bremach t-rex fire
DESCRIPTION
Bremach T-REX FireTRANSCRIPT
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SupplementalInformationforEQUIPMENTMANUFACTURERS
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TABLEOFCONTENTTableofContent.................................................................................................................................................................2
INTRODUCTION...............................................................................................................................................................3
GeneralInformation...................................................................................................................................................3
Dimensionsandweights.................................................................................................................................................4
Centreofgravityposition...........................................................................................................................................7
Instructions.....................................................................................................................................................................8
Injuryprevention........................................................................................................................................................8
CHASSISMODIFICATIONS...............................................................................................................................................9
Specialprecautions.....................................................................................................................................................9
Electricalsystem:........................................................................................................................................................9
Rustandpaintprotection.........................................................................................................................................10
Framewelding..........................................................................................................................................................12
Subframe..................................................................................................................................................................12
Links..........................................................................................................................................................................13
Tippingplatforms......................................................................................................................................................14
Craneinstallation......................................................................................................................................................15
Frontsnowequipmentinstallation..........................................................................................................................17
Towingapplication....................................................................................................................................................19
Towinghookapplication...........................................................................................................................................20
POWERTAKEOFF(PTO)...............................................................................................................................................21
Engine(crankshaft)PTO...........................................................................................................................................23
GearboxPTO.............................................................................................................................................................24
TransferboxPTO......................................................................................................................................................25
FPTENGINECHARACTERISTICSCURVE:....................................................................................................................27
Chassis..........................................................................................................................................................................28
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INTRODUCTIONGENERALINFORMATIONThisdocumentgivesdirectionsandrecommendationsforvehiclemodificationsandfor
installation of custom bodies and structuresmade by independent builders onto the
vehicle.
The installationofanyequipmentontothevehiclemustbeauthorizedbyBREMACH
throughformalclearancewhichisreleasedonlyafterfeasibilityinvestigation.
The clearances issuedby themanufacturer shallbe consideredasvalidonly for the
requested installationormodification; the compliance to requirements, suggestions
and information contained in these rules, designed to ensure the functionality and
vehiclesafety,doesnotexempttheindependentbuilderfromtheresponsibilityofthe
differentachievements(project,execution,etc.)
ItistheIndependentbuildersresponsibilitytodotheinstallationsormodificationsina
professionalmanner.
Themanufacturerreservestherighttoinvalidatethewarrantyonthevehicleincase:
Thepresentruleshavenotbeencompliedwith
Thechangestothevehiclewerenotauthorized
Thechassisisnotsuitablefortheinstalledequipment
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Allmodifications and special use applications acceptedwill have to guarantee the
properandsafefunctioningofalloriginalvehicleparts.
Themodifiedvehiclemustbecapableofsafeoperationunderallproposedonroad
and/oroffroadintendedoperatingconditions.
Themodificationsand/orinstallationofadditionalequipmentmustnotmakethefinal
vehicle tobeoutof compliancewith Federal,Stateand Localapplicable safetyand
otherlawsandregulations.
TheIndependentbuilderhastoprovideatthevehicledelivery,whennecessaryforthe
added equipment instructions for its service andmaintenance and safe and proper
operation.
DIMENSIONSANDWEIGHTS
Thedimensionandmaximumweightsallowedontheaxlesarerelatedonthetechnical
descriptionsandontheofficialdocumentsreleasedbythemanufacturer.
Thetares included inthedocumentsconcernthevehicleswithstandardequipment; if
anyspecialequipmentinvolveschangesinweightsandintheweightdistributiononthe
axles,themodifiedinformationmustbesuppliedtotheenduserofthevehicle.
Note:Specificationweightsmayhave+/5%varianceduetoproductionvariations.
Beforecarryingoutanymodificationitisnecessarytoweighthechassis.
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Todefinethepositionofthepayload,thecenterofgravity,etc.
Youcanproceedaccordingtotheexampleshownbelowandonnextpage:
Wb W L
Wa W=payload(completewithinstalledthesuperstructure)
Wa=payloadloadingonthefrontaxle
Wb=payloadloadingontherearaxle
L=rearaxledistancefromthecenterofgravity
P=wheelbase
WWWP
WWPL ba ==
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Themeasuredorcalculatedresultshavetobecomparedwiththeabsoluteweightlimits
forthevehicleasperthemanufacturersdocumentation.
Particularly important istheweightonthefrontaxle, inordertoassurethenecessary
steeringattributes,inanyloadconditionandonanyroadsurface.
TheGAWRF (Gross AxleWeight Rating FRONT)must not be exceeded under any
circumstances.
Pay specialattention tovehicleswith loadconcentratedon the rearoverhang (crane,
rearexcavators)andwithelevatedcenterofgravityheight.
Therearsuperstructureoverhanghastobebuiltincompliancewiththeallowedloads
ontheaxles,therestrictionsforthelength,andthepositionoftherearbar.
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CENTREOFGRAVITYPOSITION
Regarding the allocation of the payload on the axles,we consider that it is equally
distributed, except in caseswhere the shape of load floor leads to a different load
distribution.
Obviously, for theequipment youhave to consider the centerof gravity in its actual
location.
For the superstructure installation you will need to provide loading and unloading
systems, in order to avoid excessive variations of the distribution, and/or excessive
loadsontheaxles.
Youhave todistribute loaduniformlybetweenRight and Left sidesof the vehicle, in
ordertonotaffectthebehaviour,particularlythebrakingeffect.
Themaximumequipmentheightallowedisspecifiedonourapprovaldocuments.
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INSTRUCTIONSFollowprovidedinstructionsfortheproperfunctioningofthevehiclewiththeaddedequipment.
Themodificationsandspecialuseapplicationsmustnotalter thevehicle functionality
duringthenormaloperation,beitonroadoroffroad.
ForExample:
Easyaccessatthepointsthatrequiremaintenanceandperiodicinspectionsmustbe
retained. In thecaseofclosed typeof superstructure, itmustbeprovided special
openings,coversordoorstoalloweasyaccesstoanyrequiredservicepoints;
Design for the possibility to access, remove or disassemble any components that
mayneedtobeserviced,forexample.
Assurethesamecoolingconditionsexistandanyrequiredairflow isnotrestricted
by theadditionalequipment (radiatorgrille, radiator,airpassages, cooling circuit,
etc.).
Any installedmudguardsand/orwheelarchesshouldassuretherearwheelshave
adequateroomforfreemotion,evenwhenchainsorspecialtiresarefitted.
Any exterior projectors have to be checked after the vehicle modification is
completed and for safety reasons if required additionalmarkings such as reflex
safetytapeorilluminatedmarkershavetobeinstalledifnecessary.
It isthe Independentbuildersresponsibilitytoaffixanypartssupplied loose,with
any incomplete vehicle, subject to any applicable safety or other rules or
regulations.
InjurypreventionAny structure and devices installed onto the vehicle have to comply with the any
Federal,StateorLocallawsandrequirementsapplicabletothepreventionofinjury.The
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compliancewith these requirementswill have to be addressed by the Independent
builderthatinstallstheadditionalequipmentormodifiesthevehicleinanymanner.
CHASSISMODIFICATIONS
SPECIALPRECAUTIONSDuring welding, drilling, grinding and cutting operations close to the brake system,
particularlyifinproximityofplasticbrakelinesand/orelectriccables,takeprecautions
fortheirprotection,andifnecessaryremovethesepartsduringthecustomizationwork.
ELECTRICALSYSTEM:
1) ALTERNATOR:
a) Inordertoavoiddioderectifierdamage,thebatterymustnotbedisconnectedwhentheengineisrunning.
b) Incaseyouneedtostartthevehiclebytowing,makesurethebatteryisconnected.c) Ifyouneedtodoabatteryquickcharge,Disconnectbatteryfromthevehiclecircuit.
2) GROUNDCONNECTIONS:
a) Itispreferablethatoriginalvehicleconnectionsarenotalteredb) Ifitisnecessarytomovetheselinks,makesurethattheyprovidepropergroundingtothe
vehiclemassandensuretheyareeffective.
3) ELECTRICALCABLES:Theelectricalcableshavetobeconnectedbyjunctionsofthesametypeusedoriginally.Theaddedcablelengthhastobeprotectedbyaspecialsheathappropriatelyfixedwithbrackets.
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RUSTANDPAINTPROTECTIONAll the vehicleparts (chassis, cab, etc.) that aremodifiedhave tobe protected from
oxidationandcorrosion.Theprotectionandpaintingoperationshavetobeperformed
accurately on the added parts, in accordance with the vehicle manufacturer and
adoptingmethodsanddevicesprovidedbythepaintmanufacturer.Specialprecautions
have to be taken to protect those partswhere the paint could be harmful to their
operation and/or protection (gaskets, rubber parts, flexible pipes, shafts and PTO
flanges,hydrauliccylindersetc.).Incaseofdismantlingwheels,youhavetoprotectthe
areabyhubsattack,inordertoavoidthicknessincreaseandmainlypaintaccumulation
onthewheeldiscflange
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CHASSISSECTIONANDMATERIALSUSED
COMPLETECHASSISBEAMMATERIALTubeMaterial: S355JLBreakResistance: Rm510/680N/mm2YieldLimit: ReH355N/mm2Elongation: >20%CBEAMMATERIAL: S420MCBreakResistance: Rm480/620N/mm2YieldLimit: ReH420N/mm2Elongation: >19%LOCALREINFORCEMENTS: S235JOBreakResistance: Rm360/510N/mm2YieldLimit: ReH235N/mm2Elongation: >24%
3.5tchassis 6.0tchassiswheelbases2600 3100mm
6.0tchassiswheelbase3450mm
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FRAMEWELDINGThewelding has to be carried out only by qualified and trained personnel andwith
appropriate equipment. During the welding operation connect the welder ground
directly to thepart, inorder toprotect theelectric components (battery,alternator),
andmakesurethatthenegative()clampisdisconnectedfromthebattery.
Anyplasticpipeshavetobeprotectedorremoved.Thepartstobeweldedhavetobe
withoutpaint;thereinforcedpartshavetobedeoxidized.Aftertheworkiscompleted,
themodifiedpartshavetobeprotectedeffectivelyagainstrust.SUBFRAMEThepurposeofsubframeistoensureanuniformloaddistributiononthevehiclechassis
andprovidevehicleimpactresistanceandstiffness,dependingonthevehicleuse.
Forthesubframeinstallation,note:
thematerial used for reinforced subframe and the supports for various equipment
musthavegoodweldabilitycharacteristicsandmechanicalpropertiesnotlessthan:
Rm>360N/mm(37kg/mm)i.e.Fe360C
ReH>235N/mm(24kg/mm)
A>25%.
Theadditionalstructuresparsshallbecontinuous,extendedas faraspossible toward
thefrontofthevehicle.
Theprofilesectionshape isdefinedby taking intoaccount thesubframe functionand
thetypeofsuperstructure.
Toconnectthetwobeamsofthechassis,asufficientnumberofcrossbeamswillhave
tobeplacedat the connectionsareas.For the crossmemberswe recommendopen
profiles (i.e.: C shaped) or box sections where higher stiffness is needed. To
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guaranteeenough resistance to theconnections,appropriate reinforcementsmustbe
added.
LINKSThe choice of the link type used, it is very important for the contribution of the
subframeintermsofstrengthandstiffness
Itmay be elastic or rigid type, resistant to shear forces (longitudinal and transverse
sealing plates); the choice must be made taking into consideration the kind of
superstructure to be applied, and considering the stresses that the equipment shall
forwardtothevehicleframeduringstaticordynamicconditions.
Number, size and fixing implementation, adequately distributed in the length of the
subframe,mustbesuchastoensureagoodconnectionbetweenthevehiclechassisand
subframe
Thescrewsmusthavematerialwithstrengthclassnot lessthan8.8,thenutsmustbe
fittedwithunscrewingsystem.
Theoriginalconnectionelementspresentonthechassishavetobeusedinpreference,
ifpossible.
Elastictypeconnectionsallowlimitedmovementbetweentheframeandsubframeand
leadtoconsidertworesistantsectionsthatwork inparallel, forthechassis frameand
added subframe;each structurewill takepartof thebendingaccording to its inertia.
Therigidconnectionofthetwosectionscanbeconsideredasasingleresistantsection,
ontheconditionthatthenumberanddistributionconnectionsaresuchastowithstand
theresultingstresses.
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TIPPINGPLATFORMSTheuseof tippingplatforms,both rear and trilateral generally subjects the frame to
considerablestresses.
Theinstallationmustalsobecompliedwithanyrequirementsunderthenationallaw.
Note:
The pivot positioning for tipping should be as close as possible to the rear
suspensionsupport,inordernottoaffectthevehiclestabilityduringthetippingand
tonotincreaseexcessivelythestressesonthechassis.
Pay special attentionwith the lifting device position both to establish necessary
supportstrength,andtorealizeanaccurateandconvenientconnections;itsposition
shouldbebeforethebodywiththepayloadcenterofgravity,inordertoreducethe
localizedloadweight.Theeffectivebodyvolumeshouldbeadjusted,inregardwith
themaximumweights allowed on the axles, to thematerial goodweight to be
carried (considered for thematerialexcavatedaspecificweightofabout1600kg/
m)
Thebodybuilderwilltakecaretopreservethefunctionalityandvehiclepartssafety,
incompliancewiththeexistingrules.(lightposition,hook)
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CRANEINSTALLATION
The crane should be chosen taking into account its technical characteristics (crane
weigh,maximumtorque)andvehicleperformances.
The cranepositionand thepayloadwillbe carriedout in compliancewith load limits
permittedforthevehicle.
Applying the crane, observe the legal requirements specific to it, and check those
requiredforthevehicle.
During thecraneworkphase, thestabilizers (possiblyhydraulic)willbeplacedand in
contactwiththeground.
The numbers of stabilizer and subframe installation (in particular for its tensional
rigidity: box sections, bars, etc) have to be done taking into consideration the crane
maximum liftingmomentandcraneposition.Vehiclestabilityverificationduringcrane
workingshouldbecarriedoutaccordingtotheregulations.
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FRONTSNOWEQUIPMENTINSTALLATIONThe application of snow equipments in front of the vehicle (snowplough) should be
realizedthroughappropriatesupportstructures. Itshouldbemetalltherequirements
andnationalregulationsgoverningtheapplicationofthisequipment
During snow equipment use,with amaximum speed of 40 km/h (25MPH),may be
allowed(uponrequest)toincreasethemaximumpermissibleloadonthefrontaxle.
Thecompliancewiththe loadrequiredhavetobedocumentedandguaranteedbythe
companythatmakestheinstallation
The snow installationmust entail the installation of two additional projectors to be
mountedontheframeforextraheadlightssupportappliedtothesnowploughitself.
Itisalsostrictlyprohibited,andthereforenotauthorized,toperformanytypeofdrilling
onthespaceframe.
Plate placed in the front of the twoside members, to connect thesnowploughsupport
Hole useful for lower snowploughconnection,forlongitudinalreaction.
11055
110
55
80 4
0
15075
N 4 through hole M12x1.75
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Attachmentscontrol fromthecab
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TOWINGAPPLICATION
Thewinchapplicationisnormallyperformedinthefollowingpoints:
Onthefrontofthechassis
Ontherearofthechassis
The applicationmustbemade inorder tonot affect theproper vehicle groupparts
functioning, in compliance with the heavyweights on the axes and following the
instructionsofthewinchmanufacturer.
The fixingof thegroupandbodieson thevehicle frame,shouldbeperformed taking
care to reinforcenotonly locally, theattackareasdependingon the shot ropewinch
andparticularlyofitstransversecomponent,wherethetractionisoblique.
The poweroperatedwinches are used for low power and short duration, given the
limitedcapacityofthebatteryandalternator.Complywithanysafetyrequirements.
Plate applied before incorrespondence of the two sidemembers, which will support theattachmentofwinch
11055
110
55
80 4
0
15075
N 4 through hole M12x1.75
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TOWINGHOOKAPPLICATION
BREMACHvehiclesareoutfittedfortowinghookandtowingballmounting.
The towinghookapplication ispossibleusing theappropriatedrilling situatedon the
rearcrossbar.
Thetowingballhasbeequippedwithanappropriatesupport,connectedontheupper
sidetothecrossbeamandbelowconnectedtotherearprotectionbarfixingbrackets.
Rear crossbar with mounting hole for the towing hook and towing ball
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POWERTAKEOFF(PTO)
Forauxiliaryequipment control suchas tipper, craneandmunicipal vehicles,different typesofpowertakeoffscanbefitted.Dependingonrequiredperformancesanduse,theapplicationcanbefittedon:
1. GEARBOX2. TRANSFERBOX3. ENGINE4. ONTHEREAROFTHEVEHICLE
Specificationsandperformancesareindicatedonpowertakeoffsheetattached.Fordefiningthenecessarypowerforinstrumentscontrol,especiallyifhighvaluesarerequired,itisappropriatetoconsider also assimilated losses during the power transmission phase (510% for mechanicaltransmissions,beltsandgearsandhighervaluesforhydrauliccontrols).Selectionofpowertakeoffratiohastobemadeinsuchawaythepowerabsorptionoccursintheengineconstanttorquerevingrange:lowspeeds(lowerthan1000RPM)havetobeavoided.Transmissionkinematicmechanism(angles,revs,torque)hastobecarefullyconsidered,fromthepower takeoff to the device, during the design step, and the dynamic behaviour inworkingsituation, as prescribed by the transmission manufacturer. In calculating process, values ofmaximumpowerandmaximumtorque,havetobeconsidered.Tohavegoodconstantspeedbehaviour,angleswith the samevalueat the jointsare required.Thedesignshouldavoidtoohighangularvalues.Example:ZsolutionisnormallypreferredtotheWshownbelow.
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Forfurtherexplanationorforinstallationofgroupswithspecialcharacteristics,contactBREMACH Technical Dept. Presentation and approval for any transformation by theCompetentAuthority,arereservedtothesupplier,aspernationalregulations.
EnginePTO
GearboxPTOTransferbox
PTO
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ENGINE(CRANKSHAFT)PTOIfPTOisattachedtothecrankshaft,canbeusedbothwiththevehiclestandingorwhileitisbeingdriven.ThisPTOdrivesahydraulicpumpthroughpolyVrubberbelt
EnginePTOwithelectromagneticclutch:
ENGINE:FPTF1A(85Kw)PTONotavailable
ENGINE: FPTF1C(107Kw130Kw) withpolyVbelt
POWERTAKEOFF: 13Kw(18hp)@3000rpm(pump) MAX.TORQUE: 41Nm PUMP: AP200/22 DISPLACEMENT: 22cm/rev MAXFLOW: 40l/min MAXPRESSURE: 180bar
PossibilitytofitanintegratedHydraulicSystemonboard:
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GEARBOXPTOThegearboxPTOhastobeusedonlyinneutralpositionand ithastobeengaged/disengagedwhentheclutchisdisengaged
GEARBOX: ZFS6300(F1Aengine)
POWERTAKEOFF: 34Kw@2000rpm(engine) MAX.TORQUE: 180Nm GEARPUMP: 5cm/rev(l/m)
15cm/rev(l/m) 22cm/rev(l/m) 36cm/rev(l/m)
GEARBOX: ZFS6380(F1Cengine) POWERTAKEOFF: 40Kw@2000rpm(engine) MAX.TORQUE: 180Nm GEARPUMP: 5cm/rev(l/m)
15cm/rev(l/m) 22cm/rev(l/m) 36cm/rev(l/m)
ENGINEGEARBOX
RPMENGINEPTORPMOUTPUT
F1AS300 1 0,910F1CS380 1 1,044
PTOLAT.ZF6S300PTOLAT.ZF6S
380VOTORQUE(Nm) 180 180
INSIDERATIO
1,27 1,45
TEETHNUMBER 28 32
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TRANSFERBOXPTOTransfer box PTO is normally used when the vehicle is stopped. If the applicationrequiresthevehicletobedriving,nochangeofgearhastobedone.ThisPTO,thankstotheuniversaljoint,canhavethedriveontherearchassiscrossbar.Dependingontheusage,thesuitableno.ofrevscanbechosen,selectingthesuitablegearboxselection.
POWERTAKEOFF: 55KW(forhigher/extremeuse,contactthemanufacturer) TORQUE dependingonenginecurveandgearselection UTILIZER: 1)CardanShaft
2)gearpump
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Example:PossibilitytocoolhydraulicoilwithStanleySystemonboard
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IVECO/FPTENGINECHARACTERISTICSCURVE: F1A85Kw270Nm F1C107Kw350Nm F1C130Kw400Nm
Potenza
0
20
40
60
80
100
120
140
500 1000 1500 2000 2500 3000 3500 4000 4500Rpm
KW
F1C 130 KWF1C 107 KWF1A 85KW
Coppia
0
50
100
150
200
250
300
350
400
450
500 1000 1500 2000 2500 3000 3500 4000 4500
Rpm
Nm
F1C 130 KWF1C 107 KWF1A 85 KW
TORQUE
POWER
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CHASSIS
770
860
980800
1290
130060
Lc
dr
df df '
dr '
240 4
38
T / T
1770
/ 17
85 *
2050
(with
larg
er m
irror
s- o
ptio
nal)
1700
1
900
(with
mirr
ors o
f sen
d ra
te)
* with tyre 245/70 R 17.5
3000
:vehicleloadtoMaximumTotalAdmissibleGVW
andtoMaximumRearAdmissibleMass
Dim
ensi
ons r
efer
to
the
wee
lhou
ses
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380
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N.B.Thedimensionsarereferencedtogroundwithatoleranceof20mm
wheelbase extensionGWV. GWV.
S L A B C Lc Ltot3.5t 6.0t
2600
without X X 980 4380 545
1185
1730 2620 4780
200mm X 1180 4580 745 19302800 4960
400mm X 1380 4780 945 2130
3100
without X X 980 4880 1045 2230 4960 4960
200mm X X 1180 5080 1245 2430 5480 5480
400mm X 1380 5280 1445 2630 5680 5680
3450
without X 980 5230 1395 2580 5630 5630
200mm X 1180 5430 1595 2780 5830 5830
400mm X 1380 5630 1795 2980 6030 6030
wheelbase extension GVW GVW T T T' T' 3.5t 6.0t 3.5t 6.0t 3.5t 6.0t
2600
without X XX4934
Xtreme996X4928
Xtreme987X4789
Xtreme852X4764
Xtreme839
200mm X X4939
Xtreme1002Notavailable
X4784Xtreme847
Notavailable400mm X
X4 944Xtreme1007
X4 779Xtreme842
3100
without X XX4929
Xtreme992X4924
Xtreme983X4792
Xtreme855X4766
Xtreme840
200mm X XX4933
Xtreme996X4928
Xtreme987X4788
Xtreme851X4763
Xtreme838
400 X X4938
Xtreme1000Notavailable
X4784Xtreme847
Notavailable
3450
without
X
Notavailable
X4921Xtreme981
Notavailable
X4768Xtreme841
200mm XX4925
Xtreme984X4765
Xtreme839
400mm XX4928
Xtreme987X4762
Xtreme838
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N.B.Thedimensionsarereferencedtogroundwithatoleranceof20mmWheelbase Extension GWV. GWV. df dr df dr
3.5t 6.0t 3.5t 3.5t 6.0t 6.0t
2600
without X XX4822
Xtreme887X4906
Xtreme968X4821
Xtreme887X4902
Xtreme963
200 X X4822
Xtreme887X4905
Xtreme968Notavailable Notavailable
400 X X4 822
Xtreme888X4905
Xtreme968
3100
without X XX4820
Xtreme885X4905
Xtreme969X4820
Xtreme885X4901
Xtreme962
200 X XX4820
Xtreme886X4905
Xtreme968X4820
Xtreme886X4900
Xtreme961
400 X X4820
Xtreme886X4904
Xtreme967Notavailable Notavailable
3450
without X
Notavailable Notavailable
X4819Xtreme885
X4901Xtreme962
200 XX4819
Xtreme885X4900
Xtreme961
400 XX4819
Xtreme885X4899
Xtreme960
wheelbase extensionGWV. GWV df' dr' df' dr'3.5t 6.0t 3.5t 3.5t 6.0t 6.0t
2600
without X X
X4870Xtreme937
X4809Xtreme873
X4826Xtreme873
X4 779Xtreme847
200 X Notavailable Notavailable
400 X
3100
without X XX4826
Xtreme873X4779
Xtreme847200 X X
400 X Notavailable Notavailable
3450
without X
Notavailable NotavailableX4826
Xtreme873X4779
Xtreme847200 X
400 X
DocumentupdatedtoMarch15,2010