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FT-2251 Trailer-Mounted
Fracturing Unit
Operation and Maintenance Manual
OEM
Original Equipment Manufacturer
MKT# 2654258
Stewart & Stevenson Well Servicing Products

10750 Telge Road
Houston, Texas 77095
2006 Stewart & Stevenson Front Matter
RECORD OF REVISIONS
Property of:
Company:
Address:
City: State: Zip Code:
Revision Data
Check each revision received, and insert the revised and supplementary pages in your manual.
Stewart & Stevenson assumes no liability for personal injury or equipment failure due to any
operation performed without heed to manual revisions.
Date of original publication: July 2006
Revision Number Date Brief Description
2654258 i
COPYRIGHT NOTICE
This manual is copyrighted as an unpublished work.
This manual contains the confidential and proprietary information of Stewart & Stevenson.
Neither this document, nor any information contained herein, may be reproduced or redistributed
in any form whatsoever without the express, written consent of an authorized agent of
Stewart & Stevenson.
Any attempt by any person other than an authorized agent of Stewart & Stevenson to alter the
contents of this manual in any way shall be construed as copyright infringement, punishable by
all applicable laws.
All vendor literature contained in this manual is the copyrighted property of the respective
vendors, protected by the same laws governing this operation and maintenance manual.
Copyright 2006 by Stewart & Stevenson. All rights reserved.
2654258 ii
ABOUT THIS MANUAL

This manual is not a textbook on mechanics, electronics, or hydraulics. Sufficient descriptive
material and illustrations are included to enable the operator to understand the basic construction
and theory of operation of this equipment. The intent of this manual is to guide the operators and
maintenance personnel in the proper use of the equipment. This manual is not a substitute for
properly trained personnel or common sense.
No liability, either express or implied, is given for any information contained herein. This manual is
intended only as a guide, and not as a substitute for proper training by qualified personnel.
Stewart & Stevenson assumes no responsibility for improper use of equipment, improperly
trained personnel, improperly maintained equipment, or failure to follow normal safety precau-
tions outlined here, in the vendor literature, or by properly trained personnel.
Use of this manual for any purpose other than for the safe and proper operation and mainte-
nance of the equipment and all its components constitutes misuse, and is punishable by all
applicable laws.
If there is any discrepancy between information contained in this manual and the vendor litera-
ture, the vendor literature is assumed correct. Stewart & Stevenson assumes no liability whatso-
ever for any person who fails to follow the operation and safety procedures of the original equip-
ment manufacturers.
Please read through this manual in its entirety before attempting to operate the equipment.
Stewart & Stevenson assumes no liability for failure to do so.
This manual contains different sections, depending on the equipment purchased. All manuals
contain an operation and maintenance section. Chapter 1 provides a description and specifica-
tions of the unit and the components of the unit. Chapter 2 provides operation information and
operational procedures. Chapter 3 provides maintenance information. Chapter 4 contains draw-
ings of the unit and components of the unit.
Most manuals have a manufacturers section containing information supplied by vendors of

Stewart & Stevenson. This information is available on the major components, such as engines,
transmissions, and pumps; this section will be under separate cover as a Parts Catalog.
Manufacturers literature is divided by numbered tabs. Components are arranged alphabetically
by manufacturers name with primary components first.
All information in this manual is based on the latest product information available at the time of
publication. Direct any questions concerning the contents or format of this manual to:
Stewart & Stevenson

10750 Telge Rd.
Phone: (281) 345-5100
Fax: (281) 345-1188
2654258 iii
UNIT IDENTIFICATION
To aid the technician in repair or service work on this unit, a Stewart & Stevenson identification
nameplate, similar to that shown below, is located on the frame of the equipment.
The serial number identification of each unit will appear on the nameplate (as shown above)
along with the date of manufacture. The mailing address of Stewart & Stevenson, telephone
number, telex number, and cable information are all located in the middle of the nameplate on
either side of the Stewart & Stevenson logo. This necessary information will ensure the cus-
tomer a fast and accurate response to any parts and/or service request.
Please verify the serial number on the units identification nameplate and
ENTER YOUR UNIT SERIAL NUMBER HERE:
If applicable,
ENTER YOUR COMPANY IDENTIFICATION NUMBER HERE:
TECHNICAL ASSISTANCE
For parts or warranty assistance, wire, write, or call:
Stewart & Stevenson

10750 Telge Rd.
For Parts: (281) 345-5100; ask for Parts Department.

For Service: (281) 345-5100; ask for Warranty Department.
Be sure to list the equipment model number, rating, specific nature of the problem, and the
suspected area of malfunction.
Do not use the Operators Manual to order parts. If parts or main-

tenance are needed, please refer to the Parts Catalog or the ap-
propriate component supplier.
2654258 iv
TABLE OF CONTENTS
Chapter/Section Page
Front Matter
Record of Revisions ............................................................................................................. i
Copyright Notice.. ................................................................................................................ ii
About This Manual................................................................................................................... iii
Unit Identification ................................................................................................................ iv
Technical Assistance .......................................................................................................... iv
Table of Contents ................................................................................................................ v
Safety ........................................................................................................................... vii
Safety Symbols .......................................................................................................... vii
Warning Statements .................................................................................................. viii
Cautionary Statements ................................................................................................ ix
Pump Safety ................................................................................................................ x
Chapter 1 Description and Specifications

1.1 Unit Description ..................................................................................................... 1-1
1.2 Assembly Description ............................................................................................ 1-2
1.2.1 Power Unit ................................................................................................... 1-2
1.2.2 Transmission ................................................................................................ 1-2
1.2.3 Engine Transmission Mounting .................................................................... 1-3
1.2.4 Pump Assembly ............................................................................................ 1-4
1.2.4.1 Triplex Pump ........................................................................................... 1-4
1.2.4.2 Suction Manifold ...................................................................................... 1-5
1.2.4.3 Discharge Manifold.................................................................................. 1-5
1.2.4.4 Fluid End Lubrication ............................................................................... 1-5
1.2.4.5 Power End Lubrication ............................................................................ 1-5
1.2.5 Hydraulic Systems ....................................................................................... 1-6
1.2.6 Control and Instrumentation System ............................................................ 1-6
1.2.6.1 Local Gauge Cabinet ............................................................................... 1-6
1.2.6.2 Stewart & Stevenson Intelligent Pump Control (IPC) ................................ 1-7
1.3 Specifications and Capacities ................................................................................ 1-9
1.3.1 Operating System Specifications .................................................................. 1-9
1.3.2 Component Specifications .......................................................................... 1-10
1.3.2.1 Diesel Engine ........................................................................................ 1-10
1.3.2.2 Transmission ........................................................................................ 1-15
1.3.2.3 Triplex Pump ......................................................................................... 1-16
1.3.2.4 Hydraulic System .................................................................................. 1-17
1.3.2.5 Pneumatic System ................................................................................ 1-17
1.3.2.6 Radiator ............................................................................................... 1-18
1.3.2.7 Trailer ................................................................................................... 1-19
Chapter 2 Operation
2.1 Controls and Indicators .......................................................................................... 2-1
2.1.1 Gauge Panel .............................................................................................. 2-1
2.1.2 Remote Control Suitcase ........................................................................... 2-4
2654258 v
TABLE OF CONTENTS (Cont)

Chapter/Section Page
2.2 Inspections ............................................................................................................ 2-6
2.2.1 Before-Trip Inspection ................................................................................ 2-6
2.2.2 After-Trip Inspection ................................................................................... 2-6
2.2.3 Before-Operation Inspection After Overhaul and Storage ............................ 2-7
2.2.4 After-Operation Inspection .......................................................................... 2-8
2.3 Operational Procedures ........................................................................................ 2-9
2.3.1 Before Operation Engine Test Run (Optional) ............................................ 2-9
2.3.2 Unit Startup .............................................................................................. 2-10
2.3.3 Normal Shutdown ..................................................................................... 2-11
2.3.4 Emergency Shutdown .............................................................................. 2-12
2.4 Starting Unit After Extended Storage/Major Overhaul ............................................ 2-13
2.4.1 Power Unit Assembly Preparation ............................................................ 2-13
2.4.2 Pump Assembly Preparation .................................................................... 2-16
2.5 Troubleshooting ................................................................................................... 2-18
2.5.1 General Hydraulic Problems.................................................................... 2-18
Chapter 3 Maintenance
3.1 Nature of Preventive Maintenance .......................................................................... 3-1
3.1.1 Actions ....................................................................................................... 3-1
3.2 Scheduled Maintenance ........................................................................................ 3-2
3.3 Maintenance Instructions ....................................................................................... 3-2
3.3.1 Daily Maintenance Instructions ................................................................... 3-2
3.3.2 Weekly Maintenance Instructions ............................................................... 3-6
3.3.3 Quarterly Maintenance Instructions ............................................................ 3-7
3.4 Corrosion Check .................................................................................................. 3-11
3.5 Servicing ............................................................................................................. 3-12
Chapter 4 Drawings
4.1 List of Drawings..................................................................................................... 4-1
2654258 vi
SAFETY
Due to the many hazards involved in the oilfield industry, operators of Stewart & Stevenson built
equipment should be familiar with all relevant safety regulations and precautions. Failure to
follow the specific safety procedures outlined in this section and warnings and cautions given
in other sections will result in equipment damage or failure, as well as personal injury or
death. Please read through the following safety procedures before attempting to operate the
equipment.
Safety is everyones business and must be of primary concern. Knowing the guidelines covered
in this manual will help to provide for the safety of the individual, for the safety of the group, and
for the proper operation of equipment.
SAFETY SYMBOLS
Look for these symbols that point out items of importance to the safety of the individual
and group.
Safety warnings MUST be followed. Failure to do so may result in

SERIOUS INJURY or DEATH.
Safety cautions are very important. Failure to follow them may cause
serious damage to the machine.
NOTE: is used to notify people of information that is IMPORTANT,

but not hazard-related.
The safety warnings and cautions contained in this manual are typical, and are not the only
types of general precautions that should always be observed during all phases of operation
and maintenance. Actions during any unusual circumstances should be dictated by common
sense.
2654258 vii
WARNING STATEMENTS
Always use caution when inspecting equipment. Begin only when
the equipment is shut down, isolated, and tagged OUT OF SER-
VICE. Any accidental or poorly timed operation can cause serious
injury to personnel and/or damage to equipment.
Always use caution when working around rotating equipment. Se-

rious injury to personnel and/or damage to equipment could oc-
cur.
All equipment should be shut down, turned off, isolated, and tagged
OUT OF SERVICE before any maintenance procedures are per-
formed. Do not wear loose clothing, unbuttoned shirts, shirt
sleeves, or neckties while working around moving equipment.
DO NOT LEAVE ZERK FITTINGS INSTALLED ON HIGH-PRESSURE

EQUIPMENT. Extreme pressure inside this assembly can cause
the Zerk check ball to blow out.
Hot metals can cause severe burns and/or injury to personnel.

Prior to personnel performing service on the engine, adequate
time for cooldown must be allowed after the exhaust manifold ex-
periences extremely high temperatures.
Always use lifting equipment, supports, and chains with a safe mini-
mum capacity of one and a half times that of the object being lifted
or supported. Serious injury or death can result from falling or
swinging equipment.
Exercise extreme caution when performing maintenance on the

hydraulic system. Fluid escaping under pressure can cause seri-
ous personal injury. Face shield and protective clothing must be
worn.
Prior to hoisting equipment, ensure that no loose bars, tools, parts,

and the like are lying in or on part of the unit, as they could cause
serious injury to personnel and/or damage to the unit.
2654258 viii
CAUTIONARY STATEMENTS
For your own protection, do not use substitute parts without the
approval of Stewart & Stevenson Services.
Leaking joints, fittings, and connections must be tightened only

under pressureless conditions.
When cleaning, use only an approved solvent to prevent damage

and/or deterioration to the equipment.
When using Teflon tape, always start the wrap about two threads
away from the opening. This will prevent Teflon tape contamina-
tion of the hydraulic system.
Use CAUTION when tightening brass fittings. They are easily

stripped when over torqued.
The return connector MUST be connected before any system is

operated; failure to do so will cause damage to the equipment (e.g.,
blown seals).
Particular care should be taken when working in or around seal-

ing surfaces. Grooves, nicks, and/or scratches on sealing areas
will cause immediate or premature seal failure.
Use only specified fluid types. Use only fresh fluids that are free
of contamination. Do not mix fluids.
NOTE: The warnings and precautions given in this section are gen-
eral in nature and pertain to any piece of equipment. Specific warnings
and precautions are given as needed in the appropriate sections.
2654258 ix
PUMP SAFETY
Well service fracturing pumps are to be installed and operated in
a horizontal position only. Operation in an extreme inclined posi-
tion could cause equipment failure, due to improper oil flow and/
or improperly sealing valves.
All personnel should be located away from the pump while in op-
eration. Only trained personnel should be around the pump, es-
pecially during service or operation.
Personnel must clear all pumps during operation. There is a clear

and ever present danger from gears and other moving parts to
loose clothing, hand, etc. Keep clear of moving or pressurized
components.
All personnel should maintain a safe distance from the pump when
it is rotating as well as when pressure is present. Keep hands and
clothing clear of unit at all times.
Never place hands in area of reciprocating pony rod or plunger

path. If work must be done in this area, make sure pump is disen-
gaged from driver prior to initiating activity.
Each pump is clearly marked with a maximum pressure rating. This

pressure must not be exceeded or mechanical damage can occur.
Each pump is clearly marked with a maximum horsepower rating.

This horsepower rating should not be exceeded or mechanical
damage can occur.
Well service pumps should never be used to pump gaseous, ex-

plosive or uninhibited corrosive fluids. These may result in equip-
ment failure and possible personnel injury.
Any repairs or service (routine maintenance) performed on the

pump must be performed by a trained service technician who is
qualified to work on high pressure reciprocating plunger pumps.
All such service and repairs must be supervised by qualified man-
agement personnel and only S&S replacement parts should be
utilized.
2654258 x
PUMP SAFETY (Cont)

When working on the pump, safety glasses, approved safety shoes
and hardhat must be worn. Hammering on any part or component
may cause foreign material or steel slags to become airborne.
It is a personal responsibility to use the proper tools when servic-

ing the pump. Any special tools required are furnished with the
pump when new, and should be kept with the pump for its routine
maintenance.
It is a personal responsibility to be knowledgeable and trained in

the use and handling of these tools for all maintenance of the pump.
A pump is made up of internal and external moving parts.
Each pump, its drive system, and its fluid piping should be visually
checked each time before operating. All worn, damaged or miss-
ing parts should be remedied before starting the pump.
Personnel should only hammer on the hammer wrench provided

and never directly on the pump itself. Fractures can occur from
repeated misuse. Only soft-type hammers should be used.
Personnel should never hammer on one of the valve retainer nuts

or any other pump component when pressure is present. Person-
nel should never be around the pump when the input shaft is turn-
ing under power or the unit is under pressure.
The pumps discharge connections should be properly cleaned

and lightly oiled before the downstream piping is attached. Any
worn, damaged or missing seals should be replaced before en-
gaging the pumps drive. Leaking connections can cause pump
cavitation leading to equipment failure.
A complete visual inspection of the pumps power end and fluid

end must be made prior to each use. Any leaking seals, broken
bolts, leaking hoses or improperly tightened parts must be rem-
edied prior to rotating the pump.
If a pump is used in a place where permanent piping is to be at-

tached, frame flexing or structure movements must be considered.
Do not place the discharge or suction connections in a bind. In-
spect all components of such piping structure, including any valves,
every 90 days for wash, erosion, corrosion, etc. Replace if worn.
All studs and stay rods require tightening to the proper torque.
Without proper torque, the fluid end will breathe against the
power end resulting in stud failure, stay rod failure and/or even
premature fatigue failure in the power or fluid end.
2654258 xi
PUMP SAFETY (Cont)

All covers must be tight and properly torqued. Otherwise, prema-
ture fatigue and possible fluid end or component failure can re-
sult.
All fluid cylinders must be disassembled and dimensionally in-

spected routinely. Any fluid cylinder which exhibits any loss in wall
thickness due to washing or corrosion pitting in any area must be
returned for repair and recertification prior to operating again.
All fluid cylinders must be disassembled and inspected for cracks

with a suitable ultraviolet light/magnetic particle inspection de-
vice on a routine basis. The operation of any pump with even small
surface cracks in any area of the fluid cylinder can result in equip-
ment damage and possible failure.
All fluid cylinders should be hydrostatically tested at least twice

each year by a qualified technician. Prior to any pressure testing,
all air must be evacuated from the system. The maximum test pres-
sure must not exceed the equipments rated working pressure.
The hydrostatic pressure test must be followed with an ultraviolet
light/magnetic particle inspection of the internal bores prior to
reinstalling and operating under pressure.
The pumps fluid end and related piping must always be flushed
with clean water after every job. If freezing temperatures are an-
ticipated, the fluid cylinder must be completely drained of any fluid.
Failure to do this may result in fluid cylinder damage from fluids
which have hardened or frozen.
All threaded components are right-hand threaded unless specifi-

cally designated otherwise. Any turning counterclockwise will un-
screw the assembly. Always make sure any threaded component is
made up properly with the proper power torque make-up.
All products should be properly cleaned, greased, or oiled after

each use and inspected prior to each use.
Pressure seal (line pipe) threads are not recommended for pul-
sating service above 10,000 psi or where side loading or erosion
are suspected. Non-pressure seal (round tubing) threads or
straight integral connections are recommended under these con-
ditions. In order to achieve the recommended Non-Shock Cold
Working Pressure, power-tight makeup is required on threaded
connections. Consult the factory for any usage other than normal,
constant-flow working conditions. Integral connections are rec-
ommended in lieu of pipe-threaded connections for pump applica-
tions.
2654258 xii
PUMP SAFETY (Cont)

Each integral union connection is clearly marked with a pressure
code (i.e. 1502, 15,000 psi). This pressure must not be exceeded.
This code should also be used with mating unions. Improper mat-
ing can result in failures. All integral union connections used must
match (according to size, pressure rating, etc.). These connec-
tions must also match the service of the designated string in which
they are installed.
All fluid cylinder mounting nuts must be checked routinely with a

certified torque wrench. Loose fluid cylinder mounting nuts can
cause the fluid end to separate from the power end, resulting in
extreme injury or death.
2654258 xiii
2006 Stewart & Stevenson Chapter 1
CHAPTER 1
DESCRIPTION AND SPECIFICATIONS INTRO
1.1 UNIT DESCRIPTION
The Stewart & Stevenson (S&S) Model FT-2251 is a trailer-mounted, heavy-duty fracturing unit
capable of pumping inhibited acid and other proppant laden stimulation fluids in harsh oilfiled
environments. The unit is remotely operated from an S&S Model EC-26ACD computerized data
acquisition and control unit
The units prime mover is a Detroit Diesel Corp. (DDC) Model 12V4000 engine rated for 2250
bhp at 1950 rpm. An Allison Series S9800 transmission, coupled and configured to the engine, is
used to transmit power to a triplex pump assembly designed to deliver a minimum of 2000 hhp.
The FT-2251 is mounted on a trailer incorporating a heavy-duty suspension and driveline. The
trailer is pulled by a customer supplied tractor.
GENERAL SPECIFICATIONS
Length 40 6 (12.34 m)
Width 8 (2.44 m)
Height 13 6 (4.11 m)
Weight (on rear axles) 34,000 lb (15,422 kg)
Weight (on kingpin) 26,000 lb (11,793 kg)
2654258 1-1
Chapter 1 2006 Stewart & Stevenson
1.2 ASSEMBLY DESCRIPTION
1.2.1 POWER UNIT
The deck power unit of the FT-2251 is an industrial application, turbocharged, jacket water
charge cooling, direct injection, 12-cylinder, 90 V configuration, DDC/MTU Diesel engine. The
power unit supplies power to the pump assembly, supplies power end lubrication and
hydraulically drives the radiator fan.
The 12V4000 engine is rated 2250 bhp at 1950 rpm. For complete specifications, refer to Section
1.3.
General Specifications
Model T123-7K39
Type 90 Vee, 4 cycle
Cylinders 12
Output 2250 bhp (1679 kW)
This four-cycle design Diesel engine has been specifically equipped for use as a stationary
power unit in well service applications and is designed to meet all future emission requirements.
The Series 4000 Diesel engine is complete with a turbocharger system, SCCC cooling system,
common fuel rail fuel system, and DDEC IV control system that automatically monitors operating
parameters for the engine and related assemblies.
General Information For application specifications on the Diesel engine, refer to Section 1.3.
For assembly details, refer to the S&S drawings in Chapter 4.
For complete details, specifications, and parts listing for the Diesel engine, refer to the following
DDC literature found in the FT-2251 Trailer Mounted Fracturing Unit Parts Catalog: Series 4000
Service Manual, Series 4000 Operating Instructions, Engine Service Fluid and Filter
Requirements, and DDEC III/IV Multi-ECM Troubleshooting Guide.
1.2.2 TRANSMISSION
The Allison S9810M transmission is a straight-through configuration with output to the pump
assembly. The S9810M is equipped with TC 1080 Torque Converter for reduced oil flow during
0 to 00 adaptations. An auxiliary axial-drive is coupled to the pump assembly lubrication gear
pump. A direct mounted disc brake assembly has air actuated calipers. The transmission has a
standard lockup clutch that is automatic in all gear ranges and hydraulically actuated. The
transmission is operated with a manual-electric hydraulic system with manual selection of the
operating mode solenoids to control hydraulic pressures to shift valves that control the hydraulic
clutch assembly.
A positive displacement, gear-type scavenging pump is provided for transmission lubrication. An

oil-to-water heat exchanger in a shell and tube assembly provides cooling from the engine jacket
water for the transmission fluid. Oil temperature is monitored in the transmission assembly and
in the discharge line, and is displayed on the Gauge panel. Spin on oil filter(s) are mounted in-line
for maintenance of the lubrication system.
1-2 2654258
For details, refer to Figure 1.2, Transmission Cooling System. For details, refer to Section 1.3
and to the Allison Operators Manual and the Allison Transmission Service Manual in the
FT-2251 Trailer Mounted Fracturing Unit Parts Catalog. INTRO
The electric shifting system is connected to the triplex pump over pressure indicator and will shift
the transmission to neutral in overpressure situations. The transmission shifter will only
reactivate after it has been reset to the neutral position.
Figure 1.2, Transmission Cooling System
1.2.3 ENGINE TRANSMISSION MOUNTING
Rubber pads and a front engine vibration trunion mount isolate the engine and transmission from
the trailer. This makes the engine/transmission mount combination more or less a single unit
and allows for a three point mounting consisting of a flexible mount at the front and two flexible
mounts at the rear.
This system eliminates any alignment problems on equipment where there may be flexing of the
unit. The engine and transmission mount can be separated in two pieces, so that the transmis-
sion can be removed without removing the engine mounting system. This feature simplifies unit
service and maintenance.
2654258 1-3
1.2.4 PUMP ASSEMBLY
1.2.4.1 TRIPLEX PUMP
The triplex pump, rated for 2250 bhp (1678 kW), is a positive displacement, reciprocating triplex
plunger pump designed for acidizing, fracturing, cementing, etc. The pump consists of a power
end assembly and a fluid end assembly. Refer to Figure 1.3, Triplex Pump Assembly.
For details, refer to Section 1.3 later in this chapter. For complete details, refer to the Well
Service Plunger Pump Manual in the FT-2251 Trailer Mounted Fracturing Unit Parts Catalog.
Figure 1.3, Typical Triplex Pump Assembly
1-4 2654258
1.2.4.2 SUCTION MANIFOLD
A 6 suction manifold (suitable for CO2 service with all valves removed) is included with the unit INTRO
and extends to the units edge. The manifold is equipped with two 4 butterfly valves and two 4
Fig. 200 winged union connections. Three 2 Fig. 200 openings with caps for draining the pump
end fluid are also part of this suction manifold.
The butterfly valves must be removed before use with CO2.
1.2.4.4 FLUID END LUBRICATION
A grease pump fluid end lubrication system is installed to supply lubricating oil to the plunger
packing area. This system includes all enclosed reservoirs with sight gauges and all
accessories necessary to plunger lubrication.
1.2.4.5 POWER END LUBRICATION
The triplex pumps power end is lubricated by a hydraulic pump driven off the PTO accessory
connection on the transmission. The power end lubrication system includes all relief valves,
filters, instrumentation, plumbing, and reservoir, necessary to power end lubrication.
1.2.5 HYDRAULIC SYSTEMS
The FT-2251 uses two hydraulic systems to power its various components.
The first is a hydraulic wet kit that powers the deck engine hydraulic starting system. This
system, which uses a hydraulic pump driven directly from the truck chassis transmission via a
power takeoff (PTO), includes the following components:
a transmission PTO,
an hydraulic pump,
an hydraulic reservoir,
a return filter, and
controls, quick disconnects, hoses, and fittings.
2654258 1-5
The second hydraulic system powers the radiator fan via a special front engine crankshaft
adaptation. Listed below are other pieces of equipment for the second hydraulic system.
an hydraulic oil tank,
suction and return filters,
relief, directional control, and priority valves, and
troubleshooting connections.
1.2.6 CONTROL AND INSTRUMENTATION SYSTEM
1.2.6.1 LOCAL GAUGE CABINET
A local gauge cabinet with a hinged front cover is mounted on the unit and isolated from the
chassis by shock mounts. Instruments installed in this cabinet are fluid-filled with brass and/or
stainless steel bodies. They include:
An air system pressure gauge
An engine coolant temperature gauge
An engine oil pressure gauge
A transmission oil pressure gauge
A transmission oil temperature gauge
A lube oil temperature gauge
A triplex pump power end lube oil pressure gauge
1.2.6.2 STEWART & STEVENSON INTELLIGENT PUMP CONTROL (IPC)
The IPC is a microprocessor-based system with an operator interface module stored in a

weathertight suitcase. It provides an operator interface through a touch sensitive 8.5 x 6.25
graphical display. The following control functions are available through the IPC operator interface
module:
Engine throttle
Transmission shift
Digital torque limiter control (preset at factory)
1-6 2654258
Electric power (on/off)
Transmission brake INTRO

Emergency engine shutdown
Normal engine shutdown
Engine start
The following parameters can be displayed on the touch screen display in the operator interface
module of the IPC:
Engine fault codes with translation
Engine Speed
Engine oil pressure and temperature
Engine water temperature
Transmission oil pressure and temperature
Torque converter status indicator for converter and lockup modes
Pump speed
Pump oil pressure and temperature
Pump discharge pressure with overspeed module
Pump discharge rate and total
Hydraulic horsepower production (calculated)
NOTE: Custom display values and alarms can be also be added.
The IPC control suitcase comes with a wrap containing control cable to connect the suitcase to
the trailer-mounted local electrical junction box.
NOTE: This cable may also be used to connect the trailer-mounted

local electrical interconnect cabinet to a frac control center in the
Computerized Data Acquisition Control Unit.
2654258 1-7
The IPC is also equipped with serial data (RS232) output capability for connection to external
devices, such as data acquisition systems and memory storage modules. Some optional
features that demonstrate the IPCs high level of expandability for optional programs include:
The Stewart & Stevenson soft shift module (patent pending)
Wireless control
Stewart & Stevenson Frac Box, Data Acquisition Memory Module
Stewart & Stevenson Automated Pump Control System
1-8 2654258
1.3 SPECIFICATIONS AND CAPACITIES
NOTE: Actual capacities can vary due to differences in piping. Sys- INTRO
tem capacity should be verified on site.
1.3.1 OPERATING SYSTEM SPECIFICATIONS
NOTE: Ranges determined in ambient conditions with a temperature

range of 24 C -35 C. Operating ambient conditions -40 C to +40 C.
ENGINE AND TRIPLEX PUMP OPERATING RANGES

Engine Idle 700 rpm
Engine RPM 1925 1960 rpm
HHP 1600 2250 (1193 1678 kW)
Engine Oil Pressure 90 95 psi (0.62 0.65 mPa)
Engine Temperature 172 176 F (24 32 C)
Transmission Oil Pressure Gears 1 & 2 220 250 psi (1.50 1.70 mPa)
Transmission Oil Pressure Gears 3 8 160 180 psi (1.09 1.22 mPa)
Transmission Oil Temperature 180 210 F (82 99 C)
Pump Oil Pressure 60 120 psi (0.41 0.82 mPa)
Pump Oil Temperature 105 150 F (41 66 C)
Hydraulic Fluid Temperature 75 90 F (24 32 C)
2654258 1-9
1.3.2 COMPONENT SPECIFICATIONS
1.3.2.1 DIESEL ENGINE
GENERAL ENGINE SPECIFICATIONS

Designation 12V4000
Model T1237K39
Type 90 Vee 4 Cycle
Brake Horsepower 2250 bhp (1678 kW)
Rated Speed 1950 rpm
Fuel Consumption at 100% 103.4 gal/hr (391 L/hr)
Number of Cylinders 12
Total Displacement 2975 in3 (48.76 L)
Compression Ratio 14:1
Piston Speed 2244 ft/min (684 m/min)
Charge Air Cooing System SCCC
Crankcase Vent System Open
Dry Weight 13,325 lb (6044 kg)
Wet Weight 14,171 lb (6428 kg)
Height 88.9 in (2259 mm)
Length 99.9 in (2538 mm)
Width 63.4 in (1611 mm)
NOTE: Capacities listed are for the engine block and cylinder heads
only. They do not include the radiator and hoses.
1-10 2654258
1.3.2.1 DIESEL ENGINE (Cont)
INTRO
ENGINE LUBE OIL SYSTEM CAPACITIES AND SPECIFICATIONS
Crankcase (Pan) Lubricating Oil 53 gal (200 L)
Total Engine Lubricating Oil (w/Filters) 58 gal (220 L)
Maximum Temperature 210 F (99 C)
Normal Operating Temperature 174-203 F (78-95 C)
Rated Speed Pressure 91 psi (630 kPa)
Low Idle Pressure 23 psi (150 kPa)
Maximum Crankcase Pressure 10 in-Wg (2.5 kPa)
Rated Speed Oil Flow 93 gal/min (352 L/min)
Low Idle Oil Flow 47 gal/min (178 L/min)
Low Oil Pressure Alarm 37 psi (255.1 kPa)
Low Oil Pressure Shutdown 27 psi (186.2 kPa)
High Oil Temperature Alarm 240 F (116 C)
High Oil Temperature 250 F (121 C)
Engine Lubricating Oil Specifications
Refer to DDC Engine Service Fluid and Filter Requirements in the FT-2251 Trailer Mounted Fracturing
Unit Parts Catalog for complete specifications on the types of lubricating oil used with Series 4000
engines.
2654258 1-11
ENGINE FUEL SYSTEM CAPACITIES AND SPECIFICATIONS

Fuel Consumption at 100% Load 103.4 gal/hr (391 L/hr)
Fuel Spill Rate 116 gal/hr (438 L/hr)
Total Fuel Flow 219 gal/hr (828 L/hr)
Maximum Temp at Inlet 140 F (60 C)
Fuel Pump Suction 6 in-Hg (20 kPa)
Return Pressure 7 in-Hg (24 kPa)
Fuel Tank Capacity (per tank) 200 gal (454 L)
Useful Fuel Tank Capacity 400 gal (908 L)
Maximum Fuel Tank Air Pressure 5 psi (32.9 kPa)
Secondary Filter Size 5 microns pm
Primary Filter Minimum Pressure 12 psi (82 kPa)
Primary Filter Maximum Pressure 20 psi (137 kPa)
Fuel Specifications
Refer to DDC Engine Service Fluid and Filter Requirements in the FT-2251 Trailer-Mounted
Fracturing Unit Parts Catalog for complete specifications on the types of diesel fuel used with
Series 4000 engines.
1-12 2654258
INTRO
ENGINE COOLING SYSTEM CAPACITIES AND SPECIFICATIONS
Engine Coolant Capacity 42 gal (160 L)
Engine Circuit Coolant Flow Rate 420 gal/hr (1588 L/min)
Aftercooler Circuit Coolant Flow Rate 180 gal/ min (680 L/min)
Heat Rejection 34,600 Btu/min (608 kW)
Minimum Radiator Cap Pressure 14 psi (97 kPa)
Maximum Engine Out Temperature 203 F (95 C)
Maximum Aftercooler in Temperature 153 F (67 C)
Minimum Temperature 160 F (71 C)
HTC Start to Open Thermostat Range 170 F (77 C)
HTC Fully Open Thermostat Range 185 F (85 C)
LTC Start to Open Thermostat Range 90 F (32 C)
lTC Fully Open Thermostat Range 112 F (44 C)
Maximum Temperature 210 F (99 C)
Maximum Ambient Temperature 120 F (48.8 C)
Maximum External Resistance 5 psi (34.4 kPa)
Engine Circuit Water Pump Pressure 52 psi (360 kPa)
Intercooler Circuit Water Pump Pressure 30 psi (206 kPa)
Maximum Static Head Pressure 50 psi (344 kPa)
Radiator Fan Air Flow 70,565 cfm (358 m/sec)

Minimum Radiator Fill Rate 5 gal/min (19 L/min)
Radiator Deaeratoin Time 30 minutes
High-Temperature Alarm 190 F (88 C)
High-Temperature Shutdown 250 F (121 C)
Coolant Heater On 100 F (38 C)
Coolant Heater Off 120 F (49 C)
2654258 1-13
Coolant Specifications
Refer to DDC Engine Service Fluid and Filter Requirements in the FT-2251 Trailer Mounted Frac-
turing Unit Parts Catalog for complete specifications on the types of coolants used with
Series 4000 engines.
ENGINE AIR INTAKE SYSTEM CAPACITIES AND SPECIFICATIONS

Maximum Temperature Rise 30 F (16.7 C)
Engine Air Flow 5000 cfm (2.36 m3/sec)
Turbocharger Inlet Temperature 77 F (25 C)
Engine Manifold/Airbox Pressure 37 in-Hg (125 kPa)
Maximum Drop Pressure 4 in (102 mm)
Clean Filter Maximum Air Intake Restriction 203 F (95 C)
Dirty Filter Maximum Air Intake Restriction 10.3 in-Wg (2.6 kPa)
ENGINE EXHAUST GAS SYSTEM CAPACITIES AND SPECIFICATIONS

Exhaust Gas Flow 331 lb/min (150 kg/min)
Temperature 806 F (430 C)
Maximum Allowable Back Pressure 1.5 in-Hg (5.1 kPa)
NOx Emissions at 100% Load 21,000 g/hr
CO Emissions at 100% Load 2000 g/hr
HC Emissions at 100% Load 900 g/hr
SO2 Emissions at 100% Load (0.1% fuel) 320 g/hr
Clean System Back Pressure 1.0 in-Hg (3.4 kPa)
Dirty System Back Pressure 1.5 in-Hg (5.1 kPa)
1-14 2654258
1.3.2.2 TRANSMISSION
MODEL S9880M TRANSMISSION CAPACITIES AND SPECIFICATIONS INTRO

Type Torque Converter & Planeary Gear
Input Speed Maximum 2100 rpm
Input Torque Maximum 6100 ft/lb (843 kg/m)
Input Power Maximum 2250 hp (1678 kW)
Input Rotation Clockwise
Output Rotation Clockwise
Intermittent Power Takeoff Rating 400 hp (298 kW)
Continuous Power Takeoff Rating 300 hp (224 kW)
Gear Ratio Power Takeoff Rating 1.51 x Engine rpm
First Gear 3.75:1
Second Gear 2.69:1
Third Gear 2.20:1
Fourth Gear 1.77:1
Fifth Gear 1.58:1
Sixth Gear 1.27:1
Seventh Gear 1.00:1
Eighth Gear Blocked
Transmission Oil System Type Approved Type C-4 Transmission Fluid
Sump Capacity 21 gal (79.5 L)
Refill Capacity 19 gal (76 L)
Maximum Temperature 250
Converter Out Oil Pressure 35-65 psi (242-448 kPa)
Full Throttle Main Oil Pressure 220-250 psi (1517-1723 kPa)
Converter Stalled Oil Pressure 35-75 psi (241-517 kPa)
Dry Weight 3700 lb (1678 kg)
Wet Weight 3822 lb (1706 kg)
2654258 1-15
Transmission Fluid
Dextron C4 is typical of the type of transmission oil used in this unit. Refer to Allison Operators
Guide in the FT-2251 Trailer Mounted Fracturing Unit Parts Catalog for complete specifications on
the types of transmission fluid used with S9800 transmissions.
1.3.2.3 TRIPLEX PUMP
MODEL 2250 TRIPLEX PUMPS CAPACITIES AND SPECIFICATIONS
Maximum Input Power 2250 bhp (1641 kW)
Maximum Rod Load See Parts Catalog
Stroke Length 8 (203.2 mm)
Plunger Diameter 5 (127 mm)
Gear Ratio 6.53:1
Maximum Oil Temperature 200 F (93 C)
Length 89.75 (2280 mm)
Width 59.75 (1518 mm)
Height 44.25 (1124 mm)
Dry Weight 11,750 lb (5330 kg)
Power End Lubricating Oil
SAE 80W90 is typical of the type of lubricating oil used in this pump. Refer to Well Service Plunger
Pump Manual in the FT-2251 Trailer Mounted Fracturing Unit Parts Catalog for complete
specifications on the types of lubricating oil used with the plunger pump.
Fluid End Lubricating Oil
Use SAE 90W or equivalent. For complete specifications on the type of lubricating oil used in the
plunger housing, refer to vendor data in the FT-2251 Trailer Mounted Fracturing Unit Parts Catalog.
1-16 2654258
1.3.2.4 HYDRAULIC SYSTEM
INTRO
HYDRAULIC SYSTEM
Cranks Engine 200 rpm
Rate 60 gpm (227 L/min)
Maximum Pressure 3000 psi (20.7 mPa)
Operational Pressure 2300 psi (15.9 mPa)
Pump Rated Speed 3100 rpm
Minimum Pump Speed 500 rpm
Maximum Pump Speed 3400 rpm
Pump Torque 1260 psi (2.07 Nm)
Pump Temperature Range -40 F to 240 F (-40 C to 115 C)
Reservoir 30 gal (113.6 L)
1.3.2.5 PNEUMATIC SYSTEM
PNEUMATIC SYSTEM SPECIFICATIONS
Maximum Pressure 100 psi (689 kPa)
Operating Pressure 20-100 psi (138-689 kPa)
Temperature Range 40-150 F (4-66 C)
Reservoir 4.5 gal (17 L)
2654258 1-17
1.3.2.6 RADIATOR
RADIATOR CAPACITIES AND SPECIFICATIONS

Configuration Horizontal
Engine Horsepower 2250 bhp (1641 kW)
Engine Speed 1950 rpm
Fan Speed 850 rpm
Fan Horsepower 122 hp (91 kW)
Fan Drive Motor Hydraulic
Maximum Ambient Air Temperature 120 F (49 C)
Jacketwater Rejection 34,200 Btu/min (600 kW)
Jacketwater Rejection Rate 348 gal/min (1317 L/min)
Transmission Cooler Rejection 10,500 Btu/min (184 kW)
Transmission Cooler Rejection Rate 55 gal/min (208 L/min)
Transmission Cooler Maximum Temperature In 275 F (135 C)
Jacketwater/Transmission Heat Rejection Total 49,170 Btu/min (864 kW)
Intercoooler Rejection 28,710 Btu/min (504 kW)
Intercooler Rejection Rate 150 ga;/min (113 L/min)
Intercooler Temperature In 130 F (54 C)
Power End Cooler Rejection 4200 Btu/min (74 kW)
Power End Cooler Rejection Rate 30 gal/min (113 L/min)
Power End Cooler Temperature In 219 F (104 C)
Power End Cooler Temperature Out 180 F (82 C)
Fuel Cooler Rejection 440 Btu/min (44 kW)
Fuel Cooler Rejection Rate 3.5 gal/min (13 L/min)
Fuel Cooler Temperature Out 140 F (60 C)
Hydraulic Cooler Rejection 2500 Btu/min (44 kW)
100 gal/min (50 gal internally
Hydraulic Cooler Rejection Rate
bypassed) (378 L/min)
Hydraulic Cooler Temperature In 180 F (82 C)
Hydraulic Cooler Temperature Out 125 F (52 C)
Hydraulic Cooler Pressure Drop 31 psi (214 kPa)
1-18 2654258
NOTE: For additional component specifications, refer to the vendor

data in the FT-2251 Trailer Mounted Fracturing Unit Parts Catalog.
INTRO
1.3.2.7 TRAILER
The trailer for the FT-2251 is a tandem axle, heavy duty, single drop trailer with INTRAAX
suspension. Some of the trailers more significant features include:
Heavy duty twin beam construction
160,000 lb Holland Mark V landing legs
Air ride suspension
Air type ABS brakes
Running lights for highway use
GENERAL TRAILER SPECIFICATIONS
Overall Length 483.75? (1228.725 cm)
Width 96? (243.84 cm)
2654258 1-19
This Page Intentionally Left Blank
1-20 2654258
CHAPTER 2
OPERATION
2.1 CONTROLS AND INDICATORS
This section contains instructions for safe and effective operation of the FT-2251 fracturing unit.
Keeping Records Records should be kept of all operating parameters while the FT-2251
fracturing unit is in use. These should include date, time, pressures, temperatures, and any
repairs or adjustments made. Data should be recorded at hour intervals. This will ensure that a
discrepancy, such as a gradual drop in oil pressure, can be monitored and repaired before
damage to the engine can occur. Notations of date, time, temperature, and pressures should be
kept at each startup to record any change or degradation of performance.
Control Panels The following tables and illustrations are presented to help the operators and
maintenance personnel become familiar with the operating controls and indicators of the
FT-2251 fracturing unit.
Operating personnel MUST be completely familiar with the con-

trol/indicator definitions in this section before operation.
2.1.1 GAUGE PANEL
Figure 2.1 and Table 2.1 describe the Local Gauge Panel.
Figure 2.1, Typical Local Gauge Panel
2654258 2-1
2.1.1 GAUGE PANEL (Cont)
1 3 5 7
2 4 6 8
Figure 2.1, Typical Local Gauge Panel
Gauges
The local gauge panel is located on the unit. The Figure 2.1 illustration above and following table
describe the location and data range of each gauge.
Table 2.1, Local Gauge Panel
1. ENGINE OIL PRESSURE Gauge

This gauge measures and displays the engine oil pressure. It reads from 0 psi to 160 psi.
2. ENGINE WATER TEMPERATURE Gauge

This gauge measures and displays the engine water temperature. It reads from 20 F to
220 F.
3. PUMP OIL PRESSURE Gauge

This gauge measures and displays the centrifugal pump oil pressure. It reads from 0 psi
to 160 psi.
2-2 2654258
Table 2.1, Local Gauge Panel (Cont)
4. PUMP OIL TEMPERATURE Gauge

This gauge measures and displays the pump oil temperature. It reads from 20 F to
220 F.
5. TRANSMISSION OIL PRESSURE Gauge

This gauge measures and displays the transmission oil pressure. It reads from 0 psi to
400 psi.
6. TRANSMISSION OIL TEMPERATURE Gauge

This gauge measures and displays the transmission oil temperature. It reads from 100 F
to 350 F.
7. SYSTEM AIR PRESSURE Gauge

This gauge measures and displays the system air pressure. It reads from 0 psi to 160 psi.
8. TACHOMETER/HOURMETER
This combination gauge measures and displays the engines rpm and its cumulative
operating hours.
2654258 2-3
2.1.2 REMOTE CONTROL SUITCASE
This units basic functions are controlled through a suitcase containing a touch screen for the
electronic control system. For more information on using the control system, refer to the
description of the touch screen functions that follows the description of the control suitcase
features in table 2.2. The suitcase is described and shown in Table 2.2 and Figure 2.2.
5 6 8 4
7 9
1 2 3
Figure 2.2, Typical Remote Control Suitcase
2-4 2654258
Table 2.2 Control Suitcase Features
1. INTERACTIVE CONTROL TOUCH SCREEN

This digital touch screen provides the operator control of virtually all the function of the
fracturing unit.
2. START Button
This button starts the engine.
3. STOP Button
This button is used to stop the engine under normal circumstances.
4. CONTROL CABLE Interface

This interface allows the operator to connect the suitcase to the unit via a control cable.
5. SERIAL OUTPUT Interface

This interface allows the user to connect the suitcase to an external data acquisition
device.
6. POWER Indicator Light

This indicator light illuminates to indicate that the suitcase power is on.
7. ENGINE Alarm Light

This indicator light illuminates to indicate that the engine is in an alarm condition.
8. TRANSMISSION Alarm Light

This indicator light illuminates to indicate that the transmission is in an alarm condition.
9. PUMP Alarm Light

This indicator light illuminates to indicate that the pump is in an alarm condition.
2654258 2-5
2.2 INSPECTIONS
NOTE: Refer to Chapter 3 for details on inspection procedures.
2.2.1 BEFORE-TRIP INSPECTION
Perform the following inspections before moving the FT-2251 trailer-mounted fracturing unit:
1. Check tire pressure.
2. Check work lights.
3. Check chassis and deck for any damage.
4. Check for loose or damaged components.
5. Check inadequately stowed gear.
6. Check truck brake system.
7. Check field iron inventory.
8. Check any truck to deck connections (pneumatic and electrical).
9. Check all fluid levels and fill if necessary. These include:
Engine oil
Transmission oil
Coolant
Hydraulic reservoir oil
Transmission oil
Pump end lube reservoir oil
Fluid end lube reservoir oil
Fuel tanks (2)
2.2.2 AFTER-TRIP INSPECTION
Always use caution when inspecting equipment. Begin only when

the equipment is shut down, isolated, and tagged OUT OF
SERVICE. Any accidental or poorly timed operation can cause
serious injury to personnel and/or damage to equipment.
2-6 2654258
Perform the following inspections after moving the trailer-mounted fracturing unit, prior to
operating:
1. Check for oil leaks.
2. Check for coolant leaks.
3. Check radiator core.
4. Check for damaged hoses.
5. Check for loose or damaged components.
6. Check for inadequately stowed gear.
7. Check hydraulic system.
8. Check and replenish engine oil, as required.
9. Check and replenish engine coolant, as required.
10. Check and replenish hydraulic fluid, as required.
11. Check and replenish diesel fuel as required.
12. Check transmission fluid.
13. Check pump power end lubricating fluid.
14. Check fluid end lubricating oil level.
2.2.3 BEFORE-OPERATION INSPECTION AFTER OVERHAUL AND STORAGE
Well service fracturing pumps are to be installed and operated in

a horizontal position only. Operation in an extreme inclined position
could cause equipment failure, due to improper oil flow and/or
improperly sealing valves.
All personnel should be located away from the pump while in

operation. Only trained personnel should be around the pump,
especially during service or operation.
Verify the following before operating the unit:
1. All belts are tight.
2. All guards are in place.
2654258 2-7
3. All driveline bolts are torqued.
4. All drivelines and bearings are greased.
5. Triplex pump suction valves open/caps off.
6. Fluid oil tank suction valves open.
7. Fluid tank bypass valves closed.
8. Fuel tank crossover and suction valves open.
9. Hydraulic/pump lube suction valves open.
10. Plungers lubricated.
11. Verify Emergency Kill switch on the control panel has been released by flipping
the toggle switch off (if equipped).
2.2.4 AFTER-OPERATION INSPECTION
1. Verify Emergency Kill switch on the control panel is used to lockout the power unit
from accidental starting during inspection. Tag unit Out of Service.
2. Check for oil leaks, coolant leaks, damaged hoses, and loose or damaged
components.
3. Check and replenish engine oil, coolant, and hydraulic fluid, as required.
4. Check transmission fluid and replenish, as required.
5. Check power end and fluid end lubricating oil level and replenish, as required.
6. Inspect belts, bolts, electrical connections and tighten, as required.
7. Inspect and grease all drivelines and bearings, as required.
8. Close Triplex pump suction valves and replace caps.
9. Close fluid oil tank suction valves.
10. Open fluid tank bypass valves.
11. Close fuel tank crossover and suction valves.
12. Close hydraulic/pump lube suction valves.
2-8 2654258
2.3 OPERATIONAL PROCEDURES
2.3.1 BEFORE-OPERATION ENGINE TEST RUN (OPTIONAL)
NOTE: The power unit should be shut down when beginning Unit
Startup procedure.
1. Verify that Preoperation Inspection is complete.
2. Start hydraulic boost pump and set pressure to 70 psi.
3. Clear the area. Place the gear selector in neutral and start the power unit.
4. Engine will accelerate to 900 rpm for Rapid Engine Warm-up and then move to
idle at 650 rpm.
5. With the unit at idle, perform a walk around visual inspection to check for leaks,
loose items, and operating fluid levels.
6. Set the engine at 950 rpm and monitor for anything unusual (knocks, smoke,
etc.).
7. Set engine at no load speed of 1950 rpm and monitor for anything unusual
(knocks, smoke, etc.).
8. Check all pressure and temperature gauges for proper operating setpoints.
9. Set hydraulics to required pressures.
10. Verify that the radiator fan speed is approximately 680 rpm 10%.
11. Operate the unit with the control panel and monitor for correct speed.
12. Shut down unit.
13. Check all fluid levels and fill if necessary. These include:
Engine oil
Transmission oil
Coolant
Hydraulic reservoir oil
Pump end lube reservoir oil
Fluid end lube reservoir oil
Fuel
14. Perform After-Operation Inspection.
15. Once test run is complete, implement fracturing procedure after all proper
hookups with field iron have been carried out.
2654258 2-9
2.3.2 UNIT STARTUP
NOTE: The power unit should be shut down when beginning Unit
Startup procedure.
1. Verify that Preoperation Inspection is complete.
2. Start hydraulic boost pump and set pressure to 70 psi.
3. With the unit not running, move the control panel Power ON/OFF switch to the
On position.
4. Make sure the Gear Selector indcates the transmission is set to Neutral.
5. Press Start switch on Control Panel until engine starter engages. Engine will
increase immediately to 900 rpm until Rapid Warm-up is complete, then move to
650 rpm idle.
6. Increase engine speed to 1950 rpm and monitor for operational parameters.
Do not allow power unit to exceed 2250 rpm.
7. Verify proper operation of the grease packing lube system.
Insufficient lubrication to the plungers will cause premature

packing and/or plunger failure. The plungers must have a coating
of oil at all times.
8. Press the Gear Selector indicator to Brake position to activate the

transmission brake caliper. Press the Gear Selector indicator to return to neutral
setting and release the brake.
NOTE: The controls will not allow throttle to be increased when the
brake is on. Turn the Gear Selector knob to return to neutral and
allow throttle up.
2-10 2654258
9. Start the power unit. Engine will accelerate to 900 rpm for Rapid Engine Warm-up
and then move to idle at 650 rpm.
10. Commence monitoring the unit for the specified rates and pressures.
11. Set the Over Pressure Trip Point knob to desired limit.
Allow engine to completely warm-up to operational levels before

attempting to pump.
12. Select desired operating rate/gear and throttle up or down by using the Engine
Throttle knob .
NOTE: The controls will not allow a shift from neutral if engine speed
is above 950 rpm. The unit may be shifted at any speed after initial
engagement.
13. Transmission lockup will occur at approximately 1650 rpm.
Operation in converter mode for more than a few minutes at a time

may cause the unit to overheat.
14. Perform Unit Shutdown procedure.
2.3.3 NORMAL SHUTDOWN
Use Emergency Kill switch for emergencies only. This will increase
unit life. The fracturing unit must normally be taken off-line slowly
to allow all components to properly dissipate operational heat.
1. Use the Engine Throttle knob to reduce the engine speed.
2. Turn the Gear Select knob to shift the transmission into neutral or to apply brake
as described above.
3. Allow power unit to cool down for approximately ten minutes at idle speed.
2654258 2-11
Always allow power unit to cool down completely before shutdown.

This will prolong engine life.
4. Press the Stop switch on the control panel. The engine moves to idle and
shutdown after the Caterpillar preset cool down period.
5. Perform Post-Operation Inspection.
2.3.4 EMERGENCY SHUTDOWN (If Equipped)
This procedure is for emergency shutdown situations ONLY.

Normal unit shutdown should always be used in normal operating
situations.
1. Turn the Gear Selector knob on control panel to Neutral to bring the unit off-line
quickly. This brings power unit to idle cool down mode and the transmission shifts
to neutral.
2. In emergency situation, press the Emergency Kill switch on the control panel.
This shuts down power unit immediately by the engine controls cutting off fuel
supply to injectors. The transmission shifts to neutral.
The emergency shutdown air flap is not used in this application so

emergency shutdown may not stop the engine instantly in a
hydrocarbon atmosphere. Even though the engine may still run in
cooldown mode, the transmission is shifted to neutral and the pump
will not develop pressure.
3. If the overpressure shutdown feature is activated while pumping, the engine will
immediately go to idle cooldown and the transmission will shift to neutral.
2-12 2654258
2.4 STARTING AFTER EXTENDED STORAGE/MAJOR OVERHAUL
2.4.1 POWER UNIT ASSEMBLY PREPARATION
Before starting the fracturing unit for the first time, carefully read and follow these instructions.
Follow these procedural steps when starting the fracturing unit after extended transportation or
storage or a major overhaul of one or all of the major components in the system.
Trying to run the fracturing unit before becoming familiar with these
instructions may result in serious damage to the engine and pump.
Cooling System
1. Verify that all of the drain cocks or plugs in the cooling system are installed and/or
closed properly. Unit is shipped with drain plugs installed.
2. Open the cooling system vents, if the engine is so equipped. Refer to Detroit
Diesel vendor data in the FT-2251 Trailer Mounted Fracturing Unit Parts Catalog.
3. Loosen the vents at the top of the thermostat housing.
4. Remove the filler cap and fill the cooling system with fluids recommended in
Detroit Diesel vendor data in the FT-2251 Trailer Mounted Fracturing Unit Parts
Catalog. When system is cold, keep the liquid level of the coolant on centerline of
level gauge located on the top fluid-expansion tank of the radiator.
5. Close the vents, if used, after filling the cooling system.
Lubricating System
6. The lubricating oil film on the rotating parts and bearings of a new or
remanufactured engine, or one that has been in storage may be insufficient for
proper lubrication when the engine is started for the first time.
7. Check the engine lubricating crankcase for proper level and fill, if necessary, with
the recommended grade of lubricating oil. Refer to Detroit Diesel vendor data in
the FT-2251 Trailer Mounted Fracturing Unit Parts Catalog. Use the following
methods to prelubricate a dry engine:
Never dry-fire engine after draining lubricating oil or when engine

has been in storage. Lubricating oil must be present in upper
engine components prior to starting or serious damage could occur.
a. Ensure proper lubrication of upper engine components by cranking engine

over with emergency air-flap closed or fuel solenoid disconnected. Upon
indication of lubricating oil pressure, reset the emergency air-flap or fuel
solenoid valve.
2654258 2-13
b. For engines that have been in extended storage or are being started for
the first time, bar the engine over by hand, making sure the engine rotates
freely. Refer to Detroit Diesel vendor data in the FT-2251 Trailer Mounted
Fracturing Unit Parts Catalog for this procedure. Then disable the fuel
and/or air system by manually tripping emergency air-flapclosed or dis
connecting fuel solenoid and crank engine over. Upon indication of lubri
cating oil pressure, reset the emergency air-flap or fuel solenoid valve.
8. Remove the dipstick, wipe it with a clean cloth, insert and remove again to check
the oil level in the oil pan. Add sufficient oil, if necessary, to bring it to the full mark
on the dipstick. Refer to Chapter 1 for specifications.
If preservative oil has been used in the engine for storage

purposes, it must be drained before bringing the engine into
service.
Do not overfill the lubricating system for any reason.
9. Drain preservative oil from engine crankcase, if used. Reinstall and tighten drain
plug. Fill crankcase to proper level with the recommended grade of lubricating oil.
Refer to the Detroit Diesel vendor data in the FT-2251 Trailer Mounted Fracturing
Unit Parts Catalog. Install new lubricating oil filter elements and gaskets.
Turbocharger
10. After installing a rebuilt or new turbocharger, it is very important that all moving
parts of the turbocharger center housing be lubricated as follows before starting
for the first time:
a. Clean the area and disconnect the oil inlet (supply line at the bearing
center) housing.
b. Fill the bearing housing cavity with clean engine oil. Turn the rotating
assembly by hand to coat all of the internal surfaces with oil.
c. Add additional clean engine oil to completely fill the bearing housing cavity
and reinstall the oil line. Clean off any spilled oil.
Do not attempt to touch the compressor wheel for any reason while
the engine is running as this may result in personal injury.
NOTE: It is not necessary to lubricate the turbocharger if engine

prelube procedure (Step 7 above) has been done before initial startup.
2-14 2654258
Air Filters
11. Check for a good seal on all gaskets, especially the dust cup assembly.
Fuel System
12. Fill the fuel tank with the proper fuel, as specified in to Detroit Diesel vendor data
in the FT-2251 Trailer Mounted Fracturing Unit Parts Catalog. If the unit is
equipped with a fuel valve, it must be opened.
To ensure prompt filling, fill the fuel system at the primary filters. Prime the filter
between the fuel pump and the injectors by removing the plug in the top of the
filter cover and slowly filling the filter with fuel. If there is a non-return valve in the
fuel suction circuit, filling the primary fuel filters will prime the unit from the valve to
the low-pressure pump. Refer to the Detroit Diesel vendor data in the FT-2251
Trailer Mounted Fracturing Unit Parts Catalog for details.
NOTE: The fuel system is filled with fuel before leaving the factory. If
the fuel is still in the system when preparing to start the engine,
priming should be unnecessary.
Lubrication Fittings
13. Fill all grease cups and lubricate all the fittings with a grease as specified in the
Detroit Diesel vendor data in the FT-2251 Trailer Mounted Fracturing Unit Parts
Catalog.
Inadvertent starting could cause death or injury. Deactivate starting system

power and air before performing the following inspection.
14. Check fluid level in the hydraulic reservoir. Replenish fluid through the stainer
mesh cap as required to restore to full level. Use only the approved hydraulic
fluids, refer to Chapter 1 of this manual. Also, refer to the Sauer Danfoss vendor
15. Check oil level in transmission and fill if necessary. Refer to the Allison vendor
16. Check coolant level in radiator. Coolant level should read FULL in sight gauge.
Replenish as needed. Refer to the Detroit Diesel vendor data in the
FT-2251 Trailer Mounted Fracturing Unit Parts Catalog.
17. Check available air pressure.
18. Check fuel level in tank by observing level gauge on tank.
2654258 2-15
The engine should be blown down and cranked over two complete
revolutions with the cylinder test valves open before starting. If
any fluid discharge is observed from any cylinder, find the cause
and make the necessary repairs. This practice should apply
particularly to engines that are approaching a scheduled overhaul
after several years of service, or that have had a history of water
or fuel leaks.
19. Open cylinder test valves, set to the minimum fuel position and crank engine over
two revolutions. Observe for leakage from test valves. Close test valves.
Observe camshaft bearings. If lube oil flows from camshaft

bearings with turbo lube pump running and engine shut down,
inspect turbo filter outlet check valve for proper operation.
Many leaks at fluid fittings are caused by loose fittings and can be
eliminated by simply tightening the fittings. Tapered thread fittings
(pipe fittings) must always have pipe sealant compound or Teflon
tape applied to their male threads before assembly.
2.4.2 PUMP ASSEMBLY PREPARATION
Before starting the fracturing unit for the first time, carefully read and follow these instructions.
Follow these procedural steps when starting the fracturing unit after extended transportation or
storage or a major overhaul of one or all of the major components in the system.
Attempting to run the fracturing unit before becoming familiar with

these instructions may result in serious damage to the engine and
pump.
1. Verify that the pump power end and fluid end tanks are filled with the proper
lubricant.
2. Check connections, reservoir covers, caps and packing nuts for correct
tightness.
3. Check suction dampers for correct charge.
4. Start the power unit and allow engine to accelerate through Rapid Engine Warm-
up until operational temperature is achieved.
5. Set the output power of the power end lube pump and inspect for proper
operation. Minimum pressure at the power end lube should be 40 psi.
2-16 2654258
6. Check for leaks in the system.
7. Regulate the output flow from the fluid end pump and inspect for proper operation.
Fully open the packing lubricator needle valves and rotate triplex pump at no-load.
8. Set the lubricator valves to deliver enough oil to keep the rods lightly covered with
lubricating oil.
NOTE: Engine will accelerate to 900 rpm for Rapid Engine Warm-up
and then move to idle at 700 rpm.
Insufficient lubrication to the plungers will cause premature

packing and/or plunger failure. The plungers must have a coating
of oil at all times.
9. Open the bleed valve and bleed all trapped air from the Triplex pump.
10. Run pump for approximately 30 minutes at 100 strokes per minute at 40% rated
pressure.
11. Run pump at full horsepower through the higher gears for an additional 30
minutes. Monitor for correct operating pressures, temperatures and lube pump
vacuum.
Do not allow power unit to exceed 2000 rpm.
12. Stop power unit and allow fluids to accumulate in the reservoir for approximately
five (5) minutes.
13. Recheck the power end lube reservoir for proper warm mark fluid level.
14. Change pump lubrication filter elements and clean all inlet strainers.
It is vital that the lubrication filters be changed and strainers be

cleaned every 10 hours for the first 100 hours of operation after
the Triplex pump has been overhauled.
2654258 2-17
2.5 TROUBLESHOOTING
This troubleshooting guide is mainly for the operator in the field. It does not cover all possible
causes or remedies of problems. If you, as an operator, encounter problems outside of what is
covered in this chapter, please contact your mechanic or electronic technician.
2.5.1 GENERAL HYDRAULIC PROBLEMS
GENERAL HYDRAULIC PROBLEMS
Problem Cause Action

Components not cleaned properly Service unit again; clean
after servicing components
Inadequate screening in fill pipe Install proper screens in fill pipe
Air breather left off (insufficient Install air filter element in the air
protection of air breather) breather
Dirty Oil Proper gaskets not installed in tank Install correct gaskets in tank
Hydraulic lines (pipes, hoses, etc.)
Install clean plugs in ends of
not covered or protected during
hydraulic lines during servicing
servicing
Improper tank baffles not providing
Install proper baffles in tank
settling basin for heavy materials
Oil filter elements not replaced at Change oil filter elements in a
proper intervals or when indicated timely manner.
Heat exchanger clogged Clean and unclog heat exchanger

Continuous operation at relief valve Reset relief valve higher than
setting operating pressure
Excessive slippage or internal Repair or replace motors and/or
leakage pumps
Tank too small Install a larger tank
System
Overheating Tank assembled with insufficient or Reconstruct the tank with the
no baffling correct baffling
Inside Diameter (ID) of hydraulic Re-plumb system with larger ID
lines (pipes, hoses, etc.) too small hydraulic lines
Insufficient air circulation around Move tank to allow air to circulate
tank freely around it
Raise the setting of the system
System relief valve set too low
relief valve to the proper setting
2-18 2654258
2.5.1 GENERAL HYDRAULIC PROBLEMS (Cont)
Add hydraulic fluid to bring the

fluid to the proper level
Fluid level below cooling coils
Drain water from tank
Close and seal fill port
Fill port left open
Drain water from tank
Water In Oil Replacement fluid cans contain
Get new oil drums
water
Extreme temperature differential in Enclose tank in environmentally
geographical area stable enclosure
Install water drain in lowest point
No water drain in tank
of tank
Remove pipe hydraulic lines, clean

Pipe scale not properly removed the pipe properly, re-install pipe
hydraulic lines
Drain hydraulic fluid from system,
flush system to remove
Sealing compound (pipe dope, contaminants, remanufacture joints
Teflon tape,) allowed to get inside to remove source of contaminants
fittings (start pipe compound or Teflon tape
about two threads from the
opening), refill hydraulic fluid
Foreign Improperly screened full ports and Install proper screening in fill ports
matter in the air breathers and air breathers
circuit Drain hydraulic fluid from system,
flush system to remove burrs,
Burrs inside hydraulic lines
remanufacture joints to remove
burrs, refill hydraulic fluid.
Components and open lines Keep components and open lines
unprotected during repairs free from dirt and moisture
Repair parts and replacement Keep repair and replacement
components not properly protected components protected from dust,
while stored in parts container dirt, and moisture to prevent
contamination from rust, etc.
Reset the compensator to 2800 psi;

Pressure Compensator and relief valve set
set relief valve to maximum and
Surges incorrectly
back off one turn
2654258 2-19
2.5.1 GENERAL HYDRAULIC PROBLEMS (Cont)
Problem Cause Action

Fluid return line to tank not below Fill tank to full line. Lengthen fluid
fluid level return line to bottom of tank.
Broken hydraulic line (pipe, hose,
Repair broken line.
etc.)
Line between bulkhead coupling Install line between bulkhead
and bottom of tank not installed coupling and bottom of tank.
Foaming Oil Inadequate baffles in tank Install proper baffles in tank.
Fluid contaminated with Drain contaminated oil, purge

incompatible foreign material system, fill with new oil.
Air leak in pump suction line Repair pump suction line.
Lack of anti-foaming additives. Add anti-foaming additives to
tank.
2-20 2654258
CHAPTER 3
MAINTENANCE
If the operator has ANY QUESTIONS about the safe use or

maintenance of the unit, ASK THE SUPERVISOR - NEVER GUESS
- ALWAYS CHECK.
3.1 NATURE OF MAINTENANCE

Awareness The nature of maintenance demands operator awareness of the fracturing units
operation. Awareness demands consciousness of abnormalities such as unusual knocks or
smoke. Awareness also demands knowing the fracturing units capabilities and perceiving the
equipments service needs. Being aware can also be described as being watchful, or being alert.
Promptly Corrected Regardless of the method and manner of detection, the potential failure
should be promptly corrected, in order to help avoid a shutdown or a breakdown. The corrective
actions taken or the service rendered constitute maintenance.
3.1.1 ACTIONS
The nature of maintenance calls for actions which will help avoid major repair work. These
actions can be performed at an operator level, and can usually be categorized into (1)
maintenance, (2) treating for corrosion and (3) servicing.
Maintenance The operational level maintenance described in this manual is primarily the action
of checking, adjusting and testing for the proper operation and set points (calibrating), tightening
loose components and determining operational readiness of fracturing unit systems.
Maintenance is also maintaining the proper amounts (levels) of lubricating grease, oil, coolant,
fuel, etc. and cleaning filtration systems/changing filters.
Treating for Corrosion This necessary, ongoing process consists of thorough cleaning,
lubrication, and assurance of protective finish integrity. Fracturing units transported to locations
where high humidity or high temperatures are prevalent, require extra awareness.
Servicing Servicing the unit is performing major repair work such as replacing a gasket or seal,
replacing piping, troubleshooting systems, etc. An example of major electrical repair work is
repairing/ changing wiring, troubleshooting systems, etc. Major repair work can be
accomplished by service-level personnel and by use of OEM manuals in the FT-2251 Trailer
Mounted Fracturing Unit Parts Catalog.
NOTE: While performing service on equipment, refer to the specific

equipment service manuals supplied in the FT-2251 Trailer Mounted
Fracturing Unit Parts Catalog.
2654258 3-1
3.2 SCHEDULED MAINTENANCE

General Instructions Engine, pump, and compressor fluids and lubricants should be checked
before and after each operation. Refill or replace as necessary. Fluid capacities are approximate
based on manufacturers data. Capacities on individual units may vary due to custom changes.
Filters should always be changed with the fluids they protect to ensure long equipment
life and dependability.
Visually inspect all fittings and hoses before and after each operation. Tighten any loose fittings,
and replace any worn hoses as necessary. This will ensure the longevity and dependability of the
unit.
Perform maintenance on items daily, weekly or when the hour meter registers the recommended
scheduled hours of operation.
Guideline Because operating requirements for this fracturing unit will vary, this maintenance
program should be used as a guideline in conjunction with an ongoing operational analysis
program.
3.3 MAINTENANCE INSTRUCTIONS

Table 3.1 Maintenance Procedures Intervals
3.3.1 DAILY MAINTENANCE INSTRUCTIONS
Daily maintenance is operational level service to the unit. These maintenance procedures are
part of the before and after operation checklists and operating procedures in Chapter 2.
NOTE: While performing service on equipment, always park

equipment on level ground. Chock wheels and tag unit, Out of
Service.
Before-Operation Maintenance Tasks
Check Tire Inflation
Procedure
1. Check pressure of each tire:
2. Fill to proper level, as required.
3. Proceed with maintenance or return unit to service.
3-2 2654258
Check Trailer Connections
Procedure
1. Check pneumatic and hydraulic quick-disconnects on the trailer assembly.
2. Verify that hose connect locks are in place and secure.
3. Verify that all electrical interconnections to remote control panel are in place and
secure.
Check Trailer Lights And Battery System
Procedure
1. Check all lights of the trailer assembly, electrical connections, and proper
positioning after being transported.
2. Verify that batteries are in place and connections secure.
3. Verify that all electrical interconnections to remote control panel are in place and
secure.
Check All Guards In Place
Procedure
1. Check all guards of the trailer assembly for secure and proper positioning after
being transported.
2. Verify that bolts and nuts are in place.
Check Hoses And Connections
Procedure
1. Check all hydraulic hoses and connections to manifold and equipment after being
transported.
2. Verify that no hydraulic leakage is visible.
2654258 3-3
After-Operation Maintenance Tasks
Check Fuel System
Procedure
1. Check all fuel hoses and connections of the trailer assembly, including the tank
connections to fuel filter assembly for secure and proper positioning after being
transported.
2. Verify that clamps are in place. Look for any signs of leaks or seepage around
connections.
3. Verify fuel level with fuel tank sight gauge. Fill, as required.
4. Check fuel tank isolation valves for proper positioning.
Check Cooling System
Procedure
1. Check all coolant hoses and connections for secure and proper positioning after
being operated. Make a visual check for cooling system leaks. Look for any signs
of leaks or seepage around connections.
2. Allow system to cool down before opening filler cap.
System under pressure could cause severe injury. Partially open

the filler cap to relieve pressure prior to complete removal of the
cap.
If the cooling system of a hot engine has been drained, do not fill
until the engine cools. A sudden change in temperature may cause
damage to the engine.
3. Verify coolant level with liquid level sight gauge on radiator assembly. Fill as
required.
4. Inspect radiator core for damage or blockage from dirt and/or debris. Check by
shining backlight through coil. A dirty or damaged coil will not allow much light
through fin assembly. Clean as required.
3-4 2654258
Check Engine Oil Level
NOTE: The engine oil level should be checked after that power unit
has been warmed up and has achieved idle operational; level.
Procedure
1. Check engine oil level with the sump mounted dip stick. A dipstick extends from
the side of the oil pan into the oil pan sump.
NOTE: For details, refer to DDC Engine Service and Fluid

Requirements in the FT-2251 Trailer Mounted Fracturing Unit Parts
Catalog.
2. The dipstick should show a level between LOW and FULL. The oil level with the
engine stopped should be above the FULL mark.
3. Verify that oil level is at the FULL mark.
4. Fill as required with the proper type of lubricating oils.
Do not overfill the engine sump at any time or serious equipment

damage can occur.
Use only specified lubricants. Refer to DDC Engine Service Fluid

and Filter Requirements in the FT-2251 Trailer Mounted Fracturing
Unit Parts Catalog.
Check Air System
Procedure
1. Check air intake filters for any large debris in the assembly prefilter.
2. Brush or wipe assembly clean of dust.
3. Check air restriction filter at the sleeve of the intake assembly for proper operating
range. The gauge has a readable indicator for element replacement. The
maximum allowable air cleaner restriction is 20 inches of H2O (5.0 kPa).
Do not operate the power unit with a dirty air intake system or
serious equipment damage can occur.
2654258 3-5
Clean The Unit
Procedure
1. Flush mixing tanks with fresh water and thoroughly clean mixing assemblies with
brushes, brooms, etc. Drain off the tank bilge into proper containers for disposal.
2. Spray down unit with water and brush off dirt and debris. Carefully clean up any
corrosive material accumulated on the piping and manifolds.
Never use diesel fuels as a cleaning agent as they are highly

flammable and can cause equipment damage.
3. Use centrifugal pump to circulate fresh water through the system. Continue until
water exiting the manifold is relatively clear of debris and slurry remnants.
4. Wipe down all exposed controls, indicators, and gauge panel.
3.3.2 WEEKLY MAINTENANCE INSTRUCTIONS
Check Hydraulic Fluid Level
Procedure
1. Check hydraulic fluid level with the reservoir-mounted indicator gauge.
2. Verify that oil level is at the FULL mark.
3. Fill as required with proper type hydraulic fluids.
Do not overfill the hydraulic reservoir at any time or serious

equipment damage can occur.
Use only specified fluids.
3-6 2654258
3.3.3 QUARTERLY MAINTENANCE INSTRUCTIONS
Quarterly Maintenance intervals are determined as approximately 500 hours of operation. It is for
this reason that unit operating durations and parameters are monitored and recorded. These
procedures are listed as a guideline for determining the best service interval.
Replace Air Cleaner Elements
1. Service these aircleaners when the maximum allowable air restriction has
been reached; or annually, whichever occurs first. Under no engine operating
conditions should the air inlet restriction exceed 20 in/H2O (5.0 kPa).
2. Remove air inlet outer housing from the air intake assembly.
3. Remove dirty element from the inner housing.
4. Wipe down housing and remove any debris accumulated around element gasket.
5. Insert new element into housing. Ensure that the element is properly seated
against the housing gasket assembly.
6. Replace the outer housing cover and tighten by hand only.
Replace Engine Oil and Filters
Procedure
After draining and refilling the lube oil system it is imperative that
the strainer housing be filled with oil before starting the engine.
Failure to do this may result in serious engine damage.
1. Drain lube oil while still warm to remove suspended debris in oil.
2. Remove the spin-on filter cartridge using a strap wrench and a 1/2 drive socket
wrench and extension.
3. Clean the filter adapter with a clean, lint-free cloth.
4. Lightly coat the filter gasket (seal) with clean engine oil.
5. Start the new filter on the adapter and tighten by hand until the gasket touches the
mounting adapter head. Tighten an additional two-thirds turn.
6. Add oil as required to bring the level to the full mark on the dipstick.
7. Start and run the engine for a short period and check for leaks. After any leaks
have been corrected, stop the engine long enough for oil from various parts of the
2654258 3-7
engine to drainback to the crankcase (approx. 20 minutes). Add oil as required to

bring the level to the proper mark on the dipstick.
Replace Fuel Filters
Primary Fuel Filter
Series 4000 engines use spin-on type fuel filters consisting of a shell, element, and gasket
unitized into a single cartridge and a strainer or filter cover which includes a threaded sleeve to
accept the spin-on filter cartridge.
1. With the engine shut down, close fuel shutoff valve. Place a suitable container
under the strainer or filter and unscrew the cartridge. Dispose of the cartridge in
an environmentally responsible manner.
2. To improve engine starting, have replacement elements filled with fuel and ready
to install immediately after used elements are removed.
3. Install the new fuel-filled cartridge and tighten by hand until the gasket touches the
mounting adapter head. Tighten an additional three-quarter turn.
4. Open the fuel shutoff valve. Start the engine, and check for leaks.
For more information on replacing the oil filters, refer to the DDC Series 4000 Operators Guide
in the FT-2251 Trailer Mounted Fracturing Unit Parts Catalog.
Do not overtighten as this may cause distortion or cracking of the

filter adapter.
5. Correct any leaks with the engine off.
Check Fuel Tank
1. Open the drain at the bottom of the fuel oil day tank to drain off any water
and sediment.
2. Ambient temperature changes can cause condensation in partially filled fuel oil
tanks. Water accumulation can be controlled by keeping the fuel tank filled and , if
required, the use of some fuel additives as recommended in DDC Engine Service
Fluid and Filter Requirements in the FT-2251 Trailer Mounted Fracturing Unit
Parts Catalog.
3. Microbe growth can be eliminated through the use of some commercially

available biocides. Refer to DDC Engine Service Fluid and Filter Requirements
in the FT-2251 Trailer Mounted Fracturing Unit Parts Catalog.
3-8 2654258
NOTE: Keep the fuel tank filled to reduce condensation to a

minimum. Select the proper grade of fuel oil as specified in DDC
Engine Service Fluid and Filter Requirements in the FT-2251 Trailer
Mounted Fracturing Unit Parts Catalog.
Check Coolant System
Take a sample of the coolant at least every 700 hours of operating time, and have a
complete analysis run to determine needed additives.
Flushing and Refilling Radiator
1. Clean the cooling system every 4000 hours or two years of operational service.
2. Use a good radiator cleaning solution designated as an inner coil cleaner/flushing

agent and use in accordance with the instructions on the container.
3. After the cleaning operation, flush the cooling system with soft water, adding a
good grade of rust inhibitor or a high boiling point type antifreeze.
4. When a thorough cleaning of the cooling system is required, it should always be

reverse flushed for maximum cleansing effect on the coolant galleries and lines
Radiator
1. Inspect the exterior of the radiator core every 700 hours and, if necessary, clean it
with a quality grease solvent that is designated for use as a coil cleaner.
2. Direct the solvent through the fin assembly in the opposite direction of the normal
air flow.
3. Dry with compressed air in the same manner.
Do not use fuel oil, kerosene, or gasoline as a solvent.
4. Service personnel should be aware that periodic cleaning intervals will depend on
the individual units operating conditions and ambient environment and should
adjust the cleaning /maintenance regime accordingly. In certain types of service,
deposits will form more rapidly than others. Heavy deposits will cause an
increase in the pressure drop through the heat exchanger and a decrease in the
cooling effect. Cleaning intervals can be shortened or lengthened depending on
the characteristics of the site, once the personnel have established the optimum
time frame.
2654258 3-9
Hydraulic System
Change the hydraulic fluid every 250 hours of unit operating time, or every three
months. For normal operating temperatures, use AW32 hydraulic fluid for the
system. For cold temperature operation, use all temperature AW32 or Dextron III
hydraulic fluid. For the hydraulic pump drive in all temperatures, use Silver Streak
#200 fluid.
1. Drain old fluid from the hydraulic reservoir.
2. Check strainer screens when changing the hydraulic fluid and clean, if necessary.
3. Check and clean the filter assembly when changing the hydraulic fluid.
4. Add new fluid through the strainer/filter assembly.
5. Operate the unit without load until warm. Recheck fluid level with reservoir sight
glass.
The hydraulic reservoir should only be refilled by pouring the new

fluid through the filter/strainer assembly and not directly into the
hydraulic reservoir. DO NOT OVERFILL.
Inspect Fan Bearings
1. If the fan bearing hub assembly is provided with a grease fitting, use a hand-held
grease packing gun and lubricate the bearings with one shot of Texaco Premium
RB grease or an equivalent lithium base multipurpose grease every 700 hours of
operational service or 2 to 3 months of service.
2. The operating temperature of the bearing may indicate how much lubrication is
required. Normal temperature of the bearing may range from cool to warm to the
touch, up to the point of too hot to touch for more than a few seconds;
depending on the bearing size and speed and the surrounding ambient
conditions.
3. Unusually high temperatures accompanied by excessive leakage of grease

indicates too much grease. High temperature with no grease showing at the
seals, particularly if the bearing seems noisy, usually indicates too little grease.
Normal temperature and a slight indication of grease at the seals indicates
proper lubrication levels.
4. Every 2500 hours of operational service; clean, inspect, and repack the fan
bearing hub assembly with the above recommended multipurpose grease.
3-10 2654258
Engine Intake and Exhaust
1. Inspect the mountings, intake, and exhaust ducting, and connections for tightness
and possible leaks.
2. Check the oil inlet and outlet lines for leaks and corrosion causing restrictions to
the oil flow.
3. Check for unusual noises or vibrations and, if excessive, remove the turbocharger
assembly and correct the cause (starting with the gaskets).
NOTE: It is not recommended or practical to attempt any recondition-

ing of the turbocharger in the field. It is recommended that it be re-
turned to DDC for service. However, if this is not possible, refer to the
DDC Series 4000 Service Manual in the FT-2251 Trailer Mounted
Fracturing Unit Parts Catalog.
Control System
1. With the DC potential disconnected, the control cabinet and panels should be
blown out with air and/or wiped clean inside and out.
2. A light coat of a corrosion-preventive spray solution is recommended on

unpainted/untreated surfaces. A non-oil base cleaner/lubricant spray is
recommended as an oil base spray will eventually fog the glass covers on the
gauges/indicators, making them unreadable.
3. Inspect for any loose components, terminal screws, and soldered connections.
This inspection is especially beneficial for the local control panels and electrical
enclosures which are constantly exposed to vibration from the engine.
4. Inspect the vibration absorbing neoprene panel and cabinet mounts for elasticity
and resiliency. If hardened or cracked, replace immediately.
3.4 CORROSION CHECK

Treating for corrosion before it becomes a problem is a necessary, ongoing process. A weekly
inspection for corrosion damage consists of thoroughly cleaning and preserving or lubricating all
exposed metal surfaces. The fracturing unit is sealed with several coats of industrial sealant
paint but this protective shell can breakdown at vibration sensitive areas or places exposed to
extreme heat for long periods of operation. Inspection for signs of rust should always be
conducted and ongoing during the course of routing maintenance procedures.
When the unit is not in service, every precaution should be taken against corrosion.
2654258 3-11
3.5 SERVICING
Any repairs or service (routine maintenance) performed on the

mixer must be performed by a trained service technician who is
qualified to work on reciprocating and centrifugal pumps. All such
service and repairs must be supervised by qualified management
personnel and only S&S replacement parts should be utilized.
When working on the mixer, safety glasses, approved safety shoes

and hardhat must be worn. Hammering on any part or component
may cause foreign material or steel slags to become airborne.
It is a personal responsibility to use the proper tools when servic-

ing the mixer. Any special tools required are furnished with the
mixer when new, and should be kept with the pump for its routine
maintenance. It is a personal responsibility to be knowledgeable
and trained in the use and handling of these tools for all mainte-
nance of the mixer. A mixer is made up of internal and external
moving parts.
Servicing the unit is performing major repair work such as replacing a major component and/or
or seal, replacing piping, troubleshooting systems, etc. An example of major electrical repair
work is repairing/ changing wiring, troubleshooting systems, etc.
Major repair work can be accomplished by service-level personnel and by use of OEM manuals
available from Stewart & Stevenson.
3-12 2654258
3.6 ENGINE SPARE PARTS LIST

ENGINE SPARE PARTS LIST
12V4000, 2250BHP at 1950 rpm T1237K39
Group Group Description
06A01 0929 BLK CYL 0.00LNR TABBED BRG STD OD LINER
06A01B0231 CVR CYL INSPECTION PORT 12V S4000
06A01D0014 TOP VALLEY COVER SINGLE PASSAGE INDUSTRI
06A02 0502 HEAD CYL 200 BAR HIGH SWIRL 12V S4000
06A02A0007 CYL HEAD ATTACHING HARDWARE 12V S4000
06A05 0370 ENGINE LIFTER BRACKET 8V/12V/16V S4000
06B00 1181 HSG FLYWHL WET 12V/16V S4000
06C01 0188 CRANKSHAFT RH ROT HIPO INDUSTRIAL 12V S4
06C01B0025 CRANKSHAFT MAIN BEARING RILLEN/SPUTTERED
06C01C0005 CRANKSHAFT REAR HUB WET FWH DDEC IND 12V
06C01E0003 CRANKSHAFT FRONT HUB 8V/12V/16V S4000 03
06C01F0001 CRANKSHAFT SEAL FRONT 8V/12V/16V S4000
06C01H0007 CRANKSHAFT LOCK TRANSPORT WET FLYWHL HSG
06C02 0305 DAMPER VIBRATION W/DUST RING ASM W/GUARD
06C03 1414 FLEX PLATE ASM HYDRO-FRAC W/ALLIS TRANS
06C03A0057 ADAP FLYWHL HSG HYDRO-FRAC 12V/16V S4000
06D00 1169 PISTON ASM 13.7:1 12V CARBON SCRAPER S40
06D01 0006 CONNECTION ROD ASM & BEARINGS 038.0-010.
06E00 0879 PAN OIL NPTF PORTS CAST ALUM 12V S4000
06E01 0070 SIGHT GAUGE CAST CONSTANT DEPTH ONLY 16V
06F01 0332 PUMP ASM & MTG HDW ENG OIL 12V/16V4000 3
06F02 0053 OIL PRESSURE REGULATOR S4000
06G01 0870 SYS OIL DIST FOR CAST ALUM OIL PANS 12V
06G03 1343 CLR OIL & HSG 30 PLT INDUSTRIAL S4000
06G04 1429 OIL LVL GAUGE SHORT STATIC W/FILL CAST O
06G05 0838 OIL FILTERS VERTICAL MT W/BRACKET S4000
06G05A0004 FILTER OIL CENTRIFUGAL SPINNER INDUSTRIA
06G05B0002 PISTON CLG OIL DIST SYS 12V S4000
06G09 0004 OIL DIST TURB INDUSTRIAL 12V/16V S4000
06H00 1240 BREATHER ENGINE 12V/16V S4000
06J00 0327 CVR ENGINE GEAR HSG INDUSTRIAL S4000
06K01 2234 TRUNNION MOUNTING W/O FAN 12V/16V S4000
06K01A0515 PUL CRSHF D238.76 PL 12V/16V S4000
06K01BNONE BELT FAN 00000000 W00 0 L00000 NONE
06K02 0401 PMP ENG WTR 16V4000
06K02A0717 CONN WTR HIGH TEMP CIRCUIT 12V/16V S4000
06K03 0266 WATER MANIFOLD INDUSTRIAL 12V S4000
06K05 0008 PMP WTR LOW TEMP CIRCUIT 12V4000
06K06 0006 COOLANT DISTRIBUTION HOUSING HYDROFRAC 1
06K06A0008 THERMOSTAT DUAL LTC W/SUPP HEAT S4000
06L00 0862 MANIF EXH DRY 12V S4000
06M04 0347 PUMP FUEL HIGH PRESSURE 12V/16V IND/GENS
06M04B0003 PUMP FUEL LOW PRESSURE DDEC 12V/16V S400
06M05 0025 FUEL LINES DBL WALL HI PRESS & SLEV RAIL
06M06 1146 INJ DDEC 23526589 12V4000
06M07C2417 TURB BTV7507 1.08A/R 60HZ/C&I HI ALT GAS
06M07D0063 CHARGE AIR CLR & WAT PIPING HOSE CONN 12
06M07E0012 MANIFOLD INTAKE INDUSTRIAL 12V S4000
06M07F0012 CHARGE AIR PIPING HOSE CONN 12V4000 IND
06M09 2596 FLTR & HOSES ENG MT INCL PRO 40 REM IND
06M09A0022 FUEL LINES LOW PRESS & RETURN IND 12V S4
06M10B6003 BOXED PTS S/L COOL LVL SEN
06N04 3793 DDEC CONTROLS WET FLYWHL HSG IND 12V S40
06N04C0749 APPL DDEC C&I MECH DRV HYDROFRAC S4000 &
06N04D0500 CALIB 2250HP@1900RPM 12V4000 FRAC
06N04M1373 2250HP@1900RPM 5412 00-00 12V4000 6350 F
06N05 0001 ECM DATA PAGES ACTIVATED NO OPTMZD IDLE
06Q00 0612 MT ENG FRT TRUNION INDUSTRIAL S4000
06Q01 0068 SHPG STAND & ENG SKID MTG HDW FRT TRUN I
06T00 1999 CMPR AIR 13 CFM S4000
2654258 3-13
3.6 ENGINE SPARE PARTS LIST (Cont)

Group Group Description
06X01A0648 GEAR TRAIN 'G-1' LVL BLK S4000
06X01C0003 CAMSHAFT ASM 12V S4000
06X01D0002 CAMSHAFT DRIVE/THRUST BEARING DDEC SRS 8
06X01F0005 PUSHROD ASM 54.0-010.010/020 12V4000 M90
06X01G0007 ROCKER ARM & PEDESTAL SWING ARM DBL VLV
06X03 0250 VALVE OPERATING SETTINGS/VALVE LASH S400
06X03A0759 CVR VLV RKR 12V4000
06X04 0627 DRV HYDRAULIC PUMP ASM 8V/12V/16V S4000
06Y01 2803 GEN CHRG AC24V100A B-BANK NO GUARD IND S
06Y02ANONE MTR ELEC NON
14B07 0789 PLT NA 50S 2002 12V4000 NON-ROAD CERT ST
14B09 0004 BOXED PARTS FTGS & ADAPTOR S4000
16P00D2027 SKID DOMESTIC 8V MAR W/DIR MT GEAR & 12V
17P00BNONE BAG SHIPPING NONE
24T00 0008 ENGINE TEST SPEC S4000 STD RUN
35 00 2623 DWG INSTAL COMPL U T1237K39 S4000
53T00 0057 PA PRIMER 12V4000
57T01 0004 SPEC ENGINE PREP SIX MONTHS
70R00U0009 RUNOUT FLYWHL/FLYWHL HSG & ADAP FLXPT BO
3-14 2654258
CHAPTER 4
DRAWINGS
4.1 DRAWING LIST
This section contains the mechanical and electrical drawings required to operate the system,
equipment, and components of the trailer-mounted fracturing unit manufactured by Stewart &
Stevenson. Table 4.1 drawing list contains, in this section, schematic, assembly, and installation
drawings relevant to your equipment. These drawings are correct and are the latest as-built
revisions at the time of publication. Updated drawings will be sent as revisions, as determined
necessary by Stewart & Stevenson.
Table 4.1
Drawing Revision Description Number

Number of Pages
020871 A Assembly, Fan Drive, FT-2251 IEA Radiator 1
020874 E Assembly, Trailer Sub Assembly, Frac, 12V4000 1
020879 Assembly, Gauge Panel, Frac 1
020948 J Installation, Electrical, Frac 1
020949 K Schematic, Electrical 1
020951 G Assembly, Control Suitcase 1
021084 C Assembly, Power Unit, 12V4000 1
021415 Schematic, Hydraulic, Frac Wet Kit 1
041266 Schematic, Pump End Lube 1
041514 Schematic, Hydraulic Start, FT-2251 1
041516 Schematic, Fan Drive, FT-2251 1
041517 Schematic, Pneumatic 1
041519 Schematic, External Transmission Cooling 1
050342 Assembly, Piping, Discharge, Frac 1
2654258 4-1
Table 4.1 (Cont)
Drawing Revision Description Number

Number of Pages
050498 Assembly, Pump, Triplex 1
050534 Schematic, Fluid End Lube, Air/Oil, TWS2250 Triplex Pump 1
4-2 2654258
8 7 6 5 4 3 2 1
REVISIONS
NOTES: UNLESS OTHERWISE SPECIFIED ZONE LTR
A
DESCRIPTION
PER ECN #2311008

DATE
01/03
APPROVED
B.P.
1. BOLT THROUGH TRAILER WEB.
B PER ECN #2311320 04/03 B.P.
C PER ECN #2312344 04/03 B.P.
D PER ECN #2312914 11/04 B.P.
E PER ECN #2313254 03/05 B.P.
D D
35 3/16 35 1/2 32 1/16
9 2X
C 8 NOTE 1 12X C
4 1/2
4 1/2
11 350 1/4 52 3/4 52 3/4
1 NOTE 1 2X 10 6 2X
9
49 16 1/2
9 3/4 6 3/16
2X 7
63 5/16
52 5/16
REF 2
B 4 REF B
5 REF
6 REF
18 403
483 3/4
Parts List
REF ITEM QTY PART NUMBER MATERIAL DESCRIPTION
1 1 23020853 WELDMENT, TRAILER
2 REF 249147 LANDING GEAR, 16.5" TRAVEL
3 REF TS000208 WHEEL/TIRE, ALUMINUM
4 REF TS000261 SUSPENSION/AXEL HENDRICKSON AA300EDL INTRAAX
6 2 1279 FENDER, REAR, 25-1/2" W x 111" LG

7 2 249105 FENDER,REGULAR FRONT, 25 1/2"W X 139" LG, SMOOTH
D 8 12 23041319 WELDMENT, MOUNT, FENDER
UNLESS OTHERWISE SPECIFIED TREATMENT
STEWART & STEVENSON SERVICES
A 1. TOLERANCE
INCHES
TOLERANCE
MILLIMETERS
INCHES
EQUIV. FINISH
P.O. BOX 1637 HOUSTON, TEXAS, U.S.A. A
.XX = .03 X. = .8 .0315
.XXX = .010
2. FRACTION 1/16
.X = .3 .0118 TITLE
ASSEMBLY, TRAILER, SUB-ASSEMBLY,
3. ANGULAR 0.5 CALC. WT ACT. WT. FRAC, 12V4000
4. ALL DIMENSIONS ARE IN
INCHES OR INCHES [MILLIMETERS].
5. TOLERANCES ARE NON-ACCUMULATIVE. DRAWN DATE DESIGN ACTIVITY DATE SIZE FSCM NO. DWG NO. REV
J. ROBISON 11/04 B. PARR 11/04
D 81381 020874
6. MACHINED INSIDE CORNERS 0.02 R MAX.
NEXT ASSY USED ON

7. INTERPRET DWG. PER ANSI Y 14.5M. CHECKED
B. PARR
DATE
11/04
CUSTOMER DATE
E
DESIGN DATE CONTRACT NO. DATE RELEASE DATE SHEET
SURFACE 125 REMOVE BURRS DO NOT SCALE SCALE OF
APPLICATION
FINISH AND SHARP EDGES J. ROBISON 11/04 DRAWING 1/24 1 1
8 7 6 5 4 3 2 1
1
14 1
3
3 8
4
1
2
3
4
3
8 1 1
14
3
4
1
14
1
12
8 7 6 5 4 3 2 1
REVISIONS
ZONE LTR DESCRIPTION DATE APPROVED
74 1/4
D D
TO PUMP
22
C C
32 3/4
B 3
B
4
3 16 3/8
5 2
Parts List
REV ITEM QTY PART NUMBER MATERIAL DESCRIPTION
1 1 204113 SWIVEL, 3" STYLE 10, FIG. 1502, M x F
3 2 204111 SWIVEL, 3", STYLE 50, FIG. 1502, M X F
4 1 204117 JOINT, PUP, 3" x 36", FIG. 1502, M x F
2 1 204116 JOINT, PUP, 3" x 30", FIG. 1502, M x F
5 1 204296 VALVE, CHECK, 3", FIG. 1502, M x F, TOP ENTRY
A 1. TOLERANCE
INCHES
TOLERANCE
MILLIMETERS
INCHES
EQUIV. FINISH
.XX = `.03 X. = `.8 .0315
.XXX = `.010
2. FRACTION `1/16
.X = `.3 .0118 TITLE
ASSEMBLY, PIPING, DISCHARGE
3. ANGULAR `0.5~ CALC. WT ACT. WT.
THIS DRAWING CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION OF STEWART & STEVENSON J. ROBISON 04/05 B. PARR 04/05
D 81381 23050342
SERVICES OF HOUSTON, TEXAS AND IS LOANED IN CONFIDENCE WITH THE UNDERSTANDING THAT IT WILL
NOT BE REPRODUCED NOR USED FOR ANY PURPOSE EXCEPT THAT FOR WHICH IT IS LOANED AND SHALL BE
7. INTERPRET DWG. PER ANSI Y 14.5M. CHECKED DATE CUSTOMER DATE -
NEXT ASSY USED ON B. PARR 04/05
RETURNED ON DEMAND SURFACE REMOVE BURRS DESIGN DATE CONTRACT NO. DATE DO NOT SCALE SCALE RELEASE DATE SHEET OF
APPLICATION 125
FINISH AND SHARP EDGES J. ROBISON 04/05 DRAWING 1 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
ZONE LTR DESCRIPTION DATE APPROVED
D 5 D
C C
3 6
B B
Parts List
REV ITEM QTY PART NUMBER MATERIAL DESCRIPTION
1 REF PUMP, TRIPLEX
2 1 23050542 WELDMENT, DRIP PAN, GARDNER DENVER TRIPLEX
3 1 23000978 DETAIL, PONY ROD COVER
4 1 23050342 ASSEMBLY, DISCHARGE PIPING
5 1 23050445 ASSEMBLY, PIPING, SUCTION
6 2 23940001 LEXAN, 15" X 16" X 1/2"
A 1. TOLERANCE
INCHES
TOLERANCE
MILLIMETERS
INCHES
EQUIV. FINISH
.XX = `.03 X. = `.8 .0315
.XXX = `.010
2. FRACTION `1/16
.X = `.3 .0118 TITLE
ASSEMBLY. PUMP, TRIPLEX
3. ANGULAR `0.5~ CALC. WT ACT. WT.
THIS DRAWING CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION OF STEWART & STEVENSON J. ROBISON 05/05 B. PARR B. PARR
D 81381 23050498
SERVICES OF HOUSTON, TEXAS AND IS LOANED IN CONFIDENCE WITH THE UNDERSTANDING THAT IT WILL
NOT BE REPRODUCED NOR USED FOR ANY PURPOSE EXCEPT THAT FOR WHICH IT IS LOANED AND SHALL BE
7. INTERPRET DWG. PER ANSI Y 14.5M. CHECKED DATE CUSTOMER DATE -
NEXT ASSY USED ON B. PARR 05/05
RETURNED ON DEMAND SURFACE REMOVE BURRS DESIGN DATE CONTRACT NO. DATE DO NOT SCALE SCALE RELEASE DATE SHEET OF
APPLICATION 125
FINISH AND SHARP EDGES J. ROBISON 05/05 DRAWING 1/16 1 1
8 7 6 5 4 3 2 1
Fracturing Unit
Parts Catalog
OEM
Original Equipment Manufacturer
MKT# 2654258
Stewart & Stevenson Well Servicing Products

10750 Telge Road
RECORD OF REVISIONS
Property of:
Company:
Address:
Revision Data
Stewart & Stevenson assumes no liability for personal injury or equipment failure due to any
operation performed without heed to manual revisions.
Date of original publication: July 2006
2654258 i
COPYRIGHT NOTICE

This manual contains the confidential and proprietary information of Stewart & Stevenson.
Neither this document nor any information contained herein may be reproduced or redistributed in any
form whatsoever without the express, written consent of an authorized agent of Stewart & Stevenson.
Any attempt by any person other than an authorized agent of Stewart & Stevenson to alter the contents of
this manual in any way shall be construed as copyright infringement, punishable by all applicable laws.
All vendor literature contained in this manual is the copyrighted property of the respective vendors,
protected by the same laws governing this operation and maintenance manual.
Copyright 2006 by Stewart & Stevenson. All rights reserved.
2654258 ii
ABOUT THIS MANUAL
This manual is intended as a Parts Catalog for referencing the OEM vendor manuals and/or catalogs for
in-depth service procedures and parts listings. This manual is not intended as an operation or
maintenance manual. The intent of this manual is to guide the service personnel in the proper repair
and/or service for the various components and assemblies of the equipment as manufactured by Stewart
& Stevenson.
No liability, either express or implied, is given for any information contained herein. This manual is
intended only as a guide, and not as a substitute for proper training by qualified personnel.
Stewart & Stevenson assumes no responsibility for improper use of equipment, improperly trained
personnel, improperly maintained equipment, or failure to follow normal safety precautions outlined in this
manual, in the vendor literature, or by properly trained personnel.
Use of this manual for any purpose other than for the safe and proper maintenance of the equipment and
all its components constitutes misuse, and is punishable by all applicable laws.
If there is any discrepancy between information contained in the operators manual and the vendor
literature, the vendor literature is assumed correct. Stewart & Stevenson assumes no liability whatsoever
for any person who fails to follow the operation and safety procedures of the original equipment
manufacturers.
Please read through this manual in its entirety before attempting to service the equipment. Stewart &
Stevenson assumes no liability for failure to do so.
OEM manufacturers literature is divided by numbered tabs. Components are arranged with primary
components first, if any, then alphabetically by manufacturers name. Some tabs contain more than one
set of vendor data sheets and/or manuals for that particular vendor. These different sets of data are listed
with separate descriptions and separated by blank blue sheets for your convenience.
All information in this manual is based on the latest production information available at the time of
publication. Direct any questions concerning the contents or format of this manual to:
Stewart & Stevenson
581 Garden Oaks

Phone: (713) 803-0700
Fax: (713) 803-0721
Email: tech-solutions@ssss.com
2654258 iii
UNIT IDENTIFICATION
To aid the technician in repair or service work on this unit, a Stewart & Stevenson identification
nameplate, similar to that shown below, is located on the frame of the equipment.
The serial number identification of each unit will appear on the nameplate (as shown above) along with
the date of manufacture. The mailing address of Stewart & Stevenson, telephone number, telex number,
and cable information are all located in the middle of the nameplate on either side of the Stewart &
Stevenson logo. This necessary information will ensure the customer a fast and accurate response to
any parts and/or service request.
Please verify the serial number on the units identification nameplate and
ENTER YOUR UNIT SERIAL NUMBER HERE:

If applicable,
ENTER YOUR COMPANY IDENTIFICATION NUMBER HERE:
TECHNICAL ASSISTANCE
For parts or warranty assistance, wire, write, or call:

Stewart & Stevenson
10750 Telge Rd.
For Parts: 281-345-5100; ask for Parts Department.
For Service: 281-345-5100; ask for Warranty Department.
Be sure to list the equipment model number, rating, specific nature of the problem, and the suspected
area of malfunction.
Do not use the Operators Manual to order parts. If parts or maintenance are
needed, please refer to the Parts Catalog or the appropriate component supplier.
2654258 iv
2006 Stewart & Stevenson Parts Catalog
Fracturing Unit
1.1. VENDOR LIST
Vendor information contained in this section pertains to each manufacturers major component or
assembly for the trailer-mounted fracturing unit, as built by Stewart & Stevenson.
Table 1.1 lists the major vendors in this section in alphabetical order. Some tabs contain more
than one set of vendor data sheets and/or manuals for that particular vendor. These different
sets of data are listed with separate descriptions and separated by alphabetical tabs for your
convenience.
Table 1.1 Vendor Publications
Tab Vendor Description
1. Allison Transmission A. Manual OM2034EN: 5000, 6000, 8000, 9000

Electronic Controls Off-Highway Series Transmissions
Operators Manual (May 1999)
B. Manual SM1833EN 9000 Series Off-Highway

Transmissions Service Manual (March 2000)
C. Manual PC1830EN: 9000 Series Off-Highway

Transmissions Parts Catalog (August 2002)
2. Amot Controls Form 936: Model B Thermostatic Valves
3. Circle Seal Controls Bulletin CSC-489-L: 2300 Series Check

Valves 0 to 10,000 PSIG (October 1996)
4. Chelsea Bulletin HY25-1135-M1/US [Supersedes HY25-1135-

M1/US (October 2003)]: Owners Manual Power Take-
Offs (December 2003)
5. Deltrol Data Sheets: Flow Control, Needle and Check Valves
2654258 TOC-1
Parts Catalog 2006 Stewart & Stevenson
Table 1.1 Vendor Publications (Cont)

6. Dennison Hydraulics Manual Publication No. 3-EN2850-A: Pressure

ControlsFlanged Type, Series R5 with 2 ports
7. Detroit Diesel A. Manual 6SE4009: MTU/DDC Series 4000 Operators

Guide (March 2000)
B. Manual 6SE4011: MTU/DDC Series 4000 12V/16V

Service Manual (August 2002)
C. Manual 6SE496: Detroit Diesel DDEC Multi ECM

Troubleshooting Manual (December 1999)
D. CP Catalog: Series 4000 Custom Parts Catalog

(2000)
E. Bulletin A001061/27E: Fluids and Lubrications

Specification (All MTU Series and Common Engines)
(March 2001)
F. Bulletin 7SE398: Used Lube Oil Analysis Technicians

Guide (June 1997)
8. Dodge (Rockwell Data Package: Paraflex Couplings Sales Sheets,

Automation) Selection Data, Engineering and Technical Data, etc.
9. Donaldson A. Data Sheets 000644: HMK04 Series Hydraulic Filters
B. Data Sheets 000645: HMK05/25 Series Hydraulic

Filters
10. Eaton Spicer Troubleshooting Guidelines 3119-SSDD: Spicer

Driveline Components (April 1994)
11. Eaton Vickers A. Service Data Book I-3892-S: Solenoid Controlled Pilot
Operated Directional Valve (May 1991)
TOC-2 2654258

11. Eaton Vickers (Cont) B. Technical Catalog 591: DG5S-8 and DG5SH8 Two-
Stage, Solenoid Controlled, Pilot Operated, Four-Way
Directional Valves (November 1994)
12. FMC A. Catalog: Flowline Products and Services: World

Proven Chiksan and Weco Equipment
B. Data Sheet: Chiksan Lubricants
C. Data Sheet: FMC Integral Fittings (1998)
D. Operating and Maintenance Instructions: Chiksan

Longsweep Swivel Joints (1984)
E. Repacking Instructions Form No. 50052: Chiksan

Swivel Joints, All Longsweep Models Standard
Service (February 1997)
F. Repacking Instructions Form No. 50098: Chiksan

Swivel Joints, Longsweep Triplestep Models with
Straight Bore Seal (TS) Standard Service (May 1998)
G. Safety & Technical Alert TA012 Rev A: Avoiding the

Dangers of Mismatching Swivel Joint Components
(March 2005)
H. Operating and Maintenance Manual OMS500000435

Rev A: TripleStep Swivel Joint
I. Repacking Guide MSP500000436 Rev A: TripleStep

Swivel Joint
13. FPE Fluid Power Energy Data Sheets: Three-Way Thermostatic Valves: Sizes
" to 4"
14. Fulflo Data Sheets: V-Series Valves
2654258 TOC-3

15. G T Exhaust Data Sheets: 203-4100 Series Residential Grade

Turbo Silencer
16. Gardner Denver A. Parts List 1st Edition: Well Servicing Pump Model D-
2250 CWS/ACWS (March 2003)
B. GWS Fluid End Parts List 300THD997 Rev A: Well

Servicing Pump Model HD-2250, C-2250, D-2250
Triplex Pumps (February 2005)
C. Parts List 3-1-541, 3rd Edition: HD-2250 Well Service

Pump (Power Frame Only) (April 2005)
D. Operating and Service Manual 300THD996 Rev A:

HD-2250 Well Servicing Pump (January 2005)
17. Gemini Valve A. Data Sheets ISL018-0009: Repair Instructions For

Gemini 76, 86, & 96 Series Valves
B. Data Sheets ISL002-9507: Installations For Installing

Actuator Drive Keys on 1.25-2 76 Series, 1-2
86 Series, and 0.75-1.5 96 Series Ball Valves
18. Gorman Rupp Manual No. OM-01395-OB02 Rev B: Installation,

Operation, and Maintenance Manual with Parts List
for 60 Series Pump, Model 612L20-B (July 1985)
19. Haldex Barnes Hydraulics A. Manual No. SD-97105: G20 & G30 Series Hydraulic
Gear Pumps Service Manual (August 1997)
B. Catalog G20/30: G20 & G30 Series High

Performance gear Pumps (December 2001)
20. Hendrickson Data Package: Installation Instructions, Service

Instructions, Bulletins for INTRAAX Suspensions
TOC-4 2654258

21. Holland Hitch Company A. Data Sheets XL-LG305: Operating and Maintenance
Procedures for Mark V Landing Gear (March 2000)
B. Data Sheets LG 106: Operating and Maintenance

Procedures for Mark V Landing Gear (September
1991)
C. Data Sheets XL-LG225: Repair Procedures for Mark

V Landing Gear Manufactured after May 1994
(August 1999)
22. Hydac International A. Brochure 02068122: Series HF4R Low Pressure

Filters (September 1999)
B. Brochure 02075076: Series HF4R Service and Parts

(May 2002)
C. Brochure 02070322: Flow, Needle and Check Valves

(September 1999)
23. IEA Manual: Installation, Operation and Maintenance

Manual for all Standard Radiator Models (January
1995)
24. Kitz Operation Manual MT-10: Cast Bronze, Forged Brass,

Cast Ductile Iron, and Cast Iron Valves
25. Magnaloy Coupling Data Sheets: Aluminum and Steels Subplates

Company
26. Mannesmann-Rexroth A. Manual 91 001/08.97: Fixed Displacement Motor

AA2FM (A2FM), Series 6, for Open and Closed
Circuits, Axial Piston, Bent Axis Design (August 1997)
B. Manual 91001-01-R: Repair Instructions for Fixed

Displacement Motor AA2FM (A2FM), (July 1996)
2654258 TOC-5

26. Mannesmann-Rexroth (Cont) C. Technical Sheets RA-E 06 110/2.90: Fixed
Displacement Motor AA2FM Series 61, Spare Parts
List (February 1990)
27. Marvel Engineering Co. Bulletin No. LS-101: 1500 Series for Suction, Return,
and Low Pressure Lines
28. Mico A. Form 84-500-001: Multiple Disc Brakes Catalog,

Spring Apply Hydraulic Release Multiple Disc Brakes
(June 2000)
B. Form No. 81-520-013 Installation and Service

Instructions 520 Series Caliper Disc Brake
C. Form No. 81-950-016 Recommended Brake Service

Procedures to Reduce Exposure to Non-Asbestos
Fiber
29. MSI Technical Manual: Automatic Plunger Greasing

System
30. Norgren Data Sheets: B73 Filter Regulators
31. Norriseal A. Manual NOR 202: Norris Butterfly Valves Service and
Installation Data
B. Data Sheets NOR 972: Norris R285, M285 Series

Butterfly Valves
32. Noshok A. Data Sheets: Pressure Gauges 300 Series
B. Bulletin: Selection, Installation, and Maintenance

Guide for Pressure Gauge Series 100, 200, 300, 400,
500, 600, 700, 800, and 900
TOC-6 2654258

33. PSI Automation A. Bulletin No. STR-04: Installation and Operation
Recommendations For PSI Air/Gas Starters (July
1993)
B. Bulletin No. STR-103: Models HS-200, HS-250, HS-

302, and HS-300 Hydraulic Starter Adapters Exploded
View (September 1989)
C. Bulletin No. STR-48: Hydraulic Starter Model Listing

and Installation Recommendations HS-302, HS300,
HS-250, and HS-200 Series (August 1991)
34. Pump Mates USA Product Catalog: Pulsation Dampeners, Cavitation

Elimininators, Shock Arrestors
35. Sauer Sundstrand A. Manual BLN-10015, Rev C: Loop Flushing Valve

(1994)
B. Manual BLN-10029, Rev E: Series 90 Axial Piston

Pumps Technical Information (March 1999)
C. Manual BLN-09947: Series 90 Axial Piston Pumps

and Motors Service Manual (June 1996)
D. Manual BLN-09949: Series 90 Axial Piston Pumps

and Motors Repair Manual (July 1992)
E. Manual BLN-2-41660: Series 90 42 cc thru 250 cc

Axial Piston Pump Quick Reference Service Parts
Manual (June 1996) Check Valve, Standard Service
Models 2", 3", and 4" (1999)
36. S.S. White Technologies A. Data Sheets HL116 Rev.1: Tachometer Instructions
and Calibration Chart For Electronic Programmable
Tachometers Model # HG175, HG176, HG181,
HG182
B. Data Sheets: Instructions Hourmeter, HG191, HG192,

& HG194
2654258 TOC-7

37. SPM A. Bulletin: Plug Valves (1999)
B. Bulletin: Product Safety Guide for Plug Valves
38. Stewart & Stevenson Manual: Intelligent Pump Control (IPC) System
(August 2003)
39. Stellar Technology Data Sheets: Series GT2250 4-20Ma Hazardous

Location Pressure Transmitter
40. Texco Catalog 1000: Severe Service Valves, Model IWNV-

20R, pages V-28 & 29 (March 1991)
41. Thermal Transfer (DuPont) Form 174: Installation and Service Recommendations
Shell and Tube Heat Exchangers (December 2000)
42. Victaulic A. Manual I-100: Field Assembly and Installation

Instruction Pocket Handbook (November 1995)
B. Data Sheets 1469 Rev C: Style 77 Standard Flexible

Couplings (October 2000)
43. Zinga Data Sheets: Tank Filter and Strainer (2002)
TOC-8 2654258
2654258 TOC-9
Operators Manual
5000/6000/8000/9000 Series
Electronic Control Transmissions
OM2034EN
OM2034EN
Operators
Manual
Allison Transmission
5000, 6000, 8000, 9000 Series

Electronic Control Transmissions
Division of General Motors Corporation

P.O. Box 894 Indianapolis, Indiana 46206-0894 March, 1998
Revised 199905
Printed in U.S.A. i Copyright 1998 General Motors Corp.

WARNINGS, CAUTIONS, AND NOTES
IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and
cautions described in this handbook. It is, however, important to understand that these
warnings and cautions are not exhaustive. Allison Transmission could not possibly
know, evaluate, and advise the service trade of all conceivable ways in which service
might be done or of the possible hazardous consequences of each way. Consequently,
Allison Transmission has not undertaken any such broad evaluation. Accordingly,
ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly
satisfied that neither personal safety nor equipment safety will be jeopardized by the
service methods selected.
Proper service and repair is important to the safe, reliable operation of the equipment.
The service procedures recommended by Allison Transmission and described in this
handbook are effective methods for performing service operations. Some of these
service operations require the use of tools specially designed for the purpose. The
special tools should be used when and as recommended.
Three types of headings are used in this manual to attract your attention. These
warnings and cautions advise of specific methods or actions that can result in personal
injury, damage to the equipment, or cause the equipment to become unsafe.
WARNING: A warning is used when an operating procedure, practice,

etc., if not correctly followed, could result in personal injury or loss of life.
CAUTION: A caution is used when an operating procedure,

practice, etc., if not strictly observed, could result in damage to or
destruction of equipment.
NOTE: A note is used when an operating procedure, practice, etc., is

essential to highlight.
ii
TABLE OF CONTENTS
Page
Warnings, Cautions, and Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
INTRODUCTION
A Brief Description of the 5000, 6000, 8000, 9000 Series
Transmission Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Typical 5000, 6000, 8000, 9000 Series
Transmission Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Transmission Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lockup Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Planetary Gearing (5000, 6000, 9000 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Planetary Gearing (8000 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transfer Gear Housing (Dropbox) Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SHIFT SELECTORS
Shift Selectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Positive Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATING TIPS
Status Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hold-in-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reset Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Throttle Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Range Preselection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preselection to Avoid Stall Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Downshift or Reverse Inhibitor Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Using the Engine to Slow the Vehicle or Equipment . . . . . . . . . . . . . . . . . . . . 14
Using the Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cold Weather Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
iii
Page
OPERATING TIPS (contd)
High Fluid Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Towing or Pushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power Takeoff (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Turning Off the Vehicle or Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CARE AND MAINTENANCE

Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Prevent Major Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Importance of Proper Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Transmission Fluid Level Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Allison High-Efficiency Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Care of Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Retarder Linkage Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parking Brake (Some Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TROUBLESHOOTING
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CUSTOMER SERVICE
Owner Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Allison Transmission Distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
iv
INTRODUCTION
A BRIEF DESCRIPTION OF THE 5000, 6000, 8000,

9000 SERIES TRANSMISSION MODELS
The 5000, 6000, 8000, and 9000 Series transmissions are used in applications
requiring 400 to 2400 horsepower engines. Applications are diverse and include oil-
field pumping and fracturing units, off-highway trucks, agricultural tractors, scrapers,
and winch units such as those on derricks, cranes, and ship anchors.
5000, 6000, 8000, and 9000 Series transmissions have a torque converter and lockup
clutch, planetary gear sets, and hydraulic clutches. Further needs are met by optional
equipment which may include a hydraulic retarder, parking brake, power takeoff (at
various locations), or transfer gear housing (dropbox).
The transmissions described in this handbook use an electronic control system.

For non-electronic control models, refer to OM1318EN, Automatic-Electric and
Manual-Electric Transmissions Operators Manual.
1
TYPICAL 5000, 6000, 8000, 9000 SERIES
TRANSMISSION MODELS
5000, 6000 Series
5000, 6000 Series With Dropbox
2
8000 Series
9000 Series
3
TRANSMISSION NAMEPLATE
The model number, part number (assembly number), and serial number are stamped
into the transmission nameplate. These three numbers describe the transmission and
all of its components. Use all three numbers when you are seeking information or
ordering replacement parts for the transmission. Location of the nameplate varies with
the particular transmission.
For convenience, record the nameplate information from your transmission onto the
nameplate in the illustration.
DIVISION OF
ICULTURA
AGR
GENERAL MOTORS AN
D
L
IM
PL
E
EM
ILE AEROSPAC
UAW
ENT
CORPORATION
WORKERS
INDIANAPOLIS 933
OB
OM
OF
UT AM
DA ERI
UNITE CA
INDIANA
SERIAL NO. PART NO.
MODEL
NO.
V02779
ELECTRONIC CONTROL SYSTEM

The Allison Transmission Electronic Control System consists of five major components
connected by wiring harnesses Electronic Control Unit (ECU), throttle position
sensor, speed sensor, range selector, and control valve body. The throttle position
sensor, speed sensor, and range selector transmit information to the ECU. The ECU
processes this information and then sends signals to actuate specific solenoids located
on the control valve body in the transmission. The action of the solenoids affects
hydraulic circuits which in turn control the upshifts, downshifts, and lockup functions.
In addition to controlling the operation of the transmission, the ECU monitors the
system for conditions that could affect transmission and vehicle operation. When one
of these conditions is detected, the ECU is programmed to automatically respond in a
manner which will ensure safe operation of the vehicle and the transmission.
NOTE: Allison transmissions electronic control systems are designed and

manufactured to comply with all FCC and other guidelines regarding radio
frequency interference/electromagnetic interference (RFI/EMI) for
transportation electronics. Manufacturers, assemblers, and installers of
radio-telephone or other two-way communication radios have the sole
responsibility to correctly install and integrate those devices into Allison
Transmission-equipped vehicles to customer satisfaction.
4
The ECU is programmed at the factory to provide the most suitable operating
characteristics for a specific application. This handbook does not attempt to describe
all of the possible combinations. The information contained herein describes only the
operating characteristics most frequently requested by the vehicle or equipment
manufacturer.
TORQUE CONVERTER
The torque converter consists of three elements pump, turbine, and stator. The
pump is the input element and is driven directly by the engine. The turbine is the
output element and is hydraulically driven by the pump. The stator is the reaction
(torque multiplying) element.
The torque converter is continuously filled with transmission fluid. The pump, driven
by the engine, directs the fluid against the turbine vanes which causes the turbine to
rotate. The turbine returns the fluid through the stator which redirects the flow so that
fluid strikes the pump vanes in the same direction that the pump is rotating. As the
pump turns faster in relation to the turbine, the velocity of the fluid increases and so
does the torque multiplication.
As the speed of the turbine approaches the speed of the pump, the fluid flow starts
striking the back sides of the stator vanes. This causes the stator to freewheel in the
same direction as the pump and turbine. When this occurs, the torque multiplication
stops and the torque converter functions as a fluid coupling.
LOCKUP CLUTCH
The lockup clutch is located inside the torque converter and consists of three
elementsa piston, a clutch plate, and a backplate. The piston and backplate are
driven by the engine. The clutch plate, located between the piston and backplate, is
splined to the converter turbine.
The lockup clutch is designed to engage and disengage at predetermined equipment

speeds in response to electronic signals from the ECU. When engaged, the lockup
clutch connects the engine directly to the transmission gearing. This eliminates
converter slippage to provide maximum fuel economy. When the lockup clutch is
disengaged, the torque converter acts as a torque multiplier or fluid coupling. The
lockup clutch is typically disengaged at lower speeds, and momentarily during shifts
so that the torque converter absorbs the shock of the gear ratio change. The ECU also
disengages the lockup clutch under certain operating conditions.
5
HYDRAULIC RETARDER
The optional hydraulic retarder is used to slow the vehicle on curves or downgrades.
The retarder consists of a vaned rotor splined to the turbine shaft and mounted in a
sealed housing. When the operator activates the retarder (by foot pedal or hand lever),
the retarder control valve is opened. Transmission fluid is routed to the retarder cavity
and resists the rotation of the rotor, decreasing the input torque to the range gearing.
The retarder may be applied in any forward range, but maximum retarder effect occurs
in the lowest range.
PLANETARY GEARING (5000, 6000, 9000 Series)

The planetary gear train consists of four constant-mesh planetary gear sets. The
forward set is the splitter and the three rear sets are the intermediate, low, and reverse.
These planetaries are combined with six clutches to provide six forward ranges and
one (or two, for some 5000, 6000 Series) reverse ranges.
PLANETARY GEARING (8000 Series)

The planetary gear train consists of five constant-mesh planetary gear sets. The
forward set is the splitter. The four rear sets are third-and-fourth range (intermediate),
second range, first range, and reverse. These planetaries are combined with seven
clutches to provide six forward ranges and one reverse range.
A special feature of the 8000 Series is the dual torque path. In first range, where high
torque is needed for greater tractive effort, torque from the torque converter is
transmitted by the main shaft through the transmission to a high-reduction planetary
gear set. In each succeeding range (2nd through 6th), where a balance of speed and
torque is needed, the torque from the torque converter is divided between the main
shaft and the planetary gear section. As the transmission is upshifted for increased
vehicle speed, an increased percentage of power is directed through the planetary gear
section and a decreased amount is carried by the main shaft. The dual-path flow of
power is recombined at the output planetary gear set.
6
TRANSFER GEAR HOUSING (DROPBOX) MODELS
Some 5000 Series models are equipped with a transfer gear housing (dropbox) mounted
to the rear of the transmission adapter housing. The dropbox provides a 1:1 gear ratio at
three output locations. One output is in line with the input; the remaining two outputs are
on a lower plane than the input and provide both front and rear output.
An output disconnect clutch may be mounted at any one or all three output locations
on the dropbox. A shifter shaft extending from the clutch housing is used to manually
engage or disengage the output shafts.
HYDRAULIC SYSTEM
A single, integral hydraulic system serves the torque converter, hydraulic retarder, and
the transmission gearing. Transmission fluid for all hydraulic operations flows from
and to a common sump.
Transmission-mounted filters (located at the top of the converter housing) or remote-

mounted filters provide fluid filtration. The transmission fluid is cooled by a separate
cooler, or by connection to the engine cooling system. For non-retarder models, cooler
circuit connections are located on the left side of the converter housing. For models
with retarder, cooler connections are located on the retarder control valve body.
7
SPLITTER-LOW
SPLITTER-HIGH
HIGH (FIFTH-AND-SIXTH)
INTERMEDIATE (THIRD-AND-FOURTH)
FLYWHEEL LOW (FIRST-AND-SECOND)
REVERSE
STRAIGHT
ENGINE THROUGH
INPUT TRANSMISSION
OUTPUT
TRANSFER
GEAR
SECTION
FRONT DROPBOX REAR DROPBOX

TRANSMISSION TRANSMISSION
OUTPUT OUTPUT
LOCKUP CLUTCH
HYDRAULIC
RETARDER
(OPTIONAL) DROPBOX ON 5000
ONLY
H02766.01
5000, 6000, 9600 Series Cross-Section
SPLITTER-HIGH HIGH (FIFTH-AND-SIXTH)

FLYWHEEL INTERMEDIATE (THIRD-AND-FOURTH)
SPLITTER-LOW SECOND
FIRST
REVERSE
ENGINE
INPUT
TRANSMISSION
OUTPUT
HYDRAULIC
LOCKUP CLUTCH RETARDER H02767
8000 Series Cross-Section
8
SHIFT SELECTORS
SHIFT SELECTORS
DO NOT
SHIFT
DO 1
R NOT
SHIFT
2
3
N 1 4
5
D 2 D
N
4 3 R
DO NOT
SHIFT
PUSHBUTTON LEVER
SELECTOR SELECTOR
V04657
Typical Shift Selectors
The vehicle or equipment manufacturers may choose different types of shift selectors
for their equipment. The shift selector in your Allison-equipped vehicle will be similar
to one of those shown above.
The pushbutton shift selector is an electronic control unit with membrane-type

pushbutton switches. Each pad (R, N, D, 4, 3, 2, and 1) is a switch. Push on the pad for
the desired operating range. A slight click will be felt, the pad will light up, and a beep
tone will let you know the transmission is ready to operate within the selected range.
The lever selector is an electro-mechanical control unit. The pattern of positions can
vary according to the shift selector installed. Positions (R, N, and D) are selected by
releasing a position holding button and choosing the desired range. It is possible to
move between drive positions without releasing the position holding button.
POSITIVE SHIFTING
All movements of the shift selector should be quick and positive when upshifting or
downshifting.
9
RANGE SELECTION 5, 6, 8, 9000 SERIES
WARNING: If you leave the vehicle and the engine is running, the
vehicle can move suddenly and you or others could be injured. If you
must leave the engine running, do not leave the vehicle until you:
Put the transmission in N (Neutral)and
Apply the parking brake and emergency brakes and make sure they
are properly engagedand
Chock the wheels and take any other steps necessary to keep the
vehicle from moving.
R Use Reverse to back the vehicle or equipment. Completely stop the

vehicle or equipment before shifting from forward to reverse or from
reverse to forward. The reverse warning signal is activated when this
range is selected.
WARNING: If you let the vehicle coast in N (Neutral), there is no

engine braking and you could lose control. Coasting can also cause
severe transmission damage. To help avoid injury and property
damage, do not allow the vehicle to coast in N (Neutral).
N Use Neutral when starting the engine, when checking vehicle or

equipment accessories, and for extended periods of engine idle operation.
The transmission will automatically select Neutral when the master
switch is turned on. If the engine starts in any other selected range, the
neutral start circuit is malfunctioning and must be repaired immediately.
Use Neutral when the vehicle or equipment will be left unattended with
the engine running always apply the parking brake. Neutral is also
used during stationary operation of the power takeoff (if your vehicle or
equipment is equipped with a PTO). Always select N (Neutral) prior to
turning off the vehicle engine.
D Use Drive and the vehicle or equipment will start in first range. As the
speed increases, the transmission will automatically upshift through each
range to sixth range operation. As the vehicle or equipment slows down,
the transmission will automatically downshift to the correct range.
NOTE: Even though D (Drive) is selected, it may not be attained due to

active inhibit functions such as high throttle, high engine idle speed, or
other vehicle system inhibits.
10
RANGE SELECTION 5, 6, 8, 9000 SERIES (contd)
WARNING: If you just downshift or just use service brakes when

going downhill, you can lose control and cause injury and property
damage. To help avoid loss of control, use a combination of
downshifting, braking, and other retarding devices. Downshifting to a
lower transmission range increases engine braking and helps you to
maintain control. The transmission has a feature to prevent automatic
upshifting above the lower range selected. However, during downhill
operation, if engine governed speed is exceeded in the lower range,
the transmission may upshift to the next higher range. This will
reduce braking and could cause a loss of control. Apply the vehicle
brakes or other retarding device to prevent exceeding engine governed
speed in the lower range selected.
5 Occasionally, the road, load, or traffic conditions will make it desirable to

restrict the automatic shifting to a lower range. These positions also
4 provide progressively greater engine braking for going down medium
3 grades (the lower the range, the greater the braking effect).
2
NOTE: The pushbutton shift selector does not have a fifth-range
preselect position. The automatic shift between fifth and sixth range is a
standard feature.
1 Use this range when pulling through mud and deep snow, when
maneuvering in tight spaces, while driving up or down steep grades, or
when maximum output power is required. Low range provides the vehicle
or equipment with its maximum driving power. Low range also provides
maximum engine braking power.
11
OPERATING TIPS
STATUS LIGHTS
When programmed operating parameters have been exceeded, the ECU automatically
takes action to protect the vehicle and the transmission. If this occurs, the CHECK
TRANS light on the instrument panel, or the CHECK TRANS light and the DO NOT
SHIFT light, which is located on the shift selector, will turn on. When the DO NOT
SHIFT light comes on, a buzzer is also sounded for a moment to indicate there is a
problem. Whenever either one of these lights come on, the transmission responds to
ensure the safest possible operation of the vehicle.
Every time the engine is started, the status lights come on. They go off after a few
seconds. This momentary lighting is to show that the light bulbs are working
properly. If either status light does not come on during engine start, immediately
replace the bulb.
Illumination of this light will notify the driver that the transmission is
CHECK not performing as designed. No audible alarm will alert the driver that
TRANS CHECK TRANS has been illuminated. Although the transmission
may continue to operate in a normal manner, service advice should be
sought promptly. The vehicle may be driven to complete the desired
mission if conditions can be negotiated safely. However, in some
cases the ECU will take action, such as restricting operation to one
range only.
Illumination of this light, accompanied by ten seconds of short beeps

DO NOT from the shift selector, indicates that shifts are being restricted.
SHIFT Operation may continue in order to reach service assistance. The ECU
may not respond to shift selector requests since operating limitations
are being placed on the transmission; i.e., upshifts and downshifts may
be restricted. Direction changes will not occur. If the shift lever is
moved while DO NOT SHIFT is indicated, a continuous alarm will be
sounded. The alarm will stop when the lever is moved back to the
previous position where DO NOT SHIFT was first indicated. For
pushbutton shift selectors, the ECU will not respond to operator
requests. The ECU will cause the transmission to Hold-In-Range and
disengage the lockup clutch.
12
HOLD-IN-RANGE
The hold-in-range feature prevents upshifts and downshifts when a problem is
detected in the operation of the transmission. The hold-in-range circuit permits the
transmission to continue to operate in the range it was in at the time the DO NOT
SHIFT light and buzzer came on. Selection of a different range will have no effect on
the transmission. The transmission will not upshift or downshift but will remain in the
range it was in when the ECU detected the problem. The hold-in-range circuit is
released when the engine is shut off. If the problem causing the hold-in-range
condition is still present when the engine is restarted, the transmission will be in
neutral and will remain held in neutral until the problem is corrected.
RESET PROCEDURE
When the status light (or lights) comes on, a reset procedure can be performed to clear
the system.
To reset the ECU, bring the vehicle to a stop at a safe location and shut off the
engine. Wait 10 seconds and restart the engine.
If the problem is temporary, the status light (or lights) will not come back on
and your vehicle will operate in a normal manner.
If the problem is not temporary, the status light (or lights) will come back on
and the transmission may stay in neutral, operate in only the lower ranges, or
operate in a normal manner. The type of operation permitted by the ECU will
depend on the type of problem.
THROTTLE CONTROL
The position of the throttle influences the speed at which automatic shifting occurs. At
wide open throttle, upshifts will occur automatically at high engine speeds. At part
throttle, upshifts will occur at lower engine speeds. Throttle position is sensed by the
throttle position sensor, which is connected to the engine throttle lever.
RANGE PRESELECTION
Range preselection means selection of a lower range to match driving conditions
you encounter or expect to encounter. Learning to take advantage of preselected
shifts will give you better control on slick or icy roads and on steep downgrades.
Downshifting to lower ranges increases engine braking. The selection of a lower
range often prevents cycling between a range and the next higher range on a series
of short up-and-down grades. The transmission will not shift above the selected
range unless excessively high engine speeds are attained.
13
PRESELECTION TO AVOID STALL SHIFTING
When a loaded vehicle travels up a steep grade, the vehicle can lose momentum rapidly.
As a result, a full power shift into a lower range may occur when the vehicle has almost
stopped on the grade (at or near full-converter stall). To prevent these stall shifts, the
operator should anticipate the lowest range needed to negotiate the grade and preselect it.
After negotiating the grade, the operator can reposition the shift selector to an
appropriate range for the balance of the haul cycle.
DOWNSHIFT OR REVERSE INHIBITOR FEATURE

Although the ECU does not impose a speed limitation on upshifts, there are limits on
downshifts and shifts from N (Neutral) into D (Drive) or R (Reverse). If a downshift or
Neutral-to-range shift is selected when the engine speed is too high, the ECU will
generally prevent the shift from occurring until a lower speed is reached.
USING THE ENGINE TO SLOW THE VEHICLE OR EQUIPMENT

WARNING: If you just downshift or just use service brakes when going
downhill, you can lose control and cause injury and property damage. To
help avoid loss of control, use a combination of downshifting, braking,
and other retarding devices. Downshifting to a lower transmission range
increases engine braking and helps you to maintain control. The
transmission has a feature to prevent automatic upshifting above the
lower range selected. However, during downhill operation, if engine
governed speed is exceeded in the lower range, the transmission may
upshift to the next higher range. This will reduce braking and could cause
a loss of control. Apply the vehicle brakes or other retarding device to
prevent exceeding engine governed speed in the lower range selected.
To use the engine as a braking force, select the next lower range. If the vehicle or
equipment is exceeding the maximum speed for this range, use the service brakes
and/or retarder (if equipped) to slow the vehicle. When a lower speed is reached, the
ECU will automatically downshift the transmission. Engine braking provides good
speed control for going down grades. When the vehicle is heavily loaded, or the grade
is steep, it may be desirable to preselect a lower range before reaching the grade.
14
USING THE RETARDER
WARNING: Activating the retarder while driving on a slippery surface
can cause a loss of control and a crash. Do not use the retarder on wet,
icy, or slippery roads. During inclement weather, turn off the retarder at
the master control switch.
HYDRAULIC RETARDER
Activate the retarder to control vehicle speed on curves or downgrades. The retarder
may be applied in any forward range, but maximum braking effect is obtained in the
lowest range. Preselecting a range below D (Drive) when using the retarder can
significantly improve the braking effect by preventing unexpected upshifts. If
additional braking is required, apply the service brakes.
Prolonged full or partial application of the retarder can cause overheating of the
transmission fluid. If overheating occurs, alternately fully apply and fully release the
retarder to decrease fluid temperature. Never allow the converter-out temperature to
exceed 330F (165C) during retarder operation.
COLD WEATHER STARTS

Most transmissions are programmed to restrict operation to neutral, reverse, and the
lowest range in the D (Drive) range until the following temperatures are reached.
Sump Oil DO NOT SHIFT CHECK TRANS

Temperature Light Light Operation*
10F (24C)
ON ON Neutral only
and below
Neutral, first,
9F (23C) to
OFF OFF second, or
+19F (7C)
reverse
20F (7C) Full operation
OFF OFF
and above in all ranges
* Transmissions used in emergency vehicles do not have programmed temperature restrictions.
For preheating requirements for specific transmission fluids, refer to the Care and
Maintenance section of this manual.
15
HIGH FLUID TEMPERATURE
When a transmission converter-out temperature gauge is provided, check the gauge
frequently to determine if the fluid temperature is within the normal operating range of
180220F (82103C). If the sump fluid temperature reaches 250F (121C), the
CHECK TRANS light will come ON and the ECU will inhibit operation in higher
ranges.
If the transmission overheats during normal operation, check the fluid level in the
transmission. (Refer to the fluid check procedure as described in the Care and
Maintenance section of this handbook.)
Extended operation at low vehicle or equipment speeds with the engine at full throttle
can cause excessively high fluid temperatures in the transmission. These temperatures
may tend to overheat the engine cooling system as well as cause possible transmission
damage.
If the CHECK TRANS light comes on and the engine temperature gauge indicates
a high temperature, the transmission is probably overheated. Stop the vehicle or
equipment and check the cooling system. If it appears to be functioning properly, run
the engine at 12001500 rpm with the transmission in N (Neutral). This should reduce
the transmission and engine temperatures to normal operating levels in two or three
minutes.
CAUTION: Never operate the engine for more than 30 seconds at full
throttle with the transmission in an operating range and the vehicle not
moving. Prolonged operation of this type will cause excessively high
transmission fluid temperature which will damage the transmission.
If the engine temperature gauge indicates a high temperature and the CHECK TRANS
light is not ON, an engine problem is indicated. If high temperature in either the
engine or transmission persists, stop the engine and have the overheating condition
investigated by maintenance personnel.
PARKING BRAKE
There is no P (Park) position on the shift selector. Always select N (Neutral) and apply
the parking brake to hold the vehicle when it is parked.
16
TOWING OR PUSHING
WARNING: Arc welding equipment requires dangerously high currents
and voltages which cannot be sufficiently reduced to permit its use for
jump-starting. To help avoid injury or equipment damage, do not attempt
to jump-start the equipment using an arc welder.
The engine cannot be started by pushing or towing. Before pushing or towing a

vehicle, the driveline must be disconnected or the drive wheels must be lifted off the
road. An auxiliary air supply will usually be required to release the vehicle brake
system.
CAUTION: Failure to lift drive wheels off the road, disconnect the
driveline, or remove the axle shafts before pushing or towing can cause
serious transmission damage.
POWER TAKEOFF (PTO)

A power takeoff (PTO) may be mounted on the top and/or side of the transmission.
The PTOs are engine-driven and rotate whenever the engine is running.
In most applications, the PTO is continuous and is used to drive a hydraulic pump
which supplies hydraulic pressure for operation of accessories.
In some applications it is desirable to engage or disengage the PTO from the engine.
One method is an operator-applied clutch. With this method, the engine should be at
idle speed before engagement or disengagement of the PTO. Another method is a
mechanical disconnect. With this method, the operator must stop the engine before
engaging or disengaging the power takeoff.
TURNING OFF THE VEHICLE OR EQUIPMENT

Always select N (Neutral) prior to turning off the vehicle or equipment engine.
17
CARE AND MAINTENANCE
PERIODIC INSPECTIONS
Allison transmissions require a minimum of maintenance. Careful attention to the
control linkage and to the transmission fluid level is most important. For easier
inspection, keep the transmission clean. Make periodic inspections for loose bolts,
leaking hydraulic lines, or wet splitlines. Check the condition of the electrical
harnesses regularly. Check the engine cooling system occasionally for evidence of
transmission fluid, which would indicate a faulty cooler. Report any abnormal
condition to your maintenance personnel.
PREVENT MAJOR PROBLEMS

Minor problems can be kept from becoming major problems if you notify
maintenance personnel when any of these conditions occur.
Overheating
Abnormal shifting
Transmission leaks fluid
Unusual transmission-related sounds (changes in sound level caused by
normal engine thermostatic fan cycling while climbing a long grade with a
heavy load have been mistaken for unusual transmission-related sounds).
CHECK TRANS light comes on frequently
IMPORTANCE OF PROPER FLUID LEVEL

Maintaining the proper fluid level is very important. Transmission fluid cools,
lubricates, and transmits power. If the fluid level is too low, the torque converter and
clutches will not get a proper fluid supply, which will result in poor performance and
possible damage to the transmission. If the fluid level is too high, the fluid will
become aerated and cause overheating.
Check transmission fluid regularly, at the start of each shift. If consistent daily hot
level checks have been established, and daily inspection shows no sign of fluid
leakage, less frequent checks could be made.
18
TRANSMISSION FLUID LEVEL CHECK PROCEDURE
WARNING: To help avoid injury and property damage caused by
sudden and unexpected vehicle movement, do not perform
maintenance or service procedures until you:
Put the transmission in N (Neutral)... and

Set the parking brake and service brakes, and make sure they are
properly engaged... and
Chock the wheels and take any other steps necessary to keep the
CAUTION:
Later model transmissions and parts use straight-thread hydraulic
fittings and ports. Check the compatibility of the plug or fitting to
the port before installation.
Dirt and foreign matter must not be permitted to enter the
hydraulic system. Contamination of the transmission fluid or
hydraulic system can cause stuck valves, excessive wear of
transmission parts, or clogged hydraulic passages.
A visual level indicator is mounted on the lower left side of the transmission main
housing. The indicator provides a method of checking the fluid level. The illustration
shows how to read the indicator.
Install with
knurled plug up
VISUAL LEVEL INDICATOR RED LINE
FLUID CHECK PROCEDURE:
NO RED LINE
1. FLUID ALLISON-APPROVED C-4 VISIBLE (OVERFILL)
2. TRANSMISSION AT SAFE
NORMAL OPERATING FULL MARK
OPERATIONAL (CENTER)
TEMPERATURE LEVEL AREA
(180220F; 82103C)
NO FLUID VISIBLE
3. NEUTRAL
(UNDERFILL)
ENGINE IDLE
H02777.01
Visual Level Indicator
19
NOTE: The only purpose of a Cold Check is to determine if the
transmission has enough fluid to be safely operated until a Hot Check
can be made.
Cold Check (5000, 6000 Series)

Before starting the engine, check the fluid level indicator. Remove the ADD
(lower) plug. If fluid is present in the sight glass, the transmission has
sufficient fluid to permit safe starting of the engine. If no fluid is present, add
sufficient fluid to bring the level within the indicator glass or to cause a flow
from the plug opening. Replace the plug.
Perform a hot fluid level check at the first opportunity after normal operating
temperature is reached.
Cold Check (8000, 9000 Series)

Before starting the engine, check the visual level indicator or remove the fluid
level check plug. If fluid is present in the indicator glass, the transmission has
sufficient fluid to permit safe starting of the engine. If no fluid flow is present,
add sufficient fluid to bring the fluid level within the indicator glass or to
cause a flow from the plug opening. Replace the plug.
Perform a hot fluid level check at the first opportunity after normal operating
temperature is reached.
NOTE:
A hot fluid level check is made to determine if there is sufficient fluid
for working operation of the transmission.
Observe the condition of the fluid in the indicator glass. Foaming fluid
may indicate a false level.
20
Hot Check (5000, 6000 Series)
SPEEDOMETER DRIVE
FLUID FILLER TUBE CONNECTION

HOLE (LOCATIONS VARY ON
DIFFERENT MODELS)
DRAIN PLUG
H02771
Fluid Level Service Locations (5000, 6000 Series)
Shift to N (Neutral) and start the engine. Operate the equipment until the
transmission reaches a normal operating temperature of 180220F
(82103C). Then idle the engine and, for vehicle models, apply the parking
brake. Shift through all range positions slowly to ensure all areas of the
system are filled with fluid.
Shift to N (Neutral) and set the engine speed at idle speed (1000 rpm). Check
the visual level indicator. The fluid should be within the indicator limits
shown in the illustration. Add or drain fluid as necessary to bring the fluid
level within these limits.
Hot Check (8000, 9000 Series)
Shift to N (Neutral) and start the engine. Operate the equipment until the
transmission reaches a normal operating temperature of 180220F
(82103C). Then idle the engine and, for vehicle models, apply the parking
brake. Shift through all range positions slowly to ensure all areas of the
system are filled with fluid.
21
SPEEDOMETER DRIVE
FLUID FILLER TUBE HOLE

STRAINER ASSEMBLY H02770
Fluid Level Service Location (8000, 9000 Series)
Shift to N (Neutral) and set the engine at idle speed (600650 rpm). Check the
visual level indicator. The fluid should be within the indicator limits shown in
the illustration. Add or drain fluid as necessary to bring the fluid level within
these limits.
Fluid, Filter Change

The fluid should be changed every 1200 hours of operation or sooner depending upon
operating conditions. Also, the fluid must be changed whenever there are traces of dirt
or evidence of high temperature indicated by discoloration or strong odor. Metal
particles in the fluid (except for the minute particles normally trapped in the filter)
indicate damage has occurred in the transmission. When these particles are found in
the filter, report the condition immediately to maintenance personnel.
At each fluid change, examine the fluid which is drained for evidence of dirt or water.
If there is evidence of water or engine coolant in the fluid, immediately report the
condition to maintenance personnel.
NOTE: The strainer assembly located in the pan does not require
cleaning at normal fluid and filter change intervals.
22
ALLISON HIGH-EFFICIENCY FILTER SYSTEM
Allison high-efficiency filter assemblies are equipped with a differential pressure (P)
switch to indicate when the filter element requires service. This serves two important
functions: it allows the actual change interval to be determined for each customers
application, and it is a good service requirement indicator.
NOTE: An early indication of the filter warning light on a new or newly

overhauled transmission may be due to plugging of the filter as it cleans the
system to a six micron level. Unless the fluid visibly looks contaminated,
do not change the transmission fluid. New fluid may be contaminated by
storage. If problems arise, check with your fluid supplier or perform a fluid
analysis.
Replace the high-efficiency filter elements when the filter differential pressure
warning light alerts the operator that the filter needs to be serviced. Clean the filter
shells. New gaskets and sealrings must be used when replacing filter elements. After
installation, check the filter for fluid leakage while the engine is running.
5/6/8/9000 Series Transmissions High-Efficiency Filters

Direct Mount Configuration
Nomenclature Part Number No. Required
Filter Assembly 29530556 1
Filter Bowl 23040664 2
Element 29510910 2
Ring Filter Seal 29501469 2
Switch 29529657 1
O-ring Seal 23045105 2
5/6/8/9000 Series Transmissions
Remote Mount Configuration
Nomenclature Part Number No. Required
Filter Assembly 29530557 1
Filter Bowl 23040663 1
Element 23049374 1
Ring Filter Seal 23018958 1
Switch 29529657 1
23
Keeping Fluid Clean
It is absolutely necessary that the fluid put into the transmission be clean. Fluid must
be handled in clean containers to prevent foreign material from entering the system.
CAUTION: Do not use containers or fillers for transmission fluid that

have been used for any antifreeze solution. Antifreeze and coolant
solutions contain ethylene glycol which, if introduced into the
transmission, can cause the clutch plates to fail.
Automatic Transmission Fluid Recommendations

Hydraulic fluids (oils) used in the transmission are important influences on
transmission performance, reliability, and durability. Allison-approved C-4
fluids are required for all off-highway applications.
CAUTION: Disregarding minimum fluid temperature limits can result

in transmission malfunction or reduced transmission life.
When choosing the optimum viscosity grade of fluid to use, duty cycle,
preheat capabilities, and/or geographical location must be taken into
consideration. Grade 15W-40 transmission fluid is recommended for all off-
highway operation above 5 F (15 C) ambient temperature. The table below
lists the minimum temperatures at which the transmission may be safely
operated. Below these temperatures, preheat with auxiliary heating equipment
or by running the vehicle with the transmission in N (Neutral) for a minimum
of 20 minutes before attempting range operation.
Operating Temperature Requirements for Transmission Fluid
Ambient Temperature Below

Viscosity Grade Which Preheat Is Required
Fahrenheit Celsius
SAE 10W 4 20
SAE 15W-40 5 15
SAE 30 32 0
SAE 40 50 10
Ref. 13-TR-90.
24
Transmission Fluid Capacity
Transmission Series Refill Capacity

5000, 6000
straight-through 18.5 gallons (70 liters)
dropbox 13 gallons (49 liters)
8000
straight-through 19 gallons (72 liters)
9000
straight-through 19 gallons (72 liters)
CARE OF BREATHER
Keep the breather clean at all times. Check and clean the breather regularly and as
frequently as necessary, depending on the operating conditions. A badly corroded or
plugged breather restricts proper breathing and causes a buildup of condensation and
subsequent fluid deterioration.
RETARDER LINKAGE ADJUSTMENTS

Adjust the retarder valve for 8000 and 9000 Series models (when the retarder is released)
so the valve is held firmly downward (into the valve body) to its stop. When the retarder
is applied, make sure the retarder valve is all the way up (out of the valve body).
Adjust the retarder valve for 5000 and 6000 Series models (when the retarder is
released) so the valve is held firmly upward (out of the valve body) to its stop. When
the retarder is applied, make sure the retarder valve is all the way down (into the valve
body).
Inspect the control linkage for binding, wear, or breaks.
CAUTION: If the linkage allows the retarder to be partially applied,

excessive drag and overheating will result.
25
PARKING BRAKE (Some Models)
An internal, expanding-shoe parking brake is mounted on the rear of the transmission
housing at the output.
Adjustment
Adjust the brake shoes for proper drum clearance by inserting a screwdriver
or brake adjusting tool into the adjusting slot in the brake backplate, and
rotating the star wheel adjusting screw between the lower ends of the brake
shoes. Rotate the star wheel until the shoes are held snugly against the brake
drum. Back off the adjusting screw three full turns.
Adjust the vehicle brake linkage by releasing the apply mechanism fully, and
adjusting the connecting linkage so that it can be freely connected to the apply
lever on the brake. Take all slack out of the brake, without actually moving the
brake shoes, when the linkage adjustment is made.
Burnishing
Follow the manufacturers recommendations for burnishing a new drum and
brake shoes.
CAUTION: Do not overburnish the brake.
26
TROUBLESHOOTING
Investigate transmission malfunction immediately to protect the life of the

transmission. The following chart lists the possible causes of, and remedies for,
transmission troubles. As indicated in the chart, the engine and transmission must be
considered as a single package when searching for trouble.
For additional troubleshooting of the electrical system and for repair instructions for
the transmission, refer to the transmission Service Manual.
TROUBLESHOOTING CHART
WARNING: If the control valve solenoids are activated by an external
power supply, sudden and unexpected movement of the vehicle may
occur. A runaway vehicle could only be stopped by applying the brakes
or shutting down the engine: removal of the power supply would not
stop the vehicle because of the fail-protection system. To help avoid
injury or property damage, electricity must never, under any
circumstances, be applied to any electric valve body component while
the engine is running, while the mechanic is working under the vehicle,
or while personnel are working in the vehicle path. Before any
troubleshooting of the electric-shift solenoids, always shut off the
engine, set the vehicle brakes, and chock the wheels.
Cause Remedy
A. TRANSMISSION OVERHEATS
1. High or low fluid level 1. Restore proper fluid level.
2. Aerated (foaming) fluid 2. Refer to B.
3. Vehicle or equipment overloaded 3. Reduce load.
4. Engine coolant overheated 4. Correct engine overheating.
5. Heat exchanger or lines kinked or 5. Clean or replace heat exchanger
clogged or lines.
6. Low coolant level 6. Add coolant, check for leaks.
27
Cause Remedy
A. TRANSMISSION OVERHEATS (contd)
7. Transmission fluid leaking 7. Check transmission and all external
lines. Correct leaks.
8. Low main pressure 8. Refer to V.
9. Low converter-out pressure 9. Refer to U.
10. Vehicle brakes dragging 10. Check parking and service brakes.
11. Torque converter stator locked 11. Check for low top speed of vehicle.
Check torque converter components.
12. Clutch slipping 12. Overhaul transmission. Replace worn
piston sealrings and/or clutch plates.
13. Retarder engaged 13. Disengage the retarder.
B. TRANSMISSION FLUID IS AERATED (FOAMING)
1. Incorrect fluid used 1. Change fluid. Use proper fluid.
2. High or low fluid level 2. Restore proper fluid level.
3. Air entering suction side of pump 3. Check oil pump bolts and gasket.
4. Water in transmission fluid 4. Check for source. Clean system.
C. HEAVY METAL DEBRIS IS FOUND IN TRANSMISSION FLUID,
STRAINER, OR PAN
1. Transmission internal failure 1. Completely disassemble, clean, and
repair transmission. Replace filters
and clean external lines and cooler.
D. COOLANT IS FOUND IN TRANSMISSION FLUID
1. Heat exchanger leaking 1. Completely disassemble and
thoroughly clean transmission.
Replace all friction-faced clutch
plates. Repair or replace heat
exchanger. Replace filters and clean
external lines.
E. TRANSMISSION WILL NOT OPERATE IN ANY RANGE,
REGARDLESS OF SELECTOR POSITION
1. Loss of electrical power 1. Refer to Electronic Troubleshooting
Manual TS2712EN.
2. Internal mechanical failure 2. Overhaul transmission.
3. Driveline failure 3. Check input and output of
transmission.
4. Low fluid level 4. Restore proper fluid level.
28
Cause Remedy
F. TRANSMISSION CONTINUES IN THE SAME FORWARD RANGE
REGARDLESS OF SELECTOR POSITION
1. Loss of electrical power 1. Refer to Electronic Troubleshooting
Manual TS2712EN.
G. SHIFTING IS ERRATIC
1. Refer to Electronic Troubleshooting
Manual TS2712EN.
H. TRANSMISSION OPERATES ONLY IN FIRST, NEUTRAL,
AND REVERSE
Manual TS2712EN.
I. TRANSMISSION SHIFTS TO NEUTRAL DURING REVERSE OPER-
ATION, BUT WILL OPERATE NORMALLY IN ALL FORWARD
RANGES
Manual TS2712EN.
J. VEHICLE OPERATES IN REVERSE AND MOVES BACK-
WARD IN NEUTRAL WHEN ENGINE IS ACCELERATED,
BUT STALLS IN ALL OTHER RANGES WHEN ENGINE IS
ACCELERATED ELECTRONIC TROUBLESHOOTING OK
1. Reverse clutch failed (wont release) 1. Overhaul transmission.
K. VEHICLE OPERATES IN FIRST AND SECOND RANGES AND
MOVES FORWARD IN NEUTRAL WHEN ENGINE IS ACCELER-
ATED, BUT STALLS IN ALL OTHER RANGES WHEN ENGINE IS
1. Low-range clutch failed (wont 1. Overhaul transmission.
release)
L. VEHICLE OPERATES IN THIRD AND FOURTH RANGES AND
MOVES FORWARD IN NEUTRAL WHEN ENGINE IS ACCELER-
ATED, BUT STALLS IN ALL OTHER RANGES WHEN ENGINE IS
1. Intermediate-range clutch has failed 1. Overhaul transmission.
(wont release)
29
Cause Remedy
M. VEHICLE OPERATES IN FIFTH AND SIXTH RANGES AND MOVES
FORWARD IN NEUTRAL WHEN ENGINE IS ACCELERATED, BUT
STALLS IN ALL OTHER RANGES WHEN ENGINE IS ACCELER-
ATED ELECTRONIC TROUBLESHOOTING OK
1. High-range clutch failed (wont 1. Overhaul transmission.
release)
N. NO POWER IS TRANSMITTED IN ONE RANGE (LOW
RANGE, INTERMEDIATE RANGE, HIGH RANGE, OR
REVERSE) ELECTRONIC TROUBLESHOOTING OK
1. Range clutch failed (wont apply, 1. Overhaul transmission. Check for
slipping) worn piston seals, broken piston
housing, or worn clutch plates in
that range.
O. VEHICLE WILL OPERATE IN SECOND, FOURTH, SIXTH, AND
REVERSE RANGES BUT WILL NOT OPERATE IN ALL OTHER
RANGES ELECTRONIC TROUBLESHOOTING OK
1. Splitter-high clutch wont release or 1. Overhaul transmission. Check
splitter-low clutch wont apply, splitter clutches for worn
slipping components.
P. VEHICLE WILL OPERATE IN FIRST, THIRD, AND FIFTH
RANGES BUT WILL NOT OPERATE IN ALL OTHER
RANGES ELECTRONIC TROUBLESHOOTING OK
1. Splitter-low clutch wont release or 1. Overhaul transmission. Check
splitter-high clutch wont apply, splitter clutches for worn
slipping components.
Q. SLOW CLUTCH ENGAGEMENT
1. Low transmission fluid level 1. Add fluid to proper level.
2. Foaming transmission fluid 2. Refer to B.
3. Worn piston seals 3. Overhaul transmission.
5. Low transmission fluid temperature 5. Use recommended fluid. Preheat if
required.
30
Cause Remedy
R. VEHICLE LACKS POWER AND ACCELERATION
1. Stator freewheel clutch failed 1. Overhaul transmission.
2. Engine malfunction 2. Check engine; refer to engine
service manual.
3. Aerated transmission fluid 3. Refer to B.
4. Low engine speed at converter stall 4. Refer to T.
5. High engine speed at converter stall 5. Refer to S.
6. Hydraulic retarder partially applied 6. Check linkage.
7. Vehicle brakes dragging 7. Check parking and service brakes.
S. HIGH ENGINE SPEED AT CONVERTER STALL
2. Low converter-out pressure 2. Refer to U.
3. High fluid temperature (above 275F; 3. Refer to A.
135C)
4. Clutch slipping main pressure 4. Overhaul transmission. Replace
normal clutch piston sealrings or clutch
plates.
T. LOW ENGINE SPEED AT CONVERTER STALL
1. Low engine output torque 1. Tune engine and check output.
2. Converter element interference 2. Check for noise at stall; overhaul
converter if necessary.
3. Transmission fluid below operating 3. Warm up transmission to 180220F
temperature (82103C).
U. LOW CONVERTER-OUT PRESSURE
2. Fluid line leakage (remote-mounted 2. Check for fluid leaks correct
cooler or filter) leaks.
3. Plugged strainer 3. Clean strainer.
4. Defective pump 4. Rebuild or replace pump assembly.
5. High fluid temperature 5. Refer to A.
31
Cause Remedy
V. LOW MAIN PRESSURE
2. Leaks in hydraulic system 2. Check all external points for leaks;
check each range for localizing
internal leaks.
3. Failure in main-pressure regulator 3. Overhaul valve assembly.
valve
4. Worn input pump assembly 4. Rebuild or replace pump assembly.
5. Clogged strainer 5. Clean oil strainer.
6. Air leaks at suction side of 6. Check input pump; correct leaks.
input pump
7. Converter-in check valve stuck open 7. Repair valve.
or spring failed
8. Lubrication regulator valve stuck 8. Repair valve.
open or spring failed
W. DOWNSHIFT OF TRANSMISSION IS PERMITTED DURING
LOCKUP OPERATION
Manual TS2712EN.
X. SHIFT QUADRANT NOT ILLUMINATED
1. Failed light bulb 1. Replace the light bulb.
Y. REVERSE SIGNAL NOT ENERGIZED
Manual TS2712EN.
ELECTRONIC DUAL-ELECTRIC Vehicles with Front and Rear
Transmission Units
The front transmission can have the same troubles and symptoms as any other 5000
or 6000 transmission. The controls for the rear transmission are slightly different
and therefore have some different symptoms when problems occur. The following
symptoms, causes, and remedies apply to the rear unit only.
AA. REAR TRANSMISSION SHIFTS TO NEUTRAL AND REMAINS IN

NEUTRAL REGARDLESS OF SELECTOR POSITION
1. Complete interruption of electrical 1. Refer to Electronic Troubleshooting
power Manual TS2712EN.
32
Cause Remedy
AB. REAR TRANSMISSION SHIFTS TO NEUTRAL IN ONE RANGE
BUT OPERATES NORMALLY IN ALL OTHER RANGES
1. Interruption of power to a controlling 1. Refer to Electronic Troubleshooting
solenoid Manual SA2712.
AC. REAR TRANSMISSION UPSHIFTS DURING OPERATION IN
REVERSE (HIGHER RATIO), FIRST, THIRD, OR FIFTH RANGE
1. Interruption of power to controlling 1. Refer to Electronic Troubleshooting
solenoid Manual TS2712EN.
AD. SPEED OF REAR ENGINE OUT OF SYNCHRONIZATION
WITH FRONT ENGINE
1. Interruption of power to controlling 1. Refer to Electronic Troubleshooting
solenoid Manual TS2712EN.
33
CUSTOMER SERVICE
OWNER ASSISTANCE
The satisfaction and goodwill of the owners of Allison transmissions are of primary
concern to Allison Transmission Division (ATD), its distributors, and their dealers.
As an owner of an Allison transmission, you have service locations throughout the

world that are eager to meet your parts and service needs with:
Expert service by trained personnel

Emergency service 24 hours a day in many areas
Complete parts support
Sales teams to help determine your transmission requirements
Product information and literature
Normally, any situation that arises in connection with the sale, operation, or service of
your transmission will be handled by the distributor or dealer in your area (check the
telephone directory for the Allison Transmission service outlet nearest you).
We recognize, however, that despite the best intentions of everyone concerned,

misunderstandings may occur. To further assure your complete satisfaction, we have
developed the following three-step procedure to be followed in the event you have a
problem that has not been handled satisfactorily.
Step One Discuss your problem with a member of management from the
distributorship or dealership. Frequently, complaints are the result of a breakdown
in communication and can quickly be resolved by a member of management. If you
have already discussed the problem with the Sales or Service Manager, contact the
General Manager. All ATD dealers are associated with an ATD distributor. If your
problems originate with a dealer, explain the matter to a management member of the
distributorship with whom the dealer has his service agreement. The dealer will
provide his ATD distributors name, address, and telephone number on request.
34
Step Two When it appears the problem cannot be resolved readily at the distributor
level without additional assistance, contact the Allison Transmission Regional Office
responsible for the local distributor. You will be assisted by a member of the Regional
Service Managers staff, depending on the nature of your problem.
For prompt assistance, please have the following information available:

Name and location of authorized distributor or dealer
Type and make of equipment
Transmission model number, serial number, and assembly number (if
equipped with electronic controls, also provide the ECU assembly number)
Transmission delivery date and accumulated miles and/or hours of operation
Nature of problem
Chronological summary of units history
Step Three If you contacted a regional office and you are still not satisfied, present
the entire matter to the Home Office by writing to the following address or
calling the phone number below:
Manager, Warranty Administration PF9
P.O. Box 894
Indianapolis, IN 46206-0894
Phone: (317) 242-3538
The inclusion of all pertinent information will assist the Home Office in expediting the
matter. If an additional review by the Home Office of all the facts involved indicates
that some further action can be taken, the Regional Office will be advised.
When contacting the Regional or Home Office, please keep in mind that ultimately the
problem will likely be resolved at the distributorship or dealership utilizing their
facilities, equipment, and personnel. Therefore, it is suggested that the above steps be
followed in sequence when experiencing a problem.
Your purchase of an Allison Transmission product is greatly appreciated, and it is our
sincere desire to assure complete satisfaction.
35
SERVICE LITERATURE
Additional service literature is available. This service literature provides
fully illustrated instructions for the operation, maintenance, service,
overhaul, and parts support of your transmission. To ensure that you get
maximum performance and service life from your unit, see your dealer or
distributor for the following publications.
Check the telephone directory for the Allison Transmission distributor or dealer
nearest you. If you are unable to obtain these publications from your local Allison
distributor, please contact:
Manager, Product Training and Technical Publications A01
P.O. Box 894
Indianapolis, IN 46206
Phone: (317) 242-0236
Service Literature
Service Parts Troubleshooting

Transmission Series Manual Catalog Procedures Manual
5000, 6000 SM1866EN PC1860EN TS2712EN
8000 SM1228EN PC1249EN TS2712EN
9000 SM1833EN PC1830EN TS2712EN
36
ALLISON TRANSMISSION DISTRIBUTORS
EASTERN REGION
Atlantic Detroit Diesel-Allison, Inc. Penn Detroit Diesel Allison, Inc.
180 Route 17 South 8330 State Road
Lodi, NJ 07644 Philadelphia, PA 19136-2986
201-489-5800 215-335-0500
Johnson & Towers, Inc. Western Branch Diesel, Inc.
2021 Briggs Road 3504 Shipwright Street
Mount Laurel, NJ 08054 Portsmouth, VA 23705
609-234-6990 757-484-6230
New England Detroit Diesel-Allison, Inc.
90 Bay State Road
Wakefield, MA 01880-1095
617-246-1810
SOUTHERN REGION
Caribe Detroit Diesel-Allison Stewart & Stevenson Services, Inc.
Division of GT Corporation 2707 North Loop West
Ceramic Ind. Park, Campo Rico Ave. Houston, TX 77008
Carolina, Puerto Rico 00628 713-868-7700
787-750-5000
Covington Detroit Diesel-Allison, Inc. United Engines, Inc.
6200 Swiggett Road 5555 West Reno Avenue
Greensboro, NC 27419-8949 Oklahoma City, OK 73127
910-292-9240 405-947-3321
Florida Detroit Diesel-Allison, Inc. Williams Detroit Diesel-Allison
5105 Bowden Road Southeast, Inc.
Jacksonville, FL 32216 2849 Moreland Avenue, S.E.
904-737-7330 Atlanta, GA 30315-0037
404-366-1070
Florida Detroit Diesel-Allison North, Inc.
5105 Bowden Road
Jacksonville, FL 32216
904-737-7330
37
CENTRAL REGION
Central Detroit Diesel-Allison, Inc. Inland Diesel, Inc.
9200 Liberty Drive 13015 West Custer Avenue
Liberty, MO 64068 Butler, WI 53007-0916
816-781-8070 414-781-7100
Clarke Detroit Diesel-Allison, Inc. Interstate Detroit Diesel, Inc.
3133 East Kemper Road 2501 East 80th Street
Cincinnati, OH 45241 Minneapolis, MN 55425
513-771-2200 612-854-5511
Inland Detroit Diesel-Allison, Inc. Williams Detroit Diesel-Allison
210 Alexandra Way Midwest, Inc.
Carol Stream, IL 60195 1176 Industrial Parkway, North
630-871-1111 Brunswick, OH 44212-2342
330-225-7751
WESTERN REGION
Hawaii Detroit Diesel-Allison, Inc. Spokane Detroit Diesel-Allison, Inc.
91-265 Kalaeloa Boulevard 6615 East Mallon Street
Kapolei, HI 96707 Spokane, WA 99212
808-682-2400 509-535-3663
Pacific Detroit Diesel-Allison Company Stewart & Stevenson Power, Inc.
7215 South 228th Street 5840 Dahlia Street
Kent, WA 98302 Commerce City, CO 80022
206-854-0505 303-287-7441
Sierra Detroit Diesel Allison, Inc. Valley Detroit Diesel Allison, Inc.
1755 Adams Avenue 13644 East Nelson Avenue
San Leandro, CA 94577-1001 City of Industry, CA 91746
510-635-8991 818-333-1243
Smith Detroit Diesel/Allison, Inc. Williams Detroit Diesel-Allison
250 West 3900 South Southwest, Inc.
Salt Lake City, UT 84107 2602 S. 19th Avenue
801-262-2631 Phoenix, AZ 85009
602-257-0561
38
CANADIAN REGION
Detroit Diesel-Allison British Columbia Midwest Detroit Diesel-Allison Ltd.
Ltd. 1460 Waverley Street
9300 - 192nd Street Winnipeg, Manitoba R3T OP6
Surrey, British Columbia V4N 3R8 204-452-8244
604-888-1211
Detroit Diesel-Allison Canada East, Inc. Waterous Detroit Diesel-Allison, Inc.
2997 Rue Watt 10025 - 51st Avenue
Ste. Foy, Quebec G1X 3W1 Edmonton, Alberta T6E OA8
418-651-5371 403-437-3550
Harper Detroit Diesel Ltd.
10 Diesel Drive
Toronto, Ontario M8W 2T8
416-259-3281
MEXICO REGION
Detroit Diesel-Allison De Mexico S.A. De
C.V.
Av. Paseo de la Reforma No. 2977
Del Cuajimalpa, Mexico, D.F. 05000
(525) 6-265-300
39
OM2034EN 199803 Printed in U.S.A. 199912
Bulletin HY25-1135-M1/US
Owners Manual
Power Take-Offs
Effective: December 2003
Supersedes: HY25-1135-M1/US
October 2003
100 Series 436 Series 660 Series

435 Series 489 Series
WARNING
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED
HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE.
This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors
provide product and/or system options for further investigation by users having technical expertise. It is important
that you analyze all aspects of your application and review the information concerning the product or system in the
current product catalog. Due to the variety of operating conditions and applications for these products or systems,
the user, through its own analysis and testing, is solely responsible for making the final selection of the products and
systems and assuring that all performance, safety and warning requirements of the application are met.
The products described herein, including without limitation, product features, specifications, designs, availability and
pricing, are subject to change by Parker Hannifin Corporation and its subsidiaries at any time without notice.
Offer of Sale
The items described in this document are hereby offered for sale by Parker Hannifin Corporation, its subsidiaries or
its authorized distributors. This offer and its acceptance are governed by the provisions stated in the "Offer of Sale".
Patent Information

The Chelsea Power Take-Off or its components shipped with this owners manual may be manufactured under one
or more of the following U.S. patents:
4610175 5228355 4597301 5645363 6151975 6142274 6260682
Other patents pending.
Copyright 2003, Parker Hannifin Corporation, All Rights Reserved
II Parker Hannifin Corporation

Chelsea Products Division
Olive Branch, MS 38654 USA
Bulletin HY25-1135-M1/US Owners Manual
Contents 6 and 8 Bolt P.T.O.s
General Information
Safety Information ........................................................................................................... 1-3
Direct Mount Pump Support Recommendations ............................................................... 4
Foreword ......................................................................................................................... 5
P.T.O. Safety Labels Installation ...................................................................................... 5
Installation Instructions
GMT3600 Cab-Chassis w/ZF .......................................................................................... 7-16
Mounting P.T.O. to Transmission 6 & 8 Bolts ................................................................... 17-18
880/912 Split Shaft Installation ........................................................................................ 19
Checking Backlash .......................................................................................................... 20-21
Adapter Plates, Filler Blocks, Adapter Assembly ............................................................ 22
Lubricant in Transmission/Inspect Installation ................................................................... 23
Function of Auxiliary Power Shafts .................................................................................. 24
Spicer Universal Joint Engineering Data Quick Reference ............................................... 25
Wire Shift P.T.O.
Continuity Check (379639 & 379652 indicator switches) .................................................. 26
Cable Control Installation ................................................................................................. 27-31
Automatic Transmissions
Pressure Lube Hose Connection ...................................................................................... 32
442 Series Pressure Lube for Allison 1000, 2000/2400 Series .......................................... 33
P.T.O. Openings for Automatic Transmissions ................................................................. 34-36
P.T.O. Shifting Procedure ................................................................................................ 37
Air Shift P.T.O. Installation Sketch
- 340 and 352 Series ........................................................................................................ 38
- 880 Series ..................................................................................................................... 39
- 100, 221, 260, 429, 434, 435, 436, 437, 438, 442,
447, 489, 660, 680 and 812 Series ................................................................................ 40
Electric Over Air Shift P.T.O. Installation Sketch
- 100, 221, 260, 429, 434, 435, 436, 437, 438, 442,
447, 489, 660, 680 and 812 Series ................................................................................ 41
E-Z Shift Installation Sketch for GMT/ZF
- 442 Series ..................................................................................................................... 42
Indicator Light Installation ..................................................................................................... 44
Dash Drilling Templates .................................................................................................... 44, 46, 48
P.T.O. Maintenance ............................................................................................................ 49
Offer of Sale ....................................................................................................................... 50
Loose In This Booklet
Mounting Gaskets
Sun Visor Decal
III Parker Hannifin Corporation
General Information 6 and 8 Bolt P.T.O.s
Safety Information
These instructions are for your safety and the safety of the end user. Read them carefully until
you understand them.
General Safety Information

To prevent injury to yourself and/or damage to the equipment:
Read carefully all owners manuals, service manuals, and/or other instructions.
Always follow proper procedures, and use proper tools and safety equipment.
Be sure to receive proper training.
Never work alone while under a vehicle or while repairing or maintaining equipment.
Always use proper components in applications for which they are approved.
Be sure to assemble components properly.
Never use wornout or damaged components.
Always block any raised or moving device that may injure a person working on or under a
vehicle.
Never operate the controls of the Power Take-Off or other driven equipment from any position
that could result in getting caught in the moving machinery.
Proper Matching of P.T.O.
WARNING: A Power Take-Off must be properly matched to the vehicle transmission and
to the auxiliary equipment being powered. An improperly matched Power Take-Off could cause
severe damage to the vehicle transmission, the auxiliary driveshaft, and/or to the auxiliary
equipment being powered. Damaged components or equipment could malfunction causing
serious personal injury to the vehicle operator or to others nearby.
To avoid personal injury and/or equipment damage:

Always refer to Chelsea catalogs, literature, and owners manuals and follow Chelsea
recommendations when selecting, installing, repairing, or operating a Power Take-Off.
Never attempt to use a Power Take-Off not specifically recommended by Chelsea for the
vehicle transmission.
Always match the Power Take-Offs specified output capabilities to the requirements of the
equipment to be powered.
Never use a Power Take-Off whose range of speed could exceed the maximum safe speed
of the equipment to be powered.
This symbol warns of possible personal injury.
1 Parker Hannifin Corporation

Safety Information
Cold Weather Operation of Powershift P.T.O.s
WARNING: During extreme cold weather operation [32 F (0 C) and lower], a

disengaged Powershift Power Take-Off can momentarily transmit high torque that will cause
unexpected output shaft rotation. This is caused by the high viscosity of the transmission oil
when it is extremely cold. As slippage occurs between the Power Take-Off clutch plates, the
oil will rapidly heat up and the viscous drag will quickly decrease.
The Power Take-Off output shaft rotation could cause unexpected movement of the driven
equipment resulting in serious personal injury, death, or equipment damage.
To avoid personal injury or equipment damage:

Driven equipment must have separate controls.
The driven equipment must be left in the disengaged position when not in operation.
Do not operate the driven equipment until the vehicle is allowed to warm up.
Rotating Auxiliary Driveshafts
WARNING:
Rotating auxiliary driveshafts are dangerous. You can snag clothes, skin, hair, hands, etc.
This can cause serious injury or death.
Do not go under the vehicle when the engine is running.
Do not work on or near an exposed shaft when the engine is running.
Shut off the engine before working on the Power Take-Off or driven equipment.
Exposed rotating driveshafts must be guarded.
Guarding Auxiliary Driveshafts
WARNING: We strongly recommend that a Power Take-Off and a directly mounted

pump be used to eliminate the auxiliary driveshaft whenever possible. If an auxiliary
driveshaft is used and remains exposed after installation, it is the responsibility of the
vehicle designer and P.T.O. installer to install a guard.

Safety Information
Using Set Screws
WARNING: Auxiliary driveshafts may be installed with either recessed or protruding

set screws. If you choose a square head set screw, you should be aware that it will protrude
above the hub of the yoke and may be a point where clothes, skin, hair, hands, etc. could be
snagged. A socket head set screw, which may not protrude above the hub of the yoke, does
not permit the same amount of torquing as does a square head set screw. Also, a square head
set screw, if used with a lock wire, will prevent loosening of the screw caused by vibration.
Regardless of the choice made with respect to a set screw, an exposed rotating auxiliary
driveshaft must be guarded.
Important: Safety Information and Owners Manual

Chelsea Power Take-Offs are packaged with safety information decals, instructions, and an
owners manual. These items are located in the envelope with the P.T.O. mounting gaskets.
Also, safety information and installation instructions are packaged with some individual parts
and kits. Be sure to read the owners manual before installing or operating the P.T.O. Always
install the safety information decals according to the instructions provided. Place the owners
manual in the vehicle glove compartment.
WARNING: Operating the P.T.O. with the Vehicle in Motion

Some Power Take-Offs may be operated when the vehicle is in motion. To do so, the P.T.O.
must have been properly selected to operate at highway speeds and correctly matched to the
vehicle transmission and the requirements of the driven equipment.
If in doubt about the P.T.O.s specifications and capabilities, avoid operating the P.T.O. when
the vehicle is in motion. Improper application and/or operation can cause serious personal
injury or premature failure of the vehicle, the driven equipment, and/or the P.T.O.
Always remember to disengage the P.T.O. when the driven equipment is not in operation.
Pump Installation Precautions (see next page)
Use a bracket to support the pump to the transmission if:
The pump weighs 40 pounds or more.
The combined length of the P.T.O. and pump is 18 inches or more from the P.T.O.
centerline to the end of the pump.
Also remember to pack the female pilot of the P.T.O. pump flange with grease before installing
the pump on the P.T.O.
CAUTION: When installing the 489 Series P.T.O. several direct mount pump flange options
may interfere with the mounting fasteners directly under the flange. The nut must be threaded
far enough onto the stud before the remaining (6) six capscrews and other nut are tightened to
prevent interference with the flange and possible breakage of the P.T.O. housing.

Direct Mount Pump Support Recommendations
Note: For Proper Bracketing Attach At 2 or

more Transmission Bolt Locations
and 2 or More Pump Locations.
Use caution to ensure that bracket does not pre-load pump/

P.T.O. mounting
Chelsea strongly recommends the use of pump supports (Support Brackets) in all applications.
P.T.O. warranty will be void if a pump bracket is not used when:
1) The combined weight of pump, fittings and hose exceed 40 pounds.
2) The combined length of the P.T.O. and pump is 18 inches or more from
the P.T.O. centerline to the end of the pump.
ALSO: Remember to pack the female pilot of the P.T.O. pump shaft with grease before
installing the pump on the P.T.O. (reference Chelsea grease pack 379688)

Foreword
Since it is our major objective to show you how to get additional and more profitable miles
from truck, tractor, and trailer components, we want to provide you with information on the
installation of Chelsea Power Take-Offs.
We all realize that an inadequate transmission will overwork any power take-off in a very
short period of time. In addition, a mismatched transmission/P.T.O. combination can result in
unsatisfactory performance of the equipment right from the start.
Before you order new trucks, be sure that youre getting the right transmission/P.T.O.
combination. This is vital for efficient performance and adequate power. To help you select
the proper type, size, and design of P.T.O., discuss your specific requirements with a
Chelsea P.T.O. specialist. They know their products and have easy access to equipment,
transmission, and Power Take-Off manufacturers. They can tell you everything you need to
know about power, at the right time, before you specify components.
Chelsea P.T.O. Safety Label Instructions

1. The two black and orange on white 5" x 7" pressure sensitive vinyl labels, part number
379274; must be placed on the vehicle frame rails (one (1) on each side), in a position
that would be HIGHLY visible to anyone that would go under the truck near the P.T.O.
rotating shaft. If the vehicle is to be painted after these labels are installed, cover them
with two-(2) blank masking covers. Remove the masking covers after painting.
2. Place the one (1) black and orange on white 3.5" x 5" pressure sensitive vinyl label, part
number 379275, on the visor nearest the operator of the vehicle, this must be placed
near the P.T.O. visor label.
3. Place the one (1) red and white with black lettering 3.5" x 7.5" sensitive vinyl label, part
number 379915, on the opposite side of the visor from the above label # 379275.
4. Place the one (1) white and black heavy duty card, part number 379276, in the vehicle
glove box. Again in a position highly visible to the operator, for example: try to place this
card on top of whatever may be in the glove box.
If you require additional labels, please order part number 328946X at no charge from your
local Chelsea Warehouse or send request direct to:
Parker Hannifin Corporation

8225 Hacks Cross Road
Olive Branch, MS 38654
Customer Service: (662) 895-1011


Installation Instructions 6 and 8 Bolt P.T.O.s
GMT3600 Cab-Chassis W/ZF

Overview
P.T.O. provisions have been provided as standard content (forced options) on the
2001MY C/K 3600 (Cab-Chassis) trucks with 8.1L Vortec and 6.6L Durmax Diesel
engines. These provisions are included in two forced options, M1F and P.T.O. M1F
contains provisions for P.T.O. packaging. P.T.O. contains provisions for P.T.O. Engagement
Control and P.T.O. Engine Speed Control. Both options are standard on the C/K 3600
cab-chassis trucks with the 8.1L and 6.6L engines.
M1F-provides for mounting space for transmission mounted Power Take-Off. P.T.O.
mounting space is for the right hand side of the transmission. With the ZF S6-650
manual transmissions there are two (2) openings for P.T.O. applications. The right
opening requires the use of a heat shield, direct mount pumps and hard line hydraulic
tubes for installation along with a Chelsea 442 Series Power Take-Off.
Left side applications do not require the extra hardware for installation, but may not be
usable on 4x4 vehicles due to the transfer case to front axle driveshaft.
P.T.O.-provides Engine Speed Control. P.T.O. includes the following:

P.T.O. engine control software in Powertrain Control Module (PCM)
Wiring provisions for in-cab P.T.O. Control Switch
Upfitter P.T.O. Interface Connector which is located at the left side of the
transmission.
Two P.T.O. operating speed control modes are available with the 8.1L Vortec and 6.6L
Duramax Diesel engine. The PowerTrain Control Module (PCM) may be programmed to
one of the following modes.
Preset Up to two* preset P.T.O. operating speeds.
Variable Allows variable P.T.O. speeds while vehicle is stationary or moving.
* Requires Cruise Control to control second preset speed.
Refer to GM Truck Owners Manual for Complete Information on PCM Operations

Right Side Aperture Pre-Installation

1. Drain oil from transmission. Drain plug is located
on the left side of the transmission.
2. If the vehicle is equipped with the 8.1L Gas
Engine, it may be necessary to remove the three
(3) bolts & studs that connect the right exhaust
pipe and the right side engine exhaust header.
(Fig. 1) This will allow the exhaust pipe to be
moved slightly away from the P.T.O. opening for Fig. 1
installation of the P.T.O. to the aperture pad.
3. Remove the transmission P.T.O. aperture cover
and gasket. Make sure the aperture surface is
clean and dry (Fig. 2).
4. Install the six studs and torque to 17-19 ft. lbs.
[23-26 N.m] (Fig. 3).
CAUTION: Over tightening of studs may damage Fig. 2
stud threads or transmission case threads if studs
are not installed correctly. Use of air impact tools is
not recommended.
Fig. 3

P.T.O. Installation Checking Backlash

5. Using your hand, rock the P.T.O. driver gear in
the transmission and the driver gear in the P.T.O.
assembly. Rocking the gears provides two
important factors (Fig 4).
a) It shows you the amount of backlash that has
been designed into each unit.
b) It is helpful in establishing the proper backlash
Fig. 4
when installing the P.T.O.
6. Place the correct number of gaskets over studs
(Fig. 5). Do not use Permatex between gaskets
because you may want to add or subtract
gaskets to obtain proper backlash.
When mounting a P.T.O. use gaskets
between all mounting surfaces.
Do not stack more than 3 gaskets together. Fig. 5
Usually one thick gasket .020" (.50mm) will
be required.
Remember the lubricant in the transmission
also lubricates the P.T.O. Therefore, at least
one gasket must be used on either side of
filler blocks, adapter assembly or adapter
plates. More gaskets may be required when
establishing proper backlash.
7. Secure P.T.O. to aperture pad. Torque nuts to
35 40 ft. lbs. [47-54 N.m].
8. Check backlash as in any 442 Series installation
[see page 20 of HY25-1135-M1/US].
9. Remove P.T.O. at this point.

P.T.O. & Pump Pre-Installation

10. Next install the pump flange as shown in Fig. 6.
With the P.T.O. on the workbench, shifter cover
facing towards you and the belly of the P.T.O.
down, the flange shown should be towards your
right. Orient the pump flange to the 3:30 9:30
position. Install the 6 socket head capscrews
(378446-4) and torque to 8-12 ft. lbs. [11-16 Fig. 6
N.m].
11. It will be necessary to rotate the P.T.O. shift lever
180 from the position it is normally positioned
(Fig. 7 & 8).
12. On the closed end bearing cap remove the
bottom left cap bolt as shown in Fig. 9. This will
be used later to attach the heat shield.
13. Install the pump with the bulge up*. Attach the Fig. 7
P.T.O. heat shield bracket (379862) to the pump
bolt as shown in Fig. 10 (suction port side
closest to transmission). Torque pump bolts to
32-37 ft. lbs. [ 45-50 N.m.]
* Before attaching pump, pack the female pilot of
the pump shaft with grease (Chelsea grease
pack 379688).
Fig. 8
Fig. 9
Fig. 10

P.T.O. & Pump Pre-Installation (Continued)

14. Install the two fittings for suction and discharge in
the ports on the pump. Due to the angle of the
fittings, install the discharge port fitting first. Do
not tighten these fittings at this time (See Fig. 11
& 12). Screw fittings in by hand until back-up
washer contacts the face of the boss.
NOTE: CGP-P14 shown for installation purposes.
Fig. 11
CGP-P5 and CGP-P11 pumps require additional
fittings to connect the pump to the hydraulic
tubes. See Chart below.
Fig. 12
Pump Fitting Swivel Nut Std Thd Swivel Nut Std Thd O-Ring
Series Kit Suction O-Ring Suction Discharge Discharge
CGP-P5 329335-1X 379866* 379870 379868* 379869
CGP-P11 329335-2X 379866* 379867 - 379850*
CGP-P14 329335-3X - 379849* - 379850*
* 45 Elbow Fitting
15. We will now move to the attachment of the

hydraulic hard lines to the support bracket
(379848). First attach the pump discharge tube
(379845) with tube clamp (501211-8). Next
install the pump suction tube (379846) with tube
clamp (501211-12). Insert bolt (379706) through
both tube clamps and top of bracket. Tighten nut
(379141-9) onto bolt under bracket (Fig. 13 & 14). Fig. 13
Fig. 14

Mounting P.T.O./Pump to the Transmission

16. Secure P.T.O./Pump to the transmission. (Fig. 15)
17. Use Self Locking nuts provided with P.T.O. (Fig.16)

NOTE: Self-Locking nuts do not require lock
washers.
18. Fasten the P.T.O. to the transmission (Fig. 17). Fig. 15

Torque the set of self-locking nuts (379744) to
35-40 ft. lbs. [47-54 N.m].
19. If Installing Engine/P.T.O. Interface Wiring

Harness Kit 329333-4X follow steps 19 & 20. If
not skip to step 22.
Fig. 16
20. Locate the GM upfitter P.T.O. interface connector,

located on the upper left side of the transmission.
Connect Chelsea supplied wiring harness
(379895) to the interface connector (Fig.18).
21. Run wiring harness over top of transmission and

connect the booted connector to the P.T.O. Fig. 17
indicator switch (Fig. 19). See page 14 of this
manual for in dash switch installation. Secure
harness to the transmission to protect the relay
from damage.
Fig. 18
Fig. 19

Mounting P.T.O./Pump to the Transmission

22. On the right side of the transmission is a bracket
for the oxygen sensor wiring harness (for
California vehicle w/8.1L engines). This bracket
is on all vehicles and may interfere with the
hydraulic tubes. If the oxygen sensor wiring
harness is on the vehicle, bend the bracket in
towards the center of the transmission. If the
vehicle has only the bracket, the bracket may be
removed and the bolt torqued to 17 ft. lbs. [23 Fig. 20
N.m]. Do not apply sealant to bolt (Fig. 20).
23. Next attach hydraulic tubes to the pump and
tighten the fittings to the pump and tube nuts
(Fig. 21). Position the fitting by backing out
(counter-clockwise) up to one full turn. Hold
fitting and tubing in desired position and tighten
lock nut with a wrench. Assemble tube to fitting
by tightening the assembly with wrench until Fig. 21
solid feeling is encountered. From that point,
apply one-sixth turn.
24. Attach hydraulic tube support bracket (379848)
to the transmission (Fig. 22).
25. Install P.T.O. Heat Shield (379847) to the P.T.O.
(Fig. 23). The heat shield is attached to the
closed bearing cap by re-installing capscrew
(378430-10) to the bearing cap and hex Fig. 22
capscrew (378430-8) to the heat shield support
bracket. Torque 378430-10 to 16-20 ft. lbs. [22-27
N.m].
26. Reinstall the three engine exhaust flange studs
and attach pipe with nuts. Torque the nuts to 39
ft. lbs. [50 N.m]
27. Refill transmission with GM recommended fluid.
See page 23 of this manual for complete details. Fig. 23
28. Refer to page 26-31 of this manual for procedures

on indicator continuity check and cable shift
installation.

GMT3600 Cab-Chassis W/ZF S6-650

Power Take-Off Switch
Panel Removal Instructions
1. Apply the parking brake to prevent the
2. If equipped with an automatic transmission,
move the shift lever all the way down to the
last gear.
3. Tilt the steering wheel to the full down
position.
4. Pull gently on the corners of the instrument
panel trim plate to remove it (Fig A). Fig. A
P.T.O. Switch Installation Instructions

5. Find the switch accessory housing cover to
the right of the heating and air controls. (Fig
B)
6. Remove the switch accessory housing and
the lower left switch accessory cover from
the housing. The switch accessory housing
is snapped into the instrument panel
retainer.
7. Install the Power Take-Off switch (379857)
in the lower left cavity of the switch Fig. B
accessory cover from the housing. From
the front of the housing, push until it clicks
into place.
8. Locate the Power Take-Off switch harness
and connect it to the Power Take-Off switch.
(Fig C)
9. Replace the switch accessory housing into
the instrument panel.
10. Attach bezel to the instrument panel
assembly by aligning the guide pins and
pushing gently on the bezel until it is in
place.
11. Ensure that all instrument panel bezel
retaining clips are in place and tilt the
steering wheel to the normal drive position.
12. Move the shift lever to the park position and
disengage the parking brake. Fig. C

P.T.O. Shifting Procedures & Precautions

This vehicle is equipped with a POWER TAKE-OFF
Shut Engine Off Before Working on Power Take-Off or Getting Below Vehicle.
Consult Operating Instructions Before Using. (See Sun Visor)
Power Take-Off Operation Vehicle Stationary

Manual Transmission
1. A Power Take-Off is, and should be, operated as an integral part of the main
transmission.
2. Before shifting the Power Take-Off into or out of gear disengage the clutch and
wait for the transmission or P.T.O. gears to stop rotating
3. Set parking brake
4. Shift the transmission into NEUTRAL (N)
5. Shift P.T.O. into gear
6. Release the clutch pedal
7. * Turn the dash mounted P.T.O./Engine control switch to the ON position. The
engine speed will increase to the P.T.O. Standby Speed.
NOTE: The LED on the P.T.O./Engine control switch will change from blinking to steady
state when the P.T.O. is engaged.
8. * Press either the SET or Resume switch on the cruise control or turn the P.T.O.
switch to the set position. The engine speed will jump to the P.T.O. SET or
RESUME speeds.
* Optional P.T.O. Interface Wiring Harness/In Dash Switch for Engine Speed Control.
See GM Truck Owners Manual for complete engine control speed operations.
IMPORTANT: Failure to follow proper shifting or operating sequences will result in

premature P.T.O. failure with possible damage to other equipment.
WARNING
Do not attempt to work on an installed Power Take-Off with the engine running.
Make sure to block any moving or raised device that may injure a person working
on or under the truck. A lever or its linkage may be accidentally moved causing
movement of the device, which could cause injury to a person near the device.

P.T.O. to GM P.T.O. Interface Connector

442 Series w/Wire Shift
379895
indicator switch
Connect to

Mounting the P.T.O. on the Transmission

For 6 or 8 Bolt Applications
1. Drain the oil from the transmission and remove
the P.T.O. aperture cover plate (Fig. 1).
2. Discard the cover plate and cover plate gasket

then clean the aperture pad using a putty knife
or wire brush (Fig. 2). Fig. 1
NOTE: Stuff a rag in the aperture opening to

prevent dirt from entering the transmission while
you are cleaning it.
3. Using your hand, rock the P.T.O. driver gear in the

transmission (Fig. 3) and the driven gear in the Fig. 2
P.T.O. assembly (Fig. 4). Rocking the gears
provides two important factors.
a) It shows you the amount of backlash that
has been designed into each unit.
b) It is helpful in establishing the proper
backlash when installing the P.T.O.
Fig. 3
4. Install the proper studs (furnished with P.T.O.) in
the P.T.O. aperture pad using a stud driver. Studs
may have either interference fit threads (plain) or
preapplied locking/sealing compound (See
Figure 5 for installation method).
5. Where holes are tapped through the transmis-

sion case, use studs with preapplied locking & Fig. 4
sealing compound Locktite 290 to prevent leaks.
NOTE: Avoid contact of Permatex with automatic

transmission fluid in automatics. Always check to
be sure that the studs do not interfere with
transmission gears.
Fig. 5

Mounting the P.T.O. on the Transmission (Continued)

6. Tighten studs securely and torque to 17-19
ft. lbs. (2.35-2.63 kg meters) for 6 bolt and
19-21 ft. lbs. (2.63-2.90 kg meters) for 8
bolt. CAUTION: overtightening of studs
may damage stud and/or transmission
threads (Fig. 6).
7. Place the correct number of gaskets over
studs (Fig. 7). Do not use Permatex
between gaskets because you may want to
Fig. 6
add or subtract gaskets to obtain proper
backlash.
When mounting a P.T.O. use gaskets
between all mounting surfaces.
Do not stack more than 3 gaskets
together.
Usually one thick gasket .020 (.50mm)
will be required.
Remember the lubricant in the transmis
sion also lubricates the P.T.O. Therefore,
at least one gasket must always be used
on either side of filler blocks, adapter Fig. 7
assemblies or adapter plates. More
gaskets may be required when establishing
proper backlash.
8. Secure P.T.O. to the transmission.
Use Self Locking nuts provided with P.T.O.
(Fig. 8). NOTE: Self Locking nuts do
not require lock washers.
9. Fasten the P.T.O. to the transmission (Fig.
9). Torque the set of locking nuts to their Fig. 8
proper specifications.
379744-3/8"-24 for 6-bolt applications
35-40 ft. lbs. (4.83-5.52 kg.m)
379745-7/16"-20 for 8-bolt applications
55-60 ft. lbs. (7.59-8.28 kg.m)
Torque capscrews to their proper
specifications.
6-bolt to 30-35 ft. lbs. (4.14-4.84 kg.m)
8-bolt to 45-50 ft. lbs. (6.22-6.91 kg.m)
Fig. 9

Installation Instructions for 880 Series with L* Output, Top Mounted

to 912 Series Split Shaft - Requiring Self-Lube Option
1. Drain split shaft oil at drain plug (A). Filter or screen oil & reuse if desired.
2. Remove top split shaft aperture cover plate at (B) or air shift Assembly (C) & reassemble
to either side of split shaft in place of shipping cover. Install P.T.O. on split shaft & set
backlash at .006" to .012". (See page 20 for checking proper backlash)
3. Install copper gasket (D), screened strain plug (E) & 90( elbow (F) in place of drain plug
at (A). Also install pressure lube hose (G) between elbow (F) and pump (H). (Use pipe
sealant on all pipe threads)
4. Fill split shaft with filtered, screened or new oil at fill plug (J), until oil reaches plug level,
then reinstall plug.
5. Finish P.T.O. & split shaft installation per owners manual. Also install shaft and/or pump to
be driven by P.T.O.
6. After brief P.T.O. operation, remove fill plug (J), add oil until it reaches plug level, then
reinstall plug.
IMPORTANT: Lube pump (H) must rotate clockwise (engine rotation) as view from front of
vehicle.
B
C
G D
A
F E

Checking Backlash
To check for proper backlash on P.T.O.s with
shift cover
1. Remove the P.T.O. shift housing and/or
inspection plate.
2. Mount the dial indicator so that it registers

movement of the input gear (driven gear)
of the P.T.O. (Fig. 10).
Fig. 10
NOTE: See Figure 11 for proper location of

dial indicator contact point. (Two common
type dial indicators shown).
3. Hold the P.T.O. driver gear in transmission

with a screwdriver or bar and rock the
P.T.O. input gear (driven gear) back and
forth with your hand. Note the total
movement on the dial indicator.
Fig. 11
4. Establish backlash at .006"- .012" [.15mm -
.30mm] by adding or subtracting gaskets.
NOTE: When using a 221 or 260 Series
General rule: A Chelsea .010" gasket P.T.O. with the AJ gear designation on an
will change backlash approx. .006". A Allison Automatic transmission with a six
.020" gasket changes backlash approx. bolt opening, a special gasket (35-P-41) is
.012". supplied. When installed with the P.T.O.
this gasket reduces the need for backlash
adjustment.
5. Replace the shift housing and/or inspection
plate and retorque (4) four capscrews to
16-20 ft. lbs. (2.21-2.76 kg meters).
NOTE: Apply a drop of Loctite 290 on each capscrew

before reinstalling. Capscrews that are furnished with a
conversion kit and are being installed for the first time do
not require the drop of Loctite.

2 Gear-8-Bolts - 863
An inspection hole is provided in the P.T.O. housing for feeling the mounted backlash.
Rock the P.T.O. Input Gear with your hand and correlate this backlash to the unmounted
backlash found in step 3 on page 20. Use Gaskets to get backlash feel as close to
unmounted condition as possible.
Fig. 12

Adapter Plates
Adapter plates are used to
permit mounting a 6 bolt P.T.O.
on a transmission that has an 8
bolt aperture.
NOTE: A wire locking stud kit is

recommended when mounting a
6 bolt P.T.O. to an adapter plate
on a bottom opening.
Fig. 13
Filler Blocks
Filler blocks may be required
where it is necessary to use
a spacer to mount the Power
Take-Off to a particular
transmission
Fig. 14
P.T.O. Application and Adapter Assembly

Figure 15 illustrates typical adapter assembly
configurations. Some P.T.O. applications require
adapter assemblies because it is impossible to
reach the P.T.O. driver gear in the transmission
without this assembly. An adapter assembly will
change the rotation of the P.T.O. and this may
be necessary for driving pumps or other
accessory equipment. Obstructions, such as
bulge in the transmission, exhaust pipes or
motor mounts can sometimes be compensated Fig. 15
for through the use of an adapter.
Refer to Adapter Gears Owners
Manual HY25-1670-M1/US.

Lubricant in Transmission/Inspect Installation

1. Remove the filler plug from the
transmission and add recom-
mended transmission lubricant to
the level prescribed by the
transmission or truck manufacturer
(Fig. 22).
NOTE: If the P.T.O. is mounted
below oil level, additional lubricant
will be required.
2. Run the P.T.O. for 5-10 minutes and

check for oil leaks and noise.
Fig. 22
3. Should a quiet P.T.O. become noisy P.T.O. Installation Tips for Automatic
after the universal joint connection Transmissions
is made, check the P.T.O. driveline
The procedure for installing a P.T.O. on an
components for an out of phase
automatic is basically the same as for a
condition, excessive or unequal
mechanical transmission. Power Take-Offs
joint angles or possibly worn parts for automatic transmissions are assembled
in the driven accessory. with a special drilled input shaft which allows
the input gear to be pressure lubricated
4. Re-torque all mounting bolts, nuts, during operation. (See page 32 and 33).
cap screws and set up inspection
routine of the P.T.O. driveline After installing a P.T.O. on an automatic
components and the driven transmission, connect pressure lubrication
auxiliary equipment. hose to the P.T.O. and the transmission per
NOTE: Anticipate slight increase in installation instructions shown on pages 34-36
P.T.O. noise level as oil thins out at of this booklet.
operating temperatures.
WARNING: Adapter assemblies are never used on an automatic transmission

because they do not have pressure lubricated design features.
WARNING: Use only wire control with P.T.O. made for wire cable control. If
lever is desired, order P.T.O. for level control. The internal shifting mechanism for
wire is not designed for heavy forces usually encountered with lever control linkage.

Function of Auxiliary Power Shafts

An auxiliary power shaft transmits torque from the power source to the driven accessory.
The shaft must be capable of transmitting the maximum torque and R.P.M. required of the
accessory, plus any shock loads that develop.
An auxiliary power shaft operates through constantly relative angles between the power
source and the driven accessory, therefore, the length of the auxiliary power shaft must be
capable of changing while transmitting torque. This length change, commonly called slip
movement, is caused by movement of the power train due to torque reactions and chassis
deflections.
Joint operating angles are very important in an auxiliary power joint application. In many
cases, the longevity of a joint is dependent on the operating angles. (See chart below)
This information is limited to 1000 through 1310 series applications. For applications
requiring a series larger than 1310, contact your local Chelsea distributor.
SPICER UNIVERSAL JOINT OPERATING ANGLES

PROP. SHAFT R.P.M. MAX. NORMAL PROP. SHAFT R.P.M. MAX. NORMAL
OPERATING ANGLE OPERATING ANGLE
3000 5 50' 1500 11 30'
2500 7 00' 1000 11 30'
2000 8 40' 500 11 30'
Above based on angular acceleration of 100 RAD/SEC2
Determining Shaft Type

1. Solid or tubular?
a. In applications requiring more than 1000 R.P.M. or where the application necessitates
a highly balanced auxiliary power shaft, a tubular shaft should be used.
b. Spicer solid shafting auxiliary power joints are designed for 1000 or less R.P.M.
intermittent service such as:
Driving small hydraulic pumps
Driving winches
Driving low speed product pumps
2. Joint series should be determined using the following chart.

Spicer Universal Joint Engineering Data Quick Reference Chart

JOINT SERIES 1000 1100 1280 1310
TORQUE RATING
Automotive (Gas or Diesel Engine) lbs. ft.
Continuous 50 54 95 130
TUBING
Diameter 1.750 1.250 2.500 3.00
Wall Thickness .065 .095 .083 .083
W = WELDED S = SEAMLESS W S W W
FLANGE DIAMETER (Swing Diameter)
Rectangular Type 3.500 3.500 3.875 3.875
BOLT HOLES - Flange Yoke
Circle 2.750 2.750 3.125 3.125
Diameter .312 .312 .375 .375
Number 4 4 4 4
Male Pilot Dia. 2.250 2.250 2.375 2.375
DISTANCE ACROSS LUGS
Snap Ring 2.188 2.656 3.469 3.469
Construction
BEARING DIAMETER .938 .938 1.062 1.062
MAXIMUM OPERATING SPEED * BY TUBE SIZE, SOLID SHAFT SIZE, AND LENGTH
*(For speed below 500 R.P.M. or over 2500 R.P.M., contact your Chelsea Distributor)
Tubing Dia. & MAX. INSTALLED LENGTH IN INCHES FOR GIVEN R.P.M.
Wall Thickness Centerline to Centerline of Joints For a Two Joint Assembly or
Joint & Shaft Centerline of Joint to Centerline of Center Bearing For a Joint & Shaft
(W=Welded R.P.M. - Revolutions per Minute
S=Seamless) 500 1000 1500 2000 2500
1.750" X .065" W 117" 82" 67" 58" 52"
1.250" X .095" S 91" 64" 52" 45" 40"
2.500" X .083" W 122" 87" 70" 62" 55"
3.000" X .083" W - - - 85" 76"
SOLID SHAFT
Diameter
.750" 60" 42" 35" 30" 27"
.812" 62" 44" 36" 31" 28"
.875" 65" 46" 37" 32" 29"
1.000" 69" 49" 40" 35" 31"
1.250" 77" 55" 45" 39" 35"

Continuity Check 6 and 8 Bolt P.T.O.s
Continuity Check
379639 and 379652 Indicator Switches
In order to insure that the switch is functioning

properly, the following procedure can be used
with the unit on a bench, or installed.
1. Use a continuity checker, battery type,

either meter or light. Attach one (1)
probe to the screw on the 379639 or
379652 Indicator Switch.
Note: Make sure 379639 and 379652 Fig. 23
Indicator Switches in the P.T.O. shifter
or housing are torqued to 10-15 ft. lbs.
(1.38-2.07 kg meters).
2. With the other probe, make contact with
the shifter cover or housing (Fig. 23).
3. Actuate shifting device and the meter or
light* should be actuated when P.T.O.
gear is engaged (Fig. 24).
4. Shift unit out of gear and the meter or
light* should return to normal as shown. Fig. 24
This test procedure can be used to check

Chelsea wire, lever, and air shifter covers,
although an air source would be necessary for
the latter.
* If a meter is not available the light in the
328751-1X can be used. A six volt battery is
all that is necessary for a power source.
CAUTION: Indicator switches are capable of 0.5 amps maximum.

Cable Control Installation 6 and 8 Bolt P.T.O.s
Cable Control Installation Instructions *

1. Find a suitable area on the dash to install the cable control (328346-10X) and the
control plate (68-P-18) indicator light.
Optional Location: As an option the control cable and knob can be located through
floor. Using this option the control plate and indicator light should still be located on
dash, in close proximity.
NOTE: The location of the cable control and the control plate should be as close to
each other as possible and easily accessible by the driver or operator, but should not
be an obstacle to driver movement nor interfere with other controls, instruments, or
equipment.
2. CAUTION: Before drilling any holes, make sure there is adequate room on both sides
through dash wall, drill a 1/2" (.5") diameter hole for the control cable. [1]
3. Install the control cable on the dash using the hex nuts supplied with the cable. The
knob can then be screwed into place [2]. The length of cable can then run through the
firewall and back to the P.T.O. making sure it is kept away from the exhaust,
moving parts, etc.
NOTE: Do not kink the cable. In order for the cable to operate properly, there can be
no bends smaller than 6 inch radius. Total bends in the cable should not exceed 360
(example - four 90 bends in cable).
4. Using the template found on page 44

(SK-168) drill the necessary holes for
the control plate-indicator light.
5. Install the control plate (68-P-18) stick
on decal and indicator light on the dash
using the hardware supplied in the
328751-1X installation kit (Fig. 25).
Fig. 25
* All six bolt wire shifts with the exception of the reversible, dual shift units, and some
gear boxes.
Cable Control Installation Instructions * (Continued)

6. Determine from which direction the cable must come in order for the unit to be
disengaged when the knob is all the way in.
NOTE: The shifter must always be installed in the following manner:
* CABLE IN: P.T.O. DISENGAGED(6A): OUT OF GEAR POSITION
CABLE OUT: P.T.O. ENGAGED(6B): IN GEAR POSITION
* The wire shift cable should be installed so that when the cable (knob) is
shifter, to the disengaged mode.
7. Install the wire control bracket found in either the 328380X or 328380-1X wire control
parts bag. [7]
8. Line the cable up with the wire control bracket and shifter lever (disengaged position)
on the P.T.O. cover assembly [8]
NOTE: It may be necessary to change the position of the shifter lever on the P.T.O.
To do this, remove the shifter cover from the unit. This will prevent the possible loss
of the poppet and/or spring into the transmission if the shifter post assembly should
be pushed through the cover when reinstalling the lever.
9. Shift the P.T.O. to the engaged position to see how much of the cable casing must be
cut to allow the lever enough travel to shift in and out completely. The casing need
only go just beyond the bracket, whereas, the wire must be long enough to go
through the swivel pin in the shifter lever. [9]
NOTE: In some instances the cable control may not be long enough. Chelsea has
available four longer lengths than the standard ten-foot cable. These come in five foot
increments (i.e., 328346-15X = 15-foot cable).
10. When the length of the casing has been determined, pull the wire back through until
the case can be cut without cutting the wire. Use a hacksaw or heavy pair of side
cutters to cut the casing.
NOTE: The cable can be held by a bench vise as long as the jaws are not tightened
to the point where the case mushrooms. If a vise is not accessible, a pair of vise grips
will do the job.
gear boxes.
11. Push the wire back through and install the cable using the hardware from the
previously mentioned wire control parts bag (328380X).
12. Cut the excess wire after the cable casing and wire have been installed and tightened.
gear boxes.
Indicator Light Installation

Sketch (SK-286)
13. Shift the P.T.O. to insure enough casing has been removed to allow full gear engagement.
14. Install the wiring for the indicator light using the schematic above (SK-286).
NOTE: Check both the cable and indicator light wires to be certain that they are not
near the exhaust system or any moving parts. Carefully fasten to stationary parts of the
vehicle if necessary.
15. Shift the P.T.O. The following should be adhered to:
15A. CABLE IN: P.T.O. DISENGAGED: LIGHT OUT
15B. CABLE OUT: P.T.O. ENGAGED: LIGHT ON
NOTE: The P.T.O. should be checked for continuity as per the instructions in
this manual.
NOTE: Cable must be rigidly mounted-possibly to the transmission within 12-24"
of the P.T.O.
gear boxes.
Cable Control Installation Instructions (Continued)

(Reversibles, dual shift units, and some gear boxes)
1. Use steps #1-#5 from previous

instructions.
2. In step #6 the cable can come from

either direction since the P.T.O. will
always be engaged when all the way
in or out.
3. Follow step #7 and #8.
4. In step #9 shift the P.T.O. from

forward to reverse or vice versa to
determine the amount of travel
needed and the length of casing to
be cut.
5. Follow step #10-#14.
6. Step #15 will show the folding:
CABLE IN: P.T.O. ENGAGED: LIGHT ON

CABLE OUT (1st position):
P.T.O. DISENGAGED: LIGHT OUT
CABLE OUT (2nd position):
P.T.O. ENGAGED: LIGHT ON

Automatic Transmissions 6 and 8 Bolt P.T.O.s
Automatic Transmissions
Pressure Lube Hose Connection
Tee Purchased
D Separately .032" *
"C" Hose
E
F Hose Furnished with P.T.O. Input Shaft of P.T.O.
Chart I
Dimensional Information
TEE
FITTING 378840 378880 378970 378897
D .750-16 U.N.F. 2A .875-14 U.N.F. 2A 1.062-12 U.N.F. 2A 1.312-12 U.N. 2A
E .250-18 N.P.T.F. .250-18 N.P.T.F. .250-18 N.P.T.F. .250-18 N.P.T.F.
F .750-16 N.P.T.F. .875-14 U.N.F. 2NB 1.062-12 U.N.F. 2B 1.312-12 U.N. 2B
Allison 1000, 2000/2400 Series Converter Housing Options

Converter
Housing SAE Description Chelsea
Group Number Number 1000 2000 2400 Fitting
34-561 #3 Integral Cooler Ports STD. - - 378840
34-562 #2 Manifold Pad OPT. STD. STD. 378970
The specific T fitting for each Automatic Transmission is called out at the bottom of each
transmissions application sheet. If a T fitting is not called out, then a standard pipe tee will
adapt.
* NOTE: The .032" [0.81mm] orifice is built into all pressure lubed idler
shafts No additional orifices are required when using these pressure
lubed shafts.

442 Series Pressure Lube for Allison 1000, 2000/2400 Series

(SK-382 Rev A)
442 Series
See Chart page 32

379896
Pipe Adapter
500841-1
90O Elbow Pipe
328075X Hose Assembly Left Side

329092X Hose Assembly Right Side

P.T.O. Openings for Automatic Transmissions Allison Models

HT-740
HT-750D 78T
T Fitting 378897
5.6
[142.24mm]
MAIN PRESSURE
Lube Tap 3.5
1/8 N.P.T. 90-175 P.S.I.
1 5/16 O-Ring 35-45 P.S.I. [88.9mm]
6.3-12.2 Kg/cm2
2.4-3.2 Kg/cm2
CLT-750
40T
78T
5.6
142.24mm
64T
MAIN PRESSURE
T Fitting 378897 1/8 N.P.T. 90-270 P.S.I.
Lube Tap 3.5 6.3-19 Kg/cm2
1 5/16 O-Ring 35-45 P.S.I. [88.9mm]
2.4-3.2 Kg/cm2
HT-70
40T
78T 78T
6.7 8.46
[170.18mm] 214.8mm
2.00
Lube Tap [50.8mm]
6.2 MAIN PRESSURE
1/8 N.P.T. 5-15 P.S.I.
[157.48mm] 1/8 N.P.T. 90-240 P.S.I.
.35-1.05 Kg/cm2
7.7-16.8 Kg/cm2
1. Converter driven P.T.O. Drive Gear.

2. Engine driven P.T.O. Drive Gear.

P.T.O. Openings (Continued)

5000 Series
Main Pressure
38 T
1/4 N.P.T. 100-215 P.S.I.
7-14.4 Kg/cm2
.6
[15.24mm]
1.6
[40.64mm]
46 T Lube Tap
1/4 N.P.T. 15-35 P.S.I.
1.05-2.4 Kg/cm2
8000 Series
Lube Tap 43 T
8.6 Main Pressure
3/8 N.P.T. 16-60 P.S.I. 1/4 N.P.T. 140-230 P.S.I.
[218.44mm]
1.1-4.2 Kg/cm2 9.9-15 Kg/cm2
38T
7.9
[300.66mm]
52 T
1000, 2000/2400 Series Install Tee Fitting Here

From Cooler Return Port

2. Engine driven P.T.O. Drive Gear.

P.T.O. Openings (Continued)

MT-30-42 (57 Teeth)
6 Speed
5.1
Lube Tap Main Pressure

3/8 N.P.T.12-20 P.S.I. 11.9 1/8 N.P.T. 90-200 P.S.I.
.92-1.4 Kg/cm2 [302.26mm] 6.3-14 Kg/cm2
3341 - 3441 (55 Teeth)

AT-540
Lube Tap
3/4 O-Ring 50-70 P.S.I.
3.5-4.9 Kg/cm2
T Fitting 378840
4.7
11.9 Main Pressure

[302.26mm] 1/8 N.P.T. 90-150 P.S.I.
6.3-10.5 Kg/cm2
4 Speed (64 Teeth)

MT-640
5.6
T Fitting 378880
[142.24mm]
Lube Tap
Before Nov. 1974
Use T Fitting 378880 6.4
7/8" O-Ring 25-30 P.S.I. [162.16mm]
1.75-2.1 Kg/cm2
After Nov. 1974 13.5 13 Main Pressure

Use T Fitting 378970 [342.9mm] [330.2mm] 1/8 N.P.T. 125-217 P.S.I.
1-1/16" O-Ring 25-30 P.S.I. 8.7-15.2 Kg/cm2
1.75-2.1 Kg/cm2

P.T.O. Shifting Procedure 6 and 8 Bolt P.T.O.s
P.T.O. Shifting Procedure & Precautions

This vehicle is equipped with a POWER TAKE-OFF
Shut Engine Off Before Working On Power Take-Off Or Getting Below Vehicle.
Consult Operating Instructions Before Using. (See Sun Visor)
POWER TAKE-OFF OPERATION VEHICLE STATIONARY
I. Manual Transmission
1. A Power Take-Off is, and should be, operated as an integral part of the
main transmission.
2. Before shifting the Power Take-Off into or out of gear disengage the
clutch and wait for transmission or P.T.O. gears to stop rotating.
II. Automatic Transmission with Manual Shift P.T.O. (Includes Air Shift)
On automatic transmissions, the gears in the transmission turn when the
transmission is in neutral, therefore, gear clashing will occur if the power
take-off is shifted into gear at this time.
A. With Converter Driven Gear:
1. Shift transmission lever into any of the drive positions (this will stop
transmission gear from turning).
2. Shift Power Take-Off into gear.
3. Shift transmission into neutral (this will start gears turning).
B. With Engine Driven Gear:
1. Shift P.T.O. into gear before starting engine. This procedure should
eliminate gear clash.
III. Automatic Transmission with Powershift P.T.O.
Engage P.T.O. with engine at idle speed.
Power Shift P.T.O.s: Engine must be at idle when P.T.O. is engaged.
See transmission manufacturers instructions for special procedures.
IMPORTANT: Failure to follow proper shifting or operating
sequences will result in premature P.T.O. failure with possible
damage to other equipment.
WARNING
Use only wire control with P.T.O. made for wire cable control. If lever control is desired,
order P.T.O. for lever control. The internal shifting mechanism for wire is not designed for
heavy forces usually encountered with lever control linkage.
Do not attempt to work on an installed Power Take-Off with the engine running.
Make sure to block any moving or raised device that may injure a person working on or
under the truck. A lever or its linkage may be accidentally moved causing movement of the
device which could cause injury to a person near the device.

Installation Sketches
Williams Valve (SK-228 Rev E)
38
Owners Manual
6 and 8 Bolt P.T.O.s
Warning: Connect directly to air supply.

Do not use tubing between air supply and pressure protection valve.
Air Shift Installation Sketch for 340 and 352 Series Using:
Caution: When installing nylon tubing avoid sharp angles, exhaust and manifold systems.
Note: Tube nut is reusable as long as nylon tubing is not removed from the tube nut.


Note: Template for control plate on page 46.
Installation Sketches 6 and 8 Bolt P.T.O.s
Air Shift Installation Sketch for 880 and 823 Series Using:
Williams Valve (Sk-276)
328388-61X Installation Kit
Warning: Connect directly to the air supply. Do not use tubing

between the air supply and the pressure protection valve.
Important: When this installation is used on vehicles with automatic transmissions, the P.T.O.
drive gear must be stopped before shifting.
NOTE: Tube nut is reusable as long as nylon tubing is not removed from the tube nut.
NOTE: The template for the control plate is on page 46.

Williams Valve (Sk-231 REV B)
40
Note: Connect plastic tubing to the
push connect (Air Shift Cover Ass'y).
Owners Manual
Warning: Connect directly to air supply.

Do not use tubing between air supply and pressure protection valve.
437, 438, 442, 447, 489, 660, 680 and 812 Series Using:
Important: When this installation is used on vehicles with automatic transmissions the P.T.O. drive gear must be stopped before shifting.

Air Shift Installation Sketch for 100, 221, 260, 429, 434, 435, 436,

Note: Template for control plate on page 46.
(SK-238 REV F)
379336
41
Switch
Bracket
Owners Manual
Note: Connect plastic tubing to the

push connect (Air Shift Cover Ass'y).
Warning: Connect directly to air supply. Do not use tubing between air supply and pressure protection valve.
434, 435, 436, 437, 438, 442, 447, 489, 660, 680 and 812 Series

Important: When this installation is used on vehicles with automatic transmissions the P.T.O. drive gear must be stopped before shifting.
Electric Over Air Shift Installation Sketch for 100, 221, 260, 429,

Firewall: Note - Connector will fit thru 1.00 Dia. hole drilled thru firewall. After connector
and wires are fitted thru, install sliced rubber grommet.
Cab-Chassis (SK-346)
42
Owners Manual
Note: Warranty will be void if:

1. Any E-Z Shift component or wire is cut or spliced without Chelsea engineering approval.
2. The shaft is disassembled from the motor or gear box.
Electrical Installation E-Z Shift on ZF Transmission GM 3600
3. The motor is disassembled or opened up.

4. Any E-Z Shift connector is removed.

5. Any additional circuit or components are removed without Chelsea engineering approval.
Notes

Installation Sketches 6 and 8 Bolt P.T.O.s
Indicator Light Installation & Dash Drilling Template (Sk-286 Rev D)
Dash Drilling Template (SK-168)

Dash Drilling Template 6 and 8 Bolt P.T.O.s
Dash Drilling Template for 6 & 8 Bolt Air Shift for Williams Valve
(SK-204 REV C)

Dash Drilling Template 6 and 8 Bolt P.T.O.s
Dash Drilling Template for 6 & 8 Bolt Air Shift for Williams Valve
(SK-204 REV C)

Power Take-Off Maintenance 6 and 8 Bolt P.T.O.s
Power Take-Off Maintenance
Due to the normal and sometime severe torsional vibrations that power take-off units
experience, operators should follow a set maintenance schedule for inspections. Failure
to service loose bolts or power take-off leaks could result in potential auxiliary power-
take-off or transmission damage.
Periodic P.T.O. MAINTENANCE is required by the owner/operator to ensure proper, safe

and trouble free operation.
Daily: Check all air, hydraulic and working mechanisms before operating
P.T.O. Perform maintenance as required.
Monthly: Inspect for possible leaks and tighten all air, hydraulic and
mounting hardware, if necessary. Torque all bolts, nuts, etc. to
Chelsea specifications. Insure that splines are properly
lubricated, if applicable. Perform maintenance as required.
With regards to the direct mounted pump splines, the P.T.O. requires the application of a
specially formulated anti-fretting, high pressure, high temperature grease. The addition
of the grease has been proven to reduce the effects of the torsional vibrations, which
result in fretting corrosion on the P.T.O. internal splines as well as the pump external
splines. Fretting corrosion appears as a rusting and wearing of the pump shaft splines.
Severe duty applications, which require long P.T.O. running times and high torque may
require more frequent regreasing. Applications such as Utility Trucks that run continu-
ously and are lightly loaded also require frequent regreasing due to the shear hours of
running time. It is important to note that service intervals will vary for each and every
application and is the responsibility of the end user of the product. Chelsea also
recommends that you consult your pump owners manuals and technical services for
their maintenance guidelines. Fretting corrosion is caused by many factors and without
proper maintenance; the anti-fretting grease can only reduce its effects on components.
Chelsea offers the grease to our customers in two packages. The first is a 5/8 fluid ounce
tube (379688), which is included with every applicable P.T.O., and the second is a 14-
ounce grease cartridge (379831). Chelsea also offers greaseable shafts for most all
output designators.
Warranty: Failure to comply entirely with the provisions set forth in the appropriate
Owners Manual will result in voiding of ALL Warranty consideration.

Offer of Sale
The items described in this document and other documents or descriptions provided by Parker Hannifin Corporation, its subsidiaries and
its authorized distributors are hereby offered for sale at prices to be established by Parker Hannifin Corporation, its subsidiaries and its
authorized distributors. This offer and its acceptance by any customer ("Buyer") shall be governed by all of the following Terms and
Conditions. Buyers order for any such items, when communicated to Parker Hannifin Corporation, its subsidiary or an authorized
distributor ("Seller") verbally or in writing, shall constitute acceptance of this offer.
1. Terms and Conditions of Sale: All descriptions, quotations, Unless otherwise agreed, Seller shall have the right to alter, discard
proposals, offers, acknowledgments, acceptances and sales of or otherwise dispose of any special tooling or other property in its
Sellers products are subject to and shall be governed exclusively sole discretion at any time.
by the terms and conditions stated herein. Buyers acceptance of 8. Buyers Property: Any designs, tools, patterns, materials,
any offer to sell is limited to these terms and conditions. Any terms drawings, confidential information or equipment furnished by Buyer
or conditions in addition to, or inconsistent with those stated herein, or any other items which become Buyers property, may be consid-
proposed by Buyer in any acceptance of an offer by Seller, are ered obsolete and may be destroyed by Seller after two (2)
hereby objected to. No such additional, different or inconsistent consecutive years have elapsed without Buyer placing an order for
terms and conditions shall become part of the contract between the items which are manufactured using such property, Seller shall
Buyer and Seller unless expressly accepted in writing by Seller. not be responsible for any loss or damage to such property while
Sellers acceptance of any offer to purchase by Buyer is expressly it is in Sellers possession or control.
conditional upon Buyers assent to all the terms and conditions 9. Taxes: Unless otherwise indicated on the face hereof, all prices
stated herein, including any terms in addition to, or inconsistent and charges are exclusive of excise, sales, use, property, occupa-
with those contained in Buyers offer, Acceptance of Sellers tional or like taxes which may be imposed by any taxing authority
products shall in all events constitute such assent. upon the manufacture, sale or delivery of the items sold hereunder.
2. Payment: Payment shall be made by Buyer net 30 days from the If any such taxes must be paid by Seller or if Seller is liable for the
date of delivery of the items purchased hereunder. Amounts not collection of such tax, the amount thereof shall be in addition to the
timely paid shall bear interest at the maximum rate permitted by law amounts for the items sold. Buyer agrees to pay all such taxes or
for each month or portion thereof that the Buyer is late in making to reimburse Seller therefore upon receipt of its invoice. If Buyer
payment. Any claims by Buyer for omissions or shortages in a claims exemption from any sales, use or other tax imposed by any
shipment shall be waived unless Seller receives notice thereof taxing authority, Buyer shall save Seller harmless from and against
within 30 days after Buyers receipt of the shipment. any such tax, together with any interest or penalties thereon which
3. Delivery: Unless otherwise provided on the face hereof, deliv- may be assessed if the items are held to be taxable.
ery shall be made F.O.B. Sellers plant. Regardless of the method 10. Indemnity For Infringement of Intellectual Property Rights:
of delivery, however, risk of loss shall pass to Buyer upon Sellers Seller shall have no liability for infringement of any patents, trade-
delivery to a carrier. Any delivery dates shown are approximate marks, copyrights, trade dress, trade secrets or similar rights
only and Seller shall have no liability for any delays in delivery. except as provided in this Part 10. Seller will defend and indemnify
4. Warranty: Seller warrants that the items sold hereunder shall be Buyer against allegations of infringement of U.S. Patents, U.S.
free from defects in material or workmanship for a period of: Trademarks, copyrights, trade dress and trade secrets (hereinafter
(A) All Power Take-Off units one (1) year from date of installation. Intellectual Property Rights). Seller will defend at its expense and
(B) Except 267, 277, 278, 242, 244, 245, 250, 251 and 859 series will pay the cost of any settlement or damages awarded in an action
two (2) years from date of installation. brought against Buyer based on an allegation that an item sold
THIS WARRANTY COMPRISES THE SOLE AND ENTIRE WAR- pursuant to this contract infringes the Intellectual Property Rights
RANTY PERTAINING TO ITEMS PROVIDED HEREUNDER. of a third party. Sellers obligation to defend and indemnify Buyer
SELLER MAKES NO OTHER WARRANTY, GUARANTEE, OR is contingent on Buyer notifying Seller within ten (10) days after
REPRESENTATION OF ANY KIND WHATSOEVER. ALL OTHER Buyer becomes aware of such allegations of infringement, and
WARRANTIES, INCLUDING BUT NOT LIMITED TO, MER- Seller having sole control over the defense of any allegations or
CHANTABILITY AND FITNESS FOR PURPOSE, WHETHER actions including all negotiations for settlement or compromise. If
EXPRESS, IMPLIED, OR ARISING BY OPERATION OF LAW, an item sold hereunder is subject to a claim that it infringes the
TRADE USAGE, OR COURSE OF DEALING ARE HEREBY Intellectual Property Rights of a third party, Seller may, at its sole
DISCLAIMED. NOTWITHSTANDING THE FOREGOING, THERE expense and option, procure for Buyer the right to continue using
ARE NO WARRANTIES WHATSOEVER ON ITEMS BUILT OR said item, replace or modify said item so as to make it noninfringing,
ACQUIRED WHOLLY OR PARTIALLY, TO BUYERS DESIGNS or offer to accept return of said item and return the purchase price
OR SPECIFICATIONS. less a reasonable allowance for depreciation. Notwithstanding the
5. Limitation Of Remedy: SELLERS LIABILITY ARISING FROM foregoing, Seller shall have no liability for claims of infringement
OR IN ANY WAY CONNECTED WITH THE ITEMS SOLD OR based on information provided by Buyer, or directed to items
THIS CONTRACT SHALL BE LIMITED EXCLUSIVELY TO RE- delivered hereunder for which the designs are specified in whole or
PAIR OR REPLACEMENT OF THE ITEMS SOLD OR REFUND part by Buyer, or infringements resulting from the modification,
OF THE PURCHASE PRICE PAID BY BUYER, AT SELLERS combination or use in a system of any item sold hereunder. The
SOLE OPTION. IN NO EVENT SHALL SELLER BE LIABLE FOR foregoing provisions of this Part 10 shall constitute Sellers sole and
ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES exclusive liability and Buyers sole and exclusive remedy for
OF ANY KIND OR NATURE WHATSOEVER, INCLUDING BUT infringement of Intellectual Property Rights.
NOT LIMITED TO LOST PROFITS ARISING FROM OR IN ANY If a claim is based on information provided by Buyer or if the design
WAY CONNECTED WITH THIS AGREEMENT OR ITEMS SOLD for an item delivered hereunder is specified in whole or in part by
HEREUNDER, WHETHER ALLEGED TO ARISE FROM BREACH Buyer, Buyer shall defend and indemnify Seller for all costs,
OF CONTRACT, EXPRESS OR IMPLIED WARRANTY, OR IN expenses or judgments resulting from any claim that such item
TORT, INCLUDING WITHOUT LIMITATION, NEGLIGENCE, infringes any patent, trademark, copyright, trade dress, trade
FAILURE TO WARN OR STRICT LIABILITY. secret or any similar right.
6. Changes, Reschedules and Cancellations: Buyer may re- 11. Force Majeure: Seller does not assume the risk of and shall not
quest to modify the designs or specifications for the items sold be liable for delay or failure to perform any of Sellers obligations by
hereunder as well as the quantities and delivery dates thereof, or reason of circumstances beyond the reasonable control of Seller
may request to cancel all or part of this order, however, no such (hereinafter Events of Force Majeure). Events of Force Majeure
requested modification or cancellation shall become part of the shall include without limitation, accidents, acts of God, strikes or
contract between Buyer and Seller unless accepted by Seller in a labor disputes, acts, laws, rules or regulations of any government
written amendment to this Agreement. Acceptance of any such or government agency, fires, floods, delays or failures in delivery of
requested modification or cancellation shall be at Sellers discre- carriers or suppliers, shortages of materials and any other cause
tion, and shall be upon such terms and conditions as Seller may beyond Sellers control.
require. 12. Entire Agreement/Governing Law: The terms and conditions
7. Special Tooling: A tooling charge may be imposed for any set forth herein, together with any amendments, modifications and
special tooling, including without limitation, dies, fixtures, molds any different terms or conditions expressly accepted by Seller in
and patterns, acquired to manufacture items sold pursuant to this writing, shall constitute the entire Agreement concerning the items
contract. Such special tooling shall be and remain Sellers property sold, and there are no oral or other representations or agreements
notwithstanding payment of any charges by Buyer. In no event will which pertain there/to. This Agreement shall be governed in all
Buyer acquire any interest in apparatus belonging to Seller which respects by the law of the State of Ohio. No actions arising out of
is utilized in the manufacture of the items sold hereunder, even if the sale of the items sold hereunder or this Agreement may be
such apparatus has been specially converted or adapted for such brought by either party more than two (2) years after the cause of
manufacture and notwithstanding any charges paid by Buyer. action accrues.
9/01-P

8225 Hacks Cross Road
Olive Branch, Mississippi 38654 USA
Tel: (662) 895-1011
Fax: (662) 895-1019
www.parker.com/chelsea
FP 12/03 10M
DENISON HYDRAULICS
Pressure Controls Flanged Type
Series R5 with 2 ports
Publ. 3EN 2850A, replaces 3EN 285-D

FEATURES, SYMBOL
FEATURES x Increase Operating Satefy: Flange mounted valves as illustrated in this bulletin
increase operating safety and reduce mounting costs. The R5 range of flange
bodied pressure controls enable the valves to be mounted directly on an SAE
pump outlet flange, ensuring maximum pump protection against peak pressure
and eliminating costly piping.
x High Performance: R5 valves are designed for a maximum adjustable pressure

of 210/280/350 bar and a flow capacity ranging from 90 l/min (34HH) to 600 l/min
(114HH). The pilot stage design reduces pressure overshoot and cracking flow to a
minimum, thus reducing power and production losses during high pressure
operation.
x Precise Control: With the DENISON combined Seat Valve and Pilot design, and
the range of springs available, it is possible to achieve extremely precise
pressure setting.
x Fast Response: The favourable poppet mass to area ratio is especially advanta-
geous, as it enables such features as fast response, high accuracy and quiet,
flutter free control.
x Wide Selection: In addition to the two port flange mount valve, the ordering code
offers a wide range of control options for valves and accessories.
SYMBOL
R5V
Example: R5V10
Internal Drain
SYMBOL
Example: R5R10
Only external Drain
R5R
2
DESCRIPTION
GENERAL DESCRIPTION DENISON Pressure Valves are pilot operated controls consisting of two or three
valve sections, either a high flow, poppet type seat valve section controlled by the
low flow, adjustable pilot mounted on top or in the case of the Proportional Pressure
Valve, the proportional section P2 sandwiched between the pilot valve and the
main body.
Pressure setting is achieved by means of a knurled knob or, if a tamperproof

setting is required, by an acorn nut with lead seal. A proportional pressure setting is
achieved according to the current input by R5V...P2 or R5R...P2.
PRESSURE RELIEF VALVE R5V pressure relief valves are used to limit the system pressure of a hydraulic
system, in order to control the force exerted by a hydraulic actuator. The R5V valve
may also be used to generate a pressure drop in a hydraulic circuit. Normally the
pump is connected to Port A and the tank line to Port B.
PRESSURE REDUCING VALVE R5R reducing valves are used to control pressures in a secondary part of a
hydraulic circuit and to maintain this pressure as set by the control knob on the
pilot, or according to the current input at R5R...P2. The small check valve prevents
intensification in the secondary port by allowing excess flow to drain.
The max. flow through this valve should not exceed 5 l/min.
SEQUENCE VALVE The R5S valve enables a hydraulic system to operate in a pressure sequence. After
system pressure connected to Port A has reached a preadjusted value, fluid is
allowed to pass through Port B to a secondary system.
NOTE DENISON flange valves enable the realisation of complete control systems. In
addition to the valves discussed in this publication, the following flange valves are
also available:
Publication
R5 pressure valves with 3 ports 3EN 290
F5C flow controls & R5A, R5P compensators 5EN 420
C5V check valves, direct operated 6EN 465
C5P check valves, direct & pilot operated 6EN 470
D5S seat valves with 2 ports 7EN 520
D5S seat valves with 3 ports 7EN 530
3
TECHNICAL DATA
GENERAL x Design Poppet type

x Type of mounting Flanged according to SAE-3000 psi
e.g. directly on a pump
x Port sizes 3 4 HH, 1HH, 1 1 4 HH
x Mounting position Optional

x Direction of flow AfB for R5V, R5S
BfA for R5R
x Ambient temperature range 20 . . . + 60 hC
x Suitability for special Consult DENISON
working conditions
HYDRAULIC CHARACTERISTICS x Operating pressure range

Inlet (R5V, R5S port A), (R5R port B) 0 . . . 350 bar R5* 06/08
0 . . . 280 bar R5* 10
0 . . . 210 bar R5* **C
Outlet (R5V, R5S port B), (R5R port A) 0 . . . 30 bar R5V
0 . . . 350 bar R5S, R5R 06/08
0 . . . 280 bar R5S, R5R 10
0 . . . 210 bar R5* **C
Port M 0 . . . 350 bar R5* 06/08
0 . . . 280 bar R5* 10
0 . . . 210 bar R5* **C
Port Y1 0. . . 30 bar
x Pressure setting range 7 . . . 350 bar R5* 06/08
7 . . . 280 bar R5* 10
7 . . . 210 bar R5* **C
R5*06 R5*08 R5*10
34
HH 1HH 114HH
x Max. flow 90 l/min 300 l/min 600 l/min
x Nominal flow 60 l/min 200 l/min 450 l/min
x Pilot flow 0.5 l/min at p 10 bar
1.0 l/min at p 350 bar
x Fluid Mineral oil according to
DIN 51524/25
(other fluids on request)
x Contamination level Max. permissible contamination level
according to NAS 1638 Class 8
(Class 9 for 15 Micron and smaller)
or ISO 17/14
x Fluid temperature range 18 . . . + 80 hC
x Viscosity range 10 . . . 650 cSt; optimal 30 cSt
TYPE OF ACTUATOR x Manual

x Rotation 3.75 x 360 h
x Operation torque 72 Ncm
x Electric By solenoid
x Nominal voltage Refer to ordering code page 5
x Permissible voltage difference + 5 % . . . 10 %
x Max. coil temperature + 180 hC (temperature class H)
x Type of current Alternating current (AC)
or direct current (DC)
x Input power 31 W
x Holding 78 VA
x Inrush 264 VA
x Relative operating period 100 %
x Type of protection IP 65
x Electric proportional 0 . . . 2.5 A
(Pilot stage P2) (refer to publication 3EN 220)
4
ORDERING CODE
omit
for version
without VV01
& without P2
Model Number R5. .. (.) . . . . . .. ... A 1
Series
R5V = Pressure Relief Valve
R5S = Sequence Valve
R5R = Pressure Reducing Valve
Size
06 = 34HH
08 = 1HH
10 = 114HH
Additional function
w/o code = w/o built-in return flow check
C = with built-in return flow check (max. 210 bar)
Max. pressure
3 = 210 bar (for version with return flow check)
4 = 280 bar (Size 10)
5 = 350 bar (Sizes 06/08)
Body mounting
Ports Y1, M:
5 = SAE-4 (716HH20 UNF) R5R, R5S, R5V
7 = G 14HH (R5S, R5V)
8 = G 14HH (R5R)
Pressure setting range (nominal)

1 = 7...105 bar
3 = 7...210 bar
5 = 7...350 bar
Type of control
1 = Hand knob 32 mm dia.
2 = Hand knob 50 mm dia. (not for version with vent valve VV01 or P2)
3 = Acorn nut with lead seal
4 = Adjusting device with key lock (key order no. 70070619)
Pilot connection
2 = Internal PP Internal PD (R5V)
6 = Internal PP External PD (R5V, R5S, R5R)
3-way vent valve VV01

09 = with manual override Solenoid de-energized: open to tank
10 = without manual override k Solenoid energized: vent line blocked
11 = with manual override Solenoid de-energized: vent line blocked
12 = without manual override k Solenoid energized: open to tank
P2 = Electric proportional pressure control (12 V DC only, R5V & R5R only)
Solenoid voltage and current
k k
W01 = 115 V / 60 Hz 1 ) G0R = 12 V
W02 = 230 V / 60 Hz G0Q = 24 V DC
AC
W06 = 115 V / 50 Hz G0H = 48 V
W07 = 230 V / 50 Hz 1 ) R5V/R5R . . . . P2 = 12 V DC only
Design letter
Seal class
1 = Standard (for special fluids consult DENISON)
Modifications
5
CURVES
p-Q-CURVES
R5*08
R5*10
R5*06
1HH
114HH
3 4 HH
Pressure bar
Flow l/min
Min. possible pressure setting 3 bar.

Fluid 40 cSt and 50 hC 0.5 hC.
Pressure Drop of the Return Flow Check Valve
R5.06C R5.08C
Pressure drop bar
Pressure drop bar

nominal flow
nominal flow
Flow l/min Flow l/min

R5.10C
Pressure drop bar
nominal flow
Flow l/min
6
R5R CURVES
Minimum differential pressure between inlet & outlet pressure at various flow rates
R5R06 R5R08/10
nominal flow R5R08

Differential pressure bar
Differential pressure bar

nominal flow
nominal flow R5R10

Variation in outlet pressure for variation in flow rate
R5R06 R5R08/10
Inlet 350 bar Inlet 350 bar
nominal flow R5R08
nominal flow R5R10

max. flow R5R08
max. flow R5R10

nominal flow
Outlet pressure bar
Outlet pressure bar

The effect of inlet pressure variation on outlet pressure setting
R5R06 R5R08/10
Outlet pressure bar
Outlet pressure bar
Inlet pressure bar Inlet pressure bar
7
PRESSURE RELIEF VALVE R5V
Seat Entry
open for R5V
with external drain
R5V R5V..C
Internal Drain External Drain
Ports Function Port Sizes

R5V06 R5V08 R5V10
A Pressure 34
HH SAE-61 1HH SAE-61 114HH SAE-61
B Tank 34
Only at Only at Y1 external drain

R5V . . C R5V . . C G14HH or SAE-4
M Pressure gauge
Dimensions
Size l1 l2 l3 b1 h1 h2 h3 h4 d1 d2 Weight
R5V06 34
HH 24.6 22.2 152 60 128 37 47.6 90 19 10.5 4.0 kg
R5V08 1HH 26.5 26.2 171 60 134 45 52.4 96 25 10.5 4.6 kg
R5V10 14
1 HH 34.0 30.2 179 75 147 48 58.7 109 32 12.0 5.9 kg
8
SEQUENCE VALVE R5S
Seat Entry
R5S R5S..C
External Drain

R5S06 R5S08 R5S10
A Pressure port (inlet) 34
B Secondary port (outlet) 34
Y1 external drain
Only at G14HH or SAE-4
R5S . . C M Pressure gauge
Dimensions
R5S06 34
HH 24.6 22.2 152 60 128 37 47.6 90 19 10.5 4.0 kg
R5S08 1HH 26.5 26.2 171 60 134 45 52.4 96 25 10.5 4.6 kg
R5S10 14
1 HH 34.0 30.2 179 75 147 48 58.7 109 32 12.0 5.9 kg
9
PRESSURE REDUCING VALVE R5R
Annular Entry
R5R R5R..C
External Drain

R5R06 R5R08 R5R10
B Inlet pressure 34
A Reduced outlet pressure 34
Y1 external drain
Only at G14HH or SAE-4
R5R . . C M Pressure gauge
Dimensions
R5R06 34
HH 24.6 22.2 152 60 128 37 47.6 90 19 10.5 4.0 kg
R5R08 1HH 26.5 26.2 171 60 134 45 52.4 96 25 10.5 4.6 kg
R5R10 14
1 HH 34.0 30.2 179 75 147 48 58.7 109 32 12.0 5.9 kg
10
VERSION WITH VENT VALVE VV01
Weight (VV01): 1.7 kg

Screws for additional vent valve installation.
4 x 38HH24 UNF x 312HH lg., order no. 35915340.
M Y1
Pilot
valve
Vent valve Manual override

VV01
Main valve
Plug-in connector DIN 43650

(supplied as standard)
Solenoid can be turned:

through 90 h intervals (AC)
in any position (DC)
AC 149
DC = 160
Note:
Details for vent valve VV01 see publication 3EN 215.
Symbols:
R5* Pressure Controls with Vent Valve VV01
Pressure Relief Valve Sequence Valve Pressure Reducing Valve

R5V R5S R5R
Code
Internal External External External
Drain Drain Drain Drain
11
or
12
09
or
10
11
PROPORTIONAL PRESSURE VALVES R5V . . . P2, R5R . . . P2
Screws for additional proportional section installation

4 x 38HH24 UNF x 312HH lg., Order No. 35915340. The pilot drain port must be
connected to a stable low pressure
tank line. Pressure variations in the
drain port should be avoided.
Pilot Valve
dia. 32
Drain line
external from the pilot
head (Y1), no return line
pressure permissible
Proportional
section P2
(weight 1.8 kg)
Main valve body Coil can be placed in any position

(see pages 8...10)
Distance required to remove

plug-in connector.
Plug-in connector supplied
as standard.
Important:
On initial start up
and after long shut down periods
bleed air from this plug.
Symbol
R5V..P2 R5R..P2
External drain
Note:
See publication 3EN 220 for information on Electrical Proportional Control Valve.
For additional installation with pilot operated control valves please consult DENISON.
12
ADDITIONAL TYPES OF CONTROLS, SYMBOLS
ADDITIONAL TYPES OF CONTROLS
Type of Control-Code 2 Type of Control-code 3 Type of Control-Code 4

Hand knob 50 mm dia. Acorn nut with lead seal Adjusting device with key lock.
(not for version with Key must be ordered separately
vent valve VV01 or P2) order-no. 70070619
13
SAE-FLANGES 3000 PSI (210 BAR)
Inlet flange
(only for
pipe mounting)
with G-thread socket weld
Outlet and
tank port
flange
with G-thread socket weld
Inlet flange Outlet flange Tank port

(without screws*) (without screws*) flange
only for (with screws)
pipe mounting
Port sizes
d1 Order No. Order No. Order No. l1 l2 b1 b2 b3 h1 h2 d2 l d3 l d4 l d5
G 34HH S1686520 S1686529 S1466933 34 15.9 22 40 16.5

67 47.6 22.2 52
34
HH socket weld S1686519 S1686528 S1466941 19 12
3 8 HH
10.5
UNC
G 1HH S1686523 S1686532 S1466934 34 20 22 46 16.5
72 52.4 26.2 58
1HH socket weld S1686522 S1686531 S1466942 24 14
G 114HH S1686526 S1686535 S1466935 39 22 24 54 17.5 7 16 HH

80 58.7 30.2 73 12.5
14
1 HH socket weld S1686525 S1686534 S1466943 24 14 UNC
* see page 15 for screws
14
MOUNTING INSTRUCTION
Example
Valves group B
(R5V, R5U, R5R, R5S D5S, C5P)
(2-Port and 3-Port Valves)
Pump Outlet flange
Valve group A
(C5V, refer to
Inlet flange for pipe information 6EN 465)
mounting
(with threads for bolts)
Socket weld
Qty. of valves
and group for Mounting Order No.
each stack screws for screws l1 l2 l3
1xA 38 HH UNC x 2 HH 14 358162600 25.4 59.4
1xB 38 HH UNC x 334HH 358163500 60.0 94.0
(1 x A) + (1 x B) 3 8 HH UNC x 4 3 4 HH 358163900 85.4 119.4
34
HH
3 8 HH UNC x 6HH
34.0
2xB 358164400 120.0 154.0
(1 x A) + (2 x B) 3 8 HH UNC x 7HH 358164800 145.4 179.4
3xB 3 8 HH UNC x 8 1 2 HH 358165400 180.0 214.0
1xA 3 8 HH UNC x 2 3 4 HH 358163000 30.7 64.7
1xB 3 8 HH UNC x 3 3 4 HH 358163500 60.0 94.0
(1 x A) + (1 x B) 3 8 HH UNC x 5HH 358164000 90.7 124.7
1HH 34.0
2xB 3 8 HH UNC x 6 1 4 HH 358164500 120.0 154.0
(1 x A) + (2 x B) 3 8 HH UNC x 7 1 2 HH 358165000 150.7 184.7
3xB 3 8 HH UNC x 8 1 2 HH 358165400 180.0 214.0
1xA 7 16 HH UNC x 3HH 358183200 35.0 74.0
1xB 7 16 HH UNC x 4 1 2 HH 358183800 75.0 114.0
(1 x A) + (1 x B) 7 16 HH UNC x 6HH 358184400 110.0 149.0
114HH 39.0
2xB 7 16 HH UNC x 7 1 2 HH 358185000 150.0 189.0
(1 x A) + (2 x B) 7 16 HH UNC x 9HH 358185600 185.0 224.0
3xB 7 16 HH UNC x 10 1 2 HH 358185900 225.0 264.0
Thigtening torque: 38 HH UNC = 34 Nm
7 16 HHUNC = 54 Nm
The product described is subject to continual development and the manufacturer reserves the right to change the specifications without notice.
15
Technical Publication
Fluids and Lubricants

Specification
A001061/27E
(all MTU-Series and World Engines)
Printed in Germany
2002 Copyright MTU Friedrichshafen GmbH
Diese Verffentlichung einschlielich aller seiner Teile ist urheberrechtlich geschtzt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere fr Vervielfltigung, Verbreitung, Bearbeitung,
bersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschlielich Datenbanken
und Online-Diensten.
Dieses Handbuch ist zur Vermeidung von Strungen oder Schden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen
Wartungs- und Bedienungspersonal zur Verfugung zu stellen.
nderungen bleiben vorbehalten.
Printed in Germany
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of
MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on
electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.
Imprem en Allemagne
Tout droit rserv pour cet ouvrage dans son intgralit. Toute utilisation ou exploitation requiert au pralable laccord crit de MTU
Friedrichshafen GmbH. Ceci sapplique notamment la reproduction, la diffusion, la modification, la traduction, larchivage sur microfiches,
la mmorisation et / ou le traitement sur des systmes lectroniques, y compris les bases de donnes et les services en ligne.
Le manuel devra tre observ en vue dviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous
lexploitant de le mettre la disposition du personnel charg de lentretien et de la conduite.
Modifications rserves.
Impreso en Alemania
Esta publicacin se encuentra protegida, en toda su extensin, por los derechos de autor. Cualquier utilizacin de la misma, as como su
reproduccin, difusin, transformacin, traduccin, microfilmacin, grabacin y/o procesamiento en sistemas electrnicos, entre los que se
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El manual debe tenerse presente para evitar fallos o daos durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposicin del
personal de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.
Stampato in Germania
Questa pubblicazione protetta dal diritto dautore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo alla
riproduzione, alla diffusione, alla modifica, alla traduzione, allarchiviazione in microfilm ed alla memorizzazione od allelaborazione in sistemi
elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall utente al personale addetto
alla manutenzione e alla condotta.
Con riserva di modifiche.
Impresso na Alemanha
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MTU Friedrichshafen GmbH

Abteilung SCT
88040 Friedrichshafen
GERMANY
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Publication No.:
A001061/27E
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Contents 1
Contents
Page
1 Preface.....................................................................................................................................................5
2 Lubricants ...............................................................................................................................................6
2.1 Engine Oils ...............................................................................................................................................6
2.1.1 Requirements for MTU approval (diesel engines)....................................................................................6
2.1.2 Special Features ......................................................................................................................................6
2.1.2.1 Engine Oils for Series 2000 and Series 4000 Engines ............................................................................6
2.1.2.2 Limitations for Applications under Difficult Operating Conditions.............................................................6
2.1.3 Engine Oil Requirements for Gas Engines...............................................................................................7
2.1.4 Viscosity Grade Selection.........................................................................................................................7
2.1.5 Oil Drain Intervals for Diesel Engines.......................................................................................................8
2.1.6 Oil Drain Intervals for Gas Engines ..........................................................................................................8
2.1.7 Special Additives ......................................................................................................................................8
2.1.8 Laboratory Analysis ..................................................................................................................................9
2.1.8.1 General.....................................................................................................................................................9
2.1.8.2 Used-oil Analysis ......................................................................................................................................9
2.1.8.3 Spectrometric Oil Analysis .....................................................................................................................10
2.1.9 Use of High Sulfur Fuel ..........................................................................................................................11
2.1.10 Use of Low Sulfur Fuel ...........................................................................................................................11
2.1.11 Minimum Requirements for Operational Checks ...................................................................................11
2.2 Lubricating Greases ...............................................................................................................................12
2.2.1 Requirements .........................................................................................................................................12
2.2.2 General Purposes ..................................................................................................................................12
2.2.3 High Melting-point Greases ....................................................................................................................12
2.2.4 Coupling Internal Centerings ..................................................................................................................12
2.3 Special Purpose Lubricants....................................................................................................................12
2.3.1 Turbochargers ........................................................................................................................................12
2.3.2 Gear Couplings ......................................................................................................................................12
3 Coolants ................................................................................................................................................13
3.1 Requirements .........................................................................................................................................13
3.2 Fresh Water ...........................................................................................................................................13
3.3 Emulsifiable Corrosion Preventive Oils ..................................................................................................13
3.4 Antifreezes with Corrosion Inhibiting Properties.....................................................................................14
3.4.1 General...................................................................................................................................................14
3.4.2 Limited Use of Corrosion-preventive Antifreezes ...................................................................................14
3.5 Water-soluble Corrosion Inhibitors.........................................................................................................14
3.6 Coolant Additives for Aluminum-free Engine Series (2000 C&I, 4000 C&I) ...........................................15
3.7 Operational Monitoring ...........................................................................................................................15
3.8 Tolerances for Prepared Coolant ...........................................................................................................16
3.9 Coolant Service Life ...............................................................................................................................17
3.10 Stability of Coolant Additives up to Max. 35C .......................................................................................17
4 Fuels ......................................................................................................................................................18
4.1 Diesel Fuels............................................................................................................................................18
4.1.1 Selection of a Suitable Diesel Fuel.........................................................................................................18
4.1.2 Requirements .........................................................................................................................................19
4.1.3 Low-sulfur Diesel Fuels ..........................................................................................................................19
4.1.4 Diesel Fuels in Winter Operation ...........................................................................................................19
4.1.4.1 Flow improvers .......................................................................................................................................19
4.2 Domestic Fuel ........................................................................................................................................20
4.2.1 Cetane Number ......................................................................................................................................20
4.2.2 Sulfur Content ........................................................................................................................................20
4.3 Fuel Additives .........................................................................................................................................20
4.4 Fuel for Gas Engines..............................................................................................................................21
4.5 Microorganisms in Fuel ..........................................................................................................................21
4.5.1 Approved Biocides..................................................................................................................................21
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2 Contents
5 Preservatives ........................................................................................................................................22
5.1 Requirements .........................................................................................................................................22
5.2 Types of Preservation ............................................................................................................................22
5.3 Initial Operation and Corrosion Preventive Oils for Internal Preservation ..............................................22
5.4 Corrosion Inhibitors for External Preservation........................................................................................22
5.5 Corrosion Preventive Oils for Internal Preservation of the Fuel System ................................................22
6 Approved Fluids and Lubricants ........................................................................................................23
6.1 Engine Oils .............................................................................................................................................23
6.1.1 Single-grade Oils - Category 1, SAE-grades 30 and 40 for Diesel Engines ..........................................23
6.1.2 Single-grade Oils - Category 1, SAE-grade 40 for Gas Engines............................................................26
6.1.3 Multi-grade Oils - Category 1, SAE-grades 10W-30 and 15W-40 for Diesel Engines ...........................26
6.1.4 Single-grade Oils - Category 2, SAE-grades 30 and 40 for Diesel Engines ..........................................28
6.1.5 Multi-grade Oils - Category 2, SAE-grades 5W-40, 10W-40, 15W-40 and 20W-40 for Diesel Engines ..30
6.1.6 Multi-grade Oils - Category 3, SAE-grades 5W-30, 5W-40 and 10W-40 for Diesel Engines ................32
6.2 Lubricating Greases for General Applications........................................................................................34
6.3 Coolant Additives....................................................................................................................................35
6.3.1 Emulsifiable Corrosion Preventive Oils ..................................................................................................35
6.3.2 Antifreezes with Corrosion Inhibiting Properties-Concentrates ..............................................................35
6.3.3 Antifreezes with Corrosion Inhibiting Properties - Ready Mix.................................................................36
6.3.4 Antifreezes / Corrosion Inhibitors - Concentrates - for Series 2000 C&I and 4000 C&I Engines without
Aluminum Components ..........................................................................................................................36
6.3.5 Antifreezes / Corrosion Inhibitors - Ready Mix - for Series 2000 C&I and 4000 C&I Engines without
Aluminum Components ..........................................................................................................................36
6.3.6 Water-soluble Corrosion Inhibitors - Concentrates ................................................................................37
6.3.7 Water-soluble Corrosion Inhibitors - Concentrates - for Aluminum-free Series 2000 C&I and 4000 C&I
Engines...................................................................................................................................................37
6.3.8 Water-soluble Corrosion Inhibitors - Ready Mix - for Aluminum-free Series 2000 C&I and 4000 C&I
Engines...................................................................................................................................................37
6.4 Preservation ...........................................................................................................................................38
6.4.1 Initial Operation- and Corrosion Inhibitor Oils for Internal Preservation .................................................38
6.4.2 Corrosion Inhibitors for External Preservation........................................................................................38
6.4.3 Corrosion Preventive Oils for Internal Preservation of the Fuel System ................................................38
7 Preservation..........................................................................................................................................39
7.1 Warnings ................................................................................................................................................39
7.2 Preface ...................................................................................................................................................39
7.2.1 Overview of Types of Preservation ........................................................................................................40
7.3 Short-time Shutdown..............................................................................................................................41
7.4 Shutdown................................................................................................................................................41
7.4.1 Putting Shutdown Engines into Operation..............................................................................................41
7.5 Preservation ...........................................................................................................................................42
7.5.1 Preservation of Cooling-, Lubrication and Fuel Systems .......................................................................42
7.5.2 Preservation of the Combustion Chamber .............................................................................................43
7.5.3 External Preservation .............................................................................................................................43
7.5.4 Re-preservation......................................................................................................................................44
7.5.5 De-preservation......................................................................................................................................44
7.6 Special Packing......................................................................................................................................45
7.6.1 General Information on Special Packing ................................................................................................45
7.6.2 Maintenance Intervals ............................................................................................................................45
7.6.3 Envelopes of Laminated Material ...........................................................................................................46
7.6.4 Desiccant................................................................................................................................................46
7.6.4.1 Calculation of Required Desiccant .........................................................................................................47
7.6.4.2 Calculation Example for Desiccant Units ...............................................................................................47
7.6.4.3 Humidity Indicator...................................................................................................................................48
7.6.5 Order Nos. for Packing Materials ...........................................................................................................49
7.6.6 Special Packing Procedure for Finished Products .................................................................................49
7.6.6.1 Preparation for Special Packing .............................................................................................................49
7.6.6.2 Transport Locking Device.......................................................................................................................49
7.6.6.3 Special Packing of an Engine.................................................................................................................49
7.6.6.4 Installation of Humidity Indicator.............................................................................................................51
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Contents 3
7.6.6.5 Cushioning of Engine Edges and Corners .............................................................................................52

7.6.6.6 Location of Desiccant Units....................................................................................................................52
7.6.6.7 Laminated Aluminum Foil Sealing..........................................................................................................52
7.6.7 Special Packing Checks.........................................................................................................................53
7.6.7.1 Humidity Check ......................................................................................................................................53
7.6.7.2 Desiccant Replacement .........................................................................................................................54
7.6.8 Repair of Special Packing ......................................................................................................................54
7.6.9 Manual Welding Unit ..............................................................................................................................54
7.7 Form Sheets...........................................................................................................................................55
7.7.1 Preservation Check Sheet......................................................................................................................55
7.7.2 Monitoring Sheet for Engines in Special Packing...................................................................................57
7.7.3 Check Sheet for De-preservation of Engines in Special Packing ..........................................................59
8 Flushing and Cleaning Specifications for Engine Coolant Systems ..............................................61
8.1 General Information................................................................................................................................61
8.1.1 Test Equipment, Auxiliary Materials and Fluids and Lubricants.............................................................61
8.2 Approved Cleaning Products..................................................................................................................62
8.3 Flushing Engine Coolant Systems..........................................................................................................62
8.4 Cleaning Engine Coolant Systems .........................................................................................................63
8.5 Cleaning Components............................................................................................................................63
A001061/27E 03-01 MTU

4 Contents
A001061/27E 03-01 MTU

Preface 5
1 Preface
The service life, operational reliability and function of the drive systems are largely dependent on the fluids and lu-
bricants employed. Correct selection and handling of fluids and lubricants are therefore extremely important. Rele-
vant instructions are contained in these Fluids and Lubricants Specifications.
The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using,
make sure you have the latest version.
If you have further queries, please contact your MTU representative.
Test standards for fluids and lubricants:
DIN Federal German Standards Institute
EN European Standards
ISO International Standards Organisation
ASTM American Society for Testing and Materials
IP Institute of Petroleum
NOTE:
Use of the approved fluids and lubricants, whether under the brand name or specification given in this pub-
lication, constitutes part of the warranty conditions.
The supplier of the fluids and lubricants is responsible for the world-wide standard quality of the named products.
Drive system fluids and lubricants can be inherently dangerous. Certain regulations must be
obeyed when handling, storing and disposing of these substances.
These regulations are contained in the manufacturers' instructions, legal requirements and technical guidelines
valid in the individual countries. Great differences can apply from country to country and a generally valid guide to
applicable regulations for fluids and lubricants is therefore not possible within this publication.
Users of the products named in these specifications are therefore obliged to inform themselves of the locally valid
regulations. MTU accepts no responsibility whatsoever for improper or illegal use of the fluids and lubricants ap-
proved by them.
A001061/27E 03-01 MTU

6 Lubricants
2 Lubricants
2.1 Engine Oils
2.1.1 Requirements for MTU approval (diesel engines)

The MTU requirements for approval of engine oils for diesel engines are contained in the MTU Factory Standard
MTL 5044, for first-use oils and corrosion-inhibiting oils in MTL 5051, and for gas engines in MTU Factory Standard
MTL 5074. These standards can be ordered under these titles.
The engine-oil manufacturer will be notified in writing after his product has been approved.
Approved engine oils are divided into the following MTU quality groups:
- Oil category 1: Normal quality oils
- Oil category 2: Higher quality oils
- Oil category 3: Highest quality oils
Selection of a suitable engine oil is based on fuel quality, intended oil drain interval and on-site climatic conditions.
At present there is no international industrial standard which alone takes into account all these criteria.
2.1.2 Special Features
2.1.2.1 Engine Oils for Series 2000 and Series 4000 Engines
Engine oils other than those approved in Section 6 may be used in these engines provided they meet all the specifi-
cations given in Tables 1 and 2.
Performance Requirements for Series 2000 and Series 4000 Engine Oils Table 1
Oil category 1 Minimum specification API CG-4 and ACEA E2-96
Oil category 2 Specification ACEA E3-96
Required Chemical and Physical Properties for Engine Oils Table 2

Test Method Limit Value
Total base number (TBN) ASTM D 2896 > 8mgKOH/g
ISO 3771
Shear stability ASTM D 3945 or Limit values of respective
CEC-L-14-A-88 viscosity class
1)
Deposit test DIN E 51535 Max. 120 mg
1)
Required for multi-grade oils used in closed crankcase ventilation.
NOTE:
Engine oils satisfying only one of the following standards, ACEA E1-96, API CF or API CF-4, or a combina-
tion of them, do not fulfill the entire performance requirements.
If these oils are intended for use, the oil drain interval is to be shortened by up to 50% after consultation
with MTU.
2.1.2.2 Limitations for Applications under Difficult Operating Conditions

Category 2 or Category 3 oils are generally prescribed for fast commercial ferries using Series 595 or Series 1163
engines.
Only single-grade SAE 30 oils of Category 2 or 3 are to be used in the Series 8000 engines.
A001061/27E 03-01 MTU

Lubricants 7
2.1.3 Engine Oil Requirements for Gas Engines

The selection of a suitable engine oil for gas engines depends primarily on the type of gas used to power the en-
gine. Another significant factor is the quality of the gas regarding its purity. This requires that the operator regularly
carries out gas checks. The gas-engine oils to be used feature a low ash content (< 0.6%) and total base numbers
within a range of 4-6 mgKOH/g. This prevents increased ash deposits which can lead to reduced catalytic converter
performance.
2.1.4 Viscosity Grade Selection

Selection of the viscosity grade is based primarily on the ambient temperature at which the engine is to be started
and operated. If the relevant performance criteria are observed, the engines can be operated both with single-grade
and multi-grade oils, depending on application.
If the prevailing temperature is too low, the engine oil must be preheated.
Viscosity grade SAE 40 is prescribed for gas engines!
Chart 1
A001061/27E 03-01 MTU

8 Lubricants
2.1.5 Oil Drain Intervals for Diesel Engines

Engine-oil drain interval depends on the engine-oil quality, its conditioning, the operating conditions and the fuel
used.
The given intervals are guidelines based on operational experience. (Table 3).
Oil drain intervals Table 3
Oil category Without centrifugal oil filter With centrifugal oil filter
1 250 operating hours 500 operating hours
The oil drain intervals in the table are recommended guidelines when using diesel fuels with < 0.5% sulfur content.
The limit values for used oil given in Table 4 still have to be taken into account.
The oil drain intervals must be determined by oil analysis if one or more of the following difficult operating conditions
are encountered:
- Extreme climatic conditions
- High engine start-up frequency
- Frequent and prolonged idling or low-load operation
- High fuel sulfur content of 0.5 to 1.5% by weight (see 2.1.9 "Use of High-sulfur Fuel")
New oils are to be chosen that have total base numbers corresponding to the sulfur content of the fuel used (see
2.1.8 "Laboratory Analysis").
The engine oils are to be changed after two years at the latest in applications with short operating periods.
Engine oils with higher corrosion-preventive properties (see 6.1.1) must be changed every 3 years at the latest.
In individual cases the engine-oil drain interval can be optimized by regular laboratory analyses and engine inspec-
tions:
The first or "reference" sample of the new oil must be taken from the engine after approximately 1 hour's opera-
tion.
Further samples are to be analyzed at specific intervals (see 2.1.8 "Laboratory Analysis").
The appropriate engine inspections are to be carried before and after the oil analyses.
After completion of all analyses, and depending on the findings, special agreements can be reached for individual
cases.
The oil samples must always be taken from the provided extraction point and under the same conditions.
Optimized operating times are given in the applicable Maintenance Schedules and/or Operating Instructions.
2.1.6 Oil Drain Intervals for Gas Engines

Determine the oil drain intervals based on the oil analyses as described in the Maintenance Schedules. Regular oil
analyses are necessary because of the varying gas qualities. It is recommended that oil samples be examined
every 500 operating hours.
In individual cases, the oil change intervals can also be optimized:
This requires oil samples to be analyzed every 200 - 250 operating hours (see 2.1.8 "Laboratory Analysis").
The oil samples must always be taken from the provided extraction point and under the same conditions.
Optimized operating times are given in the applicable Maintenance Schedules and/or Operating Instructions.
2.1.7 Special Additives

Engine oils approved by MTU have been specially developed for diesel engine service and have all necessary
properties, further additives are therefore superfluous and may even be harmful.
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Lubricants 9
2.1.8 Laboratory Analysis
2.1.8.1 General
Engine-oil analyses can be ordered from the MTU laboratory, oil-analysis laboratories or the oil manufacturer.
The oil sample must be extracted in accordance with the Operating Instructions.
The following data are required:
- Oil manufacturer
- Brand name with viscosity class
- Oil service life to date
- Serial number of engine from which oil sample was taken
The following must be submitted:
- Min. 0.25 liter used oil
- Min. 0.25 liter reference sample (after approx. 1 hour's operation) and new oil.
2.1.8.2 Used-oil Analysis

In order to check the used oil, it is recommended that regular oil analyses be carried out. Oil samples should be
taken at least during each oil change, and even more often under certain circumstances, depending on engine ap-
plication.
The test methods and limit values given in Table 4 and Table 5 (Analytical Limit Values for Diesel / Gas Engines)
indicate when the result of an oil-sample analysis should be regarded as abnormal.
An abnormal result requires immediate investigation and remedy of the abnormality.
Analytical Limit Values for Diesel Engines Table 4
Viscosity at 100 C ASTM D 445
2
Max. mm /s DIN 51562 SAE 30
SAE 5W-30 15.0
SAE 10W-30
SAE 40
SAE 10W-40 19.0
SAE 15W-40
2/s
Min. mm SAE 30
SAE 5W-30 9.0
SAE 10W-30
SAE 40
SAE 10W-40 10.5
SAE 15W-40
Flash point C (COC) ASTM D 92 Min. 190
ISO 2592
Flash point C (PM) ASTM D 93 Min. 150
EN 22719
Soot DIN 51452 Max. 2.5% by weight (Oil category 1)
CEC-L-82-A-97 Max. 3.0 % by weight (Oil categories 2 and 3)
Total base number (TBN) ASTM D 2896 Min. 50% of new-oil value
(mg KOH/g) ISO 3771
Water ASTM D 1744 Max. 0.2% by volume
Ethylene glycol ASTM D 2982 Max. 50 ppm
DIN 51375
-1
Aging products (1700-1750 cm ) IR-analysis Max. 25 A/cm
-1
Nitration products 1630 cm ) IR-analysis Max. 25 A/cm
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10 Lubricants
Analytical Limit Values for Gas Engines Table 5

Viscosity at 100 C ASTM D 445
2
Max. mm /s DIN 51562 SAE 40 17.5
2/s
Min. mm SAE 40 11.5
Total contamination DIN 51365 Max. 0.5% by weight
Total base number (mg KOH/g) ASTM D 2896 Min. 3
ISO 3771
Acid number (mgKOH/g) ASTM D 664 Max. 80% of actual base number
pH value Min. 4.5
Water ASTM D 1744 Max. 0.2% by volume
Oxidation at 5.8 m IR Max. 20 A/cm
Nitration at 6.1 m IR Max. 20 A/cm
Wear elements (mg/kg) RFA, ICP
Iron (Fe) Max. 30 mg/kg
Lead (Pb) Max. 20 mg/kg
Aluminum (Al) Max. 10 mg/kg
Copper (Cu) Max. 20 mg/kg
Tin (Sn) Max. 5 mg/kg
Silicon (Si) Max. 15 mg/kg
The limit values relate to individual oil samples. When these limit values are reached or exceeded, an immediate oil
change is necessary. The results of the oil analysis do not necessarily give an indication of the wear status of cer-
tain components.
In addition to the analytical limit values, engine condition, operational requirements and possible malfunctions are
also decisive factors governing the oil drain interval.
Other signs of oil deterioration are:
- Abnormally heavy deposits or precipitates in the engine or engine-mounted parts such as oil filters, centrifugal oil
filters or separators, especially in comparison with the previous analysis.
- Abnormal discoloration of components.
2.1.8.3 Spectrometric Oil Analysis

Analysis of the engine oil's additive-metal content will be carried out by the MTU laboratory to determine the brand
of oil.
MTU does not generally analyze the oil's wear-metal contents in order to determine the degree of engine wear.
These content levels are very much dependent on the following factors, among others:
- Individual engine equipment
- Tolerance scatter
- Operating conditions
- Duty profile
- Fluids and lubricants
- Miscellaneous assembly materials
It is therefore impossible to draw definite conclusions on the wear status of the respective engine parts, which
means that no limit values can be given for wear-metal contents.
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Lubricants 11
2.1.9 Use of High Sulfur Fuel

The following measures must be taken in the case of fuels with a sulfur content above 0.5%:
- Use an engine oil with a total base number (TBN) (ASTM D 2896) above 8 mgKOH/g.
- The oil drain interval is to be shortened (see 2.1.5 "Oil Drain Intervals for Diesel Engines").
Chart 2 (total base number) shows the recommended initial TBN for new oil and the recommended minimum TBN
for used oil depending on the fuel's sulfur content.
Engine Oil Total Base Numbers depending on the Fuel's Sulfur Content Chart 2
2.1.10 Use of Low Sulfur Fuel

The use of fuels with low sulfur content (< 0.5%) does not influence the oil drain intervals.
2.1.11 Minimum Requirements for Operational Checks

The oil analyses required by the Maintenance Schedule can be made using the MTU Test Kit. This test kit contains
all the necessary equipment and instructions.
The following checks can be performed:
- Determination of oil dispersing effect (spot test)
- Determination of fuel content
- Determination of water content
A001061/27E 03-01 MTU

12 Lubricants
2.2 Lubricating Greases
2.2.1 Requirements
The MTU conditions for lubricating-grease approval are specified in the MTU Factory Standard MTL 5050, which
can be ordered under this title.
The grease manufacturer will be notified in writing when his product is approved by MTU.
2.2.2 General Purposes

Lithium-saponified greases are to be used for all lubrication points with the exception of:
- Emergency air shut-off flaps located between the turbocharger and intercooler (see 2.2.3 "High Melting-point
Greases")
- Coupling internal centering
2.2.3 High Melting-point Greases

This type of grease must be used for emergency air shut-off flaps located between the turbocharger and intercooler:
- Aero Shell Grease 15
- Optimol Inertox Medium
General-purpose greases suffice for emergency air shut-off flaps located before the turbocharger or after the inter-
cooler.
2.2.4 Coupling Internal Centerings

Lubricating grease for internal centerings:
- Esso Unirex N3
2.3 Special Purpose Lubricants
2.3.1 Turbochargers
Exhaust turbochargers with integrated oil supply are generally connected to the engine oil system.
For ABB exhaust turbochargers with self-contained oil systems, IS0-VG68 viscosity-grade turbine oils with a mineral
oil base must be used.
2.3.2 Gear Couplings

Depending on the application, the following lubricants have been approved for gear couplings:
- Klber: Structovis BHD MF (highly viscous lubricating oil)
- Klber: Klberplex GE11-680 (adhesive transmission lubricant)
Guidelines on use and service life are contained in the relevant Operating Instructions and Maintenance Schedules.
A001061/27E 03-01 MTU

Coolants 13
3 Coolants
3.1 Requirements
Coolant must be prepared from suitable fresh water and an MTU-approved coolant additive.
Mixing of different coolant additives is prohibited!
The MTU conditions for coolant-additive approval are specified in MTU Factory Standards (MTL). The following
standards are available:
- Emulsifiable corrosion preventive oils, MTL 5047
- Antifreeze (corrosion inhibiting), MTL 5048
- Water-soluble corrosion inhibitors, MTL 5049
The coolant manufacturer will be informed in writing after his product has been approved by MTU.
3.2 Fresh Water

For coolant preparation, use only clean, clear water with the following values (Table 6):
Table 6
Min. Max.
)
Total alkaline earth metals1 0 mmol/l 2.7 mmol/l
(Water hardness) 0d 15d
pH-value at 20C 6.5 8.0
Chloride ions 100 mg/l
Anion total 200 mg/l
1)
Common designations for water hardness in various countries:
1mmol/l = 5.6d = 1 mg/kg CaCO3
- 1d = 17.9 mg/kg CaCO3, USA hardness
- = 1.79 French hardness
- = 1.25 British hardness
3.3 Emulsifiable Corrosion Preventive Oils

A 2.0% by volume emulsion must be used (for initial filling or refilling after cleaning the system).
Emulsions of MTU-approved corrosion preventive oils (1.0 - 2.0% by volume) and suitable fresh water provide ade-
quate corrosion protection.
Some corrosion preventive oils tend to foam if used with completely desalinated water. This can be avoided by add-
ing an appropriate quantity of harder water.
It is advisable to first mix the required quantity of corrosion preventive oil with 4 to 5 times the same amount of fresh
water in a container, and to introduce this mixture into the system with the engine running at operating temperature.
In maintenance stations or multi-engine installations the complete amount of coolant required should be prepared in
a separate container, it can then be used for initial filling or replenishment as required.
Under unfavorable conditions, individual cases of bacterial attack in the coolant emulsions
may occur. In such a case, and after consultation with the MTU chemical laboratory, the
emulsion is to be treated with biocides.
Coolant emulsions must not be used for engines with TB- (plate-core heat exchanger) and TE-cooling systems in
the 396, 4000 and 183 engine series. The coolant emulsion is not permitted for engines with coolant temperatures
>90 C.
A001061/27E 03-01 MTU

14 Coolants
3.4 Antifreezes with Corrosion Inhibiting Properties
3.4.1 General
These antifreezes are necessary for engines without heating facilities and operating in areas where below-freezing
temperatures may occur.
Provided that the specified concentrations are maintained, these MTU-approved antifreezes ensure adequate cor-
rosion protection.
The antifreeze concentration must therefore be determined not only in accordance with the minimum anticipated
temperatures but with the corrosion protection requirements also.
If a higher level of antifreeze/corrosion inhibitor is used, a higher engine temperature results.
3.4.2 Limited Use of Corrosion-preventive Antifreezes

Marine engines are subject to the following limitations when using corrosion-preventive antifreezes:
- Series 538, 595 and 956/1163 engines:
These engines are equipped with heating facilities.
Because of their heat exchanger capacity, antifreeze/corrosion inhibitors are not to be used.
- Series 099, 183, and 396 engines:
The use of antifreeze/corrosion inhibitors in these engines is permitted only with seawater temperatures of up to
20C maximum.
- Series 2000 and 4000 engines:
The use of antifreeze/corrosion inhibitors in these engines is permitted with seawater temperatures of up to 25C.
- Series 8000:
The use of antifreezes with corrosion-preventive properties is not allowed for these engines.
Antifreeze/corrosion inhibitors can be used without reservation in vehicle, locomotive and stationary applications.
3.5 Water-soluble Corrosion Inhibitors

Water-soluble corrosion inhibitors are necessary for higher coolant temperatures or higher temperature differentials
in heat exchangers, e.g. in TB- (with plate-core heat exchanger) and TE-systems in Series 396, 4000 and engines
Only water-soluble corrosion inhibitors according to 6.3.6 are to be used in Series 8000 engines.
The water-soluble corrosion inhibitors recommended by MTU ensure adequate protection provided the correct con-
centrations are used. The individual concentration tolerances are given in Section 3.6, "Water-soluble Corrosion
Inhibitors", Table 7.
Special arrangements are possible after consultation with MTU. Special arrangements presently in effect remain
valid.
NOTE:
Before the first use of water-soluble corrosion inhibitors and after every product change, the system must
first be flushed out with water. This also applies to new engines. The necessary work and cleaning agents
are described in the MTU Flushing and Cleaning Specification for Engine Coolant Systems (at the end of
this Specification).
1
Protect coolant-exposed components by adding Castrol 481/44 corrosion-inhibitor additive (5%) before a
longer shutdown period (approx. 5 days) or maintenance work on an opened engine.
1
Supplier: Deutsche Castrol Industriel
Erkelenzerstr. 20
41179 Mnchengladbach
Tel.: 02161/9093-10 or -20
Fax. 02161/9093-90 or -91
A001061/27E 03-01 MTU

Coolants 15
3.6 Coolant Additives for Aluminum-free Engine Series (2000 C&I, 4000 C&I)
All coolant additives listed under 6.3 are suitable for the aluminum-free 2000 C&I and 4000 C&I engines. Note the
limitations given under "Remarks".
Coolant additives given under 6.3.4, 6.3.5, 6.3.7 and 6.3.8 are not permitted for all other engine
series!
3.7 Operational Monitoring

Freshwater examinations and frequent coolant-mixture checks are of prime importance in ensuring trouble-free
engine operation and can be performed using the MTU Test Kit which contains the necessary equipment, chemi-
cals and instructions for use.
The following checks can be performed:
- Determination of total hardness (d)
- pH value
- Chloride content of fresh water
- Corrosion preventive oil content
- Antifreeze (corrosion inhibiting) concentration
- Water-soluble corrosion inhibitor content
Permissible Concentrations Table 7
Min. % by vol. Max. % by vol.
Emulsifiable Corrosion Preventive Oils 1.0 2.0
Antifreeze (corrosion inhibiting) 35 50

Antifreeze to approx. Antifreeze to approx.
-25C -40C
Water-soluble corrosion inhibitor
- BASF Glysacorr G93-94* 9 11

- Ginouves York 719*
- Valvoline ZEREX G-93*
- Arteco Havoline Extended Life Corrosion Inhibitor**
- Arteco Heavy Duty Extended Life Corrosion Inhibitor**
- Caltex Corrosion Inhibitor Concentrate
- Ondeo Nalco Alfloc 2000 3 4
- Ondeo Nalco Nalcool 2000
- Ondeo Nalco Nalco 2000
- Detroit Diesel Powercool 2000
- Penray Pencool 2000
- Ondeo Nalco Alfloc 3477 7 11
- Fleetguard DCA-4L 5 6
* = See reference curve ( ) for water-soluble corrosion inhibitors (Chart 3)
= See reference curve ( ) for water-soluble corrosion inhibitors (Chart 3)
Use Chart 3 together with the hand refractometer to determine concentration of the water-soluble corrosion inhibi-
tors. Calibrate the hand refractometer with clean water at coolant temperature. The coolant temperature should be
20-30C.
Test kits are available from manufacturers to determine concentration of the other water-soluble corrosion
inhibitors.
A001061/27E 03-01 MTU

16 Coolants
Reference Curve for Water-soluble Corrosion Inhibitors Chart 3
A = Degree Brix at 20C, read off from hand refractometer

B = Concentration of water-soluble corrosion inhibitor in % by volume.
NOTE:
Use of coolant emulsions can lead to light precipitation during operation. This is shown by a layer on the
surface of the coolant in the expansion tank. This is of no importance as long as the coolant concentration
remains within the specified tolerances.
Change the coolant in the event of a sudden drop in coolant additive concentration or if the additive is no
longer absorbed. If necessary, the engine coolant spaces are to be cleaned (see the Flushing and Cleaning
Specification for Engine Coolant Systems at the end of this specification).
3.8 Tolerances for Prepared Coolant Table 8

pH value when using:
- Emulsifiable corrosion preventive oil Min. 7.5 Max. 9.5
- Antifreezes (corrosion inhibiting) Min. 7.0 Max. 9.0
- Water-soluble corrosion inhibitors for engines containing aluminum parts. Min. 7.0 Max. 9.0
- Water-soluble corrosion inhibitors for engines without aluminum parts. Min. 7.0 Max. 11.0
Silicon (Si) Min. 25 mg/l
A001061/27E 03-01 MTU

Coolants 17
3.9 Coolant Service Life Table 9

Coolant service life when using: Max. Remarks
Emulsifiable corrosion preventive oil 6000 Operating hours,
1 or year See Table 6.3.1
Antifreeze (corrosion inhibiting) 9000 Operating hours,
3 or years
5 or years See Table 6.3.2, 6.3.3,
6.3.4 and 6.3.5
Water-soluble corrosion inhibitor 6000 Operating hours, See Table 6.3.6 and
2 or years 6.3.7
- BASF Glysacorr G93-94 See Table 6.3.6

- Ginouves 719
- Valvoline ZEREX G-93
- Arteco Havoline Extended Life Corrosion Inhibitor See Table 6.3.7
- Arteco Heavy Duty Extended Life Corrosion Inhibitor
- Caltex Corrosion Inhibitor Concentrate
- Caltex XL Corrosion Inhibitor 10% See Table 6.3.8
- Ondeo Nalco Alfloc 3477 See Table 6.3.7
- Ondeo Nalco Alfloc 3443 See Table 6.3.8
- Ondeo Nalco Alfloc 2000 250 Operating hours, See Table 6.3.7
- Ondeo Nalco Nalcool 2000 1 or year
- Ondeo Nalco Nalco 2000
- Detroit Diesel Powercool 2000
- Penray Pencool 2000
- Fleetguard DCA-4L 2000 Operating hours, See Table 6.3.7
1 or year
3.10 Stability of Coolant Additives up to Max. 35C Table 10

Emulsifiable corrosion preventive oil 6 months
Antifreeze (corrosion inhibiting) 5 years
Water-soluble corrosion inhibitor 1 year Arteco Havoline Extended Life Corrosion Inhibitor
Arteco Heavy Duty Extended Life Corrosion Inhibitor
Caltex Corrosion Inhibitor Concentrate
2 years Ondeo Nalco Alfloc 2000
Ondeo Nalco Nalcool 2000
Ondeo Nalco Nalco 2000
Detroit Diesel Powercool 2000
Penray Pencool 2000
3 years Alfloc 3477
BASF Glysacorr G93-94
Ginouves York 719
Valvoline ZEREX G-93
5 years Fleetguard DCA-4L
A001061/27E 03-01 MTU

18 Fuels
4 Fuels
4.1 Diesel Fuels
4.1.1 Selection of a Suitable Diesel Fuel

The quality of the fuel is very important for satisfactory engine performance, long engine service life and acceptable
exhaust emission levels. The engines can be operated with most diesel fuels sold worldwide. The properties and
limit values specified in Table 11 (fuels of comparable quality) ensure optimum engine performance.
Fuels of comparable quality with following test results: Table 11
ASTM ISO
Composition The fuel must be free of acids, visi-
ble water and solid contaminants
(sediment free)
Total contamination Max. EN 12662 24 mg/kg
Density at 15 C Min. D 1298 EN 3675 0.820 g/ml
Max. 0.860 g/ml
API at 60 F Min. D 287 41
Max. 33
2
Viscosity at 40 C Min. D 445 EN 3104 1.5 mm /s
2
Max. 4.5 mm /s
Flash point Min. D 93 EN 22719 55 C
Boiling curve: D 86 3405
- Initial boiling point 160 - 220 C
- Recovery at 250 C Max. 65% by volume
- Recover at 350 C Min. 85 % by volume
- Metallic residue and loss Max. 3% by volume
Water Max. D 1744 0.03% by volume
Conradson carbon residue Max. D 189 EN 10370 0.3 by weight %
of 10% distillation residue
Ash Max. D 482 EN 6245 0.01 by weight %
1)
Sulfur Max. D 2622 EN 14596 0.5 by weight %
Cetane number Min. D 613 EN 5165 45
Cetane index Min. D 4737 EN 4264 42
Copper corrosion Degree of D 130 EN 2160 1a
3 hrs at 50 C corrosion
Max.
3
Oxidation resistance Max. D 2274 EN 12205 25 g/m
Lubricity at 60C Max. 12156-1 0.46 mm
2)
Filter plugging point D 4359 EN 116 See Note
1)
Sulfur content of more than 0.5% requires an engine oil with a higher TBN and shorter oil drain intervals.
2)
It is the fuel supplier's responsibility to provide a fuel that will assure correct engine operation at the expected
minimum temperatures and under the given geographical and other local conditions.
A001061/27E 03-01 MTU

Fuels 19
4.1.2 Requirements
Commercially available diesel fuels meeting the following specifications are approved for use:
Diesel Fuels
- Diesel fuel as per EN 590
- Grade No. 1-D as per ASTM D 975-00
- Grade No. 2-D as per ASTM D 975-00
Marine Distillate Fuels
- DMX as per ISO 8217
The following can be used if the oil quality and service-life limitations are taken into consideration:
- DMA as per ISO 8217 (not for Series 4000)
- Other qualities available upon request
4.1.3 Low-sulfur Diesel Fuels

Sulfur is contained in chemically bound form in crude oil and therefore in fuel at varying levels.
A sulfur content of maximum 0.035% by weight has been permitted within the European Union since 1 January
2000. Sulfur contents at or below this level are designated "low in sulfur". We designate diesel fuels with a sulfur
content of maximum 10 ppm as "sulfur free". Low sulfur diesel fuels are recommended for environmental reasons.
In order to avoid wear problems, lubricity additives are also added.
4.1.4 Diesel Fuels in Winter Operation

At low outdoor temperatures, the diesel fuel's flow property can be unacceptable on account of paraffin precipita-
tion.
In order to prevent operational problems (e.g. clogged filters) during the winter months, diesel fuel with suitable
cold-flow characteristics is available on the market. Deviations are possible before and after winter and in individual
countries. If no frost-resistant diesel fuels are available, it is necessary to add petroleum before the frost period
begins: as a basic guide, adding 5% by volume achieves an improvement of frost resistance of approx. 1 C.
Add the additive to the diesel fuel in good time before the flow property of the diesel fuel is impaired by paraffin pre-
cipitation. Malfunctions resulting from paraffin precipitation can only be eliminated by heating the entire fuel system.
Petrol (gasoline) is not to be added.
4.1.4.1 Flow improvers

Although these improvers cannot prevent paraffin precipitation, they influence the size of the crystals and allow the
fuel to pass through the filter.
The effectiveness of the flow improvers is not guaranteed for every fuel.
Certainty is only assured after laboratory testing of the filtering capability.
Required quantities and mixing procedures must be carried out according to the manufacturer's instructions.
A001061/27E 03-01 MTU

20 Fuels
4.2 Domestic Fuel

Domestic fuel (heating oil) differs from diesel fuel mainly because of the following characteristics:
- Cetane number
- Sulfur content
- Oxidation stability
- Copper corrosion
- Low-temperature behavior
Domestic fuel can be used in the diesel engine if its characteristics agree technically with the diesel fuel specifica-
tions.
4.2.1 Cetane Number

The cetane number is not specified in DIN 51 603 T1. If domestic fuel is used, the cetane number must therefore be
quoted by the supplier or measured and be at least 45 as required in the MTU Fluids and Lubricants Specification.
The purely calculated cetane index must not be less than 42.
4.2.2 Sulfur Content

The maximum sulfur content for domestic fuel according to DIN 51 603 T1 is 0.2%. Depending on the production
capacity at the refineries, the market can offer domestic fuels containing diesel-fuel ingredients with a sulfur content
of< 0.05 %. Lubrication additives are never added as the oil is primarily intended for heating purposes. Lubrication
problems can therefore be expected when using these qualities of domestic fuel because of the missing additives.
Consultation with the individual fuel supplier is necessary.
4.3 Fuel Additives

The engines are so designed that satisfactory operation with normal, commercially available fuels is ensured. Many
of these fuels already contain performance-enhancing additives.
The additives are added by the supplier as the agent responsible for product quality.
Additional additives are therefore not required.
Attention is drawn to the fact that the use of other diesel fuels or additives than those stipu-
lated in the MTU Fluids and Lubricants Specification is always the responsibility of the opera-
tor.
A001061/27E 03-01 MTU

Fuels 21
4.4 Fuel for Gas Engines

The gas engines must be operated with natural gas. The quality must be checked half-yearly by gas analysis to
detect alterations of harmful components in the gas and take appropriate measures. This will prevent corrosion
damage to the engine.
If specific limit values are exceeded, engine operation must be interrupted in order to prevent damage to engine
components.
Attention is drawn to the fact that the manufacturer's warranty is cancelled if the specified
limit values are exceeded. Further operation is possible after consulting MTU and obtaining
written confirmation relating to any necessary measures.
Requirements for Gas Fuel Table 12

Methane content % by volume 80
Methane number Min. 70
3
Lower calorific value MJ/m 34
3
Sulfur content mg/m < 1170
Hydrogen sulfide % by volume Max. 0.08
3
Total halogens mg/m 0
3
Silicon mg/m 0
3
Dust mg/m < 50
Relative humidity % Max. 60 at min. operating temperature
CmHn - vapors % < 60
3
The limit values are based on methane at 100% by volume, or 10 kWh/m for each of any further combustible
gases present in normal condition.
4.5 Microorganisms in Fuel

Bacterial attack in the fuel may occur under unfavorable conditions. In such a case, the fuel must be treated with
biocides in accordance with the manufacturer's specifications.
4.5.1 Approved Biocides Table 13

Manufacturer Brand name Concentration for use
Bode Chemie Bakzid 100ml per 100l
Melanchthonstr. 27
22525 Hamburg
Tel. 040/54006-0
Tel. 040/54006-200
Schlke und Mayr GrotaMAR 71 70ml per 100l
22840 Norderstedt
Tel. 040/52100-00
Tel. 04052100/-244
A001061/27E 03-01 MTU

22 Preservation
5 Preservatives
5.1 Requirements
The MTU conditions for preservative approval are specified in MTU Factory Standards (MTL). The following stan-
dards are available:
- Initial-operation oil and corrosion-inhibitor oil for internal preservation, MTL 5051
- Preservatives; Corrosion inhibitors for external preservation, MTL 5052
The preservation product manufacturer will be informed in writing after his product has been approved by MTU.
5.2 Types of Preservation

See the Preservation Specification (Section 7.2.1)
5.3 Initial Operation and Corrosion Preventive Oils for Internal Preservation
SAE 30 viscosity grade corrosion preventive oils are to be used for internal preservation (oil-moistened compo-
nents) of MTU engines and gearboxes.
These oils may also be used for running-in and acceptance testing procedures. Some, however, are suitable for
continuous operation (see6.4.1).
5.4 Corrosion Inhibitors for External Preservation

For external preservation, all non-painted parts are to be treated with a corrosion inhibitor providing a wax-like pro-
tective coating after the inhibitor solvent has evaporated.
5.5 Corrosion Preventive Oils for Internal Preservation of the Fuel System
Fuel injection-pump test oil conforming to DIN ISO 4113 is to be used for internal preservation of the fuel system.
The engine should be run with these oils for the last 10 minutes before shutdown.
Fuel system internal preservation can also be performed using diesel fuel to which approximately 10% corrosion
preventive oil for internal preservation has been added.
A001061/27E 03-01 MTU

Engine Oils 23
6 Approved Fluids and Lubricants
6.1 Engine Oils

For details and special features see Sections 2.1 and 2.3
6.1.1 Single-grade Oils - Category 1, SAE-grades 30 and 40 for Diesel Engines
Available in:
Manufacturer Brand name SAE Remarks
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
Abu Dhabi National Adnoc HPSD 40 X X X

Oil, UAE
Addinol Lube Oil Addinol Marine MS 4011 40 X X

Addinol Turbo Diesel MD 305 30 X X
Addinol Turbo Diesel MD 405 40 X X
Agip Petroli S.p.A. Agip Cladium 120 30, 40 X X X Not Series 2000, 4000
Aral Lubricants Aral Basic Turboral 30, 40 X X X X X X
Avia Avia Special HDC 30, 40
Bharat Petroleum MAK-MA 40 40 X
BP Oil International BP Vanellus C3 Mono 30, 40 X X X X

Energol DS3-153/154 30, 40 X X X X X X
Castrol Castrol CRD-DB 30, 40 X

Castrol Marine MLC 30, 40 X X X X X X
Cepsa Lubricantes Cepsa Retto Super Serie 3 30 X

Cepsa Rodaje Y Proteccion 30 X Increased corrosion
protection
ChevronTexaco Ursa Super LA 30, 40 X X

Ursa LA 40 X
ChevronTexaco RPM Super 30, 40 X
Diesel Monograde
Cyclon Hellas Cyclon D Prime 30, 40
EKO, Greece EKO Marsa 30, 40
Emirates Lubeoil Crown Super Duty Plus 40 40

Co.
Engen, South Africa Dieselube 530 30 X

Dieselube 540 40 X
A001061/27E 03-01 MTU

24 Engine Oils
Available in:
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
Exxon Mobil Europe Essolube X 4 30, 40 X X

Essolube X 301 30, 40 X
Exxmar CM
MZK Motorenl LD30 30 X Increased corrosion
protection
Exxon Mobil Ameri- Essolube X 311 30, 40 X

cas
Fuchs Minerall- Titan Universal HD 30, 40 X X X X X X

werke GmbH
Hindustan Petr. Hylube MTU 40

Comp. Indien
Idemitsu, Singapore Daphne Marine Oil MT 40 X
Indian Oil Corp. Lt. Servo Ultra 40 RR 40 X Not Series 2000, 4000
Mexicana De Mexlub CF/CF-2 40

Lubricantes, Mexico
Motor Oil (Hellas) EMO Diesellube 4D 30, 40 X

EMO Turbo Champion Plus 30, 40
MV AG MV truck 30 30
MV truck 40 40
Pennzoil Products Supreme Duty Diesel Engine 30 Only Series 183, 396
Oil
Pertamina, Indone- Meditran SX 40

sia
Petmal, Malaysia Stalia XD 40
Petrobras Marbrax CCD 410 40 X X X X

Marbrax CCD 310 30 X X X X
Lubrax MD 400 30, 40 X X X X X X Not Series 2000, 4000
Petrogal, Portugal Galp Diesel 30 X
Petronas Dagan- Motolub CS 3/M 40

gan, Malaysia
Petrol Ofisi Turbosarj 30

Spersarj C 30, 40
Spersarj M-F 30 30
Petroliam Malaysia Petronas Motolub CS3/M 40
Petromin Lubricat- Super Diesel Engine Oil HD3 30, 40

ing Oil
A001061/27E 03-01 MTU

Engine Oils 25
Available in:
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
PTT Public Comp. PTT Navita MTU Type 1 40
Raloy Raloy Monogrado Diesel 40
Repsol Repsol Serie 3 30, 40
SRS Schmierstoff Wintershall Antikorrol M 30 X X X Increased corrosion

Vertrieb GmbH protection
Wintershall Rekord 30, 40 X X X
Shell International Shell Rimula X Monograde 30, 40 X X X X X X

Petroleum Comp. Shell Sirius Oil 30, 40 X X X X X X
Shell Gadinia Oil 30, 40 X X X X X X
Sakson Parnas Speedoil S III S 40 X
Shell, Netherlands Shell Nautica 30, 40
Singapore Petro- SPC SDM 801 30, 40 X

leum Comp. SPC SDM 706 40 X
Statoil Motorolja 20W/30 (Ref No. 20W30

SSL 92314)
Total Fina Elf Elf Performance 3D 30, 40 X X X X X X
Veba Oil Movara Extra Motorl 30, 40 X
Yukong, Korea SD 5000 40
A001061/27E 03-01 MTU

26 Engine Oils
6.1.2 Single-grade Oils - Category 1, SAE-grade 40 for Gas Engines

Available in:
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
Exxon Mobil Pegasus 705 40 X
Fuchs DEA Ectan LA 40 40
Fuchs Petrolub Fuchs Titan Ganymet LA 40
Shell Shell Mysella LA 40 40 X
SRS Schmierstoff Wintershall Mihagrun LA 40 X

Vertrieb GmbH
Total Fina Elf Nateria MH 40 40
6.1.3 Multi-grade Oils - Category 1, SAE-grades 10W-30 and 15W-40 for Diesel Engines
1)
These multi-grade oils can only be used if the crankcase ventilation is led to atmosphere.
Available in:
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
Addinol Lube Oil Addinol Super Star MX1547- 15W-40 X X
Amalie Oil Amalie XLO 15W-40 X X

Amalie XLO 10W-30 X X
Avia Avia HDC Extra UTM 15W-40 X
Bharat Petroleum MAK-MA 15W-40 X
BP Oil International BP Vanellus C5 Global 15W-40 X

BP Vanellus C3 Extra 15W-40 1)
Castrol, South Af- Castrol Myndio Plus 15W-40 X

rica
Conoco HD Fleet Hi TBN 15W-40

Hydroclear Power D Engine Oil 15W-40 1)
EKO, Greece Forza 15W-40
A001061/27E 03-01 MTU

Engine Oils 27
Available in:
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
Exxon Mobil Delvac 1300 Super 15W-40 Only Series 183, 396
1)
and
1)
Delvac HP 15W-40 X X X X X
1)
Delvac MX 15W-40 X X X X and oil change interval
of 500 operating hours
Exxon Mobil Asia Essolube XT 331 15W-40 X
Pacific
Exxon Mobil Europe Essolube XT 301 15W-40 X

Exxmar CM 15W-40 X
Exxon Mobil Amer- Essolube XT 331 15W-40 X

cas
1820 Engine Oil 15W-40 X Only Series 183, 396
1)
and
1)
Idemitsu, Singapore Daphne Marine Oil MT 15W-40 X
Koramo, Czech Mogul Diesel DT 15W-40

Republic
Lukoil, Russia Lukoil Super API CF-4/SG 15W-40

1)
Oelwerke Julius Veritas Super HDC-N 15W-40
Schindler
1)
OPET Petrolclk Turbo Omega SHPD 15W-40
MV AG MV Truck M plus 15W-40 X

MV Extra BB 15W-40 X
Petro, Canada Duron 15W-40
Petrogal, Portugal Galp MDM1 15W-40 X
Raloy Raloy Multigrado Diesel 15W-40
Shell International Rimula X 15W-40 X X X X X X
SRS Schmierstoff Wintershall Rekord 15/40 15W-40 X X X

Vertrieb GmbH Wintershall Multi Rekord 15W-40 X X X
Singapore Petro- SPC SDM 801 15W-40

leum Comp.
Suomen Petrooli Teboil Super Power 15W-40 X
Unil Opal Intercooler 400 15W-40
Yukong, Korea SD 5000 15W-40
A001061/27E 03-01 MTU

28 Engine Oils
6.1.4 Single-grade Oils - Category 2, SAE-grades 30 and 40 for Diesel Engines

Available in:
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
Abu Dhabi National Adnoc Extra Super Engine 40 X X X

Oil Co., UAE Oil
Adnoc Extra Super Plus En- 40 X X X
gine Oil
Agip Sigma GDF 40 X
Bharat Petroleum MAK-MB SHPD 40 X
BP Marine Energol HPDX 40 X X X Up to 1500 hrs permit-

ted for SKS application
Castrol Castrol Marine HLX 30, 40 X X
Cepsa Lubricants Cepsa Special SHPD 40 X

Ertoil Koral HDL 30, 40 X X
ChevronTexaco Texaco Ursa Super TD 30, 40 X

Texaco Ursa Premium TDX 40 X
Texaco Delo 400 30, 40 X X X X X X
Caltex Delo SHP 30, 40 X X X
DEA Mineraloel AG DEA Cronos Super 30, 40
Engen, South Africa Dieselube 630 30 X
Exxon Mobil Europe Exxmar CM Super 40 X
Exxon Mobil Mobil Delvac HP Monograde 30, 40 X X X X X X

Mobil Marine 40 X X
Hyrax Oil Hyrax TOP DEO 40 X
Kuweit Petroleum Q8T700 20W30 X
Motor Oil, Hellas EMO SHPD Plus 30, 40 X
Panolin AG Panolin Extra Diesel 40 X
Pennzoil Products Supreme Duty 30, 40

Supreme Duty Fleet Motor
Oil 30
Longlife EF Heavy Duty En-
gine Oil 30, 40
Petrol Ofisi Turbosarj Ekstra SAE 40-E 40
PTT Public Comp. PTT Navita MTU Type 2 40
Shell Shell Sirius X Oil 30, 40 X X X X X X
A001061/27E 03-01 MTU

Engine Oils 29
Available in:
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
Singapore Petro- SDM 900 30, 40

leum Comp.
Statoil Diesel Way 30, 40
Total Fina Elf Antar Grapholia MS 30

Antar Traxolia Z 30, 40
Elf Performance Super D 30, 40 X X X X X X
Elf Disola MT 30, 40 X X X X X X
Fina Caprano TD 30, 40 X
Total Rubia TIR XLD 40 X X X X X X
Elf DPM-MT 30 X Increased corrosion
protection
YPF, Argentina Diesel Movil AT 30, 40

Diesel YPF AT 30, 40
A001061/27E 03-01 MTU

30 Engine Oils
6.1.5 Multi-grade Oils - Category 2, SAE-grades 5W-40, 10W-40, 15W-40 and 20W-40 for Diesel Engines
Available in:
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
Addinol Lube Oil Addinol Diesel Power 15W-40 X X

MD1547
Addinol Diesel Longlife MD 15W-40 X X Not Series 4000
1546
Addinol Diesel Longlife MD 15W-40 X X
1547
Agip Petroli Agip Blitum T 15W-40 X

Agip Sigma Turbo 15W-40 X X X X
Agip Sigma Super TFE 10W-40 X
Amalie Oil Amalie Super XLO 15W-40
Aral Lubricants Aral Multigrade SHPD 15W-40 X X X

Mega Turboral 10W-40 X X X
BP Oil International BP Vanellus C6 Global 15W-40 X X X X

BP Vanellus C6 Global Plus 10W-40 X X
Castrol, Interna- Castrol RX Super Plus 15W-40 X X X X

tional Castrol Tection T 15W-40 X
Castrol, South Af- Castrol Syndio Plus 15W-40 X

rica
Cepsa Lubricants Cepsa Special SHPD 15W-40
ChevronTexaco ChevronTexaco Delo 400 15W-40 X X X X X X

Ursa Super TD 15W-40 X
Caltex Delo SHP Multigrade 15W-40 X X X
Caltex Delo 400 Multigrade 15W-40 X X X
Chinese Petroleum CPC Superfleet D5 Synthetikoil 15W-40

Corp.
Cyclon Hellas Cyclon D Super 15W-40

15W-40
Cyclon D1 SHPD
DEA Mineraloel AG DEA Cronos Synth 5W-40
Exxon Mobil Mobilgard 1 SHC 20W-40 X X X X X X Up to 1500 hrs permit-

ed for SKS application
Mobil Delvac FL 10W-40 X
Exxon Mobil Europe Engine Oil 5920 15W-40

Essolube XTS 4 10W-40
Exxon Mobil Ameri- Essolube VM 15W-40 X

cas
Fuchs Titan Unic Plus MC 10W-40 X X X X X X
A001061/27E 03-01 MTU

Engine Oils 31
Available in:
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
Fuchs DEA DEA Cronos Premium FX 10W-40 X X X X X X
Ginouves York 745 15W-40 X
Indian Oil Corp. Servo Premium (N) 15W-40 X
Koramo, Czech Mogul Diesel DTT 15W-40

Republic
Krafft S.A. Krafft SHPDO 15W-40 X
Kuweit Petroleum Q8T720 X
Motor Oil, Hellas EMO SHPD Plus 15W-40 X

Motul Tekma Mega 15W-40
Panolin AG Panolin Universal SFE 10W-40 X
Pennzoil Products Supreme Duty Fleet Motor 15W-40

Oil
Longlife EF Heavy Duty Mul- 15W-40
tigrade Engine Oil
Pertamina Meditran SMX 15W-40 X
Petro, Canada Duron XL 15W-40 X X
Repsol-YPF Lubri- Turbogrado 15W-40 X

cants
SRS Schmierstoff Wintershall Turbo Diesel 15W-40 X X X

Vertrieb GmbH Wintershall Turbo Rekord 15W-40 X X X
Shell International Shell Rimula Super (Code: 15W-40 X X X X X X

Petroleum Comp. ALX 5403)
Shell DEO Super 15W-40 X X
Rimula X CH-4 15W-40 X X X X X X
Speedmaster Speedmaster Touring HD 15W-40 X
Suomen Petrooli Teboil Super HPD 15W-40 X
Total Fina Elf Elf Performance 3D 15W-40 X X X X X X

Elf Performance Super 15W-40 X X X X X X
Elf Performance Trophy DX 15W-40 X X X X X X
Statoil Turbosynt 15W-40
Valvoline Comp. Premium Blue 2000E 15W-40 X X X X X X
Veba Oel Veba Virada ECO Truck 10W-40 X
A001061/27E 03-01 MTU

32 Engine Oils
6.1.6 Multi-grade Oils - Category 3, SAE-grades 5W-30, 5W-40 and 10W-40 for Diesel Engines
Available in:
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
Addinol Lube Oil Addinol Super Truck MD 0538 5W-30 X X

Addinol Super Truck MD 1048 10W-40 X X
Aral Lubricants Super Turboral 5W-30 X X X
Avia Turbosynth HT-E 10W-40
BP Oil International Vanellus E7 Plus 10W-40 X

Vanellus E7 Ultra 5W-30 X
Vanellus E7 Supreme 5W-40 X
Vanellus C8 Ultima 5W-30 X
BP Vanellus E 4 Plus 10W-40 X
BP Vanellus D1 5W-40
Bucher Motorex MC Power 3 10W-40
Castrol International Castrol Dynamax 10W-40 X X X X

Castrol Enduron 10W-40 X
Castrol Enduron Plus 5W-40 X
Castrol Rivermax SRX 10W-40 X
Castrol Syntruck 5W-40 X X X
Elixion 5W-30 X
Cepsa Cepsa Eurotrans SHPD 5W-30 X

Cepsa Eurotrans SHPD 10W-40 X
ChevronTexaco Ursa Premium FE 5W-30 X

Ursa Super TDX 10W-40 X
Exxon Mobil Europe Essolube XTS 501 10W-40 X

Exxmar SCM 10W-40 X
Essolube XTS 5 10W-40 X X
Exxon Mobil Mobil Delvac XHP Extra 10W-40 X X

Mobil Delvac 1 SHC 5W-40 X X
Fuchs Petrolube AG Fuchs Titan Cargo SL 5W-30 X X X X X X
INA INA Super 2000 10W-40
Kompressol Kompressol-FX 10W-40
Meguin Megol Motorenl Super Lei- 10W-40 X

chtlauf DIMO
OMV OMV super truck 5W-30 X

OMV truck FE plus 10W-40 X X
Panolin Panolin Diesel HTE 10W-40 X
Petramina Meditran SX 15W-40 X
A001061/27E 03-01 MTU

Engine Oils 33
Available in:
Australia
America
Europe
NAFTA
Viscosity
Africa
Asia
class
Petrogal Galp Galaxia LDS Ultra 10W-40
Petro Oil Petro Oil Diesel XHPDO CF 10W-40
Raiffeisen Raiffeisen Power Truck 10W-40
S.A. Espanola Lu- Gulfleet Highway 10W-40

brificantes
SRS Schmierstoff Wintershall TFL 5W-30 X X X

Vertrieb GmbH Wintershall TFG 10W-40 X X X
Shell Shell Rimula Ultra 5W-30 X X X X X X

Shell Rimula Ultra 10W-40 X X X X X X
Total Fina Elf Fina Kappa Ultra 10W-40 X

Fina Milkano SYN 10W-40 X
Elf Performance Experty FE 5W-30 X X X X X X
Elf Performance Experty 10W-40 X X X X X X
Antar Maxolia 10W-40 X
Total Rubia TIR 9200 FE 5W-30 X
Unil Opal LCM 800 10W-40
Valvoline Internatio- Valvoline Pro Fleet 5W-30 X

nal Valvoline Pro Fleet 10W-40
Veedol International Veedol Dynastar 10W-40

Veedol Dynastar FS 5W-40
A001061/27E 03-01 MTU

34 Lubricating Greases
6.2 Lubricating Greases for General Applications

See Section 2.2 for details and special features
Manufacturer Brand name Remarks
Aral Lubricants Mehrzweckfett Arallub HL2
Avia Avialith 2
BP Oil International Energrease LS2

Mehrzweckfett L2
Caltex Services, UK Marfak All Purpose 2
Castrol Spheerol AP2
ChevronTexaco Multifak EP2
DEA Mineraloel AG Glissando 20
Exxon Mobil Beacon 2

Mobilux 2
Mobilgrease HP 222
SRS Schmierstoff Vertrieb GmbH Wintershall Wiolub LFK 2
Shell Shell Retinax EP2
Total Fina Elf Fina Marson L2

Multis EP 2
Veedol International Multipurpose
A001061/27E 03-01 MTU

Coolant Additives 35
6.3 Coolant Additives

See Section 3 for details and special features
6.3.1 Emulsifiable Corrosion Preventive Oils
Deutsche Shell Shell Oil 9156 Not Series 183, 396,

4000 with plate-core
heat exchangers
Not for TE-cooling sys-
tems
6.3.2 Antifreezes with Corrosion Inhibiting Properties-Concentrates

1)
Service life: 5 years or 9000 operating hours
Manufacturer / Supplier Brand name Remarks

1)
Aral Lubricants Aral Antifreeze Extra
Aral Antifreeze T Not Series 4000
BASF Glysantin G03 = BASF Khlerschutz G03 Not Series 4000

1)
Glysantin G05 = Glysantin Antikorrosion
1)
Glysantin G48 = Glysantin Protect Plus
Glysantin G30 = Glysantin Alu Protect
BP International BP Antifrost X 2270 A
Bremin Minerall Glyco Star nitritfrei

1)
Castrol International Antifreeze NF
Clariant Genatin super
Detroit Diesel Powercool Antifreeze
Exxon Mobil Frostschutz 600

Mobil plus Khlerlangzeitschutz plus
Fuchs DEA Ecufreeze Longlife Typ H2/NF

1)
Fuchs Europe Fricofin
1)
Ginouves York 716
Ineos C 2270/1
C 2272
Krafft Refrigerante ACU 2300

1)
Maziva INA Antifriz Al Super
Old World Fleetcharge Coolant Antifreeze

1)
OMV Khlerfrostschutz
1)
Coolant plus
Panolin Switzerland Anti-Frost MT-325
A001061/27E 03-01 MTU

36 Coolant Additives
Recochem R542
1)
Shell Glyco Shell
Glyco Shell SF
1)
Total Fina Elf Glacelf MDX
1)
Valvoline Zerex G-05
1)
Zerex G-48
Zerex G-30
6.3.3 Antifreezes with Corrosion Inhibiting Properties - Ready Mix

1)
Service life: 5 years or 9000 operating hours

1)
ARAL Easyfreeze Extra (50%)
1)
BASF Khlstoff G05-24/50 (50%)
1)
Sotragal - Mont Blanc L.R.-30 Power Cooling (44%)
1)
L.R.-38 Power Cooling (52%)
1)
Total Fina Elf Coolelf MDX (40%)
6.3.4 Antifreezes / Corrosion Inhibitors - Concentrates - for Series 2000 C&I and 4000 C&I Engines without
Aluminum Components
Arteco Havoline Extended Coolant Life (XLC) Only for Series 2000
C&I
Caltex Caltex Extended Life Coolant (XLC) Only for Series 2000
C&I
ChevronTexaco DEX-COOL Extended Life Anti- Only Series 2000 C&I

freeze/Coolant
CCI L 415
Detroit Diesel Powercool Plus
INTAC C 521
Old World Final Charge Antifreeze/Coolant
Recochem Turbo Power R 824M Engine Coolant
Total Fina Elf Glacelf Supra
6.3.5 Antifreezes / Corrosion Inhibitors - Ready Mix - for Series 2000 C&I and 4000 C&I Engines without
Aluminum Components
A001061/27E 03-01 MTU

Coolant Additives 37
Arteco Havoline Extended Life Prediluted 50/50 Only for Series 2000
Antifreeze Coolant (50%) C&I
Caltex Caltex Extended Life Coolant Pre-Mixed Only for Series 2000
50/50 (50%) C&I
ChevronTexaco DEX-COOL Extended Life Prediluted 50/50 Only for Series 2000
Antifreeze Coolant (50%) C&I
Ondeo Nalco Nalcool 4100 (50%)
Total Fina Elf Coolelf Supra (40%)
6.3.6 Water-soluble Corrosion Inhibitors - Concentrates

BASF Glysacorr G93-94
Ginouves York 719
Valvoline ZEREX G-93
6.3.7 Water-soluble Corrosion Inhibitors - Concentrates - for Aluminum-free Series 2000 C&I and 4000 C&I
Engines
Arteco Havoline Extended Life Corrosion Inhibitor Only for Series 2000
Nitrite Free C&I
Heavy Duty Extended Life Corrosion Inhibi-
tor Nitrite Free
Caltex XL Corrosion Inhibitor Concentrate Only for Series 2000

C&I
Detroit Diesel Powercool 2000
Fleetguard DCA-4L
Ondeo Nalco Alfloc 2000

Nalco 2000
Nalcool 2000
Alfloc 3477
Penray Pencool 2000
6.3.8 Water-soluble Corrosion Inhibitors - Ready Mix - for Aluminum-free Series 2000 C&I and 4000 C&I
Engines
Ondeo Nalco Alfloc 3443 (7%)
Caltex Caltex XL Corrosion Inhibitor (10%) Only for Series 2000

C&I
A001061/27E 03-01 MTU

38 Preservation
6.4 Preservation
See Section 5 for details and special features
6.4.1 Initial Operation- and Corrosion Inhibitor Oils for Internal Preservation
Aral Lubricants Degol LS 30
BP Oil Motorenschutzl MEK
Cepsa Lubricants Cepsa Rodaje Y Proteccion SAE 30 Full-load engine oil as

per oil Category 1
Exxon Mobil Europe MZK Motorenl LD30 Full-load engine oil as

per oil Category 1
SRS Schmierstoff Vertrieb GmbH Wintershall Antikorrol M SAE 30 Full-load engine oil as
per oil Category 1
Shell Shell Oil S 7294 SAE 30
Total Fina Elf Elf DPM-MT SAE 30 Full-load engine oil as

per oil Category 2
6.4.2 Corrosion Inhibitors for External Preservation

Castrol Rustilo 181
Exxon Mobil Europe Rust BAN 397
Valvoline Oel Tectyl 846
6.4.3 Corrosion Preventive Oils for Internal Preservation of the Fuel System
Exxon Mobil Europe Prfl 4113
SRS Schmierstoff Vertrieb GmbH Wintershall Calibration Fluid
Deutsche Shell V - Oel 1404
A001061/27E 03-01 MTU

Preservation Specifications 39
7 Preservation
7.1 Warnings
Please note the following warnings in bold type:
CAUTION!
Work which has to be carried out exactly in order to avoid danger to persons.
ATTENTION!
Work which has to be carried out exactly in order to avoid damage or destruction of material.
NOTE:
If a certain feature has to be noted when carrying out work.
7.2 Preface
Machined and unprotected surfaces, such as those in the cylinder liners, are subject to corrosion and have to be
preserved during long out-of-service periods. The applicable engine documentation must also be considered to-
gether with this Preservation Specification. The gearbox manufacturer's preservation specification must be referred
to when complete drive systems are taken out of service.
This specification describes the following types of preservation (according to the length of the out-of-service period,
see Section 7.2.1):
Out-of-Service
(For 1 to 3 months)
Preservation
(Out-of-service from 3 to max. 36 months)
Special packing
(Out-of-service for more than 36 months)
and following storage conditions:
Normal ambient conditions (no frost, clean surroundings, relative humidity below 50%).
Difficult ambient conditions (high humidity, salty air, strongly varying temperatures, dust, etc.).
Unsuitable ambient conditions (Outside storage, in moist rooms, etc.). In such cases it is impossible to store
engines without special packing.
NOTE:
Warranty claims are invalid if the storage is not according to specifications.
Do not use natural rubber sealing material, as it is not proof against ageing.
Only MTU-approved fluids and lubricants are to be used for preservation and re-preservation. (See Section 6,
"Approved Fluids and Lubricants").
Engines that are to be shutdown for more than one month are to be preserved immediately after operation.
Refer to the engine documentation for tasks and checks to be carried out when shutting down an engine and before
re-operating an engine.
Engines also have to be preserved if they are shutdown for a planned major overhaul and the period between shut-
down and overhaul is over one month.
New engines or basic-overhauled engines are to be preserved immediately after test-stand operation. Preservation
is not necessary only if the engine is to be put into service (but only under normal ambient operating conditions)
within one month after test-stand operation.
A001061/27E 03-01 MTU

40 Preservation Specifications
7.2.1 Overview of Types of Preservation
Shutdown period Tasks
Shutdown See Section 7.4
From 1 to 3 months
Shutdown Preservation
From 3 to 36 months See Section 7.5
Re-preservation
Every 12 months under normal ambient conditions
Every 6 months under difficult ambient conditions
See Section 7.5.4
Shutdown Special packing
More than 36 months or See Section 7.6

earlier if required
Checking the humidity indicators
Check every 3 to 4 months
See Section 7.6.4.3
A001061/27E 03-01 MTU

7.3 Short-time Shutdown

Short-time shutdown of the engine means a period of maximum one month in installed condition. Close the emer-
gency air shut-off flaps if they are provided. No further special preservation measures are otherwise necessary.
7.4 Shutdown
Shutdown of the engine means for a period of 1 to 3 months.
Task description
Run engine up to operating temperature, then run up to rated speed for about 30 seconds and then shutdown at
rated speed. The engine is not to be started again. This procedure must also be carried out before removing the
engine for a shutdown period.
The following openings are to be securely sealed on engines in installed condition.

- Cooling-air inlet
- Combustion-air inlet (Close the emergency air shut-off flaps if they are provided).
- Exhaust outlet
- Crankcase breather, if possible (when venting to atmosphere).
The following system inlets and outlets/connections are always to be securely sealed off on removed engines.
- Coolant
- Fuel
- Engine oil
- Hydraulic oil
- Electrical plug connectors
7.4.1 Putting Shutdown Engines into Operation
Task description
Remove all sealing covers fitted under Section 7.4. The engine can then be put into operation according to the
engine documentation.
A001061/27E 03-01 MTU

7.5 Preservation
General
Preservation must be carried out on engines to be shutdown for a period of more than three months and a maxi-
mum of 36 months.
New or MTU basic-overhauled engine are always preserved as standard procedure.
For shutdown periods of over one month, we recommend that, for your own protection, you confirm the preservation
work as contained in the checklist, see Section 7.7.1.
For engines stored with the manufacturer's warranty, the Monitoring Sheet is to be filled out and returned to MTU in
good time before the engine is returned to service, see Section 7.7.2.
NOTE:
If there is insufficient space to access the engine for all preservation work (e.g. charge-air pipe inaccessible) then
the engine must be removed and mounted on an engine base or test stand to complete the work.
7.5.1 Preservation of Cooling-, Lubrication and Fuel Systems
Task description
- Clean engine if necessary.
- Fill cooling system with coolant consisting of 2 % emulsifiable corrosion-inhibitor oil and water, see Section 6.3.
- Fill up with corrosion-inhibitor oil at least to the "Min." mark, see Section 6.4.
-
-
- Prepare preservation fuel from a mixture of 90 % fuel and 10 % preservation oil (corrosion-inhibitor oil for inter-
nal preservation) or 100% corrosion-inhibitor oil for internal preservation of the fuel system, see Section 6.4.
- Run engine for about 10 minutes at high idle with preservation fuel. The coolant temperature must reach at
least operating temperature.
- Shutdown engine.
If there is danger of frost, fill up with antifreeze (40%)! (Only for installed engines)
A001061/27E 03-01 MTU

7.5.2 Preservation of the Combustion Chamber
Task description
- Clear access to the charge-air pipe. This may require removal of the flame-start canisters, sensors, covers or
pipes. The access to the charge-air pipe must be ensured after the intercooler, after pressure fine filter/air filter
and after turbocharger.
- Bar the warm engine with the starting equipment.
ATTENTION!
It must be ensured when barring the engine that the engine cannot start. With mechanical governors, the shutdown
lever must be at the STOP position during barring. With electronic governors, switch off the power supply and bar
the engine either with the emergency start or another suitable method.
- While the engine is being barred, use a fine-atomizing spray gun to spray preservation oil into the charge-air
manifold openings for about 15 seconds.
- Re-seal the openings to the charge-air manifolds.
NOTE:
Refer to the engine documentation.
7.5.3 External Preservation
Seal off all openings against humidity:

- Cooling-air inlet
- Combustion-air inlet
- Exhaust outlet
The following supply and return systems and openings are always to be securely sealed off on removed engines.
- Coolant
- Fuel
- Engine oil
- Hydraulic oil
- Electrical connections
- Crankcase vent (with venting to atmosphere).
1. Coat or spray bright parts with corrosion-inhibitor oil Corrosion-inhibitor oil for external preservation,
see Section 6.4).
2. Fill out the Check Sheet after conclusion of the preservation work, see Section 7.7.1.Place the
Check Sheet in a plastic holder and attach to engine at a visible location.
A001061/27E 03-01 MTU

7.5.4 Re-preservation
Task description
- Remove sealed covers from combustion-air inlet and exhaust outlet.
- Preserve combustion space, see Section 7.5.2.
- Re-seal the inlet and outlet against humidity.
- Make a visual check of the engine for corrosion. If necessary, clean the affected places and recoat with cor-
rosion-inhibiting oil.
7.5.5 De-preservation
Task description
- Clean engine if necessary.
- Remove all sealing covers as fitted under Section 7.5.3.
- Drain off remaining corrosion-preventive oil.
- Renew oil filter inserts.
- Renew fuel-filter inserts.
- Fill up with engine oil.
- Bar engine manually.
- Prepare engine for operation.
- Renew coolant
NOTE:
Put engine into operation according to the engine documentation.
A001061/27E 03-01 MTU

7.6 Special Packing

Special packing must be carried out, immediately following preservation if possible, of engines either to be shut-
down for more than 36 months, or before sea-, polar and tropical transport, see Section 7.5. For shorter periods, it
is usually an advantage to protect the engine against corrosion with special packing.
7.6.1 General Information on Special Packing
Engines / Power plants must be specially packed for transportation by sea or to polar/tropical regions and before
long-term storage. This requires that the engine is preserved according to Section 7.5 (completely drain off coolant
and preservation oil) and enclosed in special packing.
The following types of special packing are available:

- Envelopes of bonded-layer material (e.g. aluminum bonded-layers).
- Hygroscopic (water-absorbing) materials (e.g. silica gel).
The engine is sealed into a semi- (water vapor) permeable foil and the air then drawn off with a vacuum cleaner.
The climatic packing of bonded-layer material hinders the formation of condensed water on the metal surface and
resulting corrosion.
7.6.2 Maintenance Intervals
Every 3 to-4 months

- Check humidity indicators (see Section 7.6.4.3).
NOTE:
When storing the engine in special packing (with laminated-aluminum layers), it should be remembered that the
elastomers have a limited life. The calculation of the total service life of the elastomers begins with either the year of
manufacture or last engine overhaul (see nameplate). Based on current knowledge, elastomer components of
fluorocarbon rubber (e.g. O-rings) have a total service life of about 20 years, and those of the other rubber materials
(hoselines) a total service life of about 10 years.
Storage beyond 10 years (as of year of manufacture on nameplate) but before commissioning:
- Replace all rubber parts on engine (hoses, sleeves, etc.)
Storage beyond 20 years (as of year of manufacture on nameplate) but before commissioning:
- Replace all elastomers during a major overhaul of the engine.
NOTE:
A long storage period shortens the time limit for an engine's major overhaul (TBO) because of the limited total ser-
vice life of the elastomers. MTU recommends engine storage of not more than 10 years.
A001061/27E 03-01 MTU

7.6.3 Envelopes of Laminated Material
This material is made up of tightly bonded layers of aluminum composite, resistant water vapor and gas penetration,
in the form of an envelope.
The material used by MTU is composed of polyethylene - aluminum and polyester, with following properties:
- Temperature range for applications from +70C to -55C.
2
- Water vapor permeability (WVP): 0.1 g/m per day at 38 C and 80% relative humidity (compared with PVC soft
2
foil WVP 6 g/m per day)
7.6.4 Desiccant
Desiccant, mostly silica gel, is the name usually given to water-absorbing materials as used in the special packing.
The agent is in packs (units) of highly permeable (for water vapor) and strong material (e.g. Natron crpe paper)
and placed in the special transport packing.
Desiccant pack
Fig. 1
The following drying-agent packs are used for transport packing:

- MTU-No. 49542 desiccant 125 g = 4 units
- MTU No. 49545 desiccant 1000 g = 32 units
A001061/27E 03-01 MTU

7.6.4.1 Calculation of Required Desiccant
The amount of units placed in the special packing depends on the climatic conditions and type of storage at the
place of destination. The minimum amount of units to be used is calculated as follows:
Climatic zone Per laminated aluminum- Per kg auxiliary packing Desiccant units (DU)
2
foil surface in m (A) materials (APM)
A
Europe (excluding Rus-
sia) 6xA 17 x APM = DU per shipment pack-
age
B
USA
Canada 8xA 20 x APM = DU per shipment pack-
Mediterranean age
Near East
C
Russia
South and Middle Amer- 17 x A 20 x APM = DU per shipment pack-
ica age
Middle and Far East
Procedure
1. Measure surface A of the laminated aluminum foil for the packing.
2. Weigh the packing material (e.g. wood, corrugated cardboard, etc.) necessary to support and protect the
engine within the special packing envelope.
3. Determine which climatic zone(s) the protected engine will be transported and finally stored.
4. Calculate the Required Desiccant (DU).
NOTE:
If the laminated aluminum foil is replaced or repaired after being damaged, the following calculation for the required
desiccant (DU) must be carried out again, see Section 7.6.4.1.
7.6.4.2 Calculation Example for Desiccant Units
Determination of DU for the seaworthy transport of an engine to Singapore:

2
Laminated aluminum foil surface: m10
Packing material: 3 kg
Packing for climatic zone C:
2 2
17 DU/m laminated aluminum foil: x 10 m = 170
+ 20 DU/kg x 3 kg = 60
Total 230 DU
Result: Sufficient protection of the engine requires 230 drying agent units (DU).
A001061/27E 03-01 MTU

7.6.4.3 Humidity Indicator
Humidity indicators can be inserted into the foil envelope to show the saturation level of the desiccant. The indica-
tors signalize by changing color that the specified level of relative humidity has been exceeded. An increase of the
relative humidity because of leaks or damage means a risk of corrosion for the engine.
A viewing window with humidity indicator is screwed into the laminated aluminum foil at a point as far away as pos-
sible from the desiccant. It is thus possible to check the relative humidity inside the foil envelope and /or to verify
any changes.
The humidity must be checked regularly every 3 to 4 months.

30 Colored pink:
Relative humidity above 30 %.
40 Colored pink:
Relative humidity above 40 %
50 Colored pink:
Fig. 2

Reduce time between checks, i.e. check every 4 weeks.

The new desiccant must be distributed as evenly as possible in the upper section of the packing envelope (see
Section 7.6.7.2). For the number of desiccant units required for the special packing (see Section 7.6.4.1).

Check condition of packed engine, re-preserve engine (see section 7.5.4) and repack engine (see Section 7.6.6).
NOTE:
The humidity indicator regenerates itself; replacement is not necessary.
A001061/27E 03-01 MTU

7.6.5 Order Nos. for Packing Materials
Details required when ordering from MTU:

MTU No. 20447 Humidity indicator
MTU No. 20448 Viewing window
MTU No. 49542 Desiccant 125 g = 4 units
MTU No. 49576 Laminated aluminum foil 1.00 m wide
MTU No. 49578 PE (polyethylene) foam foil 1.25 m wide, 4 mm thick
7.6.6 Special Packing Procedure for Finished Products
7.6.6.1 Preparation for Special Packing
Preservation must be carried out, see Section 7.5, if the item to be packed is not a new or MTU-overhauled engine
already preserved by MTU. Coolant and preservation oil must be completely drained.
7.6.6.2 Transport Locking Device
Check whether a transportation locking-device is required (see engine documentation or consult MTU). Block
crankshaft and engine mounts as specified in the engine documentation.
7.6.6.3 Special Packing of an Engine

The laminated aluminum foil is to be clamped be-
tween two hard-rubber pads around the anchor
studs. Use a hole punch to cut out holes in the
pads for the studs.
Fig. 3
A001061/27E 03-01 MTU

Coat the intermediate pads liberally with non-

hardening sealant (Loctite 5910, MTU No.50570)
around the stud holes.
Fig. 4
After positioning the aluminum foil, coat liberally

around the stud holes with non-hardening sealant
(Loctite 5910, MTU No.50570).
Fig. 5
Position the second hard-rubber pads.
Fig. 6
A001061/27E 03-01 MTU

For additional protection of the laminated alumi-

num foil, position foam foil over the upper hard-
rubber pad. The complete system is compressed
and sealed after the engine mounts are installed
and secured.
Fig. 7
7.6.6.4 Installation of Humidity Indicator

The holes for the indicator and the viewing window
are to be cut into the laminated aluminum foil in a
clearly visible position and as far as possible from
the desiccant units. The viewing window must be
so positioned that the engine No. can be checked.
Fig. 8
Screw in the humidity indicator and the viewing

window.
Fig. 9
A001061/27E 03-01 MTU

7.6.6.5 Cushioning of Engine Edges and Corners

Engine edges and corners, which could damage
the laminated aluminum foil, must be cushioned
using foam foil or foam rubber.
Fig. 10
7.6.6.6 Location of Desiccant Units

Place the required number of desiccant units as
calculated using the formula, see Section 7.6.4.1.
The desiccant units must be arranged in the upper
third of the envelope and attached to the engine,
hanging free wherever possible. Ensure that the
desiccant units are so attached (with string, adhe-
sive tape or other suitable material) that no dam-
age can be caused to the desiccant units, the en-
gine or the laminated aluminum foil.
Fig. 11
NOTE:
The desiccant units must not be in direct contact with corrosion-sensitive engine components.
7.6.6.7 Laminated Aluminum Foil Sealing

Use a manual foil-welding unit to seal the lami-
nated-foil envelope, see Section 7.6.9).
Fig. 12
A001061/27E 03-01 MTU

Prior to finally sealing the envelope, use a vacuum

pump (e.g. vacuum cleaner) to extract the en-
trapped air.
Fig. 13
As a result of the resulting pressure drop, the

envelope must shrink into light contact with the
engine. Excessively heavy contact must be
avoided as friction damage could result during
transportation.
Fig. 14
NOTE:
Extraction of the entrapped air also reduces the humidity within the envelope thus creating a favorable initial humid-
ity status. Extraction of the air also verifies that the envelope is free from leaks. If the envelope is not correctly
sealed, it will re-expand within 30 minutes.
A leak can be found by pressurizing the envelope and repaired by welding.
7.6.7 Special Packing Checks
7.6.7.1 Humidity Check
The humidity within the envelope is to be regularly checked every 3 to 4 months, see Section 7.6.4.3). The results of
the check are to be entered on the Monitoring Sheet (see Section7.7.2). If the engine is covered by warranty, return
the Monitoring Sheet (see Section7.7.2) to MTU Friedrichshafen after initial operation of the engine.
ATTENTION!
When checking the special packing, ensure that the laminated aluminum foil is not damaged, exercise great care
when opening the transportation box (if provided).
The condition of the laminated aluminum foil is to be checked minutely at every customs, stock or storage check.
Corrosion protection is no longer guaranteed if the foil is damaged.
A001061/27E 03-01 MTU

7.6.7.2 Desiccant Replacement
Open the upper section of the envelope and remove the old desiccant. Replace with the same amount of new des-
iccant in the upper section of the envelope (see Section 7.6.6.6). Re-weld the envelope and extract air (see Section
7.6.6.7).
7.6.8 Repair of Special Packing
If the laminated aluminum foil is damaged, the damaged area can be cut out and a new section welded into posi-
tion. If a repair is necessary, the desiccant must be replaced (see Section 7.6.7.2 and the air extracted (see Section
7.6.6.7). Incorrect repairs with, e.g. adhesive tape, are not acceptable because the partial vacuum in the envelope
cannot be maintained. In order to ensure correct repair procedures, the specified packing materials (see Section
7.6.5) and the manual welding unit (see Section 7.6.9) have to be used.
7.6.9 Manual Welding Unit
A supplier of foil-welding units is, for example:
W. Kopp Verpackungsmaschinen
Stettener Strae 111-117
D-73732 Esslingen- Waeldenbronn
Designation: HSD 95 Cello manual sealing unit
Fig. 15
A001061/27E 03-01 MTU

7.7 Form Sheets

7.7.1 Preservation Check Sheet
Engine model: .............................. Engine No. .............................. Acceptance date: ..............................
Correct execution of the tasks described in the Preservation Specification is to be confirmed on this sheet by the
person carrying out the tasks.
Tasks Completed Date Name
Lubrication system
Preserved with preservation oil.

Brand of oil used:
....................................................................................................
Fuel system
Preserved with preservation fuel.

Preservation fuel used:
....................................................................................................
Fuel main and pre-filters, fuel pipework not drained.
Cooling system
Is preserved with specified coolant.
Coolant is not drained (except with special packing, engines removed from
vehicles and engines for shipping).
Non-painted parts
These are brush-coated with corrosion inhibitor. All engine openings are
sealed as specified. All parts to be kept free of paint such as flywheel, fly-
wheel ring gear and starter pinion as well as non-painted sections of the
control linkage and the (possibly) uncovered coupling flange for the three-
phase generator, are brush-coated with corrosion inhibitor.
Corrosion inhibitor used:
.....................................................................................................
Engine is preserved as specified
Re-preservation completed as specified
On completion of preservation, place the completed Check Sheet in a plastic envelope. Seal the envelope and tie it
to the engine at a clearly visible location. Keep this Check Sheet with the engine until de-preservation of the engine.
A001061/27E 03-01 MTU

A001061/27E 03-01 MTU

7.7.2 Monitoring Sheet for Engines in Special Packing
Engine model: .............................. Engine No.: .............................. Date of delivery: ..............................
The following checks are to be completed before, during and at the end of the engine storage period. Correct exe-
cution is to be confirmed with date and signature.
NOTE:
With new products, entry of the delivery date is mandatory.
No. Task Date Name
1 Visual check of special packing for damage

Relative humidity: .............................. %
2 Relative humidity: .............................. %
13 Humidity indicator check before opening the envelope

Relative humidity: .............................. %
14 De-preservation completed
15 Date of scheduled initial operation of engine
Repairs Tasks completed
To the laminated aluminum

foil or packing box
Important NOTE: Inform MTU during the warranty period:
- If two or all three humidity indicators are pink.

- If external corrosion on the engine or damage to rubber hose connections is found when the engine is de-
preserved.
Inform MTU in good time before initial operation of the engine.
A001061/27E 03-01 MTU

A001061/27E 03-01 MTU

7.7.3 Check Sheet for De-preservation of Engines in Special Packing
Check Sheet for Engine De-preservation

ATTENTION!
Before opening the envelope, read and follow this Check Sheet carefully, especially the instructions refer-
ring to any necessary reporting to MTU.
1. Read off the humidity status at the indicators 6. Record the date of de-preservation on the
and enter on the Monitoring Sheet. Monitoring Sheet.
Attention: 7. Remove the sealing covers from the engine

openings (turbocharger inlet, exhaust mani-
a. If all three indicators show blue, every- fold outlet, cooling system in- and outlets,
thing is in order. connecting flange for vent lines coolant distri-
bution pipes) only when necessary.
b. If the 30 % and 40 % fields are partly or
totally pink, check the envelope for dam- 8. Compliance with the initial-operation instruc-
age. Report damaged envelopes to MTU. tions in the engine documentation is manda-
tory.
c. If all three fields are pink, do NOT open
the envelope, report to MTU.
2. If the humidity readings are in order and there

is no visual damage, remove the laminated
aluminum foil from the engine.
3. Check the exposed engine externally for cor-

rosion or damage. Enter date and findings on
the Monitoring Sheet.
4. Inspect visually all rubber-hose connections,

they must not be brittle or swollen.
5. Report any faults to MTU immediately and

await their reply. Do not prepare the engine
for installation or make changes. Store the
engine in a dry and covered location.
A001061/27E 03-01 MTU

A001061/27E 03-01 MTU

Flushing and Cleaning Specifications for Engine Coolant Systems 61
8 Flushing and Cleaning Specifications for Engine Coolant Systems
8.1 General Information

These cleaning instructions are for cooling systems in MTU diesel engines.
Sludge deposits from ageing coolant additive can eventually accumulate in the cooling systems. Results can be
reduced cooling capacity, clogged vent lines and drain cocks plus dirty coolant-level sight glasses.
Below standard water quality or incorrect coolant preparation can also heavily contaminate the system.
If such conditions occur, the coolant system is to be flushed out with fresh water, repeatedly if necessary.
If these flushing measures are not enough or the system too heavily contaminated, the system and affected parts
have to be cleaned.
Flushing is to be carried out using only clean fresh water (no river or seawater).
Only the MTU-approved or corresponding products at the specified concentrations are to be used for cleaning pur-
poses. The specified cleaning procedure is to be complied with.
Immediately after flushing or cleaning, fill the cooling systems with engine coolant as specified in the current MTU
Fluids and Lubricants Specification A001061, see Section 6.3.
Fluids and lubricants (e.g. prepared coolant), used flushing water, cleaning agents and cleaning solutions can be
hazardous. Certain regulations must be obeyed when handling, storing and disposing of these substances.
These regulations are contained in the manufacturers' instructions, legal requirements and technical guidelines
valid in the individual countries. Great differences can apply from country to country and a generally valid guide to
applicable regulations for fluids and lubricants is therefore not possible within this publication.
Users of the products named in these specifications are therefore obliged to inform themselves of the locally valid
regulations. MTU accepts no responsibility whatsoever for improper or illegal use of the fluids and lubricants / clean-
ing agents approved by them.
Scrap oil heat-exchangers from engines with bearing or piston seizures / frictional damage!
8.1.1 Test Equipment, Auxiliary Materials and Fluids and Lubricants

MTU test kit or electric pH-value measuring instrument
- Fresh water
- Prepared engine coolant
- Superheated steam
- Compressed air
A001061/27E 03-01 MTU

8.2 Approved Cleaning Products

Manufacturer Brand name Concentration for use Order No.
For coolant systems:
4)
Henkel P3-Neutrasel 5262 2% by volume Liquid
4)
Henkel P3-Saxin 2 % by weight Powder
Novamax Grisiron 5716 2 % by weight Powder 4)
Nalco Maxi Clean 2 2% by volume Liquid 40495

For sub-assemblies:
1) 4)
Henkel P3-FD 3 to 5 % by Powder
weight
2) 4)
Henkel Porodox 5 to 10 % by Powder
weight
Kluthe Hakutex 60 100 % by volume Liquid 50602
3) 4)
Novamax Euron 1308 5 to 10 % by Powder
weight
1) 3)
For greasy lime deposits For heavy lime deposits
2) 4)
Preferred for heavy lime deposits Not stocked by MTU
8.3 Flushing Engine Coolant Systems

Drain engine coolant.
Measure pH-value of the fresh water (MTU Test Kit or electric pH-value measuring device).
Fill coolant system with fresh water.

- Never pour cold water into a hot engine!
Preheat, start and run engine until warm.
Run engine for approx. 30 minutes at increased speed.
Take flush-water sample (engine-coolant-sample extraction cock).
Shut down engine and drain flush water.
Measure pH-value of the flush water (MTU Test Kit or electric pH-value measuring device).
If pH-value after flushing is only slightly above pH-value of fresh water (< 1):
Fill system with treated coolant and start engine.
If pH-value after flushing is significantly above pH-value of fresh water (> 1):
Fill system with fresh flush water and repeat flushing process.
If pH-value after 4 to 5 flushing sequences is still significantly above pH-value of fresh water (> 1):
Clean coolant system and, if necessary, the components also.
For further information, see Operating Instructions of respective engine.
A001061/27E 03-01 MTU

Flushing and Cleaning Specifications for Engine Coolant Systems 63
8.4 Cleaning Engine Coolant Systems

Prepare concentrated solution of detergent (for coolant systems) in warm fresh water.
In the case of powdered products, stir until the detergent is completely dissolved and without sediment.
Pour solution together with fresh water into coolant system.
Start engine and run until warm.
Run engine for approx. 2 hours at increased speed.
Shut down engine.
Drain detergent and flush engine coolant system.
Take flush-water sample (engine-coolant-sample extraction cock).
Measure pH-value of the flush water (MTU Test Kit or electric pH-value measuring device).
If pH-value after flushing is only slightly above pH-value of fresh water (< 1):
Fill system with treated coolant and start engine.
If pH-value after flushing is significantly above pH-value of fresh water (> 1):
Clean components.
For further information, see Operating Instructions of respective engine.
8.5 Cleaning Components

Remove, disassemble and clean components that are exposed to heavy sludge deposits, e.g. expansion tanks,
preheating units, heat exchangers (coolant cooler, oil heat-exchanger, intercooler, charge-air pre-heater, fuel pre-
heater, etc.) and lower sections of pipework.
Before cleaning, examine degree of contamination on water-sides.
If greasy lime deposits are found, first degrease the water-side.
Stubborn deposits caused by oil mist in intercoolers can be removed with Kluthe Hakutex 60.
Remove hard lime deposits with a decalcifying product.

In the event of stubborn lime deposits, a 10% inhibited hydrochloric solution may have to be used.
Dissolve deposits on and in heat-exchange elements in a heated cleaning bath.
Use only approved detergents in the permissible application concentration.
When preparing cleaning bath, refer to manufacturer's instructions!
- Deposits on the oil side can also be dissolved in a kerosene bath.
- The period spent in the cleaning bath depends on the type and degree of contamination, as well as the tem-
perature and activity of the bath.
Clean individual components such as housings, covers, pipes, sight-glasses, heat-exchanger elements and similar,
with superheated steam, a nylon brush (soft) and a powerful water jet.
In order to avoid damage:

- Do not use hard or sharp-edged tools; wire brushes, scrapers and similar ( oxide protective layer)
- Do not set the pressure of the water jet too high (may damage cooler fins, for example).
After cleaning, blow out the heat-exchanger elements with low-pressure steam in the opposite direction to the op-
erational flow direction, rinse with clear water (until pH-value is <1) then blow dry with compressed air or hot air.
Check that all components are in perfect condition, repair or replace as necessary.
Flush oil and coolant sides of heat-exchanger elements with corrosion-inhibitor oil.
A001061/27E 03-01 MTU

- This step may be omitted if the heat exchanger is installed and taken into service immediately after cleaning.
After re-installing all components, flush engine-coolant system once.
Check coolant system for leaks during initial operation of engine.

For further information, see the Maintenance Manual of respective engine.
A001061/27E 03-01 MTU

FEATURES/BENEFITS
DODGE PARA-FLEX COUPLINGS

Finished Bore
Flange Design
Extra bore capacity
Accommodates larger shaft diameters
Allows for smaller coupling selection
Two setscrews at 65
Precision alignment flats
Ductile iron flange for clearance or
interference fits
TAPER-LOCK Flange Design

Reversible flanges for H or F style mounting
on sizes PX50-PX120
Uses standard TAPER-LOCK bushings for
wide range of bores
Torque Transmitted Through Five-Year Limited Warranty

Composite Element System Dependable product performance
Reinforced with torque-carrying 40+ years application experience
tension cords Warranty includes sizes PX40
Natural rubber or Neoprene thru PX200
Split end reinforcement
Split element for easy installation No Lubrication
Dampens torsional vibration
Less maintenance
Visual Inspection
Saves time
PT1--14
FEATURES/BENEFITS
FEWER LOOSE PARTS FOR EASY ASSEMBLY

DODGE DODGE
PARA-FLEX PARA-FLEX
Standard Spacer
Couplings Couplings
Install factory- Install shaft hubs

assembled flanges (finished bore or
(finished bore or TAPER-LOCK hubs).
TAPER-LOCK
flanges).
Twist in element. Drop in factory-

assembled spacer
center.
Tighten clamp Tighten shaft hub

ring bolts by bolts to recom-
alternating every mended torque.
other bolt.
Repeat sequence
until tightened to
recommended
torque.
Accommodates Misalignment
Takes 4 angular misalignment Takes 1/8 parallel misalignment Takes end-float of 1/4 to 5/16 Dampens vibration
PT1--15
SPECIFICATION/HOW TO
ORDER/NOMENCLATURE
PARA-FLEX
SPECIFICATION
PARA-FLEX Couplings employ a molded, non-lubricated elastomeric flexing member
loaded in shear. The flexible member is compounded natural or neoprene rubber with
textile cord reinforcement throughout and has an extra layer of reinforcement adjacent
to the split for added durability. The compound of natural rubber element shall be suit-
able for operation in ambient temperature from -45F to +180F; Neoprene -40F to
+210F.
The flexible element is attached by clamping between axially separable rings with ex-
posed SAE grade 8 cap screws4. The couplings are designed to be capable of ac-
commodating combined misalignments 1 of 4 angular, 1/8 parallel, and 5/16 end float
at the full rating of the coupling without restricting the rating or life of the coupling.
The flexible element must be replaceable without disturbing the coupled equipment
and without the requirement for realignment.
The coupling assemblies have optional methods of attachment to the shaft including
but not limited to: clearance fit, interference fit or TAPER-LOCK bushings. Clearance
fits and interference fits are supplied with an industry standard keyway and two set
screws, one over the key and one at 65.
Spacer Couplings consist of two hubs and a pre-assembled center assembly. The
center assembly is readily removable to facilitate maintenance on pumps or other con-
nected equipment and must be replaceable without disturbing the coupled equipment
and without realignment.
1PX40: 4_ angular, 1/16 parallel, 3/16 end float.
2PX110: 4_ angular, 1/8 parallel, 1/4 end float.
3PH & PF: 1 angular, 1/16 parallel, 3/16 end float.
4.FBX style couplings utilize class 10.9 metric cap screws.
HOW TO ORDER
Standard couplings consist of: Spacer Couplings consist of:
(2) Flange Assemblies (2) Hubs
(1) Flexible Element (1) Center Assembly
NOMENCLATURE
PX 40 FBX
PARA-FLEX
X=Standard
S=Spacer
H=High Speed
F=Flywheel
Size (PX, PS only) ex.: Approx. 4 O.D.
FBX=Straight Bore, Extra Capacity

FBS=Straight Bore, Short Series
TL=TAPER-LOCK R
BBS=Bored-To-Size, Steel
TBS=One Taper Bored, One Bored-To-Size, Steel
BBPS=BBS, Piloted for Floating Shaft
TBPS=TBS, Piloted for Floating Shaft
PT1--16
EASY SELECTION
PARA-FLEX
DODGE PRESELECTED PARA-FLEX COUPLINGS
FOR ELECTRIC MOTORS @ 1800 RPM
PARA-FLEX PARA-FLEX PARA-FLEX SPACER PARA-FLEX SPACER
MOTOR
TAPER-LOCK STRAIGHT BORE TAPER-LOCK STRAIGHT BORE
SERVICE FACTOR SERVICE FACTOR SERVICE FACTOR SERVICE FACTOR
SHAFT
H.P. FRAME LIGHT MEDIUM HEAVY LIGHT MEDIUM HEAVY LIGHT MEDIUM HEAVY LIGHT MEDIUM HEAVY
DIA.
1.0 1.5 2.0 1.0 1.5 2.0 1.0 1.5 2.0 1.0 1.5 2.0
1 143T 0.875 PX40 PX40 PX40 PX40 PX40 PX40 PS40 PS40 PS40 PS40 PS40 PS40
1.5 145T 0.875 PX40 PX40 PX40 PX40 PX40 PX40 PS40 PS40 PS40 PS40 PS40 PS40
7.5 213T 1.375 PX60 PX60 PX60 PX40 PX50 PX50 PS60 PS60 PS60 PS40 PS40 PS50
326T 1.875 PX80 PX80 PX80 PX60 PX60 PX70 PS70 PS70 PS70 PS60 PS60 PS70
30
286TS 1.625 PX70 PX70 PX70 PX60 PX60 PX70 PS60 PS60 PS60 PS60 PS60 PS70
40
50
60
75
100
125
444/5T 3.375 PX140 PX140 PX140 PX100 PX120 PX120 PS140 PS140 PS140 PS100 PS120 PS120
150
444/5TS 2.375 PX100 PX120 PX120 PX100 PX120 PX120 PS100 PS120 PS120 PS100 PS120 PS120
444T 3.375 PX140 * * PX110 PX120 PX140 PS140 PS140 PS140 PS110 PS120 *
200
444TS 2.375 PX110 PX120 PX140 PX110 PX120 PX140 PS110 PS120 PS140 PS110 PS120 *
* Consult catalog for other coupling types at these speeds
FEATURES/BENEFITS SPECIFICATION/HOW TO ORDER MODIFICATIONS/ACCESSORIES ENGINEERING/TECHNICAL

PAGE PT1--14 PAGE PT1--16 PAGE PT1--64 PAGE PT1--66
PT1--17
SELECTION/DIMENSIONS
Standard, Straight Bore
B B
A
A
D D
C D
D D D
E
C
A
E
E
TYPE 1 TYPE 2 TYPE 3
FBX
Coupling Min. Max. Torque Max. Dwg. Weight (1) Inertia (2)
Size Bore Bore HP/100 (In-Lbs) RPM Type A B C D E (Lbs.) (Lb-Ft 2)
PX40FBX 1/2 1-7/16 .68 429 4500 1 4.25 3.50 2.88 1.15 .76 4.10 .05
PX50FBX 5/8 1-7/8 1.43 900 4500 1 5.25 4.44 3.14 1.51 .96 7.70 .10
PX60FBX 7/8 2-3/16 2.86 1800 4000 1 6.50 5.59 4.08 1.84 1.28 13.50 .26
PX70FBX 7/8 2-3/8 3.49 2200 3600 1 7.38 6.13 4.63 2.00 1.50 19.90 .54
PX80FBX 1-7/16 2-7/8 5.72 3605 3100 1 8.38 6.69 5.39 2.30 1.50 30.00 1.06
PX90FBX 1-7/16 3-3/8 7.15 4502 2800 1 9.25 7.69 6.09 2.70 1.53 42.40 1.96
PX100FBX 1-7/16 3-3/8D 8.58 5402 2600 2 10.00 7.13 5.15 2.70 1.71 50.10 2.71
PX110FBX 1-1/2 3-3/4 G 12.30 7750 2300 2 11.00 7.14 5.56 2.79 1.56 56.00 3.10
PX120FBX 1-1/2 3-3/4 20.00 12605 2100 2 12.38 7.75 5.84 3.00 1.75 80.20 5.81
D Shallow keyway on bores of 3-1/4, 3-3/8 . Key provided.

G Shallow keyway on bores of 3-5/8, 3-3/4 . Key provided.
FBS
Coupling Min. Max. Torque Max. Dwg. Weight (1) Inertia (2)
Size Bore Bore HP/100 (In-Lbs) RPM Type A B D E (Lbs.) (Lb-Ft 2)
PX50FBS 5/8 1-3/8 1.43 900 4500 3 5.25 2.75 .88 .53 4.10 .05
PX60FBS 7/8 1-13/16 2.86 1800 4000 3 6.50 3.36 1.00 .71 8.20 .16
PX70FBS 7/8 2-3/16 3.49 2200 3600 3 7.38 3.57 1.00 .95 11.80 .32
PX80FBS 1-7/16 2-11/16 5.72 3605 3100 3 8.38 3.75 1.25 .95 16.60 .60
PX90FBS 1-7/16 2-7/8 7.15 4502 2800 3 9.25 4.03 1.75 .33 22.60 1.00
(1) Weight of complete coupling at maximum bore.

(2) Inertia of complete coupling at maximum bore.
FEATURES/BENEFITS EASY SELECTION MODIFICATIONS/ACCESSORIES ENGINEERING/TECHNICAL

PT1--18
Standard, Straight Bore -- Part Numbers (1)
FBX FLANGE ASSEMBLIES
Bore Coupling Size/Part Number
(i )
(in.) PX40FBX PX50FBX PX60FBX PX70FBX PX80FBX PX90FBX PX100FBX PX110FBX PX120FBX
Reborable 000478 000480 000481 000482 000483 000484 000485 000486 000487
Finished
Bore
Flanges
5/8 000822 000575
3/4 000823 000576
7/8 000824 000577 000590 000606
15/16 000825 000578 003251 003283
1 000826 000579 000591 000607
1-1/16 000827 000580 003252 003284
1-1/8 000828 000581 000592 000608
1-3/16 000829 000582 003253 003285
1-1/4 000830 000583 000593 000609
1-5/16 000831 000584 003254 003286
1-3/8 000832 000585 000594 000610
1-7/16 000833 000586 000595 003287 000619 000632 000649
1-1/2 000587 000596 000611 000620 000633 000650 000666 000685
1-9/16 000597 003288 003323 003356 003402 003450 003501
1-5/8 000588 000598 000612 000621 000634 000651 000667 000686
1-11/16 000599 003289 003324 003357 003403 003451 003502
1-3/4 000589 000600 000613 000622 000635 000652 000668 000687
1-7/8 000573 000601 000614 000623 000636 000653 000669 000688
1-15/16 000602 003291 003326 003359 003405 003453 003504
2 000603 000615 000624 000637 000654 000670 000689
2-1/8 000604 000616 000625 000638 000655 000671 000690
2-3/16 000605 003293 003328 003361 003407 003455 003506
2-1/4 000617 000626 000639 000656 000672 000691
2-3/8 000618 000627 000640 000657 000673 000692
2-1/2 000628 000641 000658 000674 000693
2-5/8 000629 000642 000659 000675 000694
2-3/4 000630 000643 000660 000676 000695
2-7/8 000631 000644 000661 000677 000696
3 000645 000662 000678 000697
3-1/8 000646 000663 000679 000698
3-1/4 000647 000664 000680 000699
3-3/8 000648 000665 000681 000700
3-1/2 000682 000701
3-5/8 000683 000702
3-3/4 000684 000703
FBS FLANGE ASSEMBLIES
Bore Coupling Size/Part Number

(in.) PX50FBS PX60FBS PX70FBS PX80FBS PX90FBS
Reborable 009199 009214 009215 009223 009230
(1) Standard natural rubber element Part Numbers on Page PT1--21

Stocked flange assemblies
Complete coupling consists of (2) FBX or FBS flange assemblies, and (1) element.

PT1--19
Standard, TAPER-LOCK
B B
A A
D D D D
E E
PX40 STANDARD COUPLING PX40 STANDARD COUPLING

TYPE H TAPER-LOCK TYPE F TAPER-LOCK
K B K
B J J
A D D
D D TYPE H-H TYPE F-F
E
A
TYPE H TYPE F
E 1-9/32
TYPE HF
TYPE HF PX280 & 320 ONLY
PX-50-120 PARA-FLEX TAPER-LOCK COUPLINGS PX-140-320 PARA--FLEX TAPER-LOCK COUPLINGS
Coupling Max. Torque Max. Weight Inertia

Size Bore HP/100 (In-Lbs) RPM A B D E J (1) K (2) (Lbs.) (3) (Lb-Ft 2) (4)
PX40TL 1 .68 429 4500 4.25 3.00 0.88 0.77 0.63 0.75 4.20 0.05
PX50TL 1-1/8 1.43 900 4500 5.25 2.75 0.88 0.53 0.63 0.75 4.70 0.07
PX60TL 1-7/16 2.86 1800 4000 6.50 3.34 1.00 0.72 0.81 1.06 9.20 0.21
PX70TL 1-11/16 3.49 2200 3600 7.38 3.56 1.00 0.95 0.81 1.06 13.00 0.30
PX80TL 2-1/8 5.72 3605 3100 8.38 3.75 1.25 0.77 0.94 1.38 19.60 0.73
PX90TL 2-11/16 7.15 4502 2800 9.25 4.03 1.75 0.33 1.00 1.63 28.80 1.30
PX100TL 2-11/16 8.58 5402 2600 10.00 4.22 1.75 0.52 1.00 1.63 38.00 2.20
PX110TL 2-11/16 12.30 7750 2300 11.00 4.53 1.75 0.47 1.00 1.63 52.10 3.70
PX120TL 3-1/4 20.00 12605 2100 12.38 5.03 2.00 0.44 1.19 2.06 74.40 6.60
PX140TL 3-15/16 44.00 27590 1840 14.13 7.81 3.50 0.81 1.31 2.69 156.00 18.70
PX160TL 4-7/16 60.00 37800 1560 16.63 9.19 4.00 1.19 1.63 3.38 243.00 33.70
PX200TL 4-15/16 131.00 82500 1300 20.00 10.31 4.50 1.31 1.94 4.06 417.00 101.00
PX240TL 5 240.00 151200 1080 24.13 11.91 5.00 1.91 2.31 4.81 682.00 231.00
PX280TL 7 480.00 302200 910 28.50 15.97 6.00 2.22 1.63 4.38 1148.00 544.00
PX320TL 8 719.00 453000 810 32.50 16.31 6.50 2.06 1.63 4.38 1640.00 1077.00
Notes: (1) Space required to tighten bushing with shortened hex key.
(2) Space required to loosen bushing with shortened hex key.
(3) Weight of complete coupling with bushing.
(4) Inertia of complete coupling with bushing.

PT1--20
Standard, TAPER-LOCK Part Numbers
TAPER--LOCK FLANGE ASSEMBLIES STANDARD NATURAL
Flange Assembly TAPER-LOCK
RUBBER ELEMENTS [
Coupling Part No.
Size Bushing Flexible
Type H Type F Size Coupling
Size Element
PX40 000849 000848 1008 Part No.
PX50 010601 : 1108 PX40 011529
PX60 010602 : 1310
PX50 011105
PX70 010603 : 1610 PX60 011106
PX80 010604 : 2012 PX70 011107
PX90 010605 : 2517 PX80 011108
PX90 011109
PX100 010606 : 2517
PX110 010607 : 2517 PX100 011110
PX120 010608 : 3020 PX110 011111
PX120 011112
PX140 011134 011154 3535
PX160 011137 011157 4040 PX140 011114
PX200 011140 011160 4545 PX160 011117
PX240 011144 011164 5050 PX200 011120
PX280 011455 011456 7060 PX240 011124
PX320 011472 011471 8065 PX280 011457
PX320 011463
: PX50-PX120 have a reversible flange for type H or F mount
Complete coupling consists of (2) TAPER--LOCK Flange [ See page PT1--64 for optional elements
Assemblies, and (1) element.
METRIC PARA-FLEX
TAPER-LOCK FLANGE ASSEMBLIES
Flange Assembly Taper-Lock
Coupling
Co pling Part No.
Size Bushing
Type H Type F Size
PXM40 013095 013096 1008
PXM50 013040 013041 1210
PXM60 013043 013042 1610
PXM70 013044 J 1610
PXM80 013045 J 2012
PXM90 013046 J 2517
PXM100 013047 J 2517
PXM110 013048 J 2517
PXM120 013049 J 3020
J PXM70 - PXM120 have a reversible flange for type H or F
mount.
Note: For TAPER--LOCK designs, TAPER--LOCK

bushings must be ordered separately.

PT1--21
Spacer, Straight Bore
K K
A
D D E
D D
C
C
TYPE 1 TYPE 2 SPACER COUPLING

CENTER ASSEMBLY
SPACER SHAFT HUBS

Coupling Min. Max. Torque Max. Dwg. Weight Inertia
Size Bore Bore HP/100 (In-Lbs) RPM Type C D K (1) (Lbs.) (2) (Lb. Ft. 2)
PS40FBX 1/2 1-7/16 0.68 429 4500 1 2.88 1.13 1.75 1.30 0.01
PS50FBX 5/8 1-7/8 1.43 900 4500 1 3.81 1.41 2.25 3.20 0.05
PS60FBX 2 2-3/16 2.86 1800 4000 1 4.45 1.28 2.13 4.90 0.11
PS60FBS 7/8 1-15/16 2.86 1800 4000 1 4.45 1.22 2.50 4.00 0.08
PS70FBX 2 2-3/8 3.49 2200 3600 1 5.02 1.78 2.63 7.10 0.18
PS70FBS 7/8 1-7/8 3.49 2200 3600 2 5.02 1.22 1.25 2.90 0.06
PS80FBX 2-1/8 3-3/8 5.72 3605 3100 1 6.02 2.53 3.38 12.90 0.53
PS80FBS 1-7/16 2-1/8 5.72 3605 3100 2 6.02 1.50 1.50 5.30 0.16
PS90FBX 2-1/8 3-3/8 7.15 4502 2800 1 6.02 2.53 3.38 12.90 0.53
PS90FBS 1-7/16 2-1/8 7.15 4502 2800 2 6.02 1.50 1.50 5.30 0.16
PS100FBX 2-5/8 3-3/4 8.58 5402 2600 1 6.77 2.53 3.50 16.50 0.85
PS100FBS 1-7/16 2-1/2 8.58 5402 2600 2 6.77 1.88 1.50 7.30 0.26
PS110FBX 2-5/8 3-3/4 12.3 7750 2300 1 6.77 2.53 3.50 16.50 0.85
PS110FBS 1-7/16 2-1/2 12.3 7750 2300 2 6.77 1.88 1.50 7.30 0.26
PS120FBX 2-5/8 3-3/4 20.0 12605 2100 2 8.27 2.81 1.88 14.40 0.50
PS120FBS 1-1/2 2-1/2 20.0 12605 2100 2 8.27 1.88 1.88 14.60 0.51
SPACER CENTER ASSEMBLIES

Coupling E Weight Weight Inertia Inertia
Size A Min. Max. (Lbs.) (3) Adder (4) (Lb.Ft. 2) (5) Adder (6)
PS40 4.25 2.75 5.75 4.00 0.50 0.04 0.01
PS50 5.25 2.88 7.33 6.90 1.28 0.10 0.02
PS60 6.50 3.00 7.33 9.50 1.70 0.28 0.03
PS70 7.38 3.50 7.50 12.20 2.10 0.50 0.07
PS80 8.38 3.50 10.00 16.90 2.90 0.89 0.22
PS90 9.25 3.50 10.00 21.10 2.90 1.40 0.22
PS100 10.00 3.50 10.00 23.60 3.87 2.10 0.28
PS110 11.00 3.50 10.00 41.00 3.87 3.30 0.28
PS120 12.38 4.50 10.00 56.40 5.86 7.30 0.76
(1) Screw clearance required to remove center assembly. (4) Weight adder per inch length.
(2) Hub weight at maximum bore. (5) Center assembly inertia at minimum length.
(3) Center assembly weight at minimum length. (6) Inertia adder per inch length.

PT1--22
Spacer, Straight Bore Shaft Hub -- Part Numbers (1)
Coupling Size/Part Number
Bore PS40 PS50 PS60 PS70 PS80/90 PS100/110 PS120
(in.) FBX FBX FBS FBX FBS FBX FBS FBX FBS FBX FBS FBX
Reborable 000479 000490 000492 000491 000494 000493 000496 000495 000498 000497 000500 000499
5/8 000836 000704
3/4 000837 000705
7/8 000838 000706 000719 000739
15/16 000839 000707
1 000840 000708 000720 000740
1-1/16 000841 000709
1-1/8 000842 000710 000721 000741
1-3/16 000843 000711
1-1/4 000844 000712 000722 000742
1-5/16 000845 000713
1-3/8 000846 000714 000723 000743
1-7/16 000847 000715 000724 000759 000776
1-1/2 000716 000725 000744 000760 000777 000796
1-9/16 000726
1-5/8 000717 000727 000745 000761 000778 000797
1-11/16 000728
1-3/4 000718 000729 000746 000762 000779 000798
1-7/8 000574 000730 000747 000763 000780 000799
1-15/16 000731
2 000732 000735 000764 000781 000800
2-1/8 000733 000736 000765 000748 000782 000801
2-3/16 000734
2-1/4 000737 000749 000783 000802
2-3/8 000738 000750 000784 000803
2-1/2 000751 000785 000804
2-5/8 000752 000766 000786
2-3/4 000753 000767 000787
2-7/8 000754 000768 000788
3 000755 000769 000789
3-1/8 000756 000770 000790
3-1/4 000757 000771 000791
3-3/8 000758 000772 000792
3-1/2 000773 000793
3-5/8 000774 000794
3-3/4 000775 000795
Stocked shaft hubs
(1) See page PT1--25 for spacer center assembly part numbers.
Complete coupling consists of:
(2) Shaft Hubs, TAPER--LOCK or Straight Bore
(1) Spacer Center Assembly
NOTE: Standard Bore Tolerances: Straight bore couplings from PX40 -- PX120 are furnished with clearance fit.
PX140 -- PX320 are furnished with interference fit.

PT1--23
Spacer, TAPER-LOCK
K K
A
E
C D D
TYPE 2 TYPE 1
SPACER COUPLING
CENTER ASSEMBLY
TAPER--LOCK SPACER SHAFT HUBS

Coupling Max. Torque Max. Dwg. Weight Inertia
HP/100 C D K(1)
Size Bore (In-Lbs) RPM Type (Lbs) (2) (Lb.Ft. 2)
PS40TL 1 .68 429 4500 1 2.88 0.88 1.75 1.10 0.01
PS50TL 1-1/4 1.43 900 4500 2 3.81 1.00 1.00 1.80 0.02
PS60TL 1-11/16 2.86 1800 4000 2 4.44 1.00 1.00 2.40 0.03
PS70TL 2-1/8 3.49 2200 3600 2 5.00 1.25 1.00 4.00 0.07
PS80TL 2-11/16 5.72 3605 3100 2 6.00 1.75 1.25 7.70 0.22
PS90TL 2-11/16 7.15 4502 2800 2 6.00 1.75 1.25 7.70 0.22
PS100TL 2-11/16 8.58 5402 2600 2 6.75 1.75 1.25 9.00 0.28
PS110TL 2-11/16 12.30 7750 2300 2 6.75 1.75 1.25 9.00 0.28
PS120TL 3-1/4 20.00 12605 2100 2 8.25 2.00 1.50 16.60 0.76
PS140TL 3-15/16 44.00 27590 1840 1 7.69 3.50 4.50 37.00 2.20
PS160TL 4-7/16 60.00 37800 1560 1 8.63 4.00 5.00 55.00 3.90
PS200TL 4-15/16 131.00 82500 1300 1 10.00 4.50 5.50 87.40 8.00

Coupling E Weight Weight Inertia Inertia
A
Size Min. Max. (Lbs.) (3) Adder (4) (Lb. Ft. 2) (5) Adder (6)
PS40 4.25 2.75 5.75 4.00 .50 0.04 0.01
PS50 5.25 2.88 7.33 6.90 1.28 0.10 0.02
PS60 6.50 3.00 7.33 9.50 1.70 0.28 0.03
PS70 7.38 3.50 7.50 12.20 2.10 0.50 0.07
PS80 8.38 3.50 10.00 16.90 2.90 0.89 0.22
PS90 9.25 3.50 10.00 21.10 2.90 1.40 0.22
PS100 10.00 3.50 10.00 23.60 3.87 2.10 0.28
PS110 11.00 3.50 10.00 41.00 3.87 3.30 0.28
PS120 12.38 4.50 10.00 56.40 5.86 7.30 0.76
PS140 14.13 6.44 13.00 115.00 4.49 18.70 0.80
PS160 16.63 8.06 11.44 216.00 5.58 33.70 0.90
PS200 20.00 9.94 12.88 290.00 7.65 101.00 1.60
(1) Screw clearance required to remove center assembly. (4) Weight adder per inch length.
(2) Hub weight includes bushing at max. bore. (5) Center assembly inertia at minimum length.
(3) Center assembly weight at minimum length. (6) Inertia adder per inch length.

PT1--24
Spacer, TAPER-LOCK Shaft -- Hubs Part Numbers
Coupling Shaft TAPER-LOCK
Size Hub Bushing
Part No. Size
PS40 000850 1008
PS50 011620 1210
PS60 011621 1610
PS70 011622 2012
PS80 011623 2517
PS90 011623 2517
PS100 011624 2517
PS110 011624 2517
PS120 011625 3020
PS140 011626 3535
PS160 011627 4040
PS200 011628 4545

Coupling E-Shaft Spacing Part Numbers Semi-Finished
Size Center
3-1/2 4 5 6 7 10 Assembly
PS40 000854 000855 000857 000851
PS50 011565 011723 012767 010997
PS60 011567 011729 012765 012766 010998
PS70 011569 011743 011750 011758 011765 011012
PS80 011571 011778 011785 011793 011800 009435 011000
PS90 011564 011555 011816 011824 011831 000863 011001
PS100 011579 011700 011701 011702 000864 011002
PS110 011580 011893 011705 011706 011707 000865 011005
PS120 011937 011710 011711 012029 011006
PS140 010551 010993 011113
PS160 010582 011115
PS200 010675 011119
Stock center assemblies.
For complete listing of part numbers for all BSE lengths, see pages PT1--26-PT1--27.
Complete coupling consists of: (2) shaft hubs, TAPER-LOCK or straight
bore, and (1) Spacer center assy
NOTE: For TAPER-LOCK designs, TAPER-LOCK bushings must be ordered separately.

PT1--25
PARA-FLEX
SPACER CENTER ASSEMBLY PART NUMBERS
B.S.E. PS40 PS50 PS60 PS70 PS80 PS90 PS100 PS110 PS120 PS140 PS160 PS200
2-7/8 011121
3 011125
3-1/8 011132
3-1/4 011145
3-3/8 011152 010723
3-1/2 000854 011565 011567 011569 011571 011564 011579 011580
3-5/8 011720 011726 011740 011775
3-11/16 011890
3-3/4 011721 011727 011741 011776 011589 011891
3-7/8 011722 011728 011742 011777 011892
4 011723 011729 011743 011778 011555 011893
4-1/8 011724 011730 011744 011779 011810 011850 011894
4-1/4 011725 011731 011745 011780 011811 011851 011895
4-3/8 011582 011732 011746 011781 011812 011852 011896
4-1/2 011583 011584 011586 011587 011897 011581
4-5/8 011733 011747 011782 011813 011853 011898
4-3/4 011734 011748 011783 011814 011854 011899 011935
4-7/8 011749 011784 011815 011855 011900 011936
5 000857 012767 012765 011750 011785 011816 011700 011705 011937
5-1/8 011751 011786 011817 011856 011901 011938
5-1/4 011752 011787 011818 011857 011902 011939
5-5/16 011847
5-3/8 011753 011788 011819 011858 011903 011940
5-1/2 011754 011789 011820 011859 011904 011941
5-5/8 011755 011790 011821 011860 011905 011942
5-3/4 000858 000859 000861 011756 011791 011822 011861 011906 011943
5-7/8 011757 011792 011823 011862 011907 011944
6 011758 011793 011824 011701 011706 011710
6-1/16 010547
6-1/8 011602 011794 011825 011863 011908 011945
6-1/4 011759 011795 011826 011864 011909 011946
6-5/16 010548
6-3/8 011760 011796 011827 011865 011910 011947
6-7/16 010539
6-1/2 011761 011797 011828 011866 011911 011948
6-5/8 011762 011798 011829 011867 011912 011949
6-3/4 011763 011799 011830 011868 011913 011950 010549
6-7/8 011764 011604 011606 011869 011914 011951 010550
7 012766 011765 011800 011831 011702 011707 011711 010551
7-1/8 011766 011801 011832 011870 011915 011952 010552
7-1/4 011767 011802 011833 011871 011916 011953 010553
7-1/3 000860 000862 012289 012291 012290
7-3/8 011768 011803 011834 011872 011917 011954 010554
7-1/2 011603 011804 011835 011873 011918 011955 010555
7-5/8 011805 011836 011874 011919 011956 010556
7-3/4 011806 011837 011875 011920 011957 010975
7-7/8 011807 011838 011876 011921 011958 010976
Stock Center Assemblies

PT1--26
PARA-FLEX
SPACER CENTER ASSEMBLY PART NUMBERS
B.S.E. PS40 PS50 PS60 PS70 PS80 PS90 PS100 PS110 PS120 PS140 PS160 PS200
8 011605 011839 011703 011708 011712 010977
8-1/16 010595
8-1/8 009420 011840 011877 011922 011959 010978 010567
8-3/16 009419
8-1/4 009421 011841 011878 011923 011960 010979 010568
8-3/8 009422 011842 011879 011924 011961 010980 010569
8-1/2 009423 011607 011880 011925 011962 010981 010570
8-5/8 009424 011926 011963 010982 010571
8-3/4 009425 011927 011964 010983 010572
8-7/8 009426 011928 011965 010984 010573
9 009427 011709 011713 010985 010574
9-1/8 009428 011929 011966 010986 010575
9-3/16 011930 011967
9-1/4 009429 012023 010987 010576
9-3/8 009430 012024 010988 010577
9-1/2 009431 012025 010989 010578
9-5/8 009432 012026 010990 010579
9-3/4 009433 012027 010991 010580
9-7/8 009434 012028 010992 010581
9-15/16 010699
10 009435 000863 000864 000865 012029 010993 010582 010675
10-1/8 010994 010583 010676
10-1/4 010995 010584 010677
10-5/16 010996
10-3/8 009436 010585 010678
10-1/2 009437 010586 010679
10-5/8 009438 010587 010680
10-3/4 009439 010588 010681
10-7/8 009440 010589 010682
11 009441 010590 010683
11-1/8 009442 010591 010684
11-1/4 009443 010592 010685
11-3/8 009444 010593 010686
11-7/16 010594
11-1/2 009445 010687
11-5/8 009446 010688
11-3/4 009447 010689
11-7/8 009448 010690
12 009449 010691
12-1/8 009450 010692
12-1/4 009451 010693
12-3/8 009452 010694
12-1/2 009453 010695
12-5/8 009454 010696
12-3/4 009455 010697
12-7/8 009456 010698
13 009457
Semi Fin 000851 010997 010998 011012 011000 011001 011002 011005 011006 011113 011115 011119
Stock Center Assemblies

PT1--27
Bored to Size, Type BBS
B
D D
PX60 THRU PX320 TYPE BBS COUPLINGS

Coupling Min. Max. Torque Max. Weight (1) Inertia (2)
HP/100 A B C D E
Size Bore Bore (In-Lbs) RPM (Lbs.) (Lb-Ft 2 )
PX60BBS none 1-1/2 2.86 1,800 4000 6.50 4.28 2.38 1.50 1.28 8.8 .21
PX70BBS none 2-1/8 3.49 2,200 3600 7.38 5.00 2.94 1.75 1.50 12.8 .32
PX80BBS none 2-9/16 5.72 3,605 3100 8.38 5.50 3.69 2.00 1.50 18.4 .79
PX90BBS none 2-3/4 7.15 4,502 2800 9.25 6.03 4.13 2.25 1.53 25.6 1.4
PX100BBS none 3-1/4 8.58 5,402 2600 10.00 6.97 4.94 2.63 1.72 36.4 2.5
PX110BBS none 3-15/16 12.30 7,750 2300 11.00 7.56 5.44 3.00 1.56 47.3 4.2
PX120BBS none 4 20.00 12,605 2100 12.38 8.25 5.81 3.25 1.75 68.4 7.0
PX140BBS 2-1/4 4-1/2 44.00 27,590 1840 14.13 9.81 7.00 3.88 2.44 127.2 16.4
PX160BBS 2-1/2 6 60.00 37,800 1560 16.63 12.94 8.50 5.13 3.06 210.8 39.6
PX200BBS 2-7/8 6-3/4 131.00 82,500 1300 20.00 15.56 9.38 6.13 3.75 333.5 76.9
PX240BBS 4 7-1/2 240.00 151,200 1080 24.13 14.16 10.00 5.13 4.34 481.0 188.1
PX280BBS 4-7/16 9 480.00 302,200 910 28.50 18.47 12.00 7.13 4.66 802.0 440.8
PX320BBS 5-1/2 11 719.00 453,000 810 32.50 20.75 14.00 8.13 4.94 1074.0 709.6
(1) Weight of complete coupling at maximum bore.
(2) Inertia of complete coupling at maximum bore
PX60BBS - PX320BBS PART NUMBERS
Coupling BS Flange Assemblies Standard Element When bored to size, the PX60 through PX120 BBS sizes
Size Rough Bore (2 Reqd) (1 Reqd) are furnished with clearance fit, standard keyway and two-
PX60BBS 010300 011106 set screws. PX140 and larger sizes are furnished as inter-
PX70BBS 010301 011107 ference fit with standard keyway and no setscrew.
PX80BBS 010302 011108
PX90BBS 010303 011109
Complete coupling consists of: (2) BS Flange Assem-
PX100BBS 010304 011110 blies and (1) Standard Element.
PX110BBS 010305 011111
PX120BBS 010306 011112
PX140BBS 010530 011114
PX160BBS 010531 011117
PX200BBS 010532 011120
PX240BBS 010533 011124
PX280BBS 010528 011457
PX320BBS 010529 011463

PT1--28
Mill Motor, Type TBS*
F
L
B
For Mill Min. Max. Torque Max. Weight(1) Inertia(2)
Size HP/100 B F L
Motor Size Bore Bore (In-Lbs) RPM (Lbs.) (Lb-Ft 2 )
PX60TBS 602,802* none 1-1/2 2.86 1,800 4000 5.78 3.00 0.34 10.1 .21
603 6.75 3.50 0.50
PX70TBS none 2-1/8 3 49
3.49 2 200
2,200 3600 16 1
16.1 .32
32
802B,802C 6.25 3.00 0.56
603,803 7.00 3.50 0.50
PX80TBS none 2-9/16 5 72
5.72 3 605
3,605 3100 23 2
23.2 .79
79
604,804 7.00 3.50 0.50
PX90TBS 804 none 2-3/4 7.15 4,502 2800 7.28 3.50 0.53 29.9 1.4
PX100TBS 804 none 3-1/4 8.58 5,402 2600 7.84 3.50 0.72 44.4 2.5
606,806 8.56 4.00 0.59
PX110TBS none 3-15/16 12 30
12.30 7 750
7,750 2300 62 3
62.3 42
4.2
608 9.06 4.50 0.16
806 9.00 4.00 0.63
PX120TBS none 4 20 00
20.00 12 605
12,605 2100 81 4
81.4 70
7.0
608 9.50 4.50 0.50
808 10.63 4.69 1.19
PX140TBS 610-810 2-1/4
2 1/4 4-1/2
4 1/2 44.00 27,590 1840 10.63 4.69 1.06 136.2 16.4
612 11.06 5.13 0.94
810 12.50 4.69 1.69
PX160TBS 612-812 2-1/2
2 1/2 6 60.00 37,800 1560 12.94 5.13 1.56 227.8 39.6
614 12.94 5.13 1.44
812 14.63 5.19 2.19
614-814 14.63 5.19 2.06
PX200TBS 2-7/8 6-3/4 131 00
131.00 82 500
82,500 1300 344 5
344.5 76 9
76.9
616-816 15.13 5.69 1.94
618-818 15.56 6.13 2.38
818 15.22 6.19 2.97
PX240TBS 4 7-1/2 240 00
240.00 151 200
151,200 1080 519 188 1
188.1
620 15.91 6.88 2.53
622 18.78 7.44 2.22
PX280TBS 5-1/4 9 480 00
480.00 302 200
302,200 910 836 440 8
440.8
624 20.78 9.44 2.22
z Refer to page PT1--28 for additional envelope information. *1--1/4 per foot taper on diameter
PX60 - PX280 TBS PART NUMBERS
Coupling For Mill TS Flange Assy Std. Element BS Flange Assy Coupling TS Flange Assy
Size Motor Size (1) Reqd + (1) Reqd (1) Reqd Size Rough Bore
PX60TBS 602,802* 010471 011106 PX60TBS 010510
PX70TBS 603 010472 011107 PX70TBS 010511
802B,802C 010473 PX80TBS 010512
PX80TBS 603,803 010474 011108
PX90TBS 010513
604,804
PX90TBS 804 010475 011109 PX100TBS 010514
PX100TBS 804 010476 011110 PX110TBS 010515
PX110TBS 606,806 010477 011111 PX120TBS 010516
608 010478 PX140TBS 010524
PX120TBS 606,806 010479 011112 PX160TBS 010531
608,608 010480
PX200TBS 010532
PX140TBS 608,808 008980 011114 SEE PAGE
610,810 008981 PT1--28 PX240TBS 010525
612,812 008982 PX280TBS 010526
PX160TBS 610,810 008983 011117
612,812 008984
614 008985
PX200TBS 612,812 008986 011120
Complete coupling consists of: (1) TS Flange Assem-
614,814 008987 bly, (1) BS Flange Assembly, and (1) Standard Element.
616,816 008988
618,818 008989
PX240TBS 818 008990 011124 * Key furnished for shallow keyways.
620 008991
PX280TBS 622 008992 011457 + Part numbers are finished bore flanges to fit mill motor sizes
624 008993 listed.

PT1--29
Floating Shaft, Type BBPS
B B
E BS FLG
BCS U BPS FLG ASSY
BPS ASSY
FLG FLG
ASSY ASSY
FLOATING SHAFT
TYPE BBPS T A C
L K
C L K
FLOATING SHAFT DETAIL
D E D
D D FLOATING SHAFT
PX60 -120 BBPS TYPE BBPS PX140-320 BBPS
Min. Max. Torque Max Weight Inertia

Size HP/100 A B C D E K L T U
Bore Bore (In-Lbs) RPM (Lbs) (Lb-Ft 2 )
PX60BBPS none 1-1/2 2.86 1,800 4000 6.50 4.28 2.38 1.50 1.78 2.45 0.58 .624/.6225 1.28 9.8 0.21
PX70BBPS none 2-1/8 3.49 2,200 3600 7.38 5.00 2.94 1.75 2.06 3.05 0.48 .999/.9975 1.58 14.6 0.32
PX80BBPS none 2-9/16 5.72 3,605 3100 8.38 5.50 3.69 2.00 2.00 3.30 0.45 .999/.9975 1.58 26.9 0.79
PX90BBPS none 2-3/4 7.15 4,502 2800 9.25 6.03 4.13 2.25 2.09 3.67 0.39 1.249/1.2475 1.70 29.0 1.4
PX100BBPS none 3-1/4 5.85 5,402 2600 10.00 6.97 4.94 2.63 2.16 4.13 0.44 1.249/1.2475 1.72 40.1 2.5
PX110BBPS none 3-15/16 12.30 7,750 2300 11.00 7.56 5.44 3.00 2.06 4.44 0.38 1.249/1.2475 1.69 51.0 4.2
PX120BBPS none 4 20 12,605 2100 12.38 8.25 5.81 3.25 2.44 4.89 0.45 1.499/1.497 1.98 75.7 7.0
PX140BBPS 2-1/4 4-1/2 44 27,590 1840 14.13 9.19 7.00 3.88 2.44 5.69 0.44 1.499/1.497 2.00 140.2 16.4
PX160BBPS 2-1/2 6 60 37,800 1560 16.63 12.94 8.50 5.13 3.06 7.25 0.75 1.499/1.497 2.94 230.8 39.6
PX200BBPS 2-7/8 6-3/4 131 82,500 1300 20.00 15.56 9.38 6.13 3.69 8.78 0.84 1.999/1.997 2.84 364.5 76.9
PX240BBPS 4 7-1/2 240 151,200 1080 24.13 14.16 10.00 5.13 4.28 8.06 1.16 1.999/1.997 3.12 529.0 188.1
PX280BBPS 4-7/16 9 480 302,200 910 28.50 18.47 12.00 7.13 4.59 10.22 1.31 1.999/1.997 3.28 877.0 440.8
PX320BBPS 5-1/2 11 719 453,000 810 32.50 20.75 14.00 8.13 4.88 11.38 1.44 1.999/1.997 3.44 1181.0 709.6
PX60BBPS - PX320BBPS PART NUMBERS

Coupling BCS Flange Assy BPS Flange Assy Std Element Complete coupling consists of: (1) BCS or BS Flange
Size (1) Reqd (1) Reqd (1) Reqd Assembly (depending on size of coupling), (1) BPS
PX60BBPS 010658 010657 011106 Flange Assembly, and (1) Standard Element.
PX70BBPS 010660 010659 011107
PX80BBPS 010189 010190 011108 BCS Flange Assembly consists of:
PX90BBPS 010191 010192 011109
PX100BBPS 010193 010194 011110 1. External Clamp Ring
PX110BBPS 010599 010598 011111
PX120BBPS 010195 010196 011112 2. Internal Clamp Ring
Coupling BS Flange Assy BPS Flange Assy Std Element 3. BCS Flange
Size (1) Reqd (1) Reqd (1) Reqd
BPS Flange Assembly consists of:
PX140BBPS 010530 011714 011114
PX160BBPS 010531 011715 011117 1. External Clamp Ring
PX200BBPS 010532 011716 011120
2. Piloted Internal Clamp Ring
PX240BBPS 010533 011717 011124 a. Includes floating shaft bearing assembly
PX280BBPS 010528 011718 011457
PX320BBPS 010529 011719 011463 3. BS Flange

PT1--30
MODIFICATIONS/
ACCESSORIES
PARA-FLEX Elements -- Part Numbers
Element Standard Neoprene Cordless Weight High Speed/Flywheel Elements
Size P/N P/N P/N (Lbs) Standard Neoprene
Element Size Weight (lbs)
PX40 011529 012455 012456 0.3 Part No. Part No.
PX50 011105 011296 011285 0.7 PH87 011227 011266 1.20
PX60 011106 011297 011286 1.2 PH96 011228 011267 1.80
PX70 011107 011298 011287 1.6 PH116 011230 011268 2.00
PX80 011108 011299 011288 2.2 PH131 011231 011269 3.50
PX90 011109 011300 011289 2.6 PH172 011234 011270 7.50
PX100 011110 011301 011290 2.5 PH192 011236 011271 9.30
PX110 011111 011302 3.0 PH213 011239 011272 13.90
PX120 011112 011303 011292 4.8 PH252 011242 011273 27.00
PX140 011114 011304 5.6
PX160 011117 011305 9.1
PX200 011120 011306 20.8
PX240 011124 011312 27.0
PX280 011457 011313 45.0
PX320 011463 011315 80.0
(1) Neoprene element ratings are the same as the standard nat-
ural rubber element ratings. (Yellow Sticker)
(2) Cordless elements have an average static torsional stiffness
25% of the standard element and approximately 25% of the
torque rating.
D--FLEX Coupling Sleeves -- Part Numbers

Coupling EPDM Neoprene Hytrel
Size JE JES E JN JNS N H HS
3 S004208 S004242 S004209 S004243
4 S004210 S004244 S022190 S004211 S004245 S022211
5 S004212 S004246 S022191 S004213 S004247 S022212
6 S004214 S004248 S022192 S004215 S004249 S022213 S022183 S022232
7 S004216 S004250 S022193 S004217 S004251 S022214 S022184 S022233
8 S004218 S004252 S022194 S004219 S004253 S022215 S022185 S022234
9 S004220 S004254 S022195 S022216 S022186 S022235
10 S004222 S004256 S022196 S022217 S022187 S022236
11 S022197 S022218 S022188 S022237
12 S022198 S022219 S022189 S022238
13 S021990 S021993
14 S021991 S021994
16 S021992
D--FLEX COUPLINGS PARA--FLEX COUPLINGS GRID--LIGN COUPLINGS CHAIN COUPLINGS

PT1--64
MODIFICATIONS/
ACCESSORIES
GRID-LIGN Replacement Grids, Covers, And Seals -- Part Numbers
Coupling Grid T10 Cover T10 T20 Cover T20
Size Assembly Seal Kit Assembly Seal Kit
1020T 006275 006250 006805 006260 006815
1030T 006276 006251 006806 006261 006816
1040T 006277 006252 006807 006262 006817
1050T 006278 006253 006808 006263 006818
1060T 006279 006254 006809 006264 006819
1070T 006280 006255 006810 006265 006820
1080T 006281 006256 006811 006266 006821
1090T 006282 006257 006812 006267 006822
1100T 006283 006258 006813 006268 006823
1110T 006284 006259 006814 006269 006824
Chain Coupling: Chain Assemblies And Covers -- Part Numbers

Coupling Chain Chain Assembly Cover Cover Assembly
Size Assembly Weight (Lbs.) Assembly (1) Weight (Lbs.)
4012 100480 .4 099026 1.0
4016 100490 .6 099026 1.0
5012 100489 .9 N/A N/A
5016 100481 1.4 099027 1.3
5018 100491 1.4 099027 1.3
6018 100482 2.7 099028 2.6
6020 100492 2.7 099028 2.6
8018 100483 6.1 099029 5.1
8020 100493 6.1 099029 5.1
10020 100495 11.0 099024 12.2
12018 100497 20.0 N/A N/A
12020 100496 20.0 099025 19.5
(1) Cover assemblies consist of cover halves, screws, seals, and cover gaskets.
PARA-FLEX Nickel Plated Screws

Flange Screw Part Number per
Assembly Size Size (2) Number Flange (3)
PX70, PX80 5/16-18X1-1/2 411767 5, 6
PX90, PX100 3/8-16X1-3/4 411768 6
PX120 1/2-13X2 411770 6
PX140 1/2-13X2-1/4 411771 8
(2) Nickel plated Grade 8 hex head cap screws. Screws not available from stock for PX140 with iron flanges. For sizes not listed, con-
tact DODGE.
(3) 5 required for PX70; 6 for PX80.

PT1--65
ENGINEERING/
TECHNICAL
Elastomer Compatibility
Ratings: 1- Minor Effect 2-Moderate Effect 3-Severe Effect nd-No Data
Nat. Neo-
Neo Nat. Neo-
Neo
Substance Rubber prene EPDM Hytrel Substance Rubber prene EPDM Hytrel
Acetic Acids 2 1 1 1 Hydrobromic Acid (40%) 1 2 1 nd
Acetic Anhydride 2 1 2 nd Kerosene 3 2 3 nd
Alcohols, Monohydric 2 1 2 nd Lacquers 3 3 3 2
Ammonia Anhydrous 3 1 1 nd Lead Sufamate 2 1 1 nd
ASTM A Oils 3 1 1 1 Mineral Oil 3 2 2 1
Animal Fats 3 2 2 nd Naphtha 3 2 3 1
Benzene 3 3 3 2 Nickel Chloride 1 2 1 nd
Carbonic Acid 3 2 2 nd Nitric Acid (10%) 1 2 2 2
Calcium Bisulfite 2 1 3 nd Ozone 3 2 1 nd
Chloracetone 2 2 1 2 Petroleum (<250_F) 3 2 3 nd
Chloroacetic Acid 2 1 1 nd Potassium Dichromate 2 1 1 nd
Copper Sulphate 2 1 1 1 Salt Water 1 2 1 1
Corn Oil 2 2 2 nd Silicone Oils 1 1 1 1
Diesel Oil 3 2 3 1 Sulfuric Acid (Conc.) 3 3 3 3
Fuel Oil 3 2 3 1 Vinegar 2 1 1 nd
Gasoline 2 2 3 1 Zinc Sulfate 2 1 1 nd

PT1--66
ENGINEERING/
TECHNICAL
Selection Methods:
D-FLEX, PARA-FLEX, GRID-LIGN, GEAR, CHAIN COUPLINGS
POLY-DISC, & Rigid Couplings DESIGN HP METHOD:
HP/100 METHOD:
Step 1: Obtain required service factor from Service Fac-
Step 1: Obtain required service factor from Service Fac- tor Tables on pages PT1--68 and PT1--69.
tor Tables on pages PT1--68 and PT1--69.
Step 2: Determine the application HP per 100 RPM: Step 2: Determine application HP:
HP Design = HP x SF
HP100 RPM = Motor HP x 100 x Service Factor
Coupling RPM Step 3: From rating tables, select appropriate coupling
Step 3: From Rating Tables, find a rating equal to or RPM column and find a rating equal to or greater
greater than the HP/100 RPM. Note coupling than HP design. Note coupling size from left
size from lefthand column. hand column.
Step 4: Check maximum RPM capability. Step 4: Check maximum RPM capability.
Step 5: Check maximum bore capacity. If maximum bore
is exceeded, move to larger size with adequate
borebut be sure maximum RPM of coupling is
borebut be sure maximum RPM of coupling is
not exceeded.
not exceeded.
NOTE: If spring set motor brake is used, and brake HP
is greater than prime mover, use brake HP in
place of motor HP.
TORQUE METHOD:
Step 1: Obtain required service factor from Service Fac-
tor Tables on pages PT1--68 and PT1--69.
Step 2: Determine torque required for application.
Torque (in lbs.) = 63025 x HP x SF
Coupling RPM
Step 3: From Rating Tables, find a rating equal to or
greater than the torque. Note coupling size from
lefthand column.
Step 4: Check maximum RPM capability.
bore-but be sure maximum RPM of coupling is
not exceeded.
NOTE: If system peak torque is known and is non-re-
versing, start at Step 3. If system peak torque is
known and reversing, multiply by 2.0 and start at
Step 3.

PT1--67
ENGINEERING/
TECHNICAL
Service Factors
Table 1 FACTOR n FACTOR n
PARA- PARA
FLEX/ GRID FLEX/ GRID
APPLICATION POLY- CHAIN APPLICATION POLY- CHAIN
(READ FOOTNOTES) DISC RIGID D-FLEX GEAR (READ FOOTNOTES) DISC RIGID D-FLEX GEAR
AGITATORS GENERATORS
Paddle or Propeller (Vert. or Horiz.) 1.0 1.0 1.25 1.0 Even Load 1.0 1.0 1.25 1.0
Screw 1.0 1.0 1.25 1.0 Hoist or Railway Service 1.5 1.5 1.5 1.5
BLOWERS Welder Load 2.0 2.0 2.0 2.0
Centrifugal 1.0 1.0 1.25 1.0 GRIZZLY 2.0 2.0 2.0 2.0
Lobe 1.5 1.25 1.5 1.25 KILN 2.0 2.0 2.0 2.0
vane 1.0 1.25 1.25 1.25 LAUNDRY MACHINES
BREWING & DISTILLING Tumbler Washer 2.0 2.0 2.0 2.0
Bottling Machinery, Brew Kettle, LINE SHAFTS
Cooker (Continuous Duty), Mash Driving Processing Machinery 1.0 1.5 1.25 1.5
Tub 1.0 1.0 1.25 1.0 Light 1.0 1.5 1.25 1.5
Scale Hopper-Frequent Starting LUMBER INDUSTRY
Peaks 1.5 1.75 z 1.75
Band Resaw 1.5 1.5 1.5 1.5
CAN FILLING MACHINE 1.0 1.0 1.25 1.0
Circular Resaw 1.5 1.5 1.5 1.75
CAR DUMPER 1.5 2.5 2.0 2.5
Edger Head Rig, Hog, Log Haul 2.0 2.0 2.0 2.0
CAR PULLER 1.5 1.5 1.5 1.5
Planer 1.5 1.75 1.5 1.75
CLARIFIER 1.0 1.0 1.25 1.0
Rolls Non-Reversing 1.5 1.25 1.5 1.25
CLASSIFIER 1.0 1.0 1.25 1.0
Rolls Reversing 2.0 2.0 2.0 2.0
CLAY-WORKING MACHINES
Sawdust Conveyor 1.0 1.25 1.25 1.25
Brick Press, Briquette Mach., Clay
Working Mach., Pug Mill 1.5 1.5 1.5 1.75 Slab Conveyor 1.5 1.75 1.5 1.75
COMPRESSORS** Sorting Table 1.5 1.75 1.5 1.5
Centrifugal. Lobe, Screw 1.0 1.0 1.25 1.0 MACHINE TOOLS
Lobe, Rotary 2.0 1.25 2.0 1.25 Auxiliary 1.0 1.0 1.25 1.0
Reciprocating Main Drive 1.5 1.75 1.5 1.5
1 cylinder - single acting 3.5 3.0 z 3.0 Notching Press, Planer (Reversing),
Plate Planer, Punch Press 1.5 1.75 1.5 1.75
1 cylinder - double acting 3.0 3.0 z 3.0
Traverse 1.0 1.0 1.25 1.0
2 cylinder- single acting 3.0 3.0 z 3.0
METAL FORMING MACHINES
2 cylinder - double acting 2.5 3.0 z 3.0
Draw Bench, Carriage, Main Drive,
3 cl. or more - single acting 2.5 3.0 z 3.0 Extruder, 2.0 2.0 1.5 2.0
3 cl. or more - double acting 2.0 2.0 z 2.0 Wire Drawing, Flattening Machine 2.0 2.0 1.5 1.75
CONVEYORS MILLS Rotary Type
Apron, Assembly, Belt, Chain, Ball or Pebble direct or 2.5 2.0 2.0 2.0
Flight, Oven 1.0 1.0 1.25 1.0
on LS Shaft Gear Reducer 2.5 2.0 2.0 2.0
Reciprocating 2.5 3.0 z 3.0
on HS Shaft Gear Reducer 2.0 1.5 1.5 1.5
Screw 1.0 1.0 1.25 1.0
Dryer and Cooler 1.5 1.75 1.5 1.75
CRANES AND HOISTS
Rod or Tube direct or 2.5 2.0 2.0 2.0
Main Hoist-Medium Duty 1.5 1.75 1.5 1.75
on LS Shaft Gear Reducer 2.5 2.0 2.0 2.0
Main Hoist-Heavy Duty 2.0 2.0 2.0 2.0
on HS Shaft Gear Reducer 2.0 1.5 1.5 1.5
Skip Hoist, Travel Motion, Trolley
Motion, Slope 1.5 1.75 1..5 1.75 Tumbling Barrel 1.5 1.75 2.0 1.75
CRUSHERS MIXERS
Cane 2.0 2.0 2.0 2.0 Concrete (Continuous or
intermittent) 1.5 1.75 1.5 1.75
Gyratory 2.5 2.5 z 2.5
Muller-Simpson type 1.5 1.75 1.5 1.5
DREDGES
OIL INDUSTRY
Cable Reel, Screen Drive, Stacker 1.5 1.75 1.5 1.75
Chiller 1.0 1.25 1.25 1.25
Conveyor 1.5 1.75 1.5 1.25
Oil Well Pumping (Not over 150%
Cutter Head Drive, Jig Drive 2.5 2.0 2.0 2.0 peak torque 2.0 2.0 2.0 2.0
Pump, Utility Winch 1.5 1.75 1.5 1.5 Paraffin Filter Press 1.5 1.5 1.5 1.5
DYNAMOMETER 1.0 1.0 1.25 1.0 PAPER MILLS
ELEVATORS Agitator 1.0 2.0 1.25 2.0
Bucket, Freight 2.0 1.25 2.0 1.25 Barking Drum 2.5 2.5 2.0 2.5
EXCITER 1.0 1.0 1.25 1.0 Beater and Pulper 1.5 1.75 1.5 1.75
FANS Bleacher 1.0 1.0 1.25 1.0
Centrifugal 1.0 1.0 1.25 1.0 Calender 2.0 1.75 2.0 1.75
Cooling Tower 2.0 2.0 2.0 2.0 Chipper 3.0 2.5 2.0 2.5
Heavy Duty (Forced Draft) and In- Couch Cylinder Dryer 1.5 1.75 1.5 1.75
duced Draft 1.5 1.5 2.0 1.5
Felt Stretcher 1.0 1.25 1.25 1.25
Light 1.0 1.0 1.25 1.0
Fourdrinier 1.5 1.75 1.5 1.75
Propeller Indoor 1.5 1.5 2.0 1.5
Jordan 2.0 2.0 2.0 2.0
FOOD INDUSTRY
Press 2.0 1.75 1.5 1.75
Beet Slicer 1.5 1.75 1.5 1.75
Pulp Grinder 2.0 1.75 2.0 1.75
Cereal Cooker 1.0 1.25 1.25 1.25
Stock Chest 1.5 1.5 1.5 1.5
Dough Mixer, Meat Grinder 1.5 1.75 1.5 1.75
Stock Pump
Reciprocating 2.0 2.0 z 2.0
Rotary 1.5 1.5 1.5 1.5
Suction Roll 2.0 1.75 1.5 1.75
Winder 1.5 1.5 1.5 1.5

PT1--68
ENGINEERING/
TECHNICAL
Service Factor
Table 1 (cont.) FACTOR n FACTOR n
PARA- PARA
FLEX/ GRID FLEX/ GRID
APPLICATION POLY- CHAIN APPLICATION POLY- CHAIN
(READ FOOTNOTES) DISC RIGID D-FLEX GEAR (READ FOOTNOTES) DISC RIGID D-FLEX GEAR
PARAFFIN FILTER PRESS 1.5 1.5 1.5 1.5 SCREENS
PRINTING PRESS 1.5 1.5 1.5 1.5 Air Washing 1.0 1.0 1.25 1.0
PROPELLER Marine 1.5 1.5 z 1.5 Coal and Sand Rotary 1.5 1.5 1.5 1.5
PULLERS Vibrating 2.5 2.5 2.0 2.5
Barge Hall 2.5 2.0 2.0 1.5 Water 1.0 1.0 1.25 1.0
PULVERIZERS SEWAGE DISPOSAL EQUIPMENT 1.0 1.0 1.25 1.0
Hammermill-Light Duty 1.5 1.5 1.5 1.5 SHOVEL 2.0 2.0 2.0 2.0
Hammermill-Heavy Duty 2.0 1.75 2.0 1.75 SHREDDER 1.5 1.5 1.5 1.5
Hog 2.0 1.75 2.0 1.75 STEEL INDUSTRY
Roller 1.5 1.5 1.5 1.5 Cold Mills
PUMPS Coiler up or down 1.5 2.0 z 1.5
For Stock Pumps See Paper Mills Strip, Temper 2.0 2.0 z 2.0
Centrifugal 1.0 1.0 1.25 1.0 Hot Mills
Descaling Gear Type 1.5 1.25 1.5 1.25 Coiler up or down,
Oil Well Pumping (Not over 150% Edger Drive 1.5 2.0 z 1.5
peak torque 2.0 2.0 2.0 2.0 Feed Roll Blooming 3.0 2.5 z 3.0
Rotary -other than ear 1.5 1.25 1.5 1.25 Roughing Mill Delivery 3.0 2.5 z 2.5
Reciprocating Non-reversing, Sheet Strip 3.0 2.5 z 2.5
1 cylinder-single acting 2.5 3.0 z 3.0 Rod Mill 2.5 2.5 z 2.0
1 cylinder-double acting 2.0 3.0 z 3.0 Soaking Pit Cover Drive Lift 3.0 1.5 z 1.0
2 cylinder-single acting 2.0 2.0 z 2.0 Soaking Pit Cover Drive Travel 3.0 1.5 z 2.0
2 cylinder-double acting 1.5 1.75 z 1.75 STEERING GEAR 1.0 1.0 1.25 1.0
3 cylinder or more 1.5 1.5 z 1.5 STOKER 1.0 1.25 1.0
RUBBER INDUSTRY TEXTILE MILLS
Banbury Mixer 2.5 2.5 2.0 2.5 Batcher 1.0 1.25 1.25 1.25
Calender 2.0 2.0 2.0 2.0 Calender, Card Machine, D Can 1.5 1.5 1.5 1.5
Cracker Mixing Mill Plasticator 2.5 2.5 2.0 2.5 Dyeing Machine 1.0 1.25 1.25 1.25
Refiner, Sheeter, Tire-Building Loom 1.5 1.5 1.5 1.5
Machine 2.0 2.5 2.0 2.5 Mangel, Napper, Soaper 1.0 1.25 1.25 1.25
Tire and Tube Press Opener Based Spinner, Tenter Frame 1.5 1.5 1.5 1.5
on Peak Torque 1.0 1.0 1.25 1.0
WINDLASS 1.5 1.5 1.5 1.5
Tuber and Strainer 1.5 1.75 1.5 1.75
WOODWORKING MACHINES 1.0 1.0 1.25 1.0
Warming Mill 2.0 2.0 2.0 2.0
Washer 2.5 2.5 2.0 2.5
SYSTEM SERVICE FACTOR CALCULATION
To determine the system service factor, the driver service factor drives or where the power source is an internal combustion
adder (Table 1A) must be added to the driven service factor. engine with less than four cylindersConsult DODGE. Where
(Table 1) Example: Determine the system service factor for a torsional vibrations occur as in, for example, internal combus-
PARA-FLEX coupling used to couple a barking drum and a six- tion engine or reciprocating compressor or pump applications,
cylinder diesel engine. check the coupling stiffness for the possible development of
Driven S.F. + Driver S.F. Adder = System S.F. damaging large-amplitude vibrations. A complete system tor-
2.5 +.5 = 3.0 sional analysis may be necessary.
n The service factors listed are intended only as a general guide. ** Add 0.5 to factor if without flywheel.
Where substantial shock occurs or starting and stopping is
frequent as on some inching drives and on some reversing z CONSULT DODGE FOR SELECTION ASSISTANCE.
Table 1A-Driver Service Factor Adders
Electric High Reciprocating Engine Number of Cylinders
Type of
Motor Torque Turbines
Coupling 12 or More 8 to 11 6 to 7 4 to 5 Less than 4
Std. Torque Motors
PARA-FLEX 0.0 0.0 0.0 0.0 0.5 0.5 0.5 z
METALLIC 0.0 0.0 0.0 0.0 0.5 0.5 1.0 z
IF SF< 1.25 IF SF<1.5 IF SF< 1.25ADD 0.25 z
D-FLEX 0.0 ADD 0.25 SUBTRACT 0.25
IF SF> 1.25 IF SF> 1.5 IF SF> 1.25 ADD 0.5 z
ADD 0.5 SUBTRACT 0.5

PT1--69
ENGINEERING/
TECHNICAL
Rating Tables
PARA-FLEX SELECTION/RATINGS DATA
Max. Bore
Coupling TAPER-LOCK Straight Bore Max. HP per Torque
Size STD Spacer FBX BS RPM 100 RPM (In-Lbs.)
PX40 1 1 1-3/8 4500 .68 429
PX50 1-1/8 1-1/4 1-7/8 4500 1.43 900
PX60 1-7/16 1-11/16 2-3/16 1-5/8 4000 2.86 1800
PX70 1-11/16 2-1/8 2-3/8 2-1/8 3600 3.49 2200
PX80 2-1/8 2-11/16 2-7/8 2-9/16 3100 5.72 3605
PX90 2-11/16 2-11/16 3-3/8 2-3/4 2800 7.15 4502
PX100 2-11/16 2-11/16 3-3/8 3-1/4 2600 8.58 5402
PX110 2-11/16 2-11/16 3-3/4 3-15/16 2300 12.30 7750
PX120 3-1/4 3-1/4 3-3/4 4 2100 20.00 12,605
PX140 3-15/16 3-15/16 4-1/2 1840 43.78 27,590
PX160 4-7/16 4-7/16 6 1560 59.98 37,800
PX200 4-15/16 4-7/16 6-3/4 1300 130.90 82,500
PX240 5 7-1/2 1080 239.90 151,200
PX280 7 9 910 479.49 302,200
PX320 8 11 810 718.76 453,000
D-FLEX SELECTION/RATINGS DATA

Max. Bore EPDM & Neoprene Hytrel
Straight Bore Bushed Rated Rated
Element Max Torque Torque
Size Type J Type S Type SC Type B RPM HP/100 (In-Lbs) HP/100 (In-Lbs)
3 7/8 9200 0.10 60
4 1 7600 0.19 120
5 1-1/8 1-1/4 1-1/8 7600 0.38 240
6 1-3/8 1-7/8 1-3/8 1-3/16 6000 0.71 450 2.90 1,800
7 1-7/8 1-5/8 1-3/16 5250 1.20 725 4.60 2,875
8 2-3/8 1-7/8 1-5/8 4500 1.80 1,135 7.20 4,530
9 2-7/8 2-1/8 1-15/16 3750 2.80 1,800 11.40 7,200
10 3-3/8 2-3/8 2-1/2 3600 4.60 2,875 18.00 11,350
11 3-7/8 2-7/8 2-13/16 3600 7.20 4,530 28.60 18,000
12 3-15/16 2-7/8 3-1/2 2800 11.40 7,200 50.00 31,500
13 4-1/2 3-3/8 3-15/16 2400 18.00 11,350 75.00 47,268
14 5 3-7/8 3-15/16 2200 28.60 18,000 115.00 72,480
16 6 4-1/2 1500 75.00 47,250
GEAR COUPLING SELECTION/RATINGS DATA

Coupling Max Bore
Size Flex Rigid Max RPM HP/100 Torque (In--Lbs)
1.0 1.97 2.40 8500 12.00 7,500
1.5 2.52 3.11 7700 24.00 15,000
2.0 3.15 3.78 6900 48.00 30,000
2.5 3.86 4.57 6200 84.00 53,000
3.0 4.41 5.28 5800 140.00 88,000
3.5 5.24 6.14 5100 225.00 142,000
4.0 6.22 7.24 4500 333.00 210,000
4.5 6.77 7.95 4000 476.00 300,000
5.0 7.56 8.98 3750 666.00 420,000
5.5 8.27 9.72 3550 936.00 590,000
6.0 9.13 10.83 3400 1263.00 796,000
7.0 10.87 12.32 3200 1755.00 1,106,000

PT1--70
ENGINEERING/
TECHNICAL
Rating Tables
GRID-LIGN SELECTION/RATINGS DATA
Maximum Bore Maximum RPM HP/100 Torque (In.-Lbs.)
Coupling
Size Standard Spacer Standard Spacer Standard Spacer Standard Spacer
(1)STR T-L (1)STR T-L T10 T20 T31/35 STR T-L STR T-L STR T-L STR T--L
1020T 1-1/8 1-7/16 1-1/8 4500 6000 3600 0.67 0.67 0.67 422 422 422
1030T 1-7/16 1-1/8 1-3/4 1-1/8 4500 6000 3600 1.90 1.90 1.90 1.90 1200 1200 1200 1200
1040T 1-3/4 1-1/8 2-1/4 1-7/16 4500 6000 3600 3.20 2.10 3.20 3.20 2000 1300 2000 2000
1050T 2 1-1/4 2-1/2 1-11/16 4500 6000 3600 5.60 5.60 5.60 5.60 3500 3500 3500 3500
1060T 2-1/4 1-11/16 3-1/8 2-1/8 4350 6000 3600 8.70 6.80 8.70 8.70 5500 4300 5500 5500
1070T 2-11/15 2-1/8 3-1/4 2-11/16 4125 5500 3600 13.00 11.30 13.00 13.00 8000 7150 8000 8000
1080T 3-1/4 2-11/16 3-3/4 2-11/16 3600 4750 3600 26.00 17.90 26.00 17.90 16,500 11,300 16,500 11,300
3-3/4 3-1/4 4-1/4 3-1/4
1090T 3600 4000 3600 48.00 38.10 48.00 38.10 30,000 24,000 30,000 24,000
4-1/4 3-1/4 5 3-15/1
1100T 6 2440 3250 2440 80.00 38.10 80.00 50,500 24,000 50,500
1110T 4-5/8 3-15/1 5-7/8 4-7/16 2250 3000 2250 120.00 71.10 120.00 75,000 44,800 75,000
1120T 5-3/8 6 2025 175.00 110,000
6-1/2 160,000
1130T 1800 254.00
7-1/4
1140T 1650 365.00 230,000

(1) Max. bore with rectangular key
CHAIN COUPLINGS
Basic Max. Bore Max. RPM *HP Ratings at Various RPM
Size TAPER- Finished Rebor- Without With
No. 10 20 40 60 80 100 150 200 250 300
LOCK Bore able Covers Covers
4012 ... 3/4 7/8 875 5000 .22 .43 .86 1.29 1.72 2.15 2.83 3.43 4.03 4.57
4016 1-1/8 1-1/8 1-5/16 875 5000 .38 .77 1.53 2.30 3.06 3.83 5.02 6.06 7.14 8.08
5012 ... 1-1/8 1-1/8 875 ... .40 .81 1.61 2.42 3.23 4.03 5.30 6.39 7.57 8.57
5016 ... 1-5/8 1-11/16 800 4000 .73 1.46 2.93 4.39 5.86 7.32 9.60 11.7 13.7 15.5
5018 1-11/16 ... 2 800 4000 .95 1.89 3.79 5.68 7.57 9.47 12.4 15.0 17.7 20.0
6018 ... 2-7/16 2-7/16 675 3000 1.73 3.46 6.92 10.4 13.8 17.3 22.9 27.6 32.5 36.8
6020 2-1/8 ... 2-3/4 675 3000 2.25 4.50 9.01 13.5 18.0 22.5 29.6 35.6 42.0 47.6
8018 ... 2-7/8 3-1/8 500 2000 3.86 7.72 15.4 23.2 30.9 38.6 50.8 61.4 72.3 81.5
8020 3-1/4 ... 3-9/16 500 2000 5.03 10.1 20.1 30.2 40.3 50.3 66.1 79.7 94.0 106.0
10020 3-15/16 ... 4-5/8 450 1800 8.68 17.4 34.7 52.1 69.4 86.8 115.0 139.0 162.0 184.0
12018 ... ... 4-11/16 400 ... 13.7 27.3 54.6 82.0 109.0 137.0 178.0 217.0 253.0 288.0
12020 4-7/16 ... ... 400 1600 16.8 33.6 67.2 101.0 134.0 168.0 218.0 264.0 308.0 350.0
Basic HP Ratings at Various RPM

Size
No. 350 400 500 600 800 1000 1200 1400 1600 1800 2000 2400 3000 3600 4000 5000
4012 5.10 5.57 6.55 7.56 9.42 11.3 13.1 14.9 16.6 18.2 19.9 23.3 28.2 33.1 36.2 44.2
4016 9.04 9.89 11.6 13.4 16.7 20.1 23.0 26.3 29.3 32.7 35.4 41.3 49.7 58.2 63.8 78.1
5012 9.41 10.42 12.2 14.1 17.5(2) . . . ... ... ... ... ... ... ... ... ... ...
5016 17.3 18.9 22.3 25.7 32.0 38.3 44.5 50.4 56.2 61.9 67.6 78.9 95.9 112.0 123.0 ...
5018 22.4 24.5 28.8 33.1 41.4 49.7 56.8 65.1 72.6 80.9 87.6 102.0 123.0 144.0 158.0 ...
6018 41.2 44.9 53.0 60.9 75.9 90.7 105.0 120.0 134.0 147.0 160.0 188.0 227.0 ... ... ...
6020 53.2 58.2 68.5 78.8 98.5 118.0 135.0 155.0 173.0 192.0 208.0 243.0 293.0 ... ... ...
8018 91.5 99.8 118.0 135.0 169.0 202.0 234.0 266.0 297.0 326.0 356.0 ... ... ... ... ...
8020 119.0 130.0 153.0 176.0 220.0 264.0 302.0 346.0 386.0 430.0 466.0 ... ... ... ... ...
10020 205.0 225.0 265.0 305.0 380.0 454.0 527.0 598.0 667.0 734.0 ... ... ... ... ... ...
12018 322.0 355.0 ... ... ... ... ... ... ... ... ... ... ... ... ... ...
12020 391.0 432.0 510.0 585.0 708.0 877.0 1003.0 1135.0 1273.0 ... ... ... ... ... ... ...
(2) 5012 Max. RPM is 875, HP Rating is 18.8.

* T.L. Bushings not recommended below 250 RPM

PT1--71
ENGINEERING/
TECHNICAL
COMPARATIVE TABLE
Coupling Misalignment
End Float
Type Angular Parallel
PARA-FLEX
4 .125 0.156
(PX, PS) (1) (2)
PARA-FLEX
1 0.0625 0.094
(PH, PF)
GRID-LIGN 1/2 0.012 .0.375
CHAIN 2 .015 .0.300
POLY-DISC 2 0.032
NYLIGN 1-1/2 0.022 0.125
(1) PX40 is 4 Angular /.06 Parallel/ .094 End Float (2) PX110 is 4 Angular/.125 Parallel/.125 End Float
TEMPERATURE RANGE GEAR COUPLING MISALIGNMENT

Coupling Type _F Size Misalignment
PARA-FLEX Angular (1) Parallel
PX, PS --45_F (1) to +180_F(1) 1.0 1/2_ .019
PH, PF --45_F (1) to +180_F(1) 1.5 1/2_ .020
D--FLEX 2.0 1/2_ .027
EPDM --30_F to +275_F 2.5 1/2_ .032
NEOPRENE 0_F to +200_F 3.0 1/2_ .038
HYTREL --65_F to +250_F 3.5 1/2_ .044
GRID-LIGN --35_F to +210_F 4.0 1/2_ .050
CHAIN --30_F to +225_F 4.5 1/2_ .056
GEAR --30_F to +250_F 5.0 1/2_ .063
POLY-DISC --90_F to +170_F 5.5 1/2_ .074
NYLIGN 0_F to +170_F 6.0 1/2_ .081
(1) --40_F
40 F to +210
+210_F
F for neoprene element. 7.0 1/2_ .091
(1) Angular misalignment per flex coupling half
D-FLEX MISALIGNMENT (1)

Types JE, JN, E & N Types H & HS (4)
Size Parallel (1) Angular (2) End Float (3) Parallel (2) Angular (2) End Float (3)
3 .010 1 0.030
4 .010 1 0.030
5 .015 1 0.046
6 .015 1 0.060 .010 1/4 0.060
7 .020 1 0.060 .012 1/4 0.060
8 .020 1 0.096 .015 1/4 0.096
9 .025 1 0.096 .017 1/4 0.096
10 .025 1 0.125 .020 1/4 0.125
11 .032 1 0.125 .022 1/4 0.125
12 .032 1 0.125 .025 1/4 0.125
13 .040 1 0.125 .030 1/4 0.125
14 .042 1 0.125 .035 1/4 0.125
16 .062 1 0.125
NOTE: (1) All dimensions are in inches. (3) Increase E dimension by this amount to ac-
(2) Values are for when 1/4 or more of the rated commodate end float.
torque is transmitted. Reduce values by 50% (4) Types H & HS should not be used as direct
for lower torques. replacements for EPDM or Neoprene sleeves.

PT1--72
ENGINEERING/
TECHNICAL
PARA-FLEX COUPLINGS BOLT TORQUE IN- PARA-FLEX HIGH SPEED & FLYWHEEL
FORMATION BOLT TORQUE INFORMATION
Standard For Flange (3) For Bolt Ring
PS Shaft Hub Size Iron Flg. Steel Flg. (3)
Clamp Ring Bolts (5) Bolts (3) 87 290 290 180
96 290 290 300
Torque Torque 116 480 480 360
Size No. T--L (In-Lbs) No. (In-Lbs) 131 480 480 420
PX40 4 130 4 130 172 1080 1150 600
PX50 5 130 4 180 192 2160 1150 780
PX60 5 240 5 180 213 2160 2160 840
PX70 5 290 5 180 252 3600 3600 2880
PX80 6 290 5 300 (3) SAE Grade 8.
PX90 6 480 6 300
PX100 6 480 6 300
PX110 6 480 6 300
PARA-FLEX TORSIONAL STIFFNESS
PX120 6 1080 6 720 Size In-Lbs/Degree (4)
PX140 8 1080 5 720 PX40 220
PX160 (2) 8 2160 1150 6 1296 PX50 224
PX200 12 2160 2400 8 1296 PX60 414
PX240 12 3600 4020 PX70 544
PX280 14 4320 6600 PX80 876
PX320 16 4320 6600 PX90 1088
PX100 1530
PX110 2420
(2) PX160 steel flanges have 10 clamp ring bolts
PX120 4014
(3) SAE Grade 8. PX140 8296
PX160 12,000
(5) SAE Grade 8. FBX style couplings utilize class 10.9 PX200 29,000
metric clapingring bolts. PX240 48,000
PX280 98,000
PX320 151,000
(4) Values are nominal and may vary +/- 20%. To convert static
values to approximate dynamic values, multiply the static
values by 1.2.
D-FLEX TORSIONAL STIFFNESS* D-FLEX SPACER BOLT TORQUES

EPDM & Neoprene Hytrel
Shaft Hub Bolts (1)
Size (In-Lbs/radian) (In-Lbs/radian)
3 229 Torque
4 458 Size Number Ft-Lbs
5 916 5SCH 4 4
6 1,718 10,000 6SCH 4 9
7 2,769 20,000 7SCH 4 9
8 4,335 30,000 8SCH 4 18
9 6,875 47,500 9SCH 4 31
10 10,980 100,000
10SCH 4 50
11 17,300 125,000 11SCH 4 75
12 27,500 225,000 12SCH 4 150
13 43,350 368,900 13SCH 4 150
14 68,775 593,250 14SCH 4 150
16 180,480
* Values shown are for an ambient temperature of 75F. (1) SAE Grade 8

PT1--73
ENGINEERING/
TECHNICAL
AGMA CLASS 1 FITS
Bore Dimensions
Clearance Interference
Nom. Shaft Nom. Shaft Bore Nom. Shaft Bore
Diameter (In.) Dia. Less Tolerance Dia. Less Tolerance
0 1-1/2 .000 +.001 -.000 .001 --.0005 -.000
1-1/2 2 .000 +.001 -.000 .002 --.001 -.000
2 3 .000 +.0015 -.000 .002 --.0015 -.000
3 4 .000 +.0015 -.000 .003 --.0015 -.000
4 5 .000 +.002 -.000 .0035 --.0015 -.000
5 6 .000 +.002 -.000 .004 --.0015 -.000
STANDARD KEYWAYS
Keyway
Bore Size Width For Sq. Key For Rec. Key
7/16 3/32 3/64 ...
1/2 9/16 1/8 1/16 ...
5/8 7/8 3/16 3/32 ...
15/16 1-1/4 1/4 1/8 ...
1-5/16 1-3/8 5/16 5/32 ...
1-7/16 1-3/4 3/8 3/16 1/8
1-13/16 2-1/4 1/2 1/4 3/16
2-5/16 2-3/4 5/8 5/16 7/32
2-13/16 3-1/4 3/4 3/8 1/4
3-5/16 3-3/4 7/8 7/16 5/16
3-13/16 4-1/2 1 1/2 3/8
4-9/16 5-1/2 1-1/4 5/8 7/16
METRIC BORE STANDARD

MM Bore MM MM MM Key
Keyway Width Hub Keyseat
14 5 2.3 5x5
16 5 2.3 5x5
18 6 2.8 6X6
19 6 2.8 6X6
20 6 2.8 6X6
22 6 2.8 6X6
24 8 3.3 8X7
25 6 3.3 8X7
28 8 3.3 8X7
30 8 3.3 8X7
32 10 3.3 10X8
35 10 3.3 10X8
38 10 3.3 10X8
40 12 3.3 12X8
42 12 3.3 12X8
45 14 3.8 14X9
48 14 3.8 14X9
50 14 3.8 14X9
55 16 4.3 16X10
60 18 4.4 18X11
65 18 4.4 18X11
70 & 75 20 4.9 20X12
80 & 85 22 5.4 22X14
90 25 5.4 25X14
95 25 5.4 25X14
100 28 6.4 28X16
MM bore and keyway conform to ISO standard recommendation R773, for FREE fit.

PT1--74
HMK04 Series
Hydraulic Filters
Assembly Features
High flow capacity spin-on filters for heavy-duty as well
as medium-duty use -- with the widest choice of
replacement filters available!
Static Pressure: 1000 psi / 6900 kPa / 69 bar
Working Pressure: 500 psi / 3450 kPa / 34.5 bar
Flow Range: 0-35 gpm / 0-132.5 l/min
Filter Fatigue Strength Ratings:
At 100,000 cycles 0-500 psi/0-3450 kPa
At 300,000 cycles 0-400 psi /0-2758 kPa
At 1,000,000 cycles 0-350 psi/0-2415 kPa
Port Sizes: " and 1" NPT
" and 1" SAE O-Ring
Operating Temperatures:
Synthetic Media: -20o F to 250o F / -29o C to 121o C
Cellulose Media: -20o F to 225o F / -29o C to 107o C
Assembly weight (approximate):
Short Assembly: 3.5 lbs / 1.6 kg
Long Assembly: 4.2 lbs / 1.9 kg
Replacement Filters
Lengths: 6" / 152mm and 9.4" / 240mm
Filter media uses Synteq Technology, Donaldsons
exclusive synthetic media formulation specifically
designed for liquid filtration. Natural fiber
cellulose, in standard or heavy duty, is also
available.
Filtration efficiencies to 2=75(absolute)
Heavy duty steel body, with diecast top plate for added
strength, and a special head-to-canister o-ring seal.
BunaN seals standard; Viton seals available on some
models.
Applications
Return Line & Side Loop Systems
Fluid Conditioning Systems
Power Transmissions, Case Drains
Hydrostatic Charge Pumps, Cooling Circuit Systems
Lube Oil Systems (Bearing/Gear Lube), Fuel Transfer
Duramax and Synteq are registered

trademarks of Donaldson Company, Inc.
Brochure #F112073
(Rev. 5/98)
HMK04 Assemblies
------------------------------------ Assembly Information ---------------------------- ------------------- Filter -------------------
Port Size Bypass Rating Indicator Style/Location Assembly Media Length Filter Part No.
1" NPT 25 psi / 172 kPa Visual, Left Side K045486 No. 2 9.4"/240mm P165332
Visual, Left Side K045497 No. 9 9.4"/240mm P164384
1" SAE O-Ring 25 psi / 172 kPa Visual, Left Side K045529 No. 2 9.4"/240mm P165332
Mix n Match System

The Donaldson mixn match system provides the
performance and functional advantages of custom-
engineered filters with the convenience and speedy
delivery of in-stock parts.
Choose one of the in-stock assemblies listed above, or,

if they dont meet your particular specifications, create
your own filter model from among the filters, heads
and accessories shown on the next page.
HMK04 Service Parts

Service Indicator Styles
(See table on page 5)
Plug
P165983 (remove only for
installation of Electric Indicator)
O-Rings
Spin-on Filter
Length: 6" / 152mm
9.4" / 240mm
(see table at right)
Page 2 HMK04
HMK04 Service Parts
Replacement Filters
Media B(x)=2/20/75 Media Length Part
Number Rating Technology in mm Number
No. <2/<2/2 Synteq 9.4 240 P165185
with Viton Seal
No. 1 <2/<2/3 Synteq 9.4 240 P167590

No. 2 2/3/5 Synteq 6 152 P165354
9.4 240 P165332
No. 2 2/7/10 Synteq 6 152 P176565
9.4 240 P176566
No. 3 4/12/16 Cellulose 6 152 P163405
9.4 240 P163323
Heavy Duty 6 152 P163552
Cellulose
No. 4 5/13/16 Synteq 6 152 P164375 In-Stock Heads
9.4 240 P164378
Port Bypass Standard Indicator Indicator Part
No. 5 5/13/17 Cellulose 6 152 P163412 Size Rating Style1 & Location2 Options1 Number
9.4 240 P163434 3/4" NPT 25 psi None None P169317
172 kPa D (Visual), Left Side None P169310
Heavy Duty 6 152 P163542
Cellulose 3/4" SAE 25 psi None None P167473
9.4 240 P163555
O-Ring 172 kPa D (Visual), Left Side None P166387
No. 6 5/10/13 Synteq 9.4 240 P164056
with Viton Seal No D (Visual), Left Side None P169320
No. 7 7/17/22 Synteq 6 152 P164381 Bypass None None P165434
9.4 240 P164384 No D (Visual), Left Side
None P173750
Bypass (50 psi)
No. 10 10/21/25 Cellulose 6 152 P163419
3/4" SAE 50 psi
9.4 240 P163324 O-Ring 345 kPa A (Electrical) B, C P167529
No. 15 15/30/35 Cellulose 6 152 P163496 (3 ports) To Tank
9.4 240 P163322 1" NPT 25 psi D (Visual), Both Sides A, B, C P166086
172 kPa None None P169309
Heavy Duty 9.4 240 P163561
Cellulose D (Visual), Left Side None P166416
No. 16 15/30/37 Synteq 9.4 240 P164059 1" SAE 15 psi E (Electrical) None P176569
with Viton Seal O-Ring 100 kPa
No. 20 20/33/40 Synteq 6 152 P165335 1" SAE 25 psi None None P163681
O-Ring 172 kPa D (Visual), Left Side None P166417
9.4 240 P165338
D (Visual), Both Sides A, B, C P166088
No. 25 25/50/ - Cellulose 6 152 P163428
E (Electrical) None P176568
9.4 240 P163425 A (Electrical) B, C P165537
Heavy Duty 6 152 P163546 No D (Visual), Both Sides A, B, C P166664
Cellulose
9.4 240 P163558 Bypass A (Electrical) B, C P166902
50 psi None None P167201
Filter Notes 345 kPa A (Electrical) B, C P166862
Filters with seals made of BunaN are appropriate for most
applications involving petroleum oil. Filters with seals made of Head Notes
Viton (a fluoroelastomer) are required when using diester, 1
Reference service parts drawing for key letters & drawings of indicators.
phosphate ester fluids, water glycol, water/oil emulsions, and HWCF 2
Donaldson uses the inlet port as the reference point. Left side, for instance,
(high water content fluids) over 150F. Donaldson offers both types, means that the indicator mounts on the side of the filter head that is on your left
as shown above. (Viton is a registered trademark of DuPont when you face the inlet port.
Chemical Corp.)
In Donaldson filters with Viton seals, epoxy potting is also used to
accommodate higher temperature environments. The plastisol (heat
cured) and urethane (self curing) potting materials used in other
The P167529 head is designed with a
filters perform well with petroleum-based fluids. 50 psi third port bypass valve that diverts
Synteq filter media is compatible with petroleum based fluids, and all bypass flow back to the reservoir
most phosphate esters, water oil emulsions, and HWCF (high water (instead of going straight through the head
content fluids).
and into the system, as it does in 2-ported
heads.) No unfiltered fluid is allowed into
the system in the case of plugged filters.
Designed for charge pump applications.
HMK04 Page 3
HMK04 Filter Service Indicator Choices
Electrical Schematics
Style A: Single Post DC Indicator
(Maximums: 200 mA DC @ 30 VDC)
P167455
Our 3-wire AC/DC indicators enable Our 2-wire DC electric service

remote service indication. indicators accommodate various
See table below for details. brands of connectors.
P162400
P163601
In-Oil Service Indicator Specifications P163642
P165194
Use with Bypass Indicator P163839
Valve Pressure of: Part No. Style/Description
1
Electric Models
Style B: DC 2-Wire Indicator
5 psi / 34.5 kPa P163642 Style A. Single post DC. Color-coded (Maximums: 200 mA DC @ 30 VDC)
washer: black. Normally open.
15 psi / 103 kPa P163601 Style A. Single post DC. Color-coded
washer: blue. Normally open.
P176570 Style E: AC/DC 3-wire, with connector. P171143
Silver contacts. White wire = normally
open; red = normally closed; black =
common.
25 psi / 172.5 kPa P163839 Style A. Single post DC. Color-coded
washer: red. Normally closed.
P162400 Style A. Single post DC. Color-coded
P171087
washer: green. Normally open. P170926
P171143 Style B. DC 2-wire. Canon connector
completes electrical circuit to filter head.
Normally open.
P173944 Style C. AC/DC 3-wire, no connector.
Styles C & E: AC/DC 3-Wire
open; red = normally closed; Indicator
black = common. (Maximums: 2 amps @ 24 VDC
or 2 amps @ 110 VAC)
P177361 Style E. AC/DC 3-wire, with connector.
open; red = normally closed; P173944
black = common. P173893
P176570
50 psi / 345 kPa P165194 Style A. Single post DC. Color-coded P177361
washer: red/white. Normally closed.
P167455 Style A. Single post DC. Color-coded
washer: red/green. Normally closed.
P171087 Style B. DC 2-wire. Packard Weatherpack
connector completes electrical circuit to
filter head. Normally open.
P170926 Style B. DC 2-wire. Gold contacts.
Normally open.
P173893 Style C. DC 3-wire. Gold contacts.
White wire = normally open; red =
normally closed; black = common.
Notes Indicator Spec Table
Visual Models (Non-Electric) 2 (1)
All electric models have maximum operating
temperature of 250F/ 114C.
5 psi / 34.5 kPa P162694 Style D. psi is marked on face. (2)
All non-electric models have maximum
operating temperature of 180F/ 82C.
25 psi / 172 kPa P162696 Style D. psi is marked on face.
50 psi / 345 kPa P167580 Style D. psi is marked on face.
n/a P165984 Blank Plate
Page 5 HMK04
HMK04 Performance Curves
HMK04 Filter Only (6"/152mm) HMK04 Filter Only (9.4"/240mm)
(L/MIN) (l/min)
0 20 40 60 80 100 120 0 20 40 60 80 100 120
10 10
#3 #5 #10 kkPa / bar #3 kPa / bar
#1/2 #1
#2
60 / 0.6 60 / 0.6
#6
8 8
#5
#15 50 / 0.5 50 / 0.5
Pressure Drop (psi)
#10
Pressure Drop (psi)

6 6
40 / 0.4 40 / 0.4
#2 1/2
#25
30 / 0.3 #2 & 16 30 / 0.3
4 #4 4
#9 #2 1/2 #15
20 / 0.2 20 / 0.2
2 2 #9
#20
10 / 0.1 10 / 0.1
#4 & 25 #20
0 0 / 0.0 0 0 / 0.0
0 5 10 15 20 25 30 35 0 5 10 15 20 25 30 35
Flow (gpm) Flow (gpm)
HMK04 Head Only

y
(l/min)
0 20 40 60 80 100 120
10 kPa / bar
60 /0.6
8
0.75" Port 50 /0.5
Pressure Drop (psi)
6
40 /0.4
1.0" Port
30 /0.3
4
20 /0.2
2
10 /0.1
0 0 /0.0
0 5 10 15 20 25 30 35
Flow (gpm)
Performance Notes
All flow measurements were made with 150 SSU hydraulic oil at 100oF
(37.7oC).
The numbers on the curves above refer to specific Donaldson media
formulations. Refer to service element listing for beta ratings and part
numbers.
Pressure Drop Calculation:
Clean Filter Assembly = head P + element P
Calculation Definitions:
PE = Element pressure drop from curve
P M = Corrected element pressure drop
S.G. = New specific gravity
SSU = New SSU viscosity (Saybolt Seconds Universal)
cSt = New cSt viscosity (centistokes)
cP = New cP viscosity (centipoise)
To correct element drops for viscosity and/or specific gravity, use one of these
formulae:
PM = PE x (SSU/150) x (S.G. / 0.9)
or PM = P E x (cSt/32) x (S.G. / 0.9)
or PM = PE x (cP/29)
HMK04 Page 4
HMK04 Dimensions
Measurements are in inches (millimeters)
Long Assembly Side View
Short Assembly Side View
Head Top View Head Top View

with DC Electrical Service Indicator with AC/DC Electrical Service Indicator
www.donaldson.com United States Europe Latin America & Mexico

email: Tel.: 800-846-1846 Tel.: 32-16-383811 Caribbean Tel.: 525-362-73-20
hydraulicfilters@mail.donaldson.com Fax: 612-703-4652 Fax: 32-16-400077 Tel.: 954-236-2404 Fax: 525-397-86-54
Fax: 954-236-2403
Printed In U.S.A.
Copyright 1999
HMK05/25 Series
Hydraulic Filters
Assembly Features
Full-range performance in Synteq filter media for high-flow applications,
with the ease and convenience of a spin-on! The double element head
means double flow capability, with two filters to hold more contaminant!
HMK05 (single) HMK25 (double)

Static Pressure: 800 psi/5520 kPa/55.2 bar same
Working Pressure: 350 psi/2413 kPa/24.1 bar same
Flow Range: 0-50 gpm 0-100 gpm
0-189.3 l/min 0-378.5 l/min
Port Sizes: 1" NPT 1" SAE 4-Bolt Flange
1" SAE O-Ring 1" NPT
1"SAE O-Ring
Assembly Weight: 7.5 lbs / 3.4 kg 16 lbs / 35 kg
Filter Fatigue & Strength Ratings: (both models)
100,000 cycles: 0-350 psi/ 0-2413 kPa
HMK05
300,000 cycles: 0-300 psi/ 0-2068 kPa
1,000,000 cycles: 0-250 psi/ 0-1734 kPa
HMK25 Operating Temperatures: (both models)
Synthetic Media: -20o F to 250o F / -29o C to 121o C
Cellulose Media: -20o F to 225o F / -29o C to 107o C
Wire Mesh Media: -20o F to 250o F / -29o C to 121o C
Replacement Filters
Filter Media: Donaldsons exclusive synthetic media
formulation, Synteq Technology, is specifically
designed for liquid filtration. Natural fiber cellulose
and wire mesh media are also available.
Filtration efficiencies to 3=75(absolute)
BunaN seals standard; Seals made of fluorocarbon
(such as Viton from DuPont Dow Elastomers or Fluorel from
3M Company) are available.
Applications
Return Line & Side Loop Systems
Fluid Conditioning Systems
Power Transmissions
Case Drains
Hydrostatic Charge Pumps
Cooling Circuit Systems
Lube Oil Systems
Fuel Transfer
Brochure #F112074
(Rev. 12/00)
Heads3 for HMK05 (single)
Port Bypass Standard Indicator Indicator Part
Size Rating Style & Location1,2 Options Number
1" NPT 25 psi G (Visual), Both Sides A, B, C, E, F P167294

172 kPa A (Electrical) B, C, E, F P167621
1" SAE 25 psi G (Visual), Both sides A, B, C, E, F P165973
O-Ring 172 kPa None None P167619
No Bypass G (Visual), Both sides A, B, C, E, F P166663
Heads3 for HMK25 (double)

Port Bypass Indicator Style2 Indicator Part
Size Rating & Location1 Options Number
1" NPT 25 psi G (Visual), A,B,C,E,F P169985
172 kPa Both Sides
1" SAE 25 psi G (Visual), A,B,C,E,F P167296
4-Bolt 172 kPa Both sides
Flange No G (Visual), A,B,C,E,F P169984
Bypass Both Sides
1" SAE 25 psi G (Visual), A,B,C,E,F P167297
O-Ring 172 kPa Both sides
Head Notes
1
Donaldson uses the inlet port as the reference point. Left side, for instance,
means that the indicator mounts on the side of the filter head that is on your
left when you face the inlet port.
Replacement Filters 2
Electrical indicators (styles A, B, C), which may be purchased separately, also
Media Media1 B(x) = 2/20/75 Part fit HMK05 heads.
3
Number Technology Rating2 Number The filter head snout/post must be lubricated before spinning on a new filter
to prevent thread damage.

No. 1 Synteq <2/<2/3 P170906
P1712733
No. 2 Synteq
2/3/5 P165675 Mix n Match System
P1712743
The Donaldson mixn match system provides the
No. 2 Synteq 2/7/10 P176567 performance and functional advantages of custom-
No. 4 Synteq 5/13/16 P165659 engineered filters with the convenience and speedy
P1712753 delivery of in-stock parts.

No. 9 Synteq 10/17/22 P165569
P1712763 Just pair the head you need with the spin-on filter most
No. 10 Cellulose 10/21/25 P165705
appropriate for your application and required

cleanliness level.
No. 20 Synteq 20/33/40 P165672
No. 149 Wire Mesh 149 P173943
Water Removal P179075
Filter Notes
1
Synteq filter media is compatible with petroleum based fluids, and most
phosphate esters, water oil emulsions, and HWCF (high water content
fluids).
2
Rating is per ISO4572 Test Procedure.
3
This filter has a Viton seal and epoxy potting.
Filters with seals made of BunaN are appropriate
for most applications involving petroleum oil.
Filters with seals made of V i t o n (a
fluoroelastomer) are required when using diester,
phosphate ester fluids, water glycol, water/oil
emulsions, and HWCF (high water content
fluids) over 150F. Donaldson offers both types,
as shown in the table above. (Viton is a
registered trademark of DuPont Dow
Elastomers.)
Page 2 HMK05/HMK25
HMK05/25 Service Parts
(Please refer to Indicator table on page 4.)
C, F
A
Plug P165983
(remove only for installation of
Electric Indicator)
B E G
A A
B
B
C, F
C, F
E
E
GG
HMK05/HMK25 Page 3
In-Oil Electric & Visual Indicator Electrical
Specifications Schematics
In-Oil Electric Models1
Style A: Single Post DC Indicator
Use with Bypass Indicator (Maximum: 200 mA DC @ 30 VDC)
Valve Pressure of: Part No. Style Description
5 psi / 34.5 kPa P163642 A Single post DC. Color-coded washer: black.
Normally open. P167455
P163839
15 psi / 103 kPa P163601 A Single post DC. Color-coded washer: blue.
Normally open.
25 psi / 172.5 kPa P163839 A Single post DC. Color-coded washer: red.
Normally closed.
25 psi / 172.5 kPa P162400 A Single post DC. Color-coded washer: green. P162400
Normally open. P163601
P163642
25 psi / 172.5 kPa P171143 B DC 2-wire. Cannon connector. P165194
Normally open.
25 psi / 172.5 kPa P173944 C AC/DC 3-wire. White wire = normally open;
red = normally closed; black = common.
Style B: DC 2-Wire Indicator
50 psi / 345 kPa P165194 A Single post DC. Color-coded washer:
(Maximum: 200 mA DC @ 30 VDC)
red/white. Normally open.
50 psi / 345 kPa P167455 A Single post DC. Color-coded washer:
red/green. Normally closed.
50 psi / 345 kPa P171087 B DC 2-wire. Packard Weatherpack P171143
connector. Normally open.
50 psi / 345 kPa P170926 E DC 2-wire. Compatible with micro-
processors. Normally closed. Gold contacts.
50 psi / 345 kPa P173893 F DC 3-wire. Compatible with micro-
processors. White wire = normally open;
P171087
50 psi / 345 kPa P174396 C AC/DC 3-wire. White wire = normally open;
Visual Models (Non-Electric) 2

Use with Bypass Indicator Style C, F: AC/DC
Valve Pressure of: Part No. Style Description 3-Wire Indicator
(Maximums:
15 psi / 103 kPa P162642 G PSI is marked on face. 2 amps @ 24 VDC or
2 amps @ 110 VAC)
25 psi / 172. kPa P162696 G PSI is marked on face. P173944
50 psi / 345 kPa P167580 G PSI is marked on face.
Style E: DC 2-Wire
n/a P165984 n/a Blank Plate Indicator
(Maximum:
Notes 100 mA DC @ 30 VDC)
(1)
All electric models have maximum operating temperature of 250F/ 114C.
(2)
All non-electric models have maximum operating temperature of 180F/ 82C. P170926
Synteq is Donaldson's synthetic filter media

that was specially developed for liquid
filtration. It's low-friction, high-flowing
properties result in low pressure drop through
the filter. Note the smooth, rounded fibers in
the SEM (scanning electron microscope)
photo at left. Donaldson manufactures this consistently
shaped fiber pattern, controlling fiber size, pore size, and
flow distribution pattern throughout the media mat. The
result is a media with predictable filtration efficiencies,
maximum dirt holding capacity, and low pressure drop.
Page 4 HMK05/HMK25
HMK05/25 Dimensions Measurements are in inches (millimeters)
HMK05 Assembly
Side View
HMK05 Head Top View HMK05 Head Top View

with AC/DC Electrical Service Indicator with DC Electrical Service Indicator
and Visual Indicators
Visual and Visual Indicators
Visual
HMK25 Head Top View

with DC Electrical Service Indicator
HMK25 Assembly and Visual Indicators
Visual
Side View
HMK25 Head Top View

with AC/DC Electrical Service Indicator
and Visual Indicators
Visual
Page 5 HMK05/HMK25
Performance Curves
HMK05 (single) Head Only HMK25 (double)yHead Only
(l/min) (l/min)
0 50 100 150 0 100 200 300
5 8
kPa/bar kPa/bar
50 /0.5
30 / 0.3
4
6
40 / 0.4
Pressure Drop (psi)
Pressure Drop (psi)

3 20 / 0.2
30 /0.3
1.25" Port 4
2 1.5" Port
20 /0.2
10 / 0.1
2
1
10 /0.1
0 0 / 0.0 0 0 / 0.0
0 10 20 30 40 50 0 20 40 60 80 100
Flow (gpm) Flow (gpm)
HMK05/25 Filter Only (per spin-on unit)

(l/min)
0 50 100 150 kPa/bar
6
40 / 0.4 Performance Notes
All flow measurements were made with 150 SSU hydraulic oil at 100oF (37.7oC).
#1
The numbers on the curves above refer to specific Donaldson media
5
formulations. Refer to service element listing for beta ratings and part numbers.
30 / 0.3
Pressure Drop Calculation: Clean Filter Assembly = head P + element P
4
Calculation Definitions:
Pressure Drop (psi)
PE = Element pressure drop from curve

#10
PM = Corrected element pressure drop
3 20 / 0.2 S.G. = New specific gravity
SSU = New SSU viscosity (Saybolt Seconds Universal)
cSt = New cSt viscosity (centistokes)
2
#2 cP = New cP viscosity (centipoise)
#9
10 / 0.1
#4
To correct element drops for viscosity and/or specific gravity, use one of
1 these formulae:
#2 1/2 #20 PM = PE x (SSU/150) x (S.G. / 0.9)
#149 or PM = PE x (cSt/32) x (S.G. / 0.9)
0 0 / 0.0 or PM = PE x (cP/29)
0 10 20 30 40 50
Flow (gpm)
www.donaldson.com United States Europe Latin America & Mexico

email: Tel.: 800-846-1846 Tel.: 32-16-383811 Caribbean Tel.: 525-362-73-20
hydraulicfilters@mail.donaldson.com Fax: 952-703-4652 Fax: 32-16-400077 Tel.: 954-236-2404 Fax: 525-397-86-54
Fax: 954-236-2403
Printed In U.S.A.
Copyright 2000
Flowline Products and Services
FMC Technologies is the worlds leading supplier of owline

products and services to the oileld industry and is the standard
against which all others are measured. From the original Chiksan
and Weco products to the revolutionary equipment designs and

integrated services of today, FMCs uid control family of

products and services enables customers to achieve maximum life
and value from their owline systems throughout a complete
range of applications.
The success of FMCs uid control technology stems from a

strong tradition of anticipating and responding to customer needs
in every way possible. By focusing on the delivery of top products
and services, FMC Technologies is helping its customers face
tomorrows technical and economic challenges today.
I1
Health, Safety & Environment

As a leading oileld equipment and services provider,
FMC Technologies stresses overall health, safety, and
environment (HSE) in all of its operations and processes.
With a proven record of outstanding HSE performance,
FMC is a strong advocate of HSE training that goes
beyond the basic legal requirements. The goal is to ensure
that all eld and ofce personnel are competent to carry
out HSE critical duties, having received the appropriate
training required by law, company policy, and clients.
HSE policy covers all key elements of the business,
including company safety policy statements, product
safety, risk assessment, monitoring, auditing, and review.
Manufacturing Leader
FMCs uid control manufacturing facility is located in
Stephenville, Texas. The plant was constructed in 1980
and expanded in 1984, 1987, and 1996. The facility
Experienced, Knowledgeable,
Productive People
FMCs global uid control team is structured around top
owline professionals individuals who understand your
business and are dedicated to meeting your needs. The
management, engineering, and sales support staff are
among the most experienced in the oil and gas industry.
Their knowledge and industry expertise show up in the occupies a 44-acre site and comprises 220,000 square
quality of products and services delivered to you. feet of manufacturing capacity and 48,000 square feet
of customer service, production support, and engineering
ofces. It utilizes the latest in computer numerical
controlled (CNC) machining centers, production
planning systems, computer aided design/computer aided
manufacturing (CAD/CAM) systems, and the latest
technology in order and distribution operating systems.
The Stephenville facility produces a wide range of owline
equipment for distribution worldwide.
I2
Unsurpassed Quality
FMCs uid control quality system has been surveyed and
approved by DNV and meets ISO 9001 and European
Pressure Equipment Directive 97/23/CE. Most products are
supplied with the CE marking. Chiksan and Weco products
also can be supplied with both type and case approval from
DNV, Lloyds, ABS, GGTN, and others. Products for sour
gas service meet NACE MR-01-75 and API RP-14-E.
Complete material certication and traceability are also
available.
Research and Development

To meet the evolving needs of its customers, FMC
continually invests in owline research and development.
This industry-leading effort has resulted in a host of new
products and renements to existing products. All new
products are subjected to exhaustive laboratory and eld
tests to ensure their reliability and integrity before they are
released to the marketplace. Research and development
capabilities include exhaustive laboratory and eld testing,
destructive and nondestructive testing, three-dimensional
nite element analysis, computational uid dynamics, and
the owline industrys only high-velocity ow loop.
Worldwide Distribution
Chiksan and Weco products are distributed from more than
60 locations worldwide. FMC uid control facilities stock
many owline products in the specic sizes, pressures, and
materials common in the various regions. From a replace-
ment seal for a Chiksan swivel joint to a platform full of
well servicing equipment, FMC Technologies delivers.
Integrated Services
To satisfy the total owline requirements of its customers,
FMC Technologies has consolidated its industry-leading
after-sales capabilities into a comprehensive Integrated
Services program. Integrated Services is helping customers
worldwide realize the maximum value from their owline
assets to guarantee that the right products are shipped to
the job site in top working condition. This total solutions
approach includes the InteServ tracking and management
system, mobile inspection and repair, strategically located
service centers, and genuine Chiksan and Weco spare parts.
I3
Weco Check Valves
Weco check valves are used to isolate well-servicing equipment from high-
pressure treating uids during fracturing applications. Offered in three primary
models, these rugged valves seal against a complete range of well-servicing
uids at pressures to 20,000 psi. Valves are available in 1-1/2 to 4-inch bore
sizes for standard and reverse ow. Sour gas models available. Consult factory
for congurations. Like all pressure containing products, Weco check valves
require special handling (see inside back cover for Warnings and Cautions).
ACME thread cap
Coarse, ACME thread cap
Top-Entry Check Valves can be easily removed
without having to remove the
Fast, easy service
Top-entry design and
valve from the line. removable apper assembly
Recommended service make repair fast and easy.
High-pressure well-servicing lines, fracturing
lines, testing lines, cementing and circulating
lines, and other well service and stimulation
applications
Replaceable seat
Stainless steel seat is
replaceable, reducing the
need to scrap body.
Abrasion resistant apper

Carboxylated nitrile apper face
is abrasion resistant against a
Forged design complete range of well uids.
Forged body, unique ow dynamics,
Open ow path advanced erosion characteristics,
Flapper dynamics provide and abrasion-resistant components
optimum ow through the valve combine for long service life.
and low ow differential.
See specications tables (pages CV1A and CV2A) for sizes, dimensions, weights, materials, and part numbers.
CV1
Weco Check Valves
Dart Check Valves Easy, low-cost service

Main seal is located on seat,
Recommended service reducing exposure to ow.
Extreme nitrogen and carbon Enables seal to be replaced
dioxide services; wet or dry without replacing seat or dart.
non-erosive ow
Low-inertia dart design

Hollow dart and xed stem
minimize pressure required to
start ow. Non-metallic
bushing reduces friction,
increasing dart and stem life.
Minimizes explosive
decompression N2 and CO2 capability
Explosive decompression Stainless steel internal
resistant materials and components and special
design for long service life. elastomer seal handle gas
velocities in excess of
250 feet/second.
Flapper Check Valves

Abrasion resistant apper
Recommended service Carboxylated nitrile apper face
Slick water, sand, proppant/gel, and
is abrasion resistant against a
cement services
complete range of well uids.
Replaceable seat
Separate seat/body design
ensures the seat can be
replaced as needed.
Open ow path
Flapper dynamics provide
optimum ow through the valve
and low ow differential.
See specications tables (pages CV1A and CV2A) for sizes, dimensions, weights, materials, and part numbers.
CV2
Weco Check Valve Specications

Top Entry Check Valves

Nominal Cold Working End Flow Part A B Weight
Size, in. Pressure, psi (bar) Connections Orientation Number in. (mm) in. (mm) lb (kg)
15,000 (1034) 1502 FxM Standard P521623 15.67 (398) 9.54 (242) 116 (53)
3
15,000 (1034) 1502 MxF Reverse P524440 15.67 (398) 9.54 (242) 116 (53)
10,000 (690) 1002 FxM Standard P525809 19.75 (502) 11.88 (302) 239 (109)
4
15,000 (1034) 1502 FxM Standard P524760 19.75 (502) 11.88 (302) 276 (126)
In-Line Flapper Check Valves

1.5 15,000 (1034) 1502 MxF Reverse P519734 14.04 (357) 7 (178) 81 (37)
15,000 (1034) 1502 FxM Standard 3269173 14.04 (357) 7 (178) 84 (38)
2 15,000 (1034) 1502 MxF Reverse 3269472 14.04 (357) 7 (178) 84 (38)
20,000 (1379) 2002 FxM Standard 3269158 16.91 (430) 8 (203) 123 (56)
6,000 (414) 602 FxM Standard P501959 15.67 (398) 8.12 (206) 121 (55)
6,000 (414) 602 MxF Reverse P519978 15.67 (398) 8.12 (206) 124 (56)
3 6,000 (414) 602 FxF Standard P502035 12.27 (312) 8.12 (206) 100 (45)
15,000 (1034) 1502 FxM Standard 3269052 15.67 (398) 8.12 (206) 122 (55)
15,000 (1034) 1502 MxF Reverse P518432 15.67 (398) 8.12 (206) 126 (57)
20,000 (1379) 2002 FxM Standard P520099 22.79 (579) 13 (330) 442 (201)
6,000 (414) 602 FxM Standard P513204 22.79 (579) 12.25 (311) 378 (171)
10,000 (690) 1002 FxM Standard P517718 21.13 (537) 11.25 (286) 280 (127)
4
15,000 (1034) 1502 FxM Standard P517894 22.79 (579) 12.25 (311) 385 (175)
15,000 (1034) 1502 MxF Reverse P518468 22.79 (579) 12.25 (311) 385 (38)
Dart Check Valves

15,000 (1034) 1502 FxM Standard P525269 14.04 (357) 10.31 (262) 86 (39)
1.5
15,000 (1034) 1502 MxF Reverse P523811 14.04 (357) 10.31 (262) 86 (39)
2 15,000 (1034) 1502 FxM Standard P510771 14.04 (357) 10.31 (262) 87 (40)
3 15,000 (1034) 1502 FxM Standard P510773 15.67 (398) 11.43 (290) 130 (59)
Note: Some sizes and models are available with a vent cap connection for relief of trapped pressure on downstream
side which can occur in flowlines when valve is checked closed. Consult factory for more information.
Consult factory for congurations available for models not shown above as well
as installation instructions.
CV1A
Weco Check Valve Specications

Top Entry Check Valves

A
In-Line Flapper Check Valves

A
Dart Check Valves

A
CV2A
Typical Weco and Chiksan Equipment Recommended Temperature Ranges
(Consult factory for specic values)
Product Line and Materials of Construction
Wing Unions, Wing Unions, Swivel Joints, Butterfly

Swivel Joints Plug Valves, Check Valves, Valves
Fittings, Pup Joints, Adapters
Elastomer Selection Ductile Iron Carbon Steel Alloy Steel Alloy Steel Temperature Ranges
Standard Sour Gas
Service Service
No Seal (Wing Union) X 20F (-7C) to 300F (149C)
No Seal (Wing Union) X 0F (-18C) to 300F (149C)
Nitrile X 20F (-7C) to 240F (116C)
Nitrile X 0F (-18C) to 240F (116C)
Nitrile X -20F (-29C) to 240F (116C)
Winterized Nitrile X -50F (-46C) to 240F (116C)
HNBR X 20F (-7C) to 300F (149C)
HNBR X X X 10F (-12C) to 300F (149C)
Viton
X X X X 20F (-7C) to 300F (149C)
Natural Rubber Seat X -20F (-29C) to 150F(66C)
Nitrile Seat X -20F (-29C) to 200F (93C)
EPDM, Hypalon, or PTFE Seat X -20F (-29C) to 250F (121C)
Silicone Rubber Seat X -20F (-29C) to 300F (149C)
Fluoroelestomer Seat X -10F (-23C) to 300F (149C)
Neoprene Seat X 0F (-18C) to 200F (93C)
TR1A
Warnings and Cautions
FMC Technologies cannot anticipate all of the situations a user may encounter while installing and
using FMC products. Therefore, the user of FMC products MUST know and follow all applicable industry
specications and practices on the safe installation and use of these products. For additional safety
information, refer to FMC Technologies product catalogs, product brochures, and installation, operating,
and maintenance manuals, which can be accessed at www.fmctechnologies/uidcontrol.com, or
contact FMC Technologies at 800-772-8582.
Failure to follow these safety warnings could result in death, serious personal injury, and/or severe property damage.
Never mix or assemble components, parts, or end connections with different pressure ratings. Mismatched conditions,
including but not limited to that of a 2 Figure 1502 male sub end connected to a 2 Figure 602 female sub, may fail
under pressure resulting in death, serious personal injury, or severe property damage.
Never use or substitute non FMC components or parts in FMC products or assemblies.
Never modify or repair FMC products in a manner not specically directed in instructions published by FMC
Technologies.
Never strike, tighten, loosen, or attempt repairs on pressurized components or connections.
Never exceed the rated working pressure of the product.
Complete and proper make-up of components and connections is required to attain rated working pressure. Always
apply essential care, attention, handling, and inspection to threaded components before, during and after make-up.
Never use severely worn, eroded, or corroded products. Contact FMC Technologies for more information on how to
identify the limits of erosion and corrosion.
Never strike wing union nuts having severely attened and extruded ears. This condition can result in ying debris
leading to serious personal injury and must immediately be addressed by either grinding off extruded material or
removing the nut from service.
Always follow safe practices when using products in overhead applications. Products not properly secured could fall.
- Never exceed the load rating of lifting devices on products or lifting equipment.
- Use of FMC products in suspension applications can result in over-stress conditions leading to catastrophic failure.
- If externally applied loads are anticipated, consult factory.
Always follow safe practices when manually lifting and carrying products.
Always select only appropriate product and materials for the intended service:
- Never expose standard service products to sour gas uids (Refer to NACE MR-01-75). Do not interchange sour gas
with standard service components.
- Always use appropriate safety precautions when working with ferrous products in below freezing temperatures.
Freezing temperatures lower the impact strength of ferrous materials.
Always follow manufacturers instructions and Material Safety Data Sheet directions when using solvents.
Always make certain that personnel and facilities are protected from residual hazardous uids before disassembly of
any product.
Whenever leakage is detected from FMC Technologies products, remove them from service immediately to prevent
death, serious personal injury, and/or property damage.
SAFETY INSTRUCTIONS: The applications of FMC products are in working environments and systems which must be
properly designed and controlled. Safety procedures and policies MUST be clearly established by the user and followed.
Always use appropriate protective equipment.
FMC Technologies, Inc.
1803 Gears Road
Tel +1-281-260-2121
Fax +1-281-260-2122

2825 West Washington
Stephenville, Texas 76401
Toll Free 1-800-772-8582 (U.S.)
Tel +1-254-968-2181
Fax +1-254-968-5709
www.fmctechnologies.com/uidcontrol
Chiksan Lubricants
C hiksan lubricants are formulated for
year-round use in harsh, often severe
applications. Only occasional light
greasing with a small, hand-held grease
gun is required to keep Chiksan swivel
joints on the job.
NOTE: Excessive lubrication can cause the
swivel to bind, distort the anti-extrusion
ring, displace the packing, and expose the
bearing cavities to line pressure. Use only
enough lubricant to obtain smooth rotation.
Standard lubricant (No.7)

Calcium soap base lubricating grease
for general lubrication; available in 14-1/2
ounce cartridge for use with grease gun
and in 2, 5, 7-1/2, 25, and 50 pound
containers.
Melting point 205F

Solidification point 65F
Viscosity
(SSU @ 100F) 70
Flash Point 310F to 320F
Fire Point
API gravity
365F
29.5
Chiksan lubricants
High-temperature lubricant
(No. 11)
High-quality, general purpose
nonmelting grease with inorganic thicken-
ers as base; available in 2, 5,
7-1/2, 25, and 50 pound containers.
Melting point None

Viscosity
(SSU @ 100F) 145 to 150
Flash Point 500F
Fire Point 620F
API gravity 27.5
Silicone lubricant (No. 15)

Nonmelting silicone lubricant
Temperature range 40 to 400F

Melting point None
Viscosity
(SSU @ 100F) 950
Viscosity
(SSU @ 210F) 310
Flash Point 600F
13
FMC Integral Fittings
New lightweight designs
Forged construction with full traceability
Integral Weco wing union end connections
Unlimited plug valve manifold designs
ufacturi
an n
M
Quality
g
ISO-9001
Systems
er
C
tificatio
FMC Integral Fittings
N ow theres a new Lightweight Fittings combined to suit virtually any installation. manifolds for choke-and-kill, well testing,
family that is ideal for handling a complete Like other FMC flowline products, FMCs squeeze, flow back, and cementing applica-
range of well servicing fluids at cold working Integral Fittings come with full material tions. Unlimited manifold designs using FMCs
pressures to 20,000 psi. Available in 1- to traceability and can be supplied with Charpy advanced ULT and world proven DR Plug
4-inch sizes, FMC fittings feature high-quality impact values. Valves can be easily constructed. Because
forged construction with integral Weco wing FMCs new line of integral fittings are lighter
union end connections for a high-strength, Plug Valve Manifolds and smaller, you save valuable weight and
high-integrity connection every time. Tees, FMC Integral Fittings can be used in space regardless of manifold design.
elbows, crosses, wyes, and laterals can be combination with FMC Plug Valves to create
FMC Fittings Quick Reference Chart with Approximate Weights

Integral Weco Longsweep Block Elbows Tees
Fitting Wing Elbow
Sizes Union
Figure
No.
FxM lb. FxM lb. MxM lb. FxF lb. FxFxF lb. FxFxM lb. FxMxF lb. FxMxM lb. MxMxF lb. MxMxM lb.
1-inch 1502 P506048 CF P506053 CF P506061 CF P506069 CF P506076 CF P506083 CF P506087 CF P506093 CF P506100 CF
112-inch 1502 P506049 32 P506054 44 P506062 29 P506070 31 P506077 40 P505457 40 P506088 48 P506094 48 P506101 57
2-inch 602 3262554 22 P506050 27 P506055 33 P506063 22 P506071 29 P506078 33 P506084 33 P506089 38 P506095 38 P506102 42
1502 3260403 28 P503846 30 P506056 42 P506064 27 P503842 29 P503850 38 P503840 38 P503848 46 P505362 46 P505364 54
2002 CF CF P506051 CF P506057 CF P506065 CF P506072 30 P506080 42 P505584 42 P506090 54 P506096 54 P506103 66
3-inch 602 3259683 54 3267335 101 P506058 105 P506066 97 P506073 118 P506081 107 P506085 107 P506091 117 P506097 117 P506104 121
1502 3259845 51 3265950 102 P506059 106 P506067 99 3268575 118 3263821 111 3262298 111 3265538 125 3265947 125 3268629 132
4-inch 602 P506172 86 P506052 CF P506060 CF P506068 CF P506075 98 P506082 110 P506086 110 P506092 126 P506098 126 P506105 143
1002 3261102 89 3268033 CF 3268115 CF 3268113 CF P500631 99 P500633 114 3268031 114 P500632 134 P506099 134 P506106 154
Integral Weco Longsweep Crosses Laterals Wyes

Fitting Wing Elbow
Sizes Union
W
Figure
ec
o
No. Weco
Weco
MxM lb. FxFxFxF lb. FxFxMxF lb. FxFxMxM lb. FxMxMxF lb. FxMxMxM lb. MxMxMxM lb. MxFxF lb. FxFxF lb. MxFxF lb.
1-inch 1502 P506107 CF P506113 CF P506118 CF P506129 CF P506137 CF P506146 CF P506154 CF P506160 CF P506164 CF
112-inch 1502 P503531 70 3269120 76 P506119 CF P506130 CF P506138 CF P506147 CF P505434 62 P506166 CF
2-inch 602 P506171 27 P506108 58 P506114 62 3262655 52 P506131 52 P506139 68 P506148 71 P506155 50 3262652 28
1502 3261768 34 3257972 59 3257973 66 3258450 73 3258451 73 3257976 80 3257975 87 3261420 54 3208846 27
2002 CF CF 3267282 CF P506115 CF P506120 CF P506132 CF P506140 CF P506149 CF P506156 CF 3254106 28
3-inch 602 P506174 CF P506109 164 P506116 174 P506121 185 P506133 185 P506141 195 P506150 206 P501957 142 P502133 107 P506167 83
1502 P506175 CF P506110 164 3262415 178 P506122 192 P506134 192 P506142 206 P506151 220 3266805 150 P506161 110 3268701 94
4-inch 602 P506176 CF P506111 142 P504791 157 P506123 172 P506135 172 P506144 187 P506152 202 P506158 118 P506162 111 P506168 80
1002 P506177 CF P506112 145 P506117 161 P506124 181 P506136 181 P506145 200 P506153 217 P506159 124 P506163 104 P506169 84
Integral Fittings and Plug Valve Dimensional Data
2"-7.16"
3"-10.00"
4"-12.62" 1"-7.50" 1"-6.06"
2"-7.50" FxFxMxM 2"-6.06" FxFxM
3"-8.00" 3"-8.00"
4"-8.20" 4"-8.20"
2"-5.50"
3"-7.94"
4"-9.69" MxF Cross Tee
Longsweep 1"-12.12"
Elbow 2"-12.12"
3"-16.00"
4"-16.40"
1"-15.00"
2"-15.00"
3"-16.00"
1" -10 .0 0"

4"-16.40"
-1 .5 0"
2" "-14 4.0
0.5 0"
3 "-1
0"
4
1"-5.25"
1"-6.06" 2"-5.25"
MxF 3"-7.75" MxFxF MxFxF
2"-6.06"
3"-8.00" 4"-7.75"
4"-8.20"
Block Elbow
45 Lateral
1" -5. 50 "
Wye 1"-5.25"
-5 00 "
2" "-7. .50
.00 "
2"-5.25"
3 "-7
"
1"-15.75"
4
3"-6.50"
2"-15.75" 4"-6.50"
3"-21.00"
4"-21.00"
2"-7.16"
3"-10.00"
4"-12.62" 6.00" 7.88"
22.12"
14.47"
2"-5.13" 8.05"
3"-7.68"
4"-9.69"
MxM 2.62"
3.93" 5.00"
Longsweep
Elbow 15.69"
2" DR Plug Valve - 96 lbs.
3" ULT Plug Valve - 288 lbs.
ULT Manifold
DR Manifold
The amount of wing union engagement for 2" and 3" 1502 connections is All dimensions are for reference only. End-to-end dimensions are from male sub
.346" and .377" respectively. This overlap dimension must be considered when end to female sub end.
determining end-to-end lengths or centerline lengths of connected fittings.
FMC Corporation Scotland Mexico
Fluid Control Division FMC Corporation (U.K.) Ltd. FMC Equipo Petrolero S.A. de C.V.
Fluid Control Carretera a Buena Vista km. 2.8
Fluid Control Headquarters Wellington Road Industrial Park Ranchera Miguel Hidalgo
FMC Fluid Control Wellington Circle Villahermosa, Tabasco, Mexico
6677 North Gessner Road Aberdeen AB12 3JG, Scotland Phone: 011+52+93/50-0123
Houston, TX 77040 Phone: 011+44+1224/898-555 Fax: 011+52+93/50-1661
Phone: 713/510-6800 Fax: 011+44+1224/249-460
Fax: 713/510-6803 Venezuela
Singapore FMC Fluid Control de Venezuela, S.A.
Manufacturing Facility FMC South East Asia Pte. Ltd. Avenida Intercomunal
FMC Fluid Control 149 Gul Circle Frente Carretera L
2825 West Washington Singapore 629605 Los Morochas, Estado Zulia, Venezuela
P.O. Box 1377 Phone: 011+65/862-3659 Phone: 011+58+65/26901
Stephenville, TX 76401 Fax: 011+65/861-8251 Fax: 011+58+65/23406
Toll Free: 800/772-8582 (U.S.)
Phone: 254/968-2181 United Arab Emirates FMC Services and Supplies Oriente, S.A.
Fax: 254/968-5709 FMC International S.A. Fluid Control Division
Al Moosa Tower, 17th Floor Sector San Vicente
Eastern Box 3228 Carretera Nacional Via Puerto La Cruz
FMC Fluid Control Dubai, United Arab Emirates Al lad de la E/S Guarapiche II
130 St. Nazaire Road Phone: 011+971+4/310-948 Maturin, Estado Monagas, Venezuela
Broussard, LA 70518 Fax: 011+971+4/310-950 Phone: 011+58+92/220003
P.O. Box 3091 Fax: 011+58+92/220178
Lafayette, LA 70505 The Netherlands
Phone: 318/837-9263 FMC Fluid Control (Nederland) B.V.
Fax: 318/837-5844 Europalaan 16
Box 757
Western 2400 AT, Alphen a/d Rijn
FMC Fluid Control The Netherlands
1675 Broadway, Suite 1800 Phone: 011+31+172/470-024
Denver, CO 80202 Fax: 011+31+172/470-026
Phone: 303/623-4622
Fax: 303/623-7347 France
FMC Europe S.A.
Alaska Z.I. Molina LaChazotte
FMC Fluid Control 810 Rue George Sand
700 International Airport Rd 42350 La Talaudiere, France
Building A-1 Phone: 011+33+4/7747-5015
Anchorage, AK 99518 Fax: 011+33+4/7747-5014
Phone: 907/563-3990
Fax: 907/563-5810
West Texas
FMC Fluid Control
3500 West County Road North
Odessa, TX 79764
Phone: 915/550-2084
FAX: 915/366-8538
Copyright 1998, FMC Corporation

Printed in U.S.A., SW 5M, 8-98
IF-09-98
Chiksan
Longsweep Swivel Joints
Operating and Maintenance
Instructions
Standard Service Models:
LS-7, 3-inch
LS-10, 1-, 11/2-, 2- and 3-inch
LS-15, 1-, 11/2-, 2-, 3- and 4-inch
LS-20, 2- and 3-inch
Product Description
Product Description End Connections
Chiksan Longsweep swivel joints are made to handle a variety of Weco wing union end connections have pressure ratings that are
oilfield fluids, including cement, drilling mud, fracturing fluids, crude oil consistent with the swivel joint rating. Union parts with the same figure
and other abrasive well-treating materials. numbers are interchangeable. Mixing parts with different figure numbers is
hazardous and can cause wing union failure. Substituting parts other than
Several Longsweep styles are available. These configurations provide Weco voids pressure ratings.
flexibility in making piping connections at the wellhead, blowout When tightening union nuts, personnel must wear suitable eye
preventer stack, and at other pieces of equipment used in servicing or protection to protect against metal fragments that may be loosened from the
testing wells. surfaces of the nut or hammer.
Longsweep swivel joint components are made from low-alloy steel Use of excessive hammering force or overtightening can damage wing
and are heat-treated to achieve required strength for the rated working unions and must be avoided.
pressure. Threaded end connections are machined in accordance with API Line
Primary packings are elastomeric with a bonded metal anti-extrusion Pipe Thread (LPT) Standards. Threaded ends are limited to either 7,500 or
ring. 10,000 psi cold working pressure, depending on the model. Thread
All Longsweep swivels, except for the I- and 11/2-inch sizes, have a compound and power make-up must be used to achieve rated cold working
secondary 0-ring with a leak detector port between the primary and pressure and to prevent backoff when under pressure.
secondary seals. Torques for adequate make-up of line pipe threads are estimated
If leakage should occur through the packing, the self-relieving grease as follows:
retainer will prevent pressure accumulation in the ball race chamber.
Longsweep swivel joints are available with integral Weco wing union Swivel Joint Size, in. Torque, ft-lbs
end connections of corresponding pressure ratings. Some sizes are 1 250 to 400
available with female API line pipe threads. 1 1/2 500 to 800
Swivel joint size designations indicate nominal size only. Actual 2 1,000 to 1,400
inside diameters are as follows: 3 1,500 to 2,000
Swivel Joint Nominal Size Actual Size After proper make-up, pipe threads are distorted and will not meet
LS-10, LS-15 1-inch .88-inch 22 mm gauging standards if disassembled. When such threads are disengaged for
LS-10, LS-15 11/2-inch 1.3-inch 33 mm any reason, it is recommended that parts not be reused, but be replaced with
LS-10, LS-15 2-inch 1.88-inch 47 mm new ones having unused ends.
LS-20 2-inch 1.3-inch 33 mm FMC recommends that the complete system containing threaded
LS-7, LS-10, LS-15 3-inch 2.75-inch 70 mm swivel joints be tested as a unit to the highest pressure anticipated in service.
LS-20 3-inch 3-inch 75 mm The test should not exceed the rated cold working pressure. New swivel
LS-15 4-inch 3.5-inch 89 mm joints can be subjected to a one-time test at 11/2 times the rated pressure if
other equipment involved is compatible with the test pressure.
Longsweep swivel joints are not intended for service in assemblies,
fixtures, or machines which inhibit rotation about the centerline. Alignment
Pressure/Temperature Ratings and concentricity of bearings with the end connections require a total lack of
Longsweep swivel joints are available for service at 7,500 psi to constraint to assure dependable service.
20,000 psi cold working pressure. Pressure ratings are given on
nameplates and union nuts that are part of the specific assemblies.
NOTE: Nameplates are the primary way to Identify the pressure rating of Applications
a Longsweep swivel. They must not be removed, painted or otherwise Although Longsweep swivel joints can be rotated or oscillated while
obliterated. under fluid pressure, seal and bearing life may be dramatically shortened
if they are subjected to significant motion at high pressure. Chiksan swivel
Paint color* as originally provided by FMC indicates rated joints are not recommended for use under continuous rotary motion. Swivel
working pressure as follows: joint life and warranty will be limited if joints are subjected to continuous
oscillation at high pressure.
Light Blue 20,000 psi (1380 bar) When connecting swivels to pumps on vehicles, or when installing
Red 15,000 psi (1034 bar) swivels or fabricated loops into stationary fluid lines which are subject to
Black 10,000 psi (690 bar) vibration, the swivel joints must be oriented so that line flexibility is present
Brown 7,500 psi (517 bar) in all planes. Style 50 (2 swivels) or Style 10 (3 swivels) assemblies are
suited for most of these installations. Style 40 (1 swivel) assemblies are not
*IMPORTANT: Since swivels may be repainted a different color by normally used and are not suitable for use in these applications.
users, do not use color as a primary means of Identification. Care must be exercised when installing swivel joints to prevent
subsequent mechanical loading which might cause bearing damage. Typical
CAUTION: THE RATED WORKING PRESSURE IS NOT TO BE EXCEEDED services which require special thought and care include installation of piping
DURING FIELD SERVICE OR FIELD TESTING. from pump vehicles to lines on the ground and running of lines where trucks
or other vehicles could hit or run over the lines.
Factory pressure testing is limited to 3,000 psi to avoid damage to end Acids or other corrosive fluids may cause pitting of internal surfaces
connections. Testing at higher pressures may be arranged on customer and deterioration of packing. Use of inhibitors in these fluids and
request. Users may subject new swivel joints to a one-time hydrostatic shop thorough flushing of swivels after exposure to pressure are necessary to
test at 11/2 times the rated cold working pressure. minimize damage. Examination of swivel joints following each exposure is
The maximum operating temperature for swivels with nitrile packing recommended.
(FMC Compound 00) is 225F (107C). However, exposure to well fluids at Applied bending or tensile forces will result in stresses and ball-race
temperatures above 160F (71C) may accelerate deterioration of the loads which add to those induced by internal pressure. If loads are to be
elastomeric packing as a result of compression set, tearing, chemical attack applied, consult factory to determine limitations that may result.
or gas absorption. The minimum operating temperature is -20OF (-6C). Gases at high pressures (especially carbon dioxide and hydrogen
Assemblies consisting of components with different pressure ratings sulfide) tend to permeate elastomers, resulting in blistering or rupturing
are always limited to the lowest rating given on any individual component. when pressure is released. After known exposure to gas pressures above
2,000 psi, FMC recommends that swivels be examined frequently and
damaged packings replaced. See note on sour gas service below.
Leak Detection NOTE: Standard Longsweep swivels are not suitable for use In sour
Longsweep swivel joints, except for I- and 11/2-inch sizes, have a leak gas environment, because they are susceptible to stress
detector port on the shoulder of the female ball race section. Swivels are corrosion cracking. Special swivels conforming with NACE MR-01-75
shipped from the factory with a screw sealing the leak detector port. Users are available for sour gas service.
who wish to use the leak detector port must remove the screw.
1
Longsweep swivel joints are not recommended in applications where To prevent leakage, malfunctions resulting from internal wear,
rotating torque may be a critical factor. These swivels have relatively high packing degradation, or ball-race deterioration, the user must establish a
torque levels, especially at high pressures, and torque will vary as much as Preventive Maintenance and Inspection Program. This program must
50 percent between swivels. include: inspection of parts to detect loss of wall thickness which may result
Some Longsweep swivel joints come with external seals and ball plug in decreased pressure capacity; routine replacement of packings; and,
seals which permit use in submerged service. Before installing Longsweep regularly scheduled lubrication.
swivel joints underwater, consult FMC to make sure the proper swivel joint
is used. IMPORTANT: Longsweep swivel joints which exhibit a loss of wall
thickness exceeding 20 percent at any point must be taken out of service.
Wall thickness may be measured using visual, sonic or mechanical
Swivel Life and Preventive Maintenance means.
Because normal applications for Longsweep swivel joints involve
handling of abrasive or corrosive fluids at relatively high flow velocities, After handling acids or other corrosive fluids, swivels must be flushed
internal surfaces may be subject to accelerated deterioration as indicated out with water to prevent continued corrosion and deterioration when not in
by loss of wall thickness, pitting and wear on sealing surfaces, or possible service.
ball race damage if packing leakage was not detected early.
Repacking Instructions
Special Tools CAUTION: Use extreme care In removing old packing to prevent damage
Truarc pliers, awl or similar pointed tool, vise, screwdriver, pipe wrench tosealing surfaces.
Disassembly 7. Remove 0-ring from female component.

1. Remove ball plug snap rings using Truarc pliers. 8. Remove grease retainer from male component.
2. Remove ball plugs using awl. 9. Clean all parts with petroleum solvent.
3. Secure female component in vise with ball plug holes positioned over 10. Inspect parts for excessive wear, corrosion or other damage.
a suitable container. a. Inspect ball races for dents or grooves.
4. Rotate male component, using a pipe wrench if necessary. Ball b. Check male and female components for excessive erosion or
bearings should drop out. corrosion.
c. Carefully inspect the inside surfaces of elbows for evidence of
NOTE: It may be necessary to thin hardened lubricant with petroleum erosion or corrosion.
solvent.
WARNING: Replace all parts for which visual, ultrasonic, or other
5. Separate male and female components after ball bearings have Inspection means Indicate wall section wear or thinning in elbows or
been removed. straight sections. Such damage will result in severely reduced pressure
and structural capacity. Replace all parts that show evidence of damage
CAUTION: Do not damage machined surfaces when separating In the ball races, packing seal surfaces, or other areas. (See Swivel Life
components. Protect sealing surfaces at all times. and Preventive Maintenance.)
6. Carefully remove old packing from female packing chamber using 11. Sealing surfaces must be completely smooth. Remove minor scratches
screwdriver. or pitting by polishing with fine abrasive.
12. Reclean all parts after polishing to remove metal particles and
abrasives.
2
Assembly d. Repeat step c two more times, lubricating at each quarter turn.
1. Apply a thin coat of lubricant to ball races, sealing surfaces, new e. Check smoothness of rotation.
packing and 0-ring.
CAUTION: Excessive lubrication can cause swivel joint to bind, distort
CAUTION: Make sure correct lubricant Is used for intended service the anti-extrusion ring and displace the packing. Use only enough
conditions. (See Lubricant Data.) lubricant to obtain smooth rotation. If the swivel Is more difficult to rotate
after greasing than before, or If lubricant Is detected on Inside of primary
2. Install new packing in female component and 0-ring as required. packing, or If distortion of packing Is noted on Inner diameter,
disassemble joint and carefully Inspect all seals for damage. Replace
CAUTION: Anti-extrusion ring must face outward, toward ball races. damaged seals and any packing which has been distorted or displaced
Into the bore.
3. Place grease retainer on male component and position at extreme
end of machined surface so that it is clear of female end when parts 11. Remove grease fitting and reinstall lube plug.
are initially assembled.
CAUTION: Lip on ID of grease retainer must face away from ball races Packing Identification
when installed.
Unless otherwise specified on purchase order, or required for
4. Secure female component in vise with ball plug holes on top. application described on purchase order, FMC will supply nitrile packing
5. Insert male component into female component. with brass anti-extrusion ring (OOB).
6. Look through ball plug holes to align ball races.
7. Drop balls into races. Rotate male component and add balls until Compound code* Compound Anti-extrusion ring Designation
races are filled with the specified number of balls in each race.
00 Nitrile Brass OOB
CAUTION: Count the number of balls Installed in each race to be certain
that exactly the specified number are installed. Incorrect number will *Compound code appears on inside diameter of each packing.
cause binding or excessive wear and reduced pressure or structural
capacity. (Refer to Replacement Parts List for the specified model.)
Lubricant Data
8. Install grease retainer into groove in female component, using
screwdriver. Be certain the lip on ID of retainer faces outward when Lubricant Temperature range* Part number
installed.
9. Insert ball plugs. Standard -50OF (-46C) to 3115574
10. Insert ball plug snap rings. Lube No. 7 212-F (100C)
11. Lubricate bearings as follows:
a. Remove lube fitting plug and install grease fitting. For special service conditions, consult factory for lubrication
b. Use small, hand-held grease gun to force a small amount of recommendations.
lubricant through the fitting.
*Minimum temperature for OOB packing is -20F (-6C).
CAUTION: Standard lubricant Is FMC Chiksan No. 7. (See Lubricant Data.)
**FMC Chiksan lubricants are available in various container sizes. Consult
c. Rotate male component 90 degrees (quarter turn) and add more the Chiksan Swivel Joint Price List for part numbers.
grease.
3
Hazardous Conditions
CAUTION: Following Is a list of hazardous conditions which, If

not avoided as Indicated, may result In severe property
damage, serious Injury, or death.
Hazardous Conditions Means to Avoid Hazard
Use of incompatible union end connections on mating piping or Examine the union nut for identification marking to assure that Figure
equipment will result in catastrophic failure of the connection at pressures Numbers are identical. If not identical, do not use; consult factory.
far below the rated working pressure of the swivel or union.
Mating end components not manufactured by FMC Corporation may Carefully examine all components for FMC identification marking.
result in catastrophic failure of the connection at pressures far below the FMC Corporation cannot assure compatibility or performance of
rated working pressure of the FMC union or swivel. components not made by FMC.
Inadequate make-up of pipe threads may result in loosening of the pipe Carefully make-up all pipe thread connections as recommended by the
connection, leakage of toxic or flammable fluids, structural failure of American Petroleum Institute. Refer to torque recommendations on
the connection, or catastrophic failure under pressure. Make-up outside page 1. A hydrostatic test of the system at the rated working pressure is
a shop environment does not provide adequate control of torque, required prior to use in the field.
cleanliness, pipe compound, and thread engagement to assure leak-free
performance at the rated working pressure.
Assembly of the swivel into a system which inhibits the free rotation Do not assemble or fabricate the swivel into a system which fixes the
of the swivel about its centerline will cause binding of the bearings, centerlines of both the male and the female components of the swivel.
premature bearing failure, and possible structure-pressure load Precision tolerances will not alleviate the hazard described in lefthand
combinations. This may result in catastrophic failure or structure collapse. paragraph. See page I for further information.
Use of incorrect swivels in handling fluids containing Hydrogen Sulfide Use only Chiksan swivels specifically designated and identified for Sour
(Sour Gas) may result in stress corrosion cracking and catastrophic Gas service for handling these fluids. Consult FMC Fluid Control
failure of the swivel. Division regarding swivel joints for sour gas service.
Use of swivels at pressures above the rated working pressure will result in Include rated working pressure limitations in written operating
rapid deterioration of the bearing races and possible catastrophic failure procedures and train operators in the use of the procedures.
of the swivel.
Uncontrollable hazardous conditions may result from the use of eroded, Used or worn swivels must be destroyed to prevent inadvertent or
corroded, worn, or second-hand swivels, or the modification of swivels intentional reuse and potential injury to subsequent users. Do not attempt
by welding, machining, plating, heating or substitution of components not repair. A Preventive Maintenance and Inspection Program must be
made by FMC. initiated. (See page 2.)
Use of swivels in handling acids and corrosive fluids may cause pitting of The use of inhibitors in these fluids and thorough flushing of swivels
internal surfaces, localized wall section thinning, and seal deterioration. immediately after use is required to minimize damage. See Swivel Life
This may result in external leakage, structural weakening of the swivel, and Preventive Maintenance for important requirements.
and potential catastrophic failure.
Use of swivels after initial leakage has been detected may result in Inspect swivels frequently in the area of the leak detector port or grease
contaminated bearings, binding of the swivel, external leakage of seal. Immediately discontinue use and maintain swivel per Repacking
hazardous fluids, and the introduction of mechanical loads beyond the Instructions if leaks are detected. See Leak Detection feature and
capacity of the swivel. explanation of purpose on page 1.
Use of swivels in any of the following applications may result in In most cases, special swivels and special precautions are necessary to
hazardous conditions. Means of avoiding these hazards cannot be avoid misapplication and potential hazards. Do not use swivels in these
predetermined. applications without specific recommendations from FMC. Consult FMC
-Submerged or underwater service Fluid Control. See paragraphs on Submerged Applications, Temperature
-Application of external loads Limitations, and General Service on pages 1 and 2.
-Continuous rotation or oscillation
-Extended use at temperatures above 160F or below OF
-Handling radioactive materials
-Inaccessible locations or closed environments in which the eventual
leakage of the contained fluid may create a toxic or flammable condition
Impact loads, such as hammer blows, may cause failure of pressurized Avoid conditions which expose pressurized swivel joints to impact loads.
swivel joints.
4
FMC Corporation Scotland
Fluid Control Division FMC Corporation (U.K.) Ltd.
Web: www.fmcenergysystems.com Fluid Control
Email: fluid_control@fmc.com Wellington Road Industrial Park
Wellington Circle
Fluid Control Headquarters Aberdeen AB12 3JG, Scotland
FMC Fluid Control Phone: 011 + 44 + 1224/898-555
6677 North Gessner Road Fax: 011 + 44 + 1224/249-460
Houston, TX 77040
Phone: (1) 713/510-6800 Singapore
Fax: (1) 713/510-6803 FMC South East Asia Pte. Ltd.
149 Gul Circle
Manufacturing Facility Singapore 629605
FMC Fluid Control Phone: 011 + 65/ 862-3659
2825 West Washington Fax: 011 + 65/ 861-8251
P.O. Box 1377
Stephenville, TX 76401 United Arab Emirates
Toll Free: 800/772-8582 (U.S.) FMC International S.A.
Phone: (1) 254/968-2181 Al Moosa Tower, 17th Floor
Fax: (1) 254/968-5709 Box 3228
Dubai, United Arab Emirates
Eastern Phone: 011 + 971 + 4/310-948
FMC Fluid Control Fax: 011 + 971 + 4/310-950
130 St. Nazaire Road
Broussard, LA 70518 Mexico
P.O. Box 3091 FMC Equipo Petrolero S.A. de C.V.
Lafayette, LA 70505 Carretera a Buena Vista km. 2.8
Phone: (1) 318/837-9263 Ranchera Miguel Hidalgo
Fax: (1) 318/837-5844 Villahermosa, Tabasco, Mexico
Phone: 011 + 52 + 93/50-0123
Western Fax: 011 + 52 + 93/50-1661
FMC Fluid Control
1675 Broadway, Suite 1800 Venezuela
Denver, CO 80202 FMC Services and Supplies Occidente, S.A.
Phone: (1) 303/623-4622 Fluid Control Division
Fax: (1) 303/623-7347 Avenida Intercomunal
Diagonal Carretera "L"
West Texas Sector Los Morochas, #202
FMC Fluid Control Cludad Ojeda Edo Zulia, Venezuela
3500 West County Road North Phone: 011 + 58 + 65-26901
Odessa, TX 79764 Fax: 011 + 58 + 65-23406
Phone: (1) 915/550-2084
FAX: (1) 915/366-8538
Copyright 1984, FMC Corporation

Printed in U.S.A., SS 10M, 5-84
Chiksan Swivel Joints
ALL LONGSWEEP MODELS
STANDARD SERVICE
Tools Required
Trirace shown. Some
Truarc pliers, awl or similar pointed tool, vise, screwdriver
models have two races
DISASSEMBLY
1. Remove ball plug snap rings using Truarc pliers. 8. Clean all parts with petroleum solvent.
2. Remove ball plugs using awl or pointed tool. 9. Inspect parts for excessive wear, corrosion or other damage.
3. Secure female component in vise with ball plug holes positioned over a a. Inspect ball races for dents or grooves.
suitable container. b. Check male and female components for excessive erosion or
4. Rotate male component. Ball bearings should drop out. corrosion.
NOTE: It may be necessary to thin hardened lubricant with petroleum c. Carefully inspect the inside surfaces of elbows for evidence of
solvent. erosion or corrosion.
5. Separate male and female components after ball bearings have been WARNING: Longsweep Swivel Joints exhibiting a wall thickness
removed. below the minimum allowable shall be removed from service.
CAUTION: Do not damage machined surfaces when separating Replace all parts that show evidence of damage in the ball races,
components. Protect sealing surfaces at all times. sealing surfaces, or other areas.
6. Carefully remove old packing from female packing chamber using a screw- 10. Sealing surfaces must be completely smooth. Remove minor scratches or
driver. pitting by polishing with fine abrasive.
CAUTION: Use extreme care in removing old packing to prevent 11. Reclean all parts after polishing to remove metal particles and foreign
damage to sealing surfaces. matter.
7. Remove grease retainer and secondary O-ring seal from female
component except as indicated in Inset A.
ASSEMBLY
1. Apply a thin coat of lubricant to ball races, sealing surfaces and new 11. Lubricate bearings as follows:
packing. a. Install grease fitting
CAUTION: Make sure correct lubricant is used for intended service b. Use small, hand-held grease gun to force a small amount of
conditions. (See Lubricant Data). lubricant through the fitting.
2. Install new grease retainer in female component or on male. (See CAUTION: Make sure correct lubricant is used for intended service
inset A.) conditions (See Lubricant Data).
CAUTION: Retainer lip must face away from ball races. c. Rotate male component 90 degrees (quarter turn) and add more
grease through each fitting.
3. Install new secondary O-ring seal on male component.
d. Repeat step c (above) two more times, lubricating at each
4. Install new packing in female component packing chamber.
quarter turn.
CAUTION: Anti-extrusion ring must face outward, toward ball races. e. Check smoothness of rotation.
5. Secure female component in vise with ball plug holes on top. CAUTION: Excessive lubrication can cause swivel to bind, distort the
6. Insert male component into female component. anti-extrusion ring and displace the packing. Use only enough
7. Look through ball plug hole to align ball races. lubricant to obtain smooth rotation. If the swivel is more difficult to
8. Drop balls into races. Rotate male component and add balls until rotate after greasing than before, or if lubricant is detected on inside
all three races are filled with the proper number of balls.
FORM # 50052 (2-97)
of primary packing, or if distortion of packing is noted on inner

WARNING: Count the number of balls installed in each race to be diameter, disassemble joint and carefully inspect all seals for damage.
certain that the proper number of balls are installed. Incorrect Replace damaged seals and any packing which has been distorted or
number may cause binding or excessive wear and reduced pressure or displaced into the bore.
structural capacity. 12. Remove grease fitting and install lube fitting plug.
9. Insert ball plugs. (See Inset B for 3 XHTL.) 13. After assembly the swivel joint should be pressure tested to the
10. Insert ball plug snap rings. full rated pressure.
FEATURES AND REPLACEMENT PARTS
NO. GREASE LUBE BALL REPAIR PACKING BALL PLUG SINGLE PLUG
MODEL RACES RETAINER PLUG PLUG KIT SET SET SET
1 LS10, LS15 3 a d f 3143455 3143454 3143211 3142813
1-1/2 HPLS 2 b d f 3127210 3137068 3129000 3139416
1-1/2 LS10, LS15 3 a d f 3143327 3142960 3143211 CF
2 XHLS 2 c d f 3126627 3137070 3129001 3139418
2 LS10, LS15 3 a d f 3139666 3143979 3144007 3139418
2 EHLS 2 c d f 3127211 3137071 3129001 3139418
2 LS20 3 a d f 3144633 3144636 3144007 3139418
3 HPLS 2 c d g 3124431 3137074 3129004 3139421
3 XHTL 3 c e h 3122371 3137079 3129006 3139423
3 LS7.5, LS10, LS15 3 a d f 3144795 3144796 3144007 3139418
3 EHTL 3 c e h 3124644 3137081 3129007 3139424
3 LS20 3 a d f 3145398 3145262 3145264 CF
4 XHTL 3 a e j CF 3137083 3137086 CF
4 LS15 3 a d f 3145399 3145263 3145264 CF
4 LS10 3 a d f 3261027 3261023 3145264 CF
CF = Consult Factory
(a) Female groove, (b) 42 ring, (c) notched ring in male groove, (d) screw in body, (e) screw in ball plug,
(f) rubber plug, no seal, (g) rubber plug, nylon disc, (h) rubber plug, o-ring seal, (j) metal plug, o-ring seal.
PACKING IDENTIFICATION
Unless otherwise specified on purchase order, or required for application described on purchase
order, FMC will supply nitrile packing with brass anti-extrusion ring (OOB).
Compound
Code* Compound Anti-Extrusion Ring Designation
OO Nitrile Brass OOB
HH Fluorocarbon Rubber Stainless Steel HHS
*Compound code and part number appear on inside diameter of each packing.
LUBRICANT DATA
Lubricant Temperature Range Container* Part Number

Standard Swivel Joint Lubricant 50F to 212F 2-lb can 3115574
*For special service conditions, consult factory for lubrication recommendations.
NOTE:
Refer to FMC product catalogs, brochures and installation, operating and maintenance manuals for additional product safety
information or contact FMC at 800/772-8582.
Direct orders to sales offices at the following locations:

Division Headquarters Odessa, Texas Anchorage, Alaska LaTalaudiere, France Los Morochas, Venezuela
6677 North Gessner Road Phone: 915/550-2084 Phone: 907/563-3990 Phone: (33) 4/7747-5015 Phone: (58) 65/26901
Houston, Texas 77040 U.S.A. Fax: 915/366-8538 Fax: 907-563-5810 Fax: (33) 4/7747-5014 Fax: (58) 65/23406
Phone: 713/510-6800
Fax: 713/510-6803 Broussard, Louisiana Aberdeen, Scotland Singapore Maturin, Venezuela
http://www/fmc/com/Eteg Phone: 318/837-9263 Phone: (44) 1224/898-555 Phone: (65) 862-3659 Phone: (58) 92/220003
FORM # 50052 (2-97)
E-mail: fluid_control@fmc.com Fax: 318/837-5844 Fax: (44) 1224/249-460 Fax: (65) 861-8251 Fax: (58) 92/220178
FMC Fluid Control Division Denver, Colorado The Netherlands Dubai, United Arab Emirates Villahermosa, Mexico
2825 West Washington Phone: 303/623-4622 Phone: (31) 172/470-024 Phone: (971) 4/310-948 Phone: (52) 93/50-0123
P.O. Box 1377 Fax: 303-623-7347 Fax: (31) 172/470-026 Fax: (971) 4/310-950 Fax: (52) 93/50-1661
Stephenville, Texas 76401
Toll Free: 1-800-772-8582
Fax: 254/968-5709
Chiksan Swivel Joints
LONGSWEEP TRIPLESTEP MODELS
WITH STRAIGHT BORE SEAL (TS)
STANDARD SERVICE
Identification:
TripleStep Assemblies with Straight Bore Seals and TripleStep Assemblies
with Instream Packing can be differentiated as follows:
Model # Grooves machined in coupling end
3 TS-6, TS-10, TS-15 2
3 TSi-6, TSi-10, TSi-15 3
Tools Optional
A special seal installation/removal tool is available. (See Reverse Side.)
Tools Required
Truarc pliers, awl or similar pointed tool, vise, standard or locking pliers,
rubber mallet, large screwdriver
DISASSEMBLY
1. Locate the Longsweep TripleStep Swivel Joint in an appropriate 6. Separate male and female components after ball bearings have been
position so that the female portion of the joint is secure and the removed.
male portion is free to rotate. An appropriately sized bench vise
CAUTION: Do not damage machined surfaces when separating
works well for this.
components. Protect sealing surfaces at all times.
2. Remove the ball plug snap rings using Truarc pliers.
7. Carefully remove TS seal.
3. Remove ball plugs using an awl or pointed tool. Remove lube port
CAUTION: Use extreme care in removing old TS seal to prevent
screw with screwdriver.
damage to sealing surfaces of swivel joint components.
4. Secure female component in vise with ball plug holes positioned
8. Remove grease retainer O-ring and secondary O-ring seal from
downward over a suitable container.
male component.
5. Rotate male component. Ball bearings should drop out.
9. All components should be cleaned with solvent and inspected for
NOTE: It may be necessary to thin hardened lubricant with wear and/or corrosion.
petroleum solvent in order to remove balls.
ASSEMBLY
1. Inspect parts for excessive wear, corrosion or other damage. rubber mallet, or use option seal installation/removal tool.
a. Inspect ball races for dents or grooves. NOTE: TS seal is symmetrical and no inside/outside orientation is
b. Check male and female components for excessive erosion or required.
corrosion.
7. Secure female component in vise with ball plug holes on top.
c. Carefully inspect the inside surfaces of elbows and male ball 8. Carefully insert the male component into the female component. Avoid
race bore for evidence of erosion or corrosion. damaging the seal. Hold the male piece in place and insert one ball into
WARNING: Longsweep TripleStep Swivel Joints exhibiting a wall each ball plug hole. While pushing and rotating the male piece, pry one
thickness below the minimum allowable shall be removed from ball into each race with a large screwdriver.
service. Replace all parts that show evidence of damage in the ball 9. Drop balls into races. Rotate male component and add balls until all
races, sealing surfaces, or other areas. three races are filled with the correct number of balls.
2. Sealing surfaces must be completely smooth. Remove minor scratches WARNING: Count the number of balls installed in each race to be
or pitting by polishing with a fine abrasive or wire brush. Use SBES certain that the proper number are installed. Incorrect
seal if any pitting remains after polishing. number may cause binding or excessive wear and reduced
3. Reclean all parts after polishing to remove metal particles and foreign pressure or structural capacity.
matter. Apply a thin coat of lubricant to ball races, sealing surfaces, and 10. Insert ball plugs for races #1 and #2. Leave plug #3 out for greasing.
new packing.
NOTE: Due to the nature of the stepped race, ball plug on race #1 will
CAUTION: Make sure correct lubricant is used for intended service situate deeper than on race #2, which is deeper than race #3.
conditions. (See Lubricant Data).
RACE #1
(FORM 50098 5-98)
4. Install new grease retainer O-ring on male component.

5. Install new secondary O-ring on male component. NOTE: Both O-rings
are identical RACE #2
6. Lightly coat the new TS seal with lubricant and install it in the male
component seal pocket. Using a clean, flat board to protect the seal, RACE #3
press the TS seal into the pocket by sharply striking the board with a (Assembly continued next page)
ASSEMBLY contd.
11. Insert ball plug snap rings into plugs #1 and #2. c. Repeat step b (above) two more times.
12. Lubricate bearings by: d. Check smoothness of rotation.
a. Using a small, hand-held grease gun with grease fitting adapter to e. Install ball plug #3 and insert snap ring.
force small amount of lubricant through the lube port.
NOTE: Use only enough lubricant to obtain smooth rotation.
CAUTION: Make sure correct lubricant is used for intended service
conditions. (See Lubricant Data). f. Replace lube port screw.
13. After assembly, the swivel joint should be pressure tested to the full
b. Rotate male component 90 degrees (quarter turn) and add more rated working pressure.
grease.
REPLACEMENT PARTS
Model Ball Bearings Total Ball Ball Single
Required Reqd Set Plug Plug
Set Set
Race Race Race
#1 #2 #3
3 TS6, TS10, TS15 34 35 36 105 3267882 3144007 3139418
Model Seal Seal Repair TS Seal

Material Designation Kit(1) Seal Installation/Removal
Tool
3 TS6, TS10, TS15 PTFE SBTS 3267883 3267881 P504986
3 TS6, TS10, TS15 HNBR SBES P505490 P505489 P504986
Consult Factory for information on additional sizes.
Note 1: Repair kit contains (1) ball set; (1) seal; (1) ball plug set (3 plugs & 3 snap rings); (2) o-ring seals; and (1) lube plug.
LUBRICANT DATA
Lubricant Temperature Range Container Part Number
TS-115 corrosion - 50o F to 400o F 14-1/2 oz. tube 3267513
resistant grease
TS-115 corrosion - 50o F to 400o F 2-lb can 3267515
resistant grease
For special service conditions, consult factory for lubrication recommendations.
NOTE:
Refer to FMC product catalogs, brochures and installation, operating and maintenance manuals for additional product
safety information or contact FMC at 800/772-8582.
Direct orders to sales offices at the following location:

Division Headquarters FMC Fluid Control Division
6677 North Gessner Road 2825 West Washington
(FORM 50098 5-98)
Houston, Texas 77040 U.S.A. P.O. Box 1377

Phone: 713/510-6800 Stephenville, Texas 76401
Fax: 713/510-6803 Toll Free: 1-800-772-8582
http://www/fmc/com/Eteg Fax: 254/968-5709
E-mail: fluid_control@fmc.com E-mail: fluid_control@fmc.com
Safety & Technical Alert
Avoiding the Dangers of
Mismatching Swivel Joint
Components
FMCs Longsweep swivel joint product
line has been used in oilfield flowlines
since the 1960s. FMC has continued to
develop the Longsweep product line,
culminating with the introduction of
the TripleStep (TSi) swivel joint in the
mid-1990s. The TSi swivel joint
employs a stepped ball race design,
providing significantly improved
erosion life and higher swivel load
capacity over traditional non-
stepped race designs. This bulletin
addresses potentially serious
occurrences that could result from
mismatching swivel joint components
of different designs and/or
manufacturers.
WARNING
Using SPM 3" HD-LR swivel joint com-

ponents in FMC 3" TripleStep swivel joint
assemblies can cause damage to raceways,
potentially leading to swivel separation when
under pressure. Failure to avoid this condition
may result in death, serious personal injury
and severe property damage. TA012, March 2005 Rev. A
Avoiding the Dangers of Mismatching S
Gap in 3" No step between Male race interferes
ball race second and third race with female end
SPM 3" HD-LR FMC 3" TripleStep FMC 3" TripleStep SPM 3" HD-LR
male ball race end female ball race end male ball race end female ball race end
Figure 1: Dangerous Mismatch to be Avoided Figure 2: Mismatch Avoided
During the development of the TSi product The erroneous assembly of these compo-
offering, FMC evaluated all known potential nents may falsely give the impression of a
mismatch occurrences with its existing and proper assembly, since the swivel assem-
competitive products. The final TSi design bly may feel tight and hold pressure. This
minimizes the possibility of mismatch condition is made possible because the
occurrences. Consequently, attempts to two raceways closest to the packing of
assemble TSi components with older style both designs require the same number of
Longsweep swivels or competing product balls. However, the third male race of the
components are physically impossible. HD-LR swivel does not fully engage with
the female race of the TSi swivel. The third
Like the FMC 3" TSi swivel joint, the re- race does not help carry the axial load
cently introduced SPM 3" HD-LR swivel caused by internal pressure with the other
joint employs a stepped ball race feature. two raceways (Figure 1). While the
FMCs 3" TSi swivel joints employ a one- resulting assembly may give the false
ball step in raceway diameter between sense of a correct assembly and would
each of the three raceways. SPMs HD-LR likely contain pressure, the assembly would
swivel has a step between only two of the not be structurally sound. This condition
raceways. In addition to the stepped race would result in a swivel connection that is
similarities, the axial spacing between the unsafe and could potentially lead to cata-
raceways of the two models is very similar. strophic failure of the connection.
Because of these similarities, it is physically
possible to erroneously assemble a male Please note that it is also not possible to
race end of a SPM 3" HD-LR component assemble a male ball race end of an FMC
into the female race end of an FMC 3" TSi 3" TSi swivel component into a female ball
component (Figure 1). race end of an SPM 3" HD-LR swivel com-
ponent (Figure 2).
Swivel Joint Components
Environmental Three distinct grooves
seal on female Three distinct Three machined grooves for
steps on male easy TripleStep identification
piece
FMC 3" TripleStep FMC 3" TripleStep FMC 3" TripleStep FMC 3" TripleStep
male ball race end female ball race end male ball race end female ball race end
Figure 3: Matching Assembly Figure 4: Identification of TripleStep Swivel Joint
TSi swivel joint female ball race ends are WARNING

easily identified by three machined grooves
on the OD close to the environmental seal Never assemble swivel joint components
end (Figures 3 and 4). together that are not positively identified
as to the manufacturer, service and pres-
For help with specific questions regarding sure rating. Failure to do so can result in
identification of swivel joint components, a swivel connection that may fail under
contact FMC Technologies or your nearest pressure, which can lead to death, serious
representative. When product identification personal injury and severe property
is removed or is not discernible due to damage.
wear, damage or lack of information, the
affected components must be immediately WARNING
and permanently removed from service.
Do not suspend loads with a TripleStep
Swivel Joint. Externally applied binding
or tensile loads are additive to the loads
already induced by internal pressure.
WARNING Externally applied loads can result in
an overstress condition leading to
Use of non-FMC manufactured parts in catastrophic failure. If externally applied
Chiksan and Weco products may result loads are to be applied, consult factory for
in death, personal injury or property dam- limitations.
age. The use of non-FMC parts voids all
design, type, case, test and quality approv-
als by third-party certifying authorities and
may void product warranty.
WARNING
Failure to follow these safety warnings could - Use of FMC products in suspension
result in death, serious personal injury, and/or applications can result in over-stress
severe property damage. conditions leading to catastrophic failure.
If externally applied loads are anticipated,
Never mix or assemble components, parts or consult factory.
end connections with different pressure ratings. Always follow safe practices when manually
Mismatched conditions, including but not lifting and carrying products.
limited to that of a 2" Figure 1502 male sub end
connected to a 2" Figure 602 female sub, may Always select only appropriate product and
fail under pressure resulting in death, serious materials for the intended service:
personal injury or severe property damage. - Never expose standard service products to
Never use or substitute non FMC components sour gas fluids (Refer to NACE MR-01-75).
or parts in FMC products or assemblies. Do not interchange sour gas with standard
service components.
Never modify or repair FMC products in a
manner not specifically directed in instructions - Always use appropriate safety precautions
published by FMC Technologies. when working with ferrous products in
below freezing temperatures. Freezing
Never strike, tighten, loosen or attempt repairs temperatures lower the impact strength of
on pressurized components or connections. ferrous materials.
Never exceed the rated working pressure of Always follow manufacturers instructions and
the product. Material Safety Data Sheet directions when
Complete and proper make-up of components using solvents.
and connections is required to attain rated Always make certain that personnel and
working pressure. Always apply essential care, facilities are protected from residual hazardous
attention, handling and inspection to threaded fluids before disassembly of any product.
components before, during and after make-up.
Whenever leakage is detected from FMC
Never use severely worn, eroded or corroded Technologies products, remove them from
products. Contact FMC Technologies for more service immediately to prevent death, serious
information on how to identify the limits of personal injury, and/or property damage.
erosion and corrosion.
Never strike wing union nuts having severely
flattened and extruded ears. This condition
can result in flying debris leading to serious FMC has warned against the use of non-FMC
personal injury and must immediately be ad- manufactured parts in Chiksan and Weco
dressed by either grinding off extruded material products in previous technical alerts and
product literature. Please read and follow all
or removing the nut from service.
product instructions, warnings and cautions
Always follow safe practices when using when using, maintaining or repairing Chiksan
products in overhead applications. Products and Weco products. Technical alerts and
not properly secured could fall. product literature can be accessed at
www.fmctechnologies.com/fluidcontrol.
- Never exceed the load rating of lifting
devices on products or lifting equipment.
FMC Fluid Control FMC Fluid Control For additional copies of this document,
1803 Gears Road
2825 West Washington download PDF at:
Houston, TX 77067
Phone: 281/260-2121
P.O. Box 1377
Stephenville, TX 76401
www.fmctechnologies.com/fluidcontrol
Fax: 281/260-2122 Toll free: 800/772-8582 (U.S.)
Phone: 254/968-2181
Fax: 254/968-5709 Copyright 2005, FMC Technologies, Inc.
Doc No: OMS500000435
Rev: A Page 1 of 20
FCD OPERATING AND MAINTENANCE MANUAL, TRIPLESTEP

SWIVEL JOINT
Rev ECN No. Date Reviewed By Approved By Status

A 5014302 1 5 -J u l-0 5 Soltau, James Douglas, Don RELEASED
Summary:
This document covers the safe operation, maintenance and repair of the TripleStep
Swivel Joint (model designation TSi) product line.
Subject to contractual terms and conditions to the contrary, this document and all the information contained herein are the confidential and exclusive
property of FMC Technologies, and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by FMC.
Rev: A Page 2 of 20
Table of Contents
Section Title Page
1.0 Operating Instructions ................................................................6
1.1 Product Description .......................................................................6
1.2 Service Applications ......................................................................7
1.3 Pressure/Temperature Rating .......................................................7
1.4 Motion, Rotation and External Loads ............................................8
2.0 Flow ..............................................................................................9
2.1 Installation .....................................................................................9
3.0 Maintenance Instructions .........................................................11
3.1 Identification ................................................................................11
3.2 Preventive Maintenance ..............................................................11
3.3 Periodic Inspection ......................................................................12
3.4 Disassembly ................................................................................12
3.5 Repair..........................................................................................13
4.0 Hazardous Conditions ..............................................................16
5.0 Replacement Parts ....................................................................18
6.0 Warnings and Safety Instructions ...........................................19
Rev: A Page 3 of 20
List of Tables
Tables Page
Table 1: Available models covered in this manual ............................................................7
Table 2: Flow Rates at Maximum Recommended Velocity of 40 Feet Per Second ...........9
Table 3: Hazardous Condition Avoidance .......................................................................17
Table 4: Ball Bearing and Ball Retainer Plug Sets ..........................................................18
Table 5: Repair Sets and Packing Sets ..........................................................................18
Table 6: Lubrication Data................................................................................................18
Rev: A Page 4 of 20
List of Figures
Figures Page
Figure 1: TripleStep Swivel Joint Styles............................................................................6
Figure 2: TripleStep Swivel Exploded View.....................................................................11
Figure 3: Stepped Ball Races Create Different Ball Retainer Plug Depths.....................15
Figure 4: Cross-section of Assembled TripleStep Swivel ................................................16
Rev: A Page 5 of 20
Abbreviations
The following abbreviations are used throughout this procedure.
Abbreviation Description
TSi TripleStep Swivel Joint with instream packing
CWP Cold Working Pressure
GPM Gallons per minute
BBL US Barrels (42 gallons)
Rev: A Page 6 of 20
1.0 Operating Instructions
1.1 Product Description

The FMC Technologies TripleStep Swivel Joint is a high performance swivel available in
a variety of swivel style configurations (see Figure 1 below). Its long radius forged and
bent elbows, high capacity bearings and instream primary seal are all specially
designed to overcome many previous swivel joint limitations.
Figure 1: TripleStep Swivel Joint Styles
Rev: A Page 7 of 20
The Model designations covered in the manual are as listed in the table immediately
below.
Table 1: Available models covered in this manual
Pressure Rating, Bore Size

End
Model Color CWP Inches
Connection
PSI (Bar) (mm)
3 TSi-6 Silver 6,000 (414) 3 Fig. 602 2.75 (70)

3 TSi-10 Black 10,000 (690) 3 Fig. 1002 2.75 (70)
3 TSi-15 Red 15,000 (1034) 3 Fig. 1502 2.75 (70)
3 TSi-20 Light Blue 20,000 (1380) 3 Fig. 2002 3.00 (76)
4 TSi-10 Black 10,000 (690) 4 Fig. 1002 3.75 (95)
4 TSi-15 Red 15,000 (1034) 4 Fig. 1502 3.50 (89)
1.2 Service Applications

The TripleStep Swivel Joint is made to handle a variety of oilfield fluids including
cements, fracturing fluids, drilling muds, crude oil and other abrasive fluids. It is
intended to facilitate the installation of temporary or permanent flow lines and to absorb
movement caused by pressure pulsation and thermal expansion,
1.3 Pressure/Temperature Rating

The pressure ratings and corresponding color coding for the various models are shown
in Table 1, above. The cold working pressure (CWP) is the maximum internal pressure
that is anticipated by design to be applied in the working environment (field application).
Assemblies consisting of components of different pressure ratings are always limited to
the lowest rate given on any individual component.
DO NOT EXCEED THE RATED WORKING PRESSURE OF THE

PRODUCT!
WARNING
The TripleStep Swivel Joint has a basic operating temperature rating of -20F (-29C) to
240F (116C). When operating with fluids above 185 F for extended periods the life of
the environmental o-ring seals and wing union seal ring may be reduced. Consult
factory for non-standard seals.
Rev: A Page 8 of 20
1.4 Motion, Rotation and External Loads

The FMC Technologies TripleStep Swivel Joint is not designed for continuous rotation
or oscillation.
CONTINUOUS ROTATION OR OSCILLATION MAY REDUCE THE

SWIVEL JOINT SEAL AND BEARING LIFE.
CAUTION
The swivel joint can absorb relative motion only if the styles and orientation of the
swivels allow sufficient degrees of freedom. The swivels must be oriented to provide
the required flexibility in each plane of motion and axis of rotation. When connecting
swivels between fixed end connections, regardless of subsequent relative motion,
enough freedom must exist to properly make the connection without loading or binding
the swivel. Consult factory for additional information on recommended line layout.
THE STYLES AND ORIENTATION OF SWIVELS DETERMINE THE

DEGREES OF FREEDOM AND MAGNITUDE OF RELATIVE MOTION
POSSIBLE. INCORRECT ORIENTATION AND SUBSEQUENT
WARNING BINDING CAN CAUSE BEARING FAILURE.
Externally applied binding or tensile loads are additive to the loads already induced by
internal pressure. Externally applied loads can result in an over-stress condition and
catastrophic failure. If externally applied loads are to be applied, consult factory for
limitations. For guidance on line layout in well service pumping applications, refer to
Engineering Bulletin Number 124C.
DO NOT SUSPEND LOADS WITH A TRIPLESTEP SWIVEL JOINT
WARNING
Rev: A Page 9 of 20
2.0 Flow
The FMC Technologies TripleStep Swivel Joint is specially designed to minimize the
erosive effects of abrasive fluids at high flow rates. Bore sizes should be selected to
minimize the fluid velocity when handling abrasive fluids. Fluid flow velocities greater
than 40 feet per second (12 m/sec) of abrasive fluid will result in accelerated erosion
and premature failure. See chart below for maximum recommended flow rates.
Table 2: Flow Rates at Maximum Recommended Velocity of 40 Feet Per Second
Size and Model GPM BBL/Min. Liter/Min.
3 TSi-6, TSi-10, TSi-15 741 17.6 2,803

3 TSi-20 881 20.9 3,336
4 TSi-10 1377 32.7 5,212
4 TSi-15 1200 28.5 4,540
Refer to FMC Technologies Engineering Bulletin Number 102 for minimum allowable
wall thickness values for worn swivel joints.
TRIPLESTEP SWIVEL JOINTS EXHIBITING WALL THICKNESS

BELOW THE MINIMUM ALLOWABLE SHALL BE REMOVED FROM
SERVICE.
WARNING
TO AVOID PITTING AND CORROSION, ALL WORKING FLUIDS,

ESPECIALLY ACIDS AND OTHER CORROSIVES SHOULD BE
FLUSHED THOROUGHLY AFTER EACH USE.
CAUTION
2.1 Installation
Standard practices should used when installing TripleStep Swivel Joints in a system.
There include:
1. Check that the orientation allows for the required degrees of freedom and
flexibility for the relative motion.
2. Check that the end connections are the same size, figure number and pressure
rating.
Rev: A Page 10 of 20
DO NOT CONNECT DIFFERENT SIZE, FIGURE NUMBER OR

PRESSURED RATED WING UNIONS AS THIS MAY RESULT IN
DEATH, SERIOUS PERSONAL INJURY AND/OR SEVERE
WARNING PROPERTY DAMAGE.
3. Clean and lubricate the wing union threads and check that the seal ring is present
and undamaged.
4. Fully tighten with wing union connection before applying any pressure.
WHEN TIGHTENING WING UNION NUTS, PERSONNEL MUST WEAR

SUITABLE EYE PROTECTION TO PROTECT AGAINST METAL
FRAGMENTS THAT MAY BE LOOSENED FROM THE SURFACE OF
WARNING THE NUT OR HAMMER.
DO NOT STRIKE, TIGHTEN OR LOOSEN PRESSURIZED

COMPONENTS OR CONNECTIONS.
WARNING
3.0 Maintenance Instructions
Figure 2: TripleStep Swivel Exploded View
3.1 Identification
FMC Technologies TripleStep assemblies with instream packing are differentiated from
other swivel joint models be the presence of three grooves machined in the couple end
of each swivel connection. Other swivel joint models will have a different number of
grooves or none at all.
3.2 Preventive Maintenance

The TripleStep Swivel Joint is constructed with superior sealing and corrosion
protection. Little preventive maintenance is therefore required, but should include the
following:
Working fluids, especially acids, should be thoroughly flushed from the swivel after each
use to avoid pitting, corrosion and exposure to personnel.
Leaks should be repaired immediately.
IF ANY LEAKAGE IS DETECTED FROM A TRIPLESTEP SWIVEL

JOINT, REMOVE IT FROM SERVICE IMMEDIATELY TO PREVENT
POTENTIAL PERSONNEL INJURY AND/OR DAMAGE.
WARNING
The sealed bearing construction does not normally require periodic greasing. A grease
port is provided for extreme service conditions where periodic greasing may be
desirable.
3.3 Periodic Inspection

Periodic inspection shall be undertaken to verify the condition of the swivel joint
assembly. The frequency of inspection should be matched to the frequency of use and
severity of the application. The periodic inspection should include:
Visual inspection of end connections, looking for general corrosion, end
connection thread wear and/or corrosion, and any damage or deformations.
Wall thicknesses should be verified and compared to acceptable minimums.
Determine if any leakage has occurred and if so, repair.
Inspect free rotation of the swivel and that there are no missing parts.
3.4 Disassembly
Tools required: Truarc pliers, awl or similar pointed tool, vise, standard or locking pliers,
rubber mallet, and large screwdriver.
1. Locate the TripleStep Swivel Joint in an appropriate position so that the female
portion of the joint is secure and the male portion is free to rotate. An
appropriately sized bench vise works well for this.
3. Remove ball plugs using an awl or pointed tool.
4. Remove lube port screw with screwdriver.
5. Secure female component in vise with ball plug holes positioned downward over a
suitable container.
IT MAY BE NECESSARY TO THIN HARDENED LUBRICANT WITH

PETROLEUM SOLVENT IN ORDER TO REMOVE BALLS.
NOTE
7. Separate male and female components after ball bearings have been removed.
DO NOT DAMAGE MACHINED SURFACES WHEN SEPARATING

COMPONENTS. PROTECT SEALING SURFACES AT ALL TIMES.
CAUTION
8. Carefully remove old packing from packing gland using a screwdriver.
USE EXTREME CARE IN REMOVING OLD PACKING TO PREVENT

DAMAGE TO SEALING SURFACES OF SWIVEL JOINT
COMPONENTS.
CAUTION
9. Remove grease retainer O-ring and secondary O-ring seal from male component.
10. All components should be cleaned with solvent and inspected for wear and/or
corrosion.
3.5 Repair
1. Inspect parts for excessive wear, corrosion or other damage.
a. Inspect ball races for dents or grooves.
b. Check male and female components for excessive erosion or

corrosion.
c. Carefully inspect the inside surfaces of elbows and male ball race
bore for evidence of erosion or corrosion.
TRIPLESTEP SWIVEL JOINTS EXHIBITING A WALL THICKNESS

SERVICE. REPLACE ALL PARTS THAT SHOW EVIDENCE OF
DAMAGE IN THE BALL RACES, SEALING SURFACES, OR OTHER
WARNING AREAS.
2. Sealing surfaces must be completely smooth. Remove minor scratches or pitting

by polishing with a fine abrasive or wire brush.
3. Reclean all parts after polishing to remove metal particles and foreign matter.
Apply a thin coat of lubricant to ball races, sealing surfaces, and new packing.
MAKE SURE CORRECT LUBRICANT IS USED FOR INTENDED

SERVICE CONDITIONS.
CAUTION
5. Install new secondary O-ring on male component.
THE GREASE RETAINER AND SECONDARY O-RINGS ARE

IDENTICAL.
NOTE
6. Lightly coat the new packing with lubricant and install it in the coupling end
component packing gland.
ANTI-EXTRUSION RING MUST FACE OUTWARD, TOWARD BALL

RACES.
CAUTION
8. Carefully insert the male component into the female component. Avoid damaging
the packing. Hold the male piece in place and insert one ball into each ball plug
hole. While pushing and rotating the male piece, pry one ball into each race with a
large screwdriver.
9. Drop balls into races. Rotate male component and add balls until all three races
are filled with the correct number of balls.
COUNT THE NUMBER OF BALLS INSTALLED IN EACH RACE TO BE

CERTAIN THAT THE PROPER NUMBER ARE INSTALLED.
INCORRECT NUMBER MAY CAUSE BINDING OR EXCESSIVE WEAR
WARNING AND REDUCED PRESSURE AND STRUCTURAL CAPACITY.
10. Insert ball plugs for races #1 and #2. Leave plug #3 out for greasing.
DUE TO THE NATURE OF THE STEPPED RACE, BALL PLUG ON

RACE #1 WILL SITUATE DEEPER THAN ON RACE #2, WHICH IS
DEEPER THAN RACE #3.
NOTE
Figure 3: Stepped Ball Races Create Different Ball Retainer Plug Depths
11. Insert ball plug snap rings into plugs #1 and #2.
a. Remove lube port plug screw and install grease fitting.
b. Using a small, hand-held grease gun with grease fitting adapter to

c. Rotate male component 90 degrees (quarter turn) and add more

grease.
d. Repeat step c (above) two more times.
e. Check smoothness of rotation.
f. Install ball plug #3 and insert snap ring.
g. Replace lube port screw.

SERVICE CONDITIONS.
CAUTION
EXCESSIVE LUBRICATION CAN CAUSE SWIVEL TO BIND. USE

ONLY ENOUGH LUBRICANT TO OBTAIN SMOOTH ROTATION.
CAUTION
13. After assembly, the swivel joint should be pressure tested to the full rated working
pressure.
Figure 4: Cross-section of Assembled TripleStep Swivel
4.0 Hazardous Conditions
FOLLOWING IS A LIST OF HAZARDOUS CONDITIONS SPECIFIC TO

USE OF SWIVEL JOINTS WHICH, IF NOT AVOIDED AS INDICATED,
MAY RESULT IN DEATH, SERIOUS PERSONAL INJURY OR SEVERE
WARNING PROPERTY DAMAGE.
Table 3: Hazardous Condition Avoidance
Hazardous Conditions Means to Avoid Hazard
Use of incompatible end connections on mating Examine the end connections for identification
piping or equipment may result in catastrophic failure marking to ensure that they are identical. If not
of the connection at pressures far below the rated identical, do not use; consult the factory.
working pressure of the TripleStep Swivel Joint.
Mating end components not manufactured by FMC or Carefully examine all components for
its licensees may result in catastrophic failure of the manufacturers identification marking. FMC
connections at pressures far below the rated working Technologies cannot assure compatibility or
pressure of the FMC component. performance of components of other
manufacturers.
Assembly of the TripleStep Swivel Joint into a system Do not assemble or fabricate the TripleStep
which inhibits the free rotation of the joint about its Swivel Joint into a system which fixes the
centerline will cause binding of the bearings and centerlines of both the male and female
premature bearing failure under possible structure/ components of the joint. Precision tolerances
pressure load combinations. This may result in will not alleviate the hazard described in left
catastrophic failure or structure collapse. hand paragraph.
Use of TripleStep Swivel Joints in unsupported Refer to API and IADC Safety Bulletins.
overhead applications is not recommended.
Use of TripleStep Swivel Joints at pressures above Include rated working pressure limitations in
the rated working pressure will result in rapid written operating procedures and train
deterioration of the bearing races and possible operators in the use of the procedures.
catastrophic failure of the joint.
Uncontrollable hazardous conditions may result from Used or worn TripleStep Swivel Joints must be
the use of eroded, corroded, worn, or "second hand" destroyed to prevent inadvertent or intentional
joints, or the modification of TripleStep Swivel Joints reuse and potential injury to subsequent users.
by welding, machining, plating, heating or substitution An inspection program must be initiated.
of components not made by FMC Technologies or its
licensees.
Use of TripleStep Swivel Joints in handling acids and The use of inhibitors in these fluids and
corrosive fluids may cause pitting of internal thorough flushing of TripleStep Swivel Joints
surfaces, localized wall section thinning, and seal immediately after use is required to minimize
deterioration. This may result in external leakage, damage.
structural weakening of the joint, and potential
catastrophic failure.
Use of TripleStep Swivel Joints after initial leakage Inspect TripleStep Swivel Joints for signs of
has been detected may result in contaminated leakage. Immediately discontinue use,
bearings, binding of the joint, external leakage of disassemble and repair if leakage is detected.
hazardous fluids, and the introduction of mechanical
loads beyond the capacity of the joint.
Impact loads, such as hammer blows, may cause Avoid conditions which expose pressurized
failure of pressurized TripleStep Swivel Joints. TripleStep Swivel Joints to impact loads.
Use of standard service TripleStep Swivel Joints in Use only Chiksan swivel joints specifically
handling of fluids containing hydrogen sulfide (sour) designated for Sour Gas Service. Consult FMC
gas may result in stress corrosion, cracking and Technologies regarding swivel joints for Sour
catastrophic failure of the swivel joint. Gas Service.
5.0 Replacement Parts
Table 4: Ball Bearing and Ball Retainer Plug Sets
Ball Bearings Single

Total Ball
Required Ball Ball
Size and Model Balls Plug
Set Plug
Race Race Race Reqd Set
Set
#1 #2 #3
3 TSi-6, TSi-10,
34 35 36 105 3267882 3144007 3139418
TSi-15
3 TSi-20 26 27 28 81 P530012 P530013 P530018
4 TSi-10 31 32 33 96 P516999 P516998 P516997
4 TSi-15 26 27 28 81 P530012 P530013 P530018
Table 5: Repair Sets and Packing Sets
Packing Instream
Size and Model Repair Kit (1)
Material Packing Set
3 TSi-6, TSi-10, TSi-15 00/Brs P505433 P505432

3 TSi-20 00/Brs P530020 P530022
4 TSi-10 00/Brs P516116 P516117
4 TSi-15 00/Brs P530019 P530021
Note 1: Repair kits include (1) ball set; (1) instream packing; (1) ball
plug set includes 3 ball plugs and snap rings; (2) O-ring seals; and
(1) lube port plug screw
Table 6: Lubrication Data
TS-115 Corrosion -50F (-46C) to 14 oz. tube 3267513

Resistant Grease 400F (204C) 2-lb can 3267515
6.0 Warnings and Safety Instructions

FMC Technologies cannot anticipate all of the situations a user may encounter while
installing and using FMC products. Therefore, the user of FMC products MUST know
and follow all applicable industry specifications and practices on the safe installation
and use of these products. For additional safety information, refer to FMC Technologies
product catalogs, product brochures and installation, operating and maintenance
manuals, which can be accessed at www.fmcfluidcontrol.com, or contact FMC
Technologies at 800/772-8582.
FAILURE TO FOLLOW THESE SAFETY WARNINGS COULD

RESULT IN DEATH, SERIOUS PERSONAL INJURY, AND/OR
SEVERE PROPERTY DAMAGE.
WARNING
1. Never mix or assemble components, parts or end connections with different

pressure ratings. Mismatched conditions, including but not limited to that of a 2
Figure 1502 male sub end connected to a 2 Figure 602 female sub, may fail
under pressure resulting in death, serious personal injury or severe property
damage.
2. Never use or substitute non FMC components or parts in FMC products or

assemblies.
3. Never modify or repair FMC products in a manner not specifically directed in

instructions published by FMC Technologies.
4. Never strike, tighten, loosen or attempt repairs on pressurized components or

connections.
5. Never exceed the rated working pressure of the product.
6. Complete and proper make-up of components and connections is required to

attain rated working pressure. Always apply essential care, attention, handling
and inspection to threaded components before, during and after make-up.
7. Never use severely worn, eroded or corroded products. Contact FMC

Technologies for more information on how to identify the limits of erosion and
corrosion.
8. Never strike wing union nuts having severely flattened and extruded ears. This
condition can result in flying debris leading to serious personal injury and must
immediately be addressed by either grinding off extruded material or removing the
nut from service.
9. Always follow safe practices when using products in overhead applications.

Products not properly secured could fall.
Never exceed the load rating of lifting devices on products or lifting equipment.
Use of FMC products in suspension applications can result in over-stress

conditions leading to catastrophic failure. If externally applied loads are
anticipated, consult factory.
10. Always follow safe practices when manually lifting and carrying products.
11. Always Select only appropriate product and materials for the intended service:
Never expose standard service products to sour gas fluids. (Refer to NACE
MR0175). Do not interchange sour gas with standard service components.
Always use appropriate safety precautions when working with ferrous products in
below freezing temperatures. Freezing temperatures lower the impact strength of
ferrous materials.
12. Always follow manufacturers instructions and Material Safety Data Sheet
directions when using solvents.
13. Always make certain that personnel and facilities are protected from residual
hazardous fluids before disassembly of any product.
14. Whenever leakage is detected from FMC Technologies products, remove them
from service immediately to prevent death, serious personal injury, and/or
property damage.
SAFETY INSTRUCTIONS: The applications of FMC products are in working

environments and systems which must be properly designed and controlled. Safety
procedures and policies MUST be clearly established by the user and followed. Always
use appropriate protective equipment
Doc No: MSP500000436
Rev: A Page 1 of 8
REPACKING GUIDE , TRIPLESTEP (TSI) SWIVEL JOINT
Rev ECN No. Date Reviewed By Approved By Status

A 5014302 1 5 -J u l-0 5 Soltau, James Douglas, Don RELEASED
Summary:
This document provides repair instructions for the TripleStep (TSi) Swivel Joint product
line and is to be included with repair kits and spare parts sets.
Rev: A Page 2 of 8
NOTES:
Rev: A Page 3 of 8
TripleStep Swivel Joint Repair Instructions:

3 TSi-6, TSi-10, TSi-15, TSi-20
4 TSi-10, TSi-15
Standard Service
1.0 Disassembly
Tools required: Truarc pliers, awl or similar pointed tool, vise, standard or locking pliers,
rubber mallet, and large screwdriver.
1. Locate the TripleStep Swivel Joint in an appropriate position so that the female
portion of the joint is secure and the male portion is free to rotate. An
appropriately sized bench vise works well for this.
3. Remove ball plugs using an awl or pointed tool.
4. Remove lube port screw with screwdriver.
5. Secure female component in vise with ball plug holes positioned downward over a
suitable container.
Rev: A Page 4 of 8
IT MAY BE NECESSARY TO THIN HARDENED LUBRICANT WITH

PETROLEUM SOLVENT IN ORDER TO REMOVE BALLS.
NOTE
7. Separate male and female components after ball bearings have been removed.
DO NOT DAMAGE MACHINED SURFACES WHEN SEPARATING

COMPONENTS. PROTECT SEALING SURFACES AT ALL TIMES.
CAUTION
8. Carefully remove old packing from packing gland using a screwdriver.
USE EXTREME CARE IN REMOVING OLD PACKING TO PREVENT

DAMAGE TO SEALING SURFACES OF SWIVEL JOINT
COMPONENTS.
CAUTION
9. Remove grease retainer O-ring and secondary O-ring seal from male component.
10. All components should be cleaned with solvent and inspected for wear and/or
corrosion.
2.0 Repair
1. Inspect parts for excessive wear, corrosion or other damage.
a. Inspect ball races for dents or grooves.
b. Check male and female components for excessive erosion or

corrosion.
Rev: A Page 5 of 8
c. Carefully inspect the inside surfaces of elbows and male ball race
bore for evidence of erosion or corrosion.
TRIPLESTEP SWIVEL JOINTS EXHIBITING A WALL THICKNESS

SERVICE. REPLACE ALL PARTS THAT SHOW EVIDENCE OF
DAMAGE IN THE BALL RACES, SEALING SURFACES, OR OTHER
WARNING AREAS.
2. Sealing surfaces must be completely smooth. Remove minor scratches or pitting

by polishing with a fine abrasive or wire brush.
3. Reclean all parts after polishing to remove metal particles and foreign matter.
Apply a thin coat of lubricant to ball races, sealing surfaces, and new packing.

SERVICE CONDITIONS.
CAUTION
5. Install new secondary O-ring on male component.
THE GREASE RETAINER AND SECONDARY O-RINGS ARE

IDENTICAL.
NOTE
6. Lightly coat the new packing with lubricant and install it in the coupling end
component packing gland.
ANTI-EXTRUSION RING MUST FACE OUTWARD, TOWARD BALL

RACES.
CAUTION
Rev: A Page 6 of 8
8. Carefully insert the male component into the female component. Avoid damaging
the packing. Hold the male piece in place and insert one ball into each ball plug
hole. While pushing and rotating the male piece, pry one ball into each race with a
large screwdriver.
9. Drop balls into races. Rotate male component and add balls until all three races
are filled with the correct number of balls.
COUNT THE NUMBER OF BALLS INSTALLED IN EACH RACE TO BE

CERTAIN THAT THE PROPER NUMBER ARE INSTALLED.
INCORRECT NUMBER MAY CAUSE BINDING OR EXCESSIVE WEAR
WARNING AND REDUCED PRESSURE AND STRUCTURAL CAPACITY.
10. Insert ball plugs for races #1 and #2. Leave plug #3 out for greasing.
DUE TO THE NATURE OF THE STEPPED RACE, BALL PLUG ON

RACE #1 WILL SITUATE DEEPER THAN ON RACE #2, WHICH IS
DEEPER THAN RACE #3.
NOTE
Above: Stepped Ball Races Create Different Ball Retainer Plug Depths
11. Insert ball plug snap rings into plugs #1 and #2.
a. Remove lube port plug screw and install grease fitting.
Rev: A Page 7 of 8
b. Using a small, hand-held grease gun with grease fitting adapter to

c. Rotate male component 90 degrees (quarter turn) and add more

grease.
d. Repeat step c (above) two more times.
e. Check smoothness of rotation.
f. Install ball plug #3 and insert snap ring.
g. Replace lube port screw.

SERVICE CONDITIONS.
CAUTION
EXCESSIVE LUBRICATION CAN CAUSE SWIVEL TO BIND. USE

ONLY ENOUGH LUBRICANT TO OBTAIN SMOOTH ROTATION.
CAUTION
13. After assembly, the swivel joint should be pressure tested to the full rated working
pressure.
Figure 4: Cross-section of Assembled TripleStep Swivel
Rev: A Page 8 of 8
3.0 Replacement Parts
Ball Bearing and Ball Retainer Plug Sets
Ball Bearings Single

Total Ball
Required Ball Ball
Size and Model Balls Plug
Set Plug
Race Race Race Reqd Set
Set
#1 #2 #3
3 TSi-6, TSi-10,
34 35 36 105 3267882 3144007 3139418
TSi-15
3 TSi-20 26 27 28 81 P530012 P530013 P530018
4 TSi-10 31 32 33 96 P516999 P516998 P516997
4 TSi-15 26 27 28 81 P530012 P530013 P530018
Repair Sets and Packing Sets
Packing Instream
Size and Model Repair Kit (1)
Material Packing Set
3 TSi-6, TSi-10, TSi-15 00/Brs P505433 P505432

3 TSi-20 00/Brs P530020 P530022
4 TSi-10 00/Brs P516116 P516117
4 TSi-15 00/Brs P530019 P530021
Note 1: Repair kits include (1) ball set; (1) instream packing; (1) ball
plug set which includes 3 ball plugs and 3 snap rings; (2) O-ring seals;
and (1) lube port plug screw
Lubrication Data
TS-115 Corrosion -50F (-46C) to 14 oz. tube 3267513

Resistant Grease 400F (204C) 2-lb can 3267515
V-SERIES VALVES
V-SERIES
VALVES
Standard Standard Stainless Steel Handwheel Handwheel
with Screw with Flange with Screw with Screw with Flange
Connections Connections Connections Connections Connections
APPLICATION Widely used in a variety of applications, the V

series valves are ideally suited in hydraulic and
The Fulflo V Series range in size from 1/4 lubricating systems for load regulation and
through 2 and operate efficiently with liquids of system protection. Special trim or packings are
any viscosity at pressures from 2 to 1000 P.S.I. available for use with fire resisting fluids and
The V series valves are available in flange or other liquids of this type. Unusual applications
screw type...cartridge or handwheel in a choice and special requirements should be referred to
of brass, cast iron, steel and stainless steel. our engineering staff for recommendation.
INSTALLATION should be piped back to the tank. Care must be

taken to have the discharge well below the oil
Fulflo valves can be mounted in any position. A level in the tank to prevent air entrainment and
tee may be inserted in the pump discharge line erratic operation.
to mount the valve. The correct size of valve
should be installed, preferably matching the Only if the valve is used as safety or overload
pump discharge line. Screw the valve into the relief and operates infrequently may its
nipple in the tee, or in the case of the flange discharge be piped back into the pump suction
style, bolt the valve to the companion flange line. Frequent or continuous operation under
screwed into the nipple. When the valve is used these conditions will cause excessive heating of
for frequent bypassing of oil pressure, its outlet the oil and possible damage.
11
V-SERIES
SETTING VALVES having a flow meter in the pump discharge line must
be available. With a valve adjusted for cracking
Valves may be set with a hydraulic hand pump for pressure as above, continue closing bypass until the
cracking pressure. If a test stand is available, valve required flow registers on the flow meter and observe
should be connected to the discharge header with the pressure. Readjust pressure, if necessary, to obtain
pump bypass open, and the bypass gradually closed desired pressure at desired flow.
until the desired pressure registers on the gauge.
Adjust valve adjusting screw until valve slightly bleeds
at the set bypass pressure and lock adjusting screw. MAINTENANCE
Fulflo valves are not designed to be positive shut-off, Fulflo valves provide reliable chatter-free operation
and will pass a minimal amount of leakage before the when the system is free of abrasives and foreign
V-SERIES
VALVES
set pressure. If a valve is required to bypass a given matter. Continuous filtration of the liquid used is
amount of fluid at a given pressure, a test stand strongly recommended.
TYPICAL DISASSEMBLY OF STANDARD TYPE VALVE
To dismantle valve for inspection or cleaning:

G 1. Remove cap B
2. Remove O-Ring E
3. Remove lock nut F
B
I 4. Remove adjusting screw C
5. Remove retainer D
E H 6. Remove spring G
7. Remove piston I
F 8. Remove stop ring H (Not Recommended)
A (Special tooling is required to install new stop ring.)
C Inspect valve bore and piston for wear and scoring. Replace
broken or damaged parts. Clean all parts thoroughly and
re-assemble by reversing the above procedure.
D
TYPICAL DISASSEMBLY OF HANDWHEEL TYPE VALVE

To dismantle the valve for inspection or cleaning:
1. Release spring tension by backing off handwheel as far as it
will go.
2. Remove lock nut A or set screw and take off handwheel B
3. Remove lock nut D
4. Unscrew and remove gland E
5. Unscrew and remove bonnet F
J 6. Remove O-Ring H
A
F 7. Remove adjusting screw C (turn clockwise and pull out from
B bottom of bonnet F)
D K 8. Remove O-ring packing G
9. Remove spring J
E H 10. Remove piston K
11. Remove stop ring L (Not Recommended)
G L (Special tooling is required to install new stop ring.)
Inspect valve bore and piston for wear or scoring. Replace broken
C or damaged parts. Clean all parts thoroughly and re-assemble by
reversing the above procedure.
I
12
V-SERIES
ASSEMBLY NUMBER IDENTIFICATION CHART
Symbol No. Designation Code Description
1 Style None Standard Model
H Handwheel Model
2 Series V
3 Material J Cast iron
B Brass
S Steel
SS 316 Stainless Steel
4 Connections None Screw Connections
F Flange Connections 300# Flange Class Standard (250# Flange Class - Cast Iron Standard)
V-SERIES
VALVES
5 Size -1 1/4
-2 3/8
-3 1/2
-4 3/4
-5 1
-6 11/4
-7 11/2
-8 2
6,7,8 ASA None 300# Flange Standard (no designation required)
Flange -150
Rating -600
9 Flange A Raised Face, Staggered Bolt Centers (standard on all Flange rating)
Style B Smooth Face, Staggered Bolt Centers
150# & 600# C Raised Face, Bolts on Valve Centerline
Only D Smooth Face, Bolts on Valve Centerlne
10 O-Ring R Buna O-Ring Cap Seal (standard)
Material RV Viton O-Ring Cap Seal
RS Silicone O-Ring Cap Seal
RT Teflon O-Ring Cap Seal (standard on VSS Series)
RA Aflas O-Ring Cap Seal
11 Options SP Steel Parts (used on cast iron only)
P Panel Mount on Handwheel Series
12 Piston /HS Hardened Steel
Material /SS 416 Stainless Steel
/3SS 303 Stainless Steel
13 Spring AS
US
WS
XS
YS
ZS
14 Setting Desired Pressure Setting
EXAMPLES:
VJ-1RVSP/HS/WS VJF-5R/HS/WS VJF-5-150AR/HS/WS
V J -1 RV SP /HS WS V J F -5 R /HS WS V J F -5 -150 A R /HS WS
Series Cast Iron 1/4 Viton O-Ring Steel Parts H.S. Piston WS Spring Series Cast Iron Flanged 1 Buna O-Ring H.S. Piston WS Spring Series Cast Iron Flanged 1 Rating Style Buna O-Ring H.S. Piston WS Spring
NOTE: Stainless steel pistons are supplied on brass valves, unless hardened steel is specified. Hardened steel pistons are supplied on cast iron or steel unless stainless steel is
specified. Buna O-Rings are supplied as standard unless other material is specified.
STANDARD PRESSURE RANGE CHART

Valve Valve SPRING PRESSURE AND IDENTIFICATION NO.
Pipe Flange BLACK-AS RED-US GREEN-WS YELLOW-XS WHITE-YS BLUE-ZS PURPLE-TS BROWN-RS
Size Size
Low High Low High Low High Low High Low High Low High Low High Low High
1/4 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
3/8 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
1/2 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
3/4 3 15 7 35 30 100 60 175 150 350 300 500
1 1 3 15 7 35 30 100 60 175 150 350 300 500
11/4 11/4 3 15 7 35 30 100 60 175 150 350 300 500
11/2 11/2 3 15 7 35 30 100 60 175 150 350 300 500
2 2 3 15 7 35 30 100 60 175 150 350 250 600
13
VJ VB Brass
V-SERIES VS
Cast Iron
Steel VSS Stainless Steel VJ-SP Cast Iron with Steel Parts
DIMENSIONS Valve
Size
DIMENSIONS IN INCHES
AA BB CC DD
1/4 5 / 11
32 1 /
11
32 1 /
11
32 13/8
J B 3/8 511/32 111/32 111/32 13/8
C 1/2 6 /163
1 /16
11
1 /16
7
17/16
F 3/4 615/16 115/16 113/16 111/16
1 87/32 29/32 29/32 21/16
K E
D 11/4 99/16 29/16 29/16 21/2
FULFLO
V-SERIES
AA REF.
G 1 /2 1
11 /16 1
2 /16
11
2 /16
11
27/8
VALVES
CAP A 2 13 3 3 31/4
(GASKET SEAL) I
PIPE SIZE
OUT
DD
REF
BB
H IN
CC
PIPE SIZE
DD
REF
PARTS LIST
SYM. NAME MODEL VALVE SIZE
1/4 3/8 1/2 3/4 1 11/4 11/2 2
VJ, VJ-SP 100 200 300 400 500 600 700 800
VB 100-B 200-B 300-B 400-B 500-B 600-B 700-B 800-B
A BODY VS 100-S 200-S 300-S 400-S 500-S 600-S 700-S 800-S
VSS 100-SS 200-SS 300-SS 400-SS 500-SS 600-SS 700-SS 800-SS
VJ, VJ-SP 201-SR 201-SR 301-SR 401-R 501-R 601-R 701-R 801-R
CAP VB 201-BR 201-BR 301-BR 401-BR 501-BR 601-BR 701-BR 801-BR
B (O-RING SEAL) VS 201-SR 201-SR 301-SR 401-SR 501-SR 601-SR 701-SR 801-SR
VSS 201-SSR 201-SSR 301-SSR 401-SSR 501-SSR 601-SSR 701-SSR 801-SSR
VJ, VB 202-B 202-B 302-B 402-B 502-B 602-B 702-B 802-B
C ADJUSTING VS, VJ-SP 202-S 202-S 302-S 402-S 502-S 602-S 702-S 802-S
SCREW VSS 202-SS 202-SS 302-SS 402-SS 502-SS 602-SS 702-SS 802-SS
VJ, VB 203-B 203-B 303-B 403-B 503-B 603-B 703-B 803-B
D RETAINER VS, VJ-SP 203-S 203-S 303-S 403-S 503-S 603-S 703-S 803-S
VJ, VJ-SP, VB, VS 204-* 204-* 304-* 404-* 504-* 604-* 704-* 804-*
E O-RING VSS 204-RT 204-RT 304-RT 404-RT 504-RT 604-RT 704-RT 804-RT
VJ, VJ-SP, VB, VS 205-S 205-S 305-S 405-S 505-S 605-S 705-S 805-S
F LOCK NUT VSS 205-SS 205-SS 305-SS 405-SS 505-SS 605-SS 705-SS 805-SS
G SPRING ALL MODELS 207-** 207-** 307-** 407-** 507-** 607-** 707-** 807-**
VJ, VB 208-B 208-B 308-B 408-B 508-B 608-B 708-B 808-B
H STOP RING VS, VJ-SP 208-S 208-S 308-S 408-S 508-S 608-S 708-S 808-S
HARDENED STEEL 206 206 306 406 506 606 706 806
I PISTON 416 STAINLESS STEEL 206-A 206-A 306-A 406-A 506-A 606-A 706-A 806-A
303 STAINLESS STEEL 206-SS 206-SS 306-SS 406-SS 506-SS 606-SS 706-SS 806-SS
CAP VJ, VJ-SP 201-S 201-S 301-S 401 501 601 701 801
J VB 201-B 201-B 301-B 401-B 501-B 601-B 701-B 801-B
(GASKET SEAL)
VS 201-S 201-S 301-S 401-S 501-S 601-S 701-S 801-S
VJ, VB 204 204 304 404 504 604 704 804
K GASKET 204-S 204-S 304-S 404-S 504-S 604-S 704-S 804-S
VS, VJ-SP
* See o-ring selection chart

** See spring pressure chart
Recommended spare parts
14
VJF Cast Iron VSF Steel
V-SERIES VBF Brass VSSF Stainless Steel VJF-SP Cast Iron with Steel Parts
DIMENSIONS DIMENSIONS IN INCHES
Valve
Size AA BB
J B
C 1 91/2 31/2
F
11/4 1013/16 33/4
K E
11/2 127/16 41/16
D
2 149/16 49/16
V-SERIES
G
VALVES
Note: Dimensions reflect
CAP 150# and 300# only
A
AA REF.
(GASKET SEAL) 45
I
45
221/2
PIPE SIZE
45
H
221/2
BB
-------
-------
-------
-------
FOR 2 VALVE ONLY
PIPE SIZE
BB
PARTS LIST
1 11/4 11/2 2
VJF, VJF-SP 500-F 600-F 700-F 800-F
VBF 500-BF 600-BF 700-BF 800-BF
A BODY VSF 500-SF 600-SF 700-SF 800-SF
VSSF 500-SSF 600-SSF 700-SSF 800-SSF
VJF, VJF-SP 501-R 601-R 701-R 801-R
CAP VBF 501-BR 601-BR 701-BR 801-BR
B (O-RING SEAL) VSF 501-SR 601-SR 701-SR 801-SR
VSSF 501-SSR 601-SSR 701-SSR 801-SSR
VJF, VBF 502-B 602-B 702-B 802-B
C ADJUSTING VSF, VJF-SP 502-S 602-S 702-S 802-S
SCREW VSSF 502-SS 602-SS 702-SS 802-SS
VJF, VBF 503-B 603-B 703-B 803-B
D RETAINER VSF, VJF-SP 503-S 603-S 703-S 803-S
VSSF 503-SS 603-SS 703-SS 803-SS
VJF, VJF-SP 504* 604* 704* 804*
E O-RING VBF, VSF 504-* 604-* 704-* 804-*
VSSF 504-RT 604-RT 704-RT 804-RT
VJF, VJF-SP 505-S 605-S 705-S 805-S
F LOCK NUT VBF, VSF 505-S 605-S 705-S 805-S
VSSF 505-SS 605-SS 705-SS 805-SS
G SPRING ALL MODELS 507-** 607-** 707-** 807-**
VJF, VBF 508-B 608-B 708-B 808-B
H STOP RING VJF-SP, VSF 508-S 608-S 708-S 808-S
VSSF 508-SS 608-SS 708-SS 808-SS
HARDENED STEEL 506 606 706 806
I PISTON 416 STAINLESS STEEL 506-A 606-A 706-A 806-A
303 STAINLESS STEEL 506-SS 606-SS 706-SS 806-SS
VJF, VJF-SP 501 601 701 801
J CAP VBF 501-B 601-B 701-B 801-B
(GASKET SEAL)
VSF 501-S 601-S 701-S 801-S
VJF, VBF 504 604 704 804
K GASKET VJF-SP, VSF 504-S 604-S 704-S 804-S
15
HVJ Cast Iron HVS Steel HVJ-P Cast Iron HVS-P Steel
V-SERIES HVB BRASS HVSS Stainless Steel HVB-P Brass HVSS-P Stainless Steel
DIMENSIONS Valve
Size
DIMENSIONS IN INCHES
A AA BB CC DD EE
1/4 8/
1
8 1 /
11
32 1/3
16 1/3
8 7/8
B
C 3/8 81/8 111/32 13/16 13/8 7/8
D
E 1/2 9 /8
5
1 /16
11
1 /16
7
1 /16
7
11/8
F 3/4 93/16 115/16 111/16 113/16 13/8
AA MAXIMUM REF.
G 1 127/16 29/32 21/16 29/32 13/8
EE 11/4 137/16 29/16 21/2 29/16 15/8
THD. DIA. H
V-SERIES
1 /2
1
17 /16
1
2 /16
11
2 /8
7
2 /16
11
21/4
VALVES
M I
FULFLO
J 2 171/16 3 33/8 3 21/4
K
F
PIPE SIZE
REF
OUT
CC
BB
L
PANEL MOUNT IN
PIPE SIZE DD
CC
REF.
PARTS LIST
1/4 3/8 1/2 3/4 1 11/4 11/2 2
A LOCK NUT OR 1/4-20 1/4-20 1/4-20 205-S 205-S 1/4-20 1/4-20 1/4-20
SET SCREW ALL MODELS
COMM. COMM. COMM. COMM. COMM. COMM.
B HANDWHEEL ALL MODELS 229 229 229 429 429 629 629 629
ADJUSTING HVJ(P), HVS(P) 222-S 222-S 322-S 422-S 522-S 622-S 722-S 822-S
C HVB(P) 222-B 222-B 322-B 422-B 522-B 622-B 722-B 822-B
SCREW HVSS(P) 222-SS 222-SS 322-SS 422-SS 522-SS 622-SS 722-SS 822-SS
HVJ(P), HVS(P) 205-S 205-S 205-S 305-S 305-S 655-S 655-S 655-S
D LOCK NUT HVB(P) 205-S 205-S 205-S 305-S 305-S 655-S 655-S 655-S
HVSS(P) only 205-SS 205-SS 205-SS 305-SS 305-SS 655-SS 655-SS 655-SS
E GLAND HVB(P) 225-B 225-B 325-B 525-B 525-B 625-B 725-B 825-B
HVSS(P) 225-SS 225-SS 325-SS 525-SS 525-SS 625-SS 725-SS 825-SS
HVJ, HVS 223-SR 223-SR 323-SR 423-SR 523-SR 623-SR 723-SR 823-SR
HVB 223-BR 223-BR 323-BR 423-BR 523-BR 623-BR 723-BR 823-BR
HVSS 223-SSR 223-SSR 323-SSR 423-SSR 523-SSR 623-SSR 723-SSR 823-SSR
F BONNET 228-SR 228-SR 328-SR 428-SR 528-SR 628-SR 728-SR 828-SR
HVJP, HVSP
HVBP 228-BR 228-BR 328-BR 428-BR 528-BR 628-BR 728-BR 828-BR
HVSSP 228-SSR 228-SSR 328-SSR 428-SSR 528-SSR 628-SSR 728-SSR 828-SSR
HVJ(P), HVS(P) 224* 224* 224* 424* 424* 624* 624* 624*
G O-RING HVB(P) 224-* 224-* 224-* 424-* 424-* 624-* 624-* 624-*
HVSS(P) only 224-RT 224-RT 224-RT 424-RT 424-RT 624-RT 624-RT 624-RT
HVJ(P), HVS(P) 204* 204* 304* 404* 504* 604* 704* 804*
H O-RING HVB(P) 204-* 204-* 304-* 404-* 504-* 604-* 704-* 804-*
HVSS(P) only 204-RT 204-RT 304-RT 404-RT 504-RT 604-RT 704-RT 804-RT
HVJ(P) 100 200 300 400 500 600 700 800
HVB(P) 100-B 200-B 300-B 400-B 500-B 600-B 700-B 800-B
I BODY HVS(P) 100-S 200-S 300-S 400-S 500-S 600-S 700-S 800-S
J SPRING ALL MODELS 207-** 207-** 307-** 407-** 507-** 607-** 707-** 807-**
HARDENED STEEL 206 206 306 406 506 606 706 806
K PISTON 416 STAINLESS STEEL 206-A 206-A 306-A 406-A 506-A 606-A 706-A 806-A
303 STAINLESS STEEL 206-SS 206-SS 306-SS 406-SS 506-SS 606-SS 706-SS 806-SS
L STOP RING HVB(P) 208-B 208-B 308-B 408-B 508-B 608-B 708-B 808-B
HVJP, HVSP, 505-S 505-S 605-S 705-S 705-S 805-S 745-S 745-S
M LOCK NUTS 505-S 505-S 605-S 705-S 705-S 805-S 745-S 745-S
HVBP
2 REQD HVSSP 505-SS 505-SS 605-SS 705-SS 705-SS 805-SS 745-SS 745-SS
16
V-SERIES HVJF
HVBF
Cast Iron
Brass
HVSF Steel HVJF-P Cast Iron HVSF-P Steel
HVSSF Stainless Steel HVBF-P Brass HVSSF-P Stainless Steel
DIMENSIONS A DIMENSIONS IN INCHES
B Valve
Size AA BB EE
C
D 13 /16 31/2 13/8
11
1
E
11/4 1411/16 33/4 15/8
F
G 11/2 187/16 41/16 21/4
AA MAXIMUM REF.
2 185/8 49/16 21/4
H
EE Note: Dimensions reflect
THD. DIA. 150# and 300# only
I
V-SERIES
M
VALVES
J 221/2
K 45
45
45
PIPE SIZE
F
221/2
L
BB
PANEL MOUNT
PIPE SIZE
-------
-------
-------
-------
BB FOR 2 VALVE ONLY
PARTS LIST
SYM. NAME MODEL DIMENSIONS IN INCHES
1 11/4 11/2 2
A LOCK NUT OR ALL MODELS 1/4-20 1/4-20 1/4-20
SET SCREW 205-S COMM. COMM. COMM.
B HANDWHEEL ALL MODELS 429 629 629 629
HVJF(P) HVSF(P) 522-S 622-S 722-S 822-S
ADJUSTING HVBF(P) 522-B 622-B 722-B 822-B
C
SCREW HVSSF(P) 522-SS 622-SS 722-SS 822-SS
HVJF(P), HVSF(P) 305-S 655-S 655-S 655-S
D LOCK NUT HVBF(P) 305-S 655-S 655-S 655-S
HVSSF(P) only 305-SS 655-SS 655-SS 655-SS
HVJF(P), HVSF(P) 525-S 625-S 725-S 825-S
E GLAND HVBF(P) 525-B 625-B 725-B 825-B
HVSSF(P) 525-SS 625-SS 725-SS 825-SS
HVJF, HVSF 523-SR 623-SR 723-SR 823-SR
HVBF 523-BR 623-BR 723-BR 823-BR
HVSSF 523-SSR 623-SSR 723-SSR 823-SSR
F BONNET HVJPF, HVSPF 528-SR 628-SR 728-SR 828-SR
HVBPF 528-BR 628-BR 728-BR 828-BR
HVSSFP 528-SSR 628-SSR 728-SSR 828-SSR
HVJF(P), HVSF(P) 424* 624* 624* 624*
G O-RING HVBF(P) 424-* 624-* 624-* 624-*
HVSSF(P) only 424-RT 624-RT 624-RT 624-RT
HVJF(P), HVSF(P) 504* 604* 704* 804*
H O-RING HVBF(P) 504-* 604-* 704-* 804-*
HVSSF(P) only 504-RT 604-RT 704-RT 804-RT
HVJF(P) 500-F 600-F 700-F 800-F
HVBF(P) 500-BF 600-BF 700-BF 800-BF
I BODY HVSF(P) 500-SF 600-SF 700-SF 800-SF
HVSSF(P) 500-SSF 600-SSF 700-SSF 800-SSF
J SPRING ALL MODELS 507-** 607-** 707-** 807-**
HARDENED STEEL 506 606 706 806
K PISTON 416 STAINLESS STEEL 506-A 606-A 706-A 806-A
303 STAINLESS STEEL 506-SS 606-SS 706-SS 806-SS
HVJF(P), HVSF(P) 508-S 608-S 708-S 808-S
L STOP RING HVBF(P) 508-B 608-B 708-B 808-B
HVSSF(P) 508-SS 608-SS 708-SS 808-SS
LOCK NUTS HVJFP, HVSFP, 705-S 805-S 745-S 745-S
M HVBFP 705-S 805-S 745-S 745-S
2 REQD HVSSFP 705-SS 805-SS 745-SS 745-SS
17
V-SERIES PERFORMANCE CHARTS
All valve tests 110F. to 120F. Oil Viscosity 150 S.S.U. at 100F.
(Charts good from 30 to 500 S.S.U.)
1/4 VALVE TESTS 3/8 VALVE TESTS
V-SERIES
6
VALVES
5 XS
4 Rated Capacity WS 10 XS
3 G.P.M.
3 Rated Capacity
5 G.P.M.
WS
2 US 5
GALLONS PER MINUTE
RS
GALLONS PER MINUTE

AS 4 US RS
TS
3
1 ZS AS TS
.8 2 ZS
YS PRESSURE RANGE IN P.S.I. PRESSURE RANGE IN P.S.I.
.6 207-AS = 3-15 207-AS = 3-15
207-US = 7-35 YS 207-US = 7-35
207-WS = 30-100 207-WS = 30-100
.4 207-XS = 60-175 1 207-XS = 60-175
207-YS = 150-350 207-YS = 150-350
207-ZS = 300-500 207-ZS = 300-500
207-TS = 400-600 207-TS = 400-600
207-RS = 600-750 207-RS = 600-750
.2 .5
1 2 4 6 8 10 20 40 60 80 100 150 1 2 4 6 8 10 20 40 60 80 100 150
OVERPRESSURE IN P.S.I. OVERPRESSURE IN P.S.I.
1/2 VALVE TESTS 3/4 VALVE TESTS
PRESSURE RANGE IN P.S.I.

307-AS = 3-15
307-US = 7-35
307-WS = 30-100
307-XS = 60-175 40
307-YS = 150-350
307-ZS = 300-500 30
307-TS = 400-600
25 307-RS = 600-750
20 Rated Capacity
20 16 G.P.M.
15 15
Rated Capacity
11 G.P.M. WS ZS
GALLONS PER MINUTE
GALLONS PER MINUTE
10 10 US
XS YS
AS
RS
5 WS XS
5
4 US TS 4
PRESSURE RANGE IN P.S.I.
3 AS ZS 3 407-AS = 3-15
407-US = 7-35
407-WS = 30-100
2 YS 2 407-XS = 60-175
407-YS = 150-350
407-ZS = 300-500
1 1
1 2 4 6 8 10 20 40 60 80 100 150 1 2 4 6 8 10 20 40 60 80 100 150
18
V-SERIES PERFORMANCE CHARTS
All valve tests 110F. to 120F. Oil Viscosity 150 S.S.U. at 100F.
(Charts good from 30 to 500 S.S.U.)
1 VALVE TESTS 11/4 VALVE TESTS
PRESSURE RANGE IN P.S.I. PRESSURE RANGE IN P.S.I.

507-AS = 3-15 607-AS = 3-15
507-US = 7-35 607-US = 7-35
507-WS = 30-100 607-WS = 30-100
507-XS = 60-175 607-XS = 60-175
V-SERIES
507-YS = 150-350 607-YS = 150-350
VALVES
507-ZS = 300-500 120 607-ZS = 300-500
60 507-R = 500-900 607-R = 500-800
50 100
40 80
Rated Capacity Rated Capacity
30 25 G.P.M.
60 50 G.P.M.
20 ZS
GALLONS PER MINUTE
GALLONS PER MINUTE

WS 40 WS
ZS
US US YS
YS
10 AS R 20 XS
8 XS 16 AS
6 12
R
4 8
21 2 4 6 8 10 20 40 60 80 100 150 41 2 4 6 8 10 20 40 60 80 100 150

11/2 VALVE TESTS 2 VALVE TESTS
PRESSURE RANGE IN P.S.I. PRESSURE RANGE IN P.S.I.

707-AS = 3-15 807-AS = 3-15
707-US = 7-35 807-US = 7-35
707-WS = 30-100 807-WS = 30-100
707-XS = 60-175 807-XS = 60-175
707-YS = 150-350 807-YS = 150-350
707-ZS = 300-500 807-ZS = 250-600
707-R = 500-900
200
160 200 Rated Capacity
150 G.P.M.
120 Rated Capacity 150
80 G.P.M.
80 100
GALLONS PER MINUTE
GALLONS PER MINUTE
R
WS ZS
40 AS
50
32 US YS ZS 40
WS XS
24 AS 30 US
16 XS 20 YS
8 10
1 2 4 6 8 10 20 40 60 80 100 150 1 2 4 6 8 10 20 40 60 80 100 150
19
GT Exhaust Systems, Inc. 203-4100 Series
Phone: 402-323-7272 Fax: 402-323-7270 Residential Grade Turbo Silencer
APPLICATION
A residential grade silencer configured for use on turbo charged
engines. Excellent for areas where ambient noise levels are low. B C
Typical Attenuation: 20 to 25 dBA
FLOW
INSTALLATION A
May be installed in any position
CONSTRUCTION
Silencers feature an all welded heavy-duty construction. A
straight through (line of sight) absorption silencer with special STYLE 1 DRAIN
thermal acoustical fiberglass packing. Standard with threaded
pipe nipples on sizes 2 thru 3.5, and 125/150# ANSI steel plate
flanges on sizes 4 and up.
B D
MATERIAL OPTIONS
A variety of material options are provided to satisfy most
applications and budgets: FLOW
A
C Carbon Steel
AS Aluminized Shell G
AH Aluminized Shell and Heads
S Stainless Steel DRAIN
STYLE 2 F
FINISH
Standard finish is high heat silicone black or aluminum, depending
on material options. Consult factory for optional coatings.
STAINLESS STEEL OPTIONS: 304, 316, & 316L
CUSTOM PRODUCTS A B C D F
Special requirements? GT can customize its products to meet your Model SIZE DIA OAL-1 OAL-2 MIN
G WT*
Specifications. 203-4102 2 6 28 30 3 6 16
203-41025 2.5 6 30 32 3 6 18
203-4103 3 8 36 39 3 7 20
203-41035 3.5 9 40 44 4 7.5 50
203-4104 4 9 54 59 5 9 65
203-4105 5 10 54 62 5 9 80
203-4106 6 12 67 73 5 10 105
203-4108 8 14 78 90 7 11 135
203-4110 10 16 82 91 10 12 170
203-4112 12 22 89 106 11 15 290
203-4114 14 26 110 128 12 17 390
203-4116 16 26 132 151 14 17 545
203-4118 18 36 185 219 15 22 1385
203-4120 20 42 200 227 19 25 1680
203-4122 22 45 200 227 21 26.5 2720
203-4124 24 48 261 295 22 28 3210
Pressure Drop for 203-4100
203-4126 26 54 264 321 24 31 3640
16
14 * SIDE INLET MODELS ARE APPROXIMATELY 10% HEAVIER
INCHES OF WATER
PRESSURE DROP
12 THAN THE CATALOG POSTED WEIGHTS SHOWN ABOVE

10
203-4100 STYLE 2: INLET
SIDE
8
ORDERING INFORMATION
6
4 203-4100 STYLE 1: END INLET
2 When ordering, please place Material and Style Options as illustrated in
0 the examples below:
0.1 0.2 0.9 2.1 3.7 5.8 8.4 11.4 14.9
EXIT VEL OCI TY I N THOUS AND FT PER MI NUTE 203-4104-2-C Carbon Steel Construction with Style 2 -- Side Inlet
203-4112-1-AS Aluminized Shell with Style 1 -- End Inlet
All dimensions are in inches. 203-4108-2-S Stainless Steel with Style 2 -- Side Inlet
Inlet Sizes available up to 30
13
Page ii
Page iii
Page 1
Page 2
Page 3
For additional information contact your local representative or
Gardner Denver Inc.
4747 South 83rd East Avenue, Tulsa, OK 74145
PH: (918) 664-1151, (800) 637-8099
FAX: (918) 664-6225
www.gardnerdenver.com
Specifications subject to change without notice.

Copyright 2001 Gardner Denver, Inc. Litho in U.S.A.
ECN 1024565
300THDB997 Page 1
300THDB997 Page 2
300THDB997 Page 3
300THDB997 Page 4
300THDB997 Page 5
300THDB997 Page 6
300THDB997 Page 7
300THDB997 Page 8
300THDB997 Page 9
300THDB997 Page 10
300THDB997 Page 11
300THDB997 Page 12
300THDB997 Page 13
300THDB997 Page 14
300THDB997 Page 15
300THDB997 Page 16
300THDB997 Page 17
300THDB997 Page 18
300THDB997 Page 19
300THDB997 Page 20
3-1-541 Page 1
3-1-541 Page 2
3-1-541 Page 3
3-1-541 Page 4
3-1-541 Page 5
3-1-541 Page 6
Order by Part Number and Description.
Reference Numbers are shown for your convenience only.
3-1-541 Page 7
Order by Part Number and Description.
Reference Numbers are shown for your convenience only.
3-1-541 Page 8
3-1-541 Page 9
3-1-541 Page 10
Gardner Denver Inc.
PH: (918) 664-1151, (800) 637-8099
FAX: (918) 664-6225

ECN 1024137
9
10
2.
FLUID END (FIGURE 2-4)

13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
RECOMMENDED TORQUES FOR HD-2250 PUMP MAINTENANCE
34
35
The Company will provide labor, by Company representative or authorized service personnel, for
repair or replacement of any product or part thereof which in the Company's judgment is proved not to
be as warranted. Labor shall be limited to the amount specified in the Company's labor rate schedule.
Labor costs in excess of the Company rate schedules caused by, but not limited to, location or
inaccessibility of the equipment, or labor provided by unauthorized service personnel is not provided for
by this warranty.
All costs of transportation of product or parts claimed not to be as warranted and, of repaired or
replacement parts to or from such service facility shall be borne by the Purchaser. The Company may
require the return of any part claimed not to be as warranted to one of its facilities as designated by the
Company, transportation prepaid by the Purchaser, to establish a claim under this warranty.
Replacement parts provided under the terms of this warranty are warranted for the remainder of the
Warranty Period of the product upon which installed to the same extent as if such parts were original
components.
Except as to title, the foregoing warranty is the sole and exclusive warranty of the Company. The
Company hereby extends other manufactures warranty or guaranties, if any given to Company by such
manufacturer, but only to the extent the Company is able to enforce such warranty or guaranties. The
Company has not authorized any party to make any representation or warranty other than as expressly
set forthherein. SELLER HEREBY DISCLAIMS AND EXCLUDES ANY OTHER EXPRESS,
IMPLIED OR STATUTORY WARRANTIES, ARISING BY OPERATION OF LAW OR OTHERWISE,
INCLUDING, WITHOUT LIMITATION, ANY WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. COMPANY MAKES NO WARRANTIES OR
REPRESENTATIONS OF ANY KIND WHATSOEVER (EXPRESS, IMPLIED OR STATUTORY), OF
LAW OR OTHERWISE, ON ANY EQUIPMENT, COMPONENT PARTS OR ACCESSORIES SOLD
HEREUNDER WHICH, ARE NOT MANUFACTURED BY COMPANY.
NOTWITHSTANDING ANYTHING HEREIN TO THE CONTRARY, THE FOREGOING

WARRANTY SHALL BE THE SOLE AND EXCLUSIVE REMEDY AVAILABLE TO THE
PURCHASER. UNDER NO CIRCUMSTANCES, WHETHER IN CONTRACT, TORT OR
OTHERWISE, SHALL THE COMPANYS TOTAL LIABILITY ARISING IN CONNECTION WITH
ANY PURCHASE ORDER EXCEED THE AMOUNT OF ANY SALES OR OTHER PROCEEDS
RECEIVED PURSUANT THERETO. IN ADDITION, UNDER NO CIRCUMSTANCES, WHETHER
IN CONTRACT, TORT OR OTHERWISE, SHALL THE COMPANY BE LIABLE FOR
LIQUIDATED, SPECIAL, INDIRECT, INCIDENTAL, EXEMPLARY, OR CONSEQUENTIAL
DAMAGES, EXPENSES OR COSTS, INCLUDING, WITHOUT LIMITATION, LOST PROFITS OR
FACILITY DOWNTIME, HOWEVER CAUSED AND EVEN IF THE POTENTIAL OF SUCH
DAMAGES WAS DISCLOSED AND/OR KNOWN.
No statement, representation, agreement, or understanding, oral or written, made by any agent,

distributor, representative, or employee of the Company which is not contained in this Warranty will be
binding upon the Company unless made in writing and executed by an officer of the Company.
36
Facsimile: (918) 664-6225
37
Gardner Denver Inc.
PH: (918) 664-1151, (800) 637-8099
FAX: (918) 664-6225

Repair Instructions for Gemini 76, 86 & 96
Series Valves
2 Otter Court, Raymond, New Hampshire 03077 Tel. (603) 895-4761 FAX (603) 895-6785
86 and 96 Series Valves

The Gemini Series 86 and 96 valves are of two piece body design, which permits disassembly for inspection
and repair. Care in cleaning and handling of valve components is particularly important when overhauling ball
valves, as a small nick or scratch, causing by mishandling, can be the source of leakage in service. These
instructions deal with valve equipped with lever handles. If your valve has another type handle or is equipped
with an actuator, the steps required to complete the stem assembly will differ somewhat from those referred
to in the instruction sheet.
Procedure
1. Place valve body in vise with 3. Clean all parts. Inspect area of Belleville springs become fully
end plug facing upward. The use end plug and body, which forms compressed (flatten); the torque
of smooth vice jaws will prevent metal to metal seal, for scratches required to tighten the nut further
maring of the valve. Break end and / or burrs. Lubricate all parts increases sharply when this point
plug loose with wrench; remove with a lubricant giving special at- is reached. Do not tighten the
end plug. tention to the end plug / body seal stem nut beyond this point.
area and the end plug threads.
2. Remove valve from vise, turn 5. Place new seat in body. Turn
handle to closed position. Re- 4. Place new stem seal on stem, handle to closed position, insert
move ball. Remove seat from position stem in body, place new ball, making sure that lower end
valve body. Remove stem nut, thrustwasher over stem, install of stem engages slot in ball. Turn
handle, grounding spring, follower (small flat metal washer) handle to open position. Place
Belleville springs, follower and over stem. Position two Belleville valve body in vise as in step 1.
thrustwasher. Remove stem by springs (cupped) on stem with Install new seat in end plug.
pushing into valve. Make sure concave surfaces facing one an- Tighten end plug into body to
stem seal is removed when stem other, place grounding spring in torque given in chart.
is withdrawn from body. Remove position over stem. Complete
seat from valve body and from stem assembly by placing handle 6. Test valve. Reinstall.
end plug. Discard used seats, on stem and securing with stem
stem seal and thrustwasher. nut. Tighten stem nut until
76 Series Valves
Although Series 76 valves which have become unserviceable are ordinarily replaced rather than repaired, re-
newal of the seats and stem seal will permit their being returned to service in many cases. The Series 76 is not
regarded as a maintainable product by Gemini Valve, and the publication of these instructions should not be
interpreted as implying the advisability of attempting repairs. The use of a tool is necessary in dismantling and
reassembling the valve. A design is suggestion is offered below. These instructions deal with valves which are
equipped with lever handles. If your valve has another style handle or is equipped with an actuator, the steps
required to complete the stem assembly will differ somewhat for those referred to in this instruction sheet. When
the repaired valve is reinstalled, the insert should face upstream.
Procedure
1. Place tool in wrenching slots of withdrawn from valve body; discard of the stem engages the slot in
insert. Place valve with the in- stem seal. ball. Turn handle to open posi-
serted tool in vise lengthwise. 4. Clean all parts. The use of a lu- tion. Reassemble insert to body
bricant is recommended on all parts. hand tight using assembly tool.
Place valve and tool in vise as in
5. Place new stem seal on stem, Step 1, tighten insert to torque
position stem in body, place new value given in chart.
thrustwasher over stem, install fol-
lower (flat metal washer) over stem.
Position two Belleville springs
(cupped) on stem with concave sur-
2. Break insert loose by turning faces facing one another, put
tool with a wrench while holding grounding spring over stem, posi-
valve body with a second wrench. tion handle on stem atop Belleville
Remove valve from vise, un- springs. Secure assembly with stem
screw insert, remove seat from in- nut. Tighten stem nut until Belleville
sert and discard. springs become fully compressed
(flattened); the torque required to
3. Turn handle to closed posi- tighten the nut further increases
tion, remove ball. Remove seat sharply when this point is reached.
from body and discard. Remove Do not tighten the stem nut beyond
stem nut, handle grounding this point. 7. Test valve for leak tightness in
spring, Belleville springs, follower, upstream-to-downstream direc-
and thrustwasher. Remove stem 6. Position new seat in valve. Place tion. If leaks appear through
by pushing into valve. Discard new seat in loose insert. With valve, retighten the insert. if valve
thrustwasher. Make sure stem handle in closed position, insert leaks through stem, increase
seal is removed when stem is ball, making sure that the lower end torque on stem nut. Retest valve.
ISL018-0009
G20 & G30 Series
Hydraulic Gear Pumps
Inspection / Servicing
Service Manual
No. SD - 97105
August 1997
G20 / G30 Series Gear Pumps
G20 Series Cross Sectional Drawing
G30 Series Cross Sectional Drawing
Note: The drawings on this

page are not proportional in
size.
2
Haldex Barnes G20 / G30 Series Gear Pumps
G20 Series Exploded View Drawing
Nut
Stud
Lockwasher
Front Cover
Square Section O-ring
Seal Gland
Seal Retainer
Center Section
Driven Gear
Wear Plate
Rear Cover
Shaft Seal
Seal Retainer
Shaft Seal
Assembly Notches
(Refer to Drive Gear
paragraph 3 below)
Wear Plates (G30 Series)
Tools Required
Socket Set (1/2 drive) 4. Remove key from drive shaft if applicable.
Internal Snap Ring Pliers
5. Clamp pump across protected ports in large vise or
Shaft Seal Sleeve or clear tape
holding fixture with shaft end up.
Torque Wrench - 200 lb-ft capacity
Plastic hammer
Torque wrench box end adapters
(Sturtevant Co. P/N BX-11/16 & BX-7/8)
Disassembly
Note:The following general instructions apply to both
the G20 and G30 Series gear pumps, the G20 Series
is shown in the photographs. The following instruc-
tions also apply to double gear pumps.
1. It is very important to work in a clean work area when

repairing hydraulic products. Plug ports and wash exte- 6. Loosen and remove the eight nuts and lockwashers
rior of pump with a proper cleaning solvent before con- from the stud bolts.
tinuing.
7. Remove pump from vise and place on clean work
2. Remove port plugs and drain oil from pump. bench. Use a plastic mallet to separate the front cover
from the rest of the pump. The two dowel pins which align
3. It is not necessary to mark the outside of pump before the front cover, center section and rear cover are a tight
disassembly as the front cover, center section and rear fit and will require the use of the plastic mallet to separate
cover all have notches cast into the edges of these parts. these parts. (Do not use a screwdriver or other pry tool to
By lining up the notches of these three parts the pump separate these parts as damage will result).
will be properly assembled and proper rotation of the pump
will be assured. (Refer to exploded view drawing above).
3
Identifying marks
on intersecting teeth
8. Remove front cover. Identify intersecting teeth of drive 11. Remove the eight studs from rear cover.
and driven gears with a marking fluid before removing
from pump. Carefully remove drive gear from pump and
place on work bench.
9. Remove driven gear from pump and place on clean 12. Remove wear plate from rear cover.
work bench.
10. Remove center section from pump . 13. Remove seal retainer from rear cover and discard as
it will be replaced as a new part.
4
14. Remove the seal gland from rear cover and discard 17. Remove seal retainer from front cover and discard as
as it will be replaced as a new part. it will be replaced as a new part.
15. Remove square cross section o-ring from rear cover 18. Remove seal gland from front cover and discard as it
and discard as it will be replaced as a new part. will be replaced as a new part.
16. Remove wear plate from front cover. Remove rubber 19. Remove square cross section o-ring from front cover
plug from seal weep hole. and discard as it will be replaced as a new part.
5
gear teeth are sharp, they will mill into the wear plates. If
wear on the face of the gears has occurred, the gears
must be replaced.
20. Remove seal retainer if applicable from front cover

and use a screwdriver or seal removal tool to remove the
shaft seal from front cover.
Inspect Parts For Wear 5. Inspect bearings in front cover for excessive wear,
scoring, flaking or movement of bearings.
1. Clean and dry all parts thoroughly prior to inspection.
It is not necessary to inspect the seals as they will be
replaced as new items.
Check these points
2. Check drive gear spline for twisted or broken teeth, 6. Inspect bearings in rear cover for excessive wear, scor-
nicks or excessive wear. Inspect gear journals for ing, flaking or movement of bearings.
scratches and discoloration. Any discoloration of shaft
requires replacement of drive gear. Inspect gear teeth for
spalding, scratches or excessive wear. Replace if neces-
sary. Light stoning of teeth to remove sharp edges is
permissable.
Check gear face Check edge of gear teeth
7. Inspect the gear pockets inside the center section. It is

normal for the surface inside the gear housing to show a
clean wipe on the inside gear pocket wall on the intake
4. Inspect gear face of both the drive gear and driven side. There should not be excessive wear or deep
gear for scoring or excessive wear. If the face edge of scratches and gauges.
6
G20 Wear Plate
G30 Wear Plate

8. Inspect bronze side of both wear plates for erosion, Contents of typical G20 Series Seal Repair Kit.
pitting, scratches or scoring, replace if damaged.
General Information
It is important that the relationship of the front cover,

center section and rear cover is correct. Notches cast
into the outside surface of these three parts must be
aligned for proper reassembly of this pump. Failure to prop-
erly assemble this pump will result in low flow, low pres-
sure and possible damage to the pump.
Note: Upon reassembly of pump, all parts should be

lightly oiled with clean hydraulic fluid or approved
assembly fluid. Use small amounts of graphite grease 1. Install new shaft seal in front cover, make sure the
to hold seal retainer and seal in place during assem- spring loaded member of shaft seal faces the inside of
bly. pump. Press the seal into the seal bore until the seal
reaches the bottom of the bore. Uniform pressure must
Shaft Rotation of Pump (Note: This pump is not be used to prevent misalignment or damage to the seal.
Retain with retaining ring if applicable. Coat seal land with
bi-rotational and the shaft rotation cannot be re-
graphite grease after installation.
versed).
Double Shaft Seal arrangement - Install first shaft seal
Reassembly
and retaining ring as instructed in the paragraph above.
Next install a new outer shaft seal which has a larger O.D.
(Note: New seal glands, seal retainers, square cross
in seal cavity. Make sure the spring loaded member of
section o-rings, shaft seals should be installed upon
shaft seal faces the inside of pump. Uniform pressure must
reassembly of pump and are included in the seal kits
be used to prevent misalignment or damage to the seal.
available for these pumps).
Press until seal is seated properly.
Seal Kit Part Numbers:
866855 - Standard Seal Kit for G20 Series

Gear Pump.
920097 - Standard Seal Kit for G30 Series

Gear Pump.
2. Place rear cover on clean work bench with seal cavity

area facing up. Coat seal cavity with graphite grease to
hold seals in place.
7
3. Coat both the seal gland and plastic seal retainer with 6. Apply a light coating of graphite grease to the square
graphite grease. Carefully install the seal gland in the cross section o-ring and carefully install in groove in rear
groove in the seal retainer, make sure the seal gland is cover. Be very careful that the o-ring does not twist in the
seated completely in the seal retainer. groove, it must be flat in the groove or the pump will leak
at this seam.
4. Install the assembled seal gland and seal retainer in 7. Install the eight studs in the rear cover. The course
the cavity in the rear cover. Very carefully press this as- thread end of the studs thread into the rear cover. Torque
sembly in place until it is firmly seated in the machined studs to 300-420 lb-in / 25-35 lb-ft / or 33.9 - 47.5 Nm.
recess. This is important for proper installation of the
bronze wear plate.
5. Lubricate the bronze face of the wear plate and install 8. Install center section over studs, make very sure the
over the seal retainer. When properly placed the bronze notches are in alignment with the notch in the rear cover.
face will be next to the gears and flush with the surface of It may be necessary to use a plastic mallet to seat the
the rear cover. This photo shows the G20 wear plate, the center section due to the tight fit of the dowel pins.Hold
G30 wear plate covers the full surface of the cover plates. the wearplate in position while tapping center section.
8
9. Lubricate the drive gear and driven gear and install the 12. Install the assembled seal gland and seal retainer in
gears in the proper bearings in the rear cover. Align marked the cavity in the front cover. Very carefully press this as-
gear teeth at this time. sembly in place until it is firmly seated in the machined
recess. This is important for proper installation of the
bronze wear plate.
10. Place front cover on clean work bench with seal cav- 13. Apply a light coating of graphite grease to the square
ity area facing up. Coat seal cavity with graphite grease to cross section o-ring and carefully install in groove in front
hold seals in place. cover. Be very carefull that the o-ring does not twist in the
groove, it must be flat in the groove or the pump will leak
at this seam.
11. Coat both the seal gland and plastic seal retainer 14. Lubricate the steel side of the bronze wear plate with
with graphite grease. Carefully install the seal gland in graphite grease and install over the seal retainer. When
the groove in the seal retainer, make sure the gland is properly positioned, the bronze face will be next to the
seated completely in the seal retainer. gears and flush with the surface of the front cover.
16. Place a small amount of clean oil in the inlet of the

pump and rotate the drive shaft away from the inlet one
revolution. No binding should be evident during this op-
eration. The breakaway torque to turn the drive shaft must
not exceed 35 lb-ft / 47.5 Nm after assembly.
17. The name plate located on the end cover contains

the build date code and the model number. Please refer
to this information when corresponding with the
Barnes Hydraulics Service Department.
15. Place a seal sleeve (sleeve must be used with keyed

shafts) or tape over drive shaft end and very carefully
slide front cover over drive shaft and studs. Engage front Date Code Identification:
cover over dowel pins. Press firmly until front cover is fully
seated against center section. Make sure all notches are 3 4 97
in alignment, if not pump is incorrectly assembled. Make
sure all seals and wear plate have stayed in their proper
position. Month Year
Week of Month
Install lock washers and nuts on studs. Torque nuts to 65-
75 lb-ft / 88-101 Nm on G20 models and 145-155 lb-ft /
196-210 Nm on G30 models.
Placing Pump Back Into Service
1. If shop test stand is available, the following procedure for 2. If shop test stand is not available, the following proce-
testing rebuilt pumps is recommended: dure for testing rebuilt pumps is recommended:
A. Mount pump on test stand making sure that the proper A. For engine driven pumps, mount pump on equipment
level of clean oil is available in the reservoir. Check suction line and run pump at 1/2 engine speed at zero pressure for three
for leaks and obstructions. minutes.
B. Start pump and run for three minutes at zero pressure. B. By operating control valve, build pressure intermittently for
three minutes.
C. Intermittently load pump to 500 P.S.I. for three minutes.
C. Increase engine speed to full throttle and build pressure
D. Intermittently load pump to 1000 P.S.I. for three minutes. intermittently for three minutes.
E. Intermittently load pump to 2000 P.S.I. for three minutes. D. Stop engine and check pump for external leaks.
F. Remove pump from test stand and check for freeness of E. For electric motor driven pumps, run pump at little or no
drive shaft. Check pump for signs of external leakage. load for three minutes, gradually increase load on pump and
cycle each succeeding load for three minutes. Check pump for
external leaks after break-in test.
10
Single or Double Pump Trouble Shooting
PUMP TROUBLE PROBABLE CAUSE REMEDY
1. Pump does not develop full pressure. a. System relief valve set too low or leaking. a. Check system relief valve for proper setting.
b. Oil viscosity too low. (oil too thin) b. Change to proper viscosity oil.
c. Pump is worn out. c. Repair or replace pump.
d. Seal Retainer O-ring pinched. d. Disassemble pump and check o-ring.
2. Pump will not pump oil. a. Reservoir low or empty. a. Fill reservoir to proper level.
b. Suction strainer clogged. b. Clean suction strainer.
c. Incorrect shaft rotation. c. Check for proper rotation of pump shaft.
3. Noisy pump caused by cavitation. a. Oil too thick. a. Change to proper viscosity.
b. Oil suction filter plugged. b. Clean filters.
c. Suction line plugged or too small. c. Clean line and check for proper size.
4. Oil heating. a. Oil supply low. a. Fill reservoir to proper level.

b. Contaminated oil. b. Drain reservoir and refill with clean oil.
c. Setting of relief valve too high or too low. c. Set to correct pressure.
d. Oil viscosity too low. d. Drain reservoir and fill with proper viscosity.
5. Foaming oil. a. Low oil level. a. Fill reservoir to proper level.

b. Air leaking into suction line. b. Tighten fittings, check condition of line.
c. Wrong kind of oil. c. Drain reservoir, fill with non-foaming oil.
6. Shaft seal leakage. a. Worn shaft seal or cut seal lip. a. Replace shaft seal.
b. Worn shaft in seal area. b. Replace drive shaft and seal.
c. Wrong pump shaft rotation. c. Check for proper rotation of pump shaft.
NOTES
11
AUTHORIZED DISTRIBUTOR
214 JAMES FARM ROAD 2222 - 15TH STREET POSTFACH 1507 95014 HOF RINGVAGEN 3 BOX 95
STATESVILLE, NC 28677 USA ROCKFORD, IL 61104 USA SELIGENWEG 12 95028 HOF S-280 40 SKANES FAGERHULT
PHONE: (704) 873-2587 PHONE: (815) 398-4400 GERMANY SWEDEN
FAX, SERVICE DEPT.: (704) 838-7987 FAX, SERVICE DEPT.: (815) 398-9817 PHONE: (49) 9281 8950 PHONE: (46) 433 302 90
FAX, SALES DEPT.: (815) 398-5977 FAX: (49) 9281 87133 FAX: (46) 433 305 46
Form No. SD-97105 Copyright Barnes Hydraulics 1997

All Rights Reserved
Printed in USA
PARTS OF SUSPENSION
AIR SPRING
SHOCK ABSORBER SHOCK MOUNT
FRAME BRACKET
PIVOT AIR SPRING

CONNECTION
SUSPENSION IDENTIFICATION
U-BOLT
BEAM ASSEMBLY
AXLE SEAT BUSHING
STANDARD TERMINOLOGY
AIR SPRING TERMINOLOGY
AIR SPRING An inflatable bag designed to hold a volume of air. Sometimes referred to as air bag. Supports the
trailer with air pressure.
FLEX MEMBER Inflatable rubber portion of the air spring.
PISTON Bottom portion of the air spring that attaches to the flex member. Used to mount the air spring to the
suspension beam.
BEAD PLATE Mounting surface of the air spring that is attached to the flex member.
AXLE TERMINOLOGY
AXLE TRACK The lateral distance between the center of the dual tires on an axle.
HN SPINDLE Similar to the D22 or TN spindle. A tapered spindle with small outer wheel bearings and large
inner wheel bearings.
HP SPINDLE Similar to the P22 or TP spindle. A straight spindle with the same inner and outer wheel bearings.
6
BEAM TERMINOLOGY
BEAM ASSEMBLY Sometimes referred to as walking beams or trailing arms. Load carrying structure that
pivots at the frame bracket; connects to the axle tube and the air spring.
Y BEAM Suspension beam assembly that straddles the trailer frame at the pivot.
FRAME BRACKET TERMINOLOGY

FRAME BRACKET Sometimes referred to as hangers, towers or support boxes. Load carrying structure
that bolts or welds to the trailer frame and attaches to the beam assembly at the pivot connection.
WINGED FRAME BRACKET A frame bracket with an integral gusset on the inside rear surface for lateral
support.
WINGLESS FRAME BRACKET A frame bracket that does not include an integral gusset. Typically uses a
separate 3 C-Channel to provide lateral support.
WELD-ON FRAME BRACKET A frame bracket that welds to a steel trailer frame.
BOLT-ON FRAME BRACKET A frame bracket with holes in the top plate for bolting to an aluminum frame.
WELDABLE BOLT-ON FRAME BRACKET A frame bracket that bolts to an aluminum frame using OEM
provided mounting plate.
GENERAL TERMINOLOGY
RIDE HEIGHT Distance from the center of the axle to the mounting surface of the suspension (bottom of
trailer frame or slider frame) at normal operating position.
JOUNCE The maximum upward motion of the axle from ride height toward the frame, including bumper
compression.
REBOUND The maximum amount of downward axle travel allowed by the suspension; controlled by
the shock absorber.
TOP MOUNT A suspension where the beam assembly is on top of the axle.
UNDERSLUNG A suspension where the beam assembly is under the axle.
TRI-FUNCTIONAL BUSHING Rubber bushing located in the beam assembly at the pivot connection.
Controls vehicle roll and axle alignment.
SHOCK STRAP Strap that is mounted around the shock that is used to provide additional strength for
limiting rebound.
PIVOT BOLT The bolt that attaches the beam assembly to the frame bracket at the pivot connection.
WELDED ALIGNMENT Suspension alignment connection where the alignment is secured by welding.
QUIK-ALIGN Suspension alignment connection where the alignment is adjusted using an eccentric
alignment washer and secured by torquing the pivot bolt.
UNITIZED/ASSEMBLED The unit is shipped with the frame brackets attached to the beam assemblies.
NON-UNITIZED/UNASSEMBLED The unit is shipped with the frame brackets and pivot bolts loose.
LOADED TIRE RADIUS The distance between the axle spindle centerline and the ground when the vehicle
is in its loaded condition. Determined by the size and design of the tire.
7
HENDRICKSON PRODUCT TERMINOLOGY

T SERIES Hendricksons first trailer suspension products. Offered in various capacities and configurations.
HT SERIES Hendricksons improvement on the T model; similar capacities and configurations.
INTRAAX Hendricksons integrated axle, beam assembly and brake system.
SURELOK A device used to maintain trailer deck height during loading and unloading. Also used in place of
a dump valve to protect against trailer walk.
HEIGHT CONTROL VALVE Sometimes referred to as a leveling valve. An air valve that automatically responds
to the position of the axle and vehicle frame. It maintains the distance from the centerline of the axle to the
underside of the frame.
DUMP VALVE Air dump or exhaust valve. Added to the trailer suspension air system to exhaust the air from the
air suspensions and increase stability during loading and unloading.
CENTER LIFT KIT An air operated mechanism that is used to raise a trailer axle off of the ground.
BUSHING TOOL Special tool used to remove and replace the Tri-Functional Bushing of a beam assembly.
SLIDER TERMINOLOGY
SLIDER Sometimes referred to as a bogie or subframe. Movable suspension mounting used to reposition the
trailer axle(s).
BODY RAIL Steel rail that is mounted to the trailer. Contains holes that align with the slider locking pins.
MANUAL STOP BAR A bar that is inserted into a set of slider body rails that is used to stop the movement of
the slider while being repositioned.
LOCKING PIN Pin within a slider box assembly that keeps the slider from moving. Retracts to allow for the
repositioning of the slider.
8
HOW TO IDENTIFY A MODEL
STEP 1. Find the identification tag on the suspension

model by referencing the following chart for R
tag location.
MODEL
STEP 2. If no tag is found, contact the trailer DESC.
manufacturer with the necessary information
SERIAL NO.
(i.e. trailer serial number) to determine what
suspension model is on the trailer. TRI-FUNCTIONAL
BUSHING
STEP 3. If no suspension model can be obtained
by completing steps 1 and 2, refer to the CAPACITY SUSPENSION / AXLE ONLY lb
Identification Guides to help determine what MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING PATENTS:
OTHER PATENTS PENDING. U.S. PATENT NOS. 5,037,126-4,166,640
suspension model is on the trailer. See 5,171,036 - 4,261,597 - 4,371,190 - 4,566,719 - 4,775,166
4,991,868 - 5,366,237 - 5,403,031 AUSTRALIA - 525,185 -
instructions below. 631,071 CANADA - 1,102,831 - 1,121,998 - 1,132,163
ENGLAND - 2,019,327 FRANCE - PV7,909,507
GERMANY - DE2912533C2 ITALY - 1,115,791
MEXICO - 151,215
SUSPENSION MODEL TAG LOCATION
T Primary Suspension Front of roadside frame bracket.
HT Primary Suspension Front of roadside frame bracket or inside of curbside beam.
INTRAAX Primary Suspension Inside of curbside beam.
HS Slider with HT Suspensions Front crossmember on HS box.
HIS Slider with INTRAAX Suspensions* Front crossmember on HS box.
K-2 Slider with HT Suspensions On roadside slider box side rail above front frame bracket.
K-2 Slider with INTRAAX On roadside slider box side rail above front frame bracket.
Also has blank INTRAAX tag on inside of curbside beam.
* If the part is an HIS with INTRAAX Suspension, contact Hendrickson for assistance.
That specific suspension model is not listed in this parts catalog.
IDENTIFICATION GUIDE INSTRUCTIONS

STEP 1. Determine if unit is a fixed or slider suspension.
STEP 2. If it is a slider, use the following Identification Guides to determine the slider box type and the
suspension model. Proceed to that model in the Slider Suspension Section.
If it is fixed, use the following Identification Guides to determine the suspension model. Proceed
to that model in the Primary Suspension Section.
9
SLIDER BOXES
IDENTIFICATION GUIDE
INSTRUCTIONS
Hendrickson slider boxes are manufactured in two designs. In order to determine the box type, check
to see if the crossmembers are in a ladder orientation or if the orientation forms two Ks (see graphics).
If the orientation forms a ladder, refer to the HS190T/230 box below. If the crossmembers form the K
orientation, use the dimensions provided on the following page to determine which model it is.
HS190T/230 BOX
Box height
is 10
10
SLIDER BOXES
HKA180 VANTRAAX BOX
Box height is 8
Hanger width
is 4.12
Bottom width of
frame rail is 4.88
HK190T/230 AND HKA200/HKA250 VANTRAAX BOX
Box height is 8
Hanger width
is 7.25
Bottom width of
frame rail is 7.69
11
TOP MOUNT SUSPENSIONS
INSTRUCTIONS
Top mount suspensions are those with the beam assembly on top of the axle. The graphics illustrate
the distinguishing characteristics of the various Hendrickson top mount suspensions. In order to
determine the suspension model, find the graphic with the same identifying characteristics.
HT190 AND HT230 TOP MOUNTS

Single stud air spring
8 or 10
Straight beam
HT250T TOP MOUNTS
8 or 10
Straight beam with dropped

air spring seat
12
TOP MOUNT SUSPENSIONS
HT300 TOP MOUNTS
Double stud air spring
9 or 11
Straight beam
T TOP MOUNTS
7-1/4 or 9
Straight beam
No axle spacer
13
UNDERSLUNG SUSPENSIONS
INSTRUCTIONS
Underslung suspensions are those with the beam assembly under the axle. The graphics illustrate the
distinguishing characteristics of the various Hendrickson underslung suspensions. In order to determine
the suspension model, find the graphic with the same identifying characteristics.
HT190U UNDERSLUNGS
Upper shock bracket mounts in frame

cross member (remote shock)
Straight beam
HT250U UNDERSLUNGS
Curved beam
Upper shock bracket mounts

to frame bracket
14
UNDERSLUNG SUSPENSIONS
HT250US UNDERSLUNGS
Straight beam

to frame bracket
HT300U UNDERSLUNGS
Curved beam

to frame bracket
T UNDERSLUNGS

to air spring plate
Curved beam
15
INTRAAX SUSPENSIONS
INSTRUCTIONS
Hendricksons INTRAAX suspensions have an integrated axle and beam assembly. The graphics
illustrate the distinguishing characteristics of the top mount and low ride models. In order to determine
the suspension model, find the graphic with the same identifying characteristics.
AA230T/AA250T INTRAAX
Straight beam with

air spring seat
located above
the axle
Integrated axle and

beam assembly
16
INTRAAX SUSPENSIONS
AA230L/AA250L INTRAAX
Straight beam with
dropped air spring
seat located behind
the axle
Integrated axle and

beam assembly
17
18
NOTES
SECTION CONTENTS
DESCRIPTION PAGE
AIR SPRING COMPONENTS .............................................................................................................20
AIR SPRING HOW TO IDENTIFY ...................................................................................................21
AIR SPRING IDENTIFICATION CHART................................................................................................21
AIR SPRING APPLICATION CHART....................................................................................................23
AIR SPRING ROTATION DEFINITIONS ................................................................................................24
AIR SPRING TOP BEAD PLATE BOLT PATTERNS .................................................................................25
AIR SPRING BOTTOM BEAD PLATE BOLT PATTERNS ...........................................................................28
AIR SPRINGS
19
AIR SPRING
COMPONENTS
ROLLING LOBE (REVERSIBLE SLEEVE) STYLE
STUD COMBO STUD

BEAD PLATE
FLEX MEMBER
BUMPER
PISTON BOLT
PISTON
DOUBLE CONVOLUTED STYLE
AIR FITTING HOLE

(NPTF Designation) BLIND NUT
(UNC Designation)
AIR SPRINGS
BEAD PLATE
FLEX MEMBER
BUMPER
BEAD PLATE
20
AIR SPRING
HOW TO IDENTIFY
Dimension A
STEP 1. Remove air spring from trailer.
STEP 2. Find the diameter of the top bead
plate (Dim. A) by measuring as
indicated on graphic.
STEP 3. Find the diameter of the bottom
bead plate (Dim. B) by measur-
ing as indicated on graphic.
STEP 4. Find the collapsed height of the
air spring (Dim. C) by first
opening the air port and pushing
Dimension C the air spring down until a hard
stop is made. Make sure the
flex member is not pinched
between the bumper and the
bottom bead plate. Find the
dimension as indicated on
graphic.
Dimension B
AIR SPRING
IDENTIFICATION CHART
HENDRICKSON TYPE TOP BEAD BOTTOM BEAD COLLAPSED TOP ROTATION BOTTOM
PART NO. PLATE DIA. PLATE DIA. HEIGHT PATTERN1 PATTERN1
(Dim. A) (Dim. B) (Dim. C)
B-1080 Double Convoluted 11.31 11.31 3.8 - 4.2 E 00 DD
B-1159 Double Convoluted 9 9 4.1 - 4.2 B 00 BB
B-1245 Rolling Lobe 9 10.1 6.1 A 45 AA
B-2063 Rolling Lobe 11.31 10.25 8.9 F 00 AA
B-2064 Rolling Lobe 9 9.25 4.4 - 4.8 A 00 PP
AIR SPRINGS
B-2066 Rolling Lobe 9 10.2 7.7 - 8.0 A 45 AA
B-2734 Double Convoluted 11.31 11.31 3.8 - 4.2 E 00 DD
B-3184 Double Convoluted 11.31 11.31 3.8 - 4.2 F 00 EE
B-3467 Rolling Lobe 11.31 10.25 8.9 A 45 AA
B-3648 Rolling Lobe 11.31 11.81 5.6 - 5.7 E 45 AA
B-3798 Double Convoluted 9 9 3.7 D 00 BB
B-3830 Rolling Lobe clamp plate 10.24 8.9 A 45 AA
B-3839 Rolling Lobe 11.31 11.81 5.7 F 00 AA
B-4375 Rolling Lobe 9 10.25 9.2 - 9.5 D 45 AA
B-4771 Rolling Lobe 11.31 11.5 5.7 - 5.8 C 45 AA
B-5060 Rolling Lobe 9 10.25 9.5 - 10.1 B 45 AA
B-5468 Double Convoluted 9 9 3.5 B 00 OO
1
See Bolt Pattern Section to determine top and bottom style.
21
AIR SPRING
IDENTIFICATION CHART cont.
HENDRICKSON TYPE TOP BEAD BOTTOM BEAD COLLAPSED TOP ROTATION BOTTOM
PART NO. PLATE DIA. PLATE DIA. HEIGHT PATTERN1 PATTERN1
(Dim. A) (Dim. B) (Dim. C)
B-6412 Double Convoluted 11.31 11.31 4.8 C 00 EE
B-7193 Rolling Lobe 9 9.45 6.4 A 00 KK
B-8988 Rolling Lobe 9 10.25 10.1 M 45 AA
B-9001 Rolling Lobe 11.31 11.8 5.7 C 45 AA
B-9830 Double Convoluted 9 9 3.7 N 00 BB
B-10170 Double Convoluted 9 9 4.2 D 90 BB
B-10352 Rolling Lobe 9 10.12 9.4 D 45 AA
B-11566 Rolling Lobe 9 9.5 7.1 A 00 MM
B-11650 Rolling Lobe 9 9.5 4.8 A 00 PP
B-12335 Double Convoluted 9 9 3.12 B 00 BB
B-12514-4 Rolling Lobe 10.25 10.13 8.75 F 00 AA
B-12514-5 Double Convoluted 9 9 3 B 00 BB
B-12514-8 Rolling Lobe 10.25 10.25 8.75 A 45 AA
B-12514-12 Rolling Lobe 11.31 11.5 5.5 - 5.9 A 45 AA
B-13029 Double Convoluted 11.31 11.31 4.8 C 00 BB
B-14147 Rolling Lobe clamp plate 9.5 7 L 00 KK
B-14249 Rolling Lobe 9 10.25 9.2 D 45 AA
B-14395 Double Convoluted 5.31 5.31 3 U 00 TT
B-20228 Rolling Lobe 9 9.5 4.5 G 90 KK
B-21323 Double Convoluted 6.4 6.4 3.6 - 3.8 K 00 CC
C-7364 Rolling Lobe 9 9.45 6 D 00 KK
C-13122 Rolling Lobe 11.31 10.25 10.1 C 45 AA
C-20010 Rolling Lobe 9 9.5 5.6 G 00 JJ
C-20127 Rolling Lobe 10.38 10.23 7.3 G 00 FF
C-20223 Rolling Lobe 9 9.75 5.4 - 5.5 G 00 JJ
C-20414 Rolling Lobe 9 10.23 7.3 G 45 FF
C-20716 Rolling Lobe 9 11.06 7.3 G 00 FF
C-20900 Rolling Lobe 10.3 9.21 6.8 V 00 UU
AIR SPRINGS
C-21208 Rolling Lobe 9 9.49 5.6 T 45 JJ

C-21623 Rolling Lobe 10.38 7.88 7.3 V 00 JJ
C-21966 Rolling Lobe 10.38 9.21 8 V 00 UU
C-22173 Rolling Lobe 10.3 10.2 8.9 A 45 AA
C-22948 Rolling Lobe 10.38 9.21 8 V 00 UU
C-23114 Double Convoluted 6.31 6.31 3 S 00 CC
C-23611 Rolling Lobe 9 10.25 7.4 V 00 UU
D-22697 Rolling Lobe 10.38 9.5 11.5 A 45 JJ
22 1
See Bolt Pattern Section to determine top and bottom style.
AIR SPRING
APPLICATION CHART
HENDRICKSON PART NO. MODEL(S) WHERE USED2 NOTE

B-1080 CL, T
B-1159 AB, LD
B-1245 T
B-1345 CL, HTBL, VCL, T, TMB
B-2063 T
B-2064 T, TDC
B-2066 T, MB, T23-US
B-2734 CL, T
B-2827 T, TMB, T23-US
B-3184 T
B-3411 T23-US
B-3467 T
B-3648 Replaced by B-4771 for RL models
with frame modifications
B-3798 LD
B-3830 HT300U, T
B-3839 Replaced by B-4771 for RL models
with frame modifications
B-3842 T23-US
B-4041 T
B-4375 T, TMB
B-4771 HC300, HS300, HT300, T, T23-RL
B-4773 T, TMB
B-5060 T
B-5468 TMB
B-6195 T, T23, TMB
B-6242 HTCL
B-6412 T
B-7193 TL
B-8988 T
B-9001 T
B-9830 T
B-10170 LD
B-10352 T23-US
B-11566 T
B-11650 T, TMB
AIR SPRINGS
B-12335 VCL, HTBL
B-12353 T, T23-US
B-12514-4 T30
B-12514-5 CL, BL
B-12514-8 T30
B-12514-12 T25
B-13029 LD
B-14147 TL
B-14249 HT250U
B-14395 VBL
B-20228 HT190U
B-21323 HTHL
C-7364 CC
C-13122 HC250U, HS250U, HT250U, HTDOLLY
C-20010 HC230, HF230, HS230, HT230,
HTDOLLY, HT250US
C-20124 HS250U, HT250T, HT250U, HT250US
2
Air spring listed may not be the only air spring available for specified model.
23
AIR SPRING
APPLICATION CHART cont.
HENDRICKSON PART NO. MODEL(S) WHERE USED2 NOTE

C-20127 HT250T, HT250US, HT250US
C-20217 HC190U, HF190U, HS190U, HT190U,
HTDOLLY
C-20223 HC190T, HF190T, HS190T, HT190T,
HTDOLLY
C-20413 HK200U, HT250U, HT250US
C-20414 HT250U, HT250US
C-20716 HT250U, HT250US
C-20900 AA230
C-20901 Replaced by C-21784 for AA250 models
C-21208 HC230, HT230
C-21623 Replaced by C-22045
C-21624 Replaced by C-22046
C-21784 AA250, HKA250
C-21800 AA200, AA230, HIK, HIS, HKA180
C-21966 AA200, AA230, HIK, HKA200 Replaced by C-22948 for HKA180 models
C-22045 HK190T
C-22046 HK230
C-22173 HT300U
C-22948 HKA180
C-23114 UBL
C-23611 AA250L
C-23612 AA250L
C-23613 AA230L
C-23614 AA230L
C-23720 AA230L
C-23721 AA250L
D-22697 HT200UAM, HK200M
2
Air spring listed may not be the only air spring available for specified model.
AIR SPRING
ROTATION DEFINITIONS
BOTTOM BEAD PLATE VIEW
TOP BEAD PLATE VIEW
AIR SPRINGS
PARALLEL ALIGNMENT 45 DEGREE ALIGNMENT
I.
II.
90 DEGREE ALIGNMENT
III.
NOTE: ALIGNMENT IS BASED ON THE ORIENTATION OF THE BOTTOM BEAD PLATE OR PISTON COMPARED TO THE TOP BEAD PLATE.
24
AIR SPRING
TOP BEAD PLATE BOLT PATTERNS
A B
3/8-16 UNC
1/2-13 Stud
5.50 5.50
3/4-16 3/4-16 Combo Stud

Combo Stud
C D
2X 3/4-16 Combo Stud 1/2-13 Stud
7.75
6.20
1.38
3/4-16 Combo Stud
E F
4X 3/8-16 UNC 4X 1/2-13 Stud
6.25 6.25
1/4 NPTF 1/4 NPTF AIR SPRINGS

2X 3/8-16 UNC
G 3/4-16 H
Combo Stud
3.50
3.050 1/4 NPTF

1.75
25
AIR SPRING
TOP BEAD PLATE BOLT PATTERNS cont.
J 2X 1/2-13 Stud K 1/2-20 Stud
3.50
3.38
1/4 NPTF
1.75
3/4-16 Combo Stud
L 1/2-20 or 13 Stud
M 2X 3/4-16 Combo Stud
4.75
4.75
1.50
3/4-16 Combo Stud
N 2X 3/8-16 UNC P 2X 3/8-16 UNC
6.20 6.20
1/4 1/4 NPTF

NPTF
AIR SPRINGS
2.88 3.10
R 2X 1/2-13 UNC Stud S

3/4-16 UNF Combo
Stud with 1/4 NPTF
6.20
3/4 NPTF
2.88
26
AIR SPRING
TOP BEAD PLATE BOLT PATTERNS cont.
3/4-16 Combo Stud 2X 3/8-16 UNC

T U
2X 3/8-16 UNC
2.75
1.73
2.16
1.73
2.16
V
2X 3/4-16
Combo Stud
5.50
1.375
AIR SPRINGS
27
AIR SPRING
BOTTOM BEAD PLATE/PISTON
BOLT PATTERNS
AA BB
2X 3/8-16 UNC
7.875
6.20
4X 1/2-13 UNC
CC DD
2X 3/8-16 UNC
4X 3/8-16 UNC
6.25
3.50
EE FF
4X 1/2-13 Stud
6.25 4.00
5.66
AIR SPRINGS
3X 1/2-13 UNC
GG 1/2-13
HH
UNC
4X 1/2-13 UNC
6.25
1/4 NPTF
28
AIR SPRING
BOLT PATTERNS cont.
JJ KK 2X 1/2-13 Stud
4.00
5.66 4.12
4X 1/2-13 UNC
LL MM
4X 1/2-13 Stud
5.56
7.875
5X 1/2-13 UNC
NN PP
3/4-10 2X 1/2-13 UNC
Stud
4.12
AIR SPRINGS
3/4-10 Stud
RR 2X 1/2-13 Stud SS
6.20 6.20
4X 3/8-16 UNC
29
AIR SPRING
BOLT PATTERNS cont.
TT 2X 3/8-16 UNC UU
2.75
1/2-13 UNC Stud

1/4 NPTF
AIR SPRINGS
30
SECTION CONTENTS
DESCRIPTION PAGE
SHOCK ABSORBER IDENTIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
SHOCK ABSORBER APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
SHOCK STRAP KIT REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
SHOCK ABSORBERS
31
SHOCK ABSORBER
IDENTIFICATION CHART
Dimension E
Dimension D Dimension C
Dimensions
A&B
HENDRICKSON COLLAPSED EXTENDED STROKE CYLINDER DUST SHIELD MOUNTING HOLE

PART NO.1 LENGTH (+/- 0.13) LENGTH (+/- 0.13) DIAMETER DIAMETER DIAMETER (NOM.)
(Dim. A) (Dim. B) (Dim. C) (Dim. D) (Dim. E)
A-1667 11.46 17.24 5.78 2.19 2.50 0.75
A-2160 13.71 21.74 8.03 2.19 2.50 0.75
A-2212 12.97 20.25 7.28 2.19 2.50 0.75
A-2213 16.21 26.74 10.53 2.19 2.50 0.75
A-2218 14.84 24.00 9.16 2.19 2.50 0.75
A-2240 17.71 29.74 12.03 2.19 2.50 0.75
A-2471 17.21 28.74 11.53 2.19 2.50 0.75
A-4084 15.22 24.75 9.53 2.19 2.50 0.75
A-4890 13.47 20.50 7.03 2.75 3.25 1.00
A-10023 11.38 18.21 6.83 1.81 2.25 0.50
A-10348 17.00 28.00 10.78 2.19 2.50 0.75
A-11931 11.40 17.68 6.28 2.19 2.50 0.50
A-14583 11.60 17.51 5.91 2.19 2.50 0.50
A-20001 11.59 16.97 5.38 2.02 2.38 0.75
A-20002 11.60 17.51 5.91 2.19 2.50 0.75
SHOCK ABSORBERS
A-20126 11.71 17.49 5.78 2.75 3.25 0.75

A-20345 13.83 21.86 8.03 2.75 3.25 0.75
A-20889 11.71 17.49 5.78 2.75 3.25 0.75
A-21292 9.47 13.25 3.78 2.19 2.50 0.75
B-21553 11.71 17.49 5.78 2.75 3.25 0.75
B-21699 11.74 17.37 5.63 2.75 3.25 0.75
B-21936 10.72 16.00 5.28 2.19 2.50 0.75
B-21947 9.47 13.25 3.78 2.19 2.50 0.75
B-21994 10.71 15.87 5.16 2.75 3.25 0.75
B-21995 9.46 13.24 3.78 2.75 3.25 0.75
B-22345 11.60 16.76 5.16 2.19 2.50 0.75
B-22715 11.47 17.00 5.53 2.19 2.50 0.75
B-22862 9.97 14.50 4.53 2.19 2.50 0.75
B-23361 11.60 16.76 5.16 2.19 2.50 0.75
B-23548 8.85 12.01 3.16 2.19 2.50 0.75
B-23566 11.60 17.51 5.91 2.19 2.50 0.75
B-23649 10.72 16.00 5.28 2.19 2.50 0.75
B-23650 9.47 13.25 3.78 2.19 2.50 0.75
B-23651 9.97 14.50 4.53 2.19 2.50 0.75
B-23743 10.71 15.87 5.16 2.75 3.25 0.75
B-23744 9.46 13.24 3.78 2.75 3.25 0.75
B-24023 11.71 17.49 5.78 2.75 3.25 0.75
B-24088 11.50 16.99 5.49 2.00 2.37 0.75
B-24125 11.71 17.49 5.78 2.75 3.25 0.75
1
32 Hendrickson Part No. may also begin with an S rather than an A or B. An S represents a service part.
SHOCK ABSORBER
APPLICATION CHART
HENDRICKSON PART NO.1 MODEL(S) WHERE USED2 NOTE

A-1667 AB, T-2, T-6, TDC-031, TDC-041
A-2160 T, some HT230, HTQUAD, HT250U, HT300T,
A-2212 T, HT190U-6.75, most HT250T,
HT250U MaxiLift
A-2213 T
A-2218 T
A-2240 T
A-2471 T
A-4084 T
A-4890 T
A-10023 LD-375, LT-014 Replaced by A-14583
A-10348 T30 with 5 Ride Height
A-11931 LD-365, LD-384 Replaced by A-14583
A-14583 LD-365
A-20001 Most HT190T, HS190T, HC190T, HC190U,
HF190T, HT190U, HS190U, HTDOLLY (20K)
A-20002 Most HT230, HS230, HC230, HF230, Replaced by B-23566 for AA230T/
HT250U, HS250U, HTDOLLY (23K) AA250T, HKA200, HIS and HIK models
A-20126 Most HT300T, HT300U, HS300T, HT250U, Replaced by B-24125 for AA230T/
HT230 Extended Service, HTDOLLY (30K) AA250T, HKA200/HKA250 models
A-20345 HT300T
A-20889 HT230, HC230, HT300T Urethane bushings
A-21292 HK190T, HK230
B-21553 HT250U Extended Service with High Damping, Replaced by B-24023 for AA230T/
HT250U Y Beam AA250T models
B-21699 Some HT300U
B-21936 Replaced by B-23649
SHOCK ABSORBERS
B-22715 HKA180 High Damping
B-23361 AA230T/AA250T Limited Rebound
B-23548 HT250US Std. Travel for 4 Ride Height
B-23566 AA230T/AA250T, HKA200 Std. Duty
B-23649 HT250US Std. Travel 7-1/2 to 14 Ride Heights,
Ltd. Travel 6-1/2 to 12 Ride Heights
B-23650 HT250US Std. Travel 5-1/2 and
6-1/2 Ride Heights
B-23651 HT250US Extended Rebound 6-1/2 Ride Height,
Tapered Hanger 6-1/2 Ride Height,
Tilted Hanger 7-1/2 Ride Height
B-23743 HT250US Extended Service with High Damping
for Std. Travel 7-1/2 to 14 Ride Heights
and Ltd. Travel 6-1/2 to 12 Ride Heights
B-23744 HT250US Extended Service with High Damping
for Std. Travel 5-1/2 and 6-1/2 Ride Heights
B-24023 AA230T/AA250T Extended Service with
High Damping
B-24088 HKA180 Std. Duty
B-24125 AA230T/AA250T and HKA200/HKA250
Extended Service
1
2
Hendrickson Part No. may also begin with an S rather than an A or B. An S represents a service part.
Shock listed may not be the only shock available for specified model.
33
SHOCK STRAP KIT
REFERENCE CHART
Shock Strap Shock Clevis Shock Strap
Nylon Wrap Nylon Wrap Nylon Wrap Nylon Wrap
C-23086 SHOCK STRAP KITS1 C-14587 SHOCK STRAP KITS
SHOCK ABSORBER USE SHOCK STRAP KIT MODEL(S) WHERE USED ADJUSTED
PART NO.2 PART NO. LENGTH (Dim. A)
A-1667 C-14587-1 HT250U, T 15-1/4
A-2160 C-14587-2 HT230, HTQUAD, HT250U, HT300, T 19-1/4
A-2240 C-14587 T 26-3/8
A-2212 C-14587-3 HT190U, HT250T, HC250U, 18-1/4
HT250U MaxiLift, T
A-2213 C-14587-4 T 23-3/4
A-2218 C-14587-5 HT, T 21-1/4
A-2471 C-14587-7 T 25-1/4
A-4084 C-14587-6 T 22-1/4
A-20001 C-14587-1 HT190, HS190T, HC190T, HT190U, 15-1/4
HS190U, HTDOLLY
C-23086-1 HKA180 15-1/4
A-20002 C-14587-1 HT230, HS230, HF230, HT250U, HS250U 15-1/4
C-23086-1 AA230T/AA250T, HKA200, HIS, HIK 15-1/4
A-20126 C-14587-8 HT230, HT250U, HT300T, HT300U, HS300T 19-1/4
C-23086-2 AA230T/AA250T, HKA200/HKA250 15-3/4
A-20889 C-14587-8 HT230, HT300, HC230 15-3/4
SHOCK ABSORBERS
C-23086-2 AA250T 15-3/4

A-21292 C-14587-9 HT190U, HK230, HK190T 11-7/8
B-21553 C-14587-8 HT250U 15-3/4
C-23086-2 AA230T/AA250T 15-3/4
B-21936 C-23086-5 HT250US 14-1/4
B-21947 C-23086-3 HT250US, HK200U 11-7/8
B-21994 C-23086-5 HT250US 14-1/4
B-21995 C-23086-3 HT250US 11-7/8
B-22862 C-23086-4 HT250US 12-7/8
B-23566 C-23086-1 AA230T/AA250T, HKA200/HKA250 15-1/4
B-23649 C-23086-5 HT250US 14-1/4
B-23650 C-23086-3 HT250US 11-7/8
B-23651 C-23086-4 HT250US 12-7/8
B-23743 C-23086-5 HT250US 14-1/4
B-23744 C-23086-3 HT250US 11-7/8
B-24023 C-23086-2 AA230T/AA250T 15-3/4
B-24088 C-23086-1 HKA180 15-1/4
B-24125 C-23086-2 AA230T/AA250T, HKA200 15-3/4
1
C-23086 Shock Strap Kits contain Shock Clevis to attach to lower shock mount for shock strap retention.
2
Hendrickson Part No. may also begin with an S rather than an A or B. An S represents a service part.
Dimension A
34
TECHNICAL
PROCEDURE
INTRAAX SUSPENSION SYSTEMS
SUBJECT: Installation Procedures
LIT NO: L341
DATE: January 2000 REVISION: C
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PRE-INSTALLATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SUSPENSION ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RECOMMENDED WELDING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
AIR CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESIGNED RIDE HEIGHT MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HEIGHT CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WHEEL BEARING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONMET PRESET HUB PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
AXLE ALIGNMENT QUIK-ALIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
HK SLIDER SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
FINAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
INTRAAX INSTALLATION PROCEDURES
INTRODUCTION SPECIAL NOTES

The following instructions are intended for use with the Defective or incorrect components are to be returned
Hendrickson INTRAAX Air Ride Suspension. to Hendrickson, which will supply replacements for
For instructions concerning other suspension models, the components in question per product warranty
contact the Hendrickson Trailer Suspension Systems conditions.
Technical Service Department at (330)456-7288.
It is the responsibility of the installer to determine the
NOTE: Always read the entire installation instructions correct location of the suspension in order to provide
thoroughly before proceeding with a suspension the proper trailer load distribution. The load carried by
installation. each axle must not exceed the rated capacity of the
components involved.
It is very important that the proper suspension is chosen for
the trailer application. The following criteria must be No welding of any of the suspension components is
considered when selecting a suspension: permitted, except where specified by Hendrickson.
required capacity No welding of the axle assembly or axle components is

loaded frame-to-ground measurement permitted.
axle travel
axle spacing No alteration of any of the suspension components is
permitted.
For additional information concerning suspension
selection, contact the Hendrickson Trailer Suspension Any installation deviations must be approved,
Systems Customer Service Department at in writing, by Hendrickson Trailer Suspension Systems
(330) 456-7288. Product Engineering Department at
(330) 456-7288.
CAUTION: The INTRAAX suspension system, as
with all air suspension systems, must It is the responsibility of the installer to ensure that
be installed with the proper amount of proper clearances exist between:
frame-to-ground clearance to ensure
trouble-free operation. If there is too Tires
much ground clearance, the Laterally
suspension will not carry its share of Vertically
the load. Too little ground clearance Fore and aft
may damage the suspension or other
vehicle components. Air springs when they are at their maximum diameter
(refer to suspension assembly drawing for specifications).
A correct installation must result in a
LOADED suspension ride height that is
within the range specified on the
suspension assembly drawing.
The trailer manufacturer should be

consulted before making any changes
to the vehicles frame. Typically,
cutting or altering the trailers frame or
side rail is not permitted and may
affect the manufacturers warranty
coverage.
2
PRE-INSTALLATION PROCEDURES PRE-INSTALLATION CHECKLIST

REQUIRED SUPPLIES Before beginning the installation:
The following equipment and materials are needed
when installing a Hendrickson INTRAAX suspension: 1. Check that the new suspension matches the
specifications provided by your Production or
1. Welding equipment and supplies. (See Engineering Department.
RECOMMENDED WELDING PROCEDURES.)
2. Verify that the vehicle will have the proper load
2. Torque wrench (capability of 600 ft-lbs). distribution after installation.
3. Tape measure or scale(s) and machinist square. 3. Verify that the actual trailer crossmember(s)
locations correspond with the locations specified
4. Trammel bar. on the suspension assembly drawing.
5. Crane or lifting capability. 4. Confirm that the components listed on the

suspension assembly drawing have been provided
6. Hammer or center punch (for bolt-on). in sufficient quantities. Contact the Hendrickson
Trailer Suspension Systems Customer Service
7. Compressed air supply. Department if any missing or damaged
components are found.
8. Air impact gun (capability of 600 ft-lbs).
9. Air fittings, tubing and associated tools.
10. 1/2" drive breaker bar.
11. Socket set and wrenches, including the following

sizes:
3/8"
9/16"
3/4"
11/8"
11/4" deep well socket
15/16" deep well socket
17/16" wrench
1" drive, E-20 socket
(Hendrickson P/N A-24536)
12. Suspension assembly drawing and plumbing

schematic supplied by Hendrickson.
13. Wheel chocks.
14. Frame jacks or supports.
3
SUSPENSION ASSEMBLY INSTALLATION

UPPER BAG PLATE
1. Lift and position the upper bag plates onto both the
trailer frame rail and the crossmember as specified
in the supplied suspension assembly drawing
(Figure 1).
2. Tack weld the upper bag plates into place and

recheck bag position. See suspension assembly
drawing for locating dimensions.
3. Refer to RECOMMENDED WELDING PROCEDURES Figure 1. Upper bag plate installation

section.
FRAME BRACKET
1. Lift and position the frame brackets onto the trailer
frame rails and the crossmembers as specified in
the supplied suspension assembly drawing
(Figures 2 and 3).
2. Tack weld the frame brackets into place and

recheck.
NOTE: DO NOT ATTACH the air spring mounting plate

or air spring to BOTH the trailer main rail and the
trailer crossmember. The air spring mounting is Figure 2. Frame bracket installation
not designed to resist the movement between the
trailer crossmember and the main rail.
3. Check that the frame-brackets have not been

compressed or distorted. Both alignment slots must
line up.
4. Refer to RECOMMENDED WELDING PROCEDURES

section.
FINAL WELD
1. Completely weld the frame brackets to both the
crossmembers and trailer frame rails as described
in the RECOMMENDED WELDING PROCEDURES Figure 3. Frame bracket installation for QUIK-ALIGN models
section. with winged frame brackets
AIR SPRINGS AND SHOCKS

1. Install the air springs and shocks, as per the
2. Torque the mounting bolts to Hendricksons

recommended values (see APPENDIX).
BOLT-ON ASSEMBLIES
1. For bolt-on assemblies, follow the trailer
manufacturers procedures and specifications.
4
TRAILING ARM/FRAME BRACKET

ASSEMBLY QUIK-ALIGN
CAUTION: DO NOT APPLY undercoating to the
suspension and frame bracket until
after completing the alignment.
Undercoating will effect clamp load of
the pivot connection fastener and can
damage the hardware.
If the trailing arm is not preassembled with the frame

brackets, install the trailing arm as follows:
1. Lift and position the suspension to the frame

brackets as is shown on the suspension assembly
drawing.
Figure 4. Installing trailing arm in frame bracket
2. Lower the trailing arm TRI-FUNCTIONAL BUSHINGS
into the frame brackets. Also install bushing wear
pads at this time (Figure 4).
3. Install the hardened flat washer and flanged

concentric washer onto pivot fastener (shear-type
bolt).
NOTE: If the assembly fits tightly in the frame bracket, it

may be necessary to spread the frame bracket.
DO NOT GRIND material from the bushing inner
metal.
4. Working from the inboard side of the trailer, insert

the pivot fastener through the frame bracket (toward
the tires) (Figure 4).
5. Place outer eccentric flanged washer, hardened flat

washer and torque prevailing heavy hex nut onto
fastener.
6. Tighten the torque prevailing heavy hex nut on each

shear-type bolt to hold the flanged eccentric and
concentric collars in place between the alignment
guides, but loose enough to permit the hardened
washers to rotate freely; do not shear off the torx
head until axle alignment procedure has been
performed.
5
TIRE CLEARANCE
Hendrickson specifies that the tire clearance above the
jounce requirement must include one inch for INTRAAX.
A two-inch clearance is specified between the trailer
frame and inside tire inboard sidewall. This will provide
sufficient clearance to allow for tire distortion and axle
walk (Figures 5 and 6).
FINAL ASSEMBLY
1. Install the air springs and shocks, as per the
2. Torque the mounting bolts to Hendricksons

recommended values (see APPENDIX).
3. If required, position and tack weld the frame bracket

cross channel to both frame brackets as shown on
the suspension assembly drawing.
4. Completely weld the frame bracket cross channel to

both frame brackets as described in the
RECOMMENDED WELDING PROCEDURES section. Figure 5. Inside-to-inside tire measurements
Figure 6. Alternative installation of the QUIK-ALIGN pivot bolt
6
RECOMMENDED WELDING PROCEDURES 3. Achieve spray arc transfer with the following
WARNING: IF THESE PROCEDURES AND welding parameters:
SPECIFICATIONS ARE NOT FOLLOWED,
DAMAGE TO THE AXLE OR Standard
SUSPENSION COULD RESULT. THE Electrode: AWS E-7018 (Oven Dried)
RESULTING AXLE OR SUSPENSION .125 DIA.
DAMAGE COULD CAUSE AN 120-140 AMPS D.C.
ACCIDENT, PROPERTY DAMAGE, ELECTRODE POSITIVE
AND/OR SERIOUS INJURY.
.156 DIA.
WELDING PARAMETERS 120-160 AMPS D.C.
NOTE: A welder qualified in 2G position per ANSI/AWS ELECTRODE POSITIVE
D1.1-94 Section 5 Part C Welder Qualification
must perform the welding. Standard Wire: AWS ER-70S-6
.045 DIA.
NOTE: The specification shown below is for horizontal (i.e., LA-56 or NS-115)
(2F) positioning.
Optional Wire: AWS ER-70S-3
1. Suspension components and their mating parts .045 DIA.
must be at a minimum temperature of 60F (i.e., LA-50 or NS-101)
(15.5C) and free from moisture, dirt, scale, paint
and grease. Volts: 26-30 DCRP
2. All welds must be performed in a flat, or horizontal,

position. Current: 275-325 AMPS
Wire Feed
Speed: 380-420 IPM
Electrode
3
Extension: /4"-1"
Gas: 86% Ar 14% CO2

at 30 to 35 CFH
NOTE: Any deviation from these welding parameters

must be approved by Hendrickson Trailer
Suspension Systems in writing.
7
FRAME BRACKET, CROSSMEMBER, UPPER

SHOCK BRACKET AND AIR SPRING
MOUNTING WELDING PROCEDURES
Weld all miscellaneous suspension componentry using
the parameters at the beginning of this section.
The following figures are examples of typical suspen-

sion installations. The procedures illustrated may need
to be adapted due to varying trailer designs (Figures 7
through 16).
IMPORTANT: Starting and stopping points should be no

closer than 1/2" from the mating edge of
the suspension component and the trailer
frame and/or the crossmembers. Figure 7. Typical frame bracket-to-frame attachment
NOTE: It is the responsibility of the suspension installer

and the vehicle designer to provide both
adequate vehicle frame design and proper
securing method for the suspension system.
NOTE: The suspension installer has the responsibility to

determine the proper welding parameters for the
materials being used. For specifications of the
suspension component material, contact
Hendrickson Trailer Suspension Systems.
The attachments shown are designed to properly sup-

port the suspension. The suspension frame brackets
are not to be used as a structural component of the
trailer. Close attention should be paid to the attachment
of the trailer crossmember to the trailer main rail to
ensure that the frame bracket does not support this Figure 8. Severe offset frame bracket attachment
connection. Contact Hendrickson Trailer Suspension
Systems at (330) 456-7288 with any questions con-
cerning this connection.
NOTE: DO NOT ATTACH the air spring mounting plate

or air spring to BOTH the trailer main rail and the
trailer crossmember. The air spring mounting is
not designed to resist the movement between the
trailer crossmember and the main rail.
Figure 9. Frame bracket-to-mounting plate attachment (customer

supplies bolt-on plate and gussets)
8
Figure 10. Typical QUICK-ALIGN winged frame bracket-to-frame

attachment
Figure 11. Air spring spacer attachment
Figure 12. Severe offset mounting with spacer
9
Figure 13. Air spring mounting plate attachment
Figure 14. Severe offset mounting without spacer
10
Figure 15. C-channel attachment to frame bracket
Figure 16. Frame bracket knee brace attachment
11
AIR CONTROLS INSTALLATION

Hendrickson offers a variety of air control systems for
trailer air suspensions. The installation procedures vary
depending on the specified air control kit for the trailer
and the trailers air system. A diagram showing the
component and air line arrangement is supplied with
each kit. Review the supplied suspension assembly
drawing for additional notes, such as height control
valve arm length. Fittings and air lines are not provided.
Contact Hendrickson Trailer Suspension Systems
Technical Service Department at (330) 456-7288 with
any questions regarding installation of air controls.
The following notes apply to all Hendrickson Trailer air Figure 17a. ID tag on current INTRAAX suspensions
control kits:
1. Do not add lubrication to air system.
2. All connections must be leak proof.
3. Avoid sharp bends in the air lines that can restrict

airflow and provide adequate excess air line when
connecting to moving parts.
4. D.O.T.-approved tubing and fittings are to be

furnished by the customer.
DESIGNED RIDE HEIGHT

MEASUREMENT
1. To determine the ride height of your INTRAAX
suspension, locate the suspension ID tag on the Figure 17b. ID tag on early INTRAAX suspensions
inside of the suspension beam. The model and
description information found on the tag indicates
the designed ride height as shown in the following
example (Figures 17a and 17b).
INTRAAX (early) Model: AA230TBA..J 14A1A01...

INTRAAX (current) Model: AA250TC140
Description: A14U775N7
2. Measure the ride height (Figure 18). If necessary,

adjust the height control valve. The designed ride
height is the distance from the center of the axle to
the mounting surface of the suspension.
NOTE: To determine the ride height, add half of the

diameter to the measurement shown on the tape
measure. For example, a 5" diameter axle would
have 21/2" added to the measurement. Figure 18. Measure the ride height
12
INTRAAX RIDE HEIGHT SETTINGS

SUSPENSION RIDE HEIGHT (inches)
TRAVEL NOMINAL MINIMUM MAXIMUM
AA230T/AA250T INTRAAX SUSPENSIONS
13.5 13.25 15.75
14 13.25 15.75
STANDARD 15 14.25 15.75
16 15.25 17.75
17 16.25 17.75
14 13.25 14.5
LIMITED JOUNCE 16 15.25 16.5
AA230L/AA250L INTRAAX SUSPENSIONS
6.5 6.5 7.5
7.5 6.5 7.5
9 7.25 10
12 10 13.5
STANDARD 14 11.25 15
15 12.75 15
16 13.5 17
17 14.25 17
19 16.5 19
21 18.5 21
9 8.5 10
12 11 13.5
14 12.5 15
15 13.5 15
LIMITED JOUNCE 16 14.5 17
17 15.5 17
19 17.5 19
21 19.25 21
HKA180 VANTRAAX SUSPENSIONS (INTRAAX & K-2)
14 13.75 15.25
15 14.75 15.25
16 16 17.25
STANDARD 16.5 16.5 17.25
17 17 17.25
18 18 19.25
19 19 19.25
14 13.75 15.75
15 14.75 15.75
16 16 17.75
STANDARD 16.5 16.5 17.75
17 17 17.75
18 18 19.75
19 19 19.75
16 16 17.5
16.5 16.5 17.5
STANDARD 17 17 17.5
18 18 19.75
19 19 19.75
13
HEIGHT CONTROL VALVE

THEORY OF OPERATION
The height control valve is the part of the air suspen-
sion system that imports and exports air to and from
air springs. Our height control valve maintains a con-
stant static design height and does not respond to short
duration dynamic changes in axle position.
Hendrickson Trailer Air Suspension Systems need only

one height control valve per trailer, regardless of the
number of axles. The reason is our own patented
design that uses the TRI-FUNCTIONAL BUSHING in
conjunction with a rigid axle connection. The beams
and axle act like a tension bar which, in turn, gives the
suspension its roll stability.
Hendrickson generally recommends the height control

valve be mounted on the rear axle in tandem applica-
tions and on the center axle in tri-axle applications. If a
SURELOK mechanism is installed, the height control
valve must be mounted to the same axle as the
SURELOK.
With the axle parallel to the trailer frame, the single

height control valve maintains ride height and simulta-
neously delivers and/or exhausts air from the air
springs as required. In order for the trailer to lean, the
axle must be torsionally twisted, or the axle connection
has failed.
IMPORTANT: The use of two height control valves is not

an approved practice. Continued use will
void the warranty, unless approved in
writing by the Hendrickson Trailer
Suspension Systems Engineering
Department.
A height control valve kit consists of one valve, sub-

assembly, and fittings to attach valve to air spring.
The height control valve can be used in either a right-

hand, left-hand, fore, or aft applications, with both long
and short control arm accommodations.
IMPORTANT: DO NOT USE a pipe compound or teflon

tape.
NOTE: For installation instructions, refer to materials

provided with the air control kit.
14
ADJUSTING THE HEIGHT CONTROL VALVE

1. Maintain pressure in the air system.
IMPORTANT: There must be a minimum of 80 psi air

pressure in the air reservoir to open the
brake protection valve and allow air to
flow through the height control valve.
2. Push the control arm (prior to linkage installation)

up to raise the ride height or down to lower it until
the distance between the vehicle frame and the
center of the axle matches the suspension ride
height.
3. After adjusting the ride height, insert the locating

pin into the adjusting block and bracket on the
height control valve.
4. Install the linkage between the suspension bracket

and the lever arm on the height control valve.
Adjust or replace the linkage to fit.
IMPORTANT: There are two types of linkage for the

height control valve.
Clamped-Type Linkage: Trim rod, if

required, and insert into both the
clamps and link ends. Tighten clamps
as required to hold the height control
valve in its neutral position when the
suspension is at proper ride height.
Bolted-Type Linkage: Trim, if required,

and fasten both links together with the
supplied fasteners as required to hold
the height control valve in its neutral
position when the suspension is at
proper ride height.
5. Remove the locating pin.
6. Verify ride height by measuring it.
IMPORTANT: When returning the height control valve to

the center position, wait for the air to stop
flowing through the valve before checking
the ride height.
7. Ensure that adequate component clearances have

been provided (see FINAL INSPECTION
PROCEDURES).
15
WHEEL BEARING ADJUSTMENT

1. INTRAAX typically uses the double nut wheel
attaching system of an adjusting nut, lockwasher,
jamnut and set screw (Figure 19).
NOTE: A single nut system is now available for some

combinations.
2. After mounting the hub assembly, torque the inner

adjusting nut to 200 ft-lbs (271 Nm) while
rotating the hub assembly (Figure 20).
IMPORTANT: Never use an impact wrench to adjust

wheel bearings.
Figure 19. Double nut wheel attaching system
3. Loosen the inner adjusting nut one full turn and

rotate the wheel.
4. Rotate the hub assembly while retorquing the inner

nut to 50 ft-lbs (68 Nm).
NOTE: This will position the bearings for final

adjustment.
5. Loosen the inner nut 1/4 turn.
6. Install the lock washer.
NOTE: The tang must fit in the slot cut in the spindle
while the dowel in the nut aligns with a hole in
the washer.
Figure 20. Torque the inner adjusting nut
7. If the dowel does not align, remove the washer, flip

it over and reinstall.
CAUTION: Never tighten the inner spindle nut for

dowel pin alignment. This may cause
pre-load to the bearing and cause
premature failure.
8. If necessary, loosen the inner nut slightly to align

the dowel of the nut with a hole in the washer
(Figure 21).
9. Install the outer nut.
10. Torque outer nut to 315-385 ft-lbs (427-521Nm).

Figure 21. Align the dowel of the nut with the hole in the washer
16
11. Verify the end play with a dial indicator by using
the following procedure:
a. Attach the magnetic base of the dial
indicator to the spindle end. The stem of the
dial indicator must touch the gasket surface
of the hub (Figure 22).
b. Rotate the hub slightly in both directions

while pushing the assembly inward until the
reading does not change. Zero the dial
indicator (Figure 23).
Figure 22. Attach dial to spindle head
c. Slightly rotate the hub in both directions
while pulling outward on the assembly
until the reading remains constant
(Figure 24).
NOTE: Wheel end play should be between .001-.005.

If end play is not within specifications, then
readjustment is required.
12. Install and tighten the set screw to 18-19 ft-lbs

(24-25 Nm) in the lock washer, after the wheel
end play has been verified.
CONMET PRESET HUB PROCEDURES

INSTALLING CONMET PRESET HUBS Figure 23. Measure the inward play
1. All PreSet hubs are shipped ready for installation
with a thin film of lubricant on the bearings. (If
using an oil-filled hub, additional lubricant will be
added after installation.)
2. Install the PreSet hub all the way onto the spindle.
Allow the temporary plastic alignment sleeve to be
pushed out of the Preset hub as it is installed onto
the spindle.
3. Once the bearing is on the spindle, NEVER

REMOVE THE OUTER BEARING. Removing the
outer bearing may cause the seal to become
misaligned, resulting in premature seal failure.
Figure 24. Measure the outward play
4. Remove the plastic bearing cover and install the

spindle nut.
5. Torque the inner (adjusting) nut to 300 ft-lbs

(407 Nm). Do not back off inner spindle nut.
6. Install the spindle locking nut. If the dowel pin and 7. Install the outer spindle (jam) nut. Torque to
washer are not aligned, turn it over and reinstall. If 200 ft-lbs (271 Nm).
required, tighten the nut until alignment takes
place. NEVER LOOSEN THE SPINDLE NUT FOR 8. Install and tighten the locking set screw to
DOWEL PIN ALIGNMENT. 18-19 in-lbs.
17
AXLE ALIGNMENT QUIK-ALIGN ALIGNMENT PROCEDURE

OVERVIEW 1. Tighten the torque-prevailing heavy hex nut on each
The QUIK-ALIGN alignment feature incorporates two shear-type pivot bolt to hold the flanged eccentric
flanged washers that are inserted into slots located on collar in place between the alignment guide, but
each side of the frame bracket. The outboard flanged loose enough to permit the hardened flat washers
washer is eccentric. Its outside diameter is guided by to rotate freely.
an adjustment guide. Rotating the eccentric washer
clockwise or counterclockwise provides fore and aft CAUTION: DO NOT APPLY OR ALLOW any type of
movement at the suspensions axle. The pivot connec- lubricant to contact the threads of the
tion is clamped together with a torque prevailing heavy shear-type pivot bolts. Lubricant will
hex nut, hardened flat washers and shear-type bolt. The reduce the friction between the
shear-type bolt ensures proper torque and eliminates threads of the bolts and the torque-
the need for a torque wrench. prevailing heavy hex nut. Failure of the
shear-type pivot bolts may occur.
REQUIRED MATERIALS
The following sockets and wrenches are needed to CAUTION: DO NOT APPLY undercoating to the
adjust QUIK-ALIGN equipped suspensions: suspension and frame bracket until
after completing the alignment.
1. 1" drive E-20 Torx socket (Hendrickson P/N A-24536) Undercoating will effect clamp load of
the pivot connection fastener and can
2. 17/16" wrench damage the hardware.
3. 1
/2" breaker bar IMPORTANT: You can reuse the shear-type pivot bolt
and torque-prevailing heavy hex nut one
time prior to the trailer being put into
4. Impact wrench capable of 600 ft-lbs
service. If future realignment becomes
necessary, you must use new pivot-
ALIGNMENT PREPARATION connection hardware P/N S-24679 to
1. The axle alignment site area should be flat, level
prevent failure of the pivot connection due
and free of debris.
to insufficient clamp load. Hendrickson
provides the means to achieve correct axle
NOTE: Alignment of sliders If the suspension is
alignment. However, the OEM or repair
mounted on a slider assembly, remove the slack
facility is responsible for proper assembly
in the locking pins to match the slider as closely
and performing the axle alignment.
as possible to its operational state. A
Therefore, Hendrickson assumes no
recommended procedure is to lightly apply the
liability for pivot-joint failures or incorrect
trailers brakes and gently pull forward, thus
axle alignment.
removing all of the slack. This procedure will
avoid pre-loading the TRI-FUNCTIONAL 2. Inspect the orientation of the square hole in the
BUSHINGS when moving the trailer. flanged eccentric collar (outboard side). The
2. Set the trailers bolster plate (upper coupler) to its square hole should be at the twelve oclock
designed height by adjusting the landing gear. Set (12:00) position or the middle of the alignment
suspension(s) at the ride height specified on the adjustment.
3. If necessary, adjust the flanged eccentric collar so
3. Inspect each tire set. Tires of each dual wheel set must the square hole is at the 12:00 position. To adjust
be matched to a maximum of 1/8" tire radius or a the flanged eccentric collar, insert the 1/2" square
drive breaker bar into the square hole in the flanged
maximum of 3/4" variation in tire circumference.
eccentric collar. Rotate the flanged eccentric collar
a maximum of 45 degrees clockwise or
4. Secure trailer and release the trailers brakes. This
counterclockwise to produce fore-and-aft axle
will allow wheel rotation while positioning the
positioning.
suspension fore and aft.
18
4. Repeat steps 1 through 3 on the remaining pivot 10. Torque the shear-type pivot bolt to 550 ft-lbs (45
connections. ft-lbs) with the 1" drive socket until the Torx head
shears off from the bolt.
5. Measuring from the trailers kingpin, rotate the
flanged eccentric collar on one side of the forward 11. Align the additional axles to the forward axle by
axle clockwise or counterclockwise until both axle rotating their flanged eccentric collars until the ends
ends are equal distance from the kingpin. of the axles are an equal distance from the axle in
front of it. Repeat steps 1-3 and 6-9.
IMPORTANT: A maximum of 1/8" tolerance from side to
side is considered acceptable. IMPORTANT: A maximum alignment tolerance of 1/16" is
considered acceptable on the additional
6. If the flanged eccentric collar reaches 45 degrees axle(s).
without achieving alignment, rotate the flanged
eccentric collar of the suspensions other frame
bracket; repeat step 2.
IMPORTANT: Beyond 45 degrees in either the fore or the

aft directions of the flanged eccentric
collar, there is no change in adjustment.
7. Tap on the flanged concentric collar (inboard side

of the frame bracket) with a rubber mallet during
adjustment.
IMPORTANT: The tapping allows the concentric and

eccentric collars to move in unison. If the Figure 25. Wedged pivot connection hardware
collars do not move together, the
concentric collar may wedge against the
frame bracket during the adjustment. The
result of the wedged collar (Figure 25) is
an inaccurate alignment.
IMPORTANT: Figure 27 depicts a properly positioned

eccentric collar.
8. If additional axle movement is necessary, adjust

the flanged eccentric collar on the opposite side of Figure 26. Raised eccentric collars
the forward axle from the 12:00 position.
IMPORTANT: When making these axle movements,

avoid compressing the TRI-FUNCTIONAL
BUSHING.
CAUTION: Always wear eye protection when

operating pneumatic tooling.
CAUTION: Always pin the socket to the

pneumatic tooling. Figure 27. Properly positioned eccentric collar
9. After achieving proper alignment of the forward

axle, snug the pivot-connection fasteners and
recheck alignment.
19
HK SLIDER SYSTEM INSTALLATION Failure to correctly position the components can lead to
COMPONENT POSITIONING the following trailer problems and void any future war-
The proper positioning of the slider components, rela- ranty coverage:
tive to one another as well as to the trailer components,
is crucial to extended component life. The four most Positioning Difficulties
important factors in this relationship are as follows:
(Figure 28) Improper Tracking
1. BODY RAIL SPACING Body rail spacing must be Improper/Inadequate Pin Engagement
held to permit slider longitudinal movement, and
yet limit slider misalignment. Premature Tire Wear
2. PARALLEL BODY RAILS Both body rails must Shortened Slider System/Suspension Life
remain parallel to one another both vertically and
horizontally.
3. PIN HOLE ALIGNMENT The coaxial hole

alignment must not vary more than 1/16".
4. ALIGNMENT WITH TRAILER The longitudinal

center axis of the trailer must match that of the
slider system.
Figure 28. Component positions
20
BODY RAIL INSTALLATION

1. Place both slider body rails face down (large
flange pointing down) on a flat level surface,
spaced apart at the approximate width of the slider
box (Figure 29). It is important that the surface be
level to avoid the possibility of unparallel (both
horizontally and vertically) body rails.
NOTE: A forward and rearward positive stop must be

provided and installed by the trailer OE or other
slider installer on the body rail ends. (See Figure
30 for Hendricksons recommended method.)
2. Using a flexible rule, measure the body rail hole Figure 29. Slider body rail positions
spacing (Figure 31, dimension X1). Both body
rails and slider box should possess the same hole
spacing. 2X PLUG
1.00" DIA X 1.5" LONG
3. Using the same measuring instrument, measure the

body rail width at the most forward and rearward
location. Adjust rails accordingly to achieve the 1.563 O.D. X 1.063 I.D.
W
same spacing (Figure 31) that equals that of the W = BODY RAIL SPACING
body rail clearance specification dimension located 6.0" HOLE SPACING (CTR TO CTR) PATTERN
on the overall slider assembly drawing (supplied

with the slider system). Be sure that the body rail
clearance specification corresponds to the rail 2X PLUG
1.19" DIA X 1.5" LONG
spacing in Figure 30.
4. Measure both body rail diagonals (from hole

centers) (Figure 31). If diagonals are unequal, 1.750 O.D. X 1.250 I.D.
adjust as required. Equal W and Z W
W = BODY RAIL SPACING
measurements will position the body rails correctly, 4.0" HOLE SPACING (CTR TO CTR) PATTERN
guaranteeing parallel body rail spacing and coaxial POSITIVE STOPS MUST BE PROVIDED BY INSTALLER ON BOTH ENDS OF RAILS.
(LOCATE IN FIRST AND LAST HOLES ON EACH SIDE.) PROPOSED METHOD SHOWN ABOVE.
hole alignment.
Figure 30. Positive stops installation
5. Insert positive stops in the most forward and
rearward hole of the body rails and tack weld in
place (Figure 30).
6. With the positive stops in place and tacked, weld

completely as described in the HK SLIDER
WELDING PROCEDURES section on page 24.
7. Once the positive stop welds have cooled, lift and

position the rail weldment over the top trailer
crossmembers. Lower the weldment onto the
crossmember aligning the end of the body rail with
the intended end of the trailer, making sure both are
centered to one another laterally.
Figure 31. Body rail spacing and diagonals
21
8. Starting from the most rearward location on the

body rails, inspect the width measurement
approximately every 48" (Figure 32). The value for
Y1, Y2 and Y3 comes from the width of the slider
box and whether or not shims are present (Figure
30). Adjust accordingly and completely weld the
slider body rails to the trailers crossmembers, as
described in the HK SLIDER WELDING
PROCEDURES section on page 24 (Figure 37) and
welding parameters on page 7.
SLIDER BOX INSTALLATION

The instructions that follow assume that the body rails
have been installed completely and have been inspected. Figure 32. Spacing measurements
1. Using an open-end wrench or ratcheting wrench

and socket, loosen all of the fasteners (qty. 8) that
secure four body rail clips (Figure 33).
2. Double check body rail spacing (Figure 30).
3. Inspect the condition of the slider boxs slide pads

(Figure 36). In order to achieve optimum slide
performance, it is important that all slide pad
fastener heads be located below the top surface of
the pads.
CAUTION: Check the trailer underbody to ensure

no burrs, paint, undercoating, or other
contamination exists on it, which could
damage the slide pads. If burrs, paint,
undercoating, or other contamination Figure 33. Body rail clips
exists on the trailer underbody, remove
it before installing the slider box. LOCKING PIN
DISENGAGED
NOTE: The box slide pads do not require lubrication. Its
composition (U.H.M.W. Polyethylene) is such
that many slides can be made before OPERATING
replacement is needed. HANDLE
4. Locate the slider box operating handle. The handle

SLIDE MODE
is located on the driver side at the front of the slider
box. To release the pins, raise the operating handle LOCKING PIN
ENGAGED
and lock in the up position. Inspect all four pins
for disengagement (pins must be flush with, or just
below, the box side rail) (Figure 34).
OPERATING
HANDLE
NON-SLIDE MODE
Figure 34. Locking pin position
22
5. Lift and position the trailer over top of the slider 8. Position body rail clips over the body rail flange
box. Lower the trailer onto and between the slider (Figure 35), and torque all of the body rail clip
body rails, making sure that the box end with the fasteners to the recommended value listed in the
operating handle is positioned closest to the trailer APPENDIX.
kingpin.
9. Locate the supplied K2 Operating Instructions
6. Position the body rail clips over the body rail flange sticker (L712). Remove backing and install in an
(Figures 35 and 36). area clearly visible near the sliders operating
handle.
CAUTION: Improper positioning of the body rail
clips and the body rail flange can
result in premature failure.
7. Lower the operating handle and lock in the down

position to engage the pins. Inspect pins, making
sure pin engagement (chamfered end projects
through body rail) occurs at all four locations
(Figure 34).
BODY RAIL BODY RAIL

FLANGE FLANGE
BODY RAIL
BODY RAIL
CLIP
CLIP
CONTACT
BETWEEN
BODY RAIL
FLANGE AND
BODY RAIL
CLIP
NOTE: THERE MUST BE A GAP BETWEEN THE NOTE: THE BODY RAIL FLANGE MUST NOT COME
BODY RAIL FLANGE AND THE BODY RAIL CLIP. INTO CONTACT WITH THE BODY RAIL CLIP.
SHIM
SHIM
BODY RAIL
BODY RAIL FLANGE
FLANGE
BODY RAIL
BODY RAIL CLIP
CLIP
CONTACT
SPACER
SPACER BETWEEN
BODY RAIL
FLANGE AND
BODY RAIL
CLIP
Figure 35. Correct body rail clip installation Figure 36. Incorrect body rail clip installation
23
HK SLIDER WELDING PROCEDURES

Starting and stopping points should be no closer than
1
/4" from the mating edge of the suspension component
and the trailer frame and/or the crossmembers. The
procedures illustrated may need to be adapted due to
varying trailer designs (Figures 37 and 38).
NOTE: It is the responsibility of the suspension installer

and the vehicle designer to provide both
adequate vehicle frame design and proper
securing method of the suspension system.
NOTE: The welding parameters for these procedures are

on page 21. Figure 37. HK slider recommended body rail attachment
Figure 38. HK slider recommended weld procedure
24
FINAL INSPECTION 6. Test drive the trailer and then continue the final
INSPECTION PROCEDURE installation inspection procedure.
1. Verify that the following welds have been completed
per specifications: 7. Check for proper suspension ride height. Adjust, if
necessary. For the proper procedure, refer to
Frame brackets to mounting frame Checking Trailer Ride Height (L459).
(if applicable)
Upper air spring/plate to mounting frame NOTE: The distance from the bottom of the frame to the
Body rails to trailer crossmembers (slider top of the axle must be within 1/8" from side to
system) side.
Forward and rearward stop bars to slider
8. Verify that a minimum of 2" has been provided
body rails (slider system)
from the inner tire inside sidewall to the trailer
structure to allow for lateral or fore/aft tire movement.
2. Check that all suspension bolt torques are to
Hendrickson recommended specifications.
9. Verify that a minimum of 1" has been provided
above the top of the tire when the suspension is
3. Articulate the suspension through its entire travel to
fully compressed or in its FULL jounce position.
ensure that adequate component clearances have
been provided. Special attention should be paid to
Tire Clearance at Ride Height = Jounce
both the height control valve linkage (Figure 39)
Specification + 1"
and the height control valve arm length as
specified in the supplied suspension assembly
10. Verify that the front axle alignment does not exceed
drawing.
a maximum variation of 1/8" kingpin to front axle
4. Verify that the shear-type bolts have been sheared and a maximum variation of 1/16" axle to axle on
on QUIK-ALIGN installations. any additional axles.
5. Inspect all four locking pins for proper engagement 11. Verify that a minimum of 1" clearance is
(slider system). maintained around the air spring when it is at its
maximum diameter specification.
Figure 39. Height control component travel
25
APPENDIX
TORQUE SPECIFICATIONS
Use these torque specifications when installing the fasteners covered below.
COMPONENT DESCRIPTION FT-LBS Nm

QUIK-ALIGN Pivot Connection 505 to 595 685 to 807
Welded Pivot Connection (11/8 inches) 750 to 825 1017 to 1119
Shock Bolts 210 to 235 285 to 319
Upper Air Spring Nuts 80 to 100 108 to 136
Lower Air Spring Nuts (INTRAAX) 25 to 35 34 to 47
Brake Chamber Mounting Nut (INTRAAX) 100 to 110 136 to 149
S-Cam Support Bearing Mounting Nut (INTRAAX) 35 to 45 47 to 61
COMPONENT DESCRIPTION IN-LBS Nm

ABS Bracket Bolt and Nut (INTRAAX) 75 to 100 8 to 11
Dust Shield, Bolt-to-Spider (INTRAAX) 160 to 180 18 to 20
Dust Shield, Clamp-on (INTRAAX) 95 to 170 11 to 19
NOTE: Torque values are specified for the fasteners in the

condition in which they are supplied by Hendrickson.
DO NOT APPLY ANY ADDITIONAL LUBRICANTS.
CAUTION: Overtorquing could result in fastener failure.
26
Trailer Suspension Systems Trailer Suspension Systems
2070 Industrial Place SE 250 Chrysler Drive, Unit #3
Canton, OH 44707-2600 USA Brampton, ON L6S 6B6 Canada
330.456.7288 905.789.1030
Fax 330.456.0105 Fax 905.789.1033
The Boler Company

Copyright 2000
L341 C 3-00 Printed in United States of America. www.hendrickson-intl.com All Rights Reserved

TECHNICAL
PROCEDURE
TRAILER SUSPENSION SYSTEMS
SUBJECT: System Maintenance
LIT NO: L578
DATE: December 1999
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . .2 PERIODIC INSPECTION SCHEDULE . . . . . . . . . . .7
Original-Installation Inspections . . . . . . . . . . .7
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Daily Inspections . . . . . . . . . . . . . . . . . . . . .7
TRI-FUNCTIONAL BUSHING . . . . . . . . . . . . .2 30-Day Inspection . . . . . . . . . . . . . . . . . . . .7
Rigid-Axle Connection . . . . . . . . . . . . . . . . .2 90-Day Inspection . . . . . . . . . . . . . . . . . . . .7
Roll Stability . . . . . . . . . . . . . . . . . . . . . . . .2 QUIK-ALIGN Inspection . . . . . . . . . . . . . . . .7
Soft Riding . . . . . . . . . . . . . . . . . . . . . . . . .2 Wheel End Maintenance . . . . . . . . . . . . . . . .7
Load Control . . . . . . . . . . . . . . . . . . . . . . . .2
Durability . . . . . . . . . . . . . . . . . . . . . . . . . .2 SUSPENSION SYSTEMS MAINTENANCE . . . . . . . .8
Ride Height Adjustment . . . . . . . . . . . . . . . .8
RIDE HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . .3 Air Spring . . . . . . . . . . . . . . . . . . . . . . . . . .8
Factors Affecting Ride Height . . . . . . . . . . . . .3 Shock Absorber . . . . . . . . . . . . . . . . . . . . . .8
Pivot Connection . . . . . . . . . . . . . . . . . . . . .8
CENTER LIFT SUSPENSIONS . . . . . . . . . . . . . . . .5 TRI-FUNCTIONAL BUSHING . . . . . . . . . . . . . .9
AIR CONTROL SYSTEM . . . . . . . . . . . . . . . . . . .6 TROUBLESHOOTING: TRI-FUNCTIONAL BUSHING .10

Height Control Valve . . . . . . . . . . . . . . . . . . .6 Commonly Misdiagnosed Bushing Problems .11
Air Dump Valves . . . . . . . . . . . . . . . . . . . . .6
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . .12
TRAILER SUSPENSION SYSTEM MAINTENANCE
INTRODUCTION HENDRICKSON SUSPENSION FEATURES

Hendrickson Trailer Suspension Systems TRI-FUNCTIONAL BUSHING
(Hendrickson) designs its suspension systems to The TRI-FUNCTIONAL BUSHING (located at the suspension
safely provide a long life and low-maintenance pivot) controls vehicle roll- and axle-alignment, yet allows
operation. The suspensions exhibit excellent ride easy up-and-down travel. It also controls forces generated
characteristics under all legal load conditions. Your by braking, accelerating and irregular road surfaces.
suspension was chosen to give your trailer the best Cavities located at top and bottom absorb vertical
movement. Solid rubber molded around steel center sleeve
ride, the correct load-carrying capability, and the
absorbs horizontal and lateral movement. The cavities
required amount of roll control for your vehicle. elongate to absorb forces as the vehicle turns and increase
Hendrickson trailer air suspensions are manufactured roll stability. The bushing and suspension pivot are
in modern, quality-oriented facilities. Great care is virtually maintenance free.
taken to ensure that our customers receive the best
product value for their purchasing dollar. RIGID-AXLE CONNECTION
The trailer axle is welded directly to the suspension beam.
Hendrickson trailer air suspension systems deliver This design has no flexible connections, which may lead
durability with a light-weight, simple, and trouble-free to maintenance or replacement due to instability. The HT
design. The suspensions will cushion the trailer, series axle connection is also U-bolted. The INTRAAX axle
cargo and the driver with a quality ride not attainable connection is integrated to the suspension beams with a
patented axle wrap; circular welded to neutral axis. The
without a Hendrickson air-suspension system.
beam mounting surface is machined and is continuously
Hendrickson supplies a wide variety of trailer welded to the axle wrap, eliminating axle seats and U-
suspension designs to meet your application needs. bolts. The INTRAAX rigid-axle connection provides
Each suspension system is intended for use in specific outstanding roll stability, maintains axle alignment to
beam, and contributes to a straighter axle tube and
applications with maximum load capacities.
controlled toe alignment.
For a complete listing of Hendrickson products,
contact your Hendrickson representative. ROLL STABILITY
The TRI-FUNCTIONAL BUSHING and rigid-axle connection
result in a roll-stable installation. The trailer floor remains
level, even when offset loading occurs, while using only
one height control valve per trailer.
SOFT RIDING
The air springs and TRI-FUNCTIONAL BUSHINGS support
the trailer load, while absorbing road shocks. This softer
ride protects the driver, cargo and vehicle; it also provides
longer vehicle life and greater driver comfort.
LOAD CONTROL
The single height control valve assures an evenly
distributed load across all air-ride axles when properly
installed. With the exception of tire deflection, the trailers
ride height remains constant whether loaded or unloaded.
DURABILITY
Hendrickson air suspensions and their components have
been thoroughly tested to provide a long life that is virtually
maintenance free. The sturdy construction of the trailer air
suspensions has a history of proven durability.
L578
2
RIDE HEIGHT Operating a suspension at an incorrect ride height can

Ride height is the measurement from the suspension result in improper loading and can shorten the service life
mounting surface to the center of the axle. All Hendrickson of the suspension. Hendrickson is not responsible for
air suspensions are designed to operate at a specific ride components which fail due to incorrect ride height settings.
height. Care must be taken to ensure the correct loaded
suspension ride height is maintained throughout the FACTORS AFFECTING RIDE HEIGHT
trailers usage. The following features need to be considered when
determining ride height:
To determine the ride height of your Hendrickson trailer
suspension, locate the suspension ID tag on the front of
the HT frame bracket, the front crossmember of the HS FRAME-TO-GROUND HEIGHT
The height from the bottom of the trailer frame (or
slider box or on the inside of the suspension beam on an
suspension mounting surface) to the ground must be
INTRAAX. Check the indicated (bold) number in the determined at each suspension location (Figure 1). This
following examples to find the designed ride height. dimension provides the desired trailer deck height.
HT model: HT230-14-001
HS model: HS190T-14-4801A TRAILER DECK HEIGHT
INTRAAX model (early): AA230TBA..1 14A1A01... The suspension ride height is calculated by subtracting the
INTRAAX description (current): B15U71.5... LOADED tire radius from the LOADED frame-to-ground
height. The radius of the tire will decrease as the trailer is
Changes in ride height affect the air spring height, which in loaded due to tire deflection, which in turn, affects the
turn, changes the suspensions load carrying capabilities. trailer deck height (Figure 2).
To provide an equal loading of the axles, Hendrickson
trailer suspensions are intended to be used at ride heights
which maintain equal air spring heights throughout the
application.
SUSPENSION SUSPENSION
DECK HEIGHT
SUSPENSION MOUNTING
SURFACE
FRAME-TO-GROUND FRAME-TO-GROUND
Figure 1. Frame-to-ground-height
RIDE HEIGHT LOADED DECK

LOADED TRAILER HEIGHT
FRAME-TO-GROUND
CENTER OF AXLE HEIGHT
LOADED TIRE
TIRE
Figure 2. Trailer deck height
L578
3
FIFTH WHEEL HEIGHT correct suspension ride height must be determined at each
The tractor fifth wheel affects the height of the trailer frame. suspension location (Figure 4). When ride height
(For example: a low fifth wheel height would cause the variations are required, consult the Hendrickson Trailer
trailer frame to slope downward.) Variations in the fifth Engineering Department to evaluate load equalization
wheel height will result in variations of suspension ride capabilities.
heights.
The correct suspension ride height must be determined at FRAME-TO-GROUND HEIGHT (CENTER LIFT AXLES)
each suspension location (Figure 3). When ride height The height of the bottom of the trailer frame (or suspension
variations are required, consult the Hendrickson Trailer mounting surface) from the ground must be determined at
Engineering Department to evaluate load equalization each suspension location (Figure 5). This dimension must
capabilities. provide the desired LOADED deck height.
FRAME DEFLECTION A leaf spring suspensions ride height will change under
Deflection of the trailer frame when loaded must be various loads. The auxiliary air suspensions ride height
considered. Frame deflection will result in a suspension must be specified to match the loaded leaf spring
ride height different from the installed ride height. The suspensions ride height.
SUSPENSION SUSPENSION
DECK HEIGHT
FIFTH WHEEL HEIGHT LOWER

THAN DESIGN SPECIFICATIONS VARYING
FRAME-TO-GROUND HEIGHTS
Figure 3. Fifth wheel height
DEFLECTION OF
UNLOADED FRAME
LOADED FRAME
FRAME-TO-GROUND FRAME-TO-GROUND
UNDER LOAD INSTALLED
Figure 4. Frame deflection
AUXILIARY AIR
SUSPENSION
SUSPENSION MOUNTING DECK HEIGHT

SURFACE
LOADED FRAME-TO-GROUND LOADED RIDE HEIGHT
Figure 5. Frame-to-ground height (center lift axle)
L578
4
SUSPENSION TRAVEL The top dimensions in Figure 8 are for 35-inch suspension
Hendrickson Trailer Suspension Systems uses these terms beam centers. The bottom dimensions (in parentheses)
to define the suspension travel: are for 41-inch suspension beam centers.
Jounce Maximum amount of upward axle movement

allowed by the suspension (Figure 6).
Rebound Maximum amount of downward axle travel

allowed by the suspension (Figure 6).
When selecting a suspension, the amount of axle travel must AREA OF 49" 35" SUSPENSION 461/2" MINIMUM
be considered in both the loaded and unloaded conditions. THE PIVOT (55")(41") BEAM CENTERS (561/2") INSIDE-TO-INSIDE
TIRE CLEARANCE
Unloaded, the suspension rebound must not be less than 2. BOLT
RIDE HEIGHT
JOUNCE Figure 8. Inside-to-inside tire measurements

REBOUND
If the potential exists for tire
CENTER OF AXLE interference, install the
QUIK-ALIGN shear-type pivot
bolt from the outboard side
of the frame bracket.
Figure 6. Suspension travel
Figure 9. Alternative installation of the QUIK-ALIGN pivot bolt

TIRE CLEARANCE
In selecting a suspension, the trailers tire clearance must CENTER LIFT SUSPENSIONS
be used to determine the maximum suspension jounce Hendrickson offers center lift kits, which when added during
permitted by the trailer design. Hendrickson specifies that a trailer suspension installation, provide a lifting capability
the tire clearance above the jounce requirement must (Figure 10). Only those suspensions with a minimum of 4
include one inch for the HT series and INTRAAX models of jounce are approved for use with a center lift kit.
(Figure 7). T series models require two inches of tire Hendricksons suspension jounce dimension includes an
clearance above the specified jounce requirement. A two allowance for air spring bumper compression. As a result,
inch clearance is specified between the trailer frame and the amount of lifted up travel will be less than the jounce.
inside tire inboard sidewall. This will provide sufficient
clearance to allow for tire distortion and axle walk. The suspension lift distance indicates the amount of axle
up travel. The resulting clearance under the tire will vary
Example: 3 Jounce depending on both frame and tire deflection.
+1 Clearance for the HT Series and INTRAAX model LIFT
4 of space required above the tire at ride height. (Axle Travel) RIDE
jounce + 1 = tire clearance HEIGHT
RIDE HEIGHT
CENTER OF AXLE
CENTER OF AXLE TIRE
TIRE CLEARANCE
Figure 7. Tire clearance Figure 10. Center lift suspension
L578
5
AIR CONTROL SYSTEM When the actuating lever of the height control valve moves
Many types of air controls are available for Hendrickson up, the valve opens and connects the air supply to the air
trailer air suspensions. The most common system spring. When the actuating lever moves down, the valve
automatically regulates the designed ride height by shuts off the air supply and opens the exhaust port to vent
controlling the air pressure supplied to air springs. When excess air from the air springs. A check valve prevents the
used in conjunction with other types of suspensions, such loss of air spring pressure if the air supply fails. In the
as a leaf-spring suspension, an operator-controlled central position, air does not flow in or out of the air springs.
pressure regulator is often employed. If using axle lifts or
other special features, other air control circuits and AIR DUMP VALVES
components are added. All systems operate from the Air dump (or exhaust) valves increase stability during the
compressed air supply of the vehicle. The air pressure in loading and unloading of the trailer, as well as prolong
springs controls the height or load on the axle. component life. The valves can be controlled
automatically, manually or by the use of an air-pilot valve.
The diagram (Figure 11) illustrates a typical air control
arrangement in use with a Hendrickson trailer air When suspension air is exhausted, Hendrickson trailer air
suspension. One height control valve controls any number suspensions limit the suspension up travel (jounce) by a
of primary air suspensions. Contact the trailer manufacturer rubber bumper located inside the air spring. The air-spring
for specific information about your trailer air control system. bumpers adequately support the rated suspension capacity
with the suspension air exhausted.
HEIGHT CONTROL
VALVE Hendrickson approves using air dump valves only when
the control exhausts all the trailer air springs. Also, use of
the air dump control is approved for the following situations:
AIR SPRINGS
A trailer parked for any length of time, loaded or
unloaded, either when connected to the tractor or
supported by the landing gear legs.
TO AIR SUPPLY
A trailer being loaded or unloaded, particularly
when fork lift trucks are used.
A dump trailer during the dump mode only.
A trailer experiencing a sudden off loading of
cargo, such as steel removed with a crane.
Any variation beyond these conditions must be approved in

writing by Hendrickson Applications Engineering Department.
BRAKE PROTECTION VALVE
CAUTION: Due to the geometry of all trailing-
Figure 11. Height Control Valve
beam air suspensions, the trailer
moves forward when air exhausts from
HEIGHT CONTROL VALVE the suspension and trailer brakes are
The height control valve on the Hendrickson trailer air
suspension automatically responds to the relative position locked. When supported by the trailers
of the axle and vehicle frame. It meters air into or out of landing gear, this movement may
the air springs. Variations in load or temperature only damage or collapse the legs. Always
affect the adding or exhausting of air. Since the exhaust the suspension air before
Hendrickson trailer model air suspension is a mechanical- locking the brakes. (Automatic air-
ly stable suspension, only one height control valve is nec- dump systems are available.)
essary. This system is less complex, less expensive and
less troublesome than competitive systems. Variations in trailer deck height and, therefore, the suspen-
sion ride height will cause the longitudinal movement of
In addition, it provides a safer system should an air spring
the trailer. When loading and unloading the trailer, the
blowout occur. Notice that only one height control valve is
changes in the load supported by the suspension will
used per trailer or dolly; this grouping can include two,
cause the deck height to change; this change results in the
three, four or more axles. Hendrickson generally recom-
trailer moving away from the loading dock. Unless the air
mends that the height control valve be positioned on the
is properly exhausted from the air suspension, the above
rear axle on tandem axle arrangements and on the center
movement can damage or collapse the trailer landing gear,
axle of tri-axle arrangements. For trailers equipped with
as well as result in a potentially dangerous gap between
SURELOK, it is important to place the height control valve
the trailer and the loading dock.
on the same axle as the SURELOK locking legs.
L578
6
PERIODIC INSPECTION SCHEDULE QUIK-ALIGN INSPECTION

The Hendrickson trailer air suspension requires very little Inspection of the QUIK-ALIGN occurs at 3,000 miles and at
attention. Your air suspension may well last the life of the every lining change.
vehicle by using the information in this publication and
other Hendrickson technical publications.
WHEEL END MAINTENANCE
7,500 MILES
ORIGINAL-INSTALLATION INSPECTIONS Visually inspect seal and hub cap for leakages and hub oil
The vehicle manufacturer is responsible for completing the level (if oil bath type).
installation to Hendrickson specifications. In your review of
the vehicle for the first time, check the following: 12 MONTHS OR 100,000 MILES
trailer is level At 12 months or 100,000 miles, which ever occurs first,
all welds are of acceptable quality visually inspect seal and R&I hub cap. Visually inspect for
all bolts are in place and secure contaminants, check wheel bearing adjustment, install new
pivot-connection nut tack-welded to bolt threads oil, if oil filled, and replace hub cap gasket-retorque.
(not required with a Huck fastener) Repair if necessary.
no component interferences exist
DAILY INSPECTIONS
A quick look to verify a level trailer that is riding at the
correct ride height is suggested. This inspection will help you
find any obvious problems. A closer inspection can detect
broken or loose parts before any serious problems appear.
30-DAY INSPECTION
At 30 days, inspect clearances around air springs, tires,
shock absorbers and all other moving parts. Evidence of
part interference requires immediate attention by a qualified
mechanic. The 30-day inspection includes the following
checks:
bolts are secure
axle connections are tight
any sign of wear
If you have any questions about the suspension area, call
the trailer manufacturer or Hendrickson Technical Service
Department at (330) 456-7288.
90-DAY INSPECTION
At 90 days, thoroughly check all items that were inspected at
30 days. The 90-day inspection also includes these items:
all welded connections for signs of deterioration
frame attachment joints, crossmember structures and
all pivoting and clamping connections for problems
Early detection and correction of problems can save
expenses and prolong the life of your trailer.
It is unlikely that you will find any problems with your
Hendrickson air suspension during these inspections.
However, your careful attention to these periodic inspec-
tions can save a great deal of time and expenses by
avoiding unexpected difficulties in remote locations.
Contact your Hendrickson representative or the
Hendrickson Applications Engineering Department at (330)
456-7288 to discuss any questions about the construction
and/or operation of your Hendrickson trailer air
suspension.
L578
7
SUSPENSION SYSTEMS MAINTENANCE to the nearest service facility at a lower speed. You should
By correcting minor problems when found, your try to determine the cause of a failure, so you can avoid a
Hendrickson air suspension will provide excellent service costly repeat of the problem. If you have questions about
throughout your trailers life. This section will help you to the cause of a failure, contact Hendrickson Technical
determine what to expect from your suspension Service Department at (330) 456-7288.
components and the proper maintenance procedures. To replace an air spring, follow these steps:
1. Exhaust all air from the suspension system
RIDE HEIGHT ADJUSTMENT 2. Raise and support the vehicle in a safe manner
1. Connect the vehicle to a compressed air supply with
approximately the pressure of the normal supply 3. Unbolt the air spring
system. 4. Disconnect air-supply lines
5. Replace the air spring
2. Ensure the inflation of the air springs. 6. Bolt the air spring in place
3. Measure the ride height by using this method: 7. Connect the air-supply lines
8. Lower the trailer to the ground
a. Measure from the underside of the trailer frame to 9. Supply air to the suspension system
the top of the axle
SHOCK ABSORBER
b. Add 21/2 (half the diameter of the axle) to the Shock absorbers do not absorb shock; they absorb energy
measurement to prevent suspension oscillation. Shock absorbers are also
used as rebound stops in most air suspensions. The shock
Example: 111/2 to the top of the axle with the 21/2 absorber limits the stroke of an air spring, which prevents
equals a 14 ride height the air spring from being pulled apart. In some severe
4. Raise or lower the trailer as necessary, so it is at the service applications, a shock strap is added to additionally
designed ride height. aid in limiting the stroke of an air spring.
5. Once the trailer is set at the correct designed ride height, To remove an air spring, follow these steps:
set the HCV lever to the neutral (central) position. 1. Remove the end fasteners
6. Adjust the HCV linkage to fit between HCV lever and 2. Insert the new shock absorber
lower linkage attachment. 3. Secure with correct size locknut and bolts
4. Torque fasteners to specification
IMPORTANT: When adjusting the height control valve,
If your suspension has unique travel requirements, use
block the tire and release the trailer
only Hendrickson shock absorbers for replacements.
brakes. The axle must rotate freely to
avoid a false reading. CAUTION: Do not lift the trailer without the
Some height control valves have very small openings and shock absorbers in place. If shock
a time delay of as much as 15 seconds. Allow sufficient absorbers are not in place,
time for the system to react to the adjustment. The overextension of the air springs will
response time will appear to be lengthy, but be patient. occur. Damage may occur to the
Once set to the designed ride height, test drive the trailer. overextended air springs.
After the test drive, check the ride height to assure an IMPORTANT: Hendrickson trailer air suspension
accurate adjustment.
design requires the use of specific air
Notice that the use of one height control valve removes the springs and shock absorbers. Only
requirement for synchronization found with most other air components purchased from
suspension systems. This feature will save you time and Hendrickson or a Hendrickson-approved
expense in servicing your air system. distributor can be used. Replacement
If you have any questions regarding the operation of your with other components may cause
Hendrickson trailer air system, contact the Hendrickson premature failures and void the
Technical Service at (330) 456-7288. warranty.
AIR SPRING PIVOT CONNECTION

Air springs will last almost indefinitely in most applica- A correct pivot connection is crucial to the life of the
tions. However, air springs will fail quickly when rubbed, suspension. The pivot fastener must continually provide a
scuffed, or punctured. If an air spring fails, the trailer will sufficient clamp load through the bushing to prevent
settle on the internal rubber bumpers, so you can proceed premature suspension failure.
L578
8
Hendrickson trailer air suspension models come equipped
with either a Huck-type fastener or a conventional nut-
and-bolt arrangement at this location.
The factory installs the Huck-type fastener by using
specialized hydraulic equipment. This fastener can only be
removed by cutting the fastener apart.
Other factory-installed units are equipped with a nut and
bolt at the pivot connection. This arrangement is also used
when a field replacement is necessary. The pivot bolts are
torqued to 800 ft-lbs. The nut is tack welded to the bolt
threads to assure a permanent connection.
Hendrickson INTRAAX suspension systems come equipped
with QUIK-ALIGN pivot connection hardware. The hardware
consists of a specially plated shear bolt to ensure a proper
clamp load, (550 ft-lbs, H-45 torque).
CAUTION: Failure to properly torque the pivot

bolt or tack weld the pivot nut to the
bolt will result in loss of warranty
coverage.
TRI-FUNCTIONAL BUSHING
Hendricksons TRI-FUNCTIONAL BUSHING has unique
properties that will provide years of maintenance-free
service. The TRI-FUNCTIONAL BUSHING (located at the
suspension pivot) provides a resilient connection that
allows an axle to walk without excessive flexing. The TRI-
FUNCTIONAL BUSHING, in conjunction with the rigid axle
connection, results in a roll-stable suspension design that
resists trailer lean independent of the air spring loading.
There are times when a problem seemingly in the area of
the suspension is diagnosed as a failed bushing. Closer
inspection typically reveals another component or a faulty
installation is the problem. If a problem is in the area of
the suspension, refer to the TROUBLESHOOTING section on
page 10. If a failed bushing is present, contact
Hendrickson Technical Service Department at (330) 456-
7288.
Rebushing of a suspension requires the use of a bushing
removal/installation tool and bushing kit, containing the
required components for rebushing. Contact Hendrickson
for assistance. When rebushing the suspension, refer to
L427 Bushing Replacement Procedures.
IMPORTANT: Literature is also available for installing

the TRI-FUNCTIONAL BUSHING. Rebush
using only the lubricant supplied in the
bushing kit by Hendrickson Trailer
Suspension Systems.
L578
9
TROUBLESHOOTING: TRI-FUNCTIONAL BUSHING

COMMONLY MISDIAGNOSED BUSHING PROBLEMS
While the following problems can result from a failed bushing, most often they are the result of the items listed below.
IMPORTANT: Contact Hendrickson Technical Service Department at (330) 456-7288 for assistance.
L578
10
COMMONLY MISDIAGNOSED BUSHING PROBLEMS (CONTINUED)
L578
11
Use these torque specifications when installing the fasteners covered below.
NOTE: Torque values are specified for the fasteners in the condition in which they are
supplied by Hendrickson. DO NOT APPLY ANY ADDITIONAL LUBRICANTS.
CAUTION: Overtorquing could result in fastener failure.

330.456.7288 905.789.1030
Fax 330.456.0105 Fax 905.789.1033
The Boler Company

Copyright 2000
L578 5M 7-00 Printed in United States of America. www.hendrickson-intl.com All Rights Reserved
TECHNICAL
PROCEDURE
INTRAAX SUSPENSION SYSTEMS
SUBJECT: Shock Mount Replacement Procedures
LIT NO: L724 (Supersedes AM11 Rev B and L594 Rev C)
DATE: December 1999
TABLE OF CONTENTS
PREPARATION FOR PROCEDURES REVISION C PROCEDURES
Important Information . . . . . . . . . . . . . . . . . .2 Undamaged Thread . . . . . . . . . . . . . . . . . . .4
Model Identification . . . . . . . . . . . . . . . . . . .2 Damaged Thread . . . . . . . . . . . . . . . . . . . .4
REVISION B PROCEDURES APPENDIX

Undamaged Thread . . . . . . . . . . . . . . . . . . .3 Bolt Replacement Kit for Revisions B and C . . .6
Damaged Thread . . . . . . . . . . . . . . . . . . . . .3 Revision B Suspensions . . . . . . . . . . . . . . . .6
Revision C Suspensions . . . . . . . . . . . . . . . .7
INTRAAX SHOCK MOUNT REPLACEMENT PROCEDURES
PREPARATION FOR PROCEDURES

IMPORTANT INFORMATION
WARNING: CHOCK OR BLOCK THE WHEELS ON

THE TRAILER TO PREVENT MOVEMENT
WHILE WORKING ON THE SUSPENSION
OR BRAKE SYSTEM. FAILURE TO BLOCK
THE TRAILER MAY LEAD TO SERIOUS
INJURY OR DEATH.
WARNING: DO NOT ALLOW THE BRAKE CHAMBER

TO HANG FROM THE AIR HOSE WHEN
DOING THESE PROCEDURES. IF THE
AIR HOSE IS CUT OR SEVERED,
PERSONAL INJURY OR COMPONENT
DAMAGE MAY OCCUR.
Figure 1. INTRAAX identification tag
IMPORTANT: Before removing the shock absorbers,

read the instructions provided with the new
shock absorber. Verify that the part numbers
on the new and the old shock absorbers
match. Ensure the new parts are correct
before removing the old shock absorbers.
1. Refer to the parts list on page 6 for the parts

included in kit number S-24021.
Figure 2. Assemble the shock mounting components
2. For torque specifications, refer to the table on page 6.
3. For all procedures in this technical publication, park

the trailer on a clean, dry surface. Chock the wheels.
MODEL IDENTIFICATION
1. Before continuing with this publication, you must
Position of Internal
determine the type of INTRAAX model AA230TB, Shock Backing Plate
AA250TB, AA230TC, or AA250TC.
IMPORTANT: The model number is on the suspension

identification tag, which is located on the
inboard side of the suspension beam. The Position of Shock
Spacer Assembly
"B" or "C" (the second letter after AA230 or
AA250) in the model number indicates the
suspension is a Revision B or Revision C
(Figure 1).
2. If the suspension is an INTRAAX Revision B, use Figure 3. Properly position the shock spacer
the instructions after this step. If the suspension is
an INTRAAX Revision C, use the REVISION C
PROCEDURE on page 4.
2
INTRAAX REVISION "B" PROCEDURES WARNING: YOU MUST CHOCK OR BLOCK THE
UNDAMAGED THREAD PROCEDURE WHEELS ON THE TRAILER TO PREVENT
1. Spray a penetrant type fluid on the lower shock MOVEMENT WHILE WORKING ON THE
absorber mounting bolt where it enters the SUSPENSION OR BRAKE SYSTEM.
suspension beam. Allow the penetrant to be FAILURE TO PROPERLY BLOCK THE
absorbed for several minutes before attempting TRAILER COULD LEAD TO SERIOUS
to loosen the bolts. INJURY OR DEATH.
3. Remove the slack adjuster.

2. Use a 11/8-inch wrench or socket to remove the
lower shock absorber mounting bolt, flat washer,
4. Use a 15/16-inch wrench or socket to loosen and
and spacer from between the shock absorber and
remove the nuts that attach the brake chamber to
the suspension beam; discard these parts.
the mounting bracket. Remove the brake chamber
from the mounting bracket. Store brake chamber
IMPORTANT: When removing the lower shock
out of the way for this procedure.
bolt, be careful not to strip the nut
that is located on the inside of the
suspension beam.
TO HANG FROM THE AIR HOSE
3. Visually check the threads on the nut inside the DURING THIS PROCEDURE. IF THE
suspension beam to ensure they are in good LINE SHOULD BE CUT OR SEVERED
condition. If the nut is defective, go to REVISION "B" COMPONENT DAMAGE OR PERSONAL
DAMAGED THREAD PROCEDURE. INJURY MAY OCCUR.
5. Use a hammer with a punch, or chisel, to strike the

4. Do not apply lubricants or Never-Seize to the
defective mounting pieces until the tack welds
threads of the shock mounting bolt.
break loose. Replace parts as necessary.
5. Insert the shear-type shock bolt through the
6. If tack-weld slag remains on the beam, remove it
hardened washer, shock, hardened washer, spacer
before installing the new parts.
block and into the hole in the suspension beam
(Figure 2).
7. Hold the new backing plate, spacer and nut up to
the inside of the beam at the shock mounting hole.
IMPORTANT: Check the spacer block for proper
installation. The spacer must be positioned
8. Install the shear-type shock bolt and external
properly on the beam for maximum
hardware per step #5 in the previous procedure
effectiveness (Figure 3).
(Figure 5, page 6).
6. Use an E-20 3/4-inch drive socket to tighten
the shock bolt until the shear head separates IMPORTANT: Tack welding the backing plate to the
at 210-235 ft-lbs. suspension beam is not required. It will be
necessary to hold the nut with a 11/8-inch
wrench while tightening the mounting bolt.
REVISION "B" DAMAGED THREAD
PROCEDURE 9. Use an E-20 3/4-inch drive socket to tighten the
1. If the nut in the suspension beam is damaged,
shock bolt until the shear head separates at
install a new mounting hardware kit in the beam.
210-235 ft-lbs.
2. Release the trailer parking brakes of the affected
10. Mount the brake chamber on the mounting bracket
axle by caging the brake chambers according to
and torque the bolts to 100 -110 ft-lbs.
the brake chamber manufacturers procedure.
3
11. Attach brake chamber rod clevis to slack adjuster

Suspension Beam
with the clevis pin. Install a new cotter pin in the
clevis pin. Shock
Absorber
12. Release and remove the caging tool from the brake HENDRICKSON
MADE IN CANADA
chamber; follow the brake chamber manufacturers

procedure.
Fastener Torque:
210-235 ft-lbs.
13. Visually check all components for tightened
fasteners (Figure 4).
INTRAAX REVISION "C" PROCEDURES

UNDAMAGED THREAD PROCEDURES Hardened Flat
1. Visually check the threads on the nut inside the Washers
Nut
suspension beam to ensure they are in good
Shock
condition. If the nut is defective, go to the REVISION Mounting Bolt
"C" DAMAGED THREAD PROCEDURE.
IMPORTANT: If the nut is missing, contact Hendrickson

Trailer Suspension Systems Technical
Service at (330) 456-7288 Monday Figure 4. Visually check components
through Friday 8 a.m. to 5 p.m. Eastern
Time.
2. Do not apply lubricants or Never-Seize to the

threads of the shock mounting bolt.
3. Insert the shock bolt through the hardened washer,

shock, hardened washer, spacer block and into the
hole in the suspension beam (Figure 6, page 7). WARNING: YOU MUST CHOCK OR BLOCK THE
WHEELS ON THE TRAILER TO PREVENT
IMPORTANT: Ensure spacer block is positioned flush MOVEMENT WHILE WORKING ON THE
with beam. Spacer must be positioned SUSPENSION OR BRAKE SYSTEM.
properly on the beam for maximum FAILURE TO PROPERLY BLOCK THE
effectiveness. TRAILER COULD LEAD TO SERIOUS
INJURY OR DEATH.
4. Torque the shock mounting bolt to 210-235 ft-lbs.
3. Remove the slack adjuster.
REVISION "C" DAMAGED THREAD PROCEDURE
1. If the nut in the suspension beam is damaged, it 4. Using a 15/16-inch wrench or socket, loosen and
will be necessary to install a new mounting remove the nuts that attach the brake chamber to
hardware kit in the beam. the mounting bracket. Remove brake chamber from
mounting bracket.
2. Release the trailer parking brakes of the affected
axle by caging the brake chamber using the brake 5. Store the brake chamber out of the way during this
chamber manufacturers procedure. procedure.
4

TO HANG FROM THE AIR HOSE
DURING THIS PROCEDURE. IF THE
LINE SHOULD BE CUT OR SEVERED
COMPONENT DAMAGE OR PERSONAL
INJURY MAY OCCUR.
6. Remove the lower shock mounting threads within

the suspension beam by drilling with a 3/4-inch
drill bit.
7. Insert a new prevailing torque nut through the rear

of the suspension beam and position it over the
newly drilled 3/4-inch hole.
8. Insert the shear-type shock bolt through the flat

washer, shock, flat washer and spacer, through
the 3/4-inch hole and begin threading onto the nut
(Figure 7, page 7).
9. Hold the nut with 11/8-inch wrench.
10. Use an E-20 3/4-inch drive socket to tighten the

shock bolt until the shear head separates at
210-235 ft-lbs.
11. Mount the brake chamber on the mounting bracket

and torque the bolts to 100-110 ft-lbs.
12. Reinstall the slack adjuster.
13. Attach brake chamber rod clevis to the slack

adjuster with the clevis pin. Install new cotter pin
in clevis pin.
14. Release and remove the caging tool from the brake
chamber; follow the brake chamber manufacturers
procedure.
15. Visually check all components to ensure fasteners

are tight.
5
*This kit (S-24021)

BOLT REPLACEMENT PARTS KIT (P/N S-24021)* contains parts for
use in all the
PART NUMBER PART DESCRIPTION QUANTITY REVISION(S) procedures described
in this publication
A-22577 Hardened Flat Washers 2 B and C for the revision B
and C INTRAAX
B-24058-1 3
/4"-10 x 53/4" Lower Shock 1 B and C suspensions. You
may not need all
Mount Shear-Type Bolt parts to complete
your replacement
B-23784 Shock Spacer Assembly 1 B and C procedure. You may
discard these extra
SA-8900-3 3
/4" -10 Lock Nut 2 B and C parts after completing
the replacement.
SA-1000-47 3
/4"-10 x 31/2" Upper Shock 1 B and C
Mount Bolt
A-20871 Shock Backing Plate 1 B only
A-20913 Shock Spacer 1 B only
SA-10200-1 3
/4"-16 x 41/2" Lower Shock 1 C only
Mount Bolt
PART FT-LBS. NM
Brake Chamber Fastener 100-110 136-149
Hex Head Cap Screw 210-235 285-319
Shear-Type Bolt
B-23784
Shock Spacer A-20871
Shock Backing Plate
A-22577
Hardened Flat Washers
SA-8900-3
3
/4"-10 Lock Nut
A-20913
Shock Spacer
B-24058-1 Suspension Beam

3
/4"-10 x 53/4" Lower Shock
Mount Shear-Type Bolt
Figure 5. AA230/AA250 Rev. B (Damaged Thread)
6
SA-10200-1
3
/4"-16 x 41/2" Lower
Shock Mount Bolt
B-23784
Shock Spacer
A-22577
Figure 6. AA230/AA250 Rev. C (Undamaged Thread)
IMPORTANT: Tighten shock mounting fasteners to a

torque of 210-235 ft-lbs. (285-319 Nm).
B-23784
Shock Spacer
B-24058 SA-8900-3
3
/4"-10 x 53/4" Lower Shock 3
/4"-10 Lock Nut
Mount Shear-Type Bolt
A-22577
Figure 7. AA230/AA250 Rev. C (Damaged Thread)
7
800.455.0043 905.789.1030
330.489.0045 Fax 905.789.1033
Fax 800.696.4416
The Boler Company

Copyright 2000
L724 3M 12-00 Printed in United States of America. www.hendrickson-intl.com All Rights Reserved
PARTS LIST SUSPENSION AND AXLE COMPONENTS
MODEL AA230T/AA250T INTRAAX
2b
12 7
14a
10
9b
2a
9a
PRIMARY SUSPENSIONS
10
13
14a
12
11
8
1
14b
80
MODEL AA230T/AA250T INTRAAX
ITEM DESCRIPTION PART NO. QTY NOTE

1 AXLE/BEAM WELDMENT Contact Hendrickson for assistance
2 FRAME BRACKET1 (Standard Travel) Contact Hendrickson for assistance
2a 8 Weld-on, Winged, Roadside C-21028-1 1 13-1/2, 14" and 15 ride heights
8 Weld-on, Winged, Slotted Top
Plate, Roadside C-21028-3 1 13-1/2, 14 and 15 ride heights
10 Weld-on, Winged, Roadside D-21082-1 1 16 and 17 ride heights
8 Weld-on, Winged, Curbside C-21028-2 1 13-1/2, 14 and 15 ride heights
8 Weld-on, Winged, Slotted Top
Plate, Curbside C-21028-4 1 13-1/2, 14 and 15 ride heights
10 Weld-on, Winged, Curbside D-21082-2 1 16 and 17 ride heights
2b 8 Weld-on, Wingless, Roadside D-21905-1 1 13-1/2, 14 and 15 ride heights
10 Weld-on, Wingless, Roadside D-21906-1 1 16 and 17 ride heights
8 Weld-on, Wingless, Curbside D-21905-2 1 13-1/2, 14 and 15 ride heights
10 Weld-on, Wingless, Curbside D-21906-2 1 16 and 17 ride heights
3 FRAME BRACKET CHANNEL A-1631-19 1
4 AIR SPRING
For AA230 Units Shipped Before 6/1/96 S-20900 2 Use to replace C-20900 air spring
For AA230 Units Shipped After 6/1/96 S-21800 2 Use to replace C-21800 air spring
For AA250 Units S-21784 2 Includes disk assembly; use to replace
C-20901 air spring
5 AIR SPRING MOUNTING PLATE
All Weld-on Applications B-20905 2 13-1/2 through 17 ride heights only
Various Bolt-on Applications B-21145 2 Distance from outboard side of spacer to
center of first trailer frame mounting bolt
PRIMARY SUSPENSIONS
hole is 1-1/2; 13-1/2 through 17 ride
heights only
heights only
heights only
6 AIR SPRING SPACER
Plastic, 1-1/8 Thick Spacer B-22510-1 2 Typically 15 ride height
7 AIR SPRING SPACER ASSEMBLY
Steel, Weld-on, 1-5/16 Thick
Spacer Assembly C-22302-2 2 Typically 15 ride height
Steel, Bolt-on, 4-5/16 Thick
1
Others options exist including: standard travel bolt-on frame brackets; bolt-on frame brackets for limited travel and HIGH CONTROL applications;
weld-on frame brackets for limited travel and HIGH CONTROL applications. HIGH CONTROL applications include dollies, full trailers and pups used in
81
doubles or triples. Contact Hendrickson for assistance in determining a part number for the above applications.
MODEL AA230T/AA250T INTRAAX cont.
2b
12 7
14a
10
9b
2a
9a
PRIMARY SUSPENSIONS
10
13
14a
12
11
8
1
14b
82

8 AIR SPRING MOUNTING KIT2 (Per Air Spring)
S-22619/2 2 For units with no spacer or with 1-5/16,
2-1/16, 3-5/16, 4-1/16, 4-5/16, 5-5/16
or 5-9/16 thick spacer assemblies
S-22630/2 2 For units with a 1-1/8 thick spacer
9 ALIGNMENT COLLARS
9a Eccentric, QUIK-ALIGN S-20925 2 Pivot bolt hole is offset from center of collar
9b Concentric, QUIK-ALIGN S-20924 2 Pivot bolt hole is in center of collar
10 QUIK-ALIGN PIVOT BOLT KIT2 S-21052 2 Includes bolt, TORQ-RITE Nut and washers
11 QUIK-ALIGN PIVOT BUSHING KIT2
Standard S-21166 2 Includes bushing, pivot bolt kit, wear pads
and lube
High Control S-24112 2 Includes bushing, pivot bolt kit, wear pads
and lube
12 BUSHING WEAR PAD
Standard S-11613 4 Four (4) required per axle
High Control B-21099 4 Four (4) required per axle
13 SHOCK ABSORBER3
Standard Duty S-23566 2 Use to replace A-20002 or B-23566
shock absorbers
Extended Service S-24125 2 Use to replace A-20126 or B-24125
PRIMARY SUSPENSIONS
shock absorbers
Extended Service, High Damping S-24023 2 Use to replace B-21553 or B-24023
shock absorbers
Limited Rebound S-23361 2 Use to replace B-22345 or B-23361
shock absorbers
14 SHOCK ABSORBER BOLT KIT2
14a For Units Shipped After 8/11/95 S-240214 2 One (1) required per shock
14b For Units Shipped Before 8/11/95 S-20896/2 2 One (1) required per shock
2
See AA230T/AA250T INTRAAX Kit Components Section or Service Kits Section for kit breakdown.
3
Other options exist. Contact Hendrickson for assistance.
4
Picture depicted may not resemble all models. This kit contains components necessary to repair AA230T/250T INTRAAX models manufactured
after 8/11/95.
83
PARTS LIST BRAKE AND SPINDLE COMPONENTS
24
22
20
19
21
16
18
17
PRIMARY SUSPENSIONS
16
23
21
20
22
15
24
84

15 AXLE NUT KIT2
HN Spindle Type S-20492/2 2 Includes inner axle nut, outer axle nut,
lock washer and set screw
HP Spindle Type S-20475/2 2 Includes inner axle nut, outer axle nut,
16 ABS BRACKET KIT2
HN Spindle Type S-21064 1 Includes sensor bracket, bolts, lock nuts
and flat washers
HP Spindle Type S-21070 1 Includes sensor bracket, bolts, lock nuts
and flat washers
17 ANCHOR PIN5 Included in minor overhaul brake kits and
major overhaul brake kits2
18 ANCHOR PIN BUSHING5 Included in minor overhaul brake kits and
19 BRAKE RETAINING SPRING5 Included in minor overhaul brake kits and
20 BRAKE SHOE ROLLER5 Included in brake shoe kits, minor
overhaul brake kits and major overhaul
brake kits2
21 ROLLER RETAINER5 Included in brake shoe kits, minor
overhaul brake kits, major overhaul brake
kits, axle S-cam major overhaul kits and
wheel S-cam major overhaul kits2
22 RETURN SPRING PIN5 Included in brake shoe kits, minor
PRIMARY SUSPENSIONS
brake kits2
23 BRAKE RETURN SPRING5 Included in minor overhaul brake kits and
24 BRAKE SHOE5
16-1/2 x 7 Standard Service
Brake Shoe Kit2 S-21266-13 2 ABEX 3030-197, FMSI 4515
Major Overhaul Brake Kit2 S-21184-13 2 ABEX 3030-197, FMSI 4515
16-1/2 x 7 HXS
S-23750-3 2 ABEX 931-162, FMSI 4707
S-23753-3 2 ABEX 931-162, FMSI 4707
16-1/2 x 8-5/8 HXS
S-23751-3 2 ABEX 931-162, FMSI 4711
S-23754-3 2 ABEX 931-162, FMSI 4711
2
3
5
Not sold separately.
85
PARTS LIST S-CAM AND SLACK ADJUSTER COMPONENTS
35
33
32
31
34
PRIMARY SUSPENSIONS
29
31
31
30
28 27
26
25 27 29
86

25 S-CAM
Right Hand, 28 Spline Standard S-20806-1R 1
Right Hand, 10 Spline Standard S-21717-1R 1 Not for U.S. use
Right Hand, 28 Spline HXS S-23347-1R 1
Left Hand, 28 Spline Standard S-20806-1L 1
Left Hand, 10 Spline Standard S-21717-1L 1 Not for U.S. use
Left Hand, 28 Spline HXS S-23347-1L 1
26 OUTER CAM WASHER5 Included in axle S-cam major overhaul
kits and wheel S-cam major overhaul kits2
27 SPIDER SEAL5 Included in axle S-cam major overhaul
28 SPIDER CAMSHAFT BUSHING5 Included in axle S-cam major overhaul
29 S-CAM JOURNAL WASHER5 Included in axle S-cam major overhaul
30 SPIDER RETAINING RING5 Included in axle S-cam major overhaul
31 S-CAM SUPPORT BUSHING ASSEMBLY5 Included in axle S-cam major overhaul
32 SPLINE INNER WASHER5 Included in axle S-cam major overhaul
33 SPLINE RETAINING RING5 Included in axle S-cam major overhaul
34 SLACK ADJUSTER KITS (Per Wheel)
PRIMARY SUSPENSIONS
28 Spline, Gunite, 5-1/2 S-21398-1 2 Includes unhanded autoslack, outer nut
and inner sleeve
28 Spline, Gunite, 6 S-21398-2 2 Includes unhanded autoslack, outer nut
and inner sleeve
28 Spline, Haldex, 5-1/2 S-21399-1 2 Includes unhanded autoslack, anchor stud,
nut and slack adjuster clevis assembly
28 Spline, Haldex, 6 S-21399-2 2 Includes unhanded autoslack, anchor stud,
and inner sleeve; not for U.S. use
nut and slack adjuster clevis assembly;
not for U.S. use
not for U.S. use
35 BRAKE CHAMBER (11 from mounting face to center of clevis pin)
MGM 30/30 S-20837-1 2
MGM 30/30, LTRT, Long Stroke C-24225 2
MGM 30/30, LTRT C-24246 2
MGM 30/30, Long Stroke C-24247-1 2
Haldex 30/30 S-20837-2 2
TSE 30/30 S-20837-3 2
Carlisle 30/30 C-20837-4 2
36 CLAMP-ON DUST SHIELD S-23579/2 2 Not shown
2
5
87
PARTS LIST KIT COMPONENTS
ITEM DESCRIPTION QTY PART NO.
AIR SPRING MOUNTING KITS

8 NO SPACER OR WITH 1-5/16, 2-1/16, 3-5/16, 4-1/16,
4-5/16, 5-5/16 OR 5-9/16 THICK SPACER ASSY (Per Air Spring) S-22619/2
1/4-18 NPTF Plug 1
1/2-13 Flanged Nut, Metal 1
8 1
1- /8 THICK SPACER (Per Air Spring) S-22630/2
1/4-18 NPTF Plug 1
Air Fitting, 1.10 1
Extension Nut Fitting, .65 2
8 7
1- /8 THICK SPACER (Per Air Spring) S-22631/2
1/4-18 NPTF Plug 1
Air Fitting, 2.10 1
Extension Nut Fitting, 1.73 2
Plug 1
8 3-1/8 THICK SPACER (Per Air Spring) S-22632/2
1/4-18 NPTF Plug 1
Air Fitting, 3.10 1
Plug 1
PRIMARY SUSPENSIONS
PIVOT BOLT/BUSHING KITS

10 QUIK-ALIGN PIVOT BOLT KIT (Per Hanger)6 S-21052
7/8 Hardened Flat Washer 2
7/8-9 UNC x 10 Grade 8, Hex Head Bolt 1
TORQ-RITE Nut 1
11 QUIK-ALIGN PIVOT BUSHING KIT (Per Hanger)6 S-21166
7/8-9 UNC x 10 Grade 8, Hex Head Bolt 1
TORQ-RITE Nut 1
Bushing Wear Pad 2
TRI-FUNCTIONAL II BUSHING 1
Lubricant Packet 1
6
Best installed with QUIK-ALIGN Impact Sockets S-20947 (3/4 Drive Impact) or S-21058 (1 Drive Impact).
88
SHOCK ABSORBER BOLT KITS

14a SHOCK ABSORBER BOLT KIT FOR UNITS
SHIPPED AFTER 8/11/95 (Per Shock)7 S-24021
Shock Spacer Zinc Coated 1
Shock Spacer Assembly 1
3/4-10 x 3-1/2 Hex Head Bolt 1
3/4-16 x 4-1/2 Hex Head Cap Screw 1
3/4-10 Lock Nut 2
3/4-10 x 5-3/4 Shear Type Bolt 1
Shock Backing Plate 1
14b SHOCK ABSORBER BOLT KIT FOR UNITS
SHIPPED BEFORE 8/11/95 (Per Shock) S-20896/2
Shock Spacer Zinc Coated 1
3/4-10 x 3-1/2 Hex Head Bolt 1
3/4-10 Lock Nut 2
3/4-10 x 5 Hex Socket Head Cap Screw 1
AXLE NUT KITS

15 HN SPINDLE TYPE AXLE NUT KIT (Per Wheel) S-20492/2
Inner Axle Nut 1
Outer Axle Nut 1
PRIMARY SUSPENSIONS
Lock Washer 1
8-32 x 3/8 Set Screw 1
15 HP SPINDLE TYPE AXLE NUT KIT (Per Wheel) S-20475/2
Inner Axle Nut 1
Outer Axle Nut 1
Lock Washer 1
ABS BRACKET KITS

16 HN SPINDLE TYPE ABS BRACKET KIT (Per Wheel) S-21064
Sensor Bracket 1
1/4-20 x 1-3/4 Grade 8, Hex Head Bolt 2
1/4-20 Grade 8, Lock Nut 2
1/4 Flat Washer 4
16 HP SPINDLE TYPE ABS BRACKET KIT (Per Wheel) S-21070
Sensor Bracket 1
1/4 Flat Washer 4
7
This kit contains components necessary to repair AA230T/AA250T INTRAAX models shipped after 8/11/95. Shear type bolt best installed with E-20
socket, Hendrickson Part No. A-24303.
89
BRAKE SHOE KITS

BRAKE SHOE KIT (Per Wheel)8 S-21266-1
24 Lined Brake Shoe 2
20 Brake Shoe Roller 2
21 Roller Retainer 2
22 Return Spring Pin 2
PRIMARY SUSPENSIONS

BRAKE OVERHAUL KITS

ALL STANDARD BRAKES, MINOR OVERHAUL KIT (Per Wheel) S-21183
17 Anchor Pin 2
18 Anchor Pin Bushing 2
19 Brake Retaining Spring 2
23 Brake Return Spring 1
ALL HXS BRAKES, MINOR OVERHAUL KIT (Per Wheel) S-23752
17 Anchor Pin 2
BRAKES, MAJOR OVERHAUL KIT (Per Wheel)8 S-21184-1
17 Anchor Pin 2
24 Lined Brake Shoes 2
90
8
See AA230T/AA250T INTRAAX Brake and Spindle Components Section for brake lining description.
BRAKE OVERHAUL KITS (CONTINUED)

17 Anchor Pin 2
17 Anchor Pin 2
17 Anchor Pin 2
PRIMARY SUSPENSIONS
17 Anchor Pin 2
8
See AA230T/AA250T INTRAAX Brake and Spindle Components Section for brake lining description.
91
BRAKE CONVERSION TO HXS KITS

16-1/2 x 7, HXS, ABEX 3030-197, FMSI 4707 S-23756-1
26 Outer Cam Washer 2
25 S-cam 2
16-1/2 x 8-5/8 HXS, ABEX 3030-197, FMSI 4711 S-23757-1
25 S-cam 2
S-CAM OVERHAUL KITS

AXLE S-CAM MAJOR OVERHAUL KIT FOR UNITS
SHIPPED BEFORE 11/24/97 (Per Axle) S-21181
30 Spider Retaining Ring 2
33 Spline Retaining Ring 2
PRIMARY SUSPENSIONS
29 S-cam Journal Washer 4

28 Spider Camshaft Bushing 2
31 S-cam Support Bushing Assembly 2
27 Spider Seal 4
32 Spline Inner Washer 6
SHIPPED AFTER 11/24/97 (Per Axle) S-23974
27 Spider Seal 4
92
S-CAM OVERHAUL KITS (CONTINUED)

WHEEL S-CAM MAJOR OVERHAUL KIT FOR UNITS
SHIPPED BEFORE 11/24/97 (Per Wheel) S-21181/2
27 Spider Seal 2
SHIPPED AFTER 11/24/97 (Per Wheel) S-23974/2
27 Spider Seal 2
PRIMARY SUSPENSIONS
93
MODEL AA230L/AA250L INTRAAX
15
11
10b
2 5
13
7
14
11 8
10a
4
PRIMARY SUSPENSIONS
15
13
12
9
1
94
MODEL AA230L/AA250L INTRAAX

1 AXLE/BEAM WELDMENT Contact Hendrickson for assistance
2 FRAME BRACKET Contact Hendrickson for assistance
3 FRAME BRACKET CHANNEL A-1631-19 1
4 AIR SPRING
For AA230LA 6-1/2 through 8
Ride Heights S-23720 2 Use to replace C-23720 air spring
5 AIR SPRING MOUNTING PLATE
Various Weld-on Applications,
Octagonal B-20905 2 Standard travel for 6-1/2 through 16
ride heights; Limited travel for 6-1/2
through 14 ride heights
Various Weld-on Applications,
12 Round B-23294 2 Standard travel for 6-1/2 through 16
ride heights; Limited travel for 6-1/2
PRIMARY SUSPENSIONS
through 14 ride heights
hole is 1-1/2; Standard travel for 6-1/2
through 16 ride heights; Limited travel
for 6-1/2 through 14 ride heights
6 LOWER AIR SPRING PLATE B-23294 2 Standard travel, weld-on and bolt-on
applications for 9-1/2, 10 and 13
through 16 ride heights; Limited travel,
weld-on and bolt-on applications for
8-1/2 through 14 ride heights
7 AIR SPRING SPACER
Plastic, 1-1/8 Thick Spacer B-22510-1 2
Plastic, 3/4 Thick Spacer B-22510-4 2
95
MODEL AA230L/AA250L INTRAAX cont.
15
11
10b
2 5
13
7
14
11 8
10a
4
PRIMARY SUSPENSIONS
15
13
12
9
1
96

8 AIR SPRING SPACER ASSEMBLY
Spacer Assembly C-24077-6 2
Steel, Bolt-on, 11 Thick
9 AIR SPRING MOUNTING KIT1 (Per Air Spring)
S-22619/2 2 For units with no spacer and all weld-on
and bolt-on units with a steel spacer
PRIMARY SUSPENSIONS
S-22630/2 2 For units with a 1-1/8 thick plastic spacer
S-22635/2 2 For units with a 3/4 thick plastic spacer
10 ALIGNMENT COLLARS
10a Eccentric, QUIK-ALIGN S-20925 2 Pivot bolt hole is offset from center of collar
10b Concentric, QUIK-ALIGN S-20924 2 Pivot bolt hole is in center of collar
11 QUIK-ALIGN PIVOT BOLT KIT1 S-24679 2 Includes shear type bolt, nut and washers
12 QUIK-ALIGN PIVOT BUSHING KIT1 S-24691 2 Includes bushing, pivot bolt kit, wear pads
and lube
13 BUSHING WEAR PAD S-11613 4 Four (4) required per axle
14 SHOCK ABSORBER
Standard Duty, 6-1/2 through 8
Ride Heights S-22311 2 Use to replace B-22311 shock absorber
Extended Service, High Damping,
6-1/2 through 8 Ride Heights S-22312 2 Use to replace B-22312 shock absorber
15 SHOCK ABSORBER BOLT KIT1 S-24757/2 2 One (1) required per shock
1
See AA230L/AA250L INTRAAX Kit Components Section or Service Kits Section for kit breakdown. 97
25
23
21
20
22
17
19
18
PRIMARY SUSPENSIONS
17
24
22
21
23
16
25
98

16 AXLE NUT KIT1
HN Spindle Type S-20492/2 2 Includes inner axle nut, outer axle nut,
HP Spindle Type S-20475/2 2 Includes inner axle nut, outer axle nut,
17 ABS BRACKET KIT1
HN Spindle Type S-21064 1 Includes sensor bracket, bolts, lock nuts
and flat washers
HP Spindle Type S-21070 1 Includes sensor bracket, bolts, lock nuts
and flat washers
18 ANCHOR PIN2 Included in minor overhaul brake kits and
19 ANCHOR PIN BUSHING2 Included in minor overhaul brake kits and
20 BRAKE RETAINING SPRING2 Included in minor overhaul brake kits and
21 BRAKE SHOE ROLLER2 Included in brake shoe kits, minor
brake kits1
22 ROLLER RETAINER2 Included in brake shoe kits, minor
overhaul brake kits, major overhaul brake
kits, axle S-cam major overhaul kits and
wheel S-cam major overhaul kits1
23 RETURN SPRING PIN2 Included in brake shoe kits, minor
PRIMARY SUSPENSIONS
brake kits1
24 BRAKE RETURN SPRING2 Included in minor overhaul brake kits and
25 BRAKE SHOE2
16-1/2 x 7 Standard Service
16-1/2 x 7 HXS
S-23750-3 2 ABEX 931-162, FMSI 4707
S-23753-3 2 ABEX 931-162, FMSI 4707
16-1/2 x 8-5/8 HXS
S-23751-3 2 ABEX 931-162, FMSI 4711
S-23754-3 2 ABEX 931-162, FMSI 4711
1
See AA230L/AA250L INTRAAX Kit Components Section or Service Kits Section for kit breakdown.
2
3
99
36
34
33
35
PRIMARY SUSPENSIONS
30
32
29 28
32
30
28
27 31
26
100

26 S-CAM
Right Hand, 28 Spline Standard S-20806-1R 1
Right Hand, 10 Spline Standard S-21717-1R 1 Not for U.S. use
Right Hand, 28 Spline HXS S-23347-1R 1
Left Hand, 28 Spline Standard S-20806-1L 1
Left Hand, 10 Spline Standard S-21717-1L 1 Not for U.S. use
Left Hand, 28 Spline HXS S-23347-1L 1
27 OUTER CAM WASHER2 Included in axle S-cam major overhaul
28 SPIDER SEAL2 Included in axle S-cam major overhaul
29 SPIDER CAMSHAFT BUSHING2 Included in axle S-cam major overhaul
30 S-CAM JOURNAL WASHER2 Included in axle S-cam major overhaul
31 SPIDER RETAINING RING2 Included in axle S-cam major overhaul
32 S-CAM SUPPORT BUSHING ASSEMBLY2 Included in axle S-cam major overhaul
33 SPLINE INNER WASHER2 Included in axle S-cam major overhaul
34 SPLINE RETAINING RING2 Included in axle S-cam major overhaul
35 SLACK ADJUSTER KITS (Per Wheel)
PRIMARY SUSPENSIONS
and inner sleeve
and inner sleeve
not for U.S. use
not for U.S. use
36 BRAKE CHAMBER (7 from mounting face to center of clevis pin)
MGM 30/30 C-24164-1 2
MGM 30/30, Long Stroke C-24769 2
Haldex 30/30 C-24164-2 2
TSE 30/30 C-24164-3 2
Carlisle 30/30 C-24164-4 2
37 CLAMP-ON DUST SHIELD 2 Not shown
1
See AA230L/AA250L INTRAAX Kit Components Section or Service Kits Section for kit breakdown.
2
101
AIR SPRING MOUNTING KITS

9 NO SPACER AND ALL WELD-ON AND BOLT-ON UNITS WITH
STEEL SPACER (Per Air Spring) S-22619/2
1/4-18 NPTF Plug 1
9 1
1- /8 THICK PLASTIC SPACER (Per Air Spring) S-22630/2
1/4-18 NPTF Plug 1
Air Fitting, 1.10 1
9 7
1- /8 THICK PLASTIC SPACER (Per Air Spring) S-22631/2
1/4-18 NPTF Plug 1
Air Fitting, 2.10 1
Plug 1
9 3-1/8 THICK PLASTIC SPACER (Per Air Spring) S-22632/2
1/4-18 NPTF Plug 1
Air Fitting, 3.10 1
Plug 1
PRIMARY SUSPENSIONS
9 3/4 THICK PLASTIC SPACER (Per Air Spring) S-22635/2

1/4-18 NPTF Plug 1
PIVOT BOLT/BUSHING KITS

11 QUIK-ALIGN PIVOT BOLT KIT (Per Hanger)4 S-24679
7/8-9 x 10 Shear Type Bolt 1
7/8-9 UNC Prevailing Torque Heavy Hex Nut 1
12 QUIK-ALIGN PIVOT BUSHING KIT (Per Hanger)4 S-24691
7/8-9 UNC Prevailing Torque Heavy Hex Nut 1
Bushing Wear Pad 2
TRI-FUNCTIONAL II BUSHING 1
Lubricant Packet 1
4
Best installed with E-20 Socket, Hendrickson Part No. A-24303.
102
SHOCK ABSORBER BOLT KIT

15 SHOCK ABSORBER BOLT KIT S-24757/2
3/4-10 Hex Head Bolt 1
3/4-10 Hex Nut 1
AXLE NUT KITS

16 HN SPINDLE TYPE AXLE NUT KIT (Per Wheel) S-20492/2
Inner Axle Nut 1
Outer Axle Nut 1
Lock Washer 1
16 HP SPINDLE TYPE AXLE NUT KIT (Per Wheel) S-20475/2
Inner Axle Nut 1
Outer Axle Nut 1
Lock Washer 1
ABS BRACKET KITS

17 HN SPINDLE TYPE ABS BRACKET KIT (Per Wheel) S-21064
Sensor Bracket 1
PRIMARY SUSPENSIONS
1/4 Flat Washer 4
17 HP SPINDLE TYPE ABS BRACKET KIT (Per Wheel) S-21070
Sensor Bracket 1
1/4 Flat Washer 4
103
BRAKE SHOE KITS

PRIMARY SUSPENSIONS

BRAKE OVERHAUL KITS

ALL STANDARD BRAKES, MINOR OVERHAUL KIT (Per Wheel) S-21183
18 Anchor Pin 2
ALL HXS BRAKES, MINOR OVERHAUL KIT (Per Wheel) S-23752
18 Anchor Pin 2
18 Anchor Pin 2
104
5
See AA230L/AA250L INTRAAX Brake and Spindle Components Section for brake lining description.
BRAKE OVERHAUL KITS (CONTINUED)

18 Anchor Pin 2
18 Anchor Pin 2
18 Anchor Pin 2
PRIMARY SUSPENSIONS
18 Anchor Pin 2
5
See AA230L/AA250L INTRAAX Brake and Spindle Components Section for brake lining description.
105
BRAKE CONVERSION TO HXS KITS

16-1/2 x 7, HXS, ABEX 3030-197, FMSI 4707 S-23756-1
25 S-cam 2
16-1/2 x 8-5/8 HXS, ABEX 3030-197, FMSI 4711 S-23757-1
25 S-cam 2
S-CAM OVERHAUL KITS

SHIPPED BEFORE 11/24/97 (Per Axle) S-21181
PRIMARY SUSPENSIONS

28 Spider Seal 4
SHIPPED AFTER 11/24/97 (Per Axle) S-23974
28 Spider Seal 4
106
S-CAM OVERHAUL KITS (CONTINUED)

SHIPPED BEFORE 11/24/97 (Per Wheel) S-21181/2
28 Spider Seal 2
SHIPPED AFTER 11/24/97 (Per Wheel) S-23974/2
28 Spider Seal 2
PRIMARY SUSPENSIONS
107
INTRAAX

TOP-MOUNT SPECIFICATIONS
AAT 23K / AAT 25K
AAT 30K / AAEDT 30K
LIT NO: L600
DATE: May 2001 REVISION: C
TABLE OF CONTENTS
APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Suspensions AAT 23K / AAT 25K / AAT 30K / AAEDT 30K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 3
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Brake Chambers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Slack Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
READY-TO-ROLL Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Air Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
BRAKE RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

INTRAAX TOP-MOUNT SPECIFICATIONS
APPLICATIONS
AAT 23K AAT 25K
*CAPACITY: 23,000 lbs. (10 400 kg) 25,000 lbs. (11 300 kg)
TRAILER TYPES: UNITED STATES MEXICO, CENTRAL UNITED STATES MEXICO, CENTRAL
& CANADA & SOUTH AMERICA & CANADA & SOUTH AMERICA
Container Chassis None Platform Van/Reefer
Platform Dump Container Chassis
Dump Tanker Platform
Bottom Discharge Grain Grain
Tanker Dump
Grain Pup
Pup Dolly
Dolly
AXLE DATA: 5-in. diameter round with S-cam brakes
AXLE ARRANGEMENT: Single; Tandem up to 122-in. maximum spacing
Tri- or quad-axle up to 144-in. maximum total spacing
FRAME TYPES: Steel, aluminum or composite; 96- or 102-in. wide trailers
BASE MODEL INTRAAX top-mount suspension/axle, 14-in. ride height, weld-on, winged frame
DESCRIPTION: brackets with QUIK-ALIGN, 71.5-in. axle track, HN spindles, standard shock
absorbers, 16.5 x 7-in. brakes with Abex 3030-197 brake lining
BASE MODEL WEIGHT: 542 lbs. 572 lbs.
OTHER OPTIONS: Additional options include wingless and bolt-on frame brackets, extended-service/high-
damping shock absorbers, shock straps and HIGH CONTROL. Ride heights ranging
from 13.5 to 19 ins. are available, as well as choices for 77.5-in. axle track, HP
spindles and dust shields. Contact your Hendrickson representative to discuss these
and other options, including a variety of READY-TO-ROLL brake and wheel-end
packages.
*Capacity refers to suspension and axle ratings. Ratings for brakes and wheel-end components differ depending upon options chosen.
SPECIFICATIONS
SUSPENSION AAT 23K SUSPENSION AAT 25K
1 1
RIDE HEIGHT JOUNCE REBOUND RIDE HEIGHT JOUNCE REBOUND
(inches) (inches) (inches) (inches) (inches) (inches)
13.5 3.2 5.3 13.5 3.1 5.3

14 3.7 4.8 14 3.6 4.8
15 3.8 3.8 15 3.7 3.8
16 4.0 4.7 16 3.7 4.7
17 3.9 3.7 17 3.7 3.7
18 3.8 4.8 18 3.7 4.8
19 3.7 3.8 19 3.7 3.8
1
Limited rebound is also available.
2
APPLICATIONS
AAT 30K AAEDT 30K
(Extreme-Duty)
*CAPACITY: 30,000 lbs. suspension (13 600 kg) 30,000 lbs. (13 600 kg)
25,000 lbs. axle (11 300 kg)
Platform Van/Reefer Logger Platform
Dump Platform Chip Van Tanker
Grain Dump Grain
Tanker Dump
Dump Logger
Sugar Cane

BASE MODEL INTRAAX top-mount suspension/axle, 14-in. ride height, weld-on, winged frame
DESCRIPTION: brackets with QUIK-ALIGN, 71.5-in. axle track, HN spindles (AAT 30K) HP spindles,
(AAEDT 30K), extended service/high damping shock absorbers, 16.5 x 7-in. brakes
with Abex 3030-197 brake lining
OTHER OPTIONS: Additional options include wingless and bolt-on frame brackets, shock straps,
rear-mounted shock absorbers, rebound limiters and HIGH CONTROL. Ride heights
ranging from 13.5 to 19 ins. are available, as well as choices for 77.5-in. axle track,
HP spindles and dust shields. Contact your Hendrickson representative to discuss
these and other options available, including a variety of READY-TO-ROLL brake and
wheel-end packages.
*Capacity refers to suspension and axle ratings, expect where noted. Ratings for brakes and wheel-end components differ depending upon
options chosen.
SPECIFICATIONS
SUSPENSION AAT 30K SUSPENSION AAEDT 30K
1 1
13.5 2.9 5.2 14 3.0 4.3

14 3.4 4.7 15 3.4 3.8
15 3.5 3.7 16 3.9 5.0
16 3.5 4.6 17 4.9 4.0
17 3.5 3.6 1
18 3.5 4.7
19 3.5 3.7
3
AXLE
BEARINGS
SPINDLE TUBE O.D.
TYPE INNER CONE OUTER CONE INNER CUP OUTER CUP (inches)
HN* HM218248 HM212049 HM218210 HM212011 5.0
HP HM518445 HM518445 HM518410 HM518410 5.0
* Not available on AAEDT 30K

BRAKES
SIZE LINING S-CAM S-CAM
(inches) THICKNESS DIMENSIONS SPLINES
10 ins. long
16.5 7.0 standard service 28 and 10
1.5 -in. diameter
16.5 7.0 HXS 10 ins. long
28 and 10
16.5 8.625 extended service 1.5 -in. diameter
BRAKE CHAMBERS
CHAMBER PUSH ROD HENDRICKSON PART NUMBER SORTED BY VENDOR
STROKE
TYPE LENGTH (in.) MGM HALDEX TSE CARLISLE
9.75 C-20837-1 C-20837-2 C-20837-3 C-20837-4
30/30 STD 2.5
*5.63 *C-24164-1 *C-24164-2 *C-24164-3 *C-24164-4
9.75 C-22792-1 C-22792-2 C-22792-3 C-22792-4
24/30 STD 2.5
*5.63 *C-24163-1 *C-24163-2 *C-24163-3 *C-24163-4
9.75 C-24225-1
30/30 (6 yr.) LONG 3.0
*5.63 *C-24165-1
9.75 C-24247-1 C-24247-4
30/30 LONG 3.0
*5.63 *C-24769-1 *C-24769-4
9.75 C-24828-1
30/36 LONG 2.5
*5.63 *C-24829-1
* Applies only to AAEDT 30K
SLACK ADJUSTERS:
All industry standard 5.5- and 6-in. slack adjusters are compatible.
BRAKE LINING:
See Service Brake Rating section on page 5 for lining selection when determining brake/axle GAWR.
READY-TO-ROLL OPTIONS:
Hendrickson can supply a variety of READY-TO-ROLL options to meet your needs. Various brake chambers,
slack adjusters and wheel-end components are available by contacting your Hendrickson representative.
4
AIR KITS
NON-DELAY DELAY
DUMP
VALVE .25-inch tube fitting .375-inch tube fitting .25-inch tube fitting .375-inch tube fitting
WITHOUT AKH-228-3 AKH-238-3 AK-209-3 AK-219-3
ADD-ON AKHD-228-3 AKHD-238-3 AK-209A-3 AK-219A-3

NOTE: Bolted link shown. Air kits with clamped link are also available.
BRAKE RATING (For S-Cam Brakes)
CONFIGURATION LINING HENDRICKSON FORMULATION BRAKE AL FACTOR TIRE ROLLING

(chamber area
(inches) SUPPLIER PART NUMBER NUMBER RATING (lbs.) stack length) RADIUS (inches)
16.5 7 ABEX C-21114-1 3030-197 20K 17.0 - 20.3

165 (30 5.5)
standard service
16.5 7 HXS
extended service ABEX C-22730-1 3030-197 20K 165 (30 5.5) 17.0 - 20.3
16.5 8.625 HXS

Brake ratings are determined by considering a combination of brake lining, power input (AL factor) and tire size
(static loaded radius). The information listed above applies to standard linings on an INTRAAX brake system.
It should be used by the trailer manufacturer to establish a brake rating which is certified to FMVSS/CMVSS 121,
paragraphs S5.4 and S5.6.1.
It is recommended that the combination of lining, AL factor and tire be used that most closely matches the other
system component ratings. Matching the brake rating improves truck / trailer brake balance and helps optimize
tire life and suspension dynamics.
Hendrickson can provide other standard service linings from manufacturers such as Carlisle, Haldex and
BrakePro. Application-specific requests for non-standard linings must be submitted to Hendrickson engineering
for approval.
Brake ratings defined above apply only to Hendrickson brake shoes as installed on INTRAAX. The information is
based upon dynamometer and draw bar tests conducted to show compliance to FMVSS/CMVSS 121,
5
866.RIDEAIR (866.743.3247) 905.789.1030
330.489.0045 Fax 905.789.1033
Fax 800.696.4416
The Boler Company

Copyright 2001
L600 C 10M 5-01 Printed in United States of America. www.hendrickson-intl.com All Rights Reserved
INTRAAX

LOW-RIDE /LIFTABLE
SPECIFICATIONS
AAL 23K / AAL 25K
AAL 30K / AAEDL 30K
LIT NO: L729
DATE: May 2001 REVISION: A
TABLE OF CONTENTS
APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Suspension s AAL 23K / AAL 25K / AAL 30K / AAEDL 30K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 3
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Brake Chambers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Slack Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
READY-TO-ROLL Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Air Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
BRAKE RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

INTRAAX LOW-RIDE/LIFTABLE SPECIFICATIONS
APPLICATIONS
AAL 23K AAL 25K
*CAPACITY: 23,000 lbs. (10 400 kg) 25,000 lbs. (11 300 kg)
Drop-Deck None Platform Van/Reefer
Platform Lowboy Drop Frame Van
Lowboy Drop-Deck Auto Hauler
Dump Dump Container Chassis
Bottom Discharge Tanker Platform
Tanker Grain Lowboy
Grain Livestock Drop-Deck
Livestock Curtain-Side Grain
Curtain-Side Livestock
Curtain-Side
BASE MODEL INTRAAX low-ride/liftable suspension/axle, 6.5-in. ride height, weld-on, winged frame
DESCRIPTION: brackets with QUIK-ALIGN, 71.5-in. axle track, HN spindles, standard shock
absorbers, 16.5 x 7-in. brakes with Abex 3030-197 brake lining
OTHER OPTIONS: Additional options include wingless and bolt-on frame brackets, extended-service/high-
damping shock absorbers, shock straps, rear-mounted shock absorbers, rebound
limiters and HIGH CONTROL. Ride heights ranging from 6.5 to 19 ins. are available,
as well as choices for 77.5-in. axle track, HP spindles and dust shields. Contact your
Hendrickson representative to discuss these and other options, including a variety of
READY-TO-ROLL, brake and wheel-end packages.
*Capacity refers to suspension and axle ratings. Ratings for brakes and wheel-end components differ depending upon options chosen.
SPECIFICATIONS
SUSPENSION AAL 23K / AAL 25K
1 1
6.5 2.3 4.5 15 5.6 3.4

7.5 3.3 3.5 16 5.7 4.3
9 4.8 4.2 17 6.0 3.3
12 5.3 4.8 19 5.7 3.5
14 5.9 4.4
1
2
APPLICATIONS
AAL 30K AAEDL 30K
(Extreme-Duty)
*CAPACITY: 30,000 lbs. suspension (13 600 kg) 30,000 lbs. (13 600kg)
25,000 lbs. axle (11 300 kg)
Platform Van/Reefer Logger Platform
Drop-Deck Platform Chip Van Drop-Deck
Lowboy Drop-Deck Dump Tanker
Dump Lowboy Dump
Curtain-Side Logger
Sugar Cane

AXLE ARRANGEMENT: Single; Tandem up to 122-in. maximum tandem spacing
BASE MODEL INTRAAX low-ride suspension/axle, 14-in. ride height, weld-on, winged frame
DESCRIPTION: brackets with QUIK-ALIGN, 71.5-in. axle track, HN spindles (AAL 30K) HP spindles,
(AAEDL 30K), extended service/high damping shock absorbers, 16.5 x 7-in. brakes
with Abex 3030-197 brake lining
OTHER OPTIONS: Additional options include wingless and bolt-on frame brackets, shock straps,
rear-mounted shock absorbers, rebound limiters and HIGH CONTROL. Ride heights
ranging from 9 to 19 ins. are available, as well as choices for 77.5-in. axle track
and dust shields. Contact your Hendrickson representative to discuss these and other
options available, including a variety of READY-TO-ROLL, brake and wheel-end
packages.
*Capacity refers to suspension and axle ratings, except where noted. Ratings for brakes and wheel-end components differ depending upon
options chosen.
SPECIFICATIONS
SUSPENSION AAL 30K SUSPENSION AAEDL 30K
1 1
9 4.5 4.2 9 4.6 4.0

12 5.3 4.8 12 5.3 4.6
14 5.9 4.4 14 5.9 4.3
15 5.6 3.4 15 5.6 3.3
16 5.7 4.3 16 5.7 4.2
17 6.0 3.3 17 6.0 3.2
19 5.7 3.5 19 5.7 3.4
1
3
AXLE
BEARINGS
SPINDLE TUBE O.D.
TYPE INNER CONE OUTER CONE INNER CUP OUTER CUP (inches)
HN* HM218248 HM212049 HM218210 HM212011 5.0
HP HM518445 HM518445 HM518410 HM518410 5.0

* Not available on AAEDL 30K
BRAKES
SIZE LINING S-CAM S-CAM
(inches) THICKNESS DIMENSIONS SPLINES
10 ins. long
16.5 7.0 standard service 28 and 10
1.5 -in. diameter
16.5 7.0 HXS 10 ins. long
28 and 10
16.5 8.625 extended service 1.5 -in. diameter
BRAKE CHAMBERS
CHAMBER PUSH ROD HENDRICKSON PART NUMBER SORTED BY VENDOR
STROKE
TYPE LENGTH (in.) MGM HALDEX TSE CARLISLE
30/30 STD 2.5 5.63 C-24164-1 C-24164-2 C-24164-3 C-24164-4
24/30 STD 2.5 5.63 C-24163-1 C-24163-2 C-24163-3 C-24163-4
30/30 (6 yr.) LONG 3.0 5.63 C-24165-1
30/30 LONG 3.0 5.63 C-24769-1 C-24769-4
30/36 LONG 2.5 5.63 C-24829-1
SLACK ADJUSTERS:
All industry standard 5.5- and 6-in. slack adjusters are compatible.
BRAKE LINING:
See Service Brake Rating section on page 5 for lining selection when determining brake/axle GAWR.
READY-TO-ROLL OPTIONS:
Hendrickson can supply a variety of READY-TO-ROLL options to meet your needs. Various brake chambers,
slack adjusters and wheel-end components are available by contacting your Hendrickson representative.
4
AIR KITS
NON-DELAY DELAY
DUMP
VALVE .25-inch tube fitting .375-inch tube fitting .25-inch tube fitting .375-inch tube fitting
WITHOUT AKH-225-3 AKH-235-3 AK-225-3 AK-235-3
ADD-ON AKHD-225-3 AKHD-235-3 AK-225A-3 AK-235A-3

NOTE: Bolted link shown. Air kits with clamped link are also available.
BRAKE RATING (For S-Cam Brakes)
CONFIGURATION LINING HENDRICKSON FORMULATION BRAKE AL FACTOR TIRE ROLLING

(chamber area
(inches) SUPPLIER PART NUMBER NUMBER RATING (lbs.) stack length) RADIUS (inches)
16.5 7 ABEX C-21114-1 3030-197 20K 17.0 - 20.3

165 (30 5.5)
standard service
16.5 7 HXS
16.5 8.625 HXS

Brake ratings are determined by considering a combination of brake lining, power input (AL factor) and tire size
(static loaded radius). The information listed above applies to standard linings on an INTRAAX brake system.
It should be used by the trailer manufacturer to establish a brake rating which is certified to FMVSS/CMVSS 121,
It is recommended that the combination of lining, AL factor and tire be used that most closely matches the other
system component ratings. Matching the brake rating improves truck / trailer brake balance and helps optimize
tire life and suspension dynamics.
Hendrickson can provide other standard service linings from manufacturers such as Carlisle, Haldex and
BrakePro. Application-specific requests for non-standard linings must be submitted to Hendrickson engineering
for approval.
Brake ratings defined above apply only to Hendrickson brake shoes as installed on INTRAAX. The information
is based upon dynamometer and draw bar tests conducted to show compliance to FMVSS/CMVSS 121,
5
866.RIDEAIR (866.743.3247) 905.789.1030
330.489.0045 Fax 905.789.1033
Fax 800.696.4416
The Boler Company

Copyright 2001
L729 A 10M 5-01 Printed in United States of America. www.hendrickson-intl.com All Rights Reserved
GO THE DISTANCE.
LANDING OPERATING and
GEAR
MAINTENANCE PROCEDURES
HITCH
Mark V Landing Gear
Before attempting to operate the landing gear, you must read and understand
CAUTION the following procedures:
Perform all procedures in a lighted area clear of Lifting and lowering of the trailer must always
obstacles and other personnel. be done in LOW GEAR.
Always grip the crank handle securely with both DO NOT ATTEMPT TO LIFT OR LOWER
hands. TRAILER WITH LANDING GEAR IN HIGH
Maintain proper footing at all times. GEAR, AS SERIOUS PERSONAL INJURY
COULD OCCUR.
Never attempt to shift the landing gear while
under load. Always secure the crank handle when not in use.
OPERATING INSTRUCTIONS
Before operating, identify the mounting style of your landing gear Inside or Outside Mount
(See figures below).
Figure 1
TRAILER RETRACT TRAILER RETRACT
COUNTER CLOCKWISE CLOCKWISE
HIGH LOW
LOW HIGH
EXTEND EXTEND
CLOCKWISE COUNTER CLOCKWISE
OUTSIDE MOUNT INSIDE MOUNT

Push crank handle in for low speed. Push crank handle in for high speed.
Pull crank handle out for high speed. Pull crank handle out for low speed.
Turn crank: Turn crank:

counterclockwise = retract counterclockwise = extend
clockwise = extend clockwise = retract
XL-LG305 1
COUPLING INSTRUCTIONS
STEP 1 STEP 4
Inflate tractor air suspension and back up close Adjust trailer height so that the fifth wheel will
to the trailer, centering the kingpin with the lift the trailer.
throat of the fifth wheel and STOP! DO NOT
ATTEMPT TO COUPLE UNTIL STEPS 2
THROUGH 4 ARE COMPLETED.

FIFTH WHEEL
FIFTH WHEEL WILL NOT LIFT
MUST LIFT TRAILER
4- 6 TRAILER
TRAILER

(TOP)
FIFTH WHEEL USE LOW

TILTED DOWN GEAR
KINGPIN
STEP 2 STEP 5
Chock trailer wheels. Couple and verify that
the fifth wheel locks are
Connect brake lines and light cord. properly closed around
Support slack in lines to prevent the kingpin.
interference.
Set trailer brakes.

STEP 6
While still in low
gear, retract landing
gear until pads just
come off the
USE LOW GEAR
ground. UNTIL PADS JUST
COME OFF GROUND.
STEP 3
Make sure that
the landing gear HANDLE ENGAGED
is in low speed STEP 7

(see Figure 1) Switch to high
and engage gear, fully retract
crank handle. and secure crank SECURE HANDLE
handle.
HANDLE DISENGAGED
2
UNCOUPLING INSTRUCTIONS
STEP 1 STEP 3 HANDLE
ENGAGED
Position the Shift landing gear
tractor and to high speed and HANDLE
trailer on engage crank DISENGAGED
level ground, handle.

clear of
persons and
obstacles.
STEP 4
Extend landing gear
until pads just touch
STEP 2 the ground. USE HIGH GEAR
UNTIL PADS TOUCH
GROUND.
Set trailer brakes.
Slowly back tractor tightly against trailer.
Set tractor brakes.
STEP 5
Chock trailer wheels. Switch to low gear
and crank an USE SECURE HANDLE
LOW
additional 4-8 turns. GEAR
Secure crank handle.

STEP 6
Pull fifth wheel release handle.
Disconnect air lines and light cord.
Release tractor brakes and slowly drive away
from trailer.
MAINTENANCE PROCEDURES
LUBRICATION
Lubrication should be performed at least every six months and more frequently in applications where
the landing gear are exposed to excessive moisture, waterspray, dust, or if they are not used for
extended periods. Lubricate with the trailer securely coupled to a tractor (see coupling instructions).
Employ a lubricant compatible with the original type of grease used:
Standard = Lithium base EP-2 GEARBOX BEVEL GEARS
(maintain 1 lb.) (maintain 1 lb.)
Low Temperature = Lubriplate aero-grade
1. Fully retract the landing gear, then using high
gear extend 2-3 turns.
2. Lubricate through the grease fittings as shown.
3. Extend and retract the landing gear to apply LIFT SCREWS
grease to the entire length of the screw. (maintain 1/2 lb.)
3
MAINTENANCE PROCEDURES (cont.)
HARDWARE ALIGNMENT
Tighten or replace mounting bolts as Using a square,
necessary. check that both
TRAILER
Inspect the mounting bracket for cracks or landing gear legs are END
VIEW
other signs of damage. square with the SQUARE
Repair or replace any broken or damaged part trailer and parallel CORRECT
of the landing gear assembly or mounting with each other as

structure. shown. Bent or SQUARE
Inspect the crank handle bolt and lock nut. damaged legs are an
Tighten or replace as necessary. indication of
Cross shaft connection bolts and lock nuts possible damage TRAILER SIDE VIEW
should be secure, but allow side-to-side play in to the lift screw,

the cross shaft. lift nut or other
Check for proper crank shaft engagement in internal
both high and low gear. components SQUARE
Landing gear with excessive play should be and should be

rebuilt or replaced. replaced.
TROUBLE-SHOOTING POINTS
Problem Cause Correction
Hard to crank landing gear 1. Turning crank in wrong direction. 1. See Figure 1 on Page 1 for proper crank rotation.
2. Attempting to raise or lower trailer 2. Shift into low gear (see Figure 1). DO NOT ATTEMPT TO LIFT
in high gear. OR LOWER IN HIGH GEAR.
3. Cross shaft binding 3. Inspect cross shaft bolts. Back off bolts to allow lateral
- over-tightened bolts (side-to-side) movement of the cross shaft.
- cross shaft bent or too long
4. Mis-aligned landing gear legs. 4. Legs must be parallel and extend and retract evenly. Remove
cross shaft, adjust landing gear legs to same height.
5. Lack of grease. 5. Grease landing gear legs as provided above in Maintenance
section of manual.
6. Mis-aligned crank shaft holder 6. Inspect and align crank shaft holder or extension with the
or crank shaft extension. crank shaft.
7. Damaged lift screw or lift nut. 7. Check landing gear for signs of impact (accident) damage.
Disconnect cross shaft and crank legs individually to determine
which leg is damaged. Replace damaged leg.
8. Interference between powder metal 8. Hole in trailer mounting surface may need to be enlarged.
bushing and trailer mounting surface. See Holland Service Bulletin #30.
Shaft turns but legs 1. Broken shaft or shaft bolt. 1. Replace broken bolt(s) and shaft as needed.
do not operate 2. Broken pinion gear or bevel gear 2. Replace broken gear(s) or pins.
or gear pins.
Shaft does not turn 1. Broken gear teeth. 1. Replace broken gear(s).
2. Damaged lift screw or nut. 2. Replace inner leg or entire landing gear leg.
3. Seized lift screw or nut. 3. Replace inner leg or entire landing gear leg.
4. Bent inner or outer leg tube. 4. Replace bent inner or outer leg, or entire landing gear leg.
Crankshaft skips when cranking 1. Broken gear teeth. 1. Replace broken gear(s).
Copyright March 2000 The Holland Group, Inc.

Holland Hitch Holland Binkley Co. Holland Neway International, Inc. Holland Hitch of Canada, Ltd. Holland Equipment, Ltd.
Company Divisions: Warrenton, MO Muskegon, MI Woodstock, Ontario Canada Norwich, Ontario Canada
Holland, MI Phone: 636-456-3455 Phone: 231-773-3271 Phone: 519-537-3494 Phone: 519-863-3414
Whitehouse Station, NJ Fax: 636-456-6792 Fax: 231-766-3893 Fax: 800-565-7753 Fax: 519-863-2398
Denmark, SC
Holland Binkley Co. Holland International, Inc. Holland Hitch Western, Ltd.
Wylie, TX Axle Products Division Holland, MI Surrey, British Columbia Canada
Milpitas, CA Delphos, OH Phone: 616-396-6501 Phone: 604-574-7491
Phone: 888-396-6501 Phone: 419-692-6015 Fax: 616-396-1511 Fax: 604-574-0244
Fax: 800-769-3299 Fax: 419-692-0503
4
GO THE DISTANCE.
LANDING REPAIR
GEAR
PROCEDURES
HITCH
Mark V Landing Gear
Manufactured after May 1, 1994
Before attempting to operate the landing gear, you must read and understand the
following procedures:
CAUTION
DO NOT ATTEMPT TO REPAIR ANY LANDING Always wear safety goggles.
GEAR COMPONENT WITHOUT FOLLOWING THE DO NOT strike any part of the product with a steel
INSTRUCTIONS CONTAINED IN THIS MANUAL. hammer.
DO NOT modify, change or add to the product. Use Observe standard precautions when lifting.
only genuine Holland parts.
Perform all procedures in a lighted area clear of
obstacles and other personnel.
This manual contains repair procedures for Mark V landing gear manufactured after May 1, 1994. Use the
figures below to identify your Holland Mark V landing gear.
Powdered
metal
bushings
Recessed
gearbox
Formed
cover
guide
Mark V manufactured Mark V manufactured

prior to May 1, 1994 after May 1, 1994
Before performing any landing gear repair or rebuild procedure, the following
precautions must be taken.
CAUTION
1. Position the tractor and trailer on firm level 3

4
ground free of persons and obstacles.
2. Chock the trailer wheels.
3. Securely couple tractor to trailer. 1
4. Set the tractor and trailer brakes.
5. Retract (raise) landing gear until off ground.
2 5
XL-LG 225
TROUBLESHOOTING GUIDE
Before beginning any repair or rebuild procedure, review the troubleshooting guidelines below. The guide can
help you identify specific problems and remedies for your Mark V landing gear. (The item numbers referred to
in the table are identified in the exploded view and parts list found on Page 7.)
Problem Cause Correction
Hard to crank 1. Turning the crank in wrong 1. See Mark V Operating Procedures for
landing gear direction. proper crank rotation (Holland Publication
LG-TE-11).
2. Attempting to raise or lower trailer 2. Shift into low gear. DO NOT ATTEMPT TO
in high gear. LIFT OR LOWER IN HIGH GEAR!
3. Cross shaft is binding. 3. Inspect cross shaft bolts (Items 17). Back
over-tightened bolts off bolts to allow lateral (side to side)
cross shaft bent or too long movement of the cross shaft. Straighten or
shorten cross shaft to eliminate binding.
4. Misaligned landing gear legs. 4. Legs must be parallel and extend and
retract evenly. Remove cross shaft, adjust
landing gear legs to same height.
5. Lack of grease. 5. Grease landing gear legs as provided in
Mark V Maintenance Procedures (Holland
Publication LG-TE-11).
6. Misaligned crankshaft holder or 6. Inspect and align crankshaft holder or
crankshaft extension. extension with the crankshaft.
7. Damaged lift screw or lift nut. 7. Check landing gear for signs of impact
(accident) damage. Disconnect cross shaft
and crank legs individually to determine
which leg is damaged. Replace damaged leg.
8. Interference between powder metal 8. Trailer mounting surface may need to be
bushing of gearbox and trailer modified. See Holland Service Bulletin
mounting surface. No. 30.
Crankshaft 1. Inner leg screw damage. 1. Examine the lift nut and screw of the inner
jams or skips leg assembly (Items 27, 28, or 29) for
while turning impact (accident) damage.
2. Worn, broken or damaged 2. Examine pinion, bevel pinion and all
gears (missing teeth). gearbox gears (Items 24, 26, 6, 10, 13,
and 14) for missing teeth or other signs
of damage or wear.
Will not stay 1. Shift lock ball and spring (Items 8 1. Remove gearbox cover (Item 3). Check
in gear while and 9) of crank shaft (Item 1) are condition of bushing, shaft, ball and spring.
cranking jammed, damaged or missing. (See Gearbox Disassembly Page 4.)
Crank turns 1. Gear pin(s) sheared in gearbox. 1. Remove gearbox cover (Item 3). Inspect
but legs will and replace broken pins (Items 12, 11,
not extend or and 15).
retract 2. Bevel gear pin sheared in top 2. Remove upper leg cover (Item 21). Check
of leg. for damaged or missing pins (Items 30 or
23) under bevel gear (Item 26) or in pinion
gear (Item 24).
2
REPAIR AND REBUILD 5. Referring to Figure 3, remove the gears from
the gearbox in the following order:
INSTRUCTIONS A. Slide the idler gear (Item 6) off the idler gear
shaft (Item 7).
GEARBOX ASSEMBLY
B. Slide the step gear (Item 14) off the drive
1. Remove the crank handle bolt (Item 50), shaft (Item 2).
washers (Item 51), and nut (Item 18). Remove C. Remove the idler gear shaft (Item 7).
the crank handle (Item 52). D. Remove the spur gear (Item 13).
2. To ease removal of the gearbox cover (Item 3),
remove all rust, burrs and paint and lubricate 14 STEP GEAR
the crankshaft (Item 1) and drive shaft (Item 2).
2 DRIVE SHAFT
6 IDLER GEAR
2
7 IDLER GEAR
SHAFT
13 SPUR GEAR
1
1 CRANKSHAFT
3 50
10 SHIFTER GEAR
51 Figure 3
51
52A 6. Remove the crankshaft (Item 1) by tapping it out
18 52B from behind the mounting plate (see Figure 4).
Be prepared to catch the detent ball (Item 8)
Figure 1 and spring (Item 9) as you remove the crankshaft.
7. Remove the spring pin (Item 12) from the
3. Slide off the gearbox cover (Item 3). Make sure crankshaft (Item 1) then slide off the shifter gear
that the shifter shaft stays in low gear and does (Item 10) and remove the retaining pin (Item 11).
not come out with the gearbox cover.
(Otherwise, the ball and spring will be lost in 8. Replace all worn, bent, broken, or damaged parts.
the grease, see Items 8 and 9, Figure 4). Then,
remove the six gearbox cover screws (Item 4)
and gearbox cover (Item 3).
4. Remove the cover gasket (Item 5). Use care not
to tear or damage it.
5 TAP OUT 1
3
9 8
4 DETENT BALL
AND SPRING 10
(6 REQ.)
Catch the ball and spring as
you remove the crankshaft
SLIDE OFF
SHIFTER 12 11
KEEP SHIFTER
SHAFT PUSHED IN GEAR
WHILE
REMOVING
COVER
Figure 2 1 Figure 4
10
3
LEG DISASSEMBLY 25
24
23
1. For two-speed legs, disassemble the gearbox as ACCESS
HOLE
described in Steps 1-7, on Pages 3-4.
2. Remove the bolts (Item 17) and nuts (Item 18)
from each end of the cross shaft (Item 16) and
2
remove the cross shaft.
3. Remove the eight (8) landing gear mounting
bolts from the mounting plate and remove the
landing gear leg from the trailer.
Figure 6
4. Remove the leg cover screws (Item 4), leg cover
(Item 21) and leg cover gasket (Item 22).
require the use of a gear puller or two 5/16
5. Remove the plastic plug (Item 48) from the Allen keys.
bevel pinion gear access hole (see Figure 5).
10. Support the bottom of the leg and remove the
pin (Item 30) and washer (Item 31) from lift
17
screw (Item 27, 28, or 29).
16
11. Carefully remove the support which should
18 allow the inner leg to drop out. If not, tap the
end of the lift screw with a wooden block or
brass hammer until the lift screw and inner leg
21 assembly drop out of the outerleg. Be careful
not to damage the lift screw threads.
4 12. Lift the bushing (Item 32), thrust bearing (Item

(2 REQ.) 22 33), and collar (Item 34) off the inner leg lift
screw assembly.
13. Thoroughly clean all components and replace
GRADE 8 all worn, bent, broken, or damaged parts.
MOUNTING
48 BOLTS
( 8 REQ.)
26
30
31
32
Figure 5 33
34
6. Place a punch in the access hole, align it with
27, 28, 29
LIFT OUT
the bevel pinion gear groove pin (Item 23) and OUTER LEG
drive out the groove pin (see Figure 6).
7. Carefully remove the drive shaft (Item 2) or the
bevel gear shaft (Item 19) and count the number
of shims (Item 25) used, so that the same SUPPORT
number is used during re-assembly of the leg. INNER LEG
8. Remove bevel pinion gear (Item 24).

9. Lift bevel gear (Item 26) off of the top of
Figure 7
the lift screw (Item 27, 28 or 29). This may
4
LEG ASSEMBLY 5. Place the washer (Item 31) and slide the bevel
gear pin (Item 30) through the hole in the side
1. Slide the collar (Item 34) over the lift screw in of the lift screw, centering the pin in the lift screw.
the inner leg assembly (Item 27, 28, or 29) with
the tapered portion of the collar facing down. 6. Slide the bevel gear (Item 26) over the lift screw
Place the thrust bearing (Item 33) on top of the and position it on the pin as shown in Figure 9.
collar with the cup of the bearing facing up. When properly engaged, the top of the bevel
gear will be approximately flush with the top of
2. Slide the bushing (Item 32) onto the screw and the lift screw.
push all the way down onto the bearing (Item 33).
7. Position the bevel pinion gear (Item 24) on top
3. Rotate the lift screw counter-clockwise until it is of the bevel gear. For single-speed legs the bevel
fully extended, then fill the cup area of the lift pinion gear should be on the opposite side of
nut with grease as shown in Figure 8. the landing gear mounting plate, as shown in
Figure 11. For two-speed legs, the bevel pinion
32
gear should be against the mounting plate side
33 of the landing gear, as shown in Figure 10.
34
25
24
27
28 TWO-SPEED LEG
29 FULLY EXTENDED
FILL "CUP" AREA INNER LEG SCREW
WITH GREASE
35
Figure 10
8. On two-speed legs, slide the drive shaft (Item 2)

Figure 8 into the gearbox side of the outer leg (Item 35),
through the bevel pinion gear, through any
4. Place the outer leg assembly (Item 35 or 36) shims removed previously, and through the hole
in the other side of the outer leg as shown in
over the inner leg assembly (Item 27, 28, or 29)
Figure 10.
and press down until the end of the lift screw
protrudes through the hole in the top of the On single-speed legs slide the bevel pinion gear
outer leg assembly as shown in Figure 9. shaft (Item 19) into the side of the outer leg
30
(Item 36) opposite the landing gear mounting
26
plate, through any shims removed previously,
31 through the bevel pinion gear, and through the
hole in the other side of the outer leg as shown
in Figure 11.
LIFT SCREW
PROTRUDES 19
THROUGH HOLE SINGLE-SPEED
25
OUTER 23 LEG
LEG
ASSEMBLY
35, 36
24
INNER 48 LANDING GEAR

LEG MOUNTING
ASSEMBLY PLATE
36
Figure 9 Figure 11
5
9. Align the holes in the bevel pinion gear with the
Figure 13
holes in the shaft (Item 2 or 19), partially insert
the groove pin (Item 23) through the shaft and 2
bevel pinion gear so that the shaft turns freely

and the two gears are properly engaged.
SHIFT LOCK BEARING 1
To check for proper shimming, push the shaft
and bevel pinion gear (Item 24) tight against the
9
bevel gear (Item 26). There should be no more 8
10
than 1/16 gap between the shims and the
COMPRESS BALL
outer leg. Then push the shaft and bevel pinion AND SPRING AND SLIDE
CRANKSHAFT INTO
gear (Item 24) tight against the tube wall and THE BEARING
the shaft should turn freely. 4. Lubricate the idler gear (Item 6), spur gear (Item
13), step gear (Item 14), and idler gear shaft
10. If shims (Item 25) are necessary, remove the
(Item 7) with grease. Make sure the inside bores
groove pin (Item 23), bevel pinion gear (Item
of the gears are fully lubricated.
24) and bevel pinion gear shaft (Item 19).
Install shims between the bevel pinion gear Referring to Figure 14 below, reassemble the
(Item 24) and the outer leg (Item 35 or 36). gearbox in the following order:
Once properly shimmed, drive groove pin (Item A. Engage the spur gear (Item 13) with the shifter
23) fully into shaft (Item 19). gear (Item 10) and center the spur gear (Item
13) over the center bushing of the gearbox.
11. Replace the plastic access hole plug (Item 48). B. Slide the idler gear shaft (Item 7) through the
Thoroughly grease the bevel pinion gear and spur gear (Item 13) and into the center bushing
bevel gear. A minimum of 1 lb. is recommended. of the gearbox.
Then, replace the leg cover gasket (Item 22)
C. Install the pin (Item 15) through the drive shaft
and leg cover (Item 21).
(Item 2) and slide the step gear (Item 14) over
the drive shaft. Make sure the pin is seated in
GEARBOX ASSEMBLY the cutout portion of the step gear (Item 14).
1. Install pin (Item 11) through crankshaft D. Slide the idler gear (Item 6) onto the idler gear
(Item 1) and slide the shifter gear (Item 10) in shaft (Item 7) engaging the step gear (Item 14).
place with the recess in the shifter gear over 5. Now, fully lubricate all gears and gear shafts in the
the pin. Now, secure the gear in place using gearbox. A minimum of 1 lb. is recommended.
the retaining pin (Item 12). See Figure 12.
6. Replace the gasket (Item 22) and gearbox cover
SLIDE SHIFTER GEAR
12 11 (Item 21) with the six screws (Item 4).
OVER SPRING PIN (11)
7. Remount the landing gear using eight grade 8 bolts
on the mounting plate and all necessary support
bracing required by the trailer manufacturer.
15
1
Figure 12 C
10
14 STEP GEAR
2. Insert the spring (Item 9), then ball (Item 8) 2 DRIVE SHAFT
into the blind hole in the crankshaft (Item 1).
B D
3. While compressing the ball and spring into the 6 IDLER
GEAR
hole, carefully slide the crankshaft into the shift A 7 IDLER GEAR
SHAFT
lock bearing of the gearbox as shown in Figure 13 SPUR GEAR
13. The ball and spring should be captured
under the bearing surface. Push the crankshaft
10 SHIFTER GEAR
into the gearbox until it is engaged in low gear. Figure 14
6
2
4 (2 req.)
4
2
2 5
3 4
3
63A
2 1 63B
4 2
1 2
6 60 (3 req.)
1 4 (2 req.)
HEAVY DUTY 36A
2
4
5
OUTER LEG ASSEMBLIES 2 62
4 3 A
4 1
2
1 3 61
(3 req.)
3 1 4 5 5
33A 4 55A
33B 4
34 55B
2 2 2
1
35B
35A 1
2 1 5
29A 4
1 1 3
4
7 4
4 (6 req.)
TWO-SPEED 28A 3 9
8
33A 1 1 6
33B
3 3
4
4 3
38A 27A 1 5
4 5
38B 4
38C 5 5
38D
4 64A 5
39 64B 1 52
A A
36B 1
5
4 39A 5
SINGLE-SPEED 39B
39C
29B
28B
27B HEAVY DUTY
INNER LEG
ASSEMBLIES
38E
TWO SINGLE TWO SINGLE

PART SPEED SPEED PART PART SPEED SPEED PART
ITEM NUMBER SIDE SIDE NAME ITEM NUMBER SIDE SIDE NAME
1 XA-V-06625-A thru C 1 Crankshaft (see page 9) 35A XA-V-07133-0 thru -5 1 2-speed upper leg
2 XA-V-06624-A thru D 1 Drive gear shaft (see page 9) 35B XA-H-07133-0 thru -5 2-speed H.D. upper leg (see page 9)
3 XA-V-06618 1 Gearbox cover assembly 36A XA-V-07132-0 thru -5 1 Single-speed upper leg
4 XB-06372 8 2 Thread rolling screw 36B XA-H-07132-0 thru -5 Single-speed H.D. upper leg (see page 9)
5 XB-V-06621 1 Gearbox gasket 37 XB-V-747 2 2 Wheel (03 series)
6 XA-V-06602 1 Idler gear 38A XA-V-796-B-1 1 1 Skid foot, 4.9 x 12 x 11.5 (05 series)
7 XA-V-07085 1 Idler gear shaft 38B XA-V-796-L 1 1 Low profile skid foot, 2.5 x 12 x 11.5 (13 series)
8 XB-BAL-023-01 1 Ball 38C XA-V-796-WS 1 1 Weight saver skid foot, 3.8 x 10 x 11.5 (15 series)
9 XB-SPG-020-02 1 Spring 38D XA-V-796-LWS 1 1 Low profile weight saver skid foot
10 XA-V-06604-1 1 Shifter gear 2.4 x 10 x 11.5 (23 series)
11 XA-CRP-V-06633 1 Pin, .25 x 1.44 38E XA-HV-796 1 1 Heavy duty skid foot, 4 x 12 x 16 (312 series)
12 XB-21-S-218-1500 1 Spring pin, .22 x 1.50 39A XA-V-1901-1 1 1 Standard axle
13 XA-V-06606 1 Spur gear 39B XA-V-1903-1 1 1 Solid axle
14 XA-V-06603 1 Step gear 39C XA-V-1902-1 1 1 Heavy pipe axle
15 XA-CRP-V-06634 1 Pin, .38 x 1.5 40 XA-V-1901-2 1 1 Axle (03 series)
16 XA-V-1910 1 Cross shaft (specify frame width, 41 XB-21-S-375-3000 2 2 Rollpin .38 x 3
mounting style, l.g. model no.) 42 XA-04681 1 1 Cushion skid foot (14 series)
17 XB-V-444-1 1 1 HHCS, 3/8-16 x 1.75 43 XB-04676 1 1 Rubber cushion
18 XB-338 2 1 Locknut, 3/8-16 44 XA-V-1938 1 1 Brace lug
19 XA-V-06623-A thru D 1 Bevel pinion gear shaft (single-speed) 45 XB-LG0559 1 2 Bearing
(see page 9) 46 XB-LG1570 1 2 Retainer
21 XA-V-06611 1 1 Upper leg cover 47 XB-767 3 2 Lube fitting
22 XB-V-07054 1 1 Gasket 48 XB-01789 1 1 Plastic plug
23 XB-GP-38-1-12-E 1 1 Groove pin 49 XA-V-1914 1 Crank hanger
24 XA-V-06600 1 1 Bevel pinion gear 50 XB-C-38-C-214 1 HHCS, 3/8-16 x 2.25
25 XB-01977 2 2 Shim (as required) 51 XB-1108 2 3/8 SAE washer
26 XA-V-06601 1 1 Bevel gear 52A XA-V-90-0 1 Crank
27A XA-V-06628-010-1 1 1 Inner leg & screw assy. 52B XA-V-90-2 1 Extra long crank (optional)
thru -515-1 (01 series) (see page 9) 53 XA-V-971 1 Crankshaft bracket (optional)
27B XA-H-06628-010-3 Inner leg & screw assy. 54 XB-V-1915 1 Crank hanger (optional)
thru -515-3 (012 series) (see page 9) 55A XA-V-1916 1 Extension shaft - long (optional)
28A XA-V-06628-020-2 1 1 Inner leg & screw assy. 55B XA-V-1916-1 1 Extension shaft - short (optional)
thru -514-2 (14 series) (see page 9) 56 XA-V-630-2 1 Crankshaft coupling (optional)
28B XA-H-06628-010-1 Inner leg & screw assy. 57 RK-V-07780 1 Drive gear shaft kit (2-speed)
thru -515-1 (H.D. 01 series) (see page 9) 58 RK-V-07781 1 Drive gear shaft kit (single speed)
29A XA-V-06628-000-0 1 1 Inner leg & screw assy. 59 XB-GP-38-138-5 2 Groove pin 3/8 x 1.38 (optional)
thru -505-0 (05, 13, or 15, or 23 series) (see page 9) 60 XB-3103 3 Locknut, 1/4-28 (optional)
29B XA-H-06628-000-0 Inner leg & screw assy. 61 XB-07618 3 HHCS, 1/4-28 x 3 (optional)
thru -505-0 (312 series) (see page 9) 62A XA-V-07601-1 1 Extension bracket - long (opt.) (length)
30 XA-CRP-V-06635 1 1 Pin, .38 x 2 62B XA-V-07601-2 1 Extension bracket - short (opt.) (length)
31 XB-V-06632 1 1 Washer 63A RK-V-07602-1 1 Extension bracket & shaft kitlong
32 XB-V-06630 1 1 Bushing 63B RK-V-07602-2 1 Extension bracket & shaft kitshort
33A XB-V-647 1 1 Thrust bearing 64A RK-V-1997-1 Extension bracket & shaft kitlong
33B XB-V-647-1 1 1 Thrust bearing (Heavy Duty) 64B RK-V-1997-2 Extension bracket & shaft kitshort
34 XA-V-06629 1 1 Collar
7
OUTER LEG ASSEMBLIES
STANDARD HEAVY DUTY Single-Speed Two-Speed
Travel Travel Leg Part Leg Part ORDER EXAMPLE:
Length A Length A Number Number
12.5" 23.9" 8.8" 24.7" 07132-0 07133-0 XA V 07132-1
A
13.5" 24.8" 12" 26.3" 07132-1 07133-1
Standard duty, 13.5" Travel,
15" 26.3" 13.5" 27.8" 07132-2 07133-2 Single Speed Leg
A
Standard 16.5" 27.8" 15.4" 28.9" 07132-3 07133-3
17.6" 28.9" 16.6" 30" 07132-4 07133-4 V=Standard
H=Heavy Duty
18.6" 30" 17.4" 31.4" 07132-5 07133-5
Heavy Duty
A = tube length
INNER LEG ASSEMBLIES

SKID FOOT STYLE CUSHION FOOT STYLE*
Travel Part Travel Part
Length A Number Length A Number
9.4 19.4 06628-000-0 11.5 20.5 06628-020-2
13.5 23.3 06628-101-0 13.5 24.3 06628-121-2
A 15 24.8 06628-202-0 15 25.6 06628-222-2
16.5 26.3 06628-303-0 16.5 27.3v 06628-323-2
17.6 27.4 06628-404-0 17.6 28.4" 06628-413-2
18.6 28.5 06628-505-0 18.6 29.6 06628-514-2
(05, 13, 15 or 23 Series) * Cushion foot style leg is only available in
standard duty. (14 series)
SELF-LEVELING HEAVY DUTY

SELF-LEVELING FOOT STYLE FOOT STYLE
Travel Part Travel Part
Length A Number Length A Number
12.5 19.9 06628-010-1 12.5 21.4 06628-010-3
13.5 23.6 06628-111-1 13.5 25.2 06628-111-3
15 25.2 06628-212-1 15 26.7 06628-212-3
16.5 26.6 06628-313-1 16.5 28.2 06628-313-3
17.6 27.8 06628-414-1 17.6 29.3 06628-414-3
Standard 18.6 28.9 06628-515-1 Heavy Duty 18.6 30.4 06628-515-3
(01 series) (012 series)
REPLACEMENT SHAFTS
GEAR SHAFT FOR GEAR SHAFT FOR SHIFTER SHAFT FOR
SINGLE-SPEED LEG TWO-SPEED LEG TWO-SPEED LEG
Part Part Part
A B C Number A B C D Number A B C Number
12 5.2 11.5 XA-V-06623-A 14 4.2 9.8 13.5 XA-V-06624-A 19.0 5.6 17.5 XA-V-06625-A
9.3 5.2 cut-off XA-V-06623-B 12 4.2 9.8 cut-off XA-V-06624-B 15.4 2.1 cut-off XA-V-06625-B
9.3 6.8 cut-off XA-V-06623-C 12 4.2 9.8 cut-off XA-V-06624-C 12.9 5.6 cut-off XA-V-06625-C
11.3 8.6 cut-off XA-V-06623-D 14.8 7.0 12.5 cut-off XA-V-06624-D
A A A
1/2" 1/2" 1-1/2"

B B B
C C C
D
Copyright August 1999 The Holland Group, Inc.

Holland Hitch Holland Binkley Co. Holland Neway International, Inc. Holland Hitch of Canada, Ltd. Holland Equipment, Ltd.
Company Divisions: Warrenton, MO Muskegon, MI Woodstock, Ontario Canada Norwich, Ontario Canada
Holland, MI Phone: 636-456-3455 Phone: 231-773-3271 Phone: 519-537-3494 Phone: 519-863-3414
Whitehouse Station, NJ Fax: 636-456-6792 Fax: 231-766-3893 Fax: 800-565-7753 Fax: 519-863-2398
Denmark, SC
Holland Binkley Co. Holland International, Inc. Holland Hitch Western, Ltd.
Wylie, TX Axle Products Division Holland, MI Surrey, British Columbia Canada
Milpitas, CA Delphos, OH Phone: 616-396-6501 Phone: 604-574-7491
Phone: 888-396-6501 Phone: 419-692-6015 Fax: 616-396-1511 Fax: 604-574-0244
Fax: 800-769-3299 Fax: 419-692-0503
8
LOW PRESSURE FILTERS
Series HF4R
Pressures to 100 psi Flows to 120 gpm Ports Size 1 1/2 & 2
APPLICATION
HYDAC HF4R In-Tank Low Pressure

Filters are designed for use on
hydraulic power units, machine tools,
plastics machinery, mobile equipment,
and hydraulic test equipment. These
filters can be installed in-tank to save
space and eliminate mounting
hardware. These filters can also be
mounted as In-line Return Filters.
PRODUCT FEATURES
Cast aluminum head and thin-wall

steel housing provide light weight
and low cost.
Inlet port options include SAE
straight thread O-ring boss, SAE
Flange, and NPT ports to allow easy
installation without costly adapters.
O-ring seals are used to provide
positive, reliable sealing. Choice of
O-ring materials (Nitrile or Fluoro Rubber)
provides compatibility with
petroleum oils, synthetic fluids,
water-glycols, oil/water emulsions,
and high water base fluids.
In-tank design requires minimal
space for installation.
A magnetic oil fill plug is located in
the filter head to permit the reservoir
to be filled through the filter element.
Provision is made for an additional
inlet port to allow two return lines
to be connected to the same filter.
HF4R In-Tank Filter
FILTER ELEMENT Proper support of the filter media also and to bond the seam of the media.
provides high Beta Ratio values Perforated support tubes are used to
HYDAC HF4R Filters are available (particle removal efficiency) even at provide proper flow distribution and
with disposable Betamicron BN3 high differential pressures. The protection against element collapse.
elements having 150 psid collapse efficiency of many competitive HYDAC elements are the popular K
pressure and absolute ratings of 3, 5, elements drastically deteriorates as the size used in many automotive, steel
10, and 20 micron (Beta Ratio 200). element clogs and differential pressure Industry, mining and mobile equipment
Betamicron filter media is supported increases. High quality adhesive is applications.
to achieve flow fatigue resistance. used to bond the end caps to the media
Model Code: HF4R Low Pressure Filter Assembly
HF4R - BN3 - 09 G - 3 A 1.0 / 3 B3 C
Filter Type
HF4R = In-tank return filter
HF4S = In-tank suction filter (20m BN3 or Nominal Filtration only)
Type of Media

BN3 = Betamicron BN3 Low Collapse
P = Polyester Disposable
W = Wire screen Cleanable

Element Length
09 = Single Element Length (9)
18 = Double Element Length (18)
27 = Triple Element Length (27)
Type of Connection
G = Threaded
F = Flanged
Filtration Rating in Microns
3 = 3m
3 = 3m 10 = 10m Polyester

5 = 5m Betamicron Absolute Filtration 25 = 25m Nominal Filtration
10 = 10m Low Collapse Rating (x 200) Rating
20 = 20m 25 = 25m
74 = 74m Wire Screen
149 = 149m
Type of Clogging Indicator
Static (HF4R Type Modification 1.0 see below) (Model Codes for ordering individually)
A = no clogging indicator
E = Gauge indicator VMF...E.0
G = AC/DC electric switch indicator VMF...1.4G
H = AC/DC electric switch (Hirschmann Connector) VMF...2H.0
Differential (HF4R Type Modification 2.0 see below)
B = Visual pop-up (automatic reset) B2210BHFV/SO126H
BM = Visual pop-up (manual reset) B2210BMHFV/SO126H
C = Electrical clogging indicator (electrical switch) B2210CHFV/SO126H
D = Electrical/visual (lamp) B2210DHFV/SO126H
Clogging indicator (electrical switch and light)
J = Electrical switch (Brad Harrison 5 pin mini) B2210JHFV/SO126H
(ANSI B93.55M-1981) /P
J4 = Electrical switch (Brad Harrison 4 pin micro) B2210J4HFV/SO126H
Vacuum (HF4S Type Modification 1.0 see below)
UE = Visual (vacuum gauge) VMF0.2UE.0
UG = Vacuum switch (AC/DC) VMF0.2UG.0
Type Modification Number
1.0 = Standard Connection & HF4S
2.0 = Dual Inlets (only available with Flanged Connection HF4R)
Port Configuration
3 = NPT 1 1/2"
12 = SAE-24 Straight Thread O-ring Boss
16 = SAE-32 Code 61 flange and This configuration with dual
SAE-24 Straight Thread O-ring Boss inlets selection only (contact HYDAC for availability)
Seals
(omit) = Nitrile (NBR) (standard)
V = Fluoro Rubber (FKM)
Bypass Valve
B3 = 43 psid bypass (standard) B1.7 = 25 psid bypass
B1 = 15 psid bypass B0.2 = 3 psid bypass (suction application)
Supplementary
S0103H = Modification of BN3 elements for phosphate ester fluids
S0150H = Anodized filter head for water based fluids
S0126H = Differential pressure indicator modification (required when P indicator is selected)
L24 = Lamp for 24 volts T70 = Thermal lockout at 70F
L48 = Lamp for 48 volts D-Type Clogging
L115 = Lamp for 115 volts Indicator only T100 = Thermal lockout at 100F P sensing indicators only
L230 = Lamp for 230 volts (not available on all BM indicators)
Outlet Configuration
C = Outlet check valve (1/2 psid) (HF4R models only)
O = Open end outlet
T = Threaded outlet connection (1 1/2" NPT)
Model Codes Containing Red are non-stock items Contact HYDAC for availability
2
Model Code: Return Line Filter Elements
H K 003 BN3 .
HYDAC Element
Element Length
(omit) = Single Element Length (9)
2 = Double Element Length (18)
3 = Triple Element Length (27)
Type of Elements
Filtration Ratings (Micron)
Betamicron Wire Screen Polyester Betamicron (Suction) Wire Screen (Suction)
003 = 3m 025 = 25m 003 = 3m S020 = 20m S025 = 25m
005 = 5m 074 = 74m 010 = 10m S074 = 74m
010 = 10m 149 = 149m 025 = 25m S149 = 149m
020 = 20m
Filter Media
BN3 = Betamicron (Disposable) Absolute Filtration Rating (x 200)
W/HC = Wire Screen (Cleanable)
Nominal Filtration Rating
P/HC = Polyester (Disposable)
Seals
Supplementary
S0103H = Modification of BN3 elements for phosphate ester fluids
Models Code Containing Red are non-stock items Contact HYDAC for availability
Engineering Data Design Requirements In-Tank Return Line Filter Specification
Mounting Method (4) .43 Dia. Holes on 6.25 Dia. Bolt Circle
Connections Inlet: SAE-24 (1 7/8-12UN-2B), 1 1/2NPTF
or 2 SAE Flange, Code 61 & SAE 24
Outlet: 1 1/2 NPT, Optional
Mounting Position Upright or horizontal, specify check valve for horizontal mount
Direction of Flow Inlet: Side Outlet: Bottom
Housing Pressure Ratings Operating: 100 psi / 7 bar
Proof: 150 psi / 10 bar
Fatigue: Contact HYDAC office
Burst: Contact HYDAC office

Element Collapse Betamicron BN3 Elements: 150 psid / 10 bar
Pressure Ratings (ISO 2941)
Fluid Temperature Range Operating Range: -15F to +250F (-26C to 121C)
(based on Nitrile seals at maximum continuous operating pressure)
Contact HYDAC for applications at temperatures lower than above
Fluid Compatibility Compatible with all petroleum oils, water glycols, oil/water
(ISO 2943) emulsions, high water base fluids, and synthetic fluids.
Contact HYDAC office for information on optional housing and element
constructions available for use with fluids other than petroleum based fluids.
Element Flow Fatigue Resistance Filter medium is supported to achieve flow fatigue resistance.
Cracking Pressure of P = 25 psid / 1.7 bar +10% (standard)
Bypass Value P = 15 psid / 1 bar +10% (optional)
P = 43 psid / 3 bar +10% (standard for BN3 Elements)
P = 3 psid / 0.2 bar +10% (standard for Suction Elements)
Above Subject to Technical Modifications
Weights Hydraulic Schematics

With Element Without Element INLET INLET
Model
lbs. kg. lbs. kg.
HF4R...09 12.8 5.8 10.0 4.5 HF4R HF4S
HF4R...18 20.3 9.2 14.5 6.5
HF4R...27 27.5 12.5 18.6 8.4 Bypass Pop-up Bypass
Valve
Valve Indicator
Filtration Efficiency Multi-Pass Filtration

Efficiency Ratings to ISO 4572 for Betamicron Elements Filter Filter
Element Element
Betamicron
Absolute Terminal P Across
Element Rating Filter Element Gauge
Indicator
003 BN3 3 200 25 psi
005 BN3 5 200 25 psi
010 BN3 10 200 25 psi OUTLET OUTLET
020 BN3 20 200 25 psi
3
Sizing Information HF4R/S Housing Curve
12
P Assembly = P Housing + P Element 0.8
10
Housing Curve 0.6
P in bar
The housing curve is based on test results using mineral oil 8
P in psi
with a specific gravity of 0.86. Differential pressure increases 0.4 6
in proportion to specific gravity of applicable fluid. 4
0.2
2
P Housing = P Chart x Actual Specific Gravity
0.86 0
0 20 40 60 80 100120
Bypass Valve Curves Q in gpm
Curves shown are applicable for mineral oil with a
specific gravity of 0.86. Differential pressure increases 0 100 200 300 400 500
Q in l/min
in proportion to the specific gravity of the fluid.
P Valve = P Chart x Actual Specific Gravity HF4R Bypass Curves

0.86
3.5 50
Element P Calculations
3.0 40
H_K...BN3/H_K...BH3 Betamicron 3 Plus Elements 2.5 25 psi
P in bar
P in psi
P Actual Actual 2.0 30
Element = K Factor x Q Flow (gpm) x Viscosity (SUS) x Specific Gravity 15 psi
1.5 20
141 SUS .86
1.0
HF4R/S Element (K) flow factors for filter sizing 0.5 10
Copyright 1999 HYDAC TECHNOLOGY CORPORATION - Brochure - Low Pressure Filters HF4R #02068122 / 9.99
0.0 0
Length Size 3 5 10 20
0 20 40 60 80 100 120
Single HK 0.17542 0.10817 0.08228 0.04189 Q in gpm
Double H2K 0.08596 0.05305 0.04032 0.02053
0 100 200 300 400 500
Triple H3K 0.05670 0.03497 0.02659 0.01357 Q in l/min
For Polyester (P/HC) and Wire Screen (W/HC) Elements Please Consult HYDAC
Dimensions: HF4 In-Tank Return Line Filter

HF4 with 2 SAE Flange Connection HF4 with Threaded Flange Connection
and SAE 24 Port
7.5 7.0
3.5 SAE-24 Port 3.5
(1 7/8" - 12 UN)
A or 1 1/2" NPTF
See SAE Flange Detail
SAE-24 Port Optional Inlet Port

(consult HYDAC)
INLET INLET INLET
1/8" NPTF
Guage Ports Oil FIll Port
A & Pipe Plugs 1 1/4" NPTF
(Standard Both Sides) Pipe Plug with
1/8" NPTF Gauge Ports Ceramic Magnet Insert
& Pipe Plugs Oil FIll Port
1 1/4" NPTF (3/4" Square Socket Drive)
Pipe Plug with
Ceramic Magnet Insert
(3/4" Square Socket Drive) 3.70
View A-A
SAE Flange Detail
1.62
Gasket
1/ 2"-13-2B
2.00 Top of
(4 Places)
Code 61 Flange Single Element = 8.6" Reservoir
(Reference)
Double Element = 17.8"
0.84 Triple Element= 27.0"
1.688
0.62 Min. Optional
Check Valve
1.531
3.062 Optional
1.00
1 1/2" NPT
Male Pipe Nipple
4.75
HYDAC TECHNOLOGY CORPORATION

2260 City Line Road Bethlehem, PA 18017
Phone (610) 266-0100 Fax (610) 264-3540
www.hydacusa.com powerup@hydacusa.com
FILTERS
service & parts
LOW PRESSURE
FILTERS
SERVICE INSTRUCTIONS
Series
HF4R
Ultrasonic Cleaning:
Ultrasonic cleaning is used for cleaning Wire Screen (W)
Element Changeout Procedure: elements. HYDAC can provide detailed instructions to
HF4R Low Pressure Filters customers planning to set up their own in-house ultrasonic
cleaning station. For information call 610-266-0105.
1. Shut off system.

2. Relieve reservoir pressure, if present.
3. Remove six lid screws and the lid.
4. Inspect the lid seal for damage. Replace if necessary.
5. Remove spring (item 11) and bypass valve (item 7).
Inspect the bypass valve and replace if damaged.
6. Remove filter element.
7. Discard disposable element (BH or BN).
8. Clean and degrease the cleanable filter element.
See Cleaning Procedure that follows for details.
9. Lubricate the seal on the new or cleaned element
with system fluid or silicone O-ring grease.
10. Insert the filter element into the filter housing. Use
a twisting action to avoid damaging the seal.
11. Insert bypass valve (item 7) in top of elemet.
12. Insert spring (item 11) onto bypass valve.
13. Install lid onto housing. Make certain the bolt
holes are aligned.
14. Install lid screws.
15. Pressurize filter and check for leaks.
HYDACs warranty is valid only if servicing is performed using

HYDAC replacement parts.
SERVICE & PARTS - HF4R FILTERS Manual Cleaning (Wire Screen Element)
Rounded
Needle
Cleaning Fluid
1. Remove external build-up of 2. Remove large particles in the

contamination with cleaning pleats using a rounded needle
fluid in separate tank. or tweezers.
Flow Control Lever

Clean Water
High Quality Cleaning Fluid
Water On Air Pressure
3. Immerse the element for 30 minutes 4. Flush from the inside with air-water pistol.
in high quality cleaning fluid.
Flow Control Lever

Clean Water
Isopropyl Alcohol
Water Off Air Pressure
5. Turn off water and blow from 6. Immerse in Isopropyl Alcohol to

inside with air only. remove the remaining water particles.
7. Allow element to dry, then pack element

in air tight plastic bag for future use.
2
SERVICE & PARTS - HF4R FILTERS
Parts Drawing: HF4R Low Pressure
14 15 13 5
3
7
INLET OUTLET
4
6
10
9
11
12
8
1
Parts List: HF4R Low Pressure

Item Description HF4R-09 HF4R-18 HF4R-27
1 Housing Assembly 1 1 1
2 Filter Element 5.03.09 5.03.18 5.03.27
3 Head 1 1 1
4 Seal 1 1 1
5 Tetraseal 1 1 1
6 Gasket 1 1 1
7 Bypass Valve 1 1 1
8 Shaft 1 1 1
9 Valve Plate 1 1 1
10 Gasket 1 1 1
11 Spring 1 1 1
12 E-ring 2 2 2
13 Spring 1 1 1
14 Lid 1 1 1
Hex Flanged
15 6 6 6
Head Screw
All dimensions in millimeters
1) for installation of clogging indicators, the torque specifications is: Max. 25 ft.-lbs / 34 Nm.
2) if a clogging indicator is used, O-ring 13.5 x 1.5
* - included in seal kit
Model Codes: HF4R Seal Kits
(NBR) (FKM) (EPR)
Size
Nitrile Flouro Rubber Ethylene Propylene
HF4R...G or F 0206 4703 0206 9943
for seal kits without part numbers, call 610-266-0105.
3
SERVICE & PARTS - HF4R FILTERS Model Code: HF4R Low Pressure Filters Elements
5 . 03 . 09 D 03 BN / V
Manufacturer
05 = Schroeder
Element Type
03 = Schroeder HK series interchange
Length
09 = 9 Element length
18 = 18 Element length Single Piece Elements
27 = 27 Element length
Type of Element
D = Pressure
Filtration Rating (micron)
03 = 3 m
06 = 5 m Betamicron Absolute Filtration Rating x 200
12 = 10 m
25 = 20 m
25 = 25 m
74 = 74 m Wire Screen Nominal Filtration Rating
149 =149 m
Type of Media
BN = Betamicron Low Collapse Disposable
W = Wire Screen Cleanable
Copyright 2002 HYDAC TECHNOLOGY CORPORATION - Brochure - Service HF4R #02075076 / 5.02
Seals
EPR = Ethylene Propylene (EPDM)
Supplementary Details (add these codes to the end of the main code)
SO 103 H = Modification of BN Elements for Phosphate Ester Fluids
Note: Standard 5.03.18 and 5.03.27 elements are now provided as single piece elements for ease of removal, handling, and higher surface
area. Multiple Element Connector for Multiple Stacked Elements of older 5.03.18 and 5.03.27 Configurations is Part No. 02056730.
HF4R Clogging Indicators

Indicator Type Filter Housing Type
A no clogging indicator
E Gauge VMF...E.0
G Electric Switch VMF...1.4G
H Electric Switch (Hirschgmann) VMF...2H.0
B Visual - Auto reset B2210BHFV/SO126H
BM Visual - Manual reset B2210BMHFV/SO126H
C Electric Switch B2210CHFV/SO126H
D Electric Switch and Light B2210DHFV/SO126H
J Electric Switch (5 pin mini) B2210JHF.1V/SO126H
J4 Electric Switch (4 pin micro) B2210J4HF.1V/SO126H
A no clogging indicator
U Visual VMF0.2UE.0
UG Vacuum Switch VMF0.2UG.0

HYCON Division
Phone (610) 266-0100 Fax (610) 264-3540
FLOW, NEEDLE AND
CHECK VALVES
FLOW, NEEDLE
AND CHECK VALVES
TABLE OF CONTENTS Page

Flow Control Valves 3-7
Pressure Compensated Flow Control Valves 8-9
Needle Valves 10-13
Check Valves 14-15
2
DESIGN, FEATURES AND OPTIONS
Color 1
2
Coded 3
4 Safety Screw
Flow 5
and Spindle
Indicator
Knob Threaded Spindle

Locking Housing for Panel
Set Screw Mounting Kit
Slotted
Spindle
NPT, SAE or
BSP Ports
Guided
Poppet
DESCRIPTION VALVE DESIGN PRODUCT FEATURES

The HYDAC family of flow HYDAC flow control valves can be Phosphate coated steel valve
control valves permit safe, adjusted easily and precisely by body
simple and repeatable control means of the control knob. FPM (Viton) seals
of hydraulic fluids at operating Increasing the number of turns from Slotted control spindle for
pressures to 5000 psi. the fully closed position provides a precise and linear flow
The standard slotted control steady increase of the flow rate. The adjustments
spindle allows for a wide colored scale permits accurate Exclusive safety spindle design
range of infinitely variable flow repetition of settings and the colored Graduated knob and color
adjustments with excellent coded spindle for accurate flow
triangle on the rising spindle
flow characteristics. control
provides a visual indication of the
Precise adjustment of flow is Guided poppets for smoother,
increasing cross section of the flow chatter free operation
achieved by a micrometer area. A set screw on the side locks
style adjustment knob
the knob at the desired setting. AVAILABLE OPTIONS
featuring a color coded flow
HYDAC flow control valves include
indicator for accurate, easy-to
a unique safety spindle design
Steel knobs for ambient
read visual flow reference. temperature in excess of
feature. As the valve spindle is 140F / 60C
Design modifications and
turned counter-clockwise, the Panel mounting kit
special materials are available
spindle shoulder will engage the 25 and 65 PSI cracking
for corrosive fluids such as
safety screw limiting the travel of the pressure springs (7 psi standard)
phosphate ester, acids and
caustics. spindle. The hardened, high- Zinc Plated Body
strength steel safety screw is sealed Consult HYDAC for price
in position to discourage tampering. and delivery
3
FLOW CONTROL VALVES
Specifications:
5000 psi Operating pressure
8 sizes, 1/8 - 1-1/2
NPTF or SAE O-Ring connections and manifold mounting
Flows to 80 GPM
Carbon Steel Housing
FPM (Viton) O-Rings (standard)
DRV - Inline Mounting Graduated knob and color coded spindle for accurate flow control
Provision for panel mounting
Exclusive safety spindle design
Temperature Range:
-4 to 212F
A B
DRVP - Manifold Mounting Hydraulic Symbol
Model Code
DRV - 06 - 01 . X / 5 - 25 - S-M
Flow Control Valve
DRV = Inline Mounting
DRVP = Manifold Mounting
Nominal Sizes
Nom. Size SAE (DRV only) NPT (DRV Only)
(DRV + DRVP) Tube Size Thread Size Pipe Size Pipe OD
06 -2 5/16-24 UNF 1/8 .405
08 -4 7/16-20 UNF 1/4 .540
10 -6 9/16-18 UNF 3/8 .675
12 -8 3/4-16 UNF 1/2 .840
16 -12 1-1/16-12 UN 3/4 1.050
20 -16 1-5/16-12 UN 1 1.315
25 -20 1-5/8-12 UN 1-1/4 1.660
30 -24 1-7/8-12 UN 1-1/2 1.900
Housing Material
01 = Carbon Steel
Modification Number
Port Configuration
5 = NPTF - (ANSI B1.20.3)
12 = SAE - SAEJ1926 Ports with ISO 725 Threads and O-Ring Sealing
0 = BSP to DIN 3852, Part 2 -X (Special Order)
(omit) = DRVP only
Cracking Pressure
(omit) = 7 PSI standard
25 = 25 PSI optional
65 = 65 PSI optional
Supplementary Details
S = Panel Mounting Kit
M = Steel Knob (use when ambient temperature exceeds 140F)
4
PRESSURE DROP CURVES
Flow Direction: A B
Throttled Flow
DRV / DRVP-6 DRV / DRVP-8 DRV / DRVP-10

Flow setting in turns Flow setting in turns Flow setting in turns
5 11.
2 32.5 1 2 3 4 5 6 1 2 3 4 5
100 1400 100 1400 100 1400
7
80 1200 80 1200 80 1200 6
1000 1000 1000 7
P bar
P psi
P bar
P psi
P bar
P psi
60 800 60 800 60 800
40 600 4 40 600 40 600
400 5 400 400
20 20 20
200 200 200
0 0 0
0 1 2 3 4 5 0 2 4 6 8 10 12 0 2 4 6 8 10 12 14 16
Flow gpm Flow gpm Flow gpm
0 2 4 6 8 10 12 14 16 18 20 0 10 20 30 40 50 0 10 20 30 40 50 60
Flow L/min Flow L/min Flow L/min
DRV / DRVP-12 DRV / DRVP-16 DRV / DRVP-20/25/30

Flow setting in turns Flow setting in turns Flow setting in turns
100 1 2 3 4 5 6 78 100 1 2 3 4 5 6 7 8 100 1 2 3 4 5 6
1400 1400 1400
80 1200 80 1200 9 80 1200
1000 1000 10 1000
7
P bar
P psi
P bar
P psi
P bar
P psi
60 800 60 800 60 800
8
40 600 40 600 40 600 9
400 400 400 10
20 20 20
200 200 200
0 0 0
0 4 8 12 16 20 24 0 8 16 24 32 40 48 0 10 20 30 40 50 60 70 80
0 15 30 45 60 75 90 0 30 60 90 1200 150 180 0 50 100 150 200 250 300

Flow Direction: B A
Free Flow
DRV / DRVP-06 thru 16 DRV / DRVP-20/25/30

150 150 150 150
120 120 120 120

DRV 06
20
8
DRV 0
P bar
P psi
P bar
P psi
V
0
90 90 90 90 25
DR
V1
RV 30
12
DR
60 60 60 60 D V
RV
6 DR
V1
D
DR
30 30 30 30
0 0 0 0
0 6 12 18 24 30 36 42 48 54 0 20 40 60 80 100 120 140 160
Flow gpm Flow gpm
0 40 80 120 160 200 0 100 200 300 400 500 600

Flow L/min Flow L/min
Pressure Drop curves were established by using mineral oil with kinematic viscosity 335 SUS at 86F / 30C
5
DIMENSIONS: DRV
1
2
3
4
Hex
5
6
Knob for sizes 20-30

(use hexagon
for adjustment)
2 1 0 9 8
E
F
G
1
2
3
4
5
Knob for sizes 6-16
A
open
Thickness 3 2 1 0 9
H of panel B
closed
max. .25 J
B A D
C
Note: Dimensions shown in inches (millimeters)
Port Size A B C D E F G H J1) WT

Model Hex
in in in in in in in in lbs.
Code NPTF SAE (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg)
2.17 1.97 .31 .63 1.02 1.77 .94 .51 Pg 7 .29

DRV-06 1/8 5/16-24UNF (SAE-2) -
(55) (50) (8) (16) (26) (45) (24) (13) (.13)
2.84 2.56 .49 .98 1.32 2.17 1.14 .75 .66
DRV-08 1/4 7/16-20UNF(SAE-4) Pg 11 -
(72) (65) (12.5) (25) (33.5) (55) (29) (19) (.30)
2.91 2.64 .59 1.18 1.61 2.56 1.14 .75 .99
DRV-10 3/8 9/16-18UNF(SAE-6) Pg 11 -
(74) (67) (15) (30) (41) (65) (29) (19) (.45)
3.62 3.23 .69 1.38 1.73 2.87 1.50 .91 1.76
DRV-12 1/2 3/4-16UNF(SAE-8) Pg 16 -
(92) (82) (17.5) (35) (44) (73) (38) (23) (.80)
4.17 3.78 .89 1.77 2.24 3.46 1.50 .91 2.87
DRV-16 3/4 1-1/16-12UN(SAE-12) Pg 16 -
(106) (96) (22.5) (45) (57) (88) (38) (23) (1.30)
5.71 5.04 .98 1.97 3.03 5.00 1.93 1.50 3/4 5.29
DRV-20 1 1-5/16-12UN(SAE-16) Pg 29
(145) (128) (25) (50) (77) (127) (49) (38) (19) (2.40)
5.91 5.24 1.18 2.36 3.66 5.63 1.93 1.50 3/4 7.72
DRV-25 1-1/4 1-5/8-12UN(SAE-20) Pg 29
(150) (133) (30) (60) (93) (143) (49) (38) (19) (3.50)
6.26 5.59 1.38 2.76 4.25 5.63 1.93 1.50 3/4 10.14
DRV-30 1-1/2 1-7/8-12UN(SAE-24) Pg 29
(159) (142) (35) (70) (108) (143) (49) (38) (19) (4.60)
Note: pg. style thread per DIN 40430

1)
6
DIMENSIONS: DRVP
1
2
3
4
Hex G
5
6
Knob for sizes 20-30

V (use hexagon
for adjustment)
1
2
3
4
5
2 1 0 9 8
Knob for
sizes 6-16
B closed
3 2 1 0 9
A open
W
O P D
U
F
C
M N
R
X E
S
T H
J
K
L
A B C D E F G H J K L
Model Size in in in in in in in in in in in
Code (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
2.48 2.28 .31 .43 .26 .63 .94 - 7.48 1.63 1.81
DRVP-06 1/8 (63) (58) (8) (11) (6.6) (16) (24) - (19) (41.5) (46)
3.11 2.83 .39 .43 .26 .79 1.14 - 1.378 2.50 2.64
DRVP-08 1.4 (79) (72) (10) (11) (6.6) (20) (29) - (35) (63.5) (67)
3.31 3.03 .49 .43 .26 .98 1.14 - 1.319 2.76 2.91
DRVP-10 3/8 (84) (77) (12.5) (11) (6.6) (25) (29) - (33.5) (70) (74)
4.17 3.78 .63 .43 .26 1.26 1.50 - 1.496 3.15 3.33
DRVP-12 1/2 (106) (96) (16) (11) (6.6) (32) (38) - (38) (80) (84.5)
5.04 4.65 .89 .55 .35 1.77 1.50 1.496 2.992 4.09 4.31
DRVP-16 3/4 (128) (118) (22.5) (14) (9) (45) (38) (38) (76) (104) (109.5)
6.69 6.02 .98 .55 .35 1.97 1.93 1.870 3.740 5.00 5.24
DRVP-20 1 (170) (153) (25) (14) (9) (50) (49) (47.5) (95) (127) (133)
6.89 5.91 1.08 .71 .45 2.16 1.93 2.362 4.724 6.50 6.77
DRVP-25 1-1/4 (175) (150) (27.5) (18) (11.5) (55) (49) (60) (120) (165) (172)
7.68 6.69 1048 .79 .55 2.95 1.93 2.815 5.630 7.32 7.70
DRVP-30 1-1/2 (195) (170) (37.5) (20) (14) (75) (49) (71.5) (143) (186) (195.5)
M N O P R S T U V W1) WT
Model Size in in in in in in in in in in Hex lbs.
Code (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg)
1.122 1.63 0.63 .630 .20 .382 .252 .28 .53 - .57
DRVP-06 1/8 (28.5) (41.5) (1.6) (16) (5) (9.7) (6.4) (7) (13.5) Pg 7 - (0.26)
1.319 1.81 .189 1.004 .28 .500 .559 .28 1.22 - 1.10
DRVP-08 1.4 (33.5) (46) (4.8) (25.5) (7) (12.7) (14.2) (7) (31) Pg 11 - (0.50)
1.496 2.01 .157 1.004 .39 .614 .709 .28 1.16 - 1.76
DRVP-10 3/8 (38) (51) (4) (25.5) (10) (15.6) (18) (7) (29.5) Pg 11 - (0.80)
1.752 2.26 .157 1.181 .51 .732 .827 .28 1.44 - 2.42
DRVP-12 1/2 (44.5) (57.5) (4) (30) (13) (18.6) (21) (7) (36.5) Pg 16 - (1.10)
2.126 2.76 .433 2.126 .67 .965 .551 .35 1.93 - 5.51
DRVP-16 3/4 (54) (70) (11) (54) (17) (24.5) (14) (9) (49) Pg 16 - (2.50)
2.362 3.01 .748 2.244 .87 1.201 .630 .35 1.93 3/4 8.60
DRVP-20 1 (60) (76.5) (19) (57) (22) (30.5) (16) (9) (49) Pg 29 (19) (3.90)
2.992 3.94 .811 3.130 1.12 1.472 .591 .43 3.03 3/4 14.77
DRVP-25 1-1/4 (76) (100) (20.6) (79.5) (28.5) (37.4) (15) (11) (77) Pg 29 (19) (6.70)
3.622 4.53 .937 3.740 1.38 1.709 591 .51 3.35 3/4 24.25
DRVP-30 1-1/2 (92) (115) (23.8) (95) (35) (43.4) (15) (13) (85) Pg 29 (19) (11.0)

1)
7
PRESSURE COMPENSATED
FLOW CONTROL VALVES
Specifications:
4 sizes, 1/4 - 3/4
Working Pressure:
Inlet: 102 psi min.
3045 psi max.
Outlet: 0 psi min.
2944 psi max.
Flows to 24 gpm
NPTF Connections
Graduated knob and color coded spindle for accurate flow control
SRVR - Inline Mounted Exclusive safety spindle design
Viscosity Range:
13 SUS min.
1781 SUS max.
A B
Temperature Range:
-4 to 212F
Hydraulic Symbol
Model Code
SRVR - 08 - 01 .X / 5 - S
Pressure Compensated
Flow Control Valve
(with internal check valve)
Nominal Sizes
Nom Size NPT Only
Pipe Size Pipe OD
08 1/4 .540
10 3/8 .675
12 1/2 .840
16 3/4 1.050
Housing Material
01 = Carbon Steel
Modification Number
Port Configuration
5 = NPTF (ANSI B1.20.3)
8
DIMENSIONS AND PRESSURE DROP CURVES
SRVR
G 1
2
3
4
5
B
closed
2 1 0 9 8
A Hex
H
open
E
Thickness
F
of panel
1/4" max. C
A B
D
A B C D E F G H J1) WT
Model Size in in in in in in in in Hex lbs.
Code (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg)
2.91 2.64 .59 1.18 .69 3.62 1.14 .75 .94 1.3
SRVR-08 1/4 NPTF (74) (67) (15) (30) (17.5) (92) (29) (19) Pg 11 (24) (0.6)
3.62 3.23 .69 1.38 .71 4.13 1.50 .91 1.06 2.0
SRVR-10 3/8 NPTF (92) (82) (17.5) (35) (18) (105) (38) (23) Pg 16 (27) (0.9)
4.17 3.78 .89 1.77 .83 4.92 1.50 .91 1.26 3.8
SRVR-12 1/2 NPTF (106) (96) (22.5) (45) (21) (125) (38) (23) Pg 16 (32) (1.7)
4.27 3.88 .98 1.97 1.02 5.51 1.50 .91 1.61 4.9
SRVR-16 3/4 NPTF (108.5) (98.5) (25) (50) (26) (140) (38) (23) Pg 16 (41) (2.2)
1)
Note: Pg Style Thread Per Din 40430
Flow Direction: A B
Throttled Flow
SRVR-08 SRVR-10 SRVR-8, 10, 12, & 16

16 24
4 6 10 150
14 20
5
Flow in L/min
Flow in L/min
12 8 120
Flow in gpm
3
Flow in gpm
16
10 4
P in bar
P in psi
12
SRVR 08
6 90 16
0
12
VR
R1
8 2 3 VR
SR
SR
SRV
6 8 4 60
2
4 1
4 1
2 2 30
0 0 0 0
0 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10 0
0 5 10 15 20 25
Number of Turns Number of Turns
Q in gpm
SRVR-12 SRVR-16 0 10 20 30 40 50 60 70 80 90 100
50 14 24 Q in L/min
12 80 20
Flow in L/min
Flow in L/min
40
Flow in gpm
Flow in gpm
10 60 16
30 8
12
6 40
20 6
4
10 20
2 4
0 0 0 0
0 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10
Number of Turns Number of Turns
9
NEEDLE VALVES
Specifications:
5000 psi Operating Pressure

8 Sizes, 1/8 - 1-1/2
NPT or SAE O-Ring Connections, Manifold Mounting
and Cartridge Type
Flows to 80 gpm
DV - Inline Mounting Carbon Steel Housing
Graduated knob and color coded spindle for
accurate flow control
Exclusive safety spindle design
Temperature Range:
DVP - Manifold Mounting -4 to 212F
DVE - Cartridge Valve Hydraulic Symbol
Model Code
DV - 06 - 01 .X / 5 - S-M
Needle Valve
DV = Inline Mounting
DVP = Manifold Mounting
DVE = Cartridge Valve
Nominal Sizes
Nom. Size SAE (DV only) NPTF (DV Only)
(DV + DVP) Tube Size Thread Size Pipe Size Pipe OD
06 -2 5/16-24 UNF 1/8 .405
08 -4 7/16-20 UNF 1/4 .540
10 -6 9/16-18 UNF 3/8 .675
12 -8 3/4-16 UNF 1/2 .840
16 -12 1-1/16-12 UN 3/4 1.050
20 -16 1-5/16-12 UN 1 1.315
25 -20 1-5/8-12 UN 1-1/4 1.660
30 -24 1-7/8-12 UN 1-1/2 1.900
DVE
Nom Size Thread Size
08 3/4-16 UNF
10 7/8-14 UNF
12 1-1/16-12 UN
16 1-5/16-12 UN
Housing Material
01 = Carbon Steel
Modification Number
Port Configuration
5 = NPTF - ANSI B1.20.3
0 = BSP to DIN 3852, Part 2-X (Special Order)
Omit = DVP Only
10
DV/DVP-6 DV/DVP-16 DVE-8

Flow Setting in Turns Flow Setting in Turns Flow Setting in Turns
1 1.5 2 2.5 1 2 3 4 5 6 7 50 0.5 1 1.5 2 3 4
100 1500 3 100 1500 700
8 40 5
600
80 1200 80 1200 6
9 500 7
30
900 900
P bar
P psi
P bar
P psi
P bar
P psi
60 60 10 400
600 4 600 20 300
40 40
5 200
20 300 20 300 10
100
0 0 0 0 0 0
0 1 2 3 4 5 0 10 20 30 40 50 0 3 6 9 12 15
0 4 8 12 16 20 0 40 80 120 160 200 0 10 20 30 40 50 60

DV/DVP-8 DV/DVP-20/25/30 DVE-10

Flow Setting in Turns Flow Setting in Turns Flow Setting in Turns
1 2 3 4 56 7 1 2 3 4 5 50 0.5 1 1.5 2 3 4 5
100 1500 100 1500 700
6
40 600
80 1200 80 1200
500
30 6
900 900
P bar
P psi
P bar
P psi
P bar
P psi
60 60 7 400
40 600 40 600 8 20 300 7
9 8
10 200 9
20 300 20 300 10 10
100
0 0 0 0 0 0
0 2 4 6 8 10 12 14 0 15 30 45 60 75 0 2 4 6 8 10 12 14 16 18 20
0 10 20 30 40 50 0 50 100 150 200 250 300 0 10 20 30 40 50 60 70 80

DV/DVP-10 DVE-12
Flow Setting in Turns Flow Setting in Turns
1 2 3 4 50 1 2 3 4 5 6
100 1500 700
5 40
1200 600
80 7
6 500
30 8
P bar
P psi
900
P bar
P psi
60 7 400
9
600 20 300 10
40
200
20 300 10
100
0 0 0 0
0 2 6 9 12 15 0 5 10 15 20 25 30 35 40
Flow gpm Flow gpm
0 10 20 30 40 50 60 0 20 40 60 80 100 120 140 160

DV/DVP-12 DVE-16
Flow Setting in Turns Flow Setting in Turns
1 2 3 4 4 6 7 8 50 1 2 3 4 5 6
100 1500 700
40 600
80 1200
500 7
900 30
P bar
P psi
P bar
P psi
60 400
8
40 600 20 300
9
200 10
20 300 10
100
0 0 0 0
0 5 10 15 20 25 0 5 10 15 20 25 30 35 40
Flow gpm Flow gpm
0 10 40 60 80 100 0 20 40 60 80 100 120 140 160

11
DIMENSIONS: DV
Hex extension
1
2
3
4
5
Knob for
Sizes 20-40
E has Hex extension
for wrench
F
G
1
2
3
4
5
Knob for
sizes 6-16 B
Thickness closed
of panel 3 2 1 0 9
1/4" max. H A
open
J
D
C
Port Size A B C D E F G H J1) WT

Model Hex
in in in in in in in in lbs.
Code NPTF SAE (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg)
2.16 1.97 .31 .63 .75 1.50 .94 .51 26
DV-06 1/8 5/16-24UNF Pg 7 -
(55) (50) (8) (16) (19) (38) (24) (13) (.12)
2.83 2.56 .49 .98 .94 1.89 1.14 .75 .55
DV-08 1/4 7/16-20UNF Pg 11 -
(72) (65) (12.5) (25) (24) (48) (29) (19) (.25)
2.91 2.64 .59 1.18 1.14 2.28 1.14 .75 .88
DV-10 3/8 9/16-18UNF Pg 11 -
(74) (67) (15) (30) (29) (58) (29) (19) (.40)
3.62 3.23 .69 1.38 1.34 2.68 1.50 .91 1.5
DV-12 1/2 3/4-16UNF Pg 16 -
(92) (82) (17.5) (35) (34) (68) (38) (23) (.70)
4.17 3.78 .89 1.77 1.53 3.07 1.50 .91 2.6
DV-16 3/4 1-1/16-12UN Pg 16 -
(55) (50) (8) (16) (19) (38) (24) (13) (1.2)
5.71 5.04 .98 1.97 2.13 4.25 1.93 1.50 3/4 4.6
DV-20 1 1-5/16-12UN Pg 29
(145) (128) (25) (50) (54) (108) (49) (38) (19) (2.1)
5.91 5.24 1.18 2.36 2.13 4.25 1.93 1.50 3/4 6.2
DV-25 1-1/4 1-5/8-12UN Pg 29
(150) (133) (30) (60) (54) (108) (49) (38) (19) (2.8)
6.10 5.43 1.38 2.76 2.13 4.25 1.93 1.50 3/4 7.7
DV-30 1-1/2 1-7/8-12UN Pg 29
(155) (138) (35) (70) (54) (108) (49) (38) (19) (3.5)

1)
12
DIMENSIONS: DVP and DVE
T F
1
2
3
4
5
DVE
Knob for B G
sizes 6 - 16 closed
3 2 1 0 9 1
A 2
3
U 4
5
C open C
closed
B
E
S open
O D Hex
P
M N Hex
1
2
A
3
4
OUT
5
D
K
L
IN
Knob for
E
Sizes 20-40
has Hex extension F
R G for wrench H
H
J
Dimensions: DVP
A B C D E F G H J K L M N O P R S T U1) WT
Model Size in in in in in in in in in in in in in in in in in in in Hex lbs.
Code (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg)
2.48 2.28 .43 .26 .63 .94 - .748 1.38 1.112 1.63 .059 .630 .197 .382 .315 .35 .37 - 44
DVP-06 1/8 Pg 7
(63) (58) (11) (6.6) (16) (24) - (19) (35) (28.5) (41.5) (1.5) (16) (5) (9.7) (8) (9) (9.5) - (0.2)
3.11 2.83 .43 .26 .79 1.14 - 1.378 1.87 1.319 1.81 .177 1.004 .276 .500 .256 .51 .57 - .88
DVP-08 1/4 Pg 11
(79) (72) (11) (6.6) (20) (29) - (35) (47.5) (33.5) (46) (4.5) (25.5) (7) (12.7) (6.5) (13) (12) - (0.4)
3.31 3.03 .43 .26 .98 1.14 - 1.319 2.01 1.496 2.01 1.65 1.004 .394 .614 .335 .71 .55 - 1.3
DVP-10 3/8 Pg 11
(84) (77) (11) (6.6) (25) (29) - (33.5) (51) (38) (51) (4.2) (25.5) (10) (15.6) (8.5) (18) (14) - (0.6)
3.90 3.50 .43 .26 .98 1.50 - 1.496 2.95 1.752 2.26 .157 1.181 .512 .732 .728 .71 .89 - 2.2
DVP-12 1/2 Pg 16
(99) (89) (11) (6.6) (25) (38) - (38) (75) (44.5) (57.5) (4.0) (30) (13) (18.6) (18.5) (18) (22.5) - (1.0)
4.45 4.05 .55 .35 1.18 1.50 1.496 2.992 3.68 2.126 2.76 .433 2.126 .669 .965 335 .83 .77 - 3.7
DVP-16 3/4 Pg 16
(113) (103) (14) (9.0) (30) (38) (38) (76) (93.5) (54) (70) (11) (54) (17) (24.5) (8.5) (21) (19.5) - (1.7)
6.5 5.83 .55 .35 1.77 198 1.870 3.740 4.37 2.362 3.01 .753 2.244 .866 1.201 .315 1.42 1.24 3/4 8.0
DVP-20 1 Pg 29
(165) (148) (14) (9.0) (45) (49) (47.5) (95) (111) (60) (76.5) (19.1) (57) (22) (30.5) (8) (36) (31.5) (19) (3.6)
6.5 5.83 .71 .45 1.77 1.93 2.362 4.744 5.63 2.992 3.94 819 3.130 1.122 1.472 433 1.34 1.81 3/4 12.1
DVP-25 1-1/4 Pg 29
(165) (148) (18) (11.5) (45) (49) (60) (120.5)(143) (76) (100) (20.8) (79.5) (28.5) (37.4) (11) (34) (46) (19) (5.5)
6.69 6.02 .79 .55 1.97 193 2.815 5.630 6.73 3.622 4.53 .937 3.740 1.378 1.709 .591 1.46 1.53 3/4 16.6
DVP-30 1-1/2 Pg 29
(170) (153) (20) (14) (50) (49) (71.5) (143) (171) (92) (115) (23.8) (95) (35) (43.4) (15) (37) (39) (19) (7.5)
Note: Pg Style Thread Per DIN 40430.
Dimensions: DVE
A B C D E F G H WT
Size in in in in in in in in Hex lbs.
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg)
1.00 1.85 1.57 .472 .177 .559 1.14 1-1/16 .33
DVE-08 3/4-16UNF
(26) (47) (40) (12) (4.5) (14.2) (29) (27) (.15)
1.18 2.52 2.13 .492 .315 .622 1.50 1-1/16 .55
DVE-10 7/8-14UNF
(30) (64) (54) (12.5) (8) (15.8) (38) (27) (.25)
1.57 2.56 2.17 .531 .375 .807 1.50 1-5/16 1.10
DVE-12 1-1/16-12UNF
(40) (65) (55) (13.5) (9.5) (20.5) (38) (32) (.50)
1.71 2.56 2.17 .689 .433 1.060 1.50 1-5/8 1.54
DVE-16 1-5/16-12UNF
(43.5) (65) (55) (17.5) (11) (26.9) (38) (41) (.70)
Note: Contact Factory for Certified Drawing of Cartridge Valve Cavity.
13
CHECK VALVES
Specifications:
5000 psi Operating Pressure

9 Sizes, 1/8 - 2
NPT or SAE O-Ring Connections and Manifold Mounting
Flows to 150 gpm
RV - Inline Mounting FPM (Viton) O-Rings (standard or RVP series)
Metal to Metal Seal Design
Hardened and Ground Steel Poppet
3 Cracking Pressures: 7 psi (standard),
25 psi and 65 psi (optional)
Temperature Range:
-4 to 212F
B A
RVP - Manifold Mounting
Hydraulic Symbol
Model Code
RV - 06 - 01 .X / 5 - 25
Check Valve
RV = Inline Mounting
RVP = Manifold Mounting
Nominal Sizes
Nom Size SAE (RV Only) NPTF (RV Only)
(RV + RVP) Tube Size Thread Size Pipe Size Pipe OD
06 -2 5/16-24 UNF 1/8 .405
08 -4 7/16-20 UNF 1/4 .540
10 -6 9/16-18 UNF 3/8 .675
12 -8 3/4-16 UNF 1/2 .840
16 -12 1-1/16-12 UN 3/4 1.050
20 -16 1-5/16-12 UN 1 1.315
25 -20 1-5/8-12 UN 1-1/4 1.660
30 -24 1-7/8-12 UN 1-1/2 1.900
40 -32 2-1/2-12 UN 2 2.375
Housing Material
01 = Carbon Steel
Modification Number
Port Configuration
5 = NPTF - ANSI/ASME 1.20 Taper Pipe Thread
0 = BSP to DIN 3852, Part 2-X (Special Order)
Omit = RVP Only
25 = 25 psi
65 = 65 psi Cracking Pressure
Note: RVP not available in size 40

Note: Not recommended for high-cycle applications!
14
RV 6-16 RV 20-40
160 160
10 140 10
140
RV 06
RV 08
RV 10
21
8 120 8 120
RV
P in bar
P in bar
P in psi
P in psi
100 100
20
6 80
6
80
25
RV
16
4 60 RV 4 60 RV 30
RV V 40
40 40 R
2 2
20 20
0 0 0 0
0 5 10 15 20 25 30 35 40 45 50 55 0 20 40 60 80 100 120 140 160
Flow gpm Flow gpm
0 20 40 60 80 100 120 140 160 180 200 0 50 100 150 200 250 300 350 400 450 500 550 600
DIMENSIONS: RV
B A
Hex L
Port Size L WT
Model Hex in lbs.
Code NPT UNF (mm) (kg)
11/16 1.77 22
RV-06 1/8 5/16-24 UNF
(17) (45) (0.1)
3/4 2.17 .44
RV-08 1/4 7/16-20 UNF
(19) (55) (0.2)
1 2.60 .44
RV-10 3/8 9/16-18 UNF
(24) (65) (0.2)
1-1/4 2.87 .66
RV-12 1/2 3/4-16 UNF
(30) (73) (0.3)
1-7/16 3.46 1.1
RV-16 3/4 1-1/16-12 UN
(36) (88) (0.5)
1-13/16 5.00 2.4
RV-20 1 1-5/16-12 UN
(46) (127) (1.1)
2-3/8 5.63 4.0
RV-25 1-1/4 1-5/8-12 UN
(60) (143) (1.8)
2-9/16 5.63 5.7
RV-30 1-1/2 1-7/8-12 UN
(65) (143) (2.6 )
3-3/16 6.50 9.7
RV-40 2 2-1/2-12 UN
(80) (165) (4.4)
Note: Contact HYDAC for RVP Dimensions.
15
Other Products from HYDACs Clamps, Valves, and Accessories Line
High Pressure Ball Valves
HYDAC offers a complete line of high pressure ball valves. These valves
feature full unrestricted flow, positive shut-off, and have pressure ratings of up
to 7,250 psi. Available sizes range from 1/4 thru 2 with NPT, SAE, or SAE
split flange connections. Options include locking devices, pneumatic or
electrical actuators, limit switches, and offset or straight handles. For complete
information on HYDAC High Pressure Ball Valves, contact HYDAC at
610-266-0100 and request a catalog.
Request catalog # 02068169

Hose, Tube, and Pipe Clamps
HYDAC clamps and mounting systems are available in a wide range of sizes
and materials to fit practically any application. These clamps are designed to
absorb shock, dampen vibration, and reduce noise. Rubber inserts are used
Copyright 1999 HYDAC TECHNOLOGY CORPORATION - Brochure - Flow, Needle And Check Valves #02070322 / 9.99
for applications with high cyclic pressures. Weld plates are available as
phosphate coated steel, or stainless steel. Custom arrangements are also
available. A single custom arrangement can replace many single clamps
resulting in a simplified installation, and a more compact solution that fits your
application perfectly. For more information on HYDAC Hose, Tube, and Pipe
Clamps please contact HYDAC at 610-266-0100.

Flow, Needle, and Check Valves
When it comes to flow control valves, HYDAC once again provides a complete
line of high quality solutions. Flow, Needle, and check valves are designed to
be safe, precise, and easy to use. The valves are constructed of high quality
materials to be compatible with the type of fluid being used. These valves
come with pressure ratings of up to 5,000 psi. Both inline and manifold designs
are available. HYDAC would be glad to help you determine which flow control
valve(s) would be appropriate for your application. For more information on these
products, or help selecting the right valve, contact HYDAC at 610-266-0100.

Multi Station Gauge Isolators
HYDAC Multi-Station Gauge Isolators allow for multiple pressure readings to
be taken by a single gauge. They are offered with or without a built-in gauge.
Available in 6 to 9 stations, these gauge isolators have operating pressure
ranges of 4500 psi at measuring points. For help in selecting the proper gauge
isolator for your application call HYDAC at 610-266-0100.

Phone (610) 266-0100 Fax (610) 264-3540
3. Subplates
PART NUMBER
ALUMINUM & STEEL
SUPER SAVER SUBPLATES
3-1 NFPA D03 Valves - Perimeter Ported SP-A03x-1/P & SP-S03x-1/P
3-2 NFPA D03 Valves - Down Side Ported SP-A03x-1/D & SP-S03x-1/D
3-3 NFPA D05 Valves - Perimeter Ported SP-A05x-1/P & SP-S05x-1/P
3-4 NFPA D05 Valves - Down Side Ported SP-A05x-1/D & SP-S05x-1/D 1
SUBPLATES
3-5 NFPA D03 Valves SP-A03x-1/x & SP-S03x-1/x
2
Standard Subplate - includes specified NFPA valve pattern mounting on the top
surface of the subplate, A & B ports per the specified thread type on the face of the
subplate and pressure and tank ports per the specified thread type on the back 3
surface of the subplate. Mounting provisions include two (2) counter bored
holes (4 on D08 subplate) on the top surface of the subplate.
Options:
Z - No Relief Valve Cavity - specifies that no relief valve cavity is provided (standard subplate).
B - Bottom PR - TK ports - additional pressure and tank ports per specified thread type located on the bottom of
the manifold.
4
C - Relief Valve Cavity C-10-2 - common cavity configuration added to the back surface of the manifold.
D - Down Side Porting - (Super Saver - D) - all four ports (A,B, PR & TK) are located on the bottom surface of the
subplate. No other porting or options are provided.
P - Perimeter Porting - (Super Saver - P) - locates the A, B, PR and TK ports on separate side surfaces of
the subplate. No other porting or options are provided. 5
S - Relief Valve Cavity Sun T-10A - Sun cavity configuration added to the back surface of
the manifold.
H - Hard Metric Threading - when British or ISO thread type is specified, the valve mounting holes are also metric
threaded.
M - Soft Metric Threading - indicates mixed metric threading. When British or ISO thread type is specified, valve
mounting holes are English threaded OR when NPT or SAE thread type is specified, valve mounting holes are
6
metric threaded. No code (M or H) indicates the valve mounting holes are English threaded.
MAGNALOY SUBPLATE PART NUMBER BREAKDOWN

R
S P - A 0 3 P - 1 / B
Product Code Options
SP - Subplate Z - No Relief Cavity
B - Bottom PR-TK Ports
Material Code C - Relief Valve Cavity C-10-2
A - Aluminum P - Perimeter Porting - All 4 Sides Ported
S - Steel (Super Saver-P) (No other options available)
S - Relief Valve Cavity Sun T-10A
NFPA Pattern Code D - Down Side Porting - All 4 Ports on Bottom
03 - D03 (Super Saver-D) (No other options available)
05 - D05 H - Hard Metric Threading 2 (See Notes: Page 1)
08 - D08 M - Soft Metric Threading 3 (See Notes: Page 1)
Note: For more than two combined options, consult factory.
Thread Code
P - NPTF Pipe Design Series
S - SAE ORing
B - BSPP British Parallel
T - BSPT British Taper
(See Port Chart for Standard Sizes)
magnaloy coupling company P.O. Box 455 Alpena, MI 49707 517-356-2186 3

A Division of Douville Johnston Corporation Fax: 517-354-4190 http://www.magnaloy.com
Super Saver Subplates
D03 - Perimeter Ported
2.50"
Mounting Holes for
Application: 1/4" Socket Head Cap Screw
Subplate used for mounting directional valve
with NFPA D03 Interface.
1.00"
A, B, PR & TK ports on separate sides.
B Port
TK Port 1
2.50"
THREAD
CODE PR, TK, A & B
P 3
8'' NPTF
S #6 SAE 2
B 3
8'' BSPP
T 3
8'' BSPT
2.25"
1.86"
1.00"
.50" 3
.40" .25"
1.25"
2.50" 4
2.25"
5
.25"
Two Counterbored
Mounting Holes for 1/4" SHCS
6
1.25"
2.50"
R
MAGNALOY D03 SUPER SAVER SUBPLATE PART NUMBER BREAKDOWN
S P - A 0 3 S - 1 / P
SP - Subplate P - Perimeter Porting - All 4 Sides Ported
(Super Saver-P)
Material Code
A - Aluminum Design Series
S - Steel
NFPA Pattern Code Thread Code
03 - D03 P - NPTF Pipe
S - SAE ORing
magnaloy coupling company P.O. Box 455 Alpena, MI 49707 517-356-2186 3-1
D03 - Down Side Ported
2.50"
Mounting Holes for
Application: 1/4" Socket Head Cap Screw
with NFPA D03 Interface. 1.00"
A, B, PR & TK ports on bottom.
2.50"
1
A, B, PR & TK Ports Located
on Bottom Surface
THREAD
CODE PR, TK, A & B
P 8'' NPTF
3 2
S #6 SAE
B 8'' BSPP
3
T 8'' BSPT
3
3
2.50"
1.94"
2.25" 1.00" 1.25" 4
1.86" .56"
.40" .25" A
.62"
TK 1.25" 5
2.50" 1.88"
2.25"
PR
6
B
.25"
Two Counterbored
R
S P - A 0 3 P - 1 / D
SP - Subplate D - Down Side Porting - All 4 Ports on Bottom
(No Side Porting) (Super Saver-D)
Material Code
S - Steel
S - SAE ORing
D05 - Perimeter Ported
Mounting Holes for

5/16" Socket Head Cap Screw
Application:
3.50"
1.00"
A, B, PR & TK ports on separate sides.
B Port
1
A Port
4.00"
THREAD
CODE PR, TK, A & B
2.00"
P 1
2'' NPTF 2
S #8 SAE
B 2'' BSPP
1
PR
.90"
T 1
2'' BSPT 3
1.25"
.625" .375" .625"
.375"
1.00"
2.125" B 1.875"
4
TK
3.50" 3.125"
5
3.625"
.625" A
Two Counterbored
Mounting Holes for 5/16" SHCS 6
1.75"
4.00"
R
S P - A 0 5 S - 1 / P
SP - Subplate P - Perimeter Porting - All 4 Sides Ported
(Super Saver-P)
Material Code
S - Steel
S - SAE ORing
D05 - Down Side Ported
Mounting Holes for

Application:
Subplate used for mounting directional valve 3.50"
1.00"
A, B, PR & TK ports on bottom.
1
A, B, PR & TK Ports Located
4.00" on Bottom Surface
THREAD
CODE PR, TK, A & B 2
P 1
2'' NPTF
S #8 SAE
B 1
2'' BSPP
T 1
2'' BSPT
3
Two Counterbored
2.575"
3.124" 1.25" 1.55"
4
B
A 5
3.625" 4.00"
2.62"
PR
1.78"
.90"
.375" TK .875" 6
.375" .70"
.70" 1.76"
3.50" R
S P - A 0 5 P - 1 / D
SP - Subplate D - Down Side Porting - All 4 Ports on Bottom
(No Side Porting) (Super Saver-D)
Material Code
S - Steel
S - SAE ORing
Subplates
D03 Side Ported
Application:
Mounting Holes for Subplate used for mounting directional
valve with NFPA DO3 Interface.
3"
A & B ports on a common side. PR & TK on
opposite side.
PR and TK Ports
115/32" A Special features include cartridge relief
valve cavity with the tank and pressure
connections on the bottom surface to
A&B
B
Cavity for
allow plumbing directly through the
reservoir top. 1
Ports Cartridge Relief Valve Note:
4" (Option Code C or S) Part no. includes the subplate only.
Order relief valve cartridge separately.
Alternate PR and TK
Ports Located on
PR & TK
Side Ports
2.38"
Bottom Surface
(Option Code B)
See page R-1 for Relief Valve Part
Number Equivalents.
2
(60.3)
.78"
(19.8)
PR TK
.63"
(16.0)
3
Two counterbored Mounting Holes for 1/4" Optional Cavity for Optional
Socket Head Cap Screws Relief Valve Cartridge Bottom PR & TK Ports
1.44" (Option Code C or S) (Option Code B)
.50" (36.6)
(12.7)
.79" TK
(20.1)
2.34"
A
TK
B
4
(59.4) PR
2.22"
(56.4)
PR 1.39"
(35.2) 1.22"
(31.0)
3.19"
(81.0)
.31"
(7.9)
.34"
(7.9) .59"
(15.1)
1.031"
(26.2)
THREAD 5
CODE PR, TK, A & B
1.47" 2.19"
(37.3) (55.6)
P 3
8'' NPTF
Relief Valve
2.81" 2.56"
Cartridge (See R-1)
(71.4) (65.1) S #8 SAE
1.56"
.53"
(13.5)
(39.6) Adjusted to
Maximum
B 8'' BSPP
3 6
A B T 3
8'' BSPT
MAGNALOY D03 SUBPLATE PART NUMBER BREAKDOWN R

S P - A 0 3 P - 1 / B
A - Aluminum S - Relief Valve Cavity Sun T-10A
S - Steel H - Hard Metric Threading 2 (See Notes: Page 1)
M - Soft Metric Threading 3 (See Notes: Page 1)
NFPA Pattern Code Note: For more than two combined options, consult factory.
03 - D03
Design Series
Thread Code
P - NPTF Pipe
S - SAE ORing
Subplates
D05 Side Ported
Mounting Holes for Application:
Subplate used for mounting directional
PR and TK Ports valve with NFPA DO5 Interface.
3 1/2"
A & B ports on a common side. PR & TK on
opposite side.
B Special features include cartridge relief valve

3 31/32"
cavity with the tank and pressure connections
on the bottom surface to allow plumbing
A directly through the reservoir top. 1
A & B Ports
4"
Cavity for
Relief Valve Cartridge
1.31"
(33.3) 2
(Option Code C or S) A B
Optional PR & TK Ports
Located on Bottom Surface 1.53"
(38.9)
Note: (Option Code B) 2.84"
Part no. includes the subplate only.

Order relief valve cartridge separately.
(72.2)
Two Counterbored
3
.50" 3.19"
(12.7) (81.0)
See page R-1 for Relief Valve Part Optional

Cavity for Cartridge
Number Equivalents. Relief Valve
PR (Option Code C or S)
3.50"
(88.9)
2.38"
(60.5) A
PR
B
4
1.81"
TK 2.13" TK (46.0)
(54.0) 2.03"
(51.6)
1.03"
(26.2) .63"
(16.0)
THREAD
2.19"
.94"
(23.8)
.63"
(15.9)
1.97"
1.12"
(28.4)
2.12"
(53.8)
.47"
(11.9)
5
CODE PR, TK, A & B Optional (55.6) (50.0)
2.19"
Bottom TK & PR Ports (55.6)
P 1
2'' NPTF (Option Code B) 2.56" .66"
(65.1) (16.7)
Adjusted to
S #8 SAE Maximum Length
B 1
2'' BSPP
TK PR
.78"
6
(19.8)
T 1
2'' BSPT
Relief Valve Cartridge
(See R-1)

S P - A 0 5 P - 1 / B
05 - D05
Thread Code Design Series
P - NPTF Pipe
S - SAE ORing
Subplates
D08 Side Ported
Application:
Side ported subplate used for mounting
3.56" .94" directional valves with NFPA DO8 Interface.
(90.5) (23.9) Features include A, B, and pilot pressure ports
1.53"
.59" on a common side with PR, TK, and pilot
(38.9)
(15.0) drain ports on the opposite side.
1.00"
(25.4)
See page R-1 for Relief Valve Part
B A
PP Number Equivalents. 1
Two Counterbored
Mounting Holes
6.00" for 3/8" Socket
(152.4) Head Cap Screws
Mounting Holes for

2
PP (2) Places
B A Pilot Port PD, PR and TK Ports

5.00"
2.21" (127.0)
(56.1)
PR TK 1 31/32"
3
PP
A
1.40"
PD
(35.6) B
2.09" A & B Ports 6" 5"

Cavity for
4
(53.1)
.45" 5.13" Relief Valve Cartridge
(11.4) (130.3) (Option Code C or S)
4.50"
(114.3)
2.44"
.97"
(61.9)
CATALOG PR & TK
5
PR TK
1.38" (24.6) NO. A&B PD & PP
(35.0) 1.97"
1
(50.0) P 1'' NPTF 4'' NPTF
PD S #16 SAE #4 SAE
5.03" B 1'' BSPP 1

4'' BSPP
6
(127.8)
1
T 1'' BSPT 4'' BSPT

S P - A 0 8 P - 1 / B
08 - D08
Thread Code Design Series
P - NPTF Pipe
S - SAE ORing
RA 91 001/08.97
Fixed Displacement Motor AA2FM (A2FM) RA

Series 6, for Open and Closed Circuits 91 001/08.97
Axial Piston, Bent Axis Design Replaces: RA 91001/07.95
5800 psi 6500 psi RA 91003/05.95
Brueninghaus Hydromatik Sizes 51000 Nominal Pressure up to
(400 bar)
Peak Pressure up to (450 bar) RA 91025/05.95
The fixed displacement motors AA2FM (A2FM) of axial

piston, bent axis design is made suitable for hydrostatic drives
in open and closed circuits.
Output speed is proportional to input flow and inversely

proportional to displacement. Drive torque increases with
the pressure drop across the unit.
The motor is suitable for use in mobile and industrial

applications.
Careful selection of the displacements offered, permit sizes

to be matched to practically every application.
Favourable power / weight ratio
Compact and economic design
Optimum efficiency
One piece pistons with piston rings
Patented cylinder block drive system
1
RA 91 001/08.97
Fixed Displacement Motor AA2FM (A2FM)
Ordering Code
(Ordering code size 5 see page ...) M / 6 W -
Hydraulic Fluid Hydraulic fluid
Petroleum oil (no code)
Axial piston unit
HF-Fluids Sizes 10...200 (no code)
Sizes 250...1000
(only in connection with drive shaft bearings "L") E-
Drive shaft bearings
Axial piston unit 10...180 200 250 355...1000
Mode of operation
Bent axis design, Version SAE AA2F
fixed displacement Version ISO A2F
Size
Drive shaft bearings 10...200 250...500 710...1000
Mechanical bearings (no code) Series
Long life bearings L
Mode of operation Index
Motor M
Direction of rotation
Size
^ dis- Size 10 12 16 23 28 32 45 56 63 80
Size = Seals
in3/rev 0.63 0.73 0.98 1.40 1.71 1.95 2.78 3.42 3.84 4.91
placement Size 90 107 125 160 180 200 250 355 500 710 1000
Vg cm3/rev. in3/rev 5.49 6.51 7.63 9.79 10.98 12.20 15.25 21.66 30.51 43.33 61.02 Shaft end
Series Mounting flange

6
Index Service ports
Sizes 10...180 1 AA2F 1) 10 12 16 23 28 32 45 56 63 80 90 107 125 160 180 250
Size 200 3
Sizes 250...1000 0 Ports A and B 51 0 510
SAE at rear 6 516
Viewed on shaft end bi-directional W Ports A and B 52 0 520
SAE at side 6 526
Seals 10...1000
(opposite sides)
FPM - Phosphate ester fluid V 7 527
Shaft end 10 12 16 23 28 32 45 56 63 80 90 107 125 160 180 250 Ports A and B 53 0 530
S Threaded side (opposite sides) 6 536
SAE T Ports A and B Threaded rear 54 0 540
SAE Splined shaft U
Version Q A2F 2) 200 355 500 710 1000
(AA2F) Parallel shaft B Ports A and B SAE, at rear 01 0 010
with key DIN 6885 P
SAE Parallel shaft with key K
Valves
200 355 500 710 1000
Z without valves (no code) 0
ISO Splined shaft DIN 5480 A with integrated flushing valve 6
Version P
(A2F) Parallel shaft with key DIN 6885 with built-on flushing and boost pressure relief valve 7
B
Mounting flange 10 12 16 23 28 32 45 56 63 80 90 107 125 160 180 250 Speed sensor 10...16 23 28 32 45 56 63 80 90 107 125 160 180 200...1000
SAE SAE 2-bolt C without speed sensor (no code)
Version SAE 4-bolt D
(AA2F) DN prepared for speed sensor D
200 355 500 710 1000 1
) Threads of fixing screws and service lines are SAE (UN / UNF)
ISO ISO 4-bolt B 2
Version ) Threads of fixing screws are metric
(A2F) ISO 8-bolt H
= available
= not available
= in preparation (on request)
2-3
RA 91 001/08.97
Technical Data
Hydraulic fluid Notes on the selection of the hydraulic fluid
We request that before starting a project detailed information about In order to select the correct fluid, it is necessary to know the
the choice of pressure fluids and application conditions are taken operating temperature in the loop (closed circuit) or the reservoir
from our catalogue sheets RA 90220 (petroleum oil), RA 90221 temperature (open circuit) in relation to the ambient temperature.
(environmentally acceptable hydraulic fluids) and RA 90223 (fire The hydraulic fluid should be selected so that within the operating
resistance fluids, HF). temperature range, the operating viscosity lies within the optimum
When using HF- or environmentally acceptable hydraulic fluids range (opt) (see shaded section of the selection diagram). We
possible limitations for the technical data have to be taken into recommend that the highest possible viscosity range should be
consideration. If necessary please consult us or your fluid supplier chosen in each case.
(please indicate type of the hydraulic fluid used for your application on Example: At an ambient temperature of X, the operating
the order sheet). temperature (closed circuit: loop temperature; open circuit: reservoir
temperature) is 140 F (60 C). Within the optimum operating
Operating viscosity range viscosity range (opt; shaded area), this corresponds to viscosity
In order to optain optimum efficiency and service life, we grades VG 46 or VG 68. VG 68 should be selected.
recommend that the operating viscosity (at operating tem- Important: The leakage oil (case drain oil) temperature is influenced
perature) be selected from within the range: by pressure and motor speed and is always higher than the circuit
temperature or the reservoir temperature.
However, at no point in the system may the temperature exceed
Optimum operating viscosity opt = 80...170 SUS (16...36 mm2/s)
240 F (115 C) for sizes 5...200 or 195 F (90 C) for sizes
250...1000.
referred to the loop temperature (closed circuit) or reservoir If it is not possible to comply with the above conditions because of
temperature (open circuit). extreme operating parameters or high ambient temperature, please
consult us.
Viscosity limits
The limiting values for viscosity are as follows: Filtration
The finer the filtration the better the achieved purity grade of the
Sizes 5...200 pressure fluid and the longer the life of the axial piston unit.
min = 42 SUS (5 mm2/s) To ensure the functioning of the axial piston unit a minimum purity
short term at a max. perm. temperature of tmax = 240 F (115 C) grade of:
max = 7400 SUS (1600 mm2/s) 9 to NAS 1638
short term on cold start (tmin = -40 F / C)
6 to SAE
Sizes 2501000 18/15 to ISO/DIS 4406 is necessary.
min = 60 SUS (10 mm2/s) At very high temperatures of the hydraulic fluid (195 F to max.
short term at a max. perm. leakage oil temp. of t max = 195 F (90 C) 240 F / 90 C to max. 115C, not permissible for sizes
max = 4600 SUS (1000 mm2/s) 2501000!) at least cleanless class
short term on cold start (tmin = -13 F / -25 C)
8 to NAS 1638
5 to SAE
Please note that the max. fluid temperature is also not exceeded in
17/14 to ISO/DIS 4406 is necessary.
certain areas (for instance bearing area).
If above mentioned grades cannot be maintained please consult us.
At temperatures of -13 F up to -40 F (-25 C up to -40 C) special
measures may be required for certain installation positions. Direction of flow
Please contact us for further information. clockwise rotation counter-clockwise rotation
A to B B to A
Selection diagram
(7000) 1600 (7425)
1600 (7400)
(5000) 1000 1000 (4600) Speed range
(3000)
(2000)
600 There is no limitation on minimum speed nmin. If uniformity of
400
rotation is required, however, speed nmin should not be allowed to
(1000)
V
V 68
V 32
V 46
V
200
fall below 50 rpm.
G
G
G
G
G
10
22
0
Viscosity v mm2/s (SUS)
(500) 100 See table on page 7 for max. permissible speeds.

(300) 60
(200) 40 36
Installation position
(150) (170) Any installation position possible. The motor housing must be filled
vopt.
(100) 20 with fluid prior the commissioning, and must remain full whenever
16
(80)
(80) it is operating.
(70)
(60) 10 10 (60)
For extensive information on installation postition, please consult our
data sheet RA 90270 before completing your design work.
(50)
Symbol A
5 5 (42)
(40)
-40 -20 0 20 40 60 80 100 120 140 160 180 200 220 240
Connections
(-40) (-30) (-20) (-10) (0) (10) (20) (30) (40) (50) (60) (70) (80) (90)(100) (115)
(110)
A, B Service line ports
Temperature t in F (C) T Drain port T B
4
RA 91 001/08.97
Technical Data
Case drain pressure Flushing valve
The lower the speed and the case drain pressure the higher the life In order to prevent excessive heat build-up in closed circuit
expectation of the shaft seal ring. operation, it is possible to fit a flushing valve (built into the port
plate). Two such valves are available:
Shaft seal ring FPM (fluor-caoutchouc) - an Integrated flushing valve (built into the port plate) (sizes 23...90)
The values shown in the diagram are permissible loads of the seal - a built-on flushing and boost pressure relief valve (sizes 45...180, 250)
ring and shall not be exceeded.
At stationary pressure loads in the range of the max. admissible
Integrated flushing valve (6)
- switching pressure p 115 psi / 8 bar (this value is lower than the
leakage pressure a reduction of the life experience of the seal ring
starting pressure of an unloaded motor).
will result.
- closed in centre position (p < 115 psi / 8 bar).
For a short period (t < 5 min.) are for the sizes 10200 pressure
loads up to 75 psi (5 bar) permissible, independent from rotational T2 A (B)
speeds. Sizes 23-32 45-63 80-90
Flushing gpm 0.66 0.82 1.1
Sizes 10...200 volume L/min 2,5 3,1 4,1
bar psi Values given for low pressure
10 p = 365 psi (25 bar)
140
9 T1 B (A)
sizes 10,12,16 Built-on flushing and boost pressure relief valve (7)
8 120
perm. pressure pabs. max.
This valve is built on to the fixed displacement motor. It must then be

7 noted that only a port plate with ports at side is then available
sizes 23,28,32 100
(port plate 52).
6
size 45 80 The flushing and boost pressure relief valve has a fixed setting of
5 230 psi / 16 bar (the setting of the primary boost pressure relief
sizes 107,125 valve must be noted) and is used to safeguard the minimum boost
4 60
sizes 56,63 pressure. A fixed flow of fluid is taken via an orifice from the low
sizes 160,180
3 pressure side of the circuit and fed into the motor housing. This flow
sizes 80,90
40
is then passed back to reservoir with the case drain fluid. Fluid thus
2 size 200
20 removed from the closed circuit must be made up by means of the
1 15 boost pump.
0 1000 2000 3000 4000 5000 6000 7000 8000
Different orifice sizes may be used to select varying flows of
speed n (rpm) flushing fluid.
Sizes 250...1000 Flows (at low pressure p = 365 psi / 25 bar) *
bar psi Size Flow Orifice No.
4
60
45, 56, 63 0.93 gpm (3,5 L/min) 651766/503.12.01.01
size 250 80, 90 1.32 gpm (5 L/min) 419695/503.12.01.01
3,5 50 107, 125 2.11 gpm (8 L/min) 419696/503.12.01.01
perm. pressure pabs. max.
3 160, 180 2.64 gpm (10 L/min) 419697/503.12.01.01

size 355 40 250 2.64 gpm (10 L/min)
2,5
size 500 * Standard flushing volumes (for T A (B)
2
size 710 30 sizes 45180 flushing volumes
2
of 0.93-2.64 gpm / 3,5 - 10 L/min
can be supplied. If a flushing
1,5
20 volume different from the
size 1000 standard flushing volume is
1 15
0 500 1000 1500 2000 2500 3000 required, please indicate the
speed n (rpm) requested orifice in clear text T1 B (A)
when ordering).
Special operation conditions may require limitations of these Long-Life bearings (L) (sizes 250...1000)
values. (for high life expectancy and use of HF-fluids)
Note: The outer dimensions of the axial piston motors are identical to
- maximum permissible motor speeds are given in the table on standard design (without long life bearings). The change from
page 7 standard design to long life bearing system is possible.
- max. perm. housing pressure pabs. max 145 psi / 10bar (sizes 5...200) We recommend to apply bearing flushing at port U.
60 psi / 4 bar (sizes 2501000) Bearing flushing
- the pressure in the housing must be the same as or greater For sizes 250...1000 bearing and housing flushing is possible
than the external pressure on the shaft seal. through port U.
5
RA 91 001/08.97
Technical Data
Operating pressure range
Maximum pressure at port A or B (Pressure data to DIN 24312)
AA2F Sizes 10 12 16 23 28 32 45 56 63 80 90 107 125 160 180 250 Nominal Pressure Peak Pressure
S 5800 psi (400 bar) 6500 psi (450 bar)
S 5100 psi (350 bar) 5800 psi (400 bar)
Q 4350 psi (300 bar) 5100 psi (350 bar)
Shaft Q 4000 psi (280 bar) 4600 psi (315 bar)
end: T 5800 psi (400 bar) 6500 psi (450 bar)
U 5800 psi (400 bar) 6500 psi (450 bar)
B 5100 psi (350 bar) 5800 psi (400 bar)
P 5100 psi (350 bar)1) 5800 psi (400 bar)
K 5100 psi (350 bar) 5800 psi (400 bar)
A2F Sizes 5 200 355 500 710 1000 Nominal Pressure Peak Pressure
Z 5100 psi (350 bar) 5800 psi (400 bar)
A 5800 psi (400 bar) 6500 psi (450 bar)
P 5100 psi (350 bar) 5800 psi (400 bar)
Shaft B 5100 psi (350 bar) 5800 psi (400 bar)
end: B 3000 psi (210 bar) 3600 psi (250 bar)
C 4600 psi (315 bar) 5100 psi (350 bar)
With pulsating loads over 4600 psi (315 bar), we recommend the use of a splined shaft (AA2FM 10...250: S, T or U / A2FM 200: A / A2FM 250...1000: Z)
The summ of the pressures at ports A and B may not exceed 10 000 psi / 700 bar (A2F5: 9000 psi / 630 bar)
1) Attention : shaft end with drives of radial force loads at the drive shaft (pinion, V-belt drives) necessitate reduction of the nominal
pressure to pN= 4600 psi (315 bar), please contact us.
Output Drive
Permissible axial and radial loading on drive shaft.
The values given are maximum values and not permissible for continuous operation.
AA2F Sizes 10 12 16 23 28 32 45 56 63 80 90 107 125 160 180 250
a mm 16 16 16 16 16 16 18 18 18 20 20 20 20 25 25 41
in 0.63 0.63 0.63 0.63 0.63 0.63 0.71 0.71 0.71 0.79 0.79 0.79 0.79 0.98 0.98 1,61
Fq max1) N 2100 2500 3250 3850 4800 5400 7250 8150 9150 10250 11450 12100 14100 16300 18300 12003
lbf 472 562 730 865 1079 1214 1630 1832 2057 2304 2574 2720 3170 3664 4114 270 )
Fq max 2) N 9000 9000 4000
lbf 2023 2023 899
Fax max N 320 320 320 500 500 500 630 800 800 1000 1000 1250 1250 1600 1600 1200
lbf 72 72 72 112 112 112 142 180 180 225 225 281 281 360 360 270
Fax zul./bar N/bar 3,0 3,0 3,0 5,2 5,2 5,2 7,0 8,7 8,7 10,6 10,6 12,9 12,9 16,7 16,7 4
/psi lbf/psi 0.05 0.05 0.05 0.08 0.08 0.08 0.11 0.13 0.13 0.16 0.16 0.20 0.20 0.26 0.26 )
A2F Sizes 5 200 355 500 710 1000

a mm 12 25 52,5 52,5 67,5 67,5
in 0.47 0.98 2,07 2,07 2,66 2,66
Fq max N 710 22900 15003 19003 30003 26003
lbf 160 5148 337 ) 427 ) 674 ) 584 )
+Fqx max N 180 1600 5000 6250 10000 10000
lbf 40 360 1124 1405 2248 2248
-Fax max N 180 1600 1500 1900 3000 2600
lbf 40 360 337 427 674 584
Optimal force direction of Fq (valid for sizes 10...180)
Fax perm. N/bar 1,5 16,7 4 4 4 4 By means of appropriate force directions of Fq the bearing load
lbf/psi 0,023 0,26 ) ) ) )
1 2
caused by inside rotary group forces can be reduced. An optional
) valid for all shafts except Q-shaft ) valid for Q-shaft (size 80 and 90)
3
life expectation of the bearing can be reached.
) Axial piston unit in stationary or in bypass operation, please contact us op
4 = 45 t =4
5
when appearing higher forces! ) Please contact us. Motor opt

bi-directional
Code explanation rotation
0 o
=7

a = distance of Fq from shaft shoulder (Fq) t pt =

7
op
Fq max = max. perm. radial force at distance
0
a (at intermittent operation)

Fax max = max. perm. axial force when a
stationary or when axial piston unit
is running at zero pressure
Fax perm./psi (bar) = perm. axial force/psi (bar) operating pressure
A B A B
The direction of the max. perm. axial force must be noted by
sizes 5...200 Motor Motor
Fax = increases bearing life Fax Counter-clockwise Motor Counter-clockwise
Fax = reduces bearing life (avoid if possible) rotation Clockwise rotation rotation
pressure at port B pressure at port A pressure at port B
6
RA 91 001/08.97
Technical Data
Table of values (theoretical values, without considering mh and v; values rounded)
Size 5 10 12 16 23 28 32 45 56 63 80
Displacement Vg in3 0.30 0.63 0.73 0.98 1.40 1.71 1.95 2.78 3.42 3.84 4.91
cm3 4.93 10.3 12.0 16.0 22.9 28.1 32.0 45.6 56.1 63.0 80.4
Max. speed nmax rpm 10000 8000 8000 8000 6300 6300 6300 5600 5000 5000 4500
nmax interm.1) rpm 11000 8800 8800 8800 6900 6900 6900 6200 5500 5500 5000
Max. flow qv max gpm 13 21.8 25.3 33.9 38.2 46.6 52.2 67.4 74.0 83.1 95.6
L/min 49 82 96 128 144 176 201 255 280 315 360
Torque constants Tc lb-ft/psi 0.004 0.0084 0.0097 0.013 0.019 0.023 0.026 0.037 0.045 0.051 0.065
Nm/bar 0.078 0.164 0.191 0.254 0.364 0.447 0.509 0.725 0.892 1.002 1.278
Torque at p= 5100 psi T lb-ft 182) 42 49 66 94 115 132 188 231 259 332
p= 350 bar T Nm 24.72) 57 67 88 126 156 178 254 312 350 445
p= 5800 psi T lb-ft - 48 56 75 107 131 150 213 263 295 377
p= 400 bar T Nm - 65 76 100 144 178 204 290 356 400 508
Case volume gal 0.045 0.045 0.045 0.053 0.053 0.053 0.087 0.119 0.119 0.145
L 0.17 0.17 0.17 0.20 0.20 0.20 0.33 0.45 0.45 0.55
Moment of inertia J lbs-ft2 0.0019 0.0095 0.0095 0.0095 0.0285 0.0285 0.0285 0.0569 0.0997 0.0997 0.1708
about drive axis kgm2 0.00008 0.0004 0.0004 0.0004 0.0012 0.0012 0.0012 0.0024 0.0042 0.0042 0.0072
Weight (approx.) m lbs 5.5 12 12 12 21 21 21 30 40 40 51
kg 2.5 5.4 5.4 5.4 9.5 9.5 9.5 13.5 18 18 23
Size 90 107 125 160 180 200 250 355 500 710 1000
Displacement Vg in3 5.49 6.51 7.63 9.79 10.98 12.20 15.25 21.66 30.51 43.3361.02
cm3 90.0 106.7 125.0 160.4 180 200 250 355 500 710 1000
Max. speed nmax rpm 4500 4000 4000 3600 3600 2750 2500 2240 2000 1600 1600
nmax interm.1) rpm 5000 4400 4400 4000 4000 3000 - - - - -
Max. flow qv max gpm 106.9 112.7 132.1 152.5 171.1 145.2 165 210 264 300 422
L/min 405 427 500 577 648 550 625 795 1000 1136 1600
Torque constants Tc lb-ft/psi 0.073 0.086 0.101 0.130 0.146 0.162 0.202 0.287 0.405 0.5750.809
Nm/bar 1.43 1.70 1.99 2.55 2.86 3.18 3.98 5.64 7.95 11.2915.9
Torque at p = 5100 psi T lb-ft 371 440 516 662 742 825 1031 1465 2063 2930 4127
p = 350 psi T Nm 501 595 697 889 1001 1114 1391 1979 2785 3955 5570
p = 5800 psi T lb-ft 422 500 587 753 844 938 - - - - -
p = 400 psi T Nm 572 680 796 1016 1144 1272 - - - - -
Case volume gal 0.145 0.21 0.21 0.29 0.29 0.66 0.92 2.06
L 0.55 0.8 0.8 1.1 1.1 2.5 3.5 7.8
Moment of inertia J lbs-ft2 0.1708 0.2753 0.2753 0.5221 0.5221 0.8970 1.4475 2.4205 4.2240 13.052 13.052
about drive axis kgm2 0.0072 0.0116 0.0116 0.0220 0.0220 0.0378 0.061 0.102 0.178 0.55 0.55
Weight (approx.) m lbs 51 71 71 99 99 145 161 242 342 710 741
kg 23 32 32 45 45 66 73 110 155 322 336
1
) Intermittent max. speed: overspeed at discharge and overtaking travel operations, t < 5 sec. and p < 2200 psi (150 bar).
2
) p = 4600 psi (315 bar)
Speed sensor (D) (sizes 23...180)
Calculation of size Version AA2FM...D ("prepared for speed sensor") includes gearing
on the rotary group and in addition the port M in which a speed
Flow qv = ( q = 1000
Vg n
231 v
V n
gpm
L/min )
v
g
v
sensor is screwed in.
A speed-proportional signal is produced by means of the rotating,
q 231 q 1000
rpm ( n = rpm )
v v v v
Output speed n = splined rotary group which can be picked up by a suitable sensor
V g
V g
and fed back for evaluation.
Nm )
V p V p
lb-ft ( T =
g mh g mh The speed sensor can be screwed into port M (thread metric
Output torque T = 24 20 M18x1,5).
HP ( P = kW) Sizes
Tn q p v Tn t
q p v t
Output power P = = = 23...32 45 56...63 80...90 107...125 160...180
5252 1714 9549 600
No. of teath 38 45 47 53 59 67
Vg = Geometric displacement per revolution - in3 (cm3) length of thread
p = Differential pressure - psi (bar) inches 0,5 0,44 0,58 0,58 0,58 0,58
T = Torque - lb-ft (Nm) mm 12,7 11,2 14,7 14,7 14,7 14,7
qv = Flow - gpm (L/min)
P = Power - HP (kW) The speed sensor is not included in standard supply.
n = Speed - rpm Suitable sensor (order separately):
v = Volumetric efficiency - Induktive impulse detector ID (see RA 95038)
mh = Mechanical hydraulic efficiency
t = Total efficiency (t = v mh) - Hall effect speed sensor HD (see RA 95042)
7
RA 91 001/08.97
Before finalising your design, please request a certified drawing.
Fixed Displacement Motor AA2FM (A2FM) Dimensions in inches and millimeters ( ).
Ordering Code, Size 5 A2F 5 W 6.0 3 Additional instructions in text form
Seals
The fixed Motor A2F 5 is equipped
Axial piston unit
with NBR (Nitrilcaoutchouc) seals in
Bent axis design, fixed displacement A2F standard design. In cse of need
FPM- (fluor-caoutchouc) seals
Size please indicate when ordering in
Size 5 clear text:
Displacement Vg in3 / rev. 0,30 "with FPM-seals"
cm3 / rev. 4,93
Viewed on shaft end bi-directional W
Series
6.0
Shaft end
Parallel shaft with key DIN 6885 B
Tapered shaft with spigot and spring washer DIN 6888 C
Service ports
Threaded at side, metric (opposite side) 3
Unit Dimensions, Size 5

ISO Design Y
0.31
2.76 (70) (8) 2.9
3 (7 View Y
2.3
R 0.24 0.6 0 (5 4,5)
8,5 T
(R 6) (17 9 )
,5)
A
2.3604 DIA
0.25 (6,4)
2.76 (70)
(60h8)
2.3622
5
25
2.9 )
1.91 (48,5)
(75
2)
4 (6
2.4
0.16 (4)
T
T
2.01 (51) 3.15 (80)
B
Shaft ends Connections
"C" Tapered shaft with spigot and "B" Parallel shaft with A, B Service line ports M 18x1,5 (thread metric)
spring washer 3x5(mm) key A4x4x20(mm) T Drain port M 10x1, both sides (thread metric)
DIN 6888 DIN 6885
0.16 0.94 (24)
(7,3)
0.29
(4) 1.30 (33) 0.39

(10)
0.87
DIA (13,5)
0.53
M4
(22)
0.504 DIA
(12,8)
M10x1
0, 16
(R 0.0
4)
(12k6)
R
0.4729
0.4725
taper 1:10
Nominal pressure Nomnal pressure

pN = 4600 psi (315 bar) pN = 3000 psi (210 bar)
8
RA 91 001/08.97
Unit Dimensions, Sizes 10, 12, 16

SAE Design
6.85 (174) 0.38 (9,7) 3.02 (76,6)

5.75 (146) 0.31 0.47 T1
(7,9) (12)
se
0.2 e po
(5 0 rt
4.76 (121)
4.9980 DIA
(101,6-0,05)
) pla

te
40
s
(4 .67
4.0000
)
2,5
1
(53,5)
2.11
0.20
0.56 (5)
(14,3)
( .35
A B
)
T2
3
85
Connections
A, B Service line ports (see port plates)
T1, T2 Drain ports (1 port plugged)SAE-6; 9/16" - 18 UNF-2B
Shaft ends
Sizes 10, 12, 16 Size 12, 16 Sizes 10
"S" Splined Shaft SAE 7/8", "B" Parallel shaft with key, "P" Parallel shaft with key,
13 Teeth, 16/32 Pitch AS 8x7x32mm, DIN 6885 AS 6x6x32mm, DIN 6885
ANSI B 92.1a-1976 0.16 1.26 (32) 0.16 1.26 (32)
1.102 (24,6)
(19,6)
0.969
0.3150 (4)
0.77
1.102 (17,7)
0.697
0.2362 (4)
R0 1,0
0.27
0.236
R0 1,0
0.3135
.0 )
(R
(7)
R
0.2350
.0 )
(R
4
(6)
0. ,6)
4
(R
(8h9)
06
(6h9)
1
5/16-18 UNC
1.102
1.102
(22,5)
(28)
0.88
(28)
(28)
M 10
(28)
M6
0.75 0.87 0.87
DIA
DIA
(19) (22) 0.1 (22) 0.1
0.315 (8)
(2,5) (2,5)
(25k6)
(20k6)
0.9848
0.9843
1.7880
1.7875
1.32 1.57 (40)
(33,5)
Nominal pressure Nominal pressure Nominal pressure

pN = 5800 psi (400 bar) pN = 5100 psi (350 bar) pN = 5100 psi (350 bar)
Port plate 53
4.
25
(1
08
)
2.20 (56)
3.35 (85)
B A
5.61 (142,5) 3.35 (85)
6.75 (171,5)

SAE-12; 1 1/16" - 12 UN-2B; 0.79 (20) deep
9
RA 91 001/08.97

SAE Design
45 45
0.50 3.06 (77,8) T1
(12,7)
5.75 (146) 0.79
R0.6
3 (R 0.31 (20)
16) (7,9)
se
e
0.7 po
rt
4.9980 DIA
5( pla
(127-0,05)
5.75 (146)
19 te
40
s
(5 .99
)
5.0000
0 ,6
1
8
6.3 2)
(57,6)
2.27
(16
(14,3)
0.75
0.56
(19)
( 4.17
6)
10

T2
Connections
T1, T2 Drain ports (1 port plugged) SAE-10; 7/8" - 16 UNF - 2B
0.67 (17) Deep
Shaft ends
Sizes 23, 28, 32 Size 23, 28, 32
"S" Splined Shaft SAE 1 1/4", "B" Parallel shaft with key
14 Teeth, 12/24 Pitch AS 8x7x40mm, DIN 6885
ANSI B 92.1a-1976 0.20 1.57 (40)
(29.6)
1.165
0.3150 (5)
0.27
(25,8)
1.016
(7)
0.3135
R
0. .0)
(R
04
0. ,6)
(R
(8h9)
06
1
7/16-14 UNC
1.30 (33)
1.378
M 10
1.378
(35)
(35)
1.10 0.87
DIA
(22) 0.1
(28) 0.315 (8) (2.5)
(30k6)
1.1817
1.1812
1.89 1.97 (50)

(48)
Nominal pressure Nominal pressure

Prepared for speed sensor (D), with port M

(inductive impulse detector ID see RA 95038
hall effect speed sensor HD see RA 95042,
to be ordered separately!)
3.06 (77,8)
M M 18 x 1,5
0.08 (thread metric)
(2)
2.09
1.97
(53)
(50)
Size 32 : available
Sizes 23, 28 : in preparation (on request)
10
RA 91 001/08.97
Port plates
51 52
4.53 (115)
4. 5.
76 1.59 1.59 39
(1 (40,5) (40,5) 0.
21 72 (13
0.72 (18,2)
) (1 7)
B A 8.
2)
(1 51
)
,5
2.76 (70)
3)
0.
0
3.07 (78)
(4
4.17 (106)
59
4.61 (117
1.
B A
5/16"-18 UNC
6.69 (170) 5/16"-18 UNC 0.71 (18) deep
0.51 0.71 (18) deep
7.48 (190) (13) 2.32 6.34 (161)
(59) 8.15 (207) 4.72 (120)
A, B Service line ports A, B Service line ports

SAE 1/2"; 6000 psi (420bar) high pressure series SAE 1/2"; 6000 psi (420bar) high pressure series
53 54
5. 5.
39 39
(1 (1
37 37
) ) B A
2.76 (70)
2.76 (70)
3.46 (88)
4.61 (117)
4.61 (117
B A
6.34 (161) 6.34 (161)

4.72 (120) 7.20 (183) 2.28 (58)
8.15 (207)
8.15 (207) 4.96 (126)

SAE-16; 1 5/16" - 12 UN-2B; 0.79 (20) deep SAE-16; 1 5/16" - 12 UN-2B; 0.79 (20) deep
11
RA 91 001/08.97

SAE Design
45 45
0.50 3.32 (84.4) T1
(12,7) 0.79
5.75 (146)
R0.6 0.31 (20)
3 (R
16) (7,9)
se
e
0.7 po
rt
5.0000 DIA
1(
5.75 (146)
18 pl
(127-0,05)
) at
e

40
(5 .15
4.9980
)
4,6
2
8
6.3 2)
(65,1)
2.56
(16
(14,3)
0.71
8)
0.56
1
(18)
1
.6 5(
A B
4
T2
Connections
T1, T2 Drain ports (1 port plugged) SAE-8; 3/4" - 16 UNF-2B
Shaft ends
Size 45 Size 45
"S" Splined Shaft SAE 1 1/4", "P" Parallel shaft with key
14 Teeth, 12/24 Pitch AS 8x7x50mm, DIN 6885
0.20 1.97 (50)
ANSI B 92.1a-1976 0.3150
(29,6)
1.165
(5)
(25,8)
1.016
0.27
R0 1,0
0.3135
(7)
.0 )
(R
R
(8h9)
0. ,6)
(R
06
1.30 (33)
1
7/16-14 UNC
1.378
(35)
M 12
1.378
(35)
1.10
DIA
1.10 (28) 0.1

(28) 0.315 (8) (2,5)
(30k6)
1.1817
1.1812
2.36 (60)
1.89
(48)
Prepared for speed sensor (D), with port M With built-on flushing & boost pressure relief valve (7)
hall effect speed sensor HD see RA 95042, 9.72 (247)
3.22 (84,4)
M M 18 x 1,5 Y
0.22 (thread metric)
(5,5)
(54,5)
2.15
5.94 (151)
View Y A
)
98
in preparation (on request)

6(
B
3.8
12
RA 91 001/08.97
Port plates
51 52
5.79 (147)
5. 6.
43 2.00 2.00 10
0. (1
(1 (50.8) (50.8) 94 55
38 (2 )
) 3,
B A 8)
(23,8)
)
0.94
(1 5
,8
0.7
3.15 (80)
3.50 (89)
9)
0
(5
4.80 (122)
5.24 (133)
00
2.
B A
3/8"-16 UNC
0.83 (21) deep
3/8"-16 UNC
7.48 (190) 0.75 0.82 (21) deep 7.05 (179)
(19) 9.09 (231) 5.04 (128)
8.58 (218)
2.95
(75)
SAE 3/4"; 6000 psi (420bar) high pressure series SAE 3/4"; 6000 psi (420bar) high pressure series
13
RA 91 001/08.97
Unit Dimensions, Sizes 56, 63

SAE Design
45 45
0.50 3.61 (91,6) T1
5,75 (146) (12,7) 0.79
R0.6 0.31 (20)
3 (R
16) (7,9)
se
e
0.7 po
rt
1( pl
4.9980 DIA
5.75 (146)
(127-0,05)
18 at
es
2.82 40
)
(5 .31
6)
5.0000
2
8,
8
6.3 2)
(71,6)
(16
(14,3)
8)
0.71
0.56
2
1
(18)
.0 4(
5
T2
Connections
Shaft ends
Sizes 56, 63 Sizes 56, 63 Size 56, 63
"S" Splined Shaft SAE 1 1/4", "T" Splined Shaft SAE 1 3/8", "B" Parallel shaft with key
14 T, 12/24 Pitch 21 T, 16/32 Pitch AS 10x8x50mm, DIN 6885
ANSI B 92.1a-1976 ANSI B 92.1a-1976
0.20 1.97 (50)
(34,6)
1.362
0.3937
(30,2)
(5)
0.31
(25,8)
1.016
1.18
R
(8)
0.3923
0. ,0)
R
(R
04
R
0. ,6)
(R
1
0. ,6)
(10h9)
06
(R
06
1
1
7/16-14 UNC
1.50 (38)
7/16-14 UNC
1.575
1.575
1.575
M 12
(40)
(40)
(40)
1.10 1.10
1.10
DIA
(28) (28) 0.1

(28) 0.315 (8) 0.315 (8)
(2,5)
(35k6)
1.3787
1.3780
1.89 2.36 (60)

1.89
(48) (48)

3.61 (91,6)
M M 18 x 1,5 Y
0.24 (6) (thread metric)
2.36
(60)
6.26 (159)
View Y A
8)
(9
B
6
3.8
14
RA 91 001/08.97
Port plates
51 52
5.79 (147) 6.
5. 56
89 2.00 2.00
(1 1. (1
49 (50.8) (50.8) 09 66
,5 (2 ,5
0.94 (23,8)
) 7, )
B A 8)
2)
3.43 (87)
7,
3.78 (96)
(5
5.12 (130)
5.59 (142)
0. 2.25
B A
(2 98
5)
7/16"-14 UNC
3/8"-16 UNC 0.87 (22) deep
8.11 (206) 0.75 0.82 (21) deep 7.68 (195)
9.06 (230) (19) 2.95
(75) 9.80 (249) 5.35 (136)

SAE 3/4"; 6000 psi (420 bar) high pressure series SAE 1"; 6000 psi (420 bar) high pressure series
15
RA 91 001/08.97

SAE Design
45 45
0.50 4.23 (107,5) T1
(12,7)
5,75 (146) 0.79
R0.6 0.31 (20)
3 (R
16) (7,9) se
e
0.5 po
9( rt
5.75 (146)
pl
4.9980 DIA
(127-0,05)
15 at
) es

40
(6 .58
6)
5.0000
2
8
5,
6.3 2)
3.26
(83)
(16
(14,3) 0.59
0.56
3 8)
(15)
1
3(
A B
.4
5
T2
Connections
A, B service line ports
T1, T2 drain port (1 port plugged) SAE-10; 7/8" - 14 UNF-2B
Shaft ends
Sizes 80, 90 Sizes 80, 90
"U" Splined Shaft SAE 1 3/8", "Q" Splined Shaft SAE 1 1/4",
21 Teeth, 16/32 Pitch 14 T, 12/24 Pitch
ANSI B 92.1a-1976 ANSI B 92.1a-1976
(25,8)
1.016
R 1,6
R
0. )
0. ,6)
(R
(R
06
06
7/16-14 UNC
1
7/16-14 UNC
1.77
(45)
(30,2)
1.77
1.19
(45)
1.10 1.10
(28) 0.315 (8) (28) 0.315 (8)
1.89 (48) 1.89 (48)
Nominal pressure
Nominal pressure Size 80: pN = 4350 psi (300 bar)
pN = 5800 psi (400 bar) Size 90: pN = 4000 psi (280 bar)
4.23 (104,5)
0.24 (6) M M 18 x 1,5 Y

(thread metric)
6.83 (173.5)
(65,8)
2.63
View Y A
(9 86
8)
3.
in preparation (on request) B
16
RA 91 001/08.97
Port plates
51 52
6.54 (166)
6. 7.
40 46
(1 2.25 2.25 (1
62 1. 89
,5 (57,2) (57,2) 09
) (2 ,5
7, )
B A 8)
(27,8)
1.09
4.11 (104,5)
)
,2
3.90 (99)
7
5.71 (145)
(5
6.38 (162)
25
B A
2.
(2 98
5)
0.
7/16"-16 UNC
7/16"-14 UNC 0.75 (19) deep
9.13 (232) 0.98 0.75 (19) deep 6.30 (160)
(25) 8.86 (225)
10.31 (262) 3.31 11.26 (286)
(84)
SAE 1"; 6000 psi (420bar) high pressure series SAE 1"; 6000 psi (420bar) high pressure series
17
RA 91 001/08.97

SAE Design
45 45
0.50 4.52 (114,9) T1
(12,7)
7.87 (200) 0.98
R0.7 0.31 (25)
5 (R
19) (7,9)
se
e
0.7 po
rt
5.9980 DIA
1( pl
(152,4-0,05)
7.87 (200)
18 at
) es

3.37 40
(7 .82
6.0000
6)
2
1,
0
9.0 ,6)
(85,6)
8
(22
(20,6)
0.81 0.71 (18)
)
50
(1
.91
A B
5
T2
Connections
Shaft ends
Sizes 107, 125 Sizes 107, 125 Size 107, 125
"S" Splined Shaft SAE 1 3/4", "U" Splined Shaft SAE 1 1/2", "B" Parallel shaft with key
13 T, 8/16 Pitch 23 T, 16/32 Pitch AS 14x9x63mm, DIN 6885
ANSI B 92.1a-1976 ANSI B 92.1a-1976
0.31 2.48 (63)
(44,6)
1.756
0.5512 (7,9)
R0 1,0
R
0.35
R 2,5
(9)
0.5495
.0 )
(R
(R
0. ,5)
0. )
(R
4
1
1
2
(14h9)
5/8-11 UNC
5/8-11 UNC
1.91 (48,5)
(33,4)
1.97
(50)
1.97
1.42
1.32
(50)
(36)
1.97
(50)
M 16
1.42 1.42
DIA
1.42
(36) 0.472 (12) (36) 0.315 (8) (36) 0.1
(45k6)
1.7724
1.7717
(2,5)
2.64 2.44 3.15 (80)
(67) (62)

hall effect speed sensor HD see RA 95042, 12.84 (326,1)
4.52
(114,9) M M 18 x 1,5
0.31 (thread metric) Y
(8)
7.56 (192)
2.95
(75)
View Y
A
Size 107 : available

(9 86
3.
8)
Size 125 : in preparation (on request) B
18
RA 91 001/08.97
Port plates
51 52
7.64 (194)
7. 8.
34 2.63 2.63 74
(1 1. (2
86 (66,7) (66,7) 25 22
,5 (3 )
) 1,
B A 8)
(31,8)
)
1.25
.7
4.33 (110)
4.72 (120)
6
(6
6.26 (159)
7.13 (181)
(3 6
63
1.2
2)
2.
B A
1/2"-13 UNC
1/2"-13 UNC 0.75 (19) deep
10.14 (257,5) 1.26 0.75 (19) deep 7.01 (178)
9.65 (245,1)
(32)
11,18 (284) 12.48 (317)
3.90
(99)

SAE 1 1/4"; 6000 psi (420bar) high pressure series SAE 1 1/4"; 6000 psi (420bar) high pressure series
19
RA 91 001/08.97

SAE Design
45 45
0.50 4.92 (124,9) T1
(12,7)
7.87 (200) 0.98
R0.7 0.31 (25)
5 (R
19) (7,9)
se
0.7 e
po
7( rt
7.87 (200)
pla
5.9980 DIA
19
(152,4-0,05)
,5) te
3.76 40
(7 .05
6.0000
5)
3
7,
0
9.0 ,6)
(95,6)
8
(22
(20,6) 0.77
0)
0.81
8
(19,5)
1
.09(
A B
7
T2
Connections
Shaft ends
Sizes 160, 180 Size 160, 180
"S" Splined Shaft SAE 1 3/4", "B" Parallel shaft with key
13 Teeth, 8/16 Pitch AS 14x9x70mm DIN 6885
ANSI B 92.1a-1976 0.39 2.76
0.5512 (10) (70)
R 2,5
0.35
0. )
R
(9)
(R
0.5495
1
0. ,5)
(R
(14h9)
2
2.11 (53,5)
5/8-11 UNC
1.42
2.36
(36)
(60)
2.36
M 16
(60)
1.42 1.42
DIA
(50k6)
(36) 0.472 (12) (36)

1.9692
1.9686
2.64 3.54 (90)

(67)

4.92 (124,9)
M M 18 x 1,5
0.08 (thread metric) Y
(2)
7.91 (201)
3.27
(83)
View Y
A
(9 86
in preparation (on request)

3.
8)
20
RA 91 001/08.97
Port plates
51 52
7.64 (194)
8. 2.63 2.63 9.
19 17
(2 (66.7) (66.7) 12 (2
08 5 33
) (3 )
1,
B A 8)
(31,8)
5.275 (134)
1.25
)
,7
4.76 (121)
6
7.40 (188)
(6
7.40 (188)
63
(3 26
2.
1.
2)
B A
1/2"-13 UNC
1/2"-13 UNC 0.75 (19) deep
11.18 (284) 1.26 0.75 (19) deep 7.95 (202)
10.59 (269)
(32)
12.83 (326) 12.83 (326)
3.90
(99)
SAE 1 1/4"; 6000 psi (420bar) high pressure series SAE 1 1/4"; 6000 psi (420bar) high pressure series
21
RA 91 001/08.97

ISO Design
4.09 (104)
45 45
1.57 (40) 1.26 T1
9.29 (236) (32)
0.35 7.8
(9) 0.5 3 (1
9 (1 99)
5)
1.26
(32)
7.8729 DIA
9.29 (236)
0.87 (22)
(200-0,029)
(92 2

3.6
)
25
7.8740
4
9.8 0)
(102,5)
3.31
(84)
4.04
5
6.50 (165)
( 2 0.59
11)
(15)
1 (2
8.3
A B
1.26 T2
(32) Y
11.18 (284)
12.17 (309)
8.03 (204)
View Y
2.62 2.62
(66,7) (66,7)
B A
Connections
(31,8)
1.25
SAE 1 1/4"; 6000 psi (420 bar) high pressure series
T1, T2 Drain port (1 port plugged) M 22x1,5 (thread metric)
M 14;
1.26 0.75 (19) deep
(32)
3.90
(99)
Shaft ends
"A" Splined Shaft, DIN 5480 "B" Parallel shaft with key
W 50x2x30x24x9g AS 14x9x63mm, DIN 6885
0.39 2.76 (70)
(44,6)
1.756
0.5512 (10)
R
R0 2,5
0.35
(R
0. )
(9)
0.5495
.1 )
(R
16
4
(14h9)
2.11 (53,5)
1.76 DIA
(44,6)
1.97
(50)
M 16
M 16
DIA
1.42 1.42
(36) 0.43 (11) (36) 0.1
(50k6)
1.9692
1.9686
(2,5)
2.17 3.54 (90)
(55)
22
RA 91 001/08.97

SAE Design
45 12.60 (320)
45
0.63 (16) 4.88 (124)
10.31 (262) 0.31 2.52 Port plate 51
(7,9) (64)
U T View Y
1.665
(42,3)
(115)
4.53
(105)
4.13
6.4980 DIA
1.97 1.97
10.31 (262)
(165,1h8)
(50) (50)
6.5000
0
7,5
263
31 B A
3.66
(93)
(105)
(
4.13
.50
12
(210)
(172)
8.27
6.77
.75 Y
(31,8)
R0 )
1.25
(19
0.81 0.98 T 1/2"-13 UNC)
(20,6) (25) 0,75 (19) deep
4.88
(124) 1.26 1.26
14.02 (356) (32) 2.62 2.62 (32)
(66,7) (66,7)
12.17 (309)
Port plate 52
1/2"-13 UNC)
0,75 (19) deep View Y
1.2
5 (3 9.30 (236)
1,8
)
0
263
3.23
6.77 (82)
8.27 (210)
Connections (172)
B A
A, B Service line ports SAE 1 1/4"
6000 psi (420 bar) high pressure series
(66 2
,7)
2.6
T Drain port (1 port plugged) 7/8 - 14 UNF - 2B

2)
6 (3
U Port for bearing flushing (plugged) Y

1.2
9/16 - 18 UNF - 2B 14.33 (364)
Shaft ends
"S" Splined Shaft SAE 2",
15 Teeth, 8/16 Pitch
ANSI B 92.1a-1976
5/8-11 UNC
(42,3)
1.665
1.42
(36) 0.578 (14,7)
2.63
(66,7)
Nominal pressure
pN = 5100 psi (350 bar)
23
RA 91 001/08.97

ISO Design
2230
1.97 12.60 (320)
(50) 3.27 (83)
13.20 (335) 0.55 0.93 (23,5)

45
(14)
U T
6.69 (170)
(128)
14
5.04
(36 .17
11.0204 DIA
0)
13.20 (335)
(280h8)
0.71
(18)
11.0236
0
263
(102)
4.02
0
.6
(128)
12 20)
5.04
(3
(198)
7.80
1.10 T Y
(28) 3.27
(83) 13.80 (350)
Port plate 01
View Y
1.44 1.44
(36,6) (36,6)
B A
9.65 (245)
Connections
(79,4)
3.13
T Drain port (1 port plugged) M 33x2 (thread metric)
U Port for bearing flushing (plugged) M 14x1,5 (thread metric) M16; 0.83
(21) deep
1.57 1.57
(40) (40)
2.36 2.36
(60) (60)
Shaft ends
"Z" Splined Shaft, DIN 5480 "P" Parallel Shaft with key
0.12
R
R
(3)
0. ,6)
(R
(R
0. )
06
16
1
4
2.16 DIA
(64,4)
(55)
M 20
2.54
M 20
1.65
DIA
1.65
(42) 0.43 (11) (42)
(60m6)
2.3634
2.3626
3.23 4.13 (105)

(82)

24
RA 91 001/08.97

ISO Design
2230
1.97 14.23 (361,5)
(50) 3.86 (98)
14.76 (375) 0.55 1.08 (27,5)

45
(14)
U T
7.56 (192)
(142)
15
5.59
(4 .75
12.3984 DIA
00
14.76 (375)
)
(315h8)
0.86
(22)
12.4016
(112,5)
263
4.43
7
.1
(142)
5.59
14 60)
(3
(220)
8.66
1.18 T Y
(30) 4.37
(111) 15.60 (396)
Port plate 01
View Y
1.44 1.44
(36,6) (36,6)
B A
10.63 (270)
Connections
(79,4)
3.13
U Port for bearing flushing (plugged) M 18x1,5 (htread metric) M16; 0.83
(21) deep
1.57 1.57
(40) (40)
2.56 2.56
(65) (65)
Shaft ends
0.12
R
R
(3)
0. ,6)
(R
(R
0. )
06
16
1
4
2.46 DIA
(62,7)
(74,5)
2.93
M 20
M 20
1.65
DIA
1.65
(42) 0.51 (13) (42)
(70m6)
2.7571
2.7563
3.15 4.13 (105)

(80)

25
RA 91 001/08.97

ISO Design
2230
1.97 19.13 (486)
(50) 5.16 (131)
18.31 (465) 0.55 1.63 (41,5)
45
(14)
U T
9.29 (236)
(183)
19
7.20
(5 .69
15.7445 DIA
00
)
18.31 (465)
(400h8)
15.7480
0.87
(22)

1830
(102)
4.02
2
.7
(183)
720
17 50)
( 4
(252)
9.92
1.38 T Y
(35) 6.14
(156) 19.96 (507)
Port plate 01 View Y

1.75 1.75
(44,5) (44,5)
B A
13.39 (340)
Connections
A, B Service line ports SAE 2"
(96,8)
3.81
U Port for bearing flushing (plugged) M 18x1,5 (thread metric)
M20; 1.18
(30) deep
1.97 1.97
(50) (50)
3.35 3.35
(85) (85)
Shaft ends
0.12
R
R
(3)
0. ,6)
(R
(R
0. )
06
16
1
4
2.25 DIA
(82,6)
M 24
3.74
(95)
M 24
1.97
DIA
1.97
(50) 0.55 (14) (50)
(90m6)
3.5447
3.5438
4.13 5.12 (130)

(105)

26
RA 91 001/08.97

ISO Design
2230
1.97 18.43 (468)
(50) 5.16 (131)
18.31 (465) 0.55 1.63 (41,5)

45
(14)
U T
9.29 (236)
(183)
7.20
19
15.7445 DIA
(5 .69
00
)
18.31 (465)
(400h8)
0.87
(22)
15.7480
5.63 (143)
263
2
.7
(183)
7.20
17 50)
10.98 (279)
(4
T
T
Y
1.38
(35) 6.14
(156) 20.16 (512)
Port plate 01
View Y
1.75 1.75
(44,5) (44,5)
B A
13.39 (340)
Connections
(96,8)
3.81
A, B Service line ports SAE 2"
U Port for bearing flushing (plugged) M 18x1,5 (thread metric) M20; 1.18
(30) deep
1.97 1.97
(50) (50)
3.35 3.35
(85) (85)
Shaft ends
0.12
R
R
(3)
0. ,6)
(R
0. )
(R
06
16
1
4
(82,6)
2.25
3.74
M 24
M 24
(95)
1.97
3.5438 DIA
1.97
(90m6)
(50) 0.55 (14) (50)

3.5447
4.13 5.12 (130)

(105)

27
RA 91 001/08.97
Mannesmann Rexroth Corporation

Rexroth Hydraulics Div., Industrial, 2315 City Line Road, Bethlehem, PA 18017-2131 Tel. (610) 694-8300 Fax: (610) 694-8467
Rexroth Hydraulics Div., Mobile, 1700 Old Mansfield Road, Wooster, OH 44691-0394 Tel. (330) 263-3400 Fax: (330) 263-3333
All rights reserved Subject to revision
28 Printed in U.S.A.
MANNESMANN
REXROTH
Brueninghaus Hydromatik
Reparaturanleitung
Repair Instructions
A2F
Baureihe/Series 6.1
RDE 91001-01-R
07.96
RDE 91001-01-R/07.96
Inhalt / Hinweis Reparaturanleitung A2F/6.1

Contents / Notice Repair Instructions A2F/6.1
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen Specifications, descriptions and illustrative material
entsprechen dem Informationsstand zum Zeitpunkt der shown herein were as accurate as known at the time
Drucklegung dieser Unterlage. this publication was approved for printing.
nderungen knnen den Service am Produkt beein- BRUENINGHAUS HYDROMATIK reserves the right to
flussen, Verpflichtungen entstehen uns daraus nicht. discontinue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, fr speci-fications, materials, or design without notice and
deren Resultat wir keine Haftung bernehmen knnen. with-out incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Optional equipment and accessories may add cost to
Angabe der Fabrik-Nr. bestellt, sind die Basis guter the basic unit, and some options are available only in
Reparaturen. combination with certain models or other options.
Einstell- und Prfarbeiten sind bei Betriebstemperatur For the available combinations refer to the relevant data
auf dem Teststand vorzunehmen. sheet for the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vor- Adjustment and tests have to be carried out on the test
kehrungen sicherzustellen. bench under operating temperatures.
Sachkenntnis, die Voraussetzung fr jede Service- Protection of personnel and property has to be guar-
arbeit, vermitteln wir in unseren Schulungskursen. anteed by appropriate measures.
Expert knowledge, the precondition of any service work,
can be obtained in our training courses.
INHALT Seite/ CONTENTS

Page
A2F A2F
Schnittbild 3 Sectional view

Allgemeine Reparaturhinweise 4 General repair instructions
Dichtstze und Baugruppen 5 Seal kits and sub-assemblies
Triebwelle abdichten 6-7 Sealing of the drive shaft
Anschluplatte abdichten 8-9 Sealing of the cover plate
Triebwerk ausbauen 10 Removal the rotary group
berprfungshinweise 11-12 Examination notes
Triebwerk ausbauen 13-15 Installing rotary group
Anziehdrehmomente 16 Tightening torques
Sicherheitsbestimmungen 17-18 Safety regulations
2 Brueninghaus Hydromatik
RDE 91001-01-R/07.96
Schnittbild Reparaturanleitung A2F/6.1

Sectional view Repair Instructions A2F/6.1
Mepunkte:
Siehe Serviceinfo
Measuring points:
See service information
Brueninghaus Hydromatik 3
RDE 91001-01-R/07.96
Allgemeine Reparaturhinweise Reparaturanleitung A2F/6.1

General repair instructions Repair Instructions A2F/6.1
Achtung!
Nachfolgende Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!
Attention!
Observe the following notices when carrying out repair
work at hydraulic aggregates!
Alle ffnungen der Hydraulikaggregate verschlieen.
Close all ports of the hydraulic aggregates.
Alle Dichtungen erneuern.

Nur original HYDROMATIK - Ersatzteile verwenden!
Replace all seals.

Use only original HYDROMATIK spare parts!
Alle Dicht- und Gleitflchen auf Verschlei prfen.

Achtung: Nacharbeiten an Dichtflchen z.B. durch
Schleifpapier kann die Oberflche beschdigen.
Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.
Hydraulikaggregate vor Inbetriebnahme mit

Hydraulikl befllen.
Fill up hydraulic aggregates with hydraulic oil

before start- up.
RDE 91001-01-R/07.96
Dichtstze und Baugruppen Reparaturanleitung A2F/6.1

Seal kits and sub-assemblies Repair Instructions A2F/6.1
1 uerer Dichtsatz.
External seal kit.
2 Triebwerk, mechanischer Teil; mit Dichtsatz,
mu abgestimmt werden auf Ma "A".
Rotary group, mechanical part; with seal kit,
has to be adjusted to dimension "A".
3 Triebwerk, hydraulischer Teil; mit Dichtsatz,
Abstimmung hydraulischer Teil Pos. "D".
Rotary group, hydraulic part; with seal kit,
Adjustment of the hydraulic part Pos. "D".
4 Triebwerk komplett; mit Dichtsatz, fertig vorabgestimmt.
Abstimmung hydraulischer Teil Pos. "D".
Complete rotary group, with seal kit, pre-adjusted.
Adjustment of the hydraulic part Pos. "D".
RDE 91001-01-R/07.96
Triebwelle abdichten Reparaturanleitung A2F/6.1

Sealing of the drive shaft Repair Instructions A2F/6.1
5 Bei nicht verzahnten Triebwellen: Pafeder ab-

nehmen. Triebwelle abkleben,
Remove protective cover. If keyed shaft,remove

key.
6 Sicherungsring lsen, danach ausbauen.
Free circlip and remove.
7 Verschluring abdrcken.
Prise off front cover
8 Sichtkontrolle
Wellendichtring (1), Verschluring (2), Trieb-
welle (3), Gehuse (4), O-Ring (5).
Visual check
Shaft seal (1), cover (2), drive shaft (3),
housing (4), O-ring (5).
9 Wellendichtring demontieren.
Remove old shaft seal.
RDE 91001-01-R/07.96
Triebwelle abdichten Reparaturanleitung A2F/6.1

Sealing of the drive shaft Repair Instructions A2F/6.1
10 Neuen Wellendichtring lagerichtig mit passender

Bchse einpressen.
Press in the shaft seal ring to the correCt position

with a suitable sleeve.
11 Bei tiefer Laufrille beiliegende Scheibe vor den

Wellendichtring einlegen.
If the shaft is deeply grooved, insert shim

behind seal.
12 Neuen O-Ring einlegen, auf bndiges Anliegen

achten. O-Ring sowie Dicht- und Staublippe des
wellendichtringes einfetten.
Fit new O-ring, ensure it is a snug rit. Grease

O-ring and lips or shaft seal.
13 Sicherungsring mit Durchschlag einsprengen.
Fit circlip using a punch.
14 Sitzkontrolle des Sicherungsringes in der Nut.
Check that circlip is well seated.
RDE 91001-01-R/07.96
Anschluplatte abdichten Reparaturanleitung A2F/6.1

Sealing of the cover plate Repair Instructions A2F/6.1
15 Lage der Anschluplatte zum Gehuse kennzeichnen

(Pfeil), Befestigungsschrauben lsen.
Mark position of cover plate (arrowed). Remove screws.
16 Anschluplatte um Verdrillstift schwenken (1)

und abheben (2).
Swivel port plate on locating pin and lift off.
17 Auf Montagestellung des Verdrillstiftes achten (Pfeile).
Note position of locating pin. (arrow).
18 Pumpe, Drehrichtung rechts. (Blick auf sphrische Flche.)
Pump, clockwise rotation. (viewed on spherical surface.)
19 Pumpe, Drehrichtung links. (Blick auf sphrische Flche.)
Pump, anti-clockwise rotation. (viewed on spherical

surface.)
RDE 91001-01-R/07.96
Anschluplatte abdichten Reparaturanleitung A2F/6.1

Sealing of the cover plate Repair Instructions A2F/6.1
20 Motor, beide Drehrichtungen. (Blick auf sphrische Flche.)
Motor, bi-directional. (Viewed on spherical surface.)
21 Sichtkontrolle
O-Ring (1), Einstich (2), Platte (3).
Visual check
O-ring (1), Groove (2), Plate (3).
22 Neuen O-Ring einlegen, zuvor leicht einfetten.
Lightly grease and fit O-ring.
23 Anschluplatte aufsetzen, auf Kennzeichnung

(Bild 15) und Lage des Verdrillstiftes achten (18-20).
Assemble port plate to original mark (15), noting

position of port plate (18-20).
See notes fitting control plate.
24 Befestigungsschrauben mit Drehmomentenschlssel

anziehen. Momente Seite 16.
Tighten screws using torque wrench. See page 16

for setting.
RDE 91001-01-R/07.96
Triebwerk ausbauen Reparaturanleitung A2F/6.1

Removal the rotary group Repair Instructions A2F/6.1
25 Demontage der Anschluplatte (Seite 8). Steuerplatte

drehend abheben.
Remove cover plate (page 8). Rotate control

plate to remove.
26 Demontage des Verschluringes (Seite 6, 7).
Remove front cover (page 6, 7).
27 Pascheibe(n) entnehmen.
Remove shim(s).
28 Triebwerk mit Vorrichtung ausbauen. Vorrichtung Bild 54.
Remove rotary group with extractor. (See fig.54).
29 Rckzugplatte demontieren, Schrauben sind eingeklebt.

Hinweis: Schrauben erwrmen.
Remove retaining plate. The screws are held by Loctite.

Note: Warm up screws.
RDE 91001-01-R/07.96
berprfungshinweise Reparaturanleitung A2F/6.1

Examination notes Repair Instructions A2F/6.1
30 Triebwelle
1. kein Passungsrost, nicht ausgeschlagen.
2. keine Einlaufspuren, riefenfrei (Bild 11).
3. Kalotten riefenfrei und keine Pittings.
Drive shaft
1. Free of corrosion or erosion, no damage to
splines or keyway.
2. No trace of wear, free of scratches (p. 11).
3. Cups free of scratches and no pittings.
31 1. Axiales Kolbenspiel
2. Bundhhe.
1. Axial play of piston.

2. Spigot.
32 Kolben
Riefenfrei, keine Pittings (nicht demontieren, schrg stellen).
Piston
Free of scratches, no pitting (do not dismantle - tilt).
33 Mittelzapfen
1. Riefenfrei, ohne Pittings (nicht demontieren, schrg stellen).
2. Riefenfrei.
Center pin
1. Free of scratches, no pittings (do not dismantle - tilt).
2. Free of scratches.
34 Rckzugplatte
Riefenfrei, keine Ausbrche.
Retaining plate
Free of scratches, no wear.
RDE 91001-01-R/07.96
berprfungshinweise Reparaturanleitung A2F/6.1

Examination notes Repair Instructions A2F/6.1
35 Zylinder/Steuerplatte
1. Bohrungen riefenfrei, nicht ausgelaufen.
2. Gleichmiges Tragbild, ri- und riefenfrei.
3. Mindesthrte 700 HV 10.
Cylinder block / Control plate

1. Bores unscratched, and not worn.
2. Faces, smooth and even, no cracks or
scratches.
3. Min. hardness 700 HV 10.
36 Gehuse
Im Lagerbereich riefenfrei und keine Einlaufspuren.
Housing
No damage or wear where bearings fit.
37 Nur kompletten Kolbensatz austauschen.
Only exchange piston as a complete set.
38 Zylinder und Steuerplatte nur gemeinsam austauschen.
Exchange cylinder block and control plate as a pair.
39 Mittelzapfen einsetzen, Beilagscheibe auflegen.

Rckzugplatte seitenrichtig auflegen.
Insert center pin with retaining ring.

Correctly fit retaining plate.
RDE 91001-01-R/07.96
Triebwerk einbauen Reparaturanleitung A2F/6.1

Installing rotary group Repair Instructions A2F/6.1
40 Schrauben mit Precote-Beschichtung verwenden.
Mit Kolben Rckzugplatte ausrichten.
Use screws with Precote-coating.
Fit retaining plate correctly with pistons.
41 Federteller und Tellerfedern einlegen, Teile reichlich einfetten.

Montagehilfe: Schraubendreher.
Heavily grease and fit spring pad and Belleville washers

(using screwdriver).
42 Auf richtige Schichtung aller Teile achten!

Make sure all parts are fitted in correctly !
Hinweis / Note:
A2F0 - Pumpe - 4 Tellerfedern / Federteller
A2FO - Pump - 4 Belleville washers /
Spring pad
A2FM - Motor - 6 Tellerfedern / Federteller

A2FM - Motor - 6 Belleville washers /
Spring pad
43 Kolben in Bohrung stecken.
Fit pistons in bores.
44 Bei 0-Grad-Schwenkwinkel Kolbenkugel krftig in

Kalotte drcken.
Press pistons firmly into cups with cylinder

block held in central position.
RDE 91001-01-R/07.96

45 Triebwerk max. ausschwenken. Bei Hemmung: Bild 44.
Swivel cylinder block to max. It fouling occurs fig. 44.
46 Neuer Radialwellendichtring montiert? (Vergleiche Bild 11).
Is new shaft seal fitted? (comparisons fig 11).
47 Gehuse auf ca. 80o C erwrmen.
Heat the housing to 80o C.
48 Heies Gehuse bis zum Anschlag aufsetzen.
Fit pre-heated housing up to stop.
49 Neue Montagestellung
Re-position.
RDE 91001-01-R/07.96

50 Pascheiben beilegen und weitere Montage ent-

sprechend Bild 11 - 14.
Insert shims and assemble to figs. 11 - 14.
51 Triebwerk gegen Verschluring ziehen. Kontrolle:

Verschluring spielfrei.
Pull the rotary group against the cover plate.

Check that the cover plate cannot move!
52 Fertigmontage entsprechend Bild 22 - 24.
Abstimmung Pos. D - siehe Serviceinfo
Completely assemble to figs. 22 - 24.
Adjustment of Pos. D - see service info
53 Anschlsse mit Staubschutz abdichten.

Korrosionsschutz (innen/auen). Fertig!
Seal connections to protect against dust.

Corrosion proctection (internal/external).
Assembly complete.
54 Ausziehvorrichtung fr Triebwerk (Bild 24).
Extractor for rotary group (Fig. 24).
RDE 91001-01-R/07.96
Anziehdrehmomente Reparaturanleitung A2F/6.1

Tightening torques Repair Instructions A2F/6.1
Anziehdrehmomente fr Schaftschrauben Tightening torques for shaft bolts

(Metrisches ISO-Regelgewinde) (Metric ISO Standard Thread)
Festigkeitsklassen Strength Classes
Die nebenstehenden Werte fr An- The values for tightening torques
Gewinde 8.8 10.9 12.9 Thread 8.8 10.9 12.9
ziehdrehmomente gelten nur fr shown in the table are valid only for
gre Anziehdrehmoment(Nm) size Tightening Torque (lb.ft)
Schaftschrauben mit metrischem ISO- shaft bolts with metric ISO- standard
M3 1,1 1,6 1,9 M3 0,8 1,2 1,4
Regelgewinde und Kopfauflagemaen threads and head support surface
M4 2,9 4,1 4,9 M4 2,1 3,0 3,6
nach DIN 912, DIN 931 und DIN 933. dimensions in accordance with DIN
M5 6 8,5 10 912, DIN 931 and DIN 933. These M5 4,4 6,3 7,4
Auerdem gelten diese Werte nur fr
leicht oder nicht gelte, unbehandelte M6 10 14 17 values are also valid only for light or M6 7,4 10,3 12,5
Oberflchen, sowie nur bei Verwen- M8 25 96 41 unoiled, untreated surface as well as M8 18,4 25,8 30,2
dung von Drehmoment- und Kraftbe- M10 49 69 83 for use only with torque-indicating M10 36,1 50,9 61,2
grenzungsschlsseln. M12 86 120 145 wrenches and force limiting tools. M12 63,4 88,4 106,9
M14 135 190 230 M14 99,5 140,0 169,5
M16 210 295 355 M16 154,8 217,4 261,6
M18 290 405 485 M18 213,7 298,5 357,4
M 20 410 580 690 M 20 302,2 427,5 508,5
M 22 550 780 930 M 22 405,4 574,9 685,4
M 24 710 1000 1200 M 24 523,5 737,0 884,4
M 27 1050 1500 1800 M 27 773,9 1105,5 1326,6
M 30 1450 2000 2400 M 30 1068,7 1474,0 1768,8
Anziehdrehmomente fr Verschluschrauben VSTI Tightening torques for locking screws VSTI

(Metrisches Feingewinde) (Metric ISO fine thread)
Gewindegre Bezeichnung Anziehdrehmoment(Nm) Thread size Designation Tightening torques (lb.ft)
M8x1 VSTI 8 x 1 -ED/SA =5 M8x1 VSTI 8 x 1 -ED/SA =4
M 10 x 1 VSTI 10 x1 -ED = 10 M 10 x 1 VSTI 10 x1 -ED =7
M 12 x 1,5 VSTI 12 x 1,5 -ED = 20 M 12 x 1,5 VSTI 12 x 1,5 -ED = 15
M 16 x 1,5 VSTI 16 x 1,5 -ED/SA = 30 M 16 x 1,5 VSTI 16 x 1,5 -ED/SA = 22
M 27 x 2 VSTI 27 x 2 -ED = 90 M 27 x 2 VSTI 27 x 2 -ED = 66
M 30 x 1 ,5 VSTI 30 x 1,5 -ED/SA = 100 M 30 x 1 ,5 VSTI 30 x 1,5 -ED/SA = 74
M 33 x 2 VSTI 33 x 2 -ED/SA = 120 M 33 x 2 VSTI 33 x 2 -ED/SA = 88
M 42 x 2 VSTI 42 x 2 -ED/SA = 200 M 42 x 2 VSTI 42 x 2 -ED/SA = 147
M 48 x 2 VSTI 48 x 2 -ED = 300 M 48 x 2 VSTI 48 x 2 -ED = 220
Anziehdrehmomente fr Seal-Lock Bundmuttern Tightening torques for seal-lock nuts

(Metrisches ISO-Regelgewinde) (Metric ISO-Standard Thread)
Festigkeitsklassen Strength classes
Die nebenstehenden Werte fr An- Gewinde 8.8 10.9 12.9 The values for tightening torques Thread 8.8 10.9 12.9
ziehdrehmomente gelten nur fr Seal- gre Anziehdrehmoment (Nm) shown in the table are valid only for size Tightening torque (lb.ft)
Lock Bundmuttern der Festigkeits- M6 10 seal-lock nuts of the strength class 8.8 M6 7,4
klasse 8.8 mit metrischem ISO-Regel- and with metric ISO-standard thread.
M8 22 M8 16,2
gewinde.
M 10 40 M 10 29,5
M 12 69 M 12 50,9
M 14 110 M 14 81,1
M 16 170 M 16 125,3
Anziehdrehmomente fr Linsenschrauben mit Kreuz- Tightening torques for cross-slotted lens head screws
schlitz DIN 7985 DIN 7985
(Metrisches ISO-Regelgewinde) (Metric ISO- Standard Thread)
Festigkeitsklassen Strength classes
Die nebenstehenden Werte fr An- The values for tightening torques
Gewinde 8.8 10.9 12.9 Thread 8.8 10.9 12.9
ziehdrehmomente gelten nur fr Lin- shown in the table are valid only for
gre Anziehdrehmoment(Nm) size Tightening torques (lb.ft)
senschrauben mit Kreuzschlitz DIN cross-slotted lens head screws DIN
M3 1,1 M3 0,8
7985 der Festigkeitsklasse 8.8 mit 7985 of the strength class 8.8 and with
M4 2,9 M4 2,1
metrischem ISO-Regelgewinde metric ISO-standard thread.
M5 6 M5 4,4
M6 10 M6 7,4
M8 25 M8 18,4
M10 49 M10 36,1
RDE 91001-01-R/07.96
Sicherheitsbestimmungen Reparaturanleitung A2F/6.1

Safety regulations Repair Instructions A2F/6.1
Allgemein General advice
Machen Sie sich mit der Ausstattung der Maschine Make yourself familiar with the equipment of the
vertraut. machine.
Fahren Sie die Maschine nur, wenn Sie sich vllig Only operate the machine if your are completely
mit den Bedien- und Steuerelementen sowie der familiar with the operating and control elements as
Arbeitsweise der Maschine vertraut gemacht haben. well as the functioning of the machine.
Benutzen Sie Ihre Schutzausrstung wie Use your safety equipment like helmet, safety shoes
Schutzhelm, Sicherheitsschuhe und Gehrschutz. and hearing protection.
Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. Make yourself familiar with your working field.
Benutzen Sie die Maschine nur fr den ihr zuge- Only operate the machine for its intended purpose.
dachten Zweck.
Beachten Sie bitte die Richtlinien der Berufsge- Please observe the guidelines of the Professional
nossenschaft und des Maschinenherstellers Association and the machine manufacturer.
Vor dem Start Before starting
Beachten Sie die Bedienungshinweise vor dem Observe the operating instructions before starting.
Starten. Check the machine for remarkable faults.
Prfen Sie die Maschine aut auffllige Fehler. Do not operate the machine with defective
Fahren Sie die Maschine nicht mit defekten instruments, warning lights or control elements.
Instrumenten, Kontrolleuchten oder Steuerorganen. All safety devices must be in a secure position.
Alle Schutzvorrichtungen mssen fest auf ihrem Do not carry with you movable objects or secure
Platz sein. them to the machine.
Nehmen Sie keine losen Gegenstnde mit bzw. Keep oily and inflammable material away from the
befestigen Sie diese an der Maschine. machine.
Halten Sie die Maschine von ligem und znd- Before entering thc drivers cabin, check if persons
fhigem Material frei. or obstacles are beside or beneath the machine.
Prfen Sie vor dem Besteigen der Maschine, ob Be careful when entering the drivers cabin, use
sich Personen oder Hindernisse neben oder unter stairs and handles.
der Maschine befinden. Adjust your seat before starting.
Vorsicht beim Besteigen der Maschine, bentzen
Sie Treppen und Griffe.
Stellen Sie vor dem Start Ihren Sitz ein.
RDE 91001-01-R/07.96
Sicherheitsbestimmungen Reparaturanleitung A2F/6.1

Safety regulations Repair Instructions A2F/6.1
Starten Start
Beim Starten mssen alle Bedienhebel in Neutral- When starting all operating levers must be in
stellung stehen. neutral position.
Die Maschine nur vom Fahrersitz aus Starten. Only start the machine from the drivers seat
Prfen Sie die Anzeigeinstrumente nach dem Start, Check the indicating instruments after start to
um sicher zu gehen, da alles ordnungsgem assure that all functions are in order.
funktioniert. Do not leave the machine unobserved when the
Lassen Sie die Maschine nicht unbewacht, whrend motor is running.
der Motor luft. When starting with battery connection cables
Beim Start mit Batterieverbindungskabeln verbinden connect plus with plus and minus with minus.
Sie Plus mit Plus und Minus mit Minus. Massekabel Always connect mass cable (minus) at last and cut
(Minus) immer zuletzt anschliesen und zuerst ab- off at first.
trennen.
Vorsicht Attention
Auspuffgase sind lebensgefhrlich. Bei Start in Exhaust gas is dangerous. Assure sufficient fresh
geschlossenen Rumen fr ausreichende Luftzufuhr air when starting in closed rooms!
sorgen!
Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high
Unter hohem Druck austretende Hochdruck- pressure.
Flssigkeiten (Kraftstoff, Hydraulikl) knnen High pressure fluids (fuel, hydraulic oil) which
die Haut durchdringen und schwere Ver- escape under high pressure can penetrate the
letzungen verursachen. Daher sofort einen skin and cause heavy injuries.
Arzt aufsuchen, da anderenfalls schwere Therefore immediately consult a doctor as
Infektionen entstehen knnen! otherwise heavy infections can be caused.
2. Bei der Suche nach Leckstellen wegen Ver 2. When searching leakages use appropriate auxiliary
letzungsgefahr geeignete Hilfsmittel verwenden! devices because of the danger of accidents.
3. Vor Arbeiten an der Hydraulikanlage diese un- 3. Before working at the hydraulic equipment, lower
bedingt drucklos machen und angebaute Gerte pressure to zero and lower working arms of the
absenken! rnachine.
4. Bei Arbeiten an der Hydraulikanlage unbedingt 4. When working at the hydraulic equipment,
Motor abstellen und Traktor gegen Wegrollen absolutely
sichern (Feststellbremse, Unterlegkeil)! stop motor and secure tractor against rolling away
5. Beim Anschlieen von Hydraulikzylindern und (parking brake, shim)!
-motoren ist auf vorgeschriebenen Anschlu der 5. When connecting hydraulic cylinders and motor pay
Hydraulikschluche zu achten! attention to correct connection of hydraulic flexible
6. Bei Vertauschen der Anschlsse umgekehrte hoses.
Funktionen (z.B. Heben/Senken) - Unfallgefahr! 6. In case of exchanging the ports, the tunctions are
7. Hydraulikschlauchleitungen regelmig kontrol- vice versa (f. ex. lift-up/lower) - danger of accidents!
lieren und bei Beschdigung und Alterung aus- 7. Check hydraulic flexible hoses regularly and replace
tauschen! Die Austauschschlauchleitungen ms- them in case of dammage or wear! The new hose
sen den technischen Anforderungen des Gerte- pipes must comply with the technical requirements
herstellers entsprechen! of the machine manufacturer!
le, Kraftstoffe und Filter ordnungsgem Orderly disposal or recycling of oil, fuel and
entsorgen! filters!
RDE 91001-01-R/07.96
Reparaturanleitung A2F/6.1
Repair Instructions A2F/6.1
RDE 91001-01-R/07.96
Reparaturanleitung A2F/6.1
Repair Instructions A2F/6.1
Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustrae 2, D-89275 Elchingen, Tel. (07308) 820, Telex 712538, Fax (07308) 7274
Multiple Disc
Brakes
Spring Apply Hydraulic

Release Multiple
Disc Brakes
Spring Apply, Hydraulic Release,
Multiple Disc Brakes
Introduction
Safe, sure controlled braking . . . precise con-
trol of swing booms or other vehicles and
equipment with swivel joints . . . positive load
positioning and run-away protection for
winches . . . virtual elimination of slippage in
hydraulic motors . . . These and
many other brake related
problems have been solved
by applying a superior,
quality built MICO Multiple
Disc Brake to the application.
MICO, Inc. began
operations on January
25, 1946. Since our
inception we have enjoyed
sure, steady growth and
have emerged as a leader in
our selected market areas, including
the area of Multiple Disc Brakes.
These precisely engineered brakes
are totally enclosed units applied by
built-in springs and "held off" by
hydraulic pressure. Maximum torque
is produced when hydraulic pressure
is absent, either intentionally or due
to system failure.
Many MICO brake designs have
features developed specifically to
solve problems encountered in other
brake designs . . . Such as piston
breakage, piston cocking, spring,
spline or bearing failure and low
torque and high torque pres-
sure drag.
Typical Multiple Disc Brake
applications include manlifts,
scissor lifts, swing booms,
low speed vehicles and equip-
ment used in farm harvesting.
Producing a top quality product and providing
unequalled service is what MICO customers
have come to expect . . . and that is what we
will continue to provide.
1
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Contents
Introduction . . . . . . . . . . . . . . . . . . . . . 1
Purpose of this Catalog . . . . . . . . . . . . . . 2
Purpose of MICO Advantages . . . . . . . . . . . . . . . . . 3

Multiple Disc Brake Applications . . . . . . . . . . 4
this catalog Order Number Explanation . . . . . . . . . . . . . 5
General Brake Information . . . . . . . . . . . . . 6
This catalog is designed to introduce
you to a selection of MICO Multiple MICO Multiple Disc Brakes
Disc Brakes. Each section includes (modular) Introduction . . . . . . . . . . . . . . . 7
features, specifications, dimensional SAE A - Mount . . . . . . . . . . . . . . . . 9
drawings and order information. SAE C - Mount . . . . . . . . . . . . . . . 11
The order information describes SAE D - Mount . . . . . . . . . . . . . . . 13
mounting, shaft, torque and available MICO Multiple Disc Brakes
options. The order information sys- (narrow) Introduction . . . . . . . . . . . . . . . 15
tem offers considerable versatility
SAE B - Mount . . . . . . . . . . . . . . . 17
and flexibility, enabling you to select
the product for your specific applica- MICO Multiple Disc Brakes
tion. To assist you in your selection, (gold series) Introduction . . . . . . . . . . . . . 19
we strongly recommend that you SAE B - Mount. . . . . . . . . . . . . . . . 21
complete the proper data sheet found
in the back of this catalog and mail or "Top Hat" Thru-Shaft Motor Brakes . . . . . . . . 23
fax it to your inside sales contact at
MICO West. The Engineering Posi-Torque Winch Brakes
Department will analyze your require- Introduction . . . . . . . . . . . . . . . . . . . . 24
ments and recommend the product SAE C - Mount . . . . . . . . . . . . . . . 25
best suited to your needs.
Pressure Override Brakes
Also included in this catalog are engi- SAE B - Mount. . . . . . . . . . . . . . . . 27
neering design considerations for SAE C - Mount . . . . . . . . . . . . . . . 29
Multiple Disc Brake applications.
Large Wheel Mount Brakes
Minimum quantity orders apply to (motor input) . . . . . . . . . . . . . . . . . 31
some brake combinations. All possi-
(closed input) . . . . . . . . . . . . . . . . 33
ble brake combinations are not
currently in production. Contact Mini Wheel Mount Brakes
MICO West for the availability of (closed input) . . . . . . . . . . . . . . . . 35
special brakes.
Repair Kit Cross Reference . . . . . . . . . . . . 37
We hope you will find this catalog to
be a useful reference manual as well Multiple Disc Brake Data Sheets
as a product catalog. For Winch or Holding Type
Applications Only . . . . . . . . . . . . . . 42
For Vehicle Parking or Emergency
Stop Applications Only . . . . . . . . . . . 44
For Service Braking or Pressure
Override Brakes Only . . . . . . . . . . . . 46
Limited Warranty . . . . . . . . . . . . . . . . . 50
2
Representation and
Service
In addition to the numerous design
improvements over competitive
models, you also get MICO repre-
Advantages
sentation and service which is sec-
ond to none.
Direct Access to MICO

Engineers
Involving the customer directly in
product design and testing insures Interchangeable with
that customer requirements are
met. Our engineering staff has a
Other Fail-safe Type
very strong background in spring Brakes
apply, hydraulically released MICO Multiple Disc Brakes are in-
brakes. As new technology be- terchangeable with other fail-safe
comes available, it is integrated type brakes using SAE and industry
into MICO products and when tech-
nology is not available, MICO
Engineers develop it.
standards as a guide. In most
cases engineering changes are not
required, therefore, these brakes
Quality &
Simplified Disassembly
are economical to use.
Reliability
and Assembly
Features such as inboard oil seal,
Unique Balanced
Piston Design
equal fewer
one piece piston separators, longer
torque pins and modular design
Some models feature a piston
design that virtually eliminates
field
concepts on many models help to
simplify disassembly and assembly
procedures.
areas of localized stress by more
uniformly distributing the pressure
generated load.
problems.
Large Diameter Discs
Larger disc diameters on many
models give MICO Brakes higher
torque, better heat dissipation and
fewer operating parts.
Extensive Testing
Testing on MICO Multiple Disc
Brakes include high pressure cycle,
temperature, horizontal and vertical
mount heat generation, spring life
and performance, static torque, dy-
namic torque and leak testing.
Compact Modular
Designs
Compact modular designs reduce
problems encountered in many
installations. Most models can be
installed into restricted space with
little or no additional adjustment,
alignment or special brackets.
3
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Multiple Disc Brakes
(Spring apply, hydraulic release)
MICO engineers are innovators in the design handling, agriculture, mining, sanitation,
of spring apply, hydraulic release multiple disc utilities and timber industries. They are also
brakes, wheel brakes, thru-shaft brakes, used in a multitude of winching applications.
posi-torque winch brakes and more. These Brakes of this type reduce maintenance and
engineers are committed to improving the downtime by preventing contaminants, which
product while reducing cost. Simple, straight cause brake lining wear, from entering the
forward designs result in rugged brake brake. They will provide consistent braking
products. These products require less mainte- torque, positive hold, and long life in rugged
nance because they are designed with fewer environments.
moving parts. They are truly superior in
reliability and performance.
MICO Multiple Disc Brakes are designed for
use with heavy duty machinery and off-
highway vehicles in the construction, material
Typical
Multiple Hydraulic Motor
Disc Brake MICO Multiple

Disc Brake
Gear
Reducer
Driven Load
(winch)
Applications
Hydraulic
Motor
MICO Multiple
Disc Brake
Boom
Gear Reducer
Bull
Pinion Gear Gear
MICO Multiple Chain

Disc Brake Sprocket
Hydraulic Motor
Hydraulic Motor
MICO Multiple Overhung

Disc Wheel Brake Load Adaptor
4
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The catalog code numbering system allows you to construct
the brake or other product by combining the variables that meet
Order your needs. Catalog code number example: 3A-101025-M.

A production number will be assigned by our Engineering Depart-
ment upon receipt of your order. Production order number
Number example: 13-538-196.
Explanation NOTE
For brake combinations that are not currently established, but
possible, quotation and assignment of part number must be
predicated by receipt, review, and acceptance of applicable
multiple disc brake data sheet.
Data sheets can be found in the back of this catalog or on our

web site (www.mico.com). Any combination you are unsure of,
please call MICO West. Our Engineering Department will analyze
your data and recommend the best MICO product for your appli-
cation. All data submitted will remain confidential.
Options Explanation
Z = OIL COOLED OPTION, noted as suffix Z, allows S = SPEED SENSOR OPTION, noted as suffix S,
flow-through or sump oil cooling for brakes which may allows a customer supplied magnetic pick up to simply
be required to handle limited dynamic inputs. Wet screw into the brake housing. The magnetic pick up
brakes are also used in applications where the package generates a fixed frequency of pulses per revolution.
is exposed to severe duty or to adverse environmental
conditions such as marine winches or mining vehicles. Specifications
Products that are to be used strictly wet are noted as Direct mounting of Flow-Tech or Motorola Tach
such. Oils containing slippery or antiwear additives, Drive Pickup
such as graphite or molybdenum disulfide or extreme Speed sensing range 0 - 4000 rpm
pressure (EP) type lubricants, may allow the brake to
slip at torque levels below the rated values. Speed sensor ports - 3/8-18 straight pipe or
3/4-16UNF (other sizes available upon request,
Specifications (Modular Design) consult MICO West)
Flow thru - 3.8 L/min (1.0 gpm) to a maximum of Contact MICO West for location of sensor port
26.5 L/min (7.0 gpm) Notched teeth available:
Case pressure should not exceed 1.03 bar (15 psi) C-Mount Modular: 11, 15, 18, 40, 55 & 70
Inlet ports - SAE No. 6, 9/16-18 o-ring boss B-Mount Narrow: 40 & 70
Outlet ports - SAE No. 6, 9/16-18 o-ring boss
Location of inlet and outlet ports are shown on each
individual drawing D = DOUBLE BEARING OPTION, is recommended
For sump oil cooling fluid volumes refer to individual only for special instances. In applications involving
overhung loads, such as a sprocket or drum, a double
model order information
bearing brake usually lacks the load capacity required.
Brakes are shipped dry and customer is responsible In these instances the use of a load adaptor is recom-
for adding proper type and volume of cooling oil mended.
5
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General Brake Information
1. Brake torque values listed are dry static torque
ratings except for the C-Mount Modular
Posi-torque Brakes (page 25).
a. For brakes with Z option (oil-cooled) actual
torque is 67% of the dry torque listed.
b. Static torque may vary 10% from specified
values.
2. Initial release pressure is the amount of pres-
sure required to just relieve the spring force on
the rotor stack. Zero torque with no running
clearance.
3. Full release pressure is the amount of pressure
required to achieve full running clearance of rotor
stack.
4. Maximum continuous pressure is 206.8 bar
(3000 psi) unless otherwise specified.
5. All splined shafts are 30 degree involute, flat root,
side fit per ANSI B92.1-1970 specifications unless
otherwise specified.
6. All mounting flange dimensions conform to SAE
Standard J744 JUL88 unless otherwise specified.
7. Standard piston o-rings are (Buna N) com-
patible with mineral based hydraulic fluids.
For applications with non-mineral based
fluids or extreme temperatures, other o-ring
materials are available.
8. Brakes include mounting face gaskets
and/or o-rings. Some motors and gear-
boxes allow for the use of o-rings to
seal the mounting faces on either
side of the brake. Do not use the
o-ring and face gasket together to
seal a mounting face.
9. When mounting a brake use SAE Grade 5
or better bolts. Tighten to appropriate torque
specifications for grade used.
A. If hydrostatic bench testing is performed on a brake assembly, release pressure

must not exceed 68.9 bar (1000 psi) unless additional mounting bolts are used
for supplemental clamping.
B. Pressures above 206.8 bar (3000 psi) caused by spikes in the hydraulic system
can shorten brake life and must be avoided.
C. Most brakes are designed for limited side load capability at output end. Use of
an overhung load adaptor is recommended for most applications. Contact MICO
West for further information.
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6
Multiple
Disc Brakes
(modular) Cover, Spring Plate and Pressure Plate
constructed of heavy duty ductile iron.
Features
Large diameter spline shafts virtually
eliminate spline battering
Versatile modular design
Spring loaded, hydraulically released
Powerful Chrome Silicon Die Springs
Sealed environment - isolation from automatically apply the brakes disc packs
contaminants when hydraulic pressure drops.
Nitrile case seals

High strength ductile iron construction
Standard SAE mounting flanges
Benefits
Eliminates problems found in competi-
tive brake designs, such as piston
breakage, piston cocking, spring failure,
bearing failure and low and high torque
pressure drag
Designed primarily for use on hydraulic
drive systems, can replace most fail-
safe type brakes in use today, and do it
economically
Engineering changes to replace fail-
safe designs are not required in most
cases
Balanced Piston Design
virtually eliminates areas of localized
Operation stress by uniformly distributing the pres-
MICO Modular Multiple Disc Brakes are spring sure generated load.
apply, hydraulic release brakes. Powerful chrome-
silicon die springs automatically apply the brakes
disc pack when hydraulic pressure drops, giving
safe, sure braking.
7
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Increased Bearing Support improves
shaft alignment between motor, brake
and driven load.
Spline Shafts are constructed of high

quality, heat treated 8620 steel for high
strength and long life. Larger pitch di-
ameter splines for shaft to disc interface
give, in many cases, a seven to one ad-
vantage in strength. Improved lower
tooth loading helps to eliminate spline
battering.
Inboard Oil Seal allows for gear box

lubrication of the bearing.
Friction Discs use sintered metallic

linings and 1050 steel core material for
long life. Large disc diameters are pos-
sible because the balanced piston design
has the actuating spring and piston all on
one side. Location of the torque and ten-
sion pins also permits use of the larger
discs. With a greater mean radius, the
Modular Brake develops more retarding
torque, better heat dissipation and re-
quires fewer parts than comparably sized
units. Thinner rotor material is possible
with larger spline shafts.
8
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A-Mount
Modular Brakes
FEATURES
Low release pressures - ideal for use with Heat treated 8620 shafts for high strength
closed-loop hydrostatic systems and long life
Rugged heavy duty construction with Unique balanced piston design
torques to 1017 N-m (9000 lb-in)
TYPICAL MODEL SHOWN For detailed information on other models, contact MICO West 13-538-008
(3A-060640-M)
millimeters
inches
INPUT END
OUTPUT FACE
SPECIFICATIONS
Torque range at 0 bar (0 psi) Maximum speed . . . . . . . . . . . . . . . . . . . . . . 4000 rpm
back pressure. . . . . . . . . . . . . . . . . . . 203 - 1017 N-m Approximate weight . . . . . . . . . . . . . . . . . . . 11 kg (24 lb)
(1800 - 9000 lb-in) Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil
Release pressure range . . . . . . . . 8.3 - 26.9 bar (120 - 390 psi)
Maximum operating pressure. . . . . . . . . . . 207 bar (3000 psi)
Maximum energy input . . . . . . . . . 216,960 joule (160,000 ft-lb)
(one stop, no damage)
Volume of oil to release brake . . . . . . . . . . . 8.2 cm3 (0.5 in3)
Maximum operating temperature . . . . . . . . . . 132 C (270 F)
9
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ORDER INFORMATION
Not all of the brake combinations are possible due to certain design limitations.
(See NOTE on the top of page 5)
NOTE: Dry design only, not for wet applications.
3
OUTPUT FACE OPTIONS

3A - SAE A-Mount (Available separately or
2-Bolt in combination)
3M - 4-Bolt A-Mount D - Double Bearing
S - Speed Sensor
OUTPUT SPLINE / INPUT SPLINE
06/06 SAE Designation INPUT FACE
10/10 06 = 25.4 mm (1.00") Dia. 6B M - 4-Bolt and SAE
14/14 10 = 25.4 mm (1.00") Dia. Keyed A-Mount 2-Bolt
25/25 14 = 14T 12/24
25 = 31.8 mm (1.25") Dia. Keyed TORQUE
Other configurations consult MICO West. Initial Full
Torque
Code Release Release
Rating
Pressure Pressure
N-m (lb-in) bar (psi) bar (psi)
90 * 1017 (9000) 22.8 (330) 26.9 (390)
70 * 791 (7000) 17.2 (250) 20.7 (300)
56 * 633 (5600) 14.5 (210) 17.2 (250)
48 * 542 (4800) 11.7 (170) 13.8 (200)
40 452 (4000) 14.5 (210) 17.2 (250)
39 441 (3900) 10.3 (150) 12.4 (180)
35 396 (3500) 11.7 (170) 13.8 (200)
34 384 (3400) 9.0 (130) 10.3 (150)
29 328 (2900) 10.3 (150) 12.4 (180)
25 283 (2500) 9.0 (130) 10.3 (150)
24 271 (2400) 6.9 (100) 8.3 (120)
18 203 (1800) 6.9 (100) 8.3 (120)
* For use with input and output spline codes 14 and 25 only.
Models available with speed sensor port.
Mounting Instructions
Install cover/shaft assembly on gearbox using either
two or four 1/2-13UNC x 1.00" long socket head cap INPUT FACE
screws (not included), depending on brake model
being used. See Mounting Instructions (Form No.
81-538-002) packed with each brake.
M - 4-Bolt and SAE A-Mount 2-Bolt

CATALOG PRODUCTION CATALOG PRODUCTION
CODE ORDER CODE ORDER
NUMBER NUMBER NUMBER NUMBER
3A-060618-M 13-538-004 3A-141418-M 13-538-016 CATALOG PRODUCTION CATALOG PRODUCTION
3A-060624-M 13-538-052 3A-141424-M 13-538-036 CODE ORDER CODE ORDER
3A-060625-M 13-538-230 3A-141435-M 13-538-384
3A-252535-M 13-538-370 3M-141470-M 13-538-236
3A-060629-M 13-538-054 3A-141439-M 13-538-050 3A-252540-M 13-538-242 3M-141470-MD 13-538-202
3A-060639-M 13-538-058 3A-141448-M 13-538-300 3A-252548-M 13-538-272 3M-141490-M 13-538-038
3A-060635-M 13-538-006 3A-141456-M 13-538-056
3A-252556-M 13-538-028 3M-252529-M 13-538-318
3A-060640-M 13-538-008 3A-141470-M 13-538-290 3A-252590-M 13-538-060 3M-252535-M 13-538-182
3A-060656-M 13-538-232 3A-141490-M 13-538-320 3M-060625-M 13-538-244 3M-252540-M 13-538-042
3A-100625-M 13-538-294 3A-141490-MD 13-538-034
3M-060640-M 13-538-064 3M-252556-M 13-538-382
3A-100640-M 13-538-044 3A-250625-M 13-538-200 3M-101040-M 13-538-040 3M-252590-M 13-538-048
3A-101018-M 13-538-010 3A-250629-M 13-538-030 3M-141440-M 13-538-020
3A-101025-M 13-538-196 3A-252518-M 13-538-178
3M-141440-MD 13-538-032
3A-101029-M 13-538-024 3A-252524-M 13-538-376 3M-141448-M 13-538-046
3A-101035-M 13-538-026 3A-252525-M 13-538-022 3M-141456-M 13-538-234
3A-101040-M 13-538-012 3A-252529-M 13-538-274
10
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C-Mount
Modular Brakes
More retarding torque than competitive Heat treated 8620 shafts for high strength
models and long life
Numerous mounting configurations Compact modular package simplifies
available mounting
Low release pressures, ideal for use with Unique balanced piston design
closed-loop hydrostatic systems
Rugged heavy duty construction with
torques to 1356 N-m (12,000 lb-in)
(3C-141455-CZ)
INPUT END millimeters

inches
OUTPUT FACE
SPECIFICATIONS
Torque range at 0 bar (0 psi) Approximate weight . . . . . . . . . . . . . . . . . . . 18 kg (40 lb)
back pressure . . . . . . . 509 - 1356 N-m (4500 - 12,000 lb-in) Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil
Release pressure range . . . . . . . 10.3 - 21.4 bar (150 - 310 psi)
Maximum operating pressure. . . . . . . . . . . 207 bar (3000 psi)
Maximum speed . . . . . . . . . . . . . . . . . . . . . . 4000 rpm
Volume of oil
to release brake . . . . . . . . . . . . . . . . 16.4 cm3 (1.0 in3)
Maximum operating temperature . . . . . . . . . . 132 C ( 270 F)
Maximum energy input . . . . . . . . . 542,400 joule (400,000 ft-lb)
(one stop, no damage)
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ORDER INFORMATION (See NOTE on the top of page 5)
NOTE: On oil cooled models (Z option) actual torque is 67% of value shown on torque
code chart. Recommended sump oil fluid volume when mounted:
Horizontal - 118.3 mL (4 oz), Vertical - Contact MICO West
3 C
OUTPUT FACE OPTIONS

3C - SAE C-Mount (Available separately
4-Bolt or in combination)
D - Double Bearing
OUTPUT SPLINE / INPUT SPLINE Z - Oil Cooled - see note above
04 (internal)/14 SAE Designation S - Speed Sensor
14/00 00 = Used with "R" only
14/06 04 = 14T 12/24 INPUT FACE
14/13 06 = 25.4mm (1.00") Dia. 6B
C - SAE C-Mount 4-Bolt C2 - SAE C-Mount
13 = 13T 8/16 2-Bolt Thru
14/14 M - 4-Bolt and SAE
13 = 13T 16/32 C24 - 2-Bolt and
17/17 14 = 14T 12/24 A-Mount 2-Bolt
21/00 17 = 17T 12/24 R - Closed 4-Bolt
21/21 21 = 21T 16/32 B - SAE B-Mount 2-Bolt C-Mount
Other configurations consult MICO West. K4 - Eaton
Standard 4000
TORQUE
Initial Full
Torque
Rating
Pressure Pressure
98 1107 (9800) 14.5 (210) 20.0 (290)
85 960 (8500) 11.0 (160) 15.2 (220)
80 904 (8000) 12.4 (180) 17.2 (250)
70 791 (7000) 11.0 (160) 14.5 (210)
66 746 (6600) 9.0 (130) 12.4 (180)
55 622 (5500) 9.0 (130) 11.7 (170)
54 610 (5400) 7.6 (110) 11.0 (160)
45 508 (4500) 7.6 (110) 10.3 (150)
12 1356 (12,000) 14.5 (210) 21.4 (310)
10 1130 (10,000) 12.4 (180) 17.2 (250)
Other torques available on request.
ASSIGNED NUMBERS
CATALOG PRODUCTION CATALOG PRODUCTION CATALOG PRODUCTION CATALOG PRODUCTION
CODE ORDER CODE ORDER CODE ORDER CODE ORDER
NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER
3C-041412-C 13-547-282 3C-141412-CDZ 13-547-288 3C-141466-C24 13-547-358 3C-141498-MD 13-547-378
3C-041498-C 13-547-324 3C-141412-CZ 13-547-034 3C-141466-M 13-547-204 3C-171780-C 13-547-124
3C-140012-R 13-547-272 3C-141412-K4 13-547-296 3C-141466-MZ 13-547-226 3C-171785-C 13-547-278
3C-140098-R 13-547-268 3C-141412-K4Z 13-547-036 3C-141470-C 13-547-084 3C-171785-CZ 13-547-126
3C-140612-MZ 13-547-370 3C-141412-M 13-547-038 3C-141470-CZ 13-547-086 3C-171798-C 13-547-212
3C-140645-M 13-547-264 3C-141445-C 13-547-072 3C-141480-B 13-547-342 3C-212145-C 13-547-332
3C-140655-M 13-547-232 3C-141445-K4 13-547-384 3C-141480-C 13-547-090 3C-212166-C 13-547-130
3C-140655-MZ 13-547-006 3C-141445-M 13-547-352 3C-141480-C2 13-547-092 3C-212180-C 13-547-132
3C-140680-MD 13-547-210 3C-141445-C2 13-547-208 3C-141480-K4 13-547-094 3C-212180-CZ 13-547-170
3C-140685-M 13-547-246 3C-141445-CZ 13-547-362 3C-141480-K4Z 13-547-254 3C-212185-C 13-547-220
3C-140698-M 13-547-190 3C-141454-C 13-547-074 3C-141480-M 13-547-096 3C-212198-C 13-547-134
3C-141355-B 13-547-290 3C-141455-B 13-547-354 3C-141485-C 13-547-098
3C-141380-D 13-547-410 3C-141455-BZ 13-547-298 3C-141498-C 13-547-102
3C-141398-D 13-547-016 3C-141455-C 13-547-076 3C-141498-C2 13-547-104
3C-141410-CZ 13-547-024 3C-141455-CD 13-547-344 3C-141498-CS 13-547-106
3C-141410-K4 13-547-164 3C-141455-CZ 13-547-078 3C-141498-CZ 13-547-108
3C-141412-C 13-547-030 3C-141455-M 13-547-364 3C-141498-K4 13-547-110
3C-141412-CD 13-547-316 3C-141466-C 13-547-082 3C-141498-M 13-547-116
12
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D-Mount
Modular Brakes
FEATURES
Oil cooled or dry design applications Heat treated 8620 shafts for high strength
and long life
Simple four bolt mounting configuration
Low release pressures, ideal for use with Unique balanced piston design
Rugged heavy duty construction with
torques to 2712 N-m (24,000 lb-in)
(3D-131312-DZ)
INPUT FACE
millimeters OUTPUT END

inches
SPECIFICATIONS
Torque range at 0 bar (0 psi) Maximum energy input . . . . . . . . . 610,200 joule (450,000 ft-lb)
back pressure . . . . . . . 621 - 2712 N-m (5500 - 24,000 lb-in) (one stop, no damage)
Release pressure range . . . . . . . . 7.6 - 26.9 bar (110 - 470 psi) Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil
Maximum operating pressure. . . . . . . . . . . 207 bar (3000 psi) Maximum operating temperature . . . . . . . . . . 132 C (270 F)
Maximum speed . . . . . . . . . . . . . . . . . . . . . . 4000 rpm Approximate weight . . . . . . . . . . . . . . . . . . . 24 kg (52 lb)
Volume of oil
to release brake . . . . . . . . . . . . . . . . 16.4 cm3 (1.0 in3)
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Horizontal - 147.9 ml (5 oz), Vertical - Contact MICO, Inc.
3 D
OUTPUT FACE OPTIONS

3D - SAE D-Mount Z - Oil Cooled - see
4-Bolt note above
OUTPUT SPLINE / INPUT SPLINE INPUT FACE

13/13 SAE Designation D - SAE D-Mount
13/14 13 = 13T 8/16 C - SAE C-Mount
13/15 14 = 14T 12/24 E - SAE E-Mount
15 = 15T 8/16
75/75
75 = 44.5 mm (1.75") Dia. Keyed
TORQUE
Torque
Rating
Pressure Pressure
80 904 (8000) 9.0 (130) 11.7 (170)
55 621 (5500) 5.5 (80) 7.6 (110)
24 2712 (24,000) 22.8 (330) 32.4 (470)
20 2260 (20,000) 18.6 (270) 26.2 (380)
16 1808 (16,000) 14.5 (210) 20.7 (300)
12 1356 (12,000) 11.0 (160) 15.9 (230)
INPUT FACES 10 1130 (10,000) 10.3 (150) 13.8 (200)
C - SAE C-Mount E - SAE E-Mount D - SAE D-Mount
ASSIGNED NUMBERS
3D-131310-D 13-552-040 3D-131380-E 13-552-044
3D-131310-E 13-552-042 3D-131480-C 13-552-038
3D-131312-D 13-552-002 3D-131410-C 13-552-018
3D-131312-DZ 13-552-006 3D-131512-E 13-552-078
3D-131316-C 13-552-016 3D-131516-E 13-552-090
3D-131316-D 13-552-008 3D-131520-E 13-552-074
3D-131320-D 13-552-060 3D-757516-D 13-552-084
3D-131320-E 13-552-010
3D-131324-D 13-552-070
3D-131324-DZ 13-552-086
3D-131380-D 13-552-033
3D-131380-DZ 13-552-036
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Multiple
Disc Brakes
(narrow)
Features
Complete self-contained package
Standard SAE mounting flanges
Spring loaded, hydraulically released
High strength ductile iron construction Cover Bolts are high strength grade 8
flanged type which allow for higher brake
Sealed environment - isolation from release pressure shocks without subse-
contaminants quent cover bolt damage.
Benefits
Thick discs eliminate tooth wear-out
and brake "free wheeling," resulting in
longer life between parts replacement
Large inlet port helps avoid sluggish
response if air is entrapped in the oil
One piece separator design helps
eliminate breaking and bending mo-
ments on piston, resulting in minimal
loss because of good contact on plates
Longer dowel pins simplify assembly
and keep rotor in place, reducing risk of
shearing teeth from rotor
Operation
Braking using this version is provided by a pack
of rotating friction discs splined to the shaft and
stationary separator plates restrained by pins in
the housing. Force is transmitted to the disc pack O-ring and Back-up Ring combination
through the return plate by a series of preloaded on all models.
springs. The brakes are released by hydraulic
pressure applied to the piston to compress the
springs. They are self-applying since any function
which reduces the hydraulic pressure below the
release pressure will start to initiate a brake appli-
cation. Zero pressure produces maximum brake
torque.
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Housings are constructed of high quality Piston Separator design allows for
ductile iron castings for strength and du- easier disassembly and assembly. This
rability. one piece powdered metal design as op-
posed to a split piston design, helps
eliminate breaking and bending moments
on piston.
Chrome Silicon Die Springs provide

higher torque capabilities where space is
limited, resulting in longer service life.
Spline Shafts are constructed of high

quality, heat treated 8620 steel for high
strength and long life. The one piece pre-
cision ground spline shafts reduce vibra-
tion.
Rotary Shaft Seal at output end to pre-

vent oil and other contaminants from en-
tering brake.
Friction Discs use sintered metallic lin-

ings and high strength 1050 steel core
material for long life.
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B-Mount
"Narrow" Brakes
FEATURES
Complete self-contained dry design pack- Sintered bronze friction plates for high
age strength and long lining life
Standard SAE mounting flanges Sealed environment - isolation from
contaminants
High strength ductile iron castings for
strength and durability Optional pressure override models available
for limited service braking
(LMB-131321-B)
millimeters
inches
INPUT END
OUTPUT FACE
SPECIFICATIONS
back pressure . . . . . . . . . 113 - 542 N-m (1000 - 4800 lb-in) (one stop, no damage)
Maximum speed . . . . . . . . . . . . . . . . . . . . . . 4000 rpm Approximate weight . . . . . . . . . . . . . . . . . . 10.9 kg (24 lb)
Volume of oil
to release brake . . . . . . . . . . 8.2 cm3 (0.5 in3) (new linings)
14.8 cm3 (0.9 in3) (maximum)
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Horizontal - 88.7 mL (3 oz), Vertical - Contact MICO West
L M B
OPTIONS
(Available separately or in
combination)
SERIES S - Speed Sensor
LM - MICO Z - Oil Cooled - see note
above
OUTPUT FACE
B - SAE B-Mount 2-Bolt
INPUT FACE
OUTPUT SPLINE / INPUT SPLINE M - Modified SAE A-Mount
06/06 SAE Designation
2 or 4-Bolt
13/06 06 = 25.4 mm (1.00") Dia. 6B B - SAE B-Mount 2-Bolt
13/12 12 = 12T 12/24 used with L2 input face only L2 - Eaton Bearingless 2000
13/13 13 = 13T 16/32 N - NEMA
15/12 15 = 15T 16/32
15/15
TORQUE
Initial Full
Torque
Other configurations consult MICO West. Rating
Pressure Pressure
48 542 (4800) 17.9 (260) 21.4 (310)
40 452 (4000) 15.2 (220) 17.9 (260)
35 396 (3500) 20.0 (290) 23.8 (345)
30 339 (3000) 16.5 (240) 20.0 (290)
28 316 (2800) 15.9 (230) 19.3 (280)
24 271 (2400) 12.4 (180) 15.2 (220)
21 237 (2100) 12.4 (180) 14.5 (210)
19 215 (19000 11.7 (170) 13.8 (200)
INPUT FACES 17
14
192
158
(1700)
(1400)
9.7
8.3
(140)
(120)
11.7
10.0
(170)
(145)
12 136 (1200) 13.8 (200) 16.2 (235)
10 113 (1000) 11.7 (170) 13.8 (200)
M - Modified SAE A-Mount 2 or 4-Bolt B - SAE B-Mount 2-Bolt L2 - Eaton Bearingless 2000
ASSIGNED NUMBERS
LMB-130621-M 02-556-328 LMB-131324-B 02-556-360
LMB-130628-M 02-556-378 LMB-131328-B 02-556-324
LMB-130635-M 02-556-336 LMB-131330-B 02-556-320
LMB-130640-M 02-556-358 LMB-131335-B 02-556-334
LMB-131219-L2 02-556-348 LMB-131340-B 02-556-376
LMB-131228-L2 02-556-350 LMB-151240-L2 02-556-428
LMB-131240-L2 02-556-352 LMB-151528-B 02-556-404
LMB-131310-B 02-556-322 LMB-151535-B 02-556-340
LMB-131312-B 02-556-330 LMB-151540-B 02-556-392
LMB-131314-B 02-556-318
LMB-131317-B 02-556-332 NEMA Mount
LMB-131321-B 02-556-326
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Multiple Disc
Brakes
(gold series)
Features
Non-metallic lining material
Extremely compact design
Integrated return plate/separators help
Low release pressures prevent piston cocking.
Full system pressure capacity
Low actuation volume
Benefits
Design allows for pressure spikes of up
to 4000 psi without affecting cycle life
One repair kit for all serviceable parts
Non-metallic lining material contributes
Operation
Braking is provided by stationary friction plates
and a rotating disc splined to the shaft. Force is
transmitted to the disc pack through the return
plate by a series of preloaded springs. The brake
is released by hydraulic pressure applied to the
piston to compress the springs. The brake is
self-applying since any function which reduces the
hydraulic system pressure of the brake will start to
initiate a brake application. Zero pressure pro-
duces maximum brake torque.
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High quality ductile iron casting mate-
rial for strength and durability.
Gasket design and high strength bolts

provide high pressure capability and long
life.
8620 alloy steel shafts are heat treated

for strength and shock resistance.
High performance non-metallic lining

materials contribute to high torque, low
release pressure.
Chrome silicon die

springs for long life and
higher torque.
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B-Mount
Gold Series Brakes
FEATURES
Non-metallic lining material Full system pressure capacity
Extremely compact package length Holding torque to 4000 lb-in
Low release pressures - ideal for use with Low actuation volume needed
closed loop hydraulic systems
(GB-131312-B)
millimeters
inches
INPUT END
OUTPUT FACE
SPECIFICATIONS
Torque range at 0 bar (0 psi) Volume of oil to release brake . . . . . . 8.2 cm3 (0.5 in3) minimum
back pressure . . . . . . . . . 136 - 452 N-m (1200 - 4000 lb-in) 14.8 cm3 (0.9 in3) maximum
Release pressure range . . . . . 6.9 - 20.0 bar (100 - 290 psi) initial Spline shaft . . . . . . . . . . . . . . . 30 involute, flat root side fit
7.9 - 23.4 bar (115 - 340 psi) full per ANSI B92.1 - 1970
Maximum operating pressure . . . . 207 bar (3000 psi) continuous Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil
Maximum speed . . . . . 4000 rpm shaft speed capability specified Maximum operating temperature . . . . . . . . . . 132 C / 270 F
is for brake in released condition. Approximate weight . . . . . . . . . . . . . . . . . . 10.3 kg (19 lb)
Energy absorption during apply cycle must
be carefully examined for each application.
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See below for Catalog Code Numbers already assigned.
G B
GOLD SERIES INPUT FACE

B - SAE B-Mount 2-Bolt
OUTPUT FACE M - Modified SAE A-Mount
SAE B-Mount 2-Bolt 2 or 4 Bolt
OUTPUT SPLINE / INPUT SPLINE

13/06
13/13
SAE Designation
06 = 25.4 mm (1.00") Dia. 6B
TORQUE
13 = 13T 16/32 Initial Full
Torque
Rating
Pressure Pressure
Other configurations consult MICO West. N-m (lb-in) bar (psi) bar (psi)
40 452 (4000) 20.0 (290) 23.4 (340)
35 396 (3500) 16.5 (240) 19.3 (280)
28 316 (2800) 13.8 (200) 16.2 (235)
21 237 (2100) 11.3 (165) 13.1 (190)
16 181 (1600) 8.6 (125) 10.0 (145)
14 158 (1400) 7.6 (110) 8.6 (125)
12 136 (1200) 6.9 (100) 7.9 (115)
INPUT FACE
B-SAE B-Mount 2-Bolt
ASSIGNED
NUMBERS
CATALOG PRODUCTION
CODE ORDER
NUMBER NUMBER
GB-130621-M 13-100-028
GB-131312-B 13-100-002
GB-131314-B 13-100-004
GB-131316-B 13-100-006
GB-131321-B 13-100-024
GB-131328-B 13-100-010
GB-131335-B 13-100-012
GB-131340-B 13-100-014
GB-131340-M 13-100-034
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ORDER INFORMATION
(See NOTE on the top of page 5) See below for
"Top Hat" Thru- Catalog Code Numbers already assigned.
Shaft Motor Brakes

INPUT FACE
FEATURES THRU-SHAFT M46 - Sundstrand 6.125" B.C.
BRAKE M35 - Sundstrand 5.750" B.C.
Mates with Nichols & PRODUCT CODE TORQUE
Sundstrand thru-shaft MN -Nichols Series (100, 110, 120
Initial Full
& 130) Torque
motors MS - Sundstrand
Code
Rating
Release
Pressure
Release
Pressure
Low cost with high INPUT SPLINE 56
N-m
633
(lb-in)
(5600)
bar
20.0
(psi)
(290)
bar (psi)
25.5 (370)
torque capacity 13 - 13T 16/32 42 475 (4200) 15.9 (230) 20.7 (300)
35 396 (3500) 12.4 (180) 16.5 (240)
25 282 (2500) 8.3 (120) 10.3 (150)
(MN-1356)
millimeters
inches
SPECIFICATIONS ASSIGNED
Torque rating at 0 bar (0 psi)
back pressure . . . . . . . . . 283 - 633 N-m (2500 - 5600 lb-in) NUMBERS
Release pressure range . . . . . . . 10.3 - 25.5 bar (150 - 370 psi) CATALOG PRODUCTION
Maximum operating pressure. . . . . . . . . . . 207 bar (3000 psi) CODE ORDER
Maximum speed . . . . . . . . . . . . . . . . . . . 1000 rpm (MN) NUMBER NUMBER
4000 rpm (MS) MN-1325 02-550-120
Volume of oil MN-1335 02-550-122
to release brake . . . . . . . . . . . . . . . . 7.4 cm3 (0.45 in3) MN-1342 02-550-114
Maximum operating temperature . . . . . . . . . . 132 C (270 F) MN-1356 02-550-116
Approximate Weight . . . . . . . . . . . . . . . . . . 8.2 kg (18 lb) MS-1325-M35 02-550-124
Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil MS-1325-M46 02-550-118
Maximum energy input . . . . . . . . 135,600 joule (100,000 ft-lb)
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Benefits
THE BRAKE "FREE-WHEELS" IN
Posi-Torque THE LIFT DIRECTION
The MICO Posi-Torque Brake is engaged while
Winch Brakes the load is being raised. The brakes internal over-
riding clutch "free-wheels" allowing travel in only
The compact size of these Posi-Torque Winch Brakes one direction.
permit easy installation into restricted space without
requiring special adjustment, alignment, shims or
brackets. Large diameter friction discs are possible
because of the location of the tension pins. With these
large discs the Posi-Torque Brake develops more
retarding torque than comparably sized units in use
today. The balanced piston design keeps critical com-
ponents in tension when the brake is engaged. This
helps eliminate bending or fracturing due to stress.
If winching is the application, a MICO Spring Apply,
Hydraulic Release, Multiple Disc Brake with posi-
torque option is the ideal choice. This brake is
designed primarily for use on a hydraulically driven
winch system. It combines the benefits of allowing A ONE-WAY POSITIVE POSI-
one-way winching, positive load positioning and run- TIONING WINCH BRAKE
away protection all in one single, compact package.
Once the winch stops lifting, the Posi-Torque
Brake automatically holds the load in the desired
position. Positive load positioning is immediately
Quality pays in performance and reliability available because the brake is always engaged.
There is no lag time or drift.
SAFE, RUNAWAY PROTECTION

WHEN LOWERING THE LOAD
When lowering a load, hydraulic pressure disen-
gages the Posi-Torque Brake. The load can be
powered down using the winchs hydraulic motor
for safe, slow descent. If hydraulic pressure drops
and the load begins to runaway from the motor,
the MICO Posi-Torque Brake automatically
engages to bring the load to a safe controlled
stop.
LUBRICATION
Oils containing slippery or antiwear additives, such as graphite or
molybdenum disulfide or extreme pressure (EP) type lubricants,
may allow the brake to slip at torque levels below the rated values.
MICO recommends a good grade of ATF, SAE 10 or SAE 20 oil, or
Mobil DTE; also oils meeting MIL.7808 or MIL.23699.
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C-Mount Modular
Posi-Torque Brakes
FEATURES
Oil cooled operation Metallic linings for long life
Nitrile case seals Hardened high strength steel shafts
Positions the load at the instant the winch Balanced piston design
stops
Compact size for easy installation
Large diameter discs
(3CWC-141480-CCC)
millimeters
inches
OUTPUT FACE
INPUT END
SPECIFICATIONS
Torque range at 0 bar (0 psi) (wet design) . . . . . . . . . . . . . 3.8 - 26.5 L/min (1 - 7 gpm)
back pressure . . . . . . . . . . . . . . . . Oil cooled operation Maximum case pressure . . . . . . . . . . . . . . . 2.1 bar (30 psi)
452 - 904 N-m (4000 - 8000 lb-in) Sump cooling fluid volume
Release pressure range . . . . . . . 13.1 - 25.5 bar (190 - 370 psi) (wet design). . . . . . . . . . . . . . . . . . . . 177.4 mL (6 oz)
Maximum operating pressure. . . . . . . . . . . 207 bar (3000 psi) Volume of oil
Maximum speed to release brake . . . . . . . . . . . . . . . . 16.4 cm3 (1.0 in3)
(Non-free wheeling direction) . . . . . . . . (Flow thru) 4000 rpm Maximum energy input . . . . . . . . . 542,400 joule (400,000 ft-lb)
(Sump) 3000 rpm (one stop, no damage)
(Free wheeling direction) . . . . . . . . . . (Flow thru) 4000 rpm Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil
(Sump) 4000 rpm Maximum operating temperature . . . . . . . . . . 132 C (270 F)
Optimal flow thru cooling Approximate weight . . . . . . . . . . . . . . . . . . . 19 kg (42 lb)
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NOTE: Liquid cooled only, not designed for dry applications.
(To be installed in horizontal position only)
3 C W C
3CW - C-MOUNT FREE WHEELING

POSI-TORQUE DIRECTION CODE
WINCH BRAKE (As you face the output
end of brake)
CC - Counter Clockwise
OUTPUT FACE CW - Clockwise
C - SAE C-Mount
4-Bolt INPUT FACE
C - SAE C-Mount 4-Bolt
OUTPUT SPLINE / INPUT SPLINE M - 4-Bolt and SAE
04 (internal)/14 SAE Designation A-Mount 2-Bolt
14/14 04 = 14T 12/24
14 = 14T 12/24
K4 - Eaton
Standard 4000
Other configurations consult MICO West. C24 - 2-Bolt and 4-Bolt
C-Mount
TORQUE
Initial Full
Torque
Release Release
Code Rating
Pressure Pressure
80 904 (8000) 18.6 (270) 25.5 (370)
75 848 (7500) 17.2 (250) 22.7 (330)
70 791 (7000) 15.8 (230) 21.4 (310)
65 734 (6500) 15.2 (220) 20.7 (300)
40 452 (4000) 9.6 (140) 13.1 (190)
NOTE: Torque is coded as wet (liquid cooled)
use.
INPUT FACES
C - SAE C-Mount Standard

ASSIGNED NUMBERS K4 - Eaton Standard 4000
CATALOG PRODUCTION
CODE ORDER
NUMBER NUMBER
3CWC-041475-CCW 13-602-002
3CWC-041475-CCC 13-602-014
3CWC-141440-CCC 13-602-022
3CWC-141440-MCW 13-602-004
3CWC-141440-C24CC 13-602-030
3CWC-141440-C24CW 13-602-032
3CWC-141465-CCC 13-602-010
3CWC-141465-CCW 13-602-012
3CWC-141465-MCC 13-602-024
3CWC-141465-MCW 13-602-020
3CWC-141480-CCC 13-602-006
3CWC-141480-CCW 13-602-008
3CWC-141480-K4CW 13-602-016
3CWC-141480-MCC 13-602-018 C24 - 2-Bolt and 4-Bolt C-Mount M - 4-Bolt and SAE A-Mount 2-Bolt
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B-Mount Modular
FEATURES
Secondary system for service braking with Oil cooled option for added capacity
fail-safe back up
Nitrile case seals
Standard SAE mounting flanges Compact modular design
Service brake can be modulated with auto-
motive type master cylinder or hydraulic
valve
(3PB-131328-B)
OUTPUT FACE
millimeters
INPUT END inches
SPECIFICATIONS
FAIL-SAFE BRAKE SERVICE BRAKE
Torque range at 0 bar (0 psi) Maximum torque . . . . . . . . . (dry design) 452 N-m (4000 lb-in)
back pressure . . . . . . . . 135.6 - 452 N-m (1200 - 4000 lb-in) (wet design) 384.2 N-m (3400 lb-in)
Release pressure range. . . . . . . . . 5.5 - 24.1 bar (80 - 350 psi) Calculated torque . . . . . . . . . (dry design) T = 5.50 x (psi - 80)
Maximum continuous pressure . . . . . . . . . . 207 bar (3000 psi) (wet design) T = 3.70 x (psi - 80)
Maximum speed . . . . . . . . . . . . . . . . . . . . . . 4000 rpm Maximum operating pressure . . . . (wet design) 69 bar (1000 psi)
(See note below) (dry design) 55.2 bar (800 psi)
Volume of oil Maximum energy input
to release brake . . . . . . . . . . . . . . . . . 8.2 cm3 (0.5 in3) (wet or dry design). . . . . . . . . . 189,840 joule (140,000 ft-lb)
Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil (one stop, no damage)
Maximum operating temperature . . . . . . . . . . 132 C (270 F) Maximum energy input rate
Approximate weight . . . . . . . . . . . . . . . . . . 13.6 kg (30 lb) (dry design) . . . . . . . . 54,240 joules per s (40,000 ft-lb per s)
Optimal flow thru cooling (one stop, no damage)
(wet design) . . . . . . . . . . . . . 3.8 - 26.5 L/min (1 - 7 gpm) (wet design) . . . . . . . 108,480 joules per s (80,000 ft-lb per s)
Maximum case pressure . . . . . . . . . . . . . . . 2.1 bar (30 psi) (one stop, no damage)
Sump cooling fluid volume (wet design) Piston volume . . . . . . . . . . . . . . . . . . . 3.0 cm3 (0.18 in3)
(horizontal) . . . . . . . . . . . . . . . . . . . . . 88.7 mL (3 oz) Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil
(vertical) . . . . . . . . . . . . . . . . . . . Contact MICO West
NOTE: Due to energy capacity limitations, maximum speed at time of service apply is dependent on product application.
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NOTE: On oil cooled models (Z option) actual torque is 67% of value
shown on torque code chart.
3 P B
OPTION
3P - PRESSURE Z - Oil Cooled - see note above
OVERRIDE INPUT FACE
B - SAE B-Mount
OUTPUT FACE M - 4-Bolt and SAE
B - SAE B-Mount A-Mount 2-Bolt
2-Bolt TORQUE
Initial Full
OUTPUT SPLINE / INPUT SPLINE Code
Torque
Release Release
13/06 Rating
SAE Designation Pressure Pressure
13/13 06 = 25.4 mm (1.00") Dia. 6B N-m (lb-in) bar (psi) bar (psi)
13 = 13T 16/32 60 * 678 (6000) 20.0 (290) 24.1 (350)
52 * 588 (5200) 17.2 (250) 20.7 (300)
40 452 (4000) 13.8 (200) 16.5 (240)
35 396 (3500) 12.4 (180) 14.5 (210)
28 316 (2800) 9.6 (140) 11.7 (170)
24 271 (2400) 8.3 (120) 10.3 (150)
19 215 (1900) 7.6 (110) 9.0 (130)
16 181 (1600) 6.2 (90) 7.6 (110)
NOTE: Because of the sophisticated nature of Pressure 12 136 (1200) 4.8 (70) 5.5 (80)
Override Brakes, we ask that you complete the
* Maximum dry torque is 4000 lb-in, 5200 lb-in, &
data sheet for pressure override applications 6000 lb-in are used only for coding of 3500 &
in the back of this catalog or at www.mico.com. 4000 oil cooled version brakes.
Submit written data sheets to:
MICO West Division,
701 East Francis Street
Ontario, CA 91761 U.S.A.
Attention: Engineering
INPUT FACES
B - SAE B-Mount M - 4-Bolt and SAE A-Mount 2-Bolt
ASSIGNED NUMBERS
3PB-130612-M 13-592-044 3PB-131328-B 13-592-036
3PB-130635-M 13-592-002 3PB-131335-B 13-592-010
3PB-130640-M 13-592-004 3PB-131340-B 13-592-042
3PB-130640-MZ 13-592-024 3PB-131340-MZ 13-592-022
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C-Mount Modular
FEATURES
Secondary system for service braking with Oil cooled option for added capacity
fail-safe back-up
Nitrile case seals
Standard SAE mounting flanges Compact modular design
Service brake can be modulated with auto-
motive type master cylinder or hydraulic
valve
(3PC-141470-CZ)
millimeters
inches
OUTPUT FACE
INPUT END
SPECIFICATIONS
FAIL-SAFE BRAKE SERVICE BRAKE
Torque range at 0 bar (0 psi) Maximum torque. . . . . . . . . (dry design) 1062 N-m (9400 lb-in)
back pressure . . . . . . . . 407 - 1107 N-m (3600 - 9800 lb-in) (wet design) 700.6 N-m (6200 lb-in)
Release pressure range . . . . . . . . 9.7 - 25.5 bar (140 - 370 psi) Calculated torque . . . . . . . . . (dry design) T = 10.10 x (psi - 70)
Maximum continuous pressure . . . . . . . . . . 207 bar (3000 psi) (wet design) T = 6.66 x (psi - 70)
Maximum speed . . . . . . . . . . . . . . . . . . . . . . 4000 rpm Maximum operating pressure . . . . . . . . . . . 69 bar (1000 psi)
(See note below) Maximum energy input
Volume of oil (wet or dry design). . . . . . . . . . 406,800 joule (300,000 ft-lb)
to release brake . . . . . . . . . . . . . . . . 16.4 cm3 (1.0 in3) (one stop, no damage)
Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil Maximum energy input rate
Maximum operating temperature . . . . . . . . . . 132 C (270 F) (dry design) . . . . . 101,700 joule per sec (75,000 ft-lb per sec)
Approximate weight . . . . . . . . . . . . . . . . . . . 20 kg (44 lb) (one stop, no damage)
Optimal flow thru cooling (wet design) . . . . 203,400 joule per sec (150,000 ft-lb per sec)
(wet design) . . . . . . . . . . . . . 3.8 - 26.5 L/min (1 - 7 gpm) (one stop, no damage)
Maximum case pressure . . . . . . . . . . . . . . . 2.1 bar (30 psi) Piston volume . . . . . . . . . . . . . . . . . . . 5.2 cm3 (0.32 in3)
Sump cooling fluid volume (wet design) Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil
(horizontal) . . . . . . . . . . . . . . . . . . . . 118.3 mL (4 oz)
(vertical) . . . . . . . . . . . . . . . . . . . Contact MICO West
NOTE: Due to energy capacity limitations, maximum speed at time of service apply is dependent on product application.
29
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NOTE: On oil cooled models (Z option) actual torque is 67% of value
shown on torque code chart.
3 P C
OPTIONS
3P - PRESSURE (Available separately
OVERRIDE or in combination)
S - Speed Sensor
Z - Oil Cooled - see
OUTPUT FACE note above
C - SAE C-Mount
4-Bolt INPUT FACE
M - 4-Bolt and SAE
OUTPUT SPLINE / INPUT SPLINE A-Mount 2-Bolt
14/00 SAE Designation K4 - Eaton Standard 4000
14/06 00 = used with "R" only
C - SAE C-Mount Standard
14/14 06 = 25.4 mm (1.00") Dia. 6B
14 = 14T 12/24 C24 - 2-Bolt and 4-Bolt C-Mount
R - Closed Face
Other configurations consult MICO West.
TORQUE
NOTE: Because of the sophisticated nature of Pressure Initial Full
Torque
Override Brakes, we ask that you complete the Rating
Pressure Pressure
data sheet for pressure override applications N-m (lb-in) bar (psi) bar (psi)
in the back of this catalog or at www.mico.com. 98 1107 (9800) 18.6 (270) 25.5 (370)
80 904 (8000) 15.2 (220) 20.7 (300)
Submit written data sheets to: 70 791 (7000) 13.8 (200) 19.3 (280)
55 622 (5500) 11.0 (160) 15.2 (220)
MICO West Division, 45 508 (4500) 8.3 (120) 11.7 (170)
36 407 (3600) 6.9 (100) 9.6 (140)
701 East Francis Street
Ontario, CA 91761 U.S.A.
Attention: Engineering
INPUT FACES
ASSIGNED NUMBERS C - SAE C-Mount Standard K4 - Eaton Standard 4000

CATALOG PRODUCTION
CODE ORDER
NUMBER NUMBER
3PC-140080-R 13-597-032
3PC-140645-M 13-597-034
3PC-140670-MZ 13-597-044
3PC-140680-M 13-597-026
3PC-141436-C 13-597-014
3PC-141436-C24 13-597-042
3PC-141445-C24Z 13-597-030
3PC-141455-C 13-597-002
3PC-141455-CZ 13-597-016
3PC-141470-C 13-597-004
3PC-141470-CZ 13-597-008
3PC-141480-C 13-597-018
3PC-141480-CZ 13-597-024
3PC-141436-M 13-597-040
3PC-141498-C 13-597-010 C24 - 2-Bolt and 4-Bolt C-Mount M - 4-Bolt and SAE A-Mount 2-Bolt
30
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(motor input)
FEATURES
Provision for direct mounting of brake to Torques to 1695 N-m (15,000 lb-in)
wheels
Full system pressure capability
Heat treated 8620 shafts Includes castle nut
Complete self contained dry design package
(WH-501415-M)
millimeters
inches
INPUT FACE
OUTPUT END
SPECIFICATIONS
back pressure . . . . . . . 904 - 1695 N-m (8000 - 15,000 lb-in) (one stop, no damage)
Release pressure range . . . . . . . 21.4 - 34.5 bar (310 - 500 psi) Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil
Maximum speed . . . . . . . . . . . . . . . . . . . . . . 1000 rpm Approximate weight . . . . . . . . . . . . . . . . . . 17.2 kg (38 lb)
Volume of oil
to release brake . . . . . . . . . . . . . . . . . 9.8 cm3 (0.6 in3)
31
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NOTE: Dry Design only, not for oil cooled applications.
W H
(contact MICO West for details on input

face views not shown.)
INPUT FACE
WH - WHEEL MOUNT M - 4-Bolt and SAE
BRAKE A-Mount 2-Bolt
L2 - Eaton
OUTPUT SHAFT / INPUT SHAFT Bearingless 2000
50/12 K4 - Eaton
SAE Designation
50/14 12 = 12T 12/24 modified (as required for
Standard 4000
Char-Lynn 2000 Bearingless)
14 = 14T 12/24
50 = 38.1 mm (1.50") Keyed, Taper
TORQUE
Torque
Rating
Pressure Pressure
80 904 (8000) 14.5 (210) 21.4 (310)
15 1695 (15,000) 23.4 (340) 34.5 (500)
12 1356 (12,000) 20.7 (300) 31.0 (450)
10 1130 (10,000) 17.9 (260) 26.2 (380)
LOAD CAPACITY @ 100 RPM AND B10 = 6500 HRS

325 RPM AND B10 = 2000 HRS
6000
MAX. LOAD
INPUT FACE
5000
4000
ALLOW-
ABLE
RADIAL
3000
LOAD
(LB)
2000
1000
0
+3 +2 +1
-1 -2 -3 -4
DISTANCE FROM CENTERLINE OF KEY (

( INCHES )
)
L2 - Eaton Bearingless 2000
(Refer to drawing on previous page)
ASSIGNED THRUST LOAD CAPACITY:

NUMBERS 1100 lb max. @ 100 rpm & 2000 hrs B10 life.
(Based on constant 3700 lb side load at center-
CATALOG PRODUCTION
CODE ORDER line of key)
NUMBER NUMBER
WH-501215-L2 13-587-004
WH-501280-L2 13-587-006
WH-501415-M 13-587-002
WH-501415-K4 13-587-008
WH-501480-M 13-587-012
32
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(closed input)
FEATURES
Automotive type linings Brake torques up to 1356 N-m (12,000 lb-in)
Provides direct mounting of brake to wheels Full system pressure capability
Heat treated 8620 shafts Includes castle nut
Low release pressures - ideal for use with
(SWH-50096-R)
millimeters
inches
INPUT FACE
OUTPUT END
SPECIFICATIONS
Torque range at 0 bar (0 psi)
back pressure . . . . . . . 904 - 1356 N-m (8000 - 12,000 lb-in) Volume of oil to release brake . . . . . . . . . . . 9.8 cm3 (0.6 in3)
Release pressure range. . . . . . . 21.37 - 34.5 bar (310 - 500 psi) Fluid type . . . . . . . . . . . . . . . . . Mineral base hydraulic oil
241 bar (3500 psi intermittent) Approximate weight . . . . . . . . . . . . . . . . . . 17.2 kg (38 lb)
Maximum speed . . . . . . . . . . . . . . . . . . . . . . 1000 rpm
33
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S W H O O

INPUT FACE
SWH - WHEEL MOUNT R - Closed Face
BRAKE
TORQUE
OUTPUT SHAFT Initial Full
Torque
50 SAE Designation Code
Rating
Release Release
50 = 38.1 mm (1.50) Keyed, Taper
Pressure Pressure
96 1085 (9600) 26.9 (390) 31.7 (460)
CLOSED INPUT 54
14
6102
1582
(5400)
(14,000)
24.1
40.0
(350)
(580)
27.6
45.5
(400)
(660)
11 1243 (11,000) 30.1 (445) 37.2 (540)

325 RPM AND B10 = 2000 HRS
6000
MAX. LOAD
5000
4000
ALLOW-
ABLE
RADIAL
3000
LOAD
(LB)
2000
1000
0
+3 +2 +1
-1 -2 -3 -4
DISTANCE FROM CENTERLINE OF KEY (

( INCHES )
)
THRUST LOAD CAPACITY:

1100 lb max. @ 100 rpm & 2000 hrs B10 life.
ASSIGNED (Based on constant 3700 lb side load at center-
NUMBERS line of key)
CATALOG PRODUCTION
CODE ORDER
NUMBER NUMBER
SWH-500011-R 13-587-016
SWH-500054-R 13-587-024
SWH-500096-R 13-587-020
34
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Mini Wheel Mount Brakes
(closed input)
FEATURES
Non-metallic type linings Full system pressure capability
Provides direct mounting of brake to wheel Integral hub eliminates the need for an
adaptor
Low release pressures - ideal for use with
closed-loop hydrostatic systems Superior radial wheel load capacities
Brake torques up to 1130.0 N-m
(10,000 lb-in)
(MW-054560-R)
millimeters
inches
SPECIFICATIONS
Torque range at 0 bar (0 psi) Volume of oil to release brakes . . . . . 8.2 cm3 (0.5 in3) minimum
back pressure . . . . . . . 170 - 1130 N-m (1500 to 10,000 lb-in) 14.8 cm3 (0.9 in3) maximum
Maximum sustained operating pressure . . . . . 207 bar (3000 psi)
(4000 psi intermittent)
Maximum speed . . . . . . . . . . . . . . . . . . . . . . . 200 rpm
Maximum operating temperature . . . . . . . . . . . 93 C (200 F)
Approximate weight . . . . . . . . . . . . . . . . . . 10.4 kg (23 lb)
35
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M W

INPUT FACE
MW - MINI WHEEL R - Closed Face
BRAKE
TORQUE
WHEEL MOUNT CONFIGURATION Initial Full
0440 = 4-Bolt on 4.00" BC Torque
Rating
0445 = 4-Bolt on 4.50" BC Pressure Pressure
0545 = 5-Bolt on 4.50" BC N-m (lb-in) bar (psi) bar (psi)
90 1017 (9000) 24.1 (385) 29.0 (460)
5000 = 38.1 mm (1.50) Keyed, Taper 60 678 (6000) 33.8 (490) 40.0 (580)
51 576 (5100) 25.2 (385) 29.6 (460)
40 452 (4000) 21.0 (335) 24.0 (385)
35 396 (3500) 18.6 (300) 21.0 (340)
25 283 (2500) 14.5 (230) 16.2 (260)
10 1130 (10,000) 25.2 (400) 29.6 (470)

325 RPM AND B10 = 2,000 HRS
3000
2500
MAX. LOAD
2000
ALLOW-
ABLE
RADIAL
1500
LOAD
(LB)
1000
500
0
+3 +2 +1
-1 -2 -3 -4
DISTANCE FROM EDGE OF WHEEL FLANGE (

( INCHES )
)
THRUST LOAD CAPACITY:

300 lb max. @ 100 rpm & 2000 hrs B10 life.
ASSIGNED (Based on constant 290 lb side load at edge
NUMBERS of wheel flange)
CATALOG PRODUCTION
CODE ORDER
NUMBER NUMBER
MW-054535-R 13-587-074
MW-054560-R 13-587-072
MW-054590-R 13-578-082
MW-500051-R 13-587-080
36
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Repair Kit Cross Reference
02-550-114 13-538-004 13-538-048 13-538-242
02-550-116 13-538-006 12-501-241 BEARING KIT 13-538-244
02-500-153 REPAIR KIT 13-538-008 12-501-243 LINING KIT 12-501-241 BEARING KIT
02-500-154 SPRING KIT 13-538-010 12-501-244 SPRING KIT 12-501-244 SPRING KIT
20-060-083 LINING KIT 13-538-012 12-501-246 SEAL KIT 12-501-245 LINING KIT
12-501-241 BEARING KIT 12-501-246 SEAL KIT
12-501-244 SPRING KIT
02-550-118 12-501-245 LINING KIT 13-538-050
02-500-157 SPRING KIT 12-501-242 BEARING KIT 13-538-272
02-500-158 SEAL KIT 12-501-246 SEAL KIT 12-501-243 LINING KIT 12-501-241 BEARING KIT
20-060-085 LINING KIT 12-501-244 SPRING KIT 12-501-243 LINING KIT
13-538-016 12-501-246 SEAL KIT 12-501-244 SPRING KIT
02-550-120 13-538-020 12-501-246 SEAL KIT
12-501-242 BEARING KIT
02-550-122 12-501-244 SPRING KIT 13-538-052
02-500-153 REPAIR KIT 12-501-241 BEARING KIT 13-538-274
02-500-154 SPRING KIT 12-501-245 LINING KIT 12-501-241 BEARING KIT
12-501-243 LINING KIT
20-060-083 LINING KIT 12-501-246 SEAL KIT 12-501-244 SPRING KIT
12-501-246 SEAL KIT 12-501-245 LINING KIT
02-550-124 13-538-022 12-501-246 SEAL KIT
02-500-154 SPRING KIT 13-538-024
02-500-153 REPAIR KIT 13-538-026 13-538-054
12-501-241 BEARING KIT 12-501-241 BEARING KIT 13-538-290
20-060-083 LINING KIT 12-501-244 SPRING KIT 12-501-242 BEARING KIT
12-501-245 LINING KIT 12-501-245 LINING KIT 12-501-243 LINING KIT
02-556-318 12-501-246 SEAL KIT 12-501-246 SEAL KIT 12-501-244 SPRING KIT
02-556-322 12-501-246 SEAL KIT
02-556-324
02-556-326 13-538-028 13-538-056
02-556-328 12-501-241 BEARING KIT 12-501-242 BEARING KIT 13-538-294
02-556-330 12-501-243 LINING KIT 12-501-243 LINING KIT 12-501-241 BEARING KIT
02-556-332 12-501-244 SPRING KIT 12-501-244 SPRING KIT 12-501-244 SPRING KIT
02-556-334 12-501-246 SEAL KIT 12-501-246 SEAL KIT 12-501-245 LINING KIT
02-556-336 12-501-246 SEAL KIT
02-500-141 REPAIR KIT
13-538-030 13-538-058
02-500-142 BEARING KIT 12-501-241 BEARING KIT 13-538-060 13-538-300
20-060-100 LINING KIT 12-501-244 SPRING KIT 12-501-241 BEARING KIT 12-501-242 BEARING KIT
12-501-245 LINING KIT 12-501-243 LINING KIT 12-501-243 LINING KIT
02-556-340 12-501-246 SEAL KIT 12-501-244 SPRING KIT 12-501-244 SPRING KIT
02-500-167 SEAL KIT 12-501-246 SEAL KIT 12-501-246 SEAL KIT
20-060-100 LINING KIT 13-538-032
12-501-244 SPRING KIT 13-538-064 13-538-318
12-501-245 LINING KIT 13-538-200 12-501-241 BEARING KIT
02-556-360 12-501-241 BEARING KIT 12-501-244 SPRING KIT
12-501-246 SEAL KIT
02-556-376 12-501-253 BEARING KIT
12-501-244 SPRING KIT 12-501-245 LINING KIT
02-500-141 REPAIR KIT 12-501-245 LINING KIT 12-501-246 SEAL KIT
20-060-100 LINING KIT 13-538-034
12-501-243 LINING KIT 13-538-320
12-501-244 SPRING KIT 13-538-202 12-501-242 BEARING KIT
02-556-404 12-501-246 SEAL KIT
12-501-243 LINING KIT 12-501-243 LINING KIT
02-500-167 SEAL KIT 12-501-244 SPRING KIT 12-501-244 SPRING KIT
02-500-168 BEARING KIT 12-501-253 BEARING KIT
12-501-246 SEAL KIT 12-501-246 SEAL KIT
20-060-100 LINING KIT 12-501-253 BEARING KIT
13-538-036
13-538-038 13-538-324
02-556-428 12-501-242 BEARING KIT 13-538-230 12-501-241 BEARING KIT
12-501-426 O-RING KIT 12-501-241 BEARING KIT 12-501-245 LINING KIT
12-501-427 BEARING KIT 12-501-243 LINING KIT
12-501-244 SPRING KIT 12-501-244 SPRING KIT 12-501-246 SEAL KIT
20-060-107 LINING KIT 12-501-245 LINING KIT 12-501-344 SPRING KIT
12-501-246 SEAL KIT
12-501-246 SEAL KIT
13-100-002 13-538-370
13-100-004 13-538-040
13-100-006 13-538-042 13-538-232 13-538-372
13-538-044 12-501-241 BEARING KIT 12-501-241 BEARING KIT
13-100-008 12-501-241 BEARING KIT 12-501-243 LINING KIT 12-501-244 SPRING KIT
13-100-010
13-100-012 12-501-244 SPRING KIT 12-501-244 SPRING KIT 12-501-245 LINING KIT
13-100-014 12-501-245 LINING KIT 12-501-246 SEAL KIT 12-501-246 SEAL KIT
12-501-388 REPAIR KIT 12-501-246 SEAL KIT
13-538-234 13-538-376
13-100-028 13-538-046 13-538-236 13-538-382
13-100-034 12-501-242 BEARING KIT 12-501-242 BEARING KIT 12-501-241 BEARING KIT
12-501-402 REPAIR KIT 12-501-243 LINING KIT 12-501-243 LINING KIT 12-501-243 LINING KIT
12-501-244 SPRING KIT 12-501-244 SPRING KIT 12-501-244 SPRING KIT
12-501-246 SEAL KIT 12-501-246 SEAL KIT 12-501-246 SEAL KIT
37
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13-538-384 13-547-064 13-547-118 13-547-214
12-501-242 BEARING KIT 12-501-002 SEAL KIT 12-501-002 SEAL KIT 12-501-002 SEAL KIT
12-501-244 SPRING KIT 12-501-006 BEARING KIT 12-501-006 BEARING KIT 12-501-006 BEARING KIT
12-501-245 LINING KIT 12-501-008 SPRING KIT 12-501-008 SPRING KIT 12-501-008 SPRING KIT
12-501-246 SEAL KIT 12-501-014 LINING KIT 12-501-014 LINING KIT 12-501-014 LINING KIT
13-547-002 13-547-066 13-547-120 13-547-220

13-547-006 12-501-002 SEAL KIT 12-501-002 SEAL KIT 12-501-002 SEAL KIT
12-501-002 SEAL KIT 12-501-004 LINING KIT 12-501-004 LINING KIT 12-501-006 BEARING KIT
12-501-004 LINING KIT 12-501-006 BEARING KIT 12-501-006 BEARING KIT 12-501-008 SPRING KIT
12-501-006 BEARING KIT 12-501-008 SPRING KIT 12-501-008 SPRING KIT 12-501-014 LINING KIT
13-547-068 13-547-124 13-547-226
13-547-014 12-501-004 LINING KIT 12-501-002 SEAL KIT 13-547-228
12-501-004 LINING KIT 12-501-008 SPRING KIT 12-501-004 LINING KIT 12-501-002 SEAL KIT
12-501-008 SPRING KIT 12-501-356 SEAL KIT 12-501-006 BEARING KIT 12-501-006 BEARING KIT
12-501-238 BEARING KIT 12-501-357 BEARING KIT 12-501-008 SPRING KIT 12-501-008 SPRING KIT
12-501-239 REPAIR KIT 12-501-014 LINING KIT
13-547-072 13-547-130
13-547-016 12-501-002 SEAL KIT 12-501-002 SEAL KIT 13-547-232
12-501-219 SEAL KIT 12-501-004 LINING KIT 12-501-006 BEARING KIT 12-501-002 SEAL KIT
12-501-220 BEARING KIT 12-501-006 BEARING KIT 12-501-008 SPRING KIT 12-501-004 LINING KIT
12-501-221 SPRING KIT 12-501-008 SPRING KIT 12-501-014 LINING KIT 12-501-006 BEARING KIT
12-501-222 LINING KIT 12-501-008 SPRING KIT
13-547-074 13-547-132
13-547-024 12-501-002 SEAL KIT 13-547-134 13-547-246
12-501-002 SEAL KIT 12-501-006 BEARING KIT 12-501-002 SEAL KIT 12-501-002 SEAL KIT
12-501-004 LINING KIT 12-501-008 SPRING KIT 12-501-004 LINING KIT 12-501-006 BEARING KIT
12-501-006 BEARING KIT 12-501-014 LINING KIT 12-501-006 BEARING KIT 12-501-008 SPRING KIT
12-501-008 SPRING KIT 12-501-008 SPRING KIT 12-501-014 LINING KIT
13-547-076
13-547-026 13-547-078 13-547-164 13-547-252
12-501-002 SEAL KIT 12-501-002 SEAL KIT 12-501-002 SEAL KIT 13-547-254
12-501-006 BEARING KIT 12-501-004 LINING KIT 12-501-006 BEARING KIT 12-501-002 SEAL KIT
12-501-008 SPRING KIT 12-501-006 BEARING KIT 12-501-008 SPRING KIT 12-501-004 LINING KIT
12-501-014 LINING KIT 12-501-008 SPRING KIT 12-501-014 LINING KIT 12-501-006 BEARING KIT
13-547-028 13-547-082 13-547-166
12-501-221 SPRING KIT 12-501-006 BEARING KIT 12-501-006 BEARING KIT 13-547-266
12-501-222 LINING KIT 12-501-008 SPRING KIT 12-501-008 SPRING KIT 12-501-002 SEAL KIT
12-501-360 BEARING KIT 12-501-014 LINING KIT 12-501-004 LINING KIT
13-547-182 12-501-006 BEARING KIT
13-547-030 13-547-084 12-501-002 SEAL KIT 12-501-008 SPRING KIT
13-547-034 13-547-086 12-501-006 BEARING KIT
13-547-036 13-547-090 12-501-008 SPRING KIT 13-547-268
13-547-038 13-547-092 12-501-014 LINING KIT 12-501-002 SEAL KIT
12-501-002 SEAL KIT 13-547-094 12-501-004 LINING KIT
12-501-006 BEARING KIT 13-547-096 12-501-008 SPRING KIT
12-501-008 SPRING KIT 12-501-002 SEAL KIT 13-547-190
12-501-002 SEAL KIT 12-501-182 BEARING KIT
12-501-006 BEARING KIT 13-547-272
13-547-044 12-501-008 SPRING KIT 12-501-002 SEAL KIT
12-501-002 SEAL KIT 12-501-008 SPRING KIT
12-501-006 BEARING KIT 13-547-098 12-501-014 LINING KIT
12-501-014 LINING KIT 12-501-002 SEAL KIT 13-547-204
12-501-092 SPRING KIT 12-501-006 BEARING KIT
12-501-008 SPRING KIT 13-547-276
13-547-046 12-501-014 LINING KIT 12-501-002 SEAL KIT
12-501-006 BEARING KIT 13-547-102 12-501-008 SPRING KIT
12-501-008 SPRING KIT 13-547-104 13-547-208
12-501-014 LINING KIT 12-501-002 SEAL KIT
12-501-006 BEARING KIT 12-501-006 BEARING KIT 13-547-278
13-547-048 12-501-008 SPRING KIT 12-501-002 SEAL KIT
12-501-002 SEAL KIT 12-501-008 SPRING KIT 12-501-006 BEARING KIT
12-501-004 LINING KIT 12-501-008 SPRING KIT
12-501-006 BEARING KIT 13-547-106 13-547-210
12-501-008 SPRING KIT 12-501-002 SEAL KIT
12-501-008 SPRING KIT 12-501-008 SPRING KIT 13-547-282
13-547-052 12-501-182 BEARING KIT 12-501-002 SEAL KIT
13-547-054 12-501-146 LINING KIT 12-501-006 BEARING KIT
13-547-058 12-501-008 SPRING KIT
12-501-002 SEAL KIT 13-547-108 13-547-212
12-501-004 LINING KIT 13-547-110
13-547-116 12-501-004 LINING KIT
12-501-008 SPRING KIT 12-501-002 SEAL KIT 12-501-006 BEARING KIT 13-547-286
12-501-004 LINING KIT 12-501-008 SPRING KIT 12-501-002 SEAL KIT
12-501-008 SPRING KIT 12-501-008 SPRING KIT
38
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13-547-288 13-547-378 13-547-454 13-552-074
12-501-008 SPRING KIT 12-501-004 LINING KIT 12-501-004 LINING KIT 13-552-084
12-501-014 LINING KIT 12-501-008 SPRING KIT 12-501-006 BEARING KIT 13-552-086
12-501-182 BEARING KIT 12-501-182 BEARING KIT 12-501-008 SPRING KIT 13-552-090
12-501-249 SEAL KIT
13-547-290 13-547-384 13-547-458 12-501-251 SPRING KIT
13-547-294 12-501-002 SEAL KIT 12-501-219 SEAL KIT
12-501-002 SEAL KIT 12-501-004 LINING KIT 12-501-220 BEARING KIT 12-501-306 LINING KIT
12-501-004 LINING KIT 12-501-006 BEARING KIT 12-501-221 SPRING KIT
12-501-006 BEARING KIT 12-501-008 SPRING KIT 12-501-222 LINING KIT 13-587-002
13-547-396 13-547-464 12-501-304 REPAIR KIT
13-547-296 12-501-002 SEAL KIT 12-501-002 SEAL KIT
12-501-002 SEAL KIT 12-501-004 LINING KIT 12-501-004 LINING KIT 12-501-305 SPRING KIT
12-501-006 BEARING KIT 12-501-006 BEARING KIT 12-501-006 BEARING KIT
12-501-008 SPRING KIT 12-501-008 SPRING KIT 12-501-008 SPRING KIT 13-587-004
13-547-410 13-552-002 12-501-305 SPRING KIT
13-547-298 12-501-219 SEAL KIT 13-552-006
12-501-002 SEAL KIT 12-501-220 BEARING KIT 13-552-008 12-501-376 BEARING KIT
12-501-004 LINING KIT 12-501-221 SPRING KIT 13-552-010
12-501-006 BEARING KIT 12-501-222 LINING KIT 13-552-012 13-587-006
12-501-008 SPRING KIT 13-552-016 12-501-302 LINING KIT
13-552-018 12-501-304 REPAIR KIT
13-547-416 12-501-249 SEAL KIT 12-501-305 SPRING KIT
13-547-306 12-501-002 SEAL KIT 12-501-250 BEARING KIT
12-501-002 SEAL KIT 12-501-004 LINING KIT 12-501-376 BEARING KIT
12-501-004 LINING KIT 12-501-006 BEARING KIT 12-501-306 LINING KIT 13-587-008
13-547-316 13-552-022 12-501-303 BEARING KIT
12-501-002 SEAL KIT 13-547-418 12-501-250 BEARING KIT 12-501-304 REPAIR KIT
12-501-008 SPRING KIT 12-501-002 SEAL KIT 12-501-251 SPRING KIT 12-501-305 SPRING KIT
12-501-014 LINING KIT 12-501-004 LINING KIT 12-501-292 SEAL KIT
12-501-182 BEARING KIT 12-501-008 SPRING KIT 12-501-306 LINING KIT 13-587-012
13-547-324 13-587-014
12-501-002 SEAL KIT 13-552-028 12-501-302 LINING KIT
13-547-420 12-501-249 SEAL KIT 12-501-303 BEARING KIT
12-501-004 LINING KIT 12-501-002 SEAL KIT 12-501-250 BEARING KIT 12-501-304 REPAIR KIT
12-501-006 BEARING KIT 12-501-008 SPRING KIT 12-501-251 SPRING KIT 12-501-305 SPRING KIT
12-501-008 SPRING KIT 12-501-014 LINING KIT 12-501-306 LINING KIT
13-547-332 13-587-016
13-552-032 12-501-303 BEARING KIT
13-547-334 13-547-422 12-501-250 BEARING KIT 12-501-304 REPAIR KIT
12-501-002 SEAL KIT 12-501-219 SEAL KIT
12-501-004 LINING KIT 12-501-251 SPRING KIT 12-501-365 SPRING KIT
13-587-020
13-552-033 12-501-303 BEARING KIT
13-547-344 13-547-424 13-552-036 12-501-304 REPAIR KIT
12-501-002 SEAL KIT 12-501-002 SEAL KIT
12-501-004 LINING KIT 13-552-038 12-501-305 SPRING KIT
12-501-004 LINING KIT 13-552-040
12-501-006 BEARING KIT 13-552-042
12-501-182 BEARING KIT 12-501-008 SPRING KIT 13-552-044
13-552-056 13-587-022
13-552-060 12-501-303 BEARING KIT
13-547-352 13-547-426
13-547-354 12-501-249 SEAL KIT
12-501-250 BEARING KIT 13-587-024
12-501-004 LINING KIT 12-501-251 SPRING KIT 12-501-303 BEARING KIT
12-501-238 BEARING KIT 12-501-304 REPAIR KIT
12-501-239 REPAIR KIT 12-501-305 SPRING KIT
13-552-068 12-501-370 LINING KIT
13-547-434 12-501-249 SEAL KIT
13-547-358 12-501-221 SPRING KIT
12-501-251 SPRING KIT 13-587-034
12-501-006 BEARING KIT 12-501-306 LINING KIT 13-587-048
12-501-356 SEAL KIT 12-501-424 REPAIR KIT
13-552-070 13-587-052
13-547-440 12-501-249 SEAL KIT 12-501-401 REPAIR KIT
13-547-362 12-501-356 SEAL KIT
13-547-364 12-501-250 BEARING KIT
12-501-357 BEARING KIT 13-587-072
12-501-014 LINING KIT 13-587-074
12-501-004 LINING KIT 12-501-306 LINING KIT 12-501-430 REPAIR KIT
13-547-450 13-587-080
12-501-004 LINING KIT 12-501-435 REPAIR KIT
13-547-370 12-501-006 BEARING KIT
13-547-376 12-501-008 SPRING KIT 13-587-082
39
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13-592-002 13-597-032
13-592-004 12-501-320 LINING KIT
13-592-010 12-501-323 REPAIR KIT
12-501-342 LINING KIT 13-597-034
13-597-040
13-592-022 13-597-042
13-592-024 12-501-320 LINING KIT
12-501-340 BEARING KIT 12-501-323 REPAIR KIT
12-501-341 SPRING KIT 12-501-324 SPRING KIT
13-597-044
13-592-036 12-501-321 LINING KIT
13-592-042 12-501-322 BEARING KIT
12-501-340 BEARING KIT 12-501-324 SPRING KIT
12-501-342 LINING KIT 13-602-002
13-602-004
13-592-044 13-602-006
12-501-339 SEAL KIT 13-602-008
12-501-340 BEARING KIT 13-602-010
12-501-341 SPRING KIT 13-602-012
13-602-014
13-602-016
13-597-002 13-602-018
13-597-004 13-602-020
13-602-022
12-501-322 BEARING KIT 13-602-030
12-501-323 REPAIR KIT 13-602-032
13-597-008 12-501-294 SPRING KIT
12-501-321 LINING KIT 12-501-295 SEAL KIT
13-597-010
13-597-016
13-597-018
13-597-022
13-597-024
13-597-026
13-597-030
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NOTES
41
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Multiple Disc Brake Data Sheet
(For Winch or Holding Type Applications Only) (confidential)
This data sheet must be completed in its entirety for warranty consideration.
Estimated Annual Usage ________________________ Date _____________________________
Name ________________________________________________ Title _____________________________________
Company____________________________________________________________________________________
Address _________________________________ City____________________ State_______ Zip _______________
Fax _______________________________ Phone ______________________ Country_________________________
Email _______________________________________________________________________________________
Is this a military application? o Yes o No If yes, what is the destination country? ________________________
Is this an underground coal mine application? o Yes o No
SPECIFICATIONS
Winch manufacturer and model no. _______________________________________________________________
Load weight (lb) __________________________________ Empty vehicle weight (lb) ________________________________
Outer diameter of cable when fully reeled on drum _____________inches
Gearbox manufacturer and model no. ______________________________________________ Gear ratio ____________
Minimum release pressure available ________________ psi
Maximum pressure seen at brake __________________ psi
Motor manufacturer and model no. __________________________________ Maximum torque ___________lb-in
Maximum motor speed ___________ rpm
Is this application required to conform with recommended practices or standards, if so which ones _____________
___________________________________________________________________________________________
___________________________________________________________________________________________
(Free wheeling direction only required for "Posi-Torque" brake applications)
Free wheeling direction as you face the output end of brake o Clockwise o Counter clockwise
BRAKE MOUNTING REQUIREMENTS

Brake input side Mounting pilot SAE callout o A o B o C o D o M
Brake output side Mounting pilot SAE callout o A o B o C o D o M
Brake input side spline shaft SAE designation _______________ o Internal o External
Brake output side spline shaft SAE designation ______________ o Internal o External
Other desired options __________________________________________________________________________
Comments___________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Continued . . .
42
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NOTICE
Component and system recommendations made by MICO, Incorporated are based on information supplied by po-
tential user and/or system designer. The potential user and/or designer must make final acceptance and approval
of components and system after testing performance on an actual application for which system was designed.
MICO is a registered trademark of MICO, Incorporated. MICO is registered in the U.S. Patent and Trademark Office as well as in Australia, Canada, Great Britain, Indonesia, Japan, Peoples Republic of China, and South Korea.
MICO, Incorporated MICO West Division

1911 Lee Boulevard (Zip Code 56003-2507) 701 East Francis Street (Zip Code 91761-5514)
P.O. Box 8118 / North Mankato, MN 56002-8118 U.S.A. P.O. Box 9058 / Ontario, CA 91762-9058 U.S.A.
( 507.625.6426 Facsimile 507.625.3212 ( 909.947.4077 Facsimile 909.947.6054
Web Site: www.mico.com
Form No. 80-500-008 Revised 7/15/02 Printed in U.S.A.
43
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(For Vehicle Parking or Emergency Stop Applications Only) (confidential)
Name ________________________________________________ Title _____________________________________
Company____________________________________________________________________________________
Fax _______________________________ Phone _________________________ Country ______________________
Email _______________________________________________________________________________________
Is this a military application? o Yes o No If yes, what is the destination country _________________________
SPECIFICATIONS
Type of vehicle or machine: _________________________________ Name and model no. _________________________
Gross vehicle weight _______________lb Empty vehicle weight ______________lb
Weight distribution loaded: front ____________ lb or % rear _____________ lb or %
Weight distribution empty: front _____________ lb or % rear _____________ lb or %
Wheelbase _____________inch Center of gravity (vertical): _____________loaded _____________empty
Rolling radius: front _____________ inch rear _____________ inch
Gearbox manufacturer and model no. _______________________________ gear ratio ______________________
Maximum loaded speed (level) _____________mph
Maximum grade in favor of load _____________ %
Number of brakes per machine _________________ Location of brakes _________________________________
Minimum release pressure available _____________ psi
Maximum pressure seen at brakes _____________ psi
Motor manufacturer and model no. _________________________________ maximum torque_______________lb
___________________________________________________________________________________________
___________________________________________________________________________________________

Brake input side mounting pilot SAE callout o A o B o C o D o M
Brake output side mounting pilot SAE callout o A o B o C o D o M
Comments___________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Continued . . .
44
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NOTICE

45
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(For Service Braking or Pressure Override Brakes Only) (confidential)
Name ________________________________________________ Title _____________________________________
Company____________________________________________________________________________________
Fax _______________________________ Phone _________________________ Country ______________________
Email _______________________________________________________________________________________
Is this a military application? o Yes o No If yes, what is the destination country? ________________________
SPECIFICATIONS
Type of vehicle or machine: _________________________________ Name and model no. _________________________
Gross vehicle weight _______________lb Empty vehicle weight ______________lb
Weight distribution loaded: front ____________ lb or % rear _____________ lb or %
Weight distribution empty: front _____________ lb or % rear _____________ lb or %
Wheelbase _____________inch Center of gravity (vertical): _____________loaded _____________empty
Rolling radius: front _____________ inch rear _____________ inch
Gearbox manufacturer and model no. __________________________________ Gearbox ratio _______________
Number of brakes per machine _______________ Location of brakes ___________________________________
Maximum loaded speed (level) _____________mph
Maximum grade in favor of load _____________ %
2
Rate of deceleration desired: Stop in _______________ft from _______________mph or _______________ft/s
Coefficient of friction between tire and ground (estimated) _______________ Type of road surface _____________
Desired lining life (number of stops) _______________
Duty cycle ___________________________________________________________________________________
Cooling flow available (wet brake option only) _______________gal/min
Minimum release pressure available _____________ psi
Maximum pressure seen at brakes _____________ psi
Motor manufacturer and model no. __________________________________ maximum torque_____________lb
Maximum motor speed _______________rpm
___________________________________________________________________________________________

Brake input side mounting pilot SAE callout o A o B o C o D o M
Brake output side mounting pilot SAE callout o A o B o C o D o M
Comments___________________________________________________________________________________
___________________________________________________________________________________________
Continued . . .
46
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(Fill in the following only if a pressure override brake is requested)
Maximum available service brake pressure (psi) ______________ fluid type_________________________
NOTICE

47
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NOTES
48
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NOTES
49
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MULTIPLE DISC BRAKE LIMITED WARRANTY
MICO, Incorporated warrants each new MICO Multiple Disc Brake to be free
from defects in material and workmanship under normal use and service for
twenty-four (24) months from date of original purchase.
Any part thereof which proves to be inoperative in material or workmanship in

normal use will be repaired or replaced, at the sole discretion of MICO. This
warranty does not include any charges for labor, travel or installation the sole
obligation of MICO being to repair or replace the warranty qualified unit. In
addition, MICO is in no way liable for damages to a MICO Product, users
property or any personal injuries that are traceable to improper installation or
use.
WARRANTY RETURN POLICY

1. All units should be returned freight prepaid.
A. Please contact MICO West 909.947.4077 for a Return Goods
Authorization (RGA) Number.
B. A detailed description must accompany the unit for reason of return.
2. Any units qualifying for warranty will be repaired or replaced.
3. If a unit is found to be operable, you have two options:

A. The unit can be returned to you against a service charge for inspection,
cleaning and routine replacement of all rubber components and any other
parts that show wear, plus freight.
B. We can dispose of the unit.
This warranty does not extend to any products which have been subject to mis-
use, accident, or improper application, installation or maintenance; nor does
it extend to products which have been repaired or altered outside of the MICO
plant unless authorized in writing by MICO or unless such installation, repair or
alteration is performed by MICO; nor does this warranty extend to any labor
charges for removal and/or replacement of nonconforming or inoperative product
or part thereof. THIS WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, ARISING BY OPERATION OF
LAW OR OTHERWISE, AND IN NO EVENT WILL MICO BE LIABLE FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES.
All return units must be sent directly to MICO West.
50
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MICO has made every attempt to present accurate information in
catalogs, brochures, and other printed material. MICO can accept
no responsibility for errors from unintentional oversights that may
exist. Due to a continuous program of product improvement, both
materials and specifications are subject to change without notice or
obligation. Refer to www.mico.com for the most recent versions of
our literature. If you have any further questions, please call MICO.
MICO, Incorporated
1911 Lee Boulevard (Zip Code 56003-2507)
P.O. Box 8118 / N. Mankato, MN 56002-8118 U.S.A.
( 507.625.6426 Facsimile 507. 625.3212
MICO West Division MICO is a registered trademark of MICO, Incorporated. MICO is registered in
01 East Francis Street (Zip Code 91761-5514) the U.S. Patent and Trademark Office as well as in Australia, Canada,
P.O. Box 9058 / Ontario, CA 91762-9058 U.S.A. Great Britain, Indonesia, Japan, Peoples Republic of China, and South Korea.
( 909.947.4077 Facsimile 909.947.6054
Web Site: www.mico.com Form No. 84-500-001

Revised 12/19/03 Printed in U.S.A.
Installation and Service Instructions
520 SERIES CALIPER DISC BRAKE
TABLE 1
Model Lining Repair
Numbers Kit Kit
02-520-201 (BF) Replaces 02-520-033 20-060-087 02-500-043
02-520-202 (HO) Replaces 02-520-034 20-060-087 02-500-042
02-520-203 (BF) 20-060-087 02-500-043
02-520-205 (BF) 20-060-087 02-500-043
02-520-206 (HO) 20-060-087 02-500-042
03-520-204 (HO) 20-060-089 02-500-042
03-520-205 (BF) 20-060-087 02-500-043
BF = Automotive Brake Fluid HO = Mineral Base Hydraulic Oil
BE SURE TO READ GENERAL INSTALLATION GUIDELINES SHEET (81-600-001) BEFORE PROCEEDING
MICO Disc Brake Linings do not contain asbestos. Brake lining compounds do, however, contain elements that
may become airborne during the life of the lining. To prevent any health problems associated with lining dust, we
suggest ventilators be installed as needed on enclosed or stationary equipment. A Material Safety Data Sheet is
available upon request.
When installing this MICO 520 Series Disc Brake, it 2. Using Table 2, determine "A" dimension and locate
is of utmost importance that the caliper be centered caliper mounting holes. Bolt caliper assembly se-
evenly and squarely over the disc. This will ensure curely to vehicle. SEE TORQUE NOTE.
even and equal piston travel and lining to disc contact.
This 520 Series Brake is designed to be used with a TORQUE NOTE
disc of 12.7 mm (.50") thickness. MICO recommends using 1/2-20 plated grade 8
mounting bolts and heat treated flat washers.
Torque: 122.0-135.6 N-m (90-100 lb-ft).
Minimum recommended disc thickness is 11.1 mm
(.438"). For other disc thicknesses, contact MICO, Inc. PLUMBING PROCEDURE
MOUNTING PROCEDURE 1. After caliper assembly is mounted on vehicle, install
hydraulic lines. NOTE: All porting is designed for
1. When planning or designing an installation of this
#4 SAE o-ring boss port adapter.
brake on a vehicle, the mounting surface to disc
2. Bleed the system making sure all air is eliminated.
face dimension of 57.9 mm (2.28") should be
Apply hydraulic pressure and check for leaks.
closely held. Use shims as needed to obtain the
proper distance. NOTE: Mounting surface must
be parallel with disc.
DISC CENTERLINE TO
MOUNTING HOLE DIMENSION
millimeters
Disc
inches "A" Dim.
Dia.
254 mm (10") 127.0 mm (5.00")
305 mm (12") 152.4 mm (6.00")
356 mm (14") 181.1 mm (7.13")
406 mm (16") 206.5 mm (8.13")
457 mm (18") 231.9 mm (9.13")
508 mm (20") 258.8 mm (10.19")
610 mm (24") 312.7 mm (12.31")
TABLE 2
FIGURE 1 FIGURE 2
CHANGE LINING PROCEDURE can be eased out of its bore. This is accomplished
by carefully introducing low pressure air, .7-1.0 bar
See table 1 for Repair Kit required for your brake.
(10-15 psi), through fluid inlet fittings.
1. Follow steps 1-3 of Change Repair Kit Procedure,
Disassembly (for Externally or Internally Ported
Models). Do not use high pressure as it is dangerous and un-
2. Gently press piston back into housing bore. Piston necessary. Use just enough air pressure to ease the
must bottom on housing to assure lining to disc piston out of the bore. Do not blow piston out of the
clearance on vehicle. bore. If the piston is seized or cocked or does not
3. Install new lining assemblies into housing pockets. come out readily, release the air pressure and use a
4. Complete brake assembly by following steps 10-15 soft (brass) hammer to rap sharply on and around the
(for Externally Ported Models) or steps 11-15 (for end of the piston. Reapply air pressure to remove the
Internally Ported Models) of Assembly Procedure. piston.
EXTERNALLY PORTED MODELS: While pulling piston out of its bore, work seal (6) lip
02-520-033 from piston groove. Be careful not to scratch
02-520-034 piston.
6. Remove seal (6) from housing (3) half. Remove
CHANGE REPAIR KIT PROCEDURE back-up ring (5) and o-ring (4) from inner housing
DISASSEMBLY groove. Use a small screwdriver or similar tool.
(Refer to Figure 3) Be careful not to scratch the bore.
See table 1 for Repair Kit required for your brake. 7. Repeat steps 3-6 for second housing (3) half.
1. Remove brake from vehicle by disconnecting CHANGE REPAIR KIT PROCEDURE

necessary fluid lines and removing mounting bolts. ASSEMBLY
Drain fluid from assembly. (Refer to Figure 3)
2. Separate housing (3) halves by removing cap
screws (1), washers (2), tubing assembly (10) and LUBRICATE ALL RUBBER COMPONENTS FROM
spacer (9). REPAIR KIT WITH CLEAN TYPE FLUID USED IN
3. Remove lining assembly (8) from housing (3). THE SYSTEM. MAKE SURE THE REPAIR KIT USED
4. Remove bleeder screw (12) from one housing (3) IS THE PROPER ONE FOR YOUR SYSTEM.
half. Remove o-ring (11) from bleeder screw. 1. Clean housing bore with clean type fluid used in
5. Remove piston (7) from housing (3) half by pulling system.
piston from bore. If piston fails to move, place hous- 2. Install new o-ring (4) and new back-up ring (5) in
ing half face down on bench. Protect piston face by groove of one housing (3) half. Note order of o-ring
placing a cloth between piston and bench. Support and back-up ring.
housing half on bench in such a way that piston
FIGURE 3
l Items included in Repair Kit

s Items included in Lining Kit
INTERNALLY PORTED MODELS:
When installing back-up ring (5) be sure it is positioned 02-520-201 02-520-206
on the lining side of groove. If the back-up ring is 02-520-202 03-520-204
cupped, be sure that cupped side is against o-ring (4). 02-520-203 03-520-205
3. Install new seal (6) in one housing (3) half. 02-520-205
4. Lubricate piston (7) with clean type fluid used in
system. Carefully insert piston through seal. Gently CHANGE REPAIR KIT PROCEDURE
push piston into housing (3) bore with a twisting DISASSEMBLY
motion. Piston must bottom on housing to assure (Refer to Figure 4)
lining to disc clearance.
5. Position seal (6) in piston groove. See table 1 for Repair Kit required for your brake.
6. Install lining assembly (8) in housing (3) pocket. 1. Remove brake from vehicle by disconnecting
7. Install new o-ring (11) on bleeder screw (12). Install necessary fluid lines and removing mounting bolts.
bleeder screw in housing (3) half. Drain fluid from assembly.
8. Repeat steps 1-7 for second housing (3) half. 2. Separate housing (3) halves by removing cap
9. Position spacer (9) between the housing (3) halves. screws (1) and washers (2).
Install washers (2) and cap screws (1). 3. Remove lining assembly (11) from housing (3).
Torque: 122.0-135.6 N-m (90-100 lb-ft). 4. Remove bleeder screw (4) from one housing (3)
10. Connect tubing assembly (10). half. Remove o-ring (5) from bleeder screw.
11. Install brake on vehicle with bleeder screws (4) up. 5. Remove seal (6) from housing (3).
Shim as required to center caliper over disc. SEE 6. Remove piston (10) from housing (3) half by pulling
TORQUE NOTE ON FIRST PAGE. piston from bore. If piston fails to move, place hous-
12. Connect necessary fluid lines. ing half face down on bench. Protect piston face by
13. Bleed the system making sure all air is eliminated. placing a cloth between piston and bench. Support
14. Make several static brake applications. Check for housing half on bench in such a way that piston can
leaks and bleed once more. be eased out of its bore. This is accomplished by
15. Check linings to be sure there is no drag. If lining to carefully introducing low pressure air, .7-1.0 bar
disc drag occurs, refer to step 4 above to correct. (10-15 psi), through fluid inlet fittings.
FIGURE 4
l Items included in Repair Kit

s Items included in Lining Kit
4. Lubricate piston (10) with clean type fluid used in
system. Carefully insert piston through boot (9).
Do not use high pressure as it is dangerous and un-
Gently push piston into housing (3) bore with a
necessary. Use just enough air pressure to ease the twisting motion. Piston must bottom on housing
piston out of the bore. Do not blow piston out of the to assure lining to disc clearance.
bore. If the piston is seized or cocked or does not 5. Position boot (9) in piston groove.
come out readily, release the air pressure and use a 6. Install lining assembly (11) in housing (3) pocket.
soft (brass) hammer to rap sharply on and around the 7. Install new o-ring (5) on bleeder screw (4). Install
end of the piston. Reapply air pressure to remove the bleeder screw in housing (3) half.
piston. 8. Repeat steps 1-7 for second housing (3) half.
While pulling piston out of bore, work boot (9) from 9. Install new seal (6) in one housing (3) half.
piston groove. Be careful not to scratch piston. 10. Install washers (2) and cap screws (1).
7. Remove boot (9) from housing (3) half. Remove Torque: 122.0-135.6 N-m (90-100 lb-ft).
back-up ring (8) and o-ring (7) from inner housing 11. Install brake on vehicle with bleeder screws (4) up.
groove. Use a small screwdriver or similar tool. Shim as required to center caliper over disc. SEE
Be careful not to scratch the bore. TORQUE NOTE ON FIRST PAGE.
8. Repeat steps 3-7 for second housing (3) half. 12. Connect necessary fluid lines.
13. Bleed the system making sure all air is eliminated.
CHANGE REPAIR KIT PROCEDURE 14. Make several static brake applications. Check for
ASSEMBLY leaks and bleed once more.
(Refer to Figure 4) 15. Check linings to be sure there is no drag. If lining to
disc drag occurs, refer to step 4 above to correct.
LUBRICATE ALL RUBBER COMPONENTS FROM
REPAIR KIT WITH CLEAN TYPE FLUID USED IN THE
SYSTEM. MAKE SURE THE REPAIR KIT USED IS
THE PROPER ONE FOR YOUR SYSTEM.
1. Clean housing bore with clean type fluid used in
system.
2. Install new o-ring (7) and new back-up ring (8) in
groove of one housing (3) half. Note order of o-ring
and back-up ring.
3. Install new boot (9) in one housing (3) half.
When installing back-up ring (8) be sure it is posi-

tioned on the lining side of groove. If the back-up ring
is cupped, be sure that cupped side is against o-ring
(7).
MICO could not possibly know of and give advice with respect to all conceivable applications in which this product may be used and the possible hazards and/or
results of each application. MICO has not undertaken any such wide evaluation. Therefore, anyone who uses an application which is not recommended by the
manufacturer, first must completely satisfy himself that a danger will not be created by the application selected, or by the particular model of our product that is
selected for the application.
MICO has made every attempt to present accurate information in catalogs, brochures and other printed material. MICO can accept no responsibility for errors from
unintentional oversights that may exist. Due to a continuous program of product improvement, both materials and specifications are subject to change without
notice or obligation.
MICO is a registered trademark of MICO, Incorporated. MICO is registered in the U.S. Patent and Trademark Office as well as in Canada, Great Britain, South Korea, Australia, and Japan.

P.O. Box 8118 / North Mankato, MN U.S.A. 56002-8118 P.O. Box 9058 / Ontario, CA U.S.A. 91762-9058

Technical Manual
Automatic Plunger Greasing System
Description:
An automatic plunger greasing system is available as an option from MSI. The system is
designed for the automatic lubrication of the pump packing nuts and plunger. The system
uses a dual timer, with the top adjustment being the time on and the bottom adjustment
being the time off. This unit is designed for ease of installation and reliable operation to
keep your MSI pump running smoothly.
Startup is a critical time for plunger packing. Lubrication should flow freely to the
plunger prior to stroking the pump. *Stroking dry plungers can cause the header ring
and packing to tear and fail*. MSI recommends a run time of 1 minute and an off
duration of 3.5 to 4 minutes. This will deliver 2.8 cubic centimeters of grease per plunger
every 5 minutes. Best performance has been seen using 1 minute on and 3.5 minutes off.
This lubrication system pumps very small amounts of grease. It is therefore necessary to
pre-fill the grease lines and packing nut with grease. There are grease fittings on each
pressure relief valve on the pump for this purpose. After each packing change and on
initial installation, the user should pump grease into these fittings until resistance is felt.
This will fill the lines and the packing nut with grease. There is a fourth grease fitting on
the pump housing for filling the reservoir. The top of the reservoir may be removed and
grease spooned in from the top, however this is NOT recommended. It is recommended
that the grease fitting be used to help avoid getting pump damaging contaminants in the
system.
The grease should be a synthetic or lithium based grease. MSI recommends the
following brands for the plunger greasing system:
Brand Web Site

Mobile1 Synthetic Grease www.mobil.com
Oil Center Research 157 High
www.oilcenter.com
Temperature Plating Lubricant
There are black rubber boots covering each pressure relief valve. If grease is seen coming
from one of these locations, an over-pressure (approximately 4000 psi) situation has
occurred. Either the grease line is blocked or too much grease is being applied. If this
occurs, disconnect the grease line at the packing nut check valve and cycle the pump.
You should see a small amount of grease being pushed out. If you do not see the grease,
the line is plugged and must be cleared or replaced. If the line is clear, you are applying
too much grease. Try decreasing the ON time or increasing the OFF time. The ON time
should not be less than one-half minute.
Installation:
When mounting the system, you must support the pump by using the two large bolts
sticking through the back of the container in addition to the box mounts. The system
requires 12-volt DC power for operation. The positive and negative input terminals are
marked in the container. The power draw is less than 2 amps, and the installer should
provide an in-line 2 amp (min) fuse. Please see the wiring schematic and grease system
diagrams below for further information.
MSI is a division of Dixie Iron Works, Ltd.

300 West Main St.
Alice, Texas 78332, USA
Phone: 800-242-0059
Fax: 361-664-4840
VALVES*FITTINGS*MANIFOLDS*PUMPS
www.diwmsi.com
8/9/05 Rev. 0
8/9/05 Rev. 0
1 2 3 4 5 6 7 8
6 5 4 3
TIMER
BASE
B
7 8 1 2
CONTACTS
N.C.
C
CYCLE POWER TERMINAL

D STRIP
2 AMP MIN
E
WARNING: + _ _ +
DISCONNECT ALL POWER SOURCES
PUMP LEADS
BEFORE SERVICING UNIT OR CHANGING
TIMER SETTINGS. SUPPLY OUT TO
+ IN PUMP
F PUMP ROTATION: CW (VIEWED FROM TOP)
SWITCHED SUPPLY SOURCE
_
*NOTE POLARITY OF TERMINALS
AND PUMP LEADS
NOTES UNSPECIFIED TOLERANCES REVISION CHANGE MADE ECN NUMBER DESCRIPTION
1. BREAK ALL EDGES 0.008/0.016 x 45 OR
THIS DRAWING IS THE PROPERTY OF DIXIE IRON WORKS, LTD. R0.008/0.016 EXCEPT THREADS.
2. ALL MACHINED CORNER RADII TO BE R0.031.
FRACTIONS 1/64 0 WIRING DIAGRAM
DECIMALS XX 0.015
THE BORROWER AGREES BY RECEIVING THE DRAWING TO 3. ALL DIMENSIONS ARE IN INCHES
(UNLESS OTHERWISE STATED). XXX 0.005 PLUNGER LUBE PUMP
XXXX 0.001
RETURN IT UPON REQUEST AND TO NEITHER REPRODUCE 4. BLUNT START ALL ACME THREADS.
5. ALL DIAMETERS TO BE CONCENTRIC WITHIN ANGLE 1/2
COPY OR FURNISH INFORMATION FROM IT TO OTHERS 0.005 (UNLESS OTHERWISE STATED).
WITHOUT EXPRESSED WRITTEN PERMISSION OF DIXIE IRON

6. MACHINED SURFACES TO BE 125in Ra
MATERIAL/ HEAT TREAT/ WELD PROCEDURE
300 West Main Street
G
UNLESS OTHERWISE STATED. DRAWN BY
WORKS, LTD. ALL ARTICLES MANUFACTURED IN
7. ALL DIMENSIONS IN PARENTHESIS ARE REFERENCE Alice, TX 78332
DIMENSIONS (X.XXX).
8. CL DENOTES SYMMETRY BETWEEN FEATURES, ABOUT
WJT
ACCORDANCE WITH THIS DRAWING SHALL BE CONSIDERED CL AXIS, UNLESS NOTED OTHERWISE.
www.diwmsi.com
DESIGNS OF DIXIE IRON WORKS, LTD. AND MAY NOT BE
THIRD ANGLE PROJECTION -A-
DATUM INDICATING
CONCENTRICITY ANGULARITY RUNOUT COUNTERBORE
DATE 800.242.0059
USED OR SOLD WITHOUT DIXIE IRON WORKS, LTD. WRITTEN SYMBOL 8/8/05 MSI is a division of Dixie Iron Works, Ltd.
PERMISSION. WEIGHT SHEET PART NUMBER REV
POSTION FLATNESS PERPENDICULARITY PARALLELISM COUNTERSINK
SHEET 1 OF 1 GRSA001-E 0
B73G
Excelon 73 Series Filter/Regulator
1/4", 3/8", 1/2" Port Sizes
Excelon design allows in-line or modular installation
Quick release bayonet bowl
Highly visible, prismatic liquid level indicator lens
Full flow gauge ports
Balanced valve design minimizes effect of variation

in the inlet pressure on the outlet pressure
Modular installations with Excelon 72, 73, and 74

series can be made to suit particular applications
Ordering Information. Models listed include PTF threads, knob adjustment, automatic drain, metal bowl with liquid level indicator, 40 m element,
relieving diaphragm, 5 to 150 psig (0.3 to 10 bar) outlet pressure adjustment range* with gauge.
Main Port Size Model Number Flow scfm (dm3/s) Weight lb (kg)
1/4" B73G-2AK-AD3-RMG 78 (37) 1.76 (0.82)
3/8" B73G-3AK-AD3-RMG 123 (58) 1.76 (0.82)
1/2" B73G-4AK-AD3-RMG 123 (58) 1.76 (0.82)
Typical flow with 150 psig (10 bar) inlet pressure, 90 psig (6.3 bar) set pressure and 15 psig (1 bar) droop from set.
Alternative Models B 7 3 G - - -
Port Size Substitute Gauge Substitute
1/4" 2 With G
3/8" 3 Without N
1/2" 4
Threads Substitute
PTF A Outlet Pressure Adjustment Range* Substitute
ISO Rc taper B 5 to 60 psig (0.3 to 4 bar) F
ISO G parallel G 5 to 150 psig (0.3 to 10 bar) M
10 to 250 psig (0.7 to 17 bar)** S
Adjustment Substitute
Knob K
T-bar T Diaphragm Substitute
Relieving R
Drain Substitute Non relieving N
Automatic A
Manual, 1/4 turn Q
Bowl Substitute Element Substitute

Metal with liquid level indicator D 5 m 1
Transparent with guard P 25 m 2
Transparent T 40 m 3
**Units with 250 psig (17 bar) outlet pressure range are available only with the
*Outlet pressure can be adjusted to pressures in excess of, and less than, those standard metal bowl.
specified. Do not use these units to control pressures outside of the specified ranges.
See Section ALE-25 for Accessories
ALE-13-6 Littleton, CO USA Phone 303-794-2611 Fax 303-795-9487

B73G Filter/Regulators
Technical Data All Dimensions in Inches (mm)
Fluid: Compressed air Typical Performance Characteristics
Maximum pressure FLOW CHARACTERISTICS
Transparent bowl: 150 psig (10 bar)
psig
bar
PORT SIZE: 3/8"
Metal bowl: 250 psig (17 bar) ELEMENT: 40 m
8
INLET PRESSURE: 150 psig (10 bar)
Operating temperature* RANGE: 5 to 150 psig (0.3 to 10 bar)
100
Transparent bowl: -30 to 125F (-34 to 50C)
OUTLET PRESSURE
Metal bowl: -30 to 175F (-34 to 80C) 6
* Air supply must be dry enough to avoid ice formation at temperatures below 35F (2C). 80
Particle removal: 5 m, 25 m or 40 m filter element

60
Air quality: Within ISO 8573-1, Class 3 and Class 5 (particulates) 4
Typical flow with 150 psig (10 bar) inlet pressure, 90 psig (6.3 bar) set pressure
3 40
and 15 psig (1 bar) droop from set: 123 scfm (58 dm /s)
Manual drain connection: Will fit 1/8-27 and 1/8-28 pipe thread 2
20
Automatic drain connection: Will fit 1/8-27 and 1/8-28 pipe thread - Flexible tube
with 3/16" (5mm) minimum I.D. can be connected to the automatic drain. Drain
0 0
may fail to operate if the tube I.D. is less than 3/16" (5mm). Avoid restrictions in 0 40 80 120 160 200 scfm
the tube.
0 20 40 60 80 100 dm3/s
Automatic drain operating conditions (float operated): AIR FLOW
Bowl pressure required to close drain: Greater than 5 psig (0.3 bar)
FLOW CHARACTERISTICS
Bowl pressure required to open drain: Less than 3 psig (0.2 bar)
bar
psig
PORT SIZE: 3/8"
Minimum air flow required to close drain: 0.2 scfm (0.1 dm3/s) ELEMENT: 40 m
INLET PRESSURE: 100 psig (7 bar)
Manual operation: Depress pin inside drain outlet to drain bowl RANGE: 5 to 150 psig (0.3 to 10 bar)
Nominal bowl size: 3.5 fluid ounce (0.1 liter) 100
OUTLET PRESSURE
Gauge ports: 6
14" PTF with PTF main ports 80
Rc1/4 with ISO Rc main ports

Rc1/8 with ISO G main ports 4 60
Materials
Body: Aluminum 40
Bonnet: Aluminum or Zinc 2

20
Valve: Brass
Bowl:
0 0
Transparent: Polycarbonate 0 20 40 60 80 100 scfm
Transparent with guard: Polycarbonate, steel guard
0 10 20 30 40 50 dm3/s
Metal: Aluminum AIR FLOW
Metal bowl liquid level indicator lens: Transparent nylon
Element: Sintered polypropylene Service Kits
Elastomers: Neoprene and nitrile Item Type Part Number
Service kit Relieving 4383-600
2.68 (68) Non-relieving 4383-601
1.22 (31)
5 m 4438-01
Replacement elements 25 m 4438-02
2.45 (62)
40 m 4438-03
Liquid level lens kit Prismatic 4380-020
Automatic 4000-51R
Replacement drains
2.20 (56)
Manual quarter turn 619-50

Panel mounting hole diameter 1.89" (48 mm)
Service kit includes diaphragm assembly, valve assembly, valve
Panel thickness: 0.25 (6 mm)
spring, bowl o-ring, and automatic drain seal.
2.00 (50)
0.45 (12)
4.04 (103)
3.80 (96)
ISO Symbols
1.22
(31)
8.15 (207)**
8.50 (216)**
5.80 (147)
6.15 (156)
Automatic Drain, Relieving Manual Drain, Relieving
Automatic Drain Automatic Drain, Non-Relieving Manual Drain, Non-Relieving

** Minimum clearance to remove bowl. 1/4 Turn Manual Drain
Littleton, CO USA Phone 303-794-2611 Fax 303-795-9487 ALE-13-7

B73G
Installation & Maintenance
Filter/Regulator Instructions
B73G - - -
Port Thread Form Adjustment Drain Bowl Element Diaphragm Spring (Outlet Pressure Range) * Gauge
2 ....1/4" A....PTF K....Knob A....Automatic D....Metal with liquid level indicator 1 ....5 m N....Non-relieving F ....0,3 to 4 bar (5 to 60 psig) G....With
3 ....3/8" B....ISO Rc taper T ....T-bar Q....Manual, 1/4 turn P....Transparent with guard 2 ....25 m R....Relieving M...0,3 to 10 bar (5 to 150 psig) N....Without
4 ....1/2" G....ISO G parallel T ....Transparent 3 ....40 m S....0,7 to 17 bar (10 to 250 psig)
* Outlet pressure can be adjusted to pressures in excess of, and less than, those specified. Do not use these units to control pressures outside of the specified ranges.
TECHNICAL DATA ADJUSTMENT 12

1
Fluid: Compressed air 1. Before applying inlet pressure to filter/regulator, turn
Maximum pressure: adjustment (1 or 7) counterclockwise to remove all force
Transparent bowl: 10 bar (150 psig) on regulating spring (12).
Metal bowl: 17 bar (250 psig) 2. Apply inlet pressure, then turn adjustment (1 or 7)
Operating temperature*: clockwise to increase and counterclockwise to decrease 3 13
Transparent bowl: -20 to +50C (0 to +125F) pressure setting. 2
Metal bowl: -20 to +80C (0 to +175F) 3. Always approach the desired pressure from a lower 16
* Air supply must be dry enough to avoid ice formation at pressure. When reducing from a higher to a lower
temperatures below +2C (+35F). setting, first reduce to some pressure less than that
Particle removal: 5 m, 25 m, or 40 m filter element desired, then bring up to the desired pressure. 15
Air quality: Within ISO 8573-1, Class 3 and Class 5 NOTE 4
(particulates) With non-relieving filter/regulators, make pressure
Typical flow with 10 bar (150 psig) inlet pressure, 6,3 bar reductions with some air flow in the system. If
(90 psig) set pressure and 1 bar (15 psig) droop from made under no flow (dead-end) conditions, the
set: 50 dm3/s (106 scfm) filter/regulator will trap the over-pressure in the
5
Nominal bowl size: 0,1 litre (3.5 fluid ounce) downstream line.
Manual drain connection: 1/8" 4. KNOB ADJUSTMENT. Push knob down to lock pressure 14
Automatic drain connection: 1/8" setting. Pull knob up to release. Install tamper resistant 53
Automatic drain operating conditions (float operated): cover (see Replacement Items) to make setting tamper
Bowl pressure required to close drain: Greater than 0,3 resistant. 6 54
bar (5 psig) 5. T-BAR ADJUSTMENT. Tighten lock nut (8) to lock
Bowl pressure required to open drain: Less than 0,2 bar 52
pressure setting. 7
(3 psig) 8
Minimum air flow required to close drain: 0,1 dm3/s (0.2 SERVICING
10 51
scfm) 1. Open manual drain to expel accumulated liquids. Keep
liquids below baffle (49). 9
Manual operation: Depress pin inside drain outlet to
drain bowl 2. Clean or replace filter element when dirty.
Gauge ports: DISASSEMBLY
14 PTF with PTF main ports 50
1. Filter/regulator can be disassembled without removal
Rc1/4 with ISO Rc main ports from air line. 11
Rc1/8 with ISO G main ports 2. Shut off inlet pressure. Reduce pressure in inlet and
Materials: outlet lines to zero. 49
Body: Aluminum 3. Turn adjustment (1 or 7) fully counterclockwise.
Bonnet: Aluminum 4. Remove bowl - push into body and turn
Valve: Brass counterclockwise.
Bowl: 26
5. Disassemble in general accordance with the item
Transparent: Polycarbonate numbers on exploded view. Do not remove the drains 18
Transparent with guard: Polycarbonate, steel guard 21
unless replacement is necessary. Remove and replace 25
Metal: Aluminum drains only if they malfunction.
Metal bowl liquid level indicator lens: Transparent nylon
Element: Sintered polypropylene CLEANING
23 24
Elastomers: Neoprene and nitrile 1. Clean plastic bowl (25, 35) with warm water only. Clean 17
other parts with warm water and soap.
REPLACEMENT ITEMS 2. Rinse and dry parts. Blow out internal passages in body 20
Service Kit (includes items circled on exploded view): (16) with clean, dry compressed air. Blow air through 19
Relieving.............................................................4383-600 filter element (50) from inside to outside to remove
Nonrelieving .......................................................4383-601 surface contaminants. 22
Liquid level lens kit (43, 45, 46, 47) ......................4380-020 3. Inspect parts. Replace those found to be damaged.
Filter element, 5m, red speckles (50).....................4438-01 Replace plastic bowl with a metal bowl if plastic bowl
Filter element, 25m, blue speckles (50) .................4438-02 shows signs of cracking or cloudiness.
Filter element, 40m, no speckles (50)....................4438-03 34
ASSEMBLY 28
Manual drain (18, 19, 20) ..........................................619-50 31
Automatic drain (21, 22, 23) .................................4000-51R 1. Lubricate the following items with o-ring grease.
Tamper resistant cover (knob adjustment only).......4455-51 4 (Thrust washer) - outer circumference and both sides.
27 35
5, 7 (Adjusting screw) - threads and tip.
PANEL MOUNTING DIMENSIONS 18, 28, 37 (Manual drain body) - the portion of the 33
Panel mounting hole diameter: 48 mm (1.89") body that contacts the bowl, and the hole that 30
Panel thickness: 2 to 6 mm (0.06" to 0.24") accommodates the stem of drain valve (19, 29, 38). 29
INSTALLATION 53 (Valve) - stem.
1. Shut off air pressure. Install filter/regulator in air line - 26, 34, 47, 54 (O-rings) 32
vertically (bowl down),
2. Assemble the unit as shown on the exploded view. Push
with air flow in direction of arrow on body,
bowl, or bowl with guard, into body and turn fully 47
upstream of lubricators and cycling valves,
clockwise. 37 40 48
as close as possible to the device being serviced.
3. Torque Table
Item Torque in Nm (Inch-Pounds) 46
2. Connect piping to proper ports using pipe thread sealant 36 45
on male threads only. Do not allow sealant to enter 2, 9 (Screw) 2,3 to 3,4 (20 to 30)
43
interior of unit. 22, 32, 41 (Nut) 2,3 to 2,8 (20 to 25)
42
3. Push bowl, or bowl with guard, into body and turn fully 43 (Screw) 1,7 to 3,4 (15 to 30)
39
clockwise before pressurizing. 49 (Baffle), 51 (Louver) 1,1 to 2,2 (10 to 20)
38
4. Install a pressure gauge or plug the gauge ports. Gauge
ports can also be used as additional outlets for regulated air. 44
41
Norgren 1998
IM-180.300.01 (9/98)
a subsidiary of IMI plc Supersedes 4/98
B73G
Installation & Maintenance
Instructions
CAUTION
Water vapor will pass through these units and could
condense into liquid form downstream as air temperature
drops. Install an air dryer if water condensation could have
a detrimental effect on the application.
WARNING
These products are intended for use in industrial
compressed air systems only. Do not use these products
where pressures and temperatures can exceed those listed
under Technical Data.
Polycarbonate plastic bowls can be damaged and
possibly burst if exposed to such substances as certain
solvents, strong alkalies, compressor oils containing ester-
based additives or synthetic oils. Fumes of these
substances in contact with the polycarbonate bowl,
externally or internally, can also result in damage. Clean
with warm water only.
Use metal bowl in applications where a plastic bowl
might be exposed to substances that are incompatible with
polycarbonate.
If outlet pressure in excess of the filter/regulator
pressure setting could cause downstream equipment to
rupture or malfunction, install a pressure relief device
downstream of the filter/regulator. The relief pressure and
flow capacity of the relief device must satisfy system
requirements.
The accuracy of the indication of pressure gauges can
change, both during shipment (despite care in packaging)
and during the service life. If a pressure gauge is to be
used with these products and if inaccurate indications may
be hazardous to personnel or property, the gauge should be
calibrated before initial installation and at regular intervals
during use.
Before using these products with fluids other than air,
for non industrial applications, or for life-support systems
consult Norgren.
Norgren 1998
IM-180.300.02 (9/98)
B73G
Filter/Regulator - Parts
In the following parts list, assemblies are printed in capital letters. Parts that are included with an
assembly are listed and indented directly beneath it. When an assembly is ordered, the assembly and all
1 12
parts indented beneath it are included in the shipment.
When an assembly lists a letter code in the USED ON column, parts that list the same letter code are
used in that assembly. Parts coded A are used in the Assembly coded A, parts coded B are used in the
Assembly coded B, etc.
USED
ITEM DESCRIPTION PART NO. QTY ON 3 13
1 Knob, adjusting................................................................................................4407-89 1 2
2 Screw ............................................................................................................9PM4-13 4 16
3 Bonnet .............................................................................................................4405-89 1
4 Washer, thrust .................................................................................................5183-01 1
5 Screw, adjusting ..............................................................................................5675-51 1 15
6 BONNET ASSY, T-bar adjustment ................................................................ 4405-51 1 4
7 T-bar and lock nut ..........................................................................................584-50 1
8 Nut..............................................................................................................575-01 1
9 Screw..........................................................................................................9PM4-13 4
10 Bonnet ...............................................................................Not available separately 1
11 Spring rest ..................................................................................................5044-89 1 5
12 Spring, regulating, 60 psig (4 bar)...................................................................4432-01 1
Spring, regulating, 150 psig (10 bar)...............................................................4432-02 1 14
53
Spring, regulating, 250 psig (17 bar)...............................................................4432-03 1
13 Diaphragm, relieving (service kit item) ............................................................4409-50 1 54
6
Diaphragm, non-relieving (service kit item).....................................................4409-51 1
14 Plug, pipe, 1/4 PTF (service kit item)..............................................................2891-97 2
52
Plug, pipe, 1/4 ISO Rc (service kit item) .........................................................2845-02 2 7
Plug, pipe, 1/8 ISO G (service kit item)...........................................................2338-99 2 8
15 Gauge, pressure, 1/4 PTF, 60 psig (4 bar) ................................................18-013-208 1 10 51
Gauge, pressure, 1/4 PTF, 160 psig (10 bar) ............................................18-013-209 1
Gauge, pressure, 1/4 PTF, 300 psig (20 bar) ............................................18-013-210 1 9
Gauge, pressure, 1/4 ISO Rc, 4 bar ..........................................................18-013-266 1
Gauge, pressure, 1/4 ISO Rc, 10 bar ........................................................18-013-260 1
Gauge, pressure, 1/4 ISO Rc, 20 bar ........................................................18-013-267 1 50
Gauge, pressure, 1/8 ISO G, 4 bar ............................................................18-013-012 1
Gauge, pressure, 1/8 ISO G, 10 bar ..........................................................18-013-013 1 11
Gauge, pressure, 1/8 ISO G, 20 bar ..........................................................18-013-014 1
16 Body ........................................................................................Not normally replaced 1 49
17 PLASTIC BOWL & GUARD ASSY, 1/4 turn manual drain......................4425-50RF 1 A

17 PLASTIC BOWL & GUARD ASSY, automatic drain ...............................4425-51RF 1 B
18 MANUAL DRAIN ASSY, 1/4 turn ..................................................................619-50 1 A 26
19 Valve, drain ................................................................................................617-89 1 A 18
20 O-ring .......................................................................................................2317-05 1 A 21
25
21 AUTOMATIC DRAIN ASSY ......................................................................4000-51R 1 B
22 Nut............................................................................................................2797-89 1 B
23 Gasket (service kit item) ..........................................................................2811-01 1 B
23 24
24 Guard, bowl .................................................................................................4426-01 1 AB 17
25 Bowl, plastic ..........................................................................Not normally replaced 1 AB
26 O-ring (service kit item) ...............................................................................2316-29 1 AB 20
19
27 PLASTIC BOWL ASSY, no guard, 1/4 turn manual drain......................4466-50RF 1 C
27 PLASTIC BOWL ASSY, no guard, automatic drain................................4466-51RF 1 D
28 MANUAL DRAIN ASSY, 1/4 turn ..................................................................619-50 1 C 22
29 Valve, drain ................................................................................................617-89 1 C
30 O-ring .......................................................................................................2317-05 1 C
31 AUTOMATIC DRAIN ASSY ......................................................................4000-51R 1 D
34
32 Nut............................................................................................................2797-89 1 D 28
31
33 Gasket (service kit item) ..........................................................................2811-01 1 D
34 O-ring (service kit item) ...............................................................................2316-29 1 CD
35 Bowl, plastic ..........................................................................Not normally replaced 1 CD 27 35
33
36 METAL BOWL ASSY, sight glass, 1/4 turn manual drain.....................4403-50RF 1 E 30
36 METAL BOWL ASSY, sight glass, automatic drain ...............................4403-51RF 1 F
29
37 MANUAL DRAIN ASSY, 1/4 turn ..................................................................619-50 1 E
38 Valve, drain ................................................................................................617-89 1 E
39 O-ring .......................................................................................................2317-05 1 E 32
40 AUTOMATIC DRAIN ASSY ......................................................................4000-51R 1 F
41 Nut............................................................................................................2797-89 1 F 47
42 Gasket (service kit item) ..........................................................................2811-01 1 F 37 40 48
43 Screw (service kit item) ...............................................................................9P06-12 2 EF
44 Clamp, sight glass .......................................................................................4467-01 1 EF 46
36 45
45 Lens, sight glass (service kit item) ..............................................................4421-89 1 EF
43
46 Seal, sight glass lens (service kit item) .......................................................4422-89 1 EF
42
47 O-ring, bowl (service kit item)......................................................................2316-29 1 EF
48 Bowl, metal ............................................................................Not normally replaced 1 EF 39
38
41 44
Norgren 1998
PL-180.300.01 (9/98)
B73G
Filter/Regulator - Parts
USED
1 12
ITEM DESCRIPTION PART NO. QTY ON
49 Baffle ..............................................................................................................4470-89 1
50 Element, 5-micron, red speckles .....................................................................4438-01 1
Element, 25-micron, blue speckles .................................................................4438-02 1
Element, 40-micron, no speckles ....................................................................4438-03 1
51 Louver..............................................................................................................4434-89 1 3 13
52 Spring, valve (service kit item) ........................................................................4419-01 1 2
53 VALVE ASSY (service kit item) .......................................................................4408-50 1 16
54 O-ring (service kit item) .................................................................................422-01 1
SERVICE KITS & ACCESSORIES 15

Service kit, relieving- includes items circled on exploded view ............................4383-600 4
Service kit, non-relieving- includes items circled on exploded view .....................4383-601
Metal bowl liquid level lens kit - items 43, 45, 46, 47 ...........................................4380-020
Kit, pipe plug, 1/4 PTF - item 14, contains two.......................................................3724-05
Kit, pipe plug, 1/4 ISO Rc - item 14, contains two..................................................3724-09
Kit, pipe plug, 1/8 ISO G - item 14, contains two....................................................3723-06 5
Universal wall mounting bracket kit.........................................................................4424-50
B73 neck wall mounting bracket with panel nut......................................................4461-50 14
53
B73 neck panel nut ................................................................................................5191-88
Tamper resistant cover and seal wire (use only with knob adjustment) .................4455-51 54
6
52
7
8
10 51
9
50
11
49
26
18
21
25
23 24
17
20
19
22
34
28
31
27 35
33
30
29
32
47
37 40 48
46
36 45
43
42
39
38
41 44
Norgren 1998
PL-180.300.02 (9/98)
NOSHOK Pressure Gauges 300 Series Model 310 2 1/2 Inch Dial Size Page 1 of 9
Select A Model 310 Dial Size
25-310 40-310
2 Inch 4 Inch
2 Inch Dial Size

Size & Model Number: 25-310
NPT Connection Size & Type: 1/4" NPT Brass Center Back Connection
7/16"-20 SAE (Stocked in Ranges Indicated with (*) Below)
Model Specifications: Stock Model Specifications
Standard Pressure Ranges: 30 inHg Vacuum through 15,000 psi
Dial Configurations: Single Scale psi
Dual Scale psi/kPa, psi/kg/cm, psi/bar
Options & Accessories: Regularly Stocked Options & Accessories
Ordering Information Ordering Information Sheet
Special Ordering: Contact Us for Details on Custom Configurations
STANDARD PRESSURE RANGES
Single Scale Dial Units Single Scale Options: psi
Outer Scale Options: psi

Dual Scale Dial Units
Inner Scale Options: kPa bar kg/cm
Pressure Ranges 30" Vac -30 inHg to 0 inHg 200 0 psi to 200 psi*
30-0-15 -30 inHg to 0 inHg to 15 psi 300 0 psi to 300 psi*
30-0-100 -30 inHg to 0 inHg to 100 psi 800 0 psi to 800 psi
30-0-160 -30 inHg to 0 inHg to 160 psi 1,000 0 psi to 1,000 psi*
15 0 psi to 15 psi 6,000 0 psi to 6,000 psi*
30 0 psi to 30 psi 7,500 0 psi to 7,500 psi
60 0 psi to 60 psi 10,000 0 psi to 10,000 psi
100 0 psi to 100 psi* 15,000 0 psi to 15,000 psi
160 0 psi to 160 psi*
* This Range is Also Available in a 7/16" -20 SAE Adustable Type Straight Thread Connection
http://www.noshok.com/pg/300series/model310/310_size_25.html 6/20/2003
as a Regularly Stocked Order Option
This Range is Not Regularly Stocked in the kPa Inner Scale Option
This Range is Not Regularly Stocked in the kg/cm Inner Scale Option
This Range is Not Regularly Stocked in the bar Inner Scale Option
Return to the top
STOCK MODEL SPECIFICATIONS

Dial Size 2 Inch (63 mm)
Case Die Cast Brass - Natural Brass Finish
1/4" NPT Brass Center Back Connection, Die Cast with the Case is Standard.
The 7/16" -20 SAE J1926/3 Adjustable Type Straight Thread Connection is also
Connection
Available from Stock.
See Stock Options for Additional Connection Offerings.
Stocked Ranges: 30 inHg Vacuum to 0 inHg -> 0 to 15,000 psi

Pressure
See Pressure Ranges for Specific Ranges and Dial Scale Units that are Regularly
Ranges
Stocked.
Cover Ring Polished Brass
Molded Plexiglass with O-Ring Seal. Instrument Glass, Lexan, and Safety Glass
Lens
Overlays are available stock options.
Phosphor Bronze "C" Tube for Pressures up to 600 psi.
Bourdon Tube
Coiled Safety Tube Above 600 psi.
Movement Brass and Nickel Silver with Highly Polished Bearing Surfaces
Safety
Safety Relief Disc on the Top of the Case
Protection
Accuracy 1.5% Full Scale, ASME B40.100 grade A
Pointer Balanced Aluminum, Black Finish.
Aluminum with White Background. UV Resistant.
z Single Scale psi is standard with Black Markings.

z Dual Scale psi/kPa, psi/kg/cm, psi/bar are Regularly Stocked and
Dial
Available upon Request. Outer Scale is psi in Black and the Inner Metric
Scale is Red.
z See Below for Stock Dial Configurations.
Fill Liquid Glycerine and Water

OPERATING SPECIFICATIONS
1. Working Pressure Limitations

a. Dynamic Pressure
The working pressure should be limited to 60% of the dial range.
b. Static Pressure
The working pressure, where no sharp fluctuations occur, should be limited to 90%
of the dial range.
2. Ambient Temperature
0 F to 160 F (-18 C to 71 C)
Lower operating temperatures are available to -40 F (40 C) by using a special glycerine
mixture or low temperature silicone.
Please Contact Us for assistance in selecting the best fill liquid for your application.
Note: All NOSHOK hermetically sealed gauges with ranges of 400 psi and below, including
all vacuum and compound ranges, are equipped with a vent pin in the relief disc. The vent
pin should be removed after installation of the gauge to insure accurate indication.
Return to the top
SINGLE SCALE
Stock Dial Configurations
psi
(These are regularly stocked dial configurations. Contact Us for complete availability of Pressure
Ranges and Dial Scale Units, Including Dual Scale Availability)
Click on the camera to view an actual photo of the dial.
DIAL FIGURE GRADUATION

RANGE INTERVAL INTERVAL
30 inHg Vacuum to 0 inHg -5 inHg -.5 inHg
-30 inHg to 0 inHg -10 inHg -1 inHg

0 psi to 15 psi 5 psi .5 psi
0 psi to 60 psi 10 psi 1 psi
0 psi to 1,000 psi 100 psi 10 psi
0 psi to 7,500 psi 1,000 psi 100 psi
0 psi to 10,000 psi 1,000 psi 100 psi
0 psi to 15,000 psi 3,000 psi 100 psi
Return to the top
DUAL SCALE
Outer Scale psi
Inner Scale kPa
Ranges and Dial Scale Units)

(-100) kPa to 0 kPa -20 kPa -2 kPa
0 kPa to 100 kPa 50 kPa 5 kPa
(-100) kPa to 0 kPa -100 kPa -10 kPa

(-100) kPa to 0 kPa -100 kPa -20 kPa
(-100) kPa to 0 kPa -100 kPa -50 kPa
0 kPa to 1,100 kPa 200 kPa 50 kPa
(-100) kPa to 0 kPa -100 kPa -50 kPa
(-100) kPa to 0 kPa -100 kPa -50 kPa
0 kPa to 4,100 kPa 1,000 kPa 100 kPa
0 kPa to 5,500 kPa 1,000 kPa 100 kPa
0 kPa to 7,000 kPa 2,000 kPa 100 kPa
0 kPa to 10,000 kPa 2,000 kPa 500 kPa
0 kPa to 13,600 kPa 4,000 kPa 400 kPa
0 kPa to 20,500 kPa 5,000 kPa 500 kPa
0 psi to 5,000 psi 1,000 psi 100 psi
0 kPa to 34,000 kPa 10,000 kPa 1,000 kPa
0 psi to 6,000 psi 1,000 psi 100 psi
0 kPa to 41,000 kPa 10,000 kPa 1,000 kPa
0 psi to 7,500 psi 1,000 psi 50 psi

0 kPa to 51,500 kPa 10,000 kPa 500 kPa
0 psi to 10,000 psi 2,000 psi 200 psi
0 kPa to 70,000 kPa 20,000 kPa 2,000 kPa
0 psi to 15,000 psi 3,000 psi 500 psi
0 kPa to 100,000 kPa 20,000 kPa 5,000 kPa
Return to the top
DUAL SCALE
Outer Scale psi
Inner Scale kg/cm

30 inHg Vacuum to 0 inHg 5 psi .5 psi
0 kg/cm to 1 kg/cm .2 kg/cm .02 kg/cm
(-1) kg/cm to 0 kg/cm -.5 kPa -.05 kPa
0 kg/cm to 2.1 kg/cm .5 kPa .05 kPa
(-1) kg/cm to 0 kg/cm -1 kPa -.5 kPa
0 kg/cm to 2.1 kg/cm 2 kPa .5 kPa
0 kg/cm to 1 kg/cm .2 kg/cm .05 kg/cm
0 kg/cm to 2.1 kg/cm .5 kg/cm .05 kg/cm
0 kg/cm to 4.2 kg/cm 1 kg/cm .1 kg/cm
0 kg/cm to 7 kg/cm 2 kg/cm .2 kg/cm
0 kg/cm to 11.2 kg/cm 2 kg/cm .2 kg/cm
0 kg/cm to 42 kg/cm 10 kg/cm 1 kg/cm

0 psi to 5,000 psi 1,000 psi 100 psi
0 psi to 6,000 psi 1,000 psi 100 psi
0 psi to 10,000 psi 2,000 psi 200 psi
0 psi to 15,000 psi 3,000 psi 500 psi
0 kg/cm to 1,050 kg/cm 200 kg/cm 50 kg/cm
Return to the top
DUAL SCALE
Outer Scale psi
Inner Scale bar

(-1) bar to 0 bar .2 bar .02 bar
(-1) bar to 0 bar -.5 bar -.05 bar
0 bar to 1 bar .5 bar .05 bar
(-1) bar to 0 bar -1 bar -.1 bar
0 bar to 2 bar 1 bar .1 bar
0 bar to 6.8 bar 2 bar .2 bar

0 to 15 psi 3 psi .5 psi
0 bar to 1 bar .2 bar .05 bar
0 bar to 2.05 bar .5 bar .05 bar
0 to 60 psi 10 psi 1 psi
0 bar to 41 bar 10 bar 1 bar
0 psi to 5,000 psi 1,000 psi 100 psi
0 psi to 6,000 psi 1,000 psi 100 psi
0 psi to 10,000 psi 2,000 psi 200 psi
0 psi to 15,000 psi 3,000 psi 500 psi
0 bar to 1,000 bar 200 bar 50 bar
Return to the top
Regularly Stocked Options & Accessories
Not seeing what you are looking for?
Chances are if you need it, we can put it together.

Contact Us for Details on Custom Configurations.
Ready to Order?
View the Ordering Information Sheet for this Product
Return to the top
NOSHOK Selection, Installation & Maintenance Guide
Pressure Gauge Series 100, 200, 300, 400, 500, 600, 700, 800 and 900
Installation filled NOSHOK pigtail steam syphon between the gauge
Prior to pressure gauge installation, the following and the steam line.
conditions should be considered: temperature, humidity,
vibration, pulsation, shock, and other climatic and Maintenance
environmental conditions of the application, as well as Apart from occasional calibration, NOSHOK pressure
the potential need for protective accessories and/or gauges require little or no maintenance. Some applications
special installation requirements. may be more aggressive than others, resulting in an
increased frequency in the need for calibration. The
Always use a wrench on the gauge socket when installing environmental limitations for the specific NOSHOK
a NOSHOK pressure gauge into position; never use force pressure gauge series should be observed in all cases, and
on the gauge case to tighten into position. This may result gauges applied in situations outside these requirements
in a loss of accuracy, excessive friction and/or mechanical may result in premature wear and/or failure of the gauge.
damage to the measuring element and case of the
NOSHOK pressure gauge. When surface or panel Warranty
mounting a gauge, be sure the surface is flat and the panel All NOSHOK pressure gauges carry a one or three year
cutout and/or the mounting hole configuration is correct warranty. NOSHOK warrants for three years our 300, 500,
(please refer to the NOSHOK Pressure Gauge catalog 600, and 700 series liquid filled pressure gauges to be
NK95G for these specifications). If the surface is uneven or free from defects in materials and workmanship, to remain
the panel cutout is larger than the gauges diameter, use within the cataloged accuracy and performance
an adapter ring to remove mounting strain and/or adapt specifications, and to maintain the integrity of the
the gauge to the larger diameter panel cutout. When hermetically sealed case preventing leakage. NOSHOK
connecting a gauge to a rigid pipe service, use flexible warrants for one year our 100, 200, 400, 600, 700, 800,
tubing where possible as a connector to eliminate and 900 series non-liquid filled pressure gauge. Certain
plumbing strain. Rapid pressure pulsation and extreme limitations do apply; for more information please consult
mechanical vibration may be damaging to some page three of the NOSHOK Pressure Gauges catalog
NOSHOK pressure gauge movement gearing, bushings, (NK95G).
and linkage. In extreme cases, steps should be taken to
dampen these forces. In pressure ranges over 600 psi, a Please do not hesitate to contact us with any additional
NOSHOK orifice is recommended for pulsation questions.
dampening, but in extreme pulsation applications a The
Instrumentation
NOSHOK Piston Type Pressure Snubber may be required. Company
When installing a gauge into a corrosive situation be sure

to select a pressure gauge or pressure gauge and
diaphragm seal combination suitable for your application. INCORPORATED
Gauges to be used on high temperature service should
1010 WEST BAGLEY ROAD
have a five foot or longer leg of pipe or tubing connecting
BEREA, OHIO 44017
the gauge to dissipate heat and protect the gauge
440/243-0888 FAX 440/243-3472
measuring element from damage. A gauge to be used on
E-MAIL: noshok@noshok.com
steam pressure service should be installed with a water
WEBSITE: www.noshok.com
CAUTION:
Operating conditions including, but not limited to, system pressure, media compatibility and ambient conditions must be considered when selecting gauges and accessories.
Improper selections and use of gauges could possibly cause gauge failure and lead to possible property damage or person injury
. Refer to American National Standard ANSI
B40.1 for the correct selection and use of gauges. A copy of this standard may be obtained from the American Society of Mechanical Engineers, United Engineering Center, 345
East 47th Street, New York, NY 10017.
WARNING:
Glycerine or silicone could result in a spontaneous chemical reaction or explosion when combined with strong oxidizing agents including (but not limited to) chlorine,
hydrochloric or nitric acid and hydrogen peroxide. Do not use glycerine or silicone filled gauges or accessories in these types of service. Consult factory for application
assistance.
In keeping with and for the purposes of product and/or manufacturing improvements, NOSHOK, INC. reserves the right to make design changes without prior notice.
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Loop Flushing Valve
Application Description of Operation
The Loop Flushing Valve is applied in a hydrostatic The high pressure ports (1 and 2) of the valve are
transmission circuit for the purpose of maintaining externally connected to the work or system auxiliary
high quality of the working fluid in the transmission ports of the main hydrostatic transmission circuit.
power loop. While many transmissions can operate The valve drain port (4) must be externally connected
satisfactorily with out a loop flushing valve, the addi- to the case drain return line of the transmission
tion of loop flushing with a resulting improvement in preferably at the motor so that fluid is flushed through
fluid quality will, generally, extend transmission life. the motor case to the pump and returned to the
The loop flushing valve should be considered when reservoir.
any of the following exist: The shuttle valve responds directionally to high pres-
Sustained operation at low pressure and high sure, exposing the low pressure side of the circuit to
speed the charge relief valve. The charge relief valve, when
properly set in accordance with the Adjustment Pro-
Operation where continuous pressure exceeds
cedure, will flush a desired quantity of working fluid
the 1000 hours/year rating
from the transmission power loop. This fluid is
Cylinders in the hydrostatic circuit replaced from the charge replenishing flow entering
Flow restricting valves in the power loop the loop through an integral check valve system in the
Frequent operation of high pressure relief valves main pump.
Long power loop lines A drain orifice may be specified to limit maximum
flushing flow in circuits where the low side pressure is
Extraordinary life requirements
high or varies over a large pressure range.
Monitoring of fluid quality under field operating condi-
tions for extended periods of time is recommended in
a determination of requirements for loop flushing. For
a complete discussion of loop flushing and fluid Specifications
quality, refer to Sauer-Sundstrand Bulletins BLN- System Pressure (in loop)
9886 Transmission Circuit Recommendations and Maximum High Side 6960 psi (480 bar)
BLN-9887 Fluid Quality Requirements.
Maximum Low Side 1015 psi 70 bar
Installation Drawing Charge Relief Valve Setting Range
3.74
[95.0]
.84
[21.3]
44 to 446 psi (3 to 30 bar)
3.45
ADJUSTABLE CHARGE [87.6]
.55
[14.0]
NOTE: Nominal charge relief settings are 20 psi
RELIEF VALVE
1-1/16 HEX
3.08
[78.2]
9/16-18 SAE STR
THD O-RING BOSS (11.4 bar), and are set at a flow of 1 .25 gpm
.156 [3.96] 1.45
[36.8]
1.11 DRAIN PORT
.625
4 (3.8 .9 lpm) at 120F (49C).
SCREWDRIVER SLOT [28.2]
.34
[15.9]
TYP.
Flow (Rated)
9/16-18 SAE STR [8.6]
THD O-RING BOSS
SYSTEM PRESS. d n su No Orifice 3 gpm (11.4 lpm)
.60
GAGE PORT 5 2.38
3.18 2.90 [15.2] With .093 orifice 1 gpm (3.8 lpm)
[60.5]
[80.8][73.7]
.42 DIA
[10.7]
9/16-18 SAE STR 1.25
Model Code
MOUNTING HOLES
THD O-RING BOSS [31.8]
SYSTEM PRESS. 8800485
GAGE PORT 6
9/16-18 SAE STR
THD O-RING BOSS 9/16-18 SAE STR
CHARGE PRESS. THD O-RING BOSS
GAGE PORT 3 SYSTEM PORT 2 Charge Pressure
9/16-18 SAE STR 2.39 .51 15 = 15 bar (220 psi)
THD O-RING BOSS [60.7] [13.0]
SYSTEM PORT 1 ORIFICE 20 = 20 bar (290 psi)
(OPTIONAL)
SYSTEM PRESS. X DRAIN PORT 24 = 24 bar (350 psi)
GAGE PORT 5 4
Orifice
00 = None
X SYSTEM PRESS.
XGAGE PORT 6
SYSTEM PORT SYSTEM PORT
09 = .093 in. (2.36 mm) dia.
1 CHARGE PRESS. 2
GAGE PORT 3
2 Copyright 1988, 1990, 1992, 1994, Sauer-Sundstrand Company. All rights reserved. Contents subject to change. Printed in U.S.A. 1192 H
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Loop Flushing Valve
Pressure Drop Characteristics Mounting
The Loop Flushing Valve may be mounted on any
600
convenient flat surface which provides adequate
from Low System Pressure
Max Setting
500
support around the two mounting holes provided.
to Drain Pressure (psi)
While it is not necessary to provide a continuous

Pressure Differential
400
300
Adjustment Range
mounting surface under the entire valve housing,
200 care should be taken to assure that the surfaces
100
under the mounting bolts form a flat plane. Failure to
Min Setting
provide a flat mounting surface could create valve
0
0 1 2 3 4 5 6 housing distortion when the mounting bolts are drawn
Flow Through the Valve (gpm) up to full torque. Housing distortion may result in
Valve Less Orifice binding of internal components, reducing the drive
and / or braking capacity of the system.
1000
Braking Warning!
from Low System Pressure
750
to Drain Pressure (psi)
Max Setting The loss of hydrostatic drive line power in any

Pressure Differential
500
Min Setting mode of operation may cause a loss of hydro-
static braking capacity. A braking system,
250 redundant to the hydrostatic transmission,
Adjustment Range must be provided which is adequate to stop
0
0 1 2 3 4 5 6
and hold the system should such a condition
Flow Through the Valve (gpm) develop.
Valve with 0.093" (2.36 mm) Orifice
Adjustment Procedure
Service Parts Illustration
For initial setting of the valve package:
10
1. Plumb an in-line flow meter into the drain line. (If
3
REF 9 a flow meter is not available, use a clean container
3A
11 with a known volume and a stop watch.)
REF 8 2. Set the brakes or otherwise restrict machine mo-
16
REF 7 tion and stroke the transmission pump to build at
17 1 least 500 psi (34 bar) differential system pressure.
REF 15 14
REF REF 12 3. Adjust the relief valve in the flushing valve pack-
13
14
age to obtain the desired drain flow, typically 2 to
4A 15 3 gpm (7.5 to 11.4 lpm). (Rotate the adjusting
17
4
3A
screw counter-clockwise to increase flow.) Torque
3
16 the locknut.
Part
4. Verity that pump charge pressure is above recom-
Item Number Description Qty
mended minimums. Remove the flow meter from
1 8800487 HOUSING ASSY (1/4" SPOOL) 1 the circuit.
1 8800538 HOUSING ASSY (3/8" SPOOL) 1
3/4 9005100-5600 PLUG-ST THD GAGE PORT 3
7 8800449 POPPET-CHG RELIEF 1 Service Information
8 8800476 SPRING-HELICAL COMP 1
9 8800488-1000 PLUG-CHG RELIEF 1 Component Installation Torque
10 9003575-0101 NUT-SPECIAL 1 Gage Port Plugs 20 to 35 ft.lbsf. (27 to 47 Nm)
11 9004201-6200 O-RING 1
12 8800242-0009 ORIFICE PLUG-.093" A/R Chg Relief Lock Nut 31 to 41 ft.lbsf. (42 to 55 Nm)
13 8800069 SPOOL-SHUTTLE (1/4") 1 Orifice Plug 16 to 20 ft.lbsf. (22 to 27 Nm)
13 8800550 SPOOL-SHUTTLE (3/8") 1
14 8800265 WASHER-SPECIAL (1/4") 2 Shuttle Spool Plugs 27 to 33 ft.lbsf. (36 to 44 Nm)
14 8800551 WASHER-SPECIAL (3/8") 2 Hose/Tube Fittings 20 to 35 ft.lbsf. (27 to 47 Nm)
15 8800067 SPRING (1/4") 2
15 8800563 SPRING (3/8") 2 The optional orifice plug may be removed and in-
16 9005475-0069 PLUG-SHUTTLE SPOOL(1/4") 2 stalled with a 3/16" internal hex wrench.
16 9005475-0087 PLUG-SHUTTLE SPOOL(3/8") 2
17 9004201-3700 O-RING 2
3
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Series 90
Axial Piston
Pumps and Motors
Service Manual
saue
Series 90 Introduction
Introduction
Use of this Manual
This manual includes information for the normal opera- Since dirt and contamination are the greatest enemies of
tion, maintenance, and servicing of the Series 90 family of any type of hydraulic equipment, cleanliness require-
hydrostatic pumps and motors. ments must be strictly adhered to. This is especially
important when changing the system filter and during
The manual also includes the description of the units and adjustment and repair activities.
their individual components, troubleshooting information,
adjustment instructions, and minor repair procedures. For further information refer to Series 90 Technical Infor-
Unit warranty obligations should not be affected if mainte- mation. For information about fluid requirements refer to
nance, adjustment, and minor repairs are performed SAUER-SUNDSTRAND BLN 9887 or SDF (Id No.
according to the procedures described in this manual. 697581).
Many service and adjustment activities can be performed A worldwide network of SAUER-SUNDSTRAND Autho-
without removing the unit from the vehicle or machine. rized Service Centers is available should repairs be
However, adequate access to the unit must be available, needed. Contact any SAUER-SUNDSTRAND Authorized
and the unit must be thoroughly cleaned before beginning Service Center for details. A list of all Service Centers can
maintenance, adjustment, or repair activities. be found in bulletin BLN-2-400527, or in brochure SAW
(Ident. No. 698266).
Safety Precautions
Observe the following safety precautions when using and servicing hydrostatic products.
Loss of Hydrostatic Braking Ability Fluid under High Pressure
WARNING WARNING
The loss of hydrostatic drive line power in any mode Use caution when dealing with hydraulic fluid un-
of operation (e.g. acceleration, deceleration, or neu- der pressure. Escaping hydraulic fluid under pres-
tral mode) may cause the loss of hydrostatic brak- sure can have sufficient force to penetrate your
ing capacity. A braking system, redundant to the skin causing serious injury. This fluid may also be
hydrostatic transmission must, therefore, be pro- hot enough to burn. Serious infection or reactions
vided which is adequate to stop and hold the sys- can develop if proper medical treatment is not
tem should the condition develop. administered immediately.
S000 001E S000 003E
Disable Work Function Flammable Cleaning Solvents
WARNING WARNING
Certain service procedures may require the ve- Some cleaning solvents are flammable. To avoid
hicle/machine to be disabled (wheels raised off possible fire, do not use cleaning solvents in an
the ground, work function disconnected, etc.) while area where a source of ignition may be present.
performing them in order to prevent injury to the S000 004E
technician and bystanders.

S000 005E
Copyright 1987-1999, SAUER-SUNDSTRAND GmbH & Co.

All rights reserved. Contents subject to change. S90MVCTCD
S90PVMFCD
Printed in USA (0499H)
2
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Series 90 Contents
Contents
Introduction ........................................................................................................................................................................ 2
Use of this Manual ......................................................................................................................................................................................... 2
Safety Precautions ........................................................................................................................................................................................ 2
Functional Description ...................................................................................................................................................... 5
General Description and Cross Sectional Views ........................................................................................................................................... 5
Variable Displacement Pumps ................................................................................................................................................................ 5
Fixed Displacement Motor ...................................................................................................................................................................... 5
Variable Displacement Motor .................................................................................................................................................................. 6
The System Circuit ........................................................................................................................................................................................ 7
The Basic Closed Circuit ......................................................................................................................................................................... 7
Case Drain and Heat Exchanger ............................................................................................................................................................ 7
Common Features of Pumps and Motors ..................................................................................................................................................... 8
End Caps and Shafts .............................................................................................................................................................................. 8
Speed Sensors ........................................................................................................................................................................................ 8
Pump Features .............................................................................................................................................................................................. 9
Charge Pump .......................................................................................................................................................................................... 9
Charge Relief Valve ................................................................................................................................................................................. 9
Multi-Function Valves .............................................................................................................................................................................. 9
Pressure Limiter and High Pressure Relief Valves ........................................................................................................................ 10
System Check Valves ..................................................................................................................................................................... 10
Bypass Valves ................................................................................................................................................................................. 10
Displacement Limiters ........................................................................................................................................................................... 11
Auxiliary Mounting Pads ........................................................................................................................................................................ 11
Filtration Options ................................................................................................................................................................................... 11
Pressure Override (POR) - 180 Frame Size Only ................................................................................................................................ 12
Pump Control Options ........................................................................................................................................................................... 13
Manual Displacement Control (MDC) ............................................................................................................................................. 13
Hydraulic Displacement Control (HDC) .......................................................................................................................................... 13
Electric Displacement Control (EDC) ............................................................................................................................................. 14
Automotive Control (FBA II B) ........................................................................................................................................................ 14
3-Position (FNR) Electric Control ................................................................................................................................................... 14
Motor Features ............................................................................................................................................................................................ 15
Motor Loop Flushing Valve and Charge Relief Valve ........................................................................................................................... 15
Variable Motor Displacement Limiters .................................................................................................................................................. 15
Variable Motor Controls ........................................................................................................................................................................ 16
Hydraulic 2-Position Control ........................................................................................................................................................... 16
Electric 2-Position Control .............................................................................................................................................................. 16
Technical Specifications ................................................................................................................................................. 17
General Specifications ................................................................................................................................................................................. 17
Circuit Diagrams .......................................................................................................................................................................................... 17
Hydraulic Parameters .................................................................................................................................................................................. 18
Size Specific Data ........................................................................................................................................................................................ 19
Pressure Measurement ................................................................................................................................................... 20
Required Tools ............................................................................................................................................................................................. 20
Port Locations and Pressure Gauge Installation ........................................................................................................................................ 20
Variable Pump ....................................................................................................................................................................................... 20
Fixed Motor ........................................................................................................................................................................................... 23
Variable Motor ....................................................................................................................................................................................... 24
Initial Start-Up Procedure ................................................................................................................................................ 25
Fluid and Filter Maintenance .......................................................................................................................................... 26
Troubleshooting ............................................................................................................................................................... 27
"NEUTRAL" Difficult or Impossible to Find .................................................................................................................................................. 27
System Operating Hot ................................................................................................................................................................................. 27
Transmission Operates Normally in One Direction Only ............................................................................................................................. 28
System Will Not Operate in Either Direction ............................................................................................................................................... 28
Low Motor Output Torque ............................................................................................................................................................................ 29
Improper Motor Output Speed .................................................................................................................................................................... 29
Excessive Noise and/or Vibration ................................................................................................................................................................ 30
System Response is Sluggish ..................................................................................................................................................................... 30
3
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Series 90 Contents
Inspections and Adjustments ......................................................................................................................................... 31
Pump Adjustments ...................................................................................................................................................................................... 31
Charge Pressure Relief Valve Adjustment ............................................................................................................................................ 31
Multi-Function Valve Pressure Adjustment ........................................................................................................................................... 33
Engaging the Bypass Function ............................................................................................................................................................. 35
Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) .................................................. ......................... 36
Displacement Limiter Adjustment ......................................................................................................................................................... 37
Pump Control Adjustments .......................................................................................................................................................................... 38
Standard Manual Displacement Control (MDC) Adjustment .......................................................................... ...................................... 38
Non-Linear Manual Displacement Control (MDC) ................................................................................... ............................................. 39
MDC Neutral Start Switch (NSS) Adjustments ..................................................................................................................................... 40
Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment .......................................................... 46
Motor Adjustments ....................................................................................................................................................................................... 48
Charge Relief Valve Adjustment ........................................................................................................................................................... 48
Displacement Limiter Adjustment (MV) ................................................................................................................................................ 49
Displacement Control Adjustments ....................................................................................................................................................... 49
Speed Sensor Adjustment .......................................................................................................................................................................... 50
Minor Repair Instructions ............................................................................................................................................... 51
Pump and Motor Minor Repair .................................................................................................................................................................... 53
Pump / Fitting Torques .......................................................................................................................................................................... 53
Shaft Seal and Shaft Replacement ...................................................................................................................................................... 54
Pump Minor Repairs .................................................................................................................................................................................... 56
Multi-Function Valve Cartridges ............................................................................................................................................................ 56
Pressure Override Valve (Option for 180 Frame Size) ......................................................................................................................... 57
Charge Relief Valve ............................................................................................................................................................................... 57
Charge Pump - Remove ....................................................................................................................................................................... 58
Installing the Charge Pump .................................................................................................................................................................. 60
Auxiliary Pad Installation ....................................................................................................................................................................... 62
Auxiliary Pad Conversion ...................................................................................................................................................................... 63
Filtration Options ................................................................................................................................................................................... 64
Pump controls ....................................................................................................................................................................................... 65
Cover Plate ..................................................................................................................................................................................... 65
Manual Displacement Control (MDC) ............................................................................................................................................. 66
Solenoid Override Valve for MDC ................................................................................................................................................... 67
Solenoid Override Valve for MDC with Pressure Released Brake ................................................................................................. 67
Hydraulic and Electric Displacement Controls ............................................................................................................................... 68
Pressure Control Pilot (PCP) for Electric Displacement Control .................................................................................................... 68
3-Position (FNR) Electric Control ................................................................................................................................................... 69
Displacement Control Components ............................................................................................................................................... 69
Minor Repair - Motor .................................................................................................................................................................................... 71
Loop Flushing and Charge Relief Valves .............................................................................................................................................. 71
Variable Motor Displacement Limiters .................................................................................................................................................. 73
Variable Motor Controls ............................................................................................................................................................................... 74
Electrohydraulic 2-Position Control (Types NA, NB, NC, and ND) ....................................................................................................... 74
Hydraulic 2-Position Control (Type PT) ................................................................................................................................................. 74
Control Plugs ......................................................................................................................................................................................... 74
Variable Motor Control Orifices ............................................................................................................................................................. 75
Speed Sensor .............................................................................................................................................................................................. 77
Exploded View Parts Drawings / Parts Lists ................................................................................................................. 78
Variable Pumps ............................................................................................................................................................................................ 78
Minor Repair Parts ................................................................................................................................................................................ 78
Parts List ............................................................................................................................................................................................... 79
Variable Pump Controls ........................................................................................................................................................................ 80
Control Parts List ................................................................................................................................................................................... 81
Filter and Options .................................................................................................................................................................................. 82
Parts List Filter and Options ................................................................................................................................................................. 83
Name Plates .......................................................................................................................................................................................... 83
Fixed Motor .................................................................................................................................................................................................. 84
Parts List ............................................................................................................................................................................................... 85
Name Plates .......................................................................................................................................................................................... 85
Variable Motor .............................................................................................................................................................................................. 86
Parts List ............................................................................................................................................................................................... 87
Name Plate ............................................................................................................................................................................................ 87
4
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Series 90 Functional Description
Functional Description
This section describes the operation of pumps, motors, and their various serviceable features. It is a useful reference for
readers unfamiliar with the functioning of a specific system.
General Description and Cross Sectional Views
Variable Displacement Pumps
The Variable Displacement Pump (PV) is designed to

convert an input torque into hydraulic power. The input
shaft turns the pump cylinder which contains a ring of
pistons. The pistons run against a tilted plate, called the
swashplate. This causes the pistons to compress the
hydraulic fluid which imparts the input energy into the
hydraulic fluid. The high pressure fluid is then ported out
to provide power to a remote function.
The swashplate angle can be varied by the control piston.

Altering the swashplate angle varies the displacement of
fluid in a given revolution of the input shaft.
F000 539
Series 90 Variable Displacement Pump (PV)
Slider Block
Servo Arm
Servo Valve
Cradle Hold Down
Servo Piston
Feed Back
Cradle Bearing
Cradle
Cradle Leveler
Cradle Guide
Charge Pump
P001 413E
Series 90 PV Cross Section
Fixed Displacement Motor
The Fixed Displacement Motor (MF) is designed to con-

vert an input of hydraulic power into an output torque. It
operates in the reverse manner of the pump. The high
pressure hydraulic fluid enters through the input port. The
fluid pressure builds behind the pistons causing them to
move down the swashplate (the path of least resistance).
As the piston returns up the swashplate again, the fluid is
allowed to exit through the exit port. The spinning pistons
are housed in a cylinder which is connected to the output
shaft. The output torque can be applied to a mechanical
function.
90000347
Series 90 Fixed Displacement Motor (MF)
5
saue
In the Fixed Displacement Motor the "swashplate" is fixed,

Loop Flushing Valve so any variation in motor speed and torque must be made
Valve Plate Piston by the input mechanism, i.e. the pump.
Roller Bearing
Output Shaft
Fixed Swashplate
End Cap Cylinder Block
90000190E
Series 90 MF Cross Section
Variable Displacement Motor
The Variable Displacement Motor (MV) operates in the

same manner as the fixed motor. However, its swashplate
is not fixed; it can be switched between minimum and
maximum angle to amplify torque or speed like the Vari-
able Displacement Pump.
90000348
Series 90 Variable Displacement Motor (MV)
Minimum Angle
Valve Plate Piston Control Piston
End Cap
Roller Bearing
Cradle Swashplate
Output Shaft
"A" "A" Partial Section "A-A"

Cradle Swashplate in Full
Displacement Position
Cradle Swashplate
Cylinder Block
Electric 2-Position Control (optional) Maximum Angle
Control Piston
90000234E
Series 90 MV Cross Section
6
saue
The System Circuit
System loop (low pressure)

Control Handle Displacement Control Valve
Case drain fluid
Heat Exchanger
System loop (high pressure)
Bypass Valve
Orificed Reservoir
Control fluid
Check Valve
Vacuum Gauge
Suction line
Heat Exchanger
Charge Pressure Purge Relief Valve

Multi-Function Relief Valve
Servo Control Valve
Variable Cylinder Fixed Displacement
Displacement Motor
Pump
to Pump
Case
Servo Pres.
Relief Valve
Charge Pump
Input
Output Shaft
Shaft
Multi-Function Valve Motor Swashplate
Pump Swashplate Servo Control
Cylinder Loop Flushing Valve
Pump Fixed Motor

90000800E
Circuit Diagram for Series 90 PV and 90 MF
The Basic Closed Circuit
The main ports of the pump are connected by hydraulic

lines to the main ports of the motor. Fluid flows, in either
direction, from the pump to the motor then back to the
pump in this closed circuit. Either of the hydraulic lines can
be under high pressure. In pumping mode the position of
the pump swashplate determines which line is high pres-
sure as well as the direction of fluid flow.
Case Drain and Heat Exchanger
The pump and motor require case drain lines to remove Reservoir
hot fluid from the system. The motor should be drained
from its topmost drain port to ensure the case remains full Input Output
PV MF
of fluid. The motor case drain can then be connected to the
lower drain port on the pump housing and out the top most
port. A heat exchanger, with a bypass valve, is required to
cool the case drain fluid before it returns to the reservoir.
Flow (Bi-directional)
Case Drain Line

90000803E
Basic Closed Circuit
7
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Common Features of Pumps and Motors
End Caps and Shafts
Series 90 pumps and motors can be supplied with a

variety of end caps and shafts to allow for almost any
configuration. For pumps, end caps are available with
system ports on either side ("side ports") or both ports on
one side ("twin ports"). Motors have end caps with ports
on the face of the end cap ("axial ports") or both ports on
one side ("twin ports"). See the Series 90 Technical
Information manuals (BLN-10029 and BLN-10030) or the
Series 90 Price Book (BLN-2-40588) for information on
available options.
Removing the end cap will void the warranty on a

Series 90 pump or motor.
Speed Sensors
An optional speed sensor can be installed on Series 90

pumps and motors to provide unit speed information. The
sensor reads a magnetic ring wrapped about the unit's
cylinder. See the corresponding Section to locate, install
and adjust the sensor.
90000810
Speed Sensor
8
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Pump Features
Charge Pump
The charge pump is necessary to supply cool fluid to the

system, to maintain positive pressure in the main system
loop, to provide pressure to operate the control system,
and to make up for internal leakage. Charge pressure
must be at its specified pressure under all conditions of
driving and braking to prevent damage to the transmis-
sion.
The charge pump is a fixed-displacement, gerotor type

pump installed in the variable displacement pump and
driven off the main pump shaft. Charge pressure is limited
by a relief valve.
90000243
The standard charge pump will be satisfactory for most
PV with Charge Pump
applications. However, if the charge pump sizes available
for the given main pump size are not adequate, a gear
pump may be mounted to the auxiliary mounting pad and Case
supply the required additional charge flow. Drain
Charge Relief Valve
Line
System
Charge Relief Valve Check
Valves
The charge relief valve on the pump serves to maintain Input PV PF
charge pressure at a designated level. A direct-acting
poppet valve relieves charge pressure whenever it sur- Charge
Pump
passes a certain level. This level is nominally set referenc-
ing case pressure at 1500 rpm. This nominal setting
assumes the pump is in neutral (zero flow); in forward or
reverse charge pressure will be lower. The charge relief
valve setting is specified on the model code of the pump.
Inlet Filter
Tank
90000804E
Pump Charge System
Multi-Function Valves
The multi-function valve incorporates

the system check valve,
the pressure limiter valve,
the high pressure relief valve and
the bypass valve
in a replaceable cartridge.
These functions are described separately. There are two

multi-function valve cartridges in each Series 90 pump to
handle functions in either direction. See corresponding
Sections for adjustments and repairs.
NOTE: Some multi-function valves do not include a pres- 90000243

sure limiter valve. Multi-Function Valve
9
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Pressure Limiter and High Pressure Relief Valves
Series 90 pumps are designed with a sequenced pres-

Pressure Limiter Housing High Pressure sure limiting system and high pressure relief valves.
Relief / check Check Valve When the preset pressure is reached, the pressure limiter
Pressure Limiter Valve Poppet Poppet
Lock Nut
system acts to rapidly destroke the pump so as to limit the
system pressure. For unusually rapid load application, the
high pressure relief valve acts to immediately limit system
Pressure Limiter pressure by cross-porting system flow to the low pressure
Adjustment Screw
side of the loop. The pressure limiter valve acts as the pilot
for the high pressure relief valve spool. The high pressure
relief valve is sequenced to operate at approximately
Bypass 35 bar (500 psi) above the level that initiates the pressure
Actuator Pressure Limiter Bypass limiter valve.
Valve Poppet
Both the pressure limiter sensing valves and relief valves
are built into the multi-function valves (see above).
90000806E
NOTE: For some applications, such as dual path
Cross Section of Multi-Function Valve
vehicles, the pressure limiter function may
be defeated so that only the high pressure
relief valve function remains.
System Check Valves
The system check valves allow pressurized flow from the

charge pump to enter the low pressure side of the loop
whenever system pressure dips below a certain level.
To Control This is needed as the pump will generally lose system
pressure due to leakage and other factors. Since the
Multi-Function Valve pump can operate in either direction, two system check
valves are used to direct the charge supply into the low
pressure lines. The system check valves are poppet
Servo Piston Bypass
Adjustment
valves located in the multi-function valve assembly.
Port "A"
Bypass Valves
Servo Pres.
Relief Valve
The bypass valves ("tow") can be operated when it is
Port "B"
desired to move the vehicle or mechanical function when
Servo Piston the pump is not running. The valve is opened by manually
Charge Pressure
Relief Valve
resetting the valve position.
Multi-Function Valve The bypass valves are built into the multi-function valves.
90000801E
Circuit Diagram showing Pressure
Control Mechanism
10
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Displacement Limiters
All Series 90 pumps are designed for optional mechanical

displacement (stroke) limiters. The maximum displace-
ment of the pump can be limited in either direction.
The setting can be set as low as 0 in either direction.
For instructions on adjustment see corresponding Sec-

tion.
90000244
Auxiliary Mounting Pads PV with Displacement Limiters
Auxiliary mounting pads are available on all Series 90

pumps. SAE A through E mounts are available (availabil-
ity varies by pump size). This pad is used for mounting
auxiliary hydraulic pumps and for mounting additional
Series 90 pumps to make tandem pumps. The pads allow
for full through-torque capability.
90000242
Filtration Options PV with Auxillary Mounting Pad
All Series 90 pumps are available with provisions for

either suction or charge pressure filtration (integral or
remote mounted) to filter the fluid entering the charge
circuit.
Suction Filtration
The suction filter is placed in the circuit between the

reservoir and the inlet to the charge pump. When suction
filtration is used, a reducer fitting is placed in the charge
pressure gauge port (M3). Filtration devices of this type
are provided by the user.
90000243
PV with Suction Filtration
(No filtration device attached)
Charge Pressure Filtration
The pressure filter may be integrally mounted directly on

the pump or a filter may be remotely mounted for ease of
servicing.
A 125 m screen, located in the reservoir or the charge

inlet line, is recommended when using this filtration op-
tion.
90000246 90000247
PV with Integral Charge PV with Remote Charge
Pump Pump
11
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Pressure Override (POR) - 180 Frame Size Only

To Control
The pressure override valve (POR) modulates the control

pressure to the displacement control to maintain a pump
Multi-Function Valve
displacement which will produce a system pressure level
less than or equal to the POR setting. For unusually rapid
load application, the high pressure relief valve function of
Pressure
Override Control Valve Bypass the multifunction valves is available to also limit the
Adjustment
pressure level.
Port "A"
Shuttle
The pressure override consists of a three-way normally
Valve open valve which operates in series with the pump dis-
Port "B" placement control. Control supply pressure is normally
ported through the pressure override valve to the dis-
placement control valve for controlling the pump's dis-
placement. If the system demands a pressure above the
override setting, the POR valve will override the control by
Multi-Function Valve Charge Pressure
Relief Valve reducing the control pressure supplied to the displace-
ment control. As the control pressure reduces, the internal
forces tending to rotate the swashplate overcome the
90000802E force of the servo pistons and allow the pump's displace-
POR-Valve (180 Frame Size only) ment to decrease.
12
saue
Pump Control Options
Manual Displacement Control (MDC)
The manual displacement control converts a mechanical input signal to a hydraulic signal using a spring- centered four-
way servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates
the cradle swashplate through an angular rotation of 17, thus varying the pumps displacement from full displacement
in one direction to full displacement in the opposite direction.
The MDC is designed so the angular position of the pump swashplate is proportional to the rotation of the control input shaft.
Non-Linear MDC
The non-linear manual displacement control operates in

the same manner as the regular MDC except that it is
designed so the change in the angular position of the
pump swashplate progressively increases as the control
input shaft is rotated toward its maximum displacement
position.
Solenoid Override Valve for MDC
A solenoid override valve option (not shown here) is

available for MDC. This safety feature will return the 90000237
swashplate to zero displacement position when activated. PV with Manual Displacement Control
The valve may be set in either a normally open or normally
closed mode.
Neutral Start Switch (NSS)
The neutral start switch is an optional feature available

with MDC. When connected properly with the vehicles
electrical system, the neutral start switch ensures that the
prime mover can be started only when the control is in a
neutral position.
90000239
PV with Manual Displacement Control and
Hydraulic Displacement Control (HDC) Neutral Start Switch
The hydraulic displacement control uses a hydraulic input

signal to operate a spring-centered four-way servo valve.
This valve ports hydraulic pressure to either side of a dual-
acting servo piston. The servo piston rotates the cradle
swashplate through an angular rotation of 17, thus
varying the pumps displacement from full displacement
in one direction to full displacement in the opposite direc-
tion. The HDC is designed so the angular position of the
pump swashplate is proportional to input pressure.
90000240
PV with Hydraulic Displacement Control
13
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Electric Displacement Control (EDC)
The electric displacement control is similar to the hydrau-

lic displacement control with the input signal pressure
controlled by a pressure control pilot (PCP) valve. The
PCP valve converts a DC electrical input signal to a
hydraulic signal which operates a spring- centered four-
way servo valve. This valve ports hydraulic pressure to
either side of a dual-acting servo piston. The servo piston
rotates the cradle swashplate through an angular rotation
of 17, thus varying the pumps displacement from full
displacement in one direction to full displacement in the
90000241 opposite direction. The control is designed so the angular
PV with Electric Displacement Control position of the swashplate is proportional to the EDC
input.
Automotive Control (FBA II B)
Automotive Control allows a vehicle to be driven in a

manner similar to an automobile with an automatic trans-
mission.
The Automotive Control includes a three-position electric

control to provide direction control.
3-Position (FNR) Electric Control
This control utilizes a 12 or 24 VDC electrically operated

spool valve to port pressure to either side of the pump
displacement control piston. Energizing one of the sole-
noids will cause the pump to go to its maximum displace-
ment in the corresponding direction.
All functions of the three-position (FNR) electric control

are preset at the factory.
90000354
PV with 3-Position (FNR) Electric Control
14
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Motor Features
Motor Loop Flushing Valve and Charge Relief

Valve
All Series 90 motors are designed to accommodate a loop

flushing valve. The loop flushing valve is used in instal-
lations which require additional fluid to be removed from
the main hydraulic circuit because of transmission cooling
requirements, or unusual circuits requiring additional loop
flushing to remove excessive contamination in the high
pressure circuit. 90000248
Loop Flushing Valve (MF)
A shuttle valve and charge relief valve are installed in the
motor end cap to provide the loop flushing function. The
shuttle valve provides a circuit between the low pressure
side of the closed loop and the charge relief valve in the
motor end cap.
The motor charge relief valve regulates the charge pres- Top of Motor Charge Relief Valve
sure level only when there is a pressure differential in the
main loop. The shuttle valve is spring centered to the
closed position so that no high pressure fluid is lost from
the circuit when reversing pressures.
For charge relief valve adjustment see corresponding

Section.
Loop Flushing Shuttle Valve End Cap
90000238E
Motor Charge Relief Valve and Loop Flushing

Shuttle Valve
Variable Motor Displacement Limiters
All Series 90 variable motors include mechanical dis-

placement (stroke) limiters. Both the maximum and mini-
mum displacement of the motor can be limited.
The range of the settings is as follows:
055 MV 075 MV
3
Minimum 19 - 40 cm 26 - 54 cm3
Displacement 1.2 - 2.4 in3 1.6 - 3.3 in3 90000352
Maximum MV Maximum Displacement Limiter
65 - 100 % 65 - 100 % (Minimum Displacement Limiters on opposite side)
Displacement
T002 251E
15
saue
Variable Motor Controls
Hydraulic 2-Position Control
This control utilizes a hydraulically operated three-way

hydraulic valve to port system pressure to either of the
motor displacement control pistons. The motor is normally
held at its maximum displacement. Supplying pilot hy-
draulic pressure to the valve will cause the motor to go to
its minimum displacement.
90000350
MV with Hydraulic 2-Position Control
Electric 2-Position Control
This control utilizes an electric solenoid operated three-

way hydraulic valve to port system pressure to either of
the motor displacement control pistons. The motor is
normally held at its maximum displacement. Energizing
the solenoid will cause the motor to go to its minimum
displacement.
90000351
MV with Electric 2-Position Control
16
saue
Series 90 Technical Specifications
Technical Specifications
General Specifications
Design Port Connections

(for details see chapter "Pressure Measurement")
Variable Pumps and Motors: Axial piston pump of variable
displacement, cradle swashplate design. Main pressure ports: SAE flange, Code 62,
Remaining ports: SAE straight thread O-ring boss.
Fixed Motors: Axial piston motor with fixed displacement,
fixed swashplate design. Direction of Rotation
Type of Mounting (per SAE J744) Clockwise or counterclockwise (motors are bi-directional)
SAE flange, Size "B", 2 bolts, Recommended Installation Position

SAE flange, Size "C and E", 4 bolts.
Pump installation recommended with control position on
Cartridge flange, 2 bolts (for motor only). the top or side. Consult SAUER-SUNDSTRAND for non-
conformance guidelines. The housing must always be
filled with hydraulic fluid.
Circuit Diagrams
L2 M3
A M1
M3
Vg max
X5
A
M1
M5
M4
B M2
L1
M2
B
MV with Electrohydraulic 2-Position
Control
L1 S L2
PV with Charge Pump and Manual

Displacement Control L2 M3
A M1
B M2
L1
90000811
MF 90000812
90000813
17
saue
Hydraulic Parameters
System Pressure Range bar psi Temperature range

C F
Rated Pressure 420 6000
Intermittent (cold star t) -40 -40
Maximum Pressure 480 6960 Continuous 104 220
T002 252E
Intermittent 115 240
T002 006E
Charge Pump Inlet Vacuum Viscosity

bar abs in Hg
(on pumps only) mm2/s SUS
Minimum Vacuum
0.7 10 Intermittent 7 47
(continuous)
Recommended operating range 12 - 60 70-278
Minimum Vacuum during
Cold Start 0.2 25 Intermittent (cold star t) 1 600 7 500
(Intermittent) T002 010E
T002 253E
Case Pressure bar psi Cleanliness level and -ratio

Fluid cleanliness level ISO 4406 Class 18/13
Maximum (Continuous) 3 44
-ratio for suction filtration 35-45 = 75 10 2
Maximum during Cold Start
5 73 -ratio for charge pressure filtration 15-20 = 75 10 10
(Intermittent)
T002 254E
Inlet screen size for charge
100 m - 125 m
pressure filtration
T002 007E
Hydraulic Fluid Cleanliness

Refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id Refer to SAUER-SUNDSTRAND Publications BLN 9887
No. 697581). Also refer to publication ATI-E 9101 for or SDF (NO. 697581) and ATI-E 9201.
information relating to biogradable fluids.
Refer to Series 90 technical information for definitions.
18
saue
Size Specific Data
Variable Displacement Pumps
Dimension 030 PV 042 PV 055 PV 075 PV 100 PV 130 PV 180 PV 250 PV

3
Displacement cm 30 42 55 75 100 130 180 250
(maximum) in3 1.83 2.56 3.35 4.57 6.10 7.93 10.98 15.25
Minimum Speed min-1 (rpm) 500 500 500 500 500 500 500 500
Rated Speed min-1 (rpm) 4200 4200 3900 3600 3300 3100 2600 2300
Maximum Speed min-1 (rpm) 4600 4600 4250 3950 3650 3400 2850 2500
Maximum attainable Speed

min-1 (rpm) 5000 5000 4700 4300 4000 3700 3150 2750
at max. Displacement
Theoretical Torque at Nm/bar 0.48 0.67 0.88 1.19 1.59 2.07 2.87 3.97
max. Displacement lbfin/1000 psi 290 380 530 730 870 1260 1750 2433
Weight kg 28 34 40 49 68 88 136 154
(only base unit) lb 62 75 88 108 150 195 300 340
T002 257E
Fixed and Variable Displacement Motors
Einheit 030 MF 042 MF 055 MF 075 MF 100 MF 130 MF 055 MV 075 MV
cm3 30 42 55 75 100 130 55 75

Displacement (maximum)
in3 1.83 2.56 3.35 4.57 6.10 7.93 3.35 4.57
cm3
Displacement (minimum) -- -- -- -- -- -- 19 26
in3
at maximum
min-1 (rpm) 4200 4200 3900 3600 3300 3100 3900 3600
Rated displacement
speed at minimum
min-1 (rpm) -- -- -- -- -- -- 4600 4250
displacement
at maximum
min-1 (rpm) 4600 4600 4250 3950 3650 3400 4250 3950
Maximum displacement
speed at minimum
min-1 (rpm) -- -- -- -- -- -- 5100 4700
displacement
Max. attainable speed at
min-1 (rpm) 5000 5000 4700 4300 4000 3700 4700 4300
max. displacement
Theoretical torque at max. Nm/bar 0.48 0.67 0.88 1.19 1.59 2.07 0.88 1.19
displacement lbfin/1000 psi 290 380 530 730 970 1260 530 730
Maximum flow ar max. l/min 138 193 234 296 365 442 234 296
displacement gal/min 36.5 51 62 78 96 117 62 78
kW 111 155 187 237 292 354 224 282
Max. corner power
hp 149 208 251 318 392 475 300 378
Weight kg 11 15 22 26 34 45 39 44
SAE-Flange lb 24 34 49 57 74 99 86 98
Weight kg 21 26 33 40 46
-- -- --
Cartridge Motor lb 46 57 72 88 101
T002 258E
Refer to Series 90 technical information for definitions.
19
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Series 90 Pressure Measurement
Pressure Measurement
Required Tools
The service procedures described in this manual for Pressure gauges should be calibrated frequently to en-
Series 90 pumps and motors can be performed using sure accuracy. Snubbers are recommended to protect
common mechanic's tools. Special tools, if required are pressure gauges.
shown.
Port Locations and Pressure Gauge Installation
The following sections list the ports for each type of Outline drawings showing port locations follow the tables
hydraulic unit. The recommended pressure gauge and below.
fitting are also specified.
Variable Pump
Gauge Size Gauge Size

Port Function and Port Function and
Fitting
Fitting
System Pressure 1000 bar or 10 000 psi
M1 L1 Case Pressure
Port "A" 9/16-18 O-ring 10 bar or 100 psi
L2
System Pressure 1000 bar or 10 000 psi
M2 030
Port "B" 9/16-18 O-ring fitting 7/8-14 O-ring
M3 50 bar or 1000 psi 042
Charge Pressure
(M6) 9/16-18 O-ring 055
M4 50 bar or 1000 psi 075 1-1/16-12 O-ring
Servo Pressure 100
M5 9/16-18 O-ring
T002 259E 130 1-5/16-12 O-ring
180
1-5/8-12 O-ring
250
50 bar or 1000 psi
X1 HDC / EDC 7/16-20 O-ring
X2 Control Pressure or
9/16-18 O-ring
External Control 50 bar or 1000 psi
X3
Pressure 9/16-18 O-ring
S Charge Pump Inlet Vacuum Gauge, Tee into
Inlet Line
030
1-1/16-12 O-ring
042
055
1-5/16-12 O-ring
075
100
130 1-5/8-12 O-ring
180
1-1/2 SAE-Split
250 Flange
T002 260E
20
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Servo / Displacement
Cylinder Pressure
Gauge Port M4
Case Drain
Port L1
System Pressure
Port B
Cylinder Pressure
Gauge Port M5
Top View
90000814E
System Pressure
Port B External Control Pressure
System Pressure Supply Port X3
Gauge Port M2
Speed Sensor
Charge Inlet Pressure
System Pressure
Gauge Port M1
Carge Pump
Inlet Port S System Pressure Case Drain Port L2 Charge Pressure
Port A Gauge Port M3
Left Side View Right Side View
90000815E
90000816E
PV with Side Port End Cap and Manual Displacement Control
21
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Cylinder Pressure
System Pressure Gauge Port M4
Case Drain
Gauge Port M2 Port L1
System Pressure
Port B
Charge Pump Inlet

Port S
System Pressure
Port A
System Pressure Servo / Displacement
Gauge Port M1 Cylinder Pressure
Case Drain Port L2 Gauge Port M5
Top View
Left Side View
90000819E
90000820E
PV with Twin Port End Cap and Manual Displacement Control
Charge Pressure
Gauge Port M6
(before the filter)
Port E
(from filter)
Port D
(to filter)
Charge Pressure
Gauge Port M3
Charge Pressure
(after the filter)
Gauge Port M3
(after the filter)
Rear View Rear View
90000817E
90000818E
PV with Side Port End Cap and Remote Pressure Filtra- PV with Side Port End Cap and Integral Pressure Filtra-
tion tion
22
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Fixed Motor

Fitting Fitting
System Pressure 1000 bar or 10 000 psi L1 Case Pressure)
M1 10 bar or 500 psi
Port "A" 9/16-18 O-ring L2
System Pressure 1000 bar or 10 000 psi 030
M2
Port "B" 9/16-18 O-ring 042 7/8-14 O-ring
M3 50 bar or 1000 psi 055
Charge Pressure
9/16-18 O-ring 075
T002 261E 100 1-1/16-12 O-ring
130
T002 262E
System Pressure
Gauge Port M1
Charge Pressure System Pressure
Gauge Port M3 Gauge Port M2 Case Drain Port L1
System Pressure Port B

Speed Sensor
System Pressure Port A Case Drain Port L2
Rear View Left Side View
MF with SAE Flange
System Pressure
Gauge Port M1
Charge Pressure System Pressure Case Drain Port L1
Gauge Port M3 Gauge Port M2
Speed Sensor
System Pressure Port B
System Pressure Port A Case Drain Port L2
Rear View Left Side View
90000821E
MF with Cartridge Flange
23
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Variable Motor

Fitting Fitting
Systempressure 1000 bar or 10 000 psi Control Cylinbder
M1 1000 bar or 10 000 psi
Port "A" 9/16-18 O-ring M4 Pressure "Minimum
7/16-20 O-ring
Systempressure 1000 bar or 10 000 psi Displacement"
M2
Port "B" 9/16-18 O-ring Control Cylinbder
1000 bar or 10 000 psi
M3 50 bar or 1000 psi M5 Pressure"Maximum
Charge Pressure 7/16-20 O-ring
9/16-18 O-ring Displacement"
T002 263E L1 10 bar or 500 psi
Case Pressure
L2 1-1/16-12 O-ring
T002 264E
Displacement Control
Cylinder Pressure
Gauge Port M4
System Pressure Min. Displacement
Gauge Port M2
Control Pressure Displacement Control
Port X1 Cylinder Pressure
(Hydraulic 2-Position Control) Gauge Port M5
Max. Displacement
(Earlier Production -
Not available as gauge
port with servo orifices)
System Pressure Port B Displacement Control

Cylinder Pressure
Gauge Port M5
Max. Displacement
(Newer Production)
Left Side View
MV with Cartridge Flange and Hydraulic 2-Position Control (SAE Flange Version Similar)
Case Drain Port L1

System Pressure
Gauge Port M1
charge Pressure
Gauge Port M3
(Same position as in MF)
Speed Sensor
System Pressure Port A
Case Drain Port L2

Right Side View
90000823E
MV with SAE Flange (Cartridge Flange Version Similar)
24
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Series 90 Initial Start-Up Procedures
Initial Start-Up Procedure
The following start-up procedure should always be fol- connections for EDC) be disconnected at the pump con-
lowed when starting-up a new Series 90 installation or trol until after initial start-up. This will ensure that the pump
when restarting an installation in which either the pump or remains in its neutral position.
motor had been removed.
WARNING WARNING
The following procedure may require the vehicle/ Do not start prime mover unless pump is in neu-
machine to be disabled (wheels raised off the tral position (0 swashplate angle). Take precau-
ground, work function disconnected, etc.) while tions to prevent machine movement in case pump
performing the procedure in order to prevent in- is actuated during initial start up.
jury to the technician and bystanders. Take nec- S000 008E
essary safety precautions before moving the ve-

hicle/machine.
S000 007E
Jog or slowly rotate prime mover until charge pressure
starts to rise. Start the prime mover and run at the lowest
Prior to installing the pump and/or motor, inspect the units possible RPM until charge pressure has been estab-
for damage incurred during shipping and handling. Make lished. Excess air may be bled from the high pressure
certain all system components (reservoir, hoses, valves, lines through the high pressure system gauge port.
fittings, heat exchanger, etc.) are clean prior to filling with
fluid. Once charge pressure has been established, increase
speed to normal operating RPM. Charge pressure should
Fill the reservoir with recommended hydraulic fluid. This be as indicated in the pump model code. If charge pres-
fluid should be passed through a 10 micron (nominal, no sure is inadequate, shut down and determine cause for
bypass) filter prior to entering the reservoir. The use of improper pressure. Refer to Troubleshooting.
contaminated fluid will cause damage to the components,
which may result in unexpected vehicle/machine move-
ment. See the publications BLN-9887 and SDF 697581 Caution
for further related information. Inadequate charge pressure will affect the
operators ability to control the machine.
The inlet line leading from the reservoir to the pump must S000 009E
be filled prior to start-up. Check inlet line for properly
tightened fittings and make sure it is free of restrictions Shut down the prime mover and connect the external
and air leaks. control input signal. Also reconnect the machine function
if disconnected earlier. Start the prime mover, checking to
Be certain to fill the pump and/or motor housing with be certain the pump remains in neutral. With the prime
clean hydraulic fluid prior to start up. mover at normal operating speed, slowly check for for-
ward and reverse machine operation.
Fill the housing by pouring filtered oil into the upper case
drain port. Charge pressure may slightly decrease during forward or
reverse operation. Continue to cycle slowly between
Install a 50 bar (or 1000 psi) pressure gauge in the charge forward and reverse for at least five minutes.
pressure gauge port to monitor the charge pressure
during start-up. Shut down prime mover, remove gauges, and plug ports.
Check reservoir level and add filtered fluid if needed.
It is recommended that the external control input signal
(linkage for MDC, hydraulic lines for HDC, or electrical The transmission is now ready for operation.
25
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Series 90 Fluid and Filter Maintenance
Fluid and Filter Maintenance
To ensure optimum service life of Series 90 products,

regular maintenance of the fluid and filter must be per-
formed. Contaminated fluid is the main cause of unit
Mano- failure. Care should be taken to maintain fluid cleanliness
Vacuummeter while performing any service procedure.
Hydraulic fluid reservoir Check the reservoir daily for proper fluid level, the pres-
ence of water (noted by a cloudy to milky appearance, or
Filter free water in bottom of reservoir), and rancid fluid odor
(indicating excessive heat). If either of these conditions
Charge pump
occur, change the fluid and filter immediately.
It is recommended that the fluid and filter be changed

per the vehicle/machine manufacturers recommenda-
Adjustable
Charge pressure relief valve
tions or at the following intervals:
to low
pressure
side and First change
control To pump case
500 operating hours after start up
second and subsequent changes

P000 797E
Suction Filtration Schematic every 2000 operating hours or once a year.
This recommendation applies for the most applications.

High temperatures and pressures will result in acceler-
ated fluid aging and an earlier fluid change may be
required. At lower fluid loads longer change intervalls are
Screen possible. Therefore we suggest to check the fluid with the
manufacturer for suitability. This should be done at latest
half way between fluid changes.
Hydraulic fluid reservoir
Adjustable
Charge pressure It may be necessary to change the fluid more frequently
relief valve than the above intervals if the fluid becomes contami-
nated with foreign matter (dirt, water, grease, etc.) or if the
Charge pump
fluid has been subjected to temperature levels greater
than the recommended maximum. Never reuse fluid.
to low
pressure To pump case The filter should be changed whenever the fluid is changed
side and
control or whenever the filter indicator shows that it is necessary
to change the filter.
Filter
Cleanliness level and -ratio
P000 798E
Fluid cleanliness level ISO 4406 Class 18/13
-ratio for suction filtration 35-45 = 75 10 2
Charge Pressure Filtration Schematic
(Partial flow) -ratio for charge pressure filtration 15-20 = 75 10 10
Inlet screen size for charge
100 m - 125 m
pressure filtration
T002 007E
26
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Series 90 Troubleshooting
Troubleshooting
This section provides general steps to follow if certain undesirable system conditions are observed. Follow the steps in a
section until the problem is solved. Some of the items will be system specific. For areas covered in this manual, a section
is referenced. Always observe the safety precautions listed in the section "Introduction" and related to your
specific equipment.
"NEUTRAL" Difficult or Impossible to Find
Check Description Action
1. Input to pump control. Input to control module is operating Check control input and repair or re-
improperly. place as necessary.
2. Pump displacement control. Control linkages are not secure, control Adjust, repair, or replace control mod-
orifices are blocked, etc. ule as necessary.
If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.
System Operating Hot

1. Oil level in reservoir. Insufficient hydraulic fluid will not meet Fill reservoir to proper level.
cooling demands of system.
2. Heat exchanger. Heat exchanger not sufficiently cooling Check air flow and input air temperature
the system. for heat exchanger. Clean, repair or
replace heat exchanger.
3. Charge pressure. Low charge pressure will overwork sys- Measure charge pressure. Inspect and
tem. adjust or replace charge relief valve. Or
repair leaky charge pump.
4. Charge pump inlet vacuum. High inlet vacuum will overwork sys- Check charge inlet vacuum. If high,
tem. A dirty filter will increase the inlet inspect inlet filter and replace as neces-
vacuum. Inadequate line size will re- sary. Check for adequate line size, length
strict flow. or other restrictions.
5. System relief pressure settings. If the system relief settings are too low, Verify settings of pressure limiters and
the relief valves will be overworked. high pressure relief valves and adjust or
replace multi-function valves as neces-
sary.
6. For internal leakage in motor.
Leakage will reduce low side system Monitor motor case flow without loop
pressure and overwork the system. flushing in the circuit (use defeat spool).
If flow is excessive, replace motor.
7. System pressure. High system pressure will overheat sys- Measure system pressure. If pressure
tem. is high reduce loads.

27
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Transmission Operates Normally in One Direction Only

2. Pump displacement control. Control linkages are not secure, control Repair or replace control module as
orifices are blocked, etc. necessary.
3. Interchange system pressure limit- Interchanging the multi-function valves Interchange multi-function valves. If the
ers, high pressure relief valves, and will show if the problem is related to the problem changes direction, repair or
system check valves. valve functions contained in the multi- replace the valve on the side that does
function valves. not operate.
4. Charge pressure. If charge pressure decays in one direc- Measure charge pressure in forward
tion the loop flushing valve may be and reverse. If pressure decays in one
sticking in one direction. direction, inspect and repair the motor
loop flushing valve.
System Will Not Operate in Either Direction

1. Oil level in reservoir. Insufficient hydraulic fluid to supply sys- Fill reservoir to proper level.
tem loop.
4. Ensure bypass valve(s) are closed. If bypass valve(s) is open, the system Close bypass valves. Replace multi-
loop will be depressurized. function valve if defective.
5. Charge pressure with pump in neu- Low charge pressure insufficient to re- Measure charge pressure with the pump
tral. charge system loop. in neutral. If pressure is low, go to step
6; otherwise continue with step 5.
6. Charge pressure with pump in Low charge pressure with the pump in Measure charge pressure with pump in
stroke. stroke indicates a motor charge relief stroke. If pressure is low, adjust or re-
valve or system pressure relief valve place motor charge relief valve, other-
may be improperly set. wise go to step 9.
7. Pump charge relief valve. A pump charge relief valve that is leaky Adjust or replace pump charge relief
or set too low will depressurize the valve as necessary.
system.
8. Charge pump inlet filter. A clogged filter will undersupply system Inspect filter and replace if necessary.
loop.
9. Charge pump. A malfunctioning charge pump will pro- Repair or replace the charge pump. If
vide insufficient charge flow. OK go to last step.
28
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11. System pressure. Low system pressure will not provide Measure system pressure. Continue
power necessary to move load. with next step.
12. System multi-function valves. Defective multi-function valves will Repair or replace multi-function valve(s).
cause system pressure to be low.

Low Motor Output Torque
1. System pressure at motor. Low system pressure at the motor will Measure system pressure at motor. If
reduce torque. pressure limiter setting is low, increase
setting.
2. Variable motor stuck at minimum Minimum motor displacement yields low Check control supply pressure or repair
displacement. output torque. displacement control. Check motor con-
trol orifices.
3. For internal leakage. Internal leakage will reduce system pres- Check for leakage in O-rings, gaskets,
sure. and other fittings. Repair unit as re-
quired, or replace leaky unit.

Improper Motor Output Speed
1. Oil level in reservoir. Insufficient hydraulic fluid will reduce Fill oil to proper level.
motor speed.
2. Pump output flow. Incorrect outflow will affect output speed. Measure pump output and check for
Incorrect output flow indicates the proper pump speed and see that the
swashplate is out of position. pump is in full stroke.
3. Variable motor displacement con- If variable motor displacement control is See if variable motor displacement con-
trol. not functioning correctly, variable motor trol is responding. If not, repair or re-
swashplate may be in wrong position. place control.
Internal leakage will reduce system pres-

4. For internal leakage. sure. Check for leakage in O-rings, gaskets,
and other fittings. Repair unit as re-
quired, or replace leaky unit.

29
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Excessive Noise and/or Vibration

1. Oil in reservoir. Insufficient hydraulic fluid will lead to Fill reservoir to proper level.
cavitation.
2. Air in system. Air bubbles will lead to cavitation. Look for foam in reservoir. Check for
leaks on inlet side of system loop. After-
wards, let reservoir settle until bubbles
are gone. Run system at low speed to
move system fluid to reservoir. Repeat.
3. Pump inlet vacuum. High inlet vacuum will create noise. A Inspect and replace filter as necessary.
dirty filter will increase the inlet vacuum. Check for proper suction line size.
4. Shaft couplings. A loose shaft coupling will cause exces- Replace loose shaft coupling in charge
sive noise. pump or replace pump or motor.
5. Shaft alignment. Unaligned shafts will create excessive Align shafts.

frictional noise.

System Response is Sluggish

1. Oil level in reservoir. Insufficient hydraulic fluid will reduce Fill reservoir to proper level.
output pressure.
2. Multi-function valves pressure set- Incorrect pressure settings will affect Adjust or replace multi-function valves.
tings. system reaction time.
3. Pump inlet vacuum. High pump inlet vacuum will reduce Measure charge inlet vacuum. If high
system pressure. replace inlet filter.
4. Prime mover speed. Low engine speed will reduce system Adjust engine speed.
performance.
5. Charge and control pressures. Incorrect charge or control pressures Measure charge and control pressures
will affect system performance. and correct if necessary.
6. System internal leakage. Internal leakage will reduce system pres- Check for leakage in O-rings, gaskets,
sure. and other fittings.

30
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Series 90 Inspections and Adjustments
Inspections and Adjustments

This section offers instruction on how to perform inspections and adjustments on pump and motor components. Read
through the entire related section before beginning a service activity. Refer to the corresponding section for location of
gauge ports and suggested gauge size.
Pump Adjustments
Charge Pressure Relief Valve Adjustment
The following procedure explains how to check and adjust

the charge pressure relief valve.
WARNING
The following procedure may require the vehicle/
machine to be disabled (wheels raised off the
ground, work function disconnected, etc.) while
performing the procedure in order to prevent in-
jury to the technician and bystanders. Take nec-
hicle/machine.
S000 007E
90000243
Charge Pressure Gauge Port (Reducer fitting shown - if
filtration device attached)
1. To measure pump charge pressure, install a pressure
gauge in the pump charge pressure gauge port (M3).
Also install a gauge to measure case pressure (tee
into L1 or L2 or use servo gauge port). Operate the
system with the pump in neutral (zero displacement)
when measuring pump charge pressure. Nominal
90L055 EA 1 N Charge Pressure
2. The table shows the acceptable pump charge pres- 6 S 3 C6 C 03
sure range for some nominal charge relief valve HNN 35 35 24
settings (see sample model code at right). These
pressures assume 1500 pump rpm and a reservoir Model Code on Unit Name Plate (24 bar)
temperature of 50C (120F ), and are referenced to
case pressure (see footnote on next page). Smaller
displacement charge pumps will produce charge pres-
sure readings in the lower portion of the range, while Model Code Measured Charge Pressure *
larger displacement charge pumps will produce read- 18.1 bis 21.7 bar
ings in the higher portion of the range. 20
(262 to 315 psi)
22.0 bis 26.9 bar
24
(319 to 390 psi)
25.8 bis 30.7 bar
28
(374 to 445 psi)
T002 266E
* This is the actual charge pressure port gauge reading minus the
case pressure port gauge reading.
Note: These pressures assume a pump speed of

1450 - 1500 rpm. At higher pump input speeds
(with higher charge flows) the charge pres-
sure will rise over the rated setting.
* This is the actual charge pressure port gauge reading minus

the case pressure port gauge reading.
31
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3. Earlier production Series 90 pumps are equipped

with a shim adjustable charge pressure relief valve.
Shim kits are available from SAUER-SUNDSTRAND.
Adjustment of charge pressure is accomplished by
removing the plug [1 inch Hex] and changing the shim
thickness behind the spring. The plug for this type of
charge relief valve should be torqued to 68 Nm
(50 lbfft).
Later production Series 90 pumps are equipped with

90000262 90000264 an external screw adjustable charge pressure relief
Shim Adjustable Charge Screw Adjustable Charge valve. Adjustment of the charge pressure is accom-
Pressure Relief Valve Pressure Relief Valve plished by loosening the lock nut -
(Pump) (Pump)
Frame Size Wrench Size
030 - 100 1-1/16 inch
130 - 250 1-5/8 inch
T002 267E
and turning the adjustment plug with a large screw-

driver or a 1/2 inch hex wrench.
Clockwise rotation of the plug increases the setting,

and counterclockwise rotation decreases the setting
(at a rate of approximately 3.9 bar (50 psi) per turn).
The lock nut for this type of charge relief valve should
be torqued to 52 Nm (39 lbfft).
4. Once the desired charge pressure setting is achieved,

remove the gauges.
32
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Multi-Function Valve Pressure Adjustment
Adjustment of the pressure limiter setting and the high

pressure relief valve setting is accomplished simulta-
neously. The latter is automatically set approximately
35 bar (500 psi) above the former.
In order to adjust the pressure limiter setting, the motor

output shaft must be locked so it does not rotate. This may
be accomplished by locking the vehicles brakes or rigidly
fixing the work function so it cannot rotate.
WARNING
Take necessary precautions that the motor shaft
remains stationary during the adjustment proce-
dure.
S000 010E 90000258
Multi-Function Valves on PV
1. Install two 1000 bar (or 10 000 psi) pressure gauges

in the high pressure gauge ports (M1 and M2). Install
a 50 bar (or 1000 psi) pressure gauge in the pump
charge pressure gauge port (M3).
2. Start the prime mover and operate at normal speed.
3. Loosen locking nut.

early
10 mm
042 - 100
newer
19 mm
030 - 100
early 130 13 mm
130 - 250 24 mm
T002 268E
4. Insert a internal hex wrench into the pressure adjust-

ing screw.
Frame Size Internal Hex Wrench Size

early 90000259
3 mm
042 - 100 Loosen Pressure Adjusting Screw Lock Nut
newer
5 mm
030 - 100
early 130 4 mm
130 - 250 8 mm
T002 269E
Note: A plastic dust plug is installed in the adjusting

screw on 030 and late 042 through 250 units.
33
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90L055 EA 1 N 5. The factory preset pressure limiter setting is shown
on the model code as at right. It is referenced to
6 S 3 C6 C 03 charge pressure, so the pressure limiter setting is the
HNN 35 35 24 difference between the high and low pressure sides
of the system loop. Activate or move the control input
so that pressure increases in the high pressure side
Pressure Limiter Setting
of the closed circuit to the pressure limiter pressure
Ports A and B (differential setting. The pressure limiter setting is reached when
pressure in 10s of bars, the pressure stops increasing and remains steady at
e.g. 35 = 350 bar) a given pressure level (as shown on the gauges).
6. Return the pump to its neutral (zero flow) position

and adjust the pressure limiter setting by rotating the
pressure adjusting screw with the internal hex wrench.
Clockwise rotation of the pressure adjustment screw

will increase the pressure setting, and counterclock-
wise rotation will decrease the pressure setting. Each
complete rotation of the pressure adjusting screw
changes the pressure as shown in the following table.
Approx Change per Rev of the

Frame Size
Adjusting Screw
early
80 bar (1157 psi) per Rev
042 - 100
newer
90 bar (1300 psi) per Rev
030 - 100
130 - 250 80 bar (1157 psi) per Rev
90000260
T002 270E
Rotate Pressure Adjusting Screw
7. To verify the actual pressure setting, actuate or move

the control input so that the pump again develops
pressure in the high pressure circuit to the newly
adjusted pressure limiter pressure setting, and read
the high pressure gauge. Then allow the pump to
return to its neutral position. The pressure in the
high pressure circuit should return to the charge
pressure setting.
8. While holding the pressure adjusting screw station-

ary, tighten the pressure adjusting screw lock.
Frame Size Torque

early
3 Nm (26 lbfin)
042 - 100
newer
20 Nm (15 lbfft)
030 - 100
130 - 250 40 Nm (30 lbfft)
T002 271E
Do not overtorque.
90000261 9. Shut down the prime mover, remove the gauges and
Tighten Lock Nut install the gauge port plugs. Replace the plastic dust
plugs (if used).
The same procedure is used for setting the pressure limit

of the other multi-function valve, but the control input
signal must be activated or moved in the opposite direc-
tion so that high pressure develops in the opposite side of
the closed circuit.
34
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Engaging the Bypass Function
The bypass function is performed by the multi-function

valve cartridges. The prime mover should be shut down
when opening or closing the bypass valves.
The bypass valves on both of the multi-function valves

must be opened to engaged the bypass function.
1. Using a

newer
1-1/16 inch
030 - 100
130 - 250 1-3/8 inch
T002 272E
wrench on the middle sized hex of the multi-function

90000266
valve cartridge, and a
Loosening and Rotating Bypass Hex on Multi-Function
Frame Size Wrench Size Valve
newer
1-1/4 inch Opening Bypass Valve
030 - 100
allows flow to circuit
130 - 250 1-5/8 inch Bypass through Multi-Function Valves
T002 273E Actuator
wrench on the large hex to prevent rotation of the

cartridge assembly, rotate the middle hex three revo-
lutions counterclockwise to open the bypass valve.
Do not rotate more than 3-1/2 revolutions, as
additional rotation will permit external leakage.
2. For units with an MDC-type control, prior to moving

the vehicle or otherwise causing the motor shaft to 90000827E
turn, move the control handle of the manual displace- Multi-Function Valve with Bypass Function Engaged
ment control on the pump to the maximum full forward
position. Hold the handle in this position during by-
pass valve operation.
Caution
"Tow" at extremely low speeds and for short dis-
tances only.
S000 011E
3. To close the bypass valve, rotate the middle hex

clockwise until it is seated. Then torque the middle
hex.
Frame Size Torque

newer
41 Nm (30 lbfft)
030 - 100
130 - 250 100 Nm (75 lbfft)
T002 274E
35
saue
Pressure Override (POR) Valve Pressure
Adjustment (Option for 180 Frame Size)
The Pressure Override Valve is explained in the corre-

sponding section.
1. Install two 1000 bar (or 10 000 psi) pressure gauges

Pressure Override Valve Adjusting Screw in the high pressure gauge ports (M1 and M2). Install
Lock Nut
a 50 bar (or 1000 psi) pressure gauge in the pump
charge pressure gauge port (M3).
2. Start the prime mover and operate at normal speed.
3. With the pump operating at approximately 20% dis-

placement, load the work function and note the pres-
sure as the POR valve operates (pump displacement
reduces to zero).
4. Adjustment of the pressure override setting is made

by loosening the lock nut with a 9/16 inch hex wrench
and turning the adjustment screw with a 3/16 inch
internal hex wrench. The POR setting should be at
Right Side View least 50 bar (750 psi) below the high pressure relief
90000828E valve setting of the multi-function valves for proper
Pressure Override Valve for 180 Frame Size operation.
5. Following the adjustment, torque the lock nut to

43 Nm (32 lbfft).
6. Shut down the prime mover and remove the gauges

and install the gauge port plugs.
36
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Displacement Limiter Adjustment
The maximum displacement can be limited in either

direction.
1. Loosen the seal lock nut retaining the displacement

limiter adjusting screw.

030 - 100 13 mm
130 17 mm
180 - 250 19 mm
T002 275E
2. Rotate the adjusting screw.
Frame Size Internal Hex Wrench Size

030 - 100 4 mm
90000267
130 5 mm
Loosen Displacement Limiter Lock Nut
180 - 250 6 mm
T002 276E
Rotating the adjusting screw clockwise will decrease

the maximum displacement of the pump while rotat-
ing the adjusting screw counterclockwise will increase
the maximum displacement.
Caution
Care should be taken in adjusting displacement
limiters to avoid undesirable flow or speed condi-
tions. The seal lock nut must be retorqued after
every adjustment to prevent an unexpected change
in operating conditions and to prevent external
leakage during unit operation.
S000 012E
90000268
Rotate Adjusting Screw
3. After establishing the desired maximum displace-
ment setting, tighten the lock nut on the adjusting
screw as follows.
Frame Size Torque

030 - 100 24 Nm (18 lbfft)
130 48 Nm (35 lbfft)
180 - 250 125 Nm (92 lbfft)
T002 278E
4. One turn of the adjusting screw will change the

maximum displacement approximately as follows.
Approx Change in Disp per Rev of

Frame Size
Adjusting Screw 90000269
030 2.8 cm3 / Rev (0.17 in3 / Rev) Tighten Lock Nut
042 3.5 cm3 / Rev (0.21 in3 / Rev)
055 4.2 cm3 / Rev (0.26 in3 / Rev)
075 5.1 cm3 / Rev (0.31 in3 / Rev)
100 6.2 cm3 / Rev (0.38 in3 / Rev)
130 8.8 cm3 / Rev (0.53 in3 / Rev)
180 12.5 cm3 / Rev (0.76 in3 / Rev)
250 17.3 cm3 / Rev (1.06 in3 / Rev)
T002 277E
37
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Pump Control Adjustments
Standard Manual Displacement Control (MDC)

Adjustment
There are no adjustable elements in the manual dis-

placement control. The control spool is held in its neutral
position by centering springs and washers on each end of
the spool. Since there is no centering spring on the control
input shaft, the shaft will automatically assume the appro-
priate position when the control is installed on the pump.
90000237
Variable Displacement Pump with Standard Manual
38
saue
Non-Linear Manual Displacement Control
(MDC)
A centering spring, located on the control input shaft,

locates the control shaft in its neutral position. A bias
spring on the control spool maintains a force on the spool
and the control linkage to eliminate looseness (free-
play) in the linkage.
The neutral adjustment is the only adjustment that can

be made on the nonlinear manual displacement control.
All other functions are preset at the factory.
This adjustment must be made on a test stand or on the

vehicle/machine with the prime mover operating. 90000829
Variable Displacement Pump with Non-Linear Manual
WARNING
hicle/machine.
S000 007E
1. Install two 50 bar (or 1000 psi) gauges in each of the

displacement control cylinder gauge ports (M4 and
M5). Disconnect the external control linkage from the
control handle and make certain the control shaft is in
its neutral position. Start the prime mover and oper-
ate at normal speed.
2. Loosen the lock nut on the neutral adjusting screw 90000357 90000358
with a 13 mm hex wrench. Rotate Neutral Adjusting Tighten Neutral Adjusting
Screw Screw Lock Nut
3. Using a 4 mm internal hex wrench, rotate the neutral
adjusting screw clockwise until the pressure increases
on one of the pressure gauges. Note the angular
position of the wrench.
4. Rotate the adjusting screw counterclockwise until the

pressure increases by an equal amount on the other
gauge. Note the angular position of the wrench.
5. Rotate the adjusting screw clockwise half the dis-

tance between the locations noted above. The gauges
should read the same pressure (case pressure),
indicating that the control is in its neutral position.
6. Hold the adjusting screw stationary and tighten the

lock nut to 13.5 Nm (10 lbfft). Do not overtorque the
nut.
7. Once the neutral position is set, stop the prime mover,

remove the gauges, and install the gauge port plugs.
Reconnect the external control linkage.
39
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MDC Neutral Start Switch (NSS) Adjustments
The neutral start switch (NSS) provides a means to

A A prevent the system prime mover from starting while the
pump control handle and control input shaft are in a
Control Shaft Switch Cam position which would command the pump to go in-stroke
in either the forward or reverse direction.
Switch Lock Nut When the control input shaft is in its neutral position, the
inner end of the switch pin moves into a slot on the
Neutral Start Switch
eccentric cam attached to the control shaft. This allows
Eccentric Plug the spring loaded NSS to close, completing the electrical
Switch Pin starting circuit for the prime mover.
Special Lock Nut
for Eccentric Plug
When the control input shaft is NOT in its neutral posi-
MDC with Neutral Start switch tion, the eccentric cam moves the switch pin out of the slot.
This forces the NSS to open, breaking the electrical
starting circuit for the prime mover.
The neutral start switch is threaded into the special lock

nut for the eccentric plug.
Turning the NSS clockwise (CW) into the special nut will
move the NSS closer to the switch cam on the control
Orifice Check Valve Seat shaft, and will narrow the NSS deadband. Turning the
Control Spool Assembly
Control Link Assembly
NSS counterclockwise (CCW) out of the special nut will
move the NSS farther from the switch cam on the control
View at Section A-A shaft, and will widen the NSS deadband.
90000830E
The switch pin is located in an eccentric plug which is
Components of the Standard Manual Displacement turned to move the center of the NSS deadband.
Control with Neutral Start Switch
(continued)
40
saue
The NSS must be adjusted to meet the following three
requirements:
NSS Deadband Control Shaft
(Switch closed, "ON") ("Free-Play")
i. The distance the control handle can be turned without
opening the NSS is called the NSS Deadband. The Control Deadband
distance the control handle can be moved without ("Neutral")
moving the control spool enough to port hydraulic
fluid to the pump displacement control cylinders is
Total Control
called the Control Deadband. These deadbands Shaft Rotation
must be centered in relation to each other.
Since the position of the control deadband cannot be Control Shaft

adjusted, the position of the NSS deadband must be
adjusted to match it.
ii. The NSS deadband must be wide enough so the NSS

will not open within the loose area of control handle
movement caused by normal operating clearances in
the control linkage (control shaft free-play).
By setting the NSS to open outside this area, the

control spool springs or control shaft centering spring
can always act to return the handle to neutral and re-
close the NSS.
iii. The NSS deadband must be narrow enough so the

NSS will open before the unit builds 7 bar (100 psi)
differential system pressure in either direction.
90000831E
(continued) Neutral Start Switch Adjustment Requirements
41
saue
NSS Deadband Adjustment (Conditions ii & iii)
The NSS deadband must be wide enough so the NSS will

not open within the control shaft free-play area, and it
must be narrow enough so the NSS will open before the
unit builds 7 bar (100 psi) differential system pressure in
either direction.
1. Install two 1000 bar (10 000 psi) pressure gauges in

the system pressure gauge ports M1 and M2.
2. Using two 1-1/8 inch wrenches, hold the neutral start

switch from turning and loosen the locknut.
3. Disconnect the external control linkage and make

certain the control shaft is in its neutral position.
4. Attach a continuity checker to the terminals of the

switch. With the control shaft in its neutral position,
turn the switch clockwise (CW) until electrical continu-
90000253
ity is broken, then turn the switch counterclockwise
Loosening the NSS Lock Nut
(CCW) until electrical continuity is obtained. Turn the
switch counterclockwise (CCW) an additional 1/4
turn (90) after continuity has been obtained.
5. Hold the switch in place and tighten the locknut to

27 Nm (20 lbfft) torque.
Control Shaft
6. With the continuity checker attached to the switch,
rotate the control handle (or the control shaft) in each
direction to assure continuity is broken when the
control is not in the neutral position.
Switch Lock Nut
Switch Cam 7. If continuity is obtained in neutral and satisfactorily

Neutral Start Switch
interrupted in each direction, proceed to check the
switch with the prime mover running. The switch must
open before the unit builds 7 bar (100 psi) differential
Switch Pin 1-1/8 in. hex wrench system pressure in either direction.
Torque: 27 Nm (20 lbfft)
If the switch opens after the unit builds system pres-
90000832E sure in either direction, loosen the switch lock nut and
NSS turn the switch clockwise (CW) 1/12 turn (30). Tighten
the switch lock nut and recheck the switch operation.
Repeat this procedure if necessary.
8. If continuity is not interrupted with an equal move-

ment of the control handle in each direction, turn off
prime mover, remove the pressure gauges, and con-
tinue with the next section.
9. If neutral start switch operation is satisfactory, turn off

the prime mover, remove the pressure gauges, and
reconnect the external control linkage.
90000870
Checking Continuity of NSS (System Pressure Gauges
installed on far side)
42
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Neutral Start Switch Eccentric Plug Adjustment (Con- 12.7 9.14
dition i) (0.5) (0.36)
The NSS deadband and the control deadband must be

centered in relation to each other.
Since the position of the control deadband cannot be 3.175 1.52

adjusted, the position of the NSS deadband must be (0.125) (0.06)
adjusted to match it. The switch pin is located in an 25.4+
eccentric plug which is turned to move the center of the (1.0)
NSS deadband.
90000834E
The MDC should be installed on the pump and be in its
Eccentric Plug Adjustment Tool
neutral position when adjusting the neutral start switch
eccentric plug.
The accompanying drawing provides dimensions for an

Eccentric Plug Adjustment Tool.
1. Hold the switch and eccentric plug from turning and

use two 1-1/8 inch wrenches to loosen the locknut.
Remove the neutral start switch.
WARNING Switch
Lock Nut
Do not start the prime mover while the neutral Eccentric Plug
start switch is removed from the control. Case X
Switch Pin
pressure will force the pin out of the eccentric Special Lock Nut
plug, causing oil loss. for Eccentric Plug Neutral Start Switch
S000 032E
MDC with Neutral Start Switch
Special Lock Nut

for Eccentric Plug
Control Eccentric Plug

Mounting
Surface
Switch Pin
View in Direction X
(Switch and lock nut removed)
90000833E
NSS with Eccentric Plug
2. Note the slots on the eccentric plug for the adjustment

tool. Hold the eccentric plug in place with the adjust-
ment tool, and loosen the lock nut with a
1-1/8 inch wrench.
(continued)
90000256 90000257
Loosen Eccentric Lock Nut NSS Removed
43
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3. Position the eccentric plug so the switch pin is offset
Switch Pin
toward the control mounting surface. This will provide
Eccentric Plug
the best contact between the pin and the cam on the
control shaft.
4. Hold the control shaft in its neutral position (in the

center of the control shaft free-play area). Locate
the switch pin in the slot of the switch cam by turning
the eccentric plug while checking the pin position
90 90
(depth) in the plug. When the pin engages the cam
slot, the pin will be at its maximum depth in the plug.
Eccentric Plug
Adjustment Range
Hand tighten the plug lock nut to hold the eccentric
Control Mounting plug in position.
Surface
90000835E 5. Turn the control shaft an equal amount in either
Eccentric Plug Adjustment direction from neutral. The switch pin should move
out of the eccentric plug an equal distance when the
control shaft is turned. Turn the eccentric plug to
center the switch pin with the cam slot. Only a small
amount of adjustment in either direction should be
needed to center the pin.
6. While holding the eccentric plug in place, tighten the

eccentric plug lock nut to 27 Nm (20 lbfft). Reinstall
and adjust the switch as outlined in the previous
section.
Note: The eccentric plug normally requires between

5-1/2 and 6-1/2 turns to install into the con-
trol housing .
90000256
Adjust the Eccentric Plug
Caution
Do not turn the eccentric plug into or out of the
housing beyond specifications.
S000 014E
7. Once the switch is correctly adjusted, hold the switch

in place and tighten the locknut to 27 Nm (20 lbfft)
torque.
(continued)
44
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Checking Switch Continuity
Recheck switch continuity to determine whether addi-

tional adjustment of the eccentric plug is necessary.
WARNING
hicle/machine.
S000 007E

displacement control cylinder gauge ports (M4 and
M5). Attach a continuity checker to the terminals of
the neutral start switch.
2. Energize the starter circuit, and start the prime mover.
3. While operating at normal speed and with the pump

in its neutral (zero flow) position, note the pressure
reading on the gauges. This reading should be noted
as the base pressure.
4. Slowly move the control handle in one direction while

observing the pressure gauges and the continuity
checker. Continuity must be broken before the pres-
sure on either gauge increases more than 1 bar
(12 psi) from the base pressure obtained at neutral.
5. Slowly move the control handle in the opposite direc-

tion. Again, continuity must be broken before the
gauge pressure increases more than 1 bar (12 psi)
from base pressure.
6. Continuity must again be verified when the control is

returned to neutral. 90000255
Checking Continuity of NSS
7. If continuity is not broken at base pressure plus 0 to (Gauges installed in Servo Gauge Ports)
1 bar (0 to 12 psi) in either direction, stop the prime
mover and readjust the eccentric plug as described in
the previous section. If the pressure difference is
equal in each direction but greater than 1 bar (12 psi),
loosen the switch locknut and turn the switch clock-
wise 1/12 turn (30) to increase the sensitivity. Re-
tighten the locknut and recheck pressure differences
and continuity.
8. After verifying proper control and switch operation,

stop the prime mover. Remove the continuity checker
and pressure gauges. Reinstall the servo pressure
port plugs and reconnect the electrical leads from the
machine starter circuit to the neutral start switch.
Install and adjust, if necessary, the external control
linkage.
45
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Hydraulic Displacement Control (HDC) and
Electric Displacement Control (EDC) Adjust-
ment
The neutral adjustment is the only adjustment that can

be made on hydraulic and electric displacement controls.
All other functions are preset at the factory.
This adjustment must be made on a test stand or on the

vehicle/machine with the prime mover operating.
The neutral adjustment is performed by adjusting a neu-

tral adjusting shaft (earlier production EDCs) or a neutral
90000240 adjusting screw (HDCs and current production EDCs).
PV with Hydraulic Displacement Control
WARNING
hicle/machine.
S000 007E
90000241
PV with Electric Displacement Control

two displacement control cylinder gauge ports (M4
and M5). Disconnect the external control input (hy-
draulic or electronic) from the control. Start the prime
mover and operate at normal speed.
2. Loosen the lock nut with a 17 mm hex wrench for the

neutral adjusting shaft or with a 10 mm or 13 mm hex
wrench for the neutral adjusting screw.
90000249
Install Gauges in Displacement Control Cylinder Gauge
Ports
46
saue
3. Using a 5 mm internal hex wrench for the neutral
adjusting shaft or a 3 mm or 4 mm internal hex wrench
for the neutral adjusting screw, rotate clockwise until
the pressure increases in one of the pressure gauges.
Note the angular position of the wrench. Then rotate
the neutral adjusting shaft or screw counterclockwise
until the pressure increases by an equal amount on
the other gauge. Again note the angular position of
the wrench.
4. Rotate the neutral shaft or adjusting screw clockwise 90000250 90000252

half the distance between the locations noted above. Rotate Neutral Adjusting Tighten Neutral Adjusting
Shaft Shaft Lock Nut
The gauges should read the same pressure (case
(Early production) (Early production)
pressure), indicating that the control is in its neutral
position.
5. Hold the neutral adjusting shaft or screw stationary.

Tighten the neutral shaft lock nut (early production
controls) to 22 Nm (195 lbfin.). Tighten the neutral
adjusting screw lock nut (later production controls) to
7 Nm (62 lbfin.) for the 6 mm screw or 13.5 Nm
(120 lbfin.) for the 8 mm screw. Do not overtorque
the nut.
6. Once the neutral position is set, stop the prime mover,

remove the gauges, and install the gauge port plugs. 90000251 90000318
Reconnect the external control input. Rotate Neutral Adjusting Tighten Neutral Adjusting
Screw Screw Lock Nut
(Later production) (Later production)
90000355 90000356
Rotate Neutral Adjusting Tighten Neutral Adjusting
Shaft Shaft Lock Nut
(Current production HDC) (Current production HDC)
47
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Motor Adjustments
Charge Relief Valve Adjustment
1. To measure motor charge pressure, install a 50 bar

(or 1000 psi) pressure gauge in the motor charge
pressure gauge port (M3). Size 30 and 42 dont have
the M3 gauge port. Install pressure gauge in the
motor system pressure gauge port. For this kind of
measurement add 1 bar (14.5 psi) to the nominal
values shown in the table. Also install a gauge to
measure case pressure. Operate the system with the
pump in stroke (forward or reverse) when measuring
motor charge pressure.
90000248 2. The following table shows acceptable motor charge

Charge Pressure Gauge Port (MF) pressures for some nominal charge relief valve set-
tings (see model code at right). These pressures
90M055 NC 0 N Nominal charge
assume a reservoir temperature of 50C (120F).
Pressure Setting
8 N 0 C6 W 00 They are referenced to case pressure and assume a
NNN 00 00 24 one pump/one motor system.
Motor Charge Pressure 3. Earlier production Series 90 motors are equipped

Model Code
(1.4 bar [20 psi]) with a shim adjustable charge relief valve. Shim kits
are available as service items. Adjustment of the
10 8.1 bar (117 psi)
charge pressure is accomplished by removing the
plug (7/8 inch hex) and changing the shim thickness
18 16.1 bar (233 psi)
behind the spring. The plug for this type charge relief
port should be torqued to 68 Nm (50 lbfft).
20 18.1 bar (262 psi)
Later production Series 90 motors are equipped with
24 22.1 bar (320 psi)
an external screw adjustable charge relief valve.
Adjustment of charge pressure is accomplished by
28 26.1 bar (378 psi)
loosening the lock nut,
30 30.0 bar (435 psi) Frame Size Wrench Size
030 - 130 1-1/16 inch
T002 279E
T002 293E
Model Code at the Name Plate (24 bar)
and turning the adjustment plug with a large screw-
driver or a 1/2 inch hex wrench. Clockwise rotation of
the plug increases the setting, and counterclockwise
rotation decreases the setting (at a rate of approxi-
mately 5.4 bar [78 psi] per turn). The lock nut for this
type charge relief valve should be torqued to 52 Nm
(38 lbfft).
4. Once the desired charge pressure setting is achieved,

remove the gauges.
90000263 90000343
Shim Adjustable Charge Screw Adjustable Charge
Pressure Relief Valve Pressure Relief Valve
(Motor) (Motor)
48
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Displacement Limiter Adjustment (MV)
Tamper-Resistant Cap
Both the maximum and minimum displacement may be
Seal Lock Nut
limited.
Maximum Displacement
Limiter Screw
1. Remove the tamper resistant cap from the displace-
ment limiter screw. Loosen the seal lock nut retaining
the displacement limiter adjusting screw with a 19 mm
wrench.
Caution
The displacement limiters act as travel stops for
the swashplate. Do not turn the limiter screws
counterclockwise beyond the point of contact with
the swashplate for either the maximum or mini-
mum displacement position.
S000 015E
2. All adjustments can only be done when the motor is Minimum Displacement
running and the pump is in neutral position. Steer the Limiter Screw
respective displacement limiter by the control. Seal Lock Nut
Tamper-Resistant Cap
Rotate the adjusting screw with a 6 mm internal hex
wrench. Rotating the maximum displacement adjust- SAE Flange Version shown
ing screw clockwise will decrease the maximum dis- (Cartridge Version similar)
placement of the motor. Rotating the minimum dis-
placement adjusting screw clockwise will increase 90000837E
the minimum displacement of the motor. MV Displacement Limiters
Caution
limiters to avoid undesirable flow or speed condi-
tions. See corresponding section for speed and
pressure limits.
The seal lock nut must be retorqued after every

adjustment to prevent an unexpected change in
operating conditions and to prevent external leak-
age during unit operation.
S000 016E 90000359 90000360
Rotate Adjusting Screw for Tighten Lock Nut for
Minimum Displacement Minimum Displacement
3. After establishing the desired displacement setting,
Limiter Limiter
tighten the lock nut on the adjusting screw to 54 Nm
(40 lbfft). Install a new tamper resistant cap.
4. One turn of the adjusting screw will change the

maximum or minimum displacement according to the
following chart.

Frame Size
Adjusting Screw
055 5.6 cm3 / Rev (0.34 in3 / Rev)
075 7.1 cm3 / Rev (0.43 in3 / Rev)
T002 280E
Displacement Control Adjustments
All variable motor displacement control settings do not 90000352

require adjusting. Maximum Displacement Limiter
49
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Speed Sensor Adjustment
When installing or adjusting the speed sensor on a pump

or motor, it must be set at a specific distance from the
speed ring on the units cylinder. To locate the position of
Gap the speed sensor on the unit or description see the
corresponding section.
Speed Sensor 1. Loosen the sensor lock nut with an 1-1/16 inch hex
Magnetic Speed Ring wrench.
90000838E
Cross Section View of Speed Sensor in Variable Pump 2. Turn the sensor clockwise (CW) by hand until it
contacts the speed ring.
Gap
3. Turn the sensor counterclockwise (CCW) 1/2 turn
(180) to establish the nominal gap of 0.71 mm
(0.028 inch).
4. Then turn the sensor clockwise (CW) until the wrench

Magnetic Speed Ring
flats on sensor body are positioned at a 22 angle to
Speed Sensor the pump shaft center line.
90000839E Note: Many adjustable wrenches have a 22 handle

Cross Section View of Speed Sensor in fixed Motor offset.
5. The final sensor position should be between

1/2 (180) and 1/4 turn (90) counterclockwise (CCW)
from the point where the sensor contacts the speed
Gap ring.
6. Hold sensor in position with a 1/2 inch hex wrench

Speed Sensor while tightening the lock nut to 13 Nm (10 lbfft).
Magnetic Speed Ring
90000840E
Cross Section View of Speed Sensor in Variable Motor
Shaft Centerline
1/2 in. Wrench Flats
22 22
Speed Sensor with Speed Sensor with

Packard Connector Turck Connector
Shaft Centerline
1/2 in. Wrench Flats
22 22
Speed Sensor with Speed Sensor with

Packard Connector Turck Connector
90000841E
Positioning Speed Sensor relative to Pump or Motor Shaft
50
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Series 90 Minor Repair Instructions
Minor Repair Instructions
Minor repairs may be performed, following the procedures Protect all exposed sealing surfaces and open cavities
in this section, without voiding the unit warranty. Although from damage and foreign material.
specific models are shown, these procedures apply to all
series and types of units in the Series 90 Family. It is recommended that all gaskets and O-rings be re-
placed when servicing. All gasket sealing surfaces must
Cleanliness is a primary means of ensuring satisfactory be cleaned prior to installing new gaskets. Lightly lubri-
transmission life, on either new or repaired units. Cleaning cate all O-rings with clean petroleum jelly prior to assem-
parts by using a solvent wash and air drying is adequate, bly.
providing clean solvent is used. As with any precision
equipment, the internal mechanism and related items
must be kept free of foreign materials and chemicals.
51
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Hydrostatic Unit Outlines for Minor Repair Reference
Charge Pressure
Relief Valve
Control Filtration Options

Control Orifice
Charge Pump Shaft Seal
Main Shaft Speed Sensor

(Auxiliary Pad)
Left Side View Right Side View

90000843E
SAE-Flange PV
Charge Pressure Charge Pressure

Relief Valve Relief Valve
Loop Flushing
Valve
Loop Flushing
Valve
Shaft Shaft
Seal Seal
(Speed Sensor) (Speed Sensor)
Left Side View Left Side View 90000844E
SAE Flange MF Cartridge Flange MF
Control Orifices
Maximum Angle Control Orifices
Charge Pressure Displacement Limiter
Relief Valve Charge Pressure Maximum Angle
Relief Valve Displacement Limiter
Loop Flushing Loop Flushing
Valve Valve
Shaft Shaft
Seal Seal
Control Control
Minimum Angle
Minimum Angle Displacement Limiter
Displacement Limiter
Left Side View Left Side View 90000845E
Cartridge Flange MV SAE Flange MV
52
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Pump and Motor Minor Repair
Pump / Fitting Torques

Description Torque
If any plugs or fittings are removed from the pump or motor 7/16-20 O-ring 20 Nm
during servicing, they should be torqued as indicated in 9/16 inch Hex Wrench (15 lbfft)
the accompanying table. 7/16-20 O-ring 12 Nm
3/16 inch Internal Hex Wrench (9 lbfft)
Always install new O-rings before reinstalling the plugs or 9/16-18 O-ring 37 Nm
fittings. 11/16 inch Hex Wrench (27 lbfft)
9/16-18 O-ring 23 Nm
3/4-16 O-ring 68 Nm
7/8 inch Hex Wrench (50 lbfft)
3/4-16 O-ring 68 Nm
7/8-14 O-ring 95 Nm
Caution 1 inch Hex Wrench (70 lbfft)
Plugs or fittings installed into aluminum housings 7/8-14 O-ring 68 Nm
should always be torqued to the lower values speci- 3/8 inch Internal Hex Wrench (50 lbfft)
fied for internal hex plugs of the same size. 1-1/16-12 O-ring 163 Nm
S000 017E 1 1/4 inch Hex Wrench (120 lbfft)
1-1/16-12 O-ring 115 Nm
1-5/16-12 O-ring 190 Nm
1-1/2 inch Hex Wrench (140 lbfft)
1-5/16-12 O-ring 129 Nm
1-5/8-12 O-ring 224 Nm
1-7/8 inch Hex Wrench (165 lbfft)
T002 281E
53
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Shaft Seal and Shaft Replacement
Lip type shaft seals are used on Series 90 pumps and

motors. These seals and/or the shafts can be replaced
without major disassembly of the unit. However, replace-
ment usually requires removal of the pump or motor from
the machine.
1. Position the pump with the shaft facing up.
Note: If the unit is positioned horizontally when the

shaft is removed, the cylinder block could
move out of place, making shaft installation
difficult.
2. Remove the three or four screws holding the retainer

plate and seal carrier to the housing, using a 10 mm
hex wrench (030 and 042 units), a 5 mm internal hex
90000270 90000271
Remove Screws Holding Remove Seal Carrier wrench (055 through 100 units), or a 6 mm internal
Retainer Plate and Seal hex wrench (130 through 250 units). Remove the
Carrier retainer plate.
Note: Certain earlier production units use a one

piece retainer plate and seal carrier.
3. After removing the screws, the spring force on the

shaft may move the seal carrier out of its bore by
approximately 5 mm (1/4 inch). If the seal carrier does
not move from its bore after removing the screws, pry
it from its bore as shown and/or lightly tap the end of
the shaft with a soft mallet.
4. Remove the O-ring from the seal carrier.
90000272 90000273
5. Place seal carrier and seal in an arbor press and
Press Out Old Seal New Seal Installed in Carrier
press out old seal.
Screw 6. Inspect the seal carrier, the new seal and the O-ring
Retaining Plate for any damage or nicks.
Seal Carrier
Seal 7. Using the arbor press, press the new seal into seal
Screw carrier. Be careful not to damage the seal.
Seal Carrier
(One Piece)
Note: The outside diameter of the seal may be
Seal
lightly coated with a sealant (such as Loctite
O-ring High Performance Sealant #59231) prior to
installation. This aids in preventing leaks
caused by damage to the seal bore in the
seal carrier.
90000846E
Series 90 Shaft Seal Components
54
saue
Roller Bearing
8. Inspect the sealing area on the shaft for rust, wear, or Assembly Retaining Ring
contamination. Tapered
Shaft
If the shaft is not being replaced proceed to step Splined OR Roller Bearing
Shaft
12.
OR
9. Remove shaft and roller bearing assembly from pump
OR
or motor. The bearing assembly can be transferred to Straight Key
the new shaft. Shaft
90000866E
10. Remove the retaining ring that secures roller bearing Fixed Motor Shaft Configuration
assembly with a snap ring pliers. Remove the roller
bearing assembly. Roller Bearing
Assembly Retaining Ring
11. Place roller bearing assembly on new shaft and Rollen Bearing
Splined OR
secure with the retaining ring. Shaft
Tapered
12. Wrap spline or key end of shaft with plastic film to Shaft
prevent damage to the sealing lip on the seal during OR
installation.
OR
13. Prior to assembly, lubricate the O-ring on the O.D. of
Straigt Key
the seal carrier and the I.D. of the seal with clean Shaft
petroleum jelly.
90000867E
14. Assemble the seal carrier and seal over the shaft and Variable Pump Shaft Configuration
into the housing bore. Install the retainer plate (if
used).
Roller Bearing
Assembly Retaining
15. Install the screws and torque like the tables. Ring
Splined
Pumps
Shaft
Frame Size Torque Pumps
OR
030 - 042 12 Nm (9 lbfft) Tapered
055 - 100 16 Nm (12 lbfft) Shaft
130 - 250 32 Nm (24 lbfft)
T002 282E 90000868E
Variable Motor Shaft Configuration
Motors
Frame Size Torque Motors

030 - 100 9.5 Nm (7 lbfft)
130 22.5 Nm (16.6 lbfft)
T002 283E
Note: Torque the screws in a sequenced pattern

then recheck.
90000274 90000275
Install Seal Carrier Torque Retainer Screw
55
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Pump Minor Repairs
Multi-Function Valve Cartridges
1. The multi-function valve cartridge is removed with a

hex wrench on the largest hex on the cartridge.

030 - 100 1-1/4 inch
130 - 250 1-5/8 inch
T002 284E
2. Inspect cartridge for damage to parts and O-rings.
90000276 90000277 The multi-function valve cartridge may be disas-

Remove Multi-Function Install and Torque Cartridge sembled for cleaning. However, if the pressure limiter
Valve Cartridge housing assembly is disassembled, the pressure
settings must be readjusted. Usually, if there is con-
tamination problem, it will be in the valve seat assem-
bly. If it is not necessary to clean the interior of the
cartridge, proceed to step 7.
Note: Multi-function valve components are not sold

separately as service parts (except O-rings).
90000278
Multi-Function Valve Cartridge Components 3. On early versions of the multi-function valves, the
(Earlier production)
valve seat assembly is held by a retaining ring.
Remove retaining ring with a snap ring pliers.
On late versions, the valve seat section is pressed over

a lip. Place the cartridge in a vise and pry the lower
section off with an appropriate tool. Maintain sufficient
control to prevent the contents from flying loose.
90000279
Multi-Function Valve Cartridge Components
(Later production) 4. Remove pressure limiter lock nut and bypass actuator.
5. Unscrew the pressure limiter adjustment screw from

the bypass actuator. Clean and inspect all disas-
sembled parts.
Pressure Limiter High Pressure
Pressure Limiter Relief/Check
Valve Spring 6. Reassemble with new, lightly lubricated O-rings by
Lock Nut Valve Poppet
Pressure Limiter reversing the above procedure. For early versions
Spring Seat
Housing Check Valve assemble with the retaining ring. For late versions,
Poppet place the cartridge in a vise and press on lower
assembly.
Caution
The pressure settings must be readjusted after
disassembling the pressure limiter housing of the
Valve Seat multi-function valve cartridge.
Pressure Limiter Spring
S000 018E
Pressure Limiter Valve Poppet
Adjustment Screw Pressure Limiter 7. Install cartridge in multi-function valve cavity and torque.
Valve Poppet
Bypass
Actuator Frame Size Torque
030 - 100 89 Nm (66 lbfft)
90000869E
Multi-Function Valve Cartridge Sectional View 130 - 250 210 Nm (155 lbfft)
T002 285E
Do not overtorque the multi-function valve cartridge.
56
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Screws
Pressure Override Valve (Option for 180 Frame
Size)
Pressure Override
Valve
1. Remove the four screws attaching the pressure over-
ride valve to the pump end cap with a 5 mm internal
hex wrench. Remove the O-rings. O-rings
2. Inspect valve for damage to parts.
3. Install new O-rings. Install the valve onto the pump

end cap and torque the screws to 16 Nm (12 lbfft).
Charge Relief Valve
The pump charge relief valve may be shim adjustable

(early models) or screw adjustable (late models).
90000870E
1. Remove the shim adjustable charge relief valve plug
Pressure Override Valve Components
with a 1 inch hex wrench.
Before removing the screw adjustable relief valve

plug, mark the plug, lock nut, and housing so as to
approximately maintain the original adjustment when
assembling. Remove the screw adjustable charge
relief valve plug by loosening the lock nut with a
wrench.

030 - 100 1-1/16 inch
130 - 250 1-5/8 inch
T002 286E
Unscrew the plug with a large screwdriver or 1/2 inch

hex wrench. 90000280 90000262
Remove Charge Relief Shim Adjustable Charge
Valve Relief Valve
2. Remove the spring and relief valve poppet. (Shim adjustable)
3. Inspect the poppet and mating seat in the end cap for
damage or foreign material.
When inspecting shim adjustable valves, do not alter

the shims or interchange parts with another valve.
4. Install the poppet and spring. For shim adjustable

valves, install the plug and torque to 68 Nm (50 lbfft).
For screw adjustable valves, install the plug with its
lock nut, aligning the marks made at disassembly,
and torque the lock nut to 52 Nm (38 lbfft).
90000264 90000265
Remove Charge Relief Screw Adjustable Charge
Check the charge pressure and adjust, if necessary. Valve Relief Valve
(Screw adjustable)
57
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Charge Pump - Remove
The following procedure shows how to remove and install

a charge pump.
1. For pumps with an auxiliary mounting pad, remove

the four screws holding the pad to the end cap and
remove the pad. Refer to the Auxiliary Mounting Pad
Installation instructions (next section) for details.
Note: At earlier production frame size 75 pumps

with twin ports secure the end cap to the
pump housing with a clamp to avoid gasket
damage.
90000281 90000303
Remove Auxiliary Pad Remove Auxiliary Pad
Adapter Screws Adapter
Caution
Do not allow the force of the cylinder block spring
and swashplate leveler springs to separate the
end cap from the pump housing. Gasket damage
and external leakage may result.
S000 019E
2. Remove the six screws holding the charge pump

cover retainer.
90000282 90000284 Frame Size Wrench Size
Remove Retainer Screws Remove Charge Pump
030 - 100 10 mm
Cover
130 - 250 13 mm
T002 287E
3. Remove the retainer and the charge pump cover. For

pumps with an auxiliary mounting pad, remove the
auxiliary drive coupling. Note the orientation of the
gerotor.
4. Remove the charge pump shaft and charge pump

drive key.
5. Remove the spacer plate(s), if present (intermediate

90000297 production pumps only).
Remove Drive Coupling
Remove the charge pump outer port plate, if present
(early and intermediate production pumps).
Discharge Gerotor Discharge
Assembly
Alignment Pin
Remove the charge pump gerotor assembly.
6. Remove the outer eccentric ring and alignment pin.

Inlet Inlet
Alignment Pin 7. Remove the inner port plate.

Gerotor Assembly
8. Inspect all parts for abnormal wear or damage.

Left Hand Rotation Right Hand Rotation
(Outside looking into pump) (Outside looking into pump)
90000871E
Orienting Alignment Pin
58
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Note: If a different displacement charge pump is
being installed, the gerotor assembly, gerotor Standard End Cap Screws
outer eccentric ring, and inner port plate (early Alignment Pin
and late production pumps) or outer spacer Charge Pump Assembly
plate(s) (intermediate production pumps) must Thin Port Plate
be replaced together. If different thickness
Key
port plates are used in an early production Thick Port Plate
Shaft
charge pump assembly, the thicker plate is Eccentric Ring
O-ring
the inner port plate (installed next to the pump Cover
Gerotor Assembly
end cap).
Journal Bearing
Each charge pump assembly includes a different quan- Cover Retainer
tity / types of port plates and spacer plates. Retainer Screw
The charge pump kit "No Charge Pump" includes a

90000872E
spacer. Charge Pump Components (Early Production)
Standard End Cap Screw
Alignment Pin
Thin Port Plate
Charge Pump Assembly
Key Eccentric Ring
Shaft Gerotor Assembly
O-ring Thin Port Plate
Cover Spacer Plate(s)
Journal Bearing
Cover Retainer
Retainer Screw
90000873E
Charge Pump Components (Intermediate Production)
Alignment Pin
Charge Pump Assembly
Key
Shaft Port Plate
O-ring Eccentric Ring
Cover Gerotor Assembly
Journal Bearing
Cover Retainer
Retainer Screw
90000874E
Charge Pump Components (Late Production)
Spacer
Shaft
O-ring
Cover
Plug
Journal Bearing
Cover Retainer
Retainer Screw
90000875E
"No Charge Pump" Components
59
saue
Discharge Gerotor Discharge Installing the Charge Pump
Assembly
Alignment Pin
Be sure to install the charge pump in the proper orienta-
tion. If unsure of charge pump rotation, refer to the model
Inlet Inlet code.
Alignment Pin
Note: The charge pump rotation is determined by
Gerotor Assembly
the orientation of the gerotor assembly outer
Left Hand Rotation Right Hand Rotation
eccentric ring and the location of the align-
(Outside looking into pump) (Outside looking into pump) ment pin in the end cap.
90000871E Do not mix charge pump piece parts from

Orienting Alignment Pin
different production periods. Always install
as a complete assembly.
1. Install the inner port plate and the gerotor assembly

outer ring.
2. Install the alignment pin to properly orient the port

plates and outer eccentric ring for corresponding
pump rotation.
3. Prior to installation, apply a small quantity of petro-

leum jelly to the I.D., O.D., and side faces of the
gerotor assembly to provide initial lubrication.
4. Install the gerotor assembly.

90000285 90000286
Install Inner Port Plate Install Gerotor Assembly 5. Install the outer port plate (early production and
Outer Ring intermediate production pumps only).
6. Install the spacer plate, if present (intermediate pro-

duction pumps).
7. Install the charge pump drive key into the charge

pump shaft and retain with petroleum jelly.
90000287 90000288
Install Alignment Pin Install Gerotor Assembly
90000289 90000290
Install Outer Port Plate Install Spacer Plate
(Early and intermediate (Intermediate production
production only) only)
60
saue
Note: Intermediate production 75 cc and 100 cc
pumps use the same charge pump drive shaft.
Two keyways are provided in the drive shaft
for the charge pumps used in these units. 100 75 cc
The rear keyway (with identifier groove) is cc
used in 75 cc pumps. The front keyway (clos-
est to the internally splined end of the shaft)
is used in 100 cc pumps.
8. Install the charge pump shaft. The internally splined

end of the shaft must engage the main pump shaft.
Note: The outside diameter of the internally splined

end of some early production charge pump
shafts was chamfered. Early production end 90000291 90000292
caps may not be machined to accept a non- Keyways in Charge Pump Install Charge Pump Shaft
chamfered shaft. Always use a chamfered Shaft (Intermediate Produc-
charge pump shaft in pumps with the early tion 075 and 100)
end cap.
9. For pumps with an auxiliary mounting pad, install the

auxiliary drive coupling.
10. Install a new O-ring onto the non-auxiliary pad charge

pump cover. (If an auxiliary pad is installed, an O-ring
is not used on the cover.)
11. Carefully remove the alignment pin from the charge

pump parts. Install the pin in its hole in the charge
pump cover (see previous page for correct orienta-
tion) and retain with petroleum jelly. Install the cover
(with alignment pin) into the end cap and aligned
charge pump parts. (Take care not to damage the
cover O-ring, if used.)
Caution
In order to avoid loss of charge pressure in pumps
with an auxiliary mounting pad, always install the
charge pump cover with the pad drain hole lo-
cated on the same side of the end cap as the
90000293 90000294
charge inlet port. Refer to the section "Auxiliary Alignment Pin Installed in Install Charge Pump Cover
Pad Installation" for details. Cover
S000 020E
12. Install the charge pump cover retainer and the six hex
screws and torque the screws.
Frame Size Torque

030 - 100 13.5 Nm (10 lbfft)
130 - 250 32 Nm (24 lbfft)
T002 288E
13. For pumps with auxiliary mounting pads, install the O-

ring and auxiliary mounting pad adaptor onto the end 90000283 90000295
cap. Refer to the corresponding section for instruc- Install Cover Retainer Torque Retainer Screws
tions on auxiliary pad installation.
61
saue
Auxiliary Pad Installation
1. Remove the six screws holding the charge pump

cover retainer. Remove the retainer.

030 - 100 10 mm
130 - 250 13 mm
T002 287E
2. Remove the charge pump cover and its O-ring.
Note: The original charge pump cover will not be

used when installing the auxiliary pad.
90000282 90000284
Remove Screws and Remove Charge Pump 3. Remove the four large screws which fasten the end
Retainer Cover
cap to the pump housing.
Frame Size Wrench Sizes

Internal Hex External Hex
030 -
8 mm
early 042
late 042 10 mm
055 19 mm
075 - 100 24 mm
100 - 130 14 mm
180 - 250 17 mm
T002 289E
Note: At earlier production frame size 75 pumps

90000296
Remove Large End Cap Screws with twin ports secure the end cap to the
pump housing with a clamp to avoid gasket
damage.
Charge Pump Parts
Cover
Assembly Caution
Coupling Do not allow the force of the cylinder block spring
(Typical)
Special Washer
Journal Bearing
and swashplate leveler springs to separate the
End Cap
Screw
end cap from the pump housing. Gasket damage
O-ring
and external leakage may result.
auxiliary Pad S000 019E
(Typical)
O-ring Cover Retainer
Retainer Screw
Auxiliary Pad Kit
Pad Cover
Screw
4. Take care to assure the surfaces are clean and free
of any foreign material or paint prior to installing the
auxiliary pad.
90000876E
Auxiliary Pad Components (Typical)
5. Install the auxiliary drive coupling onto the pump drive
shaft spline (auxiliary drive spline must be toward the
rear of the pump).
62
saue
6. Carefully remove the alignment pin from the charge
pump parts. Install the pin in its hole in the new charge
pump cover (with hole for the auxiliary coupling) and
retain with petroleum jelly. Install the new charge
pump cover with alignment pin into the end cap and
the aligned charge pump parts.
Caution
In order to avoid loss of charge pressure in pumps
with an auxiliary mounting pad, always install the
charge pump cover with the pad drain hole lo-
cated on the same side of the end cap as the
charge inlet port. Refer to the section "Auxiliary
Pad Installation" for details.
S000 020E 90000297 90000298
Install Drive Coupling Install Alignment Pin in
Cover (CCW rotation
7. Install the charge pump cover retainer and the six hex shown)
screws and torque the screws.
Frame Size Torque

030 - 100 13.5 Nm (10 lbfft)
130 - 250 32 Nm (24 lbfft)
T002 288E
8. Install O-ring on end cap pilot.
9. Install the auxiliary mounting pad adapter on external

pilot on rear of end cap.
90000299 90000300
10. Install four new large screws and washers through the Install New Charge Pump Install Screws and Cover
mounting pad and end cap into the housing. Torque Cover Retainer
per the accompanying table.
Frame Size Torque

030 -
58 Nm (43 lbfft)
early 042
late 042 122 Nm (90 lbfft)
055 122 Nm (90 lbfft)
075 - 100 256 Nm (189 lbfft)
100 - 130 298 Nm (220 lbfft)
180 - 250 580 Nm (429 lbfft)
T002 290E
90000302 90000303
Install O-ring on End Cap Install Auxiliary Pad
11. Install the O-ring and flange cover or auxiliary pump.
Pilot Adapter
Auxiliary Pad Conversion
To convert an auxiliary mounting pad to a different size

mounting pad, use the above procedure with the following
additions:
After removing the charge pump cover (step 2), remove

the old auxiliary drive coupling.
After removing the four end cap retaining screws, remove

the old auxiliary mounting pad adapter.
90000281 90000305
Install Auxiliary Pad Torque Pad Adapter Screws
Adapter Screws
63
saue
Filtration Options
Suction Filtration Installation
1. Install the hydraulic fitting to connect the external

suction filter to the charge pump inlet port.
2. The reducer fitting (placed on the charge pressure

gauge port) is installed as follows.
Frame Size Wrench Size Torque

030 - 042 1-1/4 inch 70 Nm (52 lbfft)
055 - 130 1-1/2 inch 122 Nm (90 lbfft)
180 - 250 1-1/2 inch 156 Nm (115 lbfft)
T002 291E
90000310 90000243
Charge Pump Inlet Reducer Fitting and
The gauge port plug takes a 1/4 inch internal hex
Gauge Port Plug wrench and is torqued to 27 Nm (20 lbfft).
Remote Charge Pressure Filtration or Integral Charge

Pressure Filtration
Install either of these two filtration devices as follows.
1. Remove the reducer fitting, located at charge pres-

sure gauge port, from pump end cap (this part will not
be used).
2. Install the filter manifold or filter head into the port.

The hydraulic tube should enter its mating bore in the
90000311 90000314
remote Pressure Filter Integral Pressure Filter pump end cap with a low force.
Manifold Head
3. After rotating the filter manifold or filter head clock-
wise so that the threads engage with the threads in
the end cap, continue to rotate it clockwise between
6 and 7 revolutions. Face manifold or head to the
desired position.
Caution
Failure to install the filter manifold or filter head to
a sufficient depth in the end cap will result in
insufficient engagement of the tube in the end cap
bore. This may allow unfiltered oil to bypass the
90000312 90000315 filter and enter the charge system.
Install Remote Pressure Install Integral Pressure S000 021E
Filter Manifold Filter Head
4. While holding the filter manifold or filter head in the

desired position, tighten the swivel lock nut.
Frame Size Wrench Size Torque

030 - 042 1-3/8 inch 70 Nm (52 lbfft)
055 - 130 1-5/8 inch 122 Nm (90 lbfft)
180 - 250 1-5/8 inch 156 Nm (115 lbfft)
T002 292E
90000313 90000316
Tighten Remote Pressure Tighten Integral Pressure 5. After installing the integral pressure filter head as-
Filter Manifold Lock Nut Filter Head Lock Nut sembly, install the filter canister per the instructions
on the filter canister.
64
saue
Pump controls
Cover Plate
1. Thoroughly clean external surfaces prior to removal

of cover plate.
2. Using a 5 mm internal hex wrench, remove the eight

cover plate mounting screws. Remove the cover plate
and gasket from housing.
Caution
Protect exposed surfaces and cavities from dam-
age and foreign material.
S000 022E 90000361
Pump with Cover Plate
3. In preparation for installing the cover plate, place a

new gasket on the housing. Place the cover plate into
position and install the screws. Torque the screws to
16 Nm (12 lbfft).
NOTE
A sealing washer must be installed under the head
of any mounting screws that are installed into "thru"
holes in the housing.
S000 023E
65
saue
Manual Displacement Control (MDC)

of control.

control mounting screws. Remove the control (with
orifice check valve and spring) and control gasket
from housing.
Caution
S000 022E
90000319 90000320
Remove Mounting Screws Remove Control 3. In preparation for installing the control, place a new
gasket on the housing. Inspect to assure that the
control orifice check valve and spring are in their
proper position in the control.
4. While setting the control into position, engage the pin

on the control linkage into the mating hole in the link
attached to the swashplate.
5. With the control in position, move control lever both

directions to check proper engagement of control
linkage pin. Proper engagement will be indicated by
centering torque as the lever is moved from center.
90000321 90000322 Non-engagement of control linkage pin is indicated
Inner Face of Control Assemble Control to by lack of centering torque as the lever is moved. In
Linkage case of non-engagement remove the control and
repeat the above procedure.
6. Align the control gasket and install the screws. Torque

the screws to 16 Nm (12 lbfft).
NOTE
of any mounting screws that are installed into "thru"
S000 023E
90000323 90000324 7. If the control is equipped with a neutral start switch,

Assemble Control to Torque Mounting Screws refer to the "MDC Neutral Start Switch Adjustment"
Pump
instructions.
WARNING
The neutral start switch "neutral" must be read-
justed after reassembling the MDC module.
S000 024E
66
saue
Solenoid Override Valve for MDC

of valve.
2. Using a 5 mm internal hex wrench, remove the two

screws and remove solenoid manifold from housing.
Remove the old gasket.
3. The solenoid may be removed from the valve by

removing the nut with a 3/4 inch hex wrench. The
solenoid valve may be removed from the manifold
with a 7/8 inch hex wrench.
4. When installing the solenoid valve into the manifold,

the valve should be torqued to 24 2.4 Nm (17.7 1.8 90000363
lbfft). When installing the solenoid onto the valve, Components of Solenoid Override for MDC
torque the nut to 6 Nm (53 12 lbfin).
5. In preparation for installing the solenoid manifold,

place a new gasket on the control housing. Install the
manifold onto the control housing, align the gasket,
and install the screws. Torque the screws to
13.5 Nm (10 lbfft).
Solenoid Override Valve for MDC with Pressure

Released Brake

of valve.
2. Using a 4 mm internal hex wrench, remove the four

solenoid valve mounting screws. Remove the sole-
noid valve (with O-rings) from the adapter plate.

adapter plate mounting screws. Remove the adapter
plate and O-rings from the control housing.
4. Remove the check valve seat and O-ring from the

control side of the adapter plate. Remove the check
ball and spring.
5. Install a new O-ring on the check valve seat and

reassemble the check valve spring, ball, and seat into
the adapter plate.
6. Install new O-rings on the adapter plate. Place the 90000364

adapter plate into position and install the screws. Components of Solenoid Override with Brake Pressure
Torque the screws to 5.4 Nm (48 lbfin). Defeat for MDC
7. Install new O-rings onto the solenoid valve assembly

and install the solenoid valve onto the adapter plate.
Install the screws and torque to 5.4 Nm (48 lbfin).
67
saue
Hydraulic and Electric Displacement Controls

of control.

control mounting screws. Remove the control (with
orifice check valve and spring) and control gasket
from housing.
Caution
S000 022E
3. In preparation for installing the control, place a new

90000325 90000326
Remove Mounting Screws Remove Control gasket on the housing. Inspect to ensure that the
control orifice check valve and spring are in their
proper position in the control.
4. While setting the control into position, engage the pin

on the control linkage into the mating hole in the link
attached to the swashplate.
5. With the control in position, move control assembly

left and right to check engagement of pin in the link.
Proper engagement will be indicated by an increasing
resistance as the control is moved away from center
position. Non-engagement of pin will be indicated by
90000327 90000328
lack of spring force. In case of non-engagement,
Inner Face of Control Assemble Control to remove control and repeat the above procedure.
Linkage
6. Align the control gasket and install the screws. Torque
the screws to 16 Nm (12 lbfft).
Caution
of any mounting screws that are installed into
"thru" holes in the housing.
S000 023E
Pressure Control Pilot (PCP) for Electric Displace-

ment Control
90000329 90000330
Install Mounting Screws Torque Mounting Screws
1. Thoroughly clean external surfaces of control.

screws and remove the PCP.
3. Check surfaces for nicks or damage. Clean internal

screens.
4. Install new O-rings in PCP Housing. Place PCP

against EDC housing and install the screws. Torque
to 5.4 Nm (48 lbfin).
Note: Do not remove black plastic cover from the

90000332 90000334
PCP Components Torque PCP Valve Screws aluminum plate. This is not a serviceable
item and will void the product warranty.
68
saue
3-Position (FNR) Electric Control

of control.

solenoid valve mounting screws. Remove the sole-
noid valve (with O-rings and orifice) from the adapter
plate.

adapter plate mounting screws. Remove the adapter
plate and gasket from housing.
Caution 90000362
Protect exposed surfaces and cavities from dam- 3-Position Electric Control Components
S000 022E
4. Inspect the orifice installed between the valve and

adapter plate. This orifice MUST be installed in the
case drain passage for proper pressure limiter opera-
tion.
5. In preparation for installing the adapter plate, place a

new gasket on the housing. Place the adapter plate
into position and install the screws. Torque the screws
to 16 Nm (12 lbfft).
NOTE
of any mounting screws that are installed into thru
S000 023E
6. Install new O-rings and the orifice onto the solenoid

valve assembly and install the solenoid valve onto the
adapter plate. Install the screws and torque to 5.4 Nm
(48 lbfin).
Displacement Control Components
Displacement Control Orifices

A
1. Remove the control assembly as described in the
B
instructions for the specific displacement control.
TA P
TB
2. Orifice plugs may be located in the control assembly,
at the pump housing face surface. Remove the orifice
plugs with a 4 mm internal hex wrench. Note the
location of each plug, do not interchange plugs.
Torque the orifice plugs to 3 Nm (26 lbfin).
3. Assemble the control onto the pump. Refer to the Orifice Plugs
instructions for the specific control.
Orifice Check Valve
90000849E
Underside of an HDC/EDC Module Showing Orifice
Locations
69
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Displacement Control Orifice Check Valve
1. Remove the control assembly as described in the

instructions for the specific displacement control.
2. The orifice check valve is located in the control

assembly, at the surface of the pump housing face.
TA A B TB Remove the spring retainer and spring from the orifice
check valve cavity and then remove the orifice check
P
valve.
3. Install the desired orifice check valve in the cavity and

then install the spring and spring retainer to hold the
orifice check valve in position.
Orifice Plugs
4. Assemble the control onto the pump. Refer to the
instructions for the specific control.
Orifice check Valve
90000848E
Underside of an MDC Module Showing Orifice Locations
Displacement Control Adapter Plate (Early produc-

tion 130 Pumps only)
The screws fastening the control adapter plate to the

housing have retaining compound on the threads. They
are removed with a 6 mm internal hex wrench.
When installing the adapter plate, ensure the O-rings are

in the proper position and torque the screws to 32 Nm
(24 lbfft).
Displacement Control Filter Screens
If the pump is equipped with control filter screens in the

pump housing (late production), they should be pressed
into position (with the rounded edge of the filter screens
facing the control until they are flush to 2.0 mm (0.08 inch)
below the surface of the housing.
90000847
Displacement Control Adapter Plate (Early production
130cc Pumps only)
70
saue
Minor Repair - Motor
Loop Flushing and Charge Relief Valves
Loop Flushing Valve
1. Using an 1-1/16 inch wrench, remove the hex plugs

and O-rings from both sides of the valve. Remove the
springs, shoulder washers, and flushing valve shuttle
spool. Note orientation of the washers. Remove the
flushing valve spool.
2. Inspect parts for damage or foreign material.
Note: Early production motors used a small diam- 90000338 90000339

eter shuttle valve spool. Late production mo- Remove Plugs Springs Remove Flushing Shuttle
tors use a larger diameter spool. Spool
3. Install flushing valve spool in end cap, then install the
shoulder washers (with shoulders facing out) and
springs on each end of the spool. Install the hex plugs
with O-rings, and torque to 41 Nm (30 lbfft) on 030
through 100 motors or 68 Nm (50 lbfft) on 130 mo-
tors.
Motor Charge Relief Valve
1. Remove the shim adjustable charge relief valve plug

with a 7/8 inch hex wrench.
90000340 90000341
Before removing the screw adjustable relief valve Install Flushing Shuttle Torque Plugs
plug, mark the plug, lock nut, and housing so as to be Spool
able to maintain the original adjustment when assem-
bling. Remove the screw adjustable charge relief
valve plug by loosening the lock nut with a 1-1/16 inch
hex wrench for 030 through 100 units, or a 1-5/8 inch
hex wrench for 130 units, and unscrewing the plug
with a large screwdriver or 1/2 inch hex wrench.
2. Remove the spring and valve poppet.
3. Inspect the poppet and mating seat in the end cap for
damage or foreign material. When inspecting shim
adjustable valves, do not alter the shims or inter- 90000342 90000343
change parts with another valve. Remove Shim Charge Relief Remove Screw Charge
Valve Relief Valve
71
saue
4. Install the poppet and spring. For shim adjustable

valves, install the plug and torque to 68 Nm (50 lbfft).
For screw adjustable valves, install the plug with its
lock nut, aligning the marks made at disassembly,
and torque the lock nut to 52 Nm (38 lbfft).
5. Check and adjust the charge pressure.
90000344 90000345
Shim Adjustable Charge Screw Adjustable Charge
Relief Valve Relief Valve
Defeating the Loop Flushing Valve

Lock Nut
Plug
Plug 1. Remove loop flushing valve components (these parts
O-ring
O-ring
will not be used).
Shims
Spring Spring
2. Install defeating spool into spool bore in end cap.
Poppet Poppet
Plug with O-ring
(defeat) 3. Install hex plugs provided and torque to 41 Nm
(30 lbfft).
4. Remove charge relief valve components (these parts

Plug with O-ring are not necessary).
(defeat)
5. Replace with the hex plug provided and torque to

Plug
41 Nm (30 lbfft).
O-ring Spool (defeat)
Spring
Plug with O-ring
(defeat)
Shoulder Washer
Note orientation of washers!

Shoulder OUT (toward spring). Spool
Shoulder Washer
Spring
O-ring
Plug
90000850E
Motor charge Relief Valve and Loop Flushing Valve Parts
72
saue
Variable Motor Displacement Limiters
1. Remove the tamper-resistant cap from the displace-

ment limiter. Measure and note the length of the
adjustment screw up to the seal lock nut. Using a
19 mm hex wrench, loosen the seal lock nut and
remove the nut. Remove the limiter screw from the
motor housing with a 6 mm internal hex wrench.
2. Install the limiter screw with the noted length between

adjustment screw and the seal lock nut. Do not install
a new tamper-resistant cap until the limiter has been
adjusted.
3. Final adjustment of the displacement limiters should

be performed on a test stand.
Do not turn the limiter screws counterclockwise

beyond their initial adjustment positions.
Caution
limiters to avoid undesirable speed conditions.
The seal lock nut must be retorqued after every
adjustment to prevent an unexpected change in
operating conditions and to prevent external leak-
age during unit operation.
S000 026E
90000851E
One full turn of the displacement limiter adjustment MV Displacement Limiters
screw will change the displacement as follows:

Frame Size
Adjusting Screw
055 5.6 cm3 / Rev (0.34 in3 / Rev)
075 7.1 cm3 / Rev (0.43 in3 / Rev)
T002 295E
4. Following the final adjustment, install new tamper

resistant caps.
73
saue
Variable Motor Controls
Electrohydraulic 2-Position Control (Types NA,

NB, NC, and ND)

of the control.
2. Disconnect the external electrical signal connection.

Note: Remove BEFORE removing control.
Install AFTER installing control. 3. Remove the hex nut and solenoid from the control
Refer to "Control Orifices" Section
valve.
4. Remove the orifice check valve for the maximum

angle control cylinder, if equipped.
Hydraulic 2-Position
Control Valve
5. Remove the control valve from the motor housing.
6. Remove O-rings from the valve.
7. Install new O-rings on the control valve.

Electric 2-Position
Control Valve
8. Install the valve into the motor housing and torque to
47 Nm (35 lbfft). Do not overtorque the control
valve. Over-torquing may result in the valve spool
sticking.
9. Install the solenoid onto the valve and torque the hex
90000852E nut to 5 Nm (44 lbfin). Do not overtorque the nut.
MV Control components
10. If previously removed, reinstall the orifice check valve.
Reconnect the external signal connection.
Hydraulic 2-Position Control (Type PT)
Follow the steps above, except that in step 2 a hydraulic

signal line will be disconnected, and steps 3 and 9 are not
applicable.
1/8 in. int. hex wrench
Torque: 5.4 Nm (48 lbfin)
Control Plugs
Remove the control plugs from the housings of earlier

9/16 in. hex wrench
Torque: 34 Nm (25 lbfft) production motors, if necessary. Install new O-rings, rein-
stall, and torque.
7/8 in. hex wrench
90000853E
MV Control Plugs
74
saue
Variable Motor Control Orifices
Control Suply Orifice
Control Supply Orifice
Screen (pressed in)
1. Remove the control supply orifice from the motor
O-ring
housing with an 1-1/16 inch hex wrench.
Backup Washer
2. Remove the O-rings and the backup washers. Check O-ring

that the filter screen is secure in the orifice body and Backup Washer
that the screen and the orifice are not plugged.
3. Install new backup washers and O-rings onto the

orifice body. Install the orifice into the motor housing O-ring
and torque to 37 Nm (27 lbfft). Backup Washer Backup Washer
Caution
Screen
Do not interchange the control supply orifice with (pressed in)
the minimum displacement orifice (next section).
S000 027E Orifice Body
O-ring
Cross-section View of
Control Supply Orifice Assembly
90000854E
MV Control Supply Orifice
Minimum Displacement Cylinder Orifice or Orifice

Check Valve
Orifice Orifice / Check Valve
Assembly
1. Remove the minimum displacement cylinder drain
orifice or the orifice check valve from the motor
O-ring
housing with an 1-1/16 inch hex wrench.
Backup Washer
2. Remove the O-rings and the backup washers. Check O-ring

that the orifice is not plugged. Check that the check Backup Washer
valve seat is secure in the body and that the check ball
is free.
3. Install new backup washers and O-rings onto the

orifice body. Install the orifice into the motor housing
and torque to 37 Nm (27 lbfft).
O-ring O-ring
Orifice Body Orifice Body

Caution
Do not interchange the control supply orifice (pre- Backup Washer
Spring Pin
Backup Washer
vious section) with the minimum displacement O-ring O-ring

orifice. Backup Washer
Kugel
Backup Washer
S000 028E
Orifice Seat
(Spot welded)
Cross-Section View of Cross-Section View of
Orifice Assembly Orifice / Check Valve
Assembly
90000855E
MV Minimum Displacement Orifice
75
saue
Maximum Displacement Cylinder Orifice Check Valve
1. Remove the seal lock nut with a 3/4 inch hex wrench.
Housing Plug Remove the maximum displacement cylinder orifice
check valve from the motor housing with a 1/4 inch
Seal Lock Nut
(seal toward housing) end wrench. Remove the O-ring. The check ball in the
valve must be free.
O-ring
2. Reinstall the check valve and torque to 15 Nm
Orifice / Check Valve Assembly
(11 lbfft). Install a new O-ring. Install the seal lock nut
with the seal toward the motor housing.
Seal Lock Nut
(seal toward housing)
Hold the check valve from turning while torquing
the seal lock nut to 34 Nm (25 lbfft).
O-ring
3. If no orifice check valve is installed, the housing plug
Orifice Body may be removed with a 9/16 inch hex wrench. Always
install a new O-ring. Reinstall the plug and torque to
Check Ball
20 Nm (15 lbfft).
Spring Pin
Cross-Section View of
Orifice / Check Valve
Assembly
90000856E
MV Maximum Displacement Orifice
76
saue
Speed Sensor
1. Remove the speed sensor by disconnecting the elec-

trical connector, loosening the lock nut, and unscrew- Housing Plug
Speed Sensor 1/4 in. int. hex wrench
ing the speed sensor from the pump or motor hous- or Torque: 23 Nm (17 lbfft)
ing.
2. Always install a new O-ring before installing the 1-1/16 in. hex wrench
sensor. After adjustment!
3. Reinstall the speed sensor (with lock nut and O-ring)

into the housing. Adjust the gap between the sensor
and the magnetic speed ring as instructed in Section
"Speed Sensor Adjustment" and torque the sensor
lock nut.
4. If a speed sensor is not installed, the housing plug

should be torqued as indicated in the accompanying 90000857E
figure. Typical Location of Speed Sensor - PV
1-1/16 in. hex wrench

After adjustment!
or
Housing Plug Speed Sensor

1/4 in. int. hex wrench
90000858E
Typical Location of Speed Sensor - MF

After adjustment!
or
Speed Sensor
Housing Plug
90000859E
Typical Location of Speed Sensor - MV
77
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Series 90 Exploded View Drawings / Parts Lists
Exploded View Parts Drawings / Parts Lists
Variable Pumps
Minor Repair Parts
K90 L35
B70 K10 K018 (Early Production
bis 075 Frame Size) (L70)
B83 G532 K50 K042
OR G536 K70
B83 (L40) L60 L70
G542 K80
G546 (B80)
L40
B82 (B90) L30
P2B_
(B70)
B90
P30 P06
P13
L50
P30
B71
P2A_ P06
P13 G512
G516
G502
G506
G172
G522 G176
G526
B80
(G502
G506) (G502
G506)
(G63)
G63
(CODE 61 OPTION)
(G64)
G64
(CODE 61 OPTION) (K018
BOTH SIDES THRU
K042)
G531
G501
G538
G508
G511
G518
OR
G541
G548
G63
(CODE 61 OPTION)
G521
G528
(G63)
(G501
G508) (G64)
G64
(G501
(CODE 61 OPTION)
G508)
90000860E
78
saue
Parts List
Item Description Qty Item Description Qty
B70 ............... Plug ......................................................... 2 G532 ............ Plug ......................................................... 1

B71 ............... Plug ......................................................... 1 G536 ............ O-ring ...................................................... 1
B80 ............... Plug ......................................................... 1 G538 ............ O-ring ...................................................... 1
B82 ............... Plug ......................................................... 1 G541 ............ Plug ......................................................... 1
B90 ............... Filter screen ............................................. 3 G542 ............ Plug ......................................................... 1
G546 ............ O-ring ...................................................... 1
G63 .............. Split flange clamp .................................... 4 G548 ............ O-ring ...................................................... 1
G64 .............. Plug ......................................................... 4
G172 ............ Plug ......................................................... 1 K10 ............... Plug assembly ......................................... 1
G176 ............ O-ring ...................................................... 1 K50 ............... O-ring ...................................................... 1
G501 ............ Plug ......................................................... 3 K70 ............... Spring ...................................................... 1
G502 ............ Plug ......................................................... 3 K80 ............... Poppet ..................................................... 1
G506 ............ O-ring ...................................................... 3 K90 ............... Nut ........................................................... 1
G508 ............ O-ring ...................................................... 3
G511 ............ Plug ......................................................... 1 L30 ............... Seal carrier .............................................. 1
G512 ............ Plug ......................................................... 1 L35 ............... Seal carrier .............................................. 1
G516 ............ O-ring ...................................................... 1 L40 ............... Lip seal .................................................... 1
G518 ............ O-ring ...................................................... 1 L50 ............... O-ring ...................................................... 1
G521 ............ Plug ......................................................... 1 L60 ............... Retainer ................................................... 1
G522 ............ Plug ......................................................... 1 L70 ............... Screw ...................................................... 3
G526 ............ O-ring ...................................................... 1
G528 ............ O-ring ...................................................... 1 L8 ................. Key .......................................................... 1
G531 ............ Plug ......................................................... 1 L9 ................. Slotted nut ............................................... 1
79
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Variable Pump Controls
M0DC
M90D M1DC M0DD
M1DD
OR
M11D
M0MA M0ME
M0MB M0MF
M0MC M0MG
M0MD M0M9 M0CA
M9ME M76M M74M M90C
M78M M1CA M87C
M92M M11C
M97M M77M
M95M M98M M75M
M96M S40
M72M
M90M
M71M
M1MA M880 OR
M1MB M7MA
T201
M1MC M7MB
THRU
T001 M1MD M7MC
T209, M0EA
THRU M1ME M7MD
T222 M0EF M91E
T009, M1MF M7ME
T250 M0EP
T022 M1MG M7MF
T050 T301 M7MG
THRU T401
M87M M11M M9EA M98E
T309, THRU
M9EP
T322 T409, M90E M95E
T422 M97E
T350
T450 M1EA M880
M1EF
M870
M1EP M96E
M860
M11E
M850
M840 M87E
M840 M810
REF
M830 M840
M820
REF
(Early Production
130 cc Frame Size)
OR
M1HA, M1HC
OR
M1HF, M1HG
M90H
M1HH, M1HJ
M880
M1HK, M1HL M87H
M1HM, M1HN
M11H M0HA, M0HC

M0HF, M0HG
M0HH, M0HJ
M0HK, M0HL
M0HM, M0HN
90000861E
80
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Control Parts List
M0CA ........... Cover plate kit ......................................... 1 M71M ........... Washer .................................................... 1
M1CA ........... Cover plate .............................................. 1 M72M ........... Nut ........................................................... 1
M11C ........... Control gasket ......................................... 1 M80 .............. Control gasket ......................................... 1
M11D ........... Control gasket ......................................... 1 M87M ........... Washer, seal (042) .................................. 1
M87C ........... Washer, seal (042) .................................. 1 M90M ........... Screw ...................................................... 6
M90C ........... Screw ...................................................... 6 S40 ............... Neutral start switch kit ............................. 1
M0DC ........... Control kit, 3-position FNR 12V ............... 1 M0MC .......... Control MDC w/ sol. valve ....................... 1
M0DD ........... Control kit, 3-position FNR 24V ............... 1 M7M ............. Control handle ......................................... 1
M1DC ........... Control, 3-position FNR 12V ................... 1 M71M ........... Washer .................................................... 1
M1DD ........... Control, 3-position FNR 24V ................... 1 M72M ........... Nut ........................................................... 1
M80 .............. Control gasket ......................................... 1 M74M ........... Solenoid valve ......................................... 1
M87D ........... Washer, seal (042) .................................. 1 M75M ........... Control manifold ...................................... 1
M90D ........... Screw ...................................................... 6 M77M ........... Manifold gasket ....................................... 1
M78M ........... Screw ...................................................... 2
M0EA ........... Control kit, EDC with M80 .............. Control gasket ......................................... 1
MS connector .......................................... 1 M87M ........... Washer, seal (042) .................................. 1
M0EP ........... Control kit, EDC with M90M ........... Screw ...................................................... 6
Packard connector .................................. 1
M1EA ........... Control, EDC with M0MD .......... Control MDC w/ sol. valve and
MS-connector .......................................... 1 neutral start switch .................................. 1
M1EP ........... Control, EDC with M7M ............. Control handle ......................................... 1
Packard-connector .................................. 1 M71M ........... Washer .................................................... 1
M9EA ........... PCP type 3 oil filled (MS) ........................ 1 M72M ........... Nut ........................................................... 1
M9EA ........... PCP type 3 oil filled (Packard) ................ 1 M75M ........... Control manifold ...................................... 1
M87E ............ Washer, seal (042) .................................. 1 M77M ........... Manifold gasket ....................................... 1
M90E ............ Screw ...................................................... 6 M78M ........... Screw ...................................................... 2
M91E ............ Plastic cap (MS) ...................................... 1 M80 .............. Control gasket ......................................... 1
M95E ............ O-ring ...................................................... 2 M87M ........... Washer, seal (042) .................................. 1
M96E ............ O-ring ...................................................... 1 M90M ........... Screw ...................................................... 6
M97E ............ O-ring ...................................................... 1 S40 ............... Neutral start switch .................................. 1
M98E ............ Screw ...................................................... 4
M1MA ........... Servovalve kit .......................................... 1 M810 ............ Adapter plate - Control (130 cc) .............. 1
M820 ............ O-ring (130 cc) ........................................ 1
M0HA ........... Control kit, hydraulic, HDC ...................... 1 M830 ............ O-ring (130 cc) ........................................ 1
M0HC ........... Control kit, hydraulic, HDC ...................... 1 M840 ............ O-ring (130 cc) ........................................ 2
M1HA ........... Control, hydraulic, HDC ........................... 1 M850 ............ Plug (130 cc) ........................................... 1
M1HC ........... Control, hydraulic, HDC ........................... 1 M860 ............ Screw (130 cc) ........................................ 6
M11H ........... Control gasket ......................................... 1 M870 ............ Plug (130 cc) ........................................... 1
M80 .............. Control gasket ......................................... 1
M87H ........... Washer, seal (042) .................................. 1 M9ME ........... 4/2 Way valve .......................................... 1
M90H ........... Screw ...................................................... 6 M92M ........... Screw ...................................................... 4
M95M ........... O-ring ...................................................... 1
M0MA ........... Control MDC M96M ........... O-ring ...................................................... 1
w/o neutral start switch ............................ 1 M97M ........... O-ring ...................................................... 1
M7M ............. Control handle ......................................... 1 M98M ........... Screw ...................................................... 4
M71M ........... Washer .................................................... 1
M72M ........... Nut ........................................................... 1 T001-9 .......... Control orifice kit ...................................... 1
M80 .............. Control gasket ......................................... 1 T201-9 .......... Orificed check valve ................................ 1
M87M ........... Washer, seal (042) .................................. 1 T301-9 .......... Spring ...................................................... 1
M90M ........... Screw ...................................................... 6 T401-9 .......... Spring retainer ......................................... 1
M0MB ........... Control MDC

w/ neutral start switch .............................. 1
M7M ............. Control handle ......................................... 1
81
saue
Variable Pump Controls
M0DC
M90D M1DC M0DD
M1DD
OR
M11D
M0MA M0ME
M0MB M0MF
M0MC M0MG
M0MD M0M9 M0CA
M9ME M76M M74M M90C
M78M M1CA M87C
M92M M11C
M97M M77M
M95M M98M M75M
M96M S40
M72M
M90M
M71M
M1MA M880 OR
M1MB M7MA
T201
M1MC M7MB
THRU
T001 M1MD M7MC
T209, M0EA
THRU M1ME M7MD
T222 M0EF M91E
T009, M1MF M7ME
T250 M0EP
T022 M1MG M7MF
T050 T301 M7MG
THRU T401
M87M M11M M9EA M98E
T309, THRU
M9EP
T322 T409, M90E M95E
T422 M97E
T350
T450 M1EA M880
M1EF
M870
M1EP M96E
M860
M11E
M850
M840 M87E
M840 M810
REF
M830 M840
M820
REF
(Early Production
130 cc Frame Size)
OR
M1HA, M1HC
OR
M1HF, M1HG
M90H
M1HH, M1HJ
M880
M1HK, M1HL M87H
M1HM, M1HN
M11H M0HA, M0HC

M0HF, M0HG
M0HH, M0HJ
M0HK, M0HL
M0HM, M0HN
90000861E
82
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Control Parts List
M0CA ........... Cover plate kit ......................................... 1 M71M ........... Washer .................................................... 1
M1CA ........... Cover plate .............................................. 1 M72M ........... Nut ........................................................... 1
M11C ........... Control gasket ......................................... 1 M80 .............. Control gasket ......................................... 1
M11D ........... Control gasket ......................................... 1 M87M ........... Washer, seal (042) .................................. 1
M87C ........... Washer, seal (042) .................................. 1 M90M ........... Screw ...................................................... 6
M90C ........... Screw ...................................................... 6 S40 ............... Neutral start switch kit ............................. 1
M0DC ........... Control kit, 3-position FNR 12V ............... 1 M0MC .......... Control MDC w/ sol. valve ....................... 1
M0DD ........... Control kit, 3-position FNR 24V ............... 1 M7M ............. Control handle ......................................... 1
M1DC ........... Control, 3-position FNR 12V ................... 1 M71M ........... Washer .................................................... 1
M1DD ........... Control, 3-position FNR 24V ................... 1 M72M ........... Nut ........................................................... 1
M87D ........... Washer, seal (042) .................................. 1 M75M ........... Control manifold ...................................... 1
M90D ........... Screw ...................................................... 6 M77M ........... Manifold gasket ....................................... 1
M78M ........... Screw ...................................................... 2
M0EA ........... Control kit, EDC with M80 .............. Control gasket ......................................... 1
MS connector .......................................... 1 M87M ........... Washer, seal (042) .................................. 1
M0EP ........... Control kit, EDC with M90M ........... Screw ...................................................... 6
Packard connector .................................. 1
M1EA ........... Control, EDC with M0MD .......... Control MDC w/ sol. valve and
MS-connector .......................................... 1 neutral start switch .................................. 1
M1EP ........... Control, EDC with M7M ............. Control handle ......................................... 1
Packard-connector .................................. 1 M71M ........... Washer .................................................... 1
M9EA ........... PCP type 3 oil filled (MS) ........................ 1 M72M ........... Nut ........................................................... 1
M9EA ........... PCP type 3 oil filled (Packard) ................ 1 M75M ........... Control manifold ...................................... 1
M87E ............ Washer, seal (042) .................................. 1 M77M ........... Manifold gasket ....................................... 1
M90E ............ Screw ...................................................... 6 M78M ........... Screw ...................................................... 2
M91E ............ Plastic cap (MS) ...................................... 1 M80 .............. Control gasket ......................................... 1
M95E ............ O-ring ...................................................... 2 M87M ........... Washer, seal (042) .................................. 1
M96E ............ O-ring ...................................................... 1 M90M ........... Screw ...................................................... 6
M97E ............ O-ring ...................................................... 1 S40 ............... Neutral start switch .................................. 1
M98E ............ Screw ...................................................... 4
M1MA ........... Servovalve kit .......................................... 1 M810 ............ Adapter plate - Control (130 cc) .............. 1
M820 ............ O-ring (130 cc) ........................................ 1
M0HA ........... Control kit, hydraulic, HDC ...................... 1 M830 ............ O-ring (130 cc) ........................................ 1
M0HC ........... Control kit, hydraulic, HDC ...................... 1 M840 ............ O-ring (130 cc) ........................................ 2
M1HA ........... Control, hydraulic, HDC ........................... 1 M850 ............ Plug (130 cc) ........................................... 1
M1HC ........... Control, hydraulic, HDC ........................... 1 M860 ............ Screw (130 cc) ........................................ 6
M11H ........... Control gasket ......................................... 1 M870 ............ Plug (130 cc) ........................................... 1
M80 .............. Control gasket ......................................... 1
M87H ........... Washer, seal (042) .................................. 1 M9ME ........... 4/2 Way valve .......................................... 1
M90H ........... Screw ...................................................... 6 M92M ........... Screw ...................................................... 4
M95M ........... O-ring ...................................................... 1
M0MA ........... Control MDC M96M ........... O-ring ...................................................... 1
w/o neutral start switch ............................ 1 M97M ........... O-ring ...................................................... 1
M7M ............. Control handle ......................................... 1 M98M ........... Screw ...................................................... 4
M71M ........... Washer .................................................... 1
M72M ........... Nut ........................................................... 1 T001-9 .......... Control orifice kit ...................................... 1
M80 .............. Control gasket ......................................... 1 T201-9 .......... Orificed check valve ................................ 1
M87M ........... Washer, seal (042) .................................. 1 T301-9 .......... Spring ...................................................... 1
M90M ........... Screw ...................................................... 6 T401-9 .......... Spring retainer ......................................... 1
M0MB ........... Control MDC

w/ neutral start switch .............................. 1
M7M ............. Control handle ......................................... 1
83
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Filter and Options
N40P
N40L
N00M
N00S
N35M
REF N35S
N10M
N10S
N30R N35M N25M Or
N00R
N20M
N10R N15M
N31R
N20R OR
N15R
N35R N25R
90000862E
H50L
H50
H40
OR H05
H30
H60
H50
H40
H30
OR H05
(H30)
J80N
H40
H60 H05
H50 OR
H60
H50
H90L
J40N
J15N
H70 J15_
J30 J10_
J30
H80 J70_
H70
OR
J80_ J50_
J60_
J90_ H80
J00_
J92_
J95_
90000863E
84
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Parts List Filter and Options
H05B-H ........ Kit - Charge pump ................................... 1 J80A-V ......... Screw ...................................................... 4
H50L ............ Spacer (No charge pump) ....................... 1 J80N ............. Screw ...................................................... 4
H30 .............. Port plate ................................................. 2 J90A-V ......... O-ring ...................................................... 1
H40 .............. Pin ........................................................... 1 J92A-V ......... Cover plate .............................................. 1
H50 .............. Charge pump shaft .................................. 1 J95A-V ......... Screw ................................................... 2/4
H60 .............. Key .......................................................... 1
H70 .............. Retaining plate ........................................ 1 N00M ........... Filtration manifold kit (Int) ........................ 1
H80 .............. Screw ...................................................... 6 N10M ........... Manifold ................................................... 1
H90L ............ Plug ......................................................... 1 N15M ........... O-ring ...................................................... 2
N20M ........... Nut ........................................................... 1
J00A ............. Aux. mtg. SAE A flange ........................... 1 N25M ........... Tube ........................................................ 1
J00B ............. Aux. mtg. SAE B flange ........................... 1 N35M ........... Plug ......................................................... 2
J00C ............. Aux. mtg. SAE C flange .......................... 1 N40L ............ Filter ........................................................ 1
J00D ............. Aux. mtg. SAE D flange .......................... 1 N40P ............ Filter ........................................................ 1
J00T ............. Aux. mtg. SAE A flange (11 T) ................ 1
J00V ............. Aux. mtg. SAE B-B flange ....................... 1 N00R ............ Filtration manifold kit (Rmt) ..................... 1
J00N ............. Aux. mtg. flange - none ........................... 1 N10R ............ Manifold ................................................... 1
J10A-V ......... Coupling .................................................. 1 N15R ............ O-ring ...................................................... 1
J15 ............... Charge pump cover assembly ................ 1 N20R ............ Nut ........................................................... 1
J15N ............. Charge pump cover assembly ................ 1 N25R ............ Tube ........................................................ 1
J30 ............... Bushing ................................................... 1 N30R ............ Plastic plug .............................................. 2
J50A-V ......... O-ring ...................................................... 1 N35R ............ Plug ......................................................... 1
J60A/T .......... Flange adaptor SAE A ............................ 1
J60B/V ......... Flange adaptor SAE B ............................ 1 N00S ............ Filtration kit (Suction Flt) .......................... 1
J60C ............. Flange adaptor SAE C ............................ 1 N10S ............ Reducer fitting (Suction Flt) ..................... 1
J60D ............. Flange adaptor SAE D ............................ 1 N35S ............ Plug ......................................................... 1
J70A-V ......... Washer .................................................... 4
Name Plates
saue saue
Ames, Iowa, U.S.A. Neumnster, Germany Ames, Iowa, U.S.A. Neumnster, Germany
Model Code Typ Model Code Typ
90L055 EA 1 N 90L055 EA 1 N
Model Model
6 S 3 C6 C 03 6 S 3 C6 C 03 Code
Code
Model Model No. Ident Nr Model Model No. Ident Nr
Number 94 2029 Number 687459
Serial Serial
Serial No. Fabr Nr Serial No. Fabr Nr
Number MADE IN U.S.A. Number MADE IN GERMANY
Place of Manufacture Place of Manufacture
Name Plate (U.S.A. Production) Name Plate (German Production)
85
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Fixed Motor
Minor Repair Parts
H68W
H60W L35
(Early Production
H62W 075 Frame Size) (L70)
H64W
(L40) L60 L70
H66W
H60N L30
L40
(H50N) (B80)
(G50)
(H50W) (H30W)
L50
(H40W)
(H20W)
G50
G70
H10N (B80)
H50N
H20W
(G63)
B80 H10W H40W
G63
H30W
(CODE 61 OPTION)
H50W
(G64) G64
(CODE 61 OPTION)
B83 B83 OR
B80
G63
(CODE 61 OPTION)
(G63)
G64
(CODE 61 OPTION) (B83)
(G64) (B83)
90000864E
86
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Parts List
B80 ............... Plug ......................................................... 2 H50W ........... Plug ......................................................... 2

B83 ............... Plug ......................................................... 1 H60W ........... Charge relief valve plug .......................... 1
B83 ............... Speed sensor .......................................... 1 H62W ........... O-ring ...................................................... 1
H64W ........... Spring ...................................................... 1
G50 .............. Plug ......................................................... 2 H66W ........... Charge relief poppet ................................ 1
G70 .............. Plug ......................................................... 1 H68W ........... Lock nut ................................................... 1
G63 .............. Split flange screw .................................... 4
G64 .............. Screw - Shipping Cover ........................... 4 L30 ............... Seal carrier .............................................. 1
L35 ............... Seal carrier .............................................. 1
H10N ............ Loop flushing spool - defeat .................... 1 L40 ............... Lip seal .................................................... 1
H50N ............ Plug ......................................................... 2 L50 ............... O-ring ...................................................... 1
L60 ............... Retainer ................................................... 1
H10W ........... Shuttle valve spool .................................. 1 L70 ............... Screw ...................................................... 3
H20W ........... Spring guide ............................................ 2
H30W ........... Spring ...................................................... 2 L8 ................. Key .......................................................... 1
H40W ........... O-ring ...................................................... 2 L9 ................. Slotted nut ............................................... 1
Name Plates
saue saue
90M055 NC 0 N 90M055 NC 0 N
8 N 0 C6 W 00 Model 8 N 0 C6 W 00 Model
Code Code
NNN 00 00 24 NNN 00 00 24
Model Model No. Ident Nr Model Model No. Ident Nr
Serial A 91 26 67890 Serial N 91 26 67890
Number MADE IN U.S.A.
Number
MADE IN GERMANY
87
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Hydraulic Power Systems
SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide
SAUER-SUNDSTRAND is a world leader in the design and SAUER-SUNDSTRAND specializes in integrating a full
manufacture of Hydraulic Power Systems. Research and range of system components to provide vehicle designers
development resources in both North America and Europe with the most advanced total-design system.
enable SAUER-SUNDSTRAND to offer a wide range of
design solutions utilizing hydraulic power system SAUER-SUNDSTRAND is Your World Source for
technology. Controlled Hydraulic Power Systems.
Heavy Duty Axial Piston Heavy Duty Bent Axis Cartridge Motors/
Pumps and Motors Variable Motors Compact Wheel Drives
Medium Duty Axial Piston Microcontrollers and Hydrostatic Transmission

Pumps and Motors Electrohydraulic Controls Packages
Open Circuit Axial Piston Pumps Gear Pumps and Motors Genuine Service Parts
Worldwide Service Support
SAUER-SUNDSTRAND provides comprehensive worldwide service for its

products through an extensive network of Authorized Service Centers
strategically located in all parts of the world.
Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.
Genuine Parts
Original
Ersatzteile
SAUER-SUNDSTRAND COMPANY SAUER-SUNDSTRAND GMBH & CO.

saue 2800 East 13th Street
Ames IA 50010 U.S.A.
Postfach 2460 D-24531 Neumnster
Krokamp 35 D-24539 Neumnster Germany
Phone: (515) 239-6000 FAX: (515) 239-6618 Phone: (04321) 871-0 Fax: (04321) 871 465
SM-SPV+SMF+SMV90-E 11/98 300047G
BLN-9947 Revision G April 1999
CONTENTS
saue
Series 90
Axial Piston
Pumps and Motors
Repair Manual
CONTENTS
saue
Axial Piston Pumps and Motors Series 90
General Description
Series 90 Variable Displacement Pumps are cradle Series 90 Fixed and Variable Displacement Motors
swashplate design units, incorporating parallel axial are swashplate design units, incorporating parallel
pistons with slippers. axial pistons with slippers.
These pumps are designed to be combined with These motors are primarily designed to be combined
other products in closed circuit systems to transfer with other products in closed circuit systems to trans-
and control hydraulic power. fer and control hydraulic power.
The pump output flow rate is proportional to the The output speed is proportional to the flow rate of the
pump's input speed and is determined by the swash- hydraulic fluid through the motor (and the motor
plate angle, which may be infinitely varied between displacement, for variable motors). Output torque is
zero and maximum displacement. proportional to the difference in the pressure levels in
the high and low sides of the fluid circuit.
The pump's flow direction is reversed by tilting the
swashplate to the opposite side of the zero displace- The motor's direction of rotation depends on the
ment position. direction of fluid flow through the motor.
A compact, responsive, closed loop servo system, Variable Displacement Motors are available with 2-
with a choice of manual, hydraulic, or electrical input, position electric solenoid or hydraluic displacement
controls the swashplate angle. An automotive drive control, and utilize internally supplied servo pres-
control is also available. sure. Variable motors normally start at maximum
displacement. Activation of the motor control results
in the motor shifting to minimum displacement.
The Series 90 Advanced Technology Today
The Most Technically Advanced Hydraulic Units in the Industry
8 Sizes of Variable Displacement Pumps
6 Sizes of Fixed Displacement Motors
Complete Family of Control Systems
Proven Reliability and Performance
Optimum Product Configurations
Compact, Lightweight
Copyright 1987, 1991, 1992, Sauer-Sundstrand Company

All rights reserved. Contents subject to change. Printed in U.S.A. 0792 H
CONTENTS
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Contents
Introduction ................................................................................................................................................. 0 - 2
Safety Precautions .................................................................................................................................... 20 - 1
Tool Information ........................................................................................................................................ 20 - 2
Exploded View of the Variable Displacement Pump ................................................................................. 40 - 1
Exploded View of the Fixed Displacement Motor .................................................................................... 40 - 13
Exploded View of the Variable Displacement Motor ............................................................................... 40 - 17
Major Repair - Variable Pump ................................................................................................................... 61 - 1
General .............................................................................................................................................. 61 - 1
Disassembly Procedures for Variable Displacement Pump ............................................................... 61 - 2
Reconditioning and Replacement of Parts ......................................................................................... 61 - 6
Assembly Procedures for Variable Displacement Pump ................................................................. 61 - 12
Major Repair - Fixed Motor ....................................................................................................................... 62 - 1
General .............................................................................................................................................. 62 - 1
Disassembly Procedures for Fixed Displacement Motor ................................................................... 62 - 2
Reconditioning and Replacement of Parts ......................................................................................... 62 - 4
Assembly Procedures for Fixed Displacement Motor ........................................................................ 62 - 6
Major Repair - Variable Motor ................................................................................................................... 63 - 1
General .............................................................................................................................................. 63 - 1
0 -1
CONTENTS
saue
Introduction
This manual provides Major Repair procedures for These repair procedures, when used in conjunction
the Series 90 variable displacement pumps and fixed with the Series 90 Service manual, Bulletin BLN-
and variable displacement motors. 9947, provide complete service and repair informa-
tion for the Series 90 products.
Minor Repairs are those repairs which can be
performed without removing the end cap or side For Technical Information on Series 90 pumps and
cover. These repairs can be performed by any motors, refer to BLN-10029 and BLN-10030.
customer without affecting the unit warranty. These
For Fluid Quality Requirements, refer to bulletin BLN-
repairs are described in the Series 90 Service
9887, or Publication SDF (Id. No. 697581).
Manual, Bulletin BLN-9947.
Sauer-Sundstrand provides a complete repair serv-
Major Repairs are those repairs which require the ice for its products. Contact any Sauer-Sundstrand
removal of the end cap or side cover. These repairs Authorized Service Center for details. Sauer-Sund-
are to be performed only by Sauer-Sundstrand Au- strand Authorized Service Center locations are listed
thorized Service Centers and/or original equipment in BLN-2-40527, or Publication SAW (Id. No. 698266).
manufacturers who have been adequately trained by
Sauer-Sundstrand to perform these repairs. Per-
forming major repairs on the Series 90 products may
affect the unit warranty status, thus the factory should
be consulted prior to undertaking such repairs.
90000015 90000016
Series 90 Variable Displacement Pump Series 90 Fixed Displacement Motor
0-2
CONTENTS
saue
Safety Precautions
When Series 90 units are used in vehicular Use caution when dealing with hydraulic
hydrostatic drive systems, the loss of hydro- fluid under pressure. Escaping hydraulic
static drive line power in any mode of opera- fluid under pressure can have sufficient
tion may cause a loss of hydrostatic braking force to penetrate your skin causing seri-
capacity. A braking system, redundant to ous injury. This fluid may also be hot
the hydrostatic transmission must, there- enough to burn. Serious infection or reac-
fore, be provided which is adequate to stop tions can develop if proper medical treat-
and/or hold the system should the condi- ment is not administered immediately.
tion develop. Some cleaning solvents are flammable. To
Certain service procedures may require the avoid possible fire, do not use cleaning
vehicle/machine to be disabled (wheels solvents in an area where a source of igni-
raised off the ground, work function discon- tion may be present.
nected, etc.) while performing them in order Always test Series 90 units prior to reinstall-
to prevent injury to the technician and by- ing in order to verify correct function of
standers. controls and other systems.
20 - 1
CONTENTS
saue
Tool Information
Certain tools are helpful in disassembling and as-
sembling Series 90 pumps and motors which are not
normally included in the typical mechanics set of
tools. These include:
An internal puller for removing the shaft journal bear-
ing from the end cap. (Example: Snap-On Tools
Puller Set CG45)
Sizing arbors for the end cap shaft journal bearing
(Sauer-Sundstrand part number 9510667-XXXX).
90000129 90000170
CAUTION
Fig. 20-1 - Removing Fig. 20-2 - Removing
The pump or motor shaft must NOT be used to
Journal Bearing (PV) Journal Bearing (MF/ size the bearing. Inadequate clearance between
MV) the shaft and bearing will result in inadequate
lubrication and shortened bearing life.
Dimensions for the sizing arbors are shown in the
B accompanying figure and table. The arbors are made
0.10 (2.54)
of AISI 4140 steel. A 4 to 8 RMS microfinish and a
A DIA hardness of 50 to 57 Rc is required on Diameter A.
Diameter A
Frame (0.0001 in. or Dimension B
5 (1)
Size 0.00254 mm) Minimum
0.02 (0.51) R
030 25.300 mm 22.0 mm
90000134 90000188
042 28.010 mm 30.5 mm
Fig. 20-3 - Sizing Fig. 20-4 - Journal
055 1.1818 in. 1.00 in.
Journal Bearing in Bearing Sizing Arbor
End Cap (PV) Dimensions 075 1.3785 in. 1.20 in.
100 1.5000 in. 1.27 in.
130 44.984 mm 40.5 mm
A tool to aid in holding and installing the assembled

cylinder block and swashplate into the variable pump
housing may be made from a positive lock, quick
release pin and a large flat washer (1 inch inside
diameter with clearance flats ground on the outside
diameter). The 1 inch diameter pin is defined by
military specification MS 17985 C 16 60, and is
available from a number of sources. These include:
90000145 90000215
QRP, Incorporated
Fig. 20-5 - Install Fig. 20-6 - Install Flat
Reach Road & North Drive, PO Box T3572
Assembly Tool (PV) Washer on Williamsport, PA 17701-0572
Assembly Tool Telephone: (717) 322-8060
Carr Lane Manufacturing Co.
4200 Carr Lane Court, PO Box 13149
St. Louis, MO 63119
Telephone: (314) 647-6200
Lockwell Products
Division of The Hartwell Corporation
900- T South Richfield Road
Placentia, CA 92670
Telephone: (714) 579-4425
20 - 2
CONTENTS
saue
Exploded View of the Variable Displacement Pump
The following information is for general parts identifi-
cation ONLY. Refer to the applicable Service Parts
List when ordering service parts.
K90 L35
B70 K018
K10 (Early Production
THRU (L70)
B83 G532 075 Frame Size)
K50 K042
OR G536
B83 K70 (L40)
G542 L60 L70
K80 (B80)
G546
L40
B82 (B90) L30
P2B_
(B70)
B90
P30 P06
P13 L50
P30
B71 (K018
THRU
P2A_ P06 K042)
P13 G512
G516
G531 G501
G502 G538
G506 G508
G172 G511
G522 G176 G518
G526 B80
(G502 G541
G506) (G502 G548
G506)
(G63)
G63
(CODE 61 OPTION) OR G63
(G64) (CODE 61 OPTION)
G64
(CODE 61 OPTION)
BOTH SIDES G521
G528 (G63) G64
(G501 (G64) (CODE 61 OPTION)
G508) (G501
G508)
saue saue
90L055 EA 1 N 90L055 EA 1 N
6 S 3 C6 C 03 Model 6 S 3 C6 C 03 Model
Code Code
Model
HNN 35 35 24 Model
HNN 35 35 24
Model No. Ident Nr Model No. Ident Nr
Number Number
94 2029 687459
Serial A 88 26 67890 Serial N 88 26 67890
Number MADE IN U.S.A.
Number MADE IN GERMANY

40 - 1
CONTENTS
saue
Exploded View of the Variable Displacement Pump (Continued)
M0MA M0ME OR M0CA

M0MB M0MF M90C
MODC
M0MC M0MG M1DC M1CA M87C
M90D MODD
M0MD M0M9 M1DD M11C
M9ME M76M M74M
M78M
M92M
M11D M0EA OR
M0EF M91E
M77M
M97M M0EP
M98M M75M
M95M
M96M S40
M72M M9EA M98E
M90M M9EP
M71M M1HA, M1HC M90E
M1MA M880 M95E
M7MA M1HF, M1HG
T201 M1MB
M7MB M1HH, M1HJ
M90H M1EA M880 M97E
THRU M1MC M880
M7MC M1HK, M1HL M87H M1EF
T001 T209, M1MD
M7MD M1HM, M1HN M1EP M96E
THRU T222 M1ME
T009, M1MF M7ME M11E
T250 M11H
T022 M1MG M7MF
T050 T301 M7MG
THRU T401 M87E
M87M M11M
T309, THRU
T322 T409,
OR OR
T350 T422
T450 M0HA, M0HC
M870 M0HF, M0HG
M0HH, M0HJ
M860 M0HK, M0HL
M850 M0HM, M0HN
M840
M840 M810
REF
M830 M840
REF M820
EARLY PRODUCTION
130CC PUMPS ONLY
40 - 2
CONTENTS
saue
W741
W740 W74A
W701
W754
W755
A W756
W751
W752
W753 W757
W756
W122 W121 W701 W755 W750
W10A W70A W754
W004 W702
W547 W304 W30A
W542 W005 W007 W41A
W004
W541
W543 W005 W006 W010
W544 W414
W548 W545 A W302
W546 M92A W009
W551
W521 W552
W554 W011
W522 W550
W523 W402
W553
W524 W013
W525
W501 W001 W012
W502 M78A W555
W503
W504 M77A W556 W014
W21A W505 W557
THRU M90A W559
W002 W26A T660 THRU T665
M1AC W558
T560 THRU T565
W560
W003 M87A W561
W008 W563
M11A W526 W562
W528
W001
W529
W527
W015 W506
40 - 3
CONTENTS
saue
N40P
N40L
N00M
N00S
N35M
REF N35S
N10M
N10S
N30R N35M N25M OR
N00R N20M
N15M
N10R N31R
N20R OR
N15R
N35R N25R
H50L
H50
H40
OR H05
H30
H60
H50
H40
H30
OR H05
(H30)
J80N
H40
H60 H05
H50 OR
H60
H50
H90L
J40N
J15N
H70 J15_, J15L, OR J15R

J30 J10_
J30
H80
J70_ H70
OR
J50_
J80_
J60_
J90_ H80
J00_, JL0_, OR JR0_
J92_
J95_
40 - 4
CONTENTS
saue
C20
C30
C50
C40
C65
C70
S07
B10
C05
C13
B50 REF
C14
C80
B20 REF
C15 D65
C16 M14E
M14H
M14M
D60 B50
B20
F20
D85 B30
D95
D80
D50
40 - 5
CONTENTS
saue
L20
S03 L10
F603
L1C3
S01 L1C6
F344 L10
L1C7
OR
F354 L1F1
F40
F603 L1S1
F50
L1S3
L1S4
F40 L8T1
F50 L1T1 L9T1
L1T2 L8T2
L9T2
L1TF (SPECIAL) L9TF
OR
L8K1
L8K2
L8K3
L1K1
S10 L1K2
L1K3
F12 F11 OR
REF REF
E30 REF E30 F11
F12 F50
E22 F40
REF F344
E81 E20
E82 E22
E80 REF F50 F354
REF F40 F60
E24 E82 S04
REF
E80 E50
E24 F60
S02
E10
E61
E40
E40 E60
REF
F 106
F 306
F 136
F 146
F 726
F 736
F 746
F 776
F 606
F 826
F 786
F 806
F 796 F 706 F 816
F 716
40 - 6
CONTENTS
saue
P80 P807
P80
P802
P70
P70 P707
P702
ENDCAP GASKET FACE ENDCAP GASKET FACE ENDCAP GASKET FACE

OF ITEM G04X (TYPICAL) OF ITEM G04X (TYPICAL) OF ITEM G04X (TYPICAL)
WITH PRESSURE LIMITERS WITH PRESSURE LIMITERS WITHOUT PRESSURE LIMITERS
RIGHT HAND ROTATION LEFT HAND ROTATION LEFT/RIGHT HAND ROTATION
G94
G93
G952 G95
G956
G302
G902 G306
G906 G078
G068 G94
G93
G20 G952 G95
P70 G182 G088 G956
G40 G186 G301
G308
P80
GASKET FACE OF ITEM G068
OR NOTES:
WITH PRESSURE LIMITERS
RIGHT HAND ROTATION G20
G042 ITEMS G042 & G046 DO NOT
G046 G40 INCLUDE ITEMS G93, G94, G95,
G902, G906, G952, & G956.
ITEMS G041 & G048 DO NOT

INCLUDE ITEMS G93, G94, G95,
P70 G041 G951, & G958
G048
P80
GASKET FACE OF ITEM G068
WITH PRESSURE LIMITERS
LEFT HAND ROTATION
40 - 7
CONTENTS
saue
B10 VARIABLE HOUSING 1 F736 SPRING GUIDE (INNER) 1
B20 PIN 2 F746 SPRING 1
B30 BEARING 1 F776 SPRING GUIDE (OUTER) 1
B50 PIN 2 F786 RETAINING RING 1
B70 PLUG 2 F796 NUT 1
B80 PLUG 1 F806 NUT - LOCK 1
B90 CONTROL FILTER SCREEN 3 F816 NUT - SEAL LOCK 1
C05 CYLINDER BLOCK ASSY 1 F826 WASHER - FLAT 4
C13 SPRING SEAT 1
C14 CYLINDER BLOCK SPRING 1 G048 END CAP - TWIN PORTS 1
C15 SPRING RETAINER 1 G046 END CAP - AXIAL PORTS 1
C16 RETAINING RING 1 G20 JOURNAL BEARING 1
C20 PISTON 9 G40 BUSHING 1
C30 SLIPPER GUIDE 1 G61 PORT SHIPPING COVER GASKET 2
C40 SLIPPER GUIDE BEARING 1 G62 PORT SHIPPING COVER 2
C50 SPACER 4 G63 SPLIT CLAMP 4
C65 WASHER 4 G64 SCREW - SHIPPING COVER 4
C70 SCREW 4 G068 VALVE HOUSING ASSY 1
C80 VALVE PLATE G078 SCREW 4
D50 SWASHPLATE ASSY 1 G088 GASKET 1
D80 CAGE LOCATOR LINK 1 G93 SPACER 1
D85 PIN 1 G94 LIFTING BRACKET 1
D95 SPRING 1 G95 WASHER 1
E10 SIDE COVER 1 G306 END CAP GASKET 1
E20 LEVELER 1 G308 END CAP GASKET 1
E22 SPRING SEAT 2 G506 PLUG 3
E24 SHIM 2 G508 PLUG 3
E30 GUIDE POST 2 G526 PLUG 1
E40 NUT 2 G546 PLUG 1
E50 O RING 1 G906 SCREW 1
E60 SCREW 6 G956 SCREW 1
E61 WASHER - FLAT 6 G958 SCREW 1
E70 PLUG 1
E80 SPRING 2 H05B-H KIT - CHARGE PUMP 1
F11 O RING 2 H05L SPACER (NO CHARGE PUMP) 1
F12 PISTON RING 2 H30 PORT PLATE 2
F20 SLIDER BLOCK 1 H40 PIN 1
H50 CHARGE PUMP SHAFT 1
F003 SERVO SLEEVE KIT - NO LIMITER 2 H60 KEY 1
F004 SERVO SLEEVE KIT - ADJUSTABLE 2 H70 RETAINING PLATE 1
F40 O RING 2 H80 SCREW 6
F50 O RING 2 H90 PLASTIC PLUG 1
F60 SCREW 6 H90L PLUG 1
F344 SCREW 2
F354 NUT 2 J00A AUX. MTG. A FLANGE 1
J00B AUX. MTG. B FLANGE 1
F106 SERVO PISTON (FBA) 1 J00C AUX. MTG. C FLANGE 1
F136 NEUTRAL SPRING CANNISTER (FBA) 1 J00D AUX. MTG. D FLANGE 1
F146 SCREW 1 J00T AUX. MTG. A FLANGE (11T) 1
F306 SERVO SLEEVE (FBA) 1 J00V AUX. MTG. B-B FLANGE 1
F606 SCREW 3 J00N AUX. MTG. FLANGE - NONE 1
F706 O-RING 1 J10A-V COUPLING 1
F716 NEUTRAL SPRING COVER (FBA) 1 J15 CHARGE PUMP COVER ASSY 1
F726 SCREW 1 J15N CHARGE PUMP COVER ASSY 1
40 - 8
CONTENTS
saue
J30 BUSHING 1 M90C SCREW 6
J40A-V O RING 1 M14 FEEDBACK LINK 1
J50A-V O RING 1
J60A/T FLANGE ADAPTOR 1 M0DC CONTROL KIT 3 POS F-N-R 12V 1
J60B/V FLANGE ADAPTOR 1 M0DD CONTROL KIT 3 POS F-N-R 24V 1
J60C FLANGE ADAPTOR 1 M1DC CONTROL 3 POS F-N-R 12V 1
J60D FLANGE ADAPTOR 1 M1DD CONTROL 3 POS F-N-R 24V 1
J70A-V WASHER 4 M80 CONTROL GASKET 1
J80A-V SCREW 4 M87D WASHER, SEAL (042) 1
J80N SCREW 4 M90D SCREW 6
J90A-V O RING 1
J92A-V COVER PLATE 1 M0EA EDC KIT W/MS CONNECTOR 1
J95A-V SCREW 2/4 M0EP EDC KIT W/PACKARD CONNECTOR 1
M1EA EDC W/MS CONNECTOR 1
K000 ADJ. CHARGE RELIEF KIT 1 M1EP EDC W/PACKARD CONNECTOR 1
K10 PLUG ASSY 1 M9EA PCP TYPE 3 OIL FILLED (MS) 1
K50 O RING 1 M9EA PCP TYPE 3 OIL FILLED (PACKARD) 1
K70 SPRING 1 M80 CONTROL GASKET 1
K80 POPPET 1 M87E WASHER, SEAL (042) 1
K90 NUT 1 M90E SCREW 6
M91E PLASTIC CAP (MS) 1
L10 ROLLER BEARING 1 M95E O RING 2
L20 RETAINING RING 1 M96E O RING 1
L35 SEAL CARRIER 1 M97E O RING 1
L40 LIP SEAL 1 M98E SCREW 4
L50 O RING 1 M14 FEEDBACK LINK 1
L70 SCREW 3
M0HA HDC KIT 1
L1C3 SHAFT - PV, SPLINED 1 M0HC HDC KIT 1
L1C6 SHAFT - PV, SPLINED 1 M1HA HDC 1
L1C7 SHAFT - PV, SPLINED 1 M1HC HDC 1
L1C8 SHAFT - PV, SPLINED 1 M80 CONTROL GASKET 1
L1F1 SHAFT - PV, SPLINED 1 M90H SCREW 6
L1K1 SHAFT - PV, STRAIGHT KEY 1 M14 FEEDBACK LINK 1
L1K2 SHAFT - PV, STRAIGHT KEY 1
L1K3 SHAFT - PV, STRAIGHT KEY 1 M0MA MDC W/O NEUTRAL START SWITCH 1
L1S1 SHAFT - PV, SPLINED 1 M7M CONTROL HANDLE 1
L1T1 SHAFT PV, TAPERED 1 M71M WASHER 1
L1T2 SHAFT PV, TAPERED 1 M72M NUT 1
L1T3 SHAFT PV, TAPERED 1 M80 CONTROL GASKET 1
L8 KEY 1 M90M SCREW 6
L9 SLOTTED NUT 1 M14 FEEDBACK LINK 1
M0AC ADAPTER PLATE - FBA CONTROL 1 M0MB MDC W/NEUTRAL START SWITCH 1
M77A ADAPTER PLATE - FBA 1 M7M CONTROL HANDLE 1
M78A SCREW 6 M71M WASHER 1
M90A SCREW 6 M72M NUT 1
M92A SCREW 2 M80 CONTROL GASKET 1
M98A SCREW 1 M90M SCREW 6
S40 NEUTRAL START SWITCH KIT 1
M0CA CONTROL - COVER PLATE KIT 1 M14 FEEDBACK LINK 1
M1C COVER PLATE 1
M80 CONTROL GASKET 1 M0MC MDC W/SOL. VALVE 1
M87C WASHER, SEAL (042) 1 M7M CONTROL HANDLE 1
40 - 9
CONTENTS
saue
M71M WASHER 1 P13 O RING 2
M72M NUT 1 P30 PLASTIC PLUG 2
M74M SOLENOID VALVE 1 P70 CHECK VALVE 2
M75M CONTROL MANIFOLD 1 P702 PLUG 1
M77M MANIFOLD GASKET 1 P80 SPECIAL PLUG 2
M78M SCREW 2 P802 SPECIAL PLUG 3
M80 CONTROL GASKET 1
M90M SCREW 6 S10 SERVO PISTON KIT 1
M14 FEEDBACK LINK 1 F11 O RING 2
F12 PISTON RING 2
M0MD MDC W/SOL. VALVE, NSS 1
M7M CONTROL HANDLE 1 T001-9 CONTROL ORIFICE KIT 1
M71M WASHER 1 T201 ORIFICED CHECK VALVE 1
M72M NUT 1 T301 SPRING 1
M75M CONTROL MANIFOLD 1 T401 SPRING RETAINER 1
M76M SOLENOID VALVE 1 T560-5 CONTROL ORIFICE (FBA) 1
M77M MANIFOLD GASKET 1 T660-5 CONTROL ORIFICE (FBA) 1
M78M SCREW 2
M80 CONTROL GASKET 1 S07 CYL. BLOCK KIT W/ PISTONS 1
M90M SCREW 6 C20 PISTON 9
S40 NEUTRAL START SWITCH KIT 1 C80 PUMP VALVE PLATE 1
M14 FEEDBACK LINK 1 S30 OVERHAUL SEAL KIT 1
C70 SCREW 4
M810 ADAPTER PLATE - CONTROL (130 CC) 1 E40 NUT 2
M820 O-RING (130 CC) 1 E50 O RING 1
M830 O-RING (130 CC) 1 E60 SCREW 6
M840 O-RING (130 CC) 2 F11 O RING 2
M850 PLUG (130 CC) 1 F12 PISTON RING 2
M860 SCREW (130 CC) 6 F40 O RING 2
M870 PLUG (130 CC) 1 F50 O RING 2
G088 GASKET 1
N00M FILTRATION MANIFOLD KIT (INT) 1 G306 END CAP GASKET - AXIAL PORTS 1
N10M MANIFOLD 1 G308 END CAP GASKET - TWIN PORTS 1
N15M O RING 2 J40A O RING 1
N20M NUT 1 J50A O RING 1
N25M TUBE 1 J90A O RING 1
N30M PLUG 2 J90B O RING 1
N40L FILTER 1 J90C O RING 1
N40P FILTER 1 K50 O RING 1
L40 LIP SEAL 1
N00R FILTRATION MANIFOLD KIT (RMT) 1 L50 O RING 1
N10R MANIFOLD 1 M77M MANIFOLD GASKET 1
N15R O RING 1 M80 CONTROL GASKET 1
N20R NUT 1 M95E O RING 2
N25R TUBE 1 M96E O RING 1
N30R PLASTIC PLUG 2 M97E O RING 1
N00R PLUG 1 N15 O RING 1
P6 O RING 2
N10S REDUCER FITTING (SUCTION FLT) 1 P13 O RING 2
N30S PLUG 1
P2A MULTI-FUNCTION VALVE ASSY 1

P2B MULTI-FUNCTION VALVE ASSY 1
P6 O RING 2
40 - 10
CONTENTS
saue
W001 VALVE BLOCK (FBA) 1 W552 PLUG (HYD INCHING) 1
W002 PLUG 1 W553 O-RING (HYD INCHING) 1
W003 PLUG 1 W554 O-RING (HYD INCHING) 1
W004 O-RING 1 W555 SPOOL (HYD INCHING) 1
W005 O-RING 1 W556 SPRING SEAT - INNER (HYD INCHING) 1
W006 STARTING THROTTLE (FBA) 1 W557 SPRING (HYD INCHING) 1
W007 NUT - SEAL LOCK 1 W558 SPRING WASHERS (HYD INCHING)
W008 PLUG - EXPANDER 4 W559 SPRING SEAT - OUTER (HYD INCHING) 1
W009 PLUG ASSY 1 W560 O-RING (HYD INCHING) 1
W010 NUT 1 W561 PLUG - THREADED (HYD INCHING) 1
W011 O RING 1 W562 NUT - SEAL LOCK (HYD INCHING) 1
W012 POPPET 1 W563 SCREW - ADJUSTING (HYD INCHING) 1
W013 SPRING 1 W70A 3 POS / 4 WAY VALVE (FBA) 1
W014 SEAT 1 W701 FNR VALVE (ELECTRICAL) 1
W015 ORIFICE 1 W702 SCREW 4
W10A THERMOVALVE (FBA) 1 W74A 3 POS / 4 WAY VALVE W/INCH (FBA) 1
W121 PLATE (FBA) 1 W740 FNR VALVE 1
W122 SCREW 4 W701 FNR VALVE (ELECTRICAL) 1
W21-26A MAIN ORIFICE (FBA) 1 W741 SCREW 4
W30A PRESSURE RELIEF VALVE (FBA) 1 W750 INCH VALVE (ROTARY) 1
W302 O-RING 1 W751 VALVE BLOCK 1
W304 NUT - SEAL LOCK W752 PLUG 1
W41A THROTTLE OR PRESS VALVE (FBA) 1 W753 VALVE SPOOL 1
W402 O-RING 1 W754 RING - RETAINING 2
W414 NUT - SEAL LOCK 1 W755 RETAINER 2
W501 SCREW (LESS INCHING) 2 W756 O-RING 2
W502 PLATE (LESS INCHING) 1 W757 GASKET 1
W503 O-RING (LESS INCHING) 1
W504 PLUG (LESS INCHING) 1
W505 SPOOL (LESS INCHING) 1
W506 PLUG (LESS INCHING) 1
W521 SCREW (MECH INCHING) 2
W522 PLATE (MECH INCHING) 1
W523 O-RING (MECH INCHING) 1
W524 PLUG (MECH INCHING) 1
W525 SPOOL (MECH INCHING) 1
W526 WASHER - FLAT (MECH INCHING) 1
W529 PLUG (MECH INCHING) 1
W541 CYLINDER ASSY (HYD INCHING) 1
W542 SCREW (HYD INCHING) 2
W543 PISTON CYLINDER(HYD INCHING) 1
W544 PISTON (HYD INCHING) 1
W545 SEAL - PISTON (HYD INCHING) 1
W546 SEAL RETAINER (HYD INCHING) 1
W547 PLUG (HYD INCHING) 1
W548 BLEED SCREW (HYD INCHING) 1
W550 PIN (HYD INCHING) 1
W551 O-RING (HYD INCHING) 1
40 - 11
CONTENTS
saue
Exploded View of the Fixed Displacement Motor
H68W
H60W L35
H62W (Early Production
075 Frame Size) (L70)
H64W
(L40) L60
H66W L70
H60N L30
L40
(B80)
(H50N)
(G50)
(H50W) (H30W)
L50
(H40W)
(H20W)
G50
G70
H10N (B80)
H50N
H20W
(G63)
B80 H10W
G63 H40W
H30W
(CODE 61 OPTION)
H50W
(G64) G64
(CODE 61 OPTION)
B83 B83 OR
B80
G63
(CODE 61 OPTION)
(G63)
G64
(CODE 61 OPTION) (G64) (B83)
(B83)
saue saue
90M055 NC 0 N 90M055 NC 0 N
8 N 0 C6 W 00 Model 8 N 0 C6 W 00 Model
Code Code
NNN 00 00 24 NNN 00 00 24
Mode Model No. Ident Nr Model Model No. Ident Nr
Serial A 91 26 67890 Serial N 91 26 67890
Number Serial No. Fabr Nr Number Serial No. Fabr Nr
MADE IN U.S.A. MADE IN GERMANY
40 - 13
CONTENTS
saue
Exploded View of the Fixed Displacement Motor (Continued)
D50
C20 L20
L10
C30
L1C6, L1C7
C40 L1F1, L1F2
S07 L10
L1S1, L1S3
C45 L8T1 OR
L8T2
L1T1
C05 L1T2
OR L9T1
C13 L9T2
C14 L8K1
OR L8K2
C15
C16 L8K3
L1K1
C50 L1K2
L1K3
C80 G25
B10
REF
G25
OR
G30
G20
G20 B10
G95
G043
G047
OR
G96 G90
G041
G048
40 - 14
CONTENTS
saue
Exploded View of the Fixed Displacement Motor (Continued)
B10 FIXED HOUSING 1 L10 ROLLER BEARING 1
B80 PLUG 2 L20 RETAINING RING 1
C05 CYLINDER BLOCK ASSY 1 L35 SEAL CARRIER 1
C13 SPRING SEAT 1 L40 LIP SEAL 1
C14 SPRING 1 L50 O RING 1
C15 SPRING RETAINER 1 L70 METRIC SCREW 3
C16 RETAINING RING 1
C20 SEE W GROUP FOR PISTONS L1C6 SHAFT - SPLINED 1
C30 SLIPPER GUIDE 1 L1C7 SHAFT - SPLINED 1
C40 SLIPPER GUIDE RETAINER 1 L1K2 SHAFT - STRAIGHT KEY 1
C45 SLIPPER GUIDE RETAINER SHIM 1 L8 KEY 1
C50 HOLD DOWN TUBE 1 L1S1 SHAFT - SPLINED 1
C80 VALVE PLATE 1 L1T2 SHAFT - TAPERED 1
D50 THRUST PLATE 1 L8 KEY 1
G25 PIN 2 L9 SLOTTED NUT 1
G30 END CAP GASKET 1
G50 PLUG 2 S07 CYLINDER BLOCK KIT W/PISTONS 1
G70 PLUG 1 C20 PISTON 9
G90 SCREW 4
G95 SCREW 2 S30 OVERHAUL REPAIR KIT 1
G96 SCREW 1 G30 END CAP GASKET 1
H40W O RING 2
G047 END CAP - AXIAL PORTS 1 K50 O RING 1
G048 END CAP - TWIN PORTS 1 L40 LIP SEAL 1
G20 JOURNAL BEARING 1 L50 O RING 1
G61 PORT SHIPPING COVER GASKET 2
G62 PORT SHIPPING COVER 2
G63 SPLIT CLAMP 4
G64 SCREW - SHIPPING COVER 4
H10N LOOP FLUSHING SPOOL - DEFEAT 1

H50N PLUG 2
H10W SHUTTLE VALVE SPOOL 1

H20W SPECIAL WASHER 2
H30W SPRING 2
H40W O RING 2
H50W SPECIAL PLUG 2
K000 PLUG 1
K10 PLUG ASSY 1

K50 O RING 1
K610 SHIM A/R
K70 SPRING 1
K80 POPPET 1
40 - 15
CONTENTS
saue
Exploded View of the Variable Displacement Motor 055 and 075
Y100 Y102
Y101
L35
Y40 (Early Production
075 Frame Size) (L70)
Y50
Y60 L70
E15 L60
E35 (Y50) (L40)
E26
L30
B83 L40
(B74)
B80
B83
L50
B76
T100
T101
T30
H68W T40
(B74) T50
H60W T60
(T50)
H62W
M1PT Y80 Y71
H64W B74 Y72
H66W Y70
M1NA, M1NB P700
H60N
M1NC, M1ND P702
(P400)
(B80)
(G50) (P401)
(P402)
(H50N) G50 E25 P601 (P403)
(B74)
P603
(H50W) E35
(H40W) (P400) P600
E15
(P401) P602
(H30W)
H10N (P402)
(H20W)
(P403)
G70 H50N
H10W
H20W
H30W
H40W H50W
(G63)
P800
G63
(G64) (CODE 61 OPTION)
G64
(CODE 61 OPTION)
saue
Ames, Iowa, U.S.A. Neumnster, Germany
Model Code Typ
90S055 NB 2 0
8 N 4 S1 W 01 Model Code
NNN 01 00 24
Model No. Ident Nr
Model Number 94 4002
Serial Number A 91 26 67890
Serial No. Fabr Nr
MADE IN U.S.A.
Place of Manufacture
Name Plate (U.S.A. Production)
40 - 17
CONTENTS
saue
Exploded View of the Variable Displacement Motor 055 and 075 (Continued)
L10 L20
D10
L1NX or
L1SX
L8TX
C20
D50
C30
S07 C50 P202 P35
C40 P203 L9TX
C65 OR
C70 L1TX
P302
P303
(B51)
C05
(B20)
P200 P35
(B30)
P201
C13
D30 C14 B51 OR P300
D20 P301
C15 B20
C16
B30
F45
L80
F15 F25 F65 F49 P102 L90

(B50) P103
C80
B50
OR
G80 P100
G82 P101
G86 (F49)
G84
(F45)
F35
(F25)
(F15) G30
G20
G95
G041
G96 G048
G90
40 - 18
CONTENTS
saue
Exploded View of the Variable Displacement Motor 055 and 075 (Continued)
B20 PIN 2 H10W SHUTTLE VALVE SPOOL 1
B30 CRADLE BEARING 2 H20W SPRING GUIDE 2
B50 PIN 2 H30W SPRING 2
B51 PIN 2 H40W O-RING 2
B74 PLUG 4 H50W SPECIAL PLUG 2
B76 PLUG 1 H60W CHARGE RELIEF VALVE PLUG 1
B80 PLUG 2 H62W O-RING 1
B83 PLUG 1 H64W SPRING 1
B83 SPEED SENSOR 1 H66W CHARGE RELIEF POPPET 1
C05 CYLINDER BLOCK ASSEMBLY 1 H68W LOCK NUT 1
2 SPRING 1
3 RETAINER 1 L1 SHAFT - SPLINED 1
4 RING 1 L2 SHAFT - TAPERED 1
5 SEAT 2 L8 KEY 1
C20 PISTON ASSEMBLY 9 L9 SLOTTED NUT 1
C30 SLIPPER GUIDE 1
C40 SLIPPER GUIDE BEARING 2 L10 RETAINING RING 1
C50 SPACER 4 L20 ROLLER BEARING 1
C65 WASHER 4 L35 SEAL CARRIER 1
C70 SCREW 4 L40 LIP SEAL 1
C80 VALVE PLATE 1 L50 O-RING 1
D10 HOLD DOWN ARM 1
D20 O-RING 1 L70 SCREW 3
D30 HOLD DOWN PIN 1 L80 FRONT COVER GASKET 1
D50 SWASHPLATE 1 L90 O-RING 1
E15 CAP 1
E25 SET SCREW 1 M1 CONTROL VALVE 1
E35 NUT - SEAL LOCK 1
F15 SPECIAL PLUG 2 P35 SCREW 4
F25 O-RING 2 P100 VARIABLE MOTOR HOUSING 1
F35 SPRING 1 P200 FRONT COVER 1
F45 SERVO PISTON ASSEMBLY 2 P300 SCREW 4
F49 PISTON SEAL RING 4 P400 PLUG 2
F65 SPRING 1 P600 PLUG 1
G20 JOURNAL BEARING 1 P601 PRESS COMPENSATOR VALVE 1
G30 END CAP GASKET 1 P700 SPECIAL PLUG 1
G41 END CAP 1 S07 CYLINDER BLOCK KIT W/PISTONS 1

G50 PLUG 2
G61 PORT SHIPPING COVER GASKET 2 T30 FILTER SCREEN 1
G62 PORT SHIPPING COVER 2 T40 O-RING 1
G63 SPLIT FLANGE CLAMP 4 T50 BACK UP RING 2
G64 SHIPPING COVER SCREW 4 T60 O-RING 1
T100 ORIFICE PLUG 1
G70 PLUG 1
G80 SPRING PIN 1 Y40 O-RING 1
G82 BALL 1 Y50 BACK UP RING 2
G84 CRUSH RING 1 Y60 O-RING 1
G86 ORIFICE 1 Y100 ORIFICE PLUG 1
G90 SCREW 4
G95 SCREW 2
G96 SCREW 1
H10N LOOP FLUSHING SPOOL - DEFEAT 1

H50N PLUG 2
H60N PLUG 1
40 - 19
CONTENTS
saue
Major Repair - Variable Pump

General
The procedures on the following pages are for the During the assembly of the Series 90 variable pump,
complete disassembly and reassembly (Major Re- all surfaces which have relative motion between two
pair) of the Series 90 Variable Displacement Pump. parts should be coated with a film of clean hydraulic
oil. This will assure that these surfaces will be
Cleanliness is a primary means of assuring satisfac- lubricated during start-up.
tory hydraulic pump life, on either new or repaired
units. Cleaning parts by using a clean solvent wash It is recommended that all O-rings and gaskets be
and air drying is usually adequate. As with any replaced. Lightly lubricate all O-rings with clean
precision equipment, all parts must be kept free of petroleum jelly prior to assembly. All gasket sealing
foreign materials and chemicals. Protect all exposed surfaces must be cleaned prior to installing new
sealing surfaces and open cavities from damage and gaskets.
foreign material.
Valve Plate Piston Control Piston Manual Displacement Control
Charge Pump
Roller Bearing
Input Shaft
Cylinder Block Cradle Swashplate

90000189
Fig. 61-1 - Cross Section View of Series 90 Variable Displacement Pump
61 - 1
CONTENTS
saue
Major Repair - Variable Pump (Continued)

Disassembly Procedures for Variable
Displacement Pump
Prior to performing Major Repairs on the Series 90

Variable Displacement Pump, remove the external
components as described in the Minor Repair sec-
tion of the Series 90 Service Manual. These include
the following:
Auxiliary Mounting Pad (Where Applicable)

Charge Pump
Control
Filter Options
Charge Relief Valve
Shaft Seal
After removal of these components, place the pump

on a work surface with the shaft up.
Remove the shaft and bearing assembly from the

housing. The bearing outside diameter is a slip fit in
the housing bore.
90000102 90000103
Fig. 61-2 - Pump Fig. 61-3 - Remove NOTE: If the shaft and bearing stick in the housing,
Positioned on End Shaft and Bearing lightly tap the end of the shaft with a soft
Cap mallet to free the bearing.
Remove the retaining ring and press the shaft out of

the bearing.
Place the pump on the work surface with the end cap
up.
NOTE: If the pump was equipped with an auxiliary

mounting pad, temporarily reinstall two (2)
of the large screws which fasten the end
90000192 90000104 cap to the housing. These screws will hold
Fig. 61-4 - Remove Fig. 61-5 - Pump the end cap against internal spring pres-
Bearing from Shaft Positioned on sure while the small screws are removed.
Mounting Flange
Using a 5 mm or 6 mm internal hex wrench or a 10 mm
hex wrench, remove the two (2) or three (3) small
screws which fasten the end cap to the pump hous-
ing.
Using an 8 mm internal hex wrench for 042 pumps, a

19 mm hex wrench for 055 pumps, a 24 mm hex
wrench for 075 and 100 pumps, or a 14 mm internal
hex wrench for 130 pumps, remove the large screws
90000193 90000105
which fasten the end cap to pump housing.
Fig. 61-6 - Remove Fig. 61-7 - Remove
Small End Cap Large End Cap
Screws Screws
61 - 2
CONTENTS
saue

Remove end cap from housing. The alignment pins
and valve plate will normally remain with the housing.
Remove the end cap gasket. Remove the swash-
plate leveler spring shims (if installed) from the spring
pockets in the end cap.
Remove three (3) springs from pump: the two (2) long
swashplate leveler (T-Bar) springs and the short
swashplate hold down spring.
90000107 90000108
NOTE: Certain units are equipped with dual swash- Fig. 61-8 - Remove Fig. 61-9 - Remove
plate leveler springs (an inner spring nested
End Cap Swashplate Springs
inside each of the standard springs).
Remove the alignment pins and valve plate, noting

direction of arrows on valve plate.
Mark the orientation of the side cover to the housing.
90000109 90000110
Fig. 61-10 - Remove Fig. 61-11 - Mark
Valve Plate Side Cover and
Housing
Straighten the locking tabs (used on earlier produc-
tion units) and remove the six (6) side cover screws
(with flat washers on later production units) using a 10
mm hex wrench for 042 pumps, a 13 mm hex wrench
for 055 thru 100 pumps, or a 17 mm hex wrench for
130 pumps.
Remove side cover and swashplate leveler (T-Bar)

assembly from housing.
90000111 90000112
NOTE: Certain units equipped with dual swashplate Fig. 61-12 - Remove Fig. 61-13 - Remove
leveler springs have spacer washers on the
Side Cover Screws Side Cover
leveler spring seats. They may be removed
at this time.
61 - 3
CONTENTS
saue
Remove spring seats from swashplate leveler.
NOTE: Earlier production pumps do not have remov-

able (hardened) spring seats.
90000194 90000195
Leveler Spring Seats Leveler Spring Seats
(Post Type) (Guide Type)
For units with leveler guide posts, remove the two (2)
guide posts and sealing nuts holding the leveler to the
side cover. Use a 17 mm open end wrench and a 10
mm hex wrench on 030 and 042 frame size pumps.
Use a 3/4 in. open end wrench and a 13 mm hex
wrench on 055, 075, and 100 frame size pumps. Use
a 24 mm open end wrench and a 17 mm hex wrench
on 130 frame size pumps. Remove swashplate
leveler from side cover. Remove the side cover O-
90000113 90000196 ring.
Leveler Post Seal Leveler (Post
Nuts (Post Type) Type)
For 130 frame size units with leveler guides, remove
the four (4) screws holding the leveler guides to the
side cover with a 5 mm internal hex wrench. Remove
the leveler guides from the cover. Remove swash-
plate leveler from side cover. Remove the side cover
O-ring.
90000197 90000198
Retaining Screws Leveler (Guide
(Guide Type) Type)
Mark the servo cylinders and housing to identity each
servo cylinder with its respective side of the housing.
Remove the three (3) or four (4) screws retaining

each servo cylinder to the housing, using a 10 mm or
13 mm hex wrench.
90000114 90000115
Fig. 61-20 - Mark Fig. 61-21 - Remove
Servo Cylinders Servo Cylinder
Screws
61 - 4
CONTENTS
saue
For earlier production units, carefully pry each cylin-
der from the housing by using a screwdriver in the
notches in the cylinder. For later production units,
install an 8 mm or 10 mm screw in the threaded hole
in the center of each cylinder, and pull the cylinders
from the housing. The servo piston will remain in the
housing.
NOTE: For later production units with displacement

limiters, remove the limiter screw from each 90000116 90000117
servo cylinder and install an 8 mm or 10 mm Fig. 61-22 - Remove Fig. 61-23 - Remove
screw in its place as a puller screw. Servo Cylinders Cylinder Block
Remove the cylinder block through the housing end
cap opening. The swashplate and piston assembly
will remain in the housing.
Remove the swashplate bearing cage link pin from

the housing through the control opening.
NOTE: A flat head screw is used as the link pin in 042

frame size pumps. It may be removed with a
3 mm internal hex wrench.
90000118 90000119
Remove the bearing cage locater link from the swash- Fig. 61-24 - Remove Fig. 61-25 - Remove
plate through the control opening. Bearing Cage Link Bearing Cage
Pin Locator Link
Remove the swashplate and pistons through the
housing side cover opening. Disengage the servo
arm from the slider block located in the servo piston
as the assembly is removed.
Remove the servo piston and slider block from hous-

ing.
NOTE: Units equipped with an automotive control

have a threaded hole in one end of the servo 90000120 90000121
piston for the centering assist spring assem- Fig. 61-26 - Remove Fig. 61-27 - Remove
bly. For these units, note the orientation of Swashplate and Servo Piston and
the servo piston in the housing. Pistons Slider Block
Remove the swashplate cradle bearing cage.
Remove the bearing races. The bearing races are a

loose fit on two (2) locating pins in the housing.
90000123 90000124
Swashplate Bearing Swashplate Bearing
Cage Races
61 - 5
CONTENTS
saue
Remove the feedback link from the head of the
special screw on the swashplate assembly.
Using a 10 mm or 13 mm hex wrench, remove the four

(4) screws holding the slipper guide hold down mecha-
nism to the swashplate.
90000199 90000125
Feedback Link Hold Down Screws
Disassemble the hold down mechanism and remove
the slipper guide and pistons from the swashplate.
NOTE: Later production pumps use a fixed-clear-

ance hold down mechanism. Earlier produc-
tion 055 thru 100 frame size pumps use a
spring-loaded hold down mechanism.
Remove the piston assemblies from the slipper guide.

90000200 90000126
Pistons and Guide Pistons and Guide
from Swashplate from Swashplate
Reconditioning and Replacement of Parts
(Later Production) (Earlier Production)
After disassembly all parts should be thoroughly
cleaned in a suitable solvent. Replace all O-rings,
gaskets, and the shaft seal.
Inspect all parts for damage, nicks, or unusual wear

patterns. Replace all parts having unusual or exces-
sive wear or discoloration.
If the end cap journal bearing needs replacement (as

90000127 90000129
evidenced by large amounts of the metal back of the
Fig. 61-34 - Remove Fig. 61-35 - Remove bearing being visible through the plastic bearing
Pistons from Slipper Journal Bearing from material), remove the bearing with a suitable puller.
Guide End Cap Do not damage the valve plate surface of the end cap.
Lightly lubricate the steel backing of a new journal

bearing. Press the journal bearing into the end cap
using a suitable press pin.
When installed correctly, the bearing will be flush to

0.020 in (0.50 mm) below the valve plate surface of
the end cap.
90000132 90000133 NOTE: For 042 frame size pumps, the bearing is
Fig. 61-36 - Install Fig. 61-37 - Journal located 0.827 to 0.846 in. (21.00 to 21.50
Journal Bearing in Bearing Installed in mm) from the front surface of the charge
End Cap End Cap pump recess in the end cap.
61 - 6
CONTENTS
saue
If a new journal bearing is installed, the bearing must
be sized with the appropriate arbor to assure the
minimum bore diameter is met. Carefully press the
sizing arbor into the bearing to size it.
CAUTION
The arbors are precision finished to size the

journal bearings without damaging them. Dam-
aged arbors must be replaced. Do not attempt 90000134 90000201
to use the drive shaft in place of an arbor. Fig. 61-38 - Sizing Fig. 61-39 - Servo
Inadequate clearance between the shaft and Journal Bearing Relief Valves and
bearing will result in inadequate lubrication Rotation Plugs in
and shortened bearing life.
End Cap (Typical)
NOTE: The charge pump shaft bushing in the end
cap may be replaced in a similar manner to
the drive shaft journal bearing.
Certain frame size pumps with twin port end caps

may have the servo relief valves and rotation plugs
located in a removable rotation block. Remove the 7 6
rotation block screws with a 5 mm internal hex wrench
and remove the block and gasket.
5 34
For pumps with pressure limiter function (except units 1
with automotive control), remove the servo relief
valves from the end cap or rotation block with a screw
driver. 2
For pumps with pressure limiter defeat and/or auto-
motive control, remove the servo relief passage plug(s)
from the end cap or rotation block with a 3/16 in.
internal hex wrench. Fig. 61-40 - 030 Pump Twin Port End Cap
Note the position of the rotation pipe plugs and

remove them from the end cap or rotation block with
a 1/8 in. internal hex wrench.
Install the servo relief valves or relief valve passage

plugs into the end cap or rotation block as shown in 6
the accompanying illustrations and chart. 3 2
NOTE: Pumps with pressure limiter function (except 1
those units with automotive control) MUST 5 4
have servo relief valves installed in the end 7
cap or rotation block to limit servo pressures.
Install the rotation pipe plugs into the end cap or

rotation block as shown in the accompanying illustra-
tions and chart.
Fig. 61-41 - 042 Pump Twin Port End Cap
61 - 7
CONTENTS
saue
6 6
2 5 4 2
4 1 1
7 7
5
3 3
Fig. 61-42 - 055 Pump Side Port End Cap Fig. 61-43 - 055 Pump Twin Port End Cap
6
4 2
1
5 1
7 3
2
5 4 3
6 7
Rotation Block
6 2 6 2
4 7 1 5 7
3 3
5 1
4
61 - 8
CONTENTS
saue
7
4
5 3
6 1 2
Fig. 61-48 - 130 Pump Twin Port End Cap
Servo Relief Valves

(O-Ring Plugs for
Pressure Limiter Pump Pipe Plugs Automotive Control) O-Ring Plugs
Port A Port B Rotation in Holes in Hole in Holes Open Holes
YES YES R (CW) 1, 3 6, 7 None 2, 4, 5
YES YES L (CCW) 2, 4 6, 7 None 1, 3, 5
NO NO EITHER 1, 2, 5 None 6 3, 4, 7
WARNING
Uncontrollable movement of the vehicle / ma-
chine and its attachments can result from in-
stalling the pressure limiter logic plugs in the
incorrect ports for the pump rotation. Correct
pressure limiter function MUST be verified.
This can be accomplished by testing the pump
before it is installed, or by defining and per-
forming a test in the vehicle / machine before it
is released from repair.
Torque the servo relief valves or relief valve passage

plugs to 9 ft.lbsf. (12 Nm). Torque the rotation pipe
plugs to 4 ft.lbsf. (5.4 Nm).
When reinstalling the rotation block and gasket, torque
the screws to 12 ft.lbsf. (16 Nm).
61 - 9
CONTENTS
saue
The threaded holes in the swashplate (for the hold
down screws) must be cleaned of old locking com-
pound prior to reassembly. A 6 mm (030 thru 100
pumps) or 8 mm (130 pumps) thread tap may be used
for this purpose.
Inspect the swashplate guide for wear. The guide

may be removed by removing the special locking
screw with a 5 mm (030, 042), 6 mm (055, 075, 100),
or 8 mm (130) internal hex wrench.
90000128
Servo arm alignment is critical to proper pump opera-
Fig. 61-49 - Clean Threaded Holes in tion. For this reason, removal of the servo arm from
Swashplate the swashplate is not recommended.
If the servo arm must be removed from the swash-

plate, remove the locking screw with a 13 mm (030,
042, 055, 075) or 17 mm (100, 130) hex wrench.
Keystone design servo arms must be parallel (within

0.010 in [0.25 mm] total) to the wide surface of the slot
in the swashplate when installed. Press fit design
servo arms must be carefully aligned with the slot and
threaded holes in the swashplate while installing, and
must be pressed completely into the swashplate slot.
NOTE: Keystone design servo arms and

swashplates are no longer available for serv-
icing 055, 075, and 100 frame size pumps. A
swashplate / servo arm kit is available to
service these units. Refer to the appropriate
Service Parts Manual for more information.
Torque the servo arm to swashplate locking screw to

24 ft.lbsf. (32 Nm) for 030, 042, 055, and 075 pumps,
31 ft.lbsf. (42 Nm) for 100 pumps, or 47 ft.lbsf. (64
Nm) for 130 pumps.
Assemble the swashplate guide to the swashplate

with the special locking screw. Torque the screw to
10 ft.lbsf. (13.5 Nm) for 030 and 042 pumps, 24 ft.lbsf.
(32 Nm) for 055, 075, and 100 pumps, or 40 ft.lbsf. (54
Nm) for 130 pumps.
NOTE: Later production 100 pumps use the same

size swashplate guide as 075 pumps. When
installing the guide onto the 100 swashplate,
be certain the straight sides of the guide are
perpendicular to the slipper surface of the
swashplate while tightening the screw.
90000202
Fig. 61-50 - Torque Swashplate Guide
Screw
61 - 10
CONTENTS
saue
If the the headed roll pin and flat washer for the
bearing cage locator link must be installed on the
swashplate, the distance between the washer and Swashplate Headed
the side of the swashplate must be as indicated Pin
below:
Flat
Pump Distance H Washer
Frame Size +0.003, -0.010 in. (+0.01, -0.25 mm) "H"
030 .100 (2.50) [washer not used]
90000203
Pump Distance H
Fig. 61-51 - Roll Pin Fig. 61-52 - Roll Pin
Frame Size 0.010 in. (0.25 mm)
and Washer Installed and Washer
042 .140 (3.60)
Dimension
055 .21 (5.33)
075 .240 (9.45)
100 .170 (4.32)
130 .220 (5.59)
180
250
Inspect the servo piston and seal rings for wear. If

worn, remove the seal rings and expander O-rings
from the piston.
Install new expander O-rings into the seal grooves in

the servo piston.
Carefully install the piston seal rings in the piston

grooves, over the expander O-rings. Do not stretch
90000204 90000141
the seal rings any more than necessary when install-
Fig. 61-53 - Install Fig. 61-54 - Install
ing.
Servo Piston Seal Servo Piston Seal
Lubricate the seal rings and carefully slide the servo Expander Ring Ring
piston into the servo cylinders. Allow the assembly to
set for at least 5 minutes to allow the seal rings to
return to their original unstretched size. Then re-
move the servo cylinders.
Compress the cylinder block spring and remove the

spiral retaining ring, retainer, spring, and spring seat.
Reassemble in the reverse order.
Fig. 61-55 - Cylinder Block Spring

Components
61 - 11
CONTENTS
saue
Assembly Procedures for Variable
Displacement Pump
Clean and lightly oil all parts prior to assembly of the
pump. Be sure to torque all threaded parts to recom-
mended torque levels.
CAUTION
Most parts have critical, high tolerance sur-

faces. Caution must be exercised to prevent
damage to these surfaces during assembly.
Protect exposed surfaces, openings, and ports
from damage and foreign material.
Assemble the piston assemblies into the slipper guide.
Lubricate the slipper running surfaces. Center the

pistons and guide on the swashplate.
NOTE: Later production pumps use a fixed-clear-

ance hold down mechanism. Earlier produc-
tion 055, 075, and 100 frame size pumps use
a spring-loaded hold down mechanism. Ser-
90000127 90000135 vice parts for the spring-loaded hold down
Fig. 61-56 - Install Fig. 61-57 - Position mechanism are no longer available. If hold
Piston Assemblies Pistons and Guide down parts require replacement on these
into Slipper Guide on Swashplate earlier production units, the fixed-clearance
hold down mechanism must be installed.
Refer to the appropriate Service Parts Man-
ual for more information.
Assemble one-half of the fixed-clearance hold down

mechanism as follows:
Position two (2) spacers over the threaded holes in

the swashplate as shown.
Position the slipper guide bearing on top of the

spacers and slipper guide.
CAUTION
The split between the slipper guide bearing

90000205 90000206 plates must be located in line with the swash-
Fig. 61-58 - Position Fig. 61-59 - Position plate arm. The bearing surface of the bearing
Spacers Guide Bearing plates must be located next to the guide.
61 - 12
CONTENTS
saue
Install two (2) new screws (with locking compound)
and flat washers through the slipper guide bearing,
and spacers. Finger tighten the screws into the
swashplate.
NOTE: Inspect the flat washers for raised edges or

burrs. The smooth side of the flat washers
must be installed next to the slipper guide
bearing.
90000136 90000137
CAUTION
Fig. 61-60 - Install Fig. 61-61 - Fixed-
Always use new screws with proper locking Screws and Flat Clearance Hold
compound. Washers Down Assembled
Assemble the other half of the fixed-clearance hold
down mechanism in a similar manner.
Assemble one-half of the spring-loaded hold down

mechanism as follows:
Lubricate the slipper guide bearing and position it on

top of the slipper guide.
CAUTION 90000207 90000208

Fig. 61-62 - Position Fig. 61-63 - Position
The split between the slipper guide bearing
Slipper Guide Spacers
plates must be located in line with the swash-
plate arm. The bearing surface of the bearing Bearing
plates must be located next to the slipper
guide.
Position two (2) spacers in the holes of the guide

bearing and over the threaded holes in the swash-
plate as shown.
Position two (2) flat washers on top of the spacers.
Position two (2) leaf springs on top of the washers.

90000209 90000210
Position two (2) spring aligners on top of the leaf Fig. 61-64 - Position Fig. 61-65 - Position
springs. Flat Washers Leaf Springs and
Spring Aligners
Install two (2) new screws (with locking compound)
through the spring aligners, leaf springs, flat washers,
and spacers. Finger tighten the screws into the
swashplate.
CAUTION
Always use new screws with proper locking

compound.
Assemble the other half of the spring-loaded hold

90000211 90000212
down mechanism in a similar manner. Fig. 61-66 - Install Fig. 61-67 - Spring-
Screws Loaded Hold Down
Assembled
61 - 13
CONTENTS
saue
Torque the hold down screws to 10 ft.lbsf. (13.5 Nm)
for 030 thru 100 frame size pumps, or 24 ft.lbsf. (32.5
Nm) for 130 pumps.. The slipper guide and piston
slippers must be able to slide freely on the swash-
plate.
Lubricate the pistons and cylinder block bores. Install

the assembled swashplate and pistons into the cylin-
der block by inserting the pistons into the cylinder
90000138 90000139 block bores. The pistons and bores are not selec-
Fig. 61-68 - Torque Fig. 61-69 - Install tively fitted, therefore no specific piston and bore
Hold Down Screws Pistons into Cylinder orientation is required.
Block
Check that the swashplate bearing race locating pins
are secure in the housing.
Install the swashplate bearing races into the housing,

positioning the races on the locating pins. Retain the
races in position with petroleum jelly. The locating
pins are offset in the housing to assure proper assem-
bly.
90000140 90000124
Fig. 61-70 - Bearing Fig. 61-71 - Install
Race Locator Pins in Swashplate Bearing
Housing Races
Assemble and lubricate the bearing cage, and install
it on the bearing races.
Install the bronze slider block on the swashplate

servo arm.
Install the feedback link on the head of the special

screw on the swashplate assembly.
90000213 90000143
WARNING
Fig. 61-72 - Bearing Fig. 61-73 - Install
To avoid the possibility of the pump sticking in
Cage Installed Slider Block
stroke, the feedback link must NOT be installed
in pumps equipped with non-feedback con-
trols (such as the cover plate, 3-position sole-
noid, and automotive control).
Position the servo piston in the housing.
NOTE: For units equipped with an automotive con-

trol, the machined end of the servo piston
(with the threaded hole) must be located on
the side of the housing where the centering
90000144 90000142 assist spring sleeve will be installed.
Fig. 61-74 - Install Fig. 61-75 - Position
Feed Back Link Servo Piston
61 - 14
CONTENTS
saue
Carefully lower the cylinder block and swashplate
assembly into the housing through the end cap open-
ing.
NOTE: A tool to aid in holding and installing the

assembled cylinder block and swashplate
may be made from a positive lock, quick
release pin and a large flat washer (1 inch
inside diameter with clearance flats ground
on the outside diameter). Insert the pin thru 90000214 90000146
the cylinder block and swashplate, and lock in Fig. 61-76 - Install Fig. 61-77 - Install
place with the flat washer under the swash- Cylinder Block and Cylinder Block and
plate. Swashplate Swashplate
Hold the cylinder block and swashplate assembly
approximately 1/2" (12 mm) above the cradle bear-
ings.
Properly position the feedback link in the control

opening.
Position the servo piston on the slider block, taking

care not to wedge the block. The parts should slide
freely.
90000151 90000148
Fig. 61-78 - Position Fig. 61-79 - Position
Feedback Link Servo Piston and
Slider Block
Lower the cylinder block and swashplate assembly

until the swashplate is properly located on the cradle
bearings.
NOTE: If an assembly tool was used to install the

cylinder block and swashplate, release and
remove the pin. The flat washer should fall
through the shaft opening of the housing.
Hold the servo piston in position and install the servo 90000216 90000149
cylinders. Fig. 61-80 - Lower Fig. 61-81 - Install
Swashplate onto Servo Cylinders
NOTE: Be sure to assemble the correct servo cylin-
Bearings
der on each side of the housing. For units
equipped with an automotive control, a spe-
cial servo cylinder is installed on the center-
ing assist spring side of the housing.
61 - 15
CONTENTS
saue
Install the three (3) or four (4) screws in each servo
cylinder. Torque to 10 ft.lbsf. (13.5 Nm) for 030 thru
055 pumps, 18 ft.lbsf. (24 Nm) for 075 pumps, and 24
ft.lbsf. (32 Nm) for 100 and 130 pumps.
NOTE: For units equipped with an automotive con-

trol, the servo cylinder screws on the center-
ing assist spring side of the housing will be
installed later.
90000150 90000152
Fig. 61-82 - Torque Fig. 61-83 - Install Align the slot in the swashplate bearing cage with the
Cylinder Screws Cage Locator Link headed spring pin in the swashplate and the pin hole
in the housing. Hook the cage locator link over the
spring pin, between the washer and the swashplate.
Rotate the link into the slot in the bearing cage.
NOTE: A washer is not installed on the spring pin in

030 frame size pumps.
Pump Cage Align the hole in the locator link with the hole in the
Housing Locator housing and install the link anchor pin thru the link and
Link into the housing.
Screw
A flat head screw is used as the link pin in 042 frame
size pumps. Install a new screw (with locking com-
"H" pound) through the locator link and into the housing.
Tighten the screw into the housing until the head of
the screw is positioned at a height (distance "H") of
90000217 0.178 to 0.188 in. (4.53 to 4.79 mm) from the ma-
Fig. 61-84 - Install Fig. 61-85 - Install chined surface of the pump housing.
Locator Link Pin Locator Link Screw
(042 Pumps) CAUTION
Always use a new screw with proper locking

compound. Do NOT torque this screw against
the locator link. The link MUST rotate freely.
Push the swashplate assembly toward the control

side of the housing until the swashplate guide con-
tacts the bearing race. Check for clearance between
the servo arm and the slider block. If no clearance is
present, recheck the assembly of the bearing cage
and races.
Position the swashplate leveler (T-Bar) on the side

cover. Note the orientation of the leveler and the
90000153 90000196 cover.
Fig. 61-86 - Check Fig. 61-87 - Install
for Servo Arm to Leveler on Side
Slider Block Cover
Clearance
61 - 16
CONTENTS
saue
For units with leveler guide posts, install the two (2)
guide posts and sealing nuts. Torque to 6.7 lbsfft (9.0
Nm) for 030 and 042 pumps, 17 lbsfft (23 Nm) for 055
thru 100 pumps, or 32 lbsfft (54 Nm) for 130 pumps.
For 130 frame size units with leveler guides, install

the guides onto the side cover. Install the four (4)
locking screws holding the guides to the side cover.
Torque to 6.7 lbsfft (9.0 Nm).
90000154 90000219
NOTE: If the screw holes in the side cover are thru Fig. 61-88 - Install Fig. 61-89 - Install
holes, the threads of the screws must be Leveler Posts and Leveler Guides and
coated with sealing compound. Nuts (Post Type) Screws (Guide
Type)
Install the leveler spring seats.
NOTE: Earlier production pumps do not have remov-

able (hardened) swashplate leveler spring
seats.
Install the inner spring spacer washers (if used).

Install a new side cover O-ring.
Hold the swashplate leveler toward the end cap end 90000220 90000155
of the housing so the leveler will clear the side of the Fig. 61-90 - Leveler Fig. 61-91 - Install
swashplate during side cover installation. Install the Spring Seats Side Cover on
side cover and swashplate leveler.
Installed Housing
Install two (2) side cover screws (with flat washers)

finger tight into the blind holes in the housing, to hold
the cover while checking the zero angle position of
the swashplate.
90000221 90000156
Fig. 61-92 - Leveler Fig. 61-93 - Install
Positioned on Two (2) Side Cover
Swashplate Screws
61 - 17
CONTENTS
saue
If all the parts which affect the zero angle setting are
being reused, rotate the side cover to align the marks
on the cover and housing that were made at disas-
sembly.
Apply a force of 5 to 10 lbsf. (22 to 44 N) to the

swashplate leveler to ensure both arms are in contact
with the swashplate. Make sure the swashplate is
properly located on its bearings. Use a depth mi-
90000158 90000159
crometer to measure the distance from the end cap
Fig. 61-94 - Measure Fig. 61-95 - Rotate face of the housing to the outer edge of the swash-
Swashplate Position Side Cover to plate surface. Take a second measurement at a point
180 from the first point of measurement (at the
Establish Zero
opposite edge of swashplate surface). These mea-
Angle surements must not vary by more than .001 in (.025
mm).
Rotate the side cover (which will also rotate the

leveler and swashplate) until the zero angle position
is established, as determined by the depth measure-
ment.
After the zero angle position has been established,

tighten the two (2) screws to hold the side cover.
Install the remaining four (4) screws with flat washers.
NOTE: The threads of the two (2) side cover screws

installed in thru holes in the housing must be
coated with a sealing compound to prevent
leaks. New screws have sealant pre-applied.
First, torque the four (4) side cover screws installed in

blind holes to 10 ft.lbsf. (13.5 Nm) for 030 and 042
pumps, 24 ft.lbsf. (32.5 Nm) for 055 thru 100 pumps,
and 47 ft.lbsf. (64 Nm) for 130 pumps.
Then, torque the two (2) side cover screws installed

in thru holes to 7.7 ft.lbsf. (10.4 Nm) for 030 and 042
pumps, 18.5 ft.lbsf. (25 Nm) for 055 thru 100 pumps,
and 37 ft.lbsf. (50 Nm) for 130 pumps.
90000160 90000109
Install the end cap alignment pins into the housing.
Fig. 61-96 - Torque Fig. 61-97 - Install
Lubricate the running surface of the cylinder block
Side Cover Screws Alignment Pins and and Install the valve plate on the alignment pins.
Valve Plate
NOTE: Note the direction of the arrow cut-outs in the
valve plate. The arrows must point in the
direction of pump rotation. For example, a
right hand (clockwise) rotation pump must
have the arrows pointing in the clockwise
direction (when viewed from the shaft end).
(The photo on this page shows a valve plate
installed for clockwise [CW] rotation.)
61 - 18
CONTENTS
saue
Install the two (2) long springs (with inner springs, if
used) on the swashplate leveler spring seats. Install
the short spring on the servo arm link. Place new end
cap gasket on the housing (located by the alignment
pins). Take care not to bend or damage the end cap
gasket during installation.
Lubricate the end cap journal bearing. Install the

hardened shims in the end cap pockets for the
swashplate leveler springs. Retain the shims with 90000222 90000223
petroleum jelly. Fig. 61-98 - Install Fig. 61-99 - Install
Springs and End Leveler Spring
Cap Gasket Shims
Lower end cap onto housing while positioning the
three (3) springs in their pockets in the end cap.
When properly installed, the end cap will engage the

alignment pins, but the springs will hold the end cap
1/8 to 1/4 in. (3 to 8 mm) away from the housing.
Install the four (4) large end cap screws. 90000162 90000106
Fig. 61-100 - Install Fig. 61-101 - End
NOTE: If the pump will be equipped with an auxiliary End Cap Cap Installed
mounting pad, temporarily install two (2) of
the large screws which fasten the end cap to
the housing. These screws will hold the end
cap against internal spring pressure while the
small screws are installed.
Tighten the large end cap screws evenly to the torque

indicated in the accompanying table.
Frame Torque
Size lbsfft Nm
030 43 58
042 55 75
055 90 122
075 189 256
90000163 90000224
100 200 271
130 220 298
Large End Cap Small End Cap
180
Screws Screws
250
Install the two (2) or three (3) smaller screws holding

the end cap to the housing. Torque the 6 mm screws
to 10 ft.lbsf (13.5 Nm), and the 8 mm screws to 28
ft.lbsf (38 Nm).
NOTE: A lifting bracket is installed on one (1) of the

smaller end cap screws.
61 - 19
CONTENTS
saue
Position the pump on its end cap.
Using caution to prevent damage to the sealing
surface, press the roller bearing onto the drive shaft.
(For units with a 3-piece bearing, press the inner race
onto the shaft, then install the outer race/cage assem-
bly and the special washer.) Install the bearing retain-
ing ring onto the shaft.
Install the shaft and bearing assembly through front of
housing, aligning the shaft spline with the cylinder
90000192 90000103
block spline. Continue to lower the shaft into the unit
Fig. 61-104 - Shaft Fig. 64-105 - Install
and carefully align the end of the shaft with the end
Bearing Installed Shaft Assembly cap journal bearing. Then lower the shaft and bearing
assembly into position.
Rotate the shaft by hand. The rotating assembly
should turn freely. If it does not rotate freely, the pump
must be disassembled and the problem corrected.
Assemble and adjust the following components as
described in the Minor Repair section of the Series
90 Service Manual:
Charge Pump
Auxiliary Mounting Pad (Where Applicable)
Shaft Seal
Control
Filter Option
Charge Relief Valve
Displacement Limiter(s)
Rotate the pump shaft with a torque wrench to assure
correct assembly. When properly assembled, the
torque required to turn the shaft (after break-away)
should be within the ranges shown in the accompany-
ing table.
Torque to Turn Shaft (Variable Pump at 0)
ft.lbsf. (Nm)
Frame Size Minimum Maximum
030 2 (2.7) 7.5 (10.2)
042
055 4 (5.4) 9 (12.2)
075 5 (6.71) 10 (13.6)
100 7.5 (10) 13 (17.6)
130 9 (12.2) 15.5 (21)
180
250
WARNING
Always test the pump prior to putting it into
service to verify correct pressure limiter and
control function. Improper function of these
systems can result in uncontrollable move-
ment of the vehicle / machine.
61 - 20
CONTENTS
saue
Major Repair - Fixed Motor
General
The procedures on the following pages are for the During the assembly of the Series 90 fixed motor, all
complete disassembly and reassembly (Major Re- surfaces which have relative motion between two
pair) of the Series 90 Fixed Displacement Motor. parts should be coated with a film of clean hydraulic
oil. This will assure that these surfaces will be lubri-
Cleanliness is a primary means of assuring satisfac- cated during start-up.
tory hydraulic motor life, on either new or repaired
units. Cleaning parts by using a clean solvent wash It is recommended that all O-rings and gaskets be
and air drying is usually adequate. As with any replaced. Lightly lubricate all O-rings with clean pe-
precision equipment, all parts must be kept free of troleum jelly prior to assembly. All gasket sealing
foreign materials and chemicals. Protect all exposed surfaces must be cleaned prior to installing new
sealing surfaces and open cavities from damage and gaskets.
foreign material.
Valve Plate Piston

Roller Bearing
Output Shaft
Loop Flushing Valve
Fixed Swashplate
Cylinder Block
90000190
Fig. 62-1 - Cross Section View of Series 90 Fixed Displacement Motor
62 - 1
CONTENTS
saue
Major Repair - Fixed Motor (Continued)
Disassembly Procedures for Fixed
Displacement Motor
Prior to performing Major Repairs on the Series 90
Fixed Displacement Motor, remove the external com-
ponents as described in the Minor Repair section of
the Series 90 Service Manual. These include the
following:
Charge Relief Valve
Loop Flushing Valve
Shaft Seal
After removal of the components defined in Minor

Repair, place motor on the end cap.
Remove the shaft and bearing assembly from the

housing. The bearing outside diameter is a slip fit in
the housing bore.
90000187 90000164
Fig. 62-2 - Motor Fig. 62-3 - Remove
Positioned on End Shaft and Bearing
Cap
Remove the retaining ring and press the shaft out of
the bearing.
Place the motor on the work surface with the end cap
up. Using a 19 mm and a 13 mm hex wrench for 055
motors, a 19 mm and a 17 mm hex wrench for 075
motors, or a 24 mm and a 17 mm hex wrench for 100
and 130 motors, loosen the screws which retain the
end cap to the housing. Remove the five (5) longer
90000225 90000165 screws.
Bearing from Shaft Longer End Cap
Screws
Place the motor on its end cap. Remove the two (2)
shorter screws holding the end cap to housing.
Lift the housing off of the end cap.
NOTE: The dowel pins and gasket should remain

with the end cap. The thrust plate should
remain in the housing. The piston assem-
blies should remain with the other internal
90000185 90000184 parts on the end cap, but may stick to the
Fig. 62-6 - Remove Fig. 62-7 - Remove thrust plate.
Shorter End Cap Housing
Screws
62 - 2
CONTENTS
saue
Place the housing on the end cap face with soft
material between end of housing and work table so
the thrust plate will not be damaged when it is freed
from housing.
Entering thru the shaft end of the housing, using a

brass rod, carefully apply a force to the I.D. of the
thrust plate and disengage from the housing.
90000167 90000168
Fig. 62-8 - Remove Fig. 62-9 - Thrust
Thrust Plate from Plate Removed
Housing
Remove the end cap gasket from the end cap.
Remove the hold down tube with the slipper guide

and piston assemblies from the end cap and cylinder
block.
90000182 90000169
End Cap Gasket Tube with Slipper
Guide and Pistons
Remove the slipper guide and piston assemblies
from the hold down tube.
Remove the slipper guide bearing.
90000226 90000227
Slipper Guide and Slipper Guide
Pistons Bearing
Remove the slipper guide bearing shim (if used).
Remove the cylinder block from the end cap.
90000179 90000228
Slipper Guide Cylinder Block
Bearing Shim
62 - 3
CONTENTS
saue
Remove the valve plate and alignment pins from the
end cap
Remove the piston assemblies from the slipper guide.
90000174 90000127
Valve Plate Pistons from Slipper
Guide
Reconditioning and Replacement of Parts
After disassembly all parts should be thoroughly
cleaned in a suitable solvent. Replace the shaft seal
and all gaskets.
Inspect all parts for damage, nicks, or unusual wear

patterns. Replace all parts having unusual or exces-
sive wear or discoloration.
90000170 90000171
Fig. 62-18 - Remove Fig. 62-19 - Install If the end cap journal bearing needs replacement (as
evidenced by large amounts of the metal back of the
Journal Bearing Journal Bearing in
bearing being visible through the plastic bearing
from End Cap End Cap material), remove the bearing with a suitable puller.
Split line in bearing
MUST be located within Do not damage the valve plate surface of the end cap.
noted arcs, but NOT in
line with drain groove in
bearing bore. Lightly lubricate the steel backing of a new journal
bearing. Press the journal bearing into the end cap
using a suitable press pin. The split line in the bearing
must be located as shown in the accompanying
illustrations, but NOT in line with the drain groove in
the end cap bearing bore.
Drain Groove
Fig. 62-20 - Orientation of Split Line in
Journal Bearing (Earlier Production)
Split line in bearing
MUST be located within
noted arc, opposite
the drain groove in
bearing bore.
Drain Groove
Fig. 62-21 - Orientation of Split Line in

Journal Bearing (Later Production)
62 - 4
CONTENTS
saue
When installed correctly, the bearing will be flush to
0.020 in (0.50 mm) below the valve plate surface of
the end cap.
If a new journal bearing was installed, the bearing

must be sized with the appropriate arbor to assure the
minimum bore diameter is met. Carefully press the
sizing arbor into the bearing to size it.
CAUTION 90000133 90000173

Fig. 62-22 - Journal Fig. 62-23 - Sizing
The arbors are precision finished to size the Bearing Installed in Journal Bearing
journal bearings without damaging them. Dam- End Cap
aged arbors must be replaced. Do not attempt
to use the drive shaft in place of an arbor.
Bearing damage and shortened life will result
from inadequate lubrication clearance.
Compress the cylinder block spring and remove the

spiral retaining ring, retainer, spring, and spring seat.
Reassemble in the reverse order.
Fig. 62-24 - Cylinder Block Spring

Components
62 - 5
CONTENTS
saue
Assembly Procedures for Fixed
Displacement Motor
Clean and lightly oil parts prior to assembly of the
motor. Be sure to torque all threaded parts to recom-
mended torque levels.
CAUTION
Most parts have critical, high tolerance sur-

faces. Caution must be exercised to prevent
damage to these surfaces during assembly.
Protect exposed surfaces, openings, and ports
from damage and foreign material.
Place the end cap on the work surface with the valve
plate surface up. Install the alignment pins in the end
cap.
NOTE: The size of the alignment pins has changed

on certain frame size motors. Refer to the
appropriate Service Parts Manual for more
information.
90000166 90000174
Fig. 62-25 - Install Fig. 62-26 - Install Install the valve plate on the end cap with the locating
Alignment Pins Valve Plate notches positioned over the alignment pins.
NOTE: This is a bi-directional valve plate, with no

directional arrow cut-outs. It can be as-
sembled with either side adjacent to the end
cap.
Lubricate the end cap journal bearing and the cylinder

block and valve plate running surfaces. Position the
cylinder block assembly on the valve plate.
90000175 90000176
Place the hold down tube over the cylinder block with
Fig. 62-27 - Position Fig. 62-28 - Install the fluted end adjacent to the end cap.
Cylinder Block Hold Down Tube
NOTE: If a new housing is to be installed, a new tube
must also be used.
Position the straight fingers on the hold down tube

over the valve plate locating tabs and in the clearance
holes in the end cap. The long side of the tube must
be positioned on the same side as the end cap gauge
ports.
90000177 90000178
Fig. 62-29 - Hold Fig. 62-30 - Position
Down Tube Fingers of Long Side of Hold
Down Tube
62 - 6
CONTENTS
saue
Place the slipper guide retainer shim on the hold
down tube. The tab with the V notch must be
positioned in the tube cutout which is located 45
counter-clockwise from the longest side of the tube
assembly.
Assemble the bronze slipper guide bearing on top of

the slipper guide retainer shim, positioning the tab
with the V notch in the same position as noted
above. 90000229 90000230
NOTE: Certain frame sizes utilize a one-piece slip- Slipper Guide Slipper Guide
per guide retainer shim and bearing. The Bearing Shim Bearing
one-piece shim and bearing is installed with
the tab with the V notch positioned as noted
above, and with its bronze side facing up
(toward the slipper guide).
Assemble the piston assemblies into the slipper guide.
Lubricate the pistons and cylinder block bores. Install

the assembled slipper guide and pistons into the
cylinder block by inserting the pistons into the cylinder
block bores. The pistons and bores are not selec-
tively fitted, therefore no specific piston and bore
orientation is required.
90000127 90000181
Pistons in Slipper Slipper Guide and
Guide Pistons
Place a new gasket on the end cap. The beaded side

of the gasket must be positioned away from the end
cap.
Lubricate the slipper running surfaces, then place the

thrust plate on the slipper faces. The side of the thrust
plate with the chamfered edge must be positioned
away from the slipper faces. The slots in the thrust
plate must be positioned over the tabs on the hold
down tube. 90000182 90000231
Fig. 62-35 - Install Fig. 62-36 - Thrust
End Cap Gasket Plate Installed
62 - 7
CONTENTS
saue
Place the housing over the assembled internal parts,
with the deep end of the cavity in the housing mated
to the long side of the hold down tube. The housing
will engage the alignment pins in the end cap. When
the housing is properly installed, the hold down tube
will hold the housing away from the end cap approxi-
mately 0.030 in. (.75 mm).
90000184 90000232
Fig. 62-37 - Install Fig. 62-38 - Housing
Housing Installed
Install and hand tighten the two (2) short end cap
screws to hold the end cap to the housing.
Place the motor on the work surface with the end cap
up, and install the remaining end cap screws. Tighten
the end cap screws evenly to the torque indicated in
the accompanying table.
Torque
90000185 90000186 Frame Large Screws Small Screws
Fig. 62-39 - Install Fig. 62-40 - Torque Size lbsfft Nm lbsfft Nm
Shorter End Cap End Cap Screws 030
Screws 042
055 90 122 30 41
075 70 95 38 52
100 150 203 38 52
130 150 203 38 52
Position the motor on its end cap.
Using caution to prevent damage to the sealing

surface, press the roller bearing onto the drive shaft.
(For units with a 3-piece bearing, press the inner race
onto the shaft, then install the outer race/cage assem-
bly and the special washer.) Install the bearing retain-
ing ring onto the shaft.
Install the shaft and bearing assembly through front of

housing, aligning the shaft spline with the cylinder
90000225 90000233
block spline. Continue to lower the shaft into the unit
Fig. 62-41 - Bearing Fig. 62-42 - Install and carefully align the end of the shaft with the end
Installed on Shaft Shaft Assembly cap journal bearing. Then lower the shaft and bearing
assembly into position.
Rotate the shaft by hand. The rotating assembly

should turn freely. If it does not rotate freely, the
motor must be disassembled and the problem cor-
rected.
62 - 8
CONTENTS
saue
Install the shaft seal as described in the Minor
Repair section of the Series 90 Service Manual.
Rotate the motor shaft with a torque wrench to assure

correct assembly. When properly assembled, the
torque required to turn the shaft (after break-away)
should be within the ranges shown in the accompany-
ing table.
Torque to Turn Shaft (Fixed Motor at 17)

lbsfft (Nm)
Frame Size Minimum Maximum
030
042
055 5 (6.8) 10 (13.6)
075 5.5 (7.5) 11 (14.9)
100 8.5 (11.5) 14 (19)
130 10.5 (14.2) 17 (23)
Assemble the following components as described in

the Minor Repair section:
Charge Pressure Relief Valve
Loop Flushing Valve
62 - 9
CONTENTS
saue
Major Repair - Variable Motor
General
The procedures for the complete disassembly and During the assembly of the Series 90 variable motor,
reassembly (Major Repair) of the Series 90 Variable all surfaces which have relative motion between two
Displacement Motor will appear in a future revision of parts should be coated with a film of clean hydraulic
this publication. oil. This will assure that these surfaces will be lubri-
cated during start-up.
Cleanliness is a primary means of assuring satisfac-
tory hydraulic motor life, on either new or repaired It is recommended that all O-rings and gaskets be
units. Cleaning parts by using a clean solvent wash replaced. Lightly lubricate all O-rings with clean pe-
and air drying is usually adequate. As with any troleum jelly prior to assembly. All gasket sealing
precision equipment, all parts must be kept free of surfaces must be cleaned prior to installing new
foreign materials and chemicals. Protect all exposed gaskets.
sealing surfaces and open cavities from damage and
foreign material.
Minimum Angle
Control Piston
Cradle Swashplate
Piston
Valve Plate
Roller Bearing
Output Shaft
"A" "A"
Cradle Swashplate Maximum Angle

Control Piston
Cylinder Block
Electric 2-Position Control (Option) Partial Section "A-A"
(4-Way, 2 Position Valve) Cradle Swashplate in full displacement position
90000234
Fig. 63-1 - Cross Section View of Series 90 Variable Displacement Motor
63 - 1
CONTENTS
saue
Hydraulic Power Systems
SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide
SAUER-SUNDSTRAND is a world leader in the design and SAUER-SUNDSTRAND specializes in integrating a full
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development resources in both North America and Europe with the most advanced total-design system.
enable SAUER-SUNDSTRAND to offer a wide range of design
solutions utilizing hydraulic power system technology. SAUER-SUNDSTRAND is Your World Source for
Controlled Hydraulic Power Systems.
Heavy Duty Axial Piston Heavy Duty Bent Axis Cartridge Motors/
Pumps and Motors Variable Motors Compact Wheel Drives
Medium Duty Axial Piston Microcontrollers and Hydrostatic Transmission

Pumps and Motors Electrohydraulic Controls Packages
Open Circuit Axial Piston Pumps Gear Pumps and Motors Genuine Service Parts
Worldwide Service Support
SAUER-SUNDSTRAND provides comprehensive worldwide service for its

products through an extensive network of Authorized Service Centers
strategically located in all parts of the world.
Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.
SAUER-SUNDSTRAND COMPANY SAUER-SUNDSTRAND GMBH & CO.

2800 East 13th Street Postfach 2460 D-24531 Neumnster
saue Ames IA 50010 U.S.A. Krokamp 35 D-24539 Neumnster Germany
Phone: (515) 239-6000 FAX: (515) 239-6618 Phone: (04321) 871-0 Fax: (04321) 871 122
BLN-9949 Rev. B July 1992
PAGE 1 OF 8
PAGE 2 OF 8
PLUG CAP
PLUG GREASE FITTING

O-RING
ONE-INCH, ONE BODY CAP
and A-HALF-INCH, BODY CAP SEAL
and TWO-INCH
PLUG
VALVES PLUG
SEAL SEGMENT PLUG O-RING

SPM plug valves are SEGMENT SEAL
rugged field-proven units
which provide easy operation
and dependable service
under severe operating con-
ditions in a variety of low temp and sour gas models.
high-pressure oilfield ap- Consult factory.
lications. These include
cementing, fracturing, CHARACTERISTICS
acidizing and other ap- Improved body cap seal
plications handling drilling arrangement eliminates
muds, slurries, abrasives cap leakage found in
and harsh chemicals. some competitive valves.
Available in standard temp, No need to remove valve
VALVE SPM PART RATED
MODEL SIZE TYPE NO. TYPE CONNECTION NSCWP*
SP50TF 1 1x1 1A12173 1"-11V FEMALE LINE PIPE THREAD 5000
SP150TM 1 1x2 1A11747 2"-11V MALE LINE PIPE THREAD LONG 15000
SP150TMF 1 1x2x1 1A11745 2"-11V MALE LPTL x 1"-11V FEMALE LPT 15000
SP150WU 1 1x1 1A12174 1" FIG. 1502 FEMALE x 1" FIG. 1502 MALE 15000
SP150WU 1 1 x 1 1A12175 1" FIG. 1502 FEMALE x 1" FIG. 1502 MALE 15000
SP150WU 1 1x2 **1A19777 2" FIG. 1502 FEMALE x 2" FIG. 1502 MALE 10000
SP150WULT 1 1x2 1A14483 2" FIG. 1502 FEMALE x 2" FIG. 1502 MALE 15000
SP150WULT 3/8 1x2 1A19748 2" FIG. 1502 FEMALE x 2" FIG. 1502 MALE 15000
SP150TF 1 1 x 1 1A12479 1"-11V FEMALE LINE PIPE THREAD 15000
SP50TF 2 2x2 1A12477 2"-11V FEMALE LINE PIPE THREAD LONG 5000
SP150WU 2 2x2 **1A14492 2" FIG. 1502 FEMALE x 2" FIG. 1502 MALE 10000
SP150WULT 2 2x2 1A14487 2" FIG. 1502 FEMALE x 2" FIG. 1502 MALE 15000
** H2S Service * Non-Shock Working Pressure

2
PAGE 3 OF 8
DIMENSIONAL DATA
from line for mainten-
ance. No special tools FEMALE UNION CONN. MALE UNION CONN.
needed for operation or

maintenance.
D
1", 1 x 2", 1" and 2" C
valve repair kits can be B
used in Weco series

"D" valves. A E
Precision-ground floating 1", 1" AND 2" 10,000 AND 15,000 NSCWP
seal segments insure PORT UNION APPROX
positive seal between MODEL NO. PART NO. A B C D E SIZE SIZE WEIGHT
fluid stream and cylin- 1" SP150WU 1A12174 10.56 2.44 4.62 7.31 4.88 .87 1" - 1502 50
drical plug. 1" SP150WU 1A12175 10.56 2.44 4.62 7.31 4.88 .87 1 - 1502 54
Excellent sealing provid- 1" SP150WULT 1A14483 10.56 2.44 4.62 7.31 4.88 .87 2" - 1502 57
*1" SP150WU 1A19777 10.56 2.44 4.62 7.31 4.88 .87 2" - 1502 57
ed by precision ground
1" SP150WULT 1A19748 10.56 2.44 4.62 7.31 4.88 .38 2" - 1502 57
metal-to-metal seal be-
1" SP150WU 1A12480 12.63 3.19 6 8.25 6.81 1.30 1" - 1502 51
tween seal segments and 1" SP150WULT 1A12481 12.63 3.19 6 8.25 6.81 1.30 1"F, 2"M 53
plug. 2" SP150WLT 1A14487 13.87 3.44 6.63 8.88 7.89 1.75 2" - 1502 100
Pressure-enhanced seal- *2" SP150WU 1A14492 13.87 3.44 6.63 8.88 7.89 1.75 2" - 1502 100
ing between segments * For sour gas 10,000 psi service
and body provided by
molded rubber static MALE LINE PIPE THD.
TYP BOTH ENDS
segment seal.
Segment design insures D
easy operation up to full C
B
working pressure of the
valve. A E
Precision-ground plug is
1" 15,000 NSCWP
plated standard for max-
PORT THREAD APPROX
imum corrosion protection. MODEL NO. PART NO. A B C D E SIZE SIZE WEIGHT
Quality components 1X2" SP150TM 1A11747 9.13 2.42 4.69 7.31 4.88 .87 2" LPTL 27
throughout unit including 1X2" SP150TMF* 1A11745 9.13 2.42 4.69 7.31 4.88 .87 2" M x 1" F 30
forged heat-treated alloy *2" Male x 1" Female Threads, both ends
steel body for greater FEMALE LINE PIPE THD.

TYP BOTH ENDS
dependability, minimum
weight and maximum
strength. C
D
Plug bar cap has visible B
indication of open or A E
closed position and de-
tent spring to insure 1" AND 2" 5,000 NSCWP
valve stays open or MODEL NO. PART NO. A B C D E

PORT THREAD
SIZE SIZE
APPROX
WEIGHT
closed. 1" SP50TF 1A12173 6 2.31 4.62 7.31 4.88 .87 1" LPT 20
Hydraulically-actuated 2" SP50MF 1A12477 8.50 2.25 4.88 7.95 6.56 1.75 2" LPTL 43
models optional.
1" AND 2" 10,000 NSCWP
Each valve is thoroughly
PORT THREAD APPROX
tested prior to shipment. MODEL NO. PART NO. A B C D E SIZE SIZE WEIGHT
Inventory stock of com- 1" SP150TF 1A12479 7.31 3.18 6 8.25 6.81 1.30 1" LPT 55
plete valves, spare parts 2" SP100TF 1A12478 8.50 3.18 6 8.63 6.81 1.75 2" LPTL 52
and seal kits.
2" 15,000 NSCWP
Remote-control actuator
PORT THREAD APPROX
available. MODEL NO. PART NO. A B C D E SIZE SIZE WEIGHT
2" SP150TF 1A11742 8.50 3.44 6.63 8.88 7.89 1.75 2" LPTL 85
3
PAGE 4 OF 8
ONE-INCH and ONE-AND-A-HALF

INCH PLUG VALVES 1
1" PART 1" PART
ITEM QTY NO. NO. DESCRIPTION 2
1 1 P10064 P10064 GREASE FITTING**
2 1 P11716 P11699 HEX NUT**
3 1 1P11707 1P12296 PLUG CAP* 3
4 1 P11715 P11715 FELT GASKET**
13
5 1 3P14481 2P13326 BODY CAP*
6 1 P11714 P12486 O-RING**
4
7 2 4A11985 4A11979 O-RING/PACKING ASSY.**
8 1 3P14482 2P12482 PLUG**
9 2 2P11710 2P12483 SEAL SEGMENTS** (must be installed 5
in pairs)
10 2 3P21062 2P12485 SIDE SEGMENTS**
11 2 3P11711 3P12484 SEAL** 6
12A 1 1P11746 - BODY, MALE LPT*
12B 1 1P11744 - BODY, MALE LPT X FEM. LPT*
7
12C 1 1P14480 1P13615 BODY, UNION CONNECTIONS* 11
12D 1 1P13338 1P13323 BODY, UNION CONNECTIONS* 10
12E 1 1P20925 - BODY, UNION CONNECTIONS* 9
12F 1 1P13652 1P13322 BODY, FEMALE LPT*
13 1 2P12258 2P16822 WRENCH, BODY CAP* 8
14A 1 4L11769 4L12487 PARTS KIT - Includes items 1, 2, 4, 6, 7,
10 7 9
8, 9, 10 and 11** Std. Svc.
4L16800 Acid/Solvent Svc. 11
14B 1 4L14203 4L14442 SEAL KIT - Includes Items 1, 2, 4, 7, 9,
10 and 11** Std. Svc.
4L16783 Acid/Solvent Svc.
WING UNION END CONNECTIONS 12 A B
1" 1502 1" 1502 2" 1502
15 1 P11944 P11945 P10232 RETAINER RING**
16 3 3P11943 3P11460 3P10231 SEGMENTS** 18 12 F
17 1 3P11520 3P11452 3P10228 WING NUT**
18 1 3P11635 3P11451 4P10229 SEAL RING**
12 C D E
15
16
17
* NOT COMPATIBLE WITH WECO 1" & 1" DR SERIES VALVES.

** INTERCHANGEABLE WITH WECO 1" & 1" DR SERIES VALVES.
STANDARD SERVICE
PARTS and SEAL KITS

SPM parts kits contain all the parts
necessary to rebuild valves in the
field or on the bench. The seal kit
contains the same parts as the
repair kit, less the plug. For proper
sealing of the valve, seal segments
should be replaced in pairs.
WECO is a registered trademark of FMC Corporation.
4
PAGE 5 OF 8
TWO-INCH PLUG VALVES

2" PART
ITEM QTY NO. DESCRIPTION
1
1 1 P10064 GREASE FITTING**
2 1 P11699 HEX NUT** 2
3 1 1P11689 PLUG CAP 1P12296 FOR SP100)*
4 1 P11698 FELT GASKET** 13
5A 1 3P14485 BODY CAP, SP150* 3
5B 1 3P11691 BODY CAP, SP100*
5C 1 2P16864 BODY CAP, SP50
6 1 P11697 O-RING** 4
7 2 4A11979 O-RING/PACKING ASSY.**
8 1 2P14486 PLUG**
5
9 2 3P11692 SEAL SEGMENTS** (must be installed
in pairs)
10 2 3P20338 SIDE SEGMENTS** 14
11 2 3P11693 SEAL** 6
12A 1 1P11743 BODY, 2" FEM. LPTL*
12B 1 1P14484 BODY, 2" FIG. 1502 UNION CONNECTIONS* 7
12C 1 1P12992 BODY, 2" FEM. LPTL SP50* 11 10
12D 1 1P12993 BODY, 2" FEM. LPTL SP100*
13 1 2P12259 WRENCH, BODY CAP*
9
14 1 P12257 BACK-UP RING (SP150 ONLY)**
8
15A 1 PARTS KIT - Includes items 1, 2, 4, 6, 7, 8, 9,
10, 11 and 14** 10 7 9
4L11982 Std. Svc.
4L16826 Acid/Solvent Svc. 11
1 4L20594 H2S Svc.
15B SEAL KIT - Includes Items 1, 2, 4, 6, 7, 9, 10,
11 and 14**
4L13694 Std. Svc.
4L16824 Acid/Solvent Svc.
4L20575 H2S Svc. 12 A C D
WING UNION END CONNECTIONS
2" 1502 19
16 1 P10232 RETAINER RING**
17 3 3P10231 SEGMENTS**
18 1 3P10228 WING NUT**
12 B E
19 1 4P10229 SEAL RING**
* NOT COMPATIBLE WITH WECO 2"
DR SERIES VALVES.
** INTERCHANGEABLE WITH WECO 16

2" DR SERIES VALVES.
17
= FOR SP150 VALVES.
== MODEL SP150WU ONLY. 18
PARTS and SEAL KITS

SPM parts kits contain all the parts
necessary to rebuild valves in the
field or on the bench. The seal kit
contains the same parts as the
repair kit, less the plug. For proper
sealing of the valve, seal segments
should be replaced in pairs.
WECO is a registered trademark of FMC Corporation.
5
PAGE 6 OF 8
drive are standard. Cylindrical balanced
Hydraulic actuator with plug utilizes sealing
either 12-volt power segments to permit
THREE-INCH system or hand-operated easier operation under
hydraulic pump are pressure and assure
PLUG optional. positive seal.
VALVES
The SPM three-inch
15,000 psi plug valve is a
rugged field-proven unit
which provides easy opera-
tion and dependable service
under severe operating
24.00"
17.70"
conditions in various high- End of Male 8.00" 4.36"

Connection 17.00"
pressure oilfield applica- 16.00"
tions. These include
cementing, fracturing,
acidizing, and other ap-
plications handling drilling
muds, abrasives, slurries,
and harsh chemicals. 16" DIA.
HAND WHEEL
4.31"
23 16 21 12 13 14
CHARACTERISTICS 24 22 28 34
15
Low operating torque
due to balanced stem 18.00"
makes valve easier to
operate.
Flanged body for easier 25
maintenance. 10
10.40"
Integral inlets and 8

outlets are standard. 2
Quality components 4 3
throughout unit including
11
forged steel body.
5
Hand crank and locked- 9 1
26
6 7
open and shut gear
6
PAGE 7 OF 8
Flanged body construction tools needed for maintenance
in lieu of top threaded or operation.
cap for safer operation and
easier maintenance. Visible quarter-turn stop
indicates when the valve
No adjustments or special is open or fully closed.
PART PART
ITEM QTY NO. DESCRIPTION ITEM QTY NO. DESCRIPTION
1 1 1P14493 Valve Body 17 1 2P10257 Wing Nut, 3" Figure 1502 Detachable
2 1 1P14495 Plug 18 3 3P10260 Retainer Segment, 3" Figure 1502
3 2 P12850 O-Ring** 19 1 P10261 Snap Ring
4 2 3P12840 Back-up Ring** 20 1 4P10258 Seal Ring, 3" Figure 1502
5 2 2P10012 Seal Segment 21 4 P11036 Screw, Hex Head
6 2 3P10013 Side Segment 22 4 P11037 Lockwasher
7 2 4P10017 Seal 23 4 P12461 Screw, Hex Head
8 1 P10064 Grease Fitting 24 4 P10456 Lockwasher
9 1 2P14494 End Plate 25 1 P13008 Back-up Ring
10 1 P12851 O-Ring 26 2 P11694 Seal Segment Pin
11 10 P18258 Screw, Socket Head Cap 28 1 4L19629 Parts Kit, includes Items 2, 3, 4,
12 1 2P10791 Adapter Shaft 5, 6, 7, 8, 10 and 25
13 1 P11040 Key (For Gear Operator) 29 1 4L13009 Seal Kit includes Items 3, 4, 5, 6,
14 1 4P18942 Gear Operator 7, 8, 10 and 25
15 1 2P10875 Plug Adapter, Gear - - 1A14496 3" SP150WU Plug Valve Assembly
Operator/Hydraulic Actuator - - 1A4496H 3" Hydraulic Assembly
16 1 2P12865 Adapter, Gear Operator/Hydraulic - - 1A14496A 3" Air Act. Assembly
Actuator
** Items 3 and 4 also offered as a packing assembly (Part No. 4A16827)
PARTS and SEAL KITS

SPM parts kits contain all the parts necessary to rebuild
valves in the field or on the bench. The seal kit contains
the same parts as the repair kit, less the plug. For
proper sealing of the valve, seal segments should be
replaced in pairs.
15
13
17
18 14
12
19
16
1 26
23 22
21
24
2
20
11 3
8 4 6
5 7
10 25
9
7
PAGE 8 OF 8
SAFETY GUIDE FOR PLUG VALVES
SPM recommends that remote controlled valves be used for these applications.
!!WARNING!!
B-9 When opening an SPM plug valve under pressure, the initial torque to start the stem
MISUSE, SIDE LOADING, IMPROPER MAINTENANCE, OR turning is always greater than the moving torque. You must position your body to be able to
DISASSEMBLY UNDER PRESSURE CAN CAUSE SERIOUS compensate for this change.
INJURY OR DEATH! B-10 Do not position any part of your body in the path of exit flow of the valve.
B-11 Do not position the exit of any plug valve, used for bleeding, where rocks or debris may be
The following information is given in good faith and should aid in the safe use of your SPM picked up by the exit stream.
products. This information is not meant to replace any existing Company's safety policies or
practices. It is important to read and understand the "General Safety Data for all SPM B-12 If any valve becomes plugged, or does not operate properly, contact a supervisor
Products" and the SPM Product Safety Guide for "Union and Union End Products". Both of immediately. DO NOT look into the end of the valve to check for debris, blockage, or for any
these are available from SPM. other reason.
B-13 If valve is slow to open or close, remove it from service. Do not hammer on the valve's
Personal Responsibilities: actuator cap.
A-1 When using these assemblies, safety glasses, approved safety shoes and hard hat must B-14 It is recommended that a rate in excess of 42 feet per second be avoided. Rates above
be used. Hammering and lifting these assemblies must be done with caution. Where unions this will cause a more rapid wear and erosion.
are present, read and understand the SPM Safety Guide for Unions and Union End Products.
B-15 Flush clean and grease after each job with water and the proper SPM valve grease. Use
A-2 Personnel should only hammer on makeup lugs and not strike union nut or valve body. only an SPM pressure rated gun for greasing.
Fractures can occur from repeated misuse. Excessive hammering can damage components.
Special Precautions:
A-3 Do not lift any valve that weighs in excess of 40 pounds. Use a lifting device if valves are
to be used above head or when weight exceeds 40 lbs. C-1 Welding, brazing, or heating on SPM plug valves is prohibited.
Proper leg lifting should be used when lifting. Back lifts should be avoided.
C-2 Valve operation sometimes require personnel to be around pressured lines. Experienced
A-4 Only the proper actuator bar should be used to turn SPM plug valves. Valves require personnel only should be dispatched for this purpose. Exposure time should be a minimum.
torque to operate. Makeshift bars can become dislodged easily and cause an accident. Use Always use remote controlled valves whenever possible. Never look into, or position yourself in,
only an SPM actuator bar, part number 3P11542, for 1" and 2" Plug Valves. It is a personal the path of the exit flow of the valve.
responsibility to become knowledgeable and trained in the proper use and handling of this
tool. C-3 Never alternate a valve's service. Acid service should never be followed by cold
temperature service. When acid etching or erosion is present, replace the valve.
A-5 Do not hammer on, or be around valve assemblies when pressure is present. C-4 SPM offers specially designed valves for torture service, cold temperature service, H2S
service, and aromatic service. Only valves designed and approved for these special services
It is recommended that plug valves with SPM remote control actuators be used wherever should be used in these applications.
possible. Hand actuation (with the appropriate actuator bar) should be done only by specially
trained personnel under direct supervisory instruction; and only when necessary due to C-5 Each integral union connection is clearly marked with a pressure code (i.e. "1502", 15,000
application. psi). This pressure must not be exceeded. This code should also be used with mating unions.
Improper mating can result in failures. All integral union connections must match (according to
On Location: size, pressure rating, etc.). These connections must also match the service of the designated
string they are installed in.
B-1 Proper transportation of plug valves is important. Racks that will secure valves and
prevent accidental unloading are critical. Never transport any SPM product in a fashion that Inspection - Repair - Testing:
would allow it to become dislodged and cause an accident.
D-1 Valves should be greased after each use. Use only the following SPM gun and grease.
B-2 Valve unions should be clean and lightly oiled prior to each use. A visual inspection for
damage should also be performed at this time. Union seals should be checked, and replaced Lube Grease: Standard Temperature: P13336; Low Temperature: P13337;
when worn or damaged. Gun Assembly: P13335
B-3 Each valve has a size and pressure code designated on the valve. Use this code for D-2 Any alteration of the SPM valve is prohibited.
proper mating and pressure limits.
D-3 Use only repair methods as outlined by SPM valve service literature. Use only the proper
!! CAUTION !! SPM repair tools. Wall charts and instruction sheets are available from SPM.
SINCE PLUG VALVES MAY BE REPAINTED IN DIFFERENT COLORS FOR VARIOUS
APPLICATIONS, DO NOT USE FACTORY COLOR AS PRIMARY MEANS OF D-4 SPM Repair Kits should be used for repair. Valve Body and all components must be clean
IDENTIFICATION. and SPM assembly grease used.
B-4 Threaded end plug valves should not be used for H2S service. Only integral type Assembly Grease:Standard Temperature: P14189; Low Temperature: P14443
plug valves should be used when sour gas is present. These must be valves specially
designed and designated for use with H2S service. D-5 Threaded end plug valves must have the API pipe threads inspected at least every 90 days.
These threads are right hand threads. Turning counter-clockwise, or to the left, will unscrew the
B-5 Valve usage should be monitored by a qualified supervisor or foreman. valve. This must never be done while the valve is in service. Always make sure any threaded
Supervisory personnel must approve proper placement, position, and handling of all component is correctly made up per the API or SPM standard.
plug valves in the system. Only specially trained personnel under direct supervisory
instruction, should actuate valves under pressure. D-6 Pressure seal (line pipe) threads are not recommended for pulsating service above 10,000
psi, or where side loading or erosion are suspected. Straight integral connections are
recommended under these conditions. In order to achieve the rated Non-Shock Cold Working
B-6 Prior to applying pressure, valves should be greased in both the opened and Pressure, API thread compound and power-tight make-up is required. Consult the factory for
closed position. This should be done before each use. If valve is excessively hard to any usage other than normal constant flow conditions.
operate, it should be removed and not used until repairs are made.
D-7 SPM recommends that weld repair not be attempted on its product. Replacing worn
B-7 It is sometimes necessary to turn valves when pressure is present. It is components is a more effective and safe approach.
recommended that remote control actuators be used for this purpose. If this is not
feasible, then only experienced specially trained personnel under direct supervisory
instruction should perform this task.
B-8 Venting flammable or explosive gases to the atmosphere through individual SPM !! CAUTION!!
plug valves must be avoided. Choke manifolds are available from SPM and should be THE RATED WORKING PRESSURE IS NOT
used for this purpose. If used for bleeding, ample anchoring of the valve manifold must TO BE EXCEEDED DURING
be done. Specially designed torture valves are available from SPM for bleedoff
applications. GASES, OR FLUIDS CONTAINING GASES, WILL CAUSE VALVES TO SERVICE OR FIELD TESTING
WHIP AND CAN CAUSE SERIOUS INJURY OR DEATH!
NQA ISO 9002

CERTIFIED
(ABERDEEN)
FORT WORTH: 7601 Wyatt Dr. Fort Worth, Texas 76108 U.S.A. Phone: 1-800-342-7458 (817) 246-2461 Fax: (817) 246-6324
HOUSTON: 363 N. Sam Houston Pkwy. E. - Suite 1100 Houston, Texas 77060 U.S.A. Phone: (281) 820-7807 Fax: (281) 820-7804
LAFAYETTE: 106 Pine Park Drive Lafayette, Louisiana 70508 U.S.A. Phone: (318) 233-3533 Fax: (318) 235-7803
ABERDEEN: Badentoy Industrial Park, Portlethen Aberdeen AB12 4YD Scotland Phone: (44) 1224-783666 Fax: (44) 1224-784184
SINGAPORE: 545 Orchard Road 15-02 Far East Shopping Ctr. Singapore 0923 Phone: (65) 738-3078 Fax: (65) 736-1106
LAS MOROCHAS: Avenida Intercomunal Las Morochas, ZP 4019, Edo Zulia Venezuela Phone: 58-65-313438 Fax: 58-65-313026
MATURIN: Final Avenida Bella Vista Maturin, Estado Mongas Venezuela Phone: 58-91-515103 Fax: 58-91-515818
DUBAI: Oilfields Center Supply L.T.D. Building 22 P.O. Box 1518 Dubai, U.A.E. Phone: 971-4-836-368 Fax: 971-4-836-485
RED DEER: 4645 - 62 Street Red Deer, Alberta T4N 2R4 Canada Phone: (403) 341-3410 Fax: (403) 341-3072
INTERNET: http://www.spmflo.com 1999 SPM FLOW CONTROL
SPM PRODUCT SAFETY GUIDE
FOR
PLUG VALVES
It is critical that, since most SPM products generate,

control or direct pressurized fluids, those who work
with these products be thoroughly trained in their
proper application and safe handling. It is also critical
that these products be used and maintained properly.
!!WARNING!!
MISUSE, SIDE LOADING, IMPROPER
MAINTENANCE, OR DISASSEMBLY
UNDER PRESSURE CAN CAUSE SERIOUS
INJURY OR DEATH!
2-1
The following information is given in good faith and
should aid in the safe use of your SPM products. This
information is not meant to replace any existing
Company's safety policies or practices. It is important
to read and understand the "General Safety Data for
all SPM Products" and the SPM Product Safety Guide
for "Union and Union End Products". Both of these
are available from SPM.
Personal Responsibilities:
A-1 When using these assemblies, safety glasses,

approved safety shoes and hard hat must be used.
Hammering and lifting these assemblies must be done
with caution. Where unions are present, read and
understand the SPM Safety Guide for Unions and
Union End Products.
A-2 Personnel should only hammer on makeup lugs

and not strike union nut or valve body. Fractures can
occur from repeated misuse. Excessive hammering
can damage components.
A-3 Do not lift any valve that weighs in excess of 40

pounds. Use a lifting device if valves are to be used
above head or when weight exceeds 40 lbs.
Proper leg lifting should be used when lifting. Back

lifts should be avoided.
A-4 Only the proper actuator bar should be used to

turn SPM plug valves. Valves require torque to
operate. Makeshift bars can become dislodged easily
and cause an accident. Use only an SPM actuator
bar, part number 3P11542, for 1" and 2" Plug Valves.
It is a personal responsibility to become
2-2
knowledgeable and trained in the proper use
and handling of this tool.
A-5 Do not hammer on, or be around valve

assemblies when pressure is present.
It is recommended that plug valves with SPM

remote control actuators be used wherever possible.
Hand actuation (with the appropriate actuator bar)
should be done only by specially trained personnel
under direct supervisory instruction; and only when
necessary due to application.
On Location:
B-1 Proper transportation of plug valves is

important. Racks that will secure valves and prevent
accidental unloading are critical. Never transport any
SPM product in a fashion that would allow it to
become dislodged and cause an accident.
B-2 Valve unions should be clean and lightly oiled

prior to each use. A visual inspection for damage
should also be performed at this time. Union seals
should be checked, and replaced when worn or
damaged.
B-3 Each valve has a size and pressure code

designated on the valve. Use this code for proper
mating and pressure limits.
!! CAUTION !!
SINCE PLUG VALVES MAY BE REPAINTED IN

DIFFERENT COLORS FOR VARIOUS
APPLICATIONS, DO NOT USE FACTORY COLOR
AS PRIMARY MEANS OF IDENTIFICATION.
2-3
B-4 Threaded end plug valves should not be used for
H2S service. Only integral type plug valves should be
used when sour gas is present. These must be valves
specially designed and designated for use with H2S
service.
B-5 Valve usage should be monitored by a qualified

supervisor or foreman. Supervisory personnel must
approve proper placement, position, and handling of
all plug valves in the system. Only specially trained
personnel under direct supervisory instruction, should
actuate valves under pressure.
B-6 Prior to applying pressure, valves should be

greased in both the opened and closed position. This
should be done before each use. If valve is
excessively hard to operate, it should be removed and
not used until repairs are made.
B-7 It is sometimes necessary to turn valves when

pressure is present. It is recommended that remote
control actuators be used for this purpose. If this is
not feasible, then only experienced specially trained
personnel under direct supervisory instruction should
perform this task.
B-8 Venting flammable or explosive gases to the

atmosphere through individual SPM plug valves must
be avoided. Choke manifolds are available from SPM
and should be used for this purpose. If used for
bleeding, ample anchoring of the valve manifold must
be done. Specially designed torture valves are
available from SPM for bleedoff applications. GASES,
OR FLUIDS CONTAINING GASES, WILL CAUSE
VALVES TO WHIP AND CAN CAUSE SERIOUS
INJURY OR DEATH!
2-4
SPM recommends that remote controlled valves be
used for these applications.
B-9 When opening an SPM plug valve under

pressure, the initial torque to start the stem turning is
always greater than the moving torque. You must
position your body to be able to compensate for this
change.
B-10 Do not position any part of your body in the

path of exit flow of the valve.
B-11 Do not position the exit of any plug valve,

used for bleeding, where rocks or debris may be
picked up by the exit stream.
B-12 If any valve becomes plugged, or does not

operate properly, contact a supervisor immediately.
DO NOT look into the end of the valve to check for
debris, blockage, or for any other reason.
B-13 If valve is slow to open or close, remove it

from service. Do not hammer on the valve's
actuator cap.
B-14 It is recommended that a rate in excess of 42

feet per second be avoided. Rates above this will
cause a more rapid wear and erosion.
B-15 Flush clean and grease after each job with

water and the proper SPM valve grease. Use only
an SPM pressure rated gun for greasing.
Special Precautions:
C-1 Welding, brazing, or heating on SPM plug

valves is prohibited.
2-5
C-2 Valve operation sometimes require personnel to
be around pressured lines. Experienced personnel
only should be dispatched for this purpose. Exposure
time should be a minimum. Always use remote
controlled valves whenever possible. Never look into,
or position yourself in, the path of the exit flow of the
valve.
C-3 Never alternate a valve's service. Acid service

should never be followed by cold temperature service.
When acid etching or erosion is present, replace the
valve.
C-4 SPM offers specially designed valves for torture

service, cold temperature service, H2S service, and
aromatic service. Only valves designed and approved
for these special services should be used in these
applications.
C-5 Each integral union connection is clearly marked

with a pressure code (i.e. "1502", 15,000 psi). This
pressure must not be exceeded. This code should
also be used with mating unions. Improper mating
can result in failures. All integral union connections
must match (according to size, pressure rating, etc.).
These connections must also match the service of the
designated string they are installed in.
Inspection - Repair - Testing:
D-1 Valves should be greased after each use. Use

only the following SPM gun and grease.
Lube Grease:
Standard Temperature.........P13336
Low Temperature................ P13337
Gun Assembly..................... P13335
2-6
D-2 Any alteration of the SPM valve is prohibited.
D-3 Use only repair methods as outlined by SPM

valve service literature. Use only the proper SPM
repair tools. Wall charts and instruction sheets are
available from SPM.
D-4 SPM Repair Kits should be used for repair.

Valve Body and all components must be clean and
SPM assembly grease used.
Assembly Grease:
Standard Temperature...........P14189
Low Temperature.................. P14443
D-5 Threaded end plug valves must have the API

pipe threads inspected at least every 90 days.
These threads are right hand threads. Turning
counter-clockwise, or to the left, will unscrew the
valve. This must never be done while the valve is in
service. Always make sure any threaded
component is correctly made up per the API or SPM
standard.
D-6 Pressure seal (line pipe) threads are not

recommended for pulsating service above 10,000
psi, or where side loading or erosion are suspected.
Straight integral connections are recommended
under these conditions. In order to achieve the
rated Non-Shock Cold Working Pressure, API thread
compound and power-tight make-up is required.
Consult the factory for any usage other than normal
constant flow conditions.
D-7 SPM recommends that weld repair not be

attempted on its product. Replacing worn
components is a more effective and safe approach.
2-7
D-8 Valves should be fully disassembled, inspected,
and pressure tested at least every 6 months and
always tested after each repair. The valve should be
tested in an opened and in a closed position.
Personnel should be a safe distance during pressure
cycles. They should never look into, or position
themselves in the exit flow path of the valve.
D-9 Pressure testing should be done with cold water.

Personnel should wear proper safety equipment and
avoid any area of danger while pressure is present.
Prior to any pressure testing, all air must be evacuated
from the system. Failure to do so could result in
PERSONAL INJURY OR DEATH!
!! CAUTION !!
THE RATED WORKING PRESSURE IS NOT
TO BE EXCEEDED DURING
FIELD SERVICE OR FIELD TESTING.
2-8
.
Stewart & Stevenson Services, Inc. Introduction
Record of Revisions
Property of:
Company:
Address:
Revision Data
Stewart & Stevenson Services, Inc. assumes no liability for personal injury or equipment failure
due to any operation performed without heed to manual revisions.
Date of original publication: August 2003
1 ______________________ _____________________
2 ______________________ _____________________
3 ______________________ _____________________
4 ______________________ _____________________
5 ______________________ _____________________
6 ______________________ _____________________
i
Copyright Notice
This manual contains the confidential and proprietary information of Stewart &
Stevenson Services, Inc.
Neither this document nor any information contained herein may be reproduced or
redistributed in any form whatsoever without the express, written consent of an authorized
agent of Stewart & Stevenson Services, Inc.
Any attempt by any person other than an authorized agent of Stewart & Stevenson Services,
Inc. to alter the contents of this manual in any way shall be construed as copyright
infringement, punishable by all applicable laws.
All vendor literature contained in this manual is the copyright property of the respective
vendors, protected by the same laws governing this operation and maintenance manual.
ii
About This Manual
This manual is not a textbook on mechanics, electronics, or hydraulics. Sufficient

descriptive material and illustrations are included to enable the operator to understand the
basic construction and theory of operation of this equipment. The intent of this manual is
to guide the operators and maintenance personnel in the proper use of the equipment. This
manual is not a substitute for properly trained personnel or common sense.
No liability, either express or implied, is given for any information contained herein. This
manual is intended only as a guide, and not as a substitute for proper training by qualified
personnel.
Stewart & Stevenson Services, Inc. assumes no responsibility for improper use of equipment,
improperly trained personnel, improperly maintained equipment, or failure to follow normal
safety precautions outlined in this manual, in the vendor literature, or by properly trained
personnel.
Use of this manual for any purpose other than for the safe and proper operation and
maintenance of the equipment and all its components constitutes misuse, and is punishable
by all applicable laws.
If there is any discrepancy between information contained in this manual and the vendor
literature, the vendor literature is assumed correct. Stewart & Stevenson Services, Inc.
assumes no liability whatsoever for any person who fails to follow the operation and safety
procedures of the original equipment manufacturers.
Please read through this manual in its entirety before attempting to operate the equipment.
Stewart & Stevenson Services, Inc. assumes no liability for failure to do so.
All information in this manual is based on the latest production information available at the
time of publication. Direct any questions concerning the contents or format of this manual
to:
The Control Systems Group

Stewart & Stevenson Services, Inc.
10750 Telge Rd.
Phone: (281) 345 5100
Fax: (281) 345 1188
Email Addresses:
Parts and Service: controls.service@ssss.com
Product Information: controls.info@ssss.com
iii
Table of Contents
Section Page
Introduction
Record of Revisions ................................................................................................................ i
Copyright Notice .................................................................................................................... ii
About This Manual ................................................................................................................iii
Table of Contents...................................................................................................................iv
Chapter 1
1.0 Overview ............................................................................................................................1
Chapter 2
2.0 Operation ...........................................................................................................................2
2.1 Control Screen...................................................................................................................2
2.2 Engine Diagnostics ...........................................................................................................3
2.3 Alarm ..................................................................................................................................3
2.4 Configuring the Over Pressure Trip Point.......... .........................................................3
Chapter 3
3.0 Maintenance.......................................................................................................................4
3.1 Setting up the Terminal................................................................................................... 4
3.1.1 Terminal Settings..............................................................................................4
3.1.2 Network Settings ..............................................................................................5
3.1.3 Display Units.....................................................................................................6
3.1.4 Communication Test .......................................................................................6
3.2 Setting Up the Engine ..................................................................................................... 7
3.2.1 Engine Setup.....................................................................................................7
3.2.2 Engine Throttle ................................................................................................7
3.3 Setting Up the Transmission .......................................................................................... 8
3.3.1 Transmission Oil Pressure ..............................................................................8
3.3.2 Transmission Filter Switch..............................................................................8
3.4 Setting Up the Pump ....................................................................................................... 9
3.4.1 Pump Characteristics .......................................................................................9
3.4.2 Pump Rate .........................................................................................................8
3.5 Configuring Alarms ........................................................................................................10
Appendix A: Troubleshooting Engine Throttle............................................................................ 11

Appendix B: Troubleshooting Allison Transmission ................................................................... 12
Appendix C: Saving Parameters to a Computer............................................................................ 13
Glossary ............................................................................................................................................... 15
Index .................................................................................................................................................... 16
iv
Stewart & Stevenson Services, Inc. Chapter 1
Chapter
1.0 Overview
Stewart & Stevensons Intelligent Pump Control System (IPC) is capable
of monitoring and controlling multiple fracturing pumps simultaneously
1
from a single location, giving the operator precise, remote control over an entire fracturing
spread. The IPC System allows users to control various functions of the equipment through
a touch screen interface. Status lights are used to notify the operator of alarms when a
problem exists with the engine, transmission, or the pump. Functions, such as
start/shutdown of the engine, increasing/decreasing throttle, and gear selection, can be
controlled via the pump control panel.
The IPC is a microprocessor-based system with a touchscreen operator interface that can be
stored in a weather tight suitcase or panel-mounted inside a Control Center. The display is a
touch sensitive 8.5 X 6.25 graphical display. IPC simplifies operations by reducing the
amount of electronic components required to control the various functions of fracturing
equipment.
Control Functions
Engine throttle
Transmission shift
Transmission brake
Engine emergency shutdown (optional)
Engine normal shutdown
Engine start
Control Parameters
Engine fault codes with translations
Figure 1: Main Menu
Engine speed
Engine oil pressure and temperature
Engine water temperature
Transmission oil pressure
Torque converter status indicator for converter and lockup modes
Pump speed
Pump oil pressure and temperature
Pump discharge pressure with overpressure module
Pump discharge rate and total hydraulic horsepower production (calculated)
1
Chapter
2.0 Operation
This chapter covers the specific details of operating the Intelligent Pump
Control System. It also explains the many different abbreviations,
buttons, screens, and controls used on the following display windows,
2
how they are used, and what they mean. These display windows include the Control Screen,
Engine Diagnostics Screen, Alarms Screen, and Over Pressure Trip Point.
2.1 Control Screen

The control screen is the main screen from which the operator controls the pump. From this
window the operator can view engine diagnostics, zero discharge pressure, modify the
alarms, increase engine throttle, and switch between gears.
To access the control screen clicking the Control button on the

Intelligent Pump Control screen.
Values displayed across the top of the

screen come from the Electronic
Control Module (ECM) sensors, and
calculated values.
Below the ECM values, the operator

can increase/decrease the engine
RPMs and change gears by pushing the
up/down arrows. Refer to Figure 2 for
more details on the Control Screen.
Figure 2: Control Screen
1. Takes the operator to the Engine Diagnostics screen, which will display all the values
from the engines ECM.
2. Clicking the Zero Discharge Pressure button will reset the Pressure (PSI) to 0.
3. Allows the operator to quickly modify the various features on the Pump Characteristics
screen.
4. Reset Totals will reset the slurry total (BBL).
5. Adjusts the Small Throttle.
6. Adjusts the Large Throttle.
7. Throttle indicator that graphically displays when the operator increases/decreases the
throttle.
8. Shifts the transmission.
9. Will set the transmission to neutral and the engine to idle.
10. Takes the operator to the Alarms screen. This button will blink when an alarm is
active.
2
2.2 Engine Diagnostics

The Engine Diagnostics screen will allow
the operator to view any diagnostic
message from the ECM. The message
will display the date, time, and
description of the problem. The
operator can then use the available
information to correct any engine
problem or malfunction.
Figure 3: Engine Diagnostics

2.3 Alarms
The Alarms screen is setup to allow the operator to view in real time all the incoming data
from the engine, transmission, and pump sensors.
To access the Alarms control screen

press the Alarms button on the Control
screen.
To configure the alarms and their high
and low limits refer to the Configuring
the Alarms section (Refer to page 9).
Figure 4: Alarms
2.4 Configuring the Over Pressure Trip Point

The Over Pressure Trip Point is a fail-safe designed to prevent damage to the well by
idling the engine, and switching the transmission to neutral if the trip point is reached.
The over pressure trip point can be set by

clicking the Pump Parameters button on
the control screen.
If the over pressure trip point value is

reached, the pressure on the control screen
will blink and the fail-safe will be engaged.
The operator must select the Instant
Idle/Neutral button in order to regain
engine and transmission control.
Figure 5: Pump Characteristics
3
Chapter
3.0 Maintenance
The maintenance section covers setting up and configuring the various
pump, transmission, and engine control parameters.
3
3.1 Setting Up the Terminal
3.1.1 Terminal Settings

The Terminal Settings display
window allows the operator to
modify the contrast, backlight, and
keyclick. From the Terminal Settings
screen, the operator can
increase/decrease the contrast and
backlight. Keyclick volume can be
turned on and off. The default
keyclick setting is on.
Other functions found on the Terminal

Settings window include:
Figure 6: Terminal Settings
Save Terminal
Stores the configured display settings into memory. In order to save your settings, Save
Terminal must be selected prior to exiting the Terminal Settings window.
Terminal Reset
Cycles the terminals power and resets terminal settings to their saved values.
Send Status To Host

Sends the information currently associated with the Intelligent Pump Control terminal will
be sent via a RS232 serial cable to the desired host.
Note: Exiting this screen without selecting the Save Terminal button will cause
the desired changes to be lost when power is turned off.
4
3.1.2 Network Settings

The Network Settings screen allows the user to set the address of the current workstation,
modify the time and date, map the network, and clear the memory.
The screen will graphically display the
node on the network, description, and
version of the software.
Display refers to the network

controller software. Pump Control
refers to the black box software. QT
Version refers to the touch screen
software. Version numbers help
determine if hardware or software
needs to be updated.
Figure 7: Network Settings Screen
Note: The address should be set to 240.
By clicking the Clear Memory button the unit will not reset all the data stored in memory.
Only the Small Throttle Step and the Large Throttle Step will be cleared of their user defined
values.
Note: Clearing the memory will default the display units to English.
Another feature that the operator can edit is the time and date. When clicking the Set
Time/Date button the user will be forwarded to the following screen:
On the left portion of the screen are all
the options related to date while on the
right side are all the options relating to
time. These can be modified by:
1. Click the desired field.
2. Entering the desired
numbers on the keypad.
3. Click Enter when
finished.
Figure 8: Time & Date
Note: The operator must click the Set button before exiting the screen or the
information will not be stored into memory.
The operator can also automatically set the date and time by clicking the Get button on
the top left corner of the screen. This option retrieves the date and time from the network if
available.
5
3.1.3 Display Units

The display units screen allows the operator to switch between the English and Metric
system units. The display units screen can be reached by clicking:
Pump Control > Display Units
English Units:
PSI RPM
DegF BPM
BBL HHP
Metric Units:
Mpa DegC
MP3M mm
M3
Figure 9: Display Units
3.1.4 Communication Test

The communication test screen allows the operator to test the stability of the network and
will report back how many iterations, packets, retries, lost packets, and the success rate. The
communication test screen can be reached by clicking:
Pump Control > Communication Test
Iterations per second: How many

times one cycle of a set of instructions
is repeated.
Total Packets: Number of packets
sent.
Retries: Reports how many
communication failures occurred
between devices.
Lost Packets: Total number of
packets lost during transmission.
Figure 10: Communication Test
Note: Test two uses every letter in the alphabet to check the transmission of
certain bytes; therefore, it is important that the operator run both test.
6
3.2 Setting Up the Engine
3.2.1 Engine Setup

This screen allows the operator to
modify the large and small throttle step.
When the operator presses the
engine RPM increases/decreases by
large throttle step. When the operator
presses the engine RPM
increases/decreases by small throttle
step.
The operator can get to this screen in a

few easy steps by clicking:
Pump Control >Hardware Setup > Engine Figure 11: Engine Setup
From here the operator can then alter the engine throttle characteristics by clicking on the
Engine Throttle button.
3.2.2 Engine Throttle

The settings on this display screen are
crucial to accurately controlling the
throttle. If the offset and gain are not
properly configured then the DAC
(Digital Analog Converter) counter
will not correspond to the right RPM.
Use the coefficient calculator located

on the Stewart & Stevenson website to
calculate the offset and gain.
Figure 12: Engine Throttle
Note: To get the coefficient calculator, go to

www.ssss.com/petroleum/download.asp
Below the offset and gain fields are the low limit and high limit fields. It is imperative
that the operator input acceptable RPMs into these fields otherwise engine complications
may result. The operator should check with S&S on what these settings should be.
The throttle control increments are shown in Figure 8. The speed of the engine will
adjust depending on the increment values and whether or not the operator is increasing or
decreasing the throttle control.
7
3.3 Setting Up the Transmission

3.3.1 Transmission Oil Pressure
To access the Transmission Oil Pressure screen, press:
Hardware Setup > Transmission > Transmission Sensor > Trans Oil Pressure
Note: There are four other screens (Transmission Oil Temperature, Pump Oil Pressure,
Pump Oil Temperature, Pump Discharge Pressure ) that have the same layout as the
Transmission Oil Pressure screen. Since these screens are identical, only the Transmission
Oil Pressure screen will be covered in detail
This screen in particular is measured in

PSI. The sensors ADC will be
calibrated based on what the user
inputs in the Min-Scale Reading and
Full-Scale Reading fields. To
calibrate:
1. Input the desired PSI into the field.

2. Click the calibrate button.
3. Click the set button.
4. Repeat process for each field pairs.
Figure 13: Hardware Calibration
1. Min-Scale Reading is the minimum value for the sensor being used. For example
on a 0-15,000 PSI transducer, the min-scale reading would be 0.
2. Full-Scale Reading is the maximum value for the sensor being used. For example
on a 0-15,000 PSI transducer, full-scale reading would be 15,000.
3. Calibrate Full-Scale adjusts the unit to read correctly at a high end set point.
4. Calibrate Min-Scale captures the current input level from the sensor.
3.3.2 Transmission Filter Switch

The transmission filter switch notifies the operator when the transmission filter needs to be
changed.
When the state is zero the filter is

bad.
When the state is one the filter is

good.
Figure 14: Transmission Filter Switch
8
3.4 Setting Up the Pump

3.4.1 Pump Characteristics
The Pump Characteristics screen is used to calculate the total barrels per minute. The
Pump Characteristics screen requires the operator to input the values for each field
depending on the manufacturers specifications. The Pump Characteristics screen can be
reached by:
Hardware Setup > Pump > Pump Parameters
To change the number of plungers:
1. Click the top left box.
2. Continue cycling through
until the desired number
appears.
Enter the plunger size, stroke, and

pump gear ratio based on the
manufacturers specifications.
The efficiency factor is used to correct Figure 15: Pump Characteristics

the theoretical displacement.
A rating of 1.00 is equal to one hundred percent efficiency.

A rating of 0.50 is equal to fifty percent efficiency.
Note: As a pump wears the efficiency tends to decrease.
3.4.2 Pump Rate

The main point of focus on this screen is setting up the K-Factor. A K-Factor is used to
convert a frequency into an engineering unit. To set the K-Factor:
If the operator knows the K-Factor:

1. Input it directly into the K-
Factor field
OR
If the operator knows the current

rate:
1. Input 1 into the K-Factor
field and click SET.
2. Input the current BPM into the
provided field. Figure 16: Pump Rate
3. Click AUTO-SCALE > SET.
9
3.5 Configuring the Alarms

As stated earlier there are three different alarm setup pages. The first page consists of all
engine alarms, the second page all transmission alarms, and the third page all pump alarms.
Note: The Engine Alarms, Transmission Alarms, and Pump Alarms screens
follow the same setup procedures.
Each alarm setup page will consist of

a High Limit and Low Limit
configurable field.
To change these fields click on them,

input the desired value with the
number pad, click Enter > SET.
Click Next to continue to the next

Alarm Setup page.
Figure 17: Engine Alarms
Note: The unit characteristics will vary between each of the different alarm
setup screens. Each screen will either have degF, PSI, and or BBL units.
10
Stewart & Stevenson Services, Inc. Appendix A
Page 11
Stewart & Stevenson Services, Inc. Appendix B
Page 12
Stewart & Stevenson Services, Inc. Appendix C
Saving Parameters to a Computer
1. Set all the dipswitches to the OFF position EXCEPT for 6 and 7.
2. Cycle the power of the pump control board.

3. Start up hyper terminal.
4. Input a connection description.
5. Click OK.
6. Select the COM Port in which

the data transfer will take
place.
7. Click OK.
8. Set Baud Rate (Bits per second) to 9600.

9. Set Data Bits to 8.
10. Set Parity to None.
11. Set Stop bits to 1.
12. Set Flow control to None.
13. Click OK.
14. Click Transfer at the top of the screen.

15. Select Capture text... from the menu.
16. Click Transfer at the
top of the screen.
17. Select Capture Text...
from the menu.
18. Click Browse.

19. Select a folder for
storage.
Page 13
Stewart & Stevenson Services, Inc. Appendix C
20. Input file name and click Save.

21. Click the Start button.
22. Press CTRL-A to retrieve data from the IPC.
To upload the saved file:
1. Click Send text file... from the transfer menu.

2. Find the desired file and click OK.
3. A screen similar to the one below will appear.
Page 14
Stewart & Stevenson Services, Inc. Glossary
Average Counts Number of readings used to acquire an average value.
BBL - Barrel.
BPM - Barrels per minute.
Calibrate Full-Scale Adjust the unit to read correctly at a high-end set point.
Calibrate Min-Scale Captures the current input level from the sensor.
Current Value Is the current value of the signal being monitored.
degC - Degree Celsius.
degF - Degree Fahrenheit.
Full-Scale Reading The maximum value for the sensor being used. For example on a 0 15,000
PSI transducer, the Full-Scale Reading would be 15,000.
Gear Ratio - Speed of rotation ratio of the powered gear to the driven gear.
HHP - Hydraulic Horsepower.
in - inches.
K - Factor Converts a frequency to an engineering unit.
M3 - Meters cubed.
M3PM - Meters cubed per minute.
Min-Scale Reading The minimum value for the sensor being used. For example on a 0 15,000
PSI transducer, the Min-Scale Reading would be 0.
mm - Millimeters.
MPa - Mega Pascal.
Node - A point on a network that either relays the transmission of data or terminates it.
Plunger - A piston used to create pressure pumps.
PSI - Pounds per square inch.
RPM - Rotations per minute.
SSCP - Stewart & Stevenson Communication Protocol.
Torque - Twisting or turning force.
Transducer An electronic apparatus that converts energy from one form to another.
Page 15
Stewart & Stevenson Services, Inc. Index
A I
Alarm Iterations per second, 7
limits, 3
Alarms K
High Limit, 14 keypad, 6
Low Limit, 14 K-Factor, 12
B M
backlight, 5 memory, 5
bbl, 2 Metric, 7
Min-Scale Reading, 10
C
contrast, 5 N
network, 6
D
DAC, 8, 10 P
date, 6 Packets, 7
Pump, 1
E alarm setup, 14
ECM, 3 Characteristics, 12
Engine, 1 Over Pressure Trip Point, 3
alarm, 14 Parameters, 4
alarm setup, 14 plungers, 12
Alarms, 3 PSI, 2
ECM, 3 rate, 12
engine diagnostics, 2 Zero Discharge Pressure, 2
Engine Diagnostics, 2, 3
gain, 8 R
high limit, 8 Reset Totals, 2
increase engine throttle, 2 Retries, 7
Large Throttle Step, 6
low limit, 8 S
malfunction, 3
serial cable, 5
offset, 8
RPM, 2, 7, 8 T
small throttle step, 8
Small Throttle Step, 6 throttle control increments, 9
English, 7 time, 6
Transmission, 1
F Alarms, 3
change gears, 2
filter, 10
Full-Scale Reading, 10 state, 10
transmission filter switch, 10
Transmission Oil Pressure, 10
Page 16
INSTALLATION AND SERVICE RECOMMENDATIONS
FOR SHELL AND TUBE HEAT EXCHANGERS
Installation
The satisfactory use of this heat exchange equipment is dependent upon certain
precautions that must be taken at the time of the installation.
1. Connect and circulate the hot fluid in the shell side (over small tubes) and
the cooling water in the tube side (inside small tubes). Note piping
diagrams
2. If an automatic water-regulating valve is used, place it on the INLET end

of the cooler. Arrange the water outlet piping so that the exchanger
remains flooded with water, but at little or no pressure. The temperature
probe is placed in the hydraulic reservoir to sense a system temperature
rise. Write the factory for water regulating valve recommendations.
3. There are normally no restrictions as to how this cooler may be mounted.

The only limitation regarding the mounting of this equipment is the
possibility of having to drain either the water or the oil chambers after the
cooler has been installed. Both fluid drain plugs should be located on the
bottom of the cooler to accomplish the draining of the fluids. Drains are on
most models.
4. It is possible to protect your cooler from high flow and pressure surges of
hot fluid by installing a fast-acting relief valve in the inlet line to the cooler.
5. It is recommended that water strainers be installed ahead of this cooler

when the source of cooling water is from other than a municipal water
supply. Dirt and debris can plug the water passages very quickly,
rendering the cooler ineffective. Write the factory for water strainer
recommendations.
6. Fixed bundle heat exchangers are generally not recommended for steam
service. For steam service applications, a floating bundle exchanger is
required. Consult factory for selection assistance.
7. Piping must be properly supported to prevent excess strain on the heat

exchanger ports. If excessive vibration is present, the use of shock
absorbing mounts and flexible connections is recommended.
Form 174 Page 1 December, 2000

Service
Each heat exchanger has been cleaned at the factory and should not require
further treatment. It may be well to inspect the unit to be sure that dirt or foreign
matter has not entered the unit during shipment. The heat exchanger should be
mounted firmly in place with pipe connections tight. Caution: If sealant tape is
used on pipe threads, the degree of resistance between mating parts is less, and
there is a greater chance for cracking the heat exchanger castings. Do not
overtighten. When storing the unit, be sure to keep the oil and water ports
sealed. If storage continues into the cold winter months, the water chamber must
be drained to prevent damage by freezing.
Performance information should be noted and recorded on newly installed units

so that any reduction in effectiveness can be detected. Any loss in efficiency can
normally be traced to an accumulation of oil sludge, or water scale.
Replace gaskets when removing end castings.
It may be necessary to drain the water chambers of the exchanger to protect it

from damage by freezing temperatures. Drains are provided in most standard
modules.
The oil chamber of the exchanger may become filled with sludge accumulation
and require cleaning. It is recommended that the unit be flooded with a
commercial solvent and left to soak for one-half hour. Backflowing with the
solvent or regular oil will remove most of the sludge. Repeated soaking and
backflowing may be required, depending on the degree of sludge buildup.
It may be necessary to clean the inside of the cooling tubes to remove any
contamination and/or scale buildup. It is recommended that a fifty-fifty percent
solution of inhibited muriatic acid and water may be used. For severe problems,
the use of a brush through the tubes may be of some help. Be sure to use a soft-
bristled brush to prevent scoring of the tube surface that can cause accelerated
corrosion. Upon completion of cleaning, be certain that all chemicals are
removed from the shellside and the tubeside before the heat exchanger is placed
into service.
When ordering replacement parts or making and injury regarding service,

Mention model number, serial number and the original purchase order number.
Form 174 Page 2 December, 2000

IPS CARBON STEEL PIPE
GROOVED COUPLINGS 06.04
R
Style 77
Standard
Flexible Coupling
PRODUCT DESCRIPTION with Vic-Plus Gasket System
TM
Style 77 couplings are Independent testing has during and after earth-
designed with cross-ribbed shown the Style 77 cou- quake conditions. Refer to
construction to provide a pling to be an effective 26.05 for further informa-
strong component for pres- stress relief and vibration tion.
sure piping attenuation device provid-
systems. Sizes -12" (26,7 ing performance superior to Vic-Plus Gasket System:
- 323,9 mm) are two-piece braided steel and elasto- Victaulic now offers a gas-
housings. Sizes 14 - 22" meric arch-type connec- ket system which requires
(355,6 - 559,0 mm) are cast tors when used in close no field lubrication. The
in four identical segments, proximity to the source of Vic-PlusTM System (patent
with larger sizes cast in six vibration. Refer to 26.04 for pending) is dry, clean, and
segments. This eases han- vibration information. non-toxic. It reduces
dling and assures concen- assembly time substantially
tricity. Independent testing has and eliminates the mess
shown that Victaulic Style and chance of over-
All sizes are provided with 77 and 75 flexible couplings lubrication.
plated bolts and nuts. Gal- and Style 07 Zero-Flex
vanized and stainless steel rigid couplings provide
housings are also available. exceptional functionality
06.04-1B
Deflect. Fr. Dimensions

DIMENSIONS SIZE Max. Max. Allow.
Pipe CL
@
Inches/millimeters
Aprx.
Nominal Work End Bolt/Nut Wgt.
Y Z Inches Pres. Load End Per Pipe No. - Size Each
Actual PSI* Lbs.* Sep. Cplg. In./Ft. Inches Lbs.
mm kPa N In./mm Deg. mm/m mm X Y Z kg
1,000 865 0 - 0.06 0.72 2.13 4.00 1.75 1.1
X 26,7 6900 3850 0 - 1,6 3 24 60 2 - 2 54 102 44 0,5
1 1,000 1,360 0 - 0.06 0.57 2.38 4.12 1.75 1.2
33,4 6900 6050 0 - 1,6 2 43 48 2 - 2 61 105 44 0,5
1 1,000 2,160 0 - 0.06 0.45 2.65 5.00 1.88 2.0
2 10 2 - 2
- 12" Sizes 42,2 6900 9610 0 - 1,6 38 67 127 48 0,9
1 1,000 2,835 0 - 0.06 0.40 3.13 5.38 1.88 2.1
48,3 6900 12615 0 - 1,6 1 56 33 2 - 2 79 137 48 1,0
2 1,000 4,430 0 - 0.06 0.32 3.63 5.88 1.88 2.6
60,3 6900 19715 0 - 1,6 1 31 26 2 - 2 92 149 48 1,2
2 1,000 6,490 0 - 0.06 0.26 4.25 6.50 1.88 3.1
73,0 6900 28880 0 - 1,6 1 15 22 2 - 2 108 165 48 1,4
3 O.D. 1,000 7,070 0 - 0.06 0.26 4.38 6.63 1.88 3.2
76,1 6900 31460 0 - 1,6 1 12 22 2 - 2 111 168 48 1,5
3 1,000 9,620 0 - 0.06 0.22 5.00 7.13 1.88 3.7
88,9 6900 46810 0 - 1,6 1 2 18 2 - 2 127 181 48 1,7
3 1,000 12,565 0 - 0.06 0.19 5.63 8.25 1.88 5.6
101,6 6900 55915 0 - 1,6 0 54 16 2 - 3 143 210 48 2,5
4 1,000 15,900 0 - 0.13 0.34 6.13 8.88 2.13 6.7
114,3 6900 70755 0 - 3,2 1 36 28 2 - 3 156 226 54 3,0
4 O.D. 1,000 14,180 0 - 0.13 0.35 2 - 16 82.5 6.00 8.63 2.13 11.0
108,0 6900 63100 0 - 3,2 1 41 29 152 219 54 5,0
5 1,000 24,300 0 - 0.13 0.27 7.75 10.65 2.13 10.6
141,3 6900 108135 0 - 3,2 1 18 23 2 - 4 197 270 54 4,8
5 O.D. 1,000 21,635 0 - 0.13 0.28 2 - 20 108 7.63 10.38 2.13 10.0
133,0 6900 96275 0 - 3,2 1 21 24 194 264 54 4,5
5 O.D. 1,000 23,745 0 - 0.13 0.28 2 - 20 108 8.63 10.65 2.13 10.0
139,7 6900 105665 0 - 3,2 1 18 24 219 270 54 4,5
6 1,000 34,470 0 - 0.13 0.23 8.63 11.88 2.13 12.0
168,3 6900 153390 0 - 3,2 1 5 18 2 - 4 219 302 54 5,4
6 O.D. 1,000 30,665 0 - 0.13 0.24 2 - 20 108 8.63 11.50 2.13 13.2
159,0 6900 136460 0 - 3,2 1 9 20 219 292 54 6,0
6 O.D. 1,000 33,185 0 - 0.13 0.23 8.88 11.63 2.13 13.2
165,1 6900 147660 0 - 3,2 1 6 19 2 - 4 226 295 54 6,0
8 800 46,740 0 - 0.13 0.18 11.00 14.75 2.50 20.8
219,1 5500 207995 0 - 3,2 0 50 14 2 - 5 279 375 63 9,4
Table continued on page 2. *@ Refer to notes on page 2.
Victaulic World Headquarters P.O. Box 31, Easton, PA 18044-0031 4901 Kesslersville Rd., Easton, PA 18040 1-800-PICK VIC FAX: 610/250-8817 www.victaulic.com
1469 Rev.C 10/00 Registered Trademark of Victaulic Copyright 1999 Victaulic Printed in U.S.A.
DIMENSIONS
06.04-1B
Y Z
Max. Max. Allow. Deflect. Fr. @ Dimensions Aprx.
SIZE CL Inches/millimeters
Nominal Work End Pipe Bolt/Nut Wgt.
Inches Pres. Load End Per Pipe No. - Size Each
Actual PSI* Lbs.* Sep. In. Cplg. In./Ft. Inches Lbs.
mm kPa N mm Deg. mm/m mm X Y Z kg
X
10 800 73,280 0 - 0.13 0.14 13.63 17.13 2.63 31.1
273,0 5500 326100 0 - 3,2 0 40 12 2-1 6 346 435 67 14,1
12 800 102,000 0 - 0.13 0.12 15.63 19.25 2.63 27.8
323,9 5500 453900 0 - 3,2 0 34 9 2 - 1 6 397 489 67 12,6
14 300 46,180 0 - 0.13 0.11 16.63 19.88 2.88 35.6
14 - 22" Sizes 355,6 2065 205500 0 - 3,2 0 31 9 4 - 1 3 422 505 73 16,1
15 300 53,000 0 - 0.13 0.10 17.88 21.63 3.00 48.8
381,0 2065 235850 0 - 3,2 0 29 9 4 - 1 5 454 549 76 22,1
Y Z
16 300 60,320 0 - 0.13 0.10 19.00 22.13 3.00 51.1
406,4 2065 268425 0 - 3,2 0 27 9 4 - 1 3 482 562 76 23,2
18 300 76,340 0 - 0.13 0.08 21.38 24.50 3.13 64.4
457,2 2065 339710 0 - 3,2 0 24 7 4 - 1 3 543 622 80 29,2
20 300 94,000 0 - 0.13 0.08 23.63 27.25 3.13 91.2
X 508,0 2065 418300 0 - 3,2 0 22 7 4 - 1 4 600 692 80 41,4
22 300 114,000 0 - 0.13 0.07 25.75 29.50 3.13 92.0
559,0 2065 507300 0 - 3,2 0 19 6 4 - 1 4 654 749 80 41,7
24 250 113,000 0 - 0.13 0.07 27.75 31.25 3.13 94.0
609,6 1725 502850 0 - 3,2 0 18 6 6 - 1 4 704 794 80 42,6
24" Sizes Couplings 8, 10, 12" (219,1, 273,0, 323,9 mm) sizes available to JIS standards. Refer to Section 06.17 for details.
*@ Refer to notes below.
MATERIAL SPECIFICATIONS
Housing: Ductile iron conform- cold +86F (+30C) and hot should be noted that there are
ing to ASTM A-395, grade 65- +180F (+82C) potable water services for which these gaskets
45-15, and ASTM A-536, grade service. NOT RECOM- are not recommended. Refer-
65-45-12. MENDED FOR PETROLEUM ence should always be made to
Housing Coating: Orange SERVICES. the latest Victaulic Gasket
enamel Grade T nitrile Selection Guide for specific gas-
Optional: Hot dipped galva- Vic-Plus Gasket System ket service recommendations
nized and others Nitrile (Orange color code). and for a listing of services
Coupling Gasket: (specify Temperature range 20F to which are not recommended.
choice*) +180F (29C to +82C). Bolts/Nuts: Heat treated car-
Grade E EPDM Recommended for petroleum bon steel, zinc electroplated to
Vic-Plus Gasket System products, air with oil vapors, ASTM B633, track-head con-
EPDM (Green color code). vegetable and mineral oils forming to physical properties of
Temperature range 30F to within the specified tempera- ASTM A-183 minimum tensile
+230F (34C to +110C). ture range. Not recom- 110,000 PSI (758340 kPa).
Recommended for hot water mended for hot water Supplemental lubricant is rec-
service within the specified services over +150F (+66C) ommended for services installed
temperature range plus a or for hot dry air over +140F at or continuously operating
variety of dilute acids, oil-free (+60C). below 0F (18C).
air and many chemical ser- *Services listed are General Ser- Optional: Type 316 stainless
vices. UL classified in accor- vice Recommendations only. It steel, Grade B-8M, Class 2.
dance with ANSI/NSF 61 for
NOTES
* Working Pressure and End Load are total, from all internal and external loads, based on standard weight (ANSI) steel pipe, standard roll or cut grooved in accor-
dance with Victaulic specifications. Contact Victaulic for performance on other pipe.
WARNING: FOR ONE TIME FIELD TEST ONLY, the Maximum Joint Working Pressure may be increased to 1 times the figures shown.
Allowable Pipe End Separation and Deflection figures show the maximum nominal range of movement available at each joint for standard roll grooved pipe.
Figures for standard cut grooved pipe may be doubled. These figures are maximums; for design and installation purposes these figures should be reduced by:
50% for - 3" (26,7 - 101,6 mm); 25% for 4" (114,3 mm) and larger.
@ Number of bolts required equals number of housing segments.
Metric thread size bolts are available (color coded gold) for all coupling sizes upon request. Contact Victaulic for details.
WARNING: Piping systems must always be depressurized and drained before attempting disassembly and removal of any Victaulic piping products.
This product shall be manufactured by Victaulic Company. All products shall be installed in accordance with current Victaulic installation/assembly instructions.
Victaulic reserves the right to change product specifications, designs and standard equipment without notice and without incurring obligations.
06.04 - 2
Zinga Web Catalog - Parts Page 1 of 3
SS & MS SERIES
INTERNALLY MOUNTED
TANK FILTER
Port Size: 3/8" Thru 6" NPTF
Standard: 100 Mesh
Optional: 30, 60 & 200 Mesh
3 PSI(6" Hg) or 5 PSI (10" Hg) optional by-pass valve
(A) Outlet (B) Wrench (C) Overall (D) Rated Flow Cap
Model
Port Flat Length OD AT 5 Ft/Sec
MS-030-
3/8 NPTF 1.20" 2.6" 1.1" 3 GPM
X-0*
SS-030-X-
3/8" NPTF 1.13" 2.2" 3.2" 3 GPM
O*
MS-050-
1/2" NPTF 1.20" 2.6" 1.1" 5 GPM
X-0*
SS-050-X-
1/2" NPTF 1.13" 2.2" 3.2" 5GPM
0*
MS-070-
3/4" NPTF 1.50" 3.9" 1.5" 8 GPM
X-X
SS-070-X-
3/4" NPTF 1.75" 3.6" 3.2" 8 GPM
X
MS-100-
1" NPTF 1.75" 3.9" 1.7" 14 GPM
X-X
SS-100-X-
1" NPTF 1.75" 4.6" 3.2" 14 GPM
X
SS-120-X- 1 1/4"
2.25" 6.6" 3.2" 23 GPM
X NPTF
SS-150-X- 1 1/2"
2.25" 8.6" 3.2" 32 GPM
http://www.zinga.com/dispart.php?part_ID=3 08/12/2002
SS-150-X- 1 1/2"
2.25" 8.6" 3.2" 32 GPM
X NPTF
SS-154-X- 1 1/2"
2.25" 7.2" 4.2" 32 GPM
X NPTF
SS-200-X-
2" NPTF 3.00" 7.2" 4.2" 53 GPM
X
SS-250-X- 2 1/2"
3.50" 9.3" 4.2" 75 GPM
X NPTF
SS-300-X-
3" NPTF 4.00" 12.4" 4.2" 116 GPM
X
SS-400-X-
4" NPTF N/A 20.1" 9.0" 275 GPM
X
SS-600-X-
6" NPTF N/A 20.1" 9.0" 600 GPM
X
ZINGA
EXCLUSIVE
All Zinga Series tank
filters have a reverse
taper on the outside
wall of the end caps.
This ensures a
positive interlock with
the epoxy edge side.
Thus preventing bond
failure in rough
terrain vehicle
applications.
Design Features:
All MS, SS & TF Series models offer rated flow capacities 5 FPS
outlet line velocities at under 1" Hg (1/2 PSI) pressure drop (with 150
S.U.S. oil).
All MS, SS & TF Series models suitable for use with All petroleum
base oils, fire resistant hydraulic fluids, coolants, and lubricants.
How To Order: MS-XXX - X - X

Sample Order Numbers are Color Coded
to Match Corresponding Tables
http://www.zinga.com/dispart.php?part_ID=3 08/12/2002
Model Code Wire Mesh Code By-Pass Valve

MS or SS Series 0 100 Mesh (Std.) 0 No Valve
2 200 Mesh 3
3 30 Mesh 5
6 60 Mesh *By-Pass Valve Not Available
These Models
Zinga Industries, Inc.

2400 Zinga Drive Reedsburg, WI 53959 US
Phone: (608) 524-4200 Fax: (608) 524-4220
Contact Us
Zinga Industries Europe

3 Brunell Business Court Thetford, Norfolk England IP24 3ND
Phone: 44 1842 820 799 Fax: 44 1842 752 424
Canadian Distribution Center

CFA Industries, Inc. Aurora, Ontario
Phone: (905) 713-3926 Fax: (905) 713-3927
Catalog 14

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FT-2251 Trailer-Mounted

Stewart & Stevenson Well Servicing Products

City: State: Zip Code:

Date of original publication: July 2006

Revision Number Date Brief Description

This manual is copyrighted as an unpublished work.

Copyright 2006 by Stewart & Stevenson. All rights reserved.

ABOUT THIS MANUAL

Most manuals have a manufacturers section containing information supplied by vendors of

Stewart & Stevenson

Stewart & Stevenson

For Parts: (281) 345-5100; ask for Parts Department.

Do not use the Operators Manual to order parts. If parts or main-

Chapter 1 Description and Specifications

TABLE OF CONTENTS (Cont)

Safety warnings MUST be followed. Failure to do so may result in

NOTE: is used to notify people of information that is IMPORTANT,

Always use caution when working around rotating equipment. Se-

DO NOT LEAVE ZERK FITTINGS INSTALLED ON HIGH-PRESSURE

Hot metals can cause severe burns and/or injury to personnel.

Exercise extreme caution when performing maintenance on the

Prior to hoisting equipment, ensure that no loose bars, tools, parts,

Leaking joints, fittings, and connections must be tightened only

When cleaning, use only an approved solvent to prevent damage

Use CAUTION when tightening brass fittings. They are easily

The return connector MUST be connected before any system is

Particular care should be taken when working in or around seal-

Personnel must clear all pumps during operation. There is a clear

Never place hands in area of reciprocating pony rod or plunger

Each pump is clearly marked with a maximum pressure rating. This

Each pump is clearly marked with a maximum horsepower rating.

Well service pumps should never be used to pump gaseous, ex-

Any repairs or service (routine maintenance) performed on the

PUMP SAFETY (Cont)

It is a personal responsibility to use the proper tools when servic-

It is a personal responsibility to be knowledgeable and trained in

Personnel should only hammer on the hammer wrench provided

Personnel should never hammer on one of the valve retainer nuts

The pumps discharge connections should be properly cleaned

A complete visual inspection of the pumps power end and fluid

If a pump is used in a place where permanent piping is to be at-

PUMP SAFETY (Cont)

All fluid cylinders must be disassembled and dimensionally in-

All fluid cylinders must be disassembled and inspected for cracks

All fluid cylinders should be hydrostatically tested at least twice

All threaded components are right-hand threaded unless specifi-

All products should be properly cleaned, greased, or oiled after

PUMP SAFETY (Cont)

All fluid cylinder mounting nuts must be checked routinely with a

Weight (on rear axles) 34,000 lb (15,422 kg)

Weight (on kingpin) 26,000 lb (11,793 kg)

1.2 ASSEMBLY DESCRIPTION

1.2.1 POWER UNIT

A positive displacement, gear-type scavenging pump is provided for transmission lubrication. An

Figure 1.2, Transmission Cooling System

1.2.3 ENGINE TRANSMISSION MOUNTING

1.2.4 PUMP ASSEMBLY

1.2.4.1 TRIPLEX PUMP

Figure 1.3, Typical Triplex Pump Assembly

1.2.4.2 SUCTION MANIFOLD

The butterfly valves must be removed before use with CO2.

1.2.4.4 FLUID END LUBRICATION

1.2.4.5 POWER END LUBRICATION