Manitou 3500 SERIES K3501 THRU K3507 2 RAIL MAST Parts Manual - PDF DOWNLOAD

CONTENTS

MANITOU NORTH AMERICA, INC. 6401 IMPERIAL DRIVE Waco, TX 76712--6803

NOTE: Manitou Forklift Manuals are continually updated and subject to change without prior notice. If your Forklift Mast Model or parts are not found in this manual, please contact your dealer or the Manitou North America Parts Department for the latest information and parts availability.

3500 SERIES 2 RAIL MAST

2,500 -- 8,000 LB. CAPACITY MODELS K3501 THRU K3507

PARTS MANUAL

For Parts Orders contact your Manitou North America Dealer or call: Manitou North America, Parts Dept. 800--425--3727 or (254) 799--0232 Parts Dept. Fax: (254) 867--6504

Website: www.manitou--na.com

CATALOG R384 R10--94

CONTENTS

GENERAL INFORMATION The purpose of this catalog is to provide illustrations for identifying and ordering Mast components/parts.

Because of the multitude of Mast Models and components utilized, the illustrations provide a general description and therefore may not show the exact shape or detail of the components/parts represented.

The Mast parts are identified by an Item Number on the illustration or picture page. Find the Item Number for the part desired, then locate that Item Number under the ”Items” column following the illustration. The Part Number will be located directly to the right of the Item Number. Also provided is a part Description, Quantity of parts required and the mast Model number.

Most important when ordering parts, is providing the correct serial number as assigned to the mast at the factory. Keep accurate records of all modifications or improvements made to the mast after manufacture. (All Mast modifications must be authorized by K--D Manitou.) Notify the Parts Dept. of any changes that may affect your parts order.

When ordering Mast parts or requesting technical information, the following numbers are required: Mast Model Number:_____________________________________________ Mast Serial Number:______________________________________________ For quick reference it is recommended these numbers be recorded as soon as possible.

The Mast Model Number is stamped on the Identification Plate located on the right side (as viewed from the driver’s seat) of the Outer Rail, at or above eye level.

MAST MODEL NO. DESCRIPTION (SAMPLE) MODEL NO. OF MAST RAILS

MODEL NO. OF OPTIONAL EQUIPMENT

K5705 -- K5797 -- K5755 -- K1479 MODEL NO. OF CARRIAGE

MODEL NO. OF MOUNTING

To order Mast Parts, contact the K- D MANITOU DEALER in your area or K- D Manitou, Parts Division, Waco, Texas.

1--800--425--3727

CONTENTS

CONTENTS MAST RAIL ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CHAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 HOSE KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CARRIAGE ASSEMBLY, 42”, 60” & 72” HOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CARRIAGE ASSEMBLY, 42”, 60” & 72” SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DECALS

CATALOG R394

-- 1 --

R/10--94

CONTENTS

MAST RAIL ASSEMBLIES 2 1

3 4

3

5* 6*

9

7*

4

8*

7*

6*

10

R/10--94

-- 2 --

CATALOG R384

CONTENTS

ITEM

PART NUMBER

DESCRIPTION

QTY

MODEL

1 1 1 1 1

R8360--5 R8362--6 R8360--7 R8360--8 R8360--16

Outer Rail Assembly Outer Rail Assembly Outer Rail Assembly Outer Rail Assembly Outer Rail Assembly

1 1 1 1 1

K3501 K3502 K3503 K3504 K3507

2 2 2 2 2

R65--2 R65--3 R65--4 R65--5 R65--16

Inner Rail Assembly Inner Rail Assembly Inner Rail Assembly Inner Rail Assembly Inner Rail Assembly

1 1 1 1 1

K3501 K3502 K3503 K3504 K3507

3 4 5* 6* 7* 8*

R22 R2 K87901 R106 R4584 R7638

Shim Roller Fitting, Grease Ring, Retaining Wiper Bearing, Mast Mounting

A/R 4 2 4 4 4

ALL

9 10

R63 K33845

Bolt, Cylinder Restraining Nut

1 1

* For use on Masts mounted to K--D Manitou M--Series Forklift Trucks only.

CATALOG R384

-- 3 --

R/10--94

CONTENTS

CYLINDER ASSEMBLY 8* 19

7

18 6 17 5* 4

21

22

2 3

20 23 9* 16

10*

11

1

TO MAST

24 25 12

13 14 15

R/10--94

TO TRUCK

-- 4 --

CATALOG R384

CONTENTS

ITEM

PART NUMBER

DESCRIPTION

QTY

MODEL

1 1 1 1 1

R2150--1 R2150--2 R2150--3 R2150--4 R2150--12

Cylinder Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly Cylinder Assembly

1 1 1 1 1

K3501 K3502 K3503 K3504 K3507

2 2 2 2 2

R2160--1 R2160--2 R2160--3 R2160--4 R2160--19

Barrel Assembly Barrel Assembly Barrel Assembly Barrel Assembly Barrel Assembly

1 1 1 1 1

K3501 K3502 K3503 K3504 K3507

3 3 3 3 3

R2165--1 R2165--2 R2165--3 R2165--4 R2165--12

Piston Assembly Piston Assembly Piston Assembly Piston Assembly Piston Assembly

1 1 1 1 1

K3501 K3502 K3503 K3504 K3507

4 5* 6 7 8* 9* 10*

R2554 -- -- -- -R347 R346 -- -- -- --- -- -- --- -- -- --

Ring, Wear Seal Retainer, Seal Snap Ring Wiper O--Ring Ring, Back Up

1 1 1 1 1 1 1

ALL

11 12 13 14 15 16

R2158 K306401 R348 K914 K62--12--14 R2156

Plug Screw, Cap Control, Flow O--Ring Adapter (Includes Item 14) Wear Ring

1 1 1 1 1 1

17 17 17 17

R2233--1 R2233--2 R2233--3 R2233--15

Spacer Spacer Spacer Spacer

1 1 1 1

18 19 20 21 22 23

R102 R13453--1 R2211--2 R2551 R2552 R2190

Washer Ring, Snap Lock Wire Screw, Button Hd Washer, Seal Seal Kit

1 1 1 1 1 1

24 25

426210 426593

Union Tube Assembly

1 1

YEAR

K3501, K3502 K3503 K3504 K3507

(M230/430CP, w/out 450 tilt) (M230/430CP, w/out 450 tilt)

* Included in Seal Kit, Item 23.

CATALOG R384

-- 5 --

R/10--94

CONTENTS

CHAIN ASSEMBLY 9 8 UPPER INNER RAIL (REF)

1

4

2 3

HYDRAULIC CYLINDER (REF)

4 6

3

5

7 CARRIAGE (REF) 5

R/10--94

-- 6 --

CATALOG R384

CONTENTS

ITEM

PART NUMBER

DESCRIPTION

QTY

MODEL

1* 1* 1* 1*

R194--2 R194--3 R194--4 R194--5

Chain Assembly (7 Leaf thickness) Chain Assembly (7 Leaf thickness) Chain Assembly (7 Leaf thickness) Chain Assembly (7 Leaf thickness)

2 2 2 2

K3501 K3502 K3503 K3504

1** 1** 1** 1** 1**

R9481--26 R9481--32 R9481--38 R9481--44 R9481--66

Chain Assembly (8 Leaf thickness) Chain Assembly (8 Leaf thickness) Chain Assembly (8 Leaf thickness) Chain Assembly (8 Leaf thickness) Chain Assembly (8 Leaf thickness)

2 2 2 2 2

K3501 K3502 K3503 K3504 K3507

2* 2**

R193 R9482

Anchor, Chain Anchor, Chain

2 2

3* 3**

R189--2 R189--3

Pin, Chain Pin, Chain

4 4

4 5 6

K72016 R32 R213

Pin, Cotter Nut, Hex Lock Nut, Rocker

8 4 2

7* 7**

R192 R9483

Anchor, Chain Anchor, Chain

2 2

8 9

R186 K97541

Sheave Ring, Snap

2 2

* For use on Mast Serial No. R280--01 thru R280--86. Add additional 14” to chain length when supplying Item 1 Chain, if used with Carriage Model K3589. ** For use on Mast Serial No. R280--87 & above. Add additional 14” to chain length when supplying Item 1 Chain, if used with Carriage Model K3589.

CATALOG R384

-- 7 --

R/11--00

CONTENTS

HOSE KITS 11 7 6

12

8

13

9 10 4 4 3 5 2

INNER RAIL

1

16

14 15 WELDS TO BACK OF INNER RAIL

17

14 16 15

R/10--94

WELDS TO CARRAGE

-- 8 --

CATALOG R384

CONTENTS

ITEM

PART NUMBER

DESCRIPTION

QTY

1 1

B760--1734 B760--1733

Hose Assembly, R.H. (Shown) Hose Assembly, L.H.

1 1

1 1 1 1

B760--989 B760--990 B760--991 B760--992

Hose Assembly Hose Assembly Hose Assembly Hose Assembly

2 2 2 2

K3561--1 K3561--2 K3561--3 K3561--4

2 3 4 5 6 6

R9064 R2362 R7332 R7333 R5271 R5272

Sheave, Hose Bearing Snap Ring, Internal Snap Ring, External Bracket Assembly, R.H. (Shown) Bracket Assembly, L.H.

2 2 4 2 1 1

ALL

7 8 9 10 11

K33799 K33924 R5283 K304796 K20472

Nut, Hex Jam Nut, Hex Sleeve, Retainer Bolt, Hex Bolt, Hex

4 4 4 4 4

12 13 14 15 16 17

R5284 K20526 K108--8 R10413 K22--8 R5268

Block Bolt, Hex Fitting, Bulkhead Plate, Mounting Nut, Lock Fitting, Adaptor

2 4 4 4 4 2

CATALOG R384

-- 9 --

MODEL Waco ’M’ Series Trucks Waco ’M’ Series Trucks

R/10--94

CONTENTS

CARRIAGE ASSEMBLY, 42”, 60” & 72” HOOK 7 5

6

4 1 2 3

8

9 10

14

11 13

R/10--94

12

-- 10 --

CATALOG R384

CONTENTS

ITEM

PART NUMBER

DESCRIPTION

QTY

MODEL

1 1 1

R3825--1 R23190--1 R3825--3

Carriage Assembly, 42” Carriage Assembly, 60” Carriage Assembly, 72”

1 1 1

K3596 K3595 K3594

2 3 4 5 6

R22 R2* R3564 R3561 R1**

Shim Roller Bolt Shaft Roller

A/R 4 2 2 2

ALL

7 8 9 10 11

K97535 R3712 R3711 K302282 R2393

Ring, Snap Shim Block, Thrust Screw, Socket Head Cap Washer

2 A/R 2 4 8

12 13 14

R4095 R4099 K305135

Roller, Inside Thrust Shaft Pin, Roll

4 2 4

* Available for replacement of the R2 Roller is a 0.015” over--sized Roller, order Part No. R446. ** Available for replacement of the R1 Roller is a 0.015” over--sized Roller, order Part No. R442.

CATALOG R384

-- 11 --

R/10--94

CONTENTS

CARRIAGE ASSEMBLY, 42”, 60” & 72” SHAFT

15

1 2 3

16

8

9 10 17

14

18

11 13

7

12 6 5 4

R/10--94

-- 12 --

CATALOG R384

CONTENTS

ITEM

PART NUMBER

DESCRIPTION

QTY

MODEL

1 1 1

R130 R155 R550

Carriage Assembly, 42” Carriage Assembly, 60” Carriage Assembly, 72”

1 1 1

K3599 K3598 K3597

2 3 4 5 6

R22 R2* R3564 R3561 R1**

Shim Roller Bolt Shaft Roller

A/R 4 2 2 2

7 8 9 10 11

K97535 R3712 R3711 K302282 R2393

Ring, Snap Shim Block, Thrust Screw, Socket Head Cap Washer

2 A/R 2 4 8

12 13 14

R4095 R4099 K305135

Roller, Inside Thrust Shaft Pin, Roll

4 2 4

15 15 15

R1187--1 R1187--2 R1187--3

Bar, Implement, 42” Bar, Implement, 60” Bar, Implement, 72”

1 1 1

16 17 18

K45548 K34807 K33799

Bolt, Hex Washer, Lock Nut, Hex

1 1 1

* Available for replacement of the R2 Roller is a 0.015” over--sized Roller, order Part No. R446. ** Available for replacement of the R1 Roller is a 0.015” over--sized Roller, order Part No. R442.

CATALOG R384

-- 13 --

R/10--94

CONTENTS

DECALS

1

1

ROUGH TERRAIN MAST 48”

2, 3

INDUSTRIAL MAST 57”

2

2, 3 3

ITEM

PART NUMBER

DESCRIPTION

QTY

MODEL

1 2 3

426641 426642 426643

Decal, ”Fork Safety” Decal, ”Pinch Point” (Small) Decal, ”Pinch Point” (Large)

2 A/R A/R

ALL