006 0C

Parts Manual
ESR4000 Series
812674_U1.p65 1 05.11.02, 09:36
TABLE OF CONTENT
Printed in Germany
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Printed in Germany
M1.0-0000-0002
M1.0-0000-0002
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TABLE OF CONTENT
Table of Content
ITD – INTRODUCTION PAGE SERIAL NR. CUT REV.

Allgemeines ........................................................................... 7
SECTION 1 – COVERS PAGE SERIAL NR. CUT REV.

Covers................................................................................... 12,14,16 .................................................... Rev.1 10/02
Reach Carriage ..................................................................... 18,20 ......................................................... Rev.1 10/02
Load Wheel ........................................................................... 22
Battery Latch ........................................................................ 24 .............................................................. Rev.1 10/02
Battery Reach Out ................................................................ 26,28
Seat & Pan ............................................................................ 30 .............................................................. Rev.1 10/02
Seat ....................................................................................... 32
Rear Mirror ............................................................................ 34
Guide Wheels ........................................................................ 36
SECTION 2 – HYDRAULIC PART PAGE SERIAL NR. CUT REV.

Tube-/Hose Layout ................................................................ 40 .............................................................. Rev.1 10/02
Hydraulic Tank ....................................................................... 42 .............................................................. Rev.2 10/02
Hydraulic TT Mast ................................................................. 44,46 ......................................................... Rev.1 10/02
Valve Block ........................................................................... 48,50 ......................................................... Rev.1 10/02
Reach Manifold ..................................................................... 52
Hydraulic Motor ..................................................................... 54
Pump ..................................................................................... 56
Pump Motor and Pump ......................................................... 58 .............................................................. Rev.1 10/02
Pump Motor ........................................................................... 60
Fan ........................................................................................ 62
SECTION 3 – DRIVE UNIT PAGE SERIAL NR. CUT REV.

Drive Unit .............................................................................. 66,68 ......................................................... Rev.1 10/02
Turntable ................................................................................ 70
Gearbox ................................................................................. 72 .............................................................. Rev.1 10/02
Drive Motor ........................................................................... 74
Fan ........................................................................................ 76 .............................................................. Rev.1 10/02
SECTION 4 – ELECTRICAL PAGE SERIAL NR. CUT REV.

Electrical Compartment ........................................................ 80,82,84 .................................................... Rev.1 10/02
Contactors............................................................................. 86
Mast Wiring ........................................................................... 88,90 ......................................................... Rev.1 10/02
Switch HGTS Lift Speed Reduction ...................................... 92 .............................................................. Rev.1 10/02
Height Encoder ..................................................................... 94,96 ......................................................... Rev.1 10/02
Joystick and Emergency Disconnector Switch ..................... 98 .............................................................. Rev.1 10/02
Direction Switch/Horn Button ................................................ 100 ............................................................ Rev.1 10/02
Floorplate .............................................................................. 102 ............................................................ Rev.1 10/02
Accelerator ............................................................................ 104 ............................................................ Rev.1 10/02
Dead Man Pedal .................................................................... 106 ............................................................ Rev.1 10/02
DC/DC Converter .................................................................. 108
Dash Panel ............................................................................ 110 ............................................................ Rev.1 10/02
Display Module ...................................................................... 112 ............................................................ Rev.1 10/02
Steer Indicator ....................................................................... 114
Flashing Beacon .................................................................... 116
Working Light ........................................................................ 118,120
Reverse Alarm ...................................................................... 122
MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany M/P-IDX-2140

REV. 2 10/02
M1.0-0000-0003
3
TABLE OF CONTENT
Horn ...................................................................................... 124 ............................................................ Rev.1 10/02
Cooling System ..................................................................... 126
SECTION5 – BRAKE SYSTEM PAGE SERIAL NR. CUT REV.

Brake Circuit ......................................................................... 130 ............................................................ Rev.1 10/02
Foot Brake ............................................................................. 132
Drive Motor Brake ................................................................. 134
Load Wheel Brake ................................................................. 136
Brake Cylinder ...................................................................... 138 ............................................................ Rev.1 10/02
SECTION 6 – STEERING PAGE SERIAL NR. CUT REV.

Steering Column .................................................................... 142,144,146 .............................................. Rev.1 10/02
SECTION 7 – MAST-/LIFT STRUCTURE PAGE SERIAL NR. CUT REV.

TT Mast 1.4t/1.6t ................................................................... 150,152 ..................................................... Rev.1 10/02
TT Mast 2.0t .......................................................................... 154,156 ..................................................... Rev.1 10/02
Lift Chain TT Mast ................................................................. 158,160 ..................................................... Rev.1 10/02
Tilt/Sideshift .......................................................................... 162,164,166 .............................................. Rev.1 10/02
Tilt/Sideshift-Hydraulic .......................................................... 168,170,172 .............................................. Rev.2 10/02
Lift Buffer ............................................................................... 174 ............................................................ Rev.1 10/02
Fork ....................................................................................... 176 ............................................................ Rev.1 10/02
Load Backrest ....................................................................... 178
Yoke ...................................................................................... 180 ............................................................ Rev.1 10/02
SECTION 8 – CYLINDER PAGE SERIAL NR. CUT REV.

Lift Cylinder 1.4t/1.6t ............................................................. 184
Lift Cylinder 2.0t .................................................................... 186 ............................................................ Rev.1 10/02
Free Lift Cylinder 1.4t/1.6t ..................................................... 188 ............................................................ Rev.1 10/02
Free Lift Cylinder 2.0t ............................................................ 190 ............................................................ Rev.1 10/02
Cylinder Reach ..................................................................... 192 ............................................................ Rev.1 10/02
SECTION10 – MISCELLANEOUS SERVICE INF. PAGE SERIAL NR. CUT REV.

Labels and Decals ................................................................. 196
M/P-IDX-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV. 2 10/02
4 4M1.0-0000-0004
INTRODUCTION
Printed in Germany
5
Printed in Germany
M1.0-0000-0006
M1.0-0000-0006
6
INTRODUCTION
Important customer information Ordering Spare Parts

To ensure the safety of the truck, you, the customer, Spare parts can be ordered by quoting:
must only carry out maintenance and repairs as
stipulated in the operator manual. ● The truck specification number
Any additional work must be performed by Crown ● The truck model number
authorised service technicians. Authorised service
technicians have the required expertise and up-to-date ● The truck serial number
service information.
This information can be found on the truck's data plate.
If you wish to have your own technicians trained, Only if this information is provided can the order be
please contact Crown for relevant training courses. processed quickly, correctly and reliably.
Subsequent Attachments and Modifications Please refer to the Technical Specifications Sheet for
made to the Truck the utilisable loads, technical data and dimensions for
this series. Brochures can be obtained from your
DANGER! CROWN dealer or from the following address:
Any proposed modification which would

alter the original condition of the truck CROWN Gabelstapler GmbH
when delivered, must first be assessed and Moosacher Str. 52
approved in writing by Crown Gabelstapler 80809 Munich
GmbH. GERMANY
Tel.: +49 (0)89 / 93 002 -0
● The net weight and position of Fax: +49 (0)89 / 93 002 -175 oder 133
attachments may considerably affect the
capacity and other truck characteristics.
● Changing the electrical system or adding
electrically operated components may
result in operating faults.
Modifications which have not been assessed may
result in fatal accidents!
MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany M/P-ITD-2140
M1.0-0000-0007
7
Printed in Germany
8
PARTS
Printed in Germany
9
Printed in Germany
10M1.0-0000-00010
SECTION 1
Printed in Germany
11
COVERS
M1576
MP-1.1-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

REV.1 10/02
12M1.0-0000-00012
COVERS
INDEX PART NUMBER PART NAME NUMBER REQUIRED
1 ..................... 791764-003 ............................ Grab Handle .......................................................................................... 1

2 ..................... 050067-023 ............................ Screw ...................................................................................................... 1
3 ..................... 050068-003 ............................ Nut .......................................................................................................... 4
4 ..................... 806686 .................................... Corner Cover ......................................................................................... 1
5 ..................... 050071-035 ............................ Screw ...................................................................................................... 4
807053-002 ............................ Clip ......................................................................................................... 4
6 ..................... 807089 .................................... Display Overlay ...................................................................................... 1
7 ..................... 807459 .................................... Hose Cover ............................................................................................ 1
8 ..................... 807352 .................................... Headrest Pad ......................................................................................... 1
050004-020 ............................ Screw ...................................................................................................... 4
9 ..................... 050068-004 ............................ Nut .......................................................................................................... 1
10 ................... 806931 .................................... Leg Pad .................................................................................................. 1
053050-012 ............................ Adhesive Tape ....................................................................................... AR
11 ................... 796328 .................................... Overhead Guard .................................................................................... 1
050067-053 ............................ Screw ...................................................................................................... 2
050068-006 ............................ Nut .......................................................................................................... 2
Always Specify Model & Serial Number
MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany MP-1.1-2140

REV. 1 10/02
13
COVERS
M1575
14M1.0-0000-00014
COVERS
1 ........................................................................ Instrumentation ...................................................................................... 1

(see Section 4.9)
2* .................... 806689 .................................... Armrest Pad ........................................................................................... 1
3* .................... 807098 .................................... Armrest Moulding ................................................................................... 1
796489 .................................... Armrest Moulding (6th Function Valve) ................................................. 1
4* .................... 050067-012 ............................ Screw ...................................................................................................... 5
5 ..................... 050071-035 ............................ Screw ...................................................................................................... 3
050009-020 ............................ Washer ................................................................................................... 2
6 ..................... 806973 .................................... Screen .................................................................................................... 1
7 ..................... 050068-003 ............................ Nut .......................................................................................................... 3
8 ..................... 806859 .................................... Plate ....................................................................................................... 1
796023 .................................... Plate (Drive in Racking) ........................................................................ 1
9 ..................... 050008-030 ............................ Nut .......................................................................................................... 3
807053-002 ............................ Insert ....................................................................................................... 3
10 ................... 806499 .................................... Cover ...................................................................................................... 1
11 ................... 050071-035 ............................ Screw ...................................................................................................... 3
12 ................... 807765 .................................... Clamp ..................................................................................................... 2
13 ................... 052068-002 ............................ Spacer .................................................................................................... 4
14 ................... 807764 .................................... Clamp ..................................................................................................... 2
15 ................... 050008-008 ............................ Nut .......................................................................................................... 3
* ..................... 806929 .................................... Armrest Assembly .................................................................................. 1

(inclusive 2-4, without 796489)

REV. 1 10/02
15
COVERS
MP-2140-020
16M1.0-0000-00016
COVERS
1 ..................... 790797-001 ............................ Block, Skid (A = 33mm) ......................................................................... 2

790797-002 ............................ Block, Skid (A = 26mm) ......................................................................... 2
2 ..................... 790798 .................................... Screw ...................................................................................................... 2
3 ..................... 810637-001 ............................ Wear Strips (1.4t/1285mm Leg Width/Load Wheel Æ 285mm) ........... 2
810637-002 ............................ Wear Strips (1.6t & 2.0t/1285mm Leg Width/Load Wheel Æ 285mm) . 2
810637-003 ............................ Wear Strips (1.6t & 2.0t/1285mm Leg Width/Load Wheel Æ 330mm) . 2
810637-004 ............................ Wear Strips (1.4t/1425&1575mm Leg Width/Load Wheel Æ 285mm) 2
810637-005 ............................ Wear Strips ............................................................................................. 2
(1.6t & 2.0t/1425&1575mm Leg Width/Load Wheel Æ 285)
810637-006 ............................ Wear Strips ............................................................................................. 2
(1.6t & 2.0t/1425&1575mm Leg Width/Load Wheel Æ 330)
4 ..................... 050003-043 ............................ Screw ...................................................................................................... 2
5 ..................... 050005-068 ............................ Screw ...................................................................................................... 2
6 ..................... 050009-026 ............................ Washer ................................................................................................... 2
17
REACH CARRIAGE
M1496
18M1.0-0000-00018
REACH CARRIAGE
1 ..................... 806409 .................................... Reach Carriage (1285mm Leg Width) .................................................. 1

807413 .................................... Reach Carriage (1425mm Leg Width) .................................................. 1
807414 .................................... Reach Carriage (1575mm Leg Width) .................................................. 1
2 ..................... 806886 .................................... Plate ....................................................................................................... 2
3 ..................... 060030-085 ............................ Shim ....................................................................................................... 10
810203 .................................... Shim ....................................................................................................... 2
4 ..................... 050005-075 ............................ Screw ...................................................................................................... 8
5 ..................... 807323 .................................... Shim ....................................................................................................... 8
807407 .................................... Washer ................................................................................................... 2
6 ..................... 050067-056 ............................ Screw ...................................................................................................... 2
050068-007 ............................ Nut .......................................................................................................... 2
7 ..................... 807525 .................................... Clamp ..................................................................................................... 1
8 ..................... 050003-035 ............................ Screw ...................................................................................................... 2
9 ..................... 807522 .................................... Clamp ..................................................................................................... 1
10 ................... 791483-001 ............................ Roller (Æ 93,6mm) ................................................................................ 4
791483-002 ............................ Roller (Æ 93,9mm) ................................................................................ 4
790332 .................................... Grease Nipple ........................................................................................ 4
11 ................... 060019-023 ............................ Screw ...................................................................................................... 16
12 ................... 810211-001 ............................ Shim (0,5mm) ......................................................................................... AR
810211-002 ............................ Shim (2,0mm) ......................................................................................... AR
13 ................... 806408 .................................... Skid Bar (16mm) .................................................................................... 4
810245 .................................... Skid Bar (19mm) .................................................................................... 4
14 ................... 050067-025 ............................ Screw ...................................................................................................... 8
15* ................... 796405 .................................... Bracket ................................................................................................... 1
16* ................... 050003-018 ............................ Screw ...................................................................................................... 2
17* ................... 790350 .................................... Magnet ................................................................................................... 2
050009-003 ............................ Washer ................................................................................................... 5
18* ................... 050008-001 ............................ Nut .......................................................................................................... 4
19* ................... 050003-043 ............................ Screw ...................................................................................................... 2
20 ...................................................................... Cylinder Reach (see Section. 8.5) ........................................................ 1
21 ................... 806467-009 ............................ Hose ....................................................................................................... 1
22 ................... 806467-012 ............................ Hose ....................................................................................................... 1
23* ................... 807486 .................................... Clamp ..................................................................................................... 1
24* ................... 807312 .................................... Bracket ................................................................................................... 1
25* ................... 050003-017 ............................ Screw ...................................................................................................... 2
26* ................... 807487-001 ............................ Proximity Switch Assembly .................................................................... 1
808122 .................................... Cable Assembly (RES) .................................................................... 1
792880-002 ............................. Socket Housing .......................................................................... 1
792882 ..................................... Socket Insert ............................................................................... 2
793090-002 ............................. Anti-Backout ............................................................................... 1
27 ................... 806429 .................................... Washer ................................................................................................... 4
28 ................... 806427 .................................... Pin .......................................................................................................... 2
29 ................... 792973 .................................... Pin Split .................................................................................................. 2
30 ................... 050006-026 ............................ Screw ...................................................................................................... 2
31 ................... 790375 .................................... Drag Link ................................................................................................ 1
32 ................... 791476-001 ............................ Drag Link Mouting Bracket .................................................................... 1
33 ................... 806779 .................................... Plate ....................................................................................................... 1
34 ................... 050003-060 ............................ Screw (1285mm Leg Width) .................................................................. 2
050003-035 ............................ Screw (1425/1575mm Leg Width) ........................................................ 2
35 ................... 790592 .................................... Drag Link Mounting Bracket .................................................................. 1
36 ................... 050068-003 ............................ Nut .......................................................................................................... 2

REV. 1 10/02
19
REACH CARRIAGE
M1496
20M1.0-0000-00020
REACH CARRIAGE
37* ................... 050003-012 ............................ Screw ...................................................................................................... 1

38* ................... 793288 .................................... Clip ......................................................................................................... 1
39* ................... 050008-008 ............................ Nut .......................................................................................................... 1
* ..................... 796406 .................................... Reach Slowdown Assembly (inclusive 15-19,23-26, 37-39) ............... 1
Not illustrated
796180 .................................... Cable Assembly (Freezer/Corriosion) ................................................... 1

796172 .................................... Bracket (Reach Carriage/Freezer/Corriosion) ...................................... 1
050008-008 ............................ Nut (Reach Carriage/Freezer/Corriosion) ............................................ 3
08089 ...................................... Cable Assembly (Chassis -Mast) .......................................................... 1
055058-003 ............................ Buffer (for Reach Carriage 807413 & 807414) .................................... 2
055058-005 ............................ Buffer (for Reach Carriage 806409) ..................................................... 2
050068-003 ............................ Nut .......................................................................................................... 2

REV. 1 10/02
21
LOAD WHEEL
MP-2140-015
22M1.0-0000-00022
LOAD WHEEL
0 ..................... 810576-001 ............................ Load Wheel Assembly Æ 285mm/1,4t .................................................. 2

810602-001 ............................ Load Wheel Assembly Æ 330mm/1,6t & 2,0t ....................................... 2
810576-002 ............................ Load Wheel Assembly Æ 285mm/1,4t (Freezer/Corrosion) ................. 2
810602-002 ............................ Load Wheel Assembly Æ 330mm/1,6t & 2,0t (Freezer/Corrosion) ...... 2
1 ........................... 807095 .................................... Load Wheel Cap .............................................................................. 2
2 ........................... 050012-009 ............................. Circlip ............................................................................................... 2
3 ........................... 790520 .................................... Washer ............................................................................................. 2
4* .......................... 050012-015 ............................. Circlip ............................................................................................... 2
5* .......................... 807655 .................................... Washer ............................................................................................. 2
6* .......................... 790519 .................................... Roller Bearing .................................................................................. 2
7* .......................... 810577 .................................... Spacer .............................................................................................. 2
8* .......................... 810574-001 ............................. Load Wheel Æ 285mm/1,4t ............................................................. 2
810583-001 ............................. Load Wheel Æ 330mm/1,6t & 2,0t ................................................... 2
810574-002 ............................. Load Wheel Æ 285mm/1,4t (Freezer/Corrosion) ............................ 2
810583-002 ............................. Load Wheel Æ 330mm/1,6t & 2,0t (Freezer/Corrosion) .................. 2
9* .......................... 790517 .................................... Needle Bearing ................................................................................ 2
10* ......................... 050012-051 ............................. Circlip ............................................................................................... 2
11 ......................... 050005-088 ............................. Screw ................................................................................................ 12
12 ......................... 810564 .................................... Brake Assy (see Section 5.6) .......................................................... 1
13 ......................... 810382 .................................... Stud Axle .......................................................................................... 2
14 ......................... 790528 .................................... End Block ......................................................................................... 2
15 ......................... 050005-033 ............................. Screw ................................................................................................ 4
16 ......................... 793333 .................................... Clip ................................................................................................... 4
17 ......................... 810598 .................................... Brake Guard 1,4t .............................................................................. 2
810597 .................................... Brake Guard 1,6t & 2,0t .................................................................... 2
18 ......................... 050071-020 ............................. Screw ................................................................................................ 4
* ........................... 810575-001 ............................. Loadwheel Æ 285mm & Bearing 1,4t Assembly (inclusive 4-10) 2
* ........................... 810601-001 ............................. Loadwheel Æ 330mm & Bearing 1,6t &2,0t Assembly ................... 2
(inclusive 4-10)
* ........................... 810575-002 Loadwheel Æ 285mm & Bearing 1,4t Assembly (inclusive 4-10) 2
* ........................... 810601-002 ............................. Loadwheel Æ 330mm & Bearing 1,6t &2,0t Assembly ................... 2
(inclusive 4-10)
Option: Load Wheel Æ 285mm for 1,6t & 2,0t only available out of Factory
23
BATTERY LOCK
M1580
24M1.0-0000-00024
BATTERY LOCK
0 ..................... 807530-001 ............................ Battery Lock ........................................................................................... 1

1 ........................... 807531 .................................... Lever ................................................................................................. 1
2 ........................... 807535 .................................... Bearing ............................................................................................. 1
3 ........................... 051058-014 ............................. Bushing ............................................................................................ 1
4 ........................... 050073-004 ............................. Spring Nut ........................................................................................ 5
5 ........................... 050070-002 ............................. Screw ................................................................................................ 5
6 ........................... 807534 .................................... Link ................................................................................................... 1
7 ........................... 050007-009 ............................. Screw ................................................................................................ 2
8 ........................... 050008-018 ............................. Nut .................................................................................................... 2
9 ........................... 807536 .................................... Bracket ............................................................................................. 1
10 ......................... 807542-001 ............................. Shim (1mm) ...................................................................................... 2
807542-002 ............................. Shim(0,6mm) .................................................................................... 1
11 ......................... 050068-004 ............................. Nut .................................................................................................... 4
12 ......................... 803310 .................................... Actuator Roller ................................................................................. 1
13 ......................... 792991 .................................... Microswitch ....................................................................................... 1
14 ......................... 050004-034 ............................. Screw ................................................................................................ 2
15 ......................... 807541 .................................... Plate .................................................................................................. 1
16 ......................... 050009-002 ............................. Washer ............................................................................................. 2
17 ......................... 050008-008 ............................. Nut .................................................................................................... 1
18 ......................... 793288 .................................... Clip ................................................................................................... 1
19 ......................... 050003-013 ............................. Screw ................................................................................................ 1
20 ......................... 051058-005 ............................. Bushing ............................................................................................ 2
21 ......................... 807539 .................................... Spring ............................................................................................... 1
22 ......................... 051058-015 ............................. Bushing ............................................................................................ 2
23 ......................... 807538 .................................... Spring ............................................................................................... 1
24 ......................... 807537 .................................... Spacer .............................................................................................. 1
25 ......................... 807786 .................................... Bracket ............................................................................................. 1
26 ......................... 806827 .................................... Shaft .................................................................................................. 1
27 ......................... 050000-069 ............................. Roll Pin ............................................................................................. 1
28 ......................... 806819 .................................... Shaft .................................................................................................. 1
29 ......................... 050000-025 ............................. Roll Pin ............................................................................................. 1
30 ......................... 050071-036 ............................. Screw ................................................................................................ 1
31 ......................... 050008-024 ............................. Nut .................................................................................................... 1
32 ......................... 050009-026 ............................. Washer ............................................................................................. 1
807540 .................................... Battery Lock (inclusive 1-3,6-9,12-24,26-29) ................................. 1

REV. 1 10/02
25
BATTERY REACH OUT
MP-2140-005
26M1.0-0000-00026
BATTERY REACH OUT
1 ..................... 807841 .................................... Battery Cover extension (Battery 560Ah) ............................................. 1

807842 .................................... Battery Cover extension (Battery 700Ah) ............................................. 1
810227 .................................... Battery Cover extension (Battery 820Ah) ............................................. 1
2 ..................... 050071-035 ............................ Screw ...................................................................................................... 4
3 ..................... 050068-003 ............................ Nut .......................................................................................................... 4
4 ..................... 810338-001 ............................ Battery Support (Battery 420Ah) ........................................................... 1
810338-002 ............................ Battery Support (Battery 560Ah) ........................................................... 1
5 ..................... 807451 .................................... Plate (1285/1425mm Leg Width, Trucks without Battery Rollers) ........ 4
808023 .................................... Plate (1575mm Leg Width, Trucks without Battery Rollers) ................. 4
6 ..................... 050003-051 ............................ Screw ...................................................................................................... 8
7 ..................... 807860-001 ............................ Skid Block (1285mm Leg Width) ........................................................... 4
807860-002 ............................ Skid Block (1425mm Leg Width) ........................................................... 4
807860-003 ............................ Skid Block (1575mm Leg Width) ........................................................... 4
8 ..................... 050005-025 ............................ Screw ...................................................................................................... 8
9 ..................... 806408 .................................... Skid Bar .................................................................................................. 4
10 ................... 050007-017 ............................ Screw ...................................................................................................... 4
11 ................... 055058-002 ............................ Buffer ...................................................................................................... 2
12 ................... 807938 .................................... Shim ....................................................................................................... 2
13 ................... 807937 .................................... Spacer .................................................................................................... AR
14 ................... 050008-015 ............................ Nut .......................................................................................................... 4
15 ................... 796380 .................................... Spacer Plate (only for 1575mm Leg Width) .......................................... 1
16 ................... 050006-027 ............................ Screw (only for 1575mm Leg Width) ..................................................... 1
17 ................... 050008-015 ............................ Nut (only for 1575mm Leg Width) ......................................................... 1
18 ................... 050003-052 ............................ Screw ...................................................................................................... 1
19 ................... 806349 .................................... Shaft ....................................................................................................... 1
20 ................... 051058-013 ............................ Bushing .................................................................................................. 1
21 ................... 796388 .................................... Latch ....................................................................................................... 1
22 ................... 808081 .................................... Shim ....................................................................................................... 2
23 ................... 807864 .................................... Washer ................................................................................................... 1
24 ................... 050068-005 ............................ Nut .......................................................................................................... 3
25 ................... 810241 .................................... Cam ........................................................................................................ 1
26 ................... 808465 .................................... Cam-Protection ...................................................................................... 1
27 ................... 810251 .................................... Bracket (only for Battery 820Ah) ........................................................... 1
28 ................... 806824 .................................... Pin .......................................................................................................... 1
29 ................... 050067-056 ............................ Screw (only for Battery 820Ah) ............................................................. 2
30 ................... 050068-007 ............................ Nut (only for Battery 820Ah) .................................................................. 2
31 ................... 050070-001 ............................ Screw ...................................................................................................... 2
32 ................... 810437 .................................... Plate ....................................................................................................... 1
33 ................... 050068-004 ............................ Nut .......................................................................................................... 2
34 ................... 055058-003 ............................ Buffer ...................................................................................................... 2
055058-004 ............................ Buffer (only for Battery 420Ah & 1285mm Leg Width) ......................... 2
35 ................... 050009-020 ............................ Washer ................................................................................................... 2
050009-025 ............................ Washer (only for Battery 420Ah & 1285mm Leg Width) ...................... 2
36 ................... 050008-024 ............................ Nut .......................................................................................................... 2
050008-030 ............................ Nut (only for Battery 420Ah & 1285mm Leg Width) .............................. 2
37 ................... 807939 .................................... Pin .......................................................................................................... 1
38 ................... 806837 .................................... Spring ..................................................................................................... 1
39 ................... 050003-050 ............................ Screw ...................................................................................................... 4
40 ................... 810428 .................................... Clamp (only for Battery 420Ah & 560Ah) ............................................. 1
810432 .................................... Clamp (only for Battery 700Ah & 820Ah) ............................................. 1
41 ................... 810429 .................................... Bracket ................................................................................................... 1
42 ................... 810427-001 ............................ Clamp (LH/only for Battery 420Ah & 560Ah) ........................................ 1
810427-002 ............................ Clamp (RH/only for Battery 420Ah & 560Ah) ....................................... 1
810431-001 ............................ Clamp (LH/only for Battery 700Ah & 820Ah) ........................................ 1
810431-002 ............................ Clamp (RH/only for Battery 700Ah & 820Ah) ....................................... 1
43 ................... 810390 .................................... Washer ................................................................................................... 1
44 ................... 810317 .................................... Lever ...................................................................................................... 1
27
BATTERY REACH OUT
MP-2140-005
28M1.0-0000-00028
BATTERY REACH OUT
For Trucks with Battery Rollers
45 ................... 804207 .................................... Roller ...................................................................................................... 6

46 ................... 804681 .................................... Bearing Ball ........................................................................................... 12
47 ................... 804208 .................................... Roller Axle ............................................................................................. 6
29
SEAT & PAN
M1484

REV. 1 10/02
30M1.0-0000-00030
SEAT & PAN
0 ..................... 806493-001 ............................ Seat & Pan (black cloth) ........................................................................ 1

806493-003 ............................ Seat & Pan (PVC) .................................................................................. 1
806493-005 ............................ Seat & Pan (48V Heated Cushion & Backrest) .................................... 1
1 .............................................................................. Seat (see Section Seat) ................................................................... 1
2 ........................... 806454 .................................... Seat Pan ........................................................................................... 1
3 ........................... 050005-064 ............................. Screw ................................................................................................ 4
4 ........................... 050008-024 ............................. Nut .................................................................................................... 4
5 ........................... 791469 .................................... Seat Moulding .................................................................................. 1
6 ........................... 050006-035 ............................. Screw ................................................................................................ 7
7 ........................... 791466 .................................... Handle Pocket .................................................................................. 1
8 ........................... 791635 .................................... Vice Action Latch ............................................................................. 1
9 ........................... 808945 .................................... Stay ................................................................................................... 1
10 ......................... 810326 .................................... Bracket ............................................................................................. 1
11 ......................... 808947 .................................... Bracket ............................................................................................. 1
12 ......................... 808949 .................................... Pin ..................................................................................................... 1
13 ......................... 050073-004 ............................. Washer ............................................................................................. 1
14 ......................... 050070-001 ............................. Screw ................................................................................................ 1
807865 .................................... Pan Mounting (inclusive 2,5,6) ........................................................ 1
Not illustrated
795289 .................................... Cable Seat ....................................................................................... 1

REV. 1 10/02
31
SEAT
M1573
32M1.0-0000-00032
SEAT
0 ..................... 807433-001 ............................ Seat (black cloth) .................................................................................. 1

807433-003 ............................ Seat (PVC) ............................................................................................ 1
807433-005 ............................ Seat (PVC/ Heated) ............................................................................... 1
1 ........................... 791653-001 ............................. Pad (only for 807433-001) ............................................................... 1
808493 .................................... Pad (only for 807433-003) ............................................................... 1
808494 .................................... Pad (only for 807433-005) ............................................................... 1
2 ........................... 791653-002 ............................. Pad (only for 807433-001) ............................................................... 1
808495 .................................... Pad (only for 807433-003) ............................................................... 1
808496 .................................... Pad (only for 807433-005) ............................................................... 1
3 ........................... 791691-001 ............................. Seat Back ......................................................................................... 1
4 ........................... 791691-002 ............................. Seat Plate ......................................................................................... 1
5 ........................... 791691-003 ............................. Attachment ....................................................................................... 3
6 ........................... 791691-004 ............................. Frame Seat ....................................................................................... 1
7 ........................... 791691-005 ............................. Wear Strips ....................................................................................... 1
8 ........................... 791691-006 ............................. Cover ................................................................................................ 1
9 ........................... 791691-007 ............................. Cable Assembly ............................................................................... 1
10 ......................... 791691-008 ............................. Latch Adjustment .............................................................................. 1
11 ......................... 791691-009 ............................. Cover Suspension ........................................................................... 1
12 ......................... 791691-010 ............................. Repair Kit .......................................................................................... 1
13 ......................... 791691-011 ............................. Weight Adjustment ........................................................................... 1
14 ......................... 791691-012 ............................. Latch (inclusive 13) .......................................................................... 1
15 ......................... 808497 .................................... Slide Non Locking ........................................................................... 1
16 ......................... 808498 .................................... Slide Locking (inclusive 29) ............................................................ 1
17 ......................... 791691-015 ............................. Support inner .................................................................................... 1
18 ......................... 791691-016 ............................. Support outer .................................................................................... 1
19 ......................... 791691-017 ............................. Buffer Kit ........................................................................................... 1
20 ......................... 791691-018 ............................. Latch ................................................................................................. 1
21 ......................... 791691-019 ............................. Bracket Weight Adjustment .............................................................. 1
22 ......................... 808499 .................................... Spring ............................................................................................... 1
23 ......................... 791691-021 ............................. Latch ................................................................................................. 1
24 ......................... 791691-022 ............................. Dashpot Assembly ........................................................................... 1
25 ......................... 791691-023 ............................. Bracket ............................................................................................. 1
26 ......................... 808500 .................................... Spring ............................................................................................... 2
27 ......................... 808501 .................................... Seat Switch Assembly (inclusive 26) .............................................. 1
28 ......................... 808502 .................................... Cover Assembly ............................................................................... 1
29 ......................... 807434 .................................... Cover Rail ........................................................................................ 1
Not illustrated
808503 .................................... Harness (only for Heated Seat) ....................................................... 1
33
REAR MIRROR
MP-2140-012
34M1.0-0000-00034
REAR MIRROR
0 ..................... 796090 .................................... Rear Mirror ............................................................................................. 1

1 ........................... 050005-062 ............................. Screw ................................................................................................ 2
053050-006 ............................. Adhesive .......................................................................................... AR
2 ........................... 795977 .................................... Clamp ............................................................................................... 1
3 ........................... 795438 .................................... Bracket ............................................................................................. 1
4 ........................... 795442 .................................... Adjuster ............................................................................................ 1
5 ........................... 050005-022 ............................. Screw ................................................................................................ 1
6 ........................... 050008-026 ............................. Nut .................................................................................................... 1
7 ........................... 793779 .................................... Mirror ................................................................................................ 1
795437 .................................... Mirror Assembly (inclusive 3-7) ....................................................... 1
35
GUIDE WHEELS
MP-2140-017
36M1.0-0000-00036
GUIDE WHEELS
0 ..................... 796057-001 ............................ Guide Wheels (A=25mm) ...................................................................... 4

796057-002 ............................ Guide Wheels (A=30mm) ...................................................................... 4
796057-003 ............................ Guide Wheels (A=35mm) ...................................................................... 4
796057-004 ............................ Guide Wheels (A=40mm) ...................................................................... 4
796057-005 ............................ Guide Wheels (A=45mm) ...................................................................... 4
796057-006 ............................ Guide Wheels (A=50mm) ...................................................................... 4
796057-007 ............................ Guide Wheels (A=55mm) ...................................................................... 4
796057-008 ............................ Guide Wheels (A=60mm) ...................................................................... 4
796057-009 ............................ Guide Wheels (A=65mm) ...................................................................... 4
796057-010 ............................ Guide Wheels (A=70mm) ...................................................................... 4
796057-011 ............................ Guide Wheels (A=75mm) ...................................................................... 4
796057-012 ............................ Guide Wheels (A=80mm) ...................................................................... 4
796057-013 ............................ Guide Wheels (A=85mm) ...................................................................... 4
796057-014 ............................ Guide Wheels (A=90mm) ...................................................................... 4
1 ........................... 796050-001 ............................. Shim (1,omm) ................................................................................... AR
796050-002 ............................. Shim (3,omm) ................................................................................... AR
2 ........................... 796046-001 ............................. Bracket (A=25mm) ........................................................................... 4
796046-002 ............................. Bracket (A=30mm) ........................................................................... 4
796046-003 ............................. Bracket (A=35mm) ........................................................................... 4
796046-004 ............................. Bracket (A=40mm) ........................................................................... 4
796046-005 ............................. Bracket (A=45mm) ........................................................................... 4
796046-006 ............................. Bracket (A=50mm) ........................................................................... 4
796046-007 ............................. Bracket (A=55mm) ........................................................................... 4
3 ........................... 050067-044 ............................. Screw ................................................................................................ 16
4* .......................... 050012-067 ............................. Circlip ............................................................................................... 8
5* .......................... 055002-025 ............................. Bearing Ball ...................................................................................... 4
6* .......................... 796146 .................................... Rim ................................................................................................... 4
796147 .................................... Wheel ................................................................................................ 4
7 ........................... 050012-056 ............................. Circlip ............................................................................................... 4
8 ........................... 796051-001 ............................. Bracket (A=60mm) ........................................................................... 4
796051-002 ............................. Bracket (A=65mm) ........................................................................... 4
796051-003 ............................. Bracket (A=70mm) ........................................................................... 4
796051-004 ............................. Bracket (A=75mm) ........................................................................... 4
796051-005 ............................. Bracket (A=80mm) ........................................................................... 4
796051-006 ............................. Bracket (A=85mm) ........................................................................... 4
796051-007 ............................. Bracket (A=90mm) ........................................................................... 4
* ........................... 796049 .................................... Wheel Assembly (inclusive 4-6) ...................................................... 4
37
Printed in Germany
38M1.0-0000-00038
SECTION 2
Printed in Germany
39
TUBE/HOSE LAYOUT
M1675-gb

REV.1 10/02
40M1.0-0000-00040
TUBE/HOSE LAYOUT
1 ..................... 807315 .................................... Bracket ................................................................................................... 1

2 ..................... 807901 .................................... Cover ...................................................................................................... 1
3 ..................... 050006-024 ............................ Screw ...................................................................................................... 3
4 ..................... 050078-002 ............................ Rivet ....................................................................................................... 2
5 ..................... 793288 .................................... Clip ......................................................................................................... 2
6 ..................... 050003-011 ............................ Screw ...................................................................................................... 2
050008-008 ............................ Nut .......................................................................................................... 2
7 ..................... 050006-050 ............................ Screw ...................................................................................................... 4
8 ..................... 050008-030 ............................ Nut .......................................................................................................... 6
9 ..................... 050006-048 ............................ Screw ...................................................................................................... 2
10 ................... 807406 .................................... Reach Manifold (see Section 2.10) ...................................................... 1
11 ................... 806467-009 ............................ Hose ....................................................................................................... 1
12 ................... 806467-012 ............................ Hose ....................................................................................................... 1
13 ................... 806467-018 ............................ Hose ....................................................................................................... 1
14 ................... 806467-010 ............................ Hose ....................................................................................................... 1
15 ................... 806467-003 ............................ Hose ....................................................................................................... 1
16 ................... 806467-016 ............................ Hose ....................................................................................................... 1
17 ................... 807846 .................................... Hose ....................................................................................................... 1
18 ................... 806467-005 ............................ Hose ....................................................................................................... 1
19 ................... 806467-011 ............................ Hose ....................................................................................................... 1
20 ................... 806467-001 ............................ Hose ....................................................................................................... 1
21 ................... 806467-002 ............................ Hose ....................................................................................................... 1
22 ................... 806467-014 ............................ Hose ....................................................................................................... 1
23 ................... 806467-015 ............................ Hose ....................................................................................................... 1
24 ................... 806467-007 ............................ Hose ....................................................................................................... 1
25 ................... 806878 .................................... Priority Valve (see Section 2.13) ........................................................... 1
26 ................... 806359 .................................... Bracket ................................................................................................... 1
27 ................... 050070-004 ............................ Screw ...................................................................................................... 2
28 ................... 050008-030 ............................ Nut .......................................................................................................... 2
29 ................... 060017-007 ............................ Screw ...................................................................................................... 2
30 ................... 811727 .................................... Valve Block (see Section 2.10) ............................................................. 1
31 ................... 807874 .................................... Bracket ................................................................................................... 1
32 ................... 060017-016 ............................ Screw ...................................................................................................... 1
33 ................... 806467-004 ............................ Hose ....................................................................................................... 1
34 ................... 807500 .................................... Clamp ..................................................................................................... 1
050006-031 ............................ Screw ...................................................................................................... 1
35 ................... 807475 .................................... Clamp ..................................................................................................... 1
050006-023 ............................ Screw ...................................................................................................... 1
36 ................... 054191-001 ............................ Clip ......................................................................................................... 2
37 ................... 054191-002 ............................ Clip ......................................................................................................... 1
38 ................... 050008-015 ............................ Nut .......................................................................................................... 3
39 ................... 810252 .................................... Plate ....................................................................................................... 1
Not illustrated
806467-006 ............................ Hose (Steer Unit - Steer Motor) ............................................................. 2

064103-058 ............................ Hose (LD Connection) ........................................................................... 1
064128-002 ............................ Cap Valve Block (D) ............................................................................... AR

REV. 1 10/02
41
HYDRAULIC TANK
M1502

REV.1 10/02
42M1.0-0000-00042
HYDRAULIC TANK
0 ..................... 806442-001 ............................ Hydraulic Tank Assembly ...................................................................... 1

1 ........................... 807464 .................................... Tank .................................................................................................. 1
804859-002 ............................. Rubber .............................................................................................. 2
2 ........................... 808360 .................................... Mat .................................................................................................... 1
3 ........................... 055053-003 ............................. Pin ..................................................................................................... 2
4 ........................... 806846 .................................... Clamp ............................................................................................... 1
5 ........................... 050008-024 ............................. Nut .................................................................................................... 2
6 ........................... 807978 .................................... Clamp ............................................................................................... 1
7 ........................... 050008-030 ............................. Nut .................................................................................................... 1
8 ........................... 050009-026 ............................. Washer ............................................................................................. 1
9 ........................... 050070-001 ............................. Screw ................................................................................................ 1
10 ......................... 806845 .................................... Clamp ............................................................................................... 1
11 ......................... 050009-014 ............................. Washer ............................................................................................. 2
12 ......................... 050006-024 ............................. Screw ................................................................................................ 2
13 ......................... 806842 .................................... Suction Line ..................................................................................... 1
14 ......................... 806835 .................................... Gasket ............................................................................................... 1
15 ......................... 050006-026 ............................. Screw ................................................................................................ 7
16 ......................... 793539 .................................... Seal Bonded .................................................................................... 1
17 ......................... 793192 .................................... Suction Filter .................................................................................... 1
18 ......................... 808413 .................................... Filter Assembly ................................................................................. 1
808504 .................................... Filter Element ................................................................................... 1
808505 .................................... Cap Breather .................................................................................... 1
19 ......................... 050008-021 ............................. Nut .................................................................................................... 2
791415-020 ............................. Washer ............................................................................................. 2
20 ......................... 808298 .................................... Adapter ............................................................................................. 1
053050-021 ............................. Teflon-Tape ....................................................................................... AR
21 ......................... 807990 .................................... Heat Shield ....................................................................................... 1
807471 .................................... Tank Assembly (inclusive 1,13-21) ................................................. 1

REV. 2 10/02
43
HYDRAULIC TT MAST
M1614-gb

REV.1 10/02
44M1.0-0000-00044
HYDRAULIC TTMAST
1 ........................................................................ Outermast (see Page 7.5)

2 ........................................................................ Lift Cylinder (see Page 8.1)
3 ........................................................................ 1 st Stage Mast (see Page 7.5)
4 ........................................................................ Free Lift Cylinder (see Page 8.2)
5 ..................... 807070 .................................... Manifold Block ....................................................................................... 1
6 ..................... 050070-003 ............................ Screw ...................................................................................................... 2
7 ..................... 050073-005 ............................ Washer ................................................................................................... 2
8 ..................... 050008-038 ............................ Nut .......................................................................................................... 2
9 ..................... 064004-015 ............................ Adaptor ................................................................................................... 2
10 ................... 064004-001 ............................ Adaptor ................................................................................................... 2
11 ................... 807326 .................................... Pipe ........................................................................................................ 2
12 ................... 064061-003 ............................ Elbow ...................................................................................................... 2
13 ................... 806992 .................................... Hose Burst Valve .................................................................................... 2
14 ................... 064091-001 ............................ Plug ........................................................................................................ 2
15 ................... 806157 .................................... Pipe ........................................................................................................ 1
050006-024 ............................ Screw ...................................................................................................... 2
050008-015 ............................ Nut .......................................................................................................... 2
16 ................... 807062-001-** ........................ Hose (see next Page) ............................................................................ 1
17 ................... 807320 .................................... Bracket ................................................................................................... 1
18 ................... 050006-040 ............................ Screw ...................................................................................................... 1
19 ................... 050068-003 ............................ Nut .......................................................................................................... 1
20 ...................................................................... Pulley Hose (see Page 7.6)
21 ................... 806158 .................................... Pipe ........................................................................................................ 1
22 ................... 050006-036 ............................ Screw ...................................................................................................... 2
23 ................... 050008-024 ............................ Nut .......................................................................................................... 2
24 ................... 064061-016 ............................ Elbow ...................................................................................................... 1
25 ................... 807075 .................................... Bracket ................................................................................................... 1
050006-024 ............................ Screw ...................................................................................................... 2
050008-015 ............................ Nut .......................................................................................................... 2
26 ................... 054176-001 ............................ Adaptor ................................................................................................... 8
27 ................... 807072-*** .............................. Pipe (see next Page) ............................................................................. 1
29 ................... 807076-001 ............................ Bracket ................................................................................................... 1
050006-040 ............................ Screw ...................................................................................................... 1
050068-003 ............................ Nut .......................................................................................................... 1
30 ................... 807062-002-** ........................ Hose ....................................................................................................... 2
31 ................... 807078 .................................... Bracket ................................................................................................... 1
050006-036 ............................ Screw ...................................................................................................... 2
050008-024 ............................ Nut .......................................................................................................... 2
34 ................... 807062-003-** ........................ Hose (see next Page) ............................................................................ 2
35 ................... 810534 .................................... Plate ....................................................................................................... 1
Not illustrated
808996 .................................... Clamp ..................................................................................................... AR

051051-009 ............................ Cable Tie ................................................................................................ AR

REV. 1 10/02
45
HYDRAULIC TT MAST
1.4t/1.6t
Position 16 Position 30 Position 34 Collapsed Height
807062-001-01 807062-002-01 807062-003-01 2022mm
807062-001-02 807062-002-02 807062-003-02 2172mm
807062-001-03 807062-002-03 807062-003-03 2322mm
807062-001-04 807062-002-04 807062-003-04 2472mm
807062-001-05 807062-002-05 807062-003-05 2572mm
807062-001-06 807062-002-06 807062-003-06 2772mm
807062-001-07 807062-002-07 807062-003-07 2922mm
807062-001-08 807062-002-08 807062-003-08 3042mm
807062-001-09 807062-002-09 807062-003-09 3192mm
807062-001-10 807062-002-10 807062-003-10 3347mm
807062-001-11 807062-002-11 807062-003-11 3492mm
807062-001-12 807062-002-12 807062-003-12 3692mm
807062-001-13 807062-002-13 807062-003-13 3842mm
807062-001-14 807062-002-14 807062-003-14 3952mm
Tab013-gb
Position 27 Position 28 Position 32 Position 33 Collapsed Height
807072-001 807074-001 806160-001 806161-001 2022mm
807072-002 807074-002 806160-002 806161-002 2172mm
807072-003 807074-003 806160-003 806161-003 2322mm
807072-004 807074-004 806160-004 806161-004 2472mm
807072-005 807074-005 806160-005 806161-005 2572mm
807072-006 807074-006 806160-006 806161-006 2772mm
807072-007 807074-007 806160-007 806161-007 2922mm
807072-008 807074-008 806160-008 806161-008 3042mm
807072-009 807074-009 806160-009 806161-009 3192mm
807072-010 807074-010 806160-010 806161-010 3347mm
807072-011 807074-011 806160-011 806161-011 3492mm
807072-012 807074-012 806160-012 806161-012 3692mm
807072-013 807074-013 806160-013 806161-013 3842mm
807072-014 807074-014 806160-014 806161-014 3952mm
Tab015-gb
46M1.0-0000-00046
HYDRAULIC TTMAST
2.0t
807062-001-01 807062-002-01 807062-003-01 2022mm
807062-001-02 807062-002-02 807062-003-02 2172mm
807062-001-04 807062-002-04 807062-003-04 2472mm
807062-001-06 807062-002-06 807062-003-06 2772mm
807062-001-07 807062-002-07 807062-003-07 2922mm
807062-001-08 807062-002-08 807062-003-08 3042mm
807062-001-10 807062-002-10 807062-003-10 3347mm
807062-001-12 807062-002-12 807062-003-12 3692mm
807062-001-13 807062-002-13 807062-003-13 3842mm
807062-001-14 807062-002-14 807062-003-14 3952mm
807062-001-15 807062-002-15 807062-003-15 4252mm
807062-001-16 807062-002-16 807062-003-16 4452mm
Tab014-gb
Position 27 Position 28 Position 32 Position 33 Collapsed Height
807072-001 807074-001 806160-001 806161-001 2022mm
807072-002 807074-002 806160-002 806161-002 2172mm
807072-004 807074-004 806160-004 806161-004 2472mm
807072-006 807074-006 806160-006 806161-006 2772mm
807072-007 807074-007 806160-007 806161-007 2922mm
807072-008 807074-008 806160-008 806161-008 3042mm
807072-010 807074-010 806160-010 806161-010 3347mm
807072-012 807074-012 806160-012 806161-012 3692mm
807072-013 807074-013 806160-013 806161-013 3842mm
807072-014 807074-014 806160-014 806161-014 3952mm
807072-015 807074-015 806160-015 806161-015 4252mm
807072-016 807074-016 806160-016 806161-016 4452mm
Tab016-gb
47
VALVE BLOC
M1509
48M1.0-0000-00048
VALVE BLOC
1 ........................................................................ Valve Block (not available as spare part) ............................................. 1

2 ..................... 064091-006 ............................ Plug ........................................................................................................ 1
3 ..................... 064143-003 ............................ Elbow ...................................................................................................... 1
4 ..................... 064091-007 ............................ Plug ........................................................................................................ 1
5 ..................... 064061-016 ............................ Elbow ...................................................................................................... 1
6 ..................... 064091-002 ............................ Plug ........................................................................................................ 10
7 ..................... 064061-014 ............................ Elbow ...................................................................................................... 1
8 ..................... 123261 .................................... Compensator Hoist ................................................................................ 1
111790-010 ............................ Kit Seal ................................................................................................... 1
9 ..................... 808506 .................................... Valve Relief Accessory .......................................................................... 1
111790-003 ............................ Kit Seal ................................................................................................... 1
10 ................... 064091-006 ............................ Plug ........................................................................................................ 2
123270-001 ............................ Orifice ..................................................................................................... 2
11 ................... 064004-001 ............................ Connector .............................................................................................. 1
12 ................... 064010-001 ............................ Branch Tee Coupling ............................................................................. 1
13 ................... 064061-002 ............................ Elbow ...................................................................................................... 2
14 ................... 064091-004 ............................ Plug ........................................................................................................ 1
123270-004 ............................ Orifice ..................................................................................................... 1
15 ................... 123255-002 ............................ Check Valve ........................................................................................... 1
111790-012 ............................ Kit Seal ................................................................................................... 1
16 ................... 808507 .................................... Plug ........................................................................................................ 2
17 ................... 123255-001 ............................ Check Valve ........................................................................................... 1
111790-009 ............................ Kit Seal ................................................................................................... 1
18 ................... 117913-002 ............................ Valve Relief Hoist .................................................................................. 1
111790-003 ............................ Kit Seal ................................................................................................... 1
19 ................... 117305-003 ............................ Valve Solenoid (SVL) ............................................................................ 1
104164-005 ............................ Coil Solenoid ......................................................................................... 1
111790-012 ............................ Kit Seal ................................................................................................... 1
20 ................... 117304-003 ............................ Valve Solenoid (SCV6) .......................................................................... 1
104164-005 ............................ Coil Solenoid ......................................................................................... 1
111790-003 ............................ Kit Seal ................................................................................................... 1
21 ................... 808508 .................................... Proportional Valve, Accy (PVA) ............................................................. 1
104164-012 ............................ Coil Solenoid ......................................................................................... 1
111790-013 ............................ Kit Seal ................................................................................................... 1
22 ................... 123257-001 ............................ Proportional Valve, Hoist (PVH) ............................................................ 1
104164-012 ............................ Coil Solenoid ......................................................................................... 1
111790-014 ............................ Kit Seal ................................................................................................... 1
23 ................... 117385-003 ............................ Valve Solenoid (SVA) ............................................................................ 1
104164-005 ............................ Coil Solenoid ......................................................................................... 1
111790-007 ............................ Kit Seal ................................................................................................... 1
24 ................... 123258 .................................... Valve Solenoid (SVP) ............................................................................ 1
104164-002 ............................ Coil Solenoid ......................................................................................... 1
111790-001 ............................ Kit Seal ................................................................................................... 1
123270-003 ............................ Orifice ..................................................................................................... 1
25 ................... 064091-001 ............................ Plug ........................................................................................................ 1

REV. 1 10/02
49
VALVE BLOC
M1510
50M1.0-0000-00050
VALVE BLOC
1 ........................................................................ Valve Block (Not available as spare part) ............................................. 1

2 ..................... 064091-001 ............................ Plug ........................................................................................................ 2
3 ..................... 064091-007 ............................ Plug ........................................................................................................ 1
4 ..................... 064091-002 ............................ Plug ........................................................................................................ 5
5 ..................... 064004-021 ............................ Adaptor ................................................................................................... 1
6 ..................... 117739 .................................... Valve Manual Lower .............................................................................. 1
111790-005 ............................ Kit Seal ................................................................................................... 1
7 ..................... 123255-001 ............................ Check Valve ........................................................................................... 1
111790-009 ............................ Kit Seal ................................................................................................... 1
8 ..................... 808509 .................................... Valve Compensator ............................................................................... 1
9 ..................... 123260 .................................... Valve Compensator By-Pass ................................................................. 1
111790-010 ............................ Kit Seal ................................................................................................... 1
10 ................... 123255-001 ............................ Check Valve ........................................................................................... 1
111790-009 ............................ Kit Seal ................................................................................................... 1
11 ................... 064061-010 ............................ Adaptor ................................................................................................... 1
51
REACH MANIFOLD
M1511
52M1.0-0000-00052
REACH MANIFOLD
0 ..................... 807406 .................................... Reach Manifold ...................................................................................... 1

1 ........................... 808510 .................................... Valve Block ....................................................................................... 1
2 ........................... 064004-003 ............................. Adaptor ............................................................................................. 5
3 ........................... 064061-002 ............................. Elbow ................................................................................................ 1
4 ........................... 808511 .................................... Counterbalance ............................................................................... 2
5 ........................... 808512 .................................... Valve Solenoid ................................................................................. 1
808513 .................................... Coil Solenoid .................................................................................... 1
6 ........................... 792880-001 ............................. Pin Housing ...................................................................................... 1
792882 .................................... Pin ..................................................................................................... 2
793090-001 ............................. Anti Backout ..................................................................................... 1
53
HYDRAULIC MOTOR
M1507
54M1.0-0000-00054
HYDRAULIC MOTOR
1 ..................... 806912 .................................... Hydraulic Motor ...................................................................................... 1

2 ..................... 064004-006 ............................ Adaptor ................................................................................................... 2
55
PUMP
M1582
56M1.0-0000-00056
PUMP
0 ..................... 790940-001 ............................ Pump 19cc (Assembly - see next Page) ............................................... 1
57
PUMP MOTOR AND PUMP
M1581

REV.1 10/02
58M1.0-0000-00058
PUMP MOTOR AND PUMP
1 ........................................................................ Pump Motor (see next Page) ................................................................. 1

2 ..................... 807934 .................................... Bracket ................................................................................................... 1
3 ..................... 790503 .................................... Bush ....................................................................................................... 4
4 ..................... 050009-031 ............................ Washer ................................................................................................... 4
5 ..................... 050007-043 ............................ Screw ...................................................................................................... 4
6 ........................................................................ Pump (see Section 2.12) ....................................................................... 1
7 ..................... 791534 .................................... Washer, Sealing ..................................................................................... 1
8 ..................... 050067-034 ............................ Screw ...................................................................................................... 2
9 ..................... 790009-010 ............................ O-Ring .................................................................................................... 1
10 ................... 808893 .................................... Inlet Pump .............................................................................................. 1
11 ................... 050005-022 ............................ Screw ...................................................................................................... 4
12 ................... 806857 .................................... Hose ....................................................................................................... 1
054191-004 ............................ Jubilee Clip ............................................................................................ 2
13 ................... 807511 .................................... Bracket ................................................................................................... 1
14 ................... 050006-036 ............................ Screw ...................................................................................................... 2
15 ................... 793288 .................................... Clip ......................................................................................................... 2
16 ................... 050003-013 ............................ Screw ...................................................................................................... 2
17 ................... 050003-008 ............................ Nut .......................................................................................................... 2
18 ................... 050006-033 ............................ Screw ...................................................................................................... 2
19 ................... 050008-024 ............................ Nut .......................................................................................................... 2
20 ................... 806878 .................................... Priority Valve .......................................................................................... 1
21 ................... 064004-021 ............................ Adapter ................................................................................................... 1
22 ................... 064061-009 ............................ Adapter ................................................................................................... 1
23 ................... 064004-002 ............................ Adapter ................................................................................................... 1
24 ................... 064061-005 ............................ Elbow ...................................................................................................... 1
25 ................... 806880 .................................... Pressure Hose ....................................................................................... 1
26 ................... 050006-040 ............................ Screw ...................................................................................................... 1
27 ................... 806362 .................................... Spacer .................................................................................................... 1
28 ................... 050006-060 ............................ Screw ...................................................................................................... 3
29 ................... 795975 .................................... Brushwear Modul Assembly (inclusive 30 & 31) .................................. 1
30 ................... 793217-008 ............................ Socket Insert .......................................................................................... 1
31 ................... 793217-009 ............................ Socket Insert .......................................................................................... 1
32 ................... 793364-005 ............................ Clamp ..................................................................................................... 1
33 ................... 050006-032 ............................ Screw ...................................................................................................... 1
34 ................... 050010-021 ............................ Washer ................................................................................................... 1
35 ................... 050008-024 ............................ Nut .......................................................................................................... 1
36 ................... 808121 .................................... Bus Bar ................................................................................................... 1
807933 .................................... Bracket & Bush (inclusive 2 & 3) ........................................................... 1

REV. 1 02/02
59
PUMP MOTOR
M1587
60M1.0-0000-00060
PUMP MOTOR
0 ..................... 807930 .................................... Pump Motor ............................................................................................ 1

1 ........................... 808514 .................................... Cover Band & Fan Assembly (see next Page) ................................ 1
2 ........................... 808515 .................................... End Cover Assembly ....................................................................... 1
808516 .................................... End Cover ........................................................................................ 1
3 ........................... 791413-031 ............................. Washer ............................................................................................. 4
4 ........................... 791413-030 ............................. Screw ................................................................................................ 4
5 ........................... 791413-029 ............................. Washer ............................................................................................. 1
6 ........................... 791413-028 ............................. Bearing Ball ...................................................................................... 1
7 ........................... 791413-020 ............................. Brush Ring Assembly ...................................................................... 1
808517 .................................... Temperature Sensor/Bracket ........................................................... 1
808518 .................................... Temperature Sensor ........................................................................ 1
8 ........................... 791413-027 ............................. Washer ............................................................................................. 2
9 ........................... 791413-022 ............................. Screw ................................................................................................ 2
10 ......................... 791413-025 ............................. Brush ................................................................................................ 3
791413-026 ............................. Brush, Signalling .............................................................................. 1
11 ......................... 791413-021 ............................. Brush Spring .................................................................................... 12
12 ......................... 791413-024 ............................. Washer ............................................................................................. 4
13 ......................... 791413-023 ............................. Screw ................................................................................................ 4
14 ......................... 808519 .................................... Armature ........................................................................................... 1
15 ......................... 791774-002 ............................. Pole Shoe ......................................................................................... 4
16 ......................... 808520 .................................... Field Coil Set .................................................................................... 1
17 ......................... 791413-001 ............................. Housing ............................................................................................ 1
18 ......................... 791413-002 ............................. Plug ................................................................................................... 2
791413-034 ............................. Pin ..................................................................................................... 3
19 ......................... 791413-003 ............................. Terminal ............................................................................................ 1
20 ......................... 791413-005 ............................. Washer ............................................................................................. 1
791413-007 ............................. Bolt Clamp ........................................................................................ 1
21 ......................... 791413-004 ............................. Insulating Tube ................................................................................. 1
22 ......................... 791413-006 ............................. Washer ............................................................................................. 3
23 ......................... 791413-008 ............................. Nut .................................................................................................... 1
24 ......................... 791413-009 ............................. Nut .................................................................................................... 2
25 ......................... 791413-012 ............................. Screw ................................................................................................ 8
26 ......................... 791413-017 ............................. Circlip ............................................................................................... 1
27 ......................... 791413-016 ............................. Bearing Ball ...................................................................................... 1
28 ......................... 791413-013 ............................. Drive End Plate ................................................................................ 1
29 ......................... 791413-015 ............................. Washer ............................................................................................. 4
30 ......................... 791413-014 ............................. Screw ................................................................................................ 4
61
FAN
M1588
62M1.0-0000-00062
FAN
1 ..................... 806895-001 ............................ Fan Assembly ......................................................................................... 1

792880-001 ............................. Pin Housing ...................................................................................... 1
792882 .................................... Pin Crimp .......................................................................................... 2
793090-001 ............................. Anti-backout ..................................................................................... 1
2 ..................... 794865-002 ............................ Finger Guard .......................................................................................... 1
3 ..................... 050004-035 ............................ Screw ...................................................................................................... 4
4 ..................... 050008-002 ............................ Nut .......................................................................................................... 4
5 ..................... 793288 .................................... Clip ......................................................................................................... 1
6 ..................... 050003-013 ............................ Screw ...................................................................................................... 1
7 ..................... 050003-008 ............................ Nut .......................................................................................................... 1
63
Printed in Germany
64M1.0-0000-00064
SECTION 3
Printed in Germany
65
DRIVE UNIT
M1506

REV.1 10/02
66M1.0-0000-00066
DRIVE UNIT
0 ..................... 807559-001 ............................ Drive Unit & Gearbox Assembly (without 2, 28-36) .............................. 1
807559-002 ............................ Drive Unit & Gearbox Assembly (without 2, 28-36/Freezer/Corrosion) 1
1 ........................... 806913 .................................... Drive Frame ...................................................................................... 1
2 ........................... 050006-071 ............................. Screw ................................................................................................ 8
3 ........................... 806910 .................................... Drive Guard ...................................................................................... 1
4 ........................... 050007-044 ............................. Screw ................................................................................................ 2
5 ........................... 806912 .................................... Hydraulic Motor (see Section 2.11) ................................................. 1
6 ........................... 790082 .................................... Sprocket ........................................................................................... 1
7 ........................... 790083 .................................... Sleeve ............................................................................................... 1
8 ........................... 790081 .................................... Disc Retainer .................................................................................... 1
9 ........................... 050067-023 ............................. Screw ................................................................................................ 1
10 ......................... 050067-048 ............................. Screw ................................................................................................ 2
11 ......................... 050068-005 ............................. Nut .................................................................................................... 2
12 ......................... 791706 .................................... Chain ................................................................................................ 1
13 ......................... 791115-001 ............................. Chain Adjuster ................................................................................. 1
14 ......................... 806899 .................................... Link Extended .................................................................................. 1
15 ......................... 790910-001 ............................. Chain Adjuster ................................................................................. 1
............................ 791705 .................................... Pin ..................................................................................................... 1
16 ......................... 790911-001 ............................. Nut .................................................................................................... 1
17 ......................... 050008-032 ............................. Nut .................................................................................................... 1
18 ......................... 791114-001 ............................. Pin ..................................................................................................... 1
19 ......................... 050012-030 ............................. Circlip ............................................................................................... 2
20 ......................... 790088 .................................... Gearbox Assembly ........................................................................... 1
Gearbox (see Section 3.1) ...............................................................
Turntable (see Section 3.0) ..............................................................
21 ......................... 790839-001 ............................. Stop Block ........................................................................................ 1
22 ......................... 050000-076 ............................. Pin ..................................................................................................... 1
23 ......................... 050005-066 ............................. Screw ................................................................................................ 2
24 ......................... 050068-003 ............................. Nut .................................................................................................... 2
25 ......................... 050007-047 ............................. Screw ................................................................................................ 6
26 ......................... 807557 .................................... Wheel ................................................................................................ 1
810240 .................................... Wheel (Freezer/Corrosion) .............................................................. 1
27 ......................... 790648-057 ............................. Nut .................................................................................................... 7
790648-058 ............................. Washer ............................................................................................. 7
28 ......................... 807644 .................................... Bracket ............................................................................................. 1
29 ......................... 793200 .................................... Potentiometer Assembly .................................................................. 1
793199 ..................................... Potentiometer .............................................................................. 1
73090-003 ............................... Anti-Backout ............................................................................... 1
792880-003 ............................. Pin Housing ................................................................................ 1
792882 ..................................... Pin Crimp .................................................................................... 1
30 ......................... 807645-002 ............................. Spur gear .......................................................................................... 1
053050-010 ............................. Adhesive .......................................................................................... AR
31 ......................... 050006-026 ............................. Screw ................................................................................................ 2
050009-012 ............................. Washer ............................................................................................. 2
32 ......................... 793288 .................................... Clip ................................................................................................... 1
33 ......................... 050003-013 ............................. Screw ................................................................................................ 1
34 ......................... 050008-008 ............................. Nut .................................................................................................... 1
35 ......................... 807645-001 ............................. Spurgear (only for Potentiometer) ................................................... 1
36 ......................... 807646 .................................... Screw (only for Potentiometer) ........................................................ 1
37 ......................... 050006-040 ............................. Screw ................................................................................................ 1
38 ......................... 050008-024 ............................. Nut .................................................................................................... 1

REV. 1 10/02
67
DRIVE UNIT
M1508

REV.1 10/02
68M1.0-0000-00068
DRIVE UNIT
1* .................... 806764 .................................... Bracket ................................................................................................... 1

2* .................... 793288 .................................... Clip ......................................................................................................... 2
3* .................... 050003-013 ............................ Screw ...................................................................................................... 2
4* .................... 050008-008 ............................ Nut .......................................................................................................... 2
5 ..................... 050006-024 ............................ Screw ...................................................................................................... 2
6 ..................... 050008-015 ............................ Nut .......................................................................................................... 2
7 ..................... 061085-001 ............................ Clip ......................................................................................................... 3
8* .................... 050005-003 ............................ Screw ...................................................................................................... 1
9* .................... 806450 .................................... Spacer .................................................................................................... 1
10* ................... 126545 .................................... Plate ....................................................................................................... 1
11* ................... 050008-001 ............................ Nut .......................................................................................................... 1
12* ................... 126699 .................................... PCB Encoder ......................................................................................... 1
13 ................... 790080 .................................... Disc Brake (see Section 5.6) ................................................................. 1
14 ................... 050012-006 ............................ Ring Retaining ....................................................................................... 1
15 ................... 050017-017 ............................ Screw ...................................................................................................... 1
16 ................... 050005-022 ............................ Screw ...................................................................................................... 2
17 ................... 806895-001 ............................ Fan Assembly (see Section 3.2) ............................................................ 1
18 ................... 790820 .................................... Washer ................................................................................................... 1
19 ................... 050005-064 ............................ Screw ...................................................................................................... 6
20 ................... 807559 .................................... Drive Unit & Gearbox (see Section 3.0) ................................................ 1
21 ................... 20707 ...................................... Traction Motor (see Section 3.2) ........................................................... 1
22 ................... 125588-001 ............................ Isolator Cup (not illustrated) .................................................................. 2
125588-003 ............................ Isolator Cup (not illustrated) .................................................................. 2
* ..................... 807593 .................................... Bracket & Encoder Assembly (inclusive 1-4,8-12) ............................... 1

REV. 1 10/02
69
TURNTABLE
1
13
12
10
11
4
7 8
5
6
M1093
70M1.0-0000-00070
TURNTABLE
0 ..................... 790149 .................................... Turntable Assembly .............................................................................. 1

1 ........................... 790150 .................................... Ring Centering ................................................................................. 1
2 ........................... 790151 .................................... Screw ................................................................................................ 3
3 ........................... 790152 .................................... Grease Nipple .................................................................................. 2
4 ........................... 790153 .................................... Dowel ................................................................................................ 2
5 ........................... 790154 .................................... Screw ................................................................................................ 8
6 ........................... 790648-054 ............................. Plug ................................................................................................... 1
7 ........................... 790648-055 ............................. Seal ................................................................................................... 1
8 ........................... 791285-093 ............................. Screw ................................................................................................ 5
9 ........................... 790160 .................................... Screw ................................................................................................ 2
10 ......................... 790103 .................................... Washer ............................................................................................. 4
11 ......................... 790162 .................................... Nut .................................................................................................... 2
12 ......................... 790163 .................................... Valve Breather .................................................................................. 1
13 ......................... 791285-094 ............................. Screw ................................................................................................ 2
14 ......................... 791757 .................................... Turntable .......................................................................................... 1
71
GEAR BOX
M1033

REV.1 10/02
72M1.0-0000-00072
GEAR BOX
0 ..................... 791682 .................................... Gearbox ................................................................................................. 1

1 ........................... 791683 .................................... Transmission Case .......................................................................... 1
2 ........................... 791684 .................................... Threaded Protect. Shield ................................................................. 1
3 ........................... 791685 .................................... Sealing Ring .................................................................................... 1
4 ........................... 790118 .................................... Shim, 0,10 mm ................................................................................. AR
790119 .................................... Shim, 0,15 mm ................................................................................. AR
790120 .................................... Shim, 0,30 mm ................................................................................. AR
790121 .................................... Shim, 0,50 mm ................................................................................. AR
5 ........................... 790114 .................................... Bearing, Tape Roller ........................................................................ 2
6 ........................... 791686 .................................... Sealing Ring .................................................................................... 1
7 ........................... 791687 .................................... Wheel Shaft ...................................................................................... 1
8 ........................... 790117 .................................... Stud Wheel ....................................................................................... 7
9 ........................... 791688 .................................... Bevel Gear Set ................................................................................. 1
10 ......................... 791689 .................................... Disk ................................................................................................... 1
11 ......................... 791690 .................................... Screw ................................................................................................ 1
12 ......................... 790130 .................................... Shim, 0,10 mm ................................................................................. AR
790131 .................................... Shim, 0,15 mm ................................................................................. AR
790132 .................................... Shim, 0,30 mm ................................................................................. AR
790133 .................................... Shim, 0,50 mm ................................................................................. AR
13 ......................... 791285-081 ............................. Bearing, Tape Roller ........................................................................ 1
14 ......................... 791729 .................................... Helical Gear ..................................................................................... 1
15 ......................... 790137 .................................... Nut .................................................................................................... 1
16 ......................... 790141 .................................... Shim, 0,10 mm ................................................................................. AR
790142 .................................... Shim, 0,15 mm ................................................................................. AR
790143 .................................... Shim, 0,30 mm ................................................................................. AR
790144 .................................... Shim, 0,50 mm ................................................................................. AR
17 ......................... 791285-078 ............................. Bearing, Tape Roller ........................................................................ 1
18 ......................... 790145 .................................... Cover ................................................................................................ 1
19 ......................... 050006-026 ............................. Screw ................................................................................................ 15
20 ......................... 790157 .................................... Seal ................................................................................................... 1
21 ......................... 791285-090 ............................. Plug, Drain ....................................................................................... 1
22 ......................... 791730 .................................... Pinion ................................................................................................ 1
23 ......................... 790820 .................................... Washer ............................................................................................. 1
24 ......................... 051069 .................................... Nut .................................................................................................... 1

REV. 1 10/02
73
DRIVE MOTOR
M1673
74M1.0-0000-00074
DRIVE MOTOR
0 ..................... 020707 .................................... Motor-Drive 48V ..................................................................................... 1

1 ........................... 020748 .................................... Plate .................................................................................................. 1
2 ........................... 060063-010 ............................. Screw ................................................................................................ 3
061004-004 ............................. Adhesive Locking ............................................................................. AR
3* .......................... 020461 .................................... Motor End Cover .............................................................................. 1
4 ........................... 060078-007 ............................. Screw ................................................................................................ 4
5* .......................... 062547 .................................... Connector ......................................................................................... 1
6* .......................... 020548 .................................... Lead .................................................................................................. 2
7* .......................... 020196 .................................... Insulator Terminal ............................................................................. 2
8* .......................... 020197 .................................... Nut Terminal ..................................................................................... 2
9 ........................... 060005-008 ............................. Spring Lock Washer ........................................................................ 4
10 ......................... 060063-011 ............................. Screw ................................................................................................ 4
11 ......................... 020543 .................................... Shroud .............................................................................................. 1
12 ......................... 060046-016 ............................. Spring Washer ................................................................................. 1
13* ......................... 020746 .................................... Brush Box ASM ................................................................................ 1
14* ......................... 020277-001 ............................. Brush ................................................................................................ 8
15* ......................... 060078-011 ............................. Screw ................................................................................................ 10
16* ......................... 118466 .................................... Brush Spring Kit ............................................................................... 1
17* ......................... 060032-051 ............................. Screw ................................................................................................ 4
18 ......................... 065081-051 ............................. Bearing Ball ...................................................................................... 1
19 ......................... 020708 .................................... Housing and Field ASM ................................................................... 1
20 ......................... 020719 .................................... Armature ........................................................................................... 1
21 ......................... 061061-001 ............................. Woodruff Key .................................................................................... 1
22** ........................ 060009-144 ............................. Retaining Ring ................................................................................. 1
23** ........................ 065081-054 ............................. Bearing Ball ...................................................................................... 1
24** ........................ 020465 .................................... Drive End Head ................................................................................ 1
25 ......................... 060078-012 ............................. Screw ................................................................................................ 6
26 ......................... 064138-013 ............................. Seal ................................................................................................... 1
27 ......................... 064260-001 ............................. O-Ring .............................................................................................. 1
* ........................... 020745 .................................... Motor End Cover Assembly (inclusive 3,5-8,13-17) ....................... 1
** .......................... 020467 .................................... Drive End Head Assembly (inclusive 22-24) .................................. 1
75
FAN
M1588
76M1.0-0000-00076
FAN
0 ..................... 806895-001 ............................ Fan Assembly ......................................................................................... 1

1 ........................... 794865-001 ............................. Fan Assembly ................................................................................... 1
792880-001 ............................. Pin Housing 2-way ..................................................................... 1
792882 ..................................... Pin Insert ..................................................................................... 2
793090-001 ............................. Anti-backout ................................................................................ 1
2 ........................... 794865-002 ............................. Finger Guard .................................................................................... 1
3 ........................... 050004-043 ............................. Screw ................................................................................................ 4
050009-001 ............................. Washer ............................................................................................. 4
4 ........................... 050008-002 ............................. Nut .................................................................................................... 4
5 ........................... 793288 .................................... Clip ................................................................................................... 1
6 ........................... 050003-013 ............................. Screw ................................................................................................ 1
7 ........................... 050008-008 ............................. Nut .................................................................................................... 1

REV. 1 10/02
77
Printed in Germany
78M1.0-0000-00078
SECTION 4
Printed in Germany
79
ELECTRICAL COMPARTMENT
MP-2140-024

REV.1 10/02
80M1.0-0000-00080
1 ..................... 796233 .................................... Tray Assembly ........................................................................................ 1

808125 .................................... Blind Rivet Nut ................................................................................. 12
050070-002 ............................. Screw ................................................................................................ 5
050073-004 ............................. Washer ............................................................................................. 5
050068-004 ............................. Nut .................................................................................................... 7
2 ..................... 796512-001 ............................ Traction Controller + Software (Access 3) ............................................ 1
126287-001 ............................. Traction Controller (Access 3) ......................................................... 1
793352 .................................... Heatsink Compound .............................................................................. AR
3 ..................... 050009-012 ............................ Washer ................................................................................................... 12
4 ..................... 050006-027 ............................ Screw ...................................................................................................... 12
5 ..................... 806706 .................................... Copper Busbar ....................................................................................... 2
6 ..................... 806709 .................................... Copper Busbar ....................................................................................... 2
7 ..................... 806707 .................................... Copper Busbar ....................................................................................... 1
8 ..................... 050010-021 ............................ Washer ................................................................................................... 10
9 ..................... 050008-024 ............................ Nut .......................................................................................................... 12
10 ................... 050006-032 ............................ Screw ...................................................................................................... 6
11 ................... 126284 .................................... Pump Controller (Access 2) .................................................................. 1
793352 .................................... Heatsink Compound .............................................................................. AR
12 ................... 806708 .................................... Copper Busbar ....................................................................................... 1
13 ................... 807782 .................................... Bracket ................................................................................................... 1
14 ................... 806895-005 ............................ Fan Assembly ......................................................................................... 2
807654-001 ............................. Fan .................................................................................................... 2
807797 .................................... Finger Guard .................................................................................... 2
792880-001 ............................. Pin Housing ...................................................................................... 2
792882 .................................... Pin Insert .......................................................................................... 4
793090-001 ............................. Anti Backout ..................................................................................... 2
810304-001 ............................ Ventilator Assembly (Drive in Racking) ................................................ 2
807654-002 ............................. Ventilator (Drive in Racking) ........................................................... 2
792880-001 ............................. Steckergehäuse (Drive in Racking) ................................................ 2
792882 .................................... Stecker (Drive in Racking) ............................................................... 4
793090-001 ............................. Zugentlastung (Drive in Racking) ................................................... 2
15 ................... 050005-003 ............................ Screw ...................................................................................................... 8
16 ................... 050008-005 ............................ Nut .......................................................................................................... 8
17 ................... 793288 .................................... Clip ......................................................................................................... 4
18 ................... 050003-013 ............................ Screw ...................................................................................................... 4
19 ................... 050008-008 ............................ Nut .......................................................................................................... 5
20 ................... 807798 .................................... Clamp ..................................................................................................... 2
808823 .................................... Spacer .................................................................................................... 2
21 ................... 807275 .................................... Plate ....................................................................................................... 1
804683-001 ............................ Cage Nut ................................................................................................ 1
22 ................... 807383 .................................... Interface Module Assembly ................................................................... 1
792880-004 ............................. Pin Housing ...................................................................................... 1
793222 .................................... Pin Blanking ..................................................................................... 1
792882 .................................... Pin Insert .......................................................................................... 5
793090-001 ............................. Anti Backout ..................................................................................... 1
23 ................... 050009-002 ............................ Washer ................................................................................................... 8
24 ................... 050004-006 ............................ Screw ...................................................................................................... 4
25 ................... 050008-004 ............................ Nut .......................................................................................................... 4
26 ................... 794582 .................................... Relay 48V .............................................................................................. 1
27 ................... 050004-007 ............................ Screw ...................................................................................................... 2
28 ................... 806702 .................................... Fuse Box ................................................................................................ 1
806703-001 ............................ Fuse 15A ................................................................................................ 1
806703-002 ............................ Fuse 5A .................................................................................................. 1
29 ................... 807857 .................................... Bracket ................................................................................................... 1
30 ................... 806498 .................................... Bracket ................................................................................................... 1
31 ................... 794033 .................................... Contactor Assembly (see Sect. 4.4) ...................................................... 2
807855 .................................... Cable ...................................................................................................... AR
32 ................... 050006-008 ............................ Screw ...................................................................................................... 4

REV. 1 10/02
81
MP-2140-024

REV.1 10/02
82M1.0-0000-00082
33 ................... 050068-003 ............................ Nut .......................................................................................................... 2

050009-024 ............................ Washer ................................................................................................... 4
34 ................... 806720-001 ............................ Fuse ........................................................................................................ 1
35 ................... 806711 .................................... Battery Connector Assembly ................................................................. 1
806718-001 ............................. Battery Connector Housing ............................................................. 1
806700-009 ............................. Power Cable (B+) ............................................................................. 1
806700-010 ............................. Power Cable (B-) .............................................................................. 1
796733 .................................... Battery Connector Assembly (only for USA) ......................................... 1
796734 .................................... Battery Connector Housing (only for USA) ..................................... 1
806700-011 ............................. Power Cable (B+) (only for USA) ..................................................... 1
806700-012 ............................. Power Cable (B-) (only for USA) ...................................................... 1
796245 .................................... Battery Connector Assembly (only for Australia) .................................. 1
794493 .................................... Battery Connector Housing (only for Australia) .............................. 1
806700-011 ............................. Power Cable (B+) (only for Australia) .............................................. 1
806700-012 ............................. Power Cable (B-) (only for Australia) ............................................... 1
36 ................... 050007-010 ............................ Screw ...................................................................................................... 2
37 ................... 050009-013 ............................ Washer ................................................................................................... 4
38 ................... 050008-015 ............................ Nut .......................................................................................................... 2
39 ................... 050008-030 ............................ Nut .......................................................................................................... 2
40 ................... 050010-032 ............................ Washer ................................................................................................... 2
41 ................... 808468 .................................... Plate ....................................................................................................... 1
Not illustrated
806701 .................................... Main Harness ......................................................................................... 1

050071-035 ............................ Screw ...................................................................................................... 5
050008-024 ............................ Nut .......................................................................................................... 8
050008-068 ............................ Nut .......................................................................................................... 2
050006-023 ............................ Screw ...................................................................................................... 2

REV. 1 10/02
83
M1501
84M1.0-0000-00084
1 ..................... 806700-006 ............................ Power Cable A (Pump Motor A) ............................................................ 1

050008-024 ............................ Nut .......................................................................................................... 1
050006-032 ............................ Screw ...................................................................................................... 1
2 ..................... 806700-007 ............................ Power Cable B- ...................................................................................... 1
050008-024 ............................ Nut .......................................................................................................... 2
050006-032 ............................ Screw ...................................................................................................... 2
3 ..................... 806700-005 ............................ Power Cable B+ ..................................................................................... 1
050008-024 ............................ Nut .......................................................................................................... 2
050006-032 ............................ Screw ...................................................................................................... 2
4 ..................... 806700-001 ............................ Power Cable F1 (Traction Motor F1) ..................................................... 1
050010-010 ............................ Washer ................................................................................................... 1
050006-008 ............................ Screw ...................................................................................................... 1
5 ..................... 806700-003 ............................ Power Cable A1 (Traction Motor A1) ..................................................... 1
050008-024 ............................ Nut .......................................................................................................... 1
050006-032 ............................ Screw ...................................................................................................... 1
6 ..................... 806700-004 ............................ Power Cable D ....................................................................................... 1
050009-024 ............................ Washer ................................................................................................... 2
7 ..................... 806700-002 ............................ Power Cable F2 (Traction Motor F2) ..................................................... 1
050010-010 ............................ Washer ................................................................................................... 1
050006-008 ............................ Screw ...................................................................................................... 1
85
CONTACTOR
M0158
86M1.0-0000-00086
CONTACTOR
0 ..................... 794033 .................................... Line Contactor ....................................................................................... 2

1 ........................... 120115 .................................... Top Cover Fixing Screw ................................................................... 4
2 ........................... 120114 .................................... Top Cover Moulding ........................................................................ 2
3 ........................... 120112 .................................... Fixed Contact ................................................................................... 4
4 ........................... 794032 .................................... Return Spring ................................................................................... 2
5 ........................... 120113 .................................... Moving Contact (contain Index 7) ................................................... 2
6 ........................... 120120 .................................... Top Cover Base Moulding ............................................................... 2
7 ........................... 120629 .................................... Moving Contact Plunger .................................................................. 2
8 ........................... 794026 .................................... Coil and Frame ................................................................................. 2
9 ........................... 120638 .................................... End Cap ........................................................................................... 2
87
MAST WIRING
M1730-gb
88M1.0-0000-00088
MAST WIRING
1 ..................... 061002-001 ............................ Clamp (5-way) ....................................................................................... 1

061002-008 ............................ Clamp (10-way) ..................................................................................... 9
2 ..................... 050005-013 ............................ Screw ...................................................................................................... 1
3 ..................... 050008-008 ............................ Nut .......................................................................................................... 1
4 ..................... 052076-001 ............................ Clamp (5-way) ....................................................................................... 3
052076-002 ............................ Clamp (10-way) ..................................................................................... 3
5 ..................... 050071-035 ............................ Screw ...................................................................................................... 2
6 ..................... 050068-003 ............................ Nut .......................................................................................................... 1
7 ..................... 122914 .................................... Spring ..................................................................................................... 1
107204 .................................... Cable Grip (5-way) ................................................................................ 1
105449 .................................... Cable Grip (10-way) .............................................................................. 1
8 ..................... 807303 .................................... Spring ..................................................................................................... 1
9 ..................... 810214-*** .............................. Cable (5-way/see next Page) ................................................................ 1
810215-*** .............................. Cable (10-way/see next Page) ............................................................. 1
051051-009 ............................ Cable Tie ................................................................................................ 9
Not shown
792880-006 ............................ Pin Housing (Reach Carriage) ............................................................. 1

792882 .................................... Pin Insert ................................................................................................ AR
793222 .................................... Blanking Pin ........................................................................................... AR
793090-006 ............................ Anti-Backout ........................................................................................... 1
793288 .................................... Clip ......................................................................................................... 1
050003-013 ............................ Screw ...................................................................................................... 1
792881-004 ............................ Pin Housing (5-way/Fork Carriage/Mast Side) .................................... 1

792881-006 ............................ Pin Housing (10-way/Fork Carriage/Mast Side) ................................... 1
792883 .................................... Pin Insert ................................................................................................ AR
793091-004 ............................ Anti-Backout (5-way) ............................................................................. 1
793091-006 ............................ Anti-Backout (10-way) ........................................................................... 1
793217-018 ............................ Connector .............................................................................................. 1
792880-004 ............................ Pin Housing (5-way/Fork Carriage/Solenoid Side) .............................. 1

792880-006 ............................ Pin Housing (10-way/Fork Carriage/Solenoid Side) ........................... 1
792882 .................................... Pin Insert ................................................................................................ AR
793222 .................................... Blanking Pin ........................................................................................... AR
793090-004 ............................ Anti-Backout (5-way) ............................................................................. 1
793090-006 ............................ Anti-Backout (10-way) ........................................................................... 1
793288 .................................... Clip ......................................................................................................... 1
050003-013 ............................ Screw ...................................................................................................... 1
050008-008 ............................ Nut .......................................................................................................... 1
only for Freezer/Corrosion
796179 .................................... Cable Assembly ..................................................................................... 1

792880-001 ............................. Pin Housing ...................................................................................... 1
792882 .................................... Pin Insert .......................................................................................... 2
793090-001 ............................. Anti-Backout ..................................................................................... 2
792881-001 ............................. Pin Housing ...................................................................................... 1
792883 .................................... Pin Insert .......................................................................................... 2

REV. 1 10/02
89
MAST WIRING
Position 9 Position 9 Collapsed Height
810214-001 810215-001 2022mm
810214-002 810215-002 2172mm
810214-003 810215-003 2322mm
810214-004 810215-004 2472mm
810214-005 810215-005 2572mm
810214-006 810215-006 2772mm
810214-007 810215-007 2922mm
810214-008 810215-008 3042mm
810214-009 810215-009 3192mm
810214-010 810215-010 3347mm
810214-011 810215-011 3492mm
810214-012 810215-012 3692mm
810214-013 810215-013 3842mm
810214-014 810215-014 3952mm
810214-015 810215-015 4252mm
810214-016 810215-016 4452mm
Tab022gb
MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany
90M1.0-0000-00090
MAST WIRING
Printed in Germany
91
HGTS - LEEFT SPEED REDUCTION
M1727

REV.1 10/02
92M1.0-0000-00092
HGTS - LEEFT SPEED REDUCTION
1 .....................050067-014 ............................ Screw ...................................................................................................... 4

2 .....................808096 .................................... Cover ...................................................................................................... 1
3 .....................808095 .................................... Cover ...................................................................................................... 1
4 .....................808038 .................................... Spacer .................................................................................................... 4
5 .....................808026 .................................... Bracket ................................................................................................... 1
6 .....................807870 .................................... Bracket ................................................................................................... 1
7 .....................050006-001 ............................ Screw ...................................................................................................... 2
8 .....................792991 .................................... Microswitch (HGTS 12) .......................................................................... 1
9 .....................803310 .................................... Actuator .................................................................................................. 1
10 ................... 807541 .................................... Plate ....................................................................................................... 1
11 ................... 050003-013 ............................ Screw ...................................................................................................... 1
12 ................... 793288 .................................... Clip ......................................................................................................... 1
13 ................... 050008-008 ............................ Nut .......................................................................................................... 1
14 ................... 792881-002 ............................ Socket Housing ...................................................................................... 1
792883 .................................... Socket Crimp .......................................................................................... 3
793091-002 ............................ Anti-Backout ........................................................................................... 1
15 ................... 050006-014 ............................ Screw ...................................................................................................... 1
16 ................... 061002-001 ............................ Clamp ..................................................................................................... 1
17 ................... 050008-008 ............................ Nut .......................................................................................................... 1
18 ................... 796008 .................................... Bracket ................................................................................................... 1

19 ................... 794611-001 ............................ Heater ..................................................................................................... 1
050004-042 ............................ Screw ...................................................................................................... 2
050008-011 ............................ Nut .......................................................................................................... 2
20 ................... 794590-001 ............................ Cable Assembly (inclusive 794611-001,792880-001, ........................ 1
792882,793090-001)
21 ................... 792880-001 ............................ Pin Housing ........................................................................................... 1
792882 .................................... Pin Insert ................................................................................................ 2
793090-001 ............................ Anti Backout ........................................................................................... 1
796173 .................................... Heater Assembly (inclusive 18-21) ....................................................... 1

REV. 1 10/02
93
HEIGHT ENCODER
MP-2140-022
94M1.0-0000-00094
HEIGHT ENCODER
0 ..................... 808904 .................................... Height Encoder (without 2, 3) ............................................................... 1

1 ........................... 808215 .................................... Bracket ............................................................................................. 1
2 ........................... 050006-033 ............................. Screw ................................................................................................ 2
3 ........................... 808733 .................................... Nut .................................................................................................... 2
4 ........................... 808896 .................................... Power Supply Assembly (inclusive 5, 6) ........................................ 1
5 ........................... 062535-006 ............................. Pin Housing ...................................................................................... 1
062536-001 ............................. Pin Insert .......................................................................................... 4
6 ........................... 792880-003 ............................. Pin Housing ...................................................................................... 1
792882 .................................... Pin Insert .......................................................................................... 4
793090-003 ............................. Anti-Backout ..................................................................................... 1
7 ........................... 050004-009 ............................. Screw ................................................................................................ 2
8 ........................... 050008-004 ............................. Nut .................................................................................................... 2
9 ........................... 793288 .................................... Clip ................................................................................................... 1
10 ......................... 050003-013 ............................. Screw ................................................................................................ 1
11 ......................... 050008-008 ............................. Nut .................................................................................................... 1
12 ......................... 808362 .................................... Case ................................................................................................. 1
13 ......................... 808379 .................................... Pin ..................................................................................................... 2
14 ......................... 808410 .................................... Bearing Ball ...................................................................................... 2
15 ......................... 808378 .................................... Pulley ................................................................................................ 2
16 ......................... 050009-014 ............................. Washer ............................................................................................. 2
17 ......................... 050012-013 ............................. Ring Retaining ................................................................................. 2
18 ......................... 808361 .................................... Pulley ................................................................................................ 1
19 ......................... 050017-018 ............................. Screw ................................................................................................ 1
20 ......................... 055002-026 ............................. Bearing Ball ...................................................................................... 1
21 ......................... 050012-069 ............................. Ring Retaining ................................................................................. 1
22 ......................... 808908 .................................... Washer ............................................................................................. 1
23 ......................... 050012-070 ............................. Ring Retaining ................................................................................. 1
24 ......................... 808380 .................................... Plate .................................................................................................. 1
25 ......................... 127785 .................................... Encoder PCP .................................................................................... 1
26 ......................... 050006-033 ............................. Screw ................................................................................................ 2
808363 .................................... Height Encoder Assembly (inclusive 12-25) ................................. 1
Not shown
810217-*** .............................. Cable-Height Encoder Assembly (see next Page) ......................... 1

808386 .................................... Wire Rope ........................................................................................ 1
807303 .................................... Spring ............................................................................................... 1
27 ......................... 794611-004 ............................. Heater ............................................................................................... 3

050004-042 ............................. Screw ................................................................................................ 6
28 ......................... 792880-001 ............................. Pin Housing ...................................................................................... 1
792882 .................................... Pin Insert .......................................................................................... 2
793090-001 ............................. Anti Backout ..................................................................................... 1
29 ......................... 796229 .................................... Cable Assembly (inclusive 794611-004,792880-001, .................. 1
792882,793090-001)

REV. 1 10/02
95
HEIGHT ENCODER
Collapsed Height
810217-001 2022mm
810217-002 2172mm
810217-003 2322mm
810217-004 2472mm
810217-005 2572mm
810217-006 2772mm
810217-007 2922mm
810217-008 3042mm
810217-009 3192mm
810217-010 3347mm
810217-011 3492mm
810217-012 3692mm
810217-013 3842mm
810217-014 3952mm
810217-015 4252mm
810217-016 4452mm
Tab023gb
MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany
96M1.0-0000-00096
HEIGHT ENCODER
Printed in Germany
97
JOYSTICK AND EMERGENCY DISCO. SWITCH
MP-2140-021

REV.1 10/02
98M1.0-0000-00098
JOYSTICK AND EMERGENCY DISCO. SWITCH
1 ..................... 810624 .................................... Bracket ................................................................................................... 1

2 ..................... 791423-002 ............................ Joystick Hole Plug ................................................................................. 1
3 ..................... 807038 .................................... Joystick Assembly (Switch) ................................................................... 1
792880-003 ............................. Pin Housing ...................................................................................... 1
792882 .................................... Pin Insert .......................................................................................... 3
4 ..................... 807037 .................................... Joystick Assembly (Pot) ......................................................................... AR
792880-003 ............................. Pin Housing ...................................................................................... AR
792882 .................................... Pin Insert .......................................................................................... AR
5 ..................... 050006-024 ............................ Screw ...................................................................................................... AR
6 ..................... 050008-015 ............................ Nut .......................................................................................................... AR
7 ..................... 807523-001 ............................ Joystick & Label/Lift ............................................................................... 1
807523-002 ............................ Joystick & Label/Tilt ............................................................................... 1
807523-003 ............................ Joystick & Label/Reach ......................................................................... 1
807523-004 ............................ Joystick & Label/Load Stabilizer ........................................................... 1
807523-005 ............................ Joystick & Label/Upender ..................................................................... 1
807523-006 ............................ Joystick & Label/Sideshift ...................................................................... 1
807523-007 ............................ Joystick & Label/Fork Arm Spread ........................................................ 1
807523-008 ............................ Joystick & Label/Clamp ......................................................................... 1
807523-009 ............................ Joystick & Label/Rotate ......................................................................... 1
807523-010 ............................ Joystick & Label/Push/Pull .................................................................... 1
8 ..................... 793288 .................................... Clip ......................................................................................................... 5
9 ..................... 050003-013 ............................ Screw ...................................................................................................... 5
10 ................... 050008-008 ............................ Nut .......................................................................................................... 5
11 ................... 792880-003 ............................ Pin Housing ........................................................................................... 1
793222 .................................... Pin Insert ................................................................................................ 4
793090-003 ............................ Anti Backout ........................................................................................... 4
12 ................... 804863-001 ............................ Cage Nut ................................................................................................ 3
13 ...................................................................... Directional Switch/Horn Button (see next Page) .................................. 1
14 ................... 050067-022 ............................ Screw ...................................................................................................... 2
15 ................... 050068-003 ............................ Nut .......................................................................................................... 2
16 ................... 807051-001 ............................ Emergency Disconnect Switch .............................................................. 1
792991 .................................... Switch ..................................................................................................... 2
793288 .................................... Clip ......................................................................................................... 2
050003-013 ............................ Vis ........................................................................................................... 2
17 ................... 050006-013 ............................ Screw ...................................................................................................... 2
18 ................... 050008-008 ............................ Nut .......................................................................................................... 4
19 ................... 050068-004 ............................ Nut .......................................................................................................... 3
only for Freezer/Corrosion (Emergency Disconnect Switch)
20 ................... 796008 .................................... Bracket ................................................................................................... 2

21 ................... 794611-001 ............................ Heater ..................................................................................................... 2
050004-042 ............................ Screw ...................................................................................................... 4
050008-011 ............................ Nut .......................................................................................................... 4
22 ................... 792880-001 ............................ Pin Housing ........................................................................................... 1
792882 .................................... Pin Insert ................................................................................................ 2
793090-001 ............................ Anti Backout ........................................................................................... 1
23 ................... 7964591-001 .......................... Cable Assembly (inclusive 794611-001,792880-001, ....................... 1
792882,793090-001)
796012 .................................... Heater Assembly (inclusive 20-23) ...................................................... 1
not shown
793217-007 ............................ Switch (6th Function Valve) ................................................................... 1

796488 .................................... Cable assembly (6th Function Valve) ................................................... 1
051051-009 ............................ Cable Tie (6th Function Valve) .............................................................. 5
796735 .................................... Label (6th Function Valve) ..................................................................... 1

REV. 1 10/02
99
DIRECTIONAL SWITCH/HORN BUTTON
MP1494

REV.1 10/02
M1.0-0000-000100
100
DIRECTIONAL SWITCH/HORN BUTTON
0 ..................... 807055 .................................... Directional Switch/Horn Button ............................................................. 1

1 ........................... 806676 .................................... Bracket ............................................................................................. 1
2 ........................... 806679 .................................... Bracket ............................................................................................. 1
3 ........................... 050003-014 ............................. Screw ................................................................................................ 2
4 ........................... 050008-008 ............................. Nut .................................................................................................... 7
5 ........................... 806746 .................................... Horn Button ...................................................................................... 1
6 ........................... 806677 .................................... Shaft .................................................................................................. 2
7 ........................... 050001-013 ............................. Pin Split ............................................................................................ 2
8 ........................... 792991 .................................... Microswitch ....................................................................................... 3
9 ........................... 050006-001 ............................. Screw ................................................................................................ 6
10 ......................... 050008-002 ............................. Nut .................................................................................................... 6
11 ......................... 050005-001 ............................. Screw ................................................................................................ 1
12 ......................... 050008-001 ............................. Nut .................................................................................................... 3
13 ......................... 793288 .................................... Clip ................................................................................................... 3
14 ......................... 050003-015 ............................. Screw ................................................................................................ 3
15 ......................... 050009-007 ............................. Washer ............................................................................................. 2
16 ......................... 803310 .................................... Actuator Roller Arm .......................................................................... 2
17 ......................... 050005-058 ............................. Screw ................................................................................................ 2
18 ......................... 806742 .................................... Spring Roller .................................................................................... 1
19 ......................... 050005-002 ............................. Screw ................................................................................................ 2
050009-003 ............................. Washer ............................................................................................. 4
20 ......................... 806745 .................................... Directional Lever .............................................................................. 1
21 ......................... 051064-006 ............................. Spring ............................................................................................... 1
22 ......................... 050009-012 ............................. Washer ............................................................................................. 2
23 ......................... 794572-002 ............................. Bracket ............................................................................................. 1

24 ......................... 794611-001 ............................. Heater ............................................................................................... 3
050004-042 ............................. Screw ................................................................................................ 6
050008-011 ............................. Nut .................................................................................................... 6
25 ......................... 796005 .................................... Bracket (Directional Lever) .............................................................. 1
26 ......................... 796004 .................................... Bracket (Horn Button) ...................................................................... 1
27 ......................... 792880-001 ............................. Pin Housing ...................................................................................... 1
792882 .................................... Pin Insert .......................................................................................... 2
793090-001 ............................. Anti Backout ..................................................................................... 1
793288 .................................... Clip ................................................................................................... 1
050003-015 ............................. Screw ................................................................................................ 1
050008-008 ............................. Nut .................................................................................................... 1
796003-001 ............................. Cable Assembly (inclusive 794611-001,792880-001, .................. 1

792882,793090-001)
796006 .................................... Heater Assembly (inclusive 23-27) ................................................. 1

REV. 1 10/02
101
FLOORPLATE
MP1479
M1.0-0000-000102
102
FLOORPLATE
0 ..................... 806486-001 ............................ Floorplate & Pedal Assembly ................................................................ 1

1 ........................... 806445 .................................... Floorplate ......................................................................................... 1
2 ........................... 793333 .................................... Lug Nut ............................................................................................. 2
3 ........................... 050005-062 ............................. Screw ................................................................................................ 2
............................ 050009-013 ............................. Washer ............................................................................................. 2
4 ........................... 806476 .................................... Accelerator Pedal ............................................................................. 1
5 ........................... 793226 .................................... Buffer ................................................................................................ 1
6 ........................... 050008-015 ............................. Nut .................................................................................................... 1
7 ........................... 104215 .................................... Pedal Rubber ................................................................................... 1
8 ........................... 055084-010 ............................. Bush .................................................................................................. 2
9 ........................... 807278 .................................... Pin ..................................................................................................... 1
10 ......................... 050000-056 ............................. Pin ..................................................................................................... 2
11 ......................... 806488 .................................... Floor Mat .......................................................................................... 1
12 ......................... 050071-035 ............................. Screw ................................................................................................ 1
13 ......................... 060102-001 ............................. Nut .................................................................................................... 1
806485 .................................... Floorplate & Pedal (inclusive 1-11) ................................................. 1
Accelerator Unit (see next Page) .................................................... 1

REV. 1 10/02
103
ACCELERATOR
M1579

REV. 1 10/02
M1.0-0000-000104
104
ACCELERATOR
0 ........................................................................ Accelerator Assembly ............................................................................ 1

1 ........................... 050012-030 ............................. Circlip ............................................................................................... 1
2 ........................... 793473 .................................... Roller ................................................................................................ 1
3 ........................... 042053-020 ............................. Bush .................................................................................................. 2
4 ........................... 793558 .................................... Lever ................................................................................................. 1
5 ........................... 042053-018 ............................. Bush .................................................................................................. 2
6 ........................... 793562 .................................... Spring ............................................................................................... 1
7 ........................... 793561 .................................... Collar Drive ...................................................................................... 1
8 ........................... 050000-069 ............................. Split Cotter Pin ................................................................................. 1
9 ........................... 795572 .................................... Bracket ............................................................................................. 1
10 ......................... 795796 .................................... Potentiometer Assembly .................................................................. 1
792880-003 ............................. Pin Housing ................................................................................ 1
792882 ..................................... Pin Crimp .................................................................................... 1
793090-003 ............................. Anti Backout ................................................................................ 1
11 ......................... 050009-002 ............................. Washer ............................................................................................. 2
12 ......................... 050006-001 ............................. Screw ................................................................................................ 4
13 ......................... 793226 .................................... Buffer ................................................................................................ 1
14 ......................... 050008-015 ............................. Nut .................................................................................................... 1
15 ......................... 792991 .................................... Microswitch ....................................................................................... 1
16 ......................... 803310 .................................... Actuator Roller Arm .......................................................................... 1
17 ......................... 050008-002 ............................. Nut .................................................................................................... 2
050009-002 ............................. Washer ............................................................................................. 1
18 ......................... 793288 .................................... Clip ................................................................................................... 2
19 ......................... 050003-013 ............................. Screw ................................................................................................ 2
20 ......................... 050008-008 ............................. Nut .................................................................................................... 2
21 ......................... 050006-035 ............................. Screw ................................................................................................ 2
22 ......................... 050008-024 ............................. Nut .................................................................................................... 2
807751 .................................... Accelerator (inclusive 1-20) ............................................................ 1
23 ......................... 796009 .................................... Bracket ............................................................................................. 1

24 ......................... 796010 .................................... Bracket ............................................................................................. 1
25 ......................... 794611-001 ............................. Heater ............................................................................................... 2
050004-042 ............................. Screw ................................................................................................ 4
050008-011 ............................. Nut .................................................................................................... 4
26 ......................... 792880-001 ............................. Pin Housing ...................................................................................... 1
792882 .................................... Pin Insert .......................................................................................... 2
793090-001 ............................. Anti Backout ..................................................................................... 1
793288 .................................... Clip ................................................................................................... 1
050003-015 ............................. Screw ................................................................................................ 1
050008-008 ............................. Nut .................................................................................................... 1
27 ......................... 794591-001 ............................. Cable Assembly (inclusive 794611-001,792880-001, .................. 1
792882,793090-001)

REV. 1 10/02
105
DEAD MAN PEDAL
MP-2140-001

REV. 1 10/02
M1.0-0000-000106
106
DEAD MAN PEDAL
0 ........................................................................ Dead Man Pedal Assembly ................................................................... 1

1 ........................... 806934 .................................... Pedal Rubber ................................................................................... 1
2 ........................... 810482 .................................... Lever ................................................................................................. 1
3 ........................... 050071-019 ............................. Screw ................................................................................................ 2
4 ........................... 810483 .................................... Bushing ............................................................................................ 1
5 ........................... 808932 .................................... Screw ................................................................................................ 2
6 ........................... 050008-015 ............................. Nut .................................................................................................... 2
7 ........................... 807048 .................................... Spring ............................................................................................... 1
8 ........................... 051058-010 ............................. Bushing ............................................................................................ 2
9 ........................... 792991 .................................... Microswitch ....................................................................................... 1
803310 .................................... Actuator ............................................................................................ 1
10 ......................... 050004-036 ............................. Screw ................................................................................................ 2
11 ......................... 807541 .................................... Plate .................................................................................................. 1
12 ......................... 050003-013 ............................. Screw ................................................................................................ 2
13 ......................... 793288 .................................... Clip ................................................................................................... 2
14 ......................... 050008-008 ............................. Nut .................................................................................................... 2
15 ......................... 810480 .................................... Bracket ............................................................................................. 1
16 ......................... 050067-034 ............................. Screw ................................................................................................ 2
17 ......................... 810469 .................................... Plate .................................................................................................. 1
18 ......................... 796007 .................................... Bracket ............................................................................................. 1

19 ......................... 794611-001 ............................. Heater ............................................................................................... 1
20 ......................... 050004-042 ............................. Screw ................................................................................................ 2
21 ......................... 050008-011 ............................. Nut .................................................................................................... 2
22 ......................... 794590-001 ............................. Cable Assembly (inclusive 794611-001) ........................................ 1
792880-001 ............................. Pin Housing ................................................................................ 1
792882 ..................................... Pin Insert ..................................................................................... 2
793090-001 ............................. Anti Backout ................................................................................ 1

REV. 1 10/02
107
DC/DC CONVERTER
MP-2140-018
M1.0-0000-000108
108
DC/DC CONVERTER
1 ..................... 795477 .................................... Bracket ................................................................................................... 1

2 ..................... 050005-023 ............................ Screw ...................................................................................................... 1
3 ..................... 050008-024 ............................ Nut .......................................................................................................... 1
4 ..................... 050005-026 ............................ Screw ...................................................................................................... 1
5 ..................... 050008-026 ............................ Nut .......................................................................................................... 1
6 ..................... 794535-002 ............................ DC/DC Converter (48V - 12V) ............................................................... 1
794535-003 ............................ DC/DC Converter (48V - 24V) ............................................................... 1
7 ..................... 796075 .................................... Cover ...................................................................................................... 1
8 ..................... 050006-013 ............................ Screw ...................................................................................................... 4
9 ..................... 050008-008 ............................ Nut .......................................................................................................... 4
10 ................... 796095 .................................... Cable Assembly ..................................................................................... 1
793217-002 ............................. Ring Terminal ................................................................................... 2
792882 .................................... Pin Insert .......................................................................................... 2
11 ................... 794582 .................................... Relay 48V .............................................................................................. 1
...................... 806703-001 ............................ Fuse 15A ................................................................................................ 2
12 ................... 050004-006 ............................ Screw ...................................................................................................... 2
13 ................... 050008-004 ............................ Nut .......................................................................................................... 2
795476-001 ............................ DC/DC Converter (48V - 12V/inclusive 1-9) ......................................... 1

795476-002 ............................ DC/DC Converter (48V - 24V/inclusive 1-9) ......................................... 1
not shown
796145 .................................... Hose Bracket .......................................................................................... 1

050071-035 ............................ Screw ...................................................................................................... 1
050008-024 ............................ Nut .......................................................................................................... 1
051051-009 ............................ Cable Tie ................................................................................................ 6
109
DASH PANEL
MP-2140-025

REV. 1 10/02
M1.0-0000-000110
110
DASH PANEL
0 ..................... 806887 .................................... Dash Panel Assembly (without 9) ......................................................... 1

1 ........................... 806898 .................................... Dash Panel ....................................................................................... 1
2 ........................... 807349 .................................... Brake Switch .................................................................................... 1
3 ........................... 807034 .................................... Key Switch Assembly ....................................................................... 1
123537 ..................................... Key Switch .................................................................................. 1
793090-002 ............................. Anti-Backout ............................................................................... 1
792880-002 ............................. Pin Housing ................................................................................ 1
792882 ..................................... Pin Crimp .................................................................................... 3
4 ........................... 109127-003 ............................. Clip Arrow Indicator (red) ................................................................. 1
5 ........................... 109127-001 ............................. Clip Arrow Indicator (green) ............................................................ 1
6 ........................... 109127-002 ............................. Clip Arrow Indicator (yellow) ........................................................... 1
7 ........................... 806888 .................................... Bracket ............................................................................................. 1
8 ........................... 803469-011 ............................. Screw ................................................................................................ 4
050009-007 ............................. Washer ............................................................................................. 6
9 ........................... 050068-004 ............................. Nut .................................................................................................... 4
10 ......................... 792940 .................................... Lug Nut ............................................................................................. 3
11 ......................... 793288 .................................... Attachment Clip ................................................................................ 3
12 ......................... 050003-015 ............................. Screw ................................................................................................ 3
13 ......................... 807033 .................................... Suppressor Assembly ...................................................................... 1
14 ......................... 050007-010 ............................. Screw ................................................................................................ 1
050009-013 ............................. Washer ............................................................................................. 1
15 ......................... 791346-003 ............................. Adjuster Button ................................................................................. 1
16 ......................... 790199-039 ............................. Spring ............................................................................................... 1
17 ......................... 806932 .................................... Pivot Pin ........................................................................................... 1
18 ......................... 790213 .................................... R-Clip ................................................................................................ 2
19 ......................... 107739 .................................... Key Assembly ................................................................................... 1
107151-002 ............................. Key .............................................................................................. 2
107763 ..................................... Ring ............................................................................................. 1
20 ......................... 808876 .................................... Finger Guard .................................................................................... 1
21 ......................... 050003-002 ............................. Screw ................................................................................................ 1

REV. 1 10/02
111
INSTRUMENTATION
M1481
M1.0-0000-000112
112
INSTRUMENTATION
0 ..................... 806930 .................................... Instrumentation ...................................................................................... 1

1 ........................... 806691 .................................... Display Cover ................................................................................... 1
2 ........................... 807854 .................................... Plate .................................................................................................. 2
3 ........................... 051068-003 ............................. Clip Spring ....................................................................................... 3
4 ........................... 050004-021 ............................. Screw ................................................................................................ 4
5 ........................... 050071-035 ............................. Screw ................................................................................................ 1
6 ........................... 807848 .................................... Spacer .............................................................................................. 1
7 ........................... 807090 .................................... Display, Overlay ............................................................................... 1
8 ........................... 124015 .................................... ASM PCB ENH ................................................................................. 1
9 ........................... 806748 .................................... Button Housing ................................................................................. 1
10 ......................... 125416 .................................... ASM PCB Switch .............................................................................. 1
11 ......................... 807354 .................................... Bracket ............................................................................................. 1
12 ......................... 803469-010 ............................. Screw ................................................................................................ 4
13 ......................... 050009-002 ............................. Washer ............................................................................................. 6
14 ......................... 050005-050 ............................. Screw ................................................................................................ 6

REV. 1 10/02
113
STEER INDICATOR
M1674
M1.0-0000-000114
114
STEER INDICATOR
0 ..................... 790752 .................................... Steer Indicator ........................................................................................ 1
115
FLASHING BEACON
MP-2140-009gb
M1.0-0000-000116
116
FLASHING BEACON
0 ..................... 795365-001 ............................ Flashing Beacon (Travel Activated) ...................................................... 1

795365-002 ............................ Flashing Beacon (Key-On Activated) .................................................... 1
795365-003 ............................ Flashing Beacon (Switch Activated) ..................................................... 1
1 ........................... 795982 .................................... Bracket ............................................................................................. 1
2 ........................... 795977 .................................... Clamp ............................................................................................... 1
3 ........................... 050005-062 ............................. Screw ................................................................................................ 2
053050-006 ............................. Adhesive .......................................................................................... AR
4 ........................... 791036-003 ............................. Beacon (Xenon) ............................................................................... 1
5 ........................... 050071-020 ............................. Screw ................................................................................................ 3
6 ........................... 796045 .................................... Clip ................................................................................................... 1
7 ........................... 050071-012 ............................. Screw ................................................................................................ 1
8 ........................... 050009-007 ............................. Washer ............................................................................................. 1
9 ........................... 050008-008 ............................. Nut .................................................................................................... 1
10 ......................... 796073 .................................... Cable ................................................................................................ 1
11 ......................... 796074 .................................... Beacon Controller (only for Key-On Activated) ............................... 1
796072 .................................... Beacon Controller (only for Switch Activated) ................................ 1
793288 .................................... Clip ................................................................................................... 1
050003-015 ............................. Screw ................................................................................................ 1
050008-008 ............................. Nut .................................................................................................... 1
12 ......................... 062595-002 ............................. Switch ............................................................................................... 1
796078 .................................... Flashing Beacon Assembly (inclusive 1-10) .................................. 1
795981 .................................... Beacon Assembly (inclusive 1,4-10) ............................................... 1
117
WORKING LIGHT
MP-2140-010-gb
M1.0-0000-000118
118
WORKING LIGHT
0 ..................... 795366-001 ............................ Working Light Assembly (Option up) .................................................... 1

795366-002 ............................ Working Light Assembly (Option down) ................................................ 1
1 ........................... 796067 .................................... Bracket ............................................................................................. 2
2 ........................... 050005-026 ............................. Screw ................................................................................................ 2
3 ........................... 793611 .................................... Working Light ................................................................................... 2
793801-001 ............................. Sleeve ............................................................................................... 2
4 ........................... 050008-025 ............................. Nut .................................................................................................... 2
5 ........................... 795977 .................................... Clamp ............................................................................................... 4
6 ........................... 050005-062 ............................. Screw ................................................................................................ 8
053050-006 ............................. Adhesive .......................................................................................... AR
7 ........................... 796094 .................................... Cable Conduit .................................................................................. 1
051051-009 ............................. Cable Tie .......................................................................................... 4
8 ........................... 796086 .................................... Cable Conduit .................................................................................. 1
9 ........................... 796071 .................................... Cable ................................................................................................ 1
10 ......................... 794582 .................................... Relay 48V ......................................................................................... 1
806703-001 ............................. Fuse 15A .......................................................................................... 1
11 ......................... 050004-034 ............................. Screw ................................................................................................ 2
12 ......................... 050008-004 ............................. Nut .................................................................................................... 2
13 ......................... 062595-002 ............................. Switch ............................................................................................... 1
795496 .................................... Working Light Assembly (inclusive 1-9/Option up) ........................ 2

795496 .................................... Working Light Assembly (inclusive 1-9/Option down) .................... 2
795986 .................................... Working Light Assembly (inclusive 1-4) .......................................... 2
119
WORKING LIGHT
MP-2140-011-gb
M1.0-0000-000120
120
WORKING LIGHT
0 ..................... 795368-001 ............................ Working Light Assembly ........................................................................ 1

1 ........................... 796067 .................................... Bracket ............................................................................................. 1
2 ........................... 050005-026 ............................. Screw ................................................................................................ 2
3 ........................... 793611 .................................... Working Light ................................................................................... 2
793801-001 ............................. Sleeve ............................................................................................... 2
4 ........................... 050008-025 ............................. Nut .................................................................................................... 2
5 ........................... 795977 .................................... Clamp ............................................................................................... 4
6 ........................... 050005-062 ............................. Screw ................................................................................................ 8
053050-006 ............................. Adhesive .......................................................................................... AR
7 ........................... 050009-020 ............................. Washer ............................................................................................. 1
8 ........................... 795472 .................................... Bracket ............................................................................................. 1
9 ........................... 796086 .................................... Cable Conduit .................................................................................. 1
10 ......................... 796085 .................................... Cable Conduit .................................................................................. 1
051051-009 ............................. Cable Tie .......................................................................................... 1
11 ......................... 796084 .................................... Cable Conduit .................................................................................. 1
051051-009 ............................. Cable Tie .......................................................................................... 1
12 ......................... 796071 .................................... Cable ................................................................................................ 1
13 ......................... 062595-002 ............................. Switch ............................................................................................... 1
14 ......................... 794582 .................................... Relay 48V ......................................................................................... 1
806703-001 ............................. Fuse 15A .......................................................................................... 1
15 ......................... 050004-034 ............................. Screw ................................................................................................ 2
16 ......................... 050008-004 ............................. Nut .................................................................................................... 2
796081 .................................... Working Light Assembly (inclusive 1-12) ....................................... 1
795986 .................................... Working Light Assembly (inclusive 1-4) .......................................... 1
795471 .................................... Working Light Assembly (inclusive 2-4,7,8) .................................... 1
121
REVERSE ALARM
MP-2140-013
M1.0-0000-000122
122
REVERSE ALARM
0 ..................... 795999 .................................... Reverse Alarm Assembly ...................................................................... 1

1 ........................... 795991 .................................... Bracket ............................................................................................. 1
2 ........................... 794582 .................................... Relay 48V ......................................................................................... 1
3 ........................... 050009-002 ............................. Washer ............................................................................................. 2
4 ........................... 050004-025 ............................. Screw ................................................................................................ 2
5 ........................... 050008-004 ............................. Nut .................................................................................................... 2
6 ........................... 050067-012 ............................. Screw ................................................................................................ 2
7 ........................... 126035 .................................... Reverse Alarm ................................................................................. 1
8 ........................... 050009-013 ............................. Washer ............................................................................................. 2
9 ........................... 050008-015 ............................. Nut .................................................................................................... 2
10 ......................... 796401 .................................... Cable ................................................................................................ 1
11 ......................... 793288 .................................... Clip ................................................................................................... 1
12 ......................... 050003-011 ............................. Screw ................................................................................................ 1
13 ......................... 050008-008 ............................. Nut .................................................................................................... 1
14 ......................... 796402 .................................... Cable ................................................................................................ 1
123
HORN
MP-2140-002

REV. 1 10/02
M1.0-0000-000124
124
HORN
1 ..................... 078708-006 ............................ Horn ........................................................................................................ 1

2 ..................... 050006-032 ............................ Screw ...................................................................................................... 1
3 ..................... 050008-024 ............................ Nut .......................................................................................................... 1
4 ..................... 109120 .................................... Filter ........................................................................................................ 1
5 ..................... 050005-003 ............................ Screw ...................................................................................................... 2
6 ..................... 050008-001 ............................ Nut .......................................................................................................... 2

REV. 1 10/02
125
COOLING SYSTEM
MP-2140-004
M1.0-0000-000126
126
COOLING SYSTEM
0 ..................... 807597-001 ............................ Cooling System ...................................................................................... 1

1 ........................... 807620 .................................... Bracket ............................................................................................. 1
2 ........................... 793288 .................................... Clip ................................................................................................... 2
3 ........................... 050003-013 ............................. Screw ................................................................................................ 2
4 ........................... 050008-008 ............................. Nut .................................................................................................... 2
5 ........................... 806895-002 ............................. Fan Assembly ................................................................................... 2
807654-002 ............................. Fan .............................................................................................. 2
792880-001 ............................. Pin Housing ................................................................................ 2
792882 ..................................... Pin Insert ..................................................................................... 4
793090-001 ............................. Anti-backout ................................................................................ 2
6 ........................... 807797 .................................... Finger Guard .................................................................................... 2
7 ........................... 050005-003 ............................. Screw ................................................................................................ 8
8 ........................... 050008-005 ............................. Nut .................................................................................................... 8
9 ........................... 050009-018 ............................. Washer ............................................................................................. 2
10 ......................... 050008-024 ............................. Nut .................................................................................................... 2
11 ......................... 807849 .................................... Bracket ............................................................................................. 1
12 ......................... 050006-022 ............................. Screw ................................................................................................ 2
127
Printed in Germany
M1.0-0000-000128
128
SECTION 5
Printed in Germany
129
BRAKE CIRCUIT
MP-2140-016gb

REV.1 10/02
M1.0-0000-000130
130
BRAKE CIRCUIT
0 ..................... 810702-001 ............................ Brake Line Assembly (1.4t/1285mm Leg Width) .................................. 1
810702-002 ............................ Brake Line Assembly (1.6-2.0t/1285mm Leg Width) ............................ 1
810702-004 ............................ Brake Line Assembly (1.4t/1425mm Leg Width) .................................. 1
810702-006 ............................ Brake Line Assembly (1.4t/1575mm Leg Width) .................................. 1
1 ........................... 810581-001 ............................. Brake Line (1.4t/1285mm Leg Width) ............................................. 1
810581-002 ............................. Brake Line (1.6-2.0t/1285mm Leg Width) ....................................... 1
810581-003 ............................. Brake Line (1.4t/1425mm Leg Width) ............................................. 1
2 ........................... 790555 .................................... Clip ................................................................................................... 2
3 ........................... 050006-008 ............................. Screw ................................................................................................ 2
4 ........................... 790548 .................................... Connector ......................................................................................... 2
5 ........................... 807553-001 ............................. Brake Line (1285/1425mm Leg Width) ........................................... 1
807553-002 ............................. Brake Line (1575mm Leg Width) .................................................... 1
6 ........................... 807585 .................................... Clip ................................................................................................... 1
7 ........................... 050070-002 ............................. Screw ................................................................................................ 3
8 ........................... 050008-030 ............................. Nut .................................................................................................... 3
9 ........................... 790550 .................................... Connector ......................................................................................... 1
10 ......................... 050007-009 ............................. Screw ................................................................................................ 1
11 ......................... 810578 .................................... Brake Line ........................................................................................ 1
12 ......................... 807499 .................................... Bracket ............................................................................................. 1
13 ......................... 810580-001 ............................. Brake Line (1.4t/1285mm Leg Width) ............................................. 1
14 ......................... 807703 .................................... Brake Line (only for 1575mm Leg Width) ....................................... 1
15 ......................... 810579 .................................... Brake Line ........................................................................................ 1
16 ......................... 050006-036 ............................. Screw ................................................................................................ 1

REV. 1 10/02
131
FOOTBRAKE
MP-2140-003
M1.0-0000-000132
132
FOOTBRAKE
0 ..................... 810699-001 ............................ Footbrake Assembly .............................................................................. 1

1 ........................... 810399 .................................... Brake Mounting Bracket .................................................................. 1
2 ........................... 050067-044 ............................. Screw ................................................................................................ 2
3 ........................... 810401 .................................... Brake Pedal ...................................................................................... 1
4 ........................... 102330 .................................... Footpedal Rubber ............................................................................ 1
5 ........................... 051058-017 ............................. Bush .................................................................................................. 2
6 ........................... 050009-053 ............................. Washer ............................................................................................. 1
7 ........................... 050012-036 ............................. Circlip ............................................................................................... 1
8 ........................... 050007-013 ............................. Screw ................................................................................................ 1
9 ........................... 807085 .................................... Spring ............................................................................................... 1
10 ......................... 050008-015 ............................. Nut .................................................................................................... 2
11 ......................... 810404 .................................... Rod Fork ........................................................................................... 1
12 ......................... 790195 .................................... Pin Clevis ......................................................................................... 1
13 ......................... 050009-018 ............................. Washer ............................................................................................. 1
14 ......................... 050001-013 ............................. Pin ..................................................................................................... 1
15 ......................... 810525 .................................... Brake Master Cylinder Assembly .................................................... 1
810589 ..................................... Brake Master Cylinder & Reservoir ........................................... 1
810591 ..................................... Reservoir Cap & Switch (BFS) ................................................... 1
16 ......................... 050006-035 ............................. Screw ................................................................................................ 1
17 ......................... 050006-043 ............................. Screw ................................................................................................ 1
810397 .................................... Footbrake Assembly (inklusive 1,3-17) ........................................... 1
810700 .................................... Repair Kit (Brake Master Cylinder) ................................................. 1
133
DRIVE MOTOR BRAKE
M1062
M1.0-0000-000134
134
DRIVE MOTOR BRAKE
0 ..................... 790080 .................................... Disc Brake Assembly ............................................................................. 1

1 ........................... 790182 .................................... Brake Ring ....................................................................................... 1
2 ........................... 790180 .................................... Key .................................................................................................... 1
3 ........................... 790179 .................................... Hub with O-Ring ............................................................................... 1
4 ........................... 790181 .................................... Circlip ............................................................................................... 1
5 ........................... 790159 .................................... Base Plate ........................................................................................ 1
6 ........................... 790165 .................................... Spring ............................................................................................... 1
7 ........................... 790166 .................................... Pin ..................................................................................................... 1
8 ........................... 790079 .................................... Bleeder Valve ................................................................................... 1
9 ........................... 790172 .................................... Cap ................................................................................................... 1
10 ......................... 790174 .................................... Bush .................................................................................................. 6
11 ......................... 790147 .................................... Shaft .................................................................................................. 1
12 ......................... 790171 .................................... Screw ................................................................................................ 2
13 ......................... 790167 .................................... Ring .................................................................................................. 1
14 ......................... 790168 .................................... Brake Piston ..................................................................................... 1
15 ......................... 790148 .................................... Cap ................................................................................................... 1
16 ......................... 790164 .................................... Setbolt .............................................................................................. 1
17 ......................... 790175 .................................... Manual Brake Lever ........................................................................ 1
18 ......................... 790176 .................................... Pin ..................................................................................................... 2
19 ......................... 790456 .................................... Split Cotter Pin ................................................................................. 4
20 ......................... 790161 .................................... Pressure Plate .................................................................................. 1
21 ......................... 790177 .................................... Brake Lever ...................................................................................... 1
22 ......................... 790178 .................................... Pin ..................................................................................................... 2
23 ......................... 790169 .................................... Nut .................................................................................................... 1
24 ......................... 790170 .................................... Adjusting Screw ............................................................................... 1
135
LOAD WHEEL BRAKE
MP-2140-014
M1.0-0000-000136
136
LOAD WHEEL BRAKE
0 ..................... 810564 .................................... Brake ...................................................................................................... 2

1 ........................... 810569 .................................... Backplate .......................................................................................... 2
2 ........................... 810634 .................................... Plug ................................................................................................... 4
3 ........................... 810572 .................................... Cylinder Assy ................................................................................... 2
4 ........................... 050006-024 ............................. Screw ................................................................................................ 4
5 ........................... 810570 .................................... Brake Shoe ....................................................................................... 4
6 ........................... 810568 .................................... Spring ............................................................................................... 4
7 ........................... 810567 .................................... Spring ............................................................................................... 4
8 ........................... 810566 .................................... Clamp ............................................................................................... 2
137
BRAKE CYLINDER
M1495

REV.1 10/02
M1.0-0000-000138
138
BRAKE CYLINDER
0 ..................... 807452 .................................... Brake Cylinder (without 2) ..................................................................... 1

1 ........................... 807059 .................................... Brake Cylinder ................................................................................. 1
2 ........................... 050006-061 ............................. Screw ................................................................................................ 2
3* .......................... 804770 .................................... Guide Ring ....................................................................................... 1
4* .......................... 808269 .................................... Seal ................................................................................................... 1
5 ........................... 808151 .................................... Piston Rod ........................................................................................ 1
6 ........................... 807015 .................................... Spacer .............................................................................................. 1
7 ........................... 808156 .................................... Spring ............................................................................................... 1
8* .......................... 808268 .................................... Guide Ring ....................................................................................... 1
9 ........................... 807017 .................................... Gland ................................................................................................ 1
10 ......................... 792285 .................................... Wire Lock .......................................................................................... 1
11* ......................... 807023 .................................... Wiper ................................................................................................ 1
12 ......................... 807784 .................................... Ring .................................................................................................. 1
13 ......................... 050000-001 ............................. Pin ..................................................................................................... 1
14 ......................... 807016 .................................... Support ............................................................................................. 1
15 ......................... 050006-040 ............................. Screw ................................................................................................ 1
16 ......................... 807020 .................................... Cable ................................................................................................ 1
17 ......................... 050008-015 ............................. Nut .................................................................................................... 7
18 ......................... 808104 .................................... Filter .................................................................................................. 1
19 ......................... 808082 .................................... Bracket ............................................................................................. 1
20 ......................... 050006-024 ............................. Screw ................................................................................................ 2
21 ......................... 793288 .................................... Clip ................................................................................................... 1
22 ......................... 050003-013 ............................. Screw ................................................................................................ 1
23 ......................... 050008-008 ............................. Nut .................................................................................................... 1
24 ......................... 803310 .................................... Actuator ............................................................................................ 1
25 ......................... 792991 .................................... Microswitch ....................................................................................... 1
26 ......................... 050004-034 ............................. Screw ................................................................................................ 2
27 ......................... 807541 .................................... Plate .................................................................................................. 1
28 ......................... 064061-004 ............................. Elbow ................................................................................................ 5
29 ......................... 807448 .................................... Tube .................................................................................................. 1
30 ......................... 807028 .................................... Solenoid Valve ................................................................................. 1
31 ......................... 807449 .................................... Adapter ............................................................................................. 1
32 ......................... 064004-007 ............................. Connector ......................................................................................... 1
33 ......................... 807026 .................................... Check Valve ...................................................................................... 1
34 ......................... 050007-011 ............................. Screw ................................................................................................ 4
807008 .................................... Brake Cylinder Assembly (inclusive 1,3-11,18,28) ........................ 1
* ........................... 808552 .................................... Seal Kit (inclusive 3,4,8,11) ............................................................. 1

REV. 1 10/02
139
Printed in Germany
M1.0-0000-000140
140
SECTION 6
Printed in Germany
141
STEERING COLUMN
M1488

REV.1 10/02
M1.0-0000-000142
142
STEERING COLUMN
0 ..................... 806974 .................................... Steering Column Assembly (without 16-19) ......................................... 1

1* .......................... 119531 .................................... Spinner Knob ................................................................................... 1
2* .......................... 060009-133 ............................. Ring Retaining ................................................................................. 1
3* .......................... 114279-002 ............................. Bearing Sleeve ................................................................................. 1
4* .......................... 060009-146 ............................. Ring Retaining ................................................................................. 1
5* .......................... 807466-002 ............................. Steering Wheel ................................................................................. 1
6 ........................... 805302 .................................... Steering Column Cover ................................................................... 1
7 ........................... 050006-022 ............................. Screw ................................................................................................ 2
8 ........................... 050071-020 ............................. Screw ................................................................................................ 5
9 .............................................................................. Steering Column & Gearbox (see next page) ................................. 1
10 ......................... 050008-052 ............................. Nut .................................................................................................... 1
11 ......................... 807467 .................................... Bracket ............................................................................................. 1
12 ......................... 794401 .................................... Spacer Tube ..................................................................................... 1
13 ......................... 805305 .................................... Steering Column Cover ................................................................... 1
14 ......................... 050003-016 ............................. Screw ................................................................................................ 1
15 ......................... 791357-010 ............................. Hole Plug .......................................................................................... 1
16 ......................... 806961 .................................... Shaft .................................................................................................. 1
17 ......................... 792973 .................................... Pin ..................................................................................................... 1
18 ......................... 050006-027 ............................. Screw ................................................................................................ 1
19 ......................... 790995 .................................... Spring Tension ................................................................................. 1
20 ......................... 806830 .................................... Cover ................................................................................................ 1
21 ......................... 807637 .................................... Bracket ............................................................................................. 1
22 ......................... 793333 .................................... Nut .................................................................................................... 1
23 ......................... 792724 .................................... Plug ................................................................................................... 1
24 ......................... 125502 .................................... Pocket Storage ................................................................................. 1
25 ......................... 050005-059 ............................. Screw ................................................................................................ 1
26 ......................... 050005-060 ............................. Screw ................................................................................................ 1
27 ......................... 125503 .................................... Mount Pocket .................................................................................... 1
28 ......................... 050068-002 ............................. Nut .................................................................................................... 2
* .......................... 807465 .................................... Steering Wheel Assembly (inclusive 1-5) ....................................... 1

REV. 1 10/02
143
STEERING COLUMN
M1487

REV.1 10/02
M1.0-0000-000144
144
STEERING COLUMN
0 ..................... 807400 .................................... Steering Column & Gaerbox Assembly ................................................ 1

1 ........................... 807393 .................................... Steering Column .............................................................................. 1
2 ........................... 050078-002 ............................. Blind Rivet Nut ................................................................................. 5
3 ........................... 807410 .................................... Spacer Plate ..................................................................................... 2
4 ........................... 807408 .................................... Spacer Block .................................................................................... 1
5 ........................... 794301 .................................... Lock Plate ......................................................................................... 1
6 ........................... 050003-059 ............................. Screw ................................................................................................ 2
050010-023 ............................. Washer ............................................................................................. 2
7 ........................... 050008-024 ............................. Nut .................................................................................................... 2
8 ........................... 807750 .................................... Spring Mount .................................................................................... 1
9 ........................... 050008-049 ............................. Nut .................................................................................................... 1
10 ......................... 807401 .................................... Bracket ............................................................................................. 1
11 ......................... 808120 .................................... Steer Sensor Module ....................................................................... 1
12 ......................... 050004-009 ............................. Screw ................................................................................................ 2
13 ......................... 050008-004 ............................. Nut .................................................................................................... 2
14 ......................... 126699 .................................... Encoder ............................................................................................ 1
15 ......................... 792814 .................................... Spur Gear ......................................................................................... 1
16 ......................... 050005-032 ............................. Screw ................................................................................................ 4
17 ......................... 807411 .................................... Steering Gearbox Assembly (see next page) ................................. 1
18 ......................... 806900 .................................... Power Steering Unit ......................................................................... 1
19 ......................... 064004-004 ............................. Adaptor ............................................................................................. 4
20 ......................... 064061-001 ............................. Adaptor ............................................................................................. 1
21 ......................... 050005-068 ............................. Screw ................................................................................................ 4
22 ......................... 050009-013 ............................. Washer ............................................................................................. 1
23 ......................... 050006-022 ............................. Screw ................................................................................................ 1
Not illustrated
793288 .................................... Clip ................................................................................................... 1

050003-013 ............................. Screw ................................................................................................ 1
050008-008 ............................. Nut .................................................................................................... 1

REV. 2 10/02
145
STEERING COLUMN
M1486
M1.0-0000-000146
146
STEERING COLUMN
0 ..................... 807411 .................................... Steering Gearbox Assembly .................................................................. 1

1 ........................... 806871 .................................... Steering Gearbox Housing .............................................................. 1
2 ........................... 055002-014 ............................. Bearing ............................................................................................. 2
3 ........................... 806960-004 ............................. Spacer .............................................................................................. 1
4 ........................... 050012-014 ............................. Circlip ............................................................................................... 1
5 ........................... 791377 .................................... Gear .................................................................................................. 1
6 ........................... 791381 .................................... Spring Torsion .................................................................................. 2
7 ........................... 791380 .................................... Gear .................................................................................................. 2
8 ........................... 806937-003 ............................. Washer ............................................................................................. 1
9 ........................... 050012-057 ............................. Circlip ............................................................................................... 1
10 ......................... 806937-001 ............................. Washer ............................................................................................. 1
11 ......................... 806937-002 ............................. Washer ............................................................................................. 1
12 ......................... 050012-009 ............................. Circlip ............................................................................................... 1
13 ......................... 806960-002 ............................. Spacer .............................................................................................. 2
14 ......................... 806960-003 ............................. Spacer .............................................................................................. 3
15 ......................... 055002-004 ............................. Bearing ............................................................................................. 3
16 ......................... 791382 .................................... Gear .................................................................................................. 1
17 ......................... 806894 .................................... Centre Shaft ..................................................................................... 1
18 ......................... 792973 .................................... Pin ..................................................................................................... 1
19 ......................... 050006-024 ............................. Screw ................................................................................................ 1
20 ......................... 791372 .................................... Gear .................................................................................................. 1
21 ......................... 806960-001 ............................. Spacer .............................................................................................. 1
22 ......................... 806300 .................................... Drive Shaft ........................................................................................ 1
23 ......................... 791375-001 ............................. Washer ............................................................................................. 1
24 ......................... 050067-034 ............................. Screw ................................................................................................ 1

REV. 1 10/02
147
Printed in Germany
M1.0-0000-000148
148
SECTION 7
Printed in Germany
149
TT MAST
1.4t/1.6t
M1503

REV.1 10/02
M1.0-0000-000150
150
TT MAST
0 ........................................................................ TT Mast (1.4/1.6t) ................................................................................... 1

1 ........................... 806101-***-** .......................... Outer Mast (see next page) ............................................................. 1
812132-***-** .......................... Outer Mast (see next page) ............................................................. 1
2 ........................... 806102-*** .............................. 1st Stage Mast (see next page) ....................................................... 1
812133-*** .............................. 1st Stage Mast (see next page) ....................................................... 1
3 ........................... 806103-*** .............................. 2nd Stage Mast (see next page) ..................................................... 1
4 ........................... 807334-002 ............................. Roller Æ 101,47mm ......................................................................... AR
807334-003 ............................. Roller Æ 102,14mm ......................................................................... AR
807334-004 ............................. Roller Æ 102,45mm ......................................................................... AR
5 ........................... 060030-057 ............................. Shim .................................................................................................. 8
060030-085 ............................. Shim .................................................................................................. 8
795534 .................................... Shim .................................................................................................. 8
6 ........................... 807327-*** .............................. Cover (see next page) ..................................................................... 1
812967-*** .............................. Cover (see next page) ..................................................................... 1
7 ........................... 050067-022 ............................. Screw ................................................................................................ AR
9 .............................................................................. Lift Cylinder (see Section 8.1) ......................................................... 2
10 ......................... 806997 .................................... Pin ..................................................................................................... 2
11 ......................... 050001-021 ............................. Pin ..................................................................................................... 2
12 ......................... 050007-014 ............................. Screw ................................................................................................ 2
13 ......................... 050008-015 ............................. Nut .................................................................................................... 2
14 ......................... 792427 .................................... Block Stop ........................................................................................ 4
15 ......................... 794661 .................................... Shim .................................................................................................. 4
16 ......................... 808861 .................................... Bracket ............................................................................................. 4
17 ......................... 092747-001 ............................. Poly Stop .......................................................................................... 4
18 ......................... 050005-062 ............................. Screw ................................................................................................ 4
19 ......................... 050006-069 ............................. Screw ................................................................................................ 8
20 ............................................................................ Freelift Cylinder (see Section 8.2) ................................................... 1
21 ......................... 807339 .................................... Protection ......................................................................................... 1
22 ......................... 050003-050 ............................. Screw ................................................................................................ 2
23 ......................... 807329 .................................... Shim .................................................................................................. 1
24 ......................... 050067-037 ............................. Screw ................................................................................................ 2
25 ............................................................................ Yoke (see Section 7.11) ................................................................... 1
26 ......................... 050000-028 ............................. Pin ..................................................................................................... 1
27 ......................... 050067-048 ............................. Screw ................................................................................................ 2
28 ......................... 050008-038 ............................. Nut .................................................................................................... 2
29 ......................... 812968 .................................... Cover (RH/only for Collapsed Height 3692,3892,3952mm) ......... 1
812969 .................................... Cover (LH/only for Collapsed Height 3692,3892,3952mm) ......... 1
30 ......................... 050067-056 ............................. Screw ................................................................................................ 2
31 ......................... 807407 .................................... Washer ............................................................................................. 2
807323 .................................... Shim .................................................................................................. 8
32 ......................... 050068-007 ............................. Nut .................................................................................................... 2
Not shown
808386 .................................... Cable (Height Encoder) ................................................................... 1

807303 .................................... Spring (Height Encoder) .................................................................. 1
790350 .................................... Magnet (FLS/LCS) ........................................................................... 1
050003-019 ............................. Screw (FLS/LCS) .............................................................................. 1
807716 .................................... Bracket (FLS/LCS) ........................................................................... 1
050005-058 ............................. Screw (FLS/LCS) .............................................................................. 1

REV. 1 10/02
151
TT MAST
1.4t/1.6t
Position 1 Position 2 Position 3 Position 6 Position 8 Collapsed Height
806101-001-01 806102-001 806103-001 807327-001 806999-001 2022mm
806101-001-02 806102-002 806103-002 807327-002 806999-002 2172mm
806101-001-03 806102-003 806103-003 807327-003 806999-003 2322mm
806101-001-04 806102-004 806103-004 807327-004 806999-004 2472mm
806101-001-05 806102-005 806103-005 807327-005 806999-005 2572mm
806101-001-06 806102-006 806103-006 807327-006 806999-006 2772mm
806101-001-07 806102-007 806103-007 807327-007 806999-007 2922mm
806101-001-08 806102-008 806103-008 807327-008 806999-008 3042mm
806101-001-09 806102-009 806103-009 807327-009 806999-009 3192mm
812132-001-10 812133-010 806103-010 812967-010 812966-010 3347mm
812132-001-11 812133-011 806103-011 812967-011 812966-011 3492mm
812132-001-12 812133-012 806103-012 812967-012 812966-012 3692mm
812132-001-13 812133-013 806103-013 812967-013 812966-013 3842mm
812132-001-14 812133-014 806103-014 812967-014 812966-014 3952mm
Tab005gb
M1.0-0000-000152
152
Printed in Germany
153
TT MAST
2.0t
M1503

REV.1 10/02
M1.0-0000-000154
154
TT MAST
0 ........................................................................ TT Mast (2.0t) ......................................................................................... 1

1 ........................... 806101-***-** .......................... Outer Mast (see next page) ............................................................. 1
812132-***-** .......................... Outer Mast (see next page) ............................................................. 1
2 ........................... 806102-*** .............................. 1st Stage Mast (see next page) ....................................................... 1
812133-*** .............................. 1st Stage Mast (see next page) ....................................................... 1
3 ........................... 806103-*** .............................. 2nd Stage Mast (see next page) ..................................................... 1
4 ........................... 807334-002 ............................. Roller Æ 101,47mm ......................................................................... AR
807334-003 ............................. Roller Æ 102,14mm ......................................................................... AR
807334-004 ............................. Roller Æ 102,45mm ......................................................................... AR
5 ........................... 060030-057 ............................. Shim .................................................................................................. 8
060030-085 ............................. Shim .................................................................................................. 8
795534 .................................... Shim .................................................................................................. 8
7 ........................... 050067-022 ............................. Screw ................................................................................................ AR
9 .............................................................................. Lift Cylinder (see Section 8.1) ......................................................... 2
10 ......................... 806997 .................................... Pin ..................................................................................................... 2
11 ......................... 050001-021 ............................. Pin ..................................................................................................... 2
12 ......................... 050007-014 ............................. Screw ................................................................................................ 2
13 ......................... 050008-015 ............................. Nut .................................................................................................... 2
14 ......................... 792427 .................................... Block Stop ........................................................................................ 4
15 ......................... 794661 .................................... Shim .................................................................................................. 4
16 ......................... 808861 .................................... Bracket ............................................................................................. 4
17 ......................... 092747-001 ............................. Poly Stop .......................................................................................... 4
18 ......................... 050005-062 ............................. Screw ................................................................................................ 4
19 ......................... 050006-069 ............................. Screw ................................................................................................ 8
20 ............................................................................ Freelift Cylinder (see Section 8.2) ................................................... 1
21 ......................... 807339 .................................... Protection ......................................................................................... 1
22 ......................... 050003-050 ............................. Screw ................................................................................................ 2
23 ......................... 807329 .................................... Shim .................................................................................................. 1
24 ......................... 050067-037 ............................. Screw ................................................................................................ 2
25 ............................................................................ Yoke (see Section 7.11) ................................................................... 1
26 ......................... 050000-028 ............................. Pin ..................................................................................................... 1
27 ......................... 050067-048 ............................. Screw ................................................................................................ 2
28 ......................... 050008-038 ............................. Nut .................................................................................................... 2
29 ......................... 050067-056 ............................. Screw ................................................................................................ 2
30 ......................... 807407 .................................... Washer ............................................................................................. 2
807323 .................................... Shim .................................................................................................. 8
31 ......................... 050068-007 ............................. Nut .................................................................................................... 2
Not shown
808386 .................................... Cable (Height Encoder) ................................................................... 1

807303 .................................... Spring (Height Encoder) .................................................................. 1
790350 .................................... Magnet (FLS/LCS) ........................................................................... 1
050003-019 ............................. Screw (FLS/LCS) .............................................................................. 1
807716 .................................... Bracket (FLS/LCS) ........................................................................... 1
050005-058 ............................. Screw (FLS/LCS) .............................................................................. 1

REV. 1 10/02
155
TT MAST
2.0t
Position 1 Position 2 Position 3 Position 6 Position 8 Collapsed Height
806101-002-01 806102-001 806103-001 807327-001 806999-001 2022mm
806101-002-02 806102-002 806103-002 807327-002 806999-002 2172mm
806101-002-04 806102-004 806103-004 807327-004 806999-004 2472mm
806101-002-06 806102-006 806103-006 807327-006 806999-006 2772mm
806101-002-07 806102-007 806103-007 807327-007 806999-007 2922mm
806101-002-08 806102-008 806103-008 807327-008 806999-008 3042mm
812132-002-10 812133-010 806103-010 812973-010-01 812973-010-02 3347mm
812132-002-12 812133-012 806103-012 812973-012-01 812973-012-02 3692mm
812132-002-13 812133-013 806103-013 812973-013-01 812973-013-02 3842mm
812132-002-14 812133-014 806103-014 812973-014-01 812973-014-02 3952mm
812132-002-15 812133-015 806103-015 812973-015-01 812973-015-02 4252mm
812132-002-16 812133-016 806103-016 812973-016-01 812973-016-02 4452mm
Tab006gb
M1.0-0000-000156
156
Printed in Germany
157
LIFT CHAIN MAST TT
M1505

REV.1 10/02
M1.0-0000-000158
158
LIFT CHAIN MAST TT
1 ..................... 050008-056 ............................ Nut .......................................................................................................... 8

2 ..................... 806993 .................................... Washer ................................................................................................... 4
3 ..................... 806995 .................................... Washer ................................................................................................... 4
4 ..................... 808489-002 ............................ Chain Anchor ......................................................................................... 2
5 ..................... 050001-027 ............................ Pin Split .................................................................................................. 4
6 ..................... 807962 .................................... Chain Pin ............................................................................................... 4
7 ..................... 050001-017 ............................ Pin Split .................................................................................................. 8
8 ..................... 050006-040 ............................ Screw ...................................................................................................... 1
9 ..................... 810434 .................................... Shaft ....................................................................................................... 1
10 ................... 807715 .................................... Shim ....................................................................................................... 3
11 ................... 127513-001 ............................ Pulley Cable .......................................................................................... 1
12 ................... 050009-051 ............................ Washer ................................................................................................... 1
13 ................... 119655-001 ............................ Pulley Hose ............................................................................................ 2
14 ................... 806267 .................................... Pulley Chain .......................................................................................... 2
15 ................... 050012-056 ............................ Ring Retaining ....................................................................................... 2
16 ................... 050007-038 ............................ Screw ...................................................................................................... 1
17 ................... 121623 .................................... Pulley Hose ............................................................................................ 1
18 ................... 806991-001 ............................ Shaft ....................................................................................................... 1
19 ................... 808489-001 ............................ Chain Anchor ......................................................................................... 2
20 ................... 050008-068 ............................ Nut .......................................................................................................... 4
21 ................... 050001-027 ............................ Pin Split .................................................................................................. 2
22 ................... 808488-001 ............................ Chain Anchor ......................................................................................... 1
23 ................... 803539 .................................... Chain Pin ............................................................................................... 2
24 ................... 050001-013 ............................ Pin Roll ................................................................................................... 4
25 ................... 808488-002 ............................ Chain Anchor ......................................................................................... 1
26 ................... 793069-*** .............................. Chain (see next page) ........................................................................... 1
27 ................... 792968-*** .............................. Chain (see next page) ........................................................................... 2
28 ................... 806994 .................................... Washer ................................................................................................... 2
29 ................... 806996 .................................... Washer ................................................................................................... 2
30 ................... 050009-025 ............................ Washer ................................................................................................... 2
31 ................... 810435 .................................... Shaft ....................................................................................................... 1

REV. 1 10/02
159
LIFT CHAIN MAST TT
Position 26 Position 27 Collapsed Height
793069-009 792968-002 2022mm
793069-010 792968-013 2172mm
793069-003 792968-019 2322mm
793069-004 792968-015 2472mm
793069-005 792968-020 2572mm
793069-006 792968-021 2772mm
793069-0012 792968-022 2922mm
793069-007 792968-018 3042mm
793069-013 792968-023 3192mm
793069-014 792968-024 3347mm
793069-015 792968-025 3492mm
793069-016 792968-026 3692mm
793069-017 792968-027 3842mm
793069-018 792968-028 3952mm
793069-019 792968-029 4252mm
793069-020 792968-030 4452mm
Tab012gb
M1.0-0000-000160
160
Printed in Germany
161
TILT AND SIDESHIFT
M1498

REV.1 10/02
M1.0-0000-000162
162
TILT AND SIDESHIFT
0 ..................... 806181-001 ............................ Tilt & Sideshift (1.4/1.6t-1285/1425mm,L.Width/Tilt 2°/4°) ................... 1

807382-001 ............................ Tilt & Sideshift (1.4/1.6t-1575mm, Leg Width/Tilt 2°/4°) ....................... 1
808418-001 ............................ Tilt & Sideshift (1.4/1.6t-1285/1425mm,L.Width/Tilt 2°/2°) ................... 1
1 ........................... 808521-001 ............................. Frame (only for 806181-001 & 808418-001) .................................. 1
808521-002 ............................. Frame (only for 807382-001) ........................................................... 1
2 ........................... 808522-001 ............................. Sleeve Bearing ................................................................................. 2
3* .......................... 808523 .................................... Groove Ring ..................................................................................... 2
4 ........................... 808524 .................................... Washer ............................................................................................. 2
5* .......................... 808525 .................................... Stripper ............................................................................................. 2
6 ........................... 808526-001 ............................. Piston Rod (only for 806181-001 & 808418-001) .......................... 2
808526-002 ............................. Piston Rod (only for 807382-001) ................................................... 2
7 ........................... 808527 .................................... Seal Ring .......................................................................................... 2
8 ........................... 808528 .................................... Dowel ................................................................................................ 2
9 ........................... 060030-057 ............................. Shim .................................................................................................. 6
10 ......................... 060030-085 ............................. Shim .................................................................................................. 6
11 ......................... 807334-002 ............................. Roller Æ101,47mm .......................................................................... AR
807334-003 ............................. Roller Æ 102,14mm ......................................................................... AR
807334-004 ............................. Roller Æ 102,45mm ......................................................................... AR
12 ......................... 808529-001 ............................. Sliding Piece .................................................................................... 5
13 ......................... 808522-002 ............................. Sleeve Bearing ................................................................................. 1
14 ......................... 808530 .................................... Piston ................................................................................................ 1
15 ......................... 808543 .................................... Cylinder (only for 806181-001 & 807382-001) .............................. 1
808562 .................................... Cylinder (only for 808418-001) ....................................................... 1
16 ......................... 808529-002 ............................. Sliding Piece .................................................................................... 1
17 ......................... 808532 .................................... Spiral Fixing Pin ............................................................................... 2
18 ......................... 808533 .................................... Hook ................................................................................................. 1
19 ......................... 808534-001 ............................. Screw ................................................................................................ 2
20 ......................... 808535-001 ............................. Fork Carriage (only for 806181-001 & 808418-001) ..................... 1
808535-002 ............................. Fork Carriage (only for 807382-001) .............................................. 1
21 ......................... 808536 .................................... Greasing Nipples ............................................................................. 3
22 ......................... 808529-003 ............................. Sliding Piece .................................................................................... 1
23 ......................... 808534-002 ............................. Screw ................................................................................................ 2
24 ......................... 808537 .................................... Pipe (only for 806181-001 & 807382-001) ..................................... 3
808560 .................................... Pipe (only for 808418-001) .............................................................. 3
25 ......................... 808534-003 ............................. Screw (only for 806181-001 & 807382-001) .................................. 3
808561 .................................... Screw (only for 808418-001) ........................................................... 3
26 ......................... 808538 .................................... Quick Clutch ..................................................................................... 2
27 ......................... 808539 .................................... Tension Device ................................................................................. 2
28 ......................... 808534-004 ............................. Screw ................................................................................................ 2
29 ......................... 795534 .................................... Shim .................................................................................................. 6
* ........................... 808541 .................................... Seal Kit (inclusive 3, 5) .................................................................... 1

REV. 1 10/02
163
TILT AND SIDESHIFT
M1500

REV.1 10/02
M1.0-0000-000164
164
TILT AND SIDESHIFT
0 ..................... 806181-002 ............................ Tilt & Sideshift (2.0t-1285/1425mm Leg Width/Tilt 2°/4°) ..................... 1
807382-002 ............................ Tilt & Sideshift (2.0t-1575mm Leg Width/Tilt 2°/4°) .............................. 1
808418-002 ............................ Tilt & Sideshift (2.0t-1285/1425mm Leg Width/Tilt 2°/2°) ..................... 1
1 ........................... 808542-001 ............................. Frame (only for 806181-002 & 808418-002) .................................. 1
808542-002 ............................. Frame (only for 807382-002) ........................................................... 1
2 ........................... 808522-001 ............................. Sleeve Bearing ................................................................................. 2
3* .......................... 808523 .................................... Groove Ring ..................................................................................... 2
4 ........................... 808524 .................................... Washer ............................................................................................. 2
5* .......................... 808525 .................................... Stripper ............................................................................................. 2
6 ........................... 808526-001 ............................. Piston Rod (only for 806181-002 & 808418-002) .......................... 2
808526-002 ............................. Piston Rod (only for 807382-002) ................................................... 2
7 ........................... 808527 .................................... Seal Ring .......................................................................................... 2
8 ........................... 808528 .................................... Dowel ................................................................................................ 2
9 ........................... 060030-057 ............................. Shim .................................................................................................. 8
10 ......................... 060030-085 ............................. Shim .................................................................................................. 8
11 ......................... 807334-002 ............................. Roller Æ 101,47mm ........................................................................ AR
807334-003 ............................. Roller Æ 102,14mm ......................................................................... AR
807334-004 ............................. Roller Æ 102,45mm ........................................................................ AR
12 ......................... 808529-001 ............................. Sliding Piece .................................................................................... 5
13 ......................... 808522-002 ............................. Sleeve Bearing ................................................................................. 1
14 ......................... 808530 .................................... Piston ................................................................................................ 1
15 ......................... 808543 .................................... Cylinder (only for 806181-002 & 807382-002) .............................. 1
808562 .................................... Cylinder (only for 808418-002) ....................................................... 1
16 ......................... 808529-002 ............................. Sliding Piece .................................................................................... 1
18 ......................... 808533 .................................... Hook ................................................................................................. 1
19 ......................... 808534-001 ............................. Screw ................................................................................................ 2
20 ......................... 808535-001 ............................. Fork Carriage (only for 806181-002 & 808418-002) ..................... 1
808535-002 ............................. Fork Carriage (only for 807382-002) .............................................. 1
22 ......................... 808529-003 ............................. Sliding Piece .................................................................................... 1
23 ......................... 808534-002 ............................. Screw ................................................................................................ 2
24 ......................... 808537 .................................... Pipe (only for 806181-002 & 807382-002) ..................................... 3
808560 .................................... Pipe (only for 808418-002) .............................................................. 3
25 ......................... 808534-003 ............................. Screw (only for 806181-002 & 807382-002) .................................. 3
808561 .................................... Screw (only for 808418-002) ........................................................... 3
26 ......................... 795534 .................................... Shim .................................................................................................. 8
27 ......................... 808538 .................................... Quick Clutch ..................................................................................... 2
28 ......................... 808539 .................................... Tension Device ................................................................................. 2
29 ......................... 808534-004 ............................. Screw ................................................................................................ 2
30 ......................... 808729 .................................... Shim .................................................................................................. 3
31 ......................... 808730 .................................... Shim .................................................................................................. 3
32 ......................... 808731 .................................... Shim .................................................................................................. 3
33 ......................... 808732 .................................... Shim .................................................................................................. 2
34 ......................... 050003-020 ............................. Screw ................................................................................................ 2
053050-006 ............................. Adhesive .......................................................................................... AR

REV. 1 10/02
165
TILT AND SIDESHIFT
MP-2140-008
M1.0-0000-000166
166
TILT AND SIDESHIFT
0 ..................... 808716 .................................... Tilt & Sideshift (Long Drop) ................................................................... 1

1 ........................... 808565 .................................... Frame ................................................................................................ 1
2 ........................... 808522-001 ............................. Sleeve Bearing ................................................................................. 2
3* .......................... 808523 .................................... Groove Ring ..................................................................................... 2
4 ........................... 808524 .................................... Washer ............................................................................................. 2
5* .......................... 808525 .................................... Stripper ............................................................................................. 2
6 ........................... 808526-001 ............................. Piston Rod ........................................................................................ 2
7 ........................... 808527 .................................... Seal Ring .......................................................................................... 2
8 ........................... 808528 .................................... Dowel ................................................................................................ 2
9 ........................... 060030-057 ............................. Shim .................................................................................................. 8
10 ......................... 060030-085 ............................. Shim .................................................................................................. 8
11 ......................... 807334-002 ............................. Roller Æ 101,47mm ......................................................................... AR
807334-003 ............................. Roller Æ 102,14mm ......................................................................... AR
807334-004 ............................. Roller Æ 102,45mm ......................................................................... AR
12 ......................... 808529-001 ............................. Sliding Piece .................................................................................... 7
13 ......................... 808522-002 ............................. Sleeve Bearing ................................................................................. 1
14 ......................... 808530 .................................... Piston ................................................................................................ 1
15 ......................... 808543 .................................... Cylinder ............................................................................................ 1
16 ......................... 808566 .................................... Sliding Piece .................................................................................... 1
18 ......................... 808533 .................................... Hook ................................................................................................. 1
19 ......................... 808534-001 ............................. Screw ................................................................................................ 2
20 ......................... 808535-002 ............................. Fork Carriage ................................................................................... 1
22 ......................... 808529-003 ............................. Sliding Piece .................................................................................... 1
23 ......................... 808534-002 ............................. Screw ................................................................................................ 2
24 ......................... 808560 .................................... Pipe ................................................................................................... 3
25 ......................... 808561 .................................... Screw ................................................................................................ 3
26 ......................... 795534 .................................... Shim .................................................................................................. 8
27 ......................... 808538 .................................... Quick Clutch ..................................................................................... 2
28 ......................... 808539 .................................... Tension Device ................................................................................. 2
29 ......................... 808534-004 ............................. Screw ................................................................................................ 2
30 ......................... 808729 .................................... Shim .................................................................................................. 3
31 ......................... 808730 .................................... Shim .................................................................................................. 3
32 ......................... 808731 .................................... Shim .................................................................................................. 3
33 ......................... 808732 .................................... Shim .................................................................................................. 2
34 ......................... 050003-020 ............................. Screw ................................................................................................ 2
053050-006 ............................. Adhesive .......................................................................................... AR
167
TILT AND SIDESHIFT
M1633

REV.1 10/02
M1.0-0000-000168
168
TILT AND SIDESHIFT
1 ..................... 808943-001 ............................ Valve Block ............................................................................................. 1

808941-001 ............................ Check Valve ........................................................................................... 1
2 ..................... 808942-001 ............................ Plug ........................................................................................................ 2
3 ..................... 808941-002 ............................ Counter Balance Valve .......................................................................... 1
4 ..................... 808553-002 ............................ Valve Solenoid ....................................................................................... 1
808940-002 ............................ Coil Solenoid ......................................................................................... 1
808553-004 ............................ Kit Seal ................................................................................................... 1
5 ..................... 808553-002 ............................ Valve Solenoid ....................................................................................... 1
808940-001 ............................ Coil Solenoid ......................................................................................... 1
808553-004 ............................ Kit Seal ................................................................................................... 1
6 ..................... 064004-002 ............................ Adaptor ................................................................................................... 1
7 ..................... 064065-002 ............................ Elbow ...................................................................................................... 1
8 ..................... 808043 .................................... Pipe (without „Long Drop“) .................................................................... 1
...................... 808872 .................................... Pipe (Long Drop) ................................................................................... 1
9 ..................... 054176-001 ............................ Adaptor (without „Long Drop“) ..............................................................
10 ................... 064061-001 ............................ Elbow ...................................................................................................... 1
11 ................... 808042 .................................... Pipe (without „Long Drop“) .................................................................... 1
808871 .................................... Pipe (Long Drop) ................................................................................... 1
12 ................... 054188-001 ............................ Elbow (with „Long Drop“ 2 pieces) ....................................................... 1
13 ................... 807479 .................................... Bracket ................................................................................................... 1
051051-004 ............................ Binder ..................................................................................................... 4
14 ................... 050006-025 ............................ Screw ...................................................................................................... 2
15 ................... 064061-004 ............................ Elbow ...................................................................................................... 4
808873 .................................... Pipe (Long Drop) ................................................................................... 1
808976 .................................... Pipe (Long Drop) ................................................................................... 1
18 ................... 064004-007 ............................ Adaptor ................................................................................................... 4
19 ................... 808974 .................................... Pipe ........................................................................................................ 1
20 ................... 808975 .................................... Pipe ........................................................................................................ 1
21 ................... 807871 .................................... Clamp ..................................................................................................... 1
22 ................... 050005-058 ............................ Screw ...................................................................................................... 1
23 ................... 064091-006 ............................ Plug ........................................................................................................ 1
24 ................... 807449 .................................... Adaptor ................................................................................................... 1
25 ................... 807476 .................................... Adaptor ................................................................................................... 1
26 ................... 808886-001 ............................ Main Harness LS/FKS Assembly (inclusive 126491Pressure Sensor)1
808886-002 ............................ Main Harness LS/FKS Assy Fork Widht 50mm (inclusive 126491) .... 1
126491 .................................... Pressure Sensor (LS) ...................................................................... 1
051051-009 ............................ Cable Tie ................................................................................................ 2
793288 .................................... Clip ......................................................................................................... 1
050003-012 ............................ Screw ...................................................................................................... 1
27 ................... 792991 .................................... Microswitch (FKS) .................................................................................. 1
807541 .................................... Plate ....................................................................................................... 1
050006-001 ............................ Screw ...................................................................................................... 2
796231 .................................... Cable Assembly (only for Freezer/Corrosion) ...................................... 1
794590-001 ............................. Cable (only for Freezer/Corrosion) .................................................. 1
796230 .................................... Heater (only for Freezer/Corrosion) ................................................ 1
050004-042 ............................. Screw (only for Freezer/Corrosion) ................................................. 2
050008-011 ............................. Nut (only for Freezer/Corrosion) ...................................................... 2
28 ................... 807488 .................................... Switch ..................................................................................................... 1
29 ................... 055058-001 ............................ Puffer ...................................................................................................... 2
30 ................... 807681 .................................... Bracket ................................................................................................... 1
050009-008 ............................ Washer ................................................................................................... 2
050006-013 ............................ Screw ...................................................................................................... 2
807953 .................................... Valve Block (inclusive 1-5) .................................................................... 1
808080 .................................... Valve Assembly (inclusive 1-7, 10, 15, 18) .......................................... 1

REV. 2 10/02
169
TILT AND SIDESHIFT
5th Function Valve
MP-2140-019
M1.0-0000-000170
170
TILT AND SIDESHIFT
1 ..................... 064061-001 ............................ Adaptor ................................................................................................... 1

2 ..................... 064010-002 ............................ Branch Tee Coupling ............................................................................. 1
3 ..................... 808837 .................................... Pipe ........................................................................................................ 1
4 ..................... 808838 .................................... Pipe ........................................................................................................ 1
5 ..................... 064061-002 ............................ Adaptor ................................................................................................... 3
6 ..................... 054183-001 ............................ Adaptor ................................................................................................... 1
7 ..................... 807403 .................................... Valve Solenoid ....................................................................................... 1
8 ..................... 050007-012 ............................ Screw ...................................................................................................... 2
9 ..................... 808836 .................................... Bracket ................................................................................................... 1
10 ................... 050008-015 ............................ Nut .......................................................................................................... 2
11 ................... 050006-025 ............................ Screw ...................................................................................................... 2
12 ................... 793288 .................................... Clip ......................................................................................................... 1
13 ................... 050003-013 ............................ Screw ...................................................................................................... 1
14 ................... 050008-008 ............................ Nut .......................................................................................................... 1
15 ................... 808841 .................................... Pipe ........................................................................................................ 1
16 ................... 808865 .................................... Pipe ........................................................................................................ 1
17 ................... 808840 .................................... Bracket ................................................................................................... 1
18 ................... 050006-032 ............................ Screw ...................................................................................................... 2
19 ................... 054176-001 ............................ Adaptor ................................................................................................... 2
20 ................... 054171-002 ............................ Adaptor ................................................................................................... 2
21 ................... 054184-002 ............................ Adaptor (only for Quick Release Coupling) .......................................... 2
22 ................... 054185-002 ............................ Adaptor (only for Quick Release Coupling) .......................................... 2
808849 .................................... Valve Assembly (inclusive 5,6,7) .......................................................... 1
171
TILT AND SIDESHIFT
6th Function Valve
MP-2140-026
M1.0-0000-000172
172
TILT AND SIDESHIFT
1 ..................... 807403 .................................... Valve Solenoid ....................................................................................... 2

2 ..................... 064061-002 ............................ Elbow ...................................................................................................... 4
3 ..................... 064004-003 ............................ Adaptor ................................................................................................... 2
4 ..................... 054183-001 ............................ Adaptor ................................................................................................... 2
5 ..................... 050007-011 ............................ Screw ...................................................................................................... 4
6 ..................... 796725 .................................... Bracket ................................................................................................... 1
7 ..................... 050008-015 ............................ Nut .......................................................................................................... 6
8 ..................... 050006-024 ............................ Screw ...................................................................................................... 2
9 ..................... 796724 .................................... Bracket ................................................................................................... 1
10 ................... 050009-018 ............................ Washer ................................................................................................... 2
11 ................... 050006-032 ............................ Screw ...................................................................................................... 2
12 ................... 796728 .................................... T-Adaptor ................................................................................................ 2
13 ................... 064073-001 ............................ Adaptor ................................................................................................... 2
14 ................... 796727 .................................... Pipe ........................................................................................................ 1
15 ................... 064061-001 ............................ Elbow ...................................................................................................... 1
16 ................... 796726 .................................... Pipe ........................................................................................................ 1
17 ................... 064010-001 ............................ T-Adaptor ................................................................................................ 1
173
LIFT BUFFER
M1631

REV.1 02/02
M1.0-0000-000174
174
LIFT BUFFER
0 ..................... 806173 .................................... Stopper (inclusive 1, 3-7) ...................................................................... 1

806199 .................................... Stopper (inclusive 2-7) .......................................................................... 1
1 ........................... 806251 .................................... Bracket ............................................................................................. 1
2 ........................... 806259 .................................... Bracket ............................................................................................. 1
3 ........................... 806178 .................................... Rubber .............................................................................................. 2
4 ........................... 806177 .................................... Plunger ............................................................................................. 2
5 ........................... 050000-056 ............................. Pin ..................................................................................................... 2
6 ........................... 124018 .................................... Buffer ................................................................................................ 2
7 ........................... 050005-022 ............................. Screw ................................................................................................ 2
053050-006 ............................. Adhesive .......................................................................................... AR
8 ........................... 050006-074 ............................. Screw ................................................................................................ 4
053002-001 ............................. Grease .............................................................................................. AR

REV. 1 02/02
175
FORK
M1578
M1.0-0000-000176
176
FORK
1 ........................................................................ Fork (see list) .......................................................................................... 2

2 ........................................................................ Handle Assembly (inclusive 2-5) .......................................................... 2
3 ........................................................................ Spring Compression .............................................................................. 2
4 ........................................................................ Pin .......................................................................................................... 2
5 ........................................................................ Detent ..................................................................................................... 2
1,4t/1,6t
Fork Widht 40mm
1000mm 1067mm 1150mm 1220mm 1500mm 1600mm
803991-003-012 803991-009-01 803991-012-012 803991-007-01 803991-011-01 803991-010-01
Tab011gb
2.0t
Fork Width 45mm
1000mm 1067mm 1150mm 1220mm 1500mm 1600mm
807596-001 807596-002 807596-003 807596-004 807596-005 807596-006
Tab018gb
1.4t,1.6t,2.0t
Fork Width 50mm
1000mm 1067mm 1150mm 1220mm 1500mm 1600mm
796418-001-01 796418-002-01 796418-003-01 796418-004-01 796418-005-01 796418-006-01
Tab019gb

REV. 1 10/02
177
LOAD BACKREST
M1577
M1.0-0000-000178
178
LOAD BACKREST
1 ..................... 806193-001 ............................ Load Backrest (Leg Width 1285/1425mm) ........................................... 1

806193-002 ............................ Load Backrest (Leg Width 1575mm) .................................................... 1
2 ..................... 050003-050 ............................ Screw ...................................................................................................... 4
Option
Load Backrest (Leg Width 1285/1425mm)
800mm 900mm 1000mm 1100mm 1200mm 1300mm 1400mm 1500mm 1600mm 1700mm
796175-019 796175-001 796175-002 796175-003 796175-004 796175-005 796175-006 796175-007 796175-008 796175-009
Tab020gb
Load Backrest (Leg Widht 1575mm)
800mm 900mm 1000mm 1100mm 1200mm 1300mm 1400mm 1500mm 1600mm 1700mm
796175-020 796175-010 796175-011 796175-012 796175-013 796175-014 796175-015 796175-016 796175-017 796175-018
Tab021gb
179
YOKE
M1489

REV.1 10/02
M1.0-0000-000180
180
YOKE
0 ..................... 806269 .................................... Yoke ........................................................................................................ 1

1 ........................... 050012-065 ............................. Circlip ............................................................................................... 2
2 ........................... 806171 .................................... Washer ............................................................................................. 3
3 ........................... 119655-001 ............................. Pulley ................................................................................................ 2
4 ........................... 050012-009 ............................. Circlip ............................................................................................... 1
5 ........................... 806154 .................................... Shaft .................................................................................................. 1
6 ........................... 050000-003 ............................. Pin ..................................................................................................... 1
7 ........................... 806253 .................................... Yoke Bracket ..................................................................................... 1
8 ........................... 060030-085 ............................. Washer ............................................................................................. 2
9 ........................... 806155 .................................... Pulley ................................................................................................ 1
10 ......................... 127513-001 ............................. Pulley ................................................................................................ 1
11 ......................... 103349 .................................... Pulley ................................................................................................ 1
12 ......................... 050009-013 ............................. Washer ............................................................................................. 1
13 ......................... 050012-013 ............................. Circlip ............................................................................................... 1
14 ......................... 810283 .................................... Plate .................................................................................................. 1
15 ......................... 050003-021 ............................. Screw ................................................................................................ 1

REV. 1 10/02
181
Printed in Germany
M1.0-0000-000182
182
SECTION 8
Printed in Germany
183
LIFT CYLINDER
M1490
M1.0-0000-000184
184
LIFT CYLINDER
0 ..................... 806200-*** .............................. Lift Cylinder ø40 (1.4/1.6t) ..................................................................... 2

1 ........................... 806204-*** .............................. Cylinder Tube ................................................................................... 2
2* .......................... 804770 .................................... Guide Ring ....................................................................................... 4
3 ........................... 804710 .................................... Piston Button .................................................................................... 2
4 ........................... 804722-*** .............................. Piston Rod ........................................................................................ 2
5* .......................... 804767 .................................... Guide Ring ....................................................................................... 4
6* .......................... 804774 .................................... O-Ring .............................................................................................. 2
7 ........................... 807745 .................................... Cylinder Cap .................................................................................... 2
8* .......................... 804761 .................................... Seal ................................................................................................... 2
9* .......................... 804755 .................................... Wiper ................................................................................................ 2
10* ......................... 54173 ....................................... Seal ................................................................................................... 2
11 ......................... 54172 ....................................... Bleed Screw ..................................................................................... 2
12* ......................... 807748 .................................... Backup Ring ..................................................................................... 2
* ........................... 808531 .................................... Seal Kit (inclusive 2,5,6,8,9,10,12) .................................................. 1
806200-001 806204-001 804722-011 2022mm
806200-002 806204-002 804722-012 2172mm
806200-003 806204-003 804722-013 2322mm
806200-004 806204-004 804722-014 2472mm
806200-005 806204-005 804722-015 2572mm
806200-006 806204-006 804722-016 2772mm
806200-007 806204-007 804722-017 2922mm
806200-008 806204-008 804722-018 3042mm
806200-009 806204-009 804722-019 3192mm
806200-010 806204-010 804722-020 3347mm
806200-011 806204-011 804722-021 3492mm
806200-012 806204-012 804722-022 3692mm
806200-013 806204-013 804722-023 3842mm
806200-014 806204-014 804722-024 3952mm
Tab001gb
185
LIFT CYLINDER
M1490
M1.0-0000-000186
186
LIFT CYLINDER
0 ..................... 806201-*** .............................. Lift Cylinder ø45 (2.0t) ........................................................................... 2

1 ........................... 806205-*** .............................. Cylinder Tube ................................................................................... 2
2* .......................... 804768 .................................... Guide Ring ....................................................................................... 4
3 ........................... 806222 .................................... Piston Button .................................................................................... 2
4 ........................... 806208-*** .............................. Piston Rod ........................................................................................ 2
5* .......................... 804770 .................................... Guide Ring ....................................................................................... 4
6* .......................... 806232 .................................... O-Ring .............................................................................................. 2
7 ........................... 806218 .................................... Cylinder Cap .................................................................................... 2
8* .......................... 806224 .................................... Seal ................................................................................................... 2
9* .......................... 806226 .................................... Wiper ................................................................................................ 2
10* ......................... 54173 ....................................... Seal ................................................................................................... 2
11 ......................... 54172 ....................................... Bleed Screw ..................................................................................... 2
12* ......................... 807749 .................................... Backup Ring ..................................................................................... 2
* ........................... 808548 .................................... Seal Kit (inclusive 2,5,6,8,9,10,12) ................................................. 1
806201-001 806205-001 806208-001 2022mm
806201-002 806205-002 806208-002 2172mm
806201-004 806205-004 806208-004 2472mm
806201-006 806205-006 806208-006 2772mm
806201-007 806205-007 806208-007 2922mm
806201-008 806205-008 806208-008 3042mm
806201-010 806205-010 806208-010 3347mm
806201-012 806205-012 806208-012 3692mm
806201-013 806205-013 806208-013 3842mm
806201-014 806205-014 806208-014 3952mm
806201-015 806205-015 806208-015 4252mm
806201-016 806205-016 806208-016 4452mm
Tab002gb

REV. 1 02/02
187
FREE LIFT CYLINDER
M1493

REV. 1 02/02
M1.0-0000-000188
188
FREE LIFT CYLINDER
0 ..................... 810047-*** .............................. Free Lift Cylinder ø56 (1.4/1.6t) ............................................................. 1

1 ........................... 810049-*** .............................. Cylinder Tube ................................................................................... 1
2 ........................... 806990 .................................... Hose Burst Valve .............................................................................. 1
3* .......................... 804772 .................................... Guide Ring ....................................................................................... 2
4 ........................... 804708 .................................... Piston Button .................................................................................... 1
5 ........................... 050012-066 ............................. Ring Retaining ................................................................................. 1
6 ........................... 806211 .................................... Piston Shut Off .................................................................................. 1
7 ........................... 806212 .................................... Spring ............................................................................................... 1
8 ........................... 806209-*** .............................. Piston Rod ........................................................................................ 1
9* .......................... 804769 .................................... Guide Ring ....................................................................................... 2
10* ......................... 804776 .................................... O-Ring .............................................................................................. 1
11 ......................... 807743 .................................... Cylinder Cap .................................................................................... 1
12* ......................... 804763 .................................... Seal ................................................................................................... 1
13* ......................... 804757 .................................... Wiper ................................................................................................ 1
14* ......................... 54173 ....................................... Seal ................................................................................................... 1
15 ......................... 54172 ....................................... Bleed Screw ..................................................................................... 1
16* ......................... 807746 .................................... Backup Ring ..................................................................................... 1
* ........................... 808549 .................................... Seal Kit (inclusive 3,9,10,12,13,14,16) .......................................... 1
810047-001 810049-001 806209-001 2022mm
810047-002 810049-002 806209-002 2172mm
810047-003 810049-003 806209-003 2322mm
810047-004 810049-004 806209-004 2472mm
810047-005 810049-005 806209-005 2572mm
810047-006 810049-006 806209-006 2772mm
810047-007 810049-007 806209-007 2922mm
810047-008 810049-008 806209-008 3042mm
810047-009 810049-009 806209-009 3192mm
810047-010 810049-010 806209-010 3347mm
810047-011 810049-011 806209-011 3492mm
810047-012 810049-012 806209-012 3692mm
810047-013 810049-013 806209-013 3842mm
810047-014 810049-014 806209-014 3952mm
Tab003gb

REV. 1 02/02
189
FREE LIFT CYLINDER
M1492

REV. 1 02/02
M1.0-0000-000190
190
FREE LIFT CYLINDER
0 ..................... 810048-*** .............................. Free Lift Cylinder ø65 (2.0t) ................................................................... 1

1 ........................... 810050-*** .............................. Cylinder Tube ................................................................................... 1
2 ........................... 806988 .................................... Hose Burst Valve .............................................................................. 1
3* .......................... 806230 .................................... Guide Ring ....................................................................................... 2
4 ........................... 806223 .................................... Piston Button .................................................................................... 1
5 ........................... 050012-066 ............................. Ring Retaining ................................................................................. 1
6 ........................... 806211 .................................... Piston Shut Off .................................................................................. 1
7 ........................... 806212 .................................... Spring ............................................................................................... 1
8 ........................... 806221-*** .............................. Piston Rod ........................................................................................ 1
9* .......................... 806231 .................................... Guide Ring ....................................................................................... 2
10* ......................... 806233 .................................... O-Ring .............................................................................................. 1
11 ......................... 806219 .................................... Cylinder Cap .................................................................................... 1
12* ......................... 806225 .................................... Seal ................................................................................................... 1
13* ......................... 806227 .................................... Wiper ................................................................................................ 1
14* ......................... 54173 ....................................... Seal ................................................................................................... 1
15 ......................... 54172 ....................................... Bleed Screw ..................................................................................... 1
16* ......................... 807747 .................................... Backup Ring ..................................................................................... 1
* ........................... 808550 .................................... Seal Kit (inclusive 3,9,10,12,13,14,16) .......................................... 1
810048-001 810050-001 806221-001 2022mm
810048-002 810050-002 806221-002 2172mm
810048-004 810050-004 806221-004 2472mm
810048-006 810050-006 806221-006 2772mm
810048-007 810050-007 806221-007 2922mm
810048-008 810050-008 806221-008 3042mm
810048-010 810050-010 806221-010 3347mm
810048-012 810050-012 806221-012 3692mm
810048-013 810050-013 806221-013 3842mm
810048-014 810050-014 806221-014 3952mm
810048-015 810050-015 806221-015 4252mm
810048-016 810050-016 806221-016 4452mm
Tab004gb

REV. 1 02/02
191
CYLINDER REACH
M1483
M1.0-0000-000192
192
CYLINDER REACH
0 ..................... 806390-001 ............................ Cylinder Reach (1.4t/inclusive 1-16) ................................................... 1

806390-002 ............................ Cylinder Reach (1.6t-2.0tinclusive 1-16) ............................................. 1
1 ........................... 806398-001 ............................. Cylinder Tube (1.4t) .......................................................................... 1
806398-002 ............................. Cylinder Tube (1.6t-2.0t) .................................................................. 1
2 ........................... 807404 .................................... Bearing ............................................................................................. 1
3* .......................... 804766 .................................... Guide Ring ....................................................................................... 2
4* .......................... 807355 .................................... Piston Seal ....................................................................................... 1
5 ........................... 807304 .................................... Piston Rod ........................................................................................ 1
6* .......................... 804771 .................................... Guide Ring ....................................................................................... 2
7* .......................... 804774 .................................... O-Ring .............................................................................................. 1
8* .......................... 807343 .................................... Washer ............................................................................................. 1
9 ........................... 807305 .................................... End, Cap .......................................................................................... 1
10* ......................... 807356 .................................... Rod Seal .......................................................................................... 1
11* ......................... 807357 .................................... Wiper ................................................................................................ 1
12 ......................... 807407 .................................... Washer ............................................................................................. 1
13 ......................... 050008-069 ............................. Nut .................................................................................................... 1
14 ......................... 806402 .................................... Rod End ........................................................................................... 1
15 ......................... 064004-003 ............................. Adaptor ............................................................................................. 1
16* ......................... 807748 .................................... Backup Ring ..................................................................................... 1
17 ......................... 806805-001 ............................. Spacer (183mm) .............................................................................. 1
806805-002 ............................. Spacer (255mm) .............................................................................. 1
806805-003 ............................. Spacer (83mm) ................................................................................. 1
806805-004 ............................. Spacer (155mm) .............................................................................. 1
806805-005 ............................. Spacer (227mm) .............................................................................. 1
18 ......................... 806810 .................................... O-Ring .............................................................................................. 2
* ........................... 808551 .................................... Seal Kit (inclusive 3,4,6,7,8,10,11,16) ............................................ 1
Position 17 420Ah 560Ah 700Ah 820Ah
1.4t. ---- 806805-001 806805-002 ----
1.6t. ---- 806805-003 806805-004 806805-005
2.0t. N/A 806805-003 806805-004 806805-005
Tab017

REV. 1 02/02
193
Printed in Germany
M1.0-0000-000194
194
SECTION 10
Printed in Germany
195
LABELS AND DECALS
MP-2140-007
M1.0-0000-000196
196
LABELS AND DECALS
1 ..................... 106158-001 ............................ Decal Crown Heavy .............................................................................. 1

4 ..................... 869009-*** .............................. Warning Stand On ................................................................................. 1
5 ..................... 869010-*** .............................. Warning Stand Under ............................................................................ 1
6 ..................... 869104-*** .............................. Warning Moving Mast ............................................................................ 1
7 ..................... 869004-*** .............................. Warning Moving Vehicle ........................................................................ 1
8 ..................... 796331 .................................... Label Wheel Torque .............................................................................. 1
9 ..................... 869005-*** .............................. Warning Rider Truck .............................................................................. 1
10 ................... 869006 .................................... Warning Hands Off ................................................................................ 2
11 ................... 869012-*** .............................. Warning Electrical Additions ................................................................. 1
12 ................... 69154 ...................................... Label Hydraulic Oil ................................................................................ 1
13 ................... 869274-*** .............................. Label Capacity Data .............................................................................. 1
14 ................... 869020-*** .............................. Danger Battery ....................................................................................... 1
15 ................... 869047-*** .............................. Caution, Charger Hook Up .................................................................... 1
*** ................... xxxxxx-001 .............................. German

xxxxxx-002 .............................. French
xxxxxx-003 .............................. Spanish
xxxxxx-004 .............................. Dutch
xxxxxx-005 .............................. Italien
xxxxxx-006 .............................. English
197
Printed in Germany
M1.0-0000-000198
198
CROWN Gabelstapler GmbH & Co. KG
- European Headquarter -
Moosacher Str. 52
80809 Munich
Germany
Telephone +49 (0)89 93 00 2 - 0
Telefax +49 (0)89 93 00 2 -175 or -133
Printed in Germany • Revision Level C

Order Number: 812674-006

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Parts Manual

ITD – INTRODUCTION PAGE SERIAL NR. CUT REV.

SECTION 1 – COVERS PAGE SERIAL NR. CUT REV.

SECTION 2 – HYDRAULIC PART PAGE SERIAL NR. CUT REV.

SECTION 3 – DRIVE UNIT PAGE SERIAL NR. CUT REV.

SECTION 4 – ELECTRICAL PAGE SERIAL NR. CUT REV.

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany M/P-IDX-2140

SECTION5 – BRAKE SYSTEM PAGE SERIAL NR. CUT REV.

SECTION 6 – STEERING PAGE SERIAL NR. CUT REV.

SECTION 7 – MAST-/LIFT STRUCTURE PAGE SERIAL NR. CUT REV.

SECTION 8 – CYLINDER PAGE SERIAL NR. CUT REV.

SECTION10 – MISCELLANEOUS SERVICE INF. PAGE SERIAL NR. CUT REV.

M/P-IDX-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

Important customer information Ordering Spare Parts

Any proposed modification which would

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany M/P-ITD-2140

MP-1.1-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

1 ..................... 791764-003 ............................ Grab Handle .......................................................................................... 1

Always Specify Model & Serial Number

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany MP-1.1-2140

MP-1.1-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

1 ........................................................................ Instrumentation ...................................................................................... 1

* ..................... 806929 .................................... Armrest Assembly .................................................................................. 1

Always Specify Model & Serial Number

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany MP-1.1-2140

MP-1.1-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

1 ..................... 790797-001 ............................ Block, Skid (A = 33mm) ......................................................................... 2

Always Specify Model & Serial Number

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany MP-1.1-2140

MP-1.2-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

1 ..................... 806409 .................................... Reach Carriage (1285mm Leg Width) .................................................. 1

Always Specify Model & Serial Number

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany MP-1.2-2140

MP-1.2-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

37* ................... 050003-012 ............................ Screw ...................................................................................................... 1

796180 .................................... Cable Assembly (Freezer/Corriosion) ................................................... 1

Always Specify Model & Serial Number

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany MP-1.2-2140

MP-1.5-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

0 ..................... 810576-001 ............................ Load Wheel Assembly Æ 285mm/1,4t .................................................. 2

Always Specify Model & Serial Number

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany MP-1.5-2140

MP-1.6-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

0 ..................... 807530-001 ............................ Battery Lock ........................................................................................... 1

807540 .................................... Battery Lock (inclusive 1-3,6-9,12-24,26-29) ................................. 1

Always Specify Model & Serial Number

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany MP-1.6-2140

MP-1.6-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

1 ..................... 807841 .................................... Battery Cover extension (Battery 560Ah) ............................................. 1

Always Specify Model & Serial Number

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany MP-1.6-2140

MP-1.6-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

For Trucks with Battery Rollers

45 ................... 804207 .................................... Roller ...................................................................................................... 6

Always Specify Model & Serial Number

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany MP-1.6-2140

MP-1.7-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany

0 ..................... 806493-001 ............................ Seat & Pan (black cloth) ........................................................................ 1

807865 .................................... Pan Mounting (inclusive 2,5,6) ........................................................ 1

795289 .................................... Cable Seat ....................................................................................... 1

Always Specify Model & Serial Number

MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany MP-1.7-2140

MP-1.7-2140 MP-ESR4000-GB 10/02 • Rev. B • Printed in Germany