P.T.O. INSTALLATION 1 2 For manual shift transmissions, drain transmission fluid. For automatic transmissions, do NOT drain transmission fluid. Remove

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P.T.O. INSTALLATION 1 2 For manual shift transmissions, drain transmission fluid. For automatic transmissions, do NOT drain transmission fluid. Remove cover plate.

7 P.T.O. INSTALLATION 1 2 For manual shift transmissions, drain transmission fluid. For automatic transmissions, do NOT drain transmission fluid. Remove cover plate. 3 Place a clean rag in the opening to prevent dirt from getting in the transmission. Clean mounting pad with spatula or wire brush. Remove rag from transmission. 4 Install the studs supplied. Torque the studs to lbs.-ft. (6 bolt pad) or lbs.-ft. (8 bolt pad). 5 Place mounting gasket/shim over studs. A thin coating of grease is recommended to seal and hold gasket/shim in place. Do not use a permanent sealant. Use grease only!! Ensure that between the teeth of the gearbox and those in the Power Take-off is a backlash of mm N.B. Do not use more than 3 gasket/shims. 6 Fit the Power Take-off to the gearbox. On the Power Take-off there is a cap which, if unscrewed, is large enough to allow manual checking of backlash between the Power Take-off and the gears of the gearbox. The correct fitting of the P.T.O. is influenced by the fitters ability to correctly fit the P.T.O., by firstly tightening the lock nuts to a minimum torque and to operate the P.T.O. for a short period remembering that the gearbox and the P.T.O. are turning without oil. This allows the gears in the gearbox to self-align and also you are able to check for any excessive noise. FITTING INSTRUCTIONS 7 Fit the Power Take-off tightly onto the gearbox. Remember to use a washer and loctite. Torque the nuts to 20 lbs.-ft. for M8 threads and 40 lbs.-ft. for M10 threads. Re-fill the gearbox with oil. Note: Before re-filling the gearbox with oil it is advisable to check the noise level of the Power Take-off by using it for a short time (remembering that at this moment there is no lubricant in the gearbox). If the Power Take-off produces a hissing noise, this means that there is insufficient backlash in which case another shim must be added. If the Power Take-off rattles, this indicates that there is too much backlash and the number of shims must be reduced. Once the gearbox has been re-filled with oil, make sure there are no leaks. If the Power Take-off becomes noisy after the additional assembly of a universal joint, make sure that the joint is not worn, nor the alignment angles are not out of phase. When using Power Take-off's in conjunction with universal joints the maximum recommended angle is 15 PAGE 2 CATAUG-5.P65/P2

CONTROL VALVES CONTROL VALVE 60L 2000 psi 1/2" BSP PART No. 4592-11012 PART No. 4592-11022 PART No. 4592-11025 PART No. 4592-12062 PART No. 4592-12065 PART No. 4592-13112 PART No. 4592-13115 PART No.

8 CONTROL VALVES CONTROL VALVE 60L 2000 psi 1/2" BSP PART No PART No PART No PART No PART No PART No PART No PART No PART No PART No "S" "D" "D" "DD" "DD" "DDD" "DDD" "DDDD" "DDDD" "DDDDD" (S/A SINGLE SPOOL) (D/A SINGLE SPOOL) (D/A SINGLE SPOOL) (D/A TWO SPOOLS) (D/A TWO SPOOLS) (D/A THREE SPOOLS) (D/A THREE SPOOLS) (D/A FOUR SPOOLS) (D/A FOUR SPOOLS) (D/A FIVE SPOOLS) CONTROL VALVE 120L 2000 psi 3/4" BSP PART No A PART No S RELIEF ASSEMBLY (S/A SINGLE SPOOL) PART No PART No PART No PART No PART No PART No PART No PART No PART No PART No PART No PART No PART No PART No S HI-FLOW D HI-FLOW D S/C D DETENT SS SD D UN ORING DS DD DD HI-FLOW DD DDD DDDD DDDD (S/A SINGLE SPOOL) (D/A SINGLE SPOOL) (D/A SINGLE SPOOL SPRING CENTRE) (D/A SINGLE SPOOL DETENT) (S/A TWO SPOOLS) (S/A SPOOL & D/A SPOOL) (D/A SINGLE SPOOL) (D/A SPOOL & S/A SPOOL) (D/A TWO SPOOLS) (D/A TWO SPOOLS) (D/A TWO SPOOLS) (D/A THREE SPOOLS) (D/A FOUR SPOOLS) (D/A FOUR SPOOLS) VALVES CATAUG-5.P65/P9 PAGE 3

ENGINEERS & MANUFACTURERS OF HYDRAULIC TRUCK EQUIPMENT. HOIST CONTROL VALVES TRUCK TRAILER VALVE (DUAL SPOOL) 110L PART No. 4592-32032 TRUCK TRAILER VALVE (SINGLE SPOOL) 110L PART No.

4193-00141 CABLE DIVERTER VALVE 110 LITRE PART No. 4592-01001 CABLE DIVERTER VALVE 250 LITRE PART No. 4592-901011 NOTE *** MULTI-FUNCTION VALVES ALSO AVAILABLE.

9 ENGINEERS & MANUFACTURERS OF HYDRAULIC TRUCK EQUIPMENT. HOIST CONTROL VALVES TRUCK TRAILER VALVE (DUAL SPOOL) 110L PART No TRUCK TRAILER VALVE (SINGLE SPOOL) 110L PART No WOMBAT VALVE PART No TIPPER VALVE 170 LITRE PART No TIPPER VALVE 100 LITRE PART No CABLE TIPPER VALVE 60 LITRE PART No CABLE DIVERTER VALVE 110 LITRE PART No CABLE DIVERTER VALVE 250 LITRE PART No NOTE *** MULTI-FUNCTION VALVES ALSO AVAILABLE. OPERATED HOIST CONTROL VALVE These models are Modular 3 position 3 way open centre, air operated valves. These valves have specifically been designed for medium flows and quick turn around. The medium flow valve's features are built in check on pump side and relief valve, a pressure range upto 345 bars (5000 psi), manual override in case of air loss, and by using the appropriate air control, progressive lowering can be obtained. FROM PUMP 1/2 BSP TO HOIST 1/2 BSP IN TO LOWER IN TO LOWER IN TO RAISE TO TANK 1 BSP (UNDERSIDE NOT SHOWN) TO TANK 3/4 BSP (UNDERSIDE NOT SHOWN) IN TO RAISE TO HOIST 1 BSP FROM PUMP 3/4 BSP PART No (70 L/min ) PART No (170 L/min ) TECHNICAL DETAILS VALVES Flow 70 L/min flow rate PART No L/min flow rate PART No Pressure Preset maximum working pressure is 138 Bar (2000 psi) Air supply Min. 5 bar. (72.5 psi) Max 9 bar. (130.6 psi) PAGE 4 CATAUG-5.P65/P4

ENGINEERS & MANUFACTURERS OF HYDRAULIC TRUCK EQUIPMENT. OPERATED HYDRAULIC HOIST CONTROL VALVE "WOMBAT MODEL" PART No.

position open centre, 12 Volt electrically operated valve. This valve has specifically been designed for medium flows for quick turn around.

The unit is electrically operated eliminating the need to fit cables and levers in the cabin. OUT This unit is also available in 24 Volt Part No.

10 ENGINEERS & MANUFACTURERS OF HYDRAULIC TRUCK EQUIPMENT. OPERATED HYDRAULIC HOIST CONTROL VALVE "WOMBAT MODEL" PART No BACK VIEW IN TO RAISE FRONT VIEW FROM PUMP IN TO LOWER FROM PUMP TO HOIST TO TANK ELECTRICALLY OPERATED HOIST CONTROL VALVE Model is a Modular 3 position open centre, 12 Volt electrically operated valve. This valve has specifically been designed for medium flows for quick turn around. The valve features a built in check on pump side and relief valve, with a pressure range upto 250 bars (3625 psi). The unit is electrically operated eliminating the need to fit cables and levers in the cabin. OUT This unit is also available in 24 Volt Part No Solenoid 12 Volt Normally open Solenoid 12 Volt Normally closed IN 1/2" BSP IN TANK TECHNICAL DETAILS Flow 40 L/min flow rate Pressure TO TANK 1/2" BSP Preset maximum working pressure is 138 Bar (2000 psi) but capable of being reset to 250 bars (3625 psi) OUT 1/2" BSP Pressure switch VALVES Mass 2.0 Kg. CATAUG-5.P65/P3 PAGE 5

VALVES OPERATED HYDRAULIC HOIST CONTROL VALVE DIVERTER VALVE 3/4" BSP () (DOUBLE PRESSURE) 250L 2000 psi 1" BSP PART No.

4592-901011 FLOW CONTROL VALVE 0-30GPM 2000 psi 3/4" NPT PART No. 4592-20025 RESTRICTOR VALVE PART No. 4592-20023 PART No.

4592-20002 3/8" BSP 1/2" BSP V1 V2 RESTRICTOR VALVE C1 C2 VALVES PART No. 4592-20020 PART No. 4592-20021 PART No.

11 VALVES OPERATED HYDRAULIC HOIST CONTROL VALVE DIVERTER VALVE 3/4" BSP () (DOUBLE PRESSURE) 250L 2000 psi 1" BSP PART No L PART No DIVERTER VALVE 1" BSP () ACCELERATOR VALVE PART No L PART No FLOW CONTROL VALVE 0-30GPM 2000 psi 3/4" NPT PART No RESTRICTOR VALVE PART No PART No /8 BSP 1/2 BSP PILOT OPERATED D/A CHECK VALVE PART No PART No /8" BSP 1/2" BSP V1 V2 RESTRICTOR VALVE C1 C2 VALVES PART No PART No PART No /8" BSP 1/2" BSP 3/4" BSP OVERCENTRE VALVE PART No PART No PART No /2" BSP 1/2" BSP 3/4" BSP V Pilot C PAGE 6 CATAUG-5.P65/P8

12 CYLINDER (415mm CRS.) CYLINDER (LOCKING PIN) (TAIL GATE OR LOCKABLE BALL RACE) (SUIT CAR CARRIER) CYLINDER PART No SEAL KIT PART No K CYLINDER (BARE) SHORT CENTRES (360mm) (TAIL GATE OR LOCKABLE BALL RACE) PART No BOOSTER TYPE 30 PART No MAXI BRAKE TYPE 30/30 CYLINDER PART No SEAL KIT PART No K CYLINDER (ASSEMBLY) SHORT CENTRES (360mm) PART No HOLD BACK VALVE (TAIL GATE OR LOCKABLE BALL RACE) PART No PILOT TYPE PART No CYLINDER (ASSEMBLY) SHORT CENTRES (360mm) DUO MATIC PART No FEMALE PART No (TAIL GATE OR LOCKABLE BALL RACE) SOLENOID TYPE 12 Volt ASSEMBLY PART No Volt ASSEMBLY PART No CYLINDER (SMALL) DOUBLE ACTING PART No SPRING RETURN PART No MALE PART No BRAKE LINE BULKHEAD 1/2" BSP PART No CONTROLS CATAUG-1.P65/P5 PAGE 7

DIVERTER VALVE FITTING INSTRUCTION NORMALLY CLOSED NORMALLY OPEN DIVERTER VALVE (SPRING OFFSET)

(SOLENOID TYPE SWITCH) DIVERTER VALVE (SPRING OFFSET) IN (P) EXHAUST (R) SWITCH S/ACTING 12V OR

INSTRUCTION (REMOTE TYPE SWITCH) DIVERTER VALVE (SPRING OFFSET) IN (P) EXHAUST (R) S/ACTING PILOT

13 DIVERTER VALVE FITTING INSTRUCTION NORMALLY CLOSED NORMALLY OPEN DIVERTER VALVE (SPRING OFFSET) PUSH / PULL S/A SWITCH SUPPLY IN (KNOB OUT) EXHAUST (KNOB IN) DIVERTER VALVE FITTING INSTRUCTION (SOLENOID TYPE SWITCH) DIVERTER VALVE (SPRING OFFSET) IN (P) EXHAUST (R) SWITCH S/ACTING 12V OR 24V SOLENOID NORMALLY CLOSED OVERRIDE NORMALLY OPEN PORT A (N/O) DIVERTER VALVE FITTING INSTRUCTION (REMOTE TYPE SWITCH) DIVERTER VALVE (SPRING OFFSET) IN (P) EXHAUST (R) S/ACTING PILOT SWITCH NORMALLY CLOSED NORMALLY OPEN FROM SWITCH IN CABIN PORT A (N/O) FITTING INSTRUCTIONS CATAUG-3.P65/P9 PAGE 17

14 This schematic diagram shows the layout of Air control lines and connections to the Hoist Hydraulic single control lever and valve system. This schematic diagram shows the layout of Air control lines and electrical wiring connections to the Hoist Hydraulic dual control lever and valve system. FITTING INSTRUCTIONS CATAUG-4.P65/P9 PAGE 19

POWER PACK SOLENOID TYPE 12V S/A 12V D/A 24V S/A 24V D/A 5 LITRE PART No. 4599-12031 PART No. 4599-12031D 10 LITRE PART No. 4599-12101 PART No. 4599-12101D 15 LITRE PART No. 4599-12151 PART No.

15 POWER PACK SOLENOID TYPE 12V S/A 12V D/A 24V S/A 24V D/A 5 LITRE PART No PART No D 10 LITRE PART No PART No D 15 LITRE PART No PART No D 20 LITRE PART No PART No D 34 LITRE PART No PART No D 48 LITRE PART No PART No D 5 LITRE PART No PART No D 10 LITRE PART No PART No D 15 LITRE PART No PART No D 20 LITRE PART No PART No D 34 LITRE PART No PART No D 48 LITRE PART No PART No D WIRING DIAGRAMS FOR SINGLE ACTING SOLENOID VALVES WIRING DIAGRAMS FOR DOUBLE ACTING SOLENOID VALVES WARNING LIGHT IF REQUIRED PUSH LOWER TOGGLE SWITCH SINGLE POLE DOUBLE HOLD THROW RAISE LOWER PUSH RAISE FUSE PRESSURE SWITCH FUSE POWER PACKS HOLD LOWER RAISE WARNING LIGHT IF REQUIRED FUSE PRESSURE SWITCH PUSH RAISE WARNING LIGHT IF REQUIRED PUSH LOWER RELAY NORMALLY OPEN COIL FUSE PAGE 24 CATAUG-4.P65/P6

16 P.T.O. CABLE PART No INNER WIRE & KNOB ONLY 3.0M PART No INNER WIRE & KNOB ONLY 4.5M PART No CABLE KIT (ADJUSTABLE) 3.0M PART No CABLE KIT (ADJUSTABLE) 4.5M VALVE CABLE PART No CABLE KIT 1.0m PART No CABLE KIT 1.5m PART No CABLE KIT 2.0m PART No CABLE KIT 2.5m PART No CABLE KIT 3.0m PART No CABLE KIT 3.5m PART No CABLE KIT 4.0m PART No CABLE KIT 4.5m PART No CABLE KIT 5.0m PART No CABLE KIT 6.0m PART No CABLE ONLY PART No CABLE ONLY PART No CABLE ONLY PART No CABLE ONLY PART No CABLE ONLY PART No CABLE ONLY PART No CABLE ONLY PART No CABLE ONLY PART No CABLE ONLY PART No CABLE ONLY PART No INNER WIRE ONLY PER METRE PART No VALVE CABLE POST PART No PTO CABLE POST PART No PTO CABLE POST (METRIC) CABLES PART No PTO CABLE INSERT PAGE 26 CATAUG-3.P65/P4

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