SEC PARTS MANUAL SERIAL NUMBERS: BODY: MAST: GRABBER: MFG. DATE: Made in the U.S.A.

Transcription

1 SEC PARTS MANUAL SERIAL NUMBERS: BODY: MAST: GRABBER: MFG. DATE: Made in the U.S.A.

2 TABLE OF CONTENTS WARRANTY WARRANTY REGISTRATION FORM TABLE OF CONTENTS PAGE I PAGE II PAGE III PARTS SECTION 1 HYDRAULICS SECTION 2 ELECTRICAL SECTION 3 AIR SECTION 4 LUBRICATION SECTION 5 OPTIONS SECTION 6 PAGE III

3 SECTION 1 PARTS CAUTION 1-1 END GATE 1-2, 1-3 ACCESS DOOR 1-4, 1-5 PACKER 1-6, 1-7 UNDER CARRIAGE 1-8, 1-9 MAST 1-10, 1-11, 1-12 MOUNTING BRACKETS 1-13, 1-14 ARMS 1-15, 1-16 DECALS 1-17

4 CAUTION Substitution of parts may affect the performance of this Challenger unit and could result in malfunctions and lead to damage of equipment and injury to personnel. Only approved parts should be used to repair this unit. Southwestern Equipment Company in an effort to improve product may change or add parts. When ordering replacement parts, specify the serial and model number of the unit being repaired so we can assure the proper part is sent. PAGE 1-1

5 END GATE PAGE 1-2

6 END GATE SEC CHALLENGER Item SEC Part number QTY Description 1 (REF.) 1 TANK STRUCTURE 2 SW STANDARD TAIL GATE STRUCTURE 2A SW BUBBLE TAIL GATE STRUCTURE 3 SW BUSHING 4 SW CAPSCREW, 1.25 x SW CAPSCREW 1 x 4 grd 8 6 SW COTTER PIN 7 SW HYDRAULIC CYLINDER 8 SW HEX NUT 9 SW NYLOCK grd 8 10 SW UPPER LIMITING WHEEL STRUCTURE 11 SW CAPSCREW,.38 x SW PIN 13 SW TAILGATE SEAL 14 SW ¼ RIVETS 15 SW CAPSCREW 1 x 7 grd 8 16 SW COUPLER STRUCTURE 17 SW SELF TAPPING SCREW,.38 x SW FLAT WASHERS 19 SW LUBE FITTING,.31 DRIVE 20 SW LUBE FITTING,.13 STRAIGHT 21 SW HYDRAULIC CYLINDER 22 SW CAPSCREW,.38 x SW HEX NUT,.38 NYLOCK PAGE 1-3

7 ACCESS DOOR PAGE 1-4

8 ACCESS DOOR SEC CHALLENGER Item SEC Part number QTY Description 1 (REF) 1 TANK STRUCTURE 2 SW R.H. ACCESS DOOR STRUCTURE 3 SW FORMED FLAT 4 SW CAPSCREW,.75 x SW FLATWASHER 6 SW HEX NUT,.75 NYLOCK 7 SW Grip 8 SW CAPSCREW,.38 x SW FORMED FLAT 10 SW HEX NUT,.38, NYLOCK PAGE 1-5

9 PACKER PAGE 1-6

10 PACKER SEC CHALLENGER Item SEC Part number QTY Description 1 SW PACKER STRUCTURE (25 YARD) 1A SW PACKER STRUCTURE (30 YARD) 2 SW WEAR PAD 3 SW SHAFT 4 SW WEAR PAD 5 SW COVER 6 SW PIN 7 (REF) 1 HYDRAULIC CYLINDER (BODY MODEL #) 8 SW CAPSCREW..50 x 1.50 SOCKETHEAD 9 SW CAPSCREW,.38 x SW HEX NUT,.38 NYLOCK 11 SW CAPSCREW,.38 x SW LOCKWASHER 13 SW CAPSCREWS.75 x 1.50 SOCKETHEAD SW CAPSCREW,.50 x SW HEX NUT,.50 NYLOCK 17 SW FLATWASHER 18 SW RUBBER BUMPER 19 SW ADAPTER 20 SW ADAPTER PAGE 1-7

11 UNDER CARRIAGE PAGE 1-8

12 UNDER CARRIAGE SEC CHALLENGER Item SEC Part number QTY Description 1 SW UNDER CARRIAGE STRUCTURE 2 SW HYDRAULIC CYCLINDER (48'') 3 SW MODIFIED CAPSCREW 4 SW '' CAM FOLLOWER (YOKE TYPE) 5 SW DRILLED CAPSCREW 7 SW LUBE FITTING,.25 8 SW HEX NUT, 1.0 SLOTTED 9 SW COTTER PIN,.19 x SW L.H. ANGLE 11 SW R.H. ANGLE 12 SW HEX NUT,.75 NYLOCK 13 SW CAPSCREW,.75 x 2.50 GRADE 8 14 SW FLATWASHERS GRADE 8 15 SW MOUNT STRUCTURE PAGE 1-9

13 MAST PAGE 1-10

14 MAST SEC CHALLENGER Item SEC Part number QTY Description 1 SW R.H. SIDE PLATE STRUCTURE 2 SW L.H. SIDE PLATE STRUCTURE 3 (REF) 2 UPPER ARM 4 SW LUBE FITTING,.25 5 SW B 2 LOWER LINK STRUCTURE 6 SW UPPER LINK STRUCTURE 7 SW SPACER BLOCKS 8 (REF) 2 LOWER ARM STRUCTURE 9 SW CROSS SHAFT 10 SW HYDRAULIC CYLINDER 11 SW EYE BOLT 12 SW HEX NUT, SW LOCKWASHER 14 SW CAM FOLLOWER 15 SW CAM FOLLOWER 16 SW LUBE FITTING,.19 DRIVE 17 SW HEX JAM NUT, SW HEX JAM NUT, SW LUBE FITTING,.25 DRIVE 20 SW CAPSCREW,.50 x 1.50 SOCKETHEAD 21 SW LUBE FITTING, SW HEX NUT,.50 NYLOCK 23 SW L.H. EAR STRUCTURE 24 SW R.H. EAR STRUCTURE 25 SW PIN STRUCTURE 26 SW BRONZE BUSHING 27 SW PIN STRUCTURE 28 SW BRONZE BUSHING 29 SW BRONZE BUSHING 30 SW CAPSCREW,.75 x 5.00 grd 8 (CONT.) PAGE 1-11

15 MAST SEC CHALLENGER Item SEC Part number QTY Description 31 SW CAPSCREW,.75 x SW HEX NUT,.75 NYLOCK 33 SW BUSHING 34 SW CAPSCREW,.38 x SW HEX NUT,.38 NYLOCK 36 SW CAPSCREW,.38 x SW HEX NUT, 1.13 CASTLE 38 SW COTTER PIN,.25 x SW MACHINE BUSHING 40 SW LIFT STRUCTURE 41 SW LIFT STRUCTURE (PAK-MOR STYLE ONLY) 42 (REF) 1 MAST STRUCTURE 43 SW MODIFIED BEARING 44 SW MACHINED BUSHING 45 SW FLAT, MCL..75 x 1.50 x SW MODIFIED CAM FOLLOWER 47 SW WEAR PAD 48 SW DOUBLE HOSE CLAMP 49 SW BRONZE BUSHING 50 SW CAPSCREW..50 x 2.00 SOCKET HEAD 51 SW PAK-MOR PAD STRUCTURE 52 SW MACHINED BUSHING 53 SW MAST GUIDE 54 SW HEX NUT, SW LOCKWASHER 56 SW CARRIAGE BOLT,.50 x SW CAPSCREW,.50 x 2.00 SOCKET HEAD PAGE 1-12

16 MOUNTING BRACKETS PAGE 1-13

17 MOUNTING BRACKETS SEC CHALLENGER Item SEC Part number QTY Description 1 SW UPPER FRONT MOUNT STRUCTURE 2 SW LOWER FRONT MOUNT STRUCTURE 3 SW UPPER REAR MOUNT STRUCTURE 4 SW LOWER REAR MOUNT STRUCTURE 5 SW CAPSCREW 1 x 7 (GRADE 8) 6 SW CAPSCREW 1 x 3.50 (GRADE 8) 7 SW CAPSCREW 5/8 x 2.50 (GRADE 8) 8 SW SPRINGS 9 SW FLATWASHER (GRADE 8) 10 SW NYLOCK HEX NUT (GRADE 8) 11 SW /8 WASHER (GRADE8) 12 SW /8 NYLOCK NUT (GRADE 8) 13 SW 2 MUD FLAP STRAP 14 SW 2 MUD FLAP SUPPORT 15 SW SEC MUD FLAPS (24 x 30) 16 SW CAPSCREW 5/16 x SW HEX NUT, SW FLATWASHER 19 SW ANTI-SAIL PAGE 1-14

18 ARMS PAGE 1-15

19 ARMS SEC CHALLENGER OPTION SEC Part number QTY Description A1 SW UPPER ARM STRUCTURE SW LOWER ARM STRUCTURE A2 SW UPPER ARM STRUCTURE SW LOWER ARM STRUCTURE B1 SW UPPER ARM STRUCTURE SW LOWER ARM STRUCTURE B2 SW UPPER ARM STRUCTURE SW LOWER ARM STRUCTURE C1 SW UPPER ARM STRUCTURE SW LOWER ARM STRUCTURE C2 SW UPPER ARM STRUCTURE SW LOWER ARM STRUCTURE D1 SW UPPER ARM STRUCTURE SW LOWER ARM STRUCTURE D2 SW UPPER ARM STRUCTURE SW LOWER ARM STRUCTURE PAGE 1-16

20 DECALS SEC CHALLENGER Item Description QTY Location 1 PINCH POINT 2 1-EA. SIDE, REAR OF TANK 2 ENTER BODY 1 LEFT OF ACCESS DOOR 3 STAND CLEAR PACKER 1 BELOW ITEM #2 4 CLOSE ACCESS DOOR 1 BELOW ITEM #3 5 STAND CLEAR TAILGATE 2 BELOW ITEM #1 6 PRECAUTION 1 DASH (INSIDE CAB) 7 LIFT CAPACITY 1 CENTER OF MAST 7a LIFT CAPACITY 1 CENTER OF MAST (GRABBER OPTION) 8 STAND CLEAR MAST 1 FRONT OF MAST (MAST SIDE) 9 STAND CLEAR CONTAINER 1 ABOVE ITEM #8 10 NOTICE 2 ABOVE DUMPSTER LIFT POINTS 11 KEEP OFF 1 BEHIND LADDER (LADDER & CATWALK OPTION) 12 WATCH YOUR STEP 1 BEHIND LADDER (LADDER & CATWALK OPTION) PAGE 1-17

21 SECTION 2 HYDRAULICS DRIVE LINE 2-1, 2-2 CONTROL VALVE 2-3, 2-4 HYDRAULIC TANK 2-5, 2-6 HYDRAULIC SYSTEM 2-7, 2-8, 2-9, 2-10 MAST HYDRAULICS 2-11, 2-12 END GATE HYDRAULICS 2-13, 2-14

22 DRIVE LINE PAGE 2-1

23 DRIVE LINE SEC CHALLENGER Item SEC Part number QTY Description 1 SW FLANGE YOKE 1A SW FLANGE YOKE 2 SW U-JOINT 3 SW YOKE & SHAFT STRUCTURE 4 SW FEMALE SLIP YOKE 5 SW YOKE 5A SW YOKE 6 SW CAPSCREW,.44 x SW LUBE FITTING 8 SW LOCKWASHER 9 SW KEY 10 SW SET SCREW,.38 x SW U-BOLT KIT PAGE 2-2

24 CONTROL VALVE PAGE 2-3

25 CONTROL VALVE SEC CHALLENGER Item SEC Part number QTY Description 1 SW INLET 2 SW VALVE SECTION 3 SW VALVE SECTION 4 SW VALVE SECTION 5 SW MIDDLE INLET 6 SW VALVE SECTION 7 SW OUTLET 8 SW VALVE SECTION 9 SW STUD ASSEMBLY 9A SW STUD ASSEMBLY 9B SW STUD ASSEMBLY 10 SW PNEUMATIC ACTIVATOR ASSEMBLY 11 SW PNEUMATIC ACTIVATOR SEAL KIT 12 SW SEAL KIT 13 SW SEAL KIT 14 SW SEAL KIT 15 SW SEAL KIT PAGE 2-4

26 HYDRAULIC TANK PAGE 2-5

27 HYDRAULIC TANK SEC CHALLENGER Item SEC Part number QTY Description 1 SW MODIFIED FILTER 2 SW R.H. HYDRAULIC TANK STRUCTURE (L.H. UNITS) 2A SW L.H. HYDRAULIC TANK STRUCTURE (R.H. UNITS) 3 SW BALL VALUE 4 SW BREATHER CAP 5 SW ADAPTER 6 SW GAUGE 7 SW ADAPTER 8 SW GASKET 9 SW SIGHT GAUGE 10 SW SUCTION STRAINER 11 SW BREATHER ASSEMBLY 12 SW SCREW, #10 x.50 PAN HEAD 13 SW NIPPLE 14 SW COMBO NIPPLE 15 SW ELL 16 SW PLUG 17 SW PLUG 18 SW CAPSCREW,.38 x SW CAPSCREW,.38 x SW LOCKWASHER 21 SW ELEMENT PAGE 2-6

28 HYDRAULIC SYSTEM PAGE 2-7

29 HYDRAULIC SYSTEM SEC CHALLENGER Item SEC Part number QTY Description 1 SW L.H. HYDRAULIC TANK ASSEMBLY 1A SW R.H. HYDRAULIC TANK ASSEMBLY 2 SW CARTRIDGE BLOCK 3 SW VALVE 3A SW VALVE (W/1 OPTIONAL SECTION) 3B SW VALVE (W/2 OPTIONAL SECTION) 4 SW TUBE ASSEMBLY 5 SW TUBE ASSEMBLY 6 SW ADAPTER 7 SW COIL SPRING 8 SW DRY VALVE 9 SW RUBBER PAD 10 SW G.P.M. CARTRIDGE 10A SW G.P.M. CARTRIDGE 10B SW G.P.M. CARTRIDGE 11 SW O-RING 12 SW O-RING 13 SW MODIFIED FITTING 14 SW PUMP 15 SW ADAPTER 16 SW MODIFIED FITTING 17 SW PLUG 18 SW ADAPTER 19 SW ADAPTER 20 SW ADAPTER 21 SW FLOW CONTROL 22 SW ADAPTER 23 SW ADAPTER 24 SW ADAPTER 25 SW HOSE CLAMP (CONT.) PAGE 2-8

30 HYDRAULIC SYSTEM SEC CHALLENGER Item SEC Part number QTY Description 26 SW NIPPLE 27 SW ADAPTER 28 SW ADAPTER 29 SW ELL 30 SW COMBO NIPPLE 31 SW ADAPTER 32 SW ADAPTER 33 SW ADAPTER 34 SW ADAPTER 35 SW ADAPTER 36 SW ADAPTER 37 SW ADAPTER 38 SW FLANGE PAD 39 SW FLANGE PAD 40 SW GAUGE 41 SW PRESSURE FILTER 42 SW ELEMENT 43 SW ADAPTER 44 SW SUCTION HOSE 2.00 x (SPECIFY LENGTH) 45 SW HOSE ASSEMBLY 46 1 HOSE ASSEMBLY 47 1 HOSE ASSEMBLY 48 SW HOSE ASSEMBLY 49 SW HOSE ASSEMBLY 50 SW HOSE ASSEMBLY (L.H. UNIT) 50A SW HOSE ASSEMBLY (R.H. UNIT) 51 SW HOSE ASSEMBLY (L.H. UNIT) 51A SW HOSE ASSEMBLY (R.H. UNIT) 52 SW HOSE ASSEMBLY 53 SW HOSE ASSEMBLY (CONT.) PAGE 2-9

31 HYDRAULIC SYSTEM SEC CHALLENGER Item SEC Part number QTY Description 54 SW HOSE ASSEMBLY 55 SW HOSE ASSEMBLY 56 SW HOSE ASSEMBLY 57 SW HOSE ASSEMBLY 58 SW HOSE ASSEMBLY 59 SW MODIFIED FITTING 60 SW FLATWASHER 61 SW HEX NUT,.50 NYLOCK 62 SW LOCKWASHER 63 SW LOCKWASHER 64 SW LOCKWASHER 65 SW CAPSCREW,.50 x SW CAPSCREW,.50 x 1.25 SOCKETHEAD 67 SW CAPSCREW,.50 x 2.00 SOCKETHEAD 68 SW CAPSCREW,.50 x 1.75 SOCKETHEAD 69 SW MODIFIED FITTING 70 SW SEAL KIT 71 SW ADAPTER 72 SW ALUMINUM BLOCK 73 SW CARTRIDGE 74 SW ADAPTER 75 SW HOSE ASSEMBLY 76 SW HOSE ASSEMBLY 77 SW HOSE ASSEMBLY 78 SW HOSE ASSEMBLY 79 SW ADAPTER 80 SW ADAPTER PAGE 2-10

32 MAST HYDRAULICS PAGE 2-11

33 MAST HYDRAULICS SEC CHALLENGER Item SEC Part number QTY Description 1 SW ADAPTER 2 SW ADAPTER 3 SW HYDRAULIC HOSE PAGE 2-12

34 END GATE HYDRAULICS PAGE 2-13

35 END GATE HYDRAULICS SEC CHALLENGER Item SEC Part number QTY Description 1 SW ADAPTER 2 SW ADAPTER 3 SW ADAPTER 4 SW HYDRAULIC HOSE 5 SW HYDRAULIC HOSE 6 SW HYDRAULIC HOSE 7 SW HYDRAULIC HOSE 8 SW HYDRAULIC HOSE 9 SW HYDRAULIC CYLINDER 10 SW HYDRAULIC CYLINDER 11 SW FLOW CONTROL 12 (REF) 2 COUPLER STRUCTURE PAGE 2-14

36 SECTION 3 ELECTRICAL Lights 3-1, 3-2 Cab Control Box Parts 3-3, 3-4 Outside Control Box Parts 3-5, 3-6 Cab Control Box Schematic 3-7 Outside Control Box Schematic 3-8

37 LIGHTS PAGE 3-1

38 LIGHTS SEC CHALLENGER Item SEC Part number QTY Description 1 SW STOP/TURN LIGHT ASSEMBLY 2 SW AMBER STROBE ASSEMBLY 3 SW CLEAR BACK-UP LIGHT ASSEMBLY 4 SW LICENSE PLATE LIGHT ASSEMBLY 5 SW AMBER 2 1/2'' LIGHT ASSEMBLY 6 SW RED 2 1/2'' MARKER LIGHT ASSEMBLY 7 SW WORK LIGHT ASSEMBLY 8 SW /2'' AMBER MARKER 9 SW /2'' STOP LIGHT PAGE 3-2

39 CAB CONTROL BOX PARTS PAGE 3-3

40 CAB CONTROL BOX PARTS SEC CHAMPION Item SEC Part number QTY Description 1 SW TWIST ON SWITCH 2 SW PACK AUTO/MANUAL SWITCH ** 3 SW PACK PUSH/PULL SWITCH 4 SW PTO LIGHT 5 SW OVERSPEED LIGHT 6 SW TAILGATE LIGHT W/BUZZER 7 SW MAST LIGHT 8 SW PACK LIGHT 9 SW EXTEND/RETRACT SWITCH 10 SW WORKLIGHT SWITCH ** 11 SW STROBE SWITCH ** 12 SW GATE UP/DOWN SWITCH **Note: Item 2, 10, and 11, are the same switch, with the exception that Item #2 requires an additional contact. PAGE 3-4

41 OUTSIDE CONTROL BOX PARTS PAGE 3-5

42 OUTSIDE CONTROL BOX PARTS SEC CHAMPION Item SEC Part number QTY Description 1 REF. 1 COMPLETE OUTSIDE CONTROL BOX 2 REF. 1 FITTING 3 SW AIR FITTING (BULKHEAD) 4 SW AIR FITTING 5 SW AIR FITTING 6 7 SW AIR FITTING 8 SW VALVES 9 SW COILS 10 REF. 1 PLATE 11 REF. 1 FITTING (BULKHEAD) 12 REF. 1 FITTING 13 SW PRESSURE SWITCH 14 SW TERMINAL STRIP 15 SW DIODE 16 SW CONNECTOR 17 SW CONNECTOR 18 SW CONNECTOR PAGE 3-6

43 CAB CONTROL BOX SCHEMATIC PAGE 3-7

44 OUTSIDE CONTROL BOX SCHEMATIC PAGE 3-8

45 SECTION 4 AIR AIR SYSTEM 4-1, 4-2

46 AIR SYSTEM PAGE 4-1

47 AIR SYSTEM SEC CHALLENGER Item SEC Part number QTY Description 1 (REF) 1 VALVE BLOCK 2 SW DRY VALVE 3 SW ADAPTER 4 SW ADAPTER 5 SW ADAPTER 6 SW ADAPTER 7 SW ADAPTER 8 (REF) 1 AIR TANK 9 SW MODIFIED FITTING 10 SW STATION VALVE BANK 11 SW ADAPTER 12 SW ADAPTER 13 SW SOLENOID 14 SW AIR VALVE (3 BANK) 14A SW AIR VALVE (2 BANK) 15 SW ONE WAY CHECK VALVE 16 SW AUTO DRAIN AIR VALVE 17 SW AIR BRAKE TUBING (SPECIFY LENGTH) 18 SW ADAPTER 19 SW ADAPTER 20 SW SINGLE VALVE BANK 21 SW PLUG,.13 HEX PAGE 4-2

48 SECTION 5 LUBRICATION MAST & LIFTING ATTACHMENTS 5-1 BODY GROUP 5-2 ACCESS DOOR 5-3

49 MAST & LIFTING ATTACHMENTS PAGE 5-1

50 BODY GROUP PAGE 5-2

51 ACCESS DOOR PAGE 5-3

52 SECTION 6 OPTIONS GRABBER 6-1, 6-2 GRABBER HYDRAULICS 6-3, 6-4

53 UNIVERSAL GRABBER Part # SW PAGE 6-1

54 UNIVERSAL GRABBER SEC CHALLENGER Item SEC Part number QTY Description 1 SW Universal Back Structure 2 SW Drilled Pin 3 SW Rubber Roller 4 SW LH Outer Arm Structure 5 SW RH Outer Arm Structure 6 SW LH Middle Arm Structure 7 SW RH Middle Arm Structure 8 SW Inner Arm Structure 9 SW Bushing 10 SW Drilled Pin 11 SW Rubber Bumper 12 SW Lube Fitting 13 SW Bushings 14 SW Bushings 15 SW Camfollower 16 SW Extension Springs 17 SW Capscrews 18 SW Capscrews 19 SW Capscrews 20 SW Setscrews 21 SW Elevator Bolts 22 SW Nylock Nut 23 SW Nylock Nut 24 SW Nylock Nut 25 SW Hex Nut 26 SW Flatwasher 27 SW Lockwashers 28 REF 2 Hydraulic Cylinder 29 REF 1 Cartridge Block 30 SW Clevis Pins 31 SW Flatwasher 32 SW Cotter Pins 33 SW Capscrews 34 SW Nylock Nut 35 SW Flatwasher PAGE 6-2

55 GRABBER HYDRAULICS Part # SW (GW200-2A Series) PAGE 6-3

56 GRABBER HYDRAULICS Part # SW SEC CHALLENGER Item SEC Part number QTY Description 1 1 VALVE 2 SW CAPSCREW 3 SW FORMED FLAT 4 SW HYDRAULIC CYLINDER 5 SW S 1 CARTRIDGE BLOCK 6 SW S 1 CARTRIDGE 7 SW S 1 PO CHECK 8 9 SW ADAPTER 10 SW ADAPTER 11 SW ADAPTER 12 SW ADAPTER 13 GRABBER BACK STRUCTURE 14 SW ADAPTER 15 SW DOUBLE HOSE CLAMP 16 SW HYDRAULIC HOSE 17 SW HYDRAULIC HOSE 18 SW ADAPTER 19 SW CLEVIS STRUCTURE 20 SW HYDRAULIC HOSE (48'' REACH) 21 SW HYDRAULIC HOSE 22 SW HYDRAULIC HOSE 23 SW /4'' LOCKWASHER 24 SW /4'' FLATWASHER 25 SW ADAPTER 26 SW ADAPTER 27 SW SETSCREWS PAGE 6-4