SupplementalInformationforEQUIPMENTMANUFACTURERS

2

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

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

4

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.

5

Todefinethepositionofthepayload,thecenterofgravity,etc.

Youcanproceedaccordingtotheexampleshownbelowandonnextpage:

Wb W L

Wa W=payload(completewithinstalledthesuperstructure)

Wa=payloadloadingonthefrontaxle

Wb=payloadloadingontherearaxle

L=rearaxledistancefromthecenterofgravity

P=wheelbase

WWWP

WWPL ba ==

6

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.

7

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.

8

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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17

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

20

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

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

28

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

29

380

30

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

31

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