1528224612cooper SP-550 Rig601 2

Dragon Rigs COOPER SP-550 Page 1 of 1
Sales and Service WORKOVER RIG
PARTS AND SERVICE MANUAL

COOPER SP-550 WORKOVER RIG
CUSTOMER ATINA INVESTMENT CORP

MANUFACTURER DRAGON RIG SALES AND
SERVICES, LTD.
MODEL NUMBER COOPER SP-550 DD-ASH
SERIAL NUMBER 4114
DATE OF MANUFACTURE 07/2014
Dragon Rigs COOPER SP-550DD-ASH Page 1 of 2
Sales and Service TABLE OF CONTENTS
1. RIG UP AND RIG DOWN INSTRUCTIONS
2. GENERAL INFORMATION:
- UNIT DATA SHEET
- LUBRICATION CHART
- POWER FLOW DIAGRAM
- GENERAL ARRANGEMENT DRAWING—COOPER SP-550
3. CARRIER AIR SYSTEM:

- SCHEMATIC—AIR SYSTEM
- DRAWING AND SCHEMATIC—DRILLER’S CONSOLE
- PARTS LISTS—AIR SYSTEM COMPONENTS
4. CARRIER HYDRAULIC SYSTEM:

- SCHEMATIC—HYDRAULIC SYSTEM
- ASSEMBLY DRAWING—HYDRAULIC VALVE BANK
- ASSEMBLY DRAWING—HYDRAULIC LEVELING JACK
- CHELSEA 852 P.T.O. MATERIAL LIST
- CHELSEA 852 P.T.O. OWNERS MANUAL
5. CARRIER ASSEMBLY:
- ASSEMBLY DRAWING—CAB
- ASSEMBLY DRAWING—DASH PANEL
- ASSEMBLY DRAWING—STEERING SYSTEM
- SCHEMATIC—POWER STEERING
- DRAWING—CARRIER RUNNING LIGHTS
6. CARRIER AXLES [STEER, DRIVE, & TAG:

- INSTALLATION DRAWING—FRONT AXLES AND SUSPENSION
- INSTALLATION DRAWING—REAR AXLES AND SUSPENSION
- PARTS LIST—FRONT STEERING AXLES
- PARTS LIST—REAR DRIVE AXLES
- PARTS LIST—HENDRICKSON R-463 WALKING BEAM SUSPENSION
- PARTS LIST—“LINK” TAG AXLE 8A000451
7. CARRIER ENGINE/TRANSMISSION PACKAGE:

- ENGINE/TRANSMISSION PACKAGE—REPLACEMENT PARTS LIST
- INSTALLATION DRAWING—ENGINE/TRANS INSTALLATION
- ERROR MESSAGE CODES—MURPHY POWER VIEW
- INSTALLATION AND OPERATIONS MANUAL—MURPHY POWER VIEW
- LIMITED WARRANTY STATEMENT—DETROIT DIESEL SERIES 60
- TRANSMISSION SPECIFICATIONS—ALLISON M5610
- LIMITED WARRANTY STATEMENT—ALLISON TRANSMISSION
8. DRAWWORKS:
- ASSEMBLY DRAWING—RIGHT ANGLE DRIVE
- ASSEMBLY DRAWING—MAIN DRUM SHAFT
- ASSEMBLY DRAWING—SAND DRUM SHAFT
- INSTALLATION DRAWING—HYDROMATIC INSTALLATION
- INSTALLATION DRAWING—HYDROMATIC PIPING
- INSTALLATION DRAWING—MAIN AND SAND DRUM SHAFT INSTALLATION
- INSTALLATION DRAWING—DRAWWORKS GUARDS
- INSTALLATION DRAWING—DRILLERS CONSOLE STAND
Dragon Rigs COOPER SP-550DD-ASH Page 2 of 2
Sales and Service TABLE OF CONTENTS
- ASSEMBLY DRAWING—DRAWWORKS BRAKE SYSTEM

- INSTALLATION DRAWING—MAIN DRUM BRAKE LINKAGE
- INSTALLATION DRAWING—SAND DRUM BRAKE LINKAGE
- BRAKE ADJUSTMENT PROCEDURE
9. CLUTCHES AND POSI STOP SYSTEM:

- PARTS LIST—WPT PO-324 CLUTCH—MAIN DRUM CLUTCH
- PARTS LIST—WPT PO-224 CLUTCH—SAND DRUM/HYDROMATIC CLUTCH
- SERVICE MANUAL—WPT PO STYLE CLUTCH
- INSTALLATION AND OPERATING MANUAL—POSI STOP SYSTEM
10. HYDROMATIC:
- MAINTENANCE CHECKLIST
- PARTS LIST
- INSTALLATION, REPAIR AND MAINTENANCE INSTRUCTUIONS
- GENERAL ASSEMBLY DRAWING
11. SERVICE WINCH:

- INSTALLATION, MAINTENANCE, AND SERVICE MANUAL
12. MAST, DRAGON PRODUCTS, 104-250-8-T:

- ASSEMBLY DRAWING—104’-250,000 MAST ASSEMBLY
- ASSEMBLY DRAWING—CROWN ASSEMBLY, 8 LINE, 1” GROOVE
- DIAGRAM—DRILL LINE STRING UP
- INSTALATION DRAWING—TUBING BOARD—55’ POSITION
- DRAWING—TUBING BOARD CAPACITY
- INSTALLATION DRAWING—ROD BOARD
- INSTALLATION DRAWING—TELESCOPING RAM
- ASSEMBLY DRAWING—TELESCOPING RAM
- ASSEMBLY DRAWING—TILT TURNBUCKLES
- DRAWING—MAST SPECIFICATION PLATE
- INSTALLATION DRAWING—LOAD AND WIND GUYLINES
- ASSEMBLY DRAWING—RAISING RAM
- INSTALLATION DRAWING—TONG LIFT CYLINDER
- INSTALLATION DRAWING—TONG CYLINDER SHEAVE BRACKETS
- INSTALLATION DRAWING—O.D.S. SERVICE WINCH SHEAVES
COOPER SP-550
RIG UP AND RIG DOWN INSTRUCTIONS
1. All operating instructions should be read and fully understood by all crew members before
attempting to operate rig.
2. Proceed slowly and carefully during all rig operations, especially during initial rig up. Always
watch for falling objects during rig-up operations [tools, debris, etc.]
3. During all operations, always watch for interference of lines, hoses, etc. with any moving
equipment.
4. Before operating any hydraulic equipment, circulate and bleed hydraulic oil as described in various
operating instructions. Air in hydraulic oil system can cause accidents.
5. Never open or close any control valves abruptly, as this can cause severe shock loads resulting in
structural damage.
6. As with any piece of heavy equipment, utmost caution must be exercised at all times to prevent
damage to equipment and/or injury to personnel.
I. SPOTTING RIG ON WELL
A. After substructure [if equipped] and related equipment has been placed over the well
proceed as follows.
B. Back the unit onto the rig mat [if equipped]. Be sure to center unit with the well center.
Back up the unit until the rear hydraulic leveling jacks on the carrier meet the specified
distance to the center of well as described on the mast specification plate.
C. Once positioned turn the engine off and switch the transmission from road gear to winch
gear. Go to the panel behind the cab and switch the control valve from “cab air” to “rig
air”. Go the driller’s console and engage the hydraulic pump. Go to hydraulic valve bank
console and verify that the hydraulic diverter valve is positioned for “rig up mode”.
D. Position jack support stands under the front and rear hydraulic leveling jacks of the unit.
Raise the front of the unit, using the hydraulic leveling jacks
E. Use the front and rear hydraulic leveling jacks to level the frame. Raise the carrier frame
deck height enough to remove the weight of the rig from the suspension, approximately 52”
to 54” from the ground or rig mat floor to the top of the carrier deck or walkways. When
leveled, lock the front and rear hydraulic leveling jacks by jamming the lock nut to the jack
sleeve.
F. Screw down the base screws on the front legs of the mast until they touch the supports on
the base beam. Just snug the screw, do not over tighten.
II. RAISING/LOWERING THE MAST
NOTE: AIR IN A HYDRAULIC SYSTEM CAN CAUSE ACCIDENTS.
A. Unhook the mast from the headache rack.

B. After the unit has been positioned and leveled, check the lean angle on the base section. It
should be 31/2 deg.
C. Insure the hydraulic pump is still engaged.
D. Circulate the hydraulic fluid for two to three minutes.
E. Before raising or lowering the mast, secure all support cables in proper position. Unreel the
guylines so they are free of the rig. Fouled lines can cause damage to equipment and injury
to crew.
F. This unit is equipped with two double acting raising rams that raise the mast from the
headache rack position to half mast. The following procedure must be followed to remove
possible entrapped air in the rams: Open the bleeder valve in the top or smallest section of
the ram, the section that pins directly to the mast, and move the mast raising control valve
handle to raise position slowly. It is necessary to open the control valve only slightly so oil
will flow in a limited amount. Excessive opening of the control valve during bleeding will
result in waste of oil, and difficulty in determining when air has been purged due to high
pressure discharge from bleeder valve. A foamy discharge from the bleeder valve indicates
air. When clear oil is discharging, close the bleeder valve finger tight. Do not use pliers or
wrenches, as seat of bleeder valve may be damaged by excessive tightening. It can be closed
off properly with finger pressure. Perform this procedure on each of the two rams
independently. Next, open the bleeder valve on the second stage of the ram-it will be just
below the location of the upper section bleeder. Move the control valve handle to the lower
position slowly as outlined above. When a clear, air free stream of oil flows from the bleeder
valve, close it as directed above.
When the mast is being lowered from half mast to headache rack follow the same bleeding
instructions as outlined above.
G. Raise the mast until approximately 12” of the middle stage is exposed. Lower the mast to the
headache rack and perform the bleeding procedure again as outline above. Once complete,
raise the mast until approximately 12” of the small stage is exposed. Lower the mast to the
headache rack and perform the bleeding procedure again as outlined above. If no air is
present then continue to the next step.
H. Open the control valve to the raising ram. Pressure will be directed to the mast raising rams.
I. Mast raising may be stopped at any point by releasing the valve handle slowly to neutral.
The mast may be lowered any amount by placing the control valve in the opposite position
from that of raising.
J. As the mast nears fully raised position, ease the mast into full tilt position.
K. When the mast is raised to the half mast position, insert the pin into the pin connection
between the base and lower section of the mast on the front legs. Install safety pins.
L. Install the appropriate tie down turnbuckles from the carrier frame to the rig mat[if equipped]
and from the mast base section to the base beam.
III. TELESCOPING THE MAST
A. Before the process for telescoping the mast begins, verify that the mast locks are fully retracted.
Damage to the mast and equipment can happen if these locks are not retracted.
B. Verify that all telescoping ram stabilizers are in proper working order.
C. Verify all reeveing lines, guylines, and hoses are free from the mast. Verify all hydraulic leveling
jacks, and base leg screws are touching the relevant supports and loaded.
D. It is necessary to bleed the air from the telescoping ram. To do so, open the bleeder on the
telescoping ram and slightly open the control valve for telescoping the mast. Once a clear, air free
stream of oil discharges from the bleeder, close the bleeder.
E. Engage the telescoping valve and telescope the mast, spooling drill line as mast scopes.
F. The racking board will fold into the working position as the upper section is extended.
G. The upper section extension may be stopped at any point by allowing the control handle to return
to neutral.
H. Extend the upper section slightly past the lock support in the middle section. The locks have to be
manually engaged. Make sure the locks are fully extended, and then slowly lower the upper
section onto the locks in the middle section.
I. Install the safety pin on the lock control lever to insure the locks can not disengage during
operation of the unit.
J. After the mast is raised, locked in vertical position, telescoped, and the locks are set properly,
either disengage the hydraulic system or kill the rig engine so no oil is being pumped. Move the
raising ram hydraulic control valve handle to “raise” and “lower” for about five seconds each.
Repeat the above procedure with the telescoping ram hydraulic control valve. This is to relieve
pressure on the rams. They are not to carry pressure except during actual raising and lowering of
the mast.
K. Open the thermal expansion valve.[If equipped]
L. Position the hydraulic diverter valve to “work mode”. This action will kill the rig up bank on the
hydraulic system, preventing any accidental operations of the incorrect valve.
IV. MAST RIGGING
A. Secure the guylines. The manufacturer recommends that the mast be guyed according to
structural mast specifications and guying instruction plate located on the mast base section.
V. TO LOWER UPPER SECTION
A. Engage hydraulic pump.

B. Position hydraulic diverter valve to “rig up mode”.
C. Remove the safety pin from the lock control lever.
D. Circulate hydraulic oil for two to three minutes if oil is cold. If hydraulic system has been
in use immediately before, this circulation is not required.
E. Verify that all telescoping ram stabilizers are in proper working order.
F. Disengage guylines.
G. Pressure up on telescoping ram to lift the upper section until the locks can be retracted.
H. Once the locks are retracted, install the safety pin to hold the locks in the retracted position.
I. Verify locks are fully retracted before proceeding to the next step.
J. Slowly lower the upper section.
K. Be sure that guylines, hoses and other equipment do not foul while lowering the upper
section.
L. Spool up tubing line as upper section is lowered.
VI. TO LOWER MAST ONTO HEADACH RACK
A. Remove all turnbuckles connecting the unit and base section to the rig mat[if equipped] and
mast base.
B. CAUTION TO OPERATOR—Bleeding the raising rams before lowering the mast is the
most important operation in the proper usage of this mast. Do not proceed to lower the mast
until the raising rams are free from air. See II-G.
C. Remove the pin from the pin connection between the base and lower section of the mast on
the front legs[closest to well]
D. Verify all guylines, hoses, and equipment will not foul while lowering the mast.
E. Start mast back by slowly pressuring pull-back stage of the cylinders. This is done by
moving the valve handle opposite to position used for raising the mast.
F. Once the mast “breaks over” it is lowered to the head rest by the raising ram.
G. Stress loads on the mast and lowering equipment can be significantly reduced if the mast is
“broken over” and lowered slowly and smoothly. Abrupt starting and stopping movements
can produce unnecessary and potentially hazardous stress loads in the mast and ram
structures.
H. Hook the mast to the headache rack to insure the mast will not bounce on the headache rack
while traveling in rough terrain.
I. Ensure the transmission is in “neutral”.
J. Unsrew locknuts on the hydraulic leveling jacks. Raise hydraulic leveling jacks until the
unit rests on the tires.
K. Tie up all lines, hoses, cables, etc. Fold handails and walkways up. Make the unit ready for
road travel.
L. Go to the operator’s panel at the engine and switch the control valve from “rig air” to “cab
air”.
M. Go to the cab and switch the toggle valve for the transmission shifter from “work” to “cab”.
N. The unit is now ready for road travel.
Sales and Service UNIT DATA SHEET
UNIT:
- JOB NUMBER—6046
- MODEL—COOPER SP-550 DD-ASH
- SERIAL NUMBER—4114
- DATE OF MANUFACTURE—7/2014
DRAWWORKS:
- MODEL—COOPER 550DD-ASH
- DESCRIPTION—42 X 12 X 38, 1” GRV
AUXILIARY BRAKE:
- MANUFACTURER—PARMAC 202
- MODEL—D632061-X
MAST:
- MANUFACTURER—DRAGON PRODUCTS, LTD.

- MODEL—104-250-8-T
MAST RAISING RAMS:
- MODEL NUMBER—SD83CC-24-131
- PART NUMBER—377 3033043
ENGINE:
- MANUFACTURER—DETROIT DIESEL
- MODEL—SERIES 60 [14L] [500 HP]
- SERIAL NUMBER—06R1061552
TRANSMISSION:
- MANUFACTURER—ALLISON
- MODEL—M5620A
Sales and Service UNIT DATA SHEET
RIGHT ANGLE DRIVE:
- MANUFACTURER—DRAGON RIGS SALES AND SERVICE, LTD.

- MODEL—COOPER 550
- PART NUMBER—DR2200-21
FRONT STEERING AXLES:
- MANUFACTURER—ARVIN MERITOR
- PART NUMBER—[ONE] FL941LX323 AND [ONE] FL941LX324
DRIVE AXLES:
- MANUFACTURER—ARVIN MERITOR
- FRONT DRIVE AXLE PART NUMBER—RP23160NCL2220 614
- REAR DRIVE AXLE PART NUMBER—RR23160NCL3737 614
TAG AXLE:
- MANUFACTURER—HENDRICKSON
- PART NUMBER—TRLAXLE.239
- DESCRIPTION—NH-S505-0714-WF1670L
- SUSPENSION PART NUMBER—8A000451 [LINK]
TIRES:
- FRONT TIRE SIZE—425/65R22.5 [FOUR REQD]

- REAR TIRE SIZE—11R22.5 [TWELVE REQD]
SERVICE WINCH:
- MANUFACTURER—PULL MASTER
- MODEL—PL-8
P.T.O.—TRANSMISSION MOUNTED:
- MANUFACTURER—CHELSEA
- MODEL NUMBER—852XBAKPF6XS
POWER STEERING PUMP—ENGINE MOUNTED:
- MODEL NUMBER—V20-F1P7P-38C8-F-20L
HYDRAULIC PUMP:
- MODEL NUMBER—P37X378BAJC 25-7

Sales and Service LUBRICATION CHART
REV--1
LUBRICATION TYPE DAILY WEEKLY MONTHLY

LOCATION
ENGINE OIL MOBILE 15W40 CHECK
API CLASS: CI-4
ENGINE ANTIFREEZE ETHYLENE CHECK
GLYCOL COOLANT
50/50.
SPEC-GM6038-M,
ASTM D 4985
TRANSMISSION OIL MOBILE 15W40 CHECK
API CLASS: CI-4
RIGHT ANGLE DRIVE 80W90 GL-5 SYN. CHECK
GEAR OIL
REAR DRIVE AXLES 80W90 GL-5 SYN. CHECK
GEAR OIL
FRONT STEER AXLE 80W90 GL-5 SYN. CHECK
WHEEL HUBS GEAR OIL
TAG AXLE WHEEL 80W90 GL-5 SYN. CHECK
HUBS GEAR OIL
KING PINS FOR MYSTIK JT-6 HI CHECK
FRONT STEER AXLES TEMP GREASE
REAR AXLE CHECK
WALKING BEAM MYSTIK JT-6 HI
CENTER PIN [IF TEMP GREASE
EQUIPPED]
TAG AXLE HINGE MYSTIK JT-6 HI CHECK
POINT TEMP GREASE
U-JOINTS MYSTIK JT-6 HI CHECK
TEMP GREASE
CROWN SHEAVES MYSTIK JT-6 HI CHECK
TEMP GREASE
MAST HINGES MYSTIK JT-6 HI CHECK
TEMP GREASE
DRAWWORKS DRUM CHECK
MYSTIK JT-6 HI
BEARINGS, BRAKE
TEMP GREASE
LINKAGE, & R.A.D.
HYDRAULIC TANKS CONOCO SUPER 68 CHECK
AND POWER
STEERING
CHAIN DRIVES CONOCO R&O 150 CHECK
Air Dryers 05−AIRLINE/AIR DRYERS
Haldex/Midland (New/Remanufactured)
PURest® Air Dryer
Features:
• Multi−Treatment Cartridge employs 5 stages of cleaning to ensure dry
system air.
• Universal mounting bracket eases retro−fit installations. Fits Pure Air
Plus, DRYest, AD type and SS type air dryer bolt patterns.
• Integrated turbo protection.
• Built−in heater prevents freezing and damage to the dryer.
Specifications:
Stages of Drying 5
Internal Purge Volume 210 cu. in.
Inlet Air Temperature −40°F to +175°F
Maximum Working Pressure 150 psi
Safety Relief Pressure 175 psi
Secondary Pressure Protection 235 psi
12, 24 Volt Heater 95W
Flow Capacity 34 SCFM
Desiccant Cartridge 3.5 lbs.
Assembly Weight 22.0 lbs.
Integrated Turbo Protection Pressure Drop 2 psi @ 15
SCFM/120 psi
Notes:
1) Fits in 17−3/4" x 9−3/4" x 9−1/2" Envelope. This includes

1/2" clearance needed for desiccant cartridge change.
2) DA34200 for Holset "E" Type Compressor application.
SKU# Product Description Heater Notes OEM Part Number

DA34100 PURest® Air Dryer 12 Volt with Bracket, Inlet Port − Left N4253AA
DA34105 PURest® Air Dryer None with Bracket, Inlet Port − Left N4253AD
DA34110 PURest® Air Dryer 24 Volt with Bracket, Inlet Port − Left N4253AB
DA34160 PURest® Air Dryer 12 Volt without Bracket, Inlet Port − Left N4253J
DA34200 PURest® Air Dryer 12 Volt with "Econ" Valve, Bracket, Inlet −Left −
DA34310 PURest® Air Dryer 24 Volt Inlet Port Right N4254AB
05 − 9
05−AIRLINE/AIR DRYERS Air Dryers
Haldex/Midland (New/Remanufactured)
PURest® Service Kits
SKU# Product Description Application Notes OEM Part Picture

Number
DA33115 Purge Assembly Kit for DA33100, DA33100X, DA33100BX, − − 2
Pure Air PlusВ™ and DA33110, DA33110X, DA33140,
PURest® Air Dryer DA33140X, DA33200, DA33200X,
DA33240, DA33240X, DA33105,
DA34100, DA34105, DA34110, DA34200
DQ6013 Heater Kit for Pure Air DA33100, DA33100X, DA33100BX, 12 Volt − For dryers date − 1
PlusВ™ and PURest® Air DA33140, DA33140X, DA33200, coded after 8/97; includes
Dryer DA33200X, DA33240, DA33240X, Heater 102655DP.
DA34100, DA34200
DQ6014 24 Volt Heater Kit for Pure DA33110, DA33110X, DA34110 24 Volt − For dryers date − 1
Air PlusВ™ and PURest® coded after 8/97; includes
Air Dryer Heater 102655DT.
DQ6023 Purge Shield Kit for Pure DA33100, DA33100X, DA33100BX, − − 6
Air PlusВ™ and PURest® DA33110, DA33110X, DA33140,
Air Dryer DA33140X, DA33200, DA33200X,
DA33240, DA33240X, DA33105,
DA34100, DA34105, DA34110, DA34200
DQ6027 Extended Purge Kit (Tank) DA33100, DA33105, DA33110, Kit contains (2) Tube and − 11
for Pure Air PlusВ™ and DA33140, DA33200, DA33240, Fitting Assembly, (1) 1/4"
PURest® Air Dryer DA34100, DA34105, DA34110, DA34200 Drain Valve, (1) 3/8" Pipe
Plug and (1) Air Reservoir.
DQ6037 Differential Feedback DA33100, DA33100X, DA33140, − − 7
Check Valve Kit for Pure DA33140X, DA33200, DA33200X,
Air PlusВ™ and PURest® DA33240, DA33240X, DA34100,
Air Dryer DA34200
DQ6050 MTC Desiccant Cartridge DA34100, DA34105, DA34110, DA34200 − − 10
Kit for PURest® Air Dryer
DQ6051 Universal Mounting DA34100, DA34105, DA34110, DA34200 − − 3
Bracket
DQ6052 Turbo Protection Valve Kit DA34100, DA34105, DA34110, DA34200 − − 4
for PURest® Air Dryer
DQ6053 Lower Housing Repair Kit DA34100, DA34105, DA34110, DA34200 − − 8
for PURest® Air Dryer
05 − 16
Air Dryers 05−AIRLINE/AIR DRYERS
DQ6054 O−Ring Kit for PURest® 47178964, DQ6050 10 pack − 13
and DRYest® Cartridge
RN60G One−Way Check Valve Kit KN33000, KN33002, KN33010 Outlet check valve kit. − 5
for Pure AirВ™, Pure Air KN33011, KN33012, DA33100
PlusВ™ and PURest® Air DA33105, DA33110, DA33140
Dryer DA33200, DA33240, DA34100
DA34105, DA34110, DA34200
05 − 17
REXROTH “A” PILOTAIR® VALVE SERVICE INFORMATION
Figure 18: 2-HA-1 PILOTAIR Valve Cam Housing Exploded View
REF. QTY. DESCRIPTION NEW PART NO. OLD PART NO.

1* 1 SCREW R431001837 P -049526-00003
1A* 1 SCREW (Latching Models Only) R431001839 P -049526-00005
2* 1 WASHER R431002408 P -049898-00000
2A* 1 WASHER (Latching Models Only) R431002408 P -049898-00000
3* 1 NAMEPLATE R431001739 P -049408-00000
4 1 KNOB, Handle R431004273 P -057662-00000
5 1 HANDLE R431004984 P -059312-00000
5A 1 SPRING, Handle Latch (Latching Models R431005355 P -059987-00000
Only)
5B 1 COLLAR (Latching Models Only) R431005865 P -061962-00000
5C 1 LATCH, Handle (Latching Models Only) R431001979 P -061762-00000
5D 1 PIN, Driv-Lok (Latching Models Only) R431001979 P -049705-00008
6 1 PLUG R431002563 P -049958-00008
7 1 HUB, Handle R431004981 P -059311-00000
8 2 WASHER R431002165 P -049804-00039
9 1 CAM R431004904 P -059080-00003
10 1 SPACER R431001740 P -049410-00001
11 2 ARBOR, Spring (Spring Returned Models R431004979 P -059307-00000
Only)
12 1 SPRING (Spring Returned Models Only) R431004978 P -059306-00001
13 1 SHAFT, Handle R431004987 P -059313-00000
14 1 RING, Retaining R431002333 P -049857-00007
15* 1 FOLLOWER, Cam R431005076 P -059370-00001
16 1 HOUSING, Cam R431004955 P -059299-00006
16A 1 HOUSING, Cam (Latching Models Only) R431004959 P -059299-00010
* All items, except these, are needed in a Cam Housing Position, see pages 10 and 11.
Page 18
REXROTH “A” PILOTAIR® VALVE SERVICE INFORMATION
COMPLETE VALVE PIECE NUMBERS

(Includes the Valve Portion and
Cam Housing
Portion with the corresponding
Handle Latch.
Figure 19: 2-HA-2

PILOTAIR Valve Cam
Housing Exploded View
REF. QTY. DESCRIPTION NEW OLD
PART NO. PART NO.
1* 1 SCREW R431001837 P -049526-00003
1A* 1 SCREW (Latching Models Only) R431001839 P -049526-00005
2* 1 WASHER R431002408 P -049898-00000
2A* 1 WASHER (Latching Models Only) R431002408 P -049898-00000
3* 1 NAMEPLATE R431001739 P -049408-00000
* All items, except these, are
4 1 KNOB, Handle R431004273 P -057662-00000 needed in a Cam Housing
5 1 HANDLE R431004984 P -059312-00000 Position, see pages 10 and
5A 1 SPRING, Handle Latch (Latching Models R431005355 P -059987-00000 11.
Only)
5B 1 COLLAR (Latching Models Only) R431005865 P -061762-00000
5C 1 LATCH, Handle (Latching Models Only) (See Figure 19) † Detents are used in
5D 1 PIN, Driv-Lok (Latching Models Only) R431001984 P -049705-00017 pairs. New Part Numbers
6 1 PLUG R431002563 P -049958-00008 R431004975;
7 1 HUB, Handle R431004981 P -059311-00000 (P -059303-00000)and
8 2 WASHER R431001576 P -048286-00000 R431004976;
9 1 SHAFT. Handle R431004988 P -059313-00001 (P -059304-00000) are
10 1 RING. Retaining R431002333 P -049857-00007 used for 3-position detent
11A 2 CAM R431004904 P -059080-00003 models and Part Number
11B 2 CAM (2-HA-2F, 2-HA-2Z & 2-HA-2LZ) R431004899 P -059072-00000 (P 059302-00000) and
12 1 SPACER R431002727 P -050688-00021 (P -059305-00000) are
13A 1 SPRING, Detent (Detent Models Only) R431004980 P -059308-00000 used for 5-position detent
13B† 1 DETENT (3-Position Detent Models Only) R431004976 P -059304-00000 models.
13C† 1 DETENT (3-Position Detent Models Only) R431004975 P -059303-00000
13D† 1 DETENT (5-Position Detent Models Only) R431004977 P -059305-00000

13E† 1 DETENT (5-Position Detent Models Only) R431004974 P -059302-00000
14A 2 ARBOR, Spring (Spring Returned Models R431004979 P -059307-00000
Only)
14B 1 SPRING (Spring Returned Models Only) R431004978 P -059306-00001
15* 2 FOLLOWER, Cam R431005076 P -059370-00001
16A 1 HOUSING, Cam R431006110 P -062647-00021
16B 1 HOUSING, Cam (Latching Models Only) R431006092 P -062647-00003
Page 19
EXPLODED VIEW
MODEL HE-2
HE-2-X CONTROLAIR®
HE-2-LX CONTROLAIR® CONTROLAIR® VALVES
HE-2-FX CONTROLAIR®
Stainless
Steel Handle
Brake Assy.
Part No. R43100130
(-850182-00000)
NOTE:
1. See Page 8 & 9 for part numbers
2. See page 12 for repair kits
3. Matched/Lapped set of Items 34-41 are in Kit, R431003892
(P -055687-00000) Pg 12
P/N (R431006914)
P -066890-00000 Pipe Bracket
37 Portion Complete Ref. 1,2,3)
18
19
17
38 16
15
7
5
30
22
35 3
31
2
34 25
33 1
32
35
29
4
33 39
41
40
Page 8
HE-2 CONTROLAIR® VALVE
PARTS LIST
REF. QTY. DESCRIPTION HE-2-X HE-2-X HE-2-LX HE-2-FX HE-2-FX
P -051692* P -062026* P -051614* P -051612* P -066625
New P/N Old P/N New P/N Old P/N New P/N Old P/N New P/N Old P/N New P/N Old P/N
1 1 Bracket, Pipe R431006882 P -066812- R431006882 P -066812- R431006882 P -066812- R431006882 P -066812- R431006882 P -066812-
00005 00005 00005 00005 00005
2 1 Strainer, Port R431006895 P -066849- R431006895 P -066849- R431006895 P -066849- R431006895 P -066849- R431006895 P -066849-
00000 00000 00000 00000 00000
3 1 Gaskets, Port R431006889 P -066823- R431006889 P -066823- R431006889 P -066823- R431006889 P -066823- R431006889 P -066823-
00000 00000 00000 00000 00000
4 3 Screw, 5/16x2-1/4 R431002440 P -049902- --- --- --- --- --- --- R431002440 P -049902-
00048 00048
5 1 Body, Complete R431002869 P -051112- --- --- --- --- --- --- --- ---
00002
Bushed & incls. #6
6 4 Stud, 5/16-18x1-3/8 R431002505 P -049906- --- --- --- --- --- --- --- ---
00014
7 1 Valve, Inlet supply SEE KITS --- --- --- --- --- --- --- --- ---
15* 2 Ring, Retainer SEE KITS --- --- --- --- --- --- --- --- ---
16* 2 “SCREEN” SEE KITS --- --- --- --- --- --- --- --- ---
17* 2 Ring, Snap R431002398 P -049882- --- --- --- --- --- --- --- ---
00059
18* 1 FOLLOWER R431003014 P -052835- --- --- --- --- --- --- --- ---
00000
19 1 SCREW R431002950 P -051856- --- --- --- --- --- --- --- ---
00000
20 1 Lever, RT. R431004871 P -058979- --- --- --- --- --- --- --- ---
00001
21 1 Roller WITH LEVER --- --- --- --- --- --- --- --- ---
22 1 Plug, Valve R431005364 P -060028- --- ---

00000
23 1 Screw, 1/4-28x1/2- WITH LEVER --- --- --- --- --- --- --- --- ---
Lever
24 1 Pin, 3/16 Lever, RT WITH LEVER --- --- --- --- --- --- --- --- ---
25 2 Washer R431002409 P -049898- --- --- --- --- --- --- --- ---
00009
26 2 Nut, 5/16-18 R431002419 P -049901- --- --- --- --- --- --- --- ---
00020
27 1 Pin, Lever R431002722 P -050686- --- --- --- --- --- --- --- ---
00007
28 2 Pin, 1/16 x 1/2 R431002541 P -049913- --- --- --- --- --- --- --- ---
00001
29 1 Spring, Exhaust SEE KITS --- --- --- --- --- --- --- --- ---
Valve
30 1 Spring, Diaphragm See Pg. 6 See Pg 6 See Pg. 6 See Pg. 6 See Pg. 6 See Pg. 6 See Pg. 6 See Pg. 6 See Pg. 6 See Pg. 6
31 1 Seat, Spring R431000036 -526347- R431004868 P -058978- R431004868 P -058978- R431004868 P -058978- R431004868 P -058978-
00000 00001 00001 00001 00001
32 1 Housing, Spring R431006822 P -066488- R431004871 P -058979- R431004871 P -058979- --- --- --- ---
w/ Nut 00002 00001 00001
33 4 Nut, 5/16-18 R431002419 P -049901- R431002722 P -050686- R431002722 P -050686- R431002722 P -050686- R431002722 P -050686-
00020 00007 00007 00007 00007
34 1 Valve, Inlet & Exh. SEE KITS --- --- --- --- --- --- --- --- ---
(Incls. #35)
35 1 Ring, 3/4 O.D. SEE KITS --- --- --- --- --- --- --- --- ---
36 1 Follower, Diaphragm SEE KITS --- --- --- --- --- --- --- --- ---
37 1 Diaphragm SEE KITS --- --- --- --- --- --- --- --- ---
NOTE: *Approximate suffix from IDENTITY SCHEDULE, Page 6, must be used to identify valve and pressure ratings. See sheet 7 for plated part
numbers for Items 43,52,53.
(CONTINUED)
Page 9
HE-2 CONTROLAIR® VALVE
PARTS LIST (Continued)
REF QTY. DESCRIPTION HE-2-X HE-2-X HE-2-LX HE-2-FX HE-2-FX
P -051692* P -062026* P -051614* P -051612* P -066625*
New P/N Old P/N New P/N Old P/N New P/N Old P/N New P/N Old P/N New P/N Old P/N
38 1 Nut, 9/16-18 SEE KITS --- --- --- --- --- --- --- --- ---
39 1 Ring, 11/16 - “O” Ring SEE KITS --- --- --- --- --- --- --- --- ---
40 1 Screw Spline Hex. Adj. R431006770 P -066209- R431006770 P -066209- R431002766 P -066209- R431006770 P -066209- R431006770 P -066209-
00000 00000 00000 00000 00000
41 1 Seat Exhaust Valve SEE KITS --- --- --- --- --- --- --- --- ---
42 2 Screw, 5/16-18 R431002505 P -049906- R431002505 P -049906- R431002505 P -049906- R431002505 P -049906- R431002505 P -049906-
00014 00014 00014 00014 00014
42A 1 Housing, Cam(Complete) R431002923 P -051622- R431002923 P -051622- R431002506 P -051622- R431002923 P -051622- R431002922 P -051622-
(Incls.42,44,45,46,66, 00003 00003 00001 00003 00002
67,68,69)
43 1 Housing Complete R431002922 P -051622- --- --- --- --- --- --- R431002769 P -050851-
(Bushed) 00002 00008
44 1 Latch SEE KITS --- --- --- --- --- --- --- --- ---
45 1 Latch Spring SEE KITS --- --- --- --- --- --- --- --- ---
46 2 Rivet SEE KITS --- --- --- --- --- --- --- --- ---
47 1 Shoe & Holder --- --- --- --- --- --- SEE KITS --- --- ---
48 1 Spring --- --- --- --- --- --- SEE KITS --- --- ---
49 1 Washer #10 --- --- --- --- --- --- SEE KITS --- --- ---
50 1 Nut, 10-32 --- --- --- --- --- --- SEE KITS --- --- ---
51 1 Nut, 1/4-28 Elastic R431001871 P -049589- --- --- --- --- --- --- --- ---
00000
52 1 Yoke R431006896 P -066852- --- --- --- --- --- --- R431006897 P -066852-
00000 00001
53 1 Shaft, Handle R431000155 -850460- --- --- --- --- --- --- R431002846 P -050979-
00000 00001
54 1 Ball R431000012 -517026- --- --- --- --- --- --- --- ---
00000
55 1 Screw, 5/16-18 SEE KITS --- --- --- --- --- --- --- --- ---
56 1 Arbor R431000136 -850254- --- --- --- --- --- --- --- ---
00000
57 1 Spacer R431002691 P -050625- --- --- --- --- --- --- --- ---
00001
58 2 Spring R431000137 -850256- --- --- --- --- --- --- --- ---
00000
59 1 Arbor R431000146 -850400- --- --- --- --- --- --- --- ---
00000
60 1 Nut, Cap R431003740 P -055465- --- --- --- --- --- --- --- ---
00000
61 1 Cam, Complete R431002928 P -051623- R431005990 P -062027- R431002419 P -051624- R431002927 P -051623- R431002682 P -050600-
00003 00001 00000 00002 00002
62 Ring, Retaining --- --- --- --- --- --- --- --- ---
63 1 Shaft, Cam Complete R431000059 -534488- --- --- --- --- --- --- ---
00000
64 1 Key --- --- --- --- --- --- R431002109 P -049767- ---
00003
65 1 Drum, Brake --- --- --- --- --- --- SEE KITS --- ---
66 4 Screw, Drive R431002597 P -049987- R431002597 P -049987- R431002597 P -049987- R431002597 P -049987- R431002597 P -04987-
00002 00002 00002 00002 00002
67 1 Escutcheon Plate R431001717 P -049197- R431000073 -536565- R431000073 -536565- R431000072 -536565- R431000072 -536565-
00002 00001 00000 00000 00000
Page 10
REPAIR KITS FOR HE-2 CONTROLAIR® VALVE
NEW PART NO. OLD PART NO. QUANTITY DESCRIPTION

PER VALVE
R431003892* P -055687-00000 1 MINOR GRADUATING VALVE PORTION -
REPAIR KIT (Includes Items 34, 35, 36, 37, 38, 39,
41) See Note 1
R431004005 P -057136-00000 1 MAJOR GRADUATING VALVE PORTION -
REPAIR KIT (Includes Items 2, 3, 18, 29 and Kit
R431003892)
R431003741 P -055474-00002 1 MINOR SIDE VALVE PORTION - CARTRIDGE
P -069350-00001 (Replaces Items 7, 8, 9, 10, 12, 14)
R431003985 P -057094-00001 1 MAJOR SIDE VALVE PORTION - REPAIR KIT
(Includes Items 15, 16, 17 and Cartridge
R431007453)
R431006521 P -064894-00002 1 COMBINED GRADUATING AND SIDE VALVE
PORTIONS - REPAIR KIT (Includes One Kit
P -057136-00000, One Kit R431003741, and Two
Each of Items 15, 16, 17)
R431006415 P -064421-00001 1 SPRING LATCH FOR LX MODEL ONLY
(Includes Items 44, 45, 46)
R431000132 -850187-00000 1 FRICTION BRAKE ASSEMBLY FOR FX MODEL
ONLY (Includes Items 47, 48, 49, 50, 65)
R431006420 P -064421-00006 1 CAM SHAFT ASSEMBLY FOR X, FX & LX
MODELS (Includes Items 52, 53, 54, 60, 63 and
Bearing R431001991)
R431006422 P -064421-00008 1 RETURN SPRING HE-2-X & HE-2-LX KIT
(Included Items 56, 58)
NOTES:
*1. The Inlet and Exhaust Valve Unit Item 34 and Exhaust Valve Seat Item 41 must be lapped
together to form a matched set. Kit contained these items factory matched.
2. Select replacement range control spring from identity schedule page 6.
3. All repair kits above include small tubes of recommended lubricant.
4. Valve portion kits listed above contain seals and other parts that are recommended for repair of
valve portion only.
5. On severely worn or damaged components, additional parts may be required especially in the
mechanical operating portions of the valve. Select these as required from parts list on pages 7,
8, and 9.
Page 13
EXPLODED VIEW
HD-2-X CONTROLAIR®
HD-2-LX CONTROLAIR®
HD-2-LS CONTROLAIR®
HD-2-XS CONTROLAIR®
67
66
60 58 58 56
63 59 57 54
53
HD-2-FX CONTROLAIR® 41 38
HD-2-FXR CONTROLAIR® Stainless
Steel
61 Handle
60 65 64 62
55 52
45
44
51
47
46
48
49
50
28 27
21
24
20
37
22
18
36
19
25 23
5 17
30 16
15 P/N R431006913
7 (P –066890-K0000) Pipe
35 3 Bracket Portion Com-
31 plete (Ref. 1,2,3, 4)
2
34 68
69 1
32
35
29
4
39 NOTE:
1. SEE PAGE 9 FOR PART NUMBERS
33 2. SEE PAGE 10 FOR REPAIR KITS
42
3. MATCHED / LAPPED SET OF ITEM 34
40 & 42 ARE IN KIT, P/N R4313892
(P –055687-00000)
Page 8
HD-2 Controlair® Valve Parts List
Ref. Qty. Description HD-2-X New P/N HD-2-X Old P/N HD-2-LX New P/N HD-2-LX Old P/N HD-2-LS
N
New P/ HD-2-LS Old P/N HD-2-XS New
P/N HD-2-XS Old P/N HD-2-FX New P/N HD-2-FX Old P/N HD-2-FXR New P/N HD-2-FXR Old P/N
Complete Device P-50973-000X P-50972-000X P-55446-000X P67556-000X P50970-000X P-51868-000X

1 1 Pipe Bracket R431006883 P -066812-00006 R431006883 P -066812-00006 R431006883 P -066812-00006 R431006883 P -066812-00006 R431006883 P -066812-00006 R431006883 P -066812-00006
2 **1 Filter R431006895 P -066849-00000 R431006895 P -066849-00000 R431006895 P -066849-00000 R431006895 P -066849-00000 R431006895 P -066849-00000 R431006895 P -066849-00000
3 **1 Gasket R431006889 P -066823-00000 R431006889 P -066823-00000 R431006889 P -066823-00000 R431006889 P -066823-00000 R431006889 P -066823-00000 R431006889 P -066823-00000
4 3 Screws R431002440 P -049902-00048 R431002440 P -049902-00048 R431002440 P -049902-00048 R431002440 P -049902-00048 R431002440 P -049902-00048 R431002440 P -049902-00048
Complete Bottom P55583-000X P55583-000X P55583-000X P55583-000X P55583-000X P55583-000X
5 1 Portion includes
items 5 thru 33 Must specify spring range, same as last digit on valve
6 1 Complete Body Bushed R431002868 P -051112-00001 R431002868 P -051112-00001 R431002868 P -051112-00001 R431002868 P -051112-00001 R431002868 P -051112-00001 R431002868 P -051112-00001
w/item 7
7 1 Cartridge Valve See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
8 2 Side Cartridge Valve R431003741 P -055474-00002 R431003741 P -055474-00002 R431003741 P -055474-00002 R431003741 P -055474-00002 R431003741 P -055474-00002 R431003741 P -055474-00002
w/2 "0" rings
8A 2 Side Cartridge Valve R431003985 P -057094-00001 R431003985 P -057094-00001 R431003985 P -057094-00001 R431003985 P -057094-00001 R431003985 P -057094-00001 R431003985 P -057094-00001
w/2 “0” rings including
4 •Snap rings See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
2 •Screens See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
15 2 Snap Ring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
16 2 Screen See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
17 2 Snap Ring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
18 **1 Cam Dog R431003014 P -052835-00000 R431003014 P -052835-00000 R431003014 P -052835-00000 R431003014 P -052835-00000 R431003014 P -052835-00000 R431003014 P -052835-00000
19 1 Cam Dog Pin R431002950 P -051856-00000 R431002950 P -051856-00000 R431002950 P -051856-00000 R431002950 P -051856-00000 R431002950 P -051856-00000 R431002950 P -051856-00000
20 1 Left Lever,includes R431004868 P -058978-00001 R431004868 P -058978-00001 R431004868 P -058978-00001 R431004868 P -058978-00001 R431004868 P -058978-00001 R431004868 P -058978-00001
Items 21, 23 & 24
21 1 Roller included with lever
22 1 Rt. Lever, includes R431004871 P -058979-00001 R431004871 P -058979-00001 R431004871 P -058979-00001 R431004871 P -058979-00001 R431004871 P -058979-00001
items 21, 23 & 24
23 1 Adjusting screw included
with lever
24 1 Pin included with lever
25 *1 Nut See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
27 1 Lever Pin R431002722 P -050686-00007 R431002722 P -050686-00007 R431002722 P -050686-00007 R431002722 P -050686-00007 R431002722 P -050686-00007 R431002722 P -050686-00007
28 2 Cotter Pins R431002541 P -049913-00001 R431002541 P -049913-00001 R431002541 P -049913-00001 R431002541 P -049913-00001 R431002541 P -049913-00001 R431002541 P -049913-00001
29 *3 Exhaust Valve Spring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
30 1 Control Springs See page 6 See page 6 See page 6 See page 6 See page 6 See page 6 See page 6 See page 6 See page 6 See page 6 See page 6 See page 6
31 1 Spring Seat R431000036 -526347-00000 R431000036 -526347-00000 R431000036 -526347-00000 R431000036 -526347-00000 R431000036 -526347-00000 R431000036 -526347-00000
32 1 Spring Housing R431006822 P -066488-00002 R431006822 P -066488-00002 R431006822 P -066488-00002 R431006822 P -066488-00002 R431006822 P -066488-00002 R431006822 P -066488-00002
33 4 Mounting Nuts R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020
34 *1 Graduating Valve includes See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
items 21 & 22
35 *2 3/4" "O"Rings See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
36 *1 Washer See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
1 Complete Top Portion R431000138 -850258-00000 R431000138 -850258-00000 R431003854 P -055592-00000 R431007218 P -067555-00000 R431000141 -850260-00000 R431003829 P -055583-00001
37 *1 Diaphragm See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
Complete Cam Housing
1 includes Items 38,39,40,41, R431002902 P -051284-00000 R4310028888 P -051205-00000 R431002888 P -051205-00000 R431002903 P -051284-00001 R431002888 P -051205-00000 R431002888 P -051205-00000
42,63 & 64
38 *1 Cam Housing with bushing R431002766 P -050851-00002 R431002766 P -050851-00002 R431002766 P -050851-00002 R431002766 P -050851-00002 R431002766 P -050851-00002 R431002766 P -050851-00002
39 *1 "O" Ring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
40 1 Adjusting screw R431006770 P -066209-00000 R431006770 P -066209-00000 R431006770 P -066209-00000 R431006770 P -066209-00000 R431006770 P -066209-00000 R431006770 P -066209-00000
41 2 Studs R431002505 P -049906-00014 R431002505 P -049906-00014 R431002505 P -049906-00014 R431002505 P -049906-00014 R431002505 P -049906-00014 R431002505 P -049906-00014
42 *1 Exhaust Valve Seat See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits Seer Repair Kits See Repair Kits
continued Page 9
HD-2 Controlair® Valve Parts List
(continued)
Ref. Qty. Description HD-2-X New P/N HD-2-X Old P/N HD-2-LX New P/N HD-2-LX Old P/N HD-2-LS New HD-2-LS Old P/N HD-2-XS New HD-2-XS Old P/N HD-2-FX New P/N HD-2-FX Old P/N HD-2-FXR New P/N HD-2-FXR Old P/N
P/N P/N
43 1 Brake Assembly includes 850187 850187

items 47, 48, 49, 50 & 65
44 1 Latch See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
45 1 Latch Spring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
46 2 Rivets See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
47 1 Brake Shoe & Holder See Repair Kits See Repair Kits See Repair Kitrs See Repair Kits
48 1 Brake Spring See Repair Kits See Repair Kits See Repair Kits See Repair Kits
49 1 Washer See Repair Kits See Repair Kits See Repair Kits See Repair Kits
50 1 Nut See Repair Kits See Repair Kits See repair Kits See Repair Kits
51 1 Nut See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
52 1 Yoke See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See repair Kits See Repair Kits
53 1 Handle Shaft See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
54 1 Ball See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
55 1 Stop Pin included with cam #61
56 1 Arbor R431000136 -850254-00000 R431002597 P -049987-00002 R431002597 P -049987-00002 R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020
57 1 Spacer Washer See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
58 2 Return Springs See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
59 1 Arbor See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
60 1 End Cap Nut R431003740 P -055465-00000 R431002505 P -049906-00014 R431002505 P -049906-00014 R431002409 P -049898-00009 R431002409 P -049898-00009 R431002409 P -049898-00009
61 1 Cam w/Stop Pin R431002796 P -050878-00003 R431002419 P -049901-00020 R431002419 P -049901-00020 R431002683 P -050600-00003 R431002683 P -050600-00002 R431002682 P -050600-00002
62 1 Cam Shaft See Repair Kits See Repair Kits See Repair Kits See Repair Kits
63 1 Cam Shaft See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits
64 1 Woodruff Key R431002109 P -049767-00003 R431002109 P -049767-00003
65 1 Brake Drum See Repair Kits See Repair Kits See Repair Kits See Repair Kits
66 4 Screws R431002597 P -049987-00002 R431002597 P -049987-00002 R431002597 P -049987-00002 R431002597 P -049987-00002 R431002597 P -049987-00002 R431002597 P -049987-00002
67 1 Escutcheon Plate R431000073 -536565-00001 R431000073 -536565- R431000073 -536565-00001 R431000073 -536565-00001 R431000073 -536565-00001 R43100073 -536565-00001
00001
68 2 Tooth Washers R431002409 P -049898-00009 R431002409 P -049898-00009 R431002409 P -049898-00009 R431002409 P -049898-00009 R431002409 P -049898-00009 R431002409 P -049898-00009
69 2 Mounting Nuts R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020 R431002419 P -049901-00020
* These items are in the a minor repair kit for graduating section See Page 10
** These items are in the major repair kit for graduating section. For Repair Kits
Page 10
Repair Kits for HD-2 Controlair® Valves
New Part No. Old Part No. Quantity Description
Per Valve
R431003892 P -055687-00000 1 Minor Graduating Valve Portion-Repair Kit
Note 1 includes items 25, 29, 34, 35, 36, 37, 39 & 42
R431004005 P -057136-00000 1 Major Graduating Valve Portion-Repair Kit
Note 1 includes items 2,3 & 18 and kit R431003892
R431003741 P -055474-00002 2 Minor Side Valve Portion-Repair Kit
includes item 7 cartridge with "O" Rings
R431003985 P -057094-00001 2 Major Side Valve Portion-Repair Kit
includes snap ring, screen and kit R431003741
R431006521 P -064894-00002 1 Complete Repair Kit for Control Portion -
Notes 1,2,3 & 4 includes (1) kit R431003892,
(2) kits R431003985, items 2, 3, 16 & 17
R431006416 P -064421-00001 1 Spring Latch Kit for LX, LS, FX and FXR Models
Note 5 includes items 44, 45 & 46
R431000132 -850187-00000 1 Friction Brake Kit for FX & FXR Models
Note 5 includes items 47, 48, 49, 50 & 65
R431006418 P -064421-00004 1 Cam Shaft Kit for FX &FXR Models
R431006419 P -064421-00005 1 Cam Shaft Kit for X, LX, LS & XS Models
R431006423 P -064421-00009 1 Return Spring and Arbor Kit for X, LX, LS & XS Models
Note 5 includes items 57, 58 & 59
R431006913 P –066890-K0000 1 Pipe Bracket Portion Kit for all Models
includes items 1, 2, 3 & 4
NOTES:
1. The inlet and exhaust valve unit Item 34 and exhaust valve seat Item 42 are lapped together to form
a matched set. Kits that contain these items from the factory include matched sets.
2. Select replacement range control spring from identity schedule on page 7.
3. All kits above include small tubes of the recommended lubricants.
4. Valve portion kits listed above contain the seals and other parts that are needed to repair the valve portion.
5. Replace all worn or damaged components, especially in the mechanical portions of the valve. The me-
chanical parts are listed on pages 7, 8 and 9.
Chrome plated HD-2 Controlair® Valves

with chrome plated parts for item numbers listed
(See Note 1 -- Page 6)
Model New Old New Item 23 Old Item 23 New Item 42 Old Item 42 New Item 43 Item 43
Complete Complete Cam Housing Cam Housing Yoke Yoke Handle Shaft Handle Shaft
Part Number Part Number Part Number Part Number Part Number Part Number Part Number Part Number
P –066514- P –051205- P –066852- P –050979-
HD-2-FX R431001204 R431002889 R431006897 R431002846
00001 00001 00001 00001
P –064924- P –051205- P –066852- 850460-
HD-2-FX R431001749 R431002888 R431006896 R431000155
00017 00000 00000 00000
Page 11
WM453M & N Series
Pneumatic
Throttle Pedal
Features and Specs

■ FMVSS-124 approved
■ Weight: 4 lb, 2 oz (1,9 kg)
■ Port size: 1/4-18 NPTF
■ Maximum supply pressure:150 PSI (1034 kPa)
■ Operating temperature: -40°F to 200°F (-40°C to 93°C)
Dimensional Data
22
Cross Section & Parts
Item Part No. Description WM453M WM453M2 WM453M3 WM453N

1 102371 Treadle Pin 1 1 1 1
3 118775 Treadle Assembly 1 1 1 1
4 103113 Roller 1 1 1 1
7 103704 Spring 1 1 1 1
8 116714 Breather 1 1 1 1
9 116697 Control Valve 1 1 1 1
10 102374 Treadle Pin 1 1 1 1
11 116721 Mounting Plate 1 1 1 1
12 106857 Retaining Ring 4 4 4 4
13 110370 Bushing 2 2 2 2
17 118388 Bushing 2 2 2 2
Serviceable items are identified above.
Service Kit Information
Kit Service Kit Number Item Numbers

Repair kit 117582 1, 4, 7, 10, 12, 13, 17
Control Valve (WM90DX) 116697 9
To Order
To order a WM453M/N model, select part number from the chart below.
Model Part Number Regulated Output Range Maximum Output Treadle Length Port Orientation
WM453M 116731 0-60/70 PSI 70 PSI 11.35 in Toward Heel

(0-414/483 kPa) (483 kPa) (288 mm)
WM453M2 117903 0-60/70 PSI 70 PSI 10.0 in Toward Heel
(0-414/483 kPa) (483 kPa) (254 mm)
WM453M3 118117 0-60/70 PSI 70 PSI 11.35 in Toward Toe
(0-414/483 kPa) (483 kPa) (288 mm)
WM453N 117270 0-85/95 PSI 95 PSI 11.35 in Toward Heel
(0-586/655 kPa) (655 kPa) (288 mm)
23
Grote Industries: Product #51002 - Red, RH Page 1 of 1
www.grote.com U.S. 800.457.9540 Canada 800.268.5612
SuperNova® Stop/Tail/Turn LED Lamp Power Module with

Sidemarker
PRODUCT NUMBER TECHNICAL SPECIFICATIONS

51002 - Red, RH Material: Steel
FMVSS:
FEATURES & BENEFITS A, I, P2, S, T
Finish: Gray
• Heavy gauge steel plate and can
Voltage Amp: 12 V - .24(I,S)/.06
• Pre-assembled with wiring (P2)/.03(T) AMP
• Uses SuperNova®, 10-Diode Pattern 4" Accessory:
LED lamps Lamp: S/T/T 53252
• Exceeds SAE J914, Nov. '87 Marker 47092
Bracket: 43655
Grommet: 91740
OTHER PRODUCT NUMBERS
51012 - Red, LH
mhtml:file://Z:\ENGINEERING DATA\ELECTRICAL COMPONENTS\Grote Industrie... 12/23/2009

Grote Industries: Product #51012 - Red, LH Page 1 of 1
SuperNova® Stop/Tail/Turn LED Lamp Power Module with

Sidemarker

51012 - Red, LH Material: Steel
FMVSS:
FEATURES & BENEFITS A, I, P2, S, T
Finish: Gray
• Heavy gauge steel plate and can
Voltage Amp: 12 V - .24(I,S)/.06
• Pre-assembled with wiring (P2)/.03(T) AMP
• Uses SuperNova®, 10-Diode Pattern 4" Accessory:
LED lamps Lamp: S/T/T 53252
• Exceeds SAE J914, Nov. '87 Marker 47092
Bracket: 43655
Grommet: 91740
51002 - Red, RH
mhtml:file://Z:\ENGINEERING DATA\ELECTRICAL COMPONENTS\Grote Industrie... 12/23/2009

Grote Industries: Product #53972 - Red w/ Stainless Steel, Theft-Resistant Flange Page 1 of 1
SuperNova® LED Oval Stop/Tail/Turn Lamp

STOP/TAIL/TURN: Material: ABS/Acrylic
53972 - Red w/ Stainless Steel, Theft- FMVSS:
Resistant Flange Red - I, P2, S, T
Yellow - P2
FEATURES & BENEFITS Finish: White
Voltage Amp: Red - 12 V - .48(I,S)/.06
• Advanced Pin Connection System uses
(T) AMP
tin-plated, solid-brass terminals
Voltage Amp: Yellow - 12 V - .48 AMP
• Encapsulant potting covers LED circuit Voltage Amp: Red - 24 V - .48(I,S)/.06
board (T) AMP
• Male pin termination for premium Voltage Amp: Yellow - 24 V - .48 AMP
sealability Bracket: 43362, 43952, 43220, 43223,
• Meets specifications for vertical & 43222, 43100, 43723
horizontal mounting Grommet: 92420, 92720
Pigtail: 66815, 66841, 67002, 66842,
67013, 66830, 67006, 66813, 66814,
66823, 66816, 66845, 67005
AUXILIARY KITS:
53123 - Yellow (53963 + 92420 + 67005)
AUXILIARY:
53963 - Yellow, Grommet Mount
53593 - Yellow w/ Gray, Theft-Resistant
Flange
53623 - Yellow w/ Black, Theft-Resistant
Flange
53973 - Yellow w/ Stainless Steel, Theft-
Resistant Flange
52073 - Yellow, 24 Volt
STOP/TAIL/TURN KIT:
53122 - Red (53962 + 92420 + 67005)
STOP/TAIL/TURN:
53962 - Red, Grommet Mount
53592 - Red w/ Gray, Theft-Resistant
Flange
53622 - Red w/ Black, Theft-Resistant
Flange
52072 - Red, 24 Volt
http://grote.com/product.php?product_number=53972&mode=print 12/23/2009
Grote Industries: Product #53973 - Yellow w/ Stainless Steel, Theft-Resistant Flange Page 1 of 1
SuperNova® LED Oval Stop/Tail/Turn Lamp

AUXILIARY: Material: ABS/Acrylic
53973 - Yellow w/ Stainless Steel, Theft- FMVSS:
Resistant Flange Red - I, P2, S, T
Yellow - P2
FEATURES & BENEFITS Finish: White
Voltage Amp: Red - 12 V - .48(I,S)/.06
• Advanced Pin Connection System uses
(T) AMP
tin-plated, solid-brass terminals
Voltage Amp: Yellow - 12 V - .48 AMP
• Encapsulant potting covers LED circuit Voltage Amp: Red - 24 V - .48(I,S)/.06
board (T) AMP
• Male pin termination for premium Voltage Amp: Yellow - 24 V - .48 AMP
sealability Bracket: 43362, 43952, 43220, 43223,
• Meets specifications for vertical & 43222, 43100, 43723
horizontal mounting Grommet: 92420, 92720
Pigtail: 66815, 66841, 67002, 66842,
67013, 66830, 67006, 66813, 66814,
66823, 66816, 66845, 67005
AUXILIARY KITS:
53123 - Yellow (53963 + 92420 + 67005)
AUXILIARY:
53963 - Yellow, Grommet Mount
53593 - Yellow w/ Gray, Theft-Resistant
Flange
53623 - Yellow w/ Black, Theft-Resistant
Flange
52073 - Yellow, 24 Volt
STOP/TAIL/TURN KIT:
53122 - Red (53962 + 92420 + 67005)
STOP/TAIL/TURN:
53962 - Red, Grommet Mount
53592 - Red w/ Gray, Theft-Resistant
Flange
53622 - Red w/ Black, Theft-Resistant
Flange
53972 - Red w/ Stainless Steel, Theft-
Resistant Flange
52072 - Red, 24 Volt
http://grote.com/product.php?product_number=53973&mode=print 12/23/2009
Revised 12/2006
160, 161 and 164 Series

Drive Axle Parts
Single Axles and Tandem Axles
Catalog PB-9250
Strength • Power • Speed • Agility
M E R I T O R PA R T S . R I G H T F R O M T H E S TA R T.
FIGURE 1
FORWARD CARRIERS OF TANDEM AXLES
(USE WITH CHART 1)
Circled numbers are diff. lock parts or parts that change when diff. lock is added.
Squared numbers are oil pump parts or parts that change when oil pump is added.
FIGURE 2
CARRIERS FOR SINGLE AXLES AND
REAR OF TANDEM AXLES
(USE WITH CHART 2)
Circled numbers are diff. lock parts or parts that change when diff. lock is added.
SUPPLEMENTAL DRAWING
CARRIERS WITH INTERNAL A.B.S.
Circled numbers are Forward Axle Assembly parts.

REAR DRIVE AXLES
Model Numbers and Designations
Axle models are identified by a letter and number system.
The letters and numbers give important information about the
specific axle model.
The first seven positions of the designation identify a basic axle

model, while the second group of letters and numbers identify
particular specifications.
Manufacturing Location
Nominal Axle Load Rating (GAWR): A - Australia
In thousands of pounds. Individual forward B - Brazil (Braseixos)
and rear axles of a tandem set (D, N, P, R) C - India Brake Type
are rated as single axles. A tandem set (T) is D - Mexico (Dirona) C - Dura-Master® Air Disc Brake
rated as the combination of the two axles and E - Europe (C.V.C.) D - RDA Stopmaster® Wedge Brake
a tridem set (Z) as the combination of the M - Europe (Maudsley) (Dual Air Chambers)
three axles. N - U.S.A. E - RDH Stopmaster® Wedge Brake
(Dual Hydraulic Cylinders)
F - RSH Stopmaster® Wedge Brake
Gearing Type Main Differential Nest Type (Single Hydraulic Cylinder)
1 - Single Speed B - Special Differential L - QPlus® Cam Brake
2 - Two Speed C - Driver Controlled Differential Lock N - None
3 - Helical Double Reduction F - Standard Differential P - Cam-Master® "P" Series Cam Brake
4 - Salisbury Single Speed H - High Traction® Differential Q - Cam-Master® "Q" Series Cam Brake
5 - Planetary Double Reduction N - NoSPIN® Differential S - RSA Stopmaster® Wedge Brake
6 - Hub Reduction (Single Air Chamber)
T - Cam-Master® "T" Series Cam Brake
W - Cam-Master® "W" Series Cam Brake
RR 23 1 6 0 N F N N 124
Axle Specification Number
Identifies specific customer axle
Hub Type (See Note 3) configurations (variations from the original
A - Aluminum axle design). For information about the
F - Ferrous variation, see the Bill of Material for that
N - None specific axle model.
Axle Type
C - Single Rear Drive Axle, Coach Axle Design Variation
D - Forward-Rear Axle of a Drive Tandem Carrier Type Indicates axle design level or
with Inter-Axle Differential Carrier size. Larger numbers variation, (e.g., RS 23 161 has a
H - Hi-Entry indicate a higher GCW rated thicker wall housing than the RS
N - Forward-Rear Axle of a Drive Tandem or carrier: i.e., larger ring gear, etc. 23 160). For information see the
Tridem without Inter-Axle Differential (Also see Tridem Axle Note 2 Bill of Material for that specific
P - Forward-Rear Axle of a Drive Tandem below.) axle model. (Also see Tridem
with Inter-Axle Differential and Pump Axle Note 2 below.)
R - Rear-Rear Axle of a Drive Tandem
S - Single Rear Drive Axle
T - Tandem Drive Axle Set
Z - Tridem Drive Axle Set
NOTE 1: NOTE 2, FOR TRIDEM AXLES ONLY:

If a complete axle designation is not required, use the first seven positions For a Tridem Drive Axle Set (RZ), the
of the model designation to identify the basic axle model. number in the sixth position designates
EXAMPLES OF BASIC AXLE MODELS: the carrier in the first axle. The number
RS 17 140 - Single Rear Drive, 17,000 lb., Single Speed, 15" Ring Gear, in the seventh position designates the
140 Carrier Model. carriers in the second and third axles.
RT 48 380 - Tandem Drive Axle Set, 48,000 lb., Helical Double Reduction,
19.62" Ring Gear, 380 Carrier Model. NOTE 3:
RZ 60 164 - Tridem Drive Axle Set, 60,000 lb., Single Speed, Includes a Some axle designations or
150 Series Forward Rear or First Axle and a 145 Series specifications do not have a hub
Tandem Axle Set as the Second and Third Axles. type code.
HOW TO USE THIS CATALOG
z There are 34 basic carriers covered in this catalog:
3200-C-1511 3200-M-1703 3200-Z-1820 3200-K-1857 3200-K-1909

3200-Z-1560 3200-P-1706 3200-A-1821 3200-L-1858 3200-D-1928
3200-P-1628 3200-R-1708 3200-C-1823 3200-T-1892 3200-E-1929
3200-J-1648 3200-V-1712 3200-E-1825 3200-V-1894 3200-J-2116
3200-T-1658 3200-W-1713 3200-Q-1837 3200-W-1895 3200-K-2117
3200-V-1660 3200-X-1818 3200-H-1854 3200-Y-1897 3200-L-2118
3200-K-1701 3200-Y-1819 3200-J-1856 3200-J-1908
Major assembly differences in a carrier are indicated by the different assembly level numbers in front
of the base carrier number, for example, A1-3200-V-1894 and A4-3200-V-1894. The Axle Models-
Carriers-Features chart inside this front cover lists all the variations covered in this book.
Note: The carriers listed in this catalog do not include yokes. A yoke is a major assembly difference, therefore,
a carrier sold with a yoke has a different assembly level number than the same carrier without the yoke.
z The charts for carriers, output shafts, and housings include the following information:
z An exploded view of each assembly, keyed to the parts list
z A description of each part
z Parts sold as assemblies that include other parts
z Which carriers or axle models the part is used on
z The quantity of the part used on the carrier or axle
z The part number of each item
z Whether the part is available in a kit
z Carrier parts:
Determine which chart and figure (1 or 2) applies to your carrier by using the following sources of information.
z Identification tag installed on the carrier
z Axle Models-Carriers-Features Chart
z Pictures and descriptions of the carriers inside the front cover and at the beginning of Chart 1 and Chart 2
z Output (thru) shafts:

This chart covers the output shafts for the forward axles of all tandems. Note that the output shaft assembly
or its components are only sold as separate items. The output shaft is not included with the purchase of a
carrier or housing.
z Housing Assemblies and Wheel End Parts:

This chart covers the housing assemblies and wheel end parts for all axles. The parts are listed according to
axle models that are used on 160, 161 and 164 series axles.
z Axle shafts:
The axle shafts are grouped in sets (L.H. and R.H.) according to the axle models they are used on. Many axle
shafts are used on more than one axle model. The axle shafts are also listed by part number with dimensions.
z Yokes and Flanges:

There are four charts that cover full round bearing yokes, wing bearing yokes, Easy Service yokes, and flanges.
Each chart lists the yokes or flanges used on each model. The yokes and flanges are listed by dimensions.
z Kits:
The first chart in this section lists all the kits available for each axle model and carrier. Following that chart,
the kits are sequenced according to the kit number and list the contents of each kit.
z Numerical Parts List:

This section lists every part number along with the page(s) on which the part is listed.
AXLE MODELS - CARRIERS - FEATURES
160, 161 & 164
Single Reduction Axles (Single & Tandem)
AXLE MODELS INTER- MAIN NO- CARRIER
(All models shown below are AXLE DIFF. SPIN ® OIL PARTS
2.38"-46 axle spline) CARRIERS DIFF. LOCK DIFF. PUMP CHART NO.
RS-21160/161 Single Axle A1-3200-P-1706 2
RS-23160/161 A34-3200-T-1892 2
RS-24160/161 A17-3200-P-1706 2
RS-25160/161
RS-26160/161
RT-40160 Forward RD-20160 A6-3200-Q-1837 (3) 1
RT-46160 RD-23160 A-3200-J-2116 1
RT-46164 RD-23164 A1-3200-J-1908 (3) 1
RT-50160 RD-25160 A3-3200-L-2118 1
RT-50164 RD-26160 A1-3200-J-2116 1
RT-52160 RP-20160 A1-3200-K-1909 (3) 1
RT-52164 RP-23160 A-3200-K-2117 1
RP-23164 A5-3200-K-1909 (3) 1
RP-25160 A3-3200-K-2117 1
RP-26160 A1-3200-K-2117 1
RP-29160
Rear RR-20160 A1-3200-P-1706 2
RR-23160 B57-3200-P-1706 (1) 2
RR-23164 A1-3200-A-1821 (3) 2
RR-25160 A1-3200-T-1892 2
RR-26160 A34-3200-T-1892 (1)(2) 2
RR-29160 A1-3200-D-1928 (3) 2
A17-3200-P-1706 2
B58-3200-P-1706 (1) 2
REMAN AXLE MODEL OFFERING

REMAN AXLE OEM PRODUCTION
DESIGNATION DESIGNATION COMMENTS
RD23160/164 RT46/50/52160 Forward
RT46/50/52164 Forward
RP23160/164 RT46/50/52160 Forward With pump
RDL23160/164 RT46/50/52160 Forward With main diff. lock
RPL23160/164 RT46/50/52160 Forward With pump and main diff. lock
RR23160 RT46/50/52160 Rear Can be used as a single axle replacement for RS23160
RT46/50/52164 Rear
RRL23160 RT46/50/52160 Rear With main diff. lock, can be used as a single axle replacement for
RT46/50/52164 Rear RS23160 with main diff. lock
(1) Shot peened (2) With DCDL switch clip (3) With thrust screw
STANDARD CARRIER SUPERCESSION LIST
ORIGINAL REPLACEMENT ORIGINAL REPLACEMENT

PART NUMBER PART NUMBER PART NUMBER PART NUMBER
A15-3200-C-1511 A1-3200-Y-1897 * A1-3200-V-1712 A1-3200-Y-1897 *
A17-3200-C-1511 A4-3200-Y-1897 * A4-3200-V-1712 A4-3200-Y-1897 *
A24-3200-Z-1560 A17-3200-P-1706 A11-3200-V-1712 A11-3200-E-1825
A26-3200-Z-1560 A1-3200-P-1706 A1-3200-W-1713 A1-3200-W-1895
A27-3200-Z-1560 A1-3200-T-1892 A1-3200-X-1818 A-3200-J-2116S
A9-3200-P-1628 A1-3200-V-1894 A4-3200-X-1818 A1-3200-J-2116S
A12-3200-P-1628 A4-3200-V-1894 A1-3200-Y-1819 A1-3200-W-1895
A14-3200-P-1628 A9-3200-V-1894 A1-3200-Z-1820 A1-3200-V-1894
A1-3200-J-1648 A1-3200-X-1818 A4-3200-Z-1820 A4-3200-V-1894
A4-3200-J-1648 A4-3200-X-1818 A6-3200-Z-1820 A9-3200-V-1894
A1-3200-T-1658 A1-3200-P-1706 A1-3200-C-1823 A1-3200-T-1892
A13-3200-T-1658 A17-3200-P-1706 A1-3200-E-1825 A1-3200-Y-1897 *
A1-3200-V-1660 A1-3200-T-1892 A4-3200-E-1825 A4-3200-Y-1897 *
A1-3200-K-1701 A1-3200-V-1894 A1-3200-T-1892 A34-3200-T-1892
A4-3200-K-1701 A4-3200-V-1894 A1-3200-V-1894 A3-3200-K-2117S
A6-3200-K-1701 A9-3200-V-1894 A4-3200-V-1894 A-3200-K-2117S
A1-3200-M-1703 A1-3200-X-1818 A9-3200-V-1894 A1-3200-K-2117S
A4-3200-M-1703 A4-3200-X-1818 A1-3200-W-1895 A3-3200-L-2118S
A1-3200-P-1706 B57-3200-P-1706 A1-3200-Y-1897 A23-3200-Y-1897 *
A17-3200-P-1706 B58-3200-P-1706 A4-3200-Y-1897 A22-3200-Y-1897 *
A1-3200-R-1708 A1-3200-T-1892
The part number supercessions listed here reflect product improvements made in several key areas.
Several of these product improvements are non-interchangeable at the component level, in these cases
kits have been developed to ease your transition to the new designs.
With the exception of reverse shift carriers built for Navistar, all carriers equipped with driver controlled
main differential lock now have a screw in shift cylinder. The Interaxle differential shift cylinder for these
carriers is also a screw in type.
* No Longer Available - can use steel (malleable) version.

TABLE OF CONTENTS
PAGE
Forward Carriers of Tandem Axles……………………………………………………… 2
Carriers for Single Axles and Rears of Tandem Axles………………………………… 8
Output (Thru) Shaft Assembly Parts………………………………………………………14
Housing Assemblies and Wheel End Parts………………………………………………15
Axle Shafts……………………………………………………………………………………16
Yokes and Flanges -

Full Round Bearing Yokes………………………………………………………19
Wing Bearing Yokes………………………………………………………………20
Easy Service Yokes………………………………………………………………21
Companion Flanges………………………………………………………………22
Axle Model to Carrier to Kit Cross Reference……………………………………………23
Kits……………………………………………………………………………………………28
42
Numerical Parts Listing………………………………………………………………………
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1
CHART 1
(Use with Figure 1, Inside Front Cover)
VISUAL IDENTIFICATION OF FORWARD CARRIERS
IAD SHIFTER AND DIFF. LOCK - IAD SHIFTER AND DIFF. LOCK -
BOLT ON FOR 1628, 1701 BOLT ON FOR 1713
SCREW-IN FOR 1820, 1894, 1909, 2117 SCREW-IN FOR 1819, 1895, 1908, 2118
OIL FILTER NO OIL FILTER
DIFF. LOCK DIFF. LOCK
FORWARD CARRIERS WITH IAD, FORWARD CARRIERS WITH IAD AND

DIFF. LOCK AND OIL PUMP DIFF. LOCK WITHOUT OIL PUMP
3200-P-1628, 3200-K-1701, 3200-Z-1820, 3200-W-1713, 3200-Y-1819, 3200-W-1895,
3200-V-1894, 3200-K-1909, 3200-K-2117 3200-J-1908, 3200-L-2118
IAD SHIFTER - IAD SHIFTER -

SCREW-IN FOR 1820, 1858, 1894, BOLT ON FOR 1648, 1703
OIL FILTER 1909, 2117 SCREW-IN FOR 1818, 1837, 1857, 2116
NO OIL FILTER
NO DIFF. LOCK NO DIFF. LOCK
FORWARD CARRIERS WITH IAD AND FORWARD CARRIERS WITH IAD

OIL PUMP WITHOUT DIFF. LOCK WITHOUT DIFF. LOCK OR OIL PUMP
3200-Z-1820, 3200-L-1858, 3200-V-1894, 3200-J-1648, 3200-M-1703, 3200-X-1818,
3200-K-1909, 3200-K-2117 3200-Q-1837, 3200-K-1857, 3200-J-2116
The following carriers are equipped with a thrust screw: 3200-Q-1837, 3200-K-1909, 3200-J-1908.
The following carriers are machined for Internal ABS Sensors: 3200-L-1857, 3200-L-1858.
2
ITEM DESCRIPTION REMARKS CARRIER QTY PART NUMBER
1 Nut - input yoke & shaft 1 40-X-1233
1A Washer - input nut 1 1229-N-1730
2, 3 Yoke & deflector assembly - input 1 SEE YOKE CHARTS
4 Capscrew - input bearing cage 7 MS-212040-1
5 Washer - input bearing cage 7 MWA-512
6 Seal & sleeve assembly - input shaft 1 A1-1205-X-2728
7, 10 Bearing, cage & cup assy. - input All less pump 1 A-3226-S-1137
All with pump A-3226-H-1126
8 Shims - input bearing .003"/.076mm Included in KIT 2429 Use as 2203-K-9241
cage .005"/.127mm req. 2203-L-9242
.010"/.254mm 2203-M-9243
9 O-ring - bearing cage 1 5-X-1034
10 Cup - input shaft bearing 1 HM813810
11 Cone - input shaft bearing 1 HM813843
12 Baffle - oil Use without oil pump 1 3221-P-1004
13 Washer - oil baffle 3 1229-E-1669
14 Capscrew - oil baffle 3 MS-208016-1
15, 1 Input shaft & nut assembly All less pump 1 A-3297-C-1199
Input shaft, nut, ball & pin assy. Carriers with pump All others A1-3297-X-1194
For old style A1-3297-H-1022 KIT 2624
input shaft
16 Thrust washer - helical drive gear Included in KIT 2796 1 1229-D-4788
17 Gear - helical drive gear 1 3892-T-4934
18 Capscrew - inter-axle diff. case 8 MS-210045A-1
19 Washer - inter-axle diff. case 8 1229-K-1597
20, 18, 19 Case assembly - inter-axle After 10/00 1 A5-3235-A-2393
Prior to 10/00. A1-3235-A-2393
Includes Items 25 & 27
20,18, 19, 21, Diff. case & pinion nest assy - inter-axle Includes Items 25 & 27 1 A3-3235-A-2393
22, 23, 27
21 Spider (cross) - inter-axle diff. Included in KIT 2248 1 3278-N-300
22 Pinion gear - inter-axle diff. 4 2233-K-245
23 Thrust washer - inter-axle diff. pinion 4 1229-Q-2929
24 Snap ring - inter-axle diff. 1 2297-S-5349
25 Clutch collar - inter-axle diff. Included in KIT 2796 After 10/00 1 3107-P-1212
Prior to 10/00. A1-3235-A-2393
Includes Items 25 & 27
26 Side gear - inter-axle diff., rear 1 2234-T-1190
27 Shift fork - inter-axle diff. 1 3296-B-1328
28 Cone - rear side gear bearing 1 JLM714149
29 Cup - rear side gear bearing 1 JLM714110
30 Adjusting screw - shift shaft 1 41-X-1208
31 Jam nut - adjusting screw 1 MN-312-1
32 Spring - shift shaft return 1 2258-U-411
33 Shift shaft - inter-axle diff. 1 2244-K-1025
34 Shift assy. - inter-axle diff. air Screw-in style 1 KIT 2825
Bolt-on style KIT 2825
35 Capscrew - air shift assembly Bolt-on style 4 10-X-1334
36, 61, 62 Differential carrier & Less pump, Ratios - 3.07, 3.21, 3.42, 3.57, 3.73 3200-J-1648 1 KIT 2644
cap assembly Less diff. lock Ratios - 3.91, 4.10, 4.30, 4.56 Original design KIT 2644A
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, KIT 2644B
6.83, 7.17
Internal ABS 3200-K-1857 A2-3200-K-1857
New differential bearing 3200-M-1703 KIT 2618
Screw-in IAD shifter, w/thrust screw 3200-Q-1837 A2-3200-Q-1837
Screw-in IAD shifter 3200-X-1818, 3200-J-2116 A2-3200-J-2116S
Less pump, Screw-in IAD & main diff. shift 3200-J-1908 A2-3200-J-1908
With diff. lock cylinder, with thrust screw
Original design 3200-W-1713 KIT 2617
Screw in IAD & main diff. shift cyl. 3200-W-1895, 3200-L-2118 A2-3200-L-2118S
Screw-in IAD shifter 3200-Y-1819 KIT 2764
With pump, Screw-in IAD shifter, w/thrust screw 3200-K-1909 A2-3200-K-1909
Less diff. lock Internal ABS 3200-L-1858 A2-3200-L-1858
Screw-in IAD shifter 3200-V-1894, 3200-K-2117 A2-3200-K-2117S
3200-Z-1820 KIT 2766
3
36, 61, 62 Differential carrier & With pump, New differential bearing 3200-K-1701 1 KIT 2616
(Cont) cap assembly With diff. lock Screw-in IAD & main diff. shift 3200-K-1909 A2-3200-K-1909
cylinder, with thrust screw
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-P-1628 KIT 2640
Ratios - 3.91, 4.10, 4.30, 4.56 Original design KIT 2640A
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, KIT 2640B
6.83, 7.17
Screw-in IAD & main diff. shift 3200-V-1894 A2-3200-K-2117S
cylinder 3200-K-2117
Screw-in IAD shifter 3200-Z-1820 KIT 2763
36A Thrust screw (not shown) 1 15-X-1167
36B Jam nut (not shown) 1 1227-D-472
36C Tapered dowels (not shown) Included in KIT 4288 For tapered dowel carriers 6 1246-V-1166
only
37 Washer - carrier to housing Ref. only - not 12 1229-W-1557
38 Nut - carrier to housing stud included with any 2 NL-110-1
39 Capscrew - carrier to Long carrier 3 10-X-1599
housing Short 7 10-X-1594
40, 50 Drive gear pinion & nut assembly 3.07 Ratio Use 1 as A-39654-1
3.21 Ratio req. A-39656-1
3.42 Ratio A-39658-1
3.58 Ratio A-39660-1
3.73 Ratio A-39662-1
3.91 Ratio A-39876-1
4.10 Ratio A-39878-1
4.30 Ratio A-39880-1
4.56 Ratio A-39882-1
4.89 Ratio A-39664-1
5.29 Ratio A-42198-1
5.38 Ratio A-39666-1
5.63 Ratio A-39672-1
6.14 Ratio A-39674-1
6.43 Ratio A-39892-1
6.83 Ratio A-41064-1
7.17 Ratio A-39896-1
41 Cone - drive pinion inner bearing 1 H715343
42 Cup - drive pinion inner bearing 1 H715311
43 Shims - pinion inner .003"/.076mm Included in KIT 2429 Use as 2203-F-2788
bearing cup .005"/.127mm req. 2203-G-2789
.010"/.254mm 2203-H-2790
44 Spacer - pinion bearing inner 1 1244-W-1765
45 Gear - helical driven 1 3892-U-4909
46 Spacers - pinion .451"/11.45mm Included in KIT 2397 Use 2 as 2203-V-9824
bearing outer .452"/11.48mm req. 2203-W-9825
(variable thickness) .453"/11.50mm 2203-X-9826
.454"/11.53mm 2203-Y-9827
.455"/11.55mm 2203-Z-9828
.459"/11.65mm 2203-A-9829
.463"/11.75mm 2203-B-9830
.467"/11.85mm 2203-C-9831
.470"/11.95mm 2203-D-9832
.474"/12.05mm 2203-E-9833
.478"/12.15mm 2203-F-9834
.482"/12.25mm 2203-G-9835
.483"/12.28mm 2203-H-9836
.484"/12.30mm 2203-J-9838
.485"/12.33mm 2203-K-9839
.486"/12.35mm 2203-L-9840
47 Cup - drive pinion outer bearing 1 65500
48 Cone - drive pinion outer bearing 1 65237
49 Washer - drive pinion 1 1229-G-4063
50 Nut - drive pinion 1 40-X-1145
51 Cover - drive pinion 1 3266-C-1095
52 Washer - drive pinion cover 5 1229-K-1597
53 Capscrew - drive pinion cover 5 MS-210020-1
4
54 Adjusting rings - diff. bearing Both sides 1628, 1648 carriers 2 2214-S-279
3200-K-1857 (ABS) 2214-Z-1144
LH side 3200-L-1858 (ABS) 1 2214-B-1146
RH side 2214-Z-1144
LH side 3200-Z-1820, 3200-V-1894 2214-J-1128
RH side 2214-G-1125
Both sides All other non-ABS 2 2214-G-1125
55 Cups - diff. bearing Both sides 1628, 1648 carriers 2 A1-1228-B-600
1703, 1818, 1837 carriers 592A
LH side All others 1 52618
RH side 592A
56 Cones - diff. bearing Both sides 1628, 1648 carriers 2 A1-1228-B-600
1703, 1818, 1837 carriers 594A
LH side All others 1 52400
RH side 594A
57 Capscrew - main diff. case 12 41-X-1275
58 Washer - main diff. case 12 1229-U-1503
59, 57, 58 Case assembly - main diff. Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-J-1648 Use 1 as A10-3235-S-1813
Ratios - 3.91, 4.10, 4.30, 4.56 Less diff. lock req. A10-3235-F-1982
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A10-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-K-1701, 3200-W-1713, A2-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 3200-Y-1819, 3200-Z-1820, A2-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, 3200-V-1894, 3200-W-1895, A2-3235-G-2113
6.83, 7.17 3200-J-1908, 3200-K-1909,
With diff. lock
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-K-1701, 3200-Z-1820, A5-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 3200-V-1894, 3200-K-1909, A5-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, Less diff. lock A5-3235-G-2113
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-M-1703, 3200-X-1818, A-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 3200-Q-1837, A-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, Less diff. lock A-3235-G-2113
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-P-1628 A12-3235-S-1813
Ratios - 3.91, 4.10, 4.30, 4.56 With diff. lock A12-3235-F-1982
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A12-3235-H-1984
6.83, 7.17
59, 57, 58, 64, Case & nest assembly - main diff. Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-J-1648 Use 1 as A11-3235-S-1813
65, 66, 67, 68 Ratios - 3.91, 4.10, 4.30, 4.56 Less diff. lock req. A11-3235-F-1982
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A11-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-K-1701, 3200-W-1713, A3-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 3200-Y-1819, 3200-Z-1820, A3-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, 3200-V-1894, 3200-W-1895, A3-3235-G-2113
6.83, 7.17 3200-J-1908, 3200-K-1909,
With diff. lock
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-K-1701, 3200-Z-1820, A6-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 3200-V-1894, 3200-K-1909, A6-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, Less diff. lock A6-3235-G-2113
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-M-1703, A1-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 3200-X-1818, A1-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, 3200-Q-1837, A1-3235-G-2113
6.83, 7.17 Less diff. lock
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-P-1628 A13-3235-S-1813
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A13-3235-H-1984
6.83, 7.17
59, 57, 58, 64, Case & nest assembly - main diff. Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-K-1857, Use 1 as A2-3235-R-2176
65, 66, 67, 68, Ratios - 3.91, 4.10, 4.30, 4.56 Internal ABS, req. A2-3235-S-2177
173, 174, 175 Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, Less diff. lock, A2-3235-T-2178
6.83, 7.17 Less pump
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-L-1858, A4-3235-R-2176
Ratios - 3.91, 4.10, 4.30, 4.56 Internal ABS, A4-3235-S-2177
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, Less diff. lock, A4-3235-T-2178
6.83, 7.17 With pump
5
59, 57, 58, Case & NoSpin assembly - main diff. Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-J-1648 Use 1 as A14-3235-S-1813
68A Ratios - 3.91, 4.10, 4.30, 4.56 req. A14-3235-F-1982
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A14-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-K-1701, 3200-Z-1820, A8-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 3200-V-1894, 3200-K-1909 A8-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A8-3235-G-2113
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-M-1703, 3200-X-1818, A7-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 3200-Q-1837 A7-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A7-3235-G-2113
6.83, 7.17
59, 57, 58, Case assembly - main diff. (ABS ready) Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-K-1857, Use 1 as A1-3235-R-2176
173, 174, 175 Ratios - 3.91, 4.10, 4.30, 4.56 Internal ABS, req. A1-3235-S-2177
6.83, 7.17 Less pump
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-L-1858, A5-3235-R-2176
6.83, 7.17 With pump
60 Bolt - gear to diff. case Included in KIT 2426 12 41-X-1276
61 Washer - diff. bearing cap 4 42-X-1024
62 Capscrew - diff. bearing cap 4 41-X-1018
63 Pin - adjusting ring lock ABS carriers 2 19-X-1087
All others 1 KIT 4284
64 Thrust washer - side gear Included in 2 1229-L-3002
65 Side gear - diff. KIT 2318 2 2234-C-1069
66 Spider - diff. (cross) with spider, 1 3278-W-335
67 Gear - diff. pinion KIT 2341 4 2233-M-1001
68 Thrust washer - diff. pinion less spider 4 1229-K-3001
68A No-Spin assembly 1 A-3230-C-1043
69 Washer - gear to diff. case Included in KIT 2426 12 1229-U-1503
70 Nut - gear to diff. case 12 40-X-1182
THE FOLLOWING PARTS ARE FOR MAIN DIFFERENTIAL LOCK

71 Sensor/switch - main diff. lock Included in KIT 4455 1 3237-W-1167
71A Clip - sensor/switch 1 2257-M-1235
71B Plug - DCDL switchport Non-DCDL applications only 1 41-X-1022
72 Lock nut - sensor/switch Used on carriers with 1 1227-P-1056
3266-F-1020 air cyl. cover
prior to 11/93
73 Spring - main diff. lock After 11/93 1 2258-N-1262
Prior to 11/93 2258-L-714
74 Roll pin - spring retaining Prior to 11/93 1 43-X-1006
75 Shift shaft - main diff. lock 3200-P-1628 1 2244-Y-51
After 11/93 KIT 2824
All others prior to 11/93 2244-L-1026
76 Washer - piston 3200-P-1628 1 42-X-1027
77 Piston - main diff. lock After 11/93 1 KIT 2824
Prior to 11/93 2230-N-170
78 O-ring - piston After 11/93 1 5-X-1198
Prior to 11/93 5-X-1153
79 Tube - air cylinder Prior to 11/93 1 3196-F-32
80 Gasket - air cylinder cover Prior to 11/93 1 2208-H-944
81 Capscrew - manual engaging After 11/93 1 41-X-1368
Prior to 11/93 41-X-1333
81A O-ring 1 5-X-521
82 Cover - air cylinder Screw-in style After 11/93 1 KIT 2824
Bolt-on style Prior to 11/93 3266-F-1020
82A Plug - screw-in DCDL cylinder hole Non-DCDL applications only 1 1250-U-1217
83 Plug - air cylinder cover Prior to 11/93 1 MS-210016-1
84 Gasket - plug Prior to 11/93 1 2208-L-1000
85 Capscrew - air cylinder cover Prior to 11/93 4 41-X-1364
86 Washer - air cylinder cover Prior to 11/93 4 MWA-506
87 Clutch collar - main diff. lock 3200-P-1628 1 3107-F-1020
All others 3107-B-1094
6
88 Shift fork - main diff. lock Three pc. design 3200-Z-1560 1 3296-B-184
One pc. design After 11/93 3296-B-1172
Prior to 11/93 3296-Y-11691
89 Pin - shift fork Three pc. design 2 43-X-1007
THE FOLLOWING PARTS ARE FOR OIL PUMP

90 Shield - filter 1 3280-Z-8398
91 Plug - oil pressure relief valve Eliminated on carriers 1 1250-N-1080
92 Washer - plug built after 5/97 1 1229-F-4062
93 Spring - oil pressure relief valve 1 2258-Z-1118
94 Pressure relief valve - oil 1 2297-U-5273
95 Dowel - input cage to oil pump No longer used 2 1246-M-1131
96 O-ring - oil pump 1 5-X-1034
97 Oil pump assembly All others 1 A-3303-P-1030
For old style A1-3297-H-1022 KIT 2624
input shaft
98 Washer - oil pump 6 1229-E-1669
99 Capscrew - oil pump 6 MS-208045-1
100 Oil filter 1 3280-V-8394
101 Adaptor - oil filter 1 2297-Z-5278
102 Screen & plug assembly - oil filter 1 A-2297-D-5334
THE FOLLOWING PARTS ARE FOR THE CARRIERS WITH INTERNAL A.B.S. SENSORS
169 Wave washer - adjusting ring 2 2258-G-1255
170 Snap ring - connector 2 1229-U-4519
171 Snap ring - adjusting ring 2 1229-F-4452
172 Sensor - ABS Both sides 3200-K-1857 2 SA1-3280-X-9150
LH side 3200-L-1858 1 SA2-3280-X-9150
RH side SA1-3280-X-9150
172A Plug - sensor attaching (not shown) Pump carrier only 3200-L-1858 (LH side) 1 1250-T-1216
173 Drive tube 2 3216-G-4375
174 Washer - drive tube 2 42-X-1408
175 Snap ring - drive tube 2 1229-D-4528
1 Prior to 11/92 all carriers (except 3200-Z-1560) used the three

piece design fork (3296-R-1084) which was replaced by
3296-Y-1169 in 11/92.
7
CHART 2
CARRIERS FOR SINGLE AXLES AND REARS OF TANDEM AXLES
(Use with Figure 2, Inside Front Cover)
VISUAL IDENTIFICATION OF REAR CARRIERS
ONE RIB - ONE RIB -

RIGHT SIDE RIGHT SIDE
OF CARRIER OF CARRIER TWO RIBS -
TWO RIBS - LEFT SIDE
NO OPENING LEFT SIDE DIFF. LOCK OF CARRIER
RIGHT SIDE OF CARRIER AIR CYLINDER
OF CARRIER OPENING -
RIGHT SIDE
OF CARRIER
SENSOR/SWITCH
HOLE
REAR CARRIERS WITHOUT DIFF. LOCK REAR CARRIERS WITH DIFF. LOCK
3200-P-1706, 3200-T-1658, 3200-C-1511, 3200-Z-1560, 3200-V-1660,
3200-A-1821, 3200-J-1856 3200-R-1708, 3200-V-1712, 3200-C-1823,
3200-E-1825, 3200-H-1854, 3200-T-1892,
3200-Y-1897, 3200-D-1928, 3200-E-1929
The following carriers are equipped with a thrust screw: 3200-A-1821, 3200-D-1928, 3200-E-1929
The following carriers are machined for Internal ABS Sensors: 3200-H-1854, 3200-J-1856
The following carriers are available with and without Diff. Lock: 3200-C-1511, 3200-Z-1560, 3200-V-1712,
3200-E-1825, 3200-Y-1897, 3200-E-1929
8
115 Nut - drive pinion 1 40-X-1233
115A Washer - pinion nut 1 1229-N-1730
116, 117 Input yoke assembly 1 SEE YOKE CHARTS
118 Oil seal assembly - rear pinion 1 A1-1205-A-2731
119 Cone - drive pinion outer bearing 1 HM813843
120 Cup - drive pinion outer bearing 1 HM813810
121 Capscrew - pinion bearing cage 8 MS-212045-1
122 Washer - pinion bearing cage 8 MWA-512
123 Pinion bearing cage & cups assembly 1 A-3226-R-1006
124 Shims - pinion bearing .002"/.050mm Included in KIT 1592 Use as 2803-Y-2755
cage .005"/.125mm req. 2803-Z-2756
.008"/.200mm 2803-A-2757
.020"/.500mm 2803-B-2758
125 Spacers - pinion .250"/6.35mm Included in KIT 1593 Use 2 2803-D-2500
bearing .251"/6.38mm as req. 2803-E-2501
.252"/6.40mm 2803-F-2502
.253"/6.43mm 2803-N-2510
.254"/6.45mm 2803-G-2503
.256"/6.50mm 2803-H-2504
.260"/6.60mm 2803-J-2506
.261"/6.63mm 2803-K-2507
.262"/6.65mm 2803-L-2508
.263"/6.68mm 2803-M-2509
126 Cup - drive pinion inner bearing 1 9220
127 Cone - drive pinion inner bearing 1 1228-V-594
128, 115 Drive gear, pinion & nut assy. 2.50 ratio Use 1 B-42776-1
2.80 ratio as req. A-41572-1
2.93 ratio A-41712-12
A-41574-1
3.07 ratio A-39898-53
A-42002-12
3.21 ratio A-39900-53
A-41990-12
3.42 ratio A-39902-53
A-42004-12
3.58 ratio A-39904-53
A-41992-12
3.73 ratio A-39906-53
A-41994-12
3.91 ratio A-42466-12
A-39884-54
4.10 ratio A-39886-54
A-42006-12
4.30 ratio A-39888-54
A-41996-12
4.56 ratio A-39890-54
A-41988-12
4.89 ratio A-40024-53
A-41998-12
5.13 ratio A-41828-1
5.13 ratio A-42468-12
5.29 ratio A-42196-1
5.38 ratio A-40104-53
A-42000-12
5.63 ratio A-42470-12
A-40106-53
6.14 ratio A-42630-12
A-40110-53
6.43 ratio A-40116-53
6.83 ratio A-41066-13
7.17 ratio A-40122-53
129 Spigot bearing - drive pinion One piece bearing Use for carriers that have been 1 1228-Y-1221
upgraded to snap ring gearsets only
Use with new snap ring design 1228-B-1042
Two piece bearing Use with original non-snap ring design A1-1228-P-1004
2 Quietride™ gearing. 3 For 3200-C-1511, 3200-Z-1560, 3200-T-1658 & 3200-V-1660 use

4 Use KIT 2468 + Ratio to upgrade the 3200-Z-1560 carriers. -6 gearsets, except for 6.83 ratio use -2 gearset.
Use KIT 2655 + Ratio to upgrade the 3200-C-1511 carriers.
9
129A Snap ring - spigot bearing Use with 1228-B-1042 and 1 46-X-1029
1228-Y-1221
130, 131 & Differential carrier & cap Less differential lock With thrust screw 3200-A-1821 1 A2-3200-A-1821
132 assy. Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-C-1511 KIT 2657
Ratios - 3.91, 4.10, 4.30, 4.56 Aluminum KIT 2657A
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, KIT 2657B
6.83, 7.17
Aluminum 3200-E-1825 KIT 2767
3200-E-1929 A2-3200-E-1929
Aluminum, ABS 3200-H-1854 A2-3200-H-1854
Internal ABS 3200-J-1856 A2-3200-J-1856
New bearings 3200-P-1706 A2-3200-P-1706
Aluminum 3200-V-1712 KIT 2634
3200-Y-1897 A2-3200-Y-1897
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-Z-1560 KIT 2642
Ratios - 3.91, 4.10, 4.30, 4.56 Original design, KIT 2642A
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, 3200-T-1658 KIT 2642B
6.83, 7.17 Wide leg design
With differential lock Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-C-1511 KIT 2658
Ratios - 3.91, 4.10, 4.30, 4.56 Aluminum KIT 2658A
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, KIT 2658B
6.83, 7.17
Revised diff. lock 3200-C-1823 KIT 2762
Malleable w/screw-in main diff. 3200-D-1928 A2-3200-D-1928
shifter
Aluminum 3200-E-1825 KIT 2765
Aluminum w/screw-in main diff. 3200-E-1929 A2-3200-E-1929
shifter
New bearings 3200-R-1708 KIT 2659
Malleable w/screw-in main diff. 3200-T-1892 A2-3200-T-1892
shifter
Aluminum 3200-V-1712 KIT 2634
Aluminum w/screw-in main diff. 3200-Y-1897 A2-3200-Y-1897
shifter
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-Z-1560 KIT 2643
Ratios - 3.91, 4.10, 4.30, 4.56 Original design, KIT 2643A
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, 3200-V-1660 KIT 2643B
6.83, 7.17 Wide leg design
130A Thrust screw (not shown) 1 15-X-1167
130B Jam nut (not shown) 1 1227-D-472
131 Washer - diff. bearing cap 4 42-X-1024
132 Capscrew - diff. bearing cap 4 41-X-1018
133 Adjusting ring - diff. bearing LH & RH 1511, 1560, 1658, 1660 2 2214-S-279
LH 1708, 1712, 1823, 1825, 1 2214-G-1125
RH 1892, 1897, 1928 2214-J-1128
LH 3200-H-1854 (ABS) 2214-B-1146
RH 2214-Z-1144
LH & RH 3200-J-1856 (ABS) 2 2214-Z-1144
3200-P-1706 2214-G-1125
134 Pin - adjusting ring ABS carriers 2 19-X-1087
All others 1 KIT 4284
135 Cup - differential bearing LH & RH 1511, 1560, 1658, 1660 2 A1-1228-B-600
LH 1708, 1712, 1823, 1825, 1 592A
RH 1892, 1897, 1928, 1929 52618
LH & RH 3200-P-1706 2 592A
135A Adhesive - diff. bearing cup 1 2297-T-41807
136 Cone - differential bearing LH & RH 1511, 1560, 1658, 1660 2 A1-1228-B-600
LH 1708, 1712, 1823, 1825, 1 594A
RH 1892, 1897, 1928, 1929 52400
LH & RH 3200-P-1706 2 594A
137 Nut - diff. case to gear Included in KIT 2426 12 40-X-1182
138 Washer - diff. case to gear 12 1229-U-1503
139 Bolt - diff. case to gear 12 41-X-1276
7 No longer available
10
140 thru 147 Case & nest assy. - main diff. Ratios - 3.07, 3.21, 3.42, 3.58, 3.73, 3200-C-1511 Use 1 as A11-3235-S-18135
All shown are 2.38"-46 axle spline. 3.91, 4.10, 4.30, 4.56 Aluminum req.
Ratios - 3.91, 4.10, 4.30, 4.56 Less diff. lock A11-3235-F-19826
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A11-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73, 3200-C-1511 A13-3235-S-18135
3.91, 4.10, 4.30, 4.56 Aluminum
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A13-3235-H-1984
6.83, 7.17
Ratios - 2.80, 2.93 3200-P-1706, A1-3235-R-2202
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-A-1821, A1-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 Less diff. lock A1-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A1-3235-G-2113
6.83, 7.17
Ratios - 2.80, 2.93 3200-R-1708, A3-3235-R-2202
3200-V-1712 Alum.,
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-C-1823, A3-3235-C-2109
3200-E-1825 Alum.,
Ratios - 3.91, 4.10, 4.30, 4.56 3200-T-1892, A3-3235-E-2111
3200-Y-1897 Alum.,
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, 3200-D-1928, A3-3235-G-2113
6.83, 7.17 3200-E-1929 Alum.,
With diff. lock
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-T-1658 A11-3235-S-1813
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A11-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-V-1600 A13-3235-S-1813
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A13-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-V-1712, 3200-E-1825, A6-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 3200-Y-1897, 3200-E-1929, A6-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, Aluminum, A6-3235-G-2113
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73, 3200-Z-1560 A3-3235-S-18135
3.91, 4.10, 4.30, 4.56 With or Without diff. lock
Ratios - 3.91, 4.10, 4.30, 4.56 A3-3235-F-19826
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A3-3235-H-1984
6.83, 7.17
140 thru 147, Case & nest assy. - main diff. Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-H-1854, Use 1 as A4-3235-R-2176
173, 174, 175 All shown are 2.38"-46 axle spline. Ratios - 3.91, 4.10, 4.30, 4.56 Internal ABS, req. A4-3235-S-2177
6.83, 7.17 Aluminum
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-J-1856, A2-3235-R-2176
6.83, 7.17 Malleable iron
140, 142A, Case & NoSpin assy. - main diff. Ratios - 3.07, 3.21, 3.42, 3.58, 3.73, 3200-C-1511 Use 1 as A14-3235-S-18135
146, 147 All shown are 2.38"-46 axle spline. 3.91, 4.10, 4.30, 4.56 Aluminum req.
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A14-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-P-1706 A7-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 Less diff. lock A7-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A7-3235-G-2113
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-T-1658 A14-3235-S-1813
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A14-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-V-1712, 3200-E-1825, A8-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 3200-Y-1897, A8-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, Aluminum A8-3235-G-2113
5 For use with carriers built prior to Sept. 1, 1988. 6 For use with carriers produced after Sept. 1, 1988 or have been
(Applies to ratios 3.91 thru 4.56 only.) retro-fitted with KIT 2468 or KIT 2655 only.
11
140, 146 & Case assy - main differential Ratios - 3.07, 3.21, 3.42, 3.58, 3.73, 3200-C-1511 Use 1 as A10-3235-S-18135
147 3.91, 4.10, 4.30, 4.56 Aluminum req.
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A10-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73, 3200-C-1511 A12-3235-S-18135
3.91, 4.10, 4.30, 4.56 Aluminum
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A12-3235-H-1984
6.83, 7.17
Ratios - 2.80, 2.93 3200-P-1706, 3200-A-1821, A-3235-R-2202
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 Less diff. lock A-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 A-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A-3235-G-2113
6.83, 7.17
Ratios - 2.80, 2.93 3200-R-1708, A2-3235-R-2202
3200-V-1712 Alum.,
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-C-1823, A2-3235-C-2109
3200-E-1825 Alum.,
Ratios - 3.91, 4.10, 4.30, 4.56 3200-T-1892, A2-3235-E-2111
3200-Y-1897 Alum.,
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, 3200-D-1928, A2-3235-G-2113
6.83, 7.17 3200-E-1929 Alum.,
With diff. lock
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-T-1658 A10-3235-S-1813
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A10-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-V-1660 A12-3235-S-1813
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A12-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-V-1712, 3200-E-1825, A5-3235-C-2109
Ratios - 3.91, 4.10, 4.30, 4.56 3200-Y-1897, 3200-E-1929, A5-3235-E-2111
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, Aluminum, A5-3235-G-2113
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73, 3200-Z-1560 A-3235-S-18135
3.91, 4.10, 4.30, 4.56 Less diff. lock
Ratios - 3.91, 4.10, 4.30, 4.56 A2-3235-F-19826
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A-3235-H-1984
6.83, 7.17
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73, 3200-Z-1560 A2-3235-S-18135
3.91, 4.10, 4.30, 4.56 With diff. lock
Ratios - 3.91, 4.10, 4.30, 4.56 A2-3235-F-19826
Ratios - 4.89, 5.38, 5.63, 6.14, 6.43, A2-3235-H-1984
6.83, 7.17
140, 146, 147, Case assy - main differential (ABS ready) Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-H-1854, Use 1 as A5-3235-R-2176
173, 174, 175 Ratios - 3.91, 4.10, 4.30, 4.56 Internal ABS, req. A5-3235-S-2177
6.83, 7.17 Aluminum
Ratios - 3.07, 3.21, 3.42, 3.58, 3.73 3200-J-1856, A1-3235-R-2176
6.83, 7.17 Malleable iron
141 Thrust washer - side gear Included in KIT 2318 2 1229-L-3002
142 Side gear - differential 46 Spline 2 2234-C-1069
50 Spline 2234-D-1070
142A No-Spin assembly 46 Spline 1 A-3230-C-1043
143 Thrust washer - diff. pinion Included in KIT 2318 4 1229-K-3001
144 Gear - diff. pinion 4 2233-M-1001
145 Spider diff. 1 3278-W-335
146 Washer - diff. case 12 1229-U-1503
147 Capscrew - diff. case 12 41-X-1275
147A Thread locking liquid 1 2297-C-7049
5 For use with carriers built prior to Sept. 1, 1988. 6 For use with carriers produced after Sept. 1, 1988 or have been
(Applies to ratios 3.91 thru 4.56 only.) retro-fitted with KIT 2468 or KIT 2655 only.
12
THE FOLLOWING PARTS ARE FOR MAIN DIFFERENTIAL LOCK

148 Sensor/switch - main diff. lock Included in KIT 4455 1 3237-W-1167
148A Clip - sensor/switch 1 2257-M-1235
148B Plug - sensor port 1 41-X-1022
149 Lock nut - sensor/switch Prior to 11/93 Used on carriers with 1 1227-P-1056
3266-F-1020 air cyl. cover
150 Shift fork - main diff. lock Three pc. design 3200-Z-1560 1 3296-B-184
One pc. design After 11/93 3296-B-1172
Prior to 11/93 3296-Y-11691
151 Spring - main diff. lock After 11/93 1 2258-N-1262
Prior to 11/93 2258-L-714
152 Shift shaft - main diff. lock 1511, 1560, 1660 1 2244-Y-51
1708, 1712, 1823 2244-L-1026
1892, 1897, 1928, 1929 KIT 2824
152A Washer - piston (not shown) Prior to 11/93 1 42-X-1027
153 Shift cylinder housing Screw-in style After 11/93 1 KIT 2824
Tube - air cylinder Bolt-on style Prior to 11/93 3196-F-32
153A Plug - cylinder hole 1 1250-U-1217
154 Piston - main diff. lock After 11/93 1 KIT 2824
Prior to 11/93 2230-N-170
155 Gasket - air cylinder cover Prior to 11/93 1 2208-H-944
156 Capscrew - manual engaging After 11/93 1 41-X-1368
Prior to 11/93 41-X-1333
156A O-ring 1 5-X-521
157 Cover - air cylinder Bolt-on style Prior to 11/93 1 3266-F-1020
158 Washer - adjusting ring lock capscrew 2 MWA-508
159 Capscrew - adjusting ring lock 2 MS-208020-1
160 Lock - adjusting ring 1 1220-K-89
161 Pin - shift fork Three pc. design 2 43-X-1007
162 Clutch collar - main diff. lock 1511, 1660, 1628 1 3107-F-1020
46 Spline 1708, 1712, 1823, 1825, 3107-B-1094
1892, 1894, 1897, 1928, 1929
50 Spline 1708, 1823 3107-C-1095
3200-Z-1560 3107-P-1030
163 Roll pin - spring retaining Prior to 11/93 1 43-X-1006
164 O-ring - piston After 11/93 1 5-X-1198
Prior to 11/93 5-X-1153
165 Washer - air cylinder cover Prior to 11/93 4 MWA-506
166 Capscrew - air cylinder cover Prior to 11/93 4 41-X-1364
167 Gasket - plug Prior to 11/93 1 2208-L-1000
168 Plug - air cylinder cover Prior to 11/93 1 MS-210016-1
THE FOLLOWING PARTS ARE FOR CARRIERS WITH INTERNAL A.B.S. SENSORS
169 Wave washer - adjusting ring 2 2258-G-1255
170 Snap ring - adjusting ring 2 1229-F-4452
171 Snap ring - sensor 2 1229-U-4519
172A Plug - sensor attaching (not shown) Aluminum only 3200-H-1854 (LH side) 1 1250-T-1216
173 Drive tube 2 3216-G-4375
174 Washer - drive tube 2 42-X-1408
175 Snap ring - drive tube 2 1229-D-4528
172 Sensor - ABS LH side 3200-H-1854 1 SA2-3280-X-9150
RH side SA1-3280-X-9150
Both sides 3200-J-1856 2 SA1-3280-X-9150
1 Prior to 11/92 all carriers (except 3200-Z-1560) used the three

piece design fork (3296-R-1084) which was replaced by
3296-Y-1169 in 11/92.
13
OUTPUT (THRU) SHAFT ASSEMBLY PARTS
ITEM DESCRIPTION REMARKS QTY PART NUMBER

200 Output (thru) shaft, bearing cage and seal assy. Includes Items 201 thru 211 1 A2-3226-T-1112S
201 Shaft - output (thru) 1 3297-V-1010
202 Bearing cage & inner cup assy. - output 1 A-3226-T-1112
202A Deflector (no longer used) 1 KIT 25831
203 Washer - output bearing cage capscrew 4 1229-K-1597
204 Capscrew - output bearing cage 4 15-X-387
205 Cups - innter & outer output bearing 2 JLM-104910
206 Cones - innter & outer output bearing 2 LM-104949
207 Snap ring (spacer) - output bearing .155 inch Included in KIT 576 Use 1 as 1229-P-2590
.158 inch req. 1229-Q-2591
.161 inch 1229-R-2592
.164 inch 1229-S-2593
.167 inch 1229-T-2594
.170 inch 1229-U-2595
.173 inch 1229-V-2596
.176 inch 1229-W-2597
.179 inch 1229-X-2598
.182 inch 1229-Y-2599
208 Snap ring spacer - output bearing/yoke 1 1229-W-4131
209 Oil seal - output bearing cage 2 piece (seal & sleeve) 1 A1-1205-Y-2729
210 Washer - yoke nut (output) Included in KIT 2637 1 1229-T-1736
211 Nut - output yoke 1 40-X-1237
1 Use A1-1205-Y-2729 seal & sleeve. Do not use deflector.
14
HOUSING ASSEMBLY PARTS
ITEM DESCRIPTION REMARKS COMMENTS QTY PART NUMBER

212 Axle housing assembly 1 AS SPECIFIED
213 Breather assembly - housing 1 A-1199-P-1394
214 Stud - carrier to housing Forward-rear only Long 1 4-X-1922
Short For 12 mtg. hole version 1 4-X-1921
For 15 mtg. hole version 2 4-X-1921
215 Plug - heat indicator Use as required 1 P-28S
216 Plug - filler hole 1 P-212
217 Washer - carrier to housing Forward-rear only For 12 mtg. hole version 2 1229-W-1557
nut For 15 mtg. hole version 3 1229-W-1557
218 Nut - carrier to housing stud Forward-rear only For 12 mtg. hole version 2 N-110-1
For 15 mtg. hole version 3 N-110-1
219 Capscrew - carrier to Forward-rear axles, 1-3/4" Long For 12 mtg. hole version 7 10-X-1594
housing RP & RD 23-160/164, For 15 mtg. hole version 9 10-X-1594
26-160/164 For tapered dowel versions 5 10-X-1594
2" Long For tapered dowel versions. 4 10-X-1595
See Item 36C for dowel
3-1/2" Long All forwards 3 10-X-1599
Rear-rear & single axles, 1-3/4" Long 8 10-X-1594
RS & RR 23-160/164, 3-1/2" Long 4 10-X-1600
26-160/164
220 Washer - carrier to housing Forward-rear only For 12 mtg. hole version 10 1229-W-1557
capscrew For 15 mtg. hole version 12 1229-W-1557
Rear-rear & singles 12 1229-W-1557
221 Plug - drain (magnetic) 1 1250-E-473
222 Oil seal assembly Unitized 2 A-1205-Q-2487
Use with wiper below 2 A-1205-T-696
222A Wiper - housing spindle inner (optional) Not shown Chrome plated 2 1199E1669
223 Cone - bearing inner wheel 2 594A
224 Cup - bearing inner wheel 2 592A
225 Cup - bearing outer wheel 2 572
226 Cone - bearing outer wheel 2 580
227 Nut - bearing adjusting inner 2 1227-W-517
228 Washer - adjusting nut Off-highway 2 1229-U-1009
229 Tanged washer & adjusting nut washer On-highway 2 1229-F-4634S
230 Nut - outer jam 2 1227-R-330
15
AXLE SHAFT SETS FOR 160, 161 and 164 SERIES AXLES
LEFT RIGHT LEFT RIGHT
HAND HAND HAND HAND
RS-20-160 Single Axle RS-24-160 Single Axle
3202-Q-8805 3202-B-8816* 3202-Y-8683 3202-P-8804

3202-Q-8805 3202-G-9003 3202-Y-8683 3202-A-8815
RS-21-160 Single Axle RS-25-160 Single Axle
3202-Q-8805 3202-B-8816* 3202-Q-8805 3202-B-8816*

3202-Q-8805 3202-G-9003 3202-Q-8805 3202-G-9003
3202-H-9004 3202-R-8806 3202-Y-9125 3202-Z-9126
3202-H-9004 3202-C-8817* 3202-Y-9125 3202-C-9129*
3202-Y-9125 3202-Z-9126 3202-J-9344 3202-K-9345
3202-Y-9125 3202-C-9129* 3202-J-9344 3202-L-9346*
3202-J-9344 3202-K-9345
3202-J-9344 3202-L-9346* RS-26-160 Single Axle
RS-22-160 Single Axle 3202-G-9393 3202-B-8816 *

3202-G-9393 3202-G-9003
3202-Q-8805 3202-B-8816*
3206-X-1532 3206-Z-1534 RD-20-160 Fwd. axle less pump
RT-40-160 Tandem
RC-23-160 Single Axle 3202-R-8806 3202-H-9004
3202-B-8816* 3202-Q-8805
3202-Q-8805 3202-G-9003 3202-G-9003 3202-Q-8805
3202-Y-8683 3202-P-8804 3202-Z-9126 3202-Y-9125
3202-C-9129* 3202-Y-9125
RS-23-160 Single Axle 3202-K-9345 3202-J-9344
3202-L-9346* 3202-J-9344
3202-X-8110 3206-T-1190
3202-Q-8805 3202-B-8816 * RD-23-160 Fwd. axle less pump
3202-Q-8805 3202-G-9003 RT-46-160 Tandem
3202-H-9004 3202-R-8806 3202-R-8806 3202-H-9004
3202-H-9004 3202-C-8817 * 3202-B-8816 * 3202-Q-8805
3202-Y-9125 3202-Z-9126 3202-C-8817 * 3202-H-9004
3202-Y-9125 3202-C-9129* 3202-G-9003 3202-Q-8805
3202-A-9127 3202-B-9128 3202-Z-9126 3202-Y-9125
3202-D-9130* 3202-A-9127 3202-A-9127 3202-D-9130*
3202-J-9344 3202-L-9346 * 3202-C-9129* 3202-Y-9125
3202-J-9344 3202-K-9345 3202-K-9345 3202-J-9344
3202-Y-9489 3202-Z-9490 3202-L-9346 * 3202-J-9344
3202-Y-9489 3202-A-9491 * 3202-Z-9490 3202-Y-9489
3202-L-9502 3202-L-9918 3202-A-9491 * 3202-Y-9489
3202-K-9553 3202-A-9647* 3202-F-9574 3202-E-9573
3202-E-9573 3202-F-9574 3202-G-9575 * 3202-E-9573
3202-E-9573 3202-G-9575 * 3202-J-9916 3202-L-9502
RS-23-161 Single Axle RD-25-160 Fwd. axle less pump

RT-50-160 Tandem
3202-Q-8805 3202-B-8816 * 3202-B-8816* 3202-Q-8805
3202-Q-8805 3202-G-9003 3202-G-9003 3202-Q-8805
3202-J-9344 3202-K-9345 3202-Z-9126 3202-Y-9125
3202-J-9344 3202-L-9346 * 3202-C-9129* 3202-Y-9125
3202-Y-9489 3202-Z-9490 3202-K-9345 3202-J-9344
3202-Y-9489 3202-A-9491 * 3202-L-9346* 3202-J-9344
3202-L-9918 3202-L-9502
* This shaft has longer splines that engage the differential lock.
16
AXLE SHAFT SETS FOR 160, 161 and 164 SERIES AXLES
LEFT RIGHT LEFT RIGHT
HAND HAND HAND HAND
RP-20-160 Fwd. axle with pump RR-23-160 Rear axle of

RT-40-160 Tandem RT-46-160 Tandem
3202-B-8816* 3202-Q-8805 3202-Q-8805 3202-B-8816 *
3202-C-8817* 3202-H-9004 3202-Q-8805 3202-G-9003
3202-G-9003 3202-Q-8805 3202-X-8110 3206-T-1190
3202-Z-9126 3202-Y-9125 3202-H-9004 3202-R-8806
3202-C-9129* 3202-Y-9125 3202-H-9004 3202-C-8817 *
3202-K-9345 3202-J-9344 3202-Y-9125 3202-Z-9126
3202-L-9346* 3202-J-9344 3202-Y-9125 3202-C-9129*
3202-A-9127 3202-B-9128
RP-23-160 Fwd. axle with pump 3202-D-9130* 3202-A-9127
RT-46-160 Tandem 3202-J-9344 3202-K-9345
3202-R-8806 3202-H-9004 3202-J-9344 3202-L-9346 *
3202-B-8816 * 3202-Q-8805 3202-Y-9489 3202-Z-9490
3202-C-8817 * 3202-H-9004 3202-Y-9489 3202-A-9491 *
3202-G-9003 3202-Q-8805 3202-L-9502 3202-J-9916
3202-Z-9126 3202-Y-9125 3202-K-9553 3202-A-9647*
3202-A-9127 3202-D-9130* 3202-E-9573 3202-F-9574
3202-B-9128 3202-A-9127 3202-E-9573 3202-G-9575 *
3202-C-9129* 3202-Y-9125 3202-L-9918 3202-L-9502
3202-K-9345 3202-J-9344
3202-L-9346 * 3202-J-9344 RR-23-164 Rear axle of
3202-Z-9490 3202-Y-9489 RT-56-164 Tandem
3202-A-9491 * 3202-Y-9489 3202-Q-8805 3202-B-8816*
3202-L-9502 3202-L-9918
3202-F-9574 3202-E-9573 RR-25-160 Rear axle of
3202-G-9575 * 3202-E-9573 RT-50-160 Tandem
3202-A-9647* 3202-K-9553 3202-Q-8805 3202-B-8816*
3206-T-1190 3202-X-8110 3202-H-9004 3202-R-8806
3202-H-9004 3202-C-8817*
RP-23-164 Fwd. axle with pump 3202-Y-9125 3202-Z-9126
RT-46-164 Tandem 3202-Y-9125 3202-C-9129*
3202-Q-8805 3202-B-8816* 3202-J-9344 3202-K-9345
3202-C-8817* 3202-H-9004 3202-J-9344 3202-L-9346*
3202-Q-8805 3202-G-9003
RP-25-160 Fwd. axle with pump
RT-50-160 Tandem RD-26-160 Fwd. axle less pump
3202-R-8806 3202-H-9004 RT-52-160 Tandem
3202-B-8816* 3202-Q-8805 3202-B-8816 * 3202-G-9393
3202-C-8817* 3202-H-9004 3202-G-9003 3202-G-9393
3202-G-9003 3202-Q-8805 3202-Q-9403* 3202-H-9004
3202-Z-9126 3202-Y-9125
3202-C-9129* 3202-Y-9125 RP-26-160 Fwd. axle with pump
3202-K-9345 3202-J-9344 RT-52-160 Tandem
3202-L-9346* 3202-J-9344 3202-B-8816 * 3202-G-9393
3202-G-9003 3202-Q-8805
RR-20-160 Rear axle of 3202-G-9003 3202-G-9393
RT-40-160 Tandem 3202-Q-9403* 3202-H-9004
3202-Q-8805 3202-B-8816*
3202-Q-8805 3202-G-9003 RR-26-160 Rear axle of
3202-H-9004 3202-R-8806 RT-52-160 Tandem
3202-H-9004 3202-C-8817* 3202-H-9004 3202-Q-9403*
3202-Y-9125 3202-Z-9126 3202-G-9393 3202-B-8816 *
3202-Y-9125 3202-C-9129* 3202-G-9393 3202-G-9003
3202-J-9344 3202-K-9345
3202-J-9344 3202-L-9346*
* This shaft has longer splines that engage the differential lock.
17
AXLE SHAFTS
Part Number Body Dia. Length Spline Size Spline Len. Flange Dia. No. of Holes Hole Size Bolt Circle Hole Type
3206-X-1532 2.00" 37.44" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3206-Z-1534 2.00" 43.80" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-J-9344 2.25" 36.57" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-Y-9125 2.25" 36.57" 2.35"-46 3.03" 8.38" 8 .78" 7.00" Straight
3202-G-9393 2.25" 37.31" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-Y-9489 2.25" 37.44" 2.35"-46 3.03" 8.38" 8 .64" 7.00" Straight
3202-Q-8805 2.25" 37.44" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-K-9553 2.25" 39.44" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-A-9127 2.25" 39.44" 2.35"-46 3.03" 8.38" 8 .78" 7.00" Straight
3202-Y-8683 2.25" 39.59" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-E-9573 2.25" 40.31" 2.35"-46 3.03" 8.38" 8 .64" 7.00" Straight
3202-H-9004 2.25" 40.31" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-P-8804 2.25" 41.57" 2.35"-46 3.03" 8.38" 8 .78" 7.00" Taper
3202-A-8815 2.25" 41.73" 2.35"-46 9.14" 8.38" 8 .78" 7.00" Straight
3202-K-9345 2.25" 42.91" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-Z-9126 2.25" 42.91" 2.35"-46 3.03" 8.38" 8 .78" 7.00" Straight
3202-L-9346 2.25" 43.07" 2.35"-46 9.14" 8.38" 8 .73" 7.00" Taper
3202-C-9129 2.25" 43.07" 2.35"-46 9.14" 8.38" 8 .78" 7.00" Straight
3202-X-8110 2.25" 43.40" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-Z-9490 2.25" 43.80" 2.35"-46 3.03" 8.38" 8 .64" 7.00" Straight
3202-G-9003 2.25" 43.80" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-A-9491 2.25" 43.93" 2.35"-46 9.14" 8.38" 8 .64" 7.00" Straight
3202-B-8816 2.25" 43.93" 2.35"-46 9.14" 8.38" 8 .73" 7.00" Taper
3202-B-9128 2.25" 45.74" 2.35"-46 3.03" 8.38" 8 .78" 7.00" Straight
3202-A-9647 2.25" 45.90" 2.35"-46 9.14" 8.38" 8 .73" 7.00" Taper
3202-D-9130 2.25" 45.90" 2.35"-46 9.14" 8.38" 8 .78" 7.00" Straight
3202-F-9574 2.25" 46.61" 2.35"-46 3.03" 8.38" 8 .64" 7.00" Straight
3202-R-8806 2.25" 46.61" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-G-9575 2.25" 46.78" 2.35"-46 9.14" 8.38" 8 .64" 7.00" Straight
3202-C-8817 2.25" 46.78" 2.35"-46 9.14" 8.38" 8 .73" 7.00" Taper
3202-Q-9403 2.25" 46.90" 2.35"-46 9.14" 8.38" 8 .73" 7.00" Taper
3206-T-1190 2.25" 49.67" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-J-9916 2.25" 52.79" 2.35"-46 3.03" 8.38" 8 .73" 7.00" Taper
3202-L-9918 2.25" 52.92" 2.35"-46 9.14" 8.38" 8 .73" 7.00" Taper
18
ROUND BEARING TYPE YOKES
Yoke
Axle Model Center to Spline Bearing Cap Dimension Spline Size Dia. - Production Part
(Location) End Length Hub Dia. Diameter Across Ears No. Teeth Part Number Number
Forward Input/ 4.94" 2.32" 3.25" 1.88" 5.31" 2.38"-46 16NYS38-8A A-3260-T-1034
Rear Axle 6.19" 1.88" 5.31" 16NYS38-12A A-3260-G-1125
5.38" 1.94" 6.09" 17N-4-7181X A-3260-U-359
6.50" 1.94" 6.09" 17NYS38-38A A-3260-R-1058
5.06" 1.94" 7.00" 176NYS38-14A A-3260-V-360
5.16" 1.94" 7.55" 18NYS38-27A A-3260-C-1147
Forward Output/ 5.54" 2.31" 3.00" 1.88" 5.31" 2.00"-39 16N-4-6271 3260-G-111
Rear Axle 6.22" 1.88" 5.31" 16N-4-6241 3260-H-112
5.16" 1.94" 6.09" 17NYS32-100 3260-Q-121
6.25" 1.94" 6.09" 17NYS32-99 3260-P-120
Rear Input/ 4.94" 2.32" 3.25" 1.88" 5.31" 2.38"-46 16NYS38-8A A-3260-T-1034
Rear Axle and 6.19" 1.88" 5.31" 16NYS38-12A A-3260-G-1125
Single Axle 5.38" 1.94" 6.09" 17N-4-7181X A-3260-U-359
Applications 6.50" 1.94" 6.09" 17NYS38-38A A-3260-R-1058
5.06" 1.94" 7.00" 176NYS38-14A A-3260-V-360
5.16" 1.94" 7.55" 18NYS38-27A A-3260-C-1147
For additional: Parts Information

Cross Reference
Production Bills of Material
visit our online catalog at: www.XpresswayPlus.com
19
WING BEARING TYPE YOKES
Spline Size
Axle Model Spline Hub Pilot Keyway Dia. - No. Production Part
(Location) Face to End Length Dia. Diameter Width Teeth Hole Type Part Number Number
Forward Input/ 4.25" 2.32" 3.25" 5.84" .63" 2.38"-46 TH 72NYS38-26A A-3260-B-1146
Rear Axle 4.25" 2.32" 3.25" 8.13" .63" 2.38"-46 TH 82NYS38-31A A-3260-H-1308
4.22" 2.32" 3.25" 8.25" .63" 2.38"-46 TH 92NYS38-73A A-3260-K-1129
Forward Output/ 3.81" 2.31" 3.00" 5.84" .63" 2.00"-39 TH 72NYS32-244 3260-S-123
Rear Axle 4.44" 2.31" 3.00" 8.25" .63" 2.00"-39 DR 92NYS32-26 3260-B-132
Rear Input/ 4.25" 2.32" 3.25" 5.84" .63" 2.38"-46 TH 72NYS38-26A A-3260-B-1146
Rear Axle and 4.25" 2.32" 3.25" 5.84" .63" 2.38"-46 DR 72NYS38-24A A-3260-Z-1144
Single Axle 4.25" 2.32" 3.25" 8.13" .63" 2.38"-46 TH 82NYS38-31A A-3260-H-1308
Applications 4.22" 2.32" 3.25" 8.25" .63" 2.38"-46 TH 92NYS38-73A A-3260-K-1129
20
EASY SERVICE (STRAP) TYPE YOKES
Distance
Axle Model Center to Spline Hub Bearing Cap Between Spline Size Production Part
(Location) End Length Dia. Diameter Nibbs Dia. - No. Teeth Hole Type Part Number Number
Forward Input/ 5.38" 2.32" 3.25" 1.94" 6.19" 2.38"-46 TH 17TYS38-76A A-3260-G-1229
Rear Axle 5.06" 1.94" 7.09" TH 176TYS38-27A A-3260-P-1264
5.16" 1.93" 7.64" TH 18TYS38-27A A-3260-L-1260
Forward Output/ 6.22" 2.31" 3.00" 1.88" 5.31" 2.00"-39 TH 16TYS32-76 3260-D-1668
Rear Axle 6.25" 1.94" 6.19" TH 17TYS32-99 3260-A-1535
5.16" 1.94" 6.19" TH 17N-4-7621-1 3260-R-1292
Rear Input/ 4.94" 2.32" 3.25" 1.88" 5.31" 2.38"-46 TH 16N-4-7341-1X A-3260-L-1234
Rear Axle and 5.38" 1.94" 6.19" TH 17TYS38-76A A-3260-G-1229
Single Axle 5.06" 1.94" 7.09" TH 176TYS38-27A A-3260-P-1264
Applications 5.16" 1.93" 7.64" TH 18TYS38-27A A-3260-L-1260
21
COMPANION FLANGES
Pilot Dia. Bolt

Axle Model Spline Hub M=Male Hole Circle Spline Size Production Part
(Location) Face to End Length Dia. F=Female Flange Dia. Size Dia. Dia. - No. Teeth Part Number Number
Forward Input/ 3.88" 2.32" 3.25" F-7.75" 8.00" .38" 7.25" 2.38"-46 5WCS38-18A A-3280-W-8265
Rear Axle
Rear Input/ 3.56" 2.32" 3.25" F-7.75" 8.00" .44" 7.25" 2.38"-46 5WCS38-23A2 A2-3260-R-1240
Rear Axle and 3.88" .38" 5WCS38-18A A-3280-W-8265
Single Axle
Applications
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22
AXLE MODEL TO CARRIER TO KIT CROSS REFERENCE
AXLE BASE KIT
MODEL CARRIER KIT DESCRIPTION NUMBER
Single Axle 3200-C-1511 Standard Pinion bearing cage shims KIT 1592
RC-23-160 3200-C-1511 Diff. lock Pinion bearing spacers KIT 1593
RS-23-160 Ring gear to case fastener kit, prior to 4/88 KIT 2317
RS-23-161 Main diff. nest kit with spider KIT 2318
RS-24-160 Main diff. nest kit less spider KIT 2341
RS-25-160 Main diff. lock actuator kit (minor) KIT 2406
RS-26-160 Main diff. lock actuator KIT 2414
Ring gear to case fasteners after 4/88 KIT 2426
Diff. case assembly kit KIT 2796
Main diff. lock piston kit KIT 2614
Diff. case and gearset upgrade KIT 2655-391
Replaces A2-3200-C-1511 fast ratios, less diff. lock. KIT 2657
Replaces A2-3200-C-1511 mid range ratios, less diff. lock. KIT 2657A
Replaces A2-3200-C-1511 std. range ratios, less diff. lock. KIT 2657B
Replaces A2-3200-C-1511 fast ratios, with diff. lock. KIT 2658
Replaces A2-3200-C-1511 mid range ratios, with diff. lock. KIT 2658A
Replaces A2-3200-C-1511 std. ratios, with diff. lock. KIT 2658B
Lock pin kit (non-ABS carriers only) KIT 4284
Bearing and seal kit KIT 4415
Major overhaul kit KIT RR23160
3200-Z-1560 Standard Pinion bearing cage shims KIT 1592
3200-Z-1560 Diff. Lock Pinion bearing spacers KIT 1593
3200-Z-1560 NoSpin diff. Ring gear to case fastener kit, prior to 4/88 KIT 2317
Main diff. nest kit with spider * KIT 2318
Main diff. nest kit less spider * KIT 2341
Main diff. lock actuator kit (minor) KIT 2406
Replaces A2-3200-Z-1560 fast ratios, less diff. lock. KIT 2642
Replaces A2-3200-Z-1560 mid range ratios, less diff. lock. KIT 2642A
Replaces A2-3200-Z-1560 std. ratios, less diff. lock. KIT 2642B
Replaces A2-3200-Z-1560 fast ratios, with diff. lock. KIT 2643
Replaces A2-3200-Z-1560 mid range ratios, with diff. lock. KIT 2643A
Replaces A2-3200-Z-1560 std. ratios, with diff. lock. KIT 2643B
3200-T-1658 Standard Pinion bearing cage shims KIT 1592
3200-T-1658 NoSpin diff. Pinion bearing spacers KIT 1593
Ring gear to case fastener kit, prior to 4/88 KIT 2317
Main diff. nest kit with spider * KIT 2318
Replaces A2-3200-T-1658 fast ratios, less diff. lock. KIT 2642
Replaces A2-3200-T-1658 mid range ratios, less diff. lock. KIT 2642A
Replaces A2-3200-T-1658 std. range ratios, less diff. lock. KIT 2642B
* Diff. nest kit not required with NoSpin.
23
AXLE BASE KIT
Single Axle 3200-R-1708 Diff. lock Pinion bearing cage shims KIT 1592
RC-23-160 3200-C-1823 Diff. lock Pinion bearing spacers KIT 1593
RS-23-160 3200-T-1892 Diff. lock Main diff. nest kit with spider KIT 2318
RS-23-161 3200-D-1928 Diff. lock Main diff. nest kit less spider KIT 2341
RS-24-160 Main diff. lock actuator kit (minor) (all except 3200-T-1892) KIT 2406
RS-25-160 Main diff. lock actuator kit (minor) (3200-T-1892) KIT 2750
RS-26-160 Ring gear to case fasteners after 4/88 KIT 2426
Main diff. lock piston kit (all except 3200-T-1892) KIT 2614
Main diff. lock piston kit (3200-T-1892) KIT 2691
Main diff. lock actuator kit (all except 3200-T-1892) KIT 2615
Main diff. lock actuator kit (3200-T-1892) KIT 2698
Replaces A2-3200-R-1708 KIT 2659
Main diff. lock kit (3200-T-1892, 3200-D-1928) KIT 2698
Major overhaul kit KIT RR23160B
Replaces A2-3200-C-1823 KIT 2762
3200-P-1706 Standard Pinion bearing cage shims KIT 1592
3200-H-1854 Standard Pinion bearing spacers KIT 1593
3200-J-1856 Standard Main diff. nest kit with spider * KIT 2318
3200-P-1706 NoSpin diff. Ring gear to case fasteners after 4/88 KIT 2426
3200-A-1821 NoSpin diff. Diff. case assembly kit KIT 2796
Major overhaul kit KIT RR23160A
3200-V-1712 Standard Pinion bearing cage shims KIT 1592
3200-Y-1897 Standard Pinion bearing spacers KIT 1593
3200-E-1929 Standard Main diff. nest kit with spider * KIT 2318
3200-V-1712 Diff. lock Ring gear to case fasteners after 4/88 KIT 2426
3200-Y-1897 Diff. lock Diff. case assembly kit KIT 2796
3200-E-1929 Diff. lock Main diff. lock piston kit (all except 3200-Y-1897,3200-E-1929) KIT 2614
Main diff. lock actuator (all except 3200-Y-1897,3200-E-1929) KIT 2615
3200-V-1712 NoSpin diff. Main diff. lock kit (3200-Y-1897,3200-E-1929) KIT 2698
3200-E-1825 NoSpin diff. Lock pin kit (non-ABS carriers only) KIT 4284
Major overhaul kit KIT RR23160B
Replaces A2-3200-E-1825 and V-1712, less diff lock KIT 2767
Replaces A2-3200-E-1825 and V-1712, with diff lock KIT 2765
3200-V-1660 Diff. lock Pinion bearing cage shims KIT 1592
Pinion bearing spacers KIT 1593
Ring gear to case fastener kit, prior to 4/88 KIT 2317
Main diff. nest kit with spider KIT 2318
Main diff. nest kit less spider KIT 2341
Main diff. lock actuator kit KIT 2414
Replaces A2-3200-Z-1560 fast ratios, with diff. lock. KIT 2643
Replaces A2-3200-Z-1560 mid range ratios, with diff. lock. KIT 2643A
Replaces A2-3200-Z-1560 std. ratios, with diff. lock. KIT 2643B
24
AXLE BASE KIT
Front 3200-J-1648 Standard Thru-shaft bearing preload spacers KIT 576
RD-20-160 3200-J-1648 NoSpin diff. Ring gear to case fastener kit, prior to 4/88 KIT 2317
RD-23-160 Main diff. nest kit with spider * KIT 2318
RD-23-164 Main diff. nest kit less spider * KIT 2341
RD-26-160 Pinion bearing spacers KIT 2397
RD-25-160 I.A.D nest with spider KIT 2424
Input and pinion shims KIT 2429
Helical gear kit KIT 2483
I.A.D. nest less spider KIT 2489
Output nut and washer upgrade KIT 2637
Input shaft nut and washer upgrade KIT 2638
Replaces A2-3200-J-1648 fast ratios KIT 2644
Replaces A2-3200-J-1648 mid range ratios KIT 2644A
Replaces A2-3200-J-1648 std. ratios KIT 2644B
Overhaul kit KIT RP23160A
3200-M-1703 Standard Thru-shaft bearing preload spacers KIT 576
3200-M-1703 NoSpin diff. Main diff. nest kit with spider * KIT 2318
I.A.D nest with spider KIT 2424
Replaces A2-3200-M-1703 KIT 2618
3200-X-1818 Standard Thru-shaft bearing preload spacers KIT 576
3200-K-1857 Standard Main diff. nest kit with spider * KIT 2318
3200-Q-1837 Standard Main diff. nest kit less spider * KIT 2341
3200-J-2116 Standard Pinion bearing spacers KIT 2397
3200-X-1818 NoSpin diff. Ring gear to case fasteners after 4/88 KIT 2426
3200-J-2116 NoSpin diff. Input and pinion shims KIT 2429
Tapered dowel Kit (3200-X-1818) KIT 4288
Front 3200-W-1713 Diff. lock Thru-shaft bearing preload spacers KIT 576
RD-20-160 Main diff. nest kit with spider KIT 2318
RD-23-160 Main diff. nest kit less spider KIT 2341
RD-23-164 Pinion bearing spacers KIT 2397
RD-26-160 Main diff. lock actuator kit (minor) KIT 2406
RD-25-160 I.A.D nest with spider KIT 2424
25
AXLE BASE KIT
Front 3200-W-1713 Diff. lock Ring gear to case fasteners after 4/88 KIT 2426
RD-20-160 (Continued) Input and pinion shims KIT 2429
RD-23-160 Helical gear kit KIT 2483
RD-23-164 I.A.D. nest less spider KIT 2489
RD-26-160 Main diff. lock piston kit KIT 2614
RD-25-160 Main diff. lock actuator kit KIT 2615
(Cont.) Replaces A2-3200-W-1713 KIT 2617
Overhaul kit KIT RP23160B
3200-Y-1819 Diff. lock Thru-shaft bearing preload spacers KIT 576
3200-W-1895 Diff. lock Main diff. nest kit with spider KIT 2318
3200-L-2118 Diff. lock Main diff. nest kit less spider KIT 2341
Main diff. lock piston kit (all except 3200-W-1895) KIT 2614
Main diff. lock actuator kit (all except 3200-W-1895) KIT 2615
Main diff. lock piston kit (3200-W-1895) KIT 2691
Tapered dowel kit (3200-L-2118) KIT 4288
Replaces A2-3200-Y-1819 KIT 2764
3200-P-1628 Standard Thru-shaft bearing preload spacers KIT 576
3200-P-1628 NoSpin diff. Ring gear to case fastener kit, prior to 4/88 KIT 2317
3200-P-1628 Pump Main diff. nest kit with spider * KIT 2318
3200-P-1628 Pump w/diff. lock Main diff. nest kit less spider * KIT 2341
3200-P-1628 Pump w/NoSpin Pinion bearing spacers KIT 2397
Input shaft and pump upgrade kit KIT 2624
Replaces A2-3200-P-1628, fast ratios, with diff. lock KIT 2640
Replaces A2-3200-P-1628, mid-range ratios, with diff. lock KIT 2640A
Replaces A2-3200-P-1628, std. ratios, with diff. lock KIT 2640B
Replaces A2-3200-P-1628, fast ratios, less diff. lock KIT 2641
Replaces A2-3200-P-1628, mid-range ratios, less diff. lock KIT 2641A
Replaces A2-3200-P-1628, std. ratios, less diff. lock KIT 2641B
Overhaul kit KIT RP23160
26
AXLE BASE KIT
Front 3200-K-1701 Pump Thru-shaft bearing preload spacers KIT 576
RP-20-160 3200-K-1701 Pump w/diff. lock Main diff. nest kit with spider * KIT 2318
RP-23-160 3200-K-1701 Pump w/NoSpin Main diff. nest kit less spider * KIT 2341
RP-23-164 Pinion bearing spacers KIT 2397
RP-25-160 Main diff. lock actuator kit (minor) KIT 2406
RP-26-160 I.A.D nest with spider KIT 2424
Replaces A2-3200-K-1701 KIT 2616
3200-Z-1820 Pump Thru-shaft bearing preload spacers KIT 576
3200-V-1894 Pump Main diff. nest kit with spider * KIT 2318
3200-K-2117 Pump Main diff. nest kit less spider * KIT 2341
3200-Z-1820 Pump w/diff. lock Main diff. lock actuator kit (minor) (all except 3200-V-1894) KIT 2406
3200-V-1894 Pump w/diff. lock Main diff. lock actuator kit (minor) (3200-V-1894) KIT 2750
3200-K-2117 Pump w/diff. lock I.A.D nest with spider KIT 2424
3200-Z-1820 Pump w/NoSpin Input and pinion shims KIT 2429
3200-V-1894 Pump w/NoSpin Helical gear kit KIT 2483
3200-K-2117 Pump w/NoSpin I.A.D. nest less spider KIT 2489
Main diff. lock piston kit (all except 3200-V-1894) KIT 2614
Main diff. lock piston kit (3200-V-1894) KIT 2691
Main diff. lock actuator kit (all except 3200-V-1894) KIT 2615
Main diff. lock actuator kit (3200-V-1894) KIT 2698
Tapered dowel kit (3200-K-2117) KIT 4288
Replaces A2-3200-Z-1820 less diff. lock KIT 2766
Replaces A2-3200-Z-1820 with diff. lock KIT 2763
Rear All Use the carriers and kits in the RS-23-160 section ---
RR-20-160
RR-23-160
RR-23-164
RR-25-160
RR-26-160
27
SERVICE KITS
KIT RP23160
ITEM PART NUMBER QTY. DESCRIPTION REMARKS
1 40-X-1145 1 Nut Forward-rear carriers with I.A.D. and without main diff. lock.
2 KIT 2318 1 Main diff. kit with spider RP-23-160, RP-23-164, RP-26-160
3 KIT 2424 1 IAD Kit with Spider 3200-J-1648, 3200-P-1628
4 KIT 2429 1 Shim Kit
5 KIT 2637 1 Input Nut and Washer Kit
6 40-X-1233 1 Pinion Nut
7 1229-N-1730 1 Pinion Washer
8 KIT 2397 1 Spacer Kit
9 KIT 4420 1 Bearing & Seal Kit
KIT RP23160A
1 40-X-1145 1 Nut Forward-rear carriers with I.A.D. and without main diff. lock.
2 40-X-1233 1 Lock Nut RD-23-160, RD-23-164, RD-26-160
3 1229-N-1730 1 Washer 3200-M-1703, 3200-Q-1837, 3200-X-1818, 3200-J-2116
4 KIT 2318 1 Main diff. kit with spider
5 KIT 2424 1 IAD Kit with Spider
KIT RP23160B
1 40-X-1145 1 Nut Forward-rear carriers with I.A.D. and with main diff. lock.
2 40-X-1233 1 Lock Nut RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
3 1229-N-1730 1 Washer RP-26-160
4 KIT 2318 1 Main diff. kit with spider 3200-J-1908, 3200-K-1701, 3200-K-1909, 3200-V-1894,
5 KIT 2397 1 Spacer Kit 3200-W-1713, 3200-W-1895, 3200-Y-1819, 3200-Z-1820
6 KIT 2424 1 IAD Kit with Spider
KIT RR23160
1 KIT 1592 1 Shim Kit Single and rear-rear carriers without main diff. lock.
2 KIT 1593 1 Spacer Kit RS-23-160, RS-23-161, RS-25-160, RS-26-160
3 KIT 2318 1 Main diff. kit with spider 3200-C-1511, 3200-T-1658, 3200-V-1660, 3200-Z-1560
4 40-X-1233 1 Pinion Nut
5 1229-N-1730 1 Pinion Washer
KIT RR23160A
1 40-X-1233 1 Lock Nut Single and rear-rear carriers without main diff. lock.
2 1229-N-1730 1 Washer RS-23-160, RS-23-161, RS-25-160, RS-26-160
3 KIT 1592 1 Shim Kit 3200-A-1821, 3200-H-1854, 3200-J-1856, 3200-P-1706
KIT RR23160B
1 40-X-1233 1 Lock Nut Single and rear-rear carriers with diff. lock.
2 1229-W-4521 1 Washer RS-23-160, RS-23-161, RS-25-160, RS-26-160
3 KIT 1592 1 Shim Kit 3200-C-1823, 3200-D-1928, 3200-E-1825, 3200-E-1929,
4 KIT 1593 1 Spacer Kit 3200-R-1708, 3200-T-1892, 3200-V-1712, 3200-Y-1897
28
SERVICE KITS
KIT 576
1 1229-P-2590 1 Snap Ring - 3.94mm/.155 in. Output shaft snap ring kit
2 1229-Q-2591 1 Snap Ring - 4.01mm/.158 in. RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
3 1229-R-2592 1 Snap Ring - 4.09mm/.161 in. RP-26-160
4 1229-S-2593 1 Snap Ring - 4.17mm/.164 in.
5 1229-T-2594 1 Snap Ring - 4.24mm/.167 in.
6 1229-U-2595 1 Snap Ring - 4.32mm/.170 in.
7 1229-V-2596 1 Snap Ring - 4.39mm/.173 in.
8 1229-W-2597 1 Snap Ring - 4.47mm/.176 in.
9 1229-X-2598 1 Snap Ring - 4.55mm/.179 in.
10 1229-Y-2599 1 Snap Ring - 4.62mm/.182 in.
KIT 1592
1 2803-Y-2755 4 0.002 in./0.050 mm Shim RS-23-160, RS-23-161, RS-25-160, RS-26-160
2 2803-Z-2756 2 0.005 in./0.125 mm Shim
3 2803-A-2757 4 0.008 in./0.200 mm Shim
4 2803-B-2758 1 0.020 in./0.500 mm Shim
KIT 1593
1 2803-D-2500 2 .250 in./6.35 mm Spacer Pinion bearing spacers
2 2803-E-2501 2 .251 in./6.38 mm Spacer RR-23-160, RS-23-160, RS-23-161, RS-25-160, RS-26-160
3 2803-F-2502 2 .252 in./6.40 mm Spacer 3200-A-1821, 3200-A-1899, 3200-C-1511, 3200-C-1823,
4 2803-N-2510 2 .253 in./6.45 mm Spacer 3200-C-1831, 3200-D-1928, 3200-E-1825, 3200-E-1929,
5 2803-G-2503 2 .254 in./6.45 mm Spacer 3200-H-1854, 3200-J-1752, 3200-J-1804, 3200-J-1856,
6 2803-H-2504 2 .256 in./6.50 mm Spacer 3200-K-1753, 3200-P-1706, 3200-R-1708, 3200-S-1839,
7 2803-J-2506 2 .260 in./6.60 mm Spacer 3200-T-1658, 3200-T-1892, 3200-U-1399, 3200-V-1660,
8 2803-K-2507 2 .261 in./6.63 mm Spacer 3200-V-1712, 3200-W-1791, 3200-Y-1897, 3200-Z-1560
9 2803-L-2508 2 .262 in./6.65 mm Spacer
10 2803-M-2509 2 .263 in./6.68 mm Spacer
KIT 2317
1 41-X-1216 12 Capscrew Gear to case bolt kit (17.0 mm bolts prior to 4-88)
2 1229-U-1503 12 Washer RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
3 40-X-1182 12 Lock Nut RP-26-160, RR-23-160, RR-23-164, RR-26-160, RS-23-160,
RS-25-160, RS-26-160
KIT 2318
1 2233-M-1001 4 Differential Pinion, Finished Main diff. kit with spider.
2 2234-C-1069 2 Differential Side Gear, Finished RS-23-160, RS-23-161, RS-25-160
3 3278-W-335 1 Differential Spider
4 1229-L-3002 2 Side Gear Thrust Washer
5 1229-K-3001 4 Differential Pinion Washer
KIT 2341
1 1229-L-3002 2 Side Gear Thrust Washer Main diff. kit less spider.
2 2234-C-1069 2 Differential Side Gear, Finished RS-23-160, RS-23-161, RS-25-160
3 2233-M-1001 4 Differential Pinion, Finished
4 1229-K-3001 4 Differential Pinion Washer
29
SERVICE KITS
KIT 2397
1 2203-V-9824 2 .451 in./11.45 mm Spacer Pinion bearing spacers
2 2203-W-9825 2 .452 in./11.48 mm Spacer RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
3 2203-X-9826 2 .453 in./11.50 mm Spacer RP-26-160
4 2203-Y-9827 2 .454 in./11.53 mm Spacer
5 2203-Z-9828 2 .455 in./11.55 mm Spacer
6 2203-A-9829 2 .459 in./11.65 mm Spacer
7 2203-B-9830 2 .463 in./11.75 mm Spacer
8 2203-C-9831 2 .467 in./11.85 mm Spacer
9 2203-D-9832 2 .470 in./11.95 mm Spacer
10 2203-E-9833 2 .474 in./12.05 mm Spacer
11 2203-F-9834 2 .478 in./12.15 mm Spacer
12 2203-G-9835 2 .482 in./12.25 mm Spacer
13 2203-H-9836 2 .483 in./12.28 mm Spacer
14 2203-J-9838 2 .484 in./12.30 mm Spacer
15 2203-K-9839 2 .485 in./12.33 mm Spacer
16 2203-L-9840 2 .486 in./12.35 mm Spacer
KIT 2406
1 3196-F-32 1 Air Cylinder tube Bolt-on shifter.
2 2230-N-170 1 Piston RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
3 5-X-1153 1 O-Ring RP-26-160, RS-23-160, RS-23-161, RS-25-160, RS-26-160
4 2208-H-944 1 Gasket 3200-C-1511, 3200-Z-1560, 3200-P-1628, 3200-V-1660,
5 41-X-1333 1 Capscrew 3200-K-1701, 3200-R-1708, 3200-V-1712, 3200-W-1713,
6 41-X-1364 4 Capscrew 3200-Y-1819, 3200-C-1823, 3200-E-1825
7 MWA-506 4 Washer
8 42-X-1027 1 Washer
KIT 2414
1 3266-F-1020 1 Cover Services carriers with main diff. lock, prior to 11/93.
2 MWA-506 4 Washer RS-23-160, RS-23-161, RS-25-160, RS-26-160
3 2208-L-1000 1 Gasket 3200-C-1511, 3200-P-1628, 3200-V-1660
4 MS-210016-1 1 Capscrew
5 41-X-1364 4 Capscrew
6 2208-H-944 1 Gasket
7 3196-F-32 1 Air Cylinder tube
8 5-X-1153 1 O-Ring
9 2230-N-170 1 Piston
10 42-X-1027 1 Washer
11 2244-Y-51 1 Shift Shaft
12 43-X-1006 1 Shift Shaft Pin
13 2258-L-714 1 Spring
14 43-X-1007 2 Shift Fork Pin
15 41-X-1333 1 Capscrew
16 3296-Y-1169 1 Shift Fork
17 3107-F-1020 1 Shift Collar
18 3237-W-1167 1 Switch Assembly Sensor
19 1227-P-1056 1 Sensor Adjusting Nut
20 2257-M-1235 1 Sensor/Switch Clip
KIT 2424
1 2234-T-1190 1 Differential Side Gear, Finished I.A.D. nest with spider
2 3892-T-4934 1 Integral Gear (Helical, Forward, Side Gear) RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
3 3278-N-300 1 Differential Spider RP-26-160
4 2233-K-245 4 Differential Pinion, Finished 3200-J-1648, 3200-J-1908, 3200-K-1701, 3200-K-1857,
5 1229-Q-2929 4 Pinion Thrust Washer 3200-K-1909, 3200-L-1858, 3200-M-1703, 3200-P-1628,
6 1229-D-4788 1 Thrust Washer 3200-Q-1837, 3200-V-1894, 3200-W-1713, 3200-W-1895,
3200-X-1818, 3200-Y-1819, 3200-Z-1820, 3200-J-2116,
3200-K-2117, 3200-L-2118
30
SERVICE KITS
KIT 2426
1 1229-U-1503 12 Washer Gear to case bolt kit (16.5 mm bolts after 4-88)
2 40-X-1182 12 Lock Nut RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
3 41-X-1276 12 Capscrew RP-26-160, RR-23-160, RR-23-164, RR-26-160, RS-23-160,
RS-23-161, RS-25-160, RS-26-160
KIT 2429
1 2203-K-9241 1 Shim - .076mm/.003 in. RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
2 2203-L-9242 1 Shim - .127mm/.005 in. RP-26-160
3 2203-M-9243 4 Shim - .254mm/.010 in.
4 2203-F-2788 1 Shim - .076mm/.003 in.
5 2203-G-2789 1 Shim - .127mm/.005 in.
6 2203-H-2790 4 Shim - .254mm/.010 in.
KIT 2483
2 3892-U-4909 1 Helical Gear RP-26-160
KIT 2489
1 2234-T-1190 1 Differential Side Gear, Finished I.A.D. nest less spider
3 2233-K-245 4 Differential Pinion, Finished RP-26-160
4 1229-Q-2929 4 Pinion Thrust Washer 3200-J-1648, 3200-J-1908, 3200-K-1701, 3200-K-1857,
5 1229-D-4788 1 Thrust Washer 3200-K-1909, 3200-L-1858, 3200-M-1703, 3200-P-1628,
3200-Q-1837, 3200-V-1894, 3200-W-1713, 3200-W-1895,
3200-X-1818, 3200-Y-1819, 3200-Z-1820, 3200-J-2116,
3200-K-2117, 3200-L-2118
KIT 2583
1 3264-J-1466 1 Deflector - Cage Bearing cage deflector for forward output cage
2 1229-Z-4940 4 Flat Washer 160 Series
KIT 2614
1 2230-N-170 1 Piston Main diff. lock piston kit.
2 5-X-1153 1 O-Ring RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
3 41-X-1333 1 Capscrew RP-26-160, RS-23-160, RS-23-161, RS-25-160, RS-26-160
4 41-X-1359 4 Shift Unit Bolt 3200-C-1511, 3200-Z-1560, 3200-P-1628, 3200-V-1660,
5 MWA-506 4 Washer 3200-K-1701, 3200-R-1708, 3200-V-1712, 3200-W-1713,
3200-Y-1819, 3200-Z-1820, 3200-C-1823, 3200-E-1825
31
SERVICE KITS
KIT 2615
1 3296-Y-1169 1 Shift Fork Main diff. lock actuator kit.
2 3107-B-1094 1 Clutch Collar RP-23-160, RP-23-164, RP-26-160, RS-23-160, RS-23-161,
3 43-X-1007 2 Shift Fork Pin RS-25-160, RS-26-160
4 2244-L-1026 1 Shift Shaft 3200-K-1701, 3200-R-1708, 3200-V-1712, 3200-W-1713,
5 43-X-1006 1 Shift Shaft Pin 3200-Y-1819, 3200-Z-1820, 3200-C-1823, 3200-E-1825
6 2258-L-714 1 Spring
7 3196-F-32 1 Air Cylinder tube
8 2230-N-170 1 Piston
9 5-X-1153 1 O-Ring
10 2208-H-944 1 Gasket
11 3266-F-1020 1 Cover
12 MWA-506 4 Washer
13 41-X-1364 4 Capscrew
14 2208-L-1000 1 Gasket
15 MS-210016-1 1 Capscrew
16 41-X-1333 1 Capscrew
18 1227-P-1056 1 Sensor Adjusting Nut
KIT 2616
1 41-X-1080 4 Capscrew Carrier and cap update kit
2 41-X-1364 4 Capscrew RP-23-160, RP-23-164, RP-26-160
3 MWA-506 4 Washer 3200-K-1701
4 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly
5 KIT 2763 1 Carrier & Cap Assembly
KIT 2617
2 41-X-1364 4 Capscrew RD-23-160, RD-23-164, RD-26-160
3 MWA-506 4 Washer 3200-W-1713
4 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly
5 KIT 2764 1 Carrier & Cap Assembly
KIT 2618
1 A2-3200-X-1818 1 Carrier & Cap Assembly Carrier and cap update kit
2 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly RD-23-160, RD-23-164, RD-26-160
3200-M-1703
KIT 2624
1 A1-3297-X-1194 1 Input Shaft Pump update kit
2 A-3303-P-1030 1 Oil Pump Assembly RD-23-160, RD-23-164, RD-26-160
3200-P-1628
KIT 2634
2 1250-U-1217 1 Plug RR-23-160, RR-23-164, RR-26-160, RS-23-160, RS-25-160,
3 KIT 2765 1 Carrier & Cap Assembly RS-26-160
3200-V-1712
32
SERVICE KITS
KIT 2637
1 40-X-1237 1 Input Nut M39 x 1.5 nut thread. Front input, rear input.
2 1229-T-1736 1 Washer RD160, RD164, RP160, RP164, RR160, RR164, RS160, RS161
KIT 2638
1 40-X-1233 1 Lock Nut M45 x 1.5 nut thread. Front input.
2 1229-W-4521 1 Washer RD160, RD164, RP160, RP164, RR160, RR164, RS160, RS161
KIT 2640
1 KIT 2763 1 Carrier & Cap Assembly Carrier and cap update kit (with diff case assembly, fast ratios) for
2 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly diff. lock
3 3107-B-1094 1 Clutch Collar RD-23-160, RD-23-164, RD-26-160
4 41-X-1364 4 Capscrew 3200-P-1628
5 MWA-506 4 Washer
6 2214-G-1125 1 Adjusting Ring
7 2214-J-1128 1 Adjusting Ring
8 592A 1 Bearing Cup
9 594A 1 Differential Bearing Cone
10 52618 1 Bearing Cup
11 52400 1 Differential Bearing Cone
12 A2-3235-C-2109 1 Unloaded Differential Case
KIT 2640A
1 KIT 2763 1 Carrier & Cap Assembly Carrier and cap update kit (with diff case assembly, mid-range
2 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly ratios) for diff. lock
4 41-X-1364 4 Capscrew 3200-P-1628
5 MWA-506 4 Washer
12 A2-3235-E-2111 1 Unloaded Differential Case
KIT 2640B
1 KIT 2763 1 Carrier & Cap Assembly Carrier and cap update kit (with diff case assembly, standard
2 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly ratios) for diff. lock
4 41-X-1364 4 Capscrew 3200-P-1628
5 MWA-506 4 Washer
12 A2-3235-G-2113 1 Unloaded Differential Case
33
SERVICE KITS
KIT 2641
1 KIT 2766 1 Carrier & Cap Assembly Carrier and cap update kit (with diff case assembly, fast ratios) less
2 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly diff. lock
4 MWA-506 4 Washer 3200-P-1628
11 A5-3235-C-2109 1 Unloaded Differential Case
KIT 2641A
2 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly ratios) less diff. lock
4 MWA-506 4 Washer 3200-P-1628
11 A5-3235-E-2111 1 Unloaded Differential Case
KIT 2641B
2 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly ratios) less diff. lock
4 MWA-506 4 Washer 3200-P-1628
11 A5-3235-G-2113 1 Unloaded Differential Case
KIT 2642
1 A2-3200-P-1706 1 Carrier & Cap Assembly Carrier and cap update kit (with diff case assembly, fast ratios) less
2 2214-G-1125 2 Adjusting Ring diff. lock
3 592A 2 Bearing Cup RS-23-160, RS-23-161, RS-25-160, RS-26-160
4 594A 2 Differential Bearing Cone 3200-T-1658, 3200-Z-1560
5 1228-B-1042 1 Spigot Bearing
6 A-3235-C-2109 1 Unloaded Differential Case
KIT 2642A
1 A2-3200-P-1706 1 Carrier & Cap Assembly Carrier and cap update kit (with diff case assembly, mid-range
2 2214-G-1125 2 Adjusting Ring ratios) less diff. lock
3 592A 2 Bearing Cup RS-23-160, RS-23-161, RS-25-160, RS-26-160
4 594A 2 Differential Bearing Cone 3200-T-1658, 3200-Z-1560
6 A-3235-E-2111 1 Unloaded Differential Case
34
SERVICE KITS
KIT 2642B
1 A2-3200-P-1706 1 Carrier & Cap Assembly Carrier and cap update kit (with diff case assembly, standard
2 A-3235-G-2113 1 Unloaded Differential Case ratios) less diff. lock
3 594A 2 Differential Bearing Cone RS-23-160, RS-23-161, RS-25-160, RS-26-160
4 592A 2 Bearing Cup 3200-T-1658, 3200-Z-1560
KIT 2643
1 KIT 2762 1 Carrier & Cap Assembly Carrier and cap update kit (with diff case assembly, fast ratios) for
2 3107-B-1094 1 Clutch Collar diff. lock.
3 A2-3235-C-2109 1 Unloaded Differential Case RS-23-160, RS-23-161, RS-25-160, RS-26-160
4 2214-G-1125 1 Adjusting Ring 3200-V-1660, 3200-Z-1560
7 41-X-1364 4 Capscrew
12 MWA-506 4 Washer
KIT 2643A
2 A2-3235-E-2111 1 Unloaded Differential Case ratios) for diff. lock
3 3107-B-1094 1 Clutch Collar RS-23-160, RS-23-161, RS-25-160, RS-26-160
4 2214-J-1128 1 Adjusting Ring 3200-V-1660, 3200-Z-1560
11 41-X-1364 4 Capscrew
12 MWA-506 4 Washer
KIT 2643B
2 A2-3235-G-2113 1 Unloaded Differential Case ratios) for diff. lock
4 2214-J-1128 1 Adjusting Ring 3200-V-1660, 3200-Z-1560
11 41-X-1364 4 Capscrew
12 MWA-506 4 Washer
KIT 2644
1 A2-3200-X-1818 1 Carrier & Cap Assembly Carrier and cap update kit (with diff case assembly, fast ratios) less
2 A-3235-C-2109 1 Unloaded Differential Case diff. lock. Conversion kit from bolt-on to screw-in I.A.D. shifter.
3 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly RD-23-160, RD-23-164, RD-26-160
4 594A 2 Differential Bearing Cone 3200-J-1648
35
SERVICE KITS
KIT 2644A
1 A2-3200-X-1818 1 Carrier & Cap Assembly Carrier and cap update kit (with diff case assembly, mid-range
2 A-3235-E-2111 1 Unloaded Differential Case ratios) less diff. lock. Conversion kit from bolt-on to screw-in I.A.D.
3 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly shifter.
4 594A 2 Differential Bearing Cone RD-23-160, RD-23-164, RD-26-160
5 592A 2 Bearing Cup 3200-J-1648
KIT 2644B
1 A2-3200-X-1818 1 Carrier & Cap Assembly Carrier and cap update kit (with diff case assembly, standard
2 A-3235-G-2113 1 Unloaded Differential Case ratios) less diff. lock. Conversion kit from bolt-on to screw-in I.A.D.
3 A2-3261-Q-1057 1 IAD Shift Cylinder Assembly shifter.
4 592A 2 Bearing Cup RD-23-160, RD-23-164, RD-26-160
5 594A 2 Differential Bearing Cone 3200-J-1648
KIT 2657
1 KIT 2634 1 Carrier & Cap Update Kit Carrier and cap update kit (with diff case assembly, fast ratios) less
2 A5-3235-C-2109 1 Unloaded Differential Case diff. lock
3 594A 1 Differential Bearing Cone RS-23-160, RS-23-161, RS-25-160, RS-26-160
4 592A 1 Bearing Cup 3200-C-1511
KIT 2657A
1 KIT 2634 1 Carrier & Cap Update Kit Carrier and cap update kit (with diff case assembly, mid-range
2 A5-3235-E-2111 1 Unloaded Differential Case ratios) less diff. lock
3 2214-G-1125 1 Adjusting Ring RS-23-160, RS-23-161, RS-25-160, RS-26-160
4 2214-J-1128 1 Adjusting Ring 3200-C-1511
KIT 2657B
1 KIT 2634 1 Carrier & Cap Update Kit Carrier and cap update kit (with diff case assembly, standard
2 A5-3235-G-2113 1 Unloaded Differential Case ratios) less diff. lock
3 2214-G-1125 1 Adjusting Ring RS-23-160, RS-23-161, RS-25-160, RS-26-160
36
SERVICE KITS
KIT 2658
1 KIT 2634 1 Carrier & Cap Update Kit Carrier and cap update kit (with diff case assembly, fast ratios) for
2 A2-3235-C-2109 1 Unloaded Differential Case diff. lock
KIT 2658A
1 KIT 2634 1 Carrier & Cap Update Kit Carrier and cap update kit (with diff case assembly, mid-range
2 A2-3235-E-2111 1 Unloaded Differential Case ratios) for diff. lock
KIT 2658B
1 KIT 2634 1 Carrier & Cap Update Kit Carrier and cap update kit (with diff case assembly, standard
2 A2-3235-G-2113 1 Unloaded Differential Case ratios) for diff. lock
KIT 2659
1 KIT 2762 1 Carrier & Cap Assembly Carrier and cap update kit (with diff. lock)
2 41-X-1364 4 Capscrew RS-23-160, RS-23-161, RS-25-160, RS-26-160
3 MWA-506 4 Washer 3200-C-1823, 3200-D-1928, 3200-R-1708, 3200-T-1892
KIT 2691
1 3261-A-1067 1 Shift Cylinder Housing Main diff. lock, screw-in shift, Services all new style screw in type
2 2230-T-1190 1 Piston main differential lock carriers
3 5-X-1198 1 O-Ring RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
4 5-X-521 1 O-Ring RP-26-160
5 41-X-1368 1 Caging Bolt 3200-T-1892, 3200-V-1894
37
SERVICE KITS
KIT 2698
1 3296-B-1172 1 Shift Fork Main diff. lock kit.
2 3107-B-1094 1 Clutch Collar RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
3 2244-V-1114 1 Push Rod RP-26-160, RR-23-160, RR-23-164, RR-26-160, RS-23-160,
4 2258-N-1262 1 Spring RS-23-161, RS-25-160, RS-26-160
5 3261-A-1067 1 Shift Cylinder Housing 3200-T-1892, 3200-V-1894, 3200-W-1895, 3200-Y-1897,
6 2230-T-1190 1 Piston 3200-J-1908, 3200-K-1909, 3200-D-1928, 3200-E-1929,
7 5-X-1198 1 O-Ring 3200-K-2117, 3200-L-2118
8 41-X-1368 1 Caging Bolt
10 5-X-521 1 O-Ring
KIT 2750
1 2230-T-1190 1 Piston Screw-in shifter.
2 2244-V-1114 1 Push Rod RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
3 2258-N-1262 1 Spring RP-26-160
4 3261-A-1067 1 Shift Cylinder Housing 3200-T-1892, 3200-V-1894, 3200-K-2117
5 41-X-1368 1 Caging Bolt
6 5-X-521 1 O-Ring
7 5-X-1198 1 O-Ring
KIT 2762
1 A2-3200-T-1892 1 Carrier & Cap Assembly Carrier and cap update kit (with diff. lock)
2 KIT 2691 1 Shift Cylinder Kit RR-23-160, RR-23-164, RR-26-160, RS-23-160, RS-23-161,
3 3296-B-1172 1 Shift Fork RS-25-160, RS-26-160
4 2258-N-1262 1 Spring 3200-C-1823, 3200-D-1928, 3200-R-1708, 3200-T-1892,
5 2244-V-1114 1 Push Rod 3200-V-1894, 3200-K-2117
6 2206-L-1156 1 Elbow Fitting
KIT 2763
1 A2-3200-V-1894 1 Carrier & Cap Assembly Carrier and cap update kit (with diff. lock, with pump)
2 KIT 2691 1 Shift Cylinder Kit RP-23-160, RP-23-164, RP-26-160
3 3296-B-1172 1 Shift Fork 3200-V-1894, 3200-Z-1820, 3200-K-2117
4 2258-N-1262 1 Spring
5 2244-V-1114 1 Push Rod
KIT 2764
1 A2-3200-W-1895 1 Carrier & Cap Assembly Carrier and cap update kit (with diff. lock, less pump)
2 KIT 2691 1 Shift Cylinder Kit RD-23-160, RD-23-164, RD-26-160
3 3296-B-1172 1 Shift Fork 3200-W-1895, 3200-Y-1819,3200-L-2118
4 2258-N-1262 1 Spring
5 2244-V-1114 1 Push Rod
KIT 2765
1 A2-3200-Y-1897 1 Carrier & Cap Assembly Carrier and cap update kit (less diff. lock)
2 KIT 2691 1 Shift Cylinder Kit RS-23-160, RS-23-161, RS-25-160, RS-26-160
3 3296-B-1172 1 Shift Fork 3200-E-1825, 3200-E-1929, 3200-V-1712, 3200-Y-1897
4 2258-N-1262 1 Spring
5 2244-V-1114 1 Push Rod
38
SERVICE KITS
KIT 2766
1 A2-3200-V-1894 1 Carrier & Cap Assembly Carrier and cap update kit (less diff. lock, with pump). RP-23-160,
2 1250-U-1217 1 Plug RP-23-164, RP-26-160. 3200-V-1894, 3200-Z-1820, 3200-K-2117
KIT 2767
1 A2-3200-Y-1897 1 Carrier & Cap Assembly Carrier and cap update kit (less diff. lock)
2 1250-U-1217 1 Plug RS-23-160, RS-23-161, RS-25-160, RS-26-160
3200-E-1825, 3200-E-1929, 3200-V-1712, 3200-W-1817,
3200-Y-1897
KIT 2796
1 A1-3235-A-2393 1 Differential Case Assembly I.A.D. assembly. RD-23-160, RD-23-164, RD-26-160, RP-23-160,
2 KIT 2424 1 IAD Kit with Spider RP-23-164, RP-26-160
KIT 2824
1 A-3261-A-1067 1 DCDL Shift Cylinder Main differential kit
2 2244-Z-1222 1 Push Rod 160 Series
KIT 2825
1 A4-3261-Q-1057 1 IAD Shift Cylinder I.A.D. kit
2 2244-Y-1221 1 Push Rod 160 Series
KIT 4284
1 41-X-1637 2 Capscrew Lock pin kit
2 1199-R-2176 2 Cotter Pin 160 Series
3 1246-P-1134 1 Spirol Pin
KIT 4288
1 10-X-1595 4 Bolt For Tapered Dowel 164EH Forward Carriers
2 10-X-1599 2 Bolt RD-23-164, RP-23-164
3 1246-V-1166 6 Dowel 3200-J-2116, 3200-K-2117, 3200-L-2118
KIT 4415
1 A-1205-Q-2591 1 Oil Seal Assembly RS-23-160, RS-23-161, RS-25-160, RS-26-160
2 HM813843 1 Bearing Cone 3200-C-1511, 3200-T-1658, 3200-V-1660, 3200-Z-1560
4 HM813810 1 Bearing Cup
5 A1-1228-B-600 2 Bearing Assembly
6 1228-V-594 1 Bearing
7 1228-D-1018 1 Bearing Race
8 1228-P-1004 1 Roller Bearing
KIT 4420
1 65500 1 Bearing Cup RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
2 65237 1 Bearing Cone RP-26-160
3 H715311 1 Bearing Cup 3200-J-1648, 3200-P-1628
4 H715343 1 Bearing Cone
6 HM813843 1 Bearing Cone
7 JLM714110 1 Bearing Cup
8 JLM714149 1 Bearing Cone
9 A1-1228-B-600 2 Bearing Assembly
10 A-1205-R-2592 1 Oil Seal Assembly
11 5-X-1034 2 O-Ring
39
SERVICE KITS
KIT 4422
1 592A 2 Bearing Cup RD-23-160, RD-23-164, RD-26-160
2 594A 2 Differential Bearing Cone 3200-K-1857, 3200-M-1703, 3200-Q-1837, 3200-X-1818,
3 65237 1 Bearing Cone 3200-J-2116
5 H715311 1 Bearing Cup
11 5-X-1034 1 O-Ring
KIT 4423
1 52400 1 Differential Bearing Cone For all diff. lock capable except original design.
2 52618 1 Bearing Cup RD-23-160, RD-23-164, RD-26-160, RP-23-160, RP-23-164,
3 592A 1 Bearing Cup RP-26-160
4 594A 1 Differential Bearing Cone 3200-K-1701, 3200-L-1858, 3200-V-1894, 3200-W-1713,
5 65237 1 Bearing Cone 3200-W1895, 3200-Y-1819, 3200-Z-1820, 3200-K-2117,
6 65500 1 Bearing Cup 3200-L-2118
9 H715311 1 Bearing Cup
10 HM-813810 1 Bearing Cup
14 5-X-1034 1 O-Ring
KIT 4426
1 1228-B-1042 1 Spigot Bearing Less Diff. Lock
2 1228-V-594 1 Bearing RS-23-160, RS-23-161, RS-25-160, RS-26-160
3 A-1205-Q-2591 1 Oil Seal Assembly 3200-A-1821, 3200-H-1854, 3200-J-1856, 3200-P-1706
KIT 4428
1 1228-B-1042 1 Spigot Bearing With Diff. Lock
2 1228-V-594 1 Bearing RS-23-160, RS-23-161, RS-25-160, RS-26-160
3 A-1205-Q-2591 1 Oil Seal Assembly 3200-C-1823, 3200-D-1928, 3200-E-1825, 3200-E-1929,
4 52400 1 Differential Bearing Cone 3200-R-1708, 3200-T-1892, 3200-V-1712, 3200-Y-1897
KIT 4455
1 3237-W-1167 1 Switch Assembly Sensor With diff. lock
2 2257-M-1235 1 Sensor/Switch Clip 160 Series
40
SERVICE KITS
KIT 2468 391
1 A2-3235-F-1982 1 Unloaded Differential Case Diff. case and gearset update with diff. lock, prior to 9/1/88.
2 A-39884-6 1 Gearset RS-23-160, RS-23-161, RS-25-160, RS-26-160
3 KIT 2426 1 Bolt Kit 3200-Z-1560
KIT 2468 410

3 KIT 2426 1 Bolt Kit 3200-Z-1560
KIT 2468 430

3 KIT 2426 1 Bolt Kit 3200-Z-1560
KIT 2468 456

3 KIT 2426 1 Bolt Kit 3200-Z-1560
KIT 2655 391

1 A-39884-6 1 Gearset Diff. case and gearset upgrade kit.
2 A12-3235-F-1982 1 Unloaded Differential Case RS-23-160, RS-23-161, RS-25-160, RS-26-160
3 KIT 2426 1 Bolt Kit 3200-C-1511
KIT 2655 410

3 KIT 2426 1 Bolt Kit 3200-C-1511
KIT 2655 430

3 KIT 2426 1 Bolt Kit 3200-C-1511
KIT 2655 456

3 KIT 2426 1 Bolt Kit 3200-C-1511
41
NUMERICAL PARTS LISTING
Part Number Page Part Number Page Part Number Page
4-X-1921 15 1229-W-1557 4,15 2203-H-9836 4
4-X-1922 15 1229-K-1597 3,4,14 2203-J-9838 4
5-X-521 6,13 1229-E-1669 3,7 2203-K-9839 4
5-X-1034 3,7 1229-N-1730 3,9 2203-L-9840 4
5-X-1153 6,13 1229-T-1736 14 2208-H-944 6,13
5-X-1198 6,13 1229-P-2590 14 2208-L-1000 6,13
10-X-1334 3 1229-Q-2591 14 2214-S-279 5,10
10-X-1594 4,15 1229-R-2592 14 2214-G-1125 5,10
10-X-1595 15 1229-S-2593 14 2214-J-1128 5,10
10-X-1599 4,15 1229-T-2594 14 2214-Z-1144 5,10
10-X-1600 15 1229-U-2595 14 2214-B-1146 5,10
15-X-387 14 1229-V-2596 14 2230-N-170 6,13
15-X-1167 4,10 1229-W-2597 14 2233-K-245 3
19-X-1087 6,10 1229-X-2598 14 2233-M-1001 6,12
40-X-1145 4 1229-Y-2599 14 2234-C-1069 6,12
40-X-1182 6,10 1229-Q-2929 3 2234-D-1070 12
40-X-1233 3,9 1229-K-3001 6,12 2234-T-1190 3
40-X-1237 14 1229-L-3002 6,12 2244-Y-51 6,13
41-X-1018 6,10 1229-F-4062 7 2244-L-1026 6,13
41-X-1022 6,13 1229-G-4063 4 2257-M-1235 6,13
41-X-1208 3 1229-W-4131 14 2258-U-411 3
41-X-1275 5,12 1229-F-4452 7,13 2258-L-714 6,13
41-X-1276 6,10 1229-U-4519 7,13 2258-Z-1118 7
41-X-1333 6,13 1229-D-4528 7,13 2258-G-1255 7,13
41-X-1364 6,13 1229-F-4634S 15 2258-N-1262 6,13
41-X-1368 6,13 1229-D-4788 3 2297-T-4180 10
42-X-1024 6,10 1244-W-1765 4 2297-U-5273 7
42-X-1027 6,13 1246-M-1131 7 2297-Z-5278 7
42-X-1408 7,13 1246-V-1166 4 A-2297-D-5334 7
43-X-1006 6,13 1250-E-473 15 2297-S-5349 3
43-X-1007 7,13 1250-N-1080 7 2297-C-7049 12
46-X-1029 10 1250-T-1216 7,13 2803-D-2500 9
A-1199-P-1394 15 1250-U-1217 6,13 2803-E-2501 9
1199-E-1669 15 2203-F-2788 4 2803-F-2502 9
A-1205-T-696 15 2203-G-2789 4 2803-G-2503 9
A-1205-Q-2487 15 2203-H-2790 4 2803-H-2504 9
A1-1205-X-2728 3 2203-K-9241 3 2803-J-2506 9
A1-1205-Y-2729 13 2203-L-9242 3 2803-K-2507 9
A1-1205-A-2731 9 2203-M-9243 3 2803-L-2508 9
1220-K-89 13 2203-V-9824 4 2803-M-2509 9
1227-R-330 15 2203-W-9825 4 2803-N-2510 9
1227-D-472 4,10 2203-X-9826 4 2803-Y-2755 9
1227-W-517 15 2203-Y-9827 4 2803-Z-2756 9
1227-P-1056 6,13 2203-Z-9828 4 2803-A-2757 9
1228-V-594 9 2203-A-9829 4 2803-B-2758 9
A1-1228-B-600 5,10 2203-B-9830 4 3107-F-1020 6,13
A1-1228-P-1004 9 2203-C-9831 4 3107-P-1030 13
1228-B-1042 9 2203-D-9832 4 3107-B-1094 6,13
1228-Y-1221 9 2203-E-9833 4 3107-C-1095 13
1229-U-1009 15 2203-F-9834 4 3107-P-1212 3
1229-U-1503 5,6,10,12 2203-G-9835 4 3196-F-32 6,13
42
A2-3200-P-1706 10 3221-P-1004 3 A6-3235-G-2113 5,11
A2-3200-A-1821 10 A-3226-R-1006 9 A7-3235-G-2113 6,11
A2-3200-Q-1837 3 A-3226-T-1112 14 A8-3235-G-2113 6,11
A2-3200-H-1854 10 A2-3226-T-1112S 14 A1-3235-R-2176 6,12
A2-3200-J-1856 10 A-3226-H-1126 3 A2-3235-R-2176 5,11
A2-3200-K-1857 3 A-3226-S-1137 3 A4-3235-R-2176 5,11
A2-3200-L-1858 3 A-3230-C-1043 6,12 A5-3235-R-2176 6,12
A2-3200-T-1892 10 A-3235-S-1813 12 A1-3235-S-2177 6,12
A2-3200-Y-1897 10 A2-3235-S-1813 12 A2-3235-S-2177 5,11
A2-3200-J-1908 3 A3-3235-S-1813 11 A4-3235-S-2177 5,11
A2-3200-K-1909 3,4 A10-3235-S-1813 5,12 A5-3235-S-2177 6,12
A2-3200-D-1928 10 A11-3235-S-1813 5,11 A1-3235-T-2178 6,12
A2-3200-E-1929 10 A12-3235-S-1813 5,12 A2-3235-T-2178 5,11
A2-3200-J-2116S 3 A13-3235-S-1813 5,11 A3-3235-T-2178 6,12
A2-3200-L-2118S 3 A14-3235-S-1813 6,11 A4-3235-T-2178 11
A2-3200-K-2117S 3,4 A2-3235-F-1982 12 A-3235-R-2202 12
3202-X-8110 18 A3-3235-F-1982 11 A1-3235-R-2202 11
3202-Y-8683 18 A10-3235-F-1982 5,12 A2-3235-R-2202 12
3202-P-8804 18 A11-3235-F-1982 5,11 A3-3235-R-2202 11
3202-Q-8805 18 A12-3235-F-1982 5,12 A1-3235-A-2393 3
3202-R-8806 18 A13-3235-F-1982 5,11 A3-3235-A-2393 3
3202-A-8815 18 A14-3235-F-1982 6,11 A5-3235-A-2393 3
3202-B-8816 18 A-3235-H-1984 12 3237-W-1167 6,13
3202-C-8817 18 A2-3235-H-1984 12 3260-P-120 18
3202-G-9003 18 A3-3235-H-1984 11 A-3261-L-350 3
3202-H-9004 18 A10-3235-H-1984 5,12 3260-P-120 18
3202-Y-9125 18 A11-3235-H-1984 5,11 3266-F-1020 6,13
3202-Z-9126 18 A12-3235-H-1984 5,12 3266-C-1095 4
3202-A-9127 18 A13-3235-H-1984 5,11 3278-N-300 3
3202-B-9128 18 A14-3235-H-1984 6,11 3278-W-335 6,12
3202-C-9129 18 A-3235-C-2109 5,12 3280-V-8394 7
3202-D-9130 18 A1-3235-C-2109 5,11 3280-Z-8398 7
3202-J-9344 18 A2-3235-C-2109 5,12 SA1-3280-X-9150 7,13
3202-K-9345 18 A3-3235-C-2109 5,11 SA2-3280-X-9150 7,13
3202-L-9346 18 A5-3235-C-2109 5,12 3296-B-184 7,13
3202-G-9393 18 A6-3235-C-2109 5,11 3296-Y-1169 7,13
3202-Q-9403 18 A7-3235-C-2109 6,11 3296-B-1172 7,13
3202-Y-9489 18 A8-3235-C-2109 6,11 3296-B-1328 3
3202-Z-9490 18 A-3235-E-2111 5,12 3297-V-1010 14
3202-A-9491 18 A1-3235-E-2111 5,11 A1-3297-X-1194 3
3202-K-9553 18 A2-3235-E-2111 5,12 A-3297-C-1199 3
3202-E-9573 18 A3-3235-E-2111 5,11 A-3303-P-1030 7
3202-F-9574 18 A5-3235-E-2111 5,12 3892-U-4909 4
3202-G-9575 18 A6-3235-E-2111 5,11 3892-T-4934 3
3202-A-9647 18 A7-3235-E-2111 6,11 572 15
3202-J-9916 18 A8-3235-E-2111 6,11 580 15
3202-L-9918 18 A-3235-G-2113 5,12 592A 5,10,15
3206-T-1190 18 A1-3235-G-2113 5,11 594A 5,10,15
3206-X-1532 18 A2-3235-G-2113 5,12 9220 9
3206-Z-1534 18 A3-3235-G-2113 5,11 52400 5,10
3216-G-4375 7,13 A5-3235-G-2113 5,12 52618 5,10
43
65237 4 A-39906-5 9 KIT 2468 430 41
65500 4 A-40024-5 9 KIT 2468 456 41
16N-4-6241 19 A-40104-5 9 KIT 2483 31
16N-4-6271 19 A-40106-5 9 KIT 2489 31
16N-4-7341-1X 21 A-40110-5 9 KIT 2583 14,31
16NYS38-12A 19 A-40116-5 9 KIT 2614 31
16NYS38-8A 19 A-40122-5 9 KIT 2615 32
16TYS32-76 21 A-41064-1 4 KIT 2616 4,32
176NYS38-14A 19 A-41066-1 9 KIT 2617 3,32
176TYS38-27A 21 A-41572-1 9 KIT 2618 3,32
17N-4-7181X 19 A-41574-1 9 KIT 2624 3,7,32
17N-4-7621-1 21 A-41712-1 9 KIT 2634 10,32
17NYS32-100 19 A-41828-1 9 KIT 2637 33
17NYS32-99 19 A-41988-1 9 KIT 2638 33
17NYS38-38A 19 A-41990-1 9 KIT 2640 4,33
17NYS38-61A 19 A-41992-1 9 KIT 2640A 4,33
17TYS32-99 21 A-41994-1 9 KIT 2640B 4,33
17TYS38-76A 21 A-41996-1 9 KIT 2641 34
18NYS38-27A 19 A-41998-1 9 KIT 2641A 34
18TYS38-27A 21 A-42000-1 9 KIT 2641B 34
5WCS38-18A 22 A-42002-1 9 KIT 2642 10,34
5WCS38-23A2 22 A-42004-1 9 KIT 2642A 10,34
72NYS32-244 20 A-42006-1 9 KIT 2642B 10,35
72NYS38-24A 20 A-42196-1 9 KIT 2643 10,35
72NYS38-26A 20 A-42198-1 4 KIT 2643A 10,35
82NYS38-31A 20 A-42466-1 9 KIT 2643B 10,35
92NYS32-26 20 A-42468-1 9 KIT 2644 3,35
92NYS38-73A 20 A-42470-1 9 KIT 2644A 3,36
A-39654-1 4 A-42630-1 9 KIT 2644B 3,36
A-39656-1 4 B-42776-1 9 KIT 2655 391 41
A-39658-1 4 H715311 4 KIT 2655 410 41
A-39660-1 4 H715343 4 KIT 2655 430 41
A-39662-1 4 HM813810 3,9 KIT 2655 456 41
A-39664-1 4 HM813843 3,9 KIT 2657 10,36
A-39666-1 4 JLM104910 14 KIT 2657A 10,36
A-39672-1 4 JLM714110 3 KIT 2657B 10,36
A-39674-1 4 JLM714149 3 KIT 2658 10,37
A-39876-1 4 KIT 576 29 KIT 2658A 10,37
A-39878-1 4 KIT 1592 29 KIT 2658B 10,37
A-39880-1 4 KIT 1593 29 KIT 2659 10,37
A-39882-1 4 KIT 2317 29 KIT 2691 37
A-39884-5 9 KIT 2318 29 KIT 2698 38
A-39886-5 9 KIT 2341 29 KIT 2750 38
A-39888-5 9 KIT 2397 30 KIT 2762 10,38
A-39890-5 9 KIT 2406 30 KIT 2763 4,38
A-39892-1 4 KIT 2414 30 KIT 2764 3,38
A-39896-1 4 KIT 2424 30 KIT 2765 10,38
A-39898-5 9 KIT 2426 31 KIT 2766 39
A-39900-5 9 KIT 2429 31 KIT 2767 10,39
A-39902-5 9 KIT 2468 391 41 KIT 2796 39
A-39904-5 9 KIT 2468 410 41 KIT 2824 6,13,39
44
KIT 2825 3,39
KIT 4284 6,10,39
KIT 4288 39
KIT 4415 39
KIT 4420 39
KIT 4422 40
KIT 4423 40
KIT 4426 40
KIT 4428 40
KIT 4455 40
KIT RP23160 28
KIT RP23160A 28
KIT RP23160B 28
KIT RR23160 28
KIT RR23160A 28
KIT RR23160B 28
LM-104949 14
MN-312-1 3
MS-208016-1 3
MS-208020-1 13
MS-208045-1 7
MS-210016-1 6,13
MS-210045A-1 3
MS-212040-1 3
MS-212045-1 9
MWA-506 6,13
MWA-508 13
MWA-512 3,9
N-110-1 15
NL-110-1 4
P-28-S 15
P-212 15
45
MERITOR AFTERMARKET PARTS WARRANTY
We warrant all new parts for one year from date of shipment to the buyer against defective material or
workmanship (but not against damage caused by accident, abuse or improper installation, maintenance
or repair) when such parts are used on vehicles the specifications of which have been approved by our
Engineering Department.
As the exclusive remedy under this warranty, we will, at our option, repair or replace such parts free of
charge, or take back the nonconforming parts and refund the monies paid by buyer for such parts, if
found on examination by us to be nonconforming and if any necessary return charges are prepaid.
If it is necessary to return any parts under this warranty, buyer agrees not to make any deduction on
account thereof from remittances on current accounts while claims are in the process of disposition.
Any expense incurred without our consent for repairs or replacement will not be allowed.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS,

EXPRESS, IMPLIED OR STATUTORY, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE. IN NO EVENT SHALL SELLER
BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE.
Only genuine Meritor replacement parts are covered by this aftermarket parts warranty.
Information contained in this publication is in

effect at the time the publication was approved Meritor Heavy Vehicle Systems, LLC
for printing and is subject to change without 7975 Dixie Highway
notice or liability. Meritor Heavy Vehicle Systems, Florence, KY 41042 USA Printed in U.S.A.
LLC, reserves the right to revise the information 888-725-9355 Revised 12/2006
presented or discontinue the production of parts www.meritorhvs.com PB-9250 (05060)
described at any time. www.xpresswayplus.com © 2006 ArvinMeritor, Inc.
Sales and Service ENGINE/TRANSMISSION
PACKAGE
5 4
1. S60……………..……….…….DETROIT DIESEL S60 ENGINE [500 HP].………….…….….…1 REQD

2. M5610…………………….…ALLISON M5610A SERIES TRANSMISSION……….…..…..…1 REQD
3. RS‐5699………………..……RADIATOR SPECIALTIES………………………………..….……….1 REQD
4. 23530573……………..……OIL FILTER, DETROIT…………………………………………..….…2 REQD
5. 23516489…………………..EXTENDED LIFE COOLING SYSTEM TREATMENT………..1 REQD
6. 23538657………..….….…….FUEL FILTER/WATER SERPERATOR DETROIT.………....1 REQD
6
PACKAGE
15 13 14
10
8 7 9
16
12
11
7. P527682……………… ………ELEMENT, AIR, DONALDSON…...……………………………….……....….1 REQD

8. G150048…………………....….AIR CLEANER HOUSING, DONALDSON …………………………....……1 REQD
9. BT8879‐MPG………….………FILTER, TRANSMISSION, BALDWIN…....……………………....….….…..2 REQD
10. P169985………………… ..…..HEAD, FILTER, DUAL, HMK25, DONALDSON..…………..….….…...….1 REQD
11. 8D……….…………………….…..BATTERY……………………………………………………..………………...…….2 REQD
12. 91‐2339…………………………DUAL BATTERY BOX…………………………………….………………………1 REQD
13. 202‐2105‐2…….………...........MUFFLER, EXHAUST……………..………………………….…...………………1 REQD
14. 28‐1400…….………..…………CLAMP, BAND, BODY, MUFFLER, GT EXHAUST ……..…...……...….…2 REQD
15. 22‐500………………..………....RAINCAP, GT EXHAUST…….………………………………………………...….1 REQD
16. 10‐761‐518….…..……….……FLEX JOINT, GT EXHAUST……………………………………………..………1 REQD
PACKAGE
18
19
20
21
17. 4262004A071…………....AIR KILL, AMOT…………………………………………………………………1 REQD

18. AB‐1203‐C4TP………..…TRANSMISSION HEAT EXCHANGER, AMERICAN IND….……......1 REQD
19. N11‐22L90.……….………FUEL TANK, 85 GALLON, 24”, NORTHSIDE INDUSTRIES …...…2 REQD
20. J‐22C ………........…..............STRAPS, FUEL TANK, NORTHSIDE INDUSTRIES …………..…...….4 REQD
PowerView Error Messages 0710170
Diagnostic Trouble Codes Text Translations provided by:
PowerView Model PV101 software version Murphy 1.00.06 12-13-07
PowerView Model PV100 software version Murphy 2.09 Section 78
Note: This list represents text descriptions for faults supported by the PowerView and does not necessarily comply with
SAE J1939. For a specific engine manufacturer’s explanation for codes, please consult the engine’s technical manual.
SPN FMI Description

28 3 % ACCEL POS3 VOLT ABOVE NORM OR SHORT HIGH
28 4 % ACCEL POS3 VOLT BELOW NORM OR SHORT LOW
29 3 % ACCEL POS2 VOLT ABOVE NORM OR SHORT HIGH
29 4 % ACCEL POS2 VOLT BELOW NORM OR SHORT LOW
84 8 TACHOMETER SIGNAL FAILED, VELOCITY SIGNAL DEFECTIVE
91 2 SPEED SET POINT1 (ACCELERATOR PEDAL DEFECTIVE)
91 3 ACCEL PEDAL POS VOLT ABOVE NORM OR SHORT HIGH
91 4 ACCEL PEDAL POS VOLT BELOW NORMAL OR SHORT LOW
91 9 ACCEL PEDAL POS A VALID THROTTLE MSG NOT RCVD
91 11 ERROR HARD SET POINT 1
91 14 ACCEL PEDAL POS THROTTLE SIG VOLT OUT OF RANGE
94 1 FUEL DELIVERY PRESSURE VERY LOW
94 3 FUEL RAIL PRESSURE VOLTAGE OUT OF RANGE HIGH
94 4 FUEL RAIL PRESSURE VOLTAGE OUT OF RANGE LOW
94 10 FUEL DELIVERY PRESSURE DROPPING TOO FAST
94 13 FUEL DELIVERY PRESSURE OUT OF CALIBRATION
94 16 FUEL DELIVERY PRESSURE HIGH
94 17 NO RAIL FUEL PRESSURE
94 18 FUEL DELIVERY PRESSURE LOW
97 0 WATER IN FUEL DETECTED
97 3 WATER IN FUEL INDICATOR VOLTAGE OUT OF RANGE HIGH
97 4 WATER IN FUEL INDICATOR VOLTAGE OUT OF RANGE LOW
98 1 OIL LEVEL SWITCH OFF
100 1 ENGINE OIL PRESSURE LOW
100 2 OIL PRESSURE SENSOR DEFECTIVE
100 3 ENGINE OIL PRESS VOLT ABOVE NORM OR SHORT HIGH SOURCE
100 4 ENGINE OIL PRESS VOLT BELOW NORM OR SHORT LOW SOURCE
100 16 ENGINE OIL PRESSURE READING INCORRECT
100 18 ENGINE OIL PRESS LOW
102 2 CHARGE AIR PRESSURE SENSOR DEFECTIVE
105 0 INTAKE MAN1 AIR TEMP HIGH
105 2 CHARGE AIR TEMPERATURE SENSOR DEFECTIVE
105 3 INTAKE MAN1 TEMP VOLT ABOVE NORM OR SHORT HIGH SOURCE
105 4 INTAKE MAN1 TEMP VOLT BELOW NORM OR SHORT LOW SOURCE
105 16 INTAKE MAN1 AIR TEMP HIGH
107 0 AIR FILT DIFF PRESS PLUGGED AIR FILTER DETECTED
107 31 AIR FILT DIFF PRESS PLUGGED AIR FILTER DETECTED
108 12 ATMOSPHERIC PRESSURE
110 0 ENG COOL TEMP HIGH
110 2 COOLANT TEMPERATURE SENSOR DEFECTIVE
110 3 ENG COOL TEMP VOLT ABOVE NORM OR SHORT HIGH SOURCE
110 4 ENG COOL TEMP VOLT BELOW NORM OR SHORT LOW SOURCE
Page 1 of 4.
PowerView Error Messages
PowerView Model PV101 software version Murphy 1.00.06
PowerView Model PV100 software version Murphy 2.09
SPN FMI Description

111 1 LOW COOLANT LEVEL
120 15 RETARDER OIL TEMPERATURE ABOVE NORMAL
158 2 KEYSWITCH INTERMITTENT
158 17 KEYSWITCH CIRCUIT PROBLEM
171 12 INTERNAL TEMPERATURE
174 0 FUEL TEMP HIGH
174 2 FUEL TEMPERATURE SENSOR DEFECTIVE
174 3 FUEL TEMP VOLT ABOVE NORM OR SHORT HIGH SOURCE
174 4 FUEL TEMP VOLT BELOW NORM OR SHORT LOW SOURCE
174 31 FUEL TEMP VOLT OUT OF RANGE
177 15 TRANSMISSION OIL TEMPERATURE ABOVE NORMAL
189 31 ENG SPEED DERATE CONDITION EXISTS DUE TO FAULT
190 0 ENGINE OVERSPEED
190 2 ENG SPD DATA ERRATIC, INTERMITTENT OR INCORRECT
190 3 ENG SPD VOLT ABOVE NORMAL OR SHORT HIGH
190 4 ENG SPD VOLT BELOW NORMAL OR SHORT LOW
190 5 ENG SPD CIRCUIT IS OPEN
190 8 ENGINE SPEED SENSOR DEFECTIVE
190 16 ENGINE OVERSPEED
201 2 SPEED SET POINT 2 (HAND THROTTLE DEFECTIVE)
441 0 AUXILIARY TEMPERATURE #1 HIGH (MOST SEVERE)
535 7 CONTROL TRAVEL DIFFERENCE
535 13 AUTO CALIBRATION BOSCH-EDC-PUMP UNSUCCESSFUL
536 12 FEEDBACK RACK POSITION
536 13 REFERENCE FEEDBACK RACK POSITION
563 2 DIGITAL OUTPUT 3 SUPERVISION (STOP SOLENOID)
563 6 EXCESS CURRENT DIGITAL OUTPUT 3 (STOP SOLENOID)
572 2 DIGITAL OUTPUT 6 SUPERVISION
611 3 INJ WIRING SHORTED TO BATTERY
611 4 INJ WIRING SHORTED TO GROUND
620 3 SENSOR VOLT1 (+5VDC)ABOVE NORMAL OR SHORT HIGH
620 4 SENSOR VOLT1 (+5VDC)BELOW NORMAL OR SHORT LOW
627 1 POWER SUPPLY LOW VOLT TO INJECTORS
627 4 POWER SUPPLY INTERRUPTION
629 13 REPROGRAM CONTROLLER ECU PROBLEM
629 19 ECU NOT RECEIVING MSG FROM PUMP
632 2 FUEL SHUTOFF VALVE ERR DETECTED
632 5 FUEL SHUTOFF VALVE NON-FUNCTIONAL
632 11 FUEL SHUTOFF VALVE SOLENOID CKT OPEN OR SHORTED
636 2 ENG POS SENSOR TIMING SIGNAL ERROR
637 2 TIMING (CRANK) SENSOR TIMING SIGNAL ERROR
Page 2 of 4.
SPN FMI Description

639 13 CAN BUS FAILURE
651 5 INJ CYLINDER1 CURRENT LESS THAN EXPECTED
651 6 INJ CYLINDER1 CURRENT INCREASES TOO RAPIDLY
651 7 INJ CYLINDER1 FUEL FLOW LOWER THAN EXPECTED
676 3 GLOW PLUG RELAY STUCK ON
676 5 GLOW PLUG RELAY WILL NOT TURN ON
702 14 SPEED (THRUST MODE) WARNING
729 3 INLET AIR HEATER DRIVER1 STUCK ON
729 5 INLET AIR HEATER DRIVER1 WILL NOT TURN ON
743 9 CAN COMMUNICATION SAE J1939, RECEIVE MESSAGES MISSING
743 12 CAN CONTROLLER, BUS OFF
743 14 LINE BREAK, SHORT OR HEAVY BUS LOAD (CAN BUS PASSIVE)
752 2 STACK-OVERFLOW
752 12 CYCLIC FLASH TEST
765 2 PARAMETER ERROR (EEPROM CHECKSUM INCORRECT)
765 12 PARAMETER PROGRAMMING (EEPROM WRITING ERROR)
766 2 INTERNAL ERROR
833 2 RACK POSITION SENSOR ERROR
833 3 RACK POSITION SENSOR VOLT ABOVE NORMAL
833 4 RACK POSITION SENSOR VOLT BELOW NORMAL
834 2 RACK ACTUATOR ERROR BLEED AIR IN FUEL SYSTEM
834 3 RACK ACTUATOR CKT VOLT ABOVE NORMAL
834 5 RACK ACTUATOR CKT OPEN
834 6 RACK ACTUATOR CKT GROUNDED
834 7 RACK ACTUATOR POSITION ERROR
898 2 ERROR CAN SET POINT 1
970 2 EXT AUX ENG SHUTDOWN SWITCH INTERMITTENT
970 11 EXT ENG PROTECTION SHUTDOWN ACTIVE
Page 3 of 4.
SPN FMI Description

970 31 EXT AUX ENG SHUTDOWN SWITCH ACTIVE
971 31 ENG DERATE SWITCH ACTIVATED
1041 2 START SIGNAL MISSING
1041 3 START SIGNAL ALWAYS ACTIVE
1076 0 FUEL INJ PUMP CONT VALVE ERROR
1077 7 FUEL INJ PUMP ERROR
1077 11 FUEL INJ PUMP CONT VP44 INPUT VOLT OUT OF RANGE
1077 12 FUEL INJ PUMP CONT VP44 SELF TEST ERROR
1077 19 FUEL INJ PUMP CONT VP44 DETECTED CAN BUS FAILURE
1077 31 FUEL INJ PUMP CONT POWER DERATED
1078 7 FUEL INJ PUMP SPD/POS SENSOR ERROR
1078 11 FUEL INJ PUMP SPD/POS SENSOR ERROR
1078 31 FUEL INJ PUMP SPD/POS VP44 UNABLE TO ACHIEVE TIMING
1079 3 SENSOR VOLT1 (+5VDC)ABOVE NORM OR SHORT HIGH
1079 4 SENSOR VOLT1 (+5VDC)BELOW NORM OR SHORT LOW
1080 3 SENSOR VOLT2 (+5VDC)ABOVE NORM OR SHORT HIGH
1080 4 SENSOR VOLT2 (+5VDC)BELOW NORM OR SHORT LOW
1109 31 ENG PROT SYSTEM APPROACHING SHUTDOWN
1110 31 ENG PROT SYSTEM SHUT ENG DOWN
1347 5 FUEL PUMP ASSY 1 CKT OPEN, SHORTED GROUND OR OVLOAD
1347 7 FUEL PUMP ASSY 1 RAIL PRESSURE CONT MISMATCH
1347 10 FUEL PUMP ASSY 1 LOW FUEL FLOW
1348 5 FUEL PUMP ASSY 2 CKT OPEN, SHORTED GROUND OR OVLOAD
1348 10 FUEL PUMP ASSY 2 LOW FUEL FLOW
1387 1 AUXILIARY PRESSURE #1 LOW (MOST SEVERE)
1485 2 ECU MAIN RELAY PUMP POWER RELAY FAULT
1569 31 ENG PROT TORQ FUEL DERATE LIMIT CONDITION EXIST
2000 6 FUEL INJECTION PUMP CONT VALVE ERROR
2000 13 SECURITY VIOLATION PROPER CONT NOT INSTALLED
2003 31 GENERAL TRANSMISSION FAULT UNKNOWN
Page 4 of 4.
ALLISON AUTOMATIC TRANSMISSIONS
S5610 (STATIONARY)
M5610 (MOBILE)
UP TO 550 HP (410 kW), 1750 LB-FT (2373 N*m)
SPECIFICATIONS
RATINGS Net Input Torque Net Input Power Turbine Torque
Ib-ft (N*m) hp (kW) Ib-ft (N*m)
Straight-Thru Models
? Winch, Auger 1750 (2373) 550(410) 3120 (4230)
US Oil Field Equipment 1750 (2373) 550 (410) 3476 (4713)
0 Rear Dump Truck, Coal Hauler, Articulated Dump 1750 (2373) 550 (410) 3120 (4230)
* Oil Field, Crash Truck, Crane Carrier 1750 (2373) 550 (410) 3476 (4713)
s
Agricultural Tractor 1485 (2013) 450 (335) 3120 (4230)
Dropbox Models
° Winch, Auger 1575(2135) 500 (373) 3120 (4230)
$ Oil Field Equipment 1575 (2135) 534 (398) 3476 (4713)
? Rear Dump Truck, Coal Hauler, Articulated Dump 1575 (2135) 500 (373) 3120(4230)
5 Oil Field, Crash Truck, Crane Carrier 1575 (2135) 534 (398) 3476 (4713)
ENGINE INTERFACE
Acceptable full-load engine governed speed 1900-2500 rpm
Minimum engine idle speed range (with transmission in Drive) 550 rpm
MOUNTING
Direct SAE No. 1 automatic flywheel housing with flexplate drive. Cradle mount using engine flywheel housing mounting
pads and transmission rear cover mounting pads (or dropbox side pads, if applicable) with 0.625-11 inch series bolts
Remote Side pads on transmission rear cover (or dropbox side pads, if applicable) plus front trunnion mount
TORQUE CONVERTER
Type Single stage, three element, polyphase
Stall Torque Ratio Kp-Factor* at Stall
TC-580 2.89 62.2 (53.4)
TC-680 (with retarder) 2.17 53.2 (45.7)
TC-680 (without retarder) 2.08 54.6 (46.9)
TC-682 1.77 43.7 (37.5)
TC-683 1.85 35.1 (30.1)
*Ko-Factor defines torque converter capacity. Kp = the ratio of converter pump speed Irpml divided by the square root of the pump torque [Ib-ft (N'
MECHANICAL RATIOS*
Range
First 4.00:1
Second 2.68:1
Third 2.01:1
Fourth 1.35:1
Fifth 1.00:1
Sixth 0.67:1
Reverse 1 -5.15:1
Reverse 2 -3.46:1
Ratio coverage
Forward 5.97
Dropbox, if applicable 1.00:1
*Gear ratios do not include torque converter multiplication.
CONTROL SYSTEM
Description Automatic electronic, manual electric, manual hydraulic
OPTIONAL ENGINE-DRIVEN POWER TAKEOFF PROVISION
Side mount Today's engine and axle options
Location 5 o'clock position, as viewed from rear
have made specifying a truck more
PTO drive gear rating Intermittent 46 tooth drive gear, 200 hp (149 kW)
Continuous 46 tooth drive gear, 125 hp (93 kW) demanding. We can help. Whether
Top mount you're looking for enhanced fuel
Location 12 o'clock position, as viewed from rear economy, increased productivity
PTO drive gear rating Intermittent 46 tooth drive gear, 200 hp (149 kW)
Continuous 46 tooth drive gear, 125 hp (93 kW) or high performance, we have the
tools to help you select an Allison
SPEEDOMETER PROVISIONS Transmission that will match your
Electronic
specific application needs. Call
Description LS-TTL signal, 39 pulses per output shaft revolution
Location Output signal from transmission ECU 1-800-252-5ATD. You'll get the right
Mechanical Drive (straight-thru) transmission for your job.
Description SAE "Heavy Duty" 5/32-inch; Ratio = 0.50:1
Location Transmission rear cover
Mechanical Drive (dropbox)
Description SAE "Heavy Duty" 5/32-inch; Ratio = 1.00:1
Location Rear surface of dropbox module
OPTIONAL RETARDER PROVISION DESIGN FEATURES

input Integral, hydraulic
Capacity Torque Power
1500 Ib-ft (2034 N-m) 600 hp (447 kW)
SIZE Straight-Thru Dropbox

(with disconnects)
Depth (below horizontal centerline) 17.0 in (432 mm) 26.7 in (678 mm)
Length (direct mount)1 2 Basic 43.2 in (1097 mm) 51.5 in (1308 mm)
With retarder 46.6 in (1184 mm) 54.9 in (1394 mm) TOP PTO COVER
Width (without filters) Basic 26.8 in (681 mm) 26.9 in (683 mm) INTEGRAL
With retarder 30.0 in (762 mm) 30.0 in (762 mm) MAIN FILTER
Height Basic 31.0 in (787 mm) 40.7 in (1034 mm)
With direct mount filters 35.5 in (902 mm) 45.2 in (1148 mm)
Dry Weight
Basic model 2200 Ib (998 kg) 2750 Ib (1247 kg)
With top engine driven PTO drive gear 2230 Ib (1012 kg) 2780 Ib (1261 kg)
With park brake 2260 Ib (1025 kg) 2810 Ib (1274 kg)
With remote mount 2255 Ib (1023 kg) 2805 Ib (1272 kg)
With retarder 2365 Ib (1073 kg) 2915 Ib (1322 kg)
OIL SYSTEM
Oil type C-4, 15W40
Capacity, excluding external circuits 18.0 gallons (68 liters)
Dropbox 13.0 gallons (49 liters)
Mam circuit oil filter
Standard Manifold for full-flow, remote mounted, replaceable element
Optional Direct-mount full flow, replaceable elements (2) FLYWHEEL/STARTER RING GEAR
Cooler circuit oil filter (optional) Replaceable element, remote-mounted (DIRECT MOUNT CONFIGURATION)
1 For remote mounting, add 10-11 inches (254-279 mm), depending on flange selection.
2 LQngtn is approximate from engine/converter mounting surface to face of typical output flange.
3) Allison
\*r Transmission
P.O. BOX 894, SPEED CODE PF38

INDIANAPOLIS, INDIANA 46206-0894
1 -8 0 0 - 2 52-5 ATD
www.allison transmission.com
NFORMATION AND SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE OR OBLIGATION. SA3028EN 12001/06) LITHO IN U.S.A
WPT Power Transmission Bill of Material Print Date: 2009-02-02 Page: 1 of 2
Part # REV Drawing UOM Description Weight
324 POWER GRIP PO CLUTCH,LESS DRIVE RING,W/QUICK RELEASE VALVES,BLANK BORE 880.0LB
W24-PO-300,P/A H DWG EA S
Comm Saleab Spare Make Buyer

Part # Item Type odity Qty BOM DWG Rev WI UOM WT/UOM Description
le Part Buy Code
Code
324 POWER GRIP PO CLUTCH,LESS DRIVE
W24-PO-300 P/A WPO MAKE BOM DWG H EA 880.0 LBS RING,W/QUICK RELEASE VALVES,BLANK
BORE
321.0 LBS HUB

|----W24-01-123 0001 P/A W01 & BACKPLATE,324 POWER GRIP PO
MAKE 1.0000 DWG I EA A0
CLUTCH,BLANK BORE
17.0 LBS FRICTION DISC,HI-CO,24H POWER GRIP/PO

|----W25-07-100 0002 P/A W07 BUY 3.0000 DWG H EA A0
CLUTCH,LARGE ID
0.05 LBS NUT,3/4"-16

|----X20-20-026 0003 P/A NF,FLEXLOC HALF
BUY 4.0000 EA A0
HEIGHT,PLATED
0.0 LBS STUD,324/330 TD STYLE PO POWER GRIP

|----X20-01-004 0004 P/A BUY 4.0000 DWG F EA A0
CLUTCH
|----W00-33-922 0005 P/A W33 MAKE 4.0000 DWG B EA 1.25 LBS SPRING,COIL,324 PO POWER GRIP CLUTCH 33
|----W24-34-104 0006 P/A W34 PLATE SEPARATOR w/PIN,324 POWER GRIP

MAKE 4.0000 BOM EA 0.0 PO CLUTCH
|----W24-11-102 0007 P/A W11 BUY 2.0000 DWG H EA 56.0 LBS PLATE,CENTER,24" POWER GRIP PO 24
PRESSURE PLATE,24" POWER GRIP PO
|----W24-11-103 0008 P/A W11 MAKE 1.0000 DWG G EA 55.0 LBS 24
CLUTCH
INSULATOR PLATE,24" POWER GRIP PO
|----W24-03-101 0009 P/A 403 BUY 1.0000 DWG L EA 30.94 LBS A0
CLUTCH, MOLDED
19.22 LBS CLAMPING

|----W24-50-100 0010 P/A W50 RING,OD,24" POWER GRIP PO
MAKE 1.0000 DWG B EA A0
CLUTCH
|----X20-08-039 0011 P/A BUY 24.0000 DWG A EA 0.06 LBS HHCS,.375-16 NC x 1.75",GR 5,PLATED 80
|----W24-20-100 0012 P/A W20 BUY 1.0000 DWG A EA 3.0 LBS DIAPHRAGM,24" POWER GRIP PO CLUTCH A0
|----X20-08-011 0013 P/A BUY 8.0000 EA 0.06 LBS HHCS,.312-18 NC x 1.75",GR 8,PLATED 80
|----X20-27-014 0014 P/A BUY 8.0000 EA 0.02 LBS WASHER,FLAT,M8 METRIC,DIN 125
|----W24-02-101 0015 P/A W02 MAKE 1.0000 DWG H EA 177.0 LBS FRONT PLATE,24" POWER GRIP PO CLUTCH 24
3.72 LBS CLAMPING

|----W24-50-101 0016 P/A W50 RING,ID,24" POWER GRIP PO
BUY 1.0000 DWG F EA 24
CLUTCH
|----X20-08-057 0017 P/A BUY 4.0000 DWG A EA 0.04 LBS HHCS,.375-16 NC x 1.00",GR 5,PLATED 80
|----X20-27-252 0018 P/A MAKE 12.0000 DWG A EA 0.04 LBS WASHER,FLAT,1" SPECIAL 80
|----X20-08-055 0019 P/A BUY 12.0000 DWG A EA 1.0 LBS HHCS,1-8 NC x 3.50",GR 5 80
0.04 LBS PIN,SLOTTED SPRING,HEAVY DUTY,1/2" x

|----X20-11-009 0020 P/A BUY 12.0000 EA 80
1.25"
0.5 LBS HHCS,1-8 NC x 1.00",GR 3,PLATED,SPECIAL

|----X20-08-017 0021 P/A BUY 3.0000 BOM DWG C EA 80
MACHINED, SEE BOM
|----X20-11-008 0022 P/A BUY 2.0000 DWG A EA 0.7 LB PIN,TAPER,#12 x 3" ANSI B18.8.2-1978 80
VALVE,QUICK RELEASE,1/4-18 NPTF,14"-42"
|----W00-10-108 0023 P/A W10 MAKE 2.0000 BOM DWG B EA 1.24 LBS PO POWER GRIP CLUTCHES,LESS BOLTS,
WASHERS AND NUTS
NAMEPLATE,SERIAL NUMBER,BRASS,.032" X
0.2 LBS 2"X
|----W00-00-901 0024 P/A W00 3",SQUARE CORNERS,(4) 0.109" DIA.
BUY 1.0000 DWG H EA HOLES,COPY COLOR NATURAL,BLACK
BACKGROUND
|----X20-01-000 0025 P/A BUY 4.0000 DWG B EA 0.05 LBS SCREW,DRIVE,#2 X 3/16" A0
|----WLS-00-012 0026 P/A LS BUY 1.0000 DWG C EA 0.0 LBS LABEL,SILVER/BLACK,LARGE PO
WPT Power Transmission Bill of Material Print Date: 2009-02-02 Page: 2 of 2
Part # REV Drawing UOM Description Weight
324 POWER GRIP PO CLUTCH,LESS DRIVE RING,W/QUICK RELEASE VALVES,BLANK BORE 880.0LB
W24-PO-300,P/A H DWG EA S
Comm Saleab Spare Make Buyer

Part # Item Type odity Qty BOM DWG Rev WI UOM WT/UOM Description
le Part Buy Code
Code
0.0 LBS STEP DRILL AND REAM POWER GRIP PO FOR

|----WL0-00-372 0027 P/A WL0 MAKE 0.0000 EA TAPERED PIN, SHOP LABOR
WPT POWER TRANSMISSION CORP. Print Date: 2009-09-23 Page: 1 of 1
P.O. BOX 8148 R
WICHITA FALLS TX 76307

USA 0/7%2 42!.3-)33)/.
Phone:940-761-1971 Fax:940-761-1989 # / 2 0 / 2 ! 4 ) / .
Sales Part List
Part # Revision Part Type UOM Part Description

W24-PO-200 E P/A EA 224 POWER GRIP PO CLUTCH,LESS DRIVE RING,W/QUICK RELEASE VALVES,BLANK BORE
Spare
Item# Qty Part # Rev UOM Description
Part
0001 1.0000 W24-01-118 M EA HUB & BACKPLATE,224 POWER GRIP PO,BLANK BORE
0002 2.0000 W25-07-100 H EA FRICTION DISC,HI-CO,24H POWER GRIP/PO CLUTCH,LARGE ID
0003 4.0000 WEX2020026 A EA NUT,3/4"-16 NF,FLEXLOC HALF HEIGHT,PLATED
0004 4.0000 WEX2001083 F EA STUD,224/230 TD STYLE PO POWER GRIP CLUTCH
0005 4.0000 W00-33-920 C EA SPRING,COIL,224/230 PO POWER GRIP CLUTCH
0006 4.0000 W24-34-103 A EA PLATE SEPARATOR,W/PIN,224/230 POWER GRIP PO CLUTCH
0007 1.0000 W24-11-102 H EA PLATE,CENTER,24" POWER GRIP PO
0008 1.0000 W24-11-103 G EA PRESSURE PLATE,24" POWER GRIP PO CLUTCH
0009 1.0000 W24-03-101 L EA INSULATOR PLATE,24" POWER GRIP PO CLUTCH, MOLDED
0010 1.0000 W24-50-100 B EA CLAMPING RING,OD,24" POWER GRIP PO CLUTCH
0011 1.0000 W24-20-100 A EA DIAPHRAGM,24" POWER GRIP PO CLUTCH
0012 24.0000 WEX2008039 B EA HHCS,.375-16UNCX1 3/4" LONG,GR 5,PLATED
0013 8.0000 WEX2008011 A EA HHCS,.312-18 NC X 1.75",GR 8,PLATED
0014 1.0000 W24-02-101 H EA FRONT PLATE,24" POWER GRIP PO CLUTCH
0015 1.0000 W24-50-101 F EA CLAMPING RING,ID,24" POWER GRIP PO CLUTCH
0016 4.0000 WEX2008057 B EA HHCS,.375-16 NC X 1.00",GR 5,PLATED
0017 12.0000 WEX2027252 B EA WASHER,FLAT,1",SPECIAL
0018 12.0000 WEX2008055 B EA HHCS,1-8 NC X 3.50",GR 5
0019 12.0000 WEX2011009 A EA PIN,SLOTTED SPRING,HEAVY DUTY,1/2" X 1.25"
0020 3.0000 WEX2008017 D EA HHCS,1-8 NC X 1.00",GR 3,PLATED,SPECIAL MACHINED, SEE BOM
0021 2.0000 WEX2011008 B EA PIN,TAPER,#12 X 3" ANSI B18.8.2-1978
0023 4.0000 WEX2001000 C EA SCREW,DRIVE,#2 X 3/16"
NAMEPLATE,SERIAL NUMBER,BRASS,.032" X 2"X 3",SQUARE CORNERS,(4) 0.109" DIA.
0024 1.0000 W00-00-901 H EA HOLES,COPY COLOR NATURAL,BLACK BACKGROUND
0025 1.0000 WLS-00-012 C EA LABEL,SILVER/BLACK,LARGE PO
0026 8.0000 WEX2027014 A EA WASHER,FLAT,M8 METRIC,DIN 125
PO STYLE AIR CLUTCH
INSTALLATION AND
MAINTENANCE MANUAL
P.O. Box 8148 Wichita Falls, Texas 76307 • 1600 Fisher Rd. Wichita Falls, Texas 76305
Phone: (940) 761-1971 • Fax: (940) 761-1989
www.WPTpower.com • email: [email protected]
WIM-PO-001-C
Section 1.
INTRODUCTION
GENERAL INFORMATION.
An assembly drawing and bill of material sheet is provided with each unit shipped from our factory. If
these are not available, they may be obtained from WPT Power Transmission Corp. or one of its
authorized stocking distributors found worldwide.
Order parts from your nearest WPT Power Transmission distributor. In most cases, they will have the
commonly needed parts ready for shipment.
The illustrations found in this manual refer to this manual only and not specifically to your clutch.
Consult the assembly drawing for your model clutch when ordering parts.
When ordering replacement parts, proceed as follows:
1. Provide the assembly number of the clutch as found on the stamped nameplate. Provide the item
number of the part from the bill of material, the description of the part, and the quantity required.
2. Furnish the complete shipping destination and physical address. All parts sales are made through
the distributor network. State specifically how the parts are to be shipped. If not advised, the
equipment will be shipped the best way, considering time and expense.
Scope.
This publication provides the information necessary for the operation and maintenance of the WPT
Power Transmission Corporation equipment specified on the cover of this manual. Specific
engineering details and performance characteristics can be obtained from WPT Power Transmission
Corporation or one of it's authorized distributors.
Operation and maintenance personnel responsible for this equipment should have this manual at
their disposal and be familiar with its contents. Following the instructions in this manual will insure
performance from the unit and will speed maintenance. Some repairs to this equipment may require
special tools.
Special Tools. .
Drawings are included for the fabrication of special tools that may be required during disassembly
and assembly of a unit. These tools are not available from WPT Power Transmission Corporation.
WPT Power Transmission Corporation absolves itself of any responsibility resulting from
modifications made without the express written approval of WPT Power Transmission Corporation. All
returned parts, new or old, resulting from any of the above stated changes will not be accepted for
credit. Any equipment which has been subjected to such changes will not be covered by a WPT
Power Transmission Corporation Warranty.
PREVENTIVE MAINTENANCE-TROUBLE SHOOTING.
NOTE
Frequent reference to the information provided in this manual regarding daily operation or adjustment
of this equipment will insure trouble free operation. Schedules are provided for the recommended
maintenance of the equipment, and if observed, minimum repairs, aside from normal wear, will result.
In the event a malfunction does occur, a trouble shooting table is provided to help identify the
problem area, and list information that will help determine the extent of the repairs necessary to get a
unit back into operation.
Important Safety Notice.

Because of the possible danger to person(s) or property from accidents which may result from the
use of manufactured products, it is important that correct procedures be followed. Products must be
used in accordance with the engineering information specified. Proper installation, maintenance, and
operation procedures must be observed. Inspection should be made as necessary to assure safe
operations under prevailing conditions. Proper guards and other suitable safety devices or
procedures that may be desirable or specified in safety codes should be provided. These devices are
neither provided by WPT Power Transmission, Incorporated nor are they the responsibility of WPT
Power Transmission, Incorporated.
LIFTING BOLT HOLES.

Most WPT Power Transmission products have provisions for attaching lifting bolts. The holes
provided are always of adequate size and number to safely lift the WPT Power Transmission product.
CAUTION
These lifting points must not be used to lift the complete power unit. Lifting excessive loads at
these points could cause failure at the lift point (or points) and result in damage or personal injury.
CAUTION
Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing.
Bolts should not contact bottom of bolt hole.
SAFETY
General.
Safe operating practices should be employed by all personnel servicing this unit. WPT Power
Transmission Corporation will not be responsible for personal injury resulting from careless use of
hand tools, lifting equipment, power tools, or unaccepted maintenance/work practices.
SOURCE OF SERVICE INFORMATION.

Each series of maintenance manuals issued by WPT Power Transmission Corporation is current at
the time of printing. When required, changes are made to reflect advancing technology and product
improvements.
Individual product service bulletins are issued to provide customers new service information. These
service bulletins are distributed to all WPT Power Transmission distributorships.
For the latest service information on WPT Power Transmission products, contact a WPT Power
Transmission Distributor, or write to WPT Power Transmission Corporation, PO Box 8148, Wichita
Falls, Texas, U.S.A. 76307
WARRANTY
Equipment for which this manual was written has a limited warranty. For details of the warranty,
contact any WPT Power Transmission distributor, or WPT Power Transmission Corporation, PO Box
8148, Wichita Falls, Texas, U.S.A. 76307
Description
The WPT PO style clutch is an air-actuated, spring-released, disc type axial clutch. Power input is
transmitted through the driving ring (1) or drive spider to which the friction discs are meshed. During
clutch engagement, pressurized air is fed into the diaphragm (x). Friction discs (3 and 5) and center
plates (4) are clamped to the hub and backplate (2). The hub and back plate (2), spline connected to
the center plate, transmits the torque through its keyed hub to the output shaft. The drive-through is
on a common center axis with the input.
Air cooling passages are provided through the clutch to carry away the heat generated during
engagement.
OPERATING SPECIFICATIONS.
PO Clutch Ratings
DYNAMIC TORQUE @ STATIC TORQUE @
100 psi (lb-in)/7 bar (Nm) 100 psi (lb-in)/7 bar (Nm)
Clutch Maximum
lb-in Nm Lb-in Nm
Size Speed
114 28,800 3,305 38,400 4,410 2,450
214 57,600 6,610 76,800 8,820 2,450
314 86,400 9,915 115,200 13,230 2,450
118 58,875 6,760 78,500 9,015 2,000
218 117,750 13,520 157,000 18,030 2,000
318 176,625 20,280 235,500 27,045 2,000
124 141,225 16,220 188,300 21,630 1,500
224 282,450 32,440 376,600 43,260 1,500
324 423,675 48,660 564,900 64,890 1,500
230 548,250 62,980 731,000 83,970 1,300
330 822,375 94,470 1,096,500 125,955 1,300
CHART 1 Bolt Torque Specifications

BOLT SIZE SOCKET HEAD CAP SCREWS HEX HEAD CAP SCREWS - GR 8 HEX HEAD CAP SCREWS - GR 5
IN INCHES LB - FT LB - IN Nm LB - FT LB - IN Nm LB - FT LB - IN Nm
1/4 13 150 17 8 100 11 6 71 8
5/16 23 305 34 17 200 23 12 142 16
3/8 45 545 62 30 360 41 22 260 29
7/16 70 840 95 48 570 64 34 410 46
1/2 108 1300 147 83 990 112 53 636 72
9/16 155 1860 210 107 1285 145 74 890 101
5/8 211 2530 286 143 1714 194 104 1250 141
3/4 367 4400 497 256 3070 347 183 2200 249
7/8 583 7000 791 417 5000 565 298 3570 403
1 867 10400 1175 625 7500 848 440 5280 597
1 - 1/8 1242 14900 1684 553 6640 750
1 - 1/4 1750 21000 2374 775 9300 1051
1 - 3/8 2317 27800 3142 1012 12140 1372
1 - 1/2 3042 36500 4125 1350 16200 1831
1 - 3/4 4950 59400 6714
2 7492 89900 10161
CLUTCH OPERATION.
ENGAGEMENT
When pressurized air is supplied to the quick release valve/s(QRV/s) of the clutch, the diaphragm of
the QRV/s move to cover the exhaust port of the valve(s). This causes full supply pressure to be
admitted to the space behind the diaphragm, moving the diaphragm, insulator plate and pressure
plate toward the friction disc/center plate stack. This clamps friction discs, center plates and
hub/backplate causing them to turn as a unit. The pressure plate also moves the plate separator
compressing the release spring.
DIS-ENGAGEMENT
Disengagement is accomplished by releasing the supply air pressure to the QRV/s. This release of
supply air pressure, causes the QRV diaphragm to move away from the exhaust port, allowing the air
behind the clutch diaphragm to be released to atmosphere. The release springs which were
compressed, move the plate separators to open up the stack so that the center plates, driven by the
hub/backplate, turn free of the friction discs.
EMERGENCY CLUTCH OPERATION.
In the event of clutch diaphragm failure, or loss of supply air pressure, it is possible to engage the
clutch mechanically. Three short cap screws (20) are removed from the front plate and replaced by
three main cap screws (23). Tighten these longer cap screws to engage the clutch.
This will force the pressure plate (through the diaphragm (13) and insulator plate(11) to clamp the
center plates (3 & 10) and friction discs (2) to the hub/back plate (4), engaging the clutch (See
diagram).
This will make a solid drive with NO RELEASE. Do not use air at this time.
NOTE
After engaging the clutch mechanically, the clutch diaphragm must be replaced. The clutch must be
disassembled, the insulator plate (11) inspected for damage which in turn could damage a new
diaphragm, a new diaphragm (13) installed, and the clutch re-assembled.
Section 4.
PREVENTIVE MAINTENANCE
1 Routinely check the following:
a. Be sure no dirt or foreign matter has collected in the driving ring or spider which would
prevent the driving plates from working freely.
b. Check pressure plate and insulator plate for plate release travel
2. In cold weather operation, air lines may contain moisture which can freeze and restrict air flow to
the clutch. The addition of denatured alcohol or Ethylene Glycol in the air receiver will eliminate this
problem.
3. Avoid the use of commercial anti-freeze or other products that may affect diaphragm life.
Section 5.
TROUBLE SHOOTING
CLUTCH SLIPPAGE.
NOTE
Maximum allowable travel of insulator plate (see chart) with the clutch engaged. Measurements
less than the specified distance indicate the clutch friction discs are worn and should be replaced.
1. Air pressure at the clutch must be 60 to 130 psi depending on the amount of torque being
transmitted. Measure this pressure at a pipe tee placed at the inlet to the rotary coupling.
2. Inspect the entire air line installation for any restrictions or leaks which could decrease the air
supply to the clutch.
3. Check the operating valve for full opening.
4. Carefully inspect the clutch for possible air leakage at the diaphragm.
5. If operating in cold weather, the air lines may be restricted due to the condensing and freezing of
moisture in the air lines or system. The addition of denatured alcohol in the air system will eliminate
moisture freezing. Avoid the use of all rust inhibitors or commercial anti-freeze.
CLUTCH OVERHEATING
1. Check all points listed previously under "Clutch Slippage."
2. Check alignment as described in Section 9. If misalignment exists, the clutch may not be
completely disengaging.
3. Be sure no dirt or foreign matter has collected in the driving ring or spider which would prevent the
driving plate from operating freely.
4. Check the pressure plate and insulator plate for complete release travel.
6. Check for grease on the clutch plates. Disassemble and clean or replace the clutch plates if they
are greasy.
Section 6.
REMOVAL AND UNIT DISASSEMBLY
GENERAL
NOTE
Wear on the clutch driving plates is determined by measuring the travel of the insulator plate
with the clutch engaged. This must be measured before disassembly.
Using suitable lifting equipment, place the clutch on a working surface, back plate down.
RELEASE VALVES
1. Remove the air lines attached to the quick release valves (14), and remove the hex-head cap
screws (15), and plain washers (14) attaching the quick release valves to the cover plate (16).
2. Remove the two quick release valves and gaskets (V6) from the front plate (16).
3. Remove the valve cover (V2), gasket (V6), spring (V3) from the valve body (V1).
4. Remove the spring seat (V5), and diaphragm (V4) from the valve body (V1).
CLUTCH.
1. Remove the hex-head capscrews (23) and washers (21) from the front cover plate (16). Use two
5/8-11 thread pusher screws in the holes provided in the front cover plate (16) to separate the front
cover plate (16) from the hub-and-back plate (4).
3. Remove the pusher screws and install eyebolts in the pusher screw holes.
4. Use a chain hoist to lift the front cover plate (16) from the hub-and-back plate (4).
5. Remove the insulator plate (11) and pressure plate (10). The insulator plate (11) and pressure
plate (10) are doweled together with roll pins (19).
6. Remove the release spring nuts (5) from the release spring studs (6).
7. Remove the center plate (3), and friction discs (2) and remove the plate separators (7) and
release springs (8) from the hub and back plate (4).
8. Remove the four separator release spring studs (7) from the hub and back plate only if parts
replacement is necessary.
9. Pry the insulator plate (11) from the pressure plate (10) only if replacement of parts is necessary.
10. Remove the roll pins (19) from the pressure plate (10) only if replacement of parts is necessary.
NOTE
The diaphragm need not be removed from the clutch assembly if clutch driving plate replacement is
all that is required. If the diaphragm must be replaced, proceed with steps 11,12 and 13.
11. Remove the hex-head cap screws (18) which secure the inner clamp ring (17) to retain the inner
bead of the diaphragm (13). Remove the inner clamp ring (17).
12. Remove the hex-head cap screws (18) which secure the outer clamp
ring (12) to the front the front cover plate (16) retaining the outer bead of the diaphragm (13).
13. Remove the diaphragm (13) from the front cover plate (16).
14. Remove the two tapered dowel pins (22) from the front cover (16) only if replacement of parts is
necessary.
15. Remove the three cap screws (25) only if replacement of parts is necessary.
Section 7.
CLEANING AND INSPECTION
CLEANING
Thoroughly clean all parts with suitable cleaning agents. After cleaning, dry with compressed air.
Lubricate all machined surfaces with clean oil. Foreign particles tend to collect in the root of the
gear teeth. Clean thoroughly and repair minor nicks with a fine file. Replace parts with
gear teeth that cannot be repaired.
INSPECTION.
1. Inspect castings for cracks. Replace cracked castings. Inspect tapped holes for damaged threads. Chase
damaged threads with a standard tap of the correct size. Replace all castings that cannot be repaired properly.
2. Inspect the teeth of the driving ring if one is used. Replace a damaged driving ring.
3. Inspect all flexible hoses for cracks, sponginess, or other damage. Replace a damaged hose. .
4. Inspect the diaphragm for surface cracks and hardening. Replace a damaged or questionable diaphragm
.
5. Inspect all gear teeth for cleanliness and damage. Examine each part after cleaning to make certain all
foreign matter has been removed.
6. It is very important that all orifices be clean and clear.
7. Inspect the driving plates for cracks, nicks or chips. Replace damaged driving plates.
8. Inspect for cracked or warped pressure plate. Replace the plate if it is damaged.
9. Inspect quick release valves to insure proper operation. Replace faulty release valves.
10. Replace return springs as standard practice after any clutch failure.
Section 9.
UNIT ASSEMBLY AND INSTALLATION
Parts of these instructions will depend on whether a single disc or multi-disc clutch is
being assembled. These instructions will have an “S” (for single) or “M” (for multiple).
Lift holes are provided where appropriate to safely handle WPT clutch components. Always use approved lifting
equipment and devices to avoid injury. Refer to the torque specification chart at the back of this manual for
torque specifications.
1. Place front cover plate(16) on a working surface with the diaphragm side up.
2. Place the diaphragm(13) on the cover plate(16) so the beads are toward the cover plate. Work the inner and
outer beads of the diaphragm(13) into their mounting grooves in the cover plate (16).
3. Position the outer clamp ring(12) over the outer bead of the diaphragm (13). Secure the outer clamp ring with
hex-head cap screws(18).
4. Position the inner clamp ring(17) over the inner bead of the diaphragm(13) and secure with hex-head cap
screws(18). Tighten these per CHART 1.
If the tapered dowel pins(22) were removed, be sure tapered dowel pin holes in the inner clamp ring(17)
are aligned with those in the front plate.
5. Position the hub-and-backplate(4) on a working surface with the splined section upward.
6M. Install the release spring studs(6) in the hub and back plate(4) making sure the threads enter
completely until bottomed.
6S. Install the springs into the spring pockets in the hub and backplate.
7M. Install the release springs(8) onto the studs and into the pockets of the
hub and backplate. Install the pins(9) in the plate separators(7) if they are not already installed.
7S. If installing a new pressure plate(10) or if the plate separators(7) are not on the pressure plate, install them
now using roll pins(22).
8. Install one friction disc(2) onto the hub and backplate(4).
9M. Install center plate(3) onto hub and backplate working the plate separators(7) into the center plate so the
center plate rests on the lips of the plate separators.
9S. Slide the pressure plate(10) with plate separators(7) attached onto the hub and backplate. Insure that the
springs have entered the pockets of the plate separators.
10M. Install plate separators onto studs(6) and into release springs(8).
11M. Install hex locking nuts(5) onto release spring studs(6) and tighten until they bottom or to a point where
the top of the plate separators(7) are approximately 1/8 inch below the top of the teeth on the hub. Insure that
the center plate(3) rests evenly on the lips of the plate separators (7).
12M. Install the friction disc (2) against center plate.
13. If the insulator plate(11) is not assembled to the pressure plate(10), proceed as follows. Install the roll
pins(19) into the pressure plate(10). Install the insulator plate(11) over the roll pins and use a rubber mallet to
seat the insulator plate against the pressure plate.
14. Install the assembled pressure plate(10) and insulator plate(11) onto the hub and back plate(4) against the
friction disc(2). Insure the plate separator pins(9) mesh between the teeth of the pressure plate(10).
15. Position the front cover plate assembly(16) onto the hub-and-back plate(4). Align the dowel pins(22) (if not
removed) with the matching holes in the hub and back plate. If the tapered dowel pins were removed, align the
dowel pin holes. Install the tapered dowel pins(22).
16. Secure the front cover plate(16) to the hub and back plate(4) with hex-head
cap screws(20) and washers(21). Torque the cap screws evenly to the values from CHART 1.
This chart refers to the parts in the diagram used in this manual. When ordering
parts, use the part numbers from the Bill of Materials supplied with the unit. If
this Bill of Materials has been lost, a copy can be obtained from WPT Power
Transmission at no charge. Please supply the Part Number and Serial Number
from the brass nameplate on the unit.
PO CLUTCH PARTS
1 Drive Ring 11 Insulator Plate 21 Washer
2 Friction Disc 12 Outer Clamp Ring 22 Tapered Dowel Pin
3 Center Plate 13 Diaphragm 23 Hex Head Cap Screw
4 Hub 14 Quick Release Valve Washer
5 Locking Nut 15 Quick Release Valve Bolt V1 Valve Body
6 Stud 16 Cover Plate V2 Valve Cap
7 Plate Separator 17 Inner Clamp Ring V3 Spring
8 Separator Spring 18 Clamp Ring Bolt V4 Diaphragm
9 Separator Roll Pin 19 Insulator Plate Roll Pin V5 Spring Seat
10 Floating Plate 20 Hex Head Cap Screw V6 Gasket
INSTRUCTION AND PARTS MANUAL
MODEL PL8
PLANETARY HYDRAULIC WINCH
THE LOGICAL CHOICE
PULLMASTER WINCH CORPORATION

8247-130th Street, Surrey, B.C. V3W 7X4, Canada
Telephone: 604-594-4444 Fax: 604-591-7332
Website: www.pullmaster.com
E-mail: [email protected]
READ THIS MANUAL BEFORE INSTALLING, OPERATING OR

SERVICING THIS PRODUCT. THIS MANUAL CONTAINS IMPORTANT
INFORMATION. MAKE THIS MANUAL AVAILABLE TO ALL PERSONS
RESPONSIBLE FOR THE OPERATION, INSTALLATION, SERVICING
AND MAINTENANCE OF THIS PRODUCT.
PMC 271 070228

Pullmaster Limited Warranty
Effective 8/1/2008
SUPERSEDES ALL PRIOR WARRANTIES
Seller warrants that each article (whether Gear Drive Products, Brake Products and/or Winch Products, all of which are covered hereunder)
sold under this order shall at the time of shipment (i) conform to applicable specifications, and (ii) be free from defects in material and
workmanship during normal and ordinary use and service (the "Warranty").
Buyer's exclusive remedy and Seller's sole obligation under this Warranty shall be, at Seller's option, to repair or replace any article or part
thereof which has proven to be defective, or to refund the purchase price of such article or part thereof. Buyer acknowledges that Buyer is
knowledgeable concerning the articles covered by this Warranty and sold in connection therewith which are being purchased, that Buyer has
reviewed this Warranty and that the remedies provided hereunder are adequate and acceptable to Buyer.
This Warranty shall expire one (1) year from the date the article is first shipped by Seller. Notice of claimed breach of this Warranty must be
given by Buyer to Seller within the applicable period. Such notice shall include an explanation of the claimed warranty defect and proof of
date of purchase of the article or part thereof for which warranty coverage is sought. No allowances shall be made by Seller for any
transportation, labor charges, parts, "in and out" costs, adjustments or repairs, or any other work, unless such items are authorized in writing
and in advance by Seller. Nor shall Seller have any obligation to repair or replace items which by their nature are expendable.
If an article is claimed to be defective in material or workmanship, or not to conform to the applicable specifications, Seller will either
examine the article at Buyer's site or issue shipping instructions for return to Seller. This Warranty shall not extend to any articles or parts
thereof which have been installed, used, or serviced otherwise than in conformity with Seller's applicable specifications, manuals, bulletins,
or instructions, or which shall have been subjected to improper installation, operation, or usage, misapplication, neglect, incorrect
installation, overloading, or employment for other than normal and ordinary use and service. This Warranty shall not apply to any article
which has been repaired, altered or disassembled, or assembled by personnel other than those of Seller. This Warranty shall not apply to
any article upon which repairs or alterations have been made (unless authorized in writing and in advance by Seller). This Warranty shall
not apply to any articles or parts thereof furnished by Seller to Buyer's specifications and/or furnished by Buyer or acquired from others at
Buyer's request.
SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND, OTHER THAN THE WARRANTY
EXPRESSLY SET FORTH ABOVE. SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to tensional vibration issues
and is not responsible for the detection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is installed.
Buyer acknowledges, understands and agrees that this Warranty does not cover failures of the unit which result in any manner from the
operation of the machine or unit at vibration frequencies at or near the natural frequency vibration of the machine in such a way that damage
may result. Buyer expressly agrees that Seller is not responsible for failure damage or accelerated wear caused by machine or ambient
vibration. Further, Buyer acknowledges and agrees that Buyer is always solely responsible for determination and final approval of the
“application factor”
which may be used in Seller’ s calculations, and this application factor is 1.0 unless otherwise stated in Seller’
s quotation
specifications.
The remedies for this Warranty shall be only those expressly set forth above, to the exclusion of any and all other remedies of whatsoever
kind. The limited remedies set forth above shall be deemed exclusive, even though they may fail their essential purpose. No agreement
varying or extending the foregoing Warranty, remedies, exclusions, or limitations shall be effective unless in a writing signed by an executive
officer of Seller and Buyer. This Warranty is non-transferable. If a party who had purchased articles from Buyer, or from persons in privity
with Buyer, brings any action or proceeding against Seller for remedies other than those set forth in this Warranty, Buyer agrees to defend
Seller against the claims asserted in such action or proceeding at Buyer’ s expense, including the payment of attorneys’ fees and costs, and
indemnify Seller and hold Seller harmless of, from and against all such claims, actions, proceedings or judgments therein. Buyer also
agrees to defend and indemnify Seller of, from and against any loss, cost, damage, claim, debt or expenses, including attorneys’ fees,
resulting from any claims by Buyer or third parties to property or injury to persons resulting from faulty installation, repair or modification of
the article and misuse or negligent operation or use of the article, whether or not such damage to property or injury to persons may be
caused by defective material, workmanship, or construction. ADVISORY: Winches and hoists are not approved for lifting or handling
personnel or persons unless specifically approved in writing from Seller for the specific intended application.
Under no circumstances shall Seller be liable (i) for any damage or loss to any property other than the warranted article or part thereof, or (ii)
for any special, indirect, incidental, or consequential damage or loss, even though such expenses, damages, or losses may be foreseeable.
The foregoing limitations on Seller's liability in the event of breach of warranty shall also be the absolute limit of Seller's liability in the event
of Seller's negligence in manufacture, installation, or otherwise, with regard to the articles covered by this Warranty, and at the expiration of
the Warranty period as above stated, all such liabilities shall terminate. Buyer’ s purchase of any article(s) covered by this Warranty shall
constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer’ s representatives, heirs and assigns.
The laws of the Province of British Columbia shall govern Buyer’ s rights and responsibilities in regard to this Warranty and the transaction(s)
subject thereto, and the Province of British Columbia shall be the exclusive forum and jurisdiction for any action or proceedings brought by
Buyer in connection herewith or any dispute hereunder. If any of the terms and conditions contained within this Warranty are void, the
remaining provisions thereof are and shall remain valid and enforceable.
Note: Prices and specifications contained in this price book are subject to change without notice.
US.DIST.01.01.07 [PULLMASTER LOGO]

SAFETY RECOMMENDATIONS
Definition: Caution indicates a potentially
hazardous situation which, if not avoided may
DANGER result in minor or moderate injury.
Definition: Warning indicates a potentially

FAILURE TO COMPLY WITH THE FOLLOWING SAFETY hazardous situation which, if not avoided could
result in death or serious injury.
RECOMMENDATIONS AND LOCAL RULES AND
REGULATIONS WILL RESULT IN PROPERTY Definition: Danger indicates a potentially
hazardous situation which, if not avoided will
DAMAGE, SEVERE INJURY OR DEATH. result in death or serious injury.
The planetary hydraulic winches and drives are made for hoisting and lowering loads and to be operated by trained and professional
personnel. They are not designed for operations involving lifting or moving personnel. The winches are powered by hydraulic power.
The ropes/cables for hoisting operations are not supplied by PULLMASTER. The winches are always assembled in an application,
they do not function as an independent machine and it is not allowed to use them as such.
The winches are to be used within the specifications as listed in the manual under “SPECIFICATIONS”. Other use as foreseen
in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER.
1. Do not install, operate or service winch before 18. Use only recommended hydraulic oil and gear
reading and understanding manufacturer’s lubricant.
instructions.
19. Keep hydraulic system clean and free from
2. The winch described herein is not designed for contamination at all times.
operations involving lifting or moving personnel.
20. Maintain winch and equipment in good operating
3. Do not lift or carry loads over people. condition. Perform scheduled maintenance regularly.
4. Do not exceed recommended operating pressure 21. Keep hands clear when winding wire rope onto
(psi) and operating volume (gpm). the winch drum.
5. Do not jerk the winch. Always smoothly 22. Do not use the wire rope as a ground for welding.
accelerate and decelerate load.
23. Rig the winch carefully. Ensure that the wire rope
6. Do not operate a damaged, noisy or is properly anchored to the correct cable anchor slot at
malfunctioning winch. the cable drum.
7. Do not leave a load suspended for any extended 24. Do not lift a load with a twisted, kinked or
period of time. damaged wire rope.
8. Never leave a suspended load unattended. 25. Consult wire rope manufacturer for size, type and
maintenance of wire rope.
9. Winch should be maintained and operated by
qualified personnel. 26. Maintain five wraps of wire rope on the cable
drum at all times.
10. Inspect winch, rigging, mounting bolts and hoses
before each shift. 27. In case of a power failure or breakdown leading
to an unexpected stop of the hydraulic power circuit,
11. Warm-up equipment before operating winch,
stand clear of the area and the load being hoisted,
particularly at low ambient temperatures.
take the necessary precautions to prevent access to
12. Verify winch function by raising and lowering a area where the load is halted.
full test load to a safe height before each shift.
28. The noise level of the winch is 89 dBA measured
13. Do not weld any part of the winch. on a distance of 1.00 meter, 1.60 meters high. The
14. Verify gear lubrication and brake circulation measuring equipment used was: Realistic #42-3019.
supply and return before operating winch. 29. Clean up any oil spillage immediately.
15. Be sure of equipment stability before operating 30. Wear proper clothing and personal protection
winch. equipment such as, footwear, safety goggles and a
16. Wear proper clothing to avoid entanglement in hard hat. Read manual first.
rotating machinery.
17. Always stand clear of the load.
271 REV.051117 PAGE 1

DESCRIPTION OF THE MODEL PL8
GENERAL DESCRIPTION:
The PULLMASTER Model PL8 is a planetary, hydraulic winch having equal speed in both directions. The main
components of this unit are:
✛ Hydraulic gear motor

✛ Multi-disc brake with static and dynamic function
✛ Over-running clutch
✛ Primary planet reduction
✛ Final planet reduction
✛ Brake housing
✛ Final drive housing
✛ Cable drum
FUNCTION IN FORWARD ROTATION (HOISTING):

In forward rotation, the output torque and rpm of the hydraulic motor are transmitted to the sungear of the primary
planet reduction. The output of the primary reduction stage is transmitted to the final reduction stage by the final
sungear shaft, which is splined to the primary planet hub. In forward rotation, or when a load is raised, an over-running
clutch, which connects the motor drive shaft to the automatic brake assembly, permits free rotation of the sun gear
without effecting the brake. When the winch rotation is stopped, the load on the cable drum causes the over-running
clutch to lock and the maximum load is held safely by the disc brake.
FUNCTION IN REVERSE ROTATION (LOWERING):

In reverse rotation, hydraulic pressure from the reversing side of the hydraulic motor is channelled to the brake piston
causing the brake piston to release the multi disc brake against a number of brake springs. The over-running clutch,
connecting the motor drive shaft to the brake assembly, locks, causing the brake discs to rotate between divider
plates which are engaged into the brake housing. If the load on the cable drum tends to effect the lowering speed,
the resulting pressure drop in the brake piston causes friction between the brake discs and the divider plates. In
this way, a completely smooth paying out speed can be achieved in a stepless operation by modulation of the winch
control handle. When the control handle is returned to neutral position, rotation stops and the disc brake applies
automatically. A hydraulic counterbalance valve or holding valve is not required for smooth and positive operation
of the automatic brake.
During the lowering operation of the winch, the friction created by the brake discs results in temperature. This
temperature is dissipated by an internal circulation flow, supplied out of the hydraulic motor or from an external
source. For models with external circulation, supply winch with approximately 2.5 (US) gpm - 9.5 l/min circulation
flow. This circulation flow must be returned directly to the reservoir with a permissible back pressure of 30 psi (2
bar).
IMPORTANT: Under no circumstances must the back pressure in the brake housing be permitted to exceed 30
psi (2 bar). Excessive pressure in the brake housing will damage the oil seal separating the brake
housing from the drum interior. Damage to this seal will cause the drum to fill up with hydraulic
fluid.
PAGE 2 271 REV.970407

EXPLANATION OF MODEL CODING
PL 8 - XX - XX - XX - X - XXXX
BASIC UNIT SERIES
SIZE OF UNIT
TYPE OF BRAKE
-3 Automatic brake, counterclockwise drum rotation,

internal circulation flow
-4 Automatic brake, external brake release, counterclockwise

drum rotation, internal circulation flow
-5 Automatic brake, external brake release, clockwise drum

rotation, internal circulation flow
-6 Automatic brake, clockwise drum rotation,

internal circulation flow
-7 Automatic brake, counterclockwise drum rotation,

external circulation flow
-8 Automatic brake, external brake release, counterclockwise

drum rotation, external circulation flow
-9 Automatic brake, external brake release, clockwise drum

rotation, external circulation flow
-10 Automatic brake, clockwise drum rotation,

external circulation flow
HYDRAULIC MOTOR
- 30 COMMERCIAL WM31 hydraulic motor, 2 inch gear section
(Other gear sections for this motor are optional)
DRUM SIZE
-1 9.6 inch drum diameter x 14.1 inch flange diameter x 8 inch length - STANDARD
(For other drum sizes refer to APPENDIX A)
DESIGN REVISION
SPECIFICATION NUMBER
Describes features not identified by preceding codes
NOTE: Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting,
established by looking at the hydraulic motor.
271 REV.950401 PAGE 3

OPTIONS
CLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model PL8 planetary winch is counterclockwise for hoisting, when
looking at the hydraulic motor of the winch. Drum rotation for clockwise hoisting direction is available as an option.
EXTERNAL BRAKE RELEASE:

PULLMASTER planetary winches can be supplied with an external brake release which permits release of the
automatic disc brake from an external pressure source.
DANGER
FAILURE TO PROPERLY VENT EXTERNAL BRAKE RELEASE PORT
WILL TRAP BRAKE PRESSURE AND ALLOW THE LOAD TO DROP,
CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
WINCHES SUPPLIED WITH EXTERNAL RELEASE OPTION
MUST BE CONNECTED ACCORDING TO TYPICAL HYDRAULIC CIRCUIT.
CABLE DRUM SIZES:

Aside from the standard drum sizes listed in APPENDIX A, the PULLMASTER Model PL8 planetary winch can
be supplied with optional drums to accommodate large wire rope storage capacity.
DRUM GROOVING:
Cable drums for the PULLMASTER Model PL8 planetary winch can be grooved. Where this option is a requirement,
it is necessary to state the size of wire rope which is to be used with the winch.
OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR:

The performance of the standard PULLMASTER Model PL8 planetary winch is based on a COMMERCIAL WM31
hydralic motor, having a 2 inch gear section. The performance of the winch can be changed by using different gear
sections. (Contact the factory for performance information of different gear sections).
HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS:

The operating pressure of the PULLMASTER Model PL8 planetary winch is limited to 2150 psi (148 bar). For
hydraulic systems operating with higher hydraulic pressure, the winch can be supplied with a hydraulic piston motor,
which will provide for the same basic performance in terms of line pull and line speed capacity (contact the factory
for this requirement).
The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements.
PAGE 4 271 REV.970407

SPECIFICATIONS
Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 1/2 inch diameter
wire rope. For other cable drums refer to APPENDIX A. Performance specifications for winches supplied with
optional motors are provided in attached supplement.
CABLE DRUM DIMENSIONS (STANDARD DRUM):

Barrel diameter 9.63 in 244 mm
Flange diameter 14.13 in 359 mm
Barrel length 8.00 in 203 mm
CABLE STORAGE CAPACITY:

(Size of wire rope) 3/16 in 1234 ft 376 m
1/4 in 684 ft 209 m
5/16 in 462 ft 141 m
3/8 in 294 ft 90 m
7/16 in 215 ft 66 m
1/2 in 196 ft 60 m
9/16 in 140 ft 43 m
MAXIMUM OPERATING PRESSURE: 2150 psi 148 bar
MAXIMUM OPERATING VOLUME: 37 (US) gpm 140 l/min
MINIMUM OPERATING VOLUME: 11 (US) gpm 42 l/min
DRUM TORQUE AT MAXIMUM PRESSURE: 35438 lb-in 4004 Nm
DRUM RPM AT MAXIMUM VOLUME: 46 rpm
LINE PULL AT MAXIMUM PRESSURE:

Bare drum 7000 lb 31.1 kN
Full drum 5202 lb 23.1 kN
LINE SPEED AT MAXIMUM VOLUME:
Bare drum 122 fpm 37 m/min
Full drum 164 fpm 50 m/min
PERMISSIBLE SYSTEM BACK PRESSURE AT

MOTOR RETURN PORT: 65 psi 4.5 bar
PERMISSIBLE PRESSURE
AT CIRCULATION RETURN PORT: 30 psi 2 bar
LUBRICATING OIL: Refer to RECOMMENDATIONS for viscosity and instructions.

Refer to APPENDIX A for oil volume required.
271 REV.011203 PAGE 5

PERFORMANCE GRAPHS
PG-PL8
LINE PULL VS. OIL PRESSURE
LINE PULL - kN
0 5.3 10.7 16.0 21.4 26.7 32.0
2150 148
M
DRU
1720 119
LL
FU
OIL PRESSURE - bar

OIL PRESSURE - psi
UM
DR
RE
BA
1290 89
860 60
430 30
0 0
0 1200 2400 3600 4800 6000 7200
LINE PULL - lb
LINE SPEED VS. OIL VOLUME

LINE SPEED - m/min
0 8 16 25 33 41 49
40 151
32 121
OIL VOLUME - (US)gpm
OIL VOLUME - l/min

M
RU UM
D DR
RE LL
BA FU
24 91
16 60
8 30
0 0
0 27 54 81 108 135 162
LINE SPEED - fpm
Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with 1/2 inch diameter
wire rope.
PAGE 6 271 REV.950401

TYPICAL HYDRAULIC CIRCUIT
HC-PL8
CIRCULATION
RETURN LINE
(MUST GO
DIRECT TO
RESERVOIR)
800 PSI [55 BAR]

1/2(US)GPM [2 L/MIN]
REQUIRED FOR MODELS
SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION
CIRCULATION SUPPLY
LINE 2.5 (US) gpm
[9.5 l/min]
EXTERNAL CIRCULATION
MODELS ONLY
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
FILTER
HYDRAULIC
PUMP
RESERVOIR
271 REV.950401 PAGE 7

RECOMMENDATIONS
HYDRAULIC FLUID: HYDRAULIC PRESSURE RELIEF:
The hydraulic fluid selected for use with PULLMASTER The hydraulic circuit for the PULLMASTER planetary
planetary winches should be a high grade, petroleum winch requires a pressure relief set at the operating
based fluid, with rust, oxidation and wear resistance. pressure (see SPECIFICATIONS). Usually, a pressure
Fluid cleanliness and operating viscosity are critical to relief is part of the hydraulic control valve. Where this
winch reliability, efficiency and service life. is not the case, a separate pressure relief valve must
be installed and set at the recommended maximum
For optimum performance, the recommended viscosity pressure.
range at operating temperature is 81 - 167 SUS (16 - 36
CS). For extreme operating conditions of short duration, HYDRAULIC RESERVOIR:
the maximum viscosity range of 58 - 4635 SUS (10 - It is recommended that the hydraulic reservoir has
1000 CS) should not be exceeded. sufficient capacity to provide good heat dissipation in
order to prevent over-heating of the hydraulic fluid. The
For optimum performance, the winch recommended hydraulic reservoir should be made from clean and
hydraulic fluid temperature operating range is 80 - scale-free material to prevent contamination of the
150F (27 - 66 C). For extreme operating conditions of hydraulic fluid. In order to prevent air from being mixed
short duration, the maximum temperature range of -5 - with the hydraulic fluid, the reservoir should have an
180F (-21 - 82 C) should not be exceeded. over-flow baffle separating the return lines from the
suction line and all return lines should enter the reservoir
LUBRICATION: below the fluid level. The reservoir should be mounted
The winch gear train requires oil bath lubrication. The close to and above the hydraulic pump in a location
winch is shipped from the factory without lubricating oil. which provides for free air circulation around the reservoir.
IMPORTANT: ADD LUBRICATING OIL UP TO HYDRAULIC HOSES:

THE LEVEL OF THE OIL FILL PORT The following hydraulic hoses are recommended for
BEFORE RUNNING WINCH. maximum efficiency of the PULLMASTER Model PL8
planetary winch:
Refer to INSTALLATION DIMENSIONS for location of
lubricating oil fill port. Refer to APPENDIX A for quantity Pressure lines: Equivalent to SAE 100R12-16
of oil required. For normal operating temperature use Circulation return line: Equivalent to SAE 100R4-12
SAE 90 lubricating oil. Consult lubricating oil supplier or
factory for temperatures beyond normal operating range. It is recommended that a larger size of hydraulic hose is
installed where the pressure lines are excessively long.
HYDRAULIC PUMP:
For maximum performance of the PULLMASTER HYDRAULIC FILTER:
planetary winch, the hydraulic pump must supply the Consult hydraulic component manufacturer for
maximum flow of hydraulic fluid at the hydraulic pressure recommendation. Generally, 5 to 10 micron filters are
stated in SPECIFICATIONS. acceptable. In order to prevent accidental stoppage of
the return line flow, the filter should have a by-pass
HYDRAULIC CONTROL VALVE: feature.
The standard control valve used for operating the
PULLMASTER planetary winch must have a four-way, USE OF AN E STOP:
spring return to neutral feature, which provides for (FOR EUROPEAN MACHINERY DIRECTIVE APPLICATIONS)
open flow from the pressure ports of the winch to the
reservoir in neutral position of the control (motor The use of an E stop (emergency) is mandatory in the
spool). It is important to point out that good speed controls circuit. The E stop is to be placed in the
control, especially when lowering a load, depends on operator’s control panel. The E stop must be designed
the “metering” characteristics of the control valve. The and placed in line with EN 60204 and EN 418.
better the oil flow is “metered” the better will be the speed
control.
PAGE 8 271 REV.011125

INSTALLATION INSTRUCTIONS
DANGER
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
The initial installation or mounting of a PULLMASTER planetary winch is critically important for proper operation and
performance. If the winch is mounted to an uneven surface, the centre line of the unit can be distorted to a point
where the winch will not operate in either direction. It is therefore very important that the following instructions are
observed when a PULLMASTER planetary winch is installed:
1) Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted.
2) Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch.
3) If there is a space between the mounting surface and one of the mounting pads, the mounting surface is not
even and the space below the mounting pad must be shimmed. If this condition exists, proceed as follows:
a) Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting
surface. For mounting bolt size and grade see INSTALLATION DIMENSIONS.
b) Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of
equivalent thickness in the space between the mounting pad and the mounting surface.
c) Only after this procedure, should the fourth mounting bolt be installed. Tighten all four bolts as per BOLT
TORQUE CHART.
4) Fill the winch with lubricating oil. (See APPENDIX A for oil volume required).
5) Use recommended circuit components and hydraulic hoses.
6) The circulation return line of the winch should be plumbed in such a manner that the brake housing remains full
of oil at all times. Connect the return line directly to reservoir. Do not connect to a common return line.
7) Before operating the winch with a load, verify adequate circulation flow through the circulation return line as
stated in TYPICAL HYDRAULIC CIRCUIT. Verify that pressure measured at the circulation supply port does
not exceed the permissible pressure stated in SPECIFICATIONS. Winches equipped with the internal
circulation option will supply circulation flow only when the winch is run in the lowering direction.
8) If, after new installation, the winch does not function properly, refer to the TROUBLESHOOTING section of
this manual.
271 REV.970407 PAGE 9

OPERATING INSTRUCTIONS
DANGER
FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
After the PULLMASTER planetary winch has been installed in accordance with the INSTALLATION
INSTRUCTIONS, the wire rope can be fastened to the cable drum.
IMPORTANT: The ropes, chains, slings, etc. are not part of the winch and are not covered by this manual.
Refer to manufacturer’s handling, inspection and maintenance recommendations to avoid
potential accidents. For selection of ropes, etc. please check following product standards: DIN
15020, prEN818-1/9, prEN 1492-1/2, prEN 1677-1/3 and other relevant product standards.
1) The cable drum of the PULLMASTER planetary winch has two cable anchor slots, one for clockwise and one
for counterclockwise hoisting. Standard rotation for hoisting is counterclockwise when looking at the hydraulic
motor of the unit. It is critical to select the cable anchor slot which will permit winding of the wire rope on the
drum in the correct direction of rotation. If the wire rope is wound on the cable drum in the wrong direction of
rotation, the winch will have no braking capacity. Each winch is shipped from the factory with a label on the drum,
indicating the correct cable anchor slot.
WIRE ROPE INSTALLATION SI1013-PL8

Counterclockwise hoisting winch shown.
(Use cable anchor slot on opposite side
of drum for clockwise hoisting winch.)
Feed the wire rope through the cable
anchor slot. Loop rope back into slot
as shown. Insert cable anchor into
slot, small end first and long side
nearest the drum flange. Pull rope CABLE ANCHOR SLOT
tight to wedge rope in slot. CABLE ANCHOR
2) On wire rope installation, care must be taken that the wire rope is wrapped completely around the cable anchor
and properly pulled into the cable anchor slot in the cable drum. The cable drum requires 5 wraps of wire rope
for safety.
3) The winch operation is controlled by a single control valve lever which has a forward, a reverse and a neutral
position. Speed control in either direction is obtained by modulation of the control valve lever. Maximum line
speed in either direction is obtained when the control valve lever is moved as far as it can go. The disc brake
of the winch will come on automatically when the winch control lever is returned to neutral.
4) Always warm up equipment prior to operating winch, particularly in low ambient temperature. Circulate
hydraulic oil through the winch control valve for several minutes to warm the hydraulic system. To prime the
winch with warm oil, operate the winch at slow speed, forward and reverse, several times.
5) Prevent corrosion damage to winch interior. If not used regularly, run winch up and down at least once every
two weeks.
6) To ensure proper winch installation and function, raise and lower a full test load to a safe height before using
winch for regular operation at the start of each shift.
If, after a new installation, the winch does not function properly, refer to the TROUBLESHOOTING section
of this manual.
PAGE 10 271 REV.051117

TROUBLE SHOOTING
GENERAL:
In most cases, when the hydraulic winch does not perform satisfactorily, the cause for malfunction is found
somewhere in the hydraulic circuit. Before the winch is removed from its mounting and disassembled, all of the
hydraulic circuit components should be checked for proper function.
IMPORTANT:
The hydraulic oil volume relates to the line speed or rpm of the winch.
Therefore, if the winch does not produce the specified maximum rated line speed or drum rpm, a loss of hydraulic
flow somewhere in the hydraulic circuit can be analysed. If this condition exists, install a flow meter into the
hydraulic circuit to check the volume of oil supplied to the pressure port of the hydraulic winch motor when the
winch control is completely opened. The flow meter should indicate the maximum operating volume. If this test
indicates a loss of hydraulic flow, check the hydraulic pump, the relief valve and the control valve. If the pump
is driven by V-belts, check for belt slippage.
The hydraulic pressure relates to the pulling capacity of the winch.
If the winch will not produce the specified maximum line pull, install a pressure gauge in the pressure line leading
to the hoisting port on the hydraulic winch motor. Stall the winch to prevent rotation of the drum and then open
the control valve. Check the hydraulic pressure reading of the installed pressure gauge. If the pressure reads
below the specified maximum operating pressure, look for trouble in the hydraulic pump, the relief valve and
the control valve. If the hydraulic pump is driven by V-belts, check for belt slippage. When checking oil pressure
and volume in the hydraulic circuit, make sure that the hydraulic reservoir is filled to the top level and the
hydraulic pump is running at maximum operating rpm.
Only after the hydraulic system has been checked and found to be in order, use the following indications for
probable causes of failure in the winch:
FAILURE PROBABLE CAUSE

Winch will not produce line pull at maximum a) Winch is mounted to an uneven surface.
pressure as listed in SPECIFICATIONS. (See INSTALLATION INSTRUCTIONS.)
b) Cable sheaves or block purchase operated with the
winch are not turning freely.
c) Damage or wear in the hydraulic motor.
d) The relief valve pressure may be set too low.
e) Excessive back pressure in the hydraulic circuit might
cause the automatic brake to release momentarily.
Winch will not produce line speed at maximum a) Winch is mounted to an uneven surface.
volume as listed in SPECIFICATIONS. (See INSTALLATION INSTRUCTIONS.)
b) Cable sheaves or block purchase operated with the
winch are not turning freely.
c) Damage or wear in the hydraulic motor.
d) Excessive back pressure in the hydraulic circuit.
Winch will not reverse. a) Leakage out of the brake piston prevents the disc brake
from being released against the brake springs. This is
caused by damaged O-ring seals on the brake piston.
b) Insufficient hydraulic pressure. (See SPECIFICATIONS
for minimum operating pressure.)
c) Winch is mounted to an uneven surface.
(See INSTALLATION INSTRUCTIONS.)
d) Hydraulic pressure is not reaching the brake piston due
to plugged passages.
271 REV.960215 PAGE 11

TROUBLE SHOOTING CONTINUED
FAILURE PROBABLE CAUSE

Brake will not hold. a) Brake plates or divider plates have been damaged by
contamination in the hydraulic fluid or lack of circulation
flow in the brake housing.
b) Brake piston is seized in the brake housing because of
contamination in the hydraulic fluid.
c) Excessive back pressure in the return line of the
hydraulic circuit causes the brake to release.
d) Control valve has incorrect spool which traps hydraulic
pressure in the brake piston when the control valve
handle is returned to neutral position. For proper function
of the automatic brake, both pressure ports of the winch
must be open to the reservoir in neutral position of the
control valve.
e) Wire rope is fastened to the incorrect cable anchor slot.
f) Sprag clutch is damaged or surface where sprag clutch
engages on motor drive shaft or brake hub are worn or
indented.
g) Winch supplied with external brake release option is
not plumbed per TYPICAL HYDRAULIC CIRCUIT.
Failure to vent external brake release port to reservoir
may trap pressure and cause winch brake to slip.
Brake vibrates when lowering a load. a) Pump is too slow. Pump rpm must be maintained at
normal operating speed when a load is lowered.
b) Brake is running too hot. This is caused by a complete
lack of, or insufficient circulation flow. To check the
circulation, observe the flow of oil from the circulation
return line of the winch (approx. 2-3 (US) gpm (8-11 l/
min) when the winch is reversed.
c) Control valve for the winch operation has poor metering
characteristics.
d) Damaged brake plates or divider plates.
e) The over-running clutch, which connects the motor
shaft with the brake assembly, is damaged.
f) Air has mixed with hydraulic oil resulting in foamy oil.
Oil leaks. a) Oil leaks from the motor flange are caused by a
damaged O-ring seal on the motor flange.
b) Oil leaks occurring between the cable drum flanges
and housing are caused by excessive pressure in the
brake housing. Excessive pressure in the brake housing
will damage the oil seal between the brake housing and
cable drum interior.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model PL8 winch.
PAGE 12 271 REV.950401

SERVICE INSTRUCTIONS
GENERAL:
Before attempting disassembly of the PULLMASTER Model PL8 planetary winch, the following instructions for
disassembly and reassembly should be read and understood:
It is suggested that all expendable parts, such as O-rings and oil seals, are not reused on reassembly. It is therefore
important to have a seal kit (Part No. 23101) and, providing the hydraulic motor has to be serviced, a seal kit (Part
No. 23131) on hand before the unit is taken apart. Two new needle bearings, item 875, may also be required (Part
No. 25322).
NOTE: Back up washers may be included with seal kit. Install with oil seals as per instructions. If not
present in seal kit, the oil seals supplied do not require backup washers.
A clean working area is of prime importance, similar to conditions used for service work on any other hydraulic
component.
All parts, as they are removed from the winch assembly, should be inspected for wear and damage. Worn or
damaged parts must be replaced. Thoroughly clean parts before reassembly. Do not use solvent to clean the brake
friction plates.
During reassembly, lubricate all O-rings and oil seals with grease before installation.
In the following service instructions, reference to parts is made by numbers and shown on the applicable group
drawings.
DISASSEMBLY:
For the majority of required service or repair work, disassembly is required only on the brake housing of the
PULLMASTER Model PL8 planetary winch. There are no special tools needed for the service or repair work and
no adjustments or calibrations are necessary. Proceed with the disassembly as follows:
DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY:

If the analysed service or repair work requires access to the interior of the brake housing, the hydraulic motor should
not be disassembled. In this case, the hydraulic motor should be removed together with the motor adaptor as a
complete assembly. If a problem has been analysed to be in the hydraulic motor, proceed with the disassembly
as follows:
1) Remove the four hex capscrews, item 951, together with the lockwashers, item 953, from the motor assembly.
IMPORTANT: Failure to exercise care when removing the motor port end cover or gear housing could
permanently damage the machined surfaces of these motor components. Take care not
to damage machined surfaces of motor components at disassembly.
2) Remove (pry loose if necessary) port end cover, item 870, together with bearings, item 875, and ring seal, item
877. Thrust plate, item 885, and dowel pins, item 865, may stay in the gear housing.
3) If thrust plate comes off with the end cover, carefully pry it off of the bearings, item 875, and discard pocket
seals, item 887.
4) Remove gear set, item 881, which consists of two gears which are a matched set.
5) Carefully pry the gear housing, item 861, off of the motor adaptor, item 800. Thrust plate, item 885, and dowel
pins, item 865, may stay in the gear housing.
6) If thrust plate stays on the motor adaptor, carefully pry it off of the bearings, item 875, and discard pocket seals,
item 887.
7) Discard body seals, item 869. It is also advisable to replace ring seals, item 877, at this time. Bearings, item
875, have to be removed to allow access to the ring seals.
271 REV.970407 PAGE 13

SERVICE INSTRUCTIONS CONTINUED
Pocket seals, body seals, and ring seals in the hydraulic motor assembly are not part of the winch seal kit. The
seal kit for the hydraulic motor can be ordered from the factory under Part No. 23131. All parts of the hydraulic
motor, with the exception of the motor adaptor, item 800, are standard parts of the COMMERCIAL WM31 hydraulic
motor, having a 2 inch gear section. All of these parts can be ordered from PULLMASTER or COMMERCIAL
INTERTECH dealers in Canada, the United States and in most overseas areas.
REMOVAL OF HYDRAULIC MOTOR ASSEMBLY

If disassembly of the hydraulic motor is not necessary, proceed as follows:
1) Remove the 12 hex head capscrews, item 821, with lockwashers, item 823, from the motor adaptor, item 800.
Since brake springs, item 752, apply pressure against inside of the motor adaptor, it is recommended that hex
capscrews are unscrewed, one turn at a time, until the spring pressure has been released. Complete motor
assembly, including motor adaptor, can now be removed from brake housing assembly.
2) Remove and discard O-ring, item 801, and O-ring, item 707. (O-ring, item 801, seals pressure transfer hole for
automatic brake release and is situated on flange of brake housing.)ffffff
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY

1) Aftermotor assembly has been removed, all parts of brake assembly are accessible. Remove 10 brake springs,
item 752. Thoroughly examine springs for damage and measure overall length. Overall spring length should
be 1.99 inches. If any spring measures less than 1.93 inches, replace all springs as a set.
2) Pull motor drive shaft, item 730, and complete brake hub assembly from brake housing.
3) Disassemble brake hub assembly by removing circlip, item 727, from motor drive shaft. Remove motor drive
shaft from brake hub, item 720. Remove sprag clutch aligners, items 722 and 724, support washers, item 717,
sprag clutch, item 723, and sprag clutch spacer, item 726, from brake hub.
DANGER
MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES
THE MOTOR DRIVE SHAFT AND BRAKE HUB, WILL RESULT IN
BRAKE FAILURE AND ALLOW THE LOAD TO DROP, CAUSING
PROPERTY DAMAGE, SEVERE INJURY OR DEATH. THOROUGHLY
INSPECT THESE AREAS AND REPLACE MOTOR DRIVESHAFT,
SPRAG CLUTCH AND BRAKE HUB AS A SET.
4) Thoroughly inspect motor drive shaft, item 730, and brake hub, item 720, particularly surfaces where sprag
clutch, item 723, engages. If any indentation or surface damage is detected, replace brake hub, sprag clutch
and motor drive shaft as a set.
5) Pull the brake piston, item 750, out of brake housing using two 7/16-14NC bolts screwed into two puller holes
in piston and discard O-rings, item 751 and item 753.
6) Thoroughly examine inner bores of the brake housing and outer diameters of the brake piston for scoring caused
by hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.
PAGE 14 271 REV.970407

DANGER
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE
BRAKING CAPACITY AND ALLOW THE LOAD TO DROP, CAUSING
PROPERTY DAMAGE, SEVERE INJURY OR DEATH. SOLVENT MAY
DAMAGE THE FRICTION PLATES. DO NOT USE SOLVENT TO CLEAN
THE FRICTION PLATES. PERFORM THOROUGH INSPECTION AND
REPLACE FRICTION AND DIVIDER PLATES AS A SET.
7) Remove four friction plates, item 715, together with five divider plates, item 714, and inspect for damage or wear.
Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction plates
should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
8) Remove brake spacer, item 712.
9) Remove oil seal, item 711, and backup washer, item 710, and discard.
All parts have now been removed from brake housing and there is no need for further disassembly unless a failure
has been analyzed in the remaining winch assembly.
DISASSEMBLY OF PRIMARY DRIVE

If primary drive requires service or repair, disassemble as follows:
1) Remove pipe plug, item 503, from cable drum, item 500, to drain lubricating oil from winch interior.
2) Remove eight capscrews, item 971, and lockwashers, item 973. Remove two tie bars, item 970. Stand winch
upright on its end housing.
3) Remove six capscrews, item 537, and lockwashers, item 541, through access opening in brake housing. Lift
brake housing with bearing flange assembly out of cable drum, item 500. Remove and discard O-ring, item 539.
4) Pull bearing flange, item 530, and ball bearing, item 533, off of brake housing, item 700.
5) Remove circlip, item 535. Push ball bearing, item 533, out of bearing flange. Inspect and replace if damged.
6) Remove and discard oil seal, item 531.
7) Inspect planet hub stopper, item 704, for damge or wear and replace if less than 0.13 inch thick.
8) Remove primary sungear, item 440.
9) Remove primary planet hub assembly from cable drum.
10) Inspect planet hub stopper, item 402, for damage or wear and replace if less than 0.13 inch thick.
11) Inspect three primary planet gears, item 420, for damage or wear. If it is necessary to remove planet gears,
remove circlip, item 411, and press planet pin, item 410, out of planet hub, item 400. Inspect needle bearing,
item 423, and two thrust washers, item 421, and replace if damaged or worn.
12) Remove final sungear, item 340, with circlip, item 341, and sungear stopper, item 344. Inspect stopper for
damage or wear. If stopper protrudes less than .03 inch from sungear, stopper should be replaced.
271 REV.970407 PAGE 15

DISASSEMBLY OF FINAL DRIVE
If final drive requires service or repair, disassemble as follows:
1) Remove final planet hub assembly from the cable drum.
2) Inspect three final planet gears, item 320, for damage or wear. If it is necessary to remove planet gears, remove
circlip, item 311, and press planet pin, item 310, out of the final planet hub, item 300. Inspect seventeen loose
rollers, item 323, and two thrust washers, item 321, and replace if damaged.
Winches with optional -2 drum only:

2A) Remove coupling, item 520, from end housing spline. Proceed to step 3.
3) Pull the end housing, item 100, out of the cable drum ball bearing, item 507.
4) Remove circlip, item 513. Push ball bearing, item 507, out of the cable drum. Inspect and replace if damaged.
5) Remove and discard oil seal, item 505.
6) Inspect cable drum gear teeth for damage or wear.
REASSEMBLY:
Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified, torque
fasteners per BOLT TORQUE CHART at back of manual.
REASSEMBLY OF FINAL DRIVE

Reassemble final drive by reversing the disassembly procedure:
1) Press a new, well-greased oil seal, item 505, into cable drum, item 500.
2) Press ball bearing, item 507, into cable drum and secure with circlip, item 513.
3) Press end housing, item 100, into the cable drum ball bearing, item 507.
Winches with optional -2 drum only:

3A) Replace coupling, item 520, onto end housing spline. Proceed to step 4.
4) Reassemble final planet hub assembly. Use grease to temporarily hold 17 loose rollers, item 323, in the bore
of the planet gear, item 320. Position thrust washers, item 321, on either side of the planet gear and press planet
pin, item 310, into the final planet hub, item 300. Retain with circlip, item 311.
5) Insert final planet hub assembly into the cable drum. Ensure that the planet hub spline is fully engaged.
REASSEMBLY OF PRIMARY DRIVE

Reassemble primary drive by reversing the disassembly procedure:
1) Press a new, well-greased oil seal, item 531, into the bearing flange, item 530. Press ball bearing, item 533,
into bearing flange and install circlip, item 535. Press bearing flange assembly onto brake housing hub.
2) Verify planet hub stopper, item 704, is installed on brake housing hub.
3) Verify sungear stopper, item 344, and circlip, item 341, are installd on final sungear, item 340.
4) Install final sungear into primary planet hub, item 400.
5) Reassemble primary planet hub assembly. Press needle bearing, item 423, into planet gear, item 420. Position
thrust washers, item 421, on either side of planet gear and press planet pin, item 410, into the primary planet
hub, item 400. Retain with circlip, item 411.
PAGE 16 271 REV.950401

6) Verify planet hub stopper, item 402, is installed on planet hub.
7) Insert primary planet hub assembly into cable drum. Ensure that the final sungear, item 340, is fully engaged
with final planet gears, item 320.
8) Install primary sungear, item 440.
9) Install new, well-greased O-ring, item 539, onto bearing flange, item 530. Lower brake housing, item 700,
complete with bearing flange assembly, into cable drum. To fasten bearing flange to cable drum, align holes
in the bearing flange with threaded holes in the cable drum. Install six capscrews, item 537, and lockwashers,
item 541, through access opening in brake housing.
10) Use eight capscrews, item 971, and lockwashers, item 973, to secure tie bars, item 970.
11) Install pipe plug, item 503, into cable drum.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY

Reassemble brake housing assembly by reversing the disassembly procedure:
1) Press needle bearing, item 733, into brake housing bore.
2) Press new, well-greased oil seal, item 711, and back-up washer, item 710, into brake housing bore.
3) Install sprag clutch, item 723, and sprag clutch spacer, item 726, into bore of brake hub, item 720. Position sprag
clutch aligners, item 722 and 724, and support washer, item 717, on either side of brake hub. Carefully slide
motor drive shaft, item 730, into brake hub assembly and secure with circlip, item 727.
IMPORTANT: For proper brake function, verify that the brake hub rotation is correct. When
viewed from the motor end, the motor drive shaft of a counterclockwise hoisting winch
must turn freely clockwise and lock in the counterclockwise direction.
4) Install motor drive shaft assembly, carefully twisting shoulder of shaft through oil seal, item 711. Ensure that
oil seal is not damaged as motor drive shaft is installed.
DANGER
INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE
STACK WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD
TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR
DEATH. REASSEMBLE PER INSTRUCTIONS
5) Install brake spacer, item 712, into brake housing, item 700. Starting and finishing with divider plate, alternately
install five divider plates, item 714, and four friction plates, item 715.
6) Install new, well-greased O-rings, item 751 and 753, into piston glands, item 750. Carefully install brake piston
in brake housing.
7) Install 10 brake springs, item 752, into the 12 holes of brake piston, leaving two holes vacant opposite each
other.
8) Use grease to temporarily hold a new O-ring, item 801, into recess on the flange of motor adapter, item 800.
Install new, well-greased O-ring item 707, onto motor adapter pilot.
9) Position motor adapter, with brake release pressure transfer holes of motor adapter and brake housing aligned.
Tighten 12 capscrews, item 821, and lockwashers, item 823, one turn at a time to evenly compress springs.
271 REV.970407 PAGE 17

REASSEMBLY OF HYDRAULIC MOTOR
If the hydraulic motor was disassembled, the following procedure should be followed for reassembly:
1) Clean all parts thoroughly before reassembly and apply grease liberally to all seals. Use only new seals (seal
kit Part No. 23131) for hydraulic motor.
2) Install six new pocket seals, item 887, on each thrust plate, item 885. The seal kit includes a single strip of
rubber. Using a sharp knife, cut lengths to fit the openings in the thrust plates. Press one of the thrust plates,
together with six pocket seals, onto bearings, item 875, installed in motor adaptor, item 800, so that pocket
seals are against motor adaptor.
3) Install a well-greased body seal, item 869, on each side of gear housing, item 861. Slide the gear housing
together with the body seals, onto motor adaptor, lined up on two dowel pins. Tap on tight using a soft headed
hammer.
4) Install gear set, item 881, in gear housing (The longer gear with the internal spline goes into the top position).
5) Press the other thrust plate, complete with six new pocket seals, onto bearings installed in port end cover so
pocket seals are facing port end cover.
6) Install port end cover, item 870, together with two bearings, item 875, and new ring seal, item 877, onto gear
housing, lined up on two dowel pins, item 865. Tap on tight using a soft headed hammer. Install and lightly torque
four hex capscrews, item 951, and lockwashers, item 953, to approximately 50 ft-lb (70 Nm).
7) Plumb winch assembly to a hydraulic supply and torque motor capscrews according to the following procedure:
- Ensure that circulation supply flow is being supplied to the brake housing.
- Run the winch, with no load, in the hoisting direction at reduced speed
(approximately 30% of maximum hydraulic volume).
- With winch running, evenly tighten four capscrews, item 951, to 200 ft-lb (270 Nm).
- Test motor operation by running winch at full speed in both directions.
IMPORTANT: Before operating the winch, add lubricating oil up to the level of the end housing oil fill port.
(Refer to INSTALLATION INSTRUCTIONS for location of fill port. Refer to APPENDIX A
for oil volume required.)
To ensure proper reassembly, run the winch in both directions without load.
DANGER
LIFTING A LOAD WITH A NEWLY SERVICED WINCH WILL
ENABLE AN INSTALLATION OR SERVICE PROBLEM TO GO
UNDETECTED AND ALLOW THE LOAD TO DROP CAUSING
PROPERTY DAMAGE, SEVERE INJURY OR DEATH. TO ENSURE
PROPER REINSTALLATION, REFER TO PROCEDURES AND
TESTS DESCRIBED IN “INSTALLATION” AND
“OPERATING INSTRUCTIONS”.
PAGE 18 271 REV.970407

RECOMMENDED MAINTENANCE
Winch gear train lubricating oil should be changed after the initial six months or 50 hours of operation, whichever
comes first. Lubricating oil should then be changed every 12 months or 500 operating hours, whichever
comes first.
Hydraulic system fluid should be changed at least once every 12 months.
For optimum performance over an extended period of time, the following preventive maintenance service should
be done every 12 months or 500 operating hours (whichever comes first):
1) Disconnect all hydraulic hoses and remove the winch from its mounting.
2) Disassemble the winch as per instructions.
3) Discard and replace all O-rings and oil seals.
4) Clean all parts and inspect for wear and damage as per instructions. Replace worn or damaged
parts as required.
5) Reassemble the winch as per instructions.
6) Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting.
When ordering parts for the PULLMASTER Model PL8 planetary winch, always quote the complete model and serial
numbers of the unit.
MODEL NO. _______________
SERIAL NO. _______________

WARNI
PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of
PULLMASTER planetary winches at any time without prior notice and without incurring any obligations.
271 REV.950401 PAGE 19

PARTS REFERENCE - DRUM GROUP
ITEM NO. QTY. PART NO. DESCRIPTION
100 1 22137 END HOUSING

101 1 25237 PIPE PLUG 3/4 - 14 NPT
300 1 20433 PLANET HUB FINAL
310 3 20438 PLANET PIN FINAL
311 3 25122 CIRCLIP ROTOR CLIP C-100
313 3 25411 CIRCLIP ROTOR CLIP SH-100
320 3 20437 PLANET GEAR FINAL
321 6 25098 THRUST WASHER TORRINGTON #TRA 1625
323 51 25308 LOOSE ROLLER 7/32 DIA X 1.50
340 1 20441 SUNGEAR FINAL
341 1 25311 CIRCLIP ANDERTON #A1000-0200
344 1 20450 SUNGEAR STOPPER
400 1 20431 PLANET HUB PRIMARY
402 1 20449 PLANET HUB STOPPER
410 3 20080 PLANET PIN PRIMARY
420 3 20439 PLANET GEAR PRIMARY
421 6 25064 THRUST WASHER TORRINGTON #TRA 1018
423 3 25269 NEEDLE BEARING TORRINGTON #BH1016
440 1 20440 SUNGEAR PRIMARY
500 1 * CABLE DRUM
502 1 20085 CABLE ANCHOR
503 1 25032 PIPE PLUG 1/2 - 14 NPT
505 1 25327 OIL SEAL
507 1 25307 BALL BEARING 080 X 125 X 22 #6016
513 1 25086 CIRCLIP ROTOR CLIP HO-500
520 1 * COUPLING
530 1 20432 BEARING FLANGE
531 1 25327 OIL SEAL
533 1 25307 BALL BEARING 080 X 125 X 22 #6016
535 1 25086 CIRCLIP ROTOR CLIP HO-500
537 6 25118 CAPSCREW - HEX HEAD 3/8 - 16NC X 1.25 GRADE 5
539 1 25109 O-RING -269 8-3/4" ID 1/8" CS
541 6 25037 LOCKWASHER 3/8"
704 1 20449 PLANET HUB STOPPER
23101 WINCH SEAL KIT, CONSISTS OF ITEMS:

505, 531, 539, 707, 710, 711, 751, 753, AND 801.
* These parts very according to cable drum code. Refer to APPENDIX B.
Refer to PAGE 22 for motor seal kit and PAGE 26 for ASSEMBLY DRAWING.
PAGE 20 271 REV.970407

DRUM GROUP
G1085-A
310 321 323 313 411 410 421 423 420 413
502
503
402
311
320
340
101
100
505
507
513
520
344
300 500 341 440 704 400 535 533 531 530 539 541 537
Group drawings may reference more parts than are actually present in a specific assembly. Parts that are referenced
on the drawing but are not on the PARTS REFERENCE list should be ignored.
271 REV.950401 PAGE 21

PARTS REFERENCE - BRAKE GROUP
ITEM NO. QTY. PART NO. DESCRIPTION
700 1 22136 BRAKE HOUSING
703 1 25331 PLASTIC CAPLUG 3/4 NPT THR'D
707 1 25192 O-RING -174 8-3/4" ID 3/32" CS
710 1 20714 BACKUP WASHER FOR 25278
711 1 25278 OIL SEAL
712 1 21377 BRAKE SPACER
714 5 21252 DIVIDER PLATE
715 4 25194 FRICTION PLATE
717 2 25729 SUPPORT WASHER ANDERTON #R.28/40/2.0
720 1 20442 BRAKE HUB
722 1 21193 SPRAG CLUTCH ALIGNER
723 1 25187 SPRAG CLUTCH
724 1 21193 SPRAG CLUTCH ALIGNER
726 1 22672 SPRAG CLUTCH SPACER
730 1 20448 MOTOR DRIVE SHAFT
733 1 25312 NEEDLE BEARING INA #HK3012
750 1 20434 PISTON
751 1 25309 O-RING -370 -90 DURO 8-1/4"ID 3/16" CS
752 10 20028 BRAKE SPRING
753 1 25309 O-RING -370 -90 DURO 8-1/4" ID 3/16" CS
800 1 21973 MOTOR ADAPTOR
801 1 25310 O-RING -012 -90 DURO 3/8" ID 1/16" CS
802 1 * SHUTTLE
803 1 25370 PIPE PLUG 1/16 - 27 NPT
804 1 * ORIFICE PLUG
805 3 25040 PIPE PLUG 1/8 - 27 NPT
807 1 * *
809 1 * PLASTIC CAPLUG 1/8 NPT
823 12 25037 LOCKWASHER 3/8"
861 1 25323 GEAR HOUSING (2" GEARS) COMM. #312 8220 327
865 4 25326 DOWEL PIN COMMERCIAL #391 2082 032
869 2 25315 SEAL - BODY COMMERCIAL #391 2884 050
870 1 21759 PORT END COVER SUB-ASSY WITH PLUGS
875 4 25322 BEARING - ROLLER COMMERCIAL #391 0381 906
877 2 25908 SEAL - RING COMMERCIAL #391 2585 024
881 1 25317 GEAR SET (2" GEARS) COMM. #312 2820 007
885 2 25320 THRUST PLATE COMMERCIAL #391 2185 059
887 1 25321 SEAL STRIP COMMERCIAL #391 2882 051
899 2 25031 PIPE PLUG 1/4 - 18 NPT
929 1 * *
950 1 * SUB-ASSY MOTOR WM31 (2" GEARS)
951 4 25324 CAPSCREW - HEX HEAD 5/8 X 5.25 GRADE 5
953 4 25325 WASHER COMMERCIAL #391 3784 028
955 2 25556 PLASTIC CAPLUG 1.312" - 12
970 2 ** TIE BAR
973 16 25328 LOCKWASHER 7/16"
23131 MOTOR SEAL KIT, CONSISTS OF ITEMS:

869, 877, AND 887.
MOTOR SUB-ASSY, ITEM 950, CONSISTS OF ITEMS:

800, 802, 803, 804, 805, 807, 809, 861, 865, 869, 870,
875, 877, 881, 885, 887, 899, 929, 951, 953, AND 955.
* These parts vary according to brake code. Refer to APPENDIX C.

** These parts vary according to drum code. Refer to APPENDIX B.
Refer to PAGE 20 for winch seal kit and PAGE 26 for ASSEMBLY DRAWING.
PAGE 22 271 REV.970407

PRIOR TO SERIAL NO. 37869:
Item 723 - Was Part No. 25071 (Borg Warner sprag clutch # X13143 - Qty. 2)
Item 726 - Omitted
271 REV.950401
717 723 724 712 715 714 752 751 804 801 805 809 807 800 802 803 950
710 953
929
869
951
955
970
971
973
877
899
BRAKE GROUP
870
875
887
730 885
733 711 722 720 726 727 700 750 703 753 707 823 821 865 731 861 881
Group drawings may reference more parts than are actually present in a specific assembly. Parts that are referenced
G1084-B
PAGE 23
on the drawing but are not on the PARTS REFERENCE list should be ignored.
OPTIONAL EXTERNAL
BRAKE RELEASE
PAGE 24
PORT 1/8-27 NPT
C D
CIRCULATION PORT 3/8NPT COUNTER-CLOCKWISE
(EXTERNAL CIRCULATION
MODELS ONLY)
PRESSURIZE FOR
FILLER PORT FILLER PORT PRESSURIZE FOR CLOCKWISE
3/4 - 14 NPT 1/2 - 14 NPT COUNTER-CLOCKWISE ROTATION
ROTATION
MOTOR PORTS
SAE O RING BOSS
SEE MOTOR CHART
FOR SIZES
F
ø A L
E
ø B
K
M
.63
4 MOUNTING HOLES DRAIN PORT [16]
21/32 DIA [16.6]
3/4-14 NPT GAUGE PORTS
USE ø 5/8 BOLTS
1/4-18 NPT
GRADE 5 OR BETTER
1.3 R c/c
H c/c
[34]
3.2
G
[81] S
J I
INSTALLATION DIMENSIONS
Standard cable anchor is suitable for 3/8 - 9/16 inch diameter rope.
FOR SAFETY: A minimum of 5 wraps of wire rope

must be maintained at all times.
271 REV.051117
I1024-1-C
INSTALLATION DIMENSIONS
I1024-2
DRUM
CODE A B C D E F G H J K M R S
in 9.6 14.1 8.0 5.9 14.3 14.3 13.3 10.557 16.5 9.1 7.25 11.750 16.0
-1
mm 244 359 203 150 364 364 337 268.15 420 230 184.2 298.45 406
in 9.6 14.1 10.0 5.9 14.3 14.3 15.3 12.557 18.5 9.1 7.25 11.750 16.0
-2
mm 244 359 254 150 364 364 388 318.95 471 230 184.2 298.45 406
HYDRAULIC MOTORS
COMMERCIAL WM31 SERIES
MOTOR GEAR MOTOR PORT SIZE

CODE WIDTH SAE O-RING
I L
2.00 in 6.0 5.4
- 30 1 5/16 - 12
50.8 mm 152 137
1.75 in 5.8 5.4

- 31 1 5/16 - 12
44.5 mm 146 137
1.50 in 5.5 5.4

- 32 1 1/16 - 12
38.1 mm 140 137
1.25 in 5.3 5.4

- 33 1 1/16 - 12
31.8 mm 133 137
271 REV.950401 PAGE 25

ASSEMBLY DRAWING
G1085-A & G1084-B-A
PAGE 26 271 REV.950401

APPENDIX A
LINE PULL LINE SPEED

LUBRICATING
AT MAXIMUM AT MAXIMUM OIL
CABLE DRUM SIZES WIRE ROPE STORAGE
PRESSURE* VOLUME* VOLUME
DRUM INCHES FEET REQUIRED
CODE (MILLIMETERS) (METERS)

U.S.
POUNDS FEET/MINUTE GALLONS
(KILONEWTONS) (METERS/MINUTE) (LITERS)
BARE FULL BARE FULL
BARREL FLANGE LENGTH 9/16 in 1/2 in 7/16 in DRUM DRUM DRUM DRUM
-1 9.6 14.1 8.0 140 196 215 7000 5202 122 164 .5
(244) (359) (203) (43) (160) (66) (31.1) (23.1) (37) (50) (1.9)
-2 9.6 14.1 10.0 175 245 269 7000 5202 122 164 .8
(244) (359) (254) (53) (75) (82) (31.1) (23.1) (37) (50) (3.0)
* Performance specifications are based on standard hydraulic motor with 1/2 inch diameter wire rope.
271 REV.991224 PAGE 27

APPENDIX B
ITEM
DRUM 500 520 970

CODE
CABLE DRUM COUPLING TIE BAR
-1 20430 - 20436
-2 20820 20826 20819
PAGE 28 271 REV.960215

APPENDIX C
BRAKE CODE
-3 -4 -5 -6 -7 -8 -9 - 10
ITEM PART
NO. DESCRIPTION
PART NUMBERS
802 SHUTTLE N/A 20849 20849 N/A N/A 20849 20849 N/A
ORIFICE
804 PLUG 21720 21720 21720 21720 N/A N/A N/A N/A
1/8-27 NPT
804 PIPE PLUG N/A N/A N/A N/A 25040 25040 25040 25040
1/8-27 NPT
807 PIPE PLUG 25040 N/A N/A 25040 25040 N/A N/A 25040
1/8-27 NPT
807 PIPE N/A 25622 25622 N/A N/A 25622 25622 N/A
ADAPTOR
809 1/8 NPT N/A 25374 25374 N/A N/A 25374 25374 N/A
CAPLUG
3/8 NPT
929 CAPLUG N/A N/A N/A N/A 25393 25393 25393 25393
3/8-18 NPT
929 PIPE PLUG 25085 25085 25085 25085 N/A N/A N/A N/A
MOTOR
950 SUB-ASSY 22026 22027 22028 22029 22303 22083 22084 22304
271 REV.950401 PAGE 29

BOLT TORQUE CHART
BOLT DIAMETER TORQUE TORQUE

Inches lb-ft Nm
1/4 9 12
5/16 18 24
3/8 32 43
7/16 50 68
1/2 75 102
9/16 110 149
5/8 150 203
3/4 265 359
7/8 420 569
1 640 868
1 1/8 800 1085
1 1/4 1000 1356
1 3/8 1200 1627
1 1/2 1500 2034
NOTE: Unless otherwise specified, torque bolts per above chart.
PAGE 30 271 REV.950401

22 0262608-50 O-RING, ARP-259 90 DURO ** 1 11 A2688 VALVE, BLEEDER,MANUAL 1 ITEM PART NUMBER DESCRIPTION QTY
23 0264200-50 BACKUP RING, ARP-259 ** 1 12 B10723-00812 WEAR RING,BRASS ** 1 1 SEE CHART BARL ASY,HYCO, 9.42 OD, DA 1
24 079-00002-00400 BUFFER RING ** 1 13 B10764-00700 WEAR RING ** 1 2 SEE CHART SLEEVE ASY,HYCO,8.12,DA,PLATED 1
25 0263980-42 U-CUP, 4.625 X 4.00 ** 1 14 B10764-00600 WEAR RING ** 2 3 SEE CHART SLEEVE ASY,7.00,PLATED 1
26 080-00001-00400 WIPER, CANNED ** 1 15 090-00001-00650 PISTON SEAL, CAPPED T ** 1 4 SEE CHART PLUN ASY,4.00,DA,PLATED 1
27 083-10001-00462 RET RING, INT 1 16 B9971-00862 RET RING, INT 1 5 011-93002-00125 GLAND,RET,9.31-12 THRD,K-WIPER 1
28 FS-901100 PLUG, .50 NPT, SQ HD 2 17 B9971-00750 RET RING, INT 1 6 011-79007-00125 GLAND,RET,7.94-12 THRD,K-WIPER 1
29 FS-910401 PLUG, .12 NPT, SQ HD 1 18 034-00022-00812 KIT,BUILD.HYCO20,PACK,K WIPER ** 1 7 011-69001-00156 GLAND,RET,6.94-12 THREAD 1
30 B15253 LABEL KIT (TO SHIP SEPARATE) 1 19 B12075-00812 GUIDE RING, TOP ** 1 8 A20419 SCREW,SET,.312-24 X .31 LONG 3
31 034-86001-83124 KIT, SEAL (ITEMS MARKED **) REF 20 B12075-00700 GUIDE RING, TOP ** 1 9 A20420 SLUG,NYLON ** 3
21 0264143-7 WEAR RING, GLAND 4.0 X 1.0 ** 1 10 005-65002-00325 GLAND 1
LOCATE BLEEDER VALVE IN RELATION

TO THE BASE END PIN HOLE
CENTERLINE AS SHOWN.
28 1/2 NPTF PORT MARK PART NUMBER, SERIAL NUMBER,
DATE CODE AND LOGO PER
"EXTEND" STANDARD SPECIFICATION 800A58.
9
23 8
12 13 14 15 1 2 3 4 16 18 17 19 5 20 6 21 22 24 25 26 7 10 27
2.44
1/8 NPTF BLEEDER 11
SHOWN OUT OF POSITION THIS VIEW
SEE END VIEW FOR TRUE LOCATION.
TYP. 2.00
1/2 NPTF PORT 28
"RETRACT"
O 1.77
2.00 O 1.77
O 8.12 O 7.00 O 4.00

O 3.69
2.25 1.75
R 1.75
O 9.42
3.12
NOTE:
SPECIAL PRESSURE TEST REQUIRED!!
1/8 NPTF PORT 29 1) TEST CYLINDER AS NORMAL PER TEST SPEC HTS-3.
2.25 O 10.00 2) ADDITIONAL PRESSURE TEST AS FOLLOWS:
3) PRESSURE TEST CYLINDER IN RETRACT 1.5 TIMES THE OPERATING
A TOTAL STROKE PRESSURE. MAINTAIN PRESSURE FOR 10 MINUTES.
B CLOSED 4) PRESSURE TEST CYLINDER EXTEND 1.5 TIMES THE OPERATING
C EXTENDED PRESSURE. MAINTAIN PRESSURE FOR 10 MINUTES.
5) RECORD TEST DATA: (REF FORM F100295E11)
DATE
CYLINDER PART NUMBER
CYLINDER SERIAL NUMBER
TEST PRESSURE
50162-813-13150 131.50 60.00 191.50 002-86050-05207 062-81019-05019 062-70024-05162 063-40220-05500 42.82 44.07 44.62 SD83CC-24-131 RETACT TEST TIME
CYLINDER NO. A REF B REF C REF ITEM No.1 ITEM No.2 ITEM No.3 ITEM No.4 STROKE STROKE STROKE EXTEND TEST TIME
REPLACES
1ST STAGE 2ND STAGE 3RD STAGE
PAINT SPECIFICATION: RED OXIDE 6) RETRACT CYLINDER. DRAIN AND PLUG PORTS.
STAGE DIAMETER 8.12 OD 7.00 OD 4.00 OD OPERATING PRESSURE: 2000PSI HYCO ALABAMA, LLC
DRAWING TITLE:
51.78 in 2 38.48 in 2 33.18 in 2 PROOF PRESSURE: 3000 PSI ARAB, ALABAMA 35016
EXTEND AREA
MAX. EXTEND FLOW: 60 G.P.M.
218 ARAD THOMPSON RD CYL,SATEL W/LAST STAGE DA
RETRACT AREA 20.62 in 2 USA
DRAWN BY: DATE: DRAWING NO:
FORCE @ 2000 PSI (EXT) 103,697 lbs 76,969 lbs 66,366 lbs TEST SPECIFICATION: SEE NOTE!! ORIGINAL DRAWING
W HEN BOX IS RED
DG 02/22/07
SAFETY FACTOR: 2:1 TO YIELD This print is provided on a restricted basis and is not to be
A RELEASED FOR APPROVAL 4/23/07 4415A FORCE @ 2000 PSI (RET) 41,233 lbs used in any way detrimental to Hyco International, Inc.
APPR BY:
JLL
SCALE:
50162-813
REV DESCRIPTION DATE E.C.O.# CHROME PLATED PLUNGERS: YES 04/20/07 3/4=1

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Dragon Rigs COOPER SP-550 Page 1 of 1

Sales and Service WORKOVER RIG

PARTS AND SERVICE MANUAL

CUSTOMER ATINA INVESTMENT CORP

1. RIG UP AND RIG DOWN INSTRUCTIONS

3. CARRIER AIR SYSTEM:

4. CARRIER HYDRAULIC SYSTEM:

6. CARRIER AXLES [STEER, DRIVE, & TAG:

7. CARRIER ENGINE/TRANSMISSION PACKAGE:

- ASSEMBLY DRAWING—DRAWWORKS BRAKE SYSTEM

9. CLUTCHES AND POSI STOP SYSTEM:

11. SERVICE WINCH:

12. MAST, DRAGON PRODUCTS, 104-250-8-T:

I. SPOTTING RIG ON WELL

II. RAISING/LOWERING THE MAST

NOTE: AIR IN A HYDRAULIC SYSTEM CAN CAUSE ACCIDENTS.

A. Unhook the mast from the headache rack.

III. TELESCOPING THE MAST

IV. MAST RIGGING

V. TO LOWER UPPER SECTION

A. Engage hydraulic pump.

VI. TO LOWER MAST ONTO HEADACH RACK

- MANUFACTURER—DRAGON PRODUCTS, LTD.

MAST RAISING RAMS:

RIGHT ANGLE DRIVE:

- MANUFACTURER—DRAGON RIGS SALES AND SERVICE, LTD.

FRONT STEERING AXLES:

- FRONT TIRE SIZE—425/65R22.5 [FOUR REQD]

POWER STEERING PUMP—ENGINE MOUNTED:

- MODEL NUMBER—P37X378BAJC 25-7

LUBRICATION TYPE DAILY WEEKLY MONTHLY

1) Fits in 17−3/4" x 9−3/4" x 9−1/2" Envelope. This includes

SKU# Product Description Heater Notes OEM Part Number

SKU# Product Description Application Notes OEM Part Picture

Figure 18: 2-HA-1 PILOTAIR Valve Cam Housing Exploded View

REF. QTY. DESCRIPTION NEW PART NO. OLD PART NO.

COMPLETE VALVE PIECE NUMBERS

Figure 19: 2-HA-2

13D† 1 DETENT (5-Position Detent Models Only) R431004977 P -059305-00000

22 1 Plug, Valve R431005364 P -060028- --- ---

NEW PART NO. OLD PART NO. QUANTITY DESCRIPTION

Complete Device P-50973-000X P-50972-000X P-55446-000X P67556-000X P50970-000X P-51868-000X

43 1 Brake Assembly includes 850187 850187

Chrome plated HD-2 Controlair® Valves

Features and Specs

Item Part No. Description WM453M WM453M2 WM453M3 WM453N

Service Kit Information

Kit Service Kit Number Item Numbers

WM453M 116731 0-60/70 PSI 70 PSI 11.35 in Toward Heel

www.grote.com U.S. 800.457.9540 Canada 800.268.5612

SuperNova® Stop/Tail/Turn LED Lamp Power Module with

PRODUCT NUMBER TECHNICAL SPECIFICATIONS

mhtml:file://Z:\ENGINEERING DATA\ELECTRICAL COMPONENTS\Grote Industrie... 12/23/2009

www.grote.com U.S. 800.457.9540 Canada 800.268.5612

SuperNova® Stop/Tail/Turn LED Lamp Power Module with

PRODUCT NUMBER TECHNICAL SPECIFICATIONS

mhtml:file://Z:\ENGINEERING DATA\ELECTRICAL COMPONENTS\Grote Industrie... 12/23/2009

www.grote.com U.S. 800.457.9540 Canada 800.268.5612

SuperNova® LED Oval Stop/Tail/Turn Lamp