Crow ESR4500

Parts Manual
ESR4500 Series
Printed in Germany ● Revision Level D
Order Number: 812704-006
This master manual is subject to continual updates.
It is meant exclusively for businesses authorized by CROWN.
It is not permitted to pass on the contents or copies thereof to third parties.
CROWN Gabelstapler GmbH & Co. KG

- European Headquarter -
Moosacher Str. 52
80809 Munich
Germany
Phone +49 (0)89 93 00 2 - 0

Fax +49 (0)89 93 00 2 - 133
All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2005
CROWN Equipment Corporation
TABLE OF CONTENTS
Printed in Germany
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Printed in Germany
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M1.0-0000-0002
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TABLE OF CONTENT
Table of Content
ITD – INTRODUCTION PAGE SERIAL NR. CUT REV.

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

Covers................................................................................... 12, 14 ..................................................... 02 Rev. 11/05
Covers................................................................................... 16 ......................... 5A204796 ................. 01 Rev. 05/05
Covers................................................................................... 16A ....................... 5A204798 ................. 02 Rev. 11/05
Skid Block and Wear Strips .................................................. 18 ......................... 5A204488
Skid Block and Wear Strips .................................................. 18A ....................... 5A204490 ................. 01 Rev. 11/05
Reach Carriage ..................................................................... 20 ........................................................... 01 Rev. 05/05
Load Wheel ........................................................................... 22 ........................................................... 01 Rev. 11/05
Battery Lock .......................................................................... 24 ........................................................... 01 Rev. 05/05
Battery Reach Out ................................................................ 26 ......................... 5A203866
Battery Reach Out ................................................................ 26A ....................... 5A203868 ................. 02 Rev. 11/05
Seat & Pan ............................................................................ 28 ........................................................... 01 Rev. 05/05
Seat ....................................................................................... 30 ......................... 5A203880
Seat ....................................................................................... 30A ....................... 5A203882 ................. 01 Rev. 05/05
Rear Mirror ............................................................................ 32
Guide Wheels ........................................................................ 34
Overhead Guard .................................................................... 36 ........................................................... 01 Rev. 05/05
Accessories .......................................................................... 38 ........................................................... 02 Rev. 11/05
SECTION 2 – HYDRAULIC PART PAGE SERIAL NR. CUT REV.

Tube-/Hose Layout ................................................................ 42 ........................................................... 02 Rev. 11/05
Hydraulic Tank ....................................................................... 44 ........................................................... 01 Rev. 05/05
Hydraulic TT Mast ................................................................. 46, 48 ................... 5A203818
Hydraulic TT Mast ................................................................. 46A ....................... 5A203820 ................. 01 Rev. 05/05
Valve Block ........................................................................... 50
Pump ..................................................................................... 52
Pump Motor and Pump ......................................................... 54 ........................................................... 01 Rev. 05/05
Pump Motor ........................................................................... 56 ........................................................... 01 Rev. 05/05
SECTION 3 – DRIVE UNIT PAGE SERIAL NR. CUT REV.

Drive Unit .............................................................................. 60 ......................... 5A204000
Drive Unit .............................................................................. 60A ....................... 5A204002 ................. 01 Rev. 05/05
Drive Unit .............................................................................. 60B ....................... 5A204798 ................. 02 Rev. 11/05
Gearbox ................................................................................. 62 ......................... 5A204796
Gearbox ................................................................................. 62A ....................... 5A204798 ................. 01 Rev. 11/05
Drive Motor ........................................................................... 64 ........................................................... 01 Rev. 05/05
SECTION 4 – ELECTRICAL PAGE SERIAL NR. CUT REV.

Electrical Compartment ........................................................ 68, 70 ................... 5A204796 ................. 01 Rev. 05/05
Electrical Compartment ........................................................ 68A, 70A .............. 5A204798 ................. 02 Rev. 11/05
Contactor .............................................................................. 72
Reach Slowdown ................................................................... 74
HGTS Lift Speed Reduction .................................................. 76 ......................... 5A203818
HGTS Lift Speed Reduction .................................................. 76A ....................... 5A203820 ................. 01 Rev. 05/05
Height Encoder ..................................................................... 78 ......................... 5A203818
Height Encoder ..................................................................... 78A ....................... 5A203820 ................. 02 Rev. 11/05
Mast Wiring ........................................................................... 80, 82 ..................................................... 01 Rev. 05/05
Joystick and Emergency Disconnector Switch ..................... 84 ......................... 5A204796 ................. 01 Rev. 05/05
Joystick and Emergency Disconnector Switch ..................... 84A, 86A .............. 5A204798 ................. 02 Rev. 11/05
Direction Switch/Horn Button ................................................ 88 ......................... 5A204796
Direction Switch/Horn Button ................................................ 88A ....................... 5A204798 ................. 01 Rev. 11/05
Floorplate .............................................................................. 90
Accelerator ............................................................................ 92 ........................................................... 01 Rev. 05/05
MP-ESR4500-GB 06/04 • Printed in Germany MP-IDX-2140

02 REV. 11/05
M1.0-0000-0003
33
TABLE DES MATIÈRES
Interrupteur de sécurité ......................................................... 94 ........................................................... 01 Rev. 05/05
DC/DC Redresseur ............................................................... 96 ........................................................... 01 Rev. 05/05
Tableau de commande .......................................................... 98 ........................................................... 01 Rev. 05/05
Tableau d'affichage ................................................................ 100 ....................... 5A204796 ................. 01 Rev. 05/05
Tableau d'affichage ................................................................ 100A ..................... 5A204798 ................. 02 Rev. 11/05
Lamp d'avertissement ........................................................... 102 ......................................................... 01 Rev. 11/05
Pares de marche ................................................................... 104 ......................................................... 01 Rev. 05/05
Pares de traval ...................................................................... 106
Signal sonore de marche-arriére .......................................... 108 ......................................................... 01 Rev. 05/05
Connexion et partie de fixation ............................................. 110
Klaxon ................................................................................... 112
System de refroidir ............................................................... 114 ......................................................... 02 Rev. 11/05
CHAPITRE 5 – SYSTEME DE FREINAGE PAGE COUPURE NR. SÉRIE REV.

Circuit de freinage ................................................................. 118
Pédale de frein ...................................................................... 120
Frein moteur .......................................................................... 122
Frein roues porteuses ........................................................... 124
CHAPITRE 6 – DIRECTION PAGE COUPURE NR. SÉRIE REV.

Moteur de direction ............................................................... 128 ....................... 5A204796
Moteur de direction ............................................................... 128A ..................... 5A204798 ................. 01 Rev. 11/05
Colonne de direction ............................................................. 130 ......................................................... 01 Rev. 05/05
CHAPITRE 7 – MÂT PAGE COUPURE NR. SÉRIE REV.

Mât TT 1.4t/1.6t ..................................................................... 134, 136 ............... 5A203818
Mât TT 1.4t/1.6t ..................................................................... 134A, 136A .......... 5A203820 ................. 01 Rev. 05/05
Mât TT 2.0t ............................................................................ 138, 140 ............... 5A203818
Mât TT 2.0t ............................................................................ 138A, 140A .......... 5A203820 ................. 01 Rev. 05/05
Chaîne de levage mât TT ...................................................... 142, 144
Inclinaison/déplacement latéral ............................................. 146, 148
Inclinaison/déplacement latéral-hydraulique ......................... 150, 152, 154 ......................................... 02 Rev. 11/05
Armotissement de levée ........................................................ 156 ......................................................... 01 Rev. 05/05
Dent de fourche ..................................................................... 158 ......................................................... 01 Rev. 05/05
Butée de charge .................................................................... 160
Poulies de guidage ................................................................ 162
CHAPITRE 8 – VÉRINS PAGE COUPURE NR. SÉRIE REV.

Vérin de levée 1.4t/1.6t ......................................................... 166 ....................... 5A203818
Vérin de levée 1.4t/1.6t ......................................................... 166A ..................... 5A203820 ................. 01 Rev. 05/05
Vérin de levée 2.0t ................................................................. 168 ....................... 5A203818
Vérin de levée 2.0t ................................................................. 168A ..................... 5A203820 ................. 01 Rev. 05/05
Vérin de levée libre 1.4t/1.6t .................................................. 170
Vérin de levée libre 2.0t ......................................................... 172
Vérin de rétration ................................................................... 174
CHAPITRE 9 – CABIN/PLATE - FORME PAGE COUPURE NR. SÉRIE REV.

Cabine chambres froides ...................................................... 178 ......................................................... 02 Rev. 02/06
CHAPITRE 10 – AUTRES INFORMATIONS SPAGE COUPURE NR. SÉRIE REV.

Autocolants et ètiquettes ....................................................... 182 ......................................................... 02 Rev. 11/05
MP-IDX-2140 MP-ESR4500-FR 06/04 • Printed in Germany

03 REV. 02/06
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, please Only if this information is provided can the order be
contact Crown for relevant training courses. processed quickly, correctly and reliably.
Subsequent Attachments and Modifications Please refer to the Technical Specifications Sheet for the
made to the Truck utilisable loads, technical data and dimensions for this
series. Brochures can be obtained from your CROWN
DANGER! dealer or from the following address:
Any proposed modification which would

alter the original condition of the truck CROWN Gabelstapler GmbH & CoKG
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-ESR4500-GB 06/04 • Printed in Germany M/P-ITD-2140
M1.0-0000-0007
77
Printed in Germany
8
PARTS
Printed in Germany
9
Printed in Germany
10M1.0-0000-00010
SECTION 1
Printed in Germany
11
COVERS
Part 1-3 2
3
5
4
6
1 8
7
5
14
10
11
13
10
12 11
MP-2140-063
MP-1.1-2140 MP-ESR4500-GB 06/04 • Printed in Germany
12M1.0-0000-00012
COVERS
INDEX PART NUMBER PART NAME NUMBER REQUIRED
1 ..................... 791764-003 .............................. Grab Handle ............................................................................................ 1

2 ..................... 813005-001 .............................. Spacer (5mm) ......................................................................................... 1
3 ..................... 813005-002 .............................. Spacer (2mm) ......................................................................................... 1
4 ..................... 050067-024 .............................. Screw ...................................................................................................... 1
5 ..................... 050068-003 .............................. Nut .......................................................................................................... 6
6 ..................... 806686-002 .............................. Corner Cover .......................................................................................... 1
7 ..................... 050071-035 .............................. Screw ...................................................................................................... 2
8 ..................... 815013 ..................................... Display Overlay ...................................................................................... 1
807053-002 .............................. Insert ...................................................................................................... 2
796164 ..................................... Display Overlay (Drive in Racking) ........................................................ 1
9* .................... 806687 ..................................... Head Rest ............................................................................................... 1
10* ................... 051068-003 .............................. Clip .......................................................................................................... 2
11* ................... 050004-020 .............................. Screw ...................................................................................................... 4
12 .................... 050068-004 .............................. Nut .......................................................................................................... 1
13 .................... 806931 ..................................... Leg Pad ................................................................................................... 1
053050-012 .............................. Adhesive Tape ......................................................................................... AR
14 .................... 812363 ..................................... Harness Cover ....................................................................................... 1
* ..................... 807352 ..................................... Head Rest Assembly (included 9 - 11) ................................................... 1
Not illustrated
796166 ..................................... Switch Cover (Drive in Racking) ............................................................ 2

050071-012 .............................. Screw (Drive in Racking) ........................................................................ 4
796708 ..................................... Headrest (Drive in Racking) ................................................................... 1
Always Specify Model & Serial Number

To select part number, refer to truck data number.
See Section ITD
MP-ESR4500-GB 06/04 • Printed in Germany MP-1.1-2140
01 REV. 05/05
13
COVERS
Part 2-3
4 3
7 5
8
12
17
8
19
13
18
15
16
11
10
14 9
MP-2140-064

01 REV. 05/05
14M1.0-0000-00014
COVERS
1 ..................... 815040 ..................................... Steering Wheel ........................................................................................ 1

2 ..................... 118917 ..................................... Spinner knob ........................................................................................... 1
3 ..................... 050010-021 .............................. Washer ................................................................................................... 1
4 ..................... 060016-019 .............................. Screw ...................................................................................................... 1
5 ..................... 050005-028 .............................. Screw ...................................................................................................... 1
6 ..................... 812138 ..................................... Steering Column Cover ........................................................................... 1
7 ..................... 050071-019 .............................. Screw ...................................................................................................... 2
8 ..................... 050071-020 .............................. Screw ...................................................................................................... 4
9 ..................... 812125 ..................................... Steering Column Cover ........................................................................... 1
10 .................... 812127 ..................................... Cover ...................................................................................................... 1
11 .................... 050003-010 .............................. Screw ...................................................................................................... 3
12 .................... 050008-001 .............................. Nut .......................................................................................................... 3
13 .................... 050003-014 .............................. Screw ...................................................................................................... 1
14 .................... 125502 ..................................... Pocket Storage ....................................................................................... 1
15 .................... 125503 ..................................... Mount Pocket .......................................................................................... 1
16 .................... 050005-060 .............................. Screw ...................................................................................................... 2
17 .................... 050068-002 .............................. Nut .......................................................................................................... 2
18 .................... 812364 ..................................... Tray ......................................................................................................... 1
19 .................... 050068-003 .............................. Nut .......................................................................................................... 4

See Section ITD
01 REV. 11/05
15
COVERS
Part 3-3
4 5
4 3
1
3
2
6 4
12
11
4 10
13 16
14
16
14 15
15
14
17
16
MP-2140-062
16M1.0-0000-00016
COVERS
1 ........................................................................ Instrumentation (see Section 4.9) ........................................................... 1

2* .................... 807098 ..................................... Armrest Moulding .................................................................................... 1
796489 ..................................... Armrest Moulding (6th Function Valve) ................................................... 1
3 ..................... 050009-020 .............................. Washer ................................................................................................... 2
4 ..................... 050071-035 .............................. Screw ...................................................................................................... 6
5* .................... 806689 ..................................... Armrest Pad ............................................................................................ 1
6* .................... 050067-012 .............................. Screw ...................................................................................................... 5
7 ........................................................................ Compartment Tray (see Section 4.1) ...................................................... 1
8 ..................... 806973 ..................................... Hand Guard ............................................................................................ 1
796024 ..................................... Hand Guard (Drive in Racking) ............................................................... 1
9 ..................... 050068-003 .............................. Nut .......................................................................................................... 3
10 .................... 812247 ..................................... Plate ........................................................................................................ 1
814887 ..................................... Plate (Drive in Racking) .......................................................................... 1
11 .................... 807053-002 .............................. Insert ...................................................................................................... 3
12 .................... 050008-030 .............................. Nut .......................................................................................................... 3
13 .................... 816196 ..................................... Cover ...................................................................................................... 1
806499 ..................................... Cover (Drive in Racking) ........................................................................ 1
14 .................... 052068-002 .............................. Spacer .................................................................................................... 4
15 .................... 816095 ..................................... Cable Clamp ........................................................................................... 2
807764 ..................................... Cable Clamp (Drive in Racking) .............................................................. 2
16 .................... 050008-008 .............................. Nut .......................................................................................................... 4
17 .................... 807765 ..................................... Cable Clamp (Drive in Racking) .............................................................. 2
* ..................... 806929 ..................................... Armrest Assembly (included 2, 5, 6/without 796489) .............................. 1

See Section ITD
01 REV. 05/05
17
COVERS
Part 3-3
4 5
4 3
1
3
2
6 4
12
11
4 10
13 16
14
16
14 15
15
MP-2140-115

01 REV. 11/05
M1.0-0000-00016
16A
COVERS
1 ........................................................................ Instrumentation (see Section 4.9) ........................................................... 1

2* .................... 807098 ..................................... Armrest Moulding .................................................................................... 1
816994 ..................................... Armrest Moulding (Dual-Axis Controls) ................................................... 1
796489 ..................................... Armrest Moulding (6th Function Valve) ................................................... 1
3 ..................... 050009-020 .............................. Washer ................................................................................................... 2
4 ..................... 050071-035 .............................. Screw ...................................................................................................... 6
5* .................... 806689 ..................................... Armrest Pad ............................................................................................ 1
6* .................... 050067-012 .............................. Screw ...................................................................................................... 5
7 ........................................................................ Compartment Tray (see Section 4.1) ...................................................... 1
8 ..................... 806973 ..................................... Hand Guard ............................................................................................ 1
796024 ..................................... Hand Guard (Drive in Racking) ............................................................... 1
9 ..................... 050068-003 .............................. Nut .......................................................................................................... 3
10 .................... 812247 ..................................... Plate ........................................................................................................ 1
814887 ..................................... Plate (Drive in Racking) .......................................................................... 1
11 .................... 807053-002 .............................. Insert ...................................................................................................... 3
12 .................... 050008-030 .............................. Nut .......................................................................................................... 3
13 .................... 816196 ..................................... Cover ...................................................................................................... 1
14 .................... 052068-002 .............................. Spacer .................................................................................................... 4
15 .................... 816095 ..................................... Cable Clamp ........................................................................................... 2
16 .................... 050008-008 .............................. Nut .......................................................................................................... 4
* ..................... 818543-001 .............................. Armrest Assembly (included 2, 5, 6/without 796489) .............................. 1

* ..................... 818543-002 .............................. Armrest Assembly (Dual-Axis Controls/included 2, 5, 6/without 796489) 1

See Section ITD
02 REV. 11/05
17A
SKID BLOCK AND WEAR STRIPS
Chassis
Chassis
6
5
MP-2140-029
18M1.0-0000-00018
1 ..................... 790797-001 .............................. Block, Skid .............................................................................................. 2

2 ..................... 790798 ..................................... Screw ...................................................................................................... 2
3 ..................... 810637-*** ............................... Wear Strips (see Table) ........................................................................... 2
814895-*** ............................... Wear Strips (see Table/Freezer/Corrosion) ............................................. 2
4 ..................... 050003-043 .............................. Screw ...................................................................................................... 2
5 ..................... 050009-026 .............................. Washer ................................................................................................... 2
6 ..................... 050005-068 .............................. Screw ...................................................................................................... 2
Position 3
1,4t 1,6t & 2,0t 1,4t 1,6t & 2,0t

Leg Witdth Leg Witdth Leg Witdth Leg Witdth
1285 mm 1285 mm 1425 & 1575 mm 1425 & 1575 mm
Load Wheel ∅ 285 mm 810637-001 810637-002 810637-004 810637-005
Load Wheel ∅ 330 mm 810637-003 810637-006
Tab019gb
Position 3 Freezer/Corrosion
1,4t 1,6t & 2,0t 1,4t 1,6t & 2,0t

Leg Witdth Leg Witdth Leg Witdth Leg Witdth
1285 mm 1285 mm 1425 & 1575 mm 1425 & 1575 mm
Load Wheel ∅ 285 mm 814895-001 814895-002 814895-004 814895-005
Load Wheel ∅ 330 mm 814895-003 814895-006
Tab020gb

See Section ITD
19
Chassis
Chassis
6
5
MP-2140-029

01 REV. 11/05
M1.0-0000-00018
18A
1 ..................... 790797-001 .............................. Block, Skid .............................................................................................. 2

2 ..................... 790798 ..................................... Screw ...................................................................................................... 2
3 ..................... 810637-*** ............................... Wear Strips (see Table) ........................................................................... 2
4 ..................... 050003-043 .............................. Screw ...................................................................................................... 2
5 ..................... 050009-026 .............................. Washer ................................................................................................... 2
6 ..................... 050005-068 .............................. Screw ...................................................................................................... 2
Position 3
1,4t 1,6t & 2,0t 1,4t 1,6t & 2,0t 1,4t 1,6t & 2,0t
Leg Witdth Leg Witdth Leg Witdth Leg Witdth Leg Witdth Leg Witdth
1285 mm 1285 mm 1425 mm 1425 mm 1575 mm 1575 mm
Load Wheel ∅
810637-001 810637-002 810637-007 810637-008 810637-004 810637-005
285 mm
Load Wheel ∅
810637-003 810637-009 810637-006
330 mm
Tab026gb

See Section ITD
01 REV. 11/05
19A
REACH CARRIAGE
30
31
34 32
7
33 4
3 5
2
6
35 8
29
9
22
28
17 18
23 10
24 21
25
20
27 11
15
26
12
13 19
16
14
MP-2140-049

01 REV. 05/05
20M1.0-0000-00020
REACH CARRIAGE
1 ..................... 811174 ..................................... Reach Carriage (1285mm Leg Width) ..................................................... 1

812062 ..................................... Reach Carriage (1425mm Leg Width) ..................................................... 1
812067 ..................................... Reach Carriage (1575mm Leg Width) ..................................................... 1
2 ..................... 050078-008 .............................. Blind Rivet Nut ........................................................................................ 3
3 ..................... 811017 ..................................... Spacer .................................................................................................... 8
4 ..................... 811012 ..................................... Bracket ................................................................................................... 2
5 ..................... 810654-001 .............................. Roller ...................................................................................................... 2
6 ..................... 811011 ..................................... Pin ........................................................................................................... 2
7 ..................... 050008-034 .............................. Nut .......................................................................................................... 2
8 ..................... 050000-009 .............................. Roll Pin ................................................................................................... 2
9 ..................... 050067-037 .............................. Screw (for 1425mm and 1575mm Leg Width) ......................................... 4
050067-037 .............................. Screw (for 1285mm Leg Width) ............................................................... 3
050007-033 .............................. Screw (for 1285mm Leg Width) ............................................................... 1
10 .................... 050067-037 .............................. Screw ...................................................................................................... 4
11 .................... 811015 ..................................... Bracket ................................................................................................... 2
12 .................... 811014 ..................................... Sliding Pin ............................................................................................... 2
13 .................... 810654-001 .............................. Roller ...................................................................................................... 2
14 .................... 811011 ..................................... Pin ........................................................................................................... 2
15 .................... 050008-034 .............................. Nut .......................................................................................................... 2
16 .................... 050000-009 .............................. Roll Pin ................................................................................................... 2
17 .................... 050017-021 .............................. Screw ...................................................................................................... 1
050006-053 .............................. Screw ...................................................................................................... 1
18 .................... 050068-004 .............................. Nut .......................................................................................................... 2
19 .................... 811001-001 .............................. Carriage Roller ........................................................................................ 4
20 .................... 050067-049 .............................. Screw ...................................................................................................... 16
21 .................... 813160 ..................................... Grease Nipple ......................................................................................... 4
22 .................... 050068-007 .............................. Nut .......................................................................................................... 2
23 .................... 050008-076 .............................. Nut .......................................................................................................... 2
24 .................... 812129 ..................................... Pin ........................................................................................................... 2
25 .................... 810654-002 .............................. Roller ...................................................................................................... 2
26 .................... 814134 ..................................... Washer ................................................................................................... 2
27 .................... 050012-021 .............................. Retaining Ring ........................................................................................ 2
28 .................... 050006-037 .............................. Screw ...................................................................................................... 1
29 .................... 807525 ..................................... Clamp ...................................................................................................... 1
30 .................... 813695 ..................................... Cover ...................................................................................................... 1
31 .................... 050067-034 .............................. Screw ...................................................................................................... 4
32 .................... 060030-085 .............................. Shim ........................................................................................................ 10
33 .................... 810203 ..................................... Shim ........................................................................................................ 2
34 .................... 806886 ..................................... Plate ........................................................................................................ 2
35 .................... 050005-075 .............................. Screw ...................................................................................................... 4
811010 ..................................... Guide Rollers Assembly (included 4 - 8) ................................................ 2
811013 ..................................... Guide Rollers Assembly (included 11 - 16) ............................................. 2
812134 ..................................... Excentric Rollers Assembly (included 24 - 27) ....................................... 2

See Section ITD
01 REV. 05/05
21
LOAD WHEEL
17
15 18
14
Chassis
16
13
11
12
10
9
7
6
5
8
4
3
2
1
MP-2140-032
22M1.0-0000-00022
LOAD WHEEL
0 ..................... 810576-001 .............................. Load Wheel Assembly ∅ 285mm/1,4t ..................................................... 2

810602-001 .............................. Load Wheel Assembly ∅ 330mm/1,6t & 2,0t ........................................... 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 ∅ 285mm/1,4t ................................................................ 2
810583-001 .............................. Load Wheel ∅ 330mm/1,6t & 2,0t ...................................................... 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 ∅ 285mm & Bearing 1,4t Assembly (inclusive 4-10) ..... 2
* ........................... 810601-001 .............................. Loadwheel ∅ 330mm & Bearing 1,6t &2,0t Assembly ....................... 2
(included 4-10)
Option: Load Wheel ∅ 285mm for 1,6t & 2,0t only available out of Factory

See Section ITD
01 REV. 11/05
23
BATTERY LOCK
22 1
23
5
20 4
3
24
21
2
7
28
26
8 6 5
29
27
9
4
14
16 10
32
22
20
17
5
13
4
11
15
18
12
25 30
19
Chassis
11
Battery Latch
31
MP-2140-035
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 .............................................................................................. AR
* ........................... 807540 ..................................... Battery Lock (inclusive 1-3,6-9,12-24,26-29) .................................... 1
only for Freezer/Corrosion
796158 ..................................... Bracket ................................................................................................... 1

793288 ..................................... Clip .......................................................................................................... 1
050003-015 .............................. Screw ...................................................................................................... 1
050008-008 .............................. Nut .......................................................................................................... 1
796159 ..................................... Bracket ................................................................................................... 1
794590-001 .............................. Resistor Assembly ................................................................................. 1
050004-042 .............................. Screw ...................................................................................................... 2
050008-011 .............................. Nut .......................................................................................................... 2
050004-008 .............................. Screw ...................................................................................................... 2

See Section ITD
01 REV. 05/05
25
BATTERY REACH OUT
47
45
46
2 39
1 18 31
6
6 5
5
34
36
35
39
41
42
4
10 11
16 12
17 32
40 43
8 33
44
10 8 24
15 20 19
13
37
7
14 38
7
9
22
9 21
23
24 25
26
30
27
28 29
MP-2140-046
26M1.0-0000-00026
BATTERY REACH OUT
1 ..................... 807841 ..................................... Battery Cover extension (Battery 560Ah) ............................................... 1

807842 ..................................... Battery Cover extension (Battery 700Ah) ............................................... 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
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 .................... 812908 ..................................... Latch ....................................................................................................... 1
22 .................... 808081 ..................................... Shim ........................................................................................................ 2
23 .................... 807864 ..................................... Washer ................................................................................................... 1
24 .................... 050068-005 .............................. Nut .......................................................................................................... 3
25 .................... 813281 ..................................... Cam ........................................................................................................ 1
26 .................... 808465 ..................................... Cam-Protection ....................................................................................... 1
27 .................... 813284 ..................................... Bracket (only for Battery 820Ah) ............................................................ 1
28 .................... 813279 ..................................... Pin ........................................................................................................... 1
29 .................... 050006-073 .............................. 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 .................... 055058-006 .............................. Buffer ...................................................................................................... 2
35 .................... 807407 ..................................... Washer (only for Battery 420Ah & 1285mm Leg Width) .......................... 2
36 .................... 050068-006 .............................. Nut .......................................................................................................... 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
43 .................... 810390 ..................................... Washer ................................................................................................... 1
44 .................... 810317 ..................................... Lever ....................................................................................................... 1
For Trucks with Battery Rollers

45 .................... 804207 ..................................... Roller ...................................................................................................... 6
46 .................... 804681 ..................................... Bearing Ball ............................................................................................. 12
47 .................... 804208 ..................................... Roller Axle .............................................................................................. 6

See Section ITD
27
BATTERY REACH OUT
46
44
45
2 39
1 18 31
6
6 5
5
34
36
35
39
41
42
4
10 11
16 12
17 32
33 40
8 43
10 8 24
15 20 19
13
37
7 Serial number cut 5A203868
14 38 only for Index 41, 42 and 43
7
9
22
9 21
23
24 25
26
30
27
28 29
MP-2140-095

01 REV. 05/05
M1.0-0000-00026
26A
BATTERY REACH OUT
1 ..................... 807841 ..................................... Battery Cover extension (Battery 560Ah) ............................................... 1

2 ..................... 050071-035 .............................. Screw ...................................................................................................... 4
3 ..................... 050068-003 .............................. Nut .......................................................................................................... 4
4 ..................... 810338-001 .............................. Battery Support (Battery 420Ah) ............................................................ 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
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 .................... 812908 ..................................... Latch ....................................................................................................... 1
22 .................... 808081 ..................................... Shim ........................................................................................................ 2
23 .................... 807864 ..................................... Washer ................................................................................................... 1
24 .................... 050068-005 .............................. Nut .......................................................................................................... 3
25 .................... 813281 ..................................... Cam ........................................................................................................ 1
26 .................... 808465 ..................................... Cam-Protection ....................................................................................... 1
27 .................... 813284 ..................................... Bracket (only for Battery 820Ah) ............................................................ 1
28 .................... 813279 ..................................... Pin ........................................................................................................... 1
29 .................... 050006-073 .............................. 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 .................... 055058-006 .............................. Buffer ...................................................................................................... 2
35 .................... 807407 ..................................... Washer (only for Battery 420Ah & 1285mm Leg Width) .......................... 2
36 .................... 050068-004 .............................. Nut .......................................................................................................... 2
37 .................... 807939 ..................................... Pin ........................................................................................................... 1
38 .................... 806837 ..................................... Spring ..................................................................................................... 1
39 .................... 050003-050 .............................. Screw ...................................................................................................... 4
40 .................... 810428 ..................................... Clamp (only for Battery 420Ah & 560Ah) ................................................ 1
816085 ..................................... Clamp (only for Battery 700Ah & 820Ah) ................................................ 1
41 .................... 814922 ..................................... Bracket ................................................................................................... 1
42 .................... 816086-001 .............................. Clamp (LH/only for Battery 420Ah & 560Ah) .......................................... 1
816026-001 .............................. Clamp (LH/only for Battery 700Ah & 820Ah) .......................................... 1
43 .................... 815006 ..................................... Lever ....................................................................................................... 1
For Trucks with Battery Rollers

44 .................... 804207 ..................................... Roller ...................................................................................................... 6
45 .................... 804681 ..................................... Bearing Ball ............................................................................................. 12
46 .................... 804208 ..................................... Roller Axle .............................................................................................. 6

See Section ITD
02 REV. 11/05
27A
SEAT AND PAN
1
3
19
7 20
2
21
8
PU
SH
21
4
6 13
9
14
11
Chassis
18 12
4
10 17
5 4 17
16
16
15
15
Drive Frame
MP-2140-067

01 REV. 05/05
28M1.0-0000-00028
SEAT AND PAN
0 ..................... 811915-001 .............................. Seat & Pan (black cloth/without Drive in Racking) .................................. 1
811915-003 .............................. Seat & Pan (PVC/without Drive in Racking) ........................................... 1
811915-005 .............................. Seat & Pan (48V Heated Cushion & Backrest/without Drive in Racking) 1
1 .............................................................................. Seat (see Section Seat) .................................................................... 1
2* .......................... 811917 ..................................... Seat Pan ............................................................................................ 1
3 ........................... 050005-022 .............................. Screw ................................................................................................ 3
4 ........................... 050008-024 .............................. Nut ..................................................................................................... 4
5* .......................... 791469-001 .............................. Seat Moulding .................................................................................... 1
6* .......................... 050006-035 .............................. Screw ................................................................................................ 7
7 ........................... 791466 ..................................... Handle Pocket ................................................................................... 1
8 ........................... 791635 ..................................... Vice Action Latch .............................................................................. 1
9 ........................... 808945 ..................................... Stay ................................................................................................... 1
10 .......................... 815247 ..................................... Bracket .............................................................................................. 1
11 .......................... 808947 ..................................... Bracket .............................................................................................. 1
12 .......................... 808949 ..................................... Pin ..................................................................................................... 1
13 .......................... 050073-004 .............................. Washer .............................................................................................. 1
14 .......................... 050070-001 .............................. Screw ................................................................................................ 1
15 .......................... 812345 ..................................... Plate .................................................................................................. 2
16 .......................... 811925 ..................................... Bracket .............................................................................................. 2
17 .......................... 050006-053 .............................. Screw ................................................................................................ 4
18 .......................... 051068-002 .............................. Spring ................................................................................................ 1
19 .......................... 050005-024 .............................. Screw ................................................................................................ 1
20 .......................... 816474 ..................................... Stop ................................................................................................... 1
21 .......................... 050009-018 .............................. Washer .............................................................................................. 2
* ........................... 811916 ..................................... Pan Mounting (included 2, 5, 6) ......................................................... 1
Not illustrated
795289 ..................................... Cable Seat ......................................................................................... 1

796216 ..................................... Seat Stop (Drive in Racking) .................................................................. 2

See Section ITD
01 REV. 05/05
29
SEAT
27 26
27
28
5
2 27
25 25
3
1 25
4 8
7
6
10 5
11
7
9
12
9
9
12 9
13
15
9
15 14
17 16
16 23
15 21
24
16 22
19
29 5
7
7
19
19
18 20
24
MP-2140-068
30M1.0-0000-00030
SEAT
0 ..................... 807433-001 .............................. Seat (black cloth) ................................................................................... 1

807433-003 .............................. Seat (PVC) ............................................................................................. 1
796781 ..................................... Seat (PVC/ Heated) ................................................................................ 1
1 ........................... 791653-001 .............................. Pad (only for 807433-001) ................................................................. 1
808493 ..................................... Pad (only for 807433-003) ................................................................. 1
808494 ..................................... Pad (only for 796781) ........................................................................ 1
2 ........................... 791653-002 .............................. Pad (only for 807433-001) ................................................................. 1
808495 ..................................... Pad (only for 807433-003) ................................................................. 1
808496 ..................................... Pad (only for 796781) ........................................................................ 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 Assembly (only for Heated Seat) ........................................ 1

808123-003 ............................... Pin Housing ................................................................................. 1
792882 ...................................... Pin Crimp ..................................................................................... 4
793091-003 ............................... Anti Back Out .............................................................................. 1

See Section ITD
31
SEAT
27 26
27
28
5
2 27
25 25
3
1 25
4 8
7
6
10 5
11
7
9
12
9
9
12 9
13
15
9
15 14
17 16
16 23
15 21
24
16 22
19
29 5
7
7
19
19
18 20
24
MP-2140-068
M1.0-0000-00030
30A
SEAT
0 ..................... 815872-001 .............................. Seat (black cloth) ................................................................................... 1

815872-003 .............................. Seat (PVC) ............................................................................................. 1
796781 ..................................... Seat (PVC/ Heated) ................................................................................ 1
1 ........................... 816634 ..................................... Pad (only for 815872-001) ................................................................. 1
816635 ..................................... Pad (only for 815872-003) ................................................................. 1
808494 ..................................... Pad (only for 796781) ........................................................................ 1
2 ........................... 791653-002 .............................. Pad (only for 815872-001) ................................................................. 1
808495 ..................................... Pad (only for 815872-003) ................................................................. 1
808496 ..................................... Pad (only for 796781) ........................................................................ 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 Assembly (only for Heated Seat) ........................................ 1

808123-003 ............................... Pin Housing ................................................................................. 1
792882 ...................................... Pin Crimp ..................................................................................... 4
793091-003 ............................... Anti Back Out .............................................................................. 1

See Section ITD
01 REV. 05/05
31A
REAR MIRROR
MP-2140-066
32M1.0-0000-00032
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 (included 3 - 7) ....................................................... 1

See Section ITD
33
GUIDE WHEELS
2
3
MP-2140-074
34M1.0-0000-00034
GUIDE WHEELS
0 ..................... 796057-*** ............................... Guide Wheels .......................................................................................... 4

1 ........................... 796050-001 .............................. Shim (1,0 mm) ................................................................................... AR
796050-002 .............................. Shim (3,0 mm) ................................................................................... AR
2 ........................... 796046-*** ................................ Bracket .............................................................................................. 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-*** ................................ Bracket .............................................................................................. 4
* ........................... 796049 ..................................... Wheel Assembly (included 4 - 6) ...................................................... 4
A Position 0 Position 2 Position 8
25 mm 796057-001 796046-001
30 mm 796057-002 796046-002
35 mm 796057-003 796046-003
40 mm 796057-004 796046-004
45 mm 796057-005 796046-005
50 mm 796057-006 796046-006
55 mm 796057-007 796046-007
60 mm 796057-008 796051-001
65 mm 796057-009 796051-002
70 mm 796057-010 796051-003
75 mm 796057-011 796051-004
80 mm 796057-012 796051-005
85 mm 796057-013 796051-006
90 mm 796057-014 796051-007
Tab017

See Section ITD
35
OVERHEAD GUARD
14
7 11
12
14
8
14
14
13
12
6
5
6
5
6
9
13
10
5
6
Chassis
MP-2140-082

01 REV. 05/05
36M1.0-0000-00036
OVERHEAD GUARD
1 ..................... 796328 ..................................... Overhead Guard ..................................................................................... 1

2 ..................... 050067-053 .............................. Screw ...................................................................................................... 2
3 ..................... 050068-006 .............................. Nut .......................................................................................................... 2
4 ..................... 815110 ..................................... Overhead Guard ..................................................................................... 1
5 ..................... 795977 ..................................... Clamp ...................................................................................................... 12
6 ..................... 050005-085 .............................. Screw ...................................................................................................... 24
050008-018 .............................. Nut .......................................................................................................... 24
7 ..................... 815111 ..................................... Cover ...................................................................................................... 1
8 ..................... 815155 ..................................... Bracket ................................................................................................... 1
9 ..................... 815154 ..................................... Bracket ................................................................................................... 1
10 .................... 815157 ..................................... Bracket ................................................................................................... 1
11 .................... 815156 ..................................... Bracket ................................................................................................... 1
12 .................... 050071-037 .............................. Screw ...................................................................................................... 2
13 .................... 050008-025 .............................. Nut .......................................................................................................... 2
14 .................... 050071-021 .............................. Screw ...................................................................................................... 13
815109 ..................................... Overhead Guard Assembly (included 4 - 6) ........................................... 1

815153 ..................................... Cover Assembly (included 5 - 14) .......................................................... 1

See Section ITD
01 REV. 05/05
37
ACCESSORIES
32
1 8
7
8 6
31 11 29
1
9
30 3
5
4
10
28
8
11
1
12
8
1
13
11 15
24
8
27 1 11
25
20 21
16 16 17
26
18
17
14
15
22
19
1 8
14 16 20 21
17
11
18
17 16
15
24 22
25 23
26
MP-2140-085

01 REV. 05/05
38M1.0-0000-00038
ACCESSORIES
1 ..................... 050005-016 .............................. Screw ...................................................................................................... AR

2 ..................... 795977 ..................................... Clamp ...................................................................................................... 3
3 ..................... 814650 ..................................... Bracket ................................................................................................... 1
4 ..................... 050008-018 .............................. Nut .......................................................................................................... 6
5 ..................... 050067-007 .............................. Screw ...................................................................................................... 4
6 ..................... 814657 ..................................... Shim ........................................................................................................ 2
7 ..................... 128362 ..................................... Clamp ...................................................................................................... 1
8 ..................... 127697 ..................................... Clamp ...................................................................................................... AR
9 ..................... 124530 ..................................... Plug ......................................................................................................... 1
10 .................... 130814-001 .............................. Tube ........................................................................................................ 1
11 .................... 128362 ..................................... Clamp ...................................................................................................... AR
12 .................... 814715 ..................................... Bracket ................................................................................................... 1
13 .................... 050003-018 .............................. Screw ...................................................................................................... 4
14 .................... 130048 ..................................... Bracket ................................................................................................... AR
15 .................... 050067-014 .............................. Screw ...................................................................................................... AR
16 .................... 130064 ..................................... Bushing ................................................................................................... AR
17 .................... 050009-025 .............................. Washer ................................................................................................... AR
18 .................... 050008-034 .............................. Nut .......................................................................................................... AR
19 .................... 814664 ..................................... Pad .......................................................................................................... 1
20 .................... 050006-022 .............................. Screw ...................................................................................................... AR
21 .................... 814566 ..................................... Housing ................................................................................................... AR
22 .................... 814594 ..................................... Spring ..................................................................................................... AR
23 .................... 130008 ..................................... Pad .......................................................................................................... 1
24 .................... 130060 ..................................... Bracket ................................................................................................... AR
25 .................... 050006-024 .............................. Screw ...................................................................................................... AR
26 .................... 130071 ..................................... Holder ..................................................................................................... AR
27 .................... 130050 ..................................... Plate ........................................................................................................ 1
28 .................... 125502 ..................................... Storage Pocket ....................................................................................... 1
29 .................... 125503 ..................................... Mount ...................................................................................................... 1
30 .................... 050005-024 .............................. Screw ...................................................................................................... 1
31 .................... 050008-025 .............................. Nut .......................................................................................................... 1
32 .................... 050005-085 .............................. Screw ...................................................................................................... 6
814652 ..................................... Bracket Assembly (included 1, 3, 5 -10) ................................................. 1

814858 ..................................... Clamp Assembly (included 1, 8, 11) ....................................................... 1
814720 ..................................... Mounting Plate Assembly (included 1, 8, 11 -13) .................................... 1
814716 ..................................... Pad Assembly (included 1, 8, 11, 14 - 22) .............................................. 1
814856 ..................................... Clip and Hook Assembly (included 1, 8, 11, 14- 18, 20 - 26) .................. 1
814722 ..................................... Hook Assembly (included 1, 8, 11, 15, 24 - 27) ...................................... 1
814857 ..................................... Storage Pocket Assembly (included 1, 8, 11, 28 - 31) ............................ 1

See Section ITD
02 REV. 11/05
39
Printed in Germany
40M1.0-0000-00040
SECTION 2
Printed in Germany
41
TUBE/HOSE LAYOUT
16
15
22
I
23 20
H
23 19
17
12
11 23 13 19
21
D
13
22
18
14
J
F
13 14
B
28
14
I
14
C G
J
F E
D
H
G
3
3
B A
5
C
2 1
7
31
24
K
4
24
30
29
25
25
E 27 5
A 26 8
9
K
10
MP-2140-070

01 REV. 05/05
42M1.0-0000-00042
TUBE/HOSE LAYOUT
1 ..................... 050017-022 .............................. Screw ...................................................................................................... 3

050068-003 .............................. Nut .......................................................................................................... 3
2 ..................... 815253 ..................................... Hose Clamp (only for 1285mm width) ..................................................... 1
816898 ..................................... Washer (only for 1285mm width) ........................................................... 1
3 ..................... 050005-076 .............................. Screw ...................................................................................................... AR
4 ..................... 813158 ..................................... Plate (only for 1285mm width) ................................................................. 1
5 ..................... 812048-001 .............................. Hose clamp ............................................................................................. 4
6 ..................... 050005-066 .............................. Screw ...................................................................................................... 2
7 ..................... 050068-003 .............................. Nut .......................................................................................................... 4
8 ..................... 813159 ..................................... Cover ...................................................................................................... 1
9 ..................... 050067-024 .............................. Screw ...................................................................................................... 2
10 .................... 050078-009 .............................. Blind Rivet Nut ........................................................................................ 2
11 .................... 813145 ..................................... Hose ....................................................................................................... 1
12 .................... 813146 ..................................... Hose ....................................................................................................... 1
13 .................... 813149 ..................................... Hollow Bolt .............................................................................................. 4
14 .................... 813150 ..................................... Seal Ring ................................................................................................ 4
15 .................... 807075 ..................................... Bracket (see Section 2.8) ....................................................................... 1
16 .................... 054176-001 .............................. Adaptor ................................................................................................... 2
17 .................... 812979 ..................................... Hose ....................................................................................................... 1
18 .................... 812980 ..................................... Hose ....................................................................................................... 1
19 .................... 054156-002 .............................. Adaptor ................................................................................................... 2
20 .................... 812039 ..................................... Counter Balance Valve ............................................................................ 1
21 .................... 812040 ..................................... Counter Balance Valve ............................................................................ 1
22 .................... 054171-002 .............................. Adaptor ................................................................................................... 2
23 .................... 812033 ..................................... Hose Assembly ....................................................................................... 1
24 .................... 813147 ..................................... Hollow Bolt .............................................................................................. 2
25 .................... 813148 ..................................... Seal Ring ................................................................................................ 2
26 .................... 812977 ..................................... Hose ....................................................................................................... 1
27 .................... 812978 ..................................... Hose ....................................................................................................... 1
28 .................... 054191-006 .............................. Hose Clamp ............................................................................................ 1
29 .................... 812048-002 .............................. Hose clamp ............................................................................................. 2
30 .................... 050005-025 .............................. Screw ...................................................................................................... 2
31 .................... 050008-024 .............................. Nut .......................................................................................................... 2

See Section ITD
02 REV. 11/05
43
HYDRAULIC TANK
4
17
16
15
2 2
3
10
6 4
14
8
13
11
12
1
19
18
MP-2140-036
44M1.0-0000-00044
HYDRAULIC TANK
0 ..................... 812312-001 .............................. Hydraulic Tank Assembly ....................................................................... 1

1* .......................... 806776 ..................................... Tank ................................................................................................... 1
805299 ..................................... Screw Plug ........................................................................................ 1
2* .......................... 804859-002 .............................. Rubber .............................................................................................. 2
3 ........................... 813252 ..................................... Clamp ................................................................................................ 1
4 ........................... 050008-021 .............................. Nut ..................................................................................................... 4
5 ........................... 807978 ..................................... Clamp ................................................................................................ 1
6 ........................... 050008-030 .............................. Nut ..................................................................................................... 2
7 ........................... 812210 ..................................... Clamp ................................................................................................ 1
8 ........................... 050006-032 .............................. Screw ................................................................................................ 2
9* .......................... 806835 ..................................... Gasket .............................................................................................. 1
10* ......................... 806842 ..................................... Suction Line ....................................................................................... 1
11* ......................... 793539 ..................................... Seal Bonded ...................................................................................... 1
12* ......................... 793192 ..................................... Suction Filter ..................................................................................... 1
13* ......................... 813251 ..................................... Heat Shield ........................................................................................ 1
14* ......................... 050006-026 .............................. Screw ................................................................................................ 7
15* ......................... 808413 ..................................... Filter Assembly ................................................................................. 1
808504 ...................................... Filter Element ............................................................................... 1
808505 ...................................... Cap Breather ............................................................................... 1
16* ......................... 051071-001 .............................. Adaptor .............................................................................................. 1
053050-021 .............................. Teflon-Tape ........................................................................................ AR
17* ......................... 791415-020 .............................. Washer .............................................................................................. 2
18 .......................... 808360 ..................................... Mat .................................................................................................... 1
19 .......................... 055053-003 .............................. Pin ..................................................................................................... 2
* ........................... 812313 ..................................... Tank Assembly (included 1, 2, 9-17) ................................................. 1

See Section ITD
01 REV. 05/05
45
HYDRAULIC TT MAST
34
20
30
20
4
18
26 17
19
Fork Carriage
26
26 16
29 32
33
13
27
35 2
28
26 26
23
31
21
15
3
22 14
26
9 36
2
8
26
25 24 10 10 12
11
Chassi
13
9
14
7
Index 14 only to serial number cut 5A203818, 12 6
see section 8.1
1
MP-2140-058
46M1.0-0000-00046
HYDRAULIC TT MAST
1 ........................................................................ Outermast (see Section 7.5)

2 ........................................................................ Lift Cylinder (see Section 8.1)
3 ........................................................................ 1 st Stage Mast (see Section 7.5)
4 ........................................................................ Free Lift Cylinder (see Section 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 ......................................................................................................... 1
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 Section 7.6)
21 .................... 806158 ..................................... Pipe ......................................................................................................... 1
22 .................... 050006-036 .............................. Screw ...................................................................................................... 2
23 .................... 050008-024 .............................. Nut .......................................................................................................... 2
24 .................... 064061-016 .............................. Elbow ...................................................................................................... 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
35 .................... 810534 ..................................... Plate ........................................................................................................ 1
36 .................... 813277 ..................................... Pipe with Pressure Switch Assembly ..................................................... 1
813278 ..................................... Switch ............................................................................................... 1
Not illustrated
808996 ..................................... Clamp ...................................................................................................... AR

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

See Section ITD
47
HYDRAULIC TT MAST
34
20
30
20
4
18
26 17
19
Fork Carriage
26
26 16
29 32
33
14
27
35 2
28
26 26
23
31
21
15
3
22
26
9 36
2
8
13
26
25 24 10 10 12
11
Chassi
13
9
7
12 6
1
MP-2140-100

01 REV. 05/05
M1.0-0000-00046
46A
HYDRAULIC TT MAST
1 ........................................................................ Outermast (see Section 7.5)

2 ........................................................................ Lift Cylinder (see Section 8.1)
3 ........................................................................ 1 st Stage Mast (see Section 7.5)
4 ........................................................................ Free Lift Cylinder (see Section 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 ......................................................................................................... 1
12 .................... 064061-003 .............................. Elbow ...................................................................................................... 2
13 .................... 806992 ..................................... Hose Burst Valve .................................................................................... 2
14 ....................................................................... Hose Burst Valve (see Section 8.2) ........................................................ 1
15 .................... 806157 ..................................... Pipe ......................................................................................................... 1
050006-024 .............................. Screw ...................................................................................................... 2
050008-015 .............................. Nut .......................................................................................................... 2
17 .................... 807320 ..................................... Bracket ................................................................................................... 1
18 .................... 050006-040 .............................. Screw ...................................................................................................... 1
19 .................... 050068-003 .............................. Nut .......................................................................................................... 1
20 ....................................................................... Pulley Hose (see Section 7.6)
21 .................... 806158 ..................................... Pipe ......................................................................................................... 1
22 .................... 050006-036 .............................. Screw ...................................................................................................... 2
23 .................... 050008-024 .............................. Nut .......................................................................................................... 2
24 .................... 064061-016 .............................. Elbow ...................................................................................................... 1
050006-024 .............................. Screw ...................................................................................................... 2
050008-015 .............................. Nut .......................................................................................................... 2
26 .................... 054176-001 .............................. Adaptor ................................................................................................... 8
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
35 .................... 810534 ..................................... Plate ........................................................................................................ 1
36 .................... 813277 ..................................... Pipe with Pressure Switch Assembly ..................................................... 1
813278 ..................................... Pipe ................................................................................................... 1
810059 ..................................... Switch ............................................................................................... 1
050011-017 .............................. Washer .............................................................................................. 1
Not illustrated
808996 ..................................... Clamp ...................................................................................................... AR

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

See Section ITD
01 REV. 05/05
47A
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
Tab013gb
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
Tab014gb
48M1.0-0000-00048
HYDRAULIC TT MAST
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
Tab015gb
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
Tab016gb
49
VALVE BLOCK
A1
P
B1
B2 1
A2
MP-2140-069
50M1.0-0000-00050
VALVE BLOCK
0 ..................... 812050 ..................................... Valve Block ............................................................................................. 1

1 ........................... 812041 ..................................... Solenoid ............................................................................................ 4
2 ........................... 812043 ..................................... Lift/Lower Valve ................................................................................. 1
3 ........................... 812051 ..................................... Pressure Relieve Valve ..................................................................... 1
4 ........................... 812044 ..................................... Filter .................................................................................................. 1
812052 ..................................... Seal Kit .............................................................................................. 1

See Section ITD
51
PUMP
MP-2140-080
52M1.0-0000-00052
PUMP
0 ..................... 790940-002 .............................. Pump (Assembly - see next Page) ......................................................... 1

See Section ITD
53
PUMP MOTOR AND PUMP
16
17
3
18
1
19
26
6
20
13
21
23
24 7
22
15 8
25 14
10
11
Drive Plate
9
13
12
MP-2140-079
54M1.0-0000-00054
PUMP MOTOR AND PUMP
0 ..................... 813734 ..................................... Pump Motor and Pump Assembly (without 26) ....................................... 1
1 ........................... 811896 ..................................... Bracket .............................................................................................. 1
2 .............................................................................. Pump Motor (see next Page) ............................................................. 1
3 ........................... 812174 ..................................... Puffer ................................................................................................ 6
4 ........................... 050009-031 .............................. Washer .............................................................................................. 3
5 ........................... 050007-045 .............................. Screw ................................................................................................ 3
6 ........................... 812889 ..................................... Puffer -Tube ....................................................................................... 3
7 ........................... 791534 ..................................... Washer Sealing ................................................................................. 1
8 .............................................................................. Pump (see Section 2.12) ................................................................... 1
9 ........................... 050067-034 .............................. Screw ................................................................................................ 2
10 .......................... 054002-035 .............................. O-Ring ............................................................................................... 1
11 .......................... 790491 ..................................... Inlet Pump ......................................................................................... 1
12 .......................... 050005-060 .............................. Screw ................................................................................................ 4
13 .......................... 054191-001 .............................. Clamp ................................................................................................ AR
054191-004 .............................. Clamp ................................................................................................ AR
14 .......................... 812204 ..................................... Hose .................................................................................................. 1
15 .......................... 054002-034 .............................. O-Ring ............................................................................................... 1
16 .......................... 812205 ..................................... Tube ................................................................................................... 1
17 .......................... 050005-063 .............................. Screw ................................................................................................ 2
18 .......................... 050005-062 .............................. Screw ................................................................................................ 2
19* ......................... 812207 ..................................... Bracket .............................................................................................. 1
20* ......................... 050078-008 .............................. Blind Rivet Nut .................................................................................. 8
21* ......................... 050078-007 .............................. Blind Rivet Nut .................................................................................. 5
22 .......................... 793288 ..................................... Clip .................................................................................................... 5
23 .......................... 050003-013 .............................. Screw ................................................................................................ 5
24* ......................... 050078-001 .............................. Blind Rivet Nut .................................................................................. 2
25 .......................... 050067-022 .............................. Screw ................................................................................................ 2
26 .................... 050067-044 .............................. Screw ...................................................................................................... 2
* ........................... 813239 ..................................... Bracket Assembly (included 19 - 21 & 24) ........................................ 1

See Section ITD
01 REV. 05/05
55
PUMP MOTOR
1
1
7
2
8
3
3 3 3
4 8
6
9 8
10
4
1
MP-2140-087

01 REV. 05/05
56M1.0-0000-00056
PUMP MOTOR
0 ..................... 811853 ..................................... Pump Motor Asssembly .......................................................................... 1

1 ........................... 816766 ..................................... Screw - Kit ......................................................................................... 1
2 ........................... 816767 ..................................... End Shield ......................................................................................... 1
3 ........................... 816768 ..................................... Pin - Kit .............................................................................................. 1
4 ........................... 816770 ..................................... Armature (included 5 & 6) ................................................................. 1
5 ................................. 816769 ...................................... Sensor Bearing ............................................................................ 1
6 ................................. 816772 ...................................... Bearing Ball ................................................................................. 1
7 ........................... 814836 ..................................... Stator ................................................................................................ 1
8 ........................... 816771 ..................................... Terminal Block - Kit ............................................................................ 1
9 .............................................................................. Power Cable (see Section 4.1) .......................................................... 3
10 .......................... 816773 ..................................... End Shield ......................................................................................... 1

See Section ITD
01 REV. 05/05
57
Printed in Germany
58M1.0-0000-00058
SECTION 3
Printed in Germany
59
DRIVE UNIT
3
2
22
21
20 20
19
19
23
23
5
15
8 1
13
24 7
14
9
25
16
17
18
12 26
11
10
MP-2140-077
60M1.0-0000-00060
DRIVE UNIT
1 ..................... 811141 ..................................... Drive Plate .............................................................................................. 1

2 ........................................................................ Drive Motor (see Section 3.2) ................................................................. 1
3 ........................................................................ Drive Motor Brake (see Section 5.6) ....................................................... 1
4 ..................... 050005-097 .............................. Screw ...................................................................................................... 3
5 ..................... 050005-024 .............................. Screw ...................................................................................................... 6
6 ..................... 812238 ..................................... Gearbox (see Section 3.1) ...................................................................... 1
7 ..................... 050010-041 .............................. Washer ................................................................................................... 6
8 ..................... 050005-096 .............................. Screw ...................................................................................................... 6
9 ..................... 050007-043 .............................. Screw ...................................................................................................... 2
10 .................... 813816 ..................................... Drive Guard ............................................................................................ 1
11 .................... 807557 ..................................... Wheel ...................................................................................................... 1
810240 ..................................... Wheel (Freezer/Corrosion) ..................................................................... 1
12 .................... 050062-001 .............................. Nut .......................................................................................................... 7
13 ....................................................................... Steer Motor (see Section 6.2) ................................................................. 1
14 .................... 050006-039 .............................. Screw ...................................................................................................... 3
15 .................... 812169 ..................................... Spacer .................................................................................................... 3
16 .................... 812993 ..................................... Pinion ...................................................................................................... 1
17 .................... 813036 ..................................... Washer ................................................................................................... 1
18 .................... 050067-023 .............................. Screw ...................................................................................................... 1
19 .................... 813243 ..................................... Bracket ................................................................................................... 2
20 .................... 050006-033 .............................. Screw ...................................................................................................... 2
21 .................... 811378-002 .............................. Sensor Inductive Assembly .................................................................... 1
792881-002 .............................. Socket Housing ................................................................................. 1
792883 ..................................... Socket Crimp .................................................................................... 3
793091-002 .............................. Anti Backout ...................................................................................... 1
792881-003 .............................. Socket Housing ................................................................................. 1
792883 ..................................... Socket Crimp .................................................................................... 3
793091-002 .............................. Anti Backout ...................................................................................... 1
23 .................... 050008-061 .............................. Nut .......................................................................................................... 2
24 .................... 050067-052 .............................. Screw ...................................................................................................... 8
25 .................... 050006-040 .............................. Screw ...................................................................................................... 1
26 .................... 050008-024 .............................. Nut .......................................................................................................... 1
813038-002 .............................. Steer Sensor Assembly (included 19 - 21, 23) ....................................... 1

813038-001 .............................. Steer Sensor Assembly (included 19, 20, 22, 23) ................................... 1

See Section ITD
61
DRIVE UNIT
3
2
22
21
13
20 20
19
19
14 23
23
5
15
8 1
24 7
27
28
9
29 25
16
17
18
12 26
30
11
10
MP-2140-111

01 REV. 05/05
M1.0-0000-00060
60A
DRIVE UNIT
1 ..................... 811141 ..................................... Drive Plate .............................................................................................. 1

4 ..................... 050005-097 .............................. Screw ...................................................................................................... 3
5 ..................... 050005-024 .............................. Screw ...................................................................................................... 6
7 ..................... 050010-041 .............................. Washer ................................................................................................... 6
8 ..................... 050005-096 .............................. Screw ...................................................................................................... 6
9 ..................... 050007-043 .............................. Screw ...................................................................................................... 2
10 .................... 813816 ..................................... Drive Guard ............................................................................................ 1
11 .................... 807557 ..................................... Wheel ...................................................................................................... 1
810240 ..................................... Wheel (Freezer/Corrosion) ..................................................................... 1
12 .................... 050062-001 .............................. Nut .......................................................................................................... 7
14 .................... 050006-030 .............................. Screw ...................................................................................................... 3
15 .................... 816532 ..................................... Spacer .................................................................................................... 3
16 .................... 816533 ..................................... Pinion ...................................................................................................... 1
17 .................... 813036 ..................................... Washer ................................................................................................... 1
18 .................... 050067-023 .............................. Screw ...................................................................................................... 1
19 .................... 813243 ..................................... Bracket ................................................................................................... 2
20 .................... 050006-033 .............................. Screw ...................................................................................................... 2
792881-003 .............................. Socket Housing ................................................................................. 1
792883 ..................................... Socket Crimp .................................................................................... 3
793091-002 .............................. Anti Backout ...................................................................................... 1
792881-002 .............................. Socket Housing ................................................................................. 1
792883 ..................................... Socket Crimp .................................................................................... 3
793091-002 .............................. Anti Backout ...................................................................................... 1
23 .................... 050008-061 .............................. Nut .......................................................................................................... 2
24 .................... 050067-052 .............................. Screw ...................................................................................................... 8
25 .................... 050006-040 .............................. Screw ...................................................................................................... 1
26 .................... 050008-024 .............................. Nut .......................................................................................................... 1
27 .................... 050012-079 .............................. Circlip ...................................................................................................... 1
28 .................... 055017-004 .............................. Bearing ................................................................................................... 1
29 .................... 816534 ..................................... Adaptor ................................................................................................... 1
30 .................... 050005-106 .............................. Screw ...................................................................................................... 6
813038-002 .............................. Steer Sensor Assembly (included 19, 21, 23) ......................................... 1
816531 ..................................... Adaptor Assembly (included 27 - 29) ...................................................... 1

See Section ITD
01 REV. 05/05
61A
DRIVE UNIT
3
2
22
21
13
20 20
19
19
14 23
23
5
15
8 1
24 7
27
28
9
29 25
16
17
18
12 26
30
11
10
MP-2140-111

01 REV. 05/05
M1.0-0000-00060
60B
DRIVE UNIT
1 ..................... 816262 ..................................... Drive Plate .............................................................................................. 1

4 ..................... 050005-097 .............................. Screw ...................................................................................................... 3
5 ..................... 050005-024 .............................. Screw ...................................................................................................... 6
7 ..................... 050010-041 .............................. Washer ................................................................................................... 6
8 ..................... 050005-096 .............................. Screw ...................................................................................................... 6
9 ..................... 050007-043 .............................. Screw ...................................................................................................... 2
10 .................... 813816 ..................................... Drive Guard ............................................................................................ 1
11 .................... 807557 ..................................... Wheel ...................................................................................................... 1
12 .................... 050062-001 .............................. Nut .......................................................................................................... 7
14 .................... 050006-030 .............................. Screw ...................................................................................................... 3
15 .................... 816532 ..................................... Spacer .................................................................................................... 3
16 .................... 816404 ..................................... Pinion ...................................................................................................... 1
17 .................... 813036 ..................................... Washer ................................................................................................... 1
18 .................... 050067-023 .............................. Screw ...................................................................................................... 1
19 .................... 813243 ..................................... Bracket ................................................................................................... 2
20 .................... 050006-033 .............................. Screw ...................................................................................................... 2
792881-003 .............................. Socket Housing ................................................................................. 1
792883 ..................................... Socket Crimp .................................................................................... 3
793091-002 .............................. Anti Backout ...................................................................................... 1
792881-002 .............................. Socket Housing ................................................................................. 1
792883 ..................................... Socket Crimp .................................................................................... 3
793091-002 .............................. Anti Backout ...................................................................................... 1
23 .................... 050008-061 .............................. Nut .......................................................................................................... 2
24 .................... 050067-052 .............................. Screw ...................................................................................................... 8
25 .................... 050006-040 .............................. Screw ...................................................................................................... 1
26 .................... 050008-024 .............................. Nut .......................................................................................................... 1
27 .................... 050012-079 .............................. Circlip ...................................................................................................... 1
28 .................... 055017-004 .............................. Bearing ................................................................................................... 1
29 .................... 816534 ..................................... Adaptor ................................................................................................... 1
30 .................... 050005-106 .............................. Screw ...................................................................................................... 6
816531 ..................................... Adaptor Assembly (included 27 - 29) ...................................................... 1

See Section ITD
02 REV. 11/05
61B
GEAR BOX
1
2
3
4
2 6 5
15
9 12
10 13 16
11
14
17
37
18
13
24
23
25
44
38
36
18 27
42 30 2
26
35 27
28
29 34
19
22
43 30
41
40 20
31
39 21
33
32
22
MP-2140-089
62M1.0-0000-00062
GEAR BOX
0 ..................... 812238 ..................................... Gear Box ................................................................................................ 1

1 ........................... 808612 ..................................... Screw ................................................................................................ 15
2 ........................... 805164 ..................................... Washer .............................................................................................. 25
3 ........................... 808593 ..................................... Turntable ............................................................................................ 1
4 ........................... 808616 ..................................... Pin ..................................................................................................... 1
5 ........................... 808603 ..................................... O-Ring ............................................................................................... 1
6 ........................... 808601 ..................................... Seal ................................................................................................... 1
7 ........................... 050005-026 .............................. Screw ................................................................................................ 2
8 ........................... 808581 ..................................... Gear Rim ........................................................................................... 1
9 ........................... 808617 ..................................... Washer .............................................................................................. 1
10 .......................... 808615 ..................................... Washer .............................................................................................. 1
11 .......................... 808594 ..................................... Block ................................................................................................. 1
12 .......................... 808604 ..................................... O-Ring ............................................................................................... 1
13 .......................... 808599 ..................................... Bearing Ball ....................................................................................... 2
14 .......................... 808582 ..................................... Pinion ................................................................................................ 1
15 .......................... 808584 ..................................... Nut ..................................................................................................... 1
16 .......................... 808583 ..................................... Helical Gear ...................................................................................... 1
17 .......................... 808595 ..................................... Bearing Ball ....................................................................................... 1
18 .......................... 808592 ..................................... Washer .............................................................................................. 2
19 .......................... 808586 ..................................... Bushing ............................................................................................. 1
20 .......................... 808591 ..................................... Washer .............................................................................................. 1
21 .......................... 808596 ..................................... Bearing Ball ....................................................................................... 1
22 .......................... 808580 ..................................... Bevel Gear Set .................................................................................. 1
23 .......................... 808577 ..................................... Transmission Case ............................................................................ 1
24 .......................... 808602 ..................................... O-Ring ............................................................................................... 1
25 .......................... 808578 ..................................... Cover - Gear Box .............................................................................. 1
26 .......................... 808611 ..................................... Screw ................................................................................................ 8
27 .......................... 808609 ..................................... Seal ................................................................................................... 2
28 .......................... 808607 ..................................... Plug Drain ......................................................................................... 1
29 .......................... 050005-072 .............................. Screw ................................................................................................ 10
30 .......................... 808614 ..................................... Washer .............................................................................................. 12
31 .......................... 808613 ..................................... Screw ................................................................................................ 2
32 .......................... 808610 ..................................... Screw ................................................................................................ 3
33 .......................... 808590 ..................................... Washer .............................................................................................. 1
34 .......................... 808598 ..................................... Bearing Ball ....................................................................................... 1
35 .......................... 808589 ..................................... Shim .................................................................................................. 1
36 .......................... 808587 ..................................... Distance Washer ............................................................................... 1
37 .......................... 808608 ..................................... Cap .................................................................................................... 1
38 .......................... 808597 ..................................... Bearing Ball ....................................................................................... 1
39 .......................... 808605 ..................................... Circlip ................................................................................................ 1
40 .......................... 808600 ..................................... Seal ................................................................................................... 1
41 .......................... 808588 ..................................... Threaded Protection Shield ............................................................... 1
42 .......................... 808579 ..................................... Wheel Shaft ....................................................................................... 1
43 .......................... 808585 ..................................... Stud Wheel ........................................................................................ 7
44 .......................... 808606 ..................................... Plug Drain ......................................................................................... 1

See Section ITD
63
GEAR BOX
1
2
3
4
2 6 5
12
9
10 13
11
14
34
15
10
21
20
22
41
35
33
15 24
39 27 2
23
32 24
25
26 31
16
19
40 27
38
37 17
28
36 18
30
29
19
MP-2140-116

01 REV. 11/05
M1.0-0000-00062
62A
GEAR BOX
0 ..................... 812238 ..................................... Gear Box ................................................................................................ 1

1 ........................... 808612 ..................................... Screw ................................................................................................ 15
2 ........................... 805164 ..................................... Washer .............................................................................................. 25
3 ........................... 808593 ..................................... Turntable ............................................................................................ 1
4 ........................... 808616 ..................................... Pin ..................................................................................................... 1
5 ........................... 808603 ..................................... O-Ring ............................................................................................... 1
6 ........................... 808601 ..................................... Seal ................................................................................................... 1
7 ........................... 050005-026 .............................. Screw ................................................................................................ 2
8 ........................... 808581 ..................................... Gear Rim ........................................................................................... 1
9 ........................... 808604 ..................................... O-Ring ............................................................................................... 1
10 .......................... 808599 ..................................... Bearing Ball ....................................................................................... 2
11 .......................... 808582 ..................................... Pinion ................................................................................................ 1
12 .......................... 808584 ..................................... Nut ..................................................................................................... 1
13 .......................... 808583 ..................................... Helical Gear ...................................................................................... 1
14 .......................... 808595 ..................................... Bearing Ball ....................................................................................... 1
15 .......................... 808592 ..................................... Washer .............................................................................................. 2
16 .......................... 808586 ..................................... Bushing ............................................................................................. 1
17 .......................... 808591 ..................................... Washer .............................................................................................. 1
18 .......................... 808596 ..................................... Bearing Ball ....................................................................................... 1
19 .......................... 808580 ..................................... Bevel Gear Set .................................................................................. 1
20 .......................... 808577 ..................................... Transmission Case ............................................................................ 1
21 .......................... 808602 ..................................... O-Ring ............................................................................................... 1
22 .......................... 808578 ..................................... Cover - Gear Box .............................................................................. 1
23 .......................... 808611 ..................................... Screw ................................................................................................ 8
24 .......................... 808609 ..................................... Seal ................................................................................................... 2
25 .......................... 808607 ..................................... Plug Drain ......................................................................................... 1
26 .......................... 050005-072 .............................. Screw ................................................................................................ 10
27 .......................... 808614 ..................................... Washer .............................................................................................. 12
28 .......................... 808613 ..................................... Screw ................................................................................................ 2
29 .......................... 808610 ..................................... Screw ................................................................................................ 3
30 .......................... 808590 ..................................... Washer .............................................................................................. 1
31 .......................... 808598 ..................................... Bearing Ball ....................................................................................... 1
32 .......................... 808589 ..................................... Shim .................................................................................................. 1
33 .......................... 808587 ..................................... Distance Washer ............................................................................... 1
34 .......................... 808608 ..................................... Cap .................................................................................................... 1
35 .......................... 808597 ..................................... Bearing Ball ....................................................................................... 1
36 .......................... 808605 ..................................... Circlip ................................................................................................ 1
37 .......................... 808600 ..................................... Seal ................................................................................................... 1
38 .......................... 808588 ..................................... Threaded Protection Shield ............................................................... 1
39 .......................... 808579 ..................................... Wheel Shaft ....................................................................................... 1
40 .......................... 808585 ..................................... Stud Wheel ........................................................................................ 7
41 .......................... 808606 ..................................... Plug Drain ......................................................................................... 1

See Section ITD
01 REV. 11/05
63A
DRIVE MOTOR
1
1
1
5
3
6
3 5
3
5
4
7
5
7
5 7
8
7
5
9
1
MP-2140-088

01 REV. 05/05
64M1.0-0000-00064
DRIVE MOTOR
0 ..................... 811852 ..................................... Drive Motor Assembly ............................................................................ 1

1 ........................... 816774 ..................................... Screw - Kit ......................................................................................... 1
2 ........................... 816775 ..................................... End Shield ......................................................................................... 1
3 ........................... 816768 ..................................... Pin - Kit .............................................................................................. 1
4 ................................. 816769 ...................................... Sensor Bearing ............................................................................ 1
5 ........................... 816776 ..................................... Armature (included 4) ........................................................................ 1
6 ........................... 814819 ..................................... Stator ................................................................................................ 1
7 ........................... 816771 ..................................... Terminal Block - Kit ............................................................................ 1
8 .............................................................................. Power Cable (see Section 4.1) .......................................................... 1
9 ........................... 816777 ..................................... End Shield ......................................................................................... 1

See Section ITD
01 REV. 05/05
65
Printed in Germany
66M1.0-0000-00066
SECTION 4
Printed in Germany
67
ELECTRICAL COMPARTMENT
Part 1-2
11
8
10
6
5 12
9
4
3
14
13
13
14
5
16
3 19
15
18 21
17 3
1
20
22
MP-2140-060
68M1.0-0000-00068
1 ..................... 811866 ..................................... Compartment Tray .................................................................................. 1

050070-002 .............................. Screw ...................................................................................................... 5
050073-004 .............................. Spring Nut ............................................................................................... 5
2 ..................... 811206 ..................................... Canion Controller .................................................................................... 1
3 ..................... 050068-002 .............................. Nut .......................................................................................................... 12
4 ..................... 813873 ..................................... Plate ........................................................................................................ 1
5 ..................... 050068-003 .............................. Nut .......................................................................................................... 14
6 ..................... 811713 ..................................... Bracket ................................................................................................... 1
7 ..................... 811240 ..................................... Steering Controller .................................................................................. 1
8 ..................... 050067-022 .............................. Screw ...................................................................................................... 2
9 ..................... 807857 ..................................... Bracket ................................................................................................... 1
10 .................... 811213 ..................................... Traction Controller ................................................................................... 1
11 .................... 811215 ..................................... Hydraulic Controller ................................................................................ 1
12 .................... 804683-001 .............................. Cage Nut ................................................................................................. 1
13 .................... 050009-012 .............................. Washer ................................................................................................... 8
14 .................... 050006-024 .............................. Screw ...................................................................................................... 8
15 ....................................................................... Joystick and Emergency Disconnect Switch (see Section 4.6) ............. 1
16 .................... 812248 ..................................... Bracket ................................................................................................... 1
17 .................... 050003-014 .............................. Screw ...................................................................................................... 1
18 .................... 793288 ..................................... Clip .......................................................................................................... 1
19 .................... 050008-008 .............................. Nut .......................................................................................................... 1
20 .................... 813941-001 .............................. Fan Assembly ......................................................................................... 1
812246 ..................................... Fan .................................................................................................... 1
792880-001 .............................. Pin Housing ....................................................................................... 1
792882 ..................................... Pin Crimp .......................................................................................... 2
793090-001 .............................. Anti-Backout ...................................................................................... 1
21 .................... 050004-013 .............................. Screw ...................................................................................................... 4
22 .................... 050008-001 .............................. Nut .......................................................................................................... 4

See Section ITD
01 REV. 05/05
69
Part 1-2
10
7
9
5
4 11
8
3
13
12
12
13
15
3 18
14
17 20
16 3
1
19
21
MP-2140-117

01 REV. 11/05
M1.0-0000-00068
68A
1 ..................... 816266 ..................................... Compartment Tray .................................................................................. 1

050070-002 .............................. Screw ...................................................................................................... 5
050073-004 .............................. Spring Nut ............................................................................................... 5
2 ..................... 816823-004 .............................. Controller ................................................................................................ 1
3 ..................... 050068-002 .............................. Nut .......................................................................................................... 12
4 ..................... 050068-003 .............................. Nut .......................................................................................................... 12
5 ..................... 811713 ..................................... Bracket ................................................................................................... 1
6 ..................... 816264-002 .............................. Steering Controller .................................................................................. 1
7 ..................... 050005-060 .............................. Screw ...................................................................................................... 4
8 ..................... 807857 ..................................... Bracket ................................................................................................... 1
9 ..................... 811213 ..................................... Traction Controller ................................................................................... 1
10 .................... 811215 ..................................... Hydraulic Controller ................................................................................ 1
11 .................... 804683-001 .............................. Cage Nut ................................................................................................. 1
12 .................... 050009-012 .............................. Washer ................................................................................................... 8
13 .................... 050006-024 .............................. Screw ...................................................................................................... 8
14 ....................................................................... Joystick and Emergency Disconnect Switch (see Section 4.6) ............. 1
15 .................... 812248 ..................................... Bracket ................................................................................................... 1
16 .................... 050003-014 .............................. Screw ...................................................................................................... 1
17 .................... 793288 ..................................... Clip .......................................................................................................... 1
18 .................... 050008-008 .............................. Nut .......................................................................................................... 1
19 .................... 813941-001 .............................. Fan Assembly ......................................................................................... 1
812246 ..................................... Fan .................................................................................................... 1
792880-001 .............................. Pin Housing ....................................................................................... 1
792882 ..................................... Pin Crimp .......................................................................................... 2
793090-001 .............................. Anti-Backout ...................................................................................... 1
20 .................... 050004-013 .............................. Screw ...................................................................................................... 4
21 .................... 050008-001 .............................. Nut .......................................................................................................... 4

See Section ITD
02 REV. 11/05
69A
Part 2-2
22
2
21 23
3
22 19 4
1
21 22
22
A
21
21 2
5
19
20
C
B 6
7
9
13
E
D
14
16
10
11
17 15
22 18
12
15 8
22 21
22
21 24 A 8
27 B
21
30 22
22
C
21 D
21
29 25
22
E 26
21
21 22
28
MP-2140-061
70M1.0-0000-00070
1 ..................... 812316 ..................................... Air Stop ................................................................................................... 1

2 ..................... 050068-002 .............................. Nut .......................................................................................................... 3
3 ..................... 812318 ..................................... Sleeve ..................................................................................................... 1
4 ..................... 812317 ..................................... Clip .......................................................................................................... 1
5 ..................... 812324 ..................................... Battery Plug Assembly (DIN 160) ........................................................... 1
813241-076 .............................. Battery Plug Housing ........................................................................ 1
812334-007 .............................. Power Cable (B+) .............................................................................. 1
812334-008 .............................. Power Cable (B-) ............................................................................... 1
813742 ..................................... Battery Plug Assembly (SBE160) ........................................................... 1
812334-011 .............................. Power Cable (B+) .............................................................................. 1
812334-012 .............................. Power Cable (B-) ............................................................................... 1
813743 ..................................... Battery Plug Assembly (SBE 350 Australia) ........................................... 1
794493 ..................................... Battery Plug Housing ........................................................................ 1
812334-009 .............................. Power Cable (B+) .............................................................................. 1
812334-008 .............................. Power Cable (B-) ............................................................................... 1
808468 ..................................... Plate .................................................................................................. 1
813755 ..................................... Battery Plug Assembly (SBE 350 USA) ................................................. 1
812334-013 .............................. Power Cable (B+) .............................................................................. 1
812334-014 .............................. Power Cable (B-) ............................................................................... 1
808468 ..................................... Plate .................................................................................................. 1
6 ..................... 050009-013 .............................. Washer ................................................................................................... AR
7 ..................... 050007-011 .............................. Screw (DIN 160) ..................................................................................... 4
050007-010 .............................. Screw (SBE160) ..................................................................................... 2
050005-063 .............................. Screw (SBE 350 Australia/SBE 350 USA) ............................................. 2
8 ..................... 050078-008 .............................. Blind Rivet Nut ........................................................................................ 6
9 ..................... 813222 ..................................... Module .................................................................................................... 1
10 .................... 811996-001 .............................. Relay Socket .......................................................................................... 2
11 .................... 050007-009 .............................. Screw ...................................................................................................... 2
12 .................... 811995-001 .............................. Relay ....................................................................................................... 2
13 .................... 806702 ..................................... Fuse Box ................................................................................................ 1
805818 ..................................... Spacer .................................................................................................... 2
806703-001 .............................. Fuse 15A ................................................................................................ AR
806703-002 .............................. Fuse 5A .................................................................................................. AR
14 .................... 050005-006 .............................. Screw ...................................................................................................... 2
15 .................... 050078-007 .............................. Blind Rivet Nut ........................................................................................ 5
16 .................... 793288 ..................................... Clip .......................................................................................................... 1
17 .................... 050003-014 .............................. Screw ...................................................................................................... 1
18 .................... 792880-003 .............................. Pin Housing ............................................................................................. 1
19 .................... 812323 ..................................... Copper Link ............................................................................................. 2
20 .................... 812322 ..................................... Copper Link ............................................................................................. 1
21 .................... 050009-018 .............................. Washer ................................................................................................... 10
22 .................... 050006-035 .............................. Screw ...................................................................................................... 10
23 .................... 812334-008 .............................. Power Cable (B-/DIN 160) ...................................................................... 1
812334-010 .............................. Power Cable (B-/SBE 350 Australia) ...................................................... 1
812334-012 .............................. Power Cable (B-/SBE160) ...................................................................... 1
812334-014 .............................. Power Cable (B-/SBE 350 USA) ............................................................. 1
24 .................... 812334-017 .............................. Power Cable (Pu) .................................................................................... 1
812334-003 .............................. Power Cable (Pu/Drive in Racking) ........................................................ 1
25 .................... 812334-016 .............................. Power Cable (Pv) .................................................................................... 1
812334-002 .............................. Power Cable (Pv/Drive in Racking) ........................................................ 1
26 .................... 812334-015 .............................. Power Cable (Pw) ................................................................................... 1
812334-001 .............................. Power Cable (Pw/Drive in Racking) ........................................................ 1
27 .................... 812334-006 .............................. Power Cable (Tu) .................................................................................... 1
28 .................... 812334-005 .............................. Power Cable (Tv) .................................................................................... 1
29 .................... 812334-004 .............................. Power Cable (Tw) .................................................................................... 1
30 .................... 812334-007 .............................. Power Cable (B+/DIN 160) ..................................................................... 1
812334-009 .............................. Power Cable (B+/SBE 350 Australia) ..................................................... 1
812334-011 .............................. Power Cable (B+/SBE160) ..................................................................... 1
812334-013 .............................. Power Cable (B+/SBE 350 USA) ............................................................ 1

See Section ITD
01 REV. 05/05
71
Part 2-2
22
2
21 23
3
22 19 4
1
21 22
22
A
21
21 2
5
19
20
C
B 6
7
9
13
E
D
14
16
10
11
17 15
22 18
12
15 8
22 21
22
21 24 A 8
27 B
21
30 22
22
C
21 D
21
29 25
22
E 26
21
21 22
28
MP-2140-061
M1.0-0000-00070
70A
1 ..................... 812316 ..................................... Air Stop ................................................................................................... 1

2 ..................... 050068-002 .............................. Nut .......................................................................................................... 3
3 ..................... 812318 ..................................... Sleeve ..................................................................................................... 1
4 ..................... 812317 ..................................... Clip .......................................................................................................... 1
816096 ..................................... Plate ........................................................................................................ 1
5 ..................... 812324 ..................................... Battery Plug Assembly (DIN 160) ........................................................... 1
813241-076 .............................. Battery Plug Housing (included Contacts/Truck Side) ....................... 1
813241-065 .............................. Battery Socket Housing (included Contacts/Battery Side) ................ 1
812334-007 .............................. Power Cable (B+) .............................................................................. 1
812334-008 .............................. Power Cable (B-) ............................................................................... 1
813742 ..................................... Battery Plug Assembly (SBE160) ........................................................... 1
812334-011 .............................. Power Cable (B+) .............................................................................. 1
812334-012 .............................. Power Cable (B-) ............................................................................... 1
813743 ..................................... Battery Plug Assembly (SBE 350 blue) .................................................. 1
812334-009 .............................. Power Cable (B+) .............................................................................. 1
812334-008 .............................. Power Cable (B-) ............................................................................... 1
808468 ..................................... Plate .................................................................................................. 1
813755 ..................................... Battery Plug Assembly (SBE 350 red) .................................................... 1
812334-013 .............................. Power Cable (B+) .............................................................................. 1
812334-014 .............................. Power Cable (B-) ............................................................................... 1
808468 ..................................... Plate .................................................................................................. 1
6 ..................... 050009-013 .............................. Washer ................................................................................................... AR
7 ..................... 050007-011 .............................. Screw (DIN 160) ..................................................................................... 4
050007-010 .............................. Screw (SBE160) ..................................................................................... 2
050005-063 .............................. Screw (SBE 350 blue/SBE 350 red) ....................................................... 2
8 ..................... 050078-008 .............................. Blind Rivet Nut ........................................................................................ 6
9 ..................... 813222 ..................................... Module .................................................................................................... 1
10 .................... 811996-001 .............................. Relay Socket .......................................................................................... 2
11 .................... 050007-009 .............................. Screw ...................................................................................................... 2
12 .................... 811995-001 .............................. Relay ....................................................................................................... 2
13 .................... 816099 ..................................... Fuse Box ................................................................................................ 1
805818 ..................................... Spacer .................................................................................................... 2
806703-001 .............................. Fuse 15A ................................................................................................ AR
806703-002 .............................. Fuse 5A .................................................................................................. AR
14 .................... 050005-006 .............................. Screw ...................................................................................................... 2
15 .................... 050078-007 .............................. Blind Rivet Nut ........................................................................................ 5
16 .................... 793288 ..................................... Clip .......................................................................................................... 1
17 .................... 050003-014 .............................. Screw ...................................................................................................... 1
18 .................... 792880-003 .............................. Pin Housing ............................................................................................. 1
19 .................... 812323 ..................................... Copper Link ............................................................................................. 2
20 .................... 812322 ..................................... Copper Link ............................................................................................. 1
21 .................... 050009-018 .............................. Washer ................................................................................................... 10
22 .................... 050006-035 .............................. Screw ...................................................................................................... 10
23 .................... 812334-008 .............................. Power Cable (B-/DIN 160) ...................................................................... 1
812334-010 .............................. Power Cable (B-/SBE 350 blue) .............................................................. 1
812334-012 .............................. Power Cable (B-/SBE160) ...................................................................... 1
812334-014 .............................. Power Cable (B-/SBE 350 red) ............................................................... 1
24 .................... 812334-017 .............................. Power Cable (Pu) .................................................................................... 1
25 .................... 812334-016 .............................. Power Cable (Pv) .................................................................................... 1
26 .................... 812334-015 .............................. Power Cable (Pw) ................................................................................... 1
27 .................... 812334-006 .............................. Power Cable (Tu) .................................................................................... 1
28 .................... 812334-005 .............................. Power Cable (Tv) .................................................................................... 1
29 .................... 812334-004 .............................. Power Cable (Tw) .................................................................................... 1
30 .................... 812334-007 .............................. Power Cable (B+/DIN 160) ..................................................................... 1
812334-009 .............................. Power Cable (B+/SBE 350 blue) ............................................................. 1
812334-011 .............................. Power Cable (B+/SBE160) ..................................................................... 1
812334-013 .............................. Power Cable (B+/SBE 350 red) .............................................................. 1

See Section ITD
02 REV. 11/05
71A
CONTACTOR
4
3
5
6
7
8
MP-2140-045
72M1.0-0000-00072
CONTACTOR
0 ..................... 813757 ..................................... Line Contactor ........................................................................................ 1

1 ........................... 120115 ..................................... Top Cover Fixing Screw .................................................................... 2
2 ........................... 805265 ..................................... Top Cover Moulding ........................................................................... 1
3 ........................... 120112 ..................................... Fixed Contact .................................................................................... 2
4 ........................... 794032 ..................................... Return Spring .................................................................................... 1
5 ........................... 120113 ..................................... Moving Contact (contain Index 7) ..................................................... 1
6 ........................... 120120 ..................................... Top Cover Base Moulding ................................................................. 1
7 ........................... 120629 ..................................... Moving Contact Plunger .................................................................... 1
8 ........................... 794026 ..................................... Coil and Frame .................................................................................. 1
9 ........................... 120638 ..................................... End Cap ............................................................................................ 1

See Section ITD
73
REACH SLOWDOWN
Chassi
Reach Carriage
11 3
8
7
7
9
4 10
6 12
6
5
MP-2140-059
74M1.0-0000-00074
REACH SLOWDOWN
1 ..................... 812870-001 .............................. Sensor Bracket (1.4t/420Ah) .................................................................. 1

812870-002 .............................. Sensor Bracket (1.4t/560Ah) .................................................................. 1
812870-006 .............................. Sensor Bracket (1.6t/2.0t/560Ah) ........................................................... 1
2 ..................... 050003-061 .............................. Screw ...................................................................................................... AR
3* .................... 812361 ..................................... Bracket ................................................................................................... 1
4* .................... 811378-004 .............................. Sensor Assembly ................................................................................... 1
792880-003 .............................. Pin Housing ....................................................................................... 1
792882 ..................................... Pin Crimp .......................................................................................... 3
793090-003 .............................. Anti-Backout ...................................................................................... 1
5* .................... 811378-003 .............................. Sensor Assembly ................................................................................... 1
792880-002 .............................. Pin Housing ....................................................................................... 1
792882 ..................................... Pin Crimp .......................................................................................... 3
793090-002 .............................. Anti-Backout ...................................................................................... 1
6* .................... 050004-015 .............................. Screw ...................................................................................................... 4
7* .................... 050009-004 .............................. Washer ................................................................................................... 4
8* .................... 050008-001 .............................. Nut .......................................................................................................... 4
9* .................... 793288 ..................................... Clip .......................................................................................................... 2
10* ................... 050003-014 .............................. Screw ...................................................................................................... 2
11* ................... 050008-008 .............................. Nut .......................................................................................................... 2
12 .................... 050067-023 .............................. Screw ...................................................................................................... 2
* ..................... 812074 ..................................... Reach Sensor Assembly (included 3 - 11) ............................................. 1

See Section ITD
75
HGTS - LIFT SPEED REDUCTION
19
21
20
11
9 3
8
22 10
12
13
14 16
15
7
3
5
17 6
18
MP-2140-086
76M1.0-0000-00076
1 .....................050067-014 .............................. Screw ...................................................................................................... 4

2 .....................808096 ..................................... Cover ...................................................................................................... 1
3 .....................808038 ..................................... Spacer .................................................................................................... 4
4 .....................808026 ..................................... Bracket ................................................................................................... 1
5 .....................050068-012 .............................. Screw ...................................................................................................... 4
6 .....................808095 ..................................... Cover ...................................................................................................... 1
7 .....................807870 ..................................... Bracket ................................................................................................... 1
8 .....................050006-001 .............................. Screw ...................................................................................................... 2
9 .....................792991 ..................................... Microswitch (HGTS 12) .......................................................................... 1
10 .................... 803310 ..................................... Actuator .................................................................................................. 1
11 .................... 807541 ..................................... Plate ........................................................................................................ 1
12 .................... 050003-013 .............................. Screw ...................................................................................................... 1
13 .................... 793288 ..................................... Clip .......................................................................................................... 1
14 .................... 050008-008 .............................. Nut .......................................................................................................... 1
15 .................... 792881-002 .............................. Socket Housing ...................................................................................... 1
792883 ..................................... Socket Crimp .......................................................................................... 3
793091-002 .............................. Anti-Backout ........................................................................................... 1
16 .................... 050006-014 .............................. Screw ...................................................................................................... 1
17 .................... 061002-001 .............................. Clamp ...................................................................................................... 1
18 .................... 050008-008 .............................. Nut .......................................................................................................... 1
19 .................... 796008 ..................................... Bracket ................................................................................................... 1

20 .................... 794590-001 .............................. Cable Assembly (inclusive 794611-001,792880-001, ............................. 1
792882,793090-001)
21 .......................... 794611-001 .............................. Heater ............................................................................................... 1
050004-042 .............................. Screw ...................................................................................................... 2
050008-011 .............................. Nut .......................................................................................................... 2
22 .......................... 792880-001 .............................. Pin Housing ....................................................................................... 1
792882 ..................................... Pin Insert ........................................................................................... 2
793090-001 .............................. Anti Backout ...................................................................................... 1
796173 ..................................... Heater Assembly (included 19 - 22) ........................................................ 1

See Section ITD
77
12
13
4 1
11
10 5
9
8
3
7
5
4
Mast
3
MP-2140-105

01 REV. 05/05
M1.0-0000-00076
76A
1 .....................050083-001 .............................. Screw ...................................................................................................... 4

2 .....................815204 ..................................... Cover ...................................................................................................... 1
3 .....................808038 ..................................... Spacer .................................................................................................... 4
4 .....................793288 ..................................... Clip .......................................................................................................... 2
5 .....................050003-006 .............................. Screw ...................................................................................................... 2
6 .....................060014-094 .............................. Screw ...................................................................................................... 2
7 .....................815207 ..................................... Shim ........................................................................................................ AR
8 .....................815556 ..................................... Height Switch .......................................................................................... 1
9 .....................050003-014 .............................. Screw ...................................................................................................... 2
10 .................... 815208 ..................................... Plate (with Height Encoder) .................................................................... 1
815210 ..................................... Plate (without Height Encoder) ............................................................... 1
11 .................... 815209 ..................................... Shim (with Height Encoder) .................................................................... AR
815211 ..................................... Shim (without Height Encoder) ............................................................... AR
12 .................... 815205 ..................................... Cover ...................................................................................................... 1
13 ....................................................................... Height Encoder (see next Page) ............................................................. 1

See Section ITD
01 REV. 05/05
77A
HEIGHT ENCODER
13
11
29
7
2
30 8
6
5
16 3 4
17
18
19 15
22 10
20
1
21 23
25
14
9
24
31
26
27 12
37
28
32
36
37
32
37
35 33
38
34
MP-2140-093
78M1.0-0000-00078
HEIGHT ENCODER
1 ..................... 808215 ..................................... Bracket ................................................................................................... 1

2 ..................... 793288 ..................................... Clip .......................................................................................................... 1
3 ..................... 050003-013 .............................. Screw ...................................................................................................... 1
4 ..................... 050008-008 .............................. Nut .......................................................................................................... 1
5 ..................... 808896 ..................................... Power Supply Assembly (included 6 & 7) .............................................. 1
6 ........................... 062535-006 .............................. Pin Housing ....................................................................................... 1
062536-001 .............................. Pin Insert ........................................................................................... 4
7 ........................... 792880-003 .............................. Pin Housing ....................................................................................... 1
792882 ..................................... Pin Insert ........................................................................................... 4
793090-003 .............................. Anti-Backout ...................................................................................... 1
8 ..................... 050004-009 .............................. Screw ...................................................................................................... 2
9 ..................... 050008-004 .............................. Nut .......................................................................................................... 2
10 .................... 050006-033 .............................. Screw ...................................................................................................... 2
11 .................... 808393 ..................................... Cable Guide ............................................................................................ 1
12 .................... 050006-023 .............................. Screw ...................................................................................................... 1
13 .................... 808733 ..................................... Blind Rivet Nut ........................................................................................ 2
14 .................... 050006-033 .............................. Screw ...................................................................................................... 2
15 .................... 808362 ..................................... Case ....................................................................................................... 1
16 .................... 808379 ..................................... Pin ........................................................................................................... 2
17 .................... 808410 ..................................... Bearing Ball ............................................................................................. 2
18 .................... 808378 ..................................... Pulley ...................................................................................................... 2
19 .................... 050009-014 .............................. Washer ................................................................................................... 2
20 .................... 050012-013 .............................. Ring Retaining ........................................................................................ 2
21 .................... 808361 ..................................... Pulley ...................................................................................................... 1
22 .................... 050017-018 .............................. Screw ...................................................................................................... 1
23 .................... 055002-026 .............................. Bearing Ball ............................................................................................. 1
24 .................... 050012-069 .............................. Ring Retaining ........................................................................................ 1
25 .................... 808908 ..................................... Washer ................................................................................................... 1
26 .................... 050012-070 .............................. Ring Retaining ........................................................................................ 1
27 .................... 808380 ..................................... Plate ........................................................................................................ 1
28 .................... 127785 ..................................... Encoder PCP .......................................................................................... 1
29 .................... 808217 ..................................... Bolt .......................................................................................................... 1
30 .................... 050000-087 .............................. Pin ........................................................................................................... 1
31 .................... 808386 ..................................... Wire Rope ............................................................................................... 1
32 .................... 808826 ..................................... Slide Piece .............................................................................................. 2
808884 ..................................... Tape ........................................................................................................ 2
051051-004 .............................. Cable Tie ................................................................................................. 1
33 .................... 807303 ..................................... Spring ..................................................................................................... 1
34 .................... 808216 ..................................... Bracket ................................................................................................... 1
35 .................... 050006-022 .............................. Screw ...................................................................................................... 1
808904 ..................................... Height EncoderMain Assembly (included 1 - 9 & 14 - 28) ....................... 1

808363 ..................................... Height Encoder Assembly (included 15 - 28) ......................................... 1
36 .................... 796229 ..................................... Cable Assembly (included 37 & 38) ....................................................... 1

050004-042 .............................. Screw ...................................................................................................... 6
37 .......................... 794611-004 .............................. Heater ............................................................................................... 3
38 .......................... 792880-001 .............................. Pin Housing ....................................................................................... 1
792882 ..................................... Pin Insert ........................................................................................... 2
793090-001 .............................. Anti Backout ...................................................................................... 1

See Section ITD
79
HEIGHT ENCODER
15
1
2 5
6
7
13
11 14
10
12
MP-2140-104

01 REV. 05/05
M1.0-0000-00078
78A
HEIGHT ENCODER
1 ..................... 127704 ..................................... Bracket ................................................................................................... 1

2 ..................... 060038-003 .............................. Pin ........................................................................................................... 1
3 ..................... 127707 ..................................... Bracket ................................................................................................... 1
4 ..................... 127684 ..................................... Spring ..................................................................................................... 1
5 ..................... 129208 ..................................... Wheel ...................................................................................................... 1
6 ..................... 061085-001 .............................. Clip .......................................................................................................... 1
7 ..................... 816019 ..................................... Senor Bearing Assembly ........................................................................ 1
808123-003 .............................. Pin Housing ....................................................................................... 1
792882 ..................................... Pin Insert ........................................................................................... 4
793090-003 .............................. Anti-Backout ...................................................................................... 1
8 ..................... 128898 ..................................... Washer ................................................................................................... 1
9 ..................... 060014-094 .............................. Screw ...................................................................................................... 1
10 .................... 128888 ..................................... Gasket .................................................................................................... 1
11 .................... 128912 ..................................... Retainer .................................................................................................. 1
12 .................... 060014-008 .............................. Screw ...................................................................................................... 1
13 .................... 125256 ..................................... Retainer .................................................................................................. 1
14 .................... 815601 ..................................... Heater ..................................................................................................... 1
803448-005 .............................. Pin Housing ............................................................................................. 2
803448-004 .............................. Pin Insert ................................................................................................ 2
15 .................... 060015-123 .............................. Screw ...................................................................................................... 2
815557 ..................................... Height Encoder Assembly (included 1 - 12) ........................................... 1

815606 ..................................... Height Encoder Assembly (Freezer/Corrosion/included 1 - 14) ............. 1

See Section ITD
02 REV. 11/05
79A
MAST WIRING
Free Lift
Cylinder
8
4
7
5
Tilt and Sideshift
4
3 Reach Carriage
1
2 5
MP-2140-091
80M1.0-0000-00080
MAST WIRING
1 ..................... 061002-001 .............................. Clamp (6-way) ........................................................................................ 1

061002-008 .............................. Clamp (10-way) ...................................................................................... 9
2 ..................... 050006-013 .............................. Screw ...................................................................................................... 1
3 ..................... 050008-008 .............................. Nut .......................................................................................................... 1
4 ..................... 052076-001 .............................. Clamp (6-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 (6-way) ................................................................................. 1
105449 ..................................... Cable Grip (10-way) ................................................................................ 1
8 ..................... 807303 ..................................... Spring ..................................................................................................... 1
9 ..................... 810214-*** ............................... Cable (6-way/see next Page) .................................................................. 1
810215-*** ............................... Cable (10-way/see next Page) ................................................................ 1
051051-009 .............................. Cable Tie ................................................................................................. 9
Not shown
810244 ..................................... Clamp ...................................................................................................... 1

050006-035 .............................. Screw ...................................................................................................... 1
808089 ..................................... Cable Assembly (Chassis - Mast) .......................................................... 1

061002-008 .............................. Clamp ...................................................................................................... 1
061002-001 .............................. Clamp ...................................................................................................... 1
050006-013 .............................. Screw ...................................................................................................... 2
050008-008 .............................. Nut .......................................................................................................... 2
810244 ..................................... Clamp ...................................................................................................... 1
050006-035 .............................. Screw ...................................................................................................... 1
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 (6-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 (6-way) .............................................................................. 1
793091-006 .............................. Anti-Backout (10-way) ............................................................................ 1
793217-018 .............................. Connector ............................................................................................... 1
792880-004 .............................. Pin Housing (6-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 (6-way) .............................................................................. 1
793090-006 .............................. Anti-Backout (10-way) ............................................................................ 1
793288 ..................................... Clip .......................................................................................................... 1
050003-013 .............................. Screw ...................................................................................................... 1
050008-008 .............................. Nut .......................................................................................................... 1

See Section ITD
01 REV. 05/05
81
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
Tab018gb
82M1.0-0000-00082
Printed in Germany
83
JOYSTICK AND EMERGENCY DISCONNECT SWITCH
19
17
18
9 25
15 24
A
14 23
10
22
7
6
21
2 8
13
11
31
6
3
12
16 A
27
20
4 28
26 19 30
29
MP-2140-044

01 REV. 05/05
84M1.0-0000-00084
1 ..................... 812213 ..................................... Bracket ................................................................................................... 1

2 ..................... 804863-001 .............................. Cage Nut ................................................................................................. 3
3 ..................... 050068-003 .............................. Nut .......................................................................................................... 3
4 ........................................................................ Directional Switch/Horn Button (see next Page) ..................................... 1
5 ..................... 050006-032 .............................. Screw ...................................................................................................... 2
050009-018 .............................. Washer ................................................................................................... 2
6 ..................... 807037 ..................................... Joystick Assembly (Pot) ......................................................................... AR
792880-003 .............................. Pin Housing ....................................................................................... AR
792882 ..................................... Pin Insert ........................................................................................... AR
793090-003 .............................. Anti-Backout ...................................................................................... AR
7 ..................... 050006-024 .............................. Screw ...................................................................................................... AR
8 ..................... 050008-015 .............................. Nut .......................................................................................................... AR
9 ..................... 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
10 .................... 791423-002 .............................. Joystick Hole Plug .................................................................................. 1
11 .................... 793288 ..................................... Clip .......................................................................................................... AR
12 .................... 050003-013 .............................. Screw ...................................................................................................... AR
13 .................... 050008-008 .............................. Nut .......................................................................................................... AR
14 .................... 802817 ..................................... Fuse Holder ............................................................................................ 1
050008-030 .............................. Nut .......................................................................................................... 2
050009-024 .............................. Washer ................................................................................................... 2
15 .................... 050004-014 .............................. Screw ...................................................................................................... 2
16 .................... 050008-001 .............................. Nut .......................................................................................................... 2
17 .................... 812320 ..................................... Copper Link ............................................................................................. 1
18 .................... 806720-001 .............................. Fuse ........................................................................................................ 1
19 .................... 050006-031 .............................. Screw ...................................................................................................... 2
20 .................... 813758 ..................................... Emergency Disconnect Switch (included 19) ......................................... 1
21 .................... 813378 ..................................... Seal ......................................................................................................... 1
22 .................... 812128 ..................................... Bracket ................................................................................................... 1
23 .................... 050009-008 .............................. Washer ................................................................................................... 2
24 .................... 050006-013 .............................. Screw ...................................................................................................... 2
25 .................... 812126 ..................................... Actuator-Emergency Disconnect Switch ................................................ 1
26 ....................................................................... Line Contactor (see Section 4.4) ............................................................ 1
27 .................... 050009-007 .............................. Washer ................................................................................................... 4
28 .................... 050006-008 .............................. Screw ...................................................................................................... 4
29 .................... 812321 ..................................... Copper Link ............................................................................................. 1
30 .................... 813382 ..................................... Heater Assembly (Freezer/Corrosion-Emergency Disconnect Switch) .. 1
813381 ..................................... Bracket .............................................................................................. 1
050004-044 .............................. Screw ................................................................................................ 2
050004-042 .............................. Screw (Heater) .................................................................................. 2
050008-011 .............................. Nut (Heater) ...................................................................................... 2
794590-001 .............................. Cable Assembly ................................................................................ 1
794611-001 ............................... Heater .......................................................................................... 1
792880-001 ............................... Pin Housing ................................................................................. 1
792882 ...................................... Pin Insert ..................................................................................... 2
793090-001 ............................... Anti Backout ................................................................................ 1
31 .................... 050008-024 .............................. Nut .......................................................................................................... 2
not shown
793217-007 .............................. Switch (6th Function Valve) ..................................................................... 1
796488 ..................................... Cable Assembly (6th Function Valve) ..................................................... 1
051051-009 .............................. Cable Ties (6th Function Valve) .............................................................. 5
796735 ..................................... Label (6th Function Valve) ....................................................................... 1

See Section ITD
01 REV. 05/05
85
MP-2140-114

02 REV. 11/05
M1.0-0000-00084
84A
1 ..................... 816978 ..................................... Bracket ................................................................................................... 1

050067-022 .............................. Screw ...................................................................................................... 2
050068-003 .............................. Nut .......................................................................................................... 2
2 ..................... 804863-001 .............................. Cage Nut ................................................................................................. 3
3 ..................... 050078-003 .............................. Blind Rivet Nut ........................................................................................ 4
4 ..................... 816679 ..................................... Bracket ................................................................................................... 1
5 ..................... 050067-014 .............................. Screw ...................................................................................................... 4
6 ..................... 816221 ..................................... Joystick Assembly (Pot) ......................................................................... AR
792880-003 .............................. Pin Housing ............................................................................................. AR
792882 ..................................... Pin Insert ................................................................................................ AR
793090-003 .............................. Anti-Backout ........................................................................................... AR
7 ..................... 050005-049 .............................. Screw ...................................................................................................... AR
8 ..................... 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
9 ..................... 791423-002 .............................. Joystick Hole Plug .................................................................................. 1
10 .................... 793288 ..................................... Clip .......................................................................................................... AR
11 .................... 050003-013 .............................. Screw ...................................................................................................... AR
12 .................... 050008-008 .............................. Nut .......................................................................................................... AR
13 .................... 802817 ..................................... Fuse Holder ............................................................................................ 1
050008-030 .............................. Nut .......................................................................................................... 2
050009-024 .............................. Washer ................................................................................................... 2
14 .................... 050004-014 .............................. Screw ...................................................................................................... 2
15 .................... 050008-001 .............................. Nut .......................................................................................................... 2
16 .................... 812320 ..................................... Copper Link ............................................................................................. 1
17 .................... 806720-001 .............................. Fuse ........................................................................................................ 1
18 .................... 050006-032 .............................. Screw ...................................................................................................... 2
19 .................... 813758 ..................................... Emergency Disconnect Switch (included 19) ......................................... 1
20 .................... 813378 ..................................... Seal ......................................................................................................... 1
21 .................... 812128 ..................................... Bracket ................................................................................................... 1
22 .................... 050009-008 .............................. Washer ................................................................................................... 2
23 .................... 050006-013 .............................. Screw ...................................................................................................... 2
24 .................... 812126 ..................................... Actuator-Emergency Disconnect Switch ................................................ 1
25 ....................................................................... Line Contactor (see Section 4.4) ............................................................ 1
26 .................... 050009-007 .............................. Washer ................................................................................................... 4
27 .................... 050006-008 .............................. Screw ...................................................................................................... 4
28 .................... 812321 ..................................... Copper Link ............................................................................................. 1
29 .................... 814958 ..................................... Fuse Holder ............................................................................................ 1
30 .................... 050005-001 .............................. Screw ...................................................................................................... 1
31 .................... 814995-002 .............................. Fuse ........................................................................................................ 1
32 .................... 813382 ..................................... Heater Assembly (Freezer/Corrosion-Emergency Disconnect Switch) .. 1
813381 ..................................... Bracket .............................................................................................. 1
050004-044 .............................. Screw ................................................................................................ 2
050004-042 .............................. Screw (Heater) .................................................................................. 2
050008-011 .............................. Nut (Heater) ...................................................................................... 2
794590-001 .............................. Cable Assembly ................................................................................ 1
794611-001 ............................... Heater .......................................................................................... 1
792880-001 ............................... Pin Housing ................................................................................. 1
792882 ...................................... Pin Insert ..................................................................................... 2
793090-001 ............................... Anti Backout ................................................................................ 1

See Section ITD
02 REV. 11/05
85A
MP-2140-114
MP-ESR4500-GB 06/04 • Printed in Germany

02 REV. 11/05
M1.0-0000-00086
86A
33 .................... 816980 ..................................... Bracket ................................................................................................... 1

34 .................... 816609-001 .............................. Dual-Axis Control .................................................................................... 1
35 .................... 816609-002 .............................. Dual-Axis Control (4 - Dual-Axis Control) ............................................... 1
816609-003 .............................. Dual-Axis Control (5 - Dual-Axis Control) ............................................... 1
069604-001 .............................. Label; Lift/Reach ..................................................................................... 1
069604-002 .............................. Label; Sideshift/Tilt .................................................................................. 1
069604-003 .............................. Label; Sideshift/Tilt/Load Stabilizer .......................................................... 1
069604-004 .............................. Label; Sideshift/Tilt/Rotate ....................................................................... 1
069604-005 .............................. Label; Sideshift/Tilt/Clamp ....................................................................... 1
069604-006 .............................. Label; Sideshift/Tilt/Fork Arm Spread ...................................................... 1
069604-007 .............................. Label; Sideshift/Tilt/Push - Pull ................................................................ 1
069604-008 .............................. Label; Sideshift/Tilt/Upender .................................................................... 1
36 .................... 050005-001 .............................. Screw ...................................................................................................... 8
not shown
816221 ..................................... Joystick Assembly (Pot - 6th Function Valve) ......................................... 1

050005-049 .............................. Screw ...................................................................................................... 4
814475 ..................................... Cable Assembly (6th Function Valve) ..................................................... 1
051051-009 .............................. Cable Ties (6th Function Valve) .............................................................. 5
796735 ..................................... Label (6th Function Valve) ....................................................................... 1

See Section ITD
MP-ESR4500-GB 06/04 • Printed in Germany
02 REV. 11/05
87A
DIRECTIONAL SWITCH/HORN BUTTON
20
24
23
24 25
27
17
1 4
16
8
7
6
24 26
3 5
10
4
17
22
19 9
12
4 11
12
18 7
10
15 8
21 6 2
4 9
13
14
MP-2140-043
88M1.0-0000-00088
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 .................... 813702 ..................................... 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 (included 794611-001, 792880-001, 792882, ............... 1

793090-001)
813701 ..................................... Heater Assembly (included 23-27) ......................................................... 1

See Section ITD
89
MP-2140-113

01 REV. 11/05
M1.0-0000-00088
88A
1 ..................... 815017 ..................................... Bracket ................................................................................................... 1

050006-032 .............................. Screw ...................................................................................................... 2
050008-024 .............................. Nut .......................................................................................................... 2
050009-018 .............................. Washer ................................................................................................... 2
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 .................... 815922 ..................................... Plate ........................................................................................................ 2
17 .................... 050009-003 .............................. Washer ................................................................................................... 2
18 .................... 815655 ..................................... Spring Roller ........................................................................................... 1
19 .................... 050005-002 .............................. Screw ...................................................................................................... 2
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 .................... 813702 ..................................... 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 (included 794611-001, 792880-001, 792882, ............... 1

793090-001)

See Section ITD
01 REV. 11/05
89A
FLOORPLATE
1
13
12
14
2 15 18
Chassis
17
17
16
4
7 3 11
9
8 10
11
6 4
10
Drive Frame
MP-2140-030
90M1.0-0000-00090
FLOORPLATE
1* .................... 811924 ..................................... Floor Mat ................................................................................................. 1

2 ..................... 050071-036 .............................. Screw ...................................................................................................... 2
3* .................... 811923 ..................................... Floorplate ................................................................................................ 1
4 ..................... 060102-001 .............................. Lug Nut ................................................................................................... 2
5 ..................... 812998 ..................................... Bracket ................................................................................................... 1
6 ..................... 050067-022 .............................. Screw ...................................................................................................... 1
7* .................... 793333 ..................................... Lug Nut ................................................................................................... 2
8* .................... 050009-013 .............................. Washer ................................................................................................... 2
9* .................... 050005-062 .............................. Screw ...................................................................................................... 2
10 .................... 812346 ..................................... Spacer .................................................................................................... 2
11 .................... 055058-003 .............................. Buffer ...................................................................................................... 2
12* ................... 806476 ..................................... Accelerator Pedal .................................................................................... 1
13* ................... 104215 ..................................... Pedal Rubber .......................................................................................... 1
14* ................... 793226 ..................................... Buffer ...................................................................................................... 1
15* ................... 050008-015 .............................. Nut .......................................................................................................... 1
16* ................... 807278 ..................................... Pin ........................................................................................................... 1
17* ................... 055084-010 .............................. Bush ........................................................................................................ 2
18* ................... 050000-056 .............................. Pin ........................................................................................................... 2
* ..................... 811922 ..................................... Floorplate & Pedal Assembly (included 1, 3, 7 - 9, 12 - 18) ..................... 1

See Section ITD
91
ACCELERATOR
9
10
23 25 22 12
14
27 11
24
17
13
26
25
21
20
18
19 8
15
12
16 7
5
1
MP-2140-042
92M1.0-0000-00092
ACCELERATOR
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 .......................................................................................... 3
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
* ..................... 807751-001 .............................. Accelerator (included 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 (included 794611-001, 792880-001, 792882, ............... 1
793090-001)

See Section ITD
01 REV. 05/05
93
SAFETY PEDAL
19
21
20
22
23
12 2
13
4
7
16
9
10
11
6 8
9 6 17
14
15
18
MP-2140-040

01 REV. 05/05
94M1.0-0000-00094
SAFETY PEDAL
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 .................... 810469 ..................................... Plate ........................................................................................................ 1
17 .................... 050067-037 .............................. Screw ...................................................................................................... 2
18 .................... 812345 ..................................... Spacer Plate ........................................................................................... 1
19 .................... 796007 ..................................... Bracket ................................................................................................... 1

20 .................... 794611-001 .............................. Heater ..................................................................................................... 1
21 .................... 050004-042 .............................. Screw ...................................................................................................... 2
22 .................... 050008-011 .............................. Nut .......................................................................................................... 2
23 .................... 794590-001 .............................. Cable Assembly (inclusive 794611-001) ................................................. 1
792880-001 .............................. Pin Housing ....................................................................................... 1
792882 ..................................... Pin Insert ........................................................................................... 2
793090-001 .............................. Anti Backout ...................................................................................... 1

See Section ITD
95
DC/DC COVERTER
12/24V
48V
MP-2140-081
96M1.0-0000-00096
DC/DC COVERTER
1 ........................................................................ Bracket Parts (see Section 4.10) ............................................................ 1

2 ..................... 814292-001 .............................. DC/DC Converter (48 - 12V) .................................................................. 1
814292-002 .............................. DC/DC Converter (48 - 24V) .................................................................. 1
3 ..................... 050005-004 .............................. Screw ...................................................................................................... 4
4 ..................... 813753 ..................................... Loom (without Option Loom) ................................................................... 1
814056 ..................................... Loom (with Option Loom) ........................................................................ 1
Not illustrated
814338-001 .............................. Cable ....................................................................................................... 1

811995-001 .............................. Relay ....................................................................................................... 2

See Section ITD
01 REV. 05/05
97
DASH PANEL
27
26
22
28 23
24
25 21
22
23
1 6
5 4
7 3 8
19
20
16 12
17 9 10
15 11
18
14
13
MP-2140-039
98M1.0-0000-00098
DASH PANEL
0 ..................... 813271 ..................................... Dash Panel Assembly (without 19 & 20 & Freezer/Corrosion) ............... 1
1 ........................... 806898 ..................................... Dash Panel ........................................................................................ 1
2 ........................... 807349 ..................................... Brake Switch ..................................................................................... 1
3 ........................... 807034 ..................................... Key Switch Assembly (included 4) .................................................... 1
123537 ...................................... Key Switch ................................................................................... 1
793090-002 ............................... Anti-Backout ................................................................................ 1
792880-002 ............................... Pin Housing ................................................................................. 1
792882 ...................................... Pin Crimp ..................................................................................... 3
4 ........................... 107739 ..................................... Key Assembly ................................................................................... 1
107151-002 ............................... Key .............................................................................................. 2
107763 ...................................... Ring ............................................................................................. 1
5 ........................... 109127-003 .............................. Clip Arrow Indicator (red) .................................................................. 1
6 ........................... 109127-001 .............................. Clip Arrow Indicator (green) .............................................................. 1
7 ........................... 109127-002 .............................. Clip Arrow Indicator (yellow) ............................................................. 1
8 ........................... 813272 ..................................... Bracket .............................................................................................. 1
9 ........................... 803469-022 .............................. Screw ................................................................................................ 5
050009-007 .............................. Washer .............................................................................................. 5
10 .......................... 792940 ..................................... Lug Nut .............................................................................................. 2
11 .......................... 793288 ..................................... Attachment Clip ................................................................................. 2
12 .......................... 050003-015 .............................. Screw ................................................................................................ 2
13 .......................... 791346-003 .............................. Adjuster Button .................................................................................. 1
14 .......................... 790199-039 .............................. Spring ................................................................................................ 1
15 .......................... 806932 ..................................... Pivot Pin ............................................................................................ 1
16 .......................... 790213 ..................................... R-Clip ................................................................................................ 2
17 .......................... 808876 ..................................... Finger Guard ..................................................................................... 1
18 .......................... 050003-002 .............................. Screw ................................................................................................ 1
19 .................... 811036 ..................................... Shim ........................................................................................................ 4
20 .................... 050068-004 .............................. Nut .......................................................................................................... 4
21 .................... 813058 ..................................... Bracket ................................................................................................... 1

22 .................... 794591-003 .............................. Heater Assembly .................................................................................... 1
794611-001 .............................. Heater ............................................................................................... 2
792880-001 .............................. Pin Housing ....................................................................................... 1
792882 ..................................... Pin Crimp .......................................................................................... 2
793090-001 .............................. Anti-Backout ...................................................................................... 1
23 .................... 050004-042 .............................. Screw ...................................................................................................... 4
24 .................... 050008-011 .............................. Nut .......................................................................................................... 4
25 .................... 813033 ..................................... Clamp ...................................................................................................... 1
26 .................... 813056 ..................................... Cover ...................................................................................................... 1
27 .................... 050067-014 .............................. Screw ...................................................................................................... 2
28 .................... 050008-015 .............................. Nut .......................................................................................................... 2
813060 ..................................... Key Switch Heater Assembly (included 21 - 28) ..................................... 1

796074 ..................................... Beacon Connector .................................................................................. 1

See Section ITD
01 REV. 05/05
99
INSTRUMENTATION
8 7
10
12 11
MP-2140-038
M1.0-0000-000100
100
INSTRUMENTATION
1* .................... 813077 ..................................... Display Cover ......................................................................................... 1

2* .................... 807854 ..................................... Plate ........................................................................................................ 2
3* .................... 051068-003 .............................. Clip Spring .............................................................................................. 2
4* .................... 050004-021 .............................. Screw ...................................................................................................... 4
5 ..................... 050071-035 .............................. Screw ...................................................................................................... 1
6* .................... 812269 ..................................... Display, Overlay ..................................................................................... 1
7* .................... 806748 ..................................... Button Housing ....................................................................................... 1
8* .................... 813274 ..................................... PCB Switch ............................................................................................. 1
9* .................... 813076 ..................................... PCB LCD Display ................................................................................... 4
10* ................... 803469-010 .............................. Screw ...................................................................................................... 4
11* ................... 050009-002 .............................. Washer ................................................................................................... 6
12* ................... 050005-050 .............................. Screw ...................................................................................................... 6
* ..................... 813733 ..................................... Display Assembly (included 1 - 4, 6 - 12) ............................................... 1

See Section ITD
01 REV. 05/05
101
INSTRUMENTATION
8 7
10
12 11
MP-2140-038
M1.0-0000-000100
100A
INSTRUMENTATION
1* .................... 813077 ..................................... Display Cover ......................................................................................... 1

2* .................... 807854 ..................................... Plate ........................................................................................................ 2
3* .................... 051068-003 .............................. Clip Spring .............................................................................................. 2
4* .................... 050004-021 .............................. Screw ...................................................................................................... 4
5 ..................... 050071-035 .............................. Screw ...................................................................................................... 1
6* .................... 869560 ..................................... Display, Overlay ..................................................................................... 1
7* .................... 806748 ..................................... Button Housing ....................................................................................... 1
8* .................... 813274 ..................................... PCB Switch ............................................................................................. 1
9* .................... 816822-005 .............................. PCB LCD Display ................................................................................... 4
10* ................... 803469-010 .............................. Screw ...................................................................................................... 4
11* ................... 050009-002 .............................. Washer ................................................................................................... 6
12* ................... 050005-050 .............................. Screw ...................................................................................................... 6
* ..................... 816555-001 .............................. Display Assembly (included 1 - 4, 6 - 12) ............................................... 1

See Section ITD
02 REV. 11/05
101A
FLASHING BEACON
1
1
8
7
6 10 8
6
2 7
9 9
10
4 3
11
5
4
5
20
18
13
17 16
12
15
19
18
14
MP-2140-071
M1.0-0000-000102
102
FLASHING BEACON
1 ..................... 791036-003 .............................. Beacon (Xenon) ...................................................................................... 1

2 ..................... 814583 ..................................... Bracket ................................................................................................... 1
3 ..................... 795982 ..................................... Bracket ................................................................................................... 1
4 ..................... 050071-020 .............................. Screw ...................................................................................................... 3
5 ..................... 050071-012 .............................. Screw ...................................................................................................... 1
6 ..................... 796045 ..................................... Clip .......................................................................................................... 1
7 ..................... 050009-007 .............................. Washer ................................................................................................... 1
8 ..................... 050008-008 .............................. Nut .......................................................................................................... 1
9 ..................... 795977 ..................................... Clamp ...................................................................................................... AR
10 .................... 050005-085 .............................. Screw ...................................................................................................... AR
11 .................... 050008-018 .............................. Nut .......................................................................................................... 4
12 .................... 818220 ..................................... Bracket ................................................................................................... 1
13 .................... 811996-001 .............................. Relay Socket .......................................................................................... 2
14 .................... 811995-001 .............................. Relay ....................................................................................................... 2
15 .................... 050071-009 .............................. Screw ...................................................................................................... 2
16 .................... 050008-008 .............................. Nut .......................................................................................................... 2
17 .................... 050071-020 .............................. Screw ...................................................................................................... 1
18 .................... 050068-002 .............................. Nut .......................................................................................................... 3
19 .................... 050067-014 .............................. Screw ...................................................................................................... 2
20 .................... 062595-002 .............................. Switch ..................................................................................................... 1
813828 ..................................... Flashing Beacon Assembly (included 1, 2, 4 - 8) .................................... 1

813827 ..................................... Flashing Beacon Assembly (included 1, 3 - 8) ........................................ 1
Not illustrated
813524 ..................................... Beacon Loom .......................................................................................... 1

813774 ..................................... Switch Loom (only for Switch Activated) ................................................ 1
793288 ..................................... Clip .......................................................................................................... 1
050003-015 .............................. Screw ...................................................................................................... 1
050008-008 .............................. Nut .......................................................................................................... 1
796495 ..................................... Pipe (Drive in Racking) ........................................................................... 1
796497 ..................................... Cable Conduit (Drive in Racking) ........................................................... 1

See Section ITD
01 REV. 11/05
103
DRIVING LIGHT
30
2 27
31
29
28
1
9
3 4
5
7 9
8
23 8
5 5
5 18
6 25
6 7
19
5 8
20
5
21 7 14
9
16 13
25 11
15
24
17
7 5
16 14
15 26
5
22
17
26
12
10
MP-2140-084
M1.0-0000-000104
104
DRIVING LIGHT
1 ..................... 796034 ..................................... Driving Light ............................................................................................ 1

796059-006 .............................. Bulb (H4) ................................................................................................. 1
796059-007 .............................. Bulb (T4) ................................................................................................. 1
2 ..................... 796033 ..................................... Driving Light ............................................................................................ 1
796059-006 .............................. Bulb (H4) ................................................................................................. 1
796059-007 .............................. Bulb (T4) ................................................................................................. 1
3 ..................... 814437 ..................................... Bracket ................................................................................................... 1
4 ..................... 814436 ..................................... Bracket ................................................................................................... 1
5 ..................... 795977 ..................................... Clamp ...................................................................................................... AR
6 ..................... 050005-062 .............................. Screw ...................................................................................................... AR
7 ..................... 050008-014 .............................. Nut .......................................................................................................... AR
8 ..................... 050005-085 .............................. Screw ...................................................................................................... AR
9 ..................... 050008-018 .............................. Nut .......................................................................................................... AR
10 .................... 814291-001 .............................. Taillight ..................................................................................................... 1
796059-008 .............................. Bulb (P21W) ............................................................................................ 1
796059-010 .............................. Bulb (R10W) ........................................................................................... 1
11 .................... 814291-002 .............................. Taillight ..................................................................................................... 1
796059-008 .............................. Bulb (P21W) ............................................................................................ 1
796059-010 .............................. Bulb (R10W) ........................................................................................... 1
12 .................... 814404-001 .............................. Bracket ................................................................................................... 1
13 .................... 814404-002 .............................. Bracket ................................................................................................... 1
14 .................... 813484 ..................................... Plate ........................................................................................................ 2
15 .................... 793288 ..................................... Clip .......................................................................................................... 2
16 .................... 050003-014 .............................. Screw ...................................................................................................... 2
17 .................... 050008-008 .............................. Nut .......................................................................................................... 2
18 .................... 814288 ..................................... Spotlight .................................................................................................. 2
796059-011 .............................. Bulb ......................................................................................................... 2
19 .................... 050009-020 .............................. Washer ................................................................................................... 2
20 .................... 814302 ..................................... Bracket ................................................................................................... 2
21 .................... 050008-021 .............................. Nut .......................................................................................................... 2
22 .................... 796086 ..................................... Cable Conduit ......................................................................................... 1
23 .................... 814792 ..................................... Cable Conduit ......................................................................................... 1
24 .................... 814793 ..................................... Cable Conduit ......................................................................................... 1
25 .................... 796094 ..................................... Cable Conduit ......................................................................................... 1
26 .................... 050005-016 .............................. Screw ...................................................................................................... 8
27 .................... 811995-001 .............................. Relay (24V) ............................................................................................. 1
28 .................... 811995-002 .............................. Relay (12V) ............................................................................................. 1
29 .................... 050004-042 .............................. Screw ...................................................................................................... 2
30 .................... 050008-011 .............................. Nut .......................................................................................................... 2
31 .................... 062595-002 .............................. Switch ..................................................................................................... 1
814435 ..................................... Driving Light Assembly (included 1 - 4) .................................................. 1

814345-001 .............................. Taillight Assembly (included 10, 12, 15 - 17) ........................................... 1
814345-002 .............................. Taillight Assembly (included 11, 13, 15 - 17) ........................................... 1
814344 ..................................... Spotlight Assembly (included 18 - 21) ..................................................... 2
Not illustrated
813836 ..................................... Loom ....................................................................................................... 1

814336 ..................................... Loom - Adapter ....................................................................................... 1

See Section ITD
01 REV. 05/05
105
WORKING LIGHT
15 16
5 13
14
10
6
2
3
4
1
6
3
8
7
2
4
7
4
6
9 7
3
2 2
8 8
3
4 6
7
9
4
8 2
11 6
5
12
MP-2140-075
M1.0-0000-000106
106
WORKING LIGHT
1 ..................... 814495 ..................................... Bracket ................................................................................................... 1

2 ..................... 795977 ..................................... Clamp ...................................................................................................... AR
3 ..................... 050005-085 .............................. Screw ...................................................................................................... AR
4 ..................... 050008-018 .............................. Nut .......................................................................................................... AR
5 ..................... 814289 ..................................... Working Light (24V) ................................................................................ AR
796059-005 .............................. Bulb (24V) ............................................................................................... AR
6 ..................... 050009-020 .............................. Washer ................................................................................................... AR
7 ..................... 050008-021 .............................. Nut .......................................................................................................... AR
8 ..................... 814302 ..................................... Bracket ................................................................................................... AR
9 ..................... 814288 ..................................... Working Light (12V) ................................................................................ AR
796059-011 .............................. Bulb (12V) ............................................................................................... AR
10 .................... 796084 ..................................... Cable Conduit ......................................................................................... 1
11 .................... 796086 ..................................... Cable Conduit ......................................................................................... 1
12 .................... 796085 ..................................... Cable Conduit ......................................................................................... 1
13 .................... 811995-001 .............................. Relay (24V) ............................................................................................. 2
811995-002 .............................. Relay (12V) ............................................................................................. 1
806703-001 .............................. Fuse (15A) .............................................................................................. 1
14 .................... 050004-034 .............................. Screw ...................................................................................................... 2
15 .................... 050008-004 .............................. Nut .......................................................................................................... 2
16 .................... 062595-002 .............................. Switch ..................................................................................................... 1
814326 ..................................... Working Light Assembly (12V/included 1, 6, 7, 9) .................................. AR

Not illustrated
813526 ..................................... Working Light Loom (12V) ...................................................................... 1

813779 ..................................... Working Light Loom (24V) ...................................................................... 1
051051-009 .............................. Cable Tie ................................................................................................. 1
793801-001 .............................. Sleeve ..................................................................................................... 1
796495 ..................................... Pipe (Drive in Racking) ........................................................................... 1

See Section ITD
107
REVERSE ALARM
12 13
Steering Column
11
4
6 3
5
1
11
10
MP-2140-072
M1.0-0000-000108
108
REVERSE ALARM
1* .................... 813395 ..................................... Bracket ................................................................................................... 1

2 ..................... 050067-012 .............................. Screw ...................................................................................................... 2
3* .................... 050068-002 .............................. Nut .......................................................................................................... 4
4* .................... 126035 ..................................... Reverse Alarm ........................................................................................ 1
5* .................... 050009-012 .............................. Washer ................................................................................................... 2
6* .................... 050006-024 .............................. Screw ...................................................................................................... 2
7* .................... 796401 ..................................... Cable ....................................................................................................... 1
8 ..................... 811996-001 .............................. Relay Socket .......................................................................................... 2
9 ..................... 050071-009 .............................. Screw ...................................................................................................... 2
10 .................... 811995-001 .............................. Relay ....................................................................................................... 2
11 .................... 050008-008 .............................. Nut .......................................................................................................... 3
12 .................... 793288 ..................................... Clip .......................................................................................................... 1
13 .................... 050003-014 .............................. Screw ...................................................................................................... 1
* ..................... 813394 ..................................... Reverse Alarm Assembly (included 1, 3 - 7) .......................................... 1
Not illustrated
813527 ..................................... Reverse Alarm Loom .............................................................................. 1

See Section ITD
01 REV. 05/05
109
BRACKET PARTS
5 6
2
3
4
2
2
3
3 9 4
MP-2140-073
M1.0-0000-000110
110
BRACKET PARTS
1* .................... 813353 ..................................... Bracket ................................................................................................... 1

2* .................... 050078-007 .............................. Blind Rivet Nut ........................................................................................ 21
3* .................... 793288 ..................................... Clip .......................................................................................................... 8
4* .................... 050003-012 .............................. Screw ...................................................................................................... 8
5 ..................... 813445 ..................................... Loom ....................................................................................................... 1
6 ..................... 050071-009 .............................. Screw ...................................................................................................... 6
7 ..................... 050070-002 .............................. Screw ...................................................................................................... 3
8 ..................... 813710 ..................................... Sleeve ..................................................................................................... 2
9 ..................... 050068-004 .............................. Nut .......................................................................................................... 2
* ..................... 813453 ..................................... Bracket Assembly (included 1 - 4) .......................................................... 1

See Section ITD
111
HORN
MP-2140-041
M1.0-0000-000112
112
HORN
1 ..................... 129574 ..................................... Horn ........................................................................................................ 1

2 ..................... 050006-032 .............................. Screw ...................................................................................................... 1
3 ..................... 050008-024 .............................. Nut .......................................................................................................... 1

See Section ITD
113
COOLING SYSTEM
2
7
3
10
9
5
7 4
13
6
13
12
1
8
9
11
MP-2140-037

01 REV. 05/05
M1.0-0000-000114
114
COOLING SYSTEM
1 ..................... 807620 ..................................... Bracket ................................................................................................... 1

2 ..................... 793288 ..................................... Clip .......................................................................................................... 2
3 ..................... 050003-013 .............................. Screw ...................................................................................................... 2
4 ..................... 050008-008 .............................. Nut .......................................................................................................... 2
5 ..................... 806895-002 .............................. Fan Assembly ......................................................................................... 2
807654-001 .............................. 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 .......................................................................................................... 2
9 ..................... 050009-018 .............................. Washer ................................................................................................... 4
10 .................... 050008-024 .............................. Nut .......................................................................................................... 2
11 .................... 807849 ..................................... Bracket ................................................................................................... 1
12 .................... 050006-022 .............................. Screw ...................................................................................................... 2
13 .................... 050078-006 .............................. Blind Rivet Nut ........................................................................................ 8

See Section ITD
02 REV. 11/05
115
Printed in Germany
M1.0-0000-000116
116
SECTION 5
Printed in Germany
117
BRAKE CIRCUIT
1
4
5
22
1
2
17
4
6
5
10 10
9 7
A
13 9
8
20
14 12
19
11
18
19
21
16 17
MP-2140-048
M1.0-0000-000118
118
BRAKE CIRCUIT
1 ........................................................................ Load Wheel Brake (see Section 5.6) ....................................................... 2

2 ..................... 810580-001 .............................. Brake Line (1.4t/1285mm Leg Width) ...................................................... 1
810580-002 .............................. Brake Line (1.6-2.0t/1285mm Leg Width) ................................................ 1
810580-003 .............................. Brake Line (1.4t/1425mm Leg Width) ...................................................... 1
3 ..................... 810581-001 .............................. Brake Line (1.4t/1285mm Leg Width) ...................................................... 1
4 ..................... 790555 ..................................... Clip .......................................................................................................... 2
5 ..................... 050006-008 .............................. Screw ...................................................................................................... 2
6 ..................... 790548 ..................................... Connector ............................................................................................... AR
7 ..................... 807553-001 .............................. Brake Line (1285/1425mm Leg Width) .................................................... 1
807553-002 .............................. Brake Line (1575mm Leg Width) ............................................................. 1
8 ..................... 807585 ..................................... Clip .......................................................................................................... 1
9 ..................... 050008-030 .............................. Nut .......................................................................................................... 3
10 .................... 050070-002 .............................. Screw ...................................................................................................... 3
11 .................... 790550 ..................................... Connector ............................................................................................... 1
12 .................... 050007-009 .............................. Screw ...................................................................................................... 1
13 .................... 807499 ..................................... Bracket ................................................................................................... 1
14 .................... 050006-036 .............................. Screw ...................................................................................................... 1
15 .................... 813003 ..................................... Brake Line ............................................................................................... 1
16 ....................................................................... Brake Master Cylinder (see Section 5.5) ................................................ 1
17 .................... 812163 ..................................... Brake Line ............................................................................................... 1
18 .................... 054193-001 .............................. Banjo Fitting ............................................................................................ 1
19 .................... 050011-015 .............................. Washer ................................................................................................... 2
20 .................... 054192-001 .............................. Screw ...................................................................................................... 1
21 ....................................................................... Drive Motor Brake (see Section 5.6) ....................................................... 1
22 .................... 807703 ..................................... Brake Line (only for 1575mm Leg Width) ................................................ 1

See Section ITD
119
FOOTBRAKE
19
17
16
18
2
10
11
12
14 15
13
9
7 6
8
Drive Frame
MP-2140-034
M1.0-0000-000120
120
FOOTBRAKE
0 ..................... 813245-001 .............................. Footbrake Assembly ............................................................................... 1

1* .......................... 810399 ..................................... Brake Mounting Bracket .................................................................... 1
2 ........................... 050067-047 .............................. Screw ................................................................................................ 2
3 ........................... 812345 ..................................... Spacer Plate ...................................................................................... 1
4* .......................... 810401 ..................................... Brake Pedal ....................................................................................... 1
5* .......................... 102330 ..................................... Footpedal Rubber .............................................................................. 1
6* .......................... 055084-009 .............................. Bush .................................................................................................. 2
7* .......................... 050009-053 .............................. Washer .............................................................................................. 1
8* .......................... 050012-036 .............................. Circlip ................................................................................................ 1
9* .......................... 050007-013 .............................. Screw ................................................................................................ 1
10* ......................... 807085 ..................................... Spring ................................................................................................ 1
11* ......................... 050008-015 .............................. Nut ..................................................................................................... 2
12* ......................... 810404 ..................................... Rod Fork ........................................................................................... 1
13* ......................... 790195 ..................................... Pin Clevis .......................................................................................... 1
14* ......................... 050001-013 .............................. Pin ..................................................................................................... 1
15* ......................... 050009-018 .............................. Washer .............................................................................................. 1
16* ......................... 810525 ..................................... Brake Master Cylinder Assembly ...................................................... 1
810589 ...................................... Brake Master Cylinder & Reservoir ............................................. 1
810591 ...................................... Reservoir Cap & Switch (BFS) .................................................... 1
17* ......................... 812293 ..................................... Brake Switch ..................................................................................... 1
18* ......................... 050006-035 .............................. Screw ................................................................................................ 1
19* ......................... 050006-043 .............................. Screw ................................................................................................ 1
* ........................... 813244-001 .............................. Footbrake Assembly (inkluded 1,4-19) .............................................. 1
810700 ..................................... Repair Kit (Brake Master Cylinder) ................................................... 1

See Section ITD
121
DRIVE MOTOR BRAKE
MP-2140-076
M1.0-0000-000122
122
DRIVE MOTOR BRAKE
0 ..................... 811000 ..................................... Drive Motor Brake Assembly .................................................................. 1

1 ........................... 050005-97 ................................ Screw ................................................................................................ 3
2 ........................... 813259 ..................................... Drive Motor Brake ............................................................................. 1
3 ........................... 792881-002 .............................. Socket Housing ................................................................................. 1
792883 ..................................... Socket Crimp .................................................................................... 2
793091-002 .............................. Anti Backout ...................................................................................... 1
4 ........................... 813041 ..................................... Hub .................................................................................................... 1
5 ........................... 813040 ..................................... Brake Rotor Disc .............................................................................. 1
6 ........................... 813042 ..................................... Brake Disk ........................................................................................ 1

See Section ITD
123
LOAD WHEEL BRAKE
5 2
MP-2140-033
M1.0-0000-000124
124
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

See Section ITD
125
Printed in Germany
M1.0-0000-000126
126
SECTION 6
Printed in Germany
127
STEER MOTOR
MP-2140-078
M1.0-0000-000128
128
STEER MOTOR
0 ..................... 812992 ..................................... Steer Motor Assembly ............................................................................ 1

1 ........................... 812995 ..................................... Steer Motor ........................................................................................ 1
2 ........................... 813039 ..................................... Coupling ............................................................................................ 1
3 ........................... 812994 ..................................... Speed Reducer ................................................................................. 1
4 ........................... 050005-099 .............................. Screw ................................................................................................ 8

See Section ITD
129
STEER MOTOR
MP-2140-078
M1.0-0000-000128
128A
STEER MOTOR
0 ..................... 818448 ..................................... Steer Motor Assembly ............................................................................ 1

1 ........................... 816263 ..................................... Steer Motor ........................................................................................ 1
2 ........................... 813039 ..................................... Coupling ............................................................................................ 1
3 ........................... 818449 ..................................... Speed Reducer ................................................................................. 1
4 ........................... 050005-099 .............................. Screw ................................................................................................ 8

See Section ITD
01 REV. 11/05
129A
STEERING COLUMN
17
18
19
20
15
3
4 14
13
2 12
31
30
32
1
11
10 2
9 29
16 28
8
7
22
6 21
24
28
23
25
26
27
MP-2140-031
M1.0-0000-000130
130
STEERING COLUMN
1* .................... 813692 ..................................... Steering Column ..................................................................................... 1

2* .................... 050078-002 .............................. Blind Rivet Nut ........................................................................................ 5
3* .................... 050003-013 .............................. Screw ...................................................................................................... 1
4* .................... 793288 ..................................... Clip .......................................................................................................... 1
5* .................... 050008-008 .............................. Nut .......................................................................................................... 1
6* .................... 050003-059 .............................. Screw ...................................................................................................... 2
7* .................... 050010-023 .............................. Washer ................................................................................................... 2
8* .................... 794301 ..................................... Lock Plate ............................................................................................... 1
9* .................... 807408 ..................................... Spacer Block .......................................................................................... 1
10* ................... 807410 ..................................... Spacer Plate ........................................................................................... 2
11* ................... 050008-024 .............................. Nut .......................................................................................................... 2
12* ................... 807750 ..................................... Spring Mount ........................................................................................... 1
13 .................... 050009-013 .............................. Washer ................................................................................................... 1
14 .................... 050006-022 .............................. Screw ...................................................................................................... 1
15 .................... 790995 ..................................... Spring ..................................................................................................... 2
16* ................... 050008-049 .............................. Nut .......................................................................................................... 1
17* ................... 050012-014 .............................. Circlip ...................................................................................................... 1
18* ................... 050012-009 .............................. Circlip ...................................................................................................... 1
19* ................... 055002-014 .............................. Bearing Ball ............................................................................................. 1
20* ................... 816549 ..................................... Bearing Stud ........................................................................................... 1
21* ................... 816548 ..................................... Brake Disc .............................................................................................. 1
22* ................... 050003-025 .............................. Screw ...................................................................................................... 3
23* ................... 050003-014 .............................. Screw ...................................................................................................... 4
24* ................... 811495 ..................................... Plate ........................................................................................................ 1
25* ................... 050006-023 .............................. Screw ...................................................................................................... 4
26* ................... 811229 ..................................... Motor ....................................................................................................... 1
27* ................... 050008-010 .............................. Nut .......................................................................................................... 4
28 .................... 051058-018 .............................. Bushing ................................................................................................... 2
803915-001 .............................. Shim (0,5 mm) ......................................................................................... AR
803915-002 .............................. Shim (1,0 mm) ......................................................................................... AR
803915-003 .............................. Shim (1,5 mm) ......................................................................................... AR
29 .................... 806961 ..................................... Shaft ........................................................................................................ 1
30 .................... 792973 ..................................... Pin ........................................................................................................... 1
31 .................... 050006-027 .............................. Screw ...................................................................................................... 1
32* ................... 812120 ..................................... Stud ......................................................................................................... 2
* ..................... 813700 ..................................... Steering Column Assembly (included 1-12, 16-27 & 32) ......................... 1

See Section ITD
01 REV. 05/05
131
Printed in Germany
M1.0-0000-000132
132
SECTION 7
Printed in Germany
133
TT MAST
1.4t/1.6t
9
25 5
10
4
11
26 18 13
12
17
14
19
8
16
6
23
24
20 7
4
9
5
7
21 7
2
11
22 10 13 31
30
12
14
29
28
15 1 27
MP-2140-055
M1.0-0000-000134
134
TT MAST
1 ..................... 806271-***-** ........................... Outer Mast (see next page) .................................................................... 1

813010-***-** ........................... Outer Mast (see next page) .................................................................... 1
2 ..................... 806272-*** ............................... 1st Stage Mast (see next page) .............................................................. 1
813011-*** ............................... 1st Stage Mast (see next page) .............................................................. 1
3 ..................... 806273-*** ............................... 2nd Stage Mast (see next page) ............................................................. 1
4 ..................... 060030-057 .............................. Shim ........................................................................................................ 8
060030-085 .............................. Shim ........................................................................................................ 8
795534 ..................................... Shim ........................................................................................................ 8
5 ..................... 807334-002 .............................. Roller ∅ 101,47mm ................................................................................. AR
807334-003 .............................. Roller ∅ 102,14mm ................................................................................. AR
807334-004 .............................. Roller ∅ 102,45mm ................................................................................. AR
6 ..................... 807327-*** ............................... Cover (see next page) ............................................................................ 1
812967-*** ............................... Cover (see next page) ............................................................................ 1
7 ..................... 050067-022 .............................. Screw ...................................................................................................... AR
9 ..................... 050006-069 .............................. Screw ...................................................................................................... 8
10 .................... 792427 ..................................... Block Stop .............................................................................................. 4
11 .................... 794661 ..................................... Shim ........................................................................................................ 4
12 .................... 808861 ..................................... Bracket ................................................................................................... 4
13 .................... 092747-001 .............................. Poly Stop ................................................................................................. 4
14 .................... 050005-062 .............................. Screw ...................................................................................................... 4
15 ....................................................................... Lift Cylinder (see Section 8.1) ................................................................. 2
16 .................... 806997 ..................................... Pin ........................................................................................................... 2
050001-021 .............................. Pin Split ................................................................................................... 2
17 .................... 050067-048 .............................. Screw ...................................................................................................... 2
050008-038 .............................. Nut .......................................................................................................... 2
18 .................... 050007-014 .............................. Screw ...................................................................................................... 2
19 .................... 050008-015 .............................. Nut .......................................................................................................... 2
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 .................... 050067-056 .............................. Screw ...................................................................................................... 2
28 .................... 807407 ..................................... Washer ................................................................................................... 2
29 .................... 807323 ..................................... Shim ........................................................................................................ 8
30 .................... 050068-007 .............................. Nut .......................................................................................................... 2
31 .................... 812968 ..................................... Cover (RH/only for Collapsed Height 3692,3892,3952mm) ................... 1
812969 ..................................... Cover (LH/only for Collapsed Height 3692,3892,3952mm) .................... 1
Not shown
790350 ..................................... Magnet (FLS/LCS) .................................................................................. AR

050003-019 .............................. Screw (FLS/LCS) ................................................................................... AR
807716 ..................................... Bracket (FLS/LCS) ................................................................................. AR
050005-058 .............................. Screw (FLS/LCS) ................................................................................... AR

See Section ITD
135
TT MAST
1.4t/1.6t
Position 1 Position 2 Position 3 Position 6 Position 8 Collapsed Height
806271-001-01 806272-001 806273-001 807327-001 806999-001 2022mm
806271-001-02 806272-002 806273-002 807327-002 806999-002 2172mm
806271-001-03 806272-003 806273-003 807327-003 806999-003 2322mm
806271-001-04 806272-004 806273-004 807327-004 806999-004 2472mm
806271-001-05 806272-005 806273-005 807327-005 806999-005 2572mm
806271-001-06 806272-006 806273-006 807327-006 806999-006 2772mm
806271-001-07 806272-007 806273-007 807327-007 806999-007 2922mm
806271-001-08 806272-008 806273-008 807327-008 806999-008 3042mm
806271-001-09 806272-009 806273-009 807327-009 806999-009 3192mm
813010-001-10 813011-010 806273-010 807327-010 806999-010 3347mm
813010-001-11 813011-011 806273-011 807327-011 806999-011 3492mm
813010-001-12 813011-012 806273-012 812967-012 812966-012 3692mm
813010-001-13 813011-013 806273-013 812967-013 812966-013 3842mm
813010-001-14 813011-014 806273-014 812967-014 812966-014 3952mm
Tab010gb
M1.0-0000-000136
136
Printed in Germany
137
TT MAST
1.4t/1.6t
9
25 5
10
4
11
26 18 13
12
17
14
19
8
16
6
23
24
20 7
4
9
5
7
21 7 31
2
11
22 Reach
10 13
30 Carriage
12
14
29
28
15 1 27
MP-2140-109

01 REV. 05/05
M1.0-0000-000134
134A
TT MAST

4 ..................... 060030-057 .............................. Shim ........................................................................................................ 8
060030-085 .............................. Shim ........................................................................................................ 8
795534 ..................................... Shim ........................................................................................................ 8
5 ..................... 813806-002 .............................. Roller ∅ 101,30 mm ................................................................................ AR
813806-003 .............................. Roller ∅ 101,72 mm ................................................................................ AR
813806-004 .............................. Roller ∅ 102,14 mm ................................................................................ AR
7 ..................... 050067-022 .............................. Screw ...................................................................................................... AR
9 ..................... 050006-069 .............................. Screw ...................................................................................................... 8
10 .................... 792427 ..................................... Block Stop .............................................................................................. 4
11 .................... 794661 ..................................... Shim ........................................................................................................ 4
12 .................... 808861 ..................................... Bracket ................................................................................................... 4
13 .................... 092747-001 .............................. Poly Stop ................................................................................................. 4
14 .................... 050005-062 .............................. Screw ...................................................................................................... 4
16 .................... 806997 ..................................... Pin ........................................................................................................... 2
050001-021 .............................. Pin Split ................................................................................................... 2
17 .................... 050067-048 .............................. Screw ...................................................................................................... 2
050008-038 .............................. Nut .......................................................................................................... 2
18 .................... 050007-014 .............................. Screw ...................................................................................................... 2
19 .................... 050008-015 .............................. Nut .......................................................................................................... 2
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 .................... 050067-059 .............................. Screw (Load Wheel 285 mm) .................................................................. 2
050067-056 .............................. Screw (Load Wheel 330 mm) .................................................................. 2
28 .................... 807407 ..................................... Washer ................................................................................................... 2
29 .................... 807323 ..................................... Shim ........................................................................................................ 8
30 .................... 050068-007 .............................. Nut .......................................................................................................... 2
31 .................... 812968 ..................................... Cover (RH/only for Collapsed Height 3692,3892,3952mm) ................... 1
812969 ..................................... Cover (LH/only for Collapsed Height 3692,3892,3952mm) .................... 1
Not shown
790350 ..................................... Magnet (FLS/LCS) .................................................................................. AR

050003-019 .............................. Screw (FLS/LCS) ................................................................................... AR
050009-008 .............................. Washer (FLS/LCS) ................................................................................. AR
050008-001 .............................. Nut (FLS/LCS) ........................................................................................ AR
050005-058 .............................. Screw (FLS/LCS) ................................................................................... AR

See Section ITD
01 REV. 05/05
135A
TT MAST
1.4t/1.6t
815491-001-01 815493-001 806103-001 807327-001 806999-001 2022mm
815491-001-02 815493-002 806103-002 807327-002 806999-002 2172mm
815491-001-03 815493-003 806103-003 807327-003 806999-003 2322mm
815491-001-04 815493-004 806103-004 807327-004 806999-004 2472mm
815491-001-05 815493-005 806103-005 807327-005 806999-005 2572mm
815491-001-06 815493-006 806103-006 807327-006 806999-006 2772mm
815491-001-07 815493-007 806103-007 807327-007 806999-007 2922mm
815491-001-08 815493-008 806103-008 807327-008 806999-008 3042mm
815491-001-09 815493-009 806103-009 807327-009 806999-009 3192mm
815492-001-10 815494-010 806103-010 807327-010 806999-010 3347mm
815492-001-11 815494-011 806103-011 807327-011 806999-011 3492mm
815492-001-12 815494-012 806103-012 812967-012 812966-012 3692mm
815492-001-13 815494-013 806103-013 812967-013 812966-013 3842mm
815492-001-14 815494-014 806103-014 812967-014 812966-014 3952mm
Tab021gb

01 REV. 05/05
M1.0-0000-000136
136A
Printed in Germany
137
TT MAST
2.0t
9
25 5
10
4
11
26 18 13
12
17
14
19
8
16
6
23
24
20 7
4
9
5
21 7
2
11
22 10 13
30
12
14
29
28
15 1 27
MP-2140-056
M1.0-0000-000138
138
TT MAST

4 ..................... 060030-057 .............................. Shim ........................................................................................................ 8
060030-085 .............................. Shim ........................................................................................................ 8
795534 ..................................... Shim ........................................................................................................ 8
5 ..................... 807334-002 .............................. Roller ∅ 101,47mm ................................................................................. AR
807334-003 .............................. Roller ∅ 102,14mm ................................................................................. AR
807334-004 .............................. Roller ∅ 102,45mm ................................................................................. AR
812973-***-01 .......................... Cover (see next page) ............................................................................ 1
7 ..................... 050067-022 .............................. Screw ...................................................................................................... AR
9 ..................... 050006-069 .............................. Screw ...................................................................................................... 8
10 .................... 792427 ..................................... Block Stop .............................................................................................. 4
11 .................... 794661 ..................................... Shim ........................................................................................................ 4
12 .................... 808861 ..................................... Bracket ................................................................................................... 4
13 .................... 092747-001 .............................. Poly Stop ................................................................................................. 4
14 .................... 050005-062 .............................. Screw ...................................................................................................... 4
16 .................... 806997 ..................................... Pin ........................................................................................................... 2
050001-021 .............................. Pin Split ................................................................................................... 2
17 .................... 050067-048 .............................. Screw ...................................................................................................... 2
050008-038 .............................. Nut .......................................................................................................... 2
18 .................... 050007-014 .............................. Screw ...................................................................................................... 2
19 .................... 050008-015 .............................. Nut .......................................................................................................... 2
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 .................... 050067-056 .............................. Screw ...................................................................................................... 2
28 .................... 807407 ..................................... Washer ................................................................................................... 2
29 .................... 807323 ..................................... Shim ........................................................................................................ 8
30 .................... 050068-007 .............................. Nut .......................................................................................................... 2
Not shown
790350 ..................................... Magnet (FLS/LCS) .................................................................................. AR

050003-019 .............................. Screw (FLS/LCS) ................................................................................... AR
050005-058 .............................. Screw (FLS/LCS) ................................................................................... AR

See Section ITD
139
TT MAST
2.0t
806271-002-01 806272-001 806273-001 807327-001 806999-001 2022mm
806271-002-02 806272-002 806273-002 807327-002 806999-002 2172mm
806271-002-04 806272-004 806273-004 807327-004 806999-004 2472mm
806271-002-06 806272-006 806273-006 807327-006 806999-006 2772mm
806271-002-07 806272-007 806273-007 807327-007 806999-007 2922mm
806271-002-08 806272-008 806273-008 807327-008 806999-008 3042mm
813010-002-10 813011-010 806273-010 812973-010-01 812973-010-02 3347mm
813010-002-12 813011-012 806273-012 812973-012-01 812973-012-02 3692mm
813010-002-13 813011-013 806273-013 812973-013-01 812973-013-02 3842mm
813010-002-14 813011-014 806273-014 812973-014-01 812973-014-02 3952mm
813010-002-15 813011-015 806273-015 812973-015-01 812973-015-02 4252mm
813010-002-16 813011-016 806273-016 812973-016-01 812973-016-02 4452mm
Tab011gb
M1.0-0000-000140
140
Printed in Germany
141
TT MAST
2.0t
9
25 5
10
4
11
26 18 13
12
17
14
19
8
16
6
23
24
20 7
4
9
5
21 7
2
11 Reach
22 10 13 Carriage
30
12
14
29
28
15 1 27
MP-2140-110

01 REV. 05/05
M1.0-0000-000138
138A
TT MAST

4 ..................... 060030-057 .............................. Shim ........................................................................................................ 8
060030-085 .............................. Shim ........................................................................................................ 8
795534 ..................................... Shim ........................................................................................................ 8
5 ..................... 813806-002 .............................. Roller ∅ 101,30 mm ................................................................................ AR
813806-003 .............................. Roller ∅ 101,72 mm ................................................................................ AR
813806-004 .............................. Roller ∅ 102,14 mm ................................................................................ AR
7 ..................... 050067-022 .............................. Screw ...................................................................................................... AR
9 ..................... 050006-069 .............................. Screw ...................................................................................................... 8
10 .................... 792427 ..................................... Block Stop .............................................................................................. 4
11 .................... 794661 ..................................... Shim ........................................................................................................ 4
12 .................... 808861 ..................................... Bracket ................................................................................................... 4
13 .................... 092747-001 .............................. Poly Stop ................................................................................................. 4
14 .................... 050005-062 .............................. Screw ...................................................................................................... 4
16 .................... 806997 ..................................... Pin ........................................................................................................... 2
050001-021 .............................. Pin Split ................................................................................................... 2
17 .................... 050067-048 .............................. Screw ...................................................................................................... 2
050008-038 .............................. Nut .......................................................................................................... 2
18 .................... 050007-014 .............................. Screw ...................................................................................................... 2
19 .................... 050008-015 .............................. Nut .......................................................................................................... 2
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 .................... 050067-059 .............................. Screw (Load Wheel 285 mm) .................................................................. 2
050067-056 .............................. Screw (Load Wheel 330 mm) .................................................................. 2
28 .................... 807407 ..................................... Washer ................................................................................................... 2
29 .................... 807323 ..................................... Shim ........................................................................................................ 8
30 .................... 050068-007 .............................. Nut .......................................................................................................... 2
Not shown
790350 ..................................... Magnet (FLS/LCS) .................................................................................. AR

050003-019 .............................. Screw (FLS/LCS) ................................................................................... AR
050009-008 .............................. Washer (FLS/LCS) ................................................................................. AR
050008-001 .............................. Nut (FLS/LCS) ........................................................................................ AR
050005-058 .............................. Screw (FLS/LCS) ................................................................................... AR

See Section ITD
01 REV. 05/05
139A
TT MAST
2.0t
815491-002-01 815493-001 806103-001 807327-001 806999-001 2022mm
815491-002-02 815493-002 806103-002 807327-002 806999-002 2172mm
815491-002-04 815493-004 806103-004 807327-004 806999-004 2472mm
815491-002-06 815493-006 806103-006 807327-006 806999-006 2772mm
815491-002-07 815493-007 806103-007 807327-007 806999-007 2922mm
815491-002-08 815493-008 806103-008 807327-008 806999-008 3042mm
815492-002-10 815494-010 806103-010 812973-010-01 812973-010-02 3347mm
815492-002-12 815494-012 806103-012 812973-012-01 812973-012-02 3692mm
815492-002-13 815494-013 806103-013 812973-013-01 812973-013-02 3842mm
815492-002-14 815494-014 806103-014 812973-014-01 812973-014-02 3952mm
815492-002-15 815494-015 806103-015 812973-015-01 812973-015-02 4252mm
815492-002-16 815494-016 806103-016 812973-016-01 812973-016-02 4452mm
Tab022gb

01 REV. 05/05
M1.0-0000-000140
140A
Printed in Germany
141
TT MAST
1.4t/1.6t & 2.0t
23
14 13 11 31
15 10
9 30 8
24
25 26 15
21
10 10
12
14
18
30
7
16
28 17 4
6
29
20
5
24
22 23
27
21 3
28 2
1
29 6
20 7
19
5
Fork Carriage
3
2
1
MP-2140-057
M1.0-0000-000142
142
TT MAST
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

See Section ITD
143
TT MAST
1.4t/1.6t & 2.0t
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
793069-012 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
M1.0-0000-000144
144
Printed in Germany
145
TILT AND SIDESHIFT
M1498
M1.0-0000-000146
146
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 .................... 813806-002 .............................. Roller ∅ 101,30mm ................................................................................. AR
813806-003 .............................. Roller ∅ 101,72mm ................................................................................. AR
813806-004 .............................. Roller ∅ 102,14mm ................................................................................. 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

See Section ITD
147
TILT AND SIDESHIFT
M1500
M1.0-0000-000148
148
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 .................... 813806-002 .............................. Roller ∅ 101,30mm ................................................................................. AR
813806-003 .............................. Roller ∅ 101,72mm ................................................................................. AR
813806-004 .............................. Roller ∅ 102,14mm ................................................................................. 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
17 .......................... 808532 ..................................... Spiral Fixing Pin ................................................................................ 2
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
21 .......................... 808536 ..................................... Greasing Nipples .............................................................................. 3
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
* ........................... 808541 ..................................... Seal Kit (inclusive 3, 5) ...................................................................... 1

See Section ITD
149
TILT AND SIDESHIFT
30
29
28
30
26
25
D
23
24
21
27
C
A 22
15
B
4
18 15
Cylinder 18
15 3
1
18 2
Cylinder
6
20
7
19
13 10
14
17
12 11
A
16
9
C
8
18
15
D
MP-2140-092
M1.0-0000-000150
150
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 ......................................................................................................... 1
9 ..................... 054176-001 .............................. Adaptor ................................................................................................... 1
10 .................... 064061-001 .............................. Elbow ...................................................................................................... 1
11 .................... 808042 ..................................... Pipe ......................................................................................................... 1
12 .................... 054188-001 .............................. Elbow ...................................................................................................... 1
13 .................... 807479 ..................................... Bracket ................................................................................................... 1
051051-004 .............................. Binder ..................................................................................................... 4
14 .................... 050006-025 .............................. Screw ...................................................................................................... 2
15 .................... 064061-004 .............................. Elbow ...................................................................................................... 4
16 .................... 808044 ..................................... Pipe ......................................................................................................... 1
17 .................... 808045 ..................................... Pipe ......................................................................................................... 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 813419Pressure Sensor) .. 1
813419 ..................................... Pressure Sensor (LS) ....................................................................... 1
051051-009 .............................. Cable Tie ................................................................................................. 2
793288 ..................................... Clip .......................................................................................................... 1
050003-012 .............................. Screw ...................................................................................................... 1
27 .................... 792991 ..................................... Microswitch (FKS) .................................................................................. 1
803310 ..................................... Actuator .................................................................................................. 1
807481 ..................................... Bracket ................................................................................................... 1
050005-011 .............................. Screw ...................................................................................................... 2
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 Bracket (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
792882 ..................................... Pin Crimp ................................................................................................ 2
29 .................... 055058-001 .............................. Puffer ...................................................................................................... 2
050008-001 .............................. Nut .......................................................................................................... 4
30 .................... 807681 ..................................... Bracket ................................................................................................... 1
050009-008 .............................. Washer ................................................................................................... 2
050005-058 .............................. Screw ...................................................................................................... 2
807953 ..................................... Valve Block (inclusive 1-5) ..................................................................... 1
808080 ..................................... Valve Assembly (inclusive 1-7, 10, 14, 15, 18) ...................................... 1

See Section ITD
02 REV. 11/05
151
TILT AND SIDESHIFT
5th Function Valve
22
22 21
20
21
20 19
9 14
19 17
12
B
13
1
A
18
15
16 2
11
10
D 3
C
7
D
B
A
5
6
5
MP-2140-065
C
M1.0-0000-000152
152
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 (included 5,6,7) ............................................................. 1

See Section ITD
153
TILT AND SIDESHIFT
6th Function Valve
3
2
5
7
3 8
1
4
5
2
7
9 12
10
12
11
13
13
14
16
15
17
MP-2140-083
M1.0-0000-000154
154
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 .................... 064010-002 .............................. T-Adaptor ................................................................................................ 1

See Section ITD
155
LIFT BUFFER
M1631
M1.0-0000-000156
156
LIFT BUFFER
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
806173 ..................................... Stopper (included 1, 3-7) ......................................................................... 1

806199 ..................................... Stopper (included 2-7) ............................................................................ 1

See Section ITD
01 REV. 05/05
157
FORK
MP-2140-051
M1.0-0000-000158
158
FORK
1 ........................................................................ Fork (see table) ....................................................................................... 2

2 ........................................................................ Handle Assembly (included 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
803991-003-01 803991-009-01 803991-012-01 803991-007-01 803991-011-01 803991-010-01
Tab004gb
2.0t
Fork Width 45mm
1000mm 1067mm 1150mm 1220mm 1300mm 1500mm 1600mm
807596-001 807596-002 807596-003 807596-004 807596-007 807596-005 807596-006
Tab023gb

See Section ITD
01 REV. 05/05
159
LOAD BACKREST
MP-2140-050
M1.0-0000-000160
160
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
Tab002gb
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
Tab003gb

See Section ITD
161
YOKE
1
2
3 2
3
4
15
6
7
14
10
1 8
11
13 12
8
MP-2140-054
M1.0-0000-000162
162
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

See Section ITD
163
Printed in Germany
M1.0-0000-000164
164
SECTION 8
Printed in Germany
165
LIFT CYLINDER
1.4t/1.6t
10
11
8
12
5 1
MP-2140-052
M1.0-0000-000166
166
LIFT CYLINDER
0 ..................... 806200-*** ............................... Lift Cylinder ø40 (1.4/1.6t) ....................................................................... 2

1 ........................... 806204-*** ................................ Cylinder Tube ..................................................................................... 2
2 ........................... 812305 ..................................... Guide Ring ........................................................................................ 2
3 ........................... 811833-001 .............................. Piston Button ..................................................................................... 2
4 ........................... 804722-*** ................................ Piston Rod ......................................................................................... 2
5 ........................... 812304 ..................................... Guide Ring ........................................................................................ 2
6 ........................... 804774 ..................................... O-Ring ............................................................................................... 2
7 ........................... 807748 ..................................... Backup Ring ...................................................................................... 2
8 ........................... 811832 ..................................... Cylinder Cap ..................................................................................... 2
9 ........................... 804761 ..................................... Seal ................................................................................................... 2
10 .......................... 804755 ..................................... Wiper ................................................................................................. 2
11 .......................... 054173 ..................................... Seal ................................................................................................... 2
12 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 2
813783 ..................................... Seal Kits ............................................................................................ 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
Tab006gb

See Section ITD
167
LIFT CYLINDER
1.4t/1.6t
10
11
8
12
5 1
MP-2140-052
M1.0-0000-000166
166A
LIFT CYLINDER
0 ..................... 815496-*** ............................... Lift Cylinder LH ø40 (1.4/1.6t) ................................................................. 1

815495-*** ............................... Lift Cylinder RH ø40 (1.4/1.6t) ................................................................ 1
1 ........................... 815500-*** ................................ Cylinder Tube LH ............................................................................... 1
815499-*** ................................ Cylinder Tube RH .............................................................................. 1
2 ........................... 812305 ..................................... Guide Ring ........................................................................................ 2
3 ........................... 811833-001 .............................. Piston Button ..................................................................................... 2
4 ........................... 804722-*** ................................ Piston Rod ......................................................................................... 2
5 ........................... 812304 ..................................... Guide Ring ........................................................................................ 2
6 ........................... 804774 ..................................... O-Ring ............................................................................................... 2
7 ........................... 807748 ..................................... Backup Ring ...................................................................................... 2
8 ........................... 811832 ..................................... Cylinder Cap ..................................................................................... 2
9 ........................... 804761 ..................................... Seal ................................................................................................... 2
10 .......................... 804755 ..................................... Wiper ................................................................................................. 2
11 .......................... 054173 ..................................... Seal ................................................................................................... 2
12 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 2
813783 ..................................... Seal Kits ............................................................................................ 1
LH / RH LH / RH --- ---
815496-001 / 815495-001 815500-001 / 815499-001 804722-011 2022mm
815496-002 / 815495-002 815500-002 / 815499-002 804722-012 2172mm
815496-003 / 815495-003 815500-003 / 815499-003 804722-013 2322mm
815496-004 / 815495-004 815500-004 / 815499-004 804722-014 2472mm
815496-005 / 815495-005 815500-005 / 815499-005 804722-015 2572mm
815496-006 / 815495-006 815500-006 / 815499-006 804722-016 2772mm
815496-007 / 815495-007 815500-007 / 815499-007 804722-017 2922mm
815496-008 / 815495-008 815500-008 / 815499-008 804722-018 3042mm
815496-009 / 815495-009 815500-009 / 815499-009 804722-019 3192mm
815496-010 / 815495-010 815500-010 / 815499-010 804722-020 3347mm
815496-011 / 815495-011 815500-011 / 815499-011 804722-021 3492mm
815496-012 / 815495-012 815500-012 / 815499-012 804722-022 3692mm
815496-013 / 815495-013 815500-013 / 815499-013 804722-023 3842mm
815496-014 / 815495-014 815500-014 / 815499-014 804722-024 3952mm
Tab024gb

See Section ITD
01 REV. 05/05
167A
LIFT CYLINDER
2.0t
10
11
8
12
5 1
MP-2140-052
M1.0-0000-000168
168
LIFT CYLINDER
0 ..................... 806201-*** ............................... Lift Cylinder ø45 (2.0t) ............................................................................ 2

1 ........................... 806205-*** ................................ Cylinder Tube ..................................................................................... 2
2 ........................... 812309 ..................................... Guide Ring ........................................................................................ 2
3 ........................... 811833-002 .............................. Piston Button ..................................................................................... 2
4 ........................... 806208-*** ................................ Piston Rod ......................................................................................... 2
5 ........................... 812305 ..................................... Guide Ring ........................................................................................ 2
6 ........................... 806232 ..................................... O-Ring ............................................................................................... 2
7 ........................... 807749 ..................................... Backup Ring ...................................................................................... 2
8 ........................... 811835 ..................................... Cylinder Cap ..................................................................................... 2
9 ........................... 806224 ..................................... Seal ................................................................................................... 2
10 .......................... 806226 ..................................... Wiper ................................................................................................. 2
11 .......................... 054173 ..................................... Seal ................................................................................................... 2
12 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 2
813784 ..................................... Seal Kits ............................................................................................ 1
Position 0 Position 1 Position 4 Bauhöhe
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
Tab007d

See Section ITD
169
LIFT CYLINDER
2.0t
10
11
8
12
5 1
MP-2140-052
M1.0-0000-000168
168A
LIFT CYLINDER
0 ..................... 815498-*** ............................... Lift Cylinder LH ø45 (2.0t) ....................................................................... 1

815497-*** ............................... Lift Cylinder RH ø45 (2.0t) ...................................................................... 1
1 ........................... 815502-*** ................................ Cylinder Tube LH ............................................................................... 1
815501-*** ................................ Cylinder Tube RH .............................................................................. 1
2 ........................... 812309 ..................................... Guide Ring ........................................................................................ 2
3 ........................... 811833-002 .............................. Piston Button ..................................................................................... 2
4 ........................... 806208-*** ................................ Piston Rod ......................................................................................... 2
5 ........................... 812305 ..................................... Guide Ring ........................................................................................ 2
6 ........................... 806232 ..................................... O-Ring ............................................................................................... 2
7 ........................... 807749 ..................................... Backup Ring ...................................................................................... 2
8 ........................... 811835 ..................................... Cylinder Cap ..................................................................................... 2
9 ........................... 806224 ..................................... Seal ................................................................................................... 2
10 .......................... 806226 ..................................... Wiper ................................................................................................. 2
11 .......................... 054173 ..................................... Seal ................................................................................................... 2
12 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 2
813784 ..................................... Seal Kits ............................................................................................ 1
LH / RH LH / RH --- ---
815498-001 / 815497-001 815502-001 / 815501-001 806208-001 2022mm
815498-002 / 815497-002 815502-002 / 815501-002 806208-002 2172mm
815498-004 / 815497-004 815502-004 / 815501-004 806208-004 2472mm
815498-006 / 815497-006 815502-006 / 815501-006 806208-006 2772mm
815498-007 / 815497-007 815502-007 / 815501-007 806208-007 2922mm
815498-008 / 815497-008 815502-008 / 815501-008 806208-008 3042mm
815498-010 / 815497-010 815502-010 / 815501-010 806208-010 3347mm
815498-012 / 815497-012 815502-012 / 815501-012 806208-012 3692mm
815498-013 / 815497-013 815502-013 / 815501-013 806208-013 3842mm
815498-014 / 815497-014 815502-014 / 815501-014 806208-014 3952mm
815498-015 / 815497-015 815502-015 / 815501-015 806208-015 4252mm
815498-016 / 815497-016 815502-016 / 815501-016 806208-016 4452mm
Tab025gb

See Section ITD
01 REV. 05/05
169A
FREE LIFT CYLINDER
1.4t/1.6t
14
8
13
16
15
12
11
10
7
9
6
3 2
MP-2140-053
M1.0-0000-000170
170
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 ........................... 812307 ..................................... Guide Ring ........................................................................................ 1
4 ........................... 811833-003 .............................. 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 ........................... 812306 ..................................... Guide Ring ........................................................................................ 1
10 .......................... 804776 ..................................... O-Ring ............................................................................................... 1
11 .......................... 807746 ..................................... Backup Ring ...................................................................................... 1
12 .......................... 811834 ..................................... Cylinder Cap ..................................................................................... 1
13 .......................... 804763 ..................................... Seal ................................................................................................... 1
14 .......................... 804757 ..................................... Wiper ................................................................................................. 1
15 .......................... 054173 ..................................... Seal ................................................................................................... 1
16 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 1
813785 ..................................... Seal Kits ............................................................................................ 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
Tab008gb

See Section ITD
171
FREE LIFT CYLINDER
2.0t
14
8
13
16
15
12
11
10
7
9
6
3 2
MP-2140-053
M1.0-0000-000172
172
FREE LIFT CYLINDER
0 ..................... 810048-*** ............................... Free Lift Cylinder ø65 (2.0t) ..................................................................... 1

1 ........................... 810050-*** ................................ Cylinder Tube ..................................................................................... 1
2 ........................... 806988 ..................................... Hose Burst Valve .............................................................................. 1
3 ........................... 812311 ..................................... Guide Ring ........................................................................................ 1
4 ........................... 811833-004 .............................. 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 ........................... 812310 ..................................... Guide Ring ........................................................................................ 1
10 .......................... 806233 ..................................... O-Ring ............................................................................................... 1
11 .......................... 807747 ..................................... Backup Ring ...................................................................................... 1
12 .......................... 811836 ..................................... Cylinder Cap ..................................................................................... 1
13 .......................... 812303 ..................................... Seal ................................................................................................... 1
14 .......................... 806227 ..................................... Wiper ................................................................................................. 1
15 .......................... 054173 ..................................... Seal ................................................................................................... 1
16 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 1
813786 ..................................... Seal Kits ............................................................................................ 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
Tab009gb

See Section ITD
173
CYLINDER REACH
20
19
18
3
17
2
1
17
4
5
21 7
8 6
9
10
22
11
12
21 13
14
17
15
16
17
18
19
20 MP-2140-047
M1.0-0000-000174
174
CYLINDER REACH
1* .................... 811185-001 .............................. Cylinder Tube (1.4t) ................................................................................. 1

811185-002 .............................. Cylinder Tube (1.6t-2.0t) .......................................................................... 1
2* .................... 807404 ..................................... Bearing ................................................................................................... 1
3* .................... 064061-002 .............................. Adaptor ................................................................................................... 2
4* .................... 812105 ..................................... Guide Ring .............................................................................................. 1
5* .................... 807355 ..................................... Piston Seal .............................................................................................. 1
6* .................... 812103 ..................................... Piston Rod .............................................................................................. 1
7* .................... 804774 ..................................... O-Ring .................................................................................................... 1
8* .................... 807748 ..................................... Backup Ring ........................................................................................... 1
9* .................... 807343 ..................................... Washer ................................................................................................... 1
10* ................... 812100 ..................................... End, Cap ................................................................................................. 1
11* ................... 812106 ..................................... Guide Ring .............................................................................................. 1
12* ................... 807356 ..................................... Rod Seal ................................................................................................. 1
13* ................... 807357 ..................................... Wiper ....................................................................................................... 1
14* ................... 807407 ..................................... Washer ................................................................................................... 1
15* ................... 050008-069 .............................. Nut .......................................................................................................... 1
16* ................... 806402 ..................................... Rod End .................................................................................................. 1
17 .................... 806429 ..................................... Washer ................................................................................................... 4
18 .................... 806427 ..................................... Pin ........................................................................................................... 2
19 .................... 792973 ..................................... Pin Split ................................................................................................... 2
20 .................... 050006-026 .............................. Screw ...................................................................................................... 2
21 .................... 806810 ..................................... O-Ring .................................................................................................... 2
22 .................... 812897-*** ............................... Spacer (see Table) .................................................................................. 1
815038-001 .............................. Seal Kit (included 4, 5, 7, 8, 11, 12, 13) ................................................... 1
* ..................... 811184-001 .............................. Cylinder Reach (1.4t/included 1-16) ....................................................... 1

811184-002 .............................. Cylinder Reach (1.6t-2.0t/included 1-16) ............................................... 1
Position 22 420Ah 560Ah 700Ah 820Ah
1.4t. ---- 812897-001 812897-002 ----
1.6t. ---- 812897-003 812897-004 812897-005
2.0t. N/A 812897-003 812897-004 812897-005
Tab001

See Section ITD
175
Printed in Germany
M1.0-0000-000176
176
SECTION 9
Printed in Germany
177
FREEZER CABIN
18
17
19
1
20
21 37
38
25 32
34
12 26
30 33
16 15 35
14 28
11 8 7 13 27 40
10
6 23 29
9 5 7 24 22 31
5 38 36
4 3
39
Door
2
40
MP-2140-106
M1.0-0000-000178
178
FREEZER CABIN
1 ..................... 808567 ..................................... Window (heated) ..................................................................................... 1

808568 ..................................... Heater 48V .............................................................................................. 1
808572 ..................................... Door Switch ............................................................................................ 1
2 ..................... 808575 ..................................... Handle .................................................................................................... 1
3 ..................... 819077 ..................................... Lever ....................................................................................................... 1
4 ..................... 050003-020 .............................. Screw ...................................................................................................... 1
5 ..................... 050003-011 .............................. Screw ...................................................................................................... 3
6 ..................... 816751 ..................................... Bracket ................................................................................................... 1
7 ..................... 050003-058 .............................. Screw ...................................................................................................... 3
8 ..................... 819076 ..................................... Handle .................................................................................................... 1
9 ..................... 050009-013 .............................. Washer ................................................................................................... 1
10 .................... 050010-015 .............................. Washer ................................................................................................... 1
11 .................... 050006-024 .............................. Screw ...................................................................................................... 1
12 .................... 816752 ..................................... Locking Wedge ....................................................................................... 1
13 .................... 816755 ..................................... Plate ........................................................................................................ 1
14 .................... 816756 ..................................... Washer ................................................................................................... 1
15 .................... 816754 ..................................... Bail .......................................................................................................... 1
16 .................... 816753 ..................................... Bolt .......................................................................................................... 1
17 .................... 808574 ..................................... Window (heated) ..................................................................................... 1
808557 ..................................... Rubber Seal ............................................................................................ 1
18 .................... 808555 ..................................... Window (no heated) ................................................................................ 1
808556 ..................................... Window (heated) ..................................................................................... 1
808557 ..................................... Rubber Seal ............................................................................................ 1
819078 ..................................... Windscreen Wiper Assembly (manual) ................................................... 1
819079 ..................................... Bearing .............................................................................................. 1
819080 ..................................... Wiper Arm ......................................................................................... 1
819081 ..................................... Wiper Blade ....................................................................................... 1
19 .................... 808573 ..................................... Window (heated) ..................................................................................... 1
808557 ..................................... Rubber Seal ............................................................................................ 1
808569 ..................................... Windscreen Wiper 12V ........................................................................... 1
20 .................... 808558 ..................................... Window (heated) ..................................................................................... 1
808557 ..................................... Rubber Seal ............................................................................................ 1
21 .................... 814738 ..................................... Bracket ................................................................................................... 1
22 .................... 050068-003 .............................. Nut .......................................................................................................... 4
23 .................... 050071-009 .............................. Screw ...................................................................................................... 1
24 .................... 811996-001 .............................. Relay Socket .......................................................................................... 1
25 .................... 814744 ..................................... Relay ....................................................................................................... 1
26 .................... 050008-010 .............................. Nut .......................................................................................................... 1
27 .................... 050004-024 .............................. Screw ...................................................................................................... 8
28 .................... 050009-004 .............................. Washer ................................................................................................... 8
29 .................... 814736 ..................................... Contactor ................................................................................................ 2
30 .................... 814740 ..................................... Terminal ................................................................................................... 1
31 .................... 050005-054 .............................. Screw ...................................................................................................... 2
32 .................... 050008-001 .............................. Nut .......................................................................................................... 2
33 .................... 050005-058 .............................. Screw ...................................................................................................... 1
34 .................... 814958 ..................................... Fuse Holder ............................................................................................ 1
35 .................... 814995-001 .............................. Fuse 30A ................................................................................................ 1
36 .................... 814995-002 .............................. Fuse 50A ................................................................................................ 1
37 .................... 050008-008 .............................. Nut .......................................................................................................... 1
38 .................... 050078-008 .............................. Blind Rivet Nut ........................................................................................ 4
39 .................... 814739 ..................................... Cover ...................................................................................................... 1
40 .................... 050071-020 .............................. Screw ...................................................................................................... 4
808559 ..................................... Door lock Assembly (included 2 -16) ...................................................... 1
not illustrated
814565-001 .............................. Loom ....................................................................................................... 1

814565-002 .............................. Loom ....................................................................................................... 1
814982 ..................................... T - Connector .......................................................................................... 1

See Section ITD
02 REV. 02/06
179
Printed in Germany
M1.0-0000-000180
180
SECTION 10
Printed in Germany
181
LABELS AND DECALS
1 6
1 2
2
3 8
4 9
5
5 5
21 13
20
18 19
14
12
10 11
17
15 16
22 23
17
24 25
MP-2140-094

01 REV. 05/05
M1.0-0000-000182
182
LABELS AND DECALS
1 ..................... 106158-020 .............................. Decal Crown Heavy ................................................................................ 2

2 ..................... 069372-034 .............................. Decal Momentum .................................................................................... 2
3 ..................... 869009-*** ............................... Warning Stand On ................................................................................... 1
4 ..................... 869010-*** ............................... Warning Stand Under .............................................................................. 1
5 ..................... 106158-001 .............................. Decal Crown Heavy ................................................................................ 3
6 ..................... 069374-001 .............................. Decal crown.com .................................................................................... 1
7 ..................... 069372-033 .............................. Decal Momentum .................................................................................... 1
8 ..................... 869104-*** ............................... Warning Moving Mast .............................................................................. 1
9 ..................... 869004-*** ............................... Warning Moving Vehicle .......................................................................... 1
10 .................... 869005-*** ............................... Warning Rider Truck ................................................................................ 1
11 .................... 869012-*** ............................... Warning Electrical Additions .................................................................... 1
12 .................... 069154 ..................................... Label Hydraulic Oil .................................................................................. 1
13 .................... 869314-*** ............................... Label Serial Number ................................................................................ 1
14 .................... 869502-*** ............................... Label Capacity Data ................................................................................ 1
15 .................... 869020-*** ............................... Danger Battery ....................................................................................... 1
16 .................... 869047-*** ............................... Caution, Charger Hook Up ..................................................................... 1
17 .................... 869006-*** ............................... Warning Hands Off ................................................................................. 2
18 .................... 869519-006 .............................. Label Info Point ....................................................................................... 1
19 .................... 869518-006 .............................. Label Info Point ....................................................................................... 1
20 .................... 869522-006 .............................. Label Info Point ....................................................................................... 1
21 .................... 869516-006 .............................. Label Info Point ....................................................................................... 1
22 .................... 869517-006 .............................. Label Info Point ....................................................................................... 1
23 .................... 869523-006 .............................. Label Info Point ....................................................................................... 1
24 .................... 869520-006 .............................. Label Info Point ....................................................................................... 1
25 .................... 869521-006 .............................. Label Info Point ....................................................................................... 1
*** ................... xxxxxx-001 .............................. German

xxxxxx-002 .............................. French
xxxxxx-003 .............................. Spanish
xxxxxx-004 .............................. Dutch
xxxxxx-005 .............................. Italien
xxxxxx-006 .............................. English
xxxxxx-010 .............................. Portoguese

See Section ITD
02 REV. 11/05
183
Printed in Germany
M1.0-0000-000184
184

Crow ESR4500

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Parts Manual

CROWN Gabelstapler GmbH & Co. KG

Phone +49 (0)89 93 00 2 - 0

All rights reserved under international and Pan-American Copyright Agreement.

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-ESR4500-GB 06/04 • Printed in Germany MP-IDX-2140

CHAPITRE 5 – SYSTEME DE FREINAGE PAGE COUPURE NR. SÉRIE REV.

CHAPITRE 6 – DIRECTION PAGE COUPURE NR. SÉRIE REV.

CHAPITRE 7 – MÂT PAGE COUPURE NR. SÉRIE REV.

CHAPITRE 8 – VÉRINS PAGE COUPURE NR. SÉRIE REV.

CHAPITRE 9 – CABIN/PLATE - FORME PAGE COUPURE NR. SÉRIE REV.

CHAPITRE 10 – AUTRES INFORMATIONS SPAGE COUPURE NR. SÉRIE REV.

MP-IDX-2140 MP-ESR4500-FR 06/04 • Printed in Germany

Important customer information Ordering Spare Parts

Any proposed modification which would

MP-ESR4500-GB 06/04 • Printed in Germany M/P-ITD-2140

MP-1.1-2140 MP-ESR4500-GB 06/04 • Printed in Germany

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

* ..................... 807352 ..................................... Head Rest Assembly (included 9 - 11) ................................................... 1

796166 ..................................... Switch Cover (Drive in Racking) ............................................................ 2

Always Specify Model & Serial Number

MP-1.1-2140 MP-ESR4500-GB 06/04 • Printed in Germany

1 ..................... 815040 ..................................... Steering Wheel ........................................................................................ 1

Always Specify Model & Serial Number

MP-1.1-2140 MP-ESR4500-GB 06/04 • Printed in Germany

1 ........................................................................ Instrumentation (see Section 4.9) ........................................................... 1

* ..................... 806929 ..................................... Armrest Assembly (included 2, 5, 6/without 796489) .............................. 1

Always Specify Model & Serial Number

MP-1.1-2140 MP-ESR4500-GB 06/04 • Printed in Germany

1 ........................................................................ Instrumentation (see Section 4.9) ........................................................... 1

* ..................... 818543-001 .............................. Armrest Assembly (included 2, 5, 6/without 796489) .............................. 1

Always Specify Model & Serial Number

MP-1.1-2140 MP-ESR4500-GB 06/04 • Printed in Germany

1 ..................... 790797-001 .............................. Block, Skid .............................................................................................. 2

1,4t 1,6t & 2,0t 1,4t 1,6t & 2,0t

Load Wheel ∅ 285 mm 810637-001 810637-002 810637-004 810637-005

Load Wheel ∅ 330 mm 810637-003 810637-006

1,4t 1,6t & 2,0t 1,4t 1,6t & 2,0t

Load Wheel ∅ 285 mm 814895-001 814895-002 814895-004 814895-005

Load Wheel ∅ 330 mm 814895-003 814895-006

Always Specify Model & Serial Number

MP-1.1-2140 MP-ESR4500-GB 06/04 • Printed in Germany

1 ..................... 790797-001 .............................. Block, Skid .............................................................................................. 2

Always Specify Model & Serial Number

MP-1.2-2140 MP-ESR4500-GB 06/04 • Printed in Germany

1 ..................... 811174 ..................................... Reach Carriage (1285mm Leg Width) ..................................................... 1

811010 ..................................... Guide Rollers Assembly (included 4 - 8) ................................................ 2

811013 ..................................... Guide Rollers Assembly (included 11 - 16) ............................................. 2

812134 ..................................... Excentric Rollers Assembly (included 24 - 27) ....................................... 2

Always Specify Model & Serial Number

MP-1.5-2140 MP-ESR4500-GB 06/04 • Printed in Germany

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

Always Specify Model & Serial Number

MP-1.6-2140 MP-ESR4500-GB 06/04 • Printed in Germany

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

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

only for Freezer/Corrosion

796158 ..................................... Bracket ................................................................................................... 1

Always Specify Model & Serial Number

MP-1.6-2140 MP-ESR4500-GB 06/04 • Printed in Germany