Crown Forklift WD2300S Series Parts Manual

Parts Manual

WD2300S Series Printed in Germany ● Revision Level A Order Number: 812712-006

This master manual is subject to continual updates.

It is meant exclusively for businesses authorized by CROWN. It is not permitted to pass on the contents or copies thereof to third parties.

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

All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2002 CROWN Equipment Corporation

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

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General ................................................................................. 7

SECTION 1 – COVERS

PAGE

Covers................................................................................... 12, 14 Caster Wheel ........................................................................ 16

SECTION 2 – HYDRAULIC PART

PAGE

Tube-/Hose Layout ................................................................ 20, 22

SECTION 3 – DRIVE UNIT

PAGE

Drive Unite ............................................................................ 26 Gearbox ................................................................................. 28 Drive Motor ........................................................................... 30 Knuckel ................................................................................. 32

SECTION 4 – ELECTRICAL

PAGE

Electrical Parts ..................................................................... 36, 38, 40 Contactor .............................................................................. 42 Control Handle ...................................................................... 44, 46 Emergency Disconnect/Battery Connector .......................... 48 Instrument ............................................................................. 50 Horn ...................................................................................... 52

SECTION5 – BRAKE SYSTEM

PAGE

Brake ..................................................................................... 56

SECTION 7 – MAST-/LIFT STRUCTURE

PAGE

Mast ...................................................................................... 60 Fork Carriage ........................................................................ 62 Mast Safty Screen ................................................................ 64 Lift Structure ......................................................................... 66 Load Backrest ....................................................................... 68

SECTION 8 – CYLINDER

PAGE

Lift Cylinder ........................................................................... 72 Free Lift Cylinder ................................................................... 74

SECTION 9 – CABIN/PLATFORM

PAGE

Platform ................................................................................. 78,80

MP-WD2300S-GB 02/05 • Printed in Germany

MP-IDX-3400

M1.0-0000-0003 33

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Printed in Germany

4

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 & CoKG 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-WD2300S-GB 02/05 • Printed in Germany

M/P-ITD-3400

M1.0-0000-0007 77

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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 Part 1-2

7 8 9

10

2

11

12 4 5

3

5

6

Power Unit

6

1

MP-3300-009 MP-1.0-3400

12M1.0-0000-00012

MP-WD2300S-GB 02/05 • Printed in Germany

COVERS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807575 ..................................... Cover ...................................................................................................... 1 2 ..................... 807379 ..................................... Cover ...................................................................................................... 1 3 ..................... 050009-020 .............................. Washer ................................................................................................... 9 4 ..................... 050068-003 .............................. Nut .......................................................................................................... 9 5 ..................... 804863-007 .............................. Cage Nut ................................................................................................. 5 6 ..................... 050003-035 .............................. Screw ...................................................................................................... 5 7 ..................... 807380 ..................................... Cover ...................................................................................................... 1 8 ..................... 816156 ..................................... Key Switch Assembly ............................................................................. 1 803678-012 .............................. Terminal tabs ........................................................................................... 2 9 ..................... 109127-003 .............................. Clip Arrow (red) ....................................................................................... 1 10 .................... 109127-001 .............................. Clip Arrow (green) ................................................................................... 1 11 .................... 050009-013 .............................. Washer ................................................................................................... 5 12 .................... 050006-024 .............................. Screw ...................................................................................................... 5

807574 ..................................... Cover Assembly (included 1 - 4) ............................................................ 1 807651 ..................................... Cover Assembly (included 7 - 10) .......................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-1.0-3400

13

COVERS Part 2-2

1

2

3

9 8

7 13 10

4

11 5

6

7 12

6 14 18

15

17 16

Forke Carriage Frame

16

MP-3300-010 MP-1.0-3400

14M1.0-0000-00014

MP-WD2300S-GB 02/05 • Printed in Germany

COVERS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 815456 ..................................... Cover Assembly ..................................................................................... 1 815270 ..................................... Rubber Pad ....................................................................................... 3 2 ..................... 805814 ..................................... Spring ..................................................................................................... 1 3 ..................... 805845 ..................................... Bracket ................................................................................................... 1 4 ..................... 050006-020 .............................. Screw ...................................................................................................... 2 5 ..................... 813614 ..................................... Hinge ....................................................................................................... 1 6 ..................... 050003-065 .............................. Screw ...................................................................................................... 4 7 ..................... 050068-002 .............................. Nut .......................................................................................................... 4 8 ..................... 813617 ..................................... Hinge ....................................................................................................... 1 9 ..................... 813613 ..................................... Lock ........................................................................................................ 1 10 .................... 050000-014 .............................. Roll Pin ................................................................................................... 1 11 .................... 813625 ..................................... Retainer .................................................................................................. 1 12 .................... 050025-008 .............................. Screw ...................................................................................................... 2 13 .................... 050068-003 .............................. Nut .......................................................................................................... 2 14 .................... 815132 ..................................... Bracket ................................................................................................... 1 15 .................... 050005-040 .............................. Screw ...................................................................................................... 2 16 .................... 804681 ..................................... Bearing ................................................................................................... 10 17 .................... 804207 ..................................... Roller ...................................................................................................... 5 18 .................... 813648 ..................................... Axle ......................................................................................................... 5

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-1.0-3400

15

CASTER WHEEL

Power Unit

5 6

1

11 2

10 8

9 3 8

7

4

7

MP-3300-007 MP-1.5-3400

16M1.0-0000-00016

MP-WD2300S-GB 02/05 • Printed in Germany

CASTER WHEEL INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 811797 ..................................... Plate ........................................................................................................ 2 2 ..................... 050012-040 .............................. Ring, Retaining ....................................................................................... 2 3 ..................... 055002-019 .............................. Bearing Ball ............................................................................................. 2 4 ..................... 050012-041 .............................. Ring, Retaining ....................................................................................... 2 5 ..................... 811796 ..................................... Accommodation ...................................................................................... 2 6 ..................... 812240 ..................................... Screw ...................................................................................................... 2 7 ..................... 811799 ..................................... Bush ........................................................................................................ 4 8 ..................... 811800 ..................................... String Guard ............................................................................................ 4 9 ..................... 811802 ..................................... Wheel ...................................................................................................... 2 10 .................... 050008-082 .............................. Nut .......................................................................................................... 2 11 .................... 050005-032 .............................. Screw ...................................................................................................... 8

811804 ..................................... Accommodation Assembly (inclusive 1-5) .............................................. 2 811805 ..................................... Caster Wheel Assembly (inclusive 1-10) ................................................ 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-1.5-3400

17

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Printed in Germany

18M1.0-0000-00018

SECTION 2

Printed in Germany

19

TUBE/HOSE LAYOUT Part 1-2

31

1

28 7 31

26

35 29 34 2

9

30 5

27 37

32

10

36 4 5

33 9

44

6

38

10

3

5 Power Unit

19

21 18

26 39 42

8

20

17 25

40 22 43 24 16 42

23

15 13

14

12

41

11

MP-3400-020 MP-2.1-3400

20M1.0-0000-00020

MP-WD2300S-GB 02/05 • Printed in Germany

TUBE/HOSE LAYOUT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Cylinder (see Section 8.4) ...................................................................... 1 2 ..................... 064004-004 .............................. Adaptor ................................................................................................... 1 3 ..................... 813634 ..................................... Tube ........................................................................................................ 1 4 ..................... 050067-022 .............................. Screw ...................................................................................................... 1 5 ..................... 803927-003 .............................. Clamp ...................................................................................................... 3 6 ..................... 050009-018 .............................. Washer ................................................................................................... AR 7 ..................... 813632 ..................................... Hose ....................................................................................................... 1 052084-009 .............................. Spiral Hose ............................................................................................. 1 8 ..................... 813633 ..................................... Tube ........................................................................................................ 1 9 ..................... 050003-031 .............................. Screw ...................................................................................................... 2 10 .................... 050068-003 .............................. Nut .......................................................................................................... 2 11 .................... 815262 ..................................... Hose ....................................................................................................... 1 12 .................... 064071-001 .............................. T-Connector ............................................................................................ 1 13 .................... 064065-002 .............................. Elbow ...................................................................................................... 1 14 .................... 810017 ..................................... Test Port .................................................................................................. 1 15 .................... 050011-017 .............................. Seal ......................................................................................................... 1 16 .................... 810059 ..................................... Pressure Switch ..................................................................................... 1 17 .................... 815452 ..................................... Valve Assembly (included 18 & 19) ........................................................ 1 18 .......................... 809687 ..................................... Solenoid Valve ................................................................................... 1 809688 ..................................... Coil .................................................................................................... 1 19 .......................... 809686 ..................................... Solenoid Valve ................................................................................... 1 809688 ..................................... Coil .................................................................................................... 1 20 .................... 813654 ..................................... Bracket ................................................................................................... 1 21 .................... 050007-014 .............................. Screw ...................................................................................................... 2 22 .................... 050008-015 .............................. Nut .......................................................................................................... 2 23 .................... 050025-008 .............................. Screw ...................................................................................................... 2 24 .................... 050073-003 .............................. Spring Nut ............................................................................................... 2 25 .................... 050068-003 .............................. Nut .......................................................................................................... 2 26 .................... 064061-002 .............................. Elbow ...................................................................................................... 2 27 .................... 815261 ..................................... Tube ........................................................................................................ 1 28 .................... 814924 ..................................... Valve Assembly ...................................................................................... 1 809689 ..................................... Solenoid Valve ................................................................................... 1 809688 ..................................... Coil .................................................................................................... 1 29 .................... 053062-001 .............................. Adaptor ................................................................................................... 1 30 .................... 054174-001 .............................. Elbow ...................................................................................................... 1 31 .................... 811845-001 .............................. Motor Assembly ...................................................................................... 1 811845-300 .............................. Motor Brush Kit ................................................................................. 1 811845-301 .............................. Motor Brush Holder & Brush Kit ........................................................ 1 811845-101 .............................. Headband .......................................................................................... 1 32 .................... 811845-100 .............................. Motor Coupler ......................................................................................... 1 33 .................... 809678 ..................................... Pump & Flange ....................................................................................... 1 34 .................... 809700 ..................................... Check Valve ............................................................................................ 1 35 .................... 805280 ..................................... Relief Valve ............................................................................................. 1 36 .................... 809721 ..................................... O-Ring .................................................................................................... 2 37 .................... 809683 ..................................... Proportional Valve Assembly .................................................................. 1 809684 ..................................... Coil .................................................................................................... 1 38 .................... 809685 ..................................... Screw ...................................................................................................... 4 39 .................... 809724 ..................................... Suction Line Assembly ........................................................................... 1 40 .......................... 809681 ..................................... O-Ring ............................................................................................... 1 41 .................... 809679 ..................................... Tank Assembly (include 40 & 42) ........................................................... 1 42 .......................... 809682 ..................................... Elbow + Filler Cap ............................................................................. 1 43 .................... 815264 ..................................... Filler Sleeve ............................................................................................ 1 44 .................... 050003-043 .............................. Screw ...................................................................................................... 2

815451 ..................................... Hydraulic Power Pack Assembly (included 31 - 42) ............................... 1 053001-003 .............................. Hydraulic Oil ........................................................................................... AR 053001-009 .............................. Hydraulic Oil (Freezer/Corrosion) ........................................................... AR

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-2.1-3400

21

TUBE/HOSE LAYOUT Part 2-2 6

6

3

4

7 8 9

4

10

3 8

7

9 5 11 Power Unit

2

14 15

5

12

13

16

1

MP-3400-022 MP-2.1-3400

22M1.0-0000-00022

MP-WD2300S-GB 02/05 • Printed in Germany

TUBE/HOSE LAYOUT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 064071-001 .............................. T-Connector ............................................................................................ 1 2 ..................... 815263 ..................................... Hose ....................................................................................................... 1 3 ..................... 064061-002 .............................. Elbow ...................................................................................................... 2 4 ........................................................................ Cylinder (see Section 8.4) ...................................................................... 2 5 ..................... 805704 ..................................... Clamp ...................................................................................................... 2 6 ..................... 050000-027 .............................. Pin ........................................................................................................... 2 7 ..................... 064009-002 .............................. T-Connector ............................................................................................ 2 8 ..................... 810017 ..................................... Test Port .................................................................................................. 2 9 ..................... 050011-017 .............................. Seal ......................................................................................................... 2 10 .................... 810059 ..................................... Pressure Switch ..................................................................................... 1 11 .................... 815453 ..................................... Pressure Switch ..................................................................................... 1 12 .................... 054165-013 .............................. Hose ....................................................................................................... 1 13 .................... 054160-004 .............................. Adaptor ................................................................................................... 1 14 .................... 807989 ..................................... Bracket ................................................................................................... 1 15 .................... 050067-022 .............................. Screw ...................................................................................................... 1 16 .................... 815260 ..................................... Tube ........................................................................................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-2.1-3400

23

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Printed in Germany

24M1.0-0000-00024

SECTION 3

Printed in Germany

25

DRIVE UNIT

1

27 Power Unit

2

26

3

4

19

A

12 5 9

10

11

21

4 11

7/C

10 12

8 13

8

9

24

20

25 22 23

16

18

7/B

A

6

17 17 18

16

14

13

15

MP-3400-007 MP-3.0-3400

26M1.0-0000-00026

MP-WD2300S-GB 02/05 • Printed in Germany

DRIVE UNIT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050006-075 .............................. Screw ...................................................................................................... 2 2 ..................... 050008-065 .............................. Nut .......................................................................................................... 2 3 ..................... 807255 ..................................... Spinner ................................................................................................... 1 4 ..................... 807243 ..................................... Pin ........................................................................................................... 8 5 ..................... 807274 ..................................... Spring ..................................................................................................... 4 6 ..................... 807256 ..................................... Cage ....................................................................................................... 1 7 ..................... N/A ........................................... Ledge ...................................................................................................... 2 8 ..................... 050067-024 .............................. Screw ...................................................................................................... 4 9 ..................... 810584 ..................................... Sleeve Nut .............................................................................................. 4 10 .................... 050008-026 .............................. Nut .......................................................................................................... 4 11 .................... 050017-019 .............................. Screw ...................................................................................................... 4 12 .................... 054011-007 .............................. Grease Nipple ......................................................................................... 2 13 .................... 808473 ..................................... Plate ........................................................................................................ 4 14 .................... 050017-013 .............................. Screw ...................................................................................................... 2 15 .................... 811697 ..................................... Sheet ....................................................................................................... 1 16 .................... 811698 ..................................... Sheet ....................................................................................................... 2 17 .................... 050009-003 .............................. Washer ................................................................................................... 4 18 .................... 050008-001 .............................. Nut .......................................................................................................... 4 19 .................... 807657 ..................................... Drive Unit Assembly (see next Page’s) ................................................... 1 20 .................... 050005-044 .............................. Screw ...................................................................................................... 2 21 .................... 807588 ..................................... Stop ......................................................................................................... 2 22 .................... 050068-004 .............................. Nut .......................................................................................................... 2 23 .................... 805961-001 .............................. Drive Tyre (Vulkollan) .............................................................................. 1 805961-002 .............................. Drive Tyre (Rubber) ................................................................................. 1 24 .................... 050062-002 .............................. Nut .......................................................................................................... 5 25 .................... 050006-054 .............................. Screw ...................................................................................................... 5 053050-006 .............................. Adhesive ................................................................................................. AR 26 .................... 804676-003 .............................. Brake Assembly (see Section 5) ............................................................ 1 27 .................... 050005-082 .............................. Screw ...................................................................................................... 3 050009-012 .............................. Washer ................................................................................................... 3

7/B ................... 807277-001 .............................. Ledge Assembly (included 7, 9, 12, 14) .................................................. 1 7/C ................... 807277-002 .............................. Ledge Assembly (included 7, 9, 12, 14) .................................................. 1

053002-001 .............................. Grease .................................................................................................... AR 053002-005 .............................. Grease (Freezer/Corrosion) .................................................................... AR

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-3.0-3400

27

GEARBOX

M1558 MP-3.1-3400

28M1.0-0000-00028

MP-WD2300S-GB 02/05 • Printed in Germany

GEARBOX INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807658 ..................................... Drive Unit ................................................................................................ 1 1 ........................... 805161 ..................................... Turntable ............................................................................................ 1 2 ........................... 805162 ..................................... Transmission Housing ....................................................................... 1 805163 ..................................... Screw ................................................................................................ 1 3 ........................... 805164 ..................................... Washer .............................................................................................. 11 4 ........................... 805165 ..................................... Screw ................................................................................................ 2 5 ........................... 805166 ..................................... Screw ................................................................................................ 9 6 ........................... 805167 ..................................... Gear .................................................................................................. 1 7 ........................... 805168 ..................................... Shim (0,1/0,3/0,5mm) ........................................................................ 1 805169 ..................................... Shim (0,15mm) .................................................................................. 1 8 ........................... 805170 ..................................... Bearing .............................................................................................. 1 9 ........................... 805171 ..................................... Bearing .............................................................................................. 1 10 .......................... 805172 ..................................... Gear .................................................................................................. 1 11 .......................... 805173 ..................................... Nut ..................................................................................................... 1 12 .......................... 805174 ..................................... Gear .................................................................................................. 1 13 .......................... 805175 ..................................... Bushing ............................................................................................. 1 14 .......................... 805176 ..................................... Shim (0,1/0,3/0,5mm) ........................................................................ 1 805177 ..................................... Shim (0,15mm) .................................................................................. 1 15 .......................... 805178 ..................................... Bearing .............................................................................................. 1 16 .......................... 805179 ..................................... Ring, Retainig .................................................................................... 1 17 .......................... 805180 ..................................... Seal ................................................................................................... 1 18 .......................... 805181 ..................................... Wheel Shaft ....................................................................................... 1 19 .......................... 805182 ..................................... Stud Wheel ........................................................................................ 5 20 .......................... 805183 ..................................... Bearing .............................................................................................. 1 21 .......................... 805184 ..................................... Shim .................................................................................................. 1 22 .......................... 805185 ..................................... Washer .............................................................................................. 1 23 .......................... 805186 ..................................... Screw ................................................................................................ 1 24 .......................... 805187 ..................................... O-Ring ............................................................................................... 1 25 .......................... 805188 ..................................... Gearbox Cover .................................................................................. 1 805189 ..................................... Screw ................................................................................................ 8 805190 ..................................... Washer .............................................................................................. 8 805191 ..................................... Magnetic Screw ................................................................................ 1 805192 ..................................... O-Ring ............................................................................................... 1

053002-004 .............................. Transmission Oil ..................................................................................... AR 053002-009 .............................. Transmission Oil (Freezer/Corrosion) ..................................................... AR

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-3.1-3400

29

DRIVE MOTOR

M1557 MP-3.2-3400

30M1.0-0000-00030

MP-WD2300S-GB 02/05 • Printed in Germany

DRIVE MOTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807659 ..................................... Drive Motor ............................................................................................. 1 1 ........................... 805193 ..................................... Ring Retaining ................................................................................... 2 2 ........................... 805194 ..................................... Bushing ............................................................................................. 1 3 ........................... 805195 ..................................... Washer .............................................................................................. 1 4 ........................... 805196 ..................................... Motor End Cover ............................................................................... 1 5 ........................... 805197 ..................................... Washer .............................................................................................. 8 6 ........................... 805198 ..................................... Screw ................................................................................................ 8 7 ........................... 805199 ..................................... Headband .......................................................................................... 1 8 ........................... 805200 ..................................... Brush Box ......................................................................................... 1 9 ........................... 805201 ..................................... Screw ................................................................................................ 2 10 .......................... 805202 ..................................... Nut ..................................................................................................... 2 11 .......................... 805203 ..................................... Brush ................................................................................................. 4 12 .......................... 805204 ..................................... Washer .............................................................................................. 1 13 .......................... 805205 ..................................... Bearing Ball ....................................................................................... 1 14 .......................... 805206 ..................................... Ring Retaining ................................................................................... 1 15 .......................... 805207 ..................................... Field Coil ........................................................................................... 1 16 .......................... 805208 ..................................... Pole Shoe .......................................................................................... 1 17 .......................... 805209 ..................................... Armature ........................................................................................... 1 18 .......................... 805210 ..................................... Key .................................................................................................... 1 19 .......................... 805211 ..................................... Woodruff Key ..................................................................................... 1 20 .......................... 805212 ..................................... Seal ................................................................................................... 1 21 .......................... 805213 ..................................... Ring Retaining ................................................................................... 1 22 .......................... 805214 ..................................... Bearing Ball ....................................................................................... 1 23 .......................... 805215 ..................................... Bushing ............................................................................................. 1 24 .......................... 805216 ..................................... O-Ring ............................................................................................... 1 25 .......................... 805217 ..................................... Ring Retaining ................................................................................... 1 26 .......................... 805218 ..................................... Nut ..................................................................................................... 1 27 .......................... 805219 ..................................... Motor Housing ................................................................................... 1 805220 ..................................... Insulating Paper ................................................................................. 1 28 .......................... 805221 ..................................... Washer .............................................................................................. 8 29 .......................... 805222 ..................................... Screw ................................................................................................ 8 30 .......................... 805223 ..................................... Terminal Strip .................................................................................... 2 31 .......................... 805224 ..................................... Screw ................................................................................................ 4 32 .......................... 805225 ..................................... Washer .............................................................................................. 8 33 .......................... 805226 ..................................... Nut ..................................................................................................... 4 34 .......................... 805227 ..................................... Bushing ............................................................................................. 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-3.2-3400

31

KNUCKLE 7

9

8

7 11 12

10 20

6

13

3

4 2

5

14

1 18

15 16

17

19

MP-3400-008 MP-3.3-3400

32M1.0-0000-00032

MP-WD2300S-GB 02/05 • Printed in Germany

KNUCKLE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807512 ..................................... Knuckle (Base) ....................................................................................... 1 2 ..................... 805943 ..................................... Knuckle ................................................................................................... 1 3 ..................... 050005-023 .............................. Screw ...................................................................................................... 4 4 ..................... 803619-001 .............................. Switch ..................................................................................................... 1 803310 ..................................... Actuator .................................................................................................. 1 5 ..................... 050008-004 .............................. Nut .......................................................................................................... 2 6 ..................... 050004-034 .............................. Screw ...................................................................................................... 2 7 ..................... 803353 ..................................... Spacer .................................................................................................... 2 8 ..................... 803013 ..................................... Spring ..................................................................................................... 2 9 ..................... 808039-001 .............................. Axle ......................................................................................................... 1 808039-002 .............................. Axle (Freezer/Corrosion) ........................................................................ 1 10 .................... 050000-015 .............................. Roll Pin ................................................................................................... 1 11 .................... 803651 ..................................... Damper ................................................................................................... 1 12 .................... 050005-002 .............................. Screw ...................................................................................................... 2 13 .................... 807515 ..................................... Cover ...................................................................................................... 1 14 .................... 050003-020 .............................. Screw ...................................................................................................... 2 15 .................... 045234 ..................................... Cable Protection ..................................................................................... 1 16 .................... 807561 ..................................... Plate ........................................................................................................ 1 17 .................... 050005-011 .............................. Screw ...................................................................................................... 2 18 .................... 050005-082 .............................. Screw ...................................................................................................... 3 19 .................... 050005-080 .............................. Screw ...................................................................................................... 3 20 .................... 050009-021 .............................. Washer (0,5 mm) .................................................................................... AR 050009-022 .............................. Washer (1,0 mm) .................................................................................... AR 050009-023 .............................. Washer (1,5 mm) .................................................................................... AR

808906 ..................................... Knuckle Assembly (included 2, 4, 5, 6, 11, 12) ....................................... 1

053002-001 .............................. Grease .................................................................................................... AR 053002-005 .............................. Grease (Freezer/Corrosion) .................................................................... AR

not illustrated 061002-005 .............................. Clamp ...................................................................................................... 1 050006-014 .............................. Screw ...................................................................................................... 1 050068-001 .............................. Nut .......................................................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-3.3-3400

33

Page intentionally left blank

Printed in Germany

34M1.0-0000-00034

SECTION 4

Printed in Germany

35

ELECTRICAL PARTS

M1610 MP-4.0-3400

36M1.0-0000-00036

MP-WD2300S-GB 02/05 • Printed in Germany

ELECTRICAL PARTS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 803450-001 .............................. Socket Housing 2 way ............................................................................ AR 803450-002 .............................. Socket Housing 4 way ............................................................................ AR 803450-003 .............................. Socket Housing 6 way ............................................................................ AR 803450-004 .............................. Socket Housing 8 way ............................................................................ AR 803450-014 .............................. Socket Housing 16 way .......................................................................... AR 2 ..................... 803450-010 .............................. Socket Insert AWG 18 ............................................................................ AR 803450-011 .............................. Socket Insert AWG 24 ............................................................................ AR 3 ..................... 803450-005 .............................. Socket Housing 2 way ............................................................................ AR 803450-006 .............................. Socket Housing 4 way ............................................................................ AR 803450-007 .............................. Socket Housing 6 way ............................................................................ AR 803450-008 .............................. Socket Housing 8 way ............................................................................ AR 803450-015 .............................. Socket Housing 10 way .......................................................................... AR 803450-009 .............................. Socket Housing 12 way .......................................................................... AR 116851 ..................................... Socket Housing 16 way .......................................................................... AR 803450-013 .............................. Socket Housing 24 way .......................................................................... AR 4 ..................... 116858 ..................................... Socket Insert AWG 18 ............................................................................ AR 803450-012 .............................. Socket Insert AWG 24 ............................................................................ AR 5 ..................... 803450-016 .............................. Socket Housing 3 way ............................................................................ AR 803450-017 .............................. Socket Housing 6 way ............................................................................ AR 803450-018 .............................. Socket Housing 8 way ............................................................................ AR 6 ..................... 803450-013 .............................. Socket Insert AWG 18 ............................................................................ AR TOOLS (not shown) 117615 ..................................... Extaction ................................................................................................. 1 117636 ..................................... Crimping .................................................................................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-4.0-3400

37

ELECTRICAL PARTS Part 1-2

1

11

13

2

17

16

12 9 11 5

15

8

4

14 10 24 18

23

6 20

3 7

18

19

22

20 18 25

29

26

18 28 21

34

36

37

39

30

27

38 45

32 42

41

40 46

35

41

33

40

31

43 44

MP-3400-018 MP-4.1-3400

38M1.0-0000-00038

MP-WD2300S-GB 02/05 • Printed in Germany

ELECTRICAL PARTS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050006-024 .............................. Screw ...................................................................................................... 2 050009-013 .............................. Washer ................................................................................................... 2 2 ..................... 816050 ..................................... Module .................................................................................................... 1 3 ..................... 813659 ..................................... Plate ........................................................................................................ 1 4 ..................... 050008-015 .............................. Nut .......................................................................................................... 2 050073-002 .............................. Spring Nut ............................................................................................... 2 5 ..................... 050006-011 .............................. Screw ...................................................................................................... 2 050009-007 .............................. Washer ................................................................................................... 2 6 ..................... 805818 ..................................... Spacer .................................................................................................... 2 7 ..................... 807549 ..................................... Plate ........................................................................................................ 1 8 ..................... 050067-023 .............................. Screw ...................................................................................................... 2 9 ..................... 065004-006 .............................. Grommet ................................................................................................. 1 10 .................... 050025-015 .............................. Screw ...................................................................................................... 1 11 .................... 050082-001 .............................. Washer ................................................................................................... 2 12 .................... 061002-006 .............................. Clamp ...................................................................................................... 1 13 .................... 050008-008 .............................. Nut .......................................................................................................... 1 14 .................... 050005-003 .............................. Screw ...................................................................................................... 2 15 .................... 131011 ..................................... Diode Block ............................................................................................. 1 16 .................... 050008-001 .............................. Nut .......................................................................................................... 2 17 .................... 050025-015 .............................. Screw ...................................................................................................... 2 18 .................... 815757 ..................................... Controller ................................................................................................ 1 053051-008 .............................. Heate Paste ............................................................................................ AR 19 .................... 050068-001 .............................. Nut .......................................................................................................... 4 20 .................... 052065-001 .............................. Power Cable ............................................................................................ 2 21 .................... 052065-058 .............................. Power Cable ............................................................................................ 1 22 .................... 052065-039 .............................. Power Cable ............................................................................................ 1 23 .................... 807636-001 .............................. Fieldcable ................................................................................................ 1 24 .................... 807636-002 .............................. Fieldcable ................................................................................................ 1 25 .................... 813661 ..................................... Plate ........................................................................................................ 1 26 .................... 050071-035 .............................. Screw ...................................................................................................... 2 27 .................... 050004-010 .............................. Screw ...................................................................................................... 4 28 .................... 807649 ..................................... Plate ........................................................................................................ 1 29 .................... 805752 ..................................... Fuse Holder ............................................................................................ 2 30 .................... 805751-001 .............................. Fuse ........................................................................................................ 1 805751-002 .............................. Fuse (Freezer/Corrosion) ....................................................................... 1 31 ....................................................................... Contactor (see section 4.4) ..................................................................... 2 32 .................... 050004-038 .............................. Screw ...................................................................................................... 4 33 .................... 052065-059 .............................. Power Cable ............................................................................................ 1 34 .................... 805824 ..................................... Fuse Holder ............................................................................................ 2 35 .................... 050004-022 .............................. Screw ...................................................................................................... 4 36 .................... 050009-016 .............................. Washer ................................................................................................... 4 37 .................... 050068-001 .............................. Nut .......................................................................................................... 4 38 .................... 812284 ..................................... Bus Bar ................................................................................................... 1 39 .................... 052051-020 .............................. Power Cable (SBE 160) .......................................................................... 1 052051-060 .............................. Power Cable (LB DIN 43589) .................................................................. 1 40 .................... 050008-051 .............................. Nut .......................................................................................................... 8 41 .................... 054152-003 .............................. Washer ................................................................................................... 8 42 .................... 802816-005 .............................. Fuse ........................................................................................................ 2 43 .................... 052065-014 .............................. Power Cable ............................................................................................ 1 44 .................... 052065-024 .............................. Power Cable ............................................................................................ 1 45 .................... 816177 ..................................... Hydraulic Control Module ........................................................................ 1 46 .................... 050007-009 .............................. Screw ...................................................................................................... 2

not illustrated 813845 ..................................... Main Harness .......................................................................................... 1 061002-009 .............................. Clamp ...................................................................................................... 2 050025-015 .............................. Screw ...................................................................................................... 2 050068-001 .............................. Nut .......................................................................................................... 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-4.1-3400

39

ELECTRICAL PARTS Part 2-2 4

1

5 6

3 7 2

9 10

8 17 16

15

Power Unit

18 12 14 13

OuterMast 22

23

11 19

21

20

MP-3400-019 MP-4.1-3400

40M1.0-0000-00040

MP-WD2300S-GB 02/05 • Printed in Germany

ELECTRICAL PARTS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050067-012 .............................. Screw ...................................................................................................... 2 2 ..................... 815446 ..................................... Bracket ................................................................................................... 1 3 ..................... 050004-034 .............................. Screw (Lift Height 1700 mm) ................................................................... 2 050004-035 .............................. Screw (Lift Height 2100 mm) ................................................................... 2 4 ..................... 803619-001 .............................. Switch ..................................................................................................... AR 803310 ..................................... Actuator .................................................................................................. AR 5 ..................... 050008-004 .............................. Nut .......................................................................................................... 2 6 ..................... 815447 ..................................... Cover ...................................................................................................... 1 7 ..................... 050071-012 .............................. Screw ...................................................................................................... 2 8 ..................... 815448-001 .............................. Tube (Lift Height 1700 mm) ..................................................................... 1 815448-002 .............................. Tube (Lift Height 2100 mm) ..................................................................... 1 9 ..................... 050009-054 .............................. Washer ................................................................................................... 2 10 .................... 050068-003 .............................. Nut .......................................................................................................... 2 11 .................... 050025-004 .............................. Screw ...................................................................................................... 2 12 .................... 805757 ..................................... Bracket ................................................................................................... 1 13 .................... 050073-002 .............................. Spring Nut ............................................................................................... 2 14 .................... 050068-002 .............................. Nut .......................................................................................................... 2 15 .................... 050004-032 .............................. Screw ...................................................................................................... 2 16 .................... 805864 ..................................... Switch ..................................................................................................... 1 808032 ..................................... Switch (Freezer/Corrosion) ..................................................................... 1 17 .................... 803310 ..................................... Actuator .................................................................................................. 1 18 .................... 050008-004 .............................. Nut .......................................................................................................... 2 19 .................... 050071-035 .............................. Screw ...................................................................................................... 2 20 .................... 813658 ..................................... Bracket ................................................................................................... 1 21 .................... 050005-003 .............................. Screw ...................................................................................................... 4 053050-006 .............................. Adhesive ................................................................................................. AR 22 .................... 806895-003 .............................. Fan Assembly ......................................................................................... 1 062007-021 .............................. Connector ......................................................................................... 2 803448-003 .............................. Insulation ........................................................................................... 2 23 .................... 050008-001 .............................. Nut .......................................................................................................... 4

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-4.1-3400

41

CONTACTOR

6

1

5

4

2

3

MP-3300-002 MP-4.4-3400

42M1.0-0000-00042

MP-WD2300S-GB 02/05 • Printed in Germany

CONTACTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 802820 ..................................... Contactor ................................................................................................ 2 1 ........................... 803689 ..................................... Contact .............................................................................................. 4 2 ........................... 803690 ..................................... Movable contact ................................................................................ 2 3 ........................... 803691 ..................................... Coil .................................................................................................... 2 4 ........................... 803692-001 .............................. Spring ................................................................................................ 2 5 ........................... 803693 ..................................... Cover ................................................................................................ 2 6 ........................... 803694 ..................................... Screw ................................................................................................ 4

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-4.4-3400

43

CONTROL HANDLE Part 1-2

4 19 3

18

16

11 15

18 17

12 17 14 16 9

8 6

8 8

7 4

14 8

13

6 8 7 12 4 10 5

1

2

2

MP-3130-0405 MP-4.5-3400

44M1.0-0000-00044

MP-WD2300S-GB 02/05 • Printed in Germany

CONTROL HANDLE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 811913-017-01 ......................... Control Handle Assembly ....................................................................... 1 811913-017-02 ......................... Control Handle Assembly (Freezer/Corrosion) ....................................... 1 1 ........................... 812255-001 .............................. Tiller .................................................................................................. 1 2 ........................... 051058-001 .............................. Bushing ............................................................................................. 2 3 ........................... 813865 ..................................... Tiller Harness .................................................................................... 1 4 ........................... 812894-002 .............................. Screw ................................................................................................ 1 5 ........................... 808986 ..................................... Lower Shell ........................................................................................ 1 6 ........................... 792940 ..................................... U-Nut Retainer .................................................................................. 2 7 ........................... 812893-003 .............................. Screw ................................................................................................ 2 8 ........................... 812893-001 .............................. Screw ................................................................................................ 6 9 ........................... 808985 ..................................... Upper Shell ........................................................................................ 1 10 .......................... 808987-002 .............................. Handgrip ............................................................................................ 1 11 .......................... 808987-001 .............................. Handgrip ............................................................................................ 1 12 .......................... 812894-005 .............................. Screw ................................................................................................ 2 13 .......................... 811932-002 .............................. Horn Switch HNS1 ............................................................................ 1 811931 ..................................... Horn Wiring ........................................................................................ 1 14 .......................... 810336 ..................................... Plug ................................................................................................... 2 15 .......................... 811932-001 .............................. Horn Switch HNS2 ............................................................................ 1 16 .......................... 814286 ..................................... Nut ..................................................................................................... 2 17 .......................... 814287 ..................................... Washer .............................................................................................. 2 18 .......................... 812893-004 .............................. Screw ................................................................................................ 2 19 ............................................................................. Contorl Handle Cap (see next Page) ................................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-4.5-3400

45

CONTROL HANDLE Part 2-2 43

41

2

42 43

39 37 38

37

38 1

40

39 2 38 38

25

35

40 36

9

23

27 30 26 29

28

31 26

24

20

19 32

10

27 22

9

33

8 21 24

23

5

9

15 9

7 6

14

9

18

16 34

17 18

13 11 9

3 4

12

9 MP-3400-015

MP-4.5-3400

46M1.0-0000-00046

MP-WD2300S-GB 02/05 • Printed in Germany

CONTROL HANDLE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 811949-015 .............................. Control Handle Cap Assembly ................................................................ 1 811949-016 .............................. Control Handle Cap Assembly (Freezer/Corrosion) ............................... 1 1 ........................... 808951-004 .............................. Switch Cover ..................................................................................... 1 2 ........................... 812893-002 .............................. Screw ................................................................................................ 2 3 ........................... 810328 ..................................... Support ............................................................................................. 1 4 ........................... 812894-002 .............................. Screw ................................................................................................ 2 5 ........................... 811935 ..................................... Micro-Switch SAS ............................................................................. 1 6 ........................... 803469-018 .............................. Screw ................................................................................................ 2 7 ........................... 051057-026 .............................. Spring ................................................................................................ 4 8 ........................... 811936 ..................................... Button Bridge ..................................................................................... 1 9 ........................... 803469-017 .............................. Screw ................................................................................................ 13 10 .......................... 808992 ..................................... Button ................................................................................................ 1 11 .......................... 812941 ..................................... Main PC Board .................................................................................. 1 812272 ..................................... Main PC Board (Freezer/Corrosion) .................................................. 1 12 .......................... 812942-002 .............................. Hydraulic PC Board (included RAS, LOS1 & LOS2) ........................ 1 812273-002 .............................. Hydraulic PC Board (included RAS, LOS1 & LOS2/Freezer/C.) ...... 1 13 .......................... 811941 ..................................... Fast/Slow Switch HSS ...................................................................... 1 812877 ..................................... Fast/Slow Switch HSS (Freezer/Corrosion) ...................................... 1 14 .......................... 808990 ..................................... Lower Cover ...................................................................................... 1 15 .......................... 810332 ..................................... Support ............................................................................................. 1 16 .......................... 051057-021 .............................. Spring ................................................................................................ 1 17 .......................... 811940 ..................................... Shaft .................................................................................................. 1 18 .......................... 050012-075 .............................. Retaining Ring ................................................................................... 2 19 .......................... 810331 ..................................... Support ............................................................................................. 1 20 .......................... 811939 ..................................... Shaft .................................................................................................. 1 21 .......................... 808989 ..................................... Lift Cover ........................................................................................... 1 22 .......................... 051057-023 .............................. Spring ................................................................................................ 1 23 .......................... 812894-004 .............................. Screw ................................................................................................ 2 24 .......................... 803469-023 .............................. Screw ................................................................................................ 2 25 .......................... 808993-001 .............................. Thumbwheel ...................................................................................... 1 26 .......................... 050012-076 .............................. Retaining Ring ................................................................................... 2 27 .......................... 810335 ..................................... Bushing ............................................................................................. 2 28 .......................... 813533 ..................................... Traction Potentiometer POT ............................................................... 1 813534 ..................................... Traction Potentiometer POT Assembly (Freezer/Corrosion) .............. 1 812315 ...................................... Heater .......................................................................................... 1 803469-021 ............................... Screw .......................................................................................... 2 29 .......................... 810333 ..................................... Spring Activator ................................................................................. 1 30 .......................... 811937 ..................................... Shaft .................................................................................................. 1 31 .......................... 812884 ..................................... Spring ................................................................................................ 1 32 .......................... 808993-002 .............................. Thumbwheel ...................................................................................... 1 33 .......................... 051057-028 .............................. Spring ................................................................................................ 1 34 .......................... 051057-022 .............................. Spring ................................................................................................ 1 35 .......................... 812879 ..................................... Bracket .............................................................................................. 1 36 .......................... 803469-020 .............................. Screw ................................................................................................ 4 37 .......................... 815307 ..................................... Stop ................................................................................................... 2 38 .......................... 803469-019 .............................. Screw ................................................................................................ 4 39 .......................... 812366 ..................................... Bracket .............................................................................................. 2 40 .......................... 812895 ..................................... Switch ............................................................................................... 1 41 .......................... 815059-001 .............................. Cap .................................................................................................... 1 42 .......................... 815059-002 .............................. Cap .................................................................................................... 1 43 .......................... 050052-005 .............................. Shaft .................................................................................................. 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-4.5-3400

47

EMERGENCY DISCONNECT/BATTERY CONNECTOR

3 4

Forke Carriage Frame 2

10

1

6

9

5

7

8

MP-3400-017 MP-4.7-3400

48M1.0-0000-00048

MP-WD2300S-GB 02/05 • Printed in Germany

EMERGENCY DISCONNECT/BATTERY CONNECTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

SBE 160 1 ..................... 050005-012 .............................. Screw ...................................................................................................... 4 2 ..................... 045239-001-01 ......................... Emergency Disconnect ........................................................................... 1 3 ..................... 805852 ..................................... Battery Connector ................................................................................... 1 4 ..................... 050068-002 .............................. Nut .......................................................................................................... 4 5 ..................... 050068-002 .............................. Nut .......................................................................................................... 2 6 ..................... 803673 ..................................... Battery Connector ................................................................................... 1 7 ..................... 052051-020 .............................. Power Cable + ........................................................................................ 1 8 ..................... 052051-018 .............................. Power Cable - ......................................................................................... 1 9 ..................... 050008-015 .............................. Nut .......................................................................................................... 4 10 .................... 050003-028 .............................. Screw ...................................................................................................... 2

805856-001 .............................. Emergency Disconnect Assembly (included 1 - 4) ................................. 1 815766 ..................................... Battery Connector Assembly (included 6 - 8) ......................................... 1

LB DIN 43589 1 ..................... 050007-010 .............................. Screw ...................................................................................................... 2 2 ..................... 045239-001-02 ......................... Emergency Disconnect ........................................................................... 1 3 ..................... 805853 ..................................... Battery Connector ................................................................................... 1 4 ..................... 050008-015 .............................. Nut .......................................................................................................... 2 5 ..................... 050068-002 .............................. Nut .......................................................................................................... 2 6 ..................... 803546-001 .............................. Battery Connector ................................................................................... 1 7 ..................... 052051-060 .............................. Power Cable + ........................................................................................ 1 8 ..................... 052051-013 .............................. Power Cable - ......................................................................................... 1 10 .................... 050003-028 .............................. Screw ...................................................................................................... 2

805856-002 .............................. Emergency Disconnect Assembly (included 1 - 4) ................................. 1 815765 ..................................... Battery Connector Assembly (included 6 - 8) ......................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-4.7-3400

49

INSTRUMENT

1

2

Cover 3

4

5

Power Unit 6

7

MP-3400-014 MP-4.9-3400

50M1.0-0000-00050

MP-WD2300S-GB 02/05 • Printed in Germany

INSTRUMENT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 115478 ..................................... Lens ........................................................................................................ 1 2 ..................... 802833 ..................................... Instrument ............................................................................................... 1 3 ..................... 804774 ..................................... O-Ring .................................................................................................... 1 4 ..................... 050025-004 .............................. Screw ...................................................................................................... 2 5 ..................... 807769 ..................................... Bracket ................................................................................................... 1 6 ..................... 050073-002 .............................. Spring Nut ............................................................................................... 2 7 ..................... 050068-002 .............................. Nut .......................................................................................................... 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-4.9-3400

51

HORN

7 6 5

4

3

2

Power Unit

1

MP-3400-016 MP-4.13-3400

52M1.0-0000-00052

MP-WD2300S-GB 02/05 • Printed in Germany

HORN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050008-015 .............................. Nut .......................................................................................................... 1 2 ..................... 815323 ..................................... Horn ........................................................................................................ 1 050082-001 .............................. Washer ................................................................................................... 3 050082-002 .............................. Washer ................................................................................................... 1 050082-003 .............................. Washer ................................................................................................... 1 3 ..................... 814481 ..................................... Bracket ................................................................................................... 1 4 ..................... 050006-026 .............................. Screw ...................................................................................................... 1 5 ..................... 050006-014 .............................. Screw ...................................................................................................... 1 6 ..................... 061002-005 .............................. Clamp ...................................................................................................... 1 7 ..................... 050008-008 .............................. Nut .......................................................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-4.13-3400

53

Page intentionally left blank

Printed in Germany

54M1.0-0000-00054

SECTION 5

Printed in Germany

55

BRAKE

MP-1720-001 MP-5.6-3400

56M1.0-0000-00056

MP-WD2300S-GB 02/05 • Printed in Germany

BRAKE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 805032 ..................................... Nut .......................................................................................................... 1 2 ..................... 805026 ..................................... Locking Plate .......................................................................................... 1 3 ..................... 050005-082 .............................. Screw ...................................................................................................... 3 4 ..................... 050004-037 .............................. Screw ...................................................................................................... 1 5 ..................... 050009-004 .............................. Washer ................................................................................................... 1 6 ..................... 805043 ..................................... Nut .......................................................................................................... 1 7 ..................... 807763-002 .............................. Magnet .................................................................................................... 1 8 ..................... 050005-006 .............................. Screw ...................................................................................................... 2 9 ..................... 050008-008 .............................. Nut .......................................................................................................... 2 10 .................... 805025 ..................................... Compression spring ................................................................................ 1 11 .................... 805228-001 .............................. Pressure Block ....................................................................................... 4 12 .................... 805228-002 .............................. Compression Spring ............................................................................... 4 13 .................... 805047 ..................................... Bushing ................................................................................................... 1 14 .................... 805023 ..................................... Armature plate ........................................................................................ 1 15 .................... 807763-003-01 ......................... Hub ......................................................................................................... 1 16 .................... 807763-004 .............................. Armature ................................................................................................. 1 17 .................... 805228-003 .............................. Sleeve ..................................................................................................... 3 18 .................... 807763-001 .............................. Friction plate ............................................................................................ 1 19 .................... 803450-010 .............................. Crimp Contact ......................................................................................... 4 20 .................... 803450-002 .............................. Plug ......................................................................................................... 1 21 .................... 050009-012 .............................. Washer ................................................................................................... 3 22 .................... 811839 ..................................... Plug ......................................................................................................... 1

804676-003 .............................. Brake (included 1,2,4-20) ........................................................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-5.6-3400

57

Page intentionally left blank

Printed in Germany

58M1.0-0000-00058

SECTION 7

Printed in Germany

59

MAST

22 Forke Carriage Frame 23 18 21 19 20 17 19

6 7 14 15

16

12

4

18

13

5

3

11

1 2

10 8 9

15

14

MP-3400-001 MP-7.1-3400

60M1.0-0000-00060

MP-WD2300S-GB 02/05 • Printed in Germany

MAST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 813588-*** ............................... Outer Mast (see Table) ........................................................................... 1 2 ..................... 813599-*** ............................... Inner Mast (see Table) ............................................................................ 1 3 ..................... 050067-058 .............................. Screw ...................................................................................................... 2 4 ..................... 807407 ..................................... Washer ................................................................................................... 2 5 ..................... 807323 ..................................... Shim ........................................................................................................ AR 6 ..................... 050017-023 .............................. Screw ...................................................................................................... 2 7 ..................... 813627 ..................................... Nut .......................................................................................................... 2 8 ..................... 803915-001 .............................. Shim (0.5 mm) ......................................................................................... AR 803915-002 .............................. Shim (1.0 mm) ......................................................................................... AR 803915-003 .............................. Shim (1.5 mm) ......................................................................................... AR 9 ..................... 810691 ..................................... Roller ...................................................................................................... 4 10 ....................................................................... Cylinder (see Section 8) ......................................................................... 1 11 .................... 050008-056 .............................. Nut .......................................................................................................... 2 12 .................... 802766 ..................................... Chain Tensioner ...................................................................................... 1 13 .................... 050001-023 .............................. Cotter Pin ................................................................................................ 1 14 .................... 802767-001 .............................. Chain Pin ................................................................................................ 2 15 .................... 050001-013 .............................. Cotter Pin ................................................................................................ 4 16 .................... 051061-*** ............................... Chain (see Table) ................................................................................... 1 17 .................... 050012-006 .............................. Retaining Ring ........................................................................................ 1 18 .................... 050012-009 .............................. Retaining Ring ........................................................................................ 2 19 .................... 060030-085 .............................. Washer ................................................................................................... 2 20 .................... 810669 ..................................... Chain Pulley ............................................................................................ 1 21 .................... 811467 ..................................... Axle ......................................................................................................... 1 22 .................... 816163 ..................................... Guard (Yoke) ........................................................................................... 1 23 .................... 050071-009 .............................. Screw ...................................................................................................... 2

Lift Height

Position 1

Position 2

Position 16

1700 mm

813588-001

811599-001

051061-021

2010 mm

813588-002

811599-002

051061-015 Tab001gb

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-7.1-3400

61

FORK CARRIAGE

1

4

2 3

MP-3400-004 MP-7.7-3400

62M1.0-0000-00062

MP-WD2300S-GB 02/05 • Printed in Germany

FORK CARRIAGE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 813577 ..................................... Fork Carriage .......................................................................................... 1 2 ..................... 803915-001 .............................. Shim (0.5 mm) ......................................................................................... AR 803915-002 .............................. Shim (1.0 mm) ......................................................................................... AR 803915-003 .............................. Shim (1.5 mm) ......................................................................................... AR 3 ..................... 810691 ..................................... Roller ...................................................................................................... 4 4 ..................... 050005-040 .............................. Screw ...................................................................................................... 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-7.7-3400

63

MAST SAFTY SCREEN

2 3

1

OuterMast

MP-3400-003 MP-7.7-3400

64M1.0-0000-00064

MP-WD2300S-GB 02/05 • Printed in Germany

MAST SAFTY SCREEN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 813626-001 .............................. Safty Screen (Lift Height 1700mm) ......................................................... 1 813626-002 .............................. Safty Screen (Lift Height 2010mm) ......................................................... 1 2 ..................... 050009-054 .............................. Washer ................................................................................................... 4 3 ..................... 050080-001 .............................. Nut .......................................................................................................... 4

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-7.7-3400

65

LIFT STRUCTURE 6

7

5 4 3

Forke Carriage Frame

2 1

5 4

Power Unit 11

10

14

13

5 8

11

9

Forke Carriage Frame 15

5 9

16

17 11 12

14

20

9

18 5 9

23

13 26

21

11

25 11

Forke Carriage Frame

11 24

25 26 22 24

19 23

MP-3400-005 MP-7.8-3400

66M1.0-0000-00066

MP-WD2300S-GB 02/05 • Printed in Germany

LIFT STRUCTURE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050067-023 .............................. Screw ...................................................................................................... 4 2 ..................... 807262 ..................................... Retainer .................................................................................................. 2 3 ..................... 050000-012 .............................. Roll Pin ................................................................................................... 2 4 ..................... 055084-008 .............................. Bushing ................................................................................................... 4 5 ..................... 054011-006 .............................. Grease Nipple ......................................................................................... 18 6 ..................... 805761-002 .............................. Link Upper .............................................................................................. 2 7 ..................... 050009-052 .............................. Washer ................................................................................................... 2 8 ..................... 805773-002-03 ......................... Link Lower .............................................................................................. 1 9 ..................... 055084-009 .............................. Bushing ................................................................................................... 20 10 .................... 807097 ..................................... Shaft ........................................................................................................ 2 11 .................... 050000-015 .............................. Roll Pin ................................................................................................... 12 12 .................... 045224 ..................................... Shaft ........................................................................................................ 2 13 .................... 045469 ..................................... Shaft ........................................................................................................ 4 14 .................... 050000-017 .............................. Roll Pin ................................................................................................... 4 15 .................... 045292-001 .............................. End Tension Bar ...................................................................................... 2 16 .................... 045482-002-37 ......................... Tension Bar ............................................................................................. 2 17 .................... 060021-019 .............................. Nut .......................................................................................................... 2 18 .................... 045292-002 .............................. End Tension Bar ...................................................................................... 2 19 .................... 813649 ..................................... Shaft ........................................................................................................ 2 20 .................... 045301-002 .............................. Riser Assembly (included 5, 9 & 21) ....................................................... 2 045301-001 .............................. Riser .................................................................................................. 2 21 .................... 804665 ..................................... Bushing ................................................................................................... 2 22 .................... 808984-001 .............................. Load Roller .............................................................................................. 4 23 .................... 806507 ..................................... Shaft ........................................................................................................ 4 24 .................... 806510 ..................................... Plate ........................................................................................................ 4 25 .................... 050009-036 .............................. Washer ................................................................................................... 4 26 .................... 050009-022 .............................. Washer ................................................................................................... AR

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-7.8-3400

67

LOAD BACKREST

1

2

2

Fork Carriage

MP-3400-011 MP-7.10-3400

68M1.0-0000-00068

MP-WD2300S-GB 02/05 • Printed in Germany

LOAD BACKREST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 815265 ..................................... Load Backrest ......................................................................................... 1 2 ..................... 050003-050 .............................. Screw ...................................................................................................... 4

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-7.10-3400

69

Page intentionally left blank

Printed in Germany

70M1.0-0000-00070

SECTION 8

Printed in Germany

71

LIFT CYLINDER

4

2

3

2

5

1

MP-3400-021 MP-8.4-3400

72M1.0-0000-00072

MP-WD2300S-GB 02/05 • Printed in Germany

LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 805840 ..................................... Lift Cylinder Assembly ............................................................................ 2 1 ........................... 805841 ..................................... Tube ................................................................................................... 2 2 ........................... 810416 ..................................... Guide Ring ........................................................................................ 4 3 ........................... 810417 ..................................... Seal ................................................................................................... 2 4 ........................... 810415 ..................................... Wiper ................................................................................................. 2 5 ........................... 805599 ..................................... Rod .................................................................................................... 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-8.4-3400

73

FREE LIFT CYLINDER

1

3 2 5 4

1 2

6 7 3

4

8

12

5 6 8 7

12

9

10 13

11 13 9 10

11

MP-3400-002 MP-8.4-3400

74M1.0-0000-00074

MP-WD2300S-GB 02/05 • Printed in Germany

FREE LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 813609-*** ............................... Free Lift Cylinder Assembly (see Table) .................................................. 1 1 ........................... 811276 ..................................... Wiper Rod ......................................................................................... 1 2 ........................... 811280 ..................................... Rod Seal ........................................................................................... 1 3 ........................... 811321 ..................................... Cap .................................................................................................... 1 4 ........................... 054172 ..................................... Bleed Screw ...................................................................................... 1 054173 ..................................... Seal Ring ........................................................................................... 1 5 ........................... 812305 ..................................... Guide Ring ........................................................................................ 1 6 ........................... 811288 ..................................... Backring ............................................................................................ 1 7 ........................... 811284 ..................................... O-Ring ............................................................................................... 1 8 ........................... 813610-*** ................................ Rod (see Table) ................................................................................. 1 9 ........................... 811268 ..................................... Retaining Ring ................................................................................... 1 10 .......................... 811028 ..................................... Piston ................................................................................................ 1 11 .......................... 050012-009 .............................. Retaining Ring ................................................................................... 1 12 .......................... 813611-*** ................................ Tube (see Table) ................................................................................ 1 13 .......................... 811336 ..................................... Hose Burst Valve .............................................................................. 1

813820 ..................................... Seal Kit (included 1, 2, 4 - 7, 10) ............................................................. 1

Lift Height

Position 0

Position 8

Position 12

1700 mm

813609-001

813610-001

813611-001

2010 mm

813609-002

813610-002

813611-002 Tab002gb

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-8.4-3400

75

Page intentionally left blank

Printed in Germany

76M1.0-0000-00076

SECTION 9

Printed in Germany

77

PLATFORM Part 1-2

2

3

1 4

3

5

23 22

19 18

17

Power Unit

20 13 12

19

11

17

16

13

9 8

16

5

14 24

15

12

10 18

20

23 9

11 5 14

8

15

24

6 10 MP-9.0-3400

78M1.0-0000-00078

7

21

MP-3400-012 MP-WD2300S-GB 02/05 • Printed in Germany

PLATFORM INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 805932-001 .............................. Side Restraints ....................................................................................... 1 2 ..................... 807506 ..................................... Pad .......................................................................................................... 2 3 ..................... 050071-009 .............................. Screw ...................................................................................................... 4 4 ..................... 805932-002 .............................. Side Restraints ....................................................................................... 1 5 ..................... 806095 ..................................... Bearing ................................................................................................... 4 6 ..................... 807497-002 .............................. Bushing ................................................................................................... 1 7 ..................... 807497-001 .............................. Bushing ................................................................................................... 1 8 ..................... 811700 ..................................... Sheet ....................................................................................................... 2 9 ..................... 050003-010 .............................. Screw ...................................................................................................... 2 10 .................... 050000-041 .............................. Split Pin ................................................................................................... 4 11 .................... 807494 ..................................... Brake Lever ............................................................................................ 2 12 .................... 806089 ..................................... Spinner ................................................................................................... 2 13 .................... 806088 ..................................... Spring ..................................................................................................... 2 14 .................... 050017-011 .............................. Screw ...................................................................................................... 2 15 .................... 806024 ..................................... Brake Lining ............................................................................................ 2 053050-010 .............................. Adhesive ................................................................................................. AR 16 .................... 050006-054 .............................. Screw ...................................................................................................... 2 17 .................... 803619-001 .............................. Switch ..................................................................................................... 2 18 .................... 803310 ..................................... Actuator .................................................................................................. 2 19 .................... 050004-034 .............................. Screw ...................................................................................................... 4 20 .................... 050008-004 .............................. Nut .......................................................................................................... 4 21 .................... 807280-001 .............................. Cover ...................................................................................................... 1 22 .................... 807280-002 .............................. Cover ...................................................................................................... 1 23 .................... 050003-030 .............................. Screw ...................................................................................................... 4 24 .................... 050071-034 .............................. Screw ...................................................................................................... 2 050009-018 .............................. Washer ................................................................................................... 2

807503-001 .............................. Side Restraints Assembly (included 1 - 3) .............................................. 1 807503-002 .............................. Side Restraints Assembly (included 2 - 4) .............................................. 1

807493 ..................................... Brake Lever Assembly (included 11 & 15) ............................................. 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-9.0-3400

79

PLATFORM Part 2-2

Power Unit

28 21 29 25 19 29

20 28 22

26

17

24 16

12 5 5

11 18 27

23

8

13 25 26

9

9

10

14

6

27 7 15

2 7 3

5

4 1

MP-3400-013 MP-9.0-3400

80M1.0-0000-00080

MP-WD2300S-GB 02/05 • Printed in Germany

PLATFORM INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807582 ..................................... Platform ................................................................................................... 1 2 ..................... 807712 ..................................... Mat .......................................................................................................... 1 053050-009 .............................. Adhesive Tape ......................................................................................... AR 3 ..................... 814662 ..................................... Plug ......................................................................................................... 10 4 ..................... 806081 ..................................... Shaft ........................................................................................................ 1 5 ..................... 050000-025 .............................. Split Pin ................................................................................................... 3 6 ..................... 806082 ..................................... Cover ...................................................................................................... 1 7 ..................... 050071-034 .............................. Screw ...................................................................................................... 4 8 ..................... 806025 ..................................... Brake Ring .............................................................................................. 1 9 ..................... 806784 ..................................... Tube ........................................................................................................ 2 10 .................... 806084-002 .............................. Spring ..................................................................................................... 1 11 .................... 806085 ..................................... Spring device .......................................................................................... 1 12 .................... 050000-045 .............................. Split Pin ................................................................................................... 1 13 .................... 806084-001 .............................. Spring ..................................................................................................... 1 14 .................... 806083 ..................................... Sleeve ..................................................................................................... 1 15 .................... 050017-008 .............................. Screw ...................................................................................................... 1 16 .................... 806023 ..................................... Brake Lever ............................................................................................ 1 17 .................... 806024 ..................................... Brake Lining ............................................................................................ 1 053050-010 .............................. Adhesive ................................................................................................. AR 18 .................... 050017-011 .............................. Screw ...................................................................................................... 1 19 .................... 806089 ..................................... Spinner ................................................................................................... 1 20 .................... 806088 ..................................... Spring ..................................................................................................... 1 21 .................... 050005-037 .............................. Screw ...................................................................................................... 1 22 .................... 803619-001 .............................. Switch ..................................................................................................... 1 803310 ..................................... Actuator .................................................................................................. 1 23 .................... 050004-009 .............................. Screw ...................................................................................................... 2 24 .................... 050008-004 .............................. Nut .......................................................................................................... 2 25 .................... 806094 ..................................... Bearing ................................................................................................... 2 26 .................... 051053-002 .............................. Spring ..................................................................................................... 40 27 .................... 806504 ..................................... Bolt .......................................................................................................... 2 28 .................... 050000-002 .............................. Split Pin ................................................................................................... 2 29 .................... 050006-042 .............................. Screw ...................................................................................................... 2

810703 ..................................... Platform Assembly (included 1 - 3) ......................................................... 1 808097 ..................................... Brake Lever Assembly (included 16 & 17) ............................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-WD2300S-GB 02/05 • Printed in Germany

MP-9.0-3400

81

Page intentionally left blank

Printed in Germany

82M1.0-0000-00082