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MX-80 BT Prime-Mover

Parts Manuals 301649-000 1992_February 301649-001 1993_April

Return BT Prime-Mover, Inc., 3305 N. Highway 38, Muscatine, Iowa 52761-8800 U.S.A Tel (563) 262-7700 • Fax (563) 262-7600

082202

PARTS MANUAL Manual Number 9202 Manual Part Number 301649-000 MX 80 ELECTRIC PALLET TRUCK

Read and observe all warnings on this unit before operating it.

DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place.

ISSUED FEBRUARY 1992

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MX 80

PARTS ORDERING INSTRUCTIONS HOW TO ORDER

FIELD MODIFICATIONS

When you order, supply the part number, quantity, model and serial numbers of your machine. Supplying this information will assure prompt, efficient handling of your order. The pictorial reference number is not needed and including it can only add confusion.

The regulations imposed by OSHA make it mandatory that alternation of industrial trucks be done only as approved in advance and in writing by the manufacturer. Their regulation apply to counter-weighting, changes in masts when such changes affect capacity and any other safety modifications. It is mandatory that nameplate and instructions be changed accordingly (1910.178 (a)(4)).

Since your dealer carries many parts in stock and maintains up-to-date prices on all parts, he will be able to process your order immediately.

If, for some reason, the part is not in stock, he will order it from the factory. In either event, he maintains a current file of service manuals, which give all available parts ordering or technical information.

All prices are FOB factory in Muscatine, Iowa.

Shipping charges are added to the price of the part shipping from the factory.

WHERE TO ORDER Always order parts from the dealer who sold you your BT PRIME-MOVER. If it is necessary for the dealer to order parts from the factory, he is able to get prompt service for you. Parts are shipped in accordance with shipping instructions given on the order.

BT PRIME-MOVER will approve such changes requested as we can properly evaluate and rerate as to capacity. Normally a change will be evaluated upon receipt of a written request with full particulars including truck and mast serial number, proposed changes, new heights of lift, etc.

If the change is approved, authorization will be sent as will new nameplates or other labeling where appropriate. The new nameplates should be installed over the earlier nameplate.

The modifier should send confirmation of the change to the factory along with pictures of the revised truck.

INSTRUCTIONS FOR RETURNING PARTS Under NO CIRCUMSTANCES will parts be accepted at the factory for credit without prior approval. THE BT PRIME-MOVER Co. cannot accept responsibility for parts returned without authorization.

If you have some parts which must be returned, contact your dealer. If he believes parts should be returned, he will arrange for authorization to return the parts.

2 Return

FEBRUARY 1992

GENERAL INFORMATION INDEX

RIGHT-HAND AND LEFT-HAND SIDES

This parts manual is arranged for easy identification of parts. The index at the front of the catalog gives location of major groups and assemblies.

The terms right-hand and left-hand used in this parts manual indicate the right and left side of the machine as viewed from the operator's line of sight for proper operation of machine or attachment.

ABBREVIATIONS AND TERMS NA - Not Available NSS - Not Sold Separately As Req'd - Use as required K - Parts of a kit * - Not shown on drawing See Fig.# - See Figure # for further break down of parts.

CHANGES When changes are made to the machine, revised pages for this manual will be issued.

These pages must be inserted in your parts manual as soon as they are received. Failure to keep your parts manuals up to date will result in confusion and may cause you to order wrong parts.

A. Right Side B. Rear C. Left Side D. Front PART LIST The FIGURE #, describes the figure you are on. The ITEM #, describes the item on the figure you are looking at. The PART # is a numerical description of the item and the part ordering number. The NAME is a description of the part number in alphabetical form. The # FOR ASSY. is the quantity used on the figure and NOT the quantity used on the machine. The UNIT describes the type or style of the part used on the figure.

EXAMPLE: FIG ITEM # #

PART #

NAME

# FOR ASSY.

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

30354-32 30354-33 30354-34 30354-35 30354-36 15898-03 40041-00 40108-00 40092-01 40092-02 40092-03 40092-04 40092-05 52-05069-00 300284-000 200037 NSS NA 200028

Hose assembly Hose assembly Hose assembly Hose assembly Hose assembly Fitting, bulkhead Tube assembly Fuse Cylinder, freelift (See Fig.# 3.6) Cylinder, freelift (See Fig.# 3.6) Cylinder, freelift (See Fig.# 3.6) Cylinder, freelift (See Fig.# 3.6) Cylinder, freelift (See Fig.# 3.6) Hose Motor, OHIO pump (See Fig.# 2.10) Pump assembly, lift Pump, lift (See Fig.# 3.8) Plug Kit, seal (CONTAINS ITEMS MARKED WITH "K")

1 1 1 1 1 1 1 1 1 1 1 1 1 As Req'd 1 1 1 1 1

12 12 12 12 12 13 14 15 16 16 16 16 16 17 18 19 20 21 K

FEBRUARY 1992 Return

UNIT 89/180 95/198 108/226 111/240 119/258

89/180 95/198 108/226 111/240 119/258

3

ALPHABETICAL INDEX NAME

FIG.#

PAGE #

4.2 4.3

4.3 4.5

0.1 1.6 1.6 2.26 2.27 1.6 1.6 2.28 2.29

0.1 1.11 1.11 2.45 2.47 1.11 1.11 2.49 2.51

2.25 3.1 3.2

2.43 3.1 3.2

3.6 4.4

3.9 4.7

2.15 2.16

2.27 2.28

*

99.1

4.5 0.2 3.5

4.9 0.2 3.7

A,B,C Carrier frame assembly Caster assembly D Decals and parts list assembly Drive motor assembly, MX 65 Advanced 12 volt Drive motor assembly, MX 65 G.E. 24 volt Drive motor assembly, MX 65 12 volt (R90-4001, Advanced) Drive motor assembly, MX 65 24 volt (5BC48JB890, G.E.) Drive motor assembly, RX 65 G.E. 24 volt Drive motor assembly, RX 65 Prestolite 12 volt Drive motor assembly, RX 65 12 volt (MLD-4009, Prestolite) Drive motor assembly, RX 65 24 volt (5BC48JB883, G.E.) E,F,G,H Hydraulic pump motor assembly Hydraulic schematic Hydraulic schematic symbols I,J,K,L Lift cylinder assembly Lift frame assembly M MX 65 Transistor electrical schematic MX 65 Transistor electrical schematic symbols N Numerical index O,P Pallet entry rollers Parts list index Pump and motor assembly

4 Return

FEBRUARY 1992

ALPHABETICAL INDEX NAME

FIG.#

PAGE #

4.7 2.7 2.13 2.6 2.3 2.1 2.2 2.8 2.12 2.10 2.11 3.3 2.14 2.14 2.14 2.14 2.14 2.9 2.4 2.5 2.17 2.18

4.13 2.11 2.23 2.9 2.3 2.1 2.2 2.13 2.21 2.17 2.19 3.3 2.25 2.25 2.25 2.25 2.25 2.15 2.5 2.7 2.29 2.30

4.1 4.6 7.1

4.1 4.11 7.1

1.3 1.3 2.21 2.21 2.19 2.22 2.23 3.4 2.20 2.24 2.24 2.24 1.1 1.4 1.5 1.2 1.2

1.5 1.5 2.35 2.35 2.31 2.37 2.39 3.5 2.33 2.41 2.41 2.41 1.1 1.7 1.9 1.3 1.3

Q,R Removable load backrest Resistor contactor assembly Resistor contactor assembly (Cableform) Resistor control panel assembly Resistor control wiring harness assembly Resistor electrical schematic Resistor electrical schematic symbols Resistor Forward & Rearward contactor assembly Resistor Fourth speed contactor panel assembly Resistor Fourth speed control wiring Resistor Fourth speed power component wiring Resistor hydraulic system Resistor power connector assembly SB-175 (GRAY) Resistor power connector assembly SB-175 (RED) Resistor power connector assembly SB-175 (YELLOW) Resistor power connector assembly SB-350 (RED) Resistor power connector assembly SB-350 (YELLOW) Resistor Third speed contactor panel assembly Resistor Third speed control wiring Resistor Third speed power component wiring RX 65 Transistor electrical schematic RX 65 Transistor electrical schematic symbols S Shield assembly Skid adapter and package guard assembly Special tools and lubrications T Thumb control resistor control handle assembly Thumb control transistor control handle assembly Transistor control panel assembly (W/Out field weakening) Transistor control panel assembly (With field weakening) Transistor control wiring harness assembly Transistor Forward & Rearward contactor assembly Transistor High speed contactor assembly Transistor hydraulic system Transistor power component wiring Transistor power connector assembly SB-175 (GRAY) Transistor power connector assembly SB-175 (RED) Transistor power connector assembly SB-350 (RED) Transmission and handle assembly Transmission assembly, PART , Transmission assembly, PART ,, Twist grip resistor control handle assembly Twist grip transistor control handle assembly U,V,W,X,Y,Z FEBRUARY 1992 Return

5

FIGURE # 0.1 DECALS AND PARTS ASSEMBLY

0.1 Return

FEBRUARY 1992

FIG ITEM # # PART # 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1

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

52-00254-00 52-00257-00 52-00221-00 52-00224-00 300771-000 49536-00 301650-000 301649-000 300207-001 NA 49384-01 49536-00 14915-03 14915-01 49384-00 52-00259-00 301651-000 NA 49384-03 49535-00

FEBRUARY 1992 Return

NAME

# FOR ASSY.

Paint, orange Spring, orange Paint, black Spring, black Box, orange manual Sleeve Manual, MX 80 Operator Manual, MX 80 Parts Manual, Lowlift Repair Tack, metal Decal, BT PRIME-MOVER Decal, NO RIDING Plug, small hole Plug, large hole Decal, BT PRIME-MOVER Strip, white (5 feet) Decal, MX 80 Serial, number plate Decal, BT PRIME-MOVER Decal, WARNING

As Req'd.

As Req'd.

As Req'd.

As Req'd.

1 1 1 1 1 4 1 1 As Req'd As Req'd.

2 As Req'd.

2 1 1 1

UNIT

0.2

FIGURE # 0.2 PARTS LIST INDEX

FIG ITEM # # PART #

NAME

0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2

Decals and parts list assembly Parts list index Transmission and handle assembly Twist grip resistor control handle assembly Twist grip transistor control handle assembly Thumb control resistor control handle assembly Thumb control transistor control handle assembly Transmission assembly, PART , Transmission assembly, PART ,, Drive motor assembly, MX 80 Advanced 12 volt Drive motor assembly, MX 80 G.E. 24 volt Drive motor assembly, RX 80 Prestolite 12 volt Drive motor assembly, RX 80 G.E. 24 volt Resistor electrical schematic

0.3 Return

1 * 2 2 27301-00 2 27301-02 2 27339-00 2 27339-02 2 2 2 20190-01 2 20844-01 2 20190-00 2 20844-02 3

FIG. # Page 0.1 0.2 1.1 1.2 1.2 1.3 1.3 1.4 1.5 1.6 1.6 1.6 1.6 2.1

0.1 0.3 1.1 1.3 1.3 1.5 1.5 1.7 1.9 1.11 1.11 1.11 1.11 2.1

FEBRUARY 1992

FIG ITEM # # PART # 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2

3 3 27259-01 3 27259-02 3 27693-01 3 27693-00 3 27692-01 3 27692-00 3 27266-01 3 27266-00 3 3 3 27267-01 3 27267-02 3 27185-00 3 27185-01 3 49855-30 3 49855-05 3 49855-31 3 49855-39 3 49855-37 3 3 3 3 3 3 3 27910-00 3 27910-01 3 27692-00 3 23015-01 3 49855-32 3 49855-21 3 49855-38 3 202327 3 202333 3 300280-000 3 27906-00 3 20680-00 3 27896-00 4 4 4 4 4 27275-00 4 27277-01 4 20895-00 5 5 5 27886-00 5 5 5 5 * * * * *

FEBRUARY 1992 Return

NAME Resistor electrical schematic symbols Resistor control wiring harness assembly Resistor third speed control wiring Resistor third speed power component wiring Resistor control panel assembly, 12 volt Resistor control panel assembly, 24 volt Resistor contactor assembly, 12 volt Resistor contactor assembly, 24 volt Resistor Forward & Rearward contactor assembly, 12 V Resistor Forward & Rearward contactor assembly, 24 V Resistor Third speed contactor panel assembly, 12 volt Resistor Third speed contactor panel assembly, 24 volt Resistor Fourth speed control wiring Resistor Fourth speed power component wiring Resistor Fourth speed contactor panel assembly, 12 V Resistor Fourth speed contactor panel assembly, 24 V Resistor contactor assembly (Cableform), 12 volt Resistor contactor assembly (Cableform), 24 volt Resistor power connector assembly SB-175 (YELLOW) Resistor power connector assembly SB-175 (GRAY) Resistor power connector assembly SB-175 (RED) Resistor power connector assembly SB-350 (YELLOW) Resistor power connector assembly SB-350 (RED) MX 80 Transistor electrical schematic MX 80 Transistor electrical schematic symbols RX 80 Transistor electrical schematic RX 80 Transistor electrical schematic symbols Transistor control wiring harness assembly Transistor power component wiring Transistor control panel assembly (W/Out field weakening) Transistor control panel assembly (With field weakening)

Transistor Forward & Rearward contactor assembly Transistor High speed contactor assembly Transistor power connector assembly SB-175 (RED) Transistor power connector assembly SB-175 (GRAY) Transistor power connector assembly SB-350 (RED) Hydraulic pump motor assembly, 12 volt Hydraulic pump motor assembly, 24 volt Drive motor assy., MX 80 12 V (R90-4001, Advanced) Drive motor assy., MX 80 24 V (5BC48JB890, G.E.) Drive motor assy., RX 80 12 V (MLD-4009, Prestolite) Drive motor assy., RX 80 24 V (5BC48JB883, G.E.) Hydraulic schematic Hydraulic schematic symbols Resistor hydraulic system Transistor hydraulic system Pump and motor assembly, 12 volt Pump and motor assembly, 24 volt Lift cylinder assembly Shield assembly Carrier frame assembly Caster assembly Lift frame assembly Pallet entry rollers Skid adapter and package guard assembly Removable load backrest Special tools and lubrications Numerical index

FIG. # Page 2.2 2.3 2.4 2.5 2.6 2.6 2.7 2.7 2.8 2.8 2.9 2.9 2.10 2.11 2.12 2.12 2.13 2.13 2.14 2.14 2.14 2.14 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.21 2.22 2.23 2.24 2.24 2.24 2.25 2.25 2.26 2.27 2.28 2.29 3.1 3.2 3.3 3.4 3.5 3.5 3.6 4.1 4.2 4.3 4.4 4.5 4.6 4.7 7.1 *

2.2 2.3 2.5 2.7 2.9 2.9 2.11 2.11 2.13 2.13 2.15 2.15 2.17 2.19 2.21 2.21 2.23 2.23 2.25 2.25 2.25 2.25 2.25 2.27 2.28 2.29 2.30 2.31 2.33 2.35 2.35 2.37 2.39 2.41 2.41 2.41 2.43 2.43 2.45 2.47 2.49 2.51 3.1 3.2 3.3 3.5 3.7 3.7 3.9 4.1 4.3 4.5 4.7 4.9 4.11 4.13 7.1 99.1 0.4

FIGURE # 1.1 TRANSMISSION AND HANDLE ASSEMBLY

1.1 Return

FEBRUARY 1992

FIG ITEM # # PART # 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1

1 2 3 4 5 6 7 8 9 10

11016-11 11009-04 11045-02 11880-08 20208-00 20212-00 11016-21 11261-01 20682-00 27301-00

1.1

10

27301-02

1.1

10

27339-00

1.1

10

27339-02

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 1.1 1.1 1.1 1.1

11 12 13 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27

23080-00 20069-01 20070-01 27143-00 11898-07 11009-08 14994-08 -------------11073-04 13813-19 20287-19 11429-04 27529-02 11170-04 20497-00 11813-06 11009-05 11854-03

FEBRUARY 1992 Return

NAME

# FOR ASSY.

Washer, flat Lockwasher Screw, cap Screw, machine Switch, interlock Bracket Washer, flat Nut Shield, motor cover Handle assembly, Twist grip RESISTOR (See Fig.# 1.2) Handle assembly, Twist grip TRANSISTOR (See Fig.# 1.2) Handle assembly, Thumb control RESISTOR (See Fig.# 1.3) Handle assembly, Thumb control TRANSISTOR (See Fig.# 1.3) Bumper Washer, flat Bearing Plate, mounting Ring, retainer Lockwasher Screw, cap Transmission assembly (See Fig.# 1.4) Pin, roll Pin, pivot Pin, pivot (cold storage) Pin, hair Rod Nut Clamp Grommet, rubber Lockwasher Screw, cap

UNIT

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

1.2

FIGURE # 1.2 TWIST GRIP RESISTOR CONTROL HANDLE ASSEMBLY (27301-00) TWIST GRIP TRANSISTOR CONTROL HANDLE ASSEMBLY (27301-02)

1.3 Return

FEBRUARY 1992

FIG ITEM # # PART # 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

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 40 41 42 42 43 44 45 46 47 48 49 50 51 52 53 53 54 55 56 56 57 57

23139-00 49519-03 23040-00 23036-00 27212-00 27210-00 23037-00 11072-13 49525-01 23067-00 11176-01 23214-00 23033-00 14900-00 11072-13 23040-00 49525-04 49519-06 49519-04 23035-00 11073-29 11047-30 23034-00 11047-03 14892-03 14892-01 20329-01 49549-00 11016-02 11854-02 23244-00 27298-00 27299-00 21542-12 23241-00 27290-00 14892-02 23026-00 11047-19 23078-00 23024-00 23369-00 27303-00 11936-04 27541-00 23032-00 11073-26 23030-00 27523-00 23061-00 23044-02 23044-01 23044-00 49506-02 49506-03 29304-00 11813-16 23081-00 27312-00 27302-00 27313-00

FEBRUARY 1992 Return

NAME Reverser assembly Screw, machine Switch Cup, spring Bar, reverser Spring Cover Lockwasher Screw, flathead Plate, switch Screw, truss head Spring Bushing, sleeve Nut Lockwasher Switch Screw, flat head Screw, machine Screw, machine Grip, hand Pin, roll Screw, Allen head Bushing Screw, Allen head 2.25" long Screw, flanged head cap Screw, flanged head cap Ring, grip Clamp Washer, flat Screw, cap Sheave Pin Anchor, chain Chain Link, connector Hand, lower Screw, flanged head 1.00" long Spring, return Screw, Allen head 1.25" long Plate, anchor Guard, hand Switch, master (RESISTOR) Switch, master (TRANSISTOR) Washer, shim Gear, miter Shaft Pin, roll Washer, stop Bushing, flanged Housing, head Bar, lower Bar, raise Bar, horn Heater (COLD STORAGE) Heater (COLD STORAGE) Potentiometer Grommet Harness, head wiring (RESISTOR) Harness, head wiring (TRANSISTOR) Harness, main wiring (RESISTOR) Harness, main wiring (TRANSISTOR)

# FOR ASSY.

UNIT

1 2 1 1 1 3 1 2 4 1 4 6 1 6 5 3 1 1 4 2 3 2 2 1 2 2 2 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 RESISTOR 1 TRANSISTOR As Req'd.

2 1 1 1 1 1 1 1 1 1 24 VOLT 1 12 VOLT 1 TRANSISTOR 1 1 RESISTOR 1 TRANSISTOR RESISTOR 1 1 TRANSISTOR 1.4

FIGURE # 1.3 THUMB CONTROL RESISTOR CONTROL HANDLE ASSEMBLY (27339-00) THUMB CONTROL TRANSISTOR CONTROL HANDLE ASSEMBLY (27339-02)

1.5 Return

FEBRUARY 1992

FIG ITEM # # PART #

NAME

1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3

Reverser assembly Screw, machine Switch Cup, spring Bar, reverser Spring Cover Lockwasher Screw, flathead Plate, switch Screw, truss head Spring Nut Lockwasher Switch Screw, flat head Screw, machine Screw, machine Washer, special Grip, hand Bushing (tapped) Ring, retainer Control, thumb Screw, flat head Screw, Allen head Screw, Allen head 2.25" long Screw, flanged head cap Screw, flanged head cap Ring, grip Grommet Clamp Washer, flat Screw, cap Sheave Pin Hand, lower Screw, round head Screw, Allen head Anchor, chain Chain Bar, coonnecting Spring, return Plate, anchor Guard, hand Switch, master (RESISTOR) Switch, master (TRANSISTOR) Bushing, flanged Washer, shim Gear, miter Shaft Pin, roll Washer, stop Housing, head Bar, lower Bar, raise Bar, horn Heater (COLD STORAGE) Heater (COLD STORAGE) Potentiometer Harness, head wiring (RESISTOR) Harness, head wiring (TRANSISTOR) Harness, main wiring (RESISTOR) Harness, main wiring (TRANSISTOR)

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 40 41 42 43 44 45 45 46 47 48 49 50 51 52 53 54 55 56 56 57 58 58 59 59

23139-00 49519-03 23040-00 23036-00 27212-00 27210-00 23037-00 11072-13 49525-01 23067-00 11176-01 23214-00 14900-00 11072-13 23040-00 49525-04 49519-06 49519-04 23381-00 23380-00 23382-00 11025-16 23384-00 11852-52 11047-30 11047-03 14892-03 14892-01 20329-01 11813-16 49549-00 11016-02 11854-02 23244-00 23124-00 27290-00 49519-04 11047-19 27299-00 21542-12 23241-00 23026-00 23078-00 23376-00 23369-00 27303-00 27523-00 11936-04 27541-00 23383-00 11073-26 23030-00 23061-00 23044-02 23044-01 23044-00 49506-02 49506-03 29304-00 23081-00 27312-00 27302-00 27313-00

FEBRUARY 1992 Return

# FOR ASSY.

UNIT

1 2 1 1 1 3 1 2 4 1 4 6 6 5 3 1 1 4 2 2 2 2 2 2 2 1 2 2 2 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 RESISTOR 1 TRANSISTOR 1 As Req'd 2 1 1 1 1 1 1 1 1 12 VOLT 1 24 VOLT 1 TRANSISTOR 1 RESISTOR TRANSISTOR 1 1 RESISTOR 1 TRANSISTOR 1.6

FIGURE # 1.4 TRANSMISSION ASSEMBLY, PART # ,

1.7 Return

FEBRUARY 1992

FIG ITEM # # PART # 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4

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

11073-15 20892-02 20897-00 11170-06 20134-00 22314-00 11015-09 20321-00 11015-31 11015-30 -------------49929-01 20003-00 11009-08 14994-08 25003-01 25003-02 20071-01 20262-01 25004-00 11445-02 25300-00 14998-01 11830-10 20190-01 20844-01 20190-00 20844-02

FEBRUARY 1992 Return

NAME Pin, roll Arm, brake Bushing Nut Screw, adjustment Nut, jam O ring Rod, brake O ring O ring Transmission assembly (See Fig.# 1.5) Bushing Ring, gear case Lockwasher Screw, cap Wheel, rubber drive Wheel, urethane drive Tire, rubber Tire, urethane Wheel, drive Screw, wheel Pin, eccentric Ring, retaining Screw, cap nylock Drive assembly, MX-80 Advanced (See Fig.# 1.6) Drive assembly, MX-80 G.E. (See Fig.# 1.6) Drive assembly, RX-80 Prestolite (See Fig.# 1.6) Drive assembly, RX-80 G.E. (See Fig.# 1.6)

# FOR ASSY.

UNIT

1 1 1 1 1 1 1 1 1 1 1 2 1 6 6 1 1 1 1 1 5 1 1 3 1 1 1 1

12 VOLT 24 VOLT 12 VOLT 24 VOLT

1.8

FIGURE # 1.5 TRANSMISSION ASSEMBLY, PART # ,,

TORQUE NUT TO 250 FT./LBS.

1.9 Return

FEBRUARY 1992

FIG ITEM # # PART # 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

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

11841-03 22277-01 11890-01 20659-00 11135-04 20620-00 22243-00 49826-00 25744-00 25745-00 20176-00 20329-01 20002-00 20045-02 11157-03 20067-00 11890-03 12459-00 20536-00 11830-06 11271-06 11878-02 11859-03 11523-06 14999-01 20064-01 11936-04 27163-00 11936-08 22313-00 27161-00 11003-05 20065-00 20281-00 11039-18 27200-00

FEBRUARY 1992 Return

NAME Screw, machine Case, gear Pin, dowel Pad, brake Pin, yoke Disc, brake separator ( 1 set of 3 ) Shim, washer Washer, curved Disc, brake Disc, brake Bolt, eye Ring, grip Cover, gear case Lever, brake actuating Pin, cotter Spring Pin, dowel Vent, air Seat, spring Screw, cap Screw, set Nut, nylock Plug, pipe Bearing, roller Screw, machine Bearing, race Race, washer .032" Gear, idler pinion Race, washer .063" Locknut Gear, drive Plug, magnetic Bearing assembly (matched set) Spacer, oil seal Seal, oil Axle, string guard drive

# FOR ASSY. 2 1 1 1 2 1 18 12 1 1 1 3 1 1 1 2 2 1 2 9 2 2 1 3 4 3 1 1 2 1 1 1 1 1 1 1

UNIT

1 set of 3

1.10

FIGURE # 1.6 DRIVE MOTOR ASSEMBLY

1.11 Return

(MX-80 Advanced 12 volt 20190-01) (MX-80 G.E. 24 volt 20844-01) (RX-80 Prestolite 12 volt 20190-00) (RX-80 G.E. 24 volt 20844-02)

FEBRUARY 1992

FIG ITEM # # PART # 1.6

1

300280-00

1.6

1

27906-00

1.6

1

20680-00

1.6

1

27896-00

1.6 1.6 1.6 1.6 1.6 1.6 1.6

2 3 4 5 6 7 8

20182-00 11015-02 20040-00 11936-07 27164-00 11025-02 11852-03

AUGUST 1991 Return

NAME Motor, MX-80 12 volt drive ADVANCED (See Fig.# 2.10) Motor, MX-80 24 volt drive G.E. (See Fig.# 2.11) Motor, RX-80 12 volt drive PRESTOLITE (See Fig.# 2.12) Motor, RX-80 24 volt drive G.E. (See Fig.# 2.13) Key, pinion O ring Plate, mounting Race, bearing Pinion, motor Ring, retainer Screw, cap

# FOR ASSY.

UNIT

1

12 VOLT

1

24 VOLT

1

12 VOLT

1

24 VOLT

1 1 1 1 1 1 4

1.12

FIGURE # 2.1 RESISTOR ELECTRICAL SCHEMATIC

2.1 Return

FEBRUARY 1992

FIGURE # 2.2 RESISTOR ELECTRICAL SCHEMATIC SYMBOLS

FEBRUARY 1992 Return

2.2

FIGURE # 2.3 RESISTOR CONTROL WIRING HARNESS ASSEMBLY

2.3 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3

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

27302-00 20208-00 27275-00 27277-00 20161-00 11009-04 11045-02 20163-07 11823-05 20163-36 49815-00 20151-00 11823-27 23228-00 23228-01 52-07901-03 27259-01 27259-02 27266-01

2.3

16

27266-00

2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3

17 18 19 20 21 22 23 24 25 26 26 27 28 29 30 30 31 32 33

49771-00 49831-00 11016-23 11170-02 11885-03 20163-02 14986-03 20479-00 11880-08 23309-00 23309-01 11016-02 11170-05 23040-00 49506-02 49506-03 49607-00 23081-00 23369-00

FEBRUARY 1992 Return

NAME Harness assembly (MAIN FRAME) Switch, brake interlock Pump & motor assembly (See Fig.# 3.5) Pump & motor assembly (See Fig.# 3.5) Bar , negative buss Lockwasher Screw, cap Wire assembly Fitting, wire Wire assembly Meter, hour Switch, key Fitting, wire Indicator, battery discharge (BDI) Indicator, battery discharge (BDI) Wire, 16 ga. RED Panel, control (See Fig.# 2.6) Panel, control (See Fig.# 2.6) Panel assembly, third speed (See Fig.# 2.9) Panel assembly, third speed (See Fig.# 2.9) Fitting, wire Thermostat Washer, flat Nut, self locking Screw, round head Wire assembly Nut, twin Switch, lift limit Screw, machine Horn, 12 volt Horn, 24 volt Washer, flat Nut Switch Heater, 12 volt Heater, 24 volt Plug, diode Harness, wiring (handle head) Switch, master (RESISTOR)

# FOR ASSY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 As Req'd.

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

UNIT

12 volt 24 volt

12 volt 24 volt 12 volt 24 volt 12 volt 24 volt

12 volt 24 volt

12 volt 24 volt

2.4

FIGURE # 2.4 RESISTOR THIRD SPEED CONTROL WIRING

2.5 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4

1 2 3 3 4 5 6 7 8

20163-37 20163-07 27275-00 27277-00 11880-08 20479-00 11823-06 14986-03 27259-01

2.4

8

27259-02

2.4 2.4 2.4 2.4 2.4

9 10 11 12 13

20163-36 11170-06 11016-03 14913-08 27266-01

2.4

13

27266-00

2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4

14 15 16 17 18 19 20 21 22 23 24 24 25 26 27 28 29 30 31 32 33 34

24070-00 21074-03 11016-21 11261-02 20163-55 20433-02 52-07901-03 11823-01 20151-00 20163-39 23309-00 23309-01 11016-02 11170-05 20163-35 20163-34 20163-33 20163-38 20163-01 20161-00 11009-04 11045-02

FEBRUARY 1992 Return

NAME Wire assembly Wire assembly Pump & motor assembly (See Fig.# 3.5) Pump & motor assembly (See Fig.# 3.5) Screw, machine Switch, lift limit Connector, butt Nut, twin Resistor control panel assembly (See Fig.# 2.6) Resistor control panel assembly (See Fig.# 2.6) Wire assembly Nut Washer, flat Screw, flat head Panel assembly, third speed (See Fig.# 2.9) Panel assembly, third speed (See Fig.# 2.9) Bracket Delay, time Washer, flat Nut Wire assembly Switch, control Wire, RED 16 gauge Connector, stud Switch, key Wire assembly Horn, 12 volt Horn, 24 volt Washer, flat Nut, lock Wire assembly Wire assembly Wire assembly Wire assembly Wire assembly Bar, negative buss Lockwasher Screw, cap

# FOR ASSY. 1 1 1 1 2 1 As Req'd.

1 1

UNIT

12 volt 24 volt

12 volt

1

24 volt

1 4 4 2 1

12 volt

1

24 volt

1 1 2 2 1 1 As Req'd.

As Req'd.

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

12 volt 24 volt

2.6

FIGURE # 2.5 RESISTOR THIRD SPEED POWER COMPONENT WIRING

12 VOLT 24 VOLT

2.7 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5

1 2 3 4 4 5 5 6

11047-16 11170-06 11016-03 27259-01 27259-02 20366-05 20366-03 27266-01

2.5

6

27266-00

2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5

7 8 9 10 10 11 12 13 14 15

49856-05 49856-11 11261-04 20143-01 20773-00 11045-02 20159-02 49856-05 20773-00 300280-000

2.5

15

27906-00

2.5

15

20680-00

2.5

15

27896-00

2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5

16 16 17 17 18 18 19 19 20 20 21 21 22 23 24 25

49856-06 49856-06 49856-04 49856-04 49856-03 49856-03 49856-03 20366-03 49856-07 49856-07 27275-00 27277-00 20161-00 11009-04 11045-02 --------------

FEBRUARY 1992 Return

NAME Screw, sock head Nut Washer, flat Panel, 12 volt control (See Fig.# 2.6) Panel, 24 volt control (See Fig.# 2.6) Cable assembly Cable assembly Panel assembly, third speed (See Fig.# 2.9) Panel assembly, third speed (See Fig.# 2.9) Cable assembly Cable assembly Nut Resistor, 12 volt Resistor, 24 volt Screw, cap Bracket Cable assembly Cable assembly Motor, MX-80 12 volt drive ADVANCED (See Fig.# 2.10) Motor, MX-80 24 volt drive G.E. (See Fig.# 2.11) Motor, RX-80 12 volt drive PRESTOLITE (See Fig.# 2.12) Motor, RX-80 24 volt drive G.E. (See Fig.# 2.13) Cable assembly Cable assembly Cable assembly Cable assembly Cable assembly Cable assembly Cable assembly Cable assembly Cable assembly Cable assembly Pump & motor assembly (See Fig.# 3.5) Pump & motor assembly (See Fig.# 3.5) Bar, negative buss Lockwasher Screw, cap Connector assembly (See Fig.# 2.14)

# FOR ASSY.

UNIT

2 6 6 1 1 1 1 1

12 volt 24 volt 12 volt 24 volt 12 volt

1

24 volt

1 1 3 1 1 3 1 2 2 1

12 volt 12 volt

1

24 volt

1

12 volt

1

24 volt

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

12 volt 24 volt 12 volt 24 volt 12 volt 24 volt 12 volt 24 volt 12 volt 24 volt 12 volt 24 volt

12 volt 24 volt

24 volt 24 volt 12 volt

2.8

FIGURE # 2.6 RESISTOR CONTROL PANEL ASSEMBLY (12 VOLT, 27259-01) (24 VOLT, 27259-02)

2.9 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.6 2.6 2.6 2.6 2.6 2.6 2.6

1 2 3 4 5 6 7

27272-00 20761-00 11045-02 11016-23 11009-02 11261-02 27692-01

2.6

7

27692-00

2.6 2.6 2.6 2.6 2.6 2.6 2.6 2.6 2.6 2.6 2.6 2.6

8 8 9 10 11 12 13 14 15 16 17 18

22226-02 22226-01 11170-04 20160-05 20140-02 20141-00 27262-00 11885-06 11004-03 20140-01 20912-00 27693-01

2.6

18

27693-00

2.6 2.6 2.6 2.6 2.6 2.6 2.6

19 20 21 22 23 24 25

27257-00 50001-11 50003-01 27258-00 20163-85 49856-70 27270-00

2.6 2.6 2.6 2.6 2.6 2.6 2.6 2.6 2.6

26K 27K 28K 29K 30K 31K 32K 33K 34

NSS NSS NSS NSS NSS NSS NSS NSS 11016-03

FEBRUARY 1992 Return

NAME Wire assembly Bracket Screw, machine Washer, flat Lockwasher Nut Contactor, forward & rearward 12 volt (See Fig.# 2.8) Contactor, forward & rearward 24 volt (See Fig.# 2.8) Contactor, 12 volt pump Contactor, 24 volt pump Nut Bar, bus Breaker, circuit Breaker, circuit Panel, electrical Screw, machine Screw, cap Breaker, circuit Bar, buss Contactor, 12 volt 2nd speed (See Fig.# 2.7) Contactor, 24 volt 2nd speed (See Fig.# 2.7) Bar, buss Lockwasher Screw, cap Bar, buss Wire assembly Cable assembly Kit, interlock switch (CONTAINS ITEMS MARKED WITH "K") Screw, machine Washer, flat Screw, machine Bracket, right hand Bracket, lift hand Screw, machine Switch, interlock Bracket, switch mounting Washer, flat

# FOR ASSY.

UNIT

1 1 6 7 7 7 1

12 volt

1

24 volt

1 1 2 1 1 1 1 7 4 2 2 1

12 volt 24 volt

1

24 volt

12 volt

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

2.10

FIGURE # 2.7 CONTACTOR ASSEMBLY (12 VOLT, 27693-01) (24 VOLT, 27693-00)

2.11 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7

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

201962 204241 200077 201963 201262 201964 200081 204240 204239 200096 200094 201966 201259 201266 201367 201215 201967 201368 201372

FEBRUARY 1992 Return

NAME Base, magnet Coil, 12 volt Coil, 24 volt Frame, magnet Spring (RED) Armature Base, buss Tip, contact Tip, contact Bushing Seat Tip, movable Cap Spring (GOLD) Washer, flat Nut, lock Clamp Lockwasher Screw, machine

# FOR ASSY. 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 4 4

UNIT

12 volt 24 volt

2.12

FIGURE # 2.8 FORWARD & REARWARD CONTACTOR ASSEMBLY (12 VOLT, 27692-01) (24 VOLT, 27692-00)

2.13 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8

1 2 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

200076 204241 200077 200078 200079 200080 200081 200082 200083 200084 201267 200085 201215 200086 200087 200088 201368 201372 200089 200090 200091 200092 200093 201367 200094 200095 200096 200097

FEBRUARY 1992 Return

NAME Base, magnet Coil, 12 volt Coil, 24 volt Frame, magnet Spring (RED) Armature Base, buss Tip, contact Tip, contact Tip, movable Spring (GOLD) Insulation Locknut Clamp Tip, contact Cover Lockwasher Screw, machine Screw, cap Lockwasher Washer, flat Tip, contact Clamp Washer, flat Seat Carrier Bushing Tip, contact

# FOR ASSY. 1 2 2 2 2 2 2 2 1 4 2 2 2 4 1 2 8 8 2 2 2 1 2 2 4 2 2 1

UNIT

12 volt 24 volt

2.14

FIGURE # 2.9 THIRD SPEED CONTACTOR PANEL ASSEMBLY (12 VOLT, 27266-01) (24 VOLT, 27266-00)

2.15 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9

1 2 3 4 5 6 7 7 8

11170-01 11016-21 21074-02 27265-00 11880-06 11004-03 27693-01 27693-00 11170-04

FEBRUARY 1992 Return

NAME Nut Washer, flat Delay, time Panel Screw, machine Screw, cap Contactor, 3rd speed (See Fig.# 2.7) Contactor, 3rd speed (See Fig.# 2.7) Nut

# FOR ASSY.

UNIT

2 2 1 1 2 2 1 1 2

2.16

FIGURE # 2.10 RESISTOR FOURTH SPEED CONTROL WIRING

2.17 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10

1 2 3 3 4 5 6 7 8

20163-37 20163-07 27275-00 27277-00 11880-08 20479-00 11823-06 14986-03 27259-01

2.10

8

27259-02

2.10 2.10 2.10 2.10 2.10

9 10 11 12 13

20163-36 11170-06 11016-03 49779-00 27267-01

2.10

13

27267-02

2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10 2.10

14 15 16 17 18 19 20 21 22 23 23 24 25 26 27 28 29 30 31

20163-40 49856-03 20163-55 20163-33 14939-00 20433-02 20163-38 20163-34 20163-53 23309-00 23309-01 11016-02 11170-05 20163-39 20151-00 11823-01 20161-00 11009-04 11045-02

FEBRUARY 1992 Return

NAME Wire assembly Wire assembly Pump & motor assembly (See Fig.# 3.5) Pump & motor assembly (See Fig.# 3.5) Screw, machine Switch, lift limit Connector, butt Nut, twin Resistor control panel assembly (See Fig.# 2.6) Resistor control panel assembly (See Fig.# 2.6) Wire assembly Nut Washer, flat Resistor Fourth speed control panel assembly (See Fig.# 2.12) Fourth speed control panel assembly (See Fig.# 2.12) Wire assembly Cable assembly Wire assembly Wire assembly Switch, horn Switch, rocket Wire assembly Wire assembly Wire assembly Horn, 12 volt Horn, 24 volt Washer, flat Nut, lock Wire assembly Switch, key Connector, stud Bar, negative buss Lockwasher Screw, cap

# FOR ASSY. 1 1 1 1 2 1 As Req'd.

1 1

UNIT

12 volt 24 volt

12 volt

1

24 volt

1 6 6 1 1

12 volt

1

24 volt

As Req'd.

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

12 volt 24 volt

2.18

FIGURE # 2.11 RESISTOR FOURTH SPEED POWER COMPONENT WIRING

12 VOLT 24 VOLT

2.19 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.11 2.11 2.11 2.11

1 2 3 4

11047-16 11170-06 11016-03 27259-01

2.11

4

27259-02

2.11 2.11 2.11

5 5 6

20366-01 20366-03 27267-01

2.11

6

27267-02

2.11 2.11 2.11 2.11 2.11 2.11 2.11 2.11 2.11 2.11

7 8 9 10 10 11 12 13 14 15

49856-05 49856-11 11261-04 49786-00 20773-00 11045-02 20159-02 49856-05 49856-06 20680-00

2.11

15

27896-00

2.11 2.11 2.11 2.11 2.11 2.11 2.11 2.11 2.11 2.11 2.11

16 17 18 19 20 21 21 22 23 24 25

49856-04 49856-03 49856-05 20366-03 49856-07 27275-00 27277-00 20161-00 11009-04 11045-02 --------------

FEBRUARY 1992 Return

NAME Screw, sock head Nut Washer, flat Resistor control panel assembly (See Fig.# 2.6) Resistor control panel assembly (See Fig.# 2.6) Cable assembly Cable assembly Fourth speed panel assembly (See Fig.# 2.12) Fourth speed panel assembly (See Fig.# 2.12) Cable assembly Cable assembly Nut Resistor, 12 volt Resistor, 24 volt Screw, cap Bracket Cable assembly Cable assembly Motor, RX-80 12 volt drive PRESTOLITE (See Fig.# 2.12) Motor, RX-80 24 volt drive G.E. (See Fig.# 2.13) Cable assembly Cable assembly Cable assembly Cable assembly Cable assembly Pump & motor assembly (See Fig.# 3.5) Pump & motor assembly (See Fig.# 3.5) Bar, negative buss Lockwasher Screw, cap Connector assembly (See Fig.# 2.14)

# FOR ASSY.

UNIT

2 8 8 1

12 volt

1

24 volt

1 1 1

12 volt

1

24 volt

1 1 3 1 1 3 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1

12 volt 24 volt

24 volt 12 volt 24 volt

12 volt 24 volt

2.20

FIGURE # 2.12 FOURTH SPEED CONTACTOR PANEL ASSEMBLY (12 volt, 27267-01) (24 volt, 27267-02)

2.21 Return

FEBRUARY 1992

FIG ITEM # # PART # 20163-49 27264-00 11885-06 11880-06 11004-03 27270-00

2.12 2.12 2.12 2.12 2.12 2.12

1 2 3 4 5 6

2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12 2.12

7K NSS 8K NSS 9K NSS 10K NSS 11K NSS 12K NSS 13K NSS 14K NSS 15 27693-01 15 27693-00 16 11170-04 17 20163-40 18 11823-01 19 25337-00 20 11170-01 21 11016-21 22 21074-02 23 20163-01 24 20163-55 25 11170-02 26 27185-00 26 27185-01

FEBRUARY 1992 Return

NAME Wire assembly Panel Screw, machine Screw, machine Screw, machine Kit, interlock switch (CONTAINS ITEMS MARKED WITH "K") Screw, machine Washer, flat Screw, machine Screw, machine Switch, interlock Bracket, switch mounting Bracket, left hand Bracket, right hand Contactor assembly (See Fig.# 2.7) Contactor assembly (See Fig.# 2.7) Nut Wire assembly Fitting, wire Diode Nut Washer Delay, time Wire assembly Wire assembly Nut Contactor assembly (See Fig.# 2.13) Contactor assembly (See Fig.# 2.13)

# FOR ASSY.

UNIT

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

12 volt 24 volt

12 volt 24 volt

2.22

FIGURE # 2.13 CONTACTOR ASSEMBLY (CABLEFORM) (12 volt, 27185-00) (24 volt, 27185-01)

2.23 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13

1 201893 2 NA 3 NA 4 201896 5 201890 5 201891 6 201902 7 201904 8 NA 9 NA 10 201910 11 NA 12 201903 13 201900 14 204238 15 201906 16 201899 17 201897 18 201895 19 NA 20 NA 21 NA 22 NA 23 204237

FEBRUARY 1992 Return

NAME Base Screw, cap Lockwasher Frame, magnet Coil, 12 volt magnet Coil, 24 volt magnet Spacer Contact, front Lockwasher Nut Front Screw, cap Pole Spring Plate, armature Contactor, movable Stud, top spring Retainer Braid Nut Nut Lockwasher Screw, cap Diode, zener

# FOR ASSY. 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1

UNIT

12 volt 24 volt

2.24

FIGURE # 2.14 RESISTOR POWER CONNECTOR ASSEMBLY (SB-175 * 49855-30 * 12 VOLT * YELLOW) (SB-175 * 49855-05 * 12 VOLT * GRAY) (SB-175 * 49855-31 * 24 VOLT * RED) (SB-175 * 49855-05 * 24 VOLT * GRAY) (SB-350 * 49855-39 * 12 VOLT * YELLOW) (SB-350 * 49855-37 * 24 VOLT * RED)

2.25 Return

FEBRUARY 1992

FIG ITEM # # PART #

NAME

# FOR ASSY.

SB-175 * 49855-30 * 12 VOLT * YELLOW 2.14 1 49855-30 Connector assembly, SB-175 YELLOW 2.14 2 49854-03 Connector, YELLOW housing 2.14 3 49852-01 Connector, tip 2.14 4 49853-02 Bushing 2.14 5 49856-09 Cable, 23.00" NEGATIVE 2.14 6 49856-10 Cable, 28.00" POSITIVE

1 1 2 2 1 1

SB-175 * 49855-05 * 12 VOLT * GRAY 2.14 1 49855-05 Connector assembly, SB-175 GRAY 2.14 2 49854-01 Connector, GRAY housing 2.14 3 49852-01 Connector, tip 2.14 4 49853-02 Bushing 2.14 5 49856-09 Cable, 23.00" NEGATIVE 2.14 6 49856-10 Cable, 28.00" POSITIVE

1 1 2 2 1 1

SB-175 * 49855-31 * 24 VOLT * RED 2.14 1 49855-31 Connector assembly, SB-175 RED 2.14 2 49854-04 Connector, RED housing 2.14 3 49852-01 Connector, tip 2.14 4 49853-02 Bushing 2.14 5 49856-09 Cable, 23.00" NEGATIVE 2.14 6 49856-10 Cable, 28.00" POSITIVE

1 1 2 2 1 1

SB-175 * 49855-05 * 24 VOLT * GRAY 2.14 1 49855-05 Connector assembly, SB-175 GRAY 2.14 2 49854-01 Connector, GRAY housing 2.14 3 49852-01 Connector, tip 2.14 4 49853-02 Bushing 2.14 5 49856-09 Cable, 23.00" NEGATIVE 2.14 6 49856-10 Cable, 28.00" POSITIVE

1 1 2 2 1 1

SB-350 * 49855-39 * 24 VOLT * YELLOW 2.14 7 49855-39 Connector assembly, SB-350 YELLOW 2.14 8 49854-06 Connector, YELLOW housing 2.14 9 49852-03 Connector, tip 2.14 10 49853-04 Bushing, large 2.14 11 49853-01 Bushing, small 2.14 12 49856-09 Cable, 23.00" NEGATIVE 2.14 13 49856-10 Cable, 28.00" POSITIVE

1 1 2 2 2 1 1

SB-350 * 49855-37 * 24 VOLT * RED 2.14 7 49855-30 Connector assembly, SB-350 RED 2.14 8 49854-05 Connector, RED housing 2.14 9 49852-01 Connector, tip 2.14 10 49853-04 Bushing, large 2.14 11 49853-02 Bushing, small 2.14 12 49856-09 Cable, 23.00" NEGATIVE 2.14 13 49856-10 Cable, 28.00" POSITIVE

1 1 2 2 2 1 1

FEBRUARY 1992 Return

UNIT

2.26

FIGURE # 2.15 MX-80 TRANSISTOR ELECTRICAL SCHEMATIC

2.27 Return

FEBRUARY 1992

FIGURE # 2.16 MX-80 TRANSISTOR ELECTRICAL SCHEMATIC SYMBOLS

FEBRUARY 1992 Return

2.28

FIGURE # 2.17 RX-80 TRANSISTOR ELECTRICAL SCHEMATIC

2.29 Return

FEBRUARY 1992

FIGURE # 2.18 RX-80 TRANSISTOR ELECTRICAL SCHEMATIC SYMBOLS

FEBRUARY 1992 Return

2.30

FIGURE # 2.19 TRANSISTOR CONTROL WIRING HARNESS ASSEMBLY NOTE: USE HEAT CONDUCTING MATERIAL FROM DOW #340 BETWEEN THE MAIN FRAME AND TRANSISTOR CONTROLLER (ITEM# 16).

2.31 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.19 2.19 2.19 2.19

1 2 3 4

27313-00 20208-00 27277-00 27910-00

2.19

4

27910-01

2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19 2.19

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

49831-00 11016-23 11170-02 11885-03 20151-00 20433-02 27096-01 27324-00 27311-00 49350-00 49815-00 26205-01 49605-00 49606-00 27325-01 23309-01 11016-02 11170-05 14986-03 20479-00 11880-08 27312-00 23040-00 49506-03 49607-00 27303-00 29304-00 20161-00 11009-04 11045-02

FEBRUARY 1992 Return

NAME Harness assembly Switch, brake interlock Pump & motor assembly (See Fig.# 3.5) Panel assembly, control W/OUT field weakening (See Fig.# 2.19) Panel assembly, control W/Field weakening (See Fig.# 2.19) Thermostat Washer, flat Nut, self locking Screw, round head Switch, key Switch, rocker (Raise/Lower) Switch, rocker (Horn/Rabbit) Plug, jumper (used with walk behind truck only) Harness, rider handle Resistor Meter, hour Indicator, battery discharge (BDI) Filter, horn Suppressor Controller, transistor (1205X) Horn, 24 volt Washer, flat Nut, lock Nut, twin Switch, lift limit Screw, machine Harness, wiring (handle head) Switch Heater, 24 volt Diode plug Switch, master control Potentiometer Bar, negative buss Lockwasher Screw, cap

# FOR ASSY.

UNIT

1 1 1 1

24 volt 24 volt

1

24 volt

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

24 volt

24 volt

24 volt

2.32

FIGURE # 2.20 TRANSISTOR POWER COMPONENT WIRING NOTE: USE HEAT CONDUCTING MATERIAL FROM DOW #340 BETWEEN THE MAIN FRAME AND TRANSISTOR CONTROLLER (ITEM# 8).

2.33 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.20 2.20 2.20 2.20 2.20

1 2 3 4 5

11047-16 -------------27277-01 49856-109 27910-00

2.20

5

27910-01

2.20 2.20 2.20 2.20 2.20 2.20 2.20 2.20 2.20 2.20 2.20 2.20 2.20 2.20 2.20 2.20

6 7 8 9 10 11

49856-81 49856-80 27325-01 49856-73 49856-75 27906-00

11

27896-00

12 13 14 15 16 17 18

49856-04 49856-58 49856-03 49856-08 20161-00 11009-04 11045-02

FEBRUARY 1992 Return

NAME Screw, socket head Connector assembly (See Fig.# 2.23) Pump & motor assembly (See Fig.# 3.5) Cable assembly Panel assembly, control W/Out Field weakening (See Fig.# 2.19) Panel assembly, control W/Field weakening (See Fig.# 2.19) Cable assembly Cable assembly Controller, transistor (1205X) Cable assembly Cable assembly Motor, MX-80 24 volt drive G.E. (See Fig.# 2.10) Motor, RX-80 24 volt drive G.E. (See Fig.# 2.11) Cable assembly Cable assembly Cable assembly Cable assembly Bar, negative buss Lockwasher Screw, cap

# FOR ASSY.

UNIT

2 1 1 1 1

24 volt

1

24 volt

1 1 1 1 1 1

24 volt

1

24 volt

24 volt

1 1 1 1 1 1 1

2.34

FIGURE # 2.21 CONTROL PANEL ASSEMBLY, 24 VOLT WITH OUT FIELD WEAKENING (27910-00) WITH FIELD WEAKENING (27910-01)

2.35 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.21 2.21 2.21 2.21 2.21

1 2 3 4 5

27319-00 49548-00 11009-03 11016-25 23015-01

2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21

6 7 8 9 10 11 12 13 * 14 15 16 17 18 19 20 21 22 23 24

27315-00 11016-04 11009-04 11045-02 23187-00 11885-05 11009-02 20141-00 49771-01 20140-02 20160-08 49367-01 11009-01 11880-03 11880-05 49521-00 22226-03 27330-00 11016-02 49352-00

2.21 2.21 2.21 2.21

* * * *

50022-01 49771-01 11072-03 27704-04

FEBRUARY 1992 Return

NAME Bar, buss Screw, machine Lockwasher Washer, flat Contactor, 24 volt field weakening (See Fig.# 2.23) Panel Washer, panel Lockwasher Screw, cap Bar, buss Screw, machine Lockwasher Breaker, circuit Connect, quick Breaker, circuit Bar, buss Relay, 24 volt Lockwasher Screw, machine Screw, machine Delay, time Contactor 24 volt lift pump Resistor, F.W. 24 volt Washer, flat Contactor, forward & rearward 100 AMP (See Fig.# 2.22) Screw, terminal Connect, quick Washer, star Suppressor, forward/rearward

# FOR ASSY.

UNIT

1 2 2 2 1

FIELD WK FIELD WK FIELD WK FIELD WK FIELD WK

1 6 6 6 1 6 6 1 2 2 1 1 As Req'd.

2 2 1 1 1 3 1

24 VOLT

FIELD WK FIELD WK 24 VOLT FIELD WK FIELD WK 24 VOLT

4 4 4 1

2.36

FIGURE # 2.22 FORWARD & REARWARD CONTACTOR ASSEMBLY (24 VOLT, 27692-00)

2.37 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22 2.22

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

200076 200077 200078 200079 200080 200081 200082 200083 200084 201266 200085 201215 200086 200087 200088 201368 201372 200089 200090 200091 200092 200093 201367 200094 200095 200096 200097

FEBRUARY 1992 Return

NAME Base, magnet Coil, 24 volt Frame, magnet Spring (RED) Armature Base, buss Tip, contact Tip, contact Tip, movable Spring (GOLD) Insulation Locknut Clamp Tip, contact Cover Lockwasher Screw, machine Screw, cap Lockwasher Washer, flat Tip, contact Clamp Washer, flat Seat Carrier Bushing Tip, contact

# FOR ASSY.

UNIT

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

2.38

FIGURE # 2.23 HIGH SPEED CONTACTOR ASSEMBLY (24 VOLT, 23015-01)

2.39 Return

FEBRUARY 1992

FIG ITEM # # PART # 2.23 2.23 2.23 2.23 2.23 2.23 2.23 2.23

1K 2K 3K 4K 5K 6 7 K

NSS NSS NSS NSS NSS NA NA 202350

FEBRUARY 1992 Return

NAME Nut Lockwasher Cover assembly Spring Bridge assembly Coil, magnet Screw, machine Kit, contact (CONTAINS ITEMS MARKED WITH "K")

# FOR ASSY.

UNIT

2 2 1 1 1 1 2 1

2.40

FIGURE # 2.24 TRANSISTOR POWER CONNECTOR ASSEMBLY (SB-175 * 49855-32 * 24 VOLT * RED) (SB-175 * 49855-21 * 24 VOLT * GRAY) (SB-350 * 49855-38 * 24 VOLT * RED)

2.41 Return

FEBRUARY 1992

FIG ITEM # # PART #

NAME

# FOR ASSY.

SB-175 * 49855-32 * 24 VOLT * RED 2.24 1 49855-32 Connector assembly, SB-175 RED 2.24 2 49854-04 Connector, RED housing 2.24 3 49852-01 Connector, tip 2.24 4 49853-02 Bushing 2.24 5 49856-110 Cable, 23.00" NEGATIVE 2.24 6 49856-111 Cable, 35.00" POSITIVE

1 1 2 2 1 1

SB-175 * 49855-21 * 24 VOLT * GRAY 2.24 1 49855-21 Connector assembly, SB-175 GRAY 2.24 2 49854-01 Connector, GRAY housing 2.24 3 49852-01 Connector, tip 2.24 4 49853-02 Bushing 2.24 5 49856-110 Cable, 23.00" NEGATIVE 2.24 6 49856-111 Cable, 35.00" POSITIVE

1 1 2 2 1 1

SB-350 * 49855-37 * 24 VOLT * RED 2.24 7 49855-38 Connector assembly, SB-350 RED 2.24 8 49854-05 Connector, RED housing 2.24 9 49852-01 Connector, tip 2.24 10 49853-04 Bushing, large 2.24 11 49853-02 Bushing, small 2.24 12 49856-110 Cable, 23.00" NEGATIVE 2.24 13 49856-111 Cable, 35.00" POSITIVE

1 1 2 2 2 1 1

FEBRUARY 1992 Return

UNIT

2.42

FIGURE # 2.25 HYDRAULIC PUMP MOTOR ASSEMBLY (12 VOLT, 202327) (24 VOLT, 202333)

PHANTOM ITEMS ARE

2.43 Return

NOT AVAILABLE

FEBRUARY 1992

FIG ITEM # # PART # 2.25 2.25 2.25 2.25 2.25 2.25 2.25 2.25 2.25 2.25 2.25 2.25 2.25 2.25 2.25

1 202403 2 202404 3 202405 3 202406 4 202413 5 202408 6 202407 7 202409 8 202410 8 202411 9 202412 10 202359 11 202358 12 202356 12 202357

FEBRUARY 1992 Return

NAME End, drive Bearing Armature, 12 volt Armature, 24 volt Washer, spring Stud, terminal Screw, pole Pole Coil, 12 volt field Coil, 24 volt field Holder, brush Mounting kit (bolt, washer) Cover kit (brush end cover, screws) Brush kit, 12 v (brushes, spring, screws) Brush kit, 24 v (brushes, spring, screws)

# FOR ASSY. 1 2 1 1 1 1 4 4 1 1 1 1 1 1 1

UNIT

12 volt 24 volt

12 volt 24 volt

12 volt 24 volt

2.44

FIGURE # 2.26 MX-80, 12 VOLT DRIVE MOTOR ASSEMBLY (R90-4001, 300280-000, ADVANCED)

PHANTOM ITEMS ARE

2.45 Return

NOT AVAILABLE

FEBRUARY 1992

FIG ITEM # # PART # 2.26 2.26 2.26 2.26 2.26 2.26 2.26 2.26 2.26 2.26 2.26 2.26 2.26 2.26

1 300439-000 2 300433-000 3 300417-000 4 300418-000 5 300431-000 6 300420-000 7 300421-000 8 300440-000 9 300435-000 10 300438-000 11 300427-000 12 300420-000 13 300437-000 14 300436-000

NAME Coil, field Terminal assembly Brush Spring, brush Plate, brush Bearing Washer, wave Head, commutator end Band, head Armature Ring, retainer Bearing Head, drive end Seal

# FOR ASSY.

UNIT

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

* - NOT SHOWN

FEBRUARY 1992 Return

2.46

FIGURE # 2.27 MX-80, 24 VOLT DRIVE MOTOR ASSEMBLY (5BC48JB890, 27906-00, G.E.)

PHANTOM ITEMS ARE

2.47 Return

NOT AVAILABLE

FEBRUARY 1992

FIG ITEM # # PART # 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27

1 300546-000 2 300544-000 3 300542-000 4 300553-000 5 300554-000 6 300545-000 7 300547-000 8 300549-000 9 300567-000 10 300555-000 11 300538-000 12 300537-000 13 300534-000 14 300535-000 * 300536-000 15 300540-000 16 300539-000 17 300569-000 18 300556-000 19 300558-000 20 300570-000 21 300560-000 22 300562-000 23 300561-000 24 300563-000 25 300565-000 26 300566-000 27 300564-000 28 300568-000

NAME Nut Washer, flat Gasket Bushing Washer Lockwasher Holder, brush Spring, brush Brush Screw, pole Plug End, shield Screw, clamp Cover, brush Screw, cap Washer Terminal Coil, field Pole, main Bearing Armature Bearing Washer, belleville Shim, washer Spacer, washer Seal, shaft Screw End, shield Shell, stator

# FOR ASSY.

UNIT

8 4 4 4 4 4 1 4 4 8 5 1 2 4 8 2 2 1 4 1 1 1 2 1 1 1 4 1 1

* - NOT SHOWN

FEBRUARY 1992 Return

2.48

FIGURE # 2.28 RX-80, 12 VOLT DRIVE MOTOR ASSEMBLY (MLD-4009, 20680-00, PRESTOLITE)

SECURE THIS PART LOCALLY

PHANTOM ITEMS ARE

2.49 Return

NOT AVAILABLE

FEBRUARY 1992

FIG ITEM # # PART # 2.28 2.28 2.28 2.28 2.28 2.28 2.28 2.28 2.28 2.28 2.28 2.28 2.28 2.28 2.28

1 200206 2 200151 3 200320 4 200314 5 200303 6 200241 7 200204 8 200178 9 200163 10 200140 11 200238 12 200306 13 200304 14 200320 15 200322

NAME Package, field coil Package, terminal stud Bearing, sealed Washer, spring Head assembly, commutator Spring set Brush set Band, cover Cover Screw, pole shoe Armature and fan assembly Fan Head assembly, drive end Bearing, sealed Seal, oil

# FOR ASSY.

UNIT

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

* - NOT SHOWN

FEBRUARY 1992 Return

2.50

FIGURE # 2.29 RX-80, 24 VOLT DRIVE MOTOR ASSEMBLY (5BC48JB883, 27896-00, G.E.)

PHANTOM ITEMS ARE

2.51 Return

NOT AVAILABLE

FEBRUARY 1992

FIG ITEM # # PART # 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29

1 300546-000 2 300544-000 3 300542-000 4 300553-000 5 300554-000 6 300545-000 7 300547-000 8 300549-000 9 300568-000 10 300555-000 11 300538-000 12 300537-000 13 300534-000 14 300535-000 * 300536-000 15 300540-000 16 300539-000 17 300557-000 18 300551-000 19 300558-000 20 300559-000 21 300560-000 22 300562-000 23 300561-000 24 300563-000 25 300565-000 26 300566-000 27 300564-000 28 300552-000

NAME Nut Washer, flat Gasket Bushing Washer Lockwasher Holder, brush Spring, brush Brush Screw, pole Plug End, shield Screw, clamp Cover, brush Screw, cap Washer Terminal Coil, field Pole, main Bearing Armature Bearing Washer, belleville Shim, washer Spacer, washer Seal, shaft Screw End, shield Shell, stator

# FOR ASSY.

UNIT

8 4 4 4 4 4 1 4 4 8 5 1 2 4 8 2 2 1 4 1 1 1 2 1 1 1 4 1 1

* - NOT SHOWN

FEBRUARY 1992 Return

2.52

FIGURE # 3.1 HYDRAULIC SCHEMATIC

LIFT CYLINDERS

2950 PSI±50

M

PUMP AND VALVE CONTROL

3.1 Return

FEBRUARY 1992

FIGURE # 3.2 HYDRAULIC SCHEMATIC SYMBOLS

COMPONENT ENCLOSURE

HYDRAULIC LINES JOINING

MOTOR (ELECTRIC)

HYDRAULIC PUMP

FILTER

RESERVOIR (VENTED) CYLINDER (SINGLE ACTING) CYLINDER (DOUBLE ACTING)

CHECK VALVE

HYDRAULIC LINES CROSSING

FEBRUARY 1992 Return

3.2

FIGURE # 3.3 RESISTOR HYDRAULIC SYSTEM

3.3 Return

FEBRUARY 1992

FIG ITEM # # PART # 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3

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

27275-00 27277-00 11143-05 14972-05 20177-01 11170-05 49358-03 14920-02 12391-05 27115-00 27886-00 22012-03 12391-05 15818-06

FEBRUARY 1992 Return

NAME Pump & motor assembly (See Fig.# 3.5) Pump & motor assembly (See Fig.# 3.5) Screw, cap Adapter Clamp Nut Hose Tee O ring Retainer Cylinder assembly (See Fig.# 3.6) Elbow, 90° O ring Hose

# FOR ASSY. 1 1 2 1 1 1 1 1 1 2 2 1 1 1

UNIT 12 VOLT 24 VOLT

3.4

FIGURE # 3.4 TRANSISTOR HYDRAULIC SYSTEM

3.5 Return

FEBRUARY 1992

FIG ITEM # # PART # 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4

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

27277-00 11143-05 14972-05 49358-01 15818-06 22012-03 12391-05 27115-00 27886-00 14920-02 12391-05 11170-05 20177-01

FEBRUARY 1992 Return

NAME Pump & motor assembly (See Fig.# 3.5) Screw, cap Adapter Hose Hose Elbow, 90° O ring Retainer Cylinder assembly (See Fig.# 3.6) Tee O ring Nut Clamp

# FOR ASSY. 1 2 1 1 1 1 2 2 1 1 1 1 1

UNIT 24 VOLT

3.6

FIGURE # 3.5 PUMP AND MOTOR ASSEMBLY (12 volt, 27275-00 24 volt, 27277-00)

3.7 Return

FEBRUARY 1992

FIG ITEM # # PART # 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

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

202394 201480 13928-00 202388 202332 202334 202393 202315 201476 202391 202392 202324 202327 202333 201450 201481 201512 201489 201487 201484 201514 202395 201504 201448 201515 201516 201493 201486 201485 201497 201466 202389 202397 201226

FEBRUARY 1992 Return

NAME Breather Reservoir Magnet Pump, 1.6 Pump, 1.2 Screw Seal, shaft O ring Adapter Fitting, pipe Cap, threaded Coupler Motor, 12 volt (See Fig.# 2.25) Motor, 24 volt (See Fig.# 2.25) Pin, dowel Spring and ball assembly Screw, relief adjustment Cap, relief Cap, check Spring and ball assembly Retainer, spring Plug Elbow, 90° Screw Solenoid, 12 volt Solenoid, 24 volt Stem, release Cap, release Spring and ball assembly Bracket Cover Tube, return Cover, suction Screw

# FOR ASSY. 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 4

UNIT

12 VOLT 24 VOLT

12 VOLT 24 VOLT

12 VOLT 24 VOLT

3.8

FIGURE # 3.6 LIFT CYLINDER ASSEMBLY (27886-00)

3.9 Return

FEBRUARY 1992

FIG ITEM # # PART # 3.6 3.6 3.6 3.6 3.6 3.6

1 2K 3K 4K 5 K

NA NSS NSS NSS NA 27893-00

NAME Rod Ring Wiper Seal Tube Kit, seal (CONTAINS ITEMS MARKED WITH "K")

# FOR ASSY.

UNIT

1 1 1 1 1 1

NA - NOT AVAILABLE NSS - NOT SOLD SEPARATELY

FEBRUARY 1992 Return

3.10

FIGURE # 4.1 SHIELDING ASSEMBLY

4.1 Return

FEBRUARY 1992

FIG ITEM # # PART # 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1

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

11429-04 11016-02 27518-00 27515-01 11813-06 20983-00 11009-05 11261-05 27827-01 27015-02 27057-03 20938-01 27057-04 27057-05 27576-01 11143-06 11143-14 27576-02 20981-00 49942-00 11073-26 27141-01 20904-01 27142-00 25203-04 25203-03 25189-02 25204-04 25204-03

FEBRUARY 1992 Return

NAME

# FOR ASSY.

Pin, cotter Washer, flat Rod, door Spring Grommet Shield, top Lockwasher Nut Frame, 8" battery carrier Frame, 13.5" battery carrier Retainer, 12 volt standard battery Retainer, 24 volt standard battery Retainer, 27.25" battery Retainer, 23.25" battery Shield, right hand bottom Screw, cap Screw, cap Shield, left hand bottom Shield, right hand door Spring Pin, roll Rod, door Bumper Shield, left hand door Shaft, 8" battery roller Shaft, 13.5" battery roller Bearing, seal Roller, 8" battery Roller, 13.5" battery

2 17 1 1 1 1 15 15 1 1 2 2 2 2 1 2 2 1 1 1 2 1 2 1 4 4 8 4 4

UNIT

12 volt 24 volt 12 volt 24 volt

12 volt 24 volt 12 volt 24 volt

4.2

FIGURE # 4.2 CARRIER FRAME ASSEMBLY

4.3 Return

FEBRUARY 1992

FIG ITEM # # PART # 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2

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

27848-00 20956-00 11176-09 11073-06 27827-00 27827-01 11894-10 25170-00 11936-04 25194-01 49787-00 27822-00 11806-10 11170-06 11806-10 27006-02 27849-00 11143-06 11170-12 11936-07 26325-01 11016-06 11143-04 11016-03 27179-00 201848

4.2

*

201849

4.2 4.2 4.2 4.2

24 25 26 27

20950-00 11009-12 14992-06 27946-00

FEBRUARY 1992 Return

NAME

# FOR ASSY.

UNIT

1 Handrail 1 Cover 6 Screw, machine 2 Pin, roll 1 Frame, 8" battery carrier 1 Frame, 13.5" battery carrier 2 Screw, cap 2 Eccentric, adjuster 4 Washer, thrust 2 Bearing 2 Bumper 2 Bracket (Installation Drawing 27947-00) 18 Nut 2 Nut, jum As Req'd.

Shim, .25" As Req'd.

Shim, .120" 2 Caster, spring loaded (See Fig.# 4.3) 8 Screw, cap 2 Nut 2 Washer, thrust 2 Bearing 4 Washer, flat 8 Screw, cap 2 Washer, flat 2 Caster, rider platform 1 Replacement wheel and bearing for caster assembly 27179-00 1 Replacement axle for caster assembly 27179-00 2 Pivot 2 Lockwasher 2 Screw, cap 1 Platfrom, rider

4.4

FIGURE # 4.3 CASTER ASSEMBLY (27849-00)

4.5 Return

FEBRUARY 1992

FIG ITEM # # PART # 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3

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

27796-00 11077-04 27810-00 27846-00 11936-17 11805-12 11073-34 27809-00 27813-00 27812-00 27807-00 49929-10 11016-27 15062-00 49910-01 27808-00 27795-00 11160-11 27799-00 11073-04 11205-25 27804-00 11009-05 11854-02

FEBRUARY 1992 Return

NAME Base, plate Bearing, thrust Seal, felt Frame Washer Nut, slotted Pin, roll Cap, hub Spring, inner Spring, outer Plate, spring Bushing Washer, shim Washer, spacer Bearing, ball Wheel Frame, wheel Fitting, grease Axle Pin, roll Bearing, roller Pin, pivot Lockwasher Screw, cap

# FOR ASSY.

UNIT

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

4.6

FIGURE # 4.4 LIFT FRAME ASSEMBLY

LEFT HAND PULL ROD IS SHOWN.

4.7 Return

FEBRUARY 1992

FIG ITEM # # PART #

NAME

4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4

Pin, roll Pin, linkage Linkage, upper Bushing Shaft Ring, retainer Frame, lift (See Chart) Shaft Bushing Fork, wheel Washer, race Bearing, sealed Bearing Wheel, load Shaft, wheel Fitting, grease Pin Bushing Pin, roll Spring (for pull rods 36" or less long) Spring (for pull rods 42" or longer) Bolt, eye Nut Rod, pull (See Chart) Bushing Pin Bushing Linkage Pin, linkage Pin, lower link Bushing Pin

1 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

11073-20 20287-22 20735-00 15032-09 20783-08 11898-01 See Chart 27608-00 49929-01 27603-00 11936-04 49910-01 11030-05 27626-00 27610-00 11160-09 27609-00 49929-05 11073-23 6-00015-04 27043-00 20224-00 11261-06 See Chart 49929-03 20287-25 49929-04 27607-00 20784-02 27604-05 15032-01 20287-23

# FOR ASSY.

STANDARD TRUCKS FIG. FORK # LENGTH

4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4

30 32 36 42 48 54 60 66 72 84 96 114 72/84 72/93 72/96

10 2 1 2 2 4 See Chart 2 8 2 4 4 4 2 2 2 2 6 2 2 4 2 or 4 2 or 4 See Chart 8 2 4 4 2 2 2 2

TRUCK WITH PACKAGE GUARD AND SKID ADAPTER

LIFT FRAME

LH Pull Rod

RH Pull Rod

LIFT FRAME

LH Pull Rod

RH Pull Rod

--------------------------27594-15 27594-16 27594-17 -------------------------------------------------27594-22 27594-23 27594-24 27595-03 27595-14 27595-04

--------------------------27783-13 27783-17 27783-21 ----------------------------------------------------27783-45 27783-53 27783-61 27783-67 27783-67 27783-67

--------------------------27783-14 27783-18 27783-22 ----------------------------------------------------27783-46 27783-54 27783-62 27783-68 27783-68 27783-68

--------------------------27594-38 27594-39 27594-40 ----------------------------------------------------27594-45 27594-46 -------------27595-07 27595-16 27595-08

--------------------------27783-15 27783-19 27783-23 ----------------------------------------------------27783-47 27783-55 -------------27783-69 27783-69 27783-69

--------------------------27783-16 27783-20 27783-24 ----------------------------------------------------27783-48 27783-56 -------------27783-70 27783-70 27783-70

FEBUARY 1992 Return

UNIT

4.8

FIGURE # 4.5 PALLET ENTRY ROLLERS

4.9 Return

FEBRUARY 1992

FIG ITEM # # PART # 4.5 4.5 4.5 4.5 4.5 4.5 4.5

1 2 3 4 5 6 7

27562-00 14994-07 11016-04 27012-01 27013-00 27519-00 11806-08

FEBRUARY 1992 Return

NAME Bar, nose Screw, cap Washer, flat Roller Sleeve Bar, mounting Nut, jam

# FOR ASSY.

UNIT

2 6 6 6 6 2 6

4.10

FIGURE # 4.6 SKID ADAPTER AND PACKAGE GUARD ASSEMBLY

4.11 Return

FEBRUARY 1992

FIG ITEM # # PART # 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6

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

11073-07 11016-03 12319-00 20379-02 20374-00 27506-03 27506-04 27506-05 27501-02 11073-24 27504-01 27509-03 27509-04 27509-05 11073-04 11854-07 20372-00 20015-01 11170-05 27504-02 20382-01 20382-03 20382-05 20382-07 20382-09 20382-11 20720-05 20371-01 20371-03 20371-05 20371-07 20371-09 20371-11 20373-00

FEBRUARY 1992 Return

NAME Pin, roll Washer, flat Spring Mounting, hook Hook Side bar Side bar Side bar Shaft, pivot Pin, roll Spacer (with hole) Bar, tie Bar, tie Bar, tie Pin, roll Screw, cap Bracket Bar, brace Nut Spacer (without hole) Support Support Support Support Support Support Plate, back-up Block Block Block Block Block Block Pin, mounting

# FOR ASSY. 6 1 1 1 1 1 1 1 1 2 2 1 1 1 2 2 2 1 2 2 2 2 2 2 2 2 1 4 4 4 4 4 4 2

UNIT

36 long 42 long 48 long

36 long 42 long 48 long

6" high 7" high 8" high 9" high 10" high 11" high 6" high 7" high 8" high 9" high 10" high 11" high

4.12

FIGURE # 4.7 REMOVABLE LOAD BACKREST

4.13 Return

FEBRUARY 1992

FIG ITEM # # PART #

NAME

4.7 4.7

Backrest, 48 inch load Backrest, 60 inch load

1 1

27617-03 27617-02

FEBRUARY 1992 Return

# FOR ASSY.

UNIT

1 1

48 inch 60 inch

4.14

FIGURE # 10.1 SPECIAL TOOLS AND LUBRICATIONS

10.1 Return

FEBRUARY 1992

FIG ITEM # # PART # 10.1 10.1 10.1

1 2 3

49670-00 200025 202154

FEBRUARY 1992 Return

NAME Lubricant, lift truck Lubricate, 2 oz. Molykote Adapter, flush and hard to reach

# FOR ASSY.

UNIT

1 1 1

10.1

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THE PRIME-MOVER CO. 3000 NORTH US HIGHWAY 61 MUSCATINE, IOWA 52761-5810

PROUDLY Made in AMERICA

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