CLARK FORKLIFT SPM-627A SERVICE MANUALS

Service and Parts Manual SPM-627A

TRUCK MODEL CSM 7/10/15

ALWAYS GIVE TRUCK SERIAL NUMBER WHEN ORDERING PARTS

CSM 7/10/15

SPM-627A

TABLE OF CONTENTS 1. Receipt Inspection ..................................................................................................................2 2. Pre-Operation Instructions .......................................................................................................2 3. Safety Information...................................................................................................................3 4. Operating Instructions .............................................................................................................4 5. Control System.......................................................................................................................4 6. Battery Discharge Indicator (BDI) - Operation ...........................................................................6 6.1

Hourmeter ...............................................................................................................6

6.2

BDI and Hourmeter ..................................................................................................7

6.3

BDI w/Lift Interlock...................................................................................................8

7. Drive Unit & Brake ..................................................................................................................9 8. Mast and Carriage ................................................................................................................10 9. Hydraulic Adjustments ..........................................................................................................10 9.1

Lifting Pressure .....................................................................................................10

9.2

Lowering Speed ....................................................................................................10

10. Planned Maintenance ...........................................................................................................11 10.1 Lubrication Points ..................................................................................................12 10.2 Lubrication Schedule .............................................................................................13 10.3 Battery Maintenance ..............................................................................................14 10.4 Battery Cable Connections .....................................................................................16 (for built-in battery / charger pack)....................................................................................16 11. Trouble Shooting Guide ........................................................................................................17 12. Intermediate Duty Stacker - Parts Listings ..............................................................................18 12.1 General Assembly Parts List...................................................................................20 12.2 Carriage Assembly Parts List..................................................................................28 12.3 Crosshead Assembly Parts List ..............................................................................30 12.4 Chain Assembly Parts List......................................................................................32 12.5 Cylinder Assembly Parts List ..................................................................................34 12.6 Power Pack Assembly ...........................................................................................38 12.7 Drive Unit Parts List ...............................................................................................40 12.8 Control Handle Parts List........................................................................................42 12.9 Control Handle Switch Parts List.............................................................................44 12.10 Brake Linkage Arrangement ...................................................................................46 12.11 Compact Drive (Gearbox) Assembly .......................................................................48 12.12 Hydraulic System Assembly ...................................................................................52 13. Electrical System ..................................................................................................................54

Issue Date: 07/08/04

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CSM 7/10/15

SPM-627A

IMPORTANT! : READ AND UNDERSTAND THE CONTENTS OF THIS MANUAL BEFORE OPERATING THE EQUIPMENT. 1. Receipt Inspection This equipment has been thoroughly inspected and tested prior to leaving the factory. Before placing the equipment in service it should be thoroughly checked for damage or loss occurring in transit.

IMPORTANT! : IF ANY DAMAGE OR LOSS IS EVIDENT, A CLAIM MUST BE MADE AGAINST THE CARRIER. Refer to: Damage in Transit information enclosed with the packing slip.

2. Pre-Operation Instructions 1. Open the drive unit cover and check the wiring harness and hydraulic hoses for damage or loose connections.

2. With the forks in the lowered position, move the battery to the left to expose the oil tank breather cap.

Remove the cap and verify that the oil level is approximately 1" (25mm) below the top of the reservoir.

Refer to Figure 4 in Section 10.1 : Lubrication Points.

3. Open the battery compartment and check that all connections are tight. Check that the batteries have not been damaged. Charge battery(s) for one shift.

Refer to Section 10.3 : Battery Maintenance 4. Refer to the Operator's Manual on unit and check that the truck operates satisfactorily.

IMPORTANT! : DURING INITIAL CYLINDER ASSEMBLY, HYDRAULIC FLUID IS USED TO LUBRICATE ALL THE COMPONENTS. THIS ASSEMBLY FLUID MAY BE PRESENT, OR ACCUMULATED IN THE UPPER HEADNUT PORTION OF THE CYLINDER DURING THE BREAK-IN PERIOD OR NORMAL USE. A SMALL AMOUNT OF FLUID IN THIS AREA IS NORMAL AND SHOULD NOT BE MISTAKEN FOR CYLINDER SEAL LEAKAGE.

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Issue Date: 07/08/04

CSM 7/10/15

SPM-627A

3. Safety Information 1. Do not operate this truck unless you have been trained and authorized to do so.

2. Do not operate this truck until you have checked its condition. Give special attention to tires, battery, controls, lifting systems (including switches), brakes, steering mechanism, guards and safety devices.

3. Report the need for truck repairs to your supervisor promptly. Do not operate the truck. Neglect may cause a minor repair to become a major service problem or cause the truck to become unsafe.

4. The stacker is intended for use on level surfaces only.

5. Do not exceed the rated capacity of the vehicle as marked on the nameplate. Do not lift with the fork tips or one fork only, and be sure load is centered and the 24" (610mm) load center is not exceeded.

6. Do not handle unstable or loosely stacked loads.

Use special care when handling long, high or wide loads, to avoid tipping, loss of load, or striking bystanders.

7. Always look in direction of travel. Keep a clear view and when load obstructs visibility, travel with load trailing (except when climbing ramps).

8. Watch swing clearance when turning near walls, racks, pillars or other obstacles.

9. Start, stop, change direction, travel and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause truck to slide or tip. Be aware that the truck behaves differently without a load than with a load.

10. Observe applicable traffic regulations and yield right of way to pedestrians. Slow down and sound horn at all aisle intersections and where vision is obstructed.

Do not ride on truck unless equipped with a rider platform.

11. Do not carry passengers.

Issue Date: 07/08/04

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4. Operating Instructions 1. Refer to OPERATOR'S MANUAL enclosed in the pouch on the control handle.

If the OPERATOR'S MANUAL is missing, contact your authorized distributor.

REMEMBER: A safe operator is a smart operator!

5. Control System The Intermediate Duty Stackers are equipped with electronic travel speed control, which offers some of the following features:

Current multiplication: One of the most intriguing aspects of the electronic travel speed controller is the fact that during acceleration, or reduced speed operation, it allows more current into the motor than what it takes out of the battery. This is possible because the controller acts like a D.C. transformer, i.e.: it takes in high voltage (the full battery voltage) and low current, and puts out low voltage and high current. Thus for these conditions the battery only has to supply a fraction of the current otherwise required by a standard resistor type controller (in which the battery current and motor current are always equal).

The result is a dramatic improvement in the vehicle’s efficiency, i.e. greater driving range per battery charge!

Plug braking: In most applications of these controllers, the vehicle motor will be of the series wound type. If a series wound motor is reversed while the vehicle is moving, an efficient form of electrical braking called plug braking will slow the vehicle down. When the motor is reversed the armature acts as a generator. Generated armature current goes through a “plug diode” built into the controller. The controller regulates the current in the motor field winding to give an appropriate level of plug braking torque. The vehicle brakes smoothly to stop, then automatically accelerates.

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Issue Date: 07/08/04

CSM 7/10/15

SPM-627A

Controller The electronic speed controller, being a sealed, solid state unit, requires almost no maintenance. It is, however, recommended that the following items be checked occasionally, as required.

WARNING! : DISCONNECT THE BATTERY AND DEPRESS HORN SWITCH TO DRAIN CONTROLLER RESIDUAL CURRENT BEFORE ATTEMPTING ANY TYPE OF INSPECTION OR SERVICE.

a) Make sure that the electrical connections to the controller (as well as those to the motor, batteries, etc.) are tight.

NOTE: When checking the controller bus bar connections for tightness, be sure to use the double-wrench technique to avoid applying torquing stress on the bus bars which could crack the seals around them. b) Remove from the terminal areas any corrosion or accumulations of dirt, acids, grease, oil, etc. It is very important that the controller terminal face be free of these substances, since their presence may lead to electrical leakage and cause faulty operation.

The controller may be wiped clean.

POWER MUST BE REMOVED DURING THIS CLEANING.

Issue Date: 07/08/04

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6. Battery Discharge Indicator (BDI) - Operation Some units may be equipped with a battery discharge indicator that may include a lift lockout feature. When the battery is severely discharged the lifting circuit will automatically be disabled. To avoid this, the operator must return the unit for charging after the last light / bar is activated. The travel circuit will remain operational to return the unit to the charging area. Although, several different style meters are available as options, their basic function is identical.

The lift lockout feature will ensure that the battery and electrical components are not subject to premature wear due to operating with a discharged battery. Always check the battery indicator, if equipped, in the event that the lifting circuit is not operational. General operation of a battery discharge indicator with or without the lift lockout feature, if equipped, is outlined on the drawing below.

Optional Parts ITEM 1 2 3

PART NO. 032-211 032-229 032-244

4

026-511

5

026-516

DESCRIPTION Hour meter Combo BDI-hour meter BDI with lift lockout Combo BDI-hour meter with lift lockout Harness for 026-511

6.1 Hourmeter The Hourmeter is activated by the control handle and records actual run time of the drive motor.

Figure 1 : Typical Hourmeter

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Issue Date: 07/08/04

CSM 7/10/15

SPM-627A

6.2 BDI and Hourmeter The display of the Battery Discharge Indicator (BDI) / Hourmeter is activated by the control handle and records actual run time of the drive motor. In addition, when the handle is in the driving position the accumulation of time is indicated by the flashing of an hourglass icon.

Figure 2 : Typical BDI/Hourmeter Inicators

The functioning of the red, yellow and green LED display on the BDI/Hourmeter is as follows: 1. The far right LED (1.) will illuminate to indicate a proper full charge.

2. As the battery’s state-of-charge condition decreases, the number of lit LEDs will also decrease.

3. At the next to last position (2.), this LED flashes indicating an “energy reserve” condition. This indicates a state-of-charge condition of approximately 70% of discharge.

4. At the empty point (3.), the 2 LEDs at the far left will alternately flash indicating a state-of-charge condition of approximately 80% discharge.

Issue Date: 07/08/04

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If the power is disconnected from the indicator during charging, the unit will reset at 2.09 volts per cell.

If the indicator remains connected during charging, a voltage of 2.35 volts per cell must be maintained in excess of 6 minutes in order to rest the unit.

6.3 BDI w/Lift Interlock The display of the BDI w/ Lift Interlock monitors the state-of-charge condition of the batteries as well as providing a Lift Interlock feature.

As the battery’s state-of-charge condition decreases, the number of lit LEDs will also decrease.

Figure 3 : Typical Battery Discharge Indicator All lights ON: Battery: - fully charged Voltage: - more than 110% of nominal Four lights ON: Battery: - fully charged Voltage: - between 110% and 100% of nominal Three lights ON: Battery: - partially discharged Voltage: - between 98% and 100% of nominal Two lights ON: Battery: - partially discharged Unit should be promptly returned for charging One light ON: Battery: - fully discharged Lift will be disabled after several minutes of continued service. Unit must be returned for charging immediately!

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Issue Date: 07/08/04

CSM 7/10/15

SPM-627A

7. Drive Unit & Brake BEFORE INSPECTING ANY PART OF THE DRIVE ASSEMBLY DISCONNECT MAIN BATTERY POWER AND DEPRESS HORN SWITCH TO DRAIN RESIDUAL CONTROLLER CURRENT The traction motor has sealed bearings and requires no external lubrication.

1. Check the condition of the drive belt and adjust the tension if necessary. The belt is correctly tensioned when a 10 lb. force applied midway between the two sprockets causes a deflection of 3/16”.

2. Check belt for unusual wear which may indicate incorrect pulley alignment. Never use force or pry when installing a new replacement belt.

3. To install a new belt reduce tension, install belt, readjust tension to achieve deflection indicated.

Rotate the belt manually by hand for several revolutions and recheck tension after all fasteners have been tightened. Normally this belt should not require further tensioning but should be re-inspected after several shifts of operation. Over-tensioning a belt will cause excessive noise, reduce belt life and impose higher bearing loads in drive components.

4. Change the oil in the gear reduction box 500 hours or three months after the equipment is placed in service and every 2000 hours or one year thereafter.

Approved gearbox oils are listed on chart below.

5. Check the brake for safe operation. Make sure the power cut off switch is open and disconnects the drive when the brakes are applied in both the up and down position. This unit is equipped with an internal multi-disc braking system that has no user adjustable parts. Brake adjustments can only be performed by qualified service personnel.

FACTORY APPROVED OILS FOR NORMAL AMBIENT OPERATING CONDITIONS APPROVED GEAR BOX OILS APPROVED HYDRAULIC OILS Canadian American Canadian American Esso Terresso #68 Exxon Teresstic #68 Sunvis 832 Dexron II Shell Tellus #68 Shell Turbo T-68 Valvoline Antiwear ISO32 Valvoline AW32 Petro Canada Harmony #68

Issue Date: 07/08/04

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8. Mast and Carriage 1. Check the condition and wear of all channel/chain rollers on a monthly basis and replace if necessary.

2. Lubricate the points as shown in Figure 4 : Lubrication Points. For best performance lubricate monthly.

3. Periodically remove the lift chains and wipe clean with dry cloths. DO NOT use chemical degreasing agents since these may make the material brittle.

Carefully examine the chain links, pins and clevises for damage, wear or stretch and replace them if any evidence of either is found. Use a paintbrush, recoat the chains with SAE 10 motor oil, or suitable chain lubricant. Adjust the chain tension so that with the carriage fully lowered, the chains are equally taut but not supporting the carriage.

4. Check the upper limit mechanical stops for damage and repair or replace.

9. Hydraulic Adjustments 9.1 Lifting Pressure The hydraulic relief valve assembly controls the maximum hydraulic system pressure. The pressure relief is factory set and adjustment will be required only if a new valve or pump is installed. For operator safety adjustment to any of these components must be made by a qualified service representative only.

9.2 Lowering Speed Lowering speed is factory set for safe lowering and should never be changed for safety reasons. For operator safety during valve replacement, adjustment to the lowering speed must be made by a qualified service representative only.

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Issue Date: 07/08/04

CSM 7/10/15

SPM-627A

10. Planned Maintenance Spotting trouble before it happens can prevent costly down-time and extensive repairs. This, in turn, makes it possible for service and repairs to be performed when the unit is not required for regular operations.

Inspection intervals outlined are for normal single-shift use and conditions. More frequent inspections are necessary for adverse conditions such as: rough floor conditions, temperature extremes, several operators, multi-shift use, dusty atmosphere, etc.

INSPECTION INTERVALS: DAILY:

• All Operating Controls (SAFETY) See Owner / Operator Manual • Battery Charge

QUARTERLY:

• Electrical System • Hydraulic System • Drive unit, motor brushes & moving mechanical parts

WARNING! : DISCONNECT THE BATTERY AND DEPRESS HORN SWITCH TO DRAIN CONTROLLER RESIDUAL CURRENT BEFORE ATTEMPTING ANY TYPE OF INSPECTION OR SERVICE.

Issue Date: 07/08/04

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CSM 7/10/15 10.1

SPM-627A

Lubrication Points

Bushing Style Only

Bushing Style Only

Note: Ball Bearing Style Rollers do NOT require lubrication.

Figure 4 : Lubrication Points

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Issue Date: 07/08/04

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SPM-627A

Important notice - During initial cylinder assembly, hydraulic fluid is used to lubricate all the components. This assembly fluid may be present, or accumulated in the upper headnut portion of the cylinder during the break-in period or normal use. A small amount of fluid in this area is normal and should not be mistaken for cylinder seal leakage.

10.2

Lubrication Schedule

LUBRICATION

(based on single shift, normal usage)

The transmission (gearbox) oil, hydraulic oil should be changed after the truck has been in service for six months, then minimum once a year, for normal single shift usage.

Every Month:

- Apply engine oil (SAE 10) or grease to all points. , including handle pivot points.

Every Three Months:

- Remove breather cap (See Figure 4) check oil level Is 1” (25mm) below the top of the reservoir and add approved oil, if necessary.

High oil level may cause leakage during rapid braking.

The breather cap should be cleaned with a suitable cleaning solvent and blown dry (safety glasses must be worn) before you reinstall.

Check gearbox oil level (See Figure 4)

Every Six Months:

- Clean drive unit swivel bearings and wheel bearings, check for smooth operation and lubricate using high quality lithium-based EP type grease.

Issue Date: 07/08/04

Yearly:

- Remove reservoir suction strainer, discard used oil and clear reservoir. inspect strainer and replace if damaged. Reinstall and add oil to 1” (25mm) below the top. For operation at normal room temperatures use only approved hydraulic oils such as: ISO 32 Sunvis 832 Esso Polar 32 Shell Tellus 29 Texaco Rando Oil HD32(150) For Transmission (Gear Box) oil use: Gulf Harmony 68 Esso Teresso 68 Shell Covil 68 or equal For low temperature operation consult the manufacturer for recommended hydraulic and transmission oils.

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CSM 7/10/15 10.3

SPM-627A

Battery Maintenance General The top of the battery should be kept clean and dry.

Wash off with clean water and baking soda when necessary. Good ventilation should be provided during charging. Do not allow electrolyte temperature to exceed 110°F (43°C). Keep open flames away from battery.

Never add acid to cells. Batteries used at temperatures below or above normal room temperature will have reduced capacity.

WARNING! : PROPER SAFETY DEVICES SUCH AS SAFETY GLASSES, APRON AND GLOVES MUST BE WORN WHEN WORKING WITH BATTERIES. Records A weekly record should be kept showing hydrometer readings of pilot cell at start and at end of charge.

Change to a different pilot cell monthly.

Once a week after the battery has received an equalizing charge, record the hydrometer readings of all cells.

CAUTION! : DO NOT DISCHARGE BELOW SPECIFIC GRAVITY OF 1.150 OR THERE WILL BE A PERMANENT LOSS OF CAPACITY. Charging industrial battery with remote charger

Refer to charger manufacturer's operating directions and manual.

Charging with built-in charger / battery pack

Plug charger cord into electrical outlet 115/1/60).

Charging will start and stop automatically.

Charging with GNB 'Champion' power pack

Refer to manufacturer’s operating directions and manual.

WARNING! : INSURE THAT BATTERY CHARGER ELECTRIC PLUG CANNOT COME INTO CONTACT WITH BATTERY TERMINAL POSTS WARNING! : DISCONNECT THE SB BATTERY CONNECTOR FROM THE MACHINE PRIOR TO CHARGING TO PREVENT ACCIDENTAL VEHICLE MOVEMENT

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Issue Date: 07/08/04

CSM 7/10/15

SPM-627A

Equalizing charge In order to equalize all the cells once a week, following a normal charge, the battery should be given a second charge, continued until there is no improvement between two consecutive hydrometer readings of each cell. This is actually a continuation of the regular charge at a low rate.

Issue Date: 07/08/04

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Battery Cable Connections (for built-in battery / charger pack)

10.4

WARNING! : VERIFY PROPER BATTERY VOLTAGE AND POLARITY BEFORE MAKING CONNECTION

Figure 5 : Typical Cabling Arrangement For 4 - 12 Volt Batteries (Series / Parallel)

CAUTION! : VERIFY THE DURATION AND AMPERAGE OF CHARGING SUITABLE FOR THE TYPE AND RATING OF BATTERIES USED. NOT ALL BATTERIES ARE DESIGNED TO TAKE HIGH AMPERAGE/SHORT CHARGING TIMES. CONSULT YOUR LOCAL CLARK DEALER FOR MORE INFORMATION.

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Issue Date: 07/08/04

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SPM-627A

11. Trouble Shooting Guide Problem

Possible Cause

NO LIFT (Motor does not run)

y y y y y y y y

Faulty wiring from fuse to lift switch in handle.

Faulty lift switch Faulty wiring from lift switch to pump contactor.

Faulty lift contactor Faulty wiring from battery positive terminal to pump contactor, or from pump contactor to pump motor.

Worn out brushes in pump motor.

Defective control circuit fuse and/or main power fuse.

y y y

Low hydraulic pressure caused by: - Pressure relief valve needing adjustment.

- Pump check valve stuck open.

- Faulty solenoid valve.

Check oil level if forks do not raise fully.

Check hydraulic pump operation.

Defective control circuit fuse.

FORKS WILL NOT LOWER

y y y y y y y y

Faulty lowering switch on steering handle.

Faulty wiring from lowering switch to solenoid valve.

Faulty solenoid coil on soft-shift control valve.

Faulty soft-shift control valve.

Faulty load lowering valve.

Faulty velocity fuse.

Faulty control circuit fuse.

Mechanical binding

NO ELECTRICAL POWER (no travel)

y

No electrical power caused by: - Key switch in “OFF” position.

- Emergency disconnect button depressed.

- Faulty SB connector (or unplugged).

- Loose battery connections.

- Defective control circuit fuse and/or main power fuse.

Faulty wiring from fuse to travel control switch.

Faulty travel control switch.

Faulty wiring from travel control switch to direction contactor.

Faulty contactor.

Check traction motor.

NO LIFT (Motor runs)

y y y y y

Issue Date: 07/08/04

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CSM 7/10/15

12. CSM 7/10/15 - Parts Listings

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CSM 7/10/15

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CSM 7/10/15 12.1

General Assembly Parts List

Figure 6 : General Assembly

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General Assembly Parts List Item

Qty

Part No

General Description

Specific Description

1

1

2 2 2 2 2 2 2 2 2 2 2 2

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

3 3 4 5 6 7 7

1 2 4 4 4 2 2

200-01484 163-0007 163-0007-1 163-0007 163-0007-2 163-0007-1 163-0007-3 163-0000 163-0000-1 163-0000-2 163-0000-3 163-0000-4 163-0000-5 163-0005 799-969 010-042 012-220 011-508 120-253 163-0008

1500 / 2200 / 3000 1500 - 52” lift 1500 - 72” lift 1500 - 90” lift 1500 - 110” lift 1500 - 130” lift 1500 - 150” lift 2200 / 3000 – 52” lift 2200 / 3000 – 72” lift 2200 / 3000 – 90” lift 2200 / 3000 – 110” lift 2200 / 3000 – 130” lift 2200 / 3000 – 150” lift 1500 - 1 Stage 1500 - 2 Stage 1500 1500 1500 2200 / 3000 - 1 Stage 2200 / 3300 - 2 Stage

8

4

011-045

9 10 10 11 12 13 14 15 15 15 15 15 15 15 15 15 15 15 15

1 1 1 1 6 6 4 1 1 1 1 1 1 1 1 1 1 1 1

037-062 038-076 038-077 037-061 011-020 011-631 014-076 162-5005 162-5005-2 162-5005 162-5005-1 162-5005-2 162-5005-3 162-5005 162-5005-2 162-5005-2 162-5005-3 162-5005-4 162-5005-5

Cover Handle Bracket - Specify Color Screen, Wire Mesh Screen, Wire Mesh Screen, Wire Mesh Screen, Wire Mesh Screen, Wire Mesh Screen, Wire Mesh Screen, Wire Mesh Screen, Wire Mesh Screen, Wire Mesh Screen, Wire Mesh Screen, Wire Mesh Screen, Wire Mesh Brace, Top Mast Assembly, Mast Guide Capscrew, 1/2”-13 x 1” LG. Washer, Lock – 1/2" Nut, Hex 1/2"-13 Block, Stop – Inner Mast (Not Shown) Block, Stop – Inner Mast (Not Shown) Capscrew, Hex Sck 3/8”-16x3/4" (Not Shown) Plate, Dash Decal, Safety – Eng./Spa. Decal, Safety – Eng./Fre. Shroud - Specify Color Screw, Machine R/H Slot 1/4"-20 x 3/4" Fastener, U-type -1/4”-20 Setscrew ,Socket Hd. 5/8"-11 x 3/4" Weldment, Body and Outer Mast Weldment, Body and Outer Mast Weldment, Body and Outer Mast Weldment, Body and Outer Mast Weldment, Body and Outer Mast Weldment, Body and Outer Mast Weldment, Body and Outer Mast Weldment, Body and Outer Mast Weldment, Body and Outer Mast Weldment, Body and Outer Mast Weldment, Body and Outer Mast Weldment, Body and Outer Mast

* - INDENTED SUB-ASSEMBLY – SHOWN ON SAME PAGE ** - SUB-ASSEMBLY SHOWN ON SEPARATE PAGE

Issue Date: 07/08/04

2200 / 3300 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 - 52” lift 1500 - 72” lift 1500 - 90” lift 1500 - 110” lift 1500 - 130” lift 1500 - 150” lift 2200 / 3000 – 52” lift 2200 / 3000 – 72” lift 2200 / 3000 – 90” lift 2200 / 3000 – 110” lift 2200 / 3000 – 130” lift 2200 / 3000 – 150” lift Continued…

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General Assembly Parts List

Figure 6 : General Assembly

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SPM-627A

General Assembly Parts List Item

Qty

Part No

General Description

Specific Description

16 17 18 19 20* 20* 20* 20*

1 1 1 1 1 1 1 1

025-977 162-5010 035-238 165-5000 783-901-1 783-901-2 183-5005 183-5010-2

Button, Emergency Stop Ass’y, Battery Cover - Specify Color Plug, Breather (Under Battery Pack) Assembly, Battery Pack Assembly, Carriage 28” Fork OD Assembly, Carriage 28” Fork OD Assembly, Carriage 28” Fork OD Assembly, Carriage 28” Fork OD

1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 – 1 Stage 1500 – 2 Stage 2200 / 3000 - 1 Stage 2200 / 3000 - 2 Stage

21 22 23 24 25** 25** 25** 25** 25** 25** 25** 25** 25** 25** 25** 25** 26** 26** 26** 26** 26** 26** 26** 26** 26** 26** 26** 26** 27* 27* 27* 27*

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

010-157 011-502 012-210 012-200 163-5018 163-5018-2 163-5018-4 163-5018-6 163-5018-8 163-5018-10 163-5018-1 163-5018-3 163-5018-5 163-5018-7 163-5018-9 163-5018-11 783-510 783-508 783-507 783-506 783-504 783-480 783-598 783-596 783-490 783-489 783-487 783-485 783-926 783-927 783-929 783-925

“U”-Bolt, 5/16” Nut, Hex - 5/16”-18 Washer, Flat - 5/16 ID Washer, Lock - 5/16” ID Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly Cross Head Assembly Cross Head Assembly Cross Head Assembly Cross Head Assembly

1500 / 2200 / 3000 1 St. 1500 / 2200 / 3000 1 St. 1500 / 2200 / 3000 1 St. 1500 / 2200 / 3000 1 St. 1500 - 52” lift 1500 - 72” lift 1500 - 90” lift 1500 - 110” lift 1500 - 130” lift 1500 - 150” lift 2200 / 3000 – 52” lift 2200 / 3000 – 72” lift 2200 / 3000 – 90” lift 2200 / 3000 – 110” lift 2200 / 3000 – 130” lift 2200 / 3000 – 150” lift 1500 - 52” lift 1500 - 72” lift 1500 - 90” lift 1500 - 110” lift 1500 - 130” lift 1500 - 150” lift 2200 / 3000 – 52” lift 2200 / 3000 – 72” lift 2200 / 3000 – 90” lift 2200 / 3000 – 110” lift 2200 / 3000 – 130” lift 2200 / 3000 – 150” lift 1500 – 1 Stage 1500 – 2 Stage 2200 / 3000 - 1 Stage 2200 / 3000 - 2 Stage

* - INDENTED SUB-ASSEMBLY – SHOWN ON SAME PAGE ** - SUB-ASSEMBLY SHOWN ON SEPARATE PAGE

Issue Date: 07/08/04

Continued…

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General Assembly Parts List

Figure 6 : General Assembly

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General Assembly Parts List Item

Qty

Part No

28*

1

192-5003-2

28*

1

192-5003-3

29*

1

192-5002-2

29*

1

192-5003-3

30 31 32 33 34 35 36 36 36 37 37 38 39 40 41** 42** 43** 44 45 46 47 48 49 50 51 52 53 53 53 53 53 53 53 53

2 2 2 2 2 2 2 2

104-000 018-500 799-944 013-024 105-878 105-880 783-963 783-854 783-853 117-922 120-454 013-026 037-065 105-5000-3 165-5006 164-5035 164-5037 011-124 030-866 783-569 783-424 026-175 011-039 780-170 780-169 010-039 163-5003 163-5003-1 163-5003-3 163-5003-5 163-5017 163-5017-1 163-5017-3 163-5017-5

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

General Description Assembly, Straddle - Left (Incl. Items 30-35) Assembly, Straddle – Left (Incl. Items 30-35) Assembly, Straddle – Right (Incl. Items 30-35) Assembly, Straddle – Right (Incl. Items 30-35) Wheel, Straddle Bearing, Wheel Axle Pin, Cotter Washer, Flat - 3/4" x 1/16” THK. Washer, Flat - 3/4" x 1/8” THK. Assembly, Forged Fork - 36” Assembly, Forged Fork - 42” Assembly, Forged Fork - 48” Bar, Fork Bar, Fork Pin, Cotter Grommet, Rubber Assembly, SB Connector Power Cable Ass’y, Power Pack Control Panel Ass’y, Drive Unit Ass’y, Hydraulic System Capscrew, Hex Hd - #10-24 x 1/4” LG. Clip Cable, #4 - 6” LG. Ass’y, Power Fuse Holder Fuse, 100A Screw, Machine – 1/4"-20 x 1”LG. Ass’y, Right Door (Battery Tray) Ass’y, Left Door (Battery Tray) Capscrew, Hex Hd. 3/8”-16 x 1”LG. Weldment, Inner Mast Weldment, Inner Mast Weldment, Inner Mast Weldment, Inner Mast Weldment, Inner Mast Weldment, Inner Mast Weldment, Inner Mast Weldment, Inner Mast

* - INDENTED SUB-ASSEMBLY – SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN ON SEPARATE PAGE

Issue Date: 07/08/04

Specific Description 1500 2200 / 3000 1500 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 - 90” lift 1500 - 110” lift 1500 - 130” lift 1500 - 150” lift 2200 / 3000 - 90” lift 2200 / 3000 - 110” lift 2200 / 3000 - 130” lift 2200 / 3000 - 150” lift Continued…

Page 25

CSM 7/10/15

General Assembly Parts List

Figure 6 : General Assembly

Page 26

Issue Date: 07/08/04

SPM-627A

CSM 7/10/15

SPM-627A

General Assembly Parts List Item

Qty

Part No

General Description

Specific Description

54 54 55 56 57 58 59 59 60 61 62 63 64 65 66 67

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

792-344 019-021 013-002 105-880 105-879 105-878 117-746 103-304 011-520 012-230 011-533 011-508 010-042 012-220 107-942 117-529

Roller, Channel Roller, Channel Ring, Retaining - 3/4” Shaft Washer - 3/4"x1-3/16”x1/8” Washer - 3/4"x1-3/16”x1/16” Washer - 3/4"x1-3/16”x1/32” Rod, Guide Rod, Guide Nut, Hex ½"-20 Washer, Lock - 1/2" Nut, Lock - 1/2"-20 Nut, Hex – 1/2"-13 Capscrew, Hex Hd. - 1/2"-13 x 1”LG. Washer, Lock - 1/2" Decal, “NO RIDING” Decal, “NO HANDS”

1500 - 2 Stage 2200 / 3000 - 2 Stage 1500 - 2 Stage 1500 - 2 Stage 1500 - 2 Stage 1500 - 2 Stage 1500 - 2 Stage 2200 / 3000 - 2 Stage 1500 - 2 Stage 1500 – 2 Stage 1500 – 2 Stage 1500 – 2 Stage 1500 – 2 Stage 1500 – 2 Stage 1500 / 2200 / 3000 1500 / 2200 / 3000

Issue Date: 07/08/04

Page 27

CSM 7/10/15 12.2

Carriage Assembly Parts List

1500 lbs

2200, 3000 lbs.

Figure 7 : Carriage Assemblies

Page 28

Issue Date: 07/08/04

SPM-627A

CSM 7/10/15

SPM-627A

Carriage Assembly Parts List Item

Qty

Part No

General Description

Specific Description

1 1 1 1 2 2 2 3 4 5 6

1 1 1 1 1 1 1 1 4 4 4 AR 4 4 AR

783-901-1 783-901-2 183-5005 183-5010-2 783-999-1 783-999-2 183-5006 183-5009-2 100-248 019-021 019-021 105-879 013-002 018-500 105-878

1500 – 1 Stage 1500 – 2 Stage 2200 / 3000 - 1 Stage 2200 / 3000 - 2 Stage 1500 – 1 Stage 1500 – 2 Stage 2200 / 3000 - 1 Stage 2200 / 3000 - 2 Stage 1500 – 1 & 2 Stage 2200 – 1 & 2 Stage 3000 – 1 & 2 Stage 1500 1500 1500

7 8

AR 4

105-880 183-5011

Assembly, Carriage 28” Fork OD Assembly, Carriage 28” Fork OD Assembly, Carriage 28” Fork OD Assembly, Carriage 28” Fork OD Carriage Weldment Carriage Weldment Carriage Weldment Carriage Weldment Carriage Roller - Bushing Style Carriage Roller - Ball Bearing Style Carriage Roller - Ball Bearing Style Spacer Washer - 3/4" x 1-3/16" x 1/16" Retaining Ring - 3/4" DIA. Bearing Spacer Washer - 1-3/16” OD x 3/4” ID x 1/32” THK Spacer Washer - 3/4" x 1-3/16” x 1/8” Side Thrust Roller

1500 1500 2200 / 3000

AR – As Required

Issue Date: 07/08/04

Page 29

CSM 7/10/15 12.3

Crosshead Assembly Parts List

1500 lbs.

2200, 3000 lbs.

Figure 8 : Crosshead Assemblies

Page 30

Issue Date: 07/08/04

SPM-627A

CSM 7/10/15

SPM-627A

Crosshead Assembly Parts List Item

Qty

Part No

General Description

Specific Description

1 1 1 1 2 2 3 3 4 4 5 5 6

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

783-926 783-927 783-929 783-925 787-060 784-427 783-928 783-968

1500 – 1 Stage 1500 – 2 Stage 2200 / 3000 - 1 Stage 2200 / 3000 - 2 Stage 1500 – 1 Stage 1500 – 2 Stage 2200 / 3000 - 1 Stage 2200 / 3000 - 2 Stage 1500 2200 / 3000 1500 2200 / 3000 1500 2200 / 3000 1500 2200 / 3000 1500

7

2

106-389

8 9

2 2

013-025 013-034

Cross Head Assembly Cross Head Assembly Cross Head Assembly Cross Head Assembly Cross Head Weldment Cross Head Weldment (c/w Mtg. Plate) Cross Head Weldment Cross Head Weldment (c/w Mtg. Plate) Cross Head Pin (Part of Weld’t) Cross Head Pin Chain Roller Chain Roller Roller Roller Bushing Bushing Spacer Washer - 3”OD x 1”ID x 12G THK Spacer Washer - 1-3/4"OD x 1"ID x 1/16”THK Cotter Pin - DIA. 3/16 “ x 1-1/2"LG Circlip - 1”

117-723 784-083 783-750 100-089 117-724 018-000 018-061 104-013

Issue Date: 07/08/04

1500 / 2200 / 3000 1500 2200 / 3000

Page 31

CSM 7/10/15 12.4

SPM-627A

Chain Assembly Parts List

Figure 9 : Chain Assembly

Item

Qty

Part No

General Description

Specific Description

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

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

163-5018 163-5018-2 163-5018-4 163-5018-6 163-5018-8 163-5018-10 163-5018-1 163-5018-3 163-5018-5 163-5018-7 163-5018-9 163-5018-11 090-066-0384 090-066-0584 090-066-0554 090-066-0654 090-066-0754 090-066-0854 090-066-0394 090-066-0594 090-066-0584 090-066-0684 090-066-0784 090-066-0884 100-061 100-061 100-062 013-015 011-501 100-061 103-951

Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Chain Assembly Leaf Chain – 1/2" Pitch – 38-1/2” Leaf Chain – 1/2" Pitch – 58-1/2” Leaf Chain – 1/2" Pitch – 55-1/2” Leaf Chain – 1/2" Pitch – 65-1/2” Leaf Chain – 1/2" Pitch – 75-1/2” Leaf Chain – 1/2" Pitch – 85-1/2” Leaf Chain – 1/2" Pitch – 39-1/2” Leaf Chain – 1/2" Pitch – 59-1/2” Leaf Chain – 1/2" Pitch – 58-1/2” Leaf Chain – 1/2" Pitch – 68-1/2” Leaf Chain – 1/2" Pitch – 78-1/2” Leaf Chain – 1/2" Pitch – 88-1/2” Clevis, 5/8”-11 x 3” LG. (Frame End) Clevis, 5/8”-11 x 3” LG. (Frame End)

1500 - 52” lift 1500 - 72” lift 1500 - 90” lift 1500 - 110” lift 1500 - 130” lift 1500 - 150” lift 2200 / 3000 – 52” lift 2200 / 3000 – 72” lift 2200 / 3000 – 90” lift 2200 / 3000 – 110” lift 2200 / 3000 – 130” lift 2200 / 3000 – 150” lift 1500 - 52” lift 1500 - 72” lift 1500 - 90” lift 1500 - 110” lift 1500 - 130” lift 1500 - 150” lift 2200 / 3000 – 52” lift 2200 / 3000 – 72” lift 2200 / 3000 – 90” lift 2200 / 3000 – 110” lift 2200 / 3000 – 130” lift 2200 / 3000 – 150” lift 1500/2200/3000 - 1 Stg. 1500/2200/3000- 2 Stg. 1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000 1500/2200/3000 - 1Stg. 1500/2200/3000- 2 Stg.

3 4 5 6 6

Page 32

Pin Pin, Cotter Nut, Huglock – 5/8”-11 Clevis, 5/8”-11 x 3” LG. (Carriage End) Clevis, 5/8”-11 x 4-1/2” LG. (Carriage End)

Issue Date: 07/08/04

CSM 7/10/15

SPM-627A

This page was left blank intentionally

Issue Date: 07/08/04

Page 33

CSM 7/10/15

12.5

Cylinder Assembly Parts List

2200, 3000 lbs.

1500 lbs.

Figure 10 : Hydraulic Cylinder Assembly

Page 34

Issue Date: 07/08/04

SPM-627A

CSM 7/10/15

SPM-627A

Cylinder Assembly Parts List Item

Qty

Part No

General Description

-

-

-

-

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

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

786-717B 783-510 783-508 783-507 783-506 783-504 783-480 786-718B 783-598 783-596 783-731B 783-490 783-489 783-487 783-485 114-800 114-802 114-804 114-805 114-807 114-809 114-800 114-802 114-816 114-817 114-819 114-821 783-526 783-524 783-522 783-521 783-519 783-517 783-590 783-471 783-516 783-520 783-518 783-511 118-365 118-387 118-362 114-976 114-977 113-542 113-629 011-530 033-663 033-837 034-515

Cylinder - 2” ID w/1-1/2” Rod Cylinder Ass’y, 2” ID w/1-1/2” Rod Cylinder Ass’y, 2” ID w/1-1/2” Rod Cylinder Ass’y, 2” ID w/1-1/2” Rod Cylinder Ass’y, 2” ID w/1-1/2” Rod Cylinder Ass’y, 2” ID w/1-1/2” Rod Cylinder Ass’y, 2” ID w/1-1/2” Rod Cylinder - 2-1/2” ID w/1-1/2” Rod Cylinder Ass’y, 2-1/2” ID w/1-1/2” Rod Cylinder Ass’y, 2-1/2” ID w/1-1/2” Rod Cylinder - 2-1/2” ID w/2” Rod Cylinder Ass’y, 2-1/2” ID w/2” Rod Cylinder Ass’y, 2-1/2” ID w/2” Rod Cylinder Ass’y, 2-1/2” ID w/2” Rod Cylinder Ass’y, 2-1/2” ID w/2” Rod Ram, 1-1/2" Rod, 52” Lift, 25-3/4” Stroke Ram, 1-1/2" Rod, 72” Lift, 42-3/4” Stroke Ram, 1-1/2" Rod, 90” Lift, 50-3/4” Stroke Ram, 1-1/2" Rod, 110” Lift, 60-3/4” Stroke Ram, 1-1/2" Rod, 130” Lift, 70-3/4” Stroke Ram, 1-1/2" Rod, 150” Lift, 80-3/4” Stroke Ram, 1-1/2" Rod, 52” Lift, 25-3/4” Stroke Ram, 1-1/2" Rod, 72” Lift, 42-3/4” Stroke Ram, 2” Rod, 90” Lift, 50-3/4” Stroke Ram, 2” Rod, 110” Lift, 60-3/4” Stroke Ram, 2” Rod, 130” Lift, 70-3/4” Stroke Ram, 2” Rod, 150” Lift, 80-3/4” Stroke Assembly, Housing - 2” ID Assembly, Housing - 2” ID Assembly, Housing - 2” ID Assembly, Housing - 2” ID Assembly, Housing - 2” ID Assembly, Housing - 2” ID Assembly, Housing - 2-1/2” ID Assembly, Housing - 2-1/2” ID Assembly, Housing - 2-1/2” ID Assembly, Housing - 2-1/2” ID Assembly, Housing - 2-1/2” ID Assembly, Housing - 2-1/2” ID Nut, Head - 2” Dia. Nut, Head - 2-1/2” Dia. (1-1/2” Rod) Nut, Head - 2-1/2” Dia. (2” Rod) Washer, Piston - 2” Dia. Washer, Piston - 2-1/2” Dia. Piston - 2” Dia. Piston - 2-1/2” Dia. Nut, Huglock - 3/4" Fuse, Velocity - 7.5 GPM Fuse, Velocity - 7.5 GPM (3.28” LG.) Fitting, Elbow - 90° - 1/4" Pipe

1 1 1 1 1 1

Specific Description 1500 1500 1500 1500 1500 1500 -

52” lift 72” lift 90” lift 110” lift 130” lift 150” lift

2200 / 3000 – 52” lift 2200 / 3000 – 72” lift 2200 / 3000 – 90” lift 2200 / 3000 – 110” lift 2200 / 3000 – 130” lift 2200 / 3000 – 150” lift 1500 - 52” lift 1500 - 72” lift 1500 - 90” lift 1500 - 110” lift 1500 - 130” lift 1500 - 150” lift 2200 / 3000 – 52” lift 2200 / 3000 – 72” lift 2200 / 3000 – 90” lift 2200 / 3000 – 110” lift 2200 / 3000 – 130” lift 2200 / 3000 – 150” lift 1500 - 52” lift 1500 - 72” lift 1500 - 90” lift 1500 - 110” lift 1500 - 130” lift 1500 - 150” lift 2200 / 3000 – 52” lift 2200 / 3000 – 72” lift 2200 / 3000 – 90” lift 2200 / 3000 – 110” lift 2200 / 3000 – 130” lift 2200 / 3000 – 150” lift 1500 2200 / 3000 - 1 Stage 2200 / 3000 - 2 Stage 1500 2200 / 3000 1500 / 2200 / 3000 2200 / 3000 1500 / 2200 / 3000 1500 2200 / 3000 1500 / 2200 / 3000

* - INDENTED SUB-ASSEMBLY – SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN ON SEPARATE PAGE Continued …

Issue Date: 07/08/04

Page 35

CSM 7/10/15

Cylinder Assembly Parts List

2200, 3000 lbs.

1500 lbs.

Figure 10 : Hydraulic Cylinder Assembly

Page 36

Issue Date: 07/08/04

SPM-627A

CSM 7/10/15

SPM-627A

Cylinder Assembly Parts List Item

Qty

Part No

General Description

Specific Description

9* 9* 9* 10 10 11 11 12 12 13 13 14 15 15 16 16

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

783-535 783-538 783-550 036-152 036-153 036-143 036-150 036-134 036-133 036-118 036-119 036-108 036-098 036-021 118-368 117-993

Kit, Seal - 2” Dia (Includes Items 10-16) Kit, Seal - 2-1/2” Dia. (Incl. Items 10-16) Kit, Seal - 2-1/2” Dia. (Incl. Items 10-16) Ring, Wear - 2” Ring, Wear - 2-1/2” Ring, Wear - (1-1/2” Rod) Ring, Wear - (2” Rod) “O”-Ring - 2” “O”-Ring - 2-1/2” “U”-Cup - 2” “U”-Cup - 2-1/2” “O”-Ring Wiper, Rod - (1-1/2” Rod) Wiper, Rod - (2” Rod) Gasket - (1-1/2” Rod) Gasket - (2” Rod)

1500 / 2200 / 2200 / 1500 2200 / 1500 / 2200 / 1500 2200 / 1500 / 2200 / 1500 / 1500 / 2200 / 1500 / 2200 /

2200 / 3000 3000 - 1 Stage 3000 - 2 Stage 3000 2200 / 3000-1 Stg 3000 – 2 Stg 3000 2200 / 3000-1 Stg 3000 – 2 Stg 2200 / 3000 2200 / 3000-1 Stg 3000 – 2 Stg 2200 / 3000-1 Stg 3000 – 2 Stg

* - INDENTED SUB-ASSEMBLY – SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN ON SEPARATE PAGE

Issue Date: 07/08/04

Page 37

CSM 7/10/15 12.6

SPM-627A

Power Pack Assembly

Figure 11 : Power Pack Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Qty 1 1 1 1 1 1 1 1 1 1 1 2 1

Part No. 165-5006 162-0018 034-602 034-511 033-105 783-424 026-175 011-039 780-481-2 780-246 165-5010-1 165-5010-2 165-5010 030-091

General Description Ass’y, Power Pack Control Panel (Rev. F) Panel, Steel 12 Gauge - Power Pack Fitting, Elbow 90° - 3/4"-16MJ - 1/4”-18MP Fitting, Elbow 90° - 5 - 4 Assembly, Pump and Motor Holder, Fuse Fuse, Power – 100A ACK Capscrew, Screw, Flat Socket - 1/4"-20 X 1" Cable, #4, 20” LG. 2-5/16” Studs (780-481) Cable, #4, 12” LG. 2-5/16” Studs (780-481) Cable,#4,23”LG,1-3/8”(116-163),1-5/16”Stud Cable,#4,34” LG,1-3/8”(116-163),1-5/16”Stud Cable,#4,9” LG. 1-3/8”(116-163),1-5/16”Stud Strip, Terminal (12 Pole)

Specific Description 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 /

* - INDENTED SUB-ASSEMBLY – SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN ON SEPARATE PAGE

Page 38

2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 Continued …

Issue Date: 07/08/04

CSM 7/10/15

SPM-627A

Power Pack Assembly Parts List Item 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

Qty 1 1 3 3 3 1 1 4 8 4 4 1 1 1 1 2 3 3 1 4 4 4 1 2 1

Part No. 026-211 026-507-1 010-037 011-502 012-200 032-458 025-974 010-039 012-211 011-008 116-163 026-513 026-146 030-032 011-002 011-003 010-072 012-202 026-402 011-507 012-201 012-225 012-223 011-516 025-717

Issue Date: 07/08/04

General Description Holder, Fuse Controller, 24V Capscrew, Hex - 5/16” -18 X 3/4" Nut, Hex - 5/16”-18 x 3/4” LG. Washer, Lock - 5/16” Horn, 24V Contactor, Fwd/Rev – 24V Capscrew, Hex - 3/8”-16 x 1" LG. Washer, Flat 5/16” Screw, Machine R/H Slot -#10-32 X 3/8" LG. Cable, #4 - 36” LG. Harness, Wiring - 10 Wire, 18 GA x 19” LG. Fuse, Control - 6A - 1/4” x 1-1/4” - Glass Clip, “P” - #3 Screw, Machine R/H Slot - #6-32 X 1/2" Screw, Machine R/H Slot - #6-32 X 1" Capscrew, Hex - 1/4"-20 x 1/2" Washer, Lock - 1/4" Helical Diode, Wire Lead 6 Amp. - 100V Nut, Hex - 3/8” - 16 Washer, Lock - 3/8” Helical Washer, Lock - #10 Internal Tooth Washer, Lock - #6 Internal Tooth Nut, Hex - #10 - 32 Solenoid 24VDC

Specific Description 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 /

2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000

Page 39

CSM 7/10/15 12.7

SPM-627A

Drive Unit Parts List

Figure 12 : Drive Unit Assembly

Item 1** 2 3 4 5 6 7

Qty Part No. 1 1 2 2 1 1 4

164-5035 200-01481 200-01478 010-000 012-202 164-0006 018-100 011-066

General Description

Specific Description

Ass’y, Drive Unit Control Handle Ass’y Pivot Pin Ass’y Capscrew, Hex 1/4"-20 X 3/4" Washer, Lock -1/ 4“ Pin, Cam Follower Bushing Capscrew, Hex Socket 5/16” -18 x 3/4"

1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 /

2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000

* - INDENTED SUB-ASSEMBLY – SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE

Page 40

Continued…

Issue Date: 07/08/04

CSM 7/10/15

SPM-627A

Drive Unit Parts List Item

Qty

Part No.

General Description

Specific Description

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 46

1 1 1 1 6 4 4 1 1 1 1 1 3 1 1 1 1 1 1 1 2 2 2 2 1 1 2 1 1 2 1 1 1 1 2 2 1 1 1

018-072 021-315 781-748 781-734 011-060 012-291 037-021 907-0022 013-005 010-057 012-221 120-321 011-508 120-279 019-500 018-507 120-318 011-599 111-653 105-5001 011-003 012-208 012-223 011-514 780-864 021-317 104-355 018-084 021-316 013-033 030-865 164-5001 164-7003 200-01475 011-181 011-515 30H21 011-005 012-205

Bushing, Taperlock Pulley, Timing Bracket, Motor Bracket, Motor Pivot Capscrew, Hex Socket 5/16” -18 x 3/4" Washer, Lock - 5/16” Protector, Terminal Motor, Drive - 24V-1HP Pin, Spring 5/32” x 1” Capscrew, 5/8” - 11 x 1-1/2” Washer, Lock - 5/8” Washer, Center Pin Nut, Hex - 1/ 2” - 13 Rod, Threaded – 1/2” -13 x 3-5/8” Nipple, Grease Bearing, Cone Pin, Center Nut, Lock - 1-1/2 “ - 12 Washer, Flat - 1.265”ID x 1/4” THK Switch and Cable Ass’y Screw, Machine - #6-32 x 1” Washer, Flat – 3/16” Washer, Flat - #6 Int.Tooth Nut, Hex - #6 - 32 Tire, Drive Ass’y Belt, Drive Key, Motor Shaft - 3/16” x 1” Bushing, Taperlock - 5/8” Shaft Pulley, Timing Ring, Retaining 5/8” OD Sleeve, Expandable Braided Linkage Ass’y, Brake Harness Bumper, Rubber Screw, Mach. Flat Hd - #8-32 x 1-1/4" Nut, Hex - #8 x 32 Clamp, Cable - 3/8” x 1/2" Wide Screw, Machine Slot #8-32 x 1/2" Washer, Flat - #8

1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 /

2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000

* - INDENTED SUB-ASSEMBLY – SHOWN ON SAME PAGE ** - SUB-ASSEMBLY SHOWN ON SEPARATE PAGE

Issue Date: 07/08/04

Page 41

CSM 7/10/15

SPM-627A

Control Handle Parts List

12.8

Figure 13 : Control Handle Assembly

Item

Qty

Part No.

General Description

Specific Description

1 2

1 1

200-01481 200-01476 200-01483

1500 / 2200 / 3000 1500 / 2200 / 3000 1500 / 2200 / 3000

3

2

012-245

4 5** 6 7 8 9 10 11 12 13 14 15

2 1 4 4 1 1 1 4 4 1

017-075 281-9451 012-200 010-188 234-5332 200-00165 120-0001 011-000 011-010 200-01478 010-000 012-202

Ass’y, Control Handle Cam, Machined Stem, Handle Machined Washer, Spacer-1”IDx13/4”ODx1/8”THK Spring, Torsion – 3/32” x 3-1/16OD Ass’y, Control Handle Switch - 24V Washer, Lock 5/16” – Helical Capscrew, Hex Hd. – M8 x 16mm Switch, Key #31-613 Plate, Handle Stem Cover Plate, Vertical – Serial Number Screw, Type U - #4 x 5/16” Screw, Machine RH Slot - #10-24 x 3/8” Assembly, Pivot Pin (Splined) Capscrew, Hex 1/4"-20 x 3/4" Washer, Lock -1/ 4“

2 2

1500 / 2200 / 3000 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 /

* - INDENTED SUB-ASSEMBLY - SHOWN ON SAME PAGE ** - SUB-ASSEMBLY SHOWN ON SEPARATE PAGE

Page 42

Issue Date: 07/08/04

2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000

CSM 7/10/15

SPM-627A

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Issue Date: 07/08/04

Page 43

CSM 7/10/15 12.9

Control Handle Switch Parts List

Figure 14 : Control Handle Switch Assembly Page 44

Issue Date: 07/08/04

SPM-627A

CSM 7/10/15

SPM-627A

Control Handle Switch Parts List Item

Qty

Part No.

Description

Specific Description

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

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

281-9451 929-442 907-0184 929-443 929-444 929-445 929-446 929-441 929-465 929-461 929-452 929-464 930-805 929-451 929-458 929-455 929-457 929-450 929-447 N/A 929-437 929-438 929-439

1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 /

21

5

929-453

22 23 24 25 26 27 28 29 30 31 32 33 34

2 1 2 2 2 2 2–4 6 2 4 1 1 1

3GM-506 929-462 1EM-50E 929-456 10E-M30 13G-M3010 3GM-812 929-454 929-463 929-448 929-440 025-998 929-460

Assy, Control Handle - 24V Cover, Plastic Cover, Plastic Button, LIFT Button, LOWER Button, HORN Bracket, Spring Retaining Bracket, LOWER / HORN Switch Bracket, LIFT SWITCH c/w Pin Thumbwheel, Butterfly (Black) Throttle, Electronic - 24V Bracket, Throttle Support Bracket, Throttle Support Housing Bracket, E/R Spring, E/R Button Button, E/R Grip Spring, Lift / Lower / Horn Button Pin, Lift Switch (included with #7) Switch, Lower / Horn Switch, Lift Screw, Switch Mounting - #3 x 16 Phillips Pan Hd. Screw, E/R & Switch Bracket Mounting - #6 x 3/8” Slot Pan Hd. Capscrew, E/R Bracket - #10-32 x 1/4" Hex Hd. Switch, E/R Washer, Flat - E/R Bracket - #10 Washer, Wide, E/R Bracket - #3 x 08 THK. Washer, Lock - Star #4 Ext. Screw, Throttle - #4-48 x 1/2” Pan Hd. Screw, Grip Screw, Button Spring Bracket – M3 x 10 Screw, E/R Switch Screw, Cover Screw, Horn Switch Mounting Plug (Grommet) Harness, Wire

Issue Date: 07/08/04

2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000

1500 / 2200 / 3000 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 /

2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000

Page 45

CSM 7/10/15 12.10

Brake Linkage Arrangement

Figure 15 : Brake Linkage Arrangement

Page 46

Issue Date: 07/08/04

SPM-627A

CSM 7/10/15

SPM-627A

Brake Linkage Parts List Item

Qty

Part No.

Description

Specific Description

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

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

164-5001 164-5003 164-0005 164-0027 013-513 017-060 011-519 012-211 013-565 013-017 014-016 200-01485 783-299 010-105 012-201

Brake Linkage Arrangement Lever, Brake (Gearbox) Rod, Linkage Rod, Brake Release Clevis, 3/8" - 3/8” Eye x 2-7/8” Spring, Compression C-18 Nut, Hex - 3/8”-24 Washer, Flat – 5/16” Pin, Clevis - 3/8" Dia. x 1-3/32" Pin, Cotter - 3/32” x 3/4” Screw, Set – 5/16”-24 Column, Drive Handle Mtg. Ass’y, Compact Drive Unit (Gearbox) Capscrew, Hex - 3/8”-16 x 2-1/2" Washer, Lock - 3/8”

1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 /

2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000

* - INDENTED SUB-ASSEMBLY – SHOWN ON SAME PAGE ** - SUB-ASSEMBLY SHOWN ON SEPARATE PAGE

Issue Date: 07/08/04

Page 47

CSM 7/10/15 12.11

Compact Drive (Gearbox) Assembly

Figure 16 : Compact Drive Gearbox Assembly

Page 48

Issue Date: 07/08/04

SPM-627A

CSM 7/10/15

SPM-627A

Compact Drive (Gearbox) Parts List 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

Qty

Part No.

Description

Specific Description

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

783-299 120-117 013-002 036-108 105-878 110-896 110-897 023-527 023-526 118-738 023-528 118-944 021-300 118-734 118-739 118-733 118-737 118-742 021-302 021-304 118-736 021-090 018-582 036-092 118-735 118-743 021-101 110-604 118-945 021-301 021-312 118-740 012-225 010-050 021-310 118-932

Compact Drive Gear Box Ass’y Shaft, Brake 8-3/4” Ring, Retaining O-Ring Washer, Spacer - 1-3/16” OD x 3/4” ID x 1/32” THK Collar, Brake Thrust Ring, Snap Disk, Inner Brake Disk, Outer Brake Sleeve, Brake Spring, Brake Separator Housing, Gear Box Bearing, Ball Shaft, Input Plate, Locking Shaft, Intermediate Gear, Intermediate Key, Square - 1/ 4” Bearing, Cone Washer, Tongue Gear, Output Plug, Socket Pipe - 3/8” Bearing, Roller Seal, Output Shaft, Output Key, Square - 3/8” Key, Shaft - 3/8” x 3” Lever, Brake Operating Cover, Gear Box Seal, Oil Bearing Spacer, 1-1/ 4” OD x .608” ID x .178” THK Washer, Star - #10 Capscrew, Hex Sock - #10-32 x 1-1/4" Washer, Lock Nut, Output Shaft

1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 /

2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000

AR – As Required

Continued…

Issue Date: 07/08/04

Page 49

CSM 7/10/15

Compact Drive (Gearbox) Assembly

Figure 16 : Compact Drive Gearbox Assembly

Page 50

Issue Date: 07/08/04

SPM-627A

CSM 7/10/15

SPM-627A

Compact Drive (Gearbox) Parts List Item

Qty

Part No

General Description

Specific Description

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

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

118-741 021-309 021-308 021-307 021-306 021-305 011-602 012-291 021-105 105-882 011-597 011-563 106-903 090-973 035-200

Plate, Cover Washer, Tongue Bearing, Cone Cup, Bearing Nut, Lock Washer, Lock Capscrew, Hex Sock 5/16”-18 X 1-1/2" Washer, High Collar - 5/16” Pin, Dowel - 3/8" Dia. x 1" Spacer, Inner Brake Disk - 1-3/4” Capscrew, Hex Socket 5/16”-18 x 1" Nut, Lock - 1-1/4”-12 Tape, Magnetic Oil, Gear Plug, Breather

1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 /

Issue Date: 07/08/04

2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000

Page 51

CSM 7/10/15 12.12

SPM-627A

Hydraulic System Assembly

8 14

SUCTION LINE LOW PRESSURE HOSE

12 1 2

BOTTOM VIEW

10

3

LINE 13 RETURN HIGH PRESSURE HOSE

5 6 11

9 4 7

20 21

22

18 19

16

SEE SECTION 12.5 : HYDRAULIC CYLINDER ASSEMBLY

Figure 17 : Hydraulic System Assembly

Page 52

Issue Date: 07/08/04

17

15

CSM 7/10/15

SPM-627A

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

Qty

Part No.

Description

Specific Description

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

164-5037 164-5038 033-734 033-735 033-501 034-507 034-509 034-500 034-607 035-000 034-501 165-5001 781-815 165-5007 165-5007-1 035-269 035-270 034-607 035-092 034-535 033-663 033-837 034-515 035-238

Hydraulic System Valve Ass’y, Load Lowering (Incl. Items 2-10) Valve, Soft Shift – 24 VDC Valve, Subplate Valve, Load Lowering Control Fitting, Straight 3/8”-18MP-3/8”-18MP Fitting, Straight-Reducer 1/2”-14MP-3/8”-18FP Fitting, 90° Elbow 3/8”-18MP – 9/16”-18MJ Fitting, 90° Elbow 3/8”-18MP - 9/16”-18MJ Plug, Square Head - 3/8”NPT Fitting, Straight 1/ 2”-20MJ - 3/8”-18MP Hose Ass’y - High Pressure #6-18” LG. Hose Ass’y - High Pressure #8-12” LG. Hose Ass’y - High Pressure #4-20” LG. Hose Ass’y - High Pressure #4-6” LG. Filter Head, Filter Fitting, 90° Elbow 5MJ-6MP Fitting, Elbow - 3/8" x 45° NPT Female Fitting, Straight - 3/8”-19MP - 3/4”-MJ Fuse, Velocity - 7.5 GPM Fuse, Velocity – 7.5 GPM (3.28”) Fitting, Elbow - 90° - 1/4" Pipe Cap, Filler - (Breather Plug)

1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 / 1500 2200 / 1500 1500 /

2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 2200 / 3000 3000 2200 / 3000

* - INDENTED SUB-ASSEMBLY – SHOWN ON SAME PAGE ** - SUB-ASSEMBLY SHOWN ON SEPARATE PAGE

Issue Date: 07/08/04

Page 53

CSM 7/10/15

13. Electrical System

Figure 18 : Electrical Schematic Page 54

Issue Date: 07/08/04

SPM-627A

CLARK Material Handling Co. 2317 Alumni Park Plaza, Suite 500 Lexington, KY 40517 (859) 422-6400