Raymond 101 Walkie Pallet Truck Parts Catalog Manual PDPM-0198 - PDF DOWNLOAD

Model - 101 Walkie Pallet Truck

Parts Catalog

PDPM-0198 S/N 101-99-10000 to 101-00-19999 Issued 7/13/01

Raymond is a registered trademark of The Raymond Corporation. © Copyright The Raymond Corporation 2001.

All Rights Reserved.

Walkie Pallet Truck, Model 101 - Table of Contents

Table of Contents SECTION 1

General Information

To Our Customer ................................................................................................................................ 1-3 How To Use Parts Catalog - If Part Number Not Known........................................................................... 1-4 How To Use Parts Catalog - If Part Number Is Known .............................................................................. 1-5 Major Assemblies ............................................................................................................................... 1-7 Recommended Spare Parts List ............................................................................................................. 1-9 Hardware Parts List ........................................................................................................................... 1-11 Bulk Items List ................................................................................................................................... 1-13

SECTION 2 Finish and Accessories Truck Major Assemblies....................................................................................................................... 2-2 Truck Final Assembly........................................................................................................................... 2-4 Finish Instructions ................................................................................................................................ 2-7 Load Backrest................................................................................................................................... 2-10

SECTION 3 Steering and Controls Handle Mounting and Installation ......................................................................................................... 3-2 Handle and Controller Assembly .......................................................................................................... 3-5 Control Assembly................................................................................................................................ 3-9 Handle Arm Assembly ....................................................................................................................... 3-10

SECTION 4 Drive and Brake Transmission Assembly ........................................................................................................................ 4-3 Drive Wheel Assembly ........................................................................................................................ 4-7 Brake Assembly .................................................................................................................................. 4-8

SECTION 5 Electrical Components and System Electrical System................................................................................................................................. 5-2 Contactor Assembly ............................................................................................................................ 5-4 Meter Installation ................................................................................................................................ 5-6 Battery Pack, 24 Volt (Wet Battery) ....................................................................................................... 5-8 Battery Tree and Cover Assembly ....................................................................................................... 5-10 Battery Pack and Cable Assembly (Wet Battery) ................................................................................... 5-12 Charger Assembly (Wet Battery)......................................................................................................... 5-14 Battery Pack, GNB Maintenance Free, 24 Volt ..................................................................................... 5-16 Charger Assembly (Maintenance Free) ................................................................................................ 5-18 Drive Motor ..................................................................................................................................... 5-20 Programmable Maintenance Tool ....................................................................................................... 5-22

SECTION 6 Hydraulic Components Hydraulic System ................................................................................................................................ 6-2 Lift Pump and Motor Assembly.............................................................................................................. 6-4 Hydraulic Cylinder.............................................................................................................................. 6-6

SECTION 7 Mast Fork Final Assembly ............................................................................................................................ 7-2 Load Wheel Assembly......................................................................................................................... 7-4

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Walkie Pallet Truck, Model 101 - Table of Contents

APPENDIX A Alphabetical Parts Index APPENDIX B Numerical Parts Index

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SECTION 1 General Information To Our Customer ................................................................................................................................ 1-3 How To Use Parts Catalog - If Part Number Not Known........................................................................... 1-4 How To Use Parts Catalog - If Part Number Is Known .............................................................................. 1-5 Major Assemblies ............................................................................................................................... 1-7 Recommended Spare Parts List ............................................................................................................. 1-9 Hardware Parts List ........................................................................................................................... 1-11 Bulk Items List ................................................................................................................................... 1-13

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Walkie Pallet Truck, Model 101 - General Information To Our Customer

To Our Customer

1

The Part Numbers in this Parts Catalog were correct at the time your truck was manufactured. It is our policy to constantly improve our products, therefore, part numbers may continue to change. When ordering parts, verify part numbers through your Dealer’s Parts Catalog, which is kept up to date. Also note that Illustrations of assemblies and components may not necessarily conform to the exact installation as they appear on your truck.

Tips for Ordering Parts In addition to Part Number and Description, have available:

• The model number and serial number of the truck • Pertinent specifications such as mast height, battery voltage, drive motor type, etc.

• Pertinent name plate data • Applicable installation or assembly numbers • Accurate Part Number

Using This Catalog This Catalog contains navigational aids to help you locate specific parts information.

• Use Section 1 to decide where to start your search for information. The overall locator views define the technical configuration of the Catalog and tie the figures in the Catalog to the engineering data base.

• Use the Table of Contents to locate assemblies and subassemblies by name.

• Use the Alphabetical Index (by Part Name) and the Numerical Index (by Part Number) to locate individual parts.

• Determine configuration differences with the “Used On” codes contained within the Parts List. The “Used On” code attaches a part number to a wide range of design variables such as operating voltage, battery size, steering type, mast height and extension speed, fork carriages, color and size of tires, guide wheel specs, etc.

Technical Assistance For Authorized Raymond Dealers Only Authorized Raymond Dealers ONLY, please fax your Technical Inquiry to (315) 463-9145.

For further assistance after faxing your Technical Inquiry, please call (315) 463-5000.

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Walkie Pallet Truck, Model 101 - General Information How To Use Parts Catalog - If Part Number Not Known

How To Use Parts Catalog - If Part Number Not Known

1

IF THE PART NUMBER IS NOT KNOWN

Major Assemblies

SECTION 7 MAST SECTION 6 HYDRAULIC COMPONENTS

DO THIS

SECTION 3 STEERING AND CONTROLS

1.

SECTION 5 SECTION 4 ELECTRICAL COMPONENTS AND

SECTION 2 FINISH AND ACCESSORIES

Determine in which Section the part is located using the illustration.

Drive and Brake

Drive Unit Assembly SYSTEMS - 271" and Above Elevated Height ..............................................................................4-2 Drive Unit Assembly - 270" and Below Elevated Height ...............................................................................4-4 Deadman Brake Assembly ........................................................................................................................4-6 SECTION(used 4 with motor 570-262/500 only) ...............................................................4-8 Brake Assembly/Installation DRIVE AND Drive Unit Brake Assembly ......................................................................................................................4-12 BRAKE .....................................................................................................................4-14 Brake Assembly Installation Inertial Dampener ..................................................................................................................................4-16

2.

Turn to the TABLE OF CONTENTS in the applicable Section.

Figure 1-1: Major Assemblies

1-3

Frame Assembly - DS/DT

7 29

5

28

30

23

12

26 25 24

20

11

22

4

6 10

19

21

17

18

16 15

14

13

31 2

9 8

40

3.

Refer to the PAGE NUMBER selected from the TABLE OF CONTENTS. Locate the desired part and note the ITEM NO.

37

36

39

3

38 1

FIGURE 2-2 ITEM NO. 1

Figure 2-2: Frame Assembly - DS/DT

2-1

QTY

PART NUMBER

5

828-005-691/003

5

828-005-691/001

5

828-005-691/002

2 3 4 5 6 7

REF 1 1 1 2 2

828-006-283 714-206 828-004-421 861-026 462-032

Roller Assembly (consists of items 36 through 40) Roller Assembly (consists of items 36 through 40) Roller Assembly (consists of items 36 through 40) Frame Weldment Door Weldment Screw Bracket, Latch Pin, Clevis Bearing

8 9 10

20 21 22 23 24 25 26 27

1 1 1 1 2 2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 2 2 1

710-264P 750-433 828-004-622 828-006-364 750-006 771-049 760-130 810-733 828-004-651 710-067 771-019 114-008-306 114-009-695 1-150-057 1-150-001 7-590-006/001 114-008-718/005 5-015-003 5-015-004 828-004-672 828-004-671 710-069 411-938/001

Screw Nut, Hex ODI Assembly ODI Assembly Nut, Hex Washer Nut, Lock Pin, Roll Bracket, Key Screw Washer Switch Assembly, Key Switch Assembly, Key Switch, Push Button Switch, Lock with Keys Switch, Push Button SMARTi Assembly Nut, Hex Nut, Hex Bracket Weldment Washer Screw Decal, Keyswitch (Not Shown)

28 29 30 31

1 1 1 1 1 1 1

411-938/003 411-938/002 411-938/004 828-004-674 828-004-683 828-004-682 154-009-117/001

Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Cable Assembly, SC to SMARTi Bracket, SMARTi Clamp, ODI Static Strap, Insulated

11 12 13 14 15 16 17 18 19

4.

Refer to the corresponding PART LIST. Use the FIGURE & ITEM NO. to find the Part Number, Description, etc.

A= 14" Battery Compartment B= 16" Battery Compartment C= 21" Battery Compartment D= Without Rear Posts E= With Rear Posts

F= Standard G= Remote H= SMARTi K= Standard/Bypass L= SMARTi/Bypass

DESCRIPTION

M= Remote/Bypass N= Remote/SMARTi O= DT 001 to 3842/DS 001 to 3802 P= Remote/SMARTi/Bypass Q= DT 001 to 3566/DS 001 to 3640

USED ON A B C A, Q S

R

O T H, L, M, P

F, H, K, L, M, R F, H, K, L, M, P, R M, R, R G, M, N, P K, L, M, P, R H, L, N, P H, L, N, P H, L, N, P

F, H G K, L M, N, P H, L, N, P H, L, N, P F, G, K, M S= DT 3567 and Up/DS 3641 and Up T= DT 3843 and Up/DS 3803 and Up R= Recommended Spare

List 2-2: Frame Assembly - DS/DT

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Walkie Pallet Truck, Model 101 - General Information How To Use Parts Catalog - If Part Number Is Known

How To Use Parts Catalog - If Part Number Is Known IF THE PART NUMBER IS KNOWN

APPENDIX B

DO THIS

1

Numerical Parts List 411-773 .................... Decal, No Riding, Bilingual ..................2-7 411-789 .................... Decal, Warning....................................2-7 411-790 .................... Decal, Warning, Bilingual ....................2-7 411-848 .................... Decal, 24 Volt Cable System .............. 5-11 411-849 .................... Decal, 24 Volt Cable System .............. 5-11 411-850 .................... Decal, Charging Warning .................. 5-11 411-851 .................... Decal, Charging Warning .................. 5-11 411-852 .................... Decal, Battery Swivel Warning ............ 5-11 411-853 .................... Decal, Battery Swivel Warning ............ 5-11 412-454 .................... Decal, ISO 9001..................................2-7 412-586 .................... Plate, Lowlift Specification (U.S.) ...........2-7 412-588 .................... Plate, Lowlift Specification (Canadian) ..2-7 441-013 .................... Bearing, Sealed....................................4-9 441-127 .................... Bearing, Shield ...................................7-5 447-098 .................... Bearing, Cone ....................................4-3 447-108 .................... Bearing, Cone ....................................4-3 447-562 .................... Bearing, Cup ......................................4-3 447-579 .................... Bearing, Cup ......................................4-3 462-029 .................... Bushing, Flanged ................................4-5 464-034 .................... Bushing .............................................. 2-3 464-035 .................... Bushing .............................................. 2-3 464-035 .................... Bushing .............................................. 7-3 464-036 .................... Bearing, Oilite Super ...........................7-5 520-078/03 .............. Plug, Shipping ..................................... 6-9 530-449 .................... O-Ring ...............................................4-5 530-490/038 ............ O-Ring, Motor ....................................4-9 540-062 /100 ........... Cylinder, Hydraulic (Eaton) ...................6-9 540-062/01 .............. Rod, Piston .........................................6-9 540-062/02 .............. Barrel Assembly ..................................6-9 540-062/03 .............. Seal Kit ...............................................6-9 540-062/200 ............ Cylinder, Hydraulic (Ultra).....................6-9 540-062 .................... Cylinder, Hydraulic............................... 6-5 560-206/123 ............ Valve, Flow Control (2 GPM) ................ 6-7 560-206/130 ............ Reservoir Kit (With Tubes) .....................6-7 560-206/132 ............ Adapter Block (With Check Valve) .........6-7 560-206/135 ............ Plug, Vent (With 40 Micron Filter) .........6-7 560-209/04 .............. Valve/Coil, Solenoid Release.................6-7 560-209/06 .............. Valve, Adjustable Relief ........................6-7 560-209/07 .............. Pump (With Coupling, Bolts & Gasket) ..6-7 560-209/08 .............. Elbow, 90 Degree ...............................6-7 560-209/09 .............. Switch, Solenoid Start ........................... 6-7 560-213/01 .............. Motor, 24 Volt DC 2 Terminal ...............6-7 560-213/01 .............. Pump Motor....................................... 5-23 560-213/02 .............. Brush Set ........................................... 5-23 560-213 .................... Pump and Motor Assembly ...................6-5 560-213 .................... Pump/Motor Assembly ........................6-7 570-271/515 ............ Brush Lead Assembly Kit .................... 5-23 570-271/516 ............ Commutator End Bearing ..................5-23 570-271/516 ............ Drive End Bearing ............................. 5-23 570-271/517 ............ Washer ............................................. 5-23 570-316/511 ............ Seal .................................................. 5-23 570-316/513 ............ Retaining Ring ...................................5-23 570-360/511 ............ Brush Set ........................................... 5-23 570-360/512 ............ Brush Spring Set.................................5-23 570-864 .................... Drive Motor - S/N 5478 & Up ............ 5-23 570-864 .................... Drive Motor, 24 Volt ...........................4-11 590-514 .................... Fuse, 15 Amp ......................................5-3 590-638/001 ............ Horn Assembly.....................................5-3 590-701 .................... Battery Connector ..............................5-15 590-701 .................... Battery Connector ..............................5-17 590-701 .................... Battery Connector ................................ 5-6 600-213 .................... Grommet .......................................... 5-15 610-307 .................... Shaft, Flexible ......................................3-7

024-296-290/260 ..... Cable Assembly ................................. 5-15 024-296-420/261 ..... Cable Assembly ................................. 5-15 024-297-280/000 ..... Cable Assembly ................................. 5-15 024-297-310/000 ..... Cable Assembly ................................. 5-15 024-297-430/000 ..... Cable Assembly ................................. 5-15 029-002-380/001 ..... Cable Assembly (MDE2 to S1) .............. 5-3 029-002-380/002 ..... Cable Assembly (MDE2 to S2) .............. 5-3 030-504-008/003 ..... Hose Assembly .................................... 6-5 1-000-013 ................ Battery, 6 Volt .................................... 5-15 1-011-011 ................ Terminal Boot, Right Hand ................. 5-15 1-011-012 ................ Terminal Boot, Left Hand .................... 5-15 1-012-502/003 ......... Bushing, Reducer ................................. 5-6 1-074-104/001 ......... Standoff .............................................. 5-3 1-085-186 ................ Cover, Internal ..................................... 2-7 1-105-216/01 ........... Contact Tip Kit ..................................... 5-5 1-105-216/04 ........... Switch/Actuator Assembly ..................... 5-5 1-105-216/05 ........... Cover, Top ........................................... 5-5 1-105-216/07 ........... Spring, Return...................................... 5-5 1-105-216/09 ........... Coil Assembly...................................... 5-5 1-105-225 ................ Contactor Assembly ............................. 5-5 1-105-225 ................ Contactor, Forward/Reverse .................. 5-3 1-110-920/092 ......... Heater................................................. 3-5 1-120-098 ................ Potentiometer, Gear ............................. 3-5 1-120-098 ................ Potentiometer, Gear ............................. 3-5 1-150-366 ................ Switch, Brake/Lift Cutout....................... 5-3 1-150-368 ................ Switch, Key .......................................... 5-3 1-150-378 ................ Switch, Key .......................................... 5-3 1-150-384 ................ Switch, Emergency, Reverse .................. 3-5 1-150-384 ................ Switch, Emergency, Reverse .................. 3-5 1-150-386 ................ Seal .................................................... 3-5 1-150-386 ................ Seal .................................................... 3-5 1-150-418 ................ Switch, Function ................................... 3-5 1-150-418 ................ Switch, Function ................................... 3-5 1-150-425 ................ Switch, Travel ....................................... 3-5 1-150-425 ................ Switch, Travel ....................................... 3-5 1-187-082 ................ Motor Controller .................................. 5-3 291-011.................... RingUSED ...................................................

4-3 DESCRIPTION ON 291-012.................... Ring ................................................... 4-3 360-049.................... Pad, Bumper Roller Assembly A ....................................... 3-3 360-062/003 ............ Guard, Cable .................................... 5-11 (consists of items 36 through 40) 360-065/001 ............ Cover, Front ........................................ 2-7 Roller Assembly B 360-068.................... Cover, Gearbox Motor ......................... 4-9 (consists of items 36 through 40) 370-637/005 ............ Tape, Double Sided.............................. 3-6 400-081/0 ................ Plate, Backing ................................... 4-15 Roller Assembly C 400-081/02 .............. Cam ................................................ 4-15 (consists of items 36 through 40) 400-081/03 .............. Lever, Brake ...................................... 4-15 Frame Weldment A, Q....................................... 4-15 400-081/04 .............. Ring, Safety 400-081/05 .............. Shoe Assembly .................................. 4-15 Door Weldment S 400-081/06 .............. Spring, Return.................................... 4-15 Screw 400-081.................... Brake Assembly ................................ 4-15 Bracket, Latch 400-081.................... Brake Assembly ................................. 4-11 400-160.................... Pinion, Drive ..................................... 4-11 Pin, Clevis 400-160.................... Pinion, Drive ........................................ 4-9 Bearing R 411-511/015 ............ Decal, Raymond .................................. 2-7 411-534.................... Decal, Emergency Disconnect ............... 2-7 Screw 411-552.................... Decal, Warning.................................... 2-7 Nut, Hex 411-582.................... Decal, Made In Canada ....................... 2-7 411-587/001 ............ Decal, No ODI Assembly ORiding, Black 9" ................... 2-7 411-633.................... Decal, Caution, Bilingual ..................... 2-7 ODI Assembly T 411-637/001 ............ Decal, Emergency Disconnect, Bilingual 2-7 Nut, Hex 411-639.................... Decal, Clear ........................................ 2-7 411-680.................... Decal, Washer H, Operating L, M, P ................................. 2-7 411-681.................... Decal, Replacement Instruction ............. 2-7

123-456-789.......................2-5

1.

Locate the Part Number in the NUMERICAL INDEX (APPENDIX B). Note the Section & page number(s) where the part is decribed.

FIGURE 2-2 ITEM NO. 1

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Frame Assembly - DS/DT

7 29

5

28

30

23

12

10

11

22

4

6

21

28 29 30 31

26 25

QTY

PART NUMBER

5

828-005-691/003

5

828-005-691/001

5

828-005-691/002

REF 1 1 1 2 2 1 1 1 1 2 2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1

828-006-283 714-206 828-004-421 861-026 462-032 710-264P 750-433 828-004-622 828-006-364 750-006 771-049 760-130 810-733 828-004-651 710-067 771-019 114-008-306 114-009-695 1-150-057 1-150-001 7-590-006/001 114-008-718/005 5-015-003 5-015-004 828-004-672 828-004-671 710-069 411-938/001 411-938/003 411-938/002 411-938/004 828-004-674 828-004-683 828-004-682 154-009-117/001

24 Compartment A= 14" Battery 20 B= 16" Battery Compartment C= 21" Battery Compartment 19 D= Without Rear Posts E= With Rear Posts 18

F= Standard G= Remote H= SMARTi

17 K= Standard/Bypass L= SMARTi/Bypass

16

15 14

Nut, Lock Pin, Roll Bracket, Key Screw Washer Switch Assembly, Key Switch Assembly, Key Switch, Push Button Switch, Lock with Keys Switch, Push Button SMARTi Assembly Nut, Hex Nut, Hex Bracket Weldment Washer Screw Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Cable Assembly, SC to SMARTi Bracket, SMARTi Clamp, ODI Static Strap, Insulated

M= Remote/Bypass N= Remote/SMARTi O= DT 001 to 3842/DS 001 to 3802 P= Remote/SMARTi/Bypass Q= DT 001 to 3566/DS 001 to 3640

B-1 F, H, K, L, M, R F, H, K, L, M, P, R M, R, R G, M, N, P K, L, M, P, R H, L, N, P H, L, N, P H, L, N, P

F, H G K, L M, N, P H, L, N, P H, L, N, P F, G, K, M S= DT 3567 and Up/DS 3641 and Up T= DT 3843 and Up/DS 3803 and Up R= Recommended Spare

2.

Find the Section & page number in the PARTS LIST referenced by the Numerical Index. Locate the Part Number. Note the part's FIGURE & ITEM NO.

List 2-2: Frame Assembly - DS/DT

13

2-7 31 2

123-456-789 9 8

40

37

36

39

3.

Find the FIGURE & ITEM NO. on the associated illustration for a pictorial view of the part.

3

38 1

Figure 2-2: Frame Assembly - DS/DT

2-1

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Walkie Pallet Truck, Model 101 - General Information Major Assemblies

Major Assemblies

1

SECTION 3 STEERING AND CONTROLS

SECTION 5

ELECTRICAL COMPONENTS AND SYSTEMS

SECTION 6 HYDRAULIC COMPONENTS

SECTION 2

FINISH AND ACCESSORIES

SECTION 7 MAST

SECTION 4 DRIVE AND BRAKE

PALLET TRUCK 30A

Figure 1-1: Major Assemblies

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Walkie Pallet Truck, Model 101 - General Information Recommended Spare Parts List

Recommended Spare Parts List Bar, Skid...................................... 939-042 ............... 2 ....... 2-2 Battery Connector ......................... 590-701 ............... 1 ....... 5-6 Battery Connector ......................... 590-701 ............... 1 ....... 5-7 Bearing, Ball ................................ 939-352/002........ 2 ....... 4-1 Bearing, Commutator End .............. 442-205 ............... 1 ....... 6-2 Bearing, Drive and Commutator End ........................... 939-352/100........ 2 ..... 5-10 Bearing, Handle ........................... 850-135-959......... 2 ....... 3-3 Bearing, Oilite Super..................... 939-154 ............... 2 ....... 7-2 Bearing, Shield............................. 441-127 ............... 2 ....... 7-2 Brush Set (4 per set) ...................... 570-316/516........ 1 ..... 5-10 Brush Set (Holder and Springs) ....... 560-213/07.......... 1 ....... 6-2 Brush Spring Set (2 per set) ............ 570-316/517........ 1 ..... 5-10 Bumper, Pump .............................. 850-138-728......... 1 ....... 6-1 Bushing, Flanged .......................... 939-352/215........ 2 ....... 3-1 Bushing ....................................... 464-034 ............... 4 ....... 2-2 Bushing ....................................... 464-035 ............. 12 ....... 7-1 Bushing ....................................... 464-035 ............... 4 ....... 2-2 Cam............................................ 400-081/02.......... 1 ....... 4-3 Circuit Breaker, 80 Amp ................ 850-136-795/080 . 1 ....... 5-1 Contact Tip, Fixed......................... 1-105-225/01 ....... 1 ....... 5-2 Decal, 24 Volt Cable System .......... 411-848 ............... 1 ....... 5-4 Decal, 24 Volt Cable System .......... 411-849 ............... 1 ....... 5-4 Decal, Battery Swivel Warning ....... 411-852 ............... 1 ....... 5-4 Decal, Battery Swivel Warning ....... 411-853 ............... 1 ....... 5-4 Decal, Charging Warning ............. 411-850 ............... 1 ....... 5-4 Decal, Charging Warning ............. 411-851 ............... 1 ....... 5-4 Fuse, 15 Amp .............................. 590-514 ............... 1 ....... 5-1 Fuse, DC Assembly ....................... 850-136-707/08 ... 1 ....... 5-7 Gear, Potentiometer ...................... 850-135-946......... 1 ....... 3-2 Heater ......................................... 1-110-920/092 ..... 1 ....... 3-2 Horn Assembly ............................. 590-638/001........ 1 ....... 5-1 Link, Lower................................... 939-352/168........ 4 ....... 7-1

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Link, Upper .................................. 850-137-275 ........ 2....... 2-2 Meter, Hour/Discharge ................. 870-248 ............... 1....... 5-3 Meter, Hour ................................. 870-251 ............... 1....... 5-3 Motor Controller........................... 1-187-082 ............ 1....... 5-1 Pad, Bumper ................................ 360-049 ............... 1....... 3-1 Pin, Link ...................................... 850-137-246/001. 2....... 2-2 Pin, Link ...................................... 939-352/192 ....... 2....... 7-1 Pin, Link ...................................... 939-352/193 ....... 2....... 7-1 Potentiometer ............................... 1-120-098 ............ 1....... 3-2 Ring, Retaining............................. 570-316/513 ....... 1..... 5-10 Seal ............................................ 570-316/511 ....... 1..... 5-10 Shaft, Flexible .............................. 610-307 ............... 2....... 3-3 Shaft, Wheel ............................... 939-352/117 ....... 1....... 7-2 Shoe Assembly............................. 400-081/05 ......... 2....... 4-3 Spring, Compression .................... 830-204 ............... 2....... 3-2 Spring, Handle Return................... 830-347 ............... 1....... 3-3 Spring, Return .............................. 1-105-216/07....... 1....... 5-2 Spring, Return .............................. 400-081/06 ......... 2....... 4-3 Spring, Tension ............................ 830-056 ............... 1....... 3-2 Switch Start Service Kit ................. 560-213/06 ......... 1....... 6-2 Switch, Brake/Lift Cutout ............... 1-150-366 ............ 2....... 5-1 Switch, Emergency, Reverse ........... 1-150-384 ............ 1....... 3-2 Switch, Function ........................... 1-150-418 ............ 3....... 3-2 Switch, Function ........................... 1-150-418 ............ 3....... 3-2 Switch, Key ................................. 1-150-368 ............ 1....... 5-1 Switch, Key ................................. 1-150-378 ............ 1....... 5-1 Switch, Travel .............................. 1-150-425 ............ 2....... 3-2 Tire, Poly ..................................... 632-095/001 ....... 1....... 4-2 Tire, Rubber ................................. 630-261 ............... 1....... 4-2 Wheel, Load................................ 632-016/001 ....... 1....... 7-2 Wheel, Load................................ 632-016/002 ....... 1....... 7-2 Wheel, Load................................ 632-016/003 ....... 1....... 7-2 Wheel, Load................................ 632-016/007 ....... 1....... 7-2

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Walkie Pallet Truck, Model 101 - General Information Recommended Spare Parts List

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Walkie Pallet Truck, Model 101 - General Information Hardware Parts List

Hardware Parts List Description

Part No.

Qty.

Description

Bolt ................................................... 939-352/047 .............2 Bolt .................................................... 714-100 .....................1 Bolt .................................................... 716-030 .....................4 Bolt .................................................... 939-352/084 .............4 Grommet ............................................ 939-352/007 .............2 Knob .................................................. 860-135 .....................2 Nut, Wheel......................................... 939-352/014 .............2 Nut .................................................... 750-006 .....................6 Nut .................................................... 750-013 .....................2 Nut .................................................... 750-019 .....................2 Nut .................................................... 750-027 .....................4 Nut .................................................... 750-036 .....................4 Nut .................................................... 939-041 .....................1 Nut .................................................... 939-352/011 .............8 Nut .................................................... 939-352/041 .............2 Nut .................................................... 939-352/049 .............5 Nut .................................................... 939-352/050 .............2 Nut .................................................... 939-352/070 .............1 Nut .................................................... 939-352/077 .............2 Pin, Cotter........................................... 810-913 .....................2 Pin, Cotter........................................... 810-945 .....................1 Pin, Cotter........................................... 810-946 .....................1 Pin, Roll .............................................. 811-145 .....................4 Pin, Spring .......................................... 810-813 .....................2 Pin, Spring .......................................... 811-138 .....................1 Screw, Set........................................... 724-399 .....................2 Screw, Set........................................... 724-414 .....................3 Screw, Set........................................... 939-352/054 .............5 Screw................................................. 1-105-216/06.............2 Screw................................................. 701-012 .....................2 Screw................................................. 701-021 .....................6 Screw................................................. 701-062 .....................1 Screw................................................. 701-115 .....................2 Screw................................................. 701-190 .....................2 Screw................................................. 701-251 .....................4 Screw................................................. 710-006 .....................5 Screw................................................. 710-008 .....................1 Screw................................................. 710-010 .....................1 Screw................................................. 710-015 .....................1 Screw................................................. 710-065 .....................2 Screw................................................. 710-127 .....................2 Screw................................................. 710-129 .....................6

PDPM - 0198

1

Part No.

Qty.

Screw .................................................710-135 ..................... 2 Screw .................................................710-202 ..................... 4 Screw .................................................714-006 ..................... 4 Screw .................................................714-011 ..................... 2 Screw .................................................714-014/004 ........... 14 Screw .................................................714-021 ..................... 4 Screw .................................................714-047 ..................... 8 Screw .................................................714-056 ..................... 2 Screw .................................................714-137 ..................... 1 Screw .................................................715-032 ..................... 4 Screw .................................................715-064 ..................... 2 Screw .................................................939-352/022 ............. 1 Screw .................................................939-352/026 ............. 4 Screw .................................................939-352/047 ............. 2 Screw .................................................939-352/066 ............. 1 Screw .................................................939-352/067 ............. 2 Screw .................................................939-352/068 ............. 4 Screw .................................................939-352/069 ............. 5 Screw .................................................939-352/086 ........... 22 Screw .................................................939-352/226 ............. 1 Screw .................................................939-352/227 ............. 2 Washer, Flat ........................................771-009..................... 4 Washer, Flat ........................................771-016..................... 1 Washer, Flat ........................................771-116..................... 8 Washer, Flat ........................................939-352/001 ........... 19 Washer, Flat ........................................939-352/088 ............. 2 Washer, Flat ........................................939-352/182 ............. 4 Washer, Lock .......................................772-112..................... 2 Washer, Lock .......................................772-116................... 11 Washer, Lock .......................................772-123..................... 5 Washer, Lock .......................................774-116..................... 2 Washer, Lock .......................................850-138-139/11 ........ 1 Washer, Lock .......................................939-352/225 ............. 1 Washer, Spring ....................................939-352/102 ............. 1 Washer ...............................................771-019..................... 2 Washer ...............................................771-024..................... 4 Washer ...............................................771-101..................... 2 Washer ...............................................771-169..................... 4 Washer ...............................................774-009................... 14 Washer ...............................................850-138-139/12 ........ 1

1-11

7/13/01

Walkie Pallet Truck, Model 101 - General Information Hardware Parts List

This Page Intentionally Blank

7/13/01

1-12

PDPM - 0198

Walkie Pallet Truck, Model 101 - General Information Bulk Items List

Bulk Items List Dry Teflon Lube ................................... 990-600/DTL ...... 10 oz.

Plastic & Metal Protectant...................... 990-600/PMP ..... 10 oz.

Web Adhesive Spray ........................... 990-600/WAS .... 14 oz.

Battery Protectant................................. 990-600/BP1...... 14 oz.

5W-30 Motor Oil ................................ 990-604/04 ........ Quart 10W-30W Motor Oil........................... 990-603/04 ........ Quart Battery Cleaner ................................... 990-600/BC1 ...... Quart Battery Cleaner ................................... 990-600/BC3 .. 5 Gallon Brake and Parts Cleaner ....................... 990-600/BR1...... 16 oz.

Electronic Contact Cleaner.................... 990-600/CC1..... 14 oz.

Degreaser ........................................... 990-600/DG1 .... 15 oz.

Q.D. Degreaser................................... 990-600/DG2 .... 14 oz.

Degreaser-non aerosol.......................... 990-600/DG3 ..2.5 Gallon Glass Cleaner ..................................... 990-600/GC1 .... 19 oz.

Hand Cleaner ..................................... 990-600/HC1.. 1 Gallon Hand Cleaner With Grit ....................... 990-600/HC2 . 1 Gallon Hand Cleaner With Grit ....................... 990-600/HC3. Pumpettes Waterless Foaming Hand Cleaner ......... 990-600/HC4..... 13 oz.

Penetrant/Lubricant.............................. 990-600/PL1 ...... 15 oz.

Concentrated Spray Cleaner ................. 990-600/SC1 ..... Gallon Spray & Wipe Cleaner......................... 990-600/SCQ ..... Quart Steam & Pressure Wash........................ 990-600/SP1... 5 Gallon Spray Teflon Grease............................. 990-600/STG .. 13.5 oz.

PDPM - 0198

1

White Lithium Grease............................990-600/WG1....14 oz.

Rubber & Gasket Adhesive ....................990-421.........5 oz. tube Loctite Quick Primer ..............................990-533........................

Loctite-Threadlock (Blue) ........................990-536.............. 10 ml.

Gear Lubricant 80W-90W ....................990-610/03 .....5 Gallon Cold Storage Hydraulic Oil (+200 to -35 F) ....................................990-615/01 .....1 Gallon Standard Hydraulic Oil .........................990-616/01 .....1 Gallon Standard Hydraulic 46 Oil ....................990-616/02 .....2 Gallon Hydraulic Oil ......................................990-616/04 ......1 Quart (Minimum Quantity 12) DOT 5 Brake Fluid................................990-625/02 ........Quarts DOT 3 Brake Fluid................................990-627/02 ........Quarts Carousel Traction Drive Fluid .................990-647/001 ......Quarts Wypall Plus Shop Rags .........................990-654........................ .......................................................... ..............Case (9 Boxes) Workhorse- Shop Rags ..........................990-654/KC.................. .......................................................... ..............Case (8 Boxes) Bearing Grease....................................99062001.................... .......................................................... ........Tube (10 per Case) Raymond Orange.................................990234 ........ Spray Can Raymond Black ....................................990236 ........ Spray Can Raymond Gray.....................................990238 ........ Spray Can

1-13

7/13/01

Walkie Pallet Truck, Model 101 - General Information Bulk Items List

This Page Intentionally Blank

7/13/01

1-14

PDPM - 0198

SECTION 2 Finish and Accessories Truck Major Assemblies .................................................................................................................................................. 2-2 Truck Final Assembly ...................................................................................................................................................... 2-4 Finish Instructions ........................................................................................................................................................... 2-7 Load Backrest............................................................................................................................................................... 2-10

PDPM - 0198

2-1

7/13/01

Walkie Pallet Truck, Model 101 - Finish and Accessories Truck Major Assemblies

Truck Major Assemblies

1

6

5

2

2

3

4

PALLET TRUCK 30A

Figure 2-1: Truck Major Assemblies

7/13/01

2-2

PDPM - 0198

Walkie Pallet Truck, Model 101 - Finish and Accessories Truck Major Assemblies FIGURE 2-1 ITEM NO. 1 2 3 4 5 6

QTY

PART NUMBER

DESCRIPTION

USED ON

Handle and Controller Assembly (See Figure 3-2a.)

Drive and Brake Assembly (See Figure 4-1a.) (See Figure 4-3.)

Fork Final Assembly (See Figure 7-1.)

Load Wheel Assembly (See Figure 7-2.)

Lift Pump and Motor Assembly (See Figure 6-2.)

Electrical Assembly (See Figure 5-1.)

List 2-1: Truck Major Assemblies

PDPM - 0198

2-3

7/13/01

Walkie Pallet Truck, Model 101 - Finish and Accessories Truck Final Assembly

Truck Final Assembly

2

19

20

22 21 23 24

14

25

13

1

10

4

5

2

8

7

9

6

17

16

15

W850_137_263_N

Figure 2-2: Truck Final Assembly

7/13/01

2-4

PDPM - 0198

Walkie Pallet Truck, Model 101 - Finish and Accessories Truck Final Assembly FIGURE 2-2 ITEM NO. 1 2 4 5 6 7 8 9 10

QTY

PART NUMBER

DESCRIPTION

1 828-001-457 4 716-030 4 464-034 2 850-137-275 4 710-202 4 771-024 4 750-027 2 939-042 1 939-352/169 1 939-352/170 13 2 710-135 14 2 750-019 15 2 811-145 16 2 850-137-246/001 17 4 464-035 19 1 850-137-023 20 2 714-056 21 2 750-006 22 2 772-116 23 2 710-065 24 2 771-019 25 1 1-085-186 A= 22 in. Frame Width B= 27 in. Frame Width R= Recommended Spare

Ring, Cable Holding Bolt Bushing Link, Upper Screw Washer Nut Bar, Skid Frame, Lift Machining Frame, Lift Machining Screw Nut Pin, Roll Pin, Link Bushing Bracket, Keys Switch Mounting Screw Nut Washer, Lock Screw Washer Cover, Internal

USED ON

R R

R A B

R R

List 2-2: Truck Final Assembly

PDPM - 0198

2-5

7/13/01

Walkie Pallet Truck, Model 101 - Finish and Accessories Truck Final Assembly

This Page Intentionally Blank

7/13/01

2-6

PDPM - 0198

Walkie Pallet Truck, Model 101 - Finish and Accessories Finish Instructions

Finish Instructions

2

17 11 25 24

1

STANDARD 26

3

2

4

19

25

5

24 VIEW C-C

28 29

W07262ANX SHT 1 OF 2

Figure 2-3a: Finish Instructions

PDPM - 0198

2-7

7/13/01

Walkie Pallet Truck, Model 101 - Finish and Accessories Finish Instructions

Finish Instructions

10

27

2

25

24

6

1 26 7

BILINGUAL

8

5

VIEW A

W07262BNA SHT 2 OF 2

Figure 2-3b: Finish Instructions

7/13/01

2-8

PDPM - 0198

Walkie Pallet Truck, Model 101 - Finish and Accessories Finish Instructions FIGURE 2-3 ITEM NO. 1 2 3 4 5

6 7 8 10 11 17 19 24 25 26 27 28 29 A= Standard B= Bilingual C= Metric

QTY

PART NUMBER

DESCRIPTION

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

411-789 411-511/015 411-534 411-552 939-352/106 939-352/108 939-352/107 411-790 411-633 411-637/001 411-773 411-587/001 860-135 360-065/001 411-680 411-681 412-720 412-748 828-006-843 813 570/002

Decal, Warning Decal, Raymond Decal, Emergency Disconnect Decal, Warning Plate, Lowlift Specification (U.S.) Plate, Lowlift Specification (Canadian) Plate, Lowlift Specification (U.S.) Decal, Warning Decal, Caution Decal, Emergency Disconnect Decal, No Riding Decal, No Riding, Black 9 in.

Knob Cover, Front Decal, Operating Decal, Replacement Instruction Decal, Fault Code Explanation Decal, Millennium Series Pocket, Manual Nail, Grip

USED ON

A A A B C B B B B A

C

List 2-3: Finish Instructions

PDPM - 0198

2-9

7/13/01

Walkie Pallet Truck, Model 101 - Finish and Accessories Load Backrest

Load Backrest

2

1

9720_000

Figure 2-4: Load Backrest FIGURE 2-4 ITEM NO. 1

QTY

PART NUMBER

1 1

850-137-147/048 850-137-147/060

DESCRIPTION

USED ON

Load Backrest, 48 in. High Load Backrest, 60 in. High

List 2-4: Load Backrest

7/13/01

2-10

PDPM - 0198

SECTION 3 Steering and Controls Handle Mounting and Installation .................................................................................................................................... 3-2 Handle and Controller Assembly...................................................................................................................................... 3-5 Control Assembly ........................................................................................................................................................... 3-9 Handle Arm Assembly .................................................................................................................................................. 3-10

PDPM - 0198

3-1

7/13/01

Walkie Pallet Truck, Model 101 - Steering and Controls Handle Mounting and Installation

Handle Mounting and Installation

3

3

8

1

2

14

5

7

6

11

4

9

10

W850_138_384_4

Figure 3-1: Handle Mounting and Installation

7/13/01

3-2

PDPM - 0198

Walkie Pallet Truck, Model 101 - Steering and Controls Handle Mounting and Installation FIGURE 3-1 ITEM NO. 1 2 3 4

QTY

PART NUMBER

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2

850-138-384/ 850-138-372 939-352/081 Ref. 850-138-383/101 850-138-383/102 360-049 680-806 939-352/022 939-352/077 810-945 710-008 771-016 939-352/112 939-352/026 939-352/215

5 6 7 8 9 10 11 12 13 14 A= Standard B= Cold Storage R= Recommended Spare

DESCRIPTION Handle Mounting and Installation Shaft, Handle Pivot Weldment Bolt, Anchor, Chain (Metric) Transmission Assembly (See Figure 4-1a.)

Handle and Controller Assembly (See Figure 3-2a.)

Handle and Controller Assembly (See Figure 3-2a.)

Pad, Bumper Link, Offset Screw Nut Pin, Cotter Screw Washer, Flat Spacer (Not Shown) Screw (Not Shown) Bushing, Flanged

USED ON

A B R

R

List 3-1: Handle Mounting and Installation

PDPM - 0198

3-3

7/13/01

Walkie Pallet Truck, Model 101 - Steering and Controls Handle Mounting and Installation

This Page Intentionally Blank

7/13/01

3-4

PDPM - 0198

Walkie Pallet Truck, Model 101 - Steering and Controls Handle and Controller Assembly

Handle and Controller Assembly

23

3

22

21 27 20

34

15 6

31 26

28 16

2 29 7

4

32

35

5

30

3 18 1 9 10

23

24

W07914 SHT 1 OF 2

Figure 3-2a: Handle and Controller Assembly

PDPM - 0198

3-5

7/13/01

Walkie Pallet Truck, Model 101 - Steering and Controls Handle and Controller Assembly

Handle and Controller Assembly

3

19

33

12

13

17

36

37

11

14

25

4100_304 SHT 2 OF 2

Figure 3-2b: Handle and Controller Assembly

7/13/01

3-6

PDPM - 0198

Walkie Pallet Truck, Model 101 - Steering and Controls Handle and Controller Assembly FIGURE 3-2 ITEM NO. 1 2 3 4 5 6 7

9

QTY

PART NUMBER

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

850-135-712 850-135-946 850-135-947/101 850-135-947/102 850-135-947/103 850-135-976/001 850-136-577 850-136-579 1-120-098 1-150-386 1-150-425 850-137-918 771-101 1-150-384 701-021 701-251 750-036 850-137-917 850-136-896 1-150-418 850-136-897 1-150-418 1-110-920/092 850-137-166 850-137-174 850-137-258 850-138-766 850-138-101 850-137-905 850-137-915 850-137-919 850-137-923 850-138-391/001 850-138-392/001 850-137-894/005 850-137-903/001 850-138-390/001 370-637/005 714-006 714-011 714-021 714-047

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 A= Standard B= Cold Storage R= Recommended Spare

DESCRIPTION Shim, Switch Gear, Potentiometer Button, Function, Horn Button, Function, Forks, Lowered Button, Function, Forks, Lift Button Assembly, Nose Harness, Travel (includes:) Harness, Travel (includes:) Potentiometer Seal Switch, Travel Bracket, Travel Washer Switch, Emergency, Reverse Screw Screw Nut Bracket, Emergency, Reverse Harness, Function (includes:) Switch, Function Harness, Function (includes:) Switch, Function Heater Sheave, Chain Link, Connecting Chain, Roller Assembly Pin, Chain Sheave Bracket, Potentiometer Cover, Side Cover Plate, Switch Plate, Spring Mount Cap, Journal Machine, Left Hand Cap, Journal Machine, Right Hand Handle/Arm (See Figure 3-4.)

Control Assembly (See Figure 3-3.)

Handle Bottom Tape, Double Sided Screw Screw Screw Screw

USED ON R

A B R R

R

A R B R B, R

List 3-2: Handle and Controller Assembly (Sheet 1 of 2)

PDPM - 0198

3-7

7/13/01

Walkie Pallet Truck, Model 101 - Steering and Controls Handle and Controller Assembly FIGURE 3-2 QTY ITEM NO. 30 14 31 14 32 1 33 1 34 2 35 4 36 1 37 1 A= Standard B= Cold Storage R= Recommended Spare

PART NUMBER 714-014/004 774-009 811-138 830-056 830-204 771-009 939-352/081 939-352/077

DESCRIPTION Screw Washer Pin, Spring Spring, Tension Spring, Compression Washer, Flat Bolt, Chain Anchor Nut

USED ON

R R

List 3-2: Handle and Controller Assembly (Sheet 2 of 2)

7/13/01

3-8

PDPM - 0198

Walkie Pallet Truck, Model 101 - Steering and Controls Control Assembly

Control Assembly

6

7

5

4

8

1

3

2

3

W07903A

Figure 3-3: Control Assembly FIGURE 3-3 ITEM NO.

QTY

PART NUMBER

850-137-903/001 1 2 850-135-959 2 2 850-138-862/001 3 1 850-137-916 4 1 850-137-920 5 1 850-138-076 6 2 610-307 7 2 810-813 8 1 830-347 R= Recommended Spare

DESCRIPTION Control Assembly Bearing, Handle Grip, Handle Assembly Spacer Shaft, Cam Actuator Actuator, Cam Assembly Shaft, Flexible Pin, Spring Spring, Handle Return

USED ON R

R R

List 3-3: Control Assembly

PDPM - 0198

3-9

7/13/01

Walkie Pallet Truck, Model 101 - Steering and Controls Handle Arm Assembly

Handle Arm Assembly

3

11

11

10

10

9

8

7

3

4

6

W07894WHA

Figure 3-4: Handle Arm Assembly FIGURE 3-4 ITEM NO.

QTY

PART NUMBER

3 4 6 7 8 9 10 11

1 1 1 1 4 2 2 4

850-137-894/005 850-138-373 850-137-895 850-138-386/001 714-137 715-032 715-064 750-013 771-169

DESCRIPTION

USED ON

Handle Arm Assembly Arm Machine Plate, Tie Handle Machining Screw Screw Screw Nut Washer

List 3-4: Handle Arm Assembly

7/13/01

3-10

PDPM - 0198

SECTION 4 Drive and Brake Transmission Assembly ................................................................................................................................................... 4-3 Drive Wheel Assembly .................................................................................................................................................... 4-7 Brake Assembly.............................................................................................................................................................. 4-8

PDPM - 0198

4-1

7/13/01

Walkie Pallet Truck, Model 101 - Drive and Brake

This Page Intentionally Blank

7/13/01

4-2

PDPM - 0198

Walkie Pallet Truck, Model 101 - Drive and Brake Transmission Assembly

Transmission Assembly

31

30

23

21

26

11

22

10

14

12

4

13

15

52

51

47

28 9

16 53

29

20

18

27

24

45

56

5

4

3

37

36 39

38

W310614_1L SHT 1 OF 2

Figure 4-1a: Transmission Assembly

PDPM - 0198

4-3

7/13/01

Walkie Pallet Truck, Model 101 - Drive and Brake Transmission Assembly

Transmission Assembly

42

4

40

43 49

50 1

44

33

10

8

11

7

32

15

15

35

15

46

3

2

34

W310614_1R SHT 2 OF 2

Figure 4-1b: Transmission Assembly

7/13/01

4-4

PDPM - 0198

Walkie Pallet Truck, Model 101 - Drive and Brake Transmission Assembly FIGURE 4-1 ITEM NO.

QTY

1 1 2 1 3 2 4 1 5 1 6 1 7 2 8 1 9 1 10 2 11 2 12 2 13 1 14 1 15 22 16 5 18 1 20 1 21 1 22 1 23 1 24 1 26 1 27 1 28 1 29 1 30 1 31 4 32 1 33 2 34 14 35 1 36 1 37 1 38 1 39 3 40 1 42 1 43 1 44 1 45 1 46 1 47 1 R= Recommended Spare

PART NUMBER 939-352/114 939-352/082 939-333 939-352/005 939-311 939-352/003 939-352/070 939-352/002 939-330 939-352/079 939-352/008 939-352/050 939-352/067 400-081 939-321 939-352/086 939-352/069 939-352/053 939-352/058 939-352/055 939-352/063 939-023 939-352/066 939-352/115 939-352/065 939-352/013 939-352/064 360-068 939-352/068 939-352/191 812-404 939-352/010 939-352/048 939-352/113 850-137-864 850-137-862 939-352/026 939-352/004 939-041 291-011 291-012 939-352/014 939-352/052 530-449

DESCRIPTION Drive Unit (Includes Gearbox Only) Case Assembly, Gear (includes:) Gear, Drive Bearing, Cup/Cone Ring Seal Nut (Not Shown) Bearing, Ball Gear, Pinion Bracket, Brake Switch Key Nut Screw Brake Assembly (See Figure 4-3.)

Drum, Brake Screw Screw Arm, Brake Bolt, Special Rod, Push Fork, Joint Combination Spring Screw Anchor, Brake Spring Bearing, Handle Clamp Retainer Cover, Brake Screw Cover, Gear Dowel Washer, Sealing Plug, Drain/Fill Guard, Wheel Strip, Reinforcing Guard, Wheel, Rubber Screw Fitting, Grease Nut Ring, Nilos (Small) Ring, Nilos (Large) Nut Gear, Idle O-Ring

USED ON

R

List 4-1: Transmission Assembly (Sheet 1 of 2)

PDPM - 0198

4-5

7/13/01

Walkie Pallet Truck, Model 101 - Drive and Brake Transmission Assembly FIGURE 4-1 QTY ITEM NO. 49 1 50 1 51 1 52 4 53 2 56 1 R= Recommended Spare

PART NUMBER 939-005 939-006 570-864/500 939-352/182 939-352/088 939-352/083

DESCRIPTION

USED ON

Bearing, Cup/Cone, Pivot (Small) Bearing, Cup/Cone, Pivot (Large) Motor Assembly, Drive Washer, Flat Washer, Flat Wheel Assembly (See Figure 4-2.)

List 4-1: Transmission Assembly (Sheet 2 of 2)

7/13/01

4-6

PDPM - 0198

Walkie Pallet Truck, Model 101 - Drive and Brake Drive Wheel Assembly

Drive Wheel Assembly

4

1

4

3

W07199

Figure 4-2: Drive Wheel Assembly FIGURE 4-2 ITEM NO. 1

QTY

1 1 3 1 4 1 A= Red/Orange Poly B= Black Rubber R= Recommended Spare

PART NUMBER 632-095/001 630-261 939-352/083 939-352/014

DESCRIPTION Tire, Poly Tire, Rubber Hub Machining, Wheel Nut, Wheel

USED ON A, R B, R

List 4-2: Drive Wheel Assembly

PDPM - 0198

4-7

7/13/01

Walkie Pallet Truck, Model 101 - Drive and Brake Brake Assembly

Brake Assembly

2

1

4

3

4

5

6

I3361_000

Figure 4-3: Brake Assembly FIGURE 4-3 ITEM NO.

QTY

1 1 2 1 3 1 4 1 5 2 6 2 R= Recommended Spare

PART NUMBER 400-081 400-081/01 400-081/02 400-081/03 400-081/04 400-081/05 400-081/06

DESCRIPTION Brake Assembly Plate, Backing Cam Lever, Brake Ring, Safety Shoe Assembly Spring, Return

USED ON

R

R R

List 4-3: Brake Assembly

7/13/01

4-8

PDPM - 0198

SECTION 5 Electrical Components and System Electrical System ............................................................................................................................................................. 5-2 Contactor Assembly........................................................................................................................................................ 5-4 Meter Installation............................................................................................................................................................ 5-6 Battery Pack, 24 Volt (Wet Battery) .................................................................................................................................. 5-8 Battery Tree and Cover Assembly................................................................................................................................... 5-10 Battery Pack and Cable Assembly (Wet Battery) .............................................................................................................. 5-12 Charger Assembly (Wet Battery).................................................................................................................................... 5-14 Battery Pack, GNB Maintenance Free, 24 Volt ................................................................................................................ 5-16 Charger Assembly (Maintenance Free)........................................................................................................................... 5-18 Drive Motor ................................................................................................................................................................. 5-20 Programmable Maintenance Tool .................................................................................................................................. 5-22

PDPM - 0198

5-1

7/13/01

Walkie Pallet Truck, Model 101 - Electrical Components and System Electrical System

Electrical System

26

22

22

25

21

20

24

1

22

18

21

11

12

6

8

5

27

28

23 SW1

22 19

TO METERS (OPTION)

CB 80A

10

MP-2 TO B-

BAT AUX

-2

M2-X

M2 M2-Y

TO FU1-2

-X -Y

PMC S1S2 M-

SECURE HARNESS TO LIFT POWER CABLE

-1 M1

B-

FU1 15A

SOL -X

B+

SOL -Y

3

16 15

TO HANDLE ASSEMBLY

14 TO B+ TO S2

S1 TO

MD-A2

MD-E2

MD-A1

2

MD -E 1

TO M

-

5

TO LIFT LIMIT SWITCH SW 10

10

17

19 22

9

23

TO BRAKE SWITCH SW 2

24 25 26

13

4

7

8

9

17

W06784

Figure 5-1: Electrical System

7/13/01

5-2

PDPM - 0198

Walkie Pallet Truck, Model 101 - Electrical Components and System Electrical System FIGURE 5-1 ITEM NO. 1 2 3

4

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

QTY

PART NUMBER

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 2 2 2 4 1 2 2 5 7 6 4 2 3 1 1 1 1

1-187-082 1-105-225 850-136-787 B24-020-110/260 B24-020-170/301 B24-022-220/272 B24-196-075/304 850-136-786 850-136-788 B24-023-380/297 B24-023-380/298 029-002-380/001 029-002-380/002 870-863 850-136-845 850-136-863 939-352/079 850-137-207 1-150-366 1-074-104/001 590-514 850-136-795/080 590-638/001 701-115 701-012 772-112 701-021 701-062 724-399 701-190 710-006 772-116 771-116 750-006 774-116 724-414 850-136-782 850-136-783 1-150-378 1-150-368

DESCRIPTION Motor Controller Contactor, Forward/Reverse (See Figure 5-2.)

Cable Kit, Tractor (includes:) Cable Assembly (B- to B-) Cable Assembly (CB to P1) Cable Assembly (B- to MP2) Cable Assembly (B+ to M1-2) Battery Connector Cable Kit, Drive (includes:) Cable Assembly (B+ to MDA2) Cable Assembly (M- to MDA1) Cable Assembly (MDE2 to S1) Cable Assembly (MDE2 to S2) Wrap, Spiral Bar, Bus (CB to M1-1) Fuse Block Bracket, Brake Switch Plate, Switch Backing Switch, Brake/Lift Cutout Standoff Fuse, 15 Amp Circuit Breaker, 80 Amp Horn Assembly Screw Screw Washer, Lock Screw Screw Screw, Set Screw Screw Washer, Lock Washer, Flat Nut Washer, Lock Screw, Set Harness, Main Harness, Main Switch, Key Switch, Key

USED ON R

R R R R

A B A, R B, R

A= Standard B= Cold Storage R= Recommended Spare

List 5-1: Electrical System

PDPM - 0198

5-3

7/13/01

Walkie Pallet Truck, Model 101 - Electrical Components and System Contactor Assembly

Contactor Assembly

5

4

1

3

1

5

2

7

W1_105_216

Figure 5-2: Contactor Assembly

7/13/01

5-4

PDPM - 0198

Walkie Pallet Truck, Model 101 - Electrical Components and System Contactor Assembly FIGURE 5-2 QTY ITEM NO. 1 1 2 1 3 1 4 2 5 1 7 1 R= Recommended Spare

PART NUMBER 1-105-225/01 1-105-225/02 1-105-216/05 1-105-216/06 1-105-216/07 1-105-216/09

DESCRIPTION Contact Tip, Fixed Contact Tip, Moving Cover, Top Screw Spring, Return Coil and Frame Assembly

USED ON R

R

List 5-2: Contactor Assembly

PDPM - 0198

5-5

7/13/01

Walkie Pallet Truck, Model 101 - Electrical Components and System Meter Installation

Meter Installation

5

2

4

Meters

1581_001, 5291_000, 5231_000

Figure 5-3: Meter Installation 7/13/01

5-6

PDPM - 0198

Walkie Pallet Truck, Model 101 - Electrical Components and System Meter Installation FIGURE 5-3 QTY ITEM NO. 2 1 4 1 R= Recommended Spare

PART NUMBER 870-251 870-248

DESCRIPTION Meter, Hour Meter, Hour/Discharge

USED ON R R

List 5-3: Meter Installation

PDPM - 0198

5-7

7/13/01

Walkie Pallet Truck, Model 101 - Electrical Components and System Battery Pack, 24 Volt (Wet Battery)

Battery Pack, 24 Volt (Wet Battery)

5

13 12

5 4 14

3

8

14 6 1 14

14

10

2

W07203

Figure 5-4: Battery Pack, 24 Volt (Wet Battery)

7/13/01

5-8

PDPM - 0198

Walkie Pallet Truck, Model 101 - Electrical Components and System Battery Pack, 24 Volt (Wet Battery) FIGURE 5-4 ITEM NO.

1 2 3 4 5 6 8 10

QTY

PART NUMBER

1 1 1 2 2 1 1 1 1 1 1 1 1 3

939-352/103 939-352/104 Ref. 939-352/034 850-136-707 939-352/047 939-352/049 411-848 411-849 411-850 411-851 411-852 411-853 714-100 772-123 360-062/003

12 13 14 A= Standard B= Bilingual R= Recommended Spare

DESCRIPTION Battery Pack, 24 Volt (Wet Battery) Battery Pack, 24 Volt (Wet Battery) Battery Tree and Cover Assembly (See Figure 5-5.)

Battery Pack and Cable Assembly Charger Assembly (See Figure 5-7.)

Screw Nut Decal, 24 Volt Cable System Decal, 24 Volt Cable System Decal, Charging Warning Decal, Charging Warning Decal, Battery Swivel Warning Decal, Battery Swivel Warning Bolt Washer, Lock Guard, Cable, 9.5 in.

USED ON A B

A, R B, R A, R B, R A, R B, R

List 5-4: Battery Pack, 24 Volt (Wet Battery)

PDPM - 0198

5-9

7/13/01

Walkie Pallet Truck, Model 101 - Electrical Components and System Battery Tree and Cover Assembly

Battery Tree and Cover Assembly

5

2

4

13 1

12

1

9

3

7

11

8

6 5

10

5111_000

Figure 5-5: Battery Tree and Cover Assembly

7/13/01

5-10

PDPM - 0198

Walkie Pallet Truck, Model 101 - Electrical Components and System Battery Tree and Cover Assembly FIGURE 5-5 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13

QTY

PART NUMBER

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

939-352/049 939-352/084 939-352/041 939-352/045 810-913 939-352/001 939-352/225 939-352/226 939-352/227 939-352/228 939-352/229 939-352/230 939-352/224

DESCRIPTION

USED ON

Nut Bolt Nut Door Weldment, Battery Box Pin, Cotter Washer, Flat Washer, Lock Screw Screw Tray Weldment Tray Weldment Edging Wrapper

List 5-5: Battery Tree and Cover Assembly

PDPM - 0198

5-11

7/13/01

Walkie Pallet Truck, Model 101 - Electrical Components and System Battery Pack and Cable Assembly (Wet Battery)

Battery Pack and Cable Assembly (Wet Battery)

10

8

13

5

5

6 2

3

-

12

+ 4

1 11

7

7

9

5112_100

Figure 5-6: Battery Pack and Cable Assembly (Wet Battery)

7/13/01

5-12

PDPM - 0198

Walkie Pallet Truck, Model 101 - Electrical Components and System Battery Pack and Cable Assembly (Wet Battery) FIGURE 5-6 QTY ITEM NO. 1 1 2 1 3 1 4 1 5 8 6 18 7 4 8 2 9 2 10 1 11 1 12 1 13 8 R= Recommended Spare

PART NUMBER 590-701 939-146 939-149 939-352/178 939-352/011 939-352/001 939-352/044 939-352/007 939-352/006 939-352/042 939-352/179 939-352/176 939-352/046

DESCRIPTION Battery Connector Cable Assembly Cable Assembly Cable Assembly Nut Washer Battery, 6 Volt Grommet Grommet Tie, Cable Cable Assembly Cable Assembly Boot, Terminal

USED ON R

List 5-6: Battery Pack and Cable Assembly (Wet Battery)

PDPM - 0198

5-13

7/13/01

Walkie Pallet Truck, Model 101 - Electrical Components and System Charger Assembly (Wet Battery)

Charger Assembly (Wet Battery)

5

16 11

17 2

7

3

9

14 8

10

WIRING DIAGRAM

4

5 12

15 13

6

1

W06707

Figure 5-7: Charger Assembly (Wet Battery)

7/13/01

5-14

PDPM - 0198

Walkie Pallet Truck, Model 101 - Electrical Components and System Charger Assembly (Wet Battery) FIGURE 5-7 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

QTY

PART NUMBER

1 850-136-707/01 1 850-136-707/02 1 850-136-707/03 1 850-136-707/04 1 850-136-707/05 1 850-136-707/06 2 850-136-707/07 1 850-136-707/08 2 850-136-707/09 1 590-701 1 850-136-707/11 1 850-136-707/12 1 850-136-707/13 1 850-136-707/14 1 850-136-707/15 1 850-136-707/16 1 850-136-707/20 17 1 850-136-707/17 A= North America B= Australian R= Recommended Spare

DESCRIPTION Ammeter Strap, Capacitor Capacitor (440 VAC) Case, Main Pallet Cord, AC, Set Cord, Wire AC Set Diode, 20A Fuse, DC Assembly Fuse, DC Fuselink Battery Connector Rectifier Assembly Relief, AC Strain Knob, Timer Timer, 12HR, 60 Hz Plate, Timer Dial TX 24V, 15A, 120VAC, 60Hz TX 24V, 15A, 120VAC, 50Hz Varistor

USED ON

R R

A B

List 5-7: Charger Assembly (Wet Battery)

PDPM - 0198

5-15

7/13/01

Walkie Pallet Truck, Model 101 - Electrical Components and System Battery Pack, GNB Maintenance Free, 24 Volt

Battery Pack, GNB Maintenance Free, 24 Volt

4

5

8 9

6 7

3

2

12

11

10

5

13

1

5113_100

Figure 5-8: Battery Pack, GNB Maintenance Free, 24 Volt

7/13/01

5-16

PDPM - 0198

Walkie Pallet Truck, Model 101 - Electrical Components and System Battery Pack, GNB Maintenance Free, 24 Volt FIGURE 5-8 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13

QTY

PART NUMBER

1 1 4 1 1 1 4 1 1 3 3 3 1

850-138-139 850-138-139/01 850-138-139/02 850-138-139/03 850-138-139/04 850-138-139/05 850-138-139/06 850-138-139/07 850-138-139/08 850-138-139/09 850-138-139/10 850-138-139/11 850-138-139/12 850-138-139/13

DESCRIPTION

USED ON

Battery Pack, GNB Maintenance Free, 24 Volt Tray Charger (See Figure 5-9.)

Battery Module, 6 Volt Plug, SB 175, Cables Cable, Inter, Battery Grommet, Rubber Label, Champion Label, Danger Plate, Name Bolt Washer, Lock Washer Pad, Foam Rubber

List 5-8: Battery Pack, GNB Maintenance Free, 24 Volt

PDPM - 0198

5-17

7/13/01

Walkie Pallet Truck, Model 101 - Electrical Components and System Charger Assembly (Maintenance Free)

Charger Assembly (Maintenance Free)

18 17

16

5

AC FUSE OR CIRCUIT BREAKER

11

12

5

13 DC FUSE OR CIRCUIT BREAKER SOLDER CONNECTION

DC NEG. BLACK

amp BELL CRIMP

AC BLACK AC GREEN

GROUND SCREW VARISTOR

.001 OHM SHUNT

HEATSINK A

1

SCR

TX PRI

AC WHITE

WHT

B C

WHT

HEATSINK

D

2

DC POS. RED

BELL CRIMP

BELL CRIMP

NOTE: VARISTOR LEADS MUST BE COVERED WITH VARFLEX

8

WHT

7

GRN

7 9

WHT

13

WHT

12 12

BLK

14

WHT

YELLOW

ORG

ORG

WHITE

BLK

YELLOW

SCR

10

11

15

6

16

17 1

8

5 GRN

7 9

13

15 BLUE

CIRCUIT BOARD HARNESS

WHT

4

STOP (N.O.)

12

3

14

2

GRN WHT

BUTT SPLICE

GREEN

8 14

D13507_9, W06707A

Figure 5-9: Charger Assembly (Maintenance Free)

7/13/01

5-18

PDPM - 0198

Walkie Pallet Truck, Model 101 - Electrical Components and System Charger Assembly (Maintenance Free) FIGURE 5-9 ITEM NO. 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

QTY

PART NUMBER

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

850-138-139/02 850-138-139/14 850-138-139/15 850-138-139/16 850-138-139/17 850-138-139/18 850-138-139/19 850-138-139/20 850-138-139/21 850-138-139/22 850-138-139/23 850-138-139/24 850-138-139/25 850-138-139/26 850-138-139/27 850-138-139/28 850-138-139/29 850-138-139/30

DESCRIPTION

USED ON

Charger Case, Back, Large Cell (Not Shown) Case, Main, Large Cell (Not Shown) Case, Top, Large Cell (Not Shown) Circuit Breaker 15A Circuit, 2400 24V 25 A 55T (With Cord) (Not Shown) Cord, DC Assembly (Not Shown) Cord, AC Assembly Plug, Mounting Bracket (Not Shown) Plug, SB175 Black (Not Shown) Rectifier Assembly Rectifier, SCR Assembly Shunt Assembly Strain Relief Switch, Red Push Button Transformer Varistor Assembly Varistor

List 5-9: Charger Assembly (Maintenance Free)

PDPM - 0198

5-19

7/13/01

Walkie Pallet Truck, Model 101 - Electrical Components and System Drive Motor

Drive Motor

4

3

2

13

5

1

6

11

12

5

3

10

8

7

570_864

Figure 5-10: Drive Motor

7/13/01

5-20

PDPM - 0198

Walkie Pallet Truck, Model 101 - Electrical Components and System Drive Motor FIGURE 5-10 ITEM NO.

QTY

1 1 2 1 3 2 4 1 5 1 6 1 7 1 8 1 10 1 11 1 12 1 13 1 R= Recommended Spare

PART NUMBER

DESCRIPTION

570-864/500 570-316/511 570-360/516 939-352/100 570-316/513 570-864/512 939-352/101 570-316/516 570-316/517 570-271/515 570-864/515 939-352/102 570-316/519

Drive Motor Seal Head, Drive End Bearing, Drive and Commutator End Ring, Retaining Armature Field Coil Kit Brush Set (4 per set) Brush Spring Set (2 per set) Brush Lead Assembly Kit Head, Commutator End Washer, Spring Plate Assembly, Cover

USED ON R R R

R R

List 5-10: Drive Motor

PDPM - 0198

5-21

7/13/01

Walkie Pallet Truck, Model 101 - Electrical Components and System Programmable Maintenance Tool

Programmable Maintenance Tool

5

1 SELECTS TEST MENU

DISPLAY WINDOW

SELECTS PROGRAM MENU

SCROLLS DISPLAY UP & DOWN

SELECTS DIAGNOSTIC MENU

CHANGES VALUE OF SELECTED ITEM

SELECTS MORE INFORMATION, SPECIAL PROGRAMS AND DIAGNOSTIC MENUS

950_180A

Figure 5-11: Programmable Maintenance Tool FIGURE 5-11 ITEM NO. 1 2

QTY

PART NUMBER

1

950-180 950-181

DESCRIPTION

USED ON

Programmable Maintenance Tool (includes:) Cable for 4000 lb. Walkie (Not Shown)

List 5-11: Programmable Maintenance Tool

7/13/01

5-22

PDPM - 0198

SECTION 6 Hydraulic Components Hydraulic System............................................................................................................................................................ 6-2 Lift Pump and Motor Assembly......................................................................................................................................... 6-4 Hydraulic Cylinder.......................................................................................................................................................... 6-6

PDPM - 0198

6-1

7/13/01

Walkie Pallet Truck, Model 101 - Hydraulic Components Hydraulic System

Hydraulic System

6

8 10

16

12 7

14

11

9

6

1

3

4

5

13

2

W850_137_201_F

Figure 6-1: Hydraulic System

7/13/01

6-2

PDPM - 0198

Walkie Pallet Truck, Model 101 - Hydraulic Components Hydraulic System FIGURE 6-1 ITEM NO.

QTY

1 1 2 1 3 1 4 1 5 2 6 1 7 1 8 1 9 1 10 6 11 2 12 4 13 1 14 1 16 2 R= Recommended Spare

PART NUMBER 850-137-201 Ref. Ref. 792-514 030-504-008/003 792-568 850-137-040 850-137-041 710-010 810-946 710-129 850-137-164 772-123 850-138-728 710-015 710-127

DESCRIPTION Hydraulic System Cylinder, Hydraulic (See Figure 6-3.)

Pump and Motor Assembly (See Figure 6-2.)

Fitting Hose Assembly Fitting Pin Pin Screw Pin, Cotter Screw Plate, Cylinder Retaining Washer, Lock Bumper, Pump Screw Screw

USED ON

R

List 6-1: Hydraulic System

PDPM - 0198

6-3

7/13/01

Walkie Pallet Truck, Model 101 - Hydraulic Components Lift Pump and Motor Assembly

Lift Pump and Motor Assembly

6

3

4

2

1

7 5

16

6

8

13

11

12

9

10

14

15

W560_215

Figure 6-2: Lift Pump and Motor Assembly

7/13/01

6-4

PDPM - 0198

Walkie Pallet Truck, Model 101 - Hydraulic Components Lift Pump and Motor Assembly FIGURE 6-2 ITEM NO.

QTY

1 1 2 2 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 1 R= Recommended Spare

PART NUMBER 560-215 560-213/03 560-204/328 560-213/07 442-205 442-210 560-213/06 560-206/131 560-206/135 560-207/114 560-206/129 560-206/123 560-213/02 560-206/125 560-213/04 560-213/05 860-626/001 560-213/01

DESCRIPTION Pump and Motor Assembly, Lift Motor (includes:) Bolt, Through Brush Set (Holder and Springs) Bearing, Commutator End Bearing, Drive End Switch Start Service Kit Pump Assembly, Lift Plug, Vent (With Micron Filter) Coil, 24 Volt Valve Stem Valve, Flow Control Valve Assembly, Check Valve, Relief Adapter Kit Reservoir Kit (With Tubes) Coupling Seal Kit (Not Shown)

USED ON

R R R

List 6-2: Lift Pump and Motor Assembly

PDPM - 0198

6-5

7/13/01

Walkie Pallet Truck, Model 101 - Hydraulic Components Hydraulic Cylinder

Hydraulic Cylinder

6

1

W540062

Figure 6-3: Hydraulic Cylinder FIGURE 6-3 QTY PART NUMBER ITEM NO. 1 1 540-062/400 A= Sold as Assembled Unit Not Serviceable

DESCRIPTION Cylinder, Hydraulic (Ultra)

USED ON A

List 6-3: Hydraulic Cylinder

7/13/01

6-6

PDPM - 0198

SECTION 7 Mast Fork Final Assembly........................................................................................................................................................ 7-2 Load Wheel Assembly .................................................................................................................................................... 7-4

PDPM - 0198

7-1

7/13/01

Walkie Pallet Truck, Model 101 - Mast Fork Final Assembly

Fork Final Assembly

7

1

13

14 15

4

3

13 14

7

15

5

5

11

12

2

8

7

11

10

2

6

2

0301_000

Figure 7-1: Fork Final Assembly

7/13/01

7-2

PDPM - 0198

Walkie Pallet Truck, Model 101 - Mast Fork Final Assembly FIGURE 7-1 ITEM NO. 1 2 3 4 5 6

QTY

PART NUMBER

DESCRIPTION

1 Ref. 4 939-352/054 2 939-352/193 2 811-145 2 939-352/192 2 939-352/141 2 939-352/142 2 939-352/143 2 939-352/144 2 939-352/145 2 939-352/146 2 939-352/147 2 939-352/148 2 939-352/149 2 939-352/150 2 939-352/151 2 939-352/152 2 939-352/153 2 939-352/154 7 12 939-352/214 12 464-035 8 12 939-352/215 10 2 850-137-246/001 11 4 939-352/168 12 2 939-352/061 13 2 939-352/047 14 2 772-116 15 2 771-116 A= Cold Storage B= Use On Serial Number 12722 and Below R= Recommended Spare

Fork and Box Weldment (Consult Technical Support) Screw, Set Pin, Link Pin, Roll, 3/16 in. x 1-1/2 in.

Pin, Link Rod, Pull, 32 in. Fork Length Rod, Pull, 36 in. Fork Length Rod, Pull, 42 in. Fork Length Rod, Pull, 46 in. Fork Length Rod, Pull, 48 in. Fork Length Rod, Pull, 54 in. Fork Length Rod, Pull, 60 in. Fork Length Rod, Pull, 32 in. Fork Length Rod, Pull, 36 in. Fork Length Rod, Pull, 42 in. Fork Length Rod, Pull, 46 in. Fork Length Rod, Pull, 48 in. Fork Length Rod, Pull, 54 in. Fork Length Rod, Pull, 60 in. Fork Length Bushing, Iron Bushing Fitting, Grease Pin, Link Link, Lower Pin, Bellcrank Pivot Bolt Washer, Lock Washer, Flat

USED ON

R R

A A A A A A A B, R A R

List 7-1: Fork Final Assembly

PDPM - 0198

7-3

7/13/01

Walkie Pallet Truck, Model 101 - Mast Load Wheel Assembly

Load Wheel Assembly

7

1

4 3

5

2

8

7

W07825A

Figure 7-2: Load Wheel Assembly

7/13/01

7-4

PDPM - 0198

Walkie Pallet Truck, Model 101 - Mast Load Wheel Assembly FIGURE 7-2 ITEM NO. 1 2

QTY

1 1 1 1 1 3 1 4 1 5 2 7 1 8 2 A= Red/Orange Poly B= Neutral Poly C= Black Poly D= Tan Poly R= Recommended Spare

PART NUMBER 939-352/116 939-352/060 632-016/001 632-016/002 632-016/003 632-016/007 939-352/117 939-352/054 441-127 840-033 939-154

DESCRIPTION Wheel, Load Assembly Fork, Trail Machining Wheel, Load Wheel, Load Wheel, Load Wheel, Load Shaft, Wheel Screw, Set Bearing, Shield Fitting, Grease Bearing, Oilite Super

USED ON

A, R B, R C, R D, R R R R

List 7-2: Load Wheel Assembly

PDPM - 0198

7-5

7/13/01

Walkie Pallet Truck, Model 101 - Mast Load Wheel Assembly

This Page Intentionally Blank

7/13/01

7-6

PDPM - 0198

Walkie Pallet Truck, Model 101 - Alphabetical Parts Index

APPENDIX A Description

Part No.

Alphabetical Parts Index Page

Description

Actuator, Cam Assembly . . . . . . . . . . . 850-138-076 . . . . . . 3-9 Adapter Kit . . . . . . . . . . . . . . . . . . . . . 560-213/04 . . . . . . 6-5 Ammeter. . . . . . . . . . . . . . . . . . . . . . . 850-136-707/01 . . 5-15 Anchor, Brake Spring . . . . . . . . . . . . . . 939-352/115 . . . . . 4-5 Arm Machine . . . . . . . . . . . . . . . . . . . 850-138-373 . . . . . 3-10 Arm, Brake . . . . . . . . . . . . . . . . . . . . . 939-352/053 . . . . . 4-5 Armature . . . . . . . . . . . . . . . . . . . . . . 570-864/512 . . . . 5-21 Bar, Bus (CB to M1-1) . . . . . . . . . . . . . 850-136-845 . . . . . . 5-3 Bar, Skid . . . . . . . . . . . . . . . . . . . . . . 939-042 . . . . . . . . . 2-5 Battery Connector . . . . . . . . . . . . . . . . 590-701 . . . . . . . . 5-13 Battery Connector . . . . . . . . . . . . . . . . 590-701 . . . . . . . . 5-15 Battery Connector . . . . . . . . . . . . . . . . 850-136-786 . . . . . . 5-3 Battery Module, 6 Volt . . . . . . . . . . . . . 850-138-139/03 . . 5-17 Battery Pack and Cable Assembly . . . . . 939-352/034 . . . . . 5-9 Battery Pack, 24 Volt (Wet Battery) . . . . 939-352/103 . . . . . 5-9 Battery Pack, 24 Volt (Wet Battery) . . . . 939-352/104 . . . . . 5-9 Battery Pack, GNB Maintenance Free, 24 Volt . . . . . . . . . . . . . . . . . . . . . . . . 850-138-139 . . . . . 5-17 Battery Tree and Cover Assembly . . . . . Ref. . . . . . . . . . . . . . 5-9 Battery, 6 Volt . . . . . . . . . . . . . . . . . . . 939-352/044 . . . . 5-13 Bearing, Ball . . . . . . . . . . . . . . . . . . . . 939-352/002 . . . . . 4-5 Bearing, Commutator End . . . . . . . . . . . 442-205 . . . . . . . . . 6-5 Bearing, Cup/Cone, Pivot (Large) . . . . . 939-006 . . . . . . . . . 4-6 Bearing, Cup/Cone, Pivot (Small) . . . . . 939-005 . . . . . . . . . 4-6 Bearing, Cup/Cone . . . . . . . . . . . . . . . 939-352/005 . . . . . 4-5 Bearing, Drive and Commutator End . . . 939-352/100 . . . . 5-21 Bearing, Drive End. . . . . . . . . . . . . . . . 442-210 . . . . . . . . . 6-5 Bearing, Handle . . . . . . . . . . . . . . . . . 850-135-959 . . . . . . 3-9 Bearing, Handle . . . . . . . . . . . . . . . . . 939-352/065 . . . . . 4-5 Bearing, Oilite Super . . . . . . . . . . . . . . 939-154 . . . . . . . . . 7-5 Bearing, Shield . . . . . . . . . . . . . . . . . . 441-127 . . . . . . . . . 7-5 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/047 . . . . . 7-3 Bolt, Anchor, Chain (Metric) . . . . . . . . . 939-352/081 . . . . . 3-3 Bolt, Chain Anchor . . . . . . . . . . . . . . . 939-352/081 . . . . . 3-8 Bolt, Special . . . . . . . . . . . . . . . . . . . . 939-352/058 . . . . . 4-5 Bolt, Through. . . . . . . . . . . . . . . . . . . . 560-204/328 . . . . . 6-5 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 714-100 . . . . . . . . . 5-9 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 716-030 . . . . . . . . . 2-5 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 850-138-139/10 . . 5-17 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/084 . . . . 5-11 Boot, Terminal . . . . . . . . . . . . . . . . . . . 939-352/046 . . . . 5-13 Bracket, Brake Switch. . . . . . . . . . . . . . 939-352/079 . . . . . 4-5 Bracket, Brake Switch. . . . . . . . . . . . . . 939-352/079 . . . . . 5-3 Bracket, Emergency, Reverse. . . . . . . . . 850-137-917 . . . . . . 3-7 Bracket, Keys Switch Mounting . . . . . . . 850-137-023 . . . . . . 2-5 Bracket, Potentiometer . . . . . . . . . . . . . 850-138-101 . . . . . . 3-7 Bracket, Travel. . . . . . . . . . . . . . . . . . . 850-137-918 . . . . . . 3-7 Brake Assembly . . . . . . . . . . . . . . . . . . 400-081 . . . . . . . . . 4-5 Brake Assembly . . . . . . . . . . . . . . . . . . 400-081 . . . . . . . . . 4-8 Brush Lead Assembly Kit . . . . . . . . . . . . 570-271/515 . . . . 5-21 Brush Set (4 per set) . . . . . . . . . . . . . . . 570-316/516 . . . . 5-21 Brush Set (Holder and Springs) . . . . . . . 560-213/07 . . . . . . 6-5 Brush Spring Set (2 per set) . . . . . . . . . . 570-316/517 . . . . 5-21 Bumper, Pump . . . . . . . . . . . . . . . . . . . 850-138-728 . . . . . . 6-3 Bushing, Flanged . . . . . . . . . . . . . . . . . 939-352/215 . . . . . 3-3 Bushing, Iron . . . . . . . . . . . . . . . . . . . . 939-352/214 . . . . . 7-3 Bushing . . . . . . . . . . . . . . . . . . . . . . . 464-034 . . . . . . . . . 2-5

PDPM - 0198

Part No.

Page

Bushing . . . . . . . . . . . . . . . . . . . . . . . 464-035 . . . . . . . . . 2-5 Bushing . . . . . . . . . . . . . . . . . . . . . . . 464-035 . . . . . . . . . 7-3 Button Assembly, Nose. . . . . . . . . . . . . 850-135-976/001 . . 3-7 Button, Function, Forks, Lift . . . . . . . . . . 850-135-947/103 . . 3-7 Button, Function, Forks, Lowered . . . . . . 850-135-947/102 . . 3-7 Button, Function, Horn . . . . . . . . . . . . . 850-135-947/101 . . 3-7 Cable Assembly (B- to B-) . . . . . . . . . . . B24-020-110/260 . . 5-3 Cable Assembly (B- to MP2) . . . . . . . . . B24-022-220/272 . . 5-3 Cable Assembly (B+ to M1-2) . . . . . . . . B24-196-075/304 . . 5-3 Cable Assembly (B+ to MDA2) . . . . . . . B24-023-380/297 . . 5-3 Cable Assembly (CB to P1) . . . . . . . . . . B24-020-170/301 . . 5-3 Cable Assembly (M- to MDA1) . . . . . . . B24-023-380/298 . . 5-3 Cable Assembly (MDE2 to S1) . . . . . . . 029-002-380/001 . . 5-3 Cable Assembly (MDE2 to S2) . . . . . . . 029-002-380/002 . . 5-3 Cable Assembly . . . . . . . . . . . . . . . . . 939-146 . . . . . . . . 5-13 Cable Assembly . . . . . . . . . . . . . . . . . 939-149 . . . . . . . . 5-13 Cable Assembly . . . . . . . . . . . . . . . . . 939-352/176 . . . . 5-13 Cable Assembly . . . . . . . . . . . . . . . . . 939-352/178 . . . . 5-13 Cable Assembly . . . . . . . . . . . . . . . . . 939-352/179 . . . . 5-13 Cable for 4000 lb. Walkie. . . . . . . . . . 950-181 . . . . . . . . 5-22 Cable Kit, Drive . . . . . . . . . . . . . . . . . 850-136-788 . . . . . . 5-3 Cable Kit, Tractor . . . . . . . . . . . . . . . . 850-136-787 . . . . . . 5-3 Cable, Inter, Battery. . . . . . . . . . . . . . . 850-138-139/05 . . 5-17 Cam . . . . . . . . . . . . . . . . . . . . . . . . . 400-081/02 . . . . . . 4-8 Cap, Journal Machine, Left Hand . . . . . 850-138-391/001 . . 3-7 Cap, Journal Machine, Right Hand . . . . 850-138-392/001 . . 3-7 Capacitor (440 VAC) . . . . . . . . . . . . . 850-136-707/03 . . 5-15 Case Assembly, Gear . . . . . . . . . . . . . 939-352/082 . . . . . 4-5 Case, Back, Large Cell. . . . . . . . . . . . . 850-138-139/14 . . 5-19 Case, Main Pallet . . . . . . . . . . . . . . . . 850-136-707/04 . . 5-15 Case, Main, Large Cell . . . . . . . . . . . . 850-138-139/15 . . 5-19 Case, Top, Large Cell . . . . . . . . . . . . . 850-138-139/16 . . 5-19 Chain, Roller Assembly . . . . . . . . . . . . 850-137-258 . . . . . . 3-7 Charger Assembly . . . . . . . . . . . . . . . . 850-136-707 . . . . . . 5-9 Charger . . . . . . . . . . . . . . . . . . . . . . . 850-138-139/02 . . 5-17 Charger . . . . . . . . . . . . . . . . . . . . . . . 850-138-139/02 . . 5-19 Circuit Breaker 15A. . . . . . . . . . . . . . . 850-138-139/17 . . 5-19 Circuit Breaker, 80 Amp . . . . . . . . . . . 850-136-795/080 . . 5-3 Circuit, 2400 24V 25 A 55T (With Cord) . . . . . . . . . . . . . . . . . . . . 850-138-139/18 . . 5-19 Clamp . . . . . . . . . . . . . . . . . . . . . . . . 939-352/013 . . . . . 4-5 Coil and Frame Assembly. . . . . . . . . . . 1-105-216/09 . . . . . 5-5 Coil, 24 Volt . . . . . . . . . . . . . . . . . . . . 560-207/114 . . . . . 6-5 Contact Tip, Fixed . . . . . . . . . . . . . . . . 1-105-225/01 . . . . . 5-5 Contact Tip, Moving . . . . . . . . . . . . . . 1-105-225/02 . . . . . 5-5 Contactor, Forward/Reverse . . . . . . . . . 1-105-225 . . . . . . . . 5-3 Control Assembly . . . . . . . . . . . . . . . . 850-137-903/001 . . 3-7 Control Assembly . . . . . . . . . . . . . . . . 850-137-903/001 . . 3-9 Cord, AC Assembly . . . . . . . . . . . . . . . 850-138-139/20 . . 5-19 Cord, AC, Set . . . . . . . . . . . . . . . . . . . 850-136-707/05 . . 5-15 Cord, DC Assembly . . . . . . . . . . . . . . . 850-138-139/19 . . 5-19 Cord, Wire AC Set . . . . . . . . . . . . . . . 850-136-707/06 . . 5-15 Coupling . . . . . . . . . . . . . . . . . . . . . . 860-626/001 . . . . . 6-5 Cover, Brake . . . . . . . . . . . . . . . . . . . 360-068 . . . . . . . . . 4-5 Cover, Front . . . . . . . . . . . . . . . . . . . . 360-065/001 . . . . . 2-9 Cover, Gear . . . . . . . . . . . . . . . . . . . . 939-352/191 . . . . . 4-5 Cover, Internal . . . . . . . . . . . . . . . . . . 1-085-186 . . . . . . . . 2-5

A-1

7/13/01

Walkie Pallet Truck, Model 101 - Alphabetical Parts Index

Description

Part No.

Page

Description

Cover, Side . . . . . . . . . . . . . . . . . . . . 850-137-905. . . . . . 3-7 Cover, Top . . . . . . . . . . . . . . . . . . . . . 1-105-216/05 . . . . . 5-5 Cover . . . . . . . . . . . . . . . . . . . . . . . . 850-137-915. . . . . . 3-7 Cylinder, Hydraulic . . . . . . . . . . . . . . . Ref. . . . . . . . . . . . . . 6-3 Cylinder, Hydraulic (Ultra) . . . . . . . . . . 540-062/400 . . . . . 6-6 Decal, 24 Volt Cable System . . . . . . . . 411-848 . . . . . . . . . 5-9 Decal, 24 Volt Cable System . . . . . . . . 411-849 . . . . . . . . . 5-9 Decal, Battery Swivel Warning . . . . . . . 411-852 . . . . . . . . . 5-9 Decal, Battery Swivel Warning . . . . . . . 411-853 . . . . . . . . . 5-9 Decal, Caution . . . . . . . . . . . . . . . . . . 411-633 . . . . . . . . . 2-9 Decal, Charging Warning . . . . . . . . . . 411-850 . . . . . . . . . 5-9 Decal, Charging Warning . . . . . . . . . . 411-851 . . . . . . . . . 5-9 Decal, Emergency Disconnect . . . . . . . . 411-534 . . . . . . . . . 2-9 Decal, Emergency Disconnect . . . . . . . . 411-637/001 . . . . . 2-9 Decal, Fault Code Explanation . . . . . . . 412-720 . . . . . . . . . 2-9 Decal, Millennium Series . . . . . . . . . . . 412-748 . . . . . . . . . 2-9 Decal, No Riding, Black 9 in. . . . . . . . . 411-587/001 . . . . . 2-9 Decal, No Riding . . . . . . . . . . . . . . . . 411-773 . . . . . . . . . 2-9 Decal, Operating . . . . . . . . . . . . . . . . 411-680 . . . . . . . . . 2-9 Decal, Raymond . . . . . . . . . . . . . . . . . 411-511/015 . . . . . 2-9 Decal, Replacement Instruction . . . . . . . 411-681 . . . . . . . . . 2-9 Decal, Warning . . . . . . . . . . . . . . . . . 411-552 . . . . . . . . . 2-9 Decal, Warning . . . . . . . . . . . . . . . . . 411-789 . . . . . . . . . 2-9 Decal, Warning . . . . . . . . . . . . . . . . . 411-790 . . . . . . . . . 2-9 Diode, 20A . . . . . . . . . . . . . . . . . . . . 850-136-707/07 . . 5-15 Door Weldment, Battery Box . . . . . . . . 939-352/045 . . . . 5-11 Dowel . . . . . . . . . . . . . . . . . . . . . . . . 812-404 . . . . . . . . . 4-5 Drive Motor . . . . . . . . . . . . . . . . . . . . 570-864/500 . . . . 5-21 Drive Unit. . . . . . . . . . . . . . . . . . . . . . 939-352/114 . . . . . 4-5 Drum, Brake . . . . . . . . . . . . . . . . . . . . 939-321 . . . . . . . . . 4-5 Edging. . . . . . . . . . . . . . . . . . . . . . . . 939-352/230 . . . . 5-11 Field Coil Kit. . . . . . . . . . . . . . . . . . . . 939-352/101 . . . . 5-21 Fitting, Grease . . . . . . . . . . . . . . . . . . 840-033 . . . . . . . . . 7-5 Fitting, Grease . . . . . . . . . . . . . . . . . . 939-352/004 . . . . . 4-5 Fitting, Grease . . . . . . . . . . . . . . . . . . 939-352/215 . . . . . 7-3 Fitting . . . . . . . . . . . . . . . . . . . . . . . . 792-514 . . . . . . . . . 6-3 Fitting . . . . . . . . . . . . . . . . . . . . . . . . 792-568 . . . . . . . . 6-3 Fork and Box Weldment . . . . . . . . . . . Ref.. . . . . . . . . . . . . 7-3 Fork, Joint Combination . . . . . . . . . . . . 939-352/063 . . . . . 4-5 Fork, Trail Machining . . . . . . . . . . . . . 939-352/060 . . . . . 7-5 Frame, Lift Machining . . . . . . . . . . . . . 939-352/169 . . . . . 2-5 Frame, Lift Machining . . . . . . . . . . . . . 939-352/170 . . . . . 2-5 Fuse Block . . . . . . . . . . . . . . . . . . . . . 850-136-863. . . . . . 5-3 Fuse, 15 Amp. . . . . . . . . . . . . . . . . . . 590-514 . . . . . . . . . 5-3 Fuse, DC Assembly . . . . . . . . . . . . . . . 850-136-707/08 . . 5-15 Fuse, DC Fuselink . . . . . . . . . . . . . . . . 850-136-707/09 . . 5-15 Gear, Drive . . . . . . . . . . . . . . . . . . . . 939-333 . . . . . . . . . 4-5 Gear, Idle . . . . . . . . . . . . . . . . . . . . . 939-352/052 . . . . . 4-5 Gear, Pinion. . . . . . . . . . . . . . . . . . . . 939-330 . . . . . . . . . 4-5 Gear, Potentiometer . . . . . . . . . . . . . . 850-135-946. . . . . . 3-7 Grip, Handle Assembly . . . . . . . . . . . . 850-138-862/001 . . 3-9 Grommet, Rubber . . . . . . . . . . . . . . . . 850-138-139/06 . . 5-17 Grommet . . . . . . . . . . . . . . . . . . . . . . 939-352/006 . . . . 5-13 Grommet . . . . . . . . . . . . . . . . . . . . . . 939-352/007 . . . . 5-13 Guard, Cable, 9.5 in. . . . . . . . . . . . . . 360-062/003 . . . . . 5-9 Guard, Wheel, Rubber . . . . . . . . . . . . 850-137-862. . . . . . 4-5 Guard, Wheel . . . . . . . . . . . . . . . . . . 939-352/113 . . . . . 4-5 Handle and Controller Assembly . . . . . . 850-138-383/101 . . 3-3 Handle and Controller Assembly . . . . . . 850-138-383/102 . . 3-3 Handle Arm Assembly . . . . . . . . . . . . . 850-137-894/005 . 3-10 Handle Bottom . . . . . . . . . . . . . . . . . . 850-138-390/001 . . 3-7

7/13/01

Part No.

Page

Handle Machining . . . . . . . . . . . . . . . 850-138-386/001. 3-10 Handle Mounting and Installation . . . . . 850-138-384/. . . . . 3-3 Handle/Arm . . . . . . . . . . . . . . . . . . . 850-137-894/005. . 3-7 Harness, Function . . . . . . . . . . . . . . . . 850-136-896 . . . . . 3-7 Harness, Function . . . . . . . . . . . . . . . . 850-136-897 . . . . . 3-7 Harness, Main . . . . . . . . . . . . . . . . . . 850-136-782 . . . . . 5-3 Harness, Main . . . . . . . . . . . . . . . . . . 850-136-783 . . . . . 5-3 Harness, Travel. . . . . . . . . . . . . . . . . . 850-136-577 . . . . . 3-7 Harness, Travel. . . . . . . . . . . . . . . . . . 850-136-579 . . . . . 3-7 Head, Commutator End . . . . . . . . . . . . 570-864/515 . . . . 5-21 Head, Drive End. . . . . . . . . . . . . . . . . 570-360/516 . . . . 5-21 Heater . . . . . . . . . . . . . . . . . . . . . . . . 1-110-920/092. . . . 3-7 Horn Assembly . . . . . . . . . . . . . . . . . . 590-638/001 . . . . . 5-3 Hose Assembly . . . . . . . . . . . . . . . . . . 030-504-008/003. . 6-3 Hub Machining, Wheel . . . . . . . . . . . . 939-352/083 . . . . . 4-7 Hydraulic System . . . . . . . . . . . . . . . . 850-137-201 . . . . . 6-3 Key . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/008 . . . . . 4-5 Knob, Timer . . . . . . . . . . . . . . . . . . . . 850-136-707/13. . 5-15 Knob . . . . . . . . . . . . . . . . . . . . . . . . . 860-135 . . . . . . . . . 2-9 Label, Champion . . . . . . . . . . . . . . . . 850-138-139/07. . 5-17 Label, Warning . . . . . . . . . . . . . . . . . 850-138-139/08. . 5-17 Lever, Brake . . . . . . . . . . . . . . . . . . . . 400-081/03 . . . . . . 4-8 Link, Connecting . . . . . . . . . . . . . . . . . 850-137-174 . . . . . 3-7 Link, Lower. . . . . . . . . . . . . . . . . . . . . 939-352/168 . . . . . 7-3 Link, Offset. . . . . . . . . . . . . . . . . . . . . 680-806 . . . . . . . . . 3-3 Link, Upper . . . . . . . . . . . . . . . . . . . . 850-137-275 . . . . . 2-5 Load Backrest, 48 in. High . . . . . . . . . 850-137-147/048. 2-10 Load Backrest, 60 in. High . . . . . . . . . 850-137-147/060. 2-10 Meter, Hour/Discharge . . . . . . . . . . . . 870-248 . . . . . . . . . 5-7 Meter, Hour . . . . . . . . . . . . . . . . . . . . 870-251 . . . . . . . . . 5-7 Motor Assembly, Drive . . . . . . . . . . . . 570-864/500 . . . . . 4-6 Motor Controller . . . . . . . . . . . . . . . . . 1-187-082 . . . . . . . 5-3 Motor . . . . . . . . . . . . . . . . . . . . . . . . 560-213/03 . . . . . . 6-5 Nail, Grip . . . . . . . . . . . . . . . . . . . . . 813 570/002 . . . . . 2-9 Nut, Wheel . . . . . . . . . . . . . . . . . . . . 939-352/014 . . . . . 4-7 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 750-006 . . . . . . . . . 2-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 750-006 . . . . . . . . . 5-3 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 750-013 . . . . . . . . 3-10 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 750-019 . . . . . . . . . 2-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 750-027 . . . . . . . . . 2-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 750-036 . . . . . . . . . 3-7 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 939-041 . . . . . . . . . 4-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/011 . . . . 5-13 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/014 . . . . . 4-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/041 . . . . 5-11 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/049 . . . . 5-11 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/049 . . . . . 5-9 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/050 . . . . . 4-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/070 . . . . . 4-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/077 . . . . . 3-3 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/077 . . . . . 3-8 O-Ring. . . . . . . . . . . . . . . . . . . . . . . . 530-449 . . . . . . . . . 4-5 Pad, Bumper . . . . . . . . . . . . . . . . . . . 360-049 . . . . . . . . . 3-3 Pad, Foam Rubber . . . . . . . . . . . . . . . 850-138-139/13. . 5-17 Pin, Bellcrank Pivot . . . . . . . . . . . . . . . 939-352/061 . . . . . 7-3 Pin, Chain Sheave . . . . . . . . . . . . . . . 850-138-766 . . . . . 3-7 Pin, Cotter . . . . . . . . . . . . . . . . . . . . . 810-913 . . . . . . . . 5-11 Pin, Cotter . . . . . . . . . . . . . . . . . . . . . 810-945 . . . . . . . . . 3-3 Pin, Cotter . . . . . . . . . . . . . . . . . . . . . 810-946 . . . . . . . . . 6-3 Pin, Link. . . . . . . . . . . . . . . . . . . . . . . 850-137-246/001. . 2-5 Pin, Link. . . . . . . . . . . . . . . . . . . . . . . 850-137-246/001. . 7-3

A-2

PDPM - 0198

Walkie Pallet Truck, Model 101 - Alphabetical Parts Index

Description

Part No.

Page

Description

Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 939-352/192 . . . . . 7-3 Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 939-352/193 . . . . . 7-3 Pin, Roll . . . . . . . . . . . . . . . . . . . . . . . 811-145 . . . . . . . . . 2-5 Pin, Roll . . . . . . . . . . . . . . . . . . . . . . . 811-145 . . . . . . . . . 7-3 Pin, Spring . . . . . . . . . . . . . . . . . . . . . 810-813 . . . . . . . . . 3-9 Pin, Spring . . . . . . . . . . . . . . . . . . . . . 811-138 . . . . . . . . . 3-8 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 850-137-040 . . . . . 6-3 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 850-137-041 . . . . . . 6-3 Plate Assembly, Cover . . . . . . . . . . . . . 570-316/519 . . . . 5-21 Plate, Backing . . . . . . . . . . . . . . . . . . . 400-081/01 . . . . . . 4-8 Plate, Cylinder Retaining. . . . . . . . . . . . 850-137-164 . . . . . . 6-3 Plate, Lowlift Specification (Canadian) . . 939-352/108 . . . . . 2-9 Plate, Lowlift Specification (U.S.) . . . . . . 939-352/106 . . . . . 2-9 Plate, Lowlift Specification (U.S.) . . . . . . 939-352/107 . . . . . 2-9 Plate, Name . . . . . . . . . . . . . . . . . . . . 850-138-139/09 . . 5-17 Plate, Spring Mount . . . . . . . . . . . . . . . 850-137-923 . . . . . . 3-7 Plate, Switch Backing . . . . . . . . . . . . . . 850-137-207 . . . . . . 5-3 Plate, Switch . . . . . . . . . . . . . . . . . . . . 850-137-919 . . . . . . 3-7 Plate, Tie . . . . . . . . . . . . . . . . . . . . . . 850-137-895 . . . . . 3-10 Plate, Timer Dial . . . . . . . . . . . . . . . . . 850-136-707/15 . . 5-15 Plug, Drain/Fill . . . . . . . . . . . . . . . . . . 939-352/048 . . . . . 4-5 Plug, Mounting Bracket. . . . . . . . . . . . . 850-138-139/21 . . 5-19 Plug, SB 175, Cables . . . . . . . . . . . . . . 850-138-139/04 . . 5-17 Plug, SB175 Black . . . . . . . . . . . . . . . . 850-138-139/22 . . 5-19 Plug, Vent (With Micron Filter) . . . . . . . . 560-206/135 . . . . . 6-5 Pocket, Manual . . . . . . . . . . . . . . . . . . 828-006-843 . . . . . . 2-9 Potentiometer . . . . . . . . . . . . . . . . . . . 1-120-098 . . . . . . . . 3-7 Programmable Maintenance Tool . . . . . 950-180 . . . . . . . . 5-22 Pump and Motor Assembly . . . . . . . . . . Ref. . . . . . . . . . . . . . 6-3 Pump and Motor Assembly, Lift . . . . . . . 560-215 . . . . . . . . . 6-5 Pump Assembly, Lift . . . . . . . . . . . . . . . 560-206/131 . . . . . 6-5 Rectifier Assembly . . . . . . . . . . . . . . . . 850-136-707/11 . . 5-15 Rectifier Assembly . . . . . . . . . . . . . . . . 850-138-139/23 . . 5-19 Rectifier, SCR Assembly . . . . . . . . . . . . 850-138-139/24 . . 5-19 Relief, AC Strain . . . . . . . . . . . . . . . . . 850-136-707/12 . . 5-15 Reservoir Kit (With Tubes) . . . . . . . . . . . 560-213/05 . . . . . . 6-5 Retainer . . . . . . . . . . . . . . . . . . . . . . . 939-352/064 . . . . . 4-5 Ring, Cable Holding . . . . . . . . . . . . . . 828-001-457 . . . . . . 2-5 Ring, Nilos (Large) . . . . . . . . . . . . . . . . 291-012 . . . . . . . . . 4-5 Ring, Nilos (Small) . . . . . . . . . . . . . . . . 291-011 . . . . . . . . . 4-5 Ring, Retaining . . . . . . . . . . . . . . . . . . 570-316/513 . . . . 5-21 Ring, Safety . . . . . . . . . . . . . . . . . . . . 400-081/04 . . . . . . 4-8 Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 939-311 . . . . . . . . . 4-5 Rod, Pull, 32 in. Fork Length . . . . . . . . . 939-352/141 . . . . . 7-3 Rod, Pull, 32 in. Fork Length . . . . . . . . . 939-352/148 . . . . . 7-3 Rod, Pull, 36 in. Fork Length . . . . . . . . . 939-352/142 . . . . . 7-3 Rod, Pull, 36 in. Fork Length . . . . . . . . . 939-352/149 . . . . . 7-3 Rod, Pull, 42 in. Fork Length . . . . . . . . . 939-352/143 . . . . . 7-3 Rod, Pull, 42 in. Fork Length . . . . . . . . . 939-352/150 . . . . . 7-3 Rod, Pull, 46 in. Fork Length . . . . . . . . . 939-352/144 . . . . . 7-3 Rod, Pull, 46 in. Fork Length . . . . . . . . . 939-352/151 . . . . . 7-3 Rod, Pull, 48 in. Fork Length . . . . . . . . . 939-352/145 . . . . . 7-3 Rod, Pull, 48 in. Fork Length . . . . . . . . . 939-352/152 . . . . . 7-3 Rod, Pull, 54 in. Fork Length . . . . . . . . . 939-352/146 . . . . . 7-3 Rod, Pull, 54 in. Fork Length . . . . . . . . . 939-352/153 . . . . . 7-3 Rod, Pull, 60 in. Fork Length . . . . . . . . . 939-352/147 . . . . . 7-3 Rod, Pull, 60 in. Fork Length . . . . . . . . . 939-352/154 . . . . . 7-3 Rod, Push . . . . . . . . . . . . . . . . . . . . . . 939-352/055 . . . . . 4-5 Screw, Set . . . . . . . . . . . . . . . . . . . . . 724-399 . . . . . . . . . 5-3 Screw, Set . . . . . . . . . . . . . . . . . . . . . 724-414 . . . . . . . . . 5-3 Screw, Set . . . . . . . . . . . . . . . . . . . . . 939-352/054 . . . . . 7-3

PDPM - 0198

Part No.

Page

Screw, Set . . . . . . . . . . . . . . . . . . . . . 939-352/054 . . . . . 7-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 1-105-216/06 . . . . . 5-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 701-012 . . . . . . . . . 5-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 701-021 . . . . . . . . . 3-7 Screw . . . . . . . . . . . . . . . . . . . . . . . . 701-021 . . . . . . . . . 5-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 701-062 . . . . . . . . . 5-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 701-115 . . . . . . . . . 5-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 701-190 . . . . . . . . . 5-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 701-251 . . . . . . . . . 3-7 Screw . . . . . . . . . . . . . . . . . . . . . . . . 710-006 . . . . . . . . . 5-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 710-008 . . . . . . . . . 3-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 710-010 . . . . . . . . . 6-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 710-015 . . . . . . . . . 6-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 710-065 . . . . . . . . . 2-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 710-127 . . . . . . . . . 6-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 710-129 . . . . . . . . . 6-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 710-135 . . . . . . . . . 2-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 710-202 . . . . . . . . . 2-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 714-006 . . . . . . . . . 3-7 Screw . . . . . . . . . . . . . . . . . . . . . . . . 714-011 . . . . . . . . . 3-7 Screw . . . . . . . . . . . . . . . . . . . . . . . . 714-014/004 . . . . . 3-8 Screw . . . . . . . . . . . . . . . . . . . . . . . . 714-021 . . . . . . . . . 3-7 Screw . . . . . . . . . . . . . . . . . . . . . . . . 714-047 . . . . . . . . . 3-7 Screw . . . . . . . . . . . . . . . . . . . . . . . . 714-056 . . . . . . . . . 2-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 714-137 . . . . . . . . 3-10 Screw . . . . . . . . . . . . . . . . . . . . . . . . 715-032 . . . . . . . . 3-10 Screw . . . . . . . . . . . . . . . . . . . . . . . . 715-064 . . . . . . . . 3-10 Screw . . . . . . . . . . . . . . . . . . . . . . . . 939-352/022 . . . . . 3-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 939-352/026 . . . . . 3-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 939-352/026 . . . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 939-352/047 . . . . . 5-9 Screw . . . . . . . . . . . . . . . . . . . . . . . . 939-352/066 . . . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 939-352/067 . . . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 939-352/068 . . . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 939-352/069 . . . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 939-352/086 . . . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 939-352/226 . . . . 5-11 Screw . . . . . . . . . . . . . . . . . . . . . . . . 939-352/227 . . . . 5-11 Seal Kit . . . . . . . . . . . . . . . . . . . . . . . 560-213/01 . . . . . . 6-5 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 1-150-386 . . . . . . . . 3-7 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 570-316/511 . . . . 5-21 Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 939-352/003 . . . . . 4-5 Shaft, Cam Actuator . . . . . . . . . . . . . . 850-137-920 . . . . . . 3-9 Shaft, Flexible . . . . . . . . . . . . . . . . . . . 610-307 . . . . . . . . . 3-9 Shaft, Handle Pivot Weldment. . . . . . . . 850-138-372 . . . . . . 3-3 Shaft, Wheel . . . . . . . . . . . . . . . . . . . 939-352/117 . . . . . 7-5 Sheave, Chain . . . . . . . . . . . . . . . . . . 850-137-166 . . . . . . 3-7 Shim, Switch . . . . . . . . . . . . . . . . . . . . 850-135-712 . . . . . . 3-7 Shoe Assembly . . . . . . . . . . . . . . . . . . 400-081/05 . . . . . . 4-8 Shunt Assembly . . . . . . . . . . . . . . . . . . 850-138-139/25 . . 5-19 Spacer . . . . . . . . . . . . . . . . . . . . . . . . 850-137-916 . . . . . . 3-9 Spacer . . . . . . . . . . . . . . . . . . . . . . . . 939-352/112 . . . . . 3-3 Spring, Compression . . . . . . . . . . . . . . 830-204 . . . . . . . . . 3-8 Spring, Handle Return . . . . . . . . . . . . . 830-347 . . . . . . . . . 3-9 Spring, Return . . . . . . . . . . . . . . . . . . . 1-105-216/07 . . . . . 5-5 Spring, Return . . . . . . . . . . . . . . . . . . . 400-081/06 . . . . . . 4-8 Spring, Tension . . . . . . . . . . . . . . . . . . 830-056 . . . . . . . . . 3-8 Spring . . . . . . . . . . . . . . . . . . . . . . . . 939-023 . . . . . . . . . 4-5 Standoff . . . . . . . . . . . . . . . . . . . . . . . 1-074-104/001 . . . . 5-3 Strain Relief . . . . . . . . . . . . . . . . . . . . 850-138-139/26 . . 5-19 Strap, Capacitor . . . . . . . . . . . . . . . . . 850-136-707/02 . . 5-15

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7/13/01

Walkie Pallet Truck, Model 101 - Alphabetical Parts Index

Description

Part No.

Page

Description

Strip, Reinforcing . . . . . . . . . . . . . . . . 850-137-864. . . . . . 4-5 Switch Start Service Kit . . . . . . . . . . . . 560-213/06 . . . . . . 6-5 Switch, Brake/Lift Cutout . . . . . . . . . . . 1-150-366. . . . . . . . 5-3 Switch, Emergency, Reverse . . . . . . . . . 1-150-384. . . . . . . . 3-7 Switch, Function . . . . . . . . . . . . . . . . . 1-150-418. . . . . . . . 3-7 Switch, Key . . . . . . . . . . . . . . . . . . . . 1-150-368. . . . . . . . 5-3 Switch, Key . . . . . . . . . . . . . . . . . . . . 1-150-378. . . . . . . . 5-3 Switch, Red Push Button . . . . . . . . . . . . 850-138-139/27 . . 5-19 Switch, Travel . . . . . . . . . . . . . . . . . . . 1-150-425. . . . . . . . 3-7 Tape, Double Sided. . . . . . . . . . . . . . . 370-637/005 . . . . . 3-7 Tie, Cable . . . . . . . . . . . . . . . . . . . . . 939-352/042 . . . . 5-13 Timer, 12HR, 60 Hz . . . . . . . . . . . . . . 850-136-707/14 . . 5-15 Tire, Poly . . . . . . . . . . . . . . . . . . . . . . 632-095/001 . . . . . 4-7 Tire, Rubber . . . . . . . . . . . . . . . . . . . . 630-261 . . . . . . . . . 4-7 Transformer . . . . . . . . . . . . . . . . . . . . 850-138-139/28 . . 5-19 Transmission Assembly . . . . . . . . . . . . Ref. . . . . . . . . . . . . . 3-3 Tray Weldment . . . . . . . . . . . . . . . . . . 939-352/228 . . . . 5-11 Tray Weldment . . . . . . . . . . . . . . . . . . 939-352/229 . . . . 5-11 Tray . . . . . . . . . . . . . . . . . . . . . . . . . 850-138-139/01 . . 5-17 TX 24V, 15A, 120VAC, 50Hz . . . . . . . 850-136-707/20 . . 5-15 TX 24V, 15A, 120VAC, 60Hz . . . . . . . 850-136-707/16 . . 5-15 Valve Assembly, Check . . . . . . . . . . . . 560-213/02 . . . . . . 6-5 Valve Stem . . . . . . . . . . . . . . . . . . . . . 560-206/129 . . . . . 6-5 Valve, Flow Control . . . . . . . . . . . . . . . 560-206/123 . . . . . 6-5 Valve, Relief . . . . . . . . . . . . . . . . . . . . 560-206/125 . . . . . 6-5 Varistor Assembly . . . . . . . . . . . . . . . . 850-138-139/29 . . 5-19 Varistor . . . . . . . . . . . . . . . . . . . . . . . 850-136-707/17 . . 5-15 Varistor . . . . . . . . . . . . . . . . . . . . . . . 850-138-139/30 . . 5-19 Washer, Flat . . . . . . . . . . . . . . . . . . . 771-009 . . . . . . . . . 3-8 Washer, Flat . . . . . . . . . . . . . . . . . . . 771-016 . . . . . . . . . 3-3 Washer, Flat . . . . . . . . . . . . . . . . . . . 771-116 . . . . . . . . . 5-3

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Part No.

Page

Washer, Flat . . . . . . . . . . . . . . . . . . . 771-116 . . . . . . . . . 7-3 Washer, Flat . . . . . . . . . . . . . . . . . . . 939-352/001 . . . . 5-11 Washer, Flat . . . . . . . . . . . . . . . . . . . 939-352/088 . . . . . 4-6 Washer, Flat . . . . . . . . . . . . . . . . . . . 939-352/182 . . . . . 4-6 Washer, Lock . . . . . . . . . . . . . . . . . . . 772-112 . . . . . . . . . 5-3 Washer, Lock . . . . . . . . . . . . . . . . . . . 772-116 . . . . . . . . . 2-5 Washer, Lock . . . . . . . . . . . . . . . . . . . 772-116 . . . . . . . . . 5-3 Washer, Lock . . . . . . . . . . . . . . . . . . . 772-116 . . . . . . . . . 7-3 Washer, Lock . . . . . . . . . . . . . . . . . . . 772-123 . . . . . . . . . 5-9 Washer, Lock . . . . . . . . . . . . . . . . . . . 772-123 . . . . . . . . . 6-3 Washer, Lock . . . . . . . . . . . . . . . . . . . 774-116 . . . . . . . . . 5-3 Washer, Lock . . . . . . . . . . . . . . . . . . . 850-138-139/11. . 5-17 Washer, Lock . . . . . . . . . . . . . . . . . . . 939-352/225 . . . . 5-11 Washer, Sealing . . . . . . . . . . . . . . . . 939-352/010 . . . . . 4-5 Washer, Spring . . . . . . . . . . . . . . . . . 939-352/102 . . . . 5-21 Washer . . . . . . . . . . . . . . . . . . . . . . . 771-019 . . . . . . . . . 2-5 Washer . . . . . . . . . . . . . . . . . . . . . . . 771-024 . . . . . . . . . 2-5 Washer . . . . . . . . . . . . . . . . . . . . . . . 771-101 . . . . . . . . . 3-7 Washer . . . . . . . . . . . . . . . . . . . . . . . 771-169 . . . . . . . . 3-10 Washer . . . . . . . . . . . . . . . . . . . . . . . 774-009 . . . . . . . . . 3-8 Washer . . . . . . . . . . . . . . . . . . . . . . . 850-138-139/12. . 5-17 Washer . . . . . . . . . . . . . . . . . . . . . . . 939-352/001 . . . . 5-13 Wheel Assembly. . . . . . . . . . . . . . . . . 939-352/083 . . . . . 4-6 Wheel, Load Assembly . . . . . . . . . . . . 939-352/116 . . . . . 7-5 Wheel, Load . . . . . . . . . . . . . . . . . . . 632-016/001 . . . . . 7-5 Wheel, Load . . . . . . . . . . . . . . . . . . . 632-016/002 . . . . . 7-5 Wheel, Load . . . . . . . . . . . . . . . . . . . 632-016/003 . . . . . 7-5 Wheel, Load . . . . . . . . . . . . . . . . . . . 632-016/007 . . . . . 7-5 Wrap, Spiral . . . . . . . . . . . . . . . . . . . 870-863 . . . . . . . . . 5-3 Wrapper . . . . . . . . . . . . . . . . . . . . . . 939-352/224 . . . . 5-11

A-4

PDPM - 0198

Walkie Pallet Truck, Model 101 - Numerical Parts Index

APPENDIX B Part No.

Description

Numerical Parts Index Page

Part No.

029-002-380/001 .....Cable Assembly (MDE2 to S1) ............. 5-3 029-002-380/002 .....Cable Assembly (MDE2 to S2) ............. 5-3 030-504-008/003 .....Hose Assembly ................................... 6-3 1-074-104/001 .........Standoff............................................. 5-3 1-085-186 .................Cover, Internal.................................... 2-5 1-105-216/05 ...........Cover, Top ......................................... 5-5 1-105-216/07 ...........Spring, Return .................................... 5-5 1-105-216/09 ...........Coil and Frame Assembly .................... 5-5 1-105-225/01 ...........Contact Tip, Fixed............................... 5-5 1-105-225/02 ...........Contact Tip, Moving............................ 5-5 1-105-225 .................Contactor, Forward/Reverse ................ 5-3 1-110-920/092 .........Heater ............................................... 3-7 1-120-098 .................Potentiometer...................................... 3-7 1-150-366 .................Switch, Brake/Lift Cutout...................... 5-3 1-150-368 .................Switch, Key ........................................ 5-3 1-150-378 .................Switch, Key ........................................ 5-3 1-150-384 .................Switch, Emergency, Reverse ................. 3-7 1-150-386 .................Seal .................................................. 3-7 1-150-418 .................Switch, Function.................................. 3-7 1-150-418 .................Switch, Function.................................. 3-7 1-150-425 .................Switch, Travel ..................................... 3-7 1-187-082 .................Motor Controller ................................. 5-3 291-011....................Ring, Nilos (Small) .............................. 4-5 291-012....................Ring, Nilos (Large) .............................. 4-5 360-049....................Pad, Bumper ...................................... 3-3 360-062/003............Guard, Cable, 9.5 in. ......................... 5-9 360-065/001............Cover, Front ....................................... 2-9 360-068....................Cover, Brake ...................................... 4-5 370-637/005............Tape, Double Sided............................. 3-7 400-081/01..............Plate, Backing .................................... 4-8 400-081/02..............Cam.................................................. 4-8 400-081/03..............Lever, Brake ....................................... 4-8 400-081/04..............Ring, Safety........................................ 4-8 400-081/05..............Shoe Assembly ................................... 4-8 400-081/06..............Spring, Return .................................... 4-8 400-081....................Brake Assembly .................................. 4-5 400-081....................Brake Assembly .................................. 4-8 411-511/015............Decal, Raymond ................................. 2-9 411-534....................Decal, Emergency Disconnect............... 2-9 411-552....................Decal, Warning .................................. 2-9 411-587/001............Decal, No Riding, Black 9 in................ 2-9 411-633....................Decal, Caution ................................... 2-9 411-637/001............Decal, Emergency Disconnect............... 2-9 411-680....................Decal, Operating................................ 2-9 411-681....................Decal, Replacement Instruction ............. 2-9 411-773....................Decal, No Riding ................................ 2-9 411-789....................Decal, Warning .................................. 2-9 411-790....................Decal, Warning .................................. 2-9 411-848....................Decal, 24 Volt Cable System ................ 5-9 411-849....................Decal, 24 Volt Cable System ................ 5-9 411-850....................Decal, Charging Warning.................... 5-9 411-851....................Decal, Charging Warning.................... 5-9 411-852....................Decal, Battery Swivel Warning ............. 5-9 411-853....................Decal, Battery Swivel Warning ............. 5-9 412-720....................Decal, Fault Code Explanation ............. 2-9 412-748....................Decal, Millennium Series...................... 2-9 441-127....................Bearing, Shield................................... 7-5 442-205....................Bearing, Commutator End .................... 6-5 442-210....................Bearing, Drive End .............................. 6-5 464-034....................Bushing ............................................. 2-5 464-035....................Bushing ............................................. 2-5 464-035....................Bushing ............................................. 7-3 530-449....................O-Ring............................................... 4-5 540-062/400............Cylinder, Hydraulic (Ultra).................... 6-6

PDPM - 0198

Description

Page

560-204/328 ........... Bolt, Through ..................................... 6-5 560-206/123 ........... Valve, Flow Control............................. 6-5 560-206/125 ........... Valve, Relief ....................................... 6-5 560-206/129 ........... Valve Stem......................................... 6-5 560-206/131 ........... Pump Assembly, Lift............................. 6-5 560-206/135 ........... Plug, Vent (With Micron Filter) .............. 6-5 560-207/114 ........... Coil, 24 Volt ...................................... 6-5 560-213/01 ............. Seal Kit ............................................. 6-5 560-213/02 ............. Valve Assembly, Check........................ 6-5 560-213/03 ............. Motor................................................ 6-5 560-213/04 ............. Adapter Kit ........................................ 6-5 560-213/05 ............. Reservoir Kit (With Tubes) .................... 6-5 560-213/06 ............. Switch Start Service Kit........................ 6-5 560-213/07 ............. Brush Set (Holder and Springs)............. 6-5 560-215 ................... Pump and Motor Assembly, Lift ............. 6-5 570-271/515 ........... Brush Lead Assembly Kit .................... 5-21 570-316/511 ........... Seal ................................................ 5-21 570-316/513 ........... Ring, Retaining................................. 5-21 570-316/516 ........... Brush Set (4 per set) .......................... 5-21 570-316/517 ........... Brush Spring Set (2 per set)................ 5-21 570-316/519 ........... Plate Assembly, Cover ....................... 5-21 570-360/516 ........... Head, Drive End............................... 5-21 570-864/500 ........... Drive Motor ..................................... 5-21 570-864/500 ........... Motor Assembly, Drive ........................ 4-6 570-864/512 ........... Armature ......................................... 5-21 570-864/515 ........... Head, Commutator End..................... 5-21 590-514 ................... Fuse, 15 Amp .................................... 5-3 590-638/001 ........... Horn Assembly................................... 5-3 590-701 ................... Battery Connector............................. 5-13 590-701 ................... Battery Connector............................. 5-15 610-307 ................... Shaft, Flexible .................................... 3-9 630-261 ................... Tire, Rubber ....................................... 4-7 632-016/001 ........... Wheel, Load ...................................... 7-5 632-016/002 ........... Wheel, Load ...................................... 7-5 632-016/003 ........... Wheel, Load ...................................... 7-5 632-016/007 ........... Wheel, Load ...................................... 7-5 632-095/001 ........... Tire, Poly ........................................... 4-7 680-806 ................... Link, Offset ........................................ 3-3 792-514 ................... Fitting................................................ 6-3 792-568 .................. Fitting................................................ 6-3 812-404 ................... Dowel ............................................... 4-5 813 570/002 ........... Nail, Grip ......................................... 2-9 828-001-457............. Ring, Cable Holding ........................... 2-5 828-006-843............. Pocket, Manual .................................. 2-9 830-056 ................... Spring, Tension................................... 3-8 830-204 ................... Spring, Compression........................... 3-8 830-347 ................... Spring, Handle Return ......................... 3-9 840-033 ................... Fitting, Grease ................................... 7-5 850-135-712............. Shim, Switch ...................................... 3-7 850-135-946............. Gear, Potentiometer ............................ 3-7 850-135-947/101..... Button, Function, Horn......................... 3-7 850-135-947/102..... Button, Function, Forks, Lowered........... 3-7 850-135-947/103..... Button, Function, Forks, Lift ................... 3-7 850-135-959............. Bearing, Handle ................................. 3-9 850-135-976/001..... Button Assembly, Nose ........................ 3-7 850-136-577............. Harness, Travel .................................. 3-7 850-136-579............. Harness, Travel .................................. 3-7 850-136-707/01....... Ammeter.......................................... 5-15 850-136-707/02....... Strap, Capacitor............................... 5-15 850-136-707/03....... Capacitor (440 VAC) ........................ 5-15 850-136-707/04....... Case, Main Pallet ............................. 5-15 850-136-707/05....... Cord, AC, Set .................................. 5-15 850-136-707/06....... Cord, Wire AC Set ........................... 5-15 850-136-707/07....... Diode, 20A ..................................... 5-15

B-1

7/13/01

Walkie Pallet Truck, Model 101 - Numerical Parts Index

Part No.

Description

Page

Part No.

850-136-707/08 ...... Fuse, DC Assembly............................5-15 850-136-707/09 ...... Fuse, DC Fuselink ..............................5-15 850-136-707/11 ...... Rectifier Assembly .............................5-15 850-136-707/12 ...... Relief, AC Strain ...............................5-15 850-136-707/13 ...... Knob, Timer......................................5-15 850-136-707/14 ...... Timer, 12HR, 60 Hz ..........................5-15 850-136-707/15 ...... Plate, Timer Dial................................5-15 850-136-707/16 ...... TX 24V, 15A, 120VAC, 60Hz ............5-15 850-136-707/17 ...... Varistor ............................................5-15 850-136-707/20 ...... TX 24V, 15A, 120VAC, 50Hz ............5-15 850-136-707 ............ Charger Assembly...............................5-9 850-136-782 ............ Harness, Main ....................................5-3 850-136-783 ............ Harness, Main ....................................5-3 850-136-786 ............ Battery Connector ...............................5-3 850-136-787 ............ Cable Kit, Tractor ................................5-3 850-136-788 ............ Cable Kit, Drive ..................................5-3 850-136-795/080 .... Circuit Breaker, 80 Amp ......................5-3 850-136-845 ............ Bar, Bus (CB to M1-1) ..........................5-3 850-136-863 ............ Fuse Block ..........................................5-3 850-136-896 ............ Harness, Function................................3-7 850-136-897 ............ Harness, Function................................3-7 850-137-023 ............ Bracket, Keys Switch Mounting .............2-5 850-137-040 ........... Pin ....................................................6-3 850-137-041 ............ Pin ....................................................6-3 850-137-147/048 .... Load Backrest, 48 in. High .................2-10 850-137-147/060 .... Load Backrest, 60 in. High .................2-10 850-137-164 ............ Plate, Cylinder Retaining ......................6-3 850-137-166 ............ Sheave, Chain ....................................3-7 850-137-174 ............ Link, Connecting .................................3-7 850-137-201 ............ Hydraulic System ................................6-3 850-137-207 ............ Plate, Switch Backing...........................5-3 850-137-246/001 .... Pin, Link .............................................2-5 850-137-246/001 .... Pin, Link .............................................7-3 850-137-258 ............ Chain, Roller Assembly ........................3-7 850-137-275 ............ Link, Upper.........................................2-5 850-137-862 ............ Guard, Wheel, Rubber ........................4-5 850-137-864 ............ Strip, Reinforcing ................................4-5 850-137-894/005 .... Handle Arm Assembly .......................3-10 850-137-894/005 .... Handle/Arm.......................................3-7 850-137-895 ............ Plate, Tie ..........................................3-10 850-137-903/001 .... Control Assembly ................................3-7 850-137-903/001 .... Control Assembly ................................3-9 850-137-905 ............ Cover, Side ........................................3-7 850-137-915 ............ Cover ................................................3-7 850-137-916 ............ Spacer ...............................................3-9 850-137-917 ............ Bracket, Emergency, Reverse ................3-7 850-137-918 ............ Bracket, Travel ....................................3-7 850-137-919 ............ Plate, Switch .......................................3-7 850-137-920 ............ Shaft, Cam Actuator ............................3-9 850-137-923 ............ Plate, Spring Mount .............................3-7 850-138-076 ............ Actuator, Cam Assembly ......................3-9 850-138-101 ............ Bracket, Potentiometer..........................3-7 850-138-139/01 ...... Tray.................................................5-17 850-138-139/02 ...... Charger ...........................................5-17 850-138-139/02 ...... Charger ...........................................5-19 850-138-139/03 ...... Battery Module, 6 Volt .......................5-17 850-138-139/04 ...... Plug, SB 175, Cables ........................5-17 850-138-139/05 ...... Cable, Inter, Battery...........................5-17 850-138-139/06 ...... Grommet, Rubber..............................5-17 850-138-139/07 ...... Label, Champion...............................5-17 850-138-139/08 ...... Label, Warning .................................5-17 850-138-139/09 ...... Plate, Name .....................................5-17 850-138-139/10 ...... Bolt .................................................5-17 850-138-139/13 ...... Pad, Foam Rubber.............................5-17 850-138-139/14 ...... Case, Back, Large Cell ......................5-19 850-138-139/15 ...... Case, Main, Large Cell ......................5-19 850-138-139/16 ...... Case, Top, Large Cell ........................5-19 850-138-139/17 ...... Circuit Breaker 15A...........................5-19

7/13/01

Description

Page

850-138-139/18 .......Circuit, 2400 24V 25 A 55T ................................(With Cord)...................................... 5-19 850-138-139/19 .......Cord, DC Assembly .......................... 5-19 850-138-139/20 .......Cord, AC Assembly .......................... 5-19 850-138-139/21 .......Plug, Mounting Bracket ...................... 5-19 850-138-139/22 .......Plug, SB175 Black ............................ 5-19 850-138-139/23 .......Rectifier Assembly ............................. 5-19 850-138-139/24 .......Rectifier, SCR Assembly ..................... 5-19 850-138-139/25 .......Shunt Assembly ................................ 5-19 850-138-139/26 .......Strain Relief...................................... 5-19 850-138-139/27 .......Switch, Red Push Button ..................... 5-19 850-138-139/28 .......Transformer ...................................... 5-19 850-138-139/29 .......Varistor Assembly.............................. 5-19 850-138-139/30 .......Varistor............................................ 5-19 850-138-139 .............Battery Pack, GNB Maintenance Free, ................................24 Volt ............................................ 5-17 850-138-372 .............Shaft, Handle Pivot Weldment .............. 3-3 850-138-373 .............Arm Machine ................................... 3-10 850-138-383/101 .....Handle and Controller Assembly........... 3-3 850-138-383/102 .....Handle and Controller Assembly........... 3-3 850-138-384/ ...........Handle Mounting and Installation ......... 3-3 850-138-386/001 .....Handle Machining ............................ 3-10 850-138-390/001 .....Handle Bottom.................................... 3-7 850-138-391/001 .....Cap, Journal Machine, Left Hand.......... 3-7 850-138-392/001 .....Cap, Journal Machine, Right Hand ....... 3-7 850-138-728 .............Bumper, Pump .................................... 6-3 850-138-766 .............Pin, Chain Sheave .............................. 3-7 850-138-862/001 .....Grip, Handle Assembly ....................... 3-9 860-626/001............Coupling ........................................... 6-5 870-248....................Meter, Hour/Discharge........................ 5-7 870-251....................Meter, Hour........................................ 5-7 870-863....................Wrap, Spiral ...................................... 5-3 939-005....................Bearing, Cup/Cone, Pivot (Small) ......... 4-6 939-006....................Bearing, Cup/Cone, Pivot (Large) ......... 4-6 939-023....................Spring ............................................... 4-5 939-042....................Bar, Skid............................................ 2-5 939-146....................Cable Assembly................................ 5-13 939-149....................Cable Assembly................................ 5-13 939-154....................Bearing, Oilite Super........................... 7-5 939-311....................Ring .................................................. 4-5 939-321....................Drum, Brake ....................................... 4-5 939-330....................Gear, Pinion....................................... 4-5 939-333....................Gear, Drive ........................................ 4-5 939-352/002............Bearing, Ball ...................................... 4-5 939-352/003............Seal .................................................. 4-5 939-352/004............Fitting, Grease.................................... 4-5 939-352/005............Bearing, Cup/Cone ............................ 4-5 939-352/006............Grommet ......................................... 5-13 939-352/008............Key ................................................... 4-5 939-352/010............Washer, Sealing ................................. 4-5 939-352/013............Clamp ............................................... 4-5 939-352/034............Battery Pack and Cable Assembly......... 5-9 939-352/042............Tie, Cable ........................................ 5-13 939-352/044............Battery, 6 Volt................................... 5-13 939-352/045............Door Weldment, Battery Box .............. 5-11 939-352/046............Boot, Terminal .................................. 5-13 939-352/048............Plug, Drain/Fill ................................... 4-5 939-352/052............Gear, Idle .......................................... 4-5 939-352/053............Arm, Brake ........................................ 4-5 939-352/055............Rod, Push........................................... 4-5 939-352/058............Bolt, Special....................................... 4-5 939-352/060............Fork, Trail Machining .......................... 7-5 939-352/061............Pin, Bellcrank Pivot.............................. 7-3 939-352/063............Fork, Joint Combination ....................... 4-5 939-352/064............Retainer ............................................. 4-5 939-352/065............Bearing, Handle ................................. 4-5 939-352/079............Bracket, Brake Switch .......................... 4-5 939-352/079............Bracket, Brake Switch .......................... 5-3

B-2

PDPM - 0198

Walkie Pallet Truck, Model 101 - Numerical Parts Index

Part No.

Description

Page

Part No.

939-352/081............Bolt, Anchor, Chain (Metric) ................. 3-3 939-352/081............Bolt, Chain Anchor.............................. 3-8 939-352/082............Case Assembly, Gear .......................... 4-5 939-352/083............Hub Machining, Wheel ....................... 4-7 939-352/083............Wheel Assembly................................. 4-6 939-352/100............Bearing, Drive and Commutator End ... 5-21 939-352/101............Field Coil Kit .................................... 5-21 939-352/103............Battery Pack, 24 Volt (Wet Battery)........ 5-9 939-352/104............Battery Pack, 24 Volt (Wet Battery)........ 5-9 939-352/106............Plate, Lowlift Specification (U.S.) ........... 2-9 939-352/107............Plate, Lowlift Specification (U.S.) ........... 2-9 939-352/108............Plate, Lowlift Specification (Canadian) ... 2-9 939-352/112............Spacer .............................................. 3-3 939-352/113............Guard, Wheel .................................... 4-5 939-352/114............Drive Unit .......................................... 4-5 939-352/115............Anchor, Brake Spring .......................... 4-5 939-352/116............Wheel, Load Assembly ........................ 7-5 939-352/117............Shaft, Wheel ...................................... 7-5 939-352/141............Rod, Pull, 32 in. Fork Length................. 7-3 939-352/142............Rod, Pull, 36 in. Fork Length................. 7-3 939-352/143............Rod, Pull, 42 in. Fork Length................. 7-3 939-352/144............Rod, Pull, 46 in. Fork Length................. 7-3 939-352/145............Rod, Pull, 48 in. Fork Length................. 7-3 939-352/146............Rod, Pull, 54 in. Fork Length................. 7-3 939-352/147............Rod, Pull, 60 in. Fork Length................. 7-3 939-352/148............Rod, Pull, 32 in. Fork Length................. 7-3 939-352/149............Rod, Pull, 36 in. Fork Length................. 7-3 939-352/150............Rod, Pull, 42 in. Fork Length................. 7-3 939-352/151............Rod, Pull, 46 in. Fork Length................. 7-3

PDPM - 0198

Description

Page

939-352/152 ........... Rod, Pull, 48 in. Fork Length ................ 7-3 939-352/153 ........... Rod, Pull, 54 in. Fork Length ................ 7-3 939-352/154 ........... Rod, Pull, 60 in. Fork Length ................ 7-3 939-352/168 ........... Link, Lower ........................................ 7-3 939-352/169 ........... Frame, Lift Machining.......................... 2-5 939-352/170 ........... Frame, Lift Machining.......................... 2-5 939-352/176 ........... Cable Assembly ............................... 5-13 939-352/178 ........... Cable Assembly ............................... 5-13 939-352/179 ........... Cable Assembly ............................... 5-13 939-352/191 ........... Cover, Gear....................................... 4-5 939-352/192 ........... Pin, Link............................................. 7-3 939-352/193 ........... Pin, Link............................................. 7-3 939-352/214 ........... Bushing, Iron...................................... 7-3 939-352/215 ........... Bushing, Flanged................................ 3-3 939-352/215 ........... Fitting, Grease ................................... 7-3 939-352/224 ........... Wrapper ......................................... 5-11 939-352/228 ........... Tray Weldment ................................. 5-11 939-352/229 ........... Tray Weldment ................................. 5-11 939-352/230 ........... Edging ............................................ 5-11 950-180 ................... Programmable Maintenance Tool........ 5-22 950-181 ................... Cable for 4000 lb. Walkie ................ 5-22 B24-020-110/260 ..... Cable Assembly (B- to B-) ..................... 5-3 B24-020-170/301 ..... Cable Assembly (CB to P1) .................. 5-3 B24-022-220/272 ..... Cable Assembly (B- to MP2)................. 5-3 B24-023-380/297 ..... Cable Assembly (B+ to MDA2)............. 5-3 B24-023-380/298 ..... Cable Assembly (M- to MDA1)............. 5-3 B24-196-075/304 ..... Cable Assembly (B+ to M1-2) .............. 5-3

B-3

7/13/01

Walkie Pallet Truck, Model 101 - Numerical Parts Index

7/13/01

B-4

PDPM - 0198