020-069 Manual

4MANUAL
INDEX A64 ExC

3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
1. INTRODUCTION /GENERAL INFORMATION
F1008 PARTS ORDER INSTRUCTIONS

F1019 PARTS RETURN POLICY
F1020 GETMAN TECHNICAL TRAINING
F1021 GETMAN WARRANTY
F1022 VEHICLE & PARTS WARRANTY REQUEST FORM
F1009 COMPONENT LIST
-------- SUGGESTED STOCKING GUIDE
M1040 A-64 OPERATION MANUAL
M1006 ANFO/ BOOM OPERATING MANUAL
M1042 DUNBAR CRANE OPERATING MANUAL
M1004 BOOM/ BASKET INSPECTION
M1071 BOLTS TORQUE SHEET
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
S1168 D-RING ANCHORAGE CONNECTOR MANUAL
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
3. ELECTRICAL SYSTEM AND INSTRUMENTS
30343 WIRING DIAGRAM S

17143 INSTRUMENT PANEL
S1100 MURPHY POWERVIEW OPERATION MANUAL
17074 ALTERNATOR
17363 BATTERY BOX ASSEMBLY
S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
4. ENGINE AND ACCESSORIES
F1017 ENGINE OPERATION & MAINTENANCE MANUAL

F1016 ENGINE PARTS MANUAL
17128 ENGINE FILTERS
13967 RADIATOR & CHARGE AIR INSTALLATION
17068 AIR INTAKE SYSTEM
11637 AIR CLEANER
13963 EXHAUST SYSTEM
S1020 EXHAUST INFORMATION
17478 CUMMINS QSB 4.5L ENGINE MOUNT
F1024 CUMMINS ENGINE WARRANTY
5. DRIVE TRAIN
S1005 TRANSMISSION MAINTENANCE & SERVICE

MANUAL
17504 TRANSMISSION
17384 DRIVE PLATE ASSEMBLY
17369 TRANSMISSION MOUNTS
17331 TRANSMISSION DIPSTICK
17493 DRIVELINE INSTALLATION
6. AXLE
S1165 AXLE SERVICE & REPAIR MANUAL

17467 AXLE ASSEMBLY
17461 CRADLE INSTALLATION
17475 TIRE & RIM
S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
7. BRAKE SYSTEM
S1163 BRAKE VALVE SERVICE

17464 BRAKE VALVE
17473 BRAKE VALVE BLOCK
S1009 DUAL CHARGE VALVE SERVICE
16483 DUAL CHARGE VALVE
8. HYDRAULIC SYSTEM
310-020-014 HYDRAULIC SCHEMATIC

S1077 HYDRAULIC SYMBOLS
17132 SERVICEJUNIOR DIGITAL PRESSURE GAUGE
13259 HYDRAULIC FILTER
S1024 STEERING ORBITROL SERVICE
12860 STEERING ORBITROL
13444 BOOM ROTATION HYDRAULIC MOTOR
12857 BOOM CONTROL VALVE (MAIN)
17171 REMOTE BOOM CONTROL VALVE (BASKET)
17170 STABILIZER CONTROL VALVE
13970 BOOM LEVELING CYLINDER
17075 BOOM LIFT CYLINDER
13429 BOOM EXTENSION CYLINDER
13628 BASKET LEVELING CYLINDER
13627 STABILIZER CYLINDER
13943 STEERING CYLINDER
M1080 PREVENTABLE PUMP FAILURE
M1081 HYDRAULIC HOSE CLEANLINESS
9. CONTROLS
13905 ELECTRIC SHIFTER

10827 STEERING WHEEL & COLUMN
13655 THROTTLE (ELECTRONIC)
S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
10. MOUNTED EQUIPMENT
17437 FIRE EXTINGUISHER & BRACKET #10

S1012 FIRE PROTECTION INFORMATION MANUAL
S1013 FIRE SUPPRESSION MAINTENANCE MANUAL
S1014 AUTO FIRE SUPPRESSION MAINTENANCE MANUAL
7334-00015 FIRE SUPPRESSION INSTALLATION (MAIN)
7334-00025 FIRE SUPPRESSION INSTALLATION
(BASKET/PLATFORM OPTION)
17344 FIRE SUPPRESSION SYSTEM
17274 AUTO DETECTION SYSTEM
17148 DUNBAR BOOM ASSEMBLY
13432 ROTATION GEAR BOX
17194 ANFO POT
-------- ANFO POT CERTIFICATION
15174 ANFO PIPING SCHEMATIC
(WITH AIR BOOST CLEAN OUT)
15175 ANFO PIPING SCHEMATIC (POT)
13712 ANFO ACTUATOR
S1027 ACTUATOR SERVICE MANUAL
S1101 EXTERNAL PNEUMATIC VIBRATOR
13651 STABILIZER INSTALLATION
S1102 COMPRESSOR OPERATION MANUAL
17197 85 CFM COMPRESSOR
17412 GROUNDING REEL & CLAMP
17165 LUBE SYSTEM INSTALLATION
S1094 LINCOLN AUTO LUBE MANUAL
17341 CHASSIS LUBE ELECTRIC GREASE PUMP
S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
1. INTRODUCTION /GENERAL INFORMATION
F1008 PARTS ORDER INSTRUCTIONS

F1019 PARTS RETURN POLICY
F1020 GETMAN TECHINCAL TRAINING
F1021 GETMAN WARRANTY
F1022 VEHICLE & PARTS WARRANTY REQUEST FORM
F1009 COMPONENT LIST
-------- SUGGESTED STOCKING GUIDE
M1040 A-64 OPERATION MANUAL
M1006 ANFO/ BOOM OPERATING MANUAL
M1042 DUNBAR CRANE OPERATING MANUAL
M1004 BOOM/ BASKET INSPECTION
M1071 BOLTS TORQUE SHEET
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
S1168 D-RING ANCHORAGE CONNECTOR MANUAL
S/N: 020-069
INSTRUCTIONS FOR ORDERING F1008
REPAIR PARTS Page 1 of 1
To avoid delays and ensure the most efficient handling of your parts orders and request for quotes,
please provide the following information:
• Truck model and serial number

• Manufacturer, model, and serial number of the major component (Engine, Transmission, Axle,
Compressor, Crane, etc.) for which the part is required.
• Part number and part description
• Quantity of parts required
• Purchase order number
• Shipping instructions (Include special handling if required)
• Billing Instructions
Please place all orders with your local Getman dealer or by emailing the Getman Parts Department at
parts@getman.com For questions or assistance you may contact a Getman Parts Department
Customer Support Representative at 1-800-533-1110 or 269-427-5611 x3.
MODEL SERIAL NO.
A64 ExC 3000 020-069
BANGOR, MICHIGAN U.S.A
Updated:
08/29/13
S/N: 020-069
F1019
PARTS RETURN POLICY
Page 1 of 1
Getman Corporation has established the following Parts Return Policy for its dealers and customers,
which is effective beginning on 01 April 2012 and supersedes all previous parts return policy
statements.
Part returns will be accepted from our dealers and customers at any time for the following reasons:
1. Parts shipped or ordered in error and/or duplicated orders

2. Parts damaged in shipment
3. Defective and/or warranty parts
Prior authorization must be obtained from a Parts Department Customer Support Representative
before returning a part to Getman, for any reason. The CSR will provide a Return Goods
Authorization (RGA) if the return is approved. Please provide the following information when
requesting an RGA:
 Getman part number and part description

 Quantity to be returned
 Purchase order number and order date
 Reason for return
 Pictures of part(s) and original packaging for parts received damaged
Part(s) must be shipped to Getman freight, prepaid. Goods must be packaged to prevent shipping
damage when returned and have a packing slip referencing the RGA number included with the
package. When possible, return the part in its original packaging. Returned parts must be received
at Getman within 60 days of the issuance of the RGA. Upon receipt, the part(s) will be inspected for
damage and to assess their quality and resale ability. Credit will not be given on a new part if it has
been installed on a truck unless it is being returned as defective or for warranty consideration.
Updated:
03/27/12
S/N: 020-069
GETMAN TECHNICAL TRAINING F1020
PROGRAM Page 1 of 1
Training is available for your Getman machine direct from the factory.
We are flexible and can design training to fit your needs.
 Operator Training
 Maintenance Training
 Receive training at Getman and tour the factory
 Let us come to you for on-site training
 Classroom lectures
 Hands-on with machines
 Multiple training sessions to accommodate large groups
 Training manuals with full color engineering drawings and troubleshooting guides
For more information about training or to schedule a training session call 1-800-627-5611 x 350
Updated:
06/05/12
S/N: 020-069
GETMAN CORPORATION STANDARD PRODUCT WARRANTY
(Effective for Vehicles, Equipment, Parts and other Products sold
after 01 July 2013)
1 Scope of Warranty. GETMAN CORPORATION warrants new Utility Vehicles, Special & Custom
Design Vehicles and Parts supplied by GETMAN CORPORATION and/or its AUTHORIZED
DEALERS/AGENTS ("Products" or "Getman Products") to be free from defects in material and
workmanship for the limited warranty periods and subject to the terms and limitations set forth below
("Warranty" or "Product Warranty").
2 Warranty Periods. The warranty periods for the Products are as follows:
i) Utility Vehicles (excluding other categories listed below):
Twelve (12) months or two thousand (2,000) engine hours or eighteen (18) months from delivery
to the end user, whichever comes first.
ii) Scissor Lift arm assemblies:
Five (5) years or ten thousand (10,000) engine hours, whichever comes first.
iii) Spare Parts:
Genuine GETMAN CORPORATION authorized parts:
Three (3) months from date of purchase.
iv) Engines, Batteries, Tires and other:
These items are warranted directly to the user by their respective manufacturers. No additional
warranty is provided by GETMAN CORPORATION.
v) Vehicle Mainframe:
Five (5) years or ten thousand (10,000) engine hours, whichever comes first.
Unless otherwise specified, all of the above-mentioned periods are calculated from the date of start-up
commissioning at the first end user’s site.
3. Parties Benefitted. Any liability whatsoever to any party other than the first end user is expressly
disclaimed. All warranties shall immediately terminate in the event that the Purchaser expressly or
impliedly purports to transfer or assign any of its rights under this Warranty to a third party. Any attempt
by the Purchaser to transfer or assign the warranties provided by GETMAN CORPORATION to any third
party shall be void unless GETMAN CORPORATION has provided its prior written consent to the
Purchaser.
4 Start-Up Commissioning Form. The unit start-up commissioning/warranty registration form shall
be filled in, signed by an authorized representative of GETMAN CORPORATION, signed by the end user,
and then scanned and entered into the GETMAN CORPORATION web site using the Start-up link within
fourteen (14) days from start-up commissioning date. The warranty period starts from the date indicated
on the start-up commissioning form. The completed start-up commissioning form must be received by
GETMAN CORPORATION before any claims for warranty will be processed.
S/N: 020-069
5 Engine Warranty. The engine warranty registration shall be completed with local engine
representative. All engine warranties shall be handled with local OEM engine representative.
6 Exclusions. This Warranty does not cover:
i) normal wear and tear of the equipment, the need for normal maintenance service such as but
not limited to, engine tune-ups, adjustments and inspections or normal replacement items (such
as service filters), and damage resulting from failure to conduct recommended maintenance;
ii) consumables such as but not limited to, seals, filters, hoses, v-belts, tires, fittings, screws,
bolts, washers, diaphragms, pick teeth, spray nozzles, idlers, rubber skirting, and wear parts
(G.E.T) etc;
iii) parts which can be repaired or corrected with minimal action such as but not limited to,
changing of seals, tightening or adjustment;
iv) damage caused by the Purchaser’s failure to store, maintain or operate vehicles, equipment or
other Products properly, or due to overloading or failure to pay proper attention to service and
operating instructions or caused by accident or working beyond rated capacities or exceeding or
not meeting recommended power inputs;
v) damage caused by negligence or failure of Purchaser to maintain the equipment in accordance

with GETMAN CORPORATION’s maintenance recommendations. Documented
service history is required to bring a Warranty claim;
vi) damage or premature failure which is caused by extremely adverse operating conditions such
as deep and/or aggressive water, poor roadways, dust, or poor ventilation;
vii) any defect or damage in materials or design provided by the Purchaser, or which are a
consequence of the Purchaser's actions;
viii) any parts or components manufactured or supplied by third parties or damage to Products
caused by such third party parts or components;
ix) any indirect costs such as labor, accommodations, meals, travel and similar costs or any
transportation unless agreed to in writing;
xi) any direct or indirect consequential damage including but not limited to loss of revenue or
profit, loss of production or loss of use of any equipment.
7 Waivers. This Warranty contains the entire warranty terms and conditions between GETMAN
CORPORATION and the Purchaser. Notwithstanding anything to the contrary contained in this Warranty
or otherwise, the Purchaser expressly waives all claims against GETMAN CORPORATION (and against
affiliates, contractors, subcontractors, consultants, employees, agents and vendors of GETMAN
CORPORATION) for any consequential, incidental, indirect, special, exemplary or punitive damages,
including, but not limited to, loss of actual or anticipated profits, revenues or product; loss by reason of
shutdown or non-operation; increased expense of manufacturing, operation, borrowing or financing; loss
of use or productivity; or increased cost of capital, and regardless of whether any such claim arises out of
breach of contract or warranty, tort (including negligence), product liability, indemnity, contribution, strict
liability or any other legal theory. All limitations in this warranty on GETMAN CORPORATION’s liability
S/N: 020-069
shall apply notwithstanding the fact that GETMAN CORPORATION’s warranties fail of their essential
purpose or are held to be invalid or unenforceable.
8 Limitations. Under no circumstances and in no conditions shall GETMAN CORPORATION's

liability whether in respect of one claim or in the aggregate, arising out of any contract, exceed the
purchase price for the warranted Product. Warranty claims less than fifty Dollars (USD 50) or the
equivalent in another currency are not covered by this Warranty.
9 Timing. On receipt of notification of a warranted defect, GETMAN CORPORATION shall remedy

the defect pursuant to an orderly schedule as business demands allow at GETMAN CORPORATION's
discretion in accordance with these terms of Warranty.
10 Authorized Parts Required. No Warranty claim will be considered, and this Warranty will be
considered null and void, if other than GENUINE GETMAN CORPORATION AUTHORIZED SPARE
PARTS are used in the warranted vehicle, equipment or other Products, or if GENUINE GETMAN
CORPORATION AUTHORIZED SPARE PARTS are dismounted and used other than in the Product
originally supplied to the Purchaser by GETMAN CORPORATION.
11 Proof of Purchase. All Warranty claims need to have a proof of purchase which may include:
i) Copy of invoice or order number; or
ii) Job Charge out report.
12 Claims Procedure. Warranty claims must be completed online using the GETMAN
CORPORATION web site by an Authorized Dealer/Agent. Claims must include digital photographs of the
failure, Equipment serial number, engine hours, and where possible detailed information about the
operations prior to the failure occurring. The hard copy forms shall be completely filled in and delivered to
a GETMAN CORPORATION representative within fourteen (14) days following the date that the
Purchaser discovers or should have discovered the alleged defect. Claims lodged after this period will be
denied. Only one failure can be reported for each claim. The warranty claim form must be sent to the
Purchaser's local GETMAN CORPORATION representative for processing.
13 Special Provisions for Parts Claims. The obligation of GETMAN CORPORATION under this
Warranty for claims related to parts is limited to:
i) refunding the purchase price of the part; or
ii) replacing the part, free of charge, with shipping prepaid, at the place of business of the
GETMAN CORPORATION representative.
The Warranty of a replaced or repaired part expires at the same time as the original Warranty of the
supplied vehicle, equipment or other Product, or in the case of a part only claim, refer to paragraph 2 of
this Warranty. The Purchaser shall retain the claimed part for 90 days from claim settlement, for
GETMAN CORPORATION/AUTHORIZED DEALER/AGENT inspection, and on request the alleged
defective part shall be sent as directed by GETMAN CORPORATION and at GETMAN
CORPORATION'S cost to a destination designated by GETMAN CORPORATION. No part may be
returned to GETMAN CORPORATION without GETMAN CORPORATION'S prior written consent. After
resolution of a Warranty claim, the title to the defective parts shall be transferred to GETMAN
CORPORATION.
14 Appeals. APPEAL PERIOD FOR GETMAN CORPORATION’S DECISION RESOLVING A

WARRANTY CLAIM IS FOURTEEN (14) DAYS FOLLOWING THE DATE OF DECISION AFTER WHICH
THE SAID DECISION IS FINAL AND ANY FURTHER WARRANTY RIGHTS SHALL BE DEEMED
WAIVED AND EXPIRED.
S/N: 020-069
15 Disclaimer. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT LIMITED TO, WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. NO OTHER WARRANTIES
EXPRESS OR IMPLIED ARE GIVEN UNLESS THEY ARE EXPRESSLY GIVEN BY GETMAN
CORPORATION IN A WRITING SIGNED BY AN AUTHORIZED GETMAN CORPORATION
REPRESENTATIVE.
16 No Suspension. This Warranty shall not be suspended on the grounds of non-use, intermittent
use or for any other reason.
S/N: 020-069
VEHICLE WARRANTY/ PARTS WARRANTY REQUEST FORM
ALL WARRANTY REQUESTS WILL NEED THE FOLLOWING INFORMATION FILLED OUT COMPLETELY
DATE_________________ SERVICE TECHNICIAN NAME_____________________________
CUSTOMER/DEALER NAME_______________________ PHONE NUMBER_______________________
CUSTOMER MINE SITE LOCATION_________________________________________________________
GETMAN REPRESENTATIVE AUTHORIZING RETURN______________________________________
MACHINE MODEL__________________________________________
MACHINE SERIAL NUMBER____________________________________
PART NUMBER OF FAILED PART__________________________________________________
PART FAILED_______________________________________________
DETAILED DESCRIPTION OF
FAILURE______________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
PART IS ORIGINAL FROM MACHINE PART WAS INSTALLED LESS THAN 6 MONTHS AGO
MACHINE COMMISSION DATE/PART INSTALLATION DATE_______________________________
DATE MACHINE/PART FAILED_________________________________
DATE PART WAS REPLACED__________________________________
ORIGINAL PART INVOICE # (If Available) ________________________________________
PLEASE PROVIDE AS MUCH DETAIL AS POSSIBLE TO HELP FUTURE VEHICLE IMPROVEMENTS
S/N: 020-069
F1009
COMPONENT LIST
Page 1 of 1
Model: A64 ExC 3000 Serial No.: 020-069
Customer: PENOLES (TOPO)
COMPONENT MANUFACTURER MODEL SERIAL NUMBER GETMAN PART NUMBER

ENGINE CUMMINS QSB 4.5 73540775 9040-20006
EXHAUST
(PURIFIER) ECS 8DZ B171978 595411
EXHAUST
(SILENCER) ECS 8DMS B161025 594372
TRANSMISSION DANA 32000 SBEA437715 9050-10005
FRONT AXLE CARRARO 28.43 01000304 7080-10003-F
REAR AXLE CARRARO 28.43 01000288 7080-10003-R
MAIN HYD PUMP COMMERCIAL P-31 NO413-2444 494169
CANOPY
(ROPS/FOPS) GETMAN NA CP1122-6-00481 N/A
OPTIONS:
ROTATION GEAR BOX GEAR PRODUCTS 003 003-37-00046 DUN16259
ROTATION GEAR BOX EATON 449 130524MOH0335 DUN 16258
MOTOR
COMPRESSOR VIPER 85CFM 30-85907 464892
ANFO POT BAYCAR 636LBS D-136-49-3921-02 465573
ROTATON BEARING GEAR PRODUCTS 449 449-214-01116 DUN16260
SAFETY VALVE
(ANFO TREE) DEPATIE FLUID V120 T5095 605582
SAFETY VALVE
(AIR TANK) DEPATIE FLUID V150 T7048 605586
SAFETY VALVE
(COMPRESOR) DEPATIE FLUID V175 T190-01 605640
†COMMON MAINTENANCE ITEMS
ENGINE OIL FILTER P/N: 150019-G

FUEL FILTER ELEMENT P/N: 150036-G
FUEL WATER SEPERATOR ELEMENT P/N: 150020-G
AIR FILTER SAFETY ELEMENT P/N: 604709-G
AIR FILTER XLP ELEMENT P/N: 604711-G
TRANSMISSION FILTER ELEMENT P/N: 24069-G
HYDRAULIC FILTER ELEMENT P/N: 534691-G
FAN/ALT BELT P/N: 9041-20062
*WHEN ORDERING PARTS, ALWAYS GIVE MODEL AND SERIAL NUMBER OF UNIT. Updated:
†SEE MAINTENANCE SECTION IN MANUAL FOR SERVICE INTERVAL ON THESE ITEMS 09/03/13
S/N: 020-069
SUGGESTED STOCKING GUIDE
PART NO: DESCRIPTION QTY
250 Hour Service

150019-G Oil Filter, QSB 4.5L 1
150036-G Fuel Filter Element, QSB 4.5L 1
150020-G Fuel/Water Sep Filter, QSB 4.5L 1
24069-G Trans Filter, Clark 32k 1
534691 Hydraulic Filter Element 1
604709 Air Filter Element, Safety 1
604711 Air Filter Element, XLP 1
Quantities Based on 2000 Hrs
Axle Cradle
19204-88 Pins 4
464693 Bushing, Bronze w/ Grease Rings 4
Electrical System
122100 Switch Pshbtn Horn w/cap no 1
124467 Battery Disconnect (Lockout Plate) 1
124163 Battery disconnect 1
124278 Sender Converter 0/400 psi 1
124007 Bulb, 24V (headlight) 2
124352 Bulb, 24V Double Contact (taillight) 2
464804 Light, White, 24V w/wp conn 1
464813 Light, Stop/tail, 24V w/wp conn 2
124380 Switch Ign/st Lockout Start 1
124396 Gauge Voltmeter 24v sd 1
124403 Gauge Conv Temp 300f sd 1
124406 Transmission Temp. Sender 1
124421 Gauge Conv psi 400psi sd 1
124423 Bulb 24v Gauge Vdo sd Type 5
124454 Murphy Powerview Display 1
124455 Murphy Engine Alarm 1
124501 Toggle Light Switch 1
134117 Breaker 10 Amp 1
134362 Fuse 1A (Blade Type) 1
134277 Fuse 5A (Blade Type, Pack of 5) 1
134294 Fuse 30A (Blade Type) 1
134167 Switch 20 PSI 1
134195 Switch psi (60) Trans 1
354006 12V Battery 1
124480 Converter 24v/12v (18/32v input) 1
134020 Park Brake Red Button 1
134019 Park Brake Switch 1
134258-101 Programmed PLC Board 1
134259 Expander I/O Board 1
464668 Backup Alarm 1
464694 Ground Strap, Articulation 1
465428 Warning Panel LED Array 1
534772 Shifter 1
594388 Horn 1
595395 Elec Throttle Pedal 2
595395-01 Sensor 2
534884 Joystick Control Single Axis 1
124070 Green Enable Light 2
S/N: 020-069
QSB 4.5L Engine Installation

150019-G Eng Oil Filter 8
150036 Fuel Filter Element 8
150020-G Fuel Water Separator Element 8
150015 Starter 1
324095 Alternator 1
9041-20062 Belt, Fan 1
Radiator Installation
11010-01 Complete Radiator Assembly 1
465480 Radiator Cap #15 Double Seal 1
12326-09 Hose (2") 1
12326-08 Hose (1.75") 1
12567-05 Silicone Hose, 4" IDx4" L 1
12567-06 Reworked Silicone Hose, 3" IDx6" L 1
Hose, 2"ID,GS Series
9047-00005 (NOTE: Comes in 25ft lengths) 25
Exhaust Installation
12253-14 Exh Elbow Weldment 1
12256-11 Flex Tube Weldment 1
594372 Silencer 1
595411 Purifier 1
Air Intake Installation

604264 Vac. Valve 1
604464 Indicator 20" 1
604709 Safety Element 6
604711 Xlp Element 10
Fuel Tank
234309 Check Valve 1
12646-04 Gasket, Tank 1
392012 Cap, Fuel 1
Clark 32K Transmission

12352-03 Dipstick 1
24069-G Filter 4
244632 Valve Cartridge 1
244637 Cartridge and Coil Ass'y 24V 1
Driveline Installation
19200-46 Driveline, Slip Assembly 1
19201-58 Driveline, w/ Center Bearing 1
362120 Center Bearing w/ Dust Shields 1
364023 Cross & Bearing 1
364024 Cross & Bearing 1
464640 Driveline, Articulation, Slip 1
S/N: 020-069
Articulation
Articulation Rebuild Kit
7093-00095 (Includes items below) 1
10697-01 Pin Cap 2
13796-03 Pin Weld Art Case Harden 2
16367-03 Insert Assembly, Includes Bushing 2
16369-02 Upper Hinge Bushing 2
16369-03 Lower Hinge Bushing 2
464420 Capscrew, Lockwire 6
594572 Shim .005 in. 6
594573 Shim .007 in. 6
594574 Shim .020 in. 6
594575 Shim .005 in. 6
594576 Shim .007 in. 6
594577 Shim .020 in. 6
Steering Control
174110 Orbitrol, Steering Valve 1
532140 Flow Control 1
534047 Relief Valve 1
Hydraulic Components
52500 Tank Cap 1
494169 Gear Pump 1
494037 Gauge 1
52100 Check Valve 30psi 1
52490 Strainer 1 1/2" 1
534106 Relief Valve 1
534106-01 Relief Valve Seal Kit 1
594605 Diverter Valve 1
534607 Accumulator 1
534627 Drain Solenoid 1
534674 Seal Kit 1
534691 Filter Element 6
594922 Dual Charge Valve 1
534293 Repair Kit, Dual Charge Valve 1
Brake System
134171 Switch 700 PSI 1
134173 Switch 1100 PSI 1
464952 Brake Pedal 1
595145 Brake Pedal Repair Kit 1
534669 Coil, Solenoid, 24V, Brake Block 1
534679 Cartridge, 3 Way Pos Solenoid 1
534745 Cartridge, Shuttle 1
Fire Suppression
334007 Blow-off cap 50
334013 Cartridge 1
334123 Cartridge 1
334146 Batt, Module 1
S/N: 020-069
Steering Circuit
13796-01 Steering Pin 2
26409-01 Bearing, Cylinder End 2
465411 Steering Cylinders 1
465411-07 Seal Kit, Steering Cylinder 1
524202 Bushing, Frame Ear 2
524203 Bushing, Cylinder End 2
Seats & Seat Belts

424279 Seat Belt 1
424398 Seat, KAB Suspension 1
424400 Canvas Seat Cover 1
Wheel & Tire Assembly*

9121-00014 Wheel & Tire Assembly 1
9121-00022 Rim Assembly 1
9121-00023 Tire 1
9121-00024 Tube 1
Stabilizers
534878 Stabilizer Control Valve 1
534490 Valve Seal Kit 1
534494 Relief Valve Seal Kit 1
534495 Valve Load Check Plug Service Kit 1
534496 Valve Load Check Plug Seal Kit 1
534215 Valve Power Beyond Service Kit 1
534498 Spool Positioner End Service Kit 1
465171 Stabilizer Kit 1
10305-01 Pad Weldment 1
10305-04 Pin, Upper 1
10305-05 Pin, Lower 1
465143 Cylinder 1
465143-08 Cylinder Seal Kit 1
Boom Hydraulics
465484 In Basket Boom Control Valve 1
464039 Boom Control Valve (on boom) 1
534490 Valve Seal Kit 1
534494 Valve Main Relief Seal Kit 1
534501 Valve Port Relief Seal Kit 1
534500 Valve Port Relief Service Kit 1
534495 Valve Load Check Plug Service Kit 1
534496 Valve Load Check Plug Seal Kit 1
534502 Valve Spool Positioner Service Kit 1
534341 Valve Spool Clevis End Seal Kit 1
465121 Cylinder, Basket Leveling 1
465121-07 Cylinder Counter Balance Valve 1
465407 Cylinder, Boom Leveling 1
DUN14671-01 Cylinder, Boom Lift 1
DUN17393 Cylinder Needle Valve 1
DUN14422 Cylinder, Extension 1
DUN14422-01 Cylinder Seal Kit 1
534209 Valve, Relief 1
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Boom Assembly
DUN16279 Bushing 2
DUN14417-05 Wear Pad Lower Basket 4
DUN14417-7 Wear Slide Pad Top-Inner 4
DUN14417-6 Wear Slide Pad Top-Outer 4
DUN14418 Wear Slide Pad Side 8
DUN14412 Wear Pad Top 4
Anfo System
465453 Relay Valve, Drain 1
464930 Filter/Reg/Lubricant (No Brass) 1
465135 Anfo Air Boost Kit 1
465162 Valve, 2" Material 1
595060 Valve, 2" Position 1
595155 Regulator 1
595181 Valve 1
605982 Vibrator, Turbine 1
605582 Valve, Safety, 120 PSI, SS 1
605585 Valve, Quick Release, Zinc 1
Anfo Pot
604240 O-ring 1
Miscellaneous
132130 Hold Down Fasteners 1
53011 Sight Gauge 2
464989 Deutsch Plug Repair Kit 1
*Wheel and Tire Assembly are for reference purposes only. If ordered, units may be
supplied with spare tire and wheel assembly per Getman.
DO NOT ORDER PARTS FROM THIS LIST UNTIL CONSULTING GETMAN CORP.
CERTAIN COMPONENTS/PRICING ARE SUBJECT TO CHANGE
S/N: 020-069
OPERATING AND MAINTENANCE M1040
MANUAL FOR MODEL A-64 CHASSIS Page 1 of 38
GETMAN CORPORATION
OPERATING AND MAINTENANCE

MANUAL
FOR
MODEL A-64 CHASSIS
EQUIPPED WITH
465313-100-OV DASH PANEL
MERCEDES or CUMMINS ENGINE
Read thoroughly before operating vehicle
TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS. Updated:
3/12/2013
S/N: 020-069
TABLE OF CONTENTS PAGE INTRODUCTION
Introduction 2
Related Manuals 2 This manual is a guide to proper, safe operation, maintenance,
General Description 3 and minor adjustment of the Getman A-64 Chassis. Each
General Safety Precautions 3-5 operator assigned to this vehicle should study this manual
Safety Alert Symbol 3 carefully before starting or operating the vehicle in order to
Rules 4 become familiar with all the controls and procedures.
Parking Procedure 5
Service Positions 5 Getman A-64 Chassis are purchased with the expectation that
Fuel Shut Off 5 it will provide long and faithful service. In its construction,
Canopy 5 we have taken every precaution to see that you receive an
Lockout Procedure 6-9 efficient, long-lived, satisfactory vehicle. However, to realize
Padlock Method 9 the full measure of value and utility that Getman has designed
Name, Warning, and Caution Plates 10 into this unit, a small amount of time and expense must be
Caution Statement 11-12 invested in the performance of regular inspections and service
Electrical System Safety 12 as recommended in this manual. The small investment will
Safety w/ Fuel, Oils, & pay off in low operating costs, minimal service expenses, and
Coolant 12 most importantly in personal safety.
Instrument Panel Descriptions 13-14
Instrument Warning Panel 15 RELATED MANUALS
Electronic Engine Data Display 16-17
Gauge Descriptions 18-19 Engine operation manual is included with the Parts and
Other Controls 19 Service Manuals supplied with this vehicle. You should
Checks Before Startup 20 become familiar with these manuals.
Starting Procedure 21
Park Brake Test Procedure 22 NOTE: For Cummins engine parts and service manuals not
Service Brake Test 22 supplied, please see Section 4 of your truck Parts & Service
After Engine Starts 23 Manual for instructions.
Operating Vehicle 24
Towing Procedures 25-26 Getman has increased the frequency of many recommended
Preparing a Vehicle 25 maintenance procedures due to the vehicles demanding
Transmission 25 application. These changes are noted at each maintenance
Brake Release 26 section end.
Maintenance Schedule – As Required 27
Maintenance Schedule – Daily 28-29 A complete parts listing of engine train components,
Maintenance Schedule – 50 Hours 30-31 applicable Electric/Air/Hydraulic systems, and mounted
ECS Catalytic Air Purifier or equipment is included in the Parts and Service Manual. This
Diesel Particulate Filter 31 manual also contains service and repair information useful to
Maintenance Schedule – 250 Hours 32-33 maintenance department personnel.
Maintenance Schedule – 500 Hours 34
Maintenance Schedule – 1000 Hours 35 If you have any questions about operating or servicing this
Specifications 36 unit, contact your local Getman dealer or Getman Corporation
Fuel 36 direct, immediately.
Tires 36
Pressures 36
Fluid Capacity Quick Reference Guide 37
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GENERAL DESCRIPTION
Getman Model A-64 Chassis is a four wheel drive, articulating parking brakes, are manually set and released by utilizing the
frame steering vehicle powered by a diesel engine. The power dash mounted push/pull control button. The front and rear
of the engine is transmitted through the torque converter to a service brakes are also used as secondary brake which
powershift transmission. From the transmission, drive shafts automatically apply in the event of loss of hydraulic or
with universal joints transmit the power to the deep reduction, transmission pressure. This brake can also be manually
inboard planetary drive axles. applied in the event of complete hydraulic system failure.
Steering is full hydraulic power type, utilizing a flange This vehicle is equipped with two red Brake Warning lights
mounted direct drive hydraulic gear pump which provides located in the instrument panel. One light for the front and
hydraulic fluid to an orbitrol valve operated by the steering one for the rear brake circuits. These warning lights will
wheel. This operates the two steer cylinders located in the illuminate if hydraulic pressure in either brake circuit drops
articulation joint. below the preset 1100 PSI (76 BAR) level. The front and rear
service brakes will automatically apply if the hydraulic
Every effort has been made to ensure that you can stop this pressure in the brake circuit drops below 1100 PSI (76 BAR).
vehicle. The service brakes (axle brakes) are fully enclosed Trucks with Brake Impending option, auto brake application
wet disc type, with a dual system, permitting separate circuitry occurs when hydraulic pressure in either front or rear brake
for front and rear brakes. Should a failure occur in either circuit falls below 1200 PSI. All the instruments required to
circuit, the other circuit remains functional. The spring set, operate the vehicle are located in the operator’s area. Become
hydraulically released, service brakes which also serve as familiar with the position and function of each.
GENERAL SAFETY PRECAUTIONS

Before operating or performing any maintenance on the SAFETY ALERT SYMBOL
vehicle, review the following safety precautions. These are
included for your protection and safety. This symbol will appear at various points
throughout the manual in conjunction with
Always observe the following general safety rules during warning statements. Its appearance means:
operation of the vehicle. Also observe the safety rules set ATTENTION! BECOME ALERT!
forth in the work place. The need for additional rules for safe YOUR SAFETY IS INVOLVED!
operation may arise due to particular mine applications. This
should only be used as guidance. This manual also uses the following messages:
Safety depends on well maintained, properly operated NOTICE: Used for special information or instructions,
equipment. Following service and maintenance relating to procedures, equipment, tools, and other special
recommendations set forth in this manual will result in a data.
reliable vehicle. Observing operating procedures can help you
avoid accidents. Listed in the following pages are some basic IMPORTANT: Used when special precautions should be
safety precautions which should be read, understood and taken to ensure correct action or to avoid damage to or
practiced. It is, however, impossible to cover every condition. malfunction of equipment.
Always be alert, think SAFETY at all times, and use common
sense. CAUTION: Used as a reminder of safety hazards which can
result in personal injury if proper precautions are not taken.
WARNING: Used when a hazard exists which can result in

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

result in serious injury or death if proper precautions are not
taken.
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GENERAL SAFETY PRECAUTIONS (CONTINUED)
RULES
 Do not re-fuel the vehicle with engine running.
 Read and carefully follow all instructions as outlined in
the vehicle manuals.  Do not drive the vehicle over electrical cables.
 Always be aware of location of nearest fire extinguisher.  Do not pump the brake pedal.
 Always ensure that excess grease, oil, etc., are cleaned up  Place transmission gear selector in neutral (N) when not
immediately to prevent a potential fire hazard. in use.
 Avoid smoking or open flame around fuel.  Engage the parking brake when not in use.
 Recognize and avoid potential hazard areas, such as the  Park vehicle on level surface, if possible, and always
articulation area. lower ground engaging implements and utilize wheel
chocks. If parking on a grade is unavoidable, point the
 Perform all recommended checks and report all vehicle vehicle towards the rib.
defects.
 Use proper tools for service.
 Check the area around entire vehicle prior to entering the
operator’s compartment.  Avoid wearing loose or baggy clothing when working
around engines or other rotating or moving equipment.
 Never allow riders in vehicles not designated to carry
passengers. Operator and passengers must be seated in  Do not arc weld on vehicle without first turning master
proper seats with seat belts fastened. switch to off position.
 Enter and exit operator’s compartment carefully. Never IMPORTANT

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

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

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

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

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

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

Close fuel line valves at tank ports
CANOPY
Your Getman vehicle could be equipped with a MSHA canopy
or cab option. These are designed to provide protection to the
operator in the event of a rollover of the vehicle or from
foreign objects falling on the operator’s area. There will be a
label attached to the structure which will include the structure
serial number, vehicle weights, and vehicle model numbers.
Modifications such as adding attachments to the cab/canopy,

welding, cutting, and/or drilling holes can weaken the
structure, lessen operator protection, and void certification.
Should your vehicle sustain damage to the structure, contact
your local distributor prior to performing repairs.
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LOCKOUT PROCEDURE
These lockout/ tagout procedures are a suggested method. It is the responsibility of the operator to follow their companies
lockout procedures.
Purpose:
This procedure establishes requirements for the lockout, or tagout, of equipment whenever maintenance, or servicing, is
performed at Getman vehicle. The procedure shall be used to ensure that equipment is stopped, isolated from all potentially hazardous
energy sources and locked, or tagged out before employees, or contractors, perform equipment repairs, or maintenance.
Compliance with This Procedure:
All employees must comply with the requirements of this procedure. Only authorized employees may lockout, or tagout
equipment. All employees, upon observing that a piece of equipment is locked out or tagged out, shall not attempt to start, energize or
use that piece of equipment until all lockout/tagout devices are removed by an authorized employee who has verified that the
equipment is safe to operate.
1. APPLICATION OF LOCKOUT CONTROL
A. Preparation for Shutdown – Personal Safety Locks (red) and keys will be kept by each
mechanic or electrician. Supervisors will also have their own locks and keys. Authorized employees shall review
the written lockout procedure to have complete understanding of the type(s) and magnitude of the energy, the
hazards of the energy to be controlled, and the methods or means to control the energy.
B. Notification of Employees – Affected employees shall be notified by the authorized employees that the machine or
equipment is going to be locked out.
C. Machine or Equipment Shutdown – The machine or equipment shall be turned off or shut down using the energy
control procedures established for the machine or equipment.
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LOCKOUT PROCEDURE (CONTINUED)
2. REMOVING EQUIPMENT FROM SERVICE
(1) Equipment that is to undergo maintenance, or repair, must be removed from service by an authorized employee.
(2) The authorized employee shall have knowledge of the type and magnitude of the energy, the hazards of the energy
to be controlled, and the method or means to control the energy before locking out, or tagging out, the equipment
(3) Prior to isolation, the equipment shall be shut down in an orderly fashion that avoids additional, or increased,
hazards.
(4) All equipment undergoing maintenance, or repair, must have all power and energy sources locked out, or tagged out,
in the “off” position by each authorized employee who will be working on the equipment. Power and energy
sources, and isolation methods, may include, but are not limited to, the following:
Electrical:
Disconnect, or isolate equipment from electric supply and lock isolation device.
Water:
Bleed off pressure; divert water utilizing valves and lock valve.
Hydraulic:
Bleed off pressure to cylinders and rams to return to no stored energy state and lock oil source.
Valve off accumulators and remove oil, or gas, and lock valves.
Lock off energy to pump drivers.
Air:
Lock out the air service valve.
Bleed off pressure.
Springs:
Disassemble or remove spring mechanism to relieve stored energy.
General:
Ensure that all items are in their lowest stored energy position and lock them in place.
Block any items that have the potential to move.
Consult equipment manuals when available to determine hazardous energy sources.
(5) Tagouts may only be used when there is no isolation device that can be locked out to prevent equipment operation,
or release of stored energy. If a tagout is used, tags must be placed at all potential sources of equipment operation
and energizing. The tags must indicate the authorized employee(s) who placed the tag(s); the energy isolating
device being tagged out and that the equipment cannot be operated.
(6) When repairs performed by a contractor, an authorized employee must be designated to ensure that equipment is
properly shut down, isolated and locked out, or tagged out. The authorized employee is also responsible for
ensuring that the contractor complies with the requirements of this procedure.
(7) If a lock is used to lock out equipment, the authorized employee that applies the lockout device should retain one
key for the device.
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3. RESTORING EQUIPMENT TO SERVICE
(1) The authorized employee who applies a lockout/tagout device to a piece of equipment is the only person authorized
to remove the device, except in case of emergency.
(2) In an emergency, the area manager may designate another authorized employee to remove the lockout/tagout device
if the following conditions are met:
– It is verified that the authorized employee who applied the lockout/tagout device is not at the facility.
– Reasonable effort has been made to contact the authorized employee concerning the removal of the lockout/tagout
device.
– Provisions have been made to ensure that the authorized employee is informed of the removal of the lockout/tagout
device before he/she resumes work at the facility.
(3) The following procedure will be used to return equipment to operation:

 Verify that the all non-essential items (tools, etc.) have been removed from the equipment and its work area.
 Verify that all equipment components are operationally intact.
 Verify that all employees are safely positioned, or removed from the equipment operating area.
 Verify that the equipment controls are in neutral.
 Remove the lockout/tagout devices and re-energize the equipment. NOTE: The removal of some forms of blocking
may require that the equipment be re-energized.
 Notify affected employees that the equipment is ready for use.
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PADLOCK METHOD
TOOLS REQUIRED
Padlock with key; E.G., the most effective method of

preventing the accidental starting of the machine during The Padlock Method is established so any person
servicing or maintenance activities is to shut off battery power who may be required to work on the machine
to the vehicle by locking the battery disconnect switch. Place receives a lock with his or her name stamped on it
the “DANGER LOCKOUT PROCEDURE IN EFFECT” and (1) key to fit that lock only. No one except
tag onto the safety lockout and place the lockout through the the person who locked the battery disconnect switch will be
splined hole of the battery disconnect switch in the off able to unlock it to restore power to start truck. If more than
position. Attach padlock (s) as shown in Figure 1. one person is working on the same machine, each person must
put his own padlock onto the multi-lock lockout, (6
maximum), like the one shown in Figure 2.
FIGURE 1
FIGURE 2
These lockout procedures are a suggested method. It is the

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

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

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

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

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

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

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

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

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

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

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

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

regulated and provided to the transmission clutches. If the
gauge fails to register pressure after engine start up, shut down
engine immediately and contact maintenance. Normal
operating pressure is approximately 300 PSI.
Voltmeter indicates current battery voltage level, charging or

discharging. There will either be a 16V gauge used for a 12V
charging system or a 32V gauge used for a 24V charging
system. With engine running a 12V charging system should
read 12-16 volts and 24 – 30 volts for a 24V charging system.
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GAUGE DESCRIPTIONS (CONTINUED)
Pressure gauges are used to measure the hydraulic pressure OPTIONAL

system. They could be used to measure brake pressure, total Exhaust back pressure is measured in inches of water (H20).
system pressure, etc. Exhaust back pressure is pressure that develops in the exhaust
system while a vehicle’s engine is running. High exhaust back
pressure is undesirable, as it reduces engine power. It’s
important to keep exhaust piping tight at all times. Do not
allow piping to become blocked. The maximum back pressure
(positive) in exhaust system at full throttle, no load, 2500
RPM must not exceed the engine manufacturer’s
recommended valve. The OM904LA diesel engine maximum
recommended valve is 40” H2O.
OTHER CONTROLS
Accelerator Pedal (Not Shown) - Push to increase engine
RPM.
Brake Pedal (Not Shown) - Push to activate service brakes.
Seat Adjustment (Not Shown) - Adjust for operator comfort.
WARNING
Never free wheel vehicle. Free wheeling
will cause serious injury and damage
vehicle.
Direction Selector Lever - Move selector lever to “F” for

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

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

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

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

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

This switch could be located on the side of the vehicle, in
the cab, or both. NOTE: Wait in minimum of 30 seconds
after Engine is shutdown to disconnect batteries.
5. Turn Start Switch to “ON” position. (a)

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

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

not show pressure shortly after stat-up, stop engine and
determine cause.
NOTICE
3. Push down Park Brake Button. Do not crank engine for more than 15
seconds. Allow starter to cool for two
minutes before cranking again.
Turbocharger (if equipped) damage can
CAUTION result, if the engine rpm is not kept low until
Transmission must be in neutral and park the engine oil pressure gauge indicates pressure is sufficient.
brake must be applied to start engine.
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PARK BRAKE TEST PROCEDURE – PERFORM DAILY
NOTICE
Depressing the Park Brake Button located in
the switch panel overrides the transmission
declutch feature.
To test the Park Brake only:
3. Place shifter in 3rd Gear. (Canadian trucks use 2nd)

Forward.
4. Fully depress Throttle. (Canadian trucks, hold at 1500

rpm)
5. Vehicle Should Not move.

1. Set Park Brake. (a)
2. Depress & hold Park Brake Test Button. (b)
To test the Park Brake Accessory Switch if Equipped:
Pull diverter valve to accessory position. Release Park Brake, Park Brake light should illuminate in warning panel and automatically
apply the park brake. If this does not occur, contact service.
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.
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AFTER ENGINE STARTS
1. Engine Oil Pressure Electronic Engine Display – Oil 6. Park Brake Test – This system is designed to hold a
pressure should read 25-50 PSI at idle with engine at fully load vehicle on a 35% grade. For safety reasons, a
operating temperature. At full engine load, pressure parking brake test should be performed at the beginning
should read between 45-60 PSI. If gauge fails to show of each shift. See Park Brake Test Procedures for
pressure after engine start up, stop engine immediately instructions on how to conduct this test.
and find cause.
2. Voltmeter – With engine running, voltage should read

12-16 volts for 12 volt vehicle systems and 24-30 volts CAUTION
for 24 volt vehicle systems. Stop engine immediately if any gauge is not
in its set range.
3. Transmission Temperature Gauge – During work
cycles, if Trans/Converter Gauge indicates temperature WARNING
above 220°F, bring vehicle to a stop, place transmission Do not operate any vehicle with a faulty
in Neutral with park brake applied and increase engine parking/service brake system. Serious
RPM to approximately 1000-1200 RPM. Maintain this personal injury or damage to vehicle may
RPM until Transmission temperature returns to normal result.
levels.
4. Transmission Pressure Gauge – Normal transmission

operating pressure is approximately 250 PSI (17.2 BAR).
Should transmission pressure fail to register upon starting
of vehicle, stop engine and contact maintenance.
5. Brake Pressure Gauges – There are two brake

accumulator pressure gauges located on the side of the
dash on the engine panel. These display the individual
hydraulic pressures existing in the front and rear brake
accumulators. Normal operating pressure in these gauges
is between 1500 and 2200 PSI (103.5-151.5 BAR).
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OPERATING VEHICLE
1. Once all gauges have been checked and are within
normal operating ranges, vehicle is ready to
operate.
2. Turn Light Switches to the “ON” position (a).
3. Depress Service Brake and hold Park Brake
Button (b).
4. Check Brake Accumulator Pressure Gauges and
check Instrument Panel Warning Display for Low
Pressure Warning Lights in Warning Panel (c).
5. Ensure all hydraulic stabilizers are in the top
position (if applicable).
6. Check to be sure area is clear of all personnel and
obstacles. Select forward by pushing the gear
selector lever to “F” position and select 1st gear
pulling gear selector lever to “1” position.
7. Pull Park Brake Button (b) to release the driveline
disc brake.
8. Depress horn button (d) on instrument panel to
sound horn.
9. Release Foot Brake Pedal, test steering for proper
operation and move vehicle slowly by gently depressing Accelerator Pedal with foot.
Acquaint yourself with the “FEEL” of the steering by driving NOTE: When traveling up a grade, select lower gear if torque
the pattern shown above. Do this several times until you converter oil temperature approaches 200°F (93 °C).
become familiar with vehicle steering and feel you would be
comfortable driving the vehicle in traffic areas. To familiarize CAUTION
yourself with vehicle response to an automatic application of When proceeding down grades, use 1st gear.
the driveline brake, drive straight, remove foot from Use of 2nd or 3rd gear could cause engine
accelerator pedal and push Park Brake Button while still over speeds and possible safety hazards to
rolling. operator.
Park brake should set and vehicle should come to a stop. If

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

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

 Perform Daily Maintenance Schedule
ITEM COMPONENT FLUID*

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

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

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

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

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

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

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

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

 Perform 50 Hour Maintenance Schedule

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

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

If vehicle is operated under heavy load with engine rpm at Cleaning Procedure:
least 70% of operating time, a minimum amount of 1. Remove center section of purifier.
maintenance will be required. If engine does not work hard 2. Dry brush inlet face of catalyst.
and is allowed to idle for excessive periods of time, the 3. Air clean through outlet face of catalyst.
catalyst may become “carboned up” and exhaust will start to 4. Continue steps 2 & 3 until inlet face is clean.
smoke after a few hours, indicating regeneration is necessary. 5. Completely soak catalyst in Stoddard, S.C. solution for
one hour.
NOTE: DO NOT allow engine to idle more than five (5) 6. Solvent-air clean through outlet face of catalyst for 10
minutes at a time, or purifier will loose efficiency. minutes.
7. Air clean through outlet face.
Before vehicle is put into service, and during every 50 Hour 8. Repeat steps 5, 6, and 7 until purifier is clean.
Maintenance, check exhaust back pressure at full throttle by 9. High pressure water wash purifier through outlet face and
connecting a back pressure or water gauge to the 1/8” NPT air dry.
test port between purifier and exhaust manifold. If back 10. Replace purifier.
pressure exceeds 40” (1016 mm) H2O or has risen 5” 11. Record back pressure at full throttle, remove gauge and
(127mm) or more since last regeneration, purifier must be tighten test plug.
regenerated.
NOTE: If high pressure steam is available, it may be
NOTE: If exhaust system is set up with a Combifilter that substituted for solvent solution. Steam clean through outlet
requires a regeneration station, follow the Engine Control face, keeping nozzle 2” (51mm) away from catalyst face.
System’s Regeneration Procedures instead of the following
listed steps. NOTE: If purifier has been regenerated but engine continues
to smoke, engine must be serviced to maintain safe exhaust
Required Equipment: conditions.
 Nylon, hard-bristle parts cleaning brush.
 Solvent-air, parts cleaning gun.
 Super concentrate degreasing solution.
 Stoddard solvent or high grade kerosene (sulfur free) – 5
parts Stoddard to 1 part S.C.
 High pressure air source (30PSI).
 Wrench.
WARNING
Flammable Solution. Use in accordance
with manufacturers recommendations.
Use in a properly ventilated area.
3/12/2013
S/N: 020-069


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

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

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

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

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

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

servicing.
Remove axle breather, clean in solvent and dry with
compressed air. Re-install in axle. Do for both axles.
3/12/2013
S/N: 020-069

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

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

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

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

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

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

NPT cap to prevent circuit contamination and possible damage
to hydraulic components.
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S/N: 020-069


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

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

lubricant until fluid level reaches bottom of oil fill plug port.
Clean and re-install differential fill plugs.
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SPECIFICATIONS
FUEL
Use No. 2 Diesel Fuel, Cetane 40 Minimum
Use a dependable brand of diesel fuel with a sulfur content of less than 0.5%. Use care when re-fueling to avoid fuel system
contamination. Use a winter grade fuel when operating vehicle in low temperatures.
NOTE: To avoid drawing air into the fuel system, do not allow vehicle to run out of fuel as this can cause extreme hard starting.
NOTICE
Using diesel fuel with lower than recommended cetane number can cause hard starting, instability, and excessive
white smoke. To maintain satisfactory operation at low ambient temperatures, it is important to specify diesel fuel
of the correct cetane number. For complete details see Engine Operation and Maintenance Manual or contact your
local Getman Distributor.
TIRES
SIZE PLY RATING TYPE PSI BAR
14.00X24 28 ____ 120 8.3
10.00X20 14 LCM 95 6.5
12.00X20 28 SMC 120 8.3
9.00X20 12 LCM 90 6.1
NOTE: This chart indicates tire pressure specifications only and may vary. The sizes are not interchangeable. Always replace with
tires of same size, type, and ply rating originally supplied with vehicle. If questions, contact Getman Service Department.
PRESSURES
TYPE PSI BAR
Engine Oil Pressure at 1000 RPM 45-60 3.1-4.1
Steering Hydraulic System at low idle with 1500-2000 103-138
vehicle turned and against stops.
Hydraulic brake charging pressure.
John Deere Axles 1650-2200 114-151
Ford/New Holland D45 & D65 Axles 1650-2200 114-151
Carraro 28.43& 28.60 Axles 1650-2200 114-151
Pressure from brake treadle valve.
John Deere Axles 1000 69.0
Ford/New Holland D45 & D65 Axles 1500 130.5
Carraro 28.43 & 28.60 Axle 700 48.3
NOTE: Checks made at 150°F (65°C) oil temperature.
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FLUID CAPACITY QUICK REFERENCE GUIDE
ENGINES
MANUFACTURER MODEL GALLONS LITERS
MERCEDES 904 W/ FILTER (OIL) 4.5 W/ FILTER (OIL) 17
MERCEDES 906 W/ FILTER (OIL) 6.75 W/ FILTER (OIL) 25.6
CUMMINS QSB SERIES W/ FILTER: W/ FILTER:
STANDARD OIL PAN 4.3 STANDARD OIL PAN 16.1
DEEP SUMP OIL PAN 5 DEEP SUMP OIL PAN 18.9
DEUTZ F3L912 W/O FILTER (OIL) 2.4 W/O FILTER (OIL) 9
W/ FILTER (OIL) 2.8 W/ FILTER (OIL) 10.4
DEUTZ F5L912 W/O FILTER (OIL) 3.6 W/O FILTER (OIL) 13.5
DEUTZ BF4M1012 & (E) & W/O FILTER (OIL) 2.3 W/O FILTER (OIL) 8.5
(C) & (EC) W/ FILTER (OIL) 2.7 W/ FILTER (OIL) 10
DEUTZ BF6M1012 & (E) & W/O FILTER (OIL) 3.3 W/O FILTER (OIL) 12.5
(C) * (EC) W/ FILTER (OIL) 3.5 W/ FILTER (OIL) 13.2
DEUTZ BF4M2012 & (C) W/O FILTER (OIL) 2.3 W/O FILTER (OIL) 8.5
DEUTZ BF8M2012C W/O FILTER (OIL) 3.3 W/O FILTER (OIL) 12.5
W/ FILTER (OIL) 3.7 W/ FILTER (OIL) 14
TRANSMISSION
CLARK/ DANA 32000 5 18.9
CLARK/ DANA 28000 REPLACED BY 32000 TRANSMISSION
CLARK/ DANA 20000 4.1 15.5
CLARK/ DANA 18000 REPLACED BY 20000 TRANSMISSION
JOHN DEERE 2000 SHORT DROP 4 15
AXLE
NEW HOLLAND D65 7.3 27.4
NEW HOLLAND D45 5.8 21.8
JOHN DEERE TMII 1200 5 18.9
NAF BOGIE GTM 01 3.2 12
CARRARO 28.43 4.5 17.1
NOTE: This should only be used as a reference, fluid requirements may very. Refer to component page in manual to determine
which components are equipped with your truck. For further information, see operation/ service manuals for each component or
contact Getman Service Department.
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NOTE: For trucks operating in temperatures below -40 degrees F (-40 C) the following fluids or their equivalents are recommended.
3/12/2013
S/N: 020-069
A-64 ANFO CHARGER/BOOM
OPERATING AND INSPECTION
M1006
MANUAL Page 1 of 19
GETMAN CORPORATION

MANUAL
FOR
A-64 ANFO CHARGER/ BOOM EMULSION
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS. Updated:
7/11/2012
S/N: 020-069
M1006
MANUAL Page 2 of 19
Introduction 2
Related Manuals 2 Operators should carefully read and understand all vehicle
General Safety Precautions 4 manuals. You must become familiar with all controls and
Safety Alert Symbol 4 procedures. Getman’s A-64 Series ANFO Truck manual is a
Rules 4 guide to safe, proper operation, and maintenance. Always
Safety Instructions 4 keep manual on vehicle at all times.
Boom Man Lift General Descriptions 5
Boom and Outrigger Operation 6-7 This Getman A-64 Series ANFO Truck has been purchased
Daily and Pre-Op Inspection 8 with expectations that it will provide long and reliable service.
Daily Inspection 8 During it’s design and construction, we have taken every
Lubrication - Weekly 9 precaution to ensure we meet those expectations. To realize
Anfo Loading System 10-11 the full valve Getman has designed into this vehicle, a small
Loading Material Into the Anfo Pots 12 amount of time and expense must be invested in the inspection
Control of the Anfo System 13-14 and maintenance procedures outlined in this manual. This
Misconceptions 13 small investment will ensure low operating cost, minimal
Basket Controls 14 service expenses and most importantly, personal safety.
Basic System Adjustments and
Operation 15-17 RELATED MANUALS
Key Items to Remember 18
Typical Boom Operation 19 This manual covers operation and maintenance of the ANFO
loading system and boom mounted on the Getman A-64
chassis. An Operators manual for the primary A-64 chassis is
also incorporated in your Parts and Service Manual for your
specific vehicle. Please read and become familiar with all
these manuals. A complete listing of engine, drive train
components, applicable Electrical, Hydraulic and Air Systems
can also be found in their respective system schematics and
Parts and Service Manuals. We have also provided Parts and
Service Manuals for major components such as axles,
transmissions, and engines. These will be located in the
Getman Parts and Service Manuals for your vehicle, or by
other means.
Getman has increased the frequency for some component

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

this vehicle, immediately contact your local Getman Dealer or
Getman Corporation direct.
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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.
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SAFETY ALERT SYMBOL  Always lower ground engaging implements and

utilize wheel chocks when vehicle is parked.
This symbol will appear at various points  If parking on a grade is unavoidable, point the
throughout the manual in conjunction with vehicle towards the rib, engage the parking brake,
warning statements. Its appearance means: lower all ground engaging implements and utilize
ATTENTION! BECOME ALERT! wheel chocks.
YOUR SAFETY IS INVOLVED!  Avoid smoking or open flame around fuel.
 Always be aware of location of nearest fire
This manual also uses the following messages: extinguisher.
 Check operation of brake circuit prior to beginning of
NOTICE: Used for special information or instructions, each shift.
relating to procedures, equipment, tools, and other special  Never utilize a vehicle for an application other than it
data. was originally designed for.
 Watch out for others. They may not be watching out
IMPORTANT: Used when special precautions should be for you!
taken to ensure correct action or to avoid damage to or
malfunction of equipment. SAFETY INSTRUCTION
CAUTION: Used as a reminder of safety hazards which can WARNING
result in personal injury if proper precautions are not taken. ANFO IS A HIGHLY EXPLOSIVE
MATERIAL!
WARNING: Used when a hazard exists which can result in All safety regulations must be followed
injury or death if proper precautions are not taken. during it’s use. The Operating Procedures
in this manual are intended for general
DANGER: Used when an extreme hazard exists which can information only! Obtain approval safety procedures and
result in serious injury or death if proper precautions are not practices from your safety inspector and material supplier.
taken.
Always wear safety glasses and gloves when operating or
RULES working near compressed air and anfo products.
Before performing any maintenance on the vehicle, review the Never disconnect any compressed air hoses or fittings when
following safety precautions. These are included for your under pressure
protection and safety.
WARNING
Always observe the following general safety rules during HAZARDS OF STATIC
operation of the vehicle. Also observe the safety rules set ELECTRICITY
forth in the work place. The need for additional rules for safe USE ONLY APPROVED
operation may arise due to particular mine applications. This PROCEDURES FOR GROUNDING
should ONLY be used as guidance. PNEUMATIC LOADING VESSEL
AND USE ONLY APPROVED SEMI-CONDUCTIVE
 Read and carefully follow all instructions as outlined (ANTI-STATIC) ANFO PLACEMENT TUBING.
in the vehicle manuals.
 Ensure that all instruments, indicators, and operating IMPORTANT
controls are functioning. In the event that the D-ring anchorage
 Never utilize operating controls as hand holds to has been subjected to stress by a fall, both
assist entering or exiting a vehicle. boom and basket must be thoroughly
 Never stand when operating a vehicle in motion. inspected for damage.
 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.
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BOOM MAN-LIFT GENERAL DESCRIPTION

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

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

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

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

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

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

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

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

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

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

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

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

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

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

range of motion. Ensure hoses are clear and
movement is smooth.
10. Remove all debris from truck, wash truck with water
and blow dry.
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LUBRICATION - WEEKLY
Put truck in service position and lubricate all grease fittings with Grade 2 Lithium Base Extreme Pressure Grease, MIL-G-1092A,
such as” Shell Super Duty Lithium, MDS, Texaco Marfok Multi-Purpose.
NOTICE
MAINTENANCE AND LUBRICATION INTERVALS WERE DEVELOPED TO PROTECT EQUIPMENT
WHEN USED IN SEVERE UNDERGROUND MINING CONDITIONS, THESE CONDITIONS MAY VARY,
AND SERVICE INTERVALS SHOULD BE ADJUSTED TO MEET YOUR REQUIREMENTS. ANY
QUESTIONS, PLEASE CONTRACT YOUR LOCAL GETMAN DISTRIBUTOR OR GETMAN
CORPORATION DIRECT.
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ANFO LOADING SYSTEM
1. VIRBRATOR: Keeps anfo moving. Turns on “only” when supply and boost are engaged.
2. ANFO SUPPLY VALVE: When air is applied to “open”, anfo is allowed to flow through to basket.
3. BOOST AIR VALVE: Opens when anfo supply valve is opened. Directs air in elbow in base of tank to create venturi
effect and push material to basket. Vibrator applies at same time.
4. HOSE CLEAN OUT VALVE: When utilized with supply valve closed, this allows supply hose to be emptied. When
used with anfo supply valve open, may add additional air for up holes.
5. REGULATED AIR: This air is main anfo pot air that is normally regulated to approx. 60PSI by an air regulating valve.
This air pushes down on top of material to ensure constant flow downward. Can be adjusted to suit operator’s
requirements.
6. PILOT AIR: This air is regulated to approx. 70PSI. It provides supply air for the relay valves, vibrators, control valves
in basket, and anfo supply valve. (Jamesbury)
7. STAINLESS STEEL DELIVERY ELBOW: This elbow is flange mounted using stainless steel bolts and can quickly
be removed if needed to remove plugging or debris.
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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.
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LOADING MATERIAL INTO THE ANFO POTS
 The stainless steel ANFO pot or pots on your Getman vehicle are equipped with a lid over the top opening to keep water
and/or debris out of the pot. This lid should only be opened when the pot is completely de-pressurized by opening the tank
drain ball valve and venting the air to atmosphere. Once the vessel is filled, the lid should be closed and latched before the
vessel is again pressurized.
 Located under the lid, is a stainless steel screen. The screen is utilized to screen out any debris that may be inadvertently
directed towards the pot. This will also help break up any larger lumps of anfo and maintain conformity in material size. Do
not remove this screen. It will provide added assurance against material plugging and added security for personnel while
loading the vessel with material.
 There is a rubber sealing cap inside the pot below the screen. The cap automatically rises and seals the pot when air pressure
is applied to the pot. The pot should never be filled to a point above the base of the cap as this may prohibit the cap from
properly sealing. The normal fill capacity would be approximately ¾ to ⅞ full.
 A “grounding reel” is provided on every ANFO vehicle Getman manufactures. The cable of the reel should be run to earth
whenever filling the ANFO pots and/or when charging holes.
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CONTROL OF THE ANFO SYSTEM
The operating controls for the anfo system are completely air powered. The main air manifold or “tree” is located between the pots on
a dual pot system in the center of the deck behind the boom. It is also located in the same general area on a single pot delivery system.
This location was chosen to provide maximum protection from falling debris while still providing easy access for operator
adjustments.
This Getman Anfo Charger has been carefully designed to create a delivery system which will function properly in almost any
application with material from various suppliers. Many updates and improvements have been made throughout the years to ensure
proper loading can always be achieved for maximum productivity. The key to successful loading will be for the operator to determine
the correct settings necessary to properly place the material in your specific application.
This manual may “not” be able to provide each and every operator with the precise settings which may be required for the best
material delivery in each application. By following the simple instructions listed in this manual, you should be able to have the
delivery system fine tuned to your particular operation in a matter of hours.
Universally, there are several suppliers of anfo material. This allows for many differences in texture, weight and conformity. Some
materials manufacturer’s provide a very dry, light product and others are heavier and stickier. This is why finding the correct air
pressure and volume settings for each application is so important.
Once the operator has utilized this system for some time and has determined what settings best fit his needs and application, further
adjustments are seldom required.
MISCONCEPTIONS
Here are some of the misconceptions that often make finding the perfect settings difficult:
If I use the maximum air volume, I’ll get the maximum amount of anfo-
While this sounds logical, we all know the goal when loading is to place the material into the hole quickly and well compacted.
Sometimes when too much boost air volume is used, the air/material ratio is too high. This means more air and less anfo travels down
the lines to the delivery hose. This means longer fill times and less productivity.
I’ll keep maximum air pressure going into the top of the anfo pot to push more material-
Again, very sound logic, but not always practical. The pot is cone shaped with a 4” outlet at the bottom. The real purpose for the air
pressure on the top of the pot is to assist the material to travel to the outlet in the bottom of the pot. Depending on the humidity factor
of the material in the pot, too high an air pressure will lead to packing the material too tight into the outlet and lead to plugging. The
boost air venturi located at the elbow at the pot outlet is truly “the mover” of the material to the basket. The pressure in the pot is
there to ensure the material can get to the outlet in a consistent manner.
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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.
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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. For detailed
operation and maintenance, see M1069 Mine Air Operation/Maintenance which will be included in truck manual in section one if
equipped with this option.
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BASIC SYSTEM ADJUSTMENTS AND OPERATION (CONTINUED)

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

As per previous pages, this vehicle can be manufactured with a mine air ANFO system, an onboard air compressor ANFO system, or a
combination of both. Regardless of the system you have chosen, once you have an air supply for your system, the system settings
become the most critical component to successful operation. Once you have placed the vehicle in the required position, lowered the
stabilizers, and connected the grounding reel cable to earth, Getman suggests you start with the following settings:
 Adjust the ANFO pot pressure regulating valve until the ANFO pot pressure gauge indicates approximately 25PSI.
 Adjust your clean out air ball valve to approximately the half (1/2) open position.
 Adjust your boost air ball valve to approximately the half (1/2) open position.
Because there will always be a short delay after the ANFO delivery valve is closed after loading a hole, we recommend you place a
piece of tape on the delivery wand approximately 10-12” from the place you want the flow of material to stop in that particular hole.
This is done so you can feel and see when the tape exits the hole and turn off the delivery system and yet fill the hole to the desired
depth.
 Now insert the loading wand into the hole to be filled and pull open the “clean out” valve control in the basket. This will
open the “clean out relay valve” and send only air through the wand to blow any water and/or debris from the hole. Be
certain to position your face and body to the side of the hole to avoid being sprayed. If the blow back is too strong, close
your clean out air ball valve slightly to reduce the volume of air being delivered.
 Once the hole has been cleaned out, it’s time to fill the hole with ANFO material. Pull open the “ANFO delivery control
valve” in the basket. This will open the material delivery valve, apply the tank vibrator and open the boost air. Because the
pot air pressure is set low and the boost air ball valve is at ½ open and should easily be controlled. This will be slow, but
will allow you to “get the feel” or the system. You will notice that when you start loading, the wand (delivery hose) will start
to push itself out of the hole. You should keep your hands gripped loosely around the hose so it can continue to come in time
with the material going in to the system.
 Once your comfortable with the feel, you can increase the material flow being delivered by increasing the pot pressure
regulator up to approximately 35PSI. Since you are delivering more material, you should now feel the wand being pushed
back out quicker than before and the hole will be filled quicker. Once you see your tape, shut off the ANFO delivery control
valve.
Now we will increase the speed by opening the Boost air ball valve. Now you may find the delivery hose (wand) is a little harder to
hold because it has more recoil. Again, the hole will be filling faster. Depending on the material type being used and the required
fragmentation, an adequate speed (force) may be critical to properly pack the material in the hole.
Continue to adjust the pressure and volumes until the system is performing to your satisfaction.
The methods mentioned above will basically be the same for loading any type of holes. The key is always going to be “getting the
settings to where they work best for you!!”
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KEY ITEMS TO REMEMBER
 MORE ANFO POT PRESSURE NORMALLY CREATES MORE MATERIAL VOLUME FLOW.

NOTICE
TOO MUCH ANFO POT PRESSURE CAN LEAD TO PLUGGING. CUSTOMER EXPERIENCE HAS
INDICATED 60PSI IS GENERALLY THE OPTIMUM SETTING FOR ANFO POT REGULATED
PRESSURE.
 INCREASE BOOST AIR (BALL VALVE) CREATES INCREASED MATERIAL DELIVERY SPEED.
 INCREASED CLEAN OUT AIR (BALL VALVE) CREATES INCREASED AIR VOLUME.
NOTICE
NEVER LEAVE MATERIAL IN THE ANFO POTS OVERNIGHT. THE CONDENSATION AND
HUMIDITY MAY LEAD TO PLUGGING PROBLEMS.
NOTICE
NEVER LEAVE THE POTS PRESSURIZED BETWEEN LOADING CYCLES. DOING SO MAY LEAD
TO POSSIBLE PLUGGING PROBLEMS
 WHENEVER ANY HOSING, FITTINGS, OR CONNECTIONS OF SMALLER SIZES ARE USED, THIS WILL
LIKELY NECESSITATE THE RE-ADJUSTMENT OF THE AIR SETTINGS. THIS IS DUE TO THE POSSIBLE
RESTRICTION CREATED BY THE SMALLER DIAMETER.
 ALWAYS EMPTY ANY MATERIAL FROM POTS PRIOR TO ENTERING MAINTENANCE SHOP FOR
WELDING OR REPAIRS.
IMPORTANT
NEVER MOVE THE BOOM FROM THE DECK WITHOUT THE STABILIZERS LOWERED AND THE
FRAM AS LEVEL AS POSSIBLE.
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TYPICAL BOOM OPERATION
BOOM ROTATION BOOM ARTICULATION (OUTER) (CONTINUED)
When the rotation valve lever is actuated as shown, the When the outer boom valve lever is actuated as shown, the
hydraulic fluid enters the rotation motor which is located on hydraulic fluid enters the outer cylinder, causing it to retract
the boom base. The rotating torque is transmitted through the and lowering the boom assembly.
gear train which then rotates the boom in a clockwise direction
When the rotation valve lever is actuated as shown, the BOOM EXTENSION
hydraulic fluid enters the rotation motor from the opposite When the extension boom valve lever is actuated as shown,
direction which causes the boom to rotate in a the hydraulic fluid passes through the valve and follows the
counterclockwise direction. hoses to the extend port of the extension boom cylinder. This
forces the cylinder rod out and extends the boom which is
attached to the rod.
BOOM LIFT (INNER)

When the inner boom valve lever is actuated as shown, the Some crane models utilize telescopic extension cylinders
hydraulic fluid enters the inner boom cylinder (some may have which will extend sequentially, thus extending multiple
two inner cylinders or more). The cylinders extend as extension booms automatically
hydraulic fluid forces the rods to extend. The base end of the
inner cylinder is attached to the mast assembly while the rod is When the extension boom valve lever is actuated as shown,
attached to the inner boom which causes the boom to rise, the extension cylinder rod will retract, brining the extension
carrying the outer and extension boom with it. This elevates boom with it, and storing the extension boom within its carried
the booms, providing lift. boom.
When the inner boom valve lever is actuated as shown, the WINCH
hydraulic fluid enters the inner cylinder, causing it to retract When the winch valve lever is actuated as shown the hydraulic
and lowering the boom assembly. fluid follows the hoses to the hydraulic motor attached to the
winch. The fluid builds up pressure against the motor port and
winch brake. The winch brake is metered off and allows the
hydraulic motor to turn, which rotates the winch, paying out
wire rope which lowers the load.
BOOM ARTICULATION (OUTER)

When the outer boom valve lever is actuated as shown, the
hydraulic fluid enters the outer boom cylinder. The cylinder
extends as hydraulic fluid forces the rod to extend. The base When the winch valve lever is actuated as shown, the
end of the outer cylinder is attached to the inner boom while hydraulic fluid again builds up pressure against the motor port
the rod is attached to the outer boom which causes the outer and winch brake but now retracts the wire rope and raises the
boom to rise, carrying the extension booms with it. load.
7/11/2012
S/N: 020-069
MANUAL DE OPERACIÓN E INSPECCION
PARA EL CAMION GETMAN CARGADOR DE M1006
EXPLOSIVOS A-64 Pag. 1 de 19
CORPORACION GETMAN
MANUAL DE OPERACIÓN Y
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:
INSTRUCCIONES EN LAS PLACAS. SPANISH VERSION 10/22/08
S/N: 020-069
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
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
 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.
S/N: 020-069
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.
S/N: 020-069
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).
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
SISTEMA DE CARGADO DE EXPLOSIVOS
465562- 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.
S/N: 020-069
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.
S/N: 020-069
CARGADO DE MATERIAL DENTRO DE LOS TANQUES PARA EXPLOSIVO
465562- 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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
CORPORACION GETMAN
MANUAL DE OPERACIÓN Y
MANTENIMIENTO
PARA
CARGADOR DE EXPLOSIVO
MODELO A-64
Lea cuidadosamente
el manual antes de operar el camiòn
S/N: 020-069
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
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
 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.
S/N: 020-069
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.
S/N: 020-069
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).
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
SISTEMA DE CARGADO DE EXPLOSIVOS
465562- 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.
S/N: 020-069
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.
S/N: 020-069
CARGADO DE MATERIAL DENTRO DE LOS TANQUES PARA EXPLOSIVO
465562- 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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
DUNBAR CRANE D20A MANUAL
M1042
Page 1 of 14
GETMAN CORPORATION

MANUAL
FOR
MODEL D20A DUNBAR CRANE
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Introduction 2
Related Manuals 2 Operators must study all manuals carefully! You must
General Construction 2 become familiar with all controls and procedures. Getman’s
Low Profile Crane 3 D20A Dunbar Crane is bought with expectations it will give
Operation Data 3 long and faithful service. In its construction, we have taken
Specifications 3 every precaution to see that you get an efficient, long –lived
Range & Lowering Diagram 4 vehicle. To realize the value and utility that Getman has
Operating Information 5 designed into this unit, a small amount of time and expense
Owner Responsibility 5 must be invested in doing regular inspections and service as
Operator Responsibility 5 recommended in this manual. The small investment will pay
Crane Maintenance 5 off in low operating costs, minimal service expenses and most
Qualifications To Operate 5 importantly, in personal safety.
Performance Qualifications 5
General Safety Precautions 6 RELATED MANUALS
Safety Alert Symbol 6
Preliminary Safety Inspection 6 This manual covers operation and maintenance schedule of
Range & Load Limits 7 D20A Dunbar Crane. An Operation and Maintenance Manual
Worksite Locations 7 is included in Parts and Service Manuals supplied with
Power Line Proximity 7 vehicle.
Operating Safely 8
Operation Startup 8 Getman has increased the frequency of many recommended
Payload Handling 9-10 maintenance procedures due to the vehicles demanding
Crane/stabilizer Operation 11 application. These changes are noted at each maintenance
Operation Shutdown 12 section end.
Equipment Maintenance 12-13
Lubrication 12 A complete parts listing of engine train components,
Hydraulic Oil Replacement 13 applicable Electric/Air/Hydraulic systems, and mounted
Regular Inspection 13 equipment is included in the Parts and Service Manual. This
Preventative Maintenance Schedule 14 manual also contains service are repair information useful to
maintenance department personnel.
GENERAL CONSTRUCTION
The crane base is an all box welded assembly which includes
rotation gear box, hydraulic motor, and turntable bearing. The
rotating mast is a one-piece weldment which is a four piece
unit with a two-stage, telescoping, enclosed cylinder. All
booms have easily serviceable slide pads on all four sides of
the extension sections that provide full support with minimal
sliding friction.
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LOW PROFILE CRANE
The figures below shows storage position options. The short retracted boom geometry allows crane storage in either a conventional or
transverse orientation in the vehicle bed.
OPERATION DATA
REACH ELEVATION LOAD

5’6” 5’6” 5,000 LB
10’3” 7’9” 3,100 LB
15’3” 10’6” 2,100 LB
SPECIFICATIONS
Hydraulic Extension 117 in. Pressure

Crane Weight 1,700 lb. Rotation Speed (340°) 30 seconds
Base Mounting Space 20 in. X 35.5 in. Boom Elevation 10 seconds
Storage Length 91 in. Boom Extension 18 seconds
Storage Height 36 in.
(bottom of base)
Pump Flow Rate 5 US GPM
Maximum Working 2, 800 psi
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RANGE & LOADING DIAGRAM
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OPERATING INFORMATION PERFORMANCE QUALIFICATIONS
Safe, efficient crane operation depends upon five basic To be qualified as an operator the person shall be able to:
conditions. These conditions are:
1. Read and accurately interpret all operator and
1. Crane and vehicle unit must be properly serviced and maintenance manuals, tags, and safety rules and
maintained. regulations.
2. The operator must be competent and thoroughly 2. Identify Getman’s defined inspection procedures and
trained. routine maintenance tasks, and be accountable for
3. Safe work practices must be exceeded. satisfactory compliance with same on assigned crane.
4. Load limits must never be exceeded. 3. Identify Getman’s defined load limits and operating
5. Control functions must be used in the prescribed, characteristics for assigned crane.
correct operating sequence. It must be stressed that 4. Demonstrate competence in emergency response
not one of these five requirements can be safely procedures pertinent to crane operation.
eliminated from the crane operating procedures. 5. Demonstrate physical, electrical, and personal hazard
recognition and avoidance pertinent to crane
OWNER RESPONSIBILITY operation.
6. Demonstrate mastery of all Getman’s prescribed
The owner of this crane is responsible for proper maintenance operating procedures and control functions for the
and repair of the unit and establishing support documentation assigned crane.
of the same. The owner is also obligated to the ongoing task
of selecting only competent operator and service candidates
and providing personnel training necessary to assure safe
operation of the crane unit.
OPERATOR RESPONSIBILITY
The operator, operator trainer, or service person is responsible
at all times for the safe transportation and use of the crane
unit. Safe transportation and use includes proper storage,
recognition and avoidance of all observable hazards to
personnel and property, pre-operation inspection, and
operating the crane at all times within load and range
restrictions
CRANE MAINTENANCE
The crane should be subject to regular inspections and
preventative maintenance procedures as prescribed in this
manual. In addition, any defect which is observed and
reported in the course of regular pre-operation inspections
should be corrected and recorded before the unit is returned to
service.
QUALIFICATIONS TO OPERATE
Authorized Personnel: Persons authorized to operate the crane
shall be limited to the following personnel:
1. Designated, trained, and qualified operators.

2. Operator qualified supervisory, maintenance, and
service personnel only within the scope of their
duties.
3. Operator trainees or any untrained persons only under
the direct supervision of qualified persons.
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Before operating or performing any maintenance on the SAFETY ALERT SYMBOL
vehicle, review the following safety precautions. These are
included for your protection and safety. This symbol will appear at various points
throughout the manual in conjunction with
Always observe the following general safety rules during warning statements. Its appearance means:
operation of the vehicle. Also observe the safety rules set ATTENTION! BECOME ALERT!
forth in the work place. The need for additional rules for safe YOUR SAFETY IS INVOLVED!
operation may arise due to particular mine applications. This
should only be used as guidance. This manual also uses the following messages:
Safety depends on well maintained, properly operated NOTICE: Used for special information or instructions,
equipment. Following service and maintenance relating to procedures, equipment, tools, and other special
recommendations set forth in this manual will result in a data.
reliable vehicle. Observing operating procedures can help you
avoid accidents. Listed in the following pages are some basic IMPORTANT: Used when special precautions should be
safety precautions which should be read, understood and taken to ensure correct action or to avoid damage to or
practiced. It is, however, impossible to cover every condition. malfunction of equipment.
Always be alert, think SAFETY at all times, and use common
sense. CAUTION: Used as a reminder of safety hazards which can
result in personal injury if proper precautions are not taken.
WARNING: Used when a hazard exists which can result in

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

result in serious injury or death if proper precautions are not
taken.
PRELIMINARY SAFETY INSPECTION NOTICE

During the control test observe system
Before operating the crane always perform the following response for any signs of unusual vibration,
safety inspection: noise, grinding, or binding . If any of these
conditions are observed STOP the test and
1. POSITION CRANE VEHICLE: Locate crane unit in make appropriate repairs.
a safe work area free from electric power lines or any
other obstructions. 7. DE-ENERGIZE EQUIPMENT FOR REPAIRS:
2. PERFORM WALK AROUND INSPECTION: When repairs are necessary always shut down or
Inspect major system components: disconnect system power before making them.
a. Hydraulic System: Inspect visible hoses, 8. CORRECT ALL MALFUNCTIONS: Before any
connections, and components for signs of work is performed with the equipment be sure that all
physical breakdown or leakage. observed defects are corrected. Failure to do so can
b. Mechanical System: Inspect visible mechanical result in serious personal injury or costly equipment
structure for damage or deformed members, and damage.
loose or missing bolts or nuts.
3. CLEAR TEST AREA: Clear intended test area NOTICE
(extended crane travel field) of all personnel. This pre-operation inspection should be
4. POWER CRANE SYSTEM: Energize crane unit performed before every use. This
power supply. inspection does not qualify as an alternative
5. POSITION OUTRIGGERS: Set outriggers in to the regular preventive maintenance
stabilizing position, making sure the supporting inspections as described in this manual.
surface provides solid footing.
6. TEST CONTROLS: At slow speed test all crane
control functions.
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RANGE & LOAD LIMITS POWER LINE PROXIMITY
A maximum Range and Load Capacity tag is shown on pages Except when the electrical distribution and transmission lines
3 & 4 as posted on the crane. The load-range limits identified have been de-energized and visibly grounded at point of work
on this tag should be read and thoroughly understood before location, or where insulating barriers are not a part of or an
any payload lifting is carried out. Do not exceed the attachment to the crane being erected to prevent proximate to,
maximum load for any range. Overloading gives risk to under, over, by, or near power lines only in accordance with
tipping and structural failure of the crane, and poses serious the following:
safety hazards. Lift all loads with crane boom.
1. For lines rated 50kV or below, minimum clearance
WARNING between the lines and any part of the crane or load
A TIPPING HAZARD EXISTS WHEN shall be 10 feet.
OPERATING THE CRANE ON A 2. For lines rated over 50kV, minimum clearance
SLOPE OR ACROSS A SLOPE between the lines and any part of the crane or load
GRADE. RATED RANGE AND LOAD shall be 10 feet plus 0.4 inch for each 1 kV over 50
CAPACITIES MUST BE RESTRICTED kV, or use twice the length of the line insulator but
TO COMPENSATE FOR SLOPE OPERATION AND TO never less than 10 feet.
AVOID TIPPING. 3. In transit with no load and boom lowered, the
clearance shall be a minimum of four feet.
WORKSITE LOCATIONS 4. It is recommended that a person be designated to
observe the clearance and give timely warning for all
The safe, recommended work site location for the crane operations where it is difficult for the operator to
vehicle is a level, dry paved surface. Unpaved ground should maintain the desired clearance by visual means.
provide solid support for gross vehicle weight and any load
lifted, and sound outrigger footing. Before the commencement of operations near electrical
lines, the person responsible for the job site shall notify
Parking on slopes requires special precautions: the owners of the lines or their authorized representative
providing them with all pertinent information and
1. Park with the grade-vehicle facing upgrade or requesting their co-operation.
downgrade.
2. Use wheel chocks on downgrade side of rear vehicle Any overhead wire shall be considered to be an energized
wheels. line unless and until the person owning such line or the
3. Parked at curbside with front facing downgrade--turn electrical utility authorities indicate that it is not an
front wheels into curb. energized line.
4. Parked at curbside with front facing upgrade--turn
front wheels into curb. Exceptions to the procedure, if approved by the owner of
5. Avoid parking cross-grade. If cross-grade parking is the electrical lines, maybe granted by the administrative
unavoidable then load lifting capacities must be or regulatory authority if the alternate procedure provides
restricted to reduce tipping risk. sufficient protection and is set forth in writing.
The working field (envelope) of the crane should be as free as
possible of overhead obstructions, equipment, and materials
which could restrict crane operation. The operator should take
note of all objects noted about and limit the crane lifting
operation to remain well clear of them. Electric power lines
pose special hazards.
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OPERATING SAFELY OPERATION STARTUP
In order to operate the crane in a safe manner the following Prior to load handling the following set of tasks must be
safety precautions should always be observed: performed to assure protection of personnel, equipment , and
payload:
1. Always perform the pre-operation inspection to
perform crane service or repair tasks. 1. SELECT SUITABLE WORKSITE: Park close to
2. Never allow unauthorized personnel to perform crane load handling site, on dry, firm, level surface, with a
service or repair tasks. crane operating field free of obstructions and power
3. Never attempt maintenance or repair on an energized lines.
crane. 2. SECURE VEHICLE: Set vehicle parking brake and
4. Never operate crane in an electrical storm or high engage parking gear or other locking device if
wind conditions. provided.
5. Always locate crane vehicle on firm, dry, level 3. CLEAR WORKSITE: Remove all personnel from
terrain. crane worksite area. Make sure all obstructions to
6. Never locate crane near electrical power lines, see crane and load travel path are removed or noted for
page 7. avoidance.
7. Always make sure crane vehicle is stabilized correctly 4. CHECK TIRES: Inspect tires and make sure they are
before load lifting begins. inflated to recommended pressure.
8. Always have all personnel clear during outrigger 5. DESIGNATE SIGNALMAN: If signalman or helper
positioning. assistance is required, designate a qualified person
9. Always keep operating area clear of all personnel. for the task and make sure all communication signals
10. Never lift people with the crane, unless there is a man are understood by both operator and helper.
basket used. 6. REMOVE RESTRAINS: Remove all tie down straps,
11. Always use the correct, prescribed sequence for latches, or hooks from crane and attachments.
energizing the crane system. 7. PERFORM WALK AROUND INSPECTIONS:
12. Always operate crane controls through a full cycle Inspect major system components – mechanical,
before load lifting. hydraulic, and electrical – as described on page 6
13. Always operate controls smoothly and at prudent 8. POWER CRANE SYSTEM
speed; avoid jerky or full open, full closed action. 9. POSITION OUTRIGGERS: Set outriggers in
14. Never exceed rated Load-Range capacities. stabilizing position, making sure the supporting
15. Always know the position of the crane. surface provides solid footing.
16. Always include the weight of load handing 10. TEST CONTROLS: At slow speed test all crane
attachments in total load weight. control functions.
17. Always keep work area in full view. 11. INSPECT ATTACHMENTS: Inspect any load
18. Never leave the control station unattended with a handling attachments for mechanical soundness and
suspended load. correct hydraulic control response.
19. Never operate or swing the crane over people. 12. DE-ENERGIZE EQUIPMENT FOR REPAIRS:
20. Always keep boom and load free of loose objects. When repairs are necessary always shut down or
21. Always start, rotate, and stop a loaded boom slowly. disconnect system power before repairs are made.
22. Always lift loads vertically. 13. CORRECT ALL MALFUNCTIONS: Before any
23. Never drag a load sideways to position for lifting; work is performed with the equipment be sure that all
side loading can cause damage or failure. observed defects are corrected. Failure to do so can
24. Always operate with load as near to grade level as result in serious personal injury or costly equipment
possible. damage.
25. Always keep boom tip as close to load as possible.
26. Always damp swaying loads.
27. Never leave crane controls unattended on energized
crane.
28. Always inspect the work side before resuming use of
the crane if it has been unattended.
29. Always store crane, outriggers, and attachments in
approved manner for transport.
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PAYLOAD HANDLING
When all OPERATION STARTUP conditions are met, load lifting can begin. During any load lifting operation the operator must
retain control of the load using the following guidelines:
1. CHECK LOAD RANGE CAPACITY: The combined weight of load and any load-handling attachment must not exceed the
rated crane load-reach capacities shown on the Capacity Chart below.
WARNING
ALL RATED CAPACITIES FOR REACH AND LOAD STATED ON A CRANE CAPACITY TAG ARE
FOR CRANE OPERATION ON SOLID, LEVEL GROUND WITH OUTRIGGERS CORRECTLY
PLACED. ANY OPERATION ON SLOPPED TERRAIN REQUESTS STABILITY TESTING AND
SEVERE LOAD-REACH RESTRICTIONS DUE TO INCREASED TIPPING HAZARD.
ALL RATED LOAD-RANGE CAPACITIES STATED ON CAPACITY TAG ARE FOR VERTICAL LIFTING ONLY –
LOAD TO BOOM TIP. SIDE LOADING IS EXPRESSLY PROHIBITED.
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PAYLOAD HANDLING CONTINUED
2. POSITION CRANE FOR LIFTING: Using crane control functions, maneuver crane tip or tip with lifting attachment into
lifting position over the load so that:
a. Crane Hook, if used, is directly over load using the most efficient load range crane boom extension for the intended load
transport.
b. Lifting Attachment, if used, is placed for correct load engagement with outside loading boom stress.
3. ENGAGE LOAD: Using correct, secure procedures, engage and secure load to hook or attachment making sure:
a. Hook is secure and safety catch is in place.
b. Rigging is correct and properly balanced so no load shift will occur during transport.
c. Load Attachment has completely and securely engaged load and no loose, falling material hazard will exist during
transport.
d. Boom Tip is positioned directly over load and hook or load attachment ring so that no side loading of boom
(dragging) will occur when load lifting begins.
DANGER
PREPARATION FOR LOAD LIFTING IS NOT COMPLETE UNTIL BOOM SIDE LOADING
POSSIBILITY HAS BEEN ELIMINATED. SIDE LOADING OR DRAGGING CAN CAUSE
EQUIPMENT FAILURE AND SERIOUS INJURY OR DEATH.
4. LIFT LOAD: Lift load slowly using the following guidelines:

a. Using Boom for lifting and lowering.
b. Keep Load in sight or in sight of designated signalman at all times.
c. Pause when load is no more than one foot above rest position to observe any down drift, load imbalance, or shifting.
If any of these conditions are observed, lower the load and take corrective action before resuming the lifting
operation.
WARNING
DO NOT PROCEED WITH LOAD LIFTING IF ANY DOWN DRIFT, LOAD IMBALANCE, OR DRIFTING IS
OBSERVED. CORRECT ANY OF THESE CONDITIONS BEFORE CONTINUING. FAILURE TO DO SO IS A LIFE
THREATENING HAZARD.
d. Raise Load to clear all obstacles in the intended travel path. Never raise load higher than necessary for safe
clearance.
5. ROTATE CRANE: With load elevated to desired height, rotate crane using a cautions speed and damping all swaying when
desired location is reached. Avoid abrupt starts and stops.
CAUTION
WHEN CRANE ROTATION IS STOPPED, SWAY WILL RESULT. SWAYING MUST BE DAMPED BY
SLOW STOPPING AND THEN ROTATING CRANE SLIGHTLY (INCHING) IN THE DIRECTION OF
THE SWAY. TO NEGLECT THIS MANEUVER CAUSES BOOM SIDE LOADING EFFECT AS
PREVIOUSLY NOTED.
6. EXTEND LOAD: When desired crane-load alignment with load landing site is reached, boom extension must not exceed
specified load-reach capacity.
7. LOWER LOAD: Using crane to assure correct load placement, lower at reasonable speed using boom.
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Page 11 of 14
CRANE/STABILIZER OPERATION
PART NUMBER 7028‐00500
PART NUMBER 7028‐00501
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Page 12 of 14
OPERATION SHUTDOWN
When loading handling is complete, shutdown is accomplished as follows:
1. STOW CRANE: Return crane to transport position.

2. RETRACT OUTRIGGERS: Return outriggers to storage position.
3. DE-ENERGIZE CRANE SYSTEM
EQUIPMENT MAINTENANCE
Routine preventive maintenance is essential to keeping crane at peak operating efficiency. The maintenance procedures and frequency
schedules outlined in this section should always be adhered to by operating and maintenance personnel.
LUBRICATION
Lubrication should be performed monthly at the following lubrication points. This is based upon normal equipment use and mild
climatic conditions. When this equipment is subjected to heavy use or severe weather conditions it may be necessary to increase
lubrication maintenance frequency. Notice: Some trucks are equipped with Auto Lube option.
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Page 13 of 14
EQUIPMENT MAINTENANCE (CONTINUED)
HYDRAULIC OIL REPLACEMENT

Hydraulic oil in the unit reservoir should be changed every six months or after 800 hours of service, and after any major hydraulic
component failure.
In addition to regular hydraulic oil replacement, the oil should be periodically sampled and examined for breakdown, sludge, and
water contamination. If any of these conditions are observed, the oil should be changed between service intervals.
Hydraulic oil replacement and system purging is as follows:
1. Prepare for procedure by having sufficient new oil on hand to completely fill the unit reservoir, cylinders, lines, and other
hydraulic components; and extra oil to allow to for loss. Also have a receptacle of adequate size to catch all waste oil.
2. Select a vehicle parking location which will provide secure outrigger footing and allow full extension of the crane unit to the
side horizontally and to full elevation range.
3. Park vehicle on selected location, extend outriggers full stoke where applicable, and extend crane to its maximum horizontal
side reach position. Shut off system power.
4. With waste oil container in place, remove drain plug in bottom of reservoir and remove dipstick to allow air flow. When
reservoir has drained completely, remove reservoir inspection cover. Remove suction strainer and wipe clean. Wipe
reservoir and suction strainer bowl clean with lint free cloth. Replace suction strainer and inspection port. Replace plug.
5. Disconnect, drain, and reconnect pump pressure hoses. Replace return line canister filter element. Make sure all connections
are secure.
NOTICE
Purging the hydraulic system consists of supplying new oil to the lines and components via the reservoir while the
return line is disconnected and the oil is diverted to a waste container. During this procedure the oil level in the
reservoir should be maintained at no less than 1/3 of reservoir capacity to insure no air introduction to the system.
6. Fill reservoir to “Full” mark on dipstick and check drain plug to assure there are no leaks.
7. Disconnect the reservoir return line hose and securely direct the oil flow to the waste container.
8. Power the system and with slow speed:
a. Retract extension booms fully.
b. Horizontally rotate crane 90°.
c. Elevate inner boom to fullest height.
d. Lower inner boom to its lowest position.
e. Retract outriggers. The system is not fully purger
9. Shut system power off. Reconnect return line and check oil level. Fill reservoir to “Full” as required.
REGULAR INSPECTION
It is recommended that the equipment user establishes a regular maintenance inspection schedule and an appropriate record system of
the same. A regular preventive maintenance schedule for this unit is provided in this manual. The user may wish to expand upon it
but at no time should the points outlined be omitted. It is also important that records be routinely kept of these inspections and actions
taken.
In addition to a regular inspection schedule it may be necessary to perform special inspections of the unit if it is subjected to periods of
unusually heavy use, long periods of idleness, or is damaged in any way.
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Page 14 of 14
PREVENTIVE MAINTENANCE SCHEDULE
ITEM DESCRIPTION INTERVAL

DAY WEEK MONTH 6 MONTH
Walk Around Inspection Inspect unit for any visible defects- oil leaks, metal
deformation, weld failure, loose or damaged chain, X
hoses, or wire rope, and other obvious flaws
Regular Maintenance This procedure is detailed below and should be a
Inspection logged task activity at indicated interval. X X X X
Structural Members Inspect all structural members for metal fatigue,
weld failure, and structural deformation. X
Load Bearing Surfaces Check all wear pads for wear, deformation, or
tearing. X
Check all bearings for displacement and obvious
wear deformation. X
Hydraulic System Check oil level. Check oil sample for
contamination and breakdown. X
Replace filter element canister X
Check hoses for flattening and outer walls for
blistering, wear, and pitting. Check hose fittings X
and surfaces for leakage signs.
Change oil and clean suction strainer. X
Perform dynamic load holding test both raising and
lowering to a stop. X
Inspect pump, motor, valves, and other hydraulic
components for signs of leakage. Check couplings X
for soundness.
7/2/2012
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GETMAN BOOM/ BASKET M1004
INSPECTION Page 1 of 12
SUGGESTIONS AND PROCEDURE FOR THE INSPECTION OF A GETMAN BOOM
The following procedure should be used when inspecting a boom/ basket for reliability and safety after a period
of 4000 hours or 5 year of use. This procedure involves the complete removal of the boom and basket and
disassembly of the boom, in order to properly evaluate its condition. This inspection is highly detailed.
Regular 50 hour maintenance checks should still be performed on the boom/ basket, and parts will have to be
replaced before this check. This inspection is highly detailed and should be performed on booms/ baskets that
have been used extensively in the field.
The information and suggestions found here are presented in a general matter. In order to find information
specific to the truck, consult the truck manual, or contact Getman Service.
HYDRAULIC SYSTEM
Before completely breaking down the boom assembly, it is important to evaluate the current working condition
of the boom/ basket before the replacement of parts or other components. Therefore the following information
should be recorded.
_____ BASKET WEIGHT TESTED AT 150% OF RATED CAPACITY __________LBS

_____ BOOM CONTROLS (OPERATE BOOM TO FULL RANGE)
AT 100% RATED CAPACITY _______ LBS
_____ RECORD PRESSURES WITH 100% RATED CAPACITY IN BASKET
Boom Up Pressure __________ Boom Down Pressure __________
Boom Up Time __________ Boom Down Time __________
Boom Ext. Pressure __________ Boom Ret. Pressure __________
Boom Ext. Time __________ Boom Ret. Time __________
Boom Rotate CW Pressure __________ Boom Rotate CCW Pressure __________
Boom Rotate CW Time __________ Boom Rotate CCW Time __________
Basket Rotate CW Pressure __________ Basket Rotate CCW Pressure __________
Basket Rotate CW Time __________ Basket Rotate CCW Time __________
Basket Up Pressure __________ Basket Down Pressure __________
Basket Up Time __________ Basket Down Time __________
Updated:
7/11/2012
S/N: 020-069
HYDRAULIC SYSTEM (CONTINUED)
If any of the functions seem excessively slow, or have a lack of power, some of the hydraulic components may
need to be replaced.
During operation and after break down the hydraulic system must be evaluated for the following points.
1. Cylinders
a. Check for leaks.
b. Check for proper extension and retraction speeds.
c. Check for damage or excessive corrosion to the component itself.
d. Check for slop or excessive movement in the rod.
2. Control Valves
a. Check for leaks.
b. Check for proper operation.
c. Check correspondence between tags and operation.
d. Check for damage or excessive corrosion to the component itself.
3. Other Components and Hoses

a. Check for leaks.
b. Check for proper operation.
c. Check routing of hoses.
d. Check for damage or excessive corrosion to the component itself.
Depending on the condition of the components and hoses, it may be wise or necessary to replace some of the
components and all of the hoses. It may also be a good opportunity to rebuild the cylinders.
PINS AND BUSHINGS
Throughout a Getman boom there are many different Pins and Bushings, it is imperative that all of them are
inspected properly in order to insure the safety and correct operation of the boom. See Figure 1 for general
location of boom pins.
1. Pins
a. Check pins for steps, grooves, or excessive wear. The pin should not be able to move up or
down in the bushing.
b. Have the pins tested for cracks using a Magnetic Particle test, or other nondestructive testing
method.
c. Replace bolts that hold pins in position.
d. Check bolt holes for worn threads or excessive slop.
2. Bushings
a. Replace all Removable Bushings.
b. Check welded bushings for excessive pin movement. The pin should not be able to move in
any direction perpendicular to the bore.
Updated:
7/11/2012
S/N: 020-069
WEAR PADS
When performing a detailed inspection of the Getman boom, involving the complete tear down of the assembly,
it is recommended that all the boom wear pads and their mounting bolts be replaced. The parts are relatively
inexpensive, and it is easy to do with the boom disassembled. See Figure 1 for general location of the wear
pads. See Figure 2 for Wear Pad Replacement Procedure.
Replacement of these wear pads should remove any excessive sag or movement in the boom, and will help
return it to proper working condition. If the wear pads are worn excessively to the point where the mounting
screws are contacting the boom, they must be replaced. This excessive wear can cause extreme damage to the
boom, and will result in failure.
WELDMENTS
A typical Getman Boom is composed of a turret, outer boom weldment, middle boom weldment, inner boom
weldment and basket. (See Figure 1) These weldments should all be inspected in depth for cracks, corrosion,
wear, and damage. Any components exhibiting these characteristics should be replaced, or properly repaired.
CORROSION
The affect of corrosion on a boom/ basket can dangerously fatigue the boom/ basket beyond repair. While
corrosion in some areas of the boom/ basket maybe less serious as others, it’s important that the boom/ basket
be relatively free of heavy corrosion if still in use. Getman suggests that the depth of corrosion, within 12
inches of the boom ends and on all pivoting components, be less then .01”. In the middle sections of the boom
where the stress on the sections is less, the corrosion can be as deep as .03”. However, with excessive
corrosion, the amount of material worn away maybe enough so that the depth of the corrosion maybe
inaccurately measured. A combination of excessive wear and corrosion can lead to failure. Getman
recommends that corrosion and wear be looked at carefully. Refer to the pictures in Figure 3 for examples of
excessive corrosion of the boom.
BASKET
The basket should be inspected regularly for bent supports, welds, corrosion, deformation, etc. See Figure 4 for
an example of a basket that is unsafe and needing replacement. If a basket has been deformed, it would be
recommended to inspect all pins, cylinders, and links on the boom for indications of damage.
FINAL INSPECTION
After the boom has been properly serviced and reassembled the boom / basket should be inspected again for
proper operation of hydraulic components. The boom/ basket should be tested with 150% of rated weight, for
proper range of motion and operation. With proper care and attention to these guidelines the Getman boom/
basket should be ready for safe use once again, however in some instances a boom/ basket may be beyond
economical repair, and should be removed from further use. If any questions or concerns arise during the
inspection please feel free to contact Getman Service for further assistance.
Updated:
7/11/2012
S/N: 020-069
FIGURE 1
Updated:
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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
 Insure that the truck is parked on a level surface
 Disconnect power at main battery disconnect switch
 Properly place wheel chocks so that the truck won’t roll
OUTER SLIDE PADS AND WEAR PADS
See Figure 3 for the following location points. Both the outer
boom (#10) and the middle boom (#25) have a slide pad (#22) on
the bottom end, and a set of side wear pads (#24). The slide pad is
attached to the bottom of the boom using a pin that is bolted in
place (#20 & #28). By putting the weight of the boom on the
basket, pressure will be relieved from the bottom slide pads and
they can be removed and serviced. The slide pads have wear pads
(#21) that can be replaced when needed. The side wear pads (#23)
can also be replaced as needed. Two bolts hold on the side wear
pads, when removed, the wear pads can be unbolted from the plate
and replaced. The replacement of the wear pads on the outside of
the boom is fairly simple, and will extend the life of the boom.
Failure to replace these pads before they are over worn can result
in extreme damage to the main boom assembly. The screws that
hold on the wear pads can cut deep grooves in the boom
components causing the boom to weaken.
FIGURE 2
Updated:
7/11/2012
S/N: 020-069
ANFO LOADER BOOM WEAR PAD REPLACEMENT PROCEDURE (CONTINUED)
WEAR PAD SHIMS
When removing wear pads, shims will be present. These shims

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

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

removing the pin connecting the basket to the boom, and the pin
connecting the hydraulic cylinder to the boom.
FIGURE 2
Updated:
7/11/2012
S/N: 020-069
ANFO LOADER BOOM WEAR PAD REPLACEMENT PROCEDRUE (CONTINUED)
The hydraulic cylinders that extend and retract the boom are bolted
to the inside of the middle boom. The ends of the cylinders are
connected to the front of the outer boom, and the end of the inner
boom. The pins that connect the cylinder ends to the boom must
be unbolted and removed in order to pull out the inner and middle
boom.
Once the cylinders have been freed from the boom assembly, the
inner and middle booms can be removed from the outer boom
together. In order to do this the slider pad and the side wear pads
on the outer boom must first be removed. Using a crane or
whatever is available, the basket end of the inner boom should be
supported and pulled out, along with the middle boom, from the
outer boom. It maybe necessary to tie the middle boom and the
inner boom together in order to pull them out together. At this
time the wear pads on the middle boom should be visible.
Placing the boom on a set of horses, or a table makes it easy to

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

boom
FIGURE 2
Updated:
7/11/2012
S/N: 020-069
EXTRA PICTURES
NO BASKET, DRILL OPTION
Updated:
7/11/2012
S/N: 020-069
FIGURE 2
Updated:
7/11/2012
S/N: 020-069
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:
7/11/2012
S/N: 020-069
ITEM DESCRIPTION QTY.
29 PIN (LEVELING CYLINDER) 1
30 PIN (EXTENSION CYLINDER) 1
31 PIN (BASKET) (REF.) 1
32 BUSHING 2
33 ROTATOR 1
34 BOLT 3
35 WASHER 3
36 CYLINDER (LEVELING) 1
37 PIN (LEVELING) 3
38 LEVELING LINK 1
39 LEVELING LINK 1
40 BASKET 1
FIGURE 3
Updated:
7/11/2012
S/N: 020-069
FIGURE 4
IMPORTANT
In the event that the D-ring anchorage
has been subjected to stress by a fall, both
boom and basket must be thoroughly
inspected for damage.
Updated:
7/11/2012
S/N: 020-069
INSPECCIÓN DE LA M1004
CANASTILLA Y PLUMA GETMAN Pag. 1 de 12
SUGERENCIAS Y PROCEDIMIENTO PARA LA INSPECCIÓN DE LA CANASTILLA Y PLUMA

GETMAN
El siguiente procedimiento deberá ser usado cuando se inspeccione una pluma/canastilla para seguridad y
confiabilidad después de un periodo de 4000 horas o 5 años de uso. Este procedimiento implica desmontar
totalmente la pluma y canastilla y desarmar la pluma, para evaluar adecuadamente su condición. Esta
inspección es detallada ampliamente.
El mantenimiento regular de 50 horas deberá también ser realizado a la pluma y canastilla y las partes dañadas
deberán ser reemplazadas antes de esta revisión. Esta inspección es detallada ampliamente y deberá ser
realizada en las plumas y canastillas que han sido utilizadas continuamente en el campo de trabajo.
La información y sugerencias encontradas aquí son presentadas de una manera general. Con el fin de encontrar
información específica para el camión, consulte el manual del camión, o contacte el servicio de Getman.
SISTEMA HIDRAULICO
Antes de desarmar completamente la pluma, es importante evaluar la condición general de trabajo de la pluma y
canastilla antes de reemplazar refacciones u otros componentes. Por lo tanto la siguiente información deberá ser
registrada.
_____ PESO PROBADO DE LA CANASTILLA A 150% DE LA CAPACIDAD DE CARGA___LBS

_____ CONTROLES DE LA PLUMA (OPERAR LA PLUMA AL LÍMITE TOTAL)
AL 100% DEL VALOR DE CAPACIDAD _______ LIBRAS
_____ PRESIONES REGISTRADAS CON 100% DEL VALOR DE CAPACIDAD EN LA
CANASTILLA
Presión al elevar la Pluma __________ Presión de descenso de la __________
Pluma
Tiempo al elevar la Pluma __________ Tiempo de descenso de la __________
Pluma
Presión para extender la __________ Presión de retracción de la __________
Pluma Pluma
Tiempo de extensión de la __________ Tiempo de retracción de la __________
Pluma Pluma
Presión de rotación de la __________ Presión de rotación de la __________
Pluma a la derecha Pluma a la izquierda
Tiempo de rotación de la __________ Tiempo de rotación de la __________
Pluma a la derecha Pluma a la izquierda
Presión de rotación de la __________ Presión de rotación de la __________
Canastilla a la derecha Canastilla a la izquierda
Tiempo de rotación de la __________ Tiempo de rotación de la __________
Canastilla a la derecha Canastilla a la izquierda
Presión de elevación de la __________ Presión de descenso de la __________
Canastilla canastilla
Tiempo de elevación de la __________ Tiempo de descenso de la __________
Canastilla Canastilla
Updated:
12/10/10
S/N: 020-069
SISTEMA HIDRÁULICO (CONTINUACIÓN)
Si alguna de las funciones se muestra excesivamente lenta o con pérdida de potencia, alguno de los
componentes del sistema hidráulico puede necesitar ser reemplazado.
Durante la operación y después de una falla el sistema hidráulico deberá ser evaluado en los siguientes puntos:
1. Cilindros
a. Revisar por fugas.
b. Revisar para velocidades correctas de extensión y retracción.
c. Revisar los componentes por daño o corrosión excesiva.
d. Revisar el vástago por movimiento o desgaste excesivos.
2. Válvulas de control
a. Revise por fugas.
b. Revisar para operación correcta.
c. Revisar la relación entre la operación y tarjetas de advertencia.
d. Revisar los componentes por daño o corrosión excesiva.
3. Otros Componentes y Mangueras

a. Revisar por fugas.
b. Revisar la operación correcta.
c. Revisar el recorrido de las mangueras.
d. Revisar los componentes por daño o corrosión excesiva.
Dependiendo de la condición de los componentes y mangueras, puede ser acertado o necesario reemplazar
alguno de los componentes y todas las mangueras. También puede ser una buena oportunidad para reconstruir
los cilindros.
PERNOS Y BUJES
A lo largo de la pluma hay diferentes pernos y bujes o casquillos, es necesario que todos ellos sean revisados
correctamente a fin de asegurar la seguridad y operación correcta de la pluma. Vea Figura 1 para la
localización general de los pernos de la pluma.
1. Pernos
a. Revisar los pernos si tienen rebordes, muescas o desgaste excesivo. El perno no deberá
moverse hacia arriba o hacia abajo dentro del buje.
b. Pruebe los pernos por posibles fisuras, utilizando la prueba con partículas magnéticas, u otro
método de prueba no destructiva.
c. Reemplace los tornillos que sostienen los pernos en su posición.
d. Revise la cuerdas interiores donde enroscan los tornillos por desgaste o sucias
2. Bujes o casquillos
a. Reemplazar todos los bujes o casquillos removibles.
b. Revisar los bujes soldados por movimiento excesivo del perno. El perno no deberá tener
movimiento en ninguna dirección perpendicular al diámetro interior del buje.
Updated:
12/10/10
S/N: 020-069
ZAPATAS DE DESGASTE
Cuando lleve a cabo una inspección detallada de la Pluma Getman, que implica el desmontaje completo del
conjunto de la Pluma, se recomienda que todas las zapatas de desgaste y sus tornillos de montaje sean
reemplazados. Las partes de repuesto son relativamente baratas, y es fácil realizarlo con la Pluma desmantelada.
Ver Figura 1 para la localización general de la zapatas de desgaste. Ver Figura 2 para el procedimiento de
reemplazar estas zapatas.
La reposición de estas zapatas debe eliminar cualquier flexión o movimiento en la Pluma, y ayudará a regresarla
a su condición apropiada de trabajo. Si las zapatas están excesivamente gastadas a tal punto que los tornillos de
montaje estén teniendo contacto con la Pluma, éstas deben ser reemplazadas. Este contacto puede causar daño
severo a la Pluma, y resultará en una falla mecánica.
ESTRUCTURAS
Una Pluma típica Getman está compuesta de una torre, estructura exterior de la pluma, estructura central de la
pluma estructura interior de la pluma y canastilla. (Ver Figura 1) Estas estructuras deben ser revisadas a fondo
por posibles fracturas, corrosión, desgaste, y daño a la estructura. Cualquiera de los componentes que muestre
estas características, deberá ser reemplazado, o reparado adecuadamente.
CORROSIÓN
El efecto de corrosión en una Pluma o Canastilla puede fatigar peligrosamente la Pluma y Canastilla sin tener ya
reparación. Mientras la corrosión en algunas áreas de la Pluma y Canastilla puede ser menos grave que en otras,
es importante que la Pluma y Canastilla estén libres de abundante corrosión si están todavía en uso. Getman
sugiere que la profundidad de corrosión, a lo largo de 12 pulgadas en los extremos de la Pluma y en todos los
componentes giratorios, sea por consiguiente menos de .01”. En las secciones del centro de la Pluma donde la
tensión en las secciones es menor, la corrosión puede ser de una profundidad de .03”. Sin embargo, con
corrosión excesiva la cantidad de material corroído y desgastado puede ser demasiada de tal manera que la
profundidad de la corrosión puede ser medida incorrectamente. Una combinación de desgaste excesivo y
corrosión pueden ocasionar una falla en los componentes. Getman recomienda que la corrosión y desgaste sean
observados cuidadosamente. Refiérase a las fotografías en la Figura 3 como ejemplos de corrosión excesiva en
la Pluma.
CANASTILLA
La canastilla deberá ser inspeccionada regularmente para localizar soportes torcidos o doblados, soldadura,
corrosión, deformación, etc. Ver Figura 4 para ejemplo de una canastilla que es insegura y necesita
reemplazarse. Si la canastilla ha sido deformada, se recomienda revisar todos los pernos, cilindros y
articulaciones de la pluma para localizar averías o daño.
INSPECCIÓN FINAL
Después de que se ha efectuado un servicio apropiado a la Pluma y armada nuevamente la Pluma y Canastilla
deberán ser inspeccionadas nuevamente para una operación adecuada de los componentes hidráulicos. La Pluma
y Canastilla deberán ser probadas con 150% de la capacidad de carga, para un rango adecuado de movimiento
y operación. Con cuidado y atención adecuada de estas indicaciones la Pluma y Canastilla Getman deberá estar
lista para usarse enseguida con seguridad nuevamente, sin embargo en algunos casos debe ser evaluado el costo
económico de la reparación de la Pluma y Canastilla y si no es costeable sustituirla por una nueva. Si existe una
pregunta o duda durante la inspección por favor contacte el servicio de Getman para una asistencia más amplia.
Updated:
12/10/10
S/N: 020-069
PERNO DE LA ESTRUCTURA ESTRUCTURA
EXTERIOR DE LA
PLUMA ESTRUCTURA CENTRAL DE LA ESTRUCTURA INTERIOR DE LA PLUMA
MUÑÓN DEL CILINDRO DE PLUMA
EXTENSIÓN PERNO DE LA
ESTRUCTURA
CUBIERTA PERNO Y BUJE DE
LA ESTRUCTURA
CILINDRO . DE EXT. INFERIOR RETEN
SUJETADOR DEL PERNO DE LA ESTRUCTURA
PERNO CILINDRO . DE EXT. SUPERIOR
PERNO DEL CIL.DE LA PLUMA ZAPATA DE DESGASTE Y DE LA
PERNO DE LA PERNO DE LA ESTRUCTURIORA ESTRUCTURA
ESTRUCTURA BUJE DE LA TORRE
CILINDRO DE LEVANTE PERNO DE LA ESTRUCTURA
PERNO DE LA ZAPATA DESLIZABLE Y ZAPATA
S/N: 020-069
ESTRUCTURA PERNO DE LA ESTRUCTURA DE DESGASTE CI LINDRO DE NIVELACIÓN
ESTRUCTURA DE LA TORRE
FIGURA 1
CILINDRO DE NIVELACIÓN ESTA FIGURA MUESTRA EL TRAZO GENERAL DE UNA PLUMA GETMAN. SIN
EMBARGO CUANDO INSPECCIONE UNA PLUMA ESPECÍFICA POR FAVOR
INSPECCIÓN DE LA
CONSULTE EL MANUAL DEL CAMIÓN GETMAN O CONTACTE AL DISTRIBUIDOR O

COMPAÑÍA GETMAN PARA NÚMEROS DE REFACCIONES Y DIBUJOS ESPECÍFICOS.
FIGURA 1
CANASTILLA Y PLUMA GETMAN
M1004
12/10/10
Updated:
Pag. 4 de 12
PROCEDIMIENTO PARA REEMPLAZAR LAS ZAPATAS DE DESGASTE EN UNA PLUMA DEL
CARGADOR DE EXPLISIVOS
Las zapatas en una Pluma del Cargador de Explosivos Getman con el
tiempo y uso se desgastan. Si estas zapatas no son reemplazadas puede
ocurrir que se dañe la Pluma, resultando en un costo de reparación muy
alto. Como las balatas del freno de un automóvil una vez que se han
gastado hasta el nivel de los tornillos que las sostienen, es el momento de
reemplazarlas. Con el fin de reducir el riesgo de causar daño, las zapatas
deberán ser revisadas cada 200 horas de trabajo.
Este procedimiento paso por paso le permitirá desarmar la pluma y
reemplazar todas las zapatas de desgaste. Los números utilizados para
describir las diferentes partes de la Pluma pueden ser consultados en el
dibujo de montaje de la Pluma al final de este manual. Dependiendo del
tipo exacto de la Pluma que se le va a dar servicio, pueden ser pequeñas
diferencias en refacciones o procedimiento del servicio. El Manual del
Usuario para el Camión que se le va a dar servicio tendrá número de
refacciones específicas para la Pluma que va a tener el servicio. Este
procedimiento ha sido escrito para un rango amplio de Plumas Getman.
PREPARACIÓN
 Asegúrese que el camión esté estacionado en una superficie
nivelada
Desconecte la potencia de la batería principal desconecte el

interruptor
Zapatas de Desgaste
 Coloque correctamente las cuñas en las llantas de tal forma que el en su posición
camión no se mueva
ZAPATAS DESLIZABLES Y ZAPATAS DE DESGASTE
Ver Figura 3 para localización de los siguientes puntos. Las dos plumas
interior (#10) y central (#25) tienen una zapara deslizable (#22) al final
de la parte inferior, y un juego de zapatas de desgaste laterales (#24). La
zapata deslizable está unida en la parte inferior de la pluma utilizando
un perno (#20 y #28) que es enroscado en su lugar. Colocando el peso de
la pluma sobre la canastilla, la presión se liberará de las zapatas
deslizables de la parte inferior y pueden dárseles servicio y ser Zapatas Deslizables en
cambiadas. Las zapatas deslizables tienen zapatas de desgaste (#21) que su posición
pueden ser cambiadas cuando lo necesiten. Las zapatas de desgaste Zapata Deslizable
laterales (#23) pueden ser cambiadas cuando lo necesitan. Dos tornillos Inferior
sostienen las zapatas laterales, cuando son cambiadas, las zapatas de
desgaste pueden desatornillarse de la placa y cambiarse. El cambio de las Perno
zapatas desgastadas en la parte exterior de la pluma es bastante simple, y
aumenta la vida de la pluma. Evitar reemplazar estas zapatas antes de
que estén sobredesgastadas puede resultar en un daño extremo a la
estructura principal de la pluma. Los tornillos que sostienen las zapatas Zapatas Deslizables
de desgaste pueden ocasionar profundas ranuras en los componentes de
la pluma causando el debilitamiento de ésta.
FIGURA 2
Updated:
12/10/10
S/N: 020-069
PROCEDIMIENTO PARA REEMPLAZAR LAS ZAPATAS DE DESGASTE EN LA PLUMA DEL
CARGADOR DE EXPLOSIVOS (CONTINUACIÓN)
CUÑAS DE LAS ZAPATAS DE DESGASTE
Cuando se cambian las zapatas aparecen las cuñas. Estas cuñas son
instaladas en la fábrica en el proceso de montaje. El propósito de estas
cuñas es centrar la pluma interior en la pluma central. Estas cuñas
también impiden que la cuña se incline en la dirección errónea. Si las
cuñas de fábrica están en buen estado, éstas deberán ser marcadas para
su posición y colocarlas en la misma posición con las nuevas zapatas. Si
las cuñas están muy dañadas, entonces a la pluma tendrá de nuevo que
instalarle nuevas cuñas con las zapatas nuevas con la finalidad de
centrar la pluma. Esta deberá ser inspeccionada de que tenga libre
movimiento. Si las zapatas están demasiado ajustadas, la pluma tendrá
un movimiento muy lento o no se moverá. Las zapatas y los tornillos de Zapatas de
Desgaste
las zapatas deberán ser cubiertas con grasa que evite que se amarre la Laterales
pluma al deslizarse antes de ser montada de nuevo. Interiores
REEMPLAZO DE LAS ZAPATAS DE DESGASTE INTERNAS

Las plumas central e internas tienen cuatro zapatas de desgaste al final
de las plumas. Las zapatas de la pluma central se deslizan en la parte
interna de la pluma exterior, y las zapatas de la pluma interior se
deslizan en la parte interna de la pluma central. En el momento de
reemplazar estas zapatas la pluma deberá ser desmontada. Dependiendo Zapatas de
de las condiciones del taller, puede ser una fácil o difícil tarea. El uso de Desgaste
interiores de la
una grúa viajera puede hacer esta tarea muy sencilla. Parte Inferior
Para sustituir las zapatas de desgaste, la pluma interior y la pluma Remueva el

central deberán ser removidas de la pluma exterior. La pluma exterior Soporte de
puede dejarse unida en el camión, y las otras plumas pueden ser sacadas Cadena
de la pluma exterior. La canastilla al final de la pluma no tiene Colgante
necesariamente que ser desmontada de la pluma interior, pero puede
hacer el trabajo más fácil.
Para empezar todas las mangueras de control piloto hidráulico Desconecte las Mangueras en
conectadas a las placas de distribución en la pluma interior o a la pluma la Placa de Unión. Coloque
central deben ser desconectadas, colocarles tapón y etiqueta. Esto Tapón y Tarjeta para
asegurará que las líneas estarán libres de materiales extraños (tierra, identificarla cuando se vuelva
a conectar.
lodo, etc), y sean conectadas nuevamente en el sitio que les corresponde
correctamente. Todos los soportes u otros cables o implementos
conectados a las plumas interior o central deben ser removidos. Tenga
cuidado cuando desconecte las líneas piloto hidráulicas, la pluma puede
tener la posibilidad de moverse suavemente hacia afuera.
Si es necesario en este momento la canastilla puede ser desconectada

removiendo el perno que conecta la canastilla con la pluma, y el perno
que conecta el cilindro hidráulico a la pluma. Quitar estos
dos Pernos
para separar
la Canastilla
FIGURA 2
Updated:
12/10/10
S/N: 020-069
PROCEDIMIENTO PARA REEMPLAZAR LAS ZAPATAS DE DESGASTE EN LA PLUMA DEL
CARGADOR DE EXPLOSIVOS (CONTINUACIÓN)
Los cilindros hidráulicos que extiende y retrae la pluma están
atornillados a la parte interna de la pluma central. Los extremos de
los cilindros están conectados a la parte frontal de la pluma
exterior, y al final de la pluma interior. Los pernos que conectan
los extremos del cilindro a la pluma deben ser desatornillados y
removidos con el fin de sacar la pluma interior y la pluma central.
Una vez que los cilindros han sido liberados del armazón de la
pluma, las plumas interior y central pueden ser removidas de la Este perno debe ser retirado para
pluma exterior juntas. Para realizar esta tarea la zapata deslizadora desconectar el cilindro de la
pluma exterior
y las zapatas de desgaste de la pluma exterior deben primeramente
ser removidas. Utilizando una grúa o lo que se tenga disponible
para realizar este trabajo. El extremo de la pluma interior que
conecta a la canastilla deberá ser sostenido y jalarse, junto con la
pluma central, de la pluma exterior, puede ser necesario amarrar la
pluma central y la pluma interior juntas con el fin de sacar las dos
al mismo tiempo. En este momento las zapatas en la pluma central
deberán ser visibles.
Este perno debe ser
Colocando la pluma sobre un juego de soportes, o un banco hace retirado para desconectar
más fácil trabajar en las dos plumas y reemplazar las zapatas de el cilindro de la pluma
desgaste. Con el fin de separar la pluma interior de la pluma interior
central, la zapata deslizable inferior y las zapatas de desgaste

laterales deberán ser removidas de la pluma central. Esto permitirá
que la pluma interior sea removida de la pluma central, y que las
zapatas de desgaste de la pluma interior puedan ser accesibles para
ser inspeccionadas y/o cambiadas.
Una vez que las zapatas han sido reemplazadas en las plumas
interior y central, éstas pueden ser montadas cuidadosamente
juntas nuevamente. En ocasiones será necesario utilizar la grúa
jalar las dos plumas, especialmente con zapatas nuevas. La pluma La pluma central siendo
removida de la pluma
se sentirá ajustada al principio, pero gradualmente se desgastará y exterior
regresará a una operación suave y normal.
INDICACIONES PARA REEMPLAZAR LAS ZAPATAS DE

DESGASTE
 Flexión excesiva de la pluma al estar totalmente extendida
 Brincos o saltos excesivos cuando se mueve la pluma
 Sonidos de raspadura extraños cuando se extiende o retrae Pluma interior siendo

la pluma removida de la pluma
central
FIGURA 2
Updated:
12/10/10
S/N: 020-069
Fotografías Extra
Conexión de la canastilla
al final de la pluma
interior con el cilindro
hidráulico
Updated:
12/10/10
S/N: 020-069
FIGURA 2
Updated:
12/10/10
S/N: 020-069
PAR DESCRIPCIÓN CANT

TIDA
ESTRUCTURA DE LA PLUMA 1
1 PERNO DEL CILINDRO DE NIVELACIÓN 2
2 CILINDRO DE NIVELACIÓN 1
3 TORRE 1
4 PERNO DEL CILINDRO DE ELEVACIÓN 1
5 BUJE DE LA TORRE 2
6 TORNILLO 8
7 TORNILLO 20
8 CUBIERTA 1
9 RETÉN 1
10 PLUMA EXTERIOR 1
11 CILINDRO DE ELEVACIÓN 1
12 PERNO DE LA TORRE 1
13 PERNO DEL CILINDRO DE EXTENSIÓN 1
14 MUÑÓN 2
15 TORNILLO CABEZA “ALLEN” 2
16 RETÉN DEL PERNO 1
17 TUERCA PLANA CABEZA “ALLEN” 24
24
18 CILINDRO DE EXTENSIÓN 1
19 PERNO DE CILINDRO DE ELEVACIÓN 1
20 PERNO DE LA ZAPATA LATERAL 1
21 CUÑA DE LA ZAPATA 12
DE DESGASTE A/R
22 ZAPATA DESLIZABLE 2
23 CUÑA DE LA ZAPATA 4
DE DESGASTE A/R
24 ENSAMBLE DE LA ZAPATA 4
25 PLUMA CENTRAL 1
26 PLUMA INTERIOR 1
27 TUERCA PLANA CABEZA “ALLEN” 8
8
28 PERNO DE LA ZAPATA DESLIZABLE 1
Updated:
12/10/10
S/N: 020-069
PAR DESCRIPCIÓN CANT

TIDA
29 PERNO DEL CILINDRO DE NIVELACIÓN 1
30 PERNO DEL CILINDRO DE EXTENSIÓN 1
31 PERNO DE LA CANASTILLA 1
32 BUJE 2
33 CHUMACERA GIRATORIA 1
34 TORNILLO 3
35 RONDANA 3
36 CILINDRO DE NIVELACIÓN 1
37 PERNO DE NIVELACIÓN 3
38 ARTICULACIÓN DE NIVELACIÓN 1
39 ARTICULACIÓN DE NIVELACIÓN 1
40 CANASTILLA 1
FIGURA 3
Updated:
12/10/10
S/N: 020-069
FIGURA 4
Updated:
12/10/10
S/N: 020-069
M1071
S/N: 020-069
M1071
S/N: 020-069
LUBRICANT CROSS F1003
REFERENCE Page 1 of 2
ENGINE OIL VISCOSITY RECOMMENDATIONS
IMPORTANT:
Whenever performing service on this vehicle, make certain it has first been placed in service
position. Basic service and maintenance procedures are illustrated in the maintenance manuals.
These are to be performed at regular intervals based on hours of operation. For further details
on service and necessary major component adjustments (i.e. engine, transmission, axles, etc.)
see respective sections in this manual. Read and become familiar with them. Any further questions, contact
your local Getman Distributor or Getman Service direct.
The viscosity of the oil is greatly influenced by the

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

NOTE: THIS SHOULD ONLY BE USED AS REFERENCE, FOR SPECIFIC COMPONENT LUBRICATE
SEE THAT COMPONENT’S OPERATION MANUAL AND IF ANY QUESTION CONTACT GETMAN
SERVICE BEFORE CHANGING/ADDING FLUID.
NOTE: THIS SHOULD ONLY BE USED AS REFERENCE, FOR SPECIFIC COMPONENT LUBRICATE SEE THAT COMPONENT’S OPERATION Updated:
MANUAL AND IF ANY QUESTION CONTACT GETMAN SERVICE BEFORE CHANGING/ADDING FLUID.
03/04/11
S/N: 020-069
LUBRICANT CROSS F1003
REFERENCE Page 2 of 2
ENGINE & AIR CLEANER (OIL BATH) AXLES – FORD, JOHN DEERE, NAF
(Engine Manufacturers Specifications)
Shell Donax TD
Shell Rotella Gear Oil 90 LS
BP Vanellus C-Extra Citgo Transgard Tractor
Citgo C-500 Motor Oil Conoco Power Trans. 11 Fluid
Conoco HD Fleet Gulf Universal Tractor Fluid
Gulf Super Duty Mobil Mobil Fluid 424
Mobil Delvac 1300 Mobillube SHC-LS
Sunoco Super-C Sunoco TH Tractor Fluid
Texaco Ursa Super Premium Texaco Super Universal Tractor Oil
Exxon XD-3 Exxon Hydraul 560
BP Energear LS 90
POWERSHIFT TRANSMISSION OIL
CLARK/DANA, JOHN DEERE/FUNK AXLES- KESSLER, CARRARO
(TYPE C-3, TO C-4)
Citgo SAE 80W-90
Shell Donax T API GL 4 OR 5
BP Autran C-4/TO-4)
Citgo Transgard Torque HYDRAULIC OIL
Converter 250
Conoco Powerdrive Fluid Shell Tellus 68
Gulf HT C-3 Fluid BP AW 68
Mobil Trans HD Citgo AW 68 Hydraulic Oil
Sunoco TO-4 Transmission Conoco Hydroclear AW 68
Texaco Texamatic 4291 Gulf Harmony AW 68
Mobil DTE 26
Torque converter/transmission lubricant must be qualified by Sunoco Sunvis 800
one of the following specifications. Texaco Rando HD 68
Exxon Nuto H68
ORDER OF PREFERENCE PER SPICER OFF
HIGHWAY: CHASSIS GREASE
1. Caterpillar TO-4 Shell Super Duty Lithium MDS

2. John Deere/Funk J20 C, D BP Energrease LC
3. Military MIL-PRF-2104G Citgo Overdrive HD
4. Allison C-4 Conoco Super Lube
5. Dexron II Equivalent Unless using graphite Gulf Crown LC3
Mobil Mobilegrease Special
LUBRICANTS NOT RECOMMEND: 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 Devac (50/50) CAT EC-1
NOTE: THIS SHOULD ONLY BE USED AS REFERENCE, FOR SPECIFIC COMPONENT LUBRICATE SEE THAT COMPONENT’S OPERATION Updated:
MANUAL AND IF ANY QUESTION CONTACT GETMAN SERVICE BEFORE CHANGING/ADDING FLUID.
03/04/11
S/N: 020-069
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 MUST be followed as described in order to
keep your warranty valid.
ENGINE
Change oil using an oil with corrosion preventing TRANSMISSION & HYDRAULICS
properties of a least a HD-S1 oil. Listed are some No special care is required except exposed cylinder
of the oils that have been approved: Esso rods should be covered with grease.
MZ20X20V7N; Texaco EKM 162; Shell V6828.
AXLE
Change oil and fuel filters. Axle housings should be filled completely to
eliminate the change of moisture condensation.
Fill fuel tank completely with a mixture of diesel
fuel and 10% corrosion inhibiting motor oil. BRAKE SYSTEM
Drain all air reservoirs of moisture.
Run engine for at least 10 minutes to fill fuel lines
and filters, injection pump and nozzles with BATTERY
preservative mixture. Remove battery; clean off top, and store in a well-
ventilated battery storage area. Do not store on
If engine is to be stored over six months, seal intake concrete or metal.
and exhaust system to keep moisture out.
EQUIPMENT STORAGE FOR LESS THAN
THREE MONTHS
When storing equipment for less than three months,
vehicles should be started and driven for a
minimum of two minutes every two weeks.
Any further questions please contact your local

Getman Distributor or the contact information
below.
Getman Corporation, 59750 34th Avenue, Bangor, Michigan 49013, U.S.A. Updated:
Telephone: (269) 427-5611/ Facsimile: (269) 427-8781/ E-mail: info@getman.com. 03/04/11
S/N: 020-069
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:
03/04/11
S/N: 020-069
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:
03/04/11
S/N: 020-069
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:
03/04/11
S/N: 020-069
S/N________ HOURS________ DATE_________
SIGNATURE______________________________
50 HOUR SERVICE

ORDERED DOWN
Check wheel nut torque
Check battery and clean posts
Check air cleaner service indicator
Check air intake clamps and connections
Clean radiator fins
Check exhaust back pressure
Check for corrosion or deformation on all major
components
Daily services
If equipped with air powered electric or air powered
hydraulic, connect mine air and check operation
Updated:
03/04/11
S/N: 020-069
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:
03/04/11
S/N: 020-069
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:
03/04/11
S/N: 020-069
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:
03/04/11
S/N: 020-069
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:
03/04/11
S/N: 020-069
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:
03/04/11
S/N: 020-069
S1168
Instructions for the following series products:

D-Ring Anchorage Connector
(Model numbers: 2101630, 2101632, 2101633,
2101634, 2101636, 2101638, 2109870)
User Instruction Manual D-ring Anchorage Connector
This manual is intended to meet the Manufacturer’s Instructions as required by ANSI Z359.1
and should be used as part of an employee training program as required by OSHA.
WARNING: This product is part of a personal fall arrest, restraint, Figure 1 - D-ring Anchorage Connector
work positioning, personnel riding, or rescue system. The user must
follow the manufacturer’s instructions for each component of the
system. These instructions must be provided to the user of this
equipment. The user must read and understand these instructions
before using this equipment. Manufacturer’s instructions must
be followed for proper use and maintenance of this equipment.
Alterations or misuse of this equipment, or failure to follow these
instructions, may result in serious injury or death.
IMPORTANT: If you have questions on the use, care, or suitability

of this equipment for your application, contact DBI‑SALA.
IMPORTANT: Record the product identification information from

the ID label in the inspection and maintenance log in section 9.0 of
this manual.
DESCRIPTION
2101630: D-ring Anchorage Connector, forged steel D-ring, stainless steel anchorage plate, 9/16-inch
diameter mounting holes.
2101634: D-ring Anchorage Connector, forged steel D-ring, hot rolled steel anchorage plate, 9/16-inch
diameter mounting holes.
2101636: D-ring Anchorage Connector, stainless steel D-ring, stainless steel anchorage plate,
9/16-inch diameter mounting holes.
1.0 APPLICATIONS
1.1 PURPOSE: The D-ring Anchorage Connector is designed for use as an attachment of a personal fall arrest, restraint, work
positioning, personnel riding, or rescue system to an anchorage. See Figure 2 for application illustrations.
A. PERSONAL FALL ARREST: The D-ring Anchorage Connector is used as a component of a personal fall arrest system
to protect the user in the event of a fall. Personal fall arrest systems typically include a full body harness and a
connecting subsystem (energy absorbing lanyard). Maximum permissible free fall is 6 feet.
B. RESTRAINT: The D-ring Anchorage Connector is used as a component of a restraint system to prevent the user
from reaching a fall hazard. Restraint systems typically include a full body harness and a lanyard or restraint line. No
vertical free fall is permitted.
C. WORK POSITIONING: The D-ring Anchorage Connector is used as a component of a work positioning system
to support the user at a work position. Work positioning systems typically include a full body harness, positioning
lanyard, and a back-up personal fall arrest system. Maximum permissible free fall is 2 feet.
D. PERSONNEL RIDING: The D-ring Anchorage Connector is used as a component of a personnel riding system to
suspend or transport the user vertically. Personnel riding systems typically include a full body harness, boatswains’s
chair or seat board, and a back-up personal fall arrest system. No vertical free fall is permitted.
E. RESCUE: The D-ring Anchorage Connector is used as a component of a rescue system. Rescue systems are
configured depending on the type of rescue. No vertical free fall is permitted.
WARNING: Do not use the D-ring Anchorage Connector for applications not addressed in this manual.
1.2 LIMITATIONS: Consider the following application limitations before using this equipment:
A. CAPACITY: The D-ring Anchorage Connector is designed for use by persons with a combined weight (clothing, tools,
etc.) of no more than 310 lbs. No more than one personal protective system may be connected at one time. Note:
For emergency rescues it may be acceptable to connect more than one system if the anchorage will
support the anticipated loads.
© Copyright 2008, DB Industries, Inc.
S/N: 020-069
S1168
Figure 2 - Applications
B. FREE FALL: Personal fall arrest systems used with this equipment must be rigged to limit the free fall to 6 feet
(ANSI Z359.1). See the personal fall arrest system manufacturer’s instructions for more information. Restraint
systems must be rigged so that no vertical free fall is possible. Work positioning systems must be rigged so that
free fall is limited to 2 feet or less. Personnel riding systems must be rigged so that no vertical free fall is possible.
Rescue systems must be rigged so that no vertical free fall is possible.
C. FALL CLEARANCE: There must be sufficient clearance below the user to arrest a fall before the user strikes the
ground or other obstruction. The clearance required is dependent on the following factors:
• Deceleration distance • Movement of attachment element Figure 3 - Swing Falls

• Free fall distance • Elevation of Anchorage Connector
• Worker height • Connecting subsystem length
See the personal fall arrest system manufacturer’s instructions for more
information.
D. SWING FALLS: See Figure 3. Swing falls occur when the anchorage point
is not directly above the point where a fall occurs. The force of striking an
object in a swing fall may cause serious injury or death. Minimize swing falls
by working as close to the anchorage point as possible. Do not permit a swing
fall if injury could occur. Swing falls will significantly increase the clearance
required when a self retracting lifeline or other variable length connecting
subsystem is used.
E. ENVIRONMENTAL HAZARDS: Use of this equipment in areas with

environmental hazards may require additional precautions to prevent injury
to the user or damage to the equipment. Hazards may include, but are not
limited to: heat, chemicals, corrosive environments, high voltage power lines,
gases, moving machinery, and sharp edges. Contact DBI‑SALA if you have
questions about using this equipment where environmental hazards exist.
F. TRAINING: This equipment must be installed and used by persons trained in

its correct application and use. See section 4.0.
1.3 Refer to national Standards including ANSI Z359 (.0, .1, .2, .3, and .4) family of standards on fall protection, ANSI
A10.32, and applicable local, state and federal (OSHA) requirements governing occupational safety for more information
about work positioning systems.
2
S/N: 020-069
S1168
2.0 SYSTEM REQUIREMENTS
2.1 COMPATIBILITY OF COMPONENTS: DBI‑SALA equipment is designed for use with DBI‑SALA approved components
and subsystems only. Substitutions or replacements made with non-approved components or subsystems may jeopardize
compatibility of equipment and may effect the safety and reliability of the complete system.
2.2 COMPATIBILITY OF CONNECTORS: Connectors are considered to be compatible with connecting elements when they
have been designed to work together in such a way that their sizes and shapes do not cause their gate mechanisms
to inadvertently open regardless of how they become oriented. Contact DBI‑SALA if you have any questions about
compatibility.
Connectors (hooks, carabiners, and D-rings) must be capable of supporting at least 5,000 lbs. (22kN). Connectors must
be compatible with the anchorage or other system components. Do not use equipment that is not compatible. Non-
compatible connectors may unintentionally disengage. See Figure 4. Connectors must be compatible in size, shape, and
strength. Self locking snap hooks and carabiners are required by ANSI Z359.1 and OSHA.
Figure 4 - Unintentional Disengagement (Roll-out)
If the connecting element that a snap hook (shown) or carabiner attaches to is undersized or irregular in shape, a situation
could occur where the connecting element applies a force to the gate of the snap hook or carabiner. This force may cause the
gate (of either a self-locking or a non-locking snap hook) to open, allowing the snap hook or carabiner to disengage from the
connecting point.
Small ring or
other
non-compatibly
shaped element
1. Force is applied to the 2. The gate presses against the 3. The gate opens allowing the
snap hook. connecting ring. snap hook to slip off.
2.3 MAKING CONNECTIONS: Only use self-locking snap hooks and carabiners with this equipment. Only use connectors
that are suitable to each application. Ensure all connections are compatible in size, shape and strength. Do not use
equipment that is not compatible. Ensure all connectors are fully closed and locked.
DBI‑SALA connectors (snap hooks and carabiners) are designed to be used only as specified in each product’s user’s
instructions. See Figure 5 for inappropriate connections. DBI‑SALA snap hooks and carabiners should not be connected:
A. To a D-ring to which another connector is attached.
B. In a manner that would result

in a load on the gate. Figure 5 - Inappropriate Connections
NOTE: Large throat opening snap

hooks should not be connected to
standard size D-rings or similar objects
which will result in a load on the gate
if the hook or D-ring twists or rotates.
Large throat snap hooks are designed
for use on fixed structural elements
such as rebar or cross members that
are not shaped in a way that can
capture the gate of the hook.
C. In a false engagement, where

features that protrude from
the snap hook or carabiner
catch on the anchor and
without visual confirmation
seems to be fully engaged to
the anchor point.
D. To each other.
3
S/N: 020-069
S1168
E. Directly to webbing or rope lanyard or tie-back (unless the manufacturer’s instructions for both the lanyard and
connector specifically allows such a connection).
F. To any object which is shaped or dimensioned such that the snap hook or carabiner will not close and lock, or that
roll-out could occur.
2.4 PERSONAL FALL ARREST SYSTEM: Personal fall arrest systems used with this equipment must meet applicable state,
federal, OSHA, and ANSI requirements. A full body harness must be worn when this equipment is used as a component
of a personal fall arrest system. As required by OSHA, the personal fall arrest system must be capable of arresting the
user’s fall with a maximum arresting force of 1,800 lbs., and limit the free fall to 6 feet or less. If the maximum free fall
distance must be exceeded, the employer must document, based on test data, that the maximum arresting force will not
be exceeded, and the personal fall arrest system will function properly.
When a free fall greater than 6 feet, and up to a maximum of 12 feet is possible, DBI‑SALA recommends using a personal
fall arrest system incorporating a DBI‑SALA Force2 Energy Absorbing Lanyard. DBI‑SALA has performed testing using
the Force2 Energy Absorbing Lanyard in free falls up to 12 feet to ensure the maximum arresting force does not exceed
1,800 lbs., and the system functions properly. The results of these tests are listed in the user instruction manual provided
with Force2 Energy Absorbing Lanyards.
2.5 RESTRAINT SYSTEM: Restraint systems used with this equipment must meet state, federal, OSHA, and ANSI
requirements.
2.6 ANCHORAGE STRENGTH: The anchorage strength required is dependent on the application type. The following are the
requirements of ANSI 359.1 for these application types:
A. Fall Arrest: Anchorages selected for fall arrest systems shall have a strength capable of sustaining static loads
applied in the directions permitted by the system of at least:
1. 5,000 lbs. (22.2 kN) for non-certified anchorages, or
2. Two times the maximum arresting force for certified anchorages. When more than one fall arrest system is
attached to an anchorage, the strengths set forth in (1) and (2) above shall be multiplied by the number of systems
attached to the anchorage.
B. RESTRAINT: Anchorages selected for restraint and travel restraint systems shall have a strength capable of
sustaining static loads applied in the directions permitted by the system of at least:
2. Two times the foreseeable force for certified anchorages. When more than one restraint and travel restraint
system is attached to an anchorage, the strengths set forth in (1) and (2) above shall be multiplied by the number of
systems attached to the anchorage.
C. WORK POSITIONING: Anchorages selected for work positioning systems shall have a strength capable of sustaining
static loads applied in the directions permitted by the system of at least: A) 3,000 pounds (13.3kN) for non-certified
anchorages or B) Two times the foreseeable force for certified anchorages
When more than one work positioning system is attached to an anchorage, the strengths previously set forth in (A)
and (B) shall be multiplied by the number of systems attached to the anchorage.
D. RESCUE: Anchorages selected for rescue systems shall have a strength capable of sustaining static loads applied in
the directions permitted by the system of at least:
2. Five times the foreseeable force for certified anchorages. When more than one rescue system is attached to an
anchorage, the strengths set forth in (1) and (2) above shall be multiplied by the number of systems attached to the
anchorage.
WARNING: Mark or label the D-ring Anchorage Connector with the intended application. Use of this equipment for an
application that does not meet the anchorage strength requirements stated above may result in serious injury or death.
3.0 INSTALLATION AND USE

WARNING: Do not alter or intentionally misuse this equipment. Consult DBI‑SALA when using this equipment in combination
with components or subsystems other than those described in this manual. Some subsystem and component combinations may
interfere with the operation of this equipment. Use caution when using this equipment around moving machinery, electrical and
chemical hazards, and sharp edges.
WARNING: Consult with your doctor if there is reason to doubt your fitness to safely absorb the shock from a fall arrest. Age
and fitness seriously affect a worker’s ability to withstand falls. Pregnant women or minors must not use the DBI‑SALA D-ring
Anchorage Connector.
3.1 BEFORE EACH USE of this equipment inspect it according to section 5.0 of this manual.
3.2 PLAN your system before installation. Consider all factors that will affect your safety during use of this equipment. The
following list gives important points to consider when planning your system:
A. ANCHORAGE: Select a rigid anchorage capable of supporting the loads specified in section 2.6.
4
S/N: 020-069
S1168
B. SHARP EDGES: Avoid working where system components may be in contact with, or abrade against, unprotected
sharp edges.
C. AFTER A FALL: Any equipment which has been subjected to the forces of arresting a fall or exhibits damage
consistent with the effect of fall arrest forces as described in section 5, must be removed from service immediately
and destroyed by the user, the rescuer, or an authorized person.
D. RESCUE: When using this equipment, the employer must have a rescue plan and the means at hand to implement it
and communicate that plan to users, authorized persons, and rescuers.
3.3 INSTALLATION REQUIREMENTS:
A. D-RING ANCHORAGE CONNECTOR LOCATION: Select a location on a suitable strength anchorage that will
provide overall safety and proper loading as shown in Figure 6. The anchorage must be free of deformities or defects
that may weaken the structure.
Figure 6 - D-ring Anchorage Connector Loads
B. INSTALLATION: The D-ring Anchorage Connector
may be attached to the structure using fasteners or
welding. Use fasteners that will meet the strength
requirements specified in section 2.6. DBI‑SALA
recommends using 1/2-inch diameter, grade 5 bolts.
Welded installations must be installed by a certified
professional welder in accordance with the latest codes
and specifications of the American Welding Society.
Welds must support the loads specified in section 2.6.
Do not weld the D-ring. The D-ring must swivel freely.
Welded installations should be verified by a qualified
person for strength by calculation or by proof loading
the installation in the intended direction(s) of intended
use to 3,600 lbs. Protect finished welds from corrosion
with paint or other finish. Do not electroplate the
D-ring. Installations should be verified by a qualified
person for strength by calculation in the intended
direction(s) of intended use.
3.4 MAKING CONNECTIONS: When using a hook to connect to the D-ring Anchorage Connector, ensure roll-out cannot
occur. Roll-out occurs when interference between the hook and mating connector causes the hook gate to unintentionally
open and release. Self locking snap hooks and carabiners should be used to reduce the possibility of roll-out. Do not use
hooks or connectors that will not completely close over the attachment object. See subsystem manufacturer’s instructions
for information on connecting to the D-ring Anchorage Connector.
4.0 TRAINING
4.1 It is the responsibility of the user and the purchaser of this equipment to assure that they are familiar with these
instructions, trained in the correct care and use of, and are aware of the operating characteristics, application limits, and
the consequences of improper use of this equipment.
IMPORTANT: Training must be conducted without exposing the user to a fall hazard. Training should be repeated on a
periodic basis.
5.0 INSPECTION
5.1 FREQUENCY:
• Before Each Use inspect the D-ring Anchorage Connector according to sections 5.2 and 5.3.
• Formal Inspection: A formal inspection of the D-ring Anchorage Connector and its connection to the structure must be
performed at least annually by a competent person other than the user. The frequency of formal inspections should
be based on conditions of use or exposure. See sections 5.2 and 5.3. Record the inspection results in the inspection
and maintenance log in section 9.0.
5.2 INSPECTION STEPS:
Step 1. Inspect the D-ring for damage or corrosion. Inspect for cracks or wear that may affect strength and operation.
Step 2. Inspect the Anchorage Plate for damage or corrosion. Inspect for cracks or wear that may affect strength and
operation.
Step 3. Inspect the attaching fasteners. Fasteners must hold the Anchorage Plate securely to the anchorage. Inspect for
damage or corrosion.
Step 4. Inspect the system components according to the manufacturer’s instructions.
Step 5. Record the inspection results in the inspection log in section 9.0.
5.3 If inspection reveals an unsafe or defective condition, remove the D-ring Anchorage Connector from service and destroy it.
5
S/N: 020-069
S1168
6.0 MAINTENANCE
6.1 Clean the D-ring Anchorage Connector with a mild soap solution. Excessive build-up of dirt may prevent the D‑ring from
swivelling.
7.0 SPECIFICATIONS
7.1 Anchorage Plate Material:
2101630,2101636: Stainless Steel, UNS S30400 or UNS S30403 per ASTM A276
2101634: Hot Rolled Steel, ASTM A36 or ASTM A529
7.2 D-ring Material:
2101636: Stainless Steel, UNS S30400 or UNS S30403 per ASTM A276
2101630, 2101634: Alloy Steel

5,000 minimum breaking strength
7.3 Dimensions:
8.0 LABELING
8.1 The following label must be present and fully legible:
6
S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
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
S/N: 020-069
10368
SIGHT GAUGE
Page 1 of 1
ITEM PART # DESCRIPTION QTY.

1 53011 WINDOW SIGHT GAUGE 1
Updated:
03/04/11
S/N: 020-069
FILL CAP 10376
Page 1 of 1

392012 CAP & SCREEN ASSEMBLY (INCLUDES ITEMS 1, 2) 1
1 392012-03 HEAD CAP ASSEMBLY 1
2 392012-02 SCREEN 1
3* 392012-01 GASKET 1
* ITEM NOT SHOWN Updated:

4/11/2012
S/N: 020-069
10398
FILL CAP (HYDRAULIC OIL)
Page 1 of 1

52500 CAP & SCREEN ASSEMBLY 1
1 54048 CAP 1
2 54003 SCREEN 1
Updated:
4/11/2012
S/N: 020-069
10448
HOLD DOWN FASTENER
Page 1 of 1

1 132130 HOLD DOWN ASSEMBLY (INCLUDES ITEMS 5, 6) 1
(NOTE: KIT COMES WITH 90⁰ LATCH HOLD DOWN,
MUST ORDER STRAIGHT LATCH, HOLD DOWN
SEPARATELY IF NEEDED.
2 594535 LATCH, HOLD DOWN, STRAIGHT 1
3 04GE04 WASHER 4
4 01GC04008 BOLT 4
5 NSS STRAP 1
6 594535-01 LATCH, HOLD DOWN, 90 DEG 1
*ITEMS NOT SHOWN Updated:

10/3/2012
S/N: 020-069
17142
SEAT ASSEMBLY
Page 1 of 2
*ITEM NOT SHOWN Updated:

03/21/08
S/N: 020-069
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
S/N: 020-069
STEERING 13942
(PINS, BEARINGS, 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
S/N: 020-069
12043
ARTICULATION JOINT
Page 1 of 3
Updated:
4/19/2012
S/N: 020-069
12043
ARTICULATION JOINT
Page 2 of 3

464579 ARTICULATION JOINT KIT (A-64 STANDARD) 1
(INCLUDES ITEMS 1-10 PLUS JOINT PLATES)
464469 ARTICULATION JOINT KIT (A-64 WIDE) 1
464332 ARTICULATION JOINT KIT (LRD 220) 1
464739 ARTICULATION JOINT KIT (LRD 220) (CAT ENGINE) 1
7093-00095 ARTICULATION REBUILD KIT
(INCLUDES ITEMS 1-10)
1 10697-01 CAP PIN 2
2 13796-03 PIN 2
3 16367-03 BEARING INSERT ASSEMBLY (INCLUDES BEARING) 2
264032 BEARING ONLY (MUST BE PRESSED IN) 2
4 16369-02 BUSHING – CAP SIDE 2
5 16369-03 BUSHING PIN SIDE 2
6 464420 CAPSCREW (HEX HD) 6
7 73GC08016 CAPSCREW (SCKT HD) 12
8 73GC08024 CAPSCREW (SCKT HD) 12
9 594572 SHIM CAP (.005 IN.) (.13MM) A/R
594573 SHIM CAP (.007 IN.) (.18MM) A/R
594574 SHIM CAP (.020 IN.) (.51MM) A/R
10 594575 SHIM INSERT (.005 IN.) (.13MM) A/R
594576 SHIM INSERT (.007 IN.) (.18MM) A/R
594577 SHIM INSERT (.020 IN.) (.51MM) A/R
Updated:
4/19/2012
S/N: 020-069
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 LOCTITE 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 LOCTITE AND TORQUE TO (1OO LB. FT.) (135 N-M). REPEAT PROCESS FOR
BOTH TOP AND BOTTOM OF JOINT.
Updated:
4/19/2012
S/N: 020-069

PAGE INTENTIONALLY LEFT BLANK
S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
3. ELECTRICAL SYSTEM AND INSTRUMENTS
30343 WIRING DIAGRAM S

17143 INSTRUMENT PANEL
S1100 MURPHY POWERVIEW OPERATION MANUAL
17074 ALTERNATOR
17363 BATTERY BOX ASSEMBLY
S/N: 020-069
S/N: 020-069
S/N: 020-069
S/N: 020-069
S/N: 020-069
S/N: 020-069
S/N: 020-069
S/N: 020-069
S/N: 020-069
S/N: 020-069
S/N: 020-069
17143
INSTRUMENT PANEL
Page 1 of 2
465313-100-OV

1 124454 ENGINE POWERVIEW GAUGE 1
2 124455 ENGINE WARNING ALARM 1
124457 RESISTOR, JUMPER 1
3 124421 CONVERTER PRESSURE GAUGE 1
* 124278 CONVERTER PRESSURE SENDER 1
4 124403 TRANSMISSION TEMPERATURE GAUGE 1
* 124406 TRANSMISSION TEMPERATURE SENDER 1
5 134019 PARK BRAKE SWITCH 1
* 134020 PARK BRAKE BUTTON 1
6 124396 VOLTMETER 1
7† 124148 WORK LIGHT SWITCH (OPTIONAL) 1
124461
8 122100 HORN BUTTON 1

†CONFIRM WHICH PART NUMBER IS USED ON YOUR TRUCK 3/5/2012
S/N: 020-069
17143
INSTRUMENT PANEL
Page 2 of 2

9 134117 (10 AMP)CIRCUIT BREAKER A/R
134009 (20 AMP)CIRCUIT BREAKER A/R
134118 (30 AMP)CIRCUIT BREAKER A/R
10 N/A SPARE SPACE N/A
11 124498 PLC RESET SWITCH 1
12† 124148 PTO FAST IDLE SWITCH (OPTIONAL) 1
124461
13 122100 PARK BRAKE TEST BUTTON 1
124433 GREY CAP 1
14 124195 LOW FUEL LIGHT (OPTIONAL) 1
124313 WARNING BUZZER (OPTIONAL) 1
15 124380 START SWITCH 1
16 124501 TOGGLE LIGHT SWITCH 2
17† 124148 BEACON LIGHT SWITCH (OPTIONAL) 1
124461
18 124148 CANOPY LIGHT SWITCH (OPTIONAL) 1
124461
19 465428 WARNING LIGHT ARRAY UNIT 1
---------- SEE ELECTRICAL SCHEMATIC & CONTACT GETMAN FOR
WARNING PANEL OVERLAY
(SEE INSTRUMENT WARNING PANEL PAGE IN THE
OPERATION MANUAL FOR DESCRIPTION)
20* 464670 RESISTOR PACK 1

†CONFIRM WHICH PART NUMBER IS USED ON YOUR TRUCK 3/5/2012
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PowerView™
Model PV-101
User’s Guide
Rev 09-10-08 00-02-0605
Catalog Section 78
S/N: 020-069
S1100
In order to consistently bring you the highest quality, full
featured products, we reserve the right to change our
specifications and designs at any time. The latest version of
this manual can be found at www.fwmurphy.com.
Warranty - A limited warranty on materials and

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

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

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

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

• Engine hours pressure
• System voltage • Transmission oil
• Percent engine load at the temperature
current RPM • Transmission gear
• Coolant temperature position
• Oil pressure • Engine configuration
• Fuel economy parameters
• Throttle position • Active fault codes
• Engine manifold air • Stored fault codes
temperature
• Current fuel consumption
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Faceplate Features
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Navigation and Keypad Functions
The keypad on the PowerView display is a capacitive touch
sensing system. There are no mechanical switches to wear
or stick. When a key is touched, feedback is provided by the
screen flashing. The keys on the keypad perform the
following functions:
Menu – Enter or exit menu screens.
Left Arrow – Scroll the screen or move the

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

hide/view an active fault code.
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Basic Navigation
1. When Menu is pressed, the main menu items are
displayed.
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2. Touching the Arrow Keys will move the selection bar to
other menu items.
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3. Certain menus have multiple pages of items. Scrolling
past the top item or bottom item on the current page will
reveal other menu items on additional pages.
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4. When the desired item is highlighted by the cursor,
pressing Enter will select that item and display the
corresponding screen.
5. Anytime the word MORE appears above the Arrow

Keys there are more screens that may be viewed. Use
the Arrow Keys to scroll to the next screen of
information.
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Operation
PowerView Menus (First Time Start Up)
1. When power is first applied to the display, the Murphy
logo appears.
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2. If the Engine ECU is broadcasting a 'Wait To Start'
message, this screen will be shown. Engine
manufacturers typically recommend against starting the
engine while this message is broadcasted from the
ECU. Once the ECU stops broadcasting this message,
this screen will no longer be displayed.
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3. Once the engine has started, the single engine
parameter appears with the engine RPM displayed.
Pressing the Right Arrow Key will display the coolant
temperature. The screen can be changed to other
parameters by pressing Menu.
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Setting Up the Display
The screen may be configured to display a single engine
parameter (1-up display), or four parameters at once (4-up
display). Default options are provided or you may customize
the display by selecting the parameters you want.
1-Up Display
Three options are available for modification of the 1-Up
display.
Use Defaults – This option contains a set of engine

parameters: Engine Hours, Engine RPM, System Voltage,
Battery Voltage, % Engine Load at Current RPM, Coolant
Temperature, and Oil Pressure.
Custom Setup – This option allows for the modification of
which parameter, the number of parameters, and the order
in which the parameters are being displayed.
Automatic Scan – Selecting the scan function will cause
the 1-Up Display to scroll through the selected set of
parameters one at a time, momentarily pausing at each.
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1-Up Display Settings
1. Touch Menu and use the Arrow Keys to highlight
SETUP 1-UP DISPLAY, then press Enter.
2. To select USE DEFAULTS, highlight the option and

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

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

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

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

the list of displayed parameters, highlight the parameter
and touch Enter.
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6. Continue to scroll and select additional parameters for
the CUSTOM 1-UP DISPLAY. Touch Menu at any time
to return to the CUSTOM SETUP menu.
7. Selecting the AUTOMATIC SCAN ON function will

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

AUTOMATIC SCAN functions have been set, touch
Menu once to return to the main menu, or twice to
display the 1-up display screen.
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4-Up Display
The 4-up display places the parameter data into four areas
of the screen known as quadrants. Factory defaults for the
4-up display include coolant temperature, engine speed, oil
pressure, and battery voltage. You may customize the 4-up
display with parameters you define for each quadrant.
1. Touch Menu and use the Arrow Keys to highlight

SETUP 4-UP DISPLAY, then press Enter.
2. To select USE DEFAULTS, highlight the option and

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

press Enter. The 4-up display appears.
4. The quadrant with the backlit parameter value is the

currently selected parameter. Use the Arrow Keys to
select which quadrant you wish to edit.
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5. Touch Enter and a list of parameters will appear.
The parameter that is highlighted is the selected
parameter for the screen. The number to the right of the
parameter indicates the quadrant in which it is
displayed.
1 = upper left quadrant

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

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

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

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

Request stored fault code information.
Engine Configuration Data*

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

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Backlight Adjustment
ADJUST BACKLIGHT allows you to select the desired
backlight intensity.
Contrast Adjustment
From ADJUST CONTRAST, you may select the desired
contrast intensity.
Select Units
From SELECT UNITS, you may select how information is
displayed. ENGLISH for Imperial units, i.e., PSI, °F or
METRIC KPA, METRIC BAR for IS units, i.e., kPa, Bar, °C.
Utilities
UTILITIES provide troubleshooting features and displays
information about the PowerView configuration. (See
“Utilities Menu”)
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Faults and Warnings
The PowerView provides two means for detecting faults and
warnings: visual LEDs on the casing (See “Faceplate
Features”) and fault indicators on the display.
Visual Indication
• Amber LED (Warning)
• Red LED (Derate / Shutdown)
Fault Indicators
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Auxiliary Gage Fault
Murphy’s PVA Gages can be attached to the PowerView. If
an auxiliary gage should fail, the 1-up or 4-up display will be
replaced with the fault message “GAGE NOT
RESPONDING”.
NOTE: The fault can only be cleared by correcting the

cause of the fault condition.
Active Fault Codes

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

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

once again will hide the fault and return the screen to
the 1-up or 4-up display.
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Utilities Menu
The following steps take place starting at the UTILITIES
menu option.
1. GAGE DATA - View information for optional connected

PVA gages.
2. REMOVE ALL GAGES - Reset the PowerView's gage

memory.
3. SOFTWARE VERSION - View the PowerView's

software version.
4. MODBUS SETUP – refer to ‘Modbus Setup’ section.
5. FAULT CODE CONVERSION - View/edit the J1939

fault code conversion method.
NOTE: There are four (4) different methods for

converting fault codes. The PowerView always looks for
J1939 Version 4 and can be set to read the code as
one of three (3) other J1939 versions if Version 4 is not
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being used. Most engine ECU’s use Version 4,
therefore in most cases adjustment of this menu option
will not be required.
Upon receiving an unrecognizable fault, change to a

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

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

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

to a specific engine ECU.
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Modbus® Setup
1. From the UTILITIES menu, select MODBUS SETUP.
2. Select either the SLAVE ACTIVE (SCADA or remote

Modbus master) or MASTER ACTIVE (auxiliary gages)
modes. Touch Enter to toggle between master and
slave.
3. Select SERIAL PORT SETUP (slave mode only), then

touch Enter.
4. Continue to scroll each selection (BAUD RATE,

PARITY, DATA BITS, STOP BITS) to configure the
serial port parameters for your Modbus slave
application.
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Selecting Engine ECU
1. From the UTILITIES menu, choose SELECT ENGINE
ECU.
2. The message “LISTEN TO ECU: ALL” is displayed as
the default setting, and indicates the PV101 is listening
to all devices on the network.
3. To change the setting to a specific address, press the
Arrow Keys to scroll through the numbers (0-253).
4. Once the target address is displayed, press Enter.
5. A confirmation screen displays. Selecting “NO” (shown
above Menu key) returns to the SELECT ENGINE ECU
screen. Selecting “YES” (shown above Enter key)
stores the selected address and returns to the
UTILITIES menu.
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Troubleshooting
“WAIT TO START PREHEATING” is displayed
The ECU is broadcasting a 'Wait To Start' message. Engine
manufacturers typically recommend against starting the
engine while the ECU is broadcasting this message. Once
the ECU stops broadcasting this message, this screen will
no longer be displayed on the PowerView.
“CANBUS FAILURE” is displayed

The PowerView has not received any valid J1939 CAN
messages for at least 30 seconds.
“TIMEOUT ECU NOT RESPONDING” is displayed

The PowerView sent a request to the ECU for Stored Fault
Code (DM2) information, and the ECU did not respond to
the request. This message on the PowerView indicates the
ECU may not support Stored Fault Code (DM2) functionality
over J1939.
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“NO STORED CODES” is displayed
The PowerView sent a request to the ECU for Stored Fault
Code (DM2) information, and the ECU responded. There
are zero stored codes.
“NO GAGE DATA” is displayed

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

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

value
The ECU is sending a message that it does not support this
parameter.
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“DATA ERROR” is displayed in place of a parameter value
The ECU is sending a message that there is a data error
with this parameter. Or (PV101 only) FUEL LEVEL has
been selected for display, ANALOG INPUT has been set to
FUEL LEVEL, but no Murphy Fuel Sender has been
connected to the analog input.
One of the 4-UP quadrants is empty

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

The LCD contrast may have been over or under adjusted.
Press and hold the MENU key for approximately 5
seconds. This will reset the LCD contrast setting to factory
default.
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0710172
02-13-07
Section 78
PowerView™ - Model PV101 – Troubleshooting

Message Translation
“WAIT TO START PREHEATING” is The ECU is broadcasting a 'Wait To Start'
displayed message. Engine manufacturers typically
recommend against starting the engine while the
ECU is broadcasting this message. Once the
ECU stops broadcasting this message,
this screen will no longer be displayed on the
PowerView.
“CANBUS FAILURE” is displayed The PowerView has not received any valid
J1939 CAN messages for at least 30 seconds
“TIMEOUT ECU NOT RESPONDING” The PowerView sent a request to the ECU for
is displayed Stored Fault Code (DM2) information, and the
ECU did not respond to the request. This
message on the PowerView indicates the ECU
may not support Stored Fault Code (DM2)
functionality over J1939.
“NO STORED CODES” is displayed The PowerView sent a request to the ECU for
Stored Fault Code (DM2) information, and the
ECU responded. There are zero stored codes.
“NO GAGE DATA” is displayed The PowerView has no record of gages
connected to the RS485 bus.
“NO DATA” is displayed in place of a The PowerView has not received data for the
parameter value selected parameter for at least 5 seconds
“NOT SUPPORTED” is displayed in The ECU is sending a message that it does not
place of a parameter value support this parameter
“DATA ERROR” is displayed in place The ECU is sending a message that there is a
of a parameter value data error with this parameter. Or (PV101 only)
FUEL LEVEL has been selected for display,
ANALOG INPUT has been set to FUEL LEVEL,
but no Murphy Fuel Sender has been connected
to the analog input.
One of the 4-UP quadrants is empty No parameter has been selected for display in
this quadrant.
Display is not readable, either very The LCD contrast may have been over or under
dim or very dark adjusted. Press and hold the MENU key for
approximately 5 seconds. This will reset the
LCD contrast setting to factory default.
(1)
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NOTES
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02-14-07
Section 78
PV100/PV101 Implementation of SAE J1939 Parameters*

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

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

PV101-A, software version Murphy 1.00.06
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Murphy, the Murphy logo, and PowerView are registered and/or
common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by
Murphy Industries, Inc., with all rights reserved. (c) 2008 Murphy
Industries, Inc. Other third party product or trade names
referenced herein are the property of their respective owners and
are used for identification purposes only.
S/N: 020-069
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PowerView™
Modelo PV-101
Guía del usuario
Rev. 16-02-07 00-02-0605
Sección 78 del catálogo
S/N: 020-069
S1100 (SPANISH)
Con el fin de poder ofrecerle siempre la mejor calidad y los
mejores productos, nos reservamos el derecho a modificar el
diseño y las especificaciones en cualquier momento. Si desea
obtener la versión más reciente de este manual, visite
www.fwmurphy.com.
Garantía: con este producto de FW Murphy se proporciona una

garantía limitada en materiales y mano de obra. Si desea
consultar o imprimir una copia de dicha garantía, visite
www.fwmurphy.com/support/warranty.htm
ANTES DE INSTALAR ESTE PRODUCTO DE MURPHY:

• Desconecte el dispositivo de cualquier tipo de
alimentación eléctrica.
• Asegúrese de que la unidad no esté en funcionamiento
durante el proceso de instalación.
• Siga todas las advertencias de seguridad del fabricante
del dispositivo.
• Lea y siga todas las instrucciones de instalación.
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Índice
Introducción ......................................................................1
Parámetros del motor y de la transmisión 2
Componentes del dispositivo 3
Funciones de navegación y del teclado 4
Funcionamiento ................................................................9
Menús de PowerView (al encender el dispositivo) 9
Configuración de la pantalla 12
Opciones del menú principal 19
Fallos y advertencias 22
Menú de utilidades 25
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Introducción
Enhorabuena por la adquisición del dispositivo PowerView,
una herramienta multifuncional que permite ver los
parámetros y códigos de servicio de motores electrónicos
modernos y transmisiones.
En esta guía encontrará las explicaciones necesarias para

configurar el dispositivo PowerView, así como para utilizar
el producto y conocer todas sus funciones. La sencilla
navegación por la pantalla, con funciones intuitivas pero al
mismo tiempo eficaces, le permite familiarizarse
rápidamente con el producto.
Si desea obtener más información, visite nuestro sitio Web

www.fwmurphy.com/powerview.
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Parámetros del motor y de la transmisión
Los siguientes parámetros corresponden al motor y a la
transmisión; pueden mostrarse en unidades estándar o
métricas y en inglés, español, Italiano, francés o alemán (en
caso necesario, consulte al fabricante del motor o de la
transmisión para obtener información sobre los parámetros
compatibles con SAE J1939):
• Rpm del motor • Presión del aceite de
• Horas de funcionamiento transmisión
del motor • Temperatura del
• Voltaje del sistema aceite de
• Porcentaje de carga del transmisión
motor con las rpm actuales • Posición del
• Temperatura del engranaje de
refrigerante transmisión
• Presión del aceite • Parámetros de
• Ahorro de combustible configuración del
• Posición del regulador motor
• Temperatura del aire del • Códigos de fallos
colector del motor activos
• Consumo actual de • Códigos de fallos
combustible almacenados
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Componentes del dispositivo
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Funciones de navegación y del teclado
El teclado de PowerView es un sistema sensible al tacto.
No dispone de interruptores mecánicos que se puedan
desgastar o estropear. Al presionar una tecla, la pantalla
parpadea. Las teclas del teclado ofrecen las siguientes
funciones:
Menú: para entrar y salir de las pantallas del

menú.
Flecha izquierda: para seleccionar

parámetros desplazándose por la pantalla
hacia la izquierda o hacia arriba.
Flecha derecha: para seleccionar
parámetros desplazándose por la pantalla
hacia la derecha o hacia abajo.
Tecla de retorno: para seleccionar un menú
o parámetro y ocultar o visualizar un código
de fallos activo.
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Navegación básica
1. Al presionar la tecla de menú, se muestran los
elementos del menú principal.
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S1100 (SPANISH)
Mediante las flechas, podrá seleccionar otros
elementos del menú.
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S1100 (SPANISH)
2. Algunos menús ocupan más de una página. Para pasar
a la siguiente página o a la anterior, deberá colocarse
en el último elemento y pulsar la flecha derecha o en el
primer elemento y pulsar la flecha izquierda,
respectivamente.
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S1100 (SPANISH)
3. Para seleccionar un elemento, señálelo y presione la
tecla de retorno. A continuación se mostrará la pantalla
correspondiente.
4. Cada vez que aparezca la palabra MÁS sobre las

flechas, significa que hay más pantallas disponibles.
Utilice las flechas para avanzar hacia la siguiente
pantalla de información.
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S1100 (SPANISH)
Funcionamiento
Menús de PowerView (al encender el
dispositivo)
1. Al encender el dispositivo, aparece el logotipo de
Murphy.
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S1100 (SPANISH)
2. Si la unidad de control del motor emite una orden de
espera, se mostrará la siguiente pantalla. Los
fabricantes de motores recomiendan esperar a que
desaparezca este mensaje antes de encender el motor.
Cuando la unidad de control deja de emitir dicho
mensaje, esta pantalla desaparece.
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S1100 (SPANISH)
3. Una vez que se ha encendido el motor, aparece el
parámetro único del motor y se muestran las rpm. Al
presionar la flecha derecha, se mostrará la
temperatura del refrigerante. Puede cambiar los
parámetros de la pantalla con la tecla de menú.
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S1100 (SPANISH)
Configuración de la pantalla
Es posible que la pantalla esté configurada de manera que
muestre un único parámetro del motor (visualización de 1
parámetro), o cuatro parámetros a la vez (visualización de 4
parámetros). Se proporcionan opciones preestablecidas,
pero, si lo prefiere, puede personalizar la pantalla
seleccionando los parámetros que desee.
Visualización de 1 parámetro
Dispone de tres opciones para modificar la visualización de
1 parámetro.
Parámetros preestablecidos: esta opción contiene los

siguientes parámetros del motor: horas de funcionamiento,
rpm del motor, voltaje del sistema, voltaje de la batería, %
de carga del motor con las rpm actuales, temperatura del
refrigerante y presión del aceite.
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S1100 (SPANISH)
Configuración personalizada: esta opción permite
modificar un determinado parámetro, el número total de
parámetros y el orden en que aparecen.
Búsqueda automática: si selecciona la función de

búsqueda, se visualizarán los parámetros seleccionados de
uno en uno, parándose momentáneamente en cada uno de
ellos.
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S1100 (SPANISH)
Ajustes de la visualización de 1 parámetro
1. Pulse la tecla de menú y utilice las flechas para
resaltar VISUALIZACIÓN DE 1 PARÁMETRO y, a
continuación, pulse la tecla de retorno.
2. Para seleccionar PARÁMETROS

PREESTABLECIDOS, resalte la opción y pulse la tecla
de retorno. Se mostrará el mensaje “VALORES
PREESTABLECIDOS RESTAURADOS"
3. Para seleccionar CONFIGURACIÓN

PERSONALIZADA, resalte la opción y pulse la tecla de
retorno. Se mostrará una lista de parámetros del
motor.
4. Para seleccionar un parámetro, utilice las flechas para

desplazarse por las distintas opciones. A continuación,
resalte el parámetro deseado y pulse la tecla de
retorno.
Los parámetros seleccionados aparecen con el símbolo

# a la derecha y en el orden en el que se mostrarán.
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S/N: 020-069
S1100 (SPANISH)
5. Para cambiar un parámetro seleccionado y eliminarlo
de la lista de parámetros en pantalla, resáltelo y
presione la tecla de retorno.
6. Siga desplazándose por las distintas opciones y

seleccione los parámetros adicionales que desee para
la VISUALIZACIÓN DE 1 PARÁMETRO. Pulse la tecla
de menú en cualquier momento para volver al menú de
CONFIGURACIÓN PERSONALIZADA.
7. Si selecciona la función BÚSQUEDA AUTOMÁTICA

ACTIVADA, los parámetros seleccionados se
visualizarán de uno en uno.
8. Una vez establecidas las funciones PARÁMETROS

PREESTABLECIDOS, CONFIGURACIÓN
PERSONALIZADA y BÚSQUEDA AUTOMÁTICA, pulse
la tecla de menú una vez, para volver al menú
principal, o dos veces, para que se muestre la pantalla
de visualización de 1 parámetro.
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S1100 (SPANISH)
Visualización de 4 parámetros
La visualización de 4 parámetros coloca los datos en cuatro
áreas de la pantalla llamadas cuadrantes. Los parámetros
preestablecidos para la visualización de 4 parámetros son
los siguientes: temperatura del refrigerante, velocidad del
motor, presión del aceite y voltaje de la batería. Para
personalizar la visualización de 4 parámetros, defina un
parámetro para cada cuadrante.
1. Pulse la tecla de menú y utilice las flechas para

resaltar VISUALIZACIÓN DE 4 PARÁMETROS. A
continuación, pulse la tecla de retorno.
2. Para seleccionar PARÁMETROS

PREESTABLECIDOS, resalte la opción y pulse la tecla
de retorno. Se mostrará el mensaje “VALORES
PREESTABLECIDOS RESTAURADOS"
3. Para seleccionar CONFIGURACIÓN

PERSONALIZADA, resalte la opción y pulse la tecla de
retorno. Se muestra la pantalla de visualización de 4
parámetros.
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S/N: 020-069
S1100 (SPANISH)
4. El cuadrante con el valor de parámetro iluminado es el
parámetro actualmente seleccionado. Utilice las
flechas para seleccionar el cuadrante que desea
modificar.
5. Pulse la tecla de retorno y aparecerá una lista de

parámetros.
El parámetro resaltado es el que se ha seleccionado
para la pantalla. El número que aparece a la derecha
del parámetro indica el cuadrante en el que se muestra.
1 = cuadrante superior izquierdo

2 = cuadrante inferior izquierdo
3 = cuadrante superior derecho
4 = cuadrante inferior derecho
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S1100 (SPANISH)
6. Utilice las flechas para resaltar el nuevo parámetro que
desea colocar en el cuadrante seleccionado en el paso
4, y pulse la tecla de retorno.
7. Pulse la tecla de menú para volver a la pantalla

CONFIGURACIÓN PERSONALIZADA DE
VISUALIZACIÓN DE 4 PARÁMETROS.
8. Comprobará que el parámetro del cuadrante

seleccionado ha cambiado, y que ahora se muestra el
parámetro que eligió en la pantalla anterior.
9. Repita el proceso de selección de parámetros hasta

que se llenen todos los espacios.
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Opciones del menú principal
En esta sección se describen las funciones que aparecen
en el menú principal de PowerView. Para acceder a estas
opciones, pulse la tecla de menú. Las flechas le permiten
desplazarse por los elementos y, con la tecla de retorno,
podrá seleccionar la opción resaltada.
Selección de idioma
Desde IDIOMAS, puede elegir entre las siguientes
opciones: ENGLISH, ESPAÑOL, ITALIANO, FRANÇAIS o
DEUTSCH. El idioma seleccionado actualmente aparece
seguido de un asterisco.
Códigos de fallos almacenados*

Solicite la información del código de fallos almacenados.
Datos de configuración del motor*

CONF. DEL MOTOR le permite desplazarse por los datos
de configuración del motor.
* No se garantiza la compatibilidad de esta función con
todos los fabricantes.
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S/N: 020-069
S1100 (SPANISH)
Ajuste de la luz de fondo
La opción AJUSTAR LUZ DE FONDO permite seleccionar
la intensidad de iluminación deseada.
Ajuste de contraste
Desde AJUSTAR CONTRASTE, puede seleccionar la
intensidad de contraste deseada.
Seleccionar unidades
Desde SELECCIONAR UNIDADES, puede seleccionar el
modo como desea que se muestre la información. INGLÉS
para unidades imperiales, por ej., PSI o °F; SISTEMA
MÉTRICO KPA o SISTEMA MÉTRICO BAR para el
sistema internacional de unidades, por ej., kPa, Bar o °C.
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S/N: 020-069
S1100 (SPANISH)
Utilidades
La opción UTILIDADES proporciona funciones de solución
de problemas y muestra información sobre la configuración
de PowerView (véase “Menú de utilidades”).
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S/N: 020-069
S1100 (SPANISH)
Fallos y advertencias
PowerView proporciona dos maneras de detectar fallos y
advertencias: LED visuales en la carcasa (consulte la
sección “Componentes del dispositivo”) e indicadores de
fallos en la pantalla.
Indicadores visuales
• LED ámbar (advertencia)
• LED rojo (ralentización / apagado)
Indicadores de fallos
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S/N: 020-069
S1100 (SPANISH)
Fallo del indicador auxiliar
Puede acoplar los indicadores PVA de Murphy a
PowerView. En caso de fallo de un indicador auxiliar, la
visualización de 1 o 4 parámetros se sustituirá por el
mensaje de error “EL INDICADOR NO RESPONDE”.
NOTA: el fallo sólo se puede subsanar corrigiendo la causa

que lo ha provocado.
Códigos de fallos activos

Cuando PowerView recibe un código de fallo de un motor,
la visualización de 1 o 4 parámetros se sustituye por el
mensaje de códigos de fallos activos.
Códigos de ralentización / apagado

Cuando PowerView recibe un código de fallo grave de una
unidad de control del motor, la visualización de 1 o 4
parámetros se sustituye por el mensaje de APAGADO.
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S/N: 020-069
S1100 (SPANISH)
Aceptación de códigos de fallo
1. Para aceptar y ocultar un fallo y volver a la
visualización de 1 o 4 parámetros, pulse la tecla de
retorno. La pantalla volverá a mostrar la visualización
de 1 o 4 parámetros, pero incluirá el icono de apagado.
2. Pulse la tecla de retorno para volver a mostrar el fallo.

Si vuelve a pulsar la tecla de retorno, el fallo se
ocultará de nuevo y se mostrará la visualización de 1 o
4 parámetros.
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S1100 (SPANISH)
Menú de utilidades
Seleccione la opción de menú UTILIDADES.
1. DATOS DEL INDICADOR: para ver la información de

los indicadores PVA opcionales conectados.
2. EXTRAER TODOS LOS INDICADORES: para reiniciar
la memoria del indicador de PowerView.
3. VERSIÓN DE SOFTWARE: para ver la versión de
software de PowerView.
4. CONVERSIÓN DEL CÓDIGO DE FALLOS: para ver o
modificar el método de conversión del código de fallo
J1939.
NOTA: existen cuatro (4) métodos distintos para la

conversión de los códigos de fallo. PowerView busca
siempre la versión 4 de J1939 y puede configurarse
para leer el código como las otras tres (3) versiones de
J1939, en caso de que la versión 4 no se utilice. La
mayoría de las unidades de control de los motores
utilizan la versión 4, por lo que normalmente no es
necesario ajustar esta opción de menú.
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S1100 (SPANISH)
Si recibe un fallo irreconocible, cambie de versión

J1939. Si el número de parámetro irreconocible (SPN)
del fallo no se modifica al cambiar de versión, significa
que la unidad de control del motor que ha provocado el
fallo está utilizando el método 4 de conversión de fallos.
Si el número SPN cambia pero sigue siendo
irreconocible, intente cambiar a otra versión J1939 que
no haya utilizado todavía y continúe comprobando el
número SPN.
5. ENTRADA ANALÓGICA: ofrece dos opciones de

configuración:
• ATENUADOR CON RETROILUMINACIÓN: es la

configuración predeterminada. Acepta el uso de un
atenuador con retroiluminación.
• NIVEL DE COMBUSTIBLE: acepta el uso de un

transmisor de combustible Murphy (se recomienda
el modelo ES2F) para obtener información del nivel
de combustible.
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S/N: 020-069
S1100 (SPANISH)
Configuración de® Modbus
1. Desde el menú UTILIDADES, seleccione
CONFIGURACIÓN DE MODBUS.
2. Seleccione los modos ESCLAVO ACTIVO (SCADA o

maestro de Modbus remoto) o MAESTRO ACTIVO
(indicadores auxiliares). Pulse la tecla de retorno para
cambiar del modo maestro al modo esclavo y
viceversa.
3. Seleccione CONFIGURACIÓN DE PUERTO (sólo

modo esclavo) y, a continuación, pulse la tecla de
retorno.
4. Continúe desplazándose por cada selección

(VELOCIDAD EN BAUDIOS, PARIDAD, BITS DE
DATOS, BITS DE PARADA) para configurar los
parámetros de puerto serie de su aplicación esclava de
Modbus.
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S/N: 020-069
S1100 (SPANISH)
0710172
02-13-07
Section 78
PowerView™ - Model PV101 – Troubleshooting

Message Translation
“WAIT TO START PREHEATING” is The ECU is broadcasting a 'Wait To Start'
displayed message. Engine manufacturers typically
recommend against starting the engine while the
ECU is broadcasting this message. Once the
ECU stops broadcasting this message,
this screen will no longer be displayed on the
PowerView.
“CANBUS FAILURE” is displayed The PowerView has not received any valid
J1939 CAN messages for at least 30 seconds
“TIMEOUT ECU NOT RESPONDING” The PowerView sent a request to the ECU for
is displayed Stored Fault Code (DM2) information, and the
ECU did not respond to the request. This
message on the PowerView indicates the ECU
may not support Stored Fault Code (DM2)
functionality over J1939.
“NO STORED CODES” is displayed The PowerView sent a request to the ECU for
Stored Fault Code (DM2) information, and the
ECU responded. There are zero stored codes.
“NO GAGE DATA” is displayed The PowerView has no record of gages
connected to the RS485 bus.
“NO DATA” is displayed in place of a The PowerView has not received data for the
parameter value selected parameter for at least 5 seconds
“NOT SUPPORTED” is displayed in The ECU is sending a message that it does not
place of a parameter value support this parameter
“DATA ERROR” is displayed in place The ECU is sending a message that there is a
of a parameter value data error with this parameter. Or (PV101 only)
FUEL LEVEL has been selected for display,
ANALOG INPUT has been set to FUEL LEVEL,
but no Murphy Fuel Sender has been connected
to the analog input.
One of the 4-UP quadrants is empty No parameter has been selected for display in
this quadrant.
Display is not readable, either very The LCD contrast may have been over or under
dim or very dark adjusted. Press and hold the MENU key for
approximately 5 seconds. This will reset the
LCD contrast setting to factory default.
(1)
S/N: 020-069
S1100 (SPANISH)
NOTAS
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S/N: 020-069
S1100 (SPANISH)
0710174
02-14-07
Section 78
PV100/PV101 Implementation of SAE J1939 Parameters*

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

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

PV101-A, software version Murphy 1.00.06
S/N: 020-069
S1100 (SPANISH)
Murphy, el logo de Murphy y PowerView están registrados y/o son
marca registrada bajo derecho común a nombre de Murphy
Industries, Inc. Este documento, incluyendo el texto y las
ilustraciones, está protegido por derechos de autor de Murphy
Industries, Inc. (c) 2006 Murphy Industries, Inc. Los demás
productos o marcas de otros fabricantes que se mencionen en el
presente documento son propiedad de sus respectivos titulares y
sólo se usan para efectos de identificación.
S/N: 020-069
17074
ALTERNATOR
Page 1 of 1

1 324095 ALTERNATOR (DELCO 24 VOLTS, 100 AMP) 1
2* 150025 ALTERNATOR BELT (CUMMINS QSB 4.5L) A/R
PRE 6/2011
9041-20038 ALTERNATOR BELT (CUMMINS QSB 4.5L)
STARTING 6/2011 (67”)
9041-20062 ALTERNATOR BELT (CUMMINS QSB 4.5L)
STARTING 2/2013 (66”)
3* 150030 ALTERNATOR BELT (CUMMINS QSB 6.7L) A/R
4* 9041-20004 ALTERNATOR BELT A/R
(CUMMINS QSB 4.5L & 6.7L WITH A/C) (80.5”)
5* 465460 INSULATION SHIELD BETWEEN ALTERNATOR AND 1
EXHAUST MANIFOLD (USED ON CUMMINS QSB 6.7L)

2/14/2013
S/N: 020-069
17363
BATTERY BOX ASSEMBLY
Page 1 of 3
Updated:
DWG# 12756-01 10/28/10
S/N: 020-069
17363
Page 2 of 3
Updated:
DWG# 12756-01 10/28/10
S/N: 020-069
17363
Page 3 of 3

1 01GC04008 CAPSCREW 8
3 01GD06 NUT 6
4 01GE06 FLAT WASHER 4
5 01GGS25012 SCREW, PANHEAD 2
6 04GE04 LOCK WASHER 8
8 124163 SWITCH, MASTER DISCONNECT 1
(MAYBE LOCATED ON FRONT SIDE)
9 124467 SWITCH, LOCKOUT LEVER KIT 1
(MAYBE LOCATED ON FRONT SIDE)
10 12757-01 BATTERY BOX LID 1
11 12765-01 BATTERY BOX WELDMENT, DOUBLE, W/BREAKER 1
12 132130 LATCH KIT, INCLUDES RUBBER 2
13 134217 BREAKER, 150AMP CIRCUIT 1
14 19455-03 LINER, BATTERY BOTTOM 1
15 25258-02 LINER, BATTERY BOX SIDE 2
16 29464-01 LINER, BATTERY BOTTOM 1
17 29464-04 LINER, BATTERY BOX 2
18 354006 BATTERY, 12V 925CCA, MAINT. FREE 2
19 594535 LATCH, HOLD DOWN, STRAIGHT 2
20 605781 BUMPER, NEOPRENE 3
21 67GD04 NUT, NYLOCK 2
Updated:
DWG# 12756-01 10/28/10
S/N: 020-069

S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
4. ENGINE AND ACCESSORIES
F1017 ENGINE OPERATION & MAINTENANCE MANUAL

F1016 ENGINE PARTS MANUAL
17128 ENGINE FILTERS
13967 RADIATOR & CHARGE AIR INSTALLATION
17068 AIR INTAKE SYSTEM
11637 AIR CLEANER
13963 EXHAUST SYSTEM
S1020 EXHAUST INFORMATION
17478 CUMMINS QSB 4.5L ENGINE MOUNT
F1024 CUMMINS ENGINE WARRANTY
S/N: 020-069
ENGINE OPERATION AND F1017
MAINTENANCE MANUAL Page 1 of 1
SEE CUMMINS MANUAL HARD COPY
Updated:
03/08/12
S/N: 020-069
CUMMINS ENGINE PARTS F1016
MANUAL Page 1 of 1
As an Owner/Operator of a Getman Corporation

vehicle manufactured with a Cummins Diesel
Engine, you will have three (3) options available to
you to research and/or reference part numbers for
your specific engine. All of the following three (3)
options require your engine “SERIAL NUMBER”
which can be found on the engine identification tag,
or in the Component List on page F1009 in Section
1 (Introduction/General Information) of your truck
manual.
 Contact Getman Corporation Parts

Department at:
1-800-533-1110 or
1-269-427-5611 ext. 305 or ext. 330.
Provide the specific Cummins engine Serial
Number and the required engine component.
 Contact your local Cummins Parts
Department. Provide the specific Cummins
engine Serial Number and the required engine
component.
 Purchase Cummins QuickServe from
Cummins.com for a modest annual fee and
you will obtain unlimited online access to any
Cummins parts manuals specific to the Serial
Numbers you provide. This will also provide
technical support and up to date service
support and bulletins. This would cover all
Cummins engines.
Updated:
03/05/12
S/N: 020-069
17128
QSB ENGINE FILTERS
Page 1 of 3
FILTER IS IN REMOTE LOCATION
11

1 150019-G OIL FILTER (QSB 4.5 & 6.7L) 1
2 9041-20058 HEAD, LUBE OIL FILTER 1
3 15GK1210 ADAPTER 2
Updated:
11/14/12
S/N: 020-069
17128
QSB ENGINE FILTERS
Page 2 of 3

1 150021 WATER SEPARATOR FILTER HEAD ASSEMBLY 1
2 150020-G FUEL FILTER WATER SEPARATOR ELEMENT 1
(QSB 4.5 & 6.7L)
3 9041-20049 WIRE HARNESS 1
Updated:
11/14/12
S/N: 020-069
17128
QSB ENGINE FILTERS
Page 3 of 3

1 150036-G FUEL FILTER ELEMENT (QSB 4.5 & 6.7L) 1
2 9041-20059 HEAD, FUEL FILTER 1
3 9041-20060 ADAPTER, FILTER HEAD 1
Updated:
11/14/12
S/N: 020-069
RADIATOR & CHARGE AIR 13967
INSTALLATION Page 1 of 3

1 12326-09 RADIATOR HOSE (2”) 1
2 12253-10 ADAPTER (2” – 1 ¾”) 1
3 12326-08 RADIATOR HOSE (1 ¾”) 1
4 9047-00005 HOSE, 2” ID, GS SERIES (COMES IN 25’ LENGTHS) A/R
5 12922-04 ELBOW TUBE WELDMENT 1

3/7/2012
S/N: 020-069

3/7/2012
S/N: 020-069

6 12567-06 REWORKED SILICONE HOSE (3” ID, 6” LENGTH) 2
7 13575-03 ELBOW (3”) 1
8 26524-02 TUBE WELDMENT 1
9 12567-05 REWORKED SILICONE HOSE (4” ID, 4” LENGTH) 2
10 12964-03 CHARGE AIR TUBE WELDMENT 1
11 605663 HUMP HOSE (3 ½” ID) 1
12 26524-03 ELBOW WELDMENT 1
13 605660 HUMP HOSE (3” ID) 2
14 11010-01 RADIATOR (NOTE: OLD P/N WAS 465216) 1
15 13575-02 ELBOW (3”) 1
16* 12963-01 RADIATOR MOUNT (RIGHT SIDE) 1
17* 12963-02 RADIATOR MOUNT (LEFT SIDE) 1
18* 146050 FAN 1
9047-00010 FAN, OFFSET
19* 465303 OVERFLOW SURGE TANK 1
20* 605961 OVERFLOW HOUSE FOR SURGE TANK 1
21* 465480 RADIATOR CAP #15 DOUBLE SEAL USED W/OVERFLOW 1

3/7/2012
S/N: 020-069
17068
AIR INTAKE SYSTEM
Page 1 of 1

1 604686 AIR CLEANER 1
2 604691 AIR CLEANER BANDS 2
3 604921 AIR INLET HOOD 1
4 604119 RUBBER ELBOW REDUCER 90° (5” – 4”) 1
5 19224-261 TUBE (4” X 4 ¼” LENGTH) 1
6 594330 RUBBER REDUCER (4” – 3”) 1
7 605820 RUBBER REDUCER 90° (3” – 3 ½”) 1
8 15391-08 INTAKE TUBE WELD 1
9* 604464 INDICATOR, 20” 1

07/08/10
S/N: 020-069
11637
AIR CLEANER 12”
Page 1 of 1

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

3/27/2012
S/N: 020-069
13963
EXHAUST SYSTEM
Page 1 of 1

1 12253-14 EXHAUST ELBOW WELDMENT 1
2 12256-11 FLEX TUBE WELDMENT 1
3 595411 PURIFIER 1
4 594372 SILENCER 1
5 15951-01 DIFFUSER WELDMENT 1
6 594996 CLAMP, 8D ECS 3
7* 25094-11 EXHAUST CAGE (OLD P/N WAS 25094-01) 1
8* 605537 ALUMINIZED HEAT BARRIER WRAP A/R
9* 605538 STRAP/ SNAP USE W/605537 A/R

10/31/11
S/N: 020-069
S1020
WARRANTY
( diesel exhaust gas purifiers are warranted The Corporation reserves the right to request that
"-for six months or 1,000 engine hours, whichever oc- the purifier not be removed from nor altered on the
curs first from the date of shipment, against defects vehicle on which it is installed without a prior physi-
or failure due to material or workmanship at the sole cal inspection by the Corporation.
discretion of the Corporation. The Corporation denies all liability for costs or
Subject to the terms herein the sole obligation of the damages related to return transportation charge fol-
Corporation shall be to repair or to replace in part lowing repair or replacement as aforesaid or for re-
or in whole any failed unit or components thereof installation costs. No liability for loss or damage of
provided same are returned "Transportation any nature or kind, whether arising out of or from
Prepaid" to the Corporation's nearest plant within the use of the purifier whether or not defective, is
the warranty time period. assumed.
This warranty does not cover improper or careless Except as expressly stated herein, any or other war-
installation, sizing, storage or handling, or usage con- ranties either express or implied, intended or other-
trary to the Corporation's directions, design or wise given are hereby excluded and are null and
specifications or other defects or failures due to any void.
welding to or damage to the cannister. The Corpo-
ration shall make all determinations as to the cause
of such defects or failures.
RECOMMENDED
CLEANING PROCEDURE
FOR HARD CARBON DEPOSITS: FOR SOFT CARBON DEPOSITS:
1. Dry-brush inlet face of catalyst. If high pressure steam is avaUable, steam clean
2. Air clean through outlet face of catalyst. through outlet face towards catalyst inlet face.
3. Continue steps 1 and 2 until inlet face of cata- Keep nozzle 2" away from catalyst face. Maximum
lyst is clean. allowed pressure 50 PSI.
4. Completely soak catalyst in cleaning solution for
one hour. Note caution below. RECOMMENDATION:
5. Solvent-air clean through outlet face of catalyst 1. Incorporate this procedure into preventive main-
for 10 minutes. tenance schedule of vehicle for minimal partic-
6. Air clean through outlet face. ulate accumulation and maximum purifier
performance.
7. Repeat steps 4, 5 & 6 until purifier is as clean
as possible. 2. The catalyst life may exceed 10,000 hours. The
main reasons for catalyst failure are improper
8. High pressure water wash purifier through outlet cleaning or damage to catalyst during cleaning.
face and air dry. Maximum pressure 50 PSI. Try to perform catalyst cleaning without causing
9. Re-install purifier. Make sure that purifier is re- any mechanical damage to catalyst.
installed so that the exhaust gas flows through
purifier in the same direction as before the CAUTION-
cleaning.
INFLAMMABLE SOLUTION
Use in accordance with manufacturers recommen-
dations - and in a properly ventilated area.
S/N: 020-069
RECOMMENDED S1020
CLEANING PROCEDURE continued

\._..rhe purifier cleaning cycle depends on the condition Purifier location in the engine exhaust system should
of the engine. For installations on new engines, pu- be as close to the engine exhaust manifold as pos-
rifier may not need cleaning for 6 to 8 months. For sible. This close-to-engine installation will allow soot
installations on old or poorly-tuned engines, purifier and exhaust particulates deposited on the inlet face
may need cleaning every two months or more. of the catalyst to be burned off by the heat in the
exhaust gas and will extend the cleaning cycle.
INSTALLATION, OPERATION ANI) SERVICE

INSTALLATION
Because high temperature is the primary require- engine manufacturer's recommendations. If the
ment for high efficiency operation of the purifier, in- purifier back pressure readings approach engine
stall the purifier as close to engine exhaust manifold back pressure limits, remove centre body for
as possible. The heat in the exhaust gas is neces- cleaning. Keep one additional centre body in
sary to activate the purifier for high exhaust gas stock to avoid equipment downtime during
purification as well as to burn off carbon particles cleaning.
'ieposited on the inlet face of the metallic honey- 3. In order to reduce honeycomb clogging and to
\.._.;omb for a longer cleaning cycle. extend cleaning cycle, avoid prolonged engine
Do not perform any welding on the purifier container. idling periods. Remember that the higher the en-
Any welding on the container (centre body) will void gine load, the higher the exhaust gas tempera-
our warranty. ture and the higher the gas purification efficiency.
It is recommended that the purifier be installed in
the exhaust system using standard muffler clamps. SERVICE
The inlet exhaust pipe should be fitted into the inlet 1. When replacing the purifier centre body, make
of the end cone bottoming on the built-in stop ring. sure that non-asbestos sealing gaskets are in
Check your installation to determine whether the pu- good condition. If necessary, order new gaskets
rifier is firmly located in the exhaust system and that from DCL or our representatives.
it is not in contact with any structural members of 2. Use standard SAE grade 5, 1/4"-28 x 1"
the vehicle or engine accessories. cadmium-plated bolts to connect the centre OOdy
If situation requires, attach your purifier support to to end cones.
engine. If purifier support is attached to part of ave- Use cadmium-plated internal type, anti-vibration
hicle other than engine , install flex between engine tooth lock washers and our cadmium-plated
and purifier. Any supports should be located on the heavy-duty self-locking nuts.
end cones in order not to interfere with centre body Apply approx. 8 ft. lbs. torque to secure the
removal. connection.
Bolts, washers and nuts can be ordered from
OPERATION DCL or our representatives.
1. Check engine exhaust back pressure before in-
stalling the purifier.
- Regularly check exhaust back pressure using
1/8 N.P.T. back pressure port on the inlet side
of the purifier. Compare the readings with the
S/N: 020-069
CUMMINS QSB 4.5L 17478
ENGINE MOUNT Page 1 of 1

2 17GCM12035 CAPSCREW 6
3 12253-18 ENGINE MOUNT, LH 1
4 34014 RUBBER MOUNT 2
5 NSS PART OF FRAME WELDMENT NA
6 1185-08 WASHER 2
8 12253-20 ENGINE MOUNT, RH 1
9 NSS PART OF FRAME WELDMENT NA
Updated:
3/8/2012
S/N: 020-069
Cummins Warranty
All Engines
International
Industrial (Off-Highway)
S/N: 020-069
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S/N: 020-069
Cummins Inc.
Box 3005
Columbus, IN 47202-3005
U.S.A.
Bulletin 3381322
Printed in U.S.A. Rev. 3/13
©1999 Cummins Inc.
S/N: 020-069

S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
5. DRIVE TRAIN
S1005 TRANSMISSION MAINTENANCE & SERVICE

MANUAL
17504 TRANSMISSION
17384 DRIVE PLATE ASSEMBLY
17369 TRANSMISSION MOUNTS
17331 TRANSMISSION DIPSTICK
17493 DRIVELINE INSTALLATION
S/N: 020-069
S1005
Service Manual
Powershift Transmission
32000 R & HR 3, 6, & 8-Speed
Long Drop with Range Shift
TSM-0020
November 2010
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
S/N: 020-069
S1005
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Copyright 2010 Dana Holding Corporation For product inquiries or support,

All content is subject to copyright by Dana and may not visit www.dana.com or call 419-887-6445
be reproduced in whole or in part by any means, For other service publications,
electronic or otherwise, without prior written approval. visit www.SpicerParts.com/literature.asp
THIS INFORMATION IS NOT INTENDED FOR SALE OR For online service parts ordering,
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COPIES.
S/N: 020-069
TRANSMISSION ASSEMBLY 17504
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9050-10005 TRANSMISSION ASSEMBLY 1
32000 CONVERTER HOUSING GROUP
1 N/A NOT USED ON THIS MODEL 1
2 23033 PIPE PLUG 1
3 244390 CONVERTER HOUSING & TUBE ASSEMBLY 1
(INCLUDES ITEMS 6-15, 19, 24-44)
4-5 N/A NOT USED ON THIS MODEL
6 24913 TUBE SLEEVE 1
8 24594 CONVERTER HOUSING SLEEVE 1
9 244457 WASHER 1
10 24473 LOCKWASHER 1
11 24474 CAPSCREW 1
12 24474 CAPSCREW 1
14 244457 WASHER 1
15 24594 CONVERTER HOUSING SLEEVE 1
16 24240 BREATHER, AIR 1
17 244160 FITTING, 90 DEGREE STREET ELBOW 1
18 244157 PIPE REDUCING BUSHING 1
20 24435 LOCKWASHER, PUMP MOUNTING SCREW 4
21 244195 CAPSCREW 4
25 24474 CAPSCREW 1
26 24952 O-RING 1
27 244057 SUCTION TUBE SPACER RING 1
28 24933 SUCTION TUBE ASSEMBLY 1
29 04GE06 LOCKWASHER 1

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30 24191 CAPSCREW 1
31 24474 CAPSCREW 1
33 24592 TUBE CLIP 1
34 24921 REVERSE TUBE ASSEMBLY 1
35 24684 O-RING 1
36 24474 CAPSCREW 1
38 24920 LUBE TUBE ASSEMBLY 1
39 24474 CAPSCREW 1
41 24592 TUBE CLIP 1
42 24922 3RD SPEED TUBE ASSEMBLY 1
43 24684 O-RING 1
44 24924 VALVE OIL SUPPLY TUBE 1
47 24047 CONVERTER HOUSING TO TRANSMISSION CASE 1
GASKET
48 24338 PIN 2
57* 244384 BUSHING SENSOR 1
58* 244387 SHIM WASHER A/R
59* 244388 SCREW TYPE PLUG 1
60* 244389 O-RING 1
61* 244316 FITTING PLUG 1

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TRANSMISSION CASE GROUP
1 9050-10005-001 TRANSMISSION CASE ASSEMBLY 1
(INCLUDES ITEMS: 2-26)
2 24601 SUCTION TUBE ASSEMBLY 1
3 24692 SUCTION TUBE CLIP 1
4 N/A NOT USED ON THIS MODEL
5 24337 PRESSURE TUBE SLEEVE 1
6 24598 LOW SPEED CLUTCH PRESSURE TUBE 1
7 24337 PRESSURE TUBE SLEEVE 1
8 244391 SUCTION TUBE CLIP RIVET 1
9 24693 RETAINING WASHER SCREW 2
10 ZG-230921 RETAINING WASHER 1
11 244232 SUCTION TUBE O-RING 1
12 244391 RIVET 2
13 244256 OIL BAFFLE 1
14 244257 OIL BAFFLE 1
A* 9050-10005-002 RING, SNAP 1
B* 9050-10005-003 BEARING, NEEDLE 1
15 244391 RIVET 2
25 9050-10005-004 DOWEL PIN 2
26 24467 PRESSURE TUBE O-RING 1
29 24339 MAGNETIC DRAIN PLUG 1
30 24689 OIL LEVEL PLUG 1
30A 24689 OIL LEVEL PLUG 1
31 24689 OIL LEVEL PLUG 1
32 24244 SCREEN ASSEMBLY 1
33 24203 SCREEN ASSEMBLY GASKET 1
34 24690 PLUG 1

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56* 24689 PLUG,OIL LEVEL / LOCKUP PORT 1
57* 24677 PIPE PLUG 3
58* 244384 SENSOR BUSHING 1
59* 244387 WASHER SHIM A/R
60* 244388 SCREW TYPE PLUG 1
61* 244389 O-RING 1
62* ZZ-251380 RANGE SHIFT BORE PLUG 1
63* 24688 PIPE PLUG 1

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REAR COVER GROUP
1 244726 REAR COVER 1
2 24046 GASKET, REAR COVER TO CASE 1
3 24686 CAPSCREW 21
5 24389 NUT 2
6 24654 STUD 2
7 244453 PLUG 1

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TURBINE SHAFT GROUP
1 9050-10005-005 TURBINE SHAFT 1
2 24306 BALL BEARING 1
3 24219 SNAP RING 1
4 9050-10005-006 PISTON RING 1
5 9050-10005-007 STATOR SUPPORT 1
6 9050-10005-008 STATOR SUPPORT SCREW 6
7 244498 CAPSCREW 6
8 9050-10005-009 PISTON RING 1
9 244479 OIL BAFFLE & SEAL ASS'Y (INCLUDES ITEM 10) 1
10 244480 OIL SEAL 1
11 24929 OIL BAFFLE SEAL RING 1
12 244128 OIL BAFFLE RETAINER RING 1
13 9050-10005-010 ROLLER BEARING 1
14 24081 SNAP RING 1
15 244325 PISTON RING EXPANDER SPRING 1
16 9050-10005-011 TURBINE SPACER 1
14 9050-10005-012 SNAP RING 1
18 9050-10005-013 SNAP RING 1
19 24910 IMPELLER HUB GEAR 1
20 24576 IMPELLER HUB GEAR SNAP RING 1
21 244265 TURBINE SHAFT GEAR 1

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TORQUE CONVERTER
1 9050-10005-014 TORQUE CONVERTER 1
2 9050-10005-015 PLUG KIT, TORQUE CONVERTER (INCLUDES ITEMS 3-5) 1
3 9050-10005-016 TORQUE CONVERTER PLUG 1
4 9050-10005-017 SNAP RING 1
5 9050-10005-018 O-RING 1

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-- ---------- DRIVE PLATE GROUP --
NOTE: SEE SEPARATE DRIVE PLATE PARTS PAGE

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DRIVE PUMP GROUP HIGH CAPACITY
3 24947 CAPSCREW 2
4 465563-01 DRIVE PUMP GEAR 1
5 465563-02 SUPPORT DRIVE PUMP BEARING 1
6 24909 BEARING BALL 1
7 465563-03 SNAP RING 1
8 24576 SNAP RING 1
9 465563-04 IMPELLER HUB GEAR 1
10 465563-05 DRIVE PUMP IDLER GEAR 1
11 465563-06 SUPPORT DRIVE PUMP IDLER 1
12 465563-07 BEARING BALL 6309 1
14 24947 CAPSCREW 2
15 465563-08 INTERNAL SNAP RING 1
18 24947 CAPSCREW 2
19 465563-01 DRIVE PUMP GEAR 1
20 465563-02 SUPPORT DRIVE PUMP GEAR 1
21 24909 BEARING BALL 1
22 465563-03 SNAP RING 1

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FORWARD AND REVERSE SHAFT GROUP
1 465563-09 CLUTCH DRIVEN GEAR 25T 2
2 24612 HIGH RANGE GEAR 52T 1
3 465563-10 LOW & 4TH DRIVE GEAR 1
4 244235 2ND GEAR 30T 1

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RD
REVERSE AND 3 CLUTCH SHAFT GROUP WITH
STEP SEALED PISTON
1 24347 REVERSE & 3RD CLUTCH SHAFT PISTON RING 3
2 244190 FRONT BEARING RETAINER RING 1
3 244572 WASHER 1
4 244573 BALL END PLATE 1
5 244006 REVERSE & 3RD SHAFT FRONT BEARING 1
7 24291 CLUTCH DRIVEN GEAR BEARING – SHIELD IN 1
8 244652 CLUTCH DRIVEN GEAR BEARING SNAP RING 1
9 N/A NOT USED IN THIS MODEL
10 24568 END PLATE RETAINER RING 1
11 244574 END PLATE - 3RD CLUTCH 1
12 24058 CLUTCH OUTER DRIVE DISC – 3RD CLUTCH 7
13 244546 CLUTCH INNER DISC – 3RD CLUTCH 7
14 244691 CLUTCH PISTON ASSEMBLY - 3RD CLUTCH 1
15 9050-10005-019 CLUTCH PISTON OUTER SEAL 1
16 24529 CLUTCH PISTON INNER SEAL 1
17 244692 CLUTCH PISTON METERING SEAL 1
18 244693 REVERSE & 3RD CLUTCH DRUM & PLUG ASSEMBLY 1
19 244692 CLUTCH PISTON METERING SEAL 1
22 244694 CLUTCH PISTON ASSEMBLY- REVERSE CLUTCH 1
(INCLUDES ITEMS 20 & 21)
23 244546 CLUTCH INNER DISC – REVERSE CLUTCH 6
24 24058 CLUTCH OUTER DISC – REVERSE CLUTCH 6
25 24583 END PLATE – REVERSE CLUTCH 1
27 24610 SPRING RETAINER 1
28 24609 PISTON RETURN SPRING 1

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30 24962 SPRING RETAINER SNAP RING RETAINER 1
31 24298 SPRING RETAINER SNAP RING 1
32 24293 CLUTCH DRIVEN GEAR BEARING 1
38 24962 SPRING RETAINER SNAP RING RETAINER 1
40 24611 3RD GEAR BEARING 1
41 24579 3RD GEAR BEARING SNAP RING 1
43 24613 3RD GEAR BEARING SPACER 1
44 24579 3RD GEAR BEARING SNAP RING 1
45 24614 3RD GEAR BEARING – SHIELD OUT 1
46 244559 REVERSE & 3RD SHAFT GEAR BEARING 1
47 24581 GEAR RETAINING RING 1
48 244695 LOW CLUTCH DRIVE GEAR 1
49 24612 3RD GEAR 1
50 244266 CLUTCH DRIVEN GEAR 1

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ND
FORWARD & 2 CLUTCH SHAFT GROUP WITH STEP
SEALED PISTON
1 24347 FORWARD & 2ND SHAFT PISTON RING 3
3 244572 WASHER 1
4 244573 FORWARD & 2ND SHAFT FRONT END BALL RETAINER 1
5 244006 FORWARD & 2ND SHAFT FRONT BEARING 1
6 24290 FRONT BEARING LOCATING RING 1
8 24291 CLUTCH DRIVEN GEAR BEARING – SHIELD IN 1
12 24293 CLUTCH DRIVEN GEAR BEARING 1
15 24962 SPRING RETAINER - SNAP RING RETAINER 1
20 24298 2ND GEAR RETAINING RING 1
21 244580 2ND GEAR LOCATING RING RETAINER 1
22 244224 2ND GEAR LOCATING RING RETAINER SNAP RING 1
24 24962 SPRING RETAINER - SNAP RING RETAINER 1
29 244574 END PLATE – 2ND CLUTCH 1

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30 24058 CLUTCH OUTER DISC – 2ND CLUTCH 7
31 244546 CLUTCH INNER DISC – 2ND CLUTCH 7
32 244691 CLUTCH PISTON ASSEMBLY – 2ND CLUTCH 1
35 244692 CLUTCH PISTON METERING RING 1
36 244696 FORWARD & 2ND SHAFT, CLUTCH DRUM & PLUG 1
ASSEMBLY
37 244692 CLUTCH PISTON METERING RING 1
40 244694 CLUTCH PISTON ASSEMBLY – FORWARD CLUTCH 1
41 24058 CLUTCH OUTER DISC. – FORWARD CLUTCH 6
42 244546 CLUTCH INNER DISC. – FORWARD CLUTCH 6
43 24583 END PLATE – FORWARD CLUTCH 1
45 244266 FORWARD CLUTCH DRIVEN GEAR 1
46 244235 2ND GEAR 1

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LOW SHAFT GROUP
1 244709 LOW SHAFT & DRUM ASSEMBLY 1
2 244705 LOW HUB & DRUM ASSEMBLY 1
3 244706 O-RING 1
5 244707 LOW SHAFT 1
6 244708 LOW SHAFT LUBE PLUG 1
7 244692 SEAL, CLUTCH PISTON METERING 1
8 244694 CLUTCH PISTON & SEALS ASSEMBLY 1
11 24057 CLUTCH INNER DISC 9
12 24058 CLUTCH OUTER DISC 9
13 24583 CLUTCH DISC BACKING PLATE 1
15 244697 SPRING, WAVE CLUTCH PISTON RETURN 1
17 244702 BEARING WASHER 1
20 244699 SNAP RING RETAINER 1
21 244701 LOW SPEED GEAR 1
22 244732 ROLLER BEARING 1
23 244523 PISTON RING 1
24 24915 BEARING 1
25 24667 TAPER ROLLER BEARING CUP 1
26 244601 TAPER ROLLER BEARING CONE 1
27 244714 LOW SHAFT BEARING CAP 1
28 24673 CAPSCREW 5

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30 244453 PLUG 1
31 244715 O-RING 1
32 244716 O-RING 1
33 244703 BEARING CUP 1
34 244704 BEARING CONE 1
35 244710 BEARING CAP SHIM - .004 A/R
35A 244711 BEARING CAP SHIM - .007 A/R
35B 244712 BEARING CAP SHIM - .010 A/R
35C 244713 BEARING CAP SHIM - .020 A/R

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IDLER SHAFT GROUP
1 244190 RETAINER RING 1
2 24575 SNAP RING 1
3 24545 BEARING 1
4 465563-12 IDLER SHAFT AND GEAR 45T 1
(NOT AS SHOWN: SHAFT INCLUDES ITEMS 4, 5, 6 AND
IS A ONE PIECE CONSTRUCTION)
7 24997 BEARING 1
8 24697 BALL 1
9 24627 SNAP RING 1
10 244596 LOCK NUT 1
11 24628 IDLER SHAFT BEARING CAP GASKET 1
12 SEE ITEM # 21 1
17 244536 BEARING CAPSCREW LOCKWASHER 2
20 244536 BEARING CAPSCREW LOCKWASHER 2
21 465563-13 REAR BEARING IDLER SHAFT CAP 1
22 244734 REAR BEARING SPACER 1
24 244735 PLUG, IDLER CAP SPEEDO 1

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SHORT DROP OUTPUT SHAFT GROUP
1 244562 OIL SEAL 1
2 24636 FRONT BEARING CAP 1
3 24632 BEARING CAP SHIM (.004) A/R
3A 24633 BEARING CAP SHIM (.007) A/R
3B 24634 BEARING CAP SHIM (.010) A/R
3C 24635 BEARING CAP SHIM (.013) A/R
4 24699 O-RING 1
7 244602 OUTPUT SHAFT SPACER 1
8 244603 OUTPUT SHAFT 1
11 24953 O-RING 1
12 24698 O-RING 1
14 24675 CAPSCREW 4
15 244562 OIL SEAL 1
17 24674 CAPSCREW 4
27 244605 REAR BEARING CAP 1
28 244606 OUTPUT SHAFT GEAR 1

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OUTPUT FLANGE GROUP
1 244565 FRONT OUTPUT END YOKE 1
2 244556 O-RING 1
3 244564 WASHER 1
4 24567 NUT 1
5 244565 REAR OUTPUT END YOKE 1
6 244556 O-RING 1
7 244564 WASHER 1
8 24567 NUT 1

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PRESSURE REGULATOR VALVE & CHARGING PUMP
GROUP
3 244111 V GASKET 1
4 24950 O-RING 1
5 24467 O-RING 1
6 24951 O-RING 1
7 244079 STUD 4
8 244078 VALVE BODY TO PUMP GASKET 1
9 24435 PUMP MOUNTING SCREW LOCKWASHER 4
10 24464 NUT 4
* 9050-10005-021 PRESSURE REGULATING VALVE TO SERVICE VALVE
BODY ASSY
* 9050-10005-022 CHARGING PUMP & FILTER, COMPLETE ASSY

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PRESSURE REGULATING VALVE ASSEMBLY
1 NSS VALVE BODY 1
2 24689 PIPE PLUG 1
3 244091 SAFETY VALVE SEAT 1
4 244092 SAFETY VALVE SPACER 1
5 24534 PRESSURE RELIEF VALVE PLUNGER 1
6 9050-10005-020 HELICAL-SPRING 1
7 24490 O-RING 1
8 244070 SAFETY VALVE SPRING STOP 1
9 244286 ROLL PIN 1
10 244286 ROLL PIN 1
11 24570 VALVE STOP 1
12 24080 O-RING 1
13 244736 PRESSURE REGULATOR VALVE PISTON 1
14 24572 PRESSURE REGULATOR SPRING – INNER 1
15 244109 PRESSURE REGULATOR SPRING – OUTER 1
16 24982 OIL SEAL 1
17 244093 ROLL PIN 3

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CHARGING PUMP AND FILTER
1 465563-14 20 GPM CHARGING PUMP ASSEMBLY 1
2 244192 PUMP TO FILTER ADAPTOR SCREW LOCKWASHER 4
3 244287 PUMP TO ADAPTOR SCREW 4
4 244080 PUMP TO FILTER GASKET 1
5 465563-15 FILTER ADAPTER 1
6 24069 OIL FILTER ELEMENT ASSEMBLY 1
7 244075 FILTER HOUSING 1
8 244074 FILTER ELEMENT SPRING 1
9 244165 FILTER ADAPTOR HOUSING O-RING 1
10 244071 BY-PASS FILTER DISC SPRING 1
11 244072 BY-PASS FILTER DISC 1
12 244073 BY-PASS FILTER SEAL 1
13 24043 FILTER SEAL RETAINING RING 1
14 24462 FILTER ADAPTOR PLUG 1
15 24462 FILTER ADAPTOR PLUG 1
16-23 NSS PART OF ITEM 1 1

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ELECTRIC CONTROL VALVE ASSEMBLY
7 244628 GASKET 1

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8 244167 FITTING, PLUG W/O-RING 1
* 244643 PLUG 1
* 244453 PLUG 1
17 NSS CONTROL VALVE HOUSING ASSEMBLY 1
(INCLUDES ITEMS 8-16, 18-28)
18 244405 O-RING 4
19 244171 O-RING 4
20 244630 O-RING 4
21 244631 O-RING 4
22 NSS VALVE CARTRIDGE – 4 WAY 4
23 244633 O-RING 4
24 NSS SOLENOID COIL – 24V (SEE ITEM 28) 4
25 244635 O-RING 4
26 NSS SOLENOID NUT 4
28 244637 SPOOL TYPE SOLENOID CARTRIDGE ASSEMBLY 4
30-37B N/A NOT USED ON THIS MODEL
38 244639 FITTING PLUG 6
40 244640 CAP SCREW 2
41 244641 CONTROL VALVE COVER ASSEMBLY 1
(INCLUDES ITEM 38)
42* 244642 ELECTRONIC CONTROL VALVE ASSEMBLY 1
(INCLUDES ITEMS 17, 29, 41)

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DRIVE PLATE ASSEMBLY
Page 1 of 1

1 464914 FLEXPLATE KIT 13.5” W/ WELD NUTS 1
2 244062 DRIVE PLATE BACKING RING 1
3 244393 DRIVE PLATE MOUNTING SCREW 10
4 24505 WASHER 10
Updated:
03/30/11
S/N: 020-069
17369
TRANSMISSION MOUNTS
Page 1 of 2
Updated:
11/29/10
S/N: 020-069
17369
TRANSMISSION MOUNTS
Page 2 of 2

1 7055-00002 TRANS MOUNT, FRONT LEFT 1
7055-00010 TRANS MOUNT, FRONT RIGHT 1
2 7055-00006 TRANS MOUNT , REAR LEFT 1
7055-00008 TRANS MOUNT, REAR RIGHT 1
4 27GE12 WASHER, HARDENED 8
04GE08 LOCK WASHER 4
6 17GC09032Z CAPSCREW 4
27GE09 WASHER, HARDENED 4
7 27GE09 WASHER, HARDEDED 4
9 17GD09 NUT 4
10 32290 RUBBER MOUNT 2
11 17503-01 WASHER 2
14 27GE12 WASHER, HARDENED 2
Updated:
11/29/10
S/N: 020-069
17331
TRANSMISSION DIPSTICK
Page 1 of 1
TOTAL LENGTH, REF PART NUMBER
ITEM PART # DESCRIPTION QTY./

VEHICLE
-- 10469-01 USED ON TOW TRACTORS 200/220 (17.88 INCHES) 1
-- 12352-03 USED ON A-64 WITH 32K TRANSMISSION (49.5 INCHES) 1
-- 26362-06 USED ON A-64 WITH 20K TRANSMISSION (49.5 INCHES) 1
-- 26362-07 USED ON RDG1504 ROAD BUILDER 1
WITH FUNK TRANSMISSION (49.19 INCHES)
-- 16443 USED ON 1248 REMIXERS, SCALERS, 1
AND OLD A-64 WITH 28K TRANSMISSION (24.5 INCHES)
Updated:
03/04/11
S/N: 020-069
17493
DRIVELINE INSTALLATION
Page 1 of 1

1 9081-00008 END YOKE (STD.) 1
2 SEE TRANSMISSION OUTPUT FLANGE/ END YOKE BRAKE (REAR) 1
PARTS PAGE
3 SEE TRANSMISSION OUTPUT FLANGE/ END YOKE (FRONT) 1
PARTS PAGE
4 9081-00008 END YOKE 1
5 364024 CROSS AND BEARING KIT 4
6 7061-00017 DRIVELINE ASSEMBLY (INCLUDES ITEM 7) 1
7 362120 CENTER BEARING 1
8 464640 SLIP ASSEMBLY (INCLUDES 2X OF ITEM 5) 1
9 19200-46 DRIVELINE ASSEMBLY 1
10 364023 CROSS AND BEARING KIT 1
Updated:
06/13/12
S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
6. AXLE
S1165 AXLE SERVICE & REPAIR MANUAL

17467 AXLE ASSEMBLY
17461 CRADLE INSTALLATION
17475 TIRE & RIM
S/N: 020-069
S1165
MANUALE DI RIPARAZIONE
REPAIR MANUAL
ASSALE ANTERIORE - FRONT AXLE

Mod. 28.43M FR
Rif. CA409436
1a Edizione - 1s t Edition: 02/2012 Doc. CA270263

AB10563
S/N: 020-069
S1165
Si prega di pensare all'ambiente prima di stampare questo documento.

Stampare solo il necessario e riciclare la carta dopo l’uso.
Please consider the environment before printing this document.

Print only the necessary pages and recycle the paper after use.
S/N: 020-069
S1165
Mod. 28.43M FR
Indice Index
INFORMAZIONI SULLA SICUREZZA . . . . 3 SAFETY INSTRUCTIONS . . . . . . . . . . . . 3

Indicazioni generali per la sicurezza . . . . . . . . . . 4 General safety recommendations . . . . . . . . . . . 4
Informazioni per la sicurezza . . . . . . . . . . . . . . . 5 Safety information . . . . . . . . . . . . . . . . . . . . . . . 5
Precauzioni generali . . . . . . . . . . . . . . . . . . . . . . 8 General precautions . . . . . . . . . . . . . . . . . . . . . . 8
INFORMAZIONI GENERALI . . . . . . . . . . 17 GENERAL INFORMATION . . . . . . . . . . 17

Utilizzo del manuale . . . . . . . . . . . . . . . . . . . . . 18 Manual use . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Proprietà delle informazioni . . . . . . . . . . . . . . . 19 Information property . . . . . . . . . . . . . . . . . . . . . 19
Convenzioni e definizioni . . . . . . . . . . . . . . . . . 20 Agreements and definitions . . . . . . . . . . . . . . . 20
Indicazioni generali . . . . . . . . . . . . . . . . . . . . . . 24 General description . . . . . . . . . . . . . . . . . . . . . 24
Indicazioni speciali . . . . . . . . . . . . . . . . . . . . . . 25 Special recommendations . . . . . . . . . . . . . . . . 25
CARATTERISTICHE GENERALI . . . . . . 31 GENERAL SPECIFICATIONS . . . . . . . . 31

Uso previsto . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Identificazione del prodotto . . . . . . . . . . . . . . . . 32 Product identification . . . . . . . . . . . . . . . . . . . . 32
Descrizione gruppi assale . . . . . . . . . . . . . . . . . 33 Axle groups description . . . . . . . . . . . . . . . . . . 33
Caratteristiche Tecniche . . . . . . . . . . . . . . . . . . 34 Technical Features . . . . . . . . . . . . . . . . . . . . . 34
Manutenzione e cambio olio . . . . . . . . . . . . . . . 36 Maintenance and oil change . . . . . . . . . . . . . . 36
Grasso al montaggio . . . . . . . . . . . . . . . . . . . . . 40 Grease in assembly . . . . . . . . . . . . . . . . . . . . . 40
Adesivi e coppie di serraggio . . . . . . . . . . . . . . 42 Adhesives and tightening torques . . . . . . . . . . 42
Freni . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SMONTAGGIO E ASSEMBLAGGIO . . . . 49 DISASSEMBLY AND ASSEMBLY . . . . . 49

Gruppo riduttore epicicloidale . . . . . . . . . . . . . . 50 Epicyclic reduction gear group . . . . . . . . . . . . . 50
Gruppo mozzo ruota . . . . . . . . . . . . . . . . . . . . . 55 Wheel hub group . . . . . . . . . . . . . . . . . . . . . . . 55
Gruppo tromba trave . . . . . . . . . . . . . . . . . . . . . 61 Axle beam trumpet group . . . . . . . . . . . . . . . . . 61
Gruppo freno . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Brake group . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Gruppo flangia . . . . . . . . . . . . . . . . . . . . . . . . . 82 Flange group . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Gruppo supporto differenziale . . . . . . . . . . . . . . 84 Differential support group . . . . . . . . . . . . . . . . . 84
Gruppo differenziale . . . . . . . . . . . . . . . . . . . . . 94 Differential group . . . . . . . . . . . . . . . . . . . . . . . 94
Gruppo pignone . . . . . . . . . . . . . . . . . . . . . . . . 97 Pinion group . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Interventi speciali . . . . . . . . . . . . . . . . . . . . . . 106 Special repair operations . . . . . . . . . . . . . . . . 106
Prove dopo montaggio . . . . . . . . . . . . . . . . . . 109 Testing after assembly . . . . . . . . . . . . . . . . . . 109
RICERCA GUASTI . . . . . . . . . . . . . . . . 111 TROUBLESHOOTING . . . . . . . . . . . . . 111

Controllo ed esame dei guasti . . . . . . . . . . . . 114 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 116
Diagnosi per problemi all'assale . . . . . . . . . . . 118 Axle problem and diagnosis . . . . . . . . . . . . . . 119
ATTREZZATURE SPECIALI . . . . . . . . . 121 SPECIAL TOOLS . . . . . . . . . . . . . . . . . 121

Attrezzature speciali . . . . . . . . . . . . . . . . . . . . 122 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . 122
AB10563 REVISION DATE: 02/12 DOC. CA270263 PAG. 1
S/N: 020-069
S1165
Mod. 28.43M FR
Notes
PAG. 2 REVISION DATE: 02/12 DOC. CA270263 AB10563
S/N: 020-069
S1165
INFORMAZIONI SULLA SICUREZZA
Mod. 28.43M FR SAFETY INSTRUCTIONS
A INFORMAZIONI SULLA
SICUREZZA
A SAFETY INSTRUCTIONS
AB10563 REVISION DATE: 02/12 DOC. CA270263 A PAG. 3
S/N: 020-069
S1165
INDICAZIONI GENERALI PER LA SICUREZZA
GENERAL SAFETY RECOMMENDATIONS Mod. 28.43M FR
A.1 Indicazioni generali per la A.1 General safety

sicurezza recommendations
AVVERTENZA prima di iniziare qualsiasi W A R N I N G before proceeding with any

tipo di operazione leggere attentamente questo operations please read this chapter very carefully.
capitolo.
Fig. 1
Fig. 2
Assicurati di aver letto e compreso tutto il manuale di Make sure to read and comprehend all the
manutenzione (ordinaria e straordinaria) prima di maintenance manual (ordinary and extraordinary)
intervenire sul prodotto. before start the repair operations.
Seguire scrupolosamente TUTTE le istruzioni nel Follow with care ALL the instructions in this document,
seguente documento, è vietato utilizzare scorciatoie it is forbidden to use simplified procedure to curtail the
per abbreviare i tempi di lavoro. working time.
Precauzioni per la sicurezza: Safety precautions:

Il corretto uso e la corretta riparazione dei prodotti Correct use and repair of CARRARO DRIVE TECH
CARRARO DRIVE TECH e dei loro componenti sono products and of their components is very important for
molto importanti per la sicurezza e l'affidabilità. safety and reliability.
Le procedure raccomandate e descritte in questo Recommendations and all described procedures given
manuale sono testate, quindi sono effettivi metodi in this manual have been experimented and hence are
operativi. Seguire strettamente ogni procedura facendo effective operational methods. Please follow every
uso sia del testo che delle illustrazioni. procedure. Use the text as well as the illustrations.
Alcune di queste procedure mostrano l'uso di appositi Certain procedures show use of special tools, designed
strumenti progettati perché le operazioni vengano so that the operations can be carried out in a clear and
condotte in modo chiaro e corretto. correct manner.
Alcuni strumenti specifici devono essere usati dove Special tools must be used when a particular operation
necessario per eseguire determinate operazioni. is being carried out.
E' impossibile trattare ogni metodo di lavoro o tutte le It is impossible to advise every working method or know
possibili metodologie per svolgerlo e le rischiose all possible methodologies for carrying it out or to
conseguenze di ognuna, perciò chi usa procedure o predict risky consequences of each operation. Hence,
strumenti non consigliati deve sapere che la sicurezza performing procedures or using instruments which
dell'operatore e del veicolo saranno messi a have not been advised could be dangerous for the
repentaglio. operator/mechanic as well as the vehicle.
Seguire TUTTE le istruzioni di sicurezza! Follow ALL safety instructions!

Seguite i suggerimenti e le raccomandazioni per Follow the DO’s and DON’T’s to operate in total safety.
operare in sicurezza. Unauthorized changes could endanger the functioning,
Modifiche non autorizzate possono compromettere il work safety and machine lifespan.
funzionamento, la sicurezza d'impiego e la durata della If you do not understand any instruction in this manual,
macchina. contact the nearest Carraro DriveTech agent.
Se non comprendete qualche istruzione in questo
manuale, contattate il rappresentante Carraro
DriveTech a voi più vicino.
A.1 PAG. 4 REVISION DATE: 02/12 DOC. CA270263 AB10563
S/N: 020-069
S1165
INFORMAZIONI PER LA SICUREZZA
Mod. 28.43M FR SAFETY INFORMATION
A.2 Informazioni per la sicurezza A.2 Safety information
Normativa di riferimento Reference safety standards

Le informazioni per la sicurezza presenti in questo The safety information in this manual follows the
manuale seguono le direttive contenute nelle norme recommendations of the main guidelines for the
ISO (Organizzazione Internazionale per la security ISO (International Standards Organization)
Standardizzazione) e ANSI (Istituto Nazionale and ANSI (American National Standards Institute),
Americano per gli Standard), in particolare: especially:
- ISO 3864-2 [2004] - ISO 3864-2 [2004]
- ANSI Z535.6 [2006] - ANSI Z535.6 [2006]
- ANSI Z535.3 (quando si utilizzano rappresentazioni - ANSI Z535.3 (for graphic representation intended to
grafiche senza parole come avvisi di sicurezza) convey a safety message without the use of words)
- ANSI Z535.4 (dove si richiamano simboli e/o etichette - ANSI Z535.4 (to explain the symbols and/or labels
presenti sulle macchine) applied to equipment)
Identificazione delle informazioni sulla sicurezza Recognize safety information

Le informazioni sulla sicurezza sono costituite da tre The safety information is composed of three main
elementi principali: elements:
1) simbolo di allarme 1) safety alert symbol
2) termine di segnalazione 2) signal word
3) messaggio di sicurezza 3) safety messages
il simbolo di allarme per la sicurezza è semplicemente The safety alert symbol is simply an exclamation mark
un punto esclamativo (!) all’interno di un triangolo. (!) inside of a triangle.
Nelle seguenti figure è rappresentato secondo la This symbol is represented in the following figures as
normativa ISO 3864 (Fig. 3) e secondo ANSI Z535.6 comply the ISO 3864 standard (Fig. 3) and the ANSI
(Fig. 4); in questo manuale le due rappresentazioni Z535.6 standard (Fig. 4); in this manual the two graphic
sono equivalenti. representation have the same significance.
Quando trovate questo segnale sulla macchina o sul Whenever you find it in the manual or see it on the
manuale, siete avvisati del pericolo potenziale di machine, you are being warned about potential danger
incidenti o danni alla persona. of accidents or harm to personnel.
Fig. 3
Fig. 4
Il termine di segnalazione è una parola chiave The safety signal word is a key word (DANGER,
(PERICOLO, AVVERTENZA, ATTENZIONE, AVVISO) WARNING, CAUTION, NOTICE) and it’s used with the
utilizzata insieme al simbolo di allarme in presenza di symbol for the security alert whenever there is a risk to
rischio per le persone e richiama l’attenzione sul people. This word calls attention to a safety message
messaggio (o messaggi) di sicurezza seguente o su (or messages) or a property damage message (or
possibili danni materiali ed assegna un livello o classe messages) and designates a degree or level of hazard
di pericolo al rischio che si corre. seriousness.
Nota: può essere utilizzato senza simbolo di allarme Note: can be used without safety alarm symbol where
per identificare la possibilità di soli danni materiali. alerts you if only damage materials is possible.
Vedi: tab. 1 e tab. 2 alla pagina seguente per una chiara See: tab.1 and tab. 2 in the next page to fully
comprensione dei termini segnaletici. understanding signal words.
AB10563 REVISION DATE: 02/12 DOC. CA270263 A.2 PAG. 5
S/N: 020-069
S1165
SAFETY INFORMATION Mod. 28.43M FR
Il messaggio di sicurezza segue il termine segnaletico Safety message is a word message that provides
e contiene le seguenti informazioni primarie: information primarily about:
- il tipo e l’origine del pericolo - the nature of hazardous situation
- le conseguenze possibili - the consequences if the hazard is not avoided
- i comportamenti necessari ad eliminare o ridurre il - methods for avoiding a hazardous situation (for
rischio (per esempio: indossare un’adatto Dispositivo di example: wear suitable Personal Protective Equipment,
Protezione Individuale, DPI). PPE)
Il messaggio di sicurezza può anche indirizzare il lettore The safety message can direct readers to such
al luogo dove tali informazioni sono esposte. information.
Il testo del messaggio di sicurezza può essere Safety symbols and other graphics may be used to
completato o sostituito del tutto o in parte da supplement or substitute for part or all of a word
rappresentazioni grafiche esplicative. message.
A.2.1 Significato dei termini segnaletici A.2.2 Understanding signal words

Ogni termine segnaletico definisce la classe di Each signal word defines the class of danger according
pericolosità secondo la normativa ANSI Z535.6-2006 to ANSI Z535.6-2006 as specified in the table below.
come specificato nella tabella seguente. Note: the signal words are arranged in descending
Nota: i termini sono disposti in ordine di pericolosità order of danger.
decrescente.
Tab. 1 Termini segnaletici/Livello di rischio Tab.1 Signal words/Hazard level
Gravi danni a persone

P ERICOLO Serious personal injury
max max
DANGER
Livello di rischio
AV VERTENZA
Hazard level
Possibili gravi danni a persone Possible serious personal injury

WARNING
Possibili danni moderati a persone
ATTENZIONE Possible moderate personal injury
CAUTION
Possibili danni materiali min AVV IS O min Possible product damages
NOTICE
Tab. 2 Significato dei termini segnaletici Tab. 2 Meaning of signal words

Segnala una situazione di pericolo che, se Indicates a hazardous situation which, if not
non evitata, comporta morte o gravi lesioni P ERICOLO avoided, will result in death or serious injury.
fisiche. L’utilizzo di questo termine è limitato DANGER This signal word is to be limited to the most
alle situazioni di estremo pericolo. extreme situations.
Segnala una situazione di pericolo che, se
non evitata, può comportare morte o gravi
AV VERTENZA Indicates a hazardous situation which, if not
lesioni fisiche. WARNING avoided, could result in death or serious injury.
Segnala una situazione di pericolo che, se Indicates a hazardous situation which, if not
non evitata, può comportare da leggere
A T T E N Z I O N E avoided, could result in minor or moderate
lesioni fisiche a lesioni medio-gravi. (*) CAUTION injury. (*)
Segnala una situazione di pericolo che non Is the preferred signal word to address
comporta danni alle persone ma solo danni AVV IS O practices not related to personal injury.
materiali per il prodotto o per l’ambiente. Può NOTICE The safety alert symbol shall not be used with
essere utilizzato senza il simbolo di allarme. this signal word.
(*) Secondo ANSI Z535.6-2006 è possibile utilizzare (*) Comply the ANSI Z535.6-2006 the signal word
ATTENZIONE senza il segnale di allarme al posto di CAUTION may also be used without the safety alert
AVVISO; per maggiore chiarezza questa convenzione symbol as an alternative to NOTICE; this is not applied in
non viene utilizzata in questo manuale. this manual to avoid confusion.
S/N: 020-069
S1165
Mod. 28.43M FR SAFETY INFORMATION
A.2.3 Esempi applicativi A.2.4 Application examples

Nel seguito sono illustrate delle tipiche applicazioni Some typical applications of safety information that you
delle informazioni di sicurezza che è possibile trovare can find in this manual are explained in the following
in questo manuale. figure.
Nota: nel caso in cui vengano dati in gruppo una serie Note: where grouped safety messages are listed, one
di messaggi di sicurezza, un solo simbolo di sicurezza symbol is used before the group/section of these
viene utilizzato prima di tale gruppo o della relativa messages according to ANSI Z535.6.
sezione, in accordo con quanto specificato dalla
normativa ANSI Z535.6.
S/N: 020-069
S1165
PRECAUZIONI GENERALI
GENERAL PRECAUTIONS Mod. 28.43M FR
A.3 Precauzioni generali A.3 General precautions
In ogni movimento dovranno essere osservate le norme Observe safety instructions, accident prevention rules
sulla prevenzione infortuni, tutte le regole generali di and all general safety regulations in each and every
sicurezza e di medicina del lavoro. step at work.
Prima di procedere nelle operazioni di manutenzione o Before going ahead with maintenance or repair work
sistemazione di eventuali problemi, assicurarsi del ensure that all the tools, the supporting bench, stands,
buon stato e del buon funzionamento delle attrezzature levers, extractors and spanners are in good condition
quali banchi di sostegno, cavalletti, martelli, leve, so that the work can be carried out easily.
estrattori e chiavi apposite facilitando le operazioni da Risks to various parts and components will also be
svolgere in modo ottimale riducendo i rischi sia per gli reduced in this way and working condition for the
organi ed i componenti del prodotto che della incolumità operator will also be safer.
dell'operatore. CARRARO DRIVE TECH SpA declines any
Tutte le modifiche arbitrarie apportate al prodotto responsibility in case of an accident or damage
sollevano la CARRARO DRIVE TECH SpA da ogni resulting due to changes made arbitrarily on product.
responsabilità per qualsiasi danno o incidente. The product is used for any other purpose different from
Il prodotto, se utilizzato in un impiego diverso da quello the one foreseen, than CARRARO DRIVE TECH SpA
previsto, è da considerarsi soggetto a "uso non declines any responsibility.
previsto". CARRARO DRIVE TECH SpA declina ogni In this case all consequences will be at the customer’s
responsabilità per danni o incidenti risultanti da un uso expense.
diverso da quello previsto; tali conseguenze saranno a
carico esclusivo del cliente.
AT TENZIONE CAUT ION

Durante la manutenzione e riparazione: During the maintenance and repair operations make
sure that
• l’assale deve sempre essere controllato e
sorvegliato da personale autorizzato • the axle must always checked and overseen by
authorized staff
• in caso di manomissione delle parti costituenti
l’assale, verificarne il corretto funzionamento e • in case of axle parts tampering, verify the correct
provvedere al ripristino, quando necessario working of the axle and replace them, if necessary
• ogni modifica ai segnali di sicurezza e/o • every modification of the safety signs and/or
decalcomanie deve sempre essere concordato transfers and their relative tamper must be always
preventivamente con il costruttore previously agreed with the manufacturer
AVVISO NOT ICE

• durante le lubrificazioni e ingrassaggi non • during the lubricating and greasing operations, do
confondere i tempi di manutenzione ordinaria; not confuse the ordinary maintenance times; during
durante la fase di serraggio non confondere le the tightening operations do not confuse the
rispettive coppie di serraggio tightening torques
• durante l’utilizzo dell’assale tappi, sfiati, viteria e • during the axle use plugs, breathers, screws and
relativo serraggio devono essere concordi a quanto tightening torques must be in agreement with the
prescritto regulation
PE RICOLO DANGER
• non utilizzare prodotti infiammabili come etere • do not use inflammable products like ether, oil or
petrolio o benzina rettificata per la pulizia delle parti gasoline for the parts cleaning when the parts are at
quando le stesse sono a temperature elevate o sotto elevated temperature or under the sun rays
l’esposizione di raggi solari: potrebbero essere exposure: it may causes fire
causa d’incendio
• deep impacts may damage the axle mechanical-
• urti violenti potrebbero danneggiare i componenti magnetic-electrical parts
meccanici-magnetici-elettrici dell’assale
• do not smoke-drink-eat during the assembly-
• non fumare-bere-mangiare durante le operazioni di disassembly-maintenance operations to avoid a
disassemblaggio-assemblaggio-manutenzione: possible contamination of the mechanical parts
sono possibili eventuali contaminazioni agli organi
meccanici.
S/N: 020-069
S1165
Mod. 28.43M FR GENERAL PRECAUTIONS
Norme per la manutenzione in sicurezza Safety maintenance rules

1 Operare sempre in ambiente pulito e asciutto. 1 Operate always in a clean and dry environment.
2 Pulire con cura l’ambiente di lavoro e la macchina 2 Clean carefully the working environment and the
su cui si opera sia prima che durante la machine before carry out the maintenance
manutenzione (Fig. 5). operations (Fig. 5).
3 Utilizzare solo prodotti di pulizia conformi alle 3 Use only cleaning product in agreement with the
specifiche di legge vigenti e sempre nelle modalità regulations and always use them in the prescribed
indicate dalle istruzioni d’uso del produttore. way.
4 Non inalare sostanze chimiche in concentrazioni 4 Do not inhale chemical substances in dangerous
pericolose per la salute (Fig. 6); ventilare gli concentration for the health care (Fig. 6); ventilate
ambienti in cui si utilizzano solventi con componenti the environments in which sprays and solvents,
chimici volatili o spray. with volatile chemical substances, are used.
Fig. 5
Fig. 6
5 Usare indumenti e protezioni adatte allo scopo 5 Wear suitable clothing and protection such as
come: tuta, guanti protettivi e cuffie (Fig. 7). overalls, gloves and ear safety devices (Fig. 7).
AVV ERTE NZA WARNING
Gli occhiali di sicurezza devono essere indossati Safety goggles must always be worn while carrying
sempre durante l’esecuzione di tutte le operazioni di out every assembling or disassembling operations
montaggio o smontaggio (Fig. 8). (Fig. 8).
Fig. 7
Fig. 8
6 Usare protezioni auricolari appropriate a 6 Use suitable ear protection, like ear plugs, to keep
salvaguardare l'udito, come tappi o cuffie per le out noise and prevent injury to the ears.
orecchie contro rumori molesti o fastidiosi. Una A prolonged exposure to noise can damage your
prolungata esposizione al rumore può danneggiare hearing.
l'udito 7 The operator must be very careful with the
7 Le attrezzature richiedono la piena attenzione equipment. Do not use headphones to listen music
dell'operatore. Non usare cuffie per ascoltare while you are working on the product or on the
musica mentre si interviene sul prodotto o gruppo. group.
S/N: 020-069
S1165
8 Non indossare sciarpe, cravatte o altri indumenti 8 Do not wear slings, ties or other pending clothes.
pendenti. Assicurare i capelli lunghi dietro la testa e/ Tie long hair behind the head and/or wear a
o indossare una cuffia protettiva. protective cap.
9 Non indossare anelli, bracciali, collane o altri 9 Do not wear rings, armlets, necklaces or other
oggetti metallici che sono molto pericolosi in metal objects that are dangerous when current is
presenza di corrente elettrica. present.
10 Predisporre sempre le dotazioni di pronto 10 Predispose always the first aid equipment in
intervento previste dalla normativa di sicurezza per agreement with the working environments
gli ambienti di lavoro, come la cassetta di pronto regulations, like the first aid kit (Fig. 9).
soccorso (Fig. 9). 11 Keep the phone numbers of a doctor, an
11 Tenere in evidenza il n° telefonico di medico, ambulance, a hospital and the fire department
ambulanza, ospedale e vigili del fuoco presso il within reach near the telephone set (Fig. 10).
proprio telefono (Fig. 10). In case of accident it is indispensable to quickly ask
In caso d’infortunio è indispensabile richiedere for a medical intervention.
rapidamente l’intervento del medico.
Fig. 9
Fig. 10
12 Tenere lontani mani, piedi, indumenti dalle parti in 12 Keep your hands, feet and clothing away from
movimento delle attrezzature. moving parts of the tool machines.
Rimanere a distanza di sicurezza dalla macchina se Keep the safety distance from the machine, if it is
in movimento, come durante le operazioni di moving, like during the testing operations (Fig. 11).
collaudo (Fig. 11). 13 Light properly the working area by using devices in
13 Illuminare adeguatamente l’area di lavoro con agreement with the safety regulations (Fig. 12).
strumenti che rispettino la normativa di sicurezza
(Fig. 12).
Fig. 11
Fig. 12
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14 Durante le operazioni di manutenzione è 14 During the maintenance operations it is strictly

assolutamente vietato accendere fiamme libere forbidden to light free flames (Fig. 13) and smoking
(Fig. 13) e fumare (Fig. 14). (Fig. 14).
Fig. 13
Fig. 14
15 Essere sempre pronti per bloccare eventuali 15 Always be prepared for fires. Keep the extinguisher
principi di incendio. Prima di iniziare qualsiasi within reach. Before start any maintenance
operazione individuare con certezza la posizione operation identify the extinguisher nearest to the
dell’estintore più vicino all’area di lavoro e delle working area and the prescribed fire regulations
dotazioni antincendio prescritte (Fig. 15). (Fig. 15).
Fig. 15
Fig. 16
16 L’ambiente di lavoro deve sempre essere ben 16 The working environment must be always well
aerato con i sistemi previsti dalla normativa relativa aired by using devices in agreement with the safety
agli ambienti di lavoro. regulations.
Se non sono presenti condotti di aerazione, aprire le If local vents are not present, open doors the
porte e finestre dell’area di lavoro. windows in the working area.
Evitare di respirare polvere e fumi, dato che Do not inhale dust and fumes, they can cause
possono causare malattie e portare alla morte. Non sickness or death. Do not inhale toxic substances
inalare sostanze potenzialmente tossiche used during the product maintenance. If necessary
necessarie alla manutenzione del prodotto. Se use a certified respirator.
necessario utilizzare un respiratore certificato. All the CARRARO DRIVE TECH SpA products are
Tutti i prodotti CARRARO DRIVE TECH SpA in agreement with the Italian legislation and with
soddisfano i requisiti imposti dalla legislazione the European Community technical requirements.
Italiani e dalla Comunità Europea.
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A.3.1 Eliminazione dei rischi residui A.3.2 Residual risks elimination

Si raccomanda di seguire scrupolosamente le seguenti It is recommended to follow with care the following
indicazioni generali, che sono molto importanti per general indications, that are important to prevent
evitare danni a persone e cose. damages to persons and things.
PE RICOLO DANGER
Rischio di schiacciamento e cesoiamento dovuto alla Risk of squashing and shearing due to the presence
presenza di elementi in movimento. of moving parts.
Fig. 17
Fig. 18
AV VERTENZA
Eseguire tutte le operazioni di manutenzione a WARNING
macchina ferma. Non lubrificare, manipolare o Carry out all maintenance operations when the
registrare il gruppo con parti meccaniche in machine is stationary. Do not lubricate, handle or
movimento. adjust the group with mechanical parts in movement.
Fig. 19
Fig. 20
PE RICOLO DANGER
Rischio di schiacciamento dovuto al movimento di Squashing risk due to the machines or devices
macchinari o attrezzature nell’area di lavoro. movement in the working area.
• Questi rischi residui e le procedure per eliminarli • These residual risks and the procedure to eliminate
completamente, sono evidenziati dettagliatamente them completely, are described in detail in the
nelle procedure di montaggio e smontaggio. Seguire assembly/disassembly procedures. During the
attentamente, durante la manutenzione, tutte le maintenance operations, follow carefully all the
procedure di sicurezza indicate nel manuale. security procedure indicated on the repair manual.
AV VERTENZA WARNING
Non operare con attrezzature difettose o non adatte Do not carry out any operation by using faulty or not
all’intervento da eseguire. suitable tools.
• Predisporre sempre attrezzi ed utensili • Always predispose the tools and the devices on a
ordinatamente su un adatto banco di lavoro. suitable workbench, in an orderly way.
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• Non utilizzare come piani d’appoggio superfici che • Do not use unstable shelves or not flat surfaces as
non siano piane o ben stabili. workbench.
• Il gruppo su cui si opera e gli attrezzi che si utilizzano • The serviced group and used tools must be always
devono sempre essere disposti in posizione stabile, arranged in a stable position, in order to avoid all the
evitare tutte le situazioni di equilibrio incerto. unstable equilibrium situations.
PERICOLO DANGE R
Rischio dovuto alla violenta espulsione di oggetti dalla Risk due to violent ejection of objects from the
macchina. machine
• Questi rischi residui e le procedure per eliminarli
completamente, sono evidenziati dettagliatamente • These residual risks and the suitable relative
nelle procedure di montaggio e smontaggio. Seguire procedures to eliminate them completely are
attentamente, durante la manutenzione, tutte le pointed out, in detail, in the assembly and
procedure di sicurezza indicate nel manuale. disassembly procedures. During maintenance,
follow carefully all the safety procedures indicated in
the manual.
Fig. 21
Fig. 22
PERICOLO DANGE R
Rischio dovuto alla caduta o allo sganciamento di Risk due to falling loads or unhooked objects.
oggetti.
Fig. 23
Fig. 24
• Questi rischi residui e le procedure per eliminarli • These residual risks and the procedure to eliminate
completamente, sono evidenziati dettagliatamente them completely, are described in detail in the
nelle procedure di montaggio e smontaggio. Seguire assembly/disassembly procedures. During the
attentamente, durante la manutenzione, tutte le maintenance operations, follow carefully all the
procedure di sicurezza indicate nel manuale. security procedure indicated on the repair manual.
• Prima di ogni operazione assicurare le parti pesanti • Before every operation secure all the heavy parts by
con adeguati sistemi di supporto, in modo da evitare using suitable supporting devices, in order to avoid
cadute accidentali e movimenti improvvisi. casual falls and unexpected moves.
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• Se il gruppo è sostenuto solamente da funi sospese, • If the group is only supported by hanging ropes, do
non lavorare sotto il carico sospeso. not work under the pending load.
• Utilizzare sistemi di sollevamento a norma di legge, • The used lifting devices must be in agreement with
in perfette condizioni, verificati e correttamente the current regulations, in perfect conditions, verified
manutenzionati. and correctly serviced.
PE RICOLO DANGER
Rischio dovuto all’inalazione di gas nocivi che si Risk due to inhalation of poison gases that can be
possono sviluppare scaldando le vernici durante produced by heating the varnishes during any
eventuali saldature. welding.
• Utilizzare postazioni di lavoro dotate di sistemi di • Use work stations equipped with dust and fume
evacuazione di polveri e fumi. discharging systems.
• Prima di saldare o riscaldare, rimuovere la vernice • Before welding or heating a part, remove the paint,
se presente. if present.
• Non usare spray o altri prodotti infiammabili vicino • Do not use sprays or other inflammable substances
alla zona dove si sta saldando o in prossimità di fonti near the welding area or near heat sources.
di calore.
Fig. 25
Fig. 26

Rischio dovuto all’inquinamento da sostanze Risk due to the pollution by dangerous substances.
pericolose. Lubrificanti esausti e prodotti residui delle Exhausted lubricant and the residual products of the
operazioni di pulizia e verniciatura sono considerati cleaning/painting operations are considerate special
rifiuti speciali waste.
• Utilizzare gli appositi contenitori per la raccolta dei • During the CARRARO DRIVE TECH SpA products
rifiuti liquidi e solidi durante la manutenzione dei maintenance operations, use the proper container
prodotti CARRARO DRIVE TECH SpA. for the liquid and for the solid waste raising.
Smaltire i rifiuti liquidi e solidi raccolti secondo le Dispose all liquid and solid waste in agreement with
normative vigenti nell’ambiente di lavoro in cui si the current working environment regulations.
opera.
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PERICOLO DANGE R
Rischio di incendio e scoppio dovuto ai solventi Risk of fire and explosion due to the solvents used
utilizzati e all’olio presente. and to the oil in the machine.
Fig. 27
Fig. 28
• Tenere lontano dalla zona di lavoro ogni fonte di • Keep away any heat sources from the working area.
calore.
• When solvents or paint removers are used, they
• Quando si usano solventi o svernicianti, rimuoverli should be removed with soap and water, before
con acqua e sapone prima di saldare. welding.
• Rimuovere i contenitori di solvente, sverniciante o • Remove any containers of solvent, paint remover or
altri prodotti infiammabili dall'area di lavoro. any other inflammable products from the working
area.
AVV ERTE NZA WARNING

Rischio di ustione dovuto alla presenza di elementi Burn risk due to elevated temperature of liquid or solid
solidi o fluidi ad elevata temperatura. elements.
Fig. 29
Fig. 30
• Indossare le protezioni individuali di sicurezza, a • Wear the personal protective clothes, in agreement
norma di legge, adeguate al tipo di operazione da with the current regulations, adequate to the type of
mettere in pratica. operation carried out.
• Verificare il corretto serraggio di tappi e connessioni • Verify the plugs and connectors correct tightening
prima di avviare la macchina o mettere i circuiti in before start up the machine or before give pressure
pressione to the circuits.
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AV VERTENZA WARNING
Rischio dovuto all’espulsione di fluidi caldi o in Risk due to boiling fluids ejection or pressured fluids
pressione. ejection
• Indossare le protezioni individuali di sicurezza a • Wear the personal protective clothes, in agreement
norma di legge. with the current regulations
Fig. 31
Fig. 32
• Evitare la ricerca di eventuali perdite di fluido da • Do not search possible liquid loss on pressured
condotti in pressione con le mani o altre parti del pipes by using hands or others body parts (Fig. 33),
corpo (Fig. 32), utilizzare le attrezzature preposte o use the prescribed devices or not inflammable
comunque elementi non infiammabili (Fig. 33). elements (Fig. 33).
Fig. 33
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INFORMAZIONI GENERALI
Mod. 28.43M FR GENERAL INFORMATION
B INFORMAZIONI GENERALI
B GENERAL INFORMATION
AB10563 REVISION DATE: 02/12 DOC. CA270263 B PAG. 17
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UTILIZZO DEL MANUALE
MANUAL USE Mod. 28.43M FR
B.1 Utilizzo del manuale B.1 Manual use

Destinatari End users
• Installatore • Installer
• Riparatore specializzato • Qualified technician
• Manutentore • Maintenance operator
Manutenzione e riparazione Maintenance and repair

PRENDERE VISIONE DI TUTTO IL MANUALE poiché CONSULT THIS MANUAL THOROUGHLY, as proper
il buon funzionamento ed il rendimento degli organi functioning and good efficiency of mechanical organs
meccanici dipendono principalmente da una costante e depends mostly on constant and correct routine
corretta manutenzione e assicurano la durata e maintenance ensuring product integrity and expected
l'integrità del prodotto. life duration.
Nell'eventualità di guasti od anomalie il tempestivo In case of any damages or anomalies, quick

intervento da parte di personale autorizzato da Carraro intervention of trained and highly qualified operators
Drive Tech SpA (in possesso dell’attestato di idoneità) authorized (with certificate) by Carraro Drive Tech SpA
garantisce una durata più lunga del prodotto, evitando ensure the longest life of product and avoid future
danni maggiori nel tempo provocati da una riparazione impairment caused by not authorized repairing.
non autorizzata. Important: Carraro warranty does not cover every
Importante: la garanzia non risponde di eventuali injury to personnel and damage to product caused by
danni provocati a persone o cose causati da riparazioni maintenance operations of not authorized personnel
effettuate da personale non autorizzato e/o non and/or by operations not in compliance with Carraro
conformi alle specifiche e avvertenze Carraro, safety regulations and prescribed procedures.
riguardanti la sicurezza e le procedure di manutenzione
contenute in tutte le sezioni del manuale
Le procedure per lo smontaggio/montaggio consentono The disassembly/assembly procedures have been

di eseguire la revisione totale del prodotto e sono outlined for a total product overhauling. They have also
descritte in sequenza con l’ausilio di illustrazioni, per been described in sequence through photographs with
una guida completa e sicura all’esecuzione di ogni relevant explanation for specific interventions, thus
operazione. obtaining a complete and safe guide for each and every
phase of an operation.
Nella descrizione delle operazioni si presuppone che Operation description presumes that the axle has
l’assale sia stato rimosso dal veicolo. Per la rimozione already been removed from the vehicle. To remove the
dell’assale dal veicolo consultare il manuale del axle from the vehicle refer to manual provided from
costruttore del veicolo. vehicle manufacturer.
B.1 PAG. 18 REVISION DATE: 02/12 DOC. CA270263 AB10563
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PROPRIETÀ DELLE INFORMAZIONI
Mod. 28.43M FR INFORMATION PROPERTY
B.2 Proprietà delle informazioni B.2 Information property

Questo manuale contiene informazioni di proprietà This manual should be considered confidential
riservata. Tutti i diritti sono riservati. informations. All rights reserved.
Questo manuale non può essere riprodotto o No part of this manual may be reproduced, in any form
fotocopiato, tutto o in parte, senza il preventivo or by any means, without prior written permission of
consenso scritto di CARRARO DRIVE TECH SpA. CARRARO DRIVE TECH SpA Only the customer,
L’uso di questo materiale documentale è consentito whom the manual, together with the product, has been
solo al cliente a cui il manuale è stato fornito come issued to, is allowed to use this document, and only in
corredo del prodotto, e solo per scopi di uso, order to use, maintain and repair the unit.
manutenzione e riparazione.
CARRARO DRIVE TECH SpA dichiara che le CARRARO DRIVE TECH SpA declares that the subject
informazioni contenute in questo manuale sono of this manual consists with the technical and safety
congruenti con le specifiche tecniche e di sicurezza specifications of the machine that the manual is
della macchina a cui il manuale si riferisce. Il referred to. The manufacturer shall not be held liable for
fabbricante non si assume alcuna responsabilità per direct or indirect damages to persons, things or animals
danni diretti o indiretti a persone, cose o animali, due to an improper use of this document or of the
conseguenti all’uso di questo materiale documentale o machine or to a different use of them, which does not
della macchina in condizioni diverse da quelle previste. comply with what is provided for in this manual.
Carraro Drive Tech Spa

Via Olmo, 37
35011 Campodarsego (Pd) Italia
Tel. +39 049 9219111
Fax +39 049 9289111
www.carrarodrivetech.com
AB10563 REVISION DATE: 02/12 DOC. CA270263 B.2 PAG. 19
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CONVENZIONI E DEFINIZIONI
AGREEMENTS AND DEFINITIONS Mod. 28.43M FR
B.3 Convenzioni e definizioni B.3 Agreements and definitions

Convenzioni Agreements
Le illustrazioni nel manuale NON sono in scala quindi Illustrations like pictures, drawings and components of
NON sono attendibili valutazioni delle dimensioni e dei this manual are NOT in scale, because of limited space
pesi dei componenti basate sulle stesse. and editing limits, therefore they are NOT reliable to
Le illustrazioni hanno il compito di evidenziare le obtain values about size or weight.
corrette procedure da condurre sulla macchina e sui Illustrations are supposed to point out the correct
suoi componenti, per questo potrebbero non methods to working on the machine and its
rappresentare esattamente gli elementi di questa components, therefore they could not display exactly
macchina ma componenti meccanici simili. the same elements.
Definizioni Definitions
Lato sinistro (Sx): parte sinistra del gruppo vista nel Left side (Lh): it is the left side (left hand) of the unit
senso di marcia del veicolo (Fig. 1). considering the vehicle running conditions (Fig. 1).
Lato destro (Dx): parte destra del gruppo vista nel Right side (Rh): it is the right side (right hand) of the
senso di marcia del veicolo (Fig. 1). unit considering the vehicle running conditions (Fig. 1).
Direzione di marcia Fig. 1

Driving direction
Sx Dx
Lh Rh Sx Dx
Lh Rh
Lato pignone
Fig. 2 Pinion side
Solo per gli assali con pignone Only for axle with pinion
Lato sinistro assale: parte sinistra dell’assale Axle left side: it is the left side of the axle from pinion
guardandolo dall’albero del pignone verso l’ingranaggio shaft point of view toward the pinion bevel gear (Fig. 2).
conico (Fig. 2). Axle right side: it is the right side of the axle from
Lato destro assale: parte destra dell’assale pinion shaft point of view toward the pinion bevel gear
guardandolo dall’albero del pignone verso l’ingranaggio (Fig. 2).
conico (Fig. 2).
Convenzioni tipografiche Typographic agreements

Nota: informazioni importanti, evidenziate al di fuori del Note: the notes, pointed out externally to the text they
testo a cui si riferiscono. refer, include important information.
Importante: avvertenze importanti o istruzioni critiche Important: important warnings or critical instructions
la cui inosservanza può produrre danni alla macchina o whose inobservance may result in damage to the
alle apparecchiature collegate. machine or interconnected equipment.
Vedi: richiamo ad una sezione di questo documento o See: reference to a section of this document or other
ad altri documenti (come il manuale d’uso del veicolo) documents (such as the user manual of the vehicle)
con informazioni utili allo svolgimento delle operazioni with useful information to perform the operations
descritte. Nel caso di riferimenti a questo documento si described. In the case of references to this document is
indicherà il nome della sezione oppure il riferimento ad given the section name or a reference to a specific
una sezione specifica. section.
Per esempio: For example:
Vedi: Gruppo Freno, assemblaggio. >>> cercare il Gruppo See: Brake Group, assembly. >>> Look for the Brake Group in
Freno nell’indice di questo manuale e consultare la parte the index of this manual and consult the section: assembly.
relativa all’assemblaggio. See: D.8.2.12. >>> Go to Section D, paragraph 8, section 2,
Vedi: D.8.2.12. >>> Andare al capitolo D, paragrafo 8, sezione step 12 (step number is usually shown in the upper left of each
2, passo 12 (il numero del passo è solitamente indicato in alto figure).
a sinistra su ogni figura).
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Mod. 28.43M FR AGREEMENTS AND DEFINITIONS
Unità di misura Measurements

Nel manuale si utilizzano le unità di misura del sistema This manual indicates all measurements in
internazionale (SI). Per la conversione al sistema International System (SI). Use the following conversion
anglosassone riferirsi alla seguente tabella. table to convert Imperial Measure.
Tabella di conversione unità di misura Conversion table of units of measurement
S .I . GB/USA SYSTEM
1 mm 0.03937 in
10 mm 0.3937 in
25.4 mm 1 in
6.4516 cm² 1 sq. in
1 m² 1550 sq. in
16.378 m² 1 cu. in
0.473 dm² 1 U.S. pint
1 l 61.02 cu. in
1 l 0.2642 U.S. gal
1.772 g 1 oz
0.4536 kg 1 lb
0.00070308 kg/mm² 1 lb/sq. in
1 bar 14.51 psi
1 kg.m 7.246 lb. ft
1(daN)= 10 (N)= 1,02 (kg.f) 2.24 lb. f
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AGREEMENTS AND DEFINITIONS Mod. 28.43M FR
Simbologia utilizzata nella descrizione delle Symbology used to describe maintenance (service
procedure di manutenzione (servizio e riparazione) and repair) procedures
DE SCRIZIONE SIMBOLO/ SYMBOL DES CRIPTION

WARNING/DANGER
ATTENZIONE/PERICOLO
Follow carefully all the manual instruction,
Seguire attentamente le istruzioni nel
in order to avoid the arise of damages to
manuale per evitare di provocare danni a
things or persons; also follow all the
persone o cose; seguire anche tutte le
current security regulations, in
normative di sicurezza vigenti in relazione
relationship/agreement with the operative
all’ambiente di lavoro in cui si opera.
working ambient.
Nota: la mancata osservanza delle
Note: do not follow carefully the Carraro
indicazioni Carraro e/o delle normative di
indications and/or current security
sicurezza può causare gravi danni alle
regulations can causes serious damages
persone ed alla macchina, tali danni non
to the persons or to the machines; these
sono coperti da garanzia.
damages are not warranty covered.
RIMOZIONE/INSTALLAZIONE
REMOVE/INSTALL
Si applica a: anelli-guarnizioni-filtri.
Applicable to: seals-gaskets-filters.
L’utilizzo di ricambi NON originali Carraro
The NOT original Carraro spare parts use
comporta la decadenza della garanzia
causes the loss of the machine warranty.
sulla macchina.
Note: when this symbol is encountered, it
Nota: in presenza di questo simbolo si
is recommended to follow the described
raccomanda di seguire oltre alle
procedure as well as the section B.5
procedure descritte anche le avvertenze
warnings.
in sezione B.5
RIEMPIMENTO o RABBOCCO OLIO/ OIL FILLING OR OIL LEVEL/
SCARICO OLIO OIL DRAIN
Utilizzare solo i lubrificanti indicati in Use only the prescribed lubricant,
sezione C; l’utilizzo di prodotti non indicated on section C; the use of products
corrispondenti alle specifiche indicate that are not in accordance with the
comporta la decadenza della garanzia indicated specifications involves the
Carraro. Carraro warranty decline.
Nota: in presenza di questo simbolo si Note: when this symbol is encountered, it
raccomanda di seguire oltre alle is recommended to follow the described
procedure descritte anche le avvertenze procedure as well as the section B.5
in sezione B.5. warnings.
LUBRIFICAZIONE/INGRASSAGGIO LUBRICATION/GREASING
Utilizzare solo i lubrificanti indicati in Use only the prescribed lubricant,
sezione C; l’utilizzo di prodotti non indicated on section C; the use of products
corrispondenti alle specifiche indicate that are not in accordance with the
comporta la decadenza della garanzia indicated specifications involves the
Carraro. Carraro warranty decline.
Nota: in presenza di questo simbolo si Note: when this symbol is encountered, it
raccomanda di seguire oltre alle is recommended to follow the described
procedure descritte anche le avvertenze procedure as well as the section B.5
in sezione B.5. warnings.
REGOLAZIONE/MISURAZIONE ADJUSTMENTS/MEASUREMENTS
Si applica a: coppie di serraggio- Applicable to: tightening torques-
precarichi-giochi. preloads-backlash.
Seguire con estrema cura le istruzioni Follow carefully the indicated instructions
descritte per ottenere il miglior risultato. to obtain the best result.
Nota: la mancata osservanza delle Note: do not follow carefully the Carraro
indicazioni Carraro può comportare gravi indications can causes serious damages
danni alla macchina; tali danni non sono to the machine; these damages are not
coperti da garanzia. warranty covered.
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Mod. 28.43M FR AGREEMENTS AND DEFINITIONS
DESCRIZIONE SI MB O L O / SYMBOL DE SCRIP TION

ATTREZZATURE SPECIALI SPECIAL TOOLS
Si raccomanda l’utilizzo delle attrezzature It is recommended to use the special tools
descritte senza ricorrere a sistemi non as indicated into the repair manual; avoid
collaudati che non garantiscono un buon the use of not-tested methods that can not
risultato. guarantee a good result.
ADHESIVE AND SEALING FLUIDS
APPLICAZIONE DI ADESIVI E
APPLICATION
SIGILLANTI
Use only the prescribed product, indicated
Utilizzare solo i prodotti indicati in sezione
on section C; the use of products that are
C; l’utilizzo di prodotti diversi da quelli
not in accordance with the indicated
indicati comporta la decadenza della
specifications involves the Carraro
garanzia Carraro.
warranty decline.
in sezione B.5.
warnings.
TRACCIATURA MARKING
Eseguire le operazioni descritte Carry out the described operations in the
nell’ordine prestabilito. pre-established order.
SMONTAGGIO/MONTAGGIO DI
DISASSEMBLY/ASSEMBLY OF BULKY
PARTICOLARI INGOMBRI O
PARTS OR SUBASSEMBLIES
SOTTOGRUPPI
WARNING: RESPECT ASSEMBLY

ATTENZIONE: RISPETTARE IL VERSO
ORIENTATION
DI MONTAGGIO
The assembled elements must be
Gli elementi assemblati devono avere
oriented as described in the relative
verso di montaggio corrispondente a
procedure or as indicated in the relative
quello descritto e/o illustrato.
figure.
Nota: la mancata osservanza delle
Note: do not follow carefully the Carraro
indicazioni Carraro può comportare gravi
indications can causes serious damages
danni alla macchina, tali danni non sono
to the machine; these damages are not
coperti da garanzia.
warranty covered.
PULIRE ACCURATAMENTE
CLEANING CAREFULLY
Pulire con estrema cura le parti
Clean with care the parts involved in the
interessate alle operazioni di
described maintenance procedure.
manutenzione descritte.
warnings.
in sezione B.5.
IMMETTERE FLUIDO IN PRESSIONE
APPLY PRESSURIZED FLUID
Osservare scrupolosamente le procedure
Follow with great care the indicated
indicate e mettere in pratica tutti i
procedure and follow all the security
comportamenti di sicurezza atti a
procedures in order to avoid damages to
salvaguardare l’incolumità di persone e
persons or things.
cose.
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INDICAZIONI GENERALI
GENERAL DESCRIPTION Mod. 28.43M FR
B.4 Indicazioni generali B.4 General description

La macchina deve essere controllata e/o riparata solo The machine should be checked and/or repaired only
da personale tecnico specializzato che sia a by qualified technicians, acquainted with its peculiar
conoscenza delle sue particolari caratteristiche e delle features and well aware of all safety instructions.
relative norme di sicurezza (prevenzione infortuni).
Prima di svolgere qualsiasi operazione, pulire Before performing any operation it is advisable to carry
accuratamente il gruppo rimuovendo eventuali out unit cleaning accurately by removing oil/ grease
incrostazioni ed accumuli di terriccio e/o grasso. encrustations and accumulation.
Tutti gli organi meccanici smontati devono essere All disassembled mechanical parts must be cleaned
accuratamente puliti con prodotti adeguati, per evitare accurately with suitable products to avoid possible
possibili danni. Verificarne l'integrità, sostituendoli in damage. Parts should be replaced if damaged, worn
caso di danni, usura, incrinature, grippaggi o difetti che out, cracked, seized, etc. as they could affect proper
potrebbero comprometterne il buon funzionamento. working.
In particolar modo si deve verificare l'integrità dei Rotating parts (bearings, gears, shafts) and that of
componenti in movimento (cuscinetti, ingranaggi, hardware/fasteners (O-Rings, seal rings) should be
alberi) e degli organi di tenuta (anelli OR, anelli di examined carefully, as they are subject to intense
tenuta) e di fissaggio, che sono soggetti ad intense stress, wearing and ageing.
sollecitazioni, ad usura e invecchiamento. Note: in case of replacement of one part of the bevel
Nota: si ricordi che l’eventuale sostituzione di un gear set this operation requires the replacement of the
componente della coppia conica comporta la other part too.
sostituzione anche dell'altro.
Si raccomanda di sostituire ad ogni revisione o We highly advise to replace sealing parts (O-Rings,
riparazione gli organi di tenuta (anelli OR, anelli di seal rings, gaskets) during every teardown or repair.
tenuta, guarnizioni).
Utilizzare solo le parti di ricambio e la viteria indicate, Use appropriate spare parts, nuts and bolts to avoid any
inoltre usare utensili metrici per la viteria metrica e other problems. Moreover, use metric tools for metric
inglesi per la viteria inglese. nuts and bolts and Imperial tools for the others.
Come indicato, alcune operazioni sono distruttive per Some operations are destructive for removed
gli elementi rimossi. Leggere attentamente le components.
descrizioni delle varie fasi dell'intervento ed operare Carefully reading and through understanding of these
con attenzione per non compromettere la funzionalità di instructions will avoid damage to other components.
altri elementi.
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INDICAZIONI SPECIALI
Mod. 28.43M FR SPECIAL RECOMMENDATIONS
B.5 Indicazioni speciali B.5 Special recommendations

Prima di iniziare le operazioni di smontaggio e Before starting any disassembly and assembly
montaggio leggere attentamente le seguenti operations, read carefully the following
avvertenze. recommendations.
Anelli di tenuta per alberi Shafts seals

Per il montaggio degli anelli di tenuta attenersi alle Respect the following recommendations during shaft
seguenti raccomandazioni: seal assembly:
• Pulire accuratamente l'albero ed assicurarsi che • Clean shaft very carefully and ensure that the part in
non sia danneggiato, rigato od ovalizzato nelle zone contact with the shaft seal is not damaged, cut or out
di contatto con gli anelli. of roundness.
• Non danneggiare gli anelli durante il montaggio • Do not damage the seals while assembling the
dell'albero. shaft.
• Pulire accuratamente l'albero ed assicurarsi che • Clean shaft very carefully and ensure that the part in
non sia danneggiato, rigato od ovalizzato nelle zone contact with the shaft seal is not damaged, cut or out
di contatto con gli anelli (Fig. 3). of roundness (Fig. 3).
Fig. 3
Fig. 4
• Montare gli anelli in modo che il labbro sia rivolto • Assemble the seals so that the lip is fitted towards
verso il lato olio (Fig. 4). the oil side (Fig. 4).
• Lubrificare il labbro degli anelli (usare • Lubricate seal lips (use oil) and fill 3/4 of seal cavity
preferibilmente olio) e riempire per 3/4 di grasso la with grease (Fig. 5).
camera degli anelli stessi (Fig. 5).
• Use appropriate drivers (Fig. 6).
• Montare gli anelli usando un appropriato calettatore
(Fig. 6). Important: do not use a hammer directly on the seals.
Importante: non usare il martello direttamente sugli

anelli.
Fig. 5
Fig. 6
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SPECIAL RECOMMENDATIONS Mod. 28.43M FR
Anelli OR O-rings
Lubrificarli adeguatamente prima di inserirli nella Lubricate adequately before inserting them at the right
propria sede evitando “arrotolamenti” durante il place and avoid o-ring rolling while inserting the shaft
montaggio dell'albero (Fig. 7). (Fig. 7).
Fig. 7
Fig. 8
Spessori di registro Adjusting shims

Per il montaggio degli spessori di registro attenersi alle Respect the following recommendations during the
seguenti raccomandazioni: adjustment shims assembly:
• Per le registrazioni utilizzare gli appropriati spessori • Use appropriate adjusting shims and measure each
di registro, misurandoli singolarmente (Fig. 8). one separately (Fig. 8).
• La misurazione del pacco completo o la • Complete group measurement or stampings on the
stampigliatura riportata sugli spessori stessi può shims are not always reliable: check.
risultare non sempre affidabile: verificare.
Cuscinetti Bearings
Per il montaggio dei cuscinetti attenersi alle seguenti Respect the following recommendations during the
raccomandazioni: bearings assembly:
• Prima di rimontarli, pulirli, ispezionarli e lubrificarli. • Before reassembling the bearings, clean, check and
lubricate them.
• Per un corretto montaggio è consigliabile riscaldarli
in forno ad una temperatura di 80-90 °C prima di • Its advisable to heat up bearings to 80-90 °C before
montarli sui rispettivi alberi o raffreddarli prima di assembling them onto their respective shafts or to
inserirli nelle relative sedi con piantaggio esterno cool them (dry ice) before inserting them into
(Fig. 9). corresponding bore (Fig. 9).
• Usare sempre gli estrattori idonei per rimuovere i Always use suitable extractors to remove the bearings
cuscinetti (Fig. 10). (Fig. 10).
Fig. 9
Fig. 10
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Tappi e rivetti Plugs and rivets

Mai rimuovere tappi e rivetti se non espressamente Never remove caps and rivets unless specifically
indicato nelle istruzioni di riparazione. Spesso questi indicated in the repair instructions. Often these
elementi richiedono delle apparecchiature speciali per elements require special equipment for mounting and
il montaggio e per la conseguente verifica di tenuta. for the subsequent leak test.
Vedi: Fig. 11 e Fig. 12. See: Fig. 11 and Fig. 12
AVV IS O NOTICE
Quando non espressamente indicata nelle istruzioni di If not specifically indicated in the instructions for
riparazione, la rimozione di detti elementi comporta repairing, the removal of these parts will result in
l’immediata decadenza della garanzia sul prodotto da immediate forfeiture of the product warranty by
parte di Carraro Drive Tech SpA. Carraro Drive Tech SpA.
Fig. 11 NON RIMUOVERE

DO NOT REMOVE
NON RIMUOVERE
DO NOT REMOVE Fig. 12
Spine elastiche Split pins

Per il montaggio delle spine elastiche attenersi alle Respect the following recommendations during the split
seguenti raccomandazioni: pins assembly:
• Al montaggio delle spine elastiche ad intaglio • Before assembling elastic pins, make sure that the
assicurarsi che l'intaglio delle stesse sia orientato pin notch is oriented towards the stressing force
nel senso dello sforzo sollecitante la spina (Fig. 13). (Fig. 13).
• Le spine elastiche a spirale invece non necessitano • Spiral elastic pins do not need orientation.
di alcun orientamento.
Fig. 13
Fig. 14
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Adesivi e sigillanti Adhesive and sealant

Per l’applicazione di adesivi e sigillanti attenersi alle Respect the following recommendations during the
seguenti raccomandazioni: adhesive and sealant application:
• Usare adesivi e sigillanti secondo le specifiche del • Use adhesive and sealant as advised by
produttore. manufacturer specifications.
• Non applicare adesivi e sigillanti su prodotti analoghi • Do not use adhesive or sealant where similar
già applicati in precedenza; rimuovere products has been applied previously; totally
completamente i vecchi prodotti prima di applicare i remove the old product before applying the new one.
nuovi.
• Ensure that parts to be sealed are clean, dry and
• Assicurarsi che le parti dove si applicano adesivi e completely grease free (Fig. 14) in the application
sigillanti siano pulite, asciutte e completamente area.
prive di grasso (Fig. 14).
• Read the predisposed section in this manual to
• Consultare l’apposita sezione in questo manuale know the required type of adhesive and sealant and
per conoscere i tipi di adesivi e sigillanti ammessi e relative application areas.
le zone in cui devono essere utilizzati.
Scarico dell'olio Oil drain

Prima di intervenire sul prodotto è necessario scaricare Before carry out the disassembly operations, the oil
l'olio dal gruppo. must be drained out.
Vedi: C.5 See: C.5
Smaltire gli oli esausti nel rispetto della vigenti norme Dispose of used oil in compliance with current
per la salvaguardia dell'ambiente. environment regulations.
Pulizia Cleaning
Per la pulizia dell’assale attenersi alle seguenti Respect the following recommendations during the axle
raccomandazioni: cleaning operations:
• Lavare accuratamente tutte le parti in movimento • Wash all moving parts accurately with diesel fuel or
utilizzando gasolio o cherosene. kerosene.
• E' proibito l'uso di benzina e soluzioni acquose • Gasoline and watery alkaline solutions are
alcaline. forbidden.
• Evitare lavaggi con vapore o acqua calda perché • Do not wash with steam or hot water, as it will be
sarebbe difficile eliminare completamente l'umidità very difficult to eliminate surface humidity.
superficiale.
• Dry all parts with a rag or air jet to avoid scratching
• Asciugare accuratamente tutti i particolari mediante from abrasive residuals.
un getto d'aria o stracci per evitare di rigare le
• After the cleaning operations, all the surfaces should
superfici con residui abrasivi.
be covered with lubricant so as to protect it from
• Dopo la pulizia, tutte le superfici devono essere future oxidation.
ricoperte da un leggero strato di lubrificante per
proteggerle da eventuali ossidazioni.
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Controlli Checks
Per i controlli sull’assale attenersi alle seguenti Respect the following recommendations during the axle
raccomandazioni: control operations:
• Controllare che tutti gli elementi scanalati siano privi • Check all grooves: assure that they are not worn out
di usure eccessive o di altri danneggiamenti. or damaged.
• Sostituire i particolari avariati con ricambi originali. • Replace spoiled parts with original spare parts.
• Dopo ogni smontaggio, le guarnizioni di tenuta sugli • Before the reassembly, the seals on rotating shafts
alberi rotanti devono essere sostituite. must be replaced.
• Verificare accuratamente tutti i cuscinetti, gli anelli • Examine accurately all bearings, external rings
esterni eventualmente ancora piantati nelle proprie which may be still stuck in their position and pivot
sedi e i perni su cui rotolano i rullini. pins on which rolls rotate.
• Sostituire quei particolari che presentano tracce di • Replace those parts which show signs of wear or
usura o di danneggiamento (Fig. 15). damage (Fig. 15).
• Controllare che tutti gli ingranaggi non presentino • Gears should not be spoiled and teething should not
avarie o eccessiva usura della dentatura: gli smussi be excessively worn out. Teeth smoothing should
dei denti non devono essere deteriorati (Fig. 16). not be deteriorated (Fig. 16).
Fig. 15
Fig. 16
Estremità di flange ed attrezzi speciali Ends of flanges and special tools

Prestare la massima attenzione quando si martellano le Be careful when hammering special tool or flange ends,
estremità di attrezzi speciali o di flange per evitare di in order to avoid jeopardizing functionality and integrity
compromettere la funzionalità e l’integrità sia degli of either the tools or the components on which you are
attrezzi che dei componenti su cui si opera. operating.
Impiego di lubrificante Lubricant use

Per ottenere una corretta lubrificazione ed una esatta In order to lubricate the CARRARO DRIVE TECH SpA
temperatura di funzionamento negli assali CARRARO axles correctly and to reach the exact operation
DRIVE TECH SpA, è importante usare i lubrificanti temperature, it is important to use the recommended
raccomandati, mantenendone il livello costante lubricants, keeping their level constant as indicated in
secondo quanto indicato nel presente manuale. this manual.
S/N: 020-069
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Notes
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CARATTERISTICHE GENERALI
Mod. 28.43M FR GENERAL SPECIFICATIONS
C CARATTERISTICHE GENERALI
C GENERAL SPECIFICATIONS
AB10563 REVISION DATE: 02/12 DOC. CA270263 C PAG. 31
S/N: 020-069
S1165
USO PREVISTO
INTENDED USE Mod. 28.43M FR
C.1 Uso previsto C.1 Intended use

Questo assale è stato progettato e costruito per essere This axle has been designed and manufactured to be
installato in veicoli di tipo industriale con la funzione di mounted on industrial machines to transmit the power
trasmettere la potenza dal motore alle ruote, from the engine to the wheels and to allow:
consentendo anche: • increasing of tractive force of the vehicle
• l’aumento della forza di trazione del veicolo; • adjusting of inner wheels’ speed with outer wheels’
• la compensazione della velocità delle ruote interne speed during steering of the vehicle.
con quelle esterne durante la sterzata del veicolo.
Never mount this axle on machines different from the
Non installare mai questo assale su macchine diverse ones for which it has been designed and manufactured.
da quelle per cui e stato progettato e costruito.
If the axle is used for any other purpose than the one
L'assale, se utilizzato in un impiego diverso da quello foreseen, CARRARO DRIVE TECH SpA declines any
previsto, è da considerarsi soggetto ad "uso non responsibility regarding damages or accidents caused
previsto". by it. All consequences will be at the expense of the
CARRARO DRIVE TECH SpA declina ogni client.
responsabilità per danni o incidenti risultanti da un uso However, when used as foreseen, operational
diverso da quello previsto; tali conseguenze saranno a formalities as well as regular maintenance repair
carico esclusivo del cliente. specifications given by CARRARO DRIVE TECH SpA
Costituisce inoltre un elemento essenziale, nell'ambito are to be observed strictly.
dell'uso previsto, l'osservanza scrupolosa delle
modalità di funzionamento e delle regolari
manutenzioni e riparazioni specificate da CARRARO
DRIVE TECH SpA.
C.2 Identificazione del prodotto C.2 Product identification

Targhetta di identificazione dell’assale Axle tag
C.1 PAG. 32 REVISION DATE: 02/12 DOC. CA270263 AB10563
S/N: 020-069
S1165
DESCRIZIONE GRUPPI ASSALE
Mod. 28.43M FR AXLE GROUPS DESCRIPTION
C.3 Descrizione gruppi assale C.3 Axle groups description

L’assale modulare può essere composto dai seguenti The modular axle can be made up of the following
gruppi (non tutti presenti nel vostro assale): groups (not all present in your axle):
1 RIDUTTORE EPICICLOIDALE: treno portasatelliti 1 EPICYCLIC REDUCTION GEAR: planetary carrier
con elementi di riduzione with reduction/transmission parts
2 MOZZO RUOTA: elementi di supporto della ruota e 2 WHEEL HUB: wheel support parts containing the
del riduttore epicicloidale epicyclic reduction gears
3 TROMBA TRAVE: struttura di supporto principale 3 AXLE BEAM TRUMPET: load-bearing shell
dell’assale structure of the axle
4 FRENO: componenti del freno e relativa sede 4 BRAKE: brake parts and housing
5 COMANDO FRENO: leve di comando del freno 5 BRAKE CONTROL: brake control levers
6 SUPPORTI: elementi di fissaggio dell’assale al 6 SUPPORTS: axle’s trunnion parts to install the axle
veicolo on the vehicle
7 SUPPORTO DIFFERENZIALE: supporto del diffe- 7 DIFFERENTIAL SUPPORT: differential housing
renziale e per la registrazione della coppia conica with ring bevel gear adjusting system
8 CILINDRO STERZO: componenti del cilindro di 8 STEERING CYLINDER: steering cylinder parts with
sterzo con gli elementi di regolazione adjusting system components
9 PIGNONE: pignone con gli elementi di registrazione 9 PINION: pinion with relative adjusting and support
e supporto parts
10 FLANGIA: flangia con elementi di fissaggio 10 FLANGE: flange and relative fastening parts
11 FRENO DI STAZIONAMENTO: freno a disco con 11 PARKING BRAKE: brake disc with caliper and
pinza ed elementi di supporto support parts
12 DIFFERENZIALE: scatola differenziale e corona 12 DIFFERENTIAL: differential parts with ring bevel
della coppia conica gear
Axle generic scheme
ASSALE STERZANTE ASSALE NON STERZANTE

STEERING AXLE 6 7 NOT STEERING AXLE
5 5
4 4
3 3
12
2 2
1 1
8
9
10
11
AB10563 REVISION DATE: 02/12 DOC. CA270263 C.3 PAG. 33
S/N: 020-069
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CARATTERISTICHE TECNICHE
TECHNICAL FEATURES Mod. 28.43M FR
C.4 Caratteristiche Tecniche C.4 Technical Features
CODICE CA409436 CODE

MACCHINA Assale Anteriore - Front Axle MACHINE
MODELLO 28.43M FR MODEL
TIPO DIFFERENZIALE Open DIFFERENTIAL TYPE
DESCRIZIONE VALORI/VALUES DESCRIPTION
Peso a secco 425 kg Dry weight

Riduzione coppia conica 2.333/1 Bevel gear ratio
Riduzione riduttore epicicloidale 6.923/1 Epicyclic reduction gear ratio
Riduzione totale 16.150/1 Total ratio
Rotazione in entrata Input rotation
SENSO ORARIO CLOCK WISE (C.W.)
SENSO ANTIORARIO COUNTER CLOCK WISE (C.C.W.)
Freno di servizio Vedi: C.8 Service brake

See: C.8
Flangia ingresso differenziale END YOKE 1410 Differential input flange
VALORI TIPICI DI ASSEMBLAGGIO/ASSEMBLY MAIN DATA
Gioco di accoppiamento coppia conica 0.20÷0.35 mm Bevel gear set backlash

Precarico cuscinetti pignone( 1 ) Pinion bearings preloading( 1 )
(misurato su Ø= 34.8 mm senza anello di FP = 92.0÷137.9 N (measured on Ø= 34.8 mm without seal)
tenuta)
Precarico tot. cuscinetti corona- Total preloading( 1 ) of pinion-ring gear
pignone( 1 ) bearings (measured on Ø= 34.8 mm
FT = (FP +29.6)÷(FP +44.3) N
(misurato su Ø= 34.8 mm senza anello di without seal)
tenuta)
Coppia di rotolamento( 1 ) dei cuscinetti Pinion bearings rolling torque( 1 )
MP = 1.6÷2.4 Nm
pignone misurata senza anello di tenuta measured without seal
Coppia di rotolam. totale( 1 ) dei cuscinetti Total pinion-ring gear bearing rolling
corona-pignone misurata senza a. di MT = (MP +0.51)÷(MP +0.77) Nm torque( 1 ) measured without seal
tenuta
(1)
Solo per nuovi cuscinetti (1)
Only for new bearings
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CARATTERISTICHE TECNICHE
Mod. 28.43M FR TECHNICAL FEATURES
Dimensioni principali (mm) Main dimensions (mm)
1913
1654
Ø380
Ø280
5/16”-24UNF 2B
4 Fori/Holes 40±2
M22x1.5
555 306
50
Ø335
3 Fori/Holes
M18-7H Deep 32
166
155
148
195 147
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MANUTENZIONE E CAMBIO OLIO
MAINTENANCE AND OIL CHANGE Mod. 28.43M FR
C.5 Manutenzione e cambio olio C.5 Maintenance and oil change
C.5.1 Dati caratteristici C.5.1 Main data
DESCRIZIONE VALORI/VALUES DESCRIPTION
Specifica olio Oil specification

USARE I TIPI DI OLIO INDICATI USE RECOMMENDED OIL ENRICHED IN
OPPORTUNAMENTE ADDITIVATI. API GL4 - SAE 90 ADDITIVES.
Nota: non usare olio di sintesi o vegetale Note: do not use synthetic or vegetable oil
senza il consenso del costruttore dell’assale without consent of the axle manufacturer
Quantità olio differenziale 14.5 litri/liters Differential oil capacity
Quantità olio riduttore epicicloidale (per lato) 1.3 litri/liters Epicyclic red. gear oil capacity (each side)
33
5 7 2
4 6 9
4 2 1 9
1 8
5
6 5
8 7
DESCRIZIONE POSIZIONE/POSITION DESCRIPTION
Tappo carico e livello olio differenziale 1 Differential oil filling and level plug
Tappo scarico olio differenziale 2 Differential oil drain plug
Sfiato olio 3 Oil breather
Tappo carico, livello e scarico olio riduttore Fill, level and drain plug of epicyclic
4
epicicloidale reduction gear oil
Porta olio freno di servizio 5 Service brake oil port
Sfiato olio freno di servizio 6 Service brake bleed
S/N: 020-069
S1165
Mod. 28.43M FR MAINTENANCE AND OIL CHANGE
DESCRIZIONE POSIZIONE/POSITION DESCRIPTION
Porta olio freno negativo 7 S.A.H.R. brake oil port

Attivazione freno negativo 8 S.A.H.R. brake activation
Sblocco freno 9 Unlock brake system
C.5.2 Cambio olio assale C.5.2 Axle oil change

A V V I S O eseguire tutte le operazioni di scarico, NOTICE to drain and fill the oil and to check the oil
carico e verifica livello olio con l’assale orizzontale. level the axle must be horizontal.
1
P E R I C O L O rischio di violenta espulsione di getti d’olio,
seguire tutte le procedure di sicurezza indicate in questo manuale e
3 dal costruttore del veicolo (vedi: cap. A - INFORMAZIONI SULLA
SICUREZZA.
Pulire con cura lo sfiato (3) e la zona circostante.
DANGER risk of violent oil ejection, follow carefully all the

safety procedures indicated in this manual and in the vehicle manual
(see: cap. A - SAFETY INSTRUCTIONS).
Clean with care the breather (3) and the surrounding area.
2
Per scaricare l’olio dal corpo centrale svitare e rimuovere prima il
tappo di carico (1) e poi il tappo di scarico (2).
Scaricare completamente l’olio.
Pulire con cura ed assemblare il tappo (2).
Serrare il tappo alla coppia prevista.
Vedi: C.7
1 2
To drain the oil unscrew and remove first the fill plug (1) then the drain
plug (2).
Drain all oil.
Clean with care and assemble the plug (2).
Tighten the plug to the prescribed torque.
See: C.7
3
Riempire con l’olio prescritto a filo del foro di carico (1).
Attendere che l’olio fluisca nell’assale quindi verificare il livello e
1 rabboccare se necessario.
Pulire con cura ed assemblare il tappo (1).
Vedi: C.7
Fill to the bottom of the fill plug hole (1) with the specified oil.
Wait to allow the oil to flow through the axle. Check oil level and fill to
the specified level if necessary.
Clean with care and assemble the plug (1).
See: C.7
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S1165
MAINTENANCE AND OIL CHANGE Mod. 28.43M FR
C.5.3 Cambio olio riduttore epicicloidale C.5.3 Epicyclic reduction gear oil change
1
P E R I C O L O rischio di violenta espulsione di getti d’olio,
A B seguire tutte le procedure di sicurezza indicate in questo manuale e
4 dal costruttore del veicolo.
Vedi: cap. A - INFORMAZIONI SULLA SICUREZZA
AVV IS O eseguire tutte le operazioni di scarico, carico e verifica
livello olio con l’assale orizzontale.
Prima di scaricare l’olio dal riduttore epicicloidale, ruotarlo in modo da
portare il tappo olio (4) nel punto più alto [posizione A].
Svitare il tappo parzialmente per eliminare l’eventuale pressione
interna.
Ruotare il riduttore con il tappo (4) rivolto verso il basso [posizione B].
Togliere il tappo e lasciar defluire tutto l’olio.
DANGER risk of violent oil ejection, follow carefully all the

safety procedures indicated in this manual and in the vehicle
manual.
See: cap. A - SAFETY INSTRUCTIONS
NOTICE to drain and fill the oil and to check the oil level the axle
must be horizontal.
Before draining the oil from wheel end rotate the wheel end so that the
plug (4) is at the highest position [pos.A] and partially unscrew to
release possible pressure.
Rotate the wheel end so that the plug (4) is toward the ground [pos.B].
Remove the plug and drain the oil.
2
Ruotare il riduttore fino a portare il foro (4) nella posizione indicata.
Riempire con olio prescritto.
Vedi: C.5.1.
4 Il livello dell’olio deve essere a filo del foro.
Vedi: C.7.
Rotate the wheel end so that the hole (4) is in the position as shown
in figure.
Fill to the bottom of the fill plug hole with specified oil.
See: C.5.1.
See: C.7.
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Mod. 28.43M FR MAINTENANCE AND OIL CHANGE
C.5.4 Manutenzione programmata C.5.4 Service schedule

Gli intervalli di manutenzione indicati sono per un Specified maintenance intervals are for standard-duty
impiego normale della macchina, nel caso di impieghi use.
particolarmente gravosi intervenire con maggior Severe operating conditions may require more short
frequenza. intervals.
Primo Intervento Manutenzione ordinaria

Operazione Operation
First time Ordinary maintenance
Cambio olio assale 150-200 stagionale od ogni 1500 ore(1) Axle oil change
 
ore/hours seasonally or every 1500 hours(1)
Pulizia tappo magnetico primo cambio olio ogni cambio olio Clean magnetic oil plugs
 
scarico olio first oil change every oil change
Controllo e rabbocco 50-100 mensile od ogni 300-400 ore(1) Check and adjust oil
 
olio ore/hours monthly or every 300-400 hours(1) level
Pulizia sfiato olio 150-200 mensile od ogni 300-400 ore(1) Clean oil breather
 
ore(3)/hours(3) monthly or every 300-400 hours(1)
Ingrassaggio 150-200 settimanale od ogni 150-200 ore(1)(2) Greasing
 
(se previsto) ore(2)/hours(2) weekly or every 150-200 hours(1)(2) (if required)
Lubrificazione 150-200 stagionale od ogni 1500 ore(1) Lubrication works

 
(se prevista) ore(3)/hours(3) seasonally or every 1500 hours(1) (if required)
 operazioni eseguibili solamente da personale  this operation must be performed only by personnel
autorizzato dal costruttore authorized by the manufacturer
 operazioni eseguibili solamente da personale  this operation must be performed only by trained
addestrato personnel
(1) quale delle due condizioni si verifica prima (1)
which of both conditions comes first
(2) 50 ore nel caso di impiego gravoso (2)
50 hours for severe operating condition
(3) a fine stagione nel caso di impiego inferiore a quanto (3)
at the season end if you have not reached the
indicato indicated work-hours
Campi di applicazione dei lubrificanti Lubricants application range
S/N: 020-069
S1165
GRASSO AL MONTAGGIO
GREASE IN ASSEMBLY Mod. 28.43M FR
C.6 Grasso al montaggio C.6 Grease in assembly

Importante: lubrificare tutti gli OR (anche quelli non Important: lubricate all the O-Rings (even those not
rappresentati) con olio minerale (SAE 90) o grasso al shown) with mineral oil (SAE 90) or Lithium grease;
Litio; mai usare grasso al litio sugli OR del gruppo freni never use lithium grease on the O-Ring of brake system
per evitare la contaminazione dell’olio freni. to avoid contamination of the brake oil.
.
Applicazione grasso al montaggio/Grease application in assembly
Tecnolube® Applicare sulle superfici indicate
POLYMER 400 Apply on the indicated surfaces
AGIP® Riempire/Applicare in eccesso

GR MU EP2 Fill/Apply in excess
Olio minerale (SAE 90) o grasso al Litio Applicare sulle tenute/superfici indicate
Mineral oil (SAE 90) or Lithium grease Apply on the indicated seals/surfaces
Lubrificare solo con grasso al Litio

Lubricate with Lithium grease only
S/N: 020-069
S1165
GRASSO AL MONTAGGIO
Mod. 28.43M FR GREASE IN ASSEMBLY
S/N: 020-069
S1165
ADESIVI E COPPIE DI SERRAGGIO
ADHESIVES AND TIGHTENING TORQUES Mod. 28.43M FR
C.7 Adesivi e coppie di serraggio C.7 Adhesives and tightening

torques
Applicazione Adesivi/Sigillanti - Adhesive/Sealant Application
Applicare sulle superfici piane a contatto - Apply on the flat contact surfaces
Applicare sulla filettatura delle viti o sulle superfici curve di perni e boccole
Nota: applicare solo sul lato indicato
Apply on bolts thread or on pins and bushes curved surfaces
Note: apply only on indicated side
Sigillante per guarnizioni - Gasket sealant

Rif. Carraro Marca e tipo Caratteristiche tecniche Resistenza
Carraro Ref. Brand and type Technical characteristics Strength
Loctite® 510(1) Sigillatura superfici piane Alta
A1
Superbond® 529(1) Flat surface sealing High
Loctite® 573 Sigillatura superfici piane Bassa
A2
Superbond® 519 Flat surface sealing Low
Loctite® 518 Sigillatura superfici irregolari Alta
A3
Superbond® 539 Uneven surface sealing High
Sigillatura superfici piane con possibilità di
micromovimenti Alta
A4 Loctite® 5205
Even surface sealing with possibility of High
micro movements
Sigillatura superfici piane e/o irregolari con
possibilità di micromovimenti Alta
A5 Loctite® 5188(2)
Even/uneven surface sealing with possibility High
of micro movements
Nota: (1) A3 può essere impiegato al posto di A1; (2) A5 può essere impiegato al posto di A1, A2, A3, A4.
Note: (1) A3 can be used instead of A1; (2) A5 can be used instead of A1, A2, A3, A4.
Adesivi per frenatura organi filettati - Thread parts sealant

Loctite® 542 Frenatura organi filettati Media
B1
Superbond® 321 Locking of threaded parts Medium
Loctite® 270 Frenatura organi filettati Alta
B2
Superbond® 331 Locking of threaded parts High
Loctite® 986/AVX Frenatura organi filettati Alta, appl. speciali
B3
Superbond® 438 Locking of threaded parts High, special appl.
Adesivi per fissaggio particolari - Fixing parts sealant

Loctite® 402 Adesivo per fissaggio Fissaggio medio
C1
Superbond® istant 25 Fixing adhesive Medium bond
Loctite® 638 Adesivo per fissaggio Fissaggio forte
C2
Superbond® 443 Fixing adhesive Strong bond
Loctite® 542 Adesivo per fissaggio Fissaggio medio
C3
Superbond® 321 Fixing adhesive Medium bond
Loctite® 496 Adesivo per fissaggio gomma Fissaggio forte
C4
Superbond® SB14 Rubber fixing adhesive Strong bond
S/N: 020-069
S1165
Mod. 28.43M FR ADHESIVES AND TIGHTENING TORQUES
Adesivi e coppie di serraggio Adhesives and tightening torques
B2
70 Nm
B1
79 Nm
B2
230 Nm
60 Nm 500 Nm
25 Nm
60 Nm
A 12 Nm
30 Nm
A3
A3
12 Nm
S/N: 020-069
S1165
ADHESIVES AND TIGHTENING TORQUES Mod. 28.43M FR
B2
60 Nm 13 Nm
155 Nm C2
130 Nm
60 Nm 79 Nm
40 Nm
C2 B2
25 Nm 10 Nm
10 Nm
15 Nm A1 A1
The slot must
result parallel with
the axle shaft
Sez. A-A Sez. B-B
S/N: 020-069
S1165
Mod. 28.43M FR ADHESIVES AND TIGHTENING TORQUES
C2
Sez. C-C
S/N: 020-069
S1165
FRENI
BRAKES Mod. 28.43M FR
C.8 Freni C.8 Brakes
C.8.1 Caratteristiche Freni C.8.1 Brakes Features
DATI CARATTERISTICI FRENO DI SERVIZIO - SERVICE BRAKE TYPICAL DATA
Tipo freno A dischi in bagno d’olio Brake type

Wet discs brake
Attuazione freno Idraulica/Hydraulic Brake actuation
Temperatura di esercizio freni -20°C÷150°C Brake operating temperature
Temperatura di stoccaggio -40°C÷45°C Storage temperature
Pressione max di esercizio 44 bar Maximum operating pressure
Specifica olio per azionamento freno Olio minerale Oil specification for brake actuation
Mineral oil
Volume olio per azionamento freni Oil displacement for brakes actuation
16 cc
(per lato) (each side)
DATI CARATTERISTICI FRENO S.A.H.R. - S.A.H.R. BRAKE TYPICAL DATA
Pressione di sgancio freni 18÷30 bar Brake release pressure

Volume olio per azionamento freni Oil displacement for brakes actuation
140 cc
(per lato) (each side)
Dati tecnici dischi freno (un gruppo per ogni lato) Brake disks specifications (one set for each side)
Spessore controdisco nuovo= 5.0±0.05 mm Spessore controdisco nuovo= 10.7÷10.8 mm

New separator plate thickness= 5.0±0.05 mm New separator plate thickness= 10.7÷10.8 mm
Disco rif. CA136155 - q.tà 3 Disco rif. CA136644 - q.tà 1

Plate ref. CA136155 - q.ty 3 Plate ref. CA136644 - q.ty 1
Disco rif. CA143874 - q.tà 3

Plate ref. CA143874 - q.ty 3
Spessore disco attrito nuovo= 4.8±0.05 mm

Spessore minimo disco usurato= 4.0 mm
New friction plate thickness= 4.8±0.05 mm
Worn plate minimum thickness= 4.0 mm
S/N: 020-069
S1165
FRENI
Mod. 28.43M FR BRAKES
C.8.2 Controllo usura freni C.8.2 Brakes wear check

Alcune figure che seguono potrebbero non mostrare Some of the following pictures may not show exactly
esattamente il vostro assale, ma la procedura descritta your axle, but the indicated operations are correct
è quella corretta. anyway.
Eseguire le operazioni descritte su ogni gruppo freno. Perform described operations on every brake group.
1
A macchina ferma, azionare il freno di servizio.
Svitare lo sfiato (3) per eliminare eventuale pressione interna.
Vedi: C.5.1.
Svitare e togliere il tappo (1).
1
When the machine is stationary, actuate the service brake.

Loosen the breather (3) to release possible internal pressure.
See: C.5.1.
Unscrew and remove the plug (1).
2
Verificare lo stato di usura del materiale d’attrito dei dischi freno
tentando di inserire tra i controdischi una spina di diametro 4,08 mm.
Se la spina non passa, i dischi freno sono da sostituire in quanto
usurati.
Vedi: C.8.1.
Se la spina passa, i dischi freno non sono da sostituire.
Check the wear conditions of the brake discs friction material trying to
insert a pin of diameter 4,08 mm between the counterplates.
If the pin does not fit in, the brake discs are worn; replace them.
See: C.8.1.
If the pin fits in, do not replace the brake discs.
3
Richiudere il tappo (1) serrandolo con una chiave dinamometrica alla
coppia prevista.
Vedi: C.7.
1 Procedere al controllo dell’altro gruppo freno.
Position and tighten the plug (1) with a torque wrench to the
prescribed torque.
See: C.7.
Check the other brake group.
S/N: 020-069
S1165
FRENI
BRAKES Mod. 28.43M FR
Notes
S/N: 020-069
S1165
SMONTAGGIO E ASSEMBLAGGIO
Mod. 28.43M FR DISASSEMBLY AND ASSEMBLY
D SMONTAGGIO E ASSEMBLAGGIO
D DISASSEMBLY AND ASSEMBLY
AB10563 REVISION DATE: 02/12 DOC. CA270263 D PAG. 49
S/N: 020-069
S1165
GRUPPO RIDUTTORE EPICICLOIDALE
EPICYCLIC REDUCTION GEAR GROUP Mod. 28.43M FR
D.1 Gruppo riduttore epicicloidale D.1 Epicyclic reduction gear group
14
13
12
11
4 10
9
1 8
7
6
2 5
D.1.1 Smontaggio D.1.1 Disassembly

1
Svitare il tappo (1) e scaricare completamente l’olio dal riduttore
epicicloidale.
Vedi: C.5.3.
1
Unscrew the plug (1) and drain the oil completely from the epicyclic
reduction gear.
See: C.5.3.
D.1 PAG. 50 REVISION DATE: 02/12 DOC. CA270263 AB10563
S/N: 020-069
S1165
Mod. 28.43M FR EPICYCLIC REDUCTION GEAR GROUP
2
Svitare le due viti di fissaggio (3) del treno porta satelliti (2).
2
3
Unscrew the fastening screws (3) of the planetary carrier (2).
3
Rimuovere il treno porta satelliti (2) dal mozzo ruota (14) e rimuovere
2 13 il relativo OR (13).
Nota: operazione distruttiva per l’OR (13); l’OR dovrà essere
sostituito.
Posizionare il treno porta satelliti (2) su di un piano e verificarne le
condizioni di usura.
Remove the planetary carrier (2) from the wheel hub (14) and remove
the relative O-Ring (13).
Note: destructive operation for the O-Ring (13); the O-Ring must be
replaced.
14 Position the planetary carrier (2) on a workbench and check its wear
conditions.
4
Rimuovere il semiasse corto (12) dal mozzo ruota (14).
12
Remove the short half-shaft (12) from the wheel hub (14).
5
Per eseguire l’eventuale sostituzione degli ingranaggi (8):
10 - rimuovere la vite di fissaggio (11) da ogni perno (4);
- rimuovere la rondella (10);
7
- estrarre gli ingranaggi (8) dai perni;
11
- recuperare i rullini (6) e (9) e la rondella (7);
9 - recuperare la ralla (5).
6 8 If required replace the planetary gears (8) as follows:
5
- remove the fastening bolts (11) on every pin (4);
- remove the washer (10);
- remove the planetary gears (8) from the pins;
- collect the needle bearing (6) and (9) and washer (7);
- collect the thrust washer (4).
AB10563 REVISION DATE: 02/12 DOC. CA270263 D.1 PAG. 51
S/N: 020-069
S1165
D.1.2 Montaggio D.1.2 Assembly

Vedi: D.2.2 prima del montaggio del gruppo riduttore See: D.2.2 before assemble the epicyclic reduction
epicicloidale. gear group.
1
Posizionare su un banco di lavoro il treno porta satelliti (2).
Inserire la ralla (5) su ogni perno.
2
Position the planetary carrier (2) on a workbench.

Insert the thrust washer (5) on every pin.
2
Inserire i rullini (6), la rondella (7) e i rullini (9) all’interno degli
ingranaggi satelliti (8).
Nota: ingrassare bene i rullini (6) e (9).
Inserire nei perni (4) gli ingranaggi (8) completi di rullini.
Insert the needles (6), the thrust washer (7) and the needles (9) into
the planetary gears (8).
Note: grease well the needle bearings (6) and (9).
Insert the gears (8) with assembled needles on the pins (4).
3
Montare la ralla (10) nei perni (4).
Nota: il perno sulla ralla intermedia (10) deve inserirsi nel foro sul
perno (4).
Applicare il sigillante prescritto alle viti (11), assemblare ed avvitare le
viti di fissaggio (11) alla coppia prevista.
11 Vedi: C.7.
10 Fit the thrust washer (10) to the pins (4).
Note: the pin on thrust washers (7) must be fitted into the hole of the
pins (4).
Apply the prescribed sealant on the thread of the bolts (11). Assemble
2 the fastening bolts (11) and tighten them to the requested torque.
See: C.7.
S/N: 020-069
S1165
Mod. 28.43M FR EPICYCLIC REDUCTION GEAR GROUP
4
Assemblare il semiasse corto (12) al riduttore epicicloidale (2).
2
12
Assemble the short half-shaft (12) to the epicyclic reduction gear (2).
5
Inserire un nuovo OR (13) lubrificato sul mozzo ruota (14).
13
14
Assemble a new lubricated O-Ring (13) on the wheel hub (14).
6
Con un adatto sistema di sostegno allineare il gruppo riduttore
epicicloidale al mozzo ruota (14).
A V V E R T E N Z A garantire la sicurezza dell’operatore
secondo la normativa vigente.
Align the epicyclic reduction gear group to the wheel hub (14) using
an appropriate lifting device.
W A R N I N G observe all current safety regulations to
guarantee operator’s safety.
7
Montare il gruppo riduttore epicicloidale sul mozzo ruota (14).
Assemblare le viti di fissaggio (3) e serrarle alla coppia prevista.
Vedi: C.7.
3
13 Fit the epicyclic reduction gear group to the wheel hub (14).
Assemble the fastening screws (3) and tighten them to the prescribed
2 torque.
See: C.7.
S/N: 020-069
S1165
8
Ripristinare l’olio nel riduttore epicicloidale e nel corpo dell’assale.
1 Vedi: C.5.3.
Montare il tappo (1) sul treno porta satelliti (2), e serrare alla coppia
prevista.
Vedi: C.7.
Top up the specified oil into the epicyclic reduction gear.

See: C.5.3.
2 Fit the plug (1) on the epicyclic reduction gear (2) and tighten to the
prescribed torque.
See: C.7.
S/N: 020-069
S1165
GRUPPO MOZZO RUOTA
Mod. 28.43M FR WHEEL HUB GROUP
D.2 Gruppo mozzo ruota D.2 Wheel hub group
11
14
10
13
12
6
9 3
8
2
5
4
1

Rimuovere il gruppo riduttore prima del gruppo mozzo Remove the reduction gear group before
ruota. disassembling the wheel hub group.
Vedi: D.1.1. See: D.1.1.
1
Rimuovere dal semiasse l’anello d’arresto (1), utilizzando una pinza
adatta.
2
Importante: operazione distruttiva per l’anello d’arresto (1); l’anello
1 d’arresto dovrà essere sostituito.
Sfilare e recuperare la rondella (2).
Remove the lock ring (1) from the U-Joint shaft by using suitable
pliers.
Important: destructive operation for the lock ring (1); the lock ring
must be replaced.
Slide and collect the U-Joint washer (2).
S/N: 020-069
S1165
GRUPPO MOZZO RUOTA
WHEEL HUB GROUP Mod. 28.43M FR
2
Svitare e togliere le viti di fissaggio (4) del gruppo mozzo porta
riduttore (3).
4 Recuperare la ralla (6).
3
6 Unscrew and remove the fastening screws (4) reduction gear carrier/
(3).
Collect the thrust washer (6).
3
Per estrarre il mozzo porta corona dalla sua sede, avvitare tre viti M10
nei fori di estrazione indicati.
Vedi: punto successivo.
To remove the wheel carrier group from its housing, screw three
screws with M10 thread in the shown extraction holes.
See: next point.
4
Estrarre e rimuovere il gruppo mozzo porta riduttore (3).
3
Extract and remove the reduction gear carrier group (3).
5
Rimuovere l’anello d’arresto (8) e separare il mozzo porta corona (7)
18 dalla corona epicicloidale (3).
19
14
Remove the lock ring (8) and disjoin the wheel carrier (7) from the
epicyclic ring gear (3).
S/N: 020-069
S1165
GRUPPO MOZZO RUOTA
6
A T T E N Z I O N E prima di smontare il mozzo ruota (11),
assicurarlo con una cinghia o una fune ad un paranco od altro
sistema di sostegno, per evitarne la caduta accidentale che
potrebbe danneggiare sia l’operatore che il gruppo.
5
Sfilare il mozzo ruota (11), facilitando lo smontaggio con leve e
martello.
Nota: recuperare il cono del cuscinetto (9).
C A U T I O N before disassembly the wheel hub (11), it is
advisable to secure it with a belt or a rope on a hoist or any other
supporting device, in order to avoid its accidental fall that could
damage either the operator or the wheel hub group.
Remove the wheel hub (11), using levers and a hammer to facilitate
the operation.
Note: collect the bearing cone (9).
7
Posizionare su di una superficie piana il mozzo ruota (11) ed estrarre
l’anello di tenuta (13).
11 Nota: operazione distruttiva per l’anello di tenuta (13); l’anello di
tenuta dovrà essere sostituito.
Estrarre le piste esterne dei cuscinetti (9) e (12), utilizzando un
13 tampone ed un martello oppure utilizzando un estrattore da
9
commercio.
12
Position the wheel hub (11) on a flat surface and remove the seal ring
(13).
Note: destructive operation for the seal ring (13); the seal ring must
be replaced.
Remove the bearing cups (9) and (12) by using a hammer and a
suitable drift or by using a suitable puller.
8
Estrarre, con due leve, il cono del cuscinetto (12) rimasto montato
12 sulla calotta.
Importante: non rovinare la sede del cuscinetto.
With two levers remove the bearing cone (12) still fitted on the swivel
housing.
Important: do not damage the bearing seat.
S/N: 020-069
S1165
GRUPPO MOZZO RUOTA

1
La speciale esecuzione “Set Right” dei cuscinetti non richiede
specifiche registrazioni del precarico o del gioco. In ogni caso, prima
del montaggio di nuove parti, controllare le dimensioni indicate.
A= 17.950 ÷ 18.000 mm
C C
B= 64.335 ÷ 64.385 mm
A
C= 23.071 ÷ 23.172 mm
B
The special operation “Set Right” of the bearings does not require
preload or backlash adjustment. Anyway, before assembling new
components check the indicated dimensions.
2
Posizionare il mozzo ruota (11) su di un banco di lavoro e piantare le
due coppe dei cuscinetti (9) e (12) utilizzando l’attrezzo speciale
CA715026 sotto l’azione di una pressa o di un martello.
Inserire un nuovo anello di tenuta (13) ben ingrassato nel mozzo ruota
utilizzando l’attrezzo speciale CA119143 ed un martello.
5
Position the wheel hub (11) on a workbench and force the two bearing
(9) and (12) cups in position by using the special tool CA715026
under a press or with a hammer.
Insert a new well greased seal ring (13) into the wheel hub by using
the special tool CA119143 and a hammer.
3
Attenzione: prima di assemblare il mozzo ruota (11), assicurarlo con
12 una cinghia o una fune ad un paranco od altro sistema di sostegno,
9 per evitarne la caduta accidentale che potrebbe danneggiare sia
l’operatore che il gruppo.
Assemblare il cono del cuscinetto (12) sul codolo della calotta.
Assemblare il mozzo ruota sulla calotta e posizionare l’altro cono del
cuscinetto (9).
Warning: before assembly the wheel hub (11), it is advisable to
secure it with a belt or a rope on a hoist or any other supporting device,
in order to avoid its accidental fall that could damage either the
operator or the wheel hub group.
Assemble the bearing cone (12) on the swivel housing end.
Assemble the wheel hub on the swivel housing and fit the other
bearing cone (9) in position.
S/N: 020-069
S1165
GRUPPO MOZZO RUOTA
4
Posizionare il mozzo porta corona (7) su di un banco di lavoro e
7 piantare le boccole (5) a filo della superficie utilizzando l’attrezzo
speciale CAxxxxxx (T.B.A.).
5 Almeno due boccole (diametralmente opposte) devono essere
piantate leggermente oltre il filo per essere utilizzate come spine di
centraggio.
Position the wheel carrier (7) on a workbench and force the bushes
(5) to the carrier surface level by using the special tool CAxxxxxx
(T.B.A.).
At least two bushes (diametrically opposed) must be slightly higher
than the carrier surface level to be used as dowel pins.
5
Assemblare il mozzo porta corona (7) alla corona epicicloidale (3).
Assemblare l’anello d’arresto (8) nella rispettiva sede della corona
7 epicicloidale (3).
3
Assemble the wheel carrier (7) to the epicyclic ring gear (3).
Assemble the lock ring (8) into its seat of the epicyclic ring gear (3).
6
Assemblare il gruppo mozzo porta corona sul mozzo ruota utilizzando
due boccole sporgenti come spine di centraggio.
Avvitare due delle viti (4) fino a portare il gruppo a contatto con il
mozzo ruota.
Assemble the wheel carrier group on the wheel hub using two
projecting bushes as dowel pins and screw two screws (4) in order to
put in contact the ring bevel gear with the wheel hub.
7
Piantare tutte le bussole di centraggio mozzo (5) fino a battuta
utilizzando l’attrezzo speciale CAxxxxxx (T.B.A.) ed un martello.
Applicare il sigillante prescritto alle viti (4) di fissaggio del mozzo porta
4 corona. Assemblare le viti (4) e serrarle alla coppia prevista.
Vedi: C.7.
Force all the hub dowel bushes (5) completely by using the special
tool CAxxxxxx (T.B.A.) and a hammer.
Apply the prescribed sealant on the bolts (4) thread. Assemble the
wheel carrier fastening bolts (4) and tighten them to the requested
torque.
See: C.7.
S/N: 020-069
S1165
GRUPPO MOZZO RUOTA
8
Rimuovere le due viti (4) e assemblare la ralla (6).
Vedi: punto successivo.
Assemblare e serrare tutte le viti di fissaggio (4) alla coppia prevista.
Vedi: C.7.
Remove the two screws (4) and assemble the thrust washer (6).
See: next step.
Assemble and tighten all the fastening bolts (4) to the requested
torque.
See: C.7.
9
Nota: assemblare la ralla (6) con le 4 scanalature verso l’esterno.
Note: assemble the thrust washer (6) with the 4 notches outward.
10
Infilare nel semiasse del doppio giunto la rondella di rasamento (2), e
montare un nuovo anello d’arresto (1) inserendolo all’estremità del
mozzo scanalato e spingendolo in sede.
Spingere con la mano il doppio giunto fino a fine corsa e controllare
che l’anello d’arresto (1) vada in sede.
2
Insert the thrust washer (2) into the U-Joint shaft and lock it with a new
1 lock ring (1), inserting it at the end of the splined hub and pushing it
into its housing.
Push the double U-Joint thoroughly and check the lock ring (1) is
correctly fitted in its seat.
S/N: 020-069
S1165
GRUPPO TROMBA TRAVE
Mod. 28.43M FR AXLE BEAM TRUMPET GROUP
D.3 Gruppo tromba trave D.3 Axle beam trumpet group
1
3
6
7
4
8 9
10

Rimuovere il gruppo mozzo ruota prima del gruppo Remove the wheel hub group before disassembling the
tromba trave. axle beam trumpet group.
Vedi: D.2.1. See: D.2.1.
1
A V V I S O disattivare i freni di parcheggio negativi.
Vedi: D.9.3.2
N OT I C E disable negative parking brakes

Vedi: D.9.3.2
S/N: 020-069
S1165
GRUPPO TROMBA TRAVE
AXLE BEAM TRUMPET GROUP Mod. 28.43M FR
2
Estrarre l’anello di tenuta (10) dalla tromba trave (7) con un estrattore
adatto.
7 Nota: operazione distruttiva per l’anello di tenuta (10); l’anello di
tenuta deve essere sostituito.
10
Remove the seal ring (10) from the beam trumpet (7) with a suitable
extractor.
Note: destructive operation for the seal ring (10): the seal ring must
be replaced.
3
Fare dei segni di riferimento indelebili sulle trombe trave, sui cilindri
freno e sul corpo centrale trave, per identificare con sicurezza gli
elementi accoppiati.
Put alignment marks on the beam trumpets, on the brake cylinders

and on the central body, in order to be absolutely sure to identify the
coupled parts.
4
A T T E N Z I O N E disporre l’assale su supporti adatti a
sostenere sia il corpo centrale trave che le due trombe trave, anche
dopo la loro separazione, o assicurare i gruppi separatamente con
funi o cinghie ad un sistema di sollevamento.
Svitare e togliere le viti di fissaggio (8).
8
CAUTION Position the axle on supports fitted to hold either
the central body and the two beam trumpets, even after their
disjunction, or secure the disjointed groups to a lifting device with
ropes or belts.
Unscrew and remove the fastening screws (8).
5
Staccare la tromba trave (7) e rimuovere gli OR (5) e (6).
Nota: i due OR dovranno essere sostituiti.
Importante: sostenere il semiasse lungo (2) che si libera rimuovendo
6 la tromba. Trattenere i dischi freno nella loro sede se non è necessario
rimuoverli; si consiglia di legare il pacco dischi alla flangia freno.
Remove the beam trumpet (7) and remove the O-Rings (5) and (6).
Note: the two O-Rings must be replaced.
5
Important: sustain the long axle shaft (2) that is released by removing
7 the trumpet. Hold the brake disks in their seat if it’s not necessary to
remove them; it’s advisable to tie the disk pack to the brake flange.
S/N: 020-069
S1165
GRUPPO TROMBA TRAVE
6
Estrarre la bronzina (9) dalla tromba (7) solo se le condizioni di usura
lo richiedono.
Nota: attenzione a non rovinare la sede della bronzina.
7
9 Remove the bush (9) from the beam trumpet (7) only if the wear condi-
tions require this.
Note: be careful not to damage the bush seat.
7
Estrarre l’albero (2) con il manicotto scanalato (4).
Solo se necessario rimuovere l’anello d’arresto (3) dal manicotto
scanalato.
2
4
Remove the shaft (2) and the splined sleeve (4).
Only if necessary remove the snap ring (3) from the splined sleeve.

Montare il gruppo freno prima del gruppo trombe trave. Assemble the brake group before assembling the axle
Vedi: D.4.2 beam trumpets group.
See: D.4.2
1
Infilare il semiasse (2) nel corpo centrale.
Posizionare l’anello d’arresto (3) nella sede all’interno del manicotto
(4). Infilare il manicotto (4) sul semiasse lungo (2).
Nota: spingere il manicotto fino a che l’anello di arresto interno non
2
sia andato in battuta sul semiasse lungo.
3
1
Insert the axle shaft (2) into the axle central body.
4 Fit the snap ring (3) into the its seat inside the sleeve (4).
Assemble the sleeve (4) on the long half-shaft.
Note: drive the sleeve with the snap ring rests on long half-shaft
S/N: 020-069
S1165
GRUPPO TROMBA TRAVE
AXLE BEAM TRUMPET GROUP Mod. 28.43M FR
2
Montare nella tromba trave (7) la bronzina (9) utilizzando l’attrezzo
speciale CAxxxxxx (T.B.A.) ed un martello.
7
9
Assemble on the beam trumpet (7) the bush (9) by using the special
tool CAxxxxxx (T.B.A.) and a hammer.
3
Assemblare i nuovi OR (5) e (6) alla tromba trave.
7
5
Assemble the new O-Ring (5) and (6) to the beam trumpet.
4
Assemblare la tromba trave al corpo centrale (1) rispettando i segni di
riferimento eseguiti in fase di smontaggio.
1
A T T E N Z I O N E sostenere opportunamente i gruppi come
già indicato nella fase di smontaggio.
Assemble the beam trumpet to the central body (1) using the
reference marks carried out during disassembly.
CAUT ION support the groups properly as already pointed
out for disassembly phase.
5
Avvitare le viti di fissaggio (8) e serrarle alla coppia prevista
Vedi: C.7.
Nota: per un corretto serraggio delle viti (8), seguire le indicazioni
riportate al punto successivo.
Screw in the fastening screws (8) to the requested torque.

See: C.7.
Note: for a correct bolts (8) assembly, follow the tightening procedure
indicated at the next step.
S/N: 020-069
S1165
GRUPPO TROMBA TRAVE
6
Serrare le viti di fissaggio (8) rispettando l’ordine indicato in figura.
a
e h
m d
c l
i f
Tighten the fastening screws (8) according to the sequence shown in
g b
figure.
7
Montare un nuovo anello di tenuta (10) nella tromba trave (7) con
l’attrezzo speciale CAxxxxxx (T.B.A.) ed un martello.
7 Vedi: punto successivo.
10
Assemble a new seal ring (10) in the beam trumpet (7) using the
special tool CAxxxxxx (T.B.A.) and a hammer.
See: next step.
8
Importante: orientare l’anello di tenuta (10) come in figura.
Lubrificare il labbro di tenuta dopo il montaggio.
9
10
Important: assemble the seal ring (10) as in figure.
Lubricate the seal lip after assembly.
9
A V V I S O dopo aver assemblato entrambi i gruppi tromba trave,
attivare i freni di parcheggio negativi.
Vedi: D.9.3.3
N O T I C E enable negative parking brakes after both axle beam

trumpet groups have been assembled.
Vedi: D.9.3.3
S/N: 020-069
S1165
GRUPPO FRENO
BRAKE GROUP Mod. 28.43M FR
D.4 Gruppo freno D.4 Brake group
4
19
1 5
6 18
8 17
12 16
2 10
3 15
7 14
9 20
21 11
22 13
23
25
26 27 31
24 28 32
29
30

1
AVV IS O disattivare i freni di parcheggio negativi.
Vedi: D.9.3.2
NOTICE disable negative parking brakes

Vedi: D.9.3.2
S/N: 020-069
S1165
GRUPPO FRENO
Mod. 28.43M FR BRAKE GROUP
2
Rimuovere il gruppo tromba trave dalla flangia freno (14).
Vedi: D.3.1
14
Remove the beam trumpet group from the brake flange (14).
See: D.3.1
3
Rimuovere i componenti dalla flangia freno (14): controdischi freno
(32, 30) e dischi freno (31, 29), mozzo traino dischi freno (27) e
25 controdischi freno (28, 25) con il disco freno (26).
28
27 29
31
14
26
Remove the components from the brake flange (14): brake counter
30 plates (32 and 30) and brake plates (31 and 29), brake disk carrier
32
gear (27) and brake counter plate (28 and 25) with brake plate (26).
4
Svitare e togliere le viti del kit self-adjust (24) recuperandone tutti i
componenti.
Estrarre il pistone freno positivo (23).
23
24
Unscrew and remove the self-adjust kit’s (24) screw and collect all the
components.
Remove the brake piston positive (23).
5
Rimuovere gli OR (21) e (22) dal pistone freno (23).
Nota: operazione distruttiva per gli OR (21) e (22); gli OR dovranno
essere sostituiti.
23
21
22
Remove the O-Rings (21) and (22) from the brake piston (23).
Note: destructive operation for the O-Rings (21) and (22); the O-Rings
must be replaced.
S/N: 020-069
S1165
GRUPPO FRENO
6
Togliere i tappi (19) e svitare completamente le viti (18) dalle viti freno
A parcheggio (A), (B) e (C).
Svitare alternativamente le viti (16) fino a rimuoverle completamente.
Recuperare gli anelli OR (17) ed i perni (15).
Nota: operazione distruttiva per gli OR (17); gli OR dovranno essere
sostituiti.
C
B
19
18
17
16
Remove the plugs (19) and unscrew completely the screws (18) from
15 the parking brake screws (A), (B) e (C).
Unscrew alternately the screw (16) until they are completely removed.
Collect the O-Rings (17) and the pins (15).
Note: destructive operation for the O-Rings (17); the O-Rings must be
replaced.
7
Assicurare il cilindro freno (14) ad un paranco con funi o cinghie di
sicurezza.
Rimuovere la viti (20).
AVV IS O questa operazione libera il cilindro freno (14).
20
Secure the brake cylinder (14) to a hoist with ropes or safety belts.
Remove the screw (20).
NOTICE the brake cylinder is free (14).
8
sicurezza.
Rimuovere il cilindro freno (14).
Importante: questa operazione libera la scatola differenziale.
Rimuovere l’OR (13) dal cilindro freno (14).
Nota: operazione distruttiva per l’OR (13); l’OR dovrà essere
sostituito.
Remove the brake cylinder (14).
Important: the differential box is free.
Remove the O-Ring (13) from the brake cylinder (14).
replaced.
S/N: 020-069
S1165
GRUPPO FRENO
9
Posizionare l’attrezzo CA715714 sull’anello reggispinta (3).
2 Sotto l’azione di una pressa esercitare una spinta tale da poter
CA715714
3 rimuovere l’anello d’arresto (2).
PER IC OLO questa operazione deve essere condotta con la
massima cautela.
Position the tool CA715714 on the thrust washer (3).

Using a press, apply a pressure on the entire assembly until the snap
ring (2) can be removed.
D A N G E R this operation must be performed with extreme
care.
10
Eseguire un rilascio della spinta della pressa lento e graduale,
recuperare quindi l’anello reggispinta (3) e le molle a tazza (4) e (5).
2 PE RICOL O possibile rapida espulsione delle molle a tazza.

3
4
5
Release the load of the press slowly and gradually, them collect the
thrust washer (3) and the belleville washers (4) and (5).
14
D A N G E R it is possible a rapid ejection of the belleville
washer.
11
Per l’estrazione del pistone freno negativo (8) utilizzare il foro di
12 mandata del freno applicando la minima pressione d’olio o aria
necessaria per l’espulsione.
8
PER IC OLO questa operazione deve essere condotta con la
6 massima cautela.
Rimuovere gli OR (6) e (12) dal pistone freno negativo.
essere sostituiti.
14
In order to extract the negative brake piston (8) use the hydraulic
connection applying the lowest oil or air pressure necessary to
dislodge the piston.
D A N G E R this operation must be performed with extreme
care.
Remove the O-Rings (6) and (12) from the negative brake piston.
must be replaced.
S/N: 020-069
S1165
GRUPPO FRENO
12
Togliere l’anello d’arresto (7) dal pistone freno negativo (8) ed estrarre
7 il perno di spinta (10).
Rimuovere gli OR (9) e (11) dal perno di spinta.
8 essere sostituiti.
9 Remove the snap ring (8) from the negative brake piston (8) and
10 extract the thrust pin (10).
Remove the O-Rings (9) and (11) from the thrust pin.
11 Note: destructive operation for the O-Rings (9) and (11); the O-Rings
must be replaced.

Montare il gruppo supporto differenziale prima del Assemble the differential support group before
gruppo freno. assembling the brake group.
Vedi: D.6.2 See: D.6.2
1
Montare due nuovi OR (9) e (11) ben lubrificati sui perni di spinta (10).
7 Inserire i perni di spinta nel pistone freno negativo (8) e bloccarli con
gli anelli d’arresto (7).
9
10 Assemble two new well lubricated O-Rings (9) and (11) to the thrust
pins (10).
11 Insert the thrust pins into the negative brake piston (8) and lock them
with the snap rings (7).
2
Assemblare i nuovi OR (6) e (12) ben lubrificati al pistone freno
negativo (8).
t1 Inserire il pistone freno negativo nel cilindro freno (14) utilizzando
l’attrezzo speciale CA715714 (t1) ed una leva come illustrato in figura
12 t1 oppure utilizzando una pressa.
8
6 Assemble new well lubricated O-Rings (6) and (12) to the negative
brake piston (8).
14 Insert the negative brake piston into the brake cylinder (14) by using
the special tool CA715714 (t1) and a lever as shown in figure or using
a press.
S/N: 020-069
S1165
GRUPPO FRENO
3
Posizionare le molle a tazza (4) e (5) ben centrate
Nota: rispettare la posizione indicata nella figura successiva
t1
Assemblare l’anello reggispinta (3) con la sede per l’anello d’arresto
2 (2) verso l’esterno, e l’attrezzo speciale CA715714 (t1) nel cilindro
3 freno (14).
4 Vedi: punti successivi.
5 Position the belleville washer (4) and (5) well matched.
Note: place the concave side as shown in the next figure.
14 Place the thrust washer (3) with the snap ring (2) seat outermost and
the special tool CA715714 (t1) into the brake cylinder (14).
See: next steps.
4
Sotto l’azione di una pressa esercitare una spinta sull’anello
reggispinta (3) tale da poter montare l’anello d’arresto (2).
CA715714
PE RICOL O possibile rapida espulsione delle molle a tazza.
Using a press, apply a pressure on the thrust washer (3) until the snap
ring (2) can be fitted.
D A N G E R it is possible a rapid ejection of the belleville
washer.
5
Utilizzando la pressa come protezione di sicurezza, allontanare con
cautela e solo di pochi millimetri l’attrezzo CA715714 dalle molle a
CA715714
tazza. Applicare olio alla pressione di circa 20 bar alla mandata olio
freno e far compiere almeno tre corse di lavoro al pistone freno (8)
verificando la tenuta idraulica degli anelli OR ed il corretto inserimento
dell’anello d’arresto (2).
Using the press as safety protection, move away with caution and only
for few millimeters the special tool CA715714 from the belleville
washer. Apply an oil pressure of about 20 bar through the hydraulic
connection, in order to do at least three stroke of the brake piston (8)
and check the tightness of the O-Rings and the correct insertion of the
snap ring (2).
S/N: 020-069
S1165
GRUPPO FRENO
6
Assemblare i nuovi OR (17) ben lubrificati alle viti (16).
Montare i perni (15) e le viti (16) al cilindro freno (14) nelle posizioni
A, B e C.
Attraverso la mandata applicare una pressione d’olio di circa 20 bar
nel cilindro freno ed avvitare le tre viti (16) fino al contatto con il pistone
15
freno negativo (8).
17 Importante: il piano inclinato dei perni (15) deve appoggiarsi contro
il pistone freno negativo (8), come indicato in figura.
14 19
16
18
A
Assemble new well lubricated O-Ring (17) to the screws (16).

Assemble the pins (15) and the screws (16) into the brake cylinder
(14) to the positions A, B and C.
C Apply an oil pressure of about 20 bar through the hydraulic connection
of the brake cylinder and screw the three screws (16) till to touch the
B
negative brake piston (8).
Important: the pin’s ramp (15) must seat against the negative brake
piston (8), as shown in figure.
7
Completare l’operazione chiudendo con un ulteriore quarto di giro le
18 19 tre viti (16).
Togliere la pressione dell’olio al cilindro freno.
16 Applicare il sigillante prescritto sotto la testa delle viti (18); avvitare e
serrare le viti (18) alla coppia prevista.
Vedi: C.6
Avvitare e serrare i grani (19) alla coppia prevista.
Vedi: C.6
Nota: applicare il sigillante sul filetto dei grani (19) solo dopo
l’attivazione del freno di parcheggio (vedi D.9.3.3).
Carry out the adjustment tightening the three screws (16) a further of
quarter turn.
Drop the oil pressure in the brake cylinder.
Apply prescribed sealant under the screw heads (18); assemble and
tighten the special screws (18) to the prescribed torques.
See: C.6
Assemble and tighten the lock screws (19) to te requested torque.
See: C.6
Note: only after enabling the parking brake apply sealant under the
lock screws (19) (see D.9.3.3).
S/N: 020-069
S1165
GRUPPO FRENO
8
Recuperare il pistone freno (23).
Spingere le boccole (b) nelle sedi dei self-adjust utilizzando l’attrezzo
speciale CA715033 ed un martello, fino a pareggiarle con la superficie
interna di appoggio del pistone.
b
Collect the brake piston (23).

By using special tool CA715033 and a hammer, push the bushes (b)
into the self-adjust housings till they are aligned with the piston
supporting inner surface.
9
Nota: le boccole (b) devono essere a filo della superficie interna di
b appoggio del pistone.
b
b
b Note: the bushes (b) must be aligned with the piston supporting inner
surface.
10
Assemblare due nuovi OR (21) e (22) al pistone freno (23).
Lubrificare gli OR.
23
21
22
Assemble two new O-Rings (21) and (22) to the brake piston (23).
Lubricate the O-Rings.
S/N: 020-069
S1165
GRUPPO FRENO
11
Inserire il pistone (23) nel cilindro freno (14) e posizionare l’attrezzo
speciale CA715714 sul pistone.
Nota: posizionare il pistone freno positivo (23) con una cava in
corrispondenza al foro di ricircolo olio o al foro d’ispezione del cilindro
freno (14).
Con una leva ben ancorata ad un golfare, esercitare una pressione
appena sufficiente ad inserire il pistone nella flangia freno.
Insert the piston (23) into the brake cylinder (14) and position the
special tool CA715714 on the piston.
Note: position the positive brake piston (23) with a slot aligned with
the hydraulic connection or with the inspection hole on the brake
cylinder (14).
With a lever anchored to an eyebolt, make a pressure just enough to
insert the piston into the brake flange.
12
Montare i componenti del kit self-adjust (24).
23 Vedi: punto successivo.
Applicare il sigillante prescritto sul filetto delle viti, assemblarle e
serrarle alla coppia prevista.
24 Vedi: C.6
Assemble the self-adjust kit (24).

See: next step.
Apply the prescribed sealant on the bolts thread, assemble the bolts
and tighten them the requested torque.
See: C.6
13
Schema di assemblaggio dei componenti kit self-adjust (24).
Assembly scheme of the self-adjust kit (24).
S/N: 020-069
S1165
GRUPPO FRENO
14
Montare un nuovo OR (13) ben lubrificato nella sede del cilindro freno
(14).
Assemblare il cilindro freno (14) al corpo centrale (1).
Nota: verificare che i segni di riferimento fatti allo smontaggio tra il
cilindro freno (14) ed il corpo centrale (1) coincidano.
Assemblare la scatola differenziale prima di assemblare la flangia
freno sinistra.
Assemble a new well lubricated O-Ring (13) to the brake cylinder (14)
seat.
Assemble the brake cylinder (14) on the central body (1).
Note: check that the reference marks made during the disassembly
between the brake cylinder (14) and the central body (1) coincide.
Assemble differential housing before perform the left brake cylinder
assembly.
15
Assemblare il cilindro freno (14) al corpo centrale (1).
Assemblare la vite (20) e serrarla alla coppia prescritta.
Vedi: C.7.
20
Assemble the brake cylinder (14) on the central body (1).

Assemble the screw (20) and tighten it to the prescribed torque.
See: C.7.
16
Verificare che i dischi freno ed i controdischi freno non presentino
tracce di bruciatura, in caso contrario sostituirli. Verificare inoltre
l’usura dei dischi freno.
Vedi: C.7.
Sostituire i dischi freno se necessario.
Vedi: D.5.3 [Sostituzione dischi freno].
Check that the brake plate and the brake drive plate do not present
any sign of burning, on the contrary, replace them. Furthermore check
brake plate wear.
See: C.7.
If necessary replace the brake disks.
See: D.5.3 [Brake disks replacement].
S/N: 020-069
S1165
GRUPPO FRENO
17
Importante: Nel caso in cui si sostituiscano i dischi freno usurati con
nuovi dischi è necessario ripristinare la posizione iniziale del pistone.
Vedi: D.5.3 [Sostituzione dischi freno]
Important: The brake piston must be pushed in the original position

if worn brake disks are replaced by new disks.
See: D.5.3 [Brake disks replacement].
18
Rimontare tutti gli elementi del gruppo freno come indicato in figura:
controdisco freno (25) e (28) e disco freno (26), mozzo traino dischi
25 freno (27) e dischi freno (29) e (31) e controdischi freno (30) e (32).
Importante: alla corretta posizione del gradino sul diametro esterno
27 del mozzo traino dischi freno (27).
30 Nota: inserire i dischi freno con i fori allineati.
14 32 Reassemble all the components of the brake group as is shown in
26 figure: brake counterplate (25) and (28), brake plate (26), brake disk
28 carrier (27), brake counterplates (29) and (31) and brake plates (30)
29 and (32).
31 Important: to the correct position of the step on the external diameter
of the brake disk carrier (27).
Note: assemble brake disks with holes aligned.
19
Nota: posizione corretta del gradino sul diametro esterno del mozzo
traino dischi freno (27).
27
Note: this is the correct position of the step on the external diameter
S/N: 020-069
S1165
GRUPPO FRENO
20
Rimontare il gruppo tromba trave.
Vedi: D.3.2
Assemble the beam trumpet group to the brake flange (14).

See: D.3.2
21
Vedi: D.9.3.3
N OT I C E enable negative parking brakes after both axle beams

groups have been assembled.
See: D.9.3.3
D.4.3 Sostituzione dischi freno D.4.3 Brake disks replacement

1
A V V I S O disattivare i freni di parcheggio negativi.
Vedi: D.9.3.2
N OT I C E disable negative parking brakes.

Vedi: D.9.3.2
S/N: 020-069
S1165
GRUPPO FRENO
2
A V V E R T E N Z A disporre l’assale su supporti adatti a
sostenere sia il corpo centrale che le trombe, anche dopo la loro
separazione, o assicurare i gruppi separatamente con funi o cinghie
ad un sistema di sollevamento.
Svitare e togliere le viti di fissaggio (b).
b WARNING Position the axle on supports fitted to hold either

the central body and the beam trumpets, even after their disjunction,
or secure every group to a lifting device with ropes or belts.
Unscrew and remove the fastening bolts (b).
3
Rimuovere il gruppo tromba trave/mozzo ruota dalla flangia freno
(14).
Rimuovere gli OR (o) e (r).
r Nota: i due OR dovranno essere sostituiti.
Importante: sostenere il semiasse che si libera rimuovendo la tromba.
Remove the beam trumpet/wheel hub group from the brake flange
14
(14).
Remove the O-Rings (o) and (r).
o
Note: the two O-Rings must be replaced.
Important: sustain the axle shaft that is released by removing the
trumpet.
4
Estrarre il semiasse (a) con il manicotto scanalato (c).
Nota: solo se necessario rimuovere l’anello d’arresto (b) dal
manicotto scanalato.
a
c Remove the shaft (a) and the splined sleeve (c).

Note: only if necessary remove the snap ring (b) from the splined
sleeve.
5
Rimuovere i componenti dalla flangia freno (14): controdischi freno
(32) e (30) e dischi freno (31) e (29), mozzo traino dischi freno (27) e
25 controdischi freno (28) e (25) con il disco freno (26).
28
27 29
31
14
26
Remove the components from the brake flange (14): brake counter
30 plates (32) and (30) and brake plates (31) and (29), brake disk carrier
32
gear (27) and brake counter plate (28) and (25) with brake plate (26).
S/N: 020-069
S1165
GRUPPO FRENO
6
Per sostituire i dischi freno usurati con nuovi dischi è necessario
ripristinare la posizione iniziale del pistone.
Rimuovere attacchi, sfiatatoi ed eventuali tappi dagli ingressi olio
freni.
AT TENZIONE possibile espulsione di olio dall’assale.
To replace worn brake disks with new disks the brake piston must be
pushed in the original position.
Remove straight threads, bleeds or plugs from the service brake oil
port.
CAUTION risk of ejection of oil from the axle.
7
Spingere il pistone (23) del freno in battuta utilizzando l'attrezzo
speciale CA715714 con il manico intercambiabile CA119033 ed un
martello.
Nota: posizionare il tampone con cura per non danneggiare il pistone.
Push the brake piston (23) at the end of stroke by using the special
pad CA715714 and the handle CA119033 with a hammer.
Note: position the pad with accuracy to do not damage the brake
piston.
8
Rimontare tutti gli elementi del gruppo freno come indicato in figura:
controdisco (25), nuovo disco freno (26), controdisco (28), mozzo
25 traino dischi (27) e nuovi dischi freno (29) e (31) assieme ai
controdischi (30) e (32).
27 Importante: attenzione alla corretta posizione del gradino sul mozzo
30 traino dischi freno (27); inserire i dischi freno con i fori allineati.
14 32 Reassemble all the components of the brake group as is shown in
26 figure: brake counterplate (25), new brake plate (26), brake
28 counterplate (28), brake disk carrier (27), new brake plates (29) and
29 (31) with brake counterplates (30) and (32).
31 Important: to the correct position of the step on the brake disk carrier
(27); assemble brake disks with holes aligned.
9
Nota: posizione corretta del gradino sul diametro esterno del mozzo
traino dischi freno (27).
27
Note: this is the correct position of the step on the external diameter
S/N: 020-069
S1165
GRUPPO FRENO
10
Assemblare i nuovi OR (5) e (6) alla tromba trave.
7
5
Assemble the new O-Ring (5) and (6) to the beam trumpet.
11
Assemblare il semiasse completo di manicotto al gruppo freno,
inserendolo a fondo nel differenziale.
14
a
c
Assemble the axle shaft with relative splined sleeve in the central
body, then fit it into the differential.
12
Assemblare il gruppo tromba trave/mozzo ruota alla flangia freno (14)
A T T E N Z I O N E sostenere opportunamente i gruppi come
già indicato nella fase di smontaggio.
Assemble the axle beam trumpet/wheel hub group to the brake flange
(14).
14
CAUT ION support the groups properly as already pointed
out for disassembly phase.
S/N: 020-069
S1165
GRUPPO FRENO
13
Assemblare e serrare le viti di fissaggio (b) alla coppia prevista.
Vedi: C.7.
Nota: serrare le viti di fissaggio (b) nell’ordine indicato al punto
successivo.
b
Assemble and tighten the fastening bolts (b) to the prescribed torque.
See: C.7.
Note: tighten the fastening bolts (b) according to the sequence shown
at the next step.
14
Serrare le viti di fissaggio (b) rispettando l’ordine indicato in figura.
XII I
VIII V
IV IX
X III
VI VII
Tighten the fastening bolts (b) according to the sequence shown in
II XI
figure.
15
Vedi: D.9.3.3.
N O T I C E enable negative parking brakes after both axle beam

trumpet groups have been assembled.
Vedi: D.9.3.3.
S/N: 020-069
S1165
GRUPPO FLANGIA
FLANGE GROUP Mod. 28.43M FR
D.5 Gruppo flangia D.5 Flange group
5 6
4
3

1
Togliere l’anello d’arresto (1) e sfilare la flangia (2).
6
Remove the lock ring (1) and flange (2).
S/N: 020-069
S1165
GRUPPO FLANGIA
Mod. 28.43M FR FLANGE GROUP
2
Rimuovere l’anello OR (3), la rondella (4) e l’anello di tenuta (5)
Nota: operazione distruttiva per gli anelli di tenuta.
5
4
3
6
Remove the O-ring (3), the washer (4) and the seal ring (5).
Note: destructive operation for the seal rings.

1
Montare la rondella (4) ed un nuovo anello OR (3) sul codolo del
pignone.
Montare un nuovo anello di tenuta (5) al supporto differenziale con il
tampone CA715543 ed un martello.
5
4
3
6 Assemble the washer (4) and a new O-Ring (3) to the pinion end.
Assemble a new seal ring (5) to the differential support with the special
tool CA715543 and a hammer.
2
Montare la flangia (2).
Montare l’anello d’arresto (1) sul codolo del pignone.
6
Assemble the flange (2).
Assemble the snap ring (1) to the pinion end.
S/N: 020-069
S1165
GRUPPO SUPPORTO DIFFERENZIALE
DIFFERENTIAL SUPPORT GROUP Mod. 28.43M FR
D.6 Gruppo supporto differenziale D.6 Differential support group
1
Sx Dx
Lh Rh
5
6
7
10
11 8
12
13
1
Rimuovere i dischi e controdischi freno.
Vedi: D.5.1
Remove the brake disks and counterdisks.

See: D.5.1
S/N: 020-069
S1165
Mod. 28.43M FR DIFFERENTIAL SUPPORT GROUP
2
Misurare il precarico totale iniziale FT 0 dei cuscinetti (sistema
pignone-corona) utilizzando un dinamometro con la corda avvolta sul
codolo scanalato del pignone.
Annotare il valore FT 0 che è necessario per il riassemblaggio dei
cuscinetti.
Vedi: D.6.2.12
Measure the starting total preload FT 0 of the bearings (pinion-crown

gear system), using a dynamometer whose cord is wound on the
pinion splined end.
Note the value FT 0 that is necessary in the bearings reassembly.
See: D.6.2.12
3
9 sicurezza.
Svitare la vite di fissaggio (13).
Nota: rimuovere prima il cilindro freno (9) dal lato della corona dentata
del differenziale.
13
Remove the fastening screw (13).
Note: first remove the brake cylinder (9) on the side of the differential
crown gear.
4
Rimuovere il cilindro freno.
Attenzione: questa operazione libera la scatola differenziale.
Rimuovere l’OR (8) dal cilindro freno (9).
Nota: operazione distruttiva per l’OR (8); l’OR dovrà essere sostituito.
Remove the brake cylinder.

Warning: the differential box is free.
8 Remove the O-Ring (8) from the brake cylinder (9).
9 Note: destructive operation for the O-Ring (8); the O-Ring must be
replaced.
5
Rimuovere la scatola differenziale (6).
Remove differential housing (6).
S/N: 020-069
S1165
6
Rimuovere l’OR (5) dal corpo centrale (1).
Nota: operazione distruttiva per l’OR (5); l’OR dovrà essere sostituito.
2 Sfilare il tubo (3) dal corpo centrale (1)
Rimuovere gli OR (2) e (4) dal tubo (3).
3 Nota: operazione distruttiva per gli OR (2) e (4); gli OR dovranno
essere sostituiti.
5 Remove the O-Ring (5) from the central body (1).

replaced.
4 Extract the pipe (3) from the central body (1).
Remove the O-Rings (2) and (4) from the pipe (3).
must be replaced.
7
Svitare e togliere la vite (12) ed il fermo ghiera (11) dal cilindro freno
(9).
9
11
12 Unscrew and remove the screw (12) and the ring nut retainer (11) from
the brake cylinder (12).
8
Svitare e togliere la ghiera (10) dal cilindro freno (9) con l’attrezzo
speciale CA716546.
9
10
Unscrew and remove the adjuster ring nut (10) from the brake cylinder
(9) with the special tool CA716546.
S/N: 020-069
S1165
9
Estrarre la coppa del cuscinetto (7) dal cilindro freno (9) con un
tampone ed un martello.
Attenzione: non invertire le coppe dei cuscinetti se non vengono
sostituiti.
9 Use a driver and a hammer to remove the bearing cup (7) from the
brake cylinder (9).
Warning: do not invert the bearing cups if the bearings are not
replaced.

1
Prima di montare il gruppo supporto differenziale eseguire il
montaggio del gruppo pignone
Vedi: D.8.2
Assemble the pinion group before assemble the differential support

group
See: D.8.2
2
Lubrificare ed assemblare due nuovi OR (2) e (4) sul tubo (3).
Inserire il tubo (3) nel corpo centrale (1)
2 Lubrificare ed assemblare un nuovo OR (5) su ogni lato del corpo
centrale (1).
3
5
Lubricate and assemble two new O-Rings (2) and (4) on the pipe (3).
Insert the pipe (3) into the central body (1).
4
Lubricate and assemble new O-Ring (5) on every side of the central
body (1).
S/N: 020-069
S1165
3
Posizionare il cilindro freno (9) su di una superficie piana e piantare la
coppa (7) del cuscinetto con il tampone CA715583.
Attenzione: non invertire le coppe dei cuscinetti se non vengono
sostituiti.
Position the brake cylinder (9) on a flat surface and force the bearing
cup (7) using the special tool CA715583.
Warning: do not invert the bearing cups if the bearings are not
replaced.
4
Misurare il diametro esterno C della corona dentata montata sulla
scatola differenziale. Calcolare il valore:
R=C/2 mm
Nota: questo dato è necessario per la registrazione del gioco fra
pignone e corona
Measure the external diameter C of the bevel crown gear assembled
to differential housing. Calculate the value:
C
R=C/2 mm
Note: this value is necessary to measure the backlash between pinion
and crown.
5
Montare un nuovo OR (8) ben lubrificato nella sede del cilindro freno
(9).
8
Montare prima il cilindro freno destro (Dx).
9 Nota: verificare che i segni di riferimento fatti allo smontaggio tra il
cilindro freno ed il corpo centrale coincidano.
Assemble a new well lubricated O-Ring (8) on the brake cylinder (9)
housing.
1 First assemble the right brake cylinder (Rh) to the central body (1)
Note: check that the reference marks made during the disassembly
between the brake cylinder and the central body coincide.
6
Inserire il gruppo differenziale nel corpo centrale (1).
Importante: la corona dentata deve essere sul lato sinistro (Sx).
Lubrificare e montare un nuovo OR (8) sul cilindro freno (Sx) (9).
Montare il cilindro freno sinistro (Sx).
Nota: verificare che i segni di riferimento fatti allo smontaggio tra i
cilindri freno ed il corpo centrale coincidano.
Insert the differential group into the central body (1).
Important: the bevel gear must be placed on the left side (Lh).
8 Assemble a new lubricated O-Ring (8).
Assemble the left brake cylinder (Lh).
9 Note: check that the reference marks made during the disassembly
between the brake cylinders and the central body coincide.
S/N: 020-069
S1165
7
Assemblare le viti di fissaggio (13).
M14x120 Serrare le viti di fissaggio alla coppia prevista.
Vedi: C.7
Assemblare nella posizione indicata, su entrambi i lati, una vite
aggiuntiva M14 x 120 mm e serrarla alla coppia di 79 Nm.
Assemble the fastening screws (13).

Tighten the fastening screws to the requested torque.
See: C.7
Assemble in the shown position a fastening screws M14 x 120 mm to
13
torque of 79 Nm on both sides.
8
Avvitare entrambe le ghiere di registrazione (10) utilizzando l’attrezzo
CA716546 fino ad eliminare il gioco e precaricare leggermente i
cuscinetti del differenziale.
Screw both adjuster ring nuts (10) using the tool CA716546 till the
backlash is eliminated and the differential bearings are slightly loaded.
9
Montare l’attrezzo speciale CA716520 sul foro della scatola
differenziale.
Posizionare un comparatore con il tastatore a contatto ed a 90° con
la superficie della staffetta dell’attrezzo speciale in corrispondenza del
valore calcolato R.
R
Assemble the special tool CA716520 on the differential housing hole.

Position a comparator with the feeler in contact with and at 90°
respect to the surface of the special tool bracket, in correspondence
CAla02922 with the reference R value.
S/N: 020-069
S1165
10
Muovere manualmente e alternativamente la staffa dell’attrezzatura
CA715456 montata sul foro della scatola differenziale.
Rilevare il gioco fra pignone e corona.
Verificare se il valore del gioco rilevato rientra nel campo predefinito:
0 . 2 0 ÷ 0 .3 5 m m
Effettuare la registrazione agendo sulle due ghiere con la chiave
CA716546.
Move the bracket of the tool CA715456 installed on the differential
housing hole alternately by hand.
CAts00301
Measure the backlash between pinion and crown.
Check if the measured backlash value is within the prescribed range:
0 . 2 0 ÷ 0 .3 5 m m
Set the backlash by turning the adjusting ring nuts (10) using the
wrench CA716546.
11
Registrare le ghiere (10) ricordando che:
- se il gioco rilevato è inferiore al campo di tolleranza dato, avvitare
la ghiera dal lato opposto alla corona e svitare la ghiera opposta della
A A stessa quantità (A);
- se il gioco rilevato è superiore al campo di tolleranza dato, avvitare
la ghiera dal lato della corona e svitare la ghiera opposta della stessa
10 10 quantità (B).
Adjust the ring nuts (10), remembering that:
B B - if the measured backlash is less than the given tolerance range,
screw the ring nut from the side opposite to the ring gear and unscrew
the opposite one of the same measure (A);
- if the measured backlash is greater than the given tolerance
range, screw the ring nut from the side of the ring gear and unscrew
the opposite one of the same measure (B).
12
Effettuata la registrazione del gioco pignone-corona verificare anche
che ci sia un minimo di precarico sui cuscinetti della scatola
differenziale
Ripetere l’intera sequenza delle operazioni citate fino al
raggiungimento delle condizioni indicate.
Once the adjustment of the pinion-bevel gear backlash has been

carried out, check also that there is a minimum preloading on the
differential housing bearings.
Repeat the whole sequence of the above mentioned operations till the
CAab09282 indicated conditions are reached.
S/N: 020-069
S1165
13
Stabilito il gioco pignone-corona, se i cuscinetti non sono stati
sostituiti, misurare il precarico totale FT m dei cuscinetti (sistema
pignone-corona) utilizzando un dinamometro con la corda avvolta sul
codolo scanalato del pignone.
Nota: utilizzare questo metodo solo se i cuscinetti non vengono
sostituiti, altrimenti vedi punto successivo.
Il valore misurato F T m deve rientrare nel seguente campo (vedi D.6.1
passo [2]):
F T m = F T 0 ÷ (F T0 + 1 0 ) N
Importante: tutti i precarichi vanno misurati senza anelli di tenuta.
Procedere come indicato al punto [18].
Once the pinion-ring gear backlash has been established, if the
bearings have been not replaced, measure the total preloading FT m
of the bearings (pinion-crown bevel gear system), using a
dynamometer whose cord is wound on the pinion splined end.
Note: do not use this method with new bearings, if the bearings have
been replaced see next step.
The measured value F T m should be within the following range (see
6.1 step [2]):
F T m = F T0 ÷ ( F T 0 + 1 0 ) N
Important: all the preloads should be measured without the seal rings.
Follow the operating procedures in step [18].
14
Se i cuscinetti sono stati sostituiti, misurare il precarico totale T con
un dinamometro con una cordicella avvolta sull’attrezzo CA716522,
inserito sul codolo del pignone.
Vedi: C.4
Attenzione: tutti i precarichi vanno misurati senza anelli di tenuta.
If the bearings have been replaced, measure the total preloading T of

the bearings with a dynamometer whose cord is wound on the special
tool CA716522 inserted on the end of pinion shaft.
See: C.4
Warning: all the preloads should be measured without the seal rings.
S/N: 020-069
S1165
15
Il precarico totale Tm è misurato sull’attrezzo CA716522 (diametro
calibrato Dm = 104.7 mm).
Tm Il valore misurato deve rientrare nel seguente campo:
FTm = ( F Pm + 9 . 8 6 ) ÷ ( F P m + 1 4 . 7 ) N
dove F P m è il precarico effettivo misurato sull’attrezzo CA716522
(diametro calibrato Dm = 104.7 mm).
Vedi: sezione D.8.2.
The total preloading Tm is measured on the special tool CA716522
Dm (gauge diameter Dm = 104.7 mm).
The measured value should be within the following range:
F Tm= ( F Pm+ 9 . 8 6 ) ÷ ( F Pm+ 1 4 . 7 ) N
where F P m is the effectively preloading measured on the special tool
CA716522 (gauge diameter Dm = 104.7 mm).
See: section D.8.2.
16
Stabilito il gioco pignone-corona, in alternativa ai passi [13] e [14] è
possibile misurare la coppia di rotolamento totale (MT ) dei cuscinetti
(sistema pignone-corona) con un torsiometro e la chiave speciale
CA715022.
Vedi: C.4
Attenzione: tutti i precarichi devono essere misurati senza anello di
tenuta.
Once the pinion-ring gear backlash has been established, instead
proceeding with step [13] and [14] measure the total rolling torque
(M T ) of the bearings (pinion-crown bevel gear system) with a
torquemeter and the special wrench CA715022.
See: C.4
Warning: all the preloads must be measured without the seal installed.
17
La coppia totale TT deve rientrare nel seguente campo (vedi C.4):
M T= ( M P+ 0 . 5 1 ) ÷ ( M P+ 0 . 7 7 ) N m
dove MP è il precarico sui cuscinetti del pignone.
Vedi: D.8.2 per la misura di MP
The total rolling torque MT must be within the following range (see
MT C.4):
M T= ( M P+ 0 . 5 1 ) ÷ ( M P+ 0 . 7 7 ) N m
where MP is the pinion bearings preloading.
See: D.8.2 to measure MP
S/N: 020-069
S1165
18
Se la misurazione non rientrasse nel campo prescritto, controllare
bene l’assemblaggio di ogni singolo componente ed intervenire sulle
ghiere di registrazione (10) del supporto differenziale:
A A - se il precarico totale è inferiore al campo dato, avvitare della
stessa quantità le ghiere di registrazione, mantenendo inalterato il
valore del gioco pignone-corona (A);
10 10 - se il precarico totale è superiore al campo dato, svitare della
stessa quantità le ghiere di registrazione, mantenendo inalterato il
valore del gioco pignone-corona (B).
B B
If the measurement is not within the requested range, check well the
assembly of each component and operate on the adjuster ring nuts
(10) of the differential support:
- if the total preloading is less than the given range, screw in both
adjuster ring nuts by the same measure, keeping the pinion-ring gear
backlash value unchanged (A);
- if the total preloading is greater than the given range, unscrew both
adjuster ring nuts by the same measure, keeping the pinion-ring gear
backlash value unchanged (B).
19
Dopo aver completato tutte le operazioni di registro, montare i fermi
ghiera (11) e le rispettive viti (12) serrandole alla coppia prevista.
Vedi: C.7.
Attenzione: ruotare le ghiere di registrazione (10) il minimo
indispensabile per permettere il montaggio.
Rimuovere la vite aggiuntiva M14 x 120 mm da entrambi i lati
11 Vedi: D.6.2.7.
Once all the adjustment operations have been completed, fit the
adjuster ring nut retainers (11) and their respective screws (12),
tightening them to the requested torque.
12 See: C.7.
Warning: turn the adjuster ring nuts (10) slightly in order to allow the
assembly.
Remove the fastening screws M14 x 120 mm on both sides
See: D.6.2.7.
S/N: 020-069
S1165
GRUPPO DIFFERENZIALE
DIFFERENTIAL GROUP Mod. 28.43M FR
D.7 Gruppo differenziale D.7 Differential group
13
7
6
12
4 5
11
10

1
Bloccare il differenziale in una morsa.
1 Svitare le viti (1) di fissaggio e rimuovere la corona conica (2).
Importante: questa operazione libera anche le due semiscatole
differenziale (4) e (12), non disperderne i componenti.
2 Lock the differential with a clamp.

Unscrew the fastening bolts (1) and remove the bevel gear crown (2).
Important: this will make both differential half boxes (4) and (12) free,
so take care not to drop the internal components.
S/N: 020-069
S1165
Mod. 28.43M FR DIFFERENTIAL GROUP
2
Disassemblare la scatola differenziale nelle due semiscatole (4) e
(12).
Nota: fare dei segni di riferimento sulle due semiscatole prima di
separarle.
4 Disassemblare tutti i particolari.
Verificare le condizioni di funzionalità e lo stato di usura dei
componenti.
12
Disassemble the two differential half housing (4) and (12).
Note: make alignment marks on the half boxes before split them.
Disassemble all the components.
Check the operating and wear conditions of the components.
3
Estrarre i cuscinetti (3) e (13) dalle semiscatole (4) e (12) utilizzando
12 un estrattore da commercio.
3
13
4 Remove the bearing cones (3) and (13) from the half boxes (4) and
(12) using a standard puller.

è corretta. anyway.
1
Montare i coni dei cuscinetti (3) e (13) sulle semiscatole (4) e (12),
4 utilizzando l’attrezzo speciale CA715083 ed un martello.
3
13
12 Assemble the bearing cones (3) and (13) on the half housings (4) and
(12), by using the special tool CA715083 and a hammer.
S/N: 020-069
S1165
DIFFERENTIAL GROUP Mod. 28.43M FR
2
Posizionare la semiscatola differenziale (4) sul banco di lavoro ed
assemblare con attenzione gli elementi interni: il controdisco
bloccaggio differenziale (5), l’ingranaggio (6), i due perni (7), gli
ingranaggi (8) e le rondelle di rasamento (9) come in figura.
4 Assemblare, come appena descritto, anche gli elementi interni della
semiscatola (12).
Unire le due semiscatole, allineando i riferimenti praticati sulle stesse.
12 Position a half housing (4) on a workbench and assemble all the inner
components: the locking differential counterdisk (5), the sun gear (6),
the two spider pins (7), the spider gears (8) and the thrust washers (9)
as shown in figure.
Assemble also, as yet described, the inner components of the half
housing (12).
Join the two half boxes, aligning the reference marks made during
disassembly.
3
Prima di mettere le superfici lavorate a contatto assicurarsi che non ci
siano impurità, quindi pulire bene con detergenti appositi.
2
Applicare il sigillante prescritto sulle superfici piane di contatto.
1 Vedi: C.7.
Posizionare la corona conica (2) sulla scatola differenziale.
Pulire con cura ed applicare l’adesivo prescritto al filetto delle viti (1).
Assemblare le viti di fissaggio (1) e serrarle alla coppia prevista.
Vedi: C.7.
Before matching surfaces, make sure that they are perfectly clean,
degrease and clean them with appropriate detergents.
Apply the prescribed sealant on the plain contact surfaces.
See: C.7.
Place the bevel gear (2) on the differential housing.
Clean with care and apply the prescribed adhesive to the bolts (1)
thread.
Assemble the fastening bolts (1) and tighten them to the prescribed
torque.
See: C.7.
S/N: 020-069
S1165
GRUPPO PIGNONE
Mod. 28.43M FR PINION GROUP
D.8 Gruppo pignone D.8 Pinion group
3
4
5
6
8 7
9
10

esattamente il vostro assale, ma la procedura rimane la your axle, but the indicated operations are correct
stessa. anyway.
1
Rimuovere il gruppo differenziale ed il gruppo flangia pignone.
Vedi: D.5.1, D.7.1.
Misurare il precarico iniziale F P 0 dei cuscinetti del pignone
F P0 utilizzando un dinamometro con la corda avvolta sul codolo scanalato
del pignone.
Annotare il valore FP 0 che è necessario per il riassemblaggio dei
cuscinetti.
Vedi: 8.2.14.
Remove the differential and pinion flange groups.
See: D.5.1, D.7.1.
Measure the starting preloading FP 0 of the pinion bearings using a
dynamometer whose cord is wound on the pinion splined end.
Note the value FP 0 that is necessary in the bearings reassembly.
See: 8.2.14.
S/N: 020-069
S1165
GRUPPO PIGNONE
PINION GROUP Mod. 28.43M FR
2
Svitare la ghiera di serraggio (10) utilizzando le attrezzature
CA716518 e CA716470.
Nota: operazione distruttiva per la ghiera; la ghiera (10) in fase di
montaggio deve essere sostituita.
Unscrew the ring nut (10) using special tools CA716518 and
CA716470.
Note: this operation damage the ring nut; the ring nut (10) must be
replaced when assembling the group.
3
Recuperare la rondella fermo ghiera (9).
Remove the retaining washer (9).
4
Battere con un martello di materiale tenero sul codolo per sfilare il
pignone conico (1).
Tap the end shaft with a soft hammer to remove the bevel pinion (1).
5
Tolto il pignone conico recuperare le rondelle (4) e (6), il distanziale
elastico (5) e il cono del cuscinetto (8).
Nota: il distanziale elastico (5) in fase di rimontaggio deve essere
5 8 sostituito.
Once the bevel pinion has been removed, collect the washers (4) and
4 (6), the collapsible spacer (5) and the bearing cone (8).
6 Note: the collapsible spacer (5) must be replaced when assembling
the group.
S/N: 020-069
S1165
GRUPPO PIGNONE
6
Verificare le condizioni di usura delle coppe dei cuscinetti.
Se necessaria la sostituzione dei cuscinetti, estrarre le coppe dei
cuscinetti (3) e (8) con un tampone ed un martello.
Check the bearing cups wear condition.

If bearings replacement is necessary, remove bearing cups (3) and
(8) from central body with a drift and a hammer.
7
Togliere il cono del cuscinetto (3) dal pignone conico (1) utilizzando
un estrattore di presa da commercio.
Recuperare lo spessore (2) sottostante.
3
1
Remove the bearing cone (3) of the bevel pinion (1) with a standard
extractor.
Collect the shim (2).
8
Controllare le condizioni di tutti i particolari del pignone.
Importante: la ghiera (10) ed il distanziale elastico (5) in fase di
rimontaggio devono essere sostituiti.
5
10
Check all pinion components for wear.

Important: the ring nut (10) and the collapsible spacer (5) must be
replaced when reassembling the unit.
S/N: 020-069
S1165
GRUPPO PIGNONE

esattamente il vostro assale, ma la procedura rimane la your axle, but the indicated operations are correct
stessa. anyway.
1
Posizionare su un banco di lavoro il corpo centrale (7).
Piantare le coppe dei cuscinetti (3) e (8) nelle proprie sedi con il kit
attrezzature speciali CA715380
Position the central body (6) on a workbench.

Fit the bearing cups (3) and (8) into their seats using the special tools
kit CA715380.
2
Utilizzare le attrezzature falso pignone CA715128 e falsa scatola
differenziale CA715578 per rilevare la distanza conica.
Inserire nelle sedi i coni dei cuscinetti (3) e (8) ed il falso pignone.
Serrare con la ghiera (10) fino ad eliminare il gioco.
Use the special tools false pinion CA715128 and false differential box
CA715578 to measure the conic distance.
Insert into the seats the bearing cups (3) and (8) and the false pinion.
Tighten the ring nut (10) to eliminate the backlash.
3
Verificare il corretto posizionamento dei supporti scatola differenziale
lato destro e sinistro utilizzando i riferimenti riportati sui medesimi e
sul corpo centrale (7).
Montare le due flange freno con le relative viti di fissaggio.
Check the correct positioning of the right and left brake cylinder and
differential housing supports, using the reference marks on them and
on the central body (7).
CAts00070
Assemble the two brake cylinders with their fastening bolts.
S/N: 020-069
S1165
GRUPPO PIGNONE
4
Introdurre nel corpo centrale (7) la falsa scatola differenziale
CA715578.
Verificare che la falsa scatola differenziale sia inserita in entrambe le
sedi dei supporti differenziale.
Insert the false differential box CA715578 into the central body (7).
Check that the false differential box is inserted in both differential
support housings.
5
Per registrare la coppia conica misurare con un calibro la distanza “A”.
Determinare il valore “X” come segue:
X = (A + C) - B mm
C
X
dove “B” e “C” sono valori noti.

A
B
To adjust bevel gear/pinion measure the distance “A” with a depth

gauge.
Calculate the value “X” as follows:
CAts00072 X = (A + C) - B mm
where “B” and “C” are known.
6
Dal valore “X” sottrarre il valore “V“(stampigliato sulla testa del
pignone) per ottenere il valore “S”.
S= X-V mm
From the value “X” deduct the value “V” (stamped on the pinion head)
to get the value “S”.
S= X-V mm
S/N: 020-069
S1165
GRUPPO PIGNONE
7
Scegliere lo spessore (2) di valore (S) tra la gamma di spessori a
disposizione.
GAMMA SPESSORI - SHIMS RANGE

Spess./Thick. - mm 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
Quantità/Quantity --- --- --- --- --- --- --- --- --- ---
Choose the shim (2) with thickness value (S) among the available
shims range.
8
Svitare e togliere la ghiera (10).
Rimuovere il falso pignone CA715128 ed i coni dei cuscinetti (3) e (8)
dal corpo centrale (7).
Smontare la falsa scatola differenziale CA715578 dai cilindri freno e
successivamente svitare le viti per rimuovere i cilindri freno.
Loosen and remove the ring nut (10).

Remove the false pinion CA715128 and the bearing cones (3) and (8)
from the central body (7).
Disassemble the false differential box CA715578 from the brake
cylinders and then unscrew the screws to remove the brake cylinders.
9
Inserire sul codolo del pignone lo spessore adatto (scelto in
precedenza) con lo smusso rivolto verso l’ingranaggio, come in figura.
Insert the suitable shim (chosen before) on the pinion shaft with
chamfer against the gear, as shown in figure.
10
Piantare il cuscinetto nell’albero del pignone sotto l’azione di una
pressa con il tampone CA715167, assicurandosi che sia ben
assestato.
Force the bearing into the pinion shaft and using CA715167 special
CAts00076
tool under a press, making sure that it is well set.
S/N: 020-069
S1165
GRUPPO PIGNONE
11
Assemblare lo spessore (4), un nuovo distanziale elastico (5) e lo
5 6 spessore (6) sul codolo del pignone.
3 Nota: utilizzare sempre un distanziale elastico (5) nuovo.
4
Nota: verificare il corretto ordine di assemblaggio.
Assemble the shim (4), a new collapsible spacer (5) and the shim (6)
to the pinion shaft.
Note: use always a new collapsible spacer (5).
Note: check the right assembly sequence.
12
Inserire il gruppo pignone conico (1) preassemblato nel corpo centrale
(7) ed il cuscinetto (8) sul codolo pignone.
Piantare il cuscinetto (8) con il tampone CA715167 ed un martello.
Nota: tenere spinto il pignone contro il corpo centrale durante il
piantaggio.
Insert the bevel pinion (1) unit into the central body (7) and the bearing
(8) into the pinion shaft.
Force the bearing (8) in position with the special tool CA715167 and
a hammer.
Note: push the pinion against the central body to perform this
operation.
13
Inserire la rondella fermo ghiera (9) ed avvitare una nuova ghiera di
serraggio (10) sul codolo del pignone.
Avvitare la ghiera (10) utilizzando le chiavi per ghiera CA716518 e
fermo pignone CA716470.
Importante: la coppia di serraggio è data dalla misurazione del
precarico sui cuscinetti; serrare la ghiera (10) progressivamente.
Nota: se il serraggio è eccessivo il distanziale elastico dovrà essere
sostituito e la procedura ripetuta.
Al momento di verificare il precarico è opportuno dare piccoli colpi con
martello in materiale tenero alle estremità del pignone per favorire
l’assestamento dei cuscinetti.
Insert the ring nut washer (9) and screw a new lock ring nut (10) on
the pinion end.
Screw the ring nut (10) in, using the wrench for ring nut CA716518 and
for pinion retainer CA716470.
Important: the torque setting is given by the preloading measurement
on bearings; tighten the ring nut (10) gradually.
Note: if the tightening is excessive, the elastic spacer must be
replaced and the procedure repeated.
When you check the preloading, it is advisable to beat slightly both
pinion ends with a soft hammer, so as to help setting the bearings.
S/N: 020-069
S1165
GRUPPO PIGNONE
14
Per misurare il precarico FP m dei cuscinetti conici (3) e (8), utilizzare
un dinamometro con una cordicella avvolta sul codolo del pignone (1).
Nota: utilizzare questo metodo solo se i cuscinetti non vengono
F Pm sostituiti, altrimenti vedi punto successivo.
Il valore misurato deve essere pari a quello iniziale (vedi D.9.1.1):
F Pm = F P0
procedere come indicato al punto [19].
To measure the preloading FPm of the pinion taper roller bearings (3)
and (8), use a dynamometer whose cord is wound on the end of pinion
shaft (1).
Note: do not use this method with new bearings, if the bearings have
been replaced see next step.
The measured value should must be the starting value (see D.9.1.1):
F Pm = F P0
follow the operating procedures in step [19].
15
Se si utilizzano nuovi cuscinetti conici (3) e (8), per misurare il
precarico FP m dei cuscinetti, utilizzare un dinamometro con una
F Pm cordicella avvolta sull’attrezzo CA716522, inserito sul codolo del
pignone.
La regolazione si effettua aumentando gradualmente il serraggio della
ghiera, facendo attenzione a non eccedere.
If the pinion taper roller bearings (3) and (8) are new, to measure the
preloading FPm of the bearings, use a dynamometer whose cord is
wound on the special tool CA716522 inserted on the end of pinion
shaft.
The adjustment is carried out by increasing the ring nut torque
gradually, being careful not to exceed.
16
Il precarico effettivo FPm è misurato sull’attrezzo CA716522 (diametro
calibrato Dm = 104.7 mm).
F Pm Il valore misurato deve rientrare nel seguente campo:
F Pm = 3 0 . 7 ÷ 4 5 . 9 N
Importante: valori validi con nuovi cuscinetti.
The effectively preloading FP m is measured on the special tool
CA716522 (gauge diameter Dm = 104.7 mm)
The measured value should be within the following range:
Dm
F Pm = 3 0 . 7 ÷ 4 5 . 9 N
Important: values for new bearings.
S/N: 020-069
S1165
GRUPPO PIGNONE
17
In alternativa ai passi [13] e [14] è possibile misurare la coppia di
rotolamento MP dei cuscinetti conici dell’albero del pignone con un
torsiometro e la chiave speciale CA716470.
Importante: tutti i precarichi devono essere misurati senza anello di
tenuta.
Instead proceeding with step [13] and [14] measure the pinion shaft
bearings rolling torque MP with a torquemeter and the special wrench
CA716470.
Important: all the preloads must be measured without the seal ring.
18
Il valore misurato MP deve rientrare nel seguente campo:
M P= 1 . 6 ÷ 2 . 4 N m
Vedi: C.4
MP
The measured value MP must be within the following range:

M P= 1 . 6 ÷ 2 . 4 N m
See: C.4
19
Ottenuto il prescritto valore di precarico, cianfrinare la ghiera (10)
utilizzando martello e punzone.
Once the requested preloading value is achieved, stake the ring nut
(10), using a hammer and a chisel.
20
Montare il differenziale.
Vedi: D.4.2
Assemble the differential housing.

See: D.4.2
S/N: 020-069
S1165
INTERVENTI SPECIALI
SPECIAL REPAIR OPERATIONS Mod. 28.43M FR
D.9 Interventi speciali D.9 Special repair operations
D.9.1 Freni negativi di parcheggio D.9.1 Parking negative brakes
D.9.1.1 Funzionamento del freno D.9.1.1 Parking negative brake working

negativo di parcheggio procedure
5
4 2
FRENO NEGATIVO IN PRESA FRENO NEGATIVO RILASCIATO

Negative brake engaged Negative brake released
Freno negativo in presa Negative brake engaged

Quando il sistema non è sotto pressione le molle a When the system is without pressure the belleville
tazza (1) spingono sul pistone del freno di parcheggio washers (1) push on the parking brake piston (2) and
(2) che tramite perni di spinta (3) aziona il pistone del the connected pin (3) pushes on the service brake
freno di servizio (4) sui dischi freno (5). piston (4), then on the brake disks (5).
Questo caso si verifica quando l’impianto frenante di This happens when the service brake system is not
servizio non è attivo perché il motore della macchina è active, because the vehicle engine is off or owing
spento o a causa di guasto dell’impianto frenante. to a brake system breakdown.
Per muovere il veicolo privo di energia è necessario The negative brake must be disabled to move the
disattivare il freno negativo energy less vehicle.
Vedi: D.9.1.2 See: D.9.1.2
Freno negativo rilasciato Negative brake released

Quando l’olio freno raggiunge la pressione di When the brake oil achieves the disengagement
disinnesto, il pistone del freno di parcheggio (2) ed i pressure, the parking brake piston (2) and the
relativi perni(3) vengono spinti contro le molle a tazza connected pin (3) are pushed on the belleville washers
(1) ed i dischi freno (5) sono liberi. (1) and the brake disks (5) are free.
Questo si verifica nelle normali condizioni di This happens in normal working conditions when the
funzionamento quando il veicolo fornisce energia vehicle provides energy to the brake system.
all’impianto freni.
S/N: 020-069
S1165
INTERVENTI SPECIALI
Mod. 28.43M FR SPECIAL REPAIR OPERATIONS
D.9.1.2 Disattivazione freni di parcheggio D.9.1.2 Parking brakes disable
1 2
B
Attenzione: bloccare con sistema meccanico tutte le Warning: lock with mechanical system all wheels to
ruote per impedire il movimento del veicolo una volta prevent the vehicle moving once the parking brake is
che il freno è stato disinserito; apporre gli avvisi di disabled; place prescribed warning tags on the ignition
sicurezza previsti sul volante e sulla chiave di accen- lock key and on the steering wheel.
sione.
Danger: failure to do so could result in death or serious

Pericolo: non bloccare le ruote è molto pericoloso; injury from vehicle roll away
sono possibili incidenti mortali per l’operatore.
1. On both sides release the lock screw (1)
1. Da entrambi i lati rimuovere il grano di bloccaggio (1) 2. Screw in the brake release bolts (3), 1/2 turn at a
2. Avvitare in sequenza (A, B, C) le viti di rilascio freno time, in sequence (A, B, C) until the torque drops off
(3) di 1/2 giro per volta fino a quando la coppia sharply (4÷5 turns).
resistente si riduce bruscamente (4÷5 giri).
Clear the area of any personnel before remove the
Liberare l’area circostante il veicolo da tutto il personale locking from each of the four tires and tow the vehicle
prima di rimuovere i ceppi di bloccaggio dalle quattro to a safe location.
ruote, quindi trainare il veicolo in un luogo sicuro.
Warning: always lock with mechanical system all

Attenzione: bloccare sempre con sistema meccanico wheels to prevent the vehicle moving before execute
tutte le ruote del veicolo prima di procedere con le the necessary repair operations.
operazioni di riparazione necessarie.
S/N: 020-069
S1165
INTERVENTI SPECIALI
SPECIAL REPAIR OPERATIONS Mod. 28.43M FR
D.9.1.3 Attivazione freni parcheggio D.9.1.3 Parking brakes enable
4 1 2
Attenzione: bloccare con sistema meccanico tutte e Warning: lock with mechanical system all four wheels
quattro le ruote per impedire il movimento del veicolo to prevent the vehicle from moving before execute any
prima di eseguire qualsiasi operazione. operation.
Pericolo: non bloccare le ruote è molto pericoloso; Danger: failure to do so could result in death or serious
sono possibili incidenti mortali per l’operatore. injury from vehicle roll away
1. Applicare una pressione di 13 bar alla porta di 1. Apply 13 bar pressure into the parking brake port (4).
alimentazione freno di parcheggio (4). 2. Remove the lock screws (1) and unscrew all the
2. Rimuovere i grani (1) e svitare fino a fine corsa tutte brake release bolts (3) on both sides until the end of
le viti di rilascio freno (3) da entrambi i lati. stroke has been reached.
Nota: non muovere le viti speciali (2) Note: do not move the special screws (2)
3. Togliere la pressione alla porta freno (4). 3. Release the pressure at the brakes port (4).
4. Applicare il sigillante prescritto ai grani (1) (vedi C.7). 4. Apply prescribed sealant to the screws (1) (see C.7).
5. Assemblare i grani di bloccaggio (1) alle viti (2). 5. Assemble the lock screws (1) to the bolts (2).
6. Tenendo ferme le viti (2) serrare i grani di bloccaggio 6. Lock the bolts (2) then tighten the lock screws (1) to
(1) alla coppia prevista (vedi C.7) su entrambi i lati. the specified torque (see C.7) on both sides.
I freni di parcheggio sono a questo punto riattivati e le The parking brakes should now be re-activated and the
ruote bloccate. wheels are locked.
Liberare l’area circostante il veicolo da tutto il personale Clear the area of any personnel and verify that parking
e verificare l’efficienza del freno di parcheggio prima di brake works properly before remove the locking from
rimuovere i ceppi di bloccaggio dalle quattro ruote. each of the four tires.
Rimuovere i cartelli di pericolo o di avviso dal volante e Remove any warning tags from the ignition lock key and
dalla chiave d’accensione. from the steering wheel.
S/N: 020-069
S1165
PROVE DOPO MONTAGGIO
Mod. 28.43M FR TESTING AFTER ASSEMBLY
D.10 Prove dopo montaggio D.10 Testing after assembly
D.10.1 Prova di tenuta pressione D.10.1 Pressure test

Eseguire una prova di tenuta sotto pressione Perform a pressure test on the complete assembled
sull’assale completamente assemblato e verificare che axle and check the whole system to find any possible
non siano presenti perdite. leakage.
Importante: la pressione di prova totale massima non Important: the maximum test total pressure must be
deve mai superare 1500 mbar (1.5 bar). always lower then 1500 mbar (1.5 bar).
Rimuovere le eventuali perdite prima di assemblare Stop every leak before assembling the axle to the
l’assale al veicolo. vehicle.
D.10.2 Procedure di collaudo D.10.2 Testing methods

Passo 1 Step 1
A motore spento, sollevare l'assale della ruota motrice With engine off, lift the axle so that the tyres get away
sino a che i pneumatici si siano staccati da terra. from the ground.
Nota: se presenti, disattivare i freni negativi di Note: if present, disable the negative parking brakes.
parcheggio.
Passo 2 Step 2
Ingranare la marcia in modo che il pignone sia bloccato. Engage the gear so that the pinion gets locked.
Passo 3 Step 3
Con l'aiuto di un'altra persona collocata al lato opposto, With the help of another person standing on the
iniziare la prova di montaggio ruotando per quanto opposite side, begin the assembly testing by rotating as
possibile entrambe le ruote nel senso di marcia avanti. much as possible both the wheels forward. (Both the
(Entrambe le ruote dovrebbero bloccarsi dopo poco). wheels should get locked after a while).
Passo 4 Step 4
Con il pignone sempre bloccato, liberare la ruota di Keeping the pinion locked, free the right wheel and
destra e ruotare la ruota di sinistra nel senso di marcia rotate the left one in the line of march. Rotate the right
avanti. wheels in the opposite direction.
Se il montaggio è corretto si dovrà verificare che la The wheel will move freely without difficulty and the
ruota giri liberamente senza eccessivi sforzi, e la ruota right wheel will move in the opposite direction if the
di destra ruoti in senso opposto. assembly has been carried out correctly.
Ripetere l'operazione nel senso di marcia opposto Repeat the same operation in the opposite direction
(retro marcia). (reverse gear).
SE UNA DELLE RUOTE NON GIRA LIBERAMENTE IF ONE WHEEL DOES NOT ROTATE FREELY IN
IN ENTRAMBE LE DIREZIONI, ricontrollare passo per BOTH DIRECTIONS, then check step by step all
passo il montaggio. assembly operations.
Controllare anche che i freni siano regolati in modo da Check and see that the brakes are regulated correctly
consentirne il corretto funzionamento. and functioning properly.
S/N: 020-069
S1165
PROVE DOPO MONTAGGIO
TESTING AFTER ASSEMBLY Mod. 28.43M FR
Notes
S/N: 020-069
S1165
RICERCA GUASTI
Mod. 28.43M FR TROUBLESHOOTING
E RICERCA GUASTI
E TROUBLESHOOTING
AB10563 REVISION DATE: 02/12 DOC. CA270263 E PAG. 111
S/N: 020-069
S1165
RICERCA GUASTI
TROUBLESHOOTING Mod. 28.43M FR
PROBLEMA POSSIBILI CAUSE
1 2 3 4 5 6 7 8 9 10 11
- Vibrazioni delle ruote; resistenza del pneumatico

    
anteriore; rottura del/i semiasse/i.
- Difficoltà nello sterzare; il veicolo tende ad andare
    
dritto mentre è in curva.
- Non vi è azione del differenziale; inceppamento in
   
curva.
- Rumore eccessivo nella trasmissione.
       
- Usura eccessiva del pneumatico.

       
- Rumore di attrito.
      
- In marcia avanti si avvertono vibrazioni, rumore

    
intermittente.
PROBLEMS POSSIBLE CAUSES
1 2 3 4 5 6 7 8 9 10 11
- Wheel vibration; front tyre resistance; half-shaft

    
breakage.
- Steering is difficult; vehicle goes straight while its
    
turning.
- No differential action; jamming while steering.
   
- No differential action; jamming while steering.

       
- Uneven wear of tyre.

       
- Friction noise.
      
- Vibration during forward drive, intermittent noise.

    
Azione consigliata Solving action

1 Installazione scorretta / assale difettoso 1 Incorrect installation / defective axle
Correggere l'installazione oppure, se il differenziale non Correct installation or repair or replace the differential in
supera una delle fasi di prova, ripararlo o sostituirlo. case it does not survive any one of the test phases.
2 Sovraccarico / distribuzione scorretta del peso 2 Overloading / incorrect weight distribution
Togliere il peso in eccesso e ridistribuire il carico, Remove excessive weight and redistribute load,
rispettando le istruzioni relative al veicolo. following instructions related to the vehicle.
PAG. 112 REVISION DATE: 02/12 DOC. CA270263 AB10563
S/N: 020-069
S1165
RICERCA GUASTI
3 Raggio di rotazione degli pneumatici diversi 3 Different rotation radius of the tyres
Un pneumatico con raggio più piccolo provoca un If one tyre has a smaller radius, it will cause partial
parziale slittamento della ruota quando si applica wheel slipping when force is applied. The other tyre with
energia. L'altro pneumatico con raggio maggiore dovrà bigger radius will have to support all the work. Replace
sopportare tutto il lavoro. Sostituire il pneumatico o the tyre or adjust pressure to have same radius on both
regolare la pressione di entrambi sino a che il raggio di tyre.
rotazione sia uguale. 4 Broken half-shaft
4 Semiasse rotto It is not advisable to operate the vehicle with a broken
E' sconsigliato usare un veicolo con un solo semiasse. half-shaft. It is acceptable to move the vehicle (engine
E' possibile tuttavia spostare il veicolo a vuoto con il off unloaded) a few meters away only.
differenziale bloccato per pochi metri.
5 Bent half-shaft
5 Semiasse piegato Replace half-shaft.
Sostituire i semiassi.
6 Blocked differential
6 Differenziale bloccato Abnormal functioning of the differential or breakage/
Funzionamento anomalo del differenziale e/o rottura blockage of command device. Verify assembly and all
del dispositivo di comando del bloccaggio di comando. components.
Verificare l'installazione, eventualmente smontare e Vehicles with wide steering angle may proceed with
verificare i componenti. kicks, have steering difficulty or cause pneumatic
I veicoli impostati per angoli di sterzata ampi, possono wearing at sharp turns. Reduce the steering angle to
procedere a scatti, avere difficoltà di sterzo e provocare minimum and decelerate when the vehicle begins to
un consumo del pneumatico nelle curve strette. kick.
Ridurre l'angolo di sterzata minimo e decelerare
quando il motore inizia a procedere a scatti. 7 Incorrect wheel adjustment
Verify group integrity and wheel side bearings.
7 Allineamento scorretto della ruota Adjusting according.
Verificare l'integrità della struttura, e cuscinetti lato
ruota. 8 Spoiled or worn out axle parts
Check the condition of ring gear, pinion gear, bearings
8 Parti dell'assale consumate o difettose
etc. Replace when ever necessary.
Controllare le condizioni della corona dentata,
dell'ingranaggio del pignone, dei cuscinetti, delle 9 Contamination in the axle box or incorrect
guarnizioni, ecc. Sostituire dove necessario. assembly of parts
Look for foreign particles. Check assembly of the
9 Corpi estranei nella scatola dell'assale o
various parts of the axle.
montaggio scorretto di alcune sue parti
Controllare se vi sono corpi estranei. Controllare il 10 Incorrect adjustment of bevel gear set: Parts of
montaggio delle parti dell'assale. the transmission worn out.
(transmission gears, U joints, etc.)
10 Regolazioni della coppia conica scorrette: parti
Replace or adjust as required.
di trasmissione consumate
(ingranaggi di trasmissione, giunti, ecc.). Sostituire o 11 Incorrect use of the product
regolare secondo necessità. See the vehicle producer‘s instructions once again.
11 Uso scorretto del prodotto
Rivedere le istruzioni rilasciate dal produttore del
veicolo.
S/N: 020-069
S1165
RICERCA GUASTI
E.1 Controllo ed esame dei guasti

Questo capitolo offre una guida descrittiva ed esplicativa di problemi che si possono comunemente riscontrare sugli
assali o di avarie che si possono verificare. La guida suggerisce anche le corrette procedure di riparazione.
Problema Causa Azione consigliata
Rottura verso l'estremità esterna del 1. Carico dell'ingranaggio eccessivo Sostituire la coppia conica.
dente corona dentata rispetto a quello previsto Seguire attentamente le operazioni
2. Regolazione ingranaggio scorretto raccomandate di regolazione del
(gioco eccessivo) gioco della corona dentata e del
3. Dado del pignone allentato. pignone e per la rilevazione
dell’impronta del dente.
Rottura verso l'estremità interna del 1. Urto da carico Sostituire la coppia conica.
dente corona dentata 2. Regolazione ingranaggio scorretto Seguire attentamente le operazioni
(gioco insufficiente) raccomandate di regolazione del
3. Dado del pignone allentato gioco della corona dentata e del
pignone e per la rilevazione
dell’impronta del dente
Denti del pignone e della corona 1. Lubrificazione insufficiente Sostituire la coppia conica.
dentata erosi o rigati 2. Lubrificante sporco Sostituire i cuscinetti del pignone
3. Lubrificante errato o con additivi facendo attenzione a sistemare
impoveriti correttamente la corona, il pignone e i
4. Cuscinetti del pignone consumati precarichi dei cuscinetti.
che provocano un gioco assiale del Usare il lubrificante corretto, riempire
pignone e un contatto tra pignone e fino al giusto livello e sostituirlo agli
corona scorretto. intervalli raccomandati.
Denti della corona e del pignone 1. Funzionamento prolungato a Sostituire la coppia conica.
surriscaldati. Guardare se i denti temperatura eccessiva. Usare il lubrificante corretto, riempire
dell'ingranaggio hanno perso la 2. Lubrificante scorretto fino al giusto livello e sostituirlo agli
colorazione 3. Livello dell'olio basso intervalli raccomandati.
4. Lubrificante sporco.
Denti del pignone di comando 1. Uso estremamente intenso Sostituire la coppia conica.
butterati 2. Lubrificazione insufficiente Usare il lubrificante corretto, riempire
fino al giusto livello e sostituirlo agli
intervalli raccomandati.
Corpo trave dell'assale piegato 1. Sovraccarico del veicolo Sostituire il corpo trave dell'assale
2. Veicolo incidentato
3. Urto da carico
Cuscinetti consumati o butterati 1. Lubrificazione insufficiente Sostituire i cuscinetti.
2. Lubrificante sporco Usare il lubrificante corretto, riempire
3. Uso estremamente intenso fino al giusto livello e sostituirlo agli
4. Consumo normale intervalli raccomandati.
5. Dado del pignone allentato.
Le guarnizioni perdono olio 1. Funzionamento prolungato con Sostituire la guarnizione e la
temperatura dell'olio eccessiva. superficie di accoppiamento se
2. Guarnizione dell'olio montata male danneggiata.
3. Bordo della guarnizione tagliata o Usare il lubrificante corretto, riempire
intaccata fino al giusto livello e sostituirlo agli
4. Lubrificante sporco intervalli raccomandati.
E.1 PAG. 114 REVISION DATE: 02/12 DOC. CA270263 AB10563
S/N: 020-069
S1165
RICERCA GUASTI
Usura eccessiva della scanalatura 1. Uso intenso Sostituire la flangia

della flangia di entrata. 2. Dado del pignone allentato Controllare che la scanalatura del
3. Gioco assiale del pignone pignone non sia eccessivamente
consumata
Sostituire la coppia conica, se
necessario.
Rottura per fatica del dente 1. Uso intenso Sostituire la coppia conica.
dell'ingranaggio del pignone. 2. Sovraccarico continuo
Guardare se la linea di frattura ad
onda è ben delineata (linea di
arresto).
Rottura denti pignone e corona Carico d'urto dei componenti del Controllare e/o sostituire altri
differenziale componenti differenziale.
Scanalature dell'ingranaggio Uso intenso Sostituire il gruppo ingranaggi
planetario consumate (gioco differenziale. Sostituire il semiasse, se
eccessivo) necessario.
Superfici della ralla di rasamento 1. Lubrificazione insufficiente Sostituire tutte le ralle graffiate e
consumate o graffiate 2. Lubrificazione scorretta quelle con uno spessore di 0,1 mm
3. Lubrificante sporco inferiore a quello delle ralle nuove.
Usare il lubrificante corretto, riempire
fino al giusto livello e sostituirlo agli
Diametro interno del cuscinetto a rulli 1. Uso intenso Sostituire il cuscinetto
conici del pignone consumato 2. Gioco assiale del pignone Controllare il gioco assiale del
eccessivo pignone
3. Lubrificazione inadeguata Usare il lubrificante corretto, riempire
4. Lubrificante sporco fino al giusto livello e sostituirlo agli
Semiasse ritorto o rotto Funzionamento intenso del veicolo, Sostituire il semiasse
sovraccarico
Semiasse spezzato presso la flangia 1. Supporto della ruota allentato Sostituire il semiasse
ruota 2. Corpo trave piegato Controllare la distorsione del corpo
trave. Accertarsi che il sostegno della
ruota non sia consumato o mal
regolato.
AB10563 REVISION DATE: 02/12 DOC. CA270263 E.1 PAG. 115
S/N: 020-069
S1165
RICERCA GUASTI
E.1 Troubleshooting
This chapter is a descriptive and explanatory guide to common axle problems. This guide suggests the repair correct
procedures to be followed.
Problem Cause Action
Ring gear tooth broken at the outer 1. Excessive gear load compared to Replace bevel gear set
side the one foreseen Follow carefully the recommended
2. Incorrect gear adjustment operations for the adjustment of bevel
(excessive backlash) gear set backlash
3. Pinion nut loose
Ring gear tooth broken side 1. Load bump Replace bevel gear set
2. Incorrect gear adjustment Follow carefully the recommended
(insufficient backlash) operations for the adjustment of bevel
3. Pinion nut loose gear set backlash.
Pinion or ring gear teeth or worn 1. Insufficient lubrication Replace bevel gear set.
2. Contaminated oil Follow carefully the recommended
3. Incorrect lubrication or depleted operations for the adjustment of bevel
additives gear set backlash.
4. Worn out pinion bearings that Use correct lubricants, fill up to the
cause an incorrect pinion axle right levels and replace according to
backlash and wrong contact between the recommended program.
pinion and ring.
Overheated ring and pinion teeth. 1. Prolong ed functioning at high Replace bevel gear set.
See if gear teeth have faded temperatures Use proper lubrication, fill up to right
2. Incorrect lubrication level and replace at recommended
3. Low oil level program.
4. Contaminated oil
Pinion teeth pitting 1. Excessive use Replace bevel gear set.
2. Insufficient lubrication Use correct lubrication, fill up to the
right level and substitute at
recommended intervals
Axle beam body bent 1. Vehicle over loaded Replace axle beam body
2. Vehicle's accident
3. Load bump
Worn out or pitted bearings 1. Insufficient lubrication Replace bearings.
2. Contaminated oil Use correct lubrication fill up, to the
3. Excessive use right level and replace at
4. Normal wear out recommended intervals
5. Pinion nut loose
Oil leakage form gaskets and seals 1. Prolonged functioning at high Replace the gasket or seal and
temperature of the oil matching surface if damaged.
2. Oil gasket assembled incorrectly Use correct lubrication and replace at
3. Seal lip damaged recommended intervals.
4. Contaminated oil
Excessive wearing out of input flange 1. Exhaustive use Replace the flange.
spline 2. Pinion nut loose Check that the pinion spline is not
3. Pinion axle backlash excessively worn out.
Replace bevel gear set if required.
Fatigue failure of pinion teeth 1. Exhaustive use Replace bevel gear set
See if the fracture line is well defined 2. Continuos overload
(wave lines, beach lines)
S/N: 020-069
S1165
RICERCA GUASTI
Pinion and ring teeth breakage 1. Crash load of differential Check and/or replace other differential
components components.
Side gear spline worn out Excessive use Replace differential gear group.
(Excessive backlash) Replace half-shaft if required
Thrust washer surface worn out or 1. Insufficient lubrication Use correct lubrication and fill up to
scratched. 2. Incorrect lubrication right level.
3. Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with 0,1mm thickness lower
than the new ones.
Inner diameter of tapered roller 1. Excessive use Replace bearing.
bearing worn out. 2. Excessive pinion axial backlash Check pinion axial backlash.
3. Insufficient lubrication Use proper lubrication, fill up to right
4. Contaminated oil level and replace at recommended
intervals.
Bent or broken half-shaft Vehicle intensively operated or Replace
overloaded
Half-shaft broken at wheel side 1. Wheel support loose Replace
2. Beam body bent Check that wheel support is not worn
out or wrongly adjusted.
S/N: 020-069
S1165
RICERCA GUASTI
E.2 Diagnosi per problemi all'assale
Rumore durante la guida 1. Gioco tra corona dentata e pignone 1. Regolare

eccessivo
2. Pignone e corona dentata 2. Sostituire
consumati
3. Cuscinetti del pignone consumati 3. Sostituire
4. Cuscinetti del pignone allentati 4. Regolare
5. Gioco assiale del pignone 5. Regolare
eccessivo
6. Cuscinetti del differenziale 6. Sostituire
consumati
7. Cuscinetti del differenziale allentati 7. Regolare
8. Eccessiva scentratura della corona 8. Sostituire
dentata
9. Livello lubrificante basso 9. Rabboccare
10. Lubrificante di grado povero od 10. Sostituire
errato
11. Semiasse piegato 11. Sostituire
Rumore durante l’andatura in folle 1. I rumori provenienti dall'assale con 1. Regolare o sostituire (vedere sopra)
il veicolo in movimento di solito si
sentono durante l’andatura in folle
anche se non molto forti
2. Errato gioco tra pignone e corona 2. Regolare
(il rumore che si sente decelerando
sparisce all’aumentare della velocità).
3. Usura scanalatura pignone o
flangia entrata 3. Sostituire
Rumore intermittente 1. Corona dentata danneggiata 1. Sostituire coppia conica
2. Bulloni della scatola del 2. Serrare a coppia
differenziale allentati
Rumore costante 1. Danni sui denti della corona 1. Sostituire coppia conica
dentata o del pignone
2. Cuscinetti usurati 2. Sostituire
3. Scanalature del pignone 3. Sostituire
consumate
4. Semiasse piegato 4. Sostituire
Rumore in curva 1. Satelliti planetari differenziale 1. Sostituire
consumati
2. Scatola differenziale e/o perni del 2. Sostituire
differenziale consumati
3. Ralle di rasamento del differenziale 3. Sostituire
consumate
4. Scanalature del semiasse 4. Sostituire
consumate
S/N: 020-069
S1165
RICERCA GUASTI
E.2 Axle problem and diagnosis
Noise while driving 1. Excessive backlash between 1. Adjust

pinion and ring gear
2. Worn out pinion and gear ring 2. Replace
3. Worn out pinion bearings 3. Replace
4. Pinion bearings loose 4. Adjust
5. Excessive axial pinion backlash 5. Adjust
6. Worn out differential bearings 6. Replace
7. Differential bearings loose 7. Adjust
8. Ring gear out of roundness 8. Replace
9. Low lubricant level 9. Oil level
10. Poor or wrong lubricant 10. Replace
11. Bent half-shaft 11. Replace
Noise while driving in neutral 1. Noise coming from axle are usually 1. Replace or adjust (see above)
heard when vehicle moves in neutral
gear but are not loud.
2. Incorrect backlash between pinion 2. Replace
and ring (sound heard while
decelerating disappears while
increasing the speed)
3. Pinion or input flange worn out 3. Adjust
Intermittent noise 1. Ring gear damaged 1. Replace bevel gear set
2. Differential box bolts loose 2. Tighten to torque
Constant noise 1. Ring gear teeth or pinion damaged 1. Replace bevel gear set
2. Worn out bearings 2. Replace
3.Pinion spline worn out 3. Replace
4. Bent half-shaft 4. Replace
Noise while steering 1. Worn out differential gears 1. Replace
2. Worn out differential box or spider 2. Replace
3. Differential thrust washers worn out 3. Replace
4. Half shaft spline worn out 4. Replace
S/N: 020-069
S1165
RICERCA GUASTI
Notes
S/N: 020-069
S1165
ATTREZZATURE SPECIALI
Mod. 28.43M FR SPECIAL TOOLS
F ATTREZZATURE SPECIALI
F SPECIAL TOOLS
AB10563 REVISION DATE: 02/12 DOC. CA270263 F PAG. 121
S/N: 020-069
S1165
ATTREZZATURE SPECIALI
SPECIAL TOOLS Mod. 28.43M FR
F.1 Attrezzature speciali F.1 Special tools

Battitoi e tamponi per il montaggio di tenute, cuscinetti The special drifts/pad used to assembly the seals,
e bronzine devono essere utilizzati con il manico bearings and bushes should always be used with the
intercambiabile CA119033; se ne raccomanda l’uso interchangeable handle CA119033; its use is
abbinato ad un’impugnatura di sicurezza per la recommended together with a suitable safety handle in
protezione delle mani (da commercio). order to protect the hands.
Per maggiori informazioni e per l’acquisto delle attrez- For further information or to order the special tools
zature contattare il servizio ricambi all’indirizzo e-mail please contact our spare parts sales office by email
s a l e s @ c a rr a ro ri c a m bi . c o m sales@carraroricambi.com
F.1 PAG. 122 REVISION DATE: 02/12 DOC. CA270263 AB10563
S/N: 020-069
S1165
Mod. 28.43M FR
Indice Index
INFORMAZIONI SULLA SICUREZZA . . . . 3 SAFETY INSTRUCTIONS . . . . . . . . . . . . 3

Indicazioni generali per la sicurezza . . . . . . . . . . 4 General safety recommendations . . . . . . . . . . . 4
Informazioni per la sicurezza . . . . . . . . . . . . . . . 5 Safety information . . . . . . . . . . . . . . . . . . . . . . . 5
Precauzioni generali . . . . . . . . . . . . . . . . . . . . . . 8 General precautions . . . . . . . . . . . . . . . . . . . . . . 8
INFORMAZIONI GENERALI . . . . . . . . . . 17 GENERAL INFORMATION . . . . . . . . . . 17

Utilizzo del manuale . . . . . . . . . . . . . . . . . . . . . 18 Manual use . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Proprietà delle informazioni . . . . . . . . . . . . . . . 19 Information property . . . . . . . . . . . . . . . . . . . . . 19
Convenzioni e definizioni . . . . . . . . . . . . . . . . . 20 Agreements and definitions . . . . . . . . . . . . . . . 20
Indicazioni generali . . . . . . . . . . . . . . . . . . . . . . 24 General description . . . . . . . . . . . . . . . . . . . . . 24
Indicazioni speciali . . . . . . . . . . . . . . . . . . . . . . 25 Special recommendations . . . . . . . . . . . . . . . . 25
CARATTERISTICHE GENERALI . . . . . . 31 GENERAL SPECIFICATIONS . . . . . . . . 31

Uso previsto . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Identificazione del prodotto . . . . . . . . . . . . . . . . 32 Product identification . . . . . . . . . . . . . . . . . . . . 32
Descrizione gruppi assale . . . . . . . . . . . . . . . . . 33 Axle groups description . . . . . . . . . . . . . . . . . . 33
Caratteristiche Tecniche . . . . . . . . . . . . . . . . . . 34 Technical Features . . . . . . . . . . . . . . . . . . . . . 34
Manutenzione e cambio olio . . . . . . . . . . . . . . . 36 Maintenance and oil change . . . . . . . . . . . . . . 36
Grasso al montaggio . . . . . . . . . . . . . . . . . . . . . 40 Grease in assembly . . . . . . . . . . . . . . . . . . . . . 40
Adesivi e coppie di serraggio . . . . . . . . . . . . . . 42 Adhesives and tightening torques . . . . . . . . . . 42
Freni . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SMONTAGGIO E ASSEMBLAGGIO . . . . 49 DISASSEMBLY AND ASSEMBLY . . . . . 49

Gruppo riduttore epicicloidale . . . . . . . . . . . . . . 50 Epicyclic reduction gear group . . . . . . . . . . . . . 50
Gruppo mozzo ruota . . . . . . . . . . . . . . . . . . . . . 55 Wheel hub group . . . . . . . . . . . . . . . . . . . . . . . 55
Gruppo tromba trave . . . . . . . . . . . . . . . . . . . . . 61 Axle beam trumpet group . . . . . . . . . . . . . . . . . 61
Gruppo freno . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Brake group . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Gruppo flangia . . . . . . . . . . . . . . . . . . . . . . . . . 82 Flange group . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Gruppo supporto differenziale . . . . . . . . . . . . . . 84 Differential support group . . . . . . . . . . . . . . . . . 84
Gruppo differenziale . . . . . . . . . . . . . . . . . . . . . 94 Differential group . . . . . . . . . . . . . . . . . . . . . . . 94
Gruppo pignone . . . . . . . . . . . . . . . . . . . . . . . . 97 Pinion group . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Interventi speciali . . . . . . . . . . . . . . . . . . . . . . 106 Special repair operations . . . . . . . . . . . . . . . . 106
Prove dopo montaggio . . . . . . . . . . . . . . . . . . 109 Testing after assembly . . . . . . . . . . . . . . . . . . 109
RICERCA GUASTI . . . . . . . . . . . . . . . . 111 TROUBLESHOOTING . . . . . . . . . . . . . 111

Controllo ed esame dei guasti . . . . . . . . . . . . 114 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 116
Diagnosi per problemi all'assale . . . . . . . . . . . 118 Axle problem and diagnosis . . . . . . . . . . . . . . 119
ATTREZZATURE SPECIALI . . . . . . . . . 121 SPECIAL TOOLS . . . . . . . . . . . . . . . . . 121

Attrezzature speciali . . . . . . . . . . . . . . . . . . . . 122 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . 122
S/N: 020-069
S1165
Carraro Drive Tech Spa

Via Olmo, 37
35011 Campodarsego (Pd) Italia
Tel. +39 049 9219111
Fax +39 049 9289111
www.carrarodrivetech.com
S/N: 020-069
CARRARO AXLE 28.43 17467
ASSEMBLY (9080-10003) Page 1 of 9

7080-10003-R AXLE ASSEMBLY , REAR 1
7080-10003-F AXLE ASSEMBLY, FRONT
AXLE HOUSING
1 9080-10003-001 BEAM TRUMPET 1
2 9080-10003-002 PLUG 1
3 9080-10003-003 PLUG 5
4 9080-10003-004 O-RING 4
5 9080-10003-005 BREATHER 4
6 9080-10003-006 BRAKE CYLINDER, LH 1
7 9080-10003-007 BO 2
8 9080-10003-008 BEAM TRUMPET 1
9 9080-10003-009 BRAKE CYLINDER, RH 1
10 9080-10003-010 WASHER 4
Updated:
08/28/13
S/N: 020-069

AXLE HOUSING
11 9080-10003-011 BREATHER 1
12 9080-10003-012 O-RING 5
13 9080-10003-013 BUSHING 2
14 9080-10003-014 SEAL RING 2
15 9080-10003-015 BOLT 22
16 9080-10003-016 PIN 6
17 9080-10003-017 BOLT 6
18 9080-10003-018 O-RING 6
19 9080-10003-019 CAPSCREW 6
20 9080-10003-020 PLUG 6
21 9080-10003-090 CENTRAL BODY 1
22 9080-10003-021 PLUG 4
23 9080-10003-022 O-RING 2
24 9080-10003-023 PIPE 1
25 9080-10003-024 PLUG 1
Updated:
08/28/13
S/N: 020-069

BEVEL GEAR SET
1 7081-10001 BEVEL GEAR/PINION KIT (INCLUDES ITEMS 2-5) 1
2 9080-10003-026 LOCKWASHER 1
3 9080-10003-027 RING NUT 1
4 9080-10003-028 WASHER 2
5 9080-10003-029 COLLAPSIBLE SPACER 1
6 9080-10003-030 SHIM, 2.50MM A/R
9080-10003-031 SHIM, 2.60MM A/R
9080-10003-032 SHIM, 2.70MM A/R
9080-10003-033 SHIM, 2.80MM A/R
9080-10003-034 SHIM, 2.90MM A/R
9080-10003-035 SHIM, 3.00MM A/R
9080-10003-036 SHIM, 3.20MM A/R
9080-10003-037 SHIM, 3.30MM A/R
9080-10003-038 SHIM, 3.30MM A/R
9080-10003-039 SHIM, 3.40MM A/R
7 9080-10003-040 BEARING 1
Updated:
08/28/13
S/N: 020-069

BEVEL GEAR SET
8 9080-10003-041 BEARING 1
9 9080-10003-042 SNAP RING 1
10 9081-00008 YOKE 1
11 9081-10001 SEAL RING 1
12 9081-10002 O-RING 1
13 9080-10003-043 WASHER 1
Updated:
08/28/13
S/N: 020-069

DIFFERENTIAL
1 7081-10002 DIFFERENTIAL KIT (INCLUDES ITEMS 2-4) 1
2 INCLUDED IN KIT PIN 2
3 INCLUDED IN KIT THRUST WASHER 4
4 INCLUDED IN KIT DIFFERENTIAL DRIVE PLATE 2
5 9080-10003-044 BEARING 2
6 9080-10003-045 RING NUT 2
7 9080-10003-046 BOLT 2
8 9080-10003-047 LOCKING PLATE 2
9 9080-10003-048 PIN 2
10 9080-10003-049 BOLT 10
11 9080-10003-050 DIFFERENTIAL HOUSING 1
Updated:
08/28/13
S/N: 020-069

BRAKES
1 9080-10003-051 HALF-SHAFT 2
2 9080-10003-052 COUPLING BUSHING 2
3 9080-10003-053 HUB 2
4 9080-10003-054 BRAKE DISC 6
5 9080-10003-055 BRAKE COUNTER DISC 6
6 9080-10003-056 BRAKE COUNTER DISC 2
7 9080-10003-057 SELF-ADJUST KIT 2
8 9080-10003-058 O-RING 2
9 9080-10003-059 O-RING 2
10 9080-10003-060 O-RING 4
11 9080-10003-061 POSITIVE BRAKE PISTON 2
Updated:
08/28/13
S/N: 020-069

BRAKES
12 9080-10003-062 WASHER 6
13 9080-10003-063 O-RING 6
14 9080-10003-064 PIN 6
15 9080-10003-065 O-RING 6
16 9080-10003-066 WASHER, BELLEVILLE 4
17 9080-10003-067 NEGATIVE BRAKE PISTON 2
18 9080-10003-068 RING 2
19 9080-10003-069 SLEEVE 2
20 9080-10003-070 SNAP RING 2
21 9080-10003-071 HALF-SHAFT 2
Updated:
08/28/13
S/N: 020-069

WHEEL HUB
1 9080-10003-072 SEAL RING 2
2 9080-10003-073 BEARING 4
3 9080-10003-089 STUD 20
4 7081-10003 WHEEL HUB KIT (INCLUDES ITEM 3) 2
5 9080-10003-074 O-RING 2
6 9080-10003-075 O-RING 2
7 9080-10003-076 WHEEL CARRIER 2
8 9080-10003-077 BOLT 16
9 9080-10003-078 CENTER BUSHING 16
10 9080-10003-079 CROWN GEAR 2
11 9080-10003-080 THRUST WASHER 2
Updated:
08/28/13
S/N: 020-069

FINAL REDUCTION
1 9080-10003-003 PLUG 2
2 9080-10003-081 BOLT 4
3 9080-10003-082 PLANETARY CARRIER ASSEMBLY 2
4 9080-10003-083 WASHER 6
5 9080-10003-084 NEEDLE BEARINGS (BY TENS) 37.2
6 9080-10003-085 LOCKING THRUST WASHER 6
7 9080-10003-086 GEAR 6
8 9080-10003-087 THRUST WASHER 6
9 9080-10003-088 BOLT 6
Updated:
08/28/13
S/N: 020-069
17461
AXLE CRADLE
Page 1 of 1

1 7082-00012 CRADLE ASSEMBLY 1
2 17GD12 NUT 8
3 27GE12 WASHER 8
4 ------------ LONG GREASE HOSE 1
5 ------------ SHORT GREASE HOSE 1
6 17GC12136 BOLT 8
7 464693 BUSHING 2
8 04GE10 WASHER 4
9 19204-88 PIN ASSEMBLY 2
10 17GC10024 BOLT 4
11 7081-00016 PLATE 2
Updated:
12/29/2011
S/N: 020-069
17475
TIRE/RIM
Page 1 of 1

9121-00014 WHEEL & TIRE ASSEMBLY 1
1 9121-00022 WHEEL WELDMENT 1
2 9121-00023 TIRE 1
3* 9121-00024 TUBE 1
4* 9080-10003-089 STUD 10
5* 17GDM22 LUG NUT 10
6* 27GE14 WASHER 10

11/26/12
S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
7. BRAKE SYSTEM
S1163 BRAKE VALVE SERVICE

17464 BRAKE VALVE
17473 BRAKE VALVE BLOCK
S1009 DUAL CHARGE VALVE SERVICE
16483 DUAL CHARGE VALVE
S/N: 020-069
S1163
PEDAL ACTUATED
(Modulating Valves)
Service Instructions
· Items included in Repair Kit

* Not used on all models
PEDAL DISASSEMBLY
1. Separate pedal (1) from pedal base (13) by removing 1. Attach valve assembly to base (13) using cap screws
one cotter pin (4) and one e-ring (3) from pin (5) and (11) and washers (12). Torque cap screws
sliding pin from base. NOTE: Not all models use 24.4-29.8 N·m (18-22 lb·ft).
cotter pins (4). 2. Install new bushings (9 & 10) in base (13).
2. Remove bushings (9 & 10) from pedal base (13). NOTE: Not all models use bushings (8 & 10).
NOTE: Not all models use bushings (9 & 10). 3. Align pedal (1) between ears of pedal base (13) and
3. Inspect pin (2) and cam (6) to make sure cam is in insert pin (5). Install e-ring (2) and cotter pin (4).
good working order and moving freely. It is unneces- NOTE: Not all models use cotter pins (4).
sary to remove pin (2), cam (6), cap screw (7) or nut
(8) unless damaged. NOTE: Not all models use NOTE
cap screw (7) or nut (8). If cap screw (7) or nut (8) are loosened or removed,
4. Separate valve assembly from base (13) by remov- they must be properly adjusted. With all parts
ing cap screws (11) and washers (12). assembled, adjust cap screw (7) to allow the valve
spool to fully release. After adjustment is made torque
PEDAL ASSEMBLY
nut (8) 24.4-29.8 N·m (18-22 lb·ft). NOTE: Not all
models use cap screw (7) or nut (8).
NOTE
Before assembling pin (5) lubricate with a good quality
polymer base moly grease.
Form No. 81-464-010 Revised 2011-03-08 (1) MICO, Inc.
S/N: 020-069
17464
PEDAL BRAKE VALVE
Page 1 of 1

7101-00031 BRAKE VALVE ASSEMBLY (HARDWARE INCLUDED) 1
1 9101-00016 PEDAL & BASE ASSEMBLY (NO HARDWARE) 1
2 15248-01 CAPSCREW 1
3 15248-02 CAPSCREW 1
4 67GD06 NUT 2
5 01GF01016 PIN, COTTER 2
6* 9101-00016-001 VALVE ASSEMBLY ONLY 1
7* 595145 REPAIR KIT 1
* ITEMS NOT SHOWN Updated:

12/30/2011
S/N: 020-069
BRAKE VALVE BLOCK 24V 17473
ASSEMBLY Page 1 of 2
7 4
6
BRAKE VALVE IS LOCATED FACING

PARALLEL TO CAB FIREWALL ON A64
CHASSIS
Updated:
02/23/12
S/N: 020-069
BRAKE VALVE BLOCK 24V 17473
ASSEMBLY Page 2 of 2

1 464958-03 BRAKE VALVE BLOCK 24V (INCLUDES ITEMS 2, 3, 6, 7) 1
464958 VALVE BLOCK ONLY 1
2 534669 COIL, SOLENOID, 24V 1
3 534679 CARTRIDGE, 3 WAY, 2 POSITION SOLENOID 1
4 134173 PRESSURE SWITCH, 1100 PSI 3
5 134171 PRESSURE SWITCH, 700 PSI 1
6 534744 CARTRIDGE, CAVITY PLUG 1
7 534745 CARTRIDGE, SHUTTLE VALVE 1
Updated:
02/23/12
S/N: 020-069
S1009
S/N: 020-069
S1009
S/N: 020-069
S1009
S/N: 020-069
S1009
S/N: 020-069
16483
CHARGING VALVE
Page 1 of 4
Updated:
12/11/06
S/N: 020-069
16483
CHARGING VALVE
Page 2 of 4
Updated:
12/11/06
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069

S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
8. HYDRAULIC SYSTEM
310-020-014 HYDRAULIC SCHEMATIC

S1077 HYDRAULIC SYMBOLS
17132 SERVICEJUNIOR DIGITAL PRESSURE GAUGE
13259 HYDRAULIC FILTER
S1024 STEERING ORBITROL SERVICE
12860 STEERING ORBITROL
13444 BOOM ROTATION HYDRAULIC MOTOR
12857 BOOM CONTROL VALVE (MAIN)
17171 REMOTE BOOM CONTROL VALVE (BASKET)
17170 STABILIZER CONTROL VALVE
13970 BOOM LEVELING CYLINDER
17075 BOOM LIFT CYLINDER
13429 BOOM EXTENSION CYLINDER
13628 BASKET LEVELING CYLINDER
13627 STABILIZER CYLINDER
13943 STEERING CYLINDER
M1080 PREVENTABLE PUMP FAILURE
M1081 HYDRAULIC HOSE CLEANLINESS
S/N: 020-069
S/N: 020-069
S/N: 020-069
S1077
HYDRAULIC SYMBOLS
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)
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
13259
HYDRAULIC FILTER
Page 1 of 1

1 9115-00020 FILTER HEAD ASSEMBLY (INCLUDES ITEM 3) 1
2 534691-G REPLACEMENT FILTER 1
3 534712 SERVICE INDICATOR 1
Updated:
12/19/2012
S/N: 020-069
S1024
S/N: 020-069
S1024
S/N: 020-069
S1024
S/N: 020-069
S1024
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
13444
HYDRAULIC MOTOR
Page 1 of 2

07/09/07
S/N: 020-069
13444
HYDRAULIC MOTOR
Page 2 of 2
DUN16258 MOTOR ASSEMBLY 1
* 54041 SEAL KIT (INCLUDES ITEMS 2, 4, 5, 6, 11, 14, &, 19) 1
1 54021 CAPSCREW 4
2 NSS EXCLUSION SEAL 1
3 54033 FLANGE (2 BOLT) 1
4 NSS SHAFT PRESSURE SEAL 1
5 NSS BACK-UP RING 1
6 NSS SEAL 1
7 54028 BEARING RACE 1
8 54029 BEARING THRUST NEEDLE 1
9 54031 CAPSCREW 1
10 54023 OUTPUT SHAFT 1
11 NSS O-RING 1
12 54036 PLUG 1
13 54037 HOUSING 1
14 NSS SEAL 3
15 54051 DRIVE 1
16 54022 SPACER PLATE 1
17 54052 GEROTOR SET 1
18 54027 END CAP 1
19 NSS SEAL WASHER 7
20 54020 CAPSCREW 7

07/09/07
S/N: 020-069
12857
BOOM CONTROL VALVE
Page 1 of 9
ORIENTATION

NOTE: SEE HYDRAULIC SCHEMATIC FOR EXACT LAYOUT 9/19/2011
S/N: 020-069
12857
BOOM CONTROL VALVE
Page 2 of 9

464039 BOOM CONTROL VALVE (4 SECTION) 1
534490 SEAL KIT (INCLUDES ITEMS 5, 6) 1
1 FOR SERVICE KIT REFER TO PAGE 7 1
2A FOR SERVICE KIT REFER TO PAGE 6 1
4 NSS RETAINER 2
5 NSS WASHER (BACK-UP) 2
6 NSS SEAL (O-RING) 2
7 NSS HOUSING 1
8 NSS SPOOL 1
9 MAIN RELIEF VALVE REFER TO PAGE 3 1
*10 595111 STUD KIT 1
NOTE: TORQUE STUD NUTS TO 32 F.T. LBS. (43.5 Nm)

S/N: 020-069
12857
BOOM CONTROL VALVE
Page 3 of 9

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

S/N: 020-069
12857
BOOM CONTROL VALVE
Page 4 of 9

CYLINDER PORT RELIEF
* 534700 PORT RELIEF (1000 PSI) (INCLUDES ITEMS 1-14) 1
* 534742 PORT RELIEF (1950 PSI) (INCLUDES ITEMS 1-14)
* 534500 SERVICE KIT (INCLUDES ITEMS 10 & 11) 1
* 534501 SEAL KIT (INCLUDES ITEMS 3-7) 1
1 NSS SHIM A/R
2 NSS SPRING A/R
8 NSS CAP 1
9 NSS BODY 1

S/N: 020-069
12857
BOOM CONTROL VALVE
Page 5 of 9
10 NSS POPPET 1
11 NSS RING 1
12 NSS CHECK 1
13 NSS SPRING 1
14 NSS SLEEVE 1

S/N: 020-069
12857
BOOM CONTROL VALVE
Page 6 of 9

LOAD CHECK PLUG
* 534495 SERVICE KIT (INCLUDES ITEMS 1-8) 1
* 534496 SEAL KIT (INCLUDES ITEMS 2-6) 1
1 NSS PLUG 1
7 NSS POPPET 1
8 NSS SPRING 1

S/N: 020-069
12857
BOOM CONTROL VALVE
Page 7 of 9

SPOOL POSITIONER END
534502 SERVICE KIT (INCLUDES ITEMS 1-11) 1
1 NSS WASHER (LOCK) 4
2 NSS SPRING 1
3 NSS SPRING 1
4 NSS BONNET 1
5 NSS SEAL (SQUARE – CUT) 1
6 NSS COLLAR 1
7 NSS SLEEVE 1
8 NSS PLATE 4
9 NSS SCREW (HSHC) 4
10 NSS WASHER 1
11 NSS SPUD 1

S/N: 020-069
12857
BOOM CONTROL VALVE
Page 8 of 9

SPOOL CLEVIS END WITH HANDLE OVERRIDE
1 534410 KNOB 1
2 534413 ROD 1
3 NSS NUT 1
4 NSS ADAPTOR 1
5 534417 PIN (DOWEL) 1
7 NSS WASHER (LOCK) 4
8 534414 RETAINER (SEAL) 1
9 534420 GUIDE 1
10 NSS WASHER 4
12 NSS BONNET 1

S/N: 020-069
12857
BOOM CONTROL VALVE
Page 9 of 9
13 534419 BOOT 1
14 NSS SEAL (SQUARE-CUT) 1
17 NSS SEAL (SPECIAL) 1

S/N: 020-069
BASKET VALVE 4 SECTION 17171
(IN BASKET) Page 1 of 1

465485 4 SECTION VALVE ASSEMBLY 1
1* 465485-01 90° MOUNTING BRACKET 2
2 465485-02 HYDRAULIC CONTROL JOYSTICK 4
3 465485-03 O-RING 90 DURO 6
4 465485-04 VALVE BODY 3
5 465485-05 90 DURO – 114 N90 6
6 465485-06 LOCK WASHER 4
7 465485-07 UNC HEX NUT 4
8 465485-08 TREADED ROD 2

06/27/08
S/N: 020-069
HARSH ENVIRONMENT BOOM/ JACK 17170
CONTROL VALVE ORIENTATION Page 1 of 10
NOTE: SEE HYDRAULIC SCHEMATIC FOR EXACT LAYOUT Updated:

12/23/08
S/N: 020-069

534878 BOOM/ JACK CONTROL VALVE (3 SECTION) 1
534490 SEAL KIT (INCLUDES ITEMS 5, 6) 1
1 SEE PAGE 6 SPOOL POSITIONER END 1
2 SEE PAGE 4 LOAD CHECK PLUG 2
3 SEE PAGE 7 HANDLE & BRACKET 1
4 NSS RETAINER 2
5 NSS WASHER (BACK UP) 2
7 NSS HOUSING 1
8 NSS SPOOL 1
9 SEE PAGE 3 MAIN RELIEF VALVE 1
10 SEE PAGE 5 POWER BEYOND PLUG 1
11 595154 STUD KIT 1

12/23/08
S/N: 020-069

MAIN RELIEF VALVE
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

12/23/08
S/N: 020-069

LOAD CHECK PLUG
1 NSS PLUG 1
7 NSS POPPET 1
8 NSS SPRING 1

12/23/08
S/N: 020-069

POWER BEYOND PLUG
1 NSS SEAL 1
2 NSS POWER BEYOND PLUG 1
3 NSS BACK-UP WASHER 1
4 NSS O-RING SEAL 1

12/23/08
S/N: 020-069

SPOOL POSITIONER END
534498 SERVICE KIT 1
1 NSS SPRING (RETURN) 1
2 NSS COLLAR (SPRING) 2
3 NSS COLLAR (SPOOL) 1
4 NSS BONNET 1
6 NSS LOCK WASHER 2

12/23/08
S/N: 020-069

HANDLE & BRACKET
534499 HANDLE KIT (INCLUDES ITEMS 1, 3, 5, 6) 1
534587 BRACKET KIT (INCLUDES ITEMS 2, 4) 1
1 NSS LINK 1
2 NSS BRACKET 1
3 NSS HANDLE 1
4 NSS SCREW (HCHS) 2
5 NSS PIN (COTTER) 3
6 NSS PIN 1

12/23/08
S/N: 020-069

HR POSITIONER (SPOOL POSITIONER END)
534878-01 REPLACEMENT KIT 1
(INCLUDES THE FOLLOWING ITEMS)
1 NSS LOCK WASHER 4
2 NSS SPRING 1
3 NSS SPRING 1
4 NSS HR BONNET 1
5 NSS SQUARE-CUT SEAL 1
6 NSS STOP COLLAR 1
7 NSS STOP SLEEVE 1
8 NSS BEARI NG PLATE 4
9 NSS HSHC SCREW 4
10 NSS WASHER 1
11 NSS POSITION SPUD 1

12/23/08
S/N: 020-069

HRH POSITIONER (SPOOL CLEVIS END)
534878-02 SEAL KIT 1
1 534878-03 KNOB 1
2 534878-04 VERTICAL HANDLE ROD 1
534878-05 HORIZONTAL HANDLE ROD 1
3 534878-06 JAM HEX NUT 1
(HORIZONTAL HANDLE REQUIRES TWO JAM NUTS)
4 NSS VERTICAL ADAPTOR 1
NSS HORIZONTAL ADAPTOR 1
5 NSS DOWEL PIN 1
6 NSS HSHC SCREW 4
7 NSS LOCK WASHER 4
8 NSS SEAL RETAINER 1
9 NSS BONNET GUIDE 1
10 NSS LOCK WASHER 4
11 NSS HSHC SCREW 1

12/23/08
S/N: 020-069
12 NSS HRH BONNET 1
13 NSS BOOT ASSEMBLY 1
14 NSS SQUARE-CUT SEAL 1
15 NSS O-RING SEAL 1

12/23/08
S/N: 020-069
13970
HYDRAULIC CYLINDER
Page 1 of 1

465407 CYLINDER ASSEMBLY 1
465121-08 SEAL KIT 1
1 465407-01 BARREL ASSEMBLY 1
2 465121-02 ROD ASSEMBLY 1
3 465407-03 PISTON ASSEMBLY 1
4 465407-04 ROD BEARING ASSEMBLY 1
5 465411-05 NUT (WAS P/N 465407-05) 1
6 465143-06 CAP SCREW (WAS P/N 465407-06) 1
7 465301-19 GREASE FITTING (WAS P/N 465407-07) 2
8 465121-11 BUSHING (WAS P/N 465407-08) 2
Updated:
05/30/13
S/N: 020-069
17075
BOOM LIFT CYLINDER
Page 1 of 1

DUN14671-01 CYLINDER ASSEMBLY WITH NEEDLE VALVE 1
464582-01 SEAL KIT (INCLUDES ITEMS 6-8, 10, 13, 15, 16, 17, 18) 1
1 464582-02 BUSHING 4
2 DUN17393 NEEDLE VALVE 1
3 465305-06 VALVE, COUNTER BALANCE (WAS P/N 464582-03) 1
4 464582-04 NUT 1
6 NSS WEAR RING 2
7 NSS SEAL 1
8 NSS O-RING 1
9 464582-05 PISTON 1
10 NSS O-RING 1
11 464582-06 TUBE ASSEMBLY 1
13 NSS WEAR RING 1
14 464582-08 HEAD STOCK 1
15 NSS O-RING 1
16 NSS BACK-UP 1
17 NSS U-CUP 1
18 NSS WIPER RING 1
19 464582-09 GLAND NUT 1
Updated:
11/10/11
S/N: 020-069
13429
EXTENSION CYLINDER
Page 1 of 2

DUN14422 CYLINDER ASSEMBLY 1
* DUN14422-01 SEAL KIT (INCLUDES ITEMS 7 THRU 15, 17, 18, &, 19) 1
1 DUN14422-02 TUBE WELDMENT 1
2 DUN14422-03 TUBE 1
3 DUN14422-04 PISTON ROD 1
4 DUN14422-05 PISTON ROD 1
5 DUN14422-06 TOP NUT 1
6 DUN14422-07 TOP NUT 1
7 NSS PISTON PACKING 1
8 NSS O-RING 1
9 NSS SEAL RING 1
10 NSS PISTON PACKING 1
11 NSS O-RING 1
13 NSS O-RING 1

07/09/07
S/N: 020-069
13429
EXTENSION CYLINDER
Page 2 of 2
15 NSS SEAL RING 1
16 DUN14422-08 SPACER 1
17 NSS SCRAPER RING 1
18 NSS PISTON ROD SEAL 1
19 NSS SCRAPER RING 1
20 DUNPLUG SPACER 1
21* DUN16217 ROD END EYE 1

07/09/07
S/N: 020-069
13628
BASKET LEVELING CYLINDER
Page 1 of 1

2 465121-02 ROD 1
5 465411-05 NUT 1
(WAS P/N 465121-05)
6 465143-06 SELF TAPPING SCREW (LOCK) 1
(WAS P/N 465121-06)
7 465121-07 COUNTER BALANCE VALVE 2
8 465121-08 SEAL KIT 1
9 465121-09 GREASE FITTING 2
10 465121-10 BASE END BUSHING 1
11 465121-11 ROD END BUSHING 1
Updated:
07/17/12
S/N: 020-069
13627
STABILIZER CYLINDER
Page 1 of 1

2 465143-02 ROD 1
5 465143-05 NUT 1
6 465143-06 SELF TAPPING SCREW (LOCK) 1
7 465143-07 CHECK VALVE 1
8 465143-08 SEAL KIT 1
Updated:
12/18/06
S/N: 020-069
13943
STEER CYLINDER
Page 1 of 1

465411-07 SEAL KIT 1
5 465411-05 NUT 1
6 465143-06 CAP SCREW (WAS P/N 465411-06) 1
Updated:
10/10/12
S/N: 020-069
PREVENTABLE PREMATURE M1080
PUMP FAILURE Page 1 of 2

CAVITATION DIRTY OIL

Cavitation normally develops on the suction side of the As pumps wear, they release tiny metal particles into the
pump, indicating that the available fluid is insufficient to fill hydraulic oil. The abrasive action between pistons and
the pump’s internal space. The following are typical causes cylinder barrels also can release metal particles. These metal
to pump cavitation: particles act as a grinding compound as they flow through the
system. Ordinary dirt and water are other common hydraulic
1. Oil level in reservoir is too low. oil contaminants. Any one of these contributes to premature
2. Viscosity of the oil being used is too high. failure of your hydraulic components. It’s good business to
3. A restriction in the suction line. flush and clean your hydraulic system and install new filter
4. Excessive operating speed. elements before installing a new or rebuilt hydraulic pump.
5. Air in the hydraulic oil.
EXCESSIVE PRESSURE
In areas subject to freezing temperatures, summer weight oil
may become heavy enough in winter to contribute to In gear pump systems, hydraulic relief valves can malfunction
cavitation. Winter weight oil could become too thin in the and permit excessive hydraulic pressure buildup. Before
summer, contributing to fluid leakage and heat. Follow your using this new pump, back off your system’s relief valve to
equipment’s maintenance manual’s recommendations on zero, install a pressure gauge between pump and relief valve,
specific hydraulic oils. start the pump, as an example, move a control handle to
allow a cylinder to bottom out and reset the relief valve. Set
A loose suction line fitting or a hole in the suction line can it to relieve at the maximum pressure stated in your vehicles
allow air to be drawn into the oil before it reaches the pump, hydraulic schematic.
usually causing a loud, high pitched chatter. The first
corrective steps are to check all suction line fitting threads for In piston pump systems, be sure to set the compensators to
damage and to be sure they are tightened correctly. If a the setting in the hydraulic schematic.
change in fittings or hose is involved, make sure to use the
same size fittings and hose that you are replacing. Do not When a hydraulic system begins to loose efficiency and ability
modify without authorization from Getman Service. A to do its work, some operators may want to increase the
suction line which is too small in diameter can cause pressure by screwing down the relief valve adjustment,
cavitation and severe pump damage. After installing your adjusting the pump’s compensator, or increase pump speed
new pump, you must fill the suction line with fresh clean oil. or a combination. Either of these moves will hasten costly
This is extremely important with piston pumps. failures throughout the hydraulic system. If someone has
tampered with your relief valve, your pump is subject to
The picture below shows an example of cavitation: immediate failure.

EXCESSIVE SPEED

The manufacturer of your hydraulic unit designed the
hydraulic system so that all hydraulic components are
compatible. If you drive your pump faster than the
recommended speed, your hoses, valves, and filters are no
longer compatible with the greater oil volume from the over
speeded pump. Before installing a new or rebuilt pump, the
experienced mechanic will use a tachometer to adjust the
engine governor to the speed recommended in his
equipment maintenance manual or consult Getman Service.

Give this hydraulic unit a chance to serve you dependably.
Avoid these four common causes of hydraulic pump failure.

Updated:
10/17/12
S/N: 020-069
PREVENTABLE PREMATURE M1080
PUMP FAILURE Page 2 of 2
GENERAL HYDRAULIC FLUID RECOMMENDATIONS

A good quality hydraulic oil conforming to the characteristics
listed in the Lubrications Cross Reference sheet in the vehicle
manual is essential to satisfactory performance and long life
of any hydraulic system.

Oil should be changed on regular schedules in accordance
with the manufacture’s recommendations, and the system
periodically flushed.

Oil temperature in reservoir must not exceed 200⁰ F (93.3⁰ C)
with a maximum temperature of 180⁰ F (82.2⁰ C)
recommended. Higher temperatures will result in rapid oil
deterioration.

If your vehicle is equipped with a hydraulic pre‐fill system,
hydraulic fluid must be added via the pre‐fill tank. This fluid is
filtered and de‐watered. Bypassing this by filling the
hydraulic tank in any other way will void the warranty.

WARNING!
When filling hydraulic fluid, use
the pre-fill tank and pump fluid
to main hydraulic tank. Do not
fill at main tank. Filling fluid at main
tank may result in contamination and
Warranty voidance.
Updated:
10/17/12
S/N: 020-069
HYDRAULIC HOSE CLEANLINESS M1081
RECOMMENDATIONS Page 1 of 3

PREFACE

Hydraulic system cleanliness is a term used to describe the level of solid and liquid contamination found in hydraulic systems.
“Contamination” may be defined as any substance that is not part of the hydraulic system’s working fluid. Several sources claim that
over 70% of hydraulic system failures are due to contamination. Cleanliness is becoming increasingly important to the marketplace
because:

• With the introduction of more electronics in the system, pumps and valves are more sensitive to contamination.

• Equipment users are becoming more aware of the potentially damaging affects contaminants can have on their hydraulic
systems.

• OEM’s and service centers are looking more closely at filter residue and other signs of contamination as possible causes of
hydraulic system failures. System filter residue is often analyzed to identify the contaminants and their sources.
Responsibility for failures can be costly.

• Ability to supply hydraulic hose assemblies to a specified cleanliness level can be a powerful sales tool to help you grow
your business.

• Your customers expect clean hose assemblies.

• Your competition will do it if you don’t.

Contamination of hydraulic system fluid can come from many sources, including new, unfiltered oil, particles in the tank, abrasion
wear of system components in use, and chemical degradation of components. Hose assemblies can also introduce contaminants into
a hydraulic system. This document discusses some of the major contributing factors to hose assembly contamination with
suggestions of possible measures to reduce the level of contaminates. The level of cleanliness that can be achieved with any
cleanliness program depends in large part on how well the chosen procedures are implemented.
Updated:
05/11/12
S/N: 020-069

CONTROLLING HOSE ASSEMBLY CONTAMINATION

A major contributor to hose assembly contamination occurs during cutting of the
hose to length, typically done with a circular saw. As the saw blade cuts through the hose, particles of hose tube, reinforcement, and
cover are thrown into the open hose end. This cutting debris is typically limited to a few inches of hose length at the
ends. Different cutting processes can affect the amount of debris that is deposited in the ends of the hose.

• Dry cutting: This method generates more dust and debris and puts debris into motion more than wet cutting.

• Wet cutting: Water or other liquid lubricant is used and not only lengthens the service life of the saw blade, but the liquid
suppresses dust and debris movement thereby reducing the amount of cutting contamination introduced inside the hose.

• A vacuum system aimed at the cutting site can draw dust and debris away from the ends of the hose as well as keep the
work area cleaner.

• Blowing air through hose while cutting can prevent much of the cutting debris from entering the bore end of the hose. A
possible issue with this method is cutting debris can be blown out into the work environment.

A combination of blowing air through the hose during cutting to direct debris away from the cut hose ends and vacuum to remove
debris away from the work area can minimize contamination that occurs during cutting.

The saw blade can also make a significant difference in the amount of cutting debris that is generated.

• A sharp blade will cut more quickly and smoothly and generate less debris.
Saw blades should be kept sharp and clean.

• Smooth blades generate less cutting debris than scalloped, serrated, or abrasive blades. However, smooth blades are not as
effective at cutting spiral wire reinforced hose. Smooth blades become dull quicker.

• For wire‐braided hose, serrated or scalloped blades cut hose better and faster. They also remain sharp longer since the
blade can be reversed, positioning the other side of the notch for cutting. These blades are not recommended for cutting
spiral wire reinforced hoses as they become dull rather quickly.

• Abrasive blades are recommended for cutting spiral wire reinforced hoses.
The drawback is that not only do they produce more dust and hose particle debris, but also fine particles of the abrasive
blade itself are added to the mass of potential contaminants flying about.

Updated:
05/11/12
S/N: 020-069

REMOVING HOSE ASSEMBLY CONTAMINATION

Even after concerted efforts to control hose assembly contamination during fabrication, there will still be a certain level of
contaminants present inside the hose. These contaminants should be removed prior to attaching the couplings to the ends of the
hose as they can become trapped between the hose coupling and the hose inner tube where they are not easily removed. Later,
when exposed to pressure, vibration, flexing and the dynamics of hydraulic hose applications, they can be released into the hydraulic
fluid inside the hose. As a result, it is recommended a post fabrication cleansing process be used. Commonly used hose assembly
cleaning methods include:

• Blowing shop air through the hose bore after cutting it to length. The air should be clean, dry, and filtered. Typically the
pressure from the air supply ranges from 90 psi to 120 psi. Be aware that debris from the cut end of a long piece of hose
can be moved to somewhere in the middle without completely removing it. The longer the hose, the more likely this is to
happen.

• A fluid flush with liquid can be effective as a means of cleaning the hose bore. Usually this is not done until after the
couplings are attached which can leave contaminants trapped between the coupling and the hose tube. It is important that
the cleaning liquid must be chemically compatible with the hose tube. It must also evaporate quickly so the cleaning fluid
itself does not become a contaminant. Naptha is one such solvent cleaner. It can also dissolve other residues such as
manufacturing lubricants that may adhere to the hose tube wall. Following the flushing process with a clean, dry, filtered air
flush can promote solvent drying and further clean the hose bore. This method involves safe, responsible disposal of used
cleaning fluid.

• Blowing a cleaning projectile such as a sponge pellet through the cut hose with clean, dry, filtered shop air can not only
remove cutting debris, but also any mandrel lubricants or other manufacturing residues. Soaking the projectile in a cleaning
solvent can enhance the cleaning process. This is a very fast method of cleaning. Cleaning projectiles are most effective
when used before the hose couplings are attached. As the projectile passes over the bump end of the coupling inserted into
the hose bore end it could result in wiping off the collected debris and leaving it deposited there. Blowing a
cleaning projectile through a finished assembly can possibly introduce new contamination into the system as pieces of the
projectile can be peeled off and trapped as the projectile goes past the coupling.

• Using a brush and suction at the hose end can loosen and remove debris from the inside surface at the coupling end of a
hose assembly where most contaminants are found.

None of these methods guarantee results under all conditions, which can vary considerably. The various cleaning methods offer the
potential of providing an acceptable level of cleanliness. Success depends highly upon awareness of contamination sources, how
much attention is given to detail, and how carefully the cleaning procedure is carried out.

AVOIDING CONTAMINATION OUTSIDE OF THE FABRICATION PROCESS

Being aware of contamination sources in your particular fabrication environment and taking steps to avoid contamination in the first
place will also assist in providing clean hose assemblies to your customers.

• Hoses and couplings should be stored in a clean, dry environment. Hoses should have the ends capped or remain in
shipping cartoons or sealed plastic wrap. Couplings should be kept in sealed bags, boxes, or closed bin drawers until they
are to be used.

• Completed, cleaned hose assemblies should have the ends capped or be placed in sealed bags or shipping boxes until they
are attached to equipment and put into use.

Updated:
05/11/12
S/N: 020-069

S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
9. CONTROLS
13905 ELECTRIC SHIFTER

10827 STEERING WHEEL & COLUMN
13655 THROTTLE (ELECTRONIC)
S/N: 020-069
13905
ELECTRIC SHIFTER
Page 1 of 2

04/02/13
S/N: 020-069
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,FLAT HEAD 4
6 534772-06 NUT 4
7 524812 ROTARY SWITCH (WAS P/N 534772-07) 1
(NOT SOLD SEPARATELY AS OF 1-8-10, SEE ITEM 20)
8 534772-08 SWITCH DRIVE BEARING 2
10 534772-09 SPRING LEVER ASSEMBLY (LEFT) 1
534772-10 SPRING LEVER ASSEMBLY (RIGHT) 1
11 534776-01 MOLDED HANDLE 2
(OLD P/N WAS 534772-11)
12 534772-12 WIRE HARNESS 1
14 534772-13 SCREW, FLAT HEAD 4
15 534772-14 SCREW, ROUND HEAD 4
16 534772-14 SCREW, ROUND HEAD 4
(OLD P/N WAS 534772-15)
17 534772-16 NUT 1
534772-17 PRESS IN NUT 3
18 534772-18 HEAT SHRINK END CAP SEAL 2
19 534772-19 ROTARY SWITCH 1
(NOT SOLD SEPARATELY AS OF 1-8-10, SEE ITEM 20)
20* 534772-20 ROTARY SWITCH KIT (INCLUDES ITEMS 7 & 19) 1

04/02/13
S/N: 020-069
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
S/N: 020-069
ELECTRONIC THROTTLE 13655
PEDAL Page 1 of 1

1 595395 ELECTRONIC THROTTLE PEDAL (INCLUDES BRACKET) 1
USED WITH ALL CUMMINS ENGINES AND MERCEDES
ENGINES WITH PLUS 1
2 595395-01 SENSOR (USED WITH 595395 ONLY) 1
1 9046-00007 ELECTRONIC THROTTLE PEDAL (INCLUDES BRACKET) 1
USED WITH ALL MERCEDES ENGINES WITHOUT
PLUS 1
2 9046-00008 SENSOR (USED WITH 9046-00007 ONLY) 1
Updated:
9/6/12
S/N: 020-069

S/N: 020-069
MANUAL INDEX
A64 ExC 3000
PENOLES (TOPO)
S/N 020-069
8/30/2013
10. MOUNTED EQUIPMENT
17437 FIRE EXTINGUISHER & BRACKET #10

S1012 FIRE PROTECTION INFORMATION MANUAL
S1013 FIRE SUPPRESSION MAINTENANCE MANUAL
S1014 AUTO FIRE SUPPRESSION MAINTENANCE MANUAL
7334-00015 FIRE SUPPRESSION INSTALLATION (MAIN)
7334-00025 FIRE SUPPRESSION INSTALLATION
(BASKET/PLATFORM OPTION)
17344 FIRE SUPPRESSION SYSTEM
17274 AUTO DETECTION SYSTEM
17148 DUNBAR BOOM ASSEMBLY
13432 ROTATION GEAR BOX
17194 ANFO POT
-------- ANFO POT CERTIFICATION
15174 ANFO PIPING SCHEMATIC
(WITH AIR BOOST CLEAN OUT)
15175 ANFO PIPING SCHEMATIC (POT)
13712 ANFO ACTUATOR
S1027 ACTUATOR SERVICE MANUAL
S1101 EXTERNAL PNEUMATIC VIBRATOR
13651 STABILIZER INSTALLATION
S1102 COMPRESSOR OPERATION MANUAL
17197 85 CFM COMPRESSOR
17412 GROUNDING REEL & CLAMP
17165 LUBE SYSTEM INSTALLATION
S1094 LINCOLN AUTO LUBE MANUAL
17341 CHASSIS LUBE ELECTRIC GREASE PUMP
S/N: 020-069
FIRE EXTINGUISHER & 17437
BRACKET 10# Page 1 of 1

9334-00014 EXTINGUISHER #10 1
1 9334-00015 BRACKET ASSEMBLY 1
2 322012-01 GROMMET 4
3 322012-02 GROMMET 4
Updated:
9/17/10
S/N: 020-069
S1012
Vehicle Fire Protection

An Owner’s Manual for Ansul
Fire Suppression/Detection Systems
002792
S/N: 020-069
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
S/N: 020-069
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.
S/N: 020-069
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
S/N: 020-069
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 . . .
S/N: 020-069
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
S/N: 020-069
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.
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
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.
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
S1013
A-101-10/20/30, LT-A-101-10/20/30
VEHICLE SYSTEMS
Installation, Recharge, Inspection, and Maintenance Manual
003898
S/N: 020-069
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.
S/N: 020-069
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
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
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
S/N: 020-069
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.
S/N: 020-069
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.
S/N: 020-069
S/N: 020-069
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
S/N: 020-069
S1014
006052
CHECKFIRE SC-N ELECTRIC®
DETECTION & ACTUATION SYSTEM

Installation, Recharge, Inspection, and Maintenance Manual
S/N: 020-069
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
frequency shall be performed monthly, or sooner, depending on
operating and/or environmental conditions. Maintenance shall be
performed semi-annually, or sooner, depending on operating
and/or environmental conditions.
The application and use of the CHECKFIRE SC-N system is
limited to the application and uses described in this manual. For
other applications, contact your local ANSUL distributor or the
ANSUL technical representative in your area.
ANSUL and CHECKFIRE are trademarks of Ansul Incorporated or its affiliates.
NOTE: Some sections have been removed by Getman as they do not

apply to your application needs. Any questions please call Getman
Corporation directly.
S/N: 020-069
S1014
TABLE OF CONTENTS
12-1-08 REV. 3
SECTION PAGES SECTION PAGES
SAFETY PRECAUTIONS 1 IN CASE OF FIRE 27
TOTAL SYSTEM DESCRIPTION 2–3 RECHARGE 28 – 29
SYSTEM COMPONENTS 3–7 INSPECTION AND MAINTENANCE 30 – 32

Control Module 3 Daily Inspections 30
Manual/Automatic Actuator 3 Maintenance 30 – 32
LT-10-R Cartridge 3
Mounting Brackets 4 TROUBLESHOOTING 33 – 36
Splicing Device 4 Diagnostics 33
Linear Detection Wire 4 History Buffer 33
Thermal Spot Detector 4 Troubleshooting Table 34 – 36
Pneumatic/Linear Detector 5
Triple IR (IR3) Flame Detector 5 PROGRAMMING 37 – 40
Interface Module (Triple IR) 5 Programming 37
Y-Connector Cable Assembly (Triple IR) 5 PC Programming 38
Cable Assemblies (Triple IR) 6 Explaining the Menu 39 – 40
Squib 6
RELEASE CIRCUIT TEST 41
Protracting Actuation Device 6 MODULE INSTRUCTIONS
Squib Cable Assembly 6
Protracting Actuator Cable Assembly 6 APPENDIX 42 – 45
Battery 7 Component Index 42 – 43
End-of-Line Resistor 7 Detection Wire Fluid Resistance Capability 44
Check Valve 7 Warranty 45
Remote High Level Alarm 7
Release Circuit Test Module 7
External Power Wiring Assembly 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
SYSTEM PLANNING 11 – 12
Hazard Identification 11
Pre-installation Guidelines 11 – 12
INSTALLATION 13 – 26
Installation Materials 13
Mounting Bracket Installation 13
Mounting to Existing CHECKFIRE SC Bracket 14
Manual/Automatic Actuator Installation 14
and Connection
Mounting Control Module 15
Remote High Level Alarm Installation 15
Shutdown Device Connection 16
Detection Wire Installation 16 – 18
Thermal Detector Installation 18 – 19
Optional Triple IR Flame Detector Installation 19 – 20
Pneumatic/Linear Detector Installation 21
Automatic Actuation Lead Connection 21
External Power Connection 22
Optional Pressure Switch/Electric Pull Station 22
Function Test 22 – 23
Placing the System in Service 24 – 26
S/N: 020-069
S1014
SAFETY PRECAUTIONS
12-1-08 Page 1
REV. 1
SAFETY PRECAUTIONS
For the protection of personnel and equipment being installed, this
manual contains WARNING and CAUTION statements which are ! CAUTION
listed in the steps which they apply. These warnings and cautions
are also listed here so that the manual user can become familiar The fire suppression system will discharge dry chemical if the
with them before performing any procedures. 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.
! WARNING
In case of fire, evacuate area to lessen the risk of injury from

flames, heat, hazardous vapors, explosions, or other hazards ! CAUTION
that may be created.
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
! WARNING fully discharged and electrically isolated by enclosing in a
plastic bag and sealing the bag. Do not dispose of in fire.
The squib is an explosive device. Do not attach connector until Check applicable solid waste disposal regulations for proper
squib is installed in actuator body. If the squib is actuated disposal of more than one battery.
outside of the actuator body, possible personal injury could
result.
! WARNING
On electrical initiation, the Protracting Actuation Device, Part

No. 436026, operates very quickly. A small brass septum is
ejected from the actuating end of the device which presents a
hazard to unprotected eyes. When handling the Protracting
Actuation Device, always point the actuating end of the device
away from you. Physical damage may also result from contact
with the moving piston.
! 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 manual/automatic actuator
and/or the 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.
S/N: 020-069
S1014
TOTAL SYSTEM DESCRIPTION
12-1-08 Page 2
REV. 4
TOTAL SYSTEM DESCRIPTION The control module can be used as a self contained system,
The complete CHECKFIRE SC-N system is composed of compo- powered by its own internal lithium battery. This allows the detec-
nents which are combined to provide automatic fire detection and tion system to operate around-the-clock without use of external
actuation for equipment hazard areas. The electric detection and power. Optionally, external power can be connected to the control
actuation system is designed for use only with ANSUL fire module with the internal power also connected, which results in a
suppression systems requiring pneumatic input as a means of system with battery back-up. When connected to an external
actuation. In addition to the mechanical pneumatic means of oper- 12/24 VDC supply with the internal battery also connected, the
ating the suppression system, the CHECKFIRE SC-N also external power source becomes the primary supply, while the
provides an automatic and manual electric means to perform the internal power source is maintained in a stand-by mode of opera-
same function. tion.
The CHECKFIRE SC-N system is typically used with an ANSUL The control module may be installed where the ambient tempera-
A-101 Vehicle Fire Suppression system for 24-hour protection of ture is between –40 °F to 140 °F (–40 °C to 60 °C).
equipment. The system is particularly suited for the protection of The CHECKFIRE SC-N Detection and Actuation System is
equipment that is subjected to extreme environmental and physi- Approved by FM Approvals.
cal conditions such as vehicles used in forestry, mining, agricul-
ture, construction, public transportation, public utilities, land fill, Circuits
and waste disposal. The first initiating circuit is the supervised detection circuit
Some of its features include linear (wire) and/or spot (thermal), designed to be connected to linear (wire) and/or spot type thermal
flame detection, supervised circuitry, internally powered, detectors that provide a contact closure input to initiate a fire
adjustable shutdown and discharge time delays, auxiliary relays, detected condition. The second initiating circuit is designed to
and one-button operation. accept a contact closure type of actuating device such as an elec-
tric manual pull station or a pressure switch. The initiating circuits
CHECKFIRE SC-N Electric Detection and Actuation System are low impedance and designed to eliminate nuisance alarms
consists of the following components: associated with contact bounce.
1. Control Module
2. Manual/Automatic Actuator Two field programmable time delays provide timing of shutdown
3. Mounting Bracket and release functions associated with the operation of the detec-
4. Detection Wire tion and electric manual pull/ pressure switch initiation circuits.
5. Thermal Detectors 1) DETECTION INITIATING CIRCUIT
6. Pneumatic/Linear Detection
7. Triple IR (IR3) Flame Detector The detection circuit consists of two time delays:
8. Protracting Actuation Device ‘PAD’ (not shown) The first time delay is field programmed to assign the time
9. LT-10-R Cartridge between alarm (initiation of the detection circuit) and the oper-
10. Check Valve (not shown) ation of the shutdown relay. The first time delay is field
11. Remote High Level Alarm (not shown) programmable for 5, 10, 20, or 30 seconds.
12. Release Circuit Test Module (not shown) The second time delay is field programmed to assign the time
between the completion of the first time delay (when the shut-
2 down relay operates) and the operation of the release circuit.
The second time delay is field programmable for 0, 10, 20, or
30 seconds.
1
2) ELECTRIC MANUAL PULL/PRESSURE SWITCH FEED-
BACK INITIATING CIRCUIT
The second initiating circuit is field programmable to be used
3
as either an electric manual pull or pressure switch feedback
circuit. If selected as an electric manual pull circuit, its opera-
tion will override the first time delay function and initiate a
9 second time delay condition, causing the shutdown relay to
immediately operate and system release to occur upon
completion of the second time delay. Additionally, the control
module can be field programmed to shorten the second time
delay when a manual actuation occurs. The time delay options
available with the electric manual actuation are 0, 10, 20, and
4 30 seconds, with the condition that it can only be less than or
6
equal to the programmed time delay of the detection circuit.
5
Selection of the second initiating circuit as a pressure switch
feedback circuit will result in the operation of the alarm relay
002998
and shutdown relay immediately upon receiving the signal.
The release circuit will not be initiated from this feedback
7 circuit because the system will already have been pneumati-
cally 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.
S/N: 020-069
S1014
SYSTEM COMPONENTS
12-1-08 Page 3
REV. 2
TOTAL SYSTEM DESCRIPTION (Continued) A 1/4 in. NPT street elbow is supplied with the actuator for conve-
Circuits (Continued) nient connection of the 1/4 in. actuation line to the fire suppression
system. See Figure 2.
3) A “DELAY” button is available for the operators use. Operation
SQUIB ACTUATOR,
of the “DELAY” button will restart the first time delay cycle if PART NO. 24479
STRIKE
initiated while the first time delay is active. Once the second BUTTON
time delay has started, operation of the “DELAY” button has RING
PIN
no affect. The “DELAY” button also serves the dual function of
silencing the auxiliary alarm relay. The silence function is only
effective 30 seconds or more after release or pressure switch
feedback operation has occurred.
CONTROL MODULE SQUIB

1/4 IN. NPT TO PORT
The Control Module, Part No. 423504, is the basis of the ACTUATION
CHECKFIRE SC-N detection system. The module cover and back LINE
box is made of durable Noryl SE1gfN3 material with a flammabil-

ity rating of UL94 V-1. The back box contains the field interface
terminal block, battery, and field wiring entrance ports. The cover
assembly contains the control PC board assembly, sounder, oper-
ator interface panel, and environmental seal. The enclosure meets FIGURE 2a
International Standard IEC 529 requirements for dust and water 000850
spray in all directions. Mounting pads allow mounting to any suit-

able flat surfaces. Steel mounting brackets are also available.
PROTRACTING ACTUATOR, STRIKE
All circuitry, relays, switches, and LEDs are contained on a single PART NO. 435479 BUTTON
PC board. A board mounted receptacle mates with the plug-in RING
terminal block mounted in the back box. A high pitch sounder is PIN
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
field programming from a PC and for data retrieval from a trouble
and alarm history buffer. The PC board assembly contains a DIP
TERMINAL
switch for optional manual programming functions without the use HOUSING
of a PC. See Figure 1. 1/4 IN. NPT TO
ACTUATION
LINE
FIGURE 2b
008220
LT-10-R CARTRIDGE
The LT-10-R cartridge is a pressure vessel that is factory-filled with
nitrogen to 1800 psi at 70 °F (124 bar at 21 °C). The cartridge is
installed in the manual/automatic actuator and provides the 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
FIGURE 1 and TC (Transport Canada) approval can be ordered as Part No.
002755
423423. Following operation, the cartridge must be replaced. See
Figure 3.
MANUAL/AUTOMATIC ACTUATOR
The Manual/Automatic Actuator provides a manual and automatic SAFETY
SHIPPING CAP
means of fire suppression system actuation. There are two models
(Figure 2a and Figure 2b) used with the CHECKFIRE SC-N
Detection and Control System. In an automatic mode of operation,
the model shown in Figure 2a, Part No. 24479, uses a squib to
generate pressure to force the puncture pin down to puncture the CARTRIDGE
LT-10-R Actuation Cartridge. In an automatic mode of operation,
the model shown in Figure 2b, Part No. 435479, uses the mechan-
ical output of a protracting actuation device (PAD) to force the punc-
ture pin down. Manual actuation can be accomplished with either
model by pulling the ring pin and striking the red button. The system
is automatically actuated in either model by an electrical signal
from the CHECKFIRE SC-N Control Module. FIGURE 3
000851
S/N: 020-069
S1014
SYSTEM COMPONENTS
12-1-08 Page 4
REV. 4
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. LINEAR
DETECTION 433284 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 3/8 IN. SPLICE BODY, CONDUCTORS
mounting the control module separate from the pneumatic actua- PART NO. 426783 UNDER SCREW
(1 cm)
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.
(2 cm)
The third type, Part No. 423531, is a retrofit bracket for mounting a
SC-N module to any existing CHECKFIRE bracket except
CT/CT + G. See Figure 4. FIGURE 5
000854
Note: The CHECKFIRE Detection Interface Kit includes a bracket
and mounting hardware, but if additional brackets are needed, use
bracket Part No. 423528. LINEAR DETECTION WIRE
The linear detection wire consists of two spring steel conductors
All brackets can be fastened by either bolting or welding. Brackets
which are separated by a heat-sensitive insulator. At the tempera-
are painted with red enamel paint.
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
SPRING STEEL
CONDUCTORS
FIGURE 6
COMBINED BRACKET RETROFIT BRACKET 000855
PART NO. 423525 PART NO. 423531
002756 002757
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
PART NO. CABLE CLAMP WITH
416221 PROTECTIVE TUBING,
PART NO. 416214
MODULE BRACKET ACTUATOR BRACKET

PART NO. 423528 PART NO. 416726
002758 008213 SPOT
DETECTOR
FIGURE 4
SPLICING DEVICE
The In-Line Splice Kit, Part No. 428375, is required for detection
wire connection between the control module and the linear detec-
tion wire or between separate pieces of linear detection cable.
When the splicing device is used in the system, special sealing FIGURE 7
compound is required to make a proper seal. The kit consists of the 000856
necessary number of components to assemble 10 complete Thermal detectors are available in three preset temperatures as
assemblies. See Figure 5. 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
S/N: 020-069
S1014
SYSTEM COMPONENTS
4-1-07 Page 5
REV. 2
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 BRACKET,
PART NO. 434116
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.
TRIPLE IR (IR3) FLAME
DETECTOR, PART NO. 432035
OR PART NO. 434941
DETECTOR FIGURE 9
006829
TUBE
TRIPLE IR (IR3) CHECKFIRE DETECTION INTERFACE

MODULE
The Interface Module, Part No. 434108, is used to connect the
RESPONDER linear detection cable to the Triple IR detectors. Only one interface
module is required per IR3 detection system. The module is
designed with self-resetting current protection on the supply input
voltage to the IR3 detectors. See Figure 10. Within the module,
terminals 5, 6, 7, and 8 are available for splicing capabilities for
additional detection circuits for linear or point detectors.
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 stainless steel housing Spectrex Model
20/20MI-32-S-F Triple IR (IR3) flame detector and detector bracket FIGURE 10
006830
assembly.
The Model 20/20 MI-32-S-F flame detector uses innovative tech- TRIPLE IR (IR3) Y-CONNECTOR CABLE ASSEMBLY
nology of advanced digital signal processing to analyze the The Y-Connector Cable Assembly, Part No. 434106, is used to
dynamic characteristics of fire. Three sensitive IR channels connect all detectors in the circuit, except the last one. The
process the signals. Detection performance is controlled by a Y-Connector has three connectors: two that connect to the cable
microprocessor and easily adapted to all environments, applica- assemblies and one that connects with the detector. See Figure 11.
tions, and requirements. The result is a unique and superior flame
detector, which provides excellent detection sensitivity with
extreme immunity to false alarm.
The bracket allows the detector to be easily pointed in the correct
direction for optimum cone of vision viewing.
The bracket can be welded or bolted to the vehicle, for rigid
support.
Mounting bolts and lock nuts 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. 434941 – Spectrex Model 20/20 MI-32-S-F Triple IR (IR3) FIGURE 11
Flame Detector (Stainless Steel Housing) 006831
Part No. 434116 – Detector Bracket
S/N: 020-069
S1014
SYSTEM COMPONENTS
12-1-08 Page 6
REV. 4
TRIPLE IR CABLE ASSEMBLIES

Cable assemblies are required to wire from one detector to
another. Cable assemblies attach to the “Y” connector assemblies.
Receptacle-plug cable assemblies are available in three different
lengths. See Figure 12.
Part No. 434103 – 10 ft (3.1 m) Receptacle-Plug Cable Assembly
Part No. 434104 – 20 ft (6.1 m) Receptacle-Plug Cable Assembly FIGURE 13a
001058
Part No. 434105 – 30 ft (9.1 m) Receptacle-Plug Cable Assembly

PROTRACTING ACTUATION DEVICE
! WARNING
On electrical initiation, the Protracting Actuation Device, Part

FIGURE 12 No. 436026, operates very quickly. A small brass septum is
006832 ejected from the actuating end of the device which presents a
Part No. 434107 – End-of-Line (EOL) Cable Assembly* hazard to unprotected eyes. When handling the Protracting
Actuation Device, always point the actuating end of the device
*This assembly shall be used to connect the last detector in the system. away from you. Physical damage may also result from contact
Note: During installation, all cable assemblies should be rigidly with the moving piston.
fastened (supported) within 12 in. (30.5 cm) of each connection,
and every 3 ft (0.9 m) along the length of the cable. The Protracting Actuation Device (PAD) Assembly, Part No.
436026, is the electrically-actuated component of the
SQUIB Manual/Automatic Actuator, Part No. 435479, which generates the
force to drive the puncture pin into the nitrogen cartridge seal. See
WARNING Figure 14a.
!
The PAD is provided as a component in the Shipping Assembly,
The squib is an explosive device. Do not attach connector until Part No. 436302, and must be field installed into the actuator
squib is installed in actuator body. If the squib is actuated assembly.
outside of the actuator body, possible personal injury could
result.
The Squib Assembly, Part No. 54919 (used with Manual/Automatic

Actuator, Part No. 24479), is an electrically-actuated component
containing a small charge of powder. When the circuit is closed to
the squib, a small internal wiring bridge heats up, causing ignition
of the squib. This generates pressure, which forces the puncture FIGURE 14a
008222
pin of the actuator through the seal in the nitrogen cartridge. See
Figure 13.
MANUAL/AUTOMATIC ACTUATOR (PART NO. 435479)
CABLE ASSEMBLY (PART NO. 436242) –
OPTIONAL 20 FT (6.1 m)
WARNING
Manual/Automatic Actuator, Part No. 435479, is provided with a
DEVICE CONTAINS EXPLOSIVE standard 20 in. (51.0 cm) connector/cable assembly, Part No.
CHARGE.
DO NOT REMOVE SHUNT
436114. The Optional Cable Assembly, Part No. 436242, is
UNTIL READY TO CONNECT required to supply an electrical signal from a remote module to the
INTO ELECTRICAL SYSTEM.
actuator. The cable is 20 ft (6.1 m) long and can be cut to what-
FIGURE 13 ever length is required. See Figure 14b. The maximum allowable
000858 cable length from the controller to the actuator is 20 ft (6.1 m).
MANUAL/AUTOMATIC ACTUATOR (PART NO. 24479)

SQUIB CABLE ASSEMBLY (PART NO. 79062) –
OPTIONAL 15 FT (4.6 m)
The Standard Cable, Part No. 79062 (used with Manual/Automatic
Actuator, Part No. 24479), is 20 in. (51 cm) and is included with the FIGURE 14b
control module shipping assembly. The optional squib cable, Part 008221
No. 422747, is required to supply an electrical signal from a

remote module to the squib located in the actuator body. The squib
cable is 15 ft (4.6 m) and can be cut to whatever length is required.
See Figure 13a. The maximum allowable cable length from
controller to actuator is 15 ft (4.6 m).
S/N: 020-069
S1014
SYSTEM COMPONENTS
12-1-08 Page 7
REV. 3
BATTERY 1/4 IN. NPT

The CHECKFIRE SC-N Control Module uses one 3.6 VDC lithium (BOTH ENDS)
battery, Part No. 427308. All power required to run the detection
system can be provided from this battery. The battery is supplied
with two separate plug-in connectors. CAUTION: Do not cut off
unused connector assembly. It must remain on battery module even
though it is not used. Simply tuck the extra connector assembly
along side the battery module when installing the cover. The battery
must be replaced annually, after discharge, or when the YELLOW 1 5/8 IN.
(4.1 cm)
Battery LED and the Audio Alarm are pulsing. See Figure 15.
Note: When installing battery, either on an SC-N or MP-N module,
match internal battery jack colors. Example: White battery connec- FIGURE 17
tor to white internal battery jack or black battery connector to black 000899
internal battery jack. REMOTE HIGH LEVEL ALARM

The remote high level alarm, Part No. 79559, is intended for those
installations where the noise level or operating conditions may
prevent the operator from recognizing the control module alarm
condition. This device is connected through the alarm relay of the
control module to a separately fused power source. It is capable of
102 decibels at 6 to 30 volts, 0.3 amp maximum at a temperature
range of –40 °F to 170 °F (–40 °C to 76.7 °C). See Figure 18.
BLACK WHITE
NOTE: DO NOT CUT OFF

UNUSED WIRE
ASSEMBLY
FIGURE 15
004877
FIGURE 18
000861
END-OF-LINE RESISTOR
The End-Of-Line Resistor Assembly, Part No. 426520, is required RELEASE CIRCUIT TEST MODULE
for supervision of the external input circuits. The end-of-line resis- The release circuit test module, Part No. 423541, is used in place
tor assembly is available in a package of 10, Part No. 426461. of the Manual/Automatic Actuator during test procedures to simu-
Each package consists of 10 of the required components to late operation of the actuation device. The test module will provide
assemble 10 of the resistor assemblies. See Figure 16. The an indication of whether or not the release signal from the control
package contains an instruction sheet, Part No. 423542, detailing module is of adequate strength to automatically operate the
the assembly requirements. Manual/Automatic Actuator. See Figure 19. When using the
Manual/Automatic Actuator, Part No. 435479, a Protracting
Actuation Device (PAD) Test Adaptor, Part No. 436243, is required
to connect the Protracting Actuation Device to the test module.
LOCK This adaptor is included in the shipping package.
NUT
STRAIN RELIEF
CONNECTOR
TERMINAL BLOCK
WITH 4.7 K OHM
RESISTOR
CAP FIGURE 16
003050
CHECK VALVE
FIGURE 19
The 1/4 in. check valve, Part No. 25627, is installed in the actua- 003015
tion line between the manual/automatic actuator and the pneu-

matic actuator on the connected fire suppression system. This EXTERNAL POWER WIRING ASSEMBLIES
check valve allows actuation pressure to flow to the fire suppres-
sion system, but does not allow pressure from other actuation External Power Wiring Assemblies are available to supply power
devices to back up into the manual/automatic actuator of the from the vehicle battery to the CHECKFIRE SC-N module or the
CHECKFIRE SC-N system. See Figure 17. CHECKFIRE detection interface module.
Part No. 419782 – 10 ft (3.1 m) Plug-Receptacle Cable Assembly
Other actuation devices in the fire suppression system also
Part No. 419781 – 15 ft (4.6 m) Plug-Receptacle Cable Assembly
require check valves to be installed in the same fashion. This
prevents pressure from escaping through an actuator whose Part No. 419780 – 15 ft (4.6 m) Receptacle on one end only
cartridge was inadvertently removed. Part No. 419783 – Battery Connection (5 amp fused)
S/N: 020-069
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 OD of 0.13 in. to 0.25 in.,
features and components pertaining to the CHECKFIRE SC-N 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 (NO), No. 15
(Common), No. 16 (NC)
• 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 OD of 0.13 in. to 0.25 in., • Terminal is labeled from left to right, No. 1 through No. 16
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 OD 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 NO
• Polarity need not be considered 11. Alarm NO
• Cable from splicing device must be round jacketed, with an OD 12. Alarm Common
of 0.13 to 0.25 in., suitable for the intended usage 13. Alarm NC
14. Shutdown NO
Release Circuit (Terminals No. 7 and No. 8)
15. Shutdown Common
• Polarity must be considered – Terminal No. 7 (+), Terminal No. 8 16. Shutdown NC
(–)
• 15 ft (4.6 m) maximum cable length between control module and
pneumatic actuator for squib actuation and 20 ft (6.1 m)
maximum cable length for PAD actuation
• Cable from splicing device must be round jacketed, with an OD
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 OD of 0.13 in. to 0.25 in.,
• 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 OD of 0.13 in. to 0.25 in.,
• 3 amp maximum load
• Normally open, normally closed set of contacts
• Form “C” contact arrangement
• Contacts shown in non-alarm condition – No. 11 (NO), No. 12
(Common), No. 13 (NC)
S/N: 020-069
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 The Release Trouble will also pulse after the system has
condition is detected in either of the connected supplies (inter- completed a discharge cycle or a pressure switch feed back signal
nal or external). If only one power source is used, the control has been received. The trouble signal in this condition is used to
module will automatically ignore the unconnected circuit upon indicate a recharge of the fire suppression system is necessary. A
resetting the control module. If a power source is once Release Trouble under either of these conditions can only be
connected and recognized, a subsequent loss of that power cleared by resetting the control module.
source will be recognized as a Battery Trouble condition. If a
power source is once connected, recognized, and then discon- Detection Trouble (Yellow)
nected, the disconnected supply can be ignored by operating
The Yellow Detection Trouble LED and the audio pulse once every
the RESET button.
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 seconds The sounder gives the audio indication for all alarm and trouble
indicating power is normal from both sources of input power. If outputs. The sounder will pulse at the same rate as the visual
the power drops below an acceptable level from either the inter- corresponding LED.
nal or external source of input power, the green Power LED will
be extinguished. If only one source of power is used, the green The sounder gives the audio indications of the various outputs.
Power LED will extinguish when the voltage level drops below an The sounder is rated at 85 dB at 2 ft (0.6 m).
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
control module will go into the post-discharge mode, at which
time the Alarm LED and Release LED will pulse at a rate of one
pulse per 10 seconds.
PRESSURE SWITCH CIRCUIT (FEED BACK) ACTIVATED
MODE – When this mode is actuated, the Alarm LED will pulse
a minimum of 30 seconds at 4 pulses per second. The control
module will then go into the post-discharge mode and the Alarm FIGURE 21
002760
and Release LED will pulse at a rate of one pulse per 10
seconds.
S/N: 020-069
S1014
USER INTERFACE
12-1-08 Page 10
REV. 3
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
RESET
DELAY 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
plastic bag and sealing the bag. Do not dispose of in fire.
Check applicable solid waste disposal regulations for proper
disposal of more than one battery.
FIGURE 22
0002760
External
The external power circuit can be between 12 to 24 VDC. The BATTERY REPLACEMENT
circuit must be fused at the source on the positive line. The exter- • While in use, the battery requires replacement every year or
nal power source is connected to the module terminal block on when the Yellow Battery LED and sounder are pulsing.
terminals No. 1 (+) and No. 2 (–). • The shelf life of the battery is eight (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 ment date.
system 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 four (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 pattern • Seal should always be kept clean.
is prioritized. The first trouble must be fixed before addressing • A small amount of silicone lubricant will improve the seal’s effec-
the next one. Once the first trouble is taken care of, depressing tiveness.
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
• The “RESET” button is used to re-initialize the control panel. molded-in mounting tabs on the back box. Note: Surface must
When depressed, it provides an indication that all LEDs and the be 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
• When the “RESET” button is pressed, three short audio and maximum release cable length of 15 ft (4.6 m).
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.
S/N: 020-069
S1014
IN CASE OF FIRE
12-1-08 Page 27
REV. 3
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 56. 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. PIN
1
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 56
been discharged. Remain alert until the equipment cools and 002773
the possibility of reignition is no longer a threat.
S/N: 020-069
S1014
RECHARGE
12-1-08 Page 28
REV. 4
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 four (4) screws holding the cover to the back box
and remove the cover.
BASE
2. Remove the battery from the back box and properly discard. OF STEM
LUBRICATE O-RING
Battery must be replaced after each discharge. If system WITH SILICONE GREASE
contains 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.
Note: If a Protracting Actuator, Part No. 435479, is being
used, skip to Step 5.
SPRING
4. Squib Actuator, Part No. 24479, Recharge Steps: RESET
POSITION
Note: If the system was manually actuated – proceed to step
APPROXIMATELY
6. 1/16 IN. (1.6 mm)
± 1/16 (1.6 mm) ACTUATOR
a. Unscrew the squib lead connector. Remove the squib from BODY
the manual/automatic actuator.
b. Clean and lubricate the manual/automatic actuator by
FIGURE 57a
completing the following steps. See Figure 57a. 000888
NOTICE NOTICE
If the system was actuated manually and the When puncture pin is fully reset, cutting point of
squib was not actuated, cleaning is not neces- pin will be located approximately 1/16 in.
sary. (1.6 mm) below threads in lower actuator body.
i. Remove jam nut and slide actuator out of mounting 5. Protracting Actuator, Part No. 435479, Recharge Steps (see
bracket. Figure 57b):
ii. Unscrew upper portion of actuator body. Note: If the system was manually actuated – Proceed to
iii. Using a pencil eraser, apply pressure to the bottom of Step 6.
the puncture pin. This will force the puncture pin and a. Back out the two (2) screws holding the Terminal Housing
spring out of the actuator body. and Cable Assembly to the actuator body assembly,
iv. Thoroughly clean carbon deposits from base of stem, disconnect the actuation cable from the Protracting
puncture pin, spring, and inside surface of actuator Actuation Device (PAD) leads and remove the terminal
body. housing (the screws are captive screws and should remain
secured in the terminal housing cover).
v. After all components are clean and dry, liberally lubri-
cate O-rings with a good grade of extreme temperature b. Unscrew the upper portion of the actuator body to expose
silicone grease. the bore in the top of the puncture pin.
vi. Reassemble actuator, reinstall into bracket, and c. Remove the PAD from the actuator body by lifting the PAD
securely tighten jam nut. out of the puncture pin bore and actuator body, while
pulling the PAD leads back through the port in the side of
vii. Pull ring pin and push strike button several times to the actuator.
spread grease and ensure free movement of puncture
pin. d. After the PAD has been removed, tip the actuator body
upside down, being careful not to drop the actuator pin, to
viii. With strike button in the up position, insert ring pin remove the small brass septum that was ejected from the
through actuator body into puncture pin shaft. Install PAD during discharge.
visual inspection seal, Part No. 197.
e. Before inserting the new PAD into the bore in the top of the
pin, route the PAD connector from the inside of the actua-
tor to the outside of the actuator through the port in the
actuator body. Then, as the connector is being pulled
through the port, insert the PAD into the bore in the top of
the actuation pin.
f. When the PAD is fully seated inside the bore in the actua-
tor pin, carefully pull on the PAD leads that are extending
outside the actuator body to take up the remaining slack in
the PAD lead wires. Note: Do not pull on the connector.
g. Position the upper body so that the slot in the stem base
straddles the PAD lead wires.
S/N: 020-069
S1014
RECHARGE
12-1-08 Page 29
REV. 3
RECHARGE (Continued)
5. Protracting Actuator, Part No. 435479, Recharge Steps:
(Continued)
h. Thread the upper actuator body back into the lower body.
i. Mate the PAD connector that is extending from the port in
the actuator body to the connector located on the inside of
the Terminal Housing and Cable Assembly, and using the
two (2) captive screws, re-attach the Terminal Housing and
Cable Assembly to the actuator body.
j. Rotate the actuator so that the gas outlet port is facing the
front and the Terminal Housing and Cable Assembly is
facing to the right (facing the left side of the control module)
and tighten the jam nut firmly.
UPPER
PORTION
OF BODY
BASE OF STEM
PROTRACTING
ACTUATION
DEVICE
PUNCTURE PIN
SPRING
ACTUATOR BODY
FIGURE 57b
008226
k. Install the ring pin, but do not attach seal at this time.
6. In the case of a fire, replace all linear detection wire and spot
detector cable. See Section III, Installation, for instructions.
a. Inspect all spot thermal detectors, if used, for damage, and
verify that each one has reset to its normal operational
mode. (With the detection wiring disconnected from the
detector, using a multimeter, check to verify that there is no
continuity between any of the detector pin connections.)
b. If Spectrex Model 20/20MI-32-A-F Triple IR (IR3) flame
detection is utilized, inspect detectors and verify they have
not been damaged. Make certain all detectors have been
reset to their normal operating condition. Refer to User and
Maintenance Manual (Ansul Part No. 432485) and follow
the detector maintenance instructions outlined on Page 18
in the manual to verify detector operation.
Note: The functional operation of the IR3 flame detectors
should result in an alarm condition in the CHECKFIRE SC-N
module.
7. Install new battery, Part No. 427308, in module. Record date
of installation.
8. Recharge the fire suppression system in accordance with the
corresponding manual.
9. Test the system and place into service by completing the
steps listed under “FUNCTIONAL TEST.”
10 Record date of recharge on a tag or in permanent record file.
Notify operating personnel that the system is back in service.
S/N: 020-069
S1014
INSPECTION AND MAINTENANCE
12-1-08 Page 30
REV. 2
To ensure that the CHECKFIRE SC-N Electric Detection and 4. Five Year Protracting Actuation Device Replacement
Actuation System will operate as intended, proper inspection and a. The Protracting Actuation Device (PAD) must be replaced
maintenance procedures must be performed at the specified inter- after being in service for five years. (The month and year of
vals. manufacture is printed on the label located on the PAD
leads). Proper disposal of the PAD is accomplished by
DAILY INSPECTIONS actuating the PAD within the actuator body. If this is
The vehicle operator must check the system daily by visually veri- required, skip following steps b. through d. which deal with
fying that the GREEN power LED is flashing and no other LED is installing the test module in place of the PAD. By skipping
illuminated. Also, no audio alarm should be sounding. If any other steps b. through d., the PAD will be actuated during the
conditions exist, contact the local authorized ANSUL distributor or following test procedures.
whoever has been trained and authorized by ANSUL to perform
inspection and maintenance checks. ! CAUTION
MAINTENANCE Make certain the cartridge is removed from the actua-

tor. Failure to do so will cause system discharge when
To give maximum assurance that the system will operate as
the Protracting Actuation Device is actuated.
intended, maintenance shall be performed semi-annually or
sooner, depending on the operating and/or environment condi- b. Remove the PAD Cable and Connector Housing Assembly
tions. Maintenance should be performed by an authorized ANSUL from the actuator body.
distributor or someone who has been trained and authorized by
ANSUL to perform maintenance checks. c. Disconnect the actuator cable from the PAD.
Note: The “SQUIB” setting should be used when testing a
1. Check all mounting bolts for tightness or corrosion.
CHECKFIRE SC-N model with either the Part No. 79062
2. Remove the LT-10-R cartridge from the manual/automatic cable or the Part No. 422747 cables. The “GAS MOTOR”
actuator, install shipping cap, and set aside in a safe location. setting is used for testing the CHECKFIRE MP-N model
and Protracting Actuation Device.
! CAUTION d. Connect the actuator cable to the Test Module, Part No.
423541, using the PAD Test Adaptor, Part No. 436243.
Cartridge must be removed before continuing with the
5. Open cover on CHECKFIRE SC-N module and connect
following steps or accidental system actuation will take
Extender Cable, Part No. 426601, between module backbox
place when squib is actuated.
and cover.
3. Five Year Squib Replacement (If a Protracting Actuator is 6. Inspect the detection and interconnecting wiring as follows:
being used, skip step 3 and proceed to step 4). a. Check for wear due to vibration at penetrations, around
corners, etc.
! CAUTION b. Check for damage from direct impact or other abuse.
c. Check for tightness at points of securement. Make certain
Do not actuate squib unless it is installed in actuator fasteners have not come loose which would allow the wire
body. If the squib is actuated outside of actuator body, it to sag or shift.
will detonate causing possible personal injury.
d. Disconnect the detection wiring and check the resistance
a. The squib must be replaced after being in service for five across the field wiring circuit to verify detection circuit conti-
years. (The month and year of manufacture is stamped on nuity and the proper end of line resistance. The end of line
the squib hex surface.) Proper disposal of the squib is resistance should read 4.7k ohms.
accomplished by actuating the squib within the actuator e. After the detection circuit has been tested, reconnect the
body. If this is required, skip steps b and c which deal with detection wiring to terminals TB-3 and TB-4.
installing the test module in place of the squib. By skipping 7. If IR3 flame detection is utilized, refer to User and
steps b and c, the squib will be actuated during the follow- Maintenance Manual (Ansul Part No. 432485) for detector
ing test procedures. maintenance instructions. Follow the installation steps
outlined on Page 18 in the manual.
! CAUTION Note: The functional operation of the IR3 flame detectors
should result in an alarm condition in the CHECKFIRE
Make certain the cartridge is removed from the actua- SC-N module.
tor. Failure to do so will cause system discharge when
squib is actuated. 8. If thermal detectors are used, check that they are securely
mounted and have not corroded or been damaged.
b. Remove the squib lead connector from the squib. NOTICE
If a vehicle shutdown device is installed, the
c. Hand tighten the squib lead connector onto the test vehicle should be running at this time to verify
module, Part No. 423541. that the device is functioning properly.
9. If external power is used, measure the voltage at terminals
1 and 2 to ensure that the 12/24 VDC is present. Check moni-
toring of the external power by removing the in-line fuse and
checking to see that a power trouble condition is present.
Replace fuse and depress the RESET button on the control
module.
S/N: 020-069
S1014
12-1-08 Page 31
REV. 2
MAINTENANCE (Continued) 14. Squib Replacement – Complete the following steps only if
10. Check first time delay – Alarm to Shutdown – Using a short the squib has been actuated. Otherwise, go to Step No. 15.
length of insulated wire stripped at both ends, hold one end of a. Unscrew the squib lead connector from the squib and
the wire to Terminal 3 and the other end to Terminal 4 on the remove the squib from the actuator body.
control module. See Figure 58. b. Clean manual/automatic actuator by referring to Step 4 on
DETECTION CIRCUIT Page 28 in Recharge Section.
TERMINALS 3 AND 4
c. Screw replacement squib into the upper-right hole in the
JUMPER
3 4 actuator body and wrench tighten.
d.
! CAUTION
DETECTION The control module could be damaged and the fire

CIRCUIT
WIRING
suppression system may not operate if the squib spring
(shunt) is not removed. Always remove cap and spring
(shunt) before installing squib connector.
Unscrew protective cap from replacement squib and

remove spring (shunt). Retain these components for 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.
FIGURE 58 NOTICE
002770
When squib lead connector is removed from test
Using a jumper wire, temporarily short Terminals 3 and 4, module, the YELLOW Release LED and the
removing the jumper before the end of the first time delay audio alarm on the control module will
cycle. This will test the non-latching function of the first time temporarily pulse. This will stop when squib is
delay. While the wire is being held in place, the RED Alarm connected.
LED will pulse and the sounder will operate.
16. Line up index slot in squib lead connector with index tab on
Remove the jumper wire. At this point, both the RED Alarm squib. Then, hand tighten squib connector onto squib.
LED and the sounder will stop pulsing and the first time delay
will recycle back to zero. The control module will return to 17. Protracting Actuation Device Replacement – Complete the
normal with only the GREEN Power LED on. following steps only if the PAD has been actuated. Otherwise
go to Step 18.
11. Check second time delay – Shutdown to Discharge –
Once again, hold the wire on Terminals 3 and 4. The RED a. Back out the two (2) screws holding the Terminal Housing
Alarm LED and the Audio Alarm will pulse. Hold the wire on and Cable Assembly to the actuator body assembly,
the terminals for a period longer than what the first time delay disconnect the actuation cable from the Protracting
is set up for. While holding the wire on the terminals, time the Actuation Device (PAD) leads and remove the terminal
length of the first time delay to verify that it is the same as what housing (the screws are captive screws and should remain
it was set for. secured in the terminal housing cover).
At the end of the first time delay cycle, the pulse rate of the b. Unscrew the upper portion of the actuator body to expose
Audio Alarm will change. This will start the cycle of the second the bore in the top of the puncture pin.
time delay. At this point, the timing cycle is latched, and the c. Remove the PAD from the actuator body by lifting the PAD
wire jumper need not be held on the terminals. Also at this out of the puncture pin bore and actuator body, while
point, the shutdown relay will operate, causing the vehicle to pulling the PAD leads back through the port in the side of
shutdown. the actuator.
Time the length of the second time delay to confirm that it is d. After the PAD has been removed, tip the actuator body
the same as what has been set. upside down to remove the small brass septum that was
When the second time delay cycle is completed, the release ejected from the PAD during discharge.
circuit will activate causing the GREEN LED on the test e. Before inserting the new PAD into the bore in the top of the
module to illuminate or in the case of the five year replace- pin, route the PAD connector from the inside of the actua-
ment, the actuation device will fire. tor to the outside of the actuator through the port in the
actuator body. Then, as the connector is being pulled
12. (If used) Reset test module by pressing the reset button on the
through the port, insert the PAD into the bore in the top of
tester.
the actuation pin.
13. Disconnect the actuator cable from the test module and verify f. When the PAD is fully seated inside the bore in the actua-
that the module is indicating both a RED alarm LED and a tor pin, carefully pull on the PAD leads that are extending
YELLOW release fault LED. Reconnect the Actuator Cable to outside the actuator body to take up the remaining slack in
the test module. the PAD lead wires. Note: Do not pull on the connector.
g. Position the upper body so that the slot in the stem base
straddles the PAD lead wires.
h. Thread the upper actuator body back into the lower body.
S/N: 020-069
S1014
12-1-08 Page 32
REV. 2
MAINTENANCE (Continued)
18. Disconnect the actuation cable from the tester.
NOTICE
When actuation cable is removed from test
module, the YELLOW Release LED and the
audio alarm on the control module will temporar-
ily pulse. This will stop when PAD is connected.
19. Mate the PAD connector that is extending from the port in the
actuator body to the connector located on the inside of the
Terminal Housing and Cable Assembly, and using the two (2)
captive screws, re-attach the Terminal Housing and Cable
Assembly to the actuator body.
20. Rotate the actuator so that the actuation line outlet is facing
the front and the Terminal Housing and Cable Assembly is
facing to the right (facing the left side of the control module)
and tighten jam nut firmly.
21. Install the ring pin, but do not attach seal at this time.
22. Disconnect extender cable from backbox and cover, and rein-
stall cover onto module.
23. For both Squib and PAD Actuators – Push “RESET” button
on CHECKFIRE SC-N Control Module to reset system.
! CAUTION
The fire suppression system will discharge dry chemical if

the cartridge is installed when operating the strike button.
Do not install cartridge at this time.
24. Pull ring pin and push strike button on manual/automatic actu-
ator several times to ensure smooth movement.
NOTICE
If lever does not operate smoothly, clean and
lubricate internal components by completing
Step No. 4 on Page 28 in Recharge Section.
25. Yearly – Remove control module cover screws and replace
internal 3.6 VDC lithium battery, Part No. 427308. Record date
of new battery installation on label located near battery.
Reinstall control module cover and depress “RESET” button.
! CAUTION
Contact your local waste management company for informa-

tion concerning the correct disposal of lithium batteries.
26. Reinstall LT-10-R cartridge by completing the following steps:

a. Make certain puncture pin is fully retracted and insert ring
pin through actuator body into puncture pin shaft.
Note: The tip of the puncture pin of the PAD Actuator, Part
No. 435479 only, should be retracted a distance slightly
less than 1/8 in. (3.2 mm) above the bottom of the actuator.
b. Attach visual inspection seal, Part No. 197.
c. Remove shipping cap and weigh cartridge before installing.
Replace if weight is 1/4 oz (7.1 g) or more below weight
stamped on LT-10-R cartridge.
d. Screw cartridge into actuator body and hand tighten.
27. Reset any auxiliary shutdown and alarm equipment in accor-
dance with manufacturer’s instructions.
28. Record date of maintenance on an affixed tag or in a perma-
nent record file.
S/N: 020-069
S1014
TROUBLESHOOTING
12-1-08 Page 33
REV. 2
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
symptoms by displaying a flashing code on the control module programmed or a programming change has
status LEDs. been 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
before the system will display the next one. settings.
The system must be in the trouble mode in order to display the Init Bad Log – This indicates that an error has been detected
diagnostics codes. 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 voltage
Red Alarm LED flashing 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
disconnected.
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 power- sure switch circuit.
ing of the unit or restoration of power. New events are recorded by
days: hours: minutes: seconds that have transpired from the last Squib Fault – Indicates an open in the squib circuit or that
restoration of power. If power is removed and then restored, the the squib has fired.
counter starts over at 0000:00:00:00, however, previous history Squib Release – Indicates that the control module has fired the
will be retained in the buffer. squib.
Unknown – Indicates an unexplainable event in the
control module circuitry.
All Clear – Indicates alarm condition has been reset. This
indication occurs after TD2 clears.
S/N: 020-069
S1014
TROUBLESHOOTING
12-1-08 Page 34
REV. 2
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
S/N: 020-069
S1014
TROUBLESHOOTING
12-1-08 Page 35
REV. 3
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
S/N: 020-069
S1014
TROUBLESHOOTING
12-1-08 Page 36
REV. 4
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
S/N: 020-069
S1014
APPENDIX
12-1-08 Page 42
COMPONENT INDEX
Part Shipping Weight
No. Assembly lb (kg)
Main Assemblies
436302 CHECKFIRE SC-N Electric Detection and Actuation 10 (4.5)
System includes:
423504 Control Module (module contains nuts and
washers for mounting to bracket)
435479 Manual/Automatic Actuator
423525 Combined Mounting Bracket
13193 Nitrogen Cartridge, LT-10-R
436026 Protracting Actuation Device 1/4 (0.1)
25627 1/4 in. Check Valve
79064 Label Package
53081 Owner’s Manual
436303 (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 (0.1)
426461 End-of-Line Resistor Assembly (Package of 10) 1/4 (0.1)
426520 End-of-Line Resistor Assembly (Single) 1/4 (0.1)
Accessory Equipment
423541 Release Circuit Test Module 1 (0.5)
436243 Protracting Actuation Device Test Adaptor 1/4 (0.5)
423525 Combined Bracket Shipping Assembly – 1 (0.5)
For mounting control module and actuator together
423528 Control Module Mounting Bracket – 1 (0.5)
For mounting control module separately
416726 Actuator Mounting Bracket – 1 (0.5)
For mounting actuator separately
423531 Control Module Retrofit Mounting Bracket – 1 (0.5)
For mounting control module to existing
CHECKFIRE SC mounting bracket
79559 Remote High Level Alarm 2 (0.9)
71820 Splicing Device 1/4 (0.1)
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 (0.1)
416219 325 °F (163 °C) Spot Detector 1/4 (0.1)
416220 360 °F (182 °C) Spot Detector 1/4 (0.1)
416213 Spot Detector Connector Package 1/4 (0.1)
416221 Spot Detector Bracket 1/4 (0.1)
416762 Spot Detector Cable Clamp Package (For Use 1/4 (0.1)
Without Protective Tubing)
416214 Spot Detector Cable Clamp Package (For Use 1/4 (0.1)
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 (0.5)
416113 Pneumatic/Linear Detector, 35 ft (10.7 m) 1 (0.5)
(Model 808-DRV)
416216 Cable Assembly, 15 ft (4.6 m) (For Pneumatic/ 1/4 (0.1)
Linear Detector)
416378 Mounting Clips Package For Pneumatic/Linear 1/4 (0.1)
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)
S/N: 020-069
S1014
APPENDIX
12-1-08 Page 43
COMPONENT INDEX (Continued)

Accessory Equipment (Continued)
Weight
Part No. Shipping Assembly lb. (kg)
56691 Nylon Cable Tie (Package of 20) 1 (0.5)
56692 Rubber Sleeve (Package of 20) 2 (0.9)
436114 Connector/Cable Assembly 1/4 (0.1)
436242 Cable Assembly – 20 ft (6.1 m) 1 (0.5)
419780 Power Wiring Assembly – 15 ft (4.6 m) 1 (0.5)
(Connector on one end)
(Connector on both ends)
(Connector on both ends)
419783 Battery Connection (Fused at 5 amp) 1 (0.5)
423524 RS-232 PC Interface Cable Kit 1/4 (0.1)
426601 Extender Cable Assembly 1/4 (0.1)
428042 Battery Extender Cable Assembly (White Connector) 1/4 (0.1)
426604 Battery Extender Cable Assembly (Black Connector) 1/4 (0.1)
432480 Triple IR (IR3) Flame Detector Shipping Assembly
includes Spectrex Model 20/20MI-32-S-F;
Triple IR (IR3) Flame Detector, Part No. 434941;
Detector Mounting Bracket, Part No. 434116
434103 10 ft (3.1 m) Receptacle-Plug Cable Assembly (Triple IR) 2 (0.9)
434107 End-of-Line (EOL) Cable Assembly (Triple IR) 0.5 (0.2)
434106 “Y” Connector Cable (Triple IR) 0.5 (0.2)
434102 Triple IR CHECKFIRE Detection Interface Kit 2 (0.9)
includes Interface Module, Part No. 434108;
Module Mounting Bracket, Part No. 423528;
End-of-Line (EOL) Cable Assembly, Part No. 434107
57593 High Temperature Silicone Grease (Dow Corning #4) 1/4 (0.1)
434108 Triple IR CHECKFIRE Detection Interface Module 2 (0.9)
434109 Cover, Triple IR CHECKFIRE Detection Interface Module 1/4 (0.1)
432485 Triple IR Flame Detector User and Maintenance Manual 1/4 (0.1)
RECHARGE EQUIPMENT
436026 Protracting Actuation Device 1/4 (0.1)
13193 LT-10-R Cartridge (DOT) 2 (0.9)
423423 LT-10-R Cartridge (DOT/TC) 2 (0.9)
427308 Battery Shipping Assembly (3.6 VDC) 1/4 (0.1)
423522 Installation, Maintenance, Recharge Manual 1/4 (0.1)
S/N: 020-069
S1014
APPENDIX
12-1-08 Page 44
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
S/N: 020-069
S1014
APPENDIX
12-1-08 Page 45
WARRANTY
The components of the Ansul CHECKFIRE SC-N Electric
Detection and Actuation System supplied by Ansul Incorporated,
(“ANSUL”) are warranted to you as the original purchaser for one
year from the date of delivery against defects in workmanship and
material. ANSUL will replace or repair any Ansul-supplied compo-
nent which, in its opinion, is defective and has not been tampered
with or subjected to misuse, abuse, exposed to highly corrosive
conditions or extreme high temperatures provided that written
notice of the alleged defect shall have been given to ANSUL within
30 days after discovery thereof and prior to the expiration of one
year after delivery, and further provided that if ANSUL so instructs,
such article or part thereof is promptly returned to ANSUL with
shipping charges prepaid.
Disclaimer of Liability and Limitation of Damage

The above warranty is the only one given by ANSUL concerning
this system and only to Ansul CHECKFIRE SC-N Electric
Detection and Actuation System that has been installed and main-
tained in accordance with all the directions and requirements
provided by ANSUL in the manual created for the Electric
Detection and Actuation System. THIS WARRANTY IS IN LIEU
OF ALL OTHER WARRANTIES WHETHER EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO FITNESS FOR
PURPOSE AND MERCHANTABILITY, AND ANSUL DOES NOT
ASSUME, OR AUTHORIZE ANY OTHER PERSON TO ASSUME
FOR IT, ANY OTHER LIABILITY IN CONNECTION WITH THE
SALE OF ITS PRODUCTS. ANSUL SHALL NOT BE LIABLE FOR
CONSEQUENTIAL OR SIMILAR DAMAGES.
For repairs, parts and service of the Ansul System, contact your
local Ansul representative, or Ansul Incorporated, Marinette, WI
54143-2542; 800-TO-ANSUL (800-862-6785).
S/N: 020-069
ITEM PART NUMBER DESCRIPTION QTY.
NO.
8 12 1 134167 PRESSURE SWITCH 1
10
404 2 332042 VENT, SAFETY 1
3 332043 TRIPLE TEE 1
NON-LINEAR DETECTION
INSTALLATION 4 334005 NOZZLE PKG, FIRE SUPPRESSION 4
5 334124 TANK & BRKT, AGENT LT-A-101-30 1
12 6 334125 CARTRIDGE & ACTUATOR KIT 1
4
409 NOTE: ITEM 7 SUPPLIED 7 334126 CHECK VALVE,1/4",FIRE SUPP 2
402 W/ ACTUATOR KIT 8 7334-00001 BRACKET, FIRE SUPPRESSION 2
9 7334-00004 MOUNTING BRACKET, FS TEE 1
403
405 10 7334-00006 FS NOZZLE MOUNT, 90 DEG 1
11 (#) NOZZLE MOUNT, A64 2
12 9334-00003 ACTUATOR, REMOTE 1(2)
13 9334-00004 DETECTION,SYS. AUTO SC-N 1(0)
AS
15 334010 SLEEVE, RUBBER REQ'D
16 334011 WIRE, LINEAR DETECTION 1(0)
2 17 464870 RESISTOR ASSY, DETECTION LOOP 1(0)
NOT
SHOWN - 334146 BATTERY, MODULE CHECKFIRE 1(0)
(#) ITEM 11 - P/N VARIES DUE TO ( )=QTY FOR
13 HOOD DIMENSION CENTER/CENTER: NON-LINEAR
46 3/8" - 7334-00014 DETECTION
52 3/4" - 7334-00002 SYSTEMS
61" - 7334-00010
5
408 3
HOSE# I.D. LENGTH ENDS ADAPTERS FROM TO
407 3/4" 135" 94734 84GF1212
6 401 94875 (140") 94726 89GF1212 30# TANK TRIPLE TEE
1
1/2" 94725 - RIGHT ENG
402 48" TRIPLE TEE
94874 94733 89GF0808 NOZZLE
1/2" 110 94725 - LEFT ENG
403 TRIPLE TEE
94874 94733 89GF0808 NOZZLE
1/2" 94725 - REAR ENG
406 404 40" TRIPLE TEE
94874 94733 89GF0808 NOZZLE
1/2" 94725 - HYD PUMP
405 48" TRIPLE TEE
94874 94733 89GF0808 NOZZLE
LEFT ENG NOZZLE 7 1/4" 94751 89GF0404 MAIN
406 10" 30# TANK
REAR ENG NOZZLE NOTE: FOR TRUCKS W/ 3 ACTUATORS
94878 94731 89GF0404 ACTUATOR
RIGHT ENG NOZZLE 11 (EX. SCISSOR BOOMS) SEE REAR FRAME 1/4" 94731 89GF0404 ACTUATOR CAB
9 407 94878 100" 94731 89GF0404 TEE ACTUATOR
INSTALLATION FOR CHECK VALVE LOCATIONS
1/4" 145" 94731 89GF0404 ACTUATOR
408 BULKHEAD
94878 (165") 94746 45GK0404 TEE
1/4" 94731 45GK0404 BULKHEAD REAR
409 *
REAR FENDER 94878 94731 89GF0404 ACTUATOR(S)
401
HY D PUMP
NOZZLE * LENGTH VARIES DEPENDING ON WHEEL BASE
LENGTHS SHOWN IN ( ) ARE FOR LONG FRAMES

(STANDARD SHOWN - FOR 3 (EX. 6.7L CUMMINS)
ACTUATOR SYSTEMS SEE REAR
FRAME INSTALLATION PAGE)
ZIP-TIE TO NOTES:
SUCTION 1. THIS INSTALLATION IS TO BE MADE IN ACCORDANCE WITH THE
LINE LT-A-101-30 INSTALLATION MANUAL
2. ALL HOSES MUST MEET (AS A MINIMUM) SAE 100R5 OR 100R1
HOSE SPECIFICATIONS
3. FOR ALL UNDERGROUND MINING, ALL HOSES MUST COMPLY
WITH USBM SPECIFIED FLAME RESISTANCE ACCEPTANCE
DESIGNATION "MSHA 2G-11C"
4. FOR ALL HOSE FITTINGS USE ONLY STAINLESS STEEL OR PLATED
16 METAL. USE OF STREET ELBOWS IS NOT ACCEPTABLE
15
17
NO. DESCRIPTION CN# BY DATE
STD. TOLERANCES UNLESS OTHERWISE NOTED.

QTY FRACTIONS ±1/16" DEC. ±.010 ANGLES ±1°
MATERIAL
TITLE
CONFIDENTIAL NOTICE
THIS DRAWING IS THE PROPERTY OF GETMAN CORPORATION
FS LAYOUT,A64,30# 4N
WHICH RESERVES ALL RIGHTS IN THIS DRAWING ITS
SUBJECT MATTER AND THE INVENTIONS DISCLOSED
THEREIN. THIS DRAWING IS LOANED SUBJECT TO THE
AGREEMENT AND UNDERSTANDING THAT ITS SUBJECT
MATTER IS NOT TO BE DISCLOSED, IN WHOLE OR IN
PART, TO ANY OTHER PARTY, AND THAT IT SHALL NOT
BE COPIED IN ANY MANNER WITHOUT THE EXPRESS DRAWN DATE SCALE SIZE DRW. NO.
PERMISSION OF GETMAN CORPORATION. ACCEPTANCE
OF THIS COPY WILL BE CONSTRUED AS AN ACCEPTANCE
OF THE FOREGOING CONDITION.
BL 10/19/2009 1:8 D 7334-00015
S/N: 020-069
(PARTS IN ADDITION TO THOSE SHOWN ON MAIN LAYOUT)
ITEM NO. PART NUMBER DESCRIPTION QTY.
NOTE: ACTUATORS NOT TO BE
1 9334-00003 ACTUATOR, DASHBOARD 1 INSTALLED IN JOINT AREA
2 16070-01 BULKHEAD WELDMENT, 1/4" 1
3* 334126 CHECK VALVE,1/4",FIRE SUPP 1
*NOTE: ITEM 3 SUPPLIED W/ ACTUATOR KIT NOTE: FOR STAINLESS STEEL OPTION, BOTH LOCATED IN
REAR FRAME ACTUATORS AND CHECK BASKET/PLATFORM
VALVES WILL BE REPLACED BY:
9334-00009 - CHECK VALVE,1/4", SS
9334-00010 - ACTUATOR, DASHBOARD, SS 1
9334-00012 - S-BRACKET, ACTUATOR
9334-00013 - CARTRIDGE, ACTUATOR
A
TO
AC
TO TU
BU AT
LK OR
HE
AD IN C
AB
TANK & BOTTLE FROM ENGINE END FRAME
REF DWG 7334-00015
DETAIL A
SCALE 1 : 2
2
NO. DESCRIPTION CN# BY DATE
STD. TOLERANCES UNLESS OTHERWISE NOTED.

FRACTIONS ±1/16" DEC. ±.010 ANGLES ±1°
3 QTY
MATERIAL
TITLE
CONFIDENTIAL NOTICE
THIS DRAWING IS THE PROPERTY OF GETMAN CORPORATION
FS LAYOUT,A64,BSKT/PLTFRM OPT.
WHICH RESERVES ALL RIGHTS IN THIS DRAWING ITS
SUBJECT MATTER AND THE INVENTIONS DISCLOSED
THEREIN. THIS DRAWING IS LOANED SUBJECT TO THE
AGREEMENT AND UNDERSTANDING THAT ITS SUBJECT
MATTER IS NOT TO BE DISCLOSED, IN WHOLE OR IN
PART, TO ANY OTHER PARTY, AND THAT IT SHALL NOT
BE COPIED IN ANY MANNER WITHOUT THE EXPRESS DRAWN DATE SCALE SIZE DRW. NO.
PERMISSION OF GETMAN CORPORATION. ACCEPTANCE
OF THIS COPY WILL BE CONSTRUED AS AN ACCEPTANCE
OF THE FOREGOING CONDITION.
BL 1/21/2010 NONE C 7334-00025
S/N: 020-069
17344
FIRE SUPPRESSION SYSTEMS
Page 1 of 10

5/1/2012
S/N: 020-069
17344
Page 2 of 10

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

5/1/2012
S/N: 020-069
17344
Page 3 of 10

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

5/1/2012
S/N: 020-069
17344
Page 4 of 10
NOTE: FOR ITEM 38

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

5/1/2012
S/N: 020-069
17344
Page 5 of 10

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

5/1/2012
S/N: 020-069
17344
Page 6 of 10

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

5/1/2012
S/N: 020-069
17344
Page 7 of 10

5/1/2012
S/N: 020-069
17344
Page 8 of 10

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

5/1/2012
S/N: 020-069
17344
Page 9 of 10

5/1/2012
S/N: 020-069
17344
Page 10 of 10

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

5/1/2012
S/N: 020-069
AUTO (PAD) DETECTION & 17274
ACTUATION SYSTEM Page 1 of 1

9334-00004 AUTO DETECTION SYSTEM 1
(INCLUDES ITEMS: 1, 2, 4, 5, 11)
1 334126 CHECK VALVE 1
2 9334-00004-001 ACTUATOR ASSEMBLY 1
9334-00003-009 RING PIN 1
3 9334-00004-002 COVER & CONNECTOR HOUSING 1
4 9334-00004-003 CARTRIDGE 1
5 9334-00004-004 BRACKET 1
6 9334-00004-005 PAD CABLE/CONNECTOR ASSEMBLY 1
7 334011 DETECTION WIRE (100FT (30.5M)) 1
8 464870 RESISTOR ASSEMBLY (DETECTION LOOP) 1
NOTE: COMES IN A PACK OF 10
9 334146 BATTERY MODULE 1
10 9334-00004-006 FRONT COVER ASSEMBLY 1
11 9334-00004-007 CONTROL MODULE ASSEMBLY 1
(INCLUDES ITEMS: 3, 9, 10)
Updated:
10/12/09
S/N: 020-069
17148
DUNBAR BOOM ASSEMBLY
Page 1 of 4
Updated:
10/18/10
S/N: 020-069
17148
Page 2 of 4
Updated:
10/18/10
S/N: 020-069
17148
Page 3 of 4
56409-01 DUNBAR BOOM/BASEKT ASSEMBLY 1
1 DUN16225 BASE WELDMENT 1
2 DUN17342 GEAR COVER 1
3 16555-01 WEAR PAD WELDMENT 4
4 DUN16258 HYDRAULIC MOTOR 1
5 04GE08 ½” LOCKWASHER 2
6 01GC08020 ½” CAPSCREW 2
7 16407 WEAR PAD SIDE 4
14594-01 SHIM-USE AS NECESSARY A/R
8 DUN16259 GEARBOX 1
9 09GG06016 ⅜” ALLEN SCREW 16
10 18GC10032 ⅝” CAPSCREW 4
11 04GE07 7/16” LOCKWASHER 6
12 DUN14789 GEARBOX SPACER PLATE 2
14 465407 HYDRAULIC CYLINDER 1
15 DUN17376 PIN WELDMENT 1
16 DUN14405 EXT. CYLINDER PIN 1
17 16556-08 SLIDE PAD BRACKET WELDMENT 1
(OLD P/N WAS 16656-08)
18 16556-13 SLIDE PAD BRACKET WELDMENT 1
(OLD P/N WAS 16656-27)
19 04GE06 5/16” WASHER 4
20 DUN16263 SNAP RING 1
21 17GC10028 ⅝” CAPSCREW 36
21A 73GC10024 ⅝” SOCKET HEAD SCREW 6
22 02GE10 ⅝” WASHER 38
23 DUN16260 BULLGEAR BEARING 1
24 DUN16282 ECCENTRIC RING 1
25 18GE05016 5/16” CAPSCREW 6
26 DUN17370 PIN WELDMENT 1
27 DUN14470-01 MAST WELDMENT (NOTE: OLD P/N WAS DUN14470) 1
28 04GE06 ⅜” WASHER 26
29 01GC06012 ⅜” CAPSCREW 20
30 DUN17343 COUNTER BALANCE VALVE 1
Updated:
10/18/10
S/N: 020-069
17148
Page 4 of 4
31 19204-87 PIN WELDMENT 1
32 19204-21 PIN WELDMENT 1
33 17361-02 RIGHT LIGHT MOUNT 1
34 17361-03 LEFT LIGHT MOUNT 1
35 17361-04 LIGHT MOUNT BRACE 1
36 DUN16214-01 INNER BOOM WELDMENT 1
37 DUN16215-01 INTERMEDIATE BOOM WELD 1
38 DUN16216-01 MAIN BOOM WELDMENT 1
39 67GD06 ⅜” NYLOCK NUT 16
40 01GC07028 7/16” CAPSCREW 6
41 DUN17371-03 PIN & KEEPER WELDMENT 1
42 DUN14671-01 LIFT CYLINDER 1
43 DUN14417-05 WEAR PAD LOWER 4
14594-05 SHIM-USE AS NECESSARY (OLD P/N WAS 14595-05) A/R
44 DUN15192 SNAP RING 2
45 01GE20 1¼” WASHER 2
46 DUN14406 PIN, EXT. CYLINDER 1
47 DUN16219 EXT. CYLINDER MOUNT TUBE 1
48 DUN14422 EXTENSION CYLINDER 1
49 DUN16217 EXTENSION LUG 1
50 17GC09040Z 9/16” CAPSCREW 1
51 59GD09 9/16” LOCKNUT 1
52 DUN14419 CYLINDER LOCK PIN 2
53 DUN14417-6 WEAR PAD TOP OUTER 1
54 17GC06008 ⅜” CAPSCREW 6
55 21087-02 HOSE GUARD 2
56 DUN14417-7 WEAR PAD TOP INNER 1
57 DUN14418 WEAR PAD SIDE 4
58 09GG04012 ¼” ALLEN SCREW 16
59 DUN14411 TOP RETAINER PLATE 2
60 DUN14412 WEAR PAD TOP 2
61 DUN17375-02 BOOM ASSEMBLY 20A ONLY, INCLUDES CYL. #48 1
Updated:
10/18/10
S/N: 020-069
13432
ROTATION GEAR BOX
Page 1 of 4

07/06/07
S/N: 020-069
13432
ROTATION GEAR BOX
Page 2 of 4

07/06/07
S/N: 020-069
13432
ROTATION GEAR BOX
Page 3 of 4

DUN16259 GEAR BOX ASSEMBLY 1
DUN16259-01 REPAIR KIT (INCLUDES ITEMS 6, 21, 22, 24, 26, 34, 35, 36) 1
2 DUN16259-02 COVER 1
3 DUN16259-03 WORM GEAR 1
4 DUN16259-04 RETAINER BEARING 1
5 DUN16259-05 WORM WITH KEY 1
6* NSS SHIM (.005) A/R
8 DUN16259-06 SPACER 1
10 DUN16259-07 HSG, 11/16, 15 MTG DOWN 1
11 DUN16259-08 SPACER 1
12 DUN16259-09 OUTPUT SHAFT 12T 5/7 M 1
13 DUN16259-10 NUT (CASTELL) 1
14 DUN16259-11 BEARING CONE 1
15 DUN16259-12 BEARING CUP 1
20 DUN16259-17 BEARING BALL 1
21* NSS SEAL 1
22* NSS SEAL 1
23 DUN16259-18 BUSHING 1
24* NSS O-RING 1
25 DUN16259-19 SNAP RING 1
26* NSS O-RING 1
28 DUN16259-20 ZERK 1
29 DUN16259-21 PLUG 3
30 DUN16259-22 COVER 1
31 DUN16259-23 PLUG (VENT) 1

07/06/07
S/N: 020-069
13432
ROTATION GEAR BOX
Page 4 of 4

32 DUN16259-24 SETSCR, SKT 1
33 DUN16259-25 COTTER KEY 1
34 NSS GASKET 1
35 NSS SHIM (.0156) 1
36 NSS SHIM (.0312) 1
37 DUN16259-26 DRIVE SCREW 2
38 DUN16259-27 LABEL PLATE 1
39 DUN16259-28 PLUG (PIPE) 1
41 01GC06016 BOLT 6
42 01GC8020 BOLT 4
58 27GE06 WASHER PLAIN HARDENED 6
59 02GC08 WASHER FLAT HARDENED 4

07/06/07
S/N: 020-069
17194
ANFO POT
Page 1 of 2
*PARTS ARE NOT INTERCHANGEABLE, BUT FIT/ FUNCTION ARE THE SAME Updated:
08/23/12
S/N: 020-069
17194
ANFO POT
Page 2 of 2

* 464874 ANFO POT 636Lbs. (288.5KG) 100psi (S/N 7041 AND BEFORE) A/R
* 9126-00008 ANFO POT 636Lbs. (288.5KG) 125psi (S/N 020-049 AND AFTER A/R
* 465573 ANFO POT 636Lbs. (288.5KG) 125psi (S/N 7091 AND LATER) A/R
* 464983 ANFO POT 1060Lbs. (480.8KG) 100psi (SN 6977 AND BEFORE) A/R
* 464841 ANFO POT 1060Lbs. (480.8KG) 100psi (S/N 7070 AND BEFORE) A/R
* 465562 ANFO POT 1060Lbs. (480.8KG) 125psi (S/N 7072 AND LATER) A/R
* 465342 ANFO POT 1270Lbs. (576.1KG) 100psi A/R
* 464863 ANFO POT 1900Lbs. (861.8KG) 100psi A/R
* 9126-00005 ANFO POT 2120Lbs. (961.6KG) 125psi (REPLACED 464864) A/R
* 9126-00002 ANFO POT 2600Lbs. (1179KG) 128psi
1 595366 FUNNEL WELDMENT BOLT SET 1
2 595267 ANFO POT LID 1
3 595268 ANFO POT WELDMENT (OLD P/N WAS 525268) 1

4 595240 ANFO POT SCREEN 1
5 595463 CLOSURE INSTALLATION BOLT SET (100psi) (½” DIA) 1
595464 CLOSURE INSTALLATION BOLT SET (125 & 128psi) (⅝” DIA) 1
(NOTE: 12 PER SET)
6 595365 FUNNEL/ POT GASKET 1
7 595228 CAP (PNEUMATIC CLOSURE) (100psi) 1
CAP (PNEUMATIC CLOSURE) (125 & 128psi) 1
8 595465 CLOSURE CAP BOLT (100psi) (½” DIA) 1
595466 CLOSURE CAP BOLT (125 & 128psi) (⅝” DIA) 1
9 CALL COMPLETE CLOSURE ASSEMBLY 1
(LENGTHS VERY PER POT SIZE, CALL WITH POT P/N
FOR CORRECT ASSEMBLY)
10 595467 DISCHARGE BOLT ASSEMBLY 4
11 604240 DISCHARGE O-RING 1
12 604295 DISCHARGE HOUSING 1
*PARTS ARE NOT INTERCHANGEABLE, BUT FIT/ FUNCTION ARE THE SAME Updated:
08/23/12
S/N: 020-069
S/N: 020-069
S/N: 020-069
S/N: 020-069
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:
05/20/11
S/N: 020-069
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)
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) (NOTE: NOT USED ON CURRENT 4-12
GETMAN APPLICATIONS)
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 (NOTE: NOT USED ON CURRENT 1
GETMAN APPLICATIONS)
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:
05/20/11
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
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.
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
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.
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
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
S/N: 020-069
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

S/N: 020-069
S1101
OT
OR
• EXTERNAL PNEUMATIC VIBRATORS
• DRUCKLUFTAUSSENVIBRATOREN
• VIBRATEURS EXTERNES PNEUMATIQUES
• VIBRATORI PNEUMATICI ESTERNI

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

A 100
S/N: 020-069
06.04
- DESCRIPTION S1101
S - BESCHREIBUNG
OT
- DESCRIPTION 2
OR
- DESCRIZIONE OL.2000 EX M. 3
GENERAL NOTES ALLGEMEINES REMARQUES GÉNÉRALES NOTE GENERALI

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

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

Fax: + 39.0535 - 46350
S/N: 020-069
- PNEUMATIC BALL VIBRATORS “S” S110106.04
S - DRUCKLUFT - KUGELVIBRATOREN “S”
OT
- VIBRATEURS PNEUMATIQUES A BILLE “S” 2
OR
- VIBRATORI PNEUMATICI A SFERA TIPO “S” OL.2000 EX M. 4
General indications Allgemeine Angaben Indications générales Indicazioni generali

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

Weights - Gewichte
A B C D E F G
Type H Poids - Pesi
mm in mm in mm in mm in mm in mm in mm in kg lbs
S8
50 1.97 86 3.38 20 0.79 68 2.68 4 1.57 12 0.47 7 0.27 1/4" 0.13 0.29
S 10
S 13 24 1.91 0.26 0.57
65 2.56 113 4.45 90 3.54 50 1.97 16 0.63 9 0.35 1/4"
S 16 27 1.06 0.30 0.66
S 20 33 1.30 0.53 1.17
80 3.15 128 5.04 104 4.09 60 2.36 16 0.63 9 0.35 1/4"
S 25 38 1.50 0.63 1.39
S 30 44 1.73 1.13 2.49
100 3.94 160 6.30 130 5.12 80 3.15 20 0.79 11 0.43 3/8"
S 36 50 1.97 1.34 2.95
PERFORMANCE DATA - LEISTUNGSDATEN- PERFORMANCE - PRESTAZIONI
Vibrations - Schwingungen Air consumption - Lufterverbrauch
Vibrations - Vibrazioni Fc max. kg Consommation d'air - Consumo d'aria
min -1 l/min
Type
2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi 2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi
2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi
kg lbs kg lbs kg lbs dm3 cf dm3 cf dm3 cf
S8 25,500 31,000 35,000 13 29 26 58 36 81 83 2.6 145 5.1 195 6.9
S 10 22,500 28,000 34,000 25 56 47 106 71 160 92 3.2 150 5.3 200 7.1
S 13 15,000 18,500 22,500 32 72 55 124 87 196 94 3.3 158 5.6 225 7.9
S 16 13,000 17,000 19,500 45 101 80 180 110 248 122 4.3 200 7.1 280 9.9
S 20 10,500 14,500 16,500 72 162 122 275 172 387 130 4.6 230 8.1 340 12.0
S 25 9,200 12,200 14,000 93 209 157 353 205 461 160 5.6 290 10.2 425 15.0
S 30 7,800 9,700 12,500 151 340 247 556 321 722 215 7.6 375 13.2 570 20.0
S 36 7,300 9,000 10,000 206 464 315 709 405 911 260 9.2 475 16.8 675 24.0
S/N: 020-069
06.04
- PNEUMATIC TURBINE VIBRATORS “T” S1101
S - PNEUMATISCHE DRUCKLUFT - TURBINEN-VIBRATOREN “T”
OT
- VIBRATEURS PNEUMATIQUES A TURBINE “T” 2
OR
- VIBRATORI PNEUMATICI A TURBINA “T” OL.2000 EX M. 5
General indications Allgemeines Indications générales Indicazioni generali

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

A B C D E F Weights - Gewichte - Poids - Pesi
Type x-y
mm in mm in mm in mm in mm in mm in kg lbs
OT 8 .250 .55
OT 10 50 1.97 86 3.38 68 2.68 12 0.47 33 1.30 7 0.27 1/8" .255 .56
OT 10-S .263 .58
OT 13 .565 1.24
OT 16 65 2.56 113 4.45 90 3.54 16 0.63 42 1.65 9 0.53 1/4" .580 1.28
OT 16-S .614 1.35
OT 20 1.090 2.40
OT 25 80 3.15 128 5.04 104 4.09 16 0.63 56 2.20 9 0.35 1/4" 1.120 2.46
OT 25-S 1.200 2.64
OT 30 2.200 4.85
OT 36 100 3.94 160 6.30 130 5.12 20 0.79 73 2.87 11 0.43 3/8" 2.300 5.10
OT 36-S 2.530 5.57
S/N: 020-069
06.04
- PNEUMATIC ROLL VIBRATORS “R” S1101
S - DRUCKLUFT - ROLLEN VIBRATOREN “R”
OT
- VIBRATEURS PNEUMATIQUES A ROULEX “R” 2
OR
- VIBRATORI PNEUMATICI A RULLI “R” OL.2000 EX M. 7
General indications Allgemeines Indications générales Indicazioni generali

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

A B C D E F Weights - Gewichte - Poids - Pesi
Type H
mm in mm in mm in mm in mm in mm in kg lbs
OR 50 50 1.97 86 3.38 68 2.68 12 0.47 30 1.18 7 0.27 1/8" 0.370 0.82
OR 65 65 2.56 113 4.45 90 3.54 16 0.63 36 1.42 9 0.35 1/4" 0.760 1.68
OR 80 80 3.15 128 5.04 104 4.09 16 0.63 40 1.57 9 0.35 1/4" 1.270 2.80
OR 100 100 3.94 160 6.30 130 5.12 20 0.79 52 2.05 11 0.43 3/8" 2.600 5.73
PERFORMANCE DATA - LEISTUNGSDATEN- PERFORMANCE - PRESTAZIONI
Vibrations - Schwingungen
Air consumption - Lufterverbrauch
Vibrations - Vibrazioni Fc max.
Consommation d'air - Consumo d'aria
vpm
Type
2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi 2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi
2 bar= 29 psi 4 bar= 58 psi 6 bar= 87 psi
kg lbs kg lbs kg lbs dm3 cf dm3 cf dm3 cf
OR 50 21000 25000 29500 1840 413 2760 620 3480 782 78 2.7 144 5.0 204 7.2
OR 65 19000 22000 26000 2303 518 4306 968 5420 1218 100 3.5 198 6.9 296 10.4
OR 80 14000 16000 21500 3354 754 5762 1295 6124 1377 122 4.3 255 9.0 378 13.3
OR 100 6750 9750 11000 2839 638 5924 1332 7678 1726 132 4.6 284 10.0 412 14.5
N.B.: data abtained from a vibrating
N.B.: daten wurden auf einem gefe- N.B.: les données ont été relevées N.B.: dati rilevati utilizzando un ban-
table supported by springs that per-
derten Rütteltisch ermittelt, aud dem sur un banc vibrant à ressorts, de co vibrante a molle, in modo da simu-
fectly simulates the major part of the
die Mehrzahl der möglichen Anwen- manière à simuler parfaitement la plu- lare perfettamente la maggior parte
applications possible. Frequency and
dungen perfekt simuliert wurde. Fre- part des applications possibles. La delle possibili applicazioni. Frequenza
centrifugla force increase when thequenz und Zentrifugalkraft nehmen frequence et la force centrifuge se- e forza centriga saranno maggiori ap-
vibrator is applied to more rigid struc-
bei einer Befestigung des Vibrators ront plus grandes où le vibrateur est plicando il vibratore su strutture più
tures. auf weniger elastischen Unterlagen appliqué sur une structure plus rigide. rigide.
zu.
For activation a 2/2 way electrov- Zur Betätigung ist ein 2/2 Wege- Pour l’actionnement on a besoin Per l’azionamento occorrono una
alve and filtered compressed air Ventil und gefilter Druckluft erfor- d’une èlectrovanne à 2/2 voies et elettrovalvola a 2/2 vie ed aria fil-
are required. derlich d’air filtré trata.
S/N: 020-069
- MANUFACTURING DATA S110106.04
S - KONSTRUKTIONSDATEN
OT
- DONNÉES CONSTRUCTIVES 2
OR
- DATI COSTRUZIONE OL.2000 EX M. 8
Rating plate for S or OR vibrator - Schild für Vibrator S oder OR

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

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

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

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

2) Machine serial number 2) Serien-Nr. Maschine 2) Matricule de la machine 2) Numero matricola
3) Assembly operator code 3) Monteur-Code 3) Code opérateur assembleur 3) Codice operatore assembla-
4) Year of construction 4) Baujahr der Maschine 4) Année de fabrication machi- tore
5) Group and category 5) Gruppe und Kategorie ne 4) Anno di costruzione macchi-
6) Surface Tmax 6) Tmax Oberfläche 5) Groupe et catégorie na
with T amb. -20 °C / +120°C mit T amb. -20 °C / +120°C 6) Tmax superficiel 5) Gruppo e categoria
avec T amb. -20 °C / +120°C 6) Tmax superficiale
con T amb. -20 °C / +120°C
S/N: 020-069
06.04
- SCOPE AND IMPORTANCE OF THE MANUAL S1101
S - ZWECK UND BEDEUTUNG DES HANDBUCHS
OT
- BUT ET IMPORTANCE DU MANUEL 2
OR
- SCOPO E IMPORTANZA DEL MANUALE OL.2000 EX M. 9
This manual, prepared by the manu- Dieses Handbuch, das vom Herstel- Le présent Manuel, rédigé par le cons- Il presente manuale, redatto dal co-
facturer, forms an integral part of ler erstellt wurde, ist integrierender tructeur, fait partie intégrante de la struttore, è parte integrante del vi-
the pneumatic vibrator S/OR/OT sup- Teil des Druckluft Vibrator S/OR/OT. fourniture du vibrateur pneumatique bratore pneumatico S/OR/OT; come
ply. It must therefore accompany the Daher muss es unbedingt dem Filter S/OR/OT; comme tel il doit absolu- tale deve assolutamente seguire il
filter right up to its final scrapping,folgen, bis er demontiert wird, und ment suivre le filtre jusqu’à son dé- filtro fino al suo smantellamento ed
and must be available ready at hand leicht zu finden sein, wenn der Bedie- mantèlement et être à portée de la essere facilmente reperibile per una
for quick consultation by the opera- ner oder die Baustellenleitung in ihm main pour une consultation rapide de rapida consultazione da parte degli
tors concerned and those in charge nachschlagen wollen. Bei einem Be- la part des opérateurs concernés et operatori interessati e della direzione
of operations at the work site. If the sitzerwechsel des Gerätes muss das par la direction des travaux du chan- lavori del cantiere. In caso di cambio
machine changes hands, this manu- Handbuch dem neuen Besitzer aus- tier. En cas de changement de pro- di proprietà della macchina il manuale
al must be handed over to the new gehändigt wer-den. Bevor das Be- priété de la machine, le manuel doit deve essere consegnato alla nuova
owner. Before carrying out any oper- triebspersonal irgendwelche Arbeiten être remis au nouveau propriétaire. proprietà. Prima di eseguire qualsiasi
ation on or using the pneumatic vi- an oder mit Druckluft Vibrator aus- Avant d’effectuer une quelconque operazione con, o sul vibratore pneu-
brator, the personnel concerned must führt, muss es dieses Handbuch un- opération avec ou sur le vibrateur matico ; il personale interessato deve
have read this manual carefully and bedingt mit großer Aufmerksamkeit pneumatique, le personnel concerné assolutamente ed obbligatoriamente
completely. If the manual is lost, or durchgelesen haben. Falls das Hand- doit absolument et obligatoirement aver letto con la massima attenzione
in such a condition as to make it il- buch verloren geht oder unleserlich avoir lu très attentivement le présent il presente manuale. Qualora il ma-
legible, download a new copy from wird, kann man sich eine neue Kopie manuel. Si le manuel est égaré ou nuale venga smarrito, sgualcito e tale
the OLI s.r.l internet site, and check von den Internetseiten des Herstel- abîmé de manière à ne plus être lisi- da non essere completamente leggi-
the date of the last revision. This lers OLI s.r.l herunterladen, um dann ble, une copie doit être téléchargée à bile, si deve scaricare una nuova
manual provides warnings and indi- das Datum der letzten Aktualisierung partir du site internet de OLI s.r.l en copia dal sito internet della OLI s.r.l e
cations concerning the safety regu- des Handbuchs zu prüfen. Dieses vérifiant la date de la dernière mise à verificarne la data dell’ultimo aggior-
lations for preventing accidents at Handbuch liefert Hinweise und Anga- jour. Le présent manuel fournit les namento. Il presente manuale forni-
the work site. However, the opera- ben zu den Sicherheits- und Unfall- recommandations et les indications sce avvertenze ed indicazioni relati-
tors MUST scrupulously follow the verhütungsbestimmungen am Ar- concernant les consignes de sécurité ve alle norme di sicurezza per la pre-
safety regulations meant for them beitsplatz. Die Sicherheitsbestimmun- pour la prévention contre les acci- venzione degli infortuni sul lavoro.
according to the existing legislation. gen, die laut der geltenden Bestim- dents du travail. Dans tous les cas Vanno comunque, ed in ogni caso,
Modifications to the safety regula- mungen vom Bedienungspersonal zu les consignes de sécurité conformé- osservate con il massimo scrupolo
tions made over time must be inte- beachten sind, müssen auf jeden Fall ment aux normes en vigueur doivent da parte dei vari operatori le norme di
grated and implemented. immer beachtet werden. être observées avec la plus grande sicurezza poste a loro carico dalle vi-
Etwaige Änderungen der Sicherheits- attention par les différents opérateurs. genti normative.
With the basic features of the ma- bestimmungen, die im Laufe der Zeit Les modifications éventuelles des Eventuali modifiche delle norme di
chines as described, the Manufac- vorgenommen werden, sind immer zu consignes de sécurité devront être sicurezza che nel tempo dovessero
turer reserves every right to make erfassen und umzusetzen. adoptées et mises en oeuvre. aver luogo dovranno essere recepite
modifications to parts, details and ed attuate.
accessories considered to be neces- Der Hersteller behält sich das Recht Les caractéristiques essen tielles des
sary for improving the product for vor, unter Beibehaltung der wesentli- machines décrites étant entendues, Ferme restando le caratteristiche es-
design or commercial reasons, at any chen Eigenschaften der beschriebe- le constru cteur se réserve le droit senziali delle macchine descritte, il
time without any obligation to update nen Geräte etwaige Änderungen an d’ap porter à tout moment et sans costruttore si riserva il diritto di ap-
the publication imme-diately. Organen, Teilen und Zubehör vorzu- engagement de mettre à jour en temps portare le eventuali modifiche di or-
The latest version of the present cat- nehmen, die im Zuge der Produktver- utile cette publication, des modifica- gani, dettagli ed accessori che riterrà
alogue is available under besserung erforderlich sind oder aus tions aux organes, pièces et acces- convenienti per il miglioramento del
www.olivibra.it konstruktiven oder kommerziellen soires qu’il retiendra avantageuses prodotto, o per esigenze di carattere
Erfordernissen heraus ausgeführt pour l’amélioration du produit ou pour costruttivo o commerciale, in qualun-
werden. Solche Änderungen können des exigences de fabrication ou de que momento e senza impegnarsi ad
jederzeit vorgenommen werden und commer cialisation. aggiornare tempestivamente questa
verpflichten den Hersteller nicht, die- La version toujours mise à jour de ce pubblicazione.
se Veröffentlichung gleichzeitig auf catalogue est dis-ponible sul le site La versione sempre aggiornata del
den neuesten Stand zu bringen. internet www.olivibra.it presente catalogo è reperibile sul sito
Die letzte Version dieses Katalogs internet www.olivibra.it
steht im Internet unter
www.olivibra.it
CERTIFICATE OF CONFORMITY KONFORMITÄTSERKLÄRUNG CERTIFICAT DE CONFORMITÉ ATTESTATO DI CONFORMITA’
The equipment is accompanied by a Das Gerät wird von einer den gelten- L'appareillage est accompagné d’une L'apparecchiatura è accompagnata da
declaration of conformity to existing den Richtlinien entsprechenden Kon- déclaration de conformité aux directi- una dichiarazione di conformità alle
regulations, but, since it is a compo- formitäts-erklärung begleitet, aber als ves en vigueur, mais en tant que direttive vigenti, ma, in quanto com-
nent to be integrated into a system Bestandteil einer kompletten Anlage composant devant s’intégrer dans ponente da integrarsi in un impianto
or plant, its safety is connected to ist seine Betriebs-sicherheit mit der une installation complète, sa sécurité completo, la sua sicurezza è legata al
compliance with all the directives Beachtung aller Richtlinien verbun- est étro itement lié au respect de tou- rispetto di tutte le direttive applicabili
applicable in final assembly of the den, die nach dem Einbau in die Anla- tes les directives applicables dans nell'assemblamento della macchina
machine. ge oder Maschine anwendbar sind. l’assemblage de la machine finale. finale.
Improper use of the pneumatic vi- Jede bestimmungswidrige Benutzung Toute utilisation impropre du vibra- Ogni utilizzo improprio del vibratore
brator without following the instruc- des Druckluft Vibrator ohne Befol- teur pneumatique sans suivre les in- pneumatico senza seguire le indica-
tions in this manual frees the Manu- gung der Angaben dieses Handbuchs dications du présent manuel dégage zioni del presente manuale solleverà
facturer of all responsibility for poor entbindet den Hersteller von jeglicher le constructeur de toutes responsabi- il costruttore da ogni responsabilità
working of the pneumatic vibrator. Haftung hinsichtlich der fehlerhaften lités ayant trait à un mauvais fonc- inerenti ad un cattivo funzionamento
As this is a subject in the process of Funktion des Druckluft Vibrator. tionnement du vibrateur pneumatique del vibratore pneumatico stesso.
significant technical and normative Da es sich um Produkte handelt, die lui-même. Trattandosi di materia in forte evolu-
evolution, the Manufacturer reserves einer schnellen technischen Entwick- Etant donnée qu’il s’agit d’une matiè- zione tecnica e normativa, il costrut-
the right to upgrade its products as lung unterliegen, behält es sich der re en forte évolution technique et ré- tore si riserva di adeguare con la
fast as possible with all the techno- Hersteller vor, die eigenen Erzeug- glementaire, le constructeur se ré- massima celerità i propri manufatti a
logical know-how and official stand- nisse so schnell wie möglich an alle serve d’adapter avec rapidité ses pro- tutte le conoscenze tecnologiche e le
ards applicable (EN, UNI) which are technologischen Erkenntnisse und die pres produits manufacturés à toutes norme ufficiali applicabili (EN, UNI)
available at the time. anwendbaren offiziellen Normen (EN, les connaissances techno logiques che di volta in volta si rendessero
UNI) anzupassen, die von Fall zu Fall et les normes of ficielles applicables disponibili.
erforderlich sind. (EN, UNI) au fur et à mesure de leur
parution.
S/N: 020-069
- CERTIFICATE OF CONFORMITY S110106.04
S - KONFORMITÄTSBESCHEINIGUNG
OT
- CERTIFICAT DE CONFORMITÉ 2
OR
- ATTESTATO DI CONFORMITA’ OL.2000 EX M. 10
OLI S.r.l.
Via Canalazzo, 35 – I - Medolla (MO)
ITALY
CERTIFICATE OF CONFORMITY
with the Directives of the European Union
The OLI percussion guns model
S/OR/OT....ATEX (Code: SX....)
are manufactured in conformity with the following directives:
- Directive “Machines” 98/37/CE of 22nd June, 1998

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

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

OLI S.r.l.
Adriano Marchesini
(General Manager)
S/N: 020-069
- WARNING S110106.04
S - HINWEISE
OT
- RECOMMANDATIONS 2
OR
- AVVERTENZE OL.2000 EX M. 14
SAFETY SICHERHEIT SÉCURITÉ SICUREZZA

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

The Air Compressor needs to be Saubere, gefilterte (Filter < Le fluide d’entraînement est l’air Il compressore pneumatico va
kept clean and filtered (filter 50µm) Druckluft oder Stickstoff comprimé exempt d’impuretés et tenuto pulito e l’aria filtrata (filtro
<50pm). Compressed air or ni- (2 bis 6 bar). Die Verwendung filtré (filtre < 50 µm), ou l’azote, < 60 mm). Si richiede azoto o aria
trogen of 2 to 6 bar (30 to 90 nicht gefilterter Luft führt sous une pression de 2 à 6 bars compressa alla pressione com-
PSI) is required. The vibrators zum Ausfall der Vibratoren. (30 à 90 PSI). Les vibrateurs presa tra 2 e 6 bar (da 30 a 90
are designed for lubrication- Alle Vibratoren können öl- sont conçus pour fonction- PSI). I vibratori sono proget-
free operation. The life time frei betrieben werden, ein ner sans huile, un graisseur tati per l’uso esente da lu-
of the S and OR vibrator will Nebelöler verlängert die Le- prolongera la durée de vie brificante. La lubrificazione
be extended with lubrica- bensdauer von S und OR. des S et OR. prolunga la durata dei vibra-
tion. Non-filtered air will L’utilisation d’air non filtré tori S e OR. L’impiego di aria
damage the vibrators. entraîne la défaillance des non filtrata danneggia il vi-
vibrateurs. bratore.
Maximum operating pres- Max. Betriebsdruck Pression maximale de ser- Pressione massima d’eser-
sure vice cizio
The maximum operating pres- Der max. Betriebsdruck darf 6 La pression maximale de servi- La pressione massima d’eserci-
sure must not exceed 6 bar (90 bar (90PSI) nicht überschreiten. ce ne doit pas dépasser 6 bars zio non deve superare i 6 bar
PSI). (90 PSI). (90 PSI).
S/N: 020-069
06.04
- INDICATIONS FOR THE USE S1101
S - ANGABEN ZUM GEBRAUCH
OT
- MODES D’EMPLOI 2
OR
- INDICAZIONI PER L’USO OL.2000 EX M. 15
The pneumatic vibrators de- Die pneumatischen Vibrato- Les vibrateurs pneumati- I vibratori pneumatici descritti
scribed in this Manual are deren, die in diesem Handbuch be- ques décrits dans ce manuel ont in questo manuale sono stati pro-
signed and tested for use in po- schrieben werden, sind für den été conçus et testés pour être gettati e testati per un utilizzo in
tentially explosive areas classi- Einsatz in explosionsgefährde- utilisé dans les environnement zone potenzialmente esplosive
fied as zone 22 cat. II 3 D ac- ter Bereichen ausgelegt und explosibles classés comme zone classificate come zona 22 cat. II
cording to directive 94/9/CE. konstruiert worden, die als Zone 22 cat. II 3 D d’après la directive 3 D secondo la direttiva 94/9/CE.
The powders handled must have 22 Kat. II 3 D gemäß der Richtli- 94/9/CE. Les poussières traitées Le polveri trattate dovranno ave-
explosiveness index St1 or St2 nie 94/9/EG klassifiziert worden doivent avoir des indices d’ex- re indici di esplosività St1 o St2 e
and this must be notified to OLI sind. Die aufbereiteten Stäube plosivité St1 ou St2 ; pour un devono essere comunicate alla
s.r.l. at the time of placing the müssen Staubexplosionsklasse choix correct du composant cel- OLI s.r.l. al momento dell’ordine
order to allow correct selection St1 oder St2 haben und müssen les-ci doivent être indiquées à per una scelta corretta del com-
of the component. der Firma OLI s.r.l. bei der Be- OLI s.r.l. au moment de la componente.
stellung angegeben werden, um mande.
The user must make sure the eine korrekte Auslegung des L’utilizzatore dovrà assicurarsi
plant in which the pneumatic Bauteils zu ermöglichen. L’utilisateur doit contrôler, avant che l’impianto all’interno del qua-
vibrator is installed has been la mise en marche, que l’installa- le verrà installato il vibratore
set in safety condition from the Der Anwender muss sicherstel- tion dans laquelle est monté le pneumatico sia stato adegua-
point of view of explosion risk len, dass die Anlage, in welcher vibrateur pneumatique a été tamente messo in sicurezza da
before being started up, and that der pneumatische Vibrator mise en sécurité en ce qui con- un punto di vista di rischio esplo-
the “document on protection installiert werden soll, hinsicht- cerne le risque d’explosion. Il faut sione prima di essere avviato e
against explosions” has also lich der Explosionsgefahr auf aussi que le “document sur la che inoltre sia stato redatto il
been prepared as specified by ausreichende Weise in einen si- protection contre les explosions” “documento sulla protezione
Directive ATEX 99/92/CE. (This cheren Zustand gebracht wor- ait été rédigé conformément à la contro le esplosioni” come pre-
only applies to the European den ist, bevor sie in Betrieb ge- Directive ATEX 99/92/CE (Ceci visto dalla Direttiva ATEX 99/92/
market). nommen wird, und dass zudem n’est valable que pour le marché CE. (Questo vale unicamente per
das „Explosionsschutzdoku- européen). il mercato europeo).
ment” verfasst worden ist, so
wie es die ATEX-Richtlinie 99/92/
EG vorsieht (Dies gilt nur für den
europäischen Markt).
S/N: 020-069
06.04
- INDICATIONS FOR THE USE S1101
S - ANGABEN ZUM GEBRAUCH
OT
- MODES D’EMPLOI 2
OR
- INDICAZIONI PER L’USO OL.2000 EX M. 17
In accordance with the Directive ATEX Im Sinne der ATEX-Richtlinie 94/9/EG Le constructeur, aux termes de la Il costruttore, ai sensi della direttiva
94/9/CE, the manufacturer defines definiert der Hersteller die Außenum- directive ATEX 94/9/CE, définit l’ex- ATEX 94/9/CE, definisce l’esterno del
the outside of the pneumatic vibrator gebung des pneumatischen Klopfers térieur du vibrateur pneumatique com- vibratore pneumatico come:
as: als: me:
CAT. II 3 D KAT. II 3 D CAT. II 3 D CAT. II 3 D
IMPORTANT: specify that the non WICHTIG: Die Versionen, die nicht IMPORTANT: Spécifier que les ver- IMPORTANTE: Specificare che le
ATEX versions must not be used in ATEX sind, dürfen nicht in explosi- sions non ATEX ne doivent pas tra- versioni non ATEX non devono
potentially explosive environ- onsgefährdeten Bereichen arbei- vailler dans des atmosphères ex- operare in atmosfere potenzialmen-
ments. ten. plosibles. te esplosive.
The pneumatic vibrators are de- Die pneumatischen Vibratoren sind
signed and constructed in such a so entwickelt und konstruiert worden, Les vibrateurs pneumatiques ont I vibratori pneumatici sono stati
manner as to avoid unusual over- dass es während ihres Betriebs nicht été conçus et construits de manière progettati e costruiti in modo tale da
heating during operation. To operate zu Überhitzungen kommt. Um unter à ne pas provoquer d’échauffements non provocare surriscaldamenti ano-
in safe conditions, check to make sicheren Voraussetzungen arbeiten zu anormaux pendant le fonctionnement. mali durante il funzionamento. Per
sure the powders handled have a können, ist sicherzustellen, dass Pour travailler en condition de sécuri- poter operare in condizioni di sicurez-
minimum ignition temperature die aufbereiteten Stäube eine Min- té il faut vérifier que les poussiè- za occorre verificare che le polve-
higher than the temperature value destzündtemperatur haben, die res traitées on une température ri trattate abbiano una minima tem-
indicated on the code plate. unterhalb des Temperaturwerts d’inflammation minimale supé- peratura di ignizione superiore al
- The pneumatic vibrators must be liegt, der auf dem Typenschild rieure à la valeur de température valore di temperatura indicato sul-
installed with sufficient clearance steht. indiqué sur la plaque signaléti- la targhetta.
around to allow assembly/disas- - Die pneumatischen Vibratoren que. - I vibratori pneumatici dovranno
sembly operations, cleaning and müssen so installiert werden, dass - Les vibrateurs pneumatiques doi- essere installati con uno spazio cir-
maintenance. ringsum genügend Raum zur Ver- vent être installés avec autour un costante sufficiente per effettuare
fügung steht, um die normalen Ar- espace suffisant pour effectuer les le normali operazioni di montaggio/
Before carrying out any operation beiten für Ein- und Ausbau, Reini- opérations ordinaires de montage/ smontaggio, pulitura e manutenzio-
on the component, make sure it is gung und Wartung vornehmen zu démontage, nettoyage et mainte- ne.
in safe condition. können. nance.
Bevor man irgendeinen Eingriff an Prima di effettuare un qualsiasi
IMPORTANT: In this Manual “setting dem Bauteil vornimmt, ist sicher- Avant d’effectuer toute intervention intervento sul componente assi-
the component in safety condi- zustellen, dass es sich in einem sur le composant vérifier que ce- curarsi che questa sia messa in
tion” will include the following opera- sicheren Zustand befindet. lui-ci a été mis en sécurité. sicurezza.
tions: WICHTIG: Auf den weiteren Seiten
- Make sure the component is dis- dieses Handbuchs werden wir die IMPORTANT: Dans le présent manuel IMPORTANTE: In seguito nel presen-
connected from all electric sup- Ausdrucksweise „den Bauteil in ei- nous indiquons par “mettre en sécu- te manuale indicheremo con la dicitu-
ply sources. nen sicheren Zustand versetzen” rité le composant” les opérations ra “mettere in sicurezza il compo-
- Make sure the component is dis- benutzen, um folgende Vorgänge an- suivantes: nente” le seguenti operazioni:
connected from all compressed zugeben: - Contrôler si le composant est dé- - Accertarsi che il componente sia
air supply sources. - Sicherstellen, dass der Bauteil branché de toutes les alimenta- scollegata da tutte le alimenta-
- The area around the component von allen elektrischen Versor- tions électriques. zioni elettriche.
must be suitably lighted (opera- gungsquellen abgetrennt ist. - Contrôler si le composant est dé- - Accertarsi che il componente sia
tors can be provided with elec- - Sicherstellen, dass der Bauteil branché de toutes les alimenta- scollegata da tutte le alimenta-
tric lights suitable for zone 22 von allen pneumatischen Ver- tions pneumatiques. zioni pneumatiche.
cat. II 3 D). sorgungsquellen abgetrennt ist. - Eclairer correctement la zone qui - Provvedere a illuminare corret-
For carrying out operations on the - Dafür sorgen, dass der Bereich entoure le composant (en dotant tamente la zona circostante al
components (maintenance and clean- rings um den Bauteil korrekt aus- éventuellement les opérateurs de componente (eventualmente do-
ing), the operators must use suitable geleuchtet wird (indem die Arbeit- lampes électriques appropriées tando gli operatori di lampade
personal protection devices (PPD): nehmer eventuell mit elektri- pour zone 22 cat. II 3 D). elettriche idonee per zona 22 cat.
- Antistatic safety footwear (certi- schen Lampen ausgestattet wer- II 3 D.
fied) den, die für die Zone 22 Kat. II 3 Pour toute opération à effectuer sur
- Antistatic protective clothing (certi- D geeignet sind). le composant (entretien et nettoya- Per qualsiasi operazione da effettuarsi
fied) Für jeden Eingriff, der auf dem Baut- ge), les opérateurs doivent être mu- sul componente (manutenzioni e puli-
- Helmet eil vorzunehmen ist (Wartungen und nis des équipements de protection zia), gli operatori dovranno essere
- Antistatic cut proof gloves Reinigungen), müssen die Arbeitneh- individuelle (EPI): muniti degli appositi dispositivi di pro-
- Protective masks mer mit angemessenen persönlichen tezione individuale (DPI):
It is also necessary to use all the Schutzausrüstungen (PSA) versehen - Chaussures de protection antis-
safety devices specified in the safe- sein: tatiques (certifiées) - Scarpe antinfortunistiche anti-
ty sheet of the product handled. - antistatisches unfallsicheres - Vêtements de protection antista- statiche (certificate)
Schuhwerk (zertifiziert) tiques (certifiés) - Indumenti protettivi antistatici
NOTE: All the electrical equipment - antistatische Schutzkleidung (zer- - Casque (certificati)
used for maintenance or cleaning tifiziert) - Gants anti-coupure antistatiques - Casco
operations on the outside of the - Schutzhelm - Masques de protection - Guanti antitaglio antistatici
component must be ATEX certified - antistatische Schnittschutzhand- Il faut aussi utiliser tous les disposi- - Mascherine protettive
for zone 22 cat. II 3 D. schuhe tifs de protection prévus par la fiche Inoltre occorre utilizzare tutti i dispo-
- Schutzmasken de sécurité du produit traité. sitivi di protezione previsti dalla sche-
Außerdem sind alle Schutzvorrichtun- da di sicurezza del prodotto trattato.
gen zu verwenden, die von dem Si- N.B.: Tous les appareillages élec-
cherheitsdatenblatt des behandelten triques, utilisés pour les interven- N.B. Tutte le apparecchiature elet-
Produkts vorgesehen sind. tions de maintenance et de net- triche eventualmente utilizzate per
Anm.: Alle elektrische Ausrüstun- toyage réalisées à l’extérieur du interventi manutentivi o di pulizia
gen, die eventuell für die War- composant doivent être certifiés eseguiti all’esterno componente
tungseingriffe und die Reinigung ATEX pour zone 22 cat. II 3 D. devono essere certificate ATEX per
außerhalb des Bauteils benutzt zona 22 cat. II 3 D.
werden, müssen für Zone 22 Kat. II
3 D nach ATEX zertifiziert sein.
zona 22
S/N: 020-069
- OPERATING CONDITIONS S110106.04
S - EINSATZEINSCHRÄNKUNGEN
OT
- LIMITES D’EMPLOI 2
OR
- LIMITI DI IMPIEGO OL.2000 EX M. 18
Noise level Betriebsgeräusche Niveau de bruit Rumorosità

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

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

Poussières - Polveri Poussières - Polveri
St 1 St 2
MINIMUM IGNITION ENERGY (mj) WITHOUT INDUCTANCE
ZÜNDENERGIE (mj) OHNE INDUKTANZ
> 3 > 3
ENERGIE D’INFLAMMATION MINIMUM (mj) SANS INDUCTANCE
MINIMA ENERGIA DI IGNIZIONE (mj) SENZA INDUTTANZA
MINIMUM IGNITION TEMPERATURE (°C) MIT
TIEFSTE ZÜNDTEMPERATUR (°C) MIT
≥ 200 ≥ 200
TEMPERATURE MINIMUM D’INFLAMMABILITE' (°C) MIT
MINIMA TEMPERATURA DI IGNIZIONE (°C) MIT
IGNITION TEMPERATURE OF POWDER LAYER DEPOSITED (°C) L.I.T.
ZÜNDTEMPERATUR DER ABGELAGERTEN STAUBSCHICHT (°C) L.I.T.
≥ 200 ≥ 200
TEMP. D’INFLAMMATION DE LA COUCHE DE POUSSIÈRE DÉPOSÉE (°C) L.I.T.
TEMPERAURA DI IGNIZIONE DELLO STRATO D POLVERE DEPOSITATO (°C) L.I.T.
MAXIMUM EXPLOSION PRESSURE (bar)
HÖCHSTER EXPLOSIONSDRUCK (bar)
≤9 ≤9
PRESSION MAXIMUM D’EXPLOSION (bar)
MASSIMA PRESSIONE DI ESPLOSIONE (bar)
REACTIVITY PARAMETER KST (bar m/s)
REAKTIVITÄTSPARAMETER KST (bar m/s)
< 300 < 300
PARAMÉTRE DE RÉACTIVITÉ KST (bar m/s)
PARAMETRO DI REATTIVITA' KST (bar m/s)
SURFACE RESISTIVITY (Ω m)
OBERFLÄCHENWIDERSTAND (Ω m)
< 1 x 1012 < 1 x 10 12
RÉSISTIVITÉ SUPERFICIELLE (Ω m)
RESISTIVITA' SUPERFICIALE (Ω m)
S/N: 020-069
06.04
- WARRANTY CONDITIONS S1101
S - GARANTIEBEDINGUNGEN
OT
- CONDITIONS DE GARANTIE 2
OR
- CONDIZIONI DI GARANZIA OL.2000 EX M. 19
OLI S.r.l provides a 12-month OLI S.r.l. gewährt auf ihre Er- La Société OLI S.r.l reconnaît La OLI S.r.l riconosce un perio-
warranty on their products. This zeugnisse eine Garantie von une période de 12 mois de ga- do di 12 mesi di garanzia sui pro-
period starts from the date of the 12 Monaten. Die Garantiezeit rantie sur les produits de sa fa- dotti di propria costruzione. Il
consignment note. beginnt mit dem Datum des Lie- brication. La période prend ef- periodo decorre dalla data della
The warranty is not applicable ferscheins. fet à compter de la date indiquée bolla di consegna.
for breakage and/or defects Die Garantie ist nicht anwend- sur le bon de livraison. La garanzia non è applicabile a
caused by incorrect installation bar, wenn es sich um Schäden La garantie ne s’applique pas à seguito di rotture e/o difetti cau-
or use, or incorrect maintenan- und/oder Defekte handelt, die la suite de ruptures et/ou de dé- sati da errata installazione o uti-
ce, or modifications not authori- auf falschem Einbau oder Ge- fauts provoqués par un monta- lizzo, oppure da manutenzioni
zed by the Manufacturer. brauch, nicht korrekter Wartung ge et une utilisation impropre, non corrette o modifiche appor-
The warranty does not extend oder Änderungen beruhen, die des entretiens qui ne sont réali- tate senza autorizzazione del
to parts that wear out following ohne die Genehmigung des Her- sés correctement ou des modi- costruttore.
normal use and electrical com- stellers ausgeführt wurden. fications apportées sans autori- La garanzia non si estende alle
ponents. Die Garantie deckt keine Teile ab, sation du constructeur. parti che si logorano in seguito
The warranty elapses if the die infolge des normalen Ge- La garantie s’étend aux pièces al normale uso e alle parti elettri-
pneumatic vibrator: brauchs verschleißen, und auch qui s’usent à la suite d’une utili- che.
- has been tampered with or mo- keine elektrischen Teile. sation normale et aux parties A miglior precisazione la garan-
dified, Genauer geagt verfällt die Ga- électriques. zia decade nei casi in cui il vi-
- has not been used correctly, rantie in folgenden Fällen: Plus précisément la garantie est bratore pneumatico:
- has been used without res- - Das Druckluft Vibratoren wur- sans effet si le vibrateurs pneu- - sia stato manomesso o modifi-
pecting the limits indicated in de manipuliert oder abgeändert; matique : cato,
this manual and/or has been - wurde nicht angewandt; - a été manipulé ou modifié, - sia stato utilizzato non corret-
subjected to excessive mecha - bei seinem Gebrauch wurden - a été utilisé de manière incor tamente,
nical stress, die in diesem Handbuch ge- recte, - sia stato utilizzato non rispet-
- has not been subjected to the nannten Einsatzbeschränkun- - a été utilisé sans respecter les tando i limiti indicati nel presen-
necessary maintenance or the- gen nicht beachtet und/oder es limites indiquées dans la pré- te manuale e/o sia stato sotto-
se operations have been car- wurde zu starken mechani- sen te notice et/ou qu’il a été posto ad eccessive sollecita-
ried out partly and/or incorrect- schen Belastun gen ausge- soumis à des contraintes mé- zioni meccaniche,
ly, setzt; caniques excessives - non sia stato sottoposto alle
- has been damaged due to ca- - er wurde nicht der erforder- - il n’a pas été soumis aux en- necessarie manutenzioni o
relessness during transport, lichen Wartung unterzogen tretiens nécessaires ou que queste siano state eseguite
installation and use, oder diese wurde nur teilweise ces opérations ont été effec- solo in parte e/o non corretta-
- has been fitted with spare und/oder nicht korrekt ausge- tuées partiellement, de maniè- mente,
parts that are not original. führt; re incom plète ou incorrecte - abbia subito danni per incuria
On receiving the product, the - es wurde beschädigt, weil - a subit des dommages par né- durante il trasporto, l’installa-
user must check these for de- Transport, Einbau oder Ge- gligence pendant le transport, zione e l’utilizzo,
fects deriving from transport brauch ohne die erforderliche la mise en place et l’utilisation, - siano state inserite parti di ri-
and/or incomplete supply. Sorgfalt vorgenommen wur- - a été réparé avec des pièces cambio non originali.
Defects, damage or incom plete- den; qui ne sont pas d’origine. Al ricevimento del prodotto, il
ness of the supply must be im- - es wurden keine Original-Er- Dès réception de la marchan destinatario deve verificare che
mediately communicated to the satzteile verwendet. dise, le destinataire doit vérifier lo stesso non presenti difetti o
Manufacturer in writing and Beim Empfang der Ware hat der que celle-ci n’a pas de défauts danni derivanti dal trasporto e/o
countersigned by the haulage Empfänger sicherzustellen, ou subit de dégâts dus au tran incompletezza della fornitura.
transporter. dass die Ware keine durch den sport et que la fourniture n’est Eventuali difetti, danni o incom-
Transport verursachten Schä- pas incomplète. pletezza vanno immediatamente
den oder Defekte aufweist, und/ Tout défaut, dommage ou four segnalati al costruttore median-
oder dass der Lieferumfang voll- niture incomplète doit immédia te comunicazione scritta e con-
stän-dig ist. tement être signalée au constru trofirmata dal vettore.
Etwaige Defekte, Schäden oder cteur par communication écrite
Fehlmengen sind mittels schrift- et contresignée par le tran spor-
licher und vom Frachtführer ge- teur.
gengezeichneter Mitteilung
sofort dem Hersteller zu melden.
S/N: 020-069
- TRANSPORT AND PACKING S110106.04
S - TRANSPORT UND PACKUNG
OT
- TRANSPORT ET EMBALLAGE 2
OR
- TRASPORTO E IMBALLO OL.2000 EX M. 20
TRANSPORT TRANSPORT TRANSPORT TRASPORTO

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

NOTE: N.B.: N.B.: N.B.:
It is the installer’s responsibility Der Anlagenaufsteller ist dafür L’installateur doit, à ses frais, éli- è a cura dell’installatore smaltire
to dispose off the packaging in a verantwortlich, das Verpa- miner les emballages de manière gli imballi in modo adeguato e
suitable manner, in compliance ckungsmaterial auf angemesse- adéquate et conformément aux secondo le leggi vigenti in mate-
with existing legislation. ne Art und in Übereinstimmung lois en vigueur en la matière. ria.
mit den einschlägigen, geltenden
Gesetzen zu entsorgen.
S/N: 020-069
06.04
- STORAGE S1101
S - LAGERHALTUNG
OT
- EMMAGASINAGE 2
OR
- IMMAGAZZINAGGIO OL.2000 EX M. 21
1)STORAGE PRIOR TO IN- 1) EINLAGERUNG VOR DEM 1) EMMAGASINAGE AVANT LA 1) IMMAGAZZINAGGIO PRIMA
STALLATION EINBAU MISE EN PLACE DELL’INSTALLAZIONE
- Avoid damp, salty environ- - Feuchte und salzhaltige Luft - Si possible éviter les locaux - Evitare possibilmente ambienti
ments, if possible. für die Einlagerung vermeiden. humides et les saumâtres umidi e salmastri.
- Place the component on wood- - Den Bauteil auf einer Holzpa- - Placer le composant sur des - Sistemare il componente su
en platforms and store it pro- lette setzen und vor Witterung palettes en bois et les ranger à pedane di legno e locarle al ri-
tected from unfavourable schützen. l’abri des intempéries. paro dalle intemperie.
weather conditions.
2)PROLONGED MACHINE 2) LÄNGERE BETRIEBSRUHE 2) ARRÊT MACHINE PROLON- 2) FERMO COMPONENTE PRO-
SHUTDOWNS AFTER AS- NACH DEM EINBAU GÉ APRÈS LE MONTAGE LUNGATO DOPO IL MON-
SEMBLY - Vor der Inbetriebnahme ist der - Avant la mise en service met- TAGGIO
- Before starting up the compo- Bauteil in einen sicheren Zu- tre le composant en sécurité. - Prima della messa in servizio
nent, set it in safety status. stand zu bringen. - Avant la mise en service du mettere in sicurezza il compo-
- Before starting up the compo- - Vor der Inbetriebnahme des composant contrôler l’intégrité nente.
nent, check the condition of the Bauteils die elektrische und de l’équipement électrique et de - Prima della messa in servizio
electric and pneumatic system pneumatische Anlage und alle toutes les parties pour lesquel- del componente controllare l’in-
and all parts for which long Teile, deren Funktionstüchtig- les un arrêt prolongé pourrait tegrità dell’impianto elettrico,
shutdowns may affect work- keit die bei einem längeren Still- compromettre le fonctionne- pneumatico, e di tutte le parti
ing. stand in Frage gestellt werden ment. per le quali un prolungato arre-
könnte, prüfen. sto potrebbe compromettere la
funzionalità.
3) POSSIBLE REUSE AFTER PE- 3) MÖGLICHE WIEDERVER- 3) RÉ-UTILISATION APRÈS UNE 3)POSSIBILE REIMPIEGO
RIODS OF INACTIVITY WENDUNG NACH EINEM LÄN- PÉRIODE D’INACTIVITÉ DOPO PERIODO DI INATTIVI-
- During component halts, avoid- GEREN STILLSTAND - Pendant la période d’inactivité TA’
damp, salty environments. - Während des Stillstands des du composant éviter les locaux - Durante il fermo componente
- Place the component on wood- Bauteils Räume mit feuchter humides et saumâtres evitare ambienti umidi e salma-
en platforms and store it pro- und salzhaltiger Luft vermei- - Placer le composant sur des stri.
tected from unfavourable den. palettes en bois et les ranger à - Sistemare il componente su
weather conditions. - Den Bauteil auf eine Holzpalet- l’abri des intempéries. pedane di legno e locarle al ri-
- Set the component in safety te setzen und vor Witterung - Avant la mise en service met- paro dalle intemperie.
status before starting it up. schützen. tre le composant en sécurité - Prima della messa in servizio
- Before starting up the compo- - Vor der Inbetriebnahme ist der - Avant la mise en service du mettere in sicurezza il compo-
nent, check the condition of the Bauteil in einen sicheren Zu- composant contrôler l’intégrité nente.
electric and pneumatic sys- stand zu bringen. de l’équipement électrique et de - Prima della messa in servizio
tems and all parts for which - Vor der Inbetriebnahme des toutes les parties pour lesquel- del componente controllare l’in-
long shutdowns may affect Bauteils die elektrische und les un arrêt prolongé pourrait tegrità dell’impianto elettrico,
working. pneumatische Anlage und alle compromettre le fonctionne- pneumatico, e delle parti per le
- Before starting up the compo- Teile, deren Funktionstüchtig- ment. quali un prolungato arresto po-
nent, clean it thoroughly by fol- keit die bei einem längeren Still- - Avant la mise en service du trebbe compromettere la fun-
lowing the indications on the stand in Frage gestellt werden composant effectuer un cycle zionalità.
powder safety sheet. könnte, prüfen. complet de nettoyage en res- - Prima della messa in servizio
- If the component operates in - Vor der Inbetriebnahme des pectant ce qui est indiqué sur del componente eseguire un
conditions and with materials Bauteils ist ein vollständiger la fiche de sécurité de la pous- ciclo completo di pulizia rispet-
different from the previous ap- Abreinigungszyklus vorzuneh- sière. tando quanto riportato sulla
plication, check the compatibil- men, wobei das zu beachten - Si le composant travaille dans scheda di sicurezza della pol-
ity of this use according to the ist, was auf dem Sicherheits- des conditions et avec des ma- vere.
indications in the INDICATIONS Datenblatt des entsprechenden tières différentes de l’applica- - Se il componente opera in con-
FOR USE section. Erzeugnisses steht. tion précédente, vérifier la dizioni e con materiali diversi
- Wenn der Bauteil unter Bedin- compatibilité de cette utilisation dall’applicazione precedente,
gungen oder mit Material betrie- d’après ce qui est indiqué dans verificare la compatibilità di tale
ben wird, das vom vorherigen la section MODE D’EMPLOI. utilizzo secondo quanto ripor-
Einsatz abweicht, ist die Ver- tato nel sezione INDICAZIONE
träglichkeit für den neuen Ein- PER L’USO.
satz mit den BEDIENSUNGSAN-
LEITUNG zu vergleichen.
S/N: 020-069
- MAINTENANCE S110106.04
S - WARTUNG
OT
- ENTRETIEN 2
OR
- MANUTENZIONE OL.2000 EX M. 26
Set the component in safety Vor der Ausführung jeder Avant toute opération met- Prima di qualsiasi interven-
status before carrying out beliebiger Arbeit ist der Baut- tre le composant en condi- to mettere il componente in
any operation. eil in einen Zustand verset- tion de sécurité. sicurezza.
zen.
- If work is to be carried out on - Wo sich Teile des pneuma- - Pour atteindre des parties du - Là dove si debbano raggiun-
parts at the top of the pneu- tischen Vibrators in größerer vibrateur pneumatique en hau- gere parti del vibratore pneu-
matic vibrator, use a work area Höhe befinden, eine Arbeits- teur, utiliser une plate-forme matico in quota utilizzare una
platform which must be select- plattform zu benutzen, die so aérienne de travail qui devra piattaforma aerea di lavoro che
ed in such a manner as to avoid zu wählen ist, dass eine être choisie de manière à évi- dovrà essere scelta in modo
risk of slipping, tripping or fall- Gefährdung des Personals in ter tout danger de glissement da evitare pericoli di scivola-
ing of operators. Form von Ausrutschen, Hän- ou de chute des opérateurs. mento, inciampo o caduta per
genbleiben oder Absturz ver- gli operatori.
mieden wird.
S and OR-vibrators are mainte- S-und OR- Vibratoren sind war- Les S et OR ne réclament pas I vibratori S e OR sono esenti da
nance-free. From outside they tungsfrei. Sie können von außen d’entretien. Ils peuvent être net- manutenzione. Possono essere
can be cleaned with a water jet. mit einem Wasserstrahl gereinigt toyés extérieurement à l’eau puliti esternamente mediante get-
Operate the vibrator for a short werden. Nach der Reiningung sous pression. Après le nettoya- to d’acqua. Dopo avere eseguito
while after. den Vibrator kurz betätigen. ge, faire brièvement fonctionner questa operazione, farli funzio-
le vibrateur. nare per un breve intervallo di
tempo.
WARNING ACHTUNG ATTENTION ATTENZIONE

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

SERIES BEARINGS SERIEN „OT” ROULEMENTS SERIE “OT” CUSCINETTI SERIE “OT”
S/N: 020-069
06.04
- MAINTENANCE S1101
S - WARTUNG
OT
- ENTRETIEN 2
OR
REPLACING “OT” AUSTAUSCH DER LAGER REMPLACEMENT DES SOSTITUZIONE

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

OT 8
OT 10 607 ZTN9/C3
OT 10 S
OT 13
OT 16 6000 ZTN9/C3
OT 16 S
OT 20
OT 25 6203 ZTN9/C3
OT 25 S
OT 30
OT 36 6303 ZTN9/C3
OT 36 S
S/N: 020-069
- MAINTENANCE S110106.04
S - WARTUNG
OT
- ENTRETIEN 2
OR
PERIODIC CHECKS REGELMÄSSIGE KONTROLLEN CONTROLES PERIODIQUES CONTROLLI PERIODICI
Set the component in safety Vor der Ausführung belie- Avant toute operation met- Prima di qualsiasi interven-
status before carrying out biger Arbeiten das Bauteil in tre le composant en condi- to mettere il componente in
any operation. einen sicheren Zustand ver- tion de sécurité. sicurezza.
setzen.
- Clean dust deposits on a week- - Etwaige Staubansammlungen - Chaque semaine éliminer les - Settimanalmente rimuovere
ly basis. einmal pro Woche entfernen. dépôts de poussière qui se eventuali cumuli di polvere di
- Check the tightening of the - Die Schraubanschlüsse einmal sont accumulés. deposito.
screw connectors on a month- pro Monat auf festen Sitz prü- - Tous les mois vérifier le serra- - Verificare mensilmente, il ser-
ly basis. fen. ge des raccords à vis. raggio dei raccordi a vite.
- Check tightening torque of the - Einmal pro Monat das Anzugs- - Tous les mois vérifier le couple - Verificare mensilmente, la cop-
fixing screws on a monthly moment der Befestigungs- de serrage des vis de fixation. pia di serraggio delle viti di fis-
basis. schrauben prüfen. - Tous les mois vérifier l’équipo- saggio.
- Check the equipotential with - Einmal pro Monat die Struktur, tentialité avec la structure sur - Verificare mensilmente, l’equi-
the structure on which the vi- an der der Vibrator befestigt laquelle est fixé le vibrateur. potenzialità con la struttura su
brator is mounted, on a month- ist, auf Potentialausgleich prü- - Tous les 3000 heures rempla- cui viene fissato il vibratore.
ly basis. fen. cer les roulements à bille sur le - Sostituire ogni 3000 ore sul mo-
- Change the ball bearings on the - Alle 3000 Betriebsstunden bei modèle OT. dello OT i cuscinetti a sfera.
OT model every 3000 hours. Modell OT die Kugellager prü-
fen.
CLEANING REINIGUNG NETTOYAGE PULIZIA

Set the component in safety Vor der Ausführung belie- Avant toute operation met- Prima di qualsiasi interven-
status before carrying out biger Arbeiten das Bauteil in tre le composant en condi- to mettere il componente in
any operation. einen sicheren Zustand tion de sécurité. sicurezza.
versetzen.
While cleaning the dust deposit- En éliminant la poussière présen- Nella rimozione della polve-
ed on the component, avoid Beim Entfernen von Staub, der te sur le composant faire atten- re eventualmente presente
throwing up dust into the sur- sich eventuell auf dem Bauteil tion à ne pas la disperser dans nel componente, aver cura
roundings and avoid dust depos- gebildet hat, dafür sorgen, dass le milieu environnant et éviter tou- di non disperdere la polvere
its. der Staub nicht in die Umgebung te accumulation. stessa nell’ambiente circo-
verteilt wird, und vermeiden, stante e avere cura di evita-
- The user must choose suitable dass sich zu viel Staub ansam- - L’utilisateur doit utiliser des pro- re cumuli.
cleaning products depending melt. duits appropriés pour le net-
on the type of plant and the toyage en fonction du type - L’utilizzatore dovrà provvede-
product handled, taking care to - Der Anwender muss Reini- d’installation et du produit trai- re alla scelta dei prodotti idonei
avoid toxic and inflammable gungsmittel verwenden, die té, en faisant attention à ne pas alle fasi di pulizia in base alla
products. zum Typ der Anlage und zum employer de produits toxique tipologia di impianto ed al pro-
- If the pneumatic vibrator is to behandelten Produkt passen. ou inflammables. dotto trattato facendo comun-
be used with food products, Er muss auf jeden Fall dafür - Si le vibrateur pneumatique tra- que attenzione a non usare
use non toxic detergents suit- sorgen, dass keine giftigen vaille avec des produits alimen- prodotti tossici o infiammabili.
able for the type of application. oder feuergefährlichen Pro- taires il est obligatoire d’utiliser - Nel caso che il vibratore pneu-
- The cleaning frequency de- dukte verwendet werden. des détergents non toxiques, matico operi con prodotti ali-
pends on the type of product - Falls der pneumatische Vibra- mais appropriés au type d’ap- mentari è obbligatorio usare
handled and the plant. tor zum Verarbeiten von Le- plication. detergenti non tossici, ma ido-
- In case of harmful, toxic prod- bensmitteln benutzt wird, ist es - La fréquence des opérations nei al tipo di applicazione.
ucts, cleaning wastes must be vorgeschrieben, ungiftige Rei- de nettoyage dépend de la na- - La frequenza delle operazioni
conveyed into closed tanks and nigungsmittel zu verwenden, ture du produit traité et de l’équi- di pulizia dipendono dalla natu-
disposed off according to the die zur Anwendung passen. pement. ra del prodotto trattato e del-
indications in the products - Die Häufigkeit der Reinigung - En cas de produits nocifs ou l’impianto.
safety sheet. hängt von der Beschaffenheit toxiques, les eaux usées du - Nel caso di prodotti nocivi, tos-
des zu behandelnden Produkts nettoyage doivent être con- sici, i reflui della pulitura do-
und der Anlage ab. voyées dans une cuve fermée vranno essere convogliati in
- Falls man schädliche oder gif- adéquate et éliminées confor- idonea vasca chiusa e smaltiti
tige Erzeugnisse verarbeitet, mément à ce qui est prévu par secondo quanto previsto dalla
müssen die Reinigungsabwäs- la fiche de sécurité du produit. scheda di sicurezza del pro-
ser in einer geeigneten, ge- dotto.
schlossenen Wanne gesam-
melt und gemäß den Angaben
auf dem Sicherheits-Datenblatt
entsorgt werden.
S/N: 020-069
06.04
- RESIDUAL RISKS S1101
S - RESTRISIKEN
OT
- RISQUES RESIDUELS 2
OR
- RISCHI RESIDUI OL.2000 EX M. 29
On the basis of the use of the Je nach Verwendung des Druck- L'installateur, en fonction de l’utili- L'installatore, in base all'utilizzo
pneumatic vibrator, the installer luft Vibratoren muss der Installa- sation du vibrateur pneumatiques, del vibratore pneumatico, deve
must inform the operator by means teur das Personal durch besonde- doit informer les opérateurs, au informare gli operatori, tramite
of specific signals, regarding the re Hinweisschilder auf folgende moyen d’indications et de signali- appositi segnali, in merito ai se-
residual risks: Restrisiken hinweisen: sations prévues à cet effet, sur les guenti rischi residui :
risques résiduels suivants :
1. Mechanical risk 1.Gefahren mechanischer Art 1. Pericoli di natura meccanica
For maintenance operations, it Für die Wartungsarbeiten muss 1. Dangers de nature mécanique Per le attività di manutenzione
is compulsory for the operator das Personal immer seine per- Pour les activités d’entretien è fatto obbligo all'operatore di
to always use personal protec- sönlichen Schutzausrüstungen l’opérateur a l’obligation d’utili- impiegare sempre i dispositivi
tion equipment. benutzen. ser toujours les dispositifs de di protezione individuale.
Special warning notices on each Besondere Warnschilder an den protection individuelle. Apposite targhe monitorie nel-
section of the machine indicate einzelnen Abschnitten des Ge- Des plaques d’avertissements le singole sezioni di macchina
the obligatory personal protec- räts geben an, welche persönli- apposées dans chaque section indicano quali dispositivi di pro-
tion equipment: chen Schutzausrüstungen de la machine indiquent quels tezione individuale si rendono
jeweils erforderlich sind: sont les dispositifs de protection obbligatori:
individuelle qui sont obligatoi-
GLOVE ARE
COMPULSORY DIE BENUTZUNG res :
VON
HANDSCHUHEN
E’ OBBLIGATORIO
IST VORGESCHRIEBEN
PORT DE USARE I GUANTI
GANTS
SAFETY
OBLIGATOIRE
FOOTWEAR ARE DIE BENUTZUNG
COMPULSORY VON SICHERHEITS E’ OBBLIGATORIO
SCHUHWERK USARE LE
IST CHASSURES DE CALZATURE
VORGESCHRIEBEN SÉCURITÉ DI SICUREZZA
2. Presence of possible residu- OBLIGATOIRES
al high temperature after percus- 2. Vorliegen möglicher hoher 2. Presenza di possibili alte tem-
sion gun stop Temperaturen nach dem Still- 2. Présence de hautes tempéra- perature residue dopo l'arresto
During the course of mainte- stand der Klopfer
nance and cleaning operations tures résiduelles après l’arrêt del percussore
Im Laufe einiger Wartungs- und du percuteur Nel corso di interventi manu-
and in certain operating sec- Reinigungsarbeiten und in ei- tentivi e di pulizia e in alcune
tions, the operator may enter Au cours des interventions d’en-
nigen Arbeitsabschnitten kann tretien et de nettoyage et dans sezioni di lavoro, l'operatore può
into contact with very hot parts das Personal bei stehendem entrare in contatto, a macchina
of the percussion gun, with the certaines sections de travail,
Gerät in Kontakt mit Teilen der l’opérateur peut entrer en conferma, con parti del percussore
machine stopped. Klopfer geraten, die eine hohe pneumatico con superfici ad ele-
Special warning notices, locat- tact, quand la machine est arrê-
Temperatur aufweisen. tée, avec des parties du filtre vata temperatura.
ed at strategic points indicate Besondere Warnschilder, die an Apposite targhe monitorie, col-
the risk due to the presence of dont les surfaces sont à des tem-
den strategischen Stellen ange- pératures élevées. locate nei punti strategici indi-
very hot surfaces and the obli- bracht sind, weisen auf die Ge- cano il pericolo dovuto alla pre-
gation for the operator to wear Des plaques d’avertissement,
fahren hin, die sich durch die apposées dans les endroits stra- senza di superfici ad elevata
personal protection equipment, hohe Temperatur der Oberflä- temperatura e l'obbligo per
especially protective gloves. tégiques, signalent le danger
chen ergeben und weisen das dû à la présence de surfaces à l'operatore di utilizzare disposi-
Personal darauf hin, dass es zur des températures élevées et tivi di protezione individuale, in
Verwendung der persönlichen l’obligation de l’opérateur d’uti- particolare guanti protettivi.
GLOVES ARE Schutzausrüstungen verpflichtet
COMPULSORY liser les dispositifs de protection
ist, insbesondere zum Tragen individuelle, en particulier des E’ OBBLIGATORIO
von Schutzhandschuhen.. gants de protection. USARE I GUANTI
WARNING
DANGEROUS DIE BENUTZUNG PORT DE
TEMPERATURE VON GANTS
HANDSCHUHEN ATTENZIONE
OBLIGATOIRE TEMPERATURE
IST VORGESCHRIEBEN
PERICOLOSE
3. Presence of potentially haz-
ardous dusts ATTENTION
ACHTUNG TEMPERATURES
In the event of both routine and GEFÄHRLICHE 3. Presenza di polveri potenzial-
DANGEREUSES
extraordinary maintenance, the TEMPERATUREN mente pericolose
operator must wear suitable per- Nel caso di interventi sia ordi-
sonal protection equipment, 3. Vorhandensein potentiell ge- 3. Présence de poussières po- nari che straordinari di manu-
and in particular, use a safety fährlicher Stäube tentiellement dangereuses
tenzione l'operatore deve dotar-
mask for the respiratory tract Bei regelmäßiger und außeror- Aussi bien dans le cas d’inter-
si di idonei dispositivi di prote-
depending on the type of dust dentlicher Wartung muss das ventions d’entretien ordinaires
zione individuale ed in partico-
daalt as well as gloves and Personal geeignete pers önli- ou extraordinaires, l’opérateur
lare deve utilizzare maschere a
clothing. che Schutzausrüstungen ver- doit se doter des dispositifs de
protezione delle vie respirato-
For more details, refer to the wenden und insbesondere Mas- protection individuelle et en
rie di classe idonea in base al
safety chart of the product han- ken zum Schutz der Atemwege particulier il doit utiliser des
tipo di polvere trattata nonché
dled. mit geeigneter Klasse für den masques de classe appropriée
di guanti o indumenti.
aufbereiteten Staub, wie auch pour protéger les voies respira-
Per maggiori dettagli si deve far
Schutzhandschuhe und Schutz- toires en fonction du type de
riferimento alla scheda di sicu-
MASK IS kleidung tragen. poussière traitée ainsi que de
rezza del prodotto utilizzato.
COMPULSORY Für nähere Angaben ist Bezug gants ou de vêtements adé-
auf das Sicherheitsdatenblatt quats.
des verwendeten Produkts zu Pour plus de détails consulter E’ OBBLIGATORIO
la fiche de sécurité du produit USARE LA
nehmen. MASCHERA
utilisé.
DIE BENUTZUNG
DER MASKE IST MASQUE
VORGESCHRIEBEN OBLIGATOIRE
S/N: 020-069
- RESIDUAL RISKS S110106.04
S - RESTRISIKEN
OT
- RISQUES RESIDUELS 2
OR
- RISCHI RESIDUI OL.2000 EX M. 30
- In certain handling of dusts, - Bei bestimmten Staubbehand- - Dans des traitements détermi- - In determinati trattamenti di pol-
where hazardous substanc- lungen, wo schädliche Substan- nés de poussières où il y a la veri dove vi è la presenza di
es are present, the operator zen auftreten, muss das Perso- présence de substances no- sostanze nocive, l'operatore
concerned who has to access nal, falls es im Laufe der regel- cives, l’opérateur qui doit y che dovesse accedere, nel
the machine for routine and mäßigen oder außerordentli- avoir accès, dans le cours des corso di interventi ordinari o
extraordinary maintenance chen Wartung damit in Kontakt interventions ordinaires ou ex- straordinari, deve indossare gli
operations must wear suitable kommt, persönliche Schutzaus- traordinaires, doit porter les dis- idonei dispositivi di protezione
protective devices as indicat- rüstungen tragen, so wie auf den positifs de protection appro- come indicato dalla cartelloni-
vorhandenen Schildern ange-
ed on the notice signs provid- priés comme signalé par les stica ivi presente.
geben.
ed. panneaux indicateurs qui s’y
DIE BENUTZUNG trouvent. E’ OBBLIGATORIO
DER MASKE IST USARE LA
MASK IS MASCHERA
VORGESCHRIEBEN
COMPULSORY MASQUE
OBLIGATOIRE
ATTENZIONE
VORSICHT: SOSTANZE
WARNING SCHADSTOFFE
HURTFUL ATTENTION NOCIVE
SUBSTANCE SUBSTANCES
DANGEREUSES
DIE BENUTZUNG
VON
HANDSCHUHE E’ OBBLIGATORIO
GLOVES ARE IST VORGESCHRIEBEN USARE I GUANTI
PORT DE
COMPULSORY
GANTS
Bei der Ausführung von erhit- OBLIGATOIRE
zenden Arbeiten (Schweißen, Tutte le manutenzioni all'inter-
In case of operations involving no del vibratore pneumatico
Schneiden) ist es erforderlich, Tous les entretiens à l’intérieur
heating (welding, cutting) it is DEVONO essere effettuate ad
die Oberfläche des pneumati- du vibrateur pnumatique DOI-
necessary to clean the sur- schen Vibrators vorbeugend zu VENT être effectués quand l’ins- impianto fermo e in assenza di
face of the pneumatic vibrator behandeln, um alle Staubab- tallation est arrêtée et en ab- polvere aerodispersa. In caso
first, removing all dust depos- lagerungen und in Abwesenheit sence de poussière dispersée di lavori a caldo (saldatura, ta-
its (the layers, the deposits atembarer Stäube durchgeführt dans l’air. Dans le cas de tra- glio) è necessario bonificare
and accumulated combustible werden. Bei der Ausführung von vaux à chaud (soudure, décou- preventivamente le superfici
powder MUST be considered erhitzenden Arbeiten (Schwei- pe) il faut préalablement net- del vibratore pneumatico, ri-
like any other source which can ßen, Schneiden) ist es erforder- toyer les surfaces du vibrateur muovendo tutti i depositi di pol-
result in an explosive atmos- lich, den Vibrator so vorzube- pneumatique,, en éliminant tous vere (gli strati, i depositi ed i
phere). reiten, dass alle Staubablage- les dépôts de poussière (les cou- cumuli di polvere combustibile
Authorization for operations in- rungen entfernt werden (Schich- ches, les dépôts et les tas de DEVONO essere considerati
volving heating MUST be given ten, Ablagerungen und An- poussière combustible DOI- come qualsiasi altra sorgente
by technical personnel special- sammlungen von brennbarem VENT être considérés comme
che può dare origine ad un'at-
iz-ed and trained in the risk of Staub MÜSSEN wie jede une autre source pouvant don-
mosfera esplosiva).
andere Staubquelle betrachtet ner lieu à une atmosphère ex-
explosion from dusts (capable L'autorizzazione all'esecuzio-
werden, die zur Entstehung ei- plosive).
of checking residual risk, suit- ne dei lavori a caldo DEVE es-
ner explosiven Atmosphäre bei- L'autorisation à l’exécution des
ability of tools and a knowledge tragen kann). sere data da personale tecni-
of the procedures). travaux à chaud DOIT être don-
Die Genehmigung zur Ausfüh- née par du personnel technique co specializzato e formato sul
(The person responsible for rung von Arbeiten im erwärm- rischio esplosione da polveri
spécialisé et formé sur le risque
safety must issue a “Fire Per- ten Zustand DARF NUR durch (in grado di verificare il rischio
d’explosion des poussières (en
mit” to the operator). spezialisiertes technisches Per- mesure4 de vérifier le risque ré- residuo, l'idoneità degli utensili
4. Hazards deriving from sonal erteilt werden, das über siduel, l’aptitude des outils et e la conoscenza delle proce-
pressurized circuits (hydrau die Explosionsgefahr durch la connaissance des procédu- dure). Il responsabile della si-
lic, pneumatic) Staub unterrichtet ist (das in der res). curezza dovrà rilisciare un
During maintenance and/or Lage ist, das Restrisiko festzu- Le responsable de la sécurité “permesso di lavoro fuoco” al-
repair operations pressure stellen, das die geeigneten devra délivrer un “permis de l’operatore.
must be discharged from the Werkzeuge und auch die Pro- feu” à l’opérateur. 4. Pericoli derivanti da circuiti
plants and accumulators (if zeduren kennt). Der Werkschutz- 4. Dangers dérivant des circuits in pressione (idraulici, pneu-
present), according to the in- verantwortliche muss dem Per- sous pression (hydrauliques, matici)
sonal eine „Genehmigung zur
structions given along-side the pneumatiques) Durante le operazioni di manu-
Feuerarbeit” ausstellen.
components and in the respec- Pendant les opérations d’entre- tenzione e/o riparazione occor-
4. Gefahren durch unter Druck
tive user manuals. tien et/ou de réparation il faut
stehende Leitungen (hydrau- re porre in scarico gli impianti e
5. Hazard generated by noise lisch, pneumatisch) décharger les installations et les
gli eventuali accumulatori, se-
The user and employer are Während der Wartungsarbeiten éventuels accumulateurs, con-
formément aux instructions qui
condo le istruzioni riportate in
obliged to respect the legal und/oder Reparaturen sind die prossimità dei componenti e nei
standards as regards protec- Anlagen und die etwaigen Ak- se trouvent à proximité des com-
posants et dans les notices d’ins- rispettivi manuali d'uso.
tion from daily personal expo- kumulatoren zu entleeren, so 5. Pericoli generati da rumo-
tructions correspondantes.
sure of operators to noise (in wie es in den Anweisungen an re
5. Dangers provoqués par le
Italy L.D.277/91). de jeweiligen Komponenten
bruit E' fatto obbligo all'utilizzatore e
oder in den entsprechenden
L’utilisateur ainsi que l’em- al datore di lavoro di rispettare
Handbüchern steht.
ployeur ont l’obligation de faire le norme di legge in termine di
5. Gefährdung der Arbeitnehmer
respecter les normes de loi en protezione contro l'esposizio-
durch Lärm
matière de protection contre l’ex- ne personale quotidiana degli
Der Anwender und der Arbeit-
position personnelle quotidien- operatori al rumore (in Italia
geber sind zur Einhaltung der
ne des opérateurs au bruit (en D.Lgs.277/91).
gesetzlichen Bestimmungen in
Italie D.Lgs.277/91).
Sachen Schutz gegen tägliche
persönliche Lärmexposition der
Arbeitnehmer verpflichtet (in
Italien D.Lgs.277/91).
S/N: 020-069
06.04
- FAULT FINDING S1101
S - BETRIEBSSTÖRUNGEN UND ABHILFE
OT
- INCONVENIENTS ET SOLUTIONS 2
OR
- INCONVENIENTI E SOLUZIONI OL.2000 EX M. 31
FAULT ACTION
Check the presence of compressed-air
The vibrator does not start
Check the presence of foreign elements in the piping or in the vibrator
The vibrator increase in Check the fastening of the fixing screws and in case, make the supporting plate stiff
noisiness Lubrificate the pneumatic line
Check the feed pressure (MAX 6 BAR)
The vibrator loose its vibrating
Check the fastening of the fixing screws and in case, make the supporting plate stiff
effect
Lubrificate the pneumatic line
STÖRUNG ABHILFE
Die Druckluft kontrollieren
Der Rüttler starts nicht
Eventuelle Fremdkörper in der Leitung oder in den Rüttler kontrollieren
Den Spanndruck der Befestigungsschrauben kontrollieren und die Stutzplatte eventuell verstärken
Mehr Rüttlergeräusch
Die pneumatische Vorrichtung schmieren
Den Einlassdruck (MAX 6 BAR) kontrollieren
Verlust an Vibrierwirkung Den Spanndruck der Befestigungsschrauben kontrollieren und die Stutzplatte eventuell verstärken
Die pneumatische Vorrichtung schmieren
PROBLÈME SOLUTION
Vérifier la présence d'air comprimé
Le vibrateur ne démarre pas
Vérifier la présence d'éléments étrangers dans la tubuluru ou le vibrateur
Vérifier le serrage des vis et éventuellement raidir la plaque d'appui
Il rumore del vibratore aumenta
Lubrifier la ligne pneumatique
Vérifier la pression d'alimentation (MAX 6 BAR)
Il vibratore cala l'effetto vibrante Vérifier le serrage des vis et éventuellement raidir la plaque d'appui
Lubrifier la ligne pneumatique
PROBLEMA SOLUZIONE
Controllare presenza aria compressa
Il vibratore non parte
Controllare presenza elementi estranei nella tubazione o nel vibratore
Controllare il serraggio delle viti di fissaggio ed eventualmente irrigidire la piastra di supporto
Il rumore del vibratore aumenta
Lubrificare la linea pneumatica
Controllare la pressione di alimentazione (MAX 6 BAR)
Il vibratore cala l'effetto vibrante Controllare il serraggio delle viti di fissaggio ed eventualmente irrigidire la piastra di supporto
Lubrificare la linea pneumatica
S/N: 020-069
- SCRAPPING COMPONENT / RETURNING COMPONENT S110106.04
S - VERSCHROTTUNG DES BAUTEILS / RÜCKGABE DES BAUTEILS
OT
- DEMANTELEMENT DU COMPOSANT / RESTITUTION DU COMPOSANT 2
OR
- ROTTAMAZIONE COMPONENTE / RESO COMPONENTE OL.2000 EX M. 32
SCRAPPING VERSCHROTTUNG DES DEMANTELEMENT DU ROTTAMAZIONE

COMPONENT BAUTEILS COMPOSANT COMPONENTE
- Before proceeding with dis- - Bevor das Druckluft Vibrator - Avant mettre le vibrateur pneu- - Prima di procedere allo smalti-
posal of the pneumatic vibra- entsorgt wird, dieses vollkom- matique à la décharge le net- mento del vibratore pneumati-
tor, clean it thoroughly and dis- men reinigen und den enthalte- toyer complètement et éliminer co provvedere alla sua com-
pose off the residual dust in nen Reststaub in Übereinstim- les poussières restantes con- pleta pulizia ed allo smaltimen-
accordance with the indica- mung mit dem Sicherheitsda- formément aux indications to delle polveri residue in ac-
tions in the safety chart. tenblatt entsorgen. fournies par la fiche de sécuri- cordo con le indicazioni della
- The operators in charge of dis- - Die Arbeitnehmer, die sich um té. scheda di sicurezza.
posal must use suitable per- die Entsorgung kümmern, müs- - Les personnes préposées à la - Gli operatori addetti allo smalti-
sonal protection equipment. sen angemessene persönliche mise à la décharge doivent por- mento devono indossare di-
- For scrapping or demolition of Schutzausrüstungen verwen- ter des dispositifs personnels spositivi di protezione perso-
the component, separate the den. de protection appropriés. nale adeguati.
plastic parts (seals and com- - Wenn der Bauteil verschrottet - - En cas de mise à la décharge - In caso di rottamazione o de-
ponents) and send these to werden soll, sind die kunst- ou de démantèlement du com- molizione a fine vita del com-
special collection centres. stoffhaltigen Teile (Dichtungen posan, il faut démonter les piè- ponente, avere cura di smon-
- The other parts must be sent und Komponenten) auszubau- ces en matière plastique (joints tare le parti in materiale plasti-
for recycling ferrous materials. en und über die entsprechen- et composants) et les mettre à co (guarnizioni e componenti)
den Sammelstellen dem Recy- la décharge dans des déchet- e destinarle agli appositi centri
cling zuzuleiten. teries spécialisées. di raccolta.
- Die restlichen Teile sind als Ei- - Les pièces restantes sont à - Le restanti parti sono da desti-
senschrott zu behandeln. destiner à la récupération des nare al recupero dei materiali
matériaux ferreux. ferrosi.
RETURNING THE MACHINE RÜCKGABE DES GERÄTES RESTITUTION MACHINE RESO MACCHINA
When returning the component, Falls der Bauteil zurückgegeben En cas de restitution du compo- In caso di reso del componente
use the original packaging if it werden soll und man die Origi- sant, si l’emballage a été con- se si è conservato l’imballo rein-
has been preserved, otherwise nalverpackung aufbewahrt hat, servé, le remettre dans celui-ci, serirla nello stesso, altrimenti in-
place it in a box and cover it with ist er darin einzupacken. sinon le mettre dans une caisse serirlo in una scatola e proteg-
nylon shrink-wrap, to protect it Andernfalls ist er in einen Kar- et le protéger avec du nylon ther- gerlo con del nylon termoretrai-
as best as possible from impact ton zu packen und mit Schrumpf- morétractable, en essayant de bile, cercando di proteggerlo al
during transport. In any event, folie zu schützen, wobei man la protéger le plus possible con- meglio da eventuali urti derivanti
make sure there is no residue versucht, sie so gut wie möglich tre les chocs provoqués par le dal trasporto. In ogni caso assi-
material inside the component. vor etwaigen Stößen beim transport. Dans tous les cas s’as- curarsi che il componente non
Transport zu schützen. Auf je- surer que la machine ne contient abbia residui di materiale.
den Fall sicherstellen, dass sich pas de résidus de matière.
keine Materialreste mehr in der
Bauteil befinden.
S/N: 020-069
13651
STABILIZER INSTALLATION
Page 1 of 2
4 1
2
5

03/02/09
S/N: 020-069
13651
STABILIZER INSTALLATION
Page 2 of 2

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

03/02/09
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
S1102
S/N: 020-069
85 CFM COMPRESSOR 17197
12 AND 24 VOLT Page 1 of 12

(NOTE: UNLESS NOTED PART NUMBERS FOR 12V AND 24V SYSTEMS ARE THE SAME) 11/07/11
S/N: 020-069

INSTRUMENT PANEL & ELECTRICAL
464692 COMPRESSOR ASSEMBLY 12V HYDRAULIC A/R
464892 COMPRESSOR ASSEMBLY 24V HYDRAULIC A/R
1 524794 HOUR METER GAUGE 1
2 524798 AIR PRESSURE GAUGE 1
3 464892-116 INSTRUMENT PANEL DECAL 1
4 464892-02 INSTRUMENT PANEL 1
5 465139-58 SS CAPSCREW 2
6 465139-55 FLAT WASHER 2
7 605710 25 PSI PRESSURE SWITCH 1
8 464892-05 TEE 1
9 524814 ELBOW 1

S/N: 020-069

S/N: 020-069
OIL COOLING SYSTEM
1 605721 OIL CORE COOLER 1
2 464892-07 COOLER SHROUD 1
3 465139-100 FAN AND MOTOR MOUNTING CLIPS 6
4 605794 FAN AND MOTOR ASSEMBLY (12V) A/R
(OLD P/N WAS 464692-09)
4a 464692-10 FAN MOTOR (12V) A/R
4 605553 FAN AND MOTOR ASSEMBLY (24V) A/R
(OLD P/N WAS 464892-11)
4a 464892-12 FAN MOTOR (24V) A/R
5 464892-13 COOLER SUPPORT ANGLE 2
6 464892-14 ELBOW 2
7 464892-15 HYD VIPER HOUSE KIT 1
8 465139-66 SCREW SERRATED WASHER 8
9 465139-158 SCREW SERRATED WASHER 2
10 465139-101 NUT 4
11 464892-19 WASHER 2
12 464892-20 LOCKNUT 2
13 464892-21 SELF THREAD HEX SCREW 6

S/N: 020-069

S/N: 020-069

DISCHARGE SYSTEM
1 464892-22 ELBOW 2
2 465139-31 OIL FILTER HEAD 1
(OLD P/N WAS 464692-23)
3 605479 OIL FILTER ELEMENT 1
4 464892-24 STREET PIPE ELBOW 2
5 464892-25 NIPPLE 1
6 464892-26 TEE 1
7 524671 FAN TEMP SWITCH 1
8 464892-27 OIL FILL W/VENT CAP 1
9 464892-28 O-RING ADAPTER 1
10 464892-29 90° ELBOW 2
11 524799 OIL LEVEL SIGHT GLASS 1
12 464892-15 HYD VIPER HOSE KIT 1
(OLD P/N WAS 464692-30)
13 464892-31 PLUG 1
14 605640 RELIEF VALVE 1
(OLD P/N WAS 605484)
15 465139-36 ELBOW 1
16 464892-33 RECEIVER 1
17 464892-34 MOUNTING BAND 2
18 465139-101 NUT 4
19 464892-36 SERRATED WASHER SCREW 6
20 465139-42 NIPPLE 1
21 605878 TEMP SWITCH 1
22 464892-38 TEE 1
23 464892-39 45° ELBOW 1
24 464892-40 CONNECTOR 1
25 464892-41 ELBOW 2
26 464892-42 HEAD 1
27 524814 ELBOW 3
28 464892-44 NIPPLE 1

S/N: 020-069
29 464892-45 TEE 1
30 464892-46 ORIFICE 1
31 464892-47 REDUCER 1
32 465139-26 90° ELBOW ADAPTER 1
33 524816-49 ELBOW 1
34 605482 REGULATOR VALVE 1
35 465139-13 TEE 1
36 605483 BLOWDOWN VALVE 1
37 605706 BLOWDOWN MUFFLER 1
(OLD P/N WAS 464892-51)
38 465139-18 PLUG 1
39 605480 SEPARATOR SPIN-ON ELEMENT 1
40 464892-53 PLATE SEPARATOR 1
41 465139-66 SERATED WASHER SCREW 1
42 464892-55 DISCHARGE OUTLET SUPPORT 1
43 465139-08 SERVICE VALVE 1
(OLD P/N WAS 464692-56)
44 465139-23 NIPPLE 1
45 465139-51 LOCKING NUT 4
46 464892-59 CARRIAGE BOLT 2
47 465139-47 WASHER 4
48 134435 20 AMP CIRCUIT BREAKER 1
49 464892-89 SCREW 2

S/N: 020-069

S/N: 020-069

COMPRESSOR/ INLET VALVE DRIVE ASSEMBLY
1 464892-62 FLEX AIR INLET HOSE 1
2 464892-63 COMPLETE AIR COMPRESSOR FILTER 1
3 524793 AIR FILTER ELEMENT 1
4 464892-64 INLET AIR CHECK VALVE 1
5 464892-65 SPRING CHECK VALVE 1
6 464892-66 AIR INLET SPRING RETAINER 1
7 464892-67 AIR INLET RETAINER RING 1
8 464892-68 AIR INLET PISTON SPRING 1
9 464892-69 INLET VALVE O-RING 1
10 464892-70 INLET VALVE PISTON 1
11 464892-71 INLET VALVE CYLINDER 1
12 464892-72 INLET VALVE ASSEMBLY 1
13 464892-73 BUSHING 1
14 464892-74 3-GROOVE PULLEY 1
15 464892-75 3-GROOVE PULLEY 1
16 464892-76 BUSHING 1
17 605481 DRIVE BELT 1
18 605673 COMPRESSOR 1
19 464892-77 NIPPLE 1
20 464892-05 TEE 1
21 464892-79 ELBOW 1
22 524814 ELBOW 1
23 464892-81 NIPPLE 2
24 534761 CHECK VALVE 1
(OLD P/N WAS 464892-82)
25 464892-83 90° ELBOW 1
26 464892-84 90° ELBOW 1
27 465139-20 TUBING 1
28 N/A FLEX LOOM A/R

S/N: 020-069

S/N: 020-069
MAIN FRAME ENCLOSE AND CONTROL SYSTEM
1 464892-86 CANOPY ASSEMBLY 1
2 464892-87 CANOPY, TIP UP 1
3 464892-88 SS HINGE 1
4 464892-89 SCREW 12
5 464892-90 WASHER 7
6 464892-91 LOCKING NUT 12
7 464892-92 RUBBER BUMPER 2
8 464892-93 DRAW RUBBER LATCH 2
9 465139-58 SCREW 8
10 465139-55 WASHER 8
11 464892-96 BOLT 1
12 464892-97 NUT 1
13 465139-137 CAPSCREW 6
14 465139-68 WASHER 6
15 465139-41 LOCKING NUT 6
16 464892-101 CAPSCREW 1
17 464892-102 HYD MOTOR MOUNTING ASSEMBLY BRACKET 1
18 605741 HYD MOTOR (OLD P/N WAS 464892-103) 1
19 464892-104 90° ELBOW 1
20 464892-105 90° ELBOW 1
21 465139-66 SERRATED WASHER SCREW 4
22 465139-101 FLANGE NUT 4
23 464892-104 37° UNION 1
24 464892-109 37° UNION 1
25 464892-110 BRACKET 1
26 464892-111 HYD FRAME ASSEMBLY 1
27 464892-31 PLUG 1
28 464892-113 LOCK WASHER 3
29 464892-114 CAPSCREW 3
30 464892-15 HYD VIPER HOSE KIT 1

S/N: 020-069
31 464892-115 RUBBER BUMPER 1
* 464892-117 DECAL,HIGH PRESSURE HYDRAULIC
* 464892-118 HARNESS

S/N: 020-069
17412
GROUNDING REEL & CLAMP
Page 1 of 1

464923 GROUNDING WHEEL W/ 75’ STAINLESS STEAL CABLE 1
605657 2 POINT CONTACT HAND CLAMP 1
Updated:
07/14/11
S/N: 020-069
DUNBAR CRANE TRUCK LINCOLN 17165
LUBE SYSTEM INSTALLATION Page 1 of 3
12
9
10 8
11
8
8 8
8 8 8
8
8 8
8
8 8
Updated:
10/18/12
S/N: 020-069

1 595135 LINCOLN QUICK LUBE, OUTLET 2
595140 LINCOLN QUICK LUBE, FERRULE 2
2 595135 LINCOLN QUICK LUBE, CLOSURE PLUG 2
595140 LINCOLN QUICK LUBE, GASKET 2
8 595141 LINCOLN QUICK LUBE, CLOSURE PLUG 13
595142 LINCOLN QUICK LUBE, GASKET 13
12 595131 LINCOLN QUICK LUBE 12V PUMP 1
595132 LINCOLN QUICK LUBE 12V TIMER 1
595255 LINCOLN QUICK LUBE 24V PUMP (INCLUDES TIMER)
Updated:
10/18/12
S/N: 020-069
8 595135 LINCOLN QUICK LUBE, OUTLET
595140 LINCOLN QUICK LUBE, FERRULE
(BOOM LIFT CYL PINS)
(BOOM TURRET ROTATION PIN)
(BASKET ROTATION PIN)
11 595131 LINCOLN QUICK LUBE, 12V PUMP
595132 LINCOLN QUICK LUBE, 12V TIMER
595255 LINCOLN QUICK LUBE, 24V PUMP (INCLUDES TIMER)
NOTE: ON TIME SETTING: 1 FOR 2 MINUTES

OFF TIME SETTING: 1 FOR 1 HOUR
Updated:
10/18/12
S/N: 020-069
S1094

Models 94012, 94024

CHASSIS LUBE ELECTRIC GREASE
PUMP

OWNER/OPERATOR MANUAL

DESCRIPTION
Do not use pump without pressure relief valve. The chassis tube pump is electrically operated and used in a
progressive type centralized lubrication system. The pump consists
SPECIFICATIONS of a pump housing, electric gear motor, a timer and a plastic
Electrical Requirements reservoir with stirring paddle. The high operating pressure allows
Model 94012 ................... 12 VDC @ 3.5 amps the pump to supply lubricant up to NLGI 2 grease.
Model 94024.................... 24 VDC @ 2 amps
Enclosure Rating............. IP 6K9K- Protected from water MOUNTING THE PUMP
sprayed in all directions. Select an easily accessible place of installation which allows
On Time ........................... 2 minutes minimum 30 minutes access to the timer and lubricant reservoir filler fitting. The pump
maximum in 2 minute must be mounted vertically on an even surface by means of two
increments bolts.
Off Time ........................... 1 hour minimum 15 hours
maximum in 1 hour increments TO FILL RESERVOIR
Pump Output ................... 0.171 cu. in./min (2.8 cc/min) Fill the reservoir through the grease fitting located at the base of
Outlet Connection............ 1/8" NPT (female) the reservoir, using a hand operated grease pump. Refill reservoir
Maximum Recommended when grease reaches “MIN” mark located on the reservoir. Fill the
Operating Pressure ..... 3600 psi (248 bar) Reservoir reservoir up to the “MAX” mark located on the reservoir.
Capacity.......... 122 cu. in. (2000 cc)

Lubricant.......................... Greases up to NLGI grade 2 (
depending on the operating TO PRIME SYSTEM
temperature and type of Pump & Supply Line: After reservoir has been filled with
lubricant) recommended lubricant, loosen the supply line fitting. Operate the
Temperature Range........ -13° F (-25° C) to +158° F pump until lubricant flows from outlet, then tighten fitting.
(+70° C)

Feed Lines: Pre-fill each feed line with lubricant before connecting
Pressure Relief Valve ........ 4000 psi +/- 250 psi
to outlet of divider valve and bearing.
(276 bars) +/- (17 bars)

S/N: 020-069
S1094
S/N: 020-069
CHASSIS LUBE ELECTRIC 17341
GREASE PUMP Page 1 of 3
Updated:
05/14/10
S/N: 020-069

595255 LINCOLN QUICK LUBE, 24V PUMP ASSEMBLY 1
595359 RESERVOIR KIT – INCLUDES ITEMS 1 & 7 1
595255-01 PADDLE KIT – INCLUDES ITEMS 2, 3, & 4 1
595255-02 BEARING & SEAL KIT – INCLUDES ITEMS 4-6, & 9-11 1
595255-03 24V MOTOR KIT – INCLUDES ITEMS 13-15, 26-28, & 35 1
595255-04 HOUSING SEAL KIT – INCLUDES ITEMS 15 & 27 1
595255-05 PUMP ELEMENT KIT – INCLUDES ITEMS 31-33 1
1 NSS RESERVOIR 1
(INCLUDED IN RESERVOIR KIT 595359)
2 NSS HOSE 1
(INCLUDED IN PADDLE KIT 595255-01)
3 NSS STIRRING PADDLE 1
(INCLUDED IN PADDLE KIT 595255-01)
4 NSS WASHER 1
(INCLUDED IN PADDLE KIT 595255-01 & BEARING &
SEAL KIT 595255-02)
5 NSS BEARING RING 2
(INCLUDED IN BEARING & SEAL KIT 595255-02)
6 NSS BEARING 1
7 595255-06 O-RING 2
8 595255-07 INTERMEDIATE PLATE 1
9 NSS SHIM 1
10 NSS SNAP RING 2
11 NSS INNER RING 1
12 595255-08 ECCENTRIC CAM 1
13 NSS CAPSCREW 3
(INCLUDED IN 24V MOTOR KIT 595255-03)
14 NSS WASHER 3
15 NSS O-RING 3
(INCLUDED IN 24V MOTOR KIT 595255-03 & HOUSING
SEAL KIT 595255-04)
16 595255-09 PUMP HOUSING 1
17 595255-10 CLOSURE PLUG
Updated:
05/14/10
S/N: 020-069

18 595255-11 3 WIRE POWER CORD/PLUG 1
21 595255-12 SEALING PLUG 1
22 595255-13 NIPPLE 1
23 595255-14 CAPSCREW 10
24 595255-15 GREASE FITTING 1
25 595255-16 PRINTED CIRCUIT BOARD 1
26 NSS WOODRUFF KET 1
27 NSS RADIAL SEAL 1
(INCLUDED IN 24V MOTOR KIT 595255-02 & HOUSING
SEAL KIT 595255-04)
28 NSS 24 VDC MOTOR 1
29 595255-17 HOUSING COVER 1
31 NSS CHECK VALVE 1
(INCLUDED IN PUMP ELEMENT KIT 595255-05)
32 NSS PUMP ELEMENT 1
33 NSS GASKET 1
34 595255-18 PRESSURE RELIEF ASSEMBLY 1
35 NSS PLUG FOR MOTOR 1
36 595255-19 GREASE CAP 1
37 NSS ADAPTER FOR RELIEF ASSEMBLY 1
38 NSS INNER RING 1
Updated:
05/14/10
S/N: 020-069

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4MANUAL

INDEX A64 ExC

1. INTRODUCTION /GENERAL INFORMATION

F1008 PARTS ORDER INSTRUCTIONS

10368 SIGHT GAUGE

3. ELECTRICAL SYSTEM AND INSTRUMENTS

30343 WIRING DIAGRAM S

4. ENGINE AND ACCESSORIES

F1017 ENGINE OPERATION & MAINTENANCE MANUAL

S1005 TRANSMISSION MAINTENANCE & SERVICE

S1165 AXLE SERVICE & REPAIR MANUAL

S1163 BRAKE VALVE SERVICE

310-020-014 HYDRAULIC SCHEMATIC

13905 ELECTRIC SHIFTER

10. MOUNTED EQUIPMENT

17437 FIRE EXTINGUISHER & BRACKET #10

1. INTRODUCTION /GENERAL INFORMATION

F1008 PARTS ORDER INSTRUCTIONS

• Truck model and serial number

MODEL SERIAL NO.

A64 ExC 3000 020-069

BANGOR, MICHIGAN U.S.A

1. Parts shipped or ordered in error and/or duplicated orders

 Getman part number and part description

We are flexible and can design training to fit your needs.

i) Utility Vehicles (excluding other categories listed below):

ii) Scissor Lift arm assemblies:

iii) Spare Parts:

Genuine GETMAN CORPORATION authorized parts:

Three (3) months from date of purchase.

iv) Engines, Batteries, Tires and other:

6 Exclusions. This Warranty does not cover:

v) damage caused by negligence or failure of Purchaser to maintain the equipment in accordance

8 Limitations. Under no circumstances and in no conditions shall GETMAN CORPORATION's

9 Timing. On receipt of notification of a warranted defect, GETMAN CORPORATION shall remedy

i) Copy of invoice or order number; or

ii) Job Charge out report.

i) refunding the purchase price of the part; or

14 Appeals. APPEAL PERIOD FOR GETMAN CORPORATION’S DECISION RESOLVING A

DATE_________________ SERVICE TECHNICIAN NAME_____________________________

CUSTOMER/DEALER NAME_______________________ PHONE NUMBER_______________________

CUSTOMER MINE SITE LOCATION_________________________________________________________

GETMAN REPRESENTATIVE AUTHORIZING RETURN______________________________________

MACHINE SERIAL NUMBER____________________________________

PART NUMBER OF FAILED PART__________________________________________________

MACHINE COMMISSION DATE/PART INSTALLATION DATE_______________________________

DATE MACHINE/PART FAILED_________________________________

DATE PART WAS REPLACED__________________________________

ORIGINAL PART INVOICE # (If Available) ________________________________________

PLEASE PROVIDE AS MUCH DETAIL AS POSSIBLE TO HELP FUTURE VEHICLE IMPROVEMENTS

Model: A64 ExC 3000 Serial No.: 020-069

Customer: PENOLES (TOPO)

COMPONENT MANUFACTURER MODEL SERIAL NUMBER GETMAN PART NUMBER

†COMMON MAINTENANCE ITEMS

ENGINE OIL FILTER P/N: 150019-G

PART NO: DESCRIPTION QTY

250 Hour Service

Quantities Based on 2000 Hrs

QSB 4.5L Engine Installation

Air Intake Installation

Clark 32K Transmission

Seats & Seat Belts

Wheel & Tire Assembly*

DATE_ SERVICE TECHNICIAN NAME_____________

CUSTOMER/DEALER NAME_ PHONE NUMBER_