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PARTS MANUAL MSW 030-E, MSW 040-E (C820) MRW 020-E, MRW 030-E (C821)

Yale Materials Handling Corporation 1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011

P/N 524167345 Â© Yale Corp. 03/2003

MODEL NOMENCLATURE

NOTE: This parts manual contains alternate pages for certain assemblies. The truck model code can be used to determine many of the assemblies on your lift truck (power, tire type, mast type). The complete truck model and serial number are stamped into the nameplate. See Identification of Truck Serial Number on Page vii for further information.

SECTIONS

GENERAL TRUCK

ELECTRICAL SYSTEM

DRIVE UNIT AND BRAKE ASSEMBLY

CONTROL HANDLE

LOAD WHEEL

HYDRAULIC SYSTEM

LIFTING MECHANISM

OPTIONS

NUMERICAL INDEX

USER SUPPORT INFORMATION

This Parts Manual is divided into 10 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

GENERAL INFORMATION

ALPHABETICAL INDEX DESCRIPTION

PAGE NO.

A ABBREVIATIONS QUICK REFERENCE SHEET ................................................................................................... iv ALPHABETICAL INDEX............................................................................................................................................ i B BATTERY DISCONNECT................................................................................................................................... 1-14 BATTERY ROLLER .............................................................................................................................................. 8-2 BATTERY SPACER ............................................................................................................................................ 1-16 C CHAINS, PINS, AND ANCHORS THREE STAGE FULL FREE-LIFT MRW020-030E............................................................................................................................................ 7-10 MSW 030-040E ........................................................................................................................................... 7-12 TWO STAGE LIMITED FREE-LIFT MRW020-030E............................................................................................................................................ 7-14 MSW030-040E ............................................................................................................................................ 7-16 CONTROL HANDLE ARM ASSEMBLY................................................................................................................ 4-2 SEMI-ROTARY.................................................................................................................................................. 8-4 CONTROL HANDLE ASSEMBLY......................................................................................................................... 4-4 OPTIONAL........................................................................................................................................................ 8-6 CONTROL PANEL ASSEMBLY............................................................................................................................ 2-2 COVERS .............................................................................................................................................................. 1-2 E ELECTRIC BRAKE............................................................................................................................................... 3-2 ELECTRICAL ARRANGEMENT .......................................................................................................................... 2-4 EXTENDED CYLINDER ASSEMBLY MRW020-030E ............................................................................................................................................... 7-18 F FORK CARRIAGE MSW 030-040E............................................................................................................................................... 7-42 FORKS HOOK TYPE CARRIAGE ................................................................................................................................. 1-8 FREE-LIFT CYLINDER ASSEMBLY MRW020-030E ............................................................................................................................................... 7-20 MSW 030-040E THREE STAGE FULL FREE-LIFT .............................................................................................................. 7-22 H HEADER HOSE GROUP MRW020-030E ............................................................................................................................................... 7-24 HOW TO FIND THE DESIRED PART NUMBER..................................................................................................... vi HOW TO USE THE ILLUSTRATED PARTS MANUAL ............................................................................................ vi HYDRAULIC POWER UNIT REACH ............................................................................................................................................................. 6-2 i

GENERAL INFORMATION

DESCRIPTION

PAGE NO. H (continued)

WITH AUXILIARY ............................................................................................................................................. 6-4 WITHOUT AUXILIARY S/N C820N-0152Z⇒ ..................................................................................................................................... 6-8 ⇒S/N C820N-0152Z ..................................................................................................................................... 6-6 HYDRAULIC SYSTEM ....................................................................................................................................... 6-10 I IDENTIFICATION OF MAST SERIAL NUMBER ................................................................................................... viii IDENTIFICATION OF TRUCK SERIAL NUMBER.................................................................................................. vii INNER CARRIAGE MRW020-030E ............................................................................................................................................... 7-44 INTEGRAL TILT ASSEMBLY MRW020-030E ............................................................................................................................................... 7-26 WITH SIDESHIFT MRW020-030E............................................................................................................................................ 7-28 L LABELS AND DECALS ........................................................................................................................................ 1-4 LIFT CYLINDER ASSEMBLY MRW020-030E ............................................................................................................................................... 7-30 MSW 030-040E THREE STAGE FULL FREE-LIFT .............................................................................................................. 7-32 TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-34 LIFT CYLINDER INSTALLATION MRW020-030E ............................................................................................................................................... 7-36 MSW 030-040E THREE STAGE FULL FREE-LIFT .............................................................................................................. 7-38 TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-40 LOAD BACKREST MRW20-30E ................................................................................................................................................... 1-10 MSW30-40E.................................................................................................................................................... 1-12 LOAD WHEEL ...................................................................................................................................................... 5-2 FIXED TANDEM.............................................................................................................................................. 8-12 M MASTER DRIVE UNIT ......................................................................................................................................... 3-8 MASTER DRIVE UNIT ASSEMBLY ..................................................................................................................... 3-4 MASTER PART SHEET CROSS-REFERENCE ..................................................................................................... ix O OPERATOR GUARD ............................................................................................................................................ 1-6 THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-14 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 8-16

GENERAL INFORMATION

DESCRIPTION

PAGE NO.

S SCISSOR CARRIAGE MRW020-030E ............................................................................................................................................... 7-48 SIDE-SHIFT ASSEMBLY HANG-ON TYPE............................................................................................................................................... 8-8 SIDE-SHIFT CYLINDER HANG-ON TYPE............................................................................................................................................. 8-10 T TRACTION MOTOR ............................................................................................................................................. 2-6 U UPRIGHTS THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-2 TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-6 Z ZAPI-HANDSET KIT........................................................................................................................................... 8-18 ZAPI-LAPTOP/PC KIT (WINDOWS) .................................................................................................................. 8-19

iii

GENERAL INFORMATION

ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions:

TERM

DEFINITION

TERM

DEFINITION

Amp

Amperes

MSTS

Microprocessor Spark Timing System

As Required

NPT

National Pipe Threads

BDI

Battery Discharge Indicators

O/S

Oversize

BWI

Brush Wear Indicator

PTO

Power Take Off

Communicator End

RPM

Revolutions per Minute

CRE

Corrosive Environment

S/N

Serial Number

D/B

Date Break

TMM

Truck Management Module

dbA

Decibel "A" Scale

UL Type D

Diesel-Powered Safety Rating

Drive End

UL Type DS

Diesel-Powered Safety Rating

ECM

Electronic Control Module

UL Type E

Battery-Powered Safety Rating

ECN

Engineering Change Notice

UL Type EE

Battery-Powered Safety Rating

EEPROM

Electrically Erasable Programmable Read Only Memory

UL Type ES

Battery-Powered Safety Rating

UL Type G

Gasoline-Powered Safety Rating

EPROM

Electrically Programmable Read Only Memory

UL Type GS

Gasoline-Powered Safety Rating

FRE

Freezer Environment

UL Type LP

Gas-Powered Safety Rating

in.

inches

UL Type LPS

LP Gas-Powered Safety Rating

LPG

Liquefied Petroleum Gas

U/S

Undersize

MAP

Manifold Absolute Pressure

Underwriters Laboratory

millimeters

Volts

GENERAL INFORMATION

HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

GENERAL INFORMATION

HOW TO FIND THE DESIRED PART NUMBER WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN: 1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part. 2. Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page. WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN: 3. Determine the assembly the required part is used on. Turn to the Alphabetical Index on Page i. 4. Locate the assembly the required part is used on and turn to the page indicated for that assembly. Then locate the part on the assembly breakdown page. WHEN THE PART NUMBER IS KNOWN: 5. Use the Numerical Index on Page 9-1 to find the part number. Turn to the page listed and locate the part as indicated by the item number. GENERAL: The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts. 6. Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a parts page number in the DESCRIPTION column (☞7A56) 7. Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc. Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly. 8. Indented descriptions under the DESCRIPTION column are used to indicate assemblies and subparts of assemblies. In the example on the previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE. vi

9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly. 10. Serial number breaks identify the most current parts information and are shown as follows: ⇒ S/N A810N-2639 Indicates last serial number affected. S/N A810N-2640 ⇒ Indicates the first serial number affected. S/N A810N-1553 ⇔ S/N A810N-3291 Indicates a range of serial numbers affected. ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows: ⇒ S/N Pending Per ECN 63243 Indicates a pending serial number for last unit affected. S/N Pending Per ECN 63243 ⇒ Indicates a pending serial number for first unit affected. Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows: ⇒ D/B 3/00 Indicates that a change occurred sometime within that month for the item affected. D/B 3/00 ⇒ Indicates that a change occurred sometime within that month for the item affected. D/B 3/00 ⇔ D/B 4/00 Indicates a range of production dates of the item affected. Contact your local dealer for Yale lift trucks for serial number information for items with a ECN or a date break. ORDERING PARTS: When ordering replacement parts, give the unit serial number, part number, name of part and quantity required. For any further information on parts, service, or ordering, consult your local dealer for Yale lift trucks.

GENERAL INFORMATION

IDENTIFICATION OF TRUCK SERIAL NUMBER

NOTE: Serial Number breakdown is only for trucks built after 1994. (1) and (2)

The first letter and three numbers indicate the truck unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number of the truck.

(5)

The final letter indicates the year of manufacture starting with "A" in 1957 and 1980. The letters "I", "O", and "Q" will not be used.

For pending serial numbers contact your local dealer for Yale lift trucks.

Parts referred to in this book as right or left hand parts are in accordance with the illustration above.

vii

GENERAL INFORMATION

IDENTIFICATION OF MAST SERIAL NUMBER

(1) and (2)

The first letter and number indicates the mast unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number of the mast.

(5)

Carriage travel in millimeters stamped just below the serial number.

Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5). For pending production sequence numbers contact your local dealer for Yale lift trucks.

LIFT EQUIPMENT IDENTIFICATION 1. Fork part number, capacity rating, plant code letter, and date of manufacture are stamped approximately six inches below the top of most forks. 2. The carriage group number is stamped on the right hand side of the top crossmember (pin type) or on the back of the right hand end of the bottom crossmember (hook type). A date code has two letters in line with or below the carriage group number. 3. The mast identification number has a unit code, a letter indicating the plant of manufacture, and a serial number. Underneath the production sequence number is a four digit number that indicates the carriage travel in millimeters. 4. Tilt and lift cylinder group numbers are stamped on the cylinder shell. Always refer to the group, serial, or part number when ordering service parts. Modification of masts and carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". contact your dealer for Yale lift trucks for information on these assemblies. viii

GENERAL INFORMATION

MASTER PART SHEET CROSS-REFERENCE NOTE: Throughout this manual are references to Part Sheet Numbers. These references are usually found after the description of a part or assembly. The Part Sheet Number is found on the upper left- or righthand corner of the parts pages. EXAMPLE: ITEM

PART NO.

DESCRIPTION

QTY

31 32

505965530 504224261

Steering Cylinder (â&#x2DC;&#x17E; 6E67)..................................................................................... Pin ............................................................................................................................

1 4

Below is a numerical listing of Part Sheet Numbers found in this parts book and what page number they are on.

PART SHEET

PAGE NO.

G10641................................. 4-2 G10642................................. 5-2 G10643................................. 8-2 G10644............................... 1-14 G10646............................... 1-16 G10647................................. 1-4 G10649................................. 1-2 G10653................................. 2-6 G10670................................. 3-2 G10671................................. 2-2 G10672................................. 3-8 G10675............................... 7-40 G10676............................... 7-34 G10680............................... 7-12 G10681............................... 7-38 G10682............................... 7-22 G10683............................... 7-32 G10707................................. 2-4

PART SHEET

PAGE NO.

G10717............................... 8-12 G10721................................. 1-6 G10723............................... 6-10 G10730............................... 8-16 G10731............................... 8-14 G10732............................... 1-12 G10733............................... 1-10 G10734................................. 1-8 G10738................................. 6-8 G10739............................... 8-18 G10740............................... 8-19 G10741............................... 7-26 G10742............................... 7-28 G10743................................. 8-4 G10753............................... 7-30 G10754............................... 7-20 G10755............................... 7-36 G10756............................... 7-24

PART SHEET

PAGE NO.

G10757............................... 7-10 G10767................................. 4-4 G10770................................. 7-6 G10771................................. 7-2 G10772............................... 7-48 G10773................................. 8-6 G10774............................... 7-18 G10778............................... 7-14 G10779............................... 7-16 G10780............................... 7-44 G10781............................... 7-42 G10880................................. 8-8 G10882............................... 8-10 G10903................................. 3-4 G10912................................. 6-2 G10913................................. 6-4 G10919................................. 6-6

NOTES

SECTION 1

1 GENERAL TRUCK

GENERAL TRUCK

CONTENTS

SECTION 1 GENERAL TRUCK DESCRIPTION

PAGE

BATTERY DISCONNECT................................................................................................................................... 1-14 BATTERY SPACER ............................................................................................................................................ 1-16 COVERS .............................................................................................................................................................. 1-2 FORKS HOOK TYPE CARRIAGE ................................................................................................................................. 1-8 LABELS AND DECALS ........................................................................................................................................ 1-4 LOAD BACKREST MRW20-30E ................................................................................................................................................... 1-10 MSW30-40E.................................................................................................................................................... 1-12 OPERATOR GUARD ............................................................................................................................................ 1-6

1-1

G10649

COVERS

1-2

G10649

COVERS

ITEM

1 2 3 4 5 6 7

PART NO.

DESCRIPTION

524139728 505190200 505189200 524141549 519996802 519996803 580018747

Cover ......................................................................................................................... Plate .......................................................................................................................... Clip ............................................................................................................................ Rivet .......................................................................................................................... Base (Information Case)............................................................................................ Cover (Information Case) .......................................................................................... Screw.........................................................................................................................

QTY

1 1 1 4 1 1 2

1-3

G10647

LABELS AND DECALS

1-4

G10647

LABELS AND DECALS

ITEM

PART NO.

1 2 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17

500962500 504247500 580034336 502157203 524141185 524150809 505890500 580022643 580032544 504781201 580008064 a .. . . . 501904907 502157202 580036341 580014880 524166533 524167623

DESCRIPTION

Label (Fork Warning)................................................................................................. Label (Mast Warning) ................................................................................................ Label (Warning and Instruction) ................................................................................ Label (Yale)................................................................................................................ Label (Dash) .............................................................................................................. Operator Manual........................................................................................................ Label (Patents and Trademarks) ............................................................................... Label (Battery Discharge Notice) (Flooded Batteries)............................................... Label (Battery Discharge Notice) (Maintenance Free) .............................................. Plate (UL Rating "E" Construction)............................................................................ Cover ......................................................................................................................... Nameplate ................................................................................................................. Rivet .......................................................................................................................... Label (Yale)................................................................................................................ Label (Manual Lowering) ........................................................................................... Label (Snowflake) ...................................................................................................... Label (Sideshift)......................................................................................................... Label (Tilt)..................................................................................................................

QTY

2 2 1 2 1 1 1 1 1 1 1 1 4 2 1 2 1 1

FOOTNOTES: a Contact your dealer.

1-5

G10721

OPERATOR GUARD

1-6

G10721

OPERATOR GUARD

KEY: A: Two Stage Mast B: Three Stage Mast QTY ITEM

1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2

d d d d d d a b c

PART NO.

DESCRIPTION

754479700 503662703 503662702 503662701 503663703 503663702 503663701 503666703 503666702 503666701 503667703 503667702 503667701 015026200 062232800 016103700

Operator Guard (64")......................................................................................... Operator Guard (72")......................................................................................... Operator Guard (77")......................................................................................... Operator Guard (83")......................................................................................... Operator Guard (72")......................................................................................... Operator Guard (77")......................................................................................... Operator Guard (83")......................................................................................... Operator Guard (72")......................................................................................... Operator Guard (77")......................................................................................... Operator Guard (83")......................................................................................... Operator Guard (72")......................................................................................... Operator Guard (77")......................................................................................... Operator Guard (83")......................................................................................... Lockwasher ....................................................................................................... Capscrew........................................................................................................... Washer ..............................................................................................................

1 1 1 1 .. .. .. 1 1 1 .. .. .. 4 4 4

.. .. .. .. 1 1 1 .. .. .. 1 1 1 4 4 4

FOOTNOTES: a 83" Two Stage and Three Stage and 72" Two Stage require 6 washers. b 83" Two Stage and Three Stage require 6 capscrews. c 83" Two Stage and Three Stage require 6 washers. d Used on B455 and C821.

1-7

G10734

FORKS (HOOK TYPE CARRIAGE)

FORKSHOOK TYPE CARRIAGE

1-8

G10734

FORKS (HOOK TYPE CARRIAGE)

ITEM

1 1 1 1 1 1 2 3 4 5

PART NO.

DESCRIPTION

504111201 504110201 504111202 504110202 504111203 504110203 580034999 580035000 580026749 580035001

Fork (36 in.) ............................................................................................................... Fork (36 in.) (C820)................................................................................................... Fork (42 in.) ............................................................................................................... Fork (42 in.) (C820)................................................................................................... Fork (48 in.) ............................................................................................................... Fork (48 in.) (C820)................................................................................................... Knob .......................................................................................................................... Pin ............................................................................................................................. Spring ........................................................................................................................ Retainer Pin...............................................................................................................

QTY

2 2 2 2 2 2 1 1 1 1

1-9

G10733

LOAD BACKREST (MRW20-30E)

LOAD BACKREST MRW20-30E

1-10

G10733

LOAD BACKREST (MRW20-30E)

ITEM

1 2 3 4

PART NO.

DESCRIPTION

524143078 016110000 015026600 055485600

Load Backrest (48 in.) ............................................................................................... Washer ...................................................................................................................... Lockwasher ............................................................................................................... Capscrew...................................................................................................................

QTY

1 4 4 4

1-11

G10732

LOAD BACKREST (MSW30-40E)

LOAD BACKREST MSW30-40E

ITEM

1 2 3 4 4 4

PART NO.

504263710 909882405 061278200 b 505960578 c 501749901 a 501749903

DESCRIPTION

Load Backrest (48 in.) ............................................................................................... Nut ............................................................................................................................. Washer ...................................................................................................................... Capscrew................................................................................................................... Capscrew................................................................................................................... Capscrew...................................................................................................................

FOOTNOTES: a Used on 3000lb. without sideshift. b Used on 4000lb. c Used on 4000lb. without sideshift.

1-12

QTY

1 4 4 4 4 4

NOTES

1-13

G10644

BATTERY DISCONNECT

1-14

G10644

BATTERY DISCONNECT

ITEM

1 1 1 1 2 3 4 5 6

PART NO.

DESCRIPTION

752576436 723291300 752576437 723291304 503954200 014867800 015026000 014936500 580017790

Battery Connector and Cable Assembly (Gray)......................................................... Battery Connector (Gray) ..................................................................................... Battery Connector and Cable Assembly (Red).......................................................... Battery Connector (Red) ...................................................................................... Handle ....................................................................................................................... Screw......................................................................................................................... Lockwasher ............................................................................................................... Nut ............................................................................................................................. Nut .............................................................................................................................

QTY

1 1 1 1 1 4 2 2 2

1-15

G10646

BATTERY SPACER

ITEM

1 2 3 4 5 6

1-16

PART NO.

DESCRIPTION

501921200 502398904 015026600 520051895 503248201 580006788

Bracket ...................................................................................................................... Washer ...................................................................................................................... Lockwasher ............................................................................................................... Nut ............................................................................................................................. Spacer ....................................................................................................................... Screw.........................................................................................................................

QTY

2 2 2 2 1 2

SECTION 2

2 ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

CONTENTS

SECTION 2 ELECTRICAL SYSTEM DESCRIPTION

PAGE

CONTROL PANEL ASSEMBLY............................................................................................................................ 2-2 ELECTRICAL ARRANGEMENT .......................................................................................................................... 2-4 TRACTION MOTOR ............................................................................................................................................. 2-6

2-1

G10671

CONTROL PANEL ASSEMBLY

2-2

G10671

CONTROL PANEL ASSEMBLY

ITEM

1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

PART NO.

DESCRIPTION

524163751 524168739 524163750 524164225 524169972 449022018 449001114 524164430 449021003 519433613 940400904 449007033 512720800 580034850 449021001 449022016 449007006 504062736 580034919 518944600 524164010 524164808 524168740 524164460 524164461 524164479 524164480 524164740 524164741 524164807 524143269 449007010 449022018 449021003 449015014 449022016 449021001 505974575 580004592

Control Panel Assembly ............................................................................................ Control Panel Assembly (Straddle with Auxiliary)...................................................... Contactor Panel.................................................................................................... Controller.............................................................................................................. Controller (Straddle with Auxiliary) ....................................................................... Lockwasher .......................................................................................................... Capscrew ............................................................................................................. Contactor.............................................................................................................. Washer ................................................................................................................. Fuse Holder (2-Way) ............................................................................................ Washer ................................................................................................................. Screw ................................................................................................................... Fuse (10 Amp) ..................................................................................................... Insulated Clamp ................................................................................................... Washer ................................................................................................................. Lockwasher .......................................................................................................... Capscrew ............................................................................................................. Clamp................................................................................................................... Screw ................................................................................................................... Fuse (300 Amp) ................................................................................................... Buss Bar............................................................................................................... Wire Harness (Main) ............................................................................................ Wire Harness (Main) (Straddle with Auxiliary) ..................................................... Cable Assembly (F1)............................................................................................ Cable Assembly (F2)............................................................................................ Cable Assembly (A1)............................................................................................ Cable Assembly (A2)............................................................................................ Cable Assembly (Positive).................................................................................... Cable Assembly (Negative) .................................................................................. Wire Harness ....................................................................................................... Horn........................................................................................................................... Screw......................................................................................................................... Lockwasher ............................................................................................................... Washer ...................................................................................................................... Nut ............................................................................................................................. Lockwasher ............................................................................................................... Washer ...................................................................................................................... Capscrew................................................................................................................... Nut .............................................................................................................................

QTY

1 1 1 1 1 6 6 1 2 1 2 2 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 2 4 4 4 4 1

2-3

G10707

ELECTRICAL ARRANGEMENT

2-4

G10707

ELECTRICAL ARRANGEMENT

ITEM

PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 13 13 14

524163751 449021001 449022016 449015014 505974575 720076907 580017790 524143269 449022018 449021003 449007010 580026708 500863104 500863106 a 752411301 524165936

DESCRIPTION

Control Panel Assembly ............................................................................................ Washer ................................................................................................................. Lockwasher .......................................................................................................... Nut........................................................................................................................ Capscrew ............................................................................................................. Grommet .............................................................................................................. Nut........................................................................................................................ Horn ..................................................................................................................... Lockwasher .......................................................................................................... Washer ................................................................................................................. Screw ................................................................................................................... Indicator..................................................................................................................... Ignition Switch ........................................................................................................... Key ....................................................................................................................... Ignition Switch (Toggle) ............................................................................................. Wire Harness (Battery Jumper) (C820 Only) ............................................................

QTY

1 4 4 4 4 2 2 1 4 2 2 1 1 1 1 1

FOOTNOTES: a Optional

2-5

G10653

TRACTION MOTOR

2-6

G10653

TRACTION MOTOR

ITEM

1 2 3 4 5 6 7 8

PART NO.

DESCRIPTION

580017267 Traction Motor (150 Amp) .......................................................................................... 580026422 Armature .............................................................................................................. 580026423 Stator.................................................................................................................... 580026427 Brush Holder ........................................................................................................ 580026426 Brush and Spring Set ........................................................................................... 580026424 Plate ..................................................................................................................... 580026425 Bearing................................................................................................................. 580026428 Bracket ................................................................................................................. 580026429 Cover Band ..........................................................................................................

QTY

1 1 1 1 1 1 1 1 1

2-7

NOTES

2-8

SECTION 3

3 DRIVE UNIT AND BRAKE ASSEMBLY

DRIVE UNIT AND BRAKE ASSEMBLY

CONTENTS

SECTION 3 DRIVE UNIT AND BRAKE ASSEMBLY DESCRIPTION

PAGE

ELECTRIC BRAKE............................................................................................................................................... 3-2 MASTER DRIVE UNIT ......................................................................................................................................... 3-8 MASTER DRIVE UNIT ASSEMBLY ..................................................................................................................... 3-4

3-1

G10670

ELECTRIC BRAKE

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13

3-2

PART NO.

DESCRIPTION

524169212 524148902 524148900 .. . . . .. . . . .. . . . 524148901 .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 580008382 524148446

Electric Brake ............................................................................................................ Disc ...................................................................................................................... Brake Lining ......................................................................................................... Adjustment Tube .................................................................................................. Pressure Disk....................................................................................................... Spring (Inner) ....................................................................................................... Hub....................................................................................................................... Magnet Body ........................................................................................................ Lockwasher .......................................................................................................... Capscrew ............................................................................................................. Spring (Outer) ...................................................................................................... Tappet .................................................................................................................. Adjusting Nut........................................................................................................ Rectifier ..................................................................................................................... Enclosure Band .........................................................................................................

QTY

1 1 1 3 1 4 1 1 3 3 3 4 1 1 1

NOTES

3-3

G10903

MASTER DRIVE UNIT ASSEMBLY

3-4

G10903

MASTER DRIVE UNIT ASSEMBLY

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 22 22 22 22 22 22 22 23 24 24 24 24 24 24 24 24 25 26 27 28 29 30 30 30 30 30 30

PART NO.

DESCRIPTION

580023503 Drive Unit................................................................................................................... 580039685 Plug ...................................................................................................................... 580017124 Seal ...................................................................................................................... 580039766 Housing Support .................................................................................................. 580039687 Centering Bush .................................................................................................... 580039688 Bearing................................................................................................................. 580039689 Gasket.................................................................................................................. 580039692 Bolt ....................................................................................................................... 580039690 Upper Housing ..................................................................................................... 580039694 Bearing................................................................................................................. 580039695 Plate ..................................................................................................................... 580039696 Bolt ....................................................................................................................... 580039697 Centering Bush .................................................................................................... 580039767 Housing ................................................................................................................ 580039699 Cover.................................................................................................................... 580017125 Oil Plug................................................................................................................. 580039700 Washer ................................................................................................................. 580039701 Gear ..................................................................................................................... 580039702 Bearing................................................................................................................. 580039703 Ring Nut ............................................................................................................... 580039704 Gear ..................................................................................................................... 580039770 Bearing................................................................................................................. 580039706 Shim (1mm).......................................................................................................... 580039707 Shim (1.1mm)....................................................................................................... 580039708 Shim (1.2mm)....................................................................................................... 580039709 Shim (1.22mm)..................................................................................................... 580039710 Shim (1.24mm)..................................................................................................... 580039711 Shim (1.26mm)..................................................................................................... 580039712 Shim (1.28mm)..................................................................................................... 580039713 Shim (1.3mm)....................................................................................................... 580039771 Spacer.................................................................................................................. 580039714 Shim (1.8mm)....................................................................................................... 580039715 Shim (1.85mm)..................................................................................................... 580039716 Shim (1.9mm)....................................................................................................... 580039717 Shim (1.95mm)..................................................................................................... 580039718 Shim (2mm).......................................................................................................... 580039719 Shim (2.05mm)..................................................................................................... 580039720 Shim (2.1mm)....................................................................................................... 580039722 Shim (2.15mm)..................................................................................................... 580039723 Bevel Gear and Pinion Set ................................................................................... 580039724 Wheel Shaft.......................................................................................................... 580039725 Cover.................................................................................................................... 580032507 Hose (Suction) ..................................................................................................... 580039726 Bearing................................................................................................................. 580039727 Shim (4.15mm)..................................................................................................... 580039728 Shim (4.175mm)................................................................................................... 580039729 Shim (4.2mm)....................................................................................................... 580039730 Shim (4.225mm)................................................................................................... 580039731 Shim (4.25mm)..................................................................................................... 580039732 Shim (4.275mm)...................................................................................................

QTY

1 1 1 1 4 2 1 10 1 1 1 14 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3-5

G10903

MASTER DRIVE UNIT ASSEMBLY

ITEM

PART NO.

30 30 30 30 30 30 30 30 31 32 33 33 33 33 33 33 33 33 33 33 33 34 35 36

580039733 580039734 580039735 580039736 580039737 580039738 580039739 580039740 580033733 580039753 580039741 580039742 580039743 580039744 580039745 580039746 580039747 580039748 580039749 580039750 580039751 580039752 580025303 580025305 a 580039754 a 580039755

FOOTNOTES: a Not Illustrated

3-6

DESCRIPTION

Shim (4.3mm)....................................................................................................... Shim (4.325mm)................................................................................................... Shim (4.35mm)..................................................................................................... Shim (4.375mm)................................................................................................... Shim (4.4mm)....................................................................................................... Shim (4.45mm)..................................................................................................... Shim (4.5mm)....................................................................................................... Shim (4.55mm)..................................................................................................... Ring Nut ............................................................................................................... Bearing................................................................................................................. Shim (.90mm)....................................................................................................... Shim (.95mm)....................................................................................................... Shim (1mm).......................................................................................................... Shim (1.05mm)..................................................................................................... Shim (1.1mm)....................................................................................................... Shim (1.2mm)....................................................................................................... Shim (1.22mm)..................................................................................................... Shim (1.24mm)..................................................................................................... Shim (1.26mm)..................................................................................................... Shim (1.28mm)..................................................................................................... Shim (1.3mm)....................................................................................................... Spacer.................................................................................................................. Oil Fill Plug ........................................................................................................... Oil Fill Gasket....................................................................................................... Nut........................................................................................................................ Bolt .......................................................................................................................

QTY

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1

NOTES

3-7

G10672

MASTER DRIVE UNIT

3-8

G10672

MASTER DRIVE UNIT

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 18 19 19 20 21 22 23 24 25 26 27

b b b b

PART NO.

DESCRIPTION

449015014 449022016 940102909 449021001 580017788 580015900 524140906 524141012 524141080 932200905 580023503 580017124 580017125 580017126 524169212 580017267 524141460 524141555 524139975 501786915 517580815 524148446 580000749 580027368 501729901 449021006 449022013 449015044 504232275

Nut ............................................................................................................................. Lockwasher ............................................................................................................... Washer ...................................................................................................................... Washer ...................................................................................................................... Capscrew................................................................................................................... Capscrew................................................................................................................... Wire Guide................................................................................................................. Stud ........................................................................................................................... Nut ............................................................................................................................. Capscrew................................................................................................................... Drive Unit................................................................................................................... Seal ...................................................................................................................... Oil Plug................................................................................................................. Oil Gasket ............................................................................................................ Electric Brake ............................................................................................................ Traction Motor (150 Amp) .......................................................................................... Wheel and Tire Assembly (Rubber) .......................................................................... Wheel and Tire Assembly (Poly) ............................................................................... Drive Wheel.......................................................................................................... Tire (Poly)............................................................................................................. Tire (Rubber)........................................................................................................ Enclosure Band ......................................................................................................... Clamp ........................................................................................................................ Pin ............................................................................................................................. Capscrew................................................................................................................... Washer ...................................................................................................................... Lockwasher ............................................................................................................... Nut ............................................................................................................................. Static Strap ................................................................................................................

QTY

10 6 9 8 5 4 1 4 4 4 1 1 2 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1

FOOTNOTES: a Maintenance use only. b Poly Tire Only

3-9

NOTES

3-10

SECTION 4

4 CONTROL HANDLE

CONTROL HANDLE

CONTENTS

SECTION 4 CONTROL HANDLE DESCRIPTION

PAGE

CONTROL HANDLE ARM ASSEMBLY................................................................................................................ 4-2 CONTROL HANDLE ASSEMBLY......................................................................................................................... 4-4

4-1

G10641

CONTROL HANDLE ARM ASSEMBLY

CONTROL HANDL E ARM ASSEMBLY

4-2

G10641

CONTROL HANDLE ARM ASSEMBLY

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 14 14 14 14 15 15 16 17 18 19 20 20 20 21 22 23 24 25 26 26 26 26 26 27

f e f e d c

a a a a b

PART NO.

DESCRIPTION

524141468 059863600 016103700 524143278 524143285 524141136 504574232 524145025 580004592 580022964 519766808 449021001 580000119 524138796 524182432 524138798 524159461 524182756 524159462 524182270 524149833 524153715 751191100 580017792 524144586 524170831 449015002 524170827 505970553 449022018 520053859 580021175 580002500 580024916 580024919 449021006 449001302 449015044 620033319 524164789

Tube........................................................................................................................... Capscrew................................................................................................................... Washer ...................................................................................................................... Shaft .......................................................................................................................... Pin ............................................................................................................................. Ball Stud .................................................................................................................... Fitting......................................................................................................................... Bushing ..................................................................................................................... Nut ............................................................................................................................. Capscrew................................................................................................................... Lockwasher ............................................................................................................... Washer ...................................................................................................................... Plug ........................................................................................................................... Control Handle Assembly (C820 Standard) .............................................................. Control Handle Assembly (C820 Cold Storage) ........................................................ Control Handle Assembly (C820 Cold Storage) ........................................................ Control Handle Assembly (C821 Standard) .............................................................. Control Handle Assembly (C821 Cold Storage) ........................................................ Control Handle Assembly (C821 Cold Storage) ........................................................ Gas Spring ................................................................................................................ Gas Spring ................................................................................................................ Switch ........................................................................................................................ Plate .......................................................................................................................... Screw......................................................................................................................... Capscrew................................................................................................................... Switch Cover ............................................................................................................. Nut........................................................................................................................ Plate ..................................................................................................................... Capscrew................................................................................................................... Lockwasher ............................................................................................................... Screw......................................................................................................................... Clamp ........................................................................................................................ Clamp ........................................................................................................................ Bracket ...................................................................................................................... Stud...................................................................................................................... Washer ................................................................................................................. Capscrew ............................................................................................................. Nut........................................................................................................................ Shim (0.030 in.) ......................................................................................................... Wire Harness (C820).................................................................................................

QTY

1 1 1 1 1 2 1 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 2 3 1 1 1 1 1 1 1 1 1 2 5 1 4 3 1

FOOTNOTES: a For mounting to MDU. b Not Illustrated c ⇒ S/N PENDING PER ECN 84470 d S/N PENDING PER ECN 84470 ⇒ e ⇒ S/N PENDING PER ECN 84472 f S/N PENDING PER ECN 84472 ⇒

4-3

G10767

CONTROL HANDLE ASSEMBLY

4-4

G10767

CONTROL HANDLE ASSEMBLY

ITEM

1 1 2 2 3 3 4 5 6 7 8 9 10 11 11 12 13 14 14 14 15 16 17 18 19 20 21

PART NO.

DESCRIPTION

QTY

524138796 Control Handle Assembly (C820 Standard) .............................................................. a 524138798 Control Handle Assembly (C820 Cold Storage) ........................................................ b 524182432 Control Handle Assembly (C820 Cold Storage) ........................................................ 524159461 Control Handle Assembly (C821 Standard) .............................................................. a 524159462 Control Handle Assembly (C821 Cold Storage) ........................................................ b 524182756 Control Handle Assembly (C821 Cold Storage) ........................................................ 524182434 Control Handle (Lower) (Cold Storage)................................................................ 580011989 Control Handle (Lower) ........................................................................................ 524139006 Control Handle (Upper) (C820) ............................................................................ 524169863 Control Handle (Upper) (C821) ............................................................................ 580025595 Interface Single Board (Standard)........................................................................ 580025596 Interface Single Board (Cold Storage) ................................................................. 580013106 Camshaft.............................................................................................................. 580012962 Bushing ................................................................................................................ 524139007 Butterfly Switch (LH) ............................................................................................ 940004902 Washer ................................................................................................................. 580026296 Screw ................................................................................................................... 580012970 Spring................................................................................................................... 524139008 Butterfly Switch (RH)............................................................................................ 580011991 Switch Cover ........................................................................................................ 524139010 Cover (Creep Speed) ........................................................................................... 580012969 Spring................................................................................................................... 580013128 Switch Cover ........................................................................................................ 524148521 Switch Assembly .................................................................................................. 524148522 Proportional Switch Assembly.............................................................................. 524170074 Button................................................................................................................... 580026824 Switch................................................................................................................... 524139009 Cover.................................................................................................................... 580012967 Label (RH)............................................................................................................ 580012968 Label (LH) ............................................................................................................ 524139322 Label (Yale) .......................................................................................................... 580038175 Spring................................................................................................................... 580012969 Spring (Creep Speed) ..........................................................................................

1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 4 4 1 4 1 1 1 1 1 1

524139316 Control Handle Kit (Proportional) (C820 Standard) (Includes Items 2-12, 14, 16-19) ........................................................................................................................ 524182757 Control Handle Kit (C821 Cold Storage) (Includes Items 2-12, 14, 16-18, 20) ......... 524159463 Control Handle Kit (C821 Standard) (Includes Items 2-12, 14, 16-18, 20)................ 524153649 Creep Speed Kit (Includes Items 11-12) ...................................................................

1 1 1 1

FOOTNOTES: a ⇒ S/N PENDING PER ECN 84472 b S/N PENDING PER ECN 84472 ⇒

4-5

NOTES

4-6

SECTION 5

5 LOAD WHEEL

LOAD WHEEL

CONTENTS

SECTION 5 LOAD WHEEL DESCRIPTION

PAGE

LOAD WHEEL ...................................................................................................................................................... 5-2

5-1

G10642

LOAD WHEEL

5-2

G10642

LOAD WHEEL

KEY: A: Single B: Tandem (Optional) QTY ITEM

1 2 3 4 5 6 7 8

PART NO.

DESCRIPTION

501193100 12056430A 025884300 501195100 723624100 016092800 015628700 519645800

Drive Axle .......................................................................................................... Load Wheel ....................................................................................................... Bearing Ball ....................................................................................................... Pin ..................................................................................................................... Washer .............................................................................................................. Washer .............................................................................................................. Lube Fitting........................................................................................................ Pin .....................................................................................................................

2 2 4 2 4 8 2 ..

4 4 8 .. 8 16 4 2

5-3

NOTES

5-4

SECTION 6

6 HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

CONTENTS

SECTION 6 HYDRAULIC SYSTEM DESCRIPTION

PAGE

HYDRAULIC POWER UNIT REACH ............................................................................................................................................................. 6-2 WITH AUXILIARY ............................................................................................................................................. 6-4 WITHOUT AUXILIARY S/N C820N-0152Z⇒ ..................................................................................................................................... 6-8 ⇒S/N C820N-0152Z ..................................................................................................................................... 6-6 HYDRAULIC SYSTEM ....................................................................................................................................... 6-10

6-1

G10912

HYDRAULIC POWER UNIT (REACH)

HYDRAULIC POWER UNITREACH

6-2

G10912

HYDRAULIC POWER UNIT (REACH)

ITEM

1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 18 19

PART NO.

DESCRIPTION

580040130 Pump and Motor Assembly ....................................................................................... 580037336 Motor .................................................................................................................... 580037470 Brush Plate ...................................................................................................... 580037337 Brush Set ......................................................................................................... 580040504 Pump and Motor Assembly .................................................................................. 580037471 Oldham Nut...................................................................................................... 580040505 Pump ............................................................................................................... 580037473 Tank ................................................................................................................. 580037474 Clamp .............................................................................................................. 580037475 Filler Cap ......................................................................................................... 580039973 Block with Proportional Valve........................................................................... 580039974 Block without Proportional Valve...................................................................... 580037478 Proportional Valve............................................................................................ 580039975 Valve ................................................................................................................ 580039976 Valve Assembly................................................................................................ 580039977 Coil................................................................................................................... 580039978 Block with Valve ............................................................................................... 580039979 Block without Valve .......................................................................................... 580039980 Valve ................................................................................................................ 580015611 Strainer ............................................................................................................ 580040507 Tube ..................................................................................................................... 580039617 Relief Valve ...................................................................................................... 580037482 Check Valve ..................................................................................................... a 580040506 Flow Regulator ..................................................................................................... 580032007 Pump Repair Kit ...................................................................................................

QTY

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FOOTNOTES: a Not Illustrated

6-3

G10913

HYDRAULIC POWER UNIT (WITH AUXILIARY)

HYDRAULIC POWER UNITWITH AUXILIARY

6-4

G10913

HYDRAULIC POWER UNIT (WITH AUXILIARY)

ITEM

1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 18

PART NO.

DESCRIPTION

QTY

580038819 Pump and Motor Assembly ....................................................................................... 580037336 Motor .................................................................................................................... 580037470 Brush Plate ...................................................................................................... 580037337 Brush Set ......................................................................................................... 580037471 Oldham Nut .......................................................................................................... 580037472 Pump Support ...................................................................................................... 580037473 Tank...................................................................................................................... 580037474 Clamp................................................................................................................... 580037475 Filler Cap.............................................................................................................. 580039973 Block with Proportional Valve ............................................................................... 580039974 Block without Proportional Valve .......................................................................... 580037478 Proportional Valve ................................................................................................ 580039975 Valve..................................................................................................................... 580039976 Valve Assembly................................................................................................ 580039977 Coil................................................................................................................... 580039978 Block with Valve ................................................................................................... 580039979 Block without Valve .......................................................................................... 580039980 Valve ................................................................................................................ 580037480 Tube ................................................................................................................. 580015611 Strainer ........................................................................................................ 580039617 Relief Valve .......................................................................................................... 580037482 Check Valve .........................................................................................................

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

580032007 580039983

1 1

Pump Repair Kit (Includes Item ) ......................................................................... Mini Power Pack (Includes Item ) .........................................................................

6-5

G10919

HYDRAULIC POWER UNIT (WITHOUT AUXILIARY) (⇒S/N C820N-0152Z) HYDRAULIC POWER UNIT WITHOUT AUXILIARY⇒ S/N C820N-0152Z

6-6

G10919

HYDRAULIC POWER UNIT (WITHOUT AUXILIARY) (â&#x2021;&#x2019;S/N C820N-0152Z) ITEM

1 2 3 4 5 6 7 8 8 9 10 11 12 13 14 15

PART NO.

DESCRIPTION

580034711 Hydraulic Pump and Motor ........................................................................................ 580037336 Motor .................................................................................................................... 580037337 Brush Set ............................................................................................................. 580037470 Brush Plate........................................................................................................... 580037471 Oldham Nut .......................................................................................................... 580037473 Tank...................................................................................................................... 580037474 Clamp................................................................................................................... 580037475 Filler Cap.............................................................................................................. 580037476 Block and Valve.................................................................................................... 580037477 Block ................................................................................................................ 580037478 Proportional Valve............................................................................................ 580037472 Pump Support ...................................................................................................... 580015611 Strainer................................................................................................................. 580039617 Relief Valve .......................................................................................................... 580037484 Pump.................................................................................................................... 580037480 Tube ..................................................................................................................... 580037482 Check Valve ......................................................................................................... a 580032007 Pump Repair Kit ...................................................................................................

QTY

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1

FOOTNOTES: a Not Illustrated

6-7

G10738

HYDRAULIC POWER UNIT (WITHOUT AUXILIARY) (S/N C820N-0152Z⇒) HYDRAULIC POWER UNIT WITHOUT AUXILIARYS/N C820N-0152Z⇒

6-8

G10738

HYDRAULIC POWER UNIT (WITHOUT AUXILIARY) (S/N C820N-0152Zâ&#x2021;&#x2019;) ITEM

1 1 1 2 3 4 5 6 7 8 9 9 10 10 11 12

PART NO.

DESCRIPTION

580038818 Pump and Motor Assembly ....................................................................................... 580037336 Motor .................................................................................................................... 580037337 Brush Set ......................................................................................................... 580037470 Brush Plate ...................................................................................................... 580037471 Oldham Nut .......................................................................................................... 580037473 Tank...................................................................................................................... 580037474 Clamp .............................................................................................................. 580037475 Filler Cap ......................................................................................................... 580037476 Block and Valve.................................................................................................... 580037477 Block ................................................................................................................ 580037478 Proportional Valve............................................................................................ 580037472 Pump Support ...................................................................................................... 580037484 Pump.................................................................................................................... 580015611 Strainer................................................................................................................. 580037480 Tube ..................................................................................................................... 580039617 Relief Valve .......................................................................................................... 580037482 Check Valve ......................................................................................................... a 580032007 Pump Repair Kit ...................................................................................................

QTY

1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1

FOOTNOTES: a Not Illustrated

6-9

G10723

HYDRAULIC SYSTEM

6-10

G10723

HYDRAULIC SYSTEM

ITEM

1 1 1 2 3 4 5 6 7 8 9 10 a a ab ab a a ac ac ac

PART NO.

DESCRIPTION

580038818 580038819 580040130 524163969 524179408 057416600 016103700 504238298 449001023 449022013 524165600 524165321 524166201 524173490 524165318 524165319 524164740 524164741 524170079 524170075 524170076

Pump and Motor Assembly (Without Auxiliary) (☞ G10738) ................................... Pump and Motor Assembly (With Auxiliary) (☞ G10738) ........................................ Pump and Motor Assembly (Reach) (☞ G10738) ................................................... Isolator....................................................................................................................... Bracket ...................................................................................................................... Capscrew................................................................................................................... Washer ...................................................................................................................... Nut ............................................................................................................................. Capscrew................................................................................................................... Lockwasher ............................................................................................................... Fitting......................................................................................................................... Fitting (Auxiliary)........................................................................................................ Foam Pad .................................................................................................................. Edge Trim .................................................................................................................. Wire Harness............................................................................................................. Wire Harness (Auxiliary)............................................................................................ Cable Assembly (Positive) ......................................................................................... Cable Assembly (Negative) ....................................................................................... Wire Harness (Without Sideshift) .............................................................................. Wire Harness (With Sideshift) ................................................................................... Jumper.......................................................................................................................

QTY

1 1 1 2 1 2 2 2 2 2 1 2 1 1 1 1 1 1 1 1 1

FOOTNOTES: a Not Illustrated b Used only on the C820. c Used only on the C821.

6-11

NOTES

6-12

SECTION 7

7 LIF TING MECHANISM

LIFTING MECHANISM

CONTENTS

SECTION 7 LIFTING MECHANISM DESCRIPTION

PAGE

CHAINS, PINS, AND ANCHORS THREE STAGE FULL FREE-LIFT MRW020-030E............................................................................................................................................ 7-10 MSW 030-040E ........................................................................................................................................... 7-12 TWO STAGE LIMITED FREE-LIFT MRW020-030E............................................................................................................................................ 7-14 MSW030-040E ............................................................................................................................................ 7-16 EXTENDED CYLINDER ASSEMBLY MRW020-030E ............................................................................................................................................... 7-18 FORK CARRIAGE MSW 030-040E............................................................................................................................................... 7-42 FREE-LIFT CYLINDER ASSEMBLY MRW020-030E ............................................................................................................................................... 7-20 MSW 030-040E THREE STAGE FULL FREE-LIFT .............................................................................................................. 7-22 HEADER HOSE GROUP MRW020-030E ............................................................................................................................................... 7-24 INNER CARRIAGE MRW020-030E ............................................................................................................................................... 7-44 INTEGRAL TILT ASSEMBLY MRW020-030E ............................................................................................................................................... 7-26 WITH SIDESHIFT MRW020-030E............................................................................................................................................ 7-28 LIFT CYLINDER ASSEMBLY MRW020-030E ............................................................................................................................................... 7-30 MSW 030-040E THREE STAGE FULL FREE-LIFT .............................................................................................................. 7-32 TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-34 LIFT CYLINDER INSTALLATION MRW020-030E ............................................................................................................................................... 7-36 MSW 030-040E THREE STAGE FULL FREE-LIFT .............................................................................................................. 7-38 TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-40 SCISSOR CARRIAGE MRW020-030E ............................................................................................................................................... 7-48 UPRIGHTS THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-2 TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-6

7-1

G10771

09-02

UPRIGHTS (THREE STAGE FULL FREE-LIFT)

UPRIGHTSTHREE STAGE FULL FR EE-LIFT

7-2

G10771

09-02

UPRIGHTS (THREE STAGE FULL FREE-LIFT) MRW20-30E OALH

DESCRIPTION Mast Group Number Outer Mast

B736 3721 580036049

B736 4102 580036054

B736 4559 580037598

Intermediate Mast

580037595

580036053

580036057

Inner Mast

580036047

580036052

580037596

ITEM

MSW30-40E OALH

DESCRIPTION Mast Group Number Outer Mast

A776 3849 520095611

A776 4230 520095602

A776 4688 520095603

Intermediate Mast

518429611

518429602

518429603

Inner Mast

518428611

518428602

518428603

ITEM

KEY: A: MSW030-040E B: MRW020-030E QTY ITEM

PART NO.

1 2 3 4 4 5 5 6 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20

a .. . . . a .. . . . a .. . . . 932119907 932118906 507033500 253851200 449029009 504562100 504558100 031129200 500303502 500302502 502566904 449001418 500303501 500302501 502314100 502313100 449002197 504353200 503067200 503837201

DESCRIPTION

Outer Mast......................................................................................................... 1 Intermediate Mast.............................................................................................. 1 Inner Mast ......................................................................................................... 1 Screw................................................................................................................. .. Screw................................................................................................................. 8 Load Roller ........................................................................................................ .. Load Roller ........................................................................................................ 8 Snap Ring.......................................................................................................... 8 Plug ................................................................................................................... .. Plug ................................................................................................................... 8 Pin ..................................................................................................................... 2 Shim (LH) .......................................................................................................... 1 Wear Strip (LH).................................................................................................. 1 Washer .............................................................................................................. 4 Capscrew........................................................................................................... 4 Shim (RH).......................................................................................................... 1 Wear Strip (RH) ................................................................................................. 1 Shim .................................................................................................................. 2 Wear Plate......................................................................................................... 2 Screw................................................................................................................. 1 Cushion ............................................................................................................. 8 Plate .................................................................................................................. 2 Shim .................................................................................................................. AR

1 1 1 8 .. 8 .. 8 8 .. 2 1 1 4 4 1 1 2 2 1 8 2 AR

7-3

G10771

09-02

UPRIGHTS (THREE STAGE FULL FREE-LIFT)

QTY ITEM

21 22

PART NO.

DESCRIPTION

502566903 014716400

Washer .............................................................................................................. Capscrew...........................................................................................................

FOOTNOTES: a Refer to Table

7-4

4 4

NOTES

7-5

G10770

09-02

UPRIGHTS (TWO STAGE LIMITED FREE-LIFT)

UPRIGHTSTWO STAGE LIMITED F REE-L IFT

7-6

G10770

09-02

UPRIGHTS (TWO STAGE LIMITED FREE-LIFT) MRW020E, MRW030E OALH

DESCRIPTION Mast Group Number Outer Mast

A729 2597 580035861

A729 2851 580035860

A729 3156 580035862

A729 3613 580035863

Inner Mast

580037769

580035878

580035879

580035880

ITEM

MSW030E, MSW040E OALH

DESCRIPTION Mast Group Number Outer Mast

A775 2496 503579746

A775 2750 503579711

A775 3054 503579702

A775 3512 503579703

A775 3715 503579728

Inner Mast

503356770

503356711

503356702

503356703

503356728

ITEM

KEY: A: MSW030-040E B: MRW020-030E QTY ITEM

PART NO.

1 2 3 3 4 4 5 5 6 6 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

a .. . . . a .. . . . 932118906 932119907 937100907 937501908 253851200 507033500 449029011 449029009 504558100 504562100 058831000 058889000 .. . . . 503067200 503068200 502566903 014716600 449001418 502566904 500302502 500303502 500303501 500302501 504353200 031129200

DESCRIPTION

Outer Mast......................................................................................................... Inner Mast ......................................................................................................... Screw................................................................................................................. Screw................................................................................................................. Nut ..................................................................................................................... Nut ..................................................................................................................... Load Roller ........................................................................................................ Load Roller ........................................................................................................ Snap Ring.......................................................................................................... Snap Ring (External) ......................................................................................... Plug ................................................................................................................... Plug ................................................................................................................... Capscrew........................................................................................................... Washer .............................................................................................................. Trunnion Cap ..................................................................................................... Plate .................................................................................................................. Shim .................................................................................................................. Washer .............................................................................................................. Screw................................................................................................................. Capscrew........................................................................................................... Washer .............................................................................................................. Wear Strip.......................................................................................................... Shim (LH) .......................................................................................................... Shim (RH).......................................................................................................... Wear Strip.......................................................................................................... Cushion ............................................................................................................. Pin .....................................................................................................................

1 1 4 .. 4 .. 4 .. 4 .. 4 .. 4 4 2 .. .. 4 4 .. .. .. .. .. .. .. ..

1 1 .. 4 .. 4 .. 4 .. 4 .. 4 4 4 2 2 AR 4 4 2 2 1 1 1 1 4 2 7-7

G10770

09-02

UPRIGHTS (TWO STAGE LIMITED FREE-LIFT)

QTY ITEM

23 24

PART NO.

DESCRIPTION

503241200 016100800

Plate .................................................................................................................. 2 Shim .................................................................................................................. AR

.. ..

FOOTNOTES: a Refer to Table

7-8

NOTES

7-9

G10757

09-02

CHAINS, PINS, AND ANCHORS (THREE STAGE FULL FREE-LIFT) (MRW020-030E)

CHAINS, PINS, AND ANCHORST HREE STAGE FULL FREE-LIFTMRW020-030E

7-10

G10757

09-02

CHAINS, PINS, AND ANCHORS (THREE STAGE FULL FREE-LIFT) (MRW020-030E) MRW20-30E OALH

DESCRIPTION Mast Group Number Chain (Free-Lift)

B736 3721 504064706

B736 4102 504075716

B736 4559 504064728

Chain (Main Lift)

902977411

902977413

902977427

ITEM

PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

449030008 517045600 501217200 502925500 015126000 449029011 a .. . . . 015416200 519686300 505590500 449015011 a .. . . . 501211201 502002200

DESCRIPTION

Retaining Ring ........................................................................................................... Support...................................................................................................................... Shaft .......................................................................................................................... Sheave ...................................................................................................................... Ball Bearing ............................................................................................................... Snap Ring.................................................................................................................. Chain (Free-Lift) ........................................................................................................ Cotter Pin .................................................................................................................. Pin ............................................................................................................................. Chain Anchor............................................................................................................. Nut ............................................................................................................................. Chain (Main Lift) ........................................................................................................ Spacer ....................................................................................................................... Spacer .......................................................................................................................

QTY

4 1 1 4 4 4 2 8 8 4 8 2 2 1

FOOTNOTES: a Refer to Table

7-11

G10680

09-02

CHAINS, PINS, AND ANCHORS (THREE STAGE FULL FREE-LIFT) (MSW 030-040E)

CHAINS, PINS, AND ANCHORST HREE STAGE FULL FREE-LIFTMSW 030-040E

7-12

G10680

09-02

CHAINS, PINS, AND ANCHORS (THREE STAGE FULL FREE-LIFT) (MSW 030-040E) MSW30-40E OALH

DESCRIPTION Mast Group Number Chain (Free-Lift)

A776 3849 519653441

A776 4230 519653407

A776 4688 519653410

Chain (Hoist)

519653432

519653433

519653435

ITEM

PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

315711216 449029002 516083600 502754500 502756500 052701700 449030001 a .. . . . 015416200 508976100 502761500 449015011 502688903 508812100 502949500 502501903 449076005 a .. . . . 502001200 723624100 449025008

DESCRIPTION

O-Ring ....................................................................................................................... Snap Ring.................................................................................................................. Support...................................................................................................................... Shaft .......................................................................................................................... Sheave ...................................................................................................................... Ball Bearing ............................................................................................................... Retaining Ring ........................................................................................................... Chain (Free-Lift) ........................................................................................................ Cotter Pin .................................................................................................................. Pin ............................................................................................................................. Chain Anchor............................................................................................................. Nut ............................................................................................................................. Lockwasher ............................................................................................................... Pin ............................................................................................................................. Chain Anchor............................................................................................................. Chain Anchor............................................................................................................. Lube Fitting................................................................................................................ Chain (Hoist).............................................................................................................. Spacer ....................................................................................................................... Washer ...................................................................................................................... Cotter Pin ..................................................................................................................

QTY

1 4 1 1 4 4 4 2 8 6 4 4 8 2 2 2 2 2 1 2 2

FOOTNOTES: a Refer to Table

7-13

G10778

09-02

CHAINS, PINS, AND ANCHORS (TWO STAGE LIMITED FREE-LIFT) (MRW020-030E)

CHAINS, PINS, AND ANCHORST WO STAGE LIMIT ED FREE-LIFT MRW020-030E

7-14

G10778

09-02

CHAINS, PINS, AND ANCHORS (TWO STAGE LIMITED FREE-LIFT) (MRW020-030E)

OALH ITEM 5

DESCRIPTION Mast Group Number Chain

ITEM

1 2 3 4 5 6 7 8 9

a a a a

A729 2597 504075722

A729 2851 504065798

A729 3156 504064746

A729 3613 900002268

PART NO.

DESCRIPTION

580016812 015126000 449030008 015916300 .. . . . 015416200 580033718 518801644 504234266 449022018 580017237 449001272 449021003

Chain Sheave ............................................................................................................ Ball Bearing ............................................................................................................... Retaining Ring ........................................................................................................... Snap Ring.................................................................................................................. Chain ......................................................................................................................... Cotter Pin .................................................................................................................. Pin ............................................................................................................................. Chain Anchor............................................................................................................. Nut ............................................................................................................................. Lockwasher ............................................................................................................... Clamp ........................................................................................................................ Capscrew................................................................................................................... Washer ......................................................................................................................

QTY

2 2 2 4 2 6 2 2 2 10 1 2 10

FOOTNOTES: a Not Illustrated b Refer to Table

7-15

G10779

10-02

CHAINS, PINS, AND ANCHORS (TWO STAGE LIMITED FREE-LIFT) (MSW030-040E)

CHAINS, PINS, AND ANCHORST WO STAGE LIMIT ED FREE-LIFT MSW030-040E

7-16

G10779

10-02

CHAINS, PINS, AND ANCHORS (TWO STAGE LIMITED FREE-LIFT) (MSW030-040E) MSW030E OALH ITEM 10

DESCRIPTION Mast Group Number Chain

A775 2496 519653445

A775 2750 519653407

A775 3054 519653410

A775 3512 519653413

A775 3715 519653418

MSW040E OALH ITEM 10

DESCRIPTION Mast Group Number Chain

ITEM

PART NO.

1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

449029002 449001004 449022017 516781600 502754500 502001200 502756500 052701700 449030001 723624100 a .. . . . 015416200 508976100 502761500 449015011 502688903 508812100 502949500 502501903 449076005 449025008

A729 2597 519653409

A729 2851 519653411

A729 3156 519653414

A729 3613 519653419

DESCRIPTION

Snap Ring.................................................................................................................. Capscrew................................................................................................................... Lockwasher ............................................................................................................... Support...................................................................................................................... Shaft .......................................................................................................................... Spacer ....................................................................................................................... Sheave ...................................................................................................................... Ball Bearing ............................................................................................................... Retaining Ring ........................................................................................................... Washer ...................................................................................................................... Chain ......................................................................................................................... Cotter Pin .................................................................................................................. Pin ............................................................................................................................. Chain Anchor............................................................................................................. Nut ............................................................................................................................. Lockwasher ............................................................................................................... Pin ............................................................................................................................. Chain Anchor............................................................................................................. Chain Anchor............................................................................................................. Lube Fitting................................................................................................................ Cotter Pin ..................................................................................................................

QTY

2 1 2 2 1 2 2 2 2 2 2 4 2 2 2 4 2 2 2 2 2

FOOTNOTES: a Refer to Table

7-17

G10774

09-02

EXTENDED CYLINDER ASSEMBLY (MRW020-030E)

EXTENDED CYLINDER ASSEMBLYMRW020-030E

7-18

G10774

09-02

EXTENDED CYLINDER ASSEMBLY (MRW020-030E)

ITEM

1 2 3 4 5 5 6 7 7 8 9 10

PART NO.

DESCRIPTION

QTY

580020934 580020932 502637901 502895200 504020501 524148324 507443501 507443551 524148325 012825700 500167924 580022500 500381501 504142500

Cylinder Assembly (RH) (24 in. Reach) .................................................................... Cylinder Assembly (LH) (24 in. Reach) ..................................................................... Nut ............................................................................................................................. Piston Ring ................................................................................................................ Seal Assembly........................................................................................................... Piston ........................................................................................................................ Tube (LH) (24 in. Reach)........................................................................................... Tube (RH) (24 in. Reach) .......................................................................................... Rod ............................................................................................................................ O-Ring ....................................................................................................................... Back-Up Ring ............................................................................................................ Seal ........................................................................................................................... Wiper Ring................................................................................................................. Gland .........................................................................................................................

1 1 1 2 1 1 1 1 1 1 1 1 1 1

516149005 Packing Kit (Includes Items 3, 7-9) ............................................................................

7-19

G10754

09-02

FREE-LIFT CYLINDER ASSEMBLY (MRW020-030E)

FREE-LIFT CYLINDER ASSEMBLYMRW020-030E

7-20

G10754

09-02

FREE-LIFT CYLINDER ASSEMBLY (MRW020-030E) MRW20-30E OALH DESCRIPTION Mast Group Number Lift Cylinder

B736 3721 580036069

B736 4102 580036072

B736 4559 580035981

Tube

520672676

520672681

520672686

Rod

518895645

518895650

518895655

ITEM

PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

a .. . . . a .. . . . a .. . . . 504450756 504450754 504450757 504235239 580011167 504148200 501850904 518938600 504450758 502787903 502011929 015493500 501753904 502980502 052645500 502687901

DESCRIPTION

QTY

Lift Cylinder................................................................................................................ Tube........................................................................................................................... Rod ............................................................................................................................ Back-Up Ring ............................................................................................................ Seal ........................................................................................................................... Wear Ring.................................................................................................................. Check Valve............................................................................................................... O-Ring ....................................................................................................................... Washer ...................................................................................................................... Snap Ring.................................................................................................................. Gland ......................................................................................................................... Wiper Ring................................................................................................................. Seal ........................................................................................................................... Back-Up Ring ............................................................................................................ O-Ring ....................................................................................................................... Screw......................................................................................................................... Velocity Fuse ............................................................................................................. O-Ring (Face Seal) .............................................................................................. Seal ...........................................................................................................................

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

505136047 Seal Kit (Includes Items 3-5, 11-14, 18) ....................................................................

FOOTNOTES: a Refer to Table

7-21

G10682

09-02

FREE-LIFT CYLINDER ASSEMBLY (MSW 030-040E) (THREE STAGE FULL FREE-LIFT)

FREE-LIFT CYLINDER ASSEMBLYMSW 030-040ETHREE STAGE FULL FREE-LIFT

7-22

G10682

09-02

FREE-LIFT CYLINDER ASSEMBLY (MSW 030-040E) (THREE STAGE FULL FREE-LIFT)

OALH ITEM

DESCRIPTION Mast Group Number Lift Cylinder

A776 3849 518382607

A776 4230 518382612

A776 4688 518382618

Piston Rod

518384607

518384612

518384618

Tube

518383607

518383612

518383618

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13

PART NO.

DESCRIPTION

QTY

a .. . . . Lift Cylinder................................................................................................................ .. . . . Wiper Ring ........................................................................................................... .. . . . Seal ...................................................................................................................... 518385600 Gland.................................................................................................................... .. . . . Back-Up Ring ....................................................................................................... .. . . . O-Ring.................................................................................................................. a .. . . . Piston Rod............................................................................................................ .. . . . Wear Ring ............................................................................................................ 032640600 Ball ....................................................................................................................... 520010800 Plug ...................................................................................................................... a .. . . . Tube ..................................................................................................................... 502980503 Velocity Fuse (23 GPM) ....................................................................................... 502687901 Seal ...................................................................................................................... 501753914 Capscrew .............................................................................................................

1 1 1 1 1 1 1 1 2 2 1 1 1 1

522375004 Seal Kit (Includes Items 1-2, 4-5, 7, 12) ....................................................................

FOOTNOTES: a Refer to Table

7-23

G10756

09-02

HEADER HOSE GROUP (MRW020-030E)

HEADER HOSE GROUPMRW020-030E

7-24

G10756

09-02

HEADER HOSE GROUP (MRW020-030E)

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 16 17 18 19 20 21 22 22 22

PART NO.

DESCRIPTION

580020492 580016811 580016813 015126000 580016812 580016814 507163500 507162500 580006788 449021001 449022016 501989901 500227910 580032377 015415900 580033718 580036056 580036050 524165427 518801644 504064758 504234266 500227907 .. . . . 580036026 580037641 580036055

Free-Lift Header Assembly ........................................................................................ Cross-Head .......................................................................................................... Guard ................................................................................................................... Ball Bearing.......................................................................................................... Chain Sheave....................................................................................................... Axle ...................................................................................................................... Sheave ................................................................................................................. Sheave ................................................................................................................. Screw ................................................................................................................... Washer ................................................................................................................. Lockwasher .......................................................................................................... Snap Ring ............................................................................................................ Snap Ring ............................................................................................................ Capscrew ............................................................................................................. Cotter Pin .................................................................................................................. Pin ............................................................................................................................. Hose (239 in.) ............................................................................................................ Hose (225 in.) ............................................................................................................ Hose (210 in.) ............................................................................................................ Chain Anchor............................................................................................................. Base Ring .................................................................................................................. Nut ............................................................................................................................. Snap Ring.................................................................................................................. Free-Lift Cylinder (â&#x2DC;&#x17E; G10754) ................................................................................. Wire Assembly (213 in.) ............................................................................................ Wire Assembly (229 in.) ............................................................................................ Wire Assembly (243 in.) ............................................................................................

QTY

1 1 2 2 2 1 2 1 4 2 2 2 1 2 4 2 2 2 2 2 2 2 1 1 1 1 1

7-25

G10741

09-02

INTEGRAL TILT ASSEMBLY (MRW020-030E)

INTEGRAL TILT ASSEMBLYMRW020-030E

7-26

G10741

09-02

INTEGRAL TILT ASSEMBLY (MRW020-030E)

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

PART NO.

DESCRIPTION

QTY

580016605 Front End Assembly .................................................................................................. 580024555 Washer ................................................................................................................. 580024551 Washer ................................................................................................................. 580024550 Screw ................................................................................................................... 580024545 Screw ................................................................................................................... 580024546 Screw ................................................................................................................... 580024556 Hook..................................................................................................................... 580024589 Tilt Frame ............................................................................................................. 580024561 Shaft..................................................................................................................... 580024554 Bushing ................................................................................................................ 580024543 Bushing ................................................................................................................ 580024571 Cylinder ................................................................................................................ 580033680 Housing............................................................................................................ 580033817 Wear Band ....................................................................................................... 580033883 Piston and Rod Assembly................................................................................ 580033816 O-Ring ............................................................................................................. 580032449 Back-Up Ring................................................................................................... 580032383 Gland ............................................................................................................... 580033660 Snap Ring ........................................................................................................ 580033815 Seal.................................................................................................................. 580032450 Wiper ............................................................................................................... 580024563 Frame ................................................................................................................... 580024544 Screw ................................................................................................................... 580024548 Screw ...................................................................................................................

1 2 2 2 2 2 2 1 2 2 2 1 2 2 2 2 2 2 2 2 2 1 1 2

580033681 Seal Kit (Tilt Cylinder) (Includes Items 13, 15-16, 19-20)..........................................

7-27

G10742

09-02

INTEGRAL TILT ASSEMBLY (WITH SIDESHIFT) (MRW020-030E)

INTEGRAL TILT ASSEMBLY WITH SIDESHIFT MRW020-030E

7-28

G10742

09-02

INTEGRAL TILT ASSEMBLY (WITH SIDESHIFT) (MRW020-030E)

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

PART NO.

DESCRIPTION

580016604 580024567 580024564 580024565 580024555 580024551 580024550 580024550 580024561 580024554 580024563 580024556 580024546 580024568 580024572 580024573 580024569 580024552 580024562 580024566 580024547 580024557 580024544 580024570 580024548 580024545 580024543 580024571 580033680 580033817 580033883 580033816 580032449 580032383 580033660 580033815 580032450 503251200 503250200 580008824

Integral Side-Shift Assembly ..................................................................................... 1 Pad ....................................................................................................................... 1 Pad ....................................................................................................................... 1 Pad ....................................................................................................................... 1 Washer ................................................................................................................. 2 Washer ................................................................................................................. 2 Screw ................................................................................................................... 2 Screw ................................................................................................................... 2 Shaft..................................................................................................................... 2 Bushing ................................................................................................................ 2 Frame ................................................................................................................... 1 Hook..................................................................................................................... 2 Screw ................................................................................................................... 4 Rod....................................................................................................................... 2 Ring...................................................................................................................... 2 Snap Ring ............................................................................................................ 2 Bushing ................................................................................................................ 2 Seal ...................................................................................................................... 2 Frame ................................................................................................................... 1 Pad ....................................................................................................................... 1 Nut........................................................................................................................ 2 Frame ................................................................................................................... 1 Screw ................................................................................................................... 1 Hook..................................................................................................................... 2 Screw ................................................................................................................... 4 Screw ................................................................................................................... 2 Bushing ................................................................................................................ 2 Cylinder ................................................................................................................ 1 Housing............................................................................................................ 1 Wear Band ....................................................................................................... 2 Piston and Rod Assembly................................................................................ 2 O-Ring ............................................................................................................. 2 Back-Up Ring................................................................................................... 2 Gland ............................................................................................................... 2 Snap Ring ........................................................................................................ 2 Seal.................................................................................................................. 2 Wiper ............................................................................................................... 2 Shim .......................................................................................................................... AR Stop ........................................................................................................................... 2 Capscrew................................................................................................................... 4

580033681 Seal Kit (Tilt Cylinder) (Includes Items 29, 31-32, 35-36)..........................................

QTY

7-29

G10753

09-02

LIFT CYLINDER ASSEMBLY (MRW020-030E)

LIFT CYLINDER ASSEMBLYMRW020-030E

7-30

G10753

09-02

LIFT CYLINDER ASSEMBLY (MRW020-030E)

OALH DESCRIPTION Mast Group Number Lift Cylinder

B736 3721 580036069

B736 4102 580036072

B736 4559 580035981

Tube

520672676

520672681

520672686

Rod

518895645

518895650

518895655

ITEM

PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

a .. . . . a .. . . . a .. . . . 504161200 504160200 504024202 504235239 504232230 504148200 501850904 505593500 504163200 580022502 502978502 015492900

DESCRIPTION

QTY

Lift Cylinder................................................................................................................ Tube........................................................................................................................... Rod ............................................................................................................................ Back-Up Ring ............................................................................................................ Seal ........................................................................................................................... Wear Ring.................................................................................................................. Check Valve............................................................................................................... O-Ring ....................................................................................................................... Washer ...................................................................................................................... Snap Ring.................................................................................................................. Gland ......................................................................................................................... Wiper Ring................................................................................................................. Rod Seal.................................................................................................................... Velocity Fuse ............................................................................................................. O-Ring .......................................................................................................................

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

505136037 Seal Kit (Includes Items 3-5, 7, 11-12, 14) ................................................................

FOOTNOTES: a Refer to Table

7-31

G10683

09-02

LIFT CYLINDER ASSEMBLY (MSW 030-040E) (THREE STAGE FULL FREE-LIFT)

LIFT CYLINDER ASSEMBLYMSW 030-040ETHREE STAGE FULL FREE-LIFT

7-32

G10683

09-02

LIFT CYLINDER ASSEMBLY (MSW 030-040E) (THREE STAGE FULL FREE-LIFT) MSW30E OALH ITEM

DESCRIPTION Mast Group Number Lift Cylinder

A776 3849 518356607

A776 4230 518356612

A776 4688 518356618

Piston Rod

518340607

518340612

518340618

Tube

518335607

518335612

518335618

MSW40E OALH ITEM

DESCRIPTION Mast Group Number Lift Cylinder

A776 3849 518442607

A776 4230 518442612

A776 4688 518442618

Piston Rod

518340607

518340612

518340618

Tube

518335607

518335612

518335618

ITEM

1 2 3 4 5 6 7 8 9 10 11 11 11 12 13 14 15 16

PART NO.

DESCRIPTION

QTY

a .. . . . Lift Cylinder................................................................................................................ 1 500381512 Wiper Ring ........................................................................................................... 1 504153200 Seal ...................................................................................................................... 2 505593500 Gland.................................................................................................................... 1 012825700 O-Ring.................................................................................................................. 1 a .. . . . Piston Rod............................................................................................................ 1 504154200 Back-Up Ring ....................................................................................................... 1 504024201 Wear Ring ............................................................................................................ 1 504155200 O-Ring.................................................................................................................. 1 504147200 Check Valve ......................................................................................................... 1 504148200 Washer ................................................................................................................. 1 504151200 Shim (0.005 in.).................................................................................................... AR 504150200 Shim (0.007 in.).................................................................................................... AR 504149200 Shim (0.020 in.).................................................................................................... AR 501850904 Snap Ring ............................................................................................................ 1 504157200 Piston ................................................................................................................... 1 064570300 Snap Ring ............................................................................................................ 1 502978501 Velocity Fuse (10 GPM) ....................................................................................... 1 a .. . . . Tube ..................................................................................................................... 1 505136029 Seal Kit (Includes Items 1-2, 4, 6-8) ..........................................................................

FOOTNOTES: a Refer to Table

7-33

G10676

09-02

LIFT CYLINDER ASSEMBLY (MSW 030-040E) (TWO STAGE LIMITED FREE-LIFT)

LIFT CYLINDER ASSEMBLYMSW 030-040ETWO STAGE LIMITED FREE-LIFT

7-34

G10676

09-02

LIFT CYLINDER ASSEMBLY (MSW 030-040E) (TWO STAGE LIMITED FREE-LIFT) MSW 030E OALH DESCRIPTION Mast Group Number Lift Cylinder

A775 2496 503353703

A775 2750 503353711

A775 3054 503353716

A775 3512 503353722

A775 3715 503353731

Rod

516547603

516547611

516547616

516547622

516547631

Tube

516780603

516780611

516780616

516780622

516780631

ITEM

MSW 040E OALH DESCRIPTION Mast Group Number Lift Cylinder

A729 2597 503354711

A729 2851 503354716

A729 3156 503354722

A729 3613 503354731

Rod

516547611

516547616

516547622

516547631

Tube

516780609

516780614

516780620

516780629

ITEM

PART NO.

1 2 3 4 5 6 7 8 9 10 11

a .. . . . 516546600 .. . . . .. . . . .. . . . 311104011 .. . . . .. . . . 502117902 a .. . . . a .. . . . .. . . .

DESCRIPTION

QTY

Lift Cylinder................................................................................................................ Gland ......................................................................................................................... Wiper Ring................................................................................................................. Seal Rod.................................................................................................................... O-Ring ....................................................................................................................... Screw......................................................................................................................... O-Ring ....................................................................................................................... Back-Up Ring ............................................................................................................ Plug ........................................................................................................................... Rod ............................................................................................................................ Tube........................................................................................................................... Wear Ring..................................................................................................................

1 1 1 1 1 1 1 1 2 1 1 1

505136013 Cylinder Seal Kit (Includes Items 2-4, 6-7, 11) ..........................................................

FOOTNOTES: a Refer to Table

7-35

G10755

09-02

LIFT CYLINDER INSTALLATION (MRW020-030E)

LIFT CYLINDER INSTALLATIONMRW020-030E

7-36

G10755

09-02

LIFT CYLINDER INSTALLATION (MRW020-030E)

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO.

DESCRIPTION

500227907 504064767 580037681 449021010 449001014 449022016 524165377 449021001 .. . . . 580016684 580016685 449001170 449022018 .. . . . 580017054 909882405 580037682 449021003

Snap Ring.................................................................................................................. Washer ...................................................................................................................... Capscrew................................................................................................................... Washer ...................................................................................................................... Capscrew................................................................................................................... Lockwasher ............................................................................................................... Retainer (Cylinder) .................................................................................................... Washer ...................................................................................................................... Main Lift Cylinder (☞ G10753) ................................................................................ Plate (RH).................................................................................................................. Plate (LH) .................................................................................................................. Capscrew................................................................................................................... Lockwasher ............................................................................................................... Free Lift Cylinder (☞ G10754) ................................................................................. Clamp ........................................................................................................................ Nut ............................................................................................................................. Bracket ...................................................................................................................... Washer ......................................................................................................................

QTY

2 2 6 6 4 4 2 4 2 1 1 6 6 1 1 4 1 4

7-37

G10681

09-02

LIFT CYLINDER INSTALLATION (MSW 030-040E) (THREE STAGE FULL FREE-LIFT)

LIFT CYLINDER INSTALLATIONMSW 030-040ETHREE STAGE FULL FREE-LIFT

7-38

G10681

09-02

LIFT CYLINDER INSTALLATION (MSW 030-040E) (THREE STAGE FULL FREE-LIFT) MSW30-40E OALH ITEM 2

DESCRIPTION Mast Group Number Hose

ITEM

PART NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 25 26 26 27 27 28 29 30 31 32

501334200 a .. . . . 502911500 449029001 502673901 .. . . . 502980503 505583500 015003300 500227915 520005801 504049201 503837201 449001023 449022005 449021006 504031200 .. . . . 502978501 518572600 518571600 449001014 449022016 502664909 052641400 052645400 052229600 052645400 052642300 052645300 500252133 505676500 449001172 449022016 449022001

DESCRIPTION

A776 3849 502738903

A776 4230 502738919

A776 4688 502738931 QTY

Spacer ....................................................................................................................... 2 Hose .......................................................................................................................... 1 Sheave ...................................................................................................................... 1 Snap Ring.................................................................................................................. 1 Fitting......................................................................................................................... 1 Free-Lift Cylinder (☞ G10682) ................................................................................. 1 Velocity Fuse (23 GPM)............................................................................................. 1 Clamp ........................................................................................................................ 1 Nut ............................................................................................................................. 2 Snap Ring.................................................................................................................. 2 Washer ...................................................................................................................... 2 Bushing ..................................................................................................................... 2 Shim .......................................................................................................................... AR Capscrew................................................................................................................... 4 Lockwasher ............................................................................................................... 4 Washer ...................................................................................................................... 4 Guard ........................................................................................................................ 2 Lift Cylinder (☞ G10683) ......................................................................................... 2 Velocity Fuse (10 GPM)............................................................................................. 1 Plate (LH) .................................................................................................................. 1 Bracket (RH) .............................................................................................................. 1 Capscrew................................................................................................................... 4 Lockwasher ............................................................................................................... 4 Hose .......................................................................................................................... 2 Fitting......................................................................................................................... 1 O-Ring (Face Seal) .............................................................................................. 1 Fitting......................................................................................................................... 1 O-Ring (Face Seal) .............................................................................................. 1 Fitting......................................................................................................................... 1 O-Ring.................................................................................................................. 1 Flow Regulator (12 GPM).......................................................................................... 1 Housing ..................................................................................................................... 1 Capscrew................................................................................................................... 2 Lockwasher ............................................................................................................... 2 Lockwasher ............................................................................................................... 2

FOOTNOTES: a Refer to Table

7-39

G10675

09-02

LIFT CYLINDER INSTALLATION (MSW 030-040E) (TWO STAGE LIMITED FREE-LIFT)

LIFT CYLINDER INSTALLATIONMSW 030-040ETWO STAGE LIMITED FREE-LIF T

7-40

G10675

09-02

LIFT CYLINDER INSTALLATION (MSW 030-040E) (TWO STAGE LIMITED FREE-LIFT) MSW030E OALH

DESCRIPTION Mast Group Number Lift Cylinder

Hose

ITEM

A775 2496 503353703

A775 2750 503353711

A775 3054 503353716

A775 3512 503353722

A775 3715 503353731

a 502242937

a 502430917

a 502429938

a 502430906

a 502242918

MSW040E OALH

DESCRIPTION Mast Group Number Lift Cylinder

Hose

ITEM

PART NO.

1 2 3 4 5 5 6 6 7 8 9 9 10 11

449001016 506611100 b .. . . . 019920400 524170909 524170910 052643400 052645400 500252123 504092500 502631901 052645400 932201903 b .. . . .

A775 2750 503354711

A775 3054 503354716

A775 3512 503354722

A775 3715 503354731

a 502430917

a 502429938

a 502430906

a 502242918

DESCRIPTION

Capscrew................................................................................................................... Washer ...................................................................................................................... Lift Cylinder................................................................................................................ Fitting......................................................................................................................... Tube (23 in. Battery Box)........................................................................................... Tube (34 in. Battery Box)........................................................................................... Fitting......................................................................................................................... O-Ring (Face Seal) .............................................................................................. Regulator (10 GPM) .................................................................................................. Housing ..................................................................................................................... Fitting......................................................................................................................... O-Ring (Face Seal) .............................................................................................. Capscrew................................................................................................................... Hose ..........................................................................................................................

QTY

2 2 1 1 1 1 1 1 1 1 1 2 1 2

FOOTNOTES: a Not Illustrated b Refer to Table

7-41

G10781

10-02

FORK CARRIAGE (MSW 030-040E)

FORK CARRIAGEMSW 030-040E

7-42

G10781

10-02

FORK CARRIAGE (MSW 030-040E)

ITEM

1 1 2 3 4 5 6

PART NO.

DESCRIPTION

519955601 519958601 932118906 937100907 253851200 449029011 504558100

Carriage (MSW 030E) ............................................................................................... Carriage (MSW 040E) ............................................................................................... Screw......................................................................................................................... Nut ............................................................................................................................. Load Roller ................................................................................................................ Snap Ring.................................................................................................................. Plug ...........................................................................................................................

QTY

1 1 2 2 4 4 4

7-43

G10780

10-02

INNER CARRIAGE (MRW020-030E)

INNER CARRIAGEMRW020-030E

7-44

G10780

10-02

INNER CARRIAGE (MRW020-030E)

ITEM

1 2 3 4 5 6 6 6 7 8 9 10 11 12 13 14 15 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

PART NO.

DESCRIPTION

580020925 580016608 580020926 580027413 065771000 065069900 065069800 065069700 064424900 507033500 449029009 312233090 015628700 907806300 449022017 449001003 504562100 449015020 524150971 524149946 500412904 203191200 061643400 449001202 580033283 449022018 019899500 449001343 580020023 909086104 909086102 720217902 449021001 449001076 449022016 501921903 940600907 449001114 449001170 449021003 580023893 505970500 449015014 580027415 580027414 056363100

Rear Frame................................................................................................................ Bushing ..................................................................................................................... Valve.......................................................................................................................... Bracket ...................................................................................................................... Spacer ....................................................................................................................... Thrust Roller (3.1 in.)................................................................................................. Thrust Roller (3.0 in.)................................................................................................. Thrust Roller (2.9 in.)................................................................................................. Washer ...................................................................................................................... Load Roller ................................................................................................................ Snap Ring.................................................................................................................. Snap Ring.................................................................................................................. Lube Fitting................................................................................................................ Roller Assembly......................................................................................................... Lockwasher ............................................................................................................... Capscrew................................................................................................................... Plug ........................................................................................................................... Nut ............................................................................................................................. Hose Assembly.......................................................................................................... Hose Assembly.......................................................................................................... Clamp ........................................................................................................................ Fitting......................................................................................................................... Fitting......................................................................................................................... Capscrew................................................................................................................... Bracket ...................................................................................................................... Lockwasher ............................................................................................................... Fitting......................................................................................................................... Capscrew................................................................................................................... Sheave ...................................................................................................................... Shim (0.125 in.) ......................................................................................................... Shim (0.030 in.) ......................................................................................................... Snap Ring.................................................................................................................. Washer ...................................................................................................................... Capscrew................................................................................................................... Lockwasher ............................................................................................................... Clamp ........................................................................................................................ Washer ...................................................................................................................... Capscrew................................................................................................................... Capscrew................................................................................................................... Washer ...................................................................................................................... Plate .......................................................................................................................... Nut ............................................................................................................................. Nut ............................................................................................................................. Check Valve............................................................................................................... Valve Block........................................................................................................... Fitting ...................................................................................................................

QTY

1 2 1 1 2 1 2 4 2 6 6 2 12 2 4 4 2 2 2 2 4 4 4 2 1 13 2 2 2 2 2 2 4 2 10 4 2 7 7 1 2 1 2 1 1 2

7-45

G10780

10-02

INNER CARRIAGE (MRW020-030E)

ITEM

PART NO.

500423903 a 312850040

FOOTNOTES: a Not Illustrated

7-46

DESCRIPTION

Fitting ................................................................................................................... Strap Clamp...............................................................................................................

QTY

2 2

NOTES

7-47

G10772

09-02

SCISSOR CARRIAGE (MRW020-030E)

SCISSOR CARRIAGEMRW020-030E

7-48

G10772

09-02

SCISSOR CARRIAGE (MRW020-030E)

ITEM

PART NO.

1 1 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 14 15 16 17 18 19 20 21 22 23 24 25 26

057048200 015026400 501702902 580019789 502880205 502880200 580022320 580020928 580016607 502887202 503229200 015628700 580026788 502880201 580020023 720217902 502882200 910218101 580022409 580016608 519782800 580022319 580023849 580022515 502889200 059482800 580027564 062699900 580020934 580020932 a 449001028

DESCRIPTION

Capscrew................................................................................................................... Lockwasher ............................................................................................................... Thread Sealer............................................................................................................ Cap ............................................................................................................................ Washer ...................................................................................................................... Washer ...................................................................................................................... Arm Assembly (RH)................................................................................................... Arm Assembly (LH) ................................................................................................... Bearing ...................................................................................................................... Shim (0.050 in.) ......................................................................................................... Bearing ...................................................................................................................... Lube Fitting................................................................................................................ Bushing ..................................................................................................................... Washer ...................................................................................................................... Sheave ...................................................................................................................... Snap Ring.................................................................................................................. Load Bearing ............................................................................................................. Shim (0.020 in.) ......................................................................................................... Support...................................................................................................................... Bushing ..................................................................................................................... Bushing ..................................................................................................................... Pin ............................................................................................................................. Bolt ............................................................................................................................ Pin ............................................................................................................................. Pin ............................................................................................................................. Nut ............................................................................................................................. O-Ring ....................................................................................................................... Fitting......................................................................................................................... Cylinder Assembly (RH) (☞ G10753) ...................................................................... Cylinder Assembly (LH) (☞ G10753) ...................................................................... Capscrew...................................................................................................................

QTY

6 6 1 2 2 2 1 1 2 2 2 6 2 2 1 2 2 2 1 2 2 2 4 2 2 4 4 4 1 1 2

FOOTNOTES: a Not Illustrated

7-49

NOTES

7-50

SECTION 8

8 OPTIONS

OPTIONS

CONTENTS

SECTION 8 OPTIONS DESCRIPTION

PAGE

BATTERY ROLLER .............................................................................................................................................. 8-2 CONTROL HANDLE ARM ASSEMBLY SEMI-ROTARY.................................................................................................................................................. 8-4 CONTROL HANDLE ASSEMBLY OPTIONAL........................................................................................................................................................ 8-6 LOAD WHEEL FIXED TANDEM.............................................................................................................................................. 8-12 OPERATOR GUARD THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-14 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 8-16 SIDE-SHIFT ASSEMBLY HANG-ON TYPE............................................................................................................................................... 8-8 SIDE-SHIFT CYLINDER HANG-ON TYPE............................................................................................................................................. 8-10 ZAPI-HANDSET KIT........................................................................................................................................... 8-18 ZAPI-LAPTOP/PC KIT (WINDOWS) .................................................................................................................. 8-19

8-1

G10643

09-02

BATTERY ROLLER

BATT ERY ROL LER

8-2

G10643

09-02

BATTERY ROLLER

ITEM

PART NO.

1 1 2 2 3 4 5 6 7 8 8 8 8 9 9 10 11

524145032 524141433 504035208 504035207 055485000 016110000 015026600 014964800 507394500 502642218 502642219 524171469 502642220 580012736 a 580014878 015026000 014936500

DESCRIPTION

Battery Tray (9")......................................................................................................... Battery Tray (13")....................................................................................................... Roller Assembly (9") .................................................................................................. Roller Assembly (13") ................................................................................................ Capscrew................................................................................................................... Washer ...................................................................................................................... Lockwasher ............................................................................................................... Nut ............................................................................................................................. Retaining Gate .......................................................................................................... Battery Spacer (2.75") ............................................................................................... Battery Spacer (3") .................................................................................................... Battery Spacer (.50") ................................................................................................. Battery Spacer (3.25") ............................................................................................... Capscrew................................................................................................................... Capscrew................................................................................................................... Lockwasher ............................................................................................................... Nut .............................................................................................................................

QTY

1 1 4 4 2 2 2 2 2 2 2 2 2 4 4 4 4

FOOTNOTES: a Used with .50" battery spacer plate.

8-3

G10743

09-02

CONTROL HANDLE ARM ASSEMBLY (SEMI-ROTARY)

CONTROL HANDLE ARM ASSEMBLYSEMI-ROTARY

8-4

G10743

09-02

CONTROL HANDLE ARM ASSEMBLY (SEMI-ROTARY)

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 15 16 17 18 19 20 21 22 23 24 25 26 26 26 26 26 27 28

c d

a a a a

b b

PART NO.

DESCRIPTION

524163971 059863600 016103700 524143278 524143285 524141136 504574232 524145025 580004592 580022964 449021001 519766808 580000119 524163973 524180330 524149833 524153715 751191100 580017792 524144586 524170831 505970553 449022018 520053859 580021175 580002500 580024916 580024919 449021006 449001302 449015044 620033319 524180333 524164789 524170154

Tube (Semi-Rotary) ................................................................................................... Capscrew................................................................................................................... Washer ...................................................................................................................... Shaft .......................................................................................................................... Pin ............................................................................................................................. Ball Stud .................................................................................................................... Fitting......................................................................................................................... Bushing ..................................................................................................................... Nut ............................................................................................................................. Capscrew................................................................................................................... Washer ...................................................................................................................... Lockwasher ............................................................................................................... Plug ........................................................................................................................... Control Handle Assembly (☞ G10773) .................................................................... Control Handle Assembly (☞ G10773) .................................................................... Gas Spring ................................................................................................................ Switch ........................................................................................................................ Plate .......................................................................................................................... Screw......................................................................................................................... Capscrew................................................................................................................... Switch Cover ............................................................................................................. Capscrew................................................................................................................... Lockwasher ............................................................................................................... Screw......................................................................................................................... Clamp ........................................................................................................................ Clamp ........................................................................................................................ Bracket ...................................................................................................................... Stud...................................................................................................................... Washer ................................................................................................................. Capscrew ............................................................................................................. Nut........................................................................................................................ Shim (0.030 in.) ......................................................................................................... Screw......................................................................................................................... Wire Harness (C820)................................................................................................. Wire Harness (C821).................................................................................................

QTY

1 1 1 1 1 2 1 2 2 2 2 2 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 5 1 4 3 4 1 1

FOOTNOTES: a For mounting to MDU. b Not Illustrated c ⇒ S/N PENDING PER ECN 84431 d S/N PENDING PER ECN 84431 ⇒

8-5

G10773

09-02

CONTROL HANDLE ASSEMBLY (OPTIONAL)

CONTROL HANDLE ASSEMBLYOPTIONAL

8-6

G10773

09-02

CONTROL HANDLE ASSEMBLY (OPTIONAL)

ITEM

1 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

PART NO.

b a a b a b

DESCRIPTION

524180330 Control Handle Assembly .......................................................................................... 524163973 Control Handle Assembly .......................................................................................... 524144348 Lower Part............................................................................................................ 524180331 Lower Part............................................................................................................ 524144349 Upper Part............................................................................................................ 524180332 Upper Part............................................................................................................ 580025595 Interface Single Board (Standard)........................................................................ 580013106 Camshaft.............................................................................................................. 580012962 Bushing ................................................................................................................ 524144370 Butterfly Switch (LH) ............................................................................................ 940004902 Washer ................................................................................................................. 580026296 Screw ................................................................................................................... 580012970 Spring................................................................................................................... 524144369 Butterfly Switch (RH)............................................................................................ 580011991 Switch Cover ........................................................................................................ 580012969 Spring................................................................................................................... 580038175 Spring................................................................................................................... 524139009 Cover.................................................................................................................... 524148522 Proportional Switch Assembly.............................................................................. 580012967 Label (RH)............................................................................................................ 580012968 Label (LH) ............................................................................................................ 524144387 Label .................................................................................................................... 524144374 Actuator (Blank) ................................................................................................... 524148521 Switch Assembly .................................................................................................. 524149804 Button .............................................................................................................. 580026824 Switch ..............................................................................................................

QTY

1 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1

FOOTNOTES: a ⇒ S/N PENDING PER ECN 84431 b S/N PENDING PER ECN 84431 ⇒

8-7

G10880

11-02

SIDE-SHIFT ASSEMBLY (HANG-ON TYPE)

SIDE-SHIFT ASSEMBLYHANG-ON TYPE

8-8

G10880

11-02

SIDE-SHIFT ASSEMBLY (HANG-ON TYPE)

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 a a a a a a a a a a a

PART NO.

DESCRIPTION

QTY

506250521 580010513 580010522 518801602 504230271 504061746 449015098 504061795 519666602 015628700 504061724 518807670 518807609 931018903 504061794 580010504 523128009 500111904 052645200 062699900 056363300 515045304 524166533 506250541 504243706 504235209 518801667

Side-Shift Assembly (Hang-on) ................................................................................. 1 Bearing................................................................................................................. 1 Support ................................................................................................................ 1 Capscrew ............................................................................................................. 2 Nut........................................................................................................................ 2 Rod (Optional)...................................................................................................... 2 Locknut (Optional) ................................................................................................ 4 Shim (0.020 in.).................................................................................................... AR Side-Shift Cylinder (â&#x2DC;&#x17E; G10882) ......................................................................... 1 Lube Fitting .......................................................................................................... 3 Apron (Upper) ...................................................................................................... 1 Apron (Lower) ...................................................................................................... 1 Bearing................................................................................................................. 1 Capscrew ............................................................................................................. 4 Washer ................................................................................................................. 4 Shim ..................................................................................................................... AR Hose Kit (Hang-on Side-shift).................................................................................... 1 Fitting (90 degree)................................................................................................ 2 O-Ring (Face Seal) .......................................................................................... 1 Fitting ................................................................................................................... 2 O-Ring ............................................................................................................. 1 Hose..................................................................................................................... 2 Label (Sideshift)......................................................................................................... 1 Nameplate Attachment .............................................................................................. 1 Nameplate Blank.................................................................................................. 1 Rivet (Optional).......................................................................................................... 4 Screw......................................................................................................................... 4

FOOTNOTES: a Not Illustrated

8-9

G10882

11-02

SIDE-SHIFT CYLINDER (HANG-ON TYPE)

SIDE-SHIFT CYLINDERHANG-ON TYPE

ITEM

1 2 3 4 5 6 7 8 9

PART NO.

DESCRIPTION

519666602 504232210 506552501 580012259 500167924 012825700 513439107 504020504 519664601 519665601

Side-Shift Cylinder..................................................................................................... Wiper Ring ........................................................................................................... Gland.................................................................................................................... Seal ...................................................................................................................... Back-Up Ring ....................................................................................................... O-Ring.................................................................................................................. Spacer.................................................................................................................. Seal ...................................................................................................................... Rod....................................................................................................................... Shell .....................................................................................................................

1 2 2 2 2 2 2 1 1 1

a 505136053

Seal Kit (Includes Items 1, 3-5, 7) .............................................................................

FOOTNOTES: a Not Illustrated

8-10

QTY

NOTES

8-11

G10717

11-02

LOAD WHEEL (FIXED TANDEM)

LOAD WHEELFIXED TANDEM

8-12

G10717

11-02

LOAD WHEEL (FIXED TANDEM)

ITEM

1 2 3 4 5 6 7

PART NO.

DESCRIPTION

524150937 025884300 524150938 501195100 723624100 016092800 015628700

Load Wheel ............................................................................................................... Bearing Ball ............................................................................................................... Axle Shaft .................................................................................................................. Pin ............................................................................................................................. Washer ...................................................................................................................... Washer ...................................................................................................................... Lube Fitting................................................................................................................

QTY

2 4 2 1 4 8 2

8-13

G10731

11-02

OPERATOR GUARD (THREE STAGE FULL FREE-LIFT)

OPERATOR GUARDTHREE STAGE FUL L FR EE-LIFT

8-14

G10731

11-02

OPERATOR GUARD (THREE STAGE FULL FREE-LIFT)

ITEM

1 1 1 1 1 2 2 3 3 4 4 4 5 5 5 6 6 7 7 8 9 10 11 12 13 14 15

e a f c d b c f

PART NO.

DESCRIPTION

524171849 524171783 524173543 524173544 524172868 524172345 524171723 524171722 524172344 524171721 524172878 524172343 524171720 524172342 524172877 524171719 524172876 524171718 524172875 449007055 524172263 449021001 449022016 449015014 059716300 015026200 016103700

Operator Guard (72" and 77") ................................................................................... Operator Guard (83")................................................................................................. Operator Guard (73")................................................................................................. Operator Guard (78")................................................................................................. Operator Guard (C821 - 83") ..................................................................................... Bracket (73"/78" LH-Top) ........................................................................................... Bracket (72"/77"/83" LH-Top)..................................................................................... Bracket (RH Top) (72/77 in.) ...................................................................................... Bracket (RH Top) (73/78 in.) ...................................................................................... Bracket (72"/77"/83" LH-Middle) ................................................................................ Bracket (C821 - 83" LH-Middle)................................................................................. Bracket (73"/78" LH-Middle) ...................................................................................... Bracket (RH Middle) (72/77/83 in.) ............................................................................ Bracket (RH MIddle) (73/78 in.) ................................................................................. Bracket (RH Middle) (83 in.) (C821).......................................................................... Bracket (83" LH-Bottom)............................................................................................ Bracket (C821 - 83" LH-Bottom)................................................................................ Bracket (RH Bottom) (83 in.) ..................................................................................... Bracket (RH Bottom) (83 in.) (C821) ......................................................................... Screw......................................................................................................................... Washer ...................................................................................................................... Washer ...................................................................................................................... Lockwasher ............................................................................................................... Nut ............................................................................................................................. Capscrew................................................................................................................... Lockwasher ............................................................................................................... Washer ......................................................................................................................

FOOTNOTES: a 83" requires b 83" requires c 83" requires d 83" requires e 83" requires f 83" requires

QTY

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 8 4 4 4 4 4 4

12 washers. 6 capscrews. 6 lockwashers. 6 nuts. 6 screws. 6 washers.

8-15

G10730

11-02

OPERATOR GUARD (TWO STAGE LIMITED FREE-LIFT)

OPERATOR GUARDTWO STAGE LIMITED F REE-L IFT

8-16

G10730

11-02

OPERATOR GUARD (TWO STAGE LIMITED FREE-LIFT)

ITEM

1 1 1 1 1 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 7 7 8 9 10 11 12 13 14 15

e a f c d b c f

PART NO.

DESCRIPTION

524171848 524171849 524171783 524171845 524171844 524172346 524172347 524172867 524171853 524172345 524171723 524171853 524172344 524171722 524171853 524172343 524172878 524171853 524172342 524172877 524171853 524172876 524171853 524172875 449007055 524172263 449021001 449022016 449015014 059716300 015026200 016103700

Operator Guard (64")................................................................................................. Operator Guard (72" and 77") ................................................................................... Operator Guard (83")................................................................................................. Operator Guard (92")................................................................................................. Operator Guard (87")................................................................................................. Operator Guard (C821 - 72") ..................................................................................... Operator Guard (C821 - 77") ..................................................................................... Operator Guard (C821 - 83") ..................................................................................... Bracket (64"/72"/77"/83"/92"/87" LH-Top) .................................................................. Bracket (C821 - 72"/77" LH-Top) ............................................................................... Bracket (C821 - 83" LH-Top) ..................................................................................... Bracket (RH Top) (64/72/77/83/92/87 in.) .................................................................. Bracket (RH Top) (72/77 in.) (C821).......................................................................... Bracket (RH Top) (83 in.) (C821)............................................................................... Bracket (64"/72"/77"/83"/92"/87" LH-Middle) ............................................................. Bracket (C821 - 72"/77" LH-Middle) .......................................................................... Bracket (C821 - 83" LH-Middle)................................................................................. Bracket (RH MIddle) (64/72/77/83/92/87 in.) ............................................................. Bracket (RH Middle) (72/77 in.) (C821)..................................................................... Bracket (RH Middle) (83 in.) (C821).......................................................................... Bracket (83"/92"/87" LH-Bottom) ............................................................................... Bracket (C821-83" LH-Bottom).................................................................................. Bracket (RH Bottom) (83/92/87 in.) ........................................................................... Bracket (RH Bottom) (83 in.) (C821) ......................................................................... Screw......................................................................................................................... Washer ...................................................................................................................... Washer ...................................................................................................................... Lockwasher ............................................................................................................... Nut ............................................................................................................................. Capscrew................................................................................................................... Lockwasher ............................................................................................................... Washer ......................................................................................................................

FOOTNOTES: a 83" requires b 83" requires c 83" requires d 83" requires e 83" requires f 83" requires

QTY

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 8 4 4 4 4 4 4

12 washers. 6 capscrews. 6 lockwashers. 6 nuts. 6 screws. 6 washers.

8-17

G10739

11-02

ZAPI-HANDSET KIT

ITEM

1 2

8-18

PART NO.

DESCRIPTION

524154481 272210700 524149943

Handset Kit (ZAPI)..................................................................................................... Handset Console.................................................................................................. Adaptor Harness ..................................................................................................

QTY

1 1 1

G10740

11-02

ZAPI-LAPTOP/PC KIT (WINDOWS)

ITEM

1 2 3

PART NO.

DESCRIPTION

524154242 Laptop/PC Kit (ZAPI) (Windows) ............................................................................... 524149943 Adaptor Harness .................................................................................................. 277326000 Cable and Software Kit (Windows)....................................................................... .. . . . Cable................................................................................................................ .. . . . Software...........................................................................................................

QTY

1 1 1 1 1

8-19

NOTES

8-20

SECTION 9

NUMERICAL INDEX

PART NO.

PG. ITEM

012056430A 5-3 012825700 7-19 7-33 8-10 014716400 7-4 014716600 7-7 014867800 1-15 014936500 1-15 8-3 014964800 8-3 015003300 7-39 015026000 1-15 8-3 015026200 1-7 8-15 8-17 015026400 7-49 015026600 1-11 1-16 8-3 015126000 7-11 7-15 7-25 015415900 7-25 015416200 7-11 7-13 7-15 7-17 015492900 7-31 015493500 7-21 015628700 5-3 7-45 7-49 8-9 8-13 015916300 7-15 016092800 5-3 8-13 016100800 7-8 016103700 1-7 4-3 6-11 8-5 8-15 8-17 016110000 1-11 8-3 019899500 7-45 019920400 7-41 025884300 5-3 8-13

2 7 4 5 22 14 3 5 11 6 9 4 10 2 14 14 1 3 3 5 5 2 3 14 8 9 6 11 14 14 7 11 9 9 7 4 6 6 24 2 3 5 3 15 15 2 4 24 4 3 2

PART NO.

PG. ITEM

031129200 7-3 7-7 032640600 7-23 052229600 7-39 052641400 7-39 052642300 7-39 052643400 7-41 052645200 8-9 052645300 7-39 052645400 7-39 7-39 7-41 7-41 052645500 7-21 052701700 7-13 7-17 055485000 8-3 055485600 1-11 056363100 7-45 056363300 8-9 057048200 7-49 057416600 6-11 058831000 7-7 058889000 7-7 059482800 7-49 059716300 8-15 8-17 059863600 4-3 8-5 061278200 1-12 061643400 7-45 062232800 1-7 062699900 7-49 8-9 064424900 7-45 064570300 7-33 065069700 7-45 065069800 7-45 065069900 7-45 065771000 7-45 203191200 7-45 253851200 7-3 7-7 7-43 272210700 8-18 277326000 8-19 311104011 7-35 312233090 7-45 312850040 7-46 315711216 7-13 449001003 7-45

8 22 8 26 25 27 6 16 27 25 26 6 9 17 6 7 3 4 43 16 1 4 8 9 22 13 13 2 2 3 20 2 24 16 7 14 6 6 6 5 19 5 5 4 1 2 5 10 49 1 14

PART NO.

PG. ITEM

449001004 449001014

7-17 7-37 7-39 7-41 6-11 7-39 7-49 7-45 2-3 7-45 7-37 7-45 7-39 7-45 7-15 4-3 8-5 7-45 7-3 7-7 7-3 2-3 2-3 2-5 2-3 8-15 8-17 4-3 7-11 7-13 7-17 2-3 2-5 3-9 7-45 8-15 8-17 7-45 3-9 4-3 8-5 8-9 2-3 2-3 2-5 3-9 4-3 7-25 7-37 7-45 8-5

449001016 449001023 449001028 449001076 449001114 449001170 449001172 449001202 449001272 449001302 449001343 449001418 449002197 449007006 449007010 449007033 449007055 449015002 449015011

449015014

449015020 449015044

449015098 449021001

2 5 22 1 7 14 26 31 4 35 12 36 30 21 12 26 26 25 12 15 17 14 28 11 9 8 8 20 11 12 14 31 4 1 40 12 12 15 26 26 26 6 12 33 2 4 12 9 8 30 11

PART NO.

449021003

449021006

449021010 449022001 449022005 449022013 449022016

449022017 449022018

449025008 449029001 449029002 449029009

449029011

449030001

PG. ITEM 8-15 8-17 2-3 2-3 2-5 7-15 7-37 7-45 3-9 4-3 7-39 8-5 7-37 7-39 7-39 3-9 6-11 2-3 2-3 2-5 3-9 7-25 7-37 7-39 7-39 7-45 8-15 8-17 7-17 7-45 2-3 2-3 2-5 4-3 7-15 7-37 7-45 8-5 7-13 7-17 7-39 7-13 7-17 7-3 7-7 7-45 7-7 7-11 7-43 7-13 7-17

10 10 6 30 10 13 18 37 24 26 16 26 4 32 15 25 8 13 32 3 2 10 6 23 31 32 11 11 2 13 3 29 9 22 10 13 23 22 21 20 4 2 1 6 6 9 6 6 5 7 8 9-1

NUMERICAL INDEX

PART NO.

PG. ITEM

PART NO.

PG. ITEM

449030008

7-11 7-15 7-13 7-17 8-9 7-19 8-10 7-25 7-37 7-25 7-39 7-41 7-39 7-3 7-7 7-3 7-7 7-3 7-7 7-3 7-7 7-19 7-33 7-45 7-45 2-5 2-5 1-5 5-3 5-3 8-13 7-11 7-11 7-39 7-49 3-9 1-12 1-12 7-21 7-23 3-9 7-21 7-31 7-33 1-5 1-16 7-45 7-25 7-13 7-17 7-11

502011929 502117902 502157202 502157203 502242918 502242937 502313100 502314100 502398904 502429938 502430906 502430917 502501903

7-21 7-35 1-5 1-5 7-41 7-41 7-3 7-3 1-16 7-41 7-41 7-41 7-13 7-17 7-3 7-7 7-3 7-7 7-41 7-19 8-3 8-3 8-3 7-39 7-39 7-21 7-23 7-13 7-17 7-39 7-39 7-39 7-13 7-17 7-13 7-17 7-13 7-17 7-21 7-49 7-49 7-49 7-49 7-49 7-49 7-19 7-39 7-11 7-13 7-17 7-33

449076005 500111904 500167924 500227907 500227910 500227915 500252123 500252133 500302501 500302502 500303501 500303502 500381501 500381512 500412904 500423903 500863104 500863106 500962500 501193100 501195100 501211201 501217200 501334200 501702902 501729901 501749901 501749903 501753904 501753914 501786915 501850904

501904907 501921200 501921903 501989901 502001200 502002200 9-2

1 3 17 19 16 7 4 20 1 12 10 7 28 14 20 10 17 13 19 9 18 9 1 18 44 13 13 1 1 4 4 13 3 1 1 23 4 4 15 13 19 9 9 12 12 1 33 11 19 5 14

502566903 502566904 502631901 502637901 502642218 502642219 502642220 502664909 502673901 502687901 502688903 502738903 502738919 502738931 502754500 502756500 502761500 502787903 502880200 502880201 502880205 502882200 502887202 502889200 502895200 502911500 502925500 502949500 502978501

13 8 13 4 11 11 16 15 2 11 11 11 16 18 21 13 11 16 9 1 8 8 8 24 5 18 12 13 15 2 2 2 4 4 5 6 11 13 12 4 11 3 14 7 21 2 3 4 15 17 15

PART NO. 502978502 502980502 502980503 503067200 503068200 503229200 503241200 503248201 503250200 503251200 503353703 503353711 503353716 503353722 503353731 503354711 503354716 503354722 503354731 503356702 503356703 503356711 503356728 503356770 503579702 503579703 503579711 503579728 503579746 503662701 503662702 503662703 503663701 503663702 503663703 503666701 503666702 503666703 503667701

PG. ITEM

PART NO.

PG. ITEM

7-39 7-31 7-21 7-23 7-39 7-3 7-7 7-7 7-49 7-7 1-16 7-29 7-29 7-35 7-41 7-35 7-41 7-35 7-41 7-35 7-41 7-35 7-41 7-35 7-41 7-35 7-41 7-35 7-41 7-35 7-41 7-7 7-7 7-7 7-7 7-7 7-7 7-7 7-7 7-7 7-7 1-7 1-7 1-7 1-7 1-7 1-7 1-7 1-7 1-7 1-7

503667702 503667703 503837201

1-7 1-7 7-3 7-39 1-15 7-19 8-10 7-33 7-31 7-39 8-3 8-3 7-39 8-9 8-9 8-9 8-9 2-3 7-11 7-11 7-15 7-25 7-37 7-15 7-11 7-15 7-41 1-9 1-9 1-9 1-9 1-9 1-9 7-19 7-33 7-21 7-31 7-33 7-33 7-33 7-33 7-33 7-33 7-33 7-33 7-31 7-31 7-31 8-9 8-10 7-31

19 13 16 11 7 19 11 12 8 23 5 38 37 3 3 3 3 3 3 3 3 3 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

503954200 504020501 504020504 504024201 504024202 504031200 504035207 504035208 504049201 504061724 504061746 504061794 504061795 504062736 504064706 504064728 504064746 504064758 504064767 504065798 504075716 504075722 504092500 504110201 504110202 504110203 504111201 504111202 504111203 504142500 504147200 504148200

504149200 504150200 504151200 504153200 504154200 504155200 504157200 504160200 504161200 504163200 504230271 504232210 504232230

1 1 20 13 2 3 7 7 5 17 2 2 12 10 5 14 7 15 7 7 5 18 2 5 7 5 8 1 1 1 1 1 1 10 9 8 8 10 11 11 11 2 6 8 13 4 3 11 4 1 7

NUMERICAL INDEX

PART NO.

PG. ITEM

504232275 3-9 504234266 7-15 7-25 504235209 8-9 504235239 7-21 7-31 504238298 6-11 504243706 8-9 504247500 1-5 504263710 1-12 504353200 7-3 7-7 504450754 7-21 504450756 7-21 504450757 7-21 504450758 7-21 504558100 7-3 7-7 7-43 504562100 7-3 7-7 7-45 504574232 4-3 8-5 504781201 1-5 505136013 7-35 505136029 7-33 505136037 7-31 505136047 7-21 505136053 8-10 505189200 1-3 505190200 1-3 505583500 7-39 505590500 7-11 505593500 7-31 7-33 505676500 7-39 505890500 1-5 505960578 1-12 505970500 7-45 505970553 4-3 8-5 505974575 2-3 2-5 506250521 8-9 506250541 8-9 506552501 8-10 506611100 7-41 507033500 7-3 7-7 7-45

27 9 19 18 6 6 6 18 2 1 18 21 4 3 5 11 7 7 6 7 7 15 7 7 9 12 17 15 19 10 3 2 8 10 10 3 29 7 4 39 21 21 34 5 18 2 2 5 5 8

PART NO.

PG. ITEM

PART NO.

PG. ITEM

PART NO.

PG. ITEM

507162500 507163500 507394500 507443501 507443551 508812100

7-25 7-25 8-3 7-19 7-19 7-13 7-17 7-13 7-17 2-3 8-10 8-9 7-13 7-19 7-35 7-35 7-35 7-35 7-35 7-35 7-35 7-35 7-35 7-35 7-35 7-35 7-35 7-35 7-35 7-17 7-11 3-9 7-33 7-33 7-33 7-33 7-33 7-33 7-33 7-33 7-33 7-23 7-23 7-23 7-23 7-23 7-23 7-23 7-23 7-23 7-23

518428602 518428603 518428611 518429602 518429603 518429611 518442607 518442612 518442618 518571600 518572600 518801602 518801644

7-3 7-3 7-3 7-3 7-3 7-3 7-33 7-33 7-33 7-39 7-39 8-9 7-15 7-25 8-9 8-9 8-9 7-21 7-31 7-21 7-31 7-21 7-31 7-21 2-3 2-3 5-3 7-13 7-17 7-17 7-13 7-17 7-17 7-17 7-17 7-17 7-17 7-13 7-13 7-13 7-13 7-17 8-10 8-10 8-9 8-10 7-11 4-3 8-5 7-49 7-43

519958601 519996802 519996803 520005801 520010800 520051895 520053859

7-43 1-3 1-3 7-39 7-23 1-16 4-3 8-5 7-3 7-3 7-3 7-21 7-31 7-21 7-31 7-21 7-31 7-23 8-9 4-3 4-5 4-3 4-5 4-5 4-5 4-5 4-5 8-7 4-5 4-5 4-5 1-3 3-9 3-9 3-9 3-9 4-3 8-5 1-5 8-3 3-9 4-3 1-3 3-9 1-11 2-3 2-5 4-3 8-5 4-3 8-5

508976100 512720800 513439107 515045304 516083600 516149005 516546600 516547603 516547611 516547616 516547622 516547631 516780603 516780609 516780611 516780614 516780616 516780620 516780622 516780629 516780631 516781600 517045600 517580815 518335607 518335612 518335618 518340607 518340612 518340618 518356607 518356612 518356618 518382607 518382612 518382618 518383607 518383612 518383618 518384607 518384612 518384618 518385600

7 6 7 5 5 14 16 10 12 10 6 16 3 11 1 9 9 9 9 9 10 10 10 10 10 10 10 10 10 3 2 19 16 16 16 5 5 5

10 10 10 6 6 6 3

518801667 518807609 518807670 518895645 518895650 518895655 518938600 518944600 519433613 519645800 519653407 519653409 519653410 519653411 519653413 519653414 519653418 519653419 519653432 519653433 519653435 519653441 519653445 519664601 519665601 519666602 519686300 519766808 519782800 519955601

3 3 3 2 2 2

21 20 3 8 17 19 12 11 2 2 2 2 2 2 10 17 7 8 8 10 10 8 10 10 10 10 10 10 18 18 18 8 10 8 9 8 9 11 12 17 1

520095602 520095603 520095611 520672676 520672681 520672686 522375004 523128009 524138796 524138798 524139006 524139007 524139008 524139009 524139010 524139316 524139322 524139728 524139975 524140906 524141012 524141080 524141136 524141185 524141433 524141460 524141468 524141549 524141555 524143078 524143269 524143278 524143285

1 5 6 11 9 4 23 23 1 1 1 1 1 1 1 1 1 14 16 14 14 2 6 10 16 14 11 22 19 1 18 7 8 9 6 6 5 1 17 1 4 17 1 27 8 4 4 5 5 9-3

NUMERICAL INDEX

PART NO.

PG. ITEM

PART NO.

PG. ITEM

PART NO.

PG. ITEM

PART NO.

PG. ITEM

524144348 524144349 524144369 524144370 524144374 524144387 524144586

8-7 8-7 8-7 8-7 8-7 8-7 4-3 8-5 4-3 8-5 8-3 7-19 7-19 3-2 3-9 4-5 8-7 4-5 8-7 3-2 3-2 3-2 8-7 4-3 8-5 8-18 8-19 7-45 1-5 8-13 8-13 7-45 4-5 4-3 8-5 8-19 8-18 4-3 4-5 4-3 4-5 4-5 2-3 2-3 2-5 6-11 8-5 8-5 8-7 2-3 2-3

524164430 524164460 524164461 524164479 524164480 524164740

2-3 2-3 2-3 2-3 2-3 2-3 6-11 2-3 6-11 4-3 8-5 2-3 2-3 6-11 6-11 6-11 7-37 7-25 6-11 2-5 6-11 1-5 8-9 1-5 2-3 2-3 3-2 3-9 4-5 2-3 4-5 6-11 6-11 6-11 8-5 4-3 4-3 8-5 7-41 7-41 8-3 8-15 8-15 8-15 8-15 8-15 8-17 8-15 8-17 8-15 8-17

524171844 524171845 524171848 524171849

8-17 8-17 8-17 8-15 8-17 8-17 8-17 8-17 8-17 8-17 8-17 8-15 8-17 8-15 8-17 8-15 8-17 8-15 8-17 8-15 8-17 8-17 8-17 8-17 8-15 8-15 8-17 8-15 8-17 8-15 8-17 8-15 8-17 6-11 8-15 8-15 6-11 8-5 8-7 8-7 8-7 8-5 4-3 4-3 4-5 4-5 4-3 4-5 4-5 4-3 8-5

580000749 580002500

3-9 4-3 8-5 2-3 4-3 8-5 1-16 7-25 1-5 3-2 7-29 8-9 8-9 8-9 7-21 4-5 4-5 8-7 8-10 8-3 4-5 8-7 4-5 8-7 4-5 8-7 4-5 4-5 8-7 4-5 8-7 4-5 8-7 4-5 8-3 1-5 6-3 6-5 6-7 6-9 3-9 7-29 7-27 7-49 7-45 7-49 7-37 7-37 7-25 7-15 7-25

524145025 524145032 524148324 524148325 524148446 524148521 524148522 524148900 524148901 524148902 524149804 524149833 524149943 524149946 524150809 524150937 524150938 524150971 524153649 524153715 524154242 524154481 524159461 524159462 524159463 524163750 524163751 524163969 524163971 524163973 524164010 524164225 9-4

1 2 10 6 19 18 19 19 8 8 1 4 6 14 20 14 20 14 15 2 6 1 21 15 15 2 1 17 6 1 3 16 25 16 16

524164741 524164789 524164807 524164808 524165318 524165319 524165321 524165377 524165427 524165600 524165936 524166201 524166533 524167623 524168739 524168740 524169212 524169863 524169972 524170074 524170075 524170076 524170079 524170154 524170827 524170831

14 14 24 1 1 2 1 14 18 2

524170909 524170910 524171469 524171718 524171719 524171720 524171721 524171722 524171723 524171783

5 20 21 22 23 24 15 25 16 28 29 26 19 13 13 10 7 16 9 14 11 16 17 17 19 15 2 2 14 18 19 17 29 20 20 20 5 5 8 7 6 5 4 3 3 2 2 1 1

524171853

524172263 524172342 524172343 524172344 524172345 524172346 524172347 524172867 524172868 524172875 524172876 524172877 524172878 524173490 524173543 524173544 524179408 524180330 524180331 524180332 524180333 524182270 524182432 524182434 524182756 524182757 580000119

1 1 1 1 1 2 3 4 5 6 7 9 9 5 5 4 4 3 3 2 2 1 1 1 1 7 7 6 6 5 5 4 4 12 1 1 3 14 1 2 28 15 14 1 14 23 13 13

580004592

580006788 580008064 580008382 580008824 580010504 580010513 580010522 580011167 580011989 580011991 580012259 580012736 580012962 580012967 580012968 580012969

580012970 580013106 580013128 580014878 580014880 580015611

580015900 580016604 580016605 580016607 580016608 580016684 580016685 580016811 580016812

21 25 25 35 9 9 6 8 10 13 39 15 1 2 7 1 11 11 3 9 5 5 17 16 18 17 12 21 12 9 9 4 4 13 9 15 16 16 11 10 6

7 2 16 10 11 1 1 4

NUMERICAL INDEX

PART NO.

PG. ITEM

PART NO.

580016813 580016814 580017054 580017124

7-25 7-25 7-37 3-5 3-9 3-5 3-9 3-9 7-15 2-7 3-9 3-9 1-15 2-5 4-3 8-5 1-3 7-49 7-45 7-49 7-25 7-45 7-45 7-49 7-19 7-49 7-19 7-49 4-3 8-5 7-49 7-49 7-49 7-19 7-31 7-49 1-5 4-3 8-5 3-5 3-9 7-49 7-45 7-27 7-29 7-27 7-29 7-27 7-29 7-27 7-29

580024547 7-29 580024548 7-27 7-29 580024550 7-27 7-29 7-29 580024551 7-27 7-29 580024552 7-29 580024554 7-27 7-29 580024555 7-27 7-29 580024556 7-27 7-29 580024557 7-29 580024561 7-27 7-29 580024562 7-29 580024563 7-27 7-29 580024564 7-29 580024565 7-29 580024566 7-29 580024567 7-29 580024568 7-29 580024569 7-29 580024570 7-29 580024571 7-27 7-29 580024572 7-29 580024573 7-29 580024589 7-27 580024916 4-3 8-5 580024919 4-3 8-5 580025303 3-6 580025305 3-6 580025595 4-5 8-7 580025596 4-5 580026296 4-5 8-7 580026422 2-7 580026423 2-7 580026424 2-7 580026425 2-7 580026426 2-7 580026427 2-7 580026428 2-7

580017125 580017126 580017237 580017267 580017788 580017790 580017792 580018747 580019789 580020023 580020492 580020925 580020926 580020928 580020932 580020934 580021175 580022319 580022320 580022409 580022500 580022502 580022515 580022643 580022964 580023503 580023849 580023893 580024543 580024544 580024545 580024546

2 5 15 2 12 15 13 14 11 16 5 6 7 18 18 7 2 26 12 1 3 6 26 25 24 24 18 5 15 8 12 20 8 10 10 11 19 38 10 26 22 22 4 25 5 12

PG. ITEM 20 23 24 3 6 7 2 5 17 9 9 1 4 6 11 21 8 8 18 21 10 2 3 19 1 13 16 23 11 27 14 15 7 26 26 26 26 35 36 3 3 3 8 8 1 2 5 6 4 3 7

PART NO.

PG. ITEM

PART NO.

PG. ITEM

580026429 580026708 580026749 580026788 580026824

2-7 2-5 1-9 7-49 4-5 8-7 3-9 7-45 7-45 7-45 7-49 6-3 6-5 6-7 6-9 7-25 7-27 7-29 7-27 7-29 7-27 7-29 3-5 1-5 7-45 7-27 7-29 7-27 7-29 7-27 7-29 7-15 7-25 3-6 7-27 7-29 7-27 7-29 7-27 7-29 7-27 7-29 1-5 6-7 2-3 2-3 1-9 1-9 1-9 7-7 7-7

580035862 580035863 580035878 580035879 580035880 580035981

7-7 7-7 7-7 7-7 7-7 7-21 7-31 7-25 7-3 7-3 7-25 7-3 7-3 7-3 7-25 7-25 7-3 7-21 7-31 7-21 7-31 1-5 6-3 6-5 6-7 6-9 6-3 6-5 6-7 6-9 6-3 6-5 6-7 6-9 6-3 6-5 6-7 6-9 6-5 6-7 6-9 6-3 6-5 6-7 6-9 6-3 6-5 6-7 6-9 6-3 6-5

580027368 580027413 580027414 580027415 580027564 580032007

580032377 580032383 580032449 580032450 580032507 580032544 580033283 580033660 580033680 580033681 580033718 580033733 580033815 580033816 580033817 580033883 580034336 580034711 580034850 580034919 580034999 580035000 580035001 580035860 580035861

8 12 4 10 15 22 22 4 42 41 23 20 19 16 13 13 17 33 16 32 20 36 28 8 22 18 34 12 28 24 40 7 15 31 19 35 15 31 13 29 14 30 3 11 16 2 3 5 1 1

580036026 580036047 580036049 580036050 580036052 580036053 580036054 580036055 580036056 580036057 580036069 580036072 580036341 580037336

580037337

580037470

580037471

580037472

580037473

580037474

580037475

1 1 2 2 2

22 3 1 16 3 2 1 22 16 2

14 1 1 1 1 1 1 2 1 1 1 3 1 2 2 4 2 3 10 9 4 4 5 3 5 5 6 4 6 6 9-5

NUMERICAL INDEX

PART NO.

580037476 580037477 580037478

580037480

580037482

580037484 580037595 580037596 580037598 580037641 580037681 580037682 580037769 580038175 580038818 580038819 580039617

580039685 580039687 580039688 580039689 580039690 580039692 580039694

9-6

PG. ITEM

PART NO.

PG. ITEM

PART NO.

PG. ITEM

6-7 6-9 6-7 6-9 6-7 6-9 6-3 6-5 6-7 6-9 6-5 6-7 6-9 6-3 6-5 6-7 6-9 6-7 6-9 7-3 7-3 7-3 7-25 7-37 7-37 7-7 4-5 8-7 6-9 6-11 6-5 6-11 6-3 6-5 6-7 6-9 3-5 3-5 3-5 3-5 3-5 3-5 3-5

580039695 580039696 580039697 580039699 580039700 580039701 580039702 580039703 580039704 580039706 580039707 580039708 580039709 580039710 580039711 580039712 580039713 580039714 580039715 580039716 580039717 580039718 580039719 580039720 580039722 580039723 580039724 580039725 580039726 580039727 580039728 580039729 580039730 580039731 580039732 580039733 580039734 580039735 580039736 580039737 580039738 580039739 580039740

3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-6 3-6 3-6 3-6 3-6 3-6 3-6

580039741 580039742 580039743 580039744 580039745 580039746 580039747 580039748 580039749 580039750 580039751 580039752 580039753 580039754 580039755 580039766 580039767 580039770 580039771 580039973

3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-6 3-5 3-5 3-5 3-5 6-3 6-5 6-3 6-5 6-3 6-5 6-3 6-5 6-3 6-5 6-3 6-5 6-3 6-5 6-3 6-5 6-5 6-3 6-11 6-3 6-3 6-3 6-3 4-3

7 5 8 6 8 7 9 9 9 8 16 14 10 18 18 15 12 13 9 2 3 1 22 3 17 2 20 13 1 1 17 17 12 11 1 4 5 6 8 7 9

10 11 12 14 16 17 18 19 20 22 22 22 22 22 22 22 22 24 24 24 24 24 24 24 24 25 26 27 29 30 30 30 30 30 30 30 30 30 30 30 30 30 30

580039974 580039975 580039976 580039977 580039978 580039979 580039980 580039983 580040130 580040504 580040505 580040506 580040507 620033319

33 33 33 33 33 33 33 33 33 33 33 34 32 37 38 3 13 21 23 7 7 8 8 10 10 11 11 12 12 13 13 14 14 15 15 20 1 1 3 19 16 27

PART NO. 720076907 720217902 723291300 723291304 723624100

751191100 752411301 752576436 752576437 754479700 900002268 902977411 902977413 902977427 907806300 909086102 909086104 909882405 910218101 931018903 932118906

932119907 932200905 932201903 937100907 937501908 940004902 940102909 940400904 940600907

PG. ITEM 8-5 2-5 7-45 7-49 1-15 1-15 5-3 7-13 7-17 8-13 4-3 8-5 2-5 1-15 1-15 1-7 7-15 7-11 7-11 7-11 7-45 7-45 7-45 1-12 7-37 7-49 8-9 7-3 7-7 7-43 7-3 7-7 3-9 7-41 7-7 7-43 7-7 4-5 8-7 3-9 2-3 7-45

27 6 29 13 1 1 5 20 9 5 17 17 13 1 1 1 5 12 12 12 12 28 27 2 16 14 13 4 3 2 4 3 10 10 4 3 4 7 7 3 8 34

SECTION 10

USER SUPPORT INFORMATION

SECTION 10 USER SUPPORT INFORMATION DESCRIPTION OPERATOR TRAINING...................................................................................................................................... SERVICE PARTS ORDERING INSTRUCTIONS ............................................................................................... SERVICE TRAINING COURSE ......................................................................................................................... SERVICE TRAINING MATERIALS..................................................................................................................... TECHNICAL SERVICE PUBLICATIONS............................................................................................................

PAGE 10-2 10-2 10-2 10-2 10-2

10-1

USER SUPPORT INFORMATION

Your investment in a Yale Industrial Truck is important to you and to your Yale Dealer. You measure the return on that investment through the performance of these trucks and the drivers who operate and the mechanics who service them safely and efficiency. The following information and programs are intended to help you to achieve your investments objectives: SERVICE PARTS ORDERING INSTRUCTIONS HOW TO ORDER SERVICE PARTS In order to prevent delay, too much communication and to have your orders filled correctly, quickly, and at the least possible cost, the following is the correct procedure to use to order replacement parts. WHEN ORDERING PARTS Contact your authorized Yale Industrial Truck Dealer giving them the following information: 1. Your Purchase order number. 2. Complete addresses for sending the invoice and parts. 3. Tell us how you want your parts sent. If we do not get this information, we will send the parts using the lowest priced method. 4. Correct part number(s) and description(s). Use your parts manual as a reference. 5. Model and serial number of the truck. TECHNICAL SERVICE PUBLICATIONS Technical literature, with detailed information, is available at a nominal fee to assist users to effectively maintain Yale Industrial Trucks in a safe, useful condition. Part Manuals with complete replacement parts identification, Service Maintenance Manuals which provide service and overhaul procedures and additional copies of the Operating Manual can be obtained from your Yale Industrial Truck Dealer. SERVICE MAINTENANCE MANUALPART NO. 524167349 OPERATING MANUALPART NO. 524150809 To provide instructions for safely operating and servicing Yale Industrial Trucks, each truck is equipped with an operators manual. It describes various operating techniques and safety warnings to the operator. It contains a guide to safe maintenance practices and recommended schedules

10-2

for maintenance. If the operators manual is missing from any Yale Industrial Truck, it should be replaced. Replacement copies are available for a nominal fee from your Yale Dealer. OPERATOR TRAINING The Yale "Basic Operator Training" program helps industrial truck users increase their materials handling production and safety through correct lift truck operation, training, and motivation. The Yale program is based upon real life experienceâ&#x20AC;&#x201C;not theoretical concepts. We developed a "complete" program that is totally self-containedâ&#x20AC;&#x201C;incorporating the most modern instructional techniques including elements of self-study, audio-visual support (both video and slides), and classroom study. SERVICE TRAINING COURSE Operators and Yale dealer service technicians can improve their technical ability for maintaining and repairing Yale Industrial Trucks, which decreases repair time and cost, by taking Yale Service Training courses. Different types of mechanical, electric, and electronic subjects are available. Courses can be held at customer or Dealer locations in addition to regularly scheduled courses which are held at Yale Corporate Headquarters in Greenville, NC. SERVICE TRAINING MATERIALS Your own service training can be supported through a complete line of Yale Service Training materials. An Index is available from your Yale Dealer which lists textbooks, audio-visual programs and films. These materials will provide your training staff with everything necessary for training your group. For additional information or assistance in obtaining these user support publications and programs, contact: Yale Materials Handling Corporation 1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011

Yale Materials Handling Corporation 1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011

524167345