Getman Madero (8) 7026 Manual (3464)

MANUAL INDEX
2-500 ANFO CHARGER

FRANCISCO I MADERO
S/N 7026
08-01-08
1. INTRODUCTION /GENERAL INFORMATION
F1008 PARTS ORDER INSTRUCTIONS

F1000 GETMAN WARRANTY
F1009 COMPONENT LIST
M1039 A-64 OPERATING MANUAL
M1006 A-64 ANFO OPERATION MANUAL
M1004 BOOM INSPECTION
S1000 BOLTS TORQUE & SIZE SAE
F1003 LUBRICANTS CROSS REFERENCE
F1001 STORAGE PROCEDURES
F1002 TROUBLESHOOTING CHECK LIST
F1004 PREVENTIVE MAINTENANCE SCHEDULE FORMS
F1005 SERVICE REPORT FORM
F1006 SHIFT CHANGE CHECK LIST
2. CHASSIS
10368 SIGHT GAUGE

10376 FILL CAP (FUEL OIL)
10398 FILL CAP (HYDRAULIC OIL)
10448 HOLD DOWN FASTENERS
17142 SEAT ASSEMBLY
13942 STEERING (PINS, BEARINGS, BUSHINGS)
12043 ARTICULATION INSTALLATION
17165 LINCOLN LUBE SYSTEM INSTALLATION
3. ELECTRICAL SYSTEM AND INSTRUMENTS
30304 WIRING DIAGRAM

17144 INSTRUMENT PANEL
13918 ALTERNATOR
MANUAL INDEX
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
4. ENGINE AND ACCESSORIES
F1011 DEUTZ WARRANTY STATEMENT

F1012 DEUTZ EMISSION WARRANTIES
S1056 ENGINE OPERATION & MAINTENANCE MANUAL
S1057 ENGINE PARTS MANUAL
13715 ENGINE FILTERS
13755 RADIATOR INSTALLATION
13753 AIR INTAKE & EXHAUST SYSTEM
11968 AIR CLEANER
S1020 EXHAUST INFORMATION
5. DRIVE TRAIN
17055 TRANSMISSION
16922 TRANSMISSION MOUNTS
S1036 TRANSMISSION MAINTENANCE & SERVICE
MANUAL
13675 DRIVELINE INSTALLATION
6. AXLE
10829 AXLE ORIENTATION

13335 AXLE ASSEMBLY
13332 CRADLE INSTALLATION
S1037 AXLE SERVICE & REPAIR MANUAL
13158 BRAKE ACTUATOR
S1023 ACTUATOR INSTALLATION
10481 TIRE & RIM
S1007 TIRE SERVICE
7. BRAKE SYSTEM
31481 HYDRAULIC SCHEMATIC

13378 BRAKE VALVE
S1008 BRAKE VALVE SERVICE
16483 DUAL CHARGE VALVE
S1009 DUAL CHARGE VALVE SERVICE
12976 ACCUMULATOR
MANUAL INDEX
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
8. HYDRAULIC SYSTEM

S1077 HYDRAULIC SYMBOLS
17132 SERVICEJUNIOR DIGITAL PRESSURE GAUGE
13259 FILTER (HYDRAULIC)
12860 STEERING ORBITROL
S1024 STEERING ORBITROL SERVICE
16384 MOTOR (ROTATION GEAR BOX)
S1010 PUMP SERVICE
12504 REMOTE CONTROL BOOM VALVE (IN BASKET)
12505 BOOM CONTROL VALVE (ON BOOM)
13282 JACK CONTROL VALVE
13970 BOOM LEVELING CYLINDER
13629 BOOM LIFT CYLINDER
13648 BOOM EXTENSION CYLINDER
13628 BASKET LEVELING CYLINDER
13627 STABILIZER CYLINDER
13943 STEER CYLINDER
9. CONTROLS
13905 ELECTRIC SHIFTER

10827 STEERING WHEEL & COLUMN
13025 THROTTLE (HYDRAULIC)
13331 HAND THROTTLE LINKAGE (HYDRAULIC)
16976 RESERVOIR (HYDRAULIC)
MANUAL INDEX
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
10. MOUNTED EQUIPMENT
S1011 FIRE EXTINGUISHER #10

S1012 FIRE PROTECTION INFORMATION MANUAL
S1013 FIRE SUPPRESSION MAINTENANCE MANUAL
S1014 AUTO FIRE SUPPRESSION MAINTENANCE MANUAL
23276 FIRE SUPPRESSION INSTALLATION
16721 FIRE SUPPRESSION SYSTEM
13283 AUTO DETECTION SYSTEM
13597 BASKET DOOR INSTALLATION
16714 BOOM DOOR INSTALLATION
16572 TURRET INSTALLATION
M1005 ROTATION GEAR REMOVAL & INSTALLATION
16256 ROTATION GEAR BOX
15174 ANFO PIPING SCHEMATIC (WITH AIR BOOST
CLEAN OUT)
15175 ANFO PIPING SCHEMATIC (POT) SINGLE DELIVERY
13712 ANFO ACTUATOR
S1027 ACTUATOR SERVICE MANUAL
14053 BASKET ROTATOR
S1033 ROTATOR ACTUATOR MAINTENANCE MANUAL
13651 OUTRIGGER INSTALLATION
13390 COMPRESSOR DRIVE AND MOUNT
S1062 AIR COMPRESSOR INSTRUCTION BOOK
S1094 LINCOLN AUTO GREASE LUBE MANUAL
MANUAL INDEX
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
1. INTRODUCTION /GENERAL INFORMATION
F1008 PARTS ORDER INSTRUCTIONS

F1000 GETMAN WARRANTY
F1009 COMPONENT LIST
M1039 A-64 OPERATING MANUAL
M1006 A-64 ANFO OPERATION MANUAL
M1004 BOOM INSPECTION
S1000 BOLTS TORQUE & SIZE SAE
F1003 LUBRICANTS CROSS REFERENCE
F1001 STORAGE PROCEDURES
F1002 TROUBLESHOOTING CHECK LIST
F1004 PREVENTIVE MAINTENANCE SCHEDULE FORMS
F1005 SERVICE REPORT FORM
F1006 SHIFT CHANGE CHECK LIST
INSTRUCTIONS FOR ORDERING F1008
REPAIR PARTS Page 1 of 1
TO AVOID DELAYS AND ASSURE THE MOST EFFICIENT HANDLING, PLEASE

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

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

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

CALL 1-800-533-1110 OR 269-427-5611 ext. 305 or 330.
MODEL 2-500 TYPE ANFO
SPEC. 3464 SERIAL NO. 7026
Updated:
07/16/08
F1000
Limited Warranty
Getman Corporation warrants each new vehicle manufactured by it to be free from defects in materials and
workmanship for one (1) year or two thousand (2,000) hours of operation (whichever occurs first) from the
date of delivery to the first user, excepting the vehicle mainframe which is warranted to be free from defects
in materials and workmanship for five (5) years or ten thousand (10,000) hours of operation (whichever
occurs first).
This warranty is limited to the replacement or repair, at 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: ANFO CHARGER Type: 2-500
Shop No.: 3464 Serial No.: 7026 Truck No.: N/A
Customer: FRANCISCO I MADERO
COMPONENT MANUFACTURER MODEL SPECIFICATION SERIAL NUMBER

ENGINE DEUTZ 2012C 465231 10626981
TRANSMISSION DANA 20000 465425 KBEA 316067
FRONT AXLE NEW HOLLAND D-45I 464872 86578601 8D02 09
REAR AXLE NEW HOLLAND D-45I 464872 86578601 8D01 17
MAIN HYD PUMP COMMERCIAL P-31 494169 N0407-3809
OPTIONS:
COMPRESSOR ATLAS COPCO LE2010UV 605543 WCF435048

MAN BASKET GETMAN NA 20086-01 NA
ANFO BOT BAYCAR 1200 LBS 465342 D-136-10-2653-01
ROTATION GEAR GEAR PRODUCTS 010-00008-1 594869
BOX 515715-001
BASKET HELAC NA 22891-01 NA
ROTATOR
ASSEMBLY
†COMMON MAINTENANCE ITEMS

ENGINE OIL FILTER P/N: 44238
FUEL FILTER P/N: 44237
FUEL PREFILTER CARTRIDGE P/N: 44236
TRANSMISSION FILTER P/N: 24448
HYDRAULIC FILTER ELEMENT P/N: 534691
FAN/ALT BELT P/N: 44252
*WHEN ORDERING PARTS, ALWAYS GIVE MODEL AND SERIAL NUMBER OF UNIT. Updated:
†SEE MAINTENANCE SECTION IN MANUAL FOR SERVICE INTERVAL ON THESE ITEMS. 07/31/08
OPERATING AND MAINTENANCE M1039
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
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS. Updated:
05/29/08
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
Service Brake Procedure……………………...17
After Engine Starts……………………………18
Operating Vehicle…………………………19-20
Maintenance Schedule……..……………...21-29
Specifications…………...…………………….30
05/29/08
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.
05/29/08
• 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.
05/29/08
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.
05/29/08
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.
05/29/08
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.
05/29/08
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.
05/29/08
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.
05/29/08
7. Transmission Pressure Gauge: Transmission 17. Start Switch: Turn switch to position 1 for preheat,
pressure gauge indicates pressure being regulated and and momentary turn to position 2 to start engine.
provided to the transmission clutches. If the gauge
fails to register pressure after engine start up, shut 18. Light Switch: Toggle switchs for front and rear
down engine immediately and contact maintenance. lights.
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.
05/29/08
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.
05/29/08
• 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
05/29/08
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.
05/29/08
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.
05/29/08
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.
05/29/08
STARTING PROCEDURE
CAUTION
Transmission must be in neutral and park brake must be applied
IMPORTANT to start engine.
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.

NOTE: This switch could be located on the side of the vehicle, 4. Move Directional Lever to neutral position.
in the cab, or both.
2. Adjust and fasten Seat Belt to a comfortable operating

position.
a
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.
3. Push down Park Brake Button. 9. If engine, transmission, and hydraulic pressure gauges do
not show pressure shortly after stat-up, stop engine and
determine cause.
NOTICE
DO NOT CRANK ENGINE FOR MORE THAN 30 SECONDS. ALLOW STARTER TO COOL FOR TWO MINUTES BEFORE
CRANKING AGAIN. TURBOCHARGER (IF EQUIPPED) DAMAGE CAN RESULT, IF THE ENGINE RPM IS NOT KEPT LOW
UNTIL THE ENGINE OIL PRESSURE GAUGE INDICATES PRESSURE IS SUFFICIENT.
05/29/08
PARK BRAKE TEST PROCEDURE (PERFORM DAILY)
NOTICE
Depressing the Park Brake Button located in the switch panel overrides the transmission declutch feature.
To test the Park Brake Only:
1. Set Park Brake. (a)
2. Depress & hold Park Brake Test Button. (b)
3. Place shifter in 3rd Gear. Forward.
4. Fully depress Throttle.
5. Vehicle Should Not move.
SERVICE BRAKE TEST (PERFORM DAILY)

Test the service brake by fully depressing the service brake pedal. Placing the transmission in forward, 2nd gear, release the
parking brake and increase engine RPM to maximum for 3-5 seconds. Vehicle should not move. If vehicle moves, park and
apply wheel chocks and contact maintenance.
05/29/08
AFTER ENGINE STARTS 3

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.
05/29/08
OPERATING VEHICLE
3
1
4
• Once all gauges have been checked and are within normal operating ranges, vehicle is ready to
operate.
• Turn Light Switch’s #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.
05/29/08
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.
05/29/08
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.
05/29/08
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.
05/29/08
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.
05/29/08
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.
05/29/08
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.
05/29/08

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.
05/29/08
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.
05/29/08
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.
05/29/08
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.
05/29/08
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
05/29/08
MANUAL DE OPERACIÓN Y
M1039
MANTENIMIENTO
PARA EL CAMIÒN GETMAN A-64 Pag. 1 de 30
CORPORACION GETMAN
MANTENIMIENTO
PARA
EL CAMION GETMAN A-64
Lea cuidadosamente este manual

antes de operar el vehículo
*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS Actualizado:
INSTRUCCIONES EN LAS PLACAS. SPANISH VERSION 07/16/08
M1039
MANTENIMIENTO
INTRODUCCIÓN RELACION DE MANUALES
Este manual es una guía para una apropiada y segura Los manuales de operación está incluidos con los manuales de
operación, lubricación y ajustes menores del Camión partes y servicios suministrados con este vehículo. Usted se
Getman A-64. Cada operador asignado a este vehículo debe familiarizar con estos manuales.
deberá estudiar este manual cuidadosamente antes de
arrancar u operar el camión de tal forma que se Getman ha incrementado la frecuencia de muchos
familiarice con todos los controles y procedimientos. procedimientos de mantenimiento recomendados debido a la
aplicación de demanda. Estos cambios son señalados en cada
Los Camiones Getman A-64 son comprados con la sección de mantenimiento y en el manual de refacciones y
expectativa de que proveerá un servicio prolongado y servicio.
confiable. En su construcción, hemos tomado todas las
precauciones para asegurar que usted reciba un vehículo
eficiente y duradero. Sin embargo, para llevar a cabo la Se incluye una lista completa de componentes del motor y
medida completa de valuación y utilidad que Getman ha transmisión, sistemas aplicables eléctricas/aire/hidráulicas,
designado a esta unidad, una pequeña cantidad de tiempo este manual también contiene información del servicio y
y costo debe ser invertido en el cumplimiento de reparación útil para el personal del departamento de
inspecciones y servicio tal y como se recomienda en este mantenimiento.
manual. Esta pequeña inversión se retribuirá en bajos
costos de operación, mínimos costos de servicio y, lo más Si usted tiene algunas preguntas acerca del servicio y
importante, en seguridad del personal. operación de esta unidad, contacte al representante local de
Getman o directamente a la Corporación Getman,
TABLA DE CONTENIDOS......PAGINA 2 inmediatamente.
Introducción......................................................2
Relación de manuales.......................................2
Precauciones generales de seguridad............3-4
Nombres, placas de advertencia y precaución..5
Aviso de seguridad…….………………...........6
Cierre de combustible…………………...........6
Posición de servicio……………......................6
Procedimiento de estacionamiento………........6
Declaración de advertencia………...................7
Descripción general………………...................8
Descripción de los instrumentos del
Tablero……………………………………..9-10
Instrumentos de advertencia en el tablero...11-12
Otros controles……………………….............12
Descripción de los manómetros……..……13-14
Inspecciones antes del arranque………………15
Procedimiento de arranque…...………………16
Procedimiento de prueba del freno de
Estacionamiento………………………………17
Procedimiento Mantengo de la pruebe.............18
Después de que el motor se arranca……..........18
Operación el camión..………………………...19
Conduciendo el camion……………………….20
Programa de mantenimiento……...……….21-29
Especificaciones…………………..………......30
M1039
MANTENIMIENTO
SIMBOLO DE ALERTA DE SEGURIDAD
Este símbolo aparecerá en varios puntos a través de este manual como

declaración de advertencia. Su aparición significa:
!¡ ATENCION! ¡MANTENGASE ALERTA! ¡SU SEGURIDAD ESTA DE POR MEDIO!
Este manual también usa los siguientes mensajes:
NOTICE (ATENCIÓN): Este mensaje es usado para información o instrucciones especiales, relacionadas con procedimientos,
equipo, herramientas y otros datos especiales.
IMPORTANT (IMPORTANTE): Este mensaje se utiliza cuando se deben tomar precauciones especiales para asegurar la
acción correcta y evitar daño o anomalías al equipo.
CAUTION (PRECAUCION): Este mensaje se utiliza como recordatorio de riesgo de seguridad el cual puede resultar con daño
o lesión al personal si no se toman las precauciones apropiadas.
WARNING (ADVERTENCIA): Este mensaje se utiliza cuando existe el riesgo que puede causar lesiones o muerte si no se
toman las precauciones necesarias.
DANGER (PELIGRO): Este mensaje se usa cuando existe un alto riesgo en el cual causará la muerte o lesiones graves si no se
toman las precauciones adecuadas.
REGLAS
Antes de realizar cualquier mantenimiento en el camión, revise las siguientes precauciones de seguridad. Estas son incluidas
para su protección y seguridad.
Siempre observe las siguientes reglas de seguridad durante la operación del camión. Siempre observe las reglas de seguridad
impuestas en el lugar de trabajo. La necesidad de reglas de seguridad adicionales para una operación segura pueden
presentarse debido a particulares aplicaciones de la mina. Las siguientes reglas son solamente usadas como una guía.
• Lea y siga cuidadosamente todas las instrucciones descritas en los manuales del camión.
• Asegúrese que todos los instrumentos, indicadores y controles de operación estén funcionando.
• Nunca utilice los controles de operación como agarraderas para ayudarse a subir o salir del camión.
• Nunca se ponga de pie cuando el camión esté en movimiento.
• Nunca use ropa suelta u holgada cuando esté trabajando cerca de máquinas o equipo en movimiento.
M1039
MANTENIMIENTO
• Nunca permita personal en los camiones que no estén designados para transportar personal “pasajeros”.
• Nunca se baje de un camión a menos que los frenos estén activados.
• Siempre baje los implementos de tierra y utilice los tacones de soporte en las llantas cuando el camión esté estacionado.
• Si se estaciona inevitablemente en una pendiente, coloque el camión dirigido hacia la tabla del cerro, aplique el freno de
estacionamiento, baje los implementos de tierra y utilice los soportes de tacones en las llantas.
• Evite fumar o prender fuego cerca de combustible.
• Siempre recuerde la localización del extintor de fuego más cercano.
• Siempre asegúrese que los excesos de grasa, son limpiados inmediatamente para prevenir un riesgo potencial de incendio.
• Compruebe la operación del circuito de frenos antes de iniciar cada turno.
• Nunca quite algún elemento del escape del motor o algunas guardas de seguridad cuando el camión está en operación.
• Nunca utilice un camión para realizar una actividad o aplicación para la cual no fue diseñado originalmente.
• Cuide de otras personas. Ellas pueden no estar cuidando de usted.
CUBIERTA DE LA CABINA
• Su camión podría ser equipado con una cubierta o cabina MSHA opcional. Estas son diseñadas para proporcionar protección
al operador en caso de una volcadura del camión o de objetos que estén cayendo en el área del operador. Deberá estar una
etiqueta pegada a la estructura, la cual incluye el número de serie, pesos del camión y números del modelo del camión.
• Modificaciones tales como agregar instrumentos a la cabina/cubierta, soldadura, cortes y/o perforaciones pueden debilitar la
estructura, reducir la protección del operador, e invalidar la certificación. Si su camión sufriera un daño en la estructura,
contacte a su distribuidor antes de realizarle reparaciones.
IMPORTANTE: Cualquier modificación que no sea suministrada por la Corporación Getman o por OEM deberá ser
aprobada antes del cambio por Getman.
ADVERTENCIA: El cinturón del asiento es una parte importante del sistema de seguridad de la cubierta o cabina
del MSHA. Omitir el uso del cinturón puede causar lesiones graves o la muerte.
M1039
MANTENIMIENTO
PLACAS CON NOMBRE, ADVERTENCIA Y PRECAUCION
Localice y comprenda todas las placas de nombre, advertencia y precaución, incluyendo una placa con el Modelo/Número de
Serie y dos Placas de Advertencia. Estas están colocadas en la posición mostrada abajo para su seguridad y protección. Si alguna
de estas placas requiere ser reemplazada, por favor notifíquelo a su distribuidor Getman para ordenar la placa adecuada. Por favor
asegúrese de proporcionar el número de serie con su orden.
M1039
MANTENIMIENTO
AVISO DE SEGURIDAD
• No permita personal de más en el vehículo, los pasajeros
La seguridad depende de un buen mantenimiento y operación
deberán estar sentados en los asientos asignados y abrocharse el
adecuada del vehículo. Siguiendo las recomendaciones de
cinturón de seguridad.
servicio y mantenimiento dadas a conocer en este manual tendrá
como resultado un vehículo confiable. Observando los
procedimientos de operación le puede ayudar a evitar • No suba o baje del camión si está en movimiento.
accidentes. El listado que se describe abajo son algunas
precauciones básicas de seguridad las cuales deberán ser leídas, • No bombeé el pedal del freno.
entendidas y practicadas. Sin embargo es imposible cubrir cada
condición. Siempre esté alerta, piense en SEGURIDAD todo el • No conduzca el camión sobre cables eléctricos.
tiempo, utilice el sentido común.
• No opere el camión con un problema en el sistema de escape.
HAGALO
• Lea completamente este manual antes de operar el camión. • No recargue combustible u otro fluido con el motor trabajando.
• Aprenda a reconocer y evitar las áreas de riesgo potencial, CIERRE EL COMBUSTIBLE

tales como las uniones de articulación. Cierre las válvulas de la línea de combustible en las salidas del
tanque.
• Realice todas las inspecciones recomendadas.
POSICIÓN DE SERVICIO
• Reporte todas las anomalías o daños. A través de este manual, se le pedirá que coloque el camión en
“Posición de Servicio”. Realice esto de la siguiente forma:
• Revise el área alrededor del vehículo antes de subir a la 1. Estacione el camión en un área plana y despejada, bloquee las
cabina del operador. llantas.
• Revise cuidadosamente y abróchese el cinturón de 2. Aplique el freno de estacionamiento.

seguridad.
3. Asegure la estructura del camión conectando las barras de
• Accione el cláxon antes de encender el motor. seguridad (sólo en camiones con articulación).
• Opere el vehículo con precaución. 4. Apague el motor.
• Si es posible estacione el camión en un terreno plano y Complete procedure before servicing vehicle.
bloquee las llantas.
• Utilice el freno de estacionamiento.
• Coloque la palanca selectora de engrane de la transmisión

en neutral (N) cuando no esté en uso.
• Entre y salga con precaución a la cabina del operador. PROCEDIMIENTO DE ESTACIONA- MIENTO
1. Estacione el vehículo fuera o lejos del área de tráfico, y gire el
• Utilice la herramienta adecuada para el servicio. camión, hacia la tabla del cerro.
NO LO HAGA 2. Aplique el freno de estacionamiento y, coloque la transmisión en

• No opere el vehículo bajo la influencia del alcohol o posición neutral (N).
drogas.
3. Si el camión ha estado en operación en algún lugar de trabajo antes
de estacionarlo, permita que se enfríe el motor. Estaciónese y deje el
• No permita personal (peatones) cerca del camión cuando el
motor trabajar en vacío por 1-2 minutos.
motor está funcionando.
4. Apague el motor.
• No utilice el arco de soldadura en el camión sin antes no
haber girado el interruptor principal en la posición (off).
5. Bloqueé las llantas.
M1039
MANTENIMIENTO
RELACION DE ADVERTENCIAS 7. SISTEMA DE ADMISIÓN

Utilice este equipo solamente bajo las siguientes condiciones. El aire debe fluir libremente en el sistema de admisión. Máxima
presión (vacío) a través del sistema de admisión con el acelerador al
1. SEGURIDAD GENERAL máximo, sin carga, a 2500 RPM el motor no debe exceder el valor
Este vehículo accionado con diesel es solamente para utilizarlo recomendado por el fabricante. Este motor diesel no debe exceder
en minas que no sean de carbón. Tales minas son aquellas en (25) pulgadas de agua. Un indicador de restricción le proporcionará
que el material que está siendo minado o explotado es una indicación de advertencia en rojo cuando llega a 20” de agua.
incombustible o contiene por lo menos 65% de peso de material Verifique el purificador de aire de admisión en períodos regulares y
incombustible, y en las cuales la atmósfera subterránea o de la limpie o reemplácelo si es necesario.
mina y en cua lesquier trabajo abierto contenga menos del
0.25% por volumen de gas flamable. En opera ciones de 8. SISTEMA DE ESCAPE
cruceros y túneles en los cuales las condiciones subterráneas son Mantenga siempre ajustados los tubos de escape, no permita que los
similares a las anteriores, están en la misma categoría como las tubos de escape se lleguen a bloquear. La máxima presión de retorno
minas que no son de carbón. Cualquier pregunta relacionada con (positivo) en el sistema de escape con la aceleración total, sin carga, a
el diseño de este camión contacte a su distribuidor local Getman 2500 RPM no debe pasar el valor recomendado por el fabricante del
Realice frecuentes inspecciones para observar todos los motor.
componentes del sistema de admisión y escape, todos los
componentes eléctricos, incluyendo alambrado y todo el equipo, 9. PURIFICADOR DE ESCAPE
que estén en condiciones seguras de operación. No debe haber El purificador puede perder eficiencia cuando se utiliza en motores
cuarteaduras en ninguna parte del sistema de escape del motor que producen cantidades excesivas de humo azul y/o negro. Otras
excepto una salida de escape provista originalmente. anomalías en el motor tales como atascamiento o fugas en los
inyectores también causará pérdida de eficiencia. La pérdida de
Todos los interruptores del circuito o fusibles para protección de compresión permitirá la baja de temperatura en el escape y pérdida de
sobrecarga en los circuitos eléctricos deben mantenerse en eficiencia en el purificador.
buenas condiciones.
10. COMBUSTIBLE
2. SUJETADORES Utilice solamente el combustible diesel recomendado por el
Mantenga todos los pernos, tuercas, tornillos y otros sujetadores fabricante del motor para mantener una operación satisfactoria. El
para cajas y partes eléctricas en su lugar. Apriete y asegúrelos punto de encendido no debe ser menor a 140º F, o con contenido de
adecuadamen te. De igual forma, asegure y apriete los pernos, azufre mayor a 0.5% del peso. Cuando llene los tanques en la mina,
tornillos y tuercas de la cabeza del cilindro del motor, sistemas transporte el combustible en contenedores metálicos seguros.
de admisión y escape en su lugar, adecuadamente apretados y Almacene los contenedores de combustible en compartimentos
asegurados. cerrados e incombustibles mientras se espera transferirlo al tanque de
combustible del vehículo diesel. Mantenga los contenedores en un
3. REPARACIONES Y RECONSTRUCCIO NES área ventilada.
Tome especial cuidado cuando realice reparaciones y
reconstrucciones. Utilice refac ciones nuevas exactamente como 11. EXTINGUIDORES DE INCENDIO
las surtidas por el fabricante. Utilice empaques o juntas del Cada vehículo diesel debe cargar por lo menos un extinguidor de
fabricante únicamente. Mantenga todas las superficies de incendio tipo CO2 o tipo seco presurizado. Siempre debe tener este
contacto limpias y en condiciones adecuadas. implemento.
4. BATERIA Y CABLES 12. VEHÍCULO FUERA DE SERVICIO

Antes de trabajar cerca o con la batería, coloque el interruptor de Cada vehículo que esté fuera de servicio debe tener una etiqueta a la
batería en (off). vista que indique “FUERA DE SERVICIO”.
5. VENTILACIÓN
La cantidad de aire fresco en movimiento para ventilación en
cualquier lugar subterráneo donde el vehículo esté trabajando
debe tener los requerimientos mínimos del fabricante del motor.
Esta ventilación debe ser suministrada además de la requerida ¡ADVERTENCIA!
por otros vehículos con motores diesel y otros requerimientos.
Pare el motor siempre que la ventilación en la mina subterránea ¡La operación inapropiada de este camión puede causar serias
se suspenda por alguna razón. Se recomienda que se pare el lesiones o la muerte!
motor cuando el vehículo no se utilice. No arranque el motor en
vacío por períodos excesivamente largos.
6. MOTOR
Reemplace cualquier parte de la inyección de combustible con
repuestos del fabricante.
M1039
MANTENIMIENTO
DESCRIPCIÓN GENERAL Cada esfuerzo y empeño ha sido hecho para asegurar que
usted pueda parar este camión. El servicio de frenos (frenado
El Camión Getman modelo A-64 es un camión de cuatro de ejes) es total mente cerrado y es del tipo de disco húmedo,
llantas, consta de una estructura con dirección articulada y con un sistema dual, permitiendo por separado el frenado del
accionado por un motor diesel. La potencia del motor es circuito trasero y delantero. Si ocurriera una falla en
transmitida del convertidor de torque a una transmisión de cualesquier circuito el otro circuito se mantiene funcionando.
cambios de potencia. A través de la transmisión flechas de El juego de frenos de disco con resorte, liberado
conducción con uniones universales transmiten la hidráulicamente los frenos de servicio, los cuales también
potencia al sistema de reducción y los ejes planetarios de sirven como un frenos de estacionamiento, son aplicados
conducción. manualmente ajustado utilizando el botón de control push/pull
(empuje/jale) colocado en el tablero. Este sistema de frenado
de disco, los frenos de servicio frontal y trasero, también es
utilizado como un freno secundario, el cual se acciona
automáticamente en el momento de pérdida de potencia en la
transmisión o hidráulica del freno frontal o trasero.
PRECAUCION Este freno también se puede accionar manualmente en el
La dirección no funciona cuando el camión no está caso de una falla total del sistema hidráulico.
trabajando.
Este camión está equipado con dos luces rojas de advertencia
en el sistema de frenos localizadas en el tablero de
La dirección es totalmente de tipo hidráulico, utilizando instrumentos.
una bomba de engranes con empuje directo la cual provee Cada uno es para el circuito de frenos delantero y trasero.
el flujo hidráulico a una válvula (orbitrol) accionada por Estas luces de advertencia se iluminaran si la presión
el volante de dirección. Esta acciona los dos cilindros de hidráulica de cualquiera de los frenos trasero o delantero cae
dirección localizados en la unión articulada. por debajo del nivel previamente ajustado 1100 PSI (76 BAR).
Los frenos delantero y trasero de servicio se aplican
automáticamente si la presión hidráulica cae por debajo de
1100 PSI (76 BAR). La luz independiente del freno localizada
en el tablero de advertencia se iluminará cuando la presión cae
por debajo de 1200 PSI. Todos los instrumentos requeridos
para operar el camión se localizan en el área del operador.
Familiarícese con la posición y función de cada uno.
M1039
MANTENIMIENTO
DESCRIPCION DEL TABLERO DE INSTRUMENTOS
465313-200
1. Engine Oil PSI Gauge (Manómetro de Presión de 3. Voltmeter (Voltímetro): Indica la carga y descarga de la
Aceite del Motor): Este manómetro indica la presión de batería.
aceite en el motor. La presión normal de operación es de
45-60 PSI. 4. Hourmeter (Horómetro): Indica las horas de operación
del camión cuando el interruptor de arranque se gira a la
2. Engine Temperatura Gauge (Manómetro de posición “on” encendido.
Temperatura del Motor): Este manómetro indica la
temperatura del motor. 5. Tachometer Gauge (Tacómetro): Indica las R.P.M. del
motor.
M1039
MANTENIMIENTO
6. Converter Oil Temperatura Gauge (Manómetro de 13. PLC Reset Switch (Interruptor Restablecedor PLC)
Temperatura de Aceite del Convertidor): La (Opcional): Utilizado para reestablecer los controles del
temperatura normal de operación del convertidor de la motor. Jale durante 30 segundos. El fusible se reestablecerá.
transmisión es de 160º a 220ºF (71º a 104ºC). Si el Empuje y arranque de nuevo el motor.
manómetro indica una temperatura mayor. Pare el
camión, póngalo en neutral, aplique el freno de 14. Glowplug Override Button (Botón para Anular los
estacionamiento y trabaje el motor a 1000.1200 R.P.M. Tapones de Calentamiento): Usado cuando el motor no
hasta que la temperatura alcance el punto normal. Para necesita auxiliarse de los tapones de calentamiento para el
mayor información vea la sección 5 del Manual Para el encendido del motor.
Servicio de la Transmisión.
15. Glowplug Preheat Indicador (Indicador de
7. Transmisión Pressure Gauge (Manómetro de Precalentamiento de los Tapones de Calentamiento):
Presión de la Transmisión): El manómetro de presión de Indica al operador cuando los tapones de calentamiento están
la transmisión indica la presión que va a ser regulada y precalentados.
enviada a los embragues de la transmisión. Si el
manómetro no registra presión después de que se arranca 16. Warning Buzzer (Silbato de Advertencia): Usado para
el motor pare el motor inmediatamente y avise el alertar al operador cuando la temperatura de la transmisión
departamento de mantenimiento. sobrepasa a los 250ºF, o cuando la presión de la transmisión
La presión normal de operación es aproximadamente 300 cae por debajo de 60 PSI. Este silbato también sonará
PSI. Vea el Manual de Servicio para la Transmisión en la brevemente en el arranque.
sección 5 para más información.
17. Start Switch (Interruptor de Arranque): Gire el
8. Parking/Secondary Brake Button (Botón de Freno interruptor a la posición 1 para precalentamiento, y gire
de Estacionamiento Secundario): Empuje para momentáneamente a la posición 2 para arrancar el motor.
aplicarlo, jale para liberarlo.
18. Light Switch (Interruptor de Luces): Interruptores de
9. Park Brake Test Buttom (Botón de Prueba del palanca para luces delanteras y traseras.
Freno de Estacionamiento): Para camiones equipados
con un botón de “Prueba del Freno para 19. Beacon Light Switch (Interruptor de Luz de la
Estacionamiento”, manteniendo presionado este botón le Farola)(Opcional): Es un interruptor de palanca para
permitirá al operador embragar la transmisión para encender la farola de la cabina si está equipada.
prueba.
Siga las instrucciones como se indica: 20. Warning Panel (Tablero de Advertencia): Vea Tablero
1. Aplique el freno de estacionamiento. de Instrumentos de Advertencia para descripción más
2. Coloque la transmisión en la tercera velocidad y detallada.
en el engrane de dirección en “F”.
3. Incremente las RPM al máximo. 21. Canopo Light Switch (Interruptor de Luz de la
4. El camión no se debe mover. Cubierta de la Cabina) (Opcional): El interruptor de palanca
Si el camión se mueve, estacione el camión en un lugar enciende la luz de la cubierta si está equipada.
seguro, bloqueé las llantas y reporte al personal de
mantenimiento para que revisen y/o ajusten el sistema de
frenos. Si el camión está equipado con ejes Ford/New
Holland, los frenos de servicio actúan como el freno de
estacionamiento y son probados con este procedimiento.
10. (Boom Light Switch (Interruptor de Luces de la

Pluma) (Opcional): Accione el interruptor para encender
las luces de la pluma si está equipado con esta opción.
11. Horn Button (Botón del Cláxon): Presione para

accionarlo.
12. Circuit Breakers (Circuito de Interruptores):

Consiste de interruptores (protectores) de 10, 20 y 30
AMP, utilizados para manómetros, luces, cláxon, etc…
M1039
MANTENIMIENTO
TABLERO DE INSTRUMENTOS CON SEÑALAMIENTOS DE ADVERTENCIA
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 (PRESION HIDRAULICA BAJA): Esta luz se

ilumina cuando el sistema hidráulico detecta una disminución repentina en la presión.
• STOP ENGINE (PARAR EL MOTOR): Esta luz se ilumina en caso de que una falla en el
motor sea detectada por el sistema de control electrónico del motor. Esto es considerado ser
una falla importante, la cual requiere atención inmediata. Pare el motor tan pronto como sea
posible y avise al departamento de mantenimiento.
• PARK BRAKE (FRENO DE ESTACIONAMIENTO): Esta luz se iluminará cuando la
línea de accionamiento del freno de estacionamiento está activada. Cuando el freno de
estacionamiento es liberado para poner el camión en movimiento, esta luz no se ilumina.
M1039
MANTENIMIENTO
• TRANSMISSION (TRANSMISION): Esta luz se iluminará en el momento que baje la
presión de aceite hidráulico o se eleve la temperatura de la transmisión.
• POWER ON LIGHT (LUZ DE ENCENDIDO): La luz de arranque es una indicación de
que el interruptor de arranque ha sido girado a la posición “ON” encendido. Esta luz
permanecerá iluminada hasta que el interruptor de encendido se gire a la posición “off”
apagado.
• FRONT AND REAR BRAKES (FRENOS TRASERO Y DELANTERO): Hay dos luces
independientes en el tablero para proporcionar al operador información con respecto a una
posible auto aplicación de los frenos. Estas luces son una indicación de que hay menos de
1100 PSI aplicadas ya sea en el freno de servicio delantero o izquierdo. La aplicación de
autofrenado sucede cuando la presión del sistema de frenos cae por debajo de 1100 PSI.
• BRAKE IMPENDING (FRENADO INMINENTE): Esta luz se iluminará cuando la
presión hidráulica cae por debajo de 1200 PSI en cualquiera del circuito de frenado, ya sea
delantero o trasero. Esto es una advertencia para el operador de la posible aplicación de
autofrenado la cual ocurre con una presión debajo de 1100 PSI.
• DECLUTCH (DESEMBRAGUE): Esta luz se ilumina cuando el selector de la transmisión
está desembragado.
Dependiendo de las opciones seleccionadas, lo siguiente puede activar la opción de
desembrague.
1. El freno de estacionamiento está activado “ON”.
2. La válvula selectora está en modo de accesorios.
3. Los gatos estabilizadores no están totalmente retraídos.
4. La canastilla no está asentada a nivel sobre la cubierta o plataforma.
5. La plataforma de tijera está en la posición elevada.
OTROS CONTROLES Gear Selector Lever (Palanca Selectora de Cambios) (De

Engranes): Mueva la palanca a la posición “1” para cambio
en baja velocidad, posición “2” para la segunda velocidad y
posición “3” para la tercera velocidad.
ADVERTENCIA
Nunca deje el camión en neutral. Esto le
causará serias lesiones y daño al camión.
Accelerator Pedal (Pedal de Aceleración) (No se muestra):

Empuje para incrementar las R.P.M. del motor.
Brake Pedal (Pedal del Freno) (No se muestra): Empuje

para activar el servicio de frenos.
Direction Selector Lever (Palanca Selectora de
Dirección): Mueva la palanca a la posición “F” para
Seat Adjustment (Ajuste del Asiento) (No se muestra): Se
mover el camión hacia delante. Mueva la palanca
ajusta para comodidad del operador.
selectora a la posición “R” para reversa directa. La
posición “N” es para neutral.
M1039
MANTENIMIENTO
DESCRIPCION DE LOS MANOMETROS
Las temperaturas normales del convertidor/transmisión están entre 180ºF-220ºF (82ºC.104ºC). Si las temperaturas
subieran arriba de la escala de 220ºF, aplique el freno de estacionamiento, ponga la transmisión en neutral e
incremente la velocidad del motor aproximadamente 1000R.P.M. hasta que la temperatura regrese a la escala normal.
El manómetro de presión de la transmisión indica la presión que está siendo regulada y aplicada a los embragues de la
transmisión. Si el manómetro deja de registrar la presión después de que el motor se arranca, pare el motor
inmediatamente y avise al departamento de mantenimiento. La presión normal de operación es aproximadamente 300
PSI.
M1039
MANTENIMIENTO
DESCRIPCION DE LOS MANOMETROS CONT.
Los indicadores de combustible pueden estar fuera o dentro de la cabina. El manómetro indica el nivel del combustible existente en el depósito
de combustible.
El voltímetro indica el nivel de voltaje, carga o descarga. Puede haber voltímetros de 16V usados para un sistema de carga de 12V o un
voltímetro usado para un sistema de carga de 24V. Con un camión trabajando un sistema de cargado de 12V debería tener una lectura de 12-16
voltios y 24-30 voltios para un sistema de cargado de 24V.
Los manómetros de presión son usados para medir la presión del sistema hidráulico. Pueden ser usados para medir presión de freno, la presión
total del sistema, etc.
M1039
MANTENIMIENTO
INSPECCIONES ANTES DE ARRANCAR
Inspeccione la condición y tensión de todas las bandas, las que tengan

desgaste o cuarteaduras remplácelas de inmediato.
Inspeccione el área en torno del camión por la existencia de

algunos obstáculos que puedan dañar o causar daños al camión
cuando sea conducido.
Inspeccione el extinguidor de incendios y reemplácelo si es necesario
Inspeccione el nivel de aceite, llénese si se requiere con el

lubricante recomendado.
Asegúrese que la barra de seguridad en la articulación no esté

conectada.
Inspeccione el indicador de mirilla. Si el indicador está en la

zona roja, limpie y reemplace el elemento del filtro/s.
Visualmente inspeccione los conectores y abrazaderas ahulados.
Inspeccione el nivel del aceite hidráulico en el tanque con el

motor apagado. El nivel de aceite no debe estar en la parte alta Inspeccione las luces y cláxon para asegurarse que estén en
del indicador de mirilla o en la parte baja de la misma. Llénese condiciones de funcionar.
según requiera.
Inspeccione el cinturón del asiento para realizar algunos ajustes y si

Inspeccione la presión de las llantas, 95 PSI (6.55 BAR) es lo no está dañado o roto. Ajuste el asiento en una posición confortable
recomendado. Inspeccione las tuercas de las llantas. No para el operador. Algunos asientos tienen ajustes superiors.
conduzca el camión con tuercas flojas o faltantes.
M1039
MANTENIMIENTO
PROCEDIMIENTO DE ARRANQUE
PRECAUCION
La transmisión debe estar en neutral y el freno de
estacionamiento debe estar aplicado para arrancar el motor.
IMPORTANTE
Todo el personal de berá estar a una distancia segura del camión
antes que usted entre a la cabina del operador!
¡La barra de seguridad de articulación no debe estar

conectada!
4. Mueva la palanca de dirección a la posición neutral.

1. Gire los interruptores de la batería y ECM a la posición
“ON”.
NOTA: Este interruptor puede estar localizado en un lado del b
camión, en la cabina o en ambos.
a
2. Ajuste y abroche el cinturón a una posición confortable de
operación.
5. Gire el botón de arranque a la posición “ON” (a)
6. Verifique todos los manómetros y asegúrese que están

funcionando adecuadamente (b)
7. Presione el botón del cláxon para que éste suene ( c ).
8. Gire el interruptor de encendido a la posición de arranque

(Start) para embragar el motor de arranque y sosténgalo
hasta que el motor arranque. NOTA: No lo sostenga por
periódos mayores de 15 segundos.
9. Si los manómetros de presión del motor, transmisión e

hidráulicos no indican presión poco después del arranque,
pare el motor y determine la causa.
3. Empuje hacia abajo el botón de estacionamiento.
M1039
MANTENIMIENTO
ATENCION
NO ARRANQUE EL MOTOR POR MAS DE 30 SEGUNDOS. PERMITA QUE EL MOTOR DE ARRANQUE SE
ENFRIE POR DOS MINUTOS ANTES DE ARRANCAR DE NUEVO. EL TURBO CARGADOR (SI ESTA
EQUIPADO) PUEDE RESULTAR DAÑADO SI NO SE MANTIENEN BAJAS LAS R.P.M. HASTA QUE EL
MANOMETRO DE PRESION DE ACEITE DEL MOTOR INDIQUE QUE LA PRESION ES SUFICIENTE.
PROCEDIMIENTO DE PRUEBA DEL FRENO DE ESTACIONAMIENTO
ATENCION
Empujando el botón del freno de estacionamiento localizado en el tablero anula el desembrague de la transmisión.
Para probar el Freno de Estacionamiento solamente:
1. Aplique el freno de estacionamiento(a).
2. Empuje y sostenga el botón del freno de estacionamiento (b)
3. Coloque la palanca de velocidades en 3ª y la palanca selectora de dirección en “F”
4. Acelere totalmente
5. El camión no se deberá mover.
M1039
MANTENIMIENTO
PROCEDIMIENTO MANTENGO DE LA PRUEBA
Prueben los frenos de servicio presionando totalmente el pedal de los frenos

de servicio. Colocando la transmisión en marcha y en segunda, soltando el
freno de estacionamiento y accelerando el motor al máximo de 3 a 5 segundos.
El vehículo no debe moverse. Si el vehículo se mueve, estaciónelo, ponga las
cuñas abajo de las llantas y comuníquese con mantenimiento.
DESPUES DE ARRANCAR EL MOTOR

3
2
Engine Oil Pressure (Presión de Aceite del Motor) #1- La presión de aceite deberá leer 25-50 PSI en vacío con el motor a una temperatura de
operación. En condiciones de carga completa del motor, la presión deberá leer entre 45-60 PSI. Si el manómetro no muestra presión después de
que se arranca el motor, pare el motor inmediatamente y localice la causa.
Voltmeter (Voltímetro) #2- Con el motor trabajando, el voltaje deberá leer 12-16 voltios para camiones con sistema de 12 voltios y 24-30
voltios para camiones con sistema de 24 voltios.
Transmissión Temperature Gauge y Transmissión Pressure Gauge (Manómetro de Temperatura de la Transmisión #3 y Manómetro de
Presión de la Transmisión #4- Durante los ciclos de trabajo, si el manómetro de la transmisión/convertidor indica temperatura arriba de 220ºF,
estacione el camión y coloque la transmisión en neutral con el freno de estacionamiento aplicado e incremente las R.P.M. del motor
aproximadamente 1000-1200 R.P.M. mantenga estas revoluciones por minuto hasta que la temperatura del motor retorne a niveles normales.
La presión normal de la transmisión operando es aproximadamente 250 PSI (17.2 BAR). Si la presión de la transmisión dejara de registrarse
después de arrancar el camión, pare el motor y avise al departamento de mantenimiento.
Brake Pressure Gauges (Manómetros de Presión de Frenos): Hay dos manómetros de presión del acumulador de frenos localizados en el
lado del tablero en el panel del motor. Estos muestran la presión hidráulica independiente existente en los acumuladores de los frenos delantero
y trasero. La presión normal en estos manómetros es entre 1500 y 2200 PSI (103.5-151.5 BAR).
PRECAUCION
Pare el motor inmediatamente si alguno de los manómetros no está colocado en su escala.
Park Brake Test (Prueba del Freno de Estacionamiento)- Este sistema está diseñado para sostener un camión cargado totalmente en una
pendiente de 35%. Por razones de seguridad una prueba del freno de estacionamiento debería realizarse al inicio de cada turno. Vea los
procedimientos para prueba del freno de estaciomaiento para instrucciones de cómo realizar esta prueba.
M1039
MANTENIMIENTO
ADVERTENCIA
No opere ningún camión con falla en el sistema de frenos de estacionamiento/servicio. Puede resultar en serias lesiones al personal o daño al
camión si lo hace.
OPERANDO EL CAMION
3
1
4
• Una vez que todos los manómetros han sido verificados y están dentro de los límites de operación
normal, el camión está listo para operar.
• Gire el Interruptor de Luces (1) a la posición ON (encendido).
• Empuje el Botón de Freno de Servicio y sosténgalo (2).
• Verifique la presión de los acumuladores de los frenos y verifique el tablero de instrumentos por si
hay señales de advertencia o por baja presión en las luces de advertencia en el tablero de advertencia
(3).
• Asegúrese que todos los estabilizadores hidráulicos están retraídos totalmente (si aplica).
• Verifique para estar seguro que el área está libre de personal y obstáculos. Seleccione hacia adelante
moviendo la palanca selectora de engranes a la posición “F” y seleccione el 1er cambio moviendo la
palanca selectora de cambios a la posición “1”.
• Jale el botón del freno de estacionamiento (2) para liberar la línea de mando del freno de disco.
• Presione el botón del cláxon (4) en el tablero de instrumentos para que suene.
• Quite el pie del pedal del freno, pruebe el volante de dirección para asegurarse de su óptima
operación y mueva el camión suavemente empujando el pedal de aceleración con el pie.
M1039
MANTENIMIENTO
CONDUCIENDO EL CAMION
Por si mismo acostúmbrese a la forma de conducir Cuando confíe que puede operar el camión seguro y
moviendo el camión tomando la guía arriba satisfactoriamente, localice un lugar o camino recto y
mostrada. acelérelo. Comience con el 1er. Engrane, cambie a 2º y
Realice esta actividad varias veces hasta que se luego a 3º. (si las condiciones lo permiten). Asegúrese
familiarice con la conducción del camión y se sienta que el área elegida está libre de obstáculos y/o personal.
capaz de conducir el camión en áreas de tráfico. A velocidades más altas deberá de tratar de dar giros
Para familiarizarse con la respuesta a la aplicación muy ligeros mientras no exista el peligro de dañar el
automática de la línea de frenos, conduzca en línea camión u otro vehículo. Detenga el vehículo y regrese el
recta, y quite el pie del pedal de aceleración y selector de cambios de la transmisión a neutral (N).
empuje el botón de estacionamiento (#1) mientras Aplique el freno de estacionamiento. Revise de nuevo
está el camión todavía moviéndose. todos los manómetros para estar seguro que están
operando dentro del límite normal.
El freno de estacionamiento se activará y el camión
llegará a pararse. Si esto no sucede, realice una
inspección y ajuste del freno con el personal NOTA: Cuando esté conduciendo el camión hacia arriba
autorizado. en camino inclinado (rampa), seleccione el engrane más
bajo si la temperatura del convertidor de torque alcanza
200º F (93º C).
¡ADVERTENCIA!
Cuando esté conduciendo el camión en caminos con
inclinación negativa (hacia abajo) utilice el 1er. Engrane
(primera). El uso del 2º y 3er engrane (segunda y
tercera) podría causar que el motor se desgobierne y
agarre altas velocidades y posible riesgo en la seguridad
del operador.
M1039
MANTENIMIENTO
PROGRAMA DE MANTENIMIENTO SEGÚN REQUIERA
Coloque el camión en posición para servicio. Reemplace el elemento del filtro de seguridad cada 5 cambios
realizados del filtro primario. El cambio de filtro de seguridad
NOTA: se realiza de la misma manera que el cambio del filtro
Dependiendo de la condiciones de cantidad de polvo primario.
existente, el filtro de aire debe de requerir de servicio
diariamente. PURIFICADOR DE AIRE “FARR”
TIPO SECO
Este camión estará equipado con alguna de las opciones
siguientes de filtración de aire.
Determine con cual sistema está equipado su camión y
consulte en la sección correspondiente para las
instrucciones de servicio.
PROCEDIMIENTO PARA EL SERVICIO DEL

PURIFICADOR DE AIRE
NOTA: La pérdida de potencia del motor y/o excesiva
cantidad de humo en el escape son señales de que los
elementos del filtro de aire pueden requerir de servicio.
Revise el indicador de servicio. Limpie diariamente los
PURIFICADOR DE AIRE TIPO canales de descarga del colector de polvo. Realice el servicio
SECO DONALDSON al purificador de aire solamente cuando el indicador se
observa en la posición roja y proceda como sigue:
Verifique el indicador de servicio. Limpie diariamente los

canales de descarga del colector de polvo. Realice el
servicio al purificador de aire solamente cuando el
indicador se pone en la posición roja y proceda como
sigue:
Afloje las tuercas en la caja del purificador de aire y quite la

rejilla prelimpiadora. Quite y elimine o deseche el cartucho de
filtro de polvo. Limpie la parte interna de la caja e instale un
cartucho de filtro nuevo.
Limpie la rejilla de filtración primaria. Coloque de nuevo la

rejilla. Reajuste el indicador de servicio.
Afloje el tornillo de oreja que sostiene la tapa y sepárela,

saque y elimine el elemento de filtrado primario. Limpie
la parte interna de la caja del filtro (housing), instale un
elemento nuevo.
Cheque el empaque de la tapa para asegurar un buen

sello. Al volver a instalar el tornillo y la tapa reajuste
(reset) el indicador de servicio.
M1039
MANTENIMIENTO
PROGRAMA DE MANTENIMIENTO DIARIO O CADA CAMBIO DE TURNO
9 4
8
3
2
1
7
10
5
1 6
PARTIDA COMPONENTE FLUIDO * Cheque la presión de aire y condiciones de las llantas. No

1. Llantas ____ conduzca el camión con baja presión en las llantas. No
2. Sistema Hidráulico HO conduzca el camión con llantas malas o desgastadas y/o llantas
3. Motor EO cortadas o con muescas.
4. Limpiador de Aire
Primario ____
5. Sistema de D2
Combustible
6. Bandas ____
7. Muñones de EPG
Oscilación
8. Transmisión y
Convertidor de TF
Torque
9. Baleros y Pernos
Superior e Inf. EPG
Cheque los indicadores de mirilla del depósito hidráulico y
10. Bujes del Cilindro de
llénese según requiera. El nivel del aceite no debe estar ni por
Dirección EPG
encima o por debajo del indicador de mirilla.
*Realice el Programa de Mantenimiento como se requiere.
*Observe las Especificaciones del Fluido.
Cheque el nivel de aceite. Agregue si lo requiere.
M1039
MANTENIMIENTO
DAILY MAINTENANCE OR EVERY SHIFT CHANGE (CONT’D)
Vaciar y limpiar el recipiente del prelimpiador de polvo.
Cheque la condición y tensión de todas las bandas

“tensión y condición”. Bandas desgasta das con Cheque el nivel de combustible agregue si se requiere.
quebradura o muesca deben ser reemplazadas
inmediatamente. Cheque la tensión como sigue:
ADVERTENCIA
El motor DEBE estar apagado para checar la tensión de la
Verifique el nivel de aceite de transmisión. El aceite deberá
banda.
ser verificado con temperatura de operación normal con el
motor trabajando en vacío y la transmisión en neutral.
Agregue aceite si es necesario.
1. Empuje la banda
hacia el centro con los
dedos entre las poleas. ADVERTENCIA
Evite cualquier banda en movimiento, componentes o
2. El movimiento de la
polea debe ser 3/8” a
áreas con alta temperatura. Serias lesiones pueden resultar
5/8” (10-15 mm). por descuidos o negligencia.
Visualmente inspeccione el camión:

Con el motor trabajando cheque:
1. Fugas en el sistema hidráulico.
2. El sistema de combustible por posibles fugas.
3. Instrumentos para una operación apropiada.
Con el motor apagado cheque:

1. Que todos los controles se muevan libremente.
2. Que los pernos estén colocados en su lugar.
NOTA: Realice el mantenimiento del motor como está

indicado en el Manual del Operador o contacte a la
Corporación Getman por la información actualizada.
Engrase los muñones del eje.
M1039
MANTENIMIENTO
PROGRAMA DE MANTENIMIENTO CADA 50 HORAS DE OPERACIÓN

Coloque el vehículo en posición de servicio.
3 5
1 4
PARTICA COMPONENTE FLUIDO*

1. Llantas ____
2. Batería H2O
3. Purificador de Aire EO
4. Sistema de
Enfriamiento de Aire _ _ _ _
5. Purificadores
Catalíticos del _____
Escape
* Realice el programa de mantenimiento como es
requerido.
* Realice el programa de mantenimiento diariamente o
cada turno.
Afloje y levante la tapa de acceso a la batería. Limpie la
* Vea las especificaciones de fluido.
batería. Cheque el nivel de fluido. Añada agua destilada según
se requiera.
ADVERTENCIA
Vigile la posible acumulación de gas hidrógeno debajo de
la tapa de acceso a la batería. Mantenga la batería alejada
de chispas o flama.
IMPORTANTE
Cuide que no le caiga ácido de la batería sobre los ojos o la
Cheque las tuercas de las llantas. Deben estar apretadas a piel. Mantenga la batería alejada del fuego o flama.
300 ft./lbs. (406.7 Nm).
M1039
MANTENIMIENTO
MANTENIMIENTO DE 50 HORAS (CONTINUACIÓN)
NO deje trabajar en vacío el motor por más de cinco (5) minutos a la

vez, o el purificador perderá eficiencia.
2. Antes de poner el camión en servicio, y durante el chequeo de

cada 50 horas, cheque la presión de escape con la aceleración total,
conectando un manómetro de retorno de presión o manómetro de
agua a la conexión de prueba de 1/8” NPT que se encuentra entre el
purificador y el múltiple de escape. Si la presión de retorno excede
29” (737 mm) H2O o ha aumentado 5”(127 mm) o más desde la
última regeneración, el purificador debe ser limpiado o regenerado.
Aplique grasa a los baleros de los pernos superior e inferior.
(Vea especificaciones) REGENERACIÓN DEL PURIFICADOR ECS
Equipo requerido:
1. Cepillo de nailon, de cerda dura para limpiar.
2. Solvente con aire, y partes para pistola o soplete de aire.
3. Una solución desengrasante concentrada.
4. Solvente stoddard, solvente con alto grado de keroseno
(libre de azufre) – 5 partes stoddard con 1 parte de S.C.
5. Disponibilidad de aire comprimido (30 PSI)
6. Llave cresent.
Agregue grasa a las dos terminales de los cilindros de la
dirección.
ADVERTENCIA
Solución Inflamable. Utilícese de acuerdo a las recomendaciones
de los fabricantes, una equivocación en el seguimiento de estas
instrucciones pueden causar serias lesiones.
Procedimiento de limpieza:
1. Remueva la sección central del purificador.
Verifique todas las conexiones de la admisión de aire. Apriételas
2. Seque con cepillo la entrada del catalizador.
si se requiere.
3. Limpie con aire a través de la salida del catalizador.
4. Continúe con los pasos 1 y 2 hasta que la parte de entrada esté
limpia.
5. Sumerja completamente el catalizador en la solución S.C.
stoddard por una hora.
6. Aplique solvente con aire para limpiar la cara de salida del
catalizador por 10 minutos.
7. Limpie a través de la salida con aire.
8. Repita los pasos 4, 5 y 6 hasta que el purificador esté limpio.
9. Aplique agua a presión y limpie el purificador a través de la salida
Quite la cubierta que está del lado del motor aflojando los y seque con aire.
broches de retención. Limpie las aletas de enfriamiento, el 10. Reemplace el purificador.
enfriador de aceite, enfriador de la transmisión y el radiador si 11. Anote la presión de escape con aceleración total, quite el
existe para limpiar aplique aire comprimido. manómetro y apriete el tapón de prueba.
Camiones equipados con purificador de aire catalítico NOTA: Si se dispone de vapor a alta presión, puede ser sustituido
ECS: por la solución solvente. Limpie con el vapor a través de la cara de
1. Si el camión está operando bajo carga pesada con el motor en salida del catalizador. Manteniendo la conexión de salida del vapor
altas RPM por lo menos al 70% del tiempo de operación retirada 2” (51 mm) del frente del catalizador.
requiere de mínima cantidad de mantenimiento. Si el camión no
trabaja bajo carga y es operado en vacío por periodos de tiempo NOTA: Si el purificador ha sido regenerado, pero el motor sigue
excesivos, el catalizador puede llegar a “carbonizarse” y despidiendo humo, se le deberá dar servicio al motor para mantener
empezar a generar humo por el escape después de pocas horas, seguras las condiciones de escape.
indicando que es necesario limpiarlo o regenerarlo.
M1039
MANTENIMIENTO
Coloque el camión en posición de servicio.
4
5
3
7 2
6
PARTIDA COMPONENTE FLUIDO *

1. Línea de Mando
Crucetas y
Uniones articuladas EPG
2. Transmisión TF
3. Sistema Hidráulico HO
4. Caja del Eje MBO
Oscilante
5. Respiradero del Eje ____
6. Motor ____
7. Freno de ____
Estacionamiento
*Realice el Programa de Mantenimiento como se Agregue grasa a los yugos deslizantes, cada uno con una
requiere. grasera.
*Realice el Programa de Mantenimiento Diario o cada
turno.
*Realice el Programa de Mantenimiento de 50 horas.
*Vea las especificaciones de fluido.
Drene el aceite de transmisión quitando el tapón de drenado.

Limpie el tapón en solvente, séquelo y colóquelo de nuevo en
la transmisión.
Agregue grasa a las cinco graseras de la uniones o

crucetas de la flecha de conducción universal y los
baleros de alineación.
NOTA: Algunas uniones universales pueden no verse.
M1039
MANTENIMIENTO
MANTENIMIENTO DE 250 HORAS (CONTINUACIÓN)
Remueva el filtro de la línea de retorno. Reemplace el

elemento del filtro e instale el filtro de la línea de retorno.
Quite el filtro de transmisión. Reemplácelo con uno
Instale el tapón de drenado. Llene el depósito con aceite
nuevo. Antes de instalar el filtro, cubra el empaque con
hidráulico.
una capa ligera de aceite. Vea la Sección 5 (Servicio y
Mantenimiento de la Transmisión) para información más
detallada.
Llene y cheque la transmisión de la siguiente manera:

1. Llene la transmisión hasta la marca inferior de la varilla
de nivel.
2. Arranque el motor en vacío 500-600 RPM para llenar
el convertidor y mangueras hidráuli cas.
3. Cheque de nuevo el nivel de aceite con el motor en Cheque los indicadores de mirilla. Agregue aceite si requiere.
vacío y la transmisión neutral. Llegue el nivel de aceite El nivel no debe estar ni por encima ni por debajo de los
hasta la marca inferior de la varilla de nivel. Cuando el indicadores de mirilla.
aceite alcance la temperatura normal de operación (158º a
248º F) (70º a 120º C) haga una verificación final del
nivel de aceite y llegue el nivel de aceite hasta la marca
“full” de la varilla de nivel.
4. Verifique si no hay fugas.
Verifique el nivel de lubricación de las dos cajas del

diferencial. Remueva el tapón de llenado. El aceite de
transmisión debe estar a nivel del tapón de llenado. Agregue
lubricante si requiere. Coloque de nuevo el tapón de llenado.
Consulte la página específica para el fluido apropiado.
Remueva la tapa de llenado del depósito de aceite

hidráulico y vacíe el depósito hidráulico quitando el tapón
de drene.
Remueva el respiradero del eje, límpielo con solvente y
NOTA: Para evitar contaminación, limpie la parte séquelo con aire comprimido. Colóquelo de nuevo en el eje.
superior del depósito antes del servicio. Realice esta operación a los dos ejes.
M1039
MANTENIMIENTO

NOTA: La rosca de succión del cedazo debe ser cerrada o
tapada con un tapón hembra de 1 ½” NPT para prevenir
contaminación y posible daño a los componentes hidráulicos.
Limpie el interior de los depósitos con vapor o solvente.
Limpie o reemplace el cedazo y reinstálelo en el interior del

depósito.
PARTIDA COMPONENTE FLUIDO*

1. Sistema hidráulico HO
Quite el filtro de la línea de retorno. Reemplace el elemento
*Realice el Programa de Mantenimiento como es
del filtro. Instale el filtro a la línea de retorno.
requerido y propuesto.
*Realice el Programa de Mantenimiento Diario o Cada
Instale la placa de acceso al depósito, coloque el tapón de
Turno
drenado, y llene el depósito con aceite hidráulico. Verifique
*Realice el Mantenimiento de 50 Horas.
las especificacio nes.
*Vea las Especificaciones de Fluido.
Cheque los indicadores de mirilla del depósito de aceite

hidráulico, agregue aceite si se requiere. El nivel no debe estar
arriba de la parte superior de la mirilla o por debajo de la parte
inferior de la misma.
Remueva el capuchón de llenado del depósito. Vacíe el
depósito principal de aceite hidráulico quitando el tapón
de drenado.
NOTA: Para evitar contaminación, coloque de nuevo el

capuchón y limpie la parte superior del depósito antes de
proceder al servicio.
Remueva la placa de acceso al depósito hidráulico.

Desconecte el cedazo que está localizado en el interior del
depósito.
M1039
MANTENIMIENTO
2
1
PARTIDA COMPONENTE FLUIDO *

1. Caja del Eje Diferencial MBO
2. Respirador del Eje _ __ _ _ _
*Realice el Programa de Mantenimiento

como es requerido y propuesto.
*Realice el Programa de Mantenimiento
Diario o Cada Turno.
* Realice el Mantenimiento de 50 Horas.
* Realice el Mantenimiento de 250 Horas.
*Vea las Especificaciones de Fluido.
Remueva los tapones de drenado del eje diferencial, rontal y trasero.

Cuando el eje esté totalmente vacío de aceite, limpie el tapón de drenado
e instálelo de nuevo.
Quite los tapones de llenado del diferencial (uno por eje). Agregue
lubricante como se especifica hasta que el nivel de aceite llegue a
la parte baja de la entrada del tapón de llenado. Limpie y reinstale
los tapones de llenado del diferencial.
M1039
MANTENIMIENTO
ESPECIFICACIONES
COMBUSTIBLE
Use combustible Diesel No. 2, Cetane 40 Mínimo
Utilice la marca de diesel en la cual confía que contiene menos del 0.5% de azufre. Tenga cuidado al llenar o rellenar
el depósito para evitar la contaminación del combustible (diesel). Utilice un combustible con graduación para invierno
cuando esté operando el camión en bajas temperaturas. NOTA: Para evitar que el sistema agarre aire, no permita que
el camión trabaje hasta terminarse el combustible esto puede ocasionar un arranque difícil.
ATENCION
Utilizar combustible diesel más bajo del número recomendado de cetane puede causar un arranque difícil,
inestabilidad y humo blanco excesivo. Para mantener una operación satisfactoria en bajas temperaturas, es importante
especificar el número correcto de cetane del combustible diesel. Para detalles más completos consulte el Manual de
Operación y Mantenimiento del Motor o contacte a su distribuidor local Getman.
LLANTAS
TAMAÑO CANTIDAD TIPO PSI BAR

DE CAPAS
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
NOTA: Esta gráfica solamente indica las especificaciones de presión de la llanta. Las medidas de la llanta no
son intercambiables. Siempre reemplace llantas de la misma medida, tipo y cantidad de capas como las
originales suministradas con el camión.
PRESIONES
TIPO PSI BAR

Presión de aceite en el motor a 1000 RPM 45-60 3.1-4.1
Sistema de dirección hidráulica en vacío y el camión
girado y apoyado contra las retenidas. 1500-2000 103-138
NOTA: Inspecciones hechas a 150º F (65º C) de temperatura
en el aceite hidráulico en la presión de carga de frenado.
Presión de carga hidráulica en el freno.
Ejes John Deere 1650-2200 114-151
Ford/New Holland D45 y D65 1650-2200 114-151
Presión del freno en la válvula del pedal.
Ejes John Deere 1000 69.0
Ford/New Holland D45 y D65 1500 130.5
A-64 ANFO CHARGER OPERATING AND M1006
INSPECTION MANUAL Page 1 of 19
GETMAN CORPORATION
OPERATING AND MAINTENANCE

MANUAL
FOR
MODEL A-64 ANFO CHARGER
Read thoroughly before

operating vehicle
05/29/08
INTRODUCTION RELATED MANUALS
Operators should carefully read and understand This manual covers operation and maintenance
all vehicle manuals. You must become familiar of the ANFO loading system and boom
with all controls and procedures. Getman’s mounted on the Getman A-64 chassis. An
A-64 Series ANFO Truck manual is a guide to Operators manual for the primary A-64 chassis
safe, proper operation, and maintenance. is also incorporated in your Parts and Service
Always keep manual on vehicle at all times. Manual for your specific vehicle. Please read
and become familiar with all these manuals. A
This Getman A-64 Series ANFO Truck has complete listing of engine, drive train
been purchased with expectations that it will components, applicable Electrical, Hydraulic
provide long and reliable service. During it’s and Air Systems can also be found in their
design and construction, we have taken every respective system schematics and Parts and
precaution to ensure we meet those Service Manuals. We have also provided Parts
expectations. To realize the full valve Getman and Service Manuals for major components
has designed into this vehicle, a small amount of such as axles, transmissions, and engines.
time and expense must be invested in the These will be located in the Getman Parts and
inspection and maintenance procedures outlined Service Manuals for your vehicle, or by other
in this manual. This small investment will means.
ensure low operating cost, minimal service
expenses and most importantly, personal safety. Getman has increased the frequency for some
component manufacturer’s recommended
TABLE OF maintenance procedures. This is due to the
CONTENTS………………PAGE demanding environment and applications in
Introduction………………………………..2 which these vehicles must operate.
Related Manuals…………………………...2
Design Features……………………………3 If you have any questions in regards to
General Safety Precautions……………...4-5 operating or servicing this vehicle, immediately
Safety Instruction………………………….6 contact your local Getman Dealer or Getman
Boom Man-Lift General Description……...7 Corporation direct.
Boom/Stabilizer Operation……………...8-9
Daily and Pre-Operation Inspection……….8
ANFO Loading System……………….11-12
Loading the ANFO POTS………………...13
Control of the ANFO System…………14-15
Basic System Adjustments……………16-19
Key Items to Remember………………….20
05/29/08
DESIGN FEATURES
Getman Corporation has always had one main goal in the past 50 years. This has been to provide our
customers with the safest, most reliable product possible to positively impact your production cycle and cost
per ton.
That’s why, in 1963, Getman Corporation pioneered and produced the first complete self contained anfo
hauling/loading package. While making this the fastest way to speed up your production cycle time, this
was secondary to making it the safest method possible.
Here are just a few of the design features that make your Getman A-64 Anfo Charger the vehicle you can
count on day in and day out:
• The large man basket (available in several sizes) is self leveling and rotates in each direction to
always allow it to be square with the face to ensure maximum operator comfort and reach.
• A full set of boom/basket controls are located in the basket as well as at the base of the boom.
• All cylinders are equipped with counterbalance valves to prevent uncontrolled decent in the event of
system damage.
• The boom, basket, and outriggers have undergone complete finite element analysis and are
fabricated by certified welders to ensure maximum strength and safety.
• The basket-mounted boom controls are pilot operated and can be overridden by the base mounted
controls at the base of the boom in the event of an emergency.
• Basket-mounted anfo loading controls are fully protected from accidental activation.
• All anfo delivery fittings are made of SS304 material for maximum life and reliability.
• All the pressure vessels (anfo pots) are certified AS 1210, ASME Code Section VIII Div I UW 12.
Designed working pressure is 100PSI (6.9 BAR).
• The vehicle is equipped with detonator storage compartments which conform to MSHA regulations.
• Getman offers a selection of onboard compressors in a variety of makes and CFM rages and also
offers a mine air hyd/elec package.
These are just a few of the design features that make your Getman Anfo Charge the #1 self contained anfo
charger in the market place today.
Please not that there are numerous other available options from fully enclosed operators compartments,
boom lengths, interlocking safety systems, etc….
The following pages are provided to allow a new operator to have an understanding of the anfo delivery
system and how to best make adjustments and settings to suit your specific application.
05/29/08
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.
• Never allow riders in vehicles not designated to carry passengers.
• Never dismount from a vehicle unless brakes are set.
05/29/08
• 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.
• Check operation of brake circuit prior to beginning of each shift.
• 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!
05/29/08
SAFETY INSTRUCTION
WARNING
ANFO IS A HIGHLY EXPLOSIVE MATERIAL!
All safety regulations must be followed during it’s use. The Operating Procedures in this manual are
intended for general information only! Obtain approval safety procedures and practices from your safety
inspector and material supplier.
Always wear safety glasses and gloves when operating or working near compressed air and anfo products.
Never disconnect any compressed air hoses or fittings when under pressure
WARNING
HAZARDS OF STATIC ELECTRICITY
USE ONLY APPROVED PROCEDURES FOR GROUNDING PNEUMATIC
LOADING VESSEL AND USE ONLY APPROVED SEMI-CONDUCTIVE (ANTI-
STATIC) ANFO PLACEMENT TUBING.
05/29/08
BOOM MAN-LIFT GENERAL DESCRIPTION
The boom and turret arrangement with a man basket attached at the end is attached to the truck rear frame.
This is a three piece boom consisting of outer, middle, and inner sections. The boom can generally be
swung 50° to either the left or right of the vehicle. The basket itself can also be swiveled 45° right or left of
the boom. As the boom is raised, interconnecting hydraulic cylinders keep the basket level. The hydraulic
power necessary to move the boom and basket are provided by an engine driven pump. Air powered
hydraulics is an available option. The ANFO vessel and air control are frame mounted. A grounding reel is
also mounted on the chassis.
1. Parking Brake Control: Push to apply, 7. Boom: Outer, middle, and inner tubes.
pull to release. Used to extend and retract platform during
positioning of basket.
2. Accessory Control: Pull to activate, push
to deactivate. 8. Interconnecting Cylinders: Used to keep
basket level as boom raises and lowers.
3. Stabilizers: Used to level truck. Not to be
used to gain additional basket height. 9. Air Compressor and Controls: Used to
move ANFO material.
4. Stabilizer Controls: Used to extend and
retract stabilizers. 10. ANFO Vessel: Carries ANFO material.
5. Basket: Operator’s work platform. Raises 11. Grounding Reel: Grounds frame to earth.
and lowers.
12. Engine Start/Stop: Used to shut down or
6. Controls: Hydraulic controls used to start engine from basket (Optional).
perform all boom basket functions.
Including, raise, lower, extend, retract,
swing, and tilt.
05/29/08
BOOM AND OUTRIGGER OPERATION
Park vehicle on as flat and level surface as

possible.
Apply park brake. Pull tee handle to accessory

mode to activate boom/outrigger hydraulic
circuit.
NOTICE
Steering is disabled!
To operate boom and basket from the ground,
use truck mounted controls located at base of
boom. To operate from basket, use controls
located in basket.
LEVER FUNCTIONS
1. Boom Swing left or right.

Extend all stabilizer jacks to a solid footing 2. Boom extension in or out.
prior to raising boom off of deck. 3. Boom lift up or down.
4. Basket tilt up or down.
Connect ground cable to earth. Use approved 5. Basket rotate left or right.
grounding procedures when connecting cable. (Optional)
WARNING
OVERHEAD OBSTRUCTIONS
Be sure to have enough overhead clearance.
Connect truck to mine air. If truck is using Failure to follow this rule could cause serious
engine powered hydraulics, set engine R.P.M. injury or death.
05/29/08
BOOM AND OUTRIGGER OPERATION CONTINUED
Always use boom and basket controls to

position yourself in a desired position rather
than reaching extensively.
Booms operating using mine air to run

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

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

in a position where they will not be damaged.
05/29/08
DAILY AND PRE-OP INSPECTION 9. Raise and lower and rotate basket throughout its
full range of motion. Ensure hoses are clear and
movement is smooth.
WARNING
VESSEL AIR PRESSURE
Prior to working on the vessel or leaving vehicle
unattended, vent all existing air pressure from pots.
Failure to do so could cause serious injury.
IMPORTANT
Always make certain vehicle is in “Service Position”
before performing maintenance or service.
DAILY INSPECTION
1. Thoroughly inspect the complete vessel(s) and

accessories for wear due to corrosive nature of
ANFO material. If vessel(s) are in need of
repair or displays signs of damage to vessel
structure, retire unit from service immediately.
2. Inspect the interior of vessel(s) for foreign

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

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

in place and in good repair.
10. Remove all debris from truck, wash truck with
5. Lower stabilizers. They should all extend and water and blow dry.
retract smoothly and have foot pads attached.
NOTE: REPORT ANY UNUSUAL OR FAULTY
6. Using controls at base of boom raise boom to CONDITIONS TO YOUR MAINTENANCE
full height and lower. Carefully observe for DEPARTMENT. TAG VEHICLE OUT OF
kinks or sharp bends. SERVICE
7. Observe as hoses fold and unfold and ensure

there are no kinks or sharp bends.
8. Check hose pathways and fittings to ensure there

are no indications of leaking, chaffing or cutting.
05/29/08
ANFO LOADING SYSTEM
464841- 1060 LBS (480kg)
465342- 1270 LBS (576kg)
464863- 1900 LBS (861kg)
464864- 2120 LBS (961kg) 6
DELIVERY ELBOW (7)

2
1. Vibrator: Keeps anfo moving. Turns on “only” when supply and boost are engaged.
2. Anfo Supply Valve: When air is applied to “open”, anfo is allowed to flow through to basket.
3. Boost Air Valve: Opens when anfo supply valve is opened. Directs air in elbow in base of tank to
create venturi effect and push material to basket. Vibrator applies at same time.
4. Hose Clean Out Valve: When utilized with supply valve closed, this allows supply hose to be
emptied. When used with anfo supply valve open, may add additional air for up holes.
5. Regulated Air: This air is main anfo pot air that is normally regulated to approx. 60PSI by an air
regulating valve. This air pushes down on top of material to ensure constant flow downward. Can
be adjusted to suit operator’s requirements.
6. Pilot Air: This air is regulated to approx. 70PSI. It provides supply air for the relay valves,
vibrators, control valves in basket, and anfo supply valve. (Jamesbury)
7. Stainless Steel Delivery Elbow: This elbow is flange mounted using stainless steel bolts and can
quickly be removed if needed to remove plugging or debris.
05/29/08
ANFO LOADING SYSTEM CONTINUED
• BOOST AIR BALL VALVE (2): This ball valve can be used to increase, reduce, or stop the
“volume” of air being used for pushing material to the basket.
• CLEAN OUT BALL VALVE (2): This ball valve can be used to increase, reduce or stop the
“volume” of air being used to blow material out of the hose or clean out the hole.
• SAFETY RELIEF VALVE (2): This relief valve (set @120PSI) is used as a safety in the event air
pressure to the pots increases above 120PSI.
• ANFO POT BALL VALE (2): This ball valve can be used to increase, reduce, or stop the
“volume” or air being supplied to the tanks.
• ANFO POT PRESSURE REGULATING VALVE (2): This adjustable regulating valve can be
used to increase or decrease the “pressure” of air being supplied to the tanks.
• PILOT AIR REGULATING & LUBE (70PSI): This adjusting regulating valve can be used to
increase or decrease the “pressure” of air being supplied to the controls and relay valves and
lubricate as well.
• Air Pressure Gauges (4): You will find a total of four air pressure gauges in the anfo loading
system. As shown above, there is one for main air supply, either from onboard compressor or mine
air. Two others are for regulated air pressure for each of the individual pots and one for pilot control
regulated pressure.
05/29/08
LOADING MATERIAL INTO THE ANFO POTS
464841- 1060 LBS (480kg)
465342- 1270 LBS (576kg)
464863- 1900 LBS (861kg)
464864- 2120 LBS (961kg)
The stainless steel ANFO pot or pots on your Getman vehicle are equipped with a lid over the top opening to keep
water and/or debris out of the pot. This lid should only be opened when the pot is completely de-pressurized by
opening the tank drain ball valve and venting the air to atmosphere. Once the vessel is filled, the lid should be closed
and latched before the vessel is again pressurized.
Located under the lid, is a stainless steel screen. The screen is utilized to screen out any debris that may be
inadvertently directed towards the pot. This will also help break up any larger lumps of anfo and maintain conformity
in material size. Do not remove this screen. It will provide added assurance against material plugging and added
security for personnel while loading the vessel with material.
There is a rubber sealing cap inside the pot below the screen. The cap automatically rises and seals the pot when air
pressure is applied to the pot. The pot should never be filled to a point above the base of the cap as this may prohibit
the cap from properly sealing. The normal fill capacity would be approximately ¾ to ⅞ full.
A “grounding reel” is provided on every ANFO vehicle Getman manufactures. The cable of the reel should be run to
earth whenever filling the ANFO pots and/or when charging holes.
05/29/08
CONTROL OF THE ANFO SYSTEM
The operating controls for the anfo system are completely air powered. The main air manifold or “tree” is located
between the pots on a dual pot system in the center of the deck behind the boom. It is also located in the same general
area on a single pot delivery system. This location was chosen to provide maximum protection from falling debris
while still providing easy access for operator adjustments.
This Getman Anfo Charger has been carefully designed to create a delivery system which will function properly in
almost any application with material from various suppliers. Many updates and improvements have been made
throughout the years to ensure proper loading can always be achieved for maximum productivity. The key to
successful loading will be for the operator to determine the correct settings necessary to properly place the material in
your specific application.
This manual may “not” be able to provide each and every operator with the precise settings which may be required for
the best material delivery in each application. By following the simple instructions listed in this manual, you should
be able to have the delivery system fine tuned to your particular operation in a matter of hours.
Universally, there are several suppliers of anfo material. This allows for many differences in texture, weight and
conformity. Some materials manufacturer’s provide a very dry, light product and others are heavier and stickier. This
is why finding the correct air pressure and volume settings for each application is so important.
Once the operator has utilized this system for some time and has determined what settings best fit his needs and
application, further adjustments are seldom required.
Here are some of the misconceptions that often make finding the perfect settings difficult:
If I use the maximum air volume, I’ll get the maximum amount of anfo-
While this sounds logical, we all know the goal when loading is to place the material into the hole quickly and well
compacted. Sometimes when too much boost air volume is used, the air/material ratio is too high. This means more
air and less anfo travels down the lines to the delivery hose. This means longer fill times and less productivity.
I’ll keep maximum air pressure going into the top of the anfo pot to push more material-
Again, very sound logic, but not always practical. The pot is cone shaped with a 4” outlet at the bottom. The real
purpose for the air pressure on the top of the pot is to assist the material to travel to the outlet in the bottom of the pot.
Depending on the humidity factor of the material in the pot, too high an air pressure will lead to packing the material
too tight into the outlet and lead to plugging. The boost air venturi located at the elbow at the pot outlet is truly “the
mover” of the material to the basket. The pressure in the pot is there to ensure the material can get to the outlet in a
consistent manner.
05/29/08
CONTROL OF THE ANFO SYSTEM CONTINUED
BASKET CONTROLS:
There are two hand operated 2 position control valves in the basket which allow the operator to control the
anfo delivery system. These come conveniently hard mounted on the basket railing. There is an optional
belt attachment available which allows the operator to have the ability to have the controls mounted
remotely with them.
• CLEAN OUT CONTROL VALVE: This control valve when actuated (ON) sends pilot air to
open the relay valve located downstream from the anfo supply valve (Jamesbury). Once the relay
valve is actuated, maximum air pressure will be sent through the delivery hose at a rate dictated by
the adjustment of the “clean out ball valve.” This can be utilized to purge remaining material from
the delivery hose and/or to blow out water or rock dust from the drill hole prior to loading.
• ANFO SUPPLY CONTROL VALVE: This control valve when actuated (ON) sends pilot air to
perform three separate but related functions. #1 Opens the “anfo supply valve” located between the
elbow at the outlet of the anfo pot and the adapter/reducer where the delivery hose to the basket
commences. This allows the material to move into the delivery hose. #2 Opens the “boost air relay
valve” which can then allow regulated air flow to push material down the delivery hose to the
basket. #3 Turns on the tank mounted “vibrator” to create tank vibration to assist the material in the
pot in moving freely into the outlet elbow. Returning the control valve to the “OFF” position will
close the anfo supply valve, stop boost air from entering the outlet elbow and stop the vibrator.
05/29/08
BASIC SYSTEM ADJUSTMENTS AND OPERATION
Once you have placed the vehicle in it’s work position, apply the parking brake. At this time the operator
should then pull out the tee handle of the diverter valve located to the right side of the operator’s seat. This
valve will be labeled “Steering/Accessories”. This valve disables the steering, prohibits the release of the
parking brake and directs oil to the rear of the vehicle to provide for the hydraulic jacks, boom functions,
and hydraulic air compressor. Now the operator should proceed to the rear passenger side of the vehicle and
with the correct diverter valve placed in the “JACKS” position, the stabilizer jacks can be lowered until the
vehicle is supported and is level as possible. Depending on the vehicle configuration listed below, the
engine can be shut off. Do not utilize stabilizers to obtain extra height. Try and park the vehicle with the
front and rear frames aligned as straight as possible.
If vehicle was purchased equipped to operate the ANFO delivery system utilizing mine air, there should be a
mine air connection located on each side of the vehicle. You can now connect the mine air to whichever
side is most convenient. Please note the mine air supply house should be blown out prior to connecting to
the vehicle to ensure the supply hose is free of water or debris. Once the mine air valve is opened, you can
open the ball valve located immediately after the mine air connection. This will provide air to the “tree” for
feeding the pots and controls, the air powered hydraulic pump for the boom and outrigger functions, and the
air driven alternator which will allow operation of all work lights. The light control switches are located in
the instrument panel in the operator’s compartment. The ball valve located just prior to the air driven
alternator should be “opened” to operate the alternator.
05/29/08
BASIC SYSTEM ADJUSTMENTS AND OPERATION CONTINUED
Each loading situation is different. Therefore, the system control settings are different as well. With this
system, you can control both the volume of material being delivered and the speed or force in which that
material is being delivered. The key things to keep in mind are:
• To change the “amount” of ANFO being delivered, changes must be made to the regulated pot
pressure.
• To change the “speed or force” or the material being delivered, changes must be made to the
boost air ball valve. (Increase or Decrease Volume)
The two system adjustments mentioned above are the most important ones the operator can make to be able
to fine tune the system to his satisfaction. The key is achieving the correct balance of the two. Too much
boost volume may cause jerkiness of the delivery tube and sporadic spurts of air. Too much pot pressure
may cause intermittent plugging of material. The correct balance must be found for the application. Once
this balance is found, any further adjustments will be minor and quickly done. A lot of this will depend on
the material used, the application, and the conditions and the operator preferences. Basically, it will be
whatever works best for you.
To determine what is right for you, you must approach this system with an open mind. You should not
assume that the same settings as on an older vehicle with a different system will be right for this one. Many
of the older systems had very few adjustments available to them.
Getman has worked closely for several years with many customers in various countries to develop a
delivery system that was adjustable enough to adapt to material differences and various applications.
During these years, we have found that the best and quickest method to determine what setting are best for
your application is to start slowly with minimum pressures then grow from there. Generally within the first
hour of use, you will be near your desired settings.
PLEASE TRY THE FOLLOWING METHOD.
05/29/08
BASIC SYSTEM ADJUSTMENTS AND OPERATIONS CONTINUED
As per previous pages, this vehicle can be manufactured with a mine air ANFO system, an onboard air
compressor ANFO system, or a combination of both. Regardless of the system you have chosen, once you
have an air supply for your system, the system settings become the most critical component to successful
operation. Once you have placed the vehicle in the required position, lowered the stabilizers, and connected
the grounding reel cable to earth, Getman suggests you start with the following settings:
• Adjust the ANFO pot pressure regulating valve until the ANFO pot pressure gauge indicates
approximately 25PSI.
• Adjust your clean out air ball valve to approximately the half (1/2) open position.
• Adjust your boost air ball valve to approximately the half (1/2) open position.
Because there will always be a short delay after the ANFO delivery valve is closed after loading a hole, we
recommend you place a piece of tape on the delivery wand approximately 10-12” from the place you want
the flow of material to stop in that particular hole. This is done so you can feel and see when the tape exits
the hole and turn off the delivery system and yet fill the hole to the desired depth.
• Now insert the loading wand into the hole to be filled and pull open the “clean out” valve control in
the basket. This will open the “clean out relay valve” and send only air through the wand to blow
any water and/or debris from the hole. Be certain to position your face and body to the side of the
hole to avoid being sprayed. If the blow back is too strong, close your clean out air ball valve
slightly to reduce the volume of air being delivered.
• Once the hole has been cleaned out, it’s time to fill the hole with ANFO material. Pull open the
“ANFO delivery control valve” in the basket. This will open the material delivery valve, apply the
tank vibrator and open the boost air. Because the pot air pressure is set low and the boost air ball
valve is at ½ open and should easily be controlled. This will be slow, but will allow you to “get the
feel” or the system. You will notice that when you start loading, the wand (delivery hose) will start
to push itself out of the hole. You should keep your hands gripped loosely around the hose so it can
continue to come in time with the material going in to the system.
• Once your comfortable with the feel, you can increase the material flow being delivered by
increasing the pot pressure regulator up to approximately 35PSI. Since you are delivering more
material, you should now feel the wand being pushed back out quicker than before and the hole will
be filled quicker. Once you see your tape, shut off the ANFO delivery control valve.
05/29/08
BASIC SYSTEM ADJUSTMENTS AND OPERATION CONTINUED
Now we will increase the speed by opening the Boost air ball valve. Now you may find the delivery hose
(wand) is a little harder to hold because it has more recoil. Again, the hole will be filling faster. Depending
on the material type being used and the required fragmentation, an adequate speed (force) may be critical to
properly pack the material in the hole.
Continue to adjust the pressure and volumes until the system is performing to your satisfaction.
The methods mentioned above will basically be the same for loading any type of holes. The key is always
going to be “getting the settings to where they work best for you!!”
KEY ITEMS TO REMEMBER
• MORE ANFO POT PRESSURE NORMALLY CREATES MORE MATERIAL VOLUME

FLOW.
NOTE: TOO MUCH ANFO POT PRESSURE CAN LEAD TO PLUGGING. CUSTOMER
EXPERIENCE HAS INDICATED 60PSI IS GENERALLY THE OPTIMUM SETTING FOR
ANFO POT REGULATED PRESSURE.
• INCREASE BOOST AIR (BALL VALVE) CREATES INCREASED MATERIAL

DELIVERY SPEED.
• INCREASED CLEAN OUT AIR (BALL VALVE) CREATES INCREASED AIR VOLUME.
• NEVER LEAVE MATERIAL IN THE ANFO POTS OVERNIGHT. THE CONDENSATION

AND HUMIDITY MAY LEAD TO PLUGGING PROBLEMS.
• NEVER LEAVE THE POTS PRESSURIZED BETWEEN LOADING CYCLES. DOING SO

MAY LEAD TO POSSIBLE PLUGGING PROBLEMS
• WHENEVER ANY HOSING, FITTINGS, OR CONNECTIONS OF SMALLER SIZES ARE

USED, THIS WILL LIKELY NECESSITATE THE RE-ADJUSTMENT OF THE AIR
SETTINGS. THIS IS DUE TO THE POSSIBLE RESTRICTION CREATED BY THE
SMALLER DIAMETER.
• ALWAYS EMPTY ANY MATERIAL FROM POTS PRIOR TO ENTERING

MAINTENANCE SHOP FOR WELDING OR REPAIRS.
• NEVER MOVE THE BOOM FROM THE DECK WITHOUT THE STABILIZERS
LOWERED AND THE FRAMS AS LEVEL AS POSSIBLE.
05/29/08
MANUAL DE OPERACIÓN E INSPECCION
PARA EL CAMION GETMAN CARGADOR DE M1006
EXPLOSIVOS A-64 Pag. 1 de 19
CORPORACION GETMAN
MANTENIMIENTO
PARA
CARGADOR DE EXPLOSIVO
MODELO A-64
Lea cuidadosamente
el manual antes de operar el camiòn
*NOTA: LAS PLACAS EN LOS EQUIPOS PUEDEN DIFERIR EN LOS MANUALES. SIGA LAS Updated:
INTRODUCCIÓN RELACION DE MANUALES.
¡Los operadores deben estudiar y comprender todos Este manual describe el programa de operación y
los manuales cuidadosamente! mantenimiento de la pluma y sistema de cargado de
Usted debe familiarizarse con todos los controles y Explosivos cuando es instalada en un camión
procedimientos. El Manual del Camión Getman Getman A-64. Un manual para operadores del
Cargador de Explosivos Serie A-64, es una guía para Camión Getman A-64 es incluido en su manual de
asegurar apropiadamente la operación y refacciones y servicio específicamente para su
mantenimiento del mismo. Siempre mantenga el camión. Por favor lea y familiarícese con todos estos
manual en el camión. manuales.
Se incluye una lista completa de componentes del
Este Camión Cargador de Explosivos Getman Serie motor, y componentes de la transmisión, sistemas
A-64 ha sido comprado con la expectativa de que aplicables eléctricas/aire/hidráulicas, también
proveerá un servicio prolongado y confiable. En su pueden ser localizados en sus respectivos manuales
diseño y construcción, hemos tomado todas las de servicio, refacciones y esquemáticos. También
precauciones para asegurar que hemos logrado estas hemos provisto manuales para servicio y
expectativas. Sin embargo, para llevar a cabo la componentes principales tales como ejes,
medida completa de valuación y utilidad que transmisiones y motores.
Getman ha designado a este camión, una pequeña Todo ésto será localizado en los manuales de servi
cantidad de tiempo y costo debe ser invertido en el cio y refacciones para su camión o por otros medios.
cumplimiento de inspecciones y servicio tal y como
se recomienda en este manual. Esta pequeña Getman ha incrementado la frecuencia para algunos
inversión se retribuirá en bajos costos de operación, procedimientos de mantenimiento de los
mínimos costos de servicio y, lo más importante, en componentes recomendado por el fabricante. Debido
seguridad del personal. a la exigencia del medio ambiente y aplicaciones en
los cuales este camión debe operar.
TABLA DE CONTENIDOS….........PAGINA
Introducción.......................................................2 Si usted tiene algunas preguntas acerca del servicio y
Relación de Manuales...........................................2 operación de este camión, contacte inmediatamente
Características de diseño.…..………………….3 al representante local de Getman o directamente a la
Precauciones Generales de Seguridad..…......4-5 Corporación Getman.
Instrucción de Seguridad.………………….….6
Descripción General de la Pluma......................7
Operación de la Pluma y Gatos
Estabilizadores……………………………...8-9
Inspección Diaria y Antes de la Operación.…10
Sistema de Cargado de Explosivo……….11-12
Llenado de los Recipientes de Explosivos…..13
Control del Sistema de Explosivo……..…14-15
Ajustes Básicos del Sistema………..……16-19
Conceptos Clave para Recordar.…………….19
DESIGN FEATURES
CARACTERISTICAS DE DISEÑO
La Corporación Getman siempre ha tenido en mente un objetivo principal en los últimos 50 años. Este ha sido
proporcionar a nuestros clientes con productos lo más seguro y confiables en lo posible para impactar positivamente
su ciclo de producción y costo por tonelada.
Es por eso que, en 1963, la Corporación Getman fue el pionero y produjo el primer paquete independiente contenedor
con cargado de explosivo por medio de transporte. Haciendo esta la forma más rápida para acelerar el ciclo de
producción, esto fue secundario haciendo el método más seguro posible.
Aquí hay solo unas pocas características de diseño que hacen de su Camión Cargador de Explosivos Getman A-64 el
camión con el que usted puede contar en todo momento:
• La canastilla para el operador (disponible en varios tamaños) es nivelada de manera segura y gira en cada
dirección para siempre permitir estar perpendicular al tope de lugar de trabajo para asegurar el máximo alcance y
comodidad del operador.
• Un juego completo de controles de la pluma y canastilla se localizan en la canastilla lo mismo que en la base de la
pluma.
• Todos los cilindros están equipados con válvulas de contrabalance para prevenir un descenso sin control en caso
de una avería o daño en el sistema.
• La pluma, la canastilla, y estabilizadores han sido sometidos a un análisis completo de los componentes
terminados y son fabricados por soldadores certificados para asegurar máxima resistencia y seguridad.
• Los controles de la canastilla montada en la pluma son operados por piloto y pueden ser accionados por los
controles montados en la base de la pluma en caso de una emergencia.
• Los controles de la canastilla de cargado de explosivo están completamente protegidos para evitar una activación
accidental.
• Todas las conexiones del Cargador de Explosivos están hechas de material SS304 para mayor duración y
confiabilidad.
• Todos los tanques de presión (recipientes para explosivo) son certificados por el código AS1210, ASME sesión
VIII Div I UW 12. Diseñados para una presión de trabajo de 100 PSI (6.9 BAR).
• El camión está equipado con compartimentos para almacenar los detonantes, los cuales se ajustan (cumplen) a las
regulaciones de MSHA.
• Getman ofrece una selección de compresores montables en una variedad de formas y rangos en (CFM) pies
cúbicos por minuto y también ofrece un paquete electro/hidráulico de aire.
Estas son solo algunas de las características de diseño que hacen de su Cargador de Explosivos Getman el No. 1 con
cargador independiente de explosivo colocado en el mercado actualmente.
Por favor tome en cuenta que hay otras numerosas opciones desde compartimentos para operadores totalmente
cerrados, longitud de pluma, sistemas de seguridad enlazados, etc…
Las siguientes páginas son proporcionadas para permitirle a un nuevo operador entender y comprender el sistema de
suministro (cargado) de explosivo y como efectuar de la mejor manera las correcciones y ajustes para adecuarse a su
aplicación específica.
SIMBOLO DE ALERTA DE SEGURIDAD
Este símbolo aparecerá en varios puntos a través de este manual como

declaración de advertencia. Su aparición significa:
¡ATENCION! ¡MANTENGASE ALERTA! ¡SU SEGURIDAD ESTA DE POR MEDIO!
!
Este manual también usa los siguientes mensajes:
NOTICE (ATENCIÓN): Este mensaje es usado para información o instrucciones especiales, relacionadas con procedimientos,
equipo, herramientas y otros datos especiales.
IMPORTANT (IMPORTANTE): Este mensaje se utiliza cuando se deben tomar precauciones especiales para asegurar la
acción correcta y evitar daño o anomalías al equipo.
CAUTION (PRECAUCION): Este mensaje se utiliza como recordatorio de riesgo de seguridad el cual puede resultar con daño
o lesión al personal si no se toman las precauciones apropiadas.
WARNING (ADVERTENCIA): Este mensaje se utiliza cuando existe el riesgo que puede causar lesiones o muerte si no se
toman las precauciones necesarias.
DANGER (PELIGRO): Este mensaje se usa cuando existe un alto riesgo en el cual causará la muerte o lesiones graves si no se
toman las precauciones adecuadas.
REGLAS
Antes de realizar cualquier mantenimiento en el camión, revise las siguientes precauciones de seguridad. Estas son incluidas
para su protección y seguridad.
Siempre observe las siguientes reglas de seguridad durante la operación del camión. Siempre observe las reglas de seguridad
impuestas en el lugar de trabajo. La necesidad de reglas de seguridad adicionales para una operación segura pueden
presentarse debido a particulares aplicaciones de la mina. Estas reglas son solamente usadas como una guía.
• Lea y siga cuidadosamente todas las instrucciones descritas en los manuales del camión.
• Asegúrese que todos los instrumentos, indicadores y controles de operación estén funcionando.
• Nunca utilice los controles de operación como agarraderas para ayudarse a subir o salir del camión.
• Nunca se ponga de pie cuando el camión esté en movimiento.
• Nunca use ropa suelta u holgada cuando esté trabajando cerca de máquinas o equipo en movimiento.
• Nunca permita personal en los camiones que no estén designados para transportar personal “pasajeros”.
• Nunca se baje de un camión a menos que los frenos estén activados.
• Siempre baje los implementos de tierra y utilice los tacones de soporte en las llantas cuando el camión esté estacionado.
• Si se estaciona inevitablemente en una pendiente, coloque el camión dirigido hacia la tabla del cerro, aplique el freno de
estacionamiento, baje los implementos de tierra y utilice los soportes de tacones en las llantas.
• Evite fumar o prender fuego cerca de combustible.
• Siempre recuerde la localización del extintor de fuego más cercano.
• Compruebe la operación del circuito de frenos antes de iniciar cada turno.
• Nunca utilice un camión para realizar una actividad o aplicación para la cual no fue diseñado originalmente.
• Cuide de otras personas. Ellas pueden no estar cuidando de usted.
INSTRUCCIONES DE SEGURIDAD
ADVERTENCIA
¡El MEXAMON (ANFO) ES UN MATERIAL ALTAMENTE EXPLOSIVO!
Todas las regulaciones de seguridad deben de llevarse a cabo durante su uso y manejo. ¡Los procedimientos
de operación descritos en este manual son propuestos solamente para información general de seguridad!
Obtenga los procedimientos y prácticas de seguridad de su inspector de seguridad y del proveedor de
material explosivo.
Siempre use lentes y guantes de seguridad cuando esté operando o trabajando cerca al suministro de aire
comprimido, arena y productos explosivos.
Nunca desconecte una manguera o conexión con aire comprimido bajo presión.
ADVERTENCIA
RIESGOS DE ELECTRICIDAD ESTATICA.

USE SOLO LOS PROCEDIMIENTOS APROBADOS PARA CONECTAR A
TIERRA EL RECIPIENTE DE CARGA NEUMATICO. (AIRE COMPRIMIDO) Y
SOLAMENTE UTILICE LA TUBERIA SEMI-CONDUCTIVA (ANTIESTATICA)
APROBADA PARA CARGADO DE EXPLOSIVO.
DESCRIPCION GENERAL DE LA PLUMA PARA INYECCION DE EXPLOSIVO
La colocación de la pluma y torre con una canastilla unida al final de la pluma están conectadas a la parte posterior de
la estructura.
Esta pluma cuenta con tres secciones, exterior, medio e interior. La pluma puede oscilar 50º a la derecha o izquierda
del camión. La canastilla puede girar 45º a la derecha o izquierda de la pluma. Conforme la pluma es levantada, los
cilindros interconectados la mantienen nivelada. La potencia hidráulica, para accionar la pluma y canastilla, proviene
de una bomba accionada por el motor. Una bomba hidráulica accionada con aire es también una opción. El recipiente
para el Explosivo y los controles de aire están montados sobre el chasis. El carrete de conexión a tierra está montado
sobre el chasis del camión.
1. Parking Brake Control (Control de 7. Boom (Pluma). Los cilindros exterior, medio e
estacionamiento). Empuje para aplicarlo, jale para interior. Usados para extender y retraer la plataforma
liberarlo. durante la posición de la canastilla.
2. Accesory Control (Control de accesorios). Jale 8. Interconnecting Cilindres (Cilindros

para activarlo, empuje para desactivarlo. interconectados).Usados para mantener nive lada la
canastilla conforme la pluma sube y baja.
3. Stabilizers (Estabilizadores). Usados para
nivelar el camión. No los use para ganar altura extra. 9. Air Compressor and Controls (Compresor de aire
y controles). Usados para mover el material explosivo.
4. Stabilizer Control (Control de estabilizadores).
Usados para extender y retraer los estabilizadores. 10. ANFFO Vessel (Recipiente para el Explosivo).
Contenedor de material Explosivo.
5. Basket (Canastilla). Es una plataforma de trabajo
para subir y bajar al operador. 11. Grounding Reel (Carrete de conexión a tierra).
Conecta la estructura (chasis) a tierra.
6. Controls (Controles). Los controles hidráulicos
son usados para realizar todas las funciones de la 12. Engine Start/Stop (Botón para arrancar y parar
pluma. Incluyendo subir, bajar, extender, retraer, el motor). Accesorio para arrancar y parar el motor
girar e inclinar la canastilla. desde la canastilla (opcional).
OPERACIÓN DE LA PLUMA Y ESTABILIZADORES
Estacione el camión Cargador de Explosivo en

superficie plana y nivelada como sea posible.
Aplique el freno de estacionamiento. Jale la

“te”manualmente a la posición de accesorios para
activar el circuito hidráulico de la pluma y
estabilizadores.
¡ATENCION!
¡La dirección está inactiva!
Para operar la pluma y la canastilla desde el piso
utilice los controles que están montados en el
camión localizados en la base de la pluma. Para
moverlas desde la canastilla utilice los controles
montados sobre la misma.
FUNCIONES DE LA PALANCA
1. (Swing) Oscila la pluma izquierda o derecha.
Extienda todos los gatos estabilizadores en una 2. (Extensión) Extiende la pluma adentro o fuera.
superficie sólida antes de levantar la pluma de la 3. (Lift) Se eleva la pluma arriba o abajo.
plataforma. 4. (Basket Tilt) Canastilla se inclina arriba o abajo.
5. (Rotate) La canastilla gira a la izquierda o derecha
Conecte el cable de tierra. Use los procedimientos de (opcional).
conexión a tierra aprobados.
ADVERTENCIA
OBSTRUCCIONES EN LO ALTO O
POR ENCIMA DE LA PLUMA.
Asegúrese que tiene suficiente espacio en la parte
Conecte el camión al suministro de aire alta donde trabajará la canastilla y pluma. Si hace
comprimido de la mina. Si el camión va a ser caso omiso de cumplir esta regla puede causar serias
operado utilizando la potencia del motor, lesiones al personal o al equipo.
ponga el motor en las R.P.M. apropiadas.
OPERACIÓN DE LA PLUMA Y ESTABILIZADORES (CONT.)
Use los controles de la pluma y canastilla para colocarse

en la posición deseada, en vez de esforzarse por alcanzar
la posición que quiere.
La operación de las plumas que utilizan el aire de la

mina para activar los componentes hidráulicos
pueden operar las funciones de la pluma y canastilla
desde la misma con solo activar la válvula de aire ADVERTENCIA
montada en la canastilla para arrancar y parar la No se siente o pare sobre las soleras o viguetas de la
bomba hidráulica accionada con aire. canastilla ni permita que otras personas lo hagan.
Las plumas que utilizan el motor diesel para activar

el sistema hidráulico puede activar las funciones de
la pluma y canastilla desde la misma activando el
botón Start/stop montado en la canastilla para Cuando el trabajo se ha terminado coloque el camión en
arrancar y parar el motor diesel desde la misma. posición de viajar, realizando lo siguiente:
1. Retraiga la pluma.
2. Baje la canastilla a la posición sobre la
plataforma.
3. Retraiga totalmente los estabilizadores.
4. Recoja y guarde el cable de tierra.
5. Desconecte el aire comprimido de la mina.
6. Libere el aire comprimido de los recipientes para
explosivo.
El camión ya está listo para moverse o transportarse.
Asegúrese que las mangueras estén colocadas donde

no sean dañadas al mover la pluma.
INSPECCION DIARIA Y ANTES DE LA OPERACIÓN
ADVERTENCIA
Presión de aire en el recipiente
Antes de realizar cualquier trabajo en el recipiente o
dejar inactivo el camión, descargue toda la presión
de los recipientes. Si omite esta regla de seguridad
causará serias lesiones.
IMPORTANTE
Siempre cerciórese que el camión está en “posición
de servicio” antes de realizar un mantenimiento o
servicio.
Inspección Diaria
1. Inspeccione cuidadosamente los recipientes y los
accesorios y verifique si no tienen desgaste debido al
uso y la acción corrosiva del material explosivo. Si
los recipientes necesitan reparación o muestran
signos de daño en la estructura del recipiente, ¡retire
y ponga fuera de servicio la unidad inmediatamente!
2. Revise dentro del recipiente por si contiene
materiales tales como papel, alambre, o trozos de
madera que pudieran haber caído dentro del tanque.
3. Inspeccione el piso de la canastilla. Debe estar en
buen estado y libre de obstáculos.
4. Cheque la estructura de la canastilla y el acceso a
la misma debe estar en su lugar y en buen estado.
5. Baje los gatos estabilizadores, deben extenderse y 10. Quite todos los desperdicios que están sobre el
retraerse suavemente, asegúrese que cada uno tiene camión, lave el camión con agua y aplique aire para
su placa de soporte. secarlo.
6. Utilizando los controles en la base de la pluma
levante la pluma hasta la elevación máxima y luego NOTA: REPORTE CUALQUIER CONDICION O
bájela. Vigile que no existan mangueras dobladas o FALLA INUSUAL AL DEPARTAMENTO DE
vueltas muy forzadas. MANTENIMIEN- TO. COLOQUELE UNA
7. Vigile el despliegue y doblez de las mangueras TARJETA INDICANDO QUE ESTA FUERA DE
para asegurar que no estén dobladas ni tener vueltas SERVICIO.
muy forzadas.
8. Cheque el recorrido de las mangueras para
asegurarse que no hay indicación de fugas,
cortaduras u objetos que impidan el recorrido.
9. Levante, baje y gire la canastilla a través de su
rango total de movimiento. Asegúrese que las
mangueras estén libres y su movimiento es suave.
SISTEMA DE CARGADO DE EXPLOSIVOS
464841- 1060 LBS (480kg)
465342- 1270 LBS (576kg)
464863- 1900 LBS (861kg)
464864- 2120 LBS (961kg) 6
DELIVERY ELBOW (7)

2
1. Vibrator (Vibrador): Mantiene el explosivo en movimiento. Se activa “solamente” cuando el sistema de suministro (supply)
y el elevador de potencia de aire (boost) están activados.
2. Anfo Supply Valve (Válvula de Suministro de Explosivo): Cuando se aplica aire para “abrir”, permite que el explosivo
fluya hacia la canastilla.
3. Boost Air Valve (Válvula Elevadora de Potencia de Aire): Se abre cuando la válvula de suministro de explosivo (Anfo
Supply Valve) es abierta envía aire al codo que se encuentra en la base del tanque para crear un efecto de (venturi) e
impulsar el material hacia la canastilla. El vibrador (Vibrator) es activado al mismo tiempo.
4. Hose Clean Out Valve (Válvula de la Manguera Limpiadora): Cuando se utiliza con la Válvula de Suministro (Supply
Valve) cerrada, esto permite que la manguera de llenado esté vacía. Cuando es usada con la Válvula de Suministro de
Explosivo (Anfo Supply Valve), abierta, puede suministrar aire adicional para los barrenos ascendentes o verticales.
5. Regulated Air (Aire Regulado): Este aire en el Recipiente de Explosivo es el aire más importante que es normalmente
regulado aproximadamente a 60 PSI a través de una válvula reguladora. Este aire empuja hacia abajo en la parte superior del
material para asegurar un flujo constante hacia abajo del recipiente. Puede ser ajustada para colocarla a los requerimientos del
operador.
6. Pilot Air (Aire Piloto): Este aire es regulado aprox. 70 PSI. Y proporciona el suministro de aire a las válvulas relevadoras,
vibradores, válvulas de control en la canastilla, y a la válvula de suministro de explosivo. (Jamesbury).
7. Stainless Steel Delivery Elbow (Codo de Suministro o Alimentador): Este codo está montado con bridas utilizando
tornillos de acero inoxidable y pueden ser desmontados rápidamente si es necesario remover algún tapón u obstáculo.
SISTEMA DE CARGADO DE EXPLOSIVOS (CONT.)
• BOOST AIR BALL VALVE (VALVULA DE GLOBO PARA EL ELEVADOR DE POTENCIA DE AIRE)
(2): Esta válvula de globo puede ser usada para incrementar, reducir o parar el “volumen” de aire utilizado para
empujar el material hacia la canastilla.
• CLEAN OUT BALL VALVE (VALVULA DE GLOBO PARA LIMPIAR O SOPLETEAR) (2): Esta
válvula puede ser usada para incrementar, reducir o parar el “volumen” de aire utilizado para soplar o empujar el
material fuera de la manguera o limpiar el barreno.
• SAFETY RELIEF VALVE (VALVULA DE ALIVIO DE SEGURIDAD) (2): Esta válvula de alivio (regulada
a 120 PSI) es utilizada como un medio de seguridad en caso de que la presión de aire en los recipientes
incremente por encima de 120 PSI.
• ANFO POT BALL VALVE (VALVULA DE GLOBO PARA EL RECIPIENTE DE EXPLOSIVO) (2):
Esta válvula puede ser usada para incrementar, reducir o suspender “volumen” de aire que está suministrándose a
los tanques.
• ANFO POT PRESSURE REGULATING VALVE (VALVULA REGULADORA DE PRESION DEL
RECIPIENTE DE EXPLOSIVO) (2): Esta válvula reguladora puede ser usada para incrementar o reducir la
“presión” de aire que se esté suministrando a los tanques.
• PILOT AIR REGULATING & LUBE (70 PSI) (VALVULA PILOTO REGULADORA DE AIRE Y
LUBRICANTE): Esta válvula de ajuste regulado puede ser usada para incrementar o disminuir la “presión” que
está siendo suministrada a los controles y válvulas relevadoras y también la lubricación.
AIR PRESSURE GAUGES (MANOMETROS DE PRESION PARA EL AIRE) (4): Usted localizará un total
de cuatro manómetros de presión en el sistema cargador de explosivo. Como se muestra arriba, uno para el
suministro principal de aire, sea aire de mina o de un compresor. Otros dos son para medir la presión de aire
regulada para cada uno de los recipientes y uno para el control piloto de presión regulada.
CARGADO DE MATERIAL DENTRO DE LOS TANQUES PARA EXPLOSIVO
464841- 1060 LBS (480kg)
465342- 1270 LBS (576kg)
464863- 1900 LBS (861kg)
464864- 2120 LBS (961kg)
El acero inoxidable del o los tanques para explosivo instalados en su camión Getman están equipados con una tapa en la parte
superior abierta del tanque para evitar que caiga agua, desperdicios u objetos dentro del tanque. Esta tapa solamente deberá
abrirse cuando el recipiente esté totalmente despresurizado, esto se lleva a cabo abriendo la válvula de drenaje del tanque
liberando el aire al exterior. Una vez que el recipiente es llenado, la tapa deberá ser cerrada y colocar el cerrojo de seguridad antes
de que el recipiente sea presurizado de nuevo.
Localizada por debajo de la tapa, se encuentra una rejilla de acero inoxidable. La rejilla es utilizada para detener cualquier objeto
extraño que pudiera caer a través del recipiente inadvertidamente. Esta también ayuda a quebrar trozos grandes de explosivo en
tamaños uniformes. No remueva la rejilla. Le proporcionará la confianza de que no pase material que pudiera bloquear el sistema
y le brinda seguridad al personal mientras esté cargando el recipiente con material.
Hay una tapa con sello de hule dentro del recipiente debajo de la rejilla, esta tapa automáticamente se eleva y sella el recipiente
cuando el aire a presión es aplicado al recipiente. El recipiente nunca debe llenarse a un punto sobre la base de la tapa, ya que esto
puede evitar que la tapa selle apropiadamente.
La capacidad normal de llenado podría ser aproximadamente ¾ a 7/8 de la capacidad.
Un “carrete para conexión a tierra” es provisto en cada camión cargador de explosivo fabricado por Getman. El cable del carrete
deberá ser colocado a tierra cada vez que se estén llenando los recipientes con explosivo y/o cuando se estén cargando los
barrenos con explosivo.
CONTROL DEL SISTEMA CARGADOR DE EXPLOSIVO
Los controles para operación del sistema cargador de explosivos son completamente activados por aire. El múltiple
(tres conexiones) está localizado entre los recipientes en el sistema que consta de dos recipientes en el centro de la
plataforma detrás de la pluma. También está localizado en la misma área en un sistema con un solo recipiente. Esta
localización fue elegida para proporcionar máxima protección por caída de roca o cualquier otro objeto mientras se
esté proporcionando un fácil acceso por acondicionamiento que realice el operador.
Este Cargador de Explosivos ha sido cuidadosamente diseñado para crear un sistema de suministro el cual funcionará
adecuadamente en casi cualquier aplicación con material de varios proveedores. Varias actualizaciones y mejoras han
sido realizadas a través de los años para asegurar un cargado apropiado que pueda siempre ser aprovechado para una
máxima productividad. La clave para un cargado efectivo y con éxito será la habilidad del operador para determinar
los ajustes necesarios para colocar apropiadamente el material en su aplicación específica.
Este manual puede no ser capaz de proporcionar a uno y todos los operadores con los ajustes precisos que pueden ser
requeridos para el mejor suministro de material en cada aplicación. Mediante el seguimiento de las sencillas
instrucciones enlistadas en este manual, usted puede ser capaz de tener el sistema de suministro ajustado a su
operación particular en cuestión de horas.
Mundialmente, existen varios proveedores de material explosivo. Este permite tener muchas diferencias en textura,
peso y conformidad. Algunos fabricantes de material suministran un producto muy seco y ligero y otros son muy
pesados y pegajosos. Debido a esto el por qué la importancia de encontrar los ajustes de presión y volumen de aire
correcto para cada aplicación.
Una vez que el operador ha utilizado este sistema por algún tiempo y ha determinado cuales correcciones se ajustan
mejor a su necesidad y aplicación, ajustes posteriores raramente son requeridos
Aquí le mencionamos algunos conceptos erróneos que frecuentemente se ejecutan al tratar de encontrar los ajustes
perfectos:
Si uso el volumen máximo de aire, obtendré la cantidad máxima de explosivo.

Mientras esto suena lógico, todos sabemos que el objetivo cuando estamos cargando un barreno es colocar el material
rápidamente y bien compactado dentro del barreno. Algunas veces cuando se utiliza demasiada potencia en el
volumen del aire, la relación de aire/material es demasiado alto. Esto significa más aire y menos explosivo recorre
hacia abajo de las líneas a la manguera de abastecimiento. Esto significa mayores periodos para el cargado y menos
productividad.
Mantendré la presión máxima del aire que va a la parte superior del recipiente de explosivo para empujar más
material.
De nuevo suena muy lógico, pero no siempre es práctico. El recipiente está en forma de cono con una salida de 4”. El
propósito real de la presión de aire en la parte superior del recipiente es para ayudar al material que viaje hacia la
salida en el fondo del recipiente. Dependiendo del factor de humedad del material en el recipiente, una presión de aire
muy alta tratará de compactar el material y apretarlo demasiado dentro de la salida y tienda a taponearse. El “venturi”
elevador de potencia de aire localizado en el codo de salida del recipiente es verdaderamente el que “empuja o
mueve” el material a la canastilla. La presión en el recipiente es para asegurar que el material pueda llegar a la salida
de una manera consistente.
CONTROL DEL SISTEMA CARGADOR DE EXPLOSIVOS (CONT.)

CONTROLES DE LA CANASTILLA
SUMINISTRO DE AIRE
BASKET CONTROLS (CONTROLES DE LA CANASTILLA):

Hay dos válvulas de 2 posiciones de control manual en la canastilla, lo cual permite al operador controlar el sistema
de suministro de explosivo. Estas vienen fuerte y convenientemente montadas en
La barandilla de la canastilla. Hay un cinturón el cual es un accesorio disponible opcional que le permite al operador
la capacidad de tener los controles montados remotamente con ellos.
• CLEAN OUT CONTROL VALVE (VALVULA DE CONTROL DE LIMPIEZA O BARRIDO): Esta
válvula de control cuando es movida a la posición (ON) manda el aire piloto para abrir la válvula relevadora
localizada abajo de la válvula de suministro de explosivo (Jamesbury). Una vez que la válvula es activada, la
presión máxima será enviada a través de la manguera de suministro o “cargado” a una proporción gobernada por
el ajuste de la “válvula de limpieza o barrido”. Esta puede ser utilizada para purgar el material que se deposite en
la manguera de suministro y/o sopletear el agua o ensolve dentro del barreno antes del cargado del explosivo.
• ANFO SUPPLY CONTROL VALVE (VALVULA DE CONTROL DE SUMINISTRO DE
EXPLOSIVO): Esta válvula de control cuando es movida a la posición (ON) manda el aire piloto para efectuar
tres funciones separadas pero relacionadas No. 1 Abre la válvula de suministro de explosivo “anfo supply valve”
localizada entre el codo en la salida del recipiente de explosivo y el adaptador/reductor donde la manguera de
suministro a la canastilla comienza. Esto permite que el material se mueva dentro de la manguera de suministro.
No. 2 Abre la válvula relevadora de potencia de aire “boost air relay valve” la cual entonces permite un flujo
regulado de aire para impulsar o mover el material hacia abajo a la manguera de suministro en la canastilla. No. 3
Activa el vibrador “vibrator” montado en el tanque para crear una vibración para ayudar al material en el
depósito a moverse libremente dentro del codo de salida. Regresando la válvula de control a la posición “OFF”
cerrará la válvula alimentadora de explosivo, se cierra la potencia de aire colocado en el codo de salida y detiene
el vibrador.
SISTEMA BASICO DE AJUSTES Y OPERACIONES
Una vez que coloque el camión en posición de trabajo, aplique el freno de estacionamiento. Al mismo
tiempo el operador deberá jalar la “te” de la válvula repartidora localizada al lado derecho del asiento del
operador. Esta válvula tiene una etiqueta marcada con el nombre “Steering/Accessories”. Esta inhabilita la
dirección, evita que se libere el freno de estacionamiento y dirige aceite a la parte trasera del camión para
activar los gatos hidráulicos, funciones de la pluma y al compresor de aire hidráulico. Ahora el operador
deberá dirigirse a la parte trasera del lado del operador del camión y con válvula repartidora colocada
correctamente en la posición “JACKS”, los gatos estabilizadores pueden ser bajados hasta que el camión
esté soportado y nivelado lo mejor posible. El motor puede ser apagado, dependiendo de la configuración
del camión enlistado abajo. No utilice los gatos estabilizadores para obtener altura extra. Trate de estacionar
el camión con las estructuras frontal y trasera alineadas lo más recto posible.
Controles de los gatos estabilizadores
Si el camión fue comprado equipado para operar el sistema de cargado de explosivo utilizando para este
propósito el aire de la mina, debe haber una conexión para el aire localizada en cada lado del camión. Así
puede conectar el aire de la mina del lado que más le convenga. Por favor asegúrese de soplar la manguera
antes de conectarla a la conexión del camión para asegurar que la manguera esté libre de agua y/u otros
objetos. Una vez que la válvula del aire de la mina sea abierta, usted puede abrir la válvula de globo
localizada inmediatamente después de la conexión para el aire de la mina. Esta repartirá el aire a la conexión
de “tres salidas” para alimentar los recipientes y controles, el aire para accionar la bomba hidráulica que
activa la pluma y las funciones de los estabilizadores, y el alternador activado mediante el aire el cual hace
funcionar todas las luces de trabajo. Los interruptores de control de luces están localizados en el tablero de
instrumentos en el compartimento del operador. La válvula de globo localizada antes del alternador
accionado por aire deberá ser “abierta” para activar el alternador.
SISTEMA BASICO DE AJUSTES Y OPERACIONES (CONT.)
Cada situación de cargado es diferente. Por lo tanto, los ajustes del sistema de control son diferentes
también. Con este sistema puede controlar ambos, el volumen que va a ser suministrado y la velocidad o
fuerza con la cual ese material esté siendo suministrado. La clave de las cosas para mantener en mente son:
• Para cambiar la “cantidad” de explosivo que va a ser suministrado, los cambios deben ser hechos
a la presión regulada del recipiente.
• Para cambiar la “velocidad o fuerza” del material que está siendo suministrado, se deben hacer
cambios a la válvula de globo del elevador de potencia del aire “boost air ball valve” (Incrementa o
disminuye el volumen).
Los dos ajustes del sistema mencionados arriba son unos de los más importantes que el operador puede
realizar para ser capaz de ajustar el sistema a su satisfacción. La clave es lograr el balance correcto entre los
dos. Demasiado incremento de volumen puede causar sacudidas fuertes en el tubo de suministro y
fluctuaciones esporádicas de aire. Demasiada presión en el recipiente puede causar atascamientos
intermitentes de material. Se debe encontrar el balance correcto para la aplicación. Una vez que el balance
es encontrado ajustes posteriores serán mínimos y rápidamente hechos. Mucho de esto depende del material
utilizado, la aplicación, las condiciones y las preferencias del operador. Básicamente, todo funcionará mejor
para usted.
Para determinar que es lo mejor para usted, debe aceptar este sistema con una mente abierta. No debe
suponer que los mismos ajustes como los de un camión más antiguo con un sistema diferente será lo
correcto para este nuevo. Muchos de los sistemas más antiguos tienen muy pocos ajustes disponibles para
éstos.
Getman ha trabajado cerca de muchos clientes por varios años en varios países para desarrollar un sistema
de cargado o suministro que fue lo suficiente ajustable para adaptarse a las diferencias de material y
diferentes aplicaciones.
Durante estos años hemos descubierto que el mejor y más rápido método para determinar cuales ajustes son
los mejores para su aplicación es iniciar lentamente con mínimas presiones y luego desarrollarse a partir de
ahí. Generalmente dentro de la primera hora de trabajo, usted estará cerca de sus ajustes deseados.
POR FAVOR PRUEBE EL METODO SIGUIENTE.
SISTEMA BASICO DE AJUSTES Y OPERACIONES (CONT.)
Según páginas anteriores, este camión puede ser fabricado con un sistema cargador de explosivo utilizando el aire de
la mina, un sistema cargador de explosivo con un compresor de aire adaptado en el camión, o una combinación de
ambos. Sin tomar en cuenta el sistema que usted haya elegido, una vez que usted tenga el suministro de aire para su
sistema, los ajustes del sistema llegan a ser uno de los más críticos componentes para lograr el éxito de la operación.
Una vez que haya colocado el camión en la posición requerida, baje los gatos estabilizadores, y conecte el cable del
carrete a tierra, Getman le sugiere que inicie con los siguientes ajustes:
• Ajuste la válvula reguladora de presión en el recipiente de explosivo hasta que el manómetro en el recipiente de
explosivo indique aproximadamente 25 PSI.
• Ajuste la válvula de globo para limpieza o barrido aproximadamente a la mitad (1/2) en la posición abierta.
• Ajuste la válvula de globo del elevador de potencia de aire aproximadamente a la mitad (1/2) en la posición
abierta.
Porque siempre habrá un pequeño retraso después de cerrar la válvula de suministro de explosivo después de cargar
un barreno, le recomendamos coloque una tira de cinta o marca en la manguera del cargador de explosivo
aproximadamente a 10-12” a la distancia que usted quiera que el flujo de material se suspenda en este barreno en
particular. Esto es hecho para que usted pueda sentir y ver cuando la cinta o marca sale del barreno y cierre el sistema
de suministro del material y todavía llene el barreno a la profundidad deseada.
• Ahora coloque la manguera o “cargador” de explosivo dentro del barreno que va a ser llenado y jale para abrir la
válvula de control de barrido o limpieza “clean out control valve” en la canastilla. Esto abrirá la “válvula reguladora
de limpieza o barrido” “clean out relay valve” y enviará aire solamente a través de la manguera o cargador para
expulsar cualquier objeto o agua que se encuentre dentro del barreno. Asegúrese que su cara y cuerpo estén colocados
a un lado del barreno para evitar que el aire expulsado lo dañe. Si el flujo de retorno es demasiado fuerte, cierre su
válvula de limpieza o barrido ligeramente para reducir el volumen de aire que está siendo suministrado.
• Una vez que el barreno ha sido sopleteado, es el momento de llenar el barreno con el material explosivo. Jale para
abrir la válvula de control de suministro de explosivo “ANFO delivery control valve” que está colocada en la
canastilla. Esta abrirá la válvula de suministro de material, active el vibrador del tanque y abra la válvula elevadora de
potencia de aire. Debido a que el ajuste de presión en el recipiente es baja y la válvula elevadora de potencia de aire
está abierta a la mitad “1/2” y podría ser fácilmente controlada. Esto será lento, pero le permitirá “familiarizarse” con
el sistema. Usted notará que cuando empieza a cargar un barreno, el “cargador o manguera de cargado” empezará a
empujar por sí mismo hacia fuera del barreno. Usted deberá mantener sus manos sujetas sin presión alrededor de la
manguera, de tal manera que pueda continuar a tiempo con el material que está fluyendo en el sistema.
Una vez que tiene confianza en el cargado o llenado, usted puede incrementar el flujo de material que está siendo
suministrado, incrementando en el recipiente la presión del regulador aproximadamente a 35 PSI. Desde el momento
que esté suministrando más material, deberá sentir que la manguera o cargador será empujado hacia atrás más rápido
que antes y el barreno será llenado más rápidamente. Una vez que vea la tira de cinta o marca, cierre la válvula de
control de suministro de explosivo.
SISTEMA BASICO DE AJUSTES Y OPERACIÓN (CONT.)
Ahora incrementaremos la velocidad abriendo la válvula de potencia de aire. Ahora notará que es un poco difícil
sostener la “manguera rígida de cargado” porque tiene más potencia de aire. De nuevo el barreno será llenado más
rápido. Dependiendo del tipo de material que se esté utilizando y los requerimientos de fragmentación, una velocidad
“fuerza” adecuada puede ser crítica para alojar apropiadamente el material en el barreno.
Continúe con el ajuste de presión y volumen hasta que el sistema esté funcionando a su satisfacción.
Los métodos mencionados arriba serán básicamente los mismos para el cargado de cualquier tipo de barrenos. La
clave siempre va a ser “llegar a los ajustes donde éstos trabajen mejor para usted”.
CONCEPTOS CLAVE PARA RECORDAR
• MAS PRESION EN EL RECIPIENTE DE EXPLOSIVOS NORMALMENTE CREA MAS

VOLUMEN Y FLUJO DEL MATERIAL.
NOTA: DEMASIADA PRESION EN EL RECIPIENTE DE EXPLOSIVO PUEDE OCASIONAR
ATASCAMIENTO DEL MATERIAL. LA EXPERIENCIA DEL CLIENTE HA INDICADO QUE 60
PSI ES GENERALMENTE EL AJUSTE OPTIMO PARA LA PRESION REGULADA EN EL
RECIPIENTE DE EXPLOSIVO.
• INCREMENTAR LA POTENCIA DE AIRE EN LA “VALVULA DE GLOBO” CREA UN

INCREMENTO EN LA VELOCIDAD DEL MATERIAL SUMINISTRADO.
• AUMENTANDO LA POTENCIA DE LA VALVULA DE BARRIDO O LIMPIEZA SE

INCREMENTA EL VOLUMEN DE AIRE.
• NUNCA DEJE MATERIAL EN EL RECIPIENTE DE EXPLOSIVO DE UN DIA PARA OTRO

O DURANTE LA NOCHE. LA CONDENSACION Y LA HUMEDAD PUEDEN OCASIONAR
PROBLEMAS DE TAPONEAMIENTO.
• NUNCA DEJE LOS TANQUES PRESURIZADOS “CON PRESION DE AIRE” ENTRE LOS
CICLOS DE CARGADO. SI HACE ESTO PUEDE OCASIONAR POSIBLES PROBLEMAS DE
TAPONEAMIENTO DEL MATERIAL.
• DE VEZ EN CUANDO ALGUNA MANGUERA, ADAAPTADORES, O CONEXIONES DE

MENOR TAMAÑO SON UTILIZADOS, ESTOS PROBABLEMENTE NECESITEN SER
REAJUSTADOS A LOS AJUSTES DE AIRE. ESTO ES DEBIDO A LA POSIBLE
RESTRICCION CREADA POR EL TAMAÑO REDUCIDO.
• SIEMPRE VACIE CUALQUIER MATERIAL DE LOS RECIPIENTES ANTES DE LLEVARSE

AL TALLER DE MENTENIMIENTO PARA SOLDAR O REPARACION.
• NUNCA MUEVA LA PLUMA DE LA PLATAFORMA SIN BAJAR ANTES LOS GATOS

ESTABILIZADORES Y LAS ESTRUCTURAS NIVELADAS LO MÁS POSIBLE.
GETMAN BOOM MAJOR M1004
INSPECTION Page 1 of 11
Suggestions and Procedure for the Inspection of a Getman Boom
The following procedure should be used when inspecting a boom for reliability and safety after a period of 6000
hours or 5 year of use. This procedure involves the complete removal and disassembly of the boom, in order to
properly evaluate its condition. This inspection is highly detailed. During the regular 50 hour maintenance
checks, some parts (wear pads) may have required replacement prior to this “Major Inspection.
The information and suggestions found here are presented in a general matter. In order to find information
specific to the truck, consult the truck manual, or contact Getman Service.
Hydraulic System
Before completely breaking down the boom assembly, it is important to evaluate the current working condition of the boom
before the replacement of parts or other components. Therefore the following information should be recorded.
_____ BASKET WEIGHT TESTED AT 150% OF RATED CAPACITY __________LBS

_____ BOOM CONTROLS (OPERATE BOOM TO FULL RANGE)
AT 100% RATED CAPACITY _______ LBS _____ RECORD PRESSURES WITH 100% RATED
CAPACITY IN BASKET Boom Up Pressure ________________ Boom Down Pressure
_________________ Boom Up Time ________________ Boom Down Time _________________
Boom Ext. Pressure ________________ Boom Ret. Pressure _________________ Boom Ext. Time
________________ Boom Ret. Time _________________ Boom Rotate CW Pressure
________________ Boom Rotate CCW Pressure _________________ Boom Rotate CW Time
________________ Boom Rotate CCW Time _________________ Basket Rotate CW Pressure
________________ Basket Rotate CCW Pressure_________________ Basket Rotate CW Time
________________ Basket Rotate CCW Time _________________ Basket Up Pressure
________________ Basket Down Pressure _________________ Basket Up Time ________________
Basket Down Time _________________
If any of the functions seem excessively slow, or have a lack of power, some of the hydraulic components may
need to be replaced.
During operation and after break down the hydraulic system must be evaluated for the following points.
1. Cylinders
a. Check for leaks.
b. Check for proper extension and retraction speeds.
c. Check correspondence between tags and operation.
d. Check for slop or excessive movement in the rod.
2. Control Valves
a. Check for leaks.
b. Check for proper operation.
c. Check correspondence between tags and operation.
d. Check for damage or excessive corrosion to the component itself.
Updated:
05/02/07
3. Other Components and Hoses
a. Check for leaks.
b. Check for proper operation.
c. Check routing of hoses.
d. Check for damage or excessive corrosion to the component itself.
Depending on the condition of the components and hoses, it may be wise or necessary to replace some of the
components and all of the hoses. It may also be a good opportunity to rebuild the cylinders.
Pins and Bushings
Throughout a Getman boom there are many different Pins and Bushings, it is imperative that all of them are
inspected properly in order to insure the safety and correct operation of the boom. See Figure 1 for general
location of boom pins.
1. Pins
a. Check pins for steps, grooves, or excessive wear. The pin should not be able to move up or
down in the bushing.
b. Have the pins tested for cracks using a Magnetic Particle test, or other nondestructive testing
method.
c. Replace bolts that hold pins in position.
d. Check bolt holes for worn threads or excessive slop.
2. Bushings
a. Replace all Removable Bushings.
b. Check welded bushings for excessive pin movement. The pin should not be able to move in
any direction perpendicular to the bore.
Wear Pads
When performing a detailed inspection of the Getman boom, involving the complete tear down of the assembly,
it is recommended that all the boom wear pads and their mounting bolts be replaced. The parts are relatively
inexpensive, and it is easy to do with the boom disassembled. See Figure 1 for general location of the wear
pads. See Figure 2 for Wear Pad Replacement Procedure.
Replacement of these wear pads should remove any excessive sag or movement in the boom, and will help
return it to proper working condition.
Weldments
A typical Getman Boom is composed of a turret, outer boom weldment, middle boom weldment, inner boom
weldment and basket. (See Figure 1) These weldments should all be inspected in depth for cracks, corrosion,
wear, and damage. Any components exhibiting these characteristics should be replaced, or properly repaired.
For example, the inner surfaces of the boom tubes may have been gouged from lack of wear pad maintenance.
Updated:
05/02/07
Final Inspection
After the boom has been properly serviced and reassembled the boom should be inspected again for proper
operation of hydraulic components. The boom should be tested with 150% of rated weight, for proper range of
motion and operation. With proper care and attention to these guidelines the Getman boom should be ready for
safe use once again, however in some instances a boom may be beyond economical repair, and should be
removed from further use. If any questions or concerns arise during the inspection please feel free to contact
Getman for further assistance.
Updated:
05/02/07
Updated:
05/02/07
Anfo Loader Boom Wear Pad Replacement Procedure
The wear pads on an Anfo Loader boom will eventually wear thin.
If these pads are not replaced damage to the boom can occur,
resulting in costly repair. Like the brake pads on an automobile
once the pads have worn down to the level of the screws holding it
on, its time for replacement. In order to reduce the risk of damage,
the pads should be inspected every 200 hrs.
This step by step procedure will allow you to disassemble the

boom, and replace all of the wear pads. The numbers used to
describe the different parts of the boom can be referenced to the
assembly drawing of the boom at the end of this manual.
Depending on the exact type of Getman boom being serviced,
there may be small differences in parts or service procedure. The
owner manual for the truck will have specific Getman part
numbers for the boom being serviced. This procedure has been
written for a wide range of Getman booms.
Preparation
9 Insure that the truck is parked on a level surface
9 Disconnect power at main battery disconnect switch
9 Properly place wheel chocks so that the truck won’t roll
Outer Slide Pads and Wear Pads

Both the outer boom (#10) and the middle boom (#25) have a slide
pad (#22) on the bottom end, and a set of side wear pads (#24).
The slide pad is attached to the bottom of the boom using a pin
that is bolted in place (#20 & #28). By putting the weight of the
boom on the basket, pressure will be relieved from the bottom
slide pads and they can be removed and serviced. The slide pads
have wear pads (#21) that can be replaced when needed. The side
wear pads (#23) can also be replaced as needed. Two bolts hold on
the side wear pads, when removed the wear pads can be unbolted
from the plate and replaced. The replacement of the wear pads on
the outside of the boom is fairly simple, and will extend the life of
the boom. Failure to replace these pads before they are over worn
can result in extreme damage to the main boom assembly. The
screws that hold on the wear pads can cut deep grooves in the
boom components causing the boom to weaken.
Updated:
05/02/07
Anfo Loader Boom Wear Pad Replacement Procedure Continued
Wear Pad Shims
When removing wear pads, shims will be present. These shims are
installed in the factory assembly process. The purpose of these
shims is to center the middle boom in the outer boom, or to center
the inner boom in the middle boom. They also keep the boom from
slopping around in the wrong direction. If the factory shims are in
good shape they should be marked for their location and put back
in the same position with the new wear pad. If the shims are badly
damaged, then the boom will have to be shimmed again with the
new wear pads in order to center the boom. The boom must be
checked for free movement. If the wear pads are too tight it will
result in slow or no movement of the boom. Wear pads and wear
pad bolts should be coated with seize proof coating before being
reassembled.
Inner Wear Pad Replacement

Both the middle boom and the inner boom have four wear pads on
the end of them. The wear pads on the middle boom run on the
inside of the outer boom, and the wear pads on the inner boom run
on the inside of the middle boom. In order to replace these pads
the boom must be taken apart. Depending on the shop
environment, this can be an easy or fairly difficult task. The use of
an overhead crane can make the job simple.
To change out the wear pads, the inner boom and the middle boom
have to be removed from the outer boom. The outer boom can be
left attached to the truck, and the other booms can just be pulled
out of it. The basket on the end of the boom does not necessarily
have to be removed from the inner boom, but it may make the job
easier.
To start, all the hydraulic pilot control hoses connected to

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

the pin connecting the basket to the boom, and the pin connecting
the hydraulic cylinder to the boom.
Updated:
05/02/07
Anfo Loader Boom Wear Pad Replacement Procedure Continued
The hydraulic cylinders that extend and retract the boom are bolted
to the inside of the middle boom. The ends of the cylinders are
connected to the front of the outer boom, and the end of the inner
boom. The pins that connect the cylinder ends to the boom must be
unbolted and removed in order to pull out the inner and middle
boom.
Once the cylinders have been freed from the boom assembly, the
inner and middle booms can be removed from the outer boom
together. In order to do this the slider pad and the side wear pads
on the outer boom must first be removed. Using a crane our
whatever is available, the basket end of the inner boom should be
supported and pulled out, along with the middle boom, from the
outer boom. It may be necessary to tie the middle boom and the
inner boom together in order to pull them out together. At this time
the wear pads on the middle boom should be visible.
Placing the boom on a set of horses, or a table makes it easy to

work on the two halves and replace the wear pads. In order to
separate the inner boom from the middle boom, the bottom slider
pad, and the side wear pads must be removed from the middle
boom. This will allow the inner boom to be removed from the
middle boom, and the wear pads on the inner boom become
accessible.
Once the pads have been replaced on both the inner boom, and the
middle boom, the booms can be carefully put back together.
Sometimes the crane may have to be used in order to pull the two
booms together, especially with new wear pads. The boom will fit
tightly at first, but will eventually wear and return to normal
smooth operation.
Signs Leading to Wear Pad Replacement

9 Excessive boom sag at full extension
9 Excessive bounce when moving boom
9 Unusual scraping sounds when extending or retracting

boom
Updated:
05/02/07
Extra Pictures
Updated:
05/02/07
Updated:
05/02/07
ITEM DESCRIPTION QTY.
BOOM ASSEMBLY 1
1 PIN (LEVELING CYLINDER) 2
2 CYLINDER (LEVELING) 1
3 TURRET 1
4 PIN (LIFT CYLINDER) 1
5 BUSHING (TURRET) 2
6 BOLT 8
7 BOLT 20
8 COVER 1
9 KEEPER 1
10 OUTER BOOM 1
11 LIFT CYLINDER 1
12 PIN (TURRET) 1
13 PIN (EXTENSION CYLINDER) 1
14 TRUNNION 2
15 ALLEN HEAD 2
16 PIN RETAINER 1
17 ALLEN HEAD (FLAT) 24
NUT 24
18 EXTENSION CYLINDER ASSEMBLY 1
19 PIN (LIFT CYLINDER) 1
20 PIN (SLIDE PAD) 1
21 WEAR PAD 12
SHIM A/R
22 SLIDE PAD 2
23 WEAR PAD 4
SHIM A/R
24 PAD ASSEMBLY 4
25 MIDDLE BOOM 1
26 INNER BOOM 1
27 ALLEN HEAD (FLAT) 8
NUT 8
28 PIN (SLIDE PAD) 1
Updated:
05/02/07
29 PIN (LEVELING CYLINDER) 1
30 PIN (EXTENSION CYLINDER) 1
31 PIN (BASKET) (REF.) 1
32 BUSHING 2
33 ROTATOR 1
34 BOLT 3
35 WASHER 3
36 CYLINDER (LEVELING) 1
37 PIN (LEVELING) 3
38 LEVELING LINK 1
39 LEVELING LINK 1
40 BASKET 1
Updated:
05/02/07
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
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:
01/17/08
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
COOLANT/ ANTIFREEZE (Ethylene- Glycol Base)
Mobile Delvac (50/50) CAT EC-1
Updated:
01/17/08
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
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
2. CHASSIS
10368 SIGHT GAUGE

10376 FILL CAP (FUEL OIL)
10398 FILL CAP (HYDRAULIC OIL)
10448 HOLD DOWN FASTENERS
17142 SEAT ASSEMBLY
13942 STEERING (PINS, BEARINGS, BUSHINGS)
12043 ARTICULATION INSTALLATION
17165 LINCOLN LUBE SYSTEM 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
17142
SEAT ASSEMBLY
Page 1 of 2

03/21/08
17142
SEAT ASSEMBLY
Page 2 of 2

424398 SEAT ASSEMBLY 1
1 424398-01 BACK COVER ONLY (SMOOTH BLACK PVC VINYL) 1
2 424398-02 BACK FOAM 1
3 424398-03 BOTTOM COVER ONLY (SMOOTH BLACK PVC VINYL) 1
4 424398-04 BOTTOM FOAM 1
5 424398-05 FRAME, SIDE CONTROLS 1
6 424398-06 FRAME, FRONT CONTROLS 1
7 424398-07 RECLINER CABLE, METAL END FITTINGS 1
8 424398-08 HEIGHT RISER, FRONT CONTROLS A/R
424398-09 HEIGHT RISER, SIDE CONTROLS A/R
9 424398-10 LATCH KIT WITH FRONT CONTROLS A/R
424398-11 HANDLE KIT FOR FRONT CONTROLS A/R
10 424398-12 LATCH KIT WITH SIDE CONTROLS A/R
424398-13 HANDLE KIT FOR SIDE CONTROLS A/R
11 424398-14 SUSPENSION COVER 1
12 424398-15 DAMPER KIT 1
13 424398-16 WEIGHT ADJUSTER KIT 1
14 424398-17 SUSPENSION (INCLUDES DAMPER ONLY) 1
15 424398-18 SLIDERRAIL KIT 1
16* 424279 SEATBELT 1

03/21/08
STEERING (PINS, BEARINGS, 13942
BUSHINGS) Page 1 of 1

1 26409-01 BEARING (IN CYLINDER TUBE END) 2
2 524202 BUSHING (STEERING EAR) 8
3 13796-01 PIN (STEERING CYLINDER) 4
4 SEE SECTION 8 STEERING CYLINDER 2
5 524203 BUSHING (STEERING CYLINDER) 2
Updated:
10/17/07
12043
ARTICULATION JOINT
Page 1 of 3
Updated:
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
ANFO TRUCK LINCOLN LUBE 17165
SYSTEM INSTALLATION Page 1 of 2

1 595135 LINCOLN QUICK LUBE, OUTLET 2
595140 LINCOLN QUICK LUBE, FERRULE 2
(ENGINE END STEERING CYL PINS GREASE POINTS)
2 595141 LINCOLN QUICK LUBE, CLOSURE PLUG 12
595142 LINCOLN QUICK LUBE, GASKET 12
(CRADLE PINS GREASE POINTS)
(REAR FRAME STEERING CYL PINS GREASE POINTS)
(ARTICULATION PINS GREASE POINTS)
(BOOM LEVEL CYL PINS ROD END GREASE POINTS)
(BOOM LEVEL CYL PINS PISTON END GREASE POINTS)

06/06/08
ANFO TRUCK LINCOLN LUBE 17165
SYSTEM INSTALLATION Page 2 of 2
(BOOM LIFT CYL PINS)
(BOOM TURRET ROTATION PIN)
(BASKET ROTATION PIN)
11 595131 LINCOLN QUICK LUBE, 12V PUMP A/R
595132 LINCOLN QUICK LUBE, 12V TIMER A/R
595255 LINCOLN QUICK LUBE, 24V PUMP (INCLUDES TIMER) A/R
NOTE: ON TIME SETTING: 1 FOR 2 MINUTES

OFF TIME SETTING: 1 FOR 1 HOUR

06/06/08
MANUAL INDEX
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
3. ELECTRICAL SYSTEM AND INSTRUMENTS
30304 WIRING DIAGRAM

17144 INSTRUMENT PANEL
13918 ALTERNATOR
17144
INSTRUMENT PANEL
Page 1 of 2
465313-200

03/06/08
17144
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 2012) 1
* 44140 ENGINE OIL SENDER (DEUTZ 1013, 2012) 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, 2012) 1
* 44167 ENGINE TEMP SENDER (DEUTZ 1013, 2012) 1
3 124396 VOLTMETER GAUGE 24V 1
124395 VOLTMETER GAUGE 12V 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 (OPTIONAL) 1
15 44119 GLOWPLUG PREHEAT INDICATOR (OPTIONAL) 1
16 124313 WARNING BUZZER 1
17 124380 START SWITCH 1
18 124501 TOGGLE LIGHT SWITCH 2
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

03/06/08
13918
ALTERNATOR
Page 1 of 1

1 44260 ALTERNATOR (DEUTZ 2012 12V/140A) 1
2* 44252 ALTERNATOR BELT 1

12/07/07
MANUAL INDEX
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
4. ENGINE AND ACCESSORIES
F1011 DEUTZ WARRANTY STATEMENT

F1012 DEUTZ EMISSION WARRANTIES
S1056 ENGINE OPERATION & MAINTENANCE MANUAL
S1057 ENGINE PARTS MANUAL
13715 ENGINE FILTERS
13755 RADIATOR INSTALLATION
13753 AIR INTAKE & EXHAUST SYSTEM
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
F1012
F1012
F1012
F1012
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
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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
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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¿
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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˘¤˜
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‰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
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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

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
13755
RADIATOR INSTALLATION
Page 1 of 2

04/04/08
13755
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) 1
12 12350-01 CHARGE AIR TUBE (LH) 1
15 605726 TUBE (COOLANT) 1
16* 1185-09 WASHER (MOUNTING) 8
17* 123091 DRAINCOCK 1
18* 84229 PRESSURE CAP 1
19* 10592-07 FLANGE (ADAPTER) 1
20* 465271 FAN (BLOWER) 1
22* 534606 SIGHT GAUGE 1
23* 18483-01 TANK (SURGE) 1
24* 12457-05 TUBE, SURGE TANK (OPTIONAL) 1

04/04/08
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
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
5. DRIVE TRAIN
17055 TRANSMISSION
16922 TRANSMISSION MOUNTS
S1036 TRANSMISSION MAINTENANCE & SERVICE
MANUAL
13675 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
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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
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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
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NEUTRAL 3rd {P,C1P;,'JED SOLE\GOSAliD ,POOLS)

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S1036
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Operation of Ihe transmission S1036
6.3.2 Forward 1st speed and high range selected
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T20000 TRANSMISSION· HYDRAULIC DIAGRAM
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S1036
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S1036
6.3.3 Forward 2nd speed and high range selected
-!--- 1ST
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HIGH RANGE
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T20000 TRANSMISSION· HYDRAULIC DIAGRAM OPERATOR COMPARTMENT
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S1036
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S1036
6.3.4 Forward 3rd speed and high range selected
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T20000 TRANSMiSSiON" HYDRAULIC DIAGRAM OPERATOR COMPARTMENT
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S1036
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6.3.5 Reverse 1st speed and high range selected
REVERS Elsi ,PC','iCRRO,','1

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moDo TRANSMISSION· HYDRAULIC DIAGRAM I
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REVERSE AND 1ST CLUTCH ENGAGED
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S1036
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6.3.6 Forward 1st speed and low range selected
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S1036
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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
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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
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, I
34
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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
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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\
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/
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
'-:;;:~\\\,
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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
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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
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1
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; 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)
/ :-~"~:-_::?'~~: , ~,
,} ::.:~. '..:..~;
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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. ~.

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/ 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)
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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
, "
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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
';-
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-------
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
,
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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
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7 23
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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
13675
DRIVELINE INSTALLATION
Page 1 of 1

1 11827-01 END YOKE 1
2 244565 FLANGE YOKE 1
3 244565 FLANGE YOKE 1
4 11827-01 END YOKE 1
5 364024 CROSS AND BEARING KIT 5
6 19201-39 DRIVELINE ASSEMBLY 2
7 362120 CENTER BEARING 2
8 364023 CROSS AND BEARING KIT 1
9 464640 SLIP ASSEMBLY 1
10 19200-14 DRIVELINE ASSEMBLY 1
Updated:
02/08/07
MANUAL INDEX
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
6. AXLE
10829 AXLE ORIENTATION

13335 AXLE ASSEMBLY
13332 CRADLE INSTALLATION
S1037 AXLE SERVICE & REPAIR MANUAL
13158 BRAKE ACTUATOR
S1023 ACTUATOR INSTALLATION
10481 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
10481
TIRE & RIM
Page 1 of 1

1 11905-02 RIM ASSEMBLY (INCLUDES ITEM 2) 1
2 NSS LOCK RING 1
3 480002 TIRE 1
4* 272410 LUG NUT 8
5* 56405 URETHANE FILL (OPTIONAL) A/R

07/10/07
S1007
S1007
S1007
S1007
S1007
S1007
S1007
S1007
S1007
MANUAL INDEX
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
7. BRAKE SYSTEM

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

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

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

1 534607 ACCUMULATOR ASSEMBLY 1
2* 534608 MOUNTING BRACKET 1

12/11/06
MANUAL INDEX
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
8. HYDRAULIC SYSTEM

S1077 HYDRAULIC SYMBOLS
17132 SERVICEJUNIOR DIGITAL PRESSURE GAUGE
13259 FILTER (HYDRAULIC)
12860 STEERING ORBITROL
S1024 STEERING ORBITROL SERVICE
16384 MOTOR (ROTATION GEAR BOX)
S1010 PUMP SERVICE
12504 REMOTE CONTROL BOOM VALVE (IN BASKET)
12505 BOOM CONTROL VALVE (ON BOOM)
13282 JACK CONTROL VALVE
13970 BOOM LEVELING CYLINDER
13629 BOOM LIFT CYLINDER
13628 BASKET LEVELING CYLINDER
13627 STABILIZER CYLINDER
13943 STEER CYLINDER
HYDRAULIC SYMBOLS
S1077
Lines Hydraulic Pumps Miscellaneous Units
Line, Working (Main)

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

Hydraulic
Pneumatic
Filter, Strainer
Motors and Cylinders

Lines Crossing
Pressure Switch
Hydraulic
Fixed Displacement Pressure Indicator

Lines Joining
Variable Displacement Temperature Indicator

Lines With Fixed
Restriction
Cylinder, Single-Acting Component Enclosure

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

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

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

HYDRAULIC SYMBOLS
S1077
Color Code for Fluid

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

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

- Non-Compensated
Green Drain
Flow Control, Adjustable
(Temperature and Blank Inactive
pressure compensated)
Two-Position
Two Connection
Two-Position
Three Connection
Two-Position
Four Connection
Three-Position
Four Connection
Two-Position
In Transition
Valves Capable of Infinite

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

17132
Getman Corporation
ServiceJunior
Getman P/N 468005
The NEWServiceJunior
Digital Pressure Gauge
• 50 Times Faster than Previous Model
• 10 msec Scanning Rate
• Measure PSI, bar, mPa, and
kPa with One Gauge
• +1- 0.5% Full Scale Accuracy
• Simple Operation
• Peak and Hold Function with
Bar Graph Display
17132
Getman’s ServiceJunior
The new Getman Service Junior captures
momentary pressure spikes that are
"invisible" to normal liquid-filled gauges.
That means the maximum pressure
reading it delivers can be trusted
as a much truer reflection of the
system's actual condition; so you
can identify potential problems
better and diagnose their causes
faster. All readings are accurate
to within +/-0.5%.
ServiceJunior Features
• Easy to connect and test system pressure • Accuracy +/- 0.5% of full scale
using Parker Diagnostic test port couplings • Three pressure ranges
• Robust, dirt resistant housing • Operating temperature 14° to 122° F
• Simple to operate, four key menu • Fluid temperature -4° to 176° F
• Four digit backlit display with easy to read • Storage temperature -4° to 140° F
large 0.60" characters • Auto power off after 15 minutes or
• Minimum and maximum graphic display constant on" at the touch of a button
shows pressure peak • Zero adjustment function
• Power status displayed continuously • 10 msec scanning rate
• Can be used with most hydraulic and • Ratings:
pneumatic media Environmental Protection: EN60529 (IP 65)
• Measure PSI, bar, mPa, kPa with one gauge Vibration: IFC 60068-2-6/10 — 500Hz: 20g
Shock: IEC 60068-2-29/50g 11 msec
Measuring Overload
Resolution
Range Pressure
0 to 5800 PSI
(0 to 400 bar) 11,600 PSI 1 PSI
NOTES: 1. PD Couplers rated to 6,000 PSI max. 2. EMA3 Couplers rated to 9,000 PSI max.
Getman Corporation provides the

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

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

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

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

534214 MOTOR ASSEMBLY 1
54041 SEAL KIT (INCLUDES ITEMS 2, 4-6, 11, 13, 18) 1
1 54021 CAP SCREW 4
2 NSS EXCLUSION SEAL 1
3 54033 FLANGE (2 BOLT) 1
4 NSS SHAFT PRESSURE SEAL 1
5 NSS RING BACK-UP 1
6 NSS SEAL 1
7 54028 BEARING RACE 1
8 54029 BEARING THRUST NEEDLE 1
9 54024 SHAFT OUTPUT 1
10 54037 HOUSING 1
11 NSS O-RING 1
12 54036 PLUG 1
13 NSS SEAL 3
14 54044 DRIVE 1
15 54022 SPACER PLATE 1
16 54045 GEROTOR SET 1
17 54027 END, CAP 1
18 NSS SEAL WASHER 7
19 174029 CAP SCREW 7
Updated:
12/18/06
S1010
S1010
S1010
S1010
REMOTE HYDRAULIC VALVE 12504
ORIENTATION Page 1 of 5
Updated:
08/22/07
Updated:
08/22/07

56425 REMOTE HYDRAULIC VALVE 5 SECTION 1
(INCLUDES ITEMS 10x OF A, 1x OF B, 10x OF C)
A 534545 REMOTE VALVE SECTION (INCLUDES ITEMS 1-19) 1
B 534546 REMOTE VALVE SECTION (INCLUDES ITEMS 1-19) 1
C 534547 O-RING (VALVE SECTION) (TWO PER SECTION) 1
1 SPOOL ASSEMBLY (REFER TO PAGE 4) 1
2 NSS SPRING 2
3 NSS PLATE (BOTTOM) 1
4 NSS PLATE (TOP) 1
5 NSS BUTTON 2
6 534319 ARM (ROCKER) 1
7 NSS NUT (JAM) 2
8 534328 BOOT 1
9 534410 KNOB 1
10 534330 SEAL (O-RING) 1
11 534329 HANDLE ASSEMBLY (ROD) (INCLUDES ITEMS 7, 9) 1
12 NSS PIN (ROCKER) 1
13 NSS RING (RETAINER) 2
14 NSS NUT (JAM) 2
15 NSS PLATE (BOOT) 1
16 NSS SCREW (HSHC) 4
17 PLUNGER ASSEMBLY (REFER TO PAGE 5)
18 NSS PLUG 1
19 NSS HOUSING 1
Updated:
08/22/07

534322 SERVICE KIT (INCLUDES ITEMS 1-5) 1
1 NSS RING (RETAINING) 3
2 NSS RETAINING (SPRING) 1
3 NSS SPRING 1
4 NSS SHIM A/R
5 NSS SPOOL 1
Updated:
08/22/07

534450 SEAL KIT (INCLUDES ITEMS 1, 2) 1
1 NSS SEAL (O-RING) 1
2 NSS SEAL (U-CUP) 1
3 NSS GUIDE 1
4 NSS PIN 1
5 NSS RING 1
6 NSS RACE (FEEL) 1
Updated:
08/22/07
BOOM CONTROL VALVE 12505
Updated:
12/18/06

56424 BOOM CONTROL VALVE (5 SECTION) 1
1 FOR SERVICE ON SPOOL POSITIONER END 1
(REFER TO PAGE 6)
2 FOR SERVICE ON CYLINDER PORT RELIEF 1
(REFER TO PAGE 4)
2A FOR SERVICE ON LOAD CHECK PLUG 1
(REFER TO PAGE 5)
3 FOR SERVICE ON SPOOL CLEVIS END WITH HANDLE 1
OVERRIDE (REFER TO PAGE 7)
4 NSS RETAINER 1
5 NSS WASHER (BACK-UP) 2
7 NSS HOUSING 2
8 NSS SPOOL 1
9 FOR SERVICE ON MAIN RELIEF VALVE 1
(REFER TO PAGE 3)
10 595112 STUD KIT (TORQUE TO 32 FT LBS/ 43.5NM) 1
Updated:
12/18/06

534494 SEAL KIT (INCLUDES ITEMS 1-5) 1
2 NSS RING (BACK-UP) 1
6 NSS PISTON 1
7 NSS CAP 1
8 NSS NUT 1
9 NSS STEM 1
10 NSS NUT 1
11 NSS POPPET 1
12 NSS SPRING 1
13 NSS BODY 1
Updated:
12/18/06

534700 PORT RELIEF 1000 PSI (INCLUDES ITEMS 1-14) 1
534701 PORT RELIEF 1500 PSI (INCLUDES ITEMS 1-14) 1
534500 SERVICE KIT (INCLUDES ITEMS 10, 11) 1
1 NSS SHIM A/R
2 NSS SPRING A/R
8 NSS CAP 1
9 NSS BODY 1
10 NSS POPPET 1
11 NSS RING 1
12 NSS CHECK 1
13 NSS SPRING 1
14 NSS SLEEVE 1
Updated:
12/18/06

1 NSS PLUG 1
7 NSS POPPET 1
8 NSS SPRING 1
Updated:
12/18/06

1 NSS WASHER (LOCK) 4
2 NSS SPRING 1
3 NSS SPRING 1
4 NSS BONNET 1
5 534503 SEAL (SQUARE - CUT) 1
6 NSS COLLAR 1
7 NSS SLEEVE 1
8 NSS PLATE 4
10 NSS WASHER 1
11 NSS SPUD 1
Updated:
12/18/06

1 534410 KNOB 1
2 534413 ROD 1
3 NSS NUT 1
4 NSS ADAPTOR 1
5 534417 PIN (DOWEL) 1
8 534414 RETAINER (SEAL) 1
9 534420 GUIDE 1
10 NSS WASHER 4
12 NSS BONNET 1
13 534419 BOOT 1
14 NSS SEAL (SQUARE-CUT) 1
17 NSS SEAL (SPECIAL) 1
Updated:
12/18/06
CONTROL VALVE 13282
Updated:
12/18/06
CONTROL VALVE 13282

534731 BOOM CONTROL VALVE (3 SECTION) 1
1 SPOOL POSITIONER END (REFER TO PAGE 5) 1
2 LOAD CHECK PLUG (REFER TO PAGE 4) 1
3 SPOOL CLEVIS END WITH HANDLE OVERRIDE 1
(REFER TO PAGE 6)
4 NSS RETAINER 2
7 NSS HOUSING 1
8 NSS SPOOL 1
9 MAIN RELIEF (REFER TO PAGE 3) 1
10 595154 STUD KIT 1
Updated:
12/18/06
CONTROL VALVE 13282

534135 RELIEF VALVE 1
2 NSS RING (BACK-UP) 1
6 NSS PISTON 1
7 NSS CAP 1
8 NSS NUT 1
9 NSS STEM 1
10 NSS NUT 1
11 NSS POPPET 1
12 NSS SPRING 1
13 NSS BODY 1
Updated:
12/18/06
CONTROL VALVE 13282

1 NSS PLUG 1
7 NSS POPPET 1
8 NSS SPRING 1
Updated:
12/18/06
CONTROL VALVE 13282

2 NSS SPRING 1
3 NSS SPRING 1
4 NSS BONNET 1
5 534503 SEAL (SQUARE - CUT) 1
6 NSS COLLAR 1
7 NSS SLEEVE 1
8 NSS PLATE 4
10 NSS WASHER 1
11 NSS SPUD 1
Updated:
12/18/06
CONTROL VALVE 13282

1 534410 KNOB 1
2 534413 ROD 1
3 NSS NUT 1
4 NSS ADAPTOR 1
5 534417 PIN (DOWEL) 1
8 534414 RETAINER (SEAL) 1
9 534420 GUIDE 1
10 NSS WASHER 4
12 NSS BONNET 1
13 534419 BOOT 1
14 NSS SEAL (SQUARE-CUT) 1
17 NSS SEAL (SPECIAL) 1
Updated:
12/18/06
13970
BOOM LEVELING CYLINDER
Page 1 of 1

465407 CYLINDER ASSEMBLY 1
465121-08 SEAL KIT 1
1 465407-01 BARREL ASSEMBLY 1
2 465407-02 ROD ASSEMBLY 1
3 465407-03 PISTON ASSEMBLY 1
4 465407-04 ROD BEARING ASSEMBLY 1
5 465407-05 NUT 1
6 465407-06 CAP SCREW 1
7 465407-07 GREASE FITTING 2
Updated:
12/19/06
13629
BOOM LIFT CYLINDER
Page 1 of 1

2 465134-02 ROD 1
5 465134-05 NUT 1
6 465134-06 SELF TAPPING SCREW (LOCK) 1
7 465134-07 LOAD CHECK VALVE 1
8 465134-08 SEAL KIT 1
Updated:
12/18/06
13648
EXTENSION CYLINDER
Page 1 of 1

2 465133-02 ROD 1
5 465133-05 STROKE LIMITER ASSEMBLY 1
6 465133-06 TRANSFER TUBE ASSEMBLY 1
7 465133-07 O-RING 1
8 465133-08 BACK-UP RING 2
9 465133-09 O-RING 1
10 465133-10 BACK-UP RING 2
11 465133-11 SELF TAPPING SCREW 1
12 465133-12 SET SCREW 1
13 465133-13 NYLON PLUG 1
14 465134-07 COUNTER BALANCE VALVE 1
15* 465133-15 SEAL KIT 1
16 465166-16 PISTON END 1

09/19/07
13647
EXTENSION CYLINDER
Page 1 of 1

2 465132-02 ROD 1
5 465132-05 NUT 1
6 465132-06 CAP SCREW 1
7 465132-07 STROKE LIMITER ASSEMBLY 1
8 465132-08 SEAL KIT 1
Updated:
12/18/06
13628
BASKET LEVELING CYLINDER
Page 1 of 1

2 465121-02 ROD 1
5 465121-05 NUT 1
7 465121-07 COUNTER BALANCE VALVE 2
8 465121-08 SEAL KIT 1
Updated:
12/18/06
13627
STABILIZER CYLINDER
Page 1 of 1

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

465411-07 SEAL KIT 1
2 465411-02 ROD ASSEMBLY 1
5 465411-05 NUT 1
6 465411-06 CAP SCREW 1
Updated:
12/11/06
MANUAL INDEX
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
08-01-08
9. CONTROLS
13905 ELECTRIC SHIFTER

10827 STEERING WHEEL & COLUMN
13025 THROTTLE (HYDRAULIC)
13331 HAND THROTTLE LINKAGE (HYDRAULIC)
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
13331
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 29486-06 PEDAL MOUNT 1
8* 604026 RESERVOIR (THROTTLE) 1
9* 133021 BALL JOINT (ON ENGINE) 1
10* 32140 RETURN SPRING 1
11* 10241-01 THROTTLE CYLINDER MOUNT (ON LUCAS INJECTOR) 1
10241-02 THROTTLE CYLINDER MOUNT (ON BOSCH INJECTOR) 1
12* 10241-03 THROTTLE CYLINDER ROD 1

08/10/07
16976
RESERVOIR
Page 1 of 1

604026 RESERVOIR ASSEMBLY 1
1 534226 CAP (INCLUDES DIAPHRAGM) 1
Updated:
03/27/07
MANUAL INDEX
2-500 ANFO CHARGER
FRANCISCO I MADERO
S/N 7026
07-24-08
10. MOUNTED EQUIPMENT
S1011 FIRE EXTINGUISHER #10

S1012 FIRE PROTECTION INFORMATION MANUAL
S1013 FIRE SUPPRESSION MAINTENANCE MANUAL
S1014 AUTO FIRE SUPPRESSION MAINTENANCE MANUAL
23276 FIRE SUPPRESSION INSTALLATION
16721 FIRE SUPPRESSION SYSTEM
13283 AUTO DETECTION SYSTEM
13597 BASKET DOOR INSTALLATION
16714 BOOM DOOR INSTALLATION
16572 TURRET INSTALLATION
M1005 ROTATION GEAR REMOVAL & INSTALLATION
16256 ROTATION GEAR BOX
15174 ANFO PIPING SCHEMATIC (WITH AIR BOOST
CLEAN OUT)
15175 ANFO PIPING SCHEMATIC (POT) SINGLE DELIVERY
13712 ANFO ACTUATOR
S1027 ACTUATOR SERVICE MANUAL
14053 BASKET ROTATOR
S1033 ROTATOR ACTUATOR MAINTENANCE MANUAL
13651 OUTRIGGER INSTALLATION
13390 COMPRESSOR DRIVE AND MOUNT
S1062 AIR COMPRESSOR INSTRUCTION BOOK
S1094 LINCOLN AUTO GREASE LUBE MANUAL
S1011
S1012
Vehicle Fire Protection

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

S1012
Inspection and Maintenance Record

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

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

S1013
A-101-10/20/30, LT-A-101-10/20/30
VEHICLE SYSTEMS
Installation, Recharge, Inspection, and Maintenance Manual
003898
S1013
This manual is intended for use with the ANSUL A-101 Vehicle
Fire Suppression System.
Those who install, operate, recharge, inspect, or maintain these
fire suppression systems should read this entire manual. Specific
sections will be of particular interest depending upon one’s
responsibilities.
Design, installation, recharge, and maintenance of the system
must conform to the limitations detailed in this manual and per-
formed by an individual who attended an ANSUL training program
and became trained to design, install, recharge, and maintain the
ANSUL system(s).
Fire suppression systems are mechanical devices. They need
periodic care to provide maximum assurance that they will oper-
ate effectively and safely. Inspection frequency shall be per-
formed monthly, or sooner, depending on operating and/or envi-
ronmental conditions. Maintenance shall be performed semi-
annually or sooner, depending on operating and/or environmental
conditions.
This ANSUL systems manual is limited to uses herein described.
For other applications, contact your local ANSUL distributor,
Domestic District Manager, International Area Manager, or Ansul
Incorporated – Technical Services Department, Marinette,
Wisconsin 54143-2542.
ANSUL and CHECKFIRE are trademarks of Ansul Incorporated or its affiliates.
NOTICE: Some sections have been removed by Getman as they do not

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

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

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

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

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

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

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

53080 FORAY Multi-Purpose Dry Chemical 45 lb. Pail
16511 Fill Cap Spanner Wrench (Low Profile)
428363 Bursting Disc Package (Includes: 15 Bursting Disc
Assemblies, Part No. 428271)
75382 Cartridge Scale and Hook Assembly (LT-A-101-30)
3923 Cartridge Scale and Hook Assembly
197 Lead Wire Seal
15496 Bursting Disc Union Assembly
24327 A-101 Installation, Recharge, Inspection and
Maintenance Manual
53081 Owner’s Manual
S1014
006052
CHECKFIRE SC-N ELECTRIC

®
DETECTION & ACTUATION SYSTEM

Installation, Recharge, Inspection, and Maintenance Manual
S1014
This manual is intended for use with the CHECKFIRE® SC-N

Electric Detection and Actuation System.
Those who install, operate, inspect, or maintain this system
should read this entire manual. Specific sections will be of par-
ticular interest depending upon one’s responsibilities.
As with all electro-mechanical equipment, the electric detection
and actuation system needs periodic care to provide maximum
assurance that it will operate effectively and safely. Inspection fre-
quency shall be performed monthly, or sooner, depending on
operating and/or environmental conditions. Maintenance shall be
performed semi-annually, or sooner, depending on operating
and/or environmental conditions.
The application and use of the CHECKFIRE SC-N system is lim-
ited to the application and uses described in this manual. For
other applications, contact your local ANSUL distributor or the
ANSUL technical representative in your area.
ANSUL and CHECKFIRE are trademarks of Ansul Incorporated or its affiliates.
NOTICE: Some sections have been removed by Getman as they do not

apply to your application needs. Any questions please call Getman
Corporation directly.
S1014
SECTION PAGES SECTION PAGES
SAFETY PRECAUTIONS 1 IN CASE OF FIRE 26
TOTAL SYSTEM DESCRIPTION 2–3 RECHARGE 27
SYSTEM COMPONENTS 3–7 INSPECTION AND MAINTENANCE 28 – 29

Control Module 3 Daily Inspections 28
Manual/Automatic Actuator 3 Maintenance 28 – 29
LT-10-R Cartridge 3
Mounting Brackets 4 TROUBLESHOOTING 30 – 33
Splicing Device 4 Diagnostics 30
Linear Detection Wire 4 History Buffer 30
Thermal Spot Detector 4 Troubleshooting Table 31 – 33
Pneumatic/Linear Detector 5
Triple IR (IR3) Flame Detector 5–6 APPENDIX 39 – 41
Squib 6 Component Index 39 – 40
Squib Cable 6 Detection Wire Fluid Resistance Capability 41
Battery 6
End of Line Resistor 6
Check Valve 7
Remote High Level Alarm 7
Release Circuit Test Module 7
USER INTERFACE 8 – 10
Field Terminations 8
Front Panel Indicators 9
Power Connections 10
Front Panel Buttons 10
Battery Replacement 10
Enclosure 10
Cover Removal 10
Strain Relief Installation 10
Mounting 10
S1014
SAFETY PRECAUTIONS
9-1-98 Page 1
SAFETY PRECAUTIONS
For the protection of personnel and equipment being installed, this
manual contains WARNING and CAUTION statements which are
listed in the steps which they apply. These warnings and cautions
are also listed here so that the manual user can become familiar
with them before performing any procedures.
! WARNING
In case of fire, evacuate area to lessen the risk of injury from

flames, heat, hazardous vapors, explosions, or other hazards
that may be created.
! WARNING
The squib is an explosive device. Do not attach connector until

squib is installed in actuator body. If the squib is actuated out-
side of the actuator body, possible personal injury could result.
! CAUTION
Manual pneumatic actuation will result in immediate system

discharge which may obscure vision. Make certain vehicle is
stopped safely before manually actuating the system. Manual
actuation will bypass all auxiliary shutdown and alarm
functions.
! CAUTION
The fire suppression system could be accidentally actuated

causing the release of agent if the squib or nitrogen cartridge
is installed before the appropriate installation step is reached.
! CAUTION
The control module could be damaged and the fire suppres-

sion system may not operate if the squib spring (shunt) is not
removed before installing the squib connector.
! CAUTION
The fire suppression system will discharge dry chemical if the

cartridge is installed when operating the strike button. Do not
install cartridge unless puncture pin is fully retracted with ring
pin inserted and visual inspection seal installed.
! CAUTION
Discharged lithium batteries may contain significant amounts

of unused energy and should be handled with care. Do not
compact for disposal. Before disposal, each battery must be
fully discharged and electrically isolated by enclosing in a plas-
tic bag and sealing the bag. Do not dispose of in fire. Check
applicable solid waste disposal regulations for proper disposal
of more than one battery.
S1014
TOTAL SYSTEM DESCRIPTION

7-1-03 Page 2
REV. 2
TOTAL SYSTEM DESCRIPTION The control module can be used as a self contained system, pow-
The complete CHECKFIRE SC-N system is composed of compo- ered by its own internal lithium battery. This allows the detection
nents which are combined to provide automatic fire detection and system to operate around-the-clock without use of external power.
actuation for equipment hazard areas. The electric detection and Optionally, external power can be connected to the control module
actuation system is designed for use only with ANSUL fire sup- with the internal power also connected, which results in a system
pression systems requiring pneumatic input as a means of actua- with battery back-up. When connected to an external 12/24 VDC
tion. In addition to the mechanical pneumatic means of operating supply with the internal battery also connected, the external power
the suppression system, the CHECKFIRE SC-N also provides an source becomes the primary supply, while the internal power
automatic and manual electric means to perform the same source is maintained in a stand-by mode of operation.
function. The control module may be installed where the ambient tempera-
The CHECKFIRE SC-N system is typically used with an ANSUL ture is between –40 °F to 140 °F (–40 °C to 60 °C).
A-101 Vehicle Fire Suppression system for 24-hour protection of The CHECKFIRE SC-N Detection and Actuation System is listed
equipment. The system is particularly suited for the protection of by FM Approvals.
equipment that is subjected to extreme environmental and physi-
cal conditions such as vehicles used in forestry, mining, agricul- Circuits
ture, construction, public transportation, public utilities, land fill, The first initiating circuit is the supervised detection circuit
and waste disposal. designed to be connected to linear (wire) and/or spot type thermal
Some of its features include linear (wire) and/or spot (thermal), detectors that provide a contact closure input to initiate a fire
flame detection, supervised circuitry, internally powered, detected condition. The second initiating circuit is designed to
adjustable shutdown and discharge time delays, auxiliary relays, accept a contact closure type of actuating device such as an elec-
and one-button operation. tric manual pull station or a pressure switch. The initiating circuits
are low impedance and designed to eliminate nuisance alarms
CHECKFIRE SC-N Electric Detection and Actuation System con- associated with contact bounce.
sists of the following components:
1. Control Module Two field programmable time delays provide timing of shutdown
2. Manual/Automatic Actuator and release functions associated with the operation of the detec-
3. Mounting Bracket tion and electric manual pull/ pressure switch initiation circuits.
4. Detection Wire 1) DETECTION INITIATING CIRCUIT
5. Thermal Detectors
6. Pneumatic/Linear Detection The detection circuit consists of two time delays:
7. Triple IR (IR3) Flame Detector The first time delay is field programmed to assign the time
8. Squib (not shown) between alarm (initiation of the detection circuit) and the oper-
9. LT-10-R Cartridge ation of the shutdown relay. The first time delay is field pro-
10. Check Valve (not shown) grammable for 5, 10, 20, or 30 seconds.
11. Remote High Level Alarm (not shown) The second time delay is field programmed to assign the time
12. Squib Circuit Test Module (not shown) between the completion of the first time delay (when the shut-
down relay operates) and the operation of the release circuit.
2 The second time delay is field programmable for 0, 10, 20, or
30 seconds.
2) ELECTRIC MANUAL PULL/PRESSURE SWITCH FEED-
1
BACK INITIATING CIRCUIT
The second initiating circuit is field programmable to be used
as either an electric manual pull or pressure switch feedback
3
circuit. If selected as an electric manual pull circuit, its opera-
tion will override the first time delay function and initiate a sec-
ond time delay condition, causing the shutdown relay to
9 immediately operate and system release to occur upon com-
pletion of the second time delay. Additionally, the control mod-
ule can be field programmed to shorten the second time delay
when a manual actuation occurs. The time delay options
available with the electric manual actuation are 0, 10, 20, and
30 seconds, with the condition that it can only be less than or
4 equal to the programmed time delay of the detection circuit.
6
Selection of the second initiating circuit as a pressure switch
5
feedback circuit will result in the operation of the alarm relay
and shutdown relay immediately upon receiving the signal.
002998
The release circuit will not be initiated from this feedback cir-
cuit because the system will already have been pneumatical-
7 ly actuated from the manual pneumatic actuator.
When this initiating circuit has operated, the Alarm and
Release LEDs, along with the audio sounder, will pulse until
the pressure switch is reset and then the control panel is reset.
S1014
SYSTEM COMPONENTS
8-1-02 Page 3
REV. 1
TOTAL SYSTEM DESCRIPTION (Continued) MANUAL/AUTOMATIC ACTUATOR

Circuits (Continued) The manual/automatic actuator, Part No. 24479, provides a manu-
al and automatic means of fire suppression system actuation. By
3) A “DELAY” button is available for the operators use. Operation
pulling the ring pin and striking the red button, manual system actu-
of the “DELAY” button will restart the first time delay cycle if
ation can be accomplished. The system is automatically actuated
initiated while the first time delay is active. Once the second
by use of a squib. When the detection circuit is activated, the con-
time delay has started, operation of the “DELAY” button has
trol module will direct the electrical current to the squib, causing it
no affect. The “DELAY” button also serves the dual function of
to actuate. The pressure generated from the squib actuation forces
silencing the auxiliary alarm relay. The silence function is only
the puncture pin down automatically.
effective 30 seconds or more after release or pressure switch
feedback operation has occurred. A 1/4 in. NPT street elbow is supplied with the actuator for conve-
nient connection of the 1/4 in. actuation line to the fire suppression
CONTROL MODULE system. See Figure 2.
The Control Module, Part No. 423504, is the basis of the STRIKE
CHECKFIRE SC-N detection system. The module cover and back BUTTON
box is made of durable Noryl SE1gfN3 material with a flammabili- RING
ty rating of UL94 V-1. The back box contains the field interface ter- PIN
minal block, battery, and field wiring entrance ports. The cover
assembly contains the control PC board assembly, sounder, oper-
ator interface panel, and environmental seal. The enclosure meets
International Standard IEC 529 requirements for dust and water
spray in all directions. Mounting pads allow mounting to any suit- SQUIB
able flat surfaces. Steel mounting brackets are also available. 1/4 IN. NPT TO PORT
ACTUATION
All circuitry, relays, switches, and LEDs are contained on a single LINE
PC board. A board mounted receptacle mates with the plug-in ter-
minal block mounted in the back box. A high pitch sounder is
threaded into the cover and plugged into the PC board. The PC
board is encapsulated to provide added protection against mois-
ture and dust. An RS232 interface cable connector is provided for
FIGURE 2
field programming from a PC and for data retrieval from a trouble 000850
and alarm history buffer. The PC board assembly contains a DIP
switch for optional manual programming functions without the use LT-10-R CARTRIDGE
of a PC. See Figure 1.
The LT-10-R cartridge is a pressure vessel that is factory-filled with
nitrogen to 1800 psi at 70 °F (124 bar at 21 °C). The cartridge is
installed in the manual/automatic actuator and provides the pres-
sure required to actuate the connected fire suppression system.
Cartridges requiring DOT (Department of Transportation) approval
only can be ordered as Part No. 13193. Cartridges requiring DOT
and TC (Transport Canada) approval can be ordered as Part No.
423423. Following operation, the cartridge must be replaced. See
Figure 3.
SAFETY
SHIPPING CAP
CARTRIDGE
FIGURE 1
002755
FIGURE 3
000851
S1014
SYSTEM COMPONENTS
6-30-05 Page 4
REV. 2
MOUNTING BRACKETS STRAIN RELIEF, STRAIN RELIEF,

PART NO. 423546 LINEAR SPLICE PART NO. 423546
The CHECKFIRE SC-N Detection and Actuation System offers DETECTION BLOCK,
LINEAR WIRE PART NO. LINEAR
three types of steel mounting brackets. DETECTION 433284
LINEAR
DETECTION
DETECTION
WIRE WIRE WIRE
The first type, Part No. 423525, is a combined bracket for mount-
ing the control module and the pneumatic actuator together. See
Figure 4.
OVERLAP
The second type, Part No. 423528, is an individual bracket for CONDUCTORS
3/8 IN. SPLICE BODY,
mounting the control module separate from the pneumatic actua- (1 cm) PART NO. 426783 UNDER SCREW
TERMINALS
tor. Note: When ordering this bracket, it is also necessary to order
the pneumatic actuator bracket, Part No. 419772. See Figure 4.
3/4 IN.
The third type, Part No. 423531, is a retrofit bracket for mounting (2 cm)
a SC-N module to any existing CHECKFIRE bracket except
CT/CT + G. See Figure 4. FIGURE 5
000854
All brackets can be fastened by either bolting or welding. Brackets
are painted with red enamel paint.
LINEAR DETECTION WIRE
The linear detection wire consists of two spring steel conductors
which are separated by a heat-sensitive insulator. At the tempera-
ture rating of the wire, 356 °F (180 °C), the insulator melts, allow-
ing the two conductors to make contact. This contact provides
electrical continuity between the two conductors. The linear detec-
tion wire is supplied in lengths of 100 ft. (30.5 m), Part No. 71230,
or 500 ft. (152.4 m), Part No. 71231, and must be ordered sepa-
rately. See Figure 6.
INSULATED
COMBINED BRACKET RETROFIT BRACKET SPRING STEEL
PART NO. 423525 PART NO. 423531 CONDUCTORS
002756 002757
FIGURE 6
000855
THERMAL SPOT DETECTOR

Thermal detectors are normally open, contact closure devices.
The fixed temperature design of these detectors will cause the
contacts to close when the temperature of the surrounding air
reaches the set point temperature of the detector. See Figure 7.
CABLE CLAMP
WITHOUT PROTECTIVE
MOUNTING TUBING, PART NO.
BRACKET, 416762
MODULE BRACKET ACTUATOR BRACKET
PART NO. CABLE CLAMP WITH
PART NO. 423528 PART NO. 419772
416221 PROTECTIVE TUBING,
002758 000852
PART NO. 416214
FIGURE 4
SPLICING DEVICE
SPOT
The In-Line Splice Kit, Part No. 428375, is required for detection DETECTOR
wire connection between the control module and the linear detec-
tion wire or between separate pieces of linear detection cable.
When the splicing device is used in the system, special sealing
compound is required to make a proper seal. The kit consists of
the necessary number of components to assemble 10 complete
assemblies. See Figure 5. FIGURE 7
000856
Thermal detectors are available in three preset temperatures as

shown below. Each temperature rating is stamped on the detector.
Rated Maximum
Operating Continuous
Temperature Use Temperature Detector
°F (°C) °F (°C) Color Part No.
270 (132) 234 (112) Blue 416218
325 (163) 280 (137) Red 416219
360 (182) 312 (155) Red 416220
S1014
SYSTEM COMPONENTS
7-1-03 Page 5
REV. 1
PNEUMATIC/LINEAR DETECTOR
The pneumatic/linear detector, Part No. 416113, consists of 35 ft.
(10.7 m) of gas filled stainless steel tubing connected to a small
pressure responder. When the gas in the tubing heats up, the
increase in pressure operates the responder, thus closing the
detection circuit of the control module. The pneumatic/linear detec-
tor will operate at a temperature of 900 °F (482 °C) over 12 in.
(31 cm) or 300 °F (149 °C) over the total length. The detector
assembly connects to the control module by means of a special
wire assembly which is supplied with the detector assembly. See
Figure 8.
DETECTOR TRIPLE IR (IR3) FLAME SWIVEL BRACKET,

TUBE DETECTOR, PART NO. 432035 PART NO. 432300
FIGURE 9
006829
STARTER JUNCTION/CABLE ASSEMBLY (TRIPLE IR (IR3))

The Starter Junction/Cable Assembly, Part No. 432477, is used
RESPONDER
with the first (or only) detector in the system. This assembly allows
the interface between the first detector, the next detector (if nec-
essary), the input power source, and the CHECKFIRE SC-N
Control Module. See Figure 10.
CONNECTION TO
CONTROL MODULE
FIGURE 8
000857
TRIPLE IR (IR3) FLAME DETECTOR

Note: Triple IR Flame Detection is to be used as an optional
add-on to standard linear detection or thermal detection.
Important: Triple IR detection can only be used with 18-24
VDC power source.
Triple IR (IR3) Flame Detector Shipping Assembly, Part No.
432480, consists of a Spectrex Model 20/20MI-32-A-F Triple IR
(IR3) flame detector and swivel detector bracket assembly. See FIGURE 10
Figure 9. 006830
The Model 20/20MI-32-A-N flame detector uses innovative tech-

nology of advanced digital signal processing to analyze the FOLLOWING JUNCTION/CABLE ASSEMBLY (TRIPLE IR (IR3))
dynamic characteristics of fire. Three sensitive IR channels The Following Junction/Cable Assembly, Part No. 432478, is used
process the signals. Detection performance is controlled by a with all detectors in the system except for the first one. This
microprocessor and easily adapted to all environments, applica- assembly allows the interface between the detector and the detec-
tions, and requirements. The result is a unique and superior flame tors following in the total system. See Figure 11.
detector, which provides excellent detection sensitivity with
extreme immunity to false alarm.
The swivel bracket allows the detector to be easily pointed in the
correct direction for optimum cone of vision viewing.
The swivel bracket can be welded or bolted to the vehicle, for rigid
support.
Mounting bolts, nuts and washers are included for assembling the
detector to the bracket. Hardware is not provided for mounting the
bracket to the vehicle.
Individual components are available also.
Part No. 432035 – Spectrex Model 20/20MI-32-A-F Triple IR (IR3)
Flame Detector
Part No. 432300 – Swivel Bracket
FIGURE 11
006831
S1014
SYSTEM COMPONENTS
6-30-05 Page 6
REV. 2
CABLE ASSEMBLIES (TRIPLE IR) BATTERY

Cable assemblies are required to wire from one detector to anoth- The CHECKFIRE SC-N control module uses one 3.6 VDC lithium
er. Cable assemblies plug into the junction boxes mounted to each battery, Part No. 427308. All power required to run the detection
detector mounting plate. Plug-plug cable assemblies are available system can be provided from this battery. The battery is supplied
in three different lengths with an additional receptacle-receptacle with two separate plug-in connectors. One connector is used for
assembly available to attach one to another to make longer plugging into SC-N modules and the other connector is used for
lengths. See Figure 12. plugging into MP-N modules. CAUTION: Do not cut off unused
Part No. 432319 – 10 ft. (3.1 m) Plug-Plug Cable Assembly connector assembly. It must remain on battery module even
though it is not used. Simply tuck the extra connector assembly
Part No. 432320 – 20 ft. (6.1 m) Plug-Plug Cable Assembly along side the battery module when installing the cover. The bat-
Part No. 432324 – 30 ft. (9.1 m) Plug-Plug Cable Assembly tery must be replaced annually, after discharge, or when the YEL-
LOW Battery LED and the Audio Alarm are pulsing. See Figure 15.
Part No. 432321 – 1 ft. (.3 m) Receptacle-Receptacle Assembly
FIGURE 12
006832
SC-N MP-N
CONNECTOR CONNECTOR
SQUIB
The squib assembly, Part No. 54919, is an electrically-actuated
component containing a small charge of powder. When the circuit
NOTE: DO NOT CUT OFF
is closed to the squib, a small internal wiring bridge heats up, UNUSED WIRE
causing ignition of the squib. This generates pressure, which ASSEMBLY
forces the puncture pin of the actuator through the seal in the
nitrogen cartridge. See Figure 13.
FIGURE 15
WARNING 004877
DEVICE CONTAINS EXPLOSIVE
CHARGE.
DO NOT REMOVE SHUNT
UNTIL READY TO CONNECT
END-OF-LINE RESISTOR
INTO ELECTRICAL SYSTEM.
The End-Of-Line Resistor Assembly, Part No. 426520, is required
for supervision of the external input circuits. The end-of-line resis-
FIGURE 13 tor assembly is available in a package of 10, Part No. 426461.
000858 Each package consists of 10 of the required components to
assemble 10 of the resistor assemblies. See Figure 16. The pack-
SQUIB CABLE – OPTIONAL 15 FT. (4.6 m) age contains an instruction sheet, Part No. 423542, detailing the
The standard cable, Part No. 79062, is 20 in. (51 cm) and is assembly requirements.
included with the control module shipping assembly. The optional
squib cable, Part No. 422747, is required to supply an electrical
signal from a remote module to the squib located in the actuator
LOCK
body. The squib cable is 15 ft. (4.6 m) and can be cut to whatever NUT
length is required. See Figure 14. The maximum allowable cable
length from controller to actuator is 15 ft. (4.6 m).
STRAIN RELIEF
CONNECTOR
TERMINAL BLOCK
WITH 4.7 K OHM
RESISTOR
CAP
FIGURE 16
003050
FIGURE 14
001058
S1014
SYSTEM COMPONENTS
7-1-03 Page 7
REV. 1
CHECK VALVE RELEASE CIRCUIT TEST MODULE

The 1/4 in. check valve, Part No. 25627, is installed in the actua- The release circuit test module, Part No. 423541, is used in place of
tion line between the manual/automatic actuator and the pneu- the squib during test procedures to simulate squib actuation or gas
matic actuator on the connected fire suppression system. This motor actuation on CHECKFIRE MP systems (indicator lamp on). It
check valve allows actuation pressure to flow to the fire suppres- is also used when verifying time delay durations. See Figure 19.
sion system, but does not allow pressure from other actuation
devices to back up into the manual/automatic actuator of the
CHECKFIRE SC-N system. See Figure 17.
Other actuation devices in the fire suppression system also
require check valves to be installed in the same fashion. This pre-
vents pressure from escaping through an actuator whose car-
tridge was inadvertently removed.
1/4 IN. NPT

(BOTH ENDS)
FIGURE 19
003015
1 5/8 IN.
(4.1 cm)
FIGURE 17
000899
REMOTE HIGH LEVEL ALARM

The remote high level alarm, Part No. 79559, is intended for those
installations where the noise level or operating conditions may
prevent the operator from recognizing the control module alarm
condition. This device is connected through the alarm relay of the
control module to a separately fused power source. It is capable
of 102 decibels at 6 to 30 volts, 0.3 amp maximum at a tempera-
ture range of –40 °F to 170 °F (–40 °C to 76.7 °C). See Figure 18.
FIGURE 18
000861
S1014
USER INTERFACE
7-1-03 Page 8
REV. 1
USER INTERFACE Shut Down Relay Circuit (Terminals No. 14, No. 15, and No. 16)
This section is designed to give the user overall information on all • Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25
features and components pertaining to the CHECKFIRE SC-N in., suitable for the intended usage
Control Module itself. • 3 amp maximum load
• Relay specification: 4A 250VAC, 3A 30VDC resistive
FIELD TERMINATIONS • Normally open, normally closed set of contacts
External Power Circuit (Terminals No. 1 and No. 2) • Form “C” contact arrangement
• 12 to 24 VDC • Contacts shown in normal condition – No. 14 (N.O.), No. 15
(Common), No. 16 (N.C.)
• Polarity must be considered – Terminal No. 1 (+), Terminal No.
2 (–) Terminal Block
• 3 amp inline fuse must be used in the positive side • Terminal connections are sized for 12 - 24 AWG
• Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25 • Terminal is labeled from left to right, No. 1 through No. 16
in., suitable for the intended usage
• The terminals are designed as follows:
Detection Circuit (Terminal No. 3 and No. 4) 1. + Ext. 12/24 VDC Battery
• Cable from splicing device must be round jacketed, with an O.D. 2. – Ext. 12/24 VDC Battery
of 0.13 in. to 0.25 in., suitable for the intended usage 3. + Detection Input
• Polarity need not be considered 4. – Detection Input
5. + Manual Input
Manual Pull/Pressure Switch Circuit (Terminals No. 5 and
No. 6) 6. – Manual Input
7. + Release Output
• Can be set up for either manual pull input or pressure switch
feedback input 8. – Release Output
• When set up for pressure switch feedback input, operation does 9. Trouble Common
not discharge system 10. Trouble N.O.
• Polarity need not be considered 11.Alarm N.O.
• Cable from splicing device must be round jacketed, with an O.D. 12. Alarm Common
of 0.13 to 0.25 in., suitable for the intended usage 13. Alarm N.C.
14. Shutdown N.O.
Release Circuit (Terminals No. 7 and No. 8)
15. Shutdown Common
• Polarity must be considered – Terminal No. 7 (+), Terminal No. 16. Shutdown N.C.
8 (–)
• 15 ft. maximum cable length between control module and pneu-
matic actuator
• Cable from splicing device must be round jacketed, with an O.D.
of 0.13 to 0.25 in., suitable for the intended usage
Trouble Relay Circuit (Terminals No. 9 and No. 10)

• Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25
• 3 amp maximum load
• Contacts are normally open in the powered, non-trouble condi-
tion. Contacts close upon trouble
Alarm Relay Circuit (Terminals No. 11, No. 12, and No. 13)
• Cable must be round jacketed, with an O.D. of 0.13 in. to 0.25
• 3 amp maximum load
• Normally open, normally closed set of contacts
• Form “C” contact arrangement
• Contacts shown in non-alarm condition – No. 11 (N.O.), No. 12
(Common), No. 13 (N.C.)
S1014
USER INTERFACE
7-1-03 Page 9
REV. 1
FRONT PANEL INDICATORS (See Figure 21) Release Trouble (Yellow)
Battery Trouble (Yellow) The Yellow Release LED and the audio will pulse at a rate of once
every 10 seconds when a trouble condition is detected in the
• LED pulses once every 10 seconds when indicating battery release circuit. The control module will return to normal when the
trouble trouble condition is cleared.
• The yellow battery trouble LED will pulse when a low power con- The Release Trouble will also pulse after the system has com-
dition is detected in either of the connected supplies (internal or pleted a discharge cycle or a pressure switch feed back signal has
external). If only one power source is used, the control module been received. The trouble signal in this condition is used to indi-
will automatically ignore the unconnected circuit upon resetting cate a recharge of the fire suppression system is necessary. A
the control module. If a power source is once connected and Release Trouble under either of these conditions can only be
recognized, a subsequent loss of that power source will be rec- cleared by resetting the control module.
ognized as a Battery Trouble condition. If a power source is
once connected, recognized, and then disconnected, the dis- Detection Trouble (Yellow)
connected supply can be ignored by operating the RESET but-
The Yellow Detection Trouble LED and the audio pulse once every
ton.
10 seconds when the control module detects a trouble in the
Power Normal (Green) detection circuit. The control module will automatically return to
normal when the trouble is cleared.
• LED pulses once every 3 seconds when indicating normal
power Sounder (Audio)
• The green Power Normal LED pulses “on” once every 3 sec- The sounder gives the audio indication for all alarm and trouble
onds indicating power is normal from both sources of input outputs. The sounder will pulse at the same rate as the visual cor-
power. If the power drops below an acceptable level from either responding LED.
the internal or external source of input power, the green Power
LED will be extinguished. If only one source of power is used, The sounder gives the audio indications of the various outputs.
the green Power LED will extinguish when the voltage level The sounder is rated at 85 Db at 10 feet.
drops below an acceptable level. The pulse rates are as follows:
Alarm (Red) Alarm – Time Delay 1 = 2 pulses per second

Time Delay 2 = 4 pulses per second
• The alarm LED will flash if an alarm condition exists. An alarm
condition is caused by operation of the detection circuit or oper- Trouble – 1 pulse per 10 seconds
ation of the manual pull/pressure switch input circuit. The alarm Loss of Power – 1 pulse per 10 seconds
condition will continue until the source of the alarm is removed Release Circuit Fired – 4 pulses per second for 30 seconds, then
and the control module is reset. 1 pulse per 10 seconds
DETECTION CIRCUIT ACTIVATION MODE – Upon receipt of Low Battery – 1 pulse per 10 seconds
an input to the detection circuit, the Alarm LED and the sounder
will pulse at a rate of 2 times per second and will continue at this
rate until the first time delay period has expired.
After the first time delay, a second time delay mode is initiated.
This causes the LED and sounder to pulse at a rate of 4 times SOUNDER
per second.
After discharge, the LED and sounder will continue to pulse at GREEN
a rate of 4 times per second for 30 seconds. After that, it will YELLOW
switch to the trouble mode and pulse once every 10 seconds. RED
ELECTRIC MANUAL RELEASE MODE – The first time delay YELLOW

mode will be by-passed and the LED will pulse at a rate of 4
pulses per second. After the time delay setting is reached, it will
pulse another 30 seconds at the same rate. After that, the con-
trol module will go into the post-discharge mode, at which time
the Alarm LED and Release LED will pulse at a rate of one
pulse per 10 seconds.
PRESSURE SWITCH CIRCUIT (FEED BACK) ACTIVATED
MODE – When this mode is actuated, the Alarm LED will pulse
a minimum of 30 seconds at 4 pulses per second. The control
module will then go into the post-discharge mode and the Alarm FIGURE 21
002760
and Release LED will pulse at a rate of one pulse per 10 sec-
onds.
S1014
USER INTERFACE
7-1-03 Page 10
REV. 2
POWER CONNECTIONS
Internal
The 3.6 VDC internal lithium battery is connected to the control
module by a removable type plug. The battery must be replaced
annually or when the Yellow Battery LED and sounder are pulsing.
A label is attached near the battery mounting location for record-
ing the installation date.
! CAUTION
DELAY
RESET
DELAY RESET
BUTTON
Discharged lithium batteries may contain significant amounts BUTTON
of unused energy and should be handled with care. Do not
compact for disposal. Before disposal, each battery must be
fully discharged and electrically isolated by enclosing in a plas-
tic bag and sealing the bag. Do not dispose of in fire. Check
applicable solid waste disposal regulations for proper disposal
of more than one battery.
FIGURE 22
0002760
External
The external power circuit can be between 12 to 24 VDC. The cir- BATTERY REPLACEMENT
cuit must be fused at the source on the positive line. The external • While in use, the battery requires replacement every year or
power source is connected to the module terminal block on termi- when the Yellow Battery LED and sounder are pulsing.
nals No. 1 (+) and No. 2 (–). • The shelf life of the battery is 8 years.
Both power sources, internal and external, should be utilized • Control Module contains a label for recording battery replace-
whenever possible. This will always give the fire suppression sys- ment date.
tem a battery back-up when one of the sources are removed for
whatever reason. • Make certain used battery is disposed of properly.
FRONT PANEL BUTTONS (See Figure 22) ENCLOSURE

• The enclosure is watertight. It meets the requirements of
Delay International Standard IEC 529, “Degrees of Protection
• Pushing the “DELAY” button during the first time delay cycle will Provided by Enclosures” for an IP 66 rating.
restart the time delay cycle. If the second time delay cycle has
already started, the “DELAY” button will have no effect. COVER REMOVAL
• The cover is attached with 4, captive, slotted screws.
• The “DELAY” button can also be used to check the diagnostics
function. By depressing the delay button when the system is in • When removing and installing cover, make certain seal is always
the trouble condition, the LEDs will flash a pattern code. Each correctly in place and not twisted.
pattern code indicates a certain type of trouble. The code pat- • Seal should always be kept clean.
tern is prioritized. The first trouble must be fixed before address- • A small amount of silicone lubricant will improve the seal’s effec-
ing the next one. Once the first trouble is taken care of, depress- tiveness.
ing the “DELAY” button will cause the LEDs to indicate the code
for the next trouble, if there is one. When the “DELAY” button is STRAIN RELIEF INSTALLATION
pressed, three short audio and visual indications will acknowl-
• Always use Dow Corning 737 RTV Sealant or equal on all strain
edge the switch has been depressed properly.
relief and plug male threads.
• In a post discharge condition, pressing the DELAY button will
silence the alarm relay if the alarm relay has been programmed MOUNTING
to silence. There are four types of mounting options available for the
CHECKFIRE SC-N Control Module:
Reset
• Control Module can be mounted without a bracket. It has mold-
• The “RESET” button is used to re-initialize the control panel. ed-in mounting tabs on the back box. Note: Surface must be
When depressed, it provides an indication that all LEDs and the suitable.
sounder are functional.
• Control Module can be mounted on a combined bracket which
• It is used to upload the manual programming into the control will allow both the module and the actuator to be mounted
module. together.
• If trouble(s) has not been cleared, the trouble indication will • Control Module can be mounted on its own bracket and the
reappear after the RESET button is pressed. actuator can be also mounted on its own bracket, with a maxi-
• When the “RESET” button is pressed, three short audio and mum release cable length of 15 ft.
visual indications will acknowledge the switch has been • Control Module can be mounted to an existing CHECKFIRE SC
depressed properly. bracket by the use of a retrofit bracket.
The Control Module should never be mounted in an area which is
subject to pressure washing or steam cleaning.
S1014
IN CASE OF FIRE
7-1-03 Page 26
REV. 2
Read these precautions carefully until they are clearly understood. Manual System Actuation
All equipment operators or anyone who has any responsibility for The system can be actuated manually by pulling the ring pin and
the equipment should fully understand how the CHECKFIRE striking the red button on the manual/automatic actuator as shown
SC-N Detection and Actuation System operates. Every operator in Figure 50. Again, bring the equipment to a safe stop, shut off the
should be fully trained in these procedures. engine, manually actuate the system, move a safe distance from
1. When the system alarm sounds, bring the equipment to a safe the vehicle, and stand by with a hand portable extinguisher.
controlled stop, shut off the engine, and exit. (Equipment left
running may add fuel to the fire or reignite the fire with heat or CAUTION
sparks.) !
Automatic Equipment Shutdown – The CHECKFIRE SC-N Manual actuation will result in immediate system discharge
system is equipped with a shutdown relay and time delay. If a which may obscure vision. Make certain vehicle is stopped
shutdown device is connected to the system, all responsible safely before manually actuating the system. Manual actuation
personnel should understand shutdown device operation and will bypass all auxiliary shutdown and alarm functions.
the length of the time delay (in seconds). If the DELAY button
(on the control module cover) is pushed and released before 2
the end of the shutdown time delay period, the time delay will
automatically repeat itself. This delay can be repeated (using STRIKE
BUTTON
the DELAY button) as many times as is necessary to stop the
vehicle safely before it shuts down. (The DELAY button can
also be held in indefinitely to delay shutdown – the shutdown
delay will then restart after the button is released.)
2. Move away from the equipment taking a hand portable extin- PULL RING
guisher along if possible. 1
PIN
3.
! WARNING
In case of fire, evacuate area to lessen risk of injury from

flames, heat, hazardous vapors, explosions, or other
hazards that may be created.
Stand by with a hand portable extinguisher to guard against

any fire that may reignite after the fire suppression system has FIGURE 50
been discharged. Remain alert until the equipment cools and 002773
the possibility of reignition is no longer a threat.

S1014
RECHARGE
6-30-05 Page 27
REV. 2
For continued protection, the CHECKFIRE SC-N Detection and

Actuation System and the fire suppression system must be
recharged immediately after operation.
Before performing the recharge steps, determine the cause of the
UPPER PORTION
system discharge. OF BODY
1. Remove the 4 screws holding the cover to the back box and
remove the cover.
2. Remove the battery from the back box and properly discard. BASE
OF STEM
Battery must be replaced after each discharge. If system con- LUBRICATE O-RING
WITH SILICONE GREASE
tains optional vehicle power, also disconnect the wire leads at
the vehicle battery. PUNCTURE PIN
3. Remove the empty LT-10-R cartridge from the manual/auto-
matic actuator.
4. If the system was manually actuated – Skip steps 5, 6, and
proceed to step 7.
SPRING
5. If the system was automatically actuated – Unscrew the RESET
squib lead connector. Remove the squib from the POSITION
manual/automatic actuator. APPROXIMATELY
1/16 IN. (1.6 mm)
6. Clean and lubricate the manual/automatic actuator by com- ± 1/16 (1.6 mm) ACTUATOR
BODY
pleting the following steps. See Figure 51.
NOTICE
If the system was actuated manually and the
squib was not actuated, cleaning is not neces- FIGURE 51
000888
sary.
NOTICE
a. Remove jam nut and slide actuator out of mounting bracket.
When puncture pin is fully reset, cutting point of
b. Unscrew upper portion of actuator body. pin will be located approximately 1/16 in.
c. Using a pencil eraser, apply pressure to the bottom of the (1.6 mm) below threads in lower actuator body.
puncture pin. This will force the puncture pin and spring out 7. In the case of a fire, replace all linear detection wire and spot
of the actuator body. detector cable. See Section III, Installation, for instructions.
d. Thoroughly clean carbon deposits from base of stem, a. Inspect all spot thermal detectors, if used, for damage, and
puncture pin, spring, and inside surface of actuator body. verify that each one has reset to its normal operational
e. After all components are clean and dry, liberally lubricate mode. (With the detection wiring disconnected from the
O-rings with a good grade of extreme temperature silicone detector, using a multimeter, check to verify that there is no
grease. continuity between any of the detector pin connections.)
f. Reassemble actuator, reinstall into bracket, and securely b. If Spectrex Model 20/20MI-32-A-F Triple IR (IR3) flame
tighten jam nut. detection is utilized, inspect detectors and verify they have
not been damaged. Make certain all detectors have been
g. Pull ring pin and push strike button several times to spread reset to their normal operating condition. Refer to User and
grease and ensure free movement of puncture pin. Maintenance Manual (Ansul Part No. 432485) and follow
h. With strike button in the up position, insert ring pin through the detector maintenance instructions outlined on Page 18
actuator body into puncture pin shaft. Install visual inspec- in the manual to verify detector operation.
tion seal, Part No. 197. NOTE: The functional operation of the IR3 flame detectors
should result in an alarm condition in the CHECKFIRE SC-N
module.
8. Install new battery, Part No. 427308, in module. Record date
of installation.
9. Recharge the fire suppression system in accordance with the
corresponding manual.
10. Test the system and place into service by completing the
steps listed under “FUNCTIONAL TEST.”
11. Record date of recharge on a tag or in permanent record file.
Notify operating personnel that the system is back in service.
S1014
INSPECTION AND MAINTENANCE

6-30-05 Page 28
REV. 2
To ensure the CHECKFIRE SC-N Electric Detection and Actuation d. Disconnect the detection wiring and check the resistance
System will operate as intended, proper inspection and mainte- across the field wiring circuit to verify detection circuit con-
nance procedures must be performed at the specified intervals. tinuity and the proper end of line resistance. The end of line
resistance should read 4.7k ohms.
DAILY INSPECTIONS e. After the detection circuit has been tested, reconnect the
The vehicle operator must check the system daily by visually ver- detection wiring to terminals TB-3 and TB-4.
ifying that the GREEN power LED is flashing and no other LED is 7. If IR3 flame detection is utilized, refer to User and
illuminated. Also, no audio alarm should be sounding. If any other Maintenance Manual (Ansul Part No. 432485) for detector
conditions exist, contact the local authorized ANSUL distributor or maintenance instructions. Follow the maintenance steps out-
whoever has been trained and authorized by ANSUL to perform lined on Page 18 in the manual.
inspection and maintenance checks.
NOTE: The functional operation of the IR3 flame detectors
MAINTENANCE should result in an alarm condition in the CHECKFIRE
SC-N module.
To give maximum assurance that the system will operate as
intended, maintenance shall be performed semi-annually or soon- 8. If thermal detectors are used, check that they are securely
er, depending on the operating and/or environment conditions. mounted and have not corroded or been damaged.
Maintenance should be performed by an authorized ANSUL dis- NOTICE
tributor or someone who has been trained and authorized by If a vehicle shutdown device is installed, the
ANSUL to perform maintenance checks. vehicle should be running at this time to verify
1. Check all mounting bolts for tightness or corrosion. that the device is functioning properly.
2. Remove the LT-10-R cartridge from the manual/automatic 9. If external power is used, measure the voltage at terminals
actuator, install shipping cap, and set aside in a safe location. 1 and 2 to ensure that the 12/24 VDC is present. Check mon-
itoring of the external power by removing the in-line fuse and
checking to see that a power trouble condition is present.
! CAUTION
Replace fuse and depress the RESET button on the control
Cartridge must be removed before continuing with the module.
following steps or accidental system actuation will take 10. Check first time delay – Alarm to Shutdown – Using a short
place when squib is actuated. length of insulated wire stripped at both ends, hold one end of
the wire to Terminal 3 and the other end to Terminal 4 on the
control module. See Figure 52.
! CAUTION DETECTION CIRCUIT
TERMINALS 3 AND 4
Do not actuate squib unless it is installed in actuator JUMPER
body. If the squib is actuated outside of actuator body, it 3 4
will detonate causing possible personal injury.
3. Five Year Squib Replacement – The squib must be replaced

DETECTION
after being in service for five years. (The month and year of CIRCUIT
manufacture is stamped on the squib hex surface.) Proper WIRING
disposal of the squib is accomplished by actuating the squib
within the actuator body. If this is required, skip Steps 4 and 5
which deal with installing the test module in place of the squib.
By skipping steps 4 and 5, the squib will be actuated during
the following test procedures.
! CAUTION
Make certain the cartridge is removed from the actuator.

Failure to do so will cause system discharge when squib FIGURE 52
is actuated. 002770
Using a jumper wire, temporarily short Terminals 3 and 4,

4. Remove the squib lead connector from the squib. removing the jumper before the end of the first time delay
5. Hand tighten the squib lead connector onto the test module, cycle. This will test the non-latching function of the first time
Part No. 423541. delay. While the wire is being held in place, the RED Alarm
LED will pulse and the sounder will operate.
6. Inspect the detection and interconnecting wiring as follows:
Remove the jumper wire. At this point, both the RED Alarm
a. Check for wear due to vibration at penetrations, around LED and the sounder will stop pulsing and the first time delay
corners, etc. will recycle back to zero. The control module will return to nor-
b. Check for damage from direct impact or other abuse. mal with only the GREEN Power LED on.
c. Check for tightness at points of securement. Make certain
fasteners have not come loose which would allow the wire
to sag or shift.
S1014
INSPECTION AND MAINTENANCE

6-30-05 Page 29
REV. 2
MAINTENANCE (Continued) 17. Push “RESET” button on CHECKFIRE SC-N Control Module
11. Check second time delay – Shutdown to Discharge – to reset system.
Once again, hold the wire on Terminals 3 and 4. The RED
Alarm LED and the Audio Alarm will pulse. Hold the wire on ! CAUTION
the terminals for a period longer than what the first time delay
is set up for. While holding the wire on the terminals, time the The fire suppression system will discharge dry chemical if
length of the first time delay to verify that it is the same as the cartridge is installed when operating the strike button.
what it was set for. Do not install cartridge at this time.
At the end of the first time delay cycle, the pulse rate of the
18. Pull ring pin and push strike button on manual/automatic actu-
Audio Alarm will change. This will start the cycle of the second
ator several times to ensure smooth movement.
time delay. At this point, the timing cycle is latched, and the
wire jumper need not be held on the terminals. Also at this NOTICE
point, the shutdown relay will operate, causing the vehicle to If lever does not operate smoothly, clean and
shutdown. lubricate internal components by completing
Time the length of the second time delay to confirm that it is Step No. 6 on Page 27 in Recharge Section.
the same as what has been set. 19. Yearly – Remove control module cover screws and replace
When the second time delay cycle is completed, the release internal 3.6 VDC lithium battery, Part No. 427308. Record
circuit will activate causing the GREEN LED on the test mod- date of new battery installation on label located near battery.
ule to illuminate or in the case of the five year squib replace- Reinstall control module cover and depress “RESET” button.
ment, the squib will fire.
! CAUTION
12. (If used) Reset test module by pressing the reset button on
the tester. Contact your local waste management company for informa-
13. Disconnect the squib lead from the squib test module lead tion concerning the correct disposal of lithium batteries.
adaptor and verify that the module is indicating both a RED
alarm LED and a YELLOW release fault LED. Reconnect the
20. Reinstall LT-10-R cartridge by completing the following steps:
squib lead to the squib test module lead adaptor.
a. Make certain puncture pin is fully retracted and insert ring
14. Complete the following steps only if the squib has been actu-
pin through actuator body into puncture pin shaft. Attach
ated. Otherwise, go to Step No. 15.
visual inspection seal, Part No. 197.
a. Unscrew the squib lead connector from the squib and
b. Remove shipping cap and weigh cartridge before installing.
remove the squib from the actuator body.
Replace if weight is 1/4 ounce (7.1 g) or more below weight
b. Clean manual/automatic actuator by referring to Step 6 on stamped on LT-10-R cartridge.
Page 26 in Recharge Section.
c. Screw cartridge into actuator body and hand tighten.
c. Screw replacement squib into the upper-right hole in the
21. Reset any auxiliary shutdown and alarm equipment in accor-
actuator body and wrench tighten.
dance with manufacturer’s instructions.
d.
CAUTION 22. Record date of maintenance on an affixed tag or in a perma-
!
nent record file.
The control module could be damaged and the fire sup-
pression system may not operate if the squib spring
(shunt) is not removed. Always remove cap and spring
(shunt) before installing squib connector.
Unscrew protective cap from replacement squib and

remove spring (shunt). Retain these components for possi-
ble future use.
e. Line up index slot in squib lead connector with index tab on
squib. Then, hand tighten squib lead connector onto squib.
15. Unscrew the squib lead connector from the test module.
NOTICE
When squib lead connector is removed from test
module, the YELLOW Release LED and the
audio alarm on the control module will
temporarily pulse. This will stop when squib is
connected.
16. Line up index slot in squib lead connector with index tab on
squib. Then, hand tighten squib connector onto squib.
S1014
TROUBLESHOOTING
7-1-03 Page 30
REV. 1
DIAGNOSTICS Below is a listing and explanation of each type of recorded fault:

The diagnostics feature offers a means to pinpoint various trouble Programmed – This indicates any time the unit is pro-
symptoms by displaying a flashing code on the control module grammed or a programming change has been
status LEDs. made.
If there is more than one trouble at a time, the system will display Switch Enabled – This indicates that the manual programming
them in a pre-set priority. switch is enabled and the program settings
In multiple trouble situations, the first trouble must be cleared are being taken from the program switch set-
before the system will display the next one. tings.
The system must be in the trouble mode in order to display the Init Bad Log – This indicates that an error has been detect-
diagnostics codes. ed in the datalog. If this occurs, the datalog is
automatically cleared and reset.
With the system in the trouble mode, depress the “DELAY” button.
With the “DELAY” button depressed, the trouble codes will be indi- Bad Checksum – Indicates that an error has been detected in
cated on the LEDs. the E-Prom. If this occurs, the factory default
program settings are restored.
LED Code
_________ Trouble
_______ Soft Reset – Indicates that the Reset button has been
depressed. The clock is not reset during a soft
Yellow Battery LED flashing Internal battery disconnected reset.
Yellow Battery LED flashing External battery disconnected +12 (24V) Low – Indicates that the external power input volt-
Red Alarm LED flashing age has dropped below a “Normal” threshold
level and is in need of servicing.
Yellow Release LED flashing Release circuit is open
+12 (24V) Fault – Indicates external power input voltage has
Yellow Release LED flashing Release circuit has operated dropped below the minimum operating
Red Alarm LED flashing threshold or the external power has been dis-
connected.
Yellow Detection LED flashing Detection circuit is open Int Batt Low – Indicates the internal battery voltage has
Yellow Detection LED flashing Electric manual pull station dropped below a “Normal” threshold level and
Red Alarm LED flashing circuit is open requires servicing.
Int Batt Fault – Indicates that the internal battery voltage has
HISTORY BUFFER dropped below the minimum operating
The CHECKFIRE SC-N control module is programmed to record threshold or the battery has been
faults, alarms, and programming changes in a numerical disconnected.
sequence. The module will store approximately 50 recorded Detection TD1 – Indicates that the Time Delay 1 sequence has
events. If the number of events exceeds 50, the earlier events will been initiated. This occurs as a result of oper-
be erased to make room for the later ones. ation of the detection circuit.
A sample History Buffer screen appears as follows: Detection TD2 – Indicates the start of the Time Delay 2
Event Number Event sequence as a result of a detection input.
0 Programmed Time (dddd:hh:mm:ss) Manual TD – Indicates the start of the time delay as a result
1 Detection TD1 0000:00:01:46 of the manual input circuit being initiated.
2 Delay Engaged 0000:00:01:52 Pressure Switch – Indicates activation of the pressure switch
3 Delay Released 0000:00:02:15 input circuit.
4 Detection TD2 0000:00:02:25 Delay Engaged – Indicates the delay button has been
5 Squib Release 0000:00:02:35 depressed during TD1 of an alarm condition.
6 Soft Reset 0000:00:05:10
7 All Clear 0000:00:05:13 Delay Released – Indicates the time the Delay button was
8 Int Batt Low 385:12:24:32 released after initiating.
9 Int Batt Fault 405:20:32:07 Detection Fault – Indicates an open circuit in the detection
The recorded event indicates which circuit had a fault or an alarm circuit.
recorded. Along with the type of fault or alarm, the history buffer Manual Fault – Indicates an open in the manual pull or pres-
also records the time, relative to the first event which is the pow- sure switch circuit.
ering of the unit or restoration of power. New events are recorded
by days: hours: minutes: seconds that have transpired from the Squib Fault – Indicates an open in the squib circuit or that
last restoration of power. If power is removed and then restored, the squib has fired.
the counter starts over at 0000:00:00:00, however, previous histo- Squib Release – Indicates that the control module has fired the
ry will be retained in the buffer. squib.
Unknown – Indicates an unexplainable event in the con-
trol module circuitry.
All Clear – Indicates alarm condition has been reset. This
indication occurs after TD2 clears.
S1014
TROUBLESHOOTING
7-1-03 Page 31
REV. 1
TROUBLESHOOTING TABLE
The following table designates normal operating and trouble conditions for the CHECKFIRE SC-N Detection and Actuation System.
Green Yellow Yellow Yellow
Power Power Red Detection Release Audio Alarm Shutdown Trouble Agent
Condition
________ Normal
______ Fault
_____ Alarm
_____ Fault
________ Fault
_______ Alarm
_____ Relay
_____ Relay
_________ Relay
_______ Release
_______
battery normal pulsing off off off off off normal normal normal off
module normal once every
external power 3 seconds
not used
battery normal pulsing off off pulsing off pulsing normal normal transferred off
detection fault once every once every once every
external power 3 seconds 10 seconds 10 seconds
not used
battery normal pulsing off off off pulsing pulsing normal normal transferred off
release fault once every once every
external power 10 seconds 10 seconds
not used
battery normal pulsing off off pulsing pulsing pulsing normal normal transferred off
release fault 10 seconds 10 seconds 10 seconds
external power
not used
battery fault off pulsing off off off pulsing normal normal transferred off
external power normal once every once every
module normal 10 seconds 10 seconds
battery fault off pulsing off pulsing off pulsing normal normal transferred off
external power normal once every once every once every
detection fault 10 seconds 10 seconds 10 seconds
battery fault off pulsing off off pulsing pulsing normal normal transferred off
release fault once every once every once every
external power normal 10 seconds 10 seconds 10 seconds
battery fault off pulsing off pulsing pulsing pulsing normal normal transferred off
detection fault once every once every once every once every
release fault 10 seconds 10 seconds 10 seconds 10 seconds
external power normal
alarm detected pulsing off pulsing off off pulsing transferred normal normal off
alarm to shutdown once every twice twice every
period – TD1 3 seconds every second second
external power fault off pulsing off pulsing pulsing pulsing normal normal transferred off
detection fault once every once every once every once every
manual pull circuit fault 10 seconds 10 seconds 10 seconds 10 seconds
release fault
battery normal
external power fault once every once every
10 seconds 10 seconds
external power fault once every once every once every
S1014
TROUBLESHOOTING
7-1-03 Page 32
REV. 1
TROUBLESHOOTING TABLE (Continued)

Condition
________ Normal
______ Fault
_____ Alarm
_____ Fault
________ Fault
_______ Alarm
_____ Relay
_____ Relay
_________ Relay
_______ Release
_______
external power fault once every once every once every
manual pull circuit fault
battery fault off pulsing off pulsing pulsing pulsing normal normal transferred off
external power fault once every once every once every once every
detection fault 10 seconds 10 seconds 10 seconds 10 seconds
manual pull circuit
fault
release fault
manual pull circuit pulsing off pulsing off off pulsing transferred transferred normal off
activated once every 4 times 4 times
pre release period 3 seconds per second per second
(manual release
time delay)
pressure switch pulsing off pulsing off off pulsing transferred transferred normal off
activated (0 to 30 once every 4 times 4 times
seconds 3 seconds per second per second
after activated)
pressure switch pulsing off pulsing off pulsing pulsing transferred transferred transferred off
activated once every once every once every once every
(post 30+ seconds 3 seconds 10 seconds 10 seconds 10 seconds
period)
shutdown to release pulsing off pulsing off off pulsing transferred transferred normal off
period once every 4 times 4 times
(2nd time delay) 3 seconds per second per second
0 - 30 seconds pulsing off pulsing off off* pulsing transferred transferred transferred fired
after release once every 4 times 4 times
3 seconds per second per second
30+ seconds pulsing off pulsing off pulsing pulsing transferred** transferred transferred fired
after release once every once every once every once every
3 seconds 10 seconds 10 seconds 10 seconds
manual pull pulsing off off pulsing off pulsing normal normal transferred off
circuit fault once every once every once every
battery normal 3 seconds 10 seconds 10 seconds
manual pull pulsing off off pulsing off pulsing normal normal transferred off
circuit fault once every once every once every
battery normal
manual pull pulsing off off pulsing pulsing pulsing normal normal transferred off
circuit fault once every once every once every once every
detection fault 3 seconds 10 seconds 10 seconds 10 seconds
release fault
battery normal
S1014
TROUBLESHOOTING
7-1-03 Page 33
REV. 1
TROUBLESHOOTING TABLE (Continued)

Condition
________ Normal
______ Fault
_____ Alarm
_____ Fault
________ Fault
_______ Alarm
_____ Relay
_____ Relay
_________ Relay
_______ Release
_______
external power fault off pulsing off off off pulsing normal normal transferred off
battery normal once every once every
10 seconds 10 seconds
external power fault off pulsing off pulsing off pulsing normal normal transferred off
battery normal 10 seconds 10 seconds 10 seconds
no external power once every once every
module normal 30 seconds 30 seconds
external power 10 seconds 10 seconds 10 seconds
not used
manual pull pulsing off pulsing off off* pulsing transferred transferred transferred fired
circuit activated once every 4 times 4 times
(0-30 seconds after 3 seconds per second per second
system activation)
pressure switch pulsing off pulsing pulsing pulsing pulsing transferred transferred transferred off
activated detection once every once every once every once every once every
fault (30+ seconds 3 seconds 10 seconds 10 seconds 10 seconds 10 seconds
after system
activation)
* Will pulse if circuit opens as a result from release
** Can be silenced at this time

S1014
APPENDIX
6-30-05 Page 39
REV. 2
COMPONENT INDEX
Part Shipping Weight
No. Assembly lb. (kg)
Main Assemblies
423500 CHECKFIRE SC-N Electric Detection and Actuation 10 (4.5)
System includes:
423504 Control Module (module contains nuts and
washers for mounting to bracket)
24479 Manual/Automatic Actuator
423525 Combined Mounting Bracket
79062 Squib Cable with Connector
13193 Nitrogen Cartridge, LT-10-R
25627 1/4 in. Check Valve
79064 Label Package
53081 Owner’s Manual
423538 (Transport Canada) CHECKFIRE SC-N Electric Detection 10 (4.5)
and Actuation System includes:
(All of the standard shipping assembly components
except Nitrogen Cartridge, Part No. 13193, is replaced
with Nitrogen Cartridge, Part No. 423423)
427308 Battery Shipping Assembly (3.6 VDC) 1/4 (.1)
54919 Squib 1/4 (.1)
426461 End-of-Line Resistor Assembly (Package of 10) 1/4 (.1)
426520 End-of-Line Resistor Assembly (Single) 1/4 (.1)
Accessory Equipment
423541 Release Circuit Test Module 1 (.5)
423525 Combined Bracket Shipping Assembly – 1 (.5)
For mounting control module and actuator together
423528 Control Module Mounting Bracket – 1 (.5)
For mounting control module separately
419772 Actuator Mounting Bracket – 1 (.5)
For mounting actuator separately
423531 Control Module Retrofit Mounting Bracket – 1 (.5)
For mounting control module to existing
CHECKFIRE SC mounting bracket
79559 Remote High Level Alarm 2 (.9)
71820 Splicing Device 1/4 (.1)
71230 356 °F (180 °C) Linear Detection Wire, 100 Ft. (30.4 m) 5 (2.3)
71231 356 °F (180 °C) Linear Detection Wire, 500 Ft. (152.4 m) 10 (4.5)
416218 270 °F (132 °C) Spot Detector 1/4 (.1)
416219 325 °F (163 °C) Spot Detector 1/4 (.1)
416220 360 °F (182 °C) Spot Detector 1/4 (.1)
416213 Spot Detector Connector Package 1/4 (.1)
416221 Spot Detector Bracket 1/4 (.1)
416762 Spot Detector Cable Clamp Package (For Use 1/4 (.1)
Without Protective Tubing)
416214 Spot Detector Cable Clamp Package (For Use 1/4 (.1)
With Protective Tubing)
416215 Flex Non-Metallic Tubing 100 Ft. (30.4 m) 4 (1.8)
(For Spot Detectors)
416784 Crimp Tool (For Spot Detector) 1 (.5)
416113 Pneumatic/Linear Detector, 35 Ft. (10.7 m) 1 (.5)
(Model 808-DRV)
416216 Cable Assembly, 15 ft. (4.6 m) (For Pneumatic/ 1/4 (.1)
Linear Detector)
416378 Mounting Clips Package For Pneumatic/Linear 1/4 (.1)
Detector Sensing Element (Includes 100 Clips)
417055 Wire, 392 °F (200 °C), 18 AWG-2 W/Shield and Drain Wire 10 (4.5)
500 ft. (152 m)
S1014
APPENDIX
6-30-05 Page 40
REV. 1
COMPONENT INDEX (Continued)

Accessory Equipment (Continued)
Part Shipping Weight
No. Assembly lb. (kg)
56691 Nylon Cable Tie (Package of 20) 1 (.5)
56692 Rubber Sleeve (Package of 20) 2 (.9)
422747 Squib Cable with Connector – 15 ft. (4.6 m) 1 (.5)
419780 Power Wiring Assembly – 15 ft. (4.6 m) 1 (.5)
(Connector on one end)
(Connector on both ends)
(Connector on both ends)
419783 Battery Connection (Fused at 5 amp) 1 (.5)
423524 RS-232 PC Interface Cable Kit 1/4 (.1)
426601 Extender Cable Assembly 1/4 (.1)
426604 Battery Extender Cable Assembly 1/4 (.1)
432480 Triple IR (IR3) Flame Detector Shipping Assembly 5 (2.3)
(includes Spectrex Model 20/20MI-32-A-F Triple IR (IR3)
Flame Detector, Part No. 432035;
Swivel Bracket with Mounting Plate, Part No. 432300)
432477 Starter Junction/Cable Assembly (Triple IR) 2 (.9)
432478 Following Junction/Cable Assembly (Triple IR) 2 (.9)
432319 10 ft. (3.1 m) Plug-Plug Cable Assembly (Triple IR) 2 (.9)
432320 20 ft. (6.1 m) Plug-Plug Cable Assembly (Triple IR) 4 (1.8)
432324 30 ft. (9.1 m) Plug-Plug Cable Assembly (Triple IR) 6 (2.7)
432321 1 ft. (.3 m) Receptacle-Receptacle Cable Assembly .5 (.2)
(Triple IR)
432481 Supervision End Plug (Triple IR) 1/4 (.1)
432485 Triple IR Flame Detector User and Maintenance Manual 1/4 (.1)
432484 WinHost Programming Manual (Triple IR) 1/4 (.1)
RECHARGE EQUIPMENT
54919 Squib 1/4 (.1)
13193 LT-10-R Cartridge (DOT) 2 (.9)
423423 LT-10-R Cartridge (DOT/TC) 2 (.9)
427308 Battery Shipping Assembly (3.6 VDC) 1/4 (.1)
423522 Installation, Maintenance, Recharge Manual 1/4 (.1)
S1014
APPENDIX
7-1-03 Page 41
DETECTION WIRE FLUID RESISTANCE CAPABILITY

Resistance Rating Key:
G = GOOD
L = LIMITED
C = CONDITIONAL (Service conditions must be outlined to
ANSUL for approval of wire suitability for
applications.)
U = UNACCEPTABLE (Not to be used)
Agent Rating Agent Rating Agent Rating
Acetate Solvents, Crude U Diesel Oil, Light L Naphtha C
Acetate Solvents, Pure U Naphthalene U
Ethers U
Acetic Acid, Dilute (20%) U Nickel Chloride G
Ethyl Acetate U
Acetic Acid, Glacial U Nickel Sulfate G
Ethyl Alcohol C
Acetone U Nitric Acid, 10% L
Ethyl Chloride U
Air G Nitric Acid, 70% U
Ethylene Dichloride U
Alcohols C Nitrobenzene U
Ethylene Glycol L
Aluminum Chloride G Oleic Acid C
Aluminum Fluoride G Ferric Chloride G
Oleum Spirits U
Aluminum Sulfate G Ferric Sulfate G
Ammonia Liquid (Anhydrous) U Ferrous Salt Solutions G Perchlorethylene C
Ammonia, Chloride G Formaldehyde L Picric Acid, Molten U
Ammonium Hydroxide L Formic Acid L Picric Acid, Solution U
Ammonium Nitrate G Fuel Oil L Potassium Chloride G
Ammonium Phosphate G Furfural U Potassium Cyanide G
Ammonium Sulfate G Potassium Hydroxide C
Gasoline C
Amyl Acetate U Potassium Sulfate G
Glycerine, Glycerol L
Amyl Alcohol L Grease, Petro L Soda Ash Sodium Carbonate G
Asphalt C Sodium Bisulfate G
Heptane C
Barium Chloride G Sodium Chloride G
Hexane L
Barium Hydroxide G Sodium Cyanide G
Hydraulic Fluids & Lubricating Oils,
Barium Sulfide G Sodium Hydroxide C
Straight Petroleum Base L
Benzene, Benzol C Sodium Hypochorite C
Water and Petroleum Oil
Benzene (Petroleum Ether) C Sodium Nitrate G
Emulsion (FR) L
Benzene (Petroleum Naphtha) C Sodium Peroxide C
Water and Glycol Solution L
Borax L Sodium Phosphate G
Straight Phosphate–Ester (FR) L
Boric Acid L Sodium Silicate G
Silicone Oils L
Bromine U Sodium Sulfate G
Hydrobromic Acid U
Butyl Acetate U Sodium Sulfide C
Hydrochloric Acid, Cold C
Butyl Alcohol, Butanol L Sodium Thiosulfate, “Hypo” G
Hydrochloric Acid, Hot U
Soybean Oil L
Calcium Bisulfite L Hydrocyanic Acid C
Stannic Chloride G
Calcium Chloride G Hydrofluoric Acid, Cold C
Stearic Acid L
Calcium Hydroxide G Hydrofluoric Acid, Hot C
Sulfur Dioxide C
Calcium Hypochlorite L Hydrogen Peroxide (Dilute) G
Sulfur Trioxide C
Carbolic Acid Phenol C Hydrogen Peroxide (Concentrated) C
Sulfuric Acid, 10%, Cold L
Carbon Dioxide G Hydrogen Sulfide C
Sulfuric Acid, 10%, Hot L
Carbon Disulfide U Kerosene L Sulfuric Acid, 75%, Cold L
Carbon Monoxide, Hot U
Lacquer Solvents U Sulfuric Acid, 75%, Hot L
Carbon Tetrachloride L
Lactic Acid C Sulfuric Acid, 95%, Cold U
Carbonic Acid G
Linseed Oil L Sulfuric Acid, 95%, Hot U
Castor Oil C Sulfuric Acid, Fuming U
Chlorinated Solvents C Magnesium Chloride G Sulfurous Acid L
Chlorine, Dry U Magnesium Hydroxide G
Chlorine, Wet U Magnesium Sulfate G Tannic Acid G
Chloroacetic Acid U Mercuric Chloride U Tartaric Acid G
Chloroform U Mercury L Toluene U
Chlorosulphonic Acid U Methyl Alcohol, Methanol L Trichloroethylene U
Chromic Acid U Methyl Chloride U Turpentine L
Citric Acid L Methyl Ethyl Ketone U Varnish U
Copper Chloride G Methyl Isopropyl-Keytone U
Xylene U
Copper (II) Sulfate G Mineral Oil L
Creosote U Zinc Chloride L
Zinc Sulfate G
16721
FIRE SUPPRESSION SYSTEM
Page 1 of 4
Updated:
10/10/07
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:
10/10/07
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:
10/10/07
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 A/R
Updated:
10/10/07
AUTO DETECTION SYSTEM 13283
Page 1 of 2

01/10/07
AUTO DETECTION SYSTEM 13283
Page 2 of 2
334145 AUTO DETECTION SYSTEM (INCLUDES ITEMS 1, 2, 4, 6, 7) 1
1 NSS MOUNTING BRACKET 1
2 NSS MANUAL/AUTOMATIC ACTUATOR 1
3 334133 SQUIB 1
4 NSS CONTROL MODULE 1
5 334146 MODULE BATTERY 1
6 NSS POWER LEAD 1
7 334122 CARTRIDGE 1
8 334011 DETECTION WIRE 1
9 --------- REMOTE HIGH LEVEL ALARM 1
* 464870 RESISTOR ASSEMBLY (DETECTION LOOP) 1
* 334010 RUBBER SLEEVE A/R

01/10/07
13597
BASKET DOOR INSTALLATION
Page 1 of 1

1 102080 KNOB 1
2 19217-173 ROD 1
3 68GD06 NUT (NYLOCK) 2
4 27GE12 WASHER (FLAT) 1
5 11075-02 BRACKET (LATCH) 1
6 284160 SPRING 2
7 11075-03 ROD (LATCH) 1
8 20085-01 DOOR 1
9 605443 HINGE (DOOR) 1
Updated:
12/18/06
16714
BOOM INSTALLATION
Page 1 of 3
Updated:
05/08/07
16714
BOOM INSTALLATION
Page 2 of 3

22883 BOOM ASSEMBLY 1
1 27158-03 PIN (LEVELING CYLINDER) 2
2 26415 CYLINDER (LEVELING) 1
3 SEE TURRET PAGE TURRET 1
4 19204-78 PIN (LIFT CYLINDER) 1
5 16535-05 BUSHING (TURRET) 2
6 01GC06016 BOLT 8
7 17GC08024 BOLT 20
8 22896-05 COVER 1
9 9085-02 KEEPER 1
10 27003-01 OUTER BOOM 1
11 594130 LIFT CYLINDER 1
12 27158-01 PIN (TURRET) 1
13 27170-03 PIN (EXTENSION CYLINDER) 1
14 27238-05 TRUNNION 2
15 73GC12016 ALLEN HEAD 2
16 22893-03 PIN RETAINER 1
17 09GG06016 ALLEN HEAD (FLAT) 24
17GD06 NUT 24
18 SEE CYL. PAGE EXTENSION CYLINDER ASSEMBLY 1
19 19204-96 PIN (LIFT CYLINDER) 1
20 19204-97 PIN (SLIDE PAD) 1
21 16408 WEAR PAD 12
14594-03 SHIM A/R
22 16556-01 SLIDE PAD 2
23 16407 WEAR PAD 4
14594-01 SHIM A/R
24 16555-01 PAD ASSEMBLY 4
25 10870-01 MIDDLE BOOM 1
26 27016-01 INNER BOOM 1
27 09GG06024 ALLEN HEAD (FLAT) 8
17GD06 NUT 8
28 19204-98 PIN (SLIDE PAD) 1
Updated:
05/08/07
16714
BOOM INSTALLATION
Page 3 of 3
29 19204-99 PIN (LEVELING CYLINDER) 1
30 10898-03 PIN (EXTENSION CYLINDER) 1
31 10898-01 PIN (BASKET) (REF.) 1
32 464696 BUSHING 2
33 22891-01 ROTATOR 1
34 17GC08040 BOLT 3
35 22893-03 WASHER 3
36 465121 CYLINDER (LEVELING) 1
37 10898-01 PIN (LEVELING) 3
38 14488-01 LEVELING LINK 1
39 14488-02 LEVELING LINK 1
40 SEE COMP. PAGE BASKET 1
Updated:
05/08/07
16572
TURRET INSTALLATION
Page 1 of 2

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

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

12/19/06
BOOM ROTATION GEAR M1005
INSTALLATION Page 1 of 4
Boom Rotation Gear and Bearing Assembly

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

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

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

#2
GEAR Mobilcote-S Crater 407 Compound Poco Gearshield Sohitac #1
Compound B
Updated:
05/03/07
16256
ROTATION GEAR BOX
Page 1 of 3

12/19/06
16256
ROTATION GEAR BOX
Page 2 of 3

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

12/19/06
16256
ROTATION GEAR BOX
Page 3 of 3
30* 605010 PLUG 1
31* 605015 CAP SCREW 4

12/19/06
13712
ACTUATOR
Page 1 of 2

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

14053
BASKET ROTATOR ASSEMBLY
Page 1 of 2
Updated:
12/19/06
14053
BASKET ROTATOR ASSEMBLY
Page 2 of 2

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

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

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

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

07/11/07
13651
OUTRIGGER INSTALLATION
Page 2 of 2

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

07/11/07
COMPRESSOR DRIVE & 13390
MOUNT Page 1 of 1

1 605543 COMPRESSOR ASSEMBLY 1
2 594028 UNLOADER VALVE (INCLUDED IN ITEM 1) 1
3 605653 KEY (COMPRESSOR) 1
4 10495 COMPRESSOR MOTOR ADAPTER 1
5 164134 COUPLING ASSEMBLY 1
164135 SPYDER 1
6 13389-02 COMPRESSOR MOTOR SUPPORT 1
7 494095 MOTOR 1
8* 232160 COMPRESSOR GOVERNOR 1
9* 524330 AIR FILTER (COMPRESSOR) 1
NOTE: GENERAL INSTRUCTION MANUAL TO FOLLOW (S1062), PLEASE CALL GETMAN

PARTS DEPARTMENT TO ORDER SPECIFIC PARTS PERTAINING TO YOUR SPECIFIC AIR
COMPRESSOR

06/23/08
Instruction book
S1062
Atlas Copco Stationary Air Compressors
LE2, -3, -5, -7, -10, -15, -20

LT2, -3, -5, -7, -10 (50 Hz)
LT15/60, -15-30, -15, -20, -20-30
LF2, -3, -5, -7, -10
Instruction book
Copyright 2004, Atlas Copco Airpower n.v., Antwerp, Belgium.

Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in
particular to trademarks, model denominations, part numbers and drawings.
This instruction book meets the requirements for instructions specified by the machinery directive
98/37/EC and is valid for CE as well as non-CE labelled machines.
No. 2920 1585 00
Registration code: APC L / 38 / 985
2004-07
2920 1585 00 -1-

Instruction book
S1062
This instruction book describes how to handle the machines to ensure safe operation, optimum efficiency
and long service life.
Read this book before putting the machine into operation to ensure correct handling, operation and
proper maintenance from the beginning. The maintenance schedule comprises measures for keeping the
machine in good condition.
Keep the book available for the operator and make sure that the machine is operated and that
maintenance is carried out according to the instructions. Record all operating data, maintenance
performed, etc. in an operator's logbook available from Atlas Copco. Follow all relevant safety
precautions, including those mentioned on the cover of this book.
Repairs must be carried out by trained personnel from Atlas Copco who can be contacted for any further
information.
In all correspondence mention the type and the serial number, shown on the data plate.
For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal
data".
The company reserves the right to make changes without prior notice.
2920 1585 00 -2-

Instruction book
S1062
1 Leading particulars
1.1 General description
LE, LF and LT are air-cooled, single-acting piston compressors. LE and LT are lubricated compressors;
LF are oil-less compressors which deliver oil-free air. LF2 up to LF5, LE2 up to LE7 and LE10 50 Hz are
single-stage compressors; LE10 60 Hz, LE15, -20, LF7, -10 and LT are two-stage compressors.
LT and LE/LF2 up to -7 and LE10 50 Hz are two-cylinder compressors, LE10 60 Hz, LF10, LE15, -20 are
three-cylinder compressors.
Note: Take care that three-cylinder compressors rotate in the direction as indicated by the arrow on the
fan housing (counter-clockwise seen from fan cowl side).
LE/LF are built for effective working pressures up to 10 bar. LT are built for effective working pressures up
to 30 bar (LT2 only for 15 and 20 bar).
Fig. 1.1 Compressor Block with unloading valve Fig. 1.2 Power Pack with unloading valve
2920 1585 00 -3-

Instruction book
S1062
AF Air filter
DP Oil drain plug
FN Fan
M Motor
SG Oil level sight-glass
1 Cover
2 Intercooler
3 Air inlet silencer
4 Crankcase
5 Cooling pipe
6 Cylinder
7 Unloader
8 Relief valve
9 HP cylinder
10 LP cylinder
Fig. 1.3 Power Pack
Figs. 1.1 up to 1.3 General views, Compressor Block - Power Pack
Fig.1.5 Tank-mounted unit, LE10 60 Hz, LE5-20, LT15,

Fig. 1.4 Tank-mounted unit, LE/LT/LF2, -3,
-20 and LT/LF5-10 (standard receiver is 250 l)
horizontal receiver (standard receiver is
120 l)
2920 1585 00 -4-

Instruction book
S1062
- For LE/LF/LT5 up to -10, LT15 up to -20: the Compressor Block as described above, with flanged-on
electric motor (M) and solenoid valve (Y1-Fig. 1.5).
The Tank-mounted unit comprises:

- For LE/LF/LT2 and -3: the Power Pack mounted on a horizontal (Fig. 1.4) or vertical (Fig. 1.6) air
receiver (AR) with air outlet valve (AV), pressure gauge (Gp), safety valve (SV), air pressure switch
with on/off switches (13) and condensate drain valve (Dm).
- For LE/LF/LT5 up to -10, LE15, -20 and LT15, -20 (Fig. 1.5/1.7): the Power Pack mounted on an air
receiver (AR) with air outlet valve (AV), pressure gauge (Gp), safety valve (SV) and condensate drain
valve (Dm). An electric cubicle (6) includes the motor starter. A separate air pressure switch (13) is
provided.
A silencing canopy (1-Fig. 1.13) is available as an option. The canopy has a hinged top to allow easy
access for maintenance.
The Base-mounted unit (Fig. 1.8) is a fully operational unit with air pressure switch and on/off switches
mounted on a frame (no air receiver). A silencing hood can be added as an option.
LE, LF and LT Trolley units (Figs. 1.15 and 1.16) are mobile compressors. They are equipped with either
a directly flanged electric motor (LE/LF/LT ETROL - Fig. 1.15) or a petrol engine (LE/LF/LT PETROL - Fig.
1.16). The compressors have two outlet connections:
- a connection for compressed air at working pressure
- a connection for compressed air at reduced pressure via a pressure regulator
The Full-Feature compressor is a Tank-mounted compressor additionally provided with an FX dryer and
DD/PD filters.
1.2 Air flow
1.2.1 LE/LF2 up to -5, LE7 and LE10 50 Hz (Fig. 1.10)
Air drawn through air filter (AF) and inlet silencer (1) into cylinders (3) is compressed, then discharged
through cooler piping (4) and (6) and check valve (CV) into air receiver (AR).
1.2.2 LE10 60 Hz, LE15, -20, LF7, -10 and LT (Fig. 1.11)
Air drawn through air filter (AF) and inlet silencer (1) into LP (low-pressure) cylinder(s) (7) is compressed,
then discharged to HP (high-pressure) cylinder (8) via intercooler (10).
The air is further compressed and discharged through cooler piping (6) and check valve (CV) into air
receiver (AR).
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Instruction book
S1062
1 AF
FN FC COMPRESSED AIR (1)

3
3
4 M
4
6
SG
Gp SV DP
CV
AR
5
AV 2
Dm MDR
50980D
(1) Compressed air
Fig. 1.10 Air flow of LE and regulating system of LE/LF/LT2 up to -7 with DOL starter and separate
air pressure switch
1 AF
8
FC COMPRESSED AIR (1)
7
10 10 M
FN
6
SG UA
9
Gp SV DP
12 5 11
13 Y1
UV
CV
AV
AR
Dm
MDR
50981D
(1) Compressed air
Fig. 1.11 Air flow of LT and regulating system of LE5 up to -20, LF5 up to -10, LT5 up to -10 and
LT15 up to -20 with Y/D starter and electric cabinet
2920 1585 00 - 6-
Instruction book
S1062
1.3 Regulating system

1.3.1 LE/LF/LT2 up to -7 with DOL starter (Fig. 1.10)
The regulating system includes:
- Check valve (CV)
- Air pressure switch (MDR) with pressure release valve (2) and on/off switches (5).
Operation
Air pressure switch (MDR) opens and closes its contacts at pre-set pressures. During loaded operation,
the contacts are closed: the motor is running.
When the pressure in the air receiver reaches the pre-set maximum pressure, the contacts as well as
pressure release valve (2) are opened. The motor stops, the air at the delivery side of the compressor is
vented to atmosphere and check valve (CV) closes to prevent venting of the receiver.
When the pressure in the air receiver decreases to the pre-set minimum pressure, the contacts of the air
pressure switch close and pressure release valve (2) closes. The motor restarts and compressed air is
supplied to the receiver again.
1.3.2 LE/LT5 up to -20, LF5 up to -10, each with Y/D starter (Fig. 1.11)
The regulating system includes:
- Electric cubicle (11)
- Air pressure switch (MDR)
- On/off switch (5)
- Solenoid valve (Y1)
- Unloader (UA) with integrated check valve (CV)
Operation
Air pressure switch (MDR) opens and closes its contacts at pre-set pressures. During loaded operation,
the contacts are closed: the motor is running and solenoid valve (Y1) is energized preventing the
compressed air from flowing to unloader (UA).
When the pressure in the air receiver reaches the pre-set maximum pressure, the contacts of pressure
switch (MDR) open. The motor stops and solenoid valve (Y1) is de-energized. Compressed air from the
receiver will flow via the solenoid valve to plunger (12) which causes unloading valve (UV) to open. The
air at the delivery side of the compressor is blown through silencer (9) to atmosphere and check valve
(CV) closes to prevent venting of the receiver.
When the pressure in the air receiver decreases to the pre-set minimum pressure, the contacts of the
pressure switch close. The motor restarts and, after switching over from star to delta, solenoid valve (Y1)
is energized. Control air from the unloader plunger chamber is vented to atmosphere. Unloading valve
(UV) closes and compressed air is supplied to the receiver again.
2920 1585 00 -7-

Instruction book
S1062
2 Installation and handling
2.1 Dimension drawings
(1)
(14)
2-5 2-3
(5)
(3)
(4)
2
3
(14) 5
2
3
5
(5) (5)
(3) (3)
9820 2239 01/3

55749D
See page 35 for the text on this figure
Fig. 2.1 Dimension drawing, LE/LT2 up to -5 and LF2, -3 Power Pack
2920 1585 00 -8-

Instruction book
S1062
7 5-7 10
(1)
(14)
(3)
(5)
(4)
5
7
10
7
7
10
9820 2239 02/3
(3) 55750D
(5)
Fig. 2.2 Dimension drawing, LE/LT7, -10 and LF5, -7 Power Pack
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Instruction book
S1062
10 10 15-20
(1)
(3)
(5)
(1)
(3)
(5)
(4) (4)
10
10 9820 2239 03/2
55751D
15
20
Fig. 2.3 Dimension drawing, LE10 60 Hz, LE15, -20 and LF10 Power Pack
2920 1585 00 - 10 -
Instruction book
S1062
(1)
(14)
(3)
(5)
(4)
15
20
15-30 9821 0468 00/8
55755D
20-30
Fig. 2.4 Dimension drawing, LT15, -20 and LT15-30, LT20-30 Power Pack
2920 1585 00 - 11-

Instruction book
S1062
(1)
(14)
(3)
(15)
(4)
Base-
mounted
2
3
5 9820 2239 42/1
55752D
2
3
5
Fig. 2.5 Dimension drawing, LE/LT2 up to -5 and LF2 Base-mounted
2920 1585 00 - 12 -
Instruction book
S1062
(1)
(14)
(3)
(15)
(4) (4)
Base
-mounted
5
7
9820 2239 43/1
10 55753D
7
7
10
Fig. 2.6 Dimension drawing, LE/LT7 up to -10 and LF5, -7 Base-mounted
2920 1585 00 - 13 -
Instruction book
S1062
10 10 15 - 20
(1)
(3)
(19)
(4)
9820 2239 44
55754D
Fig. 2.7 Dimension drawing, LE10 60 Hz, LE15, -20 and LF10 Base-mounted
2920 1585 00 - 14 -
Instruction book
S1062
2-7 2-7 10
(9) (9)
(10)
(13)
(12)
(4)
2
3
5
5
7
10
9820 2239 41/4
55757D
Fig. 2.9 Dimension drawing, LE/LF/LT2 up to -7 and LE/LT10 50 Hz Pack with optional silencing hood
2920 1585 00 - 15 -
Instruction book
S1062
10 10 15-20
(3)
(5)
(7)
(6)
(8) (4)
10
10
15
9820 2239 27/5

20 55765D
Fig. 2.14 Dimension drawing, Tank-mounted LE10 up to -20 and LF10 (horizontal 250/475 l receiver)
2920 1585 00 - 16 -
Instruction book
S1062
(14) (1)
(3)
(16)
(5)
(17)
(6)
(18) (4)
15/60
15
20
(8) (4)
15/60
15
20
9821 1041 00/8

52784D
Fig. 2.15 Dimension drawing, Tank-mounted LT15, -20 (horizontal 250/475 l receiver)
2920 1585 00 - 17 -
Instruction book
S1062
5-20
(14)
(3)
(5)
(7)
(6)
2-3
(14)
(3)
(5)
(6)
(4)
2-3
7-10
7-10
15-20
7
10
9820 8006 00/3

55769D
Fig. 2.18 Dimension drawing, LE/LT/LF with CD dryer
2920 1585 00 - 18 -
Instruction book
S1062
Texts on figures 2.1 up to 2.20
(1) Air inlet

(2) Hole, 15 x 25 (4x)
(3) Cooling air inlet
(4) Net mass
(5) Compressed air outlet, G 1/2
(6) Manual condensate drain
(7) Hole, 15 x 25 (3x)
(8) Receiver
(9) Cooling air outlet
(10) Motor cooling air inlet
(11) Compressed air outlet
(12) Hole, 15 x 24 (4 x), can be used for fixing without rubber pads
(13) Compressor cooling air and air inlet
(14) For dismantling air filter
(15) Compressor air outlet with flexible (2 meter)
(16) Electric cable entry (on rear side)
(17) Hole (4x)
(18) EURO receiver
(19) Air outlet
2920 1585 00 - 19 -
Instruction book
S1062
2.4 Settings of overload relay - fuses - cable size
2.4.1 Settings of overload relay - fuses of compressors with DOL starter
50 Hz
Type Voltage Overload relay Fuses

(V) (A) (A)
LE/LF/LT2 230 (1-phase) 9.3 16
LE/LF/LT2 230 6.7 10
LE/LF/LT2 400 4.1 10
LE/LF2 500 3.5 10
LE/LF/LT3 230 (1-phase) 13.7 25

LE/LF/LT3 230 9.3 16
LE/LF/LT3 400 5.6 10
LF/LT5 230 15.7 25

LE/LF/LT5 400 9.3 16
LE/LF/LT7 230 20.3 25

LE/LT7 400 12.4 25
LT10 400 14.7 25
60 Hz

(V) (A) (A)
LE/LF/LT2 230 8.1 10
LE/LF/LT2 440 4.1 10
LE/LF/LT3 440 5.7 10
LE/LT5 380 11.1 25

LE/LT5 440 9.8 16
LE/LT5 460 9.4 16
LE/LT7 230 25.1 40

LE/LF7 440 12.8 25
LE/LT7 575 8.3 10
LE/LT10 230 28.5 40

LE/LT10 460 14.5 25
LE/LT10 575 11.7 25
LE15 230 39.9 63

LE15 460 20.2 40
LE20 575 19.9 40
2920 1585 00 - 20 -
Instruction book
S1062
2.4.2 Settings of overload relay - fuses of compressors with Y-D starter
50 Hz

(V) (A) (A)
LE/LT5 230 9.1 25
LE/LT5 400 5.4 16
LE/LT5 500 4.3 16
LE/LF/LT7 230 12.2 25

LE/LF/LT7 500 5.5 16
LE/LF/LT10 230 14.5 40

LE/LF/LT10 400 8.5 25
LF10 500 7.0 25
LE15 230 21.5 63

LE15 400 13.1 40
LE15 500 9.8 25
LE20 230 29.4 63

LE20 400 16.9 40
LE20 500 13.7 40

(V) (A) (A)
LT15-30 230 22.4 40
LT15-30 400 12.9 25
LT15 230 22.4 40

LT15 400 12.9 25
LT20 230 30.8 63

LT20 400 17.9 40
LT20-30 230 30.8 63

LT20-30 400 17.9 40
2920 1585 00 - 21 -
Instruction book
S1062
60 Hz

(V) (A) (A)
LE5 230 11.8 25
LE5 380 6.9 25
LE/LT5 440 5.7 16
LE5 460 5.4 16
LE/LT5 575 4.3 16
LE7 230 14.4 40

LE7 380 8.2 25
LF/LT7 460 6.5 16
LE/LT10 380 10.5 25

LE/LF/LT10 440 9.0 25
LE15 230 20.1 40

LE15 460 12.7 40
LE20 230 27.2 63

LE20 380 16.7 40
LE20 440 17.6 40
LE20 460 17.0 40

(V) (A) (A)
LT15-30 230 28 63
LT15-30 380 15.7 40
LT15 230 28 63
LT15 380 15.7 40
LT20 380 18.1 40
LT20-30 380 18.1 40
2.4.3 Cable size
Starter Cable size

mm²
LE/LF/LT2, -3 DOL 2.5
LE/LF/LT5, -7 DOL 4
LT10 DOL 6
LE/LT5 Y/D 2.5
LE/LF/LT7 Y/D 4
LE/LF/LT10 - LT15/60 – LT15-30 Y/D 6
LE15 - LT15 Y/D 6
LE20 – LT20 – LT20-30 Y/D 10
2920 1585 00 - 22 -
Instruction book
S1062
2.5 Pictographs
1 Temperature
2 Pressure
3 On
4 Off
5 Warning: voltage
6 Switch off voltage and depressurize before
maintenance or repair
7 Read Instruction book before starting
8 Consult Instruction book for correct direction
of rotation
9 Do not adjust switch if it is depressurized
Fig. 2.32 Pictographs (typical examples)
2920 1585 00 - 23 -
Instruction book
S1062
3 Operating instructions
Safety precautions
The operator must apply all relevant safety precautions, including those mentioned in this book.
3.1 Initial start-up
If the compressor has not run for the past 6 months (at initial start-up check the date on the data plate), it
is strongly recommended to improve the lubrication of the compressor element: drain the oil, refill the
compressor with the same oil while turning the crankshaft.
It is strongly recommended to install an interstage drain kit, to remove excess condensate, on LT

compressors with a load factor less than 20% per hour. Consult Atlas Copco.
1. For Tank-mounted units, remove the transport brackets from underneath the compressor.
2. Check the electrical installation, which must be in accordance with the instructions given in section
2.3.
3. LE/LT are filled with PAO (polyalphaolefine) compressor oil. Check that the oil level is still near the
top of the red circle of sight-glass (SG-Fig. 1.3). Top up, if necessary.
4. Switch on the voltage. Start the motor.
5. On three-cylinder compressors, check for correct direction of rotation as indicated by the arrow on the
fan housing. If the rotation direction is wrong, switch off the voltage and reverse two of the input line
connections.
6. Check the operation of the air pressure switch. See section 5.4 or 5.5. Check the operation of pilot
valve (RV) on LE/LF/LT Trolley. See section 5.6.
3.2 Starting
LE/LF/LT
1. On LE/LT, check the oil level, which must be near the top of the red circle of sight-glass (SG-Fig. 1.3).
The minimum level is the lower part of the red circle.
2. Switch on the voltage.
3. Move switch (4-Fig. 5.6) to position I or push switch (S1-Fig. 2.26) to position I.
4. Open the air outlet valve (AV-Figs. 1.4/1.6).
5. Regularly drain condensate (Dm-Figs. 1.4/1.7).
LE/LF/LT Trolley with electrical motor

2. Set pilot valve (RV-Fig. 1.12) in the unload position by turning the red handle 90 degrees (see section
5.6).
3. Attach the air lines to the air outlets.
4. Plug in and switch on the voltage at the main circuit breaker.
Warning
Never move the compressor after plugging in.
5. Move switch (4-Fig. 5.6) to position I or push switch (S1-Fig. 2.26) to position I.
2920 1585 00 - 24 -
Instruction book
S1062
6. Open the outlet valves (AV1/2-Figs. 1.12 and 1.16).

7. Set pilot valve (RV-Fig. 1.16) in the load position by turning the red handle 90 degrees (see section
5.6).
8. Turn the regulating knob of the pressure regulator (14-Fig. 1.12) clockwise or anti-clockwise to
increase or decrease the pressure at the outlet of the pressure regulator.
9. Regularly drain condensate (Dm-Fig. 1.15).
LE/LF/LT Trolley with petrol engine

2. Check the engine oil level as follows:
- Remove the oil filler cap and wipe the dipstick clean.
- Insert the dipstick into the filler neck, but do not screw it in.
- The oil level must show between the minimum and maximum marks on the dipstick.
3. Fill the fuel tank with unleaded or low-leaded petrol (gasoline).
4. Start the engine, consult the engine "Owner's manual".
5. Attach the air lines to the air outlets.
6. Open the outlet valves (AV1/2-Figs. 1.12 and 1.16).
7. Set pilot valve (RV-Fig. 1.16) in the load position by turning the red handle 90 degrees (see section
5.6).
8. Turn the regulating knob of the pressure regulator (14-Fig. 1.12) clockwise or anti-clockwise to
increase or decrease the pressure at the outlet of the pressure regulator.
9. Regularly drain condensate (Dm-Fig. 1.16).
3.3 Stopping
LE/LF/LT
1. Move switch (4-Fig. 5.6) to position 0 or push switch (S1-Fig. 2.26) to position 0.
2. Close air outlet valve (AV-Figs. 1.4/1.6).
3. Switch off the voltage.
If a compressor with pressure switch with pressure release valve stops during operation through a power
failure, the pressure from the air receiver must be released by moving the switch on top of the air pressure
switch to 0 to prevent the compressor from restarting against back-pressure when the power becomes live
again.
LE/LF/LT Trolley
1. Set pilot valve (RV-Fig. 1.16) in the unload position by turning the red handle 90 degrees (see section
5.6).
2. On LE/LF/LT Trolley with electrical motor, move switch (4-Fig. 5.6) to position 0 or push switch
(S1-Fig. 2.26) to position 0.
If the compressor is not required for immediate further use, switch off the voltage at the main circuit
breaker and unplug.
3. On LE/LF/LT Trolley with petrol engine:
Stop the engine, consult the engine "Owner's manual".
4. Close the air outlet valves (AV1/2-Fig. 1.12 and 1.16). Depressurize and disconnect the air lines from
the outlet valves.
2920 1585 00 - 25 -
Instruction book
S1062
3.4 Taking out of operation at end of compressor service life
At the end of the service life of the compressor, proceed as follows:
1. Stop the compressor and close the air outlet valve(s).

2. Switch off the voltage and disconnect the compressor from the mains.
3. Depressurize the compressor.
4. Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect the
compressor from the air net.
5. On LE/LT, drain the oil.
2920 1585 00 - 26 -
Instruction book
S1062
4 Maintenance
4.1 Petrol engine maintenance

Consult the engine "Owner's manual".
4.2 Preventive maintenance schedule of the compressor 1)

The schedule contains a summary of the maintenance instructions. Read the respective section before
taking maintenance measures.
When servicing, replace all disengaged packings, e.g. gaskets,

O-rings, washers.
The "longer interval" checks must also include the "shorter interval" checks.
Period 2) Running Consult See Preventive Operation

hours 2) section notes maintenance
below kit (Fig. 4.1)
table
Weekly ------ 3.2 1 -- On LE/LT, check oil level
" ------ -- -- -- Drain condensate from air receiver or
pulsation damper
6-monthly ------ 5.7/5.8 2 -- Test safety valve, and if provided also

relief valve
" ------ 4.4/5.3 3/4 2 Inspect air filter
Yearly 500 4.4/5.3 3/4 2 On LF10, LE15, LT15/60 LT15 and

LE/LT20, replace air filter
" 600 4.4/5.3 3/4 2 On LE/LT5, -7, -10 and LF5, -7,
replace air filter
" 800 4.4/5.3 3/4 2 On LE/LF/LT2, -3, replace air filter
" 2000 -- -- 2 Change blow-off silencer, if provided
" 2000 4.3 -- -- On LE/LT, if mineral oil is used, change
oil
2-yearly 3000 4.3 -- 5 On LE/LT, if Atlas Copco PAO oil is

used, change oil
----- 3000 to 4.4/5.1 -- 3/4 Replace check valve or unloader

4000
----- 4000 4.4/5.2 -- 1 On LE/LT2, -3, -5, LT15/60, -15, -20,
replace valve discs
----- 5000 4.4/5.2 -- 1 On LE/LT7, -10, replace
valve discs
----- 7500 4.4/5.2 -- 1 On LF, replace valve discs
Notes
1. Maintain the level in the red circle of the sight-glass.
2. Wear gloves and safety glasses.
3. For normal operation in clean surroundings. More frequently when operating in a dusty environment.
4. In a dusty environment, a heavy-duty filter (available as an option) is essential.
2920 1585 00 - 27 -
Instruction book
S1062
4.3 Lubrication of LE/LT compressors

It is strongly recommended to use the Atlas Copco approved PAO (polyalphaolefine) compressor oil to
keep the compressor in excellent operating condition.
Atlas Copco PAO oil can be ordered in following quantities:
PAO oil Ordering number

1-litre can 1503 6142 63
5-litre can 1503 6142 60
1 Valve kit
2 Filter kit
3 Check valve
4 Unloader
5 PAO oil
Fig. 4.1 Preventive maintenance kits (typical examples) 3)
4.4 Service kits

Service kits are available offering the benefits of genuine Atlas Copco parts while keeping the
maintenance budget low. The kits comprise all parts needed for servicing. Consult the Parts list for the
contents of all kits.
Service kit for air filter (AF) Ordering number Ref. on Fig. 4.1
For LE/LF/LT2, -3 1503 6143 60 2
For LE/LF/LT5 up to -7 and LE/LT10 50 Hz 1503 6129 60 2
For LE10-60 Hz, LF10, LE15, LE20, LT15 and 1503 6130 60 2
LT20
Service kit for unloader (UA) Ordering number Ref. on Fig. 4.1
For LE/LF/LT5 up to –10 1503 6176 60 4
Service kit for check valve (CV) Ordering number Ref. on Fig. 4.1
For all LE/LF/LT5 up to -20 1503 6177 60 3
2920 1585 00 - 28 -
Instruction book
S1062
Service kit for valve discs Ordering number Ref. on Fig. 4.1
For LE2 up to -5 and LF2, -3 1503 5800 60 1
For LE7, LE10 50 Hz and LF5, LF7 1503 5800 61 1
For LT2 up to -5 1503 5800 62 1
For LT7, LT10 50 Hz 1503 5800 63 1
For LE10 60 Hz, LE15, LE20 and LF10 1503 5800 64 1
For LT15/60 and LT15 1503 6140 60 1
For LT20 1503 6141 60 1
Footnotes chapter 4
1) Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not
covered by Warranty or Product Liability.
2) Whichever interval comes first. The local Sales Company may overrule the maintenance schedule,
especially the service intervals, depending upon the environmental and working conditions of the
compressor.
3) For the contents of all kits, consult the Parts list.
2920 1585 00 - 29 -
Instruction book
S1062
5 Servicing and adjustment procedures
Warning
Release the pressure from the compressor before starting repair or maintenance works. Switch off the
voltage and isolate the compressor from the mains.
5.1 Unloader or check valve

It is recommended to replace the unloader or check valve as indicated in section 4.2.
Dirt, condensate, coke formation and oxidation influence the proper operation of the valve. Depending on
the environmental and working conditions (ambient temperature, working pressure, load cycle, oil type),
the local Sales company may overrule the maintenance schedule (consult Atlas Copco).
5.2 Valves
A faulty valve must be replaced immediately. A faulty valve can be discovered as stated in section 6,
points 1 and 4. Consult Atlas Copco.
It is highly recommended to replace the valve discs, O-rings and gaskets if disassembling the cylinder
heads.
Fig. 5.1 LE2 up to -7, LE10 50 Hz, LF2 up to -5 Fig. 5.2 High-pressure side of LF7, LT15/60, LT15-
Low-pressure side of LE10 60 Hz, LE15, -20, 30, LT15, LT2 up to -10
LF7, -10, LT15/60, LT15-30, LT15, -20, LT20-
30, LT2 up to -10
2920 1585 00 - 30 -
Instruction book
S1062
12
16
5
6
7
8
9
14
15
13
3 2
4
52826D 10
Fig. 5.3 High-pressure side of LE10 60 Hz, LE15, -20, LF10, LT20, LT20-30
1 Bolt 9 Guide pin

2 Joint 10 Joint
3 O-ring 11 Cylinder
4 Spring 12 Cylinder cover
5 Outlet valve guard 13 Cylinder head
6 Outlet valve disc 14 Joint
7 Valve seat 15 Outlet cap
8 Inlet valve disc 16 Joint
Figs. 5.1 up to 5.3 Cylinder heads
2920 1585 00 - 31 -
Instruction book
S1062
5.2.1 Replacement of valve discs (Figs. 5.1 and 5.2)
LE2, -3, -5, -7 HP cylinder HP cylinder Operation sequence

LE10 50 Hz for for
LF2, -3, -5 LF7 LE10 60 Hz
LT15/60, -15 LE15, -20
LP cylinder for LT15-30 LF10
LE10 60 Hz LT2, -3, -5, -7 LT20
LE15, -20 LT10 LT20-30
LF7, -10
LT15/60, -15, -20
LT15-30, LT20-30
LT2, -3, -5, -7, -10
See Figs. 5.1/5.2 See Figs.5.1/5.2 See Fig. 5.3
X X X Remove the fan guard, unscrew the cap and remove
the cover (1-Fig. 1.1), air filter and cover of the air
inlet silencer.
X Disconnect cylinder head cover (12) from the inlet
and outlet pipe flanges. Remove cover (12).
X X Disconnect head (13) from the inlet and outlet pipe
flanges. Remove cylinder head cover (12). Remove
head (13).
X X X Remove spring (4), outlet valve guard (5) and outlet
valve disc (6).
X X X Lift off valve seat (7) and remove inlet valve disc (8).
Do not remove guide pins (9).
X X X Remove and discard all O-rings/gaskets and joints.
X X X If necessary, remove the carbon deposits from the
inlet valve guard at the cylinder top. Take care that
no dirt drops into the cylinder.
X X X Clean and inspect all parts.
X X X Fit a new joint (10). Do not stretch the cord while
inserting it in its groove; the ends should meet.
X X X Put a new inlet valve disc (8) into place and install
valve seat (7).
X X X Fit a new O-ring (3) and joint (2).
X X X Install a new outlet valve disc (6), guard (5) and
spring (4).
X Install cylinder head cover (12). Fit new O-
rings/gaskets for the pipe flanges. Fit the flange and
cylinder head bolts and tighten them alternately.
X Reinstall head (13). Fit a new joint (14). Install
cylinder head cover (12). Fit new O-rings/gaskets for
the pipe flanges. Fit the flange and cylinder head
bolts and tighten them alternately.
X Fit a new joint (16) and install head (13) and cap (15).
Fit a new joint (14). Install cylinder head cover (12).
Fit new O-rings/gaskets for the pipe flanges. Fit the
flange and cylinder head bolts and tighten them
alternately.
X X X Reinstall the fan guard, cover of the air inlet silencer,
air filter, cover (1-Fig. 1.1) and cap.
2920 1585 00 - 32 -
Instruction book
S1062
Torque value Torque value Torque value

M6: 10 Nm +/- 2 M8: 23 Nm +/- 2 M10: 46 Nm +/- 5
5.3 Air filter
1. Stop the compressor.

2. On LE/LF/LT2 up to -7, LE/LT10 50 Hz, LT15, -20 and LT15-30, LT20-30: unscrew the cap on top of
cover (1-Fig. 1.1). Lift off the cover and filter element. Take care that no dirt drops inside the suction
silencer.
On LE10 60 Hz, LF10 and LE15, -20: unscrew cap (1-Fig. 1.7) and take out the air filter. Take care
that no dirt drops inside the suction silencer.
3. Using a damp cloth, clean the filter chamber and cover. Discard damaged elements.
4. Install the new element, cover and cap.
2920 1585 00 - 33 -
Instruction book
S1062
5.4 Adjustment of MDR4S pressure switch (Figs. 5.4 up to 5.6)
The adjustment of the maximum or stopping pressure of the compressor is effected by means of the air
pressure switch. The switch also controls the pressure difference between the maximum pressure
(stopping pressure) and that at which compression is resumed (starting pressure).
Caution
- Adjust the air pressure switch while it is pressurized.
- Switch off the voltage before removing the cover of the switch; reinstall it after an adjustment has
been made and before the voltage is switched on again.
Adjustment
The maximum pressure is controlled by adjusting screw (4). Turn the screw clockwise to raise the
maximum or stopping pressure, anti-clockwise to lower it.
The pressure difference is adjusted by means of screw (5). To reduce the difference between the
stopping and starting pressures, i.e. increase the starting pressure, turn the screw anti-clockwise. To
increase the pressure difference, turn the screw clockwise. The adjustment range is shown on the
diagrams (Fig. 5.6).
Fig. 5.4 View of air pressure switch MDR4S Fig. 5.5 Adjusting screws, MDR4
1 Air pressure switch

2 Solenoid valve
3 Pressure release valve
4 Adjusting screw, stopping pressure
5 Adjusting screw, pressure difference
Figs. 5.4 and 5.5 Air pressure switch
2920 1585 00 - 34 -
Instruction book
S1062
Example: LE
Stopping pressure: 7 bar(e)
Starting pressure: adjustable between 3 and 5.7 bar(e)
Fig. 5.6 Pressure difference diagrams, MDR4S/11 bar and MDR4S/25 bar
2920 1585 00 - 35 -
Instruction book
S1062
5.5 Adjustment of MDR3 pressure switch (Figs. 5.7 and 5.8)
The switch allows the operator to select the stopping pressure and the pressure difference between
stopping and starting pressures. The stopping and starting pressures are the opening and closing
pressures of the switch.
The stopping pressure is controlled by adjusting screw (2). Turn the screw clockwise to raise the stopping
pressure, anti-clockwise to lower it.
The pressure difference between starting and stopping is adjusted by means of adjusting screw (3). The
adjustment range is given in Fig. 5.8. Turn the screw anti-clockwise to reduce the pressure difference,
clockwise to increase it.
1 Dial, overload relay

2 Adjusting screw, stopping pressure
3 Adjusting screw, pressure difference
4 On/off switch
Figs. 5.7 Air pressure switch MDR3 with ON/OFF switch (30 bar units)
52831D
STARTING PRESSURE (1)
30
26
22
18
bar(e)
14
10
6 10 14 18 22 26 30 34
STOPPING PRESSURE (2)
bar(e)
(1) Starting pressure

(2) Stopping pressure
Figs. 5.8 Pressure difference diagram, MDR3 30 bar
2920 1585 00 - 36 -
Instruction book
S1062
5.7 Safety valve (SV-Figs. 1.4, 1.6 and 1.8) 1)
Replace the valve if it does not open at the correct pressure. No adjustments are allowed.
Testing
Testing as described below shall only be carried out by competent personnel.
5.7.1 Testing on LE/LF/LT

1. Close the air outlet valve, depressurize and disconnect the hose or pipe from the valve.
2. Start the compressor and run it until it stops automatically.
3. Switch off the voltage.
Remove the cover from the air pressure switch and, with the air receiver now under pressure, turn the
adjusting screw one turn clockwise to increase the stopping pressure (see also sections 5.4/5.5).
Reinstall the cover.
4. Switch on the voltage, slightly open the outlet valve and start the compressor.
5. Gradually close the outlet valve while checking the air pressure gauge. If the safety valve has not
opened at the pressure specified in section 7, it must be replaced by a new one. If the compressor
unloads before the specified opening pressure is reached, repeat the procedure as mentioned from
step 3.
6. Readjust the unloading pressure as described in sections 5.4 and 5.5.
7. Reconnect the hose or pipe to the closed air outlet valve.
5.7.2 Testing on LE/LF/LT Trolley

1. Close the air outlet valves, depressurize and disconnect the hoses from the valves.
2. Loosen the red handle of the pilot valve (1-Fig. 5.9) and the two nuts (3).
3. Open outlet valve (AV1-Fig. 1.16) a fraction. Start the compressor.
4. Gradually turn adjusting screw (2-Fig. 5.9) clockwise while checking pressure gauge (Gp-Fig. 1.16).
If the safety valve has not opened at the pressure specified in section 7, it must be replaced by a new
one.
5. Readjust the normal working pressure after testing. Consult section 5.6.
6. Fit nuts (3-Fig. 5.9) and handle (1) in their original positions.
5.8 Relief valve (8-Fig. 1.1) on LF7, -10, LE10 up to -20 and LT
The relief valve protects the LP side of the compressor. No adjustments are allowed.
Testing
Testing as described below shall only be carried out by competent personnel.
Remove the relief valve and fit a 3/8 inch B.S.P. plug instead. Remove the safety valve from the air
receiver and replace it by the relief valve. The latter can then be tested at increasing air receiver pressure
after the compressor has been started with open air outlet valve. If the valve has not opened at the
pressure specified in section 7, it must be replaced by a new one. Reinstall the valves in their respective
places after testing.
Footnote chapter 5
1) Not on Compressor Block/Power Pack
2920 1585 00 - 37 -
Instruction book
S1062
6 Problem solving
1 Insufficient air pressure

a Air leak
a Check and correct as necessary
b Air filter choked
b Replace filter
c Air pressure switch incorrectly set
c Adjust switch
d Air consumption exceeds maximum output of compressor
d Check equipment connected
e Damaged valve
e Inspect valves and replace parts where necessary
f Unloader 1) malfunctioning
f Inspect and replace parts where necessary
g Solenoid valve 1) out of order
g Remove and check. Replace if necessary
2 Unit does not speed up

a Voltage drop at motor terminals
a Consult power supplier. Use correct size of cable
b Unloader malfunctioning
b See 1f
c Solenoid valve out of order
c See 1g
d Blow-off silencer 1) choked
d Replace
3 Air receiver pressure rises above maximum and causes safety valve to blow
a Air pressure switch or pilot valve 1) incorrectly set or out of order
a Check. Replace switch or valve, if necessary
b Solenoid valve defective
b See 1g
c Unloader malfunctioning
c See 1f
d Blow-off silencer choked
d See 2d
4 Relief valve blows 1)

a Defective inlet valve in HP cylinder head
a Inspect and replace part(s) as necessary
b Relief valve not airtight
b Replace valve
5 Receiver does not hold pressure

a Check valve leaks
a Check for broken valve and springs
b Air leaks
b Check and correct as necessary
6 Too frequent starting/too short operating periods

a Air pressure switch or pilot valve 1) incorrectly set
2920 1585 00 - 38 -
Instruction book
S1062
a Increase pressure difference

b Check valve leaks
b See 5a
7 High oil consumption on LE/LT compressors

a Oil level too high
a Do not overfill crankcase. Keep level in red circle of sight-glass
b Piston ring(s) worn or broken
b Have condition of piston rings checked
8 Unit does not start

a Electrical failure
a Have electrical system checked. Check fuses and line terminals for tightness
b Overload relay cut out
b Reset overload relay. If the relay cuts out again after starting, see point 9
c Air pressure above pre-set starting pressure
c Compressor will start when air pressure is lower than pre-set starting pressure of air pressure
switch
9 Overload relay cuts out

a Overload relay incorrectly set
a Check and adjust. Reset relay
b Solenoid valve out of order
b See 1g
c Unloader plunger jammed
c See 1f
d Blow-off silencer choked
d See 2d
e Ambient temperature too high
e Improve ventilation of room
f Motor stops and starts too frequently
f See 6
g Overcurrent due to motor or compressor failure
g Consult Atlas Copco
Footnote chapter 6
1) If provided.
2920 1585 00 - 39 -
Instruction book
S1062
7 Principal data
7.1 Reference conditions
Inlet pressure (absolute) bar 1

Relative air humidity % 0
Air inlet temperature °C 20
Working pressure:
- for LE 10 bar bar(e) 7
- for LF 10 bar bar(e) 7
- for LT 15 bar bar(e) 12
7.2 Limitations
Minimum inlet temperature °C 0

Maximum inlet temperature °C 40
Maximum working pressure bar(e) See below
7.3 Compressor data for LE 10 bar

7.3.1 50 Hz
Compressor type LE2 LE3 LE5 LE7 LE10 LE15 LE20

Maximum working pressure for LE bar(e) 10 10 10 10 10 10 10
Maximum working pressure for LE bar(e) 9.5 9.5 9.5 9.5 9.5 9.5 9.5
Trolley
Pre-set pressure difference for LE bar 1 1 1 1 1 1 1
Trolley
Temperature at outlet valve,
approx.
- Unsilenced compressor °C 40 44 66 59 80 65 91
- Silenced compressor °C 48 52 74 67 88 73 99
Power input at max. working kW 1.82 2.54 4.57 6.11 8.28 10.69 14.92
pressure
Motor shaft speed r/min 1500 1500 1500 1500 1500 1500 1500
Free air delivery 2) l/s 3.4 4.4 8.4 11.7 15.7 18.6 23.9
Oil capacity l 0.8 0.8 0.8 1.4 1.4 1.7 1.7
Opening pressure of safety valve bar(e) 11 11 11 11 11 11 11
(not for Block/Power Pack)
Maximum sound pressure level 1):
-Standard version dB(A) 78 79 79 80 81 84 85
-Silenced Tank-mounted version dB(A) 65 66 66 70 70 73 73
-Base-mounted version dB(A) 63 64 64 68 68 70 70
2920 1585 00 - 40 -
Instruction book
S1062
7.3.2 60 Hz
Compressor type LE2 LE3 LE5 LE7 LE10 LE15 LE20

Maximum working pressure for LE bar(e) 10 10 10 10 10 10 10
Maximum working pressure for LE bar(e) 9.5 9.5 9.5 9.5 9.5 9.5 9.5
Trolley
Pre-set pressure difference for LE bar 1 1 1 1 1 1 1
Trolley
approx.
pressure
Oil capacity l 0.8 0.8 0.8 1.4 1.7 1.7 1.7
Opening pressure of safety valve bar(e) 11 11 11 11 11 11 11
2920 1585 00 - 41 -
Instruction book
S1062
7.4 Compressor data for LF 10 bar
7.4.1 50 Hz
Compressor type LF2 LF3 LF5 LF7 LF9

Maximum working pressure for LF bar(e) 10 10 10 10 10
Maximum working pressure for LF bar(e) 9.5 9.5 9.5 9.5 9.5
Trolley
Pre-set pressure difference for LF bar 1 1 1 1 1
Trolley
approx.
- Unsilenced compressor °C 40 44 45 50 51
- Silenced compressor °C 48 52 53 58 59
Power input at max. working kW 2.05 2.71 5.11 5.89 8.65
pressure
Motor shaft speed r/min 1500 1500 1500 1500 1500
Free air delivery 2) l/s 3.1 4.0 7.6 9.2 14.4
Opening pressure of safety valve bar(e) 11 11 11 11 11
-Standard version dB(A) 82 83 83 84 86
-Silenced Tank-mounted version dB(A) 69 70 70 74 77
-Base-mounted version dB(A) 67 68 68 72 74
7.4.2 60 Hz
Compressor type LF2 LF3 LF5 LF7 LF10

Maximum working pressure for LF bar(e) 10 10 10 10 10
Maximum working pressure for LF bar(e) 9.5 9.5 9.5 9.5 9.5
Trolley
Pre-set pressure difference for LF bar 1 1 1 1 1
Trolley
approx.
pressure
2920 1585 00 - 42 -
Instruction book
S1062
7.5 Compressor data for LT 15 bar

7.5.1 50 Hz
Compressor type LT2 LT3 LT5 LT7 LT10

Maximum working pressure for LT bar(e) 15 15 15 15 15
Maximum working pressure for LT bar(e) 13.7 13.7 13.7 13.7 13.7
Trolley
Pre-set pressure difference for LT bar 1 1 1 1 1
Trolley
Temperature at outlet valve, °C
approx.
pressure
Oil capacity l 0.8 0.8 0.8 1.4 1.4
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5 6.5
7.5.2 60 Hz
Compressor type LT2 LT3 LT5 LT7

Maximum working pressure for LT bar(e) 15 15 15 15
Maximum working pressure for LT bar(e) 13.7 13.7 13.7 13.7
Trolley
Pre-set pressure difference for LT bar 1 1 1 1
Trolley
Temperature at outlet valve, approx.
- Unsilenced compressor °C 57 66 81 65
- Silenced compressor °C 65 74 89 73
Power input at max. working pressure kW 2.49 3.44 6.16 8.27
Motor shaft speed r/min 1800 1800 1800 1800
Free air delivery 2) l/s 3.6 4.7 7.9 10.9
Oil capacity l 0.8 0.8 0.8 1.4
Opening pressure of safety valve (not bar(e) 16 16 16 16
for Block/Power Pack)
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5
-Standard version dB(A) 80 81 81 82
-Silenced Tank-mounted version dB(A) 67 68 68 72
-Base-mounted version dB(A) 65 66 66 70
2920 1585 00 - 43 -
Instruction book
S1062
7.6.1 50 Hz
Compressor type LT2 LT3 LT5 LT7 LT10 LT15/60 LT15 LT20
Maximum working pressure bar(e) 20 20 20 20 20 20 20 20
approx.
- Unsilenced compressor °C 37 49 60 43 56 52 76 90
- Silenced compressor °C 45 57 68 51 64 60 84 96
Power input at max. working kW 2.04 2.56 4.21 5.33 6.97 6.25 9.76 12.2
pressure
Motor shaft speed r/min 1500 1500 1500 1500 1500 1500 1500 1500
Free air delivery 2) l/s 2.1 2.9 5.0 6.7 9.1 10.2 15.1 18.0
Oil capacity l 0.8 0.8 0.8 1.4 1.4 5.1 5.1 5.1
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5
Maximum sound pressure level 1)
-Standard version dB(A) 78 79 79 80 81 85 86.5 86
-Silenced Tank-mounted version dB(A) 65 66 66 70 70 76 77 80
-Base-mounted version dB(A) 63 64 64 68 68 -- 72 75
7.6.2 60 Hz
Compressor type LT2 LT3 LT5 LT7 LT15/60 LT15 LT20

Maximum working pressure bar(e) 20 20 20 20 20 20 20
approx.
pressure
Oil capacity l 0.8 0.8 0.8 1.4 5.1 5.1 5.1
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5 6.5 6.5 6.5
2920 1585 00 - 44 -
Instruction book
S1062
7.7.1 50 Hz
Compressor type LT3 LT5 LT7 LT10 LT15-30 LT20-30

Maximum working pressure bar(e) 30 30 30 30 30 30
approx.
- Unsilenced compressor °C 49 60 42 58 52 52
- Silenced compressor °C 57 68 50 66 60 60
Power input at max. working kW 2.83 4.73 6.11 7.89 6.8 13.5
pressure
Motor shaft speed r/min 1500 1500 1500 1500 1500 1500
Free air delivery 2) l/s 2.5 4.4 6.4 8.5 9.28 17.0
Oil capacity l 0.8 0.8 1.4 1.4 5.1 5.1
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5 6.5 6.5
-Standard version dB(A) 79 79 80 81 85 86
-Base-mounted version dB(A) 64 64 68 68 76 80
7.7.2 60 Hz
Compressor type LT3 LT5 LT7 LT15-30 LT20-30

Maximum working pressure bar(e) 30 30 30 30 30
Temperature at outlet valve, approx.
Power input at max. working pressure kW 3.44 5.77 7.63 8.42 16.4
Oil capacity l 0.8 0.8 1.4 5.1 5.1
Opening pressure of relief valve bar(e) 6.5 6.5 6.5 6.5 6.5
Footnotes chapter 7
1) According to CAGI PNEUROP PN8NTC2.2.

2) At reference conditions
2920 1585 00 - 45 -
Instruction book
S1062
8 Conversion list of SI units into US/British units
1 bar = 14.504 psi

1 g = 0.035 oz
1 kg = 2.205 lb
1 km/h = 0.621 mile/h
1 kW = 1.341 hp (UK and US)
1 l = 0.264 US gal
1 l = 0.220 Imp gal (UK)
1 l = 0.035 cu.ft
1 m = 3.281 ft
1 mm = 0.039 in
1 m 3/min = 35.315 cfm
1 mbar = 0.401 in wc
1 N = 0.225 lbf
1 Nm = 0.738 lbf.ft
x degrees °C = (32 + 1.8 x) °F 1)
Footnote chapter 8
1) A temperature difference of 1 °C = a temperature difference of 1.8 °F.
9 PED (Pressure Equipment Directive)
9.1 Components subject to 97/23/EC Pressure Equipment Directive
Components subject to 97/23/EC Pressure Equipment Directive greater than or equal to Category II
Part number Description PED Class

0830 1007 40 Safety valve IV
9.2 Overall rating
The compressors are conform to PED article 3 paragraph 3 (less than category I)
2920 1585 00 - 46 -
S1062
O WNERSHIP DA TA
Compressor type: ........................................ Unit serial No. compressor: ....................................
Air dryer type: .......................................... Unit serial No. dryer: .........................................
Motor type: ............................................. Motor serial No.: ............................................
Delivery date: ........................................... First start-up date: ...........................................
Service Plan: ............................................ Owner's machine No.: ........................................
Selected lubricants
Compressor: ............................................ Capacity: ..................................................
Bearing grease type, electric motor: .........................
Dryer gearbox ........................................... Capacity ...................................................
Printed Matter Nos.
Atlas Copco compressor instruction book: .................... Atlas Copco air dryer instruction book: ..........................
Atlas Copco compressor parts list: .......................... Atlas Copco air dryer parts list: ................................
Atlas Copco logbook: ....................................................................................................
Local Atlas Copco Representative
Name: ...............................................................................................................
Address: ..............................................................................................................
Telephone: ................................... Contact persons: Service: .........................................
Telex: ...................................... Parts: ...........................................
E-mail ...............................................................................................................
SAFETY PRECA U T I O N S
To be read attentively and acted accordingly before installing, operating or repairing the unit.
These recommendations apply to machinery processing or consuming air or inert gas. Processing of any other gas requires
additional safety precautions typical to the application which are not included herein.
In addition to normal safety rules which should be observed with stationary If necessary, install a suction duct. Never obstruct the air inlet. Care
air compressors and equipment, the following safety directions and shall be taken to minimize the entry of moisture with the inlet air.
precautions are of special importance.
4. The aspirated air shall be free from flammable fumes or vapours,
When operating this unit, the operator must employ safe working practices e.g. paint solvents, that can lead to internal fire or explosion.
and observe all related local work safety requirements and ordinances.
5. Air-cooled units shall be installed in such a way that an adequate
The owner is responsible for maintaining the unit in a safe operating flow of cooling air is available and that the exhausted air does not
condition. Parts and accessories shall be replaced if unsuitable for safe recirculate to the inlet.
operation.
6. Arrange the air intake so that loose clothing of people cannot be
Installation, operation, maintenance and repair shall only be performed sucked in.
by authorized, trained, competent personnel.
7. Ensure that the discharge pipe from the compressor to the aftercooler,
Normal ratings (pressures, temperatures, time settings, etc.) shall be air dryer or air net is free to expand under heat and that it is not in
durably marked. contact with or close to flammable material.
Any modification on the compressor or air dryer shall only be performed
8. No external force may be exerted on the air outlet valve; the connected
in agreement with Atlas Copco and under supervision of authorized,
pipe must be free of strain.
competent personnel.
If any statement in this book, especially with regard to safety, does not 9. If remote control is installed, the unit shall bear an obvious sign
comply with local legislation, the stricter of the two shall apply. reading:
These precautions are general and cover several machine types and DANGER: This machine is remotely controlled and may start
equipment; hence some statements may not apply to the unit(s) described without warning.
in this book.
As a further safeguard, persons switching on remotely controlled
units shall take adequate precautions to ensure that there is no one
Installation checking or working on the machine. To this end, a suitable notice
shall be affixed to the start equipment.
Apart from general engineering practice in conformity with the local
safety regulations, the following directives are specially stressed: 10. On units with automatic start-stop system, a sign stating "This
machine may start without warning" shall be attached near the
1. A compressor or air dryer shall be lifted only with adequate equipment instrument panel.
in conformity with local safety rules.
11. In multiple compressor systems manual valves shall be installed to
Loose or pivoting parts shall be securely fastened before lifting. It is isolate each compressor. Non-return valves (check valves) shall not
strictly forbidden to dwell or stay in the risk zone under a lifted load. be relied upon for isolating pressure systems.
Lifting acceleration and retardation shall be kept within safe limits.
12. Never remove or tamper with the safety devices, guards or insulations
W ear a safety helmet when working in the area of overhead or lifting
fitted on the unit. Every pressure vessel or auxiliary installed outside
equipment.
the unit to contain air above atmospheric pressure shall be protected
2. Any blanking flanges, plugs, caps and desiccant bags shall be by a pressure-relieving device or devices as required.
removed before connecting up the pipes. Distribution pipes and
connections shall be of correct size and suitable for the working 13. Pipework or other parts with a temperature in excess of 80 degrees
pressure. celsius and which may be accidentally touched by personnel in normal
operation shall be guarded or insulated. Other high-temperature
3. Place the unit where the ambient air is as cool and clean as possible. pipework shall be clearly marked.
2920 1377 03 1/2 (continued on inside of cover)

S1062
SAFETY PRECA UTIONS (continued)
14. If the ground is not level or can be subject to variable inclination, 5. Never use flammable solvents or carbon tetrachloride for cleaning
consult Atlas Copco. parts. Take safety precautions against toxic vapours of cleaning
liquids.
15. The electrical connections shall correspond to the local codes. The
units shall be grounded and protected against short circuits by fuses. 6. Scrupulously observe cleanliness during maintenance and repair.
Keep dirt away by covering the parts and exposed openings with a
Operation clean cloth, paper or tape.
1. Air hoses shall be of correct size and suitable for the working pressure. 7. Never weld or perform any operation involving heat near the oil
Never use frayed, damaged or deteriorated hoses. Use only the correct system. Oil tanks must be completely purged, e.g. by steam-cleaning,
type and size of hose end fittings and connections. When blowing before carrying out such operations.
through a hose or air line, ensure that the open end is held securely.
A free end will whip and may cause injury. Make sure that a hose is Never weld on, or in any way modify, pressure vessels.
fully depressurized before disconnecting it.
Whenever there is an indication or any suspicion that an internal
Never play with compressed air. Do not apply it to your skin or part of a machine is overheated, the machine shall be stopped but no
direct an air stream at people. Never use it to clean dirt from your inspection covers shall be opened before sufficient cooling time
clothes. When using it to clean equipment, do so with extreme caution has elapsed; this to avoid the risk of spontaneous ignition of the oil
and use eye protection. vapour when air is admitted.
2. The compressor is not considered as capable of producing air of Never use a light source with open flame for inspecting the interior
breathing quality. For breathing air quality, the compressed air must of a machine, pressure vessel, etc.
be adequately purified according to local legislation and standards.
8. Make sure that no tools, loose parts or rags are left in or on the unit.
3. Never operate the units when there is a possibility of taking in
flammable or toxic fumes. 9. Before clearing the unit for use after maintenance or overhaul, check
that operating pressures, temperatures and time settings are correct
4. Never operate the units at pressures below or in excess of their limit and that the control and shut-down devices function correctly. If
ratings as indicated on the Principal Data sheet. removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
5. Keep all bodywork doors shut during operation. The doors may be
opened for short periods only, e.g. to carry out checks. W ear ear 10. Every time the separator element is renewed, examine the discharge
protectors when opening a door. pipe and the inside of the oil separator vessel for carbon deposits; if
excessive, the deposits should be removed.
6. People staying in environments or rooms where the sound pressure
level reaches or exceeds 90 dB(A) shall wear ear protectors. 11. Protect the motor, air filter, electrical and regulating components,
etc. to prevent moisture from entering them, e.g. when steam-cleaning.
7. Periodically check that:
a. All guards are in place and securely fastened 12. Make sure that all sound-damping material, e.g. on the bodywork
b. All hoses and/or pipes inside the unit are in good condition, secure and in the air inlet and outlet systems of the compressor, is in good
and not rubbing condition. If damaged, replace it by genuine Atlas Copco material
c. There are no leaks to prevent the sound pressure level from increasing.
d. All fasteners are tight
e. All electrical leads are secure and in good order 13. Never use caustic solvents which can damage materials of the air
.
f Safety valves and other pressure-relief devices are not obstructed net, e.g. polycarbonate bowls.
by dirt or paint
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, 14. The following safety precautions are stressed when handling
valves, hoses, etc. are in good repair, free of wear or abuse refrigerant:
8. If warm cooling air from compressors is used in air heating systems, a. Never inhale refrigerant vapours. Check that the working area
e.g. to warm up a workroom, take precautions against air pollution is adequately ventilated; if required, use breathing protection.
and possible contamination of the breathing air.
b. Always wear special gloves. In case of refrigerant contact with
9. Do not remove any of, or tamper with, the sound-damping material. the skin, rinse the skin with water. If liquid refrigerant contacts
the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all
Maintenance refrigerant is flushed away; then seek medical first aid.
Maintenance and repair work shall only be carried out under supervision
of someone qualified for the job. c. Always wear safety glasses.
1. Use only the correct tools for maintenance and repair work. 15. Protect hands to avoid injury from hot machine parts, e.g. during
draining of oil.
2. Use only genuine spare parts.
3. All maintenance work, other than routine attention, shall only be Note: W ith stationary machine units driven by an internal combustion
undertaken when the unit is stopped, the main power supply is engine, allowance has to be made for extra safety precautions, e.g. spark
switched off and the machine has cooled down. Take positive arrestors, fuelling care, etc. Consult Atlas Copco.
precaution to ensure that the unit cannot be started inadvertently.
In addition, a warning sign bearing a legend such as "work in All responsibility for any damage or injuryresulting from neglecting
progress; do not start" shall be attached to the starting equipment. these precautions, or by non-observance of ordinary caution and due
carerequired in handling, operating, maintenance or repair, even if
4. Before removing any pressurized component, effectively isolate the not expressly mentioned in this book, will be disclaimed by Atlas
unit from all sources of pressure and relieve the entire system of Copco.
pressure.
2920 1377 03 2/2

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MANUAL INDEX

2-500 ANFO CHARGER

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 STATEMENT

10829 AXLE ORIENTATION

31481 HYDRAULIC SCHEMATIC

31481 HYDRAULIC SCHEMATIC

13905 ELECTRIC SHIFTER

10. MOUNTED EQUIPMENT

S1011 FIRE EXTINGUISHER #10

1. INTRODUCTION /GENERAL INFORMATION

F1008 PARTS ORDER INSTRUCTIONS

TO AVOID DELAYS AND ASSURE THE MOST EFFICIENT HANDLING, PLEASE

• MODEL TYPE AND FACTORY SERIAL NUMBER OF YOUR MACHINE.

• NAME, MODEL NUMBER, AND SERIAL NUMBER OF THE ASSEMBLY (SUCH

• PART NUMBER (REFER TO THE CORRECT REPAIR PART NUMBER).

• GIVE COMPLETE PART DESCRIPTION.

• EXACT QUANTITY OF PART REQUIRED. (DO NOT ORDER BY SET UNLESS

• SHIPPING INSTRUCTIONS (INCLUDE ROUTING WHEN POSSIBLE).

PLEASE PLACE ALL ORDERS WITH YOUR LOCAL GETMAN DISTRIBUTOR OR

MODEL 2-500 TYPE ANFO

SPEC. 3464 SERIAL NO. 7026

Model: ANFO CHARGER Type: 2-500

Shop No.: 3464 Serial No.: 7026 Truck No.: N/A

Customer: FRANCISCO I MADERO

COMPONENT MANUFACTURER MODEL SPECIFICATION SERIAL NUMBER

COMPRESSOR ATLAS COPCO LE2010UV 605543 WCF435048

†COMMON MAINTENANCE ITEMS

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