Crown Forklift WP2000S Series Parts Manual 812676-006

Parts Manual

WP2000S Series WP2000-GB 02/03 • Printed in Germany Order Number: 812676-006

This master maintenance 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 & CoKG - 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

PAGE

SERIAL NR. CUT

REV.

SERIAL NR. CUT

REV.

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

SECTION 1 – COVERS

PAGE

Covers ................................................................................... 12 .............................................................. Rev.2 02/03 Covers (Batterierollers) .......................................................... 14 .............................................................. Rev.1 02/03 Caster Wheel ......................................................................... 16

SECTION 2 – HYDRAULIC PART

PAGE

SERIAL NR. CUT

REV.

Tube/Hose Layout .................................................................. 20 .............................................................. Rev.3 02/03 Pump Motor and Pump .......................................................... 22 .............................................................. Rev.2 02/03

SECTION 3 – DRIVE UNIT

PAGE

SERIAL NR. CUT

REV.

Drive Unit ............................................................................... 26 .............................................................. Rev.3 02/03 Gearbox ................................................................................. 28 .............................................................. Rev.1 03/02 Drive Motor ............................................................................ 30 Knuckle .................................................................................. 32 .............................................................. Rev.2 02/03

SECTION 4 – ELECTRICAL

PAGE

SERIAL NR. CUT

REV.

Elektrical Parts ...................................................................... 36,38,40 .................................................... Rev.3 02/03 Contactor ............................................................................... 42 Control Handle ...................................................................... 44,46 ......................................................... Rev.1 03/02 Emergency Disconnect/Battery Connector ............................ 48 .............................................................. Rev.2 02/03 Instrument ............................................................................. 50 Horn ...................................................................................... 52 .............................................................. Rev.2 02/03

SECTION5 – BRAKE SYSTEM

PAGE

SERIAL NR. CUT

REV.

Brake ..................................................................................... 56 .............................................................. Rev.1 03/02

SECTION 7 – MAST-/LIFT STRUCTURE

PAGE

SERIAL NR. CUT

REV.

Fork Carriage (single Loadwheel) .......................................... 60,62 ......................................................... Rev.2 02/03 Fork Carriage (tandem Loadwheel) ....................................... 64,66 ......................................................... Rev.2 02/03 Lift Stucture ........................................................................... 68 .............................................................. Rev.3 02/03

SECTION 8 – CYLINDER

PAGE

SERIAL NR. CUT

REV.

SERIAL NR. CUT

REV.

Lift Cylinder ........................................................................... 72

SECTION 9 – CABIN/PLATFORM

PAGE

Platform ................................................................................. 76,78 ......................................................... Rev.1 03/02 Platform (fixed Platform) ........................................................ 80

SECTION10 – MISCELLANEOUS SERVICE INF.

PAGE

SERIAL NR. CUT

REV.

Labels and Decals ................................................................. 84

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

M/P-IDX-1720 REV. 3 03/02 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-WP2000S-GB 02/03 • Rev. C • Printed in Germany

M/P-ITD-1720

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

M1545 MP-1.0-1720

12M1.0-0000-00012

MP-WP2000S-GB 02/03 • Rev. C • 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 ..................... 050003-030 ............................. Screw ...................................................................................................... 5 804863-007 ............................. Nut .......................................................................................................... 5 6 ..................... 807380 .................................... Instrument Panel .................................................................................... 1 050009-013 ............................. Washer ................................................................................................... 5 050006-024 ............................. Screw ...................................................................................................... 5 7 ..................... 109127-003 ............................. Clip Arrow (red) ...................................................................................... 1 8 ..................... 109127-001 ............................. Clip Arrow (green) .................................................................................. 1 9 ..................... 801900 .................................... Keyswitch ............................................................................................... 1 803678-012 ............................. Crimp-Faston .......................................................................................... 2 10 .................... 807563 .................................... Support ................................................................................................... 1 11 .................... 051057-013 ............................. Spring ..................................................................................................... 2 12 .................... 805813 .................................... Wedge .................................................................................................... 1 13 .................... 050072-007 ............................. Screw ...................................................................................................... 2 14 .................... 050068-003 ............................. Nut .......................................................................................................... 2 15 .................... 807381 .................................... Battery Cover ......................................................................................... 1 16 .................... 803469-008 ............................. Screw ...................................................................................................... 4 050025-001 ............................. Screw ...................................................................................................... 4 050068-002 ............................. Nut .......................................................................................................... 4 17 .................... 805845 .................................... Plate ....................................................................................................... 1 18 .................... 805814 .................................... Spring ..................................................................................................... 1 19 .................... 050067-011 ............................. Screw ...................................................................................................... 2 20 .................... 805816 .................................... Retainer .................................................................................................. 1 21 .................... 050025-008 ............................. Screw ...................................................................................................... 2 22 .................... 050068-003 ............................. Nut .......................................................................................................... 2 807574 .................................... Cover Assembly (included 1-4) .............................................................. 1 807651 .................................... Instrument Panel Assembly (included 6-9) ........................................... 1 807562 .................................... Battery Cover Assembly (included 10-19) ............................................. 1

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-1.0-1720

REV. 2 02/03

13

COVERS Batterierollers

MP-1720-004 MP-1.0-1720

14M1.0-0000-00014

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

COVERS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 810456 .................................... Cover ...................................................................................................... 1 2 ..................... 804277 .................................... Pin Drift ................................................................................................... 2 3 ..................... 050000-009 ............................. Pin .......................................................................................................... 2 4 ..................... 805845 .................................... Plate ....................................................................................................... 1 5 ..................... 805814 .................................... Spring ..................................................................................................... 1 6 ..................... 050006-022 ............................. Screw ...................................................................................................... 2 7 ..................... 808245 .................................... Locking Handle Screw ........................................................................... 1 8 ..................... 807806 .................................... Bracket ................................................................................................... 1 9 ..................... 804863-002 ............................. Nut .......................................................................................................... 1 10 .................... 808862 .................................... Plate ....................................................................................................... 1 11 .................... 050067-012 ............................. Screw ...................................................................................................... 2 12 .................... 810385 .................................... Block ....................................................................................................... 1 13 .................... 050003-035 ............................. Screw ...................................................................................................... 2 14 .................... 804207 .................................... Roller ...................................................................................................... 5 15 .................... 804681 .................................... Bearing Ball ............................................................................................ 10 16 .................... 804208 .................................... Roller Axle .............................................................................................. 5 17 .................... 810377-002 ............................. Battery Lock ........................................................................................... 1 050007-032 ............................. Screw ...................................................................................................... 2 050009-026 ............................. Washer ................................................................................................... 4 050068-004 ............................. Nut .......................................................................................................... 2 18 .................... 810377-001 ............................. Battery Lock ........................................................................................... 1 050007-032 ............................. Screw ...................................................................................................... 2 050009-026 ............................. Washer ................................................................................................... 4 050068-004 ............................. Nut .......................................................................................................... 2

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-1.0-1720

REV. 1 02/03

15

CASTER WHEEL

12

1

11

2

3

4

5

6

10

7

8

9 8

7

MP-1720-014 MP-1.5-1720

16M1.0-0000-00016

MP-WP2000S-GB 02/03 • Rev. C • 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 12 .................... 050068-004 ............................. Nut .......................................................................................................... 8

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

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-1.5-1720

17

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Printed in Germany

18M1.0-0000-00018

SECTION 2

Printed in Germany

19

TUBE/HOSE LAYOUT

M1553 MP-2.1-1720

20M1.0-0000-00020

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

TUBE/HOSE LAYOUT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Pump Motor and Pump (see Section 2.13) ........................................... 1 2 ..................... 054174-001 ............................. Elbow ...................................................................................................... 1 3 ..................... 064010-002 ............................. T-Connector ............................................................................................ 1 4 ..................... 064009-002 ............................. Branch Tee Coupling .............................................................................. 1 5 ..................... 810059 .................................... Pressure Switch ..................................................................................... 1 810017 .................................... Adaptor ................................................................................................... 1 054004-006 ............................. Seal ........................................................................................................ 1 6 ..................... 807595 .................................... Tube ........................................................................................................ 1 7 ..................... 054165-013 ............................. Hose ....................................................................................................... 2 8 ..................... 064061-002 ............................. Elbow ...................................................................................................... 2 9 ..................... 054160-004 ............................. Connector ............................................................................................... 1 10 ....................................................................... Lift Cylinder (see Section 8.4) ............................................................... 2 11 .................... 805704 .................................... Clamp ..................................................................................................... 2 12 .................... 050000-027 ............................. Roll Pin ................................................................................................... 2 13 .................... 807989 .................................... Clamp Hose ............................................................................................ 1 050067-022 ............................. Screw ...................................................................................................... 1

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-2.1-1720

REV. 3 02/03

21

PUMP MOTOR AND PUMP

M1442 MP-2.13-1720

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

REV. 1 02/03

22M1.0-0000-00022

PUMP MOTOR AND PUMP INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 805770-001 ............................. Pump Motor and Pump (without 27 & 28) ............................................. 1 1* ............................................................................. Screw ................................................................................................ 4 2* ............................................................................. Washer .............................................................................................. 4 3* ............................................................................. Plug ................................................................................................... 1 4* ............................................................................. Circlip ................................................................................................ 1 5* ............................................................................. Rear Flange ...................................................................................... 1 6* ............................................................................. Insulating Cap .................................................................................. 1 7* ............................................................................. Brush Plate ....................................................................................... 1 8* .......................... 805140 ..................................... Brush Set .......................................................................................... 4 9* ............................................................................. Nut .................................................................................................... 4 10** ........................ N/A ........................................... Armature ........................................................................................... 1 11** ........................ N/A ........................................... Motor Housing .................................................................................. 1 12** ........................ N/A ........................................... Front Flange ..................................................................................... 1 13 .......................... 805144 ..................................... Coupling ............................................................................................ 1 14 .......................... 805145 ..................................... Pump Support (included 24) ............................................................ 1 15 .......................... 805146 ..................................... Pressure Relief Valve ....................................................................... 1 16 .......................... 805147 ..................................... Plug ................................................................................................... 1 17 .......................... 805148 ..................................... Plug ................................................................................................... 1 18 .......................... 805149 ..................................... Electro Poppet Valve ........................................................................ 1 19 .......................... 805150 ..................................... Flow Restrictor .................................................................................. 1 20 .......................... 805151 ..................................... Pressure Filter .................................................................................. 1 21 .......................... 805152 ..................................... Check Valve ...................................................................................... 1 22 .......................... 805153 ..................................... Return Pipe ....................................................................................... 1 23 .......................... 805154 ..................................... Auxiliary Return Line ........................................................................ 1 24 .......................... 805155 ..................................... Pump ................................................................................................. 1 805234 ..................................... Seal Kit ............................................................................................. 1 25 .......................... 805156 ..................................... Suction Pipe ..................................................................................... 1 26 .......................... 805157 ..................................... Filler Tank Assembly (included 29-33) ............................................ 1 805233-001 .............................. Filler Tank .................................................................................... 1 27 .................... 805762 .................................... Plate ....................................................................................................... 1 28 .................... 050006-051 ............................. Screw ...................................................................................................... 2 29 .................... 805233-002 ............................. O-Ring .................................................................................................... 1 30 .................... 805233-006 ............................. Reservoir Cap ........................................................................................ 1 31 .................... 805233-005 ............................. Flange .................................................................................................... 1 32 .................... 805233-003 ............................. Screw ...................................................................................................... 4 33 .................... 805233-004 ............................. Scheibe .................................................................................................. 4 053001-003 ............................. Hydraulic Oil ........................................................................................... AR 053001-009 ............................. Hydraulic Oil (Freezer/Corrosion) .......................................................... AR 805158 ..................................... Motor (included 1-12) ....................................................................... 1 * ........................... 805141 ..................................... Included 1-2 ...................................................................................... 1 * ........................... 805142 ..................................... Included 3-5 ...................................................................................... 1 * ........................... 805143 ..................................... Included 3,4,6,7,8 & 9 ...................................................................... 1 ** .................... N/A ........................................... Not available as spare part ....................................................................

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-2.13-1720

REV. 2 02/03

23

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Printed in Germany

24M1.0-0000-00024

SECTION 3

Printed in Germany

25

DRIVE UNIT

M1557 MP-3.0-1720

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

REV. 2 03/02

26M1.0-0000-00026

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 ..................... 807263 .................................... Ledge ..................................................................................................... 2 050017-013 ............................. Screw ...................................................................................................... 2 8 ..................... 050067-024 ............................. Screw ...................................................................................................... 4 9 ..................... 050005-044 ............................. Screw ...................................................................................................... 2 10 .................... 807588 .................................... Bush ....................................................................................................... 2 11 .................... 050068-004 ............................. Nut .......................................................................................................... 2 12 .................... 807657 .................................... Drive Unit Assembly (see next Page’s) ................................................. 1 13 .................... 805961-001 ............................. Drive Tyre (Vulkollan) ............................................................................. 1 805961-002 ............................. Drive Tyre (Rubber) ................................................................................ 1 14 .................... 050062-002 ............................. Nut .......................................................................................................... 5 15 .................... 050006-054 ............................. Screw ...................................................................................................... 5 16 .................... 808473 .................................... Washer ................................................................................................... 4 17 .................... 050017-019 ............................. Screw ...................................................................................................... 4 18 .................... 050008-026 ............................. Nut .......................................................................................................... 4 19 .................... 810584 .................................... Sleeve Nut .............................................................................................. 4 20 .................... 054011-007 ............................. Grease Nipple ........................................................................................ 2 21 .................... 811698 .................................... Sheet ...................................................................................................... 2 050009-003 ............................. Washer ................................................................................................... 4 050008-001 ............................. Nut .......................................................................................................... 4 22 .................... 811697 .................................... Sheet ...................................................................................................... 1 807277-001 ............................. Ledge Assembly (LH/included 7, 19,20) ............................................... 1 807277-002 ............................. Ledge Assembly (RH/included 7, 19,20) ............................................... 1 053002-001 ............................. Grease .................................................................................................... AR 053002-005 ............................. Grease (Freezer/Corrosion) ................................................................... AR

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-3.0-1720

REV. 2 03/02

27

GEARBOX

M1558 MP-3.1-1720

28M1.0-0000-00028

MP-WP2000S-GB 02/03 • Rev. C • 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 MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-3.1-1720

REV. 1 03/02

29

DRIVE MOTOR

M1557 MP-3.2-1720

30M1.0-0000-00030

MP-WP2000S-GB 02/03 • Rev. C • 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 MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-3.2-1720

31

KNUCKLE

M1556 MP-3.3-1720

32M1.0-0000-00032

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

KNUCKLE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 805960-001 ............................. Knuckle Assembly (without 2 & 19) ....................................................... 1 805960-003 ............................. Knuckle Assembly (Freezer/Corrosion/without 2 & 19) ......................... 1 1 ........................... 807512 ..................................... Knuckle (Base) ................................................................................. 1 2 ..................... 050005-080 ............................. Screw ...................................................................................................... 3 3 ........................... 807561 ..................................... Plate .................................................................................................. 1 4 ........................... 45234 ....................................... Cable Protection ............................................................................... 1 5 ........................... 050005-011 ............................. Screw ................................................................................................ 2 6* .......................... 805943 ..................................... Knuckle ............................................................................................. 1 7 ........................... 050005-023 ............................. Screw ................................................................................................ 4 8* .......................... 803651 ..................................... Damper ............................................................................................. 1 9* .......................... 050005-002 ............................. Screw ................................................................................................ 2 10* ......................... 803619-001 ............................. Microswitch ....................................................................................... 1 803310 ..................................... Actuator ............................................................................................ 1 11* ......................... 050004-034 ............................. Screw ................................................................................................ 2 12* ......................... 050008-004 ............................. Nut .................................................................................................... 2 13 .......................... 808039-001 ............................. Axle ................................................................................................... 1 808039-002 ............................. Axle (Freezer/Corrosion) .................................................................. 1 14 .......................... 803353 ..................................... Spacer .............................................................................................. 2 15 .......................... 803013 ..................................... Spring ............................................................................................... 2 16 .......................... 050000-015 ............................. Roll Pin ............................................................................................. 1 17 .......................... 807515 ..................................... Cover ................................................................................................ 1 18 .......................... 050003-020 ............................. Screw ................................................................................................ 2 19 .................... 050005-082 ............................. Screw ...................................................................................................... 3 * ........................... 808906 ..................................... Knuckle Assembly (included 6,8-12) ............................................... 1 053002-001 ............................. Grease .................................................................................................... AR 053002-005 ............................. Grease (Freezer/Corrosion) ................................................................... AR

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-3.3-1720

REV. 2 02/03

33

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Printed in Germany

34M1.0-0000-00034

SECTION 4

Printed in Germany

35

ELECTRICAL PARTS

M1610 MP-4.0-1720

36M1.0-0000-00036

MP-WP2000S-GB 02/03 • Rev. C • 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 MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-4.0-1720

REV. 1 09/00

37

ELECTRICAL PARTS

M1549 MP-4.0-1720

38M1.0-0000-00038

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

ELECTRICAL PARTS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807549 .................................... Plate ....................................................................................................... 1 2 ..................... 807713-001 ............................. Controller ................................................................................................ 1 807713-002 ............................. Controller (Freezer/Corrosion) ............................................................... 1 808734-001 ............................. Controller (Fix Platform) ......................................................................... 1 808734-002 ............................. Controller (Fix Platform/Australia andNew Zealand/Freezer-Corr.) ...... 1 053051-008 ............................. Heat Paste .............................................................................................. AR 3 ..................... 050025-015 ............................. Screw ...................................................................................................... 4 4 ..................... 050068-001 ............................. Nut .......................................................................................................... 4 5 ..................... 103232 .................................... Diode ...................................................................................................... 1 6 ..................... 050005-003 ............................. Screw ...................................................................................................... 2 7 ..................... 050008-001 ............................. Nut .......................................................................................................... 2 8 ..................... 065004-006 ............................. Grommet ................................................................................................. 1 9 ..................... 050067-024 ............................. Screw ...................................................................................................... 2 10 .................... 050071-036 ............................. Screw ...................................................................................................... 2 11 .................... 807550 .................................... Plate ....................................................................................................... 1 061002-005 .............................. Cable Clamp ........................................................................................... 1 050006-008 .............................. Screw ...................................................................................................... 1 050068-001 .............................. Nut .......................................................................................................... 1 12 .................... 802820 .................................... Contactor ................................................................................................ 2 804387 .................................... Contactor (Freezer/Corrosion/see Section 4.4) .................................... 2 13 .................... 807649 .................................... Plate, Fuse ............................................................................................. 1 14 .................... 805752 .................................... Fuse Holder ............................................................................................ AR 805751-001 ............................. Fuse 10A ................................................................................................ 1 805751-002 ............................. Fuse 2A (Freezer/Corrosion) ................................................................. 1 15 .................... 050004-024 ............................. Screw ...................................................................................................... 4 16 .................... 050004-038 ............................. Screw ...................................................................................................... 4 17 .................... 45250 ....................................... Bus Bar ................................................................................................... 1 18 .................... 805824 .................................... Fuse Holder ............................................................................................ 1 19 .................... 050004-022 ............................. Screw ...................................................................................................... 2 20 .................... 050068-001 ............................. Nut .......................................................................................................... 2 21 .................... 802816-002 ............................. Fuse 160A .............................................................................................. 1 22 .................... 050009-016 ............................. Washer ................................................................................................... 6 23 .................... 050008-051 ............................. Nut .......................................................................................................... 4 24 .................... 805892 .................................... Thermostat (Freezer/Corrosion) ............................................................ 1 25 .................... 050004-025 ............................. Screw (Freezer/Corrosion) ..................................................................... 2 26 .................... 050008-004 ............................. Nut (Freezer/Corrosion) ......................................................................... 2 27* ................... 805757 .................................... Holder ..................................................................................................... 1 28* ................... 805864 .................................... Microswitch ............................................................................................. 1 808032 .................................... Microswitch (Freezer/Corrosion) ............................................................ 1 29* ................... 050004-032 ............................. Screw ...................................................................................................... 2 30* ................... 803310 .................................... Actuator .................................................................................................. 1 31* ................... 050008-004 ............................. Nut .......................................................................................................... 2 32 .................... 050025-004 ............................. Screw ...................................................................................................... 2 33 .................... 050073-002 ............................. Spring Washer ........................................................................................ 2 34 .................... 050068-002 ............................. Nut .......................................................................................................... 2 35 .................... 061002-007 ............................. Clamp ..................................................................................................... 3 050025-015 ............................. Screw ...................................................................................................... 3 050068-001 ............................. Nut .......................................................................................................... 3 061002-007 ............................. Clamp ..................................................................................................... 1 050008-010 ............................. Nut .......................................................................................................... 1 36 .................... 811624 .................................... Bracket ................................................................................................... 1 37 .................... 806895-003 ............................. Fan Assembly ......................................................................................... 1 807654-003 ............................. Fan .................................................................................................... 1 792880-001 ............................. Pin Housing 2-way ............................................................................ 1 792882 ..................................... Pin Insert .......................................................................................... 2 793090-001 ............................. Anti-backout ...................................................................................... 1 38 .................... 050005-003 ............................. Screw ...................................................................................................... 4 053050-006 ............................. Adhesive ................................................................................................. AR 39 .................... 050008-001 ............................. Nut .......................................................................................................... 4

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-4.0-1720

REV. 3 02/03

39

ELECTRICAL PARTS

M1549 MP-4.0-1720

40M1.0-0000-00040

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

ELECTRICAL PARTS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

* ..................... 805855-001 ............................. Lift Limit Switch Assembly (included 27-31) ........................................ 1 * ..................... 805855-003 ............................. Lift Limit Switch Assembly (included 27-31/Freezer/Corrosion) .......... 1 Not illustrated 811668 .................................... Main Harness ......................................................................................... 1 811837 .................................... Main Harness (Fix Platform) .................................................................. 1

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-4.0-1720

REV. 3 02/03

41

CONTACTOR

$

#

"

!

M0623 MP-4.4-1720

42M1.0-0000-00042

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

CONTACTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 802820 .................................... Contactor-Main/Pump ............................................................................ 2 1 ........................... 803689 ..................................... Contact ............................................................................................. 4 2 ........................... 803690 ..................................... Movable contact ............................................................................... 2 3 ........................... 803691 ..................................... Bobbin ............................................................................................... 2 4 ........................... 803692-001 ............................. Spring ............................................................................................... 2 5 ........................... 803693 ..................................... Cover ................................................................................................ 2 6 ........................... 803694 ..................................... Screw ................................................................................................ 4 804387 .................................... Contactor-Main/Pump Assembly (Freezer/Corrosion) .......................... 2

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-4.4-1720

43

CONTROL HANDLE

M1513 MP-4.5-1720

44M1.0-0000-00044

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

CONTROL HANDLE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 805713-003 ............................. Control Handle ....................................................................................... 1 805713-004 ............................. Control Handle (Freezer/Corrosion) ...................................................... 1 805713-009 ............................. Control Handle (fixed Platform) ............................................................. 1 805713-010 ............................. Control Handle (fixed Platform/Freezer/Corrosion) ............................... 1 1 ........................... 804937 ..................................... Grip ................................................................................................... 1 2 ........................... 050005-087 ............................. Screw ................................................................................................ 1 3 ........................... 050005-054 ............................. Screw ................................................................................................ 1 050064-016 ............................. Screw (Freezer/Corrosion) ............................................................... 1 4 ........................... 050005-066 ............................. Screw ................................................................................................ 1 ............................ 050064-023 ............................. Screw (Freezer/Corrosion) ............................................................... 1 5 ........................... 805942 ..................................... Handle Arm ....................................................................................... 1 808701 ..................................... Handle Arm (fixed Platform) ............................................................. 1 6 ........................... 051058-001 ............................. Bushing ............................................................................................. 2 7 ........................... 803348 ..................................... Stop ................................................................................................... 1 8 ........................... 050004-010 ............................. Screw ................................................................................................ 2 050064-010 ............................. Screw (Freezer/Corrosion) ............................................................... 2 9 ........................... 803918 ..................................... Switch Assembly .............................................................................. 1 802842 ..................................... Switch .......................................................................................... 1 803450-006 .............................. Socket Housing ........................................................................... 1 116858 ..................................... Socket Crimp .............................................................................. 4 10 .......................... 050004-001 ............................. Screw ................................................................................................ 2 050064-001 ............................. Screw (Freezer/Corrosion) ............................................................... 2 11 .......................... 050005-010 ............................. Screw ................................................................................................ 4 050064-019 ............................. Screw (Freezer/Corrosion) ............................................................... 4 12 .......................... 051057-001 ............................. Spring ............................................................................................... 4 13 .......................... 803469-002 ............................. Screw ................................................................................................ 4 14 .......................... 803330 ..................................... Guide Plate ....................................................................................... 1 15 .......................... 803325 ..................................... Bellow ............................................................................................... 1 16 .......................... 802852 ..................................... Button ............................................................................................... 1 17 ............................................................................. Harness ............................................................................................ 1 18 .......................... 805832 ..................................... Cable Holder ..................................................................................... 1 051065 ..................................... Caple Clamp ..................................................................................... 1 19 .......................... 050004-038 ............................. Screw ................................................................................................ 1 050064-008 ............................. Screw (Freezer/Corrosion) ............................................................... 1 20 ............................................................................. Hup Cap (see next Page) ................................................................. 1 805867-003 ............................. Wiring/Handle Arm Assembly (included 17-18) .............................. 1 805867-004 ............................. Wiring/Handle Arm Assembly (included 17-18/Freezer/Corrosion) 1 053002-001 ............................. Grease .................................................................................................... AR 053002-005 ............................. Grease (Freezer/Corrosion) ................................................................... AR

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-4.5-1720

REV. 1 03/02

45

CONTROL HANDLE

MP-1720-002 MP-4.5-1720

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

REV. 1 03/02

46M1.0-0000-00046

CONTROL HANDLE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 805868-008 ............................. Hup Cap Assembly ................................................................................ 1 805868-011 ............................. Hup Cap Assembly (Freezer/Corrosion) ............................................... 1 1 ........................... 807949-001 ............................. Hup Cap ............................................................................................ 1 2 ........................... 802855 ..................................... Button, Horn ..................................................................................... 1 3 ........................... 051057-019 ............................. Spring ............................................................................................... 2 4 ........................... 803469-014 ............................. Screw ................................................................................................ 2 5 ........................... 803347 ..................................... Holder ............................................................................................... 1 803630 ..................................... Holder (Freezer/Corrosion) .............................................................. 1 6 ........................... 050064-008 ............................. Screw ................................................................................................ 4 7 ........................... 805857 ..................................... Switch Assy Harness ....................................................................... 1 8 ........................... 804357 ..................................... Button, FWD/REW ............................................................................ 1 9 ........................... 803392 ..................................... Pin, Adjusting ................................................................................... 1 10 .......................... 811903 ..................................... Shaft ................................................................................................. 1 11 .......................... 050065-003 ............................. Washer .............................................................................................. 2 12 .......................... 803393 ..................................... Spring ............................................................................................... 1 13 .......................... 803391 ..................................... Washer .............................................................................................. 2 14 .......................... 808037 ..................................... Potentiometer ................................................................................... 1 803450-003 .............................. Pin Housing ................................................................................. 1 803450-010 .............................. Pin Crimp .................................................................................... 6 15 .......................... 803390 ..................................... Washer .............................................................................................. 1 16 .......................... 802856 ..................................... Button, U/L ........................................................................................ 1 17 .......................... 051057-020 ............................. Spring ............................................................................................... 2 18 .......................... 803640 ..................................... Pin ..................................................................................................... 1 19 .......................... 050012-074 ............................. Ring, Retaining ................................................................................. 5 20 .......................... 803641 ..................................... Pin ..................................................................................................... 2 21 .......................... 810560-002 ............................. Actuator, Horn .................................................................................. 1 22 .......................... 803635-001 ............................. Bushing ............................................................................................. 1 23 .......................... 803636 ..................................... Actuator, Upper ................................................................................ 1 24 .......................... 803633 ..................................... Actuator, Lower ................................................................................. 1 25 .......................... 050064-003 ............................. Screw ................................................................................................ 2 26 .......................... 089362 ..................................... Switch (RAS, HNS, LOS1) ............................................................... 3 803676 ..................................... Cable Assy (Freezer/Corrosion) ....................................................... 1 27 .......................... 050065-001 ............................. Washer .............................................................................................. 7 28 .......................... 050066-001 ............................. Nut .................................................................................................... 7 29 .......................... 050064-004 ............................. Screw ................................................................................................ 2 30 .......................... 805607 ..................................... Console ............................................................................................. 2 806500 ..................................... Console (Freezer/Corrosion) ............................................................ 2 31 .......................... 805869-001 ............................. Bracket, Switch ................................................................................. 1 805869-002 ............................. Bracket, Switch (Freezer/Corrosion) ................................................ 1 32 .......................... 050064-010 ............................. Screw ................................................................................................ 2 33 .......................... 050065-002 ............................. Washer .............................................................................................. 2 34 .......................... 810689 ..................................... Washer .............................................................................................. 2 35 .......................... 803469-015 ............................. Screw ................................................................................................ 4 36 .......................... 050064-005 ............................. Screw ................................................................................................ 2 050066-001 ............................. Nut .................................................................................................... 2 050065-001 ............................. Washer .............................................................................................. 4 093603 ..................................... Insulation (not shown) ...................................................................... 2 083019 ..................................... Jumper (not shown) .......................................................................... 1 053002-001 ............................. Grease .................................................................................................... AR 053002-005 ............................. Grease (Freezer/Corrosion) ................................................................... AR

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-4.5-1720

REV. 1 03/02

47

EMERGENCY DISCONNECT/BATTERY CONNECTOR

8 1

Rear of Battery Compartment

3

2 4

7

5

6

M1551 MP-4.7-1720

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

REV. 1 03/02

48M1.0-0000-00048

EMERGENCY DISCONNECT/BATTERY CONNECTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

SBE 160 1 ..................... 045239-001-01 ........................ Emergency Disconnect .......................................................................... 1 2 ..................... 805852 .................................... Battery Connector .................................................................................. 1 3 ..................... 050005-012 ............................. Screw ...................................................................................................... 4 050068-002 ............................. Nut .......................................................................................................... 4 4 ..................... 050003-028 ............................. Screw ...................................................................................................... 2 5 ..................... 050008-015 ............................. Nut .......................................................................................................... 4 6 ..................... 050068-002 ............................. Nut .......................................................................................................... 2 7 ..................... 807845 .................................... Battery Connector Assembly ................................................................. 1 803673 ..................................... Battery Connector ............................................................................ 1 052051-008 ............................. Power Cable + .................................................................................. 1 052051-010 ............................. Power Cable - ................................................................................... 1 ...................... 805856-001 ............................. Emergency Disconnect Assembly (included 1-3) ................................. 1 LB DIN 43589 1 ..................... 045239-001-02 ........................ Emergency Disconnect .......................................................................... 1 2 ..................... 805853 .................................... Battery Connector .................................................................................. 1 3 ..................... 050007-010 ............................. Screw ...................................................................................................... 2 050008-015 ............................. Nut .......................................................................................................... 2 4 ..................... 050003-028 ............................. Screw ...................................................................................................... 4 5 ..................... 050068-002 ............................. Nut .......................................................................................................... 4 6 ..................... 050068-002 ............................. Nut .......................................................................................................... 2 7 ..................... 807843 .................................... Battery Connector Assembly ................................................................. 1 803546-004 ............................. Battery Connector ............................................................................ 1 052051-012 ............................. Power Cable + .................................................................................. 1 052051-013 ............................. Power Cable - ................................................................................... 1 ...................... 805856-002 ............................. Emergency Disconnect Assembly (included 1-3) ................................. 1 only for Australia and New Zealand 1 ..................... 045239-001-03 ........................ Emergency Disconnect ..........................................................................

2 ..................... 808728 .................................... Battery Connector .................................................................................. 1 3 ..................... 050005-012 ............................. Screw ...................................................................................................... 2 050068-002 ............................. Nut .......................................................................................................... 2 4 ..................... 050003-028 ............................. Screw ...................................................................................................... 2 5 ..................... 050068-002 ............................. Nut .......................................................................................................... 4 6 ..................... 050068-002 ............................. Nut .......................................................................................................... 2 7 ..................... 807844 .................................... Battery Connector Assembly ................................................................. 1 078723-007 ............................. Battery Connector ............................................................................ 1 052051-014 ............................. Power Cable + .................................................................................. 1 052051-015 ............................. Power Cable - ................................................................................... 1 8 ..................... 808719 .................................... Plate ....................................................................................................... 1 050003-020 ............................. Screw ...................................................................................................... 4 805856-003 ............................. Emergency Disconnect Assembly (included 1-3) ................................. 1

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-4.7-1720

REV. 2 02/03

49

INSTRUMENT

M1561 MP-4.9-1720

50M1.0-0000-00050

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

INSTRUMENT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

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

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-4.9-1720

51

HORN

2

1

3 4

M1552 MP-4.13-1720

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

REV. 1 02/03

52M1.0-0000-00052

HORN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807878-002 ............................. Horn ........................................................................................................ 1 2 ..................... 050025-004 ............................. Screw ...................................................................................................... 1 3 ..................... 050073-002 ............................. Spring Washer ........................................................................................ 1 4 ..................... 050068-002 ............................. Nut .......................................................................................................... 1

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-4.13-1720

REV. 2 02/03

53

Page intentionally left blank

Printed in Germany

54M1.0-0000-00054

SECTION 5

Printed in Germany

55

BRAKE

MP-1720-001 MP-5.6-1720

56M1.0-0000-00056

MP-WP2000S-GB 02/03 • Rev. C • 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 .................... 807763-003-01Hub ................. Nabe .......................................................................................................

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 MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-5.6-1720

REV. 1 03/02

57

Page intentionally left blank

Printed in Germany

58M1.0-0000-00058

SECTION 7

Printed in Germany

59

FORK CARRIAGE Europe, Australia and New Zealand

MP-1720-006 MP-7.7-1720

60M1.0-0000-00060

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

FORK CARRIAGE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

Fork Carriage Assembly (singel Loadwheel/see next page) ................ 1 805921 .................................... Load (15mm) .......................................................................................... 2 805922-001 ............................. Load (20mm/RH) .................................................................................... 2 805922-002 ............................. Load (20mm/LH) .................................................................................... 2 050067-034 ............................. Screw ...................................................................................................... 4 only for New Zealand 1 ..................... 810407 .................................... Mount,Wheel .......................................................................................... 2 2 ..................... 050003-035 ............................. Screw ...................................................................................................... 4 3 ..................... 050010-023 ............................. Washer ................................................................................................... 4 4 ..................... 080191 .................................... Shaft ....................................................................................................... 6 5 ..................... 080192 .................................... Load Wheel ............................................................................................ 6 6 ..................... 060030-049 ............................. Washer ................................................................................................... 6 7 ..................... 060036-006 ............................. Roll Pin ................................................................................................... 6 810406 .................................... Mount,Wheel Assembly (included 1,4-7) ............................................... 2 only for Batterierollers 810375 .................................... Plate ....................................................................................................... 1 050003-060 ............................. Screw ...................................................................................................... 2 050068-003 ............................. Nut .......................................................................................................... 2 808244-001 ............................. Rubber Plate (50x10x435mm) ............................................................... 8 808244-002 ............................. Rubber Plate (50x8x435mm) ................................................................ 8 808244-003 ............................. Rubber Plate (50x10x108mm) .............................................................. 8 808244-004 ............................. Rubber Plate (50x8x108mm) ............................................................... 8 808391 .................................... Adhesive Tape ........................................................................................ AR

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-7.7-1720

REV. 2 02/03

61

FORK CARRIAGE Europe and Australia Fork Carriage 300Ah / single Loadwheel Fork Lenght

Fork Spread 520 mm

540 mm

670 mm

995 mm

805903-002-01

805903-003-01

805903-004-01

1125 mm

805903-002-02

805903-003-02

805903-004-02

1210 mm

805903-002-03

805903-003-03

805903-004-03 Tab001gb

Fork Carriage 300Ah / single Loadwheel with Battery Rolleers Fork Lenght

Fork Spread 520 mm

540 mm

670 mm

995 mm

808296-002-01

808296-003-01

808296-004-01

1125 mm

808296-002-02

808296-003-02

808296-004-02

1210 mm

808296-002-03

808296-003-03

808296-004-03 Tab002gb

MP-7.7-1720

62M1.0-0000-00062

MP-WP2000-GB 02/03 • Rev. E • Printed in Germany

FORK CARRIAGE New Zealand Fork Carriage 300Ah / single Loadwheel Fork Lenght

Fork Spread 520 mm

540 mm

670 mm

995 mm

805903-102-01

805903-103-01

805903-104-01

1125 mm

805903-102-02

805903-103-02

805903-104-02

1210 mm

805903-102-03

805903-103-03

805903-104-03 Tab003gb

Fork Carriage 300Ah / single Loadwheel with Battery Rolleers Fork Lenght

Fork Spread 520 mm

540 mm

670 mm

995 mm

808296-102-01

808296-103-01

808296-104-01

1125 mm

808296-102-02

808296-103-02

808296-104-02

1210 mm

808296-102-03

808296-103-03

808296-104-03 Tab004gb

MP-WP2000-GB 02/03 • Rev. E • Printed in Germany

MP-7.7-1720

63

FORK CARRIAGE Europe, Australia and New Zealand

M1544 MP-7.7-1720

64M1.0-0000-00064

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

FORK CARRIAGE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

Fork Carriage Assembly, Tandem Loadwheel (see next page) ............ 1 805921 .................................... Load (15mm) .......................................................................................... 2 805922-001 ............................. Load (20mm/RH) .................................................................................... 2 805922-002 ............................. Load (20mm/LH) .................................................................................... 2 050067-034 ............................. Screw ...................................................................................................... 4 only for Batterierollers 810375 .................................... Plate ....................................................................................................... 1 050003-060 ............................. Screw ...................................................................................................... 2 050068-003 ............................. Nut .......................................................................................................... 2 808244-001 ............................. Rubber Plate (50x10x435mm) ............................................................... 8 808244-002 ............................. Rubber Plate (50x8x435mm) ................................................................ 8 808244-003 ............................. Rubber Plate (50x10x108mm) .............................................................. 8 808244-004 ............................. Rubber Plate (50x8x108mm) ............................................................... 8 808391 .................................... Adhesive Tape ........................................................................................ AR

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-7.7-1720

REV. 2 02/03

65

FORK CARRIAGE Europe, Australia and New Zealand Fork Carriage 300Ah / tandem Loadwheel Fork Lenght

Fork Spread 520 mm

540 mm

670 mm

995 mm

808168-002-01

808168-003-01

808168-004-01

1125 mm

808168-002-02

808168-003-02

808168-004-02

1210 mm

808168-002-03

808168-003-03

808168-004-03 Tab005gb

Fork Carriage 300Ah / tandem Loadwheel with Battery Rolleers Fork Lenght

Fork Spread 520 mm

540 mm

670 mm

995 mm

808011-002-01

808011-003-01

808011-004-01

1125 mm

808011-002-02

808011-003-02

808011-004-02

1210 mm

808011-002-03

808011-003-03

808011-004-03 Tab006gb

MP-7.7-1720

66M1.0-0000-00066

MP-WP2000-GB 02/03 • Rev. E • Printed in Germany

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67

LIFT STRUCTURE 1 3

4

2

7

4 1

6

3

10 8

1 10

5

2

Load Roller, single

6 11 11

1

8

10

6 9 1 1 6

9 6

6 12

23

6 10

24

25 13

10

1

6

15

17

16 11

14

8

6 20 19 17

9

18

10 21 18 22

20

19

M1548 MP-7.8-1720

68M1.0-0000-00068

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

LIFT STRUCTURE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ........................................................................ Lift Structure ........................................................................................... 1 1 ........................... 054011-006 ............................. Grease Nipple ................................................................................... 16 2 ........................... 805761-002 ............................. Link Upper Assembly (included1 & 3) .............................................. 2 805761-001 ............................. Link Upper ........................................................................................ 2 3 ........................... 055084-008 ............................. Bushing ............................................................................................. 4 4 ........................... 807262 ..................................... Link Upper ........................................................................................ 2 050067-023 ............................. Screw ................................................................................................ 4 050009-052 ............................. Washer .............................................................................................. 2 050000-012 ............................. Roll Pin ............................................................................................. 2 5 ........................... 805773-002-02 ........................ Link Lower Assembly (included 1 & 6/520mm Fork Spread) .......... 1 805773-002-03 ........................ Link Lower Assembly (included 1 & 6/540mm Fork Spread) .......... 1 805773-002-04 ........................ Link Lower Assembly (included 1 & 6/670mm Fork Spread) .......... 1 805773-001-02 ........................ Link Lower (520mm Fork Spread) .............................................. 1 805773-001-03 ........................ Link Lower (540mm Fork Spread) .............................................. 1 805773-001-04 ........................ Link Lower (670mm Fork Spread) .............................................. 1 6 ........................... 055084-009 ............................. Bushing ............................................................................................. 20 7 ........................... 807097 ..................................... Pin ..................................................................................................... 2 8 ........................... 045224 ..................................... Shaft ................................................................................................. 4 9 ........................... 045469 ..................................... Shaft ................................................................................................. 4 10 .......................... 050000-015 ............................. Roll Pin ............................................................................................. 8 11 .......................... 050000-017 ............................. Roll Pin ............................................................................................. 4 12 .......................... 045292-001 ............................. End Tension Bar ............................................................................... 2 13 .......................... 045482-002-04 ........................ Tension Bar Assembly (995mm Fork Lenght-300Ah) ..................... 2 045482-002-33 ........................ Tension Bar Assembly (1125mm Fork Lenght-300Ah) ................... 2 045482-002-36 ........................ Tension Bar Assembly (1210mm Fork Lenght-300Ah) ................... 2 045482-002-11 ........................ Tension Bar (995mm Fork Lenght-300Ah/Battery Rollers) ............. 2 045482-002-30 ........................ Tension Bar (1125mm Fork Lenght-300Ah/Battery Rollers) ........... 2 045482-001-21 ........................ Tension Bar (1210mm Fork Lenght-300Ah/Battery Rollers) ........... 2 14 .......................... 060021-019 ............................. Nut .................................................................................................... 2 15 .......................... 045292-002 ............................. End Tension Bar ............................................................................... 2 16 .......................... 045301-002 ............................. Riser Tandem Assembly (included 1,6 & 17) ................................... 2 045301-001 .............................. Riser (Tandem Loadwheel) ........................................................ 2 17 ................................ 804665 ..................................... Bushing (Tandem Loadwheel) .................................................... 4 18 .......................... 806510 ..................................... Plate Side (Tandem Loadwheel) ...................................................... 4 19 .......................... 050009-036 ............................. Spacer (Tandem Loadwheel) ........................................................... 4 20 .......................... 050009-023 ............................. Spacer (Tandem Loadwheel) ........................................................... AR 21 .......................... 808984-001 ............................. Load Roller (Vulkolan/Tandem Loadwheel) ..................................... 4 22 .......................... 806507 ..................................... Shaft (Tandem Loadwheel) .............................................................. 4 23 .......................... 045303-002 ............................. Riser Single Assembly (included 1 & 6) .......................................... 2 045303-001 .............................. Riser (Single Loadwheel) ........................................................... 2 24 .......................... 808909-001 ............................. Load Roller (Vulkolan/Single Loadwheel) ........................................ 2 25 .......................... 805819 ..................................... Shaft (Single Loadwheel) ................................................................. 2

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-7.8-1720

REV. 3 02/03

69

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Printed in Germany

70M1.0-0000-00070

SECTION 8

Printed in Germany

71

LIFT CYLINDER

M1435 MP-8.4-1720

72M1.0-0000-00072

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 805600 .................................... Lift Cylinder Assembly ø60 .................................................................... 2 1 ........................... 805595 ..................................... Cylinder Tube .................................................................................... 2 2 ........................... 804766 ..................................... Guide Ring ........................................................................................ 4 3 ........................... 804760 ..................................... Seal ................................................................................................... 2 4 ........................... 804754 ..................................... Wiper ................................................................................................ 2 5 ........................... 805599 ..................................... Piston Rod ........................................................................................ 2

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-8.4-1720

73

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Printed in Germany

74M1.0-0000-00074

SECTION 9

Printed in Germany

75

PLATFORM

M1550 MP-9.0-1720

76M1.0-0000-00076

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

PLATFORM INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 810703 .................................... Platform Assembly ................................................................................. 1 807712 ..................................... Mat .................................................................................................... 1 053050-009 ............................. Adhesive Tape .................................................................................. AR 811699 ..................................... Pin ..................................................................................................... 4 2 ..................... 806094 .................................... Bush ....................................................................................................... 2 3 ..................... 806083 .................................... Sleeve ..................................................................................................... 1 4 ..................... 050017-008 ............................. Screw ...................................................................................................... 1 5 ..................... 806084-001 ............................. Spring (RH wound) ................................................................................ 1 806084-002 ............................. Spring (LH wound) ................................................................................. 1 6 ..................... 806784 .................................... Tube ........................................................................................................ 2 7 ..................... 050000-045 ............................. Pin .......................................................................................................... 1 8 ..................... 806085 .................................... Spring device ......................................................................................... 1 9 ..................... 050000-025 ............................. Pin .......................................................................................................... 3 10 .................... 806081 .................................... Shaft ....................................................................................................... 1 11* ................... 806023 .................................... Brake Lever ............................................................................................ 1 12* ................... 806024 .................................... Brake lining ............................................................................................. 1 053050-010 ............................. Adhesive ................................................................................................. AR 13 .................... 806025 .................................... Brake Ring .............................................................................................. 1 14 .................... 050017-011 ............................. Screw ...................................................................................................... 1 15 .................... 806089 .................................... Spinner ................................................................................................... 1 16 .................... 806088 .................................... Spring ..................................................................................................... 1 17 .................... 050005-037 ............................. Screw ...................................................................................................... 1 18 .................... 806504 .................................... Pin .......................................................................................................... 2 19 .................... 051053-002 ............................. Spring ..................................................................................................... 38 20 .................... 050000-002 ............................. Pin .......................................................................................................... 2 21 .................... 803619-001 ............................. Switch ..................................................................................................... 1 803310 .................................... Actuator .................................................................................................. 1 22 .................... 050004-009 ............................. Screw ...................................................................................................... 2 ...................... 050008-004 ............................. Nut .......................................................................................................... 2 23 .................... 806082 .................................... Cover ...................................................................................................... 1 24 .................... 050071-034 ............................. Screw ...................................................................................................... 4 25 .................... 050006-042 ............................. Screw ...................................................................................................... 2 * ..................... 808097 .................................... Brake Assembly (included 11 & 12) ...................................................... 1

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-9.0-1720

REV. 1 03/02

77

PLATFORM

M1546 MP-9.0-1720

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

REV. 1 03/02

78M1.0-0000-00078

PLATFORM INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807503-001 ............................. Gate (LH) ................................................................................................ 1 807503-003 ............................. Gate (LH/only for fixed Platform) ........................................................... 1 807503-002 ............................. Gate (RH) ............................................................................................... 1 807506 .................................... Pad ......................................................................................................... 2 050071-009 ............................. Screw ...................................................................................................... 4 2 ..................... 806095 .................................... Bearing ................................................................................................... 4 3 ..................... 807497-001 ............................. Bushing (LH) .......................................................................................... 1 807497-002 ............................. Bushing (RH) .......................................................................................... 1 811700 .................................... Gong ....................................................................................................... 2 050003-010 ............................. Screw ...................................................................................................... 2 4 ..................... 050000-041 ............................. Pin .......................................................................................................... 4 5 ..................... 807493 .................................... Brake Lever Assembly ........................................................................... 2 806024 ..................................... Brake Lining ...................................................................................... 2 053050-010 ............................. Adhesive ........................................................................................... AR 6 ..................... 050006-054 ............................. Screw ...................................................................................................... 2 7 ..................... 803619-001 ............................. Switch ..................................................................................................... 2 803310 .................................... Actuator .................................................................................................. 2 8 ..................... 050004-034 ............................. Screw ...................................................................................................... 4 9 ..................... 050008-004 ............................. Nut .......................................................................................................... 4 10 .................... 807280-001 ............................. Cover (LH) .............................................................................................. 1 807280-002 ............................. Cover (RH) ............................................................................................. 1 050071-035 ............................. Screw ...................................................................................................... 2 11 .................... 050003-030 ............................. Screw ...................................................................................................... 4 12 .................... 050017-011 ............................. Screw ...................................................................................................... 2 not illustrated 806088 .................................... Spring ..................................................................................................... 2 806089 .................................... Spinner ................................................................................................... 2

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-9.0-1720

REV. 1 03/02

79

PLATFORM fixed Platform

MP-1720-005 MP-9.0-1720

80M1.0-0000-00080

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

PLATFORM INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 808320 .................................... Platform .................................................................................................. 1 2 ..................... 808482 .................................... Puffer ...................................................................................................... 2 3 ..................... 050067-044 ............................. Screw ...................................................................................................... 4 4 ..................... 808314-001 ............................. Platform Covers (LH) ............................................................................. 1 808305-001 ............................. Pad (LH) ................................................................................................. 1 808314-002 ............................. Platform Covers (RH) ............................................................................. 1 808305-002 ............................. Pad (RH) ................................................................................................. 1 053050-010 ............................. Adhesive ................................................................................................. AR 5 ..................... 050003-054 ............................. Screw ...................................................................................................... 6 6 ..................... 050068-005 ............................. Nut .......................................................................................................... 6 7 ..................... 808476 .................................... Support ................................................................................................... 1 8 ..................... 050003-034 ............................. Screw ...................................................................................................... 4 9 ..................... 808323 .................................... Floorplate ............................................................................................... 1 10 .................... 050071-034 ............................. Screw ...................................................................................................... 2 11 .................... 050003-012 ............................. Screw ...................................................................................................... 4 12 .................... 808366 .................................... Dead Man Pedal ..................................................................................... 1 13 .................... 808481-002 ............................. Mat .......................................................................................................... 1 053050-010 ............................. Adhesive ................................................................................................. AR 14 .................... 808481-001 ............................. Mat .......................................................................................................... 1 053050-010 ............................. Adhesive ................................................................................................. AR 15 .................... 808481-003 ............................. Mat .......................................................................................................... 1 053050-010 ............................. Adhesive ................................................................................................. AR 16 .................... 050071-035 ............................. Screw ...................................................................................................... 4 17 .................... 804863-001 ............................. Cage Nut ................................................................................................ 4 18* ................... 804606 .................................... Support ................................................................................................... 2 19* ................... 050009-008 ............................. Washer ................................................................................................... 8 20* ................... 050008-008 ............................. Nut .......................................................................................................... 8 21* ................... 804605 .................................... Screw ...................................................................................................... 2 22* ................... 051058-010 ............................. Bush ....................................................................................................... 4 23* ................... 051064-003 ............................. Spring ..................................................................................................... 2 24* ................... 808324 .................................... Lever ....................................................................................................... 2 25* ................... 050008-015 ............................. Nut .......................................................................................................... 2 26* ................... 804662 .................................... Axle ......................................................................................................... 2 27* ................... 050001-013 ............................. Pin .......................................................................................................... 2 28 .................... 803619-001 ............................. Switch ..................................................................................................... 1 803310 .................................... Actuator .................................................................................................. 1 29 .................... 050009-001 ............................. Washer ................................................................................................... 2 30 .................... 050004-033 ............................. Screw ...................................................................................................... 2 31 .................... 050008-004 ............................. Nut .......................................................................................................... 2 * ..................... 808327-001 ............................. Switch (LH/included 18,21-31) ............................................................. 1 * ..................... 808327-002 ............................. Switch (RH/included 18,21-27) ............................................................. 1

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-9.0-1720

81

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Printed in Germany

82M1.0-0000-00082

SECTION 10

Printed in Germany

83

LABELS AND DECALS

MP-1720-003 MP-10.9-1720

84M1.0-0000-00084

MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

LABELS AND DECALS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 808202-xxx-xx ......................... Labels & Decals ..................................................................................... 1 1 ........................... 106158-019 ............................. Crown Logo ...................................................................................... AR 2 ........................... 106158-001 ............................. Crown Logo ...................................................................................... AR 3 ........................... 869255-xxx .............................. Name Plate ....................................................................................... 1 69308 ....................................... Name Plate (Australia and New Zealand) ....................................... 1 4 ........................... 869020-xxx .............................. Decal Battery Warning ..................................................................... 1 5 ........................... 869012-xxx .............................. Decal Battery, Charger ..................................................................... 1 6 ........................... 869054-xxx .............................. Decal Operator Warning ................................................................... 1 69256 ....................................... Decal Operator Warning (Australia and New Zealand) ................... 1 xxxxxx-001 ............................... German xxxxxx-002 ............................... French xxxxxx-003 ............................... Spanish xxxxxx-004 ............................... Dutch xxxxxx-005 ............................... Italian xxxxxx-006 ............................... English xxxxxx-006 ............................... Australia and New Zealand Platform Standard xxxxxx-001-01 ......................... German xxxxxx-002-01 ......................... French xxxxxx-003-01 ......................... Spanish xxxxxx-004-01 ......................... Dutch xxxxxx-005-01 ......................... Italian xxxxxx-006-01 ......................... English xxxxxx-007-01 ......................... Australia and New Zealand Platform Battery Rollers xxxxxx-001-02 ......................... German xxxxxx-002-02 ......................... French xxxxxx-003-02 ......................... Spanish xxxxxx-004-02 ......................... Dutch xxxxxx-005-02 ......................... Italian xxxxxx-006-02 ......................... English xxxxxx-007-02 ......................... Australia and New Zealand fixed Platform xxxxxx-001-03 ......................... German xxxxxx-002-03 ......................... French xxxxxx-003-03 ......................... Spanish xxxxxx-004-03 ......................... Dutch xxxxxx-005-03 ......................... Italian xxxxxx-006-03 ......................... English xxxxxx-007-03 ......................... Australia and New Zealand fixed Platform & Battery Rollers xxxxxx-001-04 ......................... German xxxxxx-002-04 ......................... French xxxxxx-003-04 ......................... Spanish xxxxxx-004-04 ......................... Dutch xxxxxx-005-04 ......................... Italian xxxxxx-006-04 ......................... English xxxxxx-007-04 ......................... Australia and New Zealand

Always Specify Model & Serial Number MP-WP2000S-GB 02/03 • Rev. C • Printed in Germany

MP-10.9-1720

85

Page intentionally left blank

Printed in Germany

86M1.0-0000-00086