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020-001 Manual Exc 2-500L
020-001 Manual Exc 2-500L
2. CHASSIS
5. DRIVE TRAIN
17193 TRANSMISSION
13436 TRANSMISSION MOUNTS
17331 TRANSMISSION DIPSTICK
S1005 TRANSMISSION MAINTENANCE & SERVICE MANUAL
13675 DRIVELINE INSTALLATION
6. AXLE
7. BRAKE SYSTEM
8. HYDRAULIC SYSTEM
9. CONTROLS
• BILLING INSTRUCTIONS.
Updated:
04/16/10
F1000
Limited Warranty
Getman Corporation warrants each new vehicle manufactured by it to be free from defects in materials and
workmanship for one (1) year or two thousand (2,000) hours of operation (whichever occurs first) from the
date of delivery to the first user, excepting the vehicle mainframe which is warranted to be free from defects
in materials and workmanship for five (5) years or ten thousand (10,000) hours of operation (whichever
occurs first).
This warranty is limited to the replacement or repair, at Getman’s factory or at a point designated by Getman,
of such part which is found by Getman, after inspection, to be defective in materials or workmanship. Repair
parts provided under this warranty are warranted for the remainder of the warranty period of the vehicle to the
same extent as if such parts were original components thereof.
This warranty does not apply to:
1. Engines, tires, batteries, or other components which are warranted directly to the user by the
respective manufacturers thereof;
2. Any vehicle or component which has been repaired or altered in such a way, and in Getman’s
judgment, as to affect the product adversely;
3. Any vehicle or component which has, in Getman’s judgment, been subject to negligence, accident or
improper storage or usage;
4. Any vehicle which has not been operated and maintained in accordance with normal practices and
within the recommendations of Getman; and
5. Any vehicle or component or accessory manufactured by others and supplied by Getman on special
order by the first user.
This warranty does not obligate Getman to bear the costs of labor or transportation charges in connection with
the replacement or repair of defective vehicles or parts.
ALL WARRANTIES IN THIS AGREEMENT ARE IN LIEU OF ANY OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SAID WARRANTIES BEING
EXPRESSLY DISCLAIMED.
GETMAN WILL NOT BE LIABLE FOR ANY LOSS, DAMAGE OR INJURY RESULTING FROM
DELAY IN DELIVERY OR INSTALLATION OF THE GOODS OR FOR ANY FAILURE TO PERFORM
WHICH IS DUE TO CIRCUMSTANCES BEYOND ITS CONTROL. THE MAXIMUM LIABILITY, IF
ANY, OF GETMAN FOR ALL DAMAGES, INCLUDING WITHOUT LIMITATIONS CONTRACT
DAMAGES FOR INJURIES TO PERSONS OR PROPERTY, WHETHER ARISING FROM GETMAN’S
BREACH OF THIS AGREEMENT, BREACH OF WARRANTY, NEGLIGENCE, STRICT LIABILITY,
OR OTHER TORT WITH RESPECT TO THE GOODS, IS LIMITED AS OTHERWISE PROVIDED
HEREIN. IN NO EVENT SHALL GETMAN BE LIABLE TO BUYER FOR ANY INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES, INCLUDING WITHOUT LIMITATION LOST
REVENUES AND PROFITS, EVEN IF IT HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH
DAMAGES. THE RIGHT TO RECOVER DAMAGES WITHIN THE LIMITATION SPECIFIED IS
BUYER’S EXCLUSIVE ALTERNATIVE REMEDY IN THE EVENT THAT ANY OTHER
CONTRACTUAL REMEDY FAILS OF ITS ESSENTIAL PURPOSE.
Any dispute arising out of or relating to an alleged breach of this warranty shall be submitted for resolution to
arbitration. Such arbitration shall be conducted according to the rules of the American Arbitration
Association, and any reward shall, if deemed necessary by either party, be submitted to the appropriate
judicial body for confirmation as a judgment to such judicial body.
Getman Corporation, 59750 34th Avenue, Bangor, Michigan 49013, U.S.A./ Telephone: (269) 427-5611/ Facsimile: (269) 427-8781/ E-mail: info@getman.com.
® Registered Trademark of Getman Corporation
F1009
COMPONENT LIST
Page 1 of 1
Model: 2-500L ANFO CHARGER Serial No.: 020-001
OPTIONS:
ROTATION GEAR GEAR PRODUCTS 010-00008-1 594869 554302-002
BOX
ROTATION GEAR EATON N/A 534214 101-1083-009
B0X MOTOR
MAN BASKET GETMAN N/A 12275-01 N/A
COMPRESSOR VIPER 125CFM 465139 30-76628
ANFO POT (D.S) BAYCAR 1060LBS 465562 D-136-51-3240-01
ANFO POT (P.S) BAYCAR 1060LBS 465562 D-136-10-2663-01
BASKET ROTATOR HELAC HP15 594634 N/A
ROTATION GEAR PRODUCTS 449 594868 552852-002
BEARING
SAFETY VALVE DEPATIE FLUID V120 605582 C10 K4285
(ANFOR TREE D.S)
SAFETY VALVE DEPATIE FLUID V120 605582 C10 K4284
(ANFO TREE P.S)
SAFETY VALVE DEPATIE FLUID V150 605586 V10 DD9 19667
(AIR TANK)
SAFETY VALVE DEPATIE FLUID V175 605640 J659
(COMPRESSOR)
†COMMON MAINTENANCE ITEMS
AIR FILTER ELEMENT (PRIMARY) P/N: 604711
AIR FILTER ELEMENT (SECONDARY) P/N: 604709
ENGINE OIL FILTER P/N: 146000
FUEL FILTER P/N: 146001
FUEL WATER SEPERATOR P/N: 146022
TRANSMISIÓN FILTER P/N: 24069
HYDRAULIC FILTER ELEMENT P/N: 534691
FAN/ALT BELT P/N: 9041-10013
*WHEN ORDERING PARTS, ALWAYS GIVE MODEL AND SERIAL NUMBER OF UNIT. Updated:
†SEE MAINTENANCE SECTION IN MANUAL FOR SERVICE INTERVAL ON THESE ITEMS 06/15/10
OPERATING AND MAINTENANCE M1040
MANUAL FOR MODEL A-64 CHASSIS Page 1 of 33
GETMAN CORPORATION
FOR
MODEL A-64 CHASSIS
EQUIPPED WITH
465313-100-OV DASH PANEL
MERCEDES or CUMMINS ENGINE
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MANUAL FOR MODEL A-64 CHASSIS Page 2 of 33
TABLE OF CONTENTS PAGE INTRODUCTION
Introduction 2
Related Manuals 2 This manual is a guide to proper, safe operation, maintenance,
General Description 3 and minor adjustment of the Getman A-64 Chassis. Each
General Safety Precautions 3-5 operator assigned to this vehicle should study this manual
Safety Alert Symbol 3 carefully before starting or operating the vehicle in order to
Rules 4 become familiar with all the controls and procedures.
Parking Procedure 5
Service Positions 5 Getman A-64 Chassis are purchased with the expectation that
Fuel Shut Off 5 it will provide long and faithful service. In its construction,
Canopy 5 we have taken every precaution to see that you receive an
Name, Warning, and Caution Plates 6 efficient, long-lived, satisfactory vehicle. However, to realize
Caution Statement 7-8 the full measure of value and utility that Getman has designed
Electrical System Safety 8 into this unit, a small amount of time and expense must be
Safety w/ Fuel, Oils, & invested in the performance of regular inspections and service
Coolant 8 as recommended in this manual. The small investment will
Instrument Panel Descriptions 9-10 pay off in low operating costs, minimal service expenses, and
Instrument Warning Panel 11 most importantly in personal safety.
Electronic Engine Data Display 12-13
Gauge Descriptions 14-15 RELATED MANUALS
Other Controls 15
Checks Before Startup 16 Engine operation manual is included with the Parts and
Starting Procedure 17 Service Manuals supplied with this vehicle. You should
Park Brake Test Procedure 18 become familiar with these manuals.
Service Brake Test 18
After Engine Starts 19 NOTE: For Cummins engine parts and service manuals not
Operating Vehicle 20 supplied, please see Section 4 of your truck Parts & Service
Towing Procedures 21-22 Manual for instructions.
Preparing a Vehicle 21
Transmission 21 Getman has increased the frequency of many recommended
Brake Release 22 maintenance procedures due to the vehicles demanding
Maintenance Schedule – As Required 23 application. These changes are noted at each maintenance
Maintenance Schedule – Daily 24-25 section end.
Maintenance Schedule – 50 Hours 26-27
ECS Catalytic Air Purifier or A complete parts listing of engine train components,
Diesel Particulate Filter 27 applicable Electric/Air/Hydraulic systems, and mounted
Maintenance Schedule – 250 Hours 28-29 equipment is included in the Parts and Service Manual. This
Maintenance Schedule – 500 Hours 30 manual also contains service and repair information useful to
Maintenance Schedule – 1000 Hours 31 maintenance department personnel.
Specifications 32
Fuel 32 If you have any questions about operating or servicing this
Tires 32 unit, contact your local Getman dealer or Getman Corporation
Pressures 32 direct, immediately.
Fluid Capacity Quick Reference Guide 33
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MANUAL FOR MODEL A-64 CHASSIS Page 3 of 33
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.
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.
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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.
• 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!
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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.
5. Block wheels.
4. Stop engine.
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.
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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.
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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.
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 system. This is considered to be a major fault which will
parking brake is engaged. When the parking brake is released require immediate attention. Shut down the engine as soon as
to set the vehicle in motion, this light will not be illuminated. possible and notify maintenance.
FRONT AND REAR BRAKES: Two individual lights are BRAKE IMPENDING (OPTIONAL): This light
in the display to provide the operator with information illuminates when transmission/ converter pressure drops to
regarding possible auto brake application. These lights are an 75PSI. Auto brake application occurs when transmission/
indication that less than 1100 PSI exists in either the forward converter pressure drops to 60 PSI.
or rear brake circuit. Auto brake application occurs when
brake system pressure falls below 1100 PSI. Trucks equipped DECLUTCH: This light illuminates when the transmission
with Brake Impending option, auto brake application occurs selector is disabled. Depending on options chosen, the
when hydraulic pressure in either front or rear brake circuit following can activate the declutch option.
falls below 1200 PSI. 1. Parking Brake is “ON”.
2. Diverter valve is in Accessories mode.
POWER ON LIGHT: The power light is an indication that 3. Stabilizer Jacks are not fully retracted.
the ignition switch has been turned to the “ON” position. It 4. Man basket is not stowed level on deck.
will remain illuminated until the ignition is turned off. 5. Scissor deck is in elevated position.
CHECK ENGINE: This light illuminates in the event of an TRANSMISSION: This light illuminates in the event of low
engine fault being detected by the engine electronic control hydraulic oil pressure or high transmission temperature.
system. This is normally considered to be a minor fault where
attention should be attended whenever possible.
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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
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GAUGE DESCRIPTIONS (CONTINUED)
OTHER CONTROLS
Accelerator Pedal (Not Shown) - Push to increase engine
RPM.
WARNING
Never free wheel vehicle. Free wheeling
will cause serious injury and damage
vehicle.
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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 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.
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.
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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.
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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.
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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”.
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.
NOTE: Lack of engine power and/or excessive exhaust smoke is signs the air filter elements may require service.
Check service indicator. Clear dust collector discharge slot daily. Service air cleaner only when indicator locks in red position.
Proceed as follows:
Loosen cover clamp by unscrewing support clamp and remove cover. Unscrew filter support thumbscrew and remove and discard
primary filter element. Clean inside housing. Install new element.
Check cover gasket to ensure a good seal. Reposition cover and thumbscrew. Reset service indicator.
Replace safety filter element every 5th primary filter change. Safety filter element is replaced in same manner as primary element
change.
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MAINTENANCE SCHEDULE – DAILY OR EVERY SHIFT CHANGE
Place vehicle in service position.
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MAINTENANCE SCHEDULE – DAILY OR EVERY SHIFT CHANGE (CONTINUED)
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MAINTENANCE SCHEDULE – EVERY 50 OPERATING HOURS
Place vehicle in service position.
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.
WARNING
Flammable Solution. Use in accordance
with manufacturers recommendations.
Use in a properly ventilated area.
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MAINTENANCE SCHEDULE – EVERY 250 OPERATING HOURS
Place vehicle in service position.
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MAINTENANCE SCHEDULE – EVERY 250 OPERATING HOURS (CONTINUED)
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MAINTENANCE SCHEDULE – EVERY 500 OPERATING HOURS
Place vehicle in service position.
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.
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MAINTENANCE SCHEDULE – EVERY 1000 OPERATING HOURS
Place vehicle in service position.
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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 16 SMC 95 6.5
9.00X20 12 LCM 90 6.1
NOTE: This chart indicates tire pressure specifications only. The sizes are not interchangeable. Always replace with tires of same
size, type, and ply rating originally supplied with vehicle
PRESSURES
TYPE PSI BAR
Engine Oil Pressure at 1000 RPM 45-60 3.1-4.1
Steering Hydraulic System at low idle with 1500-2000 103-138
vehicle turned and against stops.
Hydraulic brake charging pressure.
John Deere Axles 1650-2200 114-151
Ford/New Holland D45 & D65 1650-2200 114-151
Pressure from brake treadle valve.
John Deere Axles 1000 69.0
Ford/New Holland D45 & D65 1500 130.5
NOTE: Checks made at 150°F (65°C) oil temperature.
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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 F4L912 W/O FILTER (OIL) 3.2 W/O FILTER (OIL) 12
W/ FILTER (OIL) 3.6 W/ FILTER (OIL) 13.5
DEUTZ F5L912 W/O FILTER (OIL) 3.6 W/O FILTER (OIL) 13.5
W/ FILTER (OIL) 3.8 W/ FILTER (OIL) 14.3
DEUTZ F6L912 W/O FILTER (OIL) 4.1 W/O FILTER (OIL) 15.5
W/ FILTER (OIL) 4.4 W/ FILTER (OIL) 16.5
DEUTZ F3L913 W/O FILTER (OIL) 2.1 W/O FILTER (OIL) 8
W/ FILTER (OIL) 2.6 W/ FILTER (OIL) 9.8
DEUTZ F4L913 W/O FILTER (OIL) 3.2 W/O FILTER (OIL) 12
W/ FILTER (OIL) 3.6 W/ FILTER (OIL) 13.5
DEUTZ F6L913 W/O FILTER (OIL) 4.2 W/O FILTER (OIL) 16.5
W/ FILTER (OIL) 4.9 W/ FILTER (OIL) 18.5
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
W/ FILTER (OIL) 3.3 W/ FILTER (OIL) 12.5
DEUTZ BF8M2012C W/O FILTER (OIL) 3.3 W/O FILTER (OIL) 12.5
W/ FILTER (OIL) 3.7 W/ FILTER (OIL) 14
TRANSMISSION
MANUFACTURER MODEL GALLONS LITERS
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
MANUFACTURER MODEL GALLONS LITERS
NEW HOLLAND D65 7.3 27.4
NEW HOLLAND D45 5.8 21.8
JOHN DEERE TMII 1200 5 18.9
NAF BOGIE GTM 01 3.2 12
NOTE: This should only be used as a reference, fluid requirements may very. Refer to component page in manual to determine
which components are equipped with your truck. For further information, see operation/ service manuals for each component or
contact Getman Corp direct.
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A-64 ANFO CHARGER OPERATING AND M1006
INSPECTION MANUAL Page 1 of 17
GETMAN CORPORATION
FOR
A-64 ANFO CHARGER
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A-64 ANFO CHARGER OPERATING AND M1006
INSPECTION MANUAL Page 3 of 17
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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GENERAL SAFETY PRECAUTIONS
SAFETY ALERT SYMBOL • Always lower ground engaging implements and
utilize wheel chocks when vehicle is parked.
This symbol will appear at various points • If parking on a grade is unavoidable, point the
throughout the manual in conjunction with vehicle towards the rib, engage the parking brake,
warning statements. Its appearance means: lower all ground engaging implements and utilize
ATTENTION! BECOME ALERT! wheel chocks.
YOUR SAFETY IS INVOLVED! • Avoid smoking or open flame around fuel.
• Always be aware of location of nearest fire
This manual also uses the following messages: extinguisher.
• Check operation of brake circuit prior to beginning of
NOTICE: Used for special information or instructions, each shift.
relating to procedures, equipment, tools, and other special • Never utilize a vehicle for an application other than it
data. was originally designed for.
• Watch out for others. They may not be watching out
IMPORTANT: Used when special precautions should be for you!
taken to ensure correct action or to avoid damage to or
malfunction of equipment. SAFETY INSTRUCTION
CAUTION: Used as a reminder of safety hazards which can WARNING
result in personal injury if proper precautions are not taken. ANFO IS A HIGHLY EXPLOSIVE
MATERIAL!
WARNING: Used when a hazard exists which can result in All safety regulations must be followed
injury or death if proper precautions are not taken. during it’s use. The Operating Procedures
in this manual are intended for general
DANGER: Used when an extreme hazard exists which can information only! Obtain approval safety procedures and
result in serious injury or death if proper precautions are not practices from your safety inspector and material supplier.
taken.
Always wear safety glasses and gloves when operating or
RULES working near compressed air and anfo products.
Before performing any maintenance on the vehicle, review the Never disconnect any compressed air hoses or fittings when
following safety precautions. These are included for your under pressure
protection and safety.
WARNING
Always observe the following general safety rules during HAZARDS OF STATIC
operation of the vehicle. Also observe the safety rules set ELECTRICITY
forth in the work place. The need for additional rules for safe USE ONLY APPROVED
operation may arise due to particular mine applications. This PROCEDURES FOR GROUNDING
should ONLY be used as guidance. PNEUMATIC LOADING VESSEL
AND USE ONLY APPROVED SEMI-CONDUCTIVE
• Read and carefully follow all instructions as outlined (ANTI-STATIC) ANFO PLACEMENT TUBING.
in the vehicle manuals.
• Ensure that all instruments, indicators, and operating
controls are functioning.
• Never utilize operating controls as hand holds to
assist entering or exiting a vehicle.
• Never stand when operating a vehicle in motion.
• Avoid wearing loose or baggy clothing when
working around engines or other rotating or moving
equipment.
• Never allow riders in vehicles not designated to carry
passengers.
• Never dismount from a vehicle unless brakes are set.
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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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NOTICE
STEERING IS DISABLED!
LEVER FUNCTIONS
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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.
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.
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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.
10. Remove all debris from truck, wash truck with water
and blow dry.
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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.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS. Updated:
02/22/10
A-64 ANFO CHARGER OPERATING AND M1006
INSPECTION MANUAL Page 13 of 17
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.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS. Updated:
02/22/10
A-64 ANFO CHARGER OPERATING AND M1006
INSPECTION MANUAL Page 14 of 17
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.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS. Updated:
02/22/10
A-64 ANFO CHARGER OPERATING AND M1006
INSPECTION MANUAL Page 15 of 17
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.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS. Updated:
02/22/10
A-64 ANFO CHARGER OPERATING AND M1006
INSPECTION MANUAL Page 16 of 17
• 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!!”
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS. Updated:
02/22/10
A-64 ANFO CHARGER OPERATING AND M1006
INSPECTION MANUAL Page 17 of 17
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.
*NOTE: TAGS ON EQUIPMENT MAY DIFFER FROM MANUAL. FOLLOW INSTRUCTIONS ON TAGS. Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 1 of 12
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.
Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 2 of 12
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.
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.
Throughout a Getman boom there are many different Pins and Bushings, it is imperative that all of them are
inspected properly in order to insure the safety and correct operation of the boom. See Figure 1 for general
location of boom pins.
1. Pins
a. Check pins for steps, grooves, or excessive wear. The pin should not be able to move up or
down in the bushing.
b. Have the pins tested for cracks using a Magnetic Particle test, or other nondestructive testing
method.
c. Replace bolts that hold pins in position.
d. Check bolt holes for worn threads or excessive slop.
2. Bushings
a. Replace all Removable Bushings.
b. Check welded bushings for excessive pin movement. The pin should not be able to move in
any direction perpendicular to the bore.
Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 3 of 12
WEAR PADS
When performing a detailed inspection of the Getman boom, involving the complete tear down of the assembly,
it is recommended that all the boom wear pads and their mounting bolts be replaced. The parts are relatively
inexpensive, and it is easy to do with the boom disassembled. See Figure 1 for general location of the wear
pads. See Figure 2 for Wear Pad Replacement Procedure.
Replacement of these wear pads should remove any excessive sag or movement in the boom, and will help
return it to proper working condition. If the wear pads are worn excessively to the point where the mounting
screws are contacting the boom, they must be replaced. This excessive wear can cause extreme damage to the
boom, and will result in failure.
WELDMENTS
A typical Getman Boom is composed of a turret, outer boom weldment, middle boom weldment, inner boom
weldment and basket. (See Figure 1) These weldments should all be inspected in depth for cracks, corrosion,
wear, and damage. Any components exhibiting these characteristics should be replaced, or properly repaired.
CORROSION
The affect of corrosion on a boom/ basket can dangerously fatigue the boom/ basket beyond repair. While
corrosion in some areas of the boom/ basket maybe less serious as others, it’s important that the boom/ basket
be relatively free of heavy corrosion if still in use. Getman suggests that the depth of corrosion, within 12
inches of the boom ends and on all pivoting components, be less then .01”. In the middle sections of the boom
where the stress on the sections is less, the corrosion can be as deep as .03”. However, with excessive
corrosion, the amount of material worn away maybe enough so that the depth of the corrosion maybe
inaccurately measured. A combination of excessive wear and corrosion can lead to failure. Getman
recommends that corrosion and wear be looked at carefully. Refer to the pictures in Figure 3 for examples of
excessive corrosion of the boom.
BASKET
The basket should be inspected regularly for bent supports, welds, corrosion, deformation, etc. See Figure 4 for
an example of a basket that is unsafe and needing replacement. If a basket has been deformed, it would be
recommended to inspect all pins, cylinders, and links on the boom for indications of damage.
FINAL INSPECTION
After the boom has been properly serviced and reassembled the boom / basket should be inspected again for
proper operation of hydraulic components. The boom/ basket should be tested with 150% of rated weight, for
proper range of motion and operation. With proper care and attention to these guidelines the Getman boom/
basket should be ready for safe use once again, however in some instances a boom/ basket may be beyond
economical repair, and should be removed from further use. If any questions or concerns arise during the
inspection please feel free to contact Getman Service for further assistance.
Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 4 of 12
FIGURE 1
Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 5 of 12
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.
PREPARATION
See Figure 3 for the following location points. Both the outer
boom (#10) and the middle boom (#25) have a slide pad (#22) on
the bottom end, and a set of side wear pads (#24). The slide pad is
attached to the bottom of the boom using a pin that is bolted in
place (#20 & #28). By putting the weight of the boom on the
basket, pressure will be relieved from the bottom slide pads and
they can be removed and serviced. The slide pads have wear pads
(#21) that can be replaced when needed. The side wear pads (#23)
can also be replaced as needed. Two bolts hold on the side wear
pads, when removed, the wear pads can be unbolted from the plate
and replaced. The replacement of the wear pads on the outside of
the boom is fairly simple, and will extend the life of the boom.
Failure to replace these pads before they are over worn can result
in extreme damage to the main boom assembly. The screws that
hold on the wear pads can cut deep grooves in the boom
components causing the boom to weaken.
FIGURE 2
Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 6 of 12
ANFO LOADER BOOM WEAR PAD REPLACEMENT PROCEDURE (CONTINUED)
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.
Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 7 of 12
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.
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.
FIGURE 2
Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 8 of 12
Extra Pictures
Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 9 of 12
FIGURE 2
Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 10 of 12
ITEM DESCRIPTION QTY.
BOOM ASSEMBLY 1
1 PIN (LEVELING CYLINDER) 2
2 CYLINDER (LEVELING) 1
3 TURRET 1
4 PIN (LIFT CYLINDER) 1
5 BUSHING (TURRET) 2
6 BOLT 8
7 BOLT 20
8 COVER 1
9 KEEPER 1
10 OUTER BOOM 1
11 LIFT CYLINDER 1
12 PIN (TURRET) 1
13 PIN (EXTENSION CYLINDER) 1
14 TRUNNION 2
15 ALLEN HEAD 2
16 PIN RETAINER 1
17 ALLEN HEAD (FLAT) 24
NUT 24
18 EXTENSION CYLINDER ASSEMBLY 1
19 PIN (LIFT CYLINDER) 1
20 PIN (SLIDE PAD) 1
21 WEAR PAD 12
SHIM A/R
22 SLIDE PAD 2
23 WEAR PAD 4
SHIM A/R
24 PAD ASSEMBLY 4
25 MIDDLE BOOM 1
26 INNER BOOM 1
27 ALLEN HEAD (FLAT) 8
NUT 8
28 PIN (SLIDE PAD) 1
Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 11 of 12
ITEM DESCRIPTION QTY.
29 PIN (LEVELING CYLINDER) 1
30 PIN (EXTENSION CYLINDER) 1
31 PIN (BASKET) (REF.) 1
32 BUSHING 2
33 ROTATOR 1
34 BOLT 3
35 WASHER 3
36 CYLINDER (LEVELING) 1
37 PIN (LEVELING) 3
38 LEVELING LINK 1
39 LEVELING LINK 1
40 BASKET 1
FIGURE 3
Updated:
02/22/10
GETMAN BOOM/ BASKET M1004
INSPECTION Page 12 of 12
FIGURE 4
Updated:
02/22/10
S1000
1/4" C 7/16 79 in 9 5
1/4" F 7/16 91 in 10 5
5/16" C 1/2 14 19 5
5/16" F 1/2 15 20 5
3/8" C 9/16 24 33 5
3/8" F 9/16 27 37 5
7/16" C 5/8 38 52 5
7/16" F 5/8 43 58 5
1/2" C 3/4 83 113 8
1/2" F 3/4 94 127 8
9/16" C 13/16 120 163 8
9/16" F 13/16 134 182 8
5/8" C 15/16 166 225 8
5/8" F 15/16 189 256 8
3/4" C 1 1/8 295 400 8
3/4" F 1 1/8 330 447 8
7/8" C 1 5/16 477 647 8
7/8" F 1 5/16 526 713 8
1" C 1 1/2 715 969 8
1" F 1 1/2 783 1062 8
1 1/8" C 1 11/16 1013 1373 8
1 1/8" F 1 11/16 1137 1542 8
1 1/4" C 1 7/8 1430 1939 8
1 1/4" F 1 7/8 1584 2148 8
1 3/8" C 2 1/16 1875 2542 8
1 3/8" F 2 1/16 2135 2895 8
1 1/2" C 2 1/4 2489 3375 8
1 1/2" F 2 1/4 2799 3795 8
1 3/4" C 2 5/8 3740 5071 8
1 3/4" F 2 5/8 4300 5830 8
2" C 3
2" F 3
2 1/4" C 3 3/8
2 1/4" F 3 3/8
2 1/2" C 3 3/4
2 1/2" F 3 3/4
2 3/4" C 4 1/8
2 3/4" F 4 1/8
3" C 4 1/2
3" F 4 1/2
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.
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
NOTE: THIS SHOULD ONLY BE USED AS REFERENCE, FOR SPECIFIC COMPONENT LUBRICATE SEE THAT COMPONENT’S OPERATION Updated:
MANUAL AND IF ANY QUESTION CONTACT GETMAN SERVICE BEFORE CHANGING/ADDING FLUID.
03/22/10
LUBRICANT CROSS F1003
REFERENCE Page 2 of 2
ENGINE & AIR CLEANER (OIL BATH) AXLES - FORD, JOHN DEERE, NAF, KESSLER
(Engine Manufacturers Specifications.)
NOTE: THIS SHOULD ONLY BE USED AS REFERENCE, FOR SPECIFIC COMPONENT LUBRICATE SEE THAT COMPONENT’S OPERATION Updated:
MANUAL AND IF ANY QUESTION CONTACT GETMAN SERVICE BEFORE CHANGING/ADDING FLUID.
03/22/10
GETMAN EQUIPMENT F1001
STORAGE PROCEDURES Page 1 of 1
IMPORTANT
The following instructions be followed as described in order to
keep your warranty valid.
ENGINE
Change oil using an oil with corrosion preventing TRANSMISSION & HYDRAULICS
properties of a least a HD-S1 oil. Listed are some No special care is required except exposed cylinder
of the oils that have been approved: Esso rods should be covered with grease.
MZ20X20V7N; Texaco EKM 162; Shell V6828.
AXLE
Change oil and fuel filters. Axle housings should be filled completely to
eliminate the change of moisture condensation.
Fill fuel tank completely with a mixture of diesel
fuel and 10% corrosion inhibiting motor oil. BRAKE SYSTEM
Drain all air reservoirs of moisture.
Run engine for at least 10 minutes to fill fuel lines
and filters, injection pump and nozzles with BATTERY
preservative mixture. Remove battery; clean off top, and store in a well-
ventilated battery storage area. Do not store on
If engine is to be stored over six months, seal intake concrete or metal.
and exhaust system to keep moisture out.
EQUIPMENT STORAGE FOR LESS THAN
THREE MONTHS
When storing equipment for less than three months,
vehicles should be started and driven for a
minimum of two minutes every two weeks.
Getman Corporation, 59750 34th Avenue, Bangor, Michigan 49013, U.S.A. Updated:
Telephone: (269) 427-5611/ Facsimile: (269) 427-8781/ E-mail: info@getman.com. 01/19/09
TROUBLESHOOTING CHECK F1002
LIST Page 1 of 2
CAUSE REMEDY
ENGINE OVERHEATS
Updated:
04/26/07
TROUBLESHOOTING CHECK F1002
LIST Page 2 of 2
3. PRESSURE OK BUT NOT ENGAGING 3. VERIFY CONTROL VALVE
CERTAIN GEARS ELECTRICAL SOLENOIDS
CONNECTIONS.
SEE “CONVERTER AND TRANSMISSION – SECTION 5” OF SPARE PARTS AND
MAINTENANCE MANUAL.
Updated:
04/26/07
PREVENTIVE MAINTENANCE F1004
SCHEDULE FORMS Page 1 of 5
SIGNATURE______________________________
DAILY SERVICES
Updated:
01/29/10
PREVENTIVE MAINTENANCE F1004
SCHEDULE FORMS Page 2 of 5
SIGNATURE______________________________
50 HOUR SERVICE
Updated:
01/29/10
PREVENTIVE MAINTENANCE F1004
SCHEDULE FORMS Page 3 of 5
SIGNATURE______________________________
Updated:
01/29/10
PREVENTIVE MAINTENANCE F1004
SCHEDULE FORMS Page 4 of 5
SIGNATURE______________________________
Updated:
01/29/10
PREVENTIVE MAINTENANCE F1004
SCHEDULE FORMS Page 5 of 5
SIGNATURE______________________________
Updated:
01/29/10
F1005
SERVICE REPORT FORM
Page 1 of 1
PARTS USED:
MAINTENANCE
PERSON’S SIGNATURE:________________________________________ DATE:___________________
SUPERVISOR’S
SIGNATURE:__________________________________________________ DATE:___________________
Updated:
04/26/07
F1006
SHIFT CHANGE CHECK LIST
Page 1 of 1
OK
1 CHECK FUEL OIL LEVEL
2 CHECK ENGINE OIL LEVEL
3 CHECK V-BELT CONDITION
4 CHECK HYDRAULIC OIL LEVEL
5 CHECK COMPRESSOR OIL LEVEL
6 CHECK CYLINDER PINS AND KEEPERS
7 CHECK ALL HYDRAULIC HOSES FOR LEAKS OR
WEAR
8 CHECK HORN AND LIGHTS
9 SECURE BIN DOOR
10 CHECK WHEEL LUG NUTS
11 CHECK FOR MISSING OR LOOSE NUTS, BOLTS OR
SCREWS
12 TEST PARKING BRAKE
Updated:
04/26/07
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
2. CHASSIS
Updated:
12/11/06
FILL CAP 10376
Page 1 of 1
Updated:
03/08/07
10398
FILL CAP (HYDRAULIC OIL)
Page 1 of 1
Updated:
12/11/06
10448
HOLD DOWN FASTENERS
Page 1 of 1
Updated:
10/17/07
12043
ARTICULATION JOINT
Page 1 of 3
Updated:
04/24/09
12043
ARTICULATION JOINT
Page 2 of 3
Updated:
04/24/09
12043
ARTICULATION JOINT
Page 3 of 3
2. JOINT ASSEMBLY: INSTALL BUSHINGS (TOP ITEM 3, BOTTOM ITEM 9) WITH PIN
(ITEM 10) AND CAP (ITEM 2) AND CAPSCREW (ITEM 14) TORQUE TO (100 LB. FT.) (135
N-M) AND MEASURE THE SPACE FOR THE NUMBER OF (5 ¾”) (145MM) B.C. SHIMS
REQUIRED. DISASSEMBLE AND INSERT THE REQUIRED SHIMS (LESS .010”) (.25MM)
REASSEMBLE AND TORQUE THE (ITEM 14) CAPSCREW TO (175 LB. FT.) (235 N-M),
AND LOCKWIRE THE BOLTS TOGETHER. INSTALL THE 6 CAPSCREWS (ITEM 13)
WITH LOCKTITE AND TORQUE TO (1OO LB. FT.) (135 LB. FT.). REPEAT PROCESS FOR
BOTH TOP AND BOTTOM OF JOINT.
Updated:
04/24/09
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
465313-100-OV
Updated:
12/14/06
S1100
PowerView™
Model PV-101
User’s Guide
Rev 09-10-08 00-02-0605
Catalog Section 78
S1100
In order to consistently bring you the highest quality, full
featured products, we reserve the right to change our
specifications and designs at any time. The latest version of
this manual can be found at www.fwmurphy.com.
1-Up Display
Three options are available for modification of the 1-Up
display.
Selecting a Language
From LANGUAGES, you may select ENGLISH, ESPANOL,
FRANCAIS, ITALIANO, or DEUTSCH. The currently
selected language is indicated by an asterisk.
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”)
Visual Indication
Fault Indicators
(1)
S1100
NOTES
Repairs Maintenance
To obtain warranty repairs, you must request the needed repairs DDC is not responsible for the cost of maintenance or repairs due to
within the WARRANTY PERIOD from an authorized Detroit Diesel lack of performance of required maintenance service or the failure to
Corporation (referred to as DDC)* service outlet. Only new genuine use fuel, oil, lubricants and coolant meeting DDC-recommended
parts or remanufactured parts or components supplied or approved specifications. Performance of required maintenance and use of
by DDC will be used. DDC may, at its discretion, replace rather than proper fuel, oil, lubricants and coolant are the responsibility of the
repair components. A reasonable time must be allowed to perform owner. See the Operating Manual for details.
the warranty repair. Repairs will be performed during normal busi-
ness hours. Incidental or Consequential Damages
DDC is not responsible for incidental or consequential costs or
Warranty Period expenses which the owner may incur as a result of a malfunction or
The WARRANTY PERIOD begins on the date the Engine is delivered failure covered by this warranty, such as communication expenses,
to the first retail purchaser or put in use prior to sale at retail, which- meals, lodging, overtime, towing, loss of use of the Engine or equip-
ever date occurs first, and ends at the time limits shown below: ment (“downtime”), loss of time, inconvenience, cargo loss or dam-
age, and other similar costs and expenses.
WARRANTY PERIOD Other Limitations
Warranty Limitations Repair Charge To Be
(Whichever Occurs First) Paid By Owner
The performance of REPAIRS is the exclusive Owner’s remedy under
Item this warranty. DDC does not authorize any person to assume or cre-
MONTHS ENGINE HOURS PARTS LABOR ate for it any other obligation or liability in connection with the Engine.
Engine 0-24 3,000 No Charge No Charge THIS LIMITED WARRANTY IS THE ONLY WARRANTY APPLICABLE
TO THIS ENGINE AS USED IN AGRICULTURAL, CONSTRUCTION
AND INDUSTRIAL APPLICATIONS. DETROIT DIESEL CORPORA-
Service Supplies TION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED,
INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FIT-
The cost of service supplies such as coolant, oil and filters, which are
NESS FOR A PARTICULAR PURPOSE. DETROIT DIESEL CORPO-
not reusable due to needed repairs is covered by this warranty.
RATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CON-
SEQUENTIAL DAMAGES AS DESCRIBED ABOVE.
Like Replacement Engine
Engine(s) supplied by DDC as a replacement for an Engine still Some states do not allow the limitation of how long this warranty may
under warranty will assume the identity of the Engine being replaced last or the limitation or exclusion of incidental or consequential
and be entitled to the remaining warranty coverage. damages, so the above may not apply to you. This warranty gives
you specific legal rights, and you may also have other rights which
Mechanic’s Travel Expenses may vary from state to state.
Mercedes-Benz will pay reasonable travel expenses for the repairing
mechanic to travel to and from the repair site.
17SE702 0202 Conditions of this offer are subject to change without notice. Printed in U.S.A.
S1034
Mercedes-Benz
S1034
Thank you for choosing this the art. You cannot, therefore, base any
Mercedes-Benz engine. claims on the data, illustrations or descrip-
tions in these Operating Instructions.
Please get to know your new Mercedes-
Benz engine first. Make sure you read the For further information contact a
Operating Instructions in particular before Mercedes-Benz Service Centre.
using the engine for the first time. In this
The Operating Instructions and Mainte-
way you can ensure successful and safe
nance Booklet belong with the engine. You
use. At the same time you will avoid endan-
should therefore always keep them with
gering yourself and others when operating
the engine and pass them on to the new
the engine.
owner if you sell it.
Items of special equipment are marked
The technical documentation team at
with an asterisk *. The equipment in your
DaimlerChrysler AG wishes you every suc-
Mercedes-Benz engine may vary, depend-
cess.
ing on the version. Mercedes-Benz is con-
stantly updating its engines to the state of
S1034
Symbols
T Symbols
You will find the following symbols used in ~ This symbol means that you have to do
1
....... these Operating Instructions: Environmental note something.
[>[>
page This symbol indicates the page
on which you will find further in-
formation on the subject.
This continuation symbol indi-
Warning cates an interrupted sequence
I
This tip contains advice or further infor- on the next page.
risks of accident and injury to yourself and mation you may find useful.
others. -> This symbol in the glossary of
technical terms means that the
You should therefore always read and ob-
term following the arrow is also
serve all warning notices.
explained.
S1034
Operating safety
T Operating safety
1 The operating safety of an engine firstly de-
...... pends on its proper installation into the Risk of accident Risk of accident
complete system (e.g. vehicle, machine,
etc.). Secondly, as operator or service per- Improper operation of the engine, e.g. ex- Faulty maintenance work or failure to carry
sonnel, you also have a direct influence on ceeding the permitted maximum engine out maintenance work, e.g. not changing the
the safe operation of the engine. speed in overrun mode or operating the en- oil filter or not observing the correct mainte-
gine with too little oil, can cause engine nance interval, can cause engine damage.
Some of the requirements for operating
damage. Engine damage can lead to an in- Engine damage can lead to an increase in
the engine safely can be achieved by ad-
crease in the risk of accident. the risk of accident.
hering to the specified maintenance inter-
vals and ensuring that the required Therefore, observe the notes on operating Therefore, observe the notes on engine
maintenance work is carried out correctly. the engine in these Operating Instructions. maintenance in these Operating Instruc-
tions.
However, safe engine operation also de-
pends on correct servicing, such as check-
ing the engine oil level at regular intervals.
S1034
Correct use
Risk of accident
The engine is only designed for installation
in accordance with the specifications de-
Work incorrectly carried out on electronic
termined in the contract.
components and its software could impair
the functioning of these components. Since The manufacturer of the end product is
the electronic systems are networked, this personally responsible for the complete
might also affect systems that have not system of the end product, and in particu-
been modified. lar for the correct installation and compat-
Always have work on or modifications to ibility of this engine with the complete
electronic components carried out at a qual- system.
ified specialist workshop which hasthe nec- The engine must not be modified.
essary specialist knowledge and tools to DaimlerChrysler accepts no responsibility
carry out the work required. for damage caused as the result of modifi-
Mercedes-Benz recommends that you use a cations.
Mercedes-Benz Service Centre for this pur- Correct use of the engine includes adher-
pose. ing to these Operating Instructions, adher-
ing to the maintenance intervals and
performing maintenance work correctly in
accordance with these Operating Instruc-
tions.
S1034
S1034
iocatron of sensors
Engine plate
S1034
7 )-------------..,..,..,.....-,
6 )------...."....~-----;,.:,;.
2
......
5)------~
41----------'
3)--------'
2 } - - -__-....::..,,-
CDl------......,.....~~
G01.00-3123-31
S1034
CD Fan
® Poly-V-belt tensioning pulley
o Coolant pump
@ Charge pressure pipe (with flame-start 2
system *) from intercooler
® Charge pressure pipe to intercooler
@ Crankcase ventilation system
(}) Heating delivery line* coolant line
® Oil filler neck
® Fuel filter
® Fuel prefilter
® Dipstick
@ Air compressor (with power-steering
pump*)
@ Engine control unit
S1034
®l----------==-~
2 }---------------=~ ___
0-----4--
G01.0D-3124-31
S1034
CD Flywheel housing
CD Charge-air housing
® Oil filler neck
8) Charge pressure pipe to intercooler
® Charge pressure pipe (with flame-start
system*) from intercooler
@ Exhaust manifold
o Oil filter
® Exhaust gas turbocharger
® Alternator
@ Starter motor
S1034
®r----------------. ':::::::==""'""-----~10
®r-------------F.~___::'
..... 01--------~ -----~11
"------....{12
::!.----~13
GOl.OO-3121-31
S1034
CD Fan
(3) Poly-v-belt tensioning pulley
@ Coolant pump
o Heating forward line* coolant line
® Charge pressure pipe from intercooler
@ Oil filter
o Charge pressure pipe to intercooler
® Oil filler neck
® Charge-air housing
® Cylinder head cover
® Fuel filter
@ Fuel prefilter
@ Engine control unit
@ Air compressor*
@ Dipstick
@ Power-steering pump
S1034
2
......
G01.00-3122-31
S1034
CD Starter motor
CD Flywheel housing
o Exhaust gas turbocharger
o Exhaust manifold
CD Charge-air housing
@ Cylinder head cover
CD Oil filler neck
® Charge pressure pipe to intercooler
® Charge pressure pipe from intercooler
@ Crankcase ventilation system
® Alternator
S1034
G01.0D-3127-31
S1034
Engine plate
T Engine plate
Location
The engine plate is located on the right-
hand side of the engine at the rear under-
-
2 neath the exhaust manifold (arrow).
T General
Type designation
OM 9XX L A
--
3
9XX
L
Engine type
Intercooler
A Exhaust gas turbo-
charger
Flame-start system *
The flame-start system is a cold-start aid
for starting at low outside temperatures. It
reduces the white smoke emission after
the engine is started. In addition, it reduc-
3 es the strain on the starter motor and bat-
..... teries by shortening the startup time.
Fuel can be ignited by a flame glow plug in-
tegrated in the charge-air pipe from the in-
tercooler. The fuel is supplied to the flame
glow plug via a solenoid valve with a dosing
jet.
854.30-3770-31
The flame-start system is primed after a The flame-start system is only operational
preglow time (maximum 20 seconds) if the engine is started within 30 seconds
which is dependent on the outside temper- of the flame-start system indicator lamp
ature. After this time the flame-start sys- going out.
tem indicator lamp goes out.
Once the engine has started, the flame-
start system is supplied with fuel by the en-
gine's fuel delivery pump.
S1034
Grid heater*
If the flame-start system indicator lamp The grid heater is a cold-start aid for start-
does not go out after more than 20 sec- ing at low outside temperatures. The
onds there is a malfunction in the charge-air is preheated by a heater strip in-
flame-start system. tegrated in the charge-air pipe from the in-
tercooler. In addition, it reduces the strain
See also the "Diesel fuels" section on the starter motor and battery by short-
(I> see page 60) and "Coolant" section ening the startup time.
(I> see page 63) for operation of the en-
The white smoke limit is reduced by a run-
gine at low outside temperatures.
on heating time of up to 180 seconds after
starting the engine.
S1034
Engine control unit (engine-resident) This data is evaluated along with data from
the sensors on the engine, such as those
The engine control unit is located on the DaimlerChrysler
for:
left-hand side of the engine. Elect. Control Unit
It charge-air pressure and temperature Calibration Nr. ZGS
G)----H6 I 0011
It coolant temperature ,,; I ,certification Nr.
2
It fuel temperature Unit Identif.
Engine Number
oil pressure
~;-:n7,"it-;:c'"o-;d~e------l
8
FR (drive control) unit or ADM The FR (drive control) unit and the ADM re-
(appliance-resident) ceive data from the
The engine can be adapted to meet the • operator (position of setpoint value
various application-specific requirements sensor, engine start/ stop)
by means of the FR (drive control) unit or
• engine brake switch"
adaptation module (ADM).
3
• other systems (e.g. traction control) .......
IJI engine control unit (e.g. oil pressure
and coolant temperature)
From this data, the instructions for the MR
(engine control) unit are computed and
transmitted to it via the CAN line.
The drive control unit and the ADM control
various displays, e.g. the electronics warn-
N15.00-2089-31
ing lamp, the engine brake * and the con-
stantly-open throttle valves*.
Drive control unit
If the Telligent'" engine system detects a The Operating Instructions and Mainte-
fault, this is stored as a fault code in the nance Booklet must be given to the per-
control units and can be read using the ap- sonnel responsible for operating the
propriate diagnostic equipment (STAR engine or carrying out work on the engine,
DIAGNOSIS or Minidiag 2). and should be kept in an easily accessible
place where the engine is used.
3 In addition, the electronics warning lamp is
_ switched on. Personnel must be instructed in how to
work on the engine using these Operating
Instructions. In particular, the safety notes
N54.22-2015-31
The DaimlerChrysler diagnostic testers must be explained. This is especially im-
can be connected to the equipment- Diagnostic socket
portant for personnel who only work on the
resident, 14-pin diagnostic socket. engine occasionally.
Both the malfunction memory and the Organisational measures
In addition to these Operating Instructions,
stored engine data can be read with
the country-specific legal and all other
this equipment. Risk of accident and injury .&. binding regulations for accident prevention
and protection of the environment must be
Before operatingthe engine, please read
observed.
these Operating Instructionsand other rele-
vant documentation, such as the operating
instructions for the vehicleor the machine
the engine is installed in.
You could otherwise fail to recognise dan-
gers and could injure yourself or others.
S1034
Installation
The engine is only designed for installation
in accordance with the specifications de-
termined in the contract.
The manufacturer of the end product is
3 personally responsible for the complete
..... system of the end product, and in particu-
lar for the correct installation and compat-
ibility of this engine with the complete
system.
Observe the "Correct use" (I> page 9) and
"Conversion parts and modifications to the
engine" (l> page 38) sections.
These Operating Instructions contain in-
stallation data in the "Technical data" sec-
tion.
Should you have any questions, please
contact a Mercedes-Benz Service Centre.
·ul"ming program
'i: "
~~~~-!3~n~ pints
-~1' .~' - -, ;
S1034
Safety precautions
"if' Safety precautions
Make sure that the following safety pre-
cautions are observed to prevent injury to
Note that for electric welding work, • Only use suitable test leads (e.g.
persons as well as damage to the engine,
the batteries must be disconnected DaimlerChrysler connection set) for
components and cable harness.
and both connector leads ("+" and measuring connectors.
"_") securely connected to each
• Telephones and two-way radios
other.
• Only start the engine with securely which are not connected to an ex-
connected batteries. III The control unit connectors must ternal aerial can cause malfunc-
only be removed or inserted when tions to the vehicle's electronics
• Do not disconnect the batteries
the electrical system has been and could therefore endanger the
with the engine running.
switched off. engine's operating safety.
• Only start the engine with the rota-
• Incorrect polarity of the control unit
tional speed sensor connected.
supply voltage (e.g. through incor-
',,' III Do not use a rapid charger to start rect battery polarity) can cause ir-
the engine. reparable damage to the control
• Only perform jump-starting with units.
separate batteries. • Tighten the connections to the fuel-
Please note that the battery termi- injection system to the specified
nals must be removed for rapid bat- tightening torque.
tery charging. Observe the rapid • The control units must be removed
charger operating instructions. if temperatures over 80°C (e.g. in
the drying oven) are expected.
S1034
Risk of accident
Tampering with the fuel-injection sys-
tem and engine electronics can affect
Tampering with the engine with the inten-
the engine's performance and emis-
tion to produce modifications to it can im-
sions characteristics. Compliance with
pair both its correct operation and its safety,
the factory settings and legal environ-
leading to personal injury as a consequence.
mental protection conditions can then
Always have work on or modifications to the no longer be guaranteed.
engine carried out at a qualified specialist
4
...... workshop which has the necessary special-
ist knowledge and tools to carry out the
work required.
-
• cause a deterioration in exhaust gas
emission levels or noise levels,
will result in the invalidation of the General
Operating Permit (in many countries). The
use of non-approved parts can impair safe-
ty.
Environmental note
Commissioning
'If Commissioning
When it leaves the factory, the engine is o Coolant composition (I> see page 63)
filled with engine oil in accordance with It Filling the cooling system
Sheet 228.5 ofthe Mercedes-Benz Service (I> see page 94).
Product Guidelines.
These high-quality engine oils assist the
running-in process, enabling the first oil
change to take place at the usual oil
change intervals for normal operation. This
eliminates the need for special initial oper-
ation oils and the oil change otherwise re-
~ quired.
The extended maintenance intervals can
be observed if engine oils in accordance
Oil filler neck
with Sheet 228.5 of the Mercedes-Benz
Specifications for Service Products are ~ Check the oil level and add engine oil if
used. necessary via the filler neck (arrow) up
to the maximum mark on the dipstick
(I> see page 71).
S1034
There is a danger of limbs being caught, en- The cooling system is pressurised. Hot cool- There is a risk of poisoning if coolant is swal-
trapped, crushed or torn off by rotating en- ant can spray out when the cooling system lowed.
gine parts. Therefore you should: is opened and scald your skin and eyes. It Never swallow coolant.
.. Keep a safe distance between yourself .. Only open the cooling system at coolant It Never put coolant into container nor-
and rotating engine parts, including temperatures below 90 °G. mally used for beverages.
when the engine is being started. .. Unscrew the sealing cap slowly and re- • Store coolant out of the reach of chil-
.. Wait until all engine parts have come to lease any excess pressure completely dren.
a standstill before carrying out any work before opening the cap fully.
on the engine. .. Wear suitable protective gloves, protec- ~ To check the coolant level: 5
.. Wear work clothing which is fastened tive clothing and safety goggles when .........
and close-fitting. Wear a hair net if nec- handling coolant. Leave the engine running at moderate
essary. Remove jewellery such as speeds for approximately 5 minutes.
watches and necklaces.
~ If the coolant temperature is below
50 C, check the coolant level again
0
Starting procedure
them. Before starting the engine:
In the case of vehicle engines, secure the
• Prevent the vehicle from rolling away by vehicle to prevent it from rolling away acci-
applying the parking brake and, if neces- dentally:
sary, by placing chocks under the
wheels. ~ Apply the parking brake.
• Shift the transmission into neutral. ~ Shift the transmission into neutral.
G54.3G-3771-31
~ Place wheel chocks in front of or be-
, 0 hind the wheels. CD Charge current indicator lamp
® Electronic system warning lamp
f.j Starting the engine for the first time ~ Insert the key into the ignition and turn ® Flame-start system indicator lamp or
m~ ([> see page 44). it to the driving position. grid heater
~ Carry out special measures before The following indicator and warning
If!.: starting the engine when it has been lamps light up: Start the engine within 30 seconds of the
flame-start indicator lamp going out. c-r-
stopped for a long period, see the
I
~I
~
~~
~
"Cleaning/protective treatment" sec-
tion (I> page 55).
S1034
o
Keep the engine running at idling speed The indicator lamp for the flame-start
until an oil pressure reading is dis- system lights up for approximately
played. If no oil pressure is displayed 2 seconds (function check, flame-start
after approximately 10 seconds, system not in operation) to approximate-
switch off the engine. Determine the ly 20 seconds (maximum preglow time)
cause; see the "Oil pressure" section depending on the outside temperature.
(I> page 51). If the indicator lamp for the flame-start
system does not go out after approxi-
I
~
0
If necessary, break off the starting
mately 20 seconds, there is a fault; see
the "Telligent@ engine system" section
j
.... • procedure after a maximum of 20 sec-
(I> page 50).
Start-Stop buttons
!i~
I
\~
onds, and then repeat after approxi-
mately 1 minute.
The charge current indicator lamp and
Ii ~ grid heat" ;, controlled by the drive
control unit or the ADM control unit. The
CD Stop button electronic system warning lamp must I preglow time lasts for approximately
CD Start button
~ using the starter switch on the equip-
ment
11 go out after the engine has started. If
they remain on, there are malfunctions;
i~ (I> see page 49) and (I> page 50).
~~
~ 30 seconds and depends on the temper-
ature of the coolant and the charge air.
During the preglow time, the indicator
lamp lights up and then goes out once the
~ using Start button CD on the engine. preglow time has finished.
~ Monitor the oil pressure gauge immedi-
At extremely cold temperatures, do not
ately after starting the engine.
place the cold engine under a full load im-
mediately after starting.
S1034
Charge current
I
It.l
The charge current indicator lamp must go Th, poly-v-belt contact surfaces must
out after the engine has been started. ; ;~~~~.damaged (e.g. torn), oily or
iI
~ pump will not be driven. This will result
in engine damage.
Telligent@ engine system The fault codes may be shown on a display Flame-start system*
which is part of the Telligent@ engine sys-
The electronic system warning lamp must
tem (vehicle diagnostic system).
go out after the engine has been started.
Fault codes can be read using
DaimlerChrysler diagnostic equipment
(STAR DIAGNOSIS or Minidiag 2-Tester),
(I> see page 31). If the electronic system
warning lamp lights up while the engine is
running, read or determine the fault code.
~j 0
~1 The flame-start system switches off au-
must not fall below:
•
lit
2.5 bar at rated speed
0.5 bar at idling speed
~ tomatically, if: If the pressure falls below these values,
III'~·-: .
the engine is not started within stop the engine and determine the
30 seconds of the flame-start sys- cause.
tem indicator lamp going out
"I
f"'"
- no longer needed
S1034
Y Winter operation
The following notes should be observed at Coolant
the start of the cold season: Risk of poisoning
Risk of scalding
Fuel There is a risk of poisoning if cool ant is swal-
lowed.
The cooling system is pressurised. Hot cool-
Risk of fire ant can spray out when the cooling system .. Never swallow coolant.
is opened and scald your skin and eyes. • Never put coolant into container nor-
There is an increased risk of fire when han- " Only open the cooling system at coolant mally used for beverages.
dling fuels as they are highly flammable. temperatures below 90 "C. .. Store coolant out of the reac h of chil-
Avoid fire, naked flames, and sparks and re- " Unscrew the sealing cap slowly and re- dren.
frain from smoking when handling fuels. lease any excess pressure completely
5
Use cold-resistant diesel fuel
before opening the cap fully. Check the coolant's antifreeze protection
in good time and increase the antifreeze/
........
" Wear suitable protective gloves, protec-
(I> see page 60). tive clothing and safety goggles when corrosion inhibitor concentration if neces-
handling coolant. sary (I> see page 63).
Engine oil
Batteries
Risk of explosion
Have the batteries serviced and recharged
more frequently during the cold months of
Gases escaping from batteries can explode
the year.
and injure people.
Therefore, do not allow fire, naked flames,
Risk of acid burns and the creation of sparks and do not smoke
in the vicinity of batteries.
The acid contained in batteries burns skin
and eyes on contact.
Careful maintenance and low power con-
.. Do not allow acid to come into contact sumption will help maintain the full battery
with your skin, eyes or clothing.
charge. Starting capacity is greatly re-
5
..... .. Wear suitable protective clothing, as duced in cold weather; for example, at
battery acid can burn through normal -10 DC it is only about 60% of normal ca-
clothing. In addition, protective gloves pacity. If the engine is not used for a long
and safety goggles should be worn.
period of time, store the batteries in a
.. Rinse acid splashesoff immediately with heated place if possible. Ensure good ven-
clean water and consult a doctor if nec- tilation when recharging.
essary.
S1034
V Cleaning/protective treatment
Cleaning the engine
Risk of fire and injury
Make sure that water does not enter
Risk of poisoning the intake, ventilation or bleed ducts.
Fuels are highly flammable and can injure
your health. If they are used as cleaning Protect the engine after cleaning. Be
Care and cleaning agents can be toxic and
agents, they can cause fires or skin irritation careful to protect the belt drive against
lead to severe poisoning if swallowed.
and poisoning. preservative agents.
• Always keep care and cleaning agent
Never use fuels for cleaning.
containers closed and out of the reach
~I 0
I:~:~~~~e;;:~:~:;_~~~~~:~;~:b~e," --
of children.
f:" Information about suitable cleaning
• Never store care or cleaning products in
Environmental note
foodstuff containers such as bottles so
as to avoid confusion with foodstuffs. 5
Observe the regulations for environmental
• Observe the instructions for using care protection.
and cleaning products.
Only clean the engine in a washing area de-
signed for this purpose. Dispose of empty
packaging and used cleaning materials in an
environmentally-responsible manner.
S1034
.I·
flow).
while cleaning. To avoid damage, do
I::::~::::~,:ompo"e"ts
if
I 1>1>
~.: ~ppl~mOdtehrated~retssuf:e
not aim the water jet directly at:
°lnly when
c earnng since e ra ra or ms cou ld
• otherwise be damaged.
illJ
I. hoses
Diesel fuels The 900 series engines are suitable for use
with FAME fuels in accordance with
Only use commercially available vehicle
DIN E 51606. If you do so, you must con-
diesel fuels (EN 590). Grades such as ma-
sult a Mercedes-Benz Service Centre to
rine diesel fuel, heating oils, etc. are not
have the exact operating procedures (e.g.
permitted.
maintenance intervals) explained.
Fuel additives are not necessary. The war-
ranty entitlement may be restricted if fuel Diesel fuels in extremely cold weather
additives are used.
At low outside temperatures, paraffin sep-
If diesel fuels with a sulphur content above aration may affect the flow characteristics
0.3% by weight are used, carry out an oil of diesel fuel.
5 change at shorter intervals. Observe the To prevent operating problems (e.g. as a
....... information provided in the Maintenance
result of blocked filters), diesel fuel with
Booklet.
improved cold flow properties is available
Filling the vehicle's fuel tank from drums or on the market in the winter months. Devia-
canisters may introduce impurities into the tions may be possible in the transition be-
fuel system. This can lead to fuel system tween the cold and the warm seasons, and
malfunctions. Therefore, filter the fuel in other countries. In Germany, special
when filling the tank. cold-resistant winter-grade diesel fuels are
sold. They ensure reliable operation down
to approximately -20°C. Winter-grade die-
sel fuel can normally be used without risk
of malfunctioning at the outside tempera-
tures expected in the country of sale.
S1034
..
fuel.
For this reason, you must avoid fire, na-
the entire fuel system.
Do not add additives to especially cold-
resistant winter diesel fuels, as the fuel's
volume of kerosene improves the cold-
resistance of diesel fuel by approximately
1°C. Do not exceed the maximum mixing
-
5
.&. :::1:
:~~::"·l:~~
.-l~l:
+32 .+ 0
:
Risk of fire and explosion
and explosion.
s
.... .. For this reason, you must avoid fire, na- Engine oil SAE classes
ked flames and sparks and refrain from
Engine oils are specially tested for suitabil-
smoking when handling these service
products. ity in our engines. Therefore, only use en-
gine oil brands approved by Mercedes-
.. Observe the relevant safety regulations.
Benz. These are listed in the Mercedes-
Benz Specifications for Service Products.
Observe the information provided in the
Maintenance Booklet.
8h
II
l'~ T e use 0 f non-approve d enzine
engme oil
01
brands can restrict the warranty enti-
I tlement.
S1034
I
nly use engine oils of the same grade and
dren. ~··
!\E class when topping up.
~.;.~ Information is available from any .!...
o The coolant is a mixture of water and anti-
freeze/corrosion inhibitor. The coolant
~ Mercedes-Benz Service Centre.
Work plans
S1034
.. Maintenance instructions
This section describes all maintenance The scope of maintenance and frequency
work which concerns the engine. Risk of accident of maintenance work depend on the differ-
ent operating conditions and are listed in
Faulty maintenance work or failure to carry the Maintenance Booklet.
Risk of accident
out maintenance work, e.g., not changing
Have the work which is carried out con-
the oil filter or not observing the correct
Before any maintenance work or repairs are firmed in the Maintenance Booklet. This
maintenance interval, can cause engine
carried out, please make sure that you read proof of regular maintenance is always re-
damage. Enginedamage can lead to an in-
the relevant sections of the technical docu- quired for any warranty claims.
creased risk of accident.
mentation concerned with servicing and re-
Also observe the maintenance regulations
pairs, for example: For this reason, please observe the instruc-
for special accessories.
tions on servicing the engine given in these
.. Operating Instructions and workshop in-
Operating Instructions.
II
~"
formation
Youshould alsofamiliarise yourselffirstwith The engine oil filled at the factory in
the legal requirements, for example: ., accordance with Sheet 228.5 of the
All maintenance intervals and mainte- ":' Mercedes-Benz Specifications for Serv-
.. work safety and accident prevention
regulations nance work refer to genuine Mercedes- i! ice Products must be changed if more
Benz parts and accessories specifically ".~ than 12 months elapse before the en-
You could otherwise fail to recognise dan- ,:' gine is operated for the first time.
approved for the engine by
gers and could injure yourself or others.
DaimlerChrysler.
S1034
Check for points of abrasion and incorrect Renewal interval depends on the cool-
positioning:
Engine
Lines and hoses on the engine
The valve clearance must be adjusted
during the first maintenance service
and then during the 3rd, 5th, 7th main-
tenance services and so on.
ant additive used (see Mercedes-Benz
Specifications for Service Products).
--
Intake pipe between air cleaner and en-
gine
Cooling and heating system
S1034
Engine: Checking for leaks and lines and hoses on the engine:
general condition Checking for leaks and general Risk of injury
~ Visual inspection of the engine for condition
There is a danger of limbs being caught, en-
signs of leakage. ~ Make a visual inspection of lines and
trapped, crushed or torn off by rotating en-
hoses. Also make a listening check for:
Sealing points which are slightly damp are gine parts. Therefore you should:
harmless. • leaks .. Keep a safe distance between yourself
I ~emedy • check for undamaged condition and rotating engine parts, including
more .signifi~antle~ks
involv-
ling constant ali loss Immediately.
• chafe-free routing and
..
when the engine is being started.
Wait until all engine parts have come to
• correct mounting a standstill before carrying out any work
on the engine.
Risk of scalding
Extraction:
~ Extract the engine oil through the dip-
stick guide pipe. To do this, pull out the
dipstick and insert the scavenging de-
vice sealed with an a-ring into the
guide pipe.
N18.20-2045-31
6
...... Cap with oil filter element Dipstick guide pipe
CD Cap
o Sealing ring
(}) Oil filter element
I
[I
Observe 'he operating ;""'UC';o", for
the engine oil scavenging device.
~ Replace the sealing ring on cap 0.
~ Insert new filter element in the cap and
clip it into place by pressing on it.
S1034
Draining:
G18.00-3114-31
I·~:.'~.,:• ~~~i:~:~":;~::uu,~";~:d~~~:~"~i:~eed
i
I
played. If no oil pressure is displayed
•. after approximately 10 seconds, switch
• off the engine and establish the cause.
¢ = inlet valve
.. = exhaust valve
X = flywheel end
S1034
I - inlet valve
E - exhaust valve
Checking and adjusting the valve ~ Measure the valve clearance between Concluding work
clearance the rocker arm and valve stem (exhaust
~ Refit the cylinder head cover
valve) or valve bridge (inlet valve) with
(I> see page 74).
a feeler gauge (arrow).
It must be possible to pull the feeler ~ Remove the rotation device from the
gauge through with only light resist- flywheel housing inspection hole.
ance.
~ Slacken counternut CD to adjust the
valve clearance. Adjust the valve clear-
ance by turning adjustment screw CD.
~ Retighten the counternut.
Tightening torque: 25 Nm.
~ Check the valve clearance again and
readjust if necessary.
CD Adjustment screw
CD Counternut
S1034
There is an increased risk of fire when han- Dispose of used filter elements and fuel res-
dling fuels as they are highly flammable. idue in accordance with current local regula-
Avoid fire, naked flames and sparks and re- tions.
frain from smoking when handlingfuels.
® ~ Check sealing ring ® for the cap and
~ Open the tank cap to remove excess replace if necessary.
,,--,~-0
pressure in the fuel tank. ~ Insert the filter element in the cap and
~ Clean the outside of the fuel prefilter screw the cap onto the filter housing.
and cover any hoses / lines under the Tightening torque: 25 Nm.
prefilter.
N07.0Q-Z096-31
CD Hand pump
CD Filter housing
CD Water separator (heated)
@ Water drain valve
S1034
>
Neither dirt nor water should enter the ~ Lightly grease sealing ring 0 and the
filter element seals.
filter housing; do not empty dirt trap @ To ensure the fuel system can be bled,
into the filter housing. ~ Insert dirt trap @ into filter housing the battery must have enough charge
0; observe the correct installation po- when the engine is started, since the
~ Clean cap CD and dirt trap @. sition. fuel system must fill up with fuel first.
~ Replace sealing ring 0. ~ Screw on cap and filter element and
tighten.
~ Clip new filter element 0 into cap CD.
Tightening torque: 25 Nm.
~ Start the engine and bleed the fuel sys-
tem.
S1034
Risk of injury
I! ~Place the poly-V-belt if one of the
damage patterns shown on the next
~ page is detected. For information on in-
~
Faulty poly-V-belts may tear and parts or all I stalling and removing the poly-V-belt
of the belt may be thrown off, thereby caus- lii! (I> see page 86).
~
ing injury to persons.
~ Remove the rotation device.
CII Always observe the specified mainte-
nance intervals for poly-V-belts.
CII If damage is detected, replace the poly-
V-belt concerned immediately.
Special tools
Rotation device: 904 589 04 63 00 Flywheel housing inspection hole 6
..-
~ Fit the rotation device to the flywheel ~ rotate further using the rotation device
housing inspection hole. until the chalk mark is reached again.
~ Make a chalk mark on the poly-V-belt.
Check the poly-V-belt for damage in sec-
tions; rotate the engine and poly-V-belt a
little at a time
S1034
N13.20-2075-31
S1034
Damage patterns
Removing and installing the poly-V-belt ~ Swing back the tensioning device.
Risk of injury ~ Check that the tensioning device and
belt pulley are in perfect condition (e.g.
The tensioning device is spring-tensioned.
check for worn bearings on the ten-
When it is loosened or tightened, there is a
sioning device, tensioning pulley and
risk of injury from hands or fingers being
deflection pulleys as well as wear on
crushed or trapped in pretensioned parts.
belt pulleys); replace parts if
co Make sure that the tool is handled cor- necessary.
rectly.
~ Lay the poly-V-belt (new) on all belt pul-
co Keep your fingers out of the area be-
leys, except for the tensioning pulley
tween the belt pulley and the poly-V-belt
(see illustrations for poly-V-belt rout-
when fitting or dismantling the poly-V-
ing).
belt.
co Wear work gloves when working on the ~ Swing the tensioning pulley upwards
G13.20-3110-31 G13.20-3111-31
CD Alternator CD Alternator
CD Coolant pump CD Coolant pump
® Tensioning pulley ® Tensioning pulley
@ Crankshaft @ Refrigerant compressor
® Deflection and guide pulley
@ Crankshaft
S1034
-
6 Throttle valve lever in working position
o
Throttle valve lever CD must lie against
bracket @ in the operating position
(cylinder extended) when the engine
brake is operated.
When the engine brake cylinder (with
the cylinder retracted) is in the rest po-
sition, the throttle valve lever must also
lie against the bracket; the pre-tension
of the engine brake cylinder return
spring is then sufficient.
Check the position of the throttle valve
shaft: the notches must be horizontal
when the engine brake is in the rest po-
/
sition (I> page 88, illustration on the
, left-hand side). The notches must be
vertical in the working position
1
:.~.'
:1
(I> page 88, illustration on the right-
hand side).
S1034
Special tool:
Pressure tester 001 589 83 21 00 Risk of poisoning
~!i1· " 1
~
e
A pressure relief valve is integrated in
the testing equipment so that a pres-
I¥J!\l
sure of 1.2 bar cannot be exceeded.
S1034
Renewing coolant
Risk of poisoning I «)
~_.' I l ~he
g
Risk of scalding '...."•'.'·
...• Befol·re
coo ingrenedWhin
an coolant,for
eating system check the
leaks
There is a risk of poisoning if coolant is swal-
and condition. Have the coolant renew-
lowed.
The cooling system is pressurised. Hot cool- al confirmed in the Maintenance Book-
1:
ant can spray out when the cooling system .. Never swallow coolant. .• let.
is opened and scald your skin and eyes. .. Never put coolant into containers nor-
mally used for beverages.
.. Only open the cooling system at coolant
temperatures below 90 DC. .. Store coolant out of the reach of chil-
dren.
.. Unscrew the sealing cap slowly and re-
lease any excess pressure completely
before opening the cap fully.
.. Wear suitable protective gloves, protec- Only use antifreeze / corrosion inhibitor
tive clothing and safety goggles when approved by Mercedes-Benz
handling coolant. ([> see page 59).
S1034
Draining coolant
Risk of scalding
,I.'~ere
"'~
are additional drain plugs on the
radiator.
I~
.. Only carry out work on the cooling sys-
First cover the lines, etc. beneath the
tem at coolant temperatures below
.• drain plugs and place a receptacle suit-
50 DC.
able for the volume of coolant.
• Wear suitable protective gloves, protec-
tive clothing and safety goggles when
handling coolant.
~ On heating systems: Open the heating ~ Place the drain hose on the coolant
temperature selector (regulating drain plug on the engine (arrow).
valve).
~ Loosen the drain plug (1 to 2 turns)
The coolant flows out.
S1034
Adding coolant
Environmental note
II> Start the engine and allow it to run at
different speeds for approximately
Dispose of used coolant in accordance with
1 minute.
prevailing local regulations
(I> see page 64). II> Add coolant in the specified ratio until
it reaches the lower edge of the filler
II> Clear blocked drain openings from de- neck.
posits. II> Switch off the engine and close the
II> Retighten the coolant drain plug on the cooling system again.
engine.
II> Pull off the drain hose.
II> Fit additional drain plugs (without hose
connections) with new seals and screw
·I.~r
further ;nforrnation se, the vehicle
• manufacturer's operating instructions.
tight.
S1034
S1034
You can rectify certain faults yourself Maintenance and repair work on the engine
(l> page 99). may only be carried out by personnel who
have undergone the appropriate training.
Always have faults that you cannot remedy
yourself rectified at a qualified specialist Always have work on or modifications to the
workshop. engine carried out at a qualified technical
workshop which has the necessary special-
DaimlerChrysler recommends that you vis-
ist knowledge and tools to carry out the
it a Mercedes-Benz Service Centre for this
work required.
purpose as it has the necessary specialist
knowledge and tools to carry out the work Mercedes-Benz recommends that you use a
required. In particular, work relevant to Mercedes-Benz Service Centre for this pur-
safety or on safety-related systems must pose.
be carried out at a qualified specialist
workshop.
S1034
General troubleshooting
Fuel not resistant to cold ~ Clean the pre-filter (I> page 78)
-
7 Constantly-open throttle valve* defective
~
Check control; consult a qualified spe-
cialist workshop
Carry out a function /visual inspection;
consult a qualified specialist workshop
S1034
Jump-starting
V Jump-starting
If the battery is discharged, the engine can
be started using jump leads and a donor Risk of explosion
When jump-starting the engine, the
battery.
maximum on-board voltage of 28 V
Gases escaping from batteries can explode
must not be exceeded (as this would
Risk of burning and injure people.
cause electronic damage to the control
Therefore, avoid fire, naked flames and part).
The acid contained in batteries burns skin sparks and refrain from smoking in the vicin-
and eyes on contact. ity of batteries. ~ Connect the positive terminals first and
• Avoid contact of acid with your skin, then the negative battery terminals.
eyes or clothing.
~~~ ~ Start the engine (I> see page 47) and
• Wear suitable protective clothing, as
battery acid can burn through normal
I Make sure that the donor battery and allow to run for a short while.
clothing, and also wear protective
III the starter battery have the same nom- ~ Remove the jump leads in the reverse
gloves and safety goggles. I.:.. inal voltage. Otherwise a battery could
order.
• Rinse acid splashes off immediately with
I be irreparably damaged.
clean water and consult a doctor if nec- ~ Do not place any metal parts on the
essary. batteries. There is a risk of short cir-
cuit.
Only use insulated jump leads (cable
cross section approximately 70 mm 2 )
and insulated terminal clamps. There is
a risk of short circuit.
A discharged battery can freeze at
about -10°C; it must have thawed out
before jump-starting.
S1034
adjustment values
Tightening torques
S1034
Dimensions in mm:
(Standard version, other versions on re-
quest)
OM 904 LA
OM 924 LA
c
A = Engine length 830 mm
B = Engine width 645 mm
C = Engine height 925 mm
OM 906 LA
f----B---~
OM 926 LA G01.00-3129-31 G01.00-3130-31
8
.......
S1034
Weights
OM 904 LA OM 906 LA
OM 924 LA OM 926 LA
Engine, dry 395 kg 530 kg
Engine, wet 420 kg 573 kg
General data
Displacement
OM 904 LA/OM 924 LA: 4,250 cm 3 / 4,800 cm 3
OM 906 LA/OM 926 LA: 6,370 cm 3 / 7,200 cm 3
Direction of rotation of engine viewed from flywheel Anti-clockwise
Type of starting Electric
Coolant capacity of engine without intercooler
OM 904 LA/OM 924 LA: 8.5 I
OM 906 LA/OM 926 LA: 12.51
Engine oil capacity including oil filter
OM 904 LA/OM 924 LA: min. 13 I; max. 16 I
OM 906 LA/OM 926 LA: min. 24 I; max. 29 I
8
.......
S1034
Starter motor
Voltage 24 V
Output 4.0 kW
Battery (not in scope of delivery)
Voltage 24 V
Cold test current in accordance with DIN 72311 max. 450 A
Cold start ability without jump-starting and 75% battery charge
down to max. -20 DC
Alternator
Voltage 28 V
Current rating 80 A
S1034
Valve clearance
I~ 0
All threads on mechanical parts and re-
.'I
~ lated contact sUrfac~s must ~e clea.n
I and smooth and lubncated with engine
~.~.;. . oil; other lu bricants require significant-
I Iy different tightening torques.
Designation Nm
Engine block
Cylinder head cover to cylinder head bolt 30
Oil sump bolt to cylinder crankcase 25
Poly-V-belt tensioning device to cylinder r.r;:lnkr.r1~;p support 50
Fuel/injection system
Injection line to unitpurnppressure pipe connection 35
Banjo bolts forfuellines 40
Cap to fuel filter housing 25
Starter motor/ alternator
Starter motor to tirningcase 50
Alternator support to cylinder crankcase 100
S1034
Designation Nm
Alternator to support 50
Alternator to retainer 65
Oil circuit
Oil drain plug in oil sump
M20 x 1.5 thread 65
M26 x 1.5 thread 85
Alternator retainer to oil filter 40
Oil filter housing tocylindercrankcase 25
Oil filter housing support to cylinder crankcase 25
Oil filter cap to oil filter housing 25
Pressure sensor to oil filter housing 25
Valve adjustment
Counternut on rocker arm set screw 25
Cooling circuit
Coolant line with thermostat valve to coolant pump 25
Coolant pump to cylinder crankcase 25
Belt pulley to coolant pump hub 25
S1034
Minidiag 2 TDC
DaimlerChrysler AG electronic diag- Top dead centre; term for the upper po-
nostic tool for reading faults and pa- sition of the piston in the cylinder.
rameters on commercial vehicles.
Telligent@ engine system
MR Mercedes-Benz electronic engine con-
(Engine control) control unit. Engine trol. Controls fuel injection period and
control is a monitored electronic sys- quantity depending on the current op-
tem which forms part of the Telligent@ erating conditions and driver's re-
engine system. It controls the engine quests.
functions, such as the engine idling
Tightening torque (Nm)
speed and exchanges data with the
Product of force and lever arm length
drive control.
with which bolted connections, e.g.
OM cylinder head bolts, are tightened.
Engine name, abbreviation for oil en- (Nm = Newton metres)
gine = diesel engine.
Sensor
Electronic component which converts
certain parameters (e.g. oil tempera-
ture, engine speed and others) into
electrical values for use in the engine
control unit.
STAR DIAGNOSIS
DaimlerChrysler AG electronic diag-
nostic system
S1034
Flame-start system 26
Charge current 49 Emergency running program 29 Flow improvers 61
Commissioning 42 Engine Fuel 53
Constantly-open throttle valve 28 Checking for leaks and general Filling the tank 43
Conversion parts and condition 68 Filter element 80
modifications 38 Cleaning 55 Prefilter 77
Coolant Oil change and filter replacement 69 Fuel additives 60
Mixing ratio 64 Starting 47 Fuel system
Renewing 94 Stopping 52 Bleeding 80
Coolant level. 90 Engine brake
Cooling system Checking the adjustment 89
Cleaning 56 Genuine Mercedes-Benz parts 40
Checking the condition 88
Degreasing 57 Grid heater 27, 51
Cylinder head cover
Removing and fitting 74
S1034
Oil pressure 51
(} Operating safety 8
- Overview
OM 904 LA/OM 924 LA 12
S1034
® Mercedes-Benz
Vorbemerlmngen
Dieser Bildkatalog soIl Ihnen die Ermittlung und BesteIlung von Teilen fur die Wartung bzw. Reparatur Ihres MERCEDES-BENZ
erleichtern. Er enthalt die Bildtafeln der Grundausfuhrung.
Die auf den Bildtafeln abgebildeten Teile entsprechen nicht in jedem Fall der neuesten Ausfuhrung.
Ihr MERCEDES-BENZ-Produkt kann mit Sonderausfuhrungen (SA) ausgerustet sein, die in diesem Katalog nicht aufgefuhrt sind.
Fur die Errnittlung der richtigen Teile ist die Vorlage der Fahrzeug- bzw. Motoren-Datenkarte bei den MERCEDES-BENZ-Service-
organen eine zwingende Notwendigkeit.
Die fur Ihr MERCEDES-BENZ-Produkt giiJtigen Bildtafeln sind jeweils von der Fahrzeug-ldent-No. (Fahrgestell-No.),
Motornurnmer, Fahrerhausnumrner, Aufbaunurnrner (bei Ornnibussen) abhangig (siehe Fahrzeug-Datenkarte). Beachten Sie bitte
die ersten 6 Zahlen dieser Nummer, wobei es sich um das sogenannte Baurnuster handelt.
90~910, 920, 930, 940, 941, 960, 970, 980, 990 06T
909.900, 901, 910, 911, 920, 921, 960, 970, 971 06V
924.911,915,916,920 06T
926.911-915,917,924,929 06V
Fur Teile-Bestellungen ist sehr wichtig, dass Sie auch angeben, auf welcher Seite die benotigten Teile ausgewahlt wurden.
3
S1035
Bei der Bestellung von Teilen sind, in Abhangigkeit von Teile-Bedarf, folgende Angaben unbedingt erforderlich (siehe Fahrzeug-
Datenkarte):
Fur die Lieferung von Teilen ist ausschlieBlich die Kundendienstorganisation der Mercedes-Benz AG zustiindig.
Die Teile fur Motor, Fahrgestell und bei Nutzfahrzeugen auch AufbaujFahrerhaus sind in getrennten Katalogen erfasst.
Die Bildtafeln fur die Aggregate sind im Anhang des Fahrgestell-Blldkatalogs enthalten.
4
S1035
Preliminary Remarks
This Catalog of Illustrations has been compiled to help you finding out and ordering the parts required for the maintenance and
repair of your MERCEDES-BENZ.
It comprises the illustrations of the Standard Equipment.
The parts illustrated do not in any case conform to the latest version.
Your MERCEDES-BENZ product may be equipped with Special Versions (SA's) which have not been listed in this catalog.
In order to identify the appropriate parts, it is mandatory to submit your vehicle data card, or engine data card, to the
MERCEDES-BENZ services.
The illustrations applicable to your MERCEDES-BENZ product are relative to the respective vehicle ident. No. (chassis No.),
engine number, cab number, or (in the case of buses) body number - see vehicle data card. Please mind the first six
digits of this number representing the so-called model.
90l910, 920, 930, 940, 941, 960, 970, 980, 990 06T
909.900,901,910,911,920,921,960,970,971 06V
924.911,915,916,920 06T
926.911-915,917,924,929 06V
When ordering parts, be sure to indicate the page from which you have selected the spare parts required.
5
S1035
When placing orders for parts, it is a must to specify - depending on parts requirements -. the following points (see vehicle
data card):
Only our Mercedes-Benz AG Dealer Organizations are competent for delivery of parts.
The parts for engine, chassis, and with commercial vehicles also for body/cab, have been compiled in separate catalogs.
The illustrations of units will be found in the annex of the chassis catalog of illustrations.
6
S1035
Prelimlnaires
Ce catalogue illustre doit vous faciliter la recherche et la commande de pieces pour la maintenance et la reparation de
votre MERCEDES-BENZ. II contient les planches illustrees de la version de base.
Les pieces figurant sur les planches illustrees ne sont pas toujours conformes a la version la plus recente,
Votre vehicule MERCEDES-BENZ peut etre equipe de versions speciales (SA) ne figurant pas dans ce catalogue. La
presentation de la fiche signaletique du vehicule ou du moteur aupres du service apres-vente MERCEDES-BENZ est
indispensable pour la recherche des pieces exactes.
Les planches lllustrees valables pour votre MERCEDES-BENZ sont fonction des nurneros d'identification du vehicule (n? de chas-
sis), de moteur, de cabine, de carrosserie (autocars/autobus). Voir a cet effet la fiche signaletique du vehicule, II faut abso-
lument tenir compte des 6 premiers chiffres de ces numeros correspondant a ce que nous appelons Ie modele.
924.911,915,916,920 06T
926.911-915,917,924,929 06V
En cas de commandes de pieces, vous devez absolument indiquer la page sur laquelle figurent les pieces en question.
7
S1035
En cas de comrnande de pieces, il faut - en fonction des besoins - absolument indiquer les donnees suivantes (voir fiche
signaletique du vehicule):
C'est Ie reseau de service apres-vente de la Mercedes-Benz AG qui est seul responsable pour la livraison de pieces.
Les pieces pour moteur et chassis et - lorsqu'i] s'agit de vehicules utilitaires - egalement pour carrosserie/cabine figurent dans
des catalogues separes.
Les planches illustrees pour les organes mecaniques se trouvent a l'annexe du catalogue illustre des chassis.
8
S1035
Advertencias preliminares
El presente catalogo ilustrado tiene por objeto facilitar la biisqueda y el pedido de piezas para el mantenimiento 0 reparaclon
de su MERCEDES-BENZ. Contiene las laminas i1ustradas de la ejecucion basica.
Las piezas reproducidas en las laminas no corresponden siempre a la ultima ejecucion.
Su producto MERCEDES-BENZ puede ir equipado con ejecuciones especiales (SA) que no esten incluidas en el presente
catalogo. Para la localizacion de las piezas correctas es imprescindible presentar la documentacion del vehfculo 0 la tarjeta de
los datos del motor a los organism os de servicio postventa MERCEDES-BENZ.
Las laminas validas para su producto MERCEDES-BENZ pueden reconocerse siempre por el mimero de identiflcacion
del vehfculo (rnirn. de chasis), asf como por los mimeros del motor, cabina y superestructura (en autobuses); vease la ficha de
datos del vehfculo. Sfrvase fijarse en las seis primeras cifras de dicho mimero, que corresponde al de la ejecucidn,
90Z910, 920, 930, 940, 941, 960, 970, 980, 990 06T
Motor 906.910, 911, 915, 916, 919-923, 925-928, 930, 931, 935, 85 - 161 06V
937-941,949-952,954-956,960-965,976,982
909.900,901,910,911,920,921,960,970,971 06V
Es muy importante que, al efectuar pedidos de piezas, se indique tambien la pagina en la que se eligieron las piezas reque-
ridas.
9
S1035
Para la formulaci6n del pedido de piezas, segun la demanda, son indispensables los siguientes datos (vease ficha de datos del
vehiculo):
1. Ntimero de identificaci6n del vehiculo [rnim. de chasis), asf como mimeros de motor, superestructura 0 cabina. En caso de
grupos: mimero completo del cambio, eje delantero 0 eje trasero, 0 de la direcci6n (vease ficha de datos).
2. Ntimero de impresi6n y edici6n del presente catalogo,
3. Ntimero de lamina (arriba, a la derecha) y de ilustraci6n.
4. Cantidad deseada.
Unicamente la organizaci6n del servicio postventa es la encargada del suministro de piezas de la Mercedes-Benz AG.
Las piezas para motor, chasis y, en vehiculos industriales, tarnbien para superestructura ° cabina se encuentran en catalogos
aparte.
Las tablas graficas de grupos se encuentran en el apendice del catalogo de chasis.
10
S1035
Considerazioni preliminari
Questo catalogo illustrato vi servira a determinare ed ordinare i pezzi necessari per la manutenzione risp. riparazione della
vostra MERCEDES-BENZ. Esso contiene le tavole illustrate dell'Equipaggiamento di Base.
Talvolta i pezzi raffigurati nelle tavole illustrate non corrispondono pili all'ultima versione.
II vostro prodotto MERCEDES-BENZ pub essere dotato di equipaggiamenti speciali (SA) che non sono elencati in questa
catalogo. Per stabilire gli esatti pezzi e assolutamente necessario presentare agli organi di servizio MERCEDES-BENZ la
cartolina del veicolo ovvero dei dati del motore.
Le tavole illustrate valide per la vostra MERCEDES-BENZ dipendono generalmente dai numeri d'identificazione del veicolo
(del telaio), del motore, della cabina e, per gli autobus, della carrozzeria. (Vedi scheda dei dati del veicolo). Si prega di tener
conto delle prime 6 cifre di questa numero riferentesi al cosiddetto modello di costruzione.
90~910, 920, 930, 940, 941, 960, 970, 980, 990 06T
909.900,901,910,911,920,921,960,970,971 06V
924.911,915,916,920 06T
926.911-915,917,924,929 06V
Per le ordinazioni dei pezzi e importante che indichiate anche la pagina dalla quale sono stati scelti i pezzi necessari.
11
S1035
Per l'ordinazione di pezzi e strettamente necessario, a seconda del fabbisogno, fornire i seguenti dati (vedi scheda dei dati del
veicolo):
1. W d'identificazione del veicolo (N° di telaio), numeri del motore, della carrozzeria e della cabina. Per gli aggregati l'intero
numero del cambio, dell'assale anteriore 0 posteriore 0 dello sterzo (vedi scheda dei dati).
2. Numero di stampa ed edizione di questa catalogo.
3. Numero della tavola illustrata (in alto a destra) e della figura.
4. Ouantita desiderata.
Per la consegna dei pezzi il solo responsabile e l'organizzazione assistenza clienti della Mercedes-Benz AG.
I pezzi per motore, telaio e, per i veicoli industriali, anche per la carrozzeria e la cabina si trovano in cataloghi separati.
Le tavole illustrate per gli aggregati sono contenute nell'appendice del catalogo illustrato del telaio.
12
S1035
Advertencias preliminares
Este catalogo ilustrado tern por fim facilitar a V. Sa. a identificacao e a encomenda de pecas para a manutencao e a reparacao
do seu MERCEDES-BENZ. Ele contem os quadros ilustrados da versao basica.
As Ilustracoes nos quadros nao correspondem, em todos os cas os, a versao mais recente das pecas.
E possfvel que 0 seu vefculo MERCEDES-BENZ disponha de equipamentos especiais (SA) nao mencionados neste catalogo,
Para a determinacao das pecas adequadas, e absolutamente indispensavel a apresentacao do cartao de dados do veiculo ou
do cartao de dados do motor nos postos de service MERCEDES-BENZ.
Os quadros validos para 0 seu produto MERCEDES-BENZ dependem do respectivo mimero de identificacan do veiculo (nu-
mero do chassi), do mimero do motor, do mimero da cabina, do mimero da carrocaria (em se tratando de autocarros/onibus)
- (vide cartao de dados do veiculo). Queira observar as primeiros 6 algarismos desse mimero, pois trata-se da identificacao
do respectivo modelo.
909.900,901,910,911,920,921,960,970,971 06V
924.911,915,916,920 06T
926.911-915,917,924,929 06V
Para a encomenda de pecas, e de suma importancia que V. Sa. mencione tambem a pagina da qual selecionou as pecas
necessitadas.
13
S1035
Na encomenda de pecas, sao absolutamente necessaries as seguintes dados, em dependencia cia necessiclacle de pecas (vide
cartao cle daclos cia veiculo):
1. Numero cle identificacao cia veiculo (numero do chassi), niimero cia motor, da carrocaria au da cabina, resp.
Em se tratanclo de grupos de maquinas, fornecer a mimero completo cia caixa cle mundancas, cia eixo clianteiro au traseiro,
ou da direcao (vicle cartao cle dados).
2. Ntimero cle impressao edicao cleste catalogo.
3. Niimero cia quaclro ilustrado (no alto aclireita) eo mirnero da Ilustracao.
4. Quantidacle clesejacla.
A entrega cle pecas compete exclusivamente ao service de atenclimento aos clientes da Mercedes-Benz AG.
As pecas para 0 motor, a chassi e, para veiculos utilitarios, tambern para a carrocaria e a cabina clo motorista, foram agrupadas
em catalogos em separaclo.
As ilustracoes para os grupos cle maquinas constam cia anexo do catalogo ilustrado para a chassi.
14
S1035
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15
S1035
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16
S1035
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Baumuster/Model/Modele Katalog
09 Aufladung
Turbocharger
18 Turbochargeur
Sobreahmentaclon
15 Eleklrische Ausriistung
Electrical Equipment
Equipement electrique
Equipo elect rico
22 Motoraufhanqunq
20 Motorkiihlunq Engine Suspension
Engine Cooling System Suspension du moteur
Refroidissement du moteur Suspension del motor
Refrigeracion del motor
23 Lenkhelfpumpe
Power Steering Pump
03 Triebwerkleile Pompe pour servo-direction
Moving Parts Bomba de la servodirecci6n
Organes moteurs
Piezas motrices 09 Kraltstoff-Fllter
Fuel Filter
Flltre a combustible
Filtro carburants
21
S1035
Motorqehsuse
Engine Housing
I
Carter do motor
Carter del motor
Gruppe
Group
Grupo
Grupo
Carter du moteur aaprep ABVlraTenA Groupe rpynna . 01 010 00034
Basamento motore ).,..:;.rli ~ Gruppo I u.~\
15
22
S1035
Motorgehause I
Carter do motor Gruppe I Grupo
Engine Housing
Carter du moteur
Carter del motor
aaprep ABHraTenA g;~~~e %~~~a , 01 015 00227
Basamento motore ) ~.,Ji J5_-=" Gruppo ....... ~~I
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66
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65
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23
S1035
Gruppe
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01 045 00206
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Gruppo <I....>' ~ • ------ I
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125 145
150
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24
S1035
Motorqehause
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Carter du moteur HapTep ~BV1raTenA Groupe rpynna . 0 1 060 00137
Basamento motore .J ~ ,...ll JS..-:,A> Gruppo :i....>:- _....,.:;d\
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230 0
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265 (j
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325
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300
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25
Motorgeh8use
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I
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S1035
Carter du moteur xaprep As",raTenA Groupe rpynna . 01 060 00178
Basamento motore .J~ ....-li ~ Gruppo :w:. ~~\
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240 295
235®
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105
26
S1035
Gruppe Grupo
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_ _ _ _ _ _ _ _ _ _ _ _
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rupo
01 060 00 198
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380 375 f§!;l 415
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27
S1035
Zyhnderkopf I Cu lalra
Cylmder Head . Culata
Gruppe
Group
I Grupo
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Culasse ronoBK.a 6n.oK8 l.\~m"HAPOB Groupe rpynna . 0 1 075 00208
Testata j..l...i...J1 ..,...I j Gruppo '-<--,~I
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260 ~ 250;
V 282
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28
S1035
Zylinderkopf I Culata
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Group
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Testata )..c..:.LJi ....)) Gruppo I ~J........"d.\
<j 240
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220
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215
210
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29
S1035
Zylinderkopf ICulatra
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30
S1035
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31
S1035
Zylinderkopf I
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Culasse ronoBH,a6npHa 1.1I1J1I1HAPOB Groupe rpynna , 0 1 105 00061
Testata j..L.i..J1 ,..r.J) Gruppo ......~I
50
60
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32
S1035
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48
33
S1035
Iriebwerkteile , Orgaos molores Gruppe Grupo
Moving Paris Prezas rnotnces
Organes moleurs nerana I1Bl1raTenR
Group
Groupe ~;~~~a . 03 045 00159
Manovellismo c::-h'
•.;10)'\ ""L.,,:s:.. Gruppo I :w:.~..l\
34
S1035
Steuerung I Dlstnbuicao Gruppe Grupo
Trrnmq
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pynesoe vnpaanenue
Group
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Distnbuzione ~ ~....::Ji Gruppo I ;u. ~....,.:;d.1
25
10
35
S1035
Kraftsloffpum
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d' ali pe I
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S1035
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de combustible
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rpynna .
07 090 00144
Pompa combuslJbile o~...j ~...J\ ~ Gruppo ....... ~......;dl
30 25
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37
S1035
Kraflstoff-Filter
Fuel Filter
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Filtre a combustible TonmlBHblH cPl1nbTp Groupe rpynna . 09 030 00111
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38
S1035
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116
95 98
107
110
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39
S1035
Kraftstoff-Rlter
Fuel Filter
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Gruppe
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Rltre a combustible TOnm-lBHblH ¢J11DbTP Groupe rpynna . 09 060 00029
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56 57 15
40
S1035
1~rbOChargeUr ISobreahm
Aufladung
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41
S1035
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42
S1035
Aufladung
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ovrahmentazione Ha,Q,lWB acton 00158
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43
S1035
Aufladung
Turbocharger
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09 075 00185
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44
S1035
Aufladung I Sobrealirnentacao Gruppe I Grupo
Grupo
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09 07 5 00191
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45
S1035
Luftpresser
I Compressor de I Grupo
g~~~;~~eur ;~=y~or~e a~~
Air Compressor Gruppe
Group G
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blH HOMn
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13 060 00079
77~
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15 45
55
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46
S1035
Luflpresser
Air Compressor
I Compressor de ar
Cornpresor de aire
Gruppe Grupo
~~~~a
Group
Compresseur d'air B03AYWHblH HOMnpeccop Groupe . 13 075 00126
Compressore aria ,\ y-;Ji.!a..i.L." Gruppo I :\...<;. ~....=,J.\
35
70 ~
65 ~
80
90@
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47
S1035
Luftpresser I Compressor de ar Gruppe Grupo
Air Compressor Cornpresor de aire
Compresseur d'air B03,QYWHbIH HOMnpeccop
Group
Groupe ~;~~~a . 13 075 00142
Compressore ana 'I.hJi .h..i.L..:. Gruppo I ~ .,.-J.\
130
48
Saugrohr und AuspuffkrUmmer Tuba de adrnissao e calector de escape S1035
Intake and Exhaust Manifolds
Collecteurs d'admissian et
Tuba de admision y calectar de escape
BnycHHaR Tpy6a '" uoneuo
Gruppe
Group
I Grupo
Grupa
d'echappernent BblnycHHora Tpy6onpoBaAa Groupe rpynna " 14 0 1 5 00194
Condollo aspirazione e callellare scarico ~i ~,U\.J LI""~i ""'.r'i Gruppa ;u: ~\
49
S1035
Auspuffkrummer
Exhaust Manifold
IColector de escape
Colector de escape
Gruppe
Group
I Grupo
Grupo
Collecteur d'echappernent KoneKOBblnycKKoro Tpy6onpoBoila Groupe rpynna . 14030 00267
Collettore scarico ~i t,Ui Gruppo W. ~~\
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210 ~ ,\:,220 195 185 190 ~ 175 155 C?0 @ 180
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120
50
Saugrohr und AuspuffkrOmmer Tubo de adrnissao e colector de escape S1035
Intake and Exhaust Manifolds Tubo de admislon y colector de escape Gruppe Grupo
Collecteurs d'admission et Group Grupo
d'echappement
BnycHHaA Tpyoa " HoneHO
BblnycHHoro TpyoonpoBoAa Groupe rpynna . 14030 00339
Condotto aspirazione e collettore scarico ~i ~'l,J\.J ..r"~i ..,..,y-,'i Gruppo I :Ls.~~1
~ 15
51
S1035
Gruppe
Group
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Grupo
Groupe rpynna 15 010 00007
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52
S1035
Elektrische Ausrustung
Electricai Equipment
IEquipamenlo electrico
Equipo electrico
Gruppe Grupo
~;~~~a
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Equipement electrique 3neHTpoo6oPYAoBaHHe Groupe 15 010 00008
Impianto elettrico <""';~J~i dJ~i Gruppo .....J~i
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53
S1035
Elektrische AusrUstung I
Equipamento electrico Gruppe I Grupo
g;~~~e ~;~~~B.
Electrical Equipment Equipo electrico
Equipernent electrique 3J1eHTpoo6oPYAosBHHe 15 01 0 00052
Impianto elellrico :c..,,;~~-..(Ji d~~i Gruppo U.~......;;--..ll
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395
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S1035
Eleklrische Ausrustung I Equipamento electrico Gruppe Grupo
Electrical Equipment
Equipement electrique
Equipo electrico
3I1eKTpoo6oPYAos8HHe
Group
Groupe %~~~8 . 15 010 00053
Impianto eleltrico :c..".;l:~.....;5Ji ",,\~~i Gruppo I :w.J.....q-..l.1
55
Elektrische Ausrilstunq
Electrical Equipment
I
Equipamenlo electrico
Equipo etectrlco
Gruppe
Group
I Grupe
Grupo S1035
Equipement electrique anexrpoodopvnoaauae Groupe rpynna . 15 0 1 5 00173
Implanlo elettrico ~~~-.;s:Ji d~i Gruppe ....... ~~I
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56
S1035
Elektrische A "
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I~~!~~r::~nltttelectriq~e ;~eUiPoelect~i~~ectrico
Electr'
E usrustung
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HTPoo6oPy~oBaH~e
15 030 00196
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9
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S1035
~uiPeme~i~'I~~~~~ IE' I grupo
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E~~:~~~~~o. electrico
Electrical Ausrustung Gruppe
Group
pianto elettrico e
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rupo 1 5 030
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----
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S1035
Elektrische A ..
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Group
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electriq Equipo eleCr electrico
~~ ~.oPYAOBaHHe
pianto eleltrico ue 3I1eK1;looD nco
Grou
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rupo
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59
S1035
Elektrische A
E . leal Equipme
Electrl
..
usrustun 9
I quipernent elect nt
I Equipo
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el .Jo, electrico
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G @,~ 142
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67 68 46 j
92
60
S1035
Elektrische Ausrllstunq IEquipamenlo alectrlco Gruppe Grupo
Electrical Equipment
Equipement electrique
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anearpootiopvnoeaaae
Group
Groupe %~~~a . 15 045 00172
Impianto elellrico :L,..:l;~,sJi d j...~i Gruppo I :Lc .....
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61
S1035
Elektnsche Ausrtistung
Electncal Equipment
I
Equipamento electrico
Equipo electnco
Gruppe
Group
I Grupo
Grupo
15 045
Equipement electnque 3neHTPOo6opY,QosaHHe Groupe rpynna . 00202
lrnpranto eJettnco ~~~....,s:Ji ,::..I.j-".p.c:Ji Gruppo :L.>.~~\
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62
S1035
Elektrische AusrUstung IEquipamento electrlco Gruppe Grupo
%~~~a
Electrical Equipment Equipo electrico Group
Equipement electrlque snearpootiopvnoaauae Groupe 15150 00001
Implanto eletlrico ~l.:~.,sJ\ d~~\ Gruppo :u:. ~.....,;;d\
63
S1035
~~~iS~ag~
~~t?rSChmierung
glne Lubricar ILubrifica -
du ~~~ur Lubricaci: d~~ motor
o Gruppe
Group
I
Grupo
G
18 0 15
'"-"-J~i
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yn na
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n cazione mot CMa3Ha AS" motor _ Grupp 0 :P 00165
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64
S1035
Motorschmierung I Lubricaci6n
Lubrificacao do motor Gruppe Grupo
Engine Lubrication
Graissage du moteur
del motor
CMa3Ka flBl-1raTeJ1A
Group
Groupe
Grupo
rpynna
. 18 045 00270
Lubrificazione motore .J;:;.rl\ ~ Gruppo I ..... ~......,.J.i
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145
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85
65
S1035
Motorschmierung I Lubricaci6n
Lubrificacao do motor Gruppe I Grupo
Grupo
Engine Lubrication del motor Group
Groupe rpynna .
18 060 00142
Graissage du moteur CMa3Ka ABHfaTeJ1R
Lubrificazione motore .J~~.....ll ~ Gruppo ;w;.~~\
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8 @75
5
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15
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105 IJ @~15
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S1035
Grup~
- do molar
Rejrigera~~.o
RefrigeraCI~~
MolorkUhlun.g S stem
Engine Cooling I Ju moleur oxna-anen
del motor
ABl-!raTenA
..
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Group I rpynna
Grup
•
20 0 1 5 00 294
Refroidissemen tore . .;;...J.I -'-7. .,T"7'
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283 ~ 275 215
282 160
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S1035
Molorkilhlung
Engine Cooling System
IRefriqeracao do molar
Refrigeraci6n del motor
Gruppe Grupo
24
(9JJ1l
68
S1035
Mot?rkuhlun.g
Engine Cooling System
IRefriqeracao do motor
Refrigeraci6n del motor
Gruppe
Group
I Grupo
Grupe
Refroidissement du moteur oxnal-H,QeHl-ie ,QBl-iraTenA Groupe rpynna 20 0 15 00366
Raffreddamento motore ) y ~.Ji _'-'.~ Gruppo :i....<:.~1
~
385
~ 415
405 350
69
S1035
I
MotorkOhlung
Engine Cooling System
Refroidissemenl du moleur
Raffreddamenlo motore
Refrigera<;:ao do molor
Refrigeraci6n del molor
oxnaHil1eHHe.QBHraTenR
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Groupe
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Grupo
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8
106~ '~M~1l8
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70
S1035
MotorkOhlung
Engine Cooling System
IRetriqeracao do motor
Refrigeraci6n del motor
Gruppe Grupo
Refroidissement du moteur OXJ1a/t{AeHHe ABHraTenA
Group
Groupe ~;~~~a . 20 030 00125
Raffreddamento motore . ,,;;...J.i _'-'--'-:;
J..;..,I •• ~ •
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20
30
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25 50
15
52
71
S1035
MotorkGhlung I
Refngerac;iio do motor Gruppe Grupo
Engine Cooling System
Refroldissement du moteur
Refrigeraci6n del motor
oxnafH/1eHfie /1BfiraTenR
Group
Groupe
Grupo
rpynna
20 100 00007
Raffreddamento motore JY~...J\ ~_~--7 Gruppo I ~~~i
72
S1035
Motoraufhanqunq
Engine Suspension
ISuspension
Suspensao do motor
del motor
Gruppe Grupo
Suspension du moteur
Sospensione del motore
nOABeCHa ABHraTeJlR
rl
.; ~...;; i "",:>'L..r
Group
Groupe ~;~~~a . 22 015 00100
Gruppo I :<....<..~\
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75
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80
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cc
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65
55 30
73
S1035
SonderausfUhrungen IVers6es especiais Gruppe Grupo
Special Versions
Versions speciales
Ejecuciones especiales
cneu-ransuea KOMnl1eHTaL\HR
Group
Groupe
Grupo
rpynna
23 010 00001
Versioni speciali :<..-.ui dj~':Ii -,i djly-laJi Gruppo I ,--,-~i
55
@ 53
W
52
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22
40
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74
S1035
Sonderausfilhrungen I Versoes especiais Gruppe
Special Versions Ejecuciones especiales Group
Versions speclales cneuaansaas HOMnneHTalll1R Groupe 00122
Versioni speciali .........u.i dj~...;~i -,i djl.."....wi Gruppo
20 25
75
S1035
Nebenantrieb
P. T. O. ITomad Gruppe
Group I Grupo
G
Grup~o ~=~i
Prise de fore .. Toma a de forca
Presa di f orzae auxillaire aTe>LOP de fuerza u Grou e rupo 00024
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cr'L,''':11, J-:,.i..:.::Ji 23 045
n~"c%lC
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160
70 112
50
766-------
S1035
Gruppe
Grou I GGrupo
rupo
Grup~~ ~pvnna
Group
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206
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201
25
77
S1035
~ebenantrieb
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Grou I GGrupo
rupo
Grup~~ ~:~i
Prise de fore "" lorna Group
Presa di f orza
e auxilialre oro opde fuerza 00032
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106
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trPQ45
78
S1035
ITomad
cr_.~_I. : J: : :_;~.-J~i_ _ ~ruppe
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P. T. O.
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Prise de fore Toma a de forca G~~up Grupe
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400
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295' 300
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290
79
S1035
Kaltekompressor
Refrigerant Compressor
Compressor do produto refngerante
Compresor de refrigeraci6n Gruppe
Group
I Grupo
Grupo
Compresseur pour installation d'air OXJ1aAHTeJ1b
conditio nne -'--:!~\ .;,-=.:.. -'i crW
Groupe rpynna . 23 07 5 00010
Compressore irnpianto refrigeratore Gruppo t i _~\
45 20
~
55
80
Kaltekompressor Compressor do produto refrigerante S1035
Gruppe Grupo
Refrigerant Compressor Compresor de refrigeraci6n
Group Grupo
Compresseur pour installation d'air oxnaAHTeJlb
Groupe rpynna 23 075 00018
conditionne ..l-;~\ ~ "i ..,.L.,5 Gruppo :t....c..~~i
Compressore impianto refrigeratore
60 ' l - - - - - - - - - - - - - - - - - - - ,
81
S1035
SonderausfUhrungen I
Vers6es especiais Gruppe Grupe
Special Versions
Versions speciales
Ejecuciones especiales
cneuaansaas KOMnneKTaLjYlA
Group
Groupe %~~~a . 23 1 0 0 00001
Versioni speciali ~L3-i dj~,:!i Ji d)\."..Jdi Gruppe I ~_~..l.\
82
S1035
Baumuster/Modef/Modele Katalog
Motor / Engine / Moteur 906.910, 911, 915, 916, 919-923, 925-928, 930, 06V
931,935,937-941,949-952,954-956,
960-965,976,982
909.900,901,910,911,920,921,960,970,971
926.911-915,917,924,929
83
S1035
S1035
~oll:,rgehiiuse
ngme Housin
Carter d
Carter d~1 motor Gruppe
G roup
I Grup 0
Carter d u moteur
B 9 aaprep motor
) ....:; ...J.o!'1BHraTeJ1R
Grou
G pe
Grupo
rpynna 01005 00039
AJ;. ~......;JI
asamento motore
I ~ ~ I J>.-.:,.o ruppo
07 ~inspritzung
ruection
Injection
Inyeccion
13
L~ftpresser
~Ir Compressor
C~mpresseur d'air
mpressore aria
Lenkhelfpum
Power Steerl pe
Pompe po ng Pump
Bomba de~~ servo-~irectlon
Elektrische A ,. servodirecclon
Electrical E usrustunq
EqUiPemeni~\~m,:nt
Equipo elect' ctnque
20 Motorkiihl
Engine Co~7? ?_2 Motoraufh" nco
Refroidissemng System Engine su:ngun~
Refrigeracione;tldu moteur
e motor suspensiO:~nslon
Suspension du
el moteur
motor
03 Triebwerkt 'I 09
Moving pa~' e
}(raftstoff-Filt
Fuel Filter er
Or s
P' ganesmoteurs Filtre ca~~mbustiblE'
a
iezas motrices Filtro
urante
85
S1035
Motorgehause , Carter do motor Gruppe Grupo
Engine Housing Carter del motor Group Grupo
Carter du moteur aapren /jBl-fraTeJlR Groupe rpynna 01 010 00035
Basamento motore ) y:;•..J.i w~ Gruppo I w-•......:;Ji
86
S1035
Motorgehause ICarter do motor Gruppe I Grupo
Engine Housing
Carter du moteur
Carter del motor
xaprep ~B",raTenA
Group
Groupe
Grupo
rpynna .
01 015 00250
Basamento motore ) ~ J...J.\ J>--=", Gruppo A...>:. J....-l\
314
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87
S1035
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Motorgehause
Ig~rter do motor gruppe
roup
I Grupo
Grupo
;w:.~i 01 045
arter du moteur arter del motor Groupe rpynna
Basamento motore Kap~ep IClBHraTeJ1A Gruppo 00207
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15
88
S1035
Motorgehause
Engine Housing
I
Carter do motor
Carter del motor
Gruppe
Group
I Grupo
Grupo
Carter du moteur HapTep ABVlraTeIlR Groupe rpynna • 01 060 00149
Basamento motore ).,...:;rl
i J5.....:;o Gruppo ~~......".J.I
92
380
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275
260\j
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344
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89
S1035
IHapTep
Carter del moto~R g~~~~ 01 060
Carter do motor
Motorgehiius.e
Engine Housln~r i;lBV1raT
Gruppe
Group
I rpynna. 00157
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95
75
90
S1035
Gruppe
Group I GGrupe
Greu
G pe
rupo
rpynna 01 060 00177
ruppo ~~~i
195
30(i') @
35
~
166
16
91
S1035
Motorgehause
Engine Housing
I
Carter do motor
Carter del motor
Gruppe 1 Grupo
Group Grupo
Carter du moteur saorep J;\Bl-lraTeJ1A Groupe rpynna , 01 060 00265
Basamento motore ).,...:;.,...t\ J5....".o Gruppo :w:. ~......:;d \
105
92
S1035
Cylmder H~ad
Zyhnderko f I
gUlatra
Culasse
Testata
ulata
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00228
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85
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55 g 0 45
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9 I:iJ 80
10 0 : ® 75
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172~
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93
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Cylinder Head
ICulatra
Culata
Gruppe
Group
I Grupo
Grupo S1035
Culasse ronoaaa 6noHa I.\HnHH.QpoB Groupe rpynna 0 1 075 00229
Testata .)..t...:LJi ,ri.) Gruppo U. ~~i
i 240
@245
196
CD@ 198
v 195 190
, @~ ~
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220
~ 235 230
([) @«riJ[)
200
~215
210
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94
S1035
CylinderH~ad ICulatra
Zylmderko f Gruppe
Group
I
Grupo
G
Gruppo ~:~i
JG~ro~~u:~p~e
Culasse Culata
6nt
00230
Testata
r- -'-JJ~1
ronoaua
·1 Ii
Ka
l.lWlHHApOB _ _ _ _ _ _ _ _ _ _ _ _ rupo 01 075
I ,-""'.J _
320
o
325
95
S1035
H~ad I Culatra
Zylinderko f
Cylinder g~~~pe I
Grupo
~Gr~upp;pP;;~ ~=~i 01
Culasse Culata Group Grupo 00291
Testata J..L:.l.Ji
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_________ 075
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165
gj
160 \J)1J
96
S1035
Zylinderkopf ICulatra
Cylinder Head Culata
Gruppe
Group
I Grupo
Grupo
Culasse ronoaaa onoKa !.1l1nHHAPOB Groupe rpynna 0 1 105 00069
Testata .)..L-i...J i J"' i.) Gruppo '-<. ~......:;Ji
68
~
' ~160
o
150 ~
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5
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115
47
97
S1035
Zylinderkopf I
Culatra
Cylinder Head Culata
Gruppe
Group
Culasse ronoBH,a6npHa UWlI1HAPOB Groupe 00080
Testata ..>..e-:U1 ~,..,I..> Gruppo
S)
50
o
59
77
e
8
98
S1035
Triebwerkterle
Moving Parts
I
Org30s motores
Piezas motnces
Gruppe
Group
Grupo
Grupo 03 015
Organes moteurs AeT8nH ABHraTeJ1R Groupe rpynnB . 00195
Manoveilismo ;.J\,~\ <.:JL...,,:s:.. ~ Gruppo I ;w.J~\
40
46
[PD
75
70
~
Q)O 65
73
99
S1035
Triebwerkteile
Moving Parts
I
Orqaos motores
Prezas motnces
Gruppe
Group
Organes moteurs nerana .QSHraTenR Groupe 00159
Manovelilsmo o.;b:;,rl ""~ e:---W Gruppo
100
S1035
Steuerung
Timing
I
Distnburcao
Dlstrlbucron
Gruppe
Group
Distribution pynesoe vnpaane-u-e Groupe 00147
Drstnbuzione "--="'" ~...:.:Ji Gruppo
25
10
to
15
101
S1035
Kraftstoffpumpe
Fuel Pump
I Bomba de combustivel
Bomba de combustible Gruppe
Group
I Grupe
Grupo 07 030 00290
Pompe d' alimentation Tonm'BHblH Hacoc Groupe rpynna
Pompa combustibile 0 ~...j~..J\ ~ Gruppo :L.>. ~...-.J.i
17
~ 70
102
S1035
Kraflstoffpumpe
Fuel Pump
I Bomba de combustivel
Bomba de combustible
Gruppe I Grupo
Group Grupo
Pompe d' alimentation Tonm,sHblH Hacoc Groupe rpynna 07 090 00157
Pompa combustJbile .)"..:i"..J\ ~ Gruppo ti~i
30 25
ij)~
103
S1035
Kraftsloff-Filter Filtro de combustivel Gruppe Grupo
Fuel Riler Rilro de combustible
Fillre a combustible TonmlBHblH cjJl1nbTp
Group
Groupe %~~~a . 09 030 00116
Fillro carburanle J r'~..Ji ;l....i...... Gruppo I ...... ~.....-..l\
c=::J
S~
c
fe 23
23 25
45
45
15 80 85
10
9°f~
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~~
60
1 35 40
60
1 75@
0
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75@ ~65 70~ ~65 \30
70~
104
S1035
Kraftstoff-Filler
Fuel Riter
Filtro de combustivel
Fillro de combusllble
Gruppe
Group
I Grupo
Grupo
Fillre a combustible TonmlBHblH epHObTp Groupe rpvnna _ 09 030 00125
Fillro carburanle 0.r'rli;L.i...a.., Gruppo u.~\
145@
@140
155@
o
~ e130
®145
175 120
165 ([®@ 165~~ 170
r@ 160
175 ~ ~
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~ij).
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200 190
105
S1035
Kraftstoff-Filter Filtro de combustivel Gruppe Grupo
Fuel Filter Filtro de combustible Group Grupo
Filtre a combustible TonIll1BHbll1 cPl1JlbTP Groupe rpynna 0903000150
Filtro carburante ".r" ~..Ji ,L.i...a.. Gruppo I ~~.....:;d\
115 110
f\)\.
\2!J c®.
115
CP~
113
95
97
105 105
106
S1035
Kraflstoff-Filter
Fuel Filter
Flltro de combustivel
Filtro de combustible
Gruppe
Group
I Grupo
Grupo
Rltre a combustibie TOnm-lBHblH ¢WlbTP Groupe rpynna . 09 060 00032
Rltro carburante ,~....;~..Ji ,L...i..a.. Gruppo "--<:.~~I
~
140 ~~
145
160 150
~130 @~
20 25 ~~155
165
(J;;J B 110
'\5-Qo 1f 12 0
_ ~15 ~ ®@ 100
40 ~~®II(
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" 30 S ~ 105
~~
115
5
90 95
107
S1035
Aufladung
Turbocharger
, Sobreahrnentacao
Sobreailmentaci6n
Gruppe
Group
I Grupo
Grupo
Turbochargeur HaMYS Groupe rpynna . 09 075 00148
Sovrailmentazione ~i jLr.- Gruppo :i..c~~1
~315
25
65
~94
~
160 220 eu 152
diJ"
251
f'~
190
~& ~
@P
280
®
IJ75 ~
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55
108
S1035
Aufladung
Turbocharger
, Sobrealimentacao
Sobrealimentaci6n
Gruppe
Group
I Gnupo
Grupo
Turbochargeur HaMYs Groupe rpynna . 09 0 7 5 00155
Sovralimentazione ..r=-0i )L;~ Gnuppo u~~\
@
175 ~
170
160
185~
~
280
G:
Q
()
Q
0
2 00
109
S1035
Aufladung
Turbocharger
Turbochargeur
ISobreailmenta
SObreailmenta~f·o
-
Sovrailmentaz',one HaAQYB
_ ,." jl.-.-"'" on
~\
235 295
~~
~~
«
«
f'
«
~380
~375
110
S1035
Aufladung
Turbocharger ISObreahment:~~·o
Sobreahrnent - Gruppe
Group
I Grupo
G
Grup~~ ~:~i 09 075
1urbOChargeUr Grou rupo
ovrahmentazione Ha,Qiwe IOn
00172
.:,-=:J\ jLr.-
~
312
152
o
O~
94
136
~
J~205
290 ~(@
310
102 165
~
))
111
S1035
Aufladung
Turbocharger
Turbochargeur
I Sobreahmentacao
Sobreahrnentaclon
Sovralimentazione HaMYS
,:,-=-:J' jL~
I'
~l1C
~
252 240
~~
1~43
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B
253 D
~J 0 242'0
114
108
0Q330 335
~
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340
~
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112
S1035
Luflpresser
Air Compressor I Compressor de ar
gompresseur d'air Compresor de arre
ompressore ana '\r)\
803.QYWHbli:i HOMnpeccop
L...i.L.:.
~77
~40
~75
70~
65
@>60 ~ 80
IJG
15 45
~
55
~~ 25 20
113
S1035
Luftpresser I Compressor de ar Gruppe Grupo
Air Compressor Compresor de aire
Compresseur d'air B03AYWHblH HOMnpeccop
Group
Groupe %~~~a . 13 075 00123
Compressore aria '\~~.Ji ,h..i.L.;. Gruppo I :i....l:.~~\
10
184
0
~
~ 66
~<\:: ~75
255~
185 ~190
@195 Qfi375
Q68
@70
114
S1035
Luflpresser
Air Compressor
ICompresor
Compressor de ar
de aire
Gruppe
Group
I Grupo
Grupo
Compresseur d'air B03AYWHblH HOMnpeccop Groupe rpynna , 13 075 00143
Compressore aria '\~~.Ji .h.i.~ Gruppo ~~\
~85
~80
175
G ~150 i 170
~
160. 145
6 0
0
-----------~> ('~ 155
~'::;. 140 ~~ 0 160 105 ~---:l ~
125 e. ~ <, = Q<:1 165
eJ9
\f=~?
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125
~ 130;;:~.
100 ~r~~
130 ~
105
115
S1035
Luflpresser I Compressor de ar Gruppe Grupo
~;~~~a .13075
Air Compressor Compresor de aire Group
Compresseur d'air B03AYWHblH HOMnpeccop Groupe 00144
Compressore aria .\ Ji.k-<.L..:,.
n Gruppo I ........ ~~\
~60
75~ 182
~187
116
S1035
Luftpresser I Compressor de ar Gruppe I Grupo
Air Compressor Compresor de atre
Compresseur d'air B03AYWHbll1 HOMnpeccop
Compressore ana ,I,r)i ~L.;"
g;~~~e %~~~a
Gruppo ~J~\
, 13 075 0 0 1 56
235
~
168
117
Saugrohr und AuspuffkrUmmer Tubo de adrrussao e colector de escape S1035
Intake and Exhaust Manifolds Tubo de adrrnslon y colector de escape Gruppe Grupo
Collecteurs d'admission et
d'echappernent
snycKHaR Tpy6a '" xoneno
8b,nycKHoro Tpy6onpo8oAa
Group
Groupe %~~~a . 14 015 00202
Condollo aspirazione e collellore scarico ~i r,L.JI J U"'~i Y..r:'i Gruppo I ti~.-d\
55 40
~5
~
~~~
~ c5illW-'
60 45
~11
80
25
118
S1035
Saugrohr und Auspuffkrilrnmer Tubo de adrrussao e cclector de escape
Intake and Exhaust Manifolds Tubo de adrrusion y colector de escape Gruppe Grupo
Collecteurs d'admission et
d'echappernent
BnycHHaR Tpy6a " aoneao
BblnyCHHOro Tpy6onpoBoAB
Group
Groupe %~~~a . 14015 00207
Condotto aspirazione e collettore scaricc ~i ~Ol.Jl3 J"'L4:..i ,-:,~i Gruppo I U:.~.-d\
80
t[]J
65~1
52
30
75
119
AuspuffkrOmmer
Exhaust Manifold
I
Colector de escape
Colector de escape
Gruppe Grupo
S1035
.s-,
QQ
55
60
120
S1035
AuspuffkrUmmer , Colector de escape Gruppe Grupo
Exhaust Manifold Colector de escape Group
Collecteur d'echappernent HoneHOBbtnycHHoro TPy60npoBot\a Groupe ~~~~~a . 14 030 00249
Collettore scarico
. '---"-':J.i ,Ui
~
Gruppo I u.~.....-l\
~ 25
~
60
~20
121
S1035
AuspuffkrUmmer IColector de escape Gruppe Grupo
~~~~~a
Exhaust Manifold Colector de escape Group
Collecteur d'echappernent xoneao BblnycKHoro TPyoonpoBoAa Groupe 14 030 00250
Collettore scarico ~i r,Ui Gruppo u~i
25
65@
122
S1035
Auspuffk ..
COII:~tuMa~~fold I~~~ector esca~: ~ruppe I
COllett~r:~~~happement
Exh rummer Grupo
Col ector de esca roup G
nco ~i ,..,LJi
de
eHOBblnycH Horo lpy6onpoBoAa ~roupe r~~~~a 14030 00264
_ _ _ _ _ _ _ _~nruJpp~PO ~ ~i
245
~
215
G
210 ~205
195 190
© (@ct®n190 195
170 (@ ©
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1~ 1/;f %J ~145 240 235
~
I
0
©
200 90
C@
185
123
S1035
Eleklrische Ausrlistung , Equipamento electrico
Electrical Equipment Equipo electrlco
Gruppe
Group
I Grupo
Grupo
Equipement electrique aneurpoooopvnoaauae Groupe rpynna . 1 5 0 10 00009
Impianto eletlrico ~~~-;5:J\ d~\ Gruppo ~ ~~.J.\
f1]23 580
17 ~
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7
~~74
::to
9 ~406
~382
448(]'p
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400 454@W~O\rQJ
442
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y472
: III Mer~edes-B!!n2 AG
520 526 ~ ~
532
538
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::
" 502
r"":
496 (ij ~ • 562
478 490 508 550
484 544
124
S1035
Elektrische Ausriistung
Electrical Equipment
I
Equipamento electrico
Equipo electrico
Gruppe
Group
Grupo
Grupo
Equipement electrique 3J1eHTpoo6oPY.QosaH",e Groupe rpynna 15010 00010
Impianto elettrico ....;l;~.......<.Ji d~i Gruppo ~~.......,di
II
41 II
II
II
II
II
~
"IIII
II
II
""
II
II
II
II
II
~] 47
125
Elektrische AusrUslung IEquipamento electrico Gruppe I Grupo S1035
~~~~~e ~;~~~a.
Eiectrical Equipment Equipo electrlco
Equipement electrique 3J1eKTpoo6oPY.'lOSaHHe 15 010 00050
Implanto elettrico ;;..",;~~-+()\ d~1 Gruppo u~.......::J\
06
~06 ~ Y49 (~)] ~516
~L1CQ)
08 B12 ,--,
010
o
p;:'= 08 510 0 000 I 22
Zl ~===;=""'" 517
Q
~
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53 516 Bll 516 / III
e I
KlO K16 418 ~03
Kll K17
@ 190
160
tn lCJ 2 5 0 ' (\)
235
m
~~~ 205 280
~295
145
B15 510
B16
l 310
412
~ 345
360
375
126
S1035
Elektrische Ausriistunq I
Equipamento eleclrico Gruppe Grupo
Electrical Equipment
Equipement electrique
Equipo electrlco
sneurpoooopvnoaaaae
Group
Groupe ~;~~~a . 15 010 00051
Impianto elettrico <""';~~-;5Ji d~i Gruppo I u.~~1
586
127
Elektrische Ausrtistung , Equipamento electrico Gruppe Grupo S1035
Electrical Equipment Equipo electrlco
Equipement etectrique 3IleHTPOo6oPY,QosaH",e
Group
Groupe %~~~a . 15 015 00173
Impianto elettrico ~~~....,.sJ\ d~~i Gruppo I w.~~\
30
6570~
®®~
\D
15
~()(§
~25 20
10
90 85~'
(§p® '
,
,
(§p® 80
55 75
128
S1035
17
5
129
S1035
Elektrische A
l~plPement
Electri
E
..
usrustung , Equlparnento electri
ui cal Equipment Gruppe
Group
I GGrupo
~G~ro~u~pe: I ~ynna
~ rupo
electrlq Equipo elect°. electnco
tanto elettrico ue ~~ ~,OPYAOBaHHe
anexrpooti nco _ _ _ _ _ _ _ _ Gruppo A....<:.J.....".JI. 1 5 03 0 00222
_ .~-+\ d~i _
~~~
W~105
50
255
120
130
S1035
I E;~Ui~~~~~~i~~ectrico
: :~ _: ':-;c.:J=- ~i g~~~~e I ~:~i 15 030
Elektrische A "
Electrical E ~srustung
F~~I~~t~enl~~~~~~~~e ui
Grup~~
e ettnco nearpoooop
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_
_ _ _ _ _ _ _ _ _ _ _ _ _ _ ~G~r:~o~u~
grupo
rupo
00229
~
200
~ ~~ 195
~ ~
175
GJ~ij) ~
90 95 60 125
I®J~
260 235
131
S1035
Elektrische A -,
I";Pi~~t~enll
E ui
Electrical ~srustung I E
Equiprnent
electri~~ectriCO
quiparnento
' els g~~~pe I Grupe
electrique ;qUipO
e ettrico ~~~.
nexrpootio
_.~ \d~i
PYAoBaHMe Grup~~
Group
~Pynna
Grupe
"-",~,,-,,,"J.\. 15 030 00258
282 278
132
S1035
Gruppe
Group I
Grupo
Grupo 15 045
00167
Groupe ~pyr::'li
Gruppo '-"-~ ,
140 70
144 138 @
~
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145
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158
l
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135 157 !fk-
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r
15
52
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154
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148
151 155
133
S1035
Elektrische AusrUstung IEquipo
Equipamento electrico Gruppe Grupo
Electrical Equipment
Equipement electnque
electnco
anesrrpootiopvnoeauae
Group
Groupe
Grupo
rpynna
15 045 00171
lrnpranto elettnco ~~~-;-Qi d~i Gruppo I ~~....qJ.i
~
~ 1 95
185
~ o
160
50
o
20
~
70
134
S1035
Elektnsche AusrUstung
Electncal Equipment
I
Equipamento electrlco
Equipo electnco
Gruppe
Group
Grupo
80~
60
o
(@65
45
~
'- ~1 90 (@
18~,~ 50
o
<,
r9\m:D\ @}200
197 \JV
135
S1035
Elektrische AusrUstung
Electrical Equipment
I
Equipamento electrico
Equipo electrico
Gruppe
Group
Grupe
Grupe 15 045
Equipement electrlque aneHTpoo6oPY,QosaHHe Groupe rpynna 00190
Impianto eJettrico :c...,,;~~....,.sJi d~i Gruppo 1 ;w:.~~i
25
136
S1035
Elektrische Ausnlstunq
Electrical Equipment
I
Equipamento electrlco
Equipo electrico
Gruppe
Group
Grupo
Grupo 15 150 00002
Equipement electrlque anearpootiopvnoaauae Groupe rpynna
Impianto elettrico :i....,,-:~~-oSJi d~i Gruppo u~~i
137
S1035
Molorschmierung
Engine Lubrication
I
Lubrificacao do molor
Lubricaci6n del motor
Gruppe
Group
I Grupo
Grupo
Graissage du moteur CMa3Ka I1BHraTenA Groupe rpy.nna . 18 0 15 00156
Lubrificazione molore .J~~....li ~ Gruppo u.~1
,
50
o
Q
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30
35
138
S1035
Mot,?rsctu~~T~~~n
Engine d moteur c
.. cao do motor
L~~~':ac~~HraTeJ1R
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_ \ ~
Gruppe
Group
I~~~~~
rpynna.
18 045 00259
Graissag~ Ue motore
Lubrificazlon I
j.J-'.rl _ __ Gruppo
Groupe :L..>:......."dl - _ _ _ _ _ _
J I
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85~
80~
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25 5
48
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70
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46
40
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95~~
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S1035
Motorschmierung I
Lubrificacao do motor Gruppe Grupo
%~~~8 .18 045
Engine Lubrication Lubricaci6n del motor Group
00283
Graissage du moteur
Lubrificazione motore
CM83Ha ABHr8TenR
.J..,..:;.rti ~
Groupe
Gruppo I :w.~...-JI
~ 135
132 @ @b~140 100
133 \l.9I ~~~~
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130 o
125
o
0 0
0
0
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a
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a a 0
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110
105
140
S1035
Motorschmierung I Lubricaci6n
Lubrificacao do motor Gruppe Grupo
Engine Lubrication
Graissage du moteur
del motor
CMB3Ha ABl1raT€llR
Group
Groupe
Grupo
rpynna
18 060 00143
Lubrificazione motore .J~":;~....li ~ Gruppo I u_~i
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15
~90
~35 ~o@>
60
~ 125
105~ @~5
75
20
\j) 125
@ 10
141
S1035
Motorschmierung I Lubrificacao do motor Gruppe
Group
Grupo
%~~~a . 18 060
Engine Lubrication Lubricaci6n del motor
Graissage du moteur CMa3Ha ABHraTeJ1R Groupe 00144
Lubrificazione motore .;Y:;.rll ~ Gruppo I u.~1
27
d2
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@ 80
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30
_. ~65
~_~80
102 @ -::cE:J
110
Cfl
135
142
S1035
- do motor
.
Engine .Coohn~t au moteur
Motorkilhlung S stem
Refngera9~.o
. eraclon
Refng
del motor
0XJla>H~ ~ -,.'
euae ABl<raTeJ1A Gruppe
Group
I g~~~~
rpynna.
20 0 15 00317
RefrOldlssem~tomotore .,~ ~~\
Raffreddame
I
) y y-l Groupe
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160 205 D: ~
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45
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200
42
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103
100
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1
143
S1035
Motorklihlung
Engine Cooling System
IRefrigerac;ao do molor
Refrigeraci6n del molor
Gruppe I Grupe
Group Grupo
Refroidissemenl du moleur oxnal-HAeHHe ABHraTenA Groupe rpynna , 20 0 15 00327
Raffreddamento molore . .:; ~i -'-'.-,.,-:;
..,J .... ..; •
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~
340 ©)
410
~~
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~o
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400
I1J
425 Q';;::)
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305 300
430 ~
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370 375
s Q
355 440
@
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315
350
( \ 410
\J~ 325
415
144
S1035
MotorkOhlung
Engine Cooling System
I
Refriqeracao do motor
Refrigeraci6n del motor
Gruppe Grupo
%~~~a. 20015
Group
Refroidissement du moteur oxnaltlgeHl1e gBl1raTenA Groupe 00387
Raffreddamento motore , .;;,.Ji -,--,-:;
-"J.... ---' .
Gruppo I :\..s.~1
24
~
145
S1035
Molorkuhlullg
Engine Cooling System
IRefrigeraci6n
Refriqeracao do molor
del molar
Gruppe
Group
Grupo
Refroldlssement du moleur oxnaH<l1eHHe I1BHraTenA Groupe %~~~a. 20015 00400
Raffreddamenlo molore J~':;~....l\ _'--.~-:; Gruppo I w.....I~.l\
106~
226
~
<,
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~ 120
115
o
8
~210
106~
~
109
r!fI M o
V~~113
l/fJ
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146
S1035
Molorkiihlung , Refriqeracao do motor Gruppe
Engine Cooling System Refrigeraci6n del motor Group
Refroidissemenl du moleur oxna>HAeHHe ABHraTeJlR Groupe 00133
Raffreddamenlo molore . .:; ..J. i -'-' -:; Gruppo
-'.J' -' .......
20
, ~
® 45 55
50
15
10
147
S1035
MotorkGhlung IRefrigeraci6n
Refriqeracao do motor Gruppe Grupo
Engine Cooling System
RefrOidissement du moteur
del motor
oxnalH/leHl1e /lBl1raTenA
Group Grupo
rpynna
20 100 00007
Raffreddamento motore JY.ri' -'-'_~-:-'
Groupe
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...... ~~i
148
S1035
Gruppe
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Groupe ~ynna i
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®120
~5 75
om@;
88
86
~
65
149
I S1035
Motoraufhangung
Engine Suspension
Suspension du moteur
Sospensicne del motore
Suspensao do motor
Suspension del motor
nonaecxa ASHraTeJ1R
.;..,...:; y-ti c:/:IL?-
Gruppe
Group
Groupe
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30(~
80
85 ~
150
S1035
Special Ver~orungen
speci~f
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I
Versoes I
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151
S1035
SonderausfOhrungen , Vers6es especiais Gruppe Grupo
Special Versions
Versions speciales
Ejecuciones especiales
cneuaanenaa HOMnneHTaL\HR
Group
Groupe
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rpynna
23 015 00118
Versioni speciali ........LJ.i dj~~i."i djlJ...bJi Gruppo I u.J~i
20 25
152
S1035
Nebenantrieb
P. T. O. I Tomad Gruppe
Group I Grupo
G
~G~ro~~u:~~
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Prise de fore Toma a de forca
Presa di f orzae auxiliaire oT6opde fuerza
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rupo 00016
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50 70
153
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S1035
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op MOl11HOC,TH
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154
S1035
Gruppe
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230
\."
ci~~ ~~o
225
205
155
S1035
Nebenantrieb
P. T. O. , Tomad Gruppe
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Prise de fore Tom a de forca
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r----
e auxiliaire oT6op
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rupo 23 045
. I 00032
106
103
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135 140 145
<rPQ 45
156
S1035
~ebenantrieb
, T.O,de forc IToma
Tomad a de forca Gruppe
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I
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G
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405 410 415 420
@
395 400 ""'" 365
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(i)
325 15
157
Kaltekompressor Compressor do produto refrigerante
Gruppe Grupo S1035
Refrigerant Compressor Compresor de refriqeracion
%~~~a, 23 075
Group
Compresseur pour installation d'air oxnaA>1Tenb
Groupe 00007
conditlonne
Compressore impianto refrigeratore
.L.;.~\ .:r-=.:... "i U"L,5 Gruppo I w.~\
70
4125
45
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158
I S1035
SonderausfOhrungen Vers5es especiais
Special Versions
Versions speclales
Versioni speciali
Ejecuciones especiales
cneuaansaas HOMnneHTal1HA
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159
S1035
SonderausfDhrungen
Special Versions
IVers6es especiais
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S1035
SonderausfUhrungen
Special Versions
IVers6es especiais
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13807
ENGINE FILTERS
Page 1 of 1
Updated:
03/04/10
13661
RADIATOR INSTALLATION
Page 1 of 1
Updated:
03/02/10
13660
CHARGE AIR INSTALLATION
Page 2 of 2
ITEM PART # DESCRIPTION QTY.
1 465216 RADIATOR ASSEMBLY (DDC 904) 1
2 12567-05 SILICONE HOSE 4” 1
3 7043-00024 TUBE WELDMENT LOWER (CHARGE AIR) 1
(NOTE: OLD NUMBER WAS 12964-01)
4 605663 SILICONE HUMP HOSE (3 ½” ID) 1
5 12929-01 CHARGE AIR TUBE 1
6 N/A CHARGE AIR TUBE (SEE DETROIT DIESEL) 1
7 595320 SILICONE CONNECTOR (3 ½” ID) 1
8 12964-03 TUBE WELDMENT UPPER (CHARGE AIR) 1
9 12567-05 SILICONE HOSE 4” 1
10 146043 CHARGE AIR COOLER CLAMP BOLT 1
11 146042 CHARGE AIR COOLER CLAMP 1
12 146105 CHARGE AIR COOLER NUT 1
13 146044 CHARGE AIR COOLER SEAL 1
Updated:
03/02/10
13713
AIR INTAKE SYSTEM
Page 1 of 1
Updated:
12/30/09
S1020
S1020
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
5. DRIVE TRAIN
17193 TRANSMISSION
13436 TRANSMISSION MOUNTS
17331 TRANSMISSION DIPSTICK
S1005 TRANSMISSION MAINTENANCE & SERVICE
MANUAL
13675 DRIVELINE INSTALLATION
TRANSMISSION ASSEMBLY 17193
465563 Page 1 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 2 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 3 of 38
28 24933 SUCTION TUBE ASSEMBLY 1
29 04GE06 SUCTION TUBE RETAINER SCREW/LOCKWASHER 1
(PART OF ITEM 30)
30 24191 SUCTION TUBE RETAINER SCREW & LOCKWASHER 1
31 24474 TUBE CLIP SCREW 1
32 24473 TUBE CLIP SCREW LOCKWASHER 1
33 24592 TUBE CLIP 1
34 24921 REVERSE TUBE ASSEMBLY 1
35 24684 REVERSE TUBE O-RING 1
36 24474 LUBE TUBE RETAINER SCREW 1
37 24473 LUBE TUBE RETAINER SCREW LOCKWASHER 1
38 24920 LUBE TUBE ASSEMBLY 1
39 24474 TUBE CLIP SCREW 1
40 24473 TUBE CLIP SCREW LOCKWASHER 1
41 24592 TUBE CLIP 1
42 24922 3RD SPEED TUBE ASSEMBLY 1
43 24684 3RD SPEED TUBE O-RING 1
44 24924 VALVE OIL SUPPLY TUBE 1
45 24686 TRANSMISSION CASE TO CONVERTER HOUSING 10
SCREW
46 24435 TRANSMISSION CASE TO CONVERTER HOUSING 10
SCREW LOCKWASHER
47 24047 CONVERTER HOUSING TO TRANSMISSION CASE 1
GASKET
48 24338 CONVERTER HOUSING TO TRANSMISSION CASE 2
DOWEL PIN
57 244384 SPEED SENSOR ADJUSTER BUSHING 1
58 244387 SPEED SENSOR ADJUSTER SHIM A/R
59 244388 SPEED SENSOR HOLE PLUG 1
60 244389 SPEED SENSOR O-RING 1
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 4 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 5 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 6 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 7 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 8 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
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Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
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Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
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Updated:
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TRANSMISSION ASSEMBLY 17193
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Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 13 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 14 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 15 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 16 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 17 of 38
30 24962 SPRING RETAINER SNAP RING RETAINER 1
31 24298 SPRING RETAINER SNAP RING 1
32 24293 CLUTCH DRIVEN GEAR BEARING 1
33 244652 CLUTCH DRIVEN GEAR BEARING SNAP RING 1
34 NOT USED ON THIS MODEL
35 24610 SPRING RETAINER 1
36 24609 PISTON RETURN SPRING 1
37 24607 SPRING RETAINER 1
38 24962 SPRING RETAINER SNAP RING RETAINER 1
39 24298 SPRING RETAINER SNAP RING 1
40 24611 3RD GEAR BEARING 1
41 24579 3RD GEAR BEARING SNAP RING 1
42 N/A NOT USED ON THIS MODEL
43 24613 3RD GEAR BEARING SPACER 1
44 24579 3RD GEAR BEARING SNAP RING 1
45 24614 3RD GEAR BEARING – SHIELD OUT 1
46 244559 REVERSE & 3RD SHAFT REAR BEARING 1
47 24581 GEAR RETAINING RING 1
48 244695 LOW CLUTCH DRIVE GEAR 1
49 24612 3RD GEAR 1
50 244266 CLUTCH DRIVEN GEAR 1
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 18 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 19 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 20 of 38
30 24058 CLUTCH OUTER DISC – 2ND CLUTCH 7
31 244546 CLUTCH INNER DISC – 2ND CLUTCH 7
32 244691 CLUTCH PISTON ASSEMBLY – 2ND CLUTCH 1
33 24526 CLUTCH PISTON OUTER SEAL 1
34 24529 CLUTCH PISTON INNER SEAL 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
38 24529 CLUTCH PISTON INNER SEAL 1
39 24526 CLUTCH PISTON OUTER SEAL 1
40 244694 CLUTCH PISTON ASSEMBLY – FORWARD CLUTCH 1
(INCLUDES ITEMS 38 & 39)
41 24058 CLUTCH OUTER DISC. – FORWARD CLUTCH 6
42 244546 CLUTCH INNER DISC. – FORWARD CLUTCH 6
43 24583 END PLATE – FORWARD CLUTCH 1
44 24568 END PLATE RETAINER RING 1
45 244266 FORWARD CLUTCH DRIVEN GEAR 1
46 244235 2ND GEAR 1
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 21 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 22 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 23 of 38
30 244715 REAR BEARING CAP O-RING 1
31 244710 BEARING CAP SHIM - .004 A/R
31A 244711 BEARING CAP SHIM - .007 A/R
31B 244712 BEARING CAP SHIM - .010 A/R
31C 244713 BEARING CAP SHIM - .020 A/R
32 244716 O-RING PRESSURE TUBE 1
33 244453 REAR BEARING CAP PLUG 1
34 244714 REAR BEARING CAP 1
35 04GE06 REAR BEARING CAP LOCKWASHER 5
36 24673 REAR BEARING CAP CAPSCREW 5
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 24 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 25 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 26 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 27 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
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Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
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Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
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Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
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Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
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Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 33 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
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Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 35 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 36 of 38
ITEM PART # DESCRIPTION QTY.
ELECTRIC CONTROL VALVE ASSEMBLY
1 244641 CONTROL VALVE COVER ASSEMBLY 1
(INCLUDES ITEM 2)
2 244639 CLUTCH PRESSURE PORT PLUG 6
3 244638 CONTROL VALVE COVER TO HOUSING GASKET 1
4 244640 CONTROL VALVE ASSEMBLY – TO CONVERTER 2
HOUSING SCREW
5 244154 CONTROL VALVE ASSEMBLY SCREW WASHER 2
6 N/A NOT USED ON THIS MODEL
7 N/A NOT USED ON THIS MODEL
8 N/A NOT USED ON THIS MODEL
9 N/A NOT USED ON THIS MODEL
10 N/A NOT USED ON THIS MODEL
11 N/A NOT USED ON THIS MODEL
12 N/A NOT USED ON THIS MODEL
13 N/A NOT USED ON THIS MODEL
14 N/A NOT USED ON THIS MODEL
15 244628 CONTROL VALVE ASSEMBLY TO CONVERTER 1
HOUSING GASKET
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 37 of 38
Updated:
10/28/08
TRANSMISSION ASSEMBLY 17193
465563 Page 38 of 38
Updated:
10/28/08
13436
TRANSMISSION MOUNTS
Page 1 of 1
Updated:
12/11/06
17331
TRANSMISSION DIPSTICK
Page 1 of 1
Updated:
04/01/10
S1005
Specifications
Model 32000 Series Transmission
Before towing the vehicle, be sure to lift the rear wheels off the NOTE: If the transmission has 4 wheel drive, disconnect both
ground or disconnect the driveline to avoid damage to the trans- front and rear drivelineSl Because of the design otthe hydraulic
mission during towing. system, the engine cannot be started by pushing or towing.
/j
S1005
FORWARD
This manual has been prepared to provide the customer and the
maintenance personnel with information and instructions on the
maintenance and repair of the SPICER OFF-HIGHWAY COMPONENTS
DIVISION product.
Extreme care has been exercised in the design, selection of materials and
manufacturing of these units. The slight outlay in personal attention and
cost required to provide regular and proper lubrication, inspection at
stated intervals, and such adjustments as may be indicated with be
reimbursed many times in low cost operation and trouble free service.
In order to become familiar with the various parts of the product, its
principle of operation, trouble shooting and adjustments, it is urged that
the mechanic study the instructions in this manual carefully and use it as
a reference when performing maintenance and repair operations.
TABLE OF CONTENTS
Reverse and 3rd and Forward and 2nd Clutch Group Fig. D
DISASSEMBLY OF TRANSMISSION 1
REASSEMBLY OF TRANSMiSSiON 38
LUBRiCATION 57
R-MODEL SECTION 70
8 SPEED SECTION 92
TRANSMISSION ASSEMBLY
The transmission and hydraulic torque portion of the power train enacts an important role in transmitting
engine power to the driving wheels. In order to properly maintain and service these units it is important
to first understand their function and how they operate.
The transmission and torque converter function together and operate through a common hydraulic system.
It is necessary to consider both units in the study of their function and operation.
To supplement the text below, and for reference use therewith, the following illustrations are provided:
The R, HR, and MHR Model Transmissions are of three basic designs.
The R Model consists of a separate torque converter, mounted to the engine with the powershift trans-
mission remotely mounted and connected to the torque converter with a drive shaft.
The HR Model consists of a torque converter and powershifted transmission in one package mounted directly
to the engine.
The MHR version is a mid-mount torque converter and transmission assembly connected to the engine by
means of a drive shaft. (See Fig. A for basic design silhouette.)
The shift control valve assembly may be mounted directly on the side of the converter housing or front
transmission cover, or remote mounted and connected to the transmission by means of flexible hoses. The
function of the control valve assembly is to direct oil under pressure to the desired directional and speed
clutch. A provision is made on certain models to neutralize the transmission when the brakes are applied.
This is accomplished through use of a brake actuated shutoff valve. The speed and direction clutch assem-
blies are mounted inside the transmission case and are connected to the output shaft of the converter either
by direct gearing or drive shaft. The purpose of the speed or directional clutches is to direct the power
flow through the gear train to provide the desired speed range and direction.
An axle disconnect is optional and is located on the output shaft. The drive to the front or rear axle can
be disconnected or connected by manual shifting.
S1005
With the engine running, the converter charging pump draws oil from the transmission sump through the
removable oil suction screen and directs it through the pressure regulating valve and oil filter.
The pressure regulating valve maintains pressure to the transmission control cover for actuating the direc-
tion and speed clutches. This requires a small portion of the total volume of oil used in the system. The
remaining volume of oil is directed through the torque converter circuit to the oil cooler and returns to
the transmission for positive lubrication. This regulator valve consists of a hardened valve spool operating
in a closely fitted bore. The valve spool is spring loaded to hold the valve in a closed position. When a
specific pressure is achieved, the valve spool works against the spring until a port is exposed along the
side of the bore. This sequence of events provides the proper system pressure.
After entering the converter housing the oil is directed through the stator support to the converter blade
cavity and exits in the passage between the turbine shaft and converter support. The oil then flows out of
the converter to the oil cooler. After leaving the cooler, the oil is directed to a fitting on the transmission.
Then through a series of tubes and passages lubricates the transmission bearings and clutches. The oil then
gravity drains to the transmission sump.
The hydraulic torque converter consists basically of three elements and their related parts to multiply engine
torque. The engine power is transmitted from the engine flywheel to the impeller element through the
impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary com-
ponent which starts the oil flowing to the other components which results in torque multiplication. This el-
ement can be compared to a centrifugal pump in that it picks up fluid at its center and discharges at its outer
diameter.
The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the
torque converter. This element receives fluid at its outer diameter and discharges at its center. Fluid directed
by the impeller out into the particular design of blading in the turbine and reaction member is the means
by which the hydraulic torque converter multiplies torque.
The reaction member of the torque converter is located between and at the center or inner diameters of the
impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion
of the turbine and change its direction to allow correct entry for recirculation into the impeller element.
The torque converter will multiply engine torque to its designed maximum multiplication ratio when the out-
put shaft is at zero RPM. Therefore, we can say that as the output shaft is decreasing in speed the torque
multiplication is increasing.
The shift control valve assembly consists of a valve body with selector valve spools. A detent ball and spring
in the selector spool provides one position for each speed range. A detent ball and spring in the direction
spool provides three positions, one each for forward, neutral and reverse.
With the engine running and the directional control lever in neutral position, oil pressure from the regulat-
ing valve is blocked at the control valve, and the transmission is in neutral. Movement of the forward and
reverse spool will direct oil, under pressure to either the forward or reverse direction clutch as desired.
S1005
When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through
the direction selector spool. The same procedure is used in the speed selector.
The direction or speed clutch assembly consists of a drum with internal splines and a bore to receive a hy-
draulically actuated piston. The piston is "oil tight" by the use of sealing rings. A steel disc with external
splines is inserted into the drum and rests against the piston. Next, a friction disc with splines at the inner
diameter is inserted. Discs are alternated until the req uired total is achieved. A heavy back-up plate is then
inserted and secured with a snap ring. A Hub with 0.0. splines is inserted into the splines of discs with
teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direc-
tion as long as no pressure is present in that specific clutch.
To engage the clutch, as previously stated, the control valve is placed in the desired position. This allows
oil under pressure to flow from the control valve, through a tube, to a chosen clutch shaft. This shaft has
a drilled passageway for oil under pressure to enter the shaft. Oil pressure sealing rings are located on the
clutch shaft. These rings direct oil under pressure to a desired clutch. Pressure of the oil forces the piston
and discs against the heavy back-up plate. The discs, with teeth on the outer diameter, clamping against
discs with teeth on the inner diameter, enables the hub and clutch shaft to be locked together and allows
them to drive as a unit.
There are bleed balls in the clutch piston which allow quick escape for oil when the pressure to the piston
is released.
FIG. A
S1005
"
~"
\
57
58
Figure B
S1005
MHR OPTION
73
Figure C
S1005
Figure D
S1005
R OR HR32000
REVERSE & 3RD & FORWARD & 2ND CLUTCH GROUP
52
53 \ .>:
55 54
56 \ \
~GY
58 57\ \ .'~'
~~\\)
-;"
59 \ rr"~
r~i·~
\~~~
~"'"
\
60
61
74 77 78 79 80
72 73 \ \ ~\ \
71~\ ~~
76
\~. ~\,l)
75 \~~~
~~.~
70
\
~ 82 81
Figure E
S1005
_ PRESSURE 34
REGULATOR SlOE
Figure F
S1005
kli
28--~
29-1Q)
30-~
26 31-~
32_a
33~~
34'--. ~
35~§
~
r---------------T-----~-----T--------------~
I DEC.lUTCH I DEClUTCH I DEClUTCH INCHING I
FORWARD & REVERSE ONLY FORWARD ONLY
REVERSE
~-36
t" "11
37
t I
L
3J
FIG. A
_
FIG. B
38-1
t 3J
FIG.C
---l
38__ 1
39__
I 40_®
e
I 41 __ ~
I
! u--ll
~>
48 I
I
F1G:{J I
L J
8 - 20
/
NOTE:
Speed selector spacers (items 13 and 22) and the
declutch valve (item 26) are not included when the
control valve housing assembly (item 14) is ordered.
When ordering the control valve housing assembly
(Item 14) from the service Parts List also order the
spacer or spacers listed as Items 13 and 22 and the ~o
declutch valve, spool and spring needed. NOTE:
Some valves will require no spacers, some valves will
7 I
require 1 spacer and some will require 2 spacers. 8
FigureG
S1005
15 Detent Spring Plug . Figures A-B-C & D are various declutch options.
AXLE DISCONNECT
Figure H
S1005
AXLE DISCONNECT
8 Disconnect Shaft .
Lock Nut .
9 Brake Flange .
2 Washer .
10 Brake Drum .
4 Backing Plate .
12 Brake Drum Screw. . . . . . . . . . . . . . . . . . . . . . .. 6
5 Cam Shaft .
13 Brake Lining .
6 Strut Assembly .
14 Rivet Kit 24
7 Return Spring .
15 Backing Plate Screw. . . . . . . . . . . . . . . . . . . . .. 4
View"Q"
1.
HOUSln9th
spacer
used WI 12 plate
modulation only.
Figure I
S1005
Impeller Hub and Turbine Hub Assembly with & Heat nose bushing to 2000 FO (930C) before ass'y. of
Backing Ring and Special Self Locking Screws. bushing to cover.
1. Clean hub mounting surface and tapped holes
with solvent. Dry thoroughly being certain tapped Bearing shield OUT on 3rd speed clutch. Bearing shield
holes are dry & clean. IN on Fwd. & Rev. clutch.
2. Install backing ring and special self locking Must be loose internal fit bearings, No. "3" etched on
screws. bearing.
Tighten screws 40 to 45 Lbs. Ft. [54,3-61,0 N'm]
Note: Assembly of hub must be complete within a
fifteen minute period from start of screw installa-
&. (12 Plate Modulation)Two clutches, 12-outersteel plates,
12-inner friction plates. Assemble alternately, starting
tion. The special screw is to be used for one in- with outer steel plate.
stallation only. If the screw is removed for any
reason it must be replaced. The epoxy left in the Notes
hub holes must be removed with the proper tap A.. Use Permatex & Crane Sealer only where
and cleaned with solvent. Dry hole thoroughly and specified.
use a new screw for reinstallation. B. - All lead in chamfers for oil seals, piston rings &
"0" rings must be smooth & free from burrs.
Gear to be assembled with long hub length to this Inspect at ass'y.
side. C.. Lubricate all piston ring grooves & "0" rings
with oil before ass'y.
&. Three c1utches,6-outer steel plates,6-inner friction D. - Apply very light coat of Permatex NO.2 to 0.0.
of all oil seals before ass'y.
plates.Assemble alternately, starting with outer
steel plate. E.. After assembly of parts using Permatex or
Crane sealer, there must not be any free or
& See Elastic Stop Nut Torque Chart excess material that could enter the oil circuit.
F. - Apply light coat of Crane Sealer to all pipe
&, Low clutch,9-outer steel plates,9-inner friction plugs.
plates. Assemble alternately, starting with outer G. - Apply a thin coating of grease between seal
steel plate. lips on lip type seals prior to ass'y.
H. - Apply light coat of Permatex NO.2 to all thru
& See Elastic Stop Nut Torque Chart hole stud threads.
~
the disc.
Low Clutch Return Springs.
Concave side of first spring to be placed
against clutch piston. Remaining four springs
to be stacked alternately reversed as shown.
L-,~~+
5000 ,
91 - 100
64 - 70
1123,4 -
I 86,8-
135.51
94,91
82 -
57 -
90 1111,2 -
I 77,3-
122,01
85,41
128 -
141 1-173,6 -
[122,1 -
191,11
134,21
115 - 127 1156,0-172,2
63 90 -
99 80 - 88 1108,5 - 119.3
4375 41 - 45 1 55,6- 61,01 -- 37 -
41 r 50,2- 55,51 58 -
64 I 78,7- 86,71 52 - 57 r 70,6- 77,2
3750 26 - 29· I 35,3- 39,3J 23 - 25 r 31,2- 33,8\ 37 -
41 r 50,2- 55,51 33 - 36 r 44,8- 48,8
3125 16 - 20 i 21.7- 27,11 12 - 16 [ 16,3- 21,61 28 - 32 I 38,0- 43,31 26 - 30 r 35,3- 40,6
2500 9 - 11 I 12.3- 14.91 8- 10 [ 10,9- 13,5] i1- 13 [ 15,0- 17,61 9 - 11 I 12,3- 14,9]
Figure I
S1005
Figure J
S1005
The instructions contained herein cover the disassembly and shafts with and without disconnect assemblies may vary on
reassembly of the transmission in a sequence that would nor- specific models. The units are very similar to trouble shoot,
mally be followed after the unit has been removed from the
disassemble, repair, and reassemble. Drain as much oil as
machine and is to be completely overhauled. It must also be possible before disassembly. See page 70 for R-Model
understood that this is a basic HR32000 3 speed long drop
(remote mounted) transmission front cover section. See page
transmission with many options. Companion flanges and output 85 for 6 & 8 speed maintenance information.
DISASSEMBLY
Figure 1 Figure 3
Side view of 3 speed HR32000 long drop transmission. Removefilter element housing and element. NOTE: It is recom-
mended a small pan be used to catch remaining oil in element
housing.
Figure 2
Remove two valve to converter housing capscrews. Install two
aligning studs as shown. Remove remaining capscrews. Figure 4
Remove control valve and gasket.
Remove charging pump to pressure regulating valve stud nuts.
-1-
S1005
Figure 5 Figure 8
Remove charging pump and filter adaptor assembly. Remove pump adaptor bolts, adaptor and gasket.
Figure 9
Remove impeller cover bearing cap bolts. NOTE: Some
Figure 6 units will have drive plates instead of ring gear. Remove
Remove pressure regulating valve assembly and "0" rings. drive plates.
Figure 7 Figure 10
Remove pump drive sleeve and gasket. Remove bearing cap and "0" ring.
-2-
S1005
Figure 14
Remove reaction member.
Figure 11
Remove impeller cover to impeller bolts.
Figure 15
Remove reaction member spacer.
Figure 12
Remove impeller cover and turbine as an assembly.
Figure 16
Remove oil baffle retainer ring. Using pry slots in converter
housing, pry oil baffle and impeller from housing. NOTE:
Figure 13 Impeller, oil baffle and impeller hub gear are removed as an
Remove reaction member retainer ring. assembly.
-3-
S1005
Figure 20
Figure 17 Remove pump drive gear support bolts.
Remove impeller assembly.
Figure 21
Figure 18 Remove pump drive gear and bearing assemblies.
Remove stator support to housing bolts.
Figure 22
Support converter housing with a chain fall. Remove converter
Figure 19 housing to transmission housing bolts. NOTE: For converter
Remove stator support. NOTE: Support must be turned to clear housing removal on the 8 speed transmission, see Figure
pump drive gear. 1 In the 8 speed section, page 93.
-4-
S1005
Figure 23
Separate the converter housing from the transmission
housing. Remove gasket. NOTE: Forward and 2nd clutch will Figure 26
remain in converter housing. Remove turbine shaft gear.
Figure 24
Use a spreading type snap ring pliers to spread the ears on for- Figure 27
ward clutch front bearing retainer ring. Remove forward clutch Tap turbine shaft and bearing from converter housing.
with pry bar.
Figure 25 Figure 28
Remove turbine shaft gear retainer ring. Remove bearing from turbine shaft.
-5-
S1005
Figure 29 Figure 32
Remove 2nd clutch disc hub retainer ring retainer. Remove disc hub.
Figure 30 Figure 33
Remove disc hub ring retainer. Remove bearing end plate.
Figure 34
Figure 31 Remove brake drum stud nuts (used only to hold drum in place
Remove disc hub retainer ring. after drive shaft was removed).
-6-
S1005
Figure 35 Figure 38
Remove brake drum. Pry brake strut from brake bands.
Figure 36 Figure 39
Remove output flange nut, washer and "0" ring. Remove brake backing plate bolts.
Figure 37 Figure 40
Remove output flange. Remove backing plate and brake band assembly.
-7-
S1005
Figure 41 Figure 44
Remove idler shaft rear bearing cap bolts and washers. Remove rear bearing locating ring.
Figure 45
Figure 42 Remove 1st speed clutch (low) rear bearing cap bolts and
Remove bearing cap and gasket. washers.
Figure 43 Figure 46
Remove idler shaft rear bearing retainer nut and spacer. Remove bearing cap and gasket.
-8-
S1005
Figure 50
Remove rear cover bolts and washers.
Figure 47
Remove rear bearing retainer plate bolts.
Figure 51
Using pry slots provided, pry cover from transmission housing
tapping on 1st speed clutch and idler shaft to allow cover to be
Figure 48 removed without shaft binding. NOTE: The use of alignment
Remove retainer plate. studs will facilitate cover removal.
Figure 52
Figure 49 Remove 1st speed clutch double bearing cup, outer taper
Remove bearing locating ring. bearing and spacer.
-9-
S1005
Figure 53
CAUTION: Outer cone, double bearing cup, spacer and inner
bearing cone are replaced as a set.
Figure 55
Remove idler shaft assembly. NOTE: The 6 & 8 speed trans-
mission will have two gears and a heavier front bearing.
Figure 54
Remove low clutch inner bearing cone. NOTE: To remove the
inner cone bearing without damage, a special bearing puller
must be made (see diagram Fig. 54-A) or the outer cage and Figure 56
rollers may be pulled from the bearing inner race and the inner Remove 1st speed clutch drive gear retainer ring.
race can be removed after the low clutch assembly has been
removed from the transmission. See caution in Figure 53.
1-5/32
1/8
49164 CUTWITH 1/16 RUBBER
5/32 - 1/16 R.CENT. WHEELAFTERHON.
Irr
+~I~" ifr
"'
ltL~~'~~-LI
+><
4-17164
"O"RING OIA.
Figure 54-A
A timken bearing cup, No. 29520 must be used with the above Figure 57
bearing puller. Remove drive gear.
-10-
S1005
Figure 58 Figure 61
Remove 1st speed clutch assembly. Remove front output flange nut, washer, "0" ring and flange. see
6 & 8 Speed Section for RangeShiftOutputShaft Removal.
Figure 59 Figure 62
Remove 1st speed front bearing. Remove output shaft front bearing cap bolts and washers.
Figure 60 Figure 63
Remove reverse and 3rd clutch assembly. Remove bearing cap, "0" ring and shims.
-11-
S1005
Figure 64 Figure 67
Remove output shaft rear bearing cap bolts and washers. Remove rear taper bearing.
Figure 65 Figure 68
Remove bearing cap and "0" rings. Remove output shaft, gear spacer and front taper bearing.
Figure 66
Block output gear. Push or drive output shaft through taper Figure 69
bearing and output gear. Remove output gear.
-12-
S1005
Figure 70
Remove front bearing.
Figure 73
Remove taper bearing retainer ring retainer.
Figure 71
If idler shaft, idler gear or rear bearing are to be replaced,
remove bearing and gear. Turn shaft over and remove the front
bearing retainer ring and bearing.
Figure 74
1ST SPEED CLUTCH (LOW) Remove bearing retainer ring.
DISASSEMBLY AND REASSEMBLY
See 8 Speed Section for 4th Speed Clutch Repair
DISASSEMBLY
See Note In Figure 83
Figure 72 Figure 75
Remove clutch assembly front bearing inner race. Remove 1st speed gear and outer taper bearing.
-13-
S1005
Figure 76 Figure 79
Remove taper bearing spacer. Remove inner and outer clutch discs.
Figure 77 Figure 80
Remove clutch end plate retainer ring. Remove inner taper bearing.
Figure 81
Figure 78 Remove piston return disc spring retainer ring retainer washer.
Remove end plate.
-14-
S1005
Figure 82
Remove return disc spring retainer ring.
Figure 85
Figure 83
Install clutch piston outer seal ring.
Remove piston return disc spring. NOTE: Disc springs in the
low clutch are different than springs in the forward and
reverse clutch. Do not mix low clutch springs with for-
ward and reverse springs (see note at top of page). Non
modulated units will have return springs in forward &
reverse clutches.
Figure 84
Remove return spring to piston spacer. Turn clutch over and tap' Figure 86
clutch shaft on a block of wood to remove clutch piston. Install clutch piston inner seal ring. Install piston into clutch
drum. Use caution as not to damage seal rings.
See cleaning and inspection page.
-15-
S1005
Figure 90
Figure 87 Position ring retainer over retainer ring.
Install piston spacer.
Figure 91
Install one steel disc.
Figure 88
See NOTE in figure 83. Install disc springs. First spring with
large diameter toward spacer. Alternate (5) five washers. See
page 59, Figure C.
Figure 92
Install one friction disc. NOTE: The friction discs in the low
clutch has a higher co-efficient rating than the friction
discs in the other clutches, therefore the discs must not
be mixed. The low clutch inner disc can be identified by
an "X" stamped on one side of the inner teeth. The low
clutch inner disc also has a strip of non-soluble yellow
Figure 89 paint sprayed on the outer edge of the disc. Alternate steel
Position return spring retainer ring on clutch shaft. Compress and friction discs until the proper amount of discs are installed.
disc springs and install retainer ring. First disc next to the piston is steel, last disc installed is friction.
-16-
S1005
Figure 96
Figure 93 Position taper bearing spacer on shaft.
Install clutch disc end plate.
Figure 97
Install 1st gear into clutch drum. Align splines on 1st gear with
internal teeth of friction discs. Tap gear into position. Do not
Figure 94
force this operation. Gear splines must be in full position with
Install end plate retainer ring.
internal teeth of all friction discs.
Figure 95 Figure 98
Install inner clutch gear taper bearing. Install outer taper bearing.
-17-
S1005
Figure 99
Install low clutch taper bearing retainer ring.
Figure 102
NOTE: Retainer ring is selected at assembly for proper Position front bearing on clutch shaft inner race. NOTE: Bearing
thickness. A snap ring kit is available. Select the thickest could be installed in transmission case before installing clutch.
of the three rings in the kit that can be fitted into the snap
ring groove to assure a proper taper bearing tightness.
Check ring as shown for tight ring to bearing fit.
REVERSE AND 3RD CLUTCH
DISASSEMBY AND REASSEMBLY
DISASSEMBLY
(Reverse being disassembled)
Figure 100
Position ring retainer over retainer ring.
Figure 103
Remove clutch shaft piston rings. NOTE: Some units will
have Telfon piston rings and expander springs. these
Figure 101 rings are to be replaced with a new style ring and does
Install clutch shaft front bearing inner race with large diameter NOT use an expander spring. See page 79 for proper
of race down. piston ring Installation.
-18-
S1005
Figure 108
Figure 105 Pry front bearing inner race up far enough to use a bearing
Remove front bearing end plate. puller.
-19-
S1005
-20-
S1005
Figure 119
Remove clutch piston.
Figure 116
Compress piston return spring. Remove spring retainer ring.
3RD SPEED CLUTCH DISASSEMBLY
Figure 118
Remove piston return spring and retainers. NOTE: Modulated
forward and reverse clutches will have piston return disc Figure 121
springs. (See note on page 15. Figure 83.1 Remove 3rd speed gear and outer bearing.
-21-
S1005
-22-
S1005
Figure 131
Remove clutch piston.
Figure 128
Compress piston return spring. Remove return spring retainer
ring.
See cleaning and inspection page.
Figure 132
Figure 129
Install clutch piston inner and outer seal rings. Install clutch
Remove retainer ring retaining washer.
piston in clutch drum, use caution as not to damage seal rings.
Figure 133
Figure 130 Position the inner return spring retainer, the return spring and
Remove return spring retainers and spring. the outer spring retainer on clutch shaft.
-23-
S1005
Figure 135
Compress return spring and install retainer ring being certain Figure 138
ring is in full position in retaining washer and ring groove. Install clutch disc end plate.
-24-
S1005
Figure 143
Install clutch gear outer bearing. NOTE: Outer bearing has a
Figure 140 shield in it, this shield must be up.
Install clutch gear inner bearing. NOTE: The inner bearing does
not have a bearing shield.
Figure 144
Install 3rd speed clutch shaft rear bearing. NOTE: Bearing outer
Figure 141 diameter locating ring must be down.
Install clutch gear inner and outer bearing spacer.
Figure 142
Install clutch gear into clutch drum. Align splines on clutch gear
with internal teeth of friction discs. Tap gear into position. Do Figure 145
not force this operation. Gear splines must be in full position Install clutch piston inner and outer oil seal rings. Install clutch
with internal teeth of all friction discs. piston in clutch drum, use caution as not to damage seal rings.
-25-
S1005
Figure 146
Position the inner return spring retainer, the return spring and Figure 149
the outer spring retainer. NOTE: If reverse and forward Install one steel disc.
clutches are modulated, assemble disc springs as shown
in Figure A on page 59.
Figure 150
Figure 147 Install one friction disc. Alternate steel and friction discs until
Position return spring retainer ring retaining washer on clutch the proper amount of discs are installed. First disc next to the
shaft. piston is steel, last disc installed is friction.
Figure 148
Compress return spring and install retainer ring being certain Figure 151
ring is in full position in retaining washer and ring groove. Install clutch disc end plate.
-26-
S1005
Figure 152
Figure 155
Install end plate retainer ring.
Install clutch gear outer bearing. NOTE: Outer bearing has a
shield in it, this shield must be down.
Figure 153
Install clutch gear inner bearing. NOTE: This bearing does not
have a shield in it.
Figure 156
Install clutch gear outer bearing retainer ring.
Figure 154
Install clutch gear into clutch drum. Align splines on reverse
gear with internal teeth of friction discs. Do not force this Figure 157
operation. Gear splines must be in full position with internal Install clutch shaft front bearing inner race with large diameter
teeth of all friction discs. of race down.
-27-
S1005
Figure 161
Install bearing retainer ring.
Figure 158
Position front bearing over bearing race.
Figure 162
Install clutch shaft piston rings. See note in Figure 103.
-28-
S1005
-29-
S1005
Figure 175
Figure 172 Compress piston return spring. Remove return spring retainer
Remove clutch disc end plate retainer ring. ring.
-30-
S1005
Figure 176
Remove retainer ring retaining ring. Figure 179
Remove clutch disc end plate retainer ring.
Figure 177
Remove piston return spring and retainers. See note in Figure
118. Figure 180
Remove end plate.
-31-
S1005
Figure 185
Figure 182 Remove clutch piston.
Compress piston return spring. Remove return spring retainer
ring.
See cleaning and inspection page.
Figure 183
Remove retainer ring retaining washer. Figure 186
Install clutch piston inner and outer seal rings. Install clutch
piston in clutch drum, use caution as not to damage seal rings.
Figure 187
Figure 184 Position the inner return spring retainer, the return spring and
Remove return spring retainers and spring. outer spring retainer on clutch shaft.
-32-
S1005
Figure 191
Figure 188 Install one friction disc. Alternate steel and friction discs until
Position return spring retainer ring retaining washer on clutch the proper amount of discs are installed. First disc next to the
shaft. piston is steel, last disc installed is friction.
Figure 189
Compress return spring and install retainer ring, being certain Figure 192
ring is in full position in retaining washer and ring groove. Install clutch disc end plate.
-33-
S1005
Figure 197
Compress return spring and install retainer ring, being certain
Figure 194 ring is in full position in retaining washer and ring groove.
Install clutch piston inner and outer seal rings. Install piston in
clutch drum, use caution as not to damage seal rings.
Figure 199
Figure 196 Install one friction disc. Alternate steel and friction discs until
Position return spring retainer ring retaining washer on clutch the proper amount of discs are installed. First disc next to the
shaft. piston is steel, last disc installed is friction.
-34-
S1005
Figure 203
Install clutch gear into clutch drum. Align splines on clutch gear
Figure 200 with internal teeth of friction discs. Tap gear into position. Do
Install clutch disc end plate. not force this operation. Gear splines must be in full position
with internal teeth of all friction discs.
Figure 202
Install clutch gear inner bearing. NOTE: This bearing does not Figure 205
have a shield in it. Install bearing retainer ring.
-35-
S1005
Figure 206
Install clutch shaft front bearing inner race with large diameter Figure 209
of race down. Install bearing end plate, aligning notch in plate with lock ball.
Figure 211
Figure 208 Install clutch shaft piston rings. See note in Figure 103.
Position front bearing over bearing race.
-36-
S1005
Figure 215
Use a sleeve puller like the one shown.
Figure 212
Remove clutch front bearing locating ring.
Figure 216
Sleeve being removed.
Figure 217
Figure 214 Position new oil sealing ring on turbine shaft. Install turbine
Remove screw and sleeve lock. shaft bearing on shaft with bearing outer locating ring down.
-37-
S1005
Figure 220
Install drive gear retainer ring.
Figure 221
View of output shaft as it would be positioned in transmission
case. NOTE: Front cone bearing shouldered on shaft with large
diameter of bearing in, and long hub of gear toward gear spacer.
Figure 219
Install turbine shaft drive gear as shown in Figure 219-A.
DRIVE GEAR
-38-
S1005
Figure 227
Using a inch lb. torque wrench, determine the rolling torque of
the output shaft and record. Tighten front bearing cap bolts to
Figure 224 specified torque. Check rolling torque with bolts tight. Torque
Tighten bearing cap bolts to specified torque. (See torque must be 6 to 8 inch Ibs. [0,7-0,09 N.m] more than when bearing
chart.) cap bolts were loose. Add or omit shims on the front bearing
cap to achieve the proper preload.
Figure 225
. Coat outer diameter of front output oil seal with Permatex No.2. Figure 228
Install seal in bearing cap with lip of seal in. Position reverse and 3rd clutch in transmission housing.
-39-
S1005
Figure 232
Figure 229 If idler shaft was disassembled, install front bearing. Install idler
From the rear of the transmission case, install the low (1 st) gear on shaft with long hub of gear up. (6 & 8 speed will have
clutch. two gears on the idler shaft). Install rear inner taper bearing
with large diameter of taper down. Install bearing spacer and
double bearing cup with outer diameter locating ring groove
up. Install outer taper bearing with large diameter of taper up.
NOTE: Double taper bearing must be replaced as an
assembly as the bearing spacer Is pre-selected at factory.
Figure 230
Install low (1 stl speed drive gear on clutch shaft.
Figure 233
Install idler shaft assembly. NOTE: Lock ball in bearing cup.
Figure 234
Figure 231 Install low (1 stl clutch outer double taper bearing. NOTE:
Install drive gear retainer ring. Locating ring groove in bearing cup to be out (to the rear).
-40-
S1005
Figure 235
Use caution as not to lose low (1 st) and idler bearing lock balls. Figure 238
A light coat of grease will hold lock balls in place. Tap cover in place.
Figure 240
From the front, tap the low (1 stl clutch and idler shaft to the rear
Figure 237 to expose the rear bearing locating ring groove. Install locating
Align lock balls in bearing with notches in rear cover. ring.
-41-
S1005
Figure 242
Install retainer plate bolts and tighten to specified torque (see Figure 245
torque chart). Lock wire bolts together to prevent loosening. Install idler shaft rear bearing locating ring.
Figure 243
Install new "0" ring and gasket on low (1 stl clutch shaft rear Figure 246
bearing cap. Install idler shaft rear bearing spacer.
-42-
S1005
Figure 249
Install capscrews and tighten to specified torque. (See torque Figure 252
chart). Install brake strut to brake bands.
-43-
S1005
Figure 256
Position brake drum on output flange studs. Install stud nut
Figure 253 washers and stud nuts. Tighten stud nuts enough to hold drum
Install rear output flange. in place until drive shaft is installed.
Figure 255
Tighten lock nut to specified torque. (See elastic stop nut torque Figure 258
chart). Install new output flange "0" ring, washer and flange nut.
-44-
S1005
Figure 259
Tighten flange nut to proper specifications. (See elastic stop nut Figure 262
torque chart). Install disc hub retainer ring.
-45-
S1005
-46-
S1005
DISASSEMBLY
Figure 272
Tighten pump drive gear support bolts to specified torque. (See
torque chart).
Figure 275
Remove pump drive gear retainer ring.
Figure 273
Install new sealing ring expander spring and oil sealing ring on
support. NOTE: Expander spring gap to be 1800 from sealing
ring hook joint. Position support on turbine shaft, turn support
to clear pump drive gear. Align support holes with converter Figure 276
housing. Remove pump drive gear.
-47-
S1005
Figure 280
Remove hub bearing retainer ring.
Figure 277
Remove impeller hub bolts.
Figure 281
Remove hub bearing.
Figure 278
Remove backing ring. See cleaning and inspection page.
REASSEMBLY
-48-
S1005
Figure 283
Install bearing retainer ring.
Figure 286
Position backing ring on impeller.
Figure 284
Position new "0" ring on impeller hub.
Figure 287
Install (12) impeller hub special screws to approximately .06
inch [1,5] of seated position. With a calibrated torque wrench,
tighten screws to 40-45 Ibs. ft. [54,3-61,0 N.m.] torque. NOTE:
Assembly of impeller to impeller hub must be completed within
a fifteen minute period from start of screw installation. The
screws are prepared with a coating which begins to harden after
installation in the impeller hub holes. If not tightened to proper
torque within the fifteen minute period, insufficient screw
clamping tension will result. The special screw is to be used for
one installation only. If the screw is removed for any reason it
must be replaced.
The compound left in the hub holes must be removed with the
Figure 285 proper tap and cleaned with solvent. Dry hole thoroughly and
Align holes in impeller with holes in impeller hub. use a new screw for reinstallation.
-49-
S1005
Figure 291
Install pump drive gear retainer ring.
Figure 288
Apply a light coat of Permatex No. 2 on the outer diameter of
the oil baffle seal. Press seal in oil baffle with lip of seal down. DISASSEMBLY AND REASSEMBLY
OF TURBINE AND IMPELLER COVER
DISASSEMBLY
Figure 289
Install new oil baffle seal ring. Position oil baffle on impeller and
hub assembly. Figure 292
Remove turbine hub to impeller cover bearing retainer ring.
-50-
S1005
Figure 294
Separate turbine from impeller cover.
Figure 297
Position turbine and hub assembly in impeller cover assembly.
Figure 295
Remove impeller cover bearing.
REASSEMBLY
-51-
S1005
Figure 299
Install turbine hub to impeller cover retainer ring. Figure 302
Install reaction member spacer with tang facing out.
Figure 300
Greasestator support piston ring, oil baffle oil seal and seal ring
to facilitate reassembly. Install impeller and oil baffle assembly Figure 303
in converter housing. Install reaction member with thick part of blades out.
Figure 301
Position oil baffle in housing. Secure with oil baffle retainer ring, Figure 304
being sure ring is in full position in ring groove. Install reaction member retainer ring.
-52-
S1005
Figure 306
Position turbine and impeller cover on turbine shaft. NOTE: Figure 309
Some units will have drive plates instead of impeller cover Install bearing cap, bolts and washers, tighten to specified
& ring gear. See drive plate installation section. torque. (See torque chart).
-53-
S1005
Figure 312
Install control valve bolts and washers and tighten to specified Figure 315
torque. (See torque chart). Install new pressure regulating valve gasket.
-54-
S1005
Figure 318
Install washers and nuts, tighten to specified torque. (See Figure 321
torque chart). Install new filter element and filter housing.
Figure 319
Install new auxiliary pump adaptor gasket and adaptor.
-55-
S1005
The transmission, torque converter, and its allied 5. On remote mounted torque converters remove
hydraulic system are important links in the drive line drain plug from torque converter and. inspect
between the engine and the wheels. The proper oper- interior of converter housing, gears, etc. If
ation of either unit depends greatly on the condition presence of considerable foreign material is
and operation of the other; therefore, whenever repair noted, it will be necessary that converter be re-
or overhaul of one unit is performed, the balance of moved, disassembled and cleaned thoroughly.
the system must be considered before the job can be It is realized this entails extra labor; however,
considered completed. such labor is a minor cost compared to cost of
difficulties which can result from presence of
After the overhauled or repaired transmission has such foreign material in the system.
been installed in the machine, the oil cooler, and con-
necting hydraulic system must be thoroughly cleaned.
This can be accomplished in several manners and a de- 6. Reassemble all components and use only type
gree of judgment must be exercised as to the method oil recommended in lubrication section. Fill
employed. transmission through filler opening until fluid
comes up to LOW mark on transmission dipstick.
The following are considered the minimum steps to NOTE: If the dipstick is not accessible oil level
be taken: check plugs are provided.
Remove LOWER check plug, fill until oil runs
1. Drain entire system thoroughly. from LOWER oil hole. Replace filler and level
plug.
2. Disconnect and clean all hydraulic lines. Where
feasible, hydraulic lines should be removed from Run engine two minutes at 500-600 RPM to
machine for cleaning. prime torque converter and hydraulic lines. Re-
check level of fluid in transmission with engine
3. Replace oil filter elements, cleaning out filter running at idle (500-600 RPM).
cases thoroughly.
Add quantity necessary to bring fluid level
4. The oil cooler must be thoroughly cleaned. The to LOW mark on dipstick or runs freely from
cooler should be "back flushed" with oil and LOWER oil level check plug hole. Install oil
compressed air until all foreign material has been level plug or dipstick. Recheck with hot oil
removed. Flushing in direction of normal oil flow (180-200° F.) [82,2-93,3° C].
will not adequately clean the cooler. If neces- Bring oil level to FULL mark on dipstick or
sary, cooler assembly should be removed from runs freely from UPPER oil level plug.
machine for cleaning, using oil, compressed air
and steam cleaner for that purpose. DO NOT 7. Recheck all drain plugs, lines, connections, etc.,
use flushing compounds for cleaning purposes. for leaks and tighten where necessary.
TORQUE IN (LBS.-FT.)
BOLTS, CAPSCREWS, STUDS AND NUTS
Grade 5 Identification, 3 Radial Grade B Identification, 6 Radial
0
Dashes 120 Apart on Head of Bolt 0
Dashes 60 Apart on Head of Bolt
LUBRICATED OR PLATED
Grade 5 Grade 8
Nominal Fine Thread Course Thread Fine Thread Course Thread
Size Torque Lbs. Ft./N.m. Torque Lbs. Ft./N.m. Torque Lbs. Ft./N.m. Torque Lbs. Ft./N.m.
.3125 16-20 [21,7-27,1] 12-16 [16,3-21,7] 28-32 [38,0-43.4] 26-30 [35,3·40.7]
.3750 26-29 [35,3·39,3] 23-25 [31,2-33.9] 37-41 [50,2-55,6] 33-36 [44,7-48,8]
.4375 41-45 [55,6-61,0] 37·41 [50,2-55,6] 58-64 [78.6-86,8] 52·57 [70.5-77.3]
.5000 64-70 [86.8-94,9] 57·63 [77,3-85.4] 90-99 [122.0-134.2] 80-88 [108,5-119,3]
.5625 91-100 [123.4-135,6] 82-90 [111,2-122,0] 128-141 [173.5-191.2] 115·127 [156,0·172,2]
-56-
SPECIFICATIONS AND SERVICE DATA - POWER SHIFT TRANSMISSION
S1005
AND TORQUE CONVERTER
CONVERTER OUT Converter outlet oil temp. 180· - 200· F. OIL FILTRATION Full flow oil filter safety by-pass, also strainer
PRESSURE [82,3" - 93,3" C]. screen in sump at bottom of transmission case.
Transmission in NEUTRAL.
CLUTCH PRESSURE 240 - 300 psi [1654,8 - 2068, 4 kPa]- With parking
Operating specifications: brake set (see note), oil temperature 180" - 200" F.
25 PS.1. [172,4 kPa] minimum pressure at 2000 [82,2" - 93,3" C], engine at idle (400 to 600 RPM),
R.PM. engine speed AND a maximum of 70 shift thru direction and speed clutches. All clutch
PS.1. [482,6 kPa] outlet pressure with engine
operating at no-load governed speed. pressure must be equal within 5 psi. [34,5 kPaj. If
clutch pressure variers in anyone clutch more than
CONTROLS Forward and Reverse - Manual 5 psi [34,5 kPa] repair clutch.
Speed Selection - Manual NOTE: Never use service brakes while making
clutch pressure checks. Units having brake
CLUTCH TYPE Multiple discs, hydraulically actuated, spring actuated declutching in forward and/or reverse
released, automatic wear compensation and no
adjustment. All clutches oil cooled and lubricated. will not give a true reading.
ALWAYS USE PARKING BRAKE WHEN
CLUTCH INNER DISC Friction. MAKING CLUTCH PRESSURE CHECKS.
CLUTCH OUTER DISC Steel.
LUBRICATION
RECOMMENDED LUBRICANTS FOR TORQUE CONVERTERS AND POWERSHIFT TRANSMISSIONS
TYPE OFOIL See Lube Chart. (a) Drain transmission and remove sump
CAPACITY Consult Operators Manual on applicable screen. Clean screen thoroughly and
machine model for system capacity. Torque replace, using new gaskets.
Converter, Transmission and allied hydraulic (b) Drain oil filters, remove and discard filter
system must be considered as a whole to elements. Clean filter shells and install new
determine capacity. elements.
CHECK PERIOD Check oil level DAILY with engine running at
(c) Refill transmission to LOW mark.
500-600 RPM and oil at 180" to 200" F. [82,2 -
93,3" C]. Maintain oil level to FULL mark. (d) Run engine at 500 - 600 RPM to prime
NORMAL Every 500 hours, change oil filter element. converter and lines.
DRAIN PERIOD Every 1000 hours, drain and refill system as
(e) Recheck level with engine running at
follows: Drain with oil at 150" to 200" F. [65,6 -
500 • 600 RPM and add oil to bring level to
93.3" C].
LOW mark. When oil temperature is hot (180
NOTE: It is recommended that filter elements • 200" F.) [82.2 - 93,3° C] make final oil level
i:le changed after 50 and 100 hours of opera- check. BRING OIL LEVEL TO FULL MARK.
tion on new and rebuilt or repaired units.
Torque converter/transmission lubricant must be qualified by one of the following
specifications.
ORDER OF PREFERENCE: RECOMMENDED SAE J300 VISCOSITY GRADE
1. Caterpillar TO • 4 4. Allison C-4
2. John Deere J20 C , D 5. Dexron II Equivalent - See note below. BASED ON PREVAILING AMBIENT TEMPERATURE
3. Military MIL-PRF-2104G
SAE OW20
IMPORTANT: Dexron* II equivalent is acceptable: however it is not compatible with torque
converters or transmissions equipped with graphitic friction material clutch plates.
Dexron* II or equivalent I
LUBRICANTS NOT RECOMMENDED: DEXRON III, ENGINE OIL, ANY GL-5 OILS.
SAE lOW
OIL VISCOSITY -lt is recommended that the highest viscosity monograde lubricant
available be used for the anticipated ambient temperature. Typically this will be a CAT TO-4
qualified luoricant, When large swings in ambient temperature are probable, J20 C. 0 multi-
grades are recommended. Multigrade lubricants should be applied at the lower viscosity
rating for the prevailing ambient temperature, i.e. a 10W20 should be used where a lOW SAE30
monograde is used. If a C·4 multigrade is used in place of J20 lubricant it is recommended
that the viscosity span no more than 10 points, i.e. 10W20. SAE40
SYNTHETIC LUBRICANTS ARE APPROVED IF QUALIFIED BY ONE OFTHE ABOVE CELSIUS ·40 -30 -20 -10 0 10 20 30 40 50
SPECIFICATIONS. OIL VISCOSITY GUIDELINES APPLY, BUT SYNTHETIC
MULTIGRADES MAY SPAN MORE THAN 10 POINTS. FAHRENHEIT -40 -22 -4 14 32 50 68 88 104 122
FOR FIRE RESISTANT FLUID RECOMMENDATIONS PLEASE CONTACT SPICER POWER SHIFT TRANSMISSION AND TORQUE
OFF-HIGHWAY PRODUCTS. CONVERTER HYDRAULIC FLUID ANALYSIS
SUMP pREHEATERS - preheat the transmission fluid to the minimum temperature Spicer Off-Highway Components Division recommends that when
for the oil viscosity used before engine start up.
chemical sampling of a power shift transmission lubrication circuit fluid
NORMAL OIL CHANGE INTERVAL - drain and refill system every 1000 hours for average is being taken that several samples be analyzed over a period of time
environmental and duty cycle conditions. Severe or sustained high operating temperature or to establish its normal base. Large changes in particle quantity from the
very dusty atmospheric conditions will result in accelerated deterioration or contamination. normal level may indicate an abnormal condition within the transmis-
Judgement must be used to determine the required change intervals for extreme
conditions. sion or its lubrication fluid. Any conclusion made of the transmission
actual condition, or action taken by the transmission user when
EXTENPEP OIL CHANGE INTERVAL - Extended oil service life may result when using interpreting the sample results, is the full responsibility of the user.
synthetic fluids. Appropriate change intervals should be determined fur each transmission
by measuring oil oxidation and wear metals, over time, to determine a baseline. Wear metal The following part per million (PPM) values represent general guide-
analysis can provide useful information, but a transmission should not be removed from
service based solely on this analysis. lines which may be used for references as a normal limit:
Iron Fe 125 PPM
.EJ..LIE.B.S. - Service oil filter element every 500 hours under normal environmental and duty Copper Cu 350 PPM
cycle conditions. Service the high performance extended life filter element every 1000 hours
or upon warning indication from the filter back pressure sensor. Silicon Si 20 PPM
Aluminum AI 15 PPM
This recommended lubricant section does not apply'to transmissions with electronic Lead Pb 50 PPM
modulation where separate approved oils are identified.
Chromium Cr 5 PPM
Any deviation from this recommendation must have written approval from the
application engineering department of Spicer Off-Highway Products.
*Dexron is a registered trademark of General Motors Corp. - 57 -
S1005
The following data is presented as an aid to locating the others. By studying the principles of operation
the source of difficulty in a malfunctioning unit. It is together with data in this section, it may be possible
necessary to consider the torque converter charging to correct any malfunction which may occur in the
pump, transmission, oil cooler, and connecting lines system.
as a complete system when running down the source TROUBLE SHOOTING PROCEDURE BASICALLY CON-
of trouble since the proper operation of any unit there- SISTS OF TWO CLASSIFICATIONS: MECHANICAL AND
in depends greatly on the condition and operations of HYDRAULIC.
MECHANICAL CHECKS
Prior to checking any part of the system from a 2. Check shift levers and rods for binding or restric-
hydraulic standpoint, the following mechanical checks tions in travel that would prevent full engagement.
should be made: Shift levers by hand at controi valve, if full engage-
1. A check should be made to be sure all control ment cannot be obtained, difficulty may be in control
lever linkage is properly connected and adjusted at all cover and valve assembly.
connecting points.
HYDRAULIC CHECKS
Before checking on the torque converter, transmis- the converter. Where the former means is impractical,
sion, and allied hydraulic system for pressures and the latter means should be employed as follows:
rate of oil flow, it is essential that the following pre- Engage shift levers in forward and high speed and
liminary checks be made: apply brakes. Accelerate engine half to three-quarter
Check oil level in transmission. This should be done throttle.
with oil temperatures of 180 to 200 0 F. [82,2-93,3 0 C]. Hold stall until desired converter outlet temperature
DO NOT ATTEMPT THESE CHECKS WITH COLD OIl. is reached. CAUTION: FULL THROTTLE STALL SPEEDS
To bring the oil temperature to this specification it FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT
is necessary to either work the machine or "stall" out THE CONVERTER.
OVERHEATING
1. Worn oil sealing rings. 1. Remove, disassemble, and rebuild converter assem-
bly.
2. Worn oil pump. 2. Replace.
3. Low oil level. 3. Fill to proper level.
4. Pump suction line taking air. (R-32000 only) 4. Check oil line connections and tighten securely.
NOISY CONVERTER
1. Worn coupling gears. 1. Replace.
2. Worn oil pump. 2. Replace.
3. Worn or damaged bearings. 3. A complete disassembly will be necessary to deter-
mine what bearing is faulty.
LACK OF POWER
1. Low engine RPM at converter stall. 1. Tune engine check governor.
2. See "Overheating" and make same checks. 2. Make corrections as explained in "Overheating."
-58-
S1005
FIG.A
I I
III REV. & FWD.
~!~!
-------l:! -! + - - - - - - - -
_ _~t ~ - - - - - -
\\ .063 - .064
-4\--[1.600 - 1.626]
MODULATED FWD.
& REV. CLUTCHES
FIG.C
\\ .048 - .049
-4\---[1.219 - 1.245]
LOW (1st)
CLUTCH
FIG.D
(4 SPEED ONLY)
4TH
-59-
S1005
~--
---~
SEE PAGE 61
FOR INSTALLATION
PROCEDURE AND
BOLT TORQUE
l
"'l (
",..,~'--\~~ BACKING RING
243767
-60-
S1005
1. Remove all burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface
and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean.
2. Check engine flywheel and housing or housing adaptor for conformance to standard SAE. No.3 - SAE J927 and Jl033
tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine
crankshaft end play.
NOTE: Assembly of the ring gear must be completed within a fifteen minute
period from start of screw installation. The screws are prepared with an epoxy
coating which begins to harden after installation in the flywheel mounting holes. If not
tightened to proper torque within the fifteen minute period insufficient screw clamping
tension will result.
4. Install backing ring and sixteen (16) special screws to approximately .06 inch 11,5 mm I of seated position. It is permissible to use
a power wrench for this installation phase. With a calibrated torque wrench tighten screws 30 to 33 pounds feet of torque 140,7-
44,7 N.m].
To obtain maximum effectiveness of the special screw's locking feature, a minimum time period after screw installation of
twelve (12) hours is suggested before engine start-up.
The special screw is to be used for ONE installation only. If the screw is removed for any reason it MUST BE REPLACED. It is
recommended that the epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent. Dry hole
thoroughly and use a NEW screw for re-installation.
5. Assemble torque converter to engine flywheel by sliding converter into position by hand before fastening housing attachment
screws. This may require more than one trial to match the drive gear teeth. Pulling the converter into position with housing
attachment bolts is not recommended.
6. Measure engine crankshaft end play after assembly of torque converter. This value must be within one thousandth (001) of an
inch [0,0254mm] of end play recorded (in Paragraph #2) before assembly of torque converter.
802553 - 1.5 INCH [38,1] 16 SCREW RING GEAR KIT 802554 - 1.5 INCH 138.1116 SCREW RING GEAR KIT
1 249341 Torque Converter Ring Gear 1 249341 Torque Converter Ring Gear
16 236288 Ring Gear Screw 1.5 Inch 138.11 16 236288 Ring Gear Screw 1.5 Inch 138,11
1 802555 Installation Instruction Sheet 1 243767 Backing Ring
1 802555 Installation Instruction Sheet
243767 Backing Ring not included in 802553 Ring Gear Kit. Must be Ordered Separately
-61-
S1005
FORWARD
1ST (LOW)
-- - ---2ND
- - - - - 3RD
-62-
S1005
REVERSE
1ST (LOW)
_ _ _ _ _ _ 2ND
_ - _ - -3RD
-63-
S1005
1. CLEAN HUB MOUNTING SURFACE AND TAPPED HOLES WITH SOLVENT. DRY THOROUGHLY
BEING CERTAIN TAPPED HOLES ARE DRY AND CLEAN.
2. INSTALL BACKING RING AND SPECIAL SCREWS TO APPROXIMATELY .06 INCH [1.5] OF SEATED
POSITION. WITH A CALIBRATED TORQUE WRENCH, TIGHTEN SCREWS 40 TO 45 LBS. FT. TORQUE
[54,3-61,0 N.m]. NOTE: ASSEMBLY OF IMPELLER OR TURBINE HUB MUST BE COMPLETED WITHIN
A FIFTEEN MINUTE PERIOD FROM START OF SCREW INSTALLATION. THE SCREWS ARE PREPARED
WITH A COATING WHICH BEGINS TO HARDEN AFTER INSTALLATION IN THE HUB HOLES. IF NOT
TIGHTENED TO PROPER TORQUE WITHIN THE FIFTEEN MINUTE PERIOD, INSUFFICIENT SCREW
CLAMPING TENSION WILL RESULT. THE SPECIAL SCREW IS TO BE USED FOR ONE INSTALLATION
ONLY. IF THE SCREW IS REMOVED FOR ANY REASON IT MUST BE REPLACED.
THE COMPOUND LEFT IN THE HUB HOLES MUST BE REMOVED WITH THE PROPER TAP AND
CLEANED WITH SOLVENT. DRY HOLE THOROUGHLY AND USE A NEW SCREW FOR
REINSTALLATION.
-64-
S1005
Cooler inletrCOOler
pressure outlet pressure
~ ",~._-o._..... r = I y;~t~~~rtemperature
Filter type "A"---"""",\
Use replacement element
215502
Cooler DO NOT SUBSTITUTE
Port "AP"
Modulated forward
clutch check port
Port "R"
pressure
Modulated reverse
clutch check port
From cooler
to transmission
lube distributor
Port "A"
-65-
S1005
INSPECTION
The importance of careful and thorough inspection of all
parts cannot be overstressed. Replacement of all parts
showing indication of wear or stress will eliminate costly
and avoidable failures at a later date.
Bearings
Carefully inspect all rollers, cages and cups for wear,
chipping or nicks to determine fitness of bearings for
further use. Do not replace a bearing cone or cup individ-
ually without replacing the mating cup or cone at the same
time. After inspection, dip bearings in clean light oil and
wrap in clean lintless cloth or paper to protect them until
installed.
-66-
S1005
-67-
S1005
BACKING RING
TORQUE CONVERTER
RING GEAR
ENGINE FLYWHEEL
BACKING RING
236937
1. Remove all burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface
and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean.
2. Check engine flywheel and housing or housing adaptor for conformance to standard SAE. No.3 - SAE J927 and J1033
tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine
crankshaft end play.
NOTE: Assembly of the ring gear must be completed within a fifteen minute
period from start of screw installation. The screws are prepared with an epoxy
coating which begins to harden after installation in the flywheel mounting holes. If not
tightened to proper torque within the fifteen minute period insufficient screw clamping
tension will result.
4. Install backing ring and thirty-two (32) special screws to approximately .06 inch [1,5 rnrnl of seated position. It is permissible to
use a power wrench for this installation phase. With a calibrated torque wrench tighten screws 23 to 25 pounds feet of torque
[31,2 - 33,8 N.m].
To obtain maximum effectiveness of the special screw's locking feature, a minimum time period after screw installation of
twelve (12) hours is suggested before engine start-up.
The special screw is to be used for ONE installation only. If the screw is removed for any reason it MUST BE REPLACED. It is
recommended that the epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent. Dry hole
thoroughly and use a NEW screw for re-installation.
5. Assemble torque converter to engine flywheel by sliding converter into position by hand before fastening housing attachment
screws. This may require more than one trial to match the drive gear teeth. Pulling the converter into position with housing
attachment bolts is not recommended.
6. Measure engine crankshaft end play after assembly of torque converter. This value must be within one thousandth (,001l of an
inch [0,0254mm) of end play recorded (in Paragraph #2) before assembly of torque converter.
802544 - 1.5 INCH [38,1] 32 SCREW RING GEAR KIT 802547 - 2.5 INCH [63,5] 32 SCREW RING GEAR KIT
1 249265 Torque Converter Ring Gear 1 249265 Torque Converter Ring Gear
32 243970 Ring Gear Screw 1.5 Inch 138,11 32 237153 Ring Gear Screw 2.5 Inch 163,51
1 802550 Installation Instruction Sheet 1 802550 Installation Instruction Sheet
802545 - 1.75 INCH [44,4) 32 SCREW RING GEAR KIT 802548 - 3.0 INCH [76,2) 32 SCREW RING GEAR KIT
1 249265 Torque Converter Ring Gear 1 249265 Torque Converter Ring Gear
32 244903 Ring Gear Screw 1.75 Inch 144,4) 32 236938 Ring Gear Screw 3.0 Inch 176,21
1 802550 Installation Instruction Sheet 1 802550 Installation Instruction Sheet
802546 - 2.0 INCH [50,8) 32 SCREW RING GEAR KIT 802549 - M8-32 SCREW RING GEAR KIT
1 249265 Torque Converter Ring Gear 1 249265 Torque Converter Ring Gear
32 240318 Ring Gear Screw 2.0 Inch [50,8] 32 4200097 Ring Gear Screw [M8 x 1.251
1 802550 Installation Instruction Sheet 1 802550 Installation Instruction Sheet
236937 Backing Ring Not Included in Ring Gear Kit. Must be Ordered Separately.
NOTE: The initial installation drive gear mounting kit includes a converter air breather. This breather is used on C & CL 270/C &
CL 320 converters only and is not required for the HR & LHR 28000/HR & LHR 32000 applications.
-69-
S1005
R-MODEL SECTION
-70-
S1005
-71-
S1005
R·32000
ASSEMBLY INSTRUCTION ILLUST~ATION
-72-
S1005
~ (12
plates. Assemble alternately. starting with outer
steel plate. Plate Modulation) Two clutches,12-outer steel
plates,12-inner friction plates.Assemble alternately.
starting with outer steel plate.
Notes
A. - Use Permatex & Crane Sealer only where E. - After assembly of parts using Permatex or
specified. Crane sealer, there must not be any free or
B. - All lead in chamfers for oil seals, piston rings & excess material that could enter the oil circuit.
"0" rings must be smooth & free from burrs. F. - Apply light coat of Crane Sealer to all pipe
Inspect at ass'y. plugs.
C. - Lubricate all piston ring grooves & "0" rings G. - Apply a thin coating of grease between seal
with oil before ass'y. lips on lip type seals prior to ass'y.
O. - Apply very light coat of Permatex NO.2 to 0.0. H. - Apply light coat of Permatex NO.2 to all thru
of all oil seals before ass'y. hole stud threads.
View"Q"
2 Places
Low Clutch Return Springs. ELASTIC STOP NUT TORQUE
Concave side of first spring to be placed THREAO SIZE LB.-FT. [N'rn]
against clutch piston. Remaining four washers
1" - 20 150 - 200 [203,4 - 271.1]
to be stacked alternately reversed as shown.
1V4" - 18 200 - 250 (271.2 - 338.9]
1'12" - 18 300 - 350 (406.8 - 474,5]
1'/4" - 12 400 - 450 (542,4 - 610,11
-73 -
S1005
The instructions contained herein cover the dis- assemblies may vary on specific models. The units are very
assembly and reassembly ofthe transmission in a sequence similar to trouble shoot. disassemble, repair and re-
that would normally be followed after the unit has been assemble.
removed from the machine and is to be completely CAUTION: Cleanliness is of extreme importance and
overhauled. It must also be understood that this is a basic an absolute must in the repair and overhaul of this unit.
32000 transmission with many options. Companion Before attempting any repairs, the exterior of the unit must
flanges and output shafts with and without disconnect be thoroughly cleaned to prevent the possibility of dirt and
foreign matter entering the mechanism.
DISASSEMBLY
Figure 1 Figure 3
Removecontrol valve bolts and washers. Removecontrol valve. Remove front cover plug.
Use caution as not to lose detent springs and balls.
Figure 2 Figure 4
Remove companion flange nut, washer and "0" ring. Remove bolts securing front cover to transmission housing.
-74-
S1005
INSTALL INPUT SHAFT OIL SEAL IN FRONT
COVER AS SHOWN ON PAGE 72.
DRIVE GEAR
-J------'---INPUT SHAFT
Figure 6
Figure 9
Use a spreading type snap ring pliers to spread the ears on for-
Install input shaft into front bearing.
ward clutch front bearing retainer ring. Remove forward clutch
with pry bar.
Figure 7 Figure 10
If input shaft is to be removed, tap on threaded end of shaft, Support converter housing with chain fall. Spread forward
remove input shaft, gear and bearing. clutch front bearing retainer ring and tap forward and 2nd clutch
assembly into transmission case assembly. Be certain snap ring
See cleaning and inspection page. is in full position in ring groove.
-75-
S1005
Figure 11 Figure 14
Install 2nd speed clutch pilot bearing. Support front cover with a chain fall. Install alignment studs in
transmission case. Position front cover assembly on aligning
studs. Turn output flange to align clutch disc hub in clutch. Do
not force this operation. With front cover in position against the
transmission case install cover to case bolts. Tighten to
specified torque.
Figure 12
Install transmission case gasket and "0" ring seals.
Figure 15
Install front cover plug.
Figure 13 Figure 16
Install housing spacer, gasket and "0" ring seals. NOTE: Hous- Install companion flange, flange "0" ring, washer and nut. Tor-
ing spacer is used with 12 plate clutch modulation only. que nut to specified torque. (See elastic stop nut torque chart).
-76-
S1005
BEARING SHIELD
MUST FACEIN
BEARING SHIELD
MUST FACE OUT
REAR
BEARING SHIELD
-77-
S1005
-78-
INSTALLATION INSTRUCTIONS OF NEW NON-METALLIC SEALING RINGS
S1005
Proper oil sealing ring (piston ring) installation procedures. Refer to the appropriate transmission
maintenance and service manual for disassembly, cleaning, inspection and reassembly.
1. Fill the oil sealing ring grooves with a good grade of grease, this will help stabilize the sealing ring
in the ring groove for installation.
2. Carefully position the piston ring on the shaft in the inner most ring groove. Hook the piston ring
joint.
3. Repeat steps 1, and 2 for the remaining ring or rings making certain all hook joints are fastened
securely.
4. Apply a heavy coat of grease to the outer diameter of the rings and shaft. Center the piston rings
in the ring groove.
5. When installing the clutch assembly in the transmission case it is recommended a piston ring
sleeve PIN's 241309, 237576, 234265, 235314 or 248694 be used to center all of the piston rings
in their respective ring grooves. Use extreme caution to not damage piston ring when installing
the clutch shaft in the transmission case, or when installing the converter housing or front cover
on the clutch shafts.
PISTON RING
SLEEVE
USED FOR POSITIONING 234265
OF PISTON RINGS
BEARING
PISTON RINGS
18000 SERIES
PISTON RING USED FOR POSITIONING PISTON RING USED FOR POSITIONING
SLEEVE OF PISTON RINGS SLEEVE OF PISTON RINGS
241309 OR 237576 23531- 4 OR 248694
BEARING
PISTON RINGS
Be aunt that lead in charnf8r and
Intersectionof lead in ~r 10 pilton
ring bore is free of burrs end nicka.
-80-
S1005
-81-
S1005
View"Q"
Housing spacer
used with 12 plate
modulation only.
6 SPEED TRANSMISSION
NON-MODULATED
-82-
S1005
Impeller Hub and Turbine Hub Assembly with &. Heat nose bushing to 200 0 FO (93OC) before ass'y. of
Backing Ring and Special Self Locking Screws. bushing to cover.
1. Clean hub mounting surface and tapped holes
with solvent. Dry thoroughly being certain tapped Bearing shield OUT on 3rd speed clutch. Bearing shield
holes are dry & clean. IN on Fwd. & Rev. clutch.
2. Install backing ring and special self locking Must be loose internal fit bearings, No. "3" etched on
screws. bearing.
Tighten screws 40 to 45 Lbs. Ft. [54,3-61,0 N'm)
Note: Assembly of hub must be complete within a
fifteen minute period from start of screw installa-
&. (12 Plate Modulation) Two clutches, 12-outer steel plates,
12-inner friction plates. Assemble alternately, starting
tion. The special screw is to be used for one in- wit,h outer steel plate.
stallation only. If the screw is removed for any
reason it must be replaced. The epoxy left in the Notes
hub holes must be removed with the proper tap A. - Use Permatex & Crane Sealer only where
and cleaned with solvent. Dry hole thoroughly and specified.
use a new screw for reinstallation. B. - All lead in chamfers for oil seals, piston rings &
"0" rings must be smooth & free from burrs.
Gear to be assembled with long hub length to this Inspect at ass'y.
side. C. - Lubricate all piston ring grooves & "0" rings
with oil before ass'y.
Three clutches,6-outer steel plates,6-inner friction D.• Apply very light coat of Permatex NO.2 to 0.0.
plates. Assemble alternately, starting with outer of all oil seals before ass'y.
steel plate. E.. After assembly of parts using Permatex or
Crane sealer, there must not be any free or
&. See Elastic Stop Nut Torque Chart excess material that could enter the oil circuit.
F. - Apply light coat of Crane Sealer to all pipe
& Low clutch,9-outer steel plates.s-lnner friction plugs.
plates. Assemble alternately, starting with outer G. - Apply a thin coating of grease between seal
steel plate. lips on lip type seals prior to ass'y.
H. - Apply light coat of Permatex NO.2 to all thru
ill See Elastic Stop Nut Torque Chart hole stud threads.
~
the disc.
Low Clutch Return Springs.
Concave side of first spring to be placed
against clutch piston. Remainin9 four springs
to be stacked alternately reversed as shown.
~i'W'S'
Forward & Reverse Clutch Return Springs.
Concave side of first spring to be placed
against clutch piston. Remaining six springs Enlarged view of Piston Ring & Expander
of each clutch to be stacked alternately Note: Expander gap to be approx. 180 0 from ring
reversed as shown. See note on page 77. hook joint to aid ring assembly.
-~~+ 91·100 1123,4 - 135,51 82 - 90 1111.2 -122.01 128 - 141 1-173.6 - 191.11 115 - 127 1156.0 - 172.2]
5000 , 64 - 70 1 86.8- 94.91 57 - 63 r 77,3- 85,41 90 - 99 1122.1 - 134,21 80 - 88 1108.5 - 119.3]
4375 41 - 45 I 55,6- 61.01 -- 37 -
41 [ 50.2· 55,5J 58 - 64 I 78,7- 86.71 52 - 57 r 70.6- 77,21
3750 26 - 29 [ 35.3- 39.31 23 - 25 1 31.2- 33.81 37 - 41 r 50.2- 55.51 33 - 36 T 44.8- 48.81
3125 16 - 20 1 21.7- 27,'-1 12 - 16 1 16.3· 21,61 28 - 32 1 38.0· 43.31 26· 30 1 35,3- 40.61
,2500 , 9 - 11 I 12.3- 14,9) 8 - 10 I 10.9- 13,5] 11- 13 I 15.0- 17.61 9 - 11 [ 12,3- 14,9]
-83
S1005
~-
- -.::.,..
-84-
S1005
R & HR MODEL 6 & 8 SPEED
The R & HR 32000 6 speed transmission is the same as the 3 speed R & HR 32000 except the difference being in the idler and out-
put shafts. The 6-speed unit has a gear added to the idler shaft and the output shaft has a high and low range shift.
The 32000 8 speed transmission is the same as the 6 speed except the 8 speed has a 4th speed clutch.
The 6-speed transmission has 3 working range shifts and 3 The 8-speed transmission has 8 forward speeds and 8 reverse
travel range shifts. speeds.
Gear ratio determines working and travel ranges. They are as The 8-speed transmission has 4 working range shifts and 4 travel
follows: range shifts.
1st- 2nd and 4th working range. 3rd - 5th and 6th travel range. Gear ratio determines working and travel ranges. They are as follows:
NOTE: Range shift from low to high must be made with 1st - 2nd - 3rd and 5th working ranges 4th - 6th - 7th and 8th travel
machine stopped. range.
NOTE: Range shift from low to high must be made with machine
stopped.
DISASSEMBLY
Figure 55 shows the idler shaft with one gear. The 6-speed unit
will have two gears and a heavier front bearing. See Figure 55A
below:
Figure 2
Remove range shift rail support bolts. Remove rail support, rail
and range shift fork.
Flgure55A
6 & 8 speed idler shaft, gear and bearing assembly. NOTE:
Do not lose rear bearing lock ball.
Figure 1
With all clutches and shafts removed, cut lockwire on range Figure 3
shift fork lockscrew. Remove fork lockscrew. Remove output shaft rear bearing cap bolts and bearing cap.
-85-
S1005
Figure 6
Position high and low range gears, shift hub, hub sleeve and
needle bearings in transmission case as shown in Figure 5.
Insert output shaft, front bearing and thrust washer through
output gears. Use caution as not to damage high and low range
Figure 4 gear needle bearings.
Remove front output flange nut, washer, "0" ring, flange and
bearing cap from housing. Block output gears. Push output
shaft from rear through gears and taper bearing.
REASSEMBLY
Figure 7
Position output gear thrust washer and rear taper bearing on
output shaft.
Figure 5
View of output shaft as it would be positioned in transmission
case. NOTE: Front bearing cone and output gear thrust washer Figure 8
shouldered on shaft with large diameter of bearing in. Block output shaft from the front and install rear taper bearing.
-86-
S1005
Figure 11
Locate high-low range shift fork in shift hub with offset of fork
toward gear, Insert rail support and rail into bore in transmission
housing and into shift fork.
Figure 9
Using new "0" rings install rear output bearing cap and taper
bearng. cup on transmission case. Lube opening in bearing cap
must be aligned with lube opening in case. Tighten bearing cap
bolts to specified torque. (See torque chart.)
Figure 12
Tighten support bolts to specified torque. (See torque chart).
Figure 10
Using a inch lb. torque wrench, determine the rolling torque of
the output shaft and record. Tighten front bearing cap bolts to Figure 13
specified torque. Check rolling torque with bolts tight. Torque Locate lockscrew hole in shift rail with hole in shift fork. Install
must be 6 to 8 inch Ibs. [0.68 - 0.90 N'rnl more than when bear- lockscrew, tighten securely and lockwire to prevent loosening.
ing cap bolts were loose. Add or omit shims on the front bearing
cap to achieve the proper preload. Proceed with Figure 228 in the R & HR 32000 3-Speed Section.
-87-
S1005
KEY
1ST (LOW)
_ _ 2ND
• • • • 3RD (HIGH)
-88-
S1005
KEY
4TH
- _ 5TH
• • • • 6TH
-89-
S1005
LOW RANGE
1ST (LOW)
- - - - - - 2ND
- - 3RD
• • • • • • • • • • 4TH (HI)
~~.~~~~~)$.
~ - ......LOW
...... RANGE
-90-
S1005
HIGH RANGE
1ST (LOW)
- - - - - - 2ND
- - 3RD
• • • • • • • • • • 4TH (HI)
-91-
S1005
8 SPEED CLUTCH SECTION
-92-
8 SPEED SECTION S1005
DISASSEMBLY
Figure 3
Remove fourth speed clutch disc hub retainer ring.
Figure
Figure 1
Remove bolts securing converter housing to transmission
housing. Support converter housing with a chain fall. Using
spreading type snap ring pliers, spread ears on the fourth
speed clutch front bearing retaining ring. Holding snap ring
open, tap converter housing from transmission housing. The
fourth clutch will remain in the transmission housing. Figure 4
Remove fourth speed clutch disc hub.
Figure 2
Remove fourth speed clutch assembly from transmission Figure 5
housing Remove end plate retainer.
-93-
S1005
Figure 6
Remove end plate. Figure 9
Remove clutch piston.
Figure 7
Figure 10
Remove inner and outer clutch discs.
Remove clutch shaft piston rings and expander springs. See
note In Figure 103.
Figure 8 Figure 11
Compress spring retainer washer. Remove spring retainer snap Remove clutch shaft bearing retainer ring. Remove shaft bearing.
ring. Release tension on spring retainer. Remove snap ring,
spring retainer and return spring. See cleaning and inspection page.
-94-
4TH SPEED CLUTCH S1005
REASSEMBLY
(8 speed transmission only)
Figure 15
Install new clutch piston inner and outer sealing rings. Insert
clutch piston in clutch drum. Use caution as not to damage
sealing rings.
Figure 12
Install clutch shaft bearing. NOTE: Bearing snap ring groove
must be down.
Figure 16
Install clutch piston return spring, spring retainer and retainer
snap ring. Install one friction disc. Alternate steel and friction
discs until the proper amount of discs are installed. First disc
Figure 13 next to piston is friction, last disc installed is friction. (8 friction -
Install bearing retainer ring. 7 steel).
Figure 14 Figure 17
Install piston rings as explained on page 79. Install end plate.
-95-
S1005
Figure 21
Position pilot bearing on fourth speed clutch shaft. Install fourth
Figure 18
clutch on disc hub. Use caution as not to damage the pilot
Install end plate retainer ring. See transmission reassembly
bearing.
on page 38.
CONVERTER HOUSING INSTALLATION
4TH SPEED CLUTCH INSTALLATION
(8 speed only)
Figure 22
Support converter housing with a chain fall. Spread fourth
clutch front bearing retainer ring. Position converter housing to
transmission case assembly. Tap housing into place using
Figure 19
caution as not to damage any of the clutch shaft piston rings.
Position 4th speed clutch disc hub on idler shaft.
Figure 23
Figure 20 Spread forward clutch front bearing retainer ring to allow the
Install disc hub retainer ring. converter housing to position properly.
-96-
S1005
Figure 25
Figure 24 Use the same procedure for the forward clutch as explained in
A hammer puller was used to pull the fourth clutch bearing Figure 24. Be certain both snap rings are fully seated in the
forward to engage the front bearing snap ring in the bearing bearing snap ring grooves. Install converter housing to
groove. transmission housing cap screws, tighten to specified torque.
-97-
S1005
SUBJECT: 28000/32000 Series Transmission and C-270/C-320 Series Converter Drive Plate Kits.
REASON FOR BULLETIN: Proper Identification by Bolt Circle Diameter.
Measure the "A" dimension (Bolt Circle diameter) and order Drive Plate Kit listed below.
ALIGNMENT HOLES
(1) DRIVE PLATE AND
WELD NUT ASSEMBLY
BACKING RING
TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES - SEE ILLUSTRATION ABOVE.
Position drive plate and weld nut assembly on impeller cover with weld nuts toward cover. Align intermediate drive plate and
backing ring with holes in impeller cover. NOTE: Two dimples 180 0 apart in backing ring must be out (toward engine flywheel).
Install capscrews and washers. Tighten 23 to 25 ft. Ibs. torque [31,2 - 33,8 N.m].
Instruction SheeUlO2334
TSB-7.&~ev. 11-93
-98-
S1005
-99-
Control valve function of 28000 / 32000 - 4 speed: forward 1st
'I 1
S1005
F 1 F 1
2nd
SUPPLY
o
I
D 1st
I
c o
o
..-
I
3rd
~ REVER
4th
[gJ
~
"'" ,
~
R 2 3
R 2 3
It 1
OFF-HIGHWAY COMPONENTS
Control valve function of 28000 / 32000 - 4 speed: forward 2nd
It
F 1 F 1
IT]
2nd
SUPPLY
1st
I D
-'
~
I o
3rd
~ 4th
[Q]
'i 7
R 2 3
R 2 3
't 1
S1005
<$> OFF-HIGHWAYCOMPONENTS
Control valve function of 28000 / 32000 - 4 speed: forward 3rd
'I
S1005
F 1 F 1
[OJ
2nd
SUPPLY
Q
D
r 1st
o
I
C\I
....0
I
3rd
O'~ 4th
~[QJ
R 2 3
R 2 3
1
<$:> OFF-HIGHWAY COMPONENTS
Control valve function of 28000 / 32000 - 4 speed: forward 4th
'I
F 1 F 1
[Q]
2nd
SUPPLY
I
(0
~ 1st
0
(,) r
I
~
0 3rd
~J 4th
~[Q][QJ R 2 3
R 2 3
S1005
<$> OFF-HIGHWAYCOMPONENTS
Control valve function of 28000 / 32000 - 4 speed: neutral 4th
S1005
F 1 F 1
[OJ [OJ
~ ~ ----'1111
'* . ~,ili Mtli
2nd
. .. ---=- SUPPLY
Q"
~_~"'-M'''' .'''",,'-,".,
_~",',','--
I tst I
D "'"
0
.....
I
0 A>.J ~
, . ·.~:.:x:''I!!III::''F:''<:1
e-JI'· ... f::i. ·1l;11111,!lw11i&
-- . ~'M!:~'- L ~~~_
""_ _ _ ":,:,:,:,:cr~",,_::;:::m:»"'~
3rd
o1)~
"-
~ (©'i ".llll]lliltl~lltllR-~:::;!:]:(~ 4th
II II II
[Q] [Q] [Q]
s:»
R 2 3 R 2 3
<$> OFF-HIGHWAYCOMPONENTS
Control valve function of 28000 / 32000 - 4 speed: reverse 1st
1
F 1 F 1
[OJ
d
Q
I
....I
D
8:
I o
R 2 3
R 2 3
't I; '1
S1005
~ OFF-HIGHWAYCOMPONENTS
S1005
NOTES
-106-
OPERATOR COMPARTMENT
28000 I 32000transmission· hydraulic diagram t)('\ PRESSURE
PRESSURE TBIIPUATURB Total neutral \.2) CRBCK-PORT
3 speed • with total neutral GAUGB GAUGH baT
TBIIPBRATURE
x
O CRBCK-PORT
'C
Safetyva1¥e
11,6 - 13,8 bar
cl'Il:kq pressure _ r..n'l L ubril:ation
-=- .@ .@
" " .. 'u ~ 'C
.8
• 'C
'VI
t
Hose
----- Cooler Hose
Torque
converter
- ""
Pressure
repIator
valve
16,5 - 20,7 bar
I
.....
0 total neutral 2nd
"'-J I 1st I FORWARD I REVJ!RSJ!
I I I I solenoid I solenoid solenoid SOLE.OID SOLE. OlD
...
PlJIIP
@
onSUIIP • baT baT
:¢::I ¢::I
1
3rd 2nd 1st fOlWard reverse
( 1 bar =14,504 PSI) clutch
~clutch
J!
clutch
~clutch
~ clutch
S1005
PRBSSURB
CHBCK-PORT
O TBMPBRATURB
S1005
CHBCK-PORT
·C
Safety valve
9,6 - 13,8 bar
cracking pressure
Q ~ .8.8
E ' 14'--01 • U--I_J
'0
.@.@
,.'.... J.o
Hose
~
Cooler
\:.
~
Hose
h, E
L_tiD.
L....-y--' Torque
!, converter
Pressure
regulator
valve
16,5 - 20,7 bar
I
~
1st REVBRSB
solenoid SOLB.OID
By-pass ~~
. :~. - - Y-IL;E~- -:
valve ~•• _. __ • __ ~
1,7 - 4,3 bar
~
PUMP
AIR
BREATHER
»r:»,
~ IJ k~ ~
OIL SUMP •
B bn
:¢:I ,¢;:I
1 I I I I
3rd 2nd 1st forward reverse
( 1 bar = 14,504 PSI) dutch dutch dutch clutch dutch
.~ OFF-HIGHWAY COMPONENTS
~
OPERATOR COMPARTMENT
28000 I 32000 transmission . hydraulic diagram fi{\ PRESSURE
PRESSURE TEMPERATURE Forward and 2nd clutch engaged v CRBCK-PORT
3 speed • with total neutral GAUGE GAUGE hn
(j{'l TEMPERATURE
\.:) CHECK-PORT
·C
Safety valve
9,6 -13,8 bar
cracking pressure Lubrication
J@ J@
har ·C
• ' 1+=11 • II --. J ~! JS
\:.,J
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
1st REVERSE
solenoid SOLE. OlD
~
I
PUMP
...
/
§
OIL SUMP • har
:¢:I ~¢:I ~¢:I
1 I =1
3rd 2nd 1st
~~
forward reverse
J2
( 1 bar =14,504 PSI ) clutch
~clutch
.u
dutch dutch clutch
S1005
CBI!CK-PORT
'C
Safety valve
9,6 - 13,8 bar
cracking pressure
J@ LubricatJon
• • 1+-'11 • II I
bu
. . . .J.J@ 'C
t! ~
I@
~
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
I
o
,....
2nd 1st ,....
REVERSJ!
solenoid solenoid SOLI!ROID
~<.)-F-IL;I!~- -;
.....
PUIlIP
)
~ ~ L~ ~
§
~~
OIL SUIlIP
/¢:I
I I I I
Jrd 2nd 1st fnrward reverse
( 1 bar = 14,504 PSI) clutch clutch clutch clutch clutch
<$> OFF-HIGHWAYCOMPONENTS
OPERATOR COMPARTMENT
28000 I 32000 transmission· hydraulic diagram PRI!SSURI!
PRI!SSURI! TI!MPI!RATURI! Reverse and 1st clutch engaged O CBI!CK-PORT
3 speed • with total neutral GAUGE GAUGI! liar
TI!IIPI!RATURI!
O CBI!CK-PORT
'C
Safety valve
9,ll - 13,8 bar
cl'III:killg pressure L ulIic:ation
.@
bar
.@ 'C
• ' 1+-'1 • II I .... .J ~! I@
~ J
FORWARD
SOLI!.OID
......
......
......
§
OIL SUMP • liar liar liar
:¢I ~ ~
~@
1
3rd 2nd 1st fOlWlIrd reverse
( 1 bar =14,504 PSI) clutch
J£
clutch clutch clutch clutch
S1005
~ OFF-HIGHWAYCOMPONENTS
OPERATOR COMPARTMENT
28000 / 32000 transmission • hydraulic diagram
3 speed· without total neutral PRBSSURH
GAUGH
THIIPHRATURH
GAUGH
I Neutral and 3rd clutch engaged ®
hT
~'=~RT
O TIlIIPI!RATURIl
S1005
CIJBCK-PORT
'C
Safety valve
9,6 -1:3,8 bar
cracking pressure
.... .J.@
J@ LUBRICATION
• • Ihl • II I
lIu 'C
:t! ~
I@
~
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
2nd 1st I
FORWARD RIlTIlRSl! C\l
solenoid solenoid SOLDOID SOLBJrOm .....
.....
By-pass
valve
1.7 - 4.:3 bar
PUMP
.
OIL SUMP
@
• lIu
I¢=I
~
,1@ bu
I¢=I
J! bu
I¢=I
,1@ lIaT
I¢=I
1
3rd 2nd 1st fOlWard reverse
( 1 bar = 14,504 PSI) clutch clutch clutch clutch clutch
OFF-HIGHWAY COMPONENTS
OPERATOR COMPARTMENT
28000 J 32000 transmission • hydraulic diagram PRESSURE
PRESSURE TEIIPf!RATURE Forward and 1st clutch engaged CHECK-PORT
3 speed· without total neutral GAUGE GAUGl! I 0'ar
Tl!IlIPERATURf!
O CHECK-PORT
'C
Safety valve
9,6 - 13,8 bar
crackq pressure
LUBRICATION
.@ .@ 'C
• • 1"""1 • II I
'ar .....J .8 ~
::p! ~
Hose Cooler Hose
Torque
T co:nverter
Pressure
re&U1ator
VCI1ve
16,5 - 20,7 bar
By-pass
valve
1.7 - ".3 bar
AIR
&REATeR
,.............
B §
OIL SUMP
PRESSURE
CHBCK-PORT
O
S1005
TBMPERATURE
CHECK-PORT
'C
Safety valve
9,6 - 13,8 bar
cracking pressure
.@ .@
~.@
LUBRICATION
,
~
liar 'C
• • 1'-'1 • II I ! ~
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
I
......"'"
2nd 1st REVERSl!
solenoid solenoid SOU.OID
By-pass
valve
1,7 - ".3 bar
@
OIL SUMP
lrd 1st
( 1 bar =14,504 PSI) clutch
2nd
clutch dutch
fOlWard
r.lutm
reverse
dutch
.~ OFF-HIGHWAY COMPONENTS
~
OPERATOR COMPARTMENT
PRESSURE
28000 / 32000 transmission • hydraulic diagram Forward and 3rd clutch engaged CHECK-PORT
PRESSURB TEMPBRATURE O
3 speed. without total neutral GAUGB GAUGE lIu
TEMPERATURE
O CHECK-PORT
'C
Safety valve
9,6 -13,1 bar
craddna pressure LUBRICATION
·C
>J t t! .J
By-pus
n1¥e
1.7 - 43 bar
B lIu liar
OILSUIIP L
~¢:I :=
I
L@ ~¢:I
I
I]
"1 1st reverse
3rd 2nd forward
S1005
<E:;> OFF-HIGHWAYCOMPONENTS
OPERATOR COMPARTMENT
28000 J 32000 transmission • hydraulic diagram
3 speed- without total neutral PRBSSURB
GAUGH
TBIIPHRATORB
GAUGH I Reverse and 1st cl utch engaged 0hT PRI!SSU'RE
COCK-PORT
S1005
O·C
TI!IiIPI!RATORI!
COCK-PORT
Safety valve
9,6 - 13,8 bar
cracking pressure
.@ ______ .@
_'C ~ .@J
LUBRICATION
~
ltaT
, , I+--'I ,II I
Hose
\:. ~ ~
Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
I
FORWARD CD
SOLDOID
.-
-e-
By-pass ;.(..>-
," -;-
FILTn '
I
valve
1.7 - 4.3 bar
PUMP
•
1~ J! J!
@
( 1 bar
OIL SUMP
=14,504 PSI)
~~
3rd
clutch
2nd
clutch
1st
clutch
ltaT
!¢:I
forward
clutch
ltaT
!¢:I
J! hT
revel'Se
clutch
!¢:I
<$> OFF-HIGHWAYCOMPONENTS
OPERATOR COMPARTMENT
28000 I 32000 transmlsslon- hydraulic diagram (X'" PRI!SSURI!
PRI!SSURI! TI!MPI!RATURI! Total neutral ~) CHI!CK-PORT
4 speed· with total neutral GAUGI! GAUGI! liar
TI!MPI!RATURI!
O CHI!CK-PORT
·C
Safety valve
9,6 - 13,8 bar
cracking pressure II .-=., II Lubrication
-(,.~
J@ J@ J§
j lIa. • ·C
hl II - I f
~
Hose Cooler Hose
Torque
.. converter
Pressure -
regulator
valve
16,5 - 20,7 bar
1-1. I
total neutral 3rd 2nd 1st
...... I TORWARD I RI!VI!RSI!
...... I I I solenoid solenoid solenoid solenoid SOLI!lIOID SOLI!. OlD
.....
I
• • :A--
I •••
----,
TILTI!R :
...
PUMP
@
OIL SUMP liar liar lIa. liar liar liar
• ~ ¢:I ¢:I ¢:I ¢:I ¢:I
1
4th 3rd 2nd 1st forward reverse
( 1 bar =14,504 PSI) clutch
~
clutch
If J! J£
clutch clutch clutch
lr
clutch
S1005
O'C
THIiIPERATURE
CBHCK-PORT
Safety VlI1vll
!1,6 - 13,1 bar
crackiD& pressure
I@
liar
I@
~ 'C
IS
::a:
'C
Luhrleatkm
• ' 1+-'1 • II 1
Hose Cooler Hose
Torque
convener
Pressure
replatDr !t
VlI1vll
16,5 - 20,7 bar
3rd 2nd 1st FORWARD RJ!VERSE
solenoid solenoid solenoid SOLE. OlD SOLE. OlD I
«Xl
.....
.....
~
@
( 1 bar
OIL SUMP
=14,504 PSI)
•
4th
clutch
liar
:¢:I
1 1f3rd
clutch
liar
¢:I
2nd
clutch
J! J1
1st
clutch
liar
¢:I
forward
clutch
liar
¢:I
l¥
reverse
clutch
~¢:I
<$> OFF-HIGHWAY COMPONENTS
OPERATOR COMPARTMENT
28000 132000 transmission· hydraulic diagram r)('I PRESSURI!
PRI!SSURB TI!IIPI!RATURI! Forward and 1st clutch engaged \.:J COCK-PORT
4 speed • with total neutral GAUGI! GAUGI tin
Tl!llPI!RATURB
Ox COCK-PORT
'C
Safety'nI1ve
!I,lS - 13,8bar
Cl'lKkh1I pressure Lubricatlon
,@ ,@
"p '0
----r--' Torque
.!, colMll1e1'
Pressure
reauJator
'nI1ve
16,5 - 20.7 bar
Jtn1lRSB
..... • • SUIt:nUIU • aula_lulU • _'U""'". • _._••_-- • ::lItu..... u&U • SOLDOID
--"
CO
I
@
OIL S1JIIP • "p "p
-~ ~
fth
, ~3rd
~ 2nd 1l1t
1£ ~fulWlrd rev.....
~~
( 1 bar =14,504 PSI) dutch dutch dutch dutch clutch dutch
S1005
~ OFF-HIGHWAYCOMPONENTS
OPERATOR COMPARTMENT
28000 132000 transmission· hydraulic diagram
I Forward and 2nd clutch engaged v r;{I PRESSURB
S1005
TBMPERATURE
CHECK-PORT
Safety wire
11,6 -13,8 bar
Cl'lll:kiD& pressure
.@ !Jar
.s
'C
Lmril:atlon
Pressure
,..... Torque
converter
Safety valve
9.6 -13.SbaJ:'
r rae king pl'essul'e
Lubril:atlon
J@ J@
lIa. "C
i ' I+--.I • II I
Hose Cooler IiJse
Torque
converter
Pressure
regulator
vah"
16,5 - 20, i bar
@
OIL SUMP lIa. n. n. D,
• ~
1
~ ~ ~
'a~T
4th 3rd 2nd 1. forward reverse
( 1 bar = 14,504 PSI) c1utcil
Jffi
clutch
~clutch
J! J!
c1utcil clutcil
JJclutch
S1005
<$> OFF-HIGHWAYCOMPONENTS
OPERATOR COMPARTMENT
28000 132000 transmission· hydraulic diagram
4 speed • with total neutral PRI!SSURI! Tl!llPIlllATURI! I Forward and 4th clutch engaged 0 :=r-~~RT
S1005
Safety valve
l',6 -13,8 bar
cracking pressure Lmrkatlon
J@ .@
\at -c
• 'I+-'I • II I .... .J <t! ,@
\:. #
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20.7 bar
By-pass
valve
1,7 - 4,3 bar
@
OIL SUMP lIat \at J=@ lIat liar liar
• ~ ¢I ¢I ¢I ¢I
1 I I
( 1 bar =14,504 PSI) 4th
clutch
~ 3rd
clutch
J!2nd
clutch
1st
clutch
forward
lfclutch
I!
reverse
clutch
S1005
CRBCK-PORT
·C
Safety valve
9,6 -13,8 bar
Cl'lIl:kq pressure
.@
liar
.@ ·C
LUBRICATION
Hose Cooler Hose
Torque
cOllVerter
Pressure
reauJator
vain!
lCi,5 - 20,7 bar
3rd 2nd 1st FORWARD RBVBRSB
solenoid solenoid solenoid SOLBROID SOLBROID
I
~
~ Jr 1° Jr
@
OILSUIIP
I
t-:$. i
br
~
br
~
hr
~
( 1 bar =14,504 PSI) 411I
clutch
3rd
clutch
2nd
clutch
1st
clutch
forward
clutch
reverse
dutch
.~ OFF-HIGHWAY COMPONENTS
~
OPERATOR COMPARTMENT
28000 I 32000 transmtsslon- hydraulic diagram 0(\ PRIISSURB
PRJ!SSURJ! THMPJ!RATURH Forward and 18t clutch engaged \..:.J CHECK-PORT
4 speed· without total neutral GAUGJ! GAUGH
1II.r
TDlPIlRATU'RII
x
O CBIlCK-PORT
·C
Safety valve
9,6 -13,8 bar
cracking pressure
J@ J@
liar 'C
" J <t! 18
1(----
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5- 20,7 bar
2nd 1st
RIlVIlRSI!
.... solenoid solenoid SOLO om
~
I
By-pass ;<:.)-r~L;J!~--;
valve
1.7 - 4.3 bar
PUMP
...
4th 3rd
1
2nd
---=]
1@ 1st
I
L8 I
reverse
forwllrd
( 1 bar =14,504 PSI) clutch clutch
~
clutch clutch clutch
J!
clutch
S1005
CHI!CK-PORT
·C
Safety valve
9,6 - 13,8 bar
cratking pressure
.... ~
J@ J@ lUIRICATION
, , 1+=11 ,II I
liar ·C
t! .s
\:~
Hose Cooler Hose
Torque
converter
Pressure
regulator
valve
16,5 - 20,7 bar
2nd 1st RI!VI!RSI!
solenoid solenoid I
SOLI!IfOID
co
C\l
By-pass ;'(0) -F~L;~--;
valve
1,7 - 4,3 bar
PUMP
...
OIL SUMP
•
@
liar
~
1 Jf Jf 1 liar
~
liar
~
8 liar
~
~s liar
~
1;8 liar
~
( 1 bar =14,504 PSI) 4th
clutch
3rd
clutch
2nd
clutch
1st
clutch
forward
clutch
reverse
clutch
.~ OFF-HIGHWAY COMPONENTS
~
OPERATOR COMPARTMENT
28000 I 32000 transmission • hydraulic diagram PRRSSORR
PRRSSORI! TEMPERATURE Forward and 3rd clutch engaged O CHECK-PORT
4 speed· without total neutral GAUGE GAUGE liar
TRMPERATORR
O CHRCK-PORT
'C
Safety valve
9,6 - 13,8 bar
crackiJIi pressure
LUBRICATION
,@ 'C
. q: •
""'"-,; ! '-.m '"
Hose Cooler Hose
Torque
! converter
Pressure
regulator
valve
16,5 - 20,7bar. ~
By-pass ~~'~-~L;~--;
valve
1.7 - 4.3bar
....
PUIIP
@ 8
OIL SUMP liar liar liar 1lar
• ~ ~ ~ ¢2
1
~8
4th 3rd 2nd 1st forward reverse
( 1 bar = 14,504 PSI) clutch
~
clutch
J1 1
clutch clutch clutch clutch
S1005
O
x
·C
TllIIPI!RATURE
CHECK-PORT
Safety valve
96 -13,8bar
~klDa pressure II
" ~
I
@
liar
I@ LlJIRICATIIII
...,)-l
Hose Cooler Hose
- --
T
0.=.1
TOI1lUB
amvel1er
Pressure
regulator
valve
16,5 - 20,7 bar
J-l. I 3rd
solenoid G solenoid
I 11t
solenoid
FOllWARD
S OLEII om
..t fl
7a
r». IIODULATIO.
I?IULVE
I RI!VERs]!
SOLEIIOID
re
I
,....
( 1 bar
OIL SUIIP
=14,504 PSI)
•
4th
clutch
@
liar
, ~
~ 3rd
clutch
Jr 1@ JJ
2nd
dutch
liar
~
1st
clutch
lIa,.
~
forward
clutch
J£ liar
reverse
dutch
~
.~ OFF-HIGHWAY COMPONENTS
~
OPERATORCOMPARTMENT
28000 / 32000 transmission • hydraulic diagram PRl!SSURl!
PRBSSURB TEMPBRATURB Reverse and 1st clutch engaged O CHECK-PORT
4 speed· without total neutral GAUGH GAUGH 1II.r
Tl!MPl!RATURl!
O CHl!CK-PORT
·C
Safety valve
9,6 -13,8 bar
craekhll pressure
LUBRICATION
.@
1I&r
.@ ·C
.s
:) '-c
l
Hose c... lIMe
Torque
1 comlerter
Pressure
regulator
valve
16,5 - 20,7......
FORWARD Rl!Vl!RSl!
SOLDom SOLE. 010
~ .l. Fl 17\. MODULATIO.
I 7n I?-IVALVH
@
OIL SUMP 11&.. 11&.. 11&..
• ~
1
~ ~
<$> OFF-HIGHWAYCOMPONENTS
S1005
S1005
13675
DRIVELINE INSTALLATION
Page 1 of 1
Updated:
11/03/08
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
6. AXLE
Updated:
12/11/06
13335
AXLE ASSEMBLY 464872
Page 1 of 9
Updated:
03/12/07
13335
AXLE ASSEMBLY 464872
Page 2 of 9
Updated:
03/12/07
13335
AXLE ASSEMBLY 464872
Page 3 of 9
Updated:
03/12/07
13335
AXLE ASSEMBLY 464872
Page 4 of 9
Updated:
03/12/07
13335
AXLE ASSEMBLY 464872
Page 5 of 9
Updated:
03/12/07
13335
AXLE ASSEMBLY 464872
Page 6 of 9
27 444205 SPACER, (.049/.050) A/R
444105 SPACER, (.053/.054) A/R
444118 SPACER, (.057/.058) A/R
444119 SPACER, (.061/.062) A/R
444120 SPACER, (.065/.066) A/R
444106 SPACER, (.069/.070) A/R
444122 SPACER, (.073/.074) A/R
444123 SPACER, (.077/.078) A/R
444145 SPACER, (.081/.082) A/R
444237 SPACER, (.085/.086) A/R
444097 SPACER, (.089/.090) A/R
28 444142 WASHER, RETAINING 2
29 444033 LOCK BOLT 2
30 444143 BOLT, HEX HEAD 2
31 ------------ BRAKE ASSEMBLY 2
32 444144 HOUSING, REAR BRAKE OUTER 2
33 444196 HOUSING, BRAKE INNER R.H. 1
444193 HOUSING, BRAKE INNER L.H. 1
34 444125 SHIM (.038/.040) A/R
444098 SHIM (.044/.046) A/R
444126 SHIM (.050/.052) A/R
444127 SHIM (.056/.058) A/R
444099 SHIM (.062/.064) A/R
444108 SHIM (.068/.070) A/R
444100 SHIM (.074/.076) A/R
444109 SHIM (.080/.082) A/R
35 444164 CUP BEARING 1
36 444177 CUP BEARING, R.H 1
37 444008 CONE AND ROLLER ASSEMBLY L.H. 1
38 444176 CONE AND ROLLER ASSEMBLY R.H. 1
39 444249 CASE ASSEMBLY 1
40 444250 SCREW, HEX 8
41 444251 GEAR SET-MATCHED 1
42 442210 BOLT 12
43 444110 NUT-HEX LOCK 12
44 444170 GEAR-SIDE 1
45 444171 GEAR-SIDE 1
46 444178 WASHER-THRUST 2
Updated:
03/12/07
13335
AXLE ASSEMBLY 464872
Page 7 of 9
47 444169 SPIDER-DIFFERENTIAL 1
48 444172 PINION ASSEMBLY-DIFFERENTIAL 4
49 444175 WASHER-THRUST 4
50 444173 BUSHING 2
51 444854 ADAPTER 1
52 444855 SPRING 1
53 444856 COUPLING 1
54 444252 WASHER 1
55 444092 RING-LOCKING 1
56 442220 BEARING ASSEMBLY 1
57 444850 LOCK RING 1
58 442240 CONE AND ROLLER ASSEMBLY 1
59 442250 RETAINER ASSEMBLY 1
60 442260 CUP-BEARING 1
61 442270 CUP-BEARING 1
62 444253 WASHER-LOCK 1
63 444782 BOLT-HEX HEAD 1
64 444111 SPACER (1.254/1.2545) A/R
444093 SPACER (1.256/1.2565) A/R
444255 SPACER (1.258/1.2585) A/R
444112 SPACER (1.260/1.2605) A/R
444114 SPACER (1.262/1.2625) A/R
444094 SPACER (1.264/1.2645) A/R
444128 SPACER (1.266/1.2665) A/R
444129 SPACER (1.268/1.2685) A/R
444130 SPACER (1.270/1.2705) A/R
444095 SPACER (1.272/1.2725) A/R
444131 SPACER (1.274/1.2745) A/R
444132 SPACER (1.276/1.2765) A/R
444133 SPACER (1.278/1.2785) A/R
444096 SPACER (1.280/1.2805) A/R
444134 SPACER (1.282/1.2825) A/R
65 442280 SEAL, O-RING 1
66 442290 SEAL, RETAINER 1
67 444851 RETAINER 1
69 444852 SEAL, ASSEMBLY 1
Updated:
03/12/07
13335
AXLE ASSEMBLY 464872
Page 8 of 9
70 11827-01 FLANGE (STANDARD) 1
19495-01 FLANGE (DISC BRAKE) 1
71 442310 SEAL, SALINE 1
72 442320 WASHER, RETAINER 1
73 442330 NUT, HEX SLOTTED 1
74 01GF03032 PIN, COTTER 1
75 442340 CONE AND ROLLER ASSEMBLY 1
76 442350 BLOCK, THRUST 1
77 04GE07 WASHER, LOCK 2
78 444258 BOLT, HEX HEAD 2
Updated:
03/12/07
13335
AXLE ASSEMBLY 464872
Page 9 of 9
Updated:
03/12/07
13332
AXLE CRADLE
Page 1 of 1
Updated:
01/30/07
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
S1037
13158
BRAKE ACTUATOR
Page 1 of 2
Updated:
01/30/07
13158
BRAKE ACTUATOR
Page 2 of 2
Updated:
01/30/07
S1023
S1023
13938
TIRE & RIM
Page 1 of 1
7. BRAKE SYSTEM
Updated:
12/11/06
13378
PEDAL BRAKE VALVE
Page 2 of 4
Updated:
12/11/06
13378
PEDAL BRAKE VALVE
Page 3 of 4
Updated:
12/11/06
13378
PEDAL BRAKE VALVE
Page 4 of 4
26 67GD06 NUT 2
01GF01016 COTTER PIN 2
27 15248-01 PIN 1
28 NSS CAP SCREW 2
29 NSS WASHER 2
30 NSS BASE 1
31 NSS LABEL 1
32 NSS DRIVE SCREW 2
33 NSS WASHER 2
34 NSS CAP SCREW 2
35 NSS CAP SCREW 1
36 NSS NUT 1
Updated:
12/11/06
S1008
S1008
S1008
S1008
16483
CHARGING VALVE
Page 1 of 4
Updated:
12/11/06
16483
CHARGING VALVE
Page 2 of 4
Updated:
12/11/06
16483
CHARGING VALVE
Page 3 of 4
Updated:
12/11/06
16483
CHARGING VALVE
Page 4 of 4
29 NSS INSEAT 1
30 NSS SPRING 1
31 NSS END PLUG 1
32 NSS O-RING 1
33 NSS POPPET 2
34 NSS O-RING 1
35 NSS SLEEVE 1
36 NSS O-RING 1
Updated:
12/11/06
S1009
S1009
S1009
S1009
12976
ACCUMULATOR
Page 1 of 1
8. HYDRAULIC SYSTEM
Adjustable Cushion
Spring
Advance Only
Pressure Compensated
Units (Arrow parallel to
short side of symbol) Differential Piston Manual
Electric Motor
Vented
Pedal or Treadle
Accumulator,
Pressurized Spring Loaded
Mechanical
Line, To Reservoir Accumulator,
Gas Charged
Detent
Above Fluid Level
Heater
Below Fluid Level
Pressure Compensated
Vented Manifold
Two-Position
Two Connection
Two-Position
Three Connection
Two-Position
Four Connection
Three-Position
Four Connection
Two-Position
In Transition
1094 Call your local Applied® service center to order at 1-866-351-3464 or visit us online at Applied.com
Getman Corporation
ServiceJunior
Getman P/N 468005
The NEWServiceJunior
Digital Pressure Gauge
• 50 Times Faster than Previous Model
• 10 msec Scanning Rate
• Measure PSI, bar, mPa, and
kPa with One Gauge
• +1- 0.5% Full Scale Accuracy
• Simple Operation
• Peak and Hold Function with
Bar Graph Display
17132
Getman’s ServiceJunior
The new Getman Service Junior captures
momentary pressure spikes that are
"invisible" to normal liquid-filled gauges.
That means the maximum pressure
reading it delivers can be trusted
as a much truer reflection of the
system's actual condition; so you
can identify potential problems
better and diagnose their causes
faster. All readings are accurate
to within +/-0.5%.
ServiceJunior Features
• Easy to connect and test system pressure • Accuracy +/- 0.5% of full scale
using Parker Diagnostic test port couplings • Three pressure ranges
• Robust, dirt resistant housing • Operating temperature 14° to 122° F
• Simple to operate, four key menu • Fluid temperature -4° to 176° F
• Four digit backlit display with easy to read • Storage temperature -4° to 140° F
large 0.60" characters • Auto power off after 15 minutes or
• Minimum and maximum graphic display constant on" at the touch of a button
shows pressure peak • Zero adjustment function
• Power status displayed continuously • 10 msec scanning rate
• Can be used with most hydraulic and • Ratings:
pneumatic media Environmental Protection: EN60529 (IP 65)
• Measure PSI, bar, mPa, kPa with one gauge Vibration: IFC 60068-2-6/10 — 500Hz: 20g
Shock: IEC 60068-2-29/50g 11 msec
Measuring Overload
Resolution
Range Pressure
0 to 5800 PSI
(0 to 400 bar) 11,600 PSI 1 PSI
NOTES: 1. PD Couplers rated to 6,000 PSI max. 2. EMA3 Couplers rated to 9,000 PSI max.
Getman Corporation
59750 34 t h A ve n u e
Bangor, MI 49013
PH: (269) 427-5611 FAX: (269) 427-8781
www.getman.com
13259
HYDRAULIC FILTER
Page 1 of 1
Updated:
12/11/06
12860
STEERING ORBITROL
Page 1 of 2
Updated:
12/11/06
12860
STEERING ORBITROL
Page 2 of 2
Updated:
12/11/06
S1024
S1024
S1024
S1024
16384
HYDRAULIC MOTOR
Page 1 of 2
Updated:
12/18/06
16384
HYDRAULIC MOTOR
Page 2 of 2
Updated:
12/18/06
S1010
S1010
S1010
S1010
BASKET VALVE 5 SECTION 17172
(IN BASKET) Page 1 of 3
Updated:
07/09/08
BASKET VALVE 5 SECTION 17172
(IN BASKET) Page 2 of 3
Updated:
07/09/08
BASKET VALVE 5 SECTION 17172
(IN BASKET) Page 3 of 3
Updated:
07/09/08
BOOM CONTROL VALVE 12508
ORIENTATION (56476) Page 1 of 7
MAIN
HANDLE END RELIEF
PILOT SECTION
A A A A A
B B B B B
PORT RELIEF
PILOT SECTION
BOOM SWING BOOM LIFT
SECTION SECTION BASKET ROTATION
SECTION
OUTLET END BOOM BASKET
COVER EXTENSION LEVELING
SECTION SECTION
NOTE: THE “B” PORTS ON THE BOOM LIFT AND EXTENSION ARE EQUIPPED WITH MOTOR SPOOLS
IN OUT
Updated:
03/17/10
BOOM CONTROL VALVE 12508
ORIENTATION (56476) Page 2 of 7
Updated:
03/17/10
BOOM CONTROL VALVE 12508
ORIENTATION (56476) Page 3 of 7
Updated:
03/17/10
BOOM CONTROL VALVE 12508
ORIENTATION (56476) Page 4 of 7
Updated:
03/17/10
BOOM CONTROL VALVE 12508
ORIENTATION (56476) Page 5 of 7
Updated:
03/17/10
BOOM CONTROL VALVE 12508
ORIENTATION (56476) Page 6 of 7
Updated:
03/17/10
BOOM CONTROL VALVE 12508
ORIENTATION (56476) Page 7 of 7
Updated:
03/17/10
CONTROL VALVE 13282
ORIENTATION (534731) Page 1 of 6
Updated:
03/17/10
CONTROL VALVE 13282
ORIENTATION (534731) Page 2 of 6
Updated:
03/17/10
CONTROL VALVE 13282
ORIENTATION (534731) Page 3 of 6
Updated:
03/17/10
CONTROL VALVE 13282
ORIENTATION (534731) Page 4 of 6
Updated:
03/17/10
CONTROL VALVE 13282
ORIENTATION (534731) Page 5 of 6
Updated:
03/17/10
CONTROL VALVE 13282
ORIENTATION (534731) Page 6 of 6
Updated:
03/17/10
13970
HYDRAULIC CYLINDER
Page 1 of 1
Updated:
01/08/09
13629
HOIST CYLINDER
Page 1 of 1
Updated:
10/07/09
13827
EXTENSION CYLINDER
Page 1 of 1
Updated:
06/01/07
13828
EXTENSION CYLINDER
Page 1 of 1
Updated:
06/01/07
13628
BASKET LEVELING CYLINDER
Page 1 of 1
Updated:
08/19/09
13627
STABILIZER CYLINDER
Page 1 of 1
Updated:
12/18/06
13943
STEER CYLINDER
Page 1 of 1
Updated:
12/11/06
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
9. CONTROLS
Updated:
02/17/10
MANUAL INDEX
2-500L ANFO CHARGER
KOL (ARAMINE)
S/N 020-001
6/1/2010
002792
S1012
Transmission &
Turbocharger Disc Brake
Hydraulic
Pump Hose
Area
Engine
Block
Typical Vehicle
Fire Hazard Areas 002776
S1012
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
000621
000622
000623
000624
000625
000626
S1012
002777
002778
002779
002780
002781
002782
002783
S1012
002784
002785
ALL FITTINGS
TIGHT NO KINKS
IN HOSE
NO ABRASIONS
Agent Tank AUTHORIZED ANSUL Agent Tank LVS Hand Portable Fire
DISTRIBUTOR VISUAL SEAL
A-101 CERTIFICATION TAG or LT-A-101-125/250 Extinguisher IN PLACE
ATTACHED FIRMLY
MOUNTED
DISTRIBUTOR
CERTIFICATION
TAG ATTACHED
NO
EXCESSIVE
NO
WEAR
ABRASIONS
NO EXCESSIVE FIRMLY
WEAR MOUNTED NO
EXCESSIVE
NO WEAR
NO CORROSION FIRMLY
CORROSION MOUNTED
NO
CORROSION
NO
CORROSION
002794 002788
FIRMLY MOUNTED 004320
S1012
002790
FUSE IN
FUSEHOLDER
CONNECTION
SECURE CONNECTION
CARTRIDGE SECURE
INSTALLED
002789
RING PIN IN
BRACKET PLACE AND
SECURELY SEALED
WELDED OR
BOLTED
CHECK THE SYSTEM
BRACKET
DAILY BY VISUALLY
RING PIN IN SECURELY
SEALED VERIFYING THAT THE
PLACE AND WELDED OR CHECK THE SYSTEM
CARTRIDGE GREEN POWER LED
SEALED BOLTED DAILY BY VISUALLY
INSTALLED IS FLASHING ONCE
VERIFYING THAT THE EVERY THREE
GREEN BATTERY LED SECONDS AND NO
IS FLASHING ONCE OTHER LED IS FLASH-
EVERY THREE SEC- ING
ONDS AND NO
OTHER LED IS
FLASHING
BRACKET
CARTRIDGE
SECURELY
INSTALLED
WELDED OR
BOLTED
CARTRIDGE
INSTALLED
DETECTION LINE
AND/OR DETECTION LINE
DETECTORS AND/OR
SECURE AND NOT DETECTORS
DAMAGED SECURE AND NOT
DAMAGED
002791 002775
S1012
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.
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.
000627
A-101-10/20/30, LT-A-101-10/20/30
VEHICLE SYSTEMS
Installation, Recharge, Inspection, and Maintenance Manual
003898
S1013
This manual is intended for use with the ANSUL A-101 Vehicle
Fire Suppression System.
Those who install, operate, recharge, inspect, or maintain these
fire suppression systems should read this entire manual. Specific
sections will be of particular interest depending upon one’s
responsibilities.
Design, installation, recharge, and maintenance of the system
must conform to the limitations detailed in this manual and per-
formed by an individual who attended an ANSUL training program
and became trained to design, install, recharge, and maintain the
ANSUL system(s).
Fire suppression systems are mechanical devices. They need
periodic care to provide maximum assurance that they will oper-
ate effectively and safely. Inspection frequency shall be per-
formed monthly, or sooner, depending on operating and/or envi-
ronmental conditions. Maintenance shall be performed semi-
annually or sooner, depending on operating and/or environmental
conditions.
This ANSUL systems manual is limited to uses herein described.
For other applications, contact your local ANSUL distributor,
Domestic District Manager, International Area Manager, or Ansul
Incorporated – Technical Services Department, Marinette,
Wisconsin 54143-2542.
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
INTRODUCTION FM APPROVAL
The ANSUL A-101/LT-A-101 fire suppression system is a pre- The ANSUL A-101/LT-A-101 fire suppression system has been
engineered, fixed nozzle system for protection of off-highway tested and is FM approved. These tests require extinguishment of
vehicles, commercial vehicles, or industrial type applications. fire initiated in open vessels and within enclosures fueled with
Typical applications include surface mining equipment, under- flammable liquid. In each case, these fires are allowed to
ground mining machines, forest harvesting equipment, construc- progress to maximum intensity before the system is actuated.
tion equipment, farming machinery, and transportation vehicles The time of actuation in these tests is well beyond the time that a
such as municipal busses. detector would take to detect the fire and actuate the system.
The A-101/LT-A-101 system consists of three major components: Other tests required by FMRC are as follows:
a container to store the dry chemical extinguisher agent; an actu- 1. Fuel in depth splash tests under a minimum hose length,
ation system operated manually or automatically, and an agent maximum temperature, and minimum clearance condition to
distribution system which delivers the agent from the tank through ensure that the nozzle does not cause splashing of fuel.
hydraulic hose and fixed nozzles to the hazard areas. 2. Operational flow rate tests at the minimum, average, and the
The fire system described is a suppression system only and is not maximum temperatures, with maximum and minimum hose
designed or intended to extinguish all fires, particularly when lengths.
unusual amounts of combustible materials and an ample oxygen 3. Cycle tests on all mechanical and electrical devices to deter-
supply are present. It is extremely important that supplement fire mine their structural integrity.
fighting equipment be available in case the system does not total-
ly extinguish a fire. The A-101 systems which utilize carbon dioxide as the expellant
gas are approved for temperature ranges of +32 °F to +120 °F
If an automatic fire detection and actuation system has not been (0 °C to 49 °C).
supplied or has been disconnected, system actuation and dis-
charge will not occur unless the fire suppression system is manu- The LT-A-101 systems which utilize nitrogen as the expellant gas
ally actuated. (Use of manual system only must be approved by are approved for temperature ranges of –65 °F to +210 °F
authority having jurisdiction.) Reliance on a manual release sys- (–54 °C to 99 °C).
tem usually results in a slower reaction to fire. Means to shut
down the vehicle must be added to a manual or disconnected TWIN AGENT SYSTEM (LVS PORTION NOT FM APPROVED)
automatic system. The system consists of both dry chemical and liquid agent. The
The basic agent storage container is a tank filled with ANSUL dry chemical portion of the system is the ANSUL A-101/LT-A-101,
FORAY (monoammonium phosphate base) dry chemical which is 50, 125, or 250 system (either standard discharge or extended
effective on Class A, B, and C fires. A gas expellant cartridge, discharge) and the liquid agent portion of the system consists of
either carbon dioxide or nitrogen, provides pressurization of the an agent storage tank containing a premixed solution of LVS wet
dry chemical upon actuation. chemical.
Automatic detection, either electric or pneumatic, and actuation, The LVS-30 (30 gallon) system is designed to discharge for
is recommended. The A-101/LT-A-101 system is actuated manu- approximately 2 minutes when two agent discharge nozzles are
ally by a pneumatic actuator located on the dashboard or on the used.
exterior of the vehicle. The LVS Fire Suppression System is designed to operate within a
The dry chemical extinguishing agent is delivered from the tank temperature range of –40 °F to +120 °F (–40 °C to 49 °C).
through hydraulic hose and pre-set nozzles into the fire hazard The dry chemical system used in conjunction with the LVS sys-
areas or onto the fire prone surfaces. tem is the ANSUL A-101/LT-A-101, 50, 125 or 250. The dry chem-
Along with the fire suppression system, the total system design ical system is connected to the ANSUL CHECKFIRE Detection
must include a hand portable fire extinguisher(s) located on board and Control System. the dry chemical system can be designed as
the vehicle that can be used to manually suppress a fire that may a standard discharge or as an extended discharge system per the
be burning in an unprotected area. Refer to NFPA 10, “Standard requirements of the A-101/LT-A-101 Vehicle Fire suppression
For Portable Fire Extinguisher,” for additional information. Installation, Recharge, Inspection, and Maintenance Manual.
Both systems are designed to discharge simultaneously
when actuated either manually or automatically.
For detailed instructions, refer to manual Part No. 427865 regard-
ing the LT-A-101-50/125/250 system. For detailed instructions,
refer to manual Part No. 427109 regarding the LVS system.
S1013
SECTION I – GENERAL INFORMATION
5-15-02 Page 1-2
REV. 2
FROM AUTOMATIC
DETECTION SYSTEM
2
1
TO OPTIONAL
PRESSURE SWITCH
3
FIGURE 1
002581
HOW THE SYSTEM OPERATES IN CASE OF FIRE
Discharge of the A-101/LT-A-101 system manually is initiated When a fire starts, the way the operator reacts is very important.
from a remote actuator (1). Depressing the actuator plunger As soon as the operator is aware of a fire, he should do the fol-
punctures the seal on the cartridge. The released pressure is lowing four things:
transmitted to the pneumatic actuator/cartridge receiver (2). A 1. Turn the machine off and set the brake.
safety relief valve (3) at this point prevents too high an actuation
pressure build-up. The pressure drives a puncture pin through 2. Quickly actuate the system by pulling the safety ring pin on
the seal in the expellant gas cartridge (4). This releases the the manual actuator and strike the red button.
expellant gas which is then transmitted to the dry chemical tank 3. Evacuate the vehicle.
(5) where it fluidizes the dry chemical before carrying it to the fire
hazard. A sealed burst disc assembly (6) prevents the flow of dry 4. Stand by with a fire extinguisher.
chemical until sufficient pressure is built up within the dry chemi-
cal tank. When the proper pressure is reached, the disc breaks
allowing the gas/dry chemical mixture to flow to the nozzle(s) (7) ! CAUTION
and discharge onto the hazard. The fire system described in this manual is a suppression sys-
Refer to appropriate CHECKFIRE design, installation and main- tem only and is not designed or intended to extinguish all fires,
tenance manual for information on the operation of the automatic particularly when unusual amounts of combustible materials
detection system. and an ample oxygen supply are present. It is extremely
important that supplemental firefighting equipment be available
NOTE: Mechanical or electrical means must be provided to shut
in case the system does not totally extinguish a fire.
down vehicle upon system actuation.
S1013
SECTION III – SYSTEM COMPONENTS
6-30-05 Page 3-1
REV. 1
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)
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
FIGURE 3
000417 A
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)
FIGURE 4
S1013
SECTION III – SYSTEM COMPONENTS
5-15-02 Page 3-3
REV. 1
VENT HOLE
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)
003473c 3 IN.
1 1/2 IN. (7.6 cm) 3 7/16 IN.
(3.8 cm) (8.7 cm)
003460
FIGURE 7
S1013
SECTION III – SYSTEM COMPONENTS
5-15-02 Page 3-4
REV. 1
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
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
FIGURE 12 FIGURE 14
000437 000716
S1013
SECTION III – SYSTEM COMPONENTS
5-15-02 Page 3-5
REV. 1
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
1 IN.
7 7/8 IN. 3 FT.
003724 HEX 1/2 IN. NPT
(20 cm) (0.9 m)
PART NO. 53791
NAMEPLATE
FIGURE 17
2 11/32 IN.
- (5.9 cm) 5 5/8 IN.
3 9/16 IN. MOUNTING (14.2 cm)
(9 cm) HOLES
3/4 IN. CONDUIT
OUTLET
FIGURE 16
000454
S1013
SECTION IV – SYSTEM DESIGN – VEHICLE
5-15-02 Page 4-1
REV. 1
HAZARD ANALYSIS High Pressure Hoses – Hot fluid spraying from a ruptured high
Individuals responsible for the design of an A-101/LT-A-101 system pressure hose, or leaking from a loose flange or fitting could find
must be trained and hold a current ANSUL certificate in an A- its way to a source of ignition.
101/LT-A-101 training program. Knowledge of the fire hazards that Belly Pan – The belly pan can accumulate not only leaking fuel
exist in the equipment to be protected is also required. Finally, a from the vehicle, but external debris, and because of its unique
good understanding of federal and local fire protection codes and location, a fire starting in the belly pan could quickly engulf the
standards is necessary. No one should begin designing without entire vehicle.
previously becoming familiar with the applicable codes. Hydraulic/Fuel Pumps – Because of the high pressures involved
Having read about the A-101/LT-A-101 system and the basic ter- with these pumps, fluid spraying from a leaking pump could find
minology and operation of the system, you should now begin to its way to a heat source and cause ignition.
identity the fire hazards in the equipment to be protected. Every After completing the hazard analysis, determine nozzle cover-
foreseeable hazard must be identified now while you have design ages.
flexibility; once the system is installed, adding protection for
another hazard becomes more difficult. Note that the A-101/LT-A- NOZZLE COVERAGE AND LOCATION
101 system is designed only for the protection of specified equip-
The first step is to determine which nozzles are needed and
ment for the foreseeable hazards that exist due to that equipment
where they should be placed to best protect the hazard.
and its operation. The areas of protection are fixed at installation
and are limited in number. An A-101/LT-A-101 system does not Nozzle selection can be made by first determining the size of the
remove the need for a hand portable fire extinguisher on the hazard and then comparing that to the nozzle’s effective dis-
equipment. Fuel spills, welding (repair) heat or other unforesee- charge pattern.
able causes may result in fires not having A-101/LT-A-101 protec- C-1/2 Nozzle Part No. 53791 – The cone-shape discharge pat-
tion. The A-101/LT-A-101 system protects the areas with high like- tern of the C-1/2 nozzle will widen to a 3 ft. (.9 m) diameter at the
lihood of fire and potential for high damage; seldom would an maximum effective discharge range of 6 ft. (1.8 m). See Figure 1.
A-101/LT-A-101 system be designed to protect every square inch V-1/2 Nozzle Part No. 56748 – The V-1/2 nozzle creates a fan-
of the equipment to be protected. shaped discharge pattern of 160° and has a maximum effective
An effective system design is based on a through hazard analy- discharge range of 4 ft. (1219 mm) in length by 15 in. (38.1 cm) in
sis. Fire is made up of heat, fuel, and oxygen. A fire hazard is any height with a maximum width of 6 ft. (1.8 m). See Figure 1.
place that these three elements could be brought together.
F-1/2 Nozzle Part No. 16449 – The F-1/2 nozzle also produces a
Because oxygen is always present, identifying fuel and heat
fan-shaped discharge pattern, but with a 180° pattern at a maxi-
sources is most critical.
mum effective range of 33 in. (83.8 cm) in length by 15 in.
Large excavators must be considered special type hazards. See (38.1 cm) in height with a maximum width of 5 ft. 6 in. (1.7 m) See
the Appendix Section for design information or contact ANSUL Figure 1.
Application Engineering Department.
C-1/2 NOZZLE
Operator safety is also a concern when designing a fire suppres- 6 FT.
sion system. The operator must have enough time to safely exit (1.83 m)
the vehicle. In some situations, an extended discharge dry chemi-
cal system (not FM Approved) may offer the operator the addition-
al time he needs to get away from the burning vehicle. Consider
egress time when designing the final system. See Appendix
Section for extended discharge and twin agent design informa-
tion.
Some common fuel sources in vehicles include flammable liquids
and greases, rubber, plastics, upholstery, and environmental
debris such as wood chips or coal dust. 3 FT.
(0.9 m)
Common vehicle heat sources are engine blocks, exhaust sys-
V-1/2 NOZZLE
tems, pumps, and turbochargers, as well as bearings, gears, 003724a
Maintenance is a ”thorough check” of the system. It is intended to – Using a wooden dowel, push pin assembly and spring out
give maximum assurance that the system will operate effectively of the actuator body.
and safely. It includes a thorough examination and any necessary – Remove the gasket from inside the cartridge thread port.
repair or replacement. It will normally reveal if there is a need for Inspect, clean, apply a good grade of low temperature
hydrostatic testing of the tank. grease, such as Dow Corning No. 4, and reinstall the gas-
Maintenance shall be performed semi-annually or sooner, ket. Replace if necessary.
depending on operating and/or environmental conditions. The fire – Remove the O-Rings from the pin assembly and swivel
suppression system including alarms, shutdown and associated adaptor. Inspect, clean, apply a good grade of low temper-
equipment shall be thoroughly examined and checked for proper ature grease, such as Dow Corning No. 4, and reinstall the
operation by the fire protection manufacturer, authorized distribu- O-Rings. Replace if necessary.
tor or their designee in accordance with this manual.
– Apply a small amount of grease to the puncture pin shaft.
SEMI-ANNUAL MAINTENANCE There is a U-Cup guide inside the actuator body and when
the pin is reinstalled into the body, the grease on the shaft
To provide maximum assurance that your ANSUL A-101/LT-A-101 will lubricate the U-Cup.
system will operate effectively and safely:
– Clean the inner surface of the actuator body and, using a
1. Check to see that the hazard has not changed. small diameter wire, clean the vent hole. Make certain not
2. Remove all cartridges, install safety shipping caps, and put in to scratch the inner surface.
a safe place for future reinstalling. – To minimize the potential of moisture or dirt entering the
3. Note the general appearance of the system components actuator, apply a thin coat of a good grade of extreme
checking for mechanical damage or corrosion, and check that temperature silicone grease, such as Dow corning No. 4
the components are securely fastened and all hose fittings or equal, over the vent hole.
are tight. – Reinstall spring onto puncture pin shaft and insert into
4. Check nameplates to make certain they are clean, readable, actuator body. Push pin down several times to allow
and properly attached. grease to coat U-Cup. When positioned back in body,
5. Remove tank fill cap(s) and check that the agent tank is filled make certain the tip of the pin is above the gasket in the
to approximately 3 in. (76 mm) from the bottom of the fill bottom of the actuator.
opening with ANSUL FORAY dry chemical. Check the dry – Reinstall the actuator unto the cartridge. Hand tighten.
chemical for lumps.If lumps are present, drop one from a – Reinstall swivel adaptor in the correct position for the actu-
height of 4 in. (102 mm) onto a hard surface. If the lump does ation lines and wrench tighten the swivel nut. Make certain
not break up completely, the dry chemical must be replaced. all actuation and expellant lines are properly tightened into
6. Inspect threads on fill cap and on tank fill opening for nicks, the actuator.
burrs, or cross-threading. – Secure the assembly into the bracket.
7. Check fill cap gasket and quad ring for elasticity, cuts, or
checking, and lightly coat them with an extreme temperature SWIVEL NUT,
PART NO. 430210
silicone grease, such as Dow Corning No. 4 or equal.
8. Disconnect sealed bursting disc assembly.
9. Examine the disc to ensure that it is not wrinkled, kinked,
dented, or deformed in any way and then apply a thin coat of
O-RING #119, SWIVEL ADAPTOR,
a good grade of extreme temperature silicone grease, such PART NO. 24899 PART NO. 430209
as Dow Corning No. 4 or equal, to the male threads and
reconnect the sealed burst disc assembly. NOTE: Before SLAVE PISTON,
reconnecting, if needed, blow all lines clear with dry air or O-RING #210, PART NO. 56749
PART NO. 5151
nitrogen.
10. Check that the nozzle openings are not obstructed and that PUNCTURE PIN,
PART NO. 56104
the nozzles are properly aimed and have not rotated out of
position.
11. Make certain each nozzle has a blow-off cap (the opening of SPRING,
an F-1/2 nozzle can be packed with an extreme temperature PART NO. 56105
silicone grease, such as Dow Corning No. 4 or equal, to
avoid build-up of foreign material) and check that the caps
are pliable and free of cuts and checks. NOTE: Blow off caps BODY,
PART NO. 430215
must be replaced annually.
12. Unscrew the pneumatic actuator(s) from the cartridge receiv-
er(s) and inspect all threaded areas for nicks, burrs, and VENT HOLE
cross threads.
13. Clean actuator(s) (Part No. 430221) as follows: (see Figure1)
– Using two wrenches, one positioned on the swivel nut, and GASKET,
one positioned on the bottom portion of the actuator, PART NO. 181
loosen the swivel nut and remove the top portion of the
actuator. FIGURE 1
006195
S1013
SECTION VIII – MAINTENANCE
6-30-05 Page 8-2
REV. 2
The first concern in Recharge is to determine the cause of the 6. Remove the tank fill cap, discard any remaining dry chemical,
system discharge and to have the problem corrected before re- and fill each tank to its rated capacity with ANSUL FORAY dry
arming the fire suppression system. chemical as specified on the nameplate.
In the event of system discharge, the vehicle must not be 7. Check inside of tank for any signs of corrosion. Check for any
returned to service until the system has been recharged. signs of moisture and/or chemical caking. Make certain gas
The system must be recharged immediately after use. A fire con- tube and rubber check are securely in place.
dition could cause damage to the hose and nozzles and possibly 8. Before securing the fill cap, brush the dry chemical from the
support members. Check all hose supports, hose, and all fitting threads on the fill cap and tank, and clean the gasket seating
connections. Take the nozzles off, inspect for damage, corrosion, surface on the tank opening. Coat the gasket lightly with a
or obstructions, clean and re-install, making certain they are good grade of extreme temperature silicone grease, such as
aimed correctly. Blow-off caps must also be replaced. Dow Corning No. 4 or equal.
See Figure 1 when following the recharge steps. 9. Secure the fill cap, hand tighten.
10. Loosen the bolts on the expellant gas cartridge bracket or
15 17 remove the cartridge guard on the tank.
2 11 18 11. Unscrew and remove the empty expellant gas cartridge.
15 17
12. Disassemble and clean the cartridge actuator by following the
instructions stated in Step No. 13, Section VIII –
Maintenance.
16
13. Install new cartridge per the following chart. Before installing,
1 16 weigh cartridge to determine if it is within specifications
8 7 stamped on the cartridge. Weigh cartridge with shipping cap
removed.
Type of System Cartridge Part No.
A-101-10 15850 (DOT) 423439 (TC/DOT)
LT-A-101-10 423429 (TC/DOT)
A-101-20 423441 (TC/DOT)
9 10 12 13 LT-A-101-20 423435 (TC/DOT)
6 LT-LP-A-101-20 423435 (TC/DOT)
A-101-30 423443 (TC/DOT)
LT-A-101-30 423491 (TC/DOT)
3 14. Re-install cartridge guard or retaining bolts on cartridge
bracket.
15. Return tank(s) to its bracket, reconnect sealed burst disc
assembly to distribution hose, and tighten securely.
16. Depending on the type of manual actuator, either pull up the
red button or pull up the puncture lever.
14 5 4 17. Remove spent cartridge. Weigh fully charged LT-10 cartridge.
Make certain cartridge is within +/– 1/4 oz. (7.1 g) from weight
stamped on cartridge. Install cartridge.
NOTICE
If automatic detection system was used, refer
to appropriate Installation, Recharge Manual for
detailed recharge instructions.
FIGURE 1 18. Insert ring pin in actuator stem and seal with visual seal, Part
003519
No. 197.
1. Pull ring on safety relief valve to relieve actuation pressure. 19. Reconnect actuation and, if necessary, expellant gas hose.
2. Disconnect actuation system hose at cartridge receiver/actu- Wrench tighten.
ation assembly. 20. Notify operating personnel that the suppression system is
3. Open sealed burst disc assembly. back in service and record date of recharge.
4. Remove dry chemical tank from its bracket.
5. Replace ruptured sealed burst disc assembly. Remove used
sealed disc assembly from tank outlet. Clean tank threads.
Apply a non-permanent thread sealant or Teflon tape to male
threads on new sealed burst disc assembly. Install to tank out-
let. Wrench tighten. NOTE: Before reconnecting, if needed,
blow all lines clear with dry air or nitrogen.
S1013
SECTION XI – APPENDIX
5-15-02 Page 11-2
REV. 2
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
MATERIAL
TITLE
CONFIDENTIAL NOTICE
THIS DRAWING IS THE PROPERTY OF GETMAN CORPORATION
FS LAYOUT,A64,30# 4N
WHICH RESERVES ALL RIGHTS IN THIS DRAWING ITS
SUBJECT MATTER AND THE INVENTIONS DISCLOSED
THEREIN. THIS DRAWING IS LOANED SUBJECT TO THE
AGREEMENT AND UNDERSTANDING THAT ITS SUBJECT
MATTER IS NOT TO BE DISCLOSED, IN WHOLE OR IN
PART, TO ANY OTHER PARTY, AND THAT IT SHALL NOT
BE COPIED IN ANY MANNER WITHOUT THE EXPRESS DRAWN DATE SCALE SIZE DRW. NO.
PERMISSION OF GETMAN CORPORATION. ACCEPTANCE
OF THIS COPY WILL BE CONSTRUED AS AN ACCEPTANCE
OF THE FOREGOING CONDITION.
BL 10/19/2009 1:8 D 7334-00015
(PARTS IN ADDITION TO THOSE SHOWN ON MAIN LAYOUT)
ITEM NO. PART NUMBER DESCRIPTION QTY.
NOTE: ACTUATORS NOT TO BE
1 9334-00003 ACTUATOR, DASHBOARD 1 INSTALLED IN JOINT AREA
*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
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
ITEM NO. PART NUMBER DESCRIPTION QTY.
7
HOSE# I.D. LENGTH ENDS ADAPTERS FROM TO
3/4" 94734 89GF1212 20# TANK
401 * DIST TEE
94875 94734 89GF1212
405
1/2" 94733 89GF1208 DIST TEE REAR COMP
402 30"
94874 94733 89GF0808 NOZZLE
1/2" 94733 89GF1208 DIST TEE FRONT COMP
403 45"
94874 94733 89GF0808 NOZZLE
1/4" 94751 89GF0404 20# TANK MAIN
404 *
94878 94731 89GF0404 ACTUATOR
NOTE: CUT HOLE IN 1/4" 94731 89GF0404 MAIN
405 * 89GF0404 ACTUATOR RR FRAME TEE
VENTED SIDE COVER
TO ROUTE 3/4" HOSE 94878 94731
16070-03 REF
TEE WELDMENT * - HOSE LENGTH VARIES DUE TO DIFFERENT
9334-00009 REF REAR FRAME CONFIGURATIONS
SS CHECK VALVE
TO BULKHEAD
(REFERENCE DRAWING
7334-00025
BASKET/PLATFORM
OPTION)
TO REMOTE
ACTUATORS
MATERIAL
TITLE
CONFIDENTIAL NOTICE
THIS DRAWING IS THE PROPERTY OF GETMAN CORPORATION
NOTE: SEE PAGE 4, ITEM 38 FOR CARTRIDGE & ACTUATOR KIT, USED ON BOTH 30 & 50 LBS
SYSTEMS
Updated:
12/18/06
S1026
17069
BOOM INSTALLATION
Page 1 of 3
Updated:
05/25/10
17069
BOOM INSTALLATION
Page 2 of 3
Updated:
05/25/10
17069
BOOM INSTALLATION
Page 3 of 3
Updated:
05/25/10
16572
TURRET INSTALLATION
Page 1 of 2
ASSEMBLY PROCEDURE
1. Press two bearing cones (Item #9) onto worm (Item #10).
2. Press two bearing cups (Item #25) into housing (Item #23).
4. With housing (Item #23) large opening down, install bearing cone (Item #24).
8. Turn housing over; install bearing cone (Item #24). PRESS COMPLETELY ONTO SHAFT.
10. Lay worm (Item #10) with bearing cones installed into housing.
NOTE: Do not install bearing cups (Item #8) at this time.
11. Press worm gear (Item #22) onto output shaft with gear hub facing up.
CAUTION
When pressing worm gear onto shaft, position worm so not to damage bronze worm gear.
12. After pressing gear, tap gear box with hammer to loosen bearings.
13. Install nut (Item #19). Torque to approximately 5 FT. LBS. to set load on bearings.
PROCEDURE (CONTINUED)
16. Install cover to housing using six bolts and lockwashers (Item #’s 6, and 5); torque cover bolts to 58 FT.
LBS.
18. Install bearing retainer (Item #12) using one 1/32 gasket (Item #2) and one 1/64 gasket (Item #1).
19. Install four bolts (Item # 31) and fasten bearing retainer to housing. Torque bolts to 58 FT. LBS.
20. Install seal (Item #4) into bearing container (Item #7).
NOTE: Install seal with loctite sealant on outer diameter of seal; lubricate seal with loctite anti-seize
lubricate.
21. Install bearing container with seal in place 1/64 and 1/32 gaskets (Item #’s 1 and 2) required to remove
end play, but allow worm to rotate freely by hand.
22. Torque four bolts and lockwashers (Item # 6 and 5) used to fasten bearing container (Item #7) to housing
to 58 FT. LBS.
23. Install plugs, vents, and zerks (Item #’s 13, 15, and 14).
24. Lubrication:
A. Fill with 80W90 worm gear oil (3 quarts) or until oil runs out of fill and level hole. Install fill and level
plug (Item #30).
B. Grease bearings thru zerk (Item #15) located under pinion gear in housing.
Removal:
1. Secure articulation safety lock bar and block wheels.
2. Properly support boom with over head lifting device. (The boom and turret assembly can be removed
together as a single unit. Care must be taken to properly support the boom from both ends in order to lift
the boom straight up from the chassis.
3. Disconnect all hoses and wiring running from the chassis to the boom.
4. Remove the ¾” capscrews, items #6 and flat washer item #7, from the turret and rotation gear and
bearing assembly.
5. Lift the boom and turret assembly from the rotation gear and bearing.
6. Remove the ¾” capscrews, item #10 and flat washer item #9, from the bottom side of the rotation gear
and bearing mounting plate.
7. Lift the rotation gear and bearing assembly from the mounting plate.
Updated:
05/03/07
BOOM ROTATION GEAR M1005
INSTALLATION Page 2 of 4
Installation:
1. Remove all paint, grease or dirt from all mating surfaces.
2. Place the rotation gear and bearing assembly on to the chassis mounting plate. Install the ¾” capscrews,
item #10, with the hardened flat washer, item #9, using a medium strength lock tight on the bolt threads.
Note: When installation the rotation gear and bearing it’s recommended to only use new grade 8
capscrews. Do not reuse old capscrews.
Example:
1
6 11
10 7
4 3
8 9
12 5
2
4. Inspect the o-ring seal, item #16, located in the groove at the bottom edge of the turret base, item #5. Be
sure it’s free of cuts and wear. Replace if necessary.
5. Thoroughly grease the o-ring and outer surface of the rotation gear and bearing mounting plate to ease
installation of the turret assembly onto the mounting plate.
6. Lower the boom and turret assembly down onto the rotation gear and bearing assembly.
7. Install the ¾” capscrews, item #6, with hardened flat washer, item #7, into the turret and rotation gear
and bearing assemblies. Use a medium strength lock tight on bolt threads.
8. Tighten capscrews using a similar alternating sequence as described in #3. Again first torque all
capscrews to 100 LB/FT. (135.6 Nm) Then final torque to 300 LB/FT. (406.7 Nm)
9. Reconnect all hoses and wiring taking care to route them the same as prior to removal.
Updated:
05/03/07
BOOM ROTATION GEAR M1005
INSTALLATION Page 3 of 4
1. To insure the best possible performance of Rotation Bearings, we recommend the following procedures:
A. Machined, flat, rigid mounting surfaces must be provided to minimize localized internal loading
which will reduce bearing life.
B. Bearings have been mounted on unmachined surfaces by means of shimming. Gear Products,
Inc. recommends that all mounting structures to be machined. However, if shimming is used,
first remove noticeable high spots of other convex material by hand grinding. After placing
bearing on mounting surface install shims to reduce clearance on approximately .003”.
C. When bolts are used to fasten the bearing to the mounting surfaces, use SAE Grade 8 bolts. Bolts
should mount freely into holes. Bolts should be torqued to 70% of yield strength. Hardened steel
flat washers should be used under bolt heads or nuts to assure uniform bolt tension.
D. If Allen head bolts are used then a nut must be used on the opposite end because of the inability
to torque sufficiently this type of bolt into a threaded hole.
E. On all Gear Products rotation bearings the balls are plug loaded. It is preferred at installation of
the bearing on the crane that the plug be located 90 degrees from the direction of maximum
moment. This insures that the plug area will be as lightly loaded as possible.
Updated:
05/03/07
BOOM ROTATION GEAR M1005
INSTALLATION Page 4 of 4
2. After installation the following suggestion will assure longer life and service:
A. Bolts should be checked periodically and retightened to proper torque. The possibility exists that
due to the stresses applied to the rotation system, the bolts could work loose.
B. Regular periodic lubrication is the most effective way to increase the life and serviceability of
rotation bearings. Most large diameter bearings are used out-of-doors and under conditions likely
to produce internal condensation. Also, when bearings are heavily loaded, extreme lubrication is
helpful.
Below are several lubricants which are acceptable for both rust inhibiting and extreme pressure
characteristics. There are several others on the market that may also be used.
C. Gear – The chart below shows several lubricants for the gear. It is recommended that the teeth be
lubricated with a small amount of grease every 8 hours if the unit is used daily. The grease is
purged from the teeth by the very nature of this type gear drive being exposed to the elements;
therefore, close attention to the gear lubricant will provide a longer tooth life. Grease the gear at
the location of the pinion.
D. If the bearing has been stored for a long period of time before installation, it should be lubricated
before installation.
Updated:
05/03/07
17194
ANFO POT
Page 1 of 2
*PARTS ARE NOT INTERCHANGEABLE, BUT FIT/ FUNCTION ARE THE SAME Updated:
06/03/10
17194
ANFO POT
Page 2 of 2
*PARTS ARE NOT INTERCHANGEABLE, BUT FIT/ FUNCTION ARE THE SAME Updated:
06/03/10
13712
ACTUATOR
Page 1 of 2
Updated:
04/19/07
13712
ACTUATOR
Page 2 of 2
7 465162-07 BEARING (PINION BOTTOM) 1
8 465162-08 THRUST BEARING (PINION) 2
9 465162-09 PLUG (TRANSFER PORT) 2
10 465162-10 THRUST WASHER (PINION) 1
11 465162-11 O-RING (STOP CAP SCREW SEAL) 2
12 465162-12 PISTON GUIDE 2
13 465162-13 CAP SCREW (END CAP) 8
(FOR MODELS VPVL-050 THROUGH 600)
465162-13 CAP SCREW (END CAP) 12
(FOR MODELS VPVL-700 THROUGH 800)
14 465162-14 O-RING (END CAP) 2
15 465162-15 BEARING (PISTON HEAD) 2
16 465162-16 O-RING (PISTON) 2
17 465162-17 SPRING (CARTRIDGE) 4-12
18 465162-18 SPRING CLIP (PINION) 1
19 465162-19 POSITION INDICATOR 1
20 465162-20 O-RING (PINION BOTTOM) 1
21 465162-21 O-RING (PINION TOP) 1
30 465162-30 RIGHT END CAP 1
31 465162-31 LEFT END CAP 1
39 465162-39 CAP SCREW (INDICATOR) 1
40 465162-40 PISTONS 2
41 465162-41 ACTUATOR IDENTIFICATION LABEL 1
42 465162-42 END CAP LABEL 2
50 465162-50 BODY 1
60 465162-60 DRIVE SHAFT 1
Updated:
04/19/07
S1027
VALV-POWR® VPVL
MOD C VALUE-LINE®
DOUBLE-OPPOSED
PISTON ACTUATORS
TABLE OF CONTENTS
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.1 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
4.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
4.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
5 SAFETY LOCKOUT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
6 ACTUATOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
7 REPAIR KITS/SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
8 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
S1027
2
1 GENERAL
6. OPERATING THE ACTUATOR OVER TEMPERATURE LIMITS MAY
This instruction manual contains important information DAMAGE INTERNAL AND EXTERNAL COMPONENTS (DISASSEMBLY
regarding the installation, operation, and troubleshooting OF SPRING RETURN ACTUATORS MAY BE DANGEROUS).
of the Jamesbury® Valv-Powr VPVL Mod C Value-Line
7. OPERATING OVER PRESSURE LIMITS MAY RESULT IN PREMATURE
Double-Opposed Piston Actuators. Please read these
FAILURE AS WELL AS DAMAGE TO THE HOUSING.
instructions carefully and save them for further reference.
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.
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
Air supplied to Port 2 forces pistons apart and toward end posi- Loss of air pressure allows springs to force pistons toward center
tion, compressing springs. Exhaust air exits at Port 4 (a counter- position with exhaust air exiting at Port 2 (a clockwise rotation is
clockwise rotation is obtained). obtained).
Figure 2
S1027
3
3.2 Operation
19 39
1. The actuator series, size, operating pressure, output
torque,spring directions,and drive type is determined by
the actuator designation.
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
VPVL250 RKP-156 VPVL-650 RPK-164
VPVL300 RKP-157 VPVL-700 RPK-165
VPVL350 RKP-158 VPVL-800 RPK-166
VPVL400 RKP-159
Figure 4
4 S1027
A. Remove both stop cap screws (02) together with A. Holding the body (50) in a vice (or similar device),
nut (04) and washer (03). rotate the drive shaft (60) until the pistons (40)
are released. CAUTION: Air Pressure should not
B. Remove stop screw o-rings (11) and discard if be used to remove the pistons from the body.
replacing all soft parts. Clean and inspect the piston teeth for signs of
wear. Replace piston if wear seems excessive.
3. End Cap (30, 31) Disassembly, (Figure 5):
B. Remove piston o-ring seal (16) using a screwdriver.
Remove the piston head (15) and piston back (5)
bearings. Discard bearings if replacing all soft
parts.
3 5. Drive Shaft (60) and Bearing (6, 7) Disassembly,
(Figure 7):
13
1
18
10
2 8 50
30, 31
4
Figure 5
8
A. Remove the end cap bolts (13) in the sequence
shown in (Figure 5). CAUTION: When disassem-
bling a spring return actuator, the end cap 1
(30, 31) should be loose after unscrewing end 60
cap bolts (13) 4-5 turns. If there is still force on
the end cap (30, 31) after 4-5 turns of the end Figure 7
cap bolt (13), this may indicate a damaged
spring cartridge and any further disassembly A. Remove spring clip (18) carefully, using snap-ring
should be discontinued. Further disassembly pliers. Remove external thrust bearing (8) and
of the end-caps may result in serious personal thrust washer (10).
injury. Return actuator to Metso Automation
for further maintenance. B. Apply downward force to top of drive shaft (60)
until it is partially out of the bottom of the body
B. For spring return actuators, remove spring (50) and the octi-cam (1) and internal thrust
cartridges (17). bearing (8) can be removed. Remove the octi-cam
C. Remove end-cap o-rings (14) and discard if (1) and internal thrust bearing (8). Push the drive
replacing all soft parts. shaft (60) completely out of the bottom of the
body (50). If the shaft (60) does not move freely,
4. Piston (40) Disassembly, (Figure 6): gently tap with a plastic mallet.
C. Remove the top and bottom shaft bearings (6, 7)
40 and top and bottom shaft o-rings (21, 22).
Discard if replacing all soft parts.
60
6. Cleaning and Inspection.
A. When all components are disassembled, those
not being replaced should be properly cleaned
and inspected for wear prior to re-assembly.
4.3 Assembly
50 Prior to assembly, ensure that all components are clean
40 and undamaged.
18 60
1
10
8
50 50
60
Figure 9 Figure 10
6 S1027
D. Ensure that the octi-cam (1) is in the correct H. Temporarily install the position indicator (19)
position as shown by (Figure 11). onto the shaft (60) to determine whether the
correct stroke is obtained, Verify that the slot in
the top of the position indicator (19) will rotate a
minimum of 4˚ beyond the 90˚ vertical centerline
60
of the actuator body (50) and a minimum of 4˚
1
beyond the 0˚ horizontal centerline of the actuator
45˚ body as shown in (Figure 13). If the proper
stroke is not obtained, remove the pistons and
repeat from step 2d. Once the proper stroke is
verified, remove the position indicator (19).
90˚
19 4˚ Min
Figure 11 0˚
A A
Figure 12 Figure 14
S1027 7
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.
4. Assembly of Stop Screws (2) and Stroke 6. Position Indicator (19, 39) Assembly. (Figure 18):
Adjustment. (Figure 17):
A. Fit position indicator (19) on the shaft (60),
A. Insert the nut (4), washer (3), and o-ring (11) onto verifying that it indicates the correct actuator
the stop screws (2). position.
B. Screw the stop screws (2) into the body (50). B. Tighten cap screw (39) to secure the position
indicator.
8 S1027
O-ring
Washer
Nut
Travel Stop
Screw
Stop Screw
Type A
VPVL 051-300
L Min. Approx
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.
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)
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:
8 EXPLODED VIEW
5* 50 41 10 18 39 19 8* 30
11*
3
2
8*
17 4
1
21*
13
6*
42
31
* Suggested Spare Parts
60 for Maintenance
7*
20*
14* 15* 16* 40 12 9*
Figure 23
S1027 11
Notes: (1) AISI 420 for models VPVL-051 through 300; GS400-15 for models VPVL-350 through 800
(2) Qty 8 pieces for models VPVL-051 through 600; Qty 12 pieces for model VPVL-700
(3) For models VPVL500 through VPVL700, right and left end-caps are symmetric
12 S1027
OT
OR
• DRUCKLUFTAUSSENVIBRATOREN
OLI SRL
Via Canalazzo, 35
41036 Medolla (MO)
ITALY
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
≤ ≤
e x
≤ ≤
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
The equipment is accompanied by a Das Gerät wird von einer den gelten- L'appareillage est accompagné d’une L'apparecchiatura è accompagnata da
declaration of conformity to existing den Richtlinien entsprechenden Kon- déclaration de conformité aux directi- una dichiarazione di conformità alle
regulations, but, since it is a compo- formitäts-erklärung begleitet, aber als ves en vigueur, mais en tant que direttive vigenti, ma, in quanto com-
nent to be integrated into a system Bestandteil einer kompletten Anlage composant devant s’intégrer dans ponente da integrarsi in un impianto
or plant, its safety is connected to ist seine Betriebs-sicherheit mit der une installation complète, sa sécurité completo, la sua sicurezza è legata al
compliance with all the directives Beachtung aller Richtlinien verbun- est étro itement lié au respect de tou- rispetto di tutte le direttive applicabili
applicable in final assembly of the den, die nach dem Einbau in die Anla- tes les directives applicables dans nell'assemblamento della macchina
machine. ge oder Maschine anwendbar sind. l’assemblage de la machine finale. finale.
Improper use of the pneumatic vi- Jede bestimmungswidrige Benutzung Toute utilisation impropre du vibra- Ogni utilizzo improprio del vibratore
brator without following the instruc- des Druckluft Vibrator ohne Befol- teur pneumatique sans suivre les in- pneumatico senza seguire le indica-
tions in this manual frees the Manu- gung der Angaben dieses Handbuchs dications du présent manuel dégage zioni del presente manuale solleverà
facturer of all responsibility for poor entbindet den Hersteller von jeglicher le constructeur de toutes responsabi- il costruttore da ogni responsabilità
working of the pneumatic vibrator. Haftung hinsichtlich der fehlerhaften lités ayant trait à un mauvais fonc- inerenti ad un cattivo funzionamento
As this is a subject in the process of Funktion des Druckluft Vibrator. tionnement du vibrateur pneumatique del vibratore pneumatico stesso.
significant technical and normative Da es sich um Produkte handelt, die lui-même. Trattandosi di materia in forte evolu-
evolution, the Manufacturer reserves einer schnellen technischen Entwick- Etant donnée qu’il s’agit d’une matiè- zione tecnica e normativa, il costrut-
the right to upgrade its products as lung unterliegen, behält es sich der re en forte évolution technique et ré- tore si riserva di adeguare con la
fast as possible with all the techno- Hersteller vor, die eigenen Erzeug- glementaire, le constructeur se ré- massima celerità i propri manufatti a
logical know-how and official stand- nisse so schnell wie möglich an alle serve d’adapter avec rapidité ses pro- tutte le conoscenze tecnologiche e le
ards applicable (EN, UNI) which are technologischen Erkenntnisse und die pres produits manufacturés à toutes norme ufficiali applicabili (EN, UNI)
available at the time. anwendbaren offiziellen Normen (EN, les connaissances techno logiques che di volta in volta si rendessero
UNI) anzupassen, die von Fall zu Fall et les normes of ficielles applicables disponibili.
erforderlich sind. (EN, UNI) au fur et à mesure de leur
parution.
- CERTIFICATE OF CONFORMITY S110106.04
S - KONFORMITÄTSBESCHEINIGUNG
OT
- CERTIFICAT DE CONFORMITÉ 2
OR
- ATTESTATO DI CONFORMITA’ OL.2000 EX M. 10
OLI S.r.l.
Via Canalazzo, 35 – I - Medolla (MO)
ITALY
CERTIFICATE OF CONFORMITY
with the Directives of the European Union
The OLI percussion guns model
S/OR/OT....ATEX (Code: SX....)
are manufactured in conformity with the following directives:
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
Adriano Marchesini
(General Manager)
- WARNING S110106.04
S - HINWEISE
OT
- RECOMMANDATIONS 2
OR
- AVVERTENZE OL.2000 EX M. 14
Maximum operating pres- Max. Betriebsdruck Pression maximale de ser- Pressione massima d’eser-
sure vice cizio
The maximum operating pres- Der max. Betriebsdruck darf 6 La pression maximale de servi- La pressione massima d’eserci-
sure must not exceed 6 bar (90 bar (90PSI) nicht überschreiten. ce ne doit pas dépasser 6 bars zio non deve superare i 6 bar
PSI). (90 PSI). (90 PSI).
06.04
- INDICATIONS FOR THE USE S1101
S - ANGABEN ZUM GEBRAUCH
OT
- MODES D’EMPLOI 2
OR
- INDICAZIONI PER L’USO OL.2000 EX M. 15
The pneumatic vibrators de- Die pneumatischen Vibrato- Les vibrateurs pneumati- I vibratori pneumatici descritti
scribed in this Manual are de- ren, 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 com- ponente.
stellung angegeben werden, um mande.
The user must make sure the eine korrekte Auslegung des L’utilizzatore dovrà assicurarsi
plant in which the pneumatic Bauteils zu ermöglichen. L’utilisateur doit contrôler, avant che l’impianto all’interno del qua-
vibrator is installed has been la mise en marche, que l’installa- le verrà installato il vibratore
set in safety condition from the Der Anwender muss sicherstel- tion dans laquelle est monté le pneumatico sia stato adegua-
point of view of explosion risk len, dass die Anlage, in welcher vibrateur pneumatique a été tamente messo in sicurezza da
before being started up, and that der pneumatische Vibrator mise en sécurité en ce qui con- un punto di vista di rischio esplo-
the “document on protection installiert werden soll, hinsicht- cerne le risque d’explosion. Il faut sione prima di essere avviato e
against explosions” has also lich der Explosionsgefahr auf aussi que le “document sur la che inoltre sia stato redatto il
been prepared as specified by ausreichende Weise in einen si- protection contre les explosions” “documento sulla protezione
Directive ATEX 99/92/CE. (This cheren Zustand gebracht wor- ait été rédigé conformément à la contro le esplosioni” come pre-
only applies to the European den ist, bevor sie in Betrieb ge- Directive ATEX 99/92/CE (Ceci visto dalla Direttiva ATEX 99/92/
market). nommen wird, und dass zudem n’est valable que pour le marché CE. (Questo vale unicamente per
das „Explosionsschutzdoku- européen). il mercato europeo).
ment” verfasst worden ist, so
wie es die ATEX-Richtlinie 99/92/
EG vorsieht (Dies gilt nur für den
europäischen Markt).
06.04
- INDICATIONS FOR THE USE S1101
S - ANGABEN ZUM GEBRAUCH
OT
- MODES D’EMPLOI 2
OR
- INDICAZIONI PER L’USO OL.2000 EX M. 17
In accordance with the Directive ATEX Im Sinne der ATEX-Richtlinie 94/9/EG Le constructeur, aux termes de la Il costruttore, ai sensi della direttiva
94/9/CE, the manufacturer defines definiert der Hersteller die Außenum- directive ATEX 94/9/CE, définit l’ex- ATEX 94/9/CE, definisce l’esterno del
the outside of the pneumatic vibrator gebung des pneumatischen Klopfers térieur du vibrateur pneumatique com- vibratore pneumatico come:
as: als: me:
CAT. II 3 D KAT. II 3 D CAT. II 3 D CAT. II 3 D
IMPORTANT: specify that the non WICHTIG: Die Versionen, die nicht IMPORTANT: Spécifier que les ver- IMPORTANTE: Specificare che le
ATEX versions must not be used in ATEX sind, dürfen nicht in explosi- sions non ATEX ne doivent pas tra- versioni non ATEX non devono
potentially explosive environ- onsgefährdeten Bereichen arbei- vailler dans des atmosphères ex- operare in atmosfere potenzialmen-
ments. ten. plosibles. te esplosive.
The pneumatic vibrators are de- Die pneumatischen Vibratoren sind
signed and constructed in such a so entwickelt und konstruiert worden, Les vibrateurs pneumatiques ont I vibratori pneumatici sono stati
manner as to avoid unusual over- dass es während ihres Betriebs nicht été conçus et construits de manière progettati e costruiti in modo tale da
heating during operation. To operate zu Überhitzungen kommt. Um unter à ne pas provoquer d’échauffements non provocare surriscaldamenti ano-
in safe conditions, check to make sicheren Voraussetzungen arbeiten zu anormaux pendant le fonctionnement. mali durante il funzionamento. Per
sure the powders handled have a können, ist sicherzustellen, dass Pour travailler en condition de sécuri- poter operare in condizioni di sicurez-
minimum ignition temperature die aufbereiteten Stäube eine Min- té il faut vérifier que les poussiè- za occorre verificare che le polve-
higher than the temperature value destzündtemperatur haben, die res traitées on une température ri trattate abbiano una minima tem-
indicated on the code plate. unterhalb des Temperaturwerts d’inflammation minimale supé- peratura di ignizione superiore al
- The pneumatic vibrators must be liegt, der auf dem Typenschild rieure à la valeur de température valore di temperatura indicato sul-
installed with sufficient clearance steht. indiqué sur la plaque signaléti- la targhetta.
around to allow assembly/disas- - Die pneumatischen Vibratoren que. - I vibratori pneumatici dovranno
sembly operations, cleaning and müssen so installiert werden, dass - Les vibrateurs pneumatiques doi- essere installati con uno spazio cir-
maintenance. ringsum genügend Raum zur Ver- vent être installés avec autour un costante sufficiente per effettuare
fügung steht, um die normalen Ar- espace suffisant pour effectuer les le normali operazioni di montaggio/
Before carrying out any operation beiten für Ein- und Ausbau, Reini- opérations ordinaires de montage/ smontaggio, pulitura e manutenzio-
on the component, make sure it is gung und Wartung vornehmen zu démontage, nettoyage et mainte- ne.
in safe condition. können. nance.
Bevor man irgendeinen Eingriff an Prima di effettuare un qualsiasi
IMPORTANT: In this Manual “setting dem Bauteil vornimmt, ist sicher- Avant d’effectuer toute intervention intervento sul componente assi-
the component in safety condi- zustellen, dass es sich in einem sur le composant vérifier que ce- curarsi che questa sia messa in
tion” will include the following opera- sicheren Zustand befindet. lui-ci a été mis en sécurité. sicurezza.
tions: WICHTIG: Auf den weiteren Seiten
- Make sure the component is dis- dieses Handbuchs werden wir die IMPORTANT: Dans le présent manuel IMPORTANTE: In seguito nel presen-
connected from all electric sup- Ausdrucksweise „den Bauteil in ei- nous indiquons par “mettre en sécu- te manuale indicheremo con la dicitu-
ply sources. nen sicheren Zustand versetzen” rité le composant” les opérations ra “mettere in sicurezza il compo-
- Make sure the component is dis- benutzen, um folgende Vorgänge an- suivantes: nente” le seguenti operazioni:
connected from all compressed zugeben: - Contrôler si le composant est dé- - Accertarsi che il componente sia
air supply sources. - Sicherstellen, dass der Bauteil branché de toutes les alimenta- scollegata da tutte le alimenta-
- The area around the component von allen elektrischen Versor- tions électriques. zioni elettriche.
must be suitably lighted (opera- gungsquellen abgetrennt ist. - Contrôler si le composant est dé- - Accertarsi che il componente sia
tors can be provided with elec- - Sicherstellen, dass der Bauteil branché de toutes les alimenta- scollegata da tutte le alimenta-
tric lights suitable for zone 22 von allen pneumatischen Ver- tions pneumatiques. zioni pneumatiche.
cat. II 3 D). sorgungsquellen abgetrennt ist. - Eclairer correctement la zone qui - Provvedere a illuminare corret-
For carrying out operations on the - Dafür sorgen, dass der Bereich entoure le composant (en dotant tamente la zona circostante al
components (maintenance and clean- rings um den Bauteil korrekt aus- éventuellement les opérateurs de componente (eventualmente do-
ing), the operators must use suitable geleuchtet wird (indem die Arbeit- lampes électriques appropriées tando gli operatori di lampade
personal protection devices (PPD): nehmer eventuell mit elektri- pour zone 22 cat. II 3 D). elettriche idonee per zona 22 cat.
- Antistatic safety footwear (certi- schen Lampen ausgestattet wer- II 3 D.
fied) den, die für die Zone 22 Kat. II 3 Pour toute opération à effectuer sur
- Antistatic protective clothing (certi- D geeignet sind). le composant (entretien et nettoya- Per qualsiasi operazione da effettuarsi
fied) Für jeden Eingriff, der auf dem Baut- ge), les opérateurs doivent être mu- sul componente (manutenzioni e puli-
- Helmet eil vorzunehmen ist (Wartungen und nis des équipements de protection zia), gli operatori dovranno essere
- Antistatic cut proof gloves Reinigungen), müssen die Arbeitneh- individuelle (EPI): muniti degli appositi dispositivi di pro-
- Protective masks mer mit angemessenen persönlichen tezione individuale (DPI):
It is also necessary to use all the Schutzausrüstungen (PSA) versehen - Chaussures de protection antis-
safety devices specified in the safe- sein: tatiques (certifiées) - Scarpe antinfortunistiche anti-
ty sheet of the product handled. - antistatisches unfallsicheres - Vêtements de protection antista- statiche (certificate)
Schuhwerk (zertifiziert) tiques (certifiés) - Indumenti protettivi antistatici
NOTE: All the electrical equipment - antistatische Schutzkleidung (zer- - Casque (certificati)
used for maintenance or cleaning tifiziert) - Gants anti-coupure antistatiques - Casco
operations on the outside of the - Schutzhelm - Masques de protection - Guanti antitaglio antistatici
component must be ATEX certified - antistatische Schnittschutzhand- Il faut aussi utiliser tous les disposi- - Mascherine protettive
for zone 22 cat. II 3 D. schuhe tifs de protection prévus par la fiche Inoltre occorre utilizzare tutti i dispo-
- Schutzmasken de sécurité du produit traité. sitivi di protezione previsti dalla sche-
Außerdem sind alle Schutzvorrichtun- da di sicurezza del prodotto trattato.
gen zu verwenden, die von dem Si- N.B.: Tous les appareillages élec-
cherheitsdatenblatt des behandelten triques, utilisés pour les interven- N.B. Tutte le apparecchiature elet-
Produkts vorgesehen sind. tions de maintenance et de net- triche eventualmente utilizzate per
Anm.: Alle elektrische Ausrüstun- toyage réalisées à l’extérieur du interventi manutentivi o di pulizia
gen, die eventuell für die War- composant doivent être certifiés eseguiti all’esterno componente
tungseingriffe und die Reinigung ATEX pour zone 22 cat. II 3 D. devono essere certificate ATEX per
außerhalb des Bauteils benutzt zona 22 cat. II 3 D.
werden, müssen für Zone 22 Kat. II
3 D nach ATEX zertifiziert sein.
zona 22
- OPERATING CONDITIONS S110106.04
S - EINSATZEINSCHRÄNKUNGEN
OT
- LIMITES D’EMPLOI 2
OR
- LIMITI DI IMPIEGO OL.2000 EX M. 18
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
OLI S.r.l provides a 12-month OLI S.r.l. gewährt auf ihre Er- La Société OLI S.r.l reconnaît La OLI S.r.l riconosce un perio-
warranty on their products. This zeugnisse eine Garantie von une période de 12 mois de ga- do di 12 mesi di garanzia sui pro-
period starts from the date of the 12 Monaten. Die Garantiezeit rantie sur les produits de sa fa- dotti di propria costruzione. Il
consignment note. beginnt mit dem Datum des Lie- brication. La période prend ef- periodo decorre dalla data della
The warranty is not applicable ferscheins. fet à compter de la date indiquée bolla di consegna.
for breakage and/or defects Die Garantie ist nicht anwend- sur le bon de livraison. La garanzia non è applicabile a
caused by incorrect installation bar, wenn es sich um Schäden La garantie ne s’applique pas à seguito di rotture e/o difetti cau-
or use, or incorrect maintenan- und/oder Defekte handelt, die la suite de ruptures et/ou de dé- sati da errata installazione o uti-
ce, or modifications not authori- auf falschem Einbau oder Ge- fauts provoqués par un monta- lizzo, oppure da manutenzioni
zed by the Manufacturer. brauch, nicht korrekter Wartung ge et une utilisation impropre, non corrette o modifiche appor-
The warranty does not extend oder Änderungen beruhen, die des entretiens qui ne sont réali- tate senza autorizzazione del
to parts that wear out following ohne die Genehmigung des Her- sés correctement ou des modi- costruttore.
normal use and electrical com- stellers ausgeführt wurden. fications apportées sans autori- La garanzia non si estende alle
ponents. Die Garantie deckt keine Teile ab, sation du constructeur. parti che si logorano in seguito
The warranty elapses if the die infolge des normalen Ge- La garantie s’étend aux pièces al normale uso e alle parti elettri-
pneumatic vibrator: brauchs verschleißen, und auch qui s’usent à la suite d’une utili- che.
- has been tampered with or mo- keine elektrischen Teile. sation normale et aux parties A miglior precisazione la garan-
dified, Genauer geagt verfällt die Ga- électriques. zia decade nei casi in cui il vi-
- has not been used correctly, rantie in folgenden Fällen: Plus précisément la garantie est bratore pneumatico:
- has been used without res- - Das Druckluft Vibratoren wur- sans effet si le vibrateurs pneu- - sia stato manomesso o modifi-
pecting the limits indicated in de manipuliert oder abgeändert; matique : cato,
this manual and/or has been - wurde nicht angewandt; - a été manipulé ou modifié, - sia stato utilizzato non corret-
subjected to excessive mecha - bei seinem Gebrauch wurden - a été utilisé de manière incor tamente,
nical stress, die in diesem Handbuch ge- recte, - sia stato utilizzato non rispet-
- has not been subjected to the nannten Einsatzbeschränkun- - a été utilisé sans respecter les tando i limiti indicati nel presen-
necessary maintenance or the- gen nicht beachtet und/oder es limites indiquées dans la pré- te manuale e/o sia stato sotto-
se operations have been car- wurde zu starken mechani- sen te notice et/ou qu’il a été posto ad eccessive sollecita-
ried out partly and/or incorrect- schen Belastun gen ausge- soumis à des contraintes mé- zioni meccaniche,
ly, setzt; caniques excessives - non sia stato sottoposto alle
- has been damaged due to ca- - er wurde nicht der erforder- - il n’a pas été soumis aux en- necessarie manutenzioni o
relessness during transport, lichen Wartung unterzogen tretiens nécessaires ou que queste siano state eseguite
installation and use, oder diese wurde nur teilweise ces opérations ont été effec- solo in parte e/o non corretta-
- has been fitted with spare und/oder nicht korrekt ausge- tuées partiellement, de maniè- mente,
parts that are not original. führt; re incom plète ou incorrecte - abbia subito danni per incuria
On receiving the product, the - es wurde beschädigt, weil - a subit des dommages par né- durante il trasporto, l’installa-
user must check these for de- Transport, Einbau oder Ge- gligence pendant le transport, zione e l’utilizzo,
fects deriving from transport brauch ohne die erforderliche la mise en place et l’utilisation, - siano state inserite parti di ri-
and/or incomplete supply. Sorgfalt vorgenommen wur- - a été réparé avec des pièces cambio non originali.
Defects, damage or incom plete- den; qui ne sont pas d’origine. Al ricevimento del prodotto, il
ness of the supply must be im- - es wurden keine Original-Er- Dès réception de la marchan destinatario deve verificare che
mediately communicated to the satzteile verwendet. dise, le destinataire doit vérifier lo stesso non presenti difetti o
Manufacturer in writing and Beim Empfang der Ware hat der que celle-ci n’a pas de défauts danni derivanti dal trasporto e/o
countersigned by the haulage Empfänger sicherzustellen, ou subit de dégâts dus au tran incompletezza della fornitura.
transporter. dass die Ware keine durch den sport et que la fourniture n’est Eventuali difetti, danni o incom-
Transport verursachten Schä- pas incomplète. pletezza vanno immediatamente
den oder Defekte aufweist, und/ Tout défaut, dommage ou four segnalati al costruttore median-
oder dass der Lieferumfang voll- niture incomplète doit immédia te comunicazione scritta e con-
stän-dig ist. tement être signalée au constru trofirmata dal vettore.
Etwaige Defekte, Schäden oder cteur par communication écrite
Fehlmengen sind mittels schrift- et contresignée par le tran spor-
licher und vom Frachtführer ge- teur.
gengezeichneter Mitteilung
sofort dem Hersteller zu melden.
- TRANSPORT AND PACKING S110106.04
S - TRANSPORT UND PACKUNG
OT
- TRANSPORT ET EMBALLAGE 2
OR
- TRASPORTO E IMBALLO OL.2000 EX M. 20
1)STORAGE PRIOR TO IN- 1) EINLAGERUNG VOR DEM 1) EMMAGASINAGE AVANT LA 1) IMMAGAZZINAGGIO PRIMA
STALLATION EINBAU MISE EN PLACE DELL’INSTALLAZIONE
- Avoid damp, salty environ- - Feuchte und salzhaltige Luft - Si possible éviter les locaux - Evitare possibilmente ambienti
ments, if possible. für die Einlagerung vermeiden. humides et les saumâtres umidi e salmastri.
- Place the component on wood- - Den Bauteil auf einer Holzpa- - Placer le composant sur des - Sistemare il componente su
en platforms and store it pro- lette setzen und vor Witterung palettes en bois et les ranger à pedane di legno e locarle al ri-
tected from unfavourable schützen. l’abri des intempéries. paro dalle intemperie.
weather conditions.
2)PROLONGED MACHINE 2) LÄNGERE BETRIEBSRUHE 2) ARRÊT MACHINE PROLON- 2) FERMO COMPONENTE PRO-
SHUTDOWNS AFTER AS- NACH DEM EINBAU GÉ APRÈS LE MONTAGE LUNGATO DOPO IL MON-
SEMBLY - Vor der Inbetriebnahme ist der - Avant la mise en service met- TAGGIO
- Before starting up the compo- Bauteil in einen sicheren Zu- tre le composant en sécurité. - Prima della messa in servizio
nent, set it in safety status. stand zu bringen. - Avant la mise en service du mettere in sicurezza il compo-
- Before starting up the compo- - Vor der Inbetriebnahme des composant contrôler l’intégrité nente.
nent, check the condition of the Bauteils die elektrische und de l’équipement électrique et de - Prima della messa in servizio
electric and pneumatic system pneumatische Anlage und alle toutes les parties pour lesquel- del componente controllare l’in-
and all parts for which long Teile, deren Funktionstüchtig- les un arrêt prolongé pourrait tegrità dell’impianto elettrico,
shutdowns may affect work- keit die bei einem längeren Still- compromettre le fonctionne- pneumatico, e di tutte le parti
ing. stand in Frage gestellt werden ment. per le quali un prolungato arre-
könnte, prüfen. sto potrebbe compromettere la
funzionalità.
3) POSSIBLE REUSE AFTER PE- 3) MÖGLICHE WIEDERVER- 3) RÉ-UTILISATION APRÈS UNE 3)POSSIBILE REIMPIEGO
RIODS OF INACTIVITY WENDUNG NACH EINEM LÄN- PÉRIODE D’INACTIVITÉ DOPO PERIODO DI INATTIVI-
- During component halts, avoid- GEREN STILLSTAND - Pendant la période d’inactivité TA’
damp, salty environments. - Während des Stillstands des du composant éviter les locaux - Durante il fermo componente
- Place the component on wood- Bauteils Räume mit feuchter humides et saumâtres evitare ambienti umidi e salma-
en platforms and store it pro- und salzhaltiger Luft vermei- - Placer le composant sur des stri.
tected from unfavourable den. palettes en bois et les ranger à - Sistemare il componente su
weather conditions. - Den Bauteil auf eine Holzpalet- l’abri des intempéries. pedane di legno e locarle al ri-
- Set the component in safety te setzen und vor Witterung - Avant la mise en service met- paro dalle intemperie.
status before starting it up. schützen. tre le composant en sécurité - Prima della messa in servizio
- Before starting up the compo- - Vor der Inbetriebnahme ist der - Avant la mise en service du mettere in sicurezza il compo-
nent, check the condition of the Bauteil in einen sicheren Zu- composant contrôler l’intégrité nente.
electric and pneumatic sys- stand zu bringen. de l’équipement électrique et de - Prima della messa in servizio
tems and all parts for which - Vor der Inbetriebnahme des toutes les parties pour lesquel- del componente controllare l’in-
long shutdowns may affect Bauteils die elektrische und les un arrêt prolongé pourrait tegrità dell’impianto elettrico,
working. pneumatische Anlage und alle compromettre le fonctionne- pneumatico, e delle parti per le
- Before starting up the compo- Teile, deren Funktionstüchtig- ment. quali un prolungato arresto po-
nent, clean it thoroughly by fol- keit die bei einem längeren Still- - Avant la mise en service du trebbe compromettere la fun-
lowing the indications on the stand in Frage gestellt werden composant effectuer un cycle zionalità.
powder safety sheet. könnte, prüfen. complet de nettoyage en res- - Prima della messa in servizio
- If the component operates in - Vor der Inbetriebnahme des pectant ce qui est indiqué sur del componente eseguire un
conditions and with materials Bauteils ist ein vollständiger la fiche de sécurité de la pous- ciclo completo di pulizia rispet-
different from the previous ap- Abreinigungszyklus vorzuneh- sière. tando quanto riportato sulla
plication, check the compatibil- men, wobei das zu beachten - Si le composant travaille dans scheda di sicurezza della pol-
ity of this use according to the ist, was auf dem Sicherheits- des conditions et avec des ma- vere.
indications in the INDICATIONS Datenblatt des entsprechenden tières différentes de l’applica- - Se il componente opera in con-
FOR USE section. Erzeugnisses steht. tion précédente, vérifier la dizioni e con materiali diversi
- Wenn der Bauteil unter Bedin- compatibilité de cette utilisation dall’applicazione precedente,
gungen oder mit Material betrie- d’après ce qui est indiqué dans verificare la compatibilità di tale
ben wird, das vom vorherigen la section MODE D’EMPLOI. utilizzo secondo quanto ripor-
Einsatz abweicht, ist die Ver- tato nel sezione INDICAZIONE
träglichkeit für den neuen Ein- PER L’USO.
satz mit den BEDIENSUNGSAN-
LEITUNG zu vergleichen.
- MAINTENANCE S110106.04
S - WARTUNG
OT
- ENTRETIEN 2
OR
- MANUTENZIONE OL.2000 EX M. 26
Set the component in safety Vor der Ausführung jeder Avant toute opération met- Prima di qualsiasi interven-
status before carrying out beliebiger Arbeit ist der Baut- tre le composant en condi- to mettere il componente in
any operation. eil in einen Zustand verset- tion de sécurité. sicurezza.
zen.
- If work is to be carried out on - Wo sich Teile des pneuma- - Pour atteindre des parties du - Là dove si debbano raggiun-
parts at the top of the pneu- tischen Vibrators in größerer vibrateur pneumatique en hau- gere parti del vibratore pneu-
matic vibrator, use a work area Höhe befinden, eine Arbeits- teur, utiliser une plate-forme matico in quota utilizzare una
platform which must be select- plattform zu benutzen, die so aérienne de travail qui devra piattaforma aerea di lavoro che
ed in such a manner as to avoid zu wählen ist, dass eine être choisie de manière à évi- dovrà essere scelta in modo
risk of slipping, tripping or fall- Gefährdung des Personals in ter tout danger de glissement da evitare pericoli di scivola-
ing of operators. Form von Ausrutschen, Hän- ou de chute des opérateurs. mento, inciampo o caduta per
genbleiben oder Absturz ver- gli operatori.
mieden wird.
S and OR-vibrators are mainte- S-und OR- Vibratoren sind war- Les S et OR ne réclament pas I vibratori S e OR sono esenti da
nance-free. From outside they tungsfrei. Sie können von außen d’entretien. Ils peuvent être net- manutenzione. Possono essere
can be cleaned with a water jet. mit einem Wasserstrahl gereinigt toyés extérieurement à l’eau puliti esternamente mediante get-
Operate the vibrator for a short werden. Nach der Reiningung sous pression. Après le nettoya- to d’acqua. Dopo avere eseguito
while after. den Vibrator kurz betätigen. ge, faire brièvement fonctionner questa operazione, farli funzio-
le vibrateur. nare per un breve intervallo di
tempo.
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:
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.
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 con- ferma, con parti del percussore
machine stopped. Klopfer geraten, die eine hohe pneumatico con superfici ad ele-
Special warning notices, locat- tact, quand la machine est arrê-
Temperatur aufweisen. tée, avec des parties du filtre vata temperatura.
ed at strategic points indicate Besondere Warnschilder, die an Apposite targhe monitorie, col-
the risk due to the presence of dont les surfaces sont à des tem-
den strategischen Stellen ange- pératures élevées. locate nei punti strategici indi-
very hot surfaces and the obli- bracht sind, weisen auf die Ge- cano il pericolo dovuto alla pre-
gation for the operator to wear Des plaques d’avertissement,
fahren hin, die sich durch die apposées dans les endroits stra- senza di superfici ad elevata
personal protection equipment, hohe Temperatur der Oberflä- temperatura e l'obbligo per
especially protective gloves. tégiques, signalent le danger
chen ergeben und weisen das dû à la présence de surfaces à l'operatore di utilizzare disposi-
Personal darauf hin, dass es zur des températures élevées et tivi di protezione individuale, in
Verwendung der persönlichen l’obligation de l’opérateur d’uti- particolare guanti protettivi.
GLOVES ARE Schutzausrüstungen verpflichtet
COMPULSORY liser les dispositifs de protection
ist, insbesondere zum Tragen individuelle, en particulier des E’ OBBLIGATORIO
von Schutzhandschuhen.. gants de protection. USARE I GUANTI
WARNING
DANGEROUS DIE BENUTZUNG PORT DE
TEMPERATURE VON GANTS
HANDSCHUHEN ATTENZIONE
OBLIGATOIRE TEMPERATURE
IST VORGESCHRIEBEN
PERICOLOSE
3. Presence of potentially haz-
ardous dusts ATTENTION
ACHTUNG TEMPERATURES
In the event of both routine and GEFÄHRLICHE 3. Presenza di polveri potenzial-
DANGEREUSES
extraordinary maintenance, the TEMPERATUREN mente pericolose
operator must wear suitable per- Nel caso di interventi sia ordi-
sonal protection equipment, 3. Vorhandensein potentiell ge- 3. Présence de poussières po- nari che straordinari di manu-
and in particular, use a safety fährlicher Stäube tentiellement dangereuses
tenzione l'operatore deve dotar-
mask for the respiratory tract Bei regelmäßiger und außeror- Aussi bien dans le cas d’inter-
si di idonei dispositivi di prote-
depending on the type of dust dentlicher Wartung muss das ventions d’entretien ordinaires
zione individuale ed in partico-
daalt as well as gloves and Personal geeignete pers önli- ou extraordinaires, l’opérateur
lare deve utilizzare maschere a
clothing. che Schutzausrüstungen ver- doit se doter des dispositifs de
protezione delle vie respirato-
For more details, refer to the wenden und insbesondere Mas- protection individuelle et en
rie di classe idonea in base al
safety chart of the product han- ken zum Schutz der Atemwege particulier il doit utiliser des
tipo di polvere trattata nonché
dled. mit geeigneter Klasse für den masques de classe appropriée
di guanti o indumenti.
aufbereiteten Staub, wie auch pour protéger les voies respira-
Per maggiori dettagli si deve far
Schutzhandschuhe und Schutz- toires en fonction du type de
riferimento alla scheda di sicu-
MASK IS kleidung tragen. poussière traitée ainsi que de
rezza del prodotto utilizzato.
COMPULSORY Für nähere Angaben ist Bezug gants ou de vêtements adé-
auf das Sicherheitsdatenblatt quats.
des verwendeten Produkts zu Pour plus de détails consulter E’ OBBLIGATORIO
la fiche de sécurité du produit USARE LA
nehmen. MASCHERA
utilisé.
DIE BENUTZUNG
DER MASKE IST MASQUE
VORGESCHRIEBEN OBLIGATOIRE
- RESIDUAL RISKS S110106.04
S - RESTRISIKEN
OT
- RISQUES RESIDUELS 2
OR
- RISCHI RESIDUI OL.2000 EX M. 30
- In certain handling of dusts, - Bei bestimmten Staubbehand- - Dans des traitements détermi- - In determinati trattamenti di pol-
where hazardous substanc- lungen, wo schädliche Substan- nés de poussières où il y a la veri dove vi è la presenza di
es are present, the operator zen auftreten, muss das Perso- présence de substances no- sostanze nocive, l'operatore
concerned who has to access nal, falls es im Laufe der regel- cives, l’opérateur qui doit y che dovesse accedere, nel
the machine for routine and mäßigen oder außerordentli- avoir accès, dans le cours des corso di interventi ordinari o
extraordinary maintenance chen Wartung damit in Kontakt interventions ordinaires ou ex- straordinari, deve indossare gli
operations must wear suitable kommt, persönliche Schutzaus- traordinaires, doit porter les dis- idonei dispositivi di protezione
protective devices as indicat- rüstungen tragen, so wie auf den positifs de protection appro- come indicato dalla cartelloni-
vorhandenen Schildern ange-
ed on the notice signs provid- priés comme signalé par les stica ivi presente.
geben.
ed. panneaux indicateurs qui s’y
DIE BENUTZUNG trouvent. E’ OBBLIGATORIO
DER MASKE IST USARE LA
MASK IS MASCHERA
VORGESCHRIEBEN
COMPULSORY MASQUE
OBLIGATOIRE
ATTENZIONE
VORSICHT: SOSTANZE
WARNING SCHADSTOFFE
HURTFUL ATTENTION NOCIVE
SUBSTANCE SUBSTANCES
DANGEREUSES
DIE BENUTZUNG
VON
HANDSCHUHE E’ OBBLIGATORIO
GLOVES ARE IST VORGESCHRIEBEN USARE I GUANTI
PORT DE
COMPULSORY
GANTS
Bei der Ausführung von erhit- OBLIGATOIRE
zenden Arbeiten (Schweißen, Tutte le manutenzioni all'inter-
In case of operations involving no del vibratore pneumatico
Schneiden) ist es erforderlich, Tous les entretiens à l’intérieur
heating (welding, cutting) it is DEVONO essere effettuate ad
die Oberfläche des pneumati- du vibrateur pnumatique DOI-
necessary to clean the sur- schen Vibrators vorbeugend zu VENT être effectués quand l’ins- impianto fermo e in assenza di
face of the pneumatic vibrator behandeln, um alle Staubab- tallation est arrêtée et en ab- polvere aerodispersa. In caso
first, removing all dust depos- lagerungen und in Abwesenheit sence de poussière dispersée di lavori a caldo (saldatura, ta-
its (the layers, the deposits atembarer Stäube durchgeführt dans l’air. Dans le cas de tra- glio) è necessario bonificare
and accumulated combustible werden. Bei der Ausführung von vaux à chaud (soudure, décou- preventivamente le superfici
powder MUST be considered erhitzenden Arbeiten (Schwei- pe) il faut préalablement net- del vibratore pneumatico, ri-
like any other source which can ßen, Schneiden) ist es erforder- toyer les surfaces du vibrateur muovendo tutti i depositi di pol-
result in an explosive atmos- lich, den Vibrator so vorzube- pneumatique,, en éliminant tous vere (gli strati, i depositi ed i
phere). reiten, dass alle Staubablage- les dépôts de poussière (les cou- cumuli di polvere combustibile
Authorization for operations in- rungen entfernt werden (Schich- ches, les dépôts et les tas de DEVONO essere considerati
volving heating MUST be given ten, Ablagerungen und An- poussière combustible DOI- come qualsiasi altra sorgente
by technical personnel special- sammlungen von brennbarem VENT être considérés comme
che può dare origine ad un'at-
iz-ed and trained in the risk of Staub MÜSSEN wie jede une autre source pouvant don-
mosfera esplosiva).
andere Staubquelle betrachtet ner lieu à une atmosphère ex-
explosion from dusts (capable L'autorizzazione all'esecuzio-
werden, die zur Entstehung ei- plosive).
of checking residual risk, suit- ne dei lavori a caldo DEVE es-
ner explosiven Atmosphäre bei- L'autorisation à l’exécution des
ability of tools and a knowledge tragen kann). sere data da personale tecni-
of the procedures). travaux à chaud DOIT être don-
Die Genehmigung zur Ausfüh- née par du personnel technique co specializzato e formato sul
(The person responsible for rung von Arbeiten im erwärm- rischio esplosione da polveri
spécialisé et formé sur le risque
safety must issue a “Fire Per- ten Zustand DARF NUR durch (in grado di verificare il rischio
d’explosion des poussières (en
mit” to the operator). spezialisiertes technisches Per- mesure4 de vérifier le risque ré- residuo, l'idoneità degli utensili
4. Hazards deriving from sonal erteilt werden, das über siduel, l’aptitude des outils et e la conoscenza delle proce-
pressurized circuits (hydrau die Explosionsgefahr durch la connaissance des procédu- dure). Il responsabile della si-
lic, pneumatic) Staub unterrichtet ist (das in der res). curezza dovrà rilisciare un
During mainten- ance and/or Lage ist, das Restrisiko festzu- Le responsable de la sécurité “permesso di lavoro fuoco” al-
repair operations pressure stellen, das die geeigneten devra délivrer un “permis de l’operatore.
must be discharged from the Werkzeuge und auch die Pro- feu” à l’opérateur. 4. Pericoli derivanti da circuiti
plants and accumulators (if zeduren kennt). Der Werkschutz- 4. Dangers dérivant des circuits in pressione (idraulici, pneu-
present), according to the in- verantwortliche muss dem Per- sous pression (hydrauliques, matici)
sonal eine „Genehmigung zur
structions given along-side the pneumatiques) Durante le operazioni di manu-
Feuerarbeit” ausstellen.
components and in the respec- Pendant les opérations d’entre- tenzione e/o riparazione occor-
4. Gefahren durch unter Druck
tive user manuals. tien et/ou de réparation il faut
stehende Leitungen (hydrau- re porre in scarico gli impianti e
5. Hazard generated by noise lisch, pneumatisch) décharger les installations et les
gli eventuali accumulatori, se-
The user and employer are Während der Wartungsarbeiten éventuels accumulateurs, con-
formément aux instructions qui
condo le istruzioni riportate in
obliged to respect the legal und/oder Reparaturen sind die prossimità dei componenti e nei
standards as regards protec- Anlagen und die etwaigen Ak- se trouvent à proximité des com-
posants et dans les notices d’ins- rispettivi manuali d'uso.
tion from daily personal expo- kumulatoren zu entleeren, so 5. Pericoli generati da rumo-
tructions correspondantes.
sure of operators to noise (in wie es in den Anweisungen an re
5. Dangers provoqués par le
Italy L.D.277/91). de jeweiligen Komponenten
bruit E' fatto obbligo all'utilizzatore e
oder in den entsprechenden
L’utilisateur ainsi que l’em- al datore di lavoro di rispettare
Handbüchern steht.
ployeur ont l’obligation de faire le norme di legge in termine di
5. Gefährdung der Arbeitnehmer
respecter les normes de loi en protezione contro l'esposizio-
durch Lärm
matière de protection contre l’ex- ne personale quotidiana degli
Der Anwender und der Arbeit-
position personnelle quotidien- operatori al rumore (in Italia
geber sind zur Einhaltung der
ne des opérateurs au bruit (en D.Lgs.277/91).
gesetzlichen Bestimmungen in
Italie D.Lgs.277/91).
Sachen Schutz gegen tägliche
persönliche Lärmexposition der
Arbeitnehmer verpflichtet (in
Italien D.Lgs.277/91).
06.04
- FAULT FINDING S1101
S - BETRIEBSSTÖRUNGEN UND ABHILFE
OT
- INCONVENIENTS ET SOLUTIONS 2
OR
- INCONVENIENTI E SOLUZIONI OL.2000 EX M. 31
FAULT ACTION
Check the presence of compressed-air
The vibrator does not start
Check the presence of foreign elements in the piping or in the vibrator
The vibrator increase in Check the fastening of the fixing screws and in case, make the supporting plate stiff
noisiness Lubrificate the pneumatic line
Check the feed pressure (MAX 6 BAR)
The vibrator loose its vibrating
Check the fastening of the fixing screws and in case, make the supporting plate stiff
effect
Lubrificate the pneumatic line
STÖRUNG ABHILFE
Die Druckluft kontrollieren
Der Rüttler starts nicht
Eventuelle Fremdkörper in der Leitung oder in den Rüttler kontrollieren
Den Spanndruck der Befestigungsschrauben kontrollieren und die Stutzplatte eventuell verstärken
Mehr Rüttlergeräusch
Die pneumatische Vorrichtung schmieren
Den Einlassdruck (MAX 6 BAR) kontrollieren
Verlust an Vibrierwirkung Den Spanndruck der Befestigungsschrauben kontrollieren und die Stutzplatte eventuell verstärken
Die pneumatische Vorrichtung schmieren
PROBLÈME SOLUTION
Vérifier la présence d'air comprimé
Le vibrateur ne démarre pas
Vérifier la présence d'éléments étrangers dans la tubuluru ou le vibrateur
Vérifier le serrage des vis et éventuellement raidir la plaque d'appui
Il rumore del vibratore aumenta
Lubrifier la ligne pneumatique
Vérifier la pression d'alimentation (MAX 6 BAR)
Il vibratore cala l'effetto vibrante Vérifier le serrage des vis et éventuellement raidir la plaque d'appui
Lubrifier la ligne pneumatique
PROBLEMA SOLUZIONE
Controllare presenza aria compressa
Il vibratore non parte
Controllare presenza elementi estranei nella tubazione o nel vibratore
Controllare il serraggio delle viti di fissaggio ed eventualmente irrigidire la piastra di supporto
Il rumore del vibratore aumenta
Lubrificare la linea pneumatica
Controllare la pressione di alimentazione (MAX 6 BAR)
Il vibratore cala l'effetto vibrante Controllare il serraggio delle viti di fissaggio ed eventualmente irrigidire la piastra di supporto
Lubrificare la linea pneumatica
- SCRAPPING COMPONENT / RETURNING COMPONENT S110106.04
S - VERSCHROTTUNG DES BAUTEILS / RÜCKGABE DES BAUTEILS
OT
- DEMANTELEMENT DU COMPOSANT / RESTITUTION DU COMPOSANT 2
OR
- ROTTAMAZIONE COMPONENTE / RESO COMPONENTE OL.2000 EX M. 32
- 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.
14053
BASKET ROTATOR ASSEMBLY
Page 1 of 2
Updated:
12/19/06
14053
BASKET ROTATOR ASSEMBLY
Page 2 of 2
Updated:
12/19/06
S1033
MAINTENANCE
MANUAL FOR
HP SERIES PIVOT
ROTARY ACTUATORS
TABLE OF CONTENTS
PAGE 2 THEORY OF OPERATION
PAGE 3 DISASSEMBLY AND INSPECTION
PAGE 3 ASSEMBLY AND TESTING
PAGE 3 TESTING AND STORAGE
PAGE 4 HYDRAULIC LINE ATTACHMENT
PAGE 4 SEAL AND BEARING KIT ORDERING INSTRUCTIONS
PAGE 4 WARRANTY
® HP-0293
S1033
THEORY OF OPERATION The shaft (2A) is integral with the shaft flange (2B)
In reference to Figure I, fluid entering Port P2 under and bearing tube (2C). The shaft is supported
pressure will bear on the piston (4) and force the radially by the large upper radial bearing (19) and
piston sleeve (3) upwards. The left-handed spline the lower radial bearing (18). Axially, the shaft is
of the piston sleeve (3) will combine with the right- separated from the housing by the upper and
handed spline of the shaft (2A) and cause rapid lower thrust rings (20). The end cap (5) is adjusted
counter-clockwise rotation of the shaft and flange for axial clearance and locked in position by cap
(2B) (looking down). Fluid entering Port P1 will screws (7).
reverse this rotation.
Displacement and torque are identical for clockwise
and counter-clockwise rotation.
FIGURE I
Flange Mounted Pivot Actuator
20
2B
16
15
19
2C 3
21 P1
14
17
1
9
2A 11
22 4
18 P2
15 20
5 16
6 7
2
S1033
DISASSEMBLY AND INSPECTION actuator in a vertical position.
Place on a clean workbench with room to place the The end cap (5) is torqued to 60-400 FT-LB depend-
internal parts as they are removed. Remove all ing on the actuator size, such that the actuator begins
hydraulic fittings. Loosen cap screws (7) and unscrew rotation at approximately 100 PSI pressure. The shaft
locknut (6) and end cap (5). The shaft is now free to flang cannot be rotated by hand; the combined
move up and out of engagement with the piston sleeve backdrive efficiency and friction prevent manual rota-
(3). Note the orientation between the spline teeth (see tion. If the end cap is torqued too high, the actuator
Figure II), as this will greatly simplify actuator timing may require as much as 300 PSI to rotate. If the end
upon reassembly. cap is not torqued high enough, shaft axial motion and
After removing the shaft, the piston sleeve and the radial backlash will result. The end cap must be
secured against the shaft by tightening cap screws
piston assembly can now be moved down and out of
(7), or by installing axial set screws, depending on the
the housing. Remove all seals and bearings from their
grooves, except static piston seals (9) and (11).
These seals generally do not require replacement. FIGURE II
Clean all parts thoroughly and inspect for wear. A
MATCHED TIMING MATCHED TIMING
small amount of wear in the spline teeth will have little MARKS ON PISTON MARKS ON SHAFT
effect on the actuator strength. New spline sets are SLEEVE AND RING GEAR AND PISTON SLEEVE
manufactured with a backlash of about .005" per
mating set. After long service, a backlash of about
.015" per set may still be acceptable in most cases,
depending on the required accuracy of the applica-
tion.
Item (1) is the integral housing and ring gear. Check
the ring gear for wear and weld damage to the pins.
Inspect the cylinder bore for wear and scratches. The
surface finish should be 32 RMS or better; rehone if
necessary. The radial bearings (18) and (19) and the
piston bearings (17) should have a maximum radial
clearance of.006". A clearance in excess of .008"
requires replacement of the bearings. Rough and
grooved shaft journals require shaft replacement.
3
S1033
HYDRAULIC LINE ATTACHMENT
The hydraulic lines from the control valve to the the oil is cycled back and forth, and not allowed to
actuator should be as short as possible. If the lines flow to tank for filtering and cooling, resulting in
hold more oil than the actuator displaces, some of premature actuator wear.
WARRANTY INFORMATION
Helac Corporation warrants products manufactured by it to be free from defective material and factory workmanship. Helac Corporation shall replace
or repair such products, which under normal use and service disclose such defects, and return the repaired or replacement products to the purchaser
prepaid. Claims under this warranty will be satisfied only by repair or replacement of the unit or any defective part thereof. No cash payment or credit
will be made for defective materials or workmanship. Products under warranty shall be returned to Helac Corporation's manufacturing facility at 225
Battersby Avenue, Enumclaw, Washington 98022 USA, transportation prepaid by the purchaser, for inspection by Helac Corporation, whose opinion as
to defects shall be conclusive.
The warranty period shall be one year from the date of shipment from Helac Corporation's manufacturing facility for Helac Corporation approved
applications. This warranty shall be voided as to any products which have been repaired, worked upon, or altered by persons not authorized by Helac
Corporation, or which have been subject to misuse, negligence, accident, or overload. In no event shall Helac Corporation be liable for any incidental
or consequential damages.
Helac Corporation reserves the right to make changes in the design or construction of any of its products at any time without incurring any obligations
to make changes or alterations to products previously sold.
This warranty is in lieu of all other and/or prior warranties, expressed or implied, and no other company or person is authorized to represent or assume
for Helac Corporation any liability in connection with the sale of Helac Corporation products other than set forth herein.
HELAC CORPORATION
® 225 BATTERSBY AVE • ENUMCLAW, WA 98022 USA
PHONE 360/825-1601 • FAX 360/825-1603
13651
STABILIZER INSTALLATION
Page 1 of 2
4 1
2
5
Installation, Operating,
and Maintenance Manual
19015 US Hwy 12
New Buffalo, MI 49117
(800) 526-8817 10-06
Fax: 269-469-0497 POO280-2
www.vanair.com
S1028
DEFINITION OF TERMS
AD Abovedeck
ADBD Abovedeck Belt Drive
ADHD Abovedeck Hydraulic Drive
ASME American Society of Mechanical Engineers
BD Belt Drive
CA Cab to axle Length
CFM Cubic Feet per Minute
EC Electric Cooled
FC Front Cooled
GAWR Gross Axle Weight Rating
GPM Gallons per Minute
GVWR Gross Vehicle Weight Rating
HC Hydraulic Cooled
HD Hydraulic Drive
ICFM Inlet Cubic Feet per Minute
PSI Pounds per Square Inch
PSIG Pounds per Square Inch Gauge
PTO Power Take Off
RPM Revolutions per Minute
SCFM Standard Cubic Feet per Minute
SM Side Mount
TM Tractor Mount
TMBD Tractor Mount Belt Drive
UD Underdeck
UDHD Underdeck Hydraulic Drive
UDISS Underdeck Integral Split-Shaft
UDSM Underdeck Side Mount
WB Wheel Base
WARRANTY (Applies to following models: UDSM, UDISS, UDHD, ADHD, GENAIR, TMBD, ADBD)
The rotary screw compressor unit air end is warranted for life when adhering to the prescribed
maintenance schedule. The unit will be replaced or repaired at VANAIR’S option. The hydraulic motor
on the UDHD and ADHD is warranted for two (2) years. All other parts including the compressor unit
shaft seal and generator are warranted for twelve (12) months. This warranty does not cover damage
caused by accident, misuse or negligence. If a compressor unit is disassembled the warranty is void.
Any disassembly of major components must be approved by Vanair to avoid voiding of warranty. Any
and all such claims for warranty consideration must be coordinated through the Warranty-Service
Department at the address below. Do not return parts without prior authorization.
Warranty is limited to the supply of replacement parts failing within the warranty period. Credit for
labor required to refit replacement parts is NOT included. All warranted parts are to be shipped
PREPAID to VANAIR. Replacement parts will be shipped back to the customer by VANAIR via
ground shipment. Cost to expedite delivery of replacement parts will be incurred by customer. Factory
installed units will also include warranty on the installation for one year.
This statement of warranty is expressly in lieu of and disclaims all other express warranties, implied
warranties of merchantability and fitness for a particular purchase and all other implied warranties
which extend beyond the description on the face hereof. The warranty does not include incidental or
consequential damages.
This warranty shall be void and VANAIR shall have no responsibility to repair, replace or repay the
purchase price of defective or damaged parts resulting from the use of or repair of replacement parts
or fluids not of VANAIR’S manufacture or from buyer’s failure to store, install, maintain and operate the
compressor according to the recommendations contained in the Manual.
All claims under the Warranty shall be made by contacting VANAIR Warranty-Service Department.
19015 US Hwy 12
New Buffalo, MI 49117
TEL: (800) 526-8817 FAX: (269) 469-0497 PARTS FAX: (269) 469-4013
S1028
SAFETY Section 1 - Pg 01
1.1 GENERAL
Vanair Manufacturing designs and manufactures all of its products so they can be
operated safely. However, the responsibility for safe operation rests with those who use
and maintain these products. The following safety precautions are offered as a guide
which, if conscientiously followed, will minimize the possibility of accidents through the
useful life of this equipment.
The air compressor should be operated only by those who have been trained and
delegated to do so, and who have read and understood this Operator’s Manual. Failure to
follow the instructions, procedures and safety precautions in this manual can result in
accidents and injuries.
NEVER start the air compressor unless it is safe to do so DO NOT attempt to operate the
air compressor with a known unsafe condition. Tag the air compressor and render it
inoperative by disconnecting the battery so others who may not know of the unsafe
condition will not attempt to operate it until the condition is corrected.
Use and operate the air compressor only in full compliance with all pertinent OSHA
requirements and/or all pertinent Federal, State and Local codes or requirements.
Each day walk around the air compressor and inspect for leaks, loose or missing parts,
damaged parts or parts out of adjustment. Perform all recommended daily maintenance.
Inspect for torn, frayed, blistered or otherwise deteriorated and degraded hoses. Replace
as required.
NOTE: Estimated hose life based on a 5-day 8-hour work week is 3 years. These
conditions exist on an 8-hour shift only. Any other operation of the equipment
other than 8-hour shifts would deteriorate the hose life based on hours of
operation.
S1028
SAFETY Section 1 - Pg 02
2. Make sure compressor is parked or located on a firm surface that can support its
weight.
3. Park or locate compressor so the wind, if any, tends to carry the exhaust fumes and
radiator heat away from the compressor air inlet openings, and also where the
compressor will not be exposed to excessive dust from the work site.
A. Open the pressure relief valve at least weekly to make sure it is not blocked, closed,
obstructed or otherwise disabled.
B. Install an appropriate flow-limiting valve between the compressor service air outlet
and the shutoff (throttle) valve, when an air hose exceeding 1/2" (13mm) inside
diameter is to be connected to shut-off (throttle) valve, to reduce pressure in case of
failure, per OSHA Standard 20 CFR 1926.302 (b) (7) or any applicable
Federal, State and local codes, standards and regulations.
D. Provide an appropriate flow-limiting valve for each additional 75 feet (23 meters) of
hose in runs of air hose exceeding 1/2" (13mm) inside diameter to reduce pressure in
case of hose failure.
E. Flow-limiting valves are listed by pipe size and rated CFM. Select appropriate valve
accordingly.
F. DO NOT use tools that are rated below the maximum rating of this compressor.
Select tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT
exceed manufacturer’s rated safe operating pressures for these items.
S1028
SAFETY Section 1 - Pg 03
G. Secure all hose connections by wire, chain or other suitable retaining device to
prevent tools or hose ends from being accidentally disconnected and expelled.
H. Open fluid filler cap only when compressor is not running and is not pressurized.
Shut down the compressor and bleed the sump (receiver) to zero internal pressure
before removing the cap.
I. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug,
connection or other component, such as filters and line oilers, and before attempting
to refill optional air line anti-icer systems with antifreeze compound.
J. Keep personnel out of line with and away from the discharge opening of hoses, tools
or other points of compressed air discharge.
K. DO NOT use air at pressures higher than 30 psig (2.1 bar) for cleaning purposes, and
then only with effective chip guarding and personal protective equipment per OSHA
Standard 29 CFR 1910.242 (b) or any applicable Federal, State and Local codes,
standards and regulations.
L. DO NOT engage in horseplay with air hoses as death or serious injury may result.
N. If the machine is installed in an enclosed area it is necessary to vent the relief valve to
the outside of the structure or to an area of non-exposure.
O. If a manual blowdown valve is provided on the receiver, open the valve to insure all
internal pressure has been vented prior to servicing any pressurized component of the
compressor air/fluid system.
A. Refuel at a service station or from a fuel tank designed for its intended purpose. If
this is not possible, ground the compressor to the dispenser prior to refueling.
B. Clean up spills of fuel, fluid, battery electrolyte or coolant immediately if such spills
occur.
S1028
SAFETY Section 1 - Pg 04
C. Shut off air compressor and allow it to cool. Then keep sparks, flames and other
sources of ignition away and DO NOT permit smoking in the vicinity when adding
fuel, or when checking or adding electrolyte to batteries, or when checking or adding
fluid, or when checking diesel engine ether starting aid systems or replacing cylinders,
or when refilling air line anti-icer systems antifreeze compound.
D. DO NOT permit liquids, including air line anti-icer system antifreeze compound or
fluid film to accumulate on bottom covers or on any external or internal surfaces of
the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as
required. DO NOT use flammable solvents for cleaning purposes.
E. Disconnect the grounded (negative) battery connection prior to attempting any repairs
or cleaning inside the enclosure. Tag the battery connections so others will not
unexpectedly reconnect it.
F. Keep electrical wiring, including the battery terminals and other terminals, in good
condition. Replace any wiring that has cracked, cut abraded or otherwise degraded
insulation or terminals that are worn, discolored or corroded. Keep all terminals clean
and tight.
G. Turn off battery charger before making or breaking connections to the battery.
H. Keep grounded conductive objects such as tools away from exposed live electrical
parts such as terminals to avoid arcing which might serve as a source of ignition.
J. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the
compressor.
K. DO NOT operate compressor under low overhanging leaves or permit such leaves to
contact hot exhaust system surfaces when operating the compressor in forested areas.
S1028
SAFETY Section 1 - Pg 05
L. DO NOT spray ether into compressor air filter or into an air filter that serves the
compressor as serious damage to the compressor or personal injury may result.
M. Antifreeze compound used in air line anti-icer systems contains methanol which is
flammable. Use systems and refill with compound only in well-ventilated areas away
from heat, open flames or sparks. DO NOT expose any part of these systems or
antifreeze compound to temperatures above 150ΕF (66ΕC). Vapors from the
antifreeze compound are heavier than air. DO NOT store compound or discharge
treated air in confined or unventilated areas. DO NOT store containers or antifreeze
compound in direct sunlight.
N. Store flammable fluids and materials away from your work area. Know where fire
extinguishers are and how to use them, and for what type of fire they are intended.
Check readiness of fire suppression systems and detectors if so equipped.
A. Keep hands, arms and other parts of the body and also clothing away from belts,
pulleys and other moving parts.
B. DO NOT attempt to operate the compressor with the fan or other guards removed.
C. Wear snug-fitting clothing and confine long hair when working around this
compressor, especially when exposed to hot or moving parts inside the enclosure.
D. Make sure all personnel are out of and clear of the compressor prior to attempting to
start or operate it.
F. When adjusting the controls, it may require operation of the equipment during
adjustment. DO NOT come in contact with any moving parts while adjusting the
control regulator and setting the engine RPM. Make all other adjustments with the
engine shut off. When necessary, make adjustment, other than setting control
regulator and engine RPM, with the engine shut off. If necessary, start the engine and
check adjustment. If adjustment is incorrect, shut engine off, readjust, then restart the
engine to recheck adjustment.
S1028
SAFETY Section 1 - Pg 06
G. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water,
antifreeze or other liquids to minimize possibility of slips and falls.
A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and
corners.
B. Keep all parts of the body away from all points of air discharge and away from hot
exhaust gases.
C. Wear personal protective equipment including gloves and head covering when
working in, on or around the compressor.
D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury.
DO NOT ignore small cuts and burns as they may lead to infection.
A. DO NOT use air from this compressor for respiration (breathing) except in full
compliance with OSHA Standards 29 CFR 1920 and any other Federal, State or Local
codes or regulations.
DANGER: Death or serious injury may occur from inhaling compressed air
without using proper safety equipment. See OSHA standards, and/or
any Federal, State or local codes or regulations on safety equipment.
B. DO NOT use air line anti-icer systems in air lines supplying respirators or other
breathing air utilization equipment and DO NOT discharge air from these systems
into unventilated or other confined areas.
E. Locate the compressor so that exhaust fumes are not apt to be carried towards
personnel, air intakes servicing personnel areas or towards the air intake of any
portable or stationary compressor.
S1028
SAFETY Section 1 - Pg 07
F. Fuels, fluids, coolants, lubricants and battery electrolyte used in the compressor are
typical of the industry. Care should be taken to avoid accidental ingestion and/or skin
contact. In the event of ingestion seek medical treatment promptly. DO NOT induce
vomiting if fuel is ingested. Wash with soap and water in the event of skin contact.
G. If ethyl ether or air line anti-icer system anti-freeze compound enters the eyes or if
fumes irritate the eyes, they should be washed with large quantities of clean water for
15 minutes. A physician, preferably any eye specialist, should be contacted
immediately.
H. DO NOT store ether cylinders or air line anti-icer system antifreeze compound in
operator’s cabs or in other similar confined areas.
I. The antifreeze compound used in air line anti-icer systems contains methanol and is
toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid
breathing the fumes. If swallowed, induce vomiting by administering a tablespoon of
salt in each glass of clean warm water until vomit is clear, then administer two
tablespoons of baking soda in a glass of clean water. Have patient lay down and cover
eyes to exclude light. Call a physician immediately.
A. Keep the vehicle or equipment carrier, compressor hoses, tools and all personnel at
least 10 feet (3 meters) from power lines and buried cables.
B. Keep all parts of the body and any hand-held tools or other conductive objects away
from exposed live parts of electrical system. Maintain dry footing, stand on insulating
surfaces and DO NOT contact any other portion of the compressor when making
adjustments or repairs to exposed live parts of the electrical system.
C. Attempt repairs only in clean, dry and well-lighted and ventilated areas.
D. Stay clear of the compressor during electrical storms! It can attract lightning.
S1028
DESCRIPTION Section 2 - Pg 01
2.1 INTRODUCTION
The Vanair 85 thru 185 hydraulic driven Air Compressors offer superior performance and
reliability while requiring very minimal maintenance.
Your compressor is equipped with a Sullair rotary screw compressor unit. Compared to other
compressors, the Sullair is unique for its mechanical reliability, performance and durability.
The compressor never needs any inspection of the internal parts.
As you continue reading this manual and learn how the compressor operates and is maintained,
you will see how surprisingly easy it is to keep a Vanair air compressor in top operating
condition.
Fluid is injected into the compressor unit and mixes directly with the air as the rotors turn
compressing the air. The fluid has three functions:
1. As coolant, it controls the rise of air temperature normally associated with the heat of
compression.
2. Seals the leakage paths between the rotors and the stator and also between the rotors
themselves.
3. Acts as a lubricating film between the rotors allowing one rotor to directly drive the
other, which is an idler.
After the air/fluid mixture is discharged from the compressor unit, the fluid is separated from
the air. At this time, the air flows to your service line and the fluid is cooled in preparation for
re-injection.
S1028
DESCRIPTION Section 2 - Pg 02
The fluid in the system is used as both coolant and lubricant. It is housed in the receiver/sump
or sump (which will be referred to as the SUMP from hereon).
The cooler is a radiator-type that works in conjunction with an electric driven fan and electric
fan switch. The fan draws air across the cooler core removing the heat of compression from the
fluid. The fluid flows from the sump thru the oil filter, thru the cooler core, and then is injected
into the compressor chamber and bearings of the compressor. Once the oil reaches
approximately 165°F the fan switch will turn on the fan to cool the oil.
The oil filter has a replaceable spin-on element and a built-in bypass valve which allows the
fluid to flow even when the filter element becomes plugged and requires changing or when the
viscosity of the fluid is too high for adequate flow. After the fluid is properly filtered, it then
flows on to the compressor unit where it lubricates, seals and cools the compression chamber as
well as lubricates the bearings and gears.
The compressed air/fluid mixture enters the sump and is directed off the bottom of the separator
element. By change of direction and reduction of velocity, larger droplets of fluid separate and
fall to the bottom of the sump. The fractional percentage of fluid remaining in the compressed
air collects on the surface of the final separator element as the compressed air flows through the
separator. As more and more fluid collects the element’s surface, the fluid descends to the
bottom of the separator. A return line (or scavenge tube) leads from the bottom of the separator
element to the inlet region of the compressor unit. Fluid collecting on the bottom of the
separator element is returned to the compressor by the pressure difference between the area
surrounding the separator element and the compressor inlet. An orifice is included on this
return line to help assure proper flow.
S1028
DESCRIPTION Section 2 - Pg 03
The sump is ASME code rated at 175 psig working pressure. A minimum pressure/orifice
valve, located downstream from the separator, helps assure a minimum receiver pressure of 65
psig during all conditions. This pressure is necessary for proper air/fluid separation and proper
fluid circulation.
An optional check valve at the outlet of the receiver can be installed to prevent compressed air
in the service line from bleeding back into the receiver on shutdown when the compressor
is being run in parallel with other compressors tied to a large air system.
A pressure relief valve (located on the wet side of the separator) is set to open if the sump
pressure exceeds 175 psig. A temperature switch will shut down the compressor if the
discharge temperature reaches 240°F.
Fluid is added to the sump via a capped fluid filter. A glass fluid level gauge enables the
operator to visually monitor the sump fluid level.
WARNING: DO NOT remove caps, plugs, and/or other components when compressor is
running or pressurized. Stop compressor and relieve all internal pressure before doing so.
S1028
DESCRIPTION Section 2 - Pg 04
Figure 2 - 2 Compressor Discharge and Cooling and Lubrication System:
S1028
DESCRIPTION Section 2 - Pg 05
Refer to Figure 2-2. The purpose of the control system is to regulate the amount of air intake in
accordance with the amount of compressed air demand. The Control System consists of an air
inlet valve, a control regulator, blowdown valve, and tubing connecting the various
components together.
The functional descriptions of the Control System are given below in two distinct phases of
operation. These descriptions will apply to all control systems.
START - 0 TO 40 PSIG
The sump pressure will quickly rise from 0 to 40 PSIG. During this period the compressor inlet
valve control chamber has received no air signal from the pressure regulator. The spring
attached to the control plunger holds it in a wide open position allowing the compressor to work
at full-rated capacity. As the compressor operates at full-rated capacity, the engine speed
control remains fully open enabling the trucks engine to run at full speed. The rising sump
pressure begins to pass air through the minimum pressure orifice.
When air demand then increases, the sump pressure will fall below 115 psig (7.9 bar). The
control pressure regulator valve will close, and the inlet valve to open. The compressor will
then be operating at full load condition.
SHUTDOWN
The blowdown valve is normally closed. When the compressor is shutdown, system pressure
backs up to the inlet valve causing the check spring in the inlet valve to close the air inlet valve.
This sends a pressure signal to the blowdown valve causing it to open and vent the pressure in
the system. After the pressure is vented, the blowdown valve spring returns the blowdown
valve to the closed position.
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DESCRIPTION Section 2 - Pg 06
The air filter is a 2-stage dry element-type filter. This filter is capable of cleaning extremely
dirty air. However, in such cases, frequent checks of the air filter will be required. See
Section 6 for Air Filter Maintenance Procedures.
The compressor air inlet valve controls the amount of air intake of the compressor in
response to the air demand.
DESCRIPTION Section 2 - Pg 07
• The air pressure gauge continually monitors the sump pressure at various load and\or
unload conditions.
• The hour meter indicates the cumulative hours of compressor operation which is useful
for planning and logging service operations.
NOTE: When re-starting the compressor, make sure receiver tank pressure has blown
down to 10 psig can put extra load on the hydraulic system.
DESCRIPTION Section 2 - Pg 08
Vanair doesn’t supply or recommend any other hydraulic system component information.
It is recommended that the person installing a Vanair hydraulic driven compressor seek in their
area a reputable hydraulic supplier for the hydraulic components (i.e: pump, relief valve, oil
cooler, flow control, hosing, reservoir).
Following is a list of flows and pressures for the appropriate compressor model.
C.F.M. Air Pressure Compressor Speed H.P. Min. Recom. Oil Flow
Nominal psig R.P.M. System Pressure G.P.M.
85 100 1460 23.3 2300 20.5
85 150 1460 29.4 2700 20.5
125 100 1330 30.2 2200 26.4
125 150 1330 37.8 2700 26.4
160 100 1675 39.2 2300 33.5
160 150 1675 48.7 2700 33.5
185 100 1920 45.6 2400 38.5
185 150 1920 57.1 2900 38.5
SPECIFICATIONS Section 3 - Pg 01
COMPRESSOR:
WARNING- It is important that the compressor oil be of a recommended type and that t is inspected
and replace together with the oil and air filters, in accordance with this manual.
The result of poorly maintained lubricant and/or filters may produce hazardous conditions resulting in
ignition, which could cause a fire in the sump. Damage to equipment and serious bodily harm may
result.
APPLICATION GUIDE
Water must be drained from the receiver periodically. In high ambient temperature and high humidity
conditions, condensed moisture may emulsify with the oil forming a “milky” color. The fluid should
be changed if this condition develops.
DO NOT mix different types of fluids. Combinations of different fluids may lead to
operational problems such as foaming, filter plugging, orifice or line plugging.
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OPERATION Section 4 - Pg 01
4.1 GENERAL
While Vanair has built into this compressor a comprehensive array of controls and
indicators to assure you that it is operating properly, you will want to recognize and
interpret the readings which will call for service or indicate the beginning of a malfunction.
Before starting your Vanair compressor, read this section thoroughly and familiarize yourself
with the controls and indicators - their purpose, location and use.
FLUID LEVEL SIGHT GLASS Monitors the fluid level in the sump. Proper
Level is always visible in the sight glass.
Check the level when the compressor is shut
down.
OPERATION Section 4 - Pg 02
1. Position the compressor on a level surface so that proper amounts of liquid can be
added if necessary.
7. After the initial run, shut the compressor down and refill compressor with oil
and tighten any loose fittings.
For starting compressor for daily use repeat steps #3 through #6.
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INSTALLATION Section 5 - Pg 01
INSTALLATION
5.1 A location on the truck is the first thing that needs to be found. Some of the concerns are that
there has to be enough room around the compressor package to insure proper cooling. Also,
access will be needed to service the air cleaner, separator element, and oil filter. Lastly, the
instrument panel should be able to be seen for daily operations. Once a location is found, the
compressor package should be mounted down with a minimum of (4) 1/2-13 capscrews.
5.2 The hydraulic hoses must be ran into the package to the hydraulic motor. Insure the hoses
are hooked up properly to insure proper rotation. Also, insure that the hoses are run thru an area
so that no chafing of the hoses are possible.
5.3 The hydraulic compressor package should be wired per wire diagram 5.1. There are a total of
(4) wires to be run inside of the package.
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INSTALLATION Section 5 - Pg 02
Wire Diagram 5.1
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INSTALLATION Section 5 - Pg 03
RECEIVER TANK INSTALLATION:
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MAINTENANCE Section 6 - Pg 01
6.1 GENERAL
A good maintenance program is the key to long compressor life. Below is a program that
when adhered to, should keep the compressor in top operating condition. See Section 6.7, Parts
Replacement and Adjustment Procedures for a detailed description of specific compressor
system components. Units that have not yet been installed should be stored in a dry, temperature
controlled environment. Unit should be recharged with oil if it has been in extensive storage.
WARNING: DO NOT remove caps, plugs and/or other components when compressor
is running or pressurized.
Stop compressor and relieve all internal pressure before doing so.
After a routine start has been made, observe the instrument panel gauge and be sure it
monitors the correct reading for that particular phase of operation. After the compressor has
warmed up, it is recommended that a general check on the overall compressor and
instrument panel be made to assure that the compressor is running properly. Also check the air
filter maintenance indicators (if provided).
MAINTENANCE Section 6 - Pg 02
MAINTENANCE Section 6 - Pg 03
MAINTENANCE Section 6 - Pg 04
ELEMENT REPLACEMENT
1. Loosen the clamp which secures the rain cap to the body and remove the cap.
2. Remove the rubber baffle from inside the dust cap and empty all dirt particles.
3. Unscrew the wingnut from the center post to loosen the element and remove.
4. Clean the body and dust cap with a clean damp cloth inside and out. DO NOT
BLOW DIRT OUT WITH COMPRESSED AIR!
5. At this time clean or replace the element (Part No. 262092). Cleaning instructions
follow.
6. Install the element back into the body and replace the wingnut. Tighten securely.
7. Replace the rubber baffle into the dust cap and attach the cap to the body.
8. Retighten the clamp to secure the filter.
The air filter element is cleanable by using compressed air. The maximum amount of times that
an element should be cleaned is six (6) times: however, the element should be used no longer
than a period of one (1) year without changing.
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MAINTENANCE Section 6 - Pg 05
Prior to cleaning an element, check the element for damage. Damaged elements must be
replaced.
When cleaning an element, never exceed the maximum allowable pressures for compressed
air (30 PSI).
Do not strike the element against any hard surface to dislodge dust. This will damage the
sealing surfaces and possibly rupture the element. Never “blow” dirt out of the interior of
the filter housing. This may introduce dust downstream of the filter. Instead, use a clean
damp cloth. Do not oil the elements.
ELEMENT INSPECTION
1. Place a bright light inside the element to inspect for damage or leak holes.
Concentrated light will shine through the element and disclose any holes.
2. Inspect all gaskets and gasket contact surfaces of the housing. Should faulty gaskets
be evident, correct the condition immediately.
3. If the clean element is to be stored for later use, it must be stored in a clean container.
4. After the element has been installed, inspect and tighten, if necessary, all air inlet
connections prior to resuming operation.
1. Remove all piping connected to the sump cover to allow removal (return line, service
line, etc.).
2. Remove the fluid return line from the fitting in the cover.
3. Remove the eight (8) 1/2 - 13 cover bolts and lock washers and lift the cover from the sump.
4. Remove the separator element.
5. Scrape the old gasket material from the cover and the flange on the sump. Be sure to
keep all scrapings from falling inside tank.
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MAINTENANCE Section 6 - Pg 06
6. Install the element with bonded gaskets, making sure the staples in the gaskets come in
contact with the metal surface of the bolt ring and cover. DO NOT use gasket sealer
as it can insulate the staples causing the element not to be properly grounded for
operation.
7. Replace the sump cover and bolts . Run the cover bolts in finger tight, then gradually
tighten in a crisscross pattern in 4 to 5 steps. ALWAYS tighten the bolts alternately at
Opposite sides of the cover. NEVER tighten bolts adjacent to each other. Torque
bolts to 55 to 75 Ft. lbs.
8. Reconnect all piping.
9. Clean the fluid return line and clear the orifice prior to restarting the compressor.
MAINTENANCE Section 6 - Pg 07
6.6 TROUBLESHOOTING
The information contained in the Troubleshooting chart has been compiled from field report
data and factory experience. It contains symptoms and usual causes for the described problems.
However, DO NOT, assume that these are the only problems that may occur. All available data
concerning the trouble should be systematically analyzed before undertaking any repairs or
component replacement procedures.
A detailed visual inspection is worth performing for almost all problems. Doing so may
prevent damage to the compressor. Always remember to:
Should your problem persist after making the recommended check, consult your nearest
Vanair representative or Vanair Manufacturing, Inc.
COMPRESSOR SHUTS DOWN Compressor Discharge Temperature Cooling air flow is insufficient; clean WITH
AIR DEMAND PRESENT Switch is Open. cooler and check for proper ventilation.
MAINTENANCE Section 6 - Pg 08
COMPRESSOR WILL NOT Air demand is Too Great Check service lines for leaks or open
valves.
BUILD UP FULL DISCHARGE
PRESSURE
Dirty Air Filter Check the filter and change
element if required.
MAINTENANCE Section 6 - Pg 09
When ordering parts always indicate the Serial Number of the compressor. This can be
obtained from the Bill of Lading for the compressor or from the Serial Number Plate
located on the compressor.
Telephone: 269-469-4461
FAX: 269-469-0497
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INSTALLATION/TEST RECORD
Tested_________________________ Date_______________________
ANFO TRUCK LINCOLN LUBE 17165
SYSTEM INSTALLATION Page 1 of 2
Updated:
05/14/10
CHASSIS LUBE ELECTRIC 17341
GREASE PUMP Page 2 of 3
Updated:
05/14/10
CHASSIS LUBE ELECTRIC 17341
GREASE PUMP Page 3 of 3
Updated:
05/14/10