M2012C > 95 kW from Euro II - - 20 000
BF6M2012C > 143 kW from Euro II at cylinder - - 20 000
Average speed in km/h approx. ]
bore 101 mm with or 98 mm with MV system

> 135 kW from Euro II at cylinder bore 98 mm - - 20 000
with mechanical injection system
Local 40 2012 Euro I 15 000 20 000 30 000
traffic Euro II and Euro III,except for: - 20 000 30 000
BF4M2012C > 95 kW from Euro II - - 30 000
BF6M2012C > 143 kW from Euro II at cylinder - - 30 000
> 135 kW from Euro II at cylinder - - 30 000
bore 98 mm with mechanical injection system
Long 60 2012 Euro I 20 000 30 000 40 000
distance Euro II and Euro III, except for: - 30 000 40 000
traffic BF6M2012C > 143 kW from Euro II at cylinder - - 40 000
> 135 kW from Euro II at cylinder - - 40 000
bore 98 mm with mechanical injection system
If, for vehicle engines, lube oil change intervals are determined by operating hours, the lube oil change intervals indicated in table 4.1. for “Oil
use under normal duty” will apply.
© 2003
S1056
6.1.2 Check Oil Level / Change

Engine Oil
6
6.1.2.1 Check Oil Level
6.1.2.1Check 6.1.2.2 Engine Oil Change
© 25 729 0 © 26 022 0 © 26 023 0
Ensure that the engine or vehicle is in a level Run engine until warm. Place oil tray under the engine.
position. Ensure that the engine or vehicle is in a level Unscrew oil drain screw.
Engine warm: position. Drain oil.
Shut engine off, wait for 5 minutes and check - Lube oil temperature approx. 80 °C. Screw oil drain screw in with new seal ring
oil level. Switch off the engine. and tighten. (Tightening torque
Engine cold: see 9.2).
Check oil level. Pour in lube oil.
Remove the oil dipstick. - For grade / viscosity, see 4.1
Wipe the dipstick with a non-fibrous, clean - For quantity, see 9.1.
cloth. Check oil level, see 6.1.2.1.
Insert it to the stop and remove again.
Check the oil level, and if necessary, top up to Caution when draining hot oil: Risk of
the “MAX” mark. scalding!
- If the oil level is only just above the “MIN” Do not let used oil run into the soil but
© 2003
mark, more oil must be added. collect it in a container!
Dispose of this in accordance with environmental
The level must not fall below the “MIN” mark. regulations!
S1056
6.1.3 Replace Oil Filter

6
© 25 880 0 © 25 881 0 © 25 882 0
● With attached locking piston: ● Clean any dirt from the filter carrier sealing ● Tighten the lube oil filter cartridge with
Undo tensioning screws and remove surface. another half-turn.
tensioning clamps downwards.
● Lightly oil the rubber gasket of the new lube ● If locking piston is available:
● Undo the lube oil filter cartridge using a oil filter cartridge. Position tensioning clamps and tighten with
commercial tool and spin off. tensioning screws.
● Manually screw in the new cartridge until
● Catch any escaping oil. the gasket is flush. ● Check oil level, see 6.1.2.
● Check oil pressure, see 3.3.1.
● Check lube oil filter cartridge seal for leaks.

Caution is required in the case of
© 2003
hot oil: Risk of scalding!

S1056
6.1.4 Clean / Replace

Oil Filter (Cup)
6
4
© 30 074 0
● Switch off the engine. ● Replace and lightly oil the rubber gasket 2.
● Loosen lube oil filter cover 1 and unscrew ● Carefully insert new paper filter cartridge 3
in an anticlockwise direction, emties itself into guide 4.
the system automatically (drain valve). ● Tighten lube oil filter cover 1 in a clockwise
● Carefully loosen paper filter cartridge 3 direction (25 Nm).
upwards from the guide 4. ● Start engine.
● Catch any escaping oil. ● Check oil level, see 6.1.2.
● Replace paper filter cartridge 3. ● Check oil pressure, see 3.3.1.
● Clean any dirt from the sealing surface of ● Check lube oil filter attachment for leaks.
the filter carrier and lube oil filter cover 1
and fromb the guide 4.
Caution is required in the case
© 2003
of hot oil:
Risk of scalding!
S1056
Service and Maintenance 6.2 Fuel System
6.2.1 Replace Fuel Filter

6
© 25 880 0 © 25 881 0 © 25 882 0
Close the fuel shut-off valve. Apply light film of oil or diesel fuel to the
rubber gasket of the new fuel filter car- Open fuel shutoff valve.
Undo fuel filter cartridge with commercial tridge.
tool and spin off. Check for leaks.
Manually screw in the new cartridge until
Catch any escaping fuel. the gasket is flush.
Clean any dirt from the filter carrier sealing Tighten the fuel filter cartridge with a final
surface. half-turn.
The fuel system does not need

© 2003
to be bled.
Keep naked flames away when working on the
fuel system. Do not smoke!
S1056
6.2 Fuel System Service and Maintenance
6.1.4 Clean / Replace

Fuel Oil Filter (Cup)
6
4
© 30 074 0
● Switch off the engine. ● Replace and lightly oil the rubber gasket 2.
● Loosen fuel oil filter cover 1 and unscrew in ● Carefully insert new paper filter cartridge 3
an anticlockwise direction, emties itself the into guide 4.
system automatically (drain valve). ● Tighten fuel oil filter cover 1 in a clockwise
● Carefully loosen paper filter cartridge 3 direction (25 Nm).
upwards from the guide 4. ● Start engine.
● Catch any escaping oil. ● Check fuel oil filter attachment for leaks.
● Replace paper filter cartridge 3.
● Clean any dirt from the sealing surface of
the filter carrier and fuel oil filter cover 1 and
fromb the guide 4.
Keep naked flames away when
© 2003
working on the fuel system. Do
not smoke!
S1056
Service and Maintenance 6.2 Fuel System
6.2.3 Clean / purge or change fuel

6 pre-filter
in performance also after purging)

● Turn off the engine or switch to other filter in
case of changeover filter
● Close the fuel stopcock or supply (if available)
● Loosen the cover screws 3 diagonally
● Remove the cover 2
● Remove the spring cassette 4
● Remove the filter element 5 from the bracket
● Insert new filter element 5
● Place spring cassette 4 on the element
● Check that the cover seal is fit properly in the
cover 2 and check for damage (change if
necessary)
● Tighten the cover 2 with the screws 3
diagonally (torque 6 Nm)
● Check the cover 2 for proper fit and leaks
© 31 811 2
● Bleed the fuel system, see 6.2.4.
Clean (purge) - remove water:

● Turn off engine or, in the case of a change-
over filter, switch over to the other filter.
● Close the fuel stopcock or supply. (if available)
● Open the bleed screw 1 on the cover 2
● Place the fuel collector underneath the fuel The connection of a warning system
pre-filter. (lamp/horn) via contacts 7 is specified.
● Empty water and dirt from the bowl 6 by Immediate maintenance is necessary when the
opening (press in and turn slightly without warning system is triggered.
using force) the drain cock 8 and close the
drain cock 8 again
● Close the bleed screw 1 on the cover 2 again Naked flames are prohibited when
● Bleed the fuel pipe according to instructions, working on the fuel system! Do
© 2003
see 6.2.5 opposite not smoke!

Changing the filter element 5: Dispose of old fuel in an environ-
Change at least once a year or as required (drop mentally friendly way!
S1056
6.2 Fuel System Service and Maintenance
6.2.4 Bleed Fuel System 6.2.5 Bleed Fuel System

with Fuel Pre-filter without Fuel Pre-filter
6
Place fuel collection container beneath the
fuel pre-filter.
Bleed:
In the event of re-commissioning, following
maintenance work or if the tank has been 9 9
run empty, the fuel system must be bled.
Bring engine regulator into stop position.
Position fuel collection container beneath
filter housing 8 / pressure maintenance
valve 9.
Open fuel shut-off valve, pressure
maintenance valve 9, bleeder screw 1.
Turn engine over with starter (max. 20 sec.)
until bubble-free fuel escapes from bleeder
screw 1 and pressure maintenance valve © 31 812 0 © 31 812 0
9.
Firmly tighten bleeder screw 1 and pressure
maintenance valve 9. ● Bring engine regulator into stop position.
Bring engine regulator into start position ● Open fuel shut-off valve.
and start. ● Loosen pressure maintenance valve 9.
Check for leaks after starting the engine. Collect any escaping fuel and dispose of
this in an environmentally-friendly manner.
● Turn engine over with starter (max. 20 sec.)
until bubble-free fuel escapes from pressure
maintenance valve 9.
● Tighten pressure maintenance valve 9.
Keep naked flames away when ● Bring engine regulator into start position
working on the fuel system. Do and start.
not smoke! ● Check for leaks after starting the engine.
Dispose of used fuel in an envi- Keep naked flames away when
© 2003
ronmentally-friendly manner! working on the fuel system. Do
not smoke!
Dispose of used fuel in an envi-
ronmentally-friendly manner!
S1056
Service and Maintenance 6.3 Cooling System
6.3.1 Cleaning Intervals 6.3.2 Clean Cooling System

6
● The amount of contamination in the cooling Checking or cleaning intervals ● External cooling system: Clean according
system depends on the engine application. to cooling system manufacturer’s speci-
● Oil and fuel residues on the engine increase Guideline Engine application fications.
the risk of contamination. Therefore pay values OH
special attention to leaks if the engine is 2000 Ships, electrical modules in
used in dusty environments.
● Serious contamination occurs, for example: enclosed areas, pumps.
- on construction sites where there is a high 1000 Vehicles on paved roads
level of air-borne dust.
- in harvesting applications where there are 500 Tractors, fork-lift trucks,
high concentrations of chaff and chopped drivable electric units.
straw in the vicinity of the machine.
250 Vehicles on construction sites
● Because applications vary, cleaning
intervals have to be determined from case and unpaved roads, construc-
to case. The cleaning intervals given in the tion machines, compressors,
table below can be used as a guide.
underground mining units.
125 Agricultural machines, tractors
in harvesting applications.
© 2003
S1056
6.3 Cooling System Service and Maintenance
6.3.3 Drain Cooling System 6.3.4 Fill / Bleed Cooling System

2012
6
1 max
.
min.
min.
0297 9902 0
© 31 816 0 2012
● Position a collecting pan beneath screw ● Open radiator cap item 1. Bleed
plug 1. ● Loosen vent hose item 2. ● External cooling system: According to cooling
● Remove screw plug 1 at crankcase. ● Fill coolant item 1b in up to the “MAX” mark or system manufacturer’s specifications.
● Drain coolant. filling limit (if fitted, system heater valve must
● Tighten screw plug 1 again. be open).
● If screw plug 1 is not accessible, ● Connect vent hose, item 6, + tighten screw
drainage can be carried out at the engine plug item 4.
radiator (coolant channel). ● Close radiator cap item 7.
Fill / bleed cooling system see Chapter 6.3.4 ● Start engine and warm up until thermostat
opens.
● Switch off the engine.
Caution when draining hot coolant: ● Check coolant level when engine is cold, and
Risk of scalding! Collect coolant top up if necessary.
● Close radiator cap item 1.
© 2003
on draining.
Dispose of this in accordance with
environmental regulations!
S1056
Service and Maintenance 6.4 Combustion Air Filter
6.4.1 Cleaning Intervals

6
The amount of dirt in the combustion air
filter depends on the amount of dust in the
air and the size of the air filter used. If a high
level of dust is anticipated, a cyclone-type
pre-cleaner can be fitted in front of the
combustion air filter.
● Cleaning intervals must therefore be

determined from case to case.
● If dry type air filters are used, cleaning

should only be carried out according to the
service indicator or service switch.
● Filter servicing is needed when:

- Service indicator © 25 885 1
the red signal 1 is fully visible when the engine
is off.
- Service switch
the yellow pilot light comes on when the en-
gine is running.
● After carrying out service work, press the

reset button on the service indicator. The
service indicator is now ready for operation
again.
© 2003
S1056
6.4 Combustion Air Filter Service and Maintenance
6.4.2 Emtying Cyclone Type 6.4.3 Clean Oil Bath Air Filter
Precleaner
6
© 25 886 0 © 25 885 1
● Undo wing nut 1 and remove cover 2. ● Turn engine off and wait about 10 minutes ● Clean filter housing 1 if very dirty.
● Remove collector bowl 3 from lower section for the oil to drain from filter housing 1. ● Inspect and replace rubber gasket 5 and 6
4 and empty. Clean leaves, straw and other ● Loosen snap clips 2 and remove oil cup 3 if necessary.
foreign matter from lower section of with filter element 4; if necessary, loosen ● Fill oil cup with engine oil up to the mark
precleaner. filter element with the aid of a screwdriver (arrow) (for viscosity, see 4.1.2).
● Reposition collector bowl 3 onto lower at the separating point. Do not damage ● Refit oil cup and element to filter housing
section 4, fasten cover 2 in place by tight- rubber gasket 5! and secure with snap clips.
ening wing nut 1. ● Remove dirty oil and sludge. Clean oil cup.
● Clean filter element 4 in diesel fuel and
allow to drip-dry thoroughly.
Never clean filter with gasoline.
© 2003
Dispose of old oil in accordance
Never fill collector bowl with oil. Replace with environmental regulations!
collector bowl if damaged.
S1056
Service and Maintenance 6.4 Combustion Air Filter
6.4.4 Dry Type Air Filter

6 Dust Discharge Valve Filter Cartridge
© 25 888 1 © 25 889 0
● Empty dust discharge valve 1 by pressing ● Undo clip fasteners 1. ● After five filter services or after two years at
apart lips of discharge slot as indicated by ● Take off hood 2 and remove cartridge 3. the latest, replace safety cartridge 4 (never
arrows. ● Clean cartridge (replace at least once a clean!).
year) To do so:
● Clean discharge slot from time to time. ● Clean cartridge 3. - Undo hex nut 5 and remove cartridge 4.
- Using dry compressed air (max. 5 bar), - Insert new cartridge, re-install hex nut and
● Remove any caked dirt by pressing together blow out from inside outwards, tighten.
the upper section of the valve. or ● Install cartridge 3, replace hood 2 and do
- Tap out (in emergencies only). Do not up clip fasteners 1.
damage the cartridge, or
- Wash out according to manufacturer’s
specifications.
● Check paper filter (light showing through) Never clean filter cartridge with
© 2003
and gaskets for damage. Replace if gasoline or hot fluids!

necessary.
S1056
6.5 Belt Drives Service and Maintenance
6.5.1 Check V-belts

2012 Standard 2012 with Ribbed V-belt
6
© 31 817 0 © 31 818 0 © 26 261 1
● Visually inspect entire V-belt for damage. - Carefully raise the gauge without chang-
● Replace damaged V-belts. ing the position of indicator arm 1.
● After installing new belts, run engine for 15 - Read off the value where the indicator arm
minutes, then check belt tension. 1 intersects scale 5 (arrow) and read
● To check the tension of the V-belt, use a indicator arm 1 off. For settings, see 9.1.
tension gauge (see 9.3). - If necessary, retension belt and measure
- Place indicator arm 1 into gauge. again.
- Position guide 3 on V-belt 2, midway
between the pulleys, with flange 3 on
bottom of gauge against the edge of belt.
- Push slowly on the black pad 4 at right
angles to V-belt 2 until the spring is heard
or felt to trigger. Check, tension and change V-
belts only with the engine off. If
© 2003
necessary, reinstall V-belt
S1056
Service and Maintenance 6.5 Belt Drives
6.5.2 Tension V-belts 6.5.3 Replace V-belts 6.5.4 Replace V-belts

6 Coolant / Fuel Pump Coolant / Fuel Pump Ribbed V-belts
1 1 2
3 2 3 2
1
© 31 819 0 © 31 821 0 © 31 814 0
● Loosen screws 1 and 2. ● Loosen screws 1 and 2. ● Press tension roller in direction of arrow
● Press fuel pump 3 in direction of arrow until ● Press fuel pump 3 in direction of arrow. until the ribbed V-belt is free.
the correct V-belt tension has been ● Remove V-belt and position new belt. ● First remove ribbed V-belt from the small-
achieved. ● Press fuel pump counter to direction of est roller.
● Tighten screws 1 and 2 again. arrow until the correct V-belt tension has ● Position new ribbed V-belt.
been achieved. ● Press tension roller counter to direction of
● Tighten screws 1 and 2 again. arrow until the ribbed V-belt is tensioned.
Check, tension and change V- Check whether ribbed V-belt is

© 2003
belts only with the engine off. If positioned correctly in its guide.
necessary, reinstall V-belt guard.
S1056
6.5 Belt Drives Service and Maintenance
6.5.5 Tension V-belts 6.5.6 Replace V-belts

Alternator Alternator
6
5 5
4 3 1 4 3 1
2 2
© 31 820 0 © 31 822 0
Loosen screws 1, 2 and 4. Loosen fuel pump V-belt, see 6.5.3

l Adjust alternator 5 in direction of arrow by Loosen screws 1, 2 and 4.
turning screw 3 until correct V-belt tension Adjust screw 3 until V-belt can be removed.
is achieved. Position new belt.
Retighten screws 1, 2 and 4. Adjust screw 3 until the correct V-belt
tension has been achieved.
Retighten screws 1, 2 and 4.
Tension fuel pump V-belt, see 6.5.4.
Check, tension and change V-
© 2003
belts only with the engine off. If
necessary, reinstall V-belt guard.
S1056
Service and Maintenance 6.5 Belt Drives
6.5.7 Wedge rib V-belts wear limit

6 examine.
© 31 879 0
● Wear limit of the wedge ribV- belt as follows ● If „ a “ is smaller than 3 mm, then the wedge
examine: rib V- belt is to be exchanged
● Distance between the nose of the flexibiliti
clamping arm and the notice of the firm
tension adjuster housing examine.
© 2003
S1056
6.6 Adjustments Service and Maintenance
© 2003
S1056
Service and Maintenance 6.6 Adjustments
6.6.1 Check Valve Clearance,

6 Adjust if Necessary
© 19 691 2 © 26 262 1
Loosen ventilation valve and swing to the Adjust valve clearance if necessary:
side. - Release locknut 4.
Remove the cylinder head cover. - Use screwdriver 7 to turn setscrew 5 so
Position crankshaft as per schematic, see that the correct valve clearance 1 is
6.6.1.1. attained after locknut 4 has been tigh-
Before adjusting valve clearance, allow tened.
engine to cool down for at least 30 minutes. Check and adjust valve clearance on all
The oil temperature should be below 80 °C. cylinders.
Check valve clearance 1 between rocker Reinstall cylinder head cover (with new
arm / tappet contact face 2 and valve 3 with gasket if necessary).
feeler gauge 6 (there should be only slight Swing ventilation valve into position and
resistance when feeler blade is inserted). fasten.
For permissible valve clearance, see 9.1.
© 2003
S1056
6.6 Adjustments Service and Maintenance
6.6.1.1 Valve Clearance Adjustment

Schematic
6
Crankshaft Position 1:
Turn crankshaft until both valves in cylinder
1 overlap (exhaust valve about to close,
inlet valve about to open). Adjust valve
clearance according to schematic (marked
in black)
black). Mark respective rocker arm with
chalk to show that adjustment has been
carried out.
Crankshaft Position 2:
Turn crankshaft one full revolution (360°).
Adjust valve clearance according to
schematic (marked in black).
© 2003
© 26 263 2
S1056
Service and Maintenance 6.7 Accessories
6.7.1 Battery
6 6.7.1.1 Check Battery and 6.7.1.2 Check Electrolyte Level 6.7.1.3 Check Electrolyte Density
6.7.1.3Check
Cable Connections
© 25 895 0 24232 3 © 25 896 0
Keep battery clean and dry. Remove sealing caps 1. Measure the electrolyte density of individual
cells with a commercial hydrometer.
Undo dirty clamps. If testers 2 are present: The hydrometer reading (see table on
Electrolyte level should reach the base of following page) indicates the battery’s state
Clean terminal posts (+ and -) and clamps these. of charge. During measurement, the
of the battery, and grease with acid-free temperature of the electrolyte should pref-
and acid-resistant grease. Without testers: erably be 20 °C.
The electrolyte level should be 10-15 mm
When reassembling, ensure that clamps above the top of the plates.
make good contact. Tighten clamp bolts
hand-tight. If necessary, top up with distilled water.
Screw sealing caps back in.

© 2003
S1056
6.7 Accessories Service and Maintenance
6
Electrolyte density
in [kg/ l] in [°Bé (Baumé scale)*] Charge status
Normal Tropical Normal Tropical
1.28 1.23 32 27 well charged
1.20 1.12 24 16 semi-charged, re-charge
1.12 1.08 16 11 discharged, immediately charge
* Measurement of electrolyte density in ° Bé

(Baumé scale) is out of date and rarely
used today.
The gases emitted by the battery

are explosive! Keep sparks and
naked flames away from the
battery!
Do not allow battery acid to come
© 2003
into contact with skin or clothing!
Wear protective goggles!
Do not rest tools on the battery!
S1056
Service and Maintenance 6.7 Accessories
6.7.2 Rotary Current Alternator

6 6.7.3 Transportation Shackles
Notes on the three-phase system:

Never disconnect the cables between
battery, alternator and regulator while the
engine is running.
If, however, it is necessary to start and

operate the engine without the battery,
disconnect the regulator from the alternator
before starting.
Be sure not to confuse the battery terminals.
Replace defective charge pilot lamp bulb

immediately.
When cleaning the engine: Do not spray

the alternator with a direct jet of water/ © 31 826 0 © 31 827 0
steam!
Allow the engine to run warm so that the ● Only use proper lifting gear when
remaining water evaporates. transporting the engine.
The habit of touching a lead against the
frame to check whether it is live must under
no circumstances be used with three-phase
electrical systems.
In case of electric welding, connect the

ground terminal on the welder directly to
the piece being welded.
Use only the correct lifting gear !

© 2003
S1056
Faults, Causes and Remedies
7.1 Fault Table
© 2003
S1056
Faults, Causes and Remedies
7
● Faults can frequently be attributed to the fact
that the engine has been incorrectly operated
or not serviced.
● Each time a fault occurs, check whether all

operating and servicing regulations have been
complied with.
● A corresponding fault table can be found

on the opposite page.
● If the cause of a fault cannot be

determined, or you are unable to remedy a fault
yourself, then please contact your
DEUTZ Service representative.
Before starting, make sure that nobody is stand-

ing in the immediate vicinity of the engine or driven
machine.
In the event of repair work:
Caution: If the speed regulator
has been removed, the engine
© 2003
! must not be started under any

circumstances.
Disconnect the battery!
S1056
7.1 Fault Table Faults, Causes and Remedies
Faults
Engine does not start or is difficult to start (Starting speed is not achieved on starting)
Measures
Check P
7
Engine starts, but runs irregularly or fails Adjust E
Engine becomes excessively hot. Temperature warning system responds Replace W
Engine output is deficient Clean R
Engine does not run on all cylinders Top up A
Engine oil pressure is non-existant or excessively low Bleed L
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause Section
● Not declutched (where possible) Engine Operation P
● ● Below starting limit temperature P
● ● Engine shut-off lever still in stop position (shutoff magnet defective) P
● ● Oil level too low A
● ● ● ● Oil level too high S
● ● ● Excessive inclination of engine P/E
● Adjust throttle to half actuation travel P/E
● ● ● Air cleaner clogged / turbocharger defective Combustion air P / W
● ● ● Air cleaner service switch / indicator defective P
● ● CPD* defective (connection line leaks) P
● ● ● Charge air line leaking P/W
● Coolant pump defective Cooling system P / R
● ● Intercooler soiled P/R
● Coolant heat exchanger soiled P/R
Cooling fan defective, torn or loose V-belt P/W
● ● ● ● ●
(fuel pump in belt drive)
© 2003
● ● Cooling air temperature rise / heating short circuits P
● Battery defective or discharged Electrics P
*CPD = Charge pressure-dependent full-load stop Table 1 of 2
S1056
Faults, Causes and Remedies 7.1 Fault Table
7 Faults
Engine does not start or is difficult to start (Starting speed is not achieved on starting)
Measures
Check P
Engine starts, but runs irregularly or fails Adjust E
Engine becomes excessively hot. Temperature warning system responds Replace W
Engine output is deficient Clean R
Engine does not run on all cylinders Top up A
Engine oil pressure is non-existant or excessively low Reduce S
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause Section
● Cable connections, starter, electrical circuit loose or oxidised Electrics P
● Starter defective or pinion does not engage P
● ● ● ● ● Incorrect valve clearance Engine E
● ● ● ● Injection line leaks P
● Ventilation line blocked (coolant heat exchanger) P/R
● ● Sheathed glow plugs defective P
● ● ● ● ● ● ● Injection valve defective P/W
● ● ● ● Air in the fuel system P/W
● ● ● ● Fuel filter / fuel pre-cleaner soiled P/R/W
● Oil filter defective W
● ● ● Incorrect engine lube oil SAE class or quality Operating media W
● ● ● ● Fuel quality not as per operation manual P/W
● Coolant deficiency P/A
Table 2 of 2
© 2003
S1056
Engine Preservation
8.1 Preservation
© 2003
S1056
Engine Preservation 8.1 Preservation
8.1 Preservation
8
If the engine is to remain idle for an extended Preserve engine: Remove engine preservation:
period of time, it is necessary to take protec- Clean engine (poss. with cold cleaner). Remove anti-corrosion agent from
tive measures to prevent the formation of Radiator cleaning, see 6.3.2. grooves in V-belt pulleys 2.
corrosion. The preservative measures de- Run engine until warm, then turn off.
scribed here will protect the engine for up to Drain engine oil, see 6.1.2, and fill with anti- Install V-belts. Retension after brief
approx. 6 months. The procedure will have to corrosion oil. operation if necessary, see 6.5.
be reversed before the engine is Drain coolant, see 6.3.3.
recommissioned. Top up anti-corrosion agent, see specifica- Remove covers from intake port 3 and
tions. exhaust port 4.
Anti-corrosion oils to specification: Clean oil bath air filter if necessary, see
- MIL-L 21260B 6.4.3, and top up anti-corrosion oil. Disconnect coolant inlet and outlet neck
- TL 9150-037/2 Drain fuel tank. covers, remove protection and connect to
- Nato Code C 640 / 642 Make up a mixture of 90 % diesel fuel and cooling system.
10 % anti-corrosion oil, and refill fuel tank.
Recommended cleaning agent to remove Allow the engine to run for approx. 10 mins. Top up coolant, see 6.3.4.
pre servatives: Switch off the engine. System must be bled.
- Petroleum benzine (hazardous materials class Manually turn the engine over several times.
A3) When turning over with starter, set shutoff Commission engine
lever to stop position.
Remove V-belts and store in wrapped con-

dition.
Spray grooves on V-belt pulleys 2 with anti-

corrosion spray.
Drain anti-corrosion agent, see 6.3.3.
Lightly preserve coolant filler neck and seal

with cap.
Seal intake ports and exhaust ports.

© 2003
S1056
Technical Specification
9
9.1 Engine Specifications and Settings
9.2 Torque Wrench Settings
9.3 Tools
© 2003
S1056
Technical Specification 9.1 Engine Specifications and Settings
Model ----------- BF4M 2012 ------------------------ BF4M 2012 C ---------------------- BF6M 2012 C -------
9 Number of cylinders ------------------ 4 --------------------------------------- 4 ---------------------------------------- 6 ---------------
Cylinder arrangement ----------------------------------------------------- vertical in line -------------------------------------------------
Bore [mm] ---------------------------------------------------------- ø 101 -------------------------------------------------------
Stroke [mm] ----------------------------------------------------------- 126 --------------------------------------------------------
Total displacement [cm3] ---------------- 4.04 ----------------------------------- 4.04 ----------------------------------- 6.06 -------------
Compression ratio [ε]. ------------------------------------------------------------ 19 ---------------------------------------------------------
Working cycle -------------------------------------------------- Four-stroke diesel ----------------------------------------------
Combustion system ---------------------------------- with turbocharging and direct fuel injection ------------------------------
Charge air cooling --------------- without --------------------------------- with ------------------------------------ with -------------
Direction of rotation -------------------------------------------------- counter-clockwise -----------------------------------------------
Weight 2012/ C including cooling system
to DIN 70020-A [approx.kg] ------------------------------------------------- Refer to head-office ---------------------------------------------
Engine output [kW] ------------------ 75 ------------------------------------ 103 ------------------------------------ 155 -------------

Max. speed [1/rpm] ---------------------------------------------------------- 2500 -------------------------------------------------------
Valve clearance with cold engine (PTs) [mm] ----------------------------------------- Inlet 0.3 + 0.1 / exhaust 0.5 + 0.1. --------------------------------------
Valve clearance with cold engine standard [mm] ------------------------------------ Adjustment with special tool, see 6.6.1 ---------------------------------
Injector opening pressure [bar] ----------------------------------------------------------- 250 --------------------------------------------------------
Start of feed [°CS BTOC] ------------------------------------------------------------- 1). ---------------------------------------------------------
Firing order of the engine -------------- 1-3-4-2 ------------------------------- 1-3-4-2 ----------------------------- 1-5-3-6-2-4 --------
V-belt tension: -------------------------------------------- Pre-tension / re-tension 2) ----------------------------------------------------------------------
Alternator / fan [N] ----------------------------------------------------- 450 / 300 ± 50. --------------------------------------------------
Fuel pump - coolant pump [N] ----------------------------------------------------- 450 / 300 ± 50. --------------------------------------------------
Compressor [N] ----------------------------------------------------- 550 / 450 ± 50. --------------------------------------------------
Ribbed V-belt tension spring-loaded tension roller [N] ----------------------------------------------------- 900 / 600 ± 50. --------------------------------------------------
1)
Engine output, speed, start of delivery are stamped on engine rating plate, etc., see also 2.1.
© 2003
2)
Re-tension 15 minutes after the engine has been operated under load.
S1056
9.1 Engine Specifications and Settings Technical Specification
Model ----------- BF4M 2012 ------------------------ BF4M 2012 C ---------------------- BF6M 2012 C -------
ling ----------------------------------- Liquid-cooled / cooling system protection ------------------------------- 9
Coolant volume
2012/ C [ca.ltr.] ----------------- 5,6 ------------------------------------- 5,6 ------------------------------------ 7,3 --------------
Perm. constant coolant temperature
Engine exhaust, output group I [°C] ------------------------------------------------------ max.110 6) . ---------------------------------------------------
Engine exhaust, output group II-IV [°C] ------------------------------------------------------ max. 105 6) . --------------------------------------------------
Thermostat opening commencement at [°C] ------------------------------------------------------------ 7) . ---------------------------------------------------------
Thermostat fully open from [°C] ---------------------------------------------------------- 83 8) . -------------------------------------------------------
Coolant pre-heating ------------------------------------------------------------ (4 . ---------------------------------------------------------
Coolant pump
9)
Feed pressure in [bar] ------------------------------------------------------------ . ---------------------------------------------------------
Feed quantity in [m3 /h] ------------------------------------------------------------ 9)
. ---------------------------------------------------------
9)
Power consumption in [kW] ------------------------------------------------------------ . ---------------------------------------------------------
Lubrication ------------------------------------------------- Pressure lubrication ---------------------------------------------

Oil temperature in oil pan [°C] ----------------------------------------------------------- 125 --------------------------------------------------------
Min. oil pressure when warm
(120 °C and SAE oil 15 W 40 ) and low idle [bar] ------------------------------------------------------------ 0,8 --------------------------------------------------------
Oil plate filling quantity without filter [approx.ltr.] --------------- 8.5 3) . -------------------------------- 8.5 3) . ------------------------------- 12.5 3) . -----------
Oil plate filling quantity with filter [approx.ltr.] ---------------- 10 3) . ---------------------------------- 10 3). --------------------------------- 14.0 3). -----------
3)
Approx. values may vary depending on version. The upper oil dipstick mark is always authoritative.
4)
Only necessary in winter operation, see 3.5.1.
5)
Engine content without radiator only. Content of external cooling system depending on cooling system version.
6)
Other output groups have different values, consultation with head office is required.
7)
In the case of external cooling systems with outlet regulation, the thermostat begins to open at 87 °C
8)
In the case of external cooling systems with outlet regulation, the thermostat is fully open at 102 °C
9)
Consultation with head office is required (differ depending on engine version)
© 2003
S1056
Technical Specification 9.2 Screw Tightening Torques
9
Pre-tension [Nm] Re-tension [Nm] Total
Installation location Comments
1. Stage 2. Stage 3. Stage 1. Stage 2. Stage 3. Stage 4. Stage [Nm]
Cylinder head screw 8.5
Rocker arm adjustment screw 21
Foot on flywheel side 187 M16x40 8.

8.8 A 4 C
Foot on fan side 30 45 187 M16x40 8.

8.8 A 4 C
Intake manifold 8.5
Exhaust manifold 21
Oil drain screw 50
Injection valve attachment 16 Torx
Injection line attachment 30 M14x1.5
Oil pan (cast) 29
Oil pan (sheet metal) 21

© 2003
S1056
9.3 Tools Technical Specification
TORX V-belt tension gauge

9
25899 0 26002 0
A TORX wrench set is used with engines in The V-belt tension gauge can be obtained
the 2012 series. under order number 8115 + 8120 from:
This system was chosen because of the many
advantages it offers: WILBÄR
● Outstanding accessibility to bolts. Postfach 14 05 80
● High load transfer when loosening and D-42826 Remscheid
tightening.
● Almost impossible for socket to slide off
or break, thereby practically ruling out the
risk of injury.
TORX tools can be ordered from:
© 2003
WILBÄR
Postfach 14 05 80
D-42826 Remscheid
S1056
9
© 2003
S1056
Notes
en Warnings to Place on Equipment Warning in the Manual
CALIFORNIA CALIFORNIA
Proposition 65 Warning Proposition 65 Warning
Diesel engine exhaust and some of its Diesel engine exhaust and some of its
constituents are known to the State of constituents are known to the State of
California to cause cancer, birth California to cause cancer, birth
defects, and other reproductive harm. defects, and other reproductive harm.
or
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
S1056
Notes
CALIFORNIA PROPOSITION 65 INFORMATION en

TO CALIFORNIA CUSTOMERS AND
TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR
FOR USE IN CALIFORNIA.
Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under that law,
including certain chemicals in diesel engine exhaust.
Obligations of Manufactures of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the following
two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court
order containing these provisions is attached.)
1. On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California after
January 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment when (s)he is operating the
equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display,
you may usee that method of providing warning.
2. Operator Manual Warning. When the operator manual is next revised or by December 31, 1995 whichever is earlier, place the warning
in attachment 2 in the operator manual. The warning may be either printed in the manual or on a sticker.
The warning must appear in one of the following locations:

● Inside The front cover
● Inside the back cover
● Outside the front cover
● Outside the back cover
● As the first page of text
Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of an equally conspicuous
size and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be
provided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.
Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California.
Should you have any questions, please call Deutz Corporation Product Support Department.
Service
S1056
Knowing it’s DEUTZ Order-No.: 0312 0806 10

en DEUTZ has always stood for excellence in motor
construction, pioneering many developments in
the industry. As an independent motor manu-
facturer, we offer — worldwide — a com-
prehensive range of diesel and gas motors
spanning from 4kW to 7,400kW. Our products are
perfectly tailored to meet our customers’ individual
requirements.
Over 1.4 million DEUTZ motors do their job

reliably all over the world. We are determined to
preserve the high standard of performance and
dependability of our motors, thus keeping our
customers satisfied at all times. Therefore we are
represented worldwide through a network of highly
competent service partners who will meet the
needs of our customers, wherever they are.
This is why DEUTZ is not only the name for motors

which pack a lot of inventive genius. DEUTZ also
means reliable service and comprehensive support
to enhance your motor’s performance.
This index Sales & Service offers you an overview Order-No.: 0312 0807 (CD-ROM)
of the DEUTZ partners in your vicinity, including the
products for which they are responsible and the DEUTZ AG
range of services provided. But even when no direct Deutz-Mülheimer Str. 147-149
product responsibility is mentioned, your DEUTZ D-51057 Köln
partner will be happy to help you with expert advice.
Phone: 0049-221-822-0
The Index is constantly updated. Please ask your Obtainable from the local service Partner reponsible Telefax: 0049-221-822-5304
DEUTZ service partner for the latest edition. for you or from: Telex: 8812-0 khd d
http://www.deutz.de
DEUTZ AG — at your service.

S1056
DEUTZ AG
Service-Technik
Instandhaltungstechnik Motoren
Deutz-Mülheimer Str. 147-149
D-51063 Köln
Tel.: ++49 (0) 2 21- 8 22 - 0
Fax: ++49 (0) 2 21- 8 22 - 53 58
Internet: www.deutz.de
E-mail: info@deutz.de
Printed in Germany
All rights reserved
3. Edition, © 03/03
We move your world Order No.: 0297 9912 en
Beschnitt Beschnitt
S1057
Ersatzteilliste
Spare Parts Catalogue
Catalogue de Pièces de
Rechange
Lista de Piezas de Repuesto
2012
U1_Titel_2012_0297 9957
Beschnitt CYAN = HKS 49K MAGENTA = HKS 14K SCHWARZ Beschnitt

S1057
Motorbeskrivelse
de
en 1. Firmenskilt 2. Firmaskiltets placering 3. Motornummer
fr
es
A B
pt
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
Typen A, motornummeret B og ydelsesdataene er Firmaskiltet C er fastgjort på krumtaphuset. Motornummeret er stemplet ind på krumtaphuset
no stemplet ind på firmaskiltet.
Ved bestilling af reservedele skal man angive type
og på firmaskiltet.
og motornummer.
el
tr
ru
ar
pl
© 2000 4 da
S1057
Bestillingsangivelser
de
Bestillingsangivelser en
Ved bestillingen af originale DEUTZ-dele er det
nødvendigt med følgende angivelser:
Bestillingsangivelser fr
- motor-nr. Motor-nr.: es
- ident.-nr lb. nr. antal ident.-nr. anmærkning komponent pt
- antal
it
Dokumentationens opbygning nl
- Billederne i denne reservedelsliste er sorteret
efter motor-komponenter. sv
- Delmontagerne findes i motoroversigten.
da
- Ident-nr. 06/59 er opbygget af komponent
(f.eks. 06) og position (f.eks. 59).
position
fn
Symbolforklaring
no
-06- delmontagenummer (f.eks. 06) el
000 ændringsciffer (f.eks. 000)
tr
96 sidenummer (f.eks. 96)
krydshenvisning til næste side

ru
94 (f.eks. 94)
ar
A tilslutningssymbol
- optræder altid mindst parvis
(f.eks. A-A, B-B, C-C osv.)
pl
5 da © 2000
S1057
Service
de
en Man ved, det er DEUTZ. Bestillings-nr.: 0312 0806
fr Fra tidernes morgen har DEUTZ været

ensbetydende med banebrydende udviklinger
inden for fremstillingen af motorer. Som uafhængig
es motorfabrikant tilbyder vi over hele verden et
komplet spektrum af diesel- og gasmotorer med en
pt effekt på 4 til 7.400 kW. Vore produkter er perfekt
skræddersyet efter vore kunders behov.
it Over hele verden udretter mere end 1,4 millioner

DEUTZ-motorer deres arbejde til alles tilfredshed.
Vi ønsker at bevare vore motorers
nl anvendelsesberedskab og dermed også vore
kunders tilfredshed. Derfor er vi over hele verden
sv repræsenteret af et helt net af kompetente partnere,
hvis tæthed svarer til vore motorers regionale
fordeling.
da Således er DEUTZ ikke kun navnet på motorer til
stadig nye opgaver, men også på en komplet
fn servicepakke med hensyn til alt, hvad der har med
motorer at gøre, og med en service, De kan stole på. Bestillings-nr.: 0312 0807 (CD-ROM)
no Registret Sales & Service giver Dem et overblik
over DEUTZ-partnerne i Deres egn, over disses
el produkt-kompetancer og service-ydelser. Men
selvom der ikke direkte er angivet nogen produkt- Kan købes over Deres ansvarlige service-partner på DEUTZ AG
kompetance, hjælper DEUTZ-partneren Dem videre stedet eller over: Deutz-Mülheimer Str. 147-149
tr med en kompetent rådgivning. D-51057 Köln
ru Registret bliver hele tiden aktualiseret; bed Deres

DEUTZ-partner om den nyeste udgave.
Telefon: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
ar Deres DEUTZ AG
http://www.deutz.de
pl
© 2000 6 da
S1057
Varaosaluettelo
2012
Liikkeen leima
0312 0836
Mottorinumero:
Merkitse tähän moottorinumero. Sen ilmoittaminen

helpottaa asioiden käsittelyä huolto-, korjaus- ja
varaosakysymyksien yhteydessä.
Tämän varaosaluettelon kuvauksien ja tietojen suh-

teen pidätämme oikeuden muutoksiin, jotka ovat
tarpeellisia moottorin teknisen kehityksen kannalta.
Kaikenlaiseen jälkipainosten ja kopioiden tekoon,
myös osittain, tarvitaan kirjallinen lupamme.
1 fn © 2000
© 2000
S1057
Esipuhe
de
en Hyvä asiakas Tässä varaosaluettelossa lueteltuja komponentteja
tulee käyttää vain ilmoitetun tyyppisten Deutz-
fr Ilmajäähdytteiset DEUTZ-moottorit on kehitetty
laajaa käyttäjäkuntaa silmälläpitäen. Niinpä tarjolla
moottoreiden korjaustöissä (käyttötarkoituksen
mukainen käyttö).
on laaja valikoima moottorivaihtoehtoja, jotka Käyttöohjeesta (kohdasta Huoltotyöt) ja
es täyttävät asiakkaiden vaihtelevat moottoritarpeet. korjaamokäsikirjasta (kohdasta Korjaustyöt) käy
yksityiskohtaisesti ilmi, kuinka varasoat
pt Moottorinne on toimitettu tietyin varustein, eivätkä
kaikki tässä varaosaluettelossa esiintyvät osat vält-
asennetaan asianmukaisesti. Valmistaja ei vastaa
vahingoista tai henkilöiden loukkaantumisista,
tämättä kuulu moottorinne varusteisiin. jotka johtuvat siitä, että vastaavaa ohjetta ei ole
it Vaikka kaaviokuvat eivät sisällä kaikkia yksityiskoh-
noudatettu.
tia, eri vaihtoehdot on kuitenkin helppo erottaa toi-

nl sistaan moottorillenne tärkeiden varaosien tunni-
stamiseksi. Positio, rakenneryhmä- ja moottorinu-
sv meron avulla pystytään joka tapauksessa toimitta-
maan oikea varaosa.
da Varaosia tilattessa on noudatettava annettuja tilau-

sohjeita, jotta pystymme nopeasti ja varmasti toimit-
tamaan tarvittavat, kyseisen mallin viimeisintä tek-
fn nistä kehitystä vastaavat varaosat.
no Annamme mielellään lisätietoja ja vastaamme

kysymyksiinne
el DEUTZ AG
tr
ru
ar
pl
© 2000 2 fn
S1057
Esipuhe
de
DEUTZ dieselmoottorit DEUTZ varaosat DEUTZ vaihto-osat en
fr
ovat monien vuosien tutkimuksen ja kehittelyn tu- täyttävät samat, tiukat laatuvaatimukset kuin DEUTZ-vaihto-osat ovat edullinen
los. Näin saavutettu know-how yhdistyneenä kor-
keisiin laatuvaatimuksiin on tae pitkäikäisten, luo-
DEUTZ-moottoritkin. Moottorien parantamiseen
käytettyä kehitystä sovelletaan myös DEUTZ
vaihtoehto alkuperäisille DEUTZ
varaosille.
es
tettavien ja vähän polttoainetta kuluttavien mootto-
reiden valmistukselle. On itsestään selvää, että
varaosiin. Moitteeton toiminta ja luotettavuus on
taattu käyttämällä ainoastaan viimeisimmän teknii-
On myös itsestään selvää, että
näille osille asetetaan samat kor- pt
myös tarkat ympäristön suojelua koskevat mää- kan mukaan valmistettuja alkuperäisiä DEUTZ keat laatuvaatimukset kuin uusille osillekin. Toi-
räykset on otettu huomioon. varaosia. minnaltaan ja luotettavuudeltaan DEUTZ vaihto-
osat ovat samanarvoisia DEUTZ varaosien kanssa.
it
nl
sv
da
SERVICE Varo moottorin käydessä Asbesti
fn
Käyntihäiriöissä ja varaosakysymyksissä käänty- Huolto- tai korjaustyöt saa suorittaa ainoastaan Tässä moottorissa käytetyissä tii-
no
kää DEUTZ-edustajanne puoleen. Vauriotapauk- moottorin ollessa pysäytettynä. Mahdollisesti irro- visteissä ei ole asbestia.
sessa koulutettu henkilökunta huolehtii nopeasta ja
asianmukaisesta korjauksesta käyttämällä DEUTZ-
tetut suojalaitteet on asennettava töiden päätyttyä
jälleen paikoilleen. Huollettaessa käyvää moottoria
Huolto- ja korjaustöissä pyy-
dämme käyttämään vastaavia va-
el
osia. työvaatetus ei saa olla liian väljä. Moottori on py-
säytettävä tankkauksen ajaksi. Moottoria ei saa
raosia.
tr
koskaan käyttää suljetuissa tiloissa – myrkytys-
vaara. ru
ar
pl
3 fn © 2000
S1057
Moottorin kuvaus
de
en 1. Tyyppikilpi 2. Tyyppikilven paikka 3. Moottorinumero
fr
es
pt A B
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
Moottorimalli A, moottorinumero B ja tehoarvot on Tyyppikilpi C on kiinnitetty kampikammioon. Moottorinumero on stanssattu sekä kampikam-
no stanssattu tyyppikilpeen.
Varaosia tilattaessa on moottorimalli ja moottorinu-
mioon että tyyppikilpeen.
mero ilmoitettava tilauksen vastaanottajalle.

el
tr
ru
ar
pl
© 2000 4 fn
S1057
Varaosatilaus
de
Tilaustiedot en
Alkuperäisten DEUTZ-varaosien tilauksen
yhteydessä on ilmoitettava seuraavat tiedot:
Varaosatilaus fr
- moottori-nro Moottori-nro: es
- ident.-nro Jks.nro Kpl Ident.-nro Huomautus Rakenneryhmä pt
- kappalemäärä
it
Dokumentaation rakenne
- Tämän varaosaluettelon kuvat on ryhmitelty
nl
moottorin rakenneryhmien mukaan.
sv
- Rakenneryhmät käyvät selville moottorin
listasta.
da
- Identifioimis- eli tunnistusnumero 06/59
koostuu rakenneryhmästä (esim. 06) ja
osanumerosta (esim. 59).
Osanumero
fn
Symbooliselvitys
no
-06- Rakennerymänumero (esim. 06) el
000 Muutosnumero (esim. 000)
tr
96 Sivunumero (esim. 96)
Ristivittaus jatkosivulla
ru
94 (esim. 94)
ar
A Liitäntäsymbooli
- ilmenee aina vähintään parittain
(esim. A-A, B-B, C-C, j.n.e.)
pl
5 fn © 2000
S1057
Service
de
en Hyvä tietää, se on DEUTZ. Tilaus-nro: 0312 0806
fr DEUTZ on edustanut jo ammoisista ajoista saakka

uraauurtaavia uudistuksia moottorinrakennus-
alalla. Puolueettomana moottorinvalmistajana tarjo-
es amme ympäri maailmaa kokonaisen valikoiman
diesel- ja kaasumoottoreita, joiden suorituskyky
pt vaihtelee välillä 4 - 7.400 kW. Tuotteemme on
sovitettu täydellisesti asiakkaittemme vaatimusten
mukaan.
it Yli 1,4 miljoonaa DEUTZ-moottoria täyttää
ympäri maailmaa luotettavasti tehtävänsä.
nl Tarkoituksenamme on säilyttää moottoreidemme
käyttövalmius ja täten asiakkaittemme
sv tyytyväisyys. Tästä syystä olemme edustettuina
ympäri maailmaa asiantuntevien edustajien
muodostamalla verkolla, jonka tiheys vastaa
da moottoreidemme alueellista levinneisyyttä.
DEUTZ-nimi ei merkitse näin vain keksijähenkisiä

fn moottoreita. Vaan myös kokonaista moottoreihin
liittyvää suorituspakettia ja palvelua, johon voit Tilaus-nro: 0312 0807 (CD-ROM)
no luottaa.
Sales & Service -rekisteri antaa yleiskuvan lähelläsi

el olevista DEUTZ-edustajista, heidän edustamistaan
tuotteista ja palveluista. Ja vaikka yksilöllistä tuote- Voit tilata paikallisesta sopimushuoltoliikkeestä DEUTZ AG
edustusta ei olisikaan mainittu, DEUTZ-edustaja tai osoitteesta: Deutz-Mülheimer Str. 147-149
tr auttaa sinua eteenpäin asiantuntevalla neuvon-
nalla.
D-51057 Köln
ru Rekisteriä päivitetään jatkuvasti: tiedustele DEUTZ-

Puh.: 0049-221-822-0
Telefax: 0049-221-822-5304
edustajaltasi uusinta painosta. Telex: 8812-0 khd d
ar http://www.deutz.de
DEUTZ AG
pl
© 2000 6 fn
S1057
Reservedelsliste
2012
Forhandlerstempel
0312 0836
Motornummer:
Vennligst skriv op motornummeret her. Dette gjør

behandlingen av spørsmål angående service,
reparasjoner og reservedeler enklere.
Vi forbeholder oss tekniske foranderinger i våre

beskrivelser og opplysninger i denne instruksjons-
boka som er nødvendig for forbedring av motorene.
Ettertrykk og kopiering på enhver måte, også delvis,
må ikke gjøres uten vår skriftlige tillatelse.
1 no © 2000
© 2000
S1057
Allment
de
en Kjære kunde, Komponenter som er oppført på denne reser-
vedeslisten, er bare beregnet til reparasjon av
fr Væskekølte motorer av merket DEUTZ er utviklet
med tanke på mange forskjellige bruksområder.
DEUTZ motorer som tilhører de serier som er
angitt (forskriftsmessig bruk).
Et bredt spekter av varianter sikrer at mange Fagmessig innmontering av reservedeler er utførlig
es forskjellige spesielle krav kan oppfylles. beskrevet i instruksjonsboken (vedlikeholdsarbeid)
og verkstedshåndboken (reparasjonsarbeid).
pt Din motor er utstyrt for det aktuelle bruksområde.
Derfor vil ikke alle deler og komponenter som er
Produsenten påtar seg ikke ansvar for materielle
skader eller personskader som skyldes at de
oppført på denne reservedelslisten, være montert relevante anvisningene ikke har blitt fulgt.
it på din motor.
Selv om bildene ikke alltid viser alle detaljer, kan

nl de enkelte variantene tydelig skilles fra hverandre
slik at det er lett å finne frem til de relevante
sv reservedelene til din motor. Ved hjelp av
posisjonsnummer, komponentgruppenummer
og motornummer kan du i hvert enkelt tilfelle finne
da frem til riktig reservedel.
Vi ber deg vennligst følge våre anvisninger ved

fn bestilling av reservedeler slik at vi kan levere de
reservedelene du har bruk for, raskt og sikkert og
no ifølge de seneste endringer.
Vi står gjerne til din disposisjon hvis du har

el ytterligere spørsmål.
Vennlig hilsen
tr DEUTZ AG
ru
ar
pl
© 2000 2 no
S1057
Allment
de
DEUTZ-Dieselmotoren Originaldeler DEUTZ byttekomponenter en
fr
er resulotatet av mangeårig forskning og utvikling. er underkastet strenge kvalitetskrav på linje med DEUTZ byttekomponenter er et
Et omfattende know-how i forbindelse med høye
kvalitetskrav er garantien for fremstillingen av
DEUTZ motorer. Videreutvikling for å forbedre
våre motorer blir selvfølgelig fulgt opp med for-
billig alternativ til originaldeler.
Selvfølgelig gjelder også her de
es
motorer med lang levetid, stor pålitelighet og lavt
drivstofforbruk Det er en selvfølge at de store
bedringer på originaldeler. Bruk derfor bare ori-
ginaldeler som er fremstilt etter de nyeste erfarin-
høyeste kvalitetskrav på samme
måte som for nye deler. Når det pt
kravene når det gjelder miljøvern, blir oppfylt. ger for å være sikker på feilfri funksjon og høy gjelder funksjon og pålitelighet, er DEUTZ bytte-
pålitelighet. komponenter likeverdige med originaldeler „O“. it
nl
sv
da
SERVICE Vær forsiktig med motor i drift! Asbest
fn
Ta kontakt med en av våre ansvarlige service- Vedlikeholdsarbeid og reparasjoner skal bare Pakningene som benyttes i denne
no
representanter ved driftsforstyrrelser og spørsmål utføres med avslått motor. Vær sikker på at motoren motoren, er asbestfrie. Bruk reserve-
angående reservedeler. Vårt utdannete fagpersonal
sørger for rask og fagmessig reparasjon med
ikke kan starte uten oppsikt. Fare for ulykker!
Monter eventuelt fjernete beskyttelsesanordninger
deler uten asbest ved vedlike-
holds- og reparasjonsarbeid.
el
DEUTZ orignaldeler. på igjen etter avsluttet arbeid.
Tank bare med avslått motor. tr
Ta hensyn til arbeidsbeskyttelsesbestemmelsene
ved motordrift i lukkete rom eller ved arbeid under
jorda.
ru
ar
pl
3 no © 2000
S1057
Motorbeskrivekse
de
en 1. Firmaskilt 2. Firmaskiltets plassering 3. Motornummer
fr
es
A B
pt
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
Type A, motornummer B samt tytelsesdata er Firmaskiltet C er festet på veivhuset. Motornummer er stemplet inn både veivhuset og
no stemplet inn på firmaskiltet.
Type og motornummer må angis når reservedeler
på firmaskiltet.
bestilles.
el
tr
ru
ar
pl
© 2000 4 no
S1057
Reservedelsbestilling
de
Bestillingsangivelser en
Bestilling av
Ved bestilling av originale DEUTZ deler er følgende
angivelser nødvendig. reservedeler fr
- Motor-nr. Motor-nr.: es
- Ident-nr. Nr. Stuks Ident.nr. Opmerking Konstrukstionsgruppe pt
- Stykktall
it
Dokumentasjonsoversikt nl
- Illustrasjonene i denne reservedelslisten er
sortert etter motor-konstruksjonsgruppe. sv
- Delegruppen vises på motortegningen.
da
- Ident-nr. 06/59 består av konstruksjonsgruppe
(f.eks 06) og posisjon (f.eks 59)
Posisjon
fn
Symbolforklaring
no
-06- Delenummer (f.eks. 06) el
000 Endringnummer (f.eks. 000)
tr
96 Sidenummer (f.eks. 96)
Kryssreferanse på fortsettelsessiden.
ru
94 (f.eks. 94)
ar
A Koblingssymbol
- Føres alltid opp parvis
(f.eks. A-A, B-B, C-C osv.)
pl
5 no © 2000
S1057
Service
de
en Å vite at det er Deutz Bestillings-nr.: 0312 0806
fr Deutz har alltid stått for en banebrytende utvikling

av motorer. Som uavhengig motorprodusent tilbyr
vi verden over et komplett utvalg av diesel- og
es gassmotorer med en effekt på 4 til 7.400 kW. Våre
produkter er perfekt tilpasset våre kunders krav.
pt Verden over arbeider mer enn 1,4 millioner DEUTZ
motorer pålitelig. Vi vil sørge for å opprettholde
it motorenes driftsklarhet og dermed våre kunders
tilfredshet. Derfor er vi verden over representert
med et nett av kompetente partnere som er tilpasset
nl den regionale fordelingen av våre motorer.
sv DEUTZ er dermed ikke bare et navn for innfalsrike

motorer, men også for en komplett pakke med
ytelser for alt som har med motorer å gjøre og for
da en service du kan stole på.
Registeret Sales & Service gir deg en oversikt over

fn DEUTZ partnere i din nærhet, over deres produkt-
kompetanse og service-ytelser, Og selv om en Bestillings-nr.: 0312 0807 (CD-ROM)
no direkte produkt-kompetanse ikke er merket av,
hjelper DEUTZ-partneren deg med kompetente råd.
el Registeret blir permanent aktualisert; spør din

DEUTZ partner om nyeste versjon. Bestilles hos din lokale service-partner eller hos: DEUTZ AG
tr DEUTZ AG
D-51057 Köln
ru Telefon:
Telefax:
0049-221-822-0
0049-221-822-5304
Telex: 8812-0 khd d
pl
© 2000 6 no
S1057
∫·Ù¿ÏÔÁo˜ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ
2012
™ÊÚ·Á›‰· ÙÔ˘ ÂÌfiÚÔ˘
0312 0836
∞ÚÈıÌfi˜
ÎÈÓËÙ‹Ú·:
™ËÌÂÈÒÛÙÂ Û·˜ ·Ú·Î·ÏÔ‡ÌÂ Â‰Ò ÙÔÓ ·ÚÈıÌfi ÙÛ˘

ÎÈÓËÙ‹Ú· Û·˜. ªÂ ÙÔÓ ÙÚfiÔ ·˘Ùfi ‰ÈÂ˘ÎÔÏ‡ÓÂÙÂ ÙËÓ
ÂÍ¤ÏÈÍË ÙˆÓ ‰È·‰ÈÎ·ÛÈÒÓ ÂÍ˘ËÚ¤ÙËÛË˜ ÂÏ·ÙÂ›·˜,
ÂÈ‰ÈÔÚıÒÛÂˆÓ Î·È ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ.
¢È·ÙËÚÔ‡ÌÂ ÙÔ ‰ÈÎ·›ˆÌ·, Ó· ÚÔ‚·›ÓÔ˘ÌÂ ÛÂ ÙÂ¯ÓÈÎ¤˜

·ÏÏ·Á¤˜ Â› ÙˆÓ ·ÂÈÎÔÓ›ÛÂˆÓ Î·È ÂÓ‰Â›ÍÂˆÓ ÙÔ˘
Î·Ù·ÏfiÁÔ˘ ·˘ÙÔ‡ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ, ÂÊfiÛÔÓ ÔÈ ·ÏÏ·Á¤˜
·˘Ù¤˜ ·Ô‚Ï¤Ô˘Ó ÛÂ ‚ÂÏÙ›ˆÛË ÙˆÓ ÎÈÓËÙ‹ÚˆÓ.
∏ ·Ó·Ù‡ˆÛË Î·È Ë ·ÓÙÈÁÚ·Ê‹ Î¿ıÂ Â›‰Ô˘˜, ¤ÛÙˆ
Î·È Î·Ù¿ Ì¤Úo˜, Ùo˘ Î·Ù·ÏfiÁo˘ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ
ÂÈÙÚ¤oÓÙ·È ÌfiÓo ÌÂÙ¿ ·fi ¤ÁÁÚ·ÊË ¤ÁÎÚÈÛ‹ Ì·˜.
1 el © 2000
© 2000
S1057
∂ÈÛ·ÁˆÁÈÎ¤˜ ·Ú·ÙËÚ‹ÛÂÈ˜
de
en ∞ÍÈfiÙÈÌÂ ÂÏ¿ÙË, ¶ÚÔÛ¤ÍÙÂ Û·˜ ·Ú·Î·ÏÔ‡ÌÂ Î·Ù¿ ÙËÓ T· ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ÓÔ ·Ó·Ê¤ÚÔÓÙ·È ÔÙÔÓ
·Ú·ÁÁÂÏ›· ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ ÙÈ˜ Ô‰ËÁ›Â˜ Ì·˜, ·ÚfiÓÙ· Î·Ù¿ÏÔÁÔ Ú¤ÂÈ Ó· ¯ÚËÔÈÌÔÔÈÔ‡ÓÙ·È
fr ÔÈ ˘ÁÚfi„˘ÎÙÔÈ ÎÈÓËÙ‹ÚÂ˜ DEUTZ ÂÍÂÏ›¯ıËÛ·Ó
ÙÂ¯ÓÈÎ¿ ÁÈ· ÂÊ·ÚÌÔÁ‹ ÛÂ ¤Ó·Ó Â˘Ú‡ ÙÔÌ¤·
Ô˘ ¤¯Ô˘Ó Û¯¤ÛË ÌÂ ÙÈ˜ ·Ú·ÁÁÂÏ›Â˜ ·˘Ù¤˜,
ÚÔ˜ ÙÔ ÛÎÔfi fiˆ˜ Â›Ì·ÛÙÂ ÛÂ ı¤ÛË Ó·
ÌfiÓÔ ÁÈ· ÙËÓ ÂÈÔÎÂ˘‹ ÙˆÓ ÎÈÓËÙ‹ÚˆÓ ˚fi‘ÒÒ ÙË˜
ÛÂÈÚ¿˜ ÌÔÓÙ¤ÏˆÓ ÔÙËÓ ÔÔãÈ ·Ó·Ê¤ÚÔÓÙ·È
ÂÊ·ÚÌÔÁÒÓ. ∫·Ù¿ ÙËÓ ÚÔÛ¿ıÂÈ¿ Ì·˜ ·˘Ù‹ Û·˜ Î¿ÓÔ˘ÌÂ Û‡ÓÙÔÌË Î·È ÂÌÈÛÙÂ˘ÙÈÎ‹ (¯Ú‹ÔË Û‡ÊˆÓ· ÌÂ ÙÔÓ ÚÔÔÚÈÔÌfi ÙÔ˘˜).
es ÂÍ·ÛÊ·Ï›ÛÙËÎÂ Ì¤Ûˆ Ì›·˜ ÔÏ˘ÏËıÔ‡˜
ÚÔÛÊÔÚ¿˜ Î·Ù·ÛÎÂ˘·ÛÙÈÎÒÓ ·Ú·ÏÏ·ÁÒÓ,
·Ú¿‰ÔÛË ÙˆÓ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ, Ô˘ ¯ÚÂÈ¿˙ÂÛÙÂ,
ÛÙËÓ Î·Ù·ÛÎÂ˘·ÛÙÈÎ‹ ·Ú·ÏÏ·Á‹, Ë ÔÔ›·
TÔ ·ˆÔÙfi ÌÔÓÙ¿ÚÈÛÌ· ÙˆÓ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ
·˘ÙÒÓ ÂÚÈÁÚ¿ÊÂÙ·È ÂÈÔÙ·Ì¤Ó· ÔÙÈ˜ √‰ËÁãÈÂ˜
pt ÒÛÙÂ Ó· ÂÎÁËÚÒÓÔÓÙ·È fiÏÂ˜ ÔÈ ÂÈ‰ÈÎ¤˜
··ÈÙ‹ÛÂÈ˜ ÙˆÓ ÂÏ·ÙÒÓ Ì·˜.
·ÓÙ·ÔÎÚ›ÓÂÙ·È ÂÎ¿ÛÙÔÙÂ ÛÙËÓ ÙÂÏÂ˘Ù·›·
ÛÙ¿ıÌË ÌÂÙ·ÙÚÔÒÓ.
§ÂÈÙÔ˘ÚÁãÈ·˜ (ÎÂÊ¿Ï·È: ∂ÚÁ·ÔãÈÂ˜ ·˘ÓÙ‹ÚËÔË˜)
Î·È ÔÙÔ ÂÁ¯ÂÈÚãÈ‰ÈÔ Û¤Ú‚È˜ ÂÈÔÎÂ˘ÒÓ (ÎÂÊ¿Ï·È:
∂ÚÁ·ÔãÈÂ˜ ÂÙÈÔÎÂ˘Ë˜). √ Î·Ù·ÛÎÂ˘·ÔÙ‹˜
it √ ÎÈÓËÙ‹Ú·˜ Û·˜ ·˘Ùfi˜ Â›Ó·È ÂÊÔ‰È·ÛÌ¤ÓÔ˜
ÁÈ· ÂÊ·ÚÌÔÁ‹ ÙÔ˘ ÛÂ Ì›· ÂÈ‰ÈÎ‹ ÂÚ›ÙˆÛË,
µÚÈÛÎfiÌ·ÛÙÂ ¿ÓÙÔÙÂ ÛÙË ‰È¿ıÂÛ‹ Û·˜, ·Ó
¤¯ÂÙÂ ÂÚˆÙ‹Ì·Ù·, ÚÔÛÊ¤ÚÔÓÙ¿˜ Û·˜ Î·È ÙÈ˜
‰ÂÓ ¤¯ÂÈ Â˘ı‡ÓÂ˜ ÁÈ· ˙ËÌãÈÂ˜ ÛÂ ˘ÏÈÎfi Î·È
·Ù˘¯‹Ì·Ù· ÚÔÔˆÈÎÔ‡ ‹ ·Ó·ÏˆÙÒ/¯ÚËÔÙÒÓ,
Î·È ·˘Ùfi ÛËÌ·›ÓÂÈ fiÙÈ Ù· ÛÙÔÈ¯Â›· ÌË¯·ÓÒÓ, ·Ó·ÁÎ·›Â˜ Û˘Ì‚Ô˘ÏÂ˘ÙÈÎ¤˜ ˘ËÚÂÛ›Â˜. Ô˘ ÚÔ¤Ú¯ÔÓÙ·È ·fi ÙËÓ ÌË Ô˘ÌÌfiÚÊˆÔË ÚÔ˜
nl Ù· ÔÔ›· ÂÚÈÏ·Ì‚¿ÓÔÓÙ·È ÛÙÔÓ Î·Ù¿ÏÔÁÔ ·˘Ùfi
·ÓÙ·ÏÏ·ÎÙÈÎÒÓ, Î·È Ù· ˘fiÏÔÈ· Û˘ÛÙ·ÙÈÎ¿ ∏ ÂÙ·ÈÚÂ›· Û·˜
ÙÈ˜ ·Ó¿ÏÔÁÂ˜ Ô‰Ë ÁãÈÂ˜.
sv ÌË¯·ÓÈÎ¿ ÛÙÛÈ¯Â›· ‰ÂÓ Â›Ó·È ÂÍ ÔÏÔÎÏ‹ÚÔ˘

ÂÊ·ÚÌÔÛÌ¤Ó· Î·È ÛÙÔÓ ÎÈÓËÙ‹Ú· Û·˜.
DEUTZ AG
da ∞Ó Î·È ÔÈ ÁÚ·ÊÈÎ¤˜ ·Ú·ÛÙ¿ÛÂÈ˜ ‰ÂÓ Â›Ó·È

‰È·ÌÔÚÊˆÌ¤ÓÂ˜ ÌÂ fiÏÂ˜ ÙÈ˜ ÏÂÙÔÌ¤ÚÂÈÂ˜,
ÌÔÚÂ› ÂÓÙÔ‡ÙÔÈ˜ Ó· ÚÔÎ‡„ÂÈ ‰È·¯ˆÚÈÛÌfi˜
fn ÌÂÙ·Í‡ ÙˆÓ ÌÂÌÔÓˆÌ¤ÓˆÓ Î·Ù·ÛÎÂ˘·ÛÙÈÎÒÓ
·Ú·ÏÏ·ÁÒÓ Î·Ù¿ Û·Ê‹ ÙÚfiÔ, Ô‡Ùˆ˜ ÒÛÙÂ Ó·
no ÌÔÚÂ›ÙÂ Ó· ‚ÚÂ›ÙÂ ÌÂ Â˘ÎÔÏ›· Ù· ·ÓÙ·ÏÏ·ÎÙÈÎ¿
ÂÎÂ›Ó·, Ù· ÔÔ›· ·ÊÔÚÔ‡Ó ÙÔÓ ÎÈÓËÙ‹Ú· Û·˜.
ª¤Ûˆ ÙÔ˘ ·ÚÈıÌÔ‡ ı¤ÛË˜, oÌ¿‰·˜ ÂÍ·ÚÙËÌ¿ÙˆÓ
el Î·È ÎÈÓËÙ‹Ú· ÌÔÚÂ› Ó· ‰È·ÈÛÙˆıÂ› ÛÂ Î¿ıÂ
ÍÂ¯ˆÚÈÛÙ‹ ÂÚ›ÙôË ÙÔ ÛˆÛÙfi ·ÓÙ·ÏÏ·ÎÙÈÎfi.
tr
ru
ar
pl
© 2000 2 el
S1057
∂ÈÛ·ÁˆÁÈÎ¤˜ ·Ú·ÙËÚ‹ÛÂÈ˜
de
√È ÓÙÈ˙Â ÏÔÎÈÓËÙ‹ÚÂ˜ DEUTZ ∆· ÁÓ‹ÛÈ· ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ∞ÓÙ·ÏÏ·ÎÙÈÎ¿ ÂÍ·ÚÙ‹Ì·Ù· ÙË˜ DEUTZ en
fr
·ÔÙÂÏÔ‡Ó ÚÔ›fiÓ Ì·ÎÚÔ¯ÚfiÓÈ·˜ ÂÈÛÙËÌÔÓÈÎ‹˜ YfiÎÂÈÓÙ·È ÛÙÈ˜ ›‰ÈÂ˜ ·˘ÛÙËÚ¤˜ ··ÈÙ‹ÛÂÈ˜ ÔÈfiÙËÙ·˜ ∆· ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ÂÍ·ÚÙ‹Ì·Ù· ÙË˜
¤ÚÂ˘Ó·˜ Î·È ÙÂ¯ÓÈÎ‹˜ ÂÍ¤ÏÈÍË˜. ∏ ·ÔÎÙËıÂ›Û·
ÙÂ¯ÓÔ‰ÔÛ›·, Ô˘ ÚÔ¤Î˘„Â ·fi ÙÈ˜ ÂÚÁ·Û›Â˜ Ì·˜
Deutz. ∏ ÂÚ·ÈÙ¤Úˆ ÂÍ¤ÏÈÍË ÁÈ· ÙË ‚ÂÏÙ›ˆÛË ÙˆÓ
ÎÈÓËÙ‹ÚˆÓ ‰ÈÂÍ¿ÁÂÙ·È ‚Â‚·›ˆ˜ Î·È ÛÙ· ÁÓ‹ÛÈ·
DEUTZ ·ÔÙÂÏÔ‡Ó ÌÈ· ÔÈÎÔÓÔÌÈÎ¿
Û˘ÌÊ¤ÚÔ˘Û· ÂÓ·ÏÏ·ÎÙÈÎ‹ Ï‡ÛË ¤Ó·ÓÙÈ
es
·˘Ù¤˜, ·ÔÙÂÏÂ› ÛÂ Û˘Ó‰˘·ÛÌfi ÌÂ ˘„ËÏ¤˜
ÔÈÔÙÈÎ¤˜ ··ÈÙ‹ÛÂÈ˜ ÙËÓ ÂÁÁ‡ËÛË ÁÈ· ÙËÓ Î·Ù·ÛÎÂ˘‹
·ÓÙ·ÏÏ·ÎÙÈÎ¿. ªfiÓÔ Ë ¯Ú‹ÛË ÙˆÓ ÁÓ‹ÛÈˆÓ
·ÓÙ·ÏÏ·ÎÙÈÎÒÓ, Ô˘ ¤¯Ô˘Ó Î·Ù·ÛÎÂ˘·ÛÙÂ› Û‡ÌÊˆÓ·
ÛÙ· ÁÓ‹ÛÈ· ·ÓÙ·ÏÏ·ÎÙÈÎ¿. º˘ÛÈÎ¿
ÈÛ¯‡Ô˘Ó Î·È Â‰Ò Ù· ˘„ËÏfiÙÂÚ· pt
ÎÈÓËÙ‹ÚˆÓ ÌÂ Ì·ÎÚÔ¯ÚfiÓÈ· ˙ˆ‹, ÌÂÁ¿ÏË ÌÂ ÙÔ ÙÂÏÂ˘Ù·›Ô Â›Â‰Ô ÙË˜ ÙÂ¯ÓÔÏÔÁ›·˜, ·Ú¤¯ÂÈ ÛÙ¿ÓÙ·Ú ÔÈfiÙËÙ·˜ fiˆ˜ Î·È ÁÈ· Ù· Î·ÈÓÔ‡ÚÁÈ·
ÂÌÈÛÙÂ˘ÙÈÎfiÙËÙ· Î·È ÌÈÎÚ‹ Î·Ù·Ó¿ÏˆÛË Î·˘Û›ÌˆÓ.
∂›Ó·È ·˘ÙÔÓfiËÙÔ, fiÙÈ ÂÎÏËÚÔ‡ÓÙ·È ÛÙÔ˘˜ ÎÈÓËÙ‹ÚÂ˜
ÂÁÁ‡ËÛË ÁÈ· ·ÚfiÛÎÔÙË ÏÂÈÙÔ˘ÚÁ›· Î·È ˘„ËÏ‹
·ÍÈÔÈÛÙ›·.
ÂÍ·ÚÙ‹Ì·Ù·. ∆· ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ÂÍ·ÚÙ‹Ì·Ù· ÙË˜
DEUTZ Â›Ó·È ÈÛ¿ÍÈ· ÌÂ Ù· ÁÓ‹ÛÈ· ·ÓÙ·ÏÏ·ÎÙÈÎ¿
it
Ì·˜ Î·È ÔÈ ˘„ËÏ¤˜ ··ÈÙ‹ÛÂÈ˜ ÚÔÛÙ·Û›·˜ ÙÔ˘ fiÛÔÓ ·ÊÔÚ¿ ÙË ÏÂÈÙÔ˘ÚÁ›· Î·È ÙËÓ ·ÍÈÔÈÛÙ›· ÙÔ˘˜.
ÂÚÈ‚¿ÏÏÔÓÙÔ˜. nl
sv
™∂ƒµπ™ ¶ÚÔÛÔ¯‹ Î·Ù¿ ÙË ‰È¿ÚÎÂÈ· ÙË˜
ÏÂÈÙÔ˘ÚÁ›·˜ ÙÔ˘ ÎÈÓËÙ‹Ú·
∞Ì›·ÓÙÔ˜ da
∞ÔÙ·ÓıÂ›ÙÂ ÛÂ ÂÚ›ÙˆÛË ÏÂÈÙÔ˘ÚÁÈÎÒÓ ‚Ï·‚ÒÓ √È ÂÚÁ·Û›Â˜ Û˘ÓÙ‹ÚËÛË˜ ‹ ÂÈÛÎÂ˘‹˜ ÂÈÙÚ¤ÂÙ·È Ó· ∆· ÛÙÂÁ·ÓˆÎ¿ ÂÍ·ÚÙ‹Ì·Ù·, Ù·
fn
Î·È ÛÂ ÂÚ›ÙˆÛË Ô˘ ¯ÚÂÈ¿˙ÂÛÙÂ ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ÛÙÈ˜
·ÚÌfi‰ÈÂ˜ ·ÓÙÈÚÔÛˆÂ›Â˜ Ì·˜, Ô˘ ‰È·ı¤ÙÔ˘Ó
‰ÈÂÓÂÚÁÔ‡ÓÙ·È ÌfiÓÔ ÂÊfiÛÔÓ Ô ÎÈÓËÙ‹Ú·˜ ¤¯ÂÈ ÙÂıÂ›
ÂÎÙfi˜ ÏÂÈÙÔ˘ÚÁ›·˜. ™Â ÂÚ›ÙˆÛË, Î·Ù¿ ÙËÓ ÔÔ›·
ÔÔ›· ÂÊ·ÚÌfi˙ÔÓÙ·ÈÛ ·˘ÙfiÓ ÙÔÓ
ÎÈÓËÙ‹Ú·, ‰ÂÓ ÂÚÈ¤¯Ô˘Ó ·Ì›·ÓÙÔ. ™Â no
˘ËÚÂÛ›Â˜ Û¤Ú‚È˜ ÂÏ·ÙÂ›·˜. ∆Ô ÂÍÂÈ‰ÈÎÂ˘Ì¤ÓÔ Ì·˜ Î·Ù¤ÛÙË ·Ó·ÁÎ·›Ô Ó· ·ÔÌ·ÎÚ‡ÓÂÙÂ ·fi ÙÔÓ ÎÈÓËÙ‹Ú· ÂÚÈÙÒÛÂÈ˜ ÂÚÁ·ÛÈÒÓ Û˘ÓÙ‹ÚËÛË˜
ÚÔÛˆÈÎfi ÊÚÔÓÙ›˙ÂÈ ÛÂ Î¿ıÂ ÂÚ›ÙˆÛË ‚Ï·‚ÒÓ
ÁÈ· Ì›· Û‡ÓÙÔÌË Î·È ÂÍÂÈ‰ÈÎÂ˘Ì¤ÓË ÂÈ‰ÈfiÚıˆÛË
Û·˜ ÔÚÈÛÌ¤ÓÂ˜ ÚÔÛÙ·ÙÂ˘ÙÈÎ¤˜ Û˘ÛÎÂ˘¤˜ Î·Ù¿
ÙË ‰È¿ÚÎÂÈ· ÂÚÁ·ÛÈÒÓ ÂÈ‰ÈfiÚıˆÛË˜, Ú¤ÂÈ Ó·
Î·È ÂÈ‰ÈfiÚıˆÛË˜ ÂÊ·ÚÌfi˙ÂÙÂ, Û·˜
·Ú·Î·ÏÔ‡ÌÂ ·Ó¿ÏÔÁ· ·ÓÙ·ÏÏ·ÎÙÈÎ¿.
el
ÌÂ ¯ÚËÛÈÌÔÔ›ËÛË ÁÓËÛ›ˆÓ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ ÙÔ˘ ÊÚÔÓÙ›ÛÂÙÂ ÒÛÙÂ Ó· Í·Ó·ÂÊ·ÚÌÔÛÙÔ‡Ó ÔÈ Û˘ÛÎÂ˘¤˜
ÂÚÁÔÛÙ·Û›Ô˘ Ì·˜. ·˘Ù¤˜ ÌÂÙ¿ ÙÔ Ù¤ÏÔ˜ ÙË˜ ÂÈ‰ÈfiÚıˆÛË˜. ∫·Ù¿ ÙË
‰È¿ÚÎÂÈ· ÂÚÁ·ÛÈÒÓ ÛÂ ÎÈÓËÙ‹Ú·, Ô˘ ‚Ú›ÛÎÂÙ·È
tr
ÛÂ ÏÂÈÙÔ˘ÚÁ›·, Ú¤ÂÈ Ó· ÊÔÚ¿ÙÂ ÛÙÂÓ¿ ÂÚÁ·ÙÈÎ¿
ÚÔ‡¯·. ¶ÚÔ‚·›ÓÂÙÂ ÛÂ Á¤ÌÈÛÌ· ÙÔ˘ ÚÂ˙ÂÚ‚Ô˘¿Ú ÙÔ˘ ru
ÎÈÓËÙ‹Ú· ÌÂ Î·‡ÛÈÌ· ÌfiÓÔ ·ÊÔ‡ ÚÔËÁÔ˘Ì¤Óˆ˜ ¤¯ÂÙÂ
ı¤ÛÂÈ ÙÔÓ ÎÈÓËÙ‹Ú· ÂÎÙfi˜ ÏÂÈÙo˘ÚÁ›·˜. ªËÓ ·Ê‹ÓÂÙÂ
oÙ¤ Ó· ÏÂÈÙÔ˘ÚÁÂ› Ô ÎÈÓËÙ‹Ú·˜ Ì¤Û· ÛÂ ÎÏÂÈÛÙÔ‡˜
ar
¯ÒÚÔ˘˜, ÁÈ·Ù› ˘¿Ú¯ÂÈ Î›Ó‰˘ÓÔ˜ ‰ËÏËÙËÚ›·ÛË˜.
pl
3 el © 2000
S1057
¶ÂÚÈÁÚ·Ê‹ ÙÔ˘ ÎÈÓËÙ‹Ú·
de
en 1. ¶ÈÓ·Î›‰· ÙÔ˘ ÂÚÁÔÛÙ·Û›Ô˘ 2. £¤ÛË ÙË˜ ÈÓ·Î›‰·˜ ÙÔ˘ 3. ∞ÚÈıÌfi˜ ÙÔ˘ ÎÈÓËÙ‹Ú·
fr Î·Ù·ÛÎÂ˘‹˜ ÂÚÁÔÛÙ·Û›Ô˘ Î·Ù·ÛÎÂ˘‹˜
es
pt A B
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
∏ Î·Ù·ÛÎÂ˘·ÛÙÈÎ‹ ·Ú·ÏÏ·Á‹ ∞, Ô ·ÚÈıÌfi˜ ÙÔ˘ ∏ ÈÓ·Î›‰· ÙÔ˘ ÂÚÁÔÛÙ·Û›Ô˘ Î·Ù·ÛÎÂ˘‹˜ C √ ·ÚÈıÌfi˜ ÙÔ˘ ÎÈÓËÙ‹ÚÔ˜ Â›Ó·È ÛÊÚ·ÁÈÛÌ¤Óo˜
no ÎÈÓËÙ‹Ú· µ Î·ıÒ˜ Â›ÛË˜ Î·È Ù· ÙÂ¯ÓÈÎ¿ ÛÙÔÈ¯Â›·
ÈÛ¯‡Ô˜ ÙÔ˘ ÎÈÓËÙ‹Ú· ¤¯Ô˘Ó ÛÊÚ·ÁÈÛÙÂ› Â¿Óˆ
‚Ú›ÛÎÂÙ·È ÛÙÂÚÂˆÌ¤ÓË Â¿Óˆ ÛÙÔ Î›‚ÒÙÈÔ ÙÔ˘
ÛÙÚÔÊ¿ÏÔ˘.
Â¿Óˆ ÛÙÔ Î›‚ÒÙÈÔ ÙÔ˘ ÛÙÚÔÊ¿ÏÔ˘ Î·ıÒ˜ Â›ÔË˜
Î·È Â¿Óˆ oÙËÓ ÈÓ·Î›‰· ÙÔ˘ Î·Ù·ÛÎÂ˘Ë˜.
ÛÙËÓ ÈÓ·Î›‰· ÙÔ˘ ÂÚÁÔÛÙ·Û›Ô˘ Î·Ù·ÛÎÂ˘‹˜.
el ∫·Ù¿ ÙËÓ ·Ú·ÁÁÂÏ›· ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ Ú¤ÂÈ
Ó· Á›ÓÂÙ·È ·Ó·ÊÔÚ¿ ÙË˜ Î·Ù·ÛÎÂ˘·ÛÙÈÎ‹˜
tr ·Ú·ÏÏ·Á‹˜ Î·È ÙÔ˘ ·ÚÈıÌÔ‡ ÙÔ˘ ÎÈÓËÙ‹Ú·.
ru
ar
pl
© 2000 4 el
S1057
¶·Ú·ÁÁÂÏ›· ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ
de
™ÙÔÈ¯Â›· ·Ú·ÁÁÂÏ›·˜ en
¶·Ú·ÁÁÂÏ›·
∫·Ù¿ ÙËÓ ·Ú·ÁÁÂÏ›· ÙˆÓ ÁÓ‹ÛÈˆÓ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ
DEUTZ ¯ÚÂÈ¿˙ÔÓÙ·È Ù· ·ÎfiÏÔ˘ı· ÛÙÔÈ¯Â›·: ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ fr
- ∞Ú. ∫ÈÓËÙ‹Ú· ∞Ú. ∫ÈÓËÙ‹Ú· : es
- ∞Ú. ∞Ó·ÁÓÒÚÈÛË˜ TÂÌ ¶ÔÛÔÙ. ∞Ú. ∞v·Áv. ¶·Ú·ÙËÚ. ™˘ÁÎÚfiÙÌ· ∫ÈÓËÙ‹Ú· pt
- ∞Ú. ∆ÂÌ·¯›ˆÓ
it
¢È¿Ù·ÍË ÙÂÎÌËÚ›ˆÛË˜
- √È ›Ó·ÎÂ˜ ÌÂ ÂÈÎfiÓÂ˜ ·˘ÙÔ‡ ÙÔ˘ Î·Ù·ÏfiÁÔ˘
nl
·ÓÙ·ÏÏ·ÎÙÈÎÒÓ Â›Ó·È Ù·ÍÈÓÔÌËÌ¤ÓÔÈ Û‡ÌÊˆÓ·
ÌÂ Ù· Û˘ÁÎÚÔÙ‹Ì·Ù· ÎÈÓËÙ‹ÚˆÓ. sv
- ™Â Î¿ıÂ Ì¤ÚÔ˜ ˘¿Ú¯ÂÈ
Û˘ÁÎÚÔÙ‹Ì·ÙÔ˜ ÎÈÓËÙ‹Ú·
Ì›· ÂÚ›ÏË
da
- √ ·Ú. ∞Ó·ÁÓÒÚÈÛË˜ 06/59 ·ÔÙÂÏÂ›Ù·È ·fi
Û˘ÁÎÚfiÙËÌ· (.¯. 06) Î·È ı¤ÛË (.¯. 59)
∞Ú. ∆ÂÌ·¯›Ô˘
fn
no
-06- el
000
96
tr
94 ru
A
ar
pl
5 el © 2000
S1057
™∂ƒµπ™
de
en ¶Ú¤ÂÈ Ó· ÁÓˆÚ›˙ÂÙÂ, Â›Ó·È DEUTZ AÚ. ¶·Ú·ÁÁÂÏ›·˜: 0312 0806
fr ∂‰Ò Î·È ¯ÚfiÓÈ· ÙÔ fiÓÔÌ· DEUTZ Â›Ó·È Û˘ÓÒÓ˘ÌÔ ÙˆÓ

ÚÈ˙ÔÛ·ÛÙÈÎÒÓ ÂÍÂÏ›ÍÂˆÓ ÛÙËÓ Î·Ù·ÛÎÂ˘‹ ÎÈÓËÙ‹ÚˆÓ.
ø˜ ·ÓÂÍ¿ÚÙËÙÔ˜ Î·Ù·ÛÎÂ˘·ÛÙ‹˜ ÎÈÓËÙ‹ÚˆÓ
es ÚÔÛÊ¤ÚÔ˘ÌÂ ·ÁÎÔÛÌ›ˆ˜ Ì›· Ï‹ÚË ÁÎ¿Ì·
ÂÙÚÂÏ·ÈÔÎÈÓËÙ‹ÚˆÓ Î·È ÎÈÓËÙ‹ÚˆÓ ÌÂ ·¤ÚÈÔ ÛÙËÓ
pt ÂÚÈÔ¯‹ ÈÛ¯‡Ô˜ ·fi 4 ¤ˆ˜ Î·È 7400kW. ∆· ÚÔ˚fiÓÙ·
Ì·˜ Â›Ó·È Ù¤ÏÂÈ· ÚÔÛ·ÚÌÔÛÌ¤Ó· ÛÙÈ˜ ··ÈÙ‹ÛÂÈ˜ ÙˆÓ
ÂÏ·ÙÒÓ Ì·˜.
it ¶·ÁÎÔÛÌ›ˆ˜, ÂÚÈÛÛfiÙÂÚÔÈ ·fi 1,4 ÂÎ·ÙÔÌÌ‡ÚÈ·
ÎÈÓËÙ‹ÚÂ˜ DEUTZ ÂÎÙÂÏÔ‡Ó ·ÍÈfiÈÛÙ· ÙÈ˜ ˘ËÚÂÛ›Â˜
nl ÙÔ˘˜. £· ı¤Ï·ÌÂ Ó· ‰È·ÙËÚ‹ÛÔ˘ÌÂ ÙËÓ ÂÙÔÈÌfiÙËÙ·
¯Ú‹ÛË˜ ÙˆÓ ÎÈÓËÙ‹ÚˆÓ Ì·˜ Î·È ÙËÓ ÈÎ·ÓÔÔ›ËÛË ÙˆÓ
sv ÂÏ·ÙÒÓ Ì·˜. °È· ·˘Ùfi ÙÔ ÏfiÁÔ ÂÎÚÔÛˆÔ‡Ì·ÛÙÂ
·ÁÎÔÛÌ›ˆ˜ ÌÂ ¤Ó· ‰›ÎÙ˘Ô Î·Ù¿ÏÏËÏˆÓ Û˘ÓÂÚÁ·ÙÒÓ, Ë
˘ÎÓfiÙËÙ· ÙˆÓ ÔÔ›ˆÓ ·ÓÙÈÛÙÔÈ¯Â› ÛÙËÓ ÂÚÈÊÂÚÂÈ·Î‹
da Î·Ù·ÓÔÌ‹ ÙˆÓ ÎÈÓËÙ‹ÚˆÓ Ì·˜.
ŒÙÛÈ Ë DEUTZ ‰ÂÓ Â›Ó·È ÌfiÓÔ ÙÔ fiÓÔÌ· ÁÈ· ÎÈÓËÙ‹ÚÂ˜ ÌÂ

fn ÓÂ‡Ì· ·Ó·Î¿Ï˘„Ë˜, ·ÏÏ¿ Î·È ÁÈ· ¤Ó· ÔÏÔÎÏËÚˆÌ¤ÓÔ
·Î¤ÙÔ ·ÚÔ¯ÒÓ Á‡Úˆ ·fi ÙÔÓ ÎÈÓËÙ‹Ú· Î·È ¤Ó· AÚ. ¶·Ú·ÁÁÂÏ›·˜: (CD-ROM) 0312 0807
no Û¤Ú‚È˜, ÙÔ ÔÔ›Ô ÌÔÚÂ›ÙÂ Ó· ÂÌÈÛÙÂ˘fiÛ·ÛÙÂ.
√ Î·Ù¿ÏÔÁÔ˜ Sales & Service Û·˜ ÚÔÛÊ¤ÚÂÈ Ì›·

el Û˘ÓÔÙÈÎ‹ ÂÈÎfiÓ· ÁÈ· ÙÔ˘˜ Û˘ÓÂÚÁ¿ÙÂ˜ ÙË˜ DEUTZ
ÛÙËÓ ÂÚÈÔ¯‹ Û·˜, ÁÈ· Ù· ÚÔ˚fiÓÙ· Ô˘ Â›Ó·È ·ÚÌfi‰ÈÔÈ ¶ÚÔÌËıÂ‡ÂÙ·È Ì¤Ûˆ ÙÔ˘ ·ÚÌfi‰ÈÔ˘ Û˘ÓÂÚÁ¿ÙË Service DEUTZ AG
Î·È ÁÈ· ÙÈ˜ ˘ËÚÂÛ›Â˜ Û¤Ú‚È˜. ∞ÏÏ¿ ·ÎfiÌË ÎÈ fiÙ·Ó ‰ÂÓ ÙË˜ ÂÚÈÔ¯‹˜ ‹ ·fi: Deutz-Mülheimer Str. 147-149
tr ÛËÌÂÈÒÓÂÙ·È Î¿ÔÈ· ¿ÌÂÛË ·ÚÌÔ‰ÈfiÙËÙ· ÚÔ˚fiÓÙÔ˜, Ô
Û˘ÓÂÚÁ¿ÙË˜ ÙË˜ DEUTZ ı· Û·˜ ‚ÔËı‹ÛÂÈ ÌÂ
D-51057 Köln
ru Î·Ù¿ÏÏËÏÂ˜ Û˘Ì‚Ô˘Ï¤˜. TËÏ¤ÊˆÓÔ: 0049-221-822-0

º·Í: 0049-221-822-5304
√ Î·Ù¿ÏÔÁÔ˜ ·Ó·ÓÂÒÓÂÙ·È ÛÂ ÌfiÓÈÌË ‚¿ÛË. ƒˆÙ‹ÛÙÂ ÙÔ T¤ÏÂÍ: 8812-0 khd d
ar ‰ÈÎfi Û·˜ Û˘ÓÂÚÁ¿ÙË ÙË˜ DEUTZ ÁÈ· ÙË Ó¤· ¤Î‰ÔÛË. http://www.deutz.de
∏ ‰ÈÎ‹ Û·˜ DEUTZ AG

pl
© 2000 6 el
S1057
Yedek parça listesi
2012
0312 0836
Motor numarası:
Lütfen buraya motor numarası nı yazın. Böylece

müşteri hizmetleri, tamir ve yedek parça ile ilgili
konularda kolaylık sağlanır.
Yedek parça listesinde gösterilen şekiller ve teknik

bilgilerin, motorlarda yapılacak geliştirmeler
nedeniyle değiştirilmesi hakkı saklıdır. Firmamızın
yazılı izni olmaksızın, kısmen de olsa her türlü
çoğaltma ve kopyalama yasaktır.
1 tr © 2000
© 2000
S1057
Önsöz
de
en Sayın müşterimiz, Yedek parça listesinde belirtilmiş olan parçalar,
yalnızca ilgili Deutz motorlarının yapı grubu için
fr DEUTZ Marka hava/su soğutmalı motorlar geniş
geçerlidir ve yalnızca bu tip motorların tamirinde
kullanılacaktır (kullanım amacına uygun kullanım).
kullanım alanları için geliştirilmiştir. Sunulan geniş Yedek parçaların talimatlara göre doğru şekilde
es model ve tip çeşitleri ile her türlü kullanım alanının
gerektirdiği özel şartlar yerine getirilebilmektedir.
tmonte edilmesini gösteren bilgiler, kullanım kılavuzu
(bakım çalışmaları) ve atölye el kitabında (tamir
pt Sahip olduğunuz motor bağlı olduğu kullanım amacı
çalışmaları) ayrıntılı olarak açıklanmıştır. Talimatlara
aykırı yapılan çalışmalardan doğacak hasar ve
ile donatılmış olduğundan, yedek parça listesinde yaralanmalardan imalatçı firma sorumlu değildir.
it gösterilmiş olan tüm eleman ve parçalar motorunuzda
bulunmaz.
nl Gösterilmiş olan grafikler tüm detayları kapsamasa

da, motorunuz tipi için geçerli olan yedek parça
sv kolayca tespit edilebilir. Pozisyon, yapı grubu ve
motor numarası üzerinden her halukarda, motorunuz
ile ilgili doğru yedek parça tespit edilebilir.
da Yedek parça siparişinde, ihtiyacınız olan yedek
parçayı en kısa zamanda, güvenilir ve son değişiklik
fn tipinde sevk edebilmemiz için sipariş bilgilerine dikkat
ediniz.
no Sormak istediğiniz sorular olduğunda bize her zaman
başvurabilirsiniz.
el
DEUTZ AG
tr
ru
ar
pl
© 2000 2 tr
S1057
Önsöz
de
DEUTZ Dizel motorları Orijinal DEUTZ Yedek Parça DEUTZ Değiştirme komponentleri en
fr
DEUTZT Marka dizel motorları, uzun yıllardır yapılan Orijinal yedek parçalar aynı DEUTZ motorlarında DEUTZ Değiştirme komponentleri
araştırma ve geliştirmenin ürünüdür. Bu araştırma ve
geliştirmelerden elde edilen know how ve üretimde
olduğu gibi yüksek kalite standartlarına göre üretilir.
Motorların iyileştirilmesi için yapılan geliştirme
(üniteleri) uygun fiyatlı bir alternatifdir.
Aynı yeni yedek parçalarda olduğu
es
uygulanan yüksek kalite standartları, uzun ömürlü,
yüksek dayanıklı ve düşük yakıt sarfiyatlı motorların
çalışmalarında olduğu gibi yedek parçalar üzerinde
de geliştirmeler yapılır. Yalnızca en son teknolojiye
gibi bu parçalar için de yüksek
kalite standartları geçerlidir. DEUTZ pt
üretilmesini sağlamıştır. Aynı zamanda çevre koruma göre üretilmiş olan orijinal DEUTZ yedek parçaları, Değiştirme komponentlerinin fonksiyon ve
ile ilgili tüm yükümlülükler de yerine getirilmiştir. motorların mükemmel fonksiyonunu, yüksek
dayanıklılık ve güvenilirliğini sağlar.
güvenilirliği orijinal DEUTZ yedek parçalarına eşittir. it
nl
sv
da
SERVİS Motor çalışırken dikkatli olun Asbest
fn
Arıza durumları ve yedek parça konularında bilgi Bakım ve onarım çalışmaları yalnızca motor dururken Bu motorda kullanılan contalarda
no
edinmek için yetkili servislerimize başvurunuz. Bu yapılacaktır. Muhtemelen sökülmüş olan koruma asbest malzemesi bulunmaz.
durumlarda eğitimli kalifiye personelimiz, orijinal
DEUTZ parçaları kullanarak tamir çalışmalarını
düzenleri, bakım ve tamir çalışmalarından sonra
tekrar monte edilecektir. Motor çalışırken yapılan
Bakım ve onarım çalışmalarında
lüften uygun yedek parça kullanın.
el
yerine getireceklerdir. çalışmalarda bol iş elbisesi giyilmeyecektir. Yakıt
dolumu yalnızca motor dururken yapılacaktır. Motoru tr
kesinlikle kapalı mekanlarda çalıştırmayın -
Zehirlenme tehlikesi. ru
ar
pl
3 tr © 2000
S1057
Motorun tanımlanması
de
en 1. Üretici etiketi 2. Üretici etiketi pozisyonu 3. Motor numarası
fr
es
pt A B
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
Yapı türü A, motor numarası B ve motor gücü verileri Üretici etiketi C karter silindir bloğunda bağlıdır. Motor numarası, karter silindir bloğuna dövülmüş
no üretici etiketinde yazılıdır.
Yedek parça siparişinde yapı türü ve motor numarası
ve üretici etiketine yazılmıştır.
belirtilecektir.
el
tr
ru
ar
pl
© 2000 4 tr
S1057
Yedek parça siparişi
de
Sipariş bilgileri en
Orijinal DEUTZ yedek parça siparişlerinde aşağıdaki
bilgilerin belirtilmesi gereklidir:
Yedek parça siparişi fr
- Motor-Nr. Motor-Nr.: es
Sıra
- Kod Nr.
no. Adet Kod Nr. Not Yapı grubu pt
- Adet
it
Dokümantasyon yapısı
nl
- Yedek parça listesindeki şekiller ve çizimler
motor gruplarına göre ayrılmıştır sv
- Her bölümün önünde yapı grubu listesi bulunur
- 06/59 Kod numarası örneğin:

da
(örnek 06) nolu yapı grubu (örnek 59) nolu
pozisyondan oluşur.
Pozisyon
fn
Sembol açiklamasi
no
-06- Yapi grubu numarasi (Örn. 06) el
000 Değişim kudo (Örn. 000)
tr
96 Sayfa numarasi (Örn. 96)
Izleyen sayfa üzerindeki referans (Örn. 94 )

ru
94
ar
A Bağlanti semolü
- Her saman en az ikili sembol olarak
(Örn. A-A, B-B, C-C vs.gibi)
pl
5 tr © 2000
S1057
Servis
de
en Bilmek gerekir, bu DEUTZ’dur. Sipariş no: 0312 0806
fr Motor yapımında çığır açan gelişmeler demek DEUTZ

demektir. Biz, bağımsız motor üreticisi olarak dünya
genelinde 4 ile 7.400 kW gücündeki dizel ve gaz
es motorlarını palet halinde sunmaktayız. Ürünlerimiz
müşterilerimizin beklentileri için biçilmiş kaftandır.
pt
Bugün dünya genelinde 1,4 milyondan daha fazla
it sayıda DEUTZ motoru hizmet vermektedir.
Motorlarımızın etkinliğini ve bununla birlikte
müşterilerimizin memnuniyetini sürdürmek istiyoruz.
nl Bu nedenle bütün dünyada, yayılımları motorlarımızın
bölgesel dağılımına uygun olan yetkin temsilciler
sv bizleri temsil etmektedir.
DEUTZ, bu şekilde sadece motorlar için yaratıcılık

da ruhuna sahip bir isim değil, bunun yanında motorla
ilgili tam bir hizmet paketi ve güvenebileceğiniz bir
servis demektir.
fn Sales & Service cetveli size DEUTZ’un en Sipariş no: (CD-ROM) 0312 0807
no yakınınızdaki temsilcileri, onların ürün yetkileri ve
servis hizmetleri hakkında bilgi verir. Direk olarak ürün
yetkisi olmasa da DEUTZ temsilcisi size danışma
el hizmeti vererek yardım eder.
Bulunduğunuz yerdeki yetkili servisinizden veya DEUTZ AG
Cetvel sürekli olarak güncel hale getirilir. Yakınınızdaki yandaki adresimizden edinebilirsiniz: Deutz-Mülheimer Str. 147-149
tr DEUTZ temsilcisinden yeni baskıyı isteyiniz. D-51057 Köln
ru Sizin DEUTZ’unuz.
Telefon: 0049-221-822-0
Telefaks: 0049-221-822-5304
Teleks: 8812-0 khd d
pl
© 2000 6 tr
S1057
2012
0312 0836
1 ru © 2000
© 2000
S1057
de
en
fr
es
pt
it
nl
sv
da
fn
no
el
tr
ru
ar
pl
© 2000 2 ru
S1057
de
en
fr
es
pt
it
nl
sv
da
fn
no
el
tr
ru
ar
pl
3 ru © 2000
S1057
de
en
fr
es
A B
pt
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
no
el
tr
ru
ar
pl
© 2000 4 ru
S1057
Заказ на запасные части
de
Данные для заказа en
Заказ на запасные
При заказе подлинных частей фирмы ДОЙЦ
требуется указать следующие данные: части fr
- Двигатель № Двигатель № es
Пор. Шт. Идент
- Идент. №
№ № Примечание Конструктивная группа pt
- Количество
Устройство ведомости для заказа

it
- Изображения этой ведомости nl
запасных частей сортированы согласно
конструктивным группам двигателя. sv
- Для каждого раздела вначале представлен
обзор конструктивных групп. da
- Идент. № 06\59 состоит из
конструктивной группы (например, 06)
Позиция
fn
и позиции (например, 59).
no
el
tr
ru
ar
pl
5 ru © 2000
S1057
Cepис
de
en Зная - это ДОЙЦ! Заказ № 0312 0806
Индекс сбыта и сервиса
fr С давних пор ДОЙЦ - это олицетворение
новаторского развития в изготовлении
двигателей. В качестве независимого
es производителя двигателей мы предлагаем по
всему миру комплектный ассортимент
дизельных и газовых двигателей в диапазоне
pt мощности от 4 до 7400 кВт. Наша продукция в
совершентсве припасована к требованиям
it наших заказчиков.
По всему миру надежно служат более чем 1,4
миллиона двигателей “ДОЙЦ“. Мы желаем
nl сохранить готовность наших двигателей к
эксплуатации и этим - удовлетворенность
sv наших клиентов. Для этого мы представлены по
всему миру сетью компетентных партнеров,
количество которых соответствует региональному
da распределению наших двигателей.
Таким образом, ДОЙЦ является не только
fn именем для двигателей с духом
изобретательства. Но также и для комплекса
услуг по всем вопросам, касающимся Заказ № (CD-ROM) 0312 0807
no двигателей, и сервиса, на который можно
положиться.
Индекс сбыта и сервиса
el “Индекс сбыта и услуг“ дает Вам обзор

партнеров ДОЙЦа, находящихся недалеко от Заказ производится через соответствующего DEUTZ AG
Вас, и их компетентности относительно местного партнера по сервису или на фирме: Deutz-Mülheimer Str. 147-149
tr двигателей и сервисных услуг. Но даже если их
компетентность не охватывает требующегося
D-51057 Köln
ru объема частей по определенному двигателю,

партнер ДОЙЦа всегда поможет Вам
Телефон: +49-221-822-0
Телефакс: +49-221-822-5304
компетентным советом. Телекс: 8812-0 khd d
ar Индекс постоянно актуализируется - запросите
у партнера ДОЙЦа новейшее издание.
http://www.deutz.de
pl Ваше АО ДОЙЦ
© 2000 6 ru
S1057
2012
0312 0836
1 ar © 2000
© 2000
S1057
de
en
fr
es
pt
it
nl
sv
da
fn
no
el
tr
ru
ar
pl
© 2000 2 ar
S1057
de
en
fr
es
pt
it
nl
sv
da
fn
no
el
tr
ru
ar
pl
3 ar © 2000
S1057
de
en
fr
es
pt A B
it
nl
sv
C
da
© 31 823 0 © 31 488 0 © 26 332 3
fn
no
el
tr
ru
ar
pl
© 2000 4 ar
S1057
de
en
fr
es
pt
it
nl
sv
da
fn
no
el
tr
ru
ar
pl
5 ar © 2000
S1057
de
en 0312 0806
fr
es
pt
it
nl
sv
da
fn
0312 0807
no
el DEUTZ AG
tr D-51057 Köln
ru 0049-221-822-0
0049-221-822-5304
ar 8812-0 khd d
http://www.deutz.de
pl
© 2000 6 ar
S1057
Lista czЂжci zamiennych
2012
PieczИtka handlowca
0312 0836
Numer silnika:
Prosimy wpisaН numer silnika. W ten sposЧb

uЄatwiacie Paƒstwo zaЄatwienie spraw serwisu,
napraw i czЂжci zamiennych.
W opisie i danych, zawartych w niniejszej Liжcie

czЂжci zamiennych zastrzegamy sobie prawo
wprowadzenia zmian technicznych koniecznych
do ulepszenia silnika. Przedruk i powielanie w
jakikolwiek sposЧb, takэe w postaci wyciИgЧw,
wymaga naszej pisemnej zgody.
1 pl © 2000
© /2000
0297 7547
S1057
Wprowadzenie
de
en Szanowny odbiorco, Elementy wymienione w niniejszej Liжcie czЂжci
zamiennych naleэy stosowaН jedynie do naprawy
fr chЄodzone cieczИ silniki marki DEUTZ zostaЄy
opracowane dla szerokiego zakresu zasto-
wymienionego szeregu konstrukcyjnego silnikЧw
marki Deutz (uэycie zgodnie z przeznaczeniem).
sowania. Bogata oferta rЧэnych wariantЧw SzczegЧЄowe informacje o prawidЄowej zabu-
es zapewnia moэliwoжН speЄnienia wymagaƒ
specjalnych w poszczegЧlnych przypadkach.
dowie czЂжci zamiennych zawiera instrukcja
eksploatacji (czynnoжci obsЄugi technicznej)
pt Wyposaэenie silnika zamЧwionego przez
oraz ksiИэka warsztatowa (prace remontowe).
Wykonawca nie przejmuje odpowiedzialnoжci za
Paƒstwo odpowiada przypadkowi okreжlonemu szkody i obraэenia osЧb powstaЄe w wyniku
it w zamЧwieniu, t.zn. nie wszystkie czЂжci
zamienne i czЂжci skЄadowe z niniejszej Listy
nieprzestrzegania odpowiednich instrukcji.
czЂжci zamiennych zostaЄy przedstawione w

nl Paƒstwa silniku.
sv Mimo, эe zaЄИczone rysunki nie zawierajИ wielu

szczegЧЄЧw, sИ Paƒstwo w stanie wyraРnie
rozrЧэniН poszczegЧlne warianty tak, эe
da znalezienie czЂжci zamiennych do Paƒstwa
konkretnego silnika nie sprawi trudnoжci.
Poszukiwana czЂжН zamienna moэe byН w
fn kaэdym przypadku bezbЄЂdnie znaleziona na
podstawie numeru pozycji, numeru pod-
no zespoЄu i numeru silnika.
Przy zamawianiu czЂжci zamiennych prosimy

el przestrzegaН naszych wskazЧwek do zamЧ-
wienia. Zapewni nam to moэliwoжН szybkiego i
niezawodnego dostarczenia potrzebnych czЂжci
tr zamiennych z kaэdorazowym uwzglЂdnieniem
ostatnio wprowadzonych zmian.
ru Na zapytania Paƒstwa udzielimy zawsze chЂtnie
odpowiedzi.
ar Z uszanowaniem
pl DEUTZ AG
© 2000 2 pl
S1057
Wprowadzenie
de
Silniki Diesla marki DEUTZ Oryginalne czЂжci zamienne CzЂжci zastЂpcze marki DEUTZ en
marki DEUTZ
fr
zostaЄy opracowane w wyniku wieloletnich podlegajИ tym samym surowym wymaganiom CzЂжci zastЂpcze marki DEUTZ
badaƒ i rozwoju. Zdobyte w wyniku tego solidne
know how stanowi w poЄИczeniu ze speЄnieniem
jakoжci, jak i silniki marki DEUTZ. W celu poprawy
jakoжci silnikЧw podlegajИ staЄemu rozwojowi
stanowiИ alternatywЂ korzystniejszИ
cenowo. Oczywiжcie obowiИzujИ
es
wysokich wymogЧw jakoжci gwarancjЂ produkcji
silnikЧw o dЄugiej эywotnoжci, wysokiej nie-
oczywiжcie takэe oryginalne czЂжci zamienne
marki DEUTZ. Tylko zastosowanie oryginalnych
tu, jak i w stosunku do elementЧw
nowych, najwyэsze wymagania pt
zawodnoжci i niskim zuэyciu paliwa. Oczywiжcie czЂжci zamiennych marki DEUTZ, wykonanych z jakoжciowe. CzЂжci zastЂpcze marki DEUTZ sИ co
zostaЄy takэe speЄnione wysokie wymagania
ochrony жrodowiska. Umwelt erfüllt werden.
wykorzystaniem najnowszej wiedzy, zapewnia
nienaganne dziaЄanie i wysokИ niezawodnoжН
do dziaЄania i jakoжci rЧwnowaэne oryginalnym
czЂжciom zamiennym marki DEUTZ.
it
pracy.
nl
sv
da
SERVIS еrodki ostroэnoжci przy
pracujИcym silniku
Azbest
fn
W przypadkach zakЄЧceƒ eksploatacyjnych oraz Czynnoжci obsЄugowe i naprawy naleэy wyko- Uszczelnienia zastosowane w tym
no
w sprawach czЂжci zamiennych prosimy zwrЧciН nywaН tylko przy zatrzymanym silniku. Ewen-
siЂ do jednego z naszych wЄaжciwych przed-
stawicielstw serwisowych. Nasi wyszkoleni
tualnie usuniЂty osprzЂt ochronny naleэy po
zakoƒczeniu prac ponownie zamontowaН.
silniku sИ wolne od azbestu. Do
prac obsЄugowych i napraw el
prosimy uэywaН odpowiednich
specjaliжci postarajИ siЂ w przypadkach usz-
kodzeƒ o szybkИ i fachowИ naprawЂ z uэyciem
Podczas prac przy pracujИcym silniku odzieэ
robocza powinna жciжle przylegaН do ciaЄa.
czЂжci zamiennych.
tr
oryginalnych czЂжci zamiennych marki DEUTZ. Silnik moэna tankowaН tylko po jego
zatrzymaniu. Silnik nie moэe w эadnym
przypadku pracowaН w zamkniЂtym
ru
pomieszczeniu – niebezpieczeƒstwo zatrucia.
ar
pl
3 pl © 2000
S1057
Opis silnika
de
en 1. Tabliczka firmowa 2. PoЄoэenie tabliczki firmowej 3. Numer silnika
fr
es
A B
pt
it
nl
sv
C
da © 26 332 3 © 31 488 0 © 31 823 0
fn
Typ A, numer silnika B, jak i dane odnoжnie mocy Tabliczka firmowa C jest zamocowana na Numer silnika jest odciжniЂty na kadЄubie silnika
no zostaЄy odciжniЂte na tabliczce firmowej.
Przy zamawianiu czЂжci naleэy podaН typ i numer
kadЄubie silnika. oraz na tabliczce firmowej.
silnika.
el
tr
ru
ar
pl
© 2000 4 pl
S1057
ZamЧwienie czЂжci zamiennych
de
Dane zamЧwieniowe en
ZamЧwienie czЂжci
Przy zamawianiu oryginalnych czЂжci zamien-
nych marki DEUTZ naleэy podaН nastЂpujИce zamiennych fr
dane:
Numer silnika: es
- Numer silnika (Motor-Nr.)
Nr Nr
- Numer identyfikacyjny (Ident-Nr.) porz. IloжН identyf. Uwagi PodzespЧЄ pt
- IloжН it
UkЄad dokumentacji nl
- Tabele zawierajИce rysunki czЂжci zamiennych
sИ uszeregowane wedЄug podzespoЄЧw silnlka. sv
- PodzespoЄy sИ zestawione w liжcie elementЧw
silnika.
da
- Numer identyfikacyjny (Ident-Nr.) 06/59 skЄada
siЂ z podzespoЄu (np. 06) i z pozycji (np. 59).
Pozycja
fn
Objaжnienia symboli
no
-06- Numer podzespoЄu (np. 06) el
000 Cyfra zmiany
tr
96 Numer strony (np. 96)
OdsyЄacz do strony z dalszym ciИgiem

ru
94 (np. 94)
ar
A Symbol poЄИczenia
- wystЂpuje zwykle w parze
(np. A-A, B-B, C-C itd.)
pl
5 pl © 2000
S1057
Servis
de
en Wiadomo, to jest DEUTZ. Numer zamЧwienia: 0312 0806
fr Z nazwИ DEUTZ kojarzy siЂ od dawna otwierajИcy

nowe horyzonty rozwЧj w dziedzinie budowy
silnikЧw. Jako niezaleэny wytwЧrca silnikЧw
es dostarczamy na caЄym жwiecie caЄИ gamЂ silni-
kЧw Diesla i silnikЧw gazowych o mocy od 4 do
7400 kW. Nasze wyroby odpowiadajИ dokЄadnie
pt wymaganiom naszych odbiorcЧw.
Na caЄym жwiecie wykonuje niezawodnie swoje
it zadanie ponad 1,4 miliona silnikЧw firmy DEUTZ.
Jesteжmy zainteresowani w utrzymaniu wysokiej
gotowoжci do pracy naszych silnikЧw, a tym
nl samym w utrzymaniu zadowolenia naszych
odbiorcЧw. Dlatego teэ jesteжmy
sv reprezentowani w caЄym жwiecie przez sieН
kompetentnych przedstawicieli, ktЧrych
gЂstoжН rozmieszczenia odpowiada
da regionalnemu rozmieszczeniu naszych silnikЧw.
Nazwa DEUTZ jest rЧwnoznaczna nie tylko z
fn pojЂciem silnikЧw o duchu wynalazczoжci. Oz-
nacza ona teэ kompletny pakiet жwiadczeƒ we
wszystkich dotyczИcych silnikЧw dziedzinach Numer zamЧwienia: (CD-ROM) 0312 0807
no oraz serwis, ktЧremu Paƒstwo mogИ zaufaН.
Wykaz Sales & Service zawiera przeglИd
el przedstawicielstw firmy DEUTZ w pobliэu
Paƒstwa, informacje o ich kompetencjach i Do nabycia poprzez Paƒstwa wЄaжciwe przed- DEUTZ AG
жwiadczeniach serwisowych. Takэe w przy- stawicielstwo serwisowe na miejscu albo pod Deutz-Mülheimer Str. 147-149
tr padkach, kiedy nie wymieniono wprost okre-
жlonych kompetencji, przedstawiciel firmy
adresem: D-51057 Köln
ru DEUTZ udzieli Paƒstwu kompetentnej porady.

Wykaz ten jest stale aktualizowany, prosimy
Telefon: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
ar pytaН w przedstawicielstwach firmy DEUTZ o
najnowsze wydanie.
http://www.deutz.de
Z uszanowaniem DEUTZ AG
pl
© 2000 6 pl
S1057
Bildtafeln de
Illustrations en
Figures fr
Grabados es
Quadros de figuras pt
Tavole it
Afbeeldingen nl
Planscher sv
Illustrationer da
Bilder fn
Kuvat no
¢È·ÁÚ¿ÌÌ·Ù· el
sekiller tr
Иллюст ации ru
ar
Tabela z rysunkami pl
© 2000
Rechts 3
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
Ersatzteilliste de
Spare Parts Catalogue en
Catalogue de Pièces de Rechange fr
Lista de Piezas de Repuesto es
Lista de peças sobresselentes pt
Listino parti di ricambio it
Onderdelenlijst nl
Reservdelslista sv
Reservedelsliste da
Varaosaluettelo fn
Reservedelsliste no
K·Ù¿ÏoÁo˜ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ el
Yedek parça Listesi tr
Спиcок запаcных чаcтей ru
ar
Lista części zamiennych pl
Rechts 1
S1057
Ersatzteilliste
2012
Händlerstempel
0312 0836
Motornummer:
Bitte tragen Sie hier die Motornummer ein. Sie

erleichtern hierdurch die Abwicklung bei Kunden-
dienst-, Reparatur- und Ersatzteilfragen.
Gegenüber Darstellungen und Angaben dieser Er-

satzteilliste sind technische Änderungen, die zur
Verbesserung der Motoren notwendig werden,
vorbehalten. Nachdruck und Vervielfältigung jeg-
licher Art, auch auszugsweise, bedarf unserer
schriftlichen Genehmigung.
1 de © 2000
© 2000
S1057
Vorwort
de
en Sehr geehrter Kunde Die in dieser Ersatzteilliste aufgeführten Bauteile
sind nur für Reparatur von DEUTZ Motoren der
fr die flüssigkeitsgekühlten Motoren der Marke
DEUTZ sind für ein breites Anwendungsspektrum
bezeichneten Baureihe zu verwenden (bestim-
mungsgemäßer Gebrauch).
entwickelt. Dabei wird durch ein umfangreiches Über den fachgerechten Einbau von Ersatzteilen
es Angebot von Varianten sichergestellt, daß die je-
weiligen speziellen Anforderungen erfüllt werden.
informieren die Betriebsanleitung (Wartungs-
arbeiten) und das Werkstatthandbuch (Reparatur-
pt Ihr Motor ist dem Einbaufall entsprechend ausge-
arbeiten) ausführlich. Für Schäden oder Verletzun-
gen von Personen, die aus der Nichtbeachtung der
rüstet, das heißt nicht alle in dieser Ersatzteilliste entsprechenden Anleitung führen, übernimmt der
it dargestellten Bauteile und Komponenten sind an
Ihrem Motor dargestellt.
Hersteller keine Haftung.
nl Obwohl die Grafiken weitgehend nicht mit allen

Details dargestellt sind, können die einzelnen
sv Varianten deutlich unterschieden werden, so daß
das für Ihren Motor relevante Ersatzteil leicht
herauszufinden ist. Über Positions-, Baugruppen-
da und Motornummer wird in jedem Fall das richtige
Ersatzteil ermittelt.
fn Bitte beachten Sie bei dieser Ersatzteilbestellung

unsere Bestellhinweise, damit wir Ihnen schnell
no und zuverlässig die benötigten Ersatzteile in der
jeweils dem letzten Änderungsstand entsprechen-
den Ausführung liefern können.
el Für Ihre Rückfragen stehen wir Ihnen gerne
beratend zur Verfügung.
tr
ru Ihre
DEUTZ AG
ar
pl
© 2000 2 de
S1057
Vorwort
de
DEUTZ Dieselmotoren Original DEUTZ Teile DEUTZ Austauschkomponenten en
fr
sind das Produkt jahrelanger Forschung und Ent- unterliegen den gleichen strengen Qualitätsan- DEUTZ Austauschkomponenten sind
wicklung. Das dadurch gewonnene fundierte know
how in Verbindung mit hohen Qualitätsanfor-
forderungen wie die DEUTZ Motoren. Weiter-
entwicklungen, zur Verbesserung der Motoren
eine preiswerte Alternative. Selbst-
verständlich gelten auch hier wie
es
derungen ist die Garantie für die Herstellung von
Motoren mit langer Lebensdauer, hoher Zuverläs-
werden selbstverständlich auch bei den Original
DEUTZ Teilen eingeführt. Nur die Verwendung
für Neuteile höchste Qualitätsmaß-
stäbe. In Funktion und Zuverlässigkeit pt
sigkeit und geringem Kraftstoffverbrauch. Es ist von nach neuesten Erkenntnissen gefertigten sind DEUTZ Austauschkomponenten den Original
selbstverständlich, daß auch die hohen Anforde-
rungen zum Schutz der Umwelt erfüllt werden.
Original DEUTZ Teilen bietet die Gewähr einwand-
freier Funktion und hoher Zuverlässigkeit.
DEUTZ Teilen gleichwertig. it
nl
sv
da
SERVICE Vorsicht bei laufendem Motor Asbest
fn
Wenden Sie sich bei Betriebsstörungen und Ersatz- Wartungsarbeiten oder Reparaturen nur bei abge- Bei diesem Motor verwendete
no
teilfragen an eine unserer zuständigen Service- stelltem Motor durchführen. Evtl. entfernte Schutz- Dichtungen sind asbestfrei. Bitte
Vertretungen. Unser geschultes Fachpersonal
sorgt im Schadensfall für eine schnelle und fach-
vorrichtungen nach Abschluß der Arbeiten wieder
montieren. Bei Arbeiten am laufenden Motor soll
verwenden Sie bei Wartungs- und
Reparaturarbeiten entsprechende
el
gerechte Instandsetzung unter Verwendung von
Original DEUTZ Teilen.
die Arbeitskleidung fest anliegen. Nur bei abge-
stelltem Motor tanken. Motor nie in geschlossenen
Ersatzteile.
tr
Räümen laufen lassen – Vergiftungsgefahr.
ru
ar
pl
3 de © 2000
S1057
Motorbeschreibung
de
en 1. Firmenschild 2. Lage des Firmenschild 3. Motornummer
fr
es
pt
A B
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
Die Bauart A, die Motornummer B sowie die Das Firmenschild C ist am Kurbelgehäuse Die Motornummer ist auf dem Kurbelgehäuse
no Leistungsdaten sind auf dem Firmenschild ein-
gestempelt.
befestigt. sowie auf dem Firmenschild eingestempelt.
Bei der Ersatzteilbeschaffung müssen Bauart und

el Motornummer angegeben werden.
tr
ru
ar
pl
© 2000 4 de
S1057
Ersatzteilbestellung
de
Bestellangaben en
Bei der Bestellung von Original DEUTZ Teilen sind
folgende Angaben erforderlich:
Ersatzteilbestellung fr
- Motor-Nr. Motor-Nr.: es
- Ident-Nr. Lfd. Nr. Stück Ident-Nr. Bemerkung Baugruppe pt
- Stückzahl
it
Dokumentationsaufbau
nl
- Die Bildtafeln dieser Ersatzteilliste sind nach
Motor-Baugruppen sortiert. sv
- Die Baugruppen sind in der Motorübersicht
aufgeführt. da
- Die Ident-Nr. 06/59 besteht aus Baugruppe
(z.B. 06) und Position (z.B. 59).
Position
fn
Symbolerklärungen
no
-06- Baugruppennummer (z.B. 06) el
000 Änderungsziffer (z.B. 000)
tr
96 Seitennummer (z.B. 96)
Querverweiß auf Fortsetzungsseite

ru
94 (z.B. 94)
ar
A Anschlußsymbol
- tritt immer mindestens paarweise auf
(z.B. A-A, B-B, C-C etc.)
pl
5 de © 2000
S1057
Service
de
en Zu wissen, es ist DEUTZ. Bestell-Nr.: 0312 0806
fr Seit jeher steht DEUTZ für bahnbrechende Ent-

wicklungen im Motorenbau. Als unabhängiger
Motorenhersteller bieten wir weltweit eine kom-
es plette Palette von Diesel- und Gasmotoren im
Leistungsbereich von 4 bis 7.400 kW an. Unsere
pt Produkte sind auf die Anforderungen unserer
Kunden perfekt zugeschnitten.
it Weltweit verrichten mehr als 1,4 Millionen DEUTZ

Motoren zuverlässig ihren Dienst. Die Einsatz-
bereitschaft unserer Motoren und damit die
nl Zufriedenheit unserer Kunden wollen wir erhalten.
Daher sind wir weltweit mit einem Netz von
sv kompetenten Partnern vertreten, dessen Dichte der
regionalen Verteilung unserer Motoren entspricht.
da So ist DEUTZ nicht nur der Name für Motoren mit

Erfindungsgeist. Sondern auch für ein komplettes
Leistungspaket rund um den Motor und einen
fn Service, auf den Sie sich verlassen können.
Bestell-Nr.: 0312 0807 (CD-ROM)
no Das Register Sales & Service bietet Ihnen einen
Überblick über die DEUTZ Partner in ihrer Nähe,
über deren Produkt-Zuständigkeiten und Service-
el Leistungen. Aber auch wenn keine direkte Produkt-
Zuständigkeit vermerkt ist, hilft Ihnen der DEUTZ Beziehbar über Ihren zuständigen Service-Partner DEUTZ AG
Partner mit kompetenter Beratung weiter. vor Ort oder bei: Deutz-Mülheimer Str. 147-149
tr Das Register wird permanent aktualisiert; fragen
D-51057 Köln
ru Sie Ihren DEUTZ Partner nach der neuesten

Auflage.
Telefon: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
ar Ihre DEUTZ AG
http://www.deutz.de
pl
© 2000 6 de
S1057
Spare Parts Catalogue
2012
Dealer’s stamp
0312 0836
Engine
Serial No.:
Please enter here the serial No. of your engine. This

will facilitate dealing with your questions
concerning after-sales service, repair and spare
parts.
This Spare Parts Catalogue is subject to enginee-

ring changes necessary for engine advancement.
All rights reserved. No part of this publication may
be reproduced or multiplied in any form, without
our prior permission in writing.
1 en © 2000
© 2000
S1057
Preface
de
en Dear Customer The parts contained in this Catalogue are type-
specific and shall be used only for repairing
fr liquid DEUTZ diesel engines are developed to meet
the requirements of a wide range of applications.
engines belonging to the DEUTZ engine family
on the cover).
An extensive program of variant options gives them Full particulars for the correct installation of parts
es their high flexibility. are to be found in the relevant Operating
(maintenance work) and Workshop Manual
pt Your engine is custom-made, i.e. specifically equip-
ped for your requirement, which means that not all
(repair). The engine builder shall not be liable
for any damage or injury resulting from non-
of the components and assemblies contained in compliance with guidelines given in the manual.
it this Catalogue are fitted to your engine.
The greater part of the illustrations does not depict

nl all details, and yet you will find it easy to differentia-
te between versions and thus to identify the parts
sv pertaining to your engine model. Fig. Item No.,
Assembly Group No. Engine Serial No. are the
codes that infallibly lead to selection of the correct
da parts.
When placing your order, please observe our

fn ordering hints. This allow speedy and reliable
delivery of the required parts that are based on
no latest engineering standards.
If there are any questions, please do not hesitate to

el contact us.
tr Sincerely,
DEUTZ AG
ru
ar
pl
© 2000 2 en
S1057
Preface
de
DEUTZ Diesel Engines Genuine DEUTZ Parts DEUTZ Exchange Components en
fr
are products based on long-standing research and are subject to equally stringent quality require- are a cheap alternative. Of course,
development The deep funds of acquired know-
how in conjunction with high quality requirements
ments as the engines themselves. Improvements
in engine design certainly also pass into the
they are subject to the same high
quality requirements as new parts.
es
guarantee that engines leaving our works achieve a
long life, high reliability and excellent fuel eco-
genuine DEUTZ parts. To ensure that your engine
will retain its functions and high reliability, you
And as regards functions and
reliability, DEUTZ exchange components equal pt
nomy. Naturally, they also attain best ratings as should use genuine DEUTZ parts only. genuine DEUTZ parts.
regards environmental protection. it
nl
sv
da
SERVICE Beware of the Running Engine Asbestos
fn
In case of operational trouble with your equip- Be sure to shut down the engine before performing Gaskets used for this engine do not
no
ment or queries about spare parts please turn to maintenance or repair work. After repair, put back contain asbestos. Olease use suit-
your nearest service dealership. Our skilled staff of
service exoerts will trace and remedy any defect
in place any removed panels and guards. When
doing work on the running engine, working clothes
able spare parts when carrying out
maintenance and repair work.
el
quickly, using genuine DEUTZ parts. should fit tightly so that loose ends cannot get
caught. Do not run the engine in enclosed rooms tr
– poison hazard.
ru
ar
pl
3 en © 2000
S1057
Description of Engine
de
en 1. Maker’s Nameplate 2. Position of Nameplate 3. Engine Serial No.
fr
es
pt A B
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
Engine model designation A, Engine Ser. No. B The nameplate C is attached to the crankcase. The engine serial No. is stamped on the crankcase
no and the power rating are given on the maker’s
nameplate.
and also on nameplate..
Be sure to state engine model and engine serial

el number when writing out a parts order.
tr
ru
ar
pl
© 2000 4 en
S1057
Ordering spare parts
de
Order information en
Please specify the following information when
ordering original DEUTZ parts:
Ordering spare parts fr
- Engine no. Engine no.: es
- Ident no. Item Qty. Ident. no. Comments Assembly group pt
- Quantity
it
Document structure
nl
- The picture diagrams in this spare list are sorted
according to engine assembly groups. sv
- The assemblies are listed in the engine
overview. da
- The ident no. 06/59 is made up of the assembly
group (e.g. 06) and item number (e.g. 59).
Item number
fn
Explanation of symbols
no
-06- assembly No. (e.g. 06) el
000 revision level (e.g. 000)
tr
96 page number (e.g. 96)
cross reference on continuation page

ru
94 (e.g. 94)
ar
A A connection symbol
- always occurs at least in pairs
(z.B. A-A, B-B, C-C etc.)
pl
5 en © 2000
S1057
Service
de
en Knowing it’s DEUTZ Order-No.: 0312 0806
fr DEUTZ has always stood for excellence in motor

construction, pioneering many developments in
the industry. As an independent motor manu-
es facturer, we offer — worldwide — a com-
prehensive range of diesel and gas motors
pt spanning from 4kW to 7,400kW. Our products are
perfectly tailored to meet our customers’ individual
requirements.
it Over 1.4 million DEUTZ motors do their job reliably
all over the world. We are determined to
nl preserve the high standard of performance and
dependability of our motors, thus keeping our
sv customers satisfied at all times. Therefore we are
represented worldwide through a network of highly
competent service partners who will meet the
da needs of our customers, wherever they are.
This is why DEUTZ is not only the name for motors

fn which pack a lot of inventive genius. DEUTZ also
means reliable service and comprehensive support Order-No.: 0312 0807 (CD-ROM)
no to enhance your motor’s performance.
This index Sales & Service offers you an overview

el of the DEUTZ partners in your vicinity, including the
products for which they are responsible and the Obtainable from the local service Partner reponsible DEUTZ AG
range of services provided. But even when no direct for you or from: Deutz-Mülheimer Str. 147-149
tr product responsibility is mentioned, your DEUTZ
partner will be happy to help you with expert advice.
D-51057 Köln
ru The Index is constantly updated. Please ask your

Phone: 0049-221-822-0
Telefax: 0049-221-822-5304
DEUTZ service partner for the latest edition. Telex: 8812-0 khd d
DEUTZ AG — at your service.

pl
© 2000 6 en
S1057
Catalogue de Pièces de Rechange
2012
Cachet du concessionnaire
0312 0836
Numéro
du moteur:
Veuillez incrire dans les cases correspondantes

le numéro du moteur. Vous facilitez ainsi le
règlement des questions du Service après-vente
ainsi que tous les problèmes de réparation et
de pièces de rechange.
Nous nous réservons le droit dans le présent

Manuel, de procéder à toutes modifications
techniques utiles visant à améliorer la qualité des
moteurs. Toute réimpression ou reproduction du
présent Manual, faite même à titre exceptionnel,
exige notre autorisation spéciale.
1 fr © 2000
© 2000
S1057
Avant-propos
de
en Cher client, Le présent Catalogue des pièces de rechange
énumère les composants à utiliser uniquement
fr les moteurs refroidis par liquide de la marque
DEUTZ ont été développés pour les applications les
à des fins de réparation pour moteurs Diesel de
la série indiquée (utilisation spécifique).
plus variées. Il existe un grand choix de variantes Les Instructions de service (travaux d’entretien)
es répondant aux exigences spéciales demandées
dans chaque cas.
et le Manuel d’atelier (travaux de réparation)
apportent de plus amples informations sur le mon-
pt Votre moteur est équipé pour les cas d’application
tage approprié des pièces. Le fabricant décline
toute responsabilité découlant de dommages ou de
envisagée, ce qui signifie que toutes les pièces et blessures aux personnes résultant du non-respect
it composants représentés dans votre Catalogue de
pièces de rechange ne sont pas montés sur votre
des présentes instructions.
moteur.
nl Bien que les graphiques ne représentant pas tous
sv les détails, les variantes se distinguent nettement
les unes des autres, si bien que vous trouverez sans
problème la pièce de rechange correspondant à
da votre moteur. Les numéros de référence, de
l’organe et du moteur permettent en tout cas de
retrouver la pièce de rechange que vous cherchez.
fn Lors de votre commande de pièces de rechange
no veuillez respecter nos indications de commande,
afin que nous puissons vous fournir rapidement
et sûrement les pièces de rechange demandées
el dans la version correspondante réactualisée.
Pour toutes questions complémentaires nous

tr restrons à votre endière disposition.
ru DEUTZ AG
ar
pl
© 2000 2 fr
S1057
Avant-propos
de
Les moteurs Diesel DEUTZ Pièces de rechange DEUTZ Composants de rechange DEUTZ en
fr
sont le fruit de longues recherches et d’un Elles sonts soumises aux même niveau d’exigence Les composants de rechange
développment continu. Le solide savoir-faire ainsi
acquis conjugué à des exigences élevées en
de qualité que les moteurs DEUTZ. Toute progrès
visant à améliorer les moteurs est naturellement
DEUTZ sont une alternative. Lá
aussi, de même que pour les
es
matière de qualité est la garantie de fabrication
de moteurs à longue durée de vie, haute, fiabilité
immédiatement adpotée pour les pièces de
d’orgine DEUTZ. Seule l’utilisation de pièces de
pièces neuves, on applique des
normes de qualité élevées. Du pt
et faible consommation en combustible. Il va de soi d’origine DEUTZ d’origine fabriquées selon des point de vue fonction nement et fiabilité les
que les moteurs doivent aussi respecter des
exigences élevées en matiére de protection de
méthodes ultramodernes garantit un fonction-
nement irréprochable et une haute fiabilité.
composants de rechange DEUTZ sont équivalents
aux pièces de rechange DEUTZ.
it
l’environnement.
nl
sv
da
SERVICE Précaution à prendre quand
le moteur marche Amiante fn
En cas de panne d’exploitation et pour toute ques- N’effectuer les travaux d’entretien ou les répara-
Les rondelles d’étanchéité utili-
sées pour ces moteurs sont
no
tion relative à des pièces de rechange veuillez vous tions qu’à l’arrêt du moteur. A la fin des travaux exemptes d’amiante. Veuillez em-
adresser à notre point de service responsable pour
votre secteur. Notre personnel qualifié et averti
penser à remonter les dispositifs de protection
ayant été déposés. Lors de travaux à faire sur le
ployer, lors des travaux dèntretien
et de réparation, les pièces de
el
assure une remise en état rapide et appropriée de
votre moteur en n’utilisant que des piéces d’origine
moteur en marche, les vêtements de travail
doivent bien coller au corps. Ne faire le plein que
rechange correspondantes.
tr
DEUTZ. lorsque le moteur est arrêté. Ne jamais faire
fonctionner les moteurs dans des locaux fermes.
Danger d’asphyxie!
ru
ar
pl
3 fr © 2000
S1057
Description du moteur
de
en 1. Plaque du constructeur 2. Emplacement de la plaque 3. Numéro du moteur
fr du constructeur
es
A B
pt
it
nl
sv
C
da © 26 332 3 © 31 488 0 © 31 823 0
fn
Le type A, le numéro du moteur B ainsi que les La plaque du constructeur C est fixée sur le bloc Le numéro du moteur se trouve gravé sur le
no indications de puissance sont gravés sur la
plaque du constructeur.
moteur. bloc moteur et figure aussi sur la plaque du
constructeur.
Pour toute commande de pièce de rechange, veuil-
el lez indiquer le type et le numéro du moteur.
tr
ru
ar
pl
© 2000 4 fr
S1057
Commande de pièces de rechange
de
Indications de commande en
Commande de pièce
Lors d’une commande de pièces détachées
originales de DEUTZ, il est nécessaire de fournir déatachée fr
les indication:
N° de moteur es
- n° de moteur
Nom- N° d’identi-
- n° d’identification
N° bre fication Observation numéro de groupe pt
- nombre it
Structure de la documentation
nl
- Les tableaux illustrés de cette liste de pièces
détachées sont classés par groupe de moteur. sv
- Les groupes constitutifs figurent dans
récapitulatif moteur moteur. da
- Le n° d’identification 06/59 est constitué
du n° de groupe (p.ex. 06) et du n° de position
position
fn
(p.ex. 59).
Symbolerklärungen
no
-06- Numéro de groupe constitutif (p. ex. 06) el
000 Indice de modification (p. ex. 000)
tr
96 Numéro de page (p. ex. 96)
94 Renvoi à la page (p. ex. 94)

ru
A Symbol d’assemblage ar
- se présente toujours par paire
(p. ex. A-A, B-B, C-C)
pl
5 fr © 2000
S1057
Service
de
en Qu’on se le dise: c’est du DEUTZ! Référence de commande: 0312 0806
fr DEUTZ est depuis toujours synonyme d’innovation

dans le domaine de la construction de moteurs.
C’est un fabricant indépendant qui offre une
es gamme complète de moteurs diesel et à gaz d’une
puissance de 4 à 7 400 kW sur l’ensemble de la
pt planète. Nous fournissons des produits parfai-
tement adaptés aux exigences de nos clients.
it Aujourd’hui, plus de 1,4 million de moteurs DEUTZ

tournent dans le monde entier. Notre double
objectif est d’assurer la fiabilité de nos moteurs et
nl de garantir la satisfaction de nos clients. C’est
pourquoi nous sommes représentés aux quatre
coins de la planète par un réseau de partenaires
sv compétents qui correspond à la répartition
régionale de nos moteurs.
da DEUTZ, ce n’est donc pas seulement une marque
innovatrice de moteurs. C’est aussi une gamme
fn complète de services autour du moteur, c’est aussi
un nom sur lequel vous pouvez toujours compter.
Référence de commande: 0312 0807 (CD-ROM)
no Le registre Sales & Service vous donne un aperçu
des partenaires DEUTZ les plus proches, de leurs
compétences techniques et des services qu’ils
el vous offrent. Et même s’il n’est pas directement
spécialisé dans le produit qui vous intéresse, votre Peut être commandé en vous adressant à votre DEUTZ AG
partenaire DEUTZ pourra vous conseiller avec partenaire service local ou auprès de: Deutz-Mülheimer Str. 147-149
tr compétence. D-51057 Köln
Le registre est constamment actualisé. N’hésitez
ru pas à demander la dernière version en date à votre
partenaire DEUTZ.
Téléphone: 0049-221-822-0
Téléfax: 0049-221-822-5304
Téléx: 8812-0 khd d
Votre DEUTZ AG
pl
© 2000 6 fr
S1057
Lista de Piezas de Repuesto
2012
Sello del distribuidor
0312 0836
No. de motor:
Sírvase registrar en estas casillas el No. de motor.

Así facilita la tramitación de cuestiones de servicio
postventa, reparaciones y repuestos.
Nos reservamos el derecho de efectuar, frente a las

representaciones e indicaciones de esta Lista de
repuestos, las modificaciones técnicas necesarias
para perfeccionar los motores. Para la reimpresión
y reproducción en cualquier forma, también en la
de extractos, se require nuestra autorización por
escrito.
1 es © 2000
© 2000
S1057
Prefacio
de
en Estimado cliente: Los componentes indicados en esta lista de
repuestos se emplearán exclusivamente para la
fr Los motores de la marqua DEUTZ con enfriamiento
por líquido han desarrollado para una amplia gama
reparación de motores Deutz de la serie indicada
(uso conforme a la finalidad).
de aplicaciones. Una extensa oferta de variantes Respecto al correcto montaje de los repuestos,
es garantiza que se cumplen las exigencias especiales
de cada caso.
véanse los manuales de instrucciones de manejo
(trabajos de mantenimiento) y el manual de
pt Su motor se ha equipado de acuerdo con el respec-
taller (trabajos de reparación). El fabricante no
responderá por daños o lesiones de personas
tivo caso de equipo, o sea que no están montados resultantes de la inobservancia de la instrucción
it en el motor de Ud. todos las partes constructivas
y componentes representados en su Lista de
correspondiente.
repuestos.
nl Pese a que la mayoría de los gráficos no contiene
sv todos los detalles, se pueden distinguir bien las
diferentes variantes de modo que resulta fácil
identificar el repuesto correspondiente a su motor.
da E repuesto correcto para cada caso se determina a
través de los números de posición, de grupo
constructivo y de motor.
fn Le rogamos tenga en cuenta nuestras indicaciones
no al confeccionar su pedido de repuestos para que le
podamos suministrar rápida y seguramente los
repuestos requeridos en la ejecución de acuerdo
el con el último estado de modificación.
En caso de dudas, estamos gustosamente a su

tr disposición para asesorarle.
ru DEUTZ AG
ar
pl
© 2000 2 es
S1057
Prefacio
de
Motores diesel DEUTZ Repuestos DEUTZ Componentes reacondicionados DEUTZ en
fr
son el producto de trabajos de investigación y de- están sometidos a las mismas severas exigencias Componentes reacondiconados
sarrollo de largos años. El fundado know how así
logrado conjuntamente con altas exigencias de ca-
respecto a la calidad que los motores DEUTZ.
Desarrollos ulteriores para perfeccionar los
DEUTZ constituyen una alterna-
tiva económica frente a repuestos
es
lidad es la garantía para la fabricación de motores
de larga duración, gran fiabilidad y bajo consumo
motores son introducidos desde luego también
en los repuestos DEUTZ. Sólo el emplo de
originales DEUTZ.
Naturalmente rigen también aquí, pt
de combustible. Se sobreentiende que se cumplen repuestos DEUTZ originales farbricados según igual que para piezas nuevas, elevadísimas ex-
también las elevadas exigencias para le protección
del ambiente.
los conocimientos más recientes garantiza un
funcionamiento impecable y alta fiabilidad.
igencias de calidad. Los repuestos reacondiciona-
dos DEUTZ equivalen a los repuestos originales
it
DEUTZ en cuanto a funcionamiento y fiabilidad.
nl
sv
da
SERVICE Atención a motor en marcha Amianto
fn
En caso de anomalías en el funcionamiento y Realizar trabajos de mantenimiento o reparación Las juntas utilizadas en este motor
no
cuestiones de repuestos, sírvase dirigirse a uno únicamente a motor parado. Remontar una vez son exentas de amianto (asbesto).
de nuestros Servicíos Oficioles. Nuestro personal
especializado y entrenado se ocupará de subsanar
terminados los trabajos los dispositivos de protec-
ción quitados eventualmente. En caso de que se
Para trabajos de mantenimiento
y reparacion sírvase utilizar los
el
efecientemente y con rapidez cualquier desper-
fecto, utilizando repuestos originales DEUTZ.
tengan que efectuar trabajos en el motor en
marcha, la ropa de trabajo debe tocar al cuerpo para
repuestos correspondientes.
tr
evitar accidentes. Hacer el repostado sólo a motor
parado. No hacer funcionar nunca el motor en lo-
cales cerrados – peligro de intoxicación.
ru
ar
pl
3 es © 2000
S1057
Descripción del motor
de
en 1. Placa del fabricante 2. Situación de la placa del fabricante 3. No. de motor
fr
es
pt A B
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
El tipo A, el No. de motor B así como los datos de La placa del fabricante C va fijada en el cárter. El No. de motor va estampado en el cárter y en la
no potencia van estampados en la placa del fabri-
cante. El tipo y el No. de motor se han de indicar
placa del fabricante.
en los pedidos de repuestos.

el
tr
ru
ar
pl
© 2000 4 es
S1057
Pedido de repuestos
de
Indicaciones para el pedido: en
Al solicitar piezas originales de DEUTZ será
necesario indicar los siguientes datos:
Pedido de repuestos fr
- Nº de Motor: Nº de Motor: es
N° de
- Nº de identificatión N° Pos. Cant. ident. Anotación: Groupo de construcción pt
- Cantidad de piezas
it
Estructuración de la documentación
- Las tablas con las ilustraciones de dichas piezas
nl
de repuesto están clasificadas de acuerdo con el
grupo constructivo de los motores. sv
- Los grupos constructivos se indican en el
resumen correspondiente del motor.
da
- El Nº de identificación 06/59 consta del grupo
(v.g. 06) y de la posición (v.g. 59).
Posición
fn
Leyenda
no
-06- número del grupo constructivo (z.B. 06) el
000 índice de modificación (z.B. 000)
tr
96 número de página (p.ej. 96)
referencia recíproca a la página de

ru
94 continuación (p.ej. 94)
ar
A símbolo de enlace
- aparece siempre, por lo menos, como
pareja (p.ej. A-A, B-B, C-C, etc.)
pl
5 es © 2000
S1057
Servicio
de
en La confianza de saber que es DEUTZ No. Pedito: 0312 0806
fr DEUTZ siempre ha estado a la vanguardia de la

industria de fabricación de motores. Como marca
independiente, ofrecemos, a escala mundial, una
es gama muy completa de motores diesel y de gas,
con potencias comprendidas entre 4kW y 7400kW.
Nuestros productos están estudiados para
pt satisfacer plenamente las exigencias de nuestros
clientes.
it Más de 1.400.000 motores DEUTZ funcionan con

toda fiabilidad en distintas partes del mundo.
Estamos resueltos a mantener las elevadas pres-
nl taciones de nuestros motores y, por consiguiente,
la confianza y satisfacción de nuestros clientes. Por
ello, contamos con una red mundial de centros de
sv asitencia, cuya densidad corresponde a la
distribución de motores en las distintas regiones.
da Así pues, DEUTZ no es tan sólo el nombre de un
motor fruto del genio creador. DEUTZ también
significa un paquete de servicios de apoyo para
fn garantizar un funcionamiento óptimo del motor y
una asistencia técnica en la que puede Ud. confiar. No. Pedito: 0312 0807 (CD-ROM)
no El registro Sales & Service le ofrece una panorá-
mica de los centros DEUTZ en su zona geográfica,
el detallando, en particular, los productos de los que
se ocupa cada centro y la gama de servicios dispo-
nibles. Pero incluso cuando no se mencione un Obtenible a través de su servicio local corres- DEUTZ AG
tr producto determinado, puede Ud. estar seguro que
su centro de asistencia DEUTZ tendrá mucho gusto
pondiente o de: Deutz-Mülheimer Str. 147-149
D-51057 Köln
en asesorarle y ayudarle en todo lo que pueda.
ru El registro se actualiza periódicamente. No dude
Téléfono: 0049-221-822-0
Telefax: 0049-221-822-5304
en solicitar la última edición a su centro de Telex: 8812-0 khd d
ar asistencia DEUTZ. http://www.deutz.de
DEUTZ AG
pl A su servicio.
© 2000 6 es
S1057
Lista de peças sobresselentes
2012
Carimbo do vendedor
0312 0836
Número
do motor:
Inscreva aqui, por favor, o número do motor.

Facilitará, com isso, o andamento das questões
relacionadas com a assistência técnica, repa-
rações e peças sobresselentes.
Reservamo-nos o direito proceder a alterações

de ordem técnica na representação e nos dados
desta lista de peças sobresselentes que se tornem
neces-sárias para o aperfeiçoamento dos motores.
Toda e qualquer reimpressão e reprodução,
mesmo só em parte, requere a nossa autorização
por escrito.
1 pt © 2000
© 2000
S1057
Prefácio
de
en Prezado cliente: As peças e partes componentes relacionadas nesta
lista de peças sobresselentes serão utilizadas
fr Os motores refrigerados à agua DEUTZ foram
desenvolvidos para um espectro de aplicação
(uso a que se destinam) somente para a reparação
de motores Deutz da série designada.
vasto. Assegura-se ao mesmo tempo um O manual de instruções de serviço (trabalhos de
es atendimento das exigências particulares corres-
pondentes através da ampla oferta de variantes.
manutenção) e o manual de oficina (trabalhos de
reparação) proporcionam informações pormeno-
pt O Seu motor encontra-se equipado de acordo com o
rizadas quanto à montagem tecnicamente correcta
de peças sobresselentes. O fabricante não assume
caso de montagem, isto é, não estão embutidas no qualquer responsabilidade por danos ou lesões
it mesmo todas as peçass e partes componentes
representadas na Sua lista de peças sobresselentes.
pessoais resultantes da inobservãncia das
instruções correspondetes.
nl Embora os gráficos não se encontrem amplamente

representados com todos os pormenores, é possível
sv distinguir claramente cada uma das variantes, de
forma a encontrar-se facilmente a peça sobresse-
lente de importância para o Seu motor. A devida peça
da sobresselente é localizável em qualquer caso pelos
números do item, do grupo constructivo e do motor.
fn Quando do pedido de encomenda de peças sobres-

selentes queira, por favor, observar as nossas
no instruções para encomenda, a fim de podermos
fornecer-lhe rápida e seguramente as peças
sobresselentes requeridas de acordo com o tipo
el correspondente à última alteração actualizada.
Encontramo-nos com prazer a Sua disposição para

tr um aconselhamento no caso de quaisquer pedidos
de informação que nos dirigir.
ru
A Sua
ar DEUTZ
pl
© 2000 2 pt
S1057
Prefácio
de
Os motores diesel DEUTZ Peças e partes originais Peças e partes componentes en
substituíveis DEUTZ
fr
são produto de longos anos de pesquisas e desen- estão sujeitasàs mesmas exigências severas de As peças e as partes componentes
volvimento. O „know how“ consolidado assim ad-
quirido constitui, aliado às grandes axigências de
qualidade para os motores DEUTZ. Naturalmente
que se introduzem aperfeiçoamentos também nas
substituíveis DEUTZ são uma alter-
nativa económica para as peças
es
qualidade, a garantia para a fabricação de motores
com uma vida útil longa e um consumo reduzido
peças e partes originais para o melhora-mento
dos motores. Somente o emprego de peças e
sobresselentes originais DEUTZ.
Naturalmente que vigoram aqui, pt
de combustível. É compreensível que se deva partes originais fabricadas de acordo com os con- também, como para as peças novas, os padrões
obedecer também aos elevados requisitos de pre-
servação do meio ambiente.
hecimentos mais modernos poderá garantir um
funcionamento perfeito e elevada confiabilidade.
mais elevados de qualidade.
As peças e partes componentes substituíveis
it
DEUTZ são equivalentes na sua função e confiabili-
dade às peças sobresselentes DEUTZ. nl
sv
da
SERVICE Precaução com o motor em Amianto
funcionamento
fn
No caso da acorréncia de uma avaria operacional e Proceder aos trabalhos de manutenção e às repa- As vedações utilizadas neste
no
de possíveis consultas relacionadas com peças e rações apenas com o motor parado. Após termina- motor encontram-se isentas de
partes sobressalentes, queira dirigir-se a uma das
nossas representantes autorizadas do Service. O
dos os trabalhos haverá que montar de novo os di-
spositivos protectores eventulamente removidos.
amianto. Empregue, por favor, as
correspendentes peças e partes
el
nosso pessoal especialízado e bem treinado procu-
rara, em caso de uma avaria, proceder a uma repa-
No caso de trabalhos com o motor em funciona-
mento, a roupa de trabalho deverá estar bem aju-
sobressalentes quando dos trabal-
hos de manutenção e conserto. tr
ração rápida e tecnicamente eficiente, empregando stada ao corpo. Nunca se deverá deixar o motor a
peças e partes originais. trabalhar num recinto fechado, porque existe o pe-
rigo de intoxicação.
ru
ar
pl
3 pt © 2000
S1057
Descrição do motor
de
en 1. Placa do fabricante 2. Localização da placa do fabricante 3. Número de motor
fr
es
A B
pt
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
O modelo A, o número do motor B e os dados de po- A placa do fabricante C encontra-se fixada ao O número do motor encontra-se gravado no cárter
no tência encontram-se gravados na placa do fabri-
cante. Quando da aquisição de peças sobres-
cárter. e na placa do fabricante.
selentes deverão ser indicados o modelo e o

el número do motor.
tr
ru
ar
pl
© 2000 4 pt
S1057
Encomenda de peças sobressalentes
de
Dados necessários para a encomenda: en
Encomenda de peças
Para encomendar as peças originais DEUTZ é
necessário indicar os seguintes dados: sobressalentes fr
- Nº do motor Nº do motor es
Nº de
- Nº de identificação Num. peças Nº - ident. Observações Módulo pt
- Nº de peças
Organização dos documentos

it
- As figuras representativas das peças sobres- nl
salentes estão agrupadas pelos módulos do
motor. sv
- Os elementos comostos são aprentados na
vista de conjunto do motor. da
- O Nº de identifiçao 06/59 é formado a partir do
número do módulo (por ex. 06) e da posição
Posição
fn
(por ex. 59):
Explicação dos símbolos

no
-06- Número dos elemento (p.ex. 06) el
000 Algarismo de mudança (p.ex. 000)
tr
96 Número de página (p.ex. 96)
Indicação transversal referente à página

ru
94 de continuação (p.ex. 94)
ar
A Símbolo de ligação
- introduzir sempre, no mínímo, em pares
(p.ex. A-A, B-B, C-C etc.)
pl
5 pt © 2000
S1057
Service
de
en A saber, é a DEUTZ. Nº de encomenda: 0312 0806
fr Desde sempre que a DEUTZ é responsável por

progressos revolucionários na construção de
motores. Como fabricante de motores indepen-
es dente oferecemos em todo o mundo uma completa
paleta de motores a Diesel e a gás numa gama de
pt potência de 4 a 7.400 kW. Os nossos produtos são
perfeitamente cortados à medida exacta das
exigências dos nossos clientes.
it Em todo o mundo mais de 1,4 milhões de motores
DEUTZ executam o seu serviço com segurança.
nl Queremos conservar a disponibilidade de aplicação
dos nossos motores e com ela a satisfação dos
sv nossos clientes. É por isso que estamos
representados em todo o mundo com uma rede de
associados competentes cuja consistência corresponde
da à distribuição regional dos nossos motores.
Deste modo, DEUTZ é não só o nome de motores com

fn espírito inventivo, como também de um completo
conjunto de serviços relacionados com o motor e de Nº de encomenda: 0312 0807 (CD-ROM)
no uma assistência técnica na qual você pode confiar.
O catálogo Sales & Service oferece-lhe um

el panorama sobre o associado da DEUTZ mais perto
de si, acerca das suas competências de produtos e A adquirir directamente no seu serviço de DEUTZ AG
da prestação de assistência técnica. Mas também assistência técnica ou na: Deutz-Mülheimer Str. 147-149
tr quando não se observa nenhuma competência
directa de produtos, o associado da DEUTZ continua
D-51057 Köln
ru a ajudá-lo com um aconselhamento competente. Telefone: 0049-221-822-0

Fax: 0049-221-822-5304
O catálogo é permanentemente actualizado; peça Telex: 8812-0 khd d
ar ao seu associado da DEUTZ a edição mais recente. http://www.deutz.de
A sua Deutz AG
pl
© 2000 6 pt
S1057
Listino parti di ricambio
2012
Timbro del concessionario
0312 0836
Numero del
motore:
Voglia annotare qui il numero del motore. In questo

modo faciliterà il disbrigo in caso di questioni
relative all’assistenza tecnica, alla riparazione ed
ai pezzi di ricambio.
Rispetto all’illustrazione ed alle indicazioni di

questa lista dei pezzi di ricambio, ci si riserva
quelle modifiche tecniche che sono necessarie
per migliorare i motori. Per la ristampa e la
riproduzione di qualsiasi tipo è necessaria la
nostra autorizzazione scritta.
1 it © 2000
© 2000
S1057
Prefazione
de
en Egregio cliente, I componenti elencati in questa lista di pezzi di
ricambio devono essere utilizzati soltanto per la
fr i motori DEUTZ raffreddati ad agua sono stati svi-
luppati per un ampio spettro d’uso. Grazie ad una
riparazione di motori Deutz della serie denominata
(uso conforme alla destinazione).
vasta offerta di varianti viene garantito che verrà Il libretto di istruzioni (lavori di manutenzione) ed
es fatto fronte alle rispettive esigenze particolari. il manuale per officine (lavori di riparazione)
forniranno delucidazioni dettagliate sul montaggio
pt Il Suo motore è allestito secondo lo specifico caso
di montaggio, vale a dire che non tutti gli elementi
corretto dei pezzi di ricambio. Il fabbricante non si
assume nessuna responsabilità per danni o lesioni
ed i componenti illustrati nel Suo listino dei pezzi di a persone dovuti all’inosservanza delle relative
it ricambio sono integrati nel Suo motore. istruzioni.
Nonostante i grafici non siano illustrati con tutti i

nl dettagli, si possono distinguere chiaramente le
singole varianti, così che è facile trovare con facilità
sv il pezzo di ricam-bio importante per il Suo motore.
In ogni caso verrà rilevato il pezzo di ricambio
giusto tramite numero di posizione, di gruppo di
da assemblaggio e di motore.
Per l’ordinazione di pezzi di ricambio voglia osserva-

fn re le nostre indicazioni per l’ordinazione al fine di
permetterci di fornirle in modo celere e sicuro i
no pezzi di ricambio necessari nella relativa versione,
conforme all’ultima modifica.
el Siamo a Vs. completa disposizione per eventuali

chiarimenti.
tr Sua
ru DEUTZ AG
ar
pl
© 2000 2 it
S1057
Prefazione
de
I motori Diesel DEUTZ I pezzi di ricambio DEUTZ Componenti intercambiali DEUTZ en
fr
sono il prodotto di numerosi anni di ricerca e sono soggetti alle stesse severe esigenze quali- I componenti intercambiabili DEUTZ
sviluppo. Il solido know how così ottenuto in
combinazione con elevate esigenze qualitative è la
tative poste ai motori DEUTZ. I perfezionamenti
atti a migliorare i motori vengono naturalmente
sono un’alternativa economica ai
pezzi di ricambio originali.
es
garanzia per la fabbricazione di motori aventi
lunga durata, elevata affidabilità ed un basso
introdotti anche per i pezzi di ricambio originali.
Soltanto l’uso di pezzi di ricambio originali, fab-
Naturalmente anche qui, come per i
pezzi nuovi, valgono massimi criteri pt
consumo di combustibile. E’naturale che si faccia bricati secondo le più attuali conoscenze, offre la qualitativi. I componenti intercambiablili DEUTZ
fronte anche alle elevate esigenze a favore della
protezione ambientale.
garanzia di un perfetto funzionamento e di elevata
affidabilità.
sono equivalenti ai pezzi di ricambio per ciò che
concerne il loro funzionamento ed affidabilità.
it
nl
sv
da
SERVICE Prudenza con il motore acceso Ambianto
fn
In caso di avarie o richieste di ricambi, rivolgersi Eseguire i lavori di manutenzione o di riparazione Le guarnizioni utilizzate per questo
no
immediatamente ai nostri Centri di Assistenza solo con motore spento. Al termine dei lavori ri- motore sono senti da amianto.
autorizzati. Per non diminuire la sicurezza di
funzionamento, tutti i lavori devono essere
montare i dispositivi di sicurezza eventualmente
asportati. Per lavori da eseguire con il motore ac-
Per i lavori di manutenzione e di
riparazione fate uso degli appositi
el
effettuati da personale specializzato servendosi
dell’impiego di ricambi originali.
ceso, l’abbigliamento da lavoro deve aderire bene
al corpo. Fare rifornimento di combustibile solo
ricambi.
tr
con motore spento. Non lasciare il motore acceso
in locali chiusi – pericolo di avvelenamento. ru
ar
pl
3 it © 2000
S1057
Descrizione del motore
de
en 1. Targhetta di fabbricazione 2. Posizione della targhetta di 3. Numero del motore
fr fabbricazione
es
A B
pt
it
nl
sv
C
da © 26 332 3 © 31 488 0 © 31 823 0
fn
Il tipo di costruzione A, il numero del motore B ed La targhetta di fabbricazione C è fissata all’incastel- Il numero del motore è stampigliato sia
no i dati tecnici sono stampigliati sulla targhetta di
fabbricazione. Per l’acquisto di pezzi di ricambio,
latura. sull’incastellatura come pure sulla targhetta di
fabbricazione.
bisogna indicare il tipo di costruzione ed il numero
el del motore.
tr
ru
ar
pl
© 2000 4 it
S1057
Ordinazione di pezzi di ricambio
de
Dati di ordinazione en
Ordinazione di pezzi
Per l’ordinazione di pezzi di ricambio originali
DEUTZ, indicare sempre i seguenti dati:
di ricambio fr
- No. del motore No. del motore: es
- Codice d’identificazione No. Cod.
- Unità
progr. Unitá d’identif. Note Gruppo construttivo pt
Struttura della docomentazione it
- Le tavole di questa lista dei pezzi di ricambio
sono suddivise secondo i gruppi costruttivi nl
dei motori
- Gli elementi costruttivi sono specificati nella

sv
vista panoramica del motore
- Il codice d’identificazione 06/59 è costituito dal

da
gruppo costruttivo (per es. 06) e dalla posizione
(per es. 59)
Posizione
fn
Legenda no
Numero dell’elemento costruttivo
-06- (ad esempio 06) el
000 Numero variabile (ad esempio 000)
Numero della pagina (ad esempio. 96)

tr
96
94
Riferimento incrociato alla pagina di ru
continuazione (ad esempio 94)
Simbolo di collegamento
ar
A - compare sempre almeno a coppie
(ad esempio A-A, B-B, C-C, ecc.) pl
5 it © 2000
S1057
Service
de
en DEUTZ: un nome che vuol dire eccellenza! No. d’ordine 0312 0806
fr DEUTZ, da sempre sinonimo di innovazione nel

settore della fabbricazione dei motori, è un
fabbricante indipendente che offre sul mercato
es mondiale una gamma completa di motori diesel
ed a gas di potenza compresa fra 4 e 7400 kW.
pt Noi forniamo prodotti perfettamente adatti alle
specifiche esigenze dei nostri clienti.
it Oggi, più di 1,4 milioni di motori DEUTZ sono in

attività in tutto il mondo. Noi perseguiamo un
duplice obiettivo: garantire la massima affidabilità
nl dei nostri prodotti e garantire un elevato livello di
soddisfazione ai nostri clienti. Ecco perché
sv abbiamo istituito una rete mondiale di partner, la cui
densità è funzione diretta del numero di motori
in attività in ciascuna regione.
da DEUTZ non è solamente un marchio innovatore di
motori, ma anche una gamma completa di servizi in
fn grado di accentuare le loro caratteristiche di affi-
dabilità ed un nome su cui potrete sempre contare. No. d’ordine 0312 0807 (CD-ROM)
no Il registro Sales & Service vi fornisce una pano-
ramica dei partner DEUTZ più vicini, inclusa la
el gamma di servizi offerti e le famiglie di prodotti per
cui essi possono assicurarvi una manutenzione Reperibile attraverso il Vostro Partner Service DEUTZ AG
specializzata. Qualora non potessero fornirvi un locale oppure presso la: Deutz-Mülheimer Str. 147-149
tr aiuto diretto, potranno in ogni caso consigliarvi con
competenza.
D-51057 Köln
ru Il registro è sottoposta ad un regolare aggior-

Telefono: 0049-221-822-0
Telefax: 0049-221-822-5304
namento. Se necessario, potrete ottenerne l‘edizione Telex: 8812-0 khd d
ar più recente rivolgendovi al vostro partner DEUTZ. http://www.deutz.de
Il Vostro DEUTZ AG
pl
© 2000 6 it
S1057
Onderdelenlijst
2012
Stempel handelaar
0312 0836
Motornummer:
Geeft u hier a.u.b. het motornummer aan. De behan-

deling van klantenservice-, reparatie- en onderde-
lenkwesties wordt daardoor vereenvoudigd.
Wat de betreft de tekeningen en gegevens in deze

onderdelenlijst blijven technische veranderingen
die ter verbetering van de motoren noodzakelijk
worden, voorbehouden. Elke vorm van nadruk of
vermenigvuldiging, ook bij wijze van uittreksel,
mag uitsluitend met onze schriftelijke toestemming
plaatsvinden.
1 nl © 2000
© 2000
S1057
Voorwoord
de
en Geachte klant, De constructiedelen in deze onderdelenlijst mogen
alleen worden gebruikt worden reparatie van Deutz
fr de vattengekoelde DEUTZ-motoren zijn ontwikkeld voor
een breed spectrum aan toepassingsmogelijkheden.
motoren uit de vermelde bouwserie (gebruik
volgens de voorschriften).
Daarbij wordt door een uitgebreid aanbod variaties Uitvoerige informatie over de correcte inbouw van
es gewaarborgd, dat steeds kan worden voldaan aan
de desbetreffende speciale vereisten.
onderdelen is te vinden in de gebruiksaanwijzing
(onderhoudswerkzaamheden) en de
pt Uw motor is voor de individuele inbouwsituatie uit-
werkplaatshandleiding (reparaties). Voor schade
of persoonlijk letsel dat te wijten is aan niet-
gerust. Dat wil zeggen dat niet alle onderdelen uit de naleving van de desbetreffende voorschriften, is de
it lijst en niet alle componenten voor uw motor van
toepassing zijn.
fabrikant niet aansprakelijk.
nl Hoewel de grafieken niet met alle details weeggege-

ven zijn, kunnen de verschillende uitvoeringen
sv duidelijk onderscheiden worden, zodat u het voor uw
motor rele-vante onderdeel gemakkelijk kunt vinden.
Via positie-, constructie- en motornummer wordt
da in ieder geval het juiste onderdeel bepaald.
Let u bij de bestelling van onderdelen a.u.b. op

fn onze bestelgegevens. Dan kunnen wij u snel en
betrouwbaar de nodige onderdelen op de meest
no actuele stand in overeenstemming met de
uitvoering leveren.
el Voor nadere inlichtingen staan we U graag met

raad en daad terzijde.
tr Met vriendelijke groeten

ru DEUTZ AG
ar
pl
© 2000 2 nl
S1057
Voorwoord
de
DEUTZ-Dieselmotoren DEUTZ Onderdelen DEUTZ tweedehands componenten en
fr
zijn het produkt van vele jaren research en enginee- ondergaan dezelfde strenge kwaliteitscontroles als Tweedehands DEUTZ componen-
ring. Het hierdoor gewonnen, gefundeerde know
how in verbinding met hoge kwaliteitseisen is de
de DEUTZ motoren. Nieuwe ontwikkelingen ter
verbetering van de motoren vinden natuurlijk ook
ten vormen een voordelig alter-
natief voor originele onderdelen.
es
garantie voor de vervaardiging van motoren met
een lange levensduur, hoge betrouwbaarheid en
hun neerslag bij vervangende DEUTZ onderdelen.
Alleen het gebruik van originele DEUTZ onderdelen
Natuurlijk gelden ook hier, net als
bij nieuwe onderdelen, zeer hoge kwaliteitsmaat- pt
een laag brandstofverbruik. Het is vanzelfsprekend die aan de nieuwste ontwikkelingen zijn aangepast, staven. Wat functie en betrouwbaarheid betreft, zijn
dat ook aan de hoge eisen met betrekking tot de
milieubescherming voldaan wordt.
garanderen een onberispelijke functie en een hoge
betrouwbaarheid.
tweedehands DEUTZ componenten gelijkwaardig
aan nieuwe onderdelen.
it
nl
sv
da
SERVICE Voorzichtig bij draaiende motor Asbest
fn
Wendt U zich bij berijfsstoringen en bij vragen om- Onderhoudswerkzaamheden en reparaties alleen De pakkingen in deze motor bevat-
no
trent reserveonderdelen tot een van onze Service- bij uitgeschakelde motor doorvoeren. Eventueel ten geen asbest. Gebruikt u bij
vertegenwoordigingen. Ons geschoold vakperso-
neel zorgt in geval van defecten voor snelle en
verwijderde beschermplaten enz. moeten na de
werkzaamheden weer gemonteerd worden. Bij
onderhouds en reparatiewerk-
zaamheden a.u.b. onderdelen van
el
vakkundige reparatie met originele onderdelen. werken aan de draaiende motor moet nauw slui-
tende werkkleding worden gedragen. Motor nooit
dezelfde kwaliteit.
tr
in gesloten ruimten laten lopen – vergiftigingsge-
vaar. ru
ar
pl
3 nl © 2000
S1057
Beschrijving van de motor
de
en 1. Firmaplaat 2. Plaat van de firmaplaat 3. Motornummer
fr
es
A B
pt
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
De constructievorm A, het motornummer B en de De firmaplaat C is aangebracht aan de carter. Het motornummer is op de carter en op de firma-
no vermogensgegevens zijn op de firmaplaat
gestempeld. Bij bestelling van onderdelen moeten
plaat gestempeld.
constructieserie en motornummer worden aan-

el gegeven.
tr
ru
ar
pl
© 2000 4 nl
S1057
Bestelling von onderdelen
de
Bestelgegevens en
Bestellen van
Bij bestelling van originele DEUTZ onderdelen
dienen de volgende gegevens verstrekt te worden: onderdelen fr
- motornummer Motornr.: es
- identificatienummer Nr. Stuks Ident.nr. Opmerking module pt
- aantal
it
Dokumentationsaufbau
- De afbeeldingen in deze onderdelenlijst zijn
nl
geordend naar deelsamenstelling.
sv
- De constructiegroepen zijn in het overzicht van
de motoren vermeld.
da
- Het identificatienummer (bijv. 06/59) is
opgebouwd uit de deelsamenstelling (bijv. 06),
gevolgd door de positie (bijv. 59).
positic
fn
Verklaring van de symbolen
no
-06- Nummer van de constructiegroep (b.v. 06) el
000 Modificatie cijfer (b.v. 000)
tr
96 Paginanummer (b.v. 96)
Kruisverwijzing naar de volgende pagina

ru
94 (b.v. 94)
ar
A Anslutningssymbol
- verschijnt altijd ten minste paarsgewijs
(b.v. A-A, B-B, C-C etc.)
pl
5 nl © 2000
S1057
Service
de
en Te weten, het is DEUTZ. Bestelnr.: 0312 0806
fr Van oudsher staat Deutz in verband met baan-

brekende ontwikkelingen in de motorconstructie.
Als onafhankelijke motorenfabrikant bieden wij
es wereldwijd een compleet assortiment van diesel-
en gas-motoren met een vermogen van 4 tot
pt 7.400 kW aan. Onze producten zijn voortreffelijk op
de eisen van onze klanten afgestemd.
it Wereldwijd verrichten meer dan 1,4 miljoen DEUTZ

motoren precies hun functie. Wij willen de
bedrijfsvaardigheid van onze motoren en daardoor
nl de tevredenheid van onze klanten bewaren. Om die
redenen zijn wij wereldwijd vertegenwoordigd met
sv een net van competente partners waarvan de
dichtheid met de regionale distributie van onze
motoren overeenstemt.
da Zo is DEUTZ niet alleen de naam voor inventieve
motoren maar ook voor een compleet prestatie-
fn pakket omtrent de motor en een service waarop u
kunt vertrouwen. Bestelnr.: 0312 0807 (CD-ROM)
no Het register Sales & Service geeft u een overzicht
over de DEUTZ partners in uw buurt, over hun
el product-competenties en serviceprestaties. Maar
ook als er geen directe product-competentie is Verkrijgbaar via uw competente servicepartner ter DEUTZ AG
vermeldt, helpt de DEUTZ partner u verder met een plaatse of bij: Deutz-Mülheimer Str. 147-149
tr competent advies. D-51057 Köln
ru Het register wordt permanent geactualiseerd;

vraag bij uw DEUTZ partner naar de meest recente
Tel.: 0049-221-822-0
Fax: 0049-221-822-5304
uitgave. Telex: 8812-0 khd d
Uwe DEUTZ AG
pl
© 2000 6 nl
S1057
Reservdelslista
2012
Närmaste DEUTZ-representant
0312 0836
Motornumret:
För in motornumret här. Du underlättar härigenom

lösning av service-reparations- och reservdelsfrå-
gor.
Vi förbehållar oss rätt till förbättringar av motorerna

utan att därför ändra i denna reservdelslista. För ef-
tertryck och kopiering av något slag fordras vårt
skriftliga medgivande.
1 sv © 2000
© 2000
S1057
Förord
de
en Bäste kund, De i denna reservdelslista upptagna komponenter
ska endast användas vid reparationer på Deutz-
fr DEUTZ vaterkylda motorer har utvecklats för ett
stort användningsområde. Därvid har genom
motorer av angiven typ.
Ur instuktionsboken framgår utförligt hur
många varianter säkerställts att olika speciella for- reservdelarna ska monteras. För motor- och
es dringar uppfylls. personskador som orsakas av felmontering
ansvaras ej.
pt Din motor är utrustad för motsvarande inbyggnad,
d v s alla i reservdelslistan upptagna komponenter
finns ej med på Din motor.
it Trots att alla detaljer inte framgår kan de olika vari-
anterna urskiljas så att delarna för Din motor lätt går
nl att hitta. Med komponentbild- och motornummer
får man i varje fall fram rätt reservdel.
sv Observera vid beställning av reservdelar våra anvis-
ningar så att dessa snabbt och säkert kan levereras
da i senaste utförande.
Vid förfrågningar står vi gärna förfogande.

fn
DEUTZ AG
no
el
tr
ru
ar
pl
© 2000 2 sv
S1057
Förord
de
DEUTZ-dieselmotorer DEUTZ-reservdelar DEUTZ utbyteskomponenter en
fr
är produkter av årslånga forskningar och utveck- underkastas lika stränga kvalitetsfordringar som Deutz utbyteskomponenter är ett
lingar. Därigenom vunnet know how tillsammans
med höga kvalitetsfordringar är garanti för tillver-
DEUTZ-motorerna. Vidareutveckling för förbätt-
ring av motorerna görs naturligtvis också på ori-
prisvärt alternativ till original-
reservdelar. Här gäller självklart
es
kning av motorer med lång livslängd, hög tillförlit-
lighet och låg bränsleförbrukning. Självklart upp-
ginal reservdelar. Bara användning av de senaste
originalreservdelar garanterar rätt funktion och
öckså som för nya delar högsta
kvalitet. DEUTZ utbyteskomponen- pt
fylls också kraven på miljöskydd. hög tillförlitlighet. ter är i funktion och tillförlitlighet likvärdiga med
Deutz reservdelar. it
nl
sv
da
SERVICE Försiktighet vid motor som är igång Asbest
fn
Vänd er till en av våra servicerepresentanter vid Skötsel eller reparationer får bara utföras vid stilla- Tätningar som används i denna
no
störningar och reservdelsproblem. Vår specialutbil- stående motor. Montera ev borttagna skydd efter motor är asbestfria. Använd så-
dade personal reparerar snabbt och riktigt med
originalreservdelar vid behov.
avslutat arbete. Se vid arbete med motor som är
igång till att arbetskläder ej sitter löst.
dana reservdelar även vid under-
hålls- och reparationsåtgärder.
el
Tanka alltid vid stillastående motor. Kör aldrig mo-
tor i slutna rum – förgiftningsrisk. tr
ru
ar
pl
3 sv © 2000
S1057
Motorbeskrivning
de
en 1. Typskylten 2. Typskyltens placering 3. Motornummer
fr
es
pt A B
it
nl
sv
C
da
© 26 332 3 © 31 488 0 © 31 823 0
fn
Typen A, motornumret B och motordata finns på Typskylten C är fäst på vevhuset. Motornumret är instämplat på vevhuset och på
no typskylten. Vid reservdelsbeställning måste typ och
motornummer anges.
typskylten.
el
tr
ru
ar
pl
© 2000 4 sv
S1057
Beställning av reservdelar
de
Beställningsuppgifter en
För beställning av DEUTZ original reservdelar krävs
följande uppgifter:
Reservdelsbeställning fr
- Motor-nr. Motornr.: es
- Id-nr. Löpnr. Aantal Id-nr. Anmärkning Funktionsgrupp pt
- Antal
it
Dokumentationens uppbyggnad
nl
- Illustrationerna i denna reservdelslista är
sorterade enligt motorns funktionsgrupper. sv
- Konstruktionsgrupperna kommer fram i motor-
listan. da
- Id-numret 06/59 består av funktionsgrupp
(t.ex. 06) och position (t.ex.59).
Position
fn
Symbolerförklaring
no
-06- Konstruktionsgruppnummer (t.ex. 06) el
000 Förändringsnummer (t.ex. 000)
tr
96 Sidnummer (t.ex. 96)
Korsreferens på fortsättningssidan
ru
94 (t.ex. 94)
ar
A Anslutningssymbol
- kommer alltid fram parvis
(t.ex. A-A, B-B, C-C, o.s.v.)
pl
5 sv © 2000
S1057
Service
de
en Att veta, det är DEUTZ Bestell-Nr.: 0312 0806
fr Sedan gammalt står DEUTZ för banbrytande

nytänkande inom motorkonstruktion. Som obero-
ende motortillverkare saluför vi världsom-
es spännande ett komplett sortiment av diesel- och
gasmotorer i effektområdet från 4 till 7400 kW. Våra
pt produkter är skräddarsydda efter våra kunders
krav.
it Över hela världen uträttar mer än 1,4 miljoner

DEUTZ-motorer tillförlitligt sin tjänst.
Insatsberedskapen hos våra motorer och därmed
nl våra kunders belåtenhet vill vi bevara. Därför
representeras vi över hela värden av ett nät av
sv kompetenta partners, vars täthet tillmötesgår våra
motorers regionala distribution.
da Därför är DEUTZ inte bara namnet för motorer med

kreativitet, utan också för ett komplett arbetspaket
runt om motorn och en service, som ni kan lita på.
fn Registret över Sales & Service ger en överblick över Bestell-Nr.: 0312 0807 (CD-ROM)
no DEUTZ-partners i er närhet, över deras produkt-
kompetensområden och servicetjänster. Men även
om inget direkt produktkompetensområde är
el noterat, hjälper DEUTZ-partnern er vidare med
kompetent rådgivning. Kan beställas hos er lokala Deutz-partner eller hos: DEUTZ AG
tr Registret uppdateras kontinuerligt; fråga er
DEUTZ-partner om den senaste upplagan.
D-51057 Köln
ru Telefon:
Telefax:
0049-221-822-0
0049-221-822-5304
Er Deutz AG Telex: 8812-0 khd d
pl
© 2000 6 sv
S1057
Reservedelsliste
2012
Forhandlerens stempel
0312 0836
Motornummer:
Notér motornummeret her. Derved lettes afvik-

lingen i forbindelse med serviceværksted, repara-
tion og bestilling af reservedele.
Ret til tekniske ændringer, som bliver nødvendige til

forbedring af motorerne, forbeholdes. Eftertryk og
mangfoldiggørelse af enhver art, også i uddrag, kun
tilladt med vores skriftlige samtykke.
1 da © 2000
© 2000
S1057
Forord
de
en Kære kunde! De i denne reservedelsliste angivne komponenter
må kun anvendes til reparation af Deutz motorer i
fr De væskekølede motorer fra firmaet DEUTZ er udvik-
let til et bredt anvendelsesspektrum. Derved sikres
den anførte serie (formålsrelevant anvendelse).
Detaljer vedrørende den korrekte montering af
det på grund af det omfattende udbud af varianter, reservedele fremgår af instruktionsbogen (service)
es at de indivi-duelle specielle krav kan opfyldes. samt værkstedshåndbogen (reparation). Produ-
centen påtager sig intet ansvar for skader på
pt Deres motor er udstyret, så den svarer til brugstil-
fældet; d.v.s. at ikke alle elementer og komponenter,
personer eller ting som følge af, at bestemmelserne
i den relavante vejledning ikke er overholdt.
som er afbildet i denne reservedelsliste, er monteret
it på Deres motor.
Selv om de grafiske afbildninger ikke kan vises med

nl alle detaljer, kan man tydeligt se forskel på de enkelte
varianter, så De let kan finde de reservedele, som er
sv relevante til Deres motor. Ved hjælp of positions-,
type- og motornummeret kan man altid finde frem
til den rigtige reservedel.
da Første gang De bestiller reservedele, bedes De
bemærke vore bestillingshenvisninger, så vi hurtigt
fn og korrekt kan finde frem til de nødvendige reserve-
dele i den udfø-relse, som svarer til den nyeste
no ændringstilstand.
Vi står gerne til rådighed, hvis De har spørgsmål.

el
Deres
tr DEUTZ AG
ru
ar
pl
© 2000 2 da
S1057
Forord
de
DEUTZ-dieselmotorer Original dele DEUTZ udskiftningskomponenter en
fr
er produktet af mange års forskning og udvikling. underligger de samme strenge kvalitetskrav som DEUTZ-udskiftningskomponenter
Det velunderbyggede knowhow, vi dermed har vun-
det, i forbindelse med høje kvalitetskrav er Deres
DEUTZ-motorerne. Videreudviklinger til forbedring
af motorerne bliver naturligvis også anvendt ved
er et prisbilligt alternativ til origi-
nale dele. Selvfølgelig gælder
es
garanti for en produktion af motorer med lang leve-
tid, høj pålidelighed og lavt brændstofforbrug. Det
original dele. Kun hvis man anvender originale
dele, som er udfærdiget efter de nyeste erkendels-
også her de højeste kvalitetskrav
– som ved de nye dele. DEUTZ- pt
er en selvfølge, at de høje krav mht. beskyttelsen af er, har man sikkerhed for en upåklagelig funktion udskiftningskomponenter fungerer lige så godt
miljøet også opfyldes. og høj pålidelighed. og er lige så pålidelige som originale dele. it
nl
sv
da
SERVICE Forsigtig, når motoren løber Asbest
fn
I tilfælde af driftsforstyrrelser og ved reservedels- Vedligeholdelsesarbejder og reparationer må kun Pakningerne, som er anvendt til
no
spørgsmål kan De henvende Dem til en af vores an- gennemføres, når motoren er slået fra. Evt. fjernede denne motor, er asbestfrie. An-
svarlige service-repræsentationer. Vores skolede
fagpersonale sørger i tilfælde af skader for en hurtig
beskyttelsesanordninger skal atter monteres på,
når arbejderne er afsluttet. Ved arbejder med løb-
vend venligst ved vedligehol-
delses- og reparationsarbejde
el
og faglig korrekt istandsættelse under anvendelse
af originale dele.
ende motor må man ikke bære løsthængende tøj.
Der må kun fyldes brændstof på med motoren slået
tilsvarende reservedele.
tr
fra. Lad aldrig motoren løbe i lukkede rum – fare for
forgiftning. ru
ar
pl
3 da © 2000
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
S1057
Beschnitt Beschnitt
S1057
DEUTZ AG
Service-Technik
Instandhaltungstechnik Motoren
D-51057 Köln
Tel.: ++49 (0)2 21-8 22-0
Fax: ++49 (0)2 21-8 22-53 58
U4_Impr_2012_9957
http: //www.deutz.de
Printed in Germany
All rights reserved
1st Edition, © 11/02
We move your world. Order No.: 0312 0836
Beschnitt MAGENTA = HKS 14K SCHWARZ Beschnitt

F1012
F1012
F1012
F1012
DEUTZ 2012 FUEL & OIL 13715
FILTERS Page 1 of 1

1 44145 ENGINE OIL FILTER ELEMENT (SPIN ON) 1
2 44235 PRE FILTER ASSEMBLY (FUEL/WATER SEPARATOR) 1
3 44236 CARTRIDGE ONLY FOR 44235 (ITEM 2) 1
4 44239 GASKET SET ONLY FOR 44235 (ITEM 2) 1
5 44237 FUEL FILTER ELEMENT (SPIN ON) 2
6* 44252 FAN BELT (DEUTZ 2012) 1

11/05/07
17096
RADIATOR INSTALLATION
Page 1 of 2

08/22/07
17096
RADIATOR INSTALLATION
Page 2 of 2
1 465112 RADIATOR ASSEMBLY 1
2 43GH250 CLAMP 6
4 43GH400 CLAMP 4
5 12567-05 HUMP HOSE 2
6 19125-13 CHARGE AIR TUBE (RH) 1
7 12567-07 HUMP HOSE 1
8 43GH300 CLAMP 2
9 NA HOSE 2 ¾” ID A/R
11 605726 TUBE (COOLANT) A/R
12 12350-01 CHARGE AIR TUBE (LH) 1
15 605726 TUBE (COOLANT) A/R
16* 1185-09 WASHER (MOUNTING) 8
17* 84229 PRESSURE CAP 1
18* 10592-07 FLANGE (ADAPTER) 1
19* 465271 FAN (BLOWER) 1
20* 534606 SIGHT GAUGE 1
22* 18483-01 TANK (SURGE) 1
23* 12457-05 TUBE, SURGE TANK (OPTIONAL) 1

08/22/07
AIR INTAKE & EXHAUST 13753
SYSTEMS Page 1 of 1

1 94653 HOSE (3” ID) 1
2 12457-09 TUBE WELDMENT 1
3 12346-01 TUBE WELDMENT 1
4 604117 AIR INLET HOOD 1
5 604116 AIR CLEANER (10”) 1
6 604119 RUBBER ELBOW REDUCER (5” – 4”) 1
7 12456-01 EXHAUST FLANGE WELDMENT 1
8 19188-08 ELBOW (4”) 1
9 19188-07 EXHAUST TUBE WELDMENT 1
10 594993 PURIFIER 1
11 594570 SILENCER 1
12 15951-01 DIFFUSER WELDMENT 1
13* 605512 INDICATOR 1
*ITEM NOT SHOWN Updated:

11/05/07
11968
AIR CLEANER
Page 1 of 1

604116 AIR CLEANER (INCLUDES ITEMS 1-8) 1
1 604795 CUP/ASSEMBLY 1
2 604796 CLAMP ASSEMBLY 1
3 604797 PRIMARY ELEMENT 1
4 284052 SAFETY ELEMENT 1
5 604264 VACUATOR VALVE 1
6 604798 BAFFLE ASSEMBLY 1
7 604708 NUT ASSEMBLY 1
8 604799 O-RING 1
10 604117 INLET HOOD 1
11 604687 PRECLEANER 1
12 604118 MOUNTING BAND 2
Updated:
11/05/07
S1020
S1020
MANUAL INDEX
FRESNILLO
S/N 6975
12/27/07
5. DRIVE TRAIN
17055 TRANSMISSION
16922 TRANSMISSION MOUNTS
S1036 TRANSMISSION MAINTENANCE & SERVICE
MANUAL
13731 DRIVELINE INSTALLATION
17055
TRANSMISSION ASSEMBLY
Page 1 of 35
Updated:
05/25/07
17055
Page 2 of 35

CONVERTER HOUSING GROUP
465425 TRANSMISSION ASSEMBLY 1
1 244451 CONVERTER HOUSING ASSEMBLY 1
2 244452 SLEEVE (CONVERTER HOUSING) 2
3 244314 PIPE PLUG 1
4 244453 PIPE PLUG 1
5 244454 GASKET (CONVERTER HOUSING) 1
6 244455 SCREW (CONVERTER HOUSING) 18
7 244321 LOCKWASHER 18
8 244456 PIN (CONVERTER HOUSING) 1
9 244457 CLIP 2
10 24474 SCREW (CLIP) 2
11 244458 LOCKWASHER (CLIP) 2
12 24240 AIR BREATHER 1
13 244312 PLUG (INCLUDES ITEM 14) 5
14 24830 O-RING 5
15 244459 PIPE PLUG 1
16 244460 O-RING 1
17 244461 SCREW 1
Updated:
05/25/07
17055
Page 3 of 35
Updated:
05/25/07
17055
Page 4 of 35

CASE & REAR GROUP
1 244462 TRANSMISSION CASE (INCLUDES ITEMS 2-9) 1
2 244463 SUCTION TUBE (INCLUDES ITEM 7) 1
3 244464 O-RING (SUCTION TUBE) 1
4 24245 TUBE (LOW SPEED) 1
5 24337 SLEEVE 4
6 244465 TUBE (3RD) 1
7 244466 CLIP 1
8 24436 SCREW 1
11 24461 O-RING 1
13 244402 O-RING 1
14 244468 REAR COVER ASSEMBLY (INCLUDES ITEM 15) 1
16 24461 O-RING 1
17 244469 OIL BAFFLE 1
18 244470 GASKET (TRANSMISSION CASE) 1
19 24467 O-RING (CLUTCH PRESSURE TUBE) 4
20 24080 O-RING (CLUTCH PRESSURE) 1
21 244456 PIN (TRANSMISSION CASE) 2
22 244195 SCREW (REAR COVER) 20
23 244321 LOCKWASHER (REAR COVER) 20
24 24339 PLUG (MAGNETIC DRAIN) 2
25 23033 PLUG (DRAIN) 1
26 244459 PLUG (SPEED PORT) 2
27 244460 O-RING (SPEED PORT) 2
28 244461 SCREW (SPEED PORT) 2
30 244471 COVER 1
Updated:
05/25/07
17055
Page 5 of 35
31 244472 GASKET (COVER) 1
32 24191 SCREW (COVER) 2
33 244154 LOCKWASHER (COVER) 2
34 24255 DIPSTICK TUBE 1
35 24256 DIPSTICK 1
Updated:
05/25/07
17055
Page 6 of 35
Updated:
05/25/07
17055
Page 7 of 35

TURBINE SHAFT GROUP
1 244473 TURBINE SHAFT ASSEMBLY (INCLUDES ITEM 2) 1
2 24497 RETAINER RING 1
3 244474 BEARING 1
4 24258 SNAP RING 1
5 24257 WASHER 1
6 24086 RING 1
7 244475 RING (PISTON) 1
8 244476 SUPPORT (STATOR) 1
9 244477 SCREW (STATOR SUPPORT) 6
11 244669 OIL BAFFLE ASSEMBLY (INCLUDES ITEM 12) 1
12 244480 SEAL (OIL BAFFLE) 1
13 244481 RING (OIL BAFFLE SEAL) 1
14 244128 RING (OIL BAFFLE RETAINING) 1
Updated:
05/25/07
17055
Page 8 of 35

DRIVE PLATE GROUP
1 244443 DRIVE PLATE ASSEMBLY KIT (INCLUDES ITEMS 1-4) 1
2 NSS DRIVE PLATE 5
3 NSS DRIVE PLATE BACKING RING 1
4 NSS DRIVE PLATE MOUNTING SCREW & LOCKWASHER 10
Updated:
05/25/07
17055
Page 9 of 35

TORQUE CONVERTER
1 244482 TORQUE CONVERTER ASSEMBLY 1
2 24265 BEARING 1
3 244483 RING 1
4 24342 PLUG (TORQUE CONVERTER) 1
5 24077 O-RING 1
6 24524 RING (SNAP) 1
7 244484 RING (RETAINING) 2
Updated:
05/25/07
17055
Page 10 of 35

GEAR GROUP
1 244485 GEAR (REVERSE) 1
2 244670 GEAR (1ST) 1
3 244487 GEAR (LOW) 1
4 244488 GEAR (IDLER REAR) 1
5 244489 GEAR (IDLER FRONT) 1
6 244490 GEAR (OUTPUT) 1
Updated:
05/25/07
17055
Page 11 of 35

AUXILIARY PUMP DRIVE
1 244491 PUMP DRIVE BEARING SUPPORT 1
2 244492 BEARING SUPPORT SCREW 1
3 244493 PIN (BEARING) 1
4 244494 BEARING 1
5 24083 DRIVE GEAR BEARING RETAINING RING 1
6 244495 GEAR (AUX PUMP DRIVE) 1
7 244496 COVER (PUMP) 1
8 244497 GASKET (COVER) 1
9 244270 SCREW (COVER) 2
10 244498 LOCKWASHER (COVER) 2
Updated:
05/25/07
17055
Page 12 of 35

PUMP DRIVE GROUP
1 244491 PUMP DRIVE BEARING SUPPORT 1
2 244492 PIN (BEARING) 1
3 244493 SCREW (BEARING) 1
4 244494 BEARING 1
5 24083 RING (DRIVE GEAR) 1
6 244499 GEAR (CHARGING) 1
7 244500 GEAR (PUMP DRIVE) 1
8 24767 SHAFT (IDLER GEAR) 1
9 244501 BALL 1
10 24540 BEARING 1
11 24081 RING (BEARING LOCATING) 2
12 24227 RING (BEARING RETAINING) 2
Updated:
05/25/07
17055
Page 13 of 35
Updated:
05/25/07
17055
Page 14 of 35

FORWARD SHAFT GROUP
1 244502 FORWARD SHAFT DRUM ASSEMBLY 1
2 24280 CLUTCH PISTON (INCLUDES ITEMS 3, 4) 1
3 24206 CLUTCH PISTON SEAL (OUTER) 1
4 24207 CLUTCH PISTON SEAL (INNER) 1
5 24208 CLUTCH INNER DISC 8
6 24209 CLUTCH OUTER DISC 8
7 24277 SPACER (PISTON) 1
8 24279 CLUTCH DISC BACKING PLATE 1
9 24278 SNAP RING (BACKING PLATE) 1
10 24523 DISC SPRING ASSEMBLY (INCLUDES 5 WASHER) 1
11 24276 SNAP RING (SPRING RETAINING) 1
12 24347 FORWARD SHAFT PISTON RING 2
13 24275 FORWARD SHAFT PILOT BEARING 1
14 244503 BEARING 1
15 24283 GEAR RETAINING RING 1
16 244504 BEARING RETAINING RING 1
17 244670 GEAR (1ST DRIVE) 1
Updated:
05/25/07
17055
Page 15 of 35

REVERSE IDLER GROUP
1 244505 REVERSE IDLER SHAFT 1
2 24090 REVERSE IDLER GEAR BEARING 1
3 244506 WASHER 1
4 244507 NUT (BEARING RETAINER) 1
5 244508 WASHER (BEARING) 1
6 24872 LOCKBALL (IDLER SHAFT) 1
8 244510 O-RING (SHAFT) 1
Updated:
05/25/07
17055
Page 16 of 35
Updated:
05/25/07
17055
Page 17 of 35

ND
REVERSE & 2 SHAFT GROUP
ND
1 244511 REVERSE & 2 SHAFT DRUM ASSEMBLY 1
2 24280 CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 3 & 4) 1
3 24206 OUTER CLUTCH PISTON SEAL 1
4 24207 INNER CLUTCH PISTON SEAL 1
5 244331 CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 6 & 7) 1
12 24277 PISTON RETURN SPRING SPACER 1
14 24278 BACKING PLATE SNAP RING 2
15 24296 PISTON RETURN SPRING 1
16 24297 RETAINER (SPRING) 1
17 24523 DISC SPRING ASSEMBLY (INCLUDING 5 WASHER) 1
18 24298 SNAP RING (SPRING) 1
19 24293 BEARING (GEAR) 1
21 24292 RING (GEAR) 2
22 244512 BEARING 1
23 244190 RING (RETAINING) 1
24 24290 SNAP RING 1
27 244513 HUB (2ND CLUTCH) 1
28 24298 RING (2ND CLUTCH) 1
29 244514 BEARING 1
Updated:
05/25/07
17055
Page 18 of 35
30 244515 RETAINER (RING) 1
31 244516 RING (LOCATING) 1
32 244517 SPACER 1
Updated:
05/25/07
17055
Page 19 of 35
Updated:
05/25/07
17055
Page 20 of 35

LOW SPEED SHAFT GROUP
1 244518 LOW SHAFT HUB DRUM ASSEMBLY 1
2 24280 CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 3, 4) 1
3 24206 SEAL (CLUTCH PISTON OUTER) 1
4 24207 SEAL (CLUTCH PISTON INNER) 1
8 24300 BACKING PLATE RETAINING RING 1
9 24278 DISC SPRING ASSEMBLY (INCLUDES 7 WASHER) 1
10 24298 SNAP RING (SPRING RETAINER) 1
11 244520 SPACER (WASHER) 1
14 244522 RING (GEAR BEARING) 2
16 244524 BEARING 1
17 244525 SPACER (GEAR) 1
18 244526 BEARING 1
20 244527 RETAINER (WASHER) 1
21 244487 GEAR (LOW CLUTCH) 1
Updated:
05/25/07
17055
Page 21 of 35
Updated:
05/25/07
17055
Page 22 of 35

RD
3 SHAFT CLUTCH GROUP
RD
1 244529 3 CLUTCH SHAFT, DRUM & PLUG ASSEMBLY 1
2 244331 CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 3, 4) 1
7 24279 DISC BACKING PLATE 1
8 24278 BACKING PLATE SNAP RING 1
9 24296 PISTON RETURN SPRING 1
10 24297 SPRING RETAINER 1
11 24298 SPRING RETAINER SNAP RING 1
12 244190 FRONT BEARING RETAINING RING 1
13 244512 BEARING 1
14 24290 FRONT BEARING SNAP RING 1
RD
16 24347 HUB (3 CLUTCH) 1
RD
17 24300 RING (3 DISC HUB) 1
18 244514 BEARING 1
Updated:
05/25/07
17055
Page 23 of 35

IDLER SHAFT GROUP
1 244524 SHAFT (IDLER) 1
2 244474 BEARING 1
3 24258 SNAP RING (BEARING) 1
4 244530 BEARING 1
5 24064 NUT 1
6 24063 WASHER 1
7 24321 SPACER 1
8 24556 SNAP RING 1
9 244488 GEAR 1
10 244489 GEAR 1
Updated:
05/25/07
17055
Page 24 of 35
Updated:
05/25/07
17055
Page 25 of 35

OUTPUT SHAFT GROUP
1 244531 SHAFT OUTPUT 1
2 244532 BEARING OUTPUT SHAFT REAR 1
3 244533 BEARING OUTPUT SHAFT FRONT 1
4 244534 RING OUTPUT SHAFT REAR BEARING 1
5 24575 RING OUTPUT SHAFT REAR BEARING RETAINING 2
6 244235 SEAL OUTPUT SHAFT 2
7 24318 STUD BEARING CAP 4
9 24488 NUT STUD 4
10 244537 CAP OUTPUT SHAFT REAR BEARING 1
11 24491 O-RING OUTPUT SHAFT REAR BEARING 1
12 24490 O-RING OUTPUT SHAFT REAR BEARING 1
13 244538 SPACER GEAR 1
14 24321 SPACER GEAR 1
15 24489 O-RING FLANGE 1
16 24063 WASHER FLANGE 1
17 24064 NUT WASHER 1
18 24324 SPACER BEARING TO FLANGE 1
19 244490 GEAR OUTPUT 1
20 244450 FLANGE FRONT 1
21 24062 FLANGE REAR 1
Updated:
05/25/07
17055
Page 26 of 35

CHARGING PUMP GROUP
1 244539 CHARGING PUMP 1
2 24079 GASKET- PUMP ASSEMBLY TO CONVERTER HOUSING 1
3 24080 O-RING 1
4 244540 PUMP MOUNTING SCREW 1
4A 244541 PUMP MOUNTING SCREW 4
5 244321 PUMP MOUNTING SCREW LOCKWASHER 5
Updated:
05/25/07
17055
Page 27 of 35

OUTPUT FLANGE GROUP
1 24106 OUTPUT FLANGE (FRONT) 1
2 24062 OUTPUT FLANGE (REAR) 1
Updated:
05/25/07
17055
Page 28 of 35

REMOTE FILTER GROUP
244447 FILTER & ADAPTOR ASSEMBLY (INCLUDES ITEMS 1, 2) 1
1 244449 FILTER ADAPTOR 1
2 244448 FILTER (ELEMENT) 1
Updated:
05/25/07
17055
Page 29 of 35

CONTROL VALVE GROUP
(BEFORE TRANSMISSION S/N HBEA235758)
1 244671 ELECTRIC CONTROL VALVE ASSEMBLY 1
2 244335 GASKET 1
3 244334 SCREW 9
Updated:
05/25/07
17055
Page 30 of 35
Updated:
05/25/07
17055
Page 31 of 35

CONTROL VALVE ASSEMBLY
(BEFORE TRANSMISSION S/N HBEA235758)
244671 CONTROL VALVE ASSEMBLY ELECTRIC (12 VOLT) 1
244722 CONTROL VALVE ASSEMBLY ELECTRIC (24 VOLT) 1
1 244672 CONTROL VALVE HOUSING ASSEMBLY 1
2 244354 COVER CONTROL VALVE 1
3 244355 GASKET CONTROL VALVE COVER 1
4 244338 SPOOL FWD. & REV. SHIFT 2
5 244339 SPRING 2
RD
6 244361 SPOOL RANGE (3 ) 1
7 244467 VALVE HOUSING PLUG (INCLUDES ITEM 8) 2
8 244402 O-RING 2
9 244358 STOP SPOOL 1
10 244673 PIN 1
11 244360 PLUG STOP 1
12 244356 SPOOL RANGE (1ST & 2ND) 1
13 244339 SPRING 1
14 244542 PIPE PLUG 8
15 244453 PLUG 1
16 244674 SCREW 1
17 24495 SCREW 2
19 244675 SPOOL STOP 1
20 244676 FORWARD & REVERSE DECLUTCH SPOOL 1
21 244677 SPRING DECLUTCH 1
23 244159 O-RING 1
24 244139 CARTRIDGE BALL VALVE (INCLUDES ITEMS 25-27) 4
25 244682 O-RING 4
26 244406 O-RING 4
Updated:
05/25/07
17055
Page 32 of 35
27 244172 O-RING 4
28 244678 COIL (12 VOLT) 4
244408 COIL (24 VOLT) 4
29 244679 NUT 4
30 244407 O-RING 8
31 244680 COVER SOLENOID 1
32 244681 SPACER COVER 2
Updated:
05/25/07
17055
Page 33 of 35

1 244778 CONTROL VALVE ASSEMBLY 1
(STARTING WITH TRANSMISSION S/N HBEA235758)
2 244778-01 GASKET 1
3 244674 CAPSCREW 4
4 244289 CAPSCREW 3
5 244150 CAPSCREW 2
Updated:
05/25/07
17055
Page 34 of 35
Updated:
05/25/07
17055
Page 35 of 35

244778 CONTROL VALVE ASSEMBLY 1
(STARTING WITH TRANSMISSION S/N HBEA235758)
1 244776 DEUTSCH SOLENOID 24V (INCLUDES ITEMS 1A-1D) 4
1A 244776-01 O-RING 4
1B 244776-02 O-RING 4
1C 244776-03 O-RING 4
1D 244776-04 O-RING 4
2 244453 PLUG 8
3 NSS BODY 1
4 244778-02 SOLENOID COVER 1
5 244778-03 CAPSCREW 10
6 NSS EXPANSION PLUG 9
Updated:
05/25/07
16922
TRANSMISSION MOUNTS
Page 1 of 1

1 16954-03 TRANSMISSION MOUNT 1
2 16954-02 TRANSMISSION MOUNT 1
3 01GC10056 BOLT 4
4 02GE12 WASHER 8
5 01GC120128 BOLT 8
6 34014 RUBBER MOUNT 4
7 1185-08 WASHER 4
8 68GD10 NUT 4
Updated:
03/08/07
S1036
S1036
FOREWORD
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-HIGHWA Y PRODUCTS 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 wiii 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, troubleshooting
and adjustments, it is urged that the mechanic studies the instructions in this manuai carefuiiy and uses it as
a reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only SPICER OFF-HIGHWAYPRODUCTS

approved parts as listed in the applicable parts manual should be used. Use of "wiii-fit" or non-approved parts
may endanger proper operation and performance of the equipment. SPICER OFF-HIGHWA YPRODUCTS
does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not
supplied by or approved by SPICER OFF-HIGHWA Y PRODUCTS.
IMPORTANT
ALWAYS FURNiSH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS.
When checking the difference between a 6-speed with range shift, a 3-speed standard ratio and a 3-speed
deep ratio, you would notice that the difference is only on the idler and the output shaft.
.. ---"-'-A-3'~spe-e-c:r-'iIa'ncia-rdrs--si"iTlnaf-to-a--o-iweErd-Witlrrange-·shift·-w he n-- h igh--ran g e.. 1s-s el ected. ._._.

While a 3-speed deep ratio is similar to a 6-speed with range shift when low range is selected.
For this reason, we wiii use the 6-speed with range shift in most cases to explain the function of
the 3 different transmissions.
I
S1036
3-SPEED STANDARD RATIO

S1036
3-SPEED DEEP RATIO

S1036
6-SPEED RANGE SHIFT

S1036
Table of Contents
1. SAFETY PRECAUTIONS
2. CLEANING, INSPECTION AND LEGEND SYMBOLS

2.1 CLEANING 2-1
2.1.1 Bearings 2-1
2.1.2 Housings 2-1
2.2 INSPECTION 2-1
2.2.1 Bearings 2-1
2.2.2 Oil Seals, Gaskets, Etc 2-2
2.2.3 Gears and Shafts 2-2
2.2.4 Housing, Covers, etc 2-2
2.3 LEGEND SYMBOLS 2-2
3. TECHNICAL SPECIFICATIONS
3.1 IDENTIFICATION OFTHE UNIT 3-1
3.2 WEIGHT, DIMENSIONS, OIL CAPACITY 3-1
~~ .... _..... ~:J....ILG!:JIJ:J'!LN.G.I..QggI,JJ=..§..""'~.=••c".c,'c,,.c".c,.c,•.c"."c",,,,,,=,,,,,,,'c,,,,,,.c,:c.c,,,"c,,,,,,•.,,,,,,:3~~ ....._
3.3.1 Torque specifications for lubricated or plated screw threads 3·2
3.3.2 Elastic stop nut torque 3·3
3.3.3 "0" ring port plug torque chart 3·3
3.3.4 Pipe plug torque chart 3-3
3.3.5 Permanent metric plug torque chart 3·3
3.3.5 Coil and cartridge torque 3-4
3.4 PRESSURE AND TEMPERATURE SPECIFICATIONS 3·5
3.5 ELECTRICAL SPECIFICATIONS 3-6
3.6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS 3-6
4. MAINTENANCE
4.1 OIL SPECIFICATION 4-1
4.1.1 Recommended lubricants 4-1
4.2 MAINTENANCE INTERVALS 4-3
4.2.1 Daily 4-3
4.2.2 Normal drain period 4-3
4.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL 4-4
S1036
5. INSTALLATION DETAILS
5.1 CONVERTER DRIVE COUPLING 5-1
5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 5-2
5.3 EXTERNAL PLUMBING 5-3
5.3.1 Optional: remote filter 5-3
5.3.2 Cooler & filter lines specifications 5-3
5.4 SPEED SENSOR INSTALLATION 5-4
6. OPERATION OF THE TRANSMISSION

6.1 THE TRANSMISSION ASSEMBLY 6-1
6.1.1 The converter, pump drive section and pressure regulating valve 6-2
6.1.2 The input shaft and directional clutches 6-3
6.1.3 The range clutches 6-4
6.1.4 The output section 6-4
6.1.5 The transmission controls (refer to hydraulic diagram) 6-5
6.2 ELECTRIC SOLENOID CONTROLS 6-6
6.3 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT
6.3.1 Neutral, 3rd clutch engaged and high range selected 6-7
6.3.2 Forward 1st speed and high range selected 6-9
6.3.3 Forward 2nd speed and high range selected 6-11
6.3.4 Forward 3rd speed and high range selected 6-13
6.3.5 Reverse 1st speed and high range selected 6-15
6.3.6 Forward 1st speed and low range selected 6-17
6.4 GEAR AND CLUTCH LAY-OUT 6-19
6.4.1 3-Speed with standard ratio 6-19
6.4.2 3-Speed with deep ratio 6-20
6.4.2 6-Speed with range shift 6-21
7. TROUBLESHOOTING GUIDE FOR THE T20000 TRANSMISSION

7.1 T20000 TRANSMISSION 7-1
7.2 TROUBLESHOOTING PROCEDURES 7-1
7.2.1 Stall Test 7-1
7.2.2 Transmission pressure checks 7-2
7.2.3 Mechanical and electrical checks 7-2
7.2.4 Hydraulic checks 7-2
7.3 TROUBLESHOOTING GUIDE 7-3
7.3.1 Low clutch pressure 7-3
7.3.2 Low charging pump output 7-3
7.3.3 Overheating 7-3
7.3.4 Noisy converter 7-3
7.3.5 Lack of power 7-3
7.4 CHECK POINTS 7-4
7.5 SPEED SENSOR - STATIC STANDALONE TEST 7-7
S1036
8. SECTIONAL VIEWS AND PARTS IDENTIFICATION

GROUP - CONVERTER HOUSING 8-2
GROUP - TRANSMISSION CASE AND REAR COVER 8-4
GROUP - TURBINE SHAFT 8-6
GROUP - DRIVE PLATE 8-8
GROUP - TORQUE CONVERTER 8-1 0
GROUP - AUXILIARY PUMP DRIVE 8-12
GROUP - PUMP DRIVE 8-14
GROUP - FORWARD SHAFT 8-16
GROUP - REVERSE AND 2ND SHAFT 8-18
GROUP - REVERSE IDLER 8-20
GROUP - LOW SPEED SHAFT 8-22
GROUP - 3RD SHAFT 8-24
GROUP - IDLER SHAFT {USED IN 6 SPEED AND 3 SPEED WITH DEEP RATIO} 8-26
GROUP - IDLER SHAFT {USED IN 3 SPEED STANDARD RATIO} 8·28
GROUP - OUTPUT SHAFT {6 SPEED} 8-30
GROUP - OUTPUT SHAFT (3 SPEED STANDARD RATIO) 11-32
GROUP - OUTPUT SHAFT ( 3 SPEED DEEP RATIO) 11-34
GROUP - HI & LOW RANGE SHIFT CONTROL 11-36
GROUP - CHARGING PUMP & FILTER 8·38
GROUP - ELECTRIC CONTROL VALVE MOUNTING 8·40
GROUP - ELECTRIC CONTROL VALVE ASSEMBLy 8-42
9. ASSEMBLY INSTRUCTIONS
10. DISASSEMBLY AND REASSEMBLY T20000 LD TRANSMISSION
11. OPTIONS
11.1 HYDRAULIC ACTUATED AXLE DISCONNECT 11-1
11.1.1 Seclional views and parts identificalion 11-1
11.1.2 Assembly instructions 11·4
11.1.3 Disassembly of output shall with axle disconnect 11·5
11. 1.4 Rea ssem bly of output sha II with axl e discon nect 11-8
11.1.5 Disassembly of axle disconnect 11-11
11.1.6 Reassembly of axle disconnect 11-14
11.2 PARKING BRAKES 11-18
11.2.1 Mechanical Brake 11-18
11.2. 1. 1 Section al views and pa rts id entification 11-18
11.2.1.2 Adjustment and rebuild criteria 11-23
11.2.1.3 Replacing friction pads 11-23
11.2.1.4 Disassembly 11-24
11.2.1.5 Cleaning and inspection 11-24
11.2.1.6 Assembly 11·25
11.2.1.7 Replacing mount bushings 11-25
11.2.1.8 Servicing rolor assembly 11-25
S1036
11. OPTIONS (Continued)

11.2.2 Spring applied hydraulic released brake (high pressure) .» 11-26
11.2.2.1 Seclionat views and pa rts identificalion 11-26
11.2.2.2 Operation 11-31
11.2.2.7 Assembly 11-32
11.2.2.8 Inslallalion 11-33
11.2.2.9 Torque specs 11-33
11.2.3 Spring applied hydraulic released brake (low pressure) 11-34
11.2.3.1 Sectional views and parts identification 11-34
11.2.3.2 Operation 11-39
11.2.3.7 Assembly 11-40
11.2.3.8 Installation 11-41
11.2.3.9 Torque specs 11-41
12. SERVICE TOOLS

12.1 REVERSE IDLER SHAFT NUT SOCKET (TG 1304-54)
S1036
1. SAFETY PRECAUTIONS
To reduce the chance of personal injury and/or property damage, the following instruction must be carefully
observed.
Proper service and repair are important 10 the safety of tine service technician and the safe. reliable operation
of the machine. If replaceme nt parts are required the part mu st be repla ced by a spare pa rt wh ich has the
same part number or with an equlvalenl part. Do not use a spare part of lesser qualily.
The service procedures recommended in this manual are effective methods for performing service and
repa ir. Some of these proced ures req uire the use of tools specifi cally design ed for tine purpose.
Accordingly, anyone whD inlends 10 use a spare part, service procedure or 1001, which is not recommended
by SPICER OFF-HIGHWA YPRODUCTS, must first detemrine Ihal neitine r his safely no r the safe operation of
tine machine will be jeopardized by the spare part, service procedure or tool selected.
IMPORTANT
IT IS IMr:rrITA."lT TO llOTE TH.....T THIS M~Jm~L corfI~rjS V.o.\RiOUS 'CAUTtONS' u.;-D 'NOTICES' TH.A.T MUST BE
CAREFUllY OBS~"iED I rl ORDE R TO REDtKE TH E RI SK OF FERSOU~ INJURY OU RING SERVlCE OR REPAJ R,
00 TH E POSSI 81 LIT'{ l"H.A.T I',l PROPER EERvrcE OR REPA1R MAY DA.~.t!J,GE THE Url fT OR REJ.'DER IT UN SAF E.
IT lS AlSO IMPORTAhl" TO urm:::RS-T.l.J..'O THAT T;-1ES:::: 'CAUTIONS' J.1m 'NOTICES' A~E ~jOT EXHAUSTIVE,
BEC...'ill Sf: IT" IS I Pol POSS BLE TO ,....N~N ABC UT ~ll ill E POSS IoLE HAZ..ARDa US CON S=:0 UENe ES TH.....T III GHT RESULT
i=ROM F/OJlURE TO FOlta'"'' THESE 1N5TRucnorlS.
S1036
2. CLEANING, INSPECTION AND LEGEND SYMBOLS
2.1 CLEANING
Clean all parts th orou ghly usi ng solvent type cle aning II uid. II is re commen ded th at pa rts be imm ersed in
cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts
are tho roughly clea ned.
CAUTION
CARE SHOULD BE EXERCiSED TO AvmD SKIN- RASHES~ FIRE H.AL.!JR.DS, N~D tNHA1ATlm-i Or VAPour:;:s "','t+EN USL",IG
:sOl.. .'Et~T TYPE ClEMl ERS.
2.1.1 Bearings
Rem ove beari ng s from c1ea ni ng lIu id and strike lIat ag ain st a block of wood to dislodge so Ii dill ed pa rticles of
lubricant immerse again in cleaning fluid to lIush out particies. Repeat above operation until bearings are
thoTOu ghly ciea n. 0 ry bea ri ng s using moi sture-free compressed air. Be careful to direct air stream across
bearing to avoid spinning. 00 not spin bearings when drying. Bearings may be rotated slowly by hand to
fa cilitate drying pTOces s.
2.1.2 Housings
Clean interior and exterior of housings. bearing caps, etc..., thoroughly. Cast paris may be cieaned in hot
solution tanks with mild alkali solutions providing these paris do not have ground or polished surfaces.
Parts sh ou Id rem ain in solution Ion g enough to be tho roughly clean ed and heated. Th is vliIi aid the eva po ration
of the c1ea ning solution and ri nse water. Pa rts c1ea ned in solu tion tan ks mu st be th oroughIy rinsed with clean
water to remove aII traces 01 aIka11. Cast pa rls may also be cI ea ned with steam c1ea ner.
CAUTION
C~'\RE SHOULD BE EXE RC IS EO TO AVO: D IN:-tALATlorl OF VAPOU RS AND SKIN R.!I,S HES .....~EN US ING Al.J{II,L1 ClE.'JRERS.
All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soli, Iintless
absorbent \~;ping rags free of abrasive materials such as metalllliings. contaminated oil, or lapping compound.
2.2 INSPECTION
The importance 01 carelul and thorough inspection of all parts cannot be overstressed. Replacement 01 all
parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date.
2.2.1 Bea rings

Carefully inspect all rollers: cages and cups lor wear, chipping, or nicks to detemnine fitness 01 bearings for
further use. 00 not replace a bearing cone or cup indiVidually without replacing the mating cup or cone at the
same lime. After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or
paper to protect th emu ntil installed.
Cleaning, inspection and legend symbols
S1036
2.2.2 Oil Seals, Gaskets, Etc.

Replacement of spring load oil seals, "O"-rings, metal sealing rings, gaskets, and snap rings Is more economical
when unit is disassembled than premature overhaul to replace these parts at a luture time.
Further loss of lubricanl through a worn seal may result in failure of other more expensive parls 01 the
assembly. Sealing members shoutd be handled carefully, parlculariy when being installed. Culling, scratching,
or curlin gun der 0111p of seat seriously Impa Irs lIs elfid ency. When ass em bl ing new mela I type sea ling ring 5,
these should be lubricated with coat of chassis grease to stabilize rings In their grooves lor ease 01 assembly
of mating members. Lubricate all "O"-rings and seals wllh recommended type Automatic Transmission Fluid
before assem bl y.
2.2.3 Gears an d Sh afts

If magna-flux process is available, use process to check parts. Examine teeth on all gears carefully for wear,
pitting, chipping, nicks, cracks, or scores. If gear teeth show spots where case hardening is worn through or
cracked, replace wHh new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to
make cerla In th ey are not sprung, be nt, or splin es twisted, and lh at sh ails are true.
2.2-4 H0 us in g, Covers, etc.

Inspect housings, covers and bearing caps to ensure lhatthey are thoroughly clean and thai mating surfaces,
bearing bores, etc ..., are free from nicks or burrs. Check all parls carefUlly for evidence 01 cracks or conditions
which would cause subsequent oil leaks or failures.
2.3 LEGEND SYMBOLS
~
-Srrn-".3ggD di ~,.:.'1...."·gn:q:::l
[}~:;aUBTl-ti of <Is..!E:-:":'lbt1 .;....cu;;.;;
11
-,
Mc-r:t<ggi-:o di psr&:r::-!t:ri ir.;;.crrtrciU E-.1tare tErrl ~ nu~-a!W. dar.r~ ai psm

Rai~~ ~ r"'r.l::!'..::l"l p215 -.',ti:tJ f:-ad ct!lh:·dE..: j If-;:;u~rrl:}J C~..urd a;:;:::;O:.;.1 rrzt~i3t d.=rr~e, d=,-n=:-;;~ tu j:::-",rt3
! T= At:;-~tJre~~..,j P '" .r.;;¢r,:i
iT'" :S~-=-:±It-~01 P '" fa:;!:
f------~-".,--·I· R;'",,,",,,,",,,,,= ~ m7""~'

~
__ rl;:.t: ,=,,rer•.h::;·~ -::.~ inl~=l,;;~al
:1 I C",,,";:~:~:=---c·.:r-.'-r.;::J!-o-"-~~--J.::::;:--..;:.------f
i. rs~l rq:-:-:wro
1-~~----1r--~-'--'-'-~~'"
¢ E·"Ef":1..e'JT~tE- ri~'21:.t.i;b'€' (U!~~.. ·J.H-E- ~-<:! neUF~".;J)
?c·3.Sb'y s'!ii s~-..i-=-E-ilie, r·=·n",~- if r:-eCE""-5~f

S1036
3. TECHNICAL SPECIFICATIONS
SPICER OFF·H/GHWAY
TEt~ nmEl..E 3
B-B200-
I3ELGlUr.l
O!
MODEL .·.·>'i
\ SERIAL ,'co
3.1 IDENTIFICATION OFTHE UNIT

1. Model and type of the unit.
2. Serial nu m ber.
3.2 WEIGHT, DIMENSIONS, Oil CAPACITY

Weight (dry): ±174.6 kg (385 lb.)
T·model
Maximum length: 1015.6 mm (39.98")
Maximum width: 571.8 mm (22.51")
Max;mum heig hI: 1016.3 mm (40.01")
Oil capacity
±18.9 I (5.0 US Gallon) without cooler and hydraulic iines.
Consult operator's manual on applicable machine for system capacity.
Technical specificaUons
S1036
3.3 TIGHTENING TORQUES
3.3.1 Torque specifications for lubricated or plated screw threads
tlOM. SIZE GRADE 5 ED

FINETHREAO COAHSETHREAD
LBF· IT ~jm) LEF -IT IN·m)
.25W ~. \1 I !12-\5j 8-10 1\1-14]

.3125 16 - 20 I 122 - 27) 12 -16 1\6 - 22)
.3750 26 - 29 I 135 - 39j 23-25 (J\ - 34)
.4375 41-45 I 156· 01) 37 - 4j 150- 56)
.50({~ 64-70 I 187 ·95) 57 -63 177 - £5)
5625 ~1-IW 1123 -13£) 82-90 [1\1-122)
.620<1 118 -141 1174 -19\) 113 -124 1153 -le-5)
.15m 223 - 245 j301- 331) 200 - 21D [271-m)
tlOM. SIZE GRADES ®

1\
FINETHREAO COARSETHREAO
LSF -IT IRm) LEF - IT IN.m)
- -
i .25-00 11 -13 115-18) 9- 11 jl2-15)
.3125 28 - 31 130 - 43) 20-30 (JH1)
3750 37 -41 {~J - 56) 33 -:xl 145 - 49)
./315 ,·9 - 64 [79-87) 51- 57 [71- 77)
.50(-:! &3 -!tJ 1\22 -134) BO- 1·9 {1(~ -11~)
5625 128 -14\ 1\74 - 1~\) m-m I {1'.fi·172)

62503 11-03 -lga 1224 - 261) 159 - \7:i I 1118 - 237)
.75W 315 - 347 1m -4/G) 21-2 - 310 I 131-2· l 20)
NOM. SIZE GRADE a.a or 9,B GRAOE 10.9

cOARsETHREAD COARSE lli REAO
lBF - IT [N.mJ lBF - FT [NmJ
f.l6 15·20 ti--[] ~ 25] 22 - 26 PO - 35J

J.!IO 31)·37 [40 - ,(IJ 4-48 [e·D - 65J
1.112 50~55 [65 -151 74 - 81 [IC'3 - 110J
Technical specifications
S1036
3.3.2 EI asHes10p nut lorque
THREAD SIZE lB·FT (N.m!

I' - 20 150-2W 1203.4 - 271.1]
11,'4'-18 2W-150 12712 -338.9]
1112'-18 JfJll- 350 [4oo.a- 4745]
13'4'-18 4W-45O [)j2.4 -010.1]
3.3.3 "0" ring port plug torque chart
THREAD SIZE lBF ·fT (N.m]

9ft 0' -18 12 - 15 lla -2u]
J.r4~-16 20-25 [21 -34]
3.3.4 Pipe plug torque chart
TH READ IIPTF TORQUE

laF - IT [N.m]
li16-27 5-7 l7. H]

lIE - 27 7 -10 I'J- 14]
\.'4 -Ia 15 - 20 I ]20 - 27]
1'8-18 15 - 3lJ I 134 -41]
\"2-14 ~)-35
! 141-47]
l'4-W ~-45 I l)j -61]
I-Ulr2 55-50 ! [OB - 75]
1114-11112 &l-65 ! 151-18]
3.3.5 Permanent metric plug torque chart
THREAD SIZE TORQUE

lBF - IT [N.m]
M1ox1.5liH 25-)) I 1:>4-41]

1.118 x1.5 liH 45-50 I 161-6a]
Technical specifications
S1036
3.3.5 Coil and cartridge torque
... '. --..,~ .

.--/...
';. ;. ":-:~~.~~:
A: tighten cartridge 10 22-27 N.m (16-20 LBF-FT)

B: tighten cartridge nuisio 5-7 N.m {4-5 LBF·FTj
Technical specificalions
S1036
3.4 PRESSURE AND TEMPERATURE SPECIFICATIDNS

Normal operating temperature 70 - 120 "C (158 - 248 F) measured at temperature check port
converter out (port 71 - ").
Maximum allowed transmission temperature 120'C (248 F).
Transmission regulalor pressure (') - (neulral) - port 31 (").
- At 600 RPM min. 16.5 bar (240 PSI) minimum.
- At 2200 RPM: 19.3 bar (280 PSI) maximum.
Pump ncm(')
- At 1800 RPM in neutral: 54.9 Umin. minimum (14.5 GPM).
Ciutch pres 5U res (')

- 1st clutch: port 41 (").
- 2nd clutch: port 42 (").
- 3rd clutch: port 43 (").
- Forward cI utch: pori 45 (").
- Reve rse c1u lch: port 46 (").
At 2000 RPM:
- 16.5 - 19.3 bar (240 - 280 PSI) clutch activated.
- 0 - 0.2 bar (0 - 3 PSI) c1ulch released.
Filter bypass valve set at 1.5 - 1.7 bar n (22 - 24 PSI).

Lube pressure (') (pori 33) 0.7 - 1.4 bar (1G - 20 PSI) at 54.9 Ilmin. (14.5 GPM) pump flow
(±1800 RPM).
Safely valve: cracking pressure n 8.2 - 12.1 bar {120 - 175 PSI}.
Converter oul pressure (') (port 32) 1.7 bar min. {25 PSI} at 2000 RPM and max. 4.8 bar (70 PSI) at no
load governed spe ed.
(') All pressures and ftows to be measured ",ith oil temperalure of 82-93 °C (18D-200 F)
(,,) Refer 10 section 7 "Troubleshooting" for check port identification.
S1036
3.5 ELECTRICAL SPECIFICATIONS

Solenoid (forward, reverse, 1st and 2nd).
Goil resi stan ce:
- 12V: 9.79.Q ±0.5 Q.
- 24V: 39.3 Q ±2 Q.
Speed sens or:

- Type: rna 9neto res istive se nsor.
- Sensing djstance: 0 - 1.8 rnrn (0' - O.OT).
- Se nsor s ig nal: gene rates a sq ua re cu rrent with a fixe d amplitu de cha n9jng betwee n 7 and 14 rnA
3.6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS

Mnimum 19 mrn (.75-) internal diameter for fines and fittings.
Suitable for operation from ambjentto 120 cG (248 F) continuous operating temperature.
Must withstand 20 bar (290 PSI) continuous pressure and with 40 bar (580 PSi) intermittent surges.
Conform SAE J1019 and SAE J517, 100RI.
S1036
4. MAINTENANCE
4.1 OIL SPECIFICATION
4.1.1 Recommended lubricants

1. Catmpillar TO-4.
2. John Deere J20C, O.
3. Military MIL-PRF-2104G.
4. Allison C-4.
5. Dexmn' II Equivalenl- See nole below.
Note
DE)Roroi:~ II EOUWALENT IS ACCEPTI'...ELE; Hm'iPlER IT IS NOT COMPATiBlE WITH TOROUE cmNERTERS OR
TRqlSWSSION-S- EQUiPPED "','rrH C...ft.'\PHItlC FRICTION p.,V..TERlAL CLUTCH PLA.TES.
Caution
DE'RON' III, ENGirlE O1L OR GL-5 OILS flRE NOT RECO,",ME"OED.
PREFERRED OIL VISCOSITY

II is recommended that the highest viscosity monograde lubricant available be used for lhe anlicipaled
ambient temperature. Typically this will be a CAT TO-4 qualified lubricant. When large swings In ambient
temperature are probable, J20 C, 0 mulUgrades are recommended. Multigrade lubricants should be applied
at the lower viscosity rating lor the prevailing ambienl temperature, I.e. a 10W20 should be used where a
10W monog rade is use d. If a C -4 multig ra de is used instead of J20 Iubricant ~ is recom me nded that lhe
viscosity span no more than 10 points, I.e. 10W20.
Caution
SYNTH31C lU BR ICNfTS ARE APPRcP....EO IF Q Ll,!J,!J;:1 ED BY OKE OF Ttl E ABOVE SP ECLFICATlON-S.
OIL VISCOSITY GU IOEUN ES .APPLY, BUT SYr-.,,7H Ell C M JlTlGR"'DES UAY SPNI MORE TW.N 10 POL~rrs.
FOR flRE RESiSTANT FLUID RECm,~EllDAnO"S PLEASE CO"TACT SPICER OFF-HIGHWAYPRODUCTS.
: I I . I
W~~~11~'~~f~:i~~~¥~m ~-i~!il
I' "@.sAt'A'i"'b;1
I I
: p;
CElli -4) ·l) ) II }j
;::i'rE-l;.~t -4J ·n 11 53 ,I
Maintenance S1036
SUMP PREHEATERS
Preheat the transmission fluid to the minimum temperature for the oil viscosity used before engine start up.
NORMAL OIL CHANGE INTERVAL

Drain and refill system every 1000 hours for average environmental and duty cycle conditions. Severe or
su stai ned high ope raling te mperat ure or ve ry dusly atm os pheric eond jji 0 ns wi II re su II ina eeel erated
deterioration or contamination. Judgement must be used to determine the required change intervals lor
extreme eond itions.
EXTENDED OIL CHANGE INTERVAL

Extended oil service lile may result when using synthetic fluids. Appropriate change intervals shouid be
determined lor each transmission by measuring oil oxidation and wear metals, over time, to determine a
baseline. Wear melal analysis can provide useful inlormation but a transmission should not be removed from
service based solely on this analysis.
FILTERS
Service 0 Hfi Iters eIem ent every 500 hours und er normal enviro nmental and duty cycle conditions.
'Dexron is a registered trademark 01 GENERAL MOTORS CORPORATION.

Maintenance
S1036
4.2 MAINTENANCE INTERVALS
4.2.1 Daily
Check oil level daily wilh engine running al idle (600 RPM) and oil al82 - 93°C (180-200 Fl.
Maintain oil level al full mark.
4.2.2 Normal drain period

Norm al d rain period an d oil filter el ement ch ange are for averag e environment and dUly cycle can dition.
Severe or suslained high operating lemperature or very dusty atmospheric conditions wiil cause accelerated
delerioralion and contam in ation.
For extreme conditions jUdgement musl be used 10 delermine the required change inlervals.
Every 500 hours
Cha nge oil fi Iler elem ent.
Every 1000 hours
orain and refill syste m as follows (0 ra in with oil at 65 - 93'C (150 - 200 F)):
1. 0 rain trans mi ssion.
2. Remove and discard filter. Install new filter.
3. Refi II transmission to FUll mark.
4. Ru n eng ine aI 500 - 600 RPM to prim a converto rand lines.
5. Recheck leval with engine running al500 - 600 RPM and add oil to bring leval to lOW mark.
When oil temperalure is hal 82.2 - 93.3 "C (180- 200 F) make final oilleval check and adjust if
ne cess aty 10 bring 0 illevel to FU II mark.
Nole
l T is I1ECOh'lMBlD ED TI-'AT 01 L FI LTER BEe H'.J!.lm~ "FTER 100 HOU R-S OF OP ERo\TlON mi II EW ~
REBU It.T 00 REP,.\] RED U rl fT.
Maintenance
S1036
4.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL

The transmission, torque converter, and ils allied hydraulic system are imporlant links in the driveline bBtween
Ihe engine and the wheels. The proper operation of either unit depends greatly on the condition and operation
olthe olher. Therefore, whenever repair or overhaul of one unit is performed, the balance of Ihe system must
be considered before the job can be considered complele.
Aller the overhauled or repaired transmission has been installed in the machlne,lhe oil cooler, and connecting
hydraUlic system must be thoroughly cleaned, This can be accomplished In several manners and a degree 01
j udg eme nt mu sl be exercised as to the method employed.
The follo",ing are considered the minimum steps to be laken:

1. Drai n e nti re syste m lhoro ug hIy,
2. Disconnect and clean all hydraulic lines. Where feasible hydraulic lines should be removed from machine
lor cleanin g.
3. Replace oil filler element.
4. The oil cooler musl bB lhoroughly cleaned. The cooler should be "back lIushed" with oil and compressed
air until all foreign material has been removed, Flushing in direction 01 normal olillow will not adequately
c1ea n the cooler. If necessa ry, cooler as sem bly sho uld be rem oved from machin e lor cI eanin g, usi ng oil,
com press ed air, and stea mclean er for that pu rpcse.
IMPORTANT
Da NOT USE FlU5hlN G CCM?ot'NDS FOR C lEAtn~G Hi RPOSES.
···_~--~--·5.-Roassemble·nll,cDmpollenI5-0nd-use-only-type·oil-{See·chapler-4A",1,'"Recommended-!ubrfcanI5"j-,
~_ ..
Fii I the tran 8m iss Ion lh rou gh fi IIer 0 pen ing until II uid com es up to FULL mark on tra nsmission dipstick.
• Remove filler plug and fill oil until FULL mark.
• Run engine two mlnules at 500 - 600 RPM to prime torque convertor and hydraulic lines.
• Rech eck level of IiuId in tra nsm IS5 ion wllh en 9Ine run ning aI Idle (500 .. 600 RPM),
• Add quantity necess a ry to bri ng II uid level to LOW ma rk on dipstick.
• Recheck with hot oil 82.2 - 93, 3°e (180 - 200 F).
• Adjusl oil level to FULL mark on dipstick.
6, Recheck all drain plugs, lines, connections, etc ...., for leaks and tighten where necessary.
S1036
5. INSTALLATION DETAILS
5.1 CONVERTER DRIVE COUPLING

Mea su re the·A" dim enslon (bolt cI rei e d ia meter) and order drive plate ki t listed below. Note th ree (3) kits
have two (2) Intermediate drive plates and one (1) drive ptate and weld nut assembty. Three (3) kits with
three inte rmed iate d rive pia tes.
"A" Dimension (Boll cireie diameter) "A" Dimension (Boll circle diameter)
11.380" (288,900 mm) diameter 11.380· (288.900 mm) diameter
Kit No. 814978. Kil No. 814979.
13.125" (333,38 mm) diameter 13.125" (333.38 mm) diameter
Kit No. 814977. Kit No. 814980.
13.500" (342.90 mm) diameter 13.500" (342.90 mm) diameter
Kit No. 814975. Kit No. 814981.
Each kit will ineiu de the followl ng pa rts: Each kit will in cl ude the 1011owl ng pa rts:
2 Interm ed iate d rive plates. 3 Intermediate drive plates.
1 Drwe plate and weld nut assembiy. 1 Backin g ring.
1 Backing ring. 6 Mounting screws.
6 Mounting screws. 6 lockwashers.
6 lockwa sh ers. 1 Instruction sh eel.
1 Instruction sheel
Position drive plate and weld nul assembly on lorque converter assembly with weld nuts toward converter.
Align intermediate drive plates and backing plate wilh holes in torque converter assembly.
Nole
T'1't'O on.1Pl£S 180<:: ~PA~T Ir, BACKING Rlrw MUST BE OUT TO'....ARO ENGINE FLYWHEEL
{Hotlm'/ SIDE Ft..C1NG TORQUE CONVERTER ASSEMBLY}. [NSTAlL CAP SCRE\.','S .AND lOCKY'iASHERS.
TIGHTEN CAP SCREWS TOROUE 40 - 50 N,M. (30 - 37 lEF. FT.).
Installation delai/s
S1036
5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
1. Re move aII burrs from flywheel rno unting face and

nose pilol bore. Clean drive plate surface with
solvent.
2. Check engin e flywheel & hou sing fo r con forma nce
to standard SAE No.3 per SAE J927 and J1 033
tolerance specifications for pilot bore size, pilot
bore ru nout an d mou ntin g fa ce fl atn ess. Mea sure
and re co rd en gine cran ks!] aft en d play (Rg. 1).
3. Inslaillwo 63,50 mm {2.50"} long transmission 10
lIywheel housing guide sluds in Ihe engine
flywheel housing as shown. Rotale Ihe engine
flywheel to align a drive piate mounting screw hole FIG.1
with the flywheel hous Ing access hole
(Fig. 2).
'4. Install a 101,60 mm (4.00") long drive plate
locating stud .3750-24 fine Ihread in a drive plate
nul. Align the locating st ud in th e drive pi ate with
Ihe flywheel drive plate mounting screw hole
positioned in step No.3.
C""1i~",m
5. Rotale Ihe transmission lorque converter to align
!he loca Ii ng slud in the drive plale with the flywh eel
"ne ; W,
, i)'
drive plale mou nti ng screw hole pos itio ned In slep
NO.3. Lo cate tran smissi on on flywhee I h 0 using.
:t{
:
· .. ·--~--- ....'AligmngdrivEfjjialetollywneel aniflransmlsslon

,,1
rt-------~ . ~.-.-.-.-.-.-.~
to flywheel housing guide sluds. Install 1\

transmission 10 flywheel housing screws. Tighten
screws 10 specified torque. Remove lransmission
to eng in e g uide slu ds. In sta II remaining screws
and lighten to specified torque.
'6. Remove drive plale locating stud. .:FE·:';,o..L s:"LO........ 'S-€.i'l ,!.NO
:::ELF L'X~: .'lJT rLF~~:~-I-::0
,,'-.......... i-ffl '...;:lu:;.r ~3 3"( £J'.:GrE rJ .......F ...::TUi".E
7. In sta II drive plate allac hing screw and wash ef.
Snug screw bul do nol Iighlen. Some engine
flywheel housings have a hole located on the
lIywheel housing circumference in line with Ihe
drive plate screw acce ss hole. A screwdriver or
pry bar used 10 hold Ihe drive plale against the
flywh eel wili fecilitate Inslallation of !h e drive pIate
screws. Rotate the eng Ine flY'iheel an d In sta It th e
remaining seven (7) flywheel to drive plate
attaching screws. Snug screws bul do not lighten.
After all eighl (8) screws are installed.
Torq ue each on e 35 to 39 N. m. (25.. 29ft.! bs.). This
wi II requIre lighlen Ing each screw and rotali ng th e
en gin e flywh eel un Ii I the full amo unl of eig ht (8)
screws have been tig hte ned to sp eciITed torqu e.
8. Measure engine crankshaft end play after
transmission has been completely Installed on
engine lIywheel. This value must be within
0,025 mm (0.00l") of lhe end play recorded in
step No.2.
Does not apply to units having 3 Intermediate dri,'e
plates. See Fig.4.
lnstalla lion delails
S1036
5.3 EXTERNAL PLUMBING
F'OT =::F..,r t.:J

1r~~lliU1 if;
5.3.1 Optional: remote filter
-375(1..1 S FJU: • 23 Tr;J-

M[n.J;)rr---=-7~~S
5.3.2 Cooler & filler lines specifications

• Minimum 19 mm (.75 inch) internal diameter for lines and fillings.
• Suitable lor operation from ambient to 120 "C (248 F) continuous operating temperalure.
• Mu sl with sta nd 20 bar (290 psi) con Iinuou s pressu re ano with 40 ba r (580 psi) i nte rmitlent surges.
• Conform SAE J1 019 and SAE J517,1 OORI.
Installation details S1036
5.4 SPEED SENSOR INSTALLATION
;:~/
On the senSDr bDdy there is a small plastic triangular pDsitiDn
sign. Make sure the pDsitiDn sign Dn the senSDr pDints as shDwn
Position sign
belDw in the directiDn Df the mDvement Df the gearteeth (Teeth
rotatiDn as shDwn).
r
Teeth rolation
Plug Screw
nghlen 10 5.9· 7.4lbl-1\
"O".rin~ 18-IONml
ditl~
Sensor Inslalled Hole plugged
Sensor position on transmission

Turbine speed sensor location
Engine speed sensor location

Installation details
S1036
5.4 SPEED SENSOR INSTALLATION (Continued)
Position sign
~
Pin 2 I . ) Pin 1 I + )
~
The magneto resistive sensor generates a square wave current with a fixed amplitude changing
between 7 mA and 14 mA.
The sensor has an integrated AMP superseal2 pin connector.
The two pins are numbered 1 and 2.
Foilowing table shows the relation between wire colour. pin number and connection.
COLOUR PIN NUMBER FUNCTION CONNECTION

BROWN 1 Currenl input Hot wire
BLUE 2 Current output Ground wire
Note
THE SENSOR WIRES HAVE A POLARITY.
BE SURE TO CORRECTLY OBSERVE SENSOR POLARITIES, AS WRONG CONNECTIONS WILL DEACTIVATE THE SENSOR!
S1036
6. OPERATION OF THE TRANSMISSION
6.1 THE TRANSMISSION ASSEMBLY
Basically the transmission is composed of five main assemblies:

1. p"" . ","e! The converter, pump drive section and pressure regulating valve.
2. f &¥ The input shaft and directional clutches.
3. M'M The range clutches.
4. "*;;;;;;;;;;J The output section.
5. I" -.""o,m The transmission control valve.
Operation of the transmission
S1036
6.1.1 The converter, pump drive section and pressure regulating valve
Engine power is transmitted from Ihe engine ftywheelto the impeller through the impeller cover.
This etement is the pump porlion of the hydraulic torque converter and is the primary component which starts
the oil flowing to the other components which resulls in torque mulliplicalion. This element can be compared
to a centrifugal pump, that picks up fluid at its centre and discharges it at the outer diameter.
The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the
torque converter. This element receives fluid at its outer diameter and discharges it at its centre.
The reaclion member of the torque converter is located between and at the centre of the inner diameters of
the impeller and turbine elements. Its function is to take the fluid which is exhausling from the inner portion of
the turbine and change its direction to allow correct entry for recirculation into the impeller element.
This recirculation will make the converter to mulliply torque.
The torque mulliplicalion is funclion of the blading (impeller, turbine and reaclion member) and the converter
output speed (turbine speed). The converter will mulliply engine torque to its designed maximum mulliplication
ratio when the turbine shaft is at zero RPM (stall).
Therefore we can say that as the turbine shaft is decreasing in speed, the torque mulliplication is increasing.
The hydraulic pump is connected with the pump drive gear. This pump drive gear is driven by the impeller hub
gear. Since the impeller hub gear is connected with the impeller cover, the pump speed is in direct relation
with the engine speed.
Note
THE PRESSURE REGULATOR VALVE AND SAFETY VALVE ARE MOUNTED BEHIND THE FILTER,
IN THE FILTER ADAPTER HOUSING.
I I THE CONVERTER, PUMP DRIVE SECTION AND PRESSURE REGULATING VALVE

Operation of the transmission S1036
6.1.2 The input shaft and directional clutches

The turbine shaft driven from the turbine transmits power to the forward or reverse clutch.
These clutches consist of a drum with internal splines and a bore to receive a hydraulic actuated piston.
The piston is oil tight by the use of sealing rings. The steel discs with external splines, and friction discs
with internal splines, are alternated until the required total is achieved.
A back-up plate is then inserted and secured with a retainer ring. A hub with outer diameter splines is
inserted into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in
speed or rotate in the opposite direction as long as no pressure is present in that specific clutch.
To engage the clutch, the solenoid will direct oil under pressure through tubes and passages to the selected
clutch shafts.
Oil sealing rings are located on the clutch shafts. These rings direct the oil through a drilled passage in the
shaft to the desired clutch.
Pressure of the oil forces the piston and discs against the back-up plate. The discs with splines on the outer
diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked
together and allows them to drive as one unit.
When the clutch is released, a return spring will push the piston back and oil will drain back via the shift spool,
the bleed valve or holes in the clutch piston into the transmission sump.
These bleed valves will only allow quick escape of oil when the pressure to the piston is released.
As an option the engagement of the directional clutches can be modulated. This means that clutch pressure
is built up gradually. This will enable the unit to make forward, reverse shifts while the vehicle is still moving
and will allow smooth engagement of drive. The modulation is done hydraulically.
~ THE INPUT SHAFT AND DIRECTIONAL CLUTCHES

S1036
6.1.3 The range clutches

Once a directional clutch is engaged power is transmitted to the range clutches (1 st, 2nd or 3rd).
Operation and actuation of the range clutches is similar to the directionat clutches.
The engagement of the range clutches are not modulated.
6.1.4 The output section

With a range clutch engaged, power is finally transmitted to the output shaft.
Output rotation is opposite as the engine rotation when the forward clutch is engaged.
A front and/or rear axle disconnect is optional and is located on the output shaft. The drive to the front and/
or rear axle can be disconnected or connected by manual shifting.
Note
To ENGAGE DR DISENGAGE THE AXLE DISCONNECT, THE VEHiCLE IS NOT ALLOWED TO DRIVE,
BUT NEEDS TO BE AT STANDSTILL.
The 6-speed range shift transmission has a manual shifting to select low or high range.
Note
To SHIFT THE RANGE SHIFT, THE VEHiCLE IS NOT ALLOWED TO DRIVE,
BUT NEEDS TO BE AT STANDSTILL.
~ THE RANGE CLUTCHES it44-' THE OUTPUT SECTION

6.1.5 The transmission controls (refer to hydraulic diagram)

The transmission is controlled by the control valve. The control valve assembly is mounted direclly on the
side of the converter housing. The function of the control vaive assembly is to direct oil under pressure to
the desired directional and speed clutch. A provision is made on certain models for inching or declutch
when the brakes are applied.
Thi s is accompi ished th rough use of a brake actu ated va Ive.
The controt valve has 4 soienoids and 4 shift spools.
Operation of the valve
Forward can be seiected by activating the fonvard solenoid. The forward solenoid will then alimv pilot pressure
to move th e forward sh ill spool. 0 ue to th is movement of the shift spool th e fo rwa rd clutch is fed with oil
pressure.
When the reverse solenoid is a ctivated, pilot pressure will move the reverse shilt spool.
The reve rse clu tch wi II be fed with 0 iI pre ssure.
The sh in spools 01 forward and reve rse are loca ted opposite each othe r se parated by a retu rn spring.
Thi 5 ens ures th at only on e direction can be selected.
tlll _. l I
t;--: '-~'---.-J THE 1R~SMISSION CONTROLS
Selection of range
II the ra ng e solenoids 1st an d 2n d are activated, reg ulated pressu re is fed throu 9h th e sh iIt spo 01 s to the
1st clutch.
If th e ra nge soleno id 2nd is activated, reg ulated pres sme is fed th rou gh the shill spools to th e 2nd cI utch.
If no range solenoids ere activated, the reguiated pressure is fed to the 3rd clutch.
S1036
6.2 ELECTRIC SOLENOlD CONTROLS
Transmission gear Activated solenoids Activate d cl utches

Forward 3 Forward Forward. 3rd
Forward 2 Forward. 2n d Forward. 2nd
Forward 1 Forward. 1st, 2nd Forward. 1st
Neutral 3 - 3rd
Neutral 2 2nd 2nd
Neutral 1 1st, 2nd 1st
Reverse 3 Reverse Revers e, 3rd

Reverse 2 Revers e. 2n d Revers e. 2nd
Reverse 1 Revers e. 1st, 2nd Revers e. 1st
6.3 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT
6.3.1 Neulral, 3rd clutch engaged and high range selected
Ii
ji
NEUTRAL 3rd .;pOolERFWNj

HIGH RANGE
;1M- S'FPLY
REiERSE -l-w--
-+--"1
ITD
o
1- ?
NEUTRAL 3rd {P,C1P;,'JED SOLE\GOSAliD ,POOLS)

HiGH RANGE
\. \, "'\'
!,
. f.\ 'I
!"..lIj"
I,', "'l~,'.'1
[!'J L _J ~
!'"
I~
T20000 TRANSMISSION· HYDRAULIC DIAGRAM OPERATOR COMPARTMENT
'"
:...
o :~f1~53I.lRf.
-g~
3AND 6SPEED WITH RANGE SHIFT TRANSMISSION PIlF~!iIIRE mlP~RATUnli
GIIU[;E l;AUCf. par r.HF.r.K p'JRT
NEUTRAL AND 3RD CLUTCH ENGAGED Z ~,
f) CD .
'0
TFlAl'FIlATURf
GlI~GKl'Cfil
-'"
c:
§l ...
Q
f,AFm VALV~
H,l- \1.1 ~AIi
'"a. -
:r
III
~M~~lrlO fHmlillE
l® !~ m I@ m@
-
!l
c: ~
=
"I.....,~
lIo!l~
.~
COOLER
(, t1Q5[
~ , ' E"",~"", n
:r
"'"
lC
III
lC
,,
I
III
3-,
III
III
a'
r(lfl(.ltl~
C(JI/II~!ll~1l
ll>
C.
III
=
":::r
C.
rl1F.SSIIII~
IlfCUl/lTCA
WiVe
-L
~ L _,",' lC
I~,~-lfl:ltw :r
;;:
OrTlGljAL _ ~ _ ~ _ Q,:!~O!I~l ~ __
"
lC
ll>
i'~"~--'--"--~~~
III
~!m
SOLEIlQl[l
",
~::JI,E!jOI[)
mnWAIlO
~Cl[j~:JI[)
llJ:vm~
5::lDiOIIl
!E-
ll>
n~
ll>
C.
-----------,
O!'.PA55 flllEA I
n0
VAl.V~
1.5- U~~,
:--------li!- -----
i(:
"=:
".<:
~
c.
"1] ®
..
@
b.
ru~r
1/ iY
AI, ~ ~
BH~A1I1t~
..
~ 5CnEE!1
C2J @ @ @ @
o.
OIUiU~tP
"' "' "'
~'<=> ~'<=> ~,<=> , • ,.<=> , • _;¢::J
S1036
:l!m fOflWAl1D !IE\I~I!sf.
(Hor' 14504 PSII
'"'
C111Tl;11 GlLJlt:11
1ST
cum:!! CUJTDi ClVltH
Operation of Ihe transmission S1036
6.3.2 Forward 1st speed and high range selected
-~~J~~~~~~
CIT~_n 11
L.J.B::-r---
a;j
S'PHY
, '1
~2'D
·..-lI--lST
:m
fOR'....ARD lsi ~',CmATtD SOLENOiDS A\DSPOO,S,I

HiGH RANGE
T20000 TRANSMISSION· HYDRAULIC DIAGRAM
"""'''''''''''''''_._'---
OPERATOR COMPARTMENT
.. ""w .§'
I
3AND 6SPEED WITH RANGE SHIFT TRANSMiSSION
FORWARD AND 1ST CLUTCH ENGAGED
rIlm\lRf
GAUGE
'~t.l~~llJI,lLJH~
l~lJ(~ o
b~r
o
rnmUflE
CHECK PaRT
;.,
"T1
..~
~,
OD 'C
:TFUPFIIAlUllf
cl1rc~ l'OIlT
0
.
:i
~
c.
0
::I
.....
0
:r
..
~
~A~~lYVAlV~ III III
~~·1~,1BAR ~
cnAc~lrm PIl~S~IJRf III

I -, - II @-
"C i:
,~~L~Ll9\_L_t , , /
i~ !~ ! '"'C."
~
;1
HO~E
v
(1)
r,OlJlf.H
"- /1
H:m
C@
E," " " " .

"C.
=.
te
III
3
~,
III
on
Ci'
~
lr:mcllt ::r
COll\f.IlTEII
1il
~~[~~U~[
!~[l.I~l.Alurl
"
te
\lA~vf
In ~ -jill h~r '"
III
'"
...j
';"
.. ---- --- -. - .- - _.-
Ornall-·ll
-- - -.
,--- --- Cr.TIOllAl -----
-iii"
n
'C".
n
~!~b ';' lUI nrvt:llm:: 0
~OlHjlJll1 50IH~OI(1
, SOlf!IOIO :::l
'"c:
:::l
~Y,PA~~ flLTEfI '"

.E:
VAlVe )
!.~_ l t hili
i '" - ',"
I'lIU~
AI"
::i
nHfAtlM~
/
/" ~CR[[Ij
! l\1 ! IL..__... J @
h~r
@
"" .
@ ®
"
@
""
OllSUl.lr
I ="<=0 = ';= ,_.:..;¢OJ <¢OJ
S1036
I. I •
1=1 I •
'RO J,m lsI ~OIlWAIIU IlE~Hl~E

II ~'" 14.5114 PSII cllJlcll ("l.lfWI t'.wrr.l! ctUTCIt CllfTCl1
S1036
6.3.3 Forward 2nd speed and high range selected
-!--- 1ST
@::J
FORWARD 2nd (ACTl'lATED SCtEl,OOS AN 0 SPOC~s I

HIGH RANGE
!"
I~
T20000 TRANSMISSION· HYDRAULIC DIAGRAM OPERATOR COMPARTMENT
'"
3AND 6SPEED WITH RANGE SHIFT TRANSMISSION
FORWARD AND 2ND CLUTCH ENGAGED
!~lf~~URf.
r,AUGE
mwt"RATlJRE
lIAUG~
@
II~r
o.,
·1'HE;'~lI!lt
r.HEC~ f'fJRT '"
"T1
1lI
..o'
ii:
_,,
aD .Mll
:Tl].l~ERATUn!i
~flfi~KI'8I\T
0
~
a. .."...
Q
::r
~A~W VAl,V~
~:-1:,11!AK
Cl\AG~IIIG rl\E~SURE
"'"
Co ..ii:
III
o "\)"
~ ~"' -\I;'(i'~~
n@nrCiJr.;;:,
lCi? "'''""" =
~I" m II OJ!
(
C, ..)f HO~E
(~
cnnl ~
"-...? E LUORICA,IOH
'Co"
'""Co
;:r
cO'
III
3-.
Q
_.
III
III
;:,
PRmUR[
~TOllo.IJf.
tML COIIVEIlITIl
-"'"
;:r
!l[liULAIOR
VAI.VE '"'"
le 5· t~ ~ II~I
''""
•• _~~lO!lI)l .... ,-_.'-' OflTlmlAL
-
ii>
n
'C"o
I
",'--"-.-.
".
I .;r ronWAIlD :kJ , n-O
I
~Im l~t ~ODUl.ATlml REV[R!l1;
: .....,.~ \lAJ.\t~
l;LllDIClIO
E~IIQIO o eOmlQl1l 0 BO~htlOllJ
"""
2J ' , • ,- "I :
Ih'.IlA5~ flLTUl
"" ""{
~'"
Co
VALVE
!.5,1.1bJf
~ II T '._ ..... _- - • • • • • • I ',,. ., _, w.
@ u®"' .-
, u®
f>lIU~ ""
- /"
- ~ - i
AI~ .,
I!
DREATHEA ( __) ~(;Il[[/l
l] L_.."~_..JL.J
,r---"
SU~lr
_. @
,,, @
'"
@
b.
@
"" ""
all
<:;::0 <;:o:J <;:o:J <:;::0 "<"",
S1036
1=--:1
JH[J ~!m m failWAHO RtVH~5E
(1 ~<lr ~ 14.5ll4 PSI) cI.I.ll01 l:urrrJI CLIITCIt CLUICH Gl.UICH
S1036
6.3.4 Forward 3rd speed and high range selected
Cl ...
- SUPPLY
i>m'j;-+-- I ST
ITt!
FORWARD 3rd (~miArtD W.£!HWS ,m SF{K:tSi

HIGH R.!NGE
p>
T20000 TRANSMiSSiON" HYDRAULIC DIAGRAM OPERATOR COMPARTMENT
'" ~
:.. I
FORWARD AND 3RO CLUTCH ENGAGED
,,"Fr.~lJRP
~!JC~
rHWb.!\A!U!\~
GAUroE
o
b~1
:l'!lpa~UlIP
CHECIt 1'0ilT ...,
III
..g'
Dl
e) OD G) . rHI~H\A!lJkl:.
:c CIIl,:K PQI'IT
0
~
'"a. .....
Cl
::r
~AlT;lt VALVE
a ~_ \1.liIAk '"a. lD
~1l~C!lltIG f'I1ES~IJI~E iI _.~"~,"M,~m.= "NMm,"_,
'"
." .,
:;
l@ l@ ~~ m@
~~I
lD
lD
:I
< , '"
Co
'"
i. I~l" iJ Ii I LUlIfllCATIOI/
'"
:::I
Co =
iii'
HO~E COOlE~ I1CSf :r
.c"
'6'"
1"·'·'"rn,·",··J
I.~,l
TOnQUE
WllV[IlT[1l .'"
:r
::I
f'HESSlilIE
m:GULAT1Jfl
--J
11""'1
L :::I
Ie
lD
VAlve
III fl· 1!1]~;lf
'"
~
-
lD
n
CO
2~m
.;" l:uflWI\lIO R[IJ[R~[
,'""" ~ ..
DfTliOllAl.
, , , " ,". ~ ~
-
Co
n
-
1ST 0
MEl/aiD llDl!tIOID ~IJU:tl(llll 6otHIOIll :::I
IY , 5"
I:
-
~
lD
nv·rA~~ ~ ~ILf~k Co
VAl'/[ (
\.!i. \.tbitl -
<. ~ I~~~~_~--
. ~L~~ ~ _~ ~
@ :;;@
l'Ulll'
", U ~~r
.\I~
~ ~
B~~Ajll~fl
,~--.. 5CREEtj
@ @ @ @ @
", "' ~~! II. OM
Gil. ~!JU~
~e:;, ~'<= <= ,.= ,:=
S1036
I • I •
I--'"::::=]
(lb'" 14.504 PSil ,"" mo lllT fORWARD !IEvEME
[;l.l!TCH CWICH l~lJrr.H cwmt CLVJt::H
6.3.5 Reverse 1st speed and high range selected
REVERS Elsi ,PC','iCRRO,','1

HIGH RANGE ' ~"t1~~~~i:i~
.J
'(RIiARDlfi0r~'-'~ H;-+f--JRJ
REiERSE I
-----f"*'-~y
--+--IST
-SUFr::'Y
REVERS E1sl !;.G,r,mm SOLWJI ['S PliO SFOOLS)

HIGHR~rWE
m
OPERATOR COMPART'MENT .§l
''""
moDo TRANSMISSION· HYDRAULIC DIAGRAM I
o I 'Q"l
REVERSE AND 1ST CLUTCH ENGAGED
rru:ssunE
GAUGE
TEurr:nAT\I/lf.
r-AJIr,~
tr~
·f'l1r.~~1I11F.
CHEer, !'CflT
;C
..
.,
I~_- ~f-f
(;) :t~~!~~f{f,IUll~ 0
'"'" I
"(; 1;l1l1':~ I~Jt(l
til'" I '"
...
I ..
0
'" :;.
-
~
SAfET1'Vil,lVE til ~
6.~, \~.l DAR
~
~I<AGlm4G ~ll[~SUlU: til
n !® !~ I @l
'0
'"'"
ElU""~;""
::I
m®
8 I-"'rffi fi II I
, v"" 'I'
"
'C
i) ".;,J .
Q.
"
Q.
UI
3
.,
til
UI
110~E comHI HOSE :r C'
",' ::I
1-1---.J :r
rltfSS\lllf.
TOIH::Uc
CQllvmrr:r1 .
~
:::I
!If[;lJl.ATOR
'"
V~LVr:
1e,5-19Har '"
UI
!Eo
/'
i" ~~ -- - g~Ttc!i~l... _
-'"'"
<'l
Q.
n-
1ST
30lHKJIIJ
rOnWA!I[I
~~tlwIO
-
O
:::l
5'
c:
I\"-!'A~S rlLTER '"
.,E,
VAlVt
!.5 . ~ ,j' ~I!
1 1 '.
C) 1'),"
(~
CllsmlP
SCRWl
Gil
",
~
r=
L@ r1®
' b~r
'. tl~r
, /¢:;;J
b;@ no
~ ~
S1036
1=1 -'-1= 1-''''''1
(1 ~lIrli 1.\.504 PSI) ,eo 11m 11\1 roRWAAll REVERSE
ClUTCIl (;l.UTCH CUItCH l:tlJml ClUTeI'!
6.3.6 Forward 1st speed and low range selected
REVERSE ----J--+t--.n
!iF' -t-- I 8T
o
i: I
FORWARD 151 !ICli.. .ATEiJ 80310D8 IMSPOC'lSi

WI/RANGE
~
I~
T2DDDD TRANSMISSION. HYORAULIC DIAGRAM OPERATOR COMPARTMENT
'"<r> 11I
o",
-iil0'
PlIF.f.SIIIIF. lHM!lAluH~
rflESSU!1E
GAUGii lIIIuUIi GI1~CK paRT
FORWARD AND 1ST CLUTCH ENGAGED
f) OD
"T1
o : IfLl~H1Alu~f 0
~ "...0
CIIL::;KP'Jlll
--
"
1_,_,"IT--,,---, ~' a.
~A~~r¥VA;'~I:
~ ~. 1~,I!IAfi
CHA::lwm 1'!i~~~lJH~
,
..._...._.,... "~.,..,',",,."'."_m""'="wn'~.
[=,._._=.,='"= - i @ a @ l @ i @
~
-"
~
III
I II
:r
11I
iil
M 1'-'1 1'1 i II I
'J V ",
p
~( /.1'"
~V
i.'
"--'"
...1 ", E llillhlw<fI~l~
til
til
C.
CI
'"C.
"3-,
III
III
III
IiO~E COOLf.!1 I1D5f. 0' 0'
:.:
1"",,£, I fOnClU[
cuwmTtIl OJ "
PllmUR[
k[!il.Jl1ITUR
'"
to
til
v.l.I,\lf
16 5-1~ J tl~1 "'
til
10
(JPflC)l,(AI. .. ~ ~~I~rJ~~:. _
-.
n
c.
~
r-----------~~-- n
"
'
~tm \5f fCHWAJlP : r9t I,lOOlJI.A1IOlj 1lf.~F.llBE 0
501,fN0111 U[l!.W~llJl 5OlfllOIO : 15.1 VIII.V[ 5lJWlDID
'"
:::
.'"
om"
\JAllI~
()
I,H.TlJ.ar
Flmll
l' 7
h
-
"'"
:
:,
,
._ ... - -- --
l:
C.
~
c PUMP
u©
~
'I"
IlR[ATH[R
..
~
SC!(Wl
@ ® ® @ @
! 1'1
OIL SUI,IP
II I bJI
""
~~I
""
':~ , • 'i= , • 'i= , • ','=
S1036
I • ,__"!!c.:,,j=
~1l11 "In m r·onWAlllJ IlEvt:R5E
(1 b:lf:a1Igo·1 F!SI) cl.lJlr:11 cWTCl1 CLUlCti CLU1CI1 Cl.lJf(;~
Operation of Ihe transmission
S1036
6.4 GEAR AND CLUTCH LAY-OUT
6.4.1 3 -S pl!l! d with sta nd ard rati 0
1§~;;AI ;:~(,j.Yd
r:'::-:;',,--::-;~;:l 1~.1r.j ~-,j F,';-,'e-:!£l
I:;"-E;:-~~ 'H R=\~~:£: jj:*

S1036
6.4.2 3-g pee d w ilh dee p ra lio

Operation of the Iransmjssion
S1036
6.4.2 6-Speed with range shift
I::.t~",-~;;g-:l ;:::;.. ~~
I:;i;t~~_:~d l!t.lr.j =.r.j R;.,sr-~
1'2 ,cc"C';c1 R,•• ! , dOl
=="",1 ,ej cU ~f",
t':;;-=;;C::I (",>,.<So:>:;.
S1036
7. TROU BLESHOOTIN G GUIDE FOR TH E T20000 TRANSMISS ION
The following information is presented as an aid to isolating and determining the specific problem area in a
!fa nsmis sion th at is not functioni ng co rrectly.
When troubleshooting a "transmission" problem, it should be kept in mind thatlhe transmission is only the
central unit of a group of related powertrain components. Proper operation of the transmission depends on
the condHion and correct functioning 01 the other components of the group. Therefore, to properly diagnose
a suspected pro blem in the tra nsm ission, il is nece ssary to co ns id er the trans mis sion flu id, cha rg ing pum p,
torque converter, transmission assembiy, oil cooler, filler, connecting lines, and controls, inciuding the engine,
as a co mplele syslem.
By analysing the principles of operation logelher wilh the information in this section, it should be possible to
identify and correct any malfu nction which may occur in the system.
7,1 T20000TRANSMISSION
T20000 (power shift with torque converler transmission) troubles fall into Ihree general categories:
1. Mecha nical probiems.
2. Hydraulic problems.
3. Electrical pro blem s.
In addition to the mechanical and electrical components, all of which must be ill the proper condition and
functioning correctly, the correel functioning of the hydraulic circuit is most important. Transmission fluid is
the "life blood" of the transmission. It musl be supplied in an adequate quantity and delivered to the syslem
at the correct press ures to ells UTe co nverte rope ratioll, 10 enga ge and hold th e cI utches from slippillg, and 10
cool and iubricate the working components.
7.2 TROUBLESHOOTING PROCEDURES
7.2.1 Stall Test

A stall test to id entifles trans miSSiOIl, conve rler, or engin e probl em s.
Use following procedure:
1. Put Ihe vehicle against a solid barrier, such as a wall, and/or apply Ihe parking brake and block the
wheels.
2. Put the directional control lever in FORWARD (or REVERSE, as applicable).
3. Select the highest speed.
With ti,e engine running, slowly increase engine speed to approximately one-half throttie and hold until
transmission (converler oullel) oil lemperature reaches the operating range.
CAUTION
Do rmT OPERATE THE CQt.,;VERTER AT ST~'\l.L COrlDLTlON lmmrn IHM~ 30 S~COr-..:DS AT ONE Tl~.E, SHLFT TO hEUTfu\L
FOR 15 SECOfo..US AND R£PE~T THE PROCEDURE urml [JESIRED TEMPERATURE 1-S REACHED.
EXCESS IVE TWP ERATU RE 120 "C (250 F) JlAXI", L~l "" Ll CAJJ SE OAI.'AGE TO TRM s~, SS 10" CLUTC HES, R. U'D,
COU\tERTER, ,hnD S Eft!.S.
Troubleshooting guide S1036
7.2.2 Transmission pressure checks

Transmission problems can be Isolated by the use of pressure tests. When the stall test Indicates slipping
clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch
plate friction material failure.
In addition, converter charging pressure and transmission lubrication pressure can also be measured.
7.2.3 Mechanical and electrical checks

Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical
and electrical checks should be made:
Check the parking brake and inching pedal for correct adjustment.
Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points.
The controls are actuated electrically. Check the wiring and electrical components.
Be sure that all components of the cooling system are in good condition and operating correctly.
The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and
transmission. Air clean the radiator, if necessary.
The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct idle
and maximum no·load governed speed specifications.
7.2.4 Hydraulic checks

Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic circuit for
pressure and rate of oil flow, it is important to make the following transmission fluid check:
Check oil level in the transmission. The transmission fluid must be at the correct (full level).
i ._~ AILclutcb.e.s.and.tb.e.c.on'leLteLa nd.its.fl.uid.circuiUioes..m.u.st.b.e.fuILY..cbarged.WILed).at.all.tim.e.S ~~ _~.~~.~
Note
THE TRANSMISSION FLUIO MUST BE AT OPERATING TEMPERATURE OF 82 . 93 °C (180 . 200 F) TO OBTAIN
CORRECT FLUID LEVEL AND PRESSURE READINGS.
Do NOT ATTEMPT TO MAKE THESE CHECKS WITH COLD OIL
To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the
engine with converter at "stall" (Refer to 7.2.1 "Stall test").
CAUTION
BE CAREFUL THAT THE VEHICLE DOES NOT MOVE UNEXPECTEDLY WHEN OPERATING THE ENGINE AND
CONVERTER AT STALL RPM.
Troubleshooting guide
S1036
7.3 TROUBLESHOOTING GUIDE

Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles.
7.3.1 Low clutch pressure
CAUSE REMEDY
1. Low oil level. 1. Fill to proper level.

2. Clutch pressure regulating valve 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.
7.3.2 Low charging pump output
CAUSE REMEDY

2. Suction screen plugged. 2. Clean suction pump.
3. Defective charging pump. 3. Replace pump.
7.3.3 Overheating
Cause Remedy
1. Worn oil sealing rings. 1. Remove, disassemble, and rebuild converter

assembly.
2. Worn charging pump. 2. Replace charging pump.
4. Dirty oil cooler. 4. Clean cooler.
5. Restriction in cooler lines. 5. Change cooler lines.
7.3.4 Noisy converter
Cause Remedy
1. Worn charging pump. 1. Replace charging pump.

2. Worn or damaged bearings. 2. A complete disassembly will be necessary to
determine which bearing is faulty.
7.3.5 Lack of power
Cause Remedy
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".
7.4 CHECK POINTS
GRAVITY DRAIN PLUG PORTJJ

1·11,5NPTF CHECK PORT.\.UBE PRESSURE
.5625-HiUNF·2B
SAE '0'·RING PORT
FRONT VIEW
L1FWIGHOlE
.7511ll-1D UNC - 38 THO DEEP L12
PORTl1
CHECK PORT· CONVERTER OUT TEMPERATURE
1/Z-14NPTF
PORT 32
CHECK PORT· CONVERTER QUT PRESSURE
lIE -27 NPTF
AIMIYDRAULIC HIGH·LOW RANGE SHIFT

OPERATING PRESSURE 4.1-10.3 BAR l60-150 PSI)
ENERGIZE FOR LOW RANGE
MAGNET DRAIN PLUG

314 -14 tJPTF THO
REAR VIEW
S1036
7.4 CHECK POINTS (CONTINUED)

EliGIiJE SPEED SEtJSOR PROVISION
PUMP DRIVER GEAR BREATHER
TURfllllE SPEED SENSOR PROVISION

fORWARD CLUTCH ORUI.l GEAH -----.~~ PORT31
CLUTCH PRESSURE
5G2S-WUNF-211
SAE '0· - RING PORT
PORT45
~f~~~-~'~
CHECK PORT· FORWARD ClUTCH PRESSURE
.5625· WUNF -28 -,
SAE '0'· RJrJG PORT
"'
::11 --------- PORT42
CHECK PORT - 2ND CLUrCH PRESSURE
WWUPTF
PORH1
CHECK PORT - ISrCltJlCH PRESSURE
.5625·1BUfJF·21l
SAE ·0'· RING PORT PORT 46
CHECK PORT· REVERSE GLUTCf1 PRESSURE
lIS.27IiPTF
PORT 43
CHECK PORT· 3RDCUJTCfl PRESSURE
,5f,25-18UNF-211
SAE '0· - RING PORT
RIGHT SIDE VIEW
PORT 11
TO COOLER
1.0625· 12 Wi -2i1
SAE '0'· RING PORT
PORT 12
FROM COOLER
1,0625 -12 Wi -25
SAE '0· -RING PORT
._._. _. -11-1'11'" l-H~ AIR/HVORAULIC flIGH· lOW RANGE SHIFT

OPERATING PRESSURE 4.1-10.3 bill (6(1-150 PSI)
ENGINE FOR HIGH RANGE
LEFT SIDE VIEW

7.4 CHECK POINTS (CONTINUED)
PORT 31 _ ______.
CLUTCH PRESSURE DIPSTICK
.5625-1fiUNF-2B
SAE'O' - RING PORT
TOP VIEW
S1036
7.5 SPEED SENSOR - STATIC STANDALONE TEST
In order to be able to sense the currents, a series resistor of e.g. 200 Ohms must be used. This resistor is
integrated in the controller, but when the sensor is to be tested, it must be connected externally.
The idea is to connect the sensor to an external power source and measure the DC voltage across the series
resistor.
The voltage reading should be either 1.2V-1.6V (for the 7mA ± 1mA current level) or 2.6-3.0V
(for the 14mA ± 1mA current level)
If the teeth can be moved slowly, distinct toggling between the two levels should be noticed.
t12V
tf------'
n
sensor
200 Ohm 1 Wall

S1036
8. SECTIONAL VIEWS AND PARTS IDENTIFICATION

S1036
GROUP" CONVERTER HOUSING
t;V 12
S1036
GROUP - CONVERTER HOUSING
Item Description Quantity
1 Housing - Converter 1
2 Sleeve - Converter housing 2
3 Plug - pipe 1
4 Plug - pipe 1
5 Gasket - Converter housing to tD transmissiDn case 1
6 Screw - Converter housing tD transmission case 18
7 LDckwasher - Converter hDusing to transmission case screw 18
8 Pin - Converter housing to transmission case dowel 1
9 Clip 2
10 Screw - Clip 2
11 LDckwasher - Clip screw 2
12 Air - Breather 1
13 Plug 5
14 "O"-ring 5
15 Plug - Speed senSDr port 1
16 "O"-ring - Speed sensor 1
17 Screw - Speed senSDr 1
S1036
GROUP . TRANSMISSION CASE AN D REAR COVER
35
(-/!
1'·':.i
, I
34
i
29 ~
!
I
0 '/
I
i '
i/-(
, ,
,I
I
I
I
I
I
o
~_~/
I
2
A 3 /j /~
_/_~~ 8
/~ ,"
C
S1036
GROUP -TRANSMISSION CASE AND REAR COVER
1 Assembly - Transmission case 1

2 Assembly - Suction tube 1
3 "O"-ring - Suction tube assembly 1
4 Tube - Low speed pressure 1
5 Sleeve - Clutch pressure tube 4
6 Tube - 3rd clutch pressure 1
7 Clip 1
8 Screw - Tube clip 1
9 Lockwasher - Tube clip screw 1
10 Plug 1
11 "O"_ring 1
12 Plug 2
13 "O"-ring 1
14 Cover - Rear 1
15 Plug 1
16 "O"-ring 1
17 Oil - Baffle 1
18 Gasket - Transmission case to rear cover 1
19 "O"-ring - Clutch pressure tube 4
20 "O"-ring - Clutch pressure 1
21 Pin - Transmission case to rear cover dowel 2
22 Screw - Rear cover to transmission case 20
23 Lockwasher - Rear cover to transmission case 20
24 Plug - Magnetic drain 2
26 Plug - Speed sensor port 2

27 "O"-ring - Speed sensor 2
28 Screw - Speed sensor 2
29 Plug - Dipstick hole 1
30 Cover 1
31 Gasket - Cover 1
32 Screw - Cover 2
33 Lockwasher - Cover screw 2
34 Assembly - Dipstick hole 1
35 Dipstick 1
S1036
GROUP ·TURBINE SHAFT
'-'
I
I
< ---
I
I
,~,,- --~,
-. -~
>, , ' /
,
,, "" /
I
;, "'.
I
. 13 '., : "I:
"
S1036
GROUP - TURBINE SHAFT
1 Assembly - Turbine shaft & hub 1

2 Ring -Retainer 1
3 Bearing - Ball 1
4 Snap ring - Bearing 1
5 Washer - Bearing support 1
6 Ring - Bearing retaining 1
7 Ring - Piston 1
8 Support - Stator 1
9 Screw - Stator support 6
10 Ring - Piston 1
11 Baffle - Oil 1
12 Seal - Oil baffle 1
13 Ring - Oil baffle seal 1
14 Ring - Oil baffle retaining 1
S1036
GROUP - DRIVE PLATE
2
Cl \l
/
/ Cl\
/~/~()
/
2 \l
Cl
/
Cl ClU
/,/'a
Cl
Cl
S1036
GROUP - DRIVE PLATE
1 Assembly - Drive plate 1

2 Drive - Plate 2
3 Ring - Drive plate bacldng 1
4 Screw - Drive plate mounting 6
5 Lockwasher - Drive plate mounting 6
___________========-~G;;R~O~U;-.;P::.-:;:TO:R:::-:-----
S1036
QUE CONVERTER
'-:;;:~\\\,
, ' '
", ", \
,;;;:::~,)
2
S1036
GROUP-TORQUE CONVERTER
1 Assembly - Torque converter 1

2 Bearing - Impeller hub gear 1
3 Ring - External snap 1
4 Plug - Torque converter 1
5 "O"-ring - Torque converter plug 1
6 Ring - Snap 1
7 Ring - Turbine retaining 2
S1036
GROUP" AUXILIARY PUMP DRIVE

S1036
GROUp· AUXILIARY PUMP DRIVE
1 Support· Pump drive bearing 1

2 Screw - Bearing support 1
3 Pin - Bearing support 1
4 Bearing - Ball 1
5 Ring - Drive gear bearing retaining 1
6 Gear· Auxiliary pump drive 1
7 Cover - Pump mounting permanent 1
8 Gasket - Shipping cover 1
9 Screw· Pump mounting permanent cover 2
10 Lockwasher - Pump cover screw 2
S1036
GROUP -PUMP DRIVE

S1036
GROUP· PUMP DRIVE
1 Support - Pump drive bearing 1

2 Pin - Bearing support 1
3 Screw - Bearing support 1
4 Bearing - Ball 1
5 Ring - Drive gear bearing retaining 1
6 Gear - Charging pump drive 1
7 Gear - Pump drive idler 1
8 Shaft - Idler gear stub 1
9 Ball - Idler shaft lock 1
10 Bearing - Ball 1
11 Ring - Idler gear bearing location 2
12 Ring - Idler gear bearing retaining 2
S1036
GROUP - FORWARD SHAFT
13
. -,' '.
,, ''
, '
,
/ \j ",",
I ,',
I "
"
"
I "
I
"""
,",
I ,,
,",
I ,,
I ""
I...... - / \: j- :'~} "
"""
"
"""
I,' "
--':.'/ ::
,, ' '
,, '
' """
,
"""
'
,, '
'
""
,, '
'
,,, '
'
'
}
! !,C)
S1036
GROUP - FORWARD SHAFT
1 Assembly - Forward shaft and drum 1

2 Piston - Clutch 1
3 Seal - Clutch piston (Outer) 1
4 Seal - Clutch piston (Inner) 1
5 Disc - Clutch (Inner) 8
6 Disc - Clutch (Outer) 8
7 Spacer - Piston return spring 1
8 Plate - Clutch disk backing 1
9 Snap ring - Backing plate 1
10 Assembly - Disc spring 1
11 Snap ring - Spring retaining 1
12 Ring - Forward shaft piston 2
13 Bearing - Forward shaft pilot 1
14 Bearing - Ball 1
15 Ring - Gear retaining 1
17 Gear - First drive 1
S1036
GROUP - REVERSE AND 2ND SHAFT
S1036
GROUP - REVERSE AND 2ND SHAFT
1 Assembly - Reverse, 2nd shaft & drum 1

2 Piston - Clutch 1
4 Seal - Ciutch piston (Inner) 1
5 Piston - Clutch 1
12 Spacer - Piston return spring 1
13 Plate - Clutch disc backing 2
14 Snap ring - Backing plate 2
15 Spring - Piston return 1
16 Retaining - Spring 1
17 Assembly - Disk spring 1
19 Bearing - Clutch driven gear 1
20 Bearing - Clutch driven gear 1
21 Ring - Reverse clutch gear bearing 2
22 Bearing - Ball 1
23 Ring - Front bearing retaining 1
25 Ring - Piston 3
27 Hub - 2nd clutch 1
28 Ring - 2nd clutch disc hub retaining 1
29 Bearing - Needle 1
30 Retainer - Retaining ring 1
31 Ring - Retainer location 1
32 Spacer - Reverse clutch gear 1
33 Gear - Reverse clutch 1
S1036
GROUP • REVERSE IDLER
S1036
GROUP - REVERSE IDLER
1 Shaft - Reverse idler 1

2 Assembly - Reverse idler bearing 1
3 Washer 1
4 Nut - Bearing retaining 1
5 Washer - Bearing retaining 1
6 Lockball - Idler shaft 1
7 Gear - Reverse idler 1
8 "O"-ring - Idler shaft 1
S1036
GROUP - LOW SPEED SHAFT

S1036
GROUP - LOW SPEED SHAFT
1 Assembly - Low shaft, hub and drum 1

2 Piston - Clutch 1
7 Plate - Clutch disc backing 1
8 Ring - Backing plate retaining 1
9 Assembly - Disc spring 1
10 Snap ring - Spring retainer 1
11 Spacer - Belleville washer 1
12 Bearing - Low speed gear 1
13 Bearing - Low speed gear 1
14 Ring - Low speed gear location 2
15 Ring - Low shaft piston 1
16 Bearing - Ball 1
17 Spacer - Low speed gear bearing 1
18 Bearing - Ball 1
19 Snap ring 1
20 Retainer - Belleville washer 1
21 Gear - Low clutch 1
S1036
GROUp· 3RD SHAFT
3 4
~ /:
1
'~' :
.." -
) .'C'
; 1:',.'
5
S1036
GROUP - 3RD SHAFT
1 As sem bly - 3rd sh all & drum 1

2 As sem bly - Clutch pislo n 1
3 Seal- Clutch piston (Outer) 1
4 Sea I - CI utch pisto n (I nn er) 1
5 Disc - Clutch {Inner) 6
7 Plate - Clute h dis c ba eking 1
8 Sna pring - Ba eking pia Ie 1
9 Spring - Pistan retu m 1
10 Retainer - Spring 1
12 Ring - Front bearing retaining 1
13 Bearing - Ball 1
14 Snap ri ng - Front bea rin g 1
15 Ring - Piston 2
16 Hub - 3rd c1ulch 1
17 Ring - 3rd clutch disc hub retaining 1
18 Bearing - Needle 1
-_.~::=----
GROUP -10 LER SHAFT (USED IN 6 SPE ED AND 3 SPEED
;~
S1036
WITH DEEP RATIO)
5
6
HI 8 4
"
, ,7,
': I
:'~'
- ;~
S1036
GROUP - IDLER SHAFT (USED IN 6 SPEED AND 3 SPEED WITH DEEP RATIO)
1 Shaft - Idler 1
2 Bearing - Ball 1
4 B earing - Roll er 1
5 NuI - Bearing 1
6 Washer - Bearing nut 1
7 Spa cer - Idle r shall gea r 1
8 Snap ring 1
9 Gear - Idler 1
10 Gear - Idler 1
S1036
GROUP - IDLER SHAFT (USED IN 3 SPEED STANDARD RATIO)
7. ~
l\'~/Y
1
:~~
S1036
GROUP· IDLER SHAFT (USED IN J SPEED STANDARD RATIO)
1 Sh all - Idier 1
2 Bearing· Ball 1
4 B earl ng • Roller 1
5 Nut • Be aring 1
6 Wa sher - Bearin g nut 1
7 Spacer· IdIe r sh aft gear 1
8 Snap ring 1
9 Gea r - Idler shaft 1
S1036
GROUP - OUTPUT SHAFT (6 SPEED)
/ :-~"~:-_::?'~~: , ~,
,} ::.:~. '..:..~;
, .'
'. "-'0..
". "_-r~
'.~, ~.'
• --- • - . - +..",'
. 8
21 9 I /'
/ . 4 .// /// / 6 ~6.~~/~/
.)'$l'~11'8/17
I '~2"2 16.
// 1
1
.~.-
. -yJJ
';'l&~'
'
" " 20
i~O~
S1036
GROUP - OUTPUT SHAFT (6 SPEED)
1 Shalt - Oulput 1
2 Bea ri ng - Ou Ip ut sh aft fro nt 1
3 Bearing - Ou lpul shaft re ar 1
4 Snap ring - Front bearing relaining 2
5 Ring - Output shalt rear bearing retaining 1
6 Bearing - HilLow gear 4
7 Spacer - B ea ri ng 1
8 Spa ce r - Bea ring 1
9 Washer - Gear thru 5t 2
10 Hub - Range shilt 1
11 Cap - Rear bearing 1
12 Gasket - Rea r bearing cap 1
13 Stud - Rear bearing cap 4
14 Lockwasher - Rear bearing cap stud 4
15 Nut - Rear bearing cap stud 4
16 Seal - 0 utput sh all 2
17 "0'-ring - Output Ita nge 2
18 Washer - Outpu lit an ge 2
19 Nul- Oulput !tange 2
20 Gear - Low fa nge 1
21 Gear - High range 1
22 Fi an ge - Output fro nt 1
23 FI ange - Output re ar 1
S1036
GROUP - OUTPUT SHAFT (3 SPEED STANDARD RATIO)
,.. . :; <.-'. ,'0. ~.

) ~I ,;--;-0- .,,_ '''..' _~-' ' "
~ ~., ")- ',' ' , - . ': ,
,,';' ;' :"'._. ,+ 1 '
,~ .'/, .- '. ,
:~k;~\;~j;~: ,
.~~.'~T'Y<.· . . : ,1",/
I5 3 .& , /' 13
.'$l.\~ll ~:I 7 . I J~
/ 16I 15 14
18 ~1)~
/
S1036
GROUP - OUTPUT SHAFT (3 SPEED STANDARD RATIO)
Item Des c ripli 0 n Quantity
1 Shaft - Outpu I 1
2 Bea ring - Ou Iput sh aft rea r 1
3 Bearing - Output shaft front 1
4 Rin g - Output s hall rear bea ri ng 1
5 Ring - Output shall front bearing retaining 2
6 Was her - Ou Ip ut shaft rea r bearin g 1
7 Seal - Output shaft 2
8 Siud - Bearing cap 4
9 Lockwash er - Bea rin g ca p screw 4
10 Nut - Siud 4
11 Cap - Outp ut sh aft rea r beari ng 1
12 Ga sket - Oulput bearing ca p 1
13 Spacer - Gea r 1
14 ·O"-ring - Flange 2
15 Washer - Flan ge 2
16 Nul- Flange 2
17 Gear - Outpu I 1
18 Front - Flange 1
19 Re er - Fie nge 1
S1036
GROUP - OUTPUT SHAFT (3 SPEED DEEP RATIO)
~,.,
,,,
J
1,
1,
,,,
I
,I
,I
1
I
I
(
-'
S1036
GROUP - OUTPUT SHAFT (3 SPEEO DEEP RATIO)
Item Des cri pti 0 n Quantity
1 Shaft - 0 utpu t 1
2 Bearing - a utp ut sh aft rear 1
3 Bearing - au Ip ut sh aft front 1
4 Ring - Output shaft rear 1
5 Ring - Output shaft fro nt bearin g retainin g 2
6 Seal - a utpu t shaft 2
7 Stud - Bearing cap 4
8 Lockwa she r - Bearing cap screw 4
9 Nut- Stud 4
10 Ca p - Output shaft rea r bea ring 1
11 Gasket - Outp ut bearing cap 1
12 Spacer - Gea r 1
13 Spacer - Gea r 1
14 "O'-ring - Flange 2
15 Wa sher - Flan ge 2
16 Nut - Flange 2
17 Gea r - Outpu t 1
18 Front - Flan 9e 1
19 Rear - Flange 1
S1036
GROUP - HI & lOW RANGE SHIFT CONTROL
, "
..' .:
,. "
'I'
" ~ " ,
~ -' .
"
: ;:
", '
I . _" I
I ,"
. "
I I ••
, '"
.' , . :.,t
~ ~.. : ,
"
. " ." ",
..". "
'.
, ~ . ',".
"
_'~. f -.-'
:~: '
:-.: ' ,.". I,
-; .', ~,
;" ;2.!·)~-..... -.. . . ~ . . .
- - -:. .-..-
., -- . ''':'".
-"
--
~. ~
~, - ..-.; .
4
S1036
GROUP - HI & LOW RANGE SHIFT CONTROL
1 Fork - Shift 1
2 Screw - Shift fork 1
3 Lockwasher - Shift fork 1
4 Assembly - Air shift cylinder 1
5 "O"-ring 1
6 Stud - Pump mounting 2
7 Nut 2
8 Lockwasher 2
9 Body - Cylinder 1
10 Seal - Piston rod 1
11 "O"-ring - Seal 1
12 Tube - Cylinder 1
13 Rod - Piston 1
14 "O"-ring 1
15 Piston 1
16 Cup - Seal 2
17 Nut 1
18 "O"-ring 1
19 Cap - Cylinder end 1
S1036
GROUP - CHARGING PUMP & FILTER
';-
I -', " .
-- , '
,
, '
'
'. ,>:
-------
S1036
GROUp· CHARGING PUMP & FILTER
1 Pump· Charging 1
2 Assembly - Hydraulic spin on filter 1
3 Gasket· Pump assembiy to converter housing 1
4 "O"·ring 1
5 Screw - Pump mounting 5
6 Lockwasher - Pump mounting screw 5
S1036
GROUP - ELECTRIC CONTROL VALVE MOUNTING
,
~
2
C,
IJ
IJ
IJ IJ
(J • IJ
IJ
IJ IJ
,
S1036
GROUp· ELECTRIC CONTROL VALVE MOUNTING
1 Assembly - Electric control valve 1

2 Gasket - Control valve to front cover 1
3 Screw - Valve to converter housing 9
4 Lockwasher - Valve to converter housing screw 9
S1036
GROUP· ELECTRIC CONTROL VALVE ASSEMBLY
22 ~8
~ ~/13
7 23
6/'
Il1l
,
!.
ty
--
0',_
4 I
1
,
tI
12
,
, 19 '
: ~-/i ;
,I~-""" /' . . . ,', -~, ~I'.
~/
. './0/' 1
©/ - /~
"'-l
'---,0
'0 0 0
0
15
3
I 0
00 0
'0 0
o 0 0
,0
o 0
0
,
o ,0 2
!
o 0 0 0
0 0
0
26
o
25/..;/
1..
27
241
30l/
28
30~
A
i
.
, .
29 !
S1036
GROUP - ELECTRIC CONTROL VALVE ASSEMBLY
1 Housing control valve 1

2 Cover - Control valve 1
3 Gasket - Control valve cover 1
4 Spool - Forward and reverse shift 2
5 Spring 2
6 Spool - Range (3rd) 1
7 Valve housing plug 2
8 Valve housing plug "O"-ring 2
9 Spool stop 1
10 Pin 1
11 Plug stop 1
12 Spool- Range (1st and 2nd) 1
13 Spring 1
14 Pipe plug 8
15 Piug 1
16 Screw 1
17 Screw 2
18 Lockwasher 3
19 Stop - Spool 1
20 Forward and reverse deciutching spool 1
21 Spring - Deciutch 1
22 Plug 1
23 "O"-ring - Plug 1
24 Cartridge - Ball valve 4
26 "O"-ring - Cartridge 4
27 "O"-ring - Cartridge 4
28 Coil12V 4
29 Nut - Solenoid 4
30 "O"-ring 8
31 Cover - Soienoid 1
32 Spacer - Cover 2
S1036
9. ASSEMBLY INSTRUCTIONS
Assembly instructions
S1036
9. ASSEMBLY INSTRUCTIONS (CONTINUED)
-----.
;-
t=r
S1036
~--
GROUND DRIVEN
_~Qi--+l%~:r-- EMERGENCY STEERING
. PUMP DRIVE
OPTIONAL DISC BRAKE

LJ----- MOUNTING
@\
\-+J DRUM PARKING BRAKE
BRAKE ACTUATING LEVER
~~='='==i===~' ~. . __
- DRAIN PLUGS
S1036
FROM FILTER ---------~?~~--------TOFILTER

~~J
-Ei-i -"~~------------~------~------------"~-----
J,J
S1036
HYDRAULIC DISCONNECT
FRONT· AND REAR OUTPUT
AIR DISCONNECT
FRONT· AND REAR OUTPUT
~--~~
~~--
~----~II -v- ----et

MANUAL DISCONNECT
FRONT· AND REAR DISCONNECT
S1036

All lead in chamfers for oil seals, piston rings, and "O"-rings must be smooth and free from burrs.
Inspect at assembly.
Lubricate all piston ring grooves and "O"-rings with oil before assembly.
Apply a thin coating of grease between seal lips on lip type seals prior to assembly.
Use only precoated pipe plugs. On uncoated pipe plugs apply a light coat of Loclile no. 592.
After assembly of parts using Loctite, there must not be any free or excess material
which might enter the oil circuil.
Apply a light coat of Loctite no. 262 or no. 270 to all thru hole stud holes.
~ Tighten oil filter to 20-25Ibf.ft [27-34 N.m].
~ Fwd. and rev. with standard piston & low clutch. 8 Outer steel discs and 8 inner friction discs.
Insert one (1) Steel disc. Insert one (1) friction disc. Alternate steel and friction discs until proper
amount of discs are installed. First disc next to the piston is steel, last disc installed is friction.
~ Low clutch springs concave side of first belleville spring to be placed against clutch piston. Remaining
six springs of each clutch to be stacked alternately reversed as shown.
~ Must be loose internal fit bearing with a no. 3 etched on the bearing.
~ Shields must be sized prior to assembly.
~ Two clutches (2nd & 3rd). 6 Outer steel discs and 6 inner friction discs.
Start with outer steel disc alternate friction and steel.
~ Tighten to 200 - 250 Ibf.ft [271.2 - 339.0 N.m].
~ Shielded bearings, be sure that bearing shield is on the outside.
~ Forward and reverse clutch springs concave side of first belleville spring to be placed against clutch
piston. Remaining four springs of each clutch to be stacked alternatly reversed as shown.
S1036
~ Stator support screw assembly:
1. Clean stator support mounting surface and tapped holes with solvent. Dry thoroughly.
Being certain tapped holes are clean and dry.
2. Install 6 special stator support screws. Tighten screws to 12 -16Ibf.ft [16.3 - 21.7 N.m] torque.
Note
ASSEMBLY OF STATOR SUPPORT TO CONVERTER HOUSiNG MUST BE COMPLETEO WITHiN A 15 MINUTE PERiOO FROM
START OF SCREW INSTALLATION. THE SPECIAL SCREW IS TO BE USED FOR ONE INSTALLATION ONLY. IF SCREW IS
REMOVED FOR ANY REASON iT MUST BE REPLACED. THE LOCTITE LEFT IN THE HOLES MUST BE REMOVED WITH THE
PROPER TAP AND CLEANED WITH SOLVENT. DRY HOLE THOROUGHLY AND USE A NEW SCREW FOR REINSTALLATION.
~ Torque screws of pump cover up to 20 - 25 Ibtft [27 - 34 N.m].
~ Tighten to 91 - 100 Ibf.ft [123.4 - 135.6 N.m].
~ Snap ring is to be assembled with sharp edges to front.

Disassembly and reassembly T20000 LD transmission
S1036
Disassembly T20000 LD transmission
S1036
Figure 1 Figure 4
Front view of the T20000 series long drop Remove pressure regufating valve and charging
transmission.The transmission being disassembled pump bolts.
is the 6-speed version.
Figure 2 Figure 5
Loosen filter assembly. Remove valve and pump assembly.
Figure 3 Figure 6
It is recommended a small pan be used to catch the Remove drive plate mounting screws and washers.
oil left in the filter element. Remove filter element.
S1036
Figure 7 Figure 10
Remove drive plate and backing ring. Though bore plug hole, remove turbine retaining ring.
Figure 8 Figure 11
Remove impeller cover bore plug retainer ring. Remove torque converter assembly.
Figure 9 Figure 12
Using two small screw drivers as shown, remove Remove turbine locating ring.
plug.
S1036
Figure 13 Figure 16
Using slots provided in converter Ilousing. Remove idler gear and bearing assembly.
Remove oil baffle retaining ring.
Figure 14 Figure 17
Baffle and sealing ring removed. Remove pump drive idler gear locating ring.
Figure 15 Figure 18
Remove pump drive idler gear retaining ring. From the rear through the pump drive hole, remove
pump drive bearing support screw.
See figure 281.
S1036
Figure 19 Figure 22
From the front, tap pump drive gear and bearing From the front, tap pump drive gear and bearing
support from housing. from housing.
Figure 20 Figure 23
From the rear, remove pump hole cover, screws, Remove solenoid protection cover screw and
lockwashers and gasket. lockwashers.
Figure 21 Figure 24
Remove auxiliary pump drive bearing support Protection cover removed.
screws. See figure 284.
S1036
Figure 25 Figure 28
Remove control valve bolts and lockwashers. Support converter housing with a chain hoist.
Remove remaining bolt.
Figure 26 Figure 29
Remove control valve and gasket. Separate converter housing from
transmission case assembly.
NOTE: Reverse and 2nd and 3rd clutch
will remain in converter housing.
Figure 27 Figure 30
Remove all bolts but one securing transmission to Using spreading type snap ring pliers, spread ears
converter housing. on the reverse clutch front bearing retaining ring.
S1036
Figure 31 Figure 34
!-blding snap ring open pry reverse and Remove output snaft front flange nJt, washer,
2nd clutch assembly from convener h<}using. 'O'-ring "od flange.
Figure 32 Figure 35
Using spreadiog type snap ring p',ers, spread ears Rem:::Jv8 OJtpu! stmft rear flange nut, ...·o'asnsr, ~O'!'-ring
0'1the 3rd ciJtch front bearing reta~ning ring. and fiange.
Figure 33 Figure 36
Ha'di1g snap ring open tao 3rd clutch Rem-:J'~'e pump hde cove!, cover gasket sere.vs and
from converter hDusing. !De k\·vas hers.
Disassembly T20000 LD Iransmission
S1036
Figure 37 Figure 40
Remml6 output :)ha!t rear bearing cap nuts and Remove pi sl on md nut.
Iackwasn ers.
Figure 38 Figure 41
o utp ut shall rear bear;ng cap ",moved. Ranove shift cylinder mcunting nuts and
Ioc kt.. as hem.
Figure 39 Figure 42
Remove shift cylinder end cap. Shin cy:inder removE{f.
S1036
Figure 43 Figure 46
Remove fear cover scre...·Js and !ock'Nashers. Remove low clJlch rear bearir,g.
Figure 44 Figure 47
Using pry slots provided, pry cover from Remove 3rd crutch disc a'ld retaining ling.
transmissicn housing. Using a she-a hammer tap on
idler and output shafts to prevenl cover hc·m binding.
Figure 45 Figure 4B
Rear cover rEmoved.NOTE: O'JtpJt and idier shaH Removs 2nd clutch disc hub, retaining ring, retaining
bearing outer races remaining h cover. ring reta;nef and retainer lecating r;ng.
S1036
~-!.~'@"
"@
(~)
•
Figure 49 Figure 52
Open ears on idfer shaft front bearing 1c·cating ring so Tap the rear sufficiently so that bearirg groove is
that it is nut of tflli groove. past snap fing i.e. Vlst snap ring remain ill open
"'Ine
pas iti Oi'l 01- the b ea ri ng outer dia meter nil is
refeased.
Figure 50 Figure 53
Tap to U"'.8 re-::J st.tni CIe ntty so til:::.t Ul s- b 8ari:rg g rCDve is Remo"e the khV (1st) clutch and tile idler shaft
past snap rirg Le. ttmt snap remain- ill OPEf1 positicn en- tcgelhef.
the bearl1g Dute-r diameter '1','Tlen it is released.
NOTE: jl DEaring -SBB1""IS difficult to mDve rechBck
locating ring, being su'e ring is clear of me ring groove
if f)
t@
(~)
•
Figure 51 Figure 54
Open ears en low shaft fre-nt bear-:ng !ocaling rillgs so Remove snift fork.
that it is out of the groove.
S1036
Figure 55 Figure 58
From the front tap output shaft from the front bearing, From the front tap output shaft bearing from housing.
bearing remains in transmission case.
Figure 56 Figure 59
Remove output shaft assembly from housing. Open ears on forward shaft rear bearing locating
ring.
Figure 57 Figure 60 [t
Remove output shaft front bearing locating ring. While holding locating ring open, use a hammer ;j;
J
puller to remove forward shaft and clutch assembly.
Internal THO MiG x 1.5 deep 15mm.
Disassembly of low (1st) clutch
S1036
Figure 61 Figure 64
Remove low gear and hub, low shaft front bearing Turn clutch over. Remove inner and outer clutch
and clutch gear outer bearing. discs.Do not mix low clutch friction discs with friction
discs in other clutches.
Figure 62 Figure 65
Remove end plate retainer ring. Remove low speed gear bearing spacer.
Figure 63 Figure 66
Remove end plate. Remove low speed gear inner bearing.
Disassembly of low (1st) clutch
S1036
Figure 67 Figure 70
Remove clutch piston return spring, A 1-1/2 x 1 sleeve with a portion Remove clutch sheft piston ring.
removed is recommended for removing the clutch piston spring, washer and
retainer ring. Sleeve shown is a common pipe with a 1-1/1 x (39.0 x 26.0mm)
opening. The pipe is 6 x 3-1/4 x 2- 3/4 (155.0 x 85,0 x 78,0 mm).
Compress spring retainer washer. Through opening remove spring retainer
snap ring. Release tension on spring retainer.
Figure 68
Remove snep ring reteiner end reteining ring, disc
spring end specerNOTE: Do not mix disc springs
with eny other disc springs es they ere metched
spring pecks. SEE PAGE 10-60.
Figure 69
Turn clutch over end tep clutch sheft on e block of
wood to remove clutch piston.
Reassembly of low (1st) clutch
S1036
Figure 71 Figure 74
ReIer to tile "Cleaning and Inspection" pages. The bleed valve in tllC Inslall piston spring spacer and piston relurn
clutch drum must bl:! deiln Clnd froe of any foreign material. In~;lall
clutch piston outer seal ring. NOTE: Fling must be sized before
installing in clutch drum. SiZing is besl uccornplis!1od by rowling
clutch While holding a round object againsllhe now seal ring.
9R springs. First spring wilh large diameter
toward spacer (see figure 77). Alternate seven (7)
springs. See note in figure 68.
ROlate piston unlit sCiJl ring is !lush with outer diameter of piston.
11
Figure 72 Figure 75
Install clutch piston inner seal ring and size as Posilion spring snap ring. Compress spring and
described in figure 71. inslall snap ring.
Figure 73 Figure 76
Position piston in low clutch drum as shown. tnstall snap ring retainer.
Use caution as not to damage inner and outer
piston scaling rings.
Reassembly of low (1st) clutch S1036
Figure 77 Figure 80
Install clutch disc end plate.
Figure 78 Figure 81
Install one steel disc. Install end plate retainer ring.
Figure 79 Figure 82
Inslall one friction disc NOTE: the friction discs in the low clutch has a higher Install low speed gear inner bearing.
co-efficient rating than the friction discs in the olher clutches therefore the
discs musl not be mixed.The fow clutch friction disc has a yellow make of
non-soluble paint on the ouler diameter for permanent identification.Alternate
steel and friction discs unlillhe proper amount of discs are installed First disc
next to the piston in sleel last disc installed is friction
Reassembly of low (1st) clutch
S1036
Figure 83 Figure 86
Install low speed gear bearing spacer. Install low shaft font bearing with bearing groove up.
Figure 84 Figure 87
Install clutch driven gear and hub into clutch Install low shaft sealing ring.
drum.Align splines on clutch hub with internal
teeth of friction discs. Tap gear into position.
Do not force this operation. Gear splines must be in full
position with internal teeth of all friction discs.
Figure 85
tnstalilow speed gear outer bearing.
NOTE: outer bearing has a shieid in it, this shield
must be up.
Disassembly of reverse clutch
S1036
Figure 88 Figure 91
Remove clutch shaft piston rings. Pry reverse gear from clutch assembly far enough to
use a gear puller.
Figure 89 Figure 92
Remove clutch shaft front bearing retainer ring. Remove reverse clutch gear and outer bearing.
Figure 90 Figure 93
Remove clutch shaft front bearing. Remove clutch gear bearing spacer.
S1036
Figure 94 Figure 97
Remove end plate retainer ring. Remove clutch gear inner bearing.
Figure 95 Figure 98
Remove end plate. Compress piston return disc springs. Remove return
spring retainer ring.
Figure 96 Figure 99
Remove inner and outer discs. Remove piston return disc springs and piston
spacer. See note in figure 68.
S1036
Figure 100
Remove clutch piston,2nd being disassembled,
Disassembly of 2nd clutch
S1036
Figure 101 Figure 104

Remove end plate retainer ring, Compress piston return spring, Remove retainer ring,

Remove end plate, Remove return spring, spring retainer and retainer
ring,

Remove inner and outer clutch discs, Remove clutch piston, Reverse and 2nd clutch
reassembly 2nd being assembled,
Reassembly 2nd clutch
S1036

Refer to the "Cleaning and Inspection" pages. Compress return spring and install retainer ring.
The bleed valve in the clutch piston
must be clean and free of any foreign material.
Install clutch piston outer seal ring.
Size as explained in figure 71.

Install clutch piston inner seal ring. Install one steel disc.
Size explained in figure 71.
Install clutch piston in clutch drum.
Use caution as not to damage sealing rings.

Position piston return spring, spring retainer and Alternate steel and friction discs until the proper
retainer ring. amount of discs are installed. First disc next to the
piston is steel, last disc installed is a friction disc.
Reassembly 2nd clutch
S1036
Figure 113
Install end plate and retainer ring.
Reassembly of reverse clutch
S1036

Refer to the "Cleaning and Inspection" pages, Position spring snap ring,
The bleed valve in the clutch piston must be Compress spring,
clean and free at any foreign material. Install Install snap ring,
clutch piston outer seal ring,
Size as explained in figure 71,

Install clutch piston inner seal ring,
Size as explained in figure 71,
Install clutch piston in clutch drum,
Use caution as not to damage sealing rings,

Position spring spacer and piston return springs, Install one steel disc.
First spring with large diameter toward spacer,
see figure 118, Alternate five (5) springs,
See note in figure 68.
S1036

Install one friction disc. Alternate steel and friction Install clutch gear inner bearing.
discs until the proper amount of discs are installed. NOTE: this bearing does not have a shield in it.
First disc next to the piston is steel, last disc installed
is a friction disc.

Install end plate. Install clutch gear bearing spacer.

Install end plate retainer ring. Install reverse gear into clutch drum.
Align splines on reverse gear with internal
teeth of friction discs. Do not force this operation.
Gear splines must be in full position with internal
teeth of all friction discs.
S1036

Install clutch gear outer bearing. Install clutch shaft piston rings.
NOTE: outer bearing has a shield in it, this shield
must be up.
Figure 127
Install clutch shaft front bearing.
NOTE: bearing outer diameter locating groove
must be up.
Figure 128
Install bearing retainer ring.
Disassembly 3rd clutch
S1036

Remove end plate retainer ring. Compress piston return spring and spring retainer.
Remove retainer ring.

Remove end plate. Remove return spring, spring retainer and
retainer ring.

Remove inner and outer discs. Remove clutch piston.
Disassembly 3rd clutch
S1036
Figure 136
Remove clutch shaft piston rings.
Figure 137
Remove clutch shaft front bearing retainer ring.
Figure 138
Remove clutch shaft front bearing.
Reassembly 3rd clutch
S1036

Refer to the "Cleaning and Inspeclion" pages. Install clutch piston outer seal ring.
The bleed valve in the clutch drum musl be Size as explained in figure 71.
clean and free 01 any foreign material. Inslall
clutch shaft front bearing. NOTE: bearing outer
diameter localing ring groove must be up.

Install clutch shaft front bearing relainer ring. Install clutch piston inner seal ring.
Install clutch piston in clutch drum.
Use caution as not to damage sealing rings.

Install clutch shaft piston rings. Position piston return spring, spring retainer and
retaining ring.
Reassembly 3rd clutch
S1036

Compress return spring and install retainer ring. Install end plate.

Install on steel disc. Install end plate retainer ring.
Figure 147
Install one friction disc. Alternate steel and friction
discs until the proper amount of discs are installed.
First disc next to the piston is steel, last disc installed
is a friction disc.
Disassembly of forward clutch
S1036

Remove end plate retainer ring. Compress piston return disc springs.
Return spring retainer ring.

Remove end plate. Remove piston return disc springs and piston
spacer. See note in figure 68.

Remove inner and outer clutch discs. Remove clutch piston.
Disassembly of forward clutch
S1036

Remove forward clutch shaft piston rings. Remove forward clutch shaft rear bearing.
Figure 157
Remove 1st drive gear retaining ring.
Figure 158
Remove 1st drive gear.
Reassembly of forward clutch
S1036

Refer to the "Cleaning and Inspeclion" pages. Inslall forward clutch shaft pislon rings.
The bleed valve in Ihe clutch drum must be clean
and free of any loreign material. Install forward
~
clutch shaft rear bearing. NOTE: bearing ouler
diameter locating ring groove must be down. i1

Install 1st drive gear. Install clutch piston outer seal ring.
NOTE: with hub of gear down. Size as explained in figure 71.

fnstal11st drive gear retaining ring. Install clutch piston inner seal ring.
Install clutch piston in clutch drum, use caution as
not to damage sealing rings.
S1036

Position spring spacer and piston return springs. Install one steel disc.
First spring with large diameter toward spacer, see
figure 168. Alternate five (5) springs: see note in
figure 68.

Posifion spring nap ring. Compress spring. Install one friction disc. Alternate steel and friction
Install snap ring. discs, until the proper amount of discs are installed.
First disc next to the piston in steel, last disc installed
is a friction disc.

Install end plate.
S1036
Figure 172
Install end plate retainer ring.
Disassembly of converter housing
S1036

Straighten tang on reverse idler bearing retainer nut Remove idler gear and outer taper bearing from idler
lockplate. shaft.

Remove idler shaft bearing retainer nut. Remove idler gear bearing spacer.
Use TG 1304-54. See section 12: "Service tools".

Remove idler shaft bearing retainer nut, lockplate. Remove idler gear inner taper bearing.
S1036

Remove idler gear inner taper bearing spacer. Remove stator support screws.

Remove idler shaft, use caution as not to lose shaft Tap stator support from converter housing.
lock ball.
Figure 181 [t Figure 184

Using spreader type pliers spread ears on the +J Remove oil sealing rfng sleeve retainer and washer.
turbine shaft bearing snap ring. Remove steeve lock.
Tap turbine shaft and baring from converter housing.
S1036
Figure 1B5 Figure 1BB

Using a sleeve puller like the one shown, Remove turbine shaft oil sealing ring.
remove sleeve.
Figure 1B6 Figure 1B9

Remove support bearing retaining ring. Remove turbine shaft bearing retaining ring
and washer.
Figure 1B7 Figure 190

Remove bearing from support. Remove support oil Remove turbine shaft bearing.
seal ring.
Reassembly of converter housing
S1036
~
Refer to the "Cleaning and Inspection" pages. Install new stator support oil sealing ring.
Press turbine shaft bearing into position. Press support bearing into position.
Bearing groove must be down.
~ NOTE: bearing pari number must be up.

Position bearing spacer and bearing retaining ring. 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 new turbine shaft oil sealing ring. Install sleeve lock and cap screw, tighten screw to
specified torque (see torque chart).
S1036

Clean stator support mounting surface and tapped GJ With new "O"-ring on shaft, position idler
holes with solvent. Dry thoroughly, being certain tapped shaft in converter housing. Tap shaft into position.
holes are clean and dry. Position support in converter Install lock ball.
housing aligning holes in support with holes in housing.
Tap support into position.

Install 6 special stator support scrEWS. Tighten screws \0 12 - 16 Ibs. Ft (16.3 - 21.6
Nm.) torque. NOTE: assembly of Ihe stator suppor\10 converter housing must be
fnstall idfer shaft spacer.
completed within a 15 minute period from start of screw installation. Tile special
scrsw is 10 be used lor one installalion only. If Ihe screw is I8moved for any leason it
musl be replaced. The LocHia lell in the holes must be removed with Ihe proper tap
and cleaned with solvent. Dry hole thoroughly <lnc! use a screw for reinstallation.

Spread ears on turbine shaft bearing retainer GJ Install idler gear inner taper baring in shaft with large
ring located in reaction member support. Tap turbine diameter of taper down.
shaft and bearing into position, being certain bearing
snap ring is in full position in snap ring groove.
S1036

Position bearing spacer on shaft. Install reverse idler baring retainer nut fockplate
as shown.

Position idler gear on bearing with hub of gear up. Install reverse idler bearing nut with chamfer down.
Figure 205 Figure 20B

fnstall taper bearing on shaft with large diameter of Tighten nut 200 to 250 ft. Ibs.
taper up. Torque (271.2 - 338.B Nm.). Use TG 130~-54.
S1036

Bend over tag of lock plate that aligns with one of the Spread ears on 3rd clutch front bearing locating
slots of the lock nut, to secure it (See figure 210). ring. Tap clutch assembly into converter housing.
Align the snap ring groove in the front bearing with the
snap ring in the housing, being certain bearing snap
ring is in full position in snap ring groove.

Position the 2nd speed clutch shaft and 3rd speed
clutch pilot bearings on clutch shaft, a light coat of
good quality grease will hold bearing in position on
shaft.
Figure 211
Spread ears on reverse clutch front bearing
locating ring. Tap reverse and 2nd clutch assembly
into converter housing.Align the snap ring groove in
the bearing with the snap ring in the housing, being
certain bearing snap ring is in full position in snap
ring groove.
Disassembly of idler shaft
S1036

6-Speed cross section. The idler shaft being Remove idler shaft, rear bearing inner race spacer.
disassembled is a 6-speed (see figure above).
For 3-speed cross section see figure 215.

3-Speed cross section. Remove idler shaft gear (rear) and rear bearing inner
race.

Remove idler shaft nut. Remove idler shaft gear (front).
Disassembly of idler shaft
S1036
Figure 220
Remove idler shaft gear spacer.
Figure 221
Remove idler shaft front bearing.
Reassembly of idler shaft
S1036

Refer to the "Cleaning and Inspection" pages. Install idler shaft gear (rear) with long hub of
Install idler shaft lront bearing. gear down.
NOTE: snap ring groove in front bearing
must be up.

Install idler shaft gear spacer. Install idler shaft rear bearing inner race.

Install idler shaft gear (front) with long hub at gear up I Position bearing inner race washer and retainer nut.
Reassembly of idler shaff
S1036
Figure 228
Tighten retainer nut to 200 - 250 Ibs.ft. torque.
(271.2 - 338.8 Nm.).
Disassembly of output shaft
S1036

6-Speed cross section. The output shaft being Remove low range gear.
disassembled is a 6-speed (see figure above).
For a 3-speed cross section see figure 230.

3-Speed cross section Remove low range gear bearings and spacer.

Remove low range gear thrust washer. Remove range shaft hub.
Disassembly of output shaft S1036
Figure 235
Remove high range gear, gear thrust and rear
bearing inner raCB.
Figure 236
Remove high range gear bearings.
Reasssembly of output shaft
S1036
Figure 237 ~ Figure 240

Refer to the "Cleaning and Inspection" pages. -s ..'. Install range shift hub.
Install high range gear bearings. ~

Install high range gear. Install low range gear bearings and spacer.

Install high range gear thrust washer and rear Install low range gear.
bearing inner race.
Reasssembly of output shaft
S1036
Figure 243
Install low range gear thrust washer.
Reassembly of transmission
S1036

Refer to the "Cleaning and Inspection" Install low clutch shaft and idler shaft front bearing
pages. Install forward clutch shaft rear retaining ring.
bearing retaining ring.
[~J
Position forward assembly into transmission From the front install new output shaft seal with lip of
bearing bore. seal towards bearing side. From the rear install
output shaft front bearing and outer retaining ring.

Spread rear bearing retaining ring. Align snap ring Install front bearing inner retaining ring.
grove with snap ring, release snap ring in groove
being sure snap ring is in full position in ring groove.
S1036

Install output shaft assembly. GJ Install low clutch shaft rear bearing.

Install shaft fork and rod as an assembly
[~J Position new gasket and "O"-ring on rear of
on shift hub. transmission housing. A thin coat of chassis
grease will hold the gasl<et and "O"-ring in place.

The low clutch (1 51) and the idler shalt must be installed
[~J Install rear cover and bearing Quler races as an assembly.
[~J
in the transmission case together. The help of an assistant or NOTE: two aligning studs facilitate cover to housing
by replacing the transmission case on the front face may facilitate
this step. Spread ears on low and idler shafl front bearing retaining
ring. From the rear, lap low and idler shaft into position being sure
assembly. Tap cover bores in place aligning shaH bearings
with bearing bores. Use caution as not to damage
low clutch shalt sealing ring.
!tl
snap rings are in full position in ring grooves. Remove aligning studs and install cover bolls and locl,washers.
S1036

Tighten rear cover screws to specified torque Press new seal in bearing cap with lip of sealloward
bearing side of bearing cap. Position new gasket on
(see torque chart). bearing cap.
NOTE: some units will have uO"-rings between the cap and the cover.

Install pump hole cover, gasket, screws and Instaillockwashers and stud nuts.
lockwasher. Tighten nuts to specified torque (see torque chart).

Tighten screws to specified torque Install output flange, "O"-ring, washer and nut.
(see torque chart).
S1036
Figure 262 ~) Figure 265

Block flange to prevent turning. Tighten flange ~ Install new piston rod "O"-ring, position shift
nut 200- 250 Ibs. ft. (271.2 - 339.0 Nm.). cylinder assembly on piston rod.
Before installing shaft cylinder assembly replace all Use caution as not to damage piston rod
"O"-rings and sealing rings (see figure 263 and 264). sealing ring.

Install piston retaining lock nut.

Tighten lock nut to 26 - 29 Ibs. ft. (35 - 39 Nm.).
S1036

Position new cylinder end cap "O"-ring into Install forward clutch pilot bearing.
end cap.

Install cap and "O"-ring on cylinder tube. Install 2nd disc hub, hub retaining ring, retaining ring
Tighten cap securely. retainer and retainer locating ring. See figure 273.

Install cylinder body lockwashers and stud nuts.
Tighten nut 37 - 41 ft. Ibs. torque (50.2 - 55.5 Nm.).
Reassembly 01 transmission
S1036

Install 3rd clutch disc hub and relaining ring. PcsitiDil new ·0" -Mng and gasket on front of
transmissiDn hcusing. A fg1t coat of chassis
grease ".111 held ~O·-,ing and gasket in place.

Install frDilt output flange, "O"-ring, washer and :r-c,
1":-3 X-3 :r' ':::.'L'.-1 'T'-=;; ~.i I b:::1 L!:-l! o;:"i;'cn) "1"= =~,.-.:r= 'Y-,-,,=i--g x-It e ::.:n,i,..'-:.., r~-';l g
I:-~":.d :=•.l r:H r ~'--~T'J ""="'-'7U.. t: :·-.. r::.rh" cr ~'-"':-3"'li)", ~sf\] ~a~""-3 ::'~:7I 3; t::: d:;n-;-'"
flange nut. ::'l-1::'; :t= ':1:- d.nt d...:: td_-~. A.~..." d.r.::1 ;:dn E"E<";'" d~= -ojj,;, t..:T tu ;."t....-3 ~ i..o'\ u:::
-r
:r.::.J:: "~-3""::::U-~ 3': !:::.-T. T.... t ... 1 t~p "-"'"'" l1 01. -E: ,ULf E-'-,,~ .~:~ ~.t_, t.3 d~: -..n"
D':J r..o-' Fl:)-"(:E ~d.'; ~"'-:-~J·l 'f~u", it dJ':d-E:~ a=, ..-:c~-t,. dg-08i "1 ~ :;....-r.U:-3· 'l:::_"'>i
,. ~ t'~:ij;"1 3-~3r~ -;-'" -;:-3 1011 torJ' t".... S.,.;; ... ,,:d- ~,'.'I: t=-"h] 1: "U..<':l-Q Clf""=.... s 3.j
<::.,"'"z.s.. .
_~ ~ R3"'>:.",3 3:;r>~J r.r....::~ r £l.>.1 ""..";i "-<;1 (".r·z:",,,,~ a-u ;::'","=-H~
Figure 276 Ffgure 279

Block flange to prevent turning. Tighle.~ lIange nut TightEn cap screws to spEcified torque
2GO - 250 Ibs. ft. (371.2 - 339.0 Nrn.). (see torque chart).
S1036

Position B.ux=liary pump drive gear irl converter Posilion cllarging pump dfi'.'e gear (see ligure 2M)
housing. See l;gure 281. and instal! cap scre-."j . . vith Lochte No. 243.
l1gtlten -cap screv, to specif~ed turque
{see toque chart}.
Figure 282 Agure 285

Instali cap screw with Loelite No. 243. Tigr,ten cap Using a new gasKet and "O"-,ing, posiliDn
sc re'N to 3 pee il, ed trnq ue (see tmq LJ e ci1 art). charging pump assembly. Insta!1 cap sere·,...s
an d :OcKwas 118 rs.
T,gnten screws to spec,lfed torque (se8 toque chart).
Reassembly of fransmiss;"n
S1036

Irlstaii ca p sc rews and I[}C h'.ns hEf s: Instat1 idle! gear bBaring retain'ng ring.
!ighte~ sere'""s to specified torque (see torque chart).
Figure 267 Figure 29ll

Instal; new oil filter. Tighten 20 to 25 ft. Ibs torqJS Pcsi!ion pump idler gear and bearing
(27.1 - 33.9 N.m.). NOTE: i, is r8ccmmsnded I'm, the i~stab shalt.
filter cartridge be changed afte! 1C·8 hours 0;
operation Oil fie'"","' and r-ebuilt or repaired units.

1l1s rail pump h ofe CQ'~'€ r, fl 8'.....8 ga sket sc rmvs
I tnstal' idler gear bearing losating rrng.
and locK'Nashers. Tigtlte-n screViS to specified
torque (see torque chart).
S1036
Figure 292
Press new seal in baffle . . ·iitrl lip of sBal to\.. . ard
Figure 295
Pos iti on con'y' 61 16 r ass-a rn b1y all stato r sup-po rt
r!,;'
:,..tI
impe!l6i" hub bearing. and turbine shafL
Positioll n€",',' a-oj baffle sealing ring O~l oil baffle. NOTE: use extrem-a caution as nol to cut,
break or untlOok the- Gil sHaJing ring in tt18 support.

Fositiun oil baffle in housing and install letain'ng ring. Inslall converter assembly retaining ling.
Be sure ring is h full posi~iGn in .rlr'Jg grG-2-V9.

PositiGfl jnn-ar turbine locatin·g ri1g en turbine 8'13ft. '''~Ih new "0· ·"ng in place, install bare plug.
S1036
Figure 2SB
Install bore plug retaining ring.
Figure 301
P08,tioo conlrol valv" assembly on
[~J
argrling studs.

See special seclioo on page 5-1 for drive plate fnsta'i contml va~ve to comre-rter housing scre',','s an.d
installa!ien. !cCk'liBshers, tight8!l- sere',','s to specified toque
(see torque chart).
Figure 301l Figure 3113

To insta'l control varve assembf,., It is Install p,otecticn cover, scre'.... s and be'viashe,s.
,ecommended t",o aligning studs be used Ie Tighten sere·....s to specil;ed tc,que (see to'qUB
~>Q.slti·:Jn ne','.' control ....ar-'...e gasket chart).
Disassembly and reassembly of the T20000 LD transmission
S1036
'&Note:
CLUfCH HETURN lJiSG SPR:rm Pl"CKS lJ.F.:E CEHTIFJED AGCGFlDlrlG TO COMPHESSIOU WEIGHT SPEC,FICATIONS AND ARE
PRE·PACKED N QUMHLTiES TO REPl.. IFl ONE (1) SPECIFIC ClUfCt~.
The disc spring pac~s are to be used as complete assemblies and care should be ta~en not to intermix the
Ind ivldual disc sp ring s with d iac spri ngs in anoth er clu Ic h or disc spring pac~.
Each disc spring assembly is made up of selected springs to precisely match each part within this assembly.
Failure to replace all pis Ion return springs can result in unequal deflection within the spring pack.
The result of this imbalance may adversely alfect overall life ot springs.
S1036
11. OPTIONS
11.1 HYDRAULIC ACTUATED AXLE DISCONNECT

The information contained herein must be used in conjunction wilh a T20000 LD section.
11.1.1 Sectional views and parts Identification

Refer to following pages.
S1036
GAOUp·HYDAAULlC ACTUATED AXLE DISCONNECT

S1036
GROUP· HYDRAULIC ACTUATED AXLE DISCONNECT
Uem Descriplion Quanlily
1 Shaft - Output 1
2 Bushing 1
3 Bearing - Output sh aft Iron I 1
4 Bearing - Output shaft rear 1
5 Snap ri ng - Fro nt wari ng retaining 2
6 Ring - Output shaft rear bearing retain ing 1
7 Beari ng - Hi Low ge ar 4
8 Spacer - Bea ri ng 1
9 Spacer - Bearing 1
10 Washer - Gear thrust 2
11 Ri ng - Output sh aft rear retai ning 1
12 Hub - Range shift 1
13 Housing - Dlconnect 1
14 'O"-ring - Dieonneet housing 1
15 "O"-ring - Dkonneet housing 1
16 Plu g - Dieon nect hou sl ng 1
17 'O"-ring - Bore plug 1
18 "a'-ring - Bore plug 1
19 RI ng - Bo re plug retal ning 1
20 Shat! - Dkonnect 1
21 Stud - Disconnect housing cap 4
22 Lockwasher - Discon neet hou sing stud 4
23 Nut - Disconnect housing stud 4
24 Plug - Disconnect housing 1
~~-~~::=-:::::::::~=="----------------7----~.- ..... -.-.. -
~ ~~ 1
27 Seal - Output shaft 2
28 Piston - Hydraulic actuator 1
29 "a'-ring - Piston 1
30 Sp ri ng - AIrihydrau Iic actu ala r piston - 0 uler 1
31 Spring - Airihydrauiic actuator piston - inner 1
32 Ring - Piston seal giyd 1
33 Locksc rew - Shift fork 1
34 Hub - Shift 1
35 Fork 1
36 "O"-ring - Disconnect housing 1
37 Plug - Shipping 1
38 "a'-ring - Output flange 2
39 Washer - Oulput !lange 2
40 Nut - a utp ut II ange 2
41 Gear - Low range 1
42 Gear - High range 1
43 Flange - Output (front) 1
44 Flange - Output {rear) 1
Options
S1036
11.1.2 Assembly instructions
g
~
~Jc==:t~==~ llGfflElI SB:UREtY AliD LOCK WiRE
TO PREVEtlT LOOS E1UIG
APPLY AliGHT COAT OF LOenTE 557
TO THE ()IJT!H DIAMETER OF THE IlOOSIIKl PlUG.
S1036
11.1.3 Disassembly of output shaft with axle disconnect

Disassembly of oulput shaft with axle disconnect
S1036
Figure 1 Figure 4
6-Speed cress section '\'"ith ax1e disconnect. RemDve fo'"" range gear bBarings and spacer.
Figure 2 Figure 5
R8ffiDve tow range gear thrust ',',lasher. Remove range shilt flUb.
Figure 3 Figure 6
Remove 1m-,' range gear. Remove be ar ing j nnef rae e retai ni ng ri ng.
Disassembly of output shaff with axle disconnect
S1036
Figure 7
Remove high range gear, gear thru51 ','lasher, bearing
spacer and baaring inner race.
Figure 8
REmove tlig-'l range gear bearings.
S1036
11.1.4 Reassembly of output shall with axle disconnect

Reassembly 01 oulpuf shaff with axle disconnect
S1036
Fi[lure 9 Figure 12
Refer to the ·Cleaning and inspection" pages. Inslall, l1;g~ range gear tl1rust wasl1ar,
II bJshing wem out, install new busl1ing. bearing spacm and bearing inner mce.
Figure 10 Figure 13
Installiligh range gear bearing,. tnsta'i rear bearing inner face retainirlg rjng.
Figure 11 Figure 14
Install l1igl1 range gear. Install range shift hub.
Reassembly of output shalt with axle disconnect
S1036
FIgure 15
lnstall !ow range gear bearings and ~-pacer.
Figure 16
Install low range gear.
Figure 17
InstalI1G.....' ran.ge gear thrust '.... asher.
S1036
11.1.5 Oi sass emb Iy of axIe dise llnn eel

Disassembly of axle disconnect
S1036
Figure 18 Figure 21
Remove Ule inner and outer actuator piston springs. Remove piston bore P~U[l relair::er ring.
Figure 19 Figure 22
The c-utp ut d I SB al mU3t be de stroye d by LJ sin g a Remove disconnect stmfl ou~€r bearing reta:ner ring.
punch to d,i"e through the oil seal housing and
picking the dl seal out at tne discoonect hcusing.
Figure 211 Ftgure 23

Re move di scon ned -h 0 J srng p1u g. Remove the shift fm~ JocK scrm·...
Disassembly of axle disconnect
S1036
Figure 24 Figure 27
RBmove disconnect w.AJ3ing plug. Sn if! and snif! fork removed.
Figure 25
Remove actuator pistc-n.
Figure 26
TaD disCGnnect shaft and ooaring from hnusing.
S1036
11.1.6 Reassembly of axle dlsconnecl

Reassembly of axle disconnect S1036
Figure 28 Figure 31
Refer :athe uCl8an:rg and fr.sc-ect.jrJf1~ pa;]8S_ A!;g, hde in actuator p,ston wi!h hale in shit !ark
Position shif:: fork -CD shiH hub, fnser~ aouatcr Install shift ferk lock scm>'.'.
in~odisconnect Musing. TightEn securejy and lock ,.,,'ire to pre-vent toc-s-ening.
H~ld shift hub and fork in. n.::::u8ing. align srjf( fork and
actu atm Distcn. fnse rt piston in ~ hift fa rk.
Figure 29 Figure 32
!nstall ·O"·,ing and g1yd ring G~ actuator piston Align splines on discGnnect shaft \'"ith splines in
(88" figure 29). stci(t h:Jb.
Figure 30 Figure 33
Tap s1aft and bearing in pfacE.
Reassembly 01 axle disconnect
S1036
Figure 34 Figure 37
Install shaft bearing ollter wlainer ling. Sc-cLJre bme plug wilh retairr'ng ring.
Figure 35 Figure 38
Press seal in disconnec~ J1c.JJsing \ViUl lip of seal in. /l.pply a iight coat of loctite 577 te- the outer diamelm
of Ihe housing plug.
Tap plug into posilioo in housing.
Figure 36 Figure 39
PositicH twa new "G"-rings e-n piston bore plug. Install disconnect housing ·O"-rings in housing.
Al'g~ t1O!e rn p!ug"ith ho!e in he-using. install plug.
Reassembly of axle disconnect
S1036
Figure 40 Figure 43
Insert the actJator pislon in.oar and cuter return Install output flange ·O"-ring, wasner artd flartge nut
springs irt piston.
FIgure 41 Figure 44
Use new UO"-rjngs Oil assemb~l_ Posi:iDfl disconnect Bleck flange to prevenl turning. Tightert flange nut
assembly 0'1 discoo'lect m01Jnti'lg studs. to specified torque (see elastic step nu~ chart}.
Irtsta'i stud nuts and lock'Nashe's.
Figure 42
The actuatc-r p:stGn sprin-gs must be comprEssed
against the rear cover ~o start the stud nuts and
lock'.'iasller. TightEn stud nuts to speci'fBd torque
(see torque chart).
S1036
11.2 PARKING BRAKES
11.2.1 MechanIcal Brake
11.2.1.1 seclional views and paris Idenliflcatlon

S1036
GROUP - DISC BRAKE (MECHANICAL BRAKE)
1
S1036
GROUP - DISC BRAKE (MECHANICAL BRAKE)
1 Calipe r - Par king brake 1

2 Disc - Brake 1
3 Assem bly - Mo unti ng bracket 1
4 Screw - Bracket asse mbly 10 b rg cap mtg 4
5 Washer - Bracket assembly 10 brg cap mtg fiat screw 4
6 Screw - Flange 6
7 Screw - Caiiper 10 mounting bracket 2
8 Spacer 2
S1036
GROUP - MECHANICAL BR AKE
16
", . ~~
~:.~ .<~ )\Q).' ~~~-
tQ{,r:«<~~ /~,q,~
.. 0/' _1",3_
< 0 , , -
4
. r.c.." -~/'-'
6\f'.11'=», . ,;':;,;(J ."
1 3
S1036
GROUp· MECHANICAL BRAKE
Item Descrlp1ion auantily
1 Screw 1
2 Anti·rotalion clip 1
3 Washer 1
4 Lever 1
5 Spring 1
6 Shaft - Seal 1
7 Housing 1
8 "O"·ring 4
9 Bustling 2
10 Ball 3
11 Ball - Spacer 1
12 Rotor 1
13 Plai n bearing 1
14 Rotor - Seal 1
15 Lever side pad 1
16 Carrier side path 1
S1036
11.2.1.2 Adjustment and rebuild criteria

1. Check to insure iloating parts move freely and that all other parts are mounted securely.
Tighten hardware as required.
2, Check actuator linkage to insure that there is adequate freedom of movement for positive brake
operation. Adjustment of pad gap is to be accomplished by adjusting the actuating cable or linkage.
If adju stmentl s used up, back off cable or II nkag e. Un be nd tab 0 n anti -rotation eli p and 100 se n screw
enough to disengage lever spline. Rotate the lever one tooth, in the direction opposite the actuation
directi 0 n. an d retorq ue the sc rew maki ng su re th e splin e teeth are prope rly eng aged.
Bend up a tab that aligns with one of the screw head flats, to prevent screw rotation.
Both lever and linkage musf be free to return to home position. An external return spring is required.
3. Check disc surface condition. Replace if it is badty warped, pilted, or below minimum recommended
thickne ss. C heck for loose mou nt bo Its. Retighten if necessary.
4. Check to insure friction pads are not worn to less than .039" (1 ,Omm) thick. Replace worn friction pads.
Generally, if the disc is still running true and the pad clearance is still adjustable,
no other maintenance is required. To check for wear, measure the distance from the carrier side casting
face to disc face. If the distance is less than .060" (1.5mm), replace the friction pads.
11,2.1.3 Replacing friction pads
Note
ST/I.MPED ON TIlE B;'.CK OF E..'.,C;-t FRiCTION PAD IS A CODE. THE FlRST 1 GR 2 CoH.~RACTERS 1S ANUM2EA THAT
SPECiFIES THE FHCTION MATERIAL TYPE. CHECK TO IJlSURE NEW PADS toRE THE S;'}~E AS THE \'i~N PlillS RElI.OVED.
L--~------~REPl:A"Cl:.-'FH1Cl1C11t-'ADS"ONLYlUr'Afr-lS.
To replace the friction pads it is necessary to release the brake and disconnect the actuator
fro m the brake Ieve r.
1. Remove one brake mounling bolt. Swing the brake up over the disc to expose the brake pads.
In close cleara nee application s th e brake may be re moved fro m the ve hicle.
Using a flat bladed screw driver, pry out the used brake pads from their respective positions.
The lever side triction pad is snapped onto the plastic actuator cover. Care should be used in removing
the friction pad from the plastic actuator cover so as not to break oflthe center snap tabs.
2, Place the new f~ction pads in their respective positions.
The lever side friction pad has a center hole which snaps over the plastic snap tabs of the acfuator
cover. The flaf on the lever side pad must align wifh the flat on the plastic rotor cover, allowing the pad
to sit flat.
If fhe snap tabs are gone dab some silicone gasket adhesive around the back edge of fhe friction pad
and press firmly into place aligned as desc~bed above. Before placing the carrier pad in postilion,
clean out excisting pad glue from fhe pad compartment.
Place a layer of silicone gasket adhesive all along the back edge of the car~er friction pad and press
firmly In place. Push fhe lever side pad info the brake as far as possible.
3. Swing the brake over the disc and install the mounting bolt and tighten all mounting bolts.
4. AIter friction pad rep Iaceme nt, the brake actu ati ng lever is no 10 nger in th e correct po sIti 0 n fo r th e
actuating linkage.
Unbe nd tab 0 n anti -rotall 0 n clip and Ioos en screw e nou gh to dise ngag e th e leve r spline.
Rotate the lever to the OEM and torque screw to 110 - 140 in.lbs.(12.4 -15.8 Nm}. Bend up a tab on the
anti rotation clip tl1at aligns with one of the screw head flats, to prevent screw rotation.
Altach actuating cable or linkage to the lever. Adjustment of pad gap is accomplished by adjusting
the actualing cable or linkage.
S1036
11.2.1.4 Disassembly
Perform disassembly on a clean work bench.
1. Disconnect lhe actuator cable or linkage and remove brake from ils mounting.
2. Remove 1rieti 0 n pads. (see" Replaci ng Fricti 0 n Pads")
3. Unbend anti-rolation clip lab away from lever holding screw. Remove screw, anti-rolalion clip, washers,
lever, and spring.
4. Push out rolor assembly from lhe casling.
Caution
BAll. SPAeEH NlO 3 BALL BEMl NG S MAY COME OUT ~"ITU lHE ROTOR. ASS EM.3 LY.
(FOil HOron OISASSEP/BLY SEE "SmVICNG RmOR ASSEMBLY").
5. RemovB 3 ball bearings and ball spacer.

6. Shan seal need only be replaced il excessively worn or cracked. If replacemenl is necessary, press oul
lhe plastic shaft seal trom inside lhe casling, using a sleel spacer block 1.078"{27.38mm) diameter by
2.5" (63.5 mm) Ion 9 and an arbor pres s.
Note
POPUL,.',R £RI''lND NAM E 3/6" DR 1\' E 13/16 to HEX DEEP SOCKET "','OR KS WEU AS A SPACER BLOCK.
7. After the shaU seal is press ed 0 ut, rem ove the sl iver of plasli c lh at may be left in lh e
gro O\'e in th e casti ng.
This completes disassembly of lhe brake.
11.2.1.5 Cleaning and inspeclion

1. Clean all paris with denatured alcohol and either wipe dry with a clean linl free cloth
or blow dry with an air hose.
2. Examine all parts carefully tor signs of excessive wear, damage, or corrosion.
Replace any parts fou nd 10 be damag ed.
3. Cil eck rolor ass embly for cracks, Replace if nece ssa ry.
4. Inspecl til e ca sting ball po ckels for scoring, pi tti ng, cracks or corros ion.
A corroded or deeply sco red easti ng shou Id be repl aced_
Ughl scaring and stains may be removed.
5. Check to see lhal the disc is nol bent or misshaped.
6. Check lever sp ri ng fo r breakage.
S1036
11.2.1.6 Assembly
Pri 0 r to ass embly make su re all parts are clean and serviceable.
1. Install a new shaH seal by Inserting the seal from the outside of the casting with Ihe extended smooth
surface inserted first Using an arbor press, with a protective spacer block between the arbor press
and the seal, ga ntly pres s th e seal in u nti I il sn aps in 10 the groove In th e casti ng.
2. Coat wi Ih grease, th e ball po ckels In th e casting, Ih e shaft and bal I pockets of the rolor assem bIy.
3. Insert 3 ball bearings and ball spacer inlo the pockels in Ihe casting.
4. From Ihe inside of Ihe casting slide the shaft of the rolor assembly thru the shall seal and seal
I he ball po ckets ag ai nst Ih e ball bean ri ngs.
5. Place the spring over Ihe large diameler pllol on the oUlslde of Ihe castmg.
6. Install the lever, making sure Ihe small diameter at Ihe spring is piloted on the oUlside
01 Ihe 4 pins In the Ieve r. Set Ihe Iever in III e OEM position.
7. Instailihe washers and anli-rotalion clip with its lab Inserled inlo the lower hole in Ihe lever.
B. Insert screw Inlo rotor assembly shaft and tighlen 10 110 - 140 In.lbs.(12.4 - 15.BNm),
while guiding lever over rolor assembly spline.
9. Aller Ihe proper torque Is achieved and the lever is inlhe OEM position, bend up a tab on Ihe
anli-rolallon clip Ihal aligns wllh one of the screw head flals, to prevenl screw rolallon.
1O. Inslall th e I riclion pads onto Ihe rolo r asse mbly and carrie r. (s ee "Replacing Fricti 0 n Pad s").
11. Stroke lever In its proper direction. The lever must rolale thru 60 degrees of rotation.
Return lever 10 the OEM position and make sure Ihe lever side friction pad is fully rerurned.
11.2.1.7 Replacing mount bushings

1. Pu sh mou nt bush ing s co mplete Iy out of the brake castln g.
2. Remove the four (4) 'O"-rings from the grooves in the casting, being carefull not to damage the
grooves. Clean the grooves and the bore with denatured alcohol or cleaning solvent. Let dry.
Lubricate Ihe grooves and "O--rlngs with the grease furnished with the service kit.
Install the 'O"-rings into the grooves.
3. Coat the bushings with kil grease. Insert bushing through tlle "O"-ring.
Wi pe oil any exce ss grease.
11.2.1.6 Servicing rotor assembly

Disas sem ble brake as previ 0 usly desc rlbed.
1. Using a sharp knife, make several cuts through Ihe outside diameler of the rigid plastic rotor cover.
Sreak aparl Ih e plaslic, re move and disc ard.
2. Discard the plain bearing from under the pia sic cover
3. Thoroughly clean all dirt and grease residue trom the rotor.
4. Amply grease one face at the new plain bearing and place it into the new rotor cover, grease to plaslic.
Amply grease the olher lace 01 the insert.
5. To assemble Ihe new plastic rotor cover a bench vise is necessary.
Snap a fri cti 0 n pad 0 nto the piastic cover.
Place the plastic cover over rte rotor, place in a vice, amf slowly squeeze the cover and rotor until the
cover snaps In place. Remove the Iriction pad and reassemble the brake as previously described.
S1036
11.2.2 Sp rl ng app lied hydrau lie rei eased bra ke (h ig h press ure)
Note
PLEASE RE;'.D NSmUCllDrlS BELOW E!-EfCFlE ATTEMPllrlG M~Y WOHK ON THE BFlAKE.
11 .2.2.1 Seeti anal views and parts Ide n!iliealion

S1036
GROUP - DISC BRAKE (SPRING APPLIED HYDRAULIC RELEASED BRAKE (HIGH PRESSURE))
6~
(
,
t
S1036
GROUP - DISC BRAKE (SPRING APPLIED HYDRAULIC RELEASED BRAKE (HIGH PRESSURE))
Item De scrip lion auantity
1 Cal iper - Parki ng brake 1

2 Disc - Brake 1
3 Ass embly - M DU nti ng bracket 1
4 Screw - Bracket assembly to brg cap mtg 4
5 Was her - Bracket assembiy to brg cap mtg IIat screw 4
6 Screw - Flange 6
7 Spacer 4
S1036
~S~P~RI~N~G~A;;;PPLIED lie~~~~D~8~R~AK~E~(~HI~G~H~P~RE~S~S~U~RE)
RELEASE
_ _______ __ HYDRAU
__
, -
S1036
SPRING APPLIED HYDRAULIC RELEASED BRAKE (HIGH PRESSURE)
1tem Description Quantity
1 Torque plate 1
2 Boll- Hex 2
3 Jamnul 2
4 Ho usin g - Spring 1
5 Plug 1
6 Bolt - Adju slment 1
7 Shim AR'
8 Spring disc 10
9 Piston 1
10 Seal- "O"-ring 1
11 Back-up ring 1
12 Piston 1
13 Seal - "O"-ring 1
14 Back-up ri ng 1
16 Wiper 1
17 Boll 1
18 Nut 1
19 Uning 2
20 Bleeder 1
21 Spring - Urethane 2
22 Was her - Flat 2
23 Cap - Plug 1
24 Seal- "O"-ring 1
AR': As Required
S1036
11.2.2.2 0 peralio n
Ten disc springs (B) are used to hold the park brake in the actuated state.
The springs (B) push lhe pislons (9, 12) into lhe lining and carrier assembly (19) which squeezes
a driveline mounted disc. The brake is released by fluid entering a SAE 7/16-20 lhreaded inlet
in lhe side oj the torque plale (1) which pushes1he pistons back and compresses the springs (8).
11.2.2.3 Adjustment and rebuild criteria

1. Apply hydraulic pressure to the brake.
2. Remove plug (5) and set running clearance (.020" - .030") using the adjustment boll (6).
3. Replace plug (5).
4. Even up running clearance on each side oj the disc by adjusting the carrier retaining bolt ( 17).
The brake should be rebuilt when one or more ot the Jollowing crileria are met
1. Any sign s ot tluid leakage.
2. Lining thickness less than .031".
3. C racked or c hipped Ii ~i ng s.
11.2.2.4 Replacing friction pads

1. Apply hydraulic pressure 10 the brake and remove plug (5) and carrier boll (17).
2. With pressure applied, back-oH adjustment bolt (6) until piston (12) isllush with piston (9),
3. Re Iease hydrau lic press ure from th e brake an d re move lining and carri er assemblies (1 9).
11.2.2.5 Disassembly
IF THE FAEK 8 R.,o'IKE IS BE NG 0 IS.t..S SEM SLED "'.HI.LE eN THE VEH: CLE, fT IS " •• PORTANT ro FOLlO'''' TH E DI RECTlO rl5
F.:EGARD NG THE RBWV;'.L OF THE SfiFUW3 HOUSING (4) AND THE L1NNG AND CAA.RIE:RS (19) VERY CLOSELY.
1. Apply hydraulic pressure to the brake and remove plug (5) and carrier bolt (17).
2. With pressure applied, back'oll adjustment bolt (6) until piston (12) is Hush with piston (9).
3. Release hyd raulic pressu re Jrom th e brake an d re move Ii ni ng an d carri er assemblies (1 9).
4. Using a press, compress springs (8) to reduce the Jorce on the spring housing (4).
5. Use a spanner wrench to remove lhe spring housing (4) (counter-clockwise direction).
6. The spring s (8) will be acces sible when 1Ill! sp rin g h 0 usi ng is re moved.
Note
THE SF-fliNG H-:J'-J-S-lrlG (4) MAY HE REM{)',IED WHHOLIT COP/PRESSING THE SPRINGS ~8},
HCWE.... ER IT lS tr:t"T RECOMMENDED DUE ro THE ~IGH TORQtE P.EQU flED.
7. The adjustment bolt (6) threaded part oj lhe way into the hydraulic piston (9) may be used
to remove the pistons (9 and12) iJ brake is mounled on the vehicle.
8. If brake is not mounted to the vehicle it is easier to press the pistons out from the lining a~d carrier (19)
side of the torque Plate (1).
Caulion
Do NOT DM,\AGE SEALS (10,13,15) en BACK-UP R"'GS (11,14) en THE WIPEA (16) ',','HEr,
Awe-miG THE PISTOIIS (9 IIND12).
9. Piston (12) may be removed Jrom piston (9) by pushing on piston (12) through adjustment bolt hole
with a small nut-river or similar device,
S1036
11.2.2.6 Cleaning and Inspecllon

1. Clean all metal p arts prior to as sembi y.
2. Blow excess cleaning solulion ofl of all parts and out of all fluid passages.
11.2.2.7 Assembly
1. Apply a thin coat off fluid (compatible with mineral oil based hydraulic fluid) to seals (1 0,13,15),
Back·up rings (11,14) and the wiper (16).
2. Install seal (15) in seal groove on piston (12).
3. Slide the adjustment pislon (12) into the bore located in the hydraulic pislon (9) unlil it hits
the bollom of Ihe bore.
4. Install wiper (16), back-up ring (14), and seal (13) in the grooves located in the small hole in
the torque plale (t).
5. Install seai (10) and back·up ring (11) in larger grooves in lorque piate (1).
6. Install pislon assembly into torque ptale. (1).
7. Thread adjuslment bolt (6) into the hydraulic piston (9) until the bolt contacls
the adjustment pislon (12).
8. Place springs (8) in the lorque plate (1).
Springs should be placed in an ailernating cupped face to cupped lace orientation.
The springs on the outside ends 01 the stack should be oriented cupped lace out.
9. If the brake contained a shim (7) when it was disassembled, place the shim (7) so il wiil be in the
bottom of Ihe spring housing (4) when il is inslalled. See illustration below lor a grapllical
representation.
Nole
SPfJNGS ARE '.-lATCHED AND PRETESTED. IF NE'N SPFlIrlGS ARE BEING liSTALlED ADD A S-HL\l ONlY -iF THE rlE'....
SPR rIGs A.RE SHlfPED ....JJTH ONE.
SHI~' -~
SPRIIlGS
10. Thread spring housing (4) into torque plate (1) about 3 turns or until il makes contact,
with the springs (8).
11. Using a press, compress springs (8) to reduce the force on lhe spring housing (4).
12. Use a spanner wrench to lighten spring·housing until the face bottoms out on the counterbore lace
in the torque plate (1). Tighlen to 500 - 600 Ib,-in torque.
13. Assemble washer (22) and the urethane spring (21) on the mounling bolt (2) then slide mounting bolls
through bolt holes in Ihe torque Piate (1).
14. Thread jam nUUsleeve {3) onto mounting bolt.
The cylindrical part ollhe jam nut/sleeve should extend into the torque plate,
S1036
15. Ins la II lining and carrier assem biles (19).

Thread lining and carrier adjustment boil into hex nut (8) located in the slot in the
back side ollhe lorque plale {1).
16. lnslailihe bleeder (20) in lhe porllocaled on lhe lop side ot lhe lorque plale (1).
17. Afler brake is mounled and adjusted, snap plug (5) onlo spring housing (4).
11.2.2.8 Installation
1. Slide brake ove r disc and inlo lh e rno unli ng pos iIi 0 n.
2. Slart mounting bolls (2) into mounting surface far enough to jusl supportlhe brake,
3. Remove plug (5) and tighten adjustmenl boll (6) until linings (19) are clamped to the disc.
4. Tighlen mounling boils {2) unlit lhey make conlact wilh the urelhane springs {21},
then lighten 1 to 2l1als more.
5. Tighten jam nut/sleeve (3) againsl mounting surface to lorque shown in seclion 11.2.2.9.
Caution
BW..KE 1I~~!r~3S ,hRE SUSCEPTHLE TO CmITA1'.lINATION.
WI-lEU lNSTALUNG OR S£.F..VICllG BRAKES KEEP;'lL OIL AND FlUDS ":I'.{A\( FE-OM THE l'N:rms.
POOR BRP.KE PEEFOFlMANCE PlAY RESULT.
6. Attach brake line to inlet porI localed on Ihe side of Ihe lorque plate (1).
7. Bleed brake sysle m 10 rem ove I rapped ai r as follows.
Note
USE BLEEDER HOSE Oil BlEEDER SCREV'/S (PREFERABLY CLEAR TUEmG) TO ROUTE FLU D A'NAY
FHOM THE BRAKE AND UN NGS.
Caulion
BRA;{E USES H:G~ PRESSURE, oral E-LEEO:='R SCREW (20) VERY SLC'o',"LY ...·mEN PEFFORMI~~G 8LEED:rolG PROCEDURE.
8. Apply pressure 10 brake and slowly openlhe bleeder screw (20) observe any air bubbles
lhalliow from lhe brake.
9. Repeal above paragraph unlilno air is observed in the tluid from Ihe bleeder screl'! (20).
11.2.2.9 Torque specs
PART (ITEM 110,) THREAD SIZE DRYTORQUE

8LE E0ER SCRB'/ !20) 7.116·20 2'){J • 25(H LB-I Ni
JAI,lJWTISLEEVE 1:31 1'4·10 2>i»)j18-Ni

S1036
11.2.3 Spr i n9 appli ed hydrau Ii c relea sed bra ke (low pres su re)
Nole
PLEASE HEAD IrlSlP,UCflOrlS- BELOW ElEFOJlE AnHlPtlNG MlY Vf()HK orl THE E!fV\~E.
11.2.3.1 SecUonal views and paris Idenliflcalion

S1036
GROUP - DISC BRAKE (SPRING APPLIED HYDRAULIC RELEASED BRAKE (LOW PRESSURE))
?
L
/ : 6~
( t r
~-:;,.>\._ . _::'::'.;..~ . . _ :',">; _f_~~ __'~ f<',~~· _ I '. _~./' ., _ •
, •••. "\" '::'<.;' :.:.'.'.. ..6,:,' ~ J ;::: '.,::/ . \1

..- __ ~ '_.-..:r .\,..... .._.~.-,.':__.. , .~: \f ~~ / ,,~~_. :_~_._-:. . '::I ':I. !
" .:~::j):: '.. ," , ~,~~~]~;'"

:r\"\
{):\ . ,.':
"·~~;,.·i,:
.'
,,::~!.<i>:~: <:.~.>~~~.:/i R
I ,{,,','.
~,
;. 0i 18\/ "-4
, ~ ~.~
7 5
.. ';~~::;"):';';~"
,. -.... ," .~
-- -,'
(--'" -"
or... ,
S1036
GROUP - DISC BRAKE (SPRING APPLIED HYORAULIC RELEASED BRAKE (LOW PRESSURE))
Item Des cri pH 0 n Quantity
1 Caliper . Parking brake 1

2 Disc - Brake 1
3 As sembly • Mounting bracket 1
4 Sc rew • Bracket assembly to brg cap mig 4
5 Wa she r - Bracket assembly to brg ca p mtg II at screw 4
6 Sc rew· Flang e 6
7 Spacer 4
RELEAS~E~D~B~::-:::-::-----
S1036
SPRING APPLIED HYDRAU Lie RAKE (LOW PRESSU REJ

S1036
SPRING APPLIED HYDRAULIC RELEASED BRAKE (LOW PRESSURE)
1 Torqu e plale 1
2 Boll - Hex 2
3 Jamnut 2
4 Hau sing - Sprln g 1
5 Plug 1
6 Boll- Adjustment 1
7 Shim AR'
8 Spring disc 10
9 Cam 1
10 Ball- Bearing 3
11 Cam 1
12 Bearing - Nee1Jle 1
13 Washer - Hardened 2
15 Piston 1
17 Lever 1
18 Ring - Retainer 1
19 Boll 1
20 Nut 1
21 Pin - Callers 1
22 Uning an d carri er as sembly 2
23 Cylinder - Hydraulic 1
24 Screw 2
25 Piston 1
26 Seal - STD po Iy pack 1
27 Sliding ring 1
28 Rod 1
29 Ring - Retain ing 1
30 Rod excluder 1
31 Jamnut 1
32 Clevis 1
33 Clevis pin 1
34 Pin - Dowel 3
35 Spring - Urelhane 2
36 Washer - Flat 2
37 Cap - Plug 1
38 Seal- "O"-ring 1
AR': As Require1J
S1036
11.2.3.2 Ope ra lion

Ten disc springs (8) are used 10 Ilold the park brake in the actualed slate.
TIle springs push tile cams (9.11) and pistOil (15) into Ille lining and carrier assembly (22)
which squeezes a driveline mounted disc.
Tile brake is released by tluid entering a SAE 7/16-20 tllreaded inlet in tile top of tile hydraulic cylinder
(23) which pushes the piston {25} down, thereby rotating the lever (17) and cam (11),
compressing the springs (8).
11.2.3.3 Adj u stm ent and re build criterla

1. Apply hydraulic pressure to the brake.
2. Remove plug (5) and set running clearance (.020" - .030") using the adjustment bolt (6).
3. Replace plug (5).
4. Even up running clearance on each side of the disc by adjusting the carrier retaining bolt ( 1!l).
The brake shou Id be rebu ill when on e or m ore of the following c riteria are met:
1. Any sigl1s ot fiuid leakage.
2. Lining thickness less than .031".
3. C racked or cll ipped lil1i ngs.
11.2.3.4 Replacing friction pads

1. Apply hydraulic pressure to the brake and remove plug (5) and carrier retaining boll (19).
2. Witll pressure appiied remove adjustment boll (6).
3. Release hydraulic pressure from Ihe brake and remove lining and carrier assemblies (22).
, 11·2.3.5__Disassembll' -------
Caution
IF T"r1E PAEK EEAKE IS BEING DISASSEMBLED ...·.'HiL£ ON THE VEHICLE, IT IS L'.lPDRTAJIT TO FOUO'N THE FOLlO.. .jl~jG
DIRECTONS BEGAFDNG THE REMOV'L OF THE SPR NG HOUSING (4) AND TIlE L"''''G & CARR'Ens (22) VERY
CLOSELY.
1. Apply hydraulic pressure to the brake and remove plug (5) and carrier retaining bolt (19).
2. With pres sure app Iied remove adjustmen I bolt (6).
3. Release hydraulic pressure from the brake and remove lining and carrier assemblies (22).
4. Use a spanner wrench to remove the spring housing (4) (counter-clockwise direction).
5. The springs (8) will be accessible when the spring housing is removed.
6. Remove hair pin (21) and pin (33) from Ihe clevis (32).
7. Remove hydraulic cylinder (23) from torque plate (1) by removing cylinder mounting bolts (24).
B. Remove retaining ring (1 B) and lever (17) trom the spline on Ihe cam (11).
9. The opposing cams (9, 11), adjuslmenl piston {15} and dowel pins (34) can be removed by pressing
them out of the torque plate (1) from the lining and carrier (22) side.
10. Remove balls (10) and adjustment piston (15) from cams (9, 11).
11. The 'O--ring seal (16) can be removed from the adjustment piston (15) If necessary.
12. Remove needle bearing (12), hardened washers (13), and 'O"-fing seal (14) from Ihe torque plate (1)
once the cams (9, 11) are removed.
13. Slide the rod (28) and clevis (32) out of the hydraUlic cylinder (23).
14. Remove the rod exciuder (30) from the hydraulic cylinder {23) by prying with a small screwdriver.
15. The retaining ring (29) may be removed once the rod excluder (3D) has been removed.
16. Press piston (25) out of the hydraulic cylinder (23) by pushing on Ihe top ot tile piston
with a long slender rod.
S1036
Note
Do rIDT S-cI\A CYLINDER 'NALLS OR. WCK HiE p,Srml DURING REMO'rlAl.
11.2.3.6 Cleaning and inspectlon

1. Clean all metal parts prior to assembly.
2. Blow excess cleaning solulion 011 of all parts and out of all fluid passages.
11.2.3.7 Assembly
1. Apply a thin coat of tluid to seals (14.16).
2. Install seal (16) in seal groove on adjustmenl piston {15}.
3. Slide the adjustment piston (12) into the bore located in lhe cam (t1) untillhe seal (16) is
inside the bore.
4. Install seal (14) in the grooves located in the small hote in the torque plate (1).
5. Install needle bearing (12) between tile two Ilardened washers (13).
6. With bearing and washers (12,13) in ptace, install cam (11) and balls (10) inlo torque plate (1).
7. Install cam (9) and dowel pins (34) into torque plate (1).
8. Thread adjustmenl bolt (6) into the cam (9) until the bolt contacts the adjustment piston (15).
9. Place springs (8) in the torque plate (1).
Springs shoutd be placed in an alternating cupped lace to cupped face orientation.
The springs on the outside ends of the stack should be oriented cupped face out
10. Replace th e sh im (7) in the bolto m of the spri ng hou sing (4) before add ing th e spring s if the brake
contained a shim when it was disassembled. See illustration below for a graphicat representation.
Note
SPilrms NlE 'lATCHED A.ND P,RETESTEO.
IF r-.~w SPFHNGS ME BEING INSTALLED ADD A ScU,l ONLY IF THE NB'J SPRlrlGS ~..RE SKIPPED \'itT=-!. orfE.
SHI~' -------., SPRIIIGS
11. Apply a thin coat of Never-Seez to the spring housing (4) threads.
12. Screw spring housing (4) onto torque ptate (1). Tighten with a spanner wrench until the spring
housing lace bolloms out on lhe counterbore face in the torque plate (1).
13. Assemble washer (36) and !he urethane spring (35) on the mounting bolt (2) then slide mounting
bolts through boll holes in the torque plate (1).
14. Thread jam nutlsleeve (3) onto mounting bolt.
The cylindrical part ot the jam nutlsleeve should extend into the torque plate.
15. Apply a thin coat of fluid to seal {25} and stiding ring (27).
16. Install seal (25) and the sliding Ring (27) on the Piston (25).
S1036
17. Install piston (25) into the hydraulic cylinder (23) wilh the Hat side facing the top of the cylinder.
18. Push the piston (25) to the top of the hydraulic cylinder (23) and install the retaining ring (29) in the
groove at the bolla m of the cyiin der.
Note
MAKE SURE :INLET PORT IS UNCAPPED ,,·trla~ INSTAll!NG PiSTmJ {25)+
19. Press rod excluder (30) with the rubber side facing out of the hydraulic cylinder (23).
20. Thread clevis (32) with the 3/8-16 jam nut installed into the rod (28).
21. Insert the rod (28) and clevis (32) through the rod excluder (3D) into the hydraulic cylinder (23).
22. Position assembled hydraulic cylinder (23) onto torque plate (1) and install the cylinder mounling
bolts (24) into their respective holes.
23. Pin clevis (32) to the lever (17) with clevis pin (33) and hair pin (21).
24. Adjust rod (28) until it contacts the rod relaining hole in piston (25) and tighten the jam nut.
25. Install lever (17) on the spline of cam (11).
Th e ce nte r Ii ne of the leve r sh auld be 0 rienled parallel 10 the top olt he torqu e pi ate (1).
26. Install retaining ring (18) in groove on the cam (11).
27. Install lining and carrier assemblies (22).
28. Thread carrier adjustment boll (19) into hex nut (18) located in the siot in the back side
of the torque plate (1).
29. After brake is mounted and adjusted, snap plug (5) onto spring housing (4).
11.2.3.8 Installation
1. Slide brake over disc and inlo the mounting position (per vehicle specification).
2. Slart mou nting bolts (2) inlo rna unting surface far e nou gh to ju st su Pport the brake,
3. Remove piug (5) and tighten adjustment bolt (6) until linings (22) are ciamped to Ihe disc.
4. Tighten mounling bolls (2) untillhey make contact wilh the urethane springs (35),
III en tighten 1 to 2 flats more,
5. Tighten jam nut I sleeve (3) against mounting surface to torque shown in section 11.2,3.9.
Caution
BRAKE llN!tmS APE SUSCEPTIBLE TO corrrAMi~~Anou.
WHEN IN5TAU1NG OR SERVICING E.R/o..KES KEEP ALL OIL A~D flUIDS AW.~Y FADM THE UNI~ms.
POOR BRAo<.E PERFORMA~JCE M,A.Y RESULT.
6. Al1ach brake line to inlet port located on the top of Ihe hydraUlic cylinder (23).
11.2.3.9 Torque specs
PART (ITEM 110.) THREAOSIZE DRYTORQUE
PLUG-INLET (3 Ii 7116 - 20 12,'t7 {LBW)

,tAl.! lILIT,'SLEEVE 1:3:, H-W 2001LB-Ni
S1036
12. SERVICE TOOLS
12.1 REVERSE IDLER SHAFT NUT SOCKET (TG 1304 - 54)
Ma de from Sn ap-on 1M 662A Socket 2 1116" d Ii ve 3/4".
101"-,- - j
4 SLOTS
i
·-ill-· I
--,
I
I
S1036
13731
DRIVELINE INSTALLATION
Page 1 of 1

1 11827-01 END YOKE (STD.) 1
2 244565 FLANGE YOKE 1
3 244565 END YOKE 1
4 11827-01 END YOKE 1
5 364024 CROSS AND BEARING KIT 1
6 19201-02 DRIVELINE ASSEMBLY (INCLUDES ITEM 7) 1
7 362120 CENTER BEARING 1
9 464640 SLIP ASSEMBLY (INCLUDES ITEMS 8 & 10) 1
12 19200-14 DRIVELINE ASSEMBLY 1
Updated:
12/11/06
MANUAL INDEX
FRESNILLO
S/N 6975
12/27/07
6. AXLE
10829 AXLE ORIENTATION

13335 AXLE ASSEMBLY
13332 AXLE CRADLE INSTALLATION
S1037 AXLE SERVICE & REPAIR MANUAL
13158 BRAKE ACTUATOR
S1023 BRAKE ACTUATOR INSTALLATION
17095 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
17095
TIRE & RIM
Page 1 of 1

465099 WHEEL & TIRE 1
1 18041 RIM ASSEMBLY (INCLUDES ITEMS 2 & 3) 1
2 NSS LOCK RING 1
3 NSS SIDE RING 1
4 480002 TIRE 1
5* 17GC10136 BOLT 8
6* 27GE10 WASHER 8

08/21/07
S1007
S1007
S1007
S1007
S1007
S1007
S1007
S1007
S1007
MANUAL INDEX
FRESNILLO
S/N 6975
12/27/07
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
FRESNILLO
S/N 6975
12/27/07
8. HYDRAULIC SYSTEM

13259 FILTER (HYDRAULIC)
12860 STEERING ORBITROL
S1024 STEERING ORBITROL SERVICE
S1010 PUMP SERVICE
13943 STEERING CYLINDER
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
S1010
S1010
S1010
S1010
13943
STEER CYLINDER
Page 1 of 1

465411 CYLINDER ASSEMBLY 1
465411-07 SEAL KIT 1
1 465411-01 BARREL ASSEMBLY 1
2 465411-02 ROD ASSEMBLY 1
3 465411-03 PISTON ASSEMBLY 1
4 465411-04 ROD BEARING ASSEMBLY 1
5 465411-05 NUT 1
6 465411-06 CAP SCREW 1
Updated:
12/11/06
MANUAL INDEX
FRESNILLO
S/N 6975
12/27/07
9. CONTROLS
13905 ELECTRIC SHIFTER

10827 STEERING WHEEL & COLUMN
13025 THROTTLE (HYDRAULIC)
13305 HAND THROTTLE LINKAGE
16976 RESERVOIR (HYDRAULIC)
13905
ELECTRIC SHIFTER
Page 1 of 2
Updated:
06/20/07
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
8 534772-08 SWITCH DRIVE BEARING 2
10 534772-09 SPRING LEVER ASSEMBLY (LEFT) 1
534772-10 SPRING LEVER ASSEMBLY (RIGHT) 1
11 534772-11 MOLDED HANDLE 2
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
Updated:
06/20/07
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
13025
THROTTLE
Page 1 of 1

604791 HYDRAULIC THROTTLE KIT (INCLUDES ITEMS 1-3) 1
1 604793 ACTUATOR 1
2 604026 RESERVOIR 1
3 604794 SLAVE CYLINDER 1
Updated:
05/25/07
13305
HAND THROTTLE LINKAGE
Page 1 of 1

1 72260 HAND THROTTLE CONTROL LEVER 1
2 02GJ04 CLEVIS 1
3 11870-02 HAND THROTTLE TUBE 1
4 19217-17 HAND THROTTLE ROD 1
5 133011 BALL JOINT 1
6 604791 HYDRAULIC THROTTLE KIT 1
7 10578-04 PEDAL MOUNT 1
8* 604026 RESERVOIR OIL (THROTTLE) 1
9* 133021 BALL JOINT (ON ENGINE) 1
10* 34015 RETURN SPRING 1
11* 10590-04 THROTTLE CYLINDER MOUNT (ON ENGINE) 1

05/25/07
16976
RESERVOIR
Page 1 of 1

604026 RESERVOIR ASSEMBLY 1
1 534226 CAP (INCLUDES DIAPHRAGM) 1
Updated:
03/27/07
MANUAL INDEX
FRESNILLO
S/N 6975
12/27/07
10. MOUNTED EQUIPMENT

S1012 FIRE PROTECTION INFORMATION MANUAL
S1013 FIRE SUPPRESSION MAINTENANCE MANUAL
23276 FIRE SUPPRESSION INSTALLATION
16721 FIRE SUPPRESSION SYSTEM
17124 CABLE STRINGER ASSEMBLY
S1076 SOUTHWORTH LS SERIES LIFT TABLES MANUAL
ANSUL ® SENTRY ® MODELS
FIRE A05, AA05,
EXTINGUISHERS A05VB, AA05VB,
PARTS LIST PK05, C05
9
1 10
16
11
12
8
7 5
4 13
6
18
15
14
19
2
20
21
006004
FIG. PART NUMBER

NO. DESCRIPTION AA05 AA05VB PK05 A05 A05VB C05
— Valve Assembly 429084 429084 429084 429084 429084 429084
1 Valve Body, Machined 428062 428062 428062 428062 428062 428062
2 Tube, Pick-Up 428796 428796 428796 428796 428796 428796
3 O-Ring (Pick-up Tube) 76076 76076 76076 76076 76076 76076
4 Valve Stem Assembly (Includes O-Ring) 429099 429099 429099 429099 429099 429099
5 O-Ring 11873 11873 11873 11873 11873 11873
6 Spring 415565 415565 415565 415565 415565 415565
7 O-Ring 428327 428327 428327 428327 428327 428327
8 Gauge, Pressure 428280 428280 428280 428280 428280 428280
9 Lever, Operating 429096 429096 429096 429096 429096 429096
10 Handle, Carrying 429097 429097 429097 429097 429097 429097
11 Rivet, Operating Lever 428130 428130 428130 428130 428130 428130
12 Rivet, Carrying Handle 428130 428130 428130 428130 428130 428130
13 Pull Pin (Ring Pin) 16235 16235 16235 16235 16235 16235
14 Seal, Visual Inspection 419790 419790 419790 419790 419790 419790
15 Hose Assembly 428729 428729 428730 428728 429728 428731
16 Hanger Hook 54405 — 54405 54405 — 54405
17 Bracket Assembly (Not Shown) — 429146 — — 429146 —
18 One-Piece Nameplate, Replacement 430854 430854 — — — —
(Maintenance, w/o UL/ULC Approval) (431049-ULC) (431049-ULC)
19 Adaptor Assembly, Recharge 429642 429642 429642 429642 429642 429642
20 O-Ring 57744 57744 57744 57744 57744 57744
21 Hose Retainer 427995 427995 427995 427995 427995 427995
Indicates revision
ANSUL and SENTRY are trademarks of Ansul Incorporated or its affiliates.
ANSUL INCORPORATED, ONE STANTON STREET, MARINETTE, WI 54143-2542 715-735-7411 Form No. F-2001047-1 ©2002 Ansul Incorporated Litho in U.S.A.
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.

S1013
REVISION RECORD
6-30-05
REV. 2
DATE PAGE REV. NO. DATE PAGE REV. NO.
5-15-02 1-2 2 5-15-02 6-2 1
5-15-02 2-1 2 5-15-02 6-3 2
5-15-02 3-3 1 5-15-02 6-4 2
5-15-02 3-4 1 5-15-02 6-5 2
5-15-02 3-5 1 5-15-02 6-6 2
5-15-02 3-6 2 5-15-02 6-7 New Page
5-15-02 4-1 1 5-15-02 6-8 New Page
5-15-02 4-2 1 5-15-02 8-1 2
5-15-02 4-3 1 5-15-02 10-1 1
5-15-02 4-4 1 5-15-02 10-2 1
5-15-02 4-5 1 5-15-02 10-3 1
5-15-02 4-6 1 5-15-02 10-4 1
5-15-02 4-7 1 5-15-02 10-5 1
5-15-02 4-8 1 5-15-02 10-6 1
5-15-02 4-9 1 5-15-02 11-1 1
5-15-02 4-10 1 5-15-02 11-2 2
5-15-02 4-11 1 5-15-02 11-4 2
5-15-02 4-12 2 5-15-02 11-5 1
5-15-02 4-13 1 5-15-02 11-6 1
5-15-02 4-14 1 5-15-02 11-7 1
5-15-02 4-15 New Page 5-15-02 11-8 1
5-15-02 4-16 New Page 5-15-02 11-9 New Page
5-15-02 5-1 1 5-15-02 11-10 New Page
5-15-02 5-2 1 6-30-05 Table of Contents 3
5-15-02 5-3 1 6-30-05 1-1 2
5-15-02 5-4 1 6-30-05 3-1 1
5-15-02 6-1 1 6-30-05 3-2 2
Indicates revised information.

S1013
REVISION RECORD
6-30-05
REV. 1
DATE PAGE REV. NO. DATE PAGE REV. NO.
6-30-05 7-1 3
6-30-05 8-1 3
6-30-05 8-2 2
6-30-05 9-1 3
6-30-05 11-3 2
Indicates revised information.

S1013
TABLE OF CONTENTS
6-30-05
REV. 3
SECTION PAGES SECTION PAGES

I. GENERAL INFORMATION 1-1 – 1-2 DISTRIBUTION SYSTEM 4-2 – 4-13
REQUIREMENTS
INTRODUCTION 1-1
TWIN AGENT SYSTEM 1-1 ACTUATION AND EXPELLANT GAS LINE 4-14
REQUIREMENTS
FM APPROVAL 1-1 Actuation Gas Line 4-14
HOW THE SYSTEM OPERATES 1-2 Expellant Gas Line 4-14
IN CASE OF FIRE 1-2 DETECTION SYSTEM REQUIREMENTS 4-14
II. SYSTEM DESCRIPTION 2-1 – 2-2 SHUTDOWN REQUIREMENTS 4-15
APPLICATION METHOD 2-1 ACCESSORIES 4-16
Local Application – Vehicle 2-1
V. SYSTEM DESIGN – INDUSTRIAL 5-1 – 5-4
Total Flooding 2-1
HAZARD ANALYSIS 5-1
PIPING ARRANGEMENT 2-1
Two Nozzle 2-1 DISTRIBUTION SYSTEM REQUIREMENTS 5-1
Four Nozzle 2-1 NOZZLE COVERAGE 5-1 – 5-4
Six Nozzle 2-1
DETECTION 2-1 VI. INSTALLATION INSTRUCTIONS 6-1 – 6-8
MOUNTING THE BRACKETS 6-1
III. SYSTEM COMPONENTS 3-1 – 3-6 Nozzle Bracket 6-1
TANK ASSEMBLY 3-1 Tank Bracket 6-1
TANK BRACKET 3-1 Cartridge Bracket 6-2
Remote Actuator Bracket 6-2
DRY CHEMICAL 3-2
MOUNTING THE DISTRIBUTION, 6-2
CARTRIDGE – EXPELLANT GAS 3-2
REDUCING, AND TRIPLE TEES
CARTRIDGE – ACTUATION GAS 3-2
INSTALLING THE COMPONENTS 6-3 – 6-5
CARTRIDGE BRACKET 3-2 Installing the Tank 6-3
PNEUMATIC ACTUATOR 3-3 Installing the Nozzles 6-3
MANUAL ACTUATORS 3-3 Installing Manual Actuators 6-3 – 6-5
1/4 IN. CHECK VALVE 3-3 INSTALLING THE DISTRIBUTION 6-5
NETWORK
DISTRIBUTION TEE 3-3
General Requirements 6-5
REDUCING TEE 3-4 Distribution Hose Installation 6-5
TRIPLE TEE 3-4 INSTALLING THE ACTUATION AND 6-6 – 6-7
SAFETY RELIEF VALVE 3-4 EXPELLANT GAS LINES
General Requirements 6-6
AIR CYLINDER (OPTIONAL) 3-4 Installing Actuation Gas Line and 6-6 – 6-7
PRESSURE SWITCH – WEATHERPROOF 3-4 Pneumatic Actuators
Installing Expellant Gas Line 6-7
PRESSURE SWITCH – 3-5
NON-WEATHERPROOF INSTALLING THE DETECTION SYSTEM 6-7
PRESSURE SWITCH – EXPLOSION PROOF 3-5 INSTALLING ACTUATION CARTRIDGES 6-7
NOZZLES 3-5 VII. INSPECTION 7-1 – 7-2
NOZZLE BRACKET 3-6
VIII. MAINTENANCE 8-1 – 8-2
HOSE (SUPPLIED BY OTHERS) 3-6
SEMI-ANNUAL 8-1 – 8-2
SEALED BURST DISC ASSEMBLY 3-6
12-YEAR 8-2
ENGINE SHUTDOWN DEVICE 3-6
CHECKFIRE ELECTRIC DETECTION 3-6 IX. RECHARGE 9-1 – 9-2
AND ACTUATION SYSTEM
X. SYSTEM APPLICATION OPTIONS 10-1 – 10-6
IV. SYSTEM DESIGN – VEHICLE 4-1 – 4-16
XI. APPENDIX 11-1 – 11-10
HAZARD ANALYSIS 4-1
SYSTEM COMPONENT INDEX 11-1 – 11-2
NOZZLE COVERAGE AND LOCATION 4-1 – 4-2
STAINLESS STEEL OPTIONAL 11-3
TANK QUANTITY REQUIREMENTS 4-2 COMPONENTS FOR AN/FO
System Selection Chart LOADER APPLICATIONS
LARGE EXCAVATORS 11-4 – 11-8
EXCAVATOR PROTECTION 11-9 – 11-10
FUME HOODS 11-10
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 II – SYSTEM DESCRIPTION
5-15-02 Page 2-1
REV. 2
APPLICATION METHOD DETECTION

The A-101/LT-A-101 system provides fire protection using total Automatic electric detection is available for the A-101/LT-A-101
flooding and local application methods. These methods are system.
described below. Electric detection systems (CHECKFIRE MP-N*, Series I, and
Local Application – Vehicle SC-N) are available to provide rugged, automatic detection for
vehicle protection. These systems are either powered by the vehi-
When designing a local application system for vehicle protection, cle battery or by the internal module battery.
each individual hazard area must be surveyed and the correct
type nozzle must be chosen to give the proper coverage. It must The electric detection systems can use either linear heat detec-
also be determined if certain local application hazard areas tion or spot thermal detectors, or pneumatic linear detectors.
require screening to adequately protect them. * Not FM Approved
Total Flooding
Total flooding is described as “volume protection” and it is applied
only when a hazard is located in an enclosure. Openings such as
doors, windows, and grating shall not be more than 15% of the
enclosure’s total surface area (ceiling, floors, and all walls).
Openings of 5% or less of the total surface area are acceptable
and do not require screening. Hazards with openings greater than
5% but not over 15% can be protected by screening.
Total flooding application is accomplished by introducing a suffi-
cient quantity of FORAY dry chemical through fixed nozzles
throughout the volume of the enclosure.
To enhance the effectiveness of the total flooding system in indus-
trial applications, all fan air movements should be shut down
and/or dampered at discharge of the dry chemical system. Refer
to NFPA 17, “Standard For Dry Chemical Extinguishing Systems,”
for additional information.
PIPING ARRANGEMENT
The A-101/LT-A-101 system utilizes three methods of splitting the
dry chemical flow from the tank to the nozzles. Each method is
approved for use on vehicle or industrial type applications.
Two Nozzle System

The two nozzle system can be used in either vehicle or industrial
hazard protection. It can be used in total flooding, or as a local
application system on off-road vehicles. The supply line is split
into two branch lines by the use of a 3/4 x 1/2 x 1/2 in. reducing
tee. Two nozzles systems can be used with nominal 10, 20, and
30 lb. tank sizes.
Four Nozzle System
The four nozzle system can be used in either vehicle or industrial
hazard protection. It can be used in total flooding, or as a local
application system on off-road vehicles. The supply line is divided
into four branch lines by the use of a triple tee or a split tee. Four
nozzle systems can only be used with nominal 20, and 30 lb.
tanks. Four nozzle 30 lb. systems are preferred for all systems
protecting hazards in environments which are extremely rugged,
and very prone to Class A and Class B fuel build up in hard to
protect areas, providing more agent per nozzle and longer dis-
charge times.
Six Nozzle System

The six nozzle system can be used in vehicle or industrial hazard
protection. It can only be used in local application systems on off-
road vehicles, when minimal discharge time and agent discharge
per nozzle is acceptable. The supply line is divided into six branch
lines by the use of a distribution tee and three 1/2 in. tees. Six
nozzle systems can only be used with nominal 20, and 30 lb.
tanks.
S1013
SECTION II – SYSTEM DESCRIPTION
5-15-96 Page 2-2
NOTES:
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
5-15-02 Page 3-6
REV. 2
NOZZLE BRACKETS SEALED BURST DISC ASSEMBLY

Two styles of nozzle brackets are available for the A-101/LT-A- The Sealed Burst Disc Assembly, Part No. 428271, is a machined
101 system. Each style of bracket is constructed of unpainted brass component containing a stainless steel burst disc inside.
1/4 in. (6.4 mm) steel. They contain pre-punched mounting holes The disc assembly is designed to rupture when the proper expel-
for the nozzle. lant gas pressure is built up within the tank. The disc assembly is
part of the agent tank shipping assembly. After tank discharge,
An individual “L”-shaped bracket-shipping assembly, Part No. the complete burst disc assembly must be removed, discarded,
427149, is available. This bracket is 2 in. x 3 in. (51 mm x 76 and replaced with a new assembly. Replacement assemblies are
mm). A second “L”-shaped bracket (in packs of 12), Part No. available in a 15 pack, Part No. 428363.
73871, is also available. This “L” shaped bracket is 2 in. x 2 in.
(51 mm x 51 mm).
A straight bracket (in packs of 4), Part No. 427228, is available.
this bracket is 5 in. x 2 in. (127 mm x 51 mm). See Figure 18.
PART NO. 427228

7/8 IN. (22 mm) 2 IN.
1 3/32 IN. (51 mm)
(28 mm) HOLE
HOLE
FIGURE 20
004793
ENGINE SHUTDOWN DEVICE

5 IN.
(127 mm) The ANSUL Engine Shutdown Device, Part No. 427425, can be
PART NO. 427149
used to pneumatically shut down the vehicle fuel rack by venting
2 IN. the hydraulic pressure through the “safety system.” This can be
(51 mm)
PART NO. 73871 accomplished by installing the shutdown device in the actuation
1 IN. line. When the fire suppression system is actuated, the actuation
(2.5 cm) pressure opens the check valve located in the shutdown device,
1 3/32 IN.
7/8 IN. DIA. (28 mm) HOLE
7/8 IN. (2.2 cm)
allowing the safety system pressure to bleed into the holding
(2.2 cm) tank. The drop in pressure causes the valves in the fuel rack to
2 IN.
close, thus shutting down the engine. See Figure 21.
(51 mm)
1/4 IN.
(0.6 cm) 2 IN.
(5.1 cm)
3 IN.
2 IN. (76 mm)
(5.1 cm) 2 IN.
(5.1 cm) 004334
003474
FIGURE 18
HOSE (SUPPLIED BY OTHERS)

To assure proper performance of an A-101/LT-A-101 system, the
hose used must meet SAE 100 R5 or 100 R1 (minimum) hose FIGURE 21
004474
specification. For underground mining applications, the hose must
also be accepted by MSHA as flame resistant and marked as fol-
lows “Flame-Resistant, USMSHA No. _____”* at intervals not CHECKFIRE ELECTRIC DETECTION AND
exceeding 3 ft. (.9 m). Letters and numbers must be at least 1/4 ACTUATION SYSTEM
in. (.6 cm) high and comply all other SAE requirements including Three styles of electric detection and actuation systems are avail-
an operating temperature of –65 °F to +250 °F (–54 °C to 121 able: CHECKFIRE Electric Series I, CHECKFIRE Electric SC-N,
°C). (*This number is assigned to the manufacturer after samples and CHECKFIRE Electric MP-N*. Each electric/pneumatic system
have passed the required tests. The number will be different for consists of detection wiring, control module, actuator with nitrogen
each manufacturer.) See Figure 19. cartridge, mounting bracket, and squib (Series I and SC-N) or gas
motor (MP-N). The CHECKFIRE Electric Series I requires power
from the vehicle battery where as the CHECKFIRE SC-N and
MP-N contains its own internal Lithium batteries as the power
source. All styles of CHECKFIRE electric* are FM Approved when
consisting of all basic components.
* CHECKFIRE MP-N is not FM Approved
The temperature ratings of the system are as follows:

CHECKFIRE Series I: –40 °F to +140 °F
FIGURE 19
003475 Manual Part No. 54894 (–40 °C to +60 °C)
CHECKFIRE Series SC-N: –40 °F to +140 °F
Manual Part No. 79061 (–40 °C to +60 °C)
CHECKFIRE Series MP-N: +32 °F to +120 °F
Manual Part No. 427310 (0 °C to +49 °C)
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
5-15-02 Page 4-2
REV. 1
NOZZLE COVERAGE AND LOCATION (Continued) TANK QUANTITY REQUIREMENTS

NOTICE First consider the type of environment the vehicle will be operat-
When using any of the nozzle types, make cer- ing in and its temperatures. This will determine the type of tank to
tain no obstructions interfere with the discharge choose.
pattern as it is directed to the hazard A-101/LT-A-101 systems are available in the standard model A-
The following rules apply to selecting nozzles and nozzle loca- 101 which has a temperature range of +32 °F +120 °F (0 °C to
tions: +49 °C) and are generally used on sub-surface mining equip-
– When choosing the proper nozzle, remember the entire hazard ment.
area must be within the nozzle’s pattern and maximum effec- Also available is the extreme temperature model LT-A-101 which
tive discharge range. has a temperature range of –65 °F to +210 °F (–54 °C to +99 °C)
– The narrow pattern and longer discharge range of the C-1/2 and is typically used on above surface vehicles.
nozzle make it a good selection for protecting small areas or Knowing the number of nozzles required, next determine the type
hazards that are distant from the nozzle mounting location. or size of tank(s) required. The following “System Selection Chart”
– Larger hazard areas may require the use of V-1/2 or F-1/2 noz- will point out the various options.
zles. System Selection Chart
– Some areas may exceed the area coverage of one nozzle and Model Nozzle Effective Agent
may require an additional nozzle(s) for protection. Capacity Quantity Discharge Time per Nozzle
– In some cases, a single nozzle can cover more than one area 10 2 8.5 sec. 4 1/4 lb. (1.9 kg)
of a common hazard such as a transmission and torque con-
20 4 8.5 sec. 4 1/4 lb. (1.9 kg)
verter. NOTE: Both areas must be within the discharge pattern
of the nozzle. 20 6 5.7 sec. 2 7/8 lb. (1.3 kg)
30 4 12.5 sec. 6 1/4 lb. (2.8 kg)
– When planning nozzle locations, make certain the effective flow
30 6 8.3 sec. 4 1/8 lb. (1.9 kg)
of dry chemical to all recognized hazard areas will not be
obstructed. Nozzle quantities, discharge times and amount of agent per noz-
– If obstructions cannot be avoided, an additional nozzle(s) may zle are all factors to consider in determining the proper tank size.
be needed to provide proper coverage. Keep in mind, a longer discharge time and a greater amount of
– In areas where the environment may cause extreme build up of agent discharge per nozzle will offer better hazard protection.
materials, such as wood debris, coal dust, garbage, or oil, it is It is always best to choose the largest size tank available, but if
always a good idea to use the largest system tank available space is a problem, choose a smaller tank or choose the low pro-
and keep the nozzles per tank to a maximum of four. This file version.
allows the maximum amount of chemical per nozzle and gives When the number of tanks have been determined based on the
the longest discharge time (excluding two nozzle systems). number of nozzles for total protection, the next step in the design
– Never settle for less than full coverage of each fire hazard. process is to determine the distribution hose network required.
After establishing nozzle locations and number required, the type
and quantity of A-101/LT-A-101 tanks can be determined. DISTRIBUTION SYSTEM REQUIREMENTS
After the tank(s) and nozzle(s) location(s) have been determined,
it is necessary to sketch the hose routings to each nozzle to make
certain they can be run without interfering with vehicle compo-
nents and that the length of the supply line(s) and branch line(s)
are not exceeded.
Hose Specifications
To ensure proper performance of the ANSUL A-101/LT-A-101 sys-
tem, the hose used must meet either SAE 100 R5 or 100 R1 hose
specifications as a minimum. The hose must have an operating
temperature of –40 °F to +200 °F (–40 °C to +93 °C). The follow-
ing list of appropriate standards is for reference.
SAE Selection, Installation, and J1273 (latest revision)
Maintenance of Hose and Hose Assemblies
SAE Hydraulic Hose Fitting Standard J516 (latest revision)
SAE Hydraulic Hose Standard J517 (latest revision)
SAE Test and Procedures For J343 (latest revision)
SAE 100R Series Hydraulic Hose and
Hose Assembly Standard
For underground mining applications, hose must comply with
USBM specified flame resistance acceptance and all applicable
SAE requirements.
S1013
5-15-02 Page 4-3
REV. 1
DISTRIBUTION SYSTEM REQUIREMENTS (Continued) Permanent Crimp-on Hose Couplings

Listed below is a partial list of hose manufacturers who manufac- A permanent crimp-on hose coupling is installed as a one-piece
ture hose that meets the required SAE specification noted on assembly attached to the hose end and crimped on. The crimp is
Page 4-2: to be made following the manufacturer’s requirements for proper
Aeroquip Parker hose and coupling assembly, using a machine that will hydrauli-
Dayco Swagelok cally or electrically crimp the coupling permanently to the hose
end.
Gates Weatherhead
Goodyear When using permanent crimp-on type couplings, lubricate the
hose end, if necessary, and push the hose end all the way into
Critical Specifications from SAE J517 are listed below for refer- the fitting in accordance with hose and hose coupling assembly
ence: instructions. Then place the hose end in the appropriate crimping
machine and crimp the coupling. Follow all hose crimping
SAE 100R1 Hose machine operating instructions using equipment specified by the
Maximum Minimum Minimum hose/coupling manufacturer.
Operating Burst Bend
Size
___ Hose ID
______ Pressure
_______ Pressure
_______ Radius
______ Reusable Hose Couplings
1/4 in. .250 in. +.023 2750 psi 11000 psi 4.0 in. Reusable hose couplings can be attached to new hose in the field
–.008 with no other tools than a wrench and a vise (or two wrenches).
1/2 in. .500 in. +.031 2000 psi 8000 psi 7.0 in. When reusable hose couplings are used, make certain the corre-
–.015 sponding couplings and the assembly procedures used are in
3/4 in. .750 in. +.031 1250 psi 5000 psi 9.5 in. accordance with the manufacturer’s specifications. Failure to fol-
–.015 low the manufacturer’s instructions in their entirety may
7/8 in. .875 in. +.031 1250 psi 5000 psi 11.0 in. result in plugged nozzle orifices at system discharge due to
–.015 chips and pieces of rubber cut from the inside of the hose
during improper assembly.
SAE 100R5 Hose Reusable hose couplings include a coupling shell that fits over
1/4 in. .250 in. +.031 3000 psi 12000 psi 3.4 in. the end of the hydraulic hose and a coupling insert that installs
–.000 inside the end of the hose and mates with the coupling shell
threads. A mandrel tool may be required when using 1/4 in.
1/2 in. .500 in. +.039 1750 psi 7000 psi 5.5 in. through 1/2 in. SAE 100R5 hose to facilitate installation of the
–.000 coupling insert.
3/4 in. — — — — To attach a reusable coupling to the hose, clamp the coupling
7/8 in. .875 in. +.042 800 psi 3200 psi 7.4 in. shell in a vise and turn the end of the hydraulic hose counter-
–.000 clockwise into the coupling shell until the end is seated against
Hydraulic Hose Couplings the bottom of the shell. Then, back off 1/4 to 1/2 turn to allow for
expansion.
Before connecting a hydraulic hose to the A-101/LT-A-101 fire
suppression system, it must first be assembled utilizing a hose NOTE: Some-rubber covered hydraulic hose ends must be
coupling attached to each end of the hose. Hose couplings skived (stripped of the rubber cover) before attaching the cou-
installed on hydraulic hose can be the permanent crimp-on type pling. Refer to the appropriate manufacturer’s instructions.
or the reusable type. Female or male swivel hose couplings of Lubricate the hose, coupling insert, and mandrel tool (when
either the crimp-on type or the reusable type are also acceptable. required) in accordance with manufacturer’s instructions and
All couplings used with SAE 100R1 or SAE 100R5 hydraulic hose screw the insert clockwise into the coupling shell and hose.
must be suitable for the hose chosen and must comply with Wrench tighten the insert until the hex on the insert contacts the
Hydraulic Hose Fitting Standard J516 as a minimum. shell. If a female swivel end is being used, use the appropriate
When attaching a hose coupling to a hose, it is very important to assembly tool and leave approximately 1/32 in. to 1/16 in. (.8 to
follow all manufacturer’s installation instructions. SAE J1273, 1.6 mm) clearance between the nut and the shell to allow the nut
Selection, Installation, and Maintenance of Hose and Hose to swivel.
Assemblies, paragraph 3.2, requires that the manufacturer’s NOTE: It is important to lubricate only those surfaces specified by
assembly instructions be followed. the manufacturer of the hose and coupling used. The lubricant will
NOTICE minimize the risk of cutting or shaving the inside of the hose.
SAE J1273, paragraph 2.10, Proper End Failure to use the proper lubricant or follow the appropriate
Fitting, states that, “Care must be taken to lubrication instructions may result in pieces of hose plug-
insure proper compatibility exists between the ging the gas tube in the agent storage tank or plugging a dis-
hose and coupling selected based on the man- charge nozzle orifice. Improper lubricant or lubrication pro-
ufacturer’s recommendations substantiated by cedures may also result in contamination of the hose due to
testing to industry standards such as SAE the use of an incompatible lubricant.
J517.” After attaching hose couplings to the hose, make certain that the
Under no circumstances should hose and cou- hose is clean, dry and oil free. Use a solvent that is compatible
plings from different manufacturers be inter- with the hose, such as Stoddard Fluid or Varsol, to dissolve any
changed. oil remaining in the hose. Using dry air or nitrogen, blow out each
hose length until dry and clear of metal or rubber shavings and
Many hose manufacturers require only the couplings that they any foreign matter before making any connections to the A-101
supply to be used with their hose. One manufacturer warns that system.
they “will not be responsible when interchanging their hose and/or
couplings with hose and/or couplings of any other manufacturer.”
S1013
5-15-02 Page 4-4
REV. 1
DISTRIBUTION SYSTEM REQUIREMENTS (Continued) NOTE: When using the distribution tee, Part No. 25031, a mini-
JIC Hose Fittings and 150 lb. Fittings mum length of 15 in. (381 mm) of 3/4 in. or 18 in. (457 mm) of
7/8 in. hose, will always be required between any bend or elbow
JIC hose fittings meeting Hydraulic Hose Fitting Standard J516 and the distribution fee.
can be used in most applications. When using JIC hose fittings as
elbows, use only elbows that have a radiused bend. 150 lb. NPT 20 HOSE DIAMETERS
elbows and tees can also be used to assemble hose or pipe and MINIMUM LENGTH
REQUIRED REDUCING
attach hose or pipe to the discharge nozzles. Make certain that all TEE
REDUCING
elbows used in the agent distribution line, are of the same type TEE
(i.e., either all JIC or all 150 lb. NPT elbows). Refer to the Install-
ation Section for maximum and minimum elbow requirements.
NOTE: When figuring the maximum and minimum amount of
elbows in the A-101/LT-A-101 system, two (2) 45 ° fittings can be
counted as one 90° fitting. TRIPLE
TEE
Heat Resistant Fire Jacket for Hydraulic Hose (Non-FM
Approved)
All hose assemblies, including actuation lines, expellant gas lines,
20 HOSE DIAMETERS
and agent distribution hose that will be normally exposed to or MINIMUM LENGTH
located in areas with temperatures exceeding 200 °F (93 °C), REQUIRED
should be sleeved with an extreme temperature heat-resistant fire
jacket. (Do not route actuation hose through fire hazard areas. If
this cannot be avoided, the hose must be fire jacketed.) TRIPLE
TEE 003478
Information concerning fire jacketing should be available through
your local hose supplier. If not, Bentley Harris manufacturers a
fire jacket that will withstand continuous operating temperatures
from –65 °F to 500 °F (–54 °C to 260 °C) and short term expo-
sures up to 2000 °F (1093 °C). For a listing of distributors in your 20 HOSE DIAMETERS
area, call Bentley Harris at either 610-363-2600 or, 800-321- MINIMUM LENGTH
REQUIRED
2295.
Dry Chemical Flow Characteristics

The assembly of piping (hose) for a dry chemical system probably
lends itself to the greatest chance for error when installing the
system. Dry chemical-gas mixtures do not flow like liquids, and,
as a result, certain basic rules must be followed to assure correct 004666a
dry chemical distribution to the nozzles.
In order to obtain equal distribution at a tee, the dry chemical SAME PLANE
must enter the center opening (bull) of the tee and exist the two
side opening which are 180° apart. See Figure 2.
CORRECT INCORRECT LENGTH IS CRITICAL
WHEN BOTH THE
TEE AND THE BEND
LIE IN THE SAME
TO NOZZLE(S) TO NOZZLE(S) TO NOZZLE(S) INCOMING 004666b PLANE
IF LESS THAN 20 HOSE DIAMETERS, DRY CHEMICAL WILL FLOW

TO THE OUTSIDE, EXPELLANT GAS WILL FLOW TO INSIDE
INCOMING TO NOZZLE(S)
FIGURE 2
003477
When dry chemical makes a change of direction through an

elbow, a tee, or a hose bend, a separation of the dry chemical CRITICAL
DRY LENGTH
and gas mixture occurs. If a tee follows this change of direction CHEMICAL
where separation can occur, and if this tee lies in the same plane FLOW 004666c
as the change in direction through an elbow, tee, or hose bend,
more dry chemical will discharge through one of the tee outlets
and more gas will discharge out the other tee outlet. A certain
20 HOSE DIAMETERS
minimum length of hose must be allowed from the bend (elbow) MINIMUM LENGTH
to the tee or from the first tee to the second tee in order to permit REQUIRED
the dry chemical and gas to intermix before striking the tee. The
minimum length required is equal to 20 hose diameters. 18 in.
(457 mm) is required for 7/8 in. hose, 15 in. (381 mm) is required
for 3/4 in. hose, and 10 in. (254 mm) is required for 1/2 in. hose. 004666d
See Figure 3. SAME PLANE
FIGURE 3
S1013
GENERAL INFORMATION
5-15-02 Page 4-5
REV. 1
DISTRIBUTION SYSTEM REQUIREMENTS (Continued)

Dry Chemical Flow Characteristics (Continued)
If a tee follows a change in direction through an elbow, another
tee, or a hose bend and the directional change is in a plane that
is perpendicular to the plane of the tee following, the dry chemical
particles and gas will strike the rear of the tee before branching,
intermixing of the dry chemical and gas will occur through turbu-
lence and the length of hose from the bend (elbow) or tee pro-
ceeding it is not critical. See Figure 4.
REDUCING TEE
LENGTH NOT CRITICAL
TRIPLE TEE
LENGTH NOT
LENGTH NOT CRITICAL
CRITICAL
TRIPLE TEE 003479
TEE
OF
NE
PLA
PLANE OF BEND
PLANES OF TEE AND BEND 004665a

ARE PERPENDICULAR
PERPENDICULAR PLANES
CHEMICAL AND GAS MIX
PROPERLY WHEN
ENTERING OTHER PLANE 004665b
LENGTH NOT
CRITICAL
004665c
TWO SEPARATE PLANES
FIGURE 4
S1013
GENERAL INFORMATION
5-15-02 Page 4-6
REV. 1
DISTRIBUTION SYSTEM REQUIREMENTS (Continued) The four nozzle split tee arrangement consists of a 3/4 in. or
Supply and Branch Line Requirements 7/8 in. supply line, a 1/2 in. x 1/2 in. x 3/4 in. reducing tee, two
1/2 in. primary branch lines, two 1/2 in. tees, and four 1/2 in. sec-
Supply and branch lines for the A-101/LT-A-101 system are ondary branch lines each connected to one nozzle. See Figure 7.
defined as follows:
PRIMARY BRANCH LINES
EXTINGUISHER
TWO NOZZLE SYSTEM – Two nozzle systems consist of a 1/2 IN. I.D. SINGLE WIRE
BRAID, TEXTILE OR RUBBER
3/4 in. or 7/8 in. supply line, a 3/4 in. x 1/2 in. x 1/2 in. reducing tee, COVERED HYDRAULIC HOSE
and 1/2 in. branch lines each connected to one nozzle. See Figure 5.
1/2 IN. TEE
SUPPLY LINE 3/4 IN. OR 7/8 IN.

I.D. SINGLE WIRE BRAID,
TEXTILE OR RUBBER COVERED
HYDRAULIC HOSE
1/2 IN. TEE
SECONDARY BRANCH LINES

1/2 IN. I.D. SINGLE WIRE
SECONDARY BRANCH LINES BRAID, TEXTILE OR RUBBER
BRANCH LINES COVERED HYDRAULIC HOSE
1/2 IN. X 1/2 IN. X 3/4 IN.
1/2 IN. I.D. SINGLE
SUPPLY LINE 3/4 IN. OR 7/8 IN. REDUCING TEE
WIRE BRAID,
I.D. SINGLE WIRE BRAID, 3/4 IN. X 1/2 IN. TEXTILE OR RUBBER
TEXTILE OR RUBBER COVERED X 1/2 IN. COVERED HYDRAULIC HOSE
HYDRAULIC HOSE REDUCING
TEE FIGURE 7
003482
BRANCH LINE 1/2 IN. I.D. SINGLE
WIRE BRAID, TEXTILE OR RUBBER NOTE: On split tee arrangements, if the 1/2 in. secondary branch
COVERED HYDRAULIC HOSE
line tee is not more than 20 hose diameters from the 1/2 x 1/2 x
FIGURE 5 3/4 in. primary branch line tee, then the orientation of the tees
003480
must be perpendicular to each other as they are in a triple tee
FOUR NOZZLE SYSTEM – Four nozzle systems are divided into arrangement.
two types: Four nozzle triple tee arrangement and four nozzle
split tee arrangement. Four nozzle triple tee systems consist of a SIX NOZZLE SYSTEM – Six nozzle systems consist of a 3/4 in.
3/4 in. or 7/8 in. supply line into a triple tee assembly consisting of or 7/8 in. supply line, a special three outlet distribution tee, three
a 1/2 in. x 1/2 in. x 3/4 in. reducing tee, two close nipples, and two 1/2 in. primary branch lines, three 1/2 in. tees, and six secondary
1/2 in. tees. The primary branch line is the close nipple that con- branch lines each connected to one nozzle. See Figure 8.
nects the 1/2 in. tee to the reducing tee. Four separate secondary
branch lines are run from the 1/2 in. tee outlets each connected to
one nozzle. See Figure 6.
SUPPLY LINE
BRANCH LINES
SECONDARY
BRANCH LINES
SUPPLY LINE 3/4 IN. OR DISTRIBUTION

7/8 IN. I.D. SINGLE WIRE TEE
PRIMARY
TRIPLE TEE BRANCH LINES BRAID, TEXTILE OR
SECONDARY RUBBER COVERED
BRANCH LINES HYDRAULIC HOSE
003491
PRIMARY BRANCH LINE 1/2 IN.

I.D. SINGLE WIRE BRAID,
TEXTILE OR RUBBER COVERED
HYDRAULIC HOSE
1/2 IN. TEE

SECONDARY BRANCH LINE 1/2 IN. I.D.
SINGLE WIRE BRAID, TEXTILE OR RUBBER
PRIMARY BRANCH LINE
IS THE CLOSE NIPPLE FIGURE 8
THAT CONNECTS THE 003483
SUPPLY LINE 3/4 IN. OR 1/2 IN. TEE TO THE
7/8 IN. I.D. SINGLE WIRE REDUCING TEE
3/4 IN. TRIPLE TEE TO REMAIN

PERPENDICULAR TO 1/2 IN.
TEES AS SHIPPED
SECONDARY BRANCH LINE 1/2 IN. I.D. SINGLE
003481
WIRE BRAID, TEXTILE OR RUBBER COVERED
HYDRAULIC HOSE
FIGURE 6
S1013
5-15-02 Page 4-7
REV. 1
DISTRIBUTION SYSTEM REQUIREMENTS (Continued) – The ten pound system must be a balanced system having two
Supply and Branch Line Requirements (Continued) branch lines within 10% of each other, utilizing one reducing
tee and a maximum of two nozzles. See Figure 9D.
Depending upon the hazards to be protected and the placement
of the system components, a selection can be made from several
balanced and unbalanced distribution network arrangements:
– A balanced system must be a distribution network where the
linear length of the primary branch line on one side of the pri- 3/4 IN. SUPPLY LINE
mary tee to the secondary tee must be within 10% of the linear
length of the other primary branch line from the primary tee to
the secondary tee. Also, the linear length of the secondary 1/2 IN. X 1/2 IN. X 3/4 IN.
REDUCING TEE
branch line on one side of the secondary tee must be within
10% of the linear length of the other secondary branch line
sharing the same tee. A balanced system can be used with 1/2 IN. BRANCH
two, four, or six nozzle systems. See Figure 9A. LINE
PRIMARY SECONDARY
BRANCH LINE BRANCH LINE
1/2 IN.
3/4 X 1/2 X 1/2 IN.
SECONDARY
PRIMARY TEE
TEE FIGURE 9D
003487
– The twenty and thirty pound systems can be either balanced or

unbalanced systems, and can be arranged utilizing three differ-
ent network combinations. These include the triple tee arrange-
ment which utilizes the triple tee and four nozzles (See Figure
9E), the split tee arrangement utilizing one 3/4 in. x 1/2 in. x
NOZZLE 1/2 in. reducing tee, two 1/2 in. tees, and four nozzles (See
Figure 9F), and the distribution tee arrangement which utilizes
a distribution tee, three 1/2 in. tees, and six nozzles (See
FIGURE 9A Figure 9G).
003484
4 NOZZLE UNBALANCED TRIPLE TEE
– In an unbalanced system, the longest branch line must be no
longer in length than 3 times that of the shortest branch line,
with a maximum of 18 ft. total (primary plus two secondary
branches). See Figure 9B.
6 NOZZLE UNBALANCED DISTRIBUTION TEE SUPPLY LINE
SHORTEST BRANCH LINE LONGEST BRANCH LINE

1/2 IN. TEE
BRANCH LINES SECONDARY
BRANCH LINES
1/2 IN. TEE

PRIMARY
BRANCH
1/2 IN. TEE

SECONDARY
SECONDARY BRANCH TRIPLE TEE
DISTRIBUTION PRIMARY
BRANCH BRANCH LINES
TEE
BRANCH LINES MUST BE WITHIN A 3:1 RATIO

FIGURE 9B
003485 SECONDARY
BRANCH LINES
– Unbalanced secondary branch line lengths must also be within FIGURE 9E
003491
a 3 to 1 ratio when they are located in the same branch line.
See Figure 9C.
SECONDARY
PRIMARY BRANCH
BRANCH
SECONDARY BRANCH LINES

(ONLY ON THE SAME BRANCH
LINE) MUST BE WITHIN A 3:1 RATIO
FIGURE 9C
003486
S1013
5-15-02 Page 4-8
REV. 1
2 NOZZLE BALANCED WITH REDUCING TEE – 10 LB. SYSTEM

DISTRIBUTION SYSTEM REQUIREMENTS (Continued)
Supply and Branch Line Requirements (Continued)
4 NOZZLE UNBALANCED SPLIT TEE
PRIMARY 1/2 IN. TEE

BRANCH LINES
MAXIMUM TOTAL
LENGTH FROM
EXTINGUISHER TO
SUPPLY LINE THE FARTHEST
NOZZLE, 50 FT. 0 IN.
(15.2 m)
1/2 IN. TEE SECONDARY

BRANCH LINES
3/4 IN. OR 7/8 IN. I.D. SINGLE WIRE
COVERED HYDRAULIC HOSE – REDUCING
MAXIMUM TOTAL LENGTH FROM TEE
BRANCH LINES
EXTINGUISHER TO REDUCING
1/2 IN. X 1/2 IN. X 3/4 IN.
TEE, 30 FT. 0 IN. (9.1 m)
REDUCING TEE
SECONDARY
BRANCH LINES
FIGURE 9F BRAID, TEXTILE OR RUBBER F-1/2, C-1/2 OR V-1/2
003482 NOZZLE, MAXIMUM PER
EXTINGUISHER, 2
6 NOZZLE UNBALANCED DISTRIBUTION TEE
3X
X FIGURE 10
SECONDARY 003480
X 3X BRANCH LINES EXAMPLES OF TYPICAL 2 NOZZLE SYSTEMS
CLOSE
NIPPLE
PRIMARY
BRANCH LINE
45’
SECONDARY
1/2 IN. TEE
BRANCH LINES
50’
FIGURE 9G
003490
15’
10 lb. 2 Nozzle Balanced System With Reducing Tee

See Figure 10 and 10A. 12’
• Maximum supply line length from extinguisher to reducing 10.8’

tee is 30 ft. 0 in. (9.1 m).
• Maximum total length from extinguisher to farthest nozzle is
50 ft. 0 in. (15.2 m). 30’ MAX.
• Any combination of F-1/2, C-1/2, or V-1/2 nozzles are

acceptable. Two (2) nozzles maximum.
20’
• Maximum unbalanced allowed on the total system is 10%
different in length from reducing tee to nozzle on one line
compared to the same distance between reducing tee to 20’
nozzle on the other line.
NOTE: See Page 6-5 for fitting and bend limitations.
FIGURE 10A
003492
S1013
5-15-02 Page 4-9
REV. 1
DISTRIBUTION SYSTEM REQUIREMENTS (Continued) 20, 30 lb. 4 Nozzle Balanced System With Triple Tee
Supply and Branch Line Requirements (Continued) See Figure 12 and 12A.
20, 30 lb. 2 Nozzle Balanced System With Reducing Tee • Maximum supply line length from extinguisher to triple tee
See Figure 11 and 11A. is 40 ft. 0 in. (12.2 m)
• Maximum supply line length from extinguisher to reducing • Maximum total length from extinguisher to farthest nozzle
tee is 40 ft. 0 in. (12.2 m). is 50 ft. 0 in. (15.2 m).
• Maximum total length from extinguisher to farthest nozzle • Any combination of F-1/2, C-1/2, or V-1/2 nozzles are
is 50 ft. 0 in. (15.2 m). acceptable. Four (4) nozzles maximum.
• Any combination of F-1/2, C-1/2, or V-1/2 nozzles are • Maximum unbalanced allowed on the total system is 10%
acceptable. Two (2) nozzles maximum. different in length from 1/2 in. tee to nozzle on one line
compared to the same distance between the same 1/2 in.
• Maximum unbalanced allowed on the total system is 10% tee to nozzle on the other line.
difference in length from reducing tee to nozzle on one line
compared to the same distance between reducing tee to NOTE: See Page 6-5 for fitting and bend limitations.
nozzle on the other line.
4 NOZZLE BALANCED WITH TRIPLE TEE – 20 LB.-30 LB. SYSTEMS
2 NOZZLE BALANCED WITH REDUCING TEE – 20 LB.-30 LB. SYSTEMS
MAXIMUM TOTAL LENGTH

MAXIMUM TOTAL FROM EXTINGUISHER TO
LENGTH FROM THE FARTHEST NOZZLE,
EXTINGUISHER TO 50 FT. 0 IN. (15.2 m)
THE FARTHEST
NOZZLE, 50 FT. 0 IN.
(15.2 m)
3/4 IN. OR 7/8 IN. I.D. SINGLE WIRE F-1/2, C-1/2 OR

BRAID, TEXTILE OR RUBBER COVERED V-1/2 NOZZLE,
HYDRAULIC HOSE – MAXIMUM TOTAL MAXIMUM PER
REDUCING LENGTH FROM EXTINGUISHER TO EXTINGUISHER, 4
TEE REDUCING TEE, 40 FT. 0 IN. (12.2 m)
3/4 IN. OR 7/8 IN. I.D. SINGLE WIRE
BRAID, TEXTILE OR RUBBER COVERED 3/4 IN. TRIPLE TEE TO REMAIN
HYDRAULIC HOSE – MAXIMUM TOTAL PERPENDICULAR TO 1/2 IN. TEES AS SHIPPED
LENGTH FROM EXTINGUISHER TO
REDUCING TEE, 40 FT. 0 IN. (12.2 m)
1/2 IN. I.D. SINGLE WIRE BRAID,
F-1/2, C-1/2 OR V-1/2 TEXTILE OR RUBBER COVERED
NOZZLE, MAXIMUM HYDRAULIC HOSE
COVERED HYDRAULIC HOSE PER EXTINGUISHER, 2 FIGURE 12
003481
FIGURE 11 EXAMPLES OF TYPICAL 4 NOZZLE SYSTEMS

003480
EXAMPLES OF TYPICAL 2 NOZZLE SYSTEMS CLOSE NIPPLE
CLOSE TRIPLE TEE

NIPPLE
50’
45’ 50’
50’
50’ 50’
20’
20’
TRIPLE
13.5’ TEE
20’
15’
22’
18’
20’
40’ MAX.
40’ MAX.
TRIPLE TEE
50’ MAX. 10’
10’
10’
9’ 10’
10’
FIGURE 11A
003494 FIGURE 12A
003496
S1013
5-15-02 Page 4-10
REV. 1
DISTRIBUTION SYSTEM REQUIREMENTS (Continued) EXAMPLES OF TYPICAL 4 NOZZLE SYSTEMS

TRIPLE TEE
20, 30 lb. 4 Nozzle Unbalance System With Triple Tee
See Figure 13 and 13A. 13’
4.5’
1.5’
• Maximum supply line length from extinguisher to the triple 4.5’
tee is 40 ft. 0 in. (12.2 m).
• The longest branch line (including one primary and two 20’
secondary) is 18 ft. 0 in. (5.5 m) and must not exceed a 3:1
ratio of any other branch line(s). TRIPLE TEE
• The triple tee assembled using close nipples. It must 13.5’ MAX.
remain in the configuration as shown in Figure 13.
1.5’ 4.5’
• Any combination of F-1/2, C-1/2, or V-1/2 nozzles are 40’ MAX. 4.5’
acceptable. Four (4) nozzles maximum.
• Secondary branch lines located on the same branch line
(sharing the same tee) must not exceed a 3:1 ratio
13.5’ MAX.
between each other but are not required to be within a 3:1
ratio with secondary branch line located on other branch 20’ TRIPLE
1.5’ 4.5’
TEE
lines. 4.5’
NOTE: See Page 6-5 for fitting and bend limitations. 6’

3’
4 NOZZLE UNBALANCED WITH TRIPLE TEE – 20 LB.-30 LB. SYSTEMS 9’

TRIPLE 9’
TEE
1/2 IN. TEE
FIGURE 13A
003498
TRIPLE TEE
1/2 IN. TEE 1/2 IN. X 1/2 IN. X 3/4 IN.

REDUCING TEE
SUPPLY LINE 40 FT.

BRANCH LINES (12.2 m) MAXIMUM
SECONDARY
BRANCH LINES
PRIMARY
TRIPLE TEE BRANCH LINES
18 FT. (5.5 m) TOTAL

(PRIMARY PLUS
TWO SECONDARY F-1/2, C-1/2 OR
BRANCHES) V-1/2 NOZZLE
SECONDARY
BRANCH LINES
FIGURE 13
003497
S1013
5-15-02 Page 4-11
REV. 1
DISTRIBUTION SYSTEM REQUIREMENTS (Continued) 4 NOZZLE BALANCED WITH REDUCING TEE – 20 LB.-30 LB. SYSTEMS
Supply and Branch Line Requirements (Continued) MAXIMUM TOTAL LENGTH FROM EXTINGUISHER
TO THE FARTHEST NOZZLE, 50 FT. 0 IN. (15.2 m)
20, 30 lb. 4 Nozzle Balanced System With Reducing Tee SECONDARY
See Figure 14 and 14A. 1/2 IN. TEE
• Maximum supply line length from extinguisher to triple tee PRIMARY

TEE
is 40 ft. 0 in. (12.2 m).
PRIMARY
• Maximum total length from extinguisher to farthest nozzle BRANCH LINE SECONDARY
BRANCH LINE
is 50 ft. 0 in. (15.2 m).
• Any combination of F-1/2, C-1/2, or V-1/2 nozzles are 1/2 IN. X 1/2 IN. X 3/4 BRAID, TEXTILE OR
IN. REDUCING TEE RUBBER COVERED
acceptable. Four (4) nozzles maximum. 1/2 IN. TEE HYDRAULIC HOSE
• Linear length of the primary branch line on one side of the 3/4 IN OR 7/8 IN. I.D. SINGLE WIRE F-1/2, C-1/2 OR V-1/2 NOZZLE,
primary tee to the secondary tee must be within 10% of the BRAID, TEXTILE OR RUBBER COV- MAXIMUM PER EXTINGUISHER, 4
linear length of the other primary branch line from the pri- ERED HYDRAULIC HOSE. MAXIMUM
TOTAL LENGTH FROM EXTINGUISHER
mary tee to the secondary tee. TO REDUCING TEE, 40 FT. 0 IN. (12.2 m)
Also, the linear length of the secondary branch line on one
side of the secondary tee must be within 10% of the linear
length of the other secondary branch line sharing the same
tee. FIGURE 14
003499
EXAMPLES OF TYPICAL 4 NOZZLE SYSTEMS

EXAMPLES OF TYPICAL 4 NOZZLE SYSTEMS
CLOSE
NIPPLE
40’ MAX.
49’
CLOSE
49’
NIPPLE
1’ 44.1’ 49’
9’
1’
35’ 9’ 9’
8.1’
44.1’ 49’
9’
8.1’ 20’ 1’ 1’
2.9’ 1’
1’
1’
20’
1’
3’
30’
50’ 27’
MAX. 5’
20’
1’
18’
29’ 1’ CLOSE
10’
NIPPLE
10.8’ 29’
10’
26.1’
12’ 29’
FIGURE 14A
003500
S1013
5-15-02 Page 4-12
REV. 2
DISTRIBUTION SYSTEM REQUIREMENTS (Continued) EXAMPLE OF TYPICAL 4 NOZZLE SYSTEMS

CLOSE
Supply and Branch Line Requirements (Continued) NIPPLE
20, 30 lb. 4 Nozzle and 6 Nozzle Unbalanced System With
Reducing Tee 4’ 7’
See Figures 15 and 15A, 16 and 16A. 1’ 5’
1’
• Maximum supply line length from extinguisher to the

reducing tee is 40 ft. 0 in. (12.2 m).
• The longest branch line (including one primary plus two 20’
secondary) length is 18 ft. 0 in. (5.5 m) and must not
exceed a 3:1 ratio of any other branch line(s).
• Two secondary branch lines located on the same branch 9’
line (sharing the same tee) must not exceed a 3:1 ratio 2’
3’
between other but are not required to be within a 3:1 ratio 40’ MAX. 1’
with secondary branch lines located on other branch line. 6’
3’
• Any combination of F-1/2, C-1/2, or V-1/2 nozzles are CLOSE
acceptable. Four (4) nozzles maximum. NIPPLE
NOTE: See Page 6-5 for fitting and bend limitations. 2.5’ 7.5’
40’ MAX.
8’
4 NOZZLE UNBALANCED WITH TEE REDUCING CLOSE CLOSE
NIPPLE NIPPLE 1’
18 FT. (5.5 m) TOTAL 4.5’
(PRIMARY PLUS TWO 1.5’ 1’
SECONDARY BRANCHES)
PRIMARY 4.5’
BRANCH LINES 1/2 IN. TEE 1.5’ 16’
17.5’
1’
SUPPLY LINE
40 FT. (12.2 m) 1’ CLOSE
MAXIMUM SECONDARY NIPPLE
BRANCH LINES
1/2 IN. TEE 1/2 IN. X 1/2 IN. X 3/4

IN. REDUCING TEE FIGURE 15A
003502
F-1/2, C-1/2 OR
V-1/2 NOZZLE
BRANCH LINES
SECONDARY
18 FT. (5.5 m) TOTAL (PRIMARY
BRANCH LINES
PLUS TWO SECONDARY BRANCHES)
FIGURE 15
003482
S1013
5-15-02 Page 4-13
REV. 1
DISTRIBUTION SYSTEM REQUIREMENTS (Continued) EXAMPLE OF TYPICAL 6 NOZZLE SYSTEMS

20, 30 lb. 6 Nozzle Unbalanced System With Distribution Tee 6’
2’
See Figure 16 and 16A. 3’ 5’
CLOSE 1’
9’
NIPPLE
6 NOZZLE UNBALANCED WITH DISTRIBUTION TEE – 20 LB.-30 LB. SYSTEMS
9’ 3’
20’
CLOSE
NIPPLE 6’
2’
1.5’ 4.5’ 18’ MAX.
1’
DISTRIBUTION TEE
3/4 IN. OR 7/8 IN. I.D.
SINGLE WIRE BRAID, 40’ MAX.
TEXTILE OR RUBBER
COVERED HYDRAULIC CLOSE
HOSE – MAXIMUM NIPPLE
TOTAL LENGTH FROM
EXTINGUISHER TO 9’ 16’
DISTRIBUTION 1/2 IN. SECONDARY
BRANCH LINE 2’
TEE,
2’ 6’
40 FT. 0 IN. 1/2 IN. PRIMARY
(12.2 m) BRANCH LINE 3’
2’ 1’
1’
FIGURE 16A
003504
1/2 IN. TEE
F-1/2, C-1/2 OR V-1/2 NOZZLE,

MAXIMUM PER EXTINGUISHER, 6
FIGURE 16
003503
S1013
5-15-02 Page 4-14
REV. 1
ACTUATION AND EXPELLANT GAS LINE REQUIREMENTS A-101 SYSTEM
REMOTE MAXIMUM LENGTH 100 FT. (30.5 m) FOR LT-10 CARTRIDGE FROM
Actuation Gas Line ACTUATOR ACTUATOR TO LAST TANK (SEE NOTES 1 AND 2)
SAFETY
The actuation gas line is the line from the manual remote actua- RELIEF VALVE
CHECK
tors and/or the gas cartridge on the automatic detection system to VALVE
the gas cartridge actuator located on the last A-101/LT-A-101 tank
or the gas cartridge actuator for the last LT or LP style tanks. The
maximum number of actuators that can be actuated from a single
actuator cartridge is ten (10). The actuation line can be a maxi-
mum of 100 ft. (30.5 m) when using an LT-10 cartridge. When
CHECK
more than one actuation cartridge is in the system, a 1/4 in. check VALVE
valve, Part No. 25627, must be installed to prevent the lose of
003493
actuation gas from an actuator that may have a cartridge ACTUATOR
removed. See Figure 17.
NOTE: A MAXIMUM OF (10) TEN A-101/LT-A-101 SYSTEMS CAN BE ACTUATED
NOTE 1: If only eight (8) or less actuators are used, the actuation SIMULTANEOUSLY IN ANY COMBINATION (I.E., A-101, LT-A-101, LP-A-101,
line can be extended to 125 ft. (38.1 m). OR LT-LP-A-101) (SEE NOTES 1 AND 2)
NOTE 2: The actuation line can also utilize an LT-5 cartridge.

When this is done, only eight (8) actuators or less can be used, LT-A-101 SYSTEM
with a maximum length of 75 ft. (22.9 m). ACTUATOR SAFETY
If more than one actuator is in the system, the total length of actu- REMOTE RELIEF VALVE
ACTUATOR
ation line allowed from the actuator to the last tank must also
include any amount of hose in the other actuation lines up to the
check valves located in those lines.
CHECK
The hose for the actuation system must meet the same specifica- VALVE
tions as the hose used for the dry chemical distribution network. CHECK
See Pages 4-2 and 4-3 for hose and fitting specifications. VALVE
MAXIMUM
Expellant Gas Line EXPELLANT
GAS HOSE
The expellant gas line is the length of 1/4 in. hose located LENGTH,
between the remote expellant gas cartridge (required for LT and 20 FT. 0 IN.
LP style tanks), and the expellant gas inlet on the tank. The maxi- (6.1 m)
003495
(EACH)
mum length of this line is 20 ft. (6.1 m). See Figure 17.
NOTE: REDUCE THE MAXIMUM ALLOWABLE NUMBER OF BASIC EXTINGUISHING

UNITS BY ONE FOR EACH NON-EXTINGUISHING PNEUMATICALLY OPERATED DEVICE
EMPLOYED, I.E., BRAKE CONTROL VALVE, FUEL CONTROL AIR CYLINDER.
FIGURE 17
The hose for the expellant gas line must meet the same specifica-
tions as the hose used for the dry chemical distribution network.
See Pages 4-3 through 4-4 for hose and fitting specifications.
DETECTION SYSTEM REQUIREMENTS

Several types of automatic detection is available for use with the
A-101 Fire Suppression System. Three types of electric detection
and one type of pneumatic.
See the following Installation Manuals for detailed information on
each type of system:
• CHECKFIRE MP-N ELECTRIC SYSTEM – Manual Part No.
427310
• CHECKFIRE SC-N ELECTRIC SYSTEM – Manual Part No.
423522
• CHECKFIRE ELECTRIC SERIES I SYSTEM – Manual Part No.
54894
S1013
5-15-02 Page 4-15
SHUTDOWN REQUIREMENTS
When protecting any vehicle, especially vehicles with large wired in series with N.C. pressure switch contacts. The pressure
amounts of hydraulic fluid and fuel on board, the engine must be switch is connected to the pneumatic actuation line of the dry
shut down and hydraulic pumps shut off and lines depressurized. chemical system. The relay coil is normally energized. When the
To accomplish this, it is necessary to wire the shutdown of these pressure switch is activated by pressure in the actuation line, the
devices into the CHECKFIRE SC-N Module shutdown relay con- switch contacts will open. Loss of power or an open circuit will
tacts. A brief description of how this is accomplished is as follows: cause the solenoid valves to transfer, thus shutting down the air
Engine Shutdown – Engine shutdown can be accomplished supply.
through a normally energized fuel solenoid (supplied by others) Another means available for fuel shutdown is to pneumatically
which is wired in series with the normally closed “shutdown” relay shutdown the fuel rack by venting the hydraulic pressure through
contacts of the CHECKFIRE SC-N Control Module or in a pres- the “safety system.” This can be accomplished by installing the
sure switch. These “shutdown” relay contacts will operate (open) Ansul Engine Shutdown Device, Part No. 427425, in the dry
after the first time delay cycle is complete on the module. chemical system actuation line. (This is normally only an option on
Hydraulic Fluid Tank Air Shut Off and Venting – Solenoid some underground mining applications.) When the ANSUL fire
valves (supplied by others) can be connected to air vents of the suppression system is actuated, the actuation pressure opens the
hydraulic tank. They can be wired to N.O. contacts on a relay check valve located in the engine shutdown device, allowing the
(supplied by others). A solenoid (supplied by others), connected safety system pressure to bleed into the holding tank. The drop in
to the air supply line, if used, going to the hydraulic tank, can be pressure causes the valves in the fuel rack to close, thus shutting
wired to N.C. contracts of the same relay. The coil to the relay is down the engine. See Figure 18.
FROM AUTOMATIC
REMOTE DETECTION SYSTEM
ACTUATOR
265 PSI
RELIEF VALVE
(2) 7/16 IN.

CLEARANCE
MOUNTING
HOLE
PORT #3 IN
(265 PSI ACTUATION PRESSURE
FROM ANSUL ACTUATION LINE)
PORT #2 OUT
(RETURN TO
HYDRAULIC
TANK)
PORT #1 IN
(VEHICLE HYDRAULIC SAFETY
SYSTEM LINE PRESSURE)
FIGURE 18
004668
S1013
5-15-02 Page 4-16
ACCESSORIES
Accessories can be added to the pneumatic actuation line to
mechanically shut off fuel, electrically shut off engines, and elec-
trically sound alarms.
Air Cylinder
This component is a system accessory whose function is to shut
off the fuel supply to the engine when the fire suppression system
is actuated.
The fuel shut-off is a spring-return rocker arm on the side of the
engine which has a cable link to the vehicle dashboard. The air
cylinder rod will tie into this rocker arm, in parallel to, but not inter-
fering with, the operator’s cable control. See Figure 19.
NOTE: WHEN USING AN LT-10 CARTRIDGE, AT 125 FT. OF HOSE, THE MAXIMUM FORCE
AT THE AIR CYLINDER IS 70 LBS.
MANUAL SHUTDOWN
ROCKER
ARM
FUEL
MANIFOLD
AIR
CYLINDER
ACTUATION HOSE LINE
FIGURE 19
003489
Pressure Switch
Two styles of pressure switches are available for various electrical
functions:
PRESSURE SWITCH PART NO. 46250 (Weatherproof) – This
pressure switch is a single pole, double throw (SPDT) pressure
switch constructed with a gasketed, water tight housing. The
switch is rated at 10A – 125V, 5A – 250 VAC. This switch is suit-
able for outdoor applications.
PRESSURE SWITCH PART NO. 8372 (Non-Weatherproof) –
This pressure switch is a single pole, double throw (SPDT) pres-
sure switch. It is rated at 15A, 125, 250, or 480 VAC, 1/4 HP at
125 VAC, 1/2 HP at 250 VAC, or 1/2 A at 125 VDC. This switch is
not weather-proof and should not be used for outdoor applica-
tions.
PRESSURE SWITCH PART NO. 43241 – This pressure switch is
a double-pole, double-throw (DPDT) pressure switch. The switch
is constructed with an explosion-proof housing suitable for haz-
ardous environments. The switch contacts are rated at 10 amp at
125 VAC or 5 amp at 250 VAC.
NOTE: When installing pressure switches in the actuation line,
the hose running to the switch must always be located down-
stream of any actuation check valves.
S1013
SECTION V – SYSTEM DESIGN – INDUSTRIAL
5-15-02 Page 5-1
REV. 1
The following are typical industrial type hazards which can be 5. Electrical Considerations
protected by using the total flooding method: flammable liquid It is recommended that all electrical power sources associat-
storage, dip tanks, solvent cleaning tanks, transformer vaults, ed with the protected hazard be shut down before system dis-
quench tanks, and furnace rooms. charge. This eliminates the potential of a fire being electrical-
ly-reignited.
HAZARD ANALYSIS
6. Temperature Range
A thorough hazard analysis is required to determine the type and The following temperature ranges must be determined and
quantity of protection required. noted to ensure proper placement and operation of the A-101
Review each of the following requirements when doing a hazard system:
analysis: Hazard Area: Determine the minimum and maximum tem-
1. Hazard Type perature of the hazard to be protected. This temperature may
Record the size of the hazard, any obstructions, unclosable be any temperature that the distribution piping and detectors
openings, size and location of external ductwork or anything can withstand – only if the agent tank and accessories are
else which would concern system performance. Briefly located outside of the hazard area.
describe the type of hazard being protected. If protecting pre- Agent Tank: The temperature range for all applications is
fabricated booths, record the manufacturer model number +32 °F to +120 °F (0 °C to +48 °C) for standard type A-101
and anything unique about the hazard. tanks and –65 °F to +210 °F (–54 °C to +99 °C) for LT-A-101
low temperature type tanks.
2. Hazard Atmosphere
The A-101/LT-A-101 system can be used in most industrial DISTRIBUTION SYSTEM REQUIREMENTS
environments. If the hazard atmosphere is considered corro-
sive, such that the solvents, chemicals, or gases present are The distribution system for industrial hazards must follow the
damaging to the A-101 system tank or actuators, the hard- same requirements as listed for vehicle systems. See Section IV,
ware should not be located in the hazard. When protecting an SYSTEM DESIGN – VEHICLE, for detailed hose requirements for
area defined as hazardous per NFPA 70 National Electric agent distribution and actuation/expellant gas lines.
Code, Article 500, only equipment that has been listed or Exception: For industrial hazards, only F-1/2 nozzles, Part No.
approved for the hazardous location, may be located in that 16449, are approved for total flood.
area.
3. Hazardous Materials NOZZLE COVERAGE
The A-101/LT-A-101 system uses FORAY (ABC) dry chemi- The only nozzle approved for use with A-101/LT-A-101 industrial
cal as the extinguishing agent. The agent effectiveness and total flooding protection is the F-1/2 nozzle.
limitation is based on its ability to suppress the fire with the
design parameters of the pre-engineered system. Single System Capabilities
a. FORAY dry chemical is effective on the following types of

Model 10 lb. 20-lb. 30-lb.
fire materials:
Total 350 cu. ft. Max. 700 cu. ft. Max. 1000 cu. ft.
Class A – Surface Fires: These fires involve ordinary
Max.
combustible materials such as cloth, paper, rubber, and
Flooding (9.9 cu. m) (19.8 cu. m) (28.3 cu. m)
many plastics.
5 ft. x 10 ft. 10 ft. x 10 ft. 10 ft. x 10 ft. x
Class B – Flammable Liquid and Gas Fires: These fires
x 7 ft. high x 7 ft. high 10 ft. high
involve such materials as oils, grease, tars, oil-based
(1.5 x 3.0 x (3.0 x 3.0 x (3.0 x 3.0 x
paints, lacquers, and gasoline.
2.1 m) 2.1 m) 3.0 m)
Class C – Energized Electrical Equipment Fires:
Common Class C devices include control rooms, trans- Maximum No.
formers, oil switches, circuit breakers, rotating equipment, of Nozzles (2) Two F-1/2 (4) Four F-1/2 (4) Four F-1/2
pumps, and motors
b. FORAY dry chemical is NOT effective on the following See Figures 1 through 3 for nozzle layouts.
types of fire materials:
Deep-seated Class A Materials: Deep-seated or burrow-
ing fires in ordinary combustibles where the FORAY dry
chemical cannot reach the point of combustion.
Class D – Combustible Metals: Class D type materials
are reactive such as sodium, potassium, magnesium, and
titanium.
Chemicals Capable of Rapid Oxidation: Chemicals or
mixtures of chemicals such as cellulose nitrate.
4. Ventilation Considerations
The hazard ventilation system is very important when consid-
ering total flooding application, but should also be considered
for local application overhead and tankside.
The ventilation system should be shut down and/or dampered
before or simultaneously with the start of the A-101/LT-A-101
system discharge.
S1013
5-15-02 Page 5-2
REV. 1
NOZZLE COVERAGE (Continued)
10 LB. FIRE SUPPRESSION SYSTEM – TOTAL FLOODING APPLICATION (2 NOZZLES)
5 FT. 0 IN.
(1.5 m) MAXIMUM
10 FT. 0 IN.
(3.1 m) MAXIMUM
F-1/2 NOZZLES (2) – 7 FT. 0 IN.

PART NO. 16449 3/4 X 1/2 X 1/2 (2.1 m) MAXIMUM
REDUCING TEE
3/4 IN.
HOSE
2 FT. 6 IN.
(.8 m)
5 FT. 0 IN.
(1.5 m)
NOZZLE
DIRECTIONS
FIGURE 1
003501
S1013
5-15-02 Page 5-3
REV. 1
Nozzle Coverage (Continued)
20 LB. FIRE SUPPRESSION SYSTEM – TOTAL FLOODING APPLICATION
1/2 IN.
10 FT. 0 IN. (3.1 m) HOSE
10 FT. 0 IN. (3.1 m)
MAXIMUM
MAXIMUM
4
2 3
3/4 X 1/2 X 1/2
1 REDUCING TEE
7 FT. 0 IN. (2.1 m)

MAXIMUM
F-1/2 NOZZLES (4) –
PART NO. 16449
3/4 IN.
HOSE
2 FT. 6 IN. 2 FT. 6 IN.

(.8 m) (.8 m)
5 FT. 0 IN.
(1.5 m)
MAXIMUM
NOZZLE
DIRECTIONS
FIGURE 2
003505
S1013
5-15-02 Page 5-4
REV. 1
Nozzle Coverage (Continued)
30 LB. FIRE SUPPRESSION SYSTEM – TOTAL FLOODING APPLICATION
1/2 IN.
10 FT. 0 IN. (3.1 m) HOSE
10 FT. 0 IN. (3.1 m)
MAXIMUM
MAXIMUM
4
2 3
3/4 X 1/2 X 1/2
1 REDUCING TEE
10 FT. 0 IN. (3.1 m)

MAXIMUM
F-1/2 NOZZLES (4) –
PART NO. 16449
3/4 IN.
HOSE
2 FT. 6 IN. 2 FT. 6 IN.

(.8 m) (.8 m)
5 FT. 0 IN.
(1.5 m)
MAXIMUM
NOZZLE
DIRECTIONS
FIGURE 3
003505
S1013
SECTION VI – INSTALLATION INSTRUCTIONS
5-15-02 Page 6-1
REV. 1
The installation of an ANSUL A-101/LT-A-101 Fire Suppression NOTE: The tank must be located in an area that will not exceed
system is based on the sketch developed in the System Design temperature limitations or be subject to fire or damage.
Section IV.
When deciding on locations for mounting the agent tanks, pneu- 45° 45°
matic actuators and manual actuators, locate areas where the
components will not be abused or will not interfere with vehicle
operation. Keep in mind not only the requirements for each indi-
vidual component, but how the components are connected, and
the maximum hose lengths required between each component.
Although the sequence of installation steps may vary with each
installation, a basic A-101/LT-A-101 installation consists of four
general procedures: mounting the brackets, installing the compo-
nents, connecting the hoselines, and finally, installing the gas car-
tridges. NOTE: TANK SHOULD BE MOUNTED IN THE UPRIGHT POSITION SHOWN (SOLID
LINES), BUT DISCHARGE WILL NOT BE IMPAIRED IF THE CENTER LINE OF THE
MOUNTED TANK DOES NOT EXCEED 45° LEFT OR RIGHT OF TRUE VERTICAL.
MOUNTING THE BRACKETS
Nozzle Bracket 45°

The first step is to mount the nozzle brackets. Plan to attach noz-
zle brackets to secure places that will not be subjected to abuse
and make sure the locations will not interfere with operator or
vehicle functions.
NOTICE
When mounting the nozzle brackets, make cer- FORWARD TIP, DO NOT TIP
tain the mounting surface is rigid and that it is 45° MAXIMUM BACKWARD
allowed by the vehicle manufacturer to weld or

bolt onto that surface.
1. Based on the layout sketch, locate a secure place for mount-
ing the nozzle bracket so that the nozzle will be properly FIGURE 2
003508
aimed, and weld the bracket to the mounting surface. When
welding the bracket, make certain there is enough weld to
keep the bracket properly in place. See Figure 1. 1. Remove the agent tank from the bracket and weld the brack-
et to the mounted surface. The bracket can be secured at the
base, at the back, or both, depending on the mounting sur-
face. If the bracket cannot be welded, bolting is acceptable.
WELD 7/16 in. mounting holes are provided in the bracket to accom-
modate 3/8 in. fasteners. See Figure 3. Make certain when
mounting the bracket that the clamp arms can swing open
wide enough for removal of the tank when required.
FIGURE 1
003507
If welding is not possible, the bracket can be drilled and bolt-

ed to the mounting surface with the appropriate fasteners.
Make certain the bolting method does not allow the mounting
bracket to rotate out of position or interfere with the nozzle
discharge.
NOTE: A minimum of two bolts are required for proper
mounting.
BOLT OR WELD EXTINGUISHER TO VEHICLE –
Tank Bracket 3/8 IN. DIAMETER BOLT REQUIRED
NOTICE
The location of the tank must not cause the FIGURE 3
003509
hose length limitations to be exceeded.
When deciding on a mounting location for the agent tank, locate a
rigid area where the tank can be mounted in an upright position. If
necessary, the tank can be mounted up to 45° tilted to the left or
right of true vertical, or tipped 45° forward from true vertical. The
agent tank cannot be tipped backwards. See Figure 2.
S1013
5-15-02 Page 6-2
REV. 1
Cartridge Bracket MOUNTING THE DISTRIBUTION, REDUCING, AND TRIPLE

When installing low temperature or low profile type systems, it is TEES
necessary to mount the remote cartridge bracket also. The loca- Based on the sketch done in the Design Section, locate each tee
tion of this bracket must be such that the length of 1/4 in. hose at a point which will not cause the supply line and branch line
between the bracket and the pneumatic inlet on the agent tank lengths to be exceeded.
does not exceed 20 ft. (6.1 m) and the 1/4 in. hose from each 1. All distribution network fittings must be welded or clamped to
remote actuator does not exceed 100 ft. (30.5 m) with 10 actua- the mounting surface. See Figure 5. All welds must be made
tors maximum or 125 ft. (38.1 m) with 8 actuators maximum for before any hose has been installed to avoid damage to the
LT-10 cartridges. hose due to high welding temperatures.
1. Remove the cartridge from the bracket. Locate a rigid, pro-
2. When locating tees, make certain the locations do not cause
tected surface and weld or bolt the cartridge bracket securely.
the hose to be exposed to extreme heat or physical abuse.
When bolting the bracket, use 5/16 in. fasteners. Make cer-
tain mounting location allows for easy removal of the car- 3. Make certain the end tees on the triple tee are not twisted
tridge when required. from their original position. See Figure 5.
NOTE: The cartridge must be located in an area that will not TRIPLE TEE
exceed temperature limitations or be subject to fire or damage. BOLT OR WELD APPROPRIATE “C” CLAMP TO
FIT AROUND 1 1/4 IN. DIAMETER TO VEHICLE
Remote Actuator Bracket
A remote manual actuator must be located in the drivers compart-
ment within reach of the operator, and a remote manual actuator
should be located at a point on the vehicle accessible from
ground level. When mounting any actuator, make certain the
length of hose between the actuator and the tank or remote DO NOT TWIST
expellant gas cartridge does not exceed 100 ft. (30.5 m) with 10
actuators maximum or 125 ft. (38.1 m) with 8 actuators maximum
for LT-10 cartridges or 75 ft. (22.9 m) with 8 actuators maximum
using an LT-5 cartridge. Also, make certain there is enough room DISTRIBUTION TEE
for cartridge removal. BOLT OR WELD APPROPRIATE “C” CLAMP TO
FIT AROUND 2 1/8 IN. DIAMETER TO VEHICLE
NOTE: The actuator must be located in an area that will not
exceed temperature limitations or be subject to fire or damage.
Try to avoid mounting actuator near engine compartment.
1. Choose a suitable mounting location and weld or bolt each
actuator bracket in place. If bolting the bracket(s), use 3/8 in.
fasteners. If welding, to avoid corrosion, paint welded sur-
face. See Figure 4.
2. If mounting the remote manual actuator in the dashboard of a
vehicle, the actuator can be mounted by drilling a 1 5/16 in.
REDUCING TEE, 1/2 IN. X 1/2 IN. X 3/4 IN.
(33.3 mm) diameter hole as shown in Figure 4. Make certain
there is enough room for the actuator body, cartridge and BOLT OR WELD APPROPRIATE “C” CLAMP TO
FIT AROUND 3/4 IN. DIAMETER TO VEHICLE
1/4 in. actuation line connection under the dash.
“L” BRACKET “S” BRACKET
MOUNTING
BRACKET
003510
WELD
IF BOLTING, USE (2)
3/8 IN. CORROSION FIGURE 5
RESISTANT BOLTS 003513
000484
000483
3/8 IN. CORROSION RESISTANT
TYPE (TYP. 4 PLACES)
MOUNTING HOLE FOR
CARTRIDGE GUARD ACTUATOR
DASHBOARD LOCATION
BOLT OR
WELD BACK
ENCLOSURE
1 5/16 IN.
DIAMETER
HOLE
003511 003512
FIGURE 4
S1013
5-15-02 Page 6-3
REV. 2
INSTALLING THE COMPONENTS
Installing the Tank Installing Manual Actuators

1. Check each tank to make certain it is filled to its rated capaci- Three types of manual actuators brackets are available for the
ty with FORAY dry chemical. Then, re-tighten fill cap. A-101/LT-A-101 system: “S” bracket, “L” bracket, and cartridge
2. Unscrew the bursting disc union and check that the disc is guard. Location of all actuators must be visible and easily
free from wrinkles, dents or other deformities. reached by operator. Location must not expose actuator to physi-
cal abuse. Actuators using the “S” bracket and the cartridge guard
3. Reconnect the bursting disc union. Use a good grade of
type bracket are suitable for both internal and external mounting.
extreme temperature silicone grease, such as Dow Corning
The “L” type bracket is not suitable for external mounting and
No. 4 or equal, on the male threads to facilitate removal dur-
must be installed in a way that will provide protection for the
ing maintenance.
exposed cartridge.
4. Position the tank(s) in the mounting bracket(s), and secure
REMOTE MANUAL ACTUATOR WITH “S” BRACKET
clamps or retaining bolts.
1. If not already done, weld or bolt mounting bracket to the
Installing the Nozzles selected surface. If welding, to avoid corrosion, paint welded
1. Refer to this system layout sketch from the Design Section IV. surface. See Figure 4.
This sketch should give you the information concerning what NOTICE
nozzle to use where and the correct aiming point. Where bolting the mounting bracket is per-
2. Choose the correct nozzle(s) for each hazard area. formed, use 3/8 in. (corrosion-resistant) bolts of
appropriate length with lockwashers and nuts.
3. Install nozzle(s) in bracket by using two lockwashers, and
either 1/2 in. elbow(s) or coupling. See Figure 6. Aim the 2. Unscrew the RED actuator button from the actuator stem,
nozzle correctly and securely tighten. remove locknut, and slide actuator body through mounting
hole on bracket. See Figure 7.
3. Rotate actuator body for desired location of actuation hose
outlet connection. Screw locknut firmly onto actuator body
and insert ring pin. Apply a non-permanent thread adhesive,
such as Locktite 242 or equal, to the RED actuator button
threads and then screw button onto the stem. See Figure 7.
RED ACTUATOR
BUTTON
LOCK NUT
MOUNTING
BRACKET
ACTUATOR
BODY
RING PIN
FIGURE 6 AND CHAIN
003515
4. Either install nozzle blow-off cap(s) or pack nozzle opening(s)

with silicone grease to avoid build-up of foreign materials.
NOTE: The F-1/2 nozzle is the only nozzle which silicone
FIGURE 7
grease can be used in the opening. 000485
S1013
5-15-02 Page 6-4
REV. 2
INSTALLING THE COMPONENTS (Continued) 2. Unscrew RED actuator button from actuator stem, remove
Installing Manual Actuators (Continued) locknut, and slide actuator body through mounting hole. See
Figure 11.
4. Affix the appropriate operating nameplate adjacent to the
manual actuator so that it is visible to attending personnel. 3. Rotate actuator body for desired location of actuation hose
See Figure 8. outlet connection. Screw locknut firmly onto actuator body and
insert ring pin. Apply a non-permanent thread adhesive, such
as Locktite 242 or equal, to the RED actuator button threads
NAMEPLATE
and then screw the button onto the stem. See Figure 11.
NOTICE
The ring pin chain may not be long enough in
certain dashboard mounted locations. When
this occurs, remove the chain from the drive pin
in actuator body and attach it to an appropriate
location using either a pop rivet or a sheet
metal screw. See Figure 11.
LOCK NUT RED

ACTUATOR
FIGURE 8 ACTUATOR
BUTTON
000486
HOSE OUTLET
5. Make certain ring pin is inserted through the RED actuator CONNECTION
button to ensure safe cartridge installation. See Figure 9. ACTUATOR
BODY
6. Seal ring pin to actuator stem with visual inspection seal, Part
No. 197. Make certain visual inspection seal is looped
through ring pin and around actuator stem. Do not wrap seal POP RIVET OR
around the boot cover. See Figure 9. DO NOT INSTALL SHEET METAL SCREW
RING PIN
CARTRIDGE AT THIS TIME. AND CHAIN
RED ACTUATOR
PLACE WIRE BETWEEN RED
BUTTON
ACTUATOR BUTTON AND
BOOT COVER
BOOT COVER FIGURE 11
003517
WIRE
RING PIN 4. Affix the appropriate operating nameplate adjacent to the man-
ual actuator and visible for attending operator. See Figure 12.
5. Make certain ring pin is inserted through the RED actuator
button to ensure safe cartridge installation. See Figure 12.
NOTE: DO NOT APPLY
WIRE AROUND 6. Seal ring pin to actuator stem with visual inspection seal, Part
BOOT COVER.
through ring pin and around actuator stem. Do not wrap seal
around the boot cover. See Figure 12. DO NOT INSTALL
FIGURE 9 CARTRIDGE AT THIS TIME.
000487
REMOTE MANUAL ACTUATOR MOUNTED IN DASHBOARD

1. Punch or drill a 1 5/16 in. (33.3 mm) diameter hole for mount-
ing the actuator body. See Figure 10. Make certain there is
enough room under the dash for the actuator body, cartridge,
and the 1/4 actuation hose connection. NAMEPLATE
1 5/16 IN.
(33.3 mm)
DIAMETER
FIGURE 12
003518
FIGURE 10
003511
S1013
5-15-02 Page 6-5
REV. 2
INSTALLING THE COMPONENTS (Continued) INSTALLING THE DISTRIBUTION NETWORK

Installing Manual Actuators (Continued)
General Requirements
REMOTE MANUAL ACTUATOR WITH “L” BRACKET Refer to the system layout sketch completed in the Design
NOTICE Section IV. Make certain all hose lengths do not exceed the maxi-
Actuator must be installed in a way that will pro- mum allowed.
vide protection for the exposed cartridge from When installing the distribution hose, once again remember the
physical damage. following:
1. If not already done, weld or bolt mounting bracket to the 1. Make certain the proper type and size of hose is used.
selected surface. If welding, to avoid corrosion, paint welded
surface. See Figure 4. 2. In order to obtain equal distribution at a tee, the center open-
ing must be used as an inlet and the opposing openings used
NOTICE as outlets.
Where bolting the mounting bracket is per-
3. When any 90° bend or elbow is located in the distribution
formed, use 3/8 in. (corrosion-resistant) bolts of
hoseline preceding a tee, a minimum length of 20 hose diam-
appropriate length with lockwashers and nuts.
eters is required between the 90° bend and the tee. This
2. Unscrew the RED actuator button from the actuator stem and length of hose is called a “critical length” and exists only
slide actuator body through mounting hole on bracket. when the 90° bend and the tee lie in the same plane.
3. Rotate actuator body for desired location of actuation hose 4. The use of street elbows is not allowed.
outlet connection. Screw locknut firmly onto actuator body 5. Per SAE J1273, “Care must be taken to insure that fluid and
and insert ring pin. Apply a non-permanent thread adhesive, ambient temperatures, both static and transient, do not
such as Locktite 242 or equal, to the RED actuator button exceed the limitations of the hose. Special care must be
threads and then screw button onto the stem. taken when routing near hot manifolds.”
4. Affix the appropriate operating nameplate adjacent to the 6. Use of 90° elbows is allowed if the following requirements are
manual actuator so that it is visible to attending personnel. not exceeded:
5. Make certain ring pin is inserted through the RED actuator — Maximum of 4 elbows from the agent tank to any nozzle
button to ensure safe cartridge installation. — Maximum of 2 elbows in a primary branch line
6. Seal ring pin to actuator stem with visual inspection seal, Part — Maximum of 2 elbows in a secondary branch line
through ring pin and around actuator stem. Do not wrap seal — Minimum of 1 elbow from agent tank to a nozzle
around the boot cover. See Figure 9. DO NOT INSTALL 7. When bends are formed in the distribution hose, the following
CARTRIDGE AT THIS TIME. minimum bend radius must not be exceeded:
Hose Size 100RI 100R5
REMOTE MANUAL ACTUATOR WITH CARTRIDGE GUARD
1/4 in. 4 in. 3 in.
1. Remove back box from actuator assembly. 1/2 in. 7 in. 5 1/2 in.
2. If not already done, weld or bolt back enclosure to the select- 3/4 in. 9 1/2 in. —
ed surface. If welding, to avoid corrosion, paint welded sur- 7/8 in. 11 in. 7 3/8 in.
face. See Figure 4. NOTE: Minimum bend radius measured to inside of hose
NOTICE radius.
Where bolting the back enclosure is performed, Distribution Hose Installation
use 3/8 in. (corrosion-resistant) bolts of appro-
priate length with lockwashers and nuts. 1. Starting at the tank outlet, connect the distribution hose from
the bursting disc union to the triple, distribution, or reducing
tee. Make certain hose is routed in an ordering manner and
avoid routing hose through fire hazard areas if possible.
2. After hose has been connected, tighten bursting disc union.
3. Follow the sketch (completed in Hazard Analysis portion of
Design Section IV) and complete all hose branch line runs.
4. When connecting the hose to each nozzle, make certain the
aiming angle of each nozzle is not disturbed.
5. When routing hose through bulkheads, take precautions to
protect the hose from excessive wear due to constant vehicle
vibration.
6. When all distribution hose has been routed, make certain all
fittings are wrench tightened.
7. Finally, clamp the discharge hose securely at least every five
feet using industrial duty cable ties or conduit clamps.
8. When passing through bulkheads or grates, Schedule 40
nipples up to 6 in. in length may be used in the distribution
line. (Refer to NFPA17, Section 2-5 (Pipe and Fittings)).
NOTE: 3/4 in. and 1/2 in. Quik-Seal Adaptors can also be
used.
S1013
5-15-02 Page 6-6
REV. 2
INSTALLING ACTUATION AND EXPELLANT GAS LINES Installing The Actuation Gas line(s) and Pneumatic
Actuator(s)
General Requirements
NOTICE
1. Use only 1/4 in. hose for actuation and expellant gas lines When installing actuation gas lines, teflon tape
when used on mobile or vibrating type of installations. Hose must be utilized on all male threads. Do not
must meet the specifications noted in Design Section, Pages allow tape to overlap the pipe opening, as this
4-3 through 4-4. could cause possible blockage of the gas pres-
2. On non-mobile or non-vibrating type installations, 1/4 in. pipe sure. Thread sealant or compound must not
is acceptable. Pipe must be 1/4 in. Schedule 40 black iron, be used.
hot-dipped galvanized, chrome-plated, or stainless steel pipe
and fittings conforming to ASTM A120, A53, or A106. Refer to The actuation gas line is the 1/4 in. hose installed from the
Design Section for maximum allowable lengths. remote manual/automatic actuator(s) to the pneumatic actua-
tors(s) on the agent tank expellant gas cartridge(s). See Figure
3. When using pipe, make certain all ends are carefully reamed 13.
and blown clear of chips and scale. Inside of pipe and fittings A-101 SYSTEM
must be free of oil and dirt. REMOTE MAXIMUM LENGTH 100 FT. (30.5 m) FOR LT-10 CARTRIDGE FROM
ACTUATOR REMOTE ACTUATOR TO LAST TANK (SEE NOTES 1 AND 2)
4. When using pipe, the pipe and fitting connections must be
SAFETY
sealed with pipe tape. When applying pipe tape, start at the RELIEF VALVE
CHECK
second male thread and wrap the tape (two turns maximum) VALVE
clockwise around the threads, away from the pipe opening.
NOTICE
Do not allow tape to overlap the pipe opening,
as this could cause possible blockage of the
gas pressure. Thread sealant or compound CHECK
must not be used. VALVE
5. When passing through bulkheads or grates, up to 6 in. of 003493
Schedule 40 pipe may be used in the actuation and/or expel- ACTUATOR
lant gas lines. (Refer to NFPA17, Section 2-5 (Pipe and NOTE: A MAXIMUM OF (10) TEN A-101 SYSTEMS CAN BE ACTUATED SIMULTANEOUSLY
Fittings)). NOTE: 1/4 in. Quik-Seal Adaptors can also be IN ANY COMBINATION (I.E., A-101, LT-A-101, LP-A-101, OR LT-LP-A-101)
(SEE NOTES 1 AND 2
used.
LT-A-101 SYSTEM
6. Cast iron pipe and fittings are not allowed.
MAXIMUM LENGTH 100 FT. (30.5 m) FOR LT-10
7. Per SAE J1273, “Care must be taken to insure that fluid and ACTUATOR CARTRIDGE FROM REMOTE ACTUATOR TO LAST
REMOTE
PNEUMATIC ACTUATOR (SEE NOTES 1 AND 2)
ambient temperatures, both static and transient, do not ACTUATOR
exceed the limitations of the hose. Special care must be SAFETY
RELIEF
taken when routing near hot manifolds.” VALVE
CHECK
VALVE
CHECK
MAXIMUM
VALVE
EXPELLANT
GAS HOSE
LENGTH,
20 FT. 0 IN.
(6.1 m)
(EACH)
003495
NOTE: REDUCE THE MAXIMUM ALLOWABLE NUMBER OF BASIC EXTINGUISHING

UNITS BY ONE FOR EACH NON-EXTINGUISHING PNEUMATICALLY OPERATED
DEVICE EMPLOYED, I.E., BRAKE CONTROL VALVE, FUEL CONTROL AIR CYLINDER.
FIGURE 13
If more than one remote actuator is in the system, the total length
of actuation line allowed from the actuator to the last tank must
also include any amount of hose in the other actuation lines up to
the check valves located in those lines.
NOTE 1: If only eight (8) or less actuators are used, the actuation
line can be extended to 125 ft. (38.1 m) when using an LT-10
nitrogen cartridge.
NOTE 2: The actuation line can also utilize an LT-5 cartridge.
When this is done, only eight (8) actuators or less can be used,
with a maximum length of 75 ft. (22.9 m).
S1013
5-15-02 Page 6-7
INSTALLING ACTUATION AND EXPELLANT GAS LINES INSTALLING THE DETECTION SYSTEM
(Continued) When automatic detection is part of the total system design, see
Installing The Actuation Gas line(s) and Pneumatic the appropriate Design, Installation Manual for detailed
Actuator(s) (Continued) Information.
Complete the installation of all dry chemical actuation lines and • CHECKFIRE ELECTRIC SERIES I SYSTEM – Manual Part
components by completing the following: No. 54894
1. Install all pneumatic actuators as follows: • CHECKFIRE SC-N ELECTRIC SYSTEM – Manual Part No.
a When removing actuator from the carton, check pin to 423522
make certain it is in the upright position. See Figure 14. • CHECKFIRE MP-N ELECTRIC SYSTEM – Manual Part No.
427310
INSTALLING ACTUATION CARTRIDGES

1. Weigh each manual actuator cartridge to make certain it is
within the weight specifications stamped on the cartridge
1/4 IN. (6.4 mm)
body. This weight check must be performed with the shipping
MINIMUM cap removed. Refer to appropriate manual for detailed instal-
lation instructions if the system contains an automatic
CHECKFIRE Detection System.
FIGURE 14 2. Check that the puncture pin in each manual actuator is fully
004357
retracted so that the pin will not pierce the cartridge seal dur-
b. Securely hand tighten the pneumatic actuator cartridge ing installation.
body to cartridge.
3. Install an LT-10 nitrogen cartridge into each manual actuator
c. Position actuator and cartridge assembly into bracket. and hand tighten firmly.
d. Using two wrenches, one on the swivel nut and one on the 4. At this time, the cartridge may be installed in the CHECK-
bottom portion, loosen the swivel nut, and rotate the top FIRE detection system actuator.
portion of the actuator to the correct position to align the
two actuation line ports with the incoming and outgoing 5. Finally, document the entire installation with drawing, pho-
1/4 in. actuation line(s). tographs, and/or written description of the entire vehicle sys-
tem and store these documents in a permanent file for future
reference.
! CAUTION
Each actuator contains two (2) 1/4 in. actuation ports. If

both ports are not utilized, the open port must be plugged
with a 1/4 in. pipe plug. Failure to plug the port will cause
loss of actuation gas pressure upon system actuation.
2. Install required 1/4 in. actuation lines from the remote actua-
tor outlet port to all actuation ports on the upper portion of
each pneumatic actuator.
3. Once all lines are securely installed, wrench tighten the
swivel nut on the upper portion of each pneumatic actuator.
Installing Expellant Gas Line(s)

The expellant gas line is the 1/4 in. line between the remote
expellant gas cartridge and the agent tank. The gas line is only
required when the system is using either an LT or LP type tank.
See Figure 13.
The maximum length of 1/4 in. expellant gas line is 20 ft. (6.1m).
Make certain the hose meets all the requirements as stated in the
Design section.
S1013
5-15-02 Page 6-8
NOTES:
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 VII – INSPECTION
5-15-96 Page 7-2
NOTES:
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 IX – RECHARGE
5-15-96 Page 9-2
NOTES:
S1013
SECTION X – SYSTEM APPLICATION OPTIONS
5-15-02 Page 10-1
REV. 1
In order to help understand the design process, the following Nozzle No. 3 and 4 – Located to provide protection for the sides
example hazards are covered in this section. There may be differ- of the engine. Each is mounted on the side of the engine com-
ent design approaches that can be taken for each hazard, but the partment in front and aimed toward the rear and center to com-
examples are only intended to show the typical areas requiring pletely cover the engine sides.
protection and the number of nozzles and tanks required. They Nozzle No. 5 and 6 – Located at the top of the engine compart-
will give the designer an idea of what to look for on these types of ment toward each side. Each is positioned to discharge toward
vehicles. Also, refer to appropriate CHECKFIRE Design, the rear and center of the engine and the turbocharger.
Installation manual for detailed information concerning detection
system requirements. Nozzle No. 7 – Located under the operator’s compartment
toward one side and aimed to discharge across the pan area. In
NOTICE addition to the pan, its discharge will protect the parking brake
These are conceptual drawings. They were disc.
prepared from information provided through
vendor’s sales literature to assist field installa- Nozzle No. 8 – Located under the operator’s compartment but is
tions. The fire suppression system illustrated positioned to discharge dry chemical on the hydraulic lines in the
constitutes nominal hardware requirements. compartment. It is oriented so a portion of its discharge will pass
The detection system has not been shown for through the front bulkhead to protect the hydraulic lines leading to
the purpose of clarity. The final system design the front bucket.
must consider other potential ignition and fuel NOTE: Larger front end loaders will require additional protection.
source areas not in the vendor’s literature,
meaning a pre-installation in-depth analysis of
all likely areas of probable fire incident.
FRONT END LOADER (TYPICAL 2 TANK DESIGN)

Nozzle No. 1 and 2 – Located toward the lower rear of the
engine compartment and are aimed forward and toward the cen-
ter. They are positioned to provide complete coverage of the
entire pan area.
FIGURE 1
003520
S1013
5-15-02 Page 10-2
REV. 1
DOZER (TYPICAL 3 TANK DESIGN)

Nozzle No. 1 (N1) – Locate (1) C 1/2 nozzle to discharge dry Nozzle No. 7 (N7) – Locate (1) V 1/2 nozzle to discharge dry
chemical into the engine pan from front to back. chemical across front of engine from top to bottom.
Nozzle No. 2 (N2) – Locate (1) V 1/2 nozzle to discharge dry Nozzle No. 8 (N8) – Locate (1) C 1/2 nozzle to discharge dry
chemical diagonally over the top of the engine. chemical onto the side of engine diagonally from top to bottom.
Nozzle No. 3 (N3) – Locate (1) V 1/2 nozzle to discharge dry Nozzle No. 9 and 12 (N9 and N12) – Locate (2) V 1/2 nozzles
chemical screening right side of engine under exhaust manifold. back to back to discharge dry chemical screening hydraulic lines
Nozzle No. 4 (N4) – Locate (1) V 1/2 nozzle to discharge dry and top of transmission, discharging from center to right and left
chemical screening left side of engine under exhaust manifold. sides.
Nozzle No. 5 (N5) – Locate (1) C 1/2 nozzle to discharge dry Nozzle No. 10 (N10) – Locate (1) C 1/2 nozzle to discharge dry
chemical onto the side of engine diagonally from top to bottom. chemical into the belly pan and bottom of the transmission.
Nozzle No. 6 (N6) – Locate (1) V 1/2 nozzle to discharge dry Nozzle No. 11 (N11) – Locate (1) V 1/2 nozzle to discharge dry
chemical diagonally over the top of the engine. chemical over the top of the transmission from back to front
screening opening under cab and rear end.
NOTE: Larger dozers may require additional protection.
FIGURE 2
003521
S1013
5-15-02 Page 10-3
REV. 1
TRANSIT BUS (TYPICAL 1 TANK DESIGN)

Nozzle No. 1 (N1) – Locate (1) V 1/2 nozzle at upper left rear end Nozzle No. 4 (N4) – Locate (1) V 1/2 nozzle at right side of
of engine compartment aimed to discharge diagonally across engine midway from front to back aimed from rear to discharge
engine rear from top left to bottom rear protecting front of engine across steering pump and air compressor at engine front.
and pump filters. Nozzle No. 5 (N5) – Locate (1) V 1/2 nozzle at right side of
Nozzle No. 2 (N2) – Locate (1) V 1/2 nozzle at top rear aimed at engine between engine and bus right side aimed from back to
center to discharge horizontally across engine top and turbo front to discharge horizontally across battery connections and
charger. hydraulic reservoir.
Nozzle No. 3 (N3) – Locate (1) V 1/2 nozzle on left side of engine Nozzle No. 6 (N6) – Locate (1) V 1/2 nozzle midway up at right
midway from front to back aimed from rear at an angle to dis- side of engine rear aimed from back to front to screen right side of
charge across rear left side of engine, back of engine, and engine and starter.
hydraulic lines protecting the generator as well as discharging into
transmission area.
TO REMOTE
ACTUATOR
FIGURE 3
003522
S1013
5-15-02 Page 10-4
REV. 1
LANDFILL COMPACTOR (TYPICAL 3 TANK DESIGN)

Nozzle No. 1 and 12 (N1 and N12) – Locate (2) V 1/2 nozzles to Nozzle No. 8 and 9 (N8 and N9) – Locate (2) V 1/2 nozzles to
discharge dry chemical under engine in the pan area. discharge dry chemical from top of transmission area aimed to
Nozzle No. 2 and 3 (N2 and N3) – Locate (2) V 1/2 nozzles at discharge horizontally from rear of compartment to front of trans-
each side of engine at bottom attached to engine mount-gusset, mission top and also under cab area.
aimed up to screen engine sides. Nozzle No. 10 (N10) – Locate (1) V 1/2 nozzle at front under cab
Nozzle No. 4 (N4) – Locate (1) V 1/2 nozzle at top middle of aimed to discharge dry chemical horizontally from front to back
engine compartment, in front aimed down at 45° angle, discharg- under cab protecting valve banks.
ing vertically onto center of engine front and top. Nozzle No. 11 (N11) – Locate (1) V 1/2 nozzle up in articulation
Nozzle No. 5 (N5) – Locate (1) V 1/2 nozzle to discharge dry area aimed down with discharge pattern following vehicle center
chemical from top left rear of engine compartment onto engine line, discharging into loader tower and onto hydraulic lines in
top and turbo. articulation area.
Nozzle No. 6 and 7 (N6 and N7) – Locate (2) V 1/2 nozzles to NOTE: Larger landfill compactors may require additional protec-
discharge dry chemical from front of machine, 1/2 way up in tion.
transmission area aimed back at engine screening transmission
sides and discharging into bottom of pan area with a vertical dis-
charge pattern.
FIGURE 4
003523
S1013
5-15-02 Page 10-5
REV. 1
ORE HAULAGE TRUCK (TYPICAL 2 TANK DESIGN)

Nozzle No. 1 – Located at the top center of the engine compart- Nozzle No. 5 – Located at the top left corner of the engine com-
ment aimed toward the turbocharger at the rear of the engine. It is partment and aimed across the top of the engine to the opposite
designed to protect the top of the engine and the front of the tur- corner. Its purpose is to protect the top of the engine and parts of
bocharger. the turbocharger and exhaust manifold.
Nozzle No. 2 – Located on the right rear corner of the engine Nozzle No. 6 – Located on the left rear corner of the engine com-
compartment aimed toward the front corner with the pattern ori- partment and aimed toward the front corner with the discharge
ented vertically. This is intended to screen and protect the right pattern oriented vertically. Its purpose is to screen and protect the
side of the engine. left side of the engine.
Nozzle No. 3 – Located at the top right corner of the engine com- Nozzle No. 7 – Located at mid-engine height in the left rear cor-
partment and is aimed across the top of the engine to the oppo- ner of the engine compartment. The nozzle pattern is aimed
site corner. Its purpose is to protect the top of the engine and across the rear portion of the engine at the transmission housing.
parts of the turbocharger and exhaust manifold. This is done to protect the lower portion of the exhaust manifold,
Nozzle No. 4 – Located at mid-engine height in the right rear cor- and the left side of the transmission and accessory equipment
ner of the engine compartment. The nozzle pattern is aimed area such as the hydraulic pumps, etc.
across the rear portion of the engine at the transmission housing. Nozzle No. 8 – Located such that the dry chemical stream will hit
This nozzle is intended to protect the lower portion of the exhaust the parking break area.
manifold, and the right side of the transmission and accessory NOTE: Larger ore haulage trucks may require additional protec-
equipment area such as hydraulic pumps, etc. tion.
FIGURE 5
003524
S1013
5-15-02 Page 10-6
REV. 1
LOG SKIDDER (TYPICAL 2 TANK DESIGN)

Nozzle No. 1 and 2 – Located to discharge horizontally in the Nozzle No. 5 – Located in the compartment directly under the
front lower portion of each side of the engine compartment. This operator’s seat. It provides protection for the hydraulic lines,
allows each nozzle to be aimed upward and toward the center of pump and pan area.
the engine’s side to completely cover the side of the engine with Nozzle No. 6 – Located to discharge dry chemical on the parking
dry chemical. disc located on the rear portion of the skidder.
Nozzle No. 3 – Located just above the belly pan, aimed to com- Nozzle No. 7 and 8 – Located to provide protection for both
pletely cover the pan area. sides of the hydraulic cable reel assembly. They are located on
Nozzle No. 4 – Located toward the rear and top of the engine the rear portion of the skidder and are aimed toward each side of
compartment. It is oriented to discharge dry chemical diagonally the reel assembly.
across the top of the engine. NOTE: Larger log skidders may require additional protection.
FIGURE 6
003525
S1013
SECTION XI – APPENDIX
5-15-02 Page 11-1
REV. 1
SYSTEM COMPONENT INDEX ACTUATION DEVICE

70584 Remote Manual Actuator Package Includes: LT-10-L
BASIC UNIT (Left Hand) Cartridge, “S” Bracket, Elbow, Check
16559 A-101-10 Includes: Agent Tank, Tank Mounting Valve, Seal, Operating Instruction Labels and
Bracket, 101-10 Cartridge Installation Instructions
16430 A-101-20 Includes: Agent Tank, Tank Mounting 71699 Remote Manual Actuator Package Includes: LT-10-L
Bracket, 101-20 Cartridge (Left Hand) Cartridge “L” Bracket, Elbow Check Valve,
16131 A-101-30 Includes: Agent Tank, Tank Mounting Seal, Operating Instruction Labels and Installation
Bracket, 101-30 Cartridge Instructions
31581 LT-A-101-10 Includes: Agent Tank, Tank Mounting 57484 Remote Manual Actuator Package Includes: LT-10-R
Bracket, LT-20-R Cartridge (Right Hand) Cartridge, “S” Bracket, Elbow, Check
Valve, Seal, Operating Instruction Labels and
24306 LT-A-101-20 Includes: Agent Tank, Tank Mounting Installation Instructions
Bracket, LT-30-R Cartridge, Cartridge Bracket, and
Pneumatic Actuator 71804 Remote Manual Actuator Package Includes: LT-10-R
(Right Hand) Cartridge, “L” Bracket, Elbow, Check
53003 LT-A-101-30 Includes: Agent Tank, Tank Mounting Valve, Seal, Operating Instruction Labels and
Bracket, (Does Not Include Cartridge, Cartridge Installation Instructions
Bracket or Pneumatic Actuator)
70581 Remote Manual Actuator for LT-10-L (Left Hand)
24883 LT-A-101-30 Cartridge, Cartridge Bracket, and Cartridge Only
Pneumatic Actuator for LT-A-101-30 Unit
57452 Remote Manual Actuator for LT-10-R (Right Hand)
31344 LP-A-101-20-B Includes: Agent Tank, Tank Mounting Cartridge Only
Bracket, 101-20 Cartridge, Cartridge Bracket, and
Pneumatic Actuator 57661 “S” Type Mounting Bracket for Dashboard Actuator,
Part No. 70581 and 57452
24307 LT-LP-A-101-20-B Includes: Agent Tank, Tank
Mounting Bracket, LT-30-R Cartridge, Cartridge 70580 “L” Type Mounting Bracket for Remote Manual
Bracket, and Pneumatic Actuator Actuator, Part No. 70581 and 57452
32747 Remote Actuator Package, Cartridge Guard Type (Left
DISTRIBUTION TEES Hand) Includes: Actuator, LT-10-L Cartridge, Check
53036 Distribution Tee Package Includes: 4 Distribution Tees Valve, Operating Instruction Labels, Lead Wire Seal
25031 Distribution Tee 32739 Remote Actuator Package, Cartridge Guard Type
(Right Hand) Includes: Actuator, LT-10-R Cartridge,
53038 Triple Tee Package Includes: 2 Triple Tees Check Valve, Operating Instruction Labels, Lead Wire
16424 Triple Tee Seal
53040 Reducing Tee Package Includes: 2 Reducing Tees 16033 Operating Instruction Labels for Manual Actuator
(1/2 in. x 1/2 in. x 3/4 in.) Includes: Nameplate “IN CASE OF FIRE 1. SHUT
OFF ENGINE 2. PULL RING PIN 3. PUSH LEVER”
4655 Reducing Tee (1/2 in. x 1/2 in. x 3/4 in.)
16459 Operating Instruction Labels for Manual Actuator
419695 Y Lateral Includes: Nameplate “IN CASE OF FIRE 1. SHUT
OFF POWER 2. PULL RING PIN 3. STRIKE BUT-
NOZZLES TON”
57046 C-1/2 Nozzle Package Includes: 4 Nozzles, 4 Nozzle
Brackets, 4 Blow-Off Caps and 8 Lockwashers ACTUATION LINE DEVICES
57044 V-1/2 Nozzle Package Includes: 4 Nozzles, 4 Nozzle 15677 Safety Vent Relief Valve
Brackets, 4 Blow-Off Caps and 8 Lockwashers 53050 Safety Vent Relief Valve Package Includes: 2 Safety
53042 F-1/2 Nozzle Package Includes: 4 Nozzles, 4 Nozzle Vent Relief Valves
Brackets, 4 Blow-Off Caps and 8 Lockwashers 53051 1/4 in. Check Valve (Package of 2)
53791 Nozzle C-1/2 Includes: Nozzle, Blow-Off Cap 57488 LT and LP Model Pneumatic Actuator Assembly
56748 Nozzle V-1/2 Includes: Nozzle, Blow-Off Cap 16408 A-101 Pneumatic Actuator with Cartridge Receiver
16449 Nozzle F-1/2 Includes: Nozzle Only Assembly
415192 Blow-Off Cap With Retaining Strap Package Includes: 31579 LT-A-101-10 Pneumatic Actuator Assembly
50 Blow-Off Caps (Part No. 415108) For V-1/2 and 8372 Pressure Switch (Shutdown)
C-1/2 Nozzle Only
46250 Pressure Switch, Weather Proof, DPST (shutdown)
73870 Blow-Off Cap Package: Includes: 50 Blow-Off Caps,
Part No. 4120, For F-1/2 Nozzle 427425 Engine Shutdown Device
73871 Nozzle Bracket Package: Includes: 12 Brackets,
2 in. x 2 in. Angle
427149 Nozzle Bracket, 2 in. x 3 in. Angle
427228 Nozzle Bracket, Straight 5 in. x 2 in., 4 Brackets
73872 Nozzle Lockwasher Package: Includes: 50 Lock
washers, Part No. 25581
S1013
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
S1013
6-30-05 Page 11-3
REV. 2
STAINLESS STEEL OPTIONAL COMPONENTS FOR AN/FO

LOADER APPLICATIONS (NOT FM APPROVED)
ANSUL LT-A-101 systems are being used in mining applications
throughout the world. One such application is on an AN/FO
Loader. AN/FO is an abbreviation for ammonium nitrate and fuel
oil which are utilized in mining as explosive media. Though we
know of no incidents, a potentially hazardous condition can occur
over time when copper materials and/or the copper in brass fit-
tings are exposed to Ammonium Nitrate, forming Copper
Tetramine Nitrate. This is an impact sensitive self-explosive.
Copper Tetramine Nitrate may be present when a buildup of a
blue composition on copper or brass fittings is evident. The prox-
imity of the fittings to the ammonium nitrate will determine the
level of buildup that may result.
Although there is only a remote possibility for the above men-
tioned hazardous condition to occur, optional stainless steel com-
ponents are now available for the LT-A-101-30 Vehicle Fire
Suppression System.
Stainless Steel Assemblies for LT-A-101-30 Systems

NOTE: These assemblies are designed for AN/FO Loader appli-
cations where stainless steel components are recommended in
place of brass components and do not replace the components
on standard LT-A-101 Systems.
Part No.
_______ Description
_________
53003* LT-A-101-30 Agent Tank, Agent, Bracket
431775* TC LT-A-101-30 Agent Tank, Agent, Bracket
32028 Fill Cap Assembly, SS
432840 Pneumatic Actuator Assembly, SS
433147 Manual Actuator, SS
432824 Actuator Assembly, SS (Included w/Part No. 433149)
432831 Nozzle, V-1/2, SS (single)
432841 Nozzle, C-1/2, SS (single)
432817 Valve, Safety Vent Relief, SS (single)
432820 Sealed Burst Disc Assembly, SS (single)
432830 Check Valve, 1/4 in., Threaded (single)
433149 CHECKFIRE SC-N Assembly
(Includes Part No. 432824)
*For new installations, order Fill Cap (Part No. 32028) and
Sealed Burst Disc Assembly (Part No. 432820).
As with all fire suppression systems, regular maintenance cou-
pled with good housekeeping practices will maximize perfor-
mance.
S1013
5-15-02 Page 11-4
REV. 2
LARGE EXCAVATORS 4. The fire suppression system must automatically perform the
following functions:
Hazards and Protection
• Engine shutdown.
The following are generally considered to be fire hazard areas. • Pressurized hydraulic tank and fuel tank venting.
Hazard areas exist when an ignition source can come in contact • Fuel shutoff.
with a fuel source. This may be due to the close proximity of the • Electrical disconnect (Optional).
ignition source to the fuel source or due to the configuration of the
machine that may allow running or spraying fuel to come in con- If mine personnel refuse to allow any of the above items to
tact with an ignition source. A hazard analysis of the excavator be performed, it should be documented and kept in the job
should determine which of the following components will require file.
protection. A hazard analysis should also determine any other 5. The system must also include a Remote High Level Alarm
areas not listed below that potentially could be considered hazard Horn, Part No. 79559 and should also include a remote visu-
areas requiring protection. al alarm.
1. Engine. The engine consists of various components that con- 6. As part of the total fire suppression system package, training
tain or transfer fuels, components involved with lubrication, for mine personnel and the machine operator(s) must be
and electrical contacts and controls as well as components conducted and documented. Training should include but not
that generate heat. Protection should include but not be limit- be limited to:
ed to the following components: • A-101 and CHECKFIRE SC-N system description.
• Manifolds • System operation.
• Turbochargers • System limitations and primary intent.
• Heat exchangers • What to do in case of fire.
• Fuel lines • Vehicle maintenance and fire suppression system mainte-
• Engine block nance.
• Electrical equipment, such as starters, generators, 7. An A-101/CHECKFIRE SC-N Maintenance Contract allowing
alternators, etc. periodic service and maintenance at scheduled intervals
• Exhaust systems should also be included.
• Bottom of engine, belly pan or floor area
NOTE: Extended discharge can also be obtained by using
2. Hydraulic pump(s) and control valve banks/manifolds.
the larger LT-A-101-125/250 tanks. Refer to manual, Part No.
3. Hydraulic hoses and fuel lines, including those under opera- 427865, for details.
tor’s compartment.
4. Transmissions/gear reduction boxes.
5. Brakes and brake valves. NOTE: Brakes located in the track
mechanism are not required to be protected.
6. Drive train bearings.
7. Swing gear motors and travel clutches.
8. Ring Gear area.
9. Lubrication systems.
10. Hydraulic oil tank and fuel tank fill and outlet connections.
11. Batteries.
12. Large electrical generators and motors.
Design Parameters
1. Extended Discharge System (Not FM Approved) – Fire sup-
pression on large excavators may require an extended agent
discharge time to allow for operator egress from the
machine. In order to extend the time of agent discharge from
A-101 system nozzles, the number of tanks determined by
hazard analysis must be doubled. (Refer to drawings for
revised actuation and discharge hose connection parameters
and system operation.)
• 3/4 in. Extended Discharge Supply Hose Line Connection.
See Figure 1. (NOTE: Maximum of 24 in. from each adja-
cent tank to the common “Y” fitting.)
• 1/4 in. Actuation Hose Detail. See Figure 2.
• CHECKFIRE SC-N Wiring Diagrams. See Figures 3 and 4.
2. Each four nozzle agent distribution network will be connected
to two adjacent tanks using a “Y” fitting. See Figure 1. Six
nozzles systems are not allowed.
3. An automatic detection and actuation system will be
required, using the CHECKFIRE SC-N Detection and
Actuation system.
S1013
5-15-02 Page 11-5
REV. 1
LARGE EXCAVATORS (Continued)

Design Parameters (Continued)
FIGURE 1
003526
S1013
5-15-02 Page 11-6
REV. 1

FIGURE 2
003527
S1013
5-15-02 Page 11-7
REV. 1

FIGURE 3
006435
S1013
GENERAL INFORMATION
5-15-02 Page 11-8
REV. 1

FIGURE 4
006436
S1013
5-15-02 Page 11-9
EXCAVATOR PROTECTION • Twin-Agent Application: Large Equipment [Operating

Excavators can be classified into three categories, depending on Weight: 1,000,000 lb. (453,600 kg) and greater]
their hydraulic fluid capacity. ANSUL has researched the hydraulic Use of a twin-agent system consisting of the LVS liquid agent
fluid capacities in regard to size of equipment (operating weight). system connected to an A-101-125/250 dry chemical (extend-
With the introduction of the LVS™ Liquid Agent Suppression ed discharge) system.
System (not FM Approved), we can now offer an enhanced pro- Note 1: The liquid portion of the twin-agent scheme, at a mini-
tection scheme for large excavators, as well as other non-road mum, must protect the engine(s) and hydraulic
mobile equipment. The following protection schemes are devices (i.e., pumps, control valves, valve banks).
required for excavator of these specified sizes. They are as Additional LVS liquid agent systems may be added at
follows: the designer’s discretion to cover other areas.
• Standard Discharge Application: Small Equipment Note 2: Existing systems installed in compliance with Product
(Operating Weight: 99,000 to 200,000 lb. (44,906 to 90,720 Service Bulletin No. 77 utilizing an extended dis-
kg)) charge design, do not need to be changed to twin-
Standard discharge application of an A-101 dry chemical sys- agent system. However, for new system installations
tem can be used for this smallest class of excavators. Design or major changes to an existing hydraulic excavator,
of the suppression system shall be in accordance with the the design must follow the guidelines in this manual
LT-A-101-30 or LT-A-101-125/250 Installation, Recharge, using a twin-agent system.
Inspection, and Maintenance Manual. Excavators that fall into this class of machine include but are
Excavators that fall into this class of machine include but are not limited to:
not limited to: • DeMag: H455S, H485S, H485SP, H655S
• Caterpillar: 345BL-VG, 350, 350L, 375, 375L, 5080 • Hitachi: EX5500, EX7500
• Hitachi: UH261, UH30 • Komatsu: PC5500, PC8000
• Komatsu/DeMag: H65, PC 750-6 • Liebherr: R996
• Liebherr: R982 • O&K: RH 200, RH 300, RH 400
• Link-Belt: 5800, 6000
General Discussion
• O&K: RH 25D, RH 30E
• Poclain: 300, 400 Special design consideration must be given when protecting
large excavators to reduce the potential for reflash and provide
• Twin-Agent Application: Mid-Size Equipment [Operating additional time. ANSUL requires the following as a minimum:
Weight 200,000 to 1,000,000 lb. (90,720 to 453,600 kg)]
1. Two large size agent tanks are available: a 125 lb. (56.7 kg)
Use of a twin-agent system consisting of the LVS liquid agent tank and a 250 lb. (113.4 kg) tank. The LT-A-101-125 tank
system connected to an A-101 dry chemical (extended or stan- can utilize an 8-nozzle extended discharge or 12- or 16-noz-
dard discharge) system. The A-101 system can utilize 250 lb., zle standard discharge distribution system. The LT-A-101-250
125 lb. or 30 lb. (nominal) agent containers. tank can utilize either an 8, 12, or 16 nozzle extended dis-
Note 1: When utilizing a standard discharge design, all haz- charge or a 24 nozzle standard discharge system. Both the
ard areas will require protection using both agents. 125 lb. and 250 lb. tanks can be used where an extended dis-
charge is required. See “Extended Discharge” to determine
Note 2: When utilizing an extended discharge design, the liq- type of system required.
uid portion of the twin-agent scheme need only pro-
tect the engine(s) and hydraulic devices (i.e., pumps, 2. When utilizing 30 lb. agent containers, use four nozzles maxi-
control valves, valve banks). mum for each single or two-tank (when used as extended dis-
charge) system to provide additional agent per nozzle and
Note 3: Existing systems installed in compliance with Product maximum system discharge time. Single tank, two-nozzle
Service Bulletin No. 77 utilizing an extended dis- systems may also be used for extended discharge.
charge design, do not need to be changed to twin-
agent systems. However, for new system installations NOTE: When protecting the engine, hydraulic devices (i.e.
or major changes to an existing hydraulic excavator, pumps, control valves, valve banks), hoses and con-
the design must follow the guidelines in this manual nections on large non-road mobile equipment used in
using a twin-agent system. surface mining, landfill equipment, or other large spe-
cialized machines; only 4-nozzle 30 lb. tank systems,
Excavators that fall into this class of machine include but are or large capacity (125 lb. and 250 lb.) type systems
not limited to: are to be used.
• Caterpillar: 5130, 5130B, 5130ME, 5130FS, 5230, 5230ME
3. Fully automatic system, including automatic engine shut-
• DeMag: H95, H135S, H185S, H255S, H285S down, hydraulic oil/fuel shutoff, and agent discharge.
• Hitachi: EX1000, EX1100, EX1800, EX 2500, EX3500,
EX 3600, UH501, UH80, UH801 4. Remote high level alarm and flashing alarm strobe to
enhance machine operator warning.
• Komatsu: PC1000-6, PC1100-6, PC1400, PC1500-1,
PC1600-1, PC1800-6, PC 3000, 3560 B, PC4000 5. A safe means of egress from the operator’s compartment
• Liebherr: R984, R992, R991, R994, R995 without having to exit past fire hazard areas.
• NW Engineering: 100-DH
• O&K: RH 40E, RH 75, RH 90C, RH 120C, RH 170
• Poclain: 600, 1000
• P&H: 1200
S1013
5-15-02 Page 11-10
EXCAVATOR PROTECTION (Continued) FUME HOOD PROTECTION (Not FM Approved)

General Discussion (Continued) Fume Hood can utilize an ANSUL A-101-20 or A-101-30 system
In addition to the LT-A-101 dry chemical system and/or with 6 nozzles. See Figure 5.
LT-A-101/LVS twin-agent system with CHECKFIRE® Electric FUME HOOD
Detection and Control equipment, supplemental fire protection C-1/2 NOZZLE
should be included when considering protection of large non-road (6 FT. MAXIMUM COVERAGE)
mobile equipment:
1. Cartridge operated hand portable fire extinguishers TO A-101-20 OR A-101-30
2. Secondary means of fire suppression DISTRIBUTION

C-1/2 NOZZLE
TEE
For any fire protection to be effective, training is critical. As a min- (6 FT. MAXIMUM
PART NO.
COVERAGE)
imum, comprehensive training for the machine operator and site 25031
representatives should include:
1. Fire suppression system operation V-1/2 48 IN.
NOZZLES MAXIMUM
2. Fire suppression system performance V-1/2
NOZZLES
3. Fire suppression system capabilities
4. Fire suppression system limitations
5. Response procedures
6. Safe egress procedures
It is important to make sure the site representative understands
the LT-A-101/LVS/CHECKFIRE system capabilities as well as lim-
itations. This information needs to be discussed and reviewed
with the appropriate end-user personnel.
72 IN.
MAXIMUM
30 IN.
MAXIMUM
FIGURE 5
003530
The system can utilize a distribution tee and 3/4 in. supply piping
and 1/2 in. branch piping.
Standard A-101 nozzles are used for dry chemical discharge.
C-1/2 nozzles are used in the duct and V-1/2 nozzles are used in
the plenum and hood area.
The pipe length must not exceed the maximum requirement as
stated on Page 4-11 and 4-12 of this manual.
When utilizing an ANSUL AUTOMAN Release, use an LT-10-R
Cartridge to supply the required actuation gas pressure to the
tank cartridge.
S1013
ANSUL INCORPORATED
ONE STANTON STREET
MARINETTE, WI 54143-2542
Copyright © 2006 Ansul Incorporated
Part No. 24327-07
16721
FIRE SUPPRESSION SYSTEM
Page 1 of 4
Updated:
12/11/06
16721
Page 2 of 4

334124 FIRE SUPPRESSION SYSTEM ASSEMBLY 1
334125 FIRE SUPPRESSION SYSTEM ASSEMBLY 1
334005 NOZZLE PACKAGE (INCLUDES ITEMS 21-24) 6
1 324014 BRACKET ASSEMBLY (INCLUDES ITEMS 2-9) 2
2 NSS PAD, CLAMP ARM 4
3 NSS BOLT 2
4 NSS WASHER 1
5 NSS NUT, LOCK 1
6 NSS BUMPER PAD 1
7 NSS PAD, BASE 1
8 NSS BAND, CLAMP 1
9 NSS PAD, CLAMP BAND 1
10 334118 FILL CAP ASSEMBLY (INCLUDES ITEMS 11, 12) 1
11 NSS GASKET 1
12 NSS QUAD RING 1
13 NSS TAG, INSTRUCTION 1
14 334117 ADAPTER 1
15 334057 BURSTING DISC UNION ASSEMBLY 1
(INCLUDES ITEMS 16, 18)
16 NSS ADAPTER 1
17 NSS BURSTING DISC 1
18 NSS UNION RING AND TAIL PIECE 1
19 332043 TEE, TRIPLE A/R
20 332046 TEE, TRIPLE A/R
21 332049 LOCKWASHER, NOZZLE A/R
22 332047 NOZZLE A/R
23 334121 CAP, BLOW OFF A/R
24 NSS BRACKET, NOZZLE MOUNTING A/R
25 334119 BRACKET ASSEMBLY, CARTRIDGE 1
26 NSS BOLT, CARRIAGE 2
Updated:
12/11/06
16721
Page 3 of 4
27 NSS NUT, LOCK 2
28 NSS ARM, CLAMP 1
29 NSS PAD, CLAMP ARM 1
30 334123 CARTRIDGE ASSEMBLY (INCLUDES ITEMS 31, 32) 1
31 NSS CARTRIDGE 1
32 NSS CAP, SHIPPING 1
33 334126 VALVE, CHECK 2
34 332042 VALVE, SAFETY RELIEF 1
35 NSS ACTUATOR ASSEMBLY, PNEUMATIC 1
36 NSS BODY, ACTUATOR 1
37 NSS O-RING 1
38 NSS PISTON, PNEUMATIC SLAVE 1
39 NSS PIN, PUNCTURE 1
40 NSS SPRING 1
41 NSS O-RING 1
42 NSS ADAPTER, BODY 1
43 NSS WASHER 1
44 NSS RING, RETAINING 1
45 NSS GASKET 2
46 334013 CARTRIDGE ASSEMBLY (INCLUDES ITEMS 47, 48) 2
47 NSS CARTRIDGE 1
48 NSS CAP, SHIPPING 1
49 332044 ACTUATOR ASSEMBLY, MANUAL 1
(INCLUDES ITEMS 46-48, 50-61)
50 NSS KNOB 1
51 NSS BOOT 1
52 NSS NUT, JAM 1
53 NSS BRACKET 1
54 NSS BODY, ACTUATOR 1
55 NSS O-RING 1
56 NSS PIN, PUNCTURE 1
57 NSS ELBOW, STREET 1
Updated:
12/11/06
16721
Page 4 of 4
58 NSS SEAL, LEAD-WIRE 1
59 NSS SCREW, DRIVE 1
60 NSS CHAIN 1
61 NSS RING PIN 1
62 334003 REMOTE ACTUATOR CARTRIDGE 1
Updated:
12/11/06
17124
CABLE STRINGER ASSEMBLY
Page 1 of 2

1
2
3
4
5
6

11/05/07
17124
CABLE STRINGER ASSEMBLY
Page 2 of 2
1 14247-01 SOUTHWORTH LIFT WELDMENT 1
2 605763 PIN QUICK RELEASE (3/4”) 1
3 14247-06 CABLE LIFT INNER PIPE WELDMENT 1
4 605890 PIN QUICK RELEASE (1/2”) 1
5 14247-08 CABLE GUIDE ELBOW WELDMENT 1
6 14247-03 CABLE LIFT SIDE WELDMENT 1
7 605763 QUICK RELEASE PIN 2
8 25181-03 BUSHING ASSEMBLY 2
9 14245-10 HINGED COVERS BOTH SIDE 2
10 14246-01 REEL WELDMENT 1
11 18005-08 PIN WELDMENT 2
12 605947 SPROCKET 10 TEETH 1
13 14243-06 MOTOR MOUNT WELDMENT 1
14 322200 AIR BAG 1
15 14244-01 AIR BAG/PIVOT MT WELDMENT 1
16 605949 CHAIN 46” LONG 1
17 14243-01 ROLLER MOUNT WELDMENT 1
18 14245-05 WELD-ON MOUNT PLATE 4
19 605948 SPROCKET 17 TEETH 1
20 23801-05 SOUTHWORTH LIFT MOUNT 4
21 14245-01 REEL JIG WELDMENT 2
22 264018 PILLOW BLOCK 2
23 14244-09 KEY 1
24 14244-07 REEL DRIVE TIRE ROLLER ASSEMBLY LONG END OUT 1
25 14245-01 REEL JIG WELDMENT (PARTIAL SHOWN) 1
26 494216 CHAIN DRIVE MOTOR 1
27* 14246-01 REEL WELDMENT 1

11/05/07
S1076
OWNER’S MANUAL
LS Series Lift Tables

L, LS, LSW, LST and LSTW Models
Model # ______________________________________
Serial # ______________________________________
Date placed in Service __________________________
SOUTHWORTH PRODUCTS CORP

P.O. Box 1380 • Portland, ME 04104-1380
Telephone: (207) 878-0700 or (800) 743-1000
Fax: (207) 797-4734
www.SouthworthProducts.com
Email: service@SouthworthProducts.com
S1076
Please note: This manual was current at the time of printing.

To obtain the latest, most updated version, please contact
Southworth’s Customer Service Department or go to our website:
www.SouthworthProducts.com, under E-Parts & Service
you will find a complete list of current
owner’s manuals to print.
S1076
Southworth LS Series Lift Table Owner’s Manual

CONTENTS
INTRODUCTION ............................................................................................................ 1
Safe Servicing of the Lift ................................................................................... 2
SAFETY ......................................................................................................................... 3
INSTALLATION INSTRUCTIONS .................................................................................. 3
Preparation ........................................................................................................ 3
Positioning the Lift ............................................................................................. 4
Hydraulic Connections ...................................................................................... 4
Electrical Connections ....................................................................................... 5
Testing ............................................................................................................... 5
Completing Installation ...................................................................................... 5
Smartlift Programming ...................................................................................... 6
Charging a Battery ............................................................................................ 7
OPERATING INSTRUCTIONS ...................................................................................... 9
Operating Procedure ........................................................................................ 9
MAINTENANCE ........................................................................................................... 11
Hazards ........................................................................................................... 11
Routine Periodic Maintenance ........................................................................ 12
High Cycle Package ....................................................................................... 12
Flushmount Turntable .................................................................................... 13
Units with Air Motors ...................................................................................... 13
TROUBLESHOOTING ................................................................................................. 14
Troubleshooting Check List ............................................................................. 14
Repacking Cylinders ....................................................................................... 15
Replacing Leg Rollers ..................................................................................... 17
Ordering Replacement Parts ........................................................................... 18
Electrical Connections for Single-Phase AC ................................................... 21
Electrical Connections for Three-Phase AC .................................................... 23
List of Figures
Figure 1 Safe Servicing of Lift ................................................................................................ 2
Figure 2 Mount the Lift Securely ............................................................................................ 3
Figure 3 Using Lifting Eyes .................................................................................................... 4
Figure 4 Center the Load ........................................................................................................6
Figure 5 Secure the Load ...................................................................................................... 6
Figure 6 Pinch Points ........................................................................................................... ..9
Figure 7 Labels and Precautionary Markings, Comfort Edge Tabletops ................................9
Figure 8 Labels and Precautionary Markings,
Straight Skirt and Bevel Toe Guard Platforms ....................................................... 10
Figure 9 H-Style Cylinder ..................................................................................................... 16
Figure 10 Parts Identification, Side View ............................................................................... 17
Figure 11 Parts Identification, View of Motor and Pump ........................................................ 18
Figure 12 Parts Identification, LS-2 Models ........................................................................... 19
Figure 15 Hydraulic Pump and Down Valve .......................................................................... 20
Figure 16 Electrical Connections, Lifts Wired for Single-Phase AC ....................................... 21
Figure 17 Wiring Diagram, LIfts Wired for Single-Phase AC without limitswitch ................... 21
Figure 18 Wiring Diagram, LIfts Wired for Single-Phase AC with limitswitch ........................ 22
Figure 19 Electrical Connections, Lifts Wired for Three-Phase AC ....................................... 23
Figure 20 Schematic, Lifts Wired for Three-Phase AC .......................................................... 24
Figure 21 Hydraulic Connections ........................................................................................... 24
Figure 22 Hydraulic Diagram - Unit with Electric Motor ......................................................... 25
Figure 23 Hydraulic Diagram - Unit with Air Motor ................................................................ 25
Table 1 Electrical Interface, Supplied by Customer ............................................................ 26

Table 2 Hydraulic Oil Specifications ................................................................................... 26
S1076
S1076
SOUTHWORTH
INTRODUCTION
Southworth’s LS series is our basic lift table line, containing over 400,000
combinations of load capacity, vertical travel, table size, power source, and
other characteristics. The LS line, and this manual, also include the LST
(tandem) lifts, and the LSW (wide-base) styles. LS lift tables can also be
supplied with a large assortment of optional accessories and modifications
to suit the customer’s needs. Some variations use an air motor to power the
hydraulic pump. “High cycle” units are designed for especially heavy use.
This manual contains information to acquaint you with the safe and proper
installation, use, and upkeep of an LS series lift table. You should ensure that
this manual is available to personnel working with and on the lift table and
require its use by these personnel.
LS lift tables are designed for lifting and vertical positioning of equipment and
materials in a wide variety of industrial settings. The instructions set forth in this
manual are not necessarily all-inclusive, as Southworth cannot anticipate all
conceivable or unique situations.
Please read all of this manual carefully, and be familiar with its contents
before you install, use, or service the LS Lift Table. If you have any
questions about any of the instructions in this manual, please contact
your dealer or Southworth Products Corp.
Southworth’s product warranty is shown on the back cover of this manual. This
instruction manual is not intended to be or to create any other warranty,
express or implied, including any implied warranty of merchantability or
fitness for a particular purpose, all of which are hereby expressly
excluded.
As set forth more specifically in the product warranty, Southworth’s obligation under
that warranty is limited to the repair or replacement of defective components,
which shall be the buyer’s sole remedy, and Southworth shall not be liable for any
loss, injury, or damage to persons or property, nor for any direct, indirect, or
consequential damage of any kind resulting from the LS lift table.
1
S1076
SAFE SERVICING OF THE LIFT Rotate the

maintenance
devices
into position
WARNING !
Only authorized personnel should perform in-
spection or maintenance and service proce-
dures. Unauthorized personnel attempting
these procedures do so at the risk of severe
injury or death. Working
position
DANGER !
Failure to properly adhere to lift blocking pro-
cedures is to risk the sudden and uncontrolled Storage
Working
position
descent of the lift during maintenance or in- position
spection. A falling lift can cause severe injury
or death.
Figure 1 – Safe Servicing of Lift
This procedure describes the only factory-approved

method of working under a lift. Follow these instruc- DANGER !
tions EVERY time you plan to reach or crawl beneath If for any reason you are unable to lower the
the lift to perform service or maintenance – no matter lift completely onto the maintenance device(s),
how momentary that might be. stop immediately and consult the factory. Fail-
If the factory-provided maintenance device is dam- ure to properly use the factory approved main-
aged or missing, stop immediately and consult the fac- tenance device(s) could result in severe injury
tory for assistance. The manufacturer is not liable for or death.
your failure to use the approved maintenance device(s)
and procedures that have been provided. 5. (For single-acting hydraulic, and pneumatic lifts)
Once the maintenance device(s) is/are properly and
1. Any load must be removed from the lift prior to en- securely engaged, continue to press the down but-
gaging the maintenance device(s). These devices ton, valve or switch for an additional 5-10 seconds
are designed to support an unloaded lift only. Fail- to relieve all pressure in the operating system (add
ure to remove the load from the lift prior to blocking more specifics here as required for pneumatic lifts).
could cause the failure of the maintenance device(s)
and allow the lift to fall unexpectedly. This can re- WARNING !
sult in personal injury or death, or permanent dam- Failure to relieve operating system pressure
age to the maintenance device(s) and/or the lift. could result in the sudden and unexpected re-
lease of high pressure fluids (or air) during
2. Raise the lift to its fully raised position. If you do maintenance and/or repair of the lift and result
not, the maintenance device(s) may not be able to in severe injury or death.
be placed properly in its/their designed blocking
position. 6. Follow OSHA electrical lock-out/tag-out procedures.
Disconnect and tag all electrical and/or other power
3. Remove the maintenance device(s) from its/their sources to prevent an unplanned or unexpected ac-
storage location and place it/them into the engaged tuation of the lift.
position as shown in Figure 1. (Note: further infor-
mation may be useful here to provide additional in- 7. Once inspection or work is complete, reverse the
structions as to the location and method of storage performance of the steps above to raise the lift off
and engaged positions). the maintenance device(s) and place the device(s)
back into its/their designated storage position(s).
4. Lower the lift until it makes complete contact with
the maintenance device(s). Re-check to ensure DANGER !
that all provided devices are fully and securely en- HIGH VOLTAGE ! – Disconnect and/or lock out
gaged. If the device(s) is/are not fully engaged the the electrical supply to the power unit prior to
lift could fall unexpectedly, resulting in permanent any installation or maintenance being per-
damage to the device(s) or the lift. formed.
2
S1076
SOUTHWORTH
SAFETY
The safety of all persons operating, maintaining, repairing, or in the vicinity of the LS lift table is of paramount
concern to Southworth. The lift table is a powerful machine with moving parts, and is capable of causing personal
injury if proper precautions are not taken.
Therefore, throughout this manual, Southworth has identified certain hazards which may occur in the use of the lift
table, and provided appropriate instructions or precautions which should be taken to avoid these hazards. In
some cases, Southworth has also pointed out the consequences which may occur if Southworth’s instructions or
precautions are not followed. Southworth uses the following system of identifying the severity of the hazards
associated with its products:
SIGNAL WORD is a word or words that designate a degree or level of hazard seriousness. The signal
words for product safety signs are “DANGER, WARNING and CAUTION”. Below is each signal word
along with their definitions referenced directly from ANSI Z535.4-1998.
“DANGER” Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury. This signal word is to be limited to the most extreme situations.
“WARNING” Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
“CAUTION” Indicates a potentially hazardous situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert against unsafe practices.
Use lag bolts to hold

the unit down
(unless it is mounted
on casters)
Figure 2 –
Mount the lift on a firm,
Mount the level surface
Lift Securely
Grout the area under
each side rail with
cement
Lag plates
If necessary, insert shims

to level the lift
Please read and follow this instruction
manual, including all safety instructions
and precautions, carefully and completely.
INSTALLATION INSTRUCTIONS
Preparation
the pit have 90° angles at each corner? To check,
1. Before you start to install the lift, check for local measure across the opposite corners of the pit. The
codes and ordinances that may apply. It is your measurement on each diagonal should be the same,
responsibility to obtain any necessary permits. within 1/2 inch. The walls of the pit should be vertical.
2. Read all of these installation instructions Check with a carpenter’s square.
carefully. Be sure to read and understand all of 4. If the power unit will be mounted away from the lift
the warnings! (“external power unit”), check the mounting arrangement for
3. If your unit is designed to be installed in a pit, check the power unit. The power unit should be sheltered from the
the pit before you start to install the lift. Measure the weather. It should be mounted within 30 feet of the lift to
length and width of the lift table, then measure the pit, minimize the pressure drop in the hydraulic system. Be sure
and be sure the pit allows adequate clearance. Does the hydraulic lines have been installed properly.
3
S1076
The chain should

pull straight up
Chain spreader
Eye bolt
Captive nut
Base nut
Figure 3 – Using Lifting Eyes
WARNING! number, serial number, and date the lift is placed in

Protect the power unit from rain or moisture. service. You can find the model number and serial
If the electrical parts in the power unit get number on the name plate as shown in Figure 10. You
wet, workers may be hurt by electrical cannot see the name plate without lifting the table top.
shock. The electrical parts may fail if they Use an overhead crane or fork truck to do this. Lift the
are wet. hinged end of the table top.
WARNING! 7. Move the lift into position, supporting the base of
The electric motor in the lift can create the lift. Install the lift as shown in Figure 2. Unless the
sparks. Do not install the power unit in an lift is mounted on casters, lag the lift to the floor.
area where flammable gases may be CAUTION!
present. Do not hang the lift from the table top. This can
5. If the power unit is mounted within the lift (“internal damage the lift.
power unit”), you will need these tools: WARNING!
• A crane or lift truck that can lift the unit safely. If the lift is mounted on an unstable surface,
• Shims and lag bolts – see the pit plan if the lift will it may tip over when it is in use. You may be
be mounted in a pit. hurt, and the lift and load may be damaged.
• A masonry drill and bit to drill the holes for the lag If your lift has lifting eyes, as shown in Figure 3, use
bolts. these when you move the lift. It is best to use a chain
spreader, so the chain sections pull straight up. (You
• A power supply with the specified voltage, including
must supply the chain and spreader.) Remove the lifting
fuses or circuit breakers as specified in Figures 16
eyes once you have moved the lift.
through 20.
If the power unit will be mounted away from the lift Hydraulic Connections
(“external power unit”), you will also need:
(External Power Units Only – If Internal Power Unit,
• A compressed air source for clearing the hydraulic
proceed to step 10.)
lines.
8. Install the power unit. Install the hydraulic line
• Extra hydraulic oil for flushing the underground
between the power unit and the lift as shown on the
lines and refilling the tank. See Table 2 for the
pit plan.
oil specifications.
9. Blow out the hydraulic line with compressed air
Positioning the Lift before connecting it to the power unit. Replace the solid
plug on the hydraulic fluid tank with the vented plug
6. Remove the shipping material and unskid the lift. supplied, then attach the vent line to the vented plug.
On the front of this manual, write down the model
4
S1076
SOUTHWORTH
WARNING! 12. Raise the lift and insert the maintenance devices,
Be sure that the hydraulic line will not be as shown in Figure 1.
pinched by the lift as it raises or lowers. If 13. Make the permanent electrical connections as
you allow the line to be pinched, the lift may shown in Figure 17 or 18 (for single-phase) or Figure
not work properly. A hose may break, the 19 (for three-phase).
lift table may drop suddenly, and someone
14. Check the level of the hydraulic fluid. On most
may be hurt.
models, when the lift is fully elevated, the oil should be
CAUTION! about 3/4 inch above the bottom of the tank. Use a
It is very important to keep the hydraulic oil free dipstick to check the oil level, and add oil as necessary.
of dirt, dust, metal chips, water, and other
contamination. Most of the problems with
hydraulic systems are caused by contamination Testing
in the oil. Be sure to flush all hydraulic lines 15. Clear the area around the lift. Remove any loose
before connecting remote power units. wires, lumber, or other materials that might get in the
CAUTION! way of the lift as it raises or lowers.
If you do not install the vented plug in the tank, 16. Remove the maintenance devices and warn others
the pump may be damaged. to stay away from the lift. Operate the lift through its full
range of travel. The lift should rise smoothly with a quiet
humming sound, and lower smoothly and quietly. Raise
Electrical Connections and lower the lift a few times to check the clearances
around the lift table.
This lift will require a dedicated 20 amp circult WARNING!
serving no other electrical devices.
As the lift table moves up and down, “pinch
Do not operate this lift with an extension cord. points” are created at the places shown in
Figure 6. If you are standing too close to
the lift when it is moving, your arm or leg
DANGER! may be caught in the moving parts, and you
The lift may use a power supply of up to may be hurt. Stay away from the pinch
575 Volts AC. This voltage can kill you. Do points when the lift is moving.
not work with the electrical parts unless you
are a qualified electrician.
10. Make temporary electrical connections to the lift, Completing Installation
as shown in Figure 17 or 18 (for single-phase AC) or 17. If your lift is mounted in a pit, align the unit with the
Figure 19 (for three-phase AC). This temporary set- sides of the pit. Once you are sure the lift is positioned
up will allow you to raise the lift. correctly, mark the locations of the lag holes in the base
WARNING! frame, and drill the holes. If necessary, insert metal
The fusing requirements are shown in shims to level the base of the lift. Insert and tighten the
Table 1. To avoid fire danger, follow these lag bolts to secure the lift. Grout under the base rails to
requirements. prevent vibration and distortion of the base frame, as
shown in Figure 2.
11. On a lift designed for three-phase AC, you must
be sure the pump motor is turning in the right direction. 18. If the lift is lowering too quickly or too slowly, you can
The lift table should start to move quickly when you change the “down speed” by adjusting the flow control.
press the “up” or “down” button. If the lift table does not WARNING!
move in 2 or 3 seconds, don’t try to operate the lift! When adjusting the flow control, always
Exchange any two of the three-phase leads. If this does raise the lift table and insert the
not correct the problem, see the troubleshooting maintenance devices, as shown in Figure
instructions at the end of this manual. 1. Do not try to adjust the flow control while
CAUTION! pressing the “down” button. If you try this,
If you have a unit designed for three-phase AC the lift table may drop suddenly, and you
and you connect the power so the motor runs may be hurt.
backwards, the lift will not operate, and you may It is important that you follow these steps when adjusting
damage the pump. Do not operate the lift for the flow control:
more than 2 or 3 seconds if you think the motor • Raise the lift table and insert the maintenance
might be turning backwards. devices, as shown in Figure 1.
5
S1076
• If you want the lift to lower more slowly, turn the WARNING!
control clockwise up to 1/4 turn at a time. If you Do not continue to use the lift if this happens
want the lift to lower more quickly, turn the control – the pump will overheat very quickly, and
counterclockwise up to 1/4 turn. Do not move the may be permanently damaged. Do not try
control more than 1/4 turn at a time. to adjust the relief valve. If you change the
• Remove the maintenance devices, and check the setting on the relief valve, you may
descent speed. overwork the lift. This can cause the lift to
fail suddenly, and you may be hurt.
• Every time you want to change the adjustment
again, raise the table again and insert the 20. As a final step, clean up all spilled hydraulic fluid.
maintenance devices as shown in Figure 1. Spilled hydraulic oil is slippery, and may present a
19. Test the lift with the rated load. If the lift does not rise, fire hazard.
and you hear a loud squealing noise, the pressure relief
valve is operating. Contact Southworth for instructions.
Always place the load in the

center of the lift table.
Figure 4 – Figure 5 –
Center Secure
the Load the Load
SMARTLIFT PROGRAMMING
To program SmartLift the following steps must be taken:
FOR INCREMENTS
• TOUCH BUTTON <PROG>
• TOUCH BUTTON <INC 1 or 2>
• HOLD UP or DOWN BUTTON FOR LENGTH OF INCREMENT
FOR POSITIONS
• TOUCH BUTTON <HOME>
• TOUCH BUTTON <POS 1 or 2>
• HOLD UP BUTTON TO RAISE LIFT TO POSITION
Programming increments or positions overrides previous programs. Smartlift retains programmed
settings even when unplugged.
6
S1076
SOUTHWORTH
Preparing to Charge a Battery
1. Be sure area around the lift and battery is well ventilated while the battery is being charged.
2. The battery terminals, connections and wiring including the plug in the battery box and charger
connections should be clean and free of corrosion. When cleaning any of these components
wear a face shield or other suitable protective eyewear.
3. For a sealed battery (a battery without cell caps) carefully follow the manufacturer’s recharging
instructions that are provided with the battery. If you do not have a copy of these instructions or
the instructions for the battery charger they are available free of charge by calling Southworth
Products Corp at 1-800-743-1000.
4. Read, understand and follow all battery and battery charger manufacturer’s specific precautions
while working with and/or charging batteries.
Locating the Charger
1. Locate the charger as far away from the battery as the cables permit.
2. Do not operate the charger in a closed area or restrict ventilation in any way.
3. Locate the charger at least 18’’ above the floor.
PRECAUTIONS FOR GROUNDING

AND AC POWER CORD CONNECTION
Charger should be grounded to reduce risk of electric shock.

The charger is equipped with an electric cord having an equipment-grounding
conductor and grounding plug. The plug must be plugged into an
outlet that is properly installed and grounded in accordance
with all local codes and ordinances.
DANGER
Never alter the AC cord or plug provided. If it will not fit the outlet,
have a proper outlet installed by a qualified electrician.
Improper connection can result in a risk of an electric shock.
7
S1076
Battery Charger Connection Precautions
CAUTION: Connect and disconnect the DC output plug (or clips)

only when the AC cord is disconnected from the electric outlet.
Never allow clips to touch each other.
1. When hooking up the charger, attach the plug into the twist-lock receptacle on the side of
the battery box or connect the clips directly to the battery on units that are not pre-wired with
a plug on the side of the battery box.
FOR UNITS NOT EQUIPPED WITH A TWIST-LOCK,

PREWIRED CHARGER PLUG FOLLOW THESE
ADDITIONAL PRECAUTIONS.
1. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has larger diameter
than NEGATIVE (NEG, N, -) battery post.
2. Determine which post of the battery is grounded (connected) to the chassis of the machine.
Connect the NEGATIVE (black) clip from the battery charger to the machine chassis, as far
away from the battery as possible.
3. The POSITIVE (red or white) clip from the battery charger to the POSITIVE (POS, P, +) post
of the battery.
4. When making each connection, twist or rock clip back and forth several times to make a
good connection and to reduce the risk of a clip slipping off and creating a spark. Do not
twist or rock clip on the battery after the second clip connection is made.
5. When disconnecting the charger, disconnect AC cord from the electrical outlet before removing
any clips from the battery or chassis.
IF THESE INSTRUCTIONS ARE NOT CLEAR

OF IF THERE ARE ANY QUESTIONS,
PLEASE CONTACT SOUTHWORTH PRODUCTS CORP.
TELEPHONE: (800) 743-1000

FAX: (207) 797-4734
E-mail: service@SouthworthProducts.com
8
S1076
SOUTHWORTH
OPERATING
INSTRUCTIONS
1. Before operating the lift, read and understand this
entire section.
DANGER!
The lift may use a power supply of up to
575 Volts AC. This voltage can kill. Do not
work with the electrical parts unless you are
a qualified electrician!
2. Locate the lift on a firm, flat surface as shown in
Figure 2. Stationary lifts should be lagged to the floor.
WARNING!
If you place the lift on a soft surface, it may
tip over, especially when it is loaded or
raised. Someone may be hurt, and the lift
and load may be damaged.
3. Load the lift correctly.
• Be sure that the load weighs no more than the
maximum rated for the lift. The maximum rated load
is shown on the platform skirt.
WARNING!
Do not try to lift a load that exceeds the
maximum rating. If you try this, the lift may Figure 6 – Pinch Points
fail suddenly. Someone may be hurt, and the
lift and load may be damaged. • If you are lifting pipes or other objects which may
• Place the load in the center of the lift table, as shown be able to roll or move, fasten them down, or chock
in Figure 4. them as shown in Figure 5.
• Do not try to load the lift while the lift table is moving. 4. Be sure all workers are clear of the lift. Remove
any lumber or other material which may fall onto the lift.
Tabletops with Comfort Edge Kits
Item Part# Location

1 2986306 ....... On end of tabletop as shown
on machines without handrails or
5904643 ....... On end of tabletop as shown
on machines with handrails
2 2986307 ....... One on each side as shown.
Cut off last picture and word
message if tabletop has handrail.
3 2998429 ....... One on each side as shown.
4 Capacity decals:
On platform ends, one per end as shown.
2998433 (500#) 2998437 (3500#)
2998425 (1000#) 2998426 (4000#)
2998434 (1500#) 2998442 (5000#)
2998427 (2000#) 2998428 (6000#)
2998435 (2500#) 5900159 (Other)
2998436 (3000#)
Figure 7 – Labels and Precautionary Markings for Comfort Edge Tabletops
9
S1076
Item Part# Location Item Part# Location

*1 ........ 2986306 ........ On both sides of platform 9 ...... 2987001 (208/3/60) 5900163 (110/1/50)
or (use for standard platforms) 2987002 (230/3/60) 5900164 (220/1/50)
5904643 ........ On both sides of platform 2987003 (460/3/60) 2999416 (380/3/50)
(use for platforms with handrails) 5900162 (575/3/60) 5900165 (415/3/50)
2 ........ 2986737 ........ On lower strongback between legs Place one decal on base end plate, where power wire
3 ........ 2986968 ........ On lower strongback between legs exits the base.
4 ........ 2991927 ........ On both sides of maintenance 10 ...... 2986738. On junction box cover (alt: base end plate)
devices, both sides of base *11 ....... Capacity decals:
5 ........ 2991182 ........ On both sides of base, as close to 2998433 (500#) 2998437 (3500#)
maintenance device as possible 2998425 (1000#) 2998426 (4000#)
*6 ........ 5900158 ........ On both sides of platform 2998434 (1500#) 2998442 (5000#)
7 ........ 2986997 ........ On hydraulic tank 2998427 (2000#) 2998428 (6000#)
8 ........ Control decals: 2998435 (2500#) 5900159 (Other)
2986999 (115/1/60) 2986998 (24/1/60) 2998436 (3000#)
5900167 (110/1/50) 5900166 (24 VDC) Place one decal on platform ends, two per end.
Place one decal on base end plate, where the control 12 ...... 2921026 ........ Machines with up limit only:
wire exits the base. Locate on end of base.
9 ........ Power decals: 13 ...... 2991183 ........ Fasten to flow control located on
2987000 (115/1/60) 2991783 (12VDC) the hydraulic arrangement.
5900160 (230/1/60) 5900161 (24VDC) 14 ...... 2998365 ........ Fasten to flow control located on
the hydraulic arrangement.
Figure 8 – Labels and Precautionary Markings (straight skirt and bevel toe guard platforms)
Note: If tabletop has comfort edge refer to figure 7 on the previous page. Use other decals and
locations in place of the ones above with an asterick “*” in front of their number.
10
S1076
SOUTHWORTH
WARNING! permanently damaged. The relief valve is
Do not use the unit to lift people unless it included to protect the machine operators –
has been specially equipped for this do not change the relief pressure setting.
purpose. A specially equipped lift will 6. Wait until the lift table has stopped. Unload the lift.
include operator protection, and a velocity
fuse to keep the lift from dropping suddenly WARNING!
if a hydraulic line is damaged. Retrofit kits The warning labels on the lift are there for
are available if you want to add these features your safety. If you find that the labels are
to your lift. worn or missing, or have been painted
over, ask Maintenance to replace the
WARNING! labels before you use the lift. The labels
As the lift table moves up and down, “pinch are shown in Figures 7 and 8.
points” are created as shown in Figure 6.
Stay away from these pinch points! Part of If your machine is equipped with a flush mount
your body or clothing may become caught, turntable:
and you may be hurt. WARNING!
Do not drop the load on the turntable. If you
5. To operate the lift., press and hold the “up” button
do this while the turntable is moving, the load
to raise the lift, and “down” to lower it. If the lift does not
may shift. You may be injured, or the
operate right away, turn off the lift and call a qualified
mechanism may be damaged. If you drop
maintenance worker.
the load while the turntable is stopped, the
WARNING! machine may be damaged.
If you hear a squealing noise from the pump,
the pressure relief valve is operating. Do not Stay clear of the turntable while it is rotating.
continue to use the lift! The pump will As the pallet turns, a part of the load may
overheat very quickly, and may be rotate around and hit you.
MAINTENANCE Keep hands, feet, and loose clothing away

from these pinch points. If your hand or arm
All servicing should be done by qualified personnel. or a part of your clothing is caught, you may
Qualified personnel should be able to read and be hurt.
understand wiring and hydraulic diagrams. They should
be able to troubleshoot live electrical circuits safely and • A falling lift can cause severe personal
in accordance with accepted practice. For safety’s injury. Before working under the lift, raise
sake, if in doubt, please contact your dealer or the lift and insert the maintenance devices,
Southworth’s Customer Service Department at (207) as shown in Figure 1. Do this every time you
878-0700 or (800) 743-1000. Before servicing the lift, work under the lift!
read and understand this entire section and the section WARNINGS!
entitled “Operating Instructions.” • Do not change the setting on the relief
valve. If you do change the setting, this may
cause a hydraulic part to fail. The lift may
Hazards drop suddenly. Someone may be hurt, and
the lift and the load may be damaged. The
There are several hazards you should be aware of as hydraulic parts in the lift are designed to
you service the lift: handle a certain amount of pressure. The
DANGER! relief valve is set to relieve this pressure
The lift may use a power supply of up to before it becomes too great. The relief valve
575 Volts AC. This voltage can kill. Do not has been included for the protection of all
work with the electrical parts unless you are of the workers who use the lift.
a qualified electrician! • Release of fluids under high pressure can
WARNINGS! cause personal injury. Before you open any
• As the lift moves up and down, “pinch part of the hydraulic system, be sure to
points” are formed as shown in Figure 6. release the hydraulic pressure.
11
S1076
• The warning labels on the lift are there for WARNING!

the safety of the operators. See Figures 7 If a hydraulic fitting becomes loose, or if a
and 8. If the labels are worn or missing, or hydraulic hose breaks, the hydraulic fluid
have been painted over, replace them before may escape from the system under
releasing the lift for operation. pressure. If the lift is raised when this
happens, it can drop quickly. Someone may
be hurt, or the lift or load may be damaged.
Routine Periodic Maintenance • The clear plastic vent line and the cylinder rod(s)
should be free of hydraulic fluid. If you find much fluid
Every month: in either place, the cylinder seals may be leaking. (It is
• Visually inspect the leg rollers, center pivot bushings also possible the tank may be overfilled.) See the section
and pins, cylinder clevis pins and bushings, and the leg on “Repacking Southworth Cylinders.”
hinge pins and bushings for signs of wear. Contact • Disassemble the down valve as shown in Figure
Southworth for instructions for repair of the center pivot 15. Blow the valve plunger clean with compressed air.
pins and bushings. Reassemble and reinstall.
WARNING! • Drain and discard the hydraulic fluid. The suction
If you are going to repair the center pivot pins filter is in the tank, at the point where the suction line
and bushings, you must support the lift table runs out to the pump. Unscrew the hydraulic filter.
in a special way. Each set of leg plates, on • Blow the filter clean. Reinstall the filter in the tank
both sides of the unit, must be clamped and reassemble the hydraulic line.
together firmly, using large C-clamps. You
• Refill the tank with new hydraulic fluid.
cannot use the maintenance devices shown
in Figure 1 – with the pivot pins removed, they CAUTION!
will not support the table top. If you do not If you continue to use fluid after it has “worn
support the lift table correctly, the top may out,” the moving parts in the system will wear
drop suddenly when you remove the pivot more quickly.
pins. Please contact Southworth for • Be sure all of the warning labels are in position and
instructions. legible. The labels are shown in Figures 7 and 8. The
• Apply oil or WD-40 to the parts listed in the last step. warning labels are intended to protect your workers.
If the labels are missing, or if they have been painted
NOTE: Although the bearings are “lifetime lubricated”
over, replace them.
their performance may be extended by additional
periodic lubrication.
• Check the level and appearance of the hydraulic
fluid. First, raise the lift and insert the maintenance Minimum Required Maintenance for
devices, as shown in Figure 1. On most models, when Units with High Cycle Package
the lift is fully elevated, the oil should be about 3/4 inch • Every 10,000 cycles, visually inspect the entire lift.
above the bottom of the tank. Use a dipstick to check Replace all worn or broken parts. Lubricate all pivot
the oil level, and add oil as necessary. Change the oil if points and clean the roller track.
it has darkened, or feels gritty or sticky.
• Every 30,000 cycles, visually inspect the entire lift.
CAUTION! Check the motor starter contacts and limitswitches.
It is important to use hydraulic fluid with the Clean and lubricate all pivot points. Inspect for worn or
correct grade and properties. See the hydraulic broken parts, and replace as necessary.
oil specification in this manual, Table 2.
• Every 90,000 cycles, visually inspect the entire lift.
Check the hydraulic tank and the hydraulic lines. Clean
Every six months or 500 hours of and lubricate all pivot points. Inspect for worn or broken
parts, and replace as necessary. Repack the cylinder(s),
operation, whichever comes first:
and replace the hydraulic oil and filter.
• Raise the lift and insert the maintenance NOTE: If lubrication points will not take grease, the load
devices, as shown in Figure 1. may have to be removed from the platform, ensure the
• Check all of the hydraulic fittings and hoses, and repair grease fittings are not plugged and will take grease, or
the connections as necessary. Occasionally the fittings can the weight of the lift may need to be removed from the
be worked loose by the vibrations from the power unit. greaseable joint. A fork truck or overhead crane may
12
S1076
SOUTHWORTH
be necessary to remove any weight off of the greaseable 1. Remove the turntable as described in the last
joints. Contact Southworth’s Service Department for section.
further instructions if the machine is still unable to accept 2. Lift out the carrier plate. Collect the steel balls (48
grease. balls for the 20” dia. turntable, 72 balls for the 43” dia.
turntable).
3. Degrease the carrier plate and the steel balls.
Maintenance for Units 4. Inspect the steel balls for signs of wear. Check
with Flushmount Turntable several balls for discoloration or breakdown of the
chrome layer.
NOTE: It is normal to see some wear on the plate under
the turntable. After a short “break-in” period usually 5. Set the carrier plate back in position. Place each
100 to 200 revolutions, a work hardened wear strip will of the balls in one of the bearing positions. Be sure
develop, and further wear should be minimal. that every bearing position has a ball. The machine
uses the large number of bearings to spread out the
Every week, make a general walk-around inspection. weight of the load. If some of the balls are missing, the
Remove any dirt and debris from the turntable top. Clear machine will not work properly, and may wear more
the gap between the table and the turntable. (An air quickly.
hose may be used.)
6. Pack some grease inside the opening of each
If excessive force is used to rotate the turntable, this bearing position on the carrier plate.
may be caused by a lack of lubrication, contaminated
bearings, or dirt. To correct the problem, remove the 7. Work some grease around the center pivot pin and
turntable and inspect the mechanism. Clean and snap ring.
lubricate the parts as described in the following sections. 8. To reassemble the machine, reverse the steps
listed above.
Removing the Turntable Top
NOTE: These instructions apply only to units with the
flushmount turntable.
Maintenance for Units
1. Put the lift in the fully-lowered position. with Air Motors
On this type of unit, the air motor is used to power the
2. Unplug the machine.
hydraulic pump. (See Figure 23 - hydraulic diagram.)
3. Use a pair of snap-ring pliers to remove the snap When the lift is raised, a valve sends compressed air to
ring in the center of the turntable. the air motor. The air motor powers the pump and
4. Use a lever to lift one edge of the turntable. Lift the provides hydraulic power for the unit. When the lift is
turntable away from the machine. lowered, an air-operated down valve allows the
(The turntable weighs about 75 lbs. You will need at hydraulic fluid to escape from the cylinders.
least two people to lift this part safely. Be sure to wear The vanes in the rotary-type air motor take up their own
heavy gloves when performing this job.) wear, and will last 5,000 to 15,000 hours of operation.
5. If necessary, you can now remove the carrier plate. (The actual service life depends on the operating speed,
The steel balls used in the machine can remain in the method of oiling, operating pressure, and the
lower part of the machine. Do not remove the balls precautions taken in maintaining the machine.) The
unless you want to degrease the bearings - it can be type of shaft seal used will not withstand pressures of
time consuming to reassemble this part of the machine. more than 100 psi.
6. In the 43” diameter turntable there are 72 balls. In An automatic airline lubricator must be installed in the
the 20” diameter turntable there are 48 balls. They are airline just ahead of the air motor. (The filter, regulator,
standard chrome-plated steel balls. and lubricator are not supplied by Southworth.) The
lubricator must be adjusted to feed one drop of oil for
7. To reassemble the machine, reverse the steps listed
every 50 to 75 cfm of air going through the motor. This
above. Be sure that every bearing position has a
lubrication is necessary to reduce friction on all internal
ball. Check to see that the locking device is intact.
moving parts, and to prevent rust.
The starting torque of the air motor is greater than the
Inspecting and Lubricating the Turntable running torque. This could vary depending on the
NOTE: These instructions apply only to units with the position at which the vanes stop in relation to the air
flushmount turntable. intake port. It is advisable to use a pressure regulator
or a simple shut-off valve to obtain the desired power,
13
S1076
speed and torque, and to conserve air. the valve, contact Southworth Products
CAUTION! Corp. for instructions.
Do not allow the air motor to “run free” at high 2. If the motor is not running, check the main
speed with no load. This can cause buildup of disconnect switch, the fuse(s) and the wiring to the
excessive heat and loss of internal clearances, motor.
and can damage the motor quickly. 3. Using an external lifting mechanism, such as a
If the motor is sluggish or inefficient, try flushing it with crane or fork lift, raise the lift and insert the
solvent. To flush a motor, disconnect the airline and maintenance devices as shown in Figure 1. Be sure
muffler. Add several teaspoons of solvent directly into to lift the hinged end of the table top.
the motor. (Southworth recommends the following 4. The hydraulic oil level may be low. When the lift is
solvents for this purpose: Gast Flushing Solvent AH255, raised as far as possible, the oil should be about 3/4
Dem Kote 2X726, and Loctite Safety Solvent.) Rotate inch above the bottom of the tank. (The exact level varies
the shafts by hand in both directions for a few minutes. with different models, especially on models with tanks
Reconnect the airline and gradually increase the air that tip as the lift elevates.) Use a dipstick to check the
pressure and flow until there is no trace of the solvent in oil level.
the exhaust air. Re-lubricate the motor with a squirt of
5. If your lift has an optional up limitswitch, the lift may
oil in the chamber.
have reached this upper limit. If the switch is out of
adjustment, the lift may not be able to raise completely.
Readjust the switch if necessary.
TROUBLESHOOTING WARNING!
Do not disconnect the up limitswitch.
CHECKLIST Instead, loosen the adjusting screw, and
change the position of the arm. If you do
All servicing should be done by qualified personnel. disconnect the switch, when the lift platform
Qualified personnel should be able to read and moves up, it may not stop at the correct point.
understand wiring and hydraulic diagrams. They should If the platform rises above the normal
be able to troubleshoot live electrical circuits safely and stopping point, the frame of the unit may be
in accordance with accepted practice. For safety’s sake, damaged. People working nearby may be
if in doubt, please contact your dealer or Southworth hurt.
Products Corp.
6. On a lift with a three-phase motor, the motor may
Before servicing the lift, read and understand this entire be running backwards. If the motor has been wired
section and the section entitled “Operating correctly, the lift should start moving 2 or 3 seconds
Instructions.” after you press the “up” button. If it doesn’t, try reversing
WARNING! any two electrical leads.
Before working underneath the lift, always 7. On a lift with a three-phase motor, the motor may
raise the lift and insert the maintenance be “single phasing.” When this happens, the motor
devices, as shown in Figure 1. Failure to do hums, but does not turn. If this is the case, one lead of
so may result in damage to the lift and severe the three-phase line has been interrupted. Check the
personal injury! motor wiring and line fuses.
8. The motor voltage may be too low. Check the
voltage at the starter when the motor is under load. The
If the lift will not raise: supply voltage should be within ±10% of the rating.
CAUTION ! 9. On a lift with an external power unit, the tank vent
Do not continue to hold the “up” button for more may be plugged. You must remove the solid plug from
than 2 or 3 seconds. You may damage the pump. the tank and insert the vented plug. The vent line must
be clear.
1. Check the actual weight of the load. The rated
capacity of the lift is shown on the table skirt. 10. The suction filter may be clogged. Clean the suction
filter as described in the section on “Periodic
WARNING! Maintenance.”
Do not change the relief valve setting. This
valve has been included for the protection 11. A vacuum leak may be allowing air into the suction
of workers who install, use, or service the line, causing cavitation (loss of suction) in the pump.
lift. If it is ever necessary to repair or reset Check all fittings in the suction line, and repair as
necessary.
14
S1076
SOUTHWORTH
CAUTION! may result in damage to the lift and severe
If cavitation is allowed to continue, the pump personal injury!
may be damaged, and may have to be 2. The down valve may be de-energized. When the
replaced. lift is lowering, the down valve should be energized and
12. For the lift to raise, the down-valve must be de- fully open. Check the solenoid in the valve with a volt
energized and fully closed. Check for a problem with meter. The valve must also be clean and free to operate.
the wiring to the down-valve. Check the solenoid in the Remove the solenoid, then the down valve. Look for
valve with a volt meter. The valve must be clean and contamination which could block the valve action. Clean
free to operate. To check this, remove the solenoid and the valve plunger with kerosene, then blow it clean with
then the valve. Look for contamination which could block compressed air. The strainer screen over the lower part
the valve action. Clean the valve plunger with kerosene, of the plunger must be clean. See Figure 15. Before
then blow it clean with compressed air. The expansion reassembly, depress the plunger manually several times
nut which holds the solenoid should be finger tight only! to be sure it moves freely. The expansion nut that holds
13. If the pump has been changed, the coupling may not the solenoid should be finger tight only!
have been installed. See the pump assembly in Figure 3. The flow control may need to be adjusted. The flow
15. control must be partially open to allow the oil to return
from the cylinder(s). It is important that you follow these
steps when adjusting an internal flow control:
If the lift elevates, but fails to hold a load:
• Raise the lift and insert the maintenance
1. Raise the lift and insert the maintenance devices, as shown in Figure 1.
devices, as shown in Figure 1.
• If you want the lift to lower more slowly, turn the
WARNING! control clockwise up to 1⁄4 turn at a time. If you
Failure to insert the maintenance devices want the lift to lower more quickly, turn the control
may result in damage to the lift and severe counterclockwise up to 1⁄4 turn. Do not move the
personal injury! control more than 1⁄4 turn at a time.
2. The check valve may be leaking. Dirt on the valve • Remove the maintenance devices, and check the
seat will prevent the valve from closing fully. The check speed as the table lowers.
valve is mounted in the base of the pump housing, as • Every time you want to change the adjustment
shown in Figure 15. Remove the check valve cap and again, raise the table again and insert the
inspect the valve for dirt or metal chips which may be maintenance devices as shown in Figure 1.
preventing it from closing. You may be able to restore
the seal by lightly rapping the ball into the seat using a DANGER!
1/4" diameter rod and a small hammer. Do not try to adjust the flow control while
pressing the “down” button. If you try this,
3. The down-valve may be energized. While the lift is the lift table may drop suddenly, and you
holding a load, the down-valve should be de-energized may be hurt.
and fully closed. Check the solenoid in the valve with a
volt meter. The valve must also be clean and free to If the steps listed above do not solve the problem, please
operate. To check this, remove the solenoid and then call the Southworth’s Customer Service Department.
the valve. Look for contamination which could block the
valve action. Clean the valve plunger with kerosene, Repacking Cylinders
then blow clean with compressed air. The expansion This section will tell you how to repack an “H-style”
nut which holds the solenoid should be finger tight only! cylinder, shown in Figure 9. This type of cylinder is
4. The cylinder(s) may be leaking. Look for oil on the exclusive to Southworth, and repacking kits are only
cylinder rod(s) and in the vent line. (This may also occur available through Southworth. To order a repacking kit,
if the oil tank has been overfilled.) If you find much oil in please call the Parts Department at (207) 878- 0700 or
either place, and the tank is not overfilled, the cylinder(s) (800) 743-1000. When ordering, specify the model
need to be repacked. See the instructions in this manual number and serial number of the lift, and the cylinder
on “Repacking Southworth Lift Cylinders.” number(s), as listed on the base of the cylinder(s).
Before beginning this procedure, read and understand
If the lift fails to lower: this entire section.
1. Insert the maintenance devices, see Figure 1. WARNING!
WARNING! Before working underneath the lift, always
Failure to insert the maintenance devices raise the lift and insert the maintenance
15
S1076
Lip of wiper ring

points upward
Teflon bushing
Wiper
O-ring
Opening on
poly U-cup
opens downward Fiber wear ring
Poly U-cup
Snap ring
Cylinder number stamped here
Figure 9 – H-Style Cylinder
devices, as shown in Figure 1. Failure to do into the cylinder to drive the hydraulic fluid out through
so may result in damage to the lift and the hose into the container. You may use air pressure
severe personal injury! at the vent hole to do this. Disconnect the hydraulic
1. Before you disassemble the old cylinder, be sure line(s) from the cylinder(s). Lift the cylinder(s) out of the
you have these items on hand: lift. Be careful the cylinder is heavy!
• A repacking kit. Parts may be damaged when you 7. Figure 9 shows the parts inside a lift cylinder. At the
disassemble the cylinder. You should have upper end of the cylinder, remove the snap ring. Pull
replacement parts on hand so you can reassemble the rod and piston all the way out of the cylinder. This
the lift and use it immediately. assembly is heavy -- be careful not to drop it as it comes
free.
• A supply of new hydraulic oil. Contaminated oil may
damage the new packing. 8. Remove the press-fit bushing from the hole at the
upper end of the cylinder rod.
• A container to catch the used oil.
9. Look for deformation around the hole at the clevis
• A clean place to work. Choose a place which will
end of the cylinder rod. If necessary, clean up the rod
not be damaged if you spill some oil.
diameter with a file to allow the rod bearing to slide off
2. Raise the lift and insert the maintenance without damage.
devices, see Figure 1.
10. Remove the plastic rod bearing from the cylinder
3. Turn off electrical power at the main disconnect or circuit rod. Observe how the wiper ring sits in the rod bearing.
breaker, or unplug the machine. This will prevent the lift from Remove the wiper ring and the O-ring from the rod
moving accidentally while you are working on it. bearing. Do not try to remove the aluminum piston from
4. Disconnect the cylinder supply line at the pump, the cylinder rod, as this will damage the assembly.
and place the end into a container to collect the used Remove the poly U-cup and the fiber wear ring from the
oil. piston.
5. Disconnect the vent line at the cylinder(s). 11. Check the vent plug, and clean it if it appears dirty.
6. At the top end of the cylinder rod, remove the CAUTION!
“keeper,” and drive out the clevis pin. Push the rod back While reassembling, it is very important to keep
all of the parts free of dirt, dust, metal chips,
16
S1076
SOUTHWORTH
water, and other contamination. Most of the 16. Slide the rod bearing into the cylinder. Install a new
problems with hydraulic systems are caused snap ring to hold the rod bearing in place. Replace the
by contamination in the oil. bushing or install a new one in the top of the cylinder
12. Clean the piston surfaces, and install a new fiber rod.
wear ring. Install a new poly U-cup seal, with the open 17. Install the cylinder in the lift. Replace the clevis pin
part of the seal facing down. and “keeper.” Reconnect all of the hydraulic lines and
13. Clean all of the surfaces on the rod bearing. Install the vent line.
a new O-ring and wiper. Replace the rod bearing 18. At the start of the packing process, you drained the
assembly on the rod. cylinder(s) into a container. Replace this used oil with
CAUTION! an equal amount of fresh oil. Be sure to reinstall the
Be careful not to install the wiper backwards. vent plug when you’re done.
The lip on the wiper should point upwards, as 19. Turn on the electrical power and press the “up”
shown in the detail in Figure 9. button. The pump will self-prime. After a few seconds,
14. Clean the bore of the cylinder tube thoroughly. the cylinder should lift the table off the blocks. Remove
Inspect the bore of the tube for scratches that run up the maintenance devices. Cycle the lift up and down a
and down, along the length of the cylinder. If you do few times to remove air pockets. Check for leaks.
see any scratches, hone the inner surface of the 20. Raise the lift and check the oil level with a dipstick.
cylinder. Be sure to clean the tube thoroughly after you The oil should be about 3/4 inch above the bottom of
do this. the tank.
15. Lubricate the seal and piston with clean grease or 21. If you have spilled any oil, clean it up.
oil. Carefully insert the piston and rod back into the
DANGER!
cylinder. Be very careful not to pinch or tear the poly U-
Spilled hydraulic oil is slippery, and may
cup as the piston passes the shoulder inside the
present a fire hazard. Always clean up any
cylinder. It is helpful to tip the rod assembly and twist it
spilled oil.
as you slide it into the cylinder.
Once the piston is inside the cylinder, it should slide
easily. Replacing Leg Rollers
CAUTION! Please contact Customer Service at Southworth
If the poly U-cup is pinched or torn during Products Corp. for instructions for your model and
reassembly, the piston may not maintain application at (207) 878-0700 or (800) 743-1000.
pressure as designed.
Upper hinge pin

Cylinder and bushing
Down speed
control
Center scissor pin
and bushing
Roller
Nameplate
Figure 10 – Parts Identification, Side View
17
S1076
Ordering Replacement Parts

Southworth has carefully chosen the components in your lift to be the best available for the
purpose. Replacement parts should be identical to the original equipment. Southworth will not
be responsible for equipment failures resulting from the use of incorrect replacement
parts or from unauthorized modifications of the machine.
Southworth will gladly supply you with replacement parts for your Southworth lift. Key parts are
identified in Figures 8 through 15. With your order, please include the model number and the
serial number of the lift. You can find these numbers on the name plate, which is located on the
crossbar at the base of the cylinder(s). When you are ordering parts for a cylinder, also include
the cylinder number. This is stamped on the base of the cylinder housing.
To order replacement parts, please call the Parts Department.
Parts are shipped subject to the following terms:
• FOB factory
• Returns only with the approval of our parts department.
• Payment net 30 days (except parts covered by warranty).
• Freight collect (except parts covered by warranty).
Parts replaced under warranty are on a “charge-credit” basis. We will invoice you when we ship the
replacement part, then credit you when you return the worn or damaged part.
Parts Department
Southworth Products Corp.
Telephone 207) 878-0700 or (800) 743-1000
FAX : (207) 797-4734
repairparts@SouthworthProducts.com
Motor only
(if wired for three-phase AC)
Motor and capacitor

(if wired for single-phase AC)
Vented cap
Vent hose assembly
Down valve
Down limitswitch
Pump
Up limitswitch
Hydraulic fitting
Pigtail location
Figure 11 – Parts Identification, View of Motor and Pump (The layout of components varies from model to model)
18
S1076
SOUTHWORTH
Cylinder rod
Hose assembly
Cylinder
Flow control
Roller
Hydraulic tubing Tube fitting
Figure 12 – Parts Identification, LS-2 Models
Clevis pin
Tapped clevis
Keeper
Cylinder rod
Hose assembly
Cylinder
Flow control
Tube fitting
Roller
Hydraulic tubing
Formed hydraulic tube
Tube fitting
19
S1076
Clevis pin keeper
Clevis
Tapped clevis
Clevis pin
Cylinder rod
Cylinder
Hose assembly Tube fitting
Hydraulic tubing,
Hydraulic tubing, right side
left side
Flow control
Tube fitting
Tube fitting Tube fitting
Hydraulic tubing
Down valve plunger

Down valve strainer
Relief valve cap

Retainer ring Nut
Relief valve
adjusting screw
Down valve solenoid

Outer spring
Check valve cap
Inner spring
O-ring
Relief valve poppet
Check valve spring
Coupling – pump
to motor Check valve ball
Gasket
Figure 15 – Hydraulic Pump and Down Valve
20
S1076
SOUTHWORTH
Electrical Connections for Single-Phase AC
Enclosure with contactor

(see detail below)
Up limitswitch (optional)
wired normally closed Ground Red
Black Pushbutton or
UP
footswitch
DOWN
Circuit breaker or
20A time-delay fuse
White (installed by user)
120VAC
in
Ground
Power cord Receptacle

NEMA 5-15R
(installed by user)
Tank Motor Down

and pump valve
Fig. 16 – Electrical Connections, Lifts Wired for Single-Phase AC
Connections shown above are for lifts operating on 120 VAC. For lifts operating on 230 VAC, a NEMA L6-15R
receptacle is required. The pump, motor, and down valve may be mounted on the lift unit itself (internal power
unit) or in a separate location (external power unit).
Figure 17 – Wiring Diagram, Lifts Wired for Single-Phase AC – without limitswitch
21
S1076
Electrical Connections for Single-Phase AC, continued
*NOTES:
1. Ground wires from motor, power cord,
up limit switch and pushbutton or
footswitch are not shown. Attach all
ground wires to the enclosure
ground lug.
2. Entry locations for electrical fittings may
differ from those shown.
Figure 18 – Wiring Diagram, Lifts Wired for Single-Phase AC – with limitswitch
22
S1076
SOUTHWORTH
Electrical Connections for Three-Phase AC
Figure 19 – Electrical Connections, Lifts Wired for Three-Phase AC
Connect the power and control wiring to the proper terminals located in the control panel.
The pump, motor and valve may be mounted on the lift unit itself (internal power unit) or
in a separate location (external power unit). The control panel may be wall mounted.
CAUTION!
If on power-up the motor rotates in the wrong direction, don’t continue to operate
the lift. You may damage the pump. To correct the problem, interchange any two of
the motor leads (T1, T2 or T3).
23
S1076
Electrical Connections for Three-Phase AC, continued
Figure 20 – Schematic, Lifts Wired for Three-Phase AC
Main power
Tank Filler unit Connectors near lift table Hydraulic Flow control
(external power units only) cylinder (down speed control)
Motor
Pump
Down
valve
Hydraulic supply line
Vent / return line Hydraulic

cylinder
Filter and
suction line Connectors near main power unit
(external power units only)
Figure 21 – Hydraulic Connections
24
S1076
SOUTHWORTH
Cylinder vent line
Typical for
1, 2, or 3
cylinders
Cylinder
Down speed flow control

Load check pressure compensated
System relief
Down solenoid valve
Pump
Tank
Figure 22 – Hydraulic Diagram - Unit Powered by Electric Motor
Cylinder vent line Typical for

1, 2 or 3
cylinders
Down speed
flow control
Compressed air source Air-operated

80 psi, 80 cfm recommended Hydraulic down valve
pump (n.c.)
Regulator, filter, and Air

lubricator motor
(supplied by customer)
Filter
Handvalve or
footvalve
Figure 23 – Hydraulic Diagram - Unit Powered by Air Motor
25
S1076
Table 1 – Electrical Interface, Supplied by Customer

Motor Required Fuse Required Fuse Wire
Voltage 1.0 HP Motor 3.2 HP Motor Gauge
*115/1/60 20 AMP — 12 AWG

208/1/60 20 AMP — 12 AWG
240/1/60 20 AMP — 12 AWG
208/3/60 10 AMP 12 AMP 14 AWG
240/3/60 10 AMP 10 AMP 14 AWG
480/3/60 5 AMP 5 AMP 14 AWG
575/3/60 5 AMP 5 AMP 14 AWG
* This lift requires a dedicated 20 amp circuit servicing no other electrical devices.
Do not operate this lift with an extension cord.
Table 1 – Hydraulic Oil Specifications
If the lift will be used at normal ambient temperatures, Southworth supplies the unit with Citgo AW 32
oil. This may be replaced by any other good quality oil with 150 SSU at 100° F and rust and oxidation
inhibitors and anti-wear properties.
If the lift will be used at ambient temperatures below 0°F, use aircraft hydraulic oil. Use Type 15
aircraft hydraulic oil.
The following are equivalent to CITGO AW32:
TYPE MANUFACTURER
DTE 24 .............................. EXXON/MOBIL
NUTO H32 ........................ EXXON/MOBIL
AMOCO AW32 .................. CHEVRON (AMOCO CO.)
CAUTION!
It is very important to keep the hydraulic oil free of dirt, dust, metal chips, water, and
other contamination. Most of the problems with hydraulic systems are caused by
contamination in the oil.
26
S1076
SOUTHWORTH
27
S1076
2 YEAR WARRANTY
Southworth Products Corp warrants this product to be free from defects in material or
workmanship for a period of two (2) years of single shift usage from date of shipment,
providing claim is made in writing within that time period. This warranty shall not
cover modified designs for special applications, failure or defective operation caused by
misuse, misapplication, negligence or accident, exceeding recommended capacities,
failure to perform required maintenance or altering or repairing, unless alteration is
authorized by Southworth Products Corp. Except as set forth herein, there are no other
warranties, express or implied, including the warranties of merchantability and fitness
for a particular purpose, all of which are hereby excluded.
Southworth Products Corp makes no warranty or representation with respect to the

compliance of any product with state or local safety or product standard codes, and any
failure to comply with such codes shall not be considered a defect of material or work-
manship under this warranty. Southworth Products Corp shall not be liable for any di-
rect or consequential damages arising out of such noncompliance.
Southworth Products Corp’s obligation under this warranty is limited to the replace-
ment or repair of defective components at its factory or another location at Southworth
Products Corp’s discretion. This is buyer’s sole remedy. Except as stated herein,
Southworth Products Corp will not be liable for any loss, injury or damage to persons or
property, nor for direct, indirect, or consequential damage of any kind, resulting from
failure or defective operation of said product.
This warranty may be altered only in writing by Southworth Products Corp, Portland,
Maine.
SOUTHWORTH PRODUCTS CORP

P.O. Box 1380, Portland, ME 04104-1380
Telephone: (800) 743-1000 • (207) 878-0700
Fax: (207) 797-4734
JANUARY 2003
28

6975 Manual (3414)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

6975 Manual (3414)

Uploaded by

Copyright:

Available Formats

MANUAL INDEX

A-64N CABLE STRINGER TRUCK

1. INTRODUCTION /GENERAL INFORMATION

F1008 PARTS ORDER INSTRUCTIONS

10368 SIGHT GAUGE

3. ELECTRICAL SYSTEM AND INSTRUMENTS

30304 WIRING DIAGRAM

4. ENGINE AND ACCESSORIES

F1011 DEUTZ WARRANTY POLICY

10829 AXLE ORIENTATION

31516 HYDRAULIC SCHEMATIC

31516 HYDRAULIC SCHEMATIC

13905 ELECTRIC SHIFTER

10. MOUNTED EQUIPMENT

S1025 FIRE EXTINGUISHER

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

MODEL A-64N TYPE CABLE STRINGER

SPEC. 3414 SERIAL NO. 6975

Model: CABLE STRINGER Type: A-64N

Shop No.: 3414 Serial No.: 6975 Truck No.: N/A

COMPONENT MANUFACTURER MODEL SPECIFICATION SERIAL NUMBER

OPERATING AND MAINTENANCE

Read thoroughly before

INTRODUCTION RELATED MANUALS

SAFETY ALERT SYMBOL

This symbol will appear at various points throughout the manual in

This manual also uses the following messages:

• Never stand when operating a vehicle in motion.

• Never allow riders in vehicles not designated to carry passengers.

• Never dismount from a vehicle unless brakes are set.

• Avoid smoking or open flame around fuel.

• Always be aware of location of nearest fire extinguisher.

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

NAME, WARNING AND CAUTION PLATES

SAFETY NOTICE • Do not allow riders. Passengers must be seated in proper

• Do perform all recommended checks. SERVICE POSITION

• Do operate vehicle with caution. 4. Stop engine.

• Do use parking brake.

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

• Do enter and exit operator’s compartment carefully. PARKING PROCEDURE

CAUTION STATEMENT 8. EXHAUST SYSTEM

2. FASTENERS 11. FIRE EXTINGUISHER

4. BATTERY AND CABLES

This vehicle is equipped with two red Brake Warning lights

INSTRUMENT PANEL DESCRIPTIONS

10. Boom Light Switch (Optional): Toggle switch to

11. Horn Button: Push to sound horn.

12. Circuit Breakers: Consists of 10, 20 and 30 AMP

13. PLC Reset Switch (Optional): Used to reset engine

14. Glowplug Override Button: Used when engine

15. Glowplug Preheat Indicator: Informs operator

16. Warning Buzzer: Used to alert operator when

17. Start Switch: Turn switch to position 1 for preheat,

INSTRUMENT WARNING PANEL