TBL280 Mk4 SPARE PARTS MANUAL

Transcription

1 TBL280 Mk4 SPARE PARTS MANUAL

2 SPARE PARTS MANUAL FOR DOUGLAS-KALMAR TUGMASTER MODEL TBL280 INDEX 1. CHASSIS AND ACCESSORIES 2. BODYWORK 3. AXLE AND ACCESSORIES 4. SUPPORT WHEELS AND SUSPENSION 5. ENGINE AND TRANSMISSION 6. TRANSFER BOX 7. NOSE WHEEL CRADLE 8. COOLING SYSTEM 9. INDUCTION SYSTEM 10. EXHAUST SYSTEM 11. FUEL SYSTEM 12. HYDRAULIC TANK ASSEMBLY 13. HYDRAULICS CHASSIS 14. PNEUMATICS CHASSIS 15. JUNCTION BOX ASSEMBLY 16. ELECTRICS CHASSIS 17. CAB ASSEMBLY 18. AUTOMATIC LUBRICATION SYSTEM 19. WHEELS AND TYRES 20. PAINT 21. NAMEPLATES 22. EXTERNAL MIRRORS 23 TOOL KIT ( IF REQUIRED) 24 OPTIONAL EXTRAS 25 AMENDMENTS/BULLETINS 26 FILTER KIT

3 FOREWORD Douglas Equipment, (the Company) reserves the right to change the specification, design, material, procedures and dimensions of the vehicle described within this manual without prior notice at any time in the future, in accordance with the company policy of continuous product improvement. The Company has taken every reasonable effort to supply an accurate and comprehensive guide to the safe and economic running of the vehicle. Following the instructions for basic maintenance will help to minimise down-time and prolong the vehicle life between major overhauls. ALL RIGHTS RESERVED No part of this publication may be reproduced, stored in any retrieval system or transmitted in any form without prior permission of Douglas Equipment, (the Company). Compiled and published by Technical Publications Department at the address below. Douglas Equipment A division of Curtiss-Wright Flow Control (UK) Limited Douglas House, Village Road, Arle, Cheltenham, Gloucestershire GL51 0AB, England Telephone: Fax:

4 MODEL: CHASSIS No: Douglas Equipment A division of Curtiss-Wright Flow Control (UK) Limited Douglas House, Village Road, Arle, Cheltenham, Gloucestershire GL51 0AB, England Telephone: Fax:

5 CHANGE OF OWNERSHIP FORM IN THE EVENT OF THIS TUGMASTER CHANGING OWNERS, PLEASE COMPLETE THIS FORM AND RETURN IT TO DOUGLAS EQUIPMENT, AT THE ADDRESS GIVEN BELOW. COMPANY NAME... COMPANY ADDRESS POSTAL CODE... TELEPHONE NUMBER... FAX NUMBER... DATE PURCHASED... MODEL: CHASSIS No: Douglas Equipment A division of Curtiss-Wright Flow Control (UK) Limited Douglas House, Village Road, Arle, Cheltenham, Gloucestershire GL51 0AB, England Telephone: Fax:

6 SERVICE BULLETINS FORWARDING ADDRESS DETAILS (To be completed BY THE CUSTOMER on first receipt of a new DOUGLAS Tugmaster) OCCASIONALLY, IT MAY BE NECESSARY FOR DOUGLAS EQUIPMENT TO SEND OUT SERVICE BULLETINS CONCERNING THIS NEW TRACTOR. TO ENSURE THESE DOCUMENTS REACH THE CORRECT AUTHORITIES, PLEASE COMPLETE THIS FORM AND RETURN IT TO THE AFTER SALES MANAGER, DOUGLAS EQUIPMENT, AT THE ADDRESS GIVEN BELOW. CUSTOMER COMPANY NAME... SERVICING AUTHORITY CONTACT ADDRESS POSTAL CODE... TELEPHONE NUMBER... FAX NUMBER... VEHICLE TYPE... CHASSIS NUMBER/S... Douglas Equipment A division of Curtiss-Wright Flow Control (UK) Limited Douglas House Village Road Cheltenham GLOS GL51 0AB Phone: +44 (0) Fax: +44 (0)

7 CHASSIS CONFORMITY PLATE When contacting the Service department, to assist you in looking after your vehicle, it is recommended that you have available the data from the Chassis Conformity Plate, (example shown above). This plate is fitted to the chassis frame and will have the unique chassis number for your vehicle. Douglas Equipment A division of Curtiss-Wright Flow Control (UK) Limited Douglas House, Village Road, Arle, Cheltenham, Gloucestershire GL51 0AB, England Telephone: Fax:

8 NOTE CHECK OPTIONAL EXTRAS SECTION BEFORE ORDERING SPARE PARTS

9 CHASSIS AND ACCESSORIES Page 1

10 TBL280 SPARE PARTS MANUAL CHASSIS & ACCESSORIES FIG S01970 sht1 1-3 Page 3

11 TBL280 SPARE PARTS MANUAL CHASSIS & ACCESSORIES FIG S01970 sht Page 5

12 TBL280 SPARE PARTS MANUAL CHASSIS & ACCESSORIES FIG S01970 Sht Page 7

13 TBL280 SPARE PARTS MANUAL CHASSIS AND ACCESSORIES S D45531/L Chassis frame assembly 1 2 D9891/1 Mounting bracket - emergency steering pump D Ultrabush D20 D40 I40 L D33585/S Plate-jacking point 2 5 D33588/S Pin jacking plate 2 6 D35301/S Pin cradle 4 7 D35736/P Cradle stop spring 2 8 D35740/S Washer - cradle stop spring 2 10 P1001/6/M Towing pin-2 diameter 1 11 TM1043/S Lock - tow pin D Bolt-M24 X 320 hex 8 13 D35640/S Shim plate-axle mounting D Shock absorber D Buffer D Bush D Thrust washer 8 18 D35198/S Pivot shaft - suspension assembly 2 19 D35995/S Washer - hinge pin D Flexible mounting - conical D Nitrile cap D Washer - rebound 6 23 D35372/S Washer - engine/transmission mounting 6 24 SK1949/S Cylinder - cradle lift D Spring disc DS1027/104/M Washer 20.5x50x6mm 2 27 D37967/S Adaptor - grease nipple D Air spring assembly (8 ) D Shock absorber D Clip terry D Crowbar (900 x diameter 25) D Disc brake-mechanical type D Nut - lock left hand M12x D35469/S Lever - brake caliper (MOD) D Bellows assembly /2 x D44152/P Stabiliser - cab - top 1 40 D44153/S Stabiliser - cab - front 1 41 D44154/S Stabiliser - cab - RH 1 42 D44155/S Stabiliser - cab - LH 1 43 D35423/S Mounting bracket - battery isolator 1 44 D22814/S Mounting bracket - air reservoir 1 45 D35411/S Mounting bracket - levelling valve 1 48 D33228/S Washer - ram pin 8 49 D41825/S Mounting bracket - R/L transducer 1 50 D35714/S Mounting bracket - flood light 1 51 D45504/S Modification to clamp plate Page

14 TBL280 SPARE PARTS MANUAL CHASSIS AND ACCESSORIES S D44537/S Bracket - hydraulic pipes ns - chassis to cradle 1 53 D44673/S Bolt - shock absorber 3 57 D44543/P Mounting plate - Danfoss valve 1 58 D44546/S Mounting bracket - air dryer 1 59 D44551/S Clamp plate - rear light pods 2 60 D44605/S Bracket - bump stop - inner o/s front 1 61 D44606/S Bracket - bump stop - outer o/s front D44504/S Mounting bracket - GPU fuel connectors D44720/S Clamping strip - mudflap - rear 4 64 D44721/S Clamping strip - mudflap lower 4 65 D44722/P Mudflap - rear wheel fwd 2 66 D44723/P Mudflap - rear lights D Buffer - rubber coned 2 68 D44859/S Mounting bracket - hydraulic pressure gauge 1 69 D45027/S Mounting bracket - washer bottle D Grip handle black 1 71 D35760/S Mounting - camera D Buffer 2 73 D45616 Mounting bracket - brake fluid reservoir D Insulation kit 1 75 D45537/S Mounting bracket - water pipe D Cap screw - airbag mounting 2 77 D38334/S Mounting bracket - battery box LH 1 78 D38335/S Mounting bracket - battery box RH D Slide assembly - closed 2 80 D38333/M Battery box 1 81 D38332/M Door - battery box 1 82 D40678/S Clamp - battery D Bolt - spring D Hardwood 55x110x D Hardwood 85x35x Page 10

15 DISC BRAKE - MECHANICAL 21492D ILL No. PART No. DESCRIPTION QTY Operating lever Operating lever Pin Brake spider (08054D) Spring (43173D) Adjusting screw Lock plate - spring (16593D) Locknut (09905D) Circlip (42282D) Seal (26226D) Brake pad c/w back plate (09906D) Washer (D35469/S) Brake lever - expander unit 1 Spares\21492d

16 BELLOWS ASSEMBLY /2 X 1 PNP (DB1416) 21447D ILL No. PART No. DESCRIPTION QTY. 1 DB1410 Bellows 1 2 DB1452 Clamping ring 2 3 DB1461 Clamp plate 1 4 DB1471 Clamp plate (air inlet) 1 Spares\21447d

17 BODYWORK Page 15

18 TBL280 SPARE PARTS MANUAL BODYWORK FIG S01977 sht Page 16

19 TBL280 SPARE PARTS MANUAL BODYWORK FIG S01977 sht Page 17

20 TBL280 SPARE PARTS MANUAL BODYWORK FIG S01977 sht Page 18

21 TBL280 SPARE PARTS MANUAL BODYWORK S D44773/S Spreader PLT body support RH top 1 2 D44160/P Bonnet front LH 1 3 D44161/P Bonnet top RH 1 4 D44162/P Bonnet top LH 1 5 D44186/P Grill front LH 1 6 D44187/P Grill front RH 1 7 D44188/P Grill LHS 1 8 D44189/P Grill RHS 1 9 D44190/P Grill RHS 1 16 D46704 Side Cabinet RH 1 17 D45625 Body Structure RH 1 18 D45626 Body Structure LH 1 19 D44184/S Body Support RH 1 20 D46703 Side body panel RH 1 21 D45686 Support body centre 1 22 D44192 Side body panel LH 1 23 D44212/P Cover panel support leg LH 1 24 D44213/P Cover panel support leg RH D Hinge continuous 3 26 D44215/S Cover/step support leg D Lever latch no key D Hinge flat c/w grease nipple D Spring gas D Carrier buffer strip D Buffer strip female 2 38 D42721/P Cover panel rear D Lifting ring SS flush fit D Spring latch slotted head riveted D Spring gas (locking) 1 42 D44429/P Mounting plate rear lights D Spring gas locking 1 44 D44435/M Light pod rear 2 45 D44436/M Cover cab entry D Spring gas D Handle recessed D Hinge flat c/w grease nipple D Handle D Buffer rubber D Spring gas 1 52 D42976 Grill 200x600 Aperture D Spring gas 1 54 D44416/M Decking plate top 1 55 D44417/M Decking plate front axle 1 56 D44421/M Decking plate cradle 1 57 D46708 Side cover LH 1 58 D46709 Side cover RH Page

22 TBL280 SPARE PARTS MANUAL BODYWORK S D44571/P Hatch cover front axle decking 1 60 D44512/S Support bracket rear bonnet o/s 1 61 D44413/P Support bracket rear bonnet 1 62 D44420/P Support bracket gas strut engine 1 63 D44408/S Mounting bonnet front RH 1 64 D44407/S Mounting bonnet front LH 1 66 D45521/M Cover junction box compartment D Foam adhesive back Neoprn D44733/S Guard plate front bonnet handle D Tape polyurethane facing D44525/S Bracker gas strut bonnet front D Spring gas locking 1 76 D44921/S Mounting Bracket gas spring D44159/M Bonnet front RH D Gas spring 2 79 D43709/S Buffer bracket 4 80 D45030 Plate reinforcement- BNT mirror 1 81 D44654/S Air intake engine 1 82 D45036 Plate sealing assembly 1 83 D45164 Mounting bracket bonnet catch upper 2 84 D45168 Mounting bracket bonnet catch 1 85 D45169 Mounting bracket bonnet catch lower D Retainer door D Anti slip kit D Bonnet foam kit 1 90 D45410 Heat shield plate assembly D Buffer rubber coned 2 92 D45542/S Mounting bracket side body panel RH 1 93 D44738/S Kick strip Cab entry Page 20

23 AXLE AND ACCESSORIES Page 21

24 TBL280 SPARE PARTS MANUAL AXLE & ACCESSORIES FIG S Page 22

25 TBL280 SPARE PARTS MANUAL AXLE & ACCESSORIES S D Axle - steer/drive - type LT D Nut - wheel N22F D35754/S Modification to axle plug D Switch - differential lock D Switch - oil temperature - 70º C D Transducer - safety angle 2 9 D40680/S Bracket - steering potentiometer 2 10 D40682/S Spacer - steering potentiometer D Rod end - spherical - M D Rod end - spherical - M8 L.H D38234/S Adjusting bar - L & R.H. thread - M D Nut - M8 L.H. thread 2 15 D43863/P Brake disc 1 16 D44113/S Pin - steering ram - front 2 17 SK2006/S Ram - steering - front D Ball joint - tapered - 1:10 - R.H.T D44607/S Support bracket - Brake cylinder - front N/S 1 20 D44608/S Support bracket - Brake cylinder - front O/S D Clamp - U bolt type - 1.⅞ 8 24 D44398/S Spacer - steering pin 2 25 D44670/S Support bracket - brake - cylinder - rear O/S 1 26 D44609/S Support bracket - brake - cylinder - rear N/S 1 27 D44472/S Brake pipe - front axle 2 28 D44719/P Front axle modification D Nut - M30 x 1.5 thin castle 4 30 D45184 Mounting bracket - brake hose - R.H D45185 Mounting bracket - brake hose - L.H Page

26 SPARE PARTS LIST FOR STEER/DRIVE AXLE LT81PL488NLB3340 ( a) 34206D Page 25

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44 SUPPORT WHEELS & SUSPENSION Page 43

45 TBL280 SPARE PARTS MANUAL SUPPORT WHEELS AND SUSPENSION FIG S01463 sht Page 45

46 TBL280 SPARE PARTS MANUAL SUPPORT WHEELS AND SUSPENSION FIG S01463 sht Page 46

47 TBL280 SPARE PARTS MANUAL SUPPORT WHEELS S D Actuator - brake - type SK1998/M Hub assembly - R.H. 1 3 SK1999/M Hub assembly - L.H. 1 4 D43845/M Suspension arm assembly - R.H. 1 5 D43846/M Suspension arm assembly - L.H. 1 7 D35199/S King pin - nose wheel 2 8 D35200/S Bush - king pin 4 9 D35201/S Thrust washer - king pin 4 10 D35203/S Retaining plate - king pin - bottom 2 12 DS1007/27/M Dowel - 6mm diameter x 10mm long 8 13 DS1027/102/M Washer - 13 x 55 x 6mm 4 14 D44100/S Spacer - steering ram D Clevis - ⅝" U.N.F. - 14mm pin 2 16 D40683/S Mounting bracket - sensor - steering 2 17 D35502/S Mounting bracket - potentiometer 2 19 D36965/S Lock pin - steering ram D Rod end - spherical - M8 R.H D Rod end - spherical - M8 L.H D Nut - M8 L.H. thread 2 24 D38234/S Adjusting bar - L & R thread - M D Transducer - safety angle D Bush 4 28 D37967/S Adaptor - grease nipple D Slack adjuster D Circlip - slack adjuster D Washer 4 32 D40988/S Gasket - king pin cover 2 33 D40989/S Gasket - king pin cover 2 34 SK2004/S Ram - steering - rear - R.H D44099/S Pin - steering ram - rear 4 37 SK2017/S Ram - steering - rear - L.H D Clip - Terry - 1" 2 39 D36427/P Stowage bracket - chocks Page

48 BRAKE ACTUATOR - TYPE 20 II D ILL No. PART No. DESCRIPTION QTY K (41370D) Diaphragm Push rod (41772D) Return spring Air pressure plate 1 5 SK2950/7 * (26179D) Clamp ring assembly Clamp ring nut Clamp ring bolt 2 * The clamp ring assembly includes the relevant nuts, bolts, packing pieces, warning tags and clamp rings. Page 49 Spares\14003d

49 HUB ASSEMBLY SK1999/M - (L.H.) SK1998/M - (R.H.) Page 50 Illustrations - Misc\SK1998 & SK1999m

50 HUB ASSEMBLY SK1999/M - (L.H.) SK1998/M - (R.H.) ILL No. PART No. DESCRIPTION QTY. 1 Axle beam assembly - LH 1 Axle beam assembly - RH D (786113) Wheel bolt M22 x 1.5 single D (786114) Grease/oil seal DS (502281) Roller bearing - Outer (65 mm) Hub - 10 stud ISO D (502917) Wheel nut - M22 x 1.5 ISO DS (502284) Roller bearing - Inner (90 mm) D (502461) Spindle nut D (501123) Spindle lockwasher D (502462) Spindle locknut D (507228) Gasket, hub cap - grease lube axle D (800048) Hub cap - grease lube axle D (507746/16) Screw, self locking - M8 x D (SK3835) Drum - 10 stud D (502904/02) Unlined brake shoe assembly D (507153) Lined brake shoe - asbestos free D (507155) Lining, cam end - asbestos free D (507154) Lining, anchor end - asbestos free D (502245) Rivet D (501551) Return spring D (501995) Anchor pin D (758525) Circlip /02 Grease valve D (500375) 'O' Ring D (500374) 'O' Ring D (500358) Washer D (504877/R) Camshaft RH D (504877/L) Camshaft LH D (800006) Cam roller D (520123) Roller retainer spring D (500372) Pin - return spring DS (501787) Bush - anchor pin D (NB1203) Slack adjuster 2 Page 51 Spares/SK1998m

51 ENGINE AND TRANSMISSION Page 53

52 TBL280 SPARE PARTS MANUAL ENGINE AND TRANSMISSION FIG S Page 54

53 TBL280 SPARE PARTS MANUAL ENGINE & TRANSMISSION S D Engine - Deutz TCD2013 L6 2V D Transmission - ZF 3WG D35211/P Mounting bracket - engine - front 2 4 D35225/P Mounting bracket - engine - rear 2 5 D44014/P Mounting bracket - transmission - L.H. 1 6 D44015/P Mounting bracket - transmission - R.H D Pump - variable - 75cc/rev D Pump - hydraulic cc/rev. 1 9 D44343/S Mounting - alternator D Alternator - 24V/110A 1 11 D44437/S Modification - banjo (fuel return) 1 12 D44474/S Dipstick assembly - transmission 1 13 HPK097 Hydraulic kit - engine 1 14 D44411/P Mounting bracket - fuel filter 1 15 D44761/S Modification - transmission - dipstick tube 1 17 D45123 Mounting bracket - water hose 1 18 D45179 Mounting bracket - wiring loom D Locknut - M12 x D Connector - hose 22mm D Elbow - rubber - 22mm i/dia D Clamp - pipe 32mm D Banjo 5/ Page

54 NOTE FOR FURTHER INFORMATION REGARDING THE ENGINE, REFER TO THE MANUFACTURER S MANUALS SUPPLIED Page 57

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121 SPARE PARTS CATALOGUE CD-ROM 'ELCAT' 1/ WG-211 ZF parts list no.: customer: DOUGLAS Page 124

122 parts list: WG-211 / / DOUGLAS ZF-ELCAT technical information sheet CD 1/ sheet 2 item text mod. no. A10 WANDLER: W 340 K01620/06 IMPULSZAHL/ ABTRIEB: 47 K01620/06 WANDLERDURCHKUPPLUNG: OHNE K01620/06 WANDLERBEZEICHNUNG: 034 H 090 K01620/06 KUNDENNAME: DOUGLAS *** K01620/06 LAND/ORT: GB K01620/06 FAHRZEUGBEZEICHNUNG: TRACTOR TBL 280 K01620/06 FAHRZEUGM. LEER (TO): 15 K01620/06 MOTOR: DEUTZ TCD 2013 L06 K01620/06 MOTORLEISTUNG (KW): 190 K01620/06 BEI DREHZAHL (1/MIN): 2300 K01620/06 MOTORDREHMOMENT (NM): 1000 K01620/06 BEI DREHZAHL (1/MIN) 1500 K01620/06 REIFENGROESSE: 445/65 R22.5 K01620/06 REIFENRADIUS(M): 0,53 K01620/06 ACHSUEBERSETZUNG: 14,58 K01620/06 ENDGESCH. (KM/H): 34 K01620/06 FESTBREMSDREHZ.(1/MIN): 2105 K01620/06 PRODUKTBESCHREIBUNG: ZF-ERGOPOWER GETRIEBE K01620/06 VARIANTE: STANDARD K01620/06 FAHRZEUG: FLURFOERDERFAHRZEUGE K01620/06 GETRIEBETYP: 3 WG 211 K01620/06 ACHSABSTAND: 190 MM K01620/06 UEBERS. VORWAERTS: 1-3G/5,683-2,304-0,963 K01620/06 UEBERS. RUECKWAERTS: 1-3G/5,041-2,044-0,854 K01620/06 IMPULSZAHL/MOTOR: 4 K01620/06 IMPULSZAHL/TURBINE: 54 K01620/06 IMPULSZAHL MRK: 56 K01620/06 WANDLERAUFNAHME 177 NM K01620/06 LEITRADFREILAUF: OHNE K01620/06 MOTORANSCHLUSS: DIREKTANBAU K01620/06 MOTOR: DEUTZ K01620/06 SAE-ANSCHLU~: SAE 3 K01620/06 ABTRIEB PTO-SEITE: OHNE FESTSTELLBREMSE K01620/06 ABTRIEBSFL. PTO SEITE: DIN 150 KV K01620/06 SCHRAUBEN: 4 X M12 X 1,5 X 45 K01620/06 NEBENABTRIEB: 1 PTO KOAXIAL MOTORABHAENGIG K01620/06 Page 125

123 parts list: WG-211 / / DOUGLAS ZF-ELCAT technical information sheet CD 1/ sheet 3 item text mod. no. FLANSCH: SAE C 2/4 LOCH K01620/06 MITNEHMER/PROFIL: SAE C 12/24 DP 14 Z K01620/06 SCHALTUNG: ZF-ERGOSHIFT/ PROP. VENTIL K01620/06 SPANNUNG: 24 VOLT K01620/06 ARBEITSDRUCK: BAR K01620/06 ELEKTRIKTEILE: SEPARATE BESTELLUNG K01620/06 SEPARATE BESTELLUNG: K01620/06 STEUERUNG: EST 37A K01620/06 BORDNETZSPANNUNG: 24 VOLT K01620/06 FAHRSCHALTER: DW-3 K01620/06 DISPLAY: F}R INTEGRIERTE MONTAGE K01620/06 VERKABELUNG: OHNE K01620/06 ANSCHLU~ST. F}R EST 37A BAJONETT K01620/06 TEMPERATURGEBER: }BER EST K01620/06 TACHO: ELEKTR. }BER ANSCHLUSS EST K01620/06 OELSTANDSROHR ANBAU: PTO - SEITE K01620/06 OELSTANDSROHR: KURZ/GERADE-MONTIERT K01620/06 FILTERANBAU: DIREKT K01620/06 DIFFERENZDRUCKSCHALTER: SCHLIE~ER K01620/06 GETRIEBEDOKUMENTATION: K01620/06 ANFAHRWANDLUNG: 2,10 K01620/06 OELSCHEMA: K01620/06 SCHNITTZEICHNUNG: K01620/06 GETRIEBESCHEMA: K01620/06 T02 GETRIEBEOELFUELLUNG: OHNE OELEINFUELLMENGE: CA. 27 LITER OELSORTE GETRIEBE: SCHMIERSTOFFLISTE TE ML 03 T46 GRUNDIERUNG: 5 TIEFSCHWARZ RAL 9005 V02 FAHRLEISTUNGSBER.: EINBAUZEICHNUNG: EINBAURICHTLINIEN: Z01 * Page 126

124 ZF-ELCAT summary of figures CD 1/ sheet 4 parts list: WG-211 / / DOUGLAS figure part no. description technical information mod. no ENGINE CONNECT CONVERTER INPUT GEARBOX HOUSING GEARBOX HOUSING GEARBOX HOUSING COUPLING K1 K01511/ COUPLING K COUPLING K3 K01511/ COUPLING K COUPLING KV K01511/ COUPLING KR K01511/ OUTPUT OUTPUT POWER TAKE-OFF GEARSHIFT SYST. K00681/ GEARSHIFT SYST GEARSHIFT SYST GEARSHIFT SYST. KOMPLETT LIEFERBAR K00681/ GEARSHIFT SYST. KOMPLETT LIEFERBAR K00681/ PRESS.REGULATOR PRESS.OIL PUMP SPEEDO IND.TRANSMITTER TEMP.SENSOR FILTER FILLER NECK Page 127

125 CD 1/ sheet 5 parts list: WG-211 / / DOUGLAS figure: ENGINE CONNECT. * depending on parts list no. Page 128

126 parts list: WG-211 / / DOUGLAS figure: ENGINE CONNECT. ( ) ZF-ELCAT parts list CD 1/ sheet 6 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant CONVERTER BELL WG211/SAE 3/ OHNE WK Z CAP SCREW M 10 X A3C 0,025 P DIAPHRAGM KPL. 0,360 P DIAPHRAGM KPL. 0,445 P H 4 HEXAGON SCREW M 12 X A3C 0,030 P WASHER A=1,0 IN CK45 0,002 P Page 129

127 CD 1/ sheet 7 parts list: WG-211 / / DOUGLAS figure: CONVERTER * depending on parts list no. Page 130

128 parts list: WG-211 / / DOUGLAS figure: CONVERTER ( ) ZF-ELCAT parts list CD 1/ sheet 8 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant CONVERTER K01596/ W340 SEG 29,000 P Page 131

129 CD 1/ sheet 9 parts list: WG-211 / / DOUGLAS figure: INPUT * depending on parts list no. Page 132

130 ZF-ELCAT parts list CD 1/ sheet 10 parts list: WG-211 / / DOUGLAS figure: INPUT ( ) item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant H 1 INPUT SHAFT Z=54 IN ZF7B 8,520 P TURBINE SHAFT Z=30 ZFN417-A SNAP RING SB 38 0,002 P ROLLER BEARING 0,677 P ROLLER BEARING 0,677 P PISTON RING 60 X 3 SH P KA NORMAU 0,010 P STATOR SHAFT K01363/06 Z=46 GGG-60 3,160 P STATOR SHAFT K01363/ IN GGG-60 Page 133

131 CD 1/ sheet 11 parts list: WG-211 / / DOUGLAS figure: GEARBOX HOUSING * depending on parts list no. Page 134

132 CD 1/ sheet 12 parts list: WG-211 / / DOUGLAS figure: GEARBOX HOUSING * depending on parts list no. Page 135

133 parts list: WG-211 / / DOUGLAS figure: GEARBOX HOUSING ( ) GEARBOX HOUSING ( ) ZF-ELCAT parts list CD 1/ sheet 13 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant HOUS.FRONT SECT ZF HOUS.REAR SECT. ZF H 2 CYLINDRICAL PIN 10 M 6X 24 16MNCR5 E 0,015 P H 26 CAP SCREW M 10 X A3C 0,047 P FIXING PLATE F270 0,090 P CAP SCREW M 10 X A3C 0,020 P SCREEN SHEET K01777/04 KPL. 0,730 P SCREEN SHEET K01777/04 ZFN410-FU270 0,430 P CAP SCREW K01777/04 M 6 X ,005 P CAP SCREW K01789/05 M 8 X A3C 0,020 F SLEEVE K01777/04 ZFN410-F270 0,060 P TYPE PLATE AUSF.C IN EN 0,004 P PLATE ZFN410-F270 10,500 P CAP SCREW M 10 X A3C 0,020 P FIXING PLATE F270 0,090 P CAP SCREW M 10 X A3C 0,020 P SUCTION TUBE KPL. 0,420 P O-RING 35 X 3 FPM ,001 P H 2 CAP SCREW K01478/05 M 8 X FE/ZN8 0,010 P SCREW PLUG CM38X1,5 KPL.MIT O-RING 0,140 P / H 1 SCREW PLUG AUSFG.B IN WW 0,140 P / O-RING 35 X 2 FPM WW 0,001 P PIPE 10X0,8 S205G2T 0,005 P O-RING 12 X 2.5 ZFN 744 FPM ,005 P PIPE 22X0,8 E235+N O-RING 24 X 3 FPM ,001 P PIPE KPL. 0,150 P SEALING RING A 14 X 18 CU 0,001 P UNION SCREW 10 0,030 P PIPE KPL. 0,080 P SEALING RING A 14 X 18 CU 0,001 P UNION SCREW 10 0,030 P PIPE KPL. 0,114 P SEALING RING A 14 X 18 CU 0,001 P UNION SCREW 10 0,030 P PIPE KPL. 0,150 P SEALING RING A 14 X 18 CU 0,001 P Page 136

134 parts list: WG-211 / / DOUGLAS figure: GEARBOX HOUSING ( ) GEARBOX HOUSING ( ) ZF-ELCAT parts list CD 1/ sheet 14 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant UNION SCREW 10 0,030 P PIPE KPL. 0,080 P SEALING RING A 14 X 18 CU 0,001 P UNION SCREW 10 0,030 P SEALING CAP K00106/05 0,001 F SEALING CAP K00001/05 12 FE/ZNPHR8F 0,001 P SCREW PLUG K00639/05 P / SCREW PLUG M 22X1,5 ST A3C WW 0,040 P / O-RING WW 0, SCREW PLUG M10X1 KPL.MIT O-RING 0,005 P / H 14 SCREW PLUG M 10X1 ST A3C WW 0,100 P / H 14 O-RING 8 X 1,5 ZFN 744 NBR WW 0,100 P SCREEN SHEET K00379/05 ZFN410-F500 0,050 P H 2 CAP SCREW K00379/05 M 8 X FE/ZN8 0,010 P Page 137

135 CD 1/ sheet 15 parts list: WG-211 / / DOUGLAS figure: GEARBOX HOUSING * depending on parts list no. Page 138

136 parts list: WG-211 / / DOUGLAS figure: GEARBOX HOUSING ( ) ZF-ELCAT parts list CD 1/ sheet 16 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant BREATHER 0,010 P Page 139

137 CD 1/ sheet 17 parts list: WG-211 / / DOUGLAS figure: COUPLING * depending on parts list no. Page 140

138 parts list: WG-211 / / DOUGLAS figure: COUPLING ( ) ZF-ELCAT parts list CD 1/ sheet 18 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant SHAFT Z=57 IN ZFN41 15,190 P STUD M 10 X ,013 P COUPLING P / H 1 DISC CARRIER IN ,650 P / PISTON 1,000 P / O-RING 75 X 3 ZFN 744 FPM ,010 P / O-RING 158 X 3 ZFN 744 FPM ,007 P / CUP SPRING 89 X 68,3 X 1,70 0,033 P / GUIDE RING 0,063 P / SNAP RING 0,015 P / DISC 0,130 P / DISC KOMPLETT LIEFERBAR 0,135 P / I.CLUTCH DISC 0,260 P / H 1 END SHIM K1 / KV / KR 1,000 P /150 1 SNAP RING P SNAP RING S=2,1 IN FEDE WW 0,035 P SNAP RING S=2,25 IN FEDEWW 0,040 P SNAP RING S=2,4 IN FEDE WW 0,040 P SNAP RING S=2,55 IN FEDEWW 0,040 P SNAP RING S=2,7 IN FEDE WW 0,043 P SNAP RING S=2,85 IN FEDEWW 0,045 P SNAP RING S=3,0 IN FEDE WW 0,048 P SNAP RING S=3,15 IN FEDEWW 0,048 P SNAP RING S=3,30 IN FEDEWW 0,048 P SNAP RING S=3,45 IN FEDEWW 0,048 P SNAP RING S=3,60 IN FEDEWW 0,048 P SNAP RING S=3,75 IN FEDEWW 0,062 P SNAP RING S=3,90 IN FEDEWW 0,063 P SNAP RING S=4,05 IN FEDEWW 0,066 P SNAP RING S=4,20 IN FEDEWW 0,070 P IDLER Z=20 LH IN ZFN 3,615 P RUNNING DISC 0,060 P AX.NEEDLE CAGE 0,050 P AXIAL WASHER 1,000 P NEEDLE CAGE K02039/99 0,256 P RETAINING RING 0,030 P ROLLER BEARING 1,180 P Page 141

139 parts list: WG-211 / / DOUGLAS figure: COUPLING ( ) ZF-ELCAT parts list CD 1/ sheet 19 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant ROLLER BEARING 1,200 P PISTON RING 0,003 P Page 142

140 CD 1/ sheet 20 parts list: WG-211 / / DOUGLAS figure: COUPLING * depending on parts list no. Page 143

141 parts list: WG-211 / / DOUGLAS figure: COUPLING ( ) ZF-ELCAT parts list CD 1/ sheet 21 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant SHAFT Z=56 IN ZF7B 10,530 P STUD K00552/97 M 10 X ,013 P COUPLING P / DISC CARRIER IN ,880 P / PISTON 0,400 P / O-RING 75 X 3 ZFN 744 FPM ,010 P / O-RING 142 X 3 ZFN 744 FPM ,005 P / CUP SPRING 89 X 68,3 X 1,70 0,033 P / GUIDE RING 0,063 P / SNAP RING 0,015 P / O.CLUTCH DISC 0,085 P / DISC 0,090 P / I.CLUTCH DISC 0,175 P / END SHIM 0,480 P /150 1 SNAP RING P SNAP RING S=2,1 IN FEDE WW 0,030 P SNAP RING S=2,25 IN FEDEWW 0,040 P SNAP RING S=2,4 IN FEDE WW 0,035 P SNAP RING S=2,55 IN FEDEWW 0,040 P SNAP RING S=2,7 IN FEDE WW 0,040 P SNAP RING S=2,85 IN FEDEWW 0,040 P SNAP RING S=3,00 IN FEDEWW 0,043 P SNAP RING S=3,15 IN FEDEWW 0,045 P SNAP RING S=3,30 IN FEDEWW 0,048 P SNAP RING S=3,45 IN FEDEWW 0,050 P SNAP RING S=3,60 IN FEDEWW 0,043 P SNAP RING S=3,75 IN FEDEWW 0,055 P SNAP RING S=3,90 IN FEDEWW 0,055 P H 1 SNAP RING S=4,05 IN FEDEWW 0,059 P SNAP RING S=4,20 IN FEDEWW 0,061 P IDLER K01027/97 Z=20 LH IN ZF7 3,227 P RUNNING DISC 0,060 P AX.NEEDLE CAGE 0,050 P AXIAL WASHER 1,000 P NEEDLE CAGE K01751/99 0,200 P RETAINING RING 0,030 P ROLLER BEARING 1,200 P Page 144

142 parts list: WG-211 / / DOUGLAS figure: COUPLING ( ) ZF-ELCAT parts list CD 1/ sheet 22 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant ROLLER BEARING 1,200 P PISTON RING K00459/98 0,003 P Page 145

143 CD 1/ sheet 23 parts list: WG-211 / / DOUGLAS figure: COUPLING * depending on parts list no. Page 146

144 parts list: WG-211 / / DOUGLAS figure: COUPLING ( ) ZF-ELCAT parts list CD 1/ sheet 24 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant SHAFT K01178/06 Z=47 ZFN417-C 21,200 P SHAFT K01178/ Z=47 WG-211 K3 ZFN PLUG LK ,010 P COUPLING P / DISC CARRIER IN ,880 P / PISTON 0,400 P / O-RING 75 X 3 ZFN 744 FPM ,010 P / O-RING 142 X 3 ZFN 744 FPM ,005 P / CUP SPRING 89 X 68,3 X 1,70 0,033 P / GUIDE RING 0,063 P / SNAP RING 0,015 P / O.CLUTCH DISC 0,085 P / DISC 0,090 P / I.CLUTCH DISC 0,175 P / END SHIM 0,480 P /150 1 SNAP RING P SNAP RING S=2,1 IN FEDE WW 0,030 P SNAP RING S=2,25 IN FEDEWW 0,040 P SNAP RING S=2,4 IN FEDE WW 0,035 P SNAP RING S=2,55 IN FEDEWW 0,040 P SNAP RING S=2,7 IN FEDE WW 0,040 P SNAP RING S=2,85 IN FEDEWW 0,040 P SNAP RING S=3,00 IN FEDEWW 0,043 P SNAP RING S=3,15 IN FEDEWW 0,045 P SNAP RING S=3,30 IN FEDEWW 0,048 P SNAP RING S=3,45 IN FEDEWW 0,050 P SNAP RING S=3,60 IN FEDEWW 0,043 P SNAP RING S=3,75 IN FEDEWW 0,055 P SNAP RING S=3,90 IN FEDEWW 0,055 P H 1 SNAP RING S=4,05 IN FEDEWW 0,059 P SNAP RING S=4,20 IN FEDEWW 0,061 P IDLER Z=55 IN ZFN41 6,621 P RUNNING DISC 0,060 P AX.NEEDLE CAGE 0,050 P AXIAL WASHER 1,000 P NEEDLE CAGE 0,200 P ROLLER BEARING 1,200 P Page 147

145 parts list: WG-211 / / DOUGLAS figure: COUPLING ( ) ZF-ELCAT parts list CD 1/ sheet 25 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant ROLLER BEARING 1,180 P PISTON RING 0,003 P PISTON RING 65 X 3 SH P NORMAUS 0,010 P Page 148

146 CD 1/ sheet 26 parts list: WG-211 / / DOUGLAS figure: COUPLING * depending on parts list no. Page 149

147 parts list: WG-211 / / DOUGLAS figure: COUPLING ( ) ZF-ELCAT parts list CD 1/ sheet 27 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant SHAFT Z=26 IN ZF7B 7,680 P GEAR Z=63 IN ZF7B 5,100 P RETAINING RING 80X2,5 0,030 P STUD M 10 X ,013 P ROLLER BEARING 1,200 P ROLLER BEARING 0,470 P PISTON RING 0,003 P Page 150

148 CD 1/ sheet 28 parts list: WG-211 / / DOUGLAS figure: COUPLING * depending on parts list no. Page 151

149 parts list: WG-211 / / DOUGLAS figure: COUPLING ( ) ZF-ELCAT parts list CD 1/ sheet 29 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant H 1 SHAFT Z=62 ZFN417-C 11,570 P STUD M 10 X ,013 P COUPLING P / H 1 DISC CARRIER IN ,440 P / PISTON 0,400 P / O-RING 75 X 3 ZFN 744 FPM ,010 P / O-RING 142 X 3 ZFN 744 FPM ,005 P / WASHER 0,025 P / GUIDE RING 0,063 P / COMPR.SPRING 0,448 P / SNAP RING 0,015 P / DISC 0,130 P / DISC KOMPLETT LIEFERBAR 0,135 P / I.CLUTCH DISC 0,260 P / H 1 END SHIM K1 / KV / KR 1,000 P /150 1 SNAP RING P SNAP RING S=2,1 IN FEDE WW 0,035 P SNAP RING S=2,25 IN FEDEWW 0,040 P SNAP RING S=2,4 IN FEDE WW 0,040 P SNAP RING S=2,55 IN FEDEWW 0,040 P SNAP RING S=2,7 IN FEDE WW 0,043 P SNAP RING S=2,85 IN FEDEWW 0,045 P SNAP RING S=3,0 IN FEDE WW 0,048 P SNAP RING S=3,15 IN FEDEWW 0,048 P SNAP RING S=3,30 IN FEDEWW 0,048 P SNAP RING S=3,45 IN FEDEWW 0,048 P SNAP RING S=3,60 IN FEDEWW 0,048 P SNAP RING S=3,75 IN FEDEWW 0,062 P SNAP RING S=3,90 IN FEDEWW 0,063 P SNAP RING S=4,05 IN FEDEWW 0,066 P SNAP RING S=4,20 IN FEDEWW 0,070 P IDLER Z=52 IN ZFN41 4,460 P NEEDLE CAGE 0,082 P BALL BEARING 0,373 P RETAINING RING 90X3 0,040 P H 1 RETAINING RING 55X2 0,010 P ROLLER BEARING 0,470 P Page 152

150 parts list: WG-211 / / DOUGLAS figure: COUPLING ( ) ZF-ELCAT parts list CD 1/ sheet 30 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant ROLLER BEARING 0,470 P PISTON RING 0,003 P Page 153

151 CD 1/ sheet 31 parts list: WG-211 / / DOUGLAS figure: COUPLING * depending on parts list no. Page 154

152 parts list: WG-211 / / DOUGLAS figure: COUPLING ( ) ZF-ELCAT parts list CD 1/ sheet 32 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant H 1 SHAFT Z=55 ZFN417-C 9,970 P STUD M 10 X ,013 P COUPLING P / H 1 DISC CARRIER IN ,440 P / PISTON 0,400 P / O-RING 75 X 3 ZFN 744 FPM ,010 P / O-RING 142 X 3 ZFN 744 FPM ,005 P / WASHER 0,025 P / GUIDE RING 0,063 P / COMPR.SPRING 0,448 P / SNAP RING 0,015 P / DISC 0,130 P / DISC KOMPLETT LIEFERBAR 0,135 P / I.CLUTCH DISC 0,260 P / H 1 END SHIM K1 / KV / KR 1,000 P /150 1 SNAP RING P SNAP RING S=2,1 IN FEDE WW 0,035 P SNAP RING S=2,25 IN FEDEWW 0,040 P SNAP RING S=2,4 IN FEDE WW 0,040 P SNAP RING S=2,55 IN FEDEWW 0,040 P SNAP RING S=2,7 IN FEDE WW 0,043 P SNAP RING S=2,85 IN FEDEWW 0,045 P SNAP RING S=3,0 IN FEDE WW 0,048 P SNAP RING S=3,15 IN FEDEWW 0,048 P SNAP RING S=3,30 IN FEDEWW 0,048 P SNAP RING S=3,45 IN FEDEWW 0,048 P SNAP RING S=3,60 IN FEDEWW 0,048 P SNAP RING S=3,75 IN FEDEWW 0,062 P SNAP RING S=3,90 IN FEDEWW 0,063 P SNAP RING S=4,05 IN FEDEWW 0,066 P SNAP RING S=4,20 IN FEDEWW 0,070 P IDLER Z=52 ZFN417-C NEEDLE CAGE 0,082 P BALL BEARING 0,373 P RETAINING RING 90X3 0,040 P H 1 RETAINING RING 55X2 0,010 P ROLLER BEARING 1,200 P Page 155

153 parts list: WG-211 / / DOUGLAS figure: COUPLING ( ) ZF-ELCAT parts list CD 1/ sheet 33 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant ROLLER BEARING 0,470 P PISTON RING 0,003 P Page 156

154 CD 1/ sheet 34 parts list: WG-211 / / DOUGLAS figure: OUTPUT * depending on parts list no. Page 157

155 ZF-ELCAT parts list CD 1/ sheet 35 parts list: WG-211 / / DOUGLAS figure: OUTPUT ( ) item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant SHAFT SEAL 0,085 P WASHER IN C45E WW.4 0,340 P H 2 HEXAGON SCREW M 10 X A3C 0,020 P TAB WASHER K01178/06 IN ST1303 0,010 P O-RING 48 X 4 NBR ,002 P Page 158

156 CD 1/ sheet 36 parts list: WG-211 / / DOUGLAS figure: OUTPUT * depending on parts list no. Page 159

157 ZF-ELCAT parts list CD 1/ sheet 37 parts list: WG-211 / / DOUGLAS figure: OUTPUT ( ) item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant OUTPUT FLANGE Z=42 IN ZF50 0,003 P SCREEN SHEET K00200/04 0,185 P H 4 HEXAGON SCREW M 12X1,5 X ,050 P Page 160

158 CD 1/ sheet 38 parts list: WG-211 / / DOUGLAS figure: POWER TAKE-OFF * depending on parts list no. Page 161

159 parts list: WG-211 / / DOUGLAS figure: POWER TAKE-OFF ( ) ZF-ELCAT parts list CD 1/ sheet 39 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant PUMP SHAFT Z=14 ZFN417-A RETAINING RING 85X3 0,080 P PISTON RING 60 X 3 SH P KA NORMAU 0,010 P H 1 BALL BEARING 0,404 P COVER PLATE IN ZFN417-F270 0,855 P O-RING 130 X 3 NBR ,005 P H 4 HEXAGON SCREW M 12 X A3C 0,030 P SEALING CAP K00816/06 12 FE/ZNPHR8F 0,001 P Page 162

160 CD 1/ sheet 40 parts list: WG-211 / / DOUGLAS figure: GEARSHIFT SYST. * depending on parts list no. Page 163

161 parts list: WG-211 / / DOUGLAS figure: GEARSHIFT SYST. ( ) ZF-ELCAT parts list CD 1/ sheet 41 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant GASKET GASKET ,001 P DUCT PLATE EN AC-ALSI8CU3SF H 1 GASKET K01631/06 WG ,019 P TORX SCREW M6X25 IN ,005 P TORX SCREW M6X60 IN ,015 P H 2 TORX SCREW M6X76 IN ,020 P H 21 TORX SCREW M6X100 IN ,025 P PISTON EN AW-6082[ALSI1MGMN] 0,015 P COMPR.SPRING DRAHT D=1,6 FEDERS 0,009 P SCREW PLUG K01394/06 M10X1 KPL.MIT O-RING 0,005 P / H 8 SCREW PLUG M 10X1 ST A3C WW 0,100 P / H 8 O-RING 8 X 1,5 ZFN 744 NBR WW 0,100 P Page 164

162 CD 1/ sheet 42 parts list: WG-211 / / DOUGLAS figure: GEARSHIFT SYST. * depending on parts list no. Page 165

163 parts list: WG-211 / / DOUGLAS figure: GEARSHIFT SYST. ( ) ZF-ELCAT parts list CD 1/ sheet 43 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant SWITCH 0,075 P Page 166

164 CD 1/ sheet 44 parts list: WG-211 / / DOUGLAS figure: GEARSHIFT SYST. * depending on parts list no. Page 167

165 parts list: WG-211 / / DOUGLAS figure: GEARSHIFT SYST. ( ) ZF-ELCAT parts list CD 1/ sheet 45 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant SCREW PLUG K01176/05 M16X1,5 KPL.MIT O-RING 0,020 P / SCREW PLUG M 16X1,5 ST A3C WW 0,020 P / O-RING 13 X 2 FPM WW 0,004 P Page 168

166 CD 1/ sheet 46 parts list: WG-211 / / DOUGLAS figure: GEARSHIFT SYST. * depending on parts list no. Page 169

167 CD 1/ sheet 47 parts list: WG-211 / / DOUGLAS figure: GEARSHIFT SYST. * depending on parts list no. Page 170

168 parts list: WG-211 / / DOUGLAS figure: GEARSHIFT SYST. ( ) GEARSHIFT SYST. ( ) ZF-ELCAT parts list CD 1/ sheet 48 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant H 1 VALVE BLOCK K01578/06 IN GD-ALSI9CU 2,200 P VALVE BLOCK K01578/ IN EN AC-ALSI ORIFICE A=0,8 IN FU27 0,001 P ORIFICE METALL IN FU PISTON NACHFOLGESCHIEBER E 0,020 P COMPR.SPRING 0,005 P PISTON EN AW-ALSIMGMN T6 WW. 0,005 P COMPR.SPRING 0,007 P PISTON EN AW-ALSIMGMN T6 0,015 P COMPR.SPRING 0,015 P CONTROL PISTON EN AW-ALSIMGMN T6 WW. 0,035 P COMPR.SPRING 0,033 P GASKET S=1, ,005 P HOUSING GD-ALSI9CU3 0,550 P H 18 TORX SCREW M5 IN ,005 P PRESS.REGULATOR KOMPLETT MIT O-RING 0,122 P / H 3 O-RING 13,5 X 2 FPM ,001 P FIXING PLATE CK67GBK MK75 0,003 P H 3 CAP SCREW M5X12 IN ,003 P GASKET S=1, ,005 P HOUSING GD-ALSI9CU3 0,550 P H 18 TORX SCREW M5 IN ,005 P PRESS.REGULATOR KOMPLETT MIT O-RING 0,122 P / H 2 O-RING 13,5 X 2 FPM ,001 P FIXING PLATE CK67GBK MK75 0,003 P H 3 CAP SCREW K00739/06 M5X12 IN ,003 P WIRING HARNESS 0,100 P GASKET S=1, ,005 P H 1 COVER AUSF.I IN GD- 0,275 P H 14 TORX SCREW M5 IN ,005 P GASKET S=1, ,005 P H 1 COVER AUSF.II IN GD- 0,535 P RETAINING CLAMP X12CRNI ,020 P H 14 TORX SCREW M5 IN ,005 P SEALING PLATE SCREEN K00166/06 MASCHENW.200MY 0,001 P DUCT PLATE GD-ALSI9CU3 0,660 P Page 171

169 parts list: WG-211 / / DOUGLAS figure: GEARSHIFT SYST. ( ) GEARSHIFT SYST. ( ) ZF-ELCAT parts list CD 1/ sheet 49 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant H 18 TORX SCREW M6X23 IN ,005 P Page 172

170 CD 1/ sheet 50 parts list: WG-211 / / DOUGLAS figure: PRESS.REGULATOR * depending on parts list no. Page 173

171 parts list: WG-211 / / DOUGLAS figure: PRESS.REGULATOR ( ) ZF-ELCAT parts list CD 1/ sheet 51 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant VALVE 0,084 P INDENTED RING K00796/04 ZJ40 0,001 P PISTON 16MNCR5 WW. A ZFN413 0,100 P COMPR.SPRING FEDERSTAHL 0,036 P SET SCREW K01751/04 M10X16 45H 0,005 P H 1 SET SCREW K00796/04 M10X12 45H 0,020 P Page 174

172 CD 1/ sheet 52 parts list: WG-211 / / DOUGLAS figure: PRESS.OIL PUMP * depending on parts list no. Page 175

173 parts list: WG-211 / / DOUGLAS figure: PRESS.OIL PUMP ( ) ZF-ELCAT parts list CD 1/ sheet 53 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant GEAR PUMP CAP SCREW 0,053 P / CAP SCREW M 10 X FE/ZN8WW 0,052 P / O-RING 9,5 X 1,6 FPM WW 0,001 P O-RING K01165/ X 3 FPM ,008 P O-RING K01165/ X 3 ACM Page 176

174 CD 1/ sheet 54 parts list: WG-211 / / DOUGLAS figure: SPEEDO * depending on parts list no. Page 177

175 ZF-ELCAT parts list CD 1/ sheet 55 parts list: WG-211 / / DOUGLAS figure: SPEEDO ( ) item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant SCREW PLUG M18X1,5 KPL.MIT O-RING 0,030 P / H 1 VERSCHL.SCHRAUB M18 X 1,5 DIN 908 ST WW 0,030 P / O-RING 15 X 2 ZFN 744 NBR WW 0,020 P Page 178

176 CD 1/ sheet 56 parts list: WG-211 / / DOUGLAS figure: IND.TRANSMITTER * depending on parts list no. Page 179

177 parts list: WG-211 / / DOUGLAS figure: IND.TRANSMITTER ( ) ZF-ELCAT parts list CD 1/ sheet 57 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant IND.TRANSMITTER K00250/97 KOMPLETT MIT O-RING 0,050 P / O-RING 15 X 2 0,002 P SPEED TRANSMITT K02042/99 KOMPLETT MIT O-RING 0,040 P / H 1 O-RING 15,54 X 2,62 ZFN 744 ACM ,001 P H 1 CAP SCREW M 8 X FE/ZN8 0,010 P SEALING CAP K01195/99 0,002 P Page 180

178 CD 1/ sheet 58 parts list: WG-211 / / DOUGLAS figure: TEMP.SENSOR * depending on parts list no. Page 181

179 parts list: WG-211 / / DOUGLAS figure: TEMP.SENSOR ( ) ZF-ELCAT parts list CD 1/ sheet 59 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant TEMP.SENSOR K00547/06 / O-RING 11 X 2 ZFN 744 FPM ,030 P Page 182

180 CD 1/ sheet 60 parts list: WG-211 / / DOUGLAS figure: FILTER * depending on parts list no. Page 183

181 ZF-ELCAT parts list CD 1/ sheet 61 parts list: WG-211 / / DOUGLAS figure: FILTER ( ) item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant PRESSURE FILTER K00109/06 P FILTER HEAD 0,051 P O-RING K01160/06 34,2 X 3 NBR TORX SCREW M8X35 IN ,020 P Page 184

182 CD 1/ sheet 62 parts list: WG-211 / / DOUGLAS figure: FILLER NECK * depending on parts list no. Page 185

183 parts list: WG-211 / / DOUGLAS figure: FILLER NECK ( ) ZF-ELCAT parts list CD 1/ sheet 63 item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant OIL LEVEL TUBE KPL. 0,860 P OIL DIPSTICK K00904/06 KPL. IN GASKET K00438/04 IN TS 9003 ARM 0,001 P HEXAGON SCREW 0,025 P **** END **** Page 186

184 ZF-ELCAT parts list CD 1/ sheet 55 parts list: WG-211 / / DOUGLAS figure: SPEEDO ( ) item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant SCREW PLUG M18X1,5 KPL.MIT O-RING 0,030 P / H 1 VERSCHL.SCHRAUB M18 X 1,5 DIN 908 ST WW 0,030 P / O-RING 15 X 2 ZFN 744 NBR WW 0,020 P Page 187

185 CD 1/ sheet 56 parts list: WG-211 / / DOUGLAS figure: IND.TRANSMITTER * depending on parts list no. Page 188

186 ZF-ELCAT parts list CD 1/ sheet 57 parts list: WG-211 / / DOUGLAS figure: IND.TRANSMITTER ( ) item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant IND.TRANSMITTER K00250/97 KOMPLETT MIT O-RING 0,050 P / O-RING 15 X 2 0,002 P SPEED TRANSMITT K02042/99 KOMPLETT MIT O-RING 0,040 P / H 1 O-RING 15,54 X 2,62 ZFN 744 ACM ,001 P H 1 CAP SCREW M 8 X FE/ZN8 0,010 P SEALING CAP K01195/99 0,002 P Page 189

187 CD 1/ sheet 58 parts list: WG-211 / / DOUGLAS figure: TEMP.SENSOR * depending on parts list no. Page 190

188 ZF-ELCAT parts list CD 1/ sheet 59 parts list: WG-211 / / DOUGLAS figure: TEMP.SENSOR ( ) item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant TEMP.SENSOR K00547/06 / O-RING 11 X 2 ZFN 744 FPM ,030 P Page 191

189 CD 1/ sheet 60 parts list: WG-211 / / DOUGLAS figure: FILTER * depending on parts list no. Page 192

190 ZF-ELCAT parts list CD 1/ sheet 61 parts list: WG-211 / / DOUGLAS figure: FILTER ( ) item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant PRESSURE FILTER K00109/06 P FILTER HEAD 0,051 P O-RING K01160/06 34,2 X 3 NBR TORX SCREW M8X35 IN ,020 P Page 193

191 CD 1/ sheet 62 parts list: WG-211 / / DOUGLAS figure: FILLER NECK * depending on parts list no. Page 194

192 ZF-ELCAT parts list CD 1/ sheet 63 parts list: WG-211 / / DOUGLAS figure: FILLER NECK ( ) item part no. OCF description mod. no. mod. intr. technical information opt. customer's code no. weight suppl.plant OIL LEVEL TUBE KPL. 0,860 P OIL DIPSTICK K00904/06 KPL. IN GASKET K00438/04 IN TS 9003 ARM 0,001 P HEXAGON SCREW 0,025 P Page 195 **** END ****

193 Error code list Ergopower- EST37/A Z F P a s s a u G m b h Donaustraße D Passau Page 196

194 Page 197

195 ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A 1 Introduction 1.1 Abbreviations o.c. s.c. OP-Mode TCU EEC PTO 1.2 ZF - Display: open circuit short circuit operating mode transmission control unit electronic engine controller power take off If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows the fault code, if the gear selector is on neutral position. If more than one fault is detected, each fault code is shown for about 1 second. 1.3 Display during operation h f e d S T O P a b c g (special symbols a-h) left character right character Symbol meaning remarks 1F, 1R 2F, 2R 3F, 3R 4F 5F 6F LF, LR F or R, no gear F or R flashing actual gear and direction left digit shows actual gear right digit shows actual direction limp home gear Clutch Cutoff direction F or R selected while turbine speed is too high NN not neutral, waiting for neutral after power up or a severe fault ** oil temperature too low, no gear available *N oil temperature low, only one gear available CAUTION gear will engage if turbine speed drops to engage a gear, first move shift selector to neutral position and again to F or R position warm up engine / transmission warm up engine / transmission TE-AB N:\Astt\Elektrikneu\Fc_37_V912.doc Page 198 Seite 3 von 53

196 ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A 1 bar (special manual mode 1 st gear symbol) 2 bars manual mode 2 nd gear 3 bars manual mode 3 rd gear 4 bars manual mode 4 th gear and also 5 th and 6 th gear in 6WG 4 bars and 2 arrows automatic mode Bars flashing 6 WG: converter lockup clutch open difference of engine and turbine speed above a certain limit and lockup clutch not activated 4 WG: Downshift mode activ Spanner at least one fault activ select neutral to get fault code displayed Fault code see faultcode list WS warning sump temperature changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) WR warning retarder temperature changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) WT warning torque converter temperature changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) WE warning high engine speed changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) PN direction F or R selected while parking brake engaged transmission in neutral until parking brake is released CAUTION: vehicle starts to move after release of parking brake EE flashing no communication with display checked wiring from TCU to display TE-AB N:\Astt\Elektrikneu\Fc_37_V912.doc Page 199 Seite 4 von 53

197 ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A 1.4 Display during AEB-Mode symbol meaning remarks PL AEB - Starter is plugged at the ST diagnostic plug AEB-Starter-button is pressed K1..K4,KV,KR calibrating clutch K1..K4, KV or KR resp. _ and Kx wait for start, initialization of clutch Kx, x: 1, 2, 3, 4, V, R fast fill time determination of clutch Kx and Kx = and Kx compensating pressure determination of clutch Kx OK calibration for all clutches finished Transmissions stays in neutral, you have to restart the TCU (ignition off/on) after removing AEB-Starter STOP AEB canceled (activation stopped) Transmissions stays in neutral, you have to restart the STOP and Kx AEB stopped, clutch Kx can't be calibrated Spanner and Kx Kx couldn't be calibrated, AEB finished E E T T FT FB engine speed too low, raise engine speed engine speed too high, lower engine speed transmission oil temperature too low, heat up transmission transmission oil temperature too high cool down transmission transmission temperature not in defined range during calibration operating mode not NORMAL or transmission temperature sensor defective or storing of Calibrated values to EEPROM-has failed. TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) FO Outputspeed_not_zero Transmissions stays in neutral, you have to restart the TCU (ignition off/on) FN Shift lever not in Neutral position Transmissions stays in neutral, you have to restart the TCU (ignition off/on) FP Parkbrake_not_applied Transmissions stays in neutral, you have to restart the STOP AEB - Starter was used incorrect or is defective. Wrong device or wrong cable used TCU (ignition off/on) Transmissions stays in neutral, you have to restart the TCU (ignition off/on) TE-AB N:\Astt\Elektrikneu\Fc_37_V912.doc Page 200 Seite 5 von 53

198 ZF Friedrichshafen AG Faultcodes ERGO-Control EST37A 2 definition of operating modes NORMAL: There's no failure detected in the transmission-system or the failure has no or slight effects on transmission control. TCU will work without or in special cases with little limitations. (see following table) SUBSTITUTE CLUTCH CONTROL: TCU can't change the gears or the direction under the control of the normal clutch modulation. TCU uses the substitute strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25) LIMP-HOME: The detected failure in the system has strong limitations to transmission control. TCU can engage only one gear in each direction. In some cases only one direction will be possible. TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift the gear selector into neutral position. If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into forward or reverse, the TCU will select the limp-home gear. If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected direction. If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has to slow down the vehicle and must shift the gear selector into neutral position. TRANSMISSION-SHUTDOWN: TCU has detected a severe failure that disables control of the transmission. TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1). Transmission shifts to Neutral. The park brake will operate normally, also the other functions which use ADM 1 to ADM 8. The operator has to slow down the vehicle. The transmission will stay in neutral. TCU-SHUTDOWN: TCU has detected a severe failure that disables control of system. TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park brake will engage, also all functions are disabled which use ADM 1 to ADM 8. The transmission will stay in neutral. TE-AB N:\Astt\Elektrikneu\Fc_37_V912.doc Page 201 Seite 6 von 53

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244 ZF Friedrichshafen AG description of fault codes for ERGO-Control measuring of resistance at actuator/sensors and cable 4.1 actuator: 1 2 R G open circuit: R 12 R 1G R 2G short cut to ground: R 12 R; R 1G 0, R 2G R or R 1G R, R 2G 0 (for s.c. to ground, G is connected to vehicle ground) short cut to battery: R 12 R; R 1G 0, R 2G R or R 1G R, R 2G 0 (for s.c. to battery, G is connected to battery voltage) 4.2 cable: TCU U Bat 1 2 open circuit: R 12 R 1P R 1C R 2P R 2C short cut to ground: R 12 0; R 1C R 2C 0, R 1P R 2P short cut to battery: R 12 0, R 1C R 2C, R 1P R 2P 0 Gnd P (power supply) Actuator / Sensor C (chassis) TE-AB N:\Astt\Elektrikneu\Fc_37_V912.doc Page 247 Seite 52 von 53

245 ZF Friedrichshafen AG description of fault codes for ERGO-Control TE-AB N:\Astt\Elektrikneu\Fc_37_V912.doc Seite 53 von 53 Page 248

246 TRANSFER AND BEVEL BOX Page 249

247 TBL280 SPARE PARTS MANUAL TRANSFER AND BEVEL BOX FIG S Page 250

248 TBL280 SPARE PARTS MANUAL TRANSFER BOX S D Transfer box - W D43972/P Support bracket - transfer box 1 3 E730/ND Propshaft - DIN150KV/ x mm w/length 1 4 E731/ND Propshaft - DIN x mm w/length 1 5 D35236/S Support plate - transfer box D Coupling - male stud 1 7 D44702/P Tube - dipstick - transfer box 1 8 D35734/S Dipstick - transfer box D Connector - female D Connector - male 1 11 D45026/S Pipe - transfer box breather Page

249 PROPSHAFT E730/ND ILL No. PART No. DESCRIPTION QTY. 1 E730/ND Propshaft D Coupling repair kit Page 253 Spares\E730-ND

250 PROPSHAFT E731/ND ILL No. PART No. DESCRIPTION QTY. 1 E731/ND Propshaft D Coupling repair kit Page 255 Spares\E731-ND

251 SPARE PARTS LIST FOR TRANSFER BOX - W1600 W D Page 257

252 Page 258

253 Page 259

254 Page 260

255 Page 261

256 Page 262

257 Page 263

258 NOSE WHEEL CRADLE Page 265

259 TBL280 SPARE PARTS MANUAL NOSE WHEEL S D Light flood D Buffer D Washer shake proof D Transmitter pressure 4-20mA D Transducer cable extension D Proximity switch no plug type D Proximity switch nc-plug type D Proximity switch cable D Switch reed solid state D Cable reed solid state 5m D Nut M16 x D Cylinder air compact 50mm D Trunnion detachable D Trunnion support D Nut half M12 x D Clevis - M12 thread 16 dia hole D Manifold PO check D Through beam transmitter D Through beam receiver 2 20 AGS1186-A Seal 1/ D13394/S Adaptor M20 to 1/ D34704/S Handle gate lock release 1 23 D36157/P Link cradle 4 24 D36729/S Mounting bracket - sensor (transmitter) 1 25 D36730/S Mounting bracket sensor outer R/H 2 26 D37779/S Cover photo trans/receiver 4 27 D40927/S Cover w/s error switches 1 28 D40986/S Lever bar cradle 1 29 D41822/S Adjustment bar w/s transducer 2 30 D44440/P Hydraulic pipe gate hinge cylinder cradle 1 31 D44441/P Hydraulic pipe - gate hinge cylinder cradle 1 32 D44442/P Hydraulic pipe rear safety bar 1 33 D44443/P Hydraulic pipe rear safety bar 1 34 D44444/P Hydraulic pipe t-rear safety bar 1 35 D44445/P Hydraulic pipe gate hook cylinder cradle 1 36 D44446/P Hydraulic pipe - gate hook cylinder cradle 1 37 D44538/S Bracket hydraulic pipe - bulkheads cradle 1 38 D44539/S Bracket hydraulic pipes - front cradle offside 1 39 D44540/S Bracket hydraulic pipes - front cradle nearside 1 40 D44562/P Bracket w/s transducer 1 41 D44568/P Support bracket cradle cover Page

260 TBL280 SPARE PARTS MANUAL NOSE WHEEL CRADLE S D44602/S Mounting bracket transducer - wheel size 1 43 D46039 Bolt cradle stop 2 44 E03744/L Cradle assembly 1 45 E03757 Cradle rams 1 46 HPK131 Hydraulic kit cradle Page 267

261 TBL NOSE WHEEL CRADLE ASSEMBLY FIG E03744 sht

262 TBL CRADLE ASSEMBLY - MAIN E03744 ILL No. PART No. DESCRIPTION QTY. 1A D44074/L Cradle frame assembly 1 3A D36153/P Guide - cradle - R.H. 1 4A D36154/P Guide - cradle - L.H. 1 5A D36155/S Pivot bracket 4 6A D36156/S Mounting - wheel support ram 4 8A D36158/S Spacer - pivot bracket 8 9A D44072/M Yoke - cradle 1 10A D36160/S Spacer - yoke pivot 1 11A D44432/S Pivot bracket - yoke 1 12A D44073/L Wheel support - cradle 1 15A D42634/L Gate - cradle 1 16A D44433/P Pivot tube - gate pin 1 17A D42635/M Safety bar - gate - R.H. 1 18A D42636/M Safety bar - gate - L.H. 1 19A D36169/M Safety bar - cradle - R.H. 1 20A D36170/M Safety bar - cradle - L.H. 1 21A D36171/S Hinge assembly - safety bar - cradle 4 22A D36172/S Washer - gate pin 4 23A D36173/S Collar - gate pin 1 24A D36174/S Keep plate - link pin 4 26A D36176/S Mounting bracket - gate sensor 1 27A D36177/S Mounting bracket - cradle up/down sensor 2 28A D44224/M Assembly - gate lock 1 29A D36187/P Shaft - yoke 1 30A D36188/P Pin - pivot bracket 4 31A D36189/S Pin - ram - plough 2 32A D42638/S Pin - safety bar - ram - gate 2 33A D44980 Pin - safety bar - gate - inner - R.H. 1 34A D44979 Pin - safety bar - gate - outer 2 35A D36193/S Pin - ram - safety bar - cradle 2 36A D36190/S Pin - ram - safety bars - gate 1 43A D35262/S Modification to bush 2 44A 24744D Ball unit 2 45A D38810/S Pivot bracket - safety bar - ram 4 46A D36194/S Pin - gate ram 1 47A D42640/S Packer - gate - O/C pin 2 48A D44089/S Spacer - wheel support 6 49A D44090/S Axle - wheel support 2 51A D44981 Pin - safety bar - gate - inner - L.H. 1 52A SK2043/S Gate position 1 Spares\E03744-REF - cradle

263 TBL NOSE WHEEL CRADLE ASSEMBLY FIG E03744 sht

264 TBL CRADLE CYLINDERS E03757 ILL No. PART No. DESCRIPTION QTY. 6B SK2003/S Cylinder - gate open/close - adjustable 1 7B SK2005/S Cylinder - gate lock 1 8B SK1946/S Cylinder - wheel support 2 9B SK1947/S Cylinder - safety bar - cradle 2 10B SK1948/S Cylinder - safety bar - gate 2 11B 34320D Heavy duty bearing - nylon wheel kgs 4 Spares\E cradle cylinders

265 TBL NOSE WHEEL CRADLE ASSEMBLY FIG E03744 sht

266 COOLING SYSTEM Page 269

267 TBL280 SPARE PARTS MANUAL COOLING SYSTEM FIG S01467 Sht Page 270

268 TBL280 SPARE PARTS MANUAL COOLING SYSTEM FIG S01467 Sht Page 271

269 TBL280 SPARE PARTS MANUAL COOLING SYSTEM FIG S01467 Sht Page 273

270 TBL280 SPARE PARTS MANUAL COOLING SYSTEM FIG S01467 sht Page 275

271 TBL280 SPARE PARTS MANUAL COOLING SYSTEM S D Cooling package assembly D Hydraulic power pack-24v - 9 litres - 3cc/rev D Filter - return 1 5 D44266/P Header tank - 12 litres D Hose - red - silicone/nomex - 80mm i/d 6 7 HA1037/S Hose - elbow - 90º - 51mm i/d D Hose - blue - silicone/nomex - 50mm i/d D Clamp - hose - stainless steel - (86-91) D Clamp - U bolt type - 2" D Clamp - U bolt type - 3.⅛" 3 12 D44475/S Pipe - brake cooling - (pump/filter) 1 13 D44476/S Pipe - brake cooling - (axle/pump) 1 14 D44477/S Pipe - brake cooling - (filter) 1 15 D44478/P Pipe - brake cooling - (axle/flexible) D Sight glass 1" B.S.P HPK094 Hydraulic kit - brake cooling 1 18 HPK095 Hydraulic kit - transmission cooling D Cap - radiator - 13psi 1 21 D44678/P Pipe - charged air cooler 2 22 D44679/P Pipe - charged air cooler - rear - upper 1 23 D44680/S Pipe - charged air cooler - rear - lower 1 24 D44681/S Pipe - charged air cooler - front - upper 1 25 D44511/S Bracket - support - intercooler - pipe 1 26 D44604/P Baffle plate - cooler - rear - upper 1 27 D44414/P Support bracket - radiator - rear 1 28 D44415/P Support bracket - radiator - front 1 29 D44418/S Support bracket - header tank R/H 1 30 D44419/S Support bracket - header tank L/H 1 31 D44533/P Mounting bracket - filter - brake - cooling 1 32 D44544/S Support plate - water pipes - engine near side 1 33 D44545/S Bracket - intercooler pipes - rear engine 1 34 D44603/P Baffle plate - cooler - rear - lower 1 35 D44682/P Water pipe - radiator - engine Page

272 TBL280 SPARE PARTS MANUAL COOLING SYSTEM S D44683/P Water pipe - radiator - engine 1 37 D44684/P Water pipe - radiator - engine 1 38 D44685/P Water pipe - radiator - engine 1 39 D44703/P Baffle - cooler - top 1 40 D44704/P Baffle - cooler - bottom 1 41 D44705/P Baffle - cooler - R.H. side 1 42 D44728/P Under/body baffle plate - transmission oil cooler D Steady bar assembly D Hose radiator 19mm I/D D Hose radiator 22mm I/D D Band clamp 3.5/ Page 277

273 HYDRAULIC POWER PACK - 24V MHS A D ILL No. PART No. DESCRIPTION QTY. 1 FNMF 0049 Thermal switch 1 2 FNKMD5 24V Electric motor W dual term 1 3 FNKP31 (42456D) Gear pump cc 1 4 FNKN10 End head - centre section - B.S.P. 1 5 FNKC07 Valve kit relief & check 1 6 FNKH Horizontal mounting kit 1 7 FNKR52 (42463D) Reservoir - 5 litre (plastic) 1 8 FNKS5 (23497D) 12/24 VCD start solenoid 1 9 MFTSDG16R0AAA (43513D) F/breather & dipstick - 3 / 8 B.S.P. Service kits are not available for this unit. Failed items should be replaced. Page 279 Spares\21556d

274 RETURN FILTER MXA D ILL No. PART No. DESCRIPTION QTY. 1 MXR.8550 (26150D) Element 1 Page 281 Spares\21557d

275 INDUCTION SYSTEM Page 283

276 TBL280 SPARE PARTS MANUAL INDUCTION SYSTEM FIG S Page 284

277 TBL280 SPARE PARTS MANUAL INDUCTION SYSTEM S D Air cleaner - two stage D Indicator - restriction D Mounting band - air cleaner 2 4 HA1017/ND Hose (hump) 6" i/dia. > 5" i/dia D Clamp - hose - 5.½" D Clamp - hose - 6.½" D Clamp - hose - 6" D Clamp - hose - 5" D Clamp - hose mm D Clamp - hose mm D Clamp - U bolt type - 5" i/dia D Clamp - hose - 3.½" 2 14 D44676/P Induction pipe - upper 1 15 D44677/P Induction pipe - lower 1 16 D44541/S Bracket - clamp - air cleaner 1 17 HA1002/ND Hose elbow - 5" i/dia. x 90º D Hose - compressor feed 1.2m 1-1 Page

278 AIR CLEANER - TWO STAGE 09021D ILL No. PART No. DESCRIPTION QTY D Element D Element 1 Spares\09021d

279 EXHAUST SYSTEM Page 287

280 TBL280 SPARE PARTS MANUAL EXHAUST SYSTEM S D Silencer - stainless steel D Clamp - flexible pipe - 90/94mm internal diameter D Band clamp - stainless steel - 3.⅝" D Clamp - U bolt type - 4" D Flexible exhaust - 90mm i/dia. - stainless steel - 270mm long 1 6 D44576/P Pipe - exhaust - engine to flexible pipe 1 7 D44574/S Pipe - exhaust - front of silencer 1 8 D44575/P Pipe - exhaust - rear of silencer 1 9 D44577/M Tailpipe - exhaust D Tape (glass fibre base) 1 roll 11 D44754/S Plate - deflection - exhaust D Thermal sheeting - aluminised 2sht 13 D45256 Mounting bracket - exhaust Page

281 FUEL SYSTEM Page 291

282 TBL280 SPARE PARTS MANUAL FUEL SYSTEM S D Cap assembly - fuel oil D Element - suction - ½" 2 3 D44164/S Cover - fuel tank D Sender - fuel 1 5 D34211/S Filter basket D Gasket - filler cap 1 8 D36964/S Gasket - fuel tank cover 1 10 D36969/S Modification - coupling - male stud 2 11 D44707/S Suction pipe - fuel 2 15 D38639/S Eberspacher blanking plate D Paint - fuel tank - integral D Fire sleeve - 29mm internal diameter 4 19 HPK121 Hydraulic kit - fuel 1 20 D44708/S Pipe - return - fuel 2 21 D44785/S Fuel level sender adjustment 1 22 D44788/S Pipe - fuel overflow Page

283 HYDRAULIC TANK ASSEMBLY NOTE FOR LAYOUTS APPLICABLE TO THIS SECTION REFER TO THE LAYOUTS AND DRAWINGS MANUAL Page 295

284 TBL280 SPARE PARTS MANUAL HYDRAULIC TANK ASSEMBLY S D44097/M Oil tank - 60 litres D Cap assembly hydraulic oil - tank D Element - suction -1.½" D Gauge - fluid level/temperature 1 5 D19735/S Gasket 1 6 D35984/S Flange - suction element 1 7 D44392/S Cover plate - oil tank 1 8 D44393/S Gasket - oil tank 1 9 D44483/S Hydraulic pipe return 28mm 1 10 D44484/S Hydraulic pipe return 18mm 2 11 D44485/S Hydraulic pipe return 15mm 2 12 D44486/S Hydraulic pipe return 10mm 1 14 HPK098 Hydraulic kit - hydraulic tank Page

285 HYDRAULICS CHASSIS NOTE FOR LAYOUTS APPLICABLE TO THIS SECTION REFER TO THE LAYOUTS AND DRAWINGS MANUAL Page 299

286 TBL280 SPARE PARTS MANUAL HYDRAULICS - CHASSIS S D Proportional hydraulic valve D Pump - manual D Gauge - pressure (0-400 bar) 1 6 D35845/S Gasket - hand pump D Pressure filter c/w indicator D Pump - electric/hydraulic 1 9 D33378/S Mounting tank - hand valve D Valve - proportional - 7 section D Clamp assembly - 1.½" pipe 4 12 D45630 Pipe - steel - cradle - lift 1 13 D44458/S Hydraulic pipe - manifold to block - N/S 1 14 D44459/S Hydraulic pipe - manifold to block - N/S 1 15 D44460/S Hydraulic pipe - manifold to block - N/S 1 16 D44461/S Hydraulic pipe - manifold to block - N/S 1 17 D44462/S Hydraulic pipe - manifold to block - N/S 1 18 D44463/S Hydraulic pipe - manifold to block - N/S 1 19 D44464/S Hydraulic pipe - manifold to block - N/S 1 20 D44465/S Hydraulic pipe - manifold to block - N/S 1 21 D44466/S Hydraulic pipe - manifold to block - N/S 1 22 D44467/S Hydraulic pipe - manifold to block - N/S 1 23 D44468/S Hydraulic pipe - manifold to block - N/S 1 24 D44469/S Hydraulic pipe - manifold to block - N/S 1 25 D44470/S Hydraulic pipe - manifold to block - N/S 1 26 D44488/S Pipe - hydraulic - rear steering - L.H D44489/S Pipe - hydraulic - rear steering - L.H D44490/S Pipe - hydraulic - rear steering - R.H D44491/S Pipe - hydraulic - rear steering - R.H D44471/S Hydraulic pipe - block to hand pump 1 31 D44492/P Hydraulic pipe - pump to filter 1 32 D44493/S Hydraulic pipe - steering module to manifold Page

287 TBL280 SPARE PARTS MANUAL HYDRAULICS - CHASSIS S HPK132 Hydraulic kit - chassis 1 34 D44426/S Handle modification - hydraulic pump 1 37 DS1006/149/M Stud - Danfoss valve D Flow divider (A50%, B50%) D Clamp - pipe mm D Clamp - pipe mm Page 302

288 SPARE PARTS LIST FOR MANUAL HYDRAULIC PUMP PM25S D Page 303 Spares\15680d

289 PUMP - MANUAL PM25S D Page Spares\15680d

290 PUMP - MANUAL PM25S D ILL No. PART No. DESCRIPTION QTY 'O' ring - 4 x Tight tapered piston 'O' ring Cup for wheel Drain cock Bellows gasket 'O' ring (118) Rod seal mm diameter special seal Lever grip handle Lever - 600mm long Hand pump lever Gudgeon pin - 8mm dia. x 30mm long Screw - high tensile hexagon head - M6 x 10mm Gudgeon pin - 8mm dia. x 26mm long Circlip - RS Connecting link - 25 x 81 x 5mm Gudgeon pin - 8mm dia. x 41mm long Spacer - H = x Circlip - external AV-17E 'O' ring Gasket - tank/pump Barrel Special piston seal Piston head Piston rod - 17mm diameter 'O' ring Circlip - internal Spring locator Ball - 7 / 16 " diameter Gauze filter Suction valve spring Suction valve body Screw plug for relief valve Hand pump body Washer - 17 x 23 x 1.5 ( 3 / 8 ") / 8 " - 3 / 8 " male/female adaptor Socket caphead screw - M8 x 25mm Protection cap Suction cap Suction tube 1 Page 305 Spares\15680d

291 PNEUMATICS CHASSIS NOTE FOR LAYOUTS APPLICABLE TO THIS SECTION REFER TO THE LAYOUTS AND DRAWINGS MANUAL Page 307

292 TBL280 SPARE PARTS MANUAL PNEUMATICS - CHASSIS S D Air dryer - LA D Reservoir - 30 litres c/w bracket D Reservoir - 20 litres c/w bracket D Reservoir - 10 litres D Valve - multi-circuit protection D Valve - relay D Valve - quick release D Sender - air pressure - insulated D Switch - low pressure (>4 bar) D Valve - double check - metric D Valve - levelling - kit D Reservoir - hydraulic fluid - mineral oil D Cap - reservoir c/w float D Valve - self levelling D Rod D Valve - spool - knob - push/pull - 5/ D Adaptor - T piece 5/16" o/dia D Washer - shake proof D Hydraulic hose - oil/air 9mts D Transmitter - pressure - 1-6V out D Actuator - air D Master cylinder D Adaptor - master cylinder 4 25 D44763/S Actuator - park brake 1 26 PPK033 Pneumatic plumbing kit - chassis 1 28 D44241/S Adaptor - brake actuator 1 29 D44242/S Clevis - brake actuator 1 30 D35480/S Pin - clevis 1 31 D38790/P Compressor pipe D Regulator - pressure D Silencer - air - ¼" BSP brass D Silencer - air - ⅛" BSP brass D Flow regulator/silencer - ⅜" BSPT D Valve assembly D Clamp - pipe - 16mm - aluminium D Nut - M18 x 1.5 thin D Nut - M18 x 1.5 thin L/H thread 1 42 D45384/S Modification - to adaptor 33121D D Cap screw - M4 x 50 s/steel 4 44 D47097 Spacer - for item D47982 Modification to adaptor Page

293 AIR DRYER - LA D ITEM No. PART No. DESCRIPTION QTY /008 (42098D) General repair kit - contains items 2/2, 9, 11, 12, 14, 15, 19, 24, 25 (x2), 29, 31, 35, 36/1, 38, 39, 51, 53, 54, 56 and /0051 (42099D) Gasket and seal kit - contains items 2/2, 12, 14, 15, 19, 24, 25 (x2), 31, 35, 36/1, 38, 51, 53, 54 and /004 Heater - Item SP (11649D) Cartridge - Item 36 1 Page 311 Spares\40220d

294 VALVE - MULTI CIRCUIT PROTECTION VPS 45 AY 31495D ILL No. PART No. DESCRIPTION QTY. This valve is not serviced separately. Page 313 Spares\31495d

295 QUICK-RELEASE VALVE SK1294/ D ILL No. PART No. DESCRIPTION QTY. 1 Diaphragm 1 2 O Ring 1 3 O Ring 1 4 Exhaust flap 1 NOTE:- Item 3 for use on tube mounted spring brakes with integral quick release. Replace item 4 where fitted. Page 315 Spares\31695d

296 VALVE - RELAY AC574CXY 31696D ILL No. PART No. DESCRIPTION QTY. The only parts available for this valve are contained in:- Repair kit No Page 317 Spares\31696d