Toyota Forklift 6HBW20 Parts Catalog Manual SN 17001 - PDF DOWNLOAD

PARTS CATALOG FOR MODEL 6HBW20 Starting With Serial Number 17001

M/N 00715-00015-08

Final Issue 6/17/2008

Copyright ® 2008 by Toyota Industrial Equipment

All rights reserved. No portion of this manual may be reproduced mechanically, electronically or by any other means, including photocopying, electronic retrieval or transfer, or recording without the written permission of the publisher.

Toyota Industrial Equipment believes the information in this manual is accurate and current as of the publication date; such information is subject to change without notice. Toyota Industrial Equipment is not responsible for any errors that may appear in the manual.

1058725B

Model 6HBW20 - Table of Contents

Table of Contents SECTION 1 General Information To Our Customer ................................................................................................................................ 1-2 How To Use Catalog If Part Number Is Not Known ................................................................................. 1-3 How To Use Catalog If Part Number Is Known ....................................................................................... 1-4 Major Sections ................................................................................................................................... 1-5 Recommended Spare Parts List ............................................................................................................. 1-6 Hardware Parts List ............................................................................................................................. 1-7

SECTION 2 Finish and Accessories Major Assemblies ............................................................................................................................... 2-2 Truck Final Assembly........................................................................................................................... 2-4 Finish Instructions ................................................................................................................................ 2-6 Load Backrest................................................................................................................................... 2-10

SECTION 3 Steering and Controls Handle Mounting and Installation ......................................................................................................... 3-2 Handle Assembly................................................................................................................................ 3-4 Controller Assembly With Knuckle Guard .............................................................................................. 3-6 Controller Assembly ............................................................................................................................ 3-8

SECTION 4 Drive and Brake Drive Unit Installation .......................................................................................................................... 4-3 Drive Wheel Assembly ........................................................................................................................ 4-8 Brake Assembly ................................................................................................................................ 4-10

SECTION 5 Electrical Components and Systems Electrical System ................................................................................................................................. 5-3 Contactor Assembly ............................................................................................................................ 5-6 Meter Installation ................................................................................................................................ 5-8 Battery Pack, 24 Volt (Wet Battery) ..................................................................................................... 5-10 Battery Tree and Cover Assembly ....................................................................................................... 5-12 Battery Pack and Cable Assembly (Wet Battery) ................................................................................... 5-14 Charger Assembly ............................................................................................................................ 5-16 GNB Maintenance Free 24 Volt Battery............................................................................................... 5-18 GNB Charger Assembly .................................................................................................................... 5-20 Battery Pack, Optima ........................................................................................................................ 5-22 Drive Motor Assembly ....................................................................................................................... 5-24 Maintenance Tool, Programmable ...................................................................................................... 5-26

SECTION 6 Hydraulic Components Hydraulic System ................................................................................................................................ 6-2 Lift Pump and Motor Assembly.............................................................................................................. 6-5 Hydraulic Cylinder.............................................................................................................................. 6-8

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

00715-00015-08, Final Issue 6/17/2008

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i

Model 6HBW20 - Table of Contents

APPENDIX A Alphabetical Parts Index APPENDIX A Numerical Parts Index

ii

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00715-00015-08, Final Issue 6/17/2008

SECTION 1 General Information To Our Customer ................................................................................................................................................. 1-2 How To Use Catalog If Part Number Is Not Known .................................................................................................. 1-3 How To Use Catalog If Part Number Is Known......................................................................................................... 1-4 Major Sections .................................................................................................................................................... 1-5 Recommended Spare Parts List............................................................................................................................... 1-6 Hardware Parts List .............................................................................................................................................. 1-7

00715-00015-08, Final Issue 6/17/2008

1-1

Model 6HBW20 - 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 database.

• 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.

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00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - General Information How To Use Catalog If Part Number Is Not Known

How To Use Catalog If Part Number Is Not Known Major Assemblies

1

IF THE PART NUMBER IS NOT KNOWN

SECTION 7 MAST SECTION 6 HYDRAULIC COMPONENTS

DO THIS

SECTION 3 STEERING AND CONTROLS

1.

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

SECTION 5 SECTION 4 ELECTRICAL COMPONENTS AND

SECTION 2 FINISH AND ACCESSORIES

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

4-1

2

9 8

40

3.

37

36

39

3 38

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

1

FIGURE 2-2 ITEM NO. 1

Figure 2-2: Frame Assembly - DS/DT

2-1

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

4.

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

28 29 30 31

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

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 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 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) 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

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

2-7

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Model 6HBW20 - General Information How To Use Catalog If Part Number Is Known

How To Use Catalog If Part Number Is Known

1

IF THE PART NUMBER IS KNOWN APPENDIX B

DO THIS

Part No.

Description

Numerical Parts List Page

Part No.

Description

Page

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 Roller Assembly A ....................................... 3-3 360-049.................... Pad, Bumper 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

1-4

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00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - General Information Major Sections

Major Sections

1

Figure 1-1: Major Sections

SECTION 3: Steering and Controls

SECTION 5: Electrical Components and Systems

SECTION 4: Drive and Brake

SECTION 2: Finish and Accessories

SECTION 7: Mast

SECTION 6: Hydraulic Components

4100_004

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1-5

Model 6HBW20 - General Information Recommended Spare Parts List

Recommended Spare Parts List Description

Part No.

Qty.

Fig.

Bar, Skid, Adjustable .....................00590-40761-71 ...2 .......2-2 Bearing, Ball ................................00590-40384-71 ...2 .......4-1 Bearing, Commutator End ..............00590-40636-71 ...1 .......1-2 Bearing, Cup/Cone ......................00590-40382-71 ...2 .......4-1 Bearing, Cup/Cone, Pivot, Large ....00590-40391-71 ...1 .......4-1 Bearing, Cup/Cone, Pivot, Small ....00590-40392-71 ...1 .......4-1 Bearing, Double Sealed .................00590-41592-71 ...2 .......2-2 Bearing, Drive End and Commutator End ........................ ........... ...................................................00590-40709-71 ...2 .....5-11 Bearing, Drive End ........................00590-04736-71 ...1 .......1-2 Bearing, Handle ...........................00590-40383-71 ...1 .......4-1 Bearing, Shield .............................00590-40817-71 ...2 .......2-2 Bearing, Super, Oil-Impregnated .....00590-05133-71 ...2 .......2-2 Block, Fuse ...................................00590-01962-71 ...1 .......5-1 Breaker, Circuit, 80 Amp ...............00590-40295-71 ...1 .......5-1 Bushing .......................................00590-43550-71 ...4 .......2-2 Bushing, Iron ...............................00590-05134-71 ...4 .......2-2 Bushing, Iron ................................00590-05134-71 .12 .......2-1 Bushing, Poly................................00590-43276-71 .12 .......2-1 Cam ...........................................00590-39571-71 ...1 .......4-3 Connector, Battery ........................00590-00581-71 ...1 .......5-7 Connector, Battery ........................00590-00581-71 ...1 .......5-6 Connector, Battery ........................00590-45248-71 ...1 .......5-1 Controller, Motor...........................00590-02365-71 ...1 .......5-1 Decal, Cable System, 24 Volt .........00590-01573-71 ...1 .......5-4 Decal, Cable System, 24 Volt .........00590-40797-71 ...1 .......5-4 Decal, Warning, Battery Swivel ....00590-01575-71 ...1 .......5-4 Decal, Warning, Battery Swivel ....00590-40799-71 ...1 .......5-4 Decal, Warning, Charging.............00590-01574-71 ...1 .......5-4 Decal, Warning, Charging.............00590-40798-71 ...1 .......5-4 Fuse Assembly, DC .......................00590-04633-71 ...1 .......5-7 Fuse, 15 Amp...............................00590-00552-71 ...1 .......5-1 Fuse, Fuselink, DC ........................00590-04634-71 ...2 .......5-7 Gear, Potentiometer.......................00590-00122-71 ...1 .......3-4 Heater .........................................00590-00202-71 ...1 .......3-4 Horn Assembly .............................00590-40670-71 ...1 .......5-1 Key, Set of 2.................................00590-04577-71 ...1 .......5-1 Kit, Adapter..................................00590-00956-71 ...1 .......3-4 Kit, Adapter..................................00590-05342-71 ...1 .......1-2 Kit, Brush Lead Assembly ..............00590-40712-71 ...1 .....5-11 Kit, Cable ....................................00590-46747-71 ...1 .....5-10 Kit, Field Coil................................00590-04747-71 ...1 .....5-11 Kit, Hardware...............................00590-04980-71 ...1 .......5-2 Kit, Reservoir, with Tubes (Plastic) ....00590-40301-71 ...1 .......1-2 Kit, Reservoir, with Tubes (Steel) ......00590-05343-71 ...1 .......1-2 Kit, Seal .......................................00590-05345-71 ...1 .......1-2 Kit, Seal .......................................00590-40809-71 ...1 .......1-3 Kit, Service, Start Switch ................00590-05340-71 ...1 .......1-2

1-6

Description

1

Part No.

Qty.

Fig.

Link Assembly, Upper .................... 00590-04656-71... 2 ....... 2-2 Link, Lower................................... 00590-40815-71... 1 ....... 2-1 Link, Lower................................... 00590-40816-71... 1 ....... 2-1 Link, Lower................................... 00590-46761-71... 1 ....... 2-1 Link, Lower................................... 00590-46762-71... 1 ....... 2-1 Meter, Hour ................................. 00590-01785-71... 1 ....... 5-3 Meter, Hour/Discharge ................ 00590-00610-71... 1 ....... 5-3 O-Ring......................................... 00590-00943-71... 1 ....... 4-1 Pin, Link ...................................... 00590-40716-71... 2 ....... 2-1 Pin, Link ...................................... 00590-40717-71... 2 ....... 2-1 Pin, Link ...................................... 00590-40765-71... 2 ....... 2-2 Pin, Link ...................................... 00590-40765-71... 2 ....... 2-1 Pin, Link ...................................... 00590-46755-71... 2 ....... 2-2 Pin, Link ...................................... 00590-46755-71... 2 ....... 2-1 Potentiometer ............................... 00590-01684-71... 1 ....... 3-4 Seal ............................................ 00590-04742-71... 1 ..... 5-11 Seal ............................................ 00590-40378-71... 1 ....... 4-1 Set, Brush (4 per set) ..................... 00590-04748-71... 1 ..... 5-11 Set, Brush Holder and Springs ........ 00590-05339-71... 1 ....... 1-2 Shaft, Wheel................................ 00590-40735-71... 1 ....... 2-2 Shaft, Wheel................................ 00590-46383-71... 1 ....... 2-2 Shaft, Wheel................................ 00590-46767-71... 1 ....... 2-2 Shoe Assembly ............................ 00590-39575-71... 2 ....... 4-3 Spring ......................................... 00590-00829-71... 1 ....... 3-2 Spring ......................................... 00590-40406-71... 1 ....... 4-1 Spring, Compression..................... 00590-00138-71... 6 ....... 3-4 Spring, Return .............................. 00590-39570-71... 2 ....... 4-3 Strainer ....................................... 00590-46914-71... 1 ....... 1-2 Switch, Cutout, Brake/Lift ............. 00590-03798-71... 2 ....... 5-1 Switch, Cutout, Brake/Lift ............. 00590-40669-71... 2 ....... 5-1 Switch, Emergency Reverse ............ 00590-00952-71... 1 ....... 3-4 Switch, Key.................................. 00590-00538-71... 1 ....... 5-1 Switch, Key.................................. 00590-01843-71... 1 ....... 5-1 Switch, Main, On/Off................... 00590-40983-71... 1 ....... 5-1 Switch, Push Button, Red ................ 00590-40704-71... 1 ....... 5-9 Switch, Travel............................... 00590-00953-71... 2 ....... 3-4 Tire, Poly .................................... 00590-04583-71... 1 ....... 4-2 Tire, Rubber, Lugged, Black............ 00590-41210-71... 1 ....... 4-2 Tire, Rubber, Smooth, Black ........... 00590-41212-71... 1 ....... 4-2 Valve Assembly, Check .................. 00590-05341-71... 1 ....... 1-2 Valve, Flow Control....................... 00590-04695-71... 1 ....... 1-2 Valve, Relief ................................. 00590-04893-71... 1 ....... 1-2 Valve, Stem .................................. 00590-04554-71... 1 ....... 1-2 Wheel, Load ............................... 00590-00773-71... 1 ....... 2-2 Wheel, Load ............................... 00590-00777-71... 1 ....... 2-2 Wheel, Load ............................... 00590-00779-71... 1 ....... 2-2 Wheel, Load ............................... 00590-46766-71... 1 ....... 2-2

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - General Information Hardware Parts List

Hardware Parts List Description

Part No.

Qty.

Bolt ................................................... 00590-03917-71 ........1 Bolt ................................................... 00590-40679-71 ........4 Bolt, Pivot ........................................... 00590-40759-71 ........8 Grommet ........................................... 00590-40421-71 ........2 Nut ................................................... 00590-43542-71 ........2 Nut .................................................... 00590-00131-71 ......10 Nut .................................................... 00590-00180-71 ........2 Nut .................................................... 00590-03924-71 ........2 Nut .................................................... 00590-39580-71 ........1 Nut .................................................... 00590-40377-71 ........6 Nut .................................................... 00590-40394-71 ........3 Nut .................................................... 00590-40396-71 ........2 Nut .................................................... 00590-40420-71 ........8 Nut .................................................... 00590-40760-71 ........2 Nut, Clip ............................................ 00590-40771-71 ........2 Nut, Clip ............................................ 00590-43542-71 ........1 Nut, Flanged....................................... 00590-40678-71 ........4 Pin, Cotter .......................................... 00590-03671-71 ........2 Screw ................................................ 00590-03911-71 ........4 Screw ................................................ 00590-46740-71 ........1 Screw................................................. 00590-00106-71 ........2 Screw................................................. 00590-00129-71 ........8 Screw................................................. 00590-00179-71 ........2 Screw................................................. 00590-00954-71 ........2 Screw................................................. 00590-00955-71 ........2 Screw................................................. 00590-03911-71 ........4 Screw................................................. 00590-03915-71 ......17 Screw................................................. 00590-03920-71 ........1 Screw................................................. 00590-40371-71 ........5

00715-00015-08, Final Issue 6/17/2008

Description

1

Part No.

Qty.

Screw .................................................00590-40373-71 ...... 22 Screw .................................................00590-40386-71 ........ 2 Screw .................................................00590-40395-71 ........ 4 Screw .................................................00590-40401-71 ........ 5 Screw .................................................00590-40651-71 ........ 4 Screw .................................................00590-40652-71 ........ 4 Screw .................................................00590-40872-71 ........ 1 Screw .................................................00590-42657-71 ........ 2 Screw .................................................00590-46725-71 ........ 1 Screw .................................................00590-46753-71 ........ 2 Screw, Fast Thread ...............................00590-40769-71 ........ 2 Screw, Set ...........................................00590-00130-71 ........ 3 Screw, Set ...........................................00590-03913-71 ...... 11 Screw, Set ...........................................00590-40649-71 ........ 1 Screw, Top Cover .................................00590-04856-71 ........ 3 Washer ...............................................00590-00143-71 ........ 1 Washer ...............................................00590-40690-71 ........ 1 Washer ...............................................00590-46707-71 ........ 6 Washer, Flat ........................................00590-05149-71 ........ 6 Washer, Flat ........................................00590-40147-71 ........ 9 Washer, Flat ........................................00590-40388-71 ........ 2 Washer, Lock ......................................00590-00005-71 ........ 1 Washer, Lock ......................................00590-40135-71 ........ 1 Washer, Lock .......................................00590-00133-71 ...... 16 Washer, Lock .......................................00590-00134-71 ........ 4 Washer, Lock .......................................00590-04689-71 ........ 1 Washer, Sealing...................................00590-40387-71 ........ 1 Washer, Shake Proof ............................00590-01679-71 ........ 1 Washer, Spring ....................................00590-04752-71 ........ 1

Top of Section

1-7

Model 6HBW20 - General Information Hardware Parts List

1-8

Top of Section

00715-00015-08, Final Issue 6/17/2008

SECTION 2 Finish and Accessories Major Assemblies ................................................................................................................................................ 2-2 Truck Final Assembly ............................................................................................................................................ 2-4 Finish Instructions ................................................................................................................................................. 2-6 Load Backrest .................................................................................................................................................... 2-10

00715-00015-08, Final Issue 6/17/2008

2-1

Model 6HBW20 - Finish and Accessories Major Assemblies

Major Assemblies

2

Figure 2-1: Major Assemblies

1

3

4

5

6

2

4100_004

2-2

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Finish and Accessories Major Assemblies List 2-1: Major Assemblies FIGURE 2-1 ITEM NO. 1 2 3 4 5 6

QTY Ref. Ref. Ref. Ref. Ref. Ref.

PART NUMBER Ref. Ref. Ref. Ref. Ref. Ref.

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION

USED ON

Handle Assembly (See Figure 3-2.)

Drive Unit Installation (See Figure 4-1a.)

Electrical System (See Figure 5-1a.)

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

Fork Final Assembly (See Figure 7-1.)

Wheel Assembly, Load (See Figure 7-2.)

Top of Section

2-3

Model 6HBW20 - Finish and Accessories Truck Final Assembly

Truck Final Assembly

2

Figure 2-2: Truck Final Assembly

14

13 SEE DETAIL A DETAIL A

1

10

18

3

17

15 8 18

5 9 6

4

2

18

16

11

311085_F1, W313073

2-4

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Finish and Accessories Truck Final Assembly List 2-2: Truck Final Assembly FIGURE 2-2 ITEM NO. 1 2 3 4 5 6 8 9 10 11 13 14 15 16

QTY

PART NUMBER

1 4 2 4 2 4 4 2 1 1 2 2 2 2 2 4 AR

00590-40758-71 00590-40759-71 00590-40760-71 00590-43550-71 00590-04656-71 00590-40759-71 00590-40377-71 00590-40761-71 Ref. 00590-42656-71 00590-42657-71 00590-03924-71 00590-03913-71 00590-40765-71 00590-46755-71 00590-05134-71 00590-03673-71

17 18 A= Standard B= Cold Storage C= Contact Technical Support R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION Ring, Holding, Cable, Metric Bolt, Pivot Nut Bushing Link Assembly, Upper Bolt, Pivot Nut Bar, Skid, Adjustable Frame, Lift Bracket, Retainer Screw Nut Screw, Set Pin, Link Pin, Link Bushing, Iron Fitting, Grease

Top of Section

USED ON

R R

R C

A, R B, R R

2-5

Model 6HBW20 - Finish and Accessories Finish Instructions

Finish Instructions

2

Figure 2-3a: Finish Instructions

3

16

4

B

Emergency Disconnect

B

TOP VIEW 6

15

A 1 A

7

VIEW A-A

SIDE VIEW W411-534-BW, 311096_E6, 411-928, 311096_E1, _E7 SHT 1 OF 3

2-6

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Finish and Accessories Finish Instructions

Finish Instructions

2

Figure 2-3b: Finish Instructions

2

8

5

7

SHOWN WITHOUT COVERS W412-423-A, W411-552, 311096_E2, _E4, _E5 SHT 2 OF 3

00715-00015-08, Final Issue 6/17/2008

Top of Section

2-7

Model 6HBW20 - Finish and Accessories Finish Instructions

Finish Instructions

2

Figure 2-3c: Finish Instructions

SECTION B-B

9

12

13

14

19 15 18

17

16

19

11 10 W850_137_613_M_D, 311096_E7, 0341-001 SHT 3 OF 3

2-8

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Finish and Accessories Finish Instructions List 2-3: Finish Instructions FIGURE 2-3 QTY PART NUMBER ITEM NO. 1 2 00590-04497-71 2 1 00590-01443-71 3 1 00590-40842-71 4 1 00590-01258-71 5 1 00590-01942-71 6 1 00590-40767-71 7 1 Ref. 8 1 00590-43331-71 9 2 00590-03911-71 10 2 00590-40768-71 11 4 00590-03915-71 12 2 00590-05149-71 13 2 00590-40769-71 14 2 00590-40770-71 15 1 00590-40772-71 16 1 00590-40773-71 17 2 00590-40771-71 18 1 00590-40766-71 19 2 00590-03915-71 A= Contact Technical Support

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION Decal, TOYOTA Decal, Operating Manual Decal, Warning, TOYOTA Decal, Emergency Disconnect Decal, Warning Decal, No Riding Decal, Specification Plate Decal, Steam Clean Screw Bracket, Mounting, Cover Screw Washer, Flat Screw, Fast Thread Retainer Cover, Front, Orange Cover, Internal Nut, Clip Bracket, Mounting, Key Switch Screw

Top of Section

USED ON

A

2-9

Model 6HBW20 - Finish and Accessories Load Backrest

Load Backrest

2

Figure 2-4: Load Backrest

1

BACKREST

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

2-10

QTY

PART NUMBER

DESCRIPTION

1 1

00590-40774-71 00590-40775-71

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

Top of Section

USED ON

00715-00015-08, Final Issue 6/17/2008

SECTION 3 Steering and Controls Handle Mounting and Installation........................................................................................................................... 3-2 Handle Assembly ................................................................................................................................................. 3-4 Controller Assembly With Knuckle Guard................................................................................................................ 3-6 Controller Assembly ............................................................................................................................................. 3-8

00715-00015-08, Final Issue 6/17/2008

3-1

Model 6HBW20 - Steering and Controls Handle Mounting and Installation

Handle Mounting and Installation

3

Figure 3-1: Handle Mounting and Installation

13 3

4

12

8 5 7

6

1

14

W850_138_384_4

3-2

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Steering and Controls Handle Mounting and Installation List 3-1: Handle Mounting and Installation FIGURE 3-1 ITEM NO. 1 3 4 5 6 7 8 12 13 14

QTY

PART NUMBER

1 1 1 1 1 1 1 1 1 2

00590-40648-71 Ref. 00590-00825-71 00590-00215-71 00590-40367-71 00590-40649-71 00590-40396-71 00590-40650-71 00590-40395-71 00590-40370-71

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION

USED ON

Shaft, Handle Pivot Weldment Drive Unit Installation (See Figure 4-1a.)

Handle Assembly (See Figure 3-2.)

Pad, Bumper Bolt, Chain Anchor Screw, Set Nut Spacer Screw Bushing, Flanged

Top of Section

3-3

Model 6HBW20 - Steering and Controls Handle Assembly

Handle Assembly

3

Figure 3-2: Handle Assembly

8

1

13

3

5

2

7

6

11

12

9

4

10

850-137-281

3-4

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Steering and Controls Handle Assembly List 3-2: Handle Assembly FIGURE 3-2 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13

QTY

PART NUMBER

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

00590-00825-71 00590-01416-71 00590-00829-71 00590-41771-71 00590-40654-71 00590-00205-71 00590-00833-71 00590-00835-71 00590-40554-71 00590-00830-71 00590-00827-71 00590-40403-71 00590-40872-71 00590-43542-71 00590-01435-71 00590-01437-71

DESCRIPTION Handle Assembly Handle Spring Tube Link, Connecting Pin, Roll Chain Assembly, Roller (includes:) Link, Connecting (Not Shown) Sheave, Chain Pin, Sheave, Chain Ring, Retaining Clamp, Cable Screw Nut, Clip Controller Assembly with Knuckle Guard (See Figure 3-3.)

Controller Assembly with Knuckle Guard (See Figure 3-3.)

USED ON

R

A B

A= Standard B= Cold Storage R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

Top of Section

3-5

Model 6HBW20 - Steering and Controls Controller Assembly With Knuckle Guard

Controller Assembly With Knuckle Guard

3

Figure 3-3: Controller Assembly With Knuckle Guard

1

4

7

5

8

2

3

9

6

W850_137_268_C

3-6

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Steering and Controls Controller Assembly With Knuckle Guard List 3-3: Controller Assembly With Knuckle Guard FIGURE 3-3 ITEM NO.

QTY

PART NUMBER

2 1 1 2 4 2 2 1 4 2

00590-01435-71 00590-01437-71 00590-00106-71 00590-01436-71 00590-01438-71 00590-00100-71 00590-40651-71 00590-00114-71 00590-00170-71 00590-00949-71 00590-40652-71 00590-01421-71

1 2 3 4 5 6 7 8 9 A= Standard B= Cold Storage

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION Controller Assembly with Knuckle Guard Controller Assembly with Knuckle Guard Screw Controller Assembly (See Figure 3-4.)

Controller Assembly (See Figure 3-4.)

Grip, Hand Screw Pin, Spring Plug Guard, Knuckle Screw Knob, Butterfly

Top of Section

USED ON A B A B

3-7

Model 6HBW20 - Steering and Controls Controller Assembly

Controller Assembly

3

Figure 3-4: Controller Assembly 21

3

42

17

40

1

20

8

26

28

41

23 6

31

39

29

12

30

4

5 11

9

12

19

24

2 30

10 13

33

32 36 37

22 36 18

38 34 25

27 15 7

14

16

35

W850_137_269_KB

3-8

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Steering and Controls Controller Assembly List 3-4: Controller Assembly (Sheet 1 of 2) FIGURE 3-4 ITEM NO.

1 2 3 4 5 6 7

QTY

PART NUMBER

1 1 2 1 1 1 1 1 1 1 2 1 6 1 10 2 1 2 2 6 1 1 1 1 1 1 1 2 1 1 2 2 8 16 4 1 1 2 3 1 1 4

00590-01436-71 00590-01438-71 00590-01770-71 00590-00122-71 00590-01411-71 00590-01412-71 00590-01413-71 00590-01422-71 00590-01929-71 00590-01684-71 00590-00953-71 00590-46706-71 00590-46707-71 00590-00952-71 00590-00131-71 00590-00136-71 00590-00202-71 00590-00179-71 00590-00180-71 00590-00121-71 00590-00951-71 00590-01778-71 00590-00196-71 00590-00141-71 00590-00143-71 00590-00956-71 00590-00148-71 00590-00149-71 00590-40653-71 00590-01780-71 00590-00954-71 00590-00955-71 00590-00129-71 00590-00133-71 00590-00134-71 00590-01679-71 00590-01779-71 00590-00135-71 00590-00130-71 00590-00140-71 00590-00137-71 00590-00139-71

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 A= Standard B= Cold Storage R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION Controller Assembly Controller Assembly Spacer Gear, Potentiometer Button, Function, Horn Button, Function, Forks Lowered Button, Function, Forks Lift Button, Nose Assembly Harness, Control (includes:) Potentiometer Switch, Travel Bracket Washer Switch, Emergency Reverse Nut Pin, Spring Heater Screw Nut Spacer, Threaded Cam, Controller Lever, Return Shim Cover, Switch Washer Kit, Adapter Cover, Steering Bushing Bracket Shaft, Actuator Screw Screw Screw Washer, Lock Washer, Lock Washer, Shake Proof Pin, Roll Pin, Spring Screw, Set Spring, Torsion Pin, Spring Spring, Compression

Top of Section

USED ON A B R

R R

R

B, R B B

R

3-9

Model 6HBW20 - Steering and Controls Controller Assembly List 3-4: Controller Assembly (Sheet 2 of 2) FIGURE 3-4 QTY PART NUMBER ITEM NO. 40 1 00590-00962-71 41 3 00590-00150-71 42 6 00590-00138-71 A= Standard B= Cold Storage R= Recommended Spare

3-10

DESCRIPTION Bracket Bracket, Switch Assembly, Function Spring, Compression

Top of Section

USED ON

R

00715-00015-08, Final Issue 6/17/2008

SECTION 4 Drive and Brake Drive Unit Installation............................................................................................................................................ 4-3 Drive Wheel Assembly.......................................................................................................................................... 4-8 Brake Assembly ................................................................................................................................................. 4-10

00715-00015-08, Final Issue 6/17/2008

4-1

Model 6HBW20 - Drive and Brake

This Page Intentionally Blank

4-2

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Drive and Brake Drive Unit Installation

Drive Unit Installation

4

Figure 4-1a: Drive Unit Installation

31

30

23

21

31

26

22

11

10

14

12

13

15

52

51

47

6

28 9

16

53

16

37

29

20

18

27

24

45

55

5

4

3

39

38

36

W310614_1A SHT 1 OF 2

00715-00015-08, Final Issue 6/17/2008

Top of Section

4-3

Model 6HBW20 - Drive and Brake Drive Unit Installation

Drive Unit Installation

4

Figure 4-1b: Drive Unit Installation

42 40

43 49

50 1

33

10

8

11

7

46

32

15

44 15

25 19

35

15

34

3

2

W310614_1B SHT 2 OF 2

4-4

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Drive and Brake Drive Unit Installation List 4-1: Drive Unit Installation (Sheet 1 of 2) FIGURE 4-1 ITEM NO.

QTY

PART NUMBER

DESCRIPTION

00590-40405-71 1 1 00590-40369-71 2 1 00590-40375-71 3 2 00590-40382-71 4 1 00590-40385-71 5 1 00590-40378-71 6 1 00590-40394-71 7 2 00590-40384-71 8 1 00590-40376-71 9 1 00590-43049-71 10 2 00590-40379-71 11 2 00590-40377-71 12 2 00590-40386-71 13 1 00590-03834-71 14 1 00590-40374-71 15 22 00590-40373-71 16 5 00590-40371-71 18 1 00590-40368-71 19 1 00590-40367-71 20 1 00590-40381-71 21 1 00590-40398-71 22 1 00590-40407-71 23 1 00590-40406-71 24 1 00590-03920-71 25 1 00590-40396-71 26 1 00590-43608-71 27 1 00590-40383-71 28 1 00590-40403-71 29 1 00590-40402-71 30 1 00590-39877-71 31 5 00590-40401-71 32 1 00590-40400-71 33 2 00590-40399-71 34 1 00590-40387-71 35 1 00590-40397-71 36 1 00590-40408-71 37 1 00590-01823-71 38 1 00590-40408-71 39 3 00590-40395-71 40 1 00590-03673-71 42 1 00590-39580-71 43 1 00590-00907-71 44 1 00590-00908-71 45 1 00590-40394-71 R= Recommended Spare

Drive Unit (includes: Gearbox Only) Case Assembly, Gear (includes:) Gear, Drive Bearing, Cup/Cone Ring Seal Nut Bearing, Ball Gear, Pinion Bracket, Brake Switch Key Nut Screw Brake Assembly (See Figure 4-3.)

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

00715-00015-08, Final Issue 6/17/2008

Top of Section

USED ON

R R R

R

R

4-5

Model 6HBW20 - Drive and Brake Drive Unit Installation List 4-1: Drive Unit Installation (Sheet 2 of 2) FIGURE 4-1 QTY PART NUMBER ITEM NO. 46 1 00590-40393-71 47 1 00590-00943-71 49 1 00590-40392-71 50 1 00590-40391-71 51 1 00590-40389-71 52 4 00590-05149-71 53 2 00590-40388-71 54 1 00590-03847-71 55 1 Ref. R= Recommended Spare

4-6

DESCRIPTION Gear, Idle O-Ring Bearing, Cup/Cone, Pivot, Small Bearing, Cup/Cone, Pivot, Large Motor Assembly, Drive (See Figure 5-11.)

Washer, Flat Washer, Flat Cable Tie (Not Shown) Wheel Assembly, Drive (See Figure 4-2.)

Top of Section

USED ON R R R

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Drive and Brake Drive Unit Installation

This Page Intentionally Blank

00715-00015-08, Final Issue 6/17/2008

Top of Section

4-7

Model 6HBW20 - Drive and Brake Drive Wheel Assembly

Drive Wheel Assembly

4

Figure 4-2: Drive Wheel Assembly

3

1

1

4

3

W850_137_199, W07199

4-8

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Drive and Brake Drive Wheel Assembly List 4-2: Drive Wheel Assembly FIGURE 4-2 ITEM NO. 1

QTY

PART NUMBER

1 00590-04583-71 1 00590-41212-71 1 00590-41211-71 1 00590-41210-71 1 00590-41209-71 1 00590-47957-71 3 1 00590-40657-71 4 1 00590-40394-71 R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION Tire, Poly Tire, Rubber, Smooth, Black Tire, Rubber, Smooth, White, Non-Marking Tire, Rubber, Lugged, Black Tire, Rubber, Smooth, Black, Grip, Shell Tire, Rubber, Smooth, Black, Flat, Siped Hub Machining, Wheel Nut

Top of Section

USED ON R R R

4-9

Model 6HBW20 - Drive and Brake Brake Assembly

Brake Assembly

4

Figure 4-3: Brake Assembly

2

5

1

3

4

6

W400_081

4-10

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Drive and Brake Brake Assembly List 4-3: Brake Assembly FIGURE 4-3 ITEM NO.

QTY

PART NUMBER

00590-03834-71 1 1 00590-43656-71 2 1 00590-39571-71 3 1 00590-05286-71 4 1 00590-03891-71 5 2 00590-39575-71 6 2 00590-39570-71 R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

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

Top of Section

USED ON

R

R R

4-11

Model 6HBW20 - Drive and Brake Brake Assembly

This Page Intentionally Blank

4-12

Top of Section

00715-00015-08, Final Issue 6/17/2008

SECTION 5 Electrical Components and Systems Electrical System .................................................................................................................................................. 5-3 Contactor Assembly ............................................................................................................................................. 5-6 Meter Installation ................................................................................................................................................. 5-8 Battery Pack, 24 Volt (Wet Battery) ...................................................................................................................... 5-10 Battery Tree and Cover Assembly......................................................................................................................... 5-12 Battery Pack and Cable Assembly (Wet Battery) .................................................................................................... 5-14 Charger Assembly.............................................................................................................................................. 5-16 GNB Maintenance Free 24 Volt Battery ................................................................................................................ 5-18 GNB Charger Assembly ..................................................................................................................................... 5-20 Battery Pack, Optima.......................................................................................................................................... 5-22 Drive Motor Assembly ........................................................................................................................................ 5-24 Maintenance Tool, Programmable........................................................................................................................ 5-26

00715-00015-08, Final Issue 6/17/2008

5-1

Model 6HBW20 - Electrical Components and Systems

This Page Intentionally Blank

5-2

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems Electrical System

Electrical System

5

Figure 5-1a: Electrical System

14

1

29

5

11

6

2

12

10

20

3d 3c

30

4b 3b

4d 4a

4c

18

3a

13

311426

00715-00015-08, Final Issue 6/17/2008

Top of Section

5-3

Model 6HBW20 - Electrical Components and Systems Electrical System

Electrical System

5

Figure 5-1b: Electrical System

31

28

37 9

7

8

38 39 4100-501F, W939_352

5-4

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems Electrical System List 5-1: Electrical System FIGURE 5-1 ITEM NO. 1 2 3a 3b 3c 3d 4a 4b 4c 4d 5 6 7 8 9 10 11 12 13 14 18 19 20 28

QTY

PART NUMBER

1 1

00590-02365-71 00590-40776-71 00590-40777-71 00590-40778-71 00590-40779-71 00590-40780-71 00590-40781-71 00590-40782-71 00590-40783-71 00590-40784-71 00590-40785-71 00590-01962-71 00590-43049-71 00590-03773-71 00590-40669-71 00590-03798-71 00590-40786-71 00590-00552-71 00590-40295-71 00590-40670-71 00590-03915-71 00590-46725-71 00590-40789-71 00590-40791-71 00590-01843-71 00590-00538-71 00590-04577-71 00590-40790-71 00590-40871-71 00590-40983-71 00590-45248-71 00590-40796-71 00590-40795-71

1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 9 1 1 1 1 1 1 1 1 1 1 1 1

29 30 31 37 38 39 A= Standard B= Cold Storage R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION

USED ON

Controller, Motor Contactor, Main Cable Assembly (CB Auxiliary to P1) Cable Assembly (B- to MP2) Cable Assembly (B+ to M1-2) Cable Assembly (M1-1 to A2) Cable Assembly (M- to A1) Cable Assembly (A2 to A2) Cable Assembly (M1-4 to S1) Cable Assembly (M1-2 to S2) Bar, Bus (CB Auxiliary to M1-1) Block, Fuse Bracket, Brake Switch Plate, Switch Backing Switch, Cutout, Brake/Lift Switch, Cutout, Brake/Lift Panel, Electrical Fuse, 15 Amp Breaker, Circuit, 80 Amp Horn Assembly Screw Screw Harness, Main (Not Shown) Contactor Assembly, Forward and Reverse (See Figure 5-2.)

Switch, Key Switch, Key Key, Set of 2 Bar, Bus (M1-2 to M2-3) Resistor Assembly Switch, Main, On/Off Connector, Battery Cable, B+ Cable, B-

R

Top of Section

R

A, R B, R R R R

A, R B, R R

R R

5-5

Model 6HBW20 - Electrical Components and Systems Contactor Assembly

Contactor Assembly

5

Figure 5-2: Contactor Assembly

2 1

3

4

5

2 7

6 10 8

9

W1105216

5-6

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems Contactor Assembly List 5-2: Contactor Assembly FIGURE 5-2 ITEM NO.

QTY

PART NUMBER

00590-40791-71 1 3 00590-04856-71 2 1 00590-04980-71 3 1 00590-04861-71 4 2 00590-04862-71 5 1 00590-04863-71 6 1 00590-04864-71 7 1 00590-04865-71 8 2 00590-04866-71 9 1 00590-40792-71 10 1 00590-40793-71 R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION Contactor Assembly, Forward and Reverse Screw, Top Cover Kit, Hardware Top Cover, Assembled Spring, Return Contact, Movable, Assembled Contact, Fixed Insulator Peg Frame and Coil Assembly without Bracket Bracket, Mounting

Top of Section

USED ON

R

5-7

Model 6HBW20 - Electrical Components and Systems Meter Installation

Meter Installation

5

Figure 5-3: Meter Installation

4

2

3

1

5

5231-001-4100-502

5-8

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems Meter Installation List 5-3: Meter Installation FIGURE 5-3 ITEM NO. 1 2 3 4

QTY

PART NUMBER

1 00590-01785-71 1 00590-46737-71 1 00590-41012-71 1 00590-00610-71 1 00590-40959-71 5 1 Ref. R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION Meter, Hour Harness, Wiring (Lift Interrupt) Plug Meter, Hour/Discharge Meter, Battery/Discharge Bracket, Mounting, Key Switch (See Figure 2-3c.)

Top of Section

USED ON R

R

5-9

Model 6HBW20 - Electrical Components and Systems Battery Pack, 24 Volt (Wet Battery)

Battery Pack, 24 Volt (Wet Battery)

5

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

4

8

5

10

3

2

13

6

12

1

W939_352_103

5-10

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems Battery Pack, 24 Volt (Wet Battery) List 5-4: 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

00590-40674-71 00590-40675-71 Ref. Ref. Ref. 00590-03911-71 00590-40678-71 00590-40797-71 00590-01573-71 00590-40798-71 00590-01574-71 00590-40799-71 00590-01575-71 00590-03917-71 00590-00005-71 00590-00799-71

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

00715-00015-08, Final Issue 6/17/2008

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 (See Figure 5-6.)

Charger Assembly (See Figure 5-7.)

Screw Nut, Flanged Decal, Cable System, 24 Volt Decal, Cable System, 24 Volt Decal, Warning, Charging Decal, Warning, Charging Decal, Warning, Battery Swivel Decal, Warning, Battery Swivel Bolt Washer, Lock Guard, Cable, 9.5 in. (Not Shown)

Top of Section

USED ON A B

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

5-11

Model 6HBW20 - Electrical Components and Systems Battery Tree and Cover Assembly

Battery Tree and Cover Assembly

5

Figure 5-5: Battery Tree and Cover Assembly 2

4

13

1

12

1 9 3

7 8

11 6

5 10

5111_000

5-12

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems Battery Tree and Cover Assembly List 5-5: 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

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

00590-40678-71 00590-40679-71 00590-43542-71 00590-40680-71 00590-03671-71 00590-40147-71 00590-40135-71 00590-46740-71 00590-03911-71 00590-40899-71 00590-40900-71 00590-40901-71 00590-40902-71

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION

USED ON

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

Top of Section

5-13

Model 6HBW20 - Electrical Components and Systems Battery Pack and Cable Assembly (Wet Battery)

Battery Pack and Cable Assembly (Wet Battery)

5

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

10

2

8

13

5

6

3

1

-

+

11

7

4

9

12

5112_100

5-14

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems Battery Pack and Cable Assembly (Wet Battery) List 5-6: Battery Pack and Cable Assembly (Wet Battery) FIGURE 5-6 QTY PART NUMBER ITEM NO. 1 1 00590-00581-71 2 1 00590-46741-71 3 1 00590-46378-71 4 1 00590-46742-71 5 8 00590-40420-71 6 8 00590-40147-71 7 4 00590-40409-71 8 2 00590-40421-71 9 2 00590-40422-71 10 1 00590-03847-71 11 1 00590-45644-71 12 1 00590-45639-71 13 8 00590-40425-71 R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

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

Top of Section

USED ON R

5-15

Model 6HBW20 - Electrical Components and Systems Charger Assembly

Charger Assembly

5

Figure 5-7: Charger Assembly

16

11 2 RECTIFIER ASSEMBLY (HEATSINK)

POWER TRANSFORMER

17

START - BLUE START TX SEC

7

FUSIBLELINK

DIODE DC POS. - RED

AC BLACK

3

9

14

8

FINISH

TIMER AC GREEN GROUND SCREW AC WHITE

FINISH WHITE

CAPACITATOR

DIODE

DC NEG. - BLK AMMETER

WIRING DIAGRAM

10

4

15

13

1

12

5

W06707

5-16

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems Charger Assembly List 5-7: Charger Assembly FIGURE 5-7 ITEM NO.

QTY

PART NUMBER

00590-43050-71 1 1 00590-04701-71 2 1 00590-04702-71 3 1 00590-04703-71 4 1 00590-04704-71 5 1 00590-04705-71 7 2 00590-04707-71 8 1 00590-04633-71 9 2 00590-04634-71 10 1 00590-00581-71 11 1 00590-04710-71 12 1 00590-04711-71 13 1 00590-04712-71 14 1 00590-04635-71 15 1 00590-04713-71 16 1 00590-04636-71 17 1 00590-04714-71 A= North America R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

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

Top of Section

USED ON

R R R

A

5-17

Model 6HBW20 - Electrical Components and Systems GNB Maintenance Free 24 Volt Battery

GNB Maintenance Free 24 Volt Battery

5

Figure 5-8: GNB Maintenance Free 24 Volt Battery

14

15

4

8

6

9

7 3

12

11

10 13 5

1 2 W939_352

5-18

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems GNB Maintenance Free 24 Volt Battery List 5-8: GNB Maintenance Free 24 Volt Battery FIGURE 5-8 ITEM NO.

QTY

PART NUMBER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

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

00590-39538-71 00590-40682-71 00590-39940-71 00590-40565-71 00590-40630-71 00590-40683-71 00590-40684-71 00590-40685-71 00590-40686-71 00590-40687-71 00590-40688-71 00590-04689-71 00590-40690-71 00590-40691-71 00590-40910-71 00590-03915-71

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION

USED ON

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

Module, Battery, 6 Volt Plug, SB175, Cables Cable, Battery, Internal Grommet, Rubber Label, Champion Label, Warning Plate, Name Bolt Washer, Lock Washer Pad, Foam Rubber Bracket Screw

Top of Section

5-19

Model 6HBW20 - Electrical Components and Systems GNB Charger Assembly

GNB Charger Assembly

5

Figure 5-9: GNB Charger Assembly 10 14

8

18 17

5

16

11

12

13

AC FUSE OR CIRCUIT BREAKER

DC FUSE OR CIRCUIT BREAKER SOLDER CONNECTION DC NEG. BLACK

amp BELL CRIMP A

1

SCR

TX PRI

AC WHITE

DC POS. RED

BELL CRIMP WHT

HEATSINK

D

2 BELL CRIMP

NOTE: VARISTOR LEADS MUST BE COVERED WITH VARFLEX

WHT

B C

8

WHT

7

GRN

7 9

WHT

13

WHT

12 12

BLK

14

WHT

YELLOW

ORG

ORG

SCR

10

11

15

16

17

6

1 BLUE 5 GRN

8 7 9

15

YELLOW

GROUND SCREW VARISTOR

BLK

AC GREEN

WHITE

AC BLACK

.001 OHM SHUNT

HEATSINK

CIRCUIT BOARD HARNESS

4

WHT STOP (N.O.)

13 12

3

14

2

GRN WHT

BUTT SPLICE

GREEN

D13507_9

5-20

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems GNB Charger Assembly List 5-9: GNB Charger Assembly FIGURE 5-9 ITEM NO.

QTY

PART NUMBER

00590-39940-71 00590-40584-71 1 1 00590-40692-71 3 1 00590-40693-71 4 1 00590-40694-71 5 1 00590-40307-71 6 1 00590-40695-71 7 1 00590-40696-71 8 1 00590-40697-71 9 1 00590-40698-71 10 1 00590-40699-71 11 1 00590-40700-71 12 1 00590-40701-71 13 1 00590-40702-71 14 1 00590-40703-71 15 1 00590-40704-71 16 1 00590-40705-71 17 1 00590-40706-71 18 1 00590-46743-71 R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

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

Top of Section

USED ON

R

5-21

Model 6HBW20 - Electrical Components and Systems Battery Pack, Optima

Battery Pack, Optima

5

Figure 5-10: Battery Pack, Optima 1

2 7

3

6

4

5

5114-001

5-22

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems Battery Pack, Optima List 5-10: Battery Pack, Optima FIGURE 5-10 QTY PART NUMBER ITEM NO. 1 1 00590-46745-71 2 1 N/A 3 1 N/A 4 1 00590-46746-71 5 1 N/A 6 4 00590-46415-71 7 1 00590-46747-71 R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION Battery Pack (includes:) Cover Box, Junction Charger Tray Battery Kit, Cable

Top of Section

USED ON

R

5-23

Model 6HBW20 - Electrical Components and Systems Drive Motor Assembly

Drive Motor Assembly

5

Figure 5-11: Drive Motor Assembly

1 2 5 3 4

6

7 8 9 10 3 11 12

13 570_864

5-24

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Electrical Components and Systems Drive Motor Assembly List 5-11: Drive Motor Assembly FIGURE 5-11 ITEM NO.

QTY

PART NUMBER

00590-40389-71 1 1 00590-04742-71 2 1 00590-40708-71 3 2 00590-40709-71 4 1 00590-04745-71 5 1 00590-40710-71 6 1 00590-04747-71 7 1 00590-04748-71 8 1 00590-04749-71 9 1 00590-40711-71 10 1 00590-40712-71 11 1 00590-04752-71 12 1 00590-40713-71 13 1 00590-04754-71 R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

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

Top of Section

USED ON R R

R R

R

5-25

Model 6HBW20 - Electrical Components and Systems Maintenance Tool, Programmable

Maintenance Tool, Programmable

5

Figure 5-12: Maintenance Tool, Programmable

1

2

W950-185

List 5-12: Maintenance Tool, Programmable FIGURE 5-12 ITEM NO. 1 2

5-26

QTY

PART NUMBER

1 1 1

00590-49981-71 00590-02415-71 00590-02416-71

DESCRIPTION

USED ON

Tool, Maintenance, Programmable (includes:) Cable, 4k Cable, 6 to 8k

Top of Section

00715-00015-08, Final Issue 6/17/2008

SECTION 6 Hydraulic Components Hydraulic System ................................................................................................................................................. 6-2 Lift Pump and Motor Assembly ............................................................................................................................... 6-5 Hydraulic Cylinder ............................................................................................................................................... 6-8

00715-00015-08, Final Issue 6/17/2008

6-1

Model 6HBW20 - Hydraulic Components Hydraulic System

Hydraulic System

6

Figure 6-1: Hydraulic System

1

3

4

2

5

W6125_100

6-2

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Hydraulic Components Hydraulic System List 6-1: Hydraulic System FIGURE 6-1 ITEM NO. 1 2 3 4 5

QTY

PART NUMBER

1 1 1 1 2

00590-42304-71 00590-40805-71 00590-40802-71 00590-40803-71 00590-46753-71

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION

USED ON

Cylinder, Hydraulic (See Figure 6-3.)

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

Fitting, Elbow Hose Assembly Screw

Top of Section

6-3

Model 6HBW20 - Hydraulic Components Hydraulic System

This Page Intentionally Blank

6-4

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Hydraulic Components Lift Pump and Motor Assembly

Lift Pump and Motor Assembly

6

Figure 6-2a: Lift Pump and Motor Assembly

1

3

4

2

16 5

6

MOTOR ASSEMBLY

W560-215PG1 SHT 1 OF 2

00715-00015-08, Final Issue 6/17/2008

Top of Section

6-5

Model 6HBW20 - Hydraulic Components Lift Pump and Motor Assembly

Lift Pump and Motor Assembly

6

Figure 6-2b: Lift Pump and Motor Assembly

17

15 7 18 13 8

14

11

12

9

10

LIFT PUMP ASSEMBLY

W560-215PG2 SHT 2 OF 2

6-6

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Hydraulic Components Lift Pump and Motor Assembly List 6-2: Lift Pump and Motor Assembly FIGURE 6-2 ITEM NO.

QTY

PART NUMBER

00590-40805-71 1 00590-05338-71 2 00590-40714-71 1 00590-05339-71 1 00590-40636-71 1 00590-04736-71 1 00590-05340-71 1 00590-04555-71 1 00590-04700-71 1 00590-04559-71 1 00590-04554-71 1 00590-04695-71 1 00590-05341-71 1 00590-04893-71 1 00590-05342-71 1 00590-40301-71 1 00590-05343-71 16 1 00590-05344-71 17 1 00590-46914-71 18 1 00590-05345-71 R= Recommended Spare 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION Lift Pump and Motor Assembly Motor (includes:) Bolt, Through Set, Brush Holder and Springs Bearing, Commutator End Bearing, Drive End Kit, Service, Start Switch Pump Assembly, Lift Plug, Vent with Micron Filter Coil, 24 Volt Valve, Stem Valve, Flow Control Valve Assembly, Check Valve, Relief Kit, Adapter Kit, Reservoir, with Tubes (Plastic) Kit, Reservoir, with Tubes (Steel) Coupling Strainer Kit, Seal

Top of Section

USED ON

R R R R

R R R R R R R R R

6-7

Model 6HBW20 - Hydraulic Components Hydraulic Cylinder

Hydraulic Cylinder

6

Figure 6-3: Hydraulic Cylinder

2

4

1

3975_058

List 6-3: Hydraulic Cylinder FIGURE 6-3 ITEM NO.

QTY

PART NUMBER

00590-43503-71 1 00590-40807-71 1 00590-45712-71 1 00590-40809-71 1 NSS 1 NSS 1 NSS R= Recommended Spare 1 2 4

6-8

DESCRIPTION Cylinder, Hydraulic Rod, Piston Barrel Assembly Kit, Seal (includes:) Seal, Wiper Ring, Retaining, Lock Seal

Top of Section

USED ON

R R R

00715-00015-08, Final Issue 6/17/2008

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

00715-00015-08, Final Issue 6/17/2008

7-1

Model 6HBW20 - Mast Fork Final Assembly

Fork Final Assembly

7

Figure 7-1: Fork Final Assembly

1

2 11

8 12

13

10

9

5

3

6

7

16

14

0301-001-101

7-2

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Mast Fork Final Assembly List 7-1: Fork Final Assembly FIGURE 7-1 ITEM NO. 1 2 3 5 6

7 8 9 10 11 12 13 14 16

QTY

PART NUMBER

1 8 2 2 2 2 2 2 2 2 2 2 2 2 12 12 2 2 1 1 1 1 2 2 2 4 2 2 2

Ref. 00590-03913-71 00590-40814-71 00590-46754-71 00590-40765-71 00590-46755-71 00590-40810-71 00590-40811-71 00590-40812-71 00590-40813-71 00590-46756-71 00590-46757-71 00590-46758-71 00590-46759-71 00590-05134-71 00590-43276-71 00590-40732-71 00590-46760-71 00590-40815-71 00590-46761-71 00590-40816-71 00590-46762-71 00590-40716-71 00590-46763-71 00590-03911-71 00590-03673-71 Ref. 00590-40717-71 00590-46764-71

DESCRIPTION Fork and Box Weldment Screw, Set Pin, Link Pin, Link Pin, Link Pin, Link 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, 36 in. Fork Length Rod, Pull, 42 in. Fork Length Rod, Pull, 46 in. Fork Length Rod, Pull, 48 in. Fork Length Bushing, Iron Bushing, Poly Pin, Pivot, Bell Crank Pin, Pivot, Bell Crank Link, Lower Link, Lower Link, Lower Link, Lower Pin, Link Pin, Link Screw Fitting, Grease Wheel Assembly, Load (See Figure 7-2.)

Pin, Link Pin, Link

USED ON D A, B C A, R B, R A A A A B, C B, C B, C B, C A, R B, R A, B C A, B, R C, R A, B, R C, R A, B, R C B A, B, R C

A= Standard B= Lubrication C= Cold Storage D= Contact Technical Support R= Recommended Spare

00715-00015-08, Final Issue 6/17/2008

Top of Section

7-3

Model 6HBW20 - Mast Load Wheel Assembly

Load Wheel Assembly

7

Figure 7-2: Load Wheel Assembly

4

1

8

9

3

2

5

7

W07825A

7-4

Top of Section

00715-00015-08, Final Issue 6/17/2008

Model 6HBW20 - Mast Load Wheel Assembly List 7-2: Load Wheel Assembly FIGURE 7-2 ITEM NO.

QTY

PART NUMBER

00590-40733-71 1 00590-40734-71 1 00590-46765-71 2 1 00590-46766-71 1 00590-00773-71 1 00590-00777-71 1 00590-00779-71 3 1 00590-46767-71 1 00590-40735-71 1 00590-46383-71 4 1 00590-03913-71 5 2 00590-40817-71 2 00590-41592-71 7 1 00590-00019-71 8 2 00590-05133-71 9 2 00590-03673-71 A= Red/Orange Poly B= Neutral Poly C= Black Poly D= Tan Poly E= Standard F= Lubrication G= Cold Storage R= Recommended Spare 1

00715-00015-08, Final Issue 6/17/2008

DESCRIPTION Load Wheel Assembly Fork Machining, Trail Fork Machining, Trail Wheel, Load Wheel, Load Wheel, Load Wheel, Load Shaft, Wheel Shaft, Wheel Shaft, Wheel Screw, Set Bearing, Shield Bearing, Double Sealed Fitting, Grease Bearing, Super, Oil-Impregnated Fitting, Grease

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USED ON E F, G A, R B, R C, R D, R E, R F, R G, R R G, R F, G R F, G

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Model 6HBW20 - Mast Load Wheel Assembly

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Top of Section

00715-00015-08, Final Issue 6/17/2008

APPENDIX A Description

Part No.

Alphabetical Parts Index Page

Ammeter . . . . . . . . . . . . . . . . . . . . . . 00590-04701-71 . . 5-17 Anchor, Spring, Brake . . . . . . . . . . . . . 00590-43608-71 . . . 4-5 Arm, Brake . . . . . . . . . . . . . . . . . . . . . 00590-40368-71 . . . 4-5 Armature . . . . . . . . . . . . . . . . . . . . . . 00590-40710-71 . . 5-25 Backrest Weldment, Load, 48 in. High . . 00590-40774-71 . . 2-10 Backrest Weldment, Load, 60 in. High . . 00590-40775-71 . . 2-10 Bar, Bus (CB Auxiliary to M1-1) . . . . . . . 00590-40785-71 . . . 5-5 Bar, Bus (M1-2 to M2-3) . . . . . . . . . . . . 00590-40790-71 . . . 5-5 Bar, Skid, Adjustable . . . . . . . . . . . . . . 00590-40761-71 . . . 2-5 Barrel Assembly . . . . . . . . . . . . . . . . . 00590-45712-71 . . . 6-8 Battery Pack . . . . . . . . . . . . . . . . . . . . 00590-46745-71 . . 5-23 Battery Pack, 24 Volt (Wet Battery) . . . . 00590-40674-71 . . 5-11 Battery Pack, 24 Volt (Wet Battery) . . . . 00590-40675-71 . . 5-11 Battery Pack, GNB, Maintenance Free, 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-39538-71 . . 5-19 Battery . . . . . . . . . . . . . . . . . . . . . . . . 00590-46415-71 . . 5-23 Battery, 6 Volt . . . . . . . . . . . . . . . . . . 00590-40409-71 . . 5-15 Bearing, Ball . . . . . . . . . . . . . . . . . . . . 00590-40384-71 . . . 4-5 Bearing, Commutator End . . . . . . . . . . . 00590-40636-71 . . . 6-7 Bearing, Cup/Cone . . . . . . . . . . . . . . . 00590-40382-71 . . . 4-5 Bearing, Cup/Cone, Pivot, Large. . . . . . 00590-40391-71 . . . 4-6 Bearing, Cup/Cone, Pivot, Small. . . . . . 00590-40392-71 . . . 4-6 Bearing, Double Sealed . . . . . . . . . . . . 00590-41592-71 . . . 7-5 Bearing, Drive End and Commutator End 00590-40709-71 . . 5-25 Bearing, Drive End. . . . . . . . . . . . . . . . 00590-04736-71 . . . 6-7 Bearing, Handle . . . . . . . . . . . . . . . . . 00590-40383-71 . . . 4-5 Bearing, Shield . . . . . . . . . . . . . . . . . . 00590-40817-71 . . . 7-5 Bearing, Super, Oil-Impregnated . . . . . . 00590-05133-71 . . . 7-5 Block, Fuse . . . . . . . . . . . . . . . . . . . . . 00590-01962-71 . . . 5-5 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-03917-71 . . 5-11 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40679-71 . . 5-13 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40688-71 . . 5-19 Bolt, Chain Anchor . . . . . . . . . . . . . . . 00590-40367-71 . . . 3-3 Bolt, Chain Anchor . . . . . . . . . . . . . . . 00590-40367-71 . . . 4-5 Bolt, Pivot . . . . . . . . . . . . . . . . . . . . . . 00590-40759-71 . . . 2-5 Bolt, Pivot . . . . . . . . . . . . . . . . . . . . . . 00590-40759-71 . . . 2-5 Bolt, Special . . . . . . . . . . . . . . . . . . . . 00590-40381-71 . . . 4-5 Bolt, Through. . . . . . . . . . . . . . . . . . . . 00590-40714-71 . . . 6-7 Boot, Terminal . . . . . . . . . . . . . . . . . . . 00590-40425-71 . . 5-15 Box Assembly, Brush . . . . . . . . . . . . . . 00590-40711-71 . . 5-25 Bracket . . . . . . . . . . . . . . . . . . . . . . . . 00590-00962-71 . . 3-10 Bracket . . . . . . . . . . . . . . . . . . . . . . . . 00590-40653-71 . . . 3-9 Bracket . . . . . . . . . . . . . . . . . . . . . . . . 00590-40910-71 . . 5-19 Bracket . . . . . . . . . . . . . . . . . . . . . . . . 00590-46706-71 . . . 3-9 Bracket, Brake Switch. . . . . . . . . . . . . . 00590-43049-71 . . . 4-5 Bracket, Brake Switch. . . . . . . . . . . . . . 00590-43049-71 . . . 5-5 Bracket, Mounting . . . . . . . . . . . . . . . . 00590-40793-71 . . . 5-7 Bracket, Mounting, Cover . . . . . . . . . . . 00590-40768-71 . . . 2-9 Bracket, Mounting, Key Switch . . . . . . . 00590-40766-71 . . . 2-9 Bracket, Mounting, Plug . . . . . . . . . . . . 00590-40698-71 . . 5-21 Bracket, Retainer . . . . . . . . . . . . . . . . . 00590-42656-71 . . . 2-5 Bracket, Switch Assembly, Function . . . . 00590-00150-71 . . 3-10 Brake Assembly . . . . . . . . . . . . . . . . . 00590-03834-71 . . 4-11 Brake Assembly . . . . . . . . . . . . . . . . . . 00590-03834-71 . . . 4-5 Breaker, Circuit, 15A . . . . . . . . . . . . . . 00590-40307-71 . . 5-21 Breaker, Circuit, 80 Amp . . . . . . . . . . . 00590-40295-71 . . . 5-5 Bushing . . . . . . . . . . . . . . . . . . . . . . . 00590-43550-71 . . . 2-5 Bushing . . . . . . . . . . . . . . . . . . . . . . . 00590-00149-71 . . . 3-9

1058725B, Final Issue 6/17/2008

Description

Part No.

Page

Bushing, Flanged. . . . . . . . . . . . . . . . . 00590-40370-71 . . . 3-3 Bushing, Iron . . . . . . . . . . . . . . . . . . . 00590-05134-71 . . . 2-5 Bushing, Iron. . . . . . . . . . . . . . . . . . . . 00590-05134-71 . . . 7-3 Bushing, Poly . . . . . . . . . . . . . . . . . . . 00590-43276-71 . . . 7-3 Button, Function, Forks Lift. . . . . . . . . . . 00590-01413-71 . . . 3-9 Button, Function, Forks Lowered. . . . . . . 00590-01412-71 . . . 3-9 Button, Function, Horn . . . . . . . . . . . . . 00590-01411-71 . . . 3-9 Button, Nose Assembly. . . . . . . . . . . . . 00590-01422-71 . . . 3-9 Cable Assembly (A2 to A2) . . . . . . . . . 00590-40782-71 . . . 5-5 Cable Assembly (B- to MP2) . . . . . . . . . 00590-40778-71 . . . 5-5 Cable Assembly (B+ to M1-2) . . . . . . . . 00590-40779-71 . . . 5-5 Cable Assembly (CB Auxiliary to P1) . . . 00590-40777-71 . . . 5-5 Cable Assembly (M- to A1) . . . . . . . . . . 00590-40781-71 . . . 5-5 Cable Assembly (M1-1 to A2) . . . . . . . . 00590-40780-71 . . . 5-5 Cable Assembly (M1-2 to S2) . . . . . . . . 00590-40784-71 . . . 5-5 Cable Assembly (M1-4 to S1) . . . . . . . . 00590-40783-71 . . . 5-5 Cable Assembly . . . . . . . . . . . . . . . . . 00590-45639-71 . . 5-15 Cable Assembly . . . . . . . . . . . . . . . . . 00590-45644-71 . . 5-15 Cable Assembly . . . . . . . . . . . . . . . . . 00590-46378-71 . . 5-15 Cable Assembly . . . . . . . . . . . . . . . . . 00590-46741-71 . . 5-15 Cable Assembly . . . . . . . . . . . . . . . . . 00590-46742-71 . . 5-15 Cable Tie . . . . . . . . . . . . . . . . . . . . . . 00590-03847-71 . . . 4-6 Cable Tie . . . . . . . . . . . . . . . . . . . . . . 00590-03847-71 . . 5-15 Cable, 4k . . . . . . . . . . . . . . . . . . . . . . 00590-02415-71 . . 5-26 Cable, 6 to 8k . . . . . . . . . . . . . . . . . . 00590-02416-71 . . 5-26 Cable, B- . . . . . . . . . . . . . . . . . . . . . . 00590-40795-71 . . . 5-5 Cable, B+. . . . . . . . . . . . . . . . . . . . . . 00590-40796-71 . . . 5-5 Cable, Battery, Internal . . . . . . . . . . . . 00590-40683-71 . . 5-19 Cam . . . . . . . . . . . . . . . . . . . . . . . . . 00590-39571-71 . . 4-11 Cam, Controller . . . . . . . . . . . . . . . . . 00590-00951-71 . . . 3-9 Capacitor, 440 VAC . . . . . . . . . . . . . 00590-04703-71 . . 5-17 Case Assembly, Gear . . . . . . . . . . . . . 00590-40369-71 . . . 4-5 Case, Back, Large Cell. . . . . . . . . . . . . 00590-40692-71 . . 5-21 Case, Main, Large Cell . . . . . . . . . . . . 00590-40693-71 . . 5-21 Case, Pallet, Main . . . . . . . . . . . . . . . 00590-04704-71 . . 5-17 Case, Top, Large Cell . . . . . . . . . . . . . 00590-40694-71 . . 5-21 Chain Assembly, Roller . . . . . . . . . . . . 00590-00833-71 . . . 3-5 Charger Assembly . . . . . . . . . . . . . . . 00590-43050-71 . . 5-17 Charger . . . . . . . . . . . . . . . . . . . . . . . 00590-39940-71 . . 5-19 Charger . . . . . . . . . . . . . . . . . . . . . . . 00590-39940-71 . . 5-21 Charger . . . . . . . . . . . . . . . . . . . . . . . 00590-46746-71 . . 5-23 Charger, 15 Amp . . . . . . . . . . . . . . . . 00590-40584-71 . . 5-21 Circuit, 2400 24V 25A 55T, with Cord . 00590-40695-71 . . 5-21 Clamp, Cable . . . . . . . . . . . . . . . . . . . 00590-40403-71 . . . 3-5 Clamp, Cable . . . . . . . . . . . . . . . . . . . 00590-40403-71 . . . 4-5 Coil, 24 Volt . . . . . . . . . . . . . . . . . . . . 00590-04559-71 . . . 6-7 Connector, Battery. . . . . . . . . . . . . . . . 00590-00581-71 . . 5-15 Connector, Battery. . . . . . . . . . . . . . . . 00590-00581-71 . . 5-17 Connector, Battery. . . . . . . . . . . . . . . . 00590-45248-71 . . . 5-5 Contact, Fixed. . . . . . . . . . . . . . . . . . . 00590-04864-71 . . . 5-7 Contact, Movable, Assembled . . . . . . . 00590-04863-71 . . . 5-7 Contactor Assembly, Forward and Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40791-71 . . . 5-5 Contactor Assembly, Forward and Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40791-71 . . . 5-7 Contactor, Main . . . . . . . . . . . . . . . . . 00590-40776-71 . . . 5-5 Controller Assembly . . . . . . . . . . . . . . 00590-01436-71 . . . 3-7 Controller Assembly . . . . . . . . . . . . . . 00590-01436-71 . . . 3-9

A-1

Model 6HBW20 - Alphabetical Parts Index

Description

Part No.

Page

Controller Assembly . . . . . . . . . . . . . . 00590-01438-71. . . 3-7 Controller Assembly . . . . . . . . . . . . . . 00590-01438-71. . . 3-9 Controller Assembly with Knuckle Guard 00590-01435-71. . . 3-5 Controller Assembly with Knuckle Guard 00590-01435-71. . . 3-7 Controller Assembly with Knuckle Guard 00590-01437-71. . . 3-5 Controller Assembly with Knuckle Guard 00590-01437-71. . . 3-7 Controller, Motor . . . . . . . . . . . . . . . . 00590-02365-71. . . 5-5 Cord Assembly, AC. . . . . . . . . . . . . . . 00590-40697-71. . 5-21 Cord Assembly, DC. . . . . . . . . . . . . . . 00590-40696-71. . 5-21 Coupling . . . . . . . . . . . . . . . . . . . . . . 00590-05344-71. . . 6-7 Cover, Brake . . . . . . . . . . . . . . . . . . . 00590-39877-71. . . 4-5 Cover, Front, Orange . . . . . . . . . . . . . 00590-40772-71. . . 2-9 Cover, Gear . . . . . . . . . . . . . . . . . . . . 00590-40400-71. . . 4-5 Cover, Internal . . . . . . . . . . . . . . . . . . 00590-40773-71. . . 2-9 Cover, Steering. . . . . . . . . . . . . . . . . . 00590-00148-71. . . 3-9 Cover, Switch . . . . . . . . . . . . . . . . . . . 00590-00141-71. . . 3-9 Cylinder, Hydraulic . . . . . . . . . . . . . . . 00590-43503-71. . . 6-8 Cylinder, Hydraulic . . . . . . . . . . . . . . . 00590-42304-71. . . 6-3 Decal, Cable System, 24 Volt . . . . . . . . 00590-01573-71. . 5-11 Decal, Cable System, 24 Volt . . . . . . . . 00590-40797-71. . 5-11 Decal, Emergency Disconnect . . . . . . . 00590-01258-71. . . 2-9 Decal, No Riding . . . . . . . . . . . . . . . . 00590-40767-71. . . 2-9 Decal, Operating Manual . . . . . . . . . . 00590-01443-71. . . 2-9 Decal, Steam Clean. . . . . . . . . . . . . . . 00590-43331-71. . . 2-9 Decal, TOYOTA . . . . . . . . . . . . . . . . . 00590-04497-71. . . 2-9 Decal, Warning . . . . . . . . . . . . . . . . . 00590-01942-71. . . 2-9 Decal, Warning, Battery Swivel . . . . . 00590-01575-71. . 5-11 Decal, Warning, Battery Swivel . . . . . 00590-40799-71. . 5-11 Decal, Warning, Charging. . . . . . . . . . 00590-01574-71. . 5-11 Decal, Warning, Charging. . . . . . . . . . 00590-40798-71. . 5-11 Decal, Warning, TOYOTA . . . . . . . . . . 00590-40842-71. . . 2-9 Diode, 20A . . . . . . . . . . . . . . . . . . . . 00590-04707-71. . 5-17 Door Weldment, Battery Box . . . . . . . . 00590-40680-71. . 5-13 Dowel . . . . . . . . . . . . . . . . . . . . . . . . 00590-40399-71. . . 4-5 Drive Unit. . . . . . . . . . . . . . . . . . . . . . 00590-40405-71. . . 4-5 Drum, Brake . . . . . . . . . . . . . . . . . . . . 00590-40374-71. . . 4-5 Edging. . . . . . . . . . . . . . . . . . . . . . . . 00590-40901-71. . 5-13 Fitting, Elbow . . . . . . . . . . . . . . . . . . . 00590-40802-71. . . 6-3 Fitting, Grease . . . . . . . . . . . . . . . . . . 00590-00019-71. . . 7-5 Fitting, Grease . . . . . . . . . . . . . . . . . . 00590-03673-71. . . 7-5 Fitting, Grease . . . . . . . . . . . . . . . . . . 00590-03673-71. . . 2-5 Fitting, Grease . . . . . . . . . . . . . . . . . . 00590-03673-71. . . 4-5 Fitting, Grease . . . . . . . . . . . . . . . . . . 00590-03673-71. . . 7-3 Fork Machining, Trail . . . . . . . . . . . . . 00590-40734-71. . . 7-5 Fork Machining, Trail . . . . . . . . . . . . . 00590-46765-71. . . 7-5 Fork/Joint Combination . . . . . . . . . . . . 00590-40407-71. . . 4-5 Frame and Coil Assembly without Bracket00590-40792-71. . . 5-7 Fuse Assembly, DC . . . . . . . . . . . . . . . 00590-04633-71. . 5-17 Fuse, 15 Amp. . . . . . . . . . . . . . . . . . . 00590-00552-71. . . 5-5 Fuse, Fuselink, DC . . . . . . . . . . . . . . . 00590-04634-71. . 5-17 Gear, Drive . . . . . . . . . . . . . . . . . . . . 00590-40375-71. . . 4-5 Gear, Idle . . . . . . . . . . . . . . . . . . . . . 00590-40393-71. . . 4-6 Gear, Pinion. . . . . . . . . . . . . . . . . . . . 00590-40376-71. . . 4-5 Gear, Potentiometer . . . . . . . . . . . . . . 00590-00122-71. . . 3-9 Grip, Hand . . . . . . . . . . . . . . . . . . . . 00590-00100-71. . . 3-7 Grommet . . . . . . . . . . . . . . . . . . . . . . 00590-40421-71. . 5-15 Grommet . . . . . . . . . . . . . . . . . . . . . . 00590-40422-71. . 5-15 Grommet, Rubber . . . . . . . . . . . . . . . . 00590-40684-71. . 5-19 Guard, Cable, 9.5 in. . . . . . . . . . . . . . 00590-00799-71. . 5-11 Guard, Knuckle. . . . . . . . . . . . . . . . . . 00590-00949-71. . . 3-7 Guard, Wheel, Rubber . . . . . . . . . . . . 00590-40408-71. . . 4-5

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Description

Part No.

Page

Guard, Wheel, Rubber . . . . . . . . . . . . 00590-40408-71 . . 4-5 Handle Assembly . . . . . . . . . . . . . . . . 00590-00825-71 . . 3-3 Handle Assembly . . . . . . . . . . . . . . . . 00590-00825-71 . . 3-5 Handle . . . . . . . . . . . . . . . . . . . . . . . 00590-01416-71 . . 3-5 Harness, Control. . . . . . . . . . . . . . . . . 00590-01929-71 . . 3-9 Harness, Main . . . . . . . . . . . . . . . . . . 00590-40789-71 . . 5-5 Harness, Wiring (Lift Interrupt) . . . . . . . 00590-46737-71 . . 5-9 Head, Commutator End . . . . . . . . . . . 00590-40713-71 . 5-25 Head, Drive End . . . . . . . . . . . . . . . . . 00590-40708-71 . 5-25 Heater . . . . . . . . . . . . . . . . . . . . . . . . 00590-00202-71 . . 3-9 Horn Assembly . . . . . . . . . . . . . . . . . . 00590-40670-71 . . 5-5 Hose Assembly . . . . . . . . . . . . . . . . . . 00590-40803-71 . . 6-3 Hub Machining, Wheel . . . . . . . . . . . . 00590-40657-71 . . 4-9 Insulator . . . . . . . . . . . . . . . . . . . . . . 00590-04865-71 . . 5-7 Key . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40379-71 . . 4-5 Key, Set of 2 . . . . . . . . . . . . . . . . . . . 00590-04577-71 . . 5-5 Kit, Adapter . . . . . . . . . . . . . . . . . . . . 00590-00956-71 . . 3-9 Kit, Adapter . . . . . . . . . . . . . . . . . . . . 00590-05342-71 . . 6-7 Kit, Brush Lead Assembly . . . . . . . . . . 00590-40712-71 . 5-25 Kit, Cable . . . . . . . . . . . . . . . . . . . . . 00590-46747-71 . 5-23 Kit, Field Coil . . . . . . . . . . . . . . . . . . . 00590-04747-71 . 5-25 Kit, Hardware . . . . . . . . . . . . . . . . . . 00590-04980-71 . . 5-7 Kit, Reservoir, with Tubes (Plastic) . . . . . 00590-40301-71 . . 6-7 Kit, Reservoir, with Tubes (Steel) . . . . . . 00590-05343-71 . . 6-7 Kit, Seal. . . . . . . . . . . . . . . . . . . . . . . 00590-05345-71 . . 6-7 Kit, Seal. . . . . . . . . . . . . . . . . . . . . . . 00590-40809-71 . . 6-8 Kit, Service, Start Switch . . . . . . . . . . . 00590-05340-71 . . 6-7 Knob, Butterfly . . . . . . . . . . . . . . . . . . 00590-01421-71 . . 3-7 Knob, Timer . . . . . . . . . . . . . . . . . . . 00590-04712-71 . 5-17 Label, Champion . . . . . . . . . . . . . . . . 00590-40685-71 . 5-19 Label, Warning . . . . . . . . . . . . . . . . . 00590-40686-71 . 5-19 Lever, Brake . . . . . . . . . . . . . . . . . . . 00590-05286-71 . 4-11 Lever, Return . . . . . . . . . . . . . . . . . . . 00590-01778-71 . . 3-9 Lift Pump and Motor Assembly . . . . . . . 00590-40805-71 . . 6-7 Link Assembly, Upper . . . . . . . . . . . . . 00590-04656-71 . . 2-5 Link, Connecting . . . . . . . . . . . . . . . . . 00590-00835-71 . . 3-5 Link, Connecting . . . . . . . . . . . . . . . . . 00590-40654-71 . . 3-5 Link, Lower. . . . . . . . . . . . . . . . . . . . . 00590-40815-71 . . 7-3 Link, Lower. . . . . . . . . . . . . . . . . . . . . 00590-40816-71 . . 7-3 Link, Lower. . . . . . . . . . . . . . . . . . . . . 00590-46761-71 . . 7-3 Link, Lower. . . . . . . . . . . . . . . . . . . . . 00590-46762-71 . . 7-3 Load Wheel Assembly . . . . . . . . . . . . 00590-40733-71 . . 7-5 Meter, Battery/Discharge . . . . . . . . . . 00590-40959-71 . . 5-9 Meter, Hour . . . . . . . . . . . . . . . . . . . . 00590-01785-71 . . 5-9 Meter, Hour/Discharge . . . . . . . . . . . 00590-00610-71 . . 5-9 Module, Battery, 6 Volt . . . . . . . . . . . . 00590-40565-71 . 5-19 Motor Assembly, Drive . . . . . . . . . . . . 00590-40389-71 . 5-25 Motor Assembly, Drive . . . . . . . . . . . . 00590-40389-71 . . 4-6 Motor . . . . . . . . . . . . . . . . . . . . . . . . 00590-05338-71 . . 6-7 Nut . . . . . . . . . . . . . . . . . . . . . . . . . 00590-43542-71 . 5-13 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-00131-71 . . 3-9 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-00180-71 . . 3-9 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-03924-71 . . 2-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-39580-71 . . 4-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40377-71 . . 2-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40377-71 . . 4-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40394-71 . . 4-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40394-71 . . 4-5 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40394-71 . . 4-9 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40396-71 . . 3-3 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40396-71 . . 4-5

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1058725B, Final Issue 6/17/2008

Model 6HBW20 - Alphabetical Parts Index

Description

Part No.

Page

Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40420-71 . . 5-15 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40760-71 . . . 2-5 Nut, Clip . . . . . . . . . . . . . . . . . . . . . . 00590-40771-71 . . . 2-9 Nut, Clip . . . . . . . . . . . . . . . . . . . . . . 00590-43542-71 . . . 3-5 Nut, Flanged. . . . . . . . . . . . . . . . . . . . 00590-40678-71 . . 5-11 Nut, Flanged. . . . . . . . . . . . . . . . . . . . 00590-40678-71 . . 5-13 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . 00590-00943-71 . . . 4-6 Pad, Bumper . . . . . . . . . . . . . . . . . . . 00590-00215-71 . . . 3-3 Pad, Foam Rubber . . . . . . . . . . . . . . . . 00590-40691-71 . . 5-19 Panel, Electrical . . . . . . . . . . . . . . . . . . 00590-40786-71 . . . 5-5 Peg . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-04866-71 . . . 5-7 Pin, Cotter . . . . . . . . . . . . . . . . . . . . . 00590-03671-71 . . 5-13 Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 00590-40716-71 . . . 7-3 Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 00590-40717-71 . . . 7-3 Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 00590-40765-71 . . . 2-5 Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 00590-40765-71 . . . 7-3 Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 00590-40814-71 . . . 7-3 Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 00590-46754-71 . . . 7-3 Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 00590-46755-71 . . . 2-5 Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 00590-46755-71 . . . 7-3 Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 00590-46763-71 . . . 7-3 Pin, Link . . . . . . . . . . . . . . . . . . . . . . . 00590-46764-71 . . . 7-3 Pin, Pivot, Bell Crank . . . . . . . . . . . . . . 00590-40732-71 . . . 7-3 Pin, Pivot, Bell Crank . . . . . . . . . . . . . . 00590-46760-71 . . . 7-3 Pin, Roll . . . . . . . . . . . . . . . . . . . . . . . 00590-00205-71 . . . 3-5 Pin, Roll . . . . . . . . . . . . . . . . . . . . . . . 00590-01779-71 . . . 3-9 Pin, Sheave, Chain . . . . . . . . . . . . . . . 00590-00830-71 . . . 3-5 Pin, Spring . . . . . . . . . . . . . . . . . . . . . 00590-00114-71 . . . 3-7 Pin, Spring . . . . . . . . . . . . . . . . . . . . . 00590-00135-71 . . . 3-9 Pin, Spring . . . . . . . . . . . . . . . . . . . . . 00590-00136-71 . . . 3-9 Pin, Spring . . . . . . . . . . . . . . . . . . . . . 00590-00137-71 . . . 3-9 Plate Assembly, Cover . . . . . . . . . . . . . 00590-04754-71 . . 5-25 Plate, Backing . . . . . . . . . . . . . . . . . . 00590-43656-71 . . 4-11 Plate, Dial, Timer . . . . . . . . . . . . . . . . . 00590-04713-71 . . 5-17 Plate, Name . . . . . . . . . . . . . . . . . . . . 00590-40687-71 . . 5-19 Plate, Switch Backing . . . . . . . . . . . . . . 00590-03773-71 . . . 5-5 Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-00170-71 . . . 3-7 Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-41012-71 . . . 5-9 Plug, Drain/Fill . . . . . . . . . . . . . . . . . . 00590-40397-71 . . . 4-5 Plug, SB175, Black . . . . . . . . . . . . . . . 00590-40699-71 . . 5-21 Plug, SB175, Cables . . . . . . . . . . . . . . 00590-40630-71 . . 5-19 Plug, Vent with Micron Filter . . . . . . . . . 00590-04700-71 . . . 6-7 Potentiometer . . . . . . . . . . . . . . . . . . . 00590-01684-71 . . . 3-9 Pump and Motor Assembly . . . . . . . . . . 00590-40805-71 . . . 6-3 Pump Assembly, Lift . . . . . . . . . . . . . . . 00590-04555-71 . . . 6-7 Rectifier Assembly . . . . . . . . . . . . . . . . 00590-04710-71 . . 5-17 Rectifier Assembly . . . . . . . . . . . . . . . . 00590-40700-71 . . 5-21 Rectifier Assembly, SCR . . . . . . . . . . . . 00590-40701-71 . . 5-21 Resistor Assembly . . . . . . . . . . . . . . . . 00590-40871-71 . . . 5-5 Retainer . . . . . . . . . . . . . . . . . . . . . . . 00590-40402-71 . . . 4-5 Retainer . . . . . . . . . . . . . . . . . . . . . . . 00590-40770-71 . . . 2-9 Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40385-71 . . . 4-5 Ring, Holding, Cable, Metric. . . . . . . . . 00590-40758-71 . . . 2-5 Ring, Nilos, Large . . . . . . . . . . . . . . . . 00590-00908-71 . . . 4-5 Ring, Nilos, Small . . . . . . . . . . . . . . . . 00590-00907-71 . . . 4-5 Ring, Retaining . . . . . . . . . . . . . . . . . . 00590-00827-71 . . . 3-5 Ring, Retaining . . . . . . . . . . . . . . . . . . 00590-04745-71 . . 5-25 Ring, Safety . . . . . . . . . . . . . . . . . . . . 00590-03891-71 . . 4-11 Rod, Piston . . . . . . . . . . . . . . . . . . . . . 00590-40807-71 . . . 6-8 Rod, Pull, 36 in. Fork Length . . . . . . . . . 00590-40810-71 . . . 7-3 Rod, Pull, 36 in. Fork Length . . . . . . . . . 00590-46756-71 . . . 7-3

1058725B, Final Issue 6/17/2008

Description

Part No.

Page

Rod, Pull, 42 in. Fork Length . . . . . . . . . 00590-40811-71 . . . 7-3 Rod, Pull, 42 in. Fork Length . . . . . . . . . 00590-46757-71 . . . 7-3 Rod, Pull, 46 in. Fork Length . . . . . . . . . 00590-40812-71 . . . 7-3 Rod, Pull, 46 in. Fork Length . . . . . . . . . 00590-46758-71 . . . 7-3 Rod, Pull, 48 in. Fork Length . . . . . . . . . 00590-40813-71 . . . 7-3 Rod, Pull, 48 in. Fork Length . . . . . . . . . 00590-46759-71 . . . 7-3 Rod, Push . . . . . . . . . . . . . . . . . . . . . . 00590-40398-71 . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-03911-71 . . 5-11 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-03911-71 . . 5-13 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-46740-71 . . 5-13 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-00106-71 . . . 3-7 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-00129-71 . . . 3-9 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-00179-71 . . . 3-9 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-00954-71 . . . 3-9 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-00955-71 . . . 3-9 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-03911-71 . . . 2-9 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-03911-71 . . . 7-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-03915-71 . . . 2-9 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-03915-71 . . . 2-9 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-03915-71 . . 5-19 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-03915-71 . . . 5-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-03920-71 . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-40371-71 . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-40373-71 . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-40386-71 . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-40395-71 . . . 3-3 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-40395-71 . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-40401-71 . . . 4-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-40651-71 . . . 3-7 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-40652-71 . . . 3-7 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-40872-71 . . . 3-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-42657-71 . . . 2-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-46725-71 . . . 5-5 Screw . . . . . . . . . . . . . . . . . . . . . . . . 00590-46753-71 . . . 6-3 Screw, Fast Thread . . . . . . . . . . . . . . . 00590-40769-71 . . . 2-9 Screw, Set . . . . . . . . . . . . . . . . . . . . . 00590-00130-71 . . . 3-9 Screw, Set . . . . . . . . . . . . . . . . . . . . . 00590-03913-71 . . . 2-5 Screw, Set . . . . . . . . . . . . . . . . . . . . . 00590-03913-71 . . . 7-3 Screw, Set . . . . . . . . . . . . . . . . . . . . . 00590-03913-71 . . . 7-5 Screw, Set . . . . . . . . . . . . . . . . . . . . . 00590-40649-71 . . . 3-3 Screw, Top Cover . . . . . . . . . . . . . . . . 00590-04856-71 . . . 5-7 Seal. . . . . . . . . . . . . . . . . . . . . . . . . . 00590-04742-71 . . 5-25 Seal. . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40378-71 . . . 4-5 Set, Brush (4 per set) . . . . . . . . . . . . . . 00590-04748-71 . . 5-25 Set, Brush Holder and Springs. . . . . . . . 00590-05339-71 . . . 6-7 Set, Cord, AC . . . . . . . . . . . . . . . . . . 00590-04705-71 . . 5-17 Set, Spring, Brush (2 per set). . . . . . . . . 00590-04749-71 . . 5-25 Shaft, Actuator . . . . . . . . . . . . . . . . . . 00590-01780-71 . . . 3-9 Shaft, Handle Pivot Weldment . . . . . . . 00590-40648-71 . . . 3-3 Shaft, Wheel . . . . . . . . . . . . . . . . . . . 00590-40735-71 . . . 7-5 Shaft, Wheel . . . . . . . . . . . . . . . . . . . 00590-46383-71 . . . 7-5 Shaft, Wheel . . . . . . . . . . . . . . . . . . . 00590-46767-71 . . . 7-5 Sheave, Chain . . . . . . . . . . . . . . . . . . 00590-40554-71 . . . 3-5 Shim . . . . . . . . . . . . . . . . . . . . . . . . . 00590-00196-71 . . . 3-9 Shoe Assembly . . . . . . . . . . . . . . . . . . 00590-39575-71 . . 4-11 Shunt Assembly . . . . . . . . . . . . . . . . . . 00590-40702-71 . . 5-21 Spacer . . . . . . . . . . . . . . . . . . . . . . . . 00590-01770-71 . . . 3-9 Spacer . . . . . . . . . . . . . . . . . . . . . . . . 00590-40650-71 . . . 3-3 Spacer, Threaded . . . . . . . . . . . . . . . . 00590-00121-71 . . . 3-9 Spring . . . . . . . . . . . . . . . . . . . . . . . . 00590-00829-71 . . . 3-5 Spring . . . . . . . . . . . . . . . . . . . . . . . . 00590-40406-71 . . . 4-5

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A-3

Model 6HBW20 - Alphabetical Parts Index

Description

Part No.

Page

Spring, Compression . . . . . . . . . . . . . . 00590-00138-71. . 3-10 Spring, Compression . . . . . . . . . . . . . . 00590-00139-71. . . 3-9 Spring, Return. . . . . . . . . . . . . . . . . . . 00590-04862-71. . . 5-7 Spring, Return. . . . . . . . . . . . . . . . . . . 00590-39570-71. . 4-11 Spring, Torsion . . . . . . . . . . . . . . . . . . 00590-00140-71. . . 3-9 Strain Relief . . . . . . . . . . . . . . . . . . . . 00590-40703-71. . 5-21 Strain Relief, AC . . . . . . . . . . . . . . . . . 00590-04711-71. . 5-17 Strainer . . . . . . . . . . . . . . . . . . . . . . . 00590-46914-71. . . 6-7 Strap, Capacitor . . . . . . . . . . . . . . . . 00590-04702-71. . 5-17 Strip, Reinforcing . . . . . . . . . . . . . . . . 00590-01823-71. . . 4-5 Switch, Cutout, Brake/Lift . . . . . . . . . . 00590-03798-71. . . 5-5 Switch, Cutout, Brake/Lift . . . . . . . . . . 00590-40669-71. . . 5-5 Switch, Emergency Reverse . . . . . . . . . 00590-00952-71. . . 3-9 Switch, Key . . . . . . . . . . . . . . . . . . . . 00590-00538-71. . . 5-5 Switch, Key . . . . . . . . . . . . . . . . . . . . 00590-01843-71. . . 5-5 Switch, Main, On/Off . . . . . . . . . . . . . 00590-40983-71. . . 5-5 Switch, Push Button, Red . . . . . . . . . . . 00590-40704-71. . 5-21 Switch, Travel . . . . . . . . . . . . . . . . . . . 00590-00953-71. . . 3-9 Timer, 12 Hour, 60 Hz . . . . . . . . . . . . 00590-04635-71. . 5-17 Tire, Poly . . . . . . . . . . . . . . . . . . . . . . 00590-04583-71. . . 4-9 Tire, Rubber, Lugged, Black . . . . . . . . . 00590-41210-71. . . 4-9 Tire, Rubber, Smooth, Black . . . . . . . . . 00590-41212-71. . . 4-9 Tire, Rubber, Smooth, Black, Flat, Siped 00590-47957-71. . . 4-9 Tire, Rubber, Smooth, Black, Grip, Shell 00590-41209-71. . . 4-9 Tire, Rubber, Smooth, White, Non-Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00590-41211-71. . . 4-9 Tool, Maintenance, Programmable . . . . 00590-49981-71. . 5-26 Top Cover, Assembled. . . . . . . . . . . . . 00590-04861-71. . . 5-7 Transformer . . . . . . . . . . . . . . . . . . . . 00590-40705-71. . 5-21 Transformer, 24V, 15A, 120VAC, 60Hz 00590-04636-71. . 5-17 Tray Weldment, Left . . . . . . . . . . . . . . 00590-40899-71. . 5-13

A-4

Description

Part No.

Page

Tray Weldment, Right . . . . . . . . . . . . . 00590-40900-71 . 5-13 Tray . . . . . . . . . . . . . . . . . . . . . . . . . 00590-40682-71 . 5-19 Tube . . . . . . . . . . . . . . . . . . . . . . . . . 00590-41771-71 . . 3-5 Valve Assembly, Check . . . . . . . . . . . . 00590-05341-71 . . 6-7 Valve, Flow Control. . . . . . . . . . . . . . . 00590-04695-71 . . 6-7 Valve, Relief. . . . . . . . . . . . . . . . . . . . 00590-04893-71 . . 6-7 Valve, Stem . . . . . . . . . . . . . . . . . . . . 00590-04554-71 . . 6-7 Varistor . . . . . . . . . . . . . . . . . . . . . . 00590-04714-71 . 5-17 Varistor Assembly . . . . . . . . . . . . . . . . 00590-40706-71 . 5-21 Varistor . . . . . . . . . . . . . . . . . . . . . . . 00590-46743-71 . 5-21 Washer . . . . . . . . . . . . . . . . . . . . . . . 00590-00143-71 . . 3-9 Washer . . . . . . . . . . . . . . . . . . . . . . . 00590-40690-71 . 5-19 Washer . . . . . . . . . . . . . . . . . . . . . . . 00590-46707-71 . . 3-9 Washer, Flat . . . . . . . . . . . . . . . . . . . 00590-05149-71 . . 2-9 Washer, Flat . . . . . . . . . . . . . . . . . . . 00590-05149-71 . . 4-6 Washer, Flat . . . . . . . . . . . . . . . . . . . 00590-40147-71 . 5-13 Washer, Flat . . . . . . . . . . . . . . . . . . . 00590-40147-71 . 5-15 Washer, Flat . . . . . . . . . . . . . . . . . . . 00590-40388-71 . . 4-6 Washer, Lock . . . . . . . . . . . . . . . . . . 00590-00005-71 . 5-11 Washer, Lock . . . . . . . . . . . . . . . . . . 00590-40135-71 . 5-13 Washer, Lock . . . . . . . . . . . . . . . . . . . 00590-00133-71 . . 3-9 Washer, Lock . . . . . . . . . . . . . . . . . . . 00590-00134-71 . . 3-9 Washer, Lock . . . . . . . . . . . . . . . . . . . 00590-04689-71 . 5-19 Washer, Sealing . . . . . . . . . . . . . . . . 00590-40387-71 . . 4-5 Washer, Shake Proof . . . . . . . . . . . . . 00590-01679-71 . . 3-9 Washer, Spring . . . . . . . . . . . . . . . . . 00590-04752-71 . 5-25 Wheel, Load . . . . . . . . . . . . . . . . . . . 00590-00773-71 . . 7-5 Wheel, Load . . . . . . . . . . . . . . . . . . . 00590-00777-71 . . 7-5 Wheel, Load . . . . . . . . . . . . . . . . . . . 00590-00779-71 . . 7-5 Wheel, Load . . . . . . . . . . . . . . . . . . . 00590-46766-71 . . 7-5 Wrapper . . . . . . . . . . . . . . . . . . . . . . 00590-40902-71 . 5-13

Top of Section

1058725B, Final Issue 6/17/2008

APPENDIX B Part No.

Description

Numerical Parts Index Page

00590-00019-71 ... Fitting, Grease ...................................... 7-5 00590-00100-71 ... Grip, Hand............................................ 3-7 00590-00114-71 ... Pin, Spring............................................. 3-7 00590-00121-71 ... Spacer, Threaded ................................... 3-9 00590-00122-71 ... Gear, Potentiometer ................................ 3-9 00590-00135-71 ... Pin, Spring............................................. 3-9 00590-00136-71 ... Pin, Spring............................................. 3-9 00590-00137-71 ... Pin, Spring............................................. 3-9 00590-00138-71 ... Spring, Compression............................. 3-10 00590-00139-71 ... Spring, Compression............................... 3-9 00590-00140-71 ... Spring, Torsion ....................................... 3-9 00590-00141-71 ... Cover, Switch......................................... 3-9 00590-00148-71 ... Cover, Steering ...................................... 3-9 00590-00149-71 ... Bushing ................................................. 3-9 00590-00150-71 ... Bracket, Switch Assembly, Function ......... 3-10 00590-00170-71 ... Plug ...................................................... 3-7 00590-00196-71 ... Shim ..................................................... 3-9 00590-00202-71 ... Heater................................................... 3-9 00590-00205-71 ... Pin, Roll................................................. 3-5 00590-00215-71 ... Pad, Bumper ......................................... 3-3 00590-00538-71 ... Switch, Key............................................ 5-5 00590-00552-71 ... Fuse, 15 Amp ........................................ 5-5 00590-00581-71 ... Connector, Battery ................................ 5-15 00590-00581-71 ... Connector, Battery ................................ 5-17 00590-00610-71 ... Meter, Hour/Discharge .......................... 5-9 00590-00773-71 ... Wheel, Load ......................................... 7-5 00590-00777-71 ... Wheel, Load ......................................... 7-5 00590-00779-71 ... Wheel, Load ......................................... 7-5 00590-00799-71 ... Guard, Cable, 9.5 in............................ 5-11 00590-00825-71 ... Handle Assembly.................................... 3-3 00590-00825-71 ... Handle Assembly.................................... 3-5 00590-00827-71 ... Ring, Retaining....................................... 3-5 00590-00829-71 ... Spring................................................... 3-5 00590-00830-71 ... Pin, Sheave, Chain ................................. 3-5 00590-00833-71 ... Chain Assembly, Roller............................ 3-5 00590-00835-71 ... Link, Connecting..................................... 3-5 00590-00907-71 ... Ring, Nilos, Small................................... 4-5 00590-00908-71 ... Ring, Nilos, Large................................... 4-5 00590-00943-71 ... O-Ring .................................................. 4-6 00590-00949-71 ... Guard, Knuckle ...................................... 3-7 00590-00951-71 ... Cam, Controller...................................... 3-9 00590-00952-71 ... Switch, Emergency Reverse...................... 3-9 00590-00953-71 ... Switch, Travel......................................... 3-9 00590-00956-71 ... Kit, Adapter ........................................... 3-9 00590-00962-71 ... Bracket................................................ 3-10 00590-01258-71 ... Decal, Emergency Disconnect ................. 2-9 00590-01411-71 ... Button, Function, Horn............................. 3-9 00590-01412-71 ... Button, Function, Forks Lowered................ 3-9 00590-01413-71 ... Button, Function, Forks Lift........................ 3-9 00590-01416-71 ... Handle .................................................. 3-5 00590-01421-71 ... Knob, Butterfly ...................................... 3-7 00590-01422-71 ... Button, Nose Assembly............................ 3-9 00590-01435-71 ... Controller Assembly with Knuckle Guard ... 3-5 00590-01435-71 ... Controller Assembly with Knuckle Guard ... 3-7 00590-01436-71 ... Controller Assembly ............................... 3-9 00590-01436-71 ... Controller Assembly ................................ 3-7 00590-01437-71 ... Controller Assembly with Knuckle Guard ... 3-5 00590-01437-71 ... Controller Assembly with Knuckle Guard ... 3-7 00590-01438-71 ... Controller Assembly ............................... 3-7 00590-01438-71 ... Controller Assembly ............................... 3-9 00590-01443-71 ... Decal, Operating Manual........................ 2-9 00590-01573-71 ... Decal, Cable System, 24 Volt................. 5-11 00590-01574-71 ... Decal, Warning, Charging .................... 5-11 00590-01575-71 ... Decal, Warning, Battery Swivel ............ 5-11

1058725B, Final Issue 6/17/2008

Part No.

Description

Page

00590-01684-71... Potentiometer ......................................... 3-9 00590-01770-71... Spacer .................................................. 3-9 00590-01778-71... Lever, Return .......................................... 3-9 00590-01779-71... Pin, Roll ................................................ 3-9 00590-01780-71... Shaft, Actuator....................................... 3-9 00590-01785-71... Meter, Hour ........................................... 5-9 00590-01823-71... Strip, Reinforcing ................................... 4-5 00590-01843-71... Switch, Key ........................................... 5-5 00590-01929-71... Harness, Control .................................... 3-9 00590-01942-71... Decal, Warning .................................... 2-9 00590-01962-71... Block, Fuse ............................................ 5-5 00590-02365-71... Controller, Motor.................................... 5-5 00590-02415-71... Cable, 4k............................................ 5-26 00590-02416-71... Cable, 6 to 8k ..................................... 5-26 00590-03673-71... Fitting, Grease ...................................... 7-5 00590-03673-71... Fitting, Grease ....................................... 2-5 00590-03673-71... Fitting, Grease ....................................... 4-5 00590-03673-71... Fitting, Grease ....................................... 7-3 00590-03773-71... Plate, Switch Backing.............................. 5-5 00590-03798-71... Switch, Cutout, Brake/Lift ....................... 5-5 00590-03834-71... Brake Assembly .................................. 4-11 00590-03834-71... Brake Assembly ..................................... 4-5 00590-03847-71... Cable Tie .............................................. 4-6 00590-03847-71... Cable Tie ............................................ 5-15 00590-03891-71... Ring, Safety ........................................ 4-11 00590-04497-71... Decal, TOYOTA ..................................... 2-9 00590-04554-71... Valve, Stem ........................................... 6-7 00590-04555-71... Pump Assembly, Lift ................................ 6-7 00590-04559-71... Coil, 24 Volt .......................................... 6-7 00590-04577-71... Key, Set of 2.......................................... 5-5 00590-04583-71... Tire, Poly .............................................. 4-9 00590-04633-71... Fuse Assembly, DC .............................. 5-17 00590-04634-71... Fuse, Fuselink, DC ............................... 5-17 00590-04635-71... Timer, 12 Hour, 60 Hz ......................... 5-17 00590-04636-71... Transformer, 24V, 15A, 120VAC, 60Hz 5-17 00590-04656-71... Link Assembly, Upper.............................. 2-5 00590-04695-71... Valve, Flow Control ................................ 6-7 00590-04700-71... Plug, Vent with Micron Filter .................... 6-7 00590-04701-71... Ammeter ............................................ 5-17 00590-04702-71... Strap, Capacitor ................................. 5-17 00590-04703-71... Capacitor, 440 VAC ............................ 5-17 00590-04704-71... Case, Pallet, Main ............................... 5-17 00590-04705-71... Set, Cord, AC ..................................... 5-17 00590-04707-71... Diode, 20A ........................................ 5-17 00590-04710-71... Rectifier Assembly ............................... 5-17 00590-04711-71... Strain Relief, AC .................................. 5-17 00590-04712-71... Knob, Timer ........................................ 5-17 00590-04713-71... Plate, Dial, Timer.................................. 5-17 00590-04714-71... Varistor .............................................. 5-17 00590-04736-71... Bearing, Drive End ................................. 6-7 00590-04742-71... Seal.................................................... 5-25 00590-04745-71... Ring, Retaining .................................... 5-25 00590-04747-71... Kit, Field Coil....................................... 5-25 00590-04748-71... Set, Brush (4 per set)............................. 5-25 00590-04749-71... Set, Spring, Brush (2 per set) ................. 5-25 00590-04754-71... Plate Assembly, Cover........................... 5-25 00590-04861-71... Top Cover, Assembled ............................ 5-7 00590-04862-71... Spring, Return........................................ 5-7 00590-04863-71... Contact, Movable, Assembled ................. 5-7 00590-04864-71... Contact, Fixed ....................................... 5-7 00590-04865-71... Insulator ................................................ 5-7 00590-04866-71... Peg ...................................................... 5-7 00590-04893-71... Valve, Relief........................................... 6-7 00590-04980-71... Kit, Hardware........................................ 5-7

B-1

Model 6HBW20 - Numerical Parts Index

Part No.

Description

Page

00590-05133-71 ...Bearing, Super, Oil-Impregnated...............7-5 00590-05134-71 ...Bushing, Iron .........................................2-5 00590-05134-71 ...Bushing, Iron ..........................................7-3 00590-05286-71 ...Lever, Brake ........................................4-11 00590-05338-71 ...Motor ....................................................6-7 00590-05339-71 ...Set, Brush Holder and Springs ..................6-7 00590-05340-71 ...Kit, Service, Start Switch ..........................6-7 00590-05341-71 ...Valve Assembly, Check ............................6-7 00590-05342-71 ...Kit, Adapter ...........................................6-7 00590-05343-71 ...Kit, Reservoir, with Tubes (Steel)................6-7 00590-05344-71 ...Coupling ...............................................6-7 00590-05345-71 ...Kit, Seal.................................................6-7 00590-39538-71 ...Battery Pack, GNB, Maintenance Free, ........ .............................24V ...................................................5-19 00590-39570-71 ...Spring, Return ......................................4-11 00590-39571-71 ...Cam ...................................................4-11 00590-39575-71 ...Shoe Assembly ....................................4-11 00590-39877-71 ...Cover, Brake ..........................................4-5 00590-39940-71 ...Charger...............................................5-19 00590-39940-71 ...Charger...............................................5-21 00590-40295-71 ...Breaker, Circuit, 80 Amp .........................5-5 00590-40301-71 ...Kit, Reservoir, with Tubes (Plastic)..............6-7 00590-40307-71 ...Breaker, Circuit, 15A ............................5-21 00590-40367-71 ...Bolt, Chain Anchor..................................3-3 00590-40367-71 ...Bolt, Chain Anchor..................................4-5 00590-40368-71 ...Arm, Brake ............................................4-5 00590-40369-71 ...Case Assembly, Gear ..............................4-5 00590-40370-71 ...Bushing, Flanged ....................................3-3 00590-40374-71 ...Drum, Brake ...........................................4-5 00590-40375-71 ...Gear, Drive ...........................................4-5 00590-40376-71 ...Gear, Pinion...........................................4-5 00590-40378-71 ...Seal ......................................................4-5 00590-40379-71 ...Key .......................................................4-5 00590-40381-71 ...Bolt, Special...........................................4-5 00590-40382-71 ...Bearing, Cup/Cone ................................4-5 00590-40383-71 ...Bearing, Handle .....................................4-5 00590-40384-71 ...Bearing, Ball ..........................................4-5 00590-40385-71 ...Ring ......................................................4-5 00590-40389-71 ...Motor Assembly, Drive.............................4-6 00590-40389-71 ...Motor Assembly, Drive...........................5-25 00590-40391-71 ...Bearing, Cup/Cone, Pivot, Large..............4-6 00590-40392-71 ...Bearing, Cup/Cone, Pivot, Small ..............4-6 00590-40393-71 ...Gear, Idle ..............................................4-6 00590-40397-71 ...Plug, Drain/Fill .......................................4-5 00590-40398-71 ...Rod, Push...............................................4-5 00590-40399-71 ...Dowel ...................................................4-5 00590-40400-71 ...Cover, Gear...........................................4-5 00590-40402-71 ...Retainer .................................................4-5 00590-40403-71 ...Clamp, Cable.........................................3-5 00590-40403-71 ...Clamp, Cable.........................................4-5 00590-40405-71 ...Drive Unit ..............................................4-5 00590-40406-71 ...Spring ...................................................4-5 00590-40407-71 ...Fork/Joint Combination ...........................4-5 00590-40408-71 ...Guard, Wheel, Rubber ............................4-5 00590-40408-71 ...Guard, Wheel, Rubber ............................4-5 00590-40409-71 ...Battery, 6 Volt ......................................5-15 00590-40422-71 ...Grommet ............................................5-15 00590-40425-71 ...Boot, Terminal ......................................5-15 00590-40554-71 ...Sheave, Chain........................................3-5 00590-40565-71 ...Module, Battery, 6 Volt .........................5-19 00590-40584-71 ...Charger, 15 Amp .................................5-21 00590-40630-71 ...Plug, SB175, Cables .............................5-19 00590-40636-71 ...Bearing, Commutator End ........................6-7 00590-40648-71 ...Shaft, Handle Pivot Weldment .................3-3 00590-40650-71 ...Spacer ..................................................3-3 00590-40653-71 ...Bracket ..................................................3-9 00590-40654-71 ...Link, Connecting .....................................3-5 00590-40657-71 ...Hub Machining, Wheel ...........................4-9

B-2

Part No.

Description

Page

00590-40669-71 ... Switch, Cutout, Brake/Lift ....................... 5-5 00590-40670-71 ... Horn Assembly....................................... 5-5 00590-40674-71 ... Battery Pack, 24 Volt (Wet Battery) ......... 5-11 00590-40675-71 ... Battery Pack, 24 Volt (Wet Battery) ......... 5-11 00590-40680-71 ... Door Weldment, Battery Box ................. 5-13 00590-40682-71 ... Tray .................................................... 5-19 00590-40683-71 ... Cable, Battery, Internal.......................... 5-19 00590-40684-71 ... Grommet, Rubber ................................. 5-19 00590-40685-71 ... Label, Champion .................................. 5-19 00590-40686-71 ... Label, Warning .................................... 5-19 00590-40687-71 ... Plate, Name......................................... 5-19 00590-40688-71 ... Bolt..................................................... 5-19 00590-40691-71 ... Pad, Foam Rubber ................................ 5-19 00590-40692-71 ... Case, Back, Large Cell.......................... 5-21 00590-40693-71 ... Case, Main, Large Cell ......................... 5-21 00590-40694-71 ... Case, Top, Large Cell............................ 5-21 00590-40695-71 ... Circuit, 2400 24V 25A 55T, with Cord .. 5-21 00590-40696-71 ... Cord Assembly, DC .............................. 5-21 00590-40697-71 ... Cord Assembly, AC .............................. 5-21 00590-40698-71 ... Bracket, Mounting, Plug ........................ 5-21 00590-40699-71 ... Plug, SB175, Black ............................... 5-21 00590-40700-71 ... Rectifier Assembly ................................ 5-21 00590-40701-71 ... Rectifier Assembly, SCR ........................ 5-21 00590-40702-71 ... Shunt Assembly .................................... 5-21 00590-40703-71 ... Strain Relief ......................................... 5-21 00590-40704-71 ... Switch, Push Button, Red........................ 5-21 00590-40705-71 ... Transformer.......................................... 5-21 00590-40706-71 ... Varistor Assembly ................................. 5-21 00590-40708-71 ... Head, Drive End................................... 5-25 00590-40709-71 ... Bearing, Drive End and Commutator End 5-25 00590-40710-71 ... Armature ............................................. 5-25 00590-40711-71 ... Box Assembly, Brush ............................. 5-25 00590-40712-71 ... Kit, Brush Lead Assembly ...................... 5-25 00590-40713-71 ... Head, Commutator End ........................ 5-25 00590-40714-71 ... Bolt, Through ......................................... 6-7 00590-40716-71 ... Pin, Link ................................................ 7-3 00590-40717-71 ... Pin, Link ................................................ 7-3 00590-40732-71 ... Pin, Pivot, Bell Crank............................... 7-3 00590-40733-71 ... Load Wheel Assembly ............................ 7-5 00590-40734-71 ... Fork Machining, Trail .............................. 7-5 00590-40735-71 ... Shaft, Wheel.......................................... 7-5 00590-40758-71 ... Ring, Holding, Cable, Metric ................... 2-5 00590-40761-71 ... Bar, Skid, Adjustable .............................. 2-5 00590-40765-71 ... Pin, Link ................................................ 2-5 00590-40765-71 ... Pin, Link ................................................ 7-3 00590-40766-71 ... Bracket, Mounting, Key Switch ................ 2-9 00590-40767-71 ... Decal, No Riding ................................... 2-9 00590-40768-71 ... Bracket, Mounting, Cover ........................ 2-9 00590-40770-71 ... Retainer................................................. 2-9 00590-40772-71 ... Cover, Front, Orange.............................. 2-9 00590-40773-71 ... Cover, Internal ....................................... 2-9 00590-40774-71 ... Backrest Weldment, Load, 48 in. High .... 2-10 00590-40775-71 ... Backrest Weldment, Load, 60 in. High .... 2-10 00590-40776-71 ... Contactor, Main ..................................... 5-5 00590-40777-71 ... Cable Assembly (CB Auxiliary to P1) ........ 5-5 00590-40778-71 ... Cable Assembly (B- to MP2)..................... 5-5 00590-40779-71 ... Cable Assembly (B+ to M1-2) .................. 5-5 00590-40780-71 ... Cable Assembly (M1-1 to A2) .................. 5-5 00590-40781-71 ... Cable Assembly (M- to A1) ...................... 5-5 00590-40782-71 ... Cable Assembly (A2 to A2) ..................... 5-5 00590-40783-71 ... Cable Assembly (M1-4 to S1) .................. 5-5 00590-40784-71 ... Cable Assembly (M1-2 to S2) .................. 5-5 00590-40785-71 ... Bar, Bus (CB Auxiliary to M1-1)................ 5-5 00590-40786-71 ... Panel, Electrical...................................... 5-5 00590-40789-71 ... Harness, Main ....................................... 5-5 00590-40790-71 ... Bar, Bus (M1-2 to M2-3) .......................... 5-5 00590-40791-71 ... Contactor Assembly, Forward and Reverse 5-5 00590-40791-71 ... Contactor Assembly, Forward and Reverse 5-7

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1058725B, Final Issue 6/17/2008

Model 6HBW20 - Numerical Parts Index

Part No.

Description

Page

00590-40792-71 ... Frame and Coil Assembly without Bracket . 5-7 00590-40793-71 ... Bracket, Mounting .................................. 5-7 00590-40795-71 ... Cable, B- ............................................... 5-5 00590-40796-71 ... Cable, B+.............................................. 5-5 00590-40797-71 ... Decal, Cable System, 24 Volt................. 5-11 00590-40798-71 ... Decal, Warning, Charging .................... 5-11 00590-40799-71 ... Decal, Warning, Battery Swivel ............ 5-11 00590-40802-71 ... Fitting, Elbow ......................................... 6-3 00590-40803-71 ... Hose Assembly....................................... 6-3 00590-40805-71 ... Lift Pump and Motor Assembly ................. 6-7 00590-40805-71 ... Pump and Motor Assembly ...................... 6-3 00590-40807-71 ... Rod, Piston ........................................... 6-8 00590-40809-71 ... Kit, Seal ................................................ 6-8 00590-40810-71 ... Rod, Pull, 36 in. Fork Length .................... 7-3 00590-40811-71 ... Rod, Pull, 42 in. Fork Length .................... 7-3 00590-40812-71 ... Rod, Pull, 46 in. Fork Length .................... 7-3 00590-40813-71 ... Rod, Pull, 48 in. Fork Length .................... 7-3 00590-40814-71 ... Pin, Link ................................................ 7-3 00590-40815-71 ... Link, Lower ............................................ 7-3 00590-40816-71 ... Link, Lower ............................................ 7-3 00590-40817-71 ... Bearing, Shield ...................................... 7-5 00590-40842-71 ... Decal, Warning, TOYOTA ....................... 2-9 00590-40871-71 ... Resistor Assembly ................................... 5-5 00590-40899-71 ... Tray Weldment, Left .............................. 5-13 00590-40900-71 ... Tray Weldment, Right ............................ 5-13 00590-40901-71 ... Edging ................................................ 5-13 00590-40902-71 ... Wrapper ............................................. 5-13 00590-40910-71 ... Bracket................................................ 5-19 00590-40959-71 ... Meter, Battery/Discharge ........................ 5-9 00590-40983-71 ... Switch, Main, On/Off............................. 5-5 00590-41012-71 ... Plug ...................................................... 5-9 00590-41209-71 ... Tire, Rubber, Smooth, Black, Grip, Shell .... 4-9 00590-41210-71 ... Tire, Rubber, Lugged, Black ..................... 4-9 00590-41211-71 ... Tire, Rubber, Smooth, White, Non-Marking 4-9 00590-41212-71 ... Tire, Rubber, Smooth, Black ..................... 4-9 00590-41592-71 ... Bearing, Double Sealed .......................... 7-5 00590-41771-71 ... Tube ..................................................... 3-5 00590-42304-71 ... Cylinder, Hydraulic................................. 6-3 00590-42656-71 ... Bracket, Retainer .................................... 2-5 00590-43049-71 ... Bracket, Brake Switch ............................. 4-5 00590-43049-71 ... Bracket, Brake Switch ............................. 5-5

1058725B, Final Issue 6/17/2008

Part No.

Description

Page

00590-43050-71... Charger Assembly ............................... 5-17 00590-43276-71... Bushing, Poly ......................................... 7-3 00590-43331-71... Decal, Steam Clean................................ 2-9 00590-43503-71... Cylinder, Hydraulic ................................ 6-8 00590-43550-71... Bushing ................................................ 2-5 00590-43608-71... Anchor, Spring, Brake ............................ 4-5 00590-43656-71... Plate, Backing ..................................... 4-11 00590-45248-71... Connector, Battery.................................. 5-5 00590-45639-71... Cable Assembly ................................... 5-15 00590-45644-71... Cable Assembly ................................... 5-15 00590-45712-71... Barrel Assembly .................................... 6-8 00590-46378-71... Cable Assembly ................................... 5-15 00590-46383-71... Shaft, Wheel ......................................... 7-5 00590-46415-71... Battery ................................................ 5-23 00590-46706-71... Bracket ................................................. 3-9 00590-46737-71... Harness, Wiring (Lift Interrupt) ................. 5-9 00590-46741-71... Cable Assembly ................................... 5-15 00590-46742-71... Cable Assembly ................................... 5-15 00590-46743-71... Varistor ............................................... 5-21 00590-46745-71... Battery Pack ........................................ 5-23 00590-46746-71... Charger .............................................. 5-23 00590-46747-71... Kit, Cable............................................ 5-23 00590-46754-71... Pin, Link ............................................... 7-3 00590-46755-71... Pin, Link ............................................... 2-5 00590-46755-71... Pin, Link ............................................... 7-3 00590-46756-71... Rod, Pull, 36 in. Fork Length .................... 7-3 00590-46757-71... Rod, Pull, 42 in. Fork Length .................... 7-3 00590-46758-71... Rod, Pull, 46 in. Fork Length .................... 7-3 00590-46759-71... Rod, Pull, 48 in. Fork Length .................... 7-3 00590-46760-71... Pin, Pivot, Bell Crank .............................. 7-3 00590-46761-71... Link, Lower ............................................ 7-3 00590-46762-71... Link, Lower ............................................ 7-3 00590-46763-71... Pin, Link ............................................... 7-3 00590-46764-71... Pin, Link ............................................... 7-3 00590-46765-71... Fork Machining, Trail.............................. 7-5 00590-46766-71... Wheel, Load ......................................... 7-5 00590-46767-71... Shaft, Wheel ......................................... 7-5 00590-46914-71... Strainer ................................................. 6-7 00590-47957-71... Tire, Rubber, Smooth, Black, Flat, Siped .... 4-9 00590-49981-71... Tool, Maintenance, Programmable ......... 5-26

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B-3

Model 6HBW20 - Numerical Parts Index

B-4

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1058725B, Final Issue 6/17/2008

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