Crown Forklift ESR4000 Series Parts Manual 812674-006

Parts Manual

ESR4000 Series 812674_U1.p65

1

05.11.02, 09:36

TABLE OF CONTENT

Printed in Germany

1

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Printed in Germany

M1.0-0000-0002 M1.0-0000-0002 2

TABLE OF CONTENT Table of Content ITD – INTRODUCTION

PAGE

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REV.

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Allgemeines ........................................................................... 7

SECTION 1 – COVERS

PAGE

Covers................................................................................... 12,14,16 .................................................... Rev.1 10/02 Reach Carriage ..................................................................... 18,20 ......................................................... Rev.1 10/02 Load Wheel ........................................................................... 22 Battery Latch ........................................................................ 24 .............................................................. Rev.1 10/02 Battery Reach Out ................................................................ 26,28 Seat & Pan ............................................................................ 30 .............................................................. Rev.1 10/02 Seat ....................................................................................... 32 Rear Mirror ............................................................................ 34 Guide Wheels ........................................................................ 36

SECTION 2 – HYDRAULIC PART

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REV.

Tube-/Hose Layout ................................................................ 40 .............................................................. Rev.1 10/02 Hydraulic Tank ....................................................................... 42 .............................................................. Rev.2 10/02 Hydraulic TT Mast ................................................................. 44,46 ......................................................... Rev.1 10/02 Valve Block ........................................................................... 48,50 ......................................................... Rev.1 10/02 Reach Manifold ..................................................................... 52 Hydraulic Motor ..................................................................... 54 Pump ..................................................................................... 56 Pump Motor and Pump ......................................................... 58 .............................................................. Rev.1 10/02 Pump Motor ........................................................................... 60 Fan ........................................................................................ 62

SECTION 3 – DRIVE UNIT

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REV.

Drive Unit .............................................................................. 66,68 ......................................................... Rev.1 10/02 Turntable ................................................................................ 70 Gearbox ................................................................................. 72 .............................................................. Rev.1 10/02 Drive Motor ........................................................................... 74 Fan ........................................................................................ 76 .............................................................. Rev.1 10/02

SECTION 4 – ELECTRICAL

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REV.

Electrical Compartment ........................................................ 80,82,84 .................................................... Rev.1 10/02 Contactors............................................................................. 86 Mast Wiring ........................................................................... 88,90 ......................................................... Rev.1 10/02 Switch HGTS Lift Speed Reduction ...................................... 92 .............................................................. Rev.1 10/02 Height Encoder ..................................................................... 94,96 ......................................................... Rev.1 10/02 Joystick and Emergency Disconnector Switch ..................... 98 .............................................................. Rev.1 10/02 Direction Switch/Horn Button ................................................ 100 ............................................................ Rev.1 10/02 Floorplate .............................................................................. 102 ............................................................ Rev.1 10/02 Accelerator ............................................................................ 104 ............................................................ Rev.1 10/02 Dead Man Pedal .................................................................... 106 ............................................................ Rev.1 10/02 DC/DC Converter .................................................................. 108 Dash Panel ............................................................................ 110 ............................................................ Rev.1 10/02 Display Module ...................................................................... 112 ............................................................ Rev.1 10/02 Steer Indicator ....................................................................... 114 Flashing Beacon .................................................................... 116 Working Light ........................................................................ 118,120 Reverse Alarm ...................................................................... 122

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

M/P-IDX-2140 REV. 2 10/02 M1.0-0000-0003 3

TABLE OF CONTENT Horn ...................................................................................... 124 ............................................................ Rev.1 10/02 Cooling System ..................................................................... 126

SECTION5 – BRAKE SYSTEM

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Brake Circuit ......................................................................... 130 ............................................................ Rev.1 10/02 Foot Brake ............................................................................. 132 Drive Motor Brake ................................................................. 134 Load Wheel Brake ................................................................. 136 Brake Cylinder ...................................................................... 138 ............................................................ Rev.1 10/02

SECTION 6 – STEERING

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REV.

Steering Column .................................................................... 142,144,146 .............................................. Rev.1 10/02

SECTION 7 – MAST-/LIFT STRUCTURE

PAGE

SERIAL NR. CUT

REV.

TT Mast 1.4t/1.6t ................................................................... 150,152 ..................................................... Rev.1 10/02 TT Mast 2.0t .......................................................................... 154,156 ..................................................... Rev.1 10/02 Lift Chain TT Mast ................................................................. 158,160 ..................................................... Rev.1 10/02 Tilt/Sideshift .......................................................................... 162,164,166 .............................................. Rev.1 10/02 Tilt/Sideshift-Hydraulic .......................................................... 168,170,172 .............................................. Rev.2 10/02 Lift Buffer ............................................................................... 174 ............................................................ Rev.1 10/02 Fork ....................................................................................... 176 ............................................................ Rev.1 10/02 Load Backrest ....................................................................... 178 Yoke ...................................................................................... 180 ............................................................ Rev.1 10/02

SECTION 8 – CYLINDER

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REV.

Lift Cylinder 1.4t/1.6t ............................................................. 184 Lift Cylinder 2.0t .................................................................... 186 ............................................................ Rev.1 10/02 Free Lift Cylinder 1.4t/1.6t ..................................................... 188 ............................................................ Rev.1 10/02 Free Lift Cylinder 2.0t ............................................................ 190 ............................................................ Rev.1 10/02 Cylinder Reach ..................................................................... 192 ............................................................ Rev.1 10/02

SECTION10 – MISCELLANEOUS SERVICE INF.

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Labels and Decals ................................................................. 196

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

M/P-IDX-2140 REV. 2 10/02

4 4M1.0-0000-0004

INTRODUCTION

Printed in Germany

5

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Printed in Germany

M1.0-0000-0006 M1.0-0000-0006 6

INTRODUCTION Important customer information

Ordering Spare Parts

To ensure the safety of the truck, you, the customer, must only carry out maintenance and repairs as stipulated in the operator manual.

Spare parts can be ordered by quoting: ●

The truck specification number

Any additional work must be performed by Crown authorised service technicians. Authorised service technicians have the required expertise and up-to-date service information.

●

The truck model number

●

The truck serial number

If you wish to have your own technicians trained, please contact Crown for relevant training courses.

Subsequent Attachments and Modifications made to the Truck DANGER! Any proposed modification which would alter the original condition of the truck when delivered, must first be assessed and approved in writing by Crown Gabelstapler GmbH. ●

The net weight and position of attachments may considerably affect the capacity and other truck characteristics.

●

Changing the electrical system or adding electrically operated components may result in operating faults.

This information can be found on the truck's data plate.

Only if this information is provided can the order be processed quickly, correctly and reliably.

Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for this series. Brochures can be obtained from your CROWN dealer or from the following address:

CROWN Gabelstapler GmbH Moosacher Str. 52 80809 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133

Modifications which have not been assessed may result in fatal accidents!

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

M/P-ITD-2140

M1.0-0000-0007 7

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Printed in Germany

8

PARTS

Printed in Germany

9

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Printed in Germany

10M1.0-0000-00010

SECTION 1

Printed in Germany

11

COVERS

M1576 MP-1.1-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02

12M1.0-0000-00012

COVERS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 791764-003 ............................ Grab Handle .......................................................................................... 1 2 ..................... 050067-023 ............................ Screw ...................................................................................................... 1 3 ..................... 050068-003 ............................ Nut .......................................................................................................... 4 4 ..................... 806686 .................................... Corner Cover ......................................................................................... 1 5 ..................... 050071-035 ............................ Screw ...................................................................................................... 4 807053-002 ............................ Clip ......................................................................................................... 4 6 ..................... 807089 .................................... Display Overlay ...................................................................................... 1 7 ..................... 807459 .................................... Hose Cover ............................................................................................ 1 8 ..................... 807352 .................................... Headrest Pad ......................................................................................... 1 050004-020 ............................ Screw ...................................................................................................... 4 9 ..................... 050068-004 ............................ Nut .......................................................................................................... 1 10 ................... 806931 .................................... Leg Pad .................................................................................................. 1 053050-012 ............................ Adhesive Tape ....................................................................................... AR 11 ................... 796328 .................................... Overhead Guard .................................................................................... 1 050067-053 ............................ Screw ...................................................................................................... 2 050068-006 ............................ Nut .......................................................................................................... 2

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.1-2140

REV. 1 10/02

13

COVERS

M1575 MP-1.1-2140

14M1.0-0000-00014

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

COVERS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Instrumentation ...................................................................................... 1 (see Section 4.9) 2* .................... 806689 .................................... Armrest Pad ........................................................................................... 1 3* .................... 807098 .................................... Armrest Moulding ................................................................................... 1 796489 .................................... Armrest Moulding (6th Function Valve) ................................................. 1 4* .................... 050067-012 ............................ Screw ...................................................................................................... 5 5 ..................... 050071-035 ............................ Screw ...................................................................................................... 3 050009-020 ............................ Washer ................................................................................................... 2 6 ..................... 806973 .................................... Screen .................................................................................................... 1 7 ..................... 050068-003 ............................ Nut .......................................................................................................... 3 8 ..................... 806859 .................................... Plate ....................................................................................................... 1 796023 .................................... Plate (Drive in Racking) ........................................................................ 1 9 ..................... 050008-030 ............................ Nut .......................................................................................................... 3 807053-002 ............................ Insert ....................................................................................................... 3 10 ................... 806499 .................................... Cover ...................................................................................................... 1 11 ................... 050071-035 ............................ Screw ...................................................................................................... 3 12 ................... 807765 .................................... Clamp ..................................................................................................... 2 13 ................... 052068-002 ............................ Spacer .................................................................................................... 4 14 ................... 807764 .................................... Clamp ..................................................................................................... 2 15 ................... 050008-008 ............................ Nut .......................................................................................................... 3

* ..................... 806929 .................................... Armrest Assembly .................................................................................. 1 (inclusive 2-4, without 796489)

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.1-2140

REV. 1 10/02

15

COVERS

MP-2140-020 MP-1.1-2140

16M1.0-0000-00016

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

COVERS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 790797-001 ............................ Block, Skid (A = 33mm) ......................................................................... 2 790797-002 ............................ Block, Skid (A = 26mm) ......................................................................... 2 2 ..................... 790798 .................................... Screw ...................................................................................................... 2 3 ..................... 810637-001 ............................ Wear Strips (1.4t/1285mm Leg Width/Load Wheel Æ 285mm) ........... 2 810637-002 ............................ Wear Strips (1.6t & 2.0t/1285mm Leg Width/Load Wheel Æ 285mm) . 2 810637-003 ............................ Wear Strips (1.6t & 2.0t/1285mm Leg Width/Load Wheel Æ 330mm) . 2 810637-004 ............................ Wear Strips (1.4t/1425&1575mm Leg Width/Load Wheel Æ 285mm) 2 810637-005 ............................ Wear Strips ............................................................................................. 2 (1.6t & 2.0t/1425&1575mm Leg Width/Load Wheel Æ 285) 810637-006 ............................ Wear Strips ............................................................................................. 2 (1.6t & 2.0t/1425&1575mm Leg Width/Load Wheel Æ 330) 4 ..................... 050003-043 ............................ Screw ...................................................................................................... 2 5 ..................... 050005-068 ............................ Screw ...................................................................................................... 2 6 ..................... 050009-026 ............................ Washer ................................................................................................... 2

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.1-2140

17

REACH CARRIAGE

M1496 MP-1.2-2140

18M1.0-0000-00018

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REACH CARRIAGE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 806409 .................................... Reach Carriage (1285mm Leg Width) .................................................. 1 807413 .................................... Reach Carriage (1425mm Leg Width) .................................................. 1 807414 .................................... Reach Carriage (1575mm Leg Width) .................................................. 1 2 ..................... 806886 .................................... Plate ....................................................................................................... 2 3 ..................... 060030-085 ............................ Shim ....................................................................................................... 10 810203 .................................... Shim ....................................................................................................... 2 4 ..................... 050005-075 ............................ Screw ...................................................................................................... 8 5 ..................... 807323 .................................... Shim ....................................................................................................... 8 807407 .................................... Washer ................................................................................................... 2 6 ..................... 050067-056 ............................ Screw ...................................................................................................... 2 050068-007 ............................ Nut .......................................................................................................... 2 7 ..................... 807525 .................................... Clamp ..................................................................................................... 1 8 ..................... 050003-035 ............................ Screw ...................................................................................................... 2 9 ..................... 807522 .................................... Clamp ..................................................................................................... 1 10 ................... 791483-001 ............................ Roller (Æ 93,6mm) ................................................................................ 4 791483-002 ............................ Roller (Æ 93,9mm) ................................................................................ 4 790332 .................................... Grease Nipple ........................................................................................ 4 11 ................... 060019-023 ............................ Screw ...................................................................................................... 16 12 ................... 810211-001 ............................ Shim (0,5mm) ......................................................................................... AR 810211-002 ............................ Shim (2,0mm) ......................................................................................... AR 13 ................... 806408 .................................... Skid Bar (16mm) .................................................................................... 4 810245 .................................... Skid Bar (19mm) .................................................................................... 4 14 ................... 050067-025 ............................ Screw ...................................................................................................... 8 15* ................... 796405 .................................... Bracket ................................................................................................... 1 16* ................... 050003-018 ............................ Screw ...................................................................................................... 2 17* ................... 790350 .................................... Magnet ................................................................................................... 2 050009-003 ............................ Washer ................................................................................................... 5 18* ................... 050008-001 ............................ Nut .......................................................................................................... 4 19* ................... 050003-043 ............................ Screw ...................................................................................................... 2 20 ...................................................................... Cylinder Reach (see Section. 8.5) ........................................................ 1 21 ................... 806467-009 ............................ Hose ....................................................................................................... 1 22 ................... 806467-012 ............................ Hose ....................................................................................................... 1 23* ................... 807486 .................................... Clamp ..................................................................................................... 1 24* ................... 807312 .................................... Bracket ................................................................................................... 1 25* ................... 050003-017 ............................ Screw ...................................................................................................... 2 26* ................... 807487-001 ............................ Proximity Switch Assembly .................................................................... 1 808122 .................................... Cable Assembly (RES) .................................................................... 1 792880-002 ............................. Socket Housing .......................................................................... 1 792882 ..................................... Socket Insert ............................................................................... 2 793090-002 ............................. Anti-Backout ............................................................................... 1 27 ................... 806429 .................................... Washer ................................................................................................... 4 28 ................... 806427 .................................... Pin .......................................................................................................... 2 29 ................... 792973 .................................... Pin Split .................................................................................................. 2 30 ................... 050006-026 ............................ Screw ...................................................................................................... 2 31 ................... 790375 .................................... Drag Link ................................................................................................ 1 32 ................... 791476-001 ............................ Drag Link Mouting Bracket .................................................................... 1 33 ................... 806779 .................................... Plate ....................................................................................................... 1 34 ................... 050003-060 ............................ Screw (1285mm Leg Width) .................................................................. 2 050003-035 ............................ Screw (1425/1575mm Leg Width) ........................................................ 2 35 ................... 790592 .................................... Drag Link Mounting Bracket .................................................................. 1 36 ................... 050068-003 ............................ Nut .......................................................................................................... 2

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.2-2140

REV. 1 10/02

19

REACH CARRIAGE

M1496 MP-1.2-2140

20M1.0-0000-00020

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REACH CARRIAGE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

37* ................... 050003-012 ............................ Screw ...................................................................................................... 1 38* ................... 793288 .................................... Clip ......................................................................................................... 1 39* ................... 050008-008 ............................ Nut .......................................................................................................... 1 * ..................... 796406 .................................... Reach Slowdown Assembly (inclusive 15-19,23-26, 37-39) ............... 1 Not illustrated 796180 .................................... Cable Assembly (Freezer/Corriosion) ................................................... 1 796172 .................................... Bracket (Reach Carriage/Freezer/Corriosion) ...................................... 1 050008-008 ............................ Nut (Reach Carriage/Freezer/Corriosion) ............................................ 3 08089 ...................................... Cable Assembly (Chassis -Mast) .......................................................... 1 055058-003 ............................ Buffer (for Reach Carriage 807413 & 807414) .................................... 2 055058-005 ............................ Buffer (for Reach Carriage 806409) ..................................................... 2 050068-003 ............................ Nut .......................................................................................................... 2

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.2-2140

REV. 1 10/02

21

LOAD WHEEL

MP-2140-015 MP-1.5-2140

22M1.0-0000-00022

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

LOAD WHEEL INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 810576-001 ............................ Load Wheel Assembly Æ 285mm/1,4t .................................................. 2 810602-001 ............................ Load Wheel Assembly Æ 330mm/1,6t & 2,0t ....................................... 2 810576-002 ............................ Load Wheel Assembly Æ 285mm/1,4t (Freezer/Corrosion) ................. 2 810602-002 ............................ Load Wheel Assembly Æ 330mm/1,6t & 2,0t (Freezer/Corrosion) ...... 2 1 ........................... 807095 .................................... Load Wheel Cap .............................................................................. 2 2 ........................... 050012-009 ............................. Circlip ............................................................................................... 2 3 ........................... 790520 .................................... Washer ............................................................................................. 2 4* .......................... 050012-015 ............................. Circlip ............................................................................................... 2 5* .......................... 807655 .................................... Washer ............................................................................................. 2 6* .......................... 790519 .................................... Roller Bearing .................................................................................. 2 7* .......................... 810577 .................................... Spacer .............................................................................................. 2 8* .......................... 810574-001 ............................. Load Wheel Æ 285mm/1,4t ............................................................. 2 810583-001 ............................. Load Wheel Æ 330mm/1,6t & 2,0t ................................................... 2 810574-002 ............................. Load Wheel Æ 285mm/1,4t (Freezer/Corrosion) ............................ 2 810583-002 ............................. Load Wheel Æ 330mm/1,6t & 2,0t (Freezer/Corrosion) .................. 2 9* .......................... 790517 .................................... Needle Bearing ................................................................................ 2 10* ......................... 050012-051 ............................. Circlip ............................................................................................... 2 11 ......................... 050005-088 ............................. Screw ................................................................................................ 12 12 ......................... 810564 .................................... Brake Assy (see Section 5.6) .......................................................... 1 13 ......................... 810382 .................................... Stud Axle .......................................................................................... 2 14 ......................... 790528 .................................... End Block ......................................................................................... 2 15 ......................... 050005-033 ............................. Screw ................................................................................................ 4 16 ......................... 793333 .................................... Clip ................................................................................................... 4 17 ......................... 810598 .................................... Brake Guard 1,4t .............................................................................. 2 810597 .................................... Brake Guard 1,6t & 2,0t .................................................................... 2 18 ......................... 050071-020 ............................. Screw ................................................................................................ 4 * ........................... 810575-001 ............................. Loadwheel Æ 285mm & Bearing 1,4t Assembly (inclusive 4-10) 2 * ........................... 810601-001 ............................. Loadwheel Æ 330mm & Bearing 1,6t &2,0t Assembly ................... 2 (inclusive 4-10) * ........................... 810575-002 Loadwheel Æ 285mm & Bearing 1,4t Assembly (inclusive 4-10) 2 * ........................... 810601-002 ............................. Loadwheel Æ 330mm & Bearing 1,6t &2,0t Assembly ................... 2 (inclusive 4-10) Load Wheel Æ 285mm for 1,6t & 2,0t only available out of Factory

Option:

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.5-2140

23

BATTERY LOCK

M1580 MP-1.6-2140

24M1.0-0000-00024

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

BATTERY LOCK INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807530-001 ............................ Battery Lock ........................................................................................... 1 1 ........................... 807531 .................................... Lever ................................................................................................. 1 2 ........................... 807535 .................................... Bearing ............................................................................................. 1 3 ........................... 051058-014 ............................. Bushing ............................................................................................ 1 4 ........................... 050073-004 ............................. Spring Nut ........................................................................................ 5 5 ........................... 050070-002 ............................. Screw ................................................................................................ 5 6 ........................... 807534 .................................... Link ................................................................................................... 1 7 ........................... 050007-009 ............................. Screw ................................................................................................ 2 8 ........................... 050008-018 ............................. Nut .................................................................................................... 2 9 ........................... 807536 .................................... Bracket ............................................................................................. 1 10 ......................... 807542-001 ............................. Shim (1mm) ...................................................................................... 2 807542-002 ............................. Shim(0,6mm) .................................................................................... 1 11 ......................... 050068-004 ............................. Nut .................................................................................................... 4 12 ......................... 803310 .................................... Actuator Roller ................................................................................. 1 13 ......................... 792991 .................................... Microswitch ....................................................................................... 1 14 ......................... 050004-034 ............................. Screw ................................................................................................ 2 15 ......................... 807541 .................................... Plate .................................................................................................. 1 16 ......................... 050009-002 ............................. Washer ............................................................................................. 2 17 ......................... 050008-008 ............................. Nut .................................................................................................... 1 18 ......................... 793288 .................................... Clip ................................................................................................... 1 19 ......................... 050003-013 ............................. Screw ................................................................................................ 1 20 ......................... 051058-005 ............................. Bushing ............................................................................................ 2 21 ......................... 807539 .................................... Spring ............................................................................................... 1 22 ......................... 051058-015 ............................. Bushing ............................................................................................ 2 23 ......................... 807538 .................................... Spring ............................................................................................... 1 24 ......................... 807537 .................................... Spacer .............................................................................................. 1 25 ......................... 807786 .................................... Bracket ............................................................................................. 1 26 ......................... 806827 .................................... Shaft .................................................................................................. 1 27 ......................... 050000-069 ............................. Roll Pin ............................................................................................. 1 28 ......................... 806819 .................................... Shaft .................................................................................................. 1 29 ......................... 050000-025 ............................. Roll Pin ............................................................................................. 1 30 ......................... 050071-036 ............................. Screw ................................................................................................ 1 31 ......................... 050008-024 ............................. Nut .................................................................................................... 1 32 ......................... 050009-026 ............................. Washer ............................................................................................. 1 807540 .................................... Battery Lock (inclusive 1-3,6-9,12-24,26-29) ................................. 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.6-2140

REV. 1 10/02

25

BATTERY REACH OUT

MP-2140-005 MP-1.6-2140

26M1.0-0000-00026

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

BATTERY REACH OUT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807841 .................................... Battery Cover extension (Battery 560Ah) ............................................. 1 807842 .................................... Battery Cover extension (Battery 700Ah) ............................................. 1 810227 .................................... Battery Cover extension (Battery 820Ah) ............................................. 1 2 ..................... 050071-035 ............................ Screw ...................................................................................................... 4 3 ..................... 050068-003 ............................ Nut .......................................................................................................... 4 4 ..................... 810338-001 ............................ Battery Support (Battery 420Ah) ........................................................... 1 810338-002 ............................ Battery Support (Battery 560Ah) ........................................................... 1 810338-003 ............................ Battery Support (Battery 700Ah) ........................................................... 1 810338-004 ............................ Battery Support (Battery 820Ah) ........................................................... 1 5 ..................... 807451 .................................... Plate (1285/1425mm Leg Width, Trucks without Battery Rollers) ........ 4 808023 .................................... Plate (1575mm Leg Width, Trucks without Battery Rollers) ................. 4 6 ..................... 050003-051 ............................ Screw ...................................................................................................... 8 7 ..................... 807860-001 ............................ Skid Block (1285mm Leg Width) ........................................................... 4 807860-002 ............................ Skid Block (1425mm Leg Width) ........................................................... 4 807860-003 ............................ Skid Block (1575mm Leg Width) ........................................................... 4 8 ..................... 050005-025 ............................ Screw ...................................................................................................... 8 9 ..................... 806408 .................................... Skid Bar .................................................................................................. 4 10 ................... 050007-017 ............................ Screw ...................................................................................................... 4 11 ................... 055058-002 ............................ Buffer ...................................................................................................... 2 12 ................... 807938 .................................... Shim ....................................................................................................... 2 13 ................... 807937 .................................... Spacer .................................................................................................... AR 14 ................... 050008-015 ............................ Nut .......................................................................................................... 4 15 ................... 796380 .................................... Spacer Plate (only for 1575mm Leg Width) .......................................... 1 16 ................... 050006-027 ............................ Screw (only for 1575mm Leg Width) ..................................................... 1 17 ................... 050008-015 ............................ Nut (only for 1575mm Leg Width) ......................................................... 1 18 ................... 050003-052 ............................ Screw ...................................................................................................... 1 19 ................... 806349 .................................... Shaft ....................................................................................................... 1 20 ................... 051058-013 ............................ Bushing .................................................................................................. 1 21 ................... 796388 .................................... Latch ....................................................................................................... 1 22 ................... 808081 .................................... Shim ....................................................................................................... 2 23 ................... 807864 .................................... Washer ................................................................................................... 1 24 ................... 050068-005 ............................ Nut .......................................................................................................... 3 25 ................... 810241 .................................... Cam ........................................................................................................ 1 26 ................... 808465 .................................... Cam-Protection ...................................................................................... 1 27 ................... 810251 .................................... Bracket (only for Battery 820Ah) ........................................................... 1 28 ................... 806824 .................................... Pin .......................................................................................................... 1 29 ................... 050067-056 ............................ Screw (only for Battery 820Ah) ............................................................. 2 30 ................... 050068-007 ............................ Nut (only for Battery 820Ah) .................................................................. 2 31 ................... 050070-001 ............................ Screw ...................................................................................................... 2 32 ................... 810437 .................................... Plate ....................................................................................................... 1 33 ................... 050068-004 ............................ Nut .......................................................................................................... 2 34 ................... 055058-003 ............................ Buffer ...................................................................................................... 2 055058-004 ............................ Buffer (only for Battery 420Ah & 1285mm Leg Width) ......................... 2 35 ................... 050009-020 ............................ Washer ................................................................................................... 2 050009-025 ............................ Washer (only for Battery 420Ah & 1285mm Leg Width) ...................... 2 36 ................... 050008-024 ............................ Nut .......................................................................................................... 2 050008-030 ............................ Nut (only for Battery 420Ah & 1285mm Leg Width) .............................. 2 37 ................... 807939 .................................... Pin .......................................................................................................... 1 38 ................... 806837 .................................... Spring ..................................................................................................... 1 39 ................... 050003-050 ............................ Screw ...................................................................................................... 4 40 ................... 810428 .................................... Clamp (only for Battery 420Ah & 560Ah) ............................................. 1 810432 .................................... Clamp (only for Battery 700Ah & 820Ah) ............................................. 1 41 ................... 810429 .................................... Bracket ................................................................................................... 1 42 ................... 810427-001 ............................ Clamp (LH/only for Battery 420Ah & 560Ah) ........................................ 1 810427-002 ............................ Clamp (RH/only for Battery 420Ah & 560Ah) ....................................... 1 810431-001 ............................ Clamp (LH/only for Battery 700Ah & 820Ah) ........................................ 1 810431-002 ............................ Clamp (RH/only for Battery 700Ah & 820Ah) ....................................... 1 43 ................... 810390 .................................... Washer ................................................................................................... 1 44 ................... 810317 .................................... Lever ...................................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.6-2140

27

BATTERY REACH OUT

MP-2140-005 MP-1.6-2140

28M1.0-0000-00028

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

BATTERY REACH OUT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

For Trucks with Battery Rollers 45 ................... 804207 .................................... Roller ...................................................................................................... 6 46 ................... 804681 .................................... Bearing Ball ........................................................................................... 12 47 ................... 804208 .................................... Roller Axle ............................................................................................. 6

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.6-2140

29

SEAT & PAN

M1484 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.7-2140

REV. 1 10/02

30M1.0-0000-00030

SEAT & PAN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806493-001 ............................ Seat & Pan (black cloth) ........................................................................ 1 806493-003 ............................ Seat & Pan (PVC) .................................................................................. 1 806493-005 ............................ Seat & Pan (48V Heated Cushion & Backrest) .................................... 1 1 .............................................................................. Seat (see Section Seat) ................................................................... 1 2 ........................... 806454 .................................... Seat Pan ........................................................................................... 1 3 ........................... 050005-064 ............................. Screw ................................................................................................ 4 4 ........................... 050008-024 ............................. Nut .................................................................................................... 4 5 ........................... 791469 .................................... Seat Moulding .................................................................................. 1 6 ........................... 050006-035 ............................. Screw ................................................................................................ 7 7 ........................... 791466 .................................... Handle Pocket .................................................................................. 1 8 ........................... 791635 .................................... Vice Action Latch ............................................................................. 1 9 ........................... 808945 .................................... Stay ................................................................................................... 1 10 ......................... 810326 .................................... Bracket ............................................................................................. 1 11 ......................... 808947 .................................... Bracket ............................................................................................. 1 12 ......................... 808949 .................................... Pin ..................................................................................................... 1 13 ......................... 050073-004 ............................. Washer ............................................................................................. 1 14 ......................... 050070-001 ............................. Screw ................................................................................................ 1 807865 .................................... Pan Mounting (inclusive 2,5,6) ........................................................ 1 Not illustrated 795289 .................................... Cable Seat ....................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.7-2140

REV. 1 10/02

31

SEAT

M1573 MP-1.7-2140

32M1.0-0000-00032

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

SEAT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807433-001 ............................ Seat (black cloth) .................................................................................. 1 807433-003 ............................ Seat (PVC) ............................................................................................ 1 807433-005 ............................ Seat (PVC/ Heated) ............................................................................... 1 1 ........................... 791653-001 ............................. Pad (only for 807433-001) ............................................................... 1 808493 .................................... Pad (only for 807433-003) ............................................................... 1 808494 .................................... Pad (only for 807433-005) ............................................................... 1 2 ........................... 791653-002 ............................. Pad (only for 807433-001) ............................................................... 1 808495 .................................... Pad (only for 807433-003) ............................................................... 1 808496 .................................... Pad (only for 807433-005) ............................................................... 1 3 ........................... 791691-001 ............................. Seat Back ......................................................................................... 1 4 ........................... 791691-002 ............................. Seat Plate ......................................................................................... 1 5 ........................... 791691-003 ............................. Attachment ....................................................................................... 3 6 ........................... 791691-004 ............................. Frame Seat ....................................................................................... 1 7 ........................... 791691-005 ............................. Wear Strips ....................................................................................... 1 8 ........................... 791691-006 ............................. Cover ................................................................................................ 1 9 ........................... 791691-007 ............................. Cable Assembly ............................................................................... 1 10 ......................... 791691-008 ............................. Latch Adjustment .............................................................................. 1 11 ......................... 791691-009 ............................. Cover Suspension ........................................................................... 1 12 ......................... 791691-010 ............................. Repair Kit .......................................................................................... 1 13 ......................... 791691-011 ............................. Weight Adjustment ........................................................................... 1 14 ......................... 791691-012 ............................. Latch (inclusive 13) .......................................................................... 1 15 ......................... 808497 .................................... Slide Non Locking ........................................................................... 1 16 ......................... 808498 .................................... Slide Locking (inclusive 29) ............................................................ 1 17 ......................... 791691-015 ............................. Support inner .................................................................................... 1 18 ......................... 791691-016 ............................. Support outer .................................................................................... 1 19 ......................... 791691-017 ............................. Buffer Kit ........................................................................................... 1 20 ......................... 791691-018 ............................. Latch ................................................................................................. 1 21 ......................... 791691-019 ............................. Bracket Weight Adjustment .............................................................. 1 22 ......................... 808499 .................................... Spring ............................................................................................... 1 23 ......................... 791691-021 ............................. Latch ................................................................................................. 1 24 ......................... 791691-022 ............................. Dashpot Assembly ........................................................................... 1 25 ......................... 791691-023 ............................. Bracket ............................................................................................. 1 26 ......................... 808500 .................................... Spring ............................................................................................... 2 27 ......................... 808501 .................................... Seat Switch Assembly (inclusive 26) .............................................. 1 28 ......................... 808502 .................................... Cover Assembly ............................................................................... 1 29 ......................... 807434 .................................... Cover Rail ........................................................................................ 1 Not illustrated 808503 .................................... Harness (only for Heated Seat) ....................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.7-2140

33

REAR MIRROR

MP-2140-012 MP-1.9-2140

34M1.0-0000-00034

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REAR MIRROR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 796090 .................................... Rear Mirror ............................................................................................. 1 1 ........................... 050005-062 ............................. Screw ................................................................................................ 2 053050-006 ............................. Adhesive .......................................................................................... AR 2 ........................... 795977 .................................... Clamp ............................................................................................... 1 3 ........................... 795438 .................................... Bracket ............................................................................................. 1 4 ........................... 795442 .................................... Adjuster ............................................................................................ 1 5 ........................... 050005-022 ............................. Screw ................................................................................................ 1 6 ........................... 050008-026 ............................. Nut .................................................................................................... 1 7 ........................... 793779 .................................... Mirror ................................................................................................ 1 795437 .................................... Mirror Assembly (inclusive 3-7) ....................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.9-2140

35

GUIDE WHEELS

MP-2140-017 MP-1.9-2140

36M1.0-0000-00036

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

GUIDE WHEELS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 796057-001 ............................ Guide Wheels (A=25mm) ...................................................................... 4 796057-002 ............................ Guide Wheels (A=30mm) ...................................................................... 4 796057-003 ............................ Guide Wheels (A=35mm) ...................................................................... 4 796057-004 ............................ Guide Wheels (A=40mm) ...................................................................... 4 796057-005 ............................ Guide Wheels (A=45mm) ...................................................................... 4 796057-006 ............................ Guide Wheels (A=50mm) ...................................................................... 4 796057-007 ............................ Guide Wheels (A=55mm) ...................................................................... 4 796057-008 ............................ Guide Wheels (A=60mm) ...................................................................... 4 796057-009 ............................ Guide Wheels (A=65mm) ...................................................................... 4 796057-010 ............................ Guide Wheels (A=70mm) ...................................................................... 4 796057-011 ............................ Guide Wheels (A=75mm) ...................................................................... 4 796057-012 ............................ Guide Wheels (A=80mm) ...................................................................... 4 796057-013 ............................ Guide Wheels (A=85mm) ...................................................................... 4 796057-014 ............................ Guide Wheels (A=90mm) ...................................................................... 4 1 ........................... 796050-001 ............................. Shim (1,omm) ................................................................................... AR 796050-002 ............................. Shim (3,omm) ................................................................................... AR 2 ........................... 796046-001 ............................. Bracket (A=25mm) ........................................................................... 4 796046-002 ............................. Bracket (A=30mm) ........................................................................... 4 796046-003 ............................. Bracket (A=35mm) ........................................................................... 4 796046-004 ............................. Bracket (A=40mm) ........................................................................... 4 796046-005 ............................. Bracket (A=45mm) ........................................................................... 4 796046-006 ............................. Bracket (A=50mm) ........................................................................... 4 796046-007 ............................. Bracket (A=55mm) ........................................................................... 4 3 ........................... 050067-044 ............................. Screw ................................................................................................ 16 4* .......................... 050012-067 ............................. Circlip ............................................................................................... 8 5* .......................... 055002-025 ............................. Bearing Ball ...................................................................................... 4 6* .......................... 796146 .................................... Rim ................................................................................................... 4 796147 .................................... Wheel ................................................................................................ 4 7 ........................... 050012-056 ............................. Circlip ............................................................................................... 4 8 ........................... 796051-001 ............................. Bracket (A=60mm) ........................................................................... 4 796051-002 ............................. Bracket (A=65mm) ........................................................................... 4 796051-003 ............................. Bracket (A=70mm) ........................................................................... 4 796051-004 ............................. Bracket (A=75mm) ........................................................................... 4 796051-005 ............................. Bracket (A=80mm) ........................................................................... 4 796051-006 ............................. Bracket (A=85mm) ........................................................................... 4 796051-007 ............................. Bracket (A=90mm) ........................................................................... 4 * ........................... 796049 .................................... Wheel Assembly (inclusive 4-6) ...................................................... 4

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-1.9-2140

37

Page intentionally left blank

Printed in Germany

38M1.0-0000-00038

SECTION 2

Printed in Germany

39

TUBE/HOSE LAYOUT

M1675-gb MP-2.1-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02

40M1.0-0000-00040

TUBE/HOSE LAYOUT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807315 .................................... Bracket ................................................................................................... 1 2 ..................... 807901 .................................... Cover ...................................................................................................... 1 3 ..................... 050006-024 ............................ Screw ...................................................................................................... 3 4 ..................... 050078-002 ............................ Rivet ....................................................................................................... 2 5 ..................... 793288 .................................... Clip ......................................................................................................... 2 6 ..................... 050003-011 ............................ Screw ...................................................................................................... 2 050008-008 ............................ Nut .......................................................................................................... 2 7 ..................... 050006-050 ............................ Screw ...................................................................................................... 4 8 ..................... 050008-030 ............................ Nut .......................................................................................................... 6 9 ..................... 050006-048 ............................ Screw ...................................................................................................... 2 10 ................... 807406 .................................... Reach Manifold (see Section 2.10) ...................................................... 1 11 ................... 806467-009 ............................ Hose ....................................................................................................... 1 12 ................... 806467-012 ............................ Hose ....................................................................................................... 1 13 ................... 806467-018 ............................ Hose ....................................................................................................... 1 14 ................... 806467-010 ............................ Hose ....................................................................................................... 1 15 ................... 806467-003 ............................ Hose ....................................................................................................... 1 16 ................... 806467-016 ............................ Hose ....................................................................................................... 1 17 ................... 807846 .................................... Hose ....................................................................................................... 1 18 ................... 806467-005 ............................ Hose ....................................................................................................... 1 19 ................... 806467-011 ............................ Hose ....................................................................................................... 1 20 ................... 806467-001 ............................ Hose ....................................................................................................... 1 21 ................... 806467-002 ............................ Hose ....................................................................................................... 1 22 ................... 806467-014 ............................ Hose ....................................................................................................... 1 23 ................... 806467-015 ............................ Hose ....................................................................................................... 1 24 ................... 806467-007 ............................ Hose ....................................................................................................... 1 25 ................... 806878 .................................... Priority Valve (see Section 2.13) ........................................................... 1 26 ................... 806359 .................................... Bracket ................................................................................................... 1 27 ................... 050070-004 ............................ Screw ...................................................................................................... 2 28 ................... 050008-030 ............................ Nut .......................................................................................................... 2 29 ................... 060017-007 ............................ Screw ...................................................................................................... 2 30 ................... 811727 .................................... Valve Block (see Section 2.10) ............................................................. 1 31 ................... 807874 .................................... Bracket ................................................................................................... 1 32 ................... 060017-016 ............................ Screw ...................................................................................................... 1 33 ................... 806467-004 ............................ Hose ....................................................................................................... 1 34 ................... 807500 .................................... Clamp ..................................................................................................... 1 050006-031 ............................ Screw ...................................................................................................... 1 35 ................... 807475 .................................... Clamp ..................................................................................................... 1 050006-023 ............................ Screw ...................................................................................................... 1 36 ................... 054191-001 ............................ Clip ......................................................................................................... 2 37 ................... 054191-002 ............................ Clip ......................................................................................................... 1 38 ................... 050008-015 ............................ Nut .......................................................................................................... 3 39 ................... 810252 .................................... Plate ....................................................................................................... 1 Not illustrated 806467-006 ............................ Hose (Steer Unit - Steer Motor) ............................................................. 2 064103-058 ............................ Hose (LD Connection) ........................................................................... 1 064128-002 ............................ Cap Valve Block (D) ............................................................................... AR

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.1-2140

REV. 1 10/02

41

HYDRAULIC TANK

M1502 MP-2.3-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02

42M1.0-0000-00042

HYDRAULIC TANK INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806442-001 ............................ Hydraulic Tank Assembly ...................................................................... 1 1 ........................... 807464 .................................... Tank .................................................................................................. 1 804859-002 ............................. Rubber .............................................................................................. 2 2 ........................... 808360 .................................... Mat .................................................................................................... 1 3 ........................... 055053-003 ............................. Pin ..................................................................................................... 2 4 ........................... 806846 .................................... Clamp ............................................................................................... 1 5 ........................... 050008-024 ............................. Nut .................................................................................................... 2 6 ........................... 807978 .................................... Clamp ............................................................................................... 1 7 ........................... 050008-030 ............................. Nut .................................................................................................... 1 8 ........................... 050009-026 ............................. Washer ............................................................................................. 1 9 ........................... 050070-001 ............................. Screw ................................................................................................ 1 10 ......................... 806845 .................................... Clamp ............................................................................................... 1 11 ......................... 050009-014 ............................. Washer ............................................................................................. 2 12 ......................... 050006-024 ............................. Screw ................................................................................................ 2 13 ......................... 806842 .................................... Suction Line ..................................................................................... 1 14 ......................... 806835 .................................... Gasket ............................................................................................... 1 15 ......................... 050006-026 ............................. Screw ................................................................................................ 7 16 ......................... 793539 .................................... Seal Bonded .................................................................................... 1 17 ......................... 793192 .................................... Suction Filter .................................................................................... 1 18 ......................... 808413 .................................... Filter Assembly ................................................................................. 1 808504 .................................... Filter Element ................................................................................... 1 808505 .................................... Cap Breather .................................................................................... 1 19 ......................... 050008-021 ............................. Nut .................................................................................................... 2 791415-020 ............................. Washer ............................................................................................. 2 20 ......................... 808298 .................................... Adapter ............................................................................................. 1 053050-021 ............................. Teflon-Tape ....................................................................................... AR 21 ......................... 807990 .................................... Heat Shield ....................................................................................... 1 807471 .................................... Tank Assembly (inclusive 1,13-21) ................................................. 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.3-2140

REV. 2 10/02

43

HYDRAULIC TT MAST

M1614-gb MP-2.8-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02

44M1.0-0000-00044

HYDRAULIC TTMAST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Outermast (see Page 7.5) 2 ........................................................................ Lift Cylinder (see Page 8.1) 3 ........................................................................ 1 st Stage Mast (see Page 7.5) 4 ........................................................................ Free Lift Cylinder (see Page 8.2) 5 ..................... 807070 .................................... Manifold Block ....................................................................................... 1 6 ..................... 050070-003 ............................ Screw ...................................................................................................... 2 7 ..................... 050073-005 ............................ Washer ................................................................................................... 2 8 ..................... 050008-038 ............................ Nut .......................................................................................................... 2 9 ..................... 064004-015 ............................ Adaptor ................................................................................................... 2 10 ................... 064004-001 ............................ Adaptor ................................................................................................... 2 11 ................... 807326 .................................... Pipe ........................................................................................................ 2 12 ................... 064061-003 ............................ Elbow ...................................................................................................... 2 13 ................... 806992 .................................... Hose Burst Valve .................................................................................... 2 14 ................... 064091-001 ............................ Plug ........................................................................................................ 2 15 ................... 806157 .................................... Pipe ........................................................................................................ 1 050006-024 ............................ Screw ...................................................................................................... 2 050008-015 ............................ Nut .......................................................................................................... 2 16 ................... 807062-001-** ........................ Hose (see next Page) ............................................................................ 1 17 ................... 807320 .................................... Bracket ................................................................................................... 1 18 ................... 050006-040 ............................ Screw ...................................................................................................... 1 19 ................... 050068-003 ............................ Nut .......................................................................................................... 1 20 ...................................................................... Pulley Hose (see Page 7.6) 21 ................... 806158 .................................... Pipe ........................................................................................................ 1 22 ................... 050006-036 ............................ Screw ...................................................................................................... 2 23 ................... 050008-024 ............................ Nut .......................................................................................................... 2 24 ................... 064061-016 ............................ Elbow ...................................................................................................... 1 25 ................... 807075 .................................... Bracket ................................................................................................... 1 050006-024 ............................ Screw ...................................................................................................... 2 050008-015 ............................ Nut .......................................................................................................... 2 26 ................... 054176-001 ............................ Adaptor ................................................................................................... 8 27 ................... 807072-*** .............................. Pipe (see next Page) ............................................................................. 1 28 ................... 807074-*** .............................. Pipe (see next Page) ............................................................................. 1 29 ................... 807076-001 ............................ Bracket ................................................................................................... 1 050006-040 ............................ Screw ...................................................................................................... 1 050068-003 ............................ Nut .......................................................................................................... 1 30 ................... 807062-002-** ........................ Hose ....................................................................................................... 2 31 ................... 807078 .................................... Bracket ................................................................................................... 1 050006-036 ............................ Screw ...................................................................................................... 2 050008-024 ............................ Nut .......................................................................................................... 2 32 ................... 806160-*** .............................. Pipe (see next Page) ............................................................................. 1 33 ................... 806161-*** .............................. Pipe (see next Page) ............................................................................. 1 34 ................... 807062-003-** ........................ Hose (see next Page) ............................................................................ 2 35 ................... 810534 .................................... Plate ....................................................................................................... 1 Not illustrated 808996 .................................... Clamp ..................................................................................................... AR 051051-009 ............................ Cable Tie ................................................................................................ AR

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.8-2140

REV. 1 10/02

45

HYDRAULIC TT MAST 1.4t/1.6t Position 16

Position 30

Position 34

Collapsed Height

807062-001-01

807062-002-01

807062-003-01

2022mm

807062-001-02

807062-002-02

807062-003-02

2172mm

807062-001-03

807062-002-03

807062-003-03

2322mm

807062-001-04

807062-002-04

807062-003-04

2472mm

807062-001-05

807062-002-05

807062-003-05

2572mm

807062-001-06

807062-002-06

807062-003-06

2772mm

807062-001-07

807062-002-07

807062-003-07

2922mm

807062-001-08

807062-002-08

807062-003-08

3042mm

807062-001-09

807062-002-09

807062-003-09

3192mm

807062-001-10

807062-002-10

807062-003-10

3347mm

807062-001-11

807062-002-11

807062-003-11

3492mm

807062-001-12

807062-002-12

807062-003-12

3692mm

807062-001-13

807062-002-13

807062-003-13

3842mm

807062-001-14

807062-002-14

807062-003-14

3952mm Tab013-gb

Position 27

Position 28

Position 32

Position 33

Collapsed Height

807072-001

807074-001

806160-001

806161-001

2022mm

807072-002

807074-002

806160-002

806161-002

2172mm

807072-003

807074-003

806160-003

806161-003

2322mm

807072-004

807074-004

806160-004

806161-004

2472mm

807072-005

807074-005

806160-005

806161-005

2572mm

807072-006

807074-006

806160-006

806161-006

2772mm

807072-007

807074-007

806160-007

806161-007

2922mm

807072-008

807074-008

806160-008

806161-008

3042mm

807072-009

807074-009

806160-009

806161-009

3192mm

807072-010

807074-010

806160-010

806161-010

3347mm

807072-011

807074-011

806160-011

806161-011

3492mm

807072-012

807074-012

806160-012

806161-012

3692mm

807072-013

807074-013

806160-013

806161-013

3842mm

807072-014

807074-014

806160-014

806161-014

3952mm Tab015-gb

MP-2.8-2140

46M1.0-0000-00046

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

HYDRAULIC TTMAST 2.0t Position 16

Position 30

Position 34

Collapsed Height

807062-001-01

807062-002-01

807062-003-01

2022mm

807062-001-02

807062-002-02

807062-003-02

2172mm

807062-001-04

807062-002-04

807062-003-04

2472mm

807062-001-06

807062-002-06

807062-003-06

2772mm

807062-001-07

807062-002-07

807062-003-07

2922mm

807062-001-08

807062-002-08

807062-003-08

3042mm

807062-001-10

807062-002-10

807062-003-10

3347mm

807062-001-12

807062-002-12

807062-003-12

3692mm

807062-001-13

807062-002-13

807062-003-13

3842mm

807062-001-14

807062-002-14

807062-003-14

3952mm

807062-001-15

807062-002-15

807062-003-15

4252mm

807062-001-16

807062-002-16

807062-003-16

4452mm Tab014-gb

Position 27

Position 28

Position 32

Position 33

Collapsed Height

807072-001

807074-001

806160-001

806161-001

2022mm

807072-002

807074-002

806160-002

806161-002

2172mm

807072-004

807074-004

806160-004

806161-004

2472mm

807072-006

807074-006

806160-006

806161-006

2772mm

807072-007

807074-007

806160-007

806161-007

2922mm

807072-008

807074-008

806160-008

806161-008

3042mm

807072-010

807074-010

806160-010

806161-010

3347mm

807072-012

807074-012

806160-012

806161-012

3692mm

807072-013

807074-013

806160-013

806161-013

3842mm

807072-014

807074-014

806160-014

806161-014

3952mm

807072-015

807074-015

806160-015

806161-015

4252mm

807072-016

807074-016

806160-016

806161-016

4452mm Tab016-gb

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.8-2140

47

VALVE BLOC

M1509 MP-2.10-2140

48M1.0-0000-00048

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

VALVE BLOC INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Valve Block (not available as spare part) ............................................. 1 2 ..................... 064091-006 ............................ Plug ........................................................................................................ 1 3 ..................... 064143-003 ............................ Elbow ...................................................................................................... 1 4 ..................... 064091-007 ............................ Plug ........................................................................................................ 1 5 ..................... 064061-016 ............................ Elbow ...................................................................................................... 1 6 ..................... 064091-002 ............................ Plug ........................................................................................................ 10 7 ..................... 064061-014 ............................ Elbow ...................................................................................................... 1 8 ..................... 123261 .................................... Compensator Hoist ................................................................................ 1 111790-010 ............................ Kit Seal ................................................................................................... 1 9 ..................... 808506 .................................... Valve Relief Accessory .......................................................................... 1 111790-003 ............................ Kit Seal ................................................................................................... 1 10 ................... 064091-006 ............................ Plug ........................................................................................................ 2 123270-001 ............................ Orifice ..................................................................................................... 2 11 ................... 064004-001 ............................ Connector .............................................................................................. 1 12 ................... 064010-001 ............................ Branch Tee Coupling ............................................................................. 1 13 ................... 064061-002 ............................ Elbow ...................................................................................................... 2 14 ................... 064091-004 ............................ Plug ........................................................................................................ 1 123270-004 ............................ Orifice ..................................................................................................... 1 15 ................... 123255-002 ............................ Check Valve ........................................................................................... 1 111790-012 ............................ Kit Seal ................................................................................................... 1 16 ................... 808507 .................................... Plug ........................................................................................................ 2 17 ................... 123255-001 ............................ Check Valve ........................................................................................... 1 111790-009 ............................ Kit Seal ................................................................................................... 1 18 ................... 117913-002 ............................ Valve Relief Hoist .................................................................................. 1 111790-003 ............................ Kit Seal ................................................................................................... 1 19 ................... 117305-003 ............................ Valve Solenoid (SVL) ............................................................................ 1 104164-005 ............................ Coil Solenoid ......................................................................................... 1 111790-012 ............................ Kit Seal ................................................................................................... 1 20 ................... 117304-003 ............................ Valve Solenoid (SCV6) .......................................................................... 1 104164-005 ............................ Coil Solenoid ......................................................................................... 1 111790-003 ............................ Kit Seal ................................................................................................... 1 21 ................... 808508 .................................... Proportional Valve, Accy (PVA) ............................................................. 1 104164-012 ............................ Coil Solenoid ......................................................................................... 1 111790-013 ............................ Kit Seal ................................................................................................... 1 22 ................... 123257-001 ............................ Proportional Valve, Hoist (PVH) ............................................................ 1 104164-012 ............................ Coil Solenoid ......................................................................................... 1 111790-014 ............................ Kit Seal ................................................................................................... 1 23 ................... 117385-003 ............................ Valve Solenoid (SVA) ............................................................................ 1 104164-005 ............................ Coil Solenoid ......................................................................................... 1 111790-007 ............................ Kit Seal ................................................................................................... 1 24 ................... 123258 .................................... Valve Solenoid (SVP) ............................................................................ 1 104164-002 ............................ Coil Solenoid ......................................................................................... 1 111790-001 ............................ Kit Seal ................................................................................................... 1 123270-003 ............................ Orifice ..................................................................................................... 1 25 ................... 064091-001 ............................ Plug ........................................................................................................ 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.10-2140

REV. 1 10/02

49

VALVE BLOC

M1510 MP-2.10-2140

50M1.0-0000-00050

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

VALVE BLOC INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Valve Block (Not available as spare part) ............................................. 1 2 ..................... 064091-001 ............................ Plug ........................................................................................................ 2 3 ..................... 064091-007 ............................ Plug ........................................................................................................ 1 4 ..................... 064091-002 ............................ Plug ........................................................................................................ 5 5 ..................... 064004-021 ............................ Adaptor ................................................................................................... 1 6 ..................... 117739 .................................... Valve Manual Lower .............................................................................. 1 111790-005 ............................ Kit Seal ................................................................................................... 1 7 ..................... 123255-001 ............................ Check Valve ........................................................................................... 1 111790-009 ............................ Kit Seal ................................................................................................... 1 8 ..................... 808509 .................................... Valve Compensator ............................................................................... 1 9 ..................... 123260 .................................... Valve Compensator By-Pass ................................................................. 1 111790-010 ............................ Kit Seal ................................................................................................... 1 10 ................... 123255-001 ............................ Check Valve ........................................................................................... 1 111790-009 ............................ Kit Seal ................................................................................................... 1 11 ................... 064061-010 ............................ Adaptor ................................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.10-2140

51

REACH MANIFOLD

M1511 MP-2.10-2140

52M1.0-0000-00052

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REACH MANIFOLD INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807406 .................................... Reach Manifold ...................................................................................... 1 1 ........................... 808510 .................................... Valve Block ....................................................................................... 1 2 ........................... 064004-003 ............................. Adaptor ............................................................................................. 5 3 ........................... 064061-002 ............................. Elbow ................................................................................................ 1 4 ........................... 808511 .................................... Counterbalance ............................................................................... 2 5 ........................... 808512 .................................... Valve Solenoid ................................................................................. 1 808513 .................................... Coil Solenoid .................................................................................... 1 6 ........................... 792880-001 ............................. Pin Housing ...................................................................................... 1 792882 .................................... Pin ..................................................................................................... 2 793090-001 ............................. Anti Backout ..................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.10-2140

53

HYDRAULIC MOTOR

M1507 MP-2.11-2140

54M1.0-0000-00054

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

HYDRAULIC MOTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 806912 .................................... Hydraulic Motor ...................................................................................... 1 2 ..................... 064004-006 ............................ Adaptor ................................................................................................... 2

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.11-2140

55

PUMP

M1582 MP-2.12-2140

56M1.0-0000-00056

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

PUMP INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 790940-001 ............................ Pump 19cc (Assembly - see next Page) ............................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.12-2140

57

PUMP MOTOR AND PUMP

M1581 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.13-2140

REV.1 10/02

58M1.0-0000-00058

PUMP MOTOR AND PUMP INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Pump Motor (see next Page) ................................................................. 1 2 ..................... 807934 .................................... Bracket ................................................................................................... 1 3 ..................... 790503 .................................... Bush ....................................................................................................... 4 4 ..................... 050009-031 ............................ Washer ................................................................................................... 4 5 ..................... 050007-043 ............................ Screw ...................................................................................................... 4 6 ........................................................................ Pump (see Section 2.12) ....................................................................... 1 7 ..................... 791534 .................................... Washer, Sealing ..................................................................................... 1 8 ..................... 050067-034 ............................ Screw ...................................................................................................... 2 9 ..................... 790009-010 ............................ O-Ring .................................................................................................... 1 10 ................... 808893 .................................... Inlet Pump .............................................................................................. 1 11 ................... 050005-022 ............................ Screw ...................................................................................................... 4 12 ................... 806857 .................................... Hose ....................................................................................................... 1 054191-004 ............................ Jubilee Clip ............................................................................................ 2 13 ................... 807511 .................................... Bracket ................................................................................................... 1 14 ................... 050006-036 ............................ Screw ...................................................................................................... 2 15 ................... 793288 .................................... Clip ......................................................................................................... 2 16 ................... 050003-013 ............................ Screw ...................................................................................................... 2 17 ................... 050003-008 ............................ Nut .......................................................................................................... 2 18 ................... 050006-033 ............................ Screw ...................................................................................................... 2 19 ................... 050008-024 ............................ Nut .......................................................................................................... 2 20 ................... 806878 .................................... Priority Valve .......................................................................................... 1 21 ................... 064004-021 ............................ Adapter ................................................................................................... 1 22 ................... 064061-009 ............................ Adapter ................................................................................................... 1 23 ................... 064004-002 ............................ Adapter ................................................................................................... 1 24 ................... 064061-005 ............................ Elbow ...................................................................................................... 1 25 ................... 806880 .................................... Pressure Hose ....................................................................................... 1 26 ................... 050006-040 ............................ Screw ...................................................................................................... 1 27 ................... 806362 .................................... Spacer .................................................................................................... 1 28 ................... 050006-060 ............................ Screw ...................................................................................................... 3 29 ................... 795975 .................................... Brushwear Modul Assembly (inclusive 30 & 31) .................................. 1 30 ................... 793217-008 ............................ Socket Insert .......................................................................................... 1 31 ................... 793217-009 ............................ Socket Insert .......................................................................................... 1 32 ................... 793364-005 ............................ Clamp ..................................................................................................... 1 33 ................... 050006-032 ............................ Screw ...................................................................................................... 1 34 ................... 050010-021 ............................ Washer ................................................................................................... 1 35 ................... 050008-024 ............................ Nut .......................................................................................................... 1 36 ................... 808121 .................................... Bus Bar ................................................................................................... 1 807933 .................................... Bracket & Bush (inclusive 2 & 3) ........................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.13-2140

REV. 1 02/02

59

PUMP MOTOR

M1587 MP-2.13-2140

60M1.0-0000-00060

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

PUMP MOTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807930 .................................... Pump Motor ............................................................................................ 1 1 ........................... 808514 .................................... Cover Band & Fan Assembly (see next Page) ................................ 1 2 ........................... 808515 .................................... End Cover Assembly ....................................................................... 1 808516 .................................... End Cover ........................................................................................ 1 3 ........................... 791413-031 ............................. Washer ............................................................................................. 4 4 ........................... 791413-030 ............................. Screw ................................................................................................ 4 5 ........................... 791413-029 ............................. Washer ............................................................................................. 1 6 ........................... 791413-028 ............................. Bearing Ball ...................................................................................... 1 7 ........................... 791413-020 ............................. Brush Ring Assembly ...................................................................... 1 808517 .................................... Temperature Sensor/Bracket ........................................................... 1 808518 .................................... Temperature Sensor ........................................................................ 1 8 ........................... 791413-027 ............................. Washer ............................................................................................. 2 9 ........................... 791413-022 ............................. Screw ................................................................................................ 2 10 ......................... 791413-025 ............................. Brush ................................................................................................ 3 791413-026 ............................. Brush, Signalling .............................................................................. 1 11 ......................... 791413-021 ............................. Brush Spring .................................................................................... 12 12 ......................... 791413-024 ............................. Washer ............................................................................................. 4 13 ......................... 791413-023 ............................. Screw ................................................................................................ 4 14 ......................... 808519 .................................... Armature ........................................................................................... 1 15 ......................... 791774-002 ............................. Pole Shoe ......................................................................................... 4 16 ......................... 808520 .................................... Field Coil Set .................................................................................... 1 17 ......................... 791413-001 ............................. Housing ............................................................................................ 1 18 ......................... 791413-002 ............................. Plug ................................................................................................... 2 791413-034 ............................. Pin ..................................................................................................... 3 19 ......................... 791413-003 ............................. Terminal ............................................................................................ 1 20 ......................... 791413-005 ............................. Washer ............................................................................................. 1 791413-007 ............................. Bolt Clamp ........................................................................................ 1 21 ......................... 791413-004 ............................. Insulating Tube ................................................................................. 1 22 ......................... 791413-006 ............................. Washer ............................................................................................. 3 23 ......................... 791413-008 ............................. Nut .................................................................................................... 1 24 ......................... 791413-009 ............................. Nut .................................................................................................... 2 25 ......................... 791413-012 ............................. Screw ................................................................................................ 8 26 ......................... 791413-017 ............................. Circlip ............................................................................................... 1 27 ......................... 791413-016 ............................. Bearing Ball ...................................................................................... 1 28 ......................... 791413-013 ............................. Drive End Plate ................................................................................ 1 29 ......................... 791413-015 ............................. Washer ............................................................................................. 4 30 ......................... 791413-014 ............................. Screw ................................................................................................ 4

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.13-2140

61

FAN

M1588 MP-2.13-2140

62M1.0-0000-00062

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

FAN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 806895-001 ............................ Fan Assembly ......................................................................................... 1 792880-001 ............................. Pin Housing ...................................................................................... 1 792882 .................................... Pin Crimp .......................................................................................... 2 793090-001 ............................. Anti-backout ..................................................................................... 1 2 ..................... 794865-002 ............................ Finger Guard .......................................................................................... 1 3 ..................... 050004-035 ............................ Screw ...................................................................................................... 4 4 ..................... 050008-002 ............................ Nut .......................................................................................................... 4 5 ..................... 793288 .................................... Clip ......................................................................................................... 1 6 ..................... 050003-013 ............................ Screw ...................................................................................................... 1 7 ..................... 050003-008 ............................ Nut .......................................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-2.13-2140

63

Page intentionally left blank

Printed in Germany

64M1.0-0000-00064

SECTION 3

Printed in Germany

65

DRIVE UNIT

M1506 MP-3.0-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02

66M1.0-0000-00066

DRIVE UNIT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807559-001 ............................ Drive Unit & Gearbox Assembly (without 2, 28-36) .............................. 1 807559-002 ............................ Drive Unit & Gearbox Assembly (without 2, 28-36/Freezer/Corrosion) 1 1 ........................... 806913 .................................... Drive Frame ...................................................................................... 1 2 ........................... 050006-071 ............................. Screw ................................................................................................ 8 3 ........................... 806910 .................................... Drive Guard ...................................................................................... 1 4 ........................... 050007-044 ............................. Screw ................................................................................................ 2 5 ........................... 806912 .................................... Hydraulic Motor (see Section 2.11) ................................................. 1 6 ........................... 790082 .................................... Sprocket ........................................................................................... 1 7 ........................... 790083 .................................... Sleeve ............................................................................................... 1 8 ........................... 790081 .................................... Disc Retainer .................................................................................... 1 9 ........................... 050067-023 ............................. Screw ................................................................................................ 1 10 ......................... 050067-048 ............................. Screw ................................................................................................ 2 11 ......................... 050068-005 ............................. Nut .................................................................................................... 2 12 ......................... 791706 .................................... Chain ................................................................................................ 1 13 ......................... 791115-001 ............................. Chain Adjuster ................................................................................. 1 14 ......................... 806899 .................................... Link Extended .................................................................................. 1 15 ......................... 790910-001 ............................. Chain Adjuster ................................................................................. 1 ............................ 791705 .................................... Pin ..................................................................................................... 1 16 ......................... 790911-001 ............................. Nut .................................................................................................... 1 17 ......................... 050008-032 ............................. Nut .................................................................................................... 1 18 ......................... 791114-001 ............................. Pin ..................................................................................................... 1 19 ......................... 050012-030 ............................. Circlip ............................................................................................... 2 20 ......................... 790088 .................................... Gearbox Assembly ........................................................................... 1 Gearbox (see Section 3.1) ...............................................................

Turntable (see Section 3.0) ..............................................................

21 ......................... 790839-001 ............................. Stop Block ........................................................................................ 1 22 ......................... 050000-076 ............................. Pin ..................................................................................................... 1 23 ......................... 050005-066 ............................. Screw ................................................................................................ 2 24 ......................... 050068-003 ............................. Nut .................................................................................................... 2 25 ......................... 050007-047 ............................. Screw ................................................................................................ 6 26 ......................... 807557 .................................... Wheel ................................................................................................ 1 810240 .................................... Wheel (Freezer/Corrosion) .............................................................. 1 27 ......................... 790648-057 ............................. Nut .................................................................................................... 7 790648-058 ............................. Washer ............................................................................................. 7 28 ......................... 807644 .................................... Bracket ............................................................................................. 1 29 ......................... 793200 .................................... Potentiometer Assembly .................................................................. 1 793199 ..................................... Potentiometer .............................................................................. 1 73090-003 ............................... Anti-Backout ............................................................................... 1 792880-003 ............................. Pin Housing ................................................................................ 1 792882 ..................................... Pin Crimp .................................................................................... 1 30 ......................... 807645-002 ............................. Spur gear .......................................................................................... 1 053050-010 ............................. Adhesive .......................................................................................... AR 31 ......................... 050006-026 ............................. Screw ................................................................................................ 2 050009-012 ............................. Washer ............................................................................................. 2 32 ......................... 793288 .................................... Clip ................................................................................................... 1 33 ......................... 050003-013 ............................. Screw ................................................................................................ 1 34 ......................... 050008-008 ............................. Nut .................................................................................................... 1 35 ......................... 807645-001 ............................. Spurgear (only for Potentiometer) ................................................... 1 36 ......................... 807646 .................................... Screw (only for Potentiometer) ........................................................ 1 37 ......................... 050006-040 ............................. Screw ................................................................................................ 1 38 ......................... 050008-024 ............................. Nut .................................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-3.0-2140

REV. 1 10/02

67

DRIVE UNIT

M1508 MP-3.0-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02

68M1.0-0000-00068

DRIVE UNIT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1* .................... 806764 .................................... Bracket ................................................................................................... 1 2* .................... 793288 .................................... Clip ......................................................................................................... 2 3* .................... 050003-013 ............................ Screw ...................................................................................................... 2 4* .................... 050008-008 ............................ Nut .......................................................................................................... 2 5 ..................... 050006-024 ............................ Screw ...................................................................................................... 2 6 ..................... 050008-015 ............................ Nut .......................................................................................................... 2 7 ..................... 061085-001 ............................ Clip ......................................................................................................... 3 8* .................... 050005-003 ............................ Screw ...................................................................................................... 1 9* .................... 806450 .................................... Spacer .................................................................................................... 1 10* ................... 126545 .................................... Plate ....................................................................................................... 1 11* ................... 050008-001 ............................ Nut .......................................................................................................... 1 12* ................... 126699 .................................... PCB Encoder ......................................................................................... 1 13 ................... 790080 .................................... Disc Brake (see Section 5.6) ................................................................. 1 14 ................... 050012-006 ............................ Ring Retaining ....................................................................................... 1 15 ................... 050017-017 ............................ Screw ...................................................................................................... 1 16 ................... 050005-022 ............................ Screw ...................................................................................................... 2 17 ................... 806895-001 ............................ Fan Assembly (see Section 3.2) ............................................................ 1 18 ................... 790820 .................................... Washer ................................................................................................... 1 19 ................... 050005-064 ............................ Screw ...................................................................................................... 6 20 ................... 807559 .................................... Drive Unit & Gearbox (see Section 3.0) ................................................ 1 21 ................... 20707 ...................................... Traction Motor (see Section 3.2) ........................................................... 1 22 ................... 125588-001 ............................ Isolator Cup (not illustrated) .................................................................. 2 125588-003 ............................ Isolator Cup (not illustrated) .................................................................. 2 * ..................... 807593 .................................... Bracket & Encoder Assembly (inclusive 1-4,8-12) ............................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-3.0-2140

REV. 1 10/02

69

TURNTABLE

2

1 13

9

12 10 11

3 4

7

8

5 6

M1093 MP-3.0-2140

70M1.0-0000-00070

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

TURNTABLE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 790149 .................................... Turntable Assembly .............................................................................. 1 1 ........................... 790150 .................................... Ring Centering ................................................................................. 1 2 ........................... 790151 .................................... Screw ................................................................................................ 3 3 ........................... 790152 .................................... Grease Nipple .................................................................................. 2 4 ........................... 790153 .................................... Dowel ................................................................................................ 2 5 ........................... 790154 .................................... Screw ................................................................................................ 8 6 ........................... 790648-054 ............................. Plug ................................................................................................... 1 7 ........................... 790648-055 ............................. Seal ................................................................................................... 1 8 ........................... 791285-093 ............................. Screw ................................................................................................ 5 9 ........................... 790160 .................................... Screw ................................................................................................ 2 10 ......................... 790103 .................................... Washer ............................................................................................. 4 11 ......................... 790162 .................................... Nut .................................................................................................... 2 12 ......................... 790163 .................................... Valve Breather .................................................................................. 1 13 ......................... 791285-094 ............................. Screw ................................................................................................ 2 14 ......................... 791757 .................................... Turntable .......................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-3.0-2140

71

GEAR BOX

M1033 MP-3.1-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02

72M1.0-0000-00072

GEAR BOX INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 791682 .................................... Gearbox ................................................................................................. 1 1 ........................... 791683 .................................... Transmission Case .......................................................................... 1 2 ........................... 791684 .................................... Threaded Protect. Shield ................................................................. 1 3 ........................... 791685 .................................... Sealing Ring .................................................................................... 1 4 ........................... 790118 .................................... Shim, 0,10 mm ................................................................................. AR 790119 .................................... Shim, 0,15 mm ................................................................................. AR 790120 .................................... Shim, 0,30 mm ................................................................................. AR 790121 .................................... Shim, 0,50 mm ................................................................................. AR 5 ........................... 790114 .................................... Bearing, Tape Roller ........................................................................ 2 6 ........................... 791686 .................................... Sealing Ring .................................................................................... 1 7 ........................... 791687 .................................... Wheel Shaft ...................................................................................... 1 8 ........................... 790117 .................................... Stud Wheel ....................................................................................... 7 9 ........................... 791688 .................................... Bevel Gear Set ................................................................................. 1 10 ......................... 791689 .................................... Disk ................................................................................................... 1 11 ......................... 791690 .................................... Screw ................................................................................................ 1 12 ......................... 790130 .................................... Shim, 0,10 mm ................................................................................. AR 790131 .................................... Shim, 0,15 mm ................................................................................. AR 790132 .................................... Shim, 0,30 mm ................................................................................. AR 790133 .................................... Shim, 0,50 mm ................................................................................. AR 13 ......................... 791285-081 ............................. Bearing, Tape Roller ........................................................................ 1 14 ......................... 791729 .................................... Helical Gear ..................................................................................... 1 15 ......................... 790137 .................................... Nut .................................................................................................... 1 16 ......................... 790141 .................................... Shim, 0,10 mm ................................................................................. AR 790142 .................................... Shim, 0,15 mm ................................................................................. AR 790143 .................................... Shim, 0,30 mm ................................................................................. AR 790144 .................................... Shim, 0,50 mm ................................................................................. AR 17 ......................... 791285-078 ............................. Bearing, Tape Roller ........................................................................ 1 18 ......................... 790145 .................................... Cover ................................................................................................ 1 19 ......................... 050006-026 ............................. Screw ................................................................................................ 15 20 ......................... 790157 .................................... Seal ................................................................................................... 1 21 ......................... 791285-090 ............................. Plug, Drain ....................................................................................... 1 22 ......................... 791730 .................................... Pinion ................................................................................................ 1 23 ......................... 790820 .................................... Washer ............................................................................................. 1 24 ......................... 051069 .................................... Nut .................................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-3.1-2140

REV. 1 10/02

73

DRIVE MOTOR

M1673 MP-3.2-2140

74M1.0-0000-00074

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

DRIVE MOTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 020707 .................................... Motor-Drive 48V ..................................................................................... 1 1 ........................... 020748 .................................... Plate .................................................................................................. 1 2 ........................... 060063-010 ............................. Screw ................................................................................................ 3 061004-004 ............................. Adhesive Locking ............................................................................. AR 3* .......................... 020461 .................................... Motor End Cover .............................................................................. 1 4 ........................... 060078-007 ............................. Screw ................................................................................................ 4 5* .......................... 062547 .................................... Connector ......................................................................................... 1 6* .......................... 020548 .................................... Lead .................................................................................................. 2 7* .......................... 020196 .................................... Insulator Terminal ............................................................................. 2 8* .......................... 020197 .................................... Nut Terminal ..................................................................................... 2 9 ........................... 060005-008 ............................. Spring Lock Washer ........................................................................ 4 10 ......................... 060063-011 ............................. Screw ................................................................................................ 4 11 ......................... 020543 .................................... Shroud .............................................................................................. 1 12 ......................... 060046-016 ............................. Spring Washer ................................................................................. 1 13* ......................... 020746 .................................... Brush Box ASM ................................................................................ 1 14* ......................... 020277-001 ............................. Brush ................................................................................................ 8 15* ......................... 060078-011 ............................. Screw ................................................................................................ 10 16* ......................... 118466 .................................... Brush Spring Kit ............................................................................... 1 17* ......................... 060032-051 ............................. Screw ................................................................................................ 4 18 ......................... 065081-051 ............................. Bearing Ball ...................................................................................... 1 19 ......................... 020708 .................................... Housing and Field ASM ................................................................... 1 20 ......................... 020719 .................................... Armature ........................................................................................... 1 21 ......................... 061061-001 ............................. Woodruff Key .................................................................................... 1 22** ........................ 060009-144 ............................. Retaining Ring ................................................................................. 1 23** ........................ 065081-054 ............................. Bearing Ball ...................................................................................... 1 24** ........................ 020465 .................................... Drive End Head ................................................................................ 1 25 ......................... 060078-012 ............................. Screw ................................................................................................ 6 26 ......................... 064138-013 ............................. Seal ................................................................................................... 1 27 ......................... 064260-001 ............................. O-Ring .............................................................................................. 1 * ........................... 020745 .................................... Motor End Cover Assembly (inclusive 3,5-8,13-17) ....................... 1 ** .......................... 020467 .................................... Drive End Head Assembly (inclusive 22-24) .................................. 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-3.2-2140

75

FAN

M1588 MP-3.2-2140

76M1.0-0000-00076

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

FAN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806895-001 ............................ Fan Assembly ......................................................................................... 1 1 ........................... 794865-001 ............................. Fan Assembly ................................................................................... 1 792880-001 ............................. Pin Housing 2-way ..................................................................... 1 792882 ..................................... Pin Insert ..................................................................................... 2 793090-001 ............................. Anti-backout ................................................................................ 1 2 ........................... 794865-002 ............................. Finger Guard .................................................................................... 1 3 ........................... 050004-043 ............................. Screw ................................................................................................ 4 050009-001 ............................. Washer ............................................................................................. 4 4 ........................... 050008-002 ............................. Nut .................................................................................................... 4 5 ........................... 793288 .................................... Clip ................................................................................................... 1 6 ........................... 050003-013 ............................. Screw ................................................................................................ 1 7 ........................... 050008-008 ............................. Nut .................................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-3.2-2140

REV. 1 10/02

77

Page intentionally left blank

Printed in Germany

78M1.0-0000-00078

SECTION 4

Printed in Germany

79

ELECTRICAL COMPARTMENT

MP-2140-024 MP-4.1-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02

80M1.0-0000-00080

ELECTRICAL COMPARTMENT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 796233 .................................... Tray Assembly ........................................................................................ 1 808125 .................................... Blind Rivet Nut ................................................................................. 12 050070-002 ............................. Screw ................................................................................................ 5 050073-004 ............................. Washer ............................................................................................. 5 050068-004 ............................. Nut .................................................................................................... 7 2 ..................... 796512-001 ............................ Traction Controller + Software (Access 3) ............................................ 1 126287-001 ............................. Traction Controller (Access 3) ......................................................... 1 793352 .................................... Heatsink Compound .............................................................................. AR 3 ..................... 050009-012 ............................ Washer ................................................................................................... 12 4 ..................... 050006-027 ............................ Screw ...................................................................................................... 12 5 ..................... 806706 .................................... Copper Busbar ....................................................................................... 2 6 ..................... 806709 .................................... Copper Busbar ....................................................................................... 2 7 ..................... 806707 .................................... Copper Busbar ....................................................................................... 1 8 ..................... 050010-021 ............................ Washer ................................................................................................... 10 9 ..................... 050008-024 ............................ Nut .......................................................................................................... 12 10 ................... 050006-032 ............................ Screw ...................................................................................................... 6 11 ................... 126284 .................................... Pump Controller (Access 2) .................................................................. 1 793352 .................................... Heatsink Compound .............................................................................. AR 12 ................... 806708 .................................... Copper Busbar ....................................................................................... 1 13 ................... 807782 .................................... Bracket ................................................................................................... 1 14 ................... 806895-005 ............................ Fan Assembly ......................................................................................... 2 807654-001 ............................. Fan .................................................................................................... 2 807797 .................................... Finger Guard .................................................................................... 2 792880-001 ............................. Pin Housing ...................................................................................... 2 792882 .................................... Pin Insert .......................................................................................... 4 793090-001 ............................. Anti Backout ..................................................................................... 2 810304-001 ............................ Ventilator Assembly (Drive in Racking) ................................................ 2 807654-002 ............................. Ventilator (Drive in Racking) ........................................................... 2 792880-001 ............................. Steckergehäuse (Drive in Racking) ................................................ 2 792882 .................................... Stecker (Drive in Racking) ............................................................... 4 793090-001 ............................. Zugentlastung (Drive in Racking) ................................................... 2 15 ................... 050005-003 ............................ Screw ...................................................................................................... 8 16 ................... 050008-005 ............................ Nut .......................................................................................................... 8 17 ................... 793288 .................................... Clip ......................................................................................................... 4 18 ................... 050003-013 ............................ Screw ...................................................................................................... 4 19 ................... 050008-008 ............................ Nut .......................................................................................................... 5 20 ................... 807798 .................................... Clamp ..................................................................................................... 2 808823 .................................... Spacer .................................................................................................... 2 21 ................... 807275 .................................... Plate ....................................................................................................... 1 804683-001 ............................ Cage Nut ................................................................................................ 1 22 ................... 807383 .................................... Interface Module Assembly ................................................................... 1 792880-004 ............................. Pin Housing ...................................................................................... 1 793222 .................................... Pin Blanking ..................................................................................... 1 792882 .................................... Pin Insert .......................................................................................... 5 793090-001 ............................. Anti Backout ..................................................................................... 1 23 ................... 050009-002 ............................ Washer ................................................................................................... 8 24 ................... 050004-006 ............................ Screw ...................................................................................................... 4 25 ................... 050008-004 ............................ Nut .......................................................................................................... 4 26 ................... 794582 .................................... Relay 48V .............................................................................................. 1 27 ................... 050004-007 ............................ Screw ...................................................................................................... 2 28 ................... 806702 .................................... Fuse Box ................................................................................................ 1 806703-001 ............................ Fuse 15A ................................................................................................ 1 806703-002 ............................ Fuse 5A .................................................................................................. 1 29 ................... 807857 .................................... Bracket ................................................................................................... 1 30 ................... 806498 .................................... Bracket ................................................................................................... 1 31 ................... 794033 .................................... Contactor Assembly (see Sect. 4.4) ...................................................... 2 807855 .................................... Cable ...................................................................................................... AR 32 ................... 050006-008 ............................ Screw ...................................................................................................... 4

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-4.1-2140

REV. 1 10/02

81

ELECTRICAL COMPARTMENT

MP-2140-024 MP-4.1-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02

82M1.0-0000-00082

ELECTRICAL COMPARTMENT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

33 ................... 050068-003 ............................ Nut .......................................................................................................... 2 050009-024 ............................ Washer ................................................................................................... 4 34 ................... 806720-001 ............................ Fuse ........................................................................................................ 1 35 ................... 806711 .................................... Battery Connector Assembly ................................................................. 1 806718-001 ............................. Battery Connector Housing ............................................................. 1 806700-009 ............................. Power Cable (B+) ............................................................................. 1 806700-010 ............................. Power Cable (B-) .............................................................................. 1 796733 .................................... Battery Connector Assembly (only for USA) ......................................... 1 796734 .................................... Battery Connector Housing (only for USA) ..................................... 1 806700-011 ............................. Power Cable (B+) (only for USA) ..................................................... 1 806700-012 ............................. Power Cable (B-) (only for USA) ...................................................... 1 796245 .................................... Battery Connector Assembly (only for Australia) .................................. 1 794493 .................................... Battery Connector Housing (only for Australia) .............................. 1 806700-011 ............................. Power Cable (B+) (only for Australia) .............................................. 1 806700-012 ............................. Power Cable (B-) (only for Australia) ............................................... 1 36 ................... 050007-010 ............................ Screw ...................................................................................................... 2 37 ................... 050009-013 ............................ Washer ................................................................................................... 4 38 ................... 050008-015 ............................ Nut .......................................................................................................... 2 39 ................... 050008-030 ............................ Nut .......................................................................................................... 2 40 ................... 050010-032 ............................ Washer ................................................................................................... 2 41 ................... 808468 .................................... Plate ....................................................................................................... 1 Not illustrated 806701 .................................... Main Harness ......................................................................................... 1 050071-035 ............................ Screw ...................................................................................................... 5 050008-024 ............................ Nut .......................................................................................................... 8 050008-068 ............................ Nut .......................................................................................................... 2 050006-023 ............................ Screw ...................................................................................................... 2

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-4.1-2140

REV. 1 10/02

83

ELECTRICAL COMPARTMENT

M1501 MP-4.1-2140

84M1.0-0000-00084

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

ELECTRICAL COMPARTMENT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 806700-006 ............................ Power Cable A (Pump Motor A) ............................................................ 1 050008-024 ............................ Nut .......................................................................................................... 1 050006-032 ............................ Screw ...................................................................................................... 1 2 ..................... 806700-007 ............................ Power Cable B- ...................................................................................... 1 050008-024 ............................ Nut .......................................................................................................... 2 050006-032 ............................ Screw ...................................................................................................... 2 3 ..................... 806700-005 ............................ Power Cable B+ ..................................................................................... 1 050008-024 ............................ Nut .......................................................................................................... 2 050006-032 ............................ Screw ...................................................................................................... 2 4 ..................... 806700-001 ............................ Power Cable F1 (Traction Motor F1) ..................................................... 1 050010-010 ............................ Washer ................................................................................................... 1 050006-008 ............................ Screw ...................................................................................................... 1 5 ..................... 806700-003 ............................ Power Cable A1 (Traction Motor A1) ..................................................... 1 050008-024 ............................ Nut .......................................................................................................... 1 050006-032 ............................ Screw ...................................................................................................... 1 6 ..................... 806700-004 ............................ Power Cable D ....................................................................................... 1 050009-024 ............................ Washer ................................................................................................... 2 7 ..................... 806700-002 ............................ Power Cable F2 (Traction Motor F2) ..................................................... 1 050010-010 ............................ Washer ................................................................................................... 1 050006-008 ............................ Screw ...................................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-4.1-2140

85

CONTACTOR

M0158 MP-4.4-2140

86M1.0-0000-00086

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

CONTACTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 794033 .................................... Line Contactor ....................................................................................... 2 1 ........................... 120115 .................................... Top Cover Fixing Screw ................................................................... 4 2 ........................... 120114 .................................... Top Cover Moulding ........................................................................ 2 3 ........................... 120112 .................................... Fixed Contact ................................................................................... 4 4 ........................... 794032 .................................... Return Spring ................................................................................... 2 5 ........................... 120113 .................................... Moving Contact (contain Index 7) ................................................... 2 6 ........................... 120120 .................................... Top Cover Base Moulding ............................................................... 2 7 ........................... 120629 .................................... Moving Contact Plunger .................................................................. 2 8 ........................... 794026 .................................... Coil and Frame ................................................................................. 2 9 ........................... 120638 .................................... End Cap ........................................................................................... 2

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-4.4-2140

87

MAST WIRING

M1730-gb MP-4.5-2140

88M1.0-0000-00088

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MAST WIRING INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 061002-001 ............................ Clamp (5-way) ....................................................................................... 1 061002-008 ............................ Clamp (10-way) ..................................................................................... 9 2 ..................... 050005-013 ............................ Screw ...................................................................................................... 1 3 ..................... 050008-008 ............................ Nut .......................................................................................................... 1 4 ..................... 052076-001 ............................ Clamp (5-way) ....................................................................................... 3 052076-002 ............................ Clamp (10-way) ..................................................................................... 3 5 ..................... 050071-035 ............................ Screw ...................................................................................................... 2 6 ..................... 050068-003 ............................ Nut .......................................................................................................... 1 7 ..................... 122914 .................................... Spring ..................................................................................................... 1 107204 .................................... Cable Grip (5-way) ................................................................................ 1 105449 .................................... Cable Grip (10-way) .............................................................................. 1 8 ..................... 807303 .................................... Spring ..................................................................................................... 1 9 ..................... 810214-*** .............................. Cable (5-way/see next Page) ................................................................ 1 810215-*** .............................. Cable (10-way/see next Page) ............................................................. 1 051051-009 ............................ Cable Tie ................................................................................................ 9 Not shown 792880-006 ............................ Pin Housing (Reach Carriage) ............................................................. 1 792882 .................................... Pin Insert ................................................................................................ AR 793222 .................................... Blanking Pin ........................................................................................... AR 793090-006 ............................ Anti-Backout ........................................................................................... 1 793288 .................................... Clip ......................................................................................................... 1 050003-013 ............................ Screw ...................................................................................................... 1

792881-004 ............................ Pin Housing (5-way/Fork Carriage/Mast Side) .................................... 1 792881-006 ............................ Pin Housing (10-way/Fork Carriage/Mast Side) ................................... 1 792883 .................................... Pin Insert ................................................................................................ AR 793091-004 ............................ Anti-Backout (5-way) ............................................................................. 1 793091-006 ............................ Anti-Backout (10-way) ........................................................................... 1 793217-018 ............................ Connector .............................................................................................. 1

792880-004 ............................ Pin Housing (5-way/Fork Carriage/Solenoid Side) .............................. 1 792880-006 ............................ Pin Housing (10-way/Fork Carriage/Solenoid Side) ........................... 1 792882 .................................... Pin Insert ................................................................................................ AR 793222 .................................... Blanking Pin ........................................................................................... AR 793090-004 ............................ Anti-Backout (5-way) ............................................................................. 1 793090-006 ............................ Anti-Backout (10-way) ........................................................................... 1 793288 .................................... Clip ......................................................................................................... 1 050003-013 ............................ Screw ...................................................................................................... 1 050008-008 ............................ Nut .......................................................................................................... 1

only for Freezer/Corrosion 796179 .................................... Cable Assembly ..................................................................................... 1 792880-001 ............................. Pin Housing ...................................................................................... 1 792882 .................................... Pin Insert .......................................................................................... 2 793090-001 ............................. Anti-Backout ..................................................................................... 2 792881-001 ............................. Pin Housing ...................................................................................... 1 792883 .................................... Pin Insert .......................................................................................... 2

Always Specify Model & Serial Number MP-4.5-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02

89

MAST WIRING

Position 9

Position 9

Collapsed Height

810214-001

810215-001

2022mm

810214-002

810215-002

2172mm

810214-003

810215-003

2322mm

810214-004

810215-004

2472mm

810214-005

810215-005

2572mm

810214-006

810215-006

2772mm

810214-007

810215-007

2922mm

810214-008

810215-008

3042mm

810214-009

810215-009

3192mm

810214-010

810215-010

3347mm

810214-011

810215-011

3492mm

810214-012

810215-012

3692mm

810214-013

810215-013

3842mm

810214-014

810215-014

3952mm

810214-015

810215-015

4252mm

810214-016

810215-016

4452mm Tab022gb

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

90M1.0-0000-00090

MAST WIRING

Page intentionally left blank

Printed in Germany

91

HGTS - LEEFT SPEED REDUCTION

M1727 MP-4.5-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02

92M1.0-0000-00092

HGTS - LEEFT SPEED REDUCTION INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050067-014 ............................ Screw ...................................................................................................... 4 2 ..................... 808096 .................................... Cover ...................................................................................................... 1 3 ..................... 808095 .................................... Cover ...................................................................................................... 1 4 ..................... 808038 .................................... Spacer .................................................................................................... 4 5 ..................... 808026 .................................... Bracket ................................................................................................... 1 6 ..................... 807870 .................................... Bracket ................................................................................................... 1 7 ..................... 050006-001 ............................ Screw ...................................................................................................... 2 8 ..................... 792991 .................................... Microswitch (HGTS 12) .......................................................................... 1 9 ..................... 803310 .................................... Actuator .................................................................................................. 1 10 ................... 807541 .................................... Plate ....................................................................................................... 1 11 ................... 050003-013 ............................ Screw ...................................................................................................... 1 12 ................... 793288 .................................... Clip ......................................................................................................... 1 13 ................... 050008-008 ............................ Nut .......................................................................................................... 1 14 ................... 792881-002 ............................ Socket Housing ...................................................................................... 1 792883 .................................... Socket Crimp .......................................................................................... 3 793091-002 ............................ Anti-Backout ........................................................................................... 1 15 ................... 050006-014 ............................ Screw ...................................................................................................... 1 16 ................... 061002-001 ............................ Clamp ..................................................................................................... 1 17 ................... 050008-008 ............................ Nut .......................................................................................................... 1 only for Freezer/Corrosion 18 ................... 796008 .................................... Bracket ................................................................................................... 1 19 ................... 794611-001 ............................ Heater ..................................................................................................... 1 050004-042 ............................ Screw ...................................................................................................... 2 050008-011 ............................ Nut .......................................................................................................... 2 20 ................... 794590-001 ............................ Cable Assembly (inclusive 794611-001,792880-001, ........................ 1 792882,793090-001) 21 ................... 792880-001 ............................ Pin Housing ........................................................................................... 1 792882 .................................... Pin Insert ................................................................................................ 2 793090-001 ............................ Anti Backout ........................................................................................... 1 796173 .................................... Heater Assembly (inclusive 18-21) ....................................................... 1

Always Specify Model & Serial Number MP-4.5-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02

93

HEIGHT ENCODER

MP-2140-022 MP-4.5-2140

94M1.0-0000-00094

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

HEIGHT ENCODER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 808904 .................................... Height Encoder (without 2, 3) ............................................................... 1 1 ........................... 808215 .................................... Bracket ............................................................................................. 1 2 ........................... 050006-033 ............................. Screw ................................................................................................ 2 3 ........................... 808733 .................................... Nut .................................................................................................... 2 4 ........................... 808896 .................................... Power Supply Assembly (inclusive 5, 6) ........................................ 1 5 ........................... 062535-006 ............................. Pin Housing ...................................................................................... 1 062536-001 ............................. Pin Insert .......................................................................................... 4 6 ........................... 792880-003 ............................. Pin Housing ...................................................................................... 1 792882 .................................... Pin Insert .......................................................................................... 4 793090-003 ............................. Anti-Backout ..................................................................................... 1 7 ........................... 050004-009 ............................. Screw ................................................................................................ 2 8 ........................... 050008-004 ............................. Nut .................................................................................................... 2 9 ........................... 793288 .................................... Clip ................................................................................................... 1 10 ......................... 050003-013 ............................. Screw ................................................................................................ 1 11 ......................... 050008-008 ............................. Nut .................................................................................................... 1 12 ......................... 808362 .................................... Case ................................................................................................. 1 13 ......................... 808379 .................................... Pin ..................................................................................................... 2 14 ......................... 808410 .................................... Bearing Ball ...................................................................................... 2 15 ......................... 808378 .................................... Pulley ................................................................................................ 2 16 ......................... 050009-014 ............................. Washer ............................................................................................. 2 17 ......................... 050012-013 ............................. Ring Retaining ................................................................................. 2 18 ......................... 808361 .................................... Pulley ................................................................................................ 1 19 ......................... 050017-018 ............................. Screw ................................................................................................ 1 20 ......................... 055002-026 ............................. Bearing Ball ...................................................................................... 1 21 ......................... 050012-069 ............................. Ring Retaining ................................................................................. 1 22 ......................... 808908 .................................... Washer ............................................................................................. 1 23 ......................... 050012-070 ............................. Ring Retaining ................................................................................. 1 24 ......................... 808380 .................................... Plate .................................................................................................. 1 25 ......................... 127785 .................................... Encoder PCP .................................................................................... 1 26 ......................... 050006-033 ............................. Screw ................................................................................................ 2 808363 .................................... Height Encoder Assembly (inclusive 12-25) ................................. 1 Not shown 810217-*** .............................. Cable-Height Encoder Assembly (see next Page) ......................... 1 808386 .................................... Wire Rope ........................................................................................ 1 807303 .................................... Spring ............................................................................................... 1 only for Freezer/Corrosion 27 ......................... 794611-004 ............................. Heater ............................................................................................... 3 050004-042 ............................. Screw ................................................................................................ 6 28 ......................... 792880-001 ............................. Pin Housing ...................................................................................... 1 792882 .................................... Pin Insert .......................................................................................... 2 793090-001 ............................. Anti Backout ..................................................................................... 1 29 ......................... 796229 .................................... Cable Assembly (inclusive 794611-004,792880-001, .................. 1 792882,793090-001)

Always Specify Model & Serial Number MP-4.5-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02

95

HEIGHT ENCODER

Collapsed Height 810217-001

2022mm

810217-002

2172mm

810217-003

2322mm

810217-004

2472mm

810217-005

2572mm

810217-006

2772mm

810217-007

2922mm

810217-008

3042mm

810217-009

3192mm

810217-010

3347mm

810217-011

3492mm

810217-012

3692mm

810217-013

3842mm

810217-014

3952mm

810217-015

4252mm

810217-016

4452mm Tab023gb

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

96M1.0-0000-00096

HEIGHT ENCODER

Page intentionally left blank

Printed in Germany

97

JOYSTICK AND EMERGENCY DISCO. SWITCH

MP-2140-021 MP-4.6-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02

98M1.0-0000-00098

JOYSTICK AND EMERGENCY DISCO. SWITCH INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 810624 .................................... Bracket ................................................................................................... 1 2 ..................... 791423-002 ............................ Joystick Hole Plug ................................................................................. 1 3 ..................... 807038 .................................... Joystick Assembly (Switch) ................................................................... 1 792880-003 ............................. Pin Housing ...................................................................................... 1 792882 .................................... Pin Insert .......................................................................................... 3 4 ..................... 807037 .................................... Joystick Assembly (Pot) ......................................................................... AR 792880-003 ............................. Pin Housing ...................................................................................... AR 792882 .................................... Pin Insert .......................................................................................... AR 5 ..................... 050006-024 ............................ Screw ...................................................................................................... AR 6 ..................... 050008-015 ............................ Nut .......................................................................................................... AR 7 ..................... 807523-001 ............................ Joystick & Label/Lift ............................................................................... 1 807523-002 ............................ Joystick & Label/Tilt ............................................................................... 1 807523-003 ............................ Joystick & Label/Reach ......................................................................... 1 807523-004 ............................ Joystick & Label/Load Stabilizer ........................................................... 1 807523-005 ............................ Joystick & Label/Upender ..................................................................... 1 807523-006 ............................ Joystick & Label/Sideshift ...................................................................... 1 807523-007 ............................ Joystick & Label/Fork Arm Spread ........................................................ 1 807523-008 ............................ Joystick & Label/Clamp ......................................................................... 1 807523-009 ............................ Joystick & Label/Rotate ......................................................................... 1 807523-010 ............................ Joystick & Label/Push/Pull .................................................................... 1 8 ..................... 793288 .................................... Clip ......................................................................................................... 5 9 ..................... 050003-013 ............................ Screw ...................................................................................................... 5 10 ................... 050008-008 ............................ Nut .......................................................................................................... 5 11 ................... 792880-003 ............................ Pin Housing ........................................................................................... 1 793222 .................................... Pin Insert ................................................................................................ 4 793090-003 ............................ Anti Backout ........................................................................................... 4 12 ................... 804863-001 ............................ Cage Nut ................................................................................................ 3 13 ...................................................................... Directional Switch/Horn Button (see next Page) .................................. 1 14 ................... 050067-022 ............................ Screw ...................................................................................................... 2 15 ................... 050068-003 ............................ Nut .......................................................................................................... 2 16 ................... 807051-001 ............................ Emergency Disconnect Switch .............................................................. 1 792991 .................................... Switch ..................................................................................................... 2 793288 .................................... Clip ......................................................................................................... 2 050003-013 ............................ Vis ........................................................................................................... 2 17 ................... 050006-013 ............................ Screw ...................................................................................................... 2 18 ................... 050008-008 ............................ Nut .......................................................................................................... 4 19 ................... 050068-004 ............................ Nut .......................................................................................................... 3 only for Freezer/Corrosion (Emergency Disconnect Switch) 20 ................... 796008 .................................... Bracket ................................................................................................... 2 21 ................... 794611-001 ............................ Heater ..................................................................................................... 2 050004-042 ............................ Screw ...................................................................................................... 4 050008-011 ............................ Nut .......................................................................................................... 4 22 ................... 792880-001 ............................ Pin Housing ........................................................................................... 1 792882 .................................... Pin Insert ................................................................................................ 2 793090-001 ............................ Anti Backout ........................................................................................... 1 23 ................... 7964591-001 .......................... Cable Assembly (inclusive 794611-001,792880-001, ....................... 1 792882,793090-001) 796012 .................................... Heater Assembly (inclusive 20-23) ...................................................... 1 not shown 793217-007 ............................ Switch (6th Function Valve) ................................................................... 1 796488 .................................... Cable assembly (6th Function Valve) ................................................... 1 051051-009 ............................ Cable Tie (6th Function Valve) .............................................................. 5 796735 .................................... Label (6th Function Valve) ..................................................................... 1

Always Specify Model & Serial Number MP-4.6-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02

99

DIRECTIONAL SWITCH/HORN BUTTON

MP1494 MP-4.6-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02 M1.0-0000-000100 100

DIRECTIONAL SWITCH/HORN BUTTON INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807055 .................................... Directional Switch/Horn Button ............................................................. 1 1 ........................... 806676 .................................... Bracket ............................................................................................. 1 2 ........................... 806679 .................................... Bracket ............................................................................................. 1 3 ........................... 050003-014 ............................. Screw ................................................................................................ 2 4 ........................... 050008-008 ............................. Nut .................................................................................................... 7 5 ........................... 806746 .................................... Horn Button ...................................................................................... 1 6 ........................... 806677 .................................... Shaft .................................................................................................. 2 7 ........................... 050001-013 ............................. Pin Split ............................................................................................ 2 8 ........................... 792991 .................................... Microswitch ....................................................................................... 3 9 ........................... 050006-001 ............................. Screw ................................................................................................ 6 10 ......................... 050008-002 ............................. Nut .................................................................................................... 6 11 ......................... 050005-001 ............................. Screw ................................................................................................ 1 12 ......................... 050008-001 ............................. Nut .................................................................................................... 3 13 ......................... 793288 .................................... Clip ................................................................................................... 3 14 ......................... 050003-015 ............................. Screw ................................................................................................ 3 15 ......................... 050009-007 ............................. Washer ............................................................................................. 2 16 ......................... 803310 .................................... Actuator Roller Arm .......................................................................... 2 17 ......................... 050005-058 ............................. Screw ................................................................................................ 2 18 ......................... 806742 .................................... Spring Roller .................................................................................... 1 19 ......................... 050005-002 ............................. Screw ................................................................................................ 2 050009-003 ............................. Washer ............................................................................................. 4 20 ......................... 806745 .................................... Directional Lever .............................................................................. 1 21 ......................... 051064-006 ............................. Spring ............................................................................................... 1 22 ......................... 050009-012 ............................. Washer ............................................................................................. 2 only for Freezer/Corrosion 23 ......................... 794572-002 ............................. Bracket ............................................................................................. 1 24 ......................... 794611-001 ............................. Heater ............................................................................................... 3 050004-042 ............................. Screw ................................................................................................ 6 050008-011 ............................. Nut .................................................................................................... 6 25 ......................... 796005 .................................... Bracket (Directional Lever) .............................................................. 1 26 ......................... 796004 .................................... Bracket (Horn Button) ...................................................................... 1 27 ......................... 792880-001 ............................. Pin Housing ...................................................................................... 1 792882 .................................... Pin Insert .......................................................................................... 2 793090-001 ............................. Anti Backout ..................................................................................... 1 793288 .................................... Clip ................................................................................................... 1 050003-015 ............................. Screw ................................................................................................ 1 050008-008 ............................. Nut .................................................................................................... 1 796003-001 ............................. Cable Assembly (inclusive 794611-001,792880-001, .................. 1 792882,793090-001) 796006 .................................... Heater Assembly (inclusive 23-27) ................................................. 1

Always Specify Model & Serial Number MP-4.6-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02

101

FLOORPLATE

MP1479 MP-4.6-2140

M1.0-0000-000102 102

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

FLOORPLATE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806486-001 ............................ Floorplate & Pedal Assembly ................................................................ 1 1 ........................... 806445 .................................... Floorplate ......................................................................................... 1 2 ........................... 793333 .................................... Lug Nut ............................................................................................. 2 3 ........................... 050005-062 ............................. Screw ................................................................................................ 2 ............................ 050009-013 ............................. Washer ............................................................................................. 2 4 ........................... 806476 .................................... Accelerator Pedal ............................................................................. 1 5 ........................... 793226 .................................... Buffer ................................................................................................ 1 6 ........................... 050008-015 ............................. Nut .................................................................................................... 1 7 ........................... 104215 .................................... Pedal Rubber ................................................................................... 1 8 ........................... 055084-010 ............................. Bush .................................................................................................. 2 9 ........................... 807278 .................................... Pin ..................................................................................................... 1 10 ......................... 050000-056 ............................. Pin ..................................................................................................... 2 11 ......................... 806488 .................................... Floor Mat .......................................................................................... 1 12 ......................... 050071-035 ............................. Screw ................................................................................................ 1 13 ......................... 060102-001 ............................. Nut .................................................................................................... 1 806485 .................................... Floorplate & Pedal (inclusive 1-11) ................................................. 1 Accelerator Unit (see next Page) .................................................... 1

Always Specify Model & Serial Number MP-4.6-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02

103

ACCELERATOR

M1579 MP-4.6-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02 M1.0-0000-000104 104

ACCELERATOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ........................................................................ Accelerator Assembly ............................................................................ 1 1 ........................... 050012-030 ............................. Circlip ............................................................................................... 1 2 ........................... 793473 .................................... Roller ................................................................................................ 1 3 ........................... 042053-020 ............................. Bush .................................................................................................. 2 4 ........................... 793558 .................................... Lever ................................................................................................. 1 5 ........................... 042053-018 ............................. Bush .................................................................................................. 2 6 ........................... 793562 .................................... Spring ............................................................................................... 1 7 ........................... 793561 .................................... Collar Drive ...................................................................................... 1 8 ........................... 050000-069 ............................. Split Cotter Pin ................................................................................. 1 9 ........................... 795572 .................................... Bracket ............................................................................................. 1 10 ......................... 795796 .................................... Potentiometer Assembly .................................................................. 1 792880-003 ............................. Pin Housing ................................................................................ 1 792882 ..................................... Pin Crimp .................................................................................... 1 793090-003 ............................. Anti Backout ................................................................................ 1 11 ......................... 050009-002 ............................. Washer ............................................................................................. 2 12 ......................... 050006-001 ............................. Screw ................................................................................................ 4 13 ......................... 793226 .................................... Buffer ................................................................................................ 1 14 ......................... 050008-015 ............................. Nut .................................................................................................... 1 15 ......................... 792991 .................................... Microswitch ....................................................................................... 1 16 ......................... 803310 .................................... Actuator Roller Arm .......................................................................... 1 17 ......................... 050008-002 ............................. Nut .................................................................................................... 2 050009-002 ............................. Washer ............................................................................................. 1 18 ......................... 793288 .................................... Clip ................................................................................................... 2 19 ......................... 050003-013 ............................. Screw ................................................................................................ 2 20 ......................... 050008-008 ............................. Nut .................................................................................................... 2 21 ......................... 050006-035 ............................. Screw ................................................................................................ 2 22 ......................... 050008-024 ............................. Nut .................................................................................................... 2 807751 .................................... Accelerator (inclusive 1-20) ............................................................ 1 only for Freezer/Corrosion 23 ......................... 796009 .................................... Bracket ............................................................................................. 1 24 ......................... 796010 .................................... Bracket ............................................................................................. 1 25 ......................... 794611-001 ............................. Heater ............................................................................................... 2 050004-042 ............................. Screw ................................................................................................ 4 050008-011 ............................. Nut .................................................................................................... 4 26 ......................... 792880-001 ............................. Pin Housing ...................................................................................... 1 792882 .................................... Pin Insert .......................................................................................... 2 793090-001 ............................. Anti Backout ..................................................................................... 1 793288 .................................... Clip ................................................................................................... 1 050003-015 ............................. Screw ................................................................................................ 1 050008-008 ............................. Nut .................................................................................................... 1 27 ......................... 794591-001 ............................. Cable Assembly (inclusive 794611-001,792880-001, .................. 1 792882,793090-001) 796013 .................................... Heater Assembly (inclusive 23-27) ................................................. 1

Always Specify Model & Serial Number MP-4.6-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02

105

DEAD MAN PEDAL

MP-2140-001 MP-4.6-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02 M1.0-0000-000106 106

DEAD MAN PEDAL INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ........................................................................ Dead Man Pedal Assembly ................................................................... 1 1 ........................... 806934 .................................... Pedal Rubber ................................................................................... 1 2 ........................... 810482 .................................... Lever ................................................................................................. 1 3 ........................... 050071-019 ............................. Screw ................................................................................................ 2 4 ........................... 810483 .................................... Bushing ............................................................................................ 1 5 ........................... 808932 .................................... Screw ................................................................................................ 2 6 ........................... 050008-015 ............................. Nut .................................................................................................... 2 7 ........................... 807048 .................................... Spring ............................................................................................... 1 8 ........................... 051058-010 ............................. Bushing ............................................................................................ 2 9 ........................... 792991 .................................... Microswitch ....................................................................................... 1 803310 .................................... Actuator ............................................................................................ 1 10 ......................... 050004-036 ............................. Screw ................................................................................................ 2 11 ......................... 807541 .................................... Plate .................................................................................................. 1 12 ......................... 050003-013 ............................. Screw ................................................................................................ 2 13 ......................... 793288 .................................... Clip ................................................................................................... 2 14 ......................... 050008-008 ............................. Nut .................................................................................................... 2 15 ......................... 810480 .................................... Bracket ............................................................................................. 1 16 ......................... 050067-034 ............................. Screw ................................................................................................ 2 17 ......................... 810469 .................................... Plate .................................................................................................. 1 only for Freezer/Corrosion 18 ......................... 796007 .................................... Bracket ............................................................................................. 1 19 ......................... 794611-001 ............................. Heater ............................................................................................... 1 20 ......................... 050004-042 ............................. Screw ................................................................................................ 2 21 ......................... 050008-011 ............................. Nut .................................................................................................... 2 22 ......................... 794590-001 ............................. Cable Assembly (inclusive 794611-001) ........................................ 1 792880-001 ............................. Pin Housing ................................................................................ 1 792882 ..................................... Pin Insert ..................................................................................... 2 793090-001 ............................. Anti Backout ................................................................................ 1 796011 .................................... Heater Assembly (inclusive 18-22) ................................................. 1

Always Specify Model & Serial Number MP-4.6-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02

107

DC/DC CONVERTER

MP-2140-018 MP-4.8-2140

M1.0-0000-000108 108

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

DC/DC CONVERTER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 795477 .................................... Bracket ................................................................................................... 1 2 ..................... 050005-023 ............................ Screw ...................................................................................................... 1 3 ..................... 050008-024 ............................ Nut .......................................................................................................... 1 4 ..................... 050005-026 ............................ Screw ...................................................................................................... 1 5 ..................... 050008-026 ............................ Nut .......................................................................................................... 1 6 ..................... 794535-002 ............................ DC/DC Converter (48V - 12V) ............................................................... 1 794535-003 ............................ DC/DC Converter (48V - 24V) ............................................................... 1 7 ..................... 796075 .................................... Cover ...................................................................................................... 1 8 ..................... 050006-013 ............................ Screw ...................................................................................................... 4 9 ..................... 050008-008 ............................ Nut .......................................................................................................... 4 10 ................... 796095 .................................... Cable Assembly ..................................................................................... 1 793217-002 ............................. Ring Terminal ................................................................................... 2 792882 .................................... Pin Insert .......................................................................................... 2 11 ................... 794582 .................................... Relay 48V .............................................................................................. 1 ...................... 806703-001 ............................ Fuse 15A ................................................................................................ 2 12 ................... 050004-006 ............................ Screw ...................................................................................................... 2 13 ................... 050008-004 ............................ Nut .......................................................................................................... 2 795476-001 ............................ DC/DC Converter (48V - 12V/inclusive 1-9) ......................................... 1 795476-002 ............................ DC/DC Converter (48V - 24V/inclusive 1-9) ......................................... 1 not shown 796145 .................................... Hose Bracket .......................................................................................... 1 050071-035 ............................ Screw ...................................................................................................... 1 050008-024 ............................ Nut .......................................................................................................... 1 051051-009 ............................ Cable Tie ................................................................................................ 6

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-4.8-2140

109

DASH PANEL

MP-2140-025 MP-4.9-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02 M1.0-0000-000110 110

DASH PANEL INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806887 .................................... Dash Panel Assembly (without 9) ......................................................... 1 1 ........................... 806898 .................................... Dash Panel ....................................................................................... 1 2 ........................... 807349 .................................... Brake Switch .................................................................................... 1 3 ........................... 807034 .................................... Key Switch Assembly ....................................................................... 1 123537 ..................................... Key Switch .................................................................................. 1 793090-002 ............................. Anti-Backout ............................................................................... 1 792880-002 ............................. Pin Housing ................................................................................ 1 792882 ..................................... Pin Crimp .................................................................................... 3 4 ........................... 109127-003 ............................. Clip Arrow Indicator (red) ................................................................. 1 5 ........................... 109127-001 ............................. Clip Arrow Indicator (green) ............................................................ 1 6 ........................... 109127-002 ............................. Clip Arrow Indicator (yellow) ........................................................... 1 7 ........................... 806888 .................................... Bracket ............................................................................................. 1 8 ........................... 803469-011 ............................. Screw ................................................................................................ 4 050009-007 ............................. Washer ............................................................................................. 6 9 ........................... 050068-004 ............................. Nut .................................................................................................... 4 10 ......................... 792940 .................................... Lug Nut ............................................................................................. 3 11 ......................... 793288 .................................... Attachment Clip ................................................................................ 3 12 ......................... 050003-015 ............................. Screw ................................................................................................ 3 13 ......................... 807033 .................................... Suppressor Assembly ...................................................................... 1 14 ......................... 050007-010 ............................. Screw ................................................................................................ 1 050009-013 ............................. Washer ............................................................................................. 1 15 ......................... 791346-003 ............................. Adjuster Button ................................................................................. 1 16 ......................... 790199-039 ............................. Spring ............................................................................................... 1 17 ......................... 806932 .................................... Pivot Pin ........................................................................................... 1 18 ......................... 790213 .................................... R-Clip ................................................................................................ 2 19 ......................... 107739 .................................... Key Assembly ................................................................................... 1 107151-002 ............................. Key .............................................................................................. 2 107763 ..................................... Ring ............................................................................................. 1 20 ......................... 808876 .................................... Finger Guard .................................................................................... 1 21 ......................... 050003-002 ............................. Screw ................................................................................................ 1

Always Specify Model & Serial Number MP-4.9-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02

111

INSTRUMENTATION

M1481 MP-4.9-2140

M1.0-0000-000112 112

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

INSTRUMENTATION INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806930 .................................... Instrumentation ...................................................................................... 1 1 ........................... 806691 .................................... Display Cover ................................................................................... 1 2 ........................... 807854 .................................... Plate .................................................................................................. 2 3 ........................... 051068-003 ............................. Clip Spring ....................................................................................... 3 4 ........................... 050004-021 ............................. Screw ................................................................................................ 4 5 ........................... 050071-035 ............................. Screw ................................................................................................ 1 6 ........................... 807848 .................................... Spacer .............................................................................................. 1 7 ........................... 807090 .................................... Display, Overlay ............................................................................... 1 8 ........................... 124015 .................................... ASM PCB ENH ................................................................................. 1 9 ........................... 806748 .................................... Button Housing ................................................................................. 1 10 ......................... 125416 .................................... ASM PCB Switch .............................................................................. 1 11 ......................... 807354 .................................... Bracket ............................................................................................. 1 12 ......................... 803469-010 ............................. Screw ................................................................................................ 4 13 ......................... 050009-002 ............................. Washer ............................................................................................. 6 14 ......................... 050005-050 ............................. Screw ................................................................................................ 6

Always Specify Model & Serial Number MP-4.9-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02

113

STEER INDICATOR

M1674 MP-4.9-2140

M1.0-0000-000114 114

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

STEER INDICATOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 790752 .................................... Steer Indicator ........................................................................................ 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-4.9-2140

115

FLASHING BEACON

MP-2140-009gb MP-4.10-2140

M1.0-0000-000116 116

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

FLASHING BEACON INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 795365-001 ............................ Flashing Beacon (Travel Activated) ...................................................... 1 795365-002 ............................ Flashing Beacon (Key-On Activated) .................................................... 1 795365-003 ............................ Flashing Beacon (Switch Activated) ..................................................... 1 1 ........................... 795982 .................................... Bracket ............................................................................................. 1 2 ........................... 795977 .................................... Clamp ............................................................................................... 1 3 ........................... 050005-062 ............................. Screw ................................................................................................ 2 053050-006 ............................. Adhesive .......................................................................................... AR 4 ........................... 791036-003 ............................. Beacon (Xenon) ............................................................................... 1 5 ........................... 050071-020 ............................. Screw ................................................................................................ 3 6 ........................... 796045 .................................... Clip ................................................................................................... 1 7 ........................... 050071-012 ............................. Screw ................................................................................................ 1 8 ........................... 050009-007 ............................. Washer ............................................................................................. 1 9 ........................... 050008-008 ............................. Nut .................................................................................................... 1 10 ......................... 796073 .................................... Cable ................................................................................................ 1 11 ......................... 796074 .................................... Beacon Controller (only for Key-On Activated) ............................... 1 796072 .................................... Beacon Controller (only for Switch Activated) ................................ 1 793288 .................................... Clip ................................................................................................... 1 050003-015 ............................. Screw ................................................................................................ 1 050008-008 ............................. Nut .................................................................................................... 1 12 ......................... 062595-002 ............................. Switch ............................................................................................... 1 796078 .................................... Flashing Beacon Assembly (inclusive 1-10) .................................. 1 795981 .................................... Beacon Assembly (inclusive 1,4-10) ............................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-4.10-2140

117

WORKING LIGHT

MP-2140-010-gb MP-4.10-2140

M1.0-0000-000118 118

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

WORKING LIGHT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 795366-001 ............................ Working Light Assembly (Option up) .................................................... 1 795366-002 ............................ Working Light Assembly (Option down) ................................................ 1 1 ........................... 796067 .................................... Bracket ............................................................................................. 2 2 ........................... 050005-026 ............................. Screw ................................................................................................ 2 3 ........................... 793611 .................................... Working Light ................................................................................... 2 793801-001 ............................. Sleeve ............................................................................................... 2 4 ........................... 050008-025 ............................. Nut .................................................................................................... 2 5 ........................... 795977 .................................... Clamp ............................................................................................... 4 6 ........................... 050005-062 ............................. Screw ................................................................................................ 8 053050-006 ............................. Adhesive .......................................................................................... AR 7 ........................... 796094 .................................... Cable Conduit .................................................................................. 1 051051-009 ............................. Cable Tie .......................................................................................... 4 8 ........................... 796086 .................................... Cable Conduit .................................................................................. 1 9 ........................... 796071 .................................... Cable ................................................................................................ 1 10 ......................... 794582 .................................... Relay 48V ......................................................................................... 1 806703-001 ............................. Fuse 15A .......................................................................................... 1 11 ......................... 050004-034 ............................. Screw ................................................................................................ 2 12 ......................... 050008-004 ............................. Nut .................................................................................................... 2 13 ......................... 062595-002 ............................. Switch ............................................................................................... 1 795496 .................................... Working Light Assembly (inclusive 1-9/Option up) ........................ 2 795496 .................................... Working Light Assembly (inclusive 1-9/Option down) .................... 2 795986 .................................... Working Light Assembly (inclusive 1-4) .......................................... 2

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-4.10-2140

119

WORKING LIGHT

MP-2140-011-gb MP-4.10-2140

M1.0-0000-000120 120

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

WORKING LIGHT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 795368-001 ............................ Working Light Assembly ........................................................................ 1 1 ........................... 796067 .................................... Bracket ............................................................................................. 1 2 ........................... 050005-026 ............................. Screw ................................................................................................ 2 3 ........................... 793611 .................................... Working Light ................................................................................... 2 793801-001 ............................. Sleeve ............................................................................................... 2 4 ........................... 050008-025 ............................. Nut .................................................................................................... 2 5 ........................... 795977 .................................... Clamp ............................................................................................... 4 6 ........................... 050005-062 ............................. Screw ................................................................................................ 8 053050-006 ............................. Adhesive .......................................................................................... AR 7 ........................... 050009-020 ............................. Washer ............................................................................................. 1 8 ........................... 795472 .................................... Bracket ............................................................................................. 1 9 ........................... 796086 .................................... Cable Conduit .................................................................................. 1 10 ......................... 796085 .................................... Cable Conduit .................................................................................. 1 051051-009 ............................. Cable Tie .......................................................................................... 1 11 ......................... 796084 .................................... Cable Conduit .................................................................................. 1 051051-009 ............................. Cable Tie .......................................................................................... 1 12 ......................... 796071 .................................... Cable ................................................................................................ 1 13 ......................... 062595-002 ............................. Switch ............................................................................................... 1 14 ......................... 794582 .................................... Relay 48V ......................................................................................... 1 806703-001 ............................. Fuse 15A .......................................................................................... 1 15 ......................... 050004-034 ............................. Screw ................................................................................................ 2 16 ......................... 050008-004 ............................. Nut .................................................................................................... 2 796081 .................................... Working Light Assembly (inclusive 1-12) ....................................... 1 795986 .................................... Working Light Assembly (inclusive 1-4) .......................................... 1 795471 .................................... Working Light Assembly (inclusive 2-4,7,8) .................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-4.10-2140

121

REVERSE ALARM

MP-2140-013 MP-4.10-2140

M1.0-0000-000122 122

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REVERSE ALARM INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 795999 .................................... Reverse Alarm Assembly ...................................................................... 1 1 ........................... 795991 .................................... Bracket ............................................................................................. 1 2 ........................... 794582 .................................... Relay 48V ......................................................................................... 1 3 ........................... 050009-002 ............................. Washer ............................................................................................. 2 4 ........................... 050004-025 ............................. Screw ................................................................................................ 2 5 ........................... 050008-004 ............................. Nut .................................................................................................... 2 6 ........................... 050067-012 ............................. Screw ................................................................................................ 2 7 ........................... 126035 .................................... Reverse Alarm ................................................................................. 1 8 ........................... 050009-013 ............................. Washer ............................................................................................. 2 9 ........................... 050008-015 ............................. Nut .................................................................................................... 2 10 ......................... 796401 .................................... Cable ................................................................................................ 1 11 ......................... 793288 .................................... Clip ................................................................................................... 1 12 ......................... 050003-011 ............................. Screw ................................................................................................ 1 13 ......................... 050008-008 ............................. Nut .................................................................................................... 1 14 ......................... 796402 .................................... Cable ................................................................................................ 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-4.10-2140

123

HORN

MP-2140-002 MP-4.13-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02 M1.0-0000-000124 124

HORN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 078708-006 ............................ Horn ........................................................................................................ 1 2 ..................... 050006-032 ............................ Screw ...................................................................................................... 1 3 ..................... 050008-024 ............................ Nut .......................................................................................................... 1 4 ..................... 109120 .................................... Filter ........................................................................................................ 1 5 ..................... 050005-003 ............................ Screw ...................................................................................................... 2 6 ..................... 050008-001 ............................ Nut .......................................................................................................... 2

Always Specify Model & Serial Number MP-4.13-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 10/02

125

COOLING SYSTEM

MP-2140-004 MP-4.14-2140

M1.0-0000-000126 126

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

COOLING SYSTEM INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807597-001 ............................ Cooling System ...................................................................................... 1 1 ........................... 807620 .................................... Bracket ............................................................................................. 1 2 ........................... 793288 .................................... Clip ................................................................................................... 2 3 ........................... 050003-013 ............................. Screw ................................................................................................ 2 4 ........................... 050008-008 ............................. Nut .................................................................................................... 2 5 ........................... 806895-002 ............................. Fan Assembly ................................................................................... 2 807654-002 ............................. Fan .............................................................................................. 2 792880-001 ............................. Pin Housing ................................................................................ 2 792882 ..................................... Pin Insert ..................................................................................... 4 793090-001 ............................. Anti-backout ................................................................................ 2 6 ........................... 807797 .................................... Finger Guard .................................................................................... 2 7 ........................... 050005-003 ............................. Screw ................................................................................................ 8 8 ........................... 050008-005 ............................. Nut .................................................................................................... 8 9 ........................... 050009-018 ............................. Washer ............................................................................................. 2 10 ......................... 050008-024 ............................. Nut .................................................................................................... 2 11 ......................... 807849 .................................... Bracket ............................................................................................. 1 12 ......................... 050006-022 ............................. Screw ................................................................................................ 2

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-4.14-2140

127

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Printed in Germany

M1.0-0000-000128 128

SECTION 5

Printed in Germany

129

BRAKE CIRCUIT

MP-2140-016gb MP-5.1-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02 M1.0-0000-000130 130

BRAKE CIRCUIT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 810702-001 ............................ Brake Line Assembly (1.4t/1285mm Leg Width) .................................. 1 810702-002 ............................ Brake Line Assembly (1.6-2.0t/1285mm Leg Width) ............................ 1 810702-004 ............................ Brake Line Assembly (1.4t/1425mm Leg Width) .................................. 1 810702-005 ............................ Brake Line Assembly (1.6-2.0t/1425mm Leg Width) ............................ 1 810702-006 ............................ Brake Line Assembly (1.4t/1575mm Leg Width) .................................. 1 810702-007 ............................ Brake Line Assembly (1.6-2.0t/1575mm Leg Width) ............................ 1 1 ........................... 810581-001 ............................. Brake Line (1.4t/1285mm Leg Width) ............................................. 1 810581-002 ............................. Brake Line (1.6-2.0t/1285mm Leg Width) ....................................... 1 810581-003 ............................. Brake Line (1.4t/1425mm Leg Width) ............................................. 1 810581-004 ............................. Brake Line (1.6-2.0t/1425mm Leg Width) ....................................... 1 810581-005 ............................. Brake Line (1.4t/1575mm Leg Width) ............................................. 1 810581-006 ............................. Brake Line (1.6-2.0t/1575mm Leg Width) ....................................... 1 2 ........................... 790555 .................................... Clip ................................................................................................... 2 3 ........................... 050006-008 ............................. Screw ................................................................................................ 2 4 ........................... 790548 .................................... Connector ......................................................................................... 2 5 ........................... 807553-001 ............................. Brake Line (1285/1425mm Leg Width) ........................................... 1 807553-002 ............................. Brake Line (1575mm Leg Width) .................................................... 1 6 ........................... 807585 .................................... Clip ................................................................................................... 1 7 ........................... 050070-002 ............................. Screw ................................................................................................ 3 8 ........................... 050008-030 ............................. Nut .................................................................................................... 3 9 ........................... 790550 .................................... Connector ......................................................................................... 1 10 ......................... 050007-009 ............................. Screw ................................................................................................ 1 11 ......................... 810578 .................................... Brake Line ........................................................................................ 1 12 ......................... 807499 .................................... Bracket ............................................................................................. 1 13 ......................... 810580-001 ............................. Brake Line (1.4t/1285mm Leg Width) ............................................. 1 810580-002 ............................. Brake Line (1.6-2.0t/1285mm Leg Width) ....................................... 1 810580-003 ............................. Brake Line (1.4t/1425mm Leg Width) ............................................. 1 810580-004 ............................. Brake Line (1.6-2.0t/1425mm Leg Width) ....................................... 1 810580-005 ............................. Brake Line (1.4t/1575mm Leg Width) ............................................. 1 810580-006 ............................. Brake Line (1.6-2.0t/1575mm Leg Width) ....................................... 1 14 ......................... 807703 .................................... Brake Line (only for 1575mm Leg Width) ....................................... 1 15 ......................... 810579 .................................... Brake Line ........................................................................................ 1 16 ......................... 050006-036 ............................. Screw ................................................................................................ 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-5.1-2140

REV. 1 10/02

131

FOOTBRAKE

MP-2140-003 MP-5.5-2140

M1.0-0000-000132 132

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

FOOTBRAKE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 810699-001 ............................ Footbrake Assembly .............................................................................. 1 1 ........................... 810399 .................................... Brake Mounting Bracket .................................................................. 1 2 ........................... 050067-044 ............................. Screw ................................................................................................ 2 3 ........................... 810401 .................................... Brake Pedal ...................................................................................... 1 4 ........................... 102330 .................................... Footpedal Rubber ............................................................................ 1 5 ........................... 051058-017 ............................. Bush .................................................................................................. 2 6 ........................... 050009-053 ............................. Washer ............................................................................................. 1 7 ........................... 050012-036 ............................. Circlip ............................................................................................... 1 8 ........................... 050007-013 ............................. Screw ................................................................................................ 1 9 ........................... 807085 .................................... Spring ............................................................................................... 1 10 ......................... 050008-015 ............................. Nut .................................................................................................... 2 11 ......................... 810404 .................................... Rod Fork ........................................................................................... 1 12 ......................... 790195 .................................... Pin Clevis ......................................................................................... 1 13 ......................... 050009-018 ............................. Washer ............................................................................................. 1 14 ......................... 050001-013 ............................. Pin ..................................................................................................... 1 15 ......................... 810525 .................................... Brake Master Cylinder Assembly .................................................... 1 810589 ..................................... Brake Master Cylinder & Reservoir ........................................... 1 810591 ..................................... Reservoir Cap & Switch (BFS) ................................................... 1 16 ......................... 050006-035 ............................. Screw ................................................................................................ 1 17 ......................... 050006-043 ............................. Screw ................................................................................................ 1 810397 .................................... Footbrake Assembly (inklusive 1,3-17) ........................................... 1 810700 .................................... Repair Kit (Brake Master Cylinder) ................................................. 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-5.5-2140

133

DRIVE MOTOR BRAKE

M1062 MP-5.6-2140

M1.0-0000-000134 134

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

DRIVE MOTOR BRAKE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 790080 .................................... Disc Brake Assembly ............................................................................. 1 1 ........................... 790182 .................................... Brake Ring ....................................................................................... 1 2 ........................... 790180 .................................... Key .................................................................................................... 1 3 ........................... 790179 .................................... Hub with O-Ring ............................................................................... 1 4 ........................... 790181 .................................... Circlip ............................................................................................... 1 5 ........................... 790159 .................................... Base Plate ........................................................................................ 1 6 ........................... 790165 .................................... Spring ............................................................................................... 1 7 ........................... 790166 .................................... Pin ..................................................................................................... 1 8 ........................... 790079 .................................... Bleeder Valve ................................................................................... 1 9 ........................... 790172 .................................... Cap ................................................................................................... 1 10 ......................... 790174 .................................... Bush .................................................................................................. 6 11 ......................... 790147 .................................... Shaft .................................................................................................. 1 12 ......................... 790171 .................................... Screw ................................................................................................ 2 13 ......................... 790167 .................................... Ring .................................................................................................. 1 14 ......................... 790168 .................................... Brake Piston ..................................................................................... 1 15 ......................... 790148 .................................... Cap ................................................................................................... 1 16 ......................... 790164 .................................... Setbolt .............................................................................................. 1 17 ......................... 790175 .................................... Manual Brake Lever ........................................................................ 1 18 ......................... 790176 .................................... Pin ..................................................................................................... 2 19 ......................... 790456 .................................... Split Cotter Pin ................................................................................. 4 20 ......................... 790161 .................................... Pressure Plate .................................................................................. 1 21 ......................... 790177 .................................... Brake Lever ...................................................................................... 1 22 ......................... 790178 .................................... Pin ..................................................................................................... 2 23 ......................... 790169 .................................... Nut .................................................................................................... 1 24 ......................... 790170 .................................... Adjusting Screw ............................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-5.6-2140

135

LOAD WHEEL BRAKE

MP-2140-014 MP-5.6-2140

M1.0-0000-000136 136

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

LOAD WHEEL BRAKE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 810564 .................................... Brake ...................................................................................................... 2 1 ........................... 810569 .................................... Backplate .......................................................................................... 2 2 ........................... 810634 .................................... Plug ................................................................................................... 4 3 ........................... 810572 .................................... Cylinder Assy ................................................................................... 2 4 ........................... 050006-024 ............................. Screw ................................................................................................ 4 5 ........................... 810570 .................................... Brake Shoe ....................................................................................... 4 6 ........................... 810568 .................................... Spring ............................................................................................... 4 7 ........................... 810567 .................................... Spring ............................................................................................... 4 8 ........................... 810566 .................................... Clamp ............................................................................................... 2

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-5.6-2140

137

BRAKE CYLINDER

M1495 MP-5.8-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02 M1.0-0000-000138 138

BRAKE CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807452 .................................... Brake Cylinder (without 2) ..................................................................... 1 1 ........................... 807059 .................................... Brake Cylinder ................................................................................. 1 2 ........................... 050006-061 ............................. Screw ................................................................................................ 2 3* .......................... 804770 .................................... Guide Ring ....................................................................................... 1 4* .......................... 808269 .................................... Seal ................................................................................................... 1 5 ........................... 808151 .................................... Piston Rod ........................................................................................ 1 6 ........................... 807015 .................................... Spacer .............................................................................................. 1 7 ........................... 808156 .................................... Spring ............................................................................................... 1 8* .......................... 808268 .................................... Guide Ring ....................................................................................... 1 9 ........................... 807017 .................................... Gland ................................................................................................ 1 10 ......................... 792285 .................................... Wire Lock .......................................................................................... 1 11* ......................... 807023 .................................... Wiper ................................................................................................ 1 12 ......................... 807784 .................................... Ring .................................................................................................. 1 13 ......................... 050000-001 ............................. Pin ..................................................................................................... 1 14 ......................... 807016 .................................... Support ............................................................................................. 1 15 ......................... 050006-040 ............................. Screw ................................................................................................ 1 16 ......................... 807020 .................................... Cable ................................................................................................ 1 17 ......................... 050008-015 ............................. Nut .................................................................................................... 7 18 ......................... 808104 .................................... Filter .................................................................................................. 1 19 ......................... 808082 .................................... Bracket ............................................................................................. 1 20 ......................... 050006-024 ............................. Screw ................................................................................................ 2 21 ......................... 793288 .................................... Clip ................................................................................................... 1 22 ......................... 050003-013 ............................. Screw ................................................................................................ 1 23 ......................... 050008-008 ............................. Nut .................................................................................................... 1 24 ......................... 803310 .................................... Actuator ............................................................................................ 1 25 ......................... 792991 .................................... Microswitch ....................................................................................... 1 26 ......................... 050004-034 ............................. Screw ................................................................................................ 2 27 ......................... 807541 .................................... Plate .................................................................................................. 1 28 ......................... 064061-004 ............................. Elbow ................................................................................................ 5 29 ......................... 807448 .................................... Tube .................................................................................................. 1 30 ......................... 807028 .................................... Solenoid Valve ................................................................................. 1 31 ......................... 807449 .................................... Adapter ............................................................................................. 1 32 ......................... 064004-007 ............................. Connector ......................................................................................... 1 33 ......................... 807026 .................................... Check Valve ...................................................................................... 1 34 ......................... 050007-011 ............................. Screw ................................................................................................ 4 807008 .................................... Brake Cylinder Assembly (inclusive 1,3-11,18,28) ........................ 1 * ........................... 808552 .................................... Seal Kit (inclusive 3,4,8,11) ............................................................. 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-5.8-2140

REV. 1 10/02

139

Page intentionally left blank

Printed in Germany

M1.0-0000-000140 140

SECTION 6

Printed in Germany

141

STEERING COLUMN

M1488 MP-6.7-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02 M1.0-0000-000142 142

STEERING COLUMN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806974 .................................... Steering Column Assembly (without 16-19) ......................................... 1 1* .......................... 119531 .................................... Spinner Knob ................................................................................... 1 2* .......................... 060009-133 ............................. Ring Retaining ................................................................................. 1 3* .......................... 114279-002 ............................. Bearing Sleeve ................................................................................. 1 4* .......................... 060009-146 ............................. Ring Retaining ................................................................................. 1 5* .......................... 807466-002 ............................. Steering Wheel ................................................................................. 1 6 ........................... 805302 .................................... Steering Column Cover ................................................................... 1 7 ........................... 050006-022 ............................. Screw ................................................................................................ 2 8 ........................... 050071-020 ............................. Screw ................................................................................................ 5 9 .............................................................................. Steering Column & Gearbox (see next page) ................................. 1 10 ......................... 050008-052 ............................. Nut .................................................................................................... 1 11 ......................... 807467 .................................... Bracket ............................................................................................. 1 12 ......................... 794401 .................................... Spacer Tube ..................................................................................... 1 13 ......................... 805305 .................................... Steering Column Cover ................................................................... 1 14 ......................... 050003-016 ............................. Screw ................................................................................................ 1 15 ......................... 791357-010 ............................. Hole Plug .......................................................................................... 1 16 ......................... 806961 .................................... Shaft .................................................................................................. 1 17 ......................... 792973 .................................... Pin ..................................................................................................... 1 18 ......................... 050006-027 ............................. Screw ................................................................................................ 1 19 ......................... 790995 .................................... Spring Tension ................................................................................. 1 20 ......................... 806830 .................................... Cover ................................................................................................ 1 21 ......................... 807637 .................................... Bracket ............................................................................................. 1 22 ......................... 793333 .................................... Nut .................................................................................................... 1 23 ......................... 792724 .................................... Plug ................................................................................................... 1 24 ......................... 125502 .................................... Pocket Storage ................................................................................. 1 25 ......................... 050005-059 ............................. Screw ................................................................................................ 1 26 ......................... 050005-060 ............................. Screw ................................................................................................ 1 27 ......................... 125503 .................................... Mount Pocket .................................................................................... 1 28 ......................... 050068-002 ............................. Nut .................................................................................................... 2 * .......................... 807465 .................................... Steering Wheel Assembly (inclusive 1-5) ....................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-6.7-2140

REV. 1 10/02

143

STEERING COLUMN

M1487 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-6.7-2140

REV.1 10/02 M1.0-0000-000144 144

STEERING COLUMN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807400 .................................... Steering Column & Gaerbox Assembly ................................................ 1 1 ........................... 807393 .................................... Steering Column .............................................................................. 1 2 ........................... 050078-002 ............................. Blind Rivet Nut ................................................................................. 5 3 ........................... 807410 .................................... Spacer Plate ..................................................................................... 2 4 ........................... 807408 .................................... Spacer Block .................................................................................... 1 5 ........................... 794301 .................................... Lock Plate ......................................................................................... 1 6 ........................... 050003-059 ............................. Screw ................................................................................................ 2 050010-023 ............................. Washer ............................................................................................. 2 7 ........................... 050008-024 ............................. Nut .................................................................................................... 2 8 ........................... 807750 .................................... Spring Mount .................................................................................... 1 9 ........................... 050008-049 ............................. Nut .................................................................................................... 1 10 ......................... 807401 .................................... Bracket ............................................................................................. 1 11 ......................... 808120 .................................... Steer Sensor Module ....................................................................... 1 12 ......................... 050004-009 ............................. Screw ................................................................................................ 2 13 ......................... 050008-004 ............................. Nut .................................................................................................... 2 14 ......................... 126699 .................................... Encoder ............................................................................................ 1 15 ......................... 792814 .................................... Spur Gear ......................................................................................... 1 16 ......................... 050005-032 ............................. Screw ................................................................................................ 4 17 ......................... 807411 .................................... Steering Gearbox Assembly (see next page) ................................. 1 18 ......................... 806900 .................................... Power Steering Unit ......................................................................... 1 19 ......................... 064004-004 ............................. Adaptor ............................................................................................. 4 20 ......................... 064061-001 ............................. Adaptor ............................................................................................. 1 21 ......................... 050005-068 ............................. Screw ................................................................................................ 4 22 ......................... 050009-013 ............................. Washer ............................................................................................. 1 23 ......................... 050006-022 ............................. Screw ................................................................................................ 1 Not illustrated 793288 .................................... Clip ................................................................................................... 1 050003-013 ............................. Screw ................................................................................................ 1 050008-008 ............................. Nut .................................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-6.7-2140

REV. 2 10/02

145

STEERING COLUMN

M1486 MP-6.7-2140

M1.0-0000-000146 146

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

STEERING COLUMN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807411 .................................... Steering Gearbox Assembly .................................................................. 1 1 ........................... 806871 .................................... Steering Gearbox Housing .............................................................. 1 2 ........................... 055002-014 ............................. Bearing ............................................................................................. 2 3 ........................... 806960-004 ............................. Spacer .............................................................................................. 1 4 ........................... 050012-014 ............................. Circlip ............................................................................................... 1 5 ........................... 791377 .................................... Gear .................................................................................................. 1 6 ........................... 791381 .................................... Spring Torsion .................................................................................. 2 7 ........................... 791380 .................................... Gear .................................................................................................. 2 8 ........................... 806937-003 ............................. Washer ............................................................................................. 1 9 ........................... 050012-057 ............................. Circlip ............................................................................................... 1 10 ......................... 806937-001 ............................. Washer ............................................................................................. 1 11 ......................... 806937-002 ............................. Washer ............................................................................................. 1 12 ......................... 050012-009 ............................. Circlip ............................................................................................... 1 13 ......................... 806960-002 ............................. Spacer .............................................................................................. 2 14 ......................... 806960-003 ............................. Spacer .............................................................................................. 3 15 ......................... 055002-004 ............................. Bearing ............................................................................................. 3 16 ......................... 791382 .................................... Gear .................................................................................................. 1 17 ......................... 806894 .................................... Centre Shaft ..................................................................................... 1 18 ......................... 792973 .................................... Pin ..................................................................................................... 1 19 ......................... 050006-024 ............................. Screw ................................................................................................ 1 20 ......................... 791372 .................................... Gear .................................................................................................. 1 21 ......................... 806960-001 ............................. Spacer .............................................................................................. 1 22 ......................... 806300 .................................... Drive Shaft ........................................................................................ 1 23 ......................... 791375-001 ............................. Washer ............................................................................................. 1 24 ......................... 050067-034 ............................. Screw ................................................................................................ 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-6.7-2140

REV. 1 10/02

147

Page intentionally left blank

Printed in Germany

M1.0-0000-000148 148

SECTION 7

Printed in Germany

149

TT MAST 1.4t/1.6t

M1503 MP-7.5-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02 M1.0-0000-000150 150

TT MAST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ........................................................................ TT Mast (1.4/1.6t) ................................................................................... 1 1 ........................... 806101-***-** .......................... Outer Mast (see next page) ............................................................. 1 812132-***-** .......................... Outer Mast (see next page) ............................................................. 1 2 ........................... 806102-*** .............................. 1st Stage Mast (see next page) ....................................................... 1 812133-*** .............................. 1st Stage Mast (see next page) ....................................................... 1 3 ........................... 806103-*** .............................. 2nd Stage Mast (see next page) ..................................................... 1 4 ........................... 807334-002 ............................. Roller Æ 101,47mm ......................................................................... AR 807334-003 ............................. Roller Æ 102,14mm ......................................................................... AR 807334-004 ............................. Roller Æ 102,45mm ......................................................................... AR 5 ........................... 060030-057 ............................. Shim .................................................................................................. 8 060030-085 ............................. Shim .................................................................................................. 8 795534 .................................... Shim .................................................................................................. 8 6 ........................... 807327-*** .............................. Cover (see next page) ..................................................................... 1 812967-*** .............................. Cover (see next page) ..................................................................... 1 7 ........................... 050067-022 ............................. Screw ................................................................................................ AR 8 ........................... 806999-*** .............................. Cover (see next page) ..................................................................... 1 812966-*** .............................. Cover (see next page) ..................................................................... 1 9 .............................................................................. Lift Cylinder (see Section 8.1) ......................................................... 2 10 ......................... 806997 .................................... Pin ..................................................................................................... 2 11 ......................... 050001-021 ............................. Pin ..................................................................................................... 2 12 ......................... 050007-014 ............................. Screw ................................................................................................ 2 13 ......................... 050008-015 ............................. Nut .................................................................................................... 2 14 ......................... 792427 .................................... Block Stop ........................................................................................ 4 15 ......................... 794661 .................................... Shim .................................................................................................. 4 16 ......................... 808861 .................................... Bracket ............................................................................................. 4 17 ......................... 092747-001 ............................. Poly Stop .......................................................................................... 4 18 ......................... 050005-062 ............................. Screw ................................................................................................ 4 19 ......................... 050006-069 ............................. Screw ................................................................................................ 8 20 ............................................................................ Freelift Cylinder (see Section 8.2) ................................................... 1 21 ......................... 807339 .................................... Protection ......................................................................................... 1 22 ......................... 050003-050 ............................. Screw ................................................................................................ 2 23 ......................... 807329 .................................... Shim .................................................................................................. 1 24 ......................... 050067-037 ............................. Screw ................................................................................................ 2 25 ............................................................................ Yoke (see Section 7.11) ................................................................... 1 26 ......................... 050000-028 ............................. Pin ..................................................................................................... 1 27 ......................... 050067-048 ............................. Screw ................................................................................................ 2 28 ......................... 050008-038 ............................. Nut .................................................................................................... 2 29 ......................... 812968 .................................... Cover (RH/only for Collapsed Height 3692,3892,3952mm) ......... 1 812969 .................................... Cover (LH/only for Collapsed Height 3692,3892,3952mm) ......... 1 30 ......................... 050067-056 ............................. Screw ................................................................................................ 2 31 ......................... 807407 .................................... Washer ............................................................................................. 2 807323 .................................... Shim .................................................................................................. 8 32 ......................... 050068-007 ............................. Nut .................................................................................................... 2

Not shown 808386 .................................... Cable (Height Encoder) ................................................................... 1 807303 .................................... Spring (Height Encoder) .................................................................. 1 790350 .................................... Magnet (FLS/LCS) ........................................................................... 1 050003-019 ............................. Screw (FLS/LCS) .............................................................................. 1 807716 .................................... Bracket (FLS/LCS) ........................................................................... 1 050005-058 ............................. Screw (FLS/LCS) .............................................................................. 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.5-2140

REV. 1 10/02

151

TT MAST 1.4t/1.6t Position 1

Position 2

Position 3

Position 6

Position 8

Collapsed Height

806101-001-01

806102-001

806103-001

807327-001

806999-001

2022mm

806101-001-02

806102-002

806103-002

807327-002

806999-002

2172mm

806101-001-03

806102-003

806103-003

807327-003

806999-003

2322mm

806101-001-04

806102-004

806103-004

807327-004

806999-004

2472mm

806101-001-05

806102-005

806103-005

807327-005

806999-005

2572mm

806101-001-06

806102-006

806103-006

807327-006

806999-006

2772mm

806101-001-07

806102-007

806103-007

807327-007

806999-007

2922mm

806101-001-08

806102-008

806103-008

807327-008

806999-008

3042mm

806101-001-09

806102-009

806103-009

807327-009

806999-009

3192mm

812132-001-10

812133-010

806103-010

812967-010

812966-010

3347mm

812132-001-11

812133-011

806103-011

812967-011

812966-011

3492mm

812132-001-12

812133-012

806103-012

812967-012

812966-012

3692mm

812132-001-13

812133-013

806103-013

812967-013

812966-013

3842mm

812132-001-14

812133-014

806103-014

812967-014

812966-014

3952mm Tab005gb

MP-7.5-2140

M1.0-0000-000152 152

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

Page intentionally left blank

Printed in Germany

153

TT MAST 2.0t

M1503 MP-7.5-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02 M1.0-0000-000154 154

TT MAST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ........................................................................ TT Mast (2.0t) ......................................................................................... 1 1 ........................... 806101-***-** .......................... Outer Mast (see next page) ............................................................. 1 812132-***-** .......................... Outer Mast (see next page) ............................................................. 1 2 ........................... 806102-*** .............................. 1st Stage Mast (see next page) ....................................................... 1 812133-*** .............................. 1st Stage Mast (see next page) ....................................................... 1 3 ........................... 806103-*** .............................. 2nd Stage Mast (see next page) ..................................................... 1 4 ........................... 807334-002 ............................. Roller Æ 101,47mm ......................................................................... AR 807334-003 ............................. Roller Æ 102,14mm ......................................................................... AR 807334-004 ............................. Roller Æ 102,45mm ......................................................................... AR 5 ........................... 060030-057 ............................. Shim .................................................................................................. 8 060030-085 ............................. Shim .................................................................................................. 8 795534 .................................... Shim .................................................................................................. 8 6 ........................... 807327-*** .............................. Cover (see next page) ..................................................................... 1 812973-*** .............................. Cover (see next page) ..................................................................... 1 7 ........................... 050067-022 ............................. Screw ................................................................................................ AR 8 ........................... 806999-*** .............................. Cover (see next page) ..................................................................... 1 812973-*** .............................. Cover (see next page) ..................................................................... 1 9 .............................................................................. Lift Cylinder (see Section 8.1) ......................................................... 2 10 ......................... 806997 .................................... Pin ..................................................................................................... 2 11 ......................... 050001-021 ............................. Pin ..................................................................................................... 2 12 ......................... 050007-014 ............................. Screw ................................................................................................ 2 13 ......................... 050008-015 ............................. Nut .................................................................................................... 2 14 ......................... 792427 .................................... Block Stop ........................................................................................ 4 15 ......................... 794661 .................................... Shim .................................................................................................. 4 16 ......................... 808861 .................................... Bracket ............................................................................................. 4 17 ......................... 092747-001 ............................. Poly Stop .......................................................................................... 4 18 ......................... 050005-062 ............................. Screw ................................................................................................ 4 19 ......................... 050006-069 ............................. Screw ................................................................................................ 8 20 ............................................................................ Freelift Cylinder (see Section 8.2) ................................................... 1 21 ......................... 807339 .................................... Protection ......................................................................................... 1 22 ......................... 050003-050 ............................. Screw ................................................................................................ 2 23 ......................... 807329 .................................... Shim .................................................................................................. 1 24 ......................... 050067-037 ............................. Screw ................................................................................................ 2 25 ............................................................................ Yoke (see Section 7.11) ................................................................... 1 26 ......................... 050000-028 ............................. Pin ..................................................................................................... 1 27 ......................... 050067-048 ............................. Screw ................................................................................................ 2 28 ......................... 050008-038 ............................. Nut .................................................................................................... 2 29 ......................... 050067-056 ............................. Screw ................................................................................................ 2 30 ......................... 807407 .................................... Washer ............................................................................................. 2 807323 .................................... Shim .................................................................................................. 8 31 ......................... 050068-007 ............................. Nut .................................................................................................... 2

Not shown 808386 .................................... Cable (Height Encoder) ................................................................... 1 807303 .................................... Spring (Height Encoder) .................................................................. 1 790350 .................................... Magnet (FLS/LCS) ........................................................................... 1 050003-019 ............................. Screw (FLS/LCS) .............................................................................. 1 807716 .................................... Bracket (FLS/LCS) ........................................................................... 1 050005-058 ............................. Screw (FLS/LCS) .............................................................................. 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.5-2140

REV. 1 10/02

155

TT MAST 2.0t Position 1

Position 2

Position 3

Position 6

Position 8

Collapsed Height

806101-002-01

806102-001

806103-001

807327-001

806999-001

2022mm

806101-002-02

806102-002

806103-002

807327-002

806999-002

2172mm

806101-002-04

806102-004

806103-004

807327-004

806999-004

2472mm

806101-002-06

806102-006

806103-006

807327-006

806999-006

2772mm

806101-002-07

806102-007

806103-007

807327-007

806999-007

2922mm

806101-002-08

806102-008

806103-008

807327-008

806999-008

3042mm

812132-002-10

812133-010

806103-010

812973-010-01

812973-010-02

3347mm

812132-002-12

812133-012

806103-012

812973-012-01

812973-012-02

3692mm

812132-002-13

812133-013

806103-013

812973-013-01

812973-013-02

3842mm

812132-002-14

812133-014

806103-014

812973-014-01

812973-014-02

3952mm

812132-002-15

812133-015

806103-015

812973-015-01

812973-015-02

4252mm

812132-002-16

812133-016

806103-016

812973-016-01

812973-016-02

4452mm Tab006gb

MP-7.5-2140

M1.0-0000-000156 156

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

Page intentionally left blank

Printed in Germany

157

LIFT CHAIN MAST TT

M1505 MP-7.6-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02 M1.0-0000-000158 158

LIFT CHAIN MAST TT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050008-056 ............................ Nut .......................................................................................................... 8 2 ..................... 806993 .................................... Washer ................................................................................................... 4 3 ..................... 806995 .................................... Washer ................................................................................................... 4 4 ..................... 808489-002 ............................ Chain Anchor ......................................................................................... 2 5 ..................... 050001-027 ............................ Pin Split .................................................................................................. 4 6 ..................... 807962 .................................... Chain Pin ............................................................................................... 4 7 ..................... 050001-017 ............................ Pin Split .................................................................................................. 8 8 ..................... 050006-040 ............................ Screw ...................................................................................................... 1 9 ..................... 810434 .................................... Shaft ....................................................................................................... 1 10 ................... 807715 .................................... Shim ....................................................................................................... 3 11 ................... 127513-001 ............................ Pulley Cable .......................................................................................... 1 12 ................... 050009-051 ............................ Washer ................................................................................................... 1 13 ................... 119655-001 ............................ Pulley Hose ............................................................................................ 2 14 ................... 806267 .................................... Pulley Chain .......................................................................................... 2 15 ................... 050012-056 ............................ Ring Retaining ....................................................................................... 2 16 ................... 050007-038 ............................ Screw ...................................................................................................... 1 17 ................... 121623 .................................... Pulley Hose ............................................................................................ 1 18 ................... 806991-001 ............................ Shaft ....................................................................................................... 1 19 ................... 808489-001 ............................ Chain Anchor ......................................................................................... 2 20 ................... 050008-068 ............................ Nut .......................................................................................................... 4 21 ................... 050001-027 ............................ Pin Split .................................................................................................. 2 22 ................... 808488-001 ............................ Chain Anchor ......................................................................................... 1 23 ................... 803539 .................................... Chain Pin ............................................................................................... 2 24 ................... 050001-013 ............................ Pin Roll ................................................................................................... 4 25 ................... 808488-002 ............................ Chain Anchor ......................................................................................... 1 26 ................... 793069-*** .............................. Chain (see next page) ........................................................................... 1 27 ................... 792968-*** .............................. Chain (see next page) ........................................................................... 2 28 ................... 806994 .................................... Washer ................................................................................................... 2 29 ................... 806996 .................................... Washer ................................................................................................... 2 30 ................... 050009-025 ............................ Washer ................................................................................................... 2 31 ................... 810435 .................................... Shaft ....................................................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.6-2140

REV. 1 10/02

159

LIFT CHAIN MAST TT

Position 26

Position 27

Collapsed Height

793069-009

792968-002

2022mm

793069-010

792968-013

2172mm

793069-003

792968-019

2322mm

793069-004

792968-015

2472mm

793069-005

792968-020

2572mm

793069-006

792968-021

2772mm

793069-0012

792968-022

2922mm

793069-007

792968-018

3042mm

793069-013

792968-023

3192mm

793069-014

792968-024

3347mm

793069-015

792968-025

3492mm

793069-016

792968-026

3692mm

793069-017

792968-027

3842mm

793069-018

792968-028

3952mm

793069-019

792968-029

4252mm

793069-020

792968-030

4452mm Tab012gb

MP-7.6-2140

M1.0-0000-000160 160

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

Page intentionally left blank

Printed in Germany

161

TILT AND SIDESHIFT

M1498 MP-7.7-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02 M1.0-0000-000162 162

TILT AND SIDESHIFT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806181-001 ............................ Tilt & Sideshift (1.4/1.6t-1285/1425mm,L.Width/Tilt 2°/4°) ................... 1 807382-001 ............................ Tilt & Sideshift (1.4/1.6t-1575mm, Leg Width/Tilt 2°/4°) ....................... 1 808418-001 ............................ Tilt & Sideshift (1.4/1.6t-1285/1425mm,L.Width/Tilt 2°/2°) ................... 1 1 ........................... 808521-001 ............................. Frame (only for 806181-001 & 808418-001) .................................. 1 808521-002 ............................. Frame (only for 807382-001) ........................................................... 1 2 ........................... 808522-001 ............................. Sleeve Bearing ................................................................................. 2 3* .......................... 808523 .................................... Groove Ring ..................................................................................... 2 4 ........................... 808524 .................................... Washer ............................................................................................. 2 5* .......................... 808525 .................................... Stripper ............................................................................................. 2 6 ........................... 808526-001 ............................. Piston Rod (only for 806181-001 & 808418-001) .......................... 2 808526-002 ............................. Piston Rod (only for 807382-001) ................................................... 2 7 ........................... 808527 .................................... Seal Ring .......................................................................................... 2 8 ........................... 808528 .................................... Dowel ................................................................................................ 2 9 ........................... 060030-057 ............................. Shim .................................................................................................. 6 10 ......................... 060030-085 ............................. Shim .................................................................................................. 6 11 ......................... 807334-002 ............................. Roller Æ101,47mm .......................................................................... AR 807334-003 ............................. Roller Æ 102,14mm ......................................................................... AR 807334-004 ............................. Roller Æ 102,45mm ......................................................................... AR 12 ......................... 808529-001 ............................. Sliding Piece .................................................................................... 5 13 ......................... 808522-002 ............................. Sleeve Bearing ................................................................................. 1 14 ......................... 808530 .................................... Piston ................................................................................................ 1 15 ......................... 808543 .................................... Cylinder (only for 806181-001 & 807382-001) .............................. 1 808562 .................................... Cylinder (only for 808418-001) ....................................................... 1 16 ......................... 808529-002 ............................. Sliding Piece .................................................................................... 1 17 ......................... 808532 .................................... Spiral Fixing Pin ............................................................................... 2 18 ......................... 808533 .................................... Hook ................................................................................................. 1 19 ......................... 808534-001 ............................. Screw ................................................................................................ 2 20 ......................... 808535-001 ............................. Fork Carriage (only for 806181-001 & 808418-001) ..................... 1 808535-002 ............................. Fork Carriage (only for 807382-001) .............................................. 1 21 ......................... 808536 .................................... Greasing Nipples ............................................................................. 3 22 ......................... 808529-003 ............................. Sliding Piece .................................................................................... 1 23 ......................... 808534-002 ............................. Screw ................................................................................................ 2 24 ......................... 808537 .................................... Pipe (only for 806181-001 & 807382-001) ..................................... 3 808560 .................................... Pipe (only for 808418-001) .............................................................. 3 25 ......................... 808534-003 ............................. Screw (only for 806181-001 & 807382-001) .................................. 3 808561 .................................... Screw (only for 808418-001) ........................................................... 3 26 ......................... 808538 .................................... Quick Clutch ..................................................................................... 2 27 ......................... 808539 .................................... Tension Device ................................................................................. 2 28 ......................... 808534-004 ............................. Screw ................................................................................................ 2 29 ......................... 795534 .................................... Shim .................................................................................................. 6 * ........................... 808541 .................................... Seal Kit (inclusive 3, 5) .................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.7-2140

REV. 1 10/02

163

TILT AND SIDESHIFT

M1500 MP-7.7-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02 M1.0-0000-000164 164

TILT AND SIDESHIFT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806181-002 ............................ Tilt & Sideshift (2.0t-1285/1425mm Leg Width/Tilt 2°/4°) ..................... 1 807382-002 ............................ Tilt & Sideshift (2.0t-1575mm Leg Width/Tilt 2°/4°) .............................. 1 808418-002 ............................ Tilt & Sideshift (2.0t-1285/1425mm Leg Width/Tilt 2°/2°) ..................... 1 1 ........................... 808542-001 ............................. Frame (only for 806181-002 & 808418-002) .................................. 1 808542-002 ............................. Frame (only for 807382-002) ........................................................... 1 2 ........................... 808522-001 ............................. Sleeve Bearing ................................................................................. 2 3* .......................... 808523 .................................... Groove Ring ..................................................................................... 2 4 ........................... 808524 .................................... Washer ............................................................................................. 2 5* .......................... 808525 .................................... Stripper ............................................................................................. 2 6 ........................... 808526-001 ............................. Piston Rod (only for 806181-002 & 808418-002) .......................... 2 808526-002 ............................. Piston Rod (only for 807382-002) ................................................... 2 7 ........................... 808527 .................................... Seal Ring .......................................................................................... 2 8 ........................... 808528 .................................... Dowel ................................................................................................ 2 9 ........................... 060030-057 ............................. Shim .................................................................................................. 8 10 ......................... 060030-085 ............................. Shim .................................................................................................. 8 11 ......................... 807334-002 ............................. Roller Æ 101,47mm ........................................................................ AR 807334-003 ............................. Roller Æ 102,14mm ......................................................................... AR 807334-004 ............................. Roller Æ 102,45mm ........................................................................ AR 12 ......................... 808529-001 ............................. Sliding Piece .................................................................................... 5 13 ......................... 808522-002 ............................. Sleeve Bearing ................................................................................. 1 14 ......................... 808530 .................................... Piston ................................................................................................ 1 15 ......................... 808543 .................................... Cylinder (only for 806181-002 & 807382-002) .............................. 1 808562 .................................... Cylinder (only for 808418-002) ....................................................... 1 16 ......................... 808529-002 ............................. Sliding Piece .................................................................................... 1 17 ......................... 808532 .................................... Spiral Fixing Pin ............................................................................... 2 18 ......................... 808533 .................................... Hook ................................................................................................. 1 19 ......................... 808534-001 ............................. Screw ................................................................................................ 2 20 ......................... 808535-001 ............................. Fork Carriage (only for 806181-002 & 808418-002) ..................... 1 808535-002 ............................. Fork Carriage (only for 807382-002) .............................................. 1 21 ......................... 808536 .................................... Greasing Nipples ............................................................................. 3 22 ......................... 808529-003 ............................. Sliding Piece .................................................................................... 1 23 ......................... 808534-002 ............................. Screw ................................................................................................ 2 24 ......................... 808537 .................................... Pipe (only for 806181-002 & 807382-002) ..................................... 3 808560 .................................... Pipe (only for 808418-002) .............................................................. 3 25 ......................... 808534-003 ............................. Screw (only for 806181-002 & 807382-002) .................................. 3 808561 .................................... Screw (only for 808418-002) ........................................................... 3 26 ......................... 795534 .................................... Shim .................................................................................................. 8 27 ......................... 808538 .................................... Quick Clutch ..................................................................................... 2 28 ......................... 808539 .................................... Tension Device ................................................................................. 2 29 ......................... 808534-004 ............................. Screw ................................................................................................ 2 30 ......................... 808729 .................................... Shim .................................................................................................. 3 31 ......................... 808730 .................................... Shim .................................................................................................. 3 32 ......................... 808731 .................................... Shim .................................................................................................. 3 33 ......................... 808732 .................................... Shim .................................................................................................. 2 34 ......................... 050003-020 ............................. Screw ................................................................................................ 2 053050-006 ............................. Adhesive .......................................................................................... AR * ........................... 808541 .................................... Seal Kit (inclusive 3, 5) .................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.7-2140

REV. 1 10/02

165

TILT AND SIDESHIFT

MP-2140-008 MP-7.7-2140

M1.0-0000-000166 166

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

TILT AND SIDESHIFT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 808716 .................................... Tilt & Sideshift (Long Drop) ................................................................... 1 1 ........................... 808565 .................................... Frame ................................................................................................ 1 2 ........................... 808522-001 ............................. Sleeve Bearing ................................................................................. 2 3* .......................... 808523 .................................... Groove Ring ..................................................................................... 2 4 ........................... 808524 .................................... Washer ............................................................................................. 2 5* .......................... 808525 .................................... Stripper ............................................................................................. 2 6 ........................... 808526-001 ............................. Piston Rod ........................................................................................ 2 7 ........................... 808527 .................................... Seal Ring .......................................................................................... 2 8 ........................... 808528 .................................... Dowel ................................................................................................ 2 9 ........................... 060030-057 ............................. Shim .................................................................................................. 8 10 ......................... 060030-085 ............................. Shim .................................................................................................. 8 11 ......................... 807334-002 ............................. Roller Æ 101,47mm ......................................................................... AR 807334-003 ............................. Roller Æ 102,14mm ......................................................................... AR 807334-004 ............................. Roller Æ 102,45mm ......................................................................... AR 12 ......................... 808529-001 ............................. Sliding Piece .................................................................................... 7 13 ......................... 808522-002 ............................. Sleeve Bearing ................................................................................. 1 14 ......................... 808530 .................................... Piston ................................................................................................ 1 15 ......................... 808543 .................................... Cylinder ............................................................................................ 1 16 ......................... 808566 .................................... Sliding Piece .................................................................................... 1 17 ......................... 808532 .................................... Spiral Fixing Pin ............................................................................... 2 18 ......................... 808533 .................................... Hook ................................................................................................. 1 19 ......................... 808534-001 ............................. Screw ................................................................................................ 2 20 ......................... 808535-002 ............................. Fork Carriage ................................................................................... 1 21 ......................... 808536 .................................... Greasing Nipples ............................................................................. 3 22 ......................... 808529-003 ............................. Sliding Piece .................................................................................... 1 23 ......................... 808534-002 ............................. Screw ................................................................................................ 2 24 ......................... 808560 .................................... Pipe ................................................................................................... 3 25 ......................... 808561 .................................... Screw ................................................................................................ 3 26 ......................... 795534 .................................... Shim .................................................................................................. 8 27 ......................... 808538 .................................... Quick Clutch ..................................................................................... 2 28 ......................... 808539 .................................... Tension Device ................................................................................. 2 29 ......................... 808534-004 ............................. Screw ................................................................................................ 2 30 ......................... 808729 .................................... Shim .................................................................................................. 3 31 ......................... 808730 .................................... Shim .................................................................................................. 3 32 ......................... 808731 .................................... Shim .................................................................................................. 3 33 ......................... 808732 .................................... Shim .................................................................................................. 2 34 ......................... 050003-020 ............................. Screw ................................................................................................ 2 053050-006 ............................. Adhesive .......................................................................................... AR * ........................... 808541 .................................... Seal Kit (inclusive 3, 5) .................................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.7-2140

167

TILT AND SIDESHIFT

M1633 MP-7.7-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02 M1.0-0000-000168 168

TILT AND SIDESHIFT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 808943-001 ............................ Valve Block ............................................................................................. 1 808941-001 ............................ Check Valve ........................................................................................... 1 2 ..................... 808942-001 ............................ Plug ........................................................................................................ 2 3 ..................... 808941-002 ............................ Counter Balance Valve .......................................................................... 1 4 ..................... 808553-002 ............................ Valve Solenoid ....................................................................................... 1 808940-002 ............................ Coil Solenoid ......................................................................................... 1 808553-004 ............................ Kit Seal ................................................................................................... 1 5 ..................... 808553-002 ............................ Valve Solenoid ....................................................................................... 1 808940-001 ............................ Coil Solenoid ......................................................................................... 1 808553-004 ............................ Kit Seal ................................................................................................... 1 6 ..................... 064004-002 ............................ Adaptor ................................................................................................... 1 7 ..................... 064065-002 ............................ Elbow ...................................................................................................... 1 8 ..................... 808043 .................................... Pipe (without „Long Drop“) .................................................................... 1 ...................... 808872 .................................... Pipe (Long Drop) ................................................................................... 1 9 ..................... 054176-001 ............................ Adaptor (without „Long Drop“) ..............................................................

10 ................... 064061-001 ............................ Elbow ...................................................................................................... 1 11 ................... 808042 .................................... Pipe (without „Long Drop“) .................................................................... 1 808871 .................................... Pipe (Long Drop) ................................................................................... 1 12 ................... 054188-001 ............................ Elbow (with „Long Drop“ 2 pieces) ....................................................... 1 13 ................... 807479 .................................... Bracket ................................................................................................... 1 051051-004 ............................ Binder ..................................................................................................... 4 14 ................... 050006-025 ............................ Screw ...................................................................................................... 2 15 ................... 064061-004 ............................ Elbow ...................................................................................................... 4 16 ................... 808044 .................................... Pipe (without „Long Drop“) .................................................................... 1 808873 .................................... Pipe (Long Drop) ................................................................................... 1 17 ................... 808045 .................................... Pipe (without „Long Drop“) .................................................................... 1 808976 .................................... Pipe (Long Drop) ................................................................................... 1 18 ................... 064004-007 ............................ Adaptor ................................................................................................... 4 19 ................... 808974 .................................... Pipe ........................................................................................................ 1 20 ................... 808975 .................................... Pipe ........................................................................................................ 1 21 ................... 807871 .................................... Clamp ..................................................................................................... 1 22 ................... 050005-058 ............................ Screw ...................................................................................................... 1 23 ................... 064091-006 ............................ Plug ........................................................................................................ 1 24 ................... 807449 .................................... Adaptor ................................................................................................... 1 25 ................... 807476 .................................... Adaptor ................................................................................................... 1 26 ................... 808886-001 ............................ Main Harness LS/FKS Assembly (inclusive 126491Pressure Sensor)1 808886-002 ............................ Main Harness LS/FKS Assy Fork Widht 50mm (inclusive 126491) .... 1 126491 .................................... Pressure Sensor (LS) ...................................................................... 1 051051-009 ............................ Cable Tie ................................................................................................ 2 793288 .................................... Clip ......................................................................................................... 1 050003-012 ............................ Screw ...................................................................................................... 1 27 ................... 792991 .................................... Microswitch (FKS) .................................................................................. 1 807541 .................................... Plate ....................................................................................................... 1 050006-001 ............................ Screw ...................................................................................................... 2 796231 .................................... Cable Assembly (only for Freezer/Corrosion) ...................................... 1 794590-001 ............................. Cable (only for Freezer/Corrosion) .................................................. 1 796230 .................................... Heater (only for Freezer/Corrosion) ................................................ 1 050004-042 ............................. Screw (only for Freezer/Corrosion) ................................................. 2 050008-011 ............................. Nut (only for Freezer/Corrosion) ...................................................... 2 28 ................... 807488 .................................... Switch ..................................................................................................... 1 29 ................... 055058-001 ............................ Puffer ...................................................................................................... 2 30 ................... 807681 .................................... Bracket ................................................................................................... 1 050009-008 ............................ Washer ................................................................................................... 2 050006-013 ............................ Screw ...................................................................................................... 2 807953 .................................... Valve Block (inclusive 1-5) .................................................................... 1 808080 .................................... Valve Assembly (inclusive 1-7, 10, 15, 18) .......................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.7-2140

REV. 2 10/02

169

TILT AND SIDESHIFT 5th Function Valve

MP-2140-019 MP-7.7-2140

M1.0-0000-000170 170

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

TILT AND SIDESHIFT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 064061-001 ............................ Adaptor ................................................................................................... 1 2 ..................... 064010-002 ............................ Branch Tee Coupling ............................................................................. 1 3 ..................... 808837 .................................... Pipe ........................................................................................................ 1 4 ..................... 808838 .................................... Pipe ........................................................................................................ 1 5 ..................... 064061-002 ............................ Adaptor ................................................................................................... 3 6 ..................... 054183-001 ............................ Adaptor ................................................................................................... 1 7 ..................... 807403 .................................... Valve Solenoid ....................................................................................... 1 8 ..................... 050007-012 ............................ Screw ...................................................................................................... 2 9 ..................... 808836 .................................... Bracket ................................................................................................... 1 10 ................... 050008-015 ............................ Nut .......................................................................................................... 2 11 ................... 050006-025 ............................ Screw ...................................................................................................... 2 12 ................... 793288 .................................... Clip ......................................................................................................... 1 13 ................... 050003-013 ............................ Screw ...................................................................................................... 1 14 ................... 050008-008 ............................ Nut .......................................................................................................... 1 15 ................... 808841 .................................... Pipe ........................................................................................................ 1 16 ................... 808865 .................................... Pipe ........................................................................................................ 1 17 ................... 808840 .................................... Bracket ................................................................................................... 1 18 ................... 050006-032 ............................ Screw ...................................................................................................... 2 19 ................... 054176-001 ............................ Adaptor ................................................................................................... 2 20 ................... 054171-002 ............................ Adaptor ................................................................................................... 2 21 ................... 054184-002 ............................ Adaptor (only for Quick Release Coupling) .......................................... 2 22 ................... 054185-002 ............................ Adaptor (only for Quick Release Coupling) .......................................... 2 808849 .................................... Valve Assembly (inclusive 5,6,7) .......................................................... 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.7-2140

171

TILT AND SIDESHIFT 6th Function Valve

MP-2140-026 MP-7.7-2140

M1.0-0000-000172 172

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

TILT AND SIDESHIFT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807403 .................................... Valve Solenoid ....................................................................................... 2 2 ..................... 064061-002 ............................ Elbow ...................................................................................................... 4 3 ..................... 064004-003 ............................ Adaptor ................................................................................................... 2 4 ..................... 054183-001 ............................ Adaptor ................................................................................................... 2 5 ..................... 050007-011 ............................ Screw ...................................................................................................... 4 6 ..................... 796725 .................................... Bracket ................................................................................................... 1 7 ..................... 050008-015 ............................ Nut .......................................................................................................... 6 8 ..................... 050006-024 ............................ Screw ...................................................................................................... 2 9 ..................... 796724 .................................... Bracket ................................................................................................... 1 10 ................... 050009-018 ............................ Washer ................................................................................................... 2 11 ................... 050006-032 ............................ Screw ...................................................................................................... 2 12 ................... 796728 .................................... T-Adaptor ................................................................................................ 2 13 ................... 064073-001 ............................ Adaptor ................................................................................................... 2 14 ................... 796727 .................................... Pipe ........................................................................................................ 1 15 ................... 064061-001 ............................ Elbow ...................................................................................................... 1 16 ................... 796726 .................................... Pipe ........................................................................................................ 1 17 ................... 064010-001 ............................ T-Adaptor ................................................................................................ 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.7-2140

173

LIFT BUFFER

M1631 MP-7.7-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 02/02 M1.0-0000-000174 174

LIFT BUFFER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806173 .................................... Stopper (inclusive 1, 3-7) ...................................................................... 1 806199 .................................... Stopper (inclusive 2-7) .......................................................................... 1 1 ........................... 806251 .................................... Bracket ............................................................................................. 1 2 ........................... 806259 .................................... Bracket ............................................................................................. 1 3 ........................... 806178 .................................... Rubber .............................................................................................. 2 4 ........................... 806177 .................................... Plunger ............................................................................................. 2 5 ........................... 050000-056 ............................. Pin ..................................................................................................... 2 6 ........................... 124018 .................................... Buffer ................................................................................................ 2 7 ........................... 050005-022 ............................. Screw ................................................................................................ 2 053050-006 ............................. Adhesive .......................................................................................... AR 8 ........................... 050006-074 ............................. Screw ................................................................................................ 4 053002-001 ............................. Grease .............................................................................................. AR

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.7-2140

REV. 1 02/02

175

FORK

M1578 MP-7.9-2140

M1.0-0000-000176 176

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

FORK INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Fork (see list) .......................................................................................... 2 2 ........................................................................ Handle Assembly (inclusive 2-5) .......................................................... 2 3 ........................................................................ Spring Compression .............................................................................. 2 4 ........................................................................ Pin .......................................................................................................... 2 5 ........................................................................ Detent ..................................................................................................... 2

1,4t/1,6t Fork Widht 40mm 1000mm

1067mm

1150mm

1220mm

1500mm

1600mm

803991-003-012

803991-009-01

803991-012-012

803991-007-01

803991-011-01

803991-010-01 Tab011gb

2.0t Fork Width 45mm 1000mm

1067mm

1150mm

1220mm

1500mm

1600mm

807596-001

807596-002

807596-003

807596-004

807596-005

807596-006 Tab018gb

1.4t,1.6t,2.0t Fork Width 50mm 1000mm

1067mm

1150mm

1220mm

1500mm

1600mm

796418-001-01

796418-002-01

796418-003-01

796418-004-01

796418-005-01

796418-006-01 Tab019gb

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.9-2140

REV. 1 10/02

177

LOAD BACKREST

M1577 MP-7.10-2140

M1.0-0000-000178 178

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

LOAD BACKREST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 806193-001 ............................ Load Backrest (Leg Width 1285/1425mm) ........................................... 1 806193-002 ............................ Load Backrest (Leg Width 1575mm) .................................................... 1 2 ..................... 050003-050 ............................ Screw ...................................................................................................... 4 Option

Load Backrest (Leg Width 1285/1425mm) 800mm

900mm

1000mm

1100mm

1200mm

1300mm

1400mm

1500mm

1600mm

1700mm

796175-019 796175-001 796175-002 796175-003 796175-004 796175-005 796175-006 796175-007 796175-008 796175-009 Tab020gb

Load Backrest (Leg Widht 1575mm) 800mm

900mm

1000mm

1100mm

1200mm

1300mm

1400mm

1500mm

1600mm

1700mm

796175-020 796175-010 796175-011 796175-012 796175-013 796175-014 796175-015 796175-016 796175-017 796175-018 Tab021gb

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.10-2140

179

YOKE

M1489 MP-7.11-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02 M1.0-0000-000180 180

YOKE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806269 .................................... Yoke ........................................................................................................ 1 1 ........................... 050012-065 ............................. Circlip ............................................................................................... 2 2 ........................... 806171 .................................... Washer ............................................................................................. 3 3 ........................... 119655-001 ............................. Pulley ................................................................................................ 2 4 ........................... 050012-009 ............................. Circlip ............................................................................................... 1 5 ........................... 806154 .................................... Shaft .................................................................................................. 1 6 ........................... 050000-003 ............................. Pin ..................................................................................................... 1 7 ........................... 806253 .................................... Yoke Bracket ..................................................................................... 1 8 ........................... 060030-085 ............................. Washer ............................................................................................. 2 9 ........................... 806155 .................................... Pulley ................................................................................................ 1 10 ......................... 127513-001 ............................. Pulley ................................................................................................ 1 11 ......................... 103349 .................................... Pulley ................................................................................................ 1 12 ......................... 050009-013 ............................. Washer ............................................................................................. 1 13 ......................... 050012-013 ............................. Circlip ............................................................................................... 1 14 ......................... 810283 .................................... Plate .................................................................................................. 1 15 ......................... 050003-021 ............................. Screw ................................................................................................ 1

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-7.11-2140

REV. 1 10/02

181

Page intentionally left blank

Printed in Germany

M1.0-0000-000182 182

SECTION 8

Printed in Germany

183

LIFT CYLINDER

M1490 MP-8.1-2140

M1.0-0000-000184 184

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806200-*** .............................. Lift Cylinder ø40 (1.4/1.6t) ..................................................................... 2 1 ........................... 806204-*** .............................. Cylinder Tube ................................................................................... 2 2* .......................... 804770 .................................... Guide Ring ....................................................................................... 4 3 ........................... 804710 .................................... Piston Button .................................................................................... 2 4 ........................... 804722-*** .............................. Piston Rod ........................................................................................ 2 5* .......................... 804767 .................................... Guide Ring ....................................................................................... 4 6* .......................... 804774 .................................... O-Ring .............................................................................................. 2 7 ........................... 807745 .................................... Cylinder Cap .................................................................................... 2 8* .......................... 804761 .................................... Seal ................................................................................................... 2 9* .......................... 804755 .................................... Wiper ................................................................................................ 2 10* ......................... 54173 ....................................... Seal ................................................................................................... 2 11 ......................... 54172 ....................................... Bleed Screw ..................................................................................... 2 12* ......................... 807748 .................................... Backup Ring ..................................................................................... 2 * ........................... 808531 .................................... Seal Kit (inclusive 2,5,6,8,9,10,12) .................................................. 1

Position 0

Position 1

Position 4

Collapsed Height

806200-001

806204-001

804722-011

2022mm

806200-002

806204-002

804722-012

2172mm

806200-003

806204-003

804722-013

2322mm

806200-004

806204-004

804722-014

2472mm

806200-005

806204-005

804722-015

2572mm

806200-006

806204-006

804722-016

2772mm

806200-007

806204-007

804722-017

2922mm

806200-008

806204-008

804722-018

3042mm

806200-009

806204-009

804722-019

3192mm

806200-010

806204-010

804722-020

3347mm

806200-011

806204-011

804722-021

3492mm

806200-012

806204-012

804722-022

3692mm

806200-013

806204-013

804722-023

3842mm

806200-014

806204-014

804722-024

3952mm Tab001gb

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-8.1-2140

185

LIFT CYLINDER

M1490 MP-8.1-2140

M1.0-0000-000186 186

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806201-*** .............................. Lift Cylinder ø45 (2.0t) ........................................................................... 2 1 ........................... 806205-*** .............................. Cylinder Tube ................................................................................... 2 2* .......................... 804768 .................................... Guide Ring ....................................................................................... 4 3 ........................... 806222 .................................... Piston Button .................................................................................... 2 4 ........................... 806208-*** .............................. Piston Rod ........................................................................................ 2 5* .......................... 804770 .................................... Guide Ring ....................................................................................... 4 6* .......................... 806232 .................................... O-Ring .............................................................................................. 2 7 ........................... 806218 .................................... Cylinder Cap .................................................................................... 2 8* .......................... 806224 .................................... Seal ................................................................................................... 2 9* .......................... 806226 .................................... Wiper ................................................................................................ 2 10* ......................... 54173 ....................................... Seal ................................................................................................... 2 11 ......................... 54172 ....................................... Bleed Screw ..................................................................................... 2 12* ......................... 807749 .................................... Backup Ring ..................................................................................... 2 * ........................... 808548 .................................... Seal Kit (inclusive 2,5,6,8,9,10,12) ................................................. 1

Position 0

Position 1

Position 4

Collapsed Height

806201-001

806205-001

806208-001

2022mm

806201-002

806205-002

806208-002

2172mm

806201-004

806205-004

806208-004

2472mm

806201-006

806205-006

806208-006

2772mm

806201-007

806205-007

806208-007

2922mm

806201-008

806205-008

806208-008

3042mm

806201-010

806205-010

806208-010

3347mm

806201-012

806205-012

806208-012

3692mm

806201-013

806205-013

806208-013

3842mm

806201-014

806205-014

806208-014

3952mm

806201-015

806205-015

806208-015

4252mm

806201-016

806205-016

806208-016

4452mm Tab002gb

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-8.1-2140

REV. 1 02/02

187

FREE LIFT CYLINDER

M1493 MP-8.2-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 02/02 M1.0-0000-000188 188

FREE LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 810047-*** .............................. Free Lift Cylinder ø56 (1.4/1.6t) ............................................................. 1 1 ........................... 810049-*** .............................. Cylinder Tube ................................................................................... 1 2 ........................... 806990 .................................... Hose Burst Valve .............................................................................. 1 3* .......................... 804772 .................................... Guide Ring ....................................................................................... 2 4 ........................... 804708 .................................... Piston Button .................................................................................... 1 5 ........................... 050012-066 ............................. Ring Retaining ................................................................................. 1 6 ........................... 806211 .................................... Piston Shut Off .................................................................................. 1 7 ........................... 806212 .................................... Spring ............................................................................................... 1 8 ........................... 806209-*** .............................. Piston Rod ........................................................................................ 1 9* .......................... 804769 .................................... Guide Ring ....................................................................................... 2 10* ......................... 804776 .................................... O-Ring .............................................................................................. 1 11 ......................... 807743 .................................... Cylinder Cap .................................................................................... 1 12* ......................... 804763 .................................... Seal ................................................................................................... 1 13* ......................... 804757 .................................... Wiper ................................................................................................ 1 14* ......................... 54173 ....................................... Seal ................................................................................................... 1 15 ......................... 54172 ....................................... Bleed Screw ..................................................................................... 1 16* ......................... 807746 .................................... Backup Ring ..................................................................................... 1 * ........................... 808549 .................................... Seal Kit (inclusive 3,9,10,12,13,14,16) .......................................... 1

Position 0

Position 1

Position 8

Collapsed Height

810047-001

810049-001

806209-001

2022mm

810047-002

810049-002

806209-002

2172mm

810047-003

810049-003

806209-003

2322mm

810047-004

810049-004

806209-004

2472mm

810047-005

810049-005

806209-005

2572mm

810047-006

810049-006

806209-006

2772mm

810047-007

810049-007

806209-007

2922mm

810047-008

810049-008

806209-008

3042mm

810047-009

810049-009

806209-009

3192mm

810047-010

810049-010

806209-010

3347mm

810047-011

810049-011

806209-011

3492mm

810047-012

810049-012

806209-012

3692mm

810047-013

810049-013

806209-013

3842mm

810047-014

810049-014

806209-014

3952mm Tab003gb

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-8.2-2140

REV. 1 02/02

189

FREE LIFT CYLINDER

M1492 MP-8.2-2140

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 1 02/02 M1.0-0000-000190 190

FREE LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 810048-*** .............................. Free Lift Cylinder ø65 (2.0t) ................................................................... 1 1 ........................... 810050-*** .............................. Cylinder Tube ................................................................................... 1 2 ........................... 806988 .................................... Hose Burst Valve .............................................................................. 1 3* .......................... 806230 .................................... Guide Ring ....................................................................................... 2 4 ........................... 806223 .................................... Piston Button .................................................................................... 1 5 ........................... 050012-066 ............................. Ring Retaining ................................................................................. 1 6 ........................... 806211 .................................... Piston Shut Off .................................................................................. 1 7 ........................... 806212 .................................... Spring ............................................................................................... 1 8 ........................... 806221-*** .............................. Piston Rod ........................................................................................ 1 9* .......................... 806231 .................................... Guide Ring ....................................................................................... 2 10* ......................... 806233 .................................... O-Ring .............................................................................................. 1 11 ......................... 806219 .................................... Cylinder Cap .................................................................................... 1 12* ......................... 806225 .................................... Seal ................................................................................................... 1 13* ......................... 806227 .................................... Wiper ................................................................................................ 1 14* ......................... 54173 ....................................... Seal ................................................................................................... 1 15 ......................... 54172 ....................................... Bleed Screw ..................................................................................... 1 16* ......................... 807747 .................................... Backup Ring ..................................................................................... 1 * ........................... 808550 .................................... Seal Kit (inclusive 3,9,10,12,13,14,16) .......................................... 1

Position 0

Position 1

Position 8

Collapsed Height

810048-001

810050-001

806221-001

2022mm

810048-002

810050-002

806221-002

2172mm

810048-004

810050-004

806221-004

2472mm

810048-006

810050-006

806221-006

2772mm

810048-007

810050-007

806221-007

2922mm

810048-008

810050-008

806221-008

3042mm

810048-010

810050-010

806221-010

3347mm

810048-012

810050-012

806221-012

3692mm

810048-013

810050-013

806221-013

3842mm

810048-014

810050-014

806221-014

3952mm

810048-015

810050-015

806221-015

4252mm

810048-016

810050-016

806221-016

4452mm Tab004gb

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-8.2-2140

REV. 1 02/02

191

CYLINDER REACH

M1483 MP-8.5-2140

M1.0-0000-000192 192

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

CYLINDER REACH INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806390-001 ............................ Cylinder Reach (1.4t/inclusive 1-16) ................................................... 1 806390-002 ............................ Cylinder Reach (1.6t-2.0tinclusive 1-16) ............................................. 1 1 ........................... 806398-001 ............................. Cylinder Tube (1.4t) .......................................................................... 1 806398-002 ............................. Cylinder Tube (1.6t-2.0t) .................................................................. 1 2 ........................... 807404 .................................... Bearing ............................................................................................. 1 3* .......................... 804766 .................................... Guide Ring ....................................................................................... 2 4* .......................... 807355 .................................... Piston Seal ....................................................................................... 1 5 ........................... 807304 .................................... Piston Rod ........................................................................................ 1 6* .......................... 804771 .................................... Guide Ring ....................................................................................... 2 7* .......................... 804774 .................................... O-Ring .............................................................................................. 1 8* .......................... 807343 .................................... Washer ............................................................................................. 1 9 ........................... 807305 .................................... End, Cap .......................................................................................... 1 10* ......................... 807356 .................................... Rod Seal .......................................................................................... 1 11* ......................... 807357 .................................... Wiper ................................................................................................ 1 12 ......................... 807407 .................................... Washer ............................................................................................. 1 13 ......................... 050008-069 ............................. Nut .................................................................................................... 1 14 ......................... 806402 .................................... Rod End ........................................................................................... 1 15 ......................... 064004-003 ............................. Adaptor ............................................................................................. 1 16* ......................... 807748 .................................... Backup Ring ..................................................................................... 1 17 ......................... 806805-001 ............................. Spacer (183mm) .............................................................................. 1 806805-002 ............................. Spacer (255mm) .............................................................................. 1 806805-003 ............................. Spacer (83mm) ................................................................................. 1 806805-004 ............................. Spacer (155mm) .............................................................................. 1 806805-005 ............................. Spacer (227mm) .............................................................................. 1 18 ......................... 806810 .................................... O-Ring .............................................................................................. 2 * ........................... 808551 .................................... Seal Kit (inclusive 3,4,6,7,8,10,11,16) ............................................ 1

Position 17

420Ah

560Ah

700Ah

820Ah

1.4t.

----

806805-001

806805-002

----

1.6t.

----

806805-003

806805-004

806805-005

2.0t.

N/A

806805-003

806805-004

806805-005 Tab017

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-8.5-2140

REV. 1 02/02

193

Page intentionally left blank

Printed in Germany

M1.0-0000-000194 194

SECTION 10

Printed in Germany

195

LABELS AND DECALS

MP-2140-007 MP-10.9-2140

M1.0-0000-000196 196

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

LABELS AND DECALS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 106158-001 ............................ Decal Crown Heavy .............................................................................. 1 2 ..................... 106158-003 ............................ Decal Crown Heavy .............................................................................. 2 3 ..................... 106158-011 ............................ Decal Crown Heavy .............................................................................. 2 4 ..................... 869009-*** .............................. Warning Stand On ................................................................................. 1 5 ..................... 869010-*** .............................. Warning Stand Under ............................................................................ 1 6 ..................... 869104-*** .............................. Warning Moving Mast ............................................................................ 1 7 ..................... 869004-*** .............................. Warning Moving Vehicle ........................................................................ 1 8 ..................... 796331 .................................... Label Wheel Torque .............................................................................. 1 9 ..................... 869005-*** .............................. Warning Rider Truck .............................................................................. 1 10 ................... 869006 .................................... Warning Hands Off ................................................................................ 2 11 ................... 869012-*** .............................. Warning Electrical Additions ................................................................. 1 12 ................... 69154 ...................................... Label Hydraulic Oil ................................................................................ 1 13 ................... 869274-*** .............................. Label Capacity Data .............................................................................. 1 14 ................... 869020-*** .............................. Danger Battery ....................................................................................... 1 15 ................... 869047-*** .............................. Caution, Charger Hook Up .................................................................... 1 *** ................... xxxxxx-001 .............................. German xxxxxx-002 .............................. French xxxxxx-003 .............................. Spanish xxxxxx-004 .............................. Dutch xxxxxx-005 .............................. Italien xxxxxx-006 .............................. English

Always Specify Model & Serial Number MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

MP-10.9-2140

197

Page intentionally left blank

Printed in Germany

M1.0-0000-000198 198

CROWN Gabelstapler GmbH & Co. KG - European Headquarter Moosacher Str. 52 80809 Munich Germany Telephone +49 (0)89 93 00 2 - 0 Telefax +49 (0)89 93 00 2 -175 or -133

Printed in Germany • Revision Level C Order Number: 812674-006