CLARK FORKLIFT SPM-630A SERVICE MANUALS

Service and Parts Manual SPM-630A

TRUCK MODEL CS 15/20

ALWAYS GIVE TRUCK SERIAL NUMBER WHEN ORDERING PARTS

CS 15/20

SPM-630A

TABLE OF CONTENTS 1. Receipt Inspection ........................................................................................................................3 2. Pre-Operation Instructions .............................................................................................................3 3. Safety Information.........................................................................................................................4 4. Operating Instructions ...................................................................................................................5 5. Control System.............................................................................................................................7 6. Battery Discharge Indicator (BDI) - Operation .................................................................................9 6.1

Hourmeter ...........................................................................................................................9

6.2

BDI and Hourmeter ............................................................................................................10

6.3

BDI w/Lift Interlock.............................................................................................................11

7. Drive Unit & Brake ......................................................................................................................12 8. Mast and Carriage ......................................................................................................................13 9. Hydraulic Adjustments ................................................................................................................13 9.1

Lifting Pressure .................................................................................................................13

9.2

Lowering Speed:................................................................................................................13

10. Planned Maintenance .................................................................................................................14 10.1 Lubrication Points ..............................................................................................................15 10.2 Lubrication Points ..............................................................................................................16 10.3 Lubrication Schedule .........................................................................................................16 10.4 Battery Maintenance ..........................................................................................................17 10.5 Battery Cable Connections .................................................................................................18 (for built-in battery / charger pack) 11. Trouble Shooting Guide ..............................................................................................................19 12. Heavy Duty Stacker - Parts Listings .............................................................................................20 12.1 General Assembly Parts List...............................................................................................22 12.2 Mast and Carriage Assembly - Single Stage ........................................................................26 12.2.1

Cylinder Assembly - 3000 Single Stage..................................................................28

12.2.2

Cylinder Assembly - 4000 Single Stage..................................................................30

12.2.3

Crosshead Assembly - Single Stage ......................................................................32

12.2.4

Chain Assembly - Single Stage..............................................................................33

12.3 Mast and Carriage Assembly - 2 Stage ...............................................................................34 12.3.1

Lift Cylinder Assembly - Two Stage........................................................................36

12.3.2

Chain Assembly - 2 Stage.....................................................................................38

12.3.3

Crosshead Assembly - 2 Stage..............................................................................39

Issue Date: 07/23/04

Page 1

CS 15/20

SM-630A

12.4 Mast and Carriage Assembly - 2 Stage Full Free .................................................................40 12.4.1

Lift Cylinder Assembly - 2 Stage 130, 150" Full Free...............................................42

12.4.2

Outboard Cylinder Assembly - 2 Stage 130, 150" Full Free......................................44

12.4.3

Chain Assembly - 2 Stage 130, 150" Lift Height ......................................................46

12.4.4

Crosshead Assembly - 2 Stage 130, 150" Lift Height...............................................47

12.5 Mast and Carriage Assembly - 3 Stage 160, 180" Lift...........................................................48 12.5.1

Cylinder Assembly - 3 Stage 160, 180" Lift Height...................................................52

12.5.2

Chain Assembly - 3 Stage 160, 180" Lift Height ......................................................54

12.5.3

Crosshead Assembly - 3 Stage 160, 180" Lift .........................................................55

12.6 Mast and Carriage Assembly - 3 Stage 172" Lift Full Free ....................................................56 12.6.1

Chain Assembly - 3 Stage 172" Lift Full Free ..........................................................58

12.6.2

Chain Assembly - 3 Stage 172" Lift Full Free ..........................................................59

12.6.3

Crosshead Assembly - 3 Stage 172" Lift Full Free...................................................60

12.6.4

Lift Cylinder Assembly - 3 Stage 172" Lift Full Free .................................................62

12.6.5

Outboard Cylinder Assembly - 3 Stage 172" Lift Full Free........................................64

12.7 Left Straddle Assembly ......................................................................................................66 12.8 Right Straddle Assembly ....................................................................................................68 12.9 Right Straddle Assembly ....................................................................................................69 12.10 Electric Drive Unit Assembly ...............................................................................................70 12.11 Drive Unit Assembly - Electrical ..........................................................................................72 12.11.1

Control Handle Assembly ..................................................................................74

12.11.2

Control Handle Head Assembly .........................................................................76

12.11.3

Controller Panel Assembly ................................................................................78

12.11.4

Drive Unit Wiring Kit ..........................................................................................80

12.11.5

Drive Unit Column Assembly - Mechanical .........................................................82

12.11.6

Drive Unit Gearbox Assembly ............................................................................84

12.11.7

Wiring Kit - Rear Battery Box Plate ....................................................................86

12.12 Hydraulic Layout ................................................................................................................88 13. Wiring/Hydraulic Schematic .........................................................................................................92 13.1 Mechanical/Hydraulic Lift Control Schematic .......................................................................92 13.2 Electric/Hydraulic Lift Control Schematic .............................................................................93

Page 2

Issue Date: 07/23/04

CS 15/20

SM-630A

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, remove the oil tank breather 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.

REMEMBER: A safe operator is a smart operator!

Issue Date: 07/23/04

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CS 15/20

SM-630A

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.

12. Before leaving the truck, fully lower the lifting mechanism and shut off power and key switch if equipped.

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Issue Date: 07/23/04

CS 15/20

SM-630A

13. Do not use forward mast tilt (if equipped) with the load elevated unless the load is directly over other support.

14. When traveling with or without a load, forks should be in lower most position and tilted back if applicable.

15. For straddle trucks, straddle distance must be equally spaced in relation to truck chassis. Straddle inside dimension must be set at a minimum of 25% of maximum lifting height. Straddle legs adjustment should be done by an authorized Service Technician.

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!

WARNING! :THE FOLLOWING IS INTENDED AS AS A BREIF OVERVIEW OF TRUCK FUNCTIONS. DO NOT PUT THE TRUCK INTO SERVICE WITHOUT READING THE OPERATOR'S MANUAL AND FULLY UNDERSTANDING THE TRUCK CONTROLS. FAILURE TO DO SO COULD RESULT IN PROPERTY DAMAGE, AND/OR SERIOUS PERSONAL INJURY OR DEATH. Travel Controls: Rotating the Thumb Wheels in the head of the control handle controls Direction and speed. This unit is equipped with a fully programmable electronic speed control and has variable speed that is regulated by turning the twist grip handle in the forward or reverse direction as required. With the electronic speed controller travel controls (reversing travel direction) may be used for braking purposes during regular use.

Brake: The brake is applied when the control handle is in the fully raised or fully lowered position. Power to the traction (drive) motor is cut off whenever the brake is applied in the fully raised or lowered position.

Equipment includes a “Deadman” safety feature. Spring loaded steering handle, when released automatically returns to upright/”Deadman” position that engages the brake and will slow the unit down to a full stop.

Issue Date: 07/23/04

Page 5

CS 15/20

SM-630A Horn: The horn pushbutton is located on the steering handle allowing instantaneous fingertip use without travel interruption.

Safety Reversing Button: Located at the top of the steering handle. When the truck is being driven in the direction of the operator and the safety-reversing button is depressed by an obstruction or trapped operator, the vehicle instantly reverses direction in high speed and the horn will sound.

NOTE: DO NOT USE THE SAFETY REVERSING BUTTON FOR NORMAL TRAVEL. Lift and Lower Controls: Manual lever control (standard) is located on the right hand side of the dash plate. Pushbutton control, if ordered, is located on the top of the control handle.

WARNING! : NEVER EXCEED THE RATED CAPACITY OF THE TRUCK AS MARKED ON THE NAMEPLATE. DO NOT LIFT WITH THE FORK TIPS OR ONE FORK ONLY. Mast Tilt Controls: Manual lever control is located on the right handle side of the dash plate. Pushbutton control, if ordered, is located on the top of the control handle.

WARNING! : DO NOT USE FORWARD TILT WITH THE LOAD ELEVATED UNLESS THE LOAD IS DIRECTLY OVER OTHER SUPPORT.

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Issue Date: 07/23/04

CS 15/20

SM-630A

5. Control System These units are factory set for normal operating conditions. This electronic speed controller provides maintenance free operation and reduces downtime and operating costs associated with contactor controlled units.

Contact your local CLARK dealer for additional information.

Current multiplication: During acceleration, or reduced speed operation, the electronic travel speed controller 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.

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.

Issue Date: 07/23/04

Page 7

CS 15/20

SM-630A 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.

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Issue Date: 07/23/04

CS 15/20

SM-630A

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

6.1

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

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

Figure 1 : Typical Hourmeter

Issue Date: 07/23/04

Page 9

CS 15/20 6.2

SM-630A

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.

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Issue Date: 07/23/04

CS 15/20

SM-630A

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!

Issue Date: 07/23/04

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CS 15/20

SM-630A

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. Qualified service personnel must perform brake adjustments only.

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

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Issue Date: 07/23/04

CS 15/20

SM-630A

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.

Issue Date: 07/23/04

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CS 15/20

SM-630A

10. Planned Maintenance Spotting trouble before it happens can prevent costly down-time and extensive repairs and make 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) Battery Charge Brake Operation

QUARTERLY: Electrical System Hydraulic System Drive Unit & Mechanical Parts

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

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Issue Date: 07/23/04

CS 15/20 10.1

SM-630A

Lubrication Points

Note: Ball Bearing Style Rollers do NOT require lubrication.

Figure 4 : Lubrication Points

Issue Date: 07/23/04

Page 15

CS 15/20

SM-630A

10.2

Lubrication Points

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 gland nut 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.

10.3

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.

Page 16

Yearly:

- Remove reservoir suction strainer, discard used oil and clean 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.

Issue Date: 07/23/04

CS 15/20 10.4

SM-630A

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

Issue Date: 07/23/04

Page 17

CS 15/20 10.5

SM-630A

Battery Cable Connections (for built-in battery / charger pack) 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 AUTHORIZED DEALER FOR MORE INFORMATION.

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Issue Date: 07/23/04

CS 15/20

SM-630A

11. Trouble Shooting Guide The following charts are intended to assist in identifying possible equipment malfunctions.

NOTE: REPAIRS / TROUBLE SHOOTING SHOULD BE PERFORMED BY AN AUTHORIZED TECHNICIAN.

BEFORE TROUBLE SHOOTING, MAIN BATTERY POWER MUST BE DISCONNECTED. PROBLEM

POSSIBLE CAUSE

NO LIFT (motor does not run)

• Discharged battery • Faulty wiring between pump motor and contactor • Faulty contactor for pump motor • Worn out brushes in pump motor • Faulty main power fuse

NO LIFT (motor runs)

• Discharged battery • Low hydraulic pressure • Pump check valve stuck open - Faulty solenoid valve • Check oil level if forks do not raise fully • Foreign material blocking lifting mechanism

FORKS WILL NOT LOWER

• Faulty solenoid coil • Faulty control valve • Obstruction in chain/mast/carriage • Faulty control fuse blown

NO ELECTRICAL POWER or NO TRAVEL

• Discharged battery • Loose/corroded battery connections • Blown main or control fuse • Faulty travel control switch • Faulty contactor or contactor tips • Check traction motor • Broken/loose drive belt • Faulty SB connector

TRUCK PERFORMS PROPERLY BUT REQUIRES CHARGING TOO FREQUENTLY

• Battery being removed from charger before recharging cycle is completed • Battery water level is too low to accept and hold a full charge • Battery capacity not adequate for workload required • Battery capacity reduced due to battery damage

FORKS WILL NOT LIFT TO FULL HEIGHT PUMP MAKES MORE NOISE THAN NORMAL

• Oil level low in oil reservoir. Refill oil reservoir, determine area of leakage • CAUTION: Use Only recommended oils

LOSS OF BRAKING POWER

• Brake requires adjustment. Must be performed by qualified personnel only

NOTE: Additional testing and diagnostics must be performed by authorized service personnel through use of the diagnostics analysis tool in the controller programmer. Consult the manufacturer or an authorized dealer for more details and assistance.

Issue Date: 07/23/04

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CS 15/20

SM-630A

12. CS 15/20 - Parts Listings

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Issue Date: 07/23/04

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SM-630A

Issue Date: 07/23/04

Page 21

CS 15/20 12.1

SM-630A

General Assembly Parts List

Figure 6 : General Assembly

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Issue Date: 07/23/04

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SM-630A

General Assembly Parts List Item

Qty

Part No

General Description

Specific Description

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

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 1 1 1 1 1 1 4 4 4

142-5000 142-5000 142-5000 142-5000 142-5000-1 142-5000 142-5000-1 142-5000 142-5000-4 142-5000 142-5000 142-5000 142-5000 142-5000 142-5000-1 142-5000 142-5000-1 142-5000 142-5000-4 142-5000 142-5000 103-5024 103-5024-2 143-5043 143-5043-1 103-5027-2 143-5043-2 103-5027-3 103-5035 143-5049 103-5035-2 103-5024-1 103-5024-3 143-5043-3 143-5043-4 103-5027-2 143-5043-5 103-5027-3 103-5035-1 143-5049 103-5035-3 103-5035-5 010-182 011-154 012-022

Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Weldment, Body Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Capscrew, 7/8” x 3” LG. Nut, Hex - 7/8”-9 Washer, Lock - 7/8”OD x .266”W

3000-63” Lift Height 3000-68” Lift Height 3000-118” Lift Height 3000-130” Lift Height 3000-130” Full Free 3000-150” Lift Height 3000-150” Full Free 3000-160” 3000-172” Full Free 3000-180” Lift Height 4000-63” Lift Height 4000-68” Lift Height 4000-118” Lift Height 4000-130” Lift Height 4000-130” Full Free 4000-150” Lift Height 4000-150” Full Free 4000-160” Lift Height 4000-172” Full Free 4000-180” Lift Height 4000-200” Lift Height 3000-63” Lift Height 3000-68” Lift Height 3000-118” Lift Height 3000-130” Lift Height 3000-130” Full Free 3000-150” Lift Height 3000-150” Full Free 3000-160” Lift Height 3000-172” Full Free 3000-180” Lift Height 4000-63” Lift Height 4000-68” Lift Height 4000-118” Lift Height 4000-130” Lift Height 4000-130” Full Free 4000-150” Lift Height 4000-150” Full Free 4000-160” Lift Height 4000-172” Full Free 4000-180” Lift Height 4000-200” Lift Height 3000/4000 3000/4000 3000/4000

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

Continued…

Issue Date: 07/23/04

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SM-630A

General Assembly Parts List

Figure 6 : General Assembly Page 24

Issue Date: 07/23/04

CS 15/20

SM-630A

General Assembly Parts List Item

Qty

Part No

6** 7** 8 9 10 11 12 13 14 15 16 17 18 19 20** 21** 21** 21** 21** 21** 21** 21** 22 23 23 23 24 25 26 26 26

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

142-5032 142-5033 014-010 037-061 037-062-31 010-000 012-202 011-631 011-020 144-0010 041-086 142-5029 142-5008 132-0031 145-5002 145-5006 145-5006-5 145-5006-6 145-5006-1 145-5006-7 145-5006-2 145-5006-3 140-5010 142-0020 142-0020-1 142-0020-2 011-124 030-866 032-211 032-229 032-244

26

1

026-511

27

1

026-516

General Description

Ass’y, Straddle – Left Ass’y, Straddle – Right Screw, Set - Hex. Socket 3/4”-10 x 3/4" Shroud, Drive Unit - Specify Color Cover, Dash - Specify Color Capscrew, Hex Hd. - 1/4"-20 x 3/4" Washer, Lock - 1/4" Helical Fastener, U-Type – 1/4"-20 Screw, Machine R/H Slot 1/4"-20 x 3/4" Bar, Shroud Support Fork, Forged 1-1/2” x 4" x 42” Rest, Back - 48” (33”OD Carriage) Tray, Battery Weld (13” W) Stop, Battery Weld Assembly, Electric Drive Unit Layout, Hydraulic Layout, Hydraulic Layout, Hydraulic Layout, Hydraulic Layout, Hydraulic Layout, Hydraulic Layout, Hydraulic Kit, Decal Screen, Wire Mesh (42”LG) Screen, Wire Mesh (46”LG) Screen, Wire Mesh (54” LG) Capscrew, Hex Socket - #10/24 x 1/4" Clamp, 1/8” Dia. 3/8”W Hour meter Battery Discharge Indicator /Hourmeter Battery Discharge Indicator w/Lift Lockout Battery Discharge Indicator /Hourmeter w/Lift Lockout Harness for 026-511 (Not Shown)

Specific Description

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 - 1&2 Stage 3000/4000-130 FullFree 3000/4000-150 FullFree 3000/4000-160 3000/4000-172 FullFree 3000/4000-180 4000-200 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

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

Issue Date: 07/23/04

Page 25

CS 15/20 12.2

SM-630A

Mast and Carriage Assembly - Single Stage

Figure 7 : Mast and Carriage Assembly - 63, 68" Lift Height

Page 26

Issue Date: 07/23/04

CS 15/20

SM-630A

Mast and Carriage Ass'y - Single Stage Item

Qty

Part No

General Description

Specific Description

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

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

103-5024 103-5024-2 103-5024-1 103-5024-3 103-5020 103-5020-2 103-5020-1 103-5020-3 101-5003 101-5003-1 101-5004 101-5004-1 103-5017 103-5017-1 103-5031 103-5031-1 103-5030-13 103-5030-12 104-146 133-5005 133-5005-1 019-011 103-5045 103-0022 018-006 011-045 010-012 012-201

Mast and Carriage Ass'y - Single Stage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Ass’y, Mast and Carriage Weldment, Mast - 63” Weldment, Mast - 68” Weldment, Mast - 63” Weldment, Mast - 68” Ass’y, Cylinder - 63” Ass’y, Cylinder - 68” Ass’y, Cylinder - 63” Ass’y, Cylinder - 68” Weldment, Crosshead Weldment, Crosshead Ass’y, Chain - 41-1/2” Ass’y, Chain - 46-1/2” Ass’y, Chain - 41-1/2” Ass’y, Chain - 46-1/2” Block, Stop Ass’y, Carriage Weldment Ass’y, Carriage Weldment Bearing, Roller Ass’y, Roller - Side Thrust Roller, 2” Dia. - Side Thrust Bushing Capscrew, Hex Socket F/H - 3/8”-16 x 3/4" Capscrew, Hex Hd. - 3/8”-16 x 3/4" Washer, Lock 3/8” - Helical

3000/4000 Single Stage 3000-63” Lift Height 3000-68” Lift Height 4000-63” Lift Height 4000-68” Lift Height 3000-63” Lift Height 3000-68” Lift Height 4000-63” Lift Height 4000-68” Lift Height 3000-63” Lift Height 3000-68” Lift Height 4000-63” Lift Height 4000-68” Lift Height 3000 - Single Stage 4000 - Single Stage 3000-63” Lift Height 3000-68” Lift Height 4000-63” Lift Height 4000-68” Lift Height 3000/4000 3000 - Single Stage 4000 - Single Stage 3000 - Single Stage 3000 - Single Stage 3000 - Single Stage 3000 - Single Stage 3000/4000 3000/4000 3000/4000

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

Issue Date: 07/23/04

Page 27

CS 15/20

SM-630A

12.2.1 Cylinder Assembly - 3000 Single Stage

Figure 8 : Lift Cylinder Assembly - 63", 68" Lift Height - 3000 lb. Capacity Page 28

Issue Date: 07/23/04

CS 15/20

SM-630A

Cylinder Assembly - 3000 Single Stage Item ◄ 1 1 2 2 3 4 5 ●6 ●7 ●8 ●9 ●10 ●11 ●12 13 ●14 -

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 -

Part No

101-5003 101-5003-1 101-0003 101-0003-1 101-5000 101-5000-1 118-362 114-977 113-629 036-153 036-150 036-133 036-119 036-108 036-021 117-993 011-530 036-176 783-550

Issue Date: 07/23/04

General Description

Ass’y, Cylinder - 63” Ass’y, Cylinder - 68” Ram, 2” Dia. x 37-3/8” LG. Ram, 2” Dia. x 39-7/8” LG. Weldment, Housing 2-1/2” Dia Weldment, Housing 2-1/2” Dia Nut, Head Washer, Piston 2-1/2” Dia Piston, 2-1/2” Dia (USE 788-599) Ring, Wear Ring, Wear “O”-Ring “U”-Cup “O”-Ring Wiper, Rod Gasket Nut, Jam 3/4”-10 “O”-Ring Kit, Seal Includes Items marked (●)

Specific Description

3000-63” Lift Height 3000-68” Lift Height 3000 -63” LH 3000 -68” LH 3000 -63” LH 3000 -68” LH 3000 -63,68” LH 3000 -63,68” LH 3000 -63,68” LH 3000 -63,68” LH 3000 -63,68” LH 3000 -63,68” LH 3000 -63,68” LH 3000 -63,68” LH 3000 -63,68” LH 3000 -63,68” LH 3000 -63,68” LH 3000 -63,68” LH 3000

Page 29

CS 15/20

SM-630A

12.2.2 Cylinder Assembly - 4000 Single Stage

Figure 9 : Lift Cylinder Assembly - 63", 68" Lift Height - 4000 lb. Capacity

Page 30

Issue Date: 07/23/04

CS 15/20

SM-630A

Cylinder Assembly - 4000 Single Stage Item ◄ 1 1 2 2 3 4 5 ●6 ●7 ●8 ●9 ●10 ●11 ●12 13 ●14 -

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 -

Part No

101-5004 101-5004-1 101-0003 101-0003-1 101-5000-1 101-5000-1 117-991 114-978 114-640 036-153 036-150 036-133 036-119 036-108 036-021 117-993 011-530 036-176 783-553

Issue Date: 07/23/04

General Description

Ass’y, Cylinder - 63” Ass’y, Cylinder - 68” Ram, 2” Dia. x 37-3/8” LG. Ram, 2” Dia. x 39-7/8” LG. Weldment, Housing 3” Dia Weldment, Housing 3” Dia Nut, Head Washer, Piston Piston, 3” Dia Ring, Wear Ring, Wear “O”-Ring “U”-Cup “O”-Ring Wiper, Rod Gasket Nut, Jam 3/4”-10 “O”-Ring Kit, Seal Includes Items marked (●)

Specific Description

4000-63” Lift Height 4000-68” Lift Height 4000-63” LH 4000-68” LH 4000-63” LH 4000-68” LH 4000-63,68” LH 4000-63,68” LH 4000-63,68” LH 4000-63,68” LH 4000-63,68” LH 4000-63,68” LH 4000-63,68” LH 4000-63,68” LH 4000-63,68” LH 4000-63,68” LH 4000-63,68” LH 4000-63,68” LH 4000

Page 31

CS 15/20

SM-630A

12.2.3 Crosshead Assembly - Single Stage

Figure 10 : Crosshead Assembly - 63", 68" Lift Height

Item ◄ 1 2 2 3 3 4 5 6 7 8

Qty

1 2 2 2 2 2 2 6 2 1

Page 32

Part No

103-5017 103-5017-1 783-088-1 781-318 792-306 120-744 100-019 018-027 103-250 114-336 013-036 014-005

General Description

Weldment, Crosshead Weldment, Crosshead Weldment, Crosshead Roller, Chain (c/w Bushing) Roller, Chain (c/w Bushing) Roller, Chain - 5/8" Roller, Chain - 7/8" Bushing Pin, Crosshead Washer, Flat Spacer Ring, Ext. Retaining - 1-1/4”ID Screw, Set - Socket 3/8”-16 x 3/8”

Specific Description

3000 - Single Stage 4000 - Single Stage 3000/4000 - Single St. 3000 - Single Stage 4000 - Single Stage 3000 - Single Stage 4000 - Single Stage 3000/4000 - Single St 3000/4000 - Single St. 3000/4000 - Single St. 3000/4000 - Single St. 3000/4000 - Single St.

Issue Date: 07/23/04

CS 15/20

SM-630A

12.2.4 Chain Assembly - Single Stage

Figure 11 : Chain Assembly - 63", 68" Lift Height

Item ◄ 1 1 1 1 2 2 3 3 4 5 5 6 6

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

Part No

103-5031 103-5031-1 103-5030-13 103-5030-12 090-066-0414 090-066-0464 090-067-0414 090-067-0464 100-061 104-532 100-062 105-372 013-015 011-501 011-535 103-951 104-532

Issue Date: 07/23/04

General Description

Ass’y, Chain - 41-1/2” Ass’y, Chain - 46-1/2” Ass’y, Chain - 41-1/2” Ass’y, Chain - 46-1/2” Leaf, Chain - 41-1/2"LG Leaf, Chain - 46-1/2"LG Leaf, Chain - 41-1/2"LG Leaf, Chain - 46-1/2"LG Clevis 3” LG 5/8”-11 Clevis Pin, Clevis 3/16” Dia. x 1” Pin, Clevis 0.2"OD x 1-1/4"LG. Pin, Cotter Pin 1/16” x 3/4" Nut, Lock 5/8”-11 Nut, Hex 3/4-10 Nylon Insert Clevis, Chain - 5/8” x 4-1/2” LG. Clevis

Specific Description

3000-63” Lift Height 3000-68” Lift Height 4000-63” Lift Height 4000-68” Lift Height 3000-63” Lift Height 3000-68” Lift Height 4000-63” Lift Height 4000-68” Lift Height 3000-63,68” LH 4000-63,68” LH 3000-63,68” LH 4000-63,68” LH 3000/4000-63,68” LH 3000-63,68” LH 4000-63,68” LH 3000-63,68” LH 4000-63,68” LH

Page 33

CS 15/20 12.3

SM-630A

Mast and Carriage Assembly - 2 Stage

Figure 12 : Mast and Carriage Assembly - 118", 130", 150" Lift Height

Page 34

Issue Date: 07/23/04

CS 15/20

SM-630A

Mast and Carriage Assembly - 2 Stage Item ◄ 1 1 1 1 1 1 2 2 2 3** 3** 4 5* 6 7 8** 8** 8** 9** 9** 9** 9** 9** 9** 10** 10** 11 12 13 14 15 16 17 18 19 20

Qty

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

Part No 143-5043 143-5043-1 143-5043-2 143-5043-3 143-5043-4 143-5043-5 103-5021 103-5021-2 103-5021-4 103-5021-1 103-5021-3 103-5021-5 103-5046 103-5046-1 103-5046-2 133-5003 133-5003-1 019-011 103-5045 103-0022 018-006 101-5003-2 101-5003-3 101-5003-4 103-5031-3 103-5031-4 103-5031-5 103-5030-7 103-5030-8 103-5030-9 780-906 780-907 118-934 103-304 011-520 011-533 012-230 019-011 010-048 012-220 010-012 012-201

General Description

Mast and Carriage Assembly - 2 Stage Mast and Carriage Assembly - 2 Stage Mast and Carriage Assembly - 2 Stage Mast and Carriage Assembly - 2 Stage Mast and Carriage Assembly - 2 Stage Mast and Carriage Assembly - 2 Stage Mast and Carriage Assembly - 2 Stage Weldment, Outer Mast Weldment, Outer Mast Weldment, Outer Mast Weldment, Outer Mast Weldment, Outer Mast Weldment, Outer Mast Weldment, Inner Mast Weldment, Inner Mast Weldment, Inner Mast Assembly, Carriage Weld’t Assembly, Carriage Weld’t Bearing, Roller Ass’y, Roller - Side Thrust Roller, 2” Dia. - Side Thrust Bushing Assembly, Cylinder - 2-1/2” Dia. Assembly, Cylinder - 2-1/2” Dia. Assembly, Cylinder - 2-1/2” Dia. Assembly, Chain - 71.5” LG. Assembly, Chain - 76.5” LG. Assembly, Chain - 86.5” LG. Assembly, Chain - 70.5” LG. Assembly, Chain - 75.5” LG. Assembly, Chain - 85.5” LG. Assembly, Crosshead Assembly, Crosshead Base Rod, Guide Nut, Hex - 1/2"-20 Nut, Hex 1/2"-20 Nylon Insert Washer, Lock Bearing, Roller Capscrew, 1/2”-13 x 1-1/2” Washer, Lock -1/2" Capscrew, Hex Hd. - 3/8”-16 x 3/4" Washer, Lock - 3/8” Helical

Specific Description

3000/4000 - 2 Stage 3000-118” Lift Height 3000-130” Lift Height 3000-150” Lift Height 4000-118” Lift Height 4000-130” Lift Height 4000-150” Lift Height 3000-118” Lift Height 3000-130” Lift Height 3000-150” Lift Height 4000-118” Lift Height 4000-130” Lift Height 4000-150” Lift Height 3000/4000-118” LH 3000/4000-130” LH 3000/4000-150” LH 3000-2 Stage 4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-118” LH 3000/4000-130” LH 3000/4000-150” LH 3000-118” Lift Height 3000-130” Lift Height 3000-150” Lift Height 4000-118” Lift Height 4000-130” Lift Height 4000-150” Lift Height 3000-2 Stage 4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage

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

Issue Date: 07/23/04

Page 35

CS 15/20

SM-630A

12.3.1 Lift Cylinder Assembly - Two Stage

Figure 13 : Lift Cylinder Assembly - 118", 130", 150" Lift Height

Page 36

Issue Date: 07/23/04

CS 15/20

SM-630A

Lift Cylinder Assembly - Two Stage Item ◄ 1 1 1 2 2 2 3 4 5 ●6 ●7 ●8 ●9 ●10 ●11 ●12 13 ●14 15 -

Qty

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

Part No

101-5003-2 101-5003-3 101-5003-4 101-0003-2 101-0003-3 101-0003-4 101-5000-2 101-5000-3 101-5000-4 118-362 114-977 113-629 036-153 036-150 036-133 036-119 036-108 036-021 117-993 011-530 036-176 101-0005 783-550

Issue Date: 07/23/04

General Description

Assembly, Cylinder - 2-1/2” Dia. Assembly, Cylinder - 2-1/2” Dia. Assembly, Cylinder - 2-1/2” Dia. Ram, 2” Dia. x 67-3/4” LG. Ram, 2” Dia. x 72-3/4”” LG. Ram, 2” Dia. x 82-3/4”” LG. Weldment, Housing 2-1/2” Dia Weldment, Housing 2-1/2” Dia Weldment, Housing 2-1/2” Dia Nut, Head Washer, Piston 2-1/2” Dia Piston, 2-1/2” Dia (USE 788-599) Ring, Wear Ring, Wear “O”-Ring “U”-Cup “O”-Ring Wiper, Rod Gasket Nut, Jam 3/4”-10 “O”-Ring Spacer, Tube 2” LG. Kit, Seal - Includes Items marked (●)

Specific Description

3000/4000-118” LH 3000/4000-130” LH 3000/4000-150” LH 3000/4000-118” LH 3000/4000-130” LH 3000/4000-150” LH 3000/4000-118” LH 3000/4000-130” LH 3000/4000-150” LH 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage 3000/4000-2 Stage

Page 37

CS 15/20

SM-630A

12.3.2 Chain Assembly - 2 Stage

Figure 14 : Chain Assembly - 118", 130", 150" Lift Height

Item

Qty

Part No

General Description

Specific Description

◄ 1 1 1 1 1 1 2 3 4 5

1 1 1 1 1 1 2 2 2 2

103-5031-3 103-5031-4 103-5031-5 103-5030-7 103-5030-8 103-5030-9 090-066-0714 090-066-0764 090-066-0864 090-067-0704 090-067-0754 090-067-0854 104-532 105-372 013-015 011-535

Assembly, Chain - 71.5” LG. Assembly, Chain - 76.5” LG. Assembly, Chain - 86.5” LG. Assembly, Chain - 70.5” LG. Assembly, Chain - 75.5” LG. Assembly, Chain - 85.5” LG. Leaf, Chain - 71-1/2” LG. Leaf, Chain - 76-1/2” LG. Leaf, Chain - 86-1/2” LG. Leaf, Chain - 70-1/2” LG. Leaf, Chain - 75-1/2” LG. Leaf, Chain - 85-1/2” LG. Clevis Pin, Clevis 0.2”OD x 1-1/4” LG. Pin, Cotter - 1/16” x 3/4" Nut, Hex 3/4”-10 Nylon Insert

3000-118” Lift Height 3000-130” Lift Height 3000-150” Lift Height 4000-118” Lift Height 4000-130” Lift Height 4000-150” Lift Height 3000-118” Lift Height 3000-130” Lift Height 3000-150” Lift Height 4000-118” Lift Height 4000-130” Lift Height 4000-150” Lift Height 3000/4000 - 2 Stage 3000/4000 - 2 Stage 3000/4000 - 2 Stage 3000/4000 - 2 Stage

Page 38

Issue Date: 07/23/04

CS 15/20

SM-630A

12.3.3 Crosshead Assembly - 2 Stage

Figure 15 : Crosshead Assembly - 118", 130", 150" Lift Height

Item ◄ 1 2 2* 3 3 4 5 6 7 8

Qty

1 2 2 2 2 2 1 6 2 1

Part No 780-906 780-907 786-472 781-318 792-306 120-744 100-019 018-027 103-250 114-336 013-036 014-005

General Description

Assembly, Crosshead Assembly, Crosshead Weldment, Crosshead Ass’y, Chain Roller - 5/8"ID Ass’y, Chain Roller - 7/8”ID x 1-1/4”OD Roller, Chain - 5/8" Roller, Chain - 7/8" Bushing Pin, Crosshead Washer, Flat Spacer Ring, Retaining Ext. Screw, Set Socket - 3/8”-16 x 3/8”

Specific Description

3000 4000 3000/4000 - 2 Stage 3000 - 2 Stage 4000 - 2 Stage 3000 - 2 Stage 4000 - 2 Stage 3000/4000 - 2 Stage 3000/4000 - 2 Stage 3000/4000 - 2 Stage 3000/4000 - 2 Stage 3000/4000 - 2 Stage

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

Issue Date: 07/23/04

Page 39

CS 15/20 12.4

SM-630A

Mast and Carriage Assembly - 2 Stage Full Free

Figure 16 : Full Free Mast and Carriage Assembly - 130", 150" Lift Height Page 40

Issue Date: 07/23/04

CS 15/20

SM-630A

Mast and Carriage Assembly - 2 Stage 130,150" Full Free Item

Qty

Part No

◄ 1 1 2 2 3** 4 5* 6 7 8** 8**

1 1 1 1 1 4 2 2 2 1 1

103-5027-2 103-5027-3 103-5039-1 103-5039-2 103-5043-4 103-5043-5 133-5004-1 019-011 103-5045 103-0022 018-006 783-199-1 783-199-2

9**

2

780-275

9**

2

780-275-1

10** 10** 11** 12 13 14 15 16* 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

2 2 1 4 1 2 1 1 1 1 7 7 4 4 1 2 2 2 2 2 3 2 4

103-5030-10 103-5030-11 783-090 019-011 143-0136 118-940 143-5116 200-00799 200-00802 018-571 010-036 012-200 010-048 012-220 012-238 011-577 035-204 010-000 012-210 012-202 013-066 104-146 011-049

General Description

Ass’y, Mast and Carriage - 2stg FF Ass’y, Mast and Carriage - 2stg FF Mast, Outer Weld (130"Lh) 2stg FF Mast, Outer Weld (150"Lh) 2stg FF Mast, Inner Weld (130") 2stg FF Mast, Inner Weld (150") 2stg FF Carriage Ass'y & Weldment Bearing, Roller Ass’y, Roller - Side Thrust Roller, 2” Dia. - Side Thrust Bushing Cylinder Ass'y 130/172/180"LH Cylinder Ass'y 150" - 38-5/8" STR. Cylinder Ass'y 1-1/2"Dia 62-1/2"Str Outbrd 2 Stg FF Cylinder Ass'y 1-1/2"Dia 72-1/2"Str Outbrd 2 Stg FF Chain Ass'y 44.5" Long Chain Ass'y 50.5" Long Crosshead Ass'y (1&2stg) Bearing, Roller Pawl Hook (PRIOR TO 2002) Cylinder Bracket - Outer Pawl Bracket (PRIOR TO 2002) Carriage Latch Ass'y Carriage Latch Bushing Capscrew, Hex Hd. 5/16"-18 x 1/2" Washer, Lock - 5/16" Helical Capscrew, Hex Hd. - 1/2"-13 x 1 1/2" Washer, Lock - 1/2" Split Reg. Washer, Spacer -1/2"ID x 1"OD x 5/64"THK Screw, Shoulder - 1/2" x 1/2" 3/8"-16 Thrd.

Clamp Capscrew, Hex Hd. - 1/4"-20 x 3/4" Washer, Flat - 1/4" Bolt S Washer, Lock - 1/4" Helical Pin, Spring - 5/32" x 1-1/4" Block, Stop Capscrew, Hex Sckt F/H - 1/2"-13 x 1"

Specific Description

3000/4000-130” FF 3000/4000-150” FF 3000/4000-130” FF 3000/4000-150” FF 3000/4000-130” FF 3000/4000-150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130” FF 3000/4000-150” FF 3000/4000-130” FF 3000/4000-150” FF 3000/4000-130” FF 3000/4000-150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF 3000/4000-130,150” FF

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

Issue Date: 07/23/04

Page 41

CS 15/20

SM-630A

12.4.1 Lift Cylinder Assembly - 2 Stage 130, 150" Fu ll Free

Figure 17 : Lift Cylinder Assembly - 130", 150" Lift Height, Full Free Mast Page 42

Issue Date: 07/23/04

CS 15/20

SM-630A

Lift Cylinder Assembly - 2 Stage 130, 150" Full Free Item ◄ 1 1 2 2 3 4 5 6● 7● 8● 9● 10● 11● 12● 13 14● 15 -

Qty

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 -

Part No

783-199-1 783-199-2 118-948 118-948-1 783-103-1 783-103-2 118-389 114-978 114-640 036-154 036-143 036-132 036-112 036-108 036-098 117-993 011-530 036-180 090-779-0024 783-536

Issue Date: 07/23/04

General Description

Cylinder Ass'y 130/172/180"LH - FF Cylinder Ass'y 150" - 38-5/8" STR. Ram (1-1/2"Dia) 41-7/8"Lg Ram (1-1/2"Dia) 46-7/8"Lg Weldment, Housing (3"ID) Weldment, Housing (3"ID) Nut, Head - 3" Dia. Cyl (1-1/2" Dia.Rod) Washer, Piston Piston - 3"Dia Cyl (2.9670+-.0020dia) Ring, Wear Piston – 3” x 1/2" Ring, Rod Wear O-Ring 3"OD x 2-3/4"ID U-Cup 3” x 2-3/8” x 1/2" O-Ring - 3/4"OD x 5/8"ID x 1/16" Wiper, 1-3/4” OD x 1-1/2” Gasket Nut, Hex Jam Plated - 3/4"-10 O-Ring Tube, Seaml. (2-1/2"Lg) Kit, Seal - Includes Items marked (●)

Specific Description

3000/4000-130" FF 3000/4000-150” FF 3000 - 130 Full Free 3000 - 150 Full Free 3000 - 130 Full Free 3000 - 150 Full Free 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF

Page 43

CS 15/20

SM-630A

12.4.2 Outboard Cylinder Assembly - 2 Stage 130, 150" Full Free

Figure 18 : Outboard Lift Cylinder Assembly - 130", 150" Lift Height, Full Free Mast

Page 44

Issue Date: 07/23/04

CS 15/20

SM-630A

Outboard Cylinder Assembly - 2 Stage 130, 150" Full Free Item ◄ 1 1 2 2 3 4 5 6● 7● 8● 9● 10● 11● 12 13● 14 -

Qty

1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 -

Part No

780-275 780-275-1 118-960 118-960-1 783-198 783-198-1 118-969 105-880 118-968 036-192 036-135 036-180 036-158 036-108 036-018 034-515 118-368 011-530 783-173

Issue Date: 07/23/04

General Description

Cylinder Ass'y Outbrd 1-1/2"Dia. 2 Stg FF Cylinder Ass'y Outbrd 1-1/2"Dia 2 Stg FF Ram, (1-1/4"Dia) Outboard Ram, (1-1/4"Dia) Outboard Weldment, Housing Weld (1.5"Dia) Outbrd Weldment, Housing Weld (1.5"Dia) Outbrd Nut, Head - (2-3/8"Dia.) Washer, Spacer - 3/4" x 1-3/16” x 1/8” Piston - F.F. Lift Ring, Wear - 1-1/2"OD x 1-1/8"ID x 1/2"W O-Ring - 1.25 x 1.5 x .139 O-Ring (Reciprocating) U-Cup - 1"ID x 1-1/2”OD x 3/8” O-Ring - 3/4"OD x 5/8"ID x 1/16" Wiper, Rod - Polyurethane AN-13 1-1/4” ID Fitting,90° Elbow -1/4" Pipe Trd Gasket - 2" Dia Cyl Nut, Hex Jam - 3/4"-10 Kit, Seal - Includes Items marked (●)

Specific Description

3000/4000 - 130 FF 3000/4000 - 150 FF 3000/4000 - 130 FF 3000/4000 - 150 FF 3000/4000 - 130 FF 3000/4000 - 150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF

Page 45

CS 15/20

SM-630A

12.4.3 Chain Assembly - 2 Stage 130, 150" Lift Height

Figure 19 : Chain Assembly - 130", 150" Lift Height, Full Free Mast

Item

Qty

Part No

General Description

Specific Description

◄ 1 1 2 3 4 5

1 1 2 2 2 2

103-5030-10 103-5030-11 090-067-0444 090-067-0504 104-532 105-372 013-015 011-535

Chain Ass'y 44.5" Long Chain Ass'y 50.5" Long Chain Leaf (44-1/2"Lg) Chain Leaf (50-1/2"Lg) Clevis Clevis Pin 0.2"O.D. x 1-1/4"Lg Cotter Pin - 1/16" x 3/4" Nut, Hex - 3/4"-10 Nylon Insert

3000/4000-130 FF 3000/4000-150 FF 3000/4000-130 FF 3000/4000-150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF

Page 46

Issue Date: 07/23/04

CS 15/20

SM-630A

12.4.4 Crosshead Assembly - 2 Stage 130, 150" Lift Height

Figure 20 : Crosshead Assembly - 130", 150" Lift Height, Full Free Mast

Item ◄ 1 2* 3 4 5 6 7 8 9

Qty

1 2 1 1 1 6 2 1 2

Part No

783-090 783-088 792-306 100-019 018-027 103-250 114-336 013-036 014-005 105-882

General Description

Crosshead Ass'y (1&2stg) Ff Weldment, Crosshead 2 Stage F.F. Mast Roller, Chain Roller, Chain - 7/8"ID x 1-1/4"OD Bushing Pin, Crosshead Washer, Flat Spacer Ring, Retaining Ext. - 1-1/4"ID Setscrew, Socket Cup Point - 3/8"-16 x 3/8" Washer, Spacer - 1-3/4" Dia

Specific Description

3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF 3000/4000-130,150 FF

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

Issue Date: 07/23/04

Page 47

CS 15/20 12.5

SM-630A

Mast and Carriage Assembly - 3 Stage 160, 180" Lift

Figure 21 : Mast and Carriage Assembly - 160", 180" Lift Height Page 48

Issue Date: 07/23/04

CS 15/20

SM-630A

Mast and Carriage Assembly - 3 Stage 160. 180 " Lift Height Item ◄ 1 1 1 2 2 2 2 2 3 3 3 4* 5 6* 7 8 9 10 11 12 13 14 15 16 17 18 19** 19** 19** 19** 19** 20** 20** 20** 21** 21** 21** 22** 22** 23 24

Qty

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

Part No

103-5035 103-5035-2 103-5035-1 103-5035-3 103-5035-5 103-5022 103-5022-1 103-5022-2 103-5014-1 103-5014-4 103-5014-2 103-5014-5 103-5014-8 103-5029 103-5029-1 103-5029-2 133-5001 019-011 103-5045 103-0022 018-006 010-012 118-611 118-674 012-201 010-040 120-845 012-220 010-044 014-002 019-011 101-5004-5 101-5004-7 101-5005 101-5005-2 101-5005-3 103-5030 103-5030-1 103-5030-2 103-5030-3 103-5030-4 103-5030-21 781-174 781-175 103-304 011-520

General Description

Mast and Carriage Assembly - 3 Stage Mast and Carriage Assembly - 3 Stage Mast and Carriage Assembly - 3 Stage Mast and Carriage Assembly - 3 Stage Mast and Carriage Assembly - 3 Stage Weldment, Mast Outer Weldment, Mast Outer Weldment, Mast Outer Weldment, Mast Center Weldment, Mast Center Weldment, Mast Center Weldment, Mast Center Weldment, Mast Center Weldment, Mast Inner Weldment, Mast Inner Weldment, Mast Inner Assembly, Carriage Weld’t Bearing, Roller Ass’y, Roller - Side Thrust Roller, 2” Dia. - Side Thrust Bushing Capscrew, Hex Hd. - 3/8”-16 x 3/4" Stop - Outer Mast Bar, Stop (7” x 3/4") Washer, Lock - 3/8” Helical Capscrew, Hex Hd. 3/8” x 1-1/2” Pin, Crosshead Washer, Lock - 1/2" Capscrew, Hex Hd. - 1/2"-13 x 2” Screw, Set - 1/4” x 3/8” Bearing, Roller Assembly, Cylinder - 3” Dia. Assembly, Cylinder - 3” Dia. Assembly, Cylinder - 3-1/2” Dia. Assembly, Cylinder - 3-1/2” Dia. Assembly, Cylinder - 3-1/2” Dia. Assembly, Chain - 71.5” LG. Assembly, Chain - 76.5” LG. Assembly, Chain - 84.5” LG. Assembly, Chain - 132.5” LG. Assembly, Chain - 142.5” LG. Assembly, Chain - 155.5” LG. Assembly, Crosshead Assembly, Crosshead Rod, Guide Nut, Hex 1/2"-20

Specific Description

3000-160” 3000-180” Lift Height 4000-160” Lift Height 4000-180” Lift Height 4000-200” Lift Height 3000/4000-160” 3000/4000-180” 4000-200” 3000-160” 3000-180” 4000-160” 4000-180” 4000-200” 3000/4000-160” 3000/4000-180” 4000-200” 3000/4000 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000-160” 3000-180” 4000-160” 4000-180” 4000-200” 3000/4000-160” 3000/4000-180” 4000-200” 3000/4000-160” 3000/4000-180” 4000-200” 3000-160, 180” 4000-160, 180, 200” 3000/4000 - 3 Stage 3000/4000 - 3 Stage

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

Continued…

Issue Date: 07/23/04

Page 49

CS 15/20

SM-630A

Mast and Carriage Assembly - 3 Stage 160, 180" Lift Height

Figure 21 : Mast and Carriage Assembly - 160", 180", 200" Lift Height Page 50

Issue Date: 07/23/04

CS 15/20

SM-630A

Mast and Carriage Assembly - 3 Stage 160, 180" Lift Height Item

Qty

Part No

General Description

Specific Description

25 26 27 28 29 30 31 32 33 34

2 2 2 2 2 2 2 2 2 2

011-533 012-212 792-306 114-336 013-036 035-204 012-210 012-202 010-000 013-066

Nut, Hex 1/2”-20 Nylon Insert Washer, Flat - 1/2" Roller, Chain (7/8”ID x 1-1/4”OD) Washer, Flat Spacer Ring, Retaining - 1-1/4”ID Clamp Washer, Flat - 1/4" Washer, Lock - 1/4" Helical Capscrew, Hex Hd. - 1/4"-20 x 3/4" Pin, Spring 5/32” x 1-1/4”

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 -

Issue Date: 07/23/04

3 Stage 3 Stage 3 Stage 3 Stage 3 Stage 3 Stage 3 Stage 3 Stage 3 Stage 3 Stage

Page 51

CS 15/20

SM-630A

12.5.1 Cylinder Assembly - 3 Stage 160, 180" Lift Height

Figure 22 : Lift Cylinder Assembly - 160", 180", 200" Lift Height

Page 52

Issue Date: 07/23/04

CS 15/20

SM-630A

Cylinder Assembly - 3 Stage 160, 180" Lift Height Item ◄ 1 1 1 1 1 2 2 2 2 2 3 3 4 4 5 5 ●6 ●6 ●7 ●7 ●8 ●8 ●9 ●9 ●10 ●11 ●11 ●12 ●12 ●13 14 15 15 15 15 15 -

Qty

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 -

Part No

101-5004-5 101-5004-7 101-5005 101-5005-2 101-5005-3 101-0003-5 101-0003-6 101-0004 101-0004-1 101-0004-2 101-5001-5 101-5001-6 101-5002 101-5002-1 101-5002-2 117-991 118-711 114-978 114-979 114-640 114-639 036-154 036-155 036-182 036-154 036-132 036-131 036-112 036-111 036-108 036-021 036-023 036-176 036-190 117-993 011-530 101-0005-4 101-0003-6 101-0006-3 101-0006-1 101-0006 783-553 780-843

Issue Date: 07/23/04

General Description

Assembly, Cylinder - 3” Dia. Assembly, Cylinder - 3” Dia. Assembly, Cylinder - 3-1/2” Dia. Assembly, Cylinder - 3-1/2” Dia. Assembly, Cylinder - 3-1/2” Dia. Ram, 2” Dia. x 66-5/16” LG. Ram, 2” Dia. x 71-5/16” LG. Ram, 2-1/2” Dia. x 66-5/16” LG. Ram, 2-1/2” Dia. x 71-5/16” LG. Ram, 2-1/2” Dia. x 77-3/4” LG. Weldment, Housing - 3”ID Weldment, Housing - 3”ID Weldment, Housing - 3-1/2”ID Weldment, Housing - 3-1/2”ID Weldment, Housing - 3-1/2”ID Nut, Head - 3” ID Cyl. Nut, Head - 3-1/2” ID Cyl. Washer, Piston Washer, Piston - 3-1/2” Piston, 3” Dia. Piston, 3-1/2” Dia. Ring, Wear Ring, Wear Ring, Wear Ring, Wear “O”-Ring “O”-Ring “U”-Cup “U”-Cup “O”-Ring Wiper. Rod Wiper. Rod “O”-Ring “O”-Ring Gasket Nut, Jam - 3/4"-10 Spacer, Tube 4-3/4” LG. Spacer, Tube 2-7/16” LG. Spacer, Tube 4-3/4” LG. Spacer, Tube 4-1/2” LG. Spacer, Tube 2-7/16” LG. Kit, Seal - Includes Items marked (●) Kit, Seal - Includes Items marked (●)

Specific Description

3000-160” 3000-180” 4000-160” 4000-180” 4000-200” 3000-160” 3000-180” 4000-160” 4000-180” 4000-200” 3000-160” 3000-180” 4000-160” 4000-180” 4000-200” 3000 - 3 Stage 4000 - 3 Stage 3000 - 3 Stage 4000 - 3 Stage 3000 - 3 Stage 4000 - 3 Stage 3000 - 3 Stage 4000 - 3 Stage 3000 - 3 Stage 4000 - 3 Stage 3000 - 3 Stage 4000 - 3 Stage 3000 - 3 Stage 4000 - 3 Stage 3000/4000 - 3 Stage 3000 - 3 Stage 4000 - 3 Stage 3000 - 3 Stage 4000 - 3 Stage 3000/4000 - 3 Stage 3000/4000 - 3 Stage 3000-160” 3000-180” 4000-160” 4000-180” 4000-200” 3000 - 3 Stage 4000 - 3 Stage

Page 53

CS 15/20

SM-630A

12.5.2 Chain Assembly - 3 Stage 160, 180" Lift Height

Figure 23 : Chain Assembly - 160", 180", 200"Lift Height

Item ◄ 1 1 1 1 1 1 2 3 4 5

Qty 1 1 1 1 1 1 2 2 2 2

Page 54

Part No

103-5030 103-5030-1 103-5030-2 103-5030-3 103-5030-4 103-5030-21 090-067-0714 090-067-0764 090-067-0844 090-067-1324 090-067-1424 090-067-1554 104-532 105-372 013-015 011-535

General Description

Assembly, Chain - 71.5” LG. Assembly, Chain - 76.5” LG. Assembly, Chain - 84.5” LG. Assembly, Chain - 132.5” LG. Assembly, Chain - 142.5” LG. Assembly, Chain - 155.5” LG. Leaf, Chain - 71-1/2” LG. Leaf, Chain - 76-1/2” LG. Leaf, Chain - 84-1/2” LG. Leaf, Chain - 132-1/2” LG. Leaf, Chain - 142-1/2” LG. Leaf, Chain - 155-1/2” LG. Clevis Pin, Clevis 0.2”OD x 1-1/4” LG, Pin, Cotter - 1/16” x 3/4" Nut, Hex - 3/4”-10 Nylon Insert

Specific Description

3000/4000-160” 3000/4000-180” 4000-200” 3000/4000-160” 3000/4000-180” 4000-200” 3000/4000-160” 3000/4000-180” 4000-200” 3000/4000-160” 3000/4000-180” 4000-200” 3000/4000-160,180,200” 3000/4000-160,180,200” 3000/4000-160,180,200” 3000/4000-160,180,200”

Issue Date: 07/23/04

CS 15/20

SM-630A

12.5.3 Crosshead Assembly - 3 Stage 160, 180" Lift

Figure 24 : Crosshead Assembly - 160", 180", 200" Lift Height

Item ◄ 1 1 2* 3 4 5 6 7 8

Qty

1 1 2 1 1 1 6 2 1

Part No 781-174 781-175 781-177 781-178 792-306 100-019 018-027 103-250 114-336 013-036 014-005

General Description

Assembly, Crosshead Assembly, Crosshead Weldment, Crosshead Weldment, Crosshead Assembly, Roller, Chain c/w Bushing Chain Roller (7/8"ID x 1-1/4"OD) Bushing Pin, Crosshead Washer, Flat Spacer Ring, Retaining Ext. 1-1/4"ID Setscrew, Socket 3/8”-16 X 3/8"

Specific Description

3000-160, 180” 4000-160, 180, 200” 3000-160, 180” 4000-160, 180, 200” 3000/4000-160,180,200” 3000/4000-160,180,200” 3000/4000-160,180,200” 3000/4000-160,180,200” 3000/4000-160,180,200” 3000/4000-160,180,200” 3000/4000-160,180,200”

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

Issue Date: 07/23/04

Page 55

CS 15/20

12.6

SM-630A

Mast and Carriage Assembly - 3 Stage 172" Lift Full Free

Figure 25 : Full Free Mast and Carriage Assembly - 172" Lift Height Page 56

Issue Date: 07/23/04

CS 15/20

SM-630A

Mast and Carriage Assembly - 3 Stage 172" Lift Full Free Item

Qty

Part No

◄

-

143-5049

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

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

133-5002 019-011 103-5045 103-0022 018-006 143-5039 103-5036 103-5047 103-5030-10 103-5030-15 781-133 783-199-1 780-272 010-048 012-220 121-626 011-577 012-239 012-238 781-575 120-884 013-117 121-339 792-306 100-019 018-027

27

4

012-286

28* 29 30

1 1 1

780-192 120-885 018-623

31

1

011-585

32 33 34 35 36

7 7 8 1 2

010-036 012-200 019-011 012-274 121-024

General Description

Mast and Carriage Assembly – 3 Stage Full Free Weldment, Carriage Bearing, Roller Ass’y, Roller - Side Thrust Roller, 2” Dia. - Side Thrust Bushing Mast, Outer Weldment 172" Lift Mast, Center Weldment Mast, Inner Weldment Ass'y, Chain - 44.5" LG Ass'y, Chain - 73.5"LG Ass'y, Crosshead Ass'y, Cylinder 130/172/180"Lh Ass'y, Cylinder (2"Dia) Outbrd 56-1/4"Str. Capscrew, Hex Hd. 1/2”-13 x 1-1/2" Washer, Lock 1/2" Hook, Pawl (1-1/4"x1"x4") Screw, Shoulder 1/2" x 1/2" 3/8”-16 Thread Washer, Spacer - 1/2"ID x 1"OD x 1/8" THK Washer, Spacer -1/2"ID x 1"OD x 5/64”THK. Pawl Pin Pin 1/4"Dia X 1-3/4” LG Pin (Threaded) Ass'y, Chain Roller (7/8"ID 1-1/4"OD) Roller, Chain (7/8") Bushing Washer, Flat 1-1/4"ID x 2-1/2"OD x 1/16" Brass Ass'y, Hose Roller Roller, Hose Bushing, 1/2"ID x 5/8" Capscrew, Shoulder Hex Socket Head 1/2"x1-1/4”- 3/8”-16 Capscrew, Hex Hd. - 5/16”-18 x 1/2" Washer, Lock - 5/16" Helical Bearing, Roller Washer, 1-1/2” OD x .540” ID Bracket, Cylinder

Specific Description 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” 3000/4000 -172” 3000/4000 -172” 3000/4000 -172” 3000/4000 -172”

FF FF FF FF FF

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

Issue Date: 07/23/04

Page 57

CS 15/20

SM-630A

12.6.1 Chain Assembly - 3 Stage 172" Lift Full Free

Figure 26 : Full Free Mast and Carriage Assembly - 172" Lift Height

Item ◄ 1 2 3 4 5

Qty 1 2 2 2 2

Page 58

Part No

103-5030-10 090-067-0444 104-532 105-372 013-015 011-535

General Description

Ass'y, Chain - 44.5" LG Leaf, Chain - 44-1/2” Clevis Pin, Clevis 0.2”OD x 1-1/4” LG, Pin, Cotter - 1/16” x 3/4" Nut, Hex - 3/4”-10 Nylon Insert

Specific Description

3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF

Issue Date: 07/23/04

CS 15/20

SM-630A

12.6.2 Chain Assembly - 3 Stage 172" Lift Full Free

Figure 27 : Chain Assembly - 172" Lift Height

Item ◄ 1 2 3 4 5

Qty

Part No

General Description

Specific Description

1 2 2 2 2

103-5030-15 090-067-0734 104-532 105-372 013-015 011-535

Ass'y, Chain - 73.5"LG Leaf, Chain - 73-1/2” Clevis Pin, Clevis 0.2”OD x 1-1/4” LG, Pin, Cotter - 1/16” x 3/4" Nut, Hex - 3/4”-10 Nylon Insert

3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF

Issue Date: 07/23/04

Page 59

CS 15/20

SM-630A

12.6.3 Crosshead Assembly - 3 Stage 172" Lift Full Free

Figure 28 : Full Free Mast and Carriage Assembly - 172" Lift Height

Page 60

Issue Date: 07/23/04

CS 15/20

SM-630A

Crosshead Assembly - 3 Stage 172" Lift Full Free Item ◄ 1* 2 3 4 5 6 7* 8 9 10 11 12 13

Qty 1 1 1 2 2 2 2 1 1 1 6 2 1

Part No

781-133 781-082 103-5055 103-5018 010-036 012-211 012-200 781-318 120-744 018-027 103-250 114-336 013-036 014-005

General Description

Ass'y, Crosshead Weldment, Crosshead Cylinder, Crosshead Weldment, Cam Capscrew, Hex Hd. 5/16" - 18 x 1/2" Washer, Flat - 5/16" Washer, Lock - 5/16" Roller, Chain (7/8"ID 1-1/4"OD) Roller Bushing Pin, Crosshead Washer, Flat Spacer Ring, Retaining Ext. 1-1/4"ID Setscrew, Socket 3/8”-16 x 3/8"

Specific Description

3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF

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

Issue Date: 07/23/04

Page 61

CS 15/20

SM-630A

12.6.4 Lift Cylinder Assembly - 3 Stage 172" Lift Full Free

Figure 29 : Lift Cylinder Assembly - 172" Lift Height

Page 62

Issue Date: 07/23/04

CS 15/20

SM-630A

Lift Cylinder Assembly - 3 Stage 172" Lift Full Free Item ◄ 1 1 2 2 3 4 5 6● 7● 8● 9● 10● 11● 12● 13 14● 15 -

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 -

Part No

783-199-1 118-948 118-948-1 783-103-1 783-103-2 118-389 114-978 114-640 036-154 036-143 036-132 036-112 036-108 036-098 117-993 011-530 036-180 090-779-0024 783-536

Issue Date: 07/23/04

General Description

Ass'y, Cylinder 130/172/180"Lh Ram (1-1/2"Dia) 41-7/8"Lg Ram (1-1/2"Dia) 46-7/8"Lg Weldment, Housing (3"ID) Weldment, Housing (3"ID) Nut, Head - 3" Dia. Cyl (1-1/2" Dia.Rod) Washer, Piston Piston - 3"Dia Cyl (2.9670+-.0020 Dia) Ring, Wear Piston – 3” x 1/2" Ring, Rod Wear O-Ring 3"OD x 2-3/4"ID U-Cup 3” x 2-3/8” x 1/2" O-Ring - 3/4"OD x 5/8"ID X 1/16" Wiper, 1-3/4” OD x 1-1/2” Gasket Nut, Hex Jam Plated - 3/4"-10 O-Ring Tube, Seaml. (2-1/2"Lg) Kit, Seal - Includes Items marked (●)

Specific Description

3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF

Page 63

CS 15/20

SM-630A

12.6.5 Outboard Cylinder Assembly - 3 Stage 172" Lift Full Free

Figure 30 : Outboard Lift Cylinder Assembly - 172" Lift Height

Page 64

Issue Date: 07/23/04

CS 15/20

SM-630A

Outboard Cylinder Assembly - 3 Stage 172" Lift Full Free Item

Qty

Part No

◄

-

780-272

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

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 -

121-030 780-875 118-365 114-976 113-542 036-152 036-143 036-134 036-118 036-108 036-098 034-515 118-368 011-530 036-180 783-536

Issue Date: 07/23/04

General Description

Ass'y , Cylinder (2"Dia) Outbrd 561/4"Stroke Ram, 1-1/2” Dia. x 56-1/4” LG. Outboard Weldment, Housing - 2”ID Outboard Nut, Head - 2” ID Cyl. Washer, Piston Piston Ring, Wear Ring, Wear “O”-Ring “U”-Cup “O”-Ring Wiper. Rod Fitting, 1/4" - 90° Elbow Gasket Nut, Hex 3/4”-10 “O”-Ring Kit Seal - Includes Items marked (●)

Specific Description 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF 3000/4000 -172” FF

Page 65

CS 15/20 12.7

SM-630A

Left Straddle Assembly

2 4

5 2 7

6

8

3 8

4 9 5 2

1 1

Figure 31 : Left Straddle Assembly

Page 66

Issue Date: 07/23/04

CS 15/20

SM-630A

Left Straddle Assembly Item ◄ 1 2 3 4 5 6 7 8 9

Qty 1 2 1 2 4 1 1 2 1

Part No

142-5032 142-5034 106-180 013-005 142-0047 018-500 142-5036 142-5037 018-010 019-500

Issue Date: 07/23/04

General Description

Left Straddle Assembly Left Straddle Weldment Wheel Urethane Spring Pin 5/32" x 1"Lg Axle Roller Bearing Bogie Axle Roller Weldment Bogie Assembly Bushing Nipple, Grease

Specific Description

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

Page 67

CS 15/20 12.8

SM-630A

Right Straddle Assembly

Figure 32 : Right Straddle Assembly

Page 68

Issue Date: 07/23/04

CS 15/20 12.9

SM-630A

Right Straddle Assembly

Item

Qty

Part No

General Description

Specific Description

◄ 1 2 3 4 5 6 7 8 9

1 2 1 2 4 1 1 2 1

142-5033 142-5035 106-180 013-005 142-0047 018-500 142-5036 142-5037 018-010 019-500

Right Straddle Assembly Right Straddle Weldment Wheel Urethane Spring Pin 5/32" x 1"Lg Axle Roller Bearing Bogie Axle Roller Weldment Bogie Assembly Bushing Nipple, Grease

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

Issue Date: 07/23/04

Page 69

CS 15/20 12.10

SM-630A

Electric Drive Unit Assembly

Figure 33 : Electric Drive Unit Assembly

Page 70

Issue Date: 07/23/04

CS 15/20

SM-630A

Electrical Sub-Assembly Item

Qty

Part No

General Description

Specific Description

◄ 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

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

145-5002 025-841 011-008 012-225 010-006 012-200 012-211 032-458 144-5016 025-977 105-5000 011-502 010-002 012-202 026-154 011-042 783-424 010-037 011-507 012-201 010-003 012-210 135-5010-2 135-5010-5 135-5010-1 135-5010-3 144-5010 018-563 103-819-1 013-010 010-067 012-233 103-890 105-137 010-154 012-202 018-562 019-500

Electric Drive Unit Assembly Contactor, High Speed & Pump Screw, Machine R/H Slot #10-32 x 3/8" Washer, Lock #10 Internal Tooth Capscrew, Hex Hd. 5/16”-18 x 1" Washer, Lock 5/16" Helical Washer, Flat 5/16" Bolt Size Horn, Electronic 12/24v Drive Unit Ass'y - Electrical Button, Emergency Stop Connector Ass'y Nut, Hex 5/16”-18 Capscrew, Hex Hd. 1/4"-20 x 1-1/2" Washer, Lock - 1/4" Helical Fuse - 150 Amp Capscrew, Hex Socket F/H 5/16”-18 x 1" Holder, Power Fuse Capscrew, Hex Hd. 5/16”-18 x 3/4" Nut, Hex - 3/8”-16 Washer, Lock - 3/8"Dia.Helical Capscrew, Hex Hd. - 1/4"-20 x 2" Washer, Flat -1/4" Wire Assembly Wire Assembly Wire Assembly Wire Assembly Kit-Wrg Rear Battery Box Plate Bearing Cone Plate, Cover Pin. Spring - 1/4" x 1-1/4” Capscrew, Hex Hd.- 3/4"-10 x 1-1/2" Washer, Lock - 3/4" Internal Tooth Clamp, Cable Strip, Rubber Capscrew, Hex Hd. - 1/4"-20 x 1-1/4" Washer, Lock - 1/4" Helical Bearing Cup Nipple Straight Grease - 1/4"

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

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Issue Date: 07/23/04

Page 71

CS 15/20 12.11

SM-630A

Drive Unit Assembly - Electrical

Figure 34 : Drive Unit Assembly - Electrical

Page 72

Issue Date: 07/23/04

CS 15/20

SM-630A

Drive Unit Assembly - Electrical Item ◄ 1 2 3 4 5 6 7 8 9 10** 11 12 13 14 15** 16 17 18 19 20 21 22 23 24 25 26 27 28 29** 30 31 32 33 34 35 36

Qty

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

Part No

144-5016 144-0015 011-005 012-205 012-224 025-535 011-003 012-204 012-233 011-514 200-01482 200-01484 200-01478 010-000 012-202 135-5006 010-012 012-201 105-137 103-890 011-017 012-208 037-003 012-225 011-500 037-021 164-0006 018-100 013-033 144-5017 30H21 011-005 012-204 164-7003 200-01475 011-576 011-515

General Description

Drive Unit Ass'y - Electrical Bracket, Switch Mntg Screw, Machine R/H Slot #8-32 X 1/2" Washer, Flat - #8 Washer, Lock - #8 Internal Tooth Switch, Micro Dead-Man Screw, Machine R/H Slot - #6-32 X 1" Washer, Flat - #6 Washer, Lock - 3/4" Internal Tooth Nut, Hex Machine Screw #6-32 Assy, Control Handle Handle Brkt. Cover Pivot Pin Assy.

Capscrew, Hex Hd. 1/4"-20 x 3/4" Washer, Lock - 1/4" Helical Panel, Controller Ass'y Capscrew, Hex Hd. - 3/8”-16 x 3/4" Washer, Lock - 3/8"Dia.Helical Strip, Rubber Clamp, Cable Screw, Machine R/H Slot #10-24 x 1-1/2" Washer, Flat - 3/16" Grommet, Rubber - 3/16”x7/16”x1/4” Washer, Lock - #10 Internal Tooth Nut, Hex Machine Screw #10-24 Protector Terminal Pin, Cam Follower (1-1/2"LG) Brk Link Arr. Bushing - 5/8"ID x 3/4"OD x 1" Ring, Retain Drive Unit Column Ass'y Clamp, 3/8 X 1/2" Wide Screw, Machine R/H Slot - #8-32 x 1/2" Washer, Flat #6 Harness, Wiring - Curtis Handle Bumper, Rubber Screw, Machine Slot Rnd - #8-32 x 1-1/4" Nut, Hex Machine Screw - #8-32

Specific Description

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

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Page 73

CS 15/20

SM-630A

12.11.1

Control Handle Assembly

14 15

13

Figure 35 : Control Handle Assembly

Page 74

Issue Date: 07/23/04

CS 15/20

SM-630A

Control Handle Assembly Item ◄ 1 2 3 4 5** 6 7 8 9 10 11 12 13 14 15

Qty

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

Part No

200-01482 200-01476 200-01483 012-245 017-075 907-0105 012-200 010-188 234-5332 200-00165 120-0001 011-000 011-010 200-01478 010-000 012-202

General Description

Assy, Control Handle Cam Machined Stem Handle Machined Washer Spacer -1"ID x 1-3/4"OD x 1/8"THK Spring, Torsion - 3/32”THK x 3-1/16”OD Handle, Curtis 24 V Ch-12 Horn Only Washer, Lock - 5/16" Helical Capscrew Hex Hd - M8x16mm Switch-Key #31-613 Plate, Handle Stem Cover Plate, Serial Number -Vertical 2-1/2" x 5" Screw, Type U R/Hd Zinc #4 x 5/16 Screw, Machine R/H Slot #10-24 x 3/8" Assembly, Pivot Pin (Splined) Capscrew, Hex 1/4" - 20 x 3/4" Washer, Lock - 1/4"

Specific Description

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

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Issue Date: 07/23/04

Page 75

CS 15/20

SM-630A

12.11.2

Control Handle Head Assembly

Figure 36 : Control Handle Head Assembly

Page 76

Issue Date: 07/23/04

CS 15/20

SM-630A

Control Handle Head Assembly 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

Qty

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

Part No

907-0105 907-0184 929-445 929-446 929-441 929-461 929-452 930-805 929-451 929-458 929-455 929-457 929-450 929-447 929-437 929-439 929-453 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

Issue Date: 07/23/04

General Description

Handle, Curtis 24 V Ch-12 Horn Only Cover-Plastic (1-Slot) Button, Horn Bracket, Spring Retaining Bracket, Horn Switch Thumbwheel, Butterfly Black Throttle, Elect.(24 Volt) CH9 Bracket, Throttle Support Housing Bracket, E/R Spring, E/R Button Button, E/R Grip Spring, Horn Button Switch, Horn Screw, Switch Mtg #3 x 16 Pan Ph. Type B Screw, #6 x 3/8” Pan Slot Type B Capscrew, Hex Hd. #10-32x1/4” Switch, E/R Washer, E/R Bracket #10 Flt/W Washer, Wide, #3x08 Thk .08 Washer, Star #4 Ext. Lock Wash Screw,Throttle #4-48x1/2” Pan Hd Screw-Grip (Use 1x011-066&1x011-176) Screw, Pan Phillips M3 x 10 Zinc Screw, E/R Switch Screw, Cover Screw, Horn Switch Mtg Plug, (Grommet) Harness, Wire

Specific Description

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

Page 77

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SM-630A

12.11.3

Controller Panel Assembly

Figure 37 : Controller Panel Assembly

Page 78

Issue Date: 07/23/04

CS 15/20

SM-630A

Controller Panel Assembly Item ◄ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18** 19 20

Qty

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

Part No

135-5006 030-091 011-003 026-227 026-146 011-002 145-0011 025-973 011-010 012-206 026-507-1 010-174 010-037 011-502 012-200 026-513 784-589 194-5000 104-5003 780-481-26 026-402

General Description

Panel, Controller Ass'y Terminal Strip - 12 Poles Screw, Machine R/H Slot #6-32 x 1" Fuseholder, Single 250 Volt Fuse, 6 Amp 1/4" Dia Screw, Machine R/H Slot #6-32 x 1/2" Plate, Controller Mntg Contactor, Fwd/Rev 24 Volt Screw, Machine R/H Slot #10-24 x 3/8" Washer, Flat #10 Controller, 24 Volt Rivet, 3/16" Capscrew, Hex Hd. 5/16”-18 x 3/4" Nut, Hex Plated 5/16”-18 Washer, Lock 5/16" Helical Harness, Wiring, 10-Wire Assembly, Cable Harness, Wire Kit-Wiring Cable - Electrical Assy Diode, Wire Lead 6 Amp, 100 Prv

Specific Description

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

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Issue Date: 07/23/04

Page 79

CS 15/20

SM-630A

12.11.4

Drive Unit Wiring Kit

Figure 38 : Drive Unit Wiring Kit

Page 80

Issue Date: 07/23/04

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SM-630A

Drive Unit Wiring Kit Item ◄ 1 2 3 4 5 6 7 8 9 10

Qty 4 2 1 1 1 1 1 1 1 1

Part No

104-5003 030-778 030-097 030-098 090-896-0015 090-896-0020 090-896-0042 090-896-0052 090-896-0062 090-896-0066 090-896-0136

Issue Date: 07/23/04

General Description

Kit-Wiring Wire Terminals Faston, .25", Red Wire Terminal Wire Terminal, Red, 5/16" Ring Wire/m (1-1/2"Lg) Red #18/16 Wire/m (2"Lg) Red #18/16 Wire/m (4-1/4"Lg) Red #18/16 Wire/m (5-1/4"Lg) Red #18/16 Wire/m (6-1/4"Lg) Red #18/16 Wire/m (6-3/4"Lg) Red #18/16 Wire/m (13-3/4"Lg)Red #18/16

Specific Description 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

Page 81

CS 15/20

SM-630A

12.11.5

Drive Unit Column Assembly - Mechanical

Figure 39 : Drive Unit Column Assembly - Mechanical

Page 82

Issue Date: 07/23/04

CS 15/20

SM-630A

Drive Unit Column Assembly - Mechanical Item ◄ 1 2 3 4 5** 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Qty

1 2 3 2 1 2 2 1 2 1 4 4 4 1 1 2 1 1 15 3 1 2 1 1 1 2 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 4

Part No

144-5017 200-01474 013-565 013-017 013-513 790-351 012-210 011-024 144-0016 011-519 907-0022 010-006 012-200 011-502 018-003 144-5005 014-003 017-031 010-125 012-211 011-552 105-394 023-025 018-073 120-101 023-212 010-077 144-5019 018-072 104-355 144-0017 011-563 111-653 010-044 012-220 018-563 780-194 021-101 010-101 011-509 104-0013 010-128 011-508 012-232 011-066

General Description

Drive Unit Column Ass'y Frame Wldm't Pin,Clevis 3/8"Dia x 1-3/32"Lg Pin, Cotter - 3/32” x 3/4” Clevis - 3/8" x 3/8” Eye x 2-7/8” Ass'y, Large Gearbox Washer, Flat -1/4" Screw, Machine F/H Slot #10-24 x 1/2" Rod, Brake (13-1/2"x3/8") Nut, Hex - 3/8”-24 Motor, 1 HP - 24 V Capscrew, Hex Hd. 5/16”-18 x 1" Washer, Lock 5/16" Helical Nut, Hex - 5/16”-18 Bushing, Bronze .

Actuator, Brake Ass'y Setscrew, Socket Hd 5/16”-18 x 5/16” Spring - 3/4" x 1" Capscrew Hex - 3/8”-16 x 3-1/4"Lg Washer, Flat - 5/16" Nut, Hex - 3/8”-16 Nylon Insert Hinge Pulley, 18 Tooth Timing Bushing C/W Set Key - 1/4"Sq x 1-3/8"Lg 1/8"Radius Belt-Drive (Timing) - 1/2"Pitch 33"Lg x 1" Capscrew, Hex Hd. 3/8”-16 x 1-1/4" Weldment, Motor Mount Plate Bushing, Taperlock Key Motor Shaft - 3/16" x 1" Arm Brake Pivot 5-1/2" x 1" x 3/8" Nut, Hex - 1-1/4"-12 Nte Series Washer, Flat Capscrew, 1/2"-13 x 2" Washer, 1/2" Split Reg. Bearing Cone - 2" Bore Tire- Hub Drive Ass'y - 10" x 4" x 6.5" Key Output Shaft And Wheel Hub Capscrew, 5/8”-11 x 3" Nut, Hex - 5/8”-11 Mount, Traction Motor Mount Capscrew, Hex Hd. 1/2"-13 x 2-1/2" Nut, Hex - 1/2"-13 Washer, Lock - 5/8" Internal Tooth Capscrew, Hex Socket - 5/16”-18 x 3/4"

Specific Description

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

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Issue Date: 07/23/04

Page 83

CS 15/20

SM-630A

12.11.6

Drive Unit Gearbox Assembly

Figure 40 : Drive Unit Gear Box Assembly

Page 84

Issue Date: 07/23/04

CS 15/20

SM-630A

Drive Unit Gearbox Assembly Item ◄ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Qty

1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 3 1 1 1 1 1 7 6 6 2 6 4 2 1 1 1 2 4 6 2 1 1 1 1 1FT 1 1 1 1 2 3 1

Part No

790-351 110-887 110-888 110-889 110-890 110-891 110-892 110-893 110-602 110-603 110-604 110-605 110-443 110-895 110-896 110-897 018-573 018-574 018-575 018-576 018-577 018-578 018-580 036-092 036-093 023-527 023-526 023-528 013-087 010-102 010-051 021-105 021-101 117-235 021-103 021-090 012-268 012-270 036-091 018-582 018-583 111-625 111-626 106-903 021-331 011-563 090-973 120-760 011-151 012-287 R3-10202-01

Issue Date: 07/23/04

General Description

Ass'y, Large Gearbox Housing - Large Gearbox Cover, Main - Large Gearbox Shaft, Input (Pinion) Shaft, Intermediate (Pinion) Gear, Intermediate Gear, Output Shaft, Output Spacer, Intermediate Shaft Shaft, Brake (11-1/2"LG) Lever, Brake Operating Cover, Output Shaft Cover (Gear Box) Plate, Input Pinion Lock Sleeve, Brake Collar, Thrust #16 Ring, Snap #17 Cup, Bearing Roller, Bearing Taper Bearing Angular Bearing U Nut - 1-1/2" Washer, Lock Washer, Lock Seal Seal Oil Disc, Inner 4574 Graphitic Disc, Outer Steel Separator, Spring Ring, Retaining Capscrew, Hex Socket - 3/8”-16 x 1-1/2" Capscrew, Hex Socket - 1/4"-20 x 1/2" Dowel, Pin - 3/8"Dia x 1" LG Key, Shaft Output And Wheel Hub Key, Square, 3/8 x 1-1/8 LG. Key - 1/4" x 51/64"LG. Round Plug, Socket Pipe, 3/8"-18 Washer, Lock Spring - 1/4" Washer, Spacer 3/8" Helical O-Ring Bearing, Roller Bearing, Roller Nut, Primary (Drive Unit) Nut, Secondary (Drive Unit) Tape, Magnetic Plug, Breather 3/8" Nut, Hex - 1-1/4"-12 NTE Series Oil, Gearoil - Premium R & O 68 Guard (Seal) Capscrew, Flat Hex Head, #10-24 x 1/2"LG. Washer,Spacer-.880"IDx1-1/4"ODx1/16"TK Washer,Thrust-7/8"IDx1-7/16"ODx1/32”THK

Specific Description

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

Page 85

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SM-630A

12.11.7

Wiring Kit - Rear Battery Box Plate

Figure 41 : Wiring Kit - Rear Battery Box Plate

Page 86

Issue Date: 07/23/04

CS 15/20

SM-630A

Wiring Kit - Rear Battery Box Plate Item ◄ 1 2 3 4 5 6 7

Qty

2 2 1 1 1 1 1

Part No

144-5010 030-043 030-778 030-098 030-788 090-892-0020 090-892-0052 090-903-0142

Issue Date: 07/23/04

General Description

Kit-Wrg Rear Battery Box Plate Wire Terminal Ins. Slv, Blue #10 Wire Terminals .25", Red Wire Terminal, Red, 5/16" Ring Terminal - 0.187" Red Wire/m (2"Lg) Black #18/16 Wire/m (5-1/4"Lg) Black #18/16 Wire/m (14-1/4" Lg.) #18/16 Blk/Wht

Specific Description

3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000 3000/4000

Page 87

CS 15/20 12.12

SM-630A

Hydraulic Layout

Figure 42 : Hydraulic Layout

Page 88

Issue Date: 07/23/04

CS 15/20

SM-630A

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

Qty

1 1 1 1 1 2 4 6 4 1

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

Part No

145-5006 145-5006-5 145-5006-6 145-5006-1 145-5006-7 145-5006-2 145-5006-3 144-5028 033-903 034-727 R1-00104 034-587 010-037 012-210 012-210 012-200 033-106-1 030-782 033-107 034-587 034-614 010-039 012-211 012-201 011-507 145-5001 145-5000 035-238 105-5002 034-500 100-5005-17 100-5005-11 100-5004-18 100-5004-18 100-5007 100-5004-18 100-5007-1 100-5007-2 100-5008 100-5010 135-5009 010-000 012-202 012-202 034-505 034-534

General Description

Layout, Hydraulic Layout, Hydraulic Layout, Hydraulic Layout, Hydraulic Layout, Hydraulic Layout, Hydraulic Layout, Hydraulic Valve Assembly Single Spool Valve, Manual Sngl.Spool Adapter, Straight -10MB-6MJ Fitting-Elbow, 3/8” JIC x 3/4"SAE Adapter, 2503-8-8 Capscrew, Hex Hd. - 5/16”-18 x 3/4" Washer, Flat - 1/4" Washer, Flat - 1/4" Washer, Lock - 5/16" Helical Powerpack Ass'y 24V Motor Pump Fitting, 90° - 8 - 8 Fitting, 90° - 12 - 10 Capscrew, Hex Hd. 3/8”-16 x 1" Washer, Flat - 5/16" Washer, Lock - 3/8"Dia. Nut, Hex - 3/8”-16 Assembly, Reservoir Reservoir Weldment Breather Cap 3/4" Filter Ass'y (Pick 034-616) Fitting, 2103-6-6 Hose 6# High Pressure (60"LG) Str-90° Hose 6# High Pressure (55"LG) Str-90° Hose 6# High Pressure (40"LG) Str-90° Hose 6# High Pressure (40"LG) Str-90° Hose 8# High Pressure (130"LG) Hose 6# High Pressure (40"LG) Str-90° Hose 8# High Pressure (135"LG) Hose 8# High Pressure (140"LG) Hose 8# Med Pressure (39"LG) Hose 12# Low Pressure (40"LG) Suction Weldment, Hose Block Capscrew, Hex Hd. 1/4”-20 x 3/4" Washer, Lock - 1/4" Helical Washer, Lock - 1/4" Helical Adapter, 90° Elbow - 2103-8-6 Fitting, Straight - 0103-4-6

Specific Description

3000/4000 - 1&2 Stage 3000/4000-130 FullFree 3000/4000-150 FullFree 3000/4000-160 FullFree 3000/4000-172 FullFree 3000/4000-180 FullFree 4000-200 FullFree 3000/4000 FullFree 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 - 1&2 Stage 3000/4000-130 Full Free 3000/4000-150 FullFree 3000/4000-160 3000/4000-172 Full Free 3000/4000-180 3000/4000-200 3000/4000 - Full Free 3000/4000 - Full Free 3000/4000 2&3 Stg. FF 3000/4000 2&3 Stg. FF 3000/4000 3000/4000 - FF 3000/4000 2&3 Stg. FF 3000/4000 2&3 Stg. FF

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Issue Date: 07/23/04

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SM-630A

Hydraulic Layout 4

3

7, 8, 43

1, 2

5 44

32 38

32

20

38

6 8 15

5 14 15 16 17 41

19 2 STAGE FF

3 STAGE FF

7 39 40 43 37 24

18 23

13

25

26

35 21 22 6, 8, 15

34

33

23 26

45 31 7, 27, 28, 29

12 30

31

33 24

32

32

30

36 172” FULL FREE ONLY

FULL FREE MAST PARTIAL TOP VIEW

Figure 42 : Hydraulic Layout

Page 90

Issue Date: 07/23/04

CS 15/20

SM-630A

Hydraulic Layout Item

Qty

Part No

General Description

Specific Description

32 32 33 33 34 35 36 37 38 39* 39* 40 41 42 43 44 45 46

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

100-5004-25 100-5005-2 100-5005-13 100-5005-14 100-5004-5 100-5004-6 100-5005-9 034-535 033-837 145-5004 145-5004-1 033-501 034-505 034-541 010-003 100-5005 033-663 010-011

Hose 6# High Pressure (32”LG.) Hose 6# High Press. (22”LG.) Str-90° Hose 6# High Press. (95”LG.) Str-90° Hose 6# High Press. (105”LG.) Str-90° Hose 6# High Press. (73”LG.) Hose 6# High Press. (78”LG.) Hose 6# High Press. (20”LG.) Str-90° Fitting, Straight - 8MJ-6MP Fuse, Velocity - 7.5GPM Valve Ass'y, Load Lowering Valve Ass'y, Load Lowering Valve, Load Lowering Control Adapter, 8-6 (QTY.1-3000/4000-3 Stage) Adapter, Fitting 8-8 Cap Screw, Hex Hd. 1/4"-20 X 2" Hose 6# High Pressure (8"LG) Str-90 Deg. Fuse, Velocity - 7.5GPM Capscrew, Hex Hd. 5/16”-18 x 2-1/2"

3000/4000 2 Stg. FF 3000/4000 3 Stg. FF 3000/4000-130 Full Free 3000/4000-150 Full Free 3000/4000-172 FF 3000/4000-172 FF 3000/4000-172 FF 3000/4000-172 FF 3000/4000 3000/4000 - 1&2 Stage 3000/4000 - 3 Stage 3000/4000 - 1&2 Stage 3000/4000 - 1&2 Stage 3000/4000 - 3 Stage 3000/4000 3000/4000 3000/4000-3 Stg. FF 3000/4000

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

Issue Date: 07/23/04

Page 91

CS 15/20

SM-630A

13. Wiring/Hydraulic Schematic 13.1

Mechanical/Hydraulic Lift Control Schematic

Figure 43 : Mechanical/Hydraulic Lift Control Schematic Page 92

Issue Date: 07/23/04

CS 15/20 13.2

SM-630A

Electric/Hydraulic Lift Control Schematic

Figure 44 : Electric/Hydraulic Lift Control Schematic

Issue Date: 07/23/04

Page 93

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