BGNR Owner's Manual - L.A. LIFT SERVICES...Heavy Duty Walkie Stacker w/Reach and Tilt Feature Page 6...

OWNER’S MANUAL

Heavy Duty Walkie Stacker w/Reach and Tilt Feature

3000 lb Capacity


Issue Date: 09/27/04 (Part #411-752) Page 1

TABLE OF CONTENTS

1. Receipt Inspection ..................................................................................................................................4 2. Pre-Operation Instructions......................................................................................................................4 3. Safety Information...................................................................................................................................5 4. Operating Instructions ............................................................................................................................7

4.1 Optional Controls ........................................................................................................................11 4.2 Basic Operation ..........................................................................................................................12

5. Control System .....................................................................................................................................13 6. Optional Instruments - Operation .........................................................................................................15

6.3 Hour Meter ..................................................................................................................................15 6.4 BDI and Hour Meter ....................................................................................................................15 6.5 BDI w/Lift Lock Out .....................................................................................................................16

7. Drive Unit & Brake ................................................................................................................................18 8. Mast and Carriage ................................................................................................................................19 9. Hydraulic Adjustments..........................................................................................................................19

9.1 Lifting Pressure...........................................................................................................................19 9.2 Lowering Speed: .........................................................................................................................19

10. Planned Maintenance...........................................................................................................................20 10.1 Lubrication Points .......................................................................................................................21 10.2 Lubrication Schedule ..................................................................................................................23 10.3 Hydraulic Reservoir Maintenance...............................................................................................24 10.4 Battery Maintenance...................................................................................................................25 10.5 Battery Cable Connections .........................................................................................................26

11. Trouble Shooting Guide........................................................................................................................27 12. Heavy Duty Stacker - Parts Listings.....................................................................................................28

12.1 General Assembly Parts List ......................................................................................................30 12.2 Mast and Carriage Assembly - Single Stage..............................................................................34

12.2.1 Reach and Tilt Assembly - Single Stage ......................................................................36 12.2.2 Mast and Carriage Weldment Ass'y - Three Stage ......................................................38 12.2.3 Lift Cylinder Assembly - Single Stage ..........................................................................40 12.2.4 Chain Assembly - Single Stage ....................................................................................42 12.2.5 Crosshead Assembly - Single Stage ............................................................................44

12.3 Mast and Carriage Assembly - 2 Stage......................................................................................46 12.3.1 Reach and Tilt Assembly - Two Stage .........................................................................48 12.3.2 Mast and Carriage Weldment Ass'y - Two Stage.........................................................50 12.3.3 Lift Cylinder Assembly - Two Stage..............................................................................52 12.3.4 Chain Assembly - 2 Stage ............................................................................................54 12.3.5 Crosshead Assembly - 2 Stage ....................................................................................56


Page 2 Issue Date: 09/27/04 (Part #411-752)

12.4 Mast and Carriage Assembly - 2 Stage Full Free.......................................................................58 12.4.1 Reach and Tilt Assembly - 2 Stage Full Free...............................................................60 12.4.2 Mast and Carriage Weldment Ass'y - Three Stage ......................................................62 12.4.3 Lift Cylinder Assembly - 2 Stage Full Free ...................................................................64 12.4.4 Outboard Cylinder Assembly - 2 Stage Full Free.........................................................66 12.4.5 Chain Assembly - 2 Stage 130" Lift Height ..................................................................68 12.4.6 Crosshead Assembly - 2 Stage 130" Lift Height ..........................................................70

12.5 Mast and Carriage Assembly - 3 Stage 160, 180" Lift................................................................72 12.5.1 Mast Chain Assembly - 3 Stage 160. 180 " Lift Height.................................................74 12.5.2 Carriage Chain Assembly - 3 Stage 160. 180 " Lift Height ..........................................76 12.5.3 Cylinder Assembly - 3 Stage 160, 180" Lift Height.......................................................78 12.5.4 Reach and Tilt Assembly - 3 Stage ..............................................................................80 12.5.5 Mast and Carriage Weldment Ass'y - Three Stage ......................................................82 12.5.6 Crosshead Assembly - Three Stage.............................................................................84

12.6 Mast and Carriage Assembly - 3 Stage Full Free.......................................................................86 12.6.1 Reach and Tilt Assembly - Three Stage Full Free .......................................................88 12.6.2 Reach/Tilt Sub-Assembly - Three Stage Full free ........................................................90 12.6.3 Mast and Carriage Weldment.......................................................................................92 12.6.4 Reach Cylinder Assembly - Three Stage 172' Full Free ..............................................94 12.6.5 Tilt Cylinders - Three Stage 172' Full Free...................................................................96 12.6.6 Chain Assembly - Three Stage 172' Full Free..............................................................98 12.6.7 Chain Assembly - Three Stage 172' Full Free............................................................100 12.6.8 Crosshead Assembly - Three Stage 172' Full Free....................................................102 12.6.9 Lift Cylinder Assembly - Three Stage 172' Full Free ..................................................104 12.6.10 Outboard Cylinder Assembly - Three Stage 172' Full Free ...................................106

12.7 Left Straddle Assembly.............................................................................................................108 12.8 Right Straddle Assembly ..........................................................................................................110 12.9 Electric Drive Unit Assembly.....................................................................................................112

12.9.1 Drive Unit Assembly - Electrical .................................................................................114 12.9.2 Control Handle Assembly ...........................................................................................116 12.9.3 Control Handle Head Assembly .................................................................................118 12.9.4 Controller Panel Assembly .........................................................................................120 12.9.5 Drive Unit Wiring Kit....................................................................................................122 12.9.6 Drive Unit Column Assembly - Mechanical ................................................................124 12.9.7 Gearbox Assembly .....................................................................................................126 12.9.8 Wiring Kit - Rear Battery Box Plate ............................................................................128



12.10 Hydraulic Layout - Single Stage ...............................................................................................130 12.10.1 Reach Cylinder Assembly - Single Stage ..............................................................132 12.10.2 Tilt Cylinder Assemblies - Single Stage .................................................................134

12.11 Hydraulic Layout - Two Stage...................................................................................................136 12.11.1 Reach Cylinder Assembly - Two Stage..................................................................138 12.11.2 Tilt Cylinder Assemblies - Two Stage ....................................................................140

12.12 Hydraulic Layout - Two Stage Full Free ...................................................................................142 12.12.1 Reach Cylinder Assembly - Two Stage..................................................................146 12.12.2 Tilt Cylinder Assemblies - Two Stage ....................................................................148

12.13 Hydraulic Layout - Three Stage................................................................................................150 12.13.1 Reach Cylinder Assembly - Three Stage ...............................................................152 12.13.2 Tilt Cylinder Assemblies - Three Stage..................................................................154

12.14 Hydraulic Layout - Three Stage Full Free.................................................................................156 12.15 Body Hydraulic Layout - One and Two Stage ..........................................................................158 12.16 Control Valve Assembly............................................................................................................160 12.17 Hydraulic Reservoir Assembly..................................................................................................162 12.18 Body Hydraulic Layout - Three Stage.......................................................................................164 12.19 Control Valve Assembly............................................................................................................166 12.20 Hydraulic Reservoir Assembly..................................................................................................168 12.21 Body Hydraulic Layout - Two Stage Full Free ..........................................................................170 12.22 Control Valve Assembly............................................................................................................172 12.23 Hydraulic Reservoir Assembly..................................................................................................174 12.24 Body Hydraulic Layout - Three Stage Full Free .......................................................................176 12.25 Control Valve Assembly............................................................................................................178 12.26 Relief Valve Assembly ..............................................................................................................180 12.27 Hydraulic Reservoir Assembly..................................................................................................182

13. Wiring/Hydraulic Schematics..............................................................................................................184 14. Service / Maintenance History............................................................................................................186 15. Warranty Policy...................................................................................................................................187



IMPORTANT! : READ AND UNDERSTAND THE CONTENTS OF THIS MANUAL BEFORE OPERATING THE EQUIPMENT.

1. Receipt Inspection

This equipment has been thoroughly inspected and tested prior to leaving the factory. Before placing the equipment in service it should be thoroughly checked for damage or loss occurred in transit.

IMPORTANT! : IF ANY DAMAGE OR LOSS IS EVIDENT, A CLAIM MUST BE MADE AGAINST THE CARRIER.

2. Pre-Operation Instructions

1. Open the drive unit shroud and check the wiring harness and hydraulic hoses for damage or loose connections.

2. Remove the breather cap from the hydraulic reservoir. and verify that the oil level is approximately 1" (25mm) below the top of the reservoir. Refer to Figure 9 in Section 10.1 : Lubrication Points.

3. Open the battery compartment and check that all connections are tight. Check that the batteries have not been damaged. Charge battery(s) for one shift. Refer to Section 10.5 : Battery Maintenance

4. Refer to the Operator's Manual on unit and check that the truck operates satisfactorily.

IMPORTANT! : DURING INITIAL CYLINDER ASSEMBLY, HYDRAULIC FLUID IS USED TO LUBRICATE ALL THE COMPONENTS. THIS ASSEMBLY FLUID MAY BE PRESENT, OR ACCUMULATED IN THE UPPER HEADNUT PORTION OF THE CYLINDER DURING THE BREAK-IN PERIOD OR NORMAL USE. A SMALL AMOUNT OF FLUID IN THIS AREA IS NORMAL AND SHOULD NOT BE MISTAKEN FOR CYLINDER SEAL LEAKAGE.

5. Complete the Warranty Validation Form provided with this manual and return it to factory.

REMEMBER: A safe operator is a smart operator!



3. Safety Information

1. Do not operate this truck unless you have been trained and authorized to do so.

2. Do not operate this truck until you have checked its condition. Give special attention to tires, battery, controls, lifting systems (including switches), brakes, steering mechanism, guards and safety devices.

3. Report the need for truck repairs to your supervisor promptly. Do not operate the truck. Neglect may cause a minor repair to become a major service problem or cause the truck to become unsafe.

4. The stacker is intended for use on level surfaces only.

5. Do not exceed the rated capacity of the vehicle as marked on the nameplate. Do not lift with the fork tips or one fork only, and be sure the load is centered and the 24" (610mm) load center is not exceeded.

6. Do not handle unstable or loosely stacked loads. Use special care when handling long, high or wide loads, to avoid tipping, loss of load, or striking bystanders.

7. Always look in direction of travel. Keep a clear view and when load obstructs visibility, travel with load trailing where possible on level surfaces only.

8. Watch swing clearance when turning near walls, racks, pillars or other obstacles.

9. Start, stop, change direction, travel and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause truck to slide or tip. Be aware that the truck behaves differently without a load than with a load.

10. Observe applicable traffic regulations and yield right of way to pedestrians. Slow down and sound horn at all aisle intersections and where vision is obstructed.

11. Do not ride on truck.

12. Do not carry passengers.

13. Before leaving the truck, fully lower the lifting mechanism and shut off power and key switch if equipped.



14. Do not use forward mast tilt (if equipped) with the load elevated unless the load is directly over other support.

15. When traveling with or without a load, forks should be in lower most position and tilted back if applicable.

16. For straddle trucks, straddle distance must be equally spaced in relation to truck chassis. Straddle inside dimension must be set at a minimum of 25% of maximum lifting height. Straddle legs adjustment should be done by an authorized Service Technician.



4. Operating Instructions

2 3 2 14

Figure 1 : Operator's Controls

All controls required for normal operation are located on the Control Head portion of the Drive Unit Assembly. 1. Key Switch This is a two position rotary key switch that can be turned to the ON or OFF positions. When turned to the "OFF" position the key switch isolates the control head from the controller. It does not isolate the battery from the rest of the stackers electrical system. When turned to the "ON" position, all drive controls are functional. 2. Travel Controls Rotating the thumb wheels in the head of the control handle controls direction and speed. Rotating the thumb wheels toward the front (fork end) of the stacker will engage the motor to drive the stacker in the forward direction. Rotating the thumb wheels in the opposite direction, toward the rear (drive unit end) of the stacker, will engage the motor to drive the stacker in the reverse direction. The speed of the stacker will vary according to the duration and pressure applied to the thumb wheels. Reversing the rotation of the thumb wheels from the desired direction will cause the stacker to slow down and eventually stop.

3. Horn This two position momentary pushbutton will sound the horn as long as the button is pressed. The horn button is located on the control head to allow for instantaneous fingertip use without travel interruption.



4. Emergency Reverse Button Located at the top of the steering handle. When the truck is being driven in the direction of the operator and the safety-reversing button is depressed by an obstruction or trapped operator, the vehicle will instantly reverse direction and the horn will sound.

NOTE: DO NOT USE THE SAFETY REVERSING BUTTON FOR NORMAL TRAVEL.

5 6 798

Figure 2 : Dash Panel Controls

WARNING! : NEVER EXCEED THE RATED CAPACITY OF THE TRUCK AS MARKED ON THE NAMEPLATE. DO NOT LIFT WITH THE FORK TIPS OR ONE FORK ONLY.

5. Lift and Lower Control Valve:

This manual lever hydraulic control valve (standard) is located on the right hand side of the dash plate. Raising the Forks The control valve will engage the stackers hydraulic system when pushed and held towards the front (fork) end of the stacker. This, in turn, forces the hydraulic cylinder in the center of the mast to extend vertically. This extension causes the carriage and forks to rise. Releasing the lever will cause the lever to return to center position and will stop the upward travel of the forks.



Lowering the Forks The control valve will engage the stackers hydraulic system when pulled and held towards the rear (drive unit) end of the stacker. This, in turn, forces the hydraulic cylinder in the center of the mast to retract vertically. This causes the carriage and forks to descend. Releasing the lever will cause the lever to return to center position and will stop the downward travel of the forks. 6. Fork Tilt Control Valve Tilting the Forks Up The control valve will engage the stackers hydraulic system when pushed and held towards the front (fork) end of the stacker. This, in turn, forces two hydraulic cylinders on either sides of the mast carriage to extend downwards. This extension causes the fork tips to rise. Releasing the lever will cause the lever to return to center position and will stop the upward tilting of the forks. Tilting the Forks Down The control valve will engage the stackers hydraulic system when pulled and held towards the rear (drive unit) end of the stacker. This, in turn, forces two hydraulic cylinders on either sides of the mast carriage to retract upwards. This extension causes the fork tips to drop to normal (level). Releasing the lever will cause the lever to return to center position and will stop the downward tilting of the forks. 7. Reach Control Valve

Extending the Reach Carriage The control valve will engage the stackers hydraulic system when pushed and held towards the front (fork) end of the stacker. This, in turn, forces a hydraulic cylinder in the center of the reach pantograph to extend outwards from the front of the stacker. This extension causes the carriage and forks to "reach" outwards. Releasing the lever will cause the lever to return to center position and will stop the outward travel of the forks. Retracting the Reach Carriage The control valve will engage the stackers hydraulic system when pulled and held towards the rear (drive unit) end of the stacker. This, in turn, forces a hydraulic cylinder in the center of the reach pantograph to retract inwards from the front of the stacker. This retraction causes the reach pantograph to compact inwards.



Releasing the lever will cause the lever to return to center position and will stop the inward travel of the forks. 8. Emergency Stop Button Located on the dash panel, this large red button will interrupt power to all systems when pressed firmly. Pressing the button again will reconnect the units electrical circuits.

9. Hour Meter / Battery Discharge Indicator

(Optional)

The dash panel may also include any one of a number of optional gauges or meters. The most common is a combination hour meter with battery discharge indicator.(BDI). An hour meter assists maintenance personnel in recording stacker performance and scheduling planned maintenance. The BDI specifically displays the discharge condition of the batteries. See Section 6 : Optional Instruments - Operation

REMEMBER: A safe operator is a smart operator!



4.1 Optional Controls

LOWER CONTROL PUSHBUTTON

LIFT CONTROL PUSHBUTTON

Figure 3 : Optional Controls

10. Lift Control Pushbutton

This pushbutton will engage the stacker's hydraulic system when pressed and held. This, in turn, forces the hydraulic cylinder in the center of the mast to extend vertically. This extension causes the carriage and forks to rise. Releasing the pushbutton will stop the upward travel of the forks.

11. Lower Control Pushbutton This pushbutton will engage the stacker's hydraulic system when pressed and held. This, in turn, forces the hydraulic cylinder in the center of the mast to retract vertically. This causes the carriage and forks to descend. Releasing the pushbutton will stop the downward travel of the forks.



4.2 Basic Operation

RIGHT

LEFT

Figure 4 : Steering with the Control Head 12. Steering

The Control Head is directly attached to the central Drive Unit so that pivoting the Control Head in the desired direction will steer the stacker in the same direction.

BRAKEAPPLIED

BRAKEAPPLIED

BRAKERELEASED

Figure 5 : Brake Controls 13. Parking Brake / Deadman Feature The drive units integral brake is applied when the control handle is in the fully raised or fully lowered position. Power to the traction (drive) motor is cut off whenever the brake is applied in the fully raised or lowered position. The drive unit also includes a �Deadman� safety feature. The spring-loaded control handle, when



released, automatically returns to the upright/�Deadman� position that engages the brake and will slow the unit down to a full stop. Regular intermittent braking is achieved by rotating the thumbwheels (See Figure 1) counter to the direction currently being traveled.

5. Control System

These units are factory set for normal operating conditions. This electronic speed controller provides maintenance free operation and reduces downtime and operating costs associated with contactor controlled units. Contact your service representative for additional information. Current multiplication:

During acceleration, or reduced speed operation, the electronic travel speed controller allows more current into the motor than what it takes out of the battery. This is possible because the controller acts like a D.C. transformer, i.e.: it takes in high voltage (the full battery voltage) and low current, and puts out low voltage and high current. Thus for these conditions the battery only has to supply a fraction of the current otherwise required by a standard resistor type controller (in which the battery current and motor current are always equal). The result is a dramatic improvement in the vehicle�s efficiency, i.e. greater driving range per battery charge! Plug braking:

In most applications of these controllers, the vehicle motor will be of the series wound type. If a series wound motor is reversed while the vehicle is moving, an efficient form of electrical braking called plug braking will slow the vehicle down. When the motor is reversed the armature acts as a generator. Generated armature current goes through a �plug diode� built into the controller. The controller regulates the current in the motor field winding to give an appropriate level of plug braking torque. The vehicle brakes smoothly to stop, then automatically accelerates.

Controller

The electronic speed controller, being a sealed, solid state unit, requires almost no maintenance. It is, however, recommended that the following items be checked occasionally, as required.



WARNING! : DISCONNECT THE BATTERY AND DEPRESS HORN SWITCH TO DRAIN CONTROLLER RESIDUAL CHARGE BEFORE ATTEMPTING ANY TYPE OF INSPECTION OR SERVICE.

a) Make sure that the electrical connections to the controller (as well as those to the motor, batteries, etc.) are tight.

NOTE: When checking the controller bus bar connections for tightness, be sure to use the double-wrench technique to avoid applying torquing stress on the bus bars which could crack the seals around them.

b) Remove from the terminal areas any corrosion or accumulations of dirt, acids, grease, oil, etc. It is very important that the controller terminal face be free of these substances, since their presence may lead to electrical leakage and cause faulty operation. The controller may be wiped clean.

POWER MUST BE REMOVED DURING THIS CLEANING.



6. Optional Instruments - Operation

6.3 Hour Meter

The Hour Meter is activated by the control handle and records actual run time of the drive motor.

Figure 6 : Typical Hour Meter

6.4 BDI and Hour Meter The display of the Battery Discharge Indicator (BDI) / Hour Meter is activated by the control handle and records actual run time of the drive motor. In addition, when the handle is in the driving position the accumulation of time is indicated by the flashing of an hourglass icon.

Figure 7 : Typical BDI/Hour Meter Indicators



The functioning of the red, yellow and green LED display on the BDI/Hour Meter is as follows:

1. The far right LED (1.) will illuminate to indicate a proper full charge.

2. As the battery�s state-of-charge condition

decreases, the number of lit LEDs will also decrease.

3. At the next to last position (2.), this LED flashes

indicating an �energy reserve� condition. This indicates a state-of-charge condition of approximately 70% of discharge.

4. At the empty point (3.), the 2 LEDs at the far left

will alternately flash indicating a state-of-charge condition of approximately 80% discharge.

If the power is disconnected from the indicator during charging, the unit will reset at 2.09 volts per cell. If the indicator remains connected during charging, a voltage of 2.35 volts per cell must be maintained in excess of 6 minutes in order to rest the unit.

6.5 BDI w/Lift Lock Out Some units may be equipped with a battery discharge indicator that may include a lift lockout feature. When the battery is severely discharged the lifting circuit will automatically be disabled. To avoid this, the operator must return the unit for charging after the last light / bar is activated. The travel circuit will remain operational to return the unit to the charging area. Although, several different style meters are available as options, their basic function is identical. The lift lockout feature will ensure that the battery and electrical components are not subject to premature wear due to operating with a discharged battery. Always check the battery indicator, if equipped, in the event that the lifting circuit is not operational. General operation of a battery discharge indicator with or without the lift lockout feature, if equipped, is outlined on the drawing below.



Figure 8 : Typical Battery Discharge Indicator The display of the BDI w/ Lift Interlock monitors the state-of-charge condition of the batteries as well as providing a Lift Interlock feature. As the battery�s state-of-charge condition decreases, the number of lit LEDs will also decrease.

All lights ON: Battery: - fully charged Voltage: - more than 110% of nominal Four lights ON: Battery: - fully charged Voltage: - between 110% and 100% of nominal Three lights ON: Battery: - partially discharged Voltage: - between 98% and 100% of nominal Two lights ON: Battery: - partially discharged Unit should be promptly returned for charging One light ON: Battery: - fully discharged Lift will be disabled after several minutes of

continued service. Unit must be returned for charging immediately!

Optional Parts ITEM PART NO. DESCRIPTION 1 032-211 Hour meter 2 032-229 Combo BDI-hour meter 3 032-244 BDI with lift lockout

4 026-511 Combo BDI-hour meter with lift lockout

5 026-516 Harness for 026-511



7. Drive Unit & Brake

BEFORE INSPECTING ANY PART OF THE DRIVE ASSEMBLY, DISCONNECT MAIN BATTERY POWER AND DEPRESS HORN SWITCH TO DRAIN RESIDUAL CONTROLLER CHARGE

The traction motor has sealed bearings and requires no external lubrication.

1. Check the condition of the drive belt and adjust the tension if necessary. The belt is correctly tensioned when a 10 lb. force applied midway between the two sprockets causes a deflection of 3/16�.

2. Check belt for unusual wear which may indicate incorrect pulley alignment. Never use force or pry when installing a new replacement belt.

3. To install a new belt; reduce tension, remove the old belt, install the new belt and readjust the tension to achieve the deflection indicated. Rotate the belt manually by hand for several revolutions and recheck tension after all fasteners have been tightened. Normally this belt should not require further tensioning but should be re-inspected after several shifts of operation. Over-tensioning a belt will cause excessive noise, reduce belt life and impose higher bearing loads in drive components.

4. Change the oil in the gear reduction box 500 hours or three months after the equipment is placed in service and every 2000 hours or one year thereafter. The gearbox will hold 1.4 Liters of fluid. Approved gearbox oils are listed on chart below.

Failure to adhere to carry out this procedure as part of a Planned Maintenance Schedule could void the owners warranty and/or seriously affect the owners right to claim.

5. Check the brake for safe operation. Make sure the power cut off switch is open and disconnects the drive when the brakes are applied in both the up and down position. This unit is equipped with an internal multi-disc braking system that has no user adjustable parts. Only qualified service personnel are permitted to perform brake adjustments.

FACTORY APPROVED OILS FOR NORMAL AMBIENT OPERATING CONDITIONS APPROVED GEAR BOX OILS APPROVED HYDRAULIC OILS

Canadian American Canadian American Esso Terresso #68 Exxon Teresstic #68 Sunvis 832 Dexron II Shell Tellus #68 Shell Turbo T-68 Valvoline Antiwear ISO32 Valvoline AW32 Petro Canada Harmony #68



8. Mast and Carriage

1. Check the condition and wear of all channel/chain rollers on a monthly basis and replace if necessary.

2. Lubricate the points as shown in Figure 9 : Lubrication Points. For best performance lubricate monthly.

3. Lubricate the points shown in Figure 10 : Lubrication Points

4. Periodically remove the lift chains and wipe clean with dry cloths. DO NOT use chemical degreasing agents. Carefully examine the chain links, pins and clevises for damage, wear or stretch and replace them if any evidence of either is found. Use a paintbrush, recoat the chains with SAE 10 motor oil, or suitable chain lubricant. Adjust the chain tension so that with the carriage fully lowered, the chains are equally taut but not supporting the carriage.

5. Check the upper limit mechanical stops for damage and repair or replace. Damage to these stops could be an indicator of a more serious problem in the lift cylinder.

9. Hydraulic Adjustments

9.1 Lifting Pressure The hydraulic relief valve assembly controls the maximum hydraulic system pressure. The pressure relief is factory set and adjustment will be required only if a new valve assembly is installed. For operator safety adjustment to any of these components must be made by a qualified service representative only.

9.2 Lowering Speed: Lowering speed is factory set for safe lowering and should never be changed for safety reasons. For operator safety during valve replacement, adjustment to the lowering speed must be made by a qualified service representative only.



10. Planned Maintenance

Spotting trouble before it happens can prevent costly down-time and extensive repairs and make it possible for service and repairs to be performed when the unit is not required for regular operations. Inspection intervals outlined are for normal single shift use and conditions. More frequent inspections are necessary for adverse conditions such as: rough floor conditions, temperature extremes, several operators, multi shift use, dusty atmosphere, etc.

Failure to adhere to a Planned Maintenance Schedule could void the owners warranty and/or seriously affect the owners right to claim. In addition, operation of a stacker in certain industries may demand regular inspections in compliance with government regulations.

INSPECTION INTERVALS DAILY: All Operating Controls (SAFETY) QUARTERLY: Electrical System Battery Charge Hydraulic System Brake Operation Drive Unit & Mechanical Parts

WARNING! : DISCONNECT THE BATTERY AND DEPRESS HORN SWITCH TO DRAIN CONTROLLER RESIDUAL CHARGE BEFORE ATTEMPTING ANY TYPE OF INSPECTION OR SERVICE



10.1 Lubrication Points

GREASE

MOTOR OIL

MAST ROLLERS

CROSSHEAD BUSHINGS/AXLE

LIFT CHAINS

STRADDLEROLLERS

SWIVEL BEARINGSTEERING

HYDRAULICRESERVOIR

GEAR BOX FLUID

STRADDLEBOGIE PIVOT

MAST CHANNEL

GUIDERODS

Note: Ball Bearing Style Rollers do NOT require lubrication.

Figure 9 : Lubrication Points - Body and Mast



GREASE

MOTOR OIL

MAST CHANNELS

MAST ROLLER BUSHINGS

TILTCYLINDERBUSHINGS

TILTACTUATORBUSHINGS

TILTCYLINDERBUSHING

SCISSORLEG/FRAMEBUSHINGS

SCISSORLEG CENTERPIN BUSHING

REACHCYLINDERBUSHINGS

SCISSORLEG/FRAMEBUSHINGS

ROLLER BUSHINGS

MAST CHANNELS

TILTCYLINDERBUSHING

Figure 10 : Lubrication Points - Reach and Tilt Carriage



Important notice - During initial cylinder assembly, hydraulic fluid is used to lubricate all the components. This assembly fluid may be present, or accumulated in the upper headnut portion of the cylinder during the break-in period or normal use. A small amount of fluid in this area is normal and should not be mistaken for cylinder seal leakage.

10.2 Lubrication Schedule LUBRICATION (based on single shift, normal usage) The transmission (gearbox) oil, hydraulic oil should be changed after the truck has been in service for six months, then minimum once a year, for normal single shift usage. Every Month:

- Yearly: -

Apply engine oil (SAE 10) or grease to all points. , including handle pivot points.

Every Three - Months:

Remove breather cap (See Figure 9) check oil level Is 1� (25mm) below the top of the reservoir and add approved oil, if necessary. High oil level may cause spillage during rapid braking. The breather cap should be cleaned with a suitable cleaning solvent and blown dry (safety glasses must be worn) before you reinstall. Check gearbox oil level (See Figure 9 : Lubrication Points - Body and Mast)

Perform procedure in Section 10.4 : Hydraulic Reservoir maintenance. For operation at normal room temperatures use only approved hydraulic oils such as: ISO 32 Sunvis 832 Esso Polar 32 Shell Tellus 29 Texaco Rando Oil HD32(150) For Transmission (Gear Box) oil use: Gulf Harmony 68 Esso Teresso 68 Shell Covil 68 or equal For low temperature operation consult the manufacturer for recommended hydraulic and gear box oils.

Every Six - Months:

Lubricate drive unit swivel bearings and wheel bearings using high quality lithium-based EP type grease. Check for smooth operation. Lubricate all Reach and Tilt Carriage Assembly pivot points. (See Figure 10 : Lubrication Points - Reach and Tilt Carriage)



10.3 Hydraulic Reservoir Maintenance

1. Drain the hydraulic oil from the reservoir by

disconnecting the hose at the base of the lift cylinder.

2. Place the end of the hose end into a collection container.

3. Operate the pump motor by operating the Lift Control Valve (or push button Lift Control if equipped) until no more oil is expelled.

4. Reconnect the hose to the base of the lift cylinder.

5. Remove the spin-on type oil filter (if equipped) at the return line to the reservoir.

6. Replace the filter with one of the same rating. The

factory supplied filter has a 10 micron (µ) - 18 psi bypass rating.

7. Apply a thin coat of hydraulic oil to the o-ring on the

filter head.

8. Fill the filter with new hydraulic oil and mount on to the filter head.

9. Remove the Drive Unit shroud to expose the

hydraulic tank breather cap.

10. Remove the breather cap and refill to 1" below the top of the reservoir.



10.4 Battery Maintenance

The Heavy Duty Stacker comes equipped with an Industrial Battery and automatic remote charger as standard equipment. The battery and charger manufacturers operation manual should be consulted for proper charging, maintenance and handling information.

General The top of the battery should be kept clean and dry. Wash off with clean water and baking soda when necessary. Good ventilation should be provided during charging. Do not allow electrolyte temperature to exceed 110°F (43°C). Keep open flames away from battery. Never add acid to cells. Batteries used at temperatures below or above normal room temperature will have reduced capacity.

CAUTION! : DO NOT DISCHARGE BELOW SPECIFIC GRAVITY OF 1.150 OR THERE WILL BE A PERMANENT LOSS OF CAPACITY.

WARNING! : ENSURE THAT BATTERY CHARGER ELECTRIC PLUG CANNOT COME INTO CONTACT WITH BATTERY TERMINAL POSTS. WARNING! : DISCONNECT THE SB BATTERY CONNECTOR FROM THE MACHINE PRIOR TO CHARGING TO PREVENT ACCIDENTAL VEHICLE MOVEMENT.

Batteries requiring maintenance The following applies to batteries equipped with cell covers that can be removed for maintenance and that require occasional addition of distilled water to battery cells. It is assumed that the personnel performing this maintenance are properly trained and authorized to do so and that procedures are being performed using the battery (and charger) manufacturers maintenance instructions. The said procedures must also be performed in compliance with government regulations (e.g. OHSA, ANSI, etc.). Do not allow distilled water temperature to exceed 110°F (43°C). Keep open flames away from battery. Never add acid to cells. Always add distilled water prior to charging and not after.

WARNING! : PROPER SAFETY DEVICES SUCH AS SAFETY GLASSES, APRON AND GLOVES MUST BE WORN WHEN WORKING WITH BATTERIES.



Records A weekly record should be kept showing hydrometer readings of pilot cell at start and at end of charge. Change to a different pilot cell monthly. Once a week after the battery has received an equalizing charge, record the hydrometer readings of all cells. Equalizing charge In order to equalize all the cells once a week, following a normal charge, the battery should be given a second charge, continued until there is no improvement between two consecutive hydrometer readings of each cell. This is actually a continuation of the regular charge at a low rate.

10.5 Battery Cable Connections

WARNING! : VERIFY PROPER BATTERY VOLTAGE AND POLARITY BEFORE MAKING CONNECTION

Figure 11 : Typical Cabling Arrangement For 4 - 12 Volt Batteries (Series / Parallel)

With Automatic Built-in Charger pack



11. Trouble Shooting Guide The following charts are intended to assist in identifying possible equipment malfunctions. NOTE: REPAIRS / TROUBLE SHOOTING SHOULD BE PERFORMED BY AN AUTHORIZED TECHNICIAN.

PROBLEM POSSIBLE CAUSE NO LIFT � Discharged battery (motor does not run) � Faulty wiring between pump motor and contactor � Faulty contactor for pump motor � Worn out brushes in pump motor

� Faulty wiring from battery positive terminal to pump contactor, or from pump contactor to pump motor.

� Defective control circuit fuse and/or main power fuse. NO LIFT � Discharged battery (motor runs) � Low hydraulic pressure � Pump check valve stuck open - Faulty solenoid valve � Check oil level if forks do not raise fully � Foreign material blocking lifting mechanism FORKS WILL NOT LOWER � Faulty control valve � Obstruction in chain/mast/carriage � Faulty control fuse blown (Push Button Control Only) � Faulty solenoid coil (Push Button Control Only) NO ELECTRICAL POWER � Discharged battery or � Loose/corroded battery connections NO TRAVEL � Blown main or control fuse � Faulty travel control switch � Faulty contactor or contactor tips � Check traction motor � Broken/loose drive belt � Faulty SB connector � Fault detected by controller causing shut down � Faulty Controller � Worn out brushes in pump motor

� Battery being removed from charger before recharging cycle is completed � Battery water level is too low to accept and hold a full charge � Battery capacity not adequate for workload required

TRUCK PERFORMS PROPERLY BUT REQUIRES CHARGING TOO FREQUENTLY

� Battery capacity reduced due to battery damage FORKS WILL NOT LIFT TO FULL HEIGHT

� Oil level low in oil reservoir. Refill oil reservoir, determine area of leakage

PUMP MAKES MORE NOISE � CAUTION: Use Only recommended oils THAN NORMAL LOSS OF BRAKING POWER � Brake requires adjustment. Must be performed by

qualified personnel only NOTE: Additional testing and diagnostics must be performed by authorized service personnel through

use of the diagnostics analysis tool in the controller programmer. Consult the manufacturer or an authorized dealer for more details and assistance.



12. Heavy Duty Stacker - Parts Listings



12.1 General Assembly Parts List

21 251314 10

3536

272829

111215

1314

9

1

19 20 3, 4, 5 16

30

25

31

27, 8 18 17 162020

3226

21 332324 25 6, 8

Figure 12 : General Assembly



General Assembly Parts List Item Qty Part No General Description Specific Description 1 1 142-5023 Body Weld't (Internal Hosing) 3000 1 1 142-5023-1 Body Weld't (Internal Hosing) 3000-130,150 FF 1 1 142-5000-4 Body Weld't (Internal Hosing) 3000-172 Full Free 2** 1 143-5074 Mast & Carriage Ass'y - 63"Lift 3000-63 2** 1 143-5074-1 Mast & Carriage Ass'y - 68� Lift 3000-68 2** 1 143-5053 Mast & Carriage Ass'y - 118� Lift 3000-118 2** 1 143-5067-2 Mast & Carriage Ass'y - 118� Lift 3000-130 Full Free 2** 1 143-5053-1 Mast & Carriage Ass'y - 130� Lift 3000-130 2** 1 143-5067 Mast & Carriage Ass'y - 130� Lift 3000-130 Full Free 2** 1 143-5053-2 Mast & Carriage Ass'y - 150� Lift 3000-150 2** 1 143-5114 Mast & Carriage Ass'y - 160� Lift 3000-160 2** 1 143-5076 Mast & Carriage Ass'y - 172� Lift 3000-172 Full Free 2** 1 143-5114-1 Mast & Carriage Ass'y - 180� Lift 3000-180 3 4 010-182 Capscrew, Hex Hd. 7/8" x 3"LG. 3000 3 4 011-164 Capscrew, Hex Hd. 7/8" x 3"LG. GR. 8 3000-172 Full Free 4 4 011-154 Nut, Hex - 7/8� - 9 (Heavy) 3000 5 4 012-022 Washer, Lock - 7/8" DIA. x .266" WD. 3000 6 1 142-5032 Assembly, Left Straddle 3000 7 1 142-5033 Assembly, Right Straddle 3000 8 2 014-010 Screw, Set - Hex Sock 3/4�-10 x 3/4" 3000 9 1 037-061-11 Shroud, Drive Unit (Black) 3000 9 1 037-061-1 Shroud, Drive Unit (Blue) 3000-172 Full Free 10 1 037-062-31 Dash Cover, Black - 3 Slot 3000 10 1 037-062-1 Dash Cover, (Yellow) 3000-172 Full Free 11 2 010-000 Capscrew, Hex Hd. 1/4"-20 x 3/4" 3000 12 2 012-202 Washer, Lock - 1/4" Helical 3000 13 6 011-631 Fastener, U-Type -1/4�-20 3000 14 6 011-020 Screw, Machine R/H - 1/4"-20 x 3/4" 3000 15 1 144-0010 Bar, Shroud Support 3000 16 2 143-5012-2 Assembly, Forged Fork - 42" 3000 16 2 041-086 Fork, Forged 1-1/2" x 4" x 42" 3000-172FF 17 1 103-913 Bar, Fork (32" Carriage Width) 3000 18 2 013-026 Cotter Pin - 3/16 X 2-1/4 3000 19 1 142-0026 Weight, Counter - 350lb 32"x12-7/8" 3000 20 2 132-0038 Stop (11-11/16"X3"Blank) 3000 20 2 132-0054 Pin, Battery Stop 3000-130FF, 172FF 21** 1 145-5002-2 Electrical Sub-Ass'y 3000 22 1 140-5010 Decal Kit, Eng./Spa 3000 23 2 143-0036 Guard, Hose (4-1/2"X2"Blank) 3000 24 4 011-104 Capscrew, Hex Skt/Btn Hd. - 1/4-20 x 1/2" 3000 * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE

Continued…



General Assembly Parts List

21 251314 10

3536

272829

111215

1314

9

1

19 20 3, 4, 5 16

30

25

31

27, 8 18 17 162020

3226

21 332324 25 6, 8

Figure 12 : General Assembly



General Assembly Parts List Item Qty Part No General Description Specific Description 25** 1 143-5075 Hydraulic Layout Mast/Reach -1stg 63" 3000-63 25** 1 143-5075-1 Hydraulic Layout Mast/Reach -1stg 68" 3000-68 25** 1 143-5104 Hydraulic Layout Mast/Reach -2stg 118" 3000-118 25** 1 143-5022-1 Hydraulic Layout Mast/Reach -2stg 130" 3000-130 25** 1 143-5104 Hydraulic Layout Mast/Reach -2stg 3000-2 Stage FF 25** 1 143-5022-2 Hydraulic Layout Mast/Reach -2stg 150" 3000-150 25** 1 143-5018 Hydraulic Layout Mast/Reach -3stg 160" 3000-160 25** 1 145-5025 Hydraulic Layout Mast/Reach -3stg 172" 3000-172 Full Free 25** 1 143-5018-1 Hydraulic Layout Mast/Reach -3stg 180" 3000-180 26** 1 145-5009 Body, Hyd. Layout � Internal Hose

Routing 3000 1&2 Stage

26** 1 145-5013 Body, Hyd. Layout � Internal Hose Routing 3000-3 Stage

26** 1 145-5011 Body, Hyd. Layout � Internal Hose Routing 3000-130, 150 FF

26** 1 145-5023 Body, Hyd. Layout � Internal Hose Routing 3000-172 Full Free

27 1 142-0020-6 Screen, Wire Mesh (42"LG.) 3000-63 27 1 142-0020-7 Screen, Wire Mesh (46"LG.) 3000-68 27 1 142-0020 Screen, Wire Mesh (42"LG.) 3000-118 27 1 142-0054 Screen, Wire Mesh (28"LG.) 3000-118 Full Free 27 1 142-0020-1 Screen, Wire Mesh (46"LG.) 3000-130 27 1 142-0054-1 Screen, Wire Mesh (34"LG.) 3000-130 Full Free 27 1 142-0020-2 Screen, Wire Mesh (42"LG.) 3000-150 27 1 142-0054-2 Screen, Wire Mesh (44"LG.) 3000-150 Full Free 27 1 142-0054 Screen, Wire Mesh (28"LG.) 3000-160 27 1 142-0020-1 Screen, Wire Mesh (46"LG.) 3000-172 Full Free 27 1 142-0054-1 Screen, Wire Mesh (34"LG.) 3000-180 28 4 011-124 Capscrew, Hex Soc, - #10-24 x 1/4" 3000 29 4 030-866 Clamp, 1/8" Dia.3/8" Wide 3000 30 1GA 039-095 Paint Hot Yellow Green 3000 31 .5GA 039-064-2 Paint, Flat Black 3000 32 1 010-044 Capscrew, Hex Hd. 1/2"-13 x 2� 3000-150 Full Free 32 2 010-085 Capscrew, Hex Hd. 1/2"-13 x 1-3/4� 3000-172 Full Free 33 1 011-650 Handle, Adjustable - Stud Type 1/2"-13 3000-150 Full Free 34 1 013-145 Clamp, Tube 3000-150 Full Free 35 4 011-623 Nut, Lock - 8/32" Nylon Insert 3000-150 Full Free 36 2 012-220 Washer, Lock 1/2" 3000-172 Full Free * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.2 Mast and Carriage Assembly - Single Stage

Figure 13 : Mast and Carriage Assembly - 63, 68" Lift Height



Mast and Carriage Ass'y - Single Stage Item Qty Part No General Description Specific Description ◄ - 143-5074 Mast & Carriage Ass'y - 63"Lift 3000-63 - 143-5074-1 Mast & Carriage Ass'y - 68� Lift 3000-68 1 1 143-5063 Mast Weld�t, (1stg,4-1/2"I-Beam)63"Lift] 3000-63 1 1 143-5063-1 Mast Weld�t, (1stg,4-1/2"I-Beam)68"Lift] 3000-68 2** 1 143-5026-3 Reach & Tilt Ass'y (1 Stg) 3000 Single Stage 3** 1 101-5004 Cylinder Ass'y (63"Lift) [1Stg] 3"Dia 3000-63 3** 1 101-5004-1 Cylinder Ass'y (68" Lift) [1Stg] 3"Dia 3000-68 4** 2 103-5030-13 Chain Ass'y - 41.5" LG 3000-63 4** 2 103-5030-12 Chain Ass'y - 46.5" LG 3000-68 5** 1 143-5015 Crosshead Ass'y (2 Stg) 3000 Single Stage 6 2 104-146 Block, Stop 3000 Single Stage 7 4 011-045 Capscrew, Hex Socket F/H 3/8-16 X 3/4" 3000 Single Stage 8 4 019-011 Bearing, Roller 3000 Single Stage 9 1 010-012 Capscrew, Hex Hd. 3/8�-16 X 3/4" 3000 Single Stage 10 1 012-201 Washer, Lock - 3/8"Dia.Helical 3000 Single Stage

* - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.2.1 Reach and Tilt Assembly - Single Stage

1 6 29

36

33

34

816

1119

1422

14, 22

1220

2528

32

4 3 5 303134

352

7

15

262728

303134

33 34

917

1018

Figure 14 : Reach and Tilt Assembly - 63, 68" Lift Height



Reach and Tilt Assembly Item Qty Part No General Description Specific Description ◄ - 143-5026-3 Reach & Tilt Ass'y (1 Stg) 3000 Single Stage 1* 1 143-5044-3 Carriage Weldm't, Inner Reach 3000 Single Stage 2* 4 103-5045 Roller, Side Thrust Ass'y 3000 Single Stage 3 4 103-0022 Roller, Side Thrust 3000 Single Stage 4 4 018-006 Bushing 3000 Single Stage 5 4 104-0005 Pin, Roller 3000 Single Stage 6* 1 143-5009 Leg, Scissor Ass'y [Bushing Style] 3000 Single Stage 7* 1 143-5010 Leg Ass'y - Left 3000 Single Stage 8 N.S.S. 120-227 Pin, Center 3000 Single Stage 9 1 143-0025 Leg, Outer Left 3000 Single Stage 10 1 143-0026 Leg, Inner Left 3000 Single Stage 11 1 013-012 Pin, Spring 1/4" X 2� 3000 Single Stage 12 1 018-070 Bushing - 1.25� ID X 1.5 Lg 3000 Single Stage 13 2 143-0027 Stud, Roller (2-7/16"Lg) 3000 Single Stage

14 3 012-286 Washer, Flat 1-1/4"IDx2-1/2"ODx1/16" Brass 3000 Single Stage

15* 1 143-5011 Leg Ass'y - Right 3000 Single Stage 16 N.S.S. 143-0058 Pin, Center 3000 Single Stage 17 1 143-0023 Leg, Outer Right 3000 Single Stage 18 1 143-0024 Leg, Inner Right 3000 Single Stage 19 1 013-012 Pin, Spring 1/4" X 2� 3000 Single Stage 20 1 018-070 Bushing - 1.25� ID X 1.5 Lg 3000 Single Stage 21 N.S.S. 143-0027 Stud, Roller (2-7/16"Lg) 3000 Single Stage


23 N.S.S. 143-0010 Bar, Crossmember 3000 Single Stage 24 4 018-061 Bushing - 1"ID x 1"Lg 3000 Single Stage 25* 4 785-863 Roller Ass'y 3000 Single Stage 26 1 018-026 Bushing 3000 Single Stage 27 1 116-035 Roller (1"LG./2.968"OD) 3000 Single Stage


29** 1 143-5055 Mast And Carriage Weldm't 3000 Single Stage 30 4 143-0022 Pin, Scissor Reach 3000 Single Stage 31 4 013-012 Pin, Spring - 1/4" X 2� 3000 Single Stage 32 4 019-011 Bearing, Roller 3000 Single Stage 33 1 018-000 Bushing 3000 Single Stage 34 1 018-061 Bushing 3000 Single Stage 35 2 018-001 Bushing 3000 Single Stage 36 2 018-010 Bushing 3000 Single Stage N.S.S. - Not Sold Separately - Due To Welding




12.2.2 Mast and Carriage Weldment Ass'y - Three Stage

6

5

67

5

76

15

98

3

17

6

11

14

12

16

14

141117

16

10

1

13

12

13

2

Figure 15 :Mast and Carriage Weldment Ass'y - 63", 68" Lift Height



Mast and Carriage Weldment Ass'y - Three Stage Item Qty Part No General Description Specific Description ◄ - 143-5055 Weldment, Mast And Carriage 3000 Single Stage 1 1 796-050 Carriage Ass'y (32"Wide) 3000 Single Stage 2 1 143-5054 Weldment, Outer Mast Reach 3000 Single Stage 3* 1 796-629 Actuator Ass'y For Tilt Forks 3000 Single Stage 4 1 796-590 Actuator Weldment 3000 Single Stage 5 2 104-208 Roller, Bottom (11"Lg) 3000 Single Stage 6 4 018-500 Bearing, 3/4�x1-5/8�x7/16� 3000 Single Stage 7 2 012-214 Washer, Flat Plain - 3/4" 3000 Single Stage 8 1 105-328 Pin, (32"Lg) 3000 Single Stage 9 1 100-140 Rod, Tilt Fork Actuator -32"Lg 3000 Single Stage 10 2 100-155 Spool, Tilt Fork Actuator - 2-7/8"Lg 3000 Single Stage 11 2 018-018 Bushing 3000 Single Stage 12 N.S.S. 100-149 Sleeve, End (1-1/2"Lg) 3000 Single Stage 13 2 013-012 Pin, Spring - 1/4� x 2� 3000 Single Stage 14 6 018-017 Bushing 3000 Single Stage 15 2 013-066 Pin, Spring - 5/32� x 1-1/4� 3000 Single Stage 16 N.S.S. 104-118 Bracket, Upper Cylinder 3000 Single Stage 17 N.S.S. 105-392 Bracket, Pivot 3000 Single Stage N.S.S. - Not Sold Separately - Due To Welding




12.2.3 Lift Cylinder Assembly - Single Stage

Figure 16 : Lift Cylinder Assembly - 63", 68" Lift Height



Lift Cylinder Assembly - Single Stage Item Qty Part No General Description Specific Description ◄ - 101-5004 Cylinder Ass'y (63"Lift) [1Stg] 3"Dia 3000-63 - - 101-5004-1 Cylinder Ass'y (68" Lift) [1Stg] 3"Dia 3000-68 1 1 101-0003 Ram, 2� Dia. x 37-3/8� LG. 3000-63� 1 101-0003-1 Ram, 2� Dia. x 39-7/8� LG. 3000-68� 2 1 101-5000 Weldment, Housing 3� ID 3000-63� 2 101-5000-1 Weldment, Housing 3� ID 3000-68� 3 1 117-991 Nut, Head 3000 - Single Stage 4 1 114-978 Washer, Piston 3000 - Single Stage 5 1 114-640 Piston, 3� Dia 3000 - Single Stage 6● 1 036-153 Ring, Wear 3000 - Single Stage 7● 1 036-150 Ring, Wear 3000 - Single Stage 8● 1 036-133 �O�-Ring 3000 - Single Stage 9● 1 036-119 �U�-Cup 3000 - Single Stage 10● 1 036-108 �O�-Ring 3000 - Single Stage 11● 1 036-021 Wiper, Rod 3000 - Single Stage 12● 1 117-993 Gasket 3000 - Single Stage 13 1 011-530 Nut, Jam 3/4�-10 3000 - Single Stage 14● 1 036-176 �O�-Ring 3000 - Single Stage - - 783-553 Kit, Seal Includes Items marked (●) 3000 - Single Stage



12.2.4 Chain Assembly - Single Stage

1

4

2

3

4

3

2

5

5

Figure 17 : Chain Assembly - 63", 68" Lift Height



Chain Assembly - Single Stage Item Qty Part No General Description Specific Description ◄ - 103-5030-13 Chain Ass'y - 41.5" LG 3000-63 - - 103-5030-12 Chain Ass'y - 46.5" LG 3000-68 1 1 090-067-0414 Leaf, Chain - 41-1/2"LG 3000-63 1 1 090-067-0464 Leaf, Chain - 46-1/2"LG 3000-68 2 2 104-532 Clevis 3000 - Single Stage 3 2 105-372 Pin, Clevis 0.2"OD x 1-1/4"LG. 3000 - Single Stage 4 2 013-015 Pin, Cotter Pin 1/16� x 3/4" 3000 - Single Stage 5 2 011-535 Nut, Hex 3/4"-10 Nylon Insert 3000 - Single Stage



12.2.5 Crosshead Assembly - Single Stage

10

8

9

7

3

45

3

6

2

1

Figure 18 : Crosshead Assembly - 63", 68" Lift Height



Crosshead Assembly - Single Stage Item Qty Part No General Description Specific Description ◄ - 143-5015 Crosshead Ass'y (2 Stg) 3000 - 1 & 2 Stage 1 1 143-5021 Crosshead Weld (2 Stg) 3000 - 1 & 2 Stage 2 1 103-250 Crosshead Pin 3000 - 1 & 2 Stage 3 6 114-336 Flat Spacer Washer 3000 - 1 & 2 Stage

4 2 792-306 Chain Roller (7/8"Id 1-1/4"Od) C/W Bushing 3000 - 1 & 2 Stage

5 1 100-019 Chain Roller 7/8"ID 3000 - 1 & 2 Stage 6 1 018-027 Bushing 3000 - 1 & 2 Stage 7 2 013-036 Retaining Ring Ext. - 1-1/4"Id 3000 - 1 & 2 Stage 8 6 143-0033 Pulley, Hose (1.5"X1.469") 3000 - 1 & 2 Stage 9 6 011-080 Screw, Hex Sck Shoulder - 1/2" X 1-1/2"Lg. 3000 - 1 & 2 Stage 10 1 014-005 Screw, Set Sck Cp - 3/8�-16 X 3/8" 3000 - 1 & 2 Stage



12.3 Mast and Carriage Assembly - 2 Stage

Figure 19 : Mast and Carriage Assembly - 118", 130", 150" Lift Height



Mast and Carriage Assembly - 2 Stage Item Qty Part No General Description Specific Description ◄ - 143-5053 Mast & Carriage Ass'y - 118� Lift 3000-118 - - 143-5053-1 Mast & Carriage Ass'y - 130� Lift 3000-130 - - 143-5053-2 Mast & Carriage Ass'y - 150� Lift 3000-150

1 1 143-5024 Outer Mast Weldm't (118"Lg) 2 Stg) 3000-118 1 1 143-5024-1 Outer Mast Weldm't (130"Lg) 2 Stg) 3000-130 1 1 143-5024-2 Outer Mast Weldm't (150"Lg) 2 Stg) 3000-150 2 1 143-5059 Mast Weldment, Inner (118"Lg) 2 Stg 3000-118 2 1 143-5059-1 Mast Weldment, Inner (130"Lg) 2 Stg 3000-130 2 1 143-5059-2 Mast Weldment, Inner (150"Lg) 2 Stg 3000-150 3** 1 143-5026 Reach & Tilt Ass'y (2 Stg) 3000 � 2 Stage 4** 1 101-5004-2 Cylinder Ass'y (118"LH) [2stg] 3" Dia 3000-118 4** 1 101-5004-3 Cylinder Ass'y (130"LH) [2stg] 3" Dia 3000-130 4** 1 101-5004-4 Cylinder Ass'y (150"LH) [2stg] 3" Dia 3000-150 5** 2 103-5030 Chain Ass'y 71.5" Long 3000-118 5** 2 103-5030-1 Chain Ass'y 76.5" Long 3000-130 5** 2 103-5030-18 Chain Ass'y 86.5" Long 3000-150 6** 1 143-5015 Crosshead Ass'y (2 Stg) 3000 � 2 Stage 7 1 118-934 Base 3000 � 2 Stage 8 2 103-304 Guide Rod (Red Channel) 3000 � 2 Stage 9 2 011-520 Nut, Hex Plated - 1/2"-20 3000 � 2 Stage 10 2 011-533 Nut, Hex - 1/2"-20 Nylon Insert 3000 � 2 Stage 11 2 012-230 Washer, Lock - 1/2" Internal Tooth 3000 � 2 Stage 12 4 019-011 Bearing, Roller 3000 � 2 Stage 13 2 010-048 Capscrew, Hex Hd. 1/2"-13 X 1-1/2" 3000 � 2 Stage 14 2 012-220 Washer, Lock 1/2" Split Reg 3000 � 2 Stage 15 1 010-012 Capscrew, Hex Hd. 3/8-16 X 3/4" 3000 � 2 Stage 16 1 012-201 Washer, Lock- 3/8"Dia.Helical 3000 � 2 Stage




12.3.1 Reach and Tilt Assembly - Two Stage

1 6 29

36

33

34

816

1119

1422

14, 22

1220

2528

32

4 3 5 303134

352

7

15

262728

303134

33 34

917

1018

Figure 20 : Reach and Tilt Assembly - 118", 130", 150" Lift Height



Reach and Tilt Assembly - Two Stage Item Qty Part No General Description Specific Description ◄ - 143-5026 Reach & Tilt Ass'y (2 Stg) 3000 � 2 Stage 1* 1 143-5044 Carriage Weldm't, Inner Reach 3000 � 2 Stage 2* 4 103-5045 Roller, Side Thrust Ass'y 3000 � 2 Stage 3 4 103-0022 Roller, Side Thrust 3000 � 2 Stage 4 4 018-006 Bushing 3000 � 2 Stage 5 4 104-0005 Pin, Roller 3000 � 2 Stage 6* 1 143-5009 Leg, Scissor Ass'y [Bushing Style] 3000 � 2 Stage 7* 1 143-5010 Leg Ass'y - Left 3000 � 2 Stage 8 N.S.S. 120-227 Pin, Center 3000 � 2 Stage 9 1 143-0025 Leg, Outer Left 3000 � 2 Stage 10 1 143-0026 Leg, Inner Left 3000 � 2 Stage 11 1 013-012 Pin, Spring 1/4" X 2� 3000 � 2 Stage 12 1 018-070 Bushing - 1.25� ID X 1.5 Lg 3000 � 2 Stage 13 N.S.S. 143-0027 Stud, Roller (2-7/16"Lg) 3000 � 2 Stage

14 3 012-286 Washer, Flat 1-1/4"IDx2-1/2"ODx1/16" Brass

3000 � 2 Stage

15* 1 143-5011 Leg Ass'y - Right 3000 � 2 Stage 16 N.S.S. 143-0058 Pin, Center 3000 � 2 Stage 17 1 143-0023 Leg, Outer Right 3000 � 2 Stage 18 1 143-0024 Leg, Inner Right 3000 � 2 Stage 19 1 013-012 Pin, Spring 1/4" X 2� 3000 � 2 Stage 20 1 018-070 Bushing - 1.25� ID X 1.5 Lg 3000 � 2 Stage 21 N.S.S. 143-0027 Stud, Roller (2-7/16"Lg) 3000 � 2 Stage


3000 � 2 Stage

23 N.S.S. 143-0010 Bar, Crossmember 3000 � 2 Stage 24 4 018-061 Bushing - 1"ID x 1"Lg 3000 � 2 Stage 25* 4 785-863 Roller Ass'y 3000 � 2 Stage 26 1 018-026 Bushing 3000 � 2 Stage 27 1 116-035 Roller (1"LG./2.968"OD) 3000 � 2 Stage


3000 � 2 Stage

29** 1 143-5055 Mast And Carriage Weldm't 3000 � 2 Stage 30 4 143-0022 Pin, Scissor Reach 3000 � 2 Stage 31 4 013-012 Pin, Spring - 1/4" X 2� 3000 � 2 Stage 32 4 019-011 Bearing, Roller 3000 � 2 Stage 33 1 018-000 Bushing 3000 � 2 Stage 34 1 018-061 Bushing 3000 � 2 Stage 35 2 018-001 Bushing 3000 � 2 Stage 36 2 018-010 Bushing 3000 � 2 Stage N.S.S. - Not Sold Separately - Due To Welding * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.3.2 Mast and Carriage Weldment Ass'y - Two Stage

6

5

67

5

76

15

98

3

17

6

11

14

12

16

14

141117

16

10

1

13

12

13

2

Figure 21 : 3000 Mast and Carriage Weldment Ass'y - 115", 130, 150" Lift Height



Mast and Carriage Weldment Ass'y - Two Stage Item Qty Part No General Description Specific Description ◄ - 143-5055 Weldment, Mast And Carriage 3000 � 2 Stage 1 1 796-050 Carriage Ass'y (32"Wide) 3000 � 2 Stage 2 1 143-5054 Weldment, Outer Mast Reach 3000 � 2 Stage 3* 1 796-629 Actuator Ass'y For Tilt Forks 3000 � 2 Stage 4 1 796-590 Actuator Weldment 3000 � 2 Stage 5 2 104-208 Roller, Bottom (11"Lg) 3000 � 2 Stage 6 4 018-500 Bearing, 3/4�x1-5/8�x7/16� 3000 � 2 Stage 7 2 012-214 Washer, Flat Plain - 3/4" 3000 � 2 Stage 8 1 105-328 Pin, (32"Lg) 3000 � 2 Stage 9 1 100-140 Rod, Tilt Fork Actuator -32"Lg 3000 � 2 Stage 10 2 100-155 Spool, Tilt Fork Actuator - 2-7/8"Lg 3000 � 2 Stage 11 2 018-018 Bushing 3000 � 2 Stage 12 N.S.S. 100-149 Sleeve, End (1-1/2"Lg) 3000 � 2 Stage 13 2 013-012 Pin, Spring - 1/4� x 2� 3000 � 2 Stage 14 6 018-017 Bushing 3000 � 2 Stage 15 2 013-066 Pin, Spring - 5/32� x 1-1/4� 3000 � 2 Stage 16 N.S.S. 104-118 Bracket, Upper Cylinder 3000 � 2 Stage 17 N.S.S. 105-392 Bracket, Pivot 3000 � 2 Stage N.S.S. - Not Sold Separately - Due To Welding * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.3.3 Lift Cylinder Assembly - Two Stage

Figure 22 : Lift Cylinder Assembly - 115", 130, 150" Lift Height



Lift Cylinder Assembly - Two Stage Item Qty Part No General Description Specific Description ◄ - 101-5004-2 Cylinder Ass'y (118"LH) [2stg] 3" Dia 3000-118 - - 101-5004-3 Cylinder Ass'y (130"LH) [2stg] 3" Dia 3000-130 - - 101-5004-4 Cylinder Ass'y (150"LH) [2stg] 3" Dia 3000-150 1 1 101-0003-2 Ram, 2� Dia. x 67-3/4� LG. 3000-118 1 1 101-0003-3 Ram, 2� Dia. x 72-3/4� LG. 3000-130 1 1 101-0003-4 Ram, 2� Dia. x 82-3/4� LG. 3000-150 2 1 101-5001-2 Weldment, Housing 3� ID 3000-118 1 1 101-5001-3 Weldment, Housing 3� ID 3000-130 2 1 101-5001-4 Weldment, Housing 3� ID 3000-150 3 1 117-991 Nut, Head 3000 - 2 Stage 4 1 114-978 Washer, Piston 3000 - 2 Stage 5 1 114-640 Piston, 3� Dia 3000 - 2 Stage 6● 1 036-153 Ring, Wear 3000 - 2 Stage 7● 1 036-150 Ring, Wear 3000 - 2 Stage 8● 1 036-133 �O�-Ring 3000 - 2 Stage 9● 1 036-119 �U�-Cup 3000 - 2 Stage 10● 1 036-108 �O�-Ring 3000 - 2 Stage 11● 1 036-021 Wiper, Rod 3000 - 2 Stage 12● 1 117-993 Gasket 3000 - 2 Stage 13 1 011-530 Nut, Jam 3/4�-10 3000 - 2 Stage 14● 1 036-176 �O�-Ring 3000 - 2 Stage - - 783-553 Kit, Seal Includes Items marked (●) 3000 - 2 Stage



12.3.4 Chain Assembly - 2 Stage

1

4

2

3

4

3

2

5

5

Figure 23 : Chain Assembly - 118", 130", 150" Lift Height



Chain Assembly - 2 Stage Item Qty Part No General Description Specific Description ◄ - 103-5030 Chain Ass'y 71.5" Long 3000-118 - - 103-5030-1 Chain Ass'y 76.5" Long 3000-130 - - 103-5030-18 Chain Ass'y 86.5" Long 3000-150 1 1 090-067-0714 Leaf, Chain - 71-1/2"LG 3000-118 1 1 090-067-0764 Leaf, Chain - 76-1/2"LG 3000-130 1 1 090-067-0864 Leaf, Chain - 86-1/2"LG 3000-150 2 2 104-532 Clevis 3000 - 2 Stage 3 2 105-372 Pin, Clevis 0.2"OD x 1-1/4"LG. 3000 - 2 Stage 4 2 013-015 Pin, Cotter Pin 1/16� x 3/4" 3000 - 2 Stage 5 2 011-535 Nut, Hex 3/4"-10 Nylon Insert 3000 - 2 Stage



12.3.5 Crosshead Assembly - 2 Stage

10

8

9

7

3

45

3

6

2

1

Figure 24 : Crosshead Assembly - 118", 130", 150" Lift Height



Crosshead Assembly - 2 Stage Item Qty Part No General Description Specific Description ◄ - 143-5015 Crosshead Ass'y (2 Stg) 3000 - 1 & 2 Stage 1 1 143-5021 Crosshead Weld (2 Stg) 3000 - 1 & 2 Stage 2 1 103-250 Crosshead Pin 3000 - 1 & 2 Stage 3 6 114-336 Flat Spacer Washer 3000 - 1 & 2 Stage 4 2 792-306 Chain Roller (7/8"Id 1-1/4"Od) C/W Bushing 3000 - 1 & 2 Stage 5 1 100-019 Chain Roller 7/8"ID 3000 - 1 & 2 Stage 6 1 018-027 Bushing 3000 - 1 & 2 Stage 7 2 013-036 Retaining Ring Ext. - 1-1/4"Id 3000 - 1 & 2 Stage 8 6 143-0033 Pulley, Hose (1.5"X1.469") 3000 - 1 & 2 Stage 9 6 011-080 Screw, Hex Sck Shoulder - 1/2" X 1-1/2"Lg. 3000 - 1 & 2 Stage 10 1 014-005 Screw, Set Sck Cp - 3/8�-16 X 3/8" 3000 - 1 & 2 Stage * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.4 Mast and Carriage Assembly - 2 Stage Full Free

Figure 25 : Full Free Mast and Carriage Assembly - 130" Lift Height



Mast and Carriage Assembly - 2 Stage Full Free Item Qty Part No General Description Specific Description ◄ - 143-5067 Mast & Carriage Ass'y - 130� Lift 3000-130 Full Free 1 1 143-5105-1 Outer Mast Assy - 2 Stg R&T 130" 3000-130" Full Free 2 1 143-5106-1 Inner Mast Assy � 2 Stg R&T 130" 3000-130" Full Free 3** 1 143-5026-1 Reach & Tilt Ass'y (2 Stg FF) 3000-130" Full Free 4** 1 783-199-1 Cylinder Ass'y 130"LH - FF 3000-130" Full Free 5** 2 780-275 Cyl. Ass'y - Outbrd 1-1/2"Dia. 2 Stg FF 3000-130" Full Free 6** 2 103-5030-23 Chain Ass'y - 45.5" Long 3000-130" Full Free 7** 1 143-5015-2 Crosshead Ass'y (2 Stg FF) 3000-130" Full Free 8 4 019-011 Bearing, Roller 3000-130" Full Free 9 1 143-0136 Hook, Pawl 3000-130" Full Free 10 2 118-940 Bracket, Cylinder Bracket - Outer Mast 3000-130" Full Free 11 1 143-5116 Bracket, Pawl 3000-130" Full Free 12 1 200-00805 Extrusion, Aluminum 3000-130" Full Free 13 7 010-036 Capscrew, Hex Hd. 5/16�-18 x 1/2" 3000-130" Full Free 14 7 012-200 Washer, Lock - 5/16" - Helical 3000-130" Full Free 15 4 010-048 Capscrew, Hex Hd. - 1/2"-13 x 1 1/2" 3000-130" Full Free 16 4 012-220 Washer, Lock - ½" Split Reg. 3000-130" Full Free 17 1 012-238 Washer, Spacer-1/2"ID x 1"OD x 5/64�THK. 3000-130" Full Free 18 2 011-649 Screw, Hex- 1/2"x5/8" (3/8"-16thrd) Sck. Sh. 3000-130" Full Free 19 2 104-146 Block, Stop 3000-130" Full Free 20 4 011-049 Capscrew, Hex Sck F/H 1/2"-13 x 1" 3000-130" Full Free




12.4.1 Reach and Tilt Assembly - 2 Stage Full Free

1 6 29

36

33

34

816

1119

1422

14, 22

1220

2528

32

4 3 5 303134

352

7

15

262728

303134

33 34

917

1018

Figure 26 : Reach and Tilt Assembly - 130" Lift Height, Full Free Mast



Reach and Tilt Assembly - 130" Lift Height Item Qty Part No General Description Specific Description ◄ - 143-5026-1 Reach & Tilt Ass'y (2 Stg FF) 3000 - 2 Stg FF 1 1 143-5044-1 Carriage Weldm't, Inner Reach 3000 - 2 Stg FF 2* 4 103-5045 Roller, Side Thrust Ass'y 3000 - 2 Stg FF 3 4 103-0022 Roller, Side Thrust 3000 - 2 Stg FF 4 4 018-006 Bushing 3000 - 2 Stg FF 5 4 104-0005 Pin, Roller 3000 - 2 Stg FF 6* 1 143-5009 Leg, Scissor Ass'y [Bushing Style] 3000 - 2 Stg FF 7* 1 143-5010 Leg Ass'y - Left 3000 - 2 Stg FF 8 N.S.S. 120-227 Pin, Center 3000 - 2 Stg FF 9 1 143-0025 Leg, Outer Left 3000 - 2 Stg FF 10 1 143-0026 Leg, Inner Left 3000 - 2 Stg FF 11 1 013-012 Pin, Spring 1/4" X 2� 3000 - 2 Stg FF 12 1 018-070 Bushing - 1.25� ID X 1.5 Lg 3000 - 2 Stg FF 13 2 143-0027 Stud, Roller (2-7/16"Lg) 3000 - 2 Stg FF


3000 - 2 Stg FF

15* 1 143-5011 Leg Ass'y - Right 3000 - 2 Stg FF 16 N.S.S. 143-0058 Pin, Center 3000 - 2 Stg FF 17 1 143-0023 Leg, Outer Right 3000 - 2 Stg FF 18 1 143-0024 Leg, Inner Right 3000 - 2 Stg FF 19 1 013-012 Pin, Spring 1/4" X 2� 3000 - 2 Stg FF 20 1 018-070 Bushing - 1.25� ID X 1.5 Lg 3000 - 2 Stg FF 21 2 143-0027 Stud, Roller (2-7/16"Lg) 3000 - 2 Stg FF


3000 - 2 Stg FF

23 N.S.S. 143-0010 Bar, Crossmember 3000 - 2 Stg FF 24 4 018-061 Bushing - 1"ID x 1"Lg 3000 - 2 Stg FF 25* 4 785-863 Roller Ass'y 3000 - 2 Stg FF 26 1 018-026 Bushing 3000 - 2 Stg FF 27 1 116-035 Roller (1"LG./2.968"OD) 3000 - 2 Stg FF


3000 - 2 Stg FF

29** 1 143-5055 Mast And Carriage Weldm't 3000 - 2 Stg FF 30 4 143-0022 Pin, Scissor Reach 3000 - 2 Stg FF 31 4 013-012 Pin, Spring - 1/4" X 2� 3000 - 2 Stg FF 32 4 019-011 Bearing, Roller 3000 - 2 Stg FF 33 1 018-000 Bushing 3000 - 2 Stg FF 34 1 018-061 Bushing 3000 - 2 Stg FF 35 2 018-001 Bushing 3000 - 2 Stg FF 36 2 018-010 Bushing 3000 - 2 Stg FF

N.S.S. - Not Sold Separately - Due To Welding * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE




6

5

67

5

76

15

98

3

17

6

11

14

12

16

14

141117

16

10

1

13

12

13

2

Figure 27 : Mast and Carriage Weldment Ass'y - 130" Lift Height, Full Free Mast



Mast and Carriage Weldment Ass'y - Three Stage Item Qty Part No General Description Specific Description ◄ - 143-5055 Weldment, Mast And Carriage 3000 - 2 Stg FF 1 1 796-050 Carriage Ass'y (32"Wide) 3000 - 2 Stg FF 2 1 143-5054 Weldment, Outer Mast Reach 3000 - 2 Stg FF 3* 1 796-629 Actuator Ass'y For Tilt Forks 3000 - 2 Stg FF 4 1 796-590 Actuator Weldment 3000 - 2 Stg FF 5 2 104-208 Roller, Bottom (11"Lg) 3000 - 2 Stg FF 6 4 018-500 Bearing, 3/4�x1-5/8�x7/16� 3000 - 2 Stg FF 7 2 012-214 Washer, Flat Plain - 3/4" 3000 - 2 Stg FF 8 1 105-328 Pin, (32"Lg) 3000 - 2 Stg FF 9 1 100-140 Rod, Tilt Fork Actuator -32"Lg 3000 - 2 Stg FF 10 2 100-155 Spool, Tilt Fork Actuator - 2-7/8"Lg 3000 - 2 Stg FF 11 N.S.S. 018-018 Bushing 3000 - 2 Stg FF 12 2 100-149 Sleeve, End (1-1/2"Lg) 3000 - 2 Stg FF 13 2 013-012 Pin, Spring - 1/4� x 2� 3000 - 2 Stg FF 14 6 018-017 Bushing 3000 - 2 Stg FF 15 2 013-066 Pin, Spring - 5/32� x 1-1/4� 3000 - 2 Stg FF 16 N.S.S. 104-118 Bracket, Upper Cylinder 3000 - 2 Stg FF 17 N.S.S. 105-392 Bracket, Pivot 3000 - 2 Stg FF

N.S.S. - Not Sold Separately - Due To Welding



12.4.3 Lift Cylinder Assembly - 2 Stage Full Free

Figure 28 : Lift Cylinder Assembly - 130" Lift Height, Full Free Mast



Lift Cylinder Assembly - 2 Stage 130 Full Free Item Qty Part No General Description Specific Description ◄ - 783-199-1 Cylinder Ass'y 130"LH - FF 3000-130 Full Free 1 1 118-948 Ram (1-1/2"Dia) 41-7/8"Lg 3000 - 130 Full Free 2 1 783-103-1 Weldment, Housing (3"ID) 3000 - 130 Full Free 3 1 118-389 Nut, Head - 3" Dia. Cyl (1-1/2" Dia.Rod) 3000 - 130 Full Free 4 1 114-978 Washer, Piston 3000 - 130 Full Free 5 1 114-640 Piston - 3"Dia Cyl (2.9670+-.0020dia) 3000 - 130 Full Free 6 1 011-530 Nut, Hex Jam Plated - 3/4"-10 3000 - 130 Full Free 7 1 090-779-0024 Tube, Seaml. (2-1/2"Lg) 3000 - 130 Full Free 8● 1 036-180 O-Ring 3000 - 130 Full Free 9● 1 117-993 Gasket 3000 - 130 Full Free 10● 1 036-098 Wiper, 1-3/4� OD x 1-1/2� 3000 - 130 Full Free 11● 1 036-108 O-Ring - 3/4"OD x 5/8"ID X 1/16" 3000 - 130 Full Free 12● 1 036-112 U-Cup 3� x 2-3/8� x 1/2" 3000 - 130 Full Free 13● 1 036-132 O-Ring 3"OD x 2-3/4"ID 3000 - 130 Full Free 14● 1 036-143 Ring, Rod Wear 3000 - 130 Full Free 15● 1 036-154 Ring, Wear Piston � 3� x 1/2" 3000 - 130 Full Free - - 783-536 Kit, Seal - Includes Items marked (●) 3000 - 130 Full Free



12.4.4 Outboard Cylinder Assembly - 2 Stage Full Free

Figure 29 : Outboard Lift Cylinder Assembly - 130" Lift Height, Full Free Mast



Outboard Cylinder Assembly - 2 Stage Full Free Item Qty Part No General Description Specific Description ◄ - 780-275 Cylinder Ass'y Outbrd 1-1/2"Dia. 2 Stg FF BGN30/40 - 130 FF 1 1 118-960 Ram, (1-1/4"Dia) Outboard BGN30/40 - 130 FF 2 1 783-198 Weldment, Housing Weld (1.5"Dia) Outbrd BGN30/40 - 130 FF 2 1 783-198-1 Weldment, Housing Weld (1.5"Dia) Outbrd BGN30/40 - 150 FF 3 1 118-969 Nut, Head - (2-3/8"Dia.) BGN30/40-130,150 FF 4 1 105-880 Washer, Spacer - 3/4" x 1-3/16� x 1/8� BGN30/40-130,150 FF 5 1 118-968 Piston - F.F. Lift BGN30/40-130,150 FF 6● 2 036-192 Ring, Wear - 1-1/2"OD x 1-1/8"ID x 1/2"W BGN30/40-130,150 FF 7● 1 036-135 O-Ring - 1.25 x 1.5 x .139 BGN30/40-130,150 FF 8● 1 036-180 O-Ring (Reciprocating) BGN30/40-130,150 FF 9● 1 036-158 U-Cup - 1"ID x 1-1/2�OD x 3/8� BGN30/40-130,150 FF 10● 1 036-108 O-Ring - 3/4"OD x 5/8"ID x 1/16" BGN30/40-130,150 FF 11● 1 036-018 Wiper, Rod - Polyurethane AN-13 1-1/4� ID BGN30/40-130,150 FF 12 1 034-515 Fitting,90° Elbow -1/4" Pipe Trd BGN30/40-130,150 FF 13● 1 118-368 Gasket - 2" Dia Cyl BGN30/40-130,150 FF 14 1 011-530 Nut, Hex Jam - 3/4"-10 BGN30/40-130,150 FF - - 783-173 Kit, Seal - Includes Items marked (●) BGN30/40-130,150 FF



12.4.5 Chain Assembly - 2 Stage 130" Lift Height

1

4

2

3

4

3

2

5

5

Figure 30 : Chain Assembly - 130" Lift Height, Full Free Mast



Chain Assembly - 2 Stage 130" Lift Height Item Qty Part No General Description Specific Description ◄ - 103-5030-23 Chain Ass'y - 45.5" Long 3000 - 130 Full Free 1 1 090-067-0454 Chain Leaf (45-1/2"LG.) 3000 - 130 Full Free 2 2 104-532 Clevis 3000 - 130 Full Free 3 2 105-372 Clevis Pin 0.2"O.D. X 1-1/4"LG 3000 - 130 Full Free 4 2 013-015 Cotter Pin - 1/16� X 3/4" 3000 - 130 Full Free 5 2 011-535 Nut, Hex - 3/4"-10 Nylon Insert 3000 - 130 Full Free



12.4.6 Crosshead Assembly - 2 Stage 130" Lift Height

10

8

9

7

3

45

3

6

2

1

Figure 31 : Crosshead Assembly - 130" Lift Height, Full Free Mast



Crosshead Assembly - 2 Stage 130" Lift Height Item Qty Part No General Description Specific Description ◄ - 143-5015-2 Crosshead Ass'y (2 Stg FF) 3000 - 130 Full Free 1 1 143-5021-2 Weldment, Crosshead (2stg FF) 3000 - 130 Full Free 2 1 103-250 Pin, Crosshead 3000 - 130 Full Free 3 6 114-336 Washer, Flat Spacer 3000 - 130 Full Free

4 2 792-306 Roller, Chain (7/8"ID x 1-1/4"OD) C/W Bushing

3000 - 130 Full Free

5* 1 100-019 Roller, Chain 7/8� ID 3000 - 130 Full Free 6 1 018-027 Bushing 3000 - 130 Full Free 7 2 013-036 Ring, Retaining Ext. - 1-1/4"ID 3000 - 130 Full Free 8 2 143-0033 Pulley, Hose - Int. (1.5" x 1.469") 3000 - 130 Full Free 9 6 011-080 Screw, Shoulder -1/2� x 1-1/2", Lg. Hex Sck. 3000 - 130 Full Free 10 6 014-005 Setscrew, Socket Cup Point - 3/8�-16 x 3/8" 3000 - 130 Full Free * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.5 Mast and Carriage Assembly - 3 Stage 160, 180" Lift

3

2

1

78

18

1920

3

2

1

6

15, 1617

72522, 23242152614, 15

13

4

74

9

101112

5

Figure 32 : Mast and Carriage Assembly - 160", 180" Lift Height



Mast and Carriage Assembly - 3 Stage 160. 180 " Lift Height Item Qty Part No General Description Specific Description ◄ - 143-5114 Mast & Carriage Ass'y - 160� Lift 3000-160 - 143-5114-1 Mast & Carriage Ass'y - 180� Lift 3000-180 1 1 143-5112 Outer Mast Weldment 3 Stg R&T 3000-160 1 1 143-5112-1 Outer Mast Weldment 3 Stg R&T 3000-180 2 1 143-5111 Center Mast Weldment 3stg R&T 3000-160 2 1 143-5111-1 Center Mast Weldment 3stg R&T 3000-180 3 1 143-5045 Mast Weldm't Inner (160"Lg) 3000-160 3 1 143-5045-1 Mast Weldm't Inner (180"Lg) 3000-180 4** 2 103-5030-16 Chain Ass'y 74-1/2"LG 160" 3Stg 3000-160 4** 2 103-5030-17 Chain Ass'y 79-1/2"LG 180" 3Stg 3000-180 5** 2 103-5030-19 Chain Ass'y 133.5" Long 3000-160 5** 2 103-5030-20 Chain Ass'y 143" Long 3000-180 6** 1 101-5005 Cylinder Ass'y (3-1/2"Dia) 160"LH/3Stg 3000-160 6** 1 101-5005-2 Cylinder Ass'y (3-1/2"Dia) 180"LH/3Stg 3000-180 7** 1 143-5026-2 Reach & Tilt Ass'y (3 Stg) 3000-160,180-3 Stg. 8** 1 143-5015-1 Crosshead Ass' y (3 Stg) 3000-160,180-3 Stg. 9 2 103-304 Guide Rod (Red Channel) 3000-160,180-3 Stg. 10 2 011-520 Nut, Hex - 1/2"-20 3000-160,180-3 Stg. 11 2 011-533 Nut, Hex - 1/2"-20 Nylon Insert 3000-160,180-3 Stg. 12 2 012-230 Washer, Lock - ½" Internal Tooth 3000-160,180-3 Stg. 13 6 019-011 Bearing, Roller 3000-160,180-3 Stg. 14 1 010-012 Capscrew, Hex Hd. 3/8�-16 x 3/4" 3000-160,180-3 Stg. 15 3 012-201 Washer, Lock - 3/8"Dia.Helical 3000-160,180-3 Stg. 16 2 010-040 Capscrew, Hex Hd. 3/8�-16 x 1-1/2" 3000-160,180-3 Stg. 17 1 143-5071 Bar, Stop Weld (5" x 1-1/4") 3000-160,180-3 Stg. 18 1 118-934 Base 3000-160,180-3 Stg. 19 2 010-048 Capscrew, Hex Hd. - 1/2"-13 x 1-1/2" 3000-160,180-3 Stg. 20 2 012-220 Washer, Lock - ½" Split Reg. 3000-160,180-3 Stg. 21 2 120-845 Pin, Crosshead (3.900"LG) 3000-160,180-3 Stg. 22 2 792-306 Roller, Chain-7/8"IDx1-1/4"OD (c/wBushing) 3000-160,180-3 Stg. 23 4 114-336 Washer, Flat Spacer 3000-160,180-3 Stg. 24 2 013-036 Retaining Ring Ext. 1-1/4"ID 3000-160,180-3 Stg. 25 2 014-002 Screw, Set - 1/4"X 3/8" 3000-160,180-3 Stg. 26 2 011-530 Nut, Hex Jam - ¾"-10 3000-160,180-3 Stg.




12.5.1 Mast Chain Assembly - 3 Stage 160. 180 " Lift Height

5

4

2

3

1

5

4

2

3

Figure 33 : Mast Chain Assembly - 160", 180" Lift Height



Mast Chain Assembly - 3 Stage 160. 180 " Lift Height Item Qty Part No General Description Specific Description ◄ - 103-5030-16 Chain Ass'y 74-1/2"LG 160" 3Stg 3000-160 - - 103-5030-17 Chain Ass'y 79-1/2"LG 180" 3Stg 3000-180 1 1 090-067-0744 Leaf, Chain (74-1/2"Lg) 3000-160 1 1 090-067-0794 Leaf, Chain (79-1/2"Lg) 3000-160 2 2 104-532 Clevis 3000-160 3 2 105-372 Pin, Clevis 0.2"O.D. X 1-1/4"Lg 3000-160 4 2 013-015 Pin, Cotter - 1/16� X 3/4" 3000-160 5 2 011-535 Nut, Hex - 3/4"-10 Nylon Insert 3000-160



12.5.2 Carriage Chain Assembly - 3 Stage 160. 180 " Lift Height

1

4

2

3

4

3

2

5

5

Figure 34 : Carriage Chain Assembly - 160", 180" Lift Height



Carriage Chain Assembly - 3 Stage 160. 180 " Lift Height Item Qty Part No General Description Specific Description ◄ - 103-5030-19 Chain Ass'y 133.5" LG 160" 3Stg 3000-160 - - 103-5030-20 Chain Ass'y 143.5e" LG 180" 3Stg 3000-180 1 1 090-067-1334 Leaf, Chain (133-1/2"Lg) 3000-160 1 1 090-067-1434 Leaf, Chain (143-1/2"Lg) 3000-180 2 2 104-532 Clevis 3000-160, 180 3 2 105-372 Pin, Clevis 0.2"O.D. X 1-1/4"Lg 3000-160, 180 4 2 013-015 Pin, Cotter - 1/16� X 3/4" 3000-160, 180 5 2 011-535 Nut, Hex - 3/4"-10 Nylon Insert 3000-160, 180



12.5.3 Cylinder Assembly - 3 Stage 160, 180" Lift Height

1

10

15

3

117

128

144

9

6

513

2

Figure 35 : Lift Cylinder Assembly - 160", 180", 200" Lift Height



Cylinder Assembly - 3 Stage 160, 180" Lift Height Item Qty Part No General Description Specific Description ◄ - 101-5005 Cylinder Ass'y (3-1/2"Dia) 160"LH/3Stg 3000-160 - - 101-5005-2 Cylinder Ass'y (3-1/2"Dia) 180"LH/3Stg 3000-180 1 1 101-0004 Ram (2-1/2"Dia) 66-5/16"Lg 3000-160 1 1 101-0004-1 Ram (2-1/2"Dia) 71-5/16"Lg 3000-180 2 1 101-5002 Weldment, Housing (3-1/2"ID) 3000-160 2 1 101-5002-1 Weldment, Housing (3-1/2"ID) 3000-180 3 1 118-711 Nut, Head - 3.5" Dia Cyl -2.5" Dia Rod 3000-160, 180 4 1 114-979 Washer, Piston Washer - 3-1/2" Dia 3000-160, 180 5 1 114-639 Piston - 3.5" Dia Cyl 3000-160, 180 6 1 011-530 Nut, Hex Jam - 3/4"-10 3000-160, 180 7 1 101-0006-3 Spacer, Tube (4-3/4"Lg) 2-1/2" Ram 3000-160 7 1 101-0006 Spacer, Tube (2-7/16"Lg) 2-1/2" Ram 3000-180 8● 1 036-155 Ring, Wear - Pist.Wd. 3-1/2� x 1/2� 3000-160, 180 9● 1 036-154 Ring, Wear - Wide Piston 3� x 1/2" 3000-160, 180 10● 1 036-131 O-Ring, 3-1/2"OD x 3-3/4"ID 3000-160, 180 11● 1 036-111 U-Cup, 3-1/2 x 2-7/8 x 1/2 3000-160, 180 12● 1 036-108 O-Ring, 3/4"OD x 5/8"ID x 1/16" 3000-160, 180 13● 1 036-023 Ring, Wiper-Rod P.U. 2-1/2�ID 3000-160, 180 14● 1 036-190 O-Ring 2-1/2"ID x 2-3/4"OD 3000-160, 180 15● 1 117-993 Gasket 3000-160, 180 - - 780-843 Kit, Seal - Includes Items marked (●) 3000-160, 180



12.5.4 Reach and Tilt Assembly - 3 Stage

1 6 29

36

33

34

816

1119

1422

14, 22

1220

2528

32

4 3 5 303134

352

7

15

262728

303134

33 34

917

1018

Figure 36 : Reach and Tilt Assembly - 160", 180" Lift Height



Reach and Tilt Assembly - 3 Stage Item Qty Part No General Description Specific Description ◄ - 143-5026-2 Reach & Tilt Ass'y (3 Stg) 3000-160, 180 1* 1 143-5044-2 Weldment, Carriage - Inner Reach 3000-160, 180 2* 4 103-5045 Roller, Side Thrust Ass'y 3000-160, 180 3 4 103-0022 Roller, Side Thrust 3000-160, 180 4 4 018-006 Bushing 3000-160, 180 5 4 104-0005 Pin, Roller 3000-160, 180 6* 1 143-5009 Leg, Scissor Ass'y 3000-160, 180 7* 1 143-5010 Leg Ass'y - Left 3000-160, 180 8 N.S.S. 120-227 Pin, Center 3000-160, 180 9 1 143-0025 Leg, Outer Left 3000-160, 180 10 1 143-0026 Leg, Inner Left 3000-160, 180 11 1 013-012 Pin, Spring 1/4" X 2� 3000-160, 180 12 1 018-070 Bushing - 1.25� ID X 1.5 Lg 3000-160, 180 13 N.S.S. 143-0027 Stud, Roller (2-7/16"Lg) 3000-160, 180

14 3 012-286 Washer, Flat 1-1/4"IDx2-1/2"ODx1/16" Brass 3000-160, 180

15* 1 143-5011 Leg Ass'y - Right 3000-160, 180 16 N.S.S. 143-0058 Pin, Center 3000-160, 180 17 1 143-0023 Leg, Outer Right 3000-160, 180 18 1 143-0024 Leg, Inner Right 3000-160, 180 19 1 013-012 Pin, Spring 1/4" X 2� 3000-160, 180 20 1 018-070 Bushing - 1.25� ID X 1.5 Lg 3000-160, 180 21 N.S.S. 143-0027 Stud, Roller (2-7/16"Lg) 3000-160, 180


23 N.S.S. 143-0010 Bar, Crossmember 3000-160, 180 24 4 018-061 Bushing - 1"ID x 1"Lg 3000-160, 180 25* 4 785-863 Roller Ass'y 3000-160, 180 26 1 018-026 Bushing 3000-160, 180 27 1 116-035 Roller (1"LG./2.968"OD) 3000-160, 180


29** 1 143-5055 Weldment, Mast And Carriage 3000-160, 180 30 4 143-0022 Pin, Scissor Pin - Reach 3000-160, 180 31 4 013-012 Pin, Spring - 1/4" X 2� 3000-160, 180 32 4 019-011 Bearing, Roller 3000-160, 180 33 1 018-000 Bushing 3000-160, 180 34 1 018-061 Bushing - 1"ID x 1"Lg 3000-160, 180 35 2 018-001 Bushing - 3/4" Lg 3000-160, 180 36 2 018-010 Bushing - 1" Lg 3000-160, 180 N.S.S. - Not Sold Separately - Due To Welding * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE




6

5

67

5

76

15

98

3

17

6

11

14

12

16

14

141117

16

10

1

13

12

13

2

Figure 37 : Mast and Carriage Weldment Ass'y - 160", 180" Lift Height



Mast and Carriage Weldment Ass'y - Three Stage Item Qty Part No General Description Specific Description ◄ - 143-5055 Weldment, Mast And Carriage 3000-160, 180 1 1 796-050 Carriage Ass'y (32"Wide) 3000-160, 180 2 1 143-5054 Weldment, Outer Mast Reach 3000-160, 180 3* 1 796-629 Actuator Ass'y For Tilt Forks 3000-160, 180 4 1 796-590 Actuator Weldment 3000-160, 180 5 2 104-208 Roller, Bottom (11"Lg) 3000-160, 180 6 4 018-500 Bearing, 3/4�x1-5/8�x7/16� 3000-160, 180 7 2 012-214 Washer, Flat Plain - 3/4" 3000-160, 180 8 1 105-328 Pin, (32"Lg) 3000-160, 180 9 1 100-140 Rod, Tilt Fork Actuator -32"Lg 3000-160, 180 10 2 100-155 Spool, Tilt Fork Actuator - 2-7/8"Lg 3000-160, 180 11 2 018-018 Bushing 3000-160, 180 12 2 100-149 Sleeve, End (1-1/2"Lg) 3000-160, 180 13 2 013-012 Pin, Spring - 1/4� x 2� 3000-160, 180 14 6 018-017 Bushing 3000-160, 180 15 2 013-066 Pin, Spring - 5/32� x 1-1/4� 3000-160, 180 16 2 104-118 Bracket, Upper Cylinder 3000-160, 180 17 2 105-392 Bracket, Pivot 3000-160, 180 * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.5.6 Crosshead Assembly - Three Stage

10

8

9

7

3

45

3

6

2

1

Figure 38 : Crosshead Ass'y - 160", 180" Lift Height



Crosshead Assembly - Three Stage Item Qty Part No General Description Specific Description ◄ - 143-5015-1 Crosshead Ass' y(3 Stg) 3000-160, 180 1 1 143-5021-1 Weldment, Crosshead (3 Stg) 3000-160, 180 2 1 103-250 Pin, Crosshead 3000-160, 180 3 6 114-336 Washer, Flat Spacer 3000-160, 180 4* 2 792-306 Ass�y, Chain Roller - 7/8"ID x 1-1/4"OD 3000-160, 180 5 1 100-019 Roller, Chain - 7/8"ID x 1-1/4"OD 3000-160, 180 6 1 018-027 Bushing 3000-160, 180 7 2 013-036 Ring, Retaining Ext. 1-1/4"Id 3000-160, 180 8 6 143-0033 Pulley, Hose (1.5" x 1.469") 3000-160, 180 9 6 011-080 Screw, Shoulder-1/2�x1-1/2", Lg Hex Sckt 3000-160, 180 10 1 014-005 Setscrew, Socket Cup Point 3/8�-16 x 3/8" 3000-160, 180




12.6 Mast and Carriage Assembly - 3 Stage Full Free

21, 22 4 23 2 3

1824

19 20

212225

1415

1617

1314

1011

12

1011

9

6

7

4

5

3

8

2

1

2122

Figure 39 : Full Free Mast and Carriage Assembly - 172" Lift Height



Mast and Carriage Assembly - 3 Stage 172" Lift Full Free Item Qty Part No General Description Specific Description ◄ - 143-5076 Mast & Carriage Ass'y - 172� Lift 3000-172 Full Free 1** 1 143-5047-3 Reach/Tilt Ass'y (3 Stg Ff) 3000-172 Full Free 2 1 143-5051 Mast Weld, Outer (172"Lift) 3 Stg Ff Hose

Reels] 3000-172 Full Free

3 1 103-5036 Mast, Center Weldm't 3 Stg Ff 3000-172 Full Free 4 1 103-5047 Mast, Inner Weldm't (3 Stg Ff) 3000-172 Full Free 5** 2 103-5030-10 Chain Ass'y 44.5" Long 3000-172 Full Free 6** 2 103-5030-15 Chain Ass'y (73.5"Lg 4#) 3000-172 Full Free 7** 1 783-090 Crosshead Ass'y (1&2stg) FF 3000-172 Full Free 8** 1 783-199-1 Cylinder Ass'y 130/172/180"LH 3000-172 Full Free 9** 2 780-272 Cylinder Ass'y Outbrd (2"Dia) [56-

1/4"Str] 3000-172 Full Free 10 2 010-048 Capscrew, 1/2"-13 X 1 1/2" 3000-172 Full Free 11 2 012-220 Washer, Lock - 1/2" Split Reg. 3000-172 Full Free 12 1 118-934 Base 3000-172 Full Free 13 1 120-884 Pin 3000-172 Full Free 14 2 013-117 Pin, Sp - 1/4"Dia X 1-3/4 Lg 3000-172 Full Free 15 1 121-339 Pin (Threaded) 3000-172 Full Free 16 2 792-306 Roller, Chain (7/8"Idx1-1/4"Od) C/W Busing 3000-172 Full Free

17 4 012-286 Washer, Flat Brass - 1-1/4"Idx2-1/2"Odx1/16" 3000-172 Full Free

18 1 780-192 Roller, Hose Assembly 3000-172 Full Free

19 1 011-585 Cap Screw, Hex Sck Hd Sh - 1/2"X1-1/4�X3/8-16unc 3000-172 Full Free

20 7 010-036 Capscrew, Hex Hd. 5/16�-18 X 1/2" 3000-172 Full Free 21 7 012-200 Washer, Lock - 5/16" Helical 3000-172 Full Free 22 8 019-011 Bearing, Roller 3000-172 Full Free 23 1 012-274 Washer 1-1/2 Od X .540 Id 3000-172 Full Free 24 2 121-024 Bracket, Cylinder 3000-172 Full Free




12.6.1 Reach and Tilt Assembly - Three Stage Full Free

1

11

1516

1516

10

30, 31, 32751314

12

121314 6 7 30, 31, 32

2252633

23

30

731

6

7

20

1718

2628

33427

2922

30,32

6

31,32

8

7

19

21202628

3

2729

34

222312,1314,1516

1112,1314,1516

10

9

242628

4

2729

34

19

7

23

22

23

33

1718

30,32

6

31,32

30,32

31,32

30,32

5

31,32

34

Figure 40 : Reach and Tilt Assembly - 172" Lift Height, Full Free Mast



Reach and Tilt Assembly - Three Stage Full Free Item Qty Part No General Description Specific Description ◄ - 143-5047-3 Reach/Tilt Ass'y (3 Stg FF) 3000-172 Full Free 1** 1 787-090-3 Reach/Tilt Ass'y (3 Stg FF) 3000-172 Full Free 2** 1 786-465 Cylinder Ass'y - 3"Dia 3000-172 Full Free 3** 1 786-176 Cylinder Ass'y (Left) 2"Dia 3000-172 Full Free 4** 1 786-177 Cylinder Ass'y (Right) 2"Dia 3000-172 Full Free 5 1 036-526 Block, Junction - Right Hand 3000-172 Full Free 6 1 036-525 Block, Junction - Left Hand 3000-172 Full Free 7 7 034-582 Fitting 3000-172 Full Free 8 1 034-704 Adapter, 3/4�-16 SAE O-Ring X 3/8� 3000-172 Full Free 9 1 034-519 Adapter, Reducer 3/8�M-1/4�F Pipe 3000-172 Full Free 10 1 100-5001 Hose (22"Lg) #4 High Pressure 3000-172 Full Free 11 1 100-5001-1 Hose (28"Lg) #4HP Str & 90° 3000-172 Full Free 12 2 035-204 Clamp 3000-172 Full Free 13 2 010-001 Capscrew, Hex Hd. - 1/4�-20 X 1" 3000-172 Full Free 14 2 012-210 Washer, Flat - 1/4" 3000-172 Full Free 15 2 012-202 Washer, Lock - 1/4" Helical 3000-172 Full Free 16 2 011-506 Nut, Hex - 1/4�-20 3000-172 Full Free 17 2 034-543 Adapter 3000-172 Full Free 18 2 100-5000 Hose Ass'y (10"Lg)#4 High Pres 3000-172 Full Free 19 2 034-514 Adapter 3000-172 Full Free 20 1 100-5002-1 Hose Ass'y - 17-1/4"LG - #4 HP Str & 90° 3000-172 Full Free 21 1 100-5003 Hose Ass'y - 12 3/4" LG - #4 HP Str & Str 3000-172 Full Free 22 1 100-5000-1 Hose Ass'y - 38"Lg - #4 High Pres 3000-172 Full Free 23 1 100-5000-2 Hose Ass'y - 59"Lg - #4 High Pres 3000-172 Full Free 24 1 100-5002 Hose Ass'y - 15"Lg - #4HP Str & 90° 3000-172 Full Free 25 2 103-916 Pin 3000-172 Full Free 26 4 013-034 Cir-Clip - 1" ID 3000-172 Full Free 27 2 104-674 Pin, Clevis - Bottom 3000-172 Full Free 28 2 104-675 Pin, Clevis - Top 3000-172 Full Free 29 8 013-002 Ring, Retaining - 3/4" Dia Shaft 3000-172 Full Free 30 2 010-012 Capscrew, Hex Hd. - 3/8�-16 x 3/4" 3000-172 Full Free 31 4 010-040 Capscrew, Hex Hd - 3/8�-16 x 1-1/2" 3000-172 Full Free 32 6 012-201 Washer, Lock - 3/8"Dia. Helical 3000-172 Full Free 33 1 103-736 Clevis 3000-172 Full Free 34 2 104-117 Clevis, Tilt Cylinder 3000-172 Full Free * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.6.2 Reach/Tilt Sub-Assembly - Three Stage Full free

1 6 29

36

33

34

816

1119

1422

14, 22

1220

2528

32

4 3 5 303134

352

7

15

262728

303134

33 34

917

1018

Figure 41 : Reach/Tilt Sub-Assembly - 172" Lift Height, Full Free Mast



Reach/Tilt Sub-Assembly Item Qty Part No General Description Specific Description ◄ - 787-090-3 Reach/Tilt Ass'y (3 Stg FF) 3000-172 Full Free 1 1 143-5005-3 Mast Weld�t (Inner) 3 Stg FF [11"Lg] 3000-172 Full Free 2* 4 103-5045 Roller, Side Thrust Ass'y 3000-172 Full Free 3 4 103-0022 Roller, Side Thrust 3000-172 Full Free 4 4 018-006 Bushing 3000-172 Full Free 5 4 104-0004 Pin, Roller 3000-172 Full Free 6* 1 143-5009 Leg, Scissor Ass'y 3000-172 Full Free 7* 1 143-5010 Leg Ass'y - Left 3000-172 Full Free 8 N.S.S. 120-227 Pin, Center 3000-172 Full Free 9 1 143-0025 Leg, Outer Left 3000-172 Full Free 10 1 143-0026 Leg, Inner Left 3000-172 Full Free 11 1 013-012 Pin, Spring 1/4" X 2� 3000-172 Full Free 12 1 018-070 Bushing - 1.25� ID X 1.5 Lg 3000-172 Full Free 13 2 143-0027 Stud, Roller (2-7/16"Lg) 3000-172 Full Free

14 3 012-286 Washer, Flat 1-1/4"IDx2-1/2"ODx1/16" Brass 3000-172 Full Free

15* 1 143-5011 Leg Ass'y - Right 3000-172 Full Free 16 N.S.S. 143-0058 Pin, Center 3000-172 Full Free 17 1 143-0023 Leg, Outer Right 3000-172 Full Free 18 1 143-0024 Leg, Inner Right 3000-172 Full Free 19 1 013-012 Pin, Spring 1/4" X 2� 3000-172 Full Free 20 1 018-070 Bushing - 1.25� ID X 1.5 Lg 3000-172 Full Free 21 2 143-0027 Stud, Roller (2-7/16"Lg) 3000-172 Full Free


23 N.S.S. 143-0010 Bar, Crossmember 3000-172 Full Free 24 4 018-061 Bushing - 1"ID x 1"Lg 3000-172 Full Free 25* 4 785-863 Roller Ass'y 3000-172 Full Free 26 1 018-026 Bushing 3000-172 Full Free 27 1 116-035 Roller (1"LG./2.968"OD) 3000-172 Full Free


29** 1 143-5008 Mast & Carriage Weldment 3000-172 Full Free 30 4 143-0022 Scissor Pin 3000-172 Full Free 31 4 013-012 Spring Pin - 1/4� X 2 3000-172 Full Free 32 4 019-011 Bearing, Roller 3000-172 Full Free 33 1 018-000 Bushing 3000-172 Full Free 34 1 018-061 Bushing - 1"ID x 1"Lg 3000-172 Full Free 35 2 018-001 Bushing - 3/4" Lg 3000-172 Full Free 36 2 018-010 Bushing - 1" Lg 3000-172 Full Free N.S.S. - Not Sold Separately - Due To Welding * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.6.3 Mast and Carriage Weldment

6

5

67

5

76

15

98

3

17

6

11

14

12

16

14

141117

16

10

1

13

12

13

2

Figure 42 : Mast and Carriage Weldment Assembly - 172" Lift Height



Mast and Carriage Weldment - Three Stage 172' Full Free Item Qty Part No General Description Specific Description ◄ - 143-5008 Mast & Carriage Weldment 3000-172 Full Free 1 1 796-050 Carriage Ass'y (32"Wide) 3000-172 Full Free 2 1 143-5007 Mast Out Weld 3000-172 Full Free 3* 1 796-629 Actuator Ass'y For Tilt Forks 3000-172 Full Free 4 1 796-590 Actuator Weldment 3000-172 Full Free 5 2 104-208 Roller, Bottom (11"Lg) 3000-172 Full Free 6 4 018-500 Bearing, 3/4�x1-5/8�x7/16� 3000-172 Full Free 7 2 012-214 Washer, Flat Plain - 3/4" 3000-172 Full Free 8 1 105-328 Pin, (32"Lg) 3000-172 Full Free 9 1 100-140 Rod, Tilt Fork Actuator -32"Lg 3000-172 Full Free 10 2 100-155 Spool, Tilt Fork Actuator - 2-7/8"Lg 3000-172 Full Free 11 2 018-018 Bushing 3000-172 Full Free 12 2 100-149 Sleeve, End (1-1/2"Lg) 3000-172 Full Free 13 2 013-012 Pin, Spring - 1/4� x 2� 3000-172 Full Free 14 6 018-017 Bushing 3000-172 Full Free 15 2 013-066 Pin, Spring - 5/32� x 1-1/4� 3000-172 Full Free 16 2 104-118 Bracket, Upper Cylinder 3000-172 Full Free 17 2 105-392 Pivot Bracket 3000-172 Full Free * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.6.4 Reach Cylinder Assembly - Three Stage 172' Full Free

9

8

10

113

1213

15

2

4

14

7

5

6

1

5 17 16 18 5

14

Figure 43 : Reach Cylinder Assembly - 172" Lift Height, Full Free Mast



Reach Cylinder Assembly - Three Stage 172' Full Free Item Qty Part No General Description Specific Description ◄ - 786-465 Cylinder Ass'y, Reach - 3"Dia 3000-172 Full Free 1 1 786-468 Weldment, Housing 3000-172 Full Free 2 1 115-074 Ram 3000-172 Full Free 3 1 115-071 Nut, Head 3000-172 Full Free 4 1 115-072 Piston 3000-172 Full Free 5 3 034-511 Adapter, 90° 5 - 4 3000-172 Full Free 6 1 034-517 Adapter, Straight 5 - 4 3000-172 Full Free 7 1 011-535 Nut, 3/4" - 10 Huglock 3000-172 Full Free 8 1 036-018 Wiper, Rod 1-1/4" ID P.U. 3000-172 Full Free 9 1 013-045 C-Clip 3000-172 Full Free 10 1 036-136 Ring, Back Up - 3"OD x 2-3/4"ID 3000-172 Full Free 11 1 036-132 O-Ring, 3"OD x 2-3/4"ID 3000-172 Full Free 12 1 036-137 Ring, Back Up - 1-1/2" OD x 1-1/4" ID 3000-172 Full Free 13 1 036-135 O-Ring - 1.25" x 1.5" x .139" 3000-172 Full Free 14 2 036-112 U-Cup - 3" x 2-3/8" x 1/2" 3000-172 Full Free 15 1 036-108 O-Ring, 3/4"OD x 5/8"ID x 1/16" 3000-172 Full Free 16 1 105-733 Ball - 1/4" Dia Steel 3000-172 Full Free 17 1 104-069 Retainer, Ball - 13/32" x 1/4" 3000-172 Full Free 18 1 786-467 Hose Ass'y #4 Hose 3000-172 Full Free - - 786-465-1 Kit, Seal 3000-172 Full Free



12.6.5 Tilt Cylinders - Three Stage 172' Full Free

11

10

78

3

56

9

2

12

13

4

13

1

14

Figure 44 : Tilt Cylinder Assembly - 172" Lift Height, Full Free Mast



Tilt Cylinder - Three Stage 172' Full Free Item Qty Part No General Description Specific Description ◄ - 786-177 Cylinder Ass'y (Right) 2"Dia 3000-172 Full Free - 786-176 Cylinder Ass'y (Left) 2"Dia 3000-172 Full Free 1 1 786-152 Housing Assembly (Right) 3000-172 Full Free 1 1 786-178 Housing Assembly (Left) 3000-172 Full Free 2 1 115-675 Ram - 2" Double Acting Cyl (3/4"Dia) 3000-172 Full Free 3 1 118-659 Nut, Head 3000-172 Full Free 4 1 115-673 Piston 3000-172 Full Free 5● 1 036-159 O-Ring - 1"OD x 3/4"ID x 1/8" 3000-172 Full Free 6● 1 036-145 Ring, Back Up - 1"OD x 3/4"ID x 1/16" 3000-172 Full Free 7● 1 036-134 O-Ring - 2"Od X 1-3/4"Id 3000-172 Full Free 8● 1 036-146 Ring, Back Up - 2" OD x1-3/4 ID x 1/16"Thk 3000-172 Full Free 9● 1 036-147 O-Ring, 5/8"OD x 1/2"ID x 1/16" 3000-172 Full Free 10● 1 036-148 Wiper, Rod - 1"OD x 3/4"ID x 1/8" 3000-172 Full Free 11 1 013-098 C-Clip, Internal Ret Ring Type Dia 2" 3000-172 Full Free 12 1 011-554 Nut, Hex - 1/2�-13 Nylon Insert 3000-172 Full Free 13● 2 036-118 U-Cup, - 2"OD x 1-3/8" x 1/2" 3000-172 Full Free 14 1 012-239 Washer, Spacer - 1/2"ID x 1"OD x 1/8"Thk 3000-172 Full Free - - 780-609 Kit Seal (Includes Items Marked ●) 3000-172 Full Free



12.6.6 Chain Assembly - Three Stage 172' Full Free

1

4

2

3

4

3

2

5

5




Chain Assembly - Three Stage 172' Full Free Item Qty Part No General Description Specific Description ◄ - 103-5030-10 Chain Ass'y 44.5" Long 3000-172 Full Free 1 1 090-067-0444 Chain Leaf (44-1/2"Lg) 3000-172 Full Free 2 2 104-532 Clevis 3000-172 Full Free 3 2 105-372 Clevis Pin 0.2"O.D. x 1-1/4"Lg 3000-172 Full Free 4 2 013-015 Cotter Pin - 1/16" x 3/4" 3000-172 Full Free 5 2 011-535 Nut, Hex - 3/4"-10 Nylon Insert 3000-172 Full Free



12.6.7 Chain Assembly - Three Stage 172' Full Free

1

4

2

3

4

3

2

5

5




Chain Assembly - Three Stage 172' Full Free Item Qty Part No General Description Specific Description ◄ - 103-5030-15 Chain Ass'y (73.5"Lg 4#) 3000-172 Full Free 1 1 090-067-0734 Chain Leaf (73-1/2"Lg) 3000-172 Full Free 2 2 104-532 Clevis 3000-172 Full Free 3 2 105-372 Clevis Pin 0.2"O.D. x 1-1/4"Lg 3000-172 Full Free 4 2 013-015 Cotter Pin - 1/16" x 3/4" 3000-172 Full Free 5 2 011-535 Nut, Hex - 3/4"-10 Nylon Insert 3000-172 Full Free



12.6.8 Crosshead Assembly - Three Stage 172' Full Free




Crosshead Assembly - Three Stage 172' Full Free Item Qty Part No General Description Specific Description ◄ - 783-090 Crosshead Ass'y FF 3000-172 Full Free 1 1 783-088 Weldment, Crosshead F.F. Mast 3000-172 Full Free 2* 2 792-306 Roller, Chain 3000-172 Full Free 3 1 100-019 Roller, Chain - 7/8"ID x 1-1/4"OD 3000-172 Full Free 4 1 018-027 Bushing 3000-172 Full Free 5 1 103-250 Pin, Crosshead 3000-172 Full Free 6 6 114-336 Washer, Flat Spacer 3000-172 Full Free 7 2 013-036 Ring, Retaining Ext. - 1-1/4"ID 3000-172 Full Free 8 1 014-005 Setscrew, Socket Cup Point - 3/8"-16 x 3/8" 3000-172 Full Free 9 2 105-882 Washer, Spacer - 1-3/4" Dia 3000-172 Full Free




12.6.9 Lift Cylinder Assembly - Three Stage 172' Full Free

Figure 48 : Lift Cylinder Assembly - 172" Lift Height, Full Free Mast



Lift Cylinder Assembly - Three Stage 172' Full Free Item Qty Part No General Description Specific Description ◄ 783-199-1 Ass'y, Cylinder 130/172/180"Lh 3000-172 Full Free 1 1 118-948 Ram, 1-1/2� Dia. x 41-7/8� LG. 3000-172 Full Free 2 1 783-103-1 Weldment, Housing - 3�ID 3000-172 Full Free 3 1 118-389 Nut, Head - 3� ID Cyl. 3000-172 Full Free 4 1 114-978 Washer, Piston 3000-172 Full Free 5 1 114-640 Piston, 3� Dia. 3000-172 Full Free ●6 1 036-154 Ring, Wear 3000-172 Full Free ●7 1 036-143 Ring, Wear 3000-172 Full Free ●8 1 036-132 �O�-Ring 3000-172 Full Free ●9 1 036-112 �U�-Cup 3000-172 Full Free ●10 1 036-108 �O�-Ring 3000-172 Full Free ●11 1 036-098 Wiper. Rod 3000-172 Full Free ●12 1 117-993 Gasket 3000-172 Full Free 13 1 011-530 Nut, Hex 3/4�-10 3000-172 Full Free ●14 1 036-180 �O�-Ring 3000-172 Full Free 15 1 090-779-0024 Tube, Spacer - 2-1/2� LG. 3000-172 Full Free - - 783-536 Kit Seal - Includes Items Marked (●) 3000-172 Full Free



12.6.10 Outboard Cylinder Assembly - Three Stage 172' Full Free

Figure 49 : Outboard Cylinder Assembly - 172" Lift Height, Full Free



Outboard Cylinder Assembly - Three Stage 172' Full Free Item Qty Part No General Description Specific Description ◄ -

780-272 Cylinder Ass'y Outbrd (2"Dia) [56-

1/4"Str] 3000-172 Full Free 1 1 121-030 Ram, 1-1/2� Dia. x 56-1/4� LG. Outboard 3000-172 Full Free 2 1 780-875 Weldment, Housing - 2�ID Outboard 3000-172 Full Free 3 1 118-365 Nut, Head - 2� ID Cyl. 3000-172 Full Free 4 1 114-976 Washer, Piston 3000-172 Full Free 5 1 113-542 Piston 3000-172 Full Free ●6 1 036-152 Ring, Wear 3000-172 Full Free ●7 1 036-143 Ring, Wear 3000-172 Full Free ●8 1 036-134 �O�-Ring 3000-172 Full Free ●9 1 036-118 �U�-Cup 3000-172 Full Free ●10 1 036-108 �O�-Ring 3000-172 Full Free ●11 1 036-098 Wiper. Rod 3000-172 Full Free 12 1 034-515 Fitting, 1/4" - 90° Elbow -2103-6-6 3000-172 Full Free ●13 1 118-368 Gasket 3000-172 Full Free 14 1 011-530 Nut, Hex 3/4�-10 3000-172 Full Free ●15 1 036-180 �O�-Ring 3000-172 Full Free - - 783-536 Kit Seal - Includes Items marked (●) 3000-172 Full Free



12.7 Left Straddle Assembly

2

9

8

3

5

4

8

6

4

25

7

1

2

1

Figure 50 : Left Straddle Assembly



Left Straddle Assembly

Item Qty Part No General Description Specific Description ◄ - 142-5032 Left Straddle Assembly 3000 1 1 142-5034 Left Straddle Weldment 3000 2 2 106-180 Wheel Urethane 3000 3 1 013-005 Spring Pin 5/32" x 1"Lg 3000 4 2 142-0047 Axle Roller 3000 5 4 018-500 Bearing 3000 6 1 142-5036 Bogie Axle Roller Weldment 3000 7 1 142-5037 Bogie Assembly 3000 8 2 018-010 Bushing 3000 9 1 019-500 Nipple, Grease 3000



12.8 Right Straddle Assembly

Figure 51 : Right Straddle Assembly



Right Straddle Assembly

Item Qty Part No General Description Specific Description ◄ - 142-5033 Right Straddle Assembly 3000 1 1 142-5035 Right Straddle Weldment 3000 2 2 106-180 Wheel Urethane 3000 3 1 013-005 Spring Pin 5/32" x 1"Lg 3000 4 2 142-0047 Axle Roller 3000 5 4 018-500 Bearing 3000 6 1 142-5036 Bogie Axle Roller Weldment 3000 7 1 142-5037 Bogie Assembly 3000 8 2 018-010 Bushing 3000 9 1 019-500 Nipple, Grease 3000



12.9 Electric Drive Unit Assembly

Figure 52 : Electric Drive Unit Assembly



Electric Drive Unit Assembly Item Qty Part No General Description Specific Description ◄ - 145-5002-2 Electric Drive Unit Ass'y 3000 1 1 025-841 Contactor High Speed & Pump - 24v Single 3000 2 2 011-008 Screw, Machine R/H Slot - #10-32 X 3/8" 3000 3 2 012-225 Washer, Lock - #10 Internal Tooth 3000 4 3 010-006 Capscrew, 5/16"-18 X 1" H.H. 3000 5 3 012-200 Washer, Lock Helical - 5/16" 3000 6 3 012-211 Washer, Flat - 5/16" Bolt Size 3000 7 1 032-458 Horn, Electronic 12/24v 3000 8** 1 144-5016 Drive Unit Ass'y - Electrical 3000 9 1 025-977 Button Ass'y, Emergency Stop - Single Pole

[Red] 3000

10 1 105-5000 Connector Ass'y (Sb Red) 3000 11 2 011-502 Nut, Hex - 5/16"-18 3000 12 2 010-002 Capscrew, Hex Hd. 1/4"-20 X 1-1/2" 3000 13 5 012-202 Washer, Lock - 1/4" Helical 3000 14 1 026-154 Fuse - 150 Amp - Ack 150 3000 15 2 011-042 Capscrew, Hex Sckt F/H - 5/16"-18 X 1" 3000 16 1 783-424 Holder, Power Fuse - Assembly 3000 17 4 010-037 Capscrew, Hex Hd. 5/16"-18 X 3/4" 3000 18 4 011-507 Nut, Hex Plated - 3/8"-16 3000 19 4 012-201 Washer, Lock - 3/8"Dia.Helical 3000 20 3 010-003 Capscrew, Hex Hd. - 1/4"-20 X 2" 3000 21 1 012-210 Washer, Flat - 1/4" Bolt S 3000 22 1 135-5010-2 Wire Assembly 3000 23 1 135-5010-5 Wire Assembly 3000 24 1 135-5010-1 Wire Assembly 3000 25 1 135-5010-3 Wire Assemby 3000 26** 1 104-5005 Kit-Wrg R Batt. Box Plate - 3 Vlv 3000 27 1 018-563 Bearing Cone - 2" Bore 3000 28 1 103-819 Cover Plate - 4-3/4" Dia) 3000 29 1 013-010 Spring Pin - 1/4" X 1-1/4" Long 3000 30 1 010-067 Capscrew, Hex Hd. - 3/4"-10 X 1-1/2" 3000 31 1 012-233 Washer, Lock - 3/4" Int. Tooth 3000 32 1 103-890 Clamp, Cable 3000 33 1 105-137 Strip, Rubber 3000 34 2 010-154 Capscrew, Hex Hd. - 1/4"-20 X 1 1/4" F/T 3000 35 2 012-202 Washer, Lock - 1/4" Helical 3000 36 2 018-562 Cup, Bearing - 2" Bore 3000 37 1 019-500 Nipple, Grease Straight - 1/4" 3000 * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.9.1 Drive Unit Assembly - Electrical

Figure 53 : Drive Unit Assembly - Electrical



Drive Unit Assembly Item Qty Part No General Description Specific Description ◄ 144-5016 Drive Unit Ass'y - Electrical 3000 1 1 144-0015 Bracket, Switch Mntg 3000 2 2 011-005 Screw, Machine R/H Slot #8-32 X 1/2" 3000 3 2 012-205 Washer, Flat - #8 3000 4 2 012-224 Washer, Lock - #8 Internal Tooth 3000 5 1 025-535 Switch, Micro Dead-Man 3000 6 2 011-003 Screw, Machine R/H Slot - #6-32 X 1" 3000 7 2 012-204 Washer, Flat - #6 3000 8 2 012-233 Washer, Lock - 3/4" Internal Tooth 3000 9 2 011-514 Nut, Hex Machine Screw #6-32 3000 10** 1 200-01482 Assy, Control Handle 3000 11 1 200-01484 Handle Brkt. Cover 3000 12 1 200-01478 Pivot Pin Assy. 3000 13 1 010-000 Capscrew, Hex Hd. 1/4"-20 x 3/4" 3000 14 1 012-202 Washer, Lock - 1/4" Helical 3000 15** 1 135-5006 Panel, Controller Ass'y 3000 16 2 010-012 Capscrew, Hex Hd. - 3/8�-16 x 3/4" 3000 17 2 012-201 Washer, Lock - 3/8"Dia.Helical 3000 18 2 105-137 Strip, Rubber 3000 19 1 103-890 Clamp, Cable 3000 20 2 011-017 Screw, Machine R/H Slot #10-24 x 1-1/2" 3000 21 4 012-208 Washer, Flat - 3/16" 3000 22 4 037-003 Grommet, Rubber - 3/16�x7/16�x1/4� 3000 23 2 012-225 Washer, Lock - #10 Internal Tooth 3000 24 2 011-500 Nut, Hex Machine Screw #10-24 3000 25 1 037-021 Protector Terminal 3000

26 1 164-0006 Pin, Cam Follower (1-1/2"LG) Brake Linkage Arr.

3000

27 1 018-100 Bushing - 5/8"ID x 3/4"OD x 1" 3000 28 2 013-033 Ring, Retain 3000 29** 1 144-5017 Drive Unit Column Ass'y 3000 30 1 30H21 Clamp, 3/8 X 1/2" Wide 3000 31 1 011-005 Screw, Machine R/H Slot - #8-32 x 1/2" 3000 32 1 012-204 Washer, Flat #6 3000 33 1 164-7003 Harness, Wiring - Curtis Handle 3000 34 1 200-01475 Bumper, Rubber 3000 35 2 011-576 Screw, Machine Slot Rnd - #8-32 x 1-1/4" 3000 36 2 011-515 Nut, Hex Machine Screw - #8-32 3000 * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.9.2 Control Handle Assembly

13

1514

Figure 54 : Control Handle Assembly



Control Handle Assembly Item Qty Part No General Description Specific Description ◄ - 200-01482 Assy, Control Handle 3000 1 1 200-01476 Cam Machined 3000 2 1 200-01483 Stem Handle Machined 3000 3 2 012-245 Washer Spacer -1"ID x 1-3/4"OD x 1/8"THK 3000 4 2 017-075 Spring, Torsion - 3/32�THK x 3-1/16�OD 3000 5** 1 907-0105 Handle, Curtis 24 V Ch-12 Horn Only 3000 6 4 012-200 Washer, Lock - 5/16" Helical 3000 7 4 010-188 Capscrew Hex Hd - M8x16mm 3000 8 1 234-5332 Switch-Key #31-613 3000 9 1 200-00165 Plate, Handle Stem Cover 3000 10 1 120-0001 Plate, Serial Number -Vertical 2-1/2" x 5" 3000 11 4 011-000 Screw, Type U R/Hd Zinc #4 x 5/16 3000 12 4 011-010 Screw, Machine R/H Slot #10-24 x 3/8" 3000 * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.9.3 Control Handle Head Assembly

Figure 55 : Control Handle Head Assembly



Control Handle Head Assembly Item Qty Part No General Description Specific Description ◄ - 907-0105 Handle, Curtis 24 V Ch-12 Horn Only 3000 1 1 907-0184 Cover-Plastic (1-Slot) 3000 2 1 929-445 Button, Horn 3000 3 2 929-446 Bracket, Spring Retaining 3000 4 1 929-441 Bracket, Lower/Horn Switch 3000 5 2 929-461 Thumbwheel, Butterfly Black 3000 6 1 929-452 Throttle, Elect.(24 Volt) Ch9 3000 7 1 930-805 Bracket, Throttle Support 3000 8 1 929-451 Housing 3000 9 1 929-458 Bracket, E/R 3000 10 2 929-455 Spring, E/R Button 3000 11 1 929-457 Button, E/R 3000 12 2 929-450 Grip 3000 13 2 929-447 Spring, Lift/Lower/Horn Button 3000 14 1 929-437 Switch, Lower/Horn 3000 15 2 929-439 Screw, Switch Mtg #3 x 16 Pan Ph. Type B 3000 16 5 929-453 Screw, #6x3/8� Pan Slot Type B 3000 17 2 3GM-506 Capscrew, Hex Hd. #10-32x1/4� 3000 18 1 929-462 Switch, E/R 3000 19 2 1EM-50E Washer, E/R Bracket #10 Flt/W 3000 20 2 929-456 Washer, Wide, #3x08 Thk .08 3000 21 2 10E-M30 Washer, Star #4 Ext. Lock Wash 3000 22 2 13G-M3010 Screw,Throttle #4-48x1/2� Pan Hd 3000

23 4 3GM-812 Screw-Grip (Use 1 x 011-066 & 1 x 011-176) 3000

24 6 929-454 Screw, Pan Phillips M3 x 10 Zinc 3000 25 2 929-463 Screw, E/R Switch 3000 26 4 929-448 Screw, Cover 3000 27 1 929-440 Screw, Horn Switch Mtg 3000 28 1 929-460 Harness, Wire 3000



12.9.4 Controller Panel Assembly

Figure 56 : Controller Panel Assembly



Controller Panel Assembly Item Qty Part No General Description Specific Description ◄ - 135-5006 Panel, Controller Ass'y 3000 1 1 030-091 Terminal Strip 12 Poles 3000 2 2 011-003 Screw, Machine R/H Slot #6-32 x 1" 3000 3 1 026-227 Fuseholder, Single 250 Volt 3000 4 1 026-146 Fuse, 6 Amp 1/4" Dia 3000 5 1 011-002 Screw, Machine R/H Slot #6-32 x 1/2" 3000 6 1 145-0011 Plate, Controller Mntg 3000 7 1 025-973 Contactor, Fwd/Rev 24 Volt 3000 8 2 011-010 Screw, Machine R/H Slot #10-24 x 3/8" 3000 9 2 012-206 Washer, Flat #10 3000 10 1 026-507-1 Controller, 24 Volt 3000 11 3 010-174 Rivet, 3/16" 3000 12 3 010-037 Capscrew, Hex Hd. 5/16�-18 x 3/4" 3000 13 3 011-502 Nut, Hex Plated 5/16�-18 3000 14 3 012-200 Washer, Lock 5/16" Helical 3000 15 1 026-513 Harness, Wiring, 10-Wire 3000 16 2 784-589 Assembly, Cable 3000 17 1 194-5000 Harness, Wire 3000 18** 1 104-5003 Kit-Wiring 3000 19 4 780-481-26 Cable - Electrical Assy 3000 20 1 026-402 Diode, Wire Lead 6 Amp, 100 PRV 3000 * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.9.5 Drive Unit Wiring Kit

Figure 57 : Drive Unit Wiring Kit



Drive Unit Wiring Kit Item Qty Part No General Description Specific Description ◄ - 104-5003 Kit-Wiring 3000 1 4 030-778 Wire Terminals Faston, .25", Red 3000 2 2 030-097 Wire Terminal 3000 3 1 030-098 Wire Terminal, Red, 5/16" Ring 3000 4 1 090-896-0015 Wire/m (1-1/2"Lg) Red #18/16 3000 5 1 090-896-0020 Wire/m (2"Lg) Red #18/16 3000 6 1 090-896-0042 Wire/m (4-1/4"Lg) Red #18/16 3000 7 1 090-896-0052 Wire/m (5-1/4"Lg) Red #18/16 3000 8 1 090-896-0062 Wire/m (6-1/4"Lg) Red #18/16 3000 9 1 090-896-0066 Wire/m (6-3/4"Lg) Red #18/16 3000 10 1 090-896-0136 Wire/m (13-3/4"Lg)Red #18/16 3000



12.9.6 Drive Unit Column Assembly - Mechanical

Figure 58 : Drive Unit Column Assembly - Mechanical



Drive Unit Column Assembly - Mechanical Item Qty Part No General Description Specific Description ◄ - 144-5017 Drive Unit Column Ass'y 3000 1 1 200-01474 Frame Wldm't 3000 2 2 013-565 Pin,Clevis 3/8"Dia X 1-3/32"Lg 3000 3 3 013-017 Pin, Cotter - 3/32� X 3/4� 3000 4 2 013-513 Clevis - 3/8"X 3/8� Eye X 2-7/8� 3000 5** 1 790-351 Ass'y, Large Gearbox 3000 6 2 012-210 Washer, Flat -1/4" 3000 7 2 011-024 Screw, Machine F/H Slot #10-24 X 1/2" 3000 8 1 144-0016 Rod, Brake (13-1/2"X3/8") 3000 9 2 011-519 Nut, Hex - 3/8�-24 3000 10 1 907-0022 Motor, 1 Hp 24 V 3000 11 4 010-006 Capscrew, Hex Hd. 5/16�-18 X 1" 3000 12 4 012-200 Washer, Lock 5/16" Helical 3000 13 4 011-502 Nut, Hex - 5/16�-18 3000 14 1 018-003 Bushing, Bronze . 3000 15 1 144-5005 Actuator, Brake Ass'y 3000 16 2 014-003 Setscrew, Socket Hd 5/16�-18 X 5/16� 3000 17 1 017-031 Spring - 3/4" X 1" 3000 18 1 010-125 Capscrew Hex - 3/8�-16 X 3-1/4"Lg 3000 19 15 012-211 Washer, Flat - 7 5/16" 3000 20 3 011-552 Nut, Hex - 3/8�-16 Nylon Insert 3000 21 1 105-394 Hinge 3000 22 2 023-025 Pulley, 18 Tooth Timing 3000 23 1 018-073 Bushing C/W Set 3000 24 1 120-101 Key - 1/4"Sq X 1-3/8"Lg 1/8"Radius 3000 25 1 023-212 Belt-Drive (Timing) - 1/2"Pitch 33"Lgx1" 3000 26 2 010-077 Capscrew, Hex Hd. 3/8�-16x1-1/4" 3000 27 1 144-5019 Weldment, Motor Mount Plate 3000 28 1 018-072 Bushing, Taperlock 3000 29 1 104-355 Key Motor Shaft - 3/16"X 1" 3000 30 1 144-0017 Arm Brake Pivot 5-1/2"X1"X3/8" 3000 31 1 011-563 Nut, Hex - 1-1/4-12 Nte Series 3000 32 1 111-653 Washer, Flat 3000 33 4 010-044 Capscrew, 1/2"-13 X 2" 3000 34 4 012-220 Washer, 1/2" Split Reg. 3000 35 1 018-563 Bearing Cone - 2" Bore 3000 36 1 780-194 Tire- Hub Drive Ass'y - 10x4x6.5 3000 37 1 021-101 Key Output Shaft And Wheel Hub 3000 38 1 010-101 Capscrew, 5/8�-11 X 3" 3000 39 1 011-509 Nut, Hex - 5/8�-11 3000 40 1 104-0013 Mount, Traction Motor Mount 3000 41 1 010-128 Capscrew, Hex Hd. 1/2"-13 X 2-1/2" 3000 42 1 011-508 Nut, Hex - 1/2"-13 3000 43 1 012-232 Washer, Lock - 5/8" Internal Tooth 3000 44 4 011-066 Capscrew, Hex Socket - 5/16�-18 X 3/4" 3000 * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.9.7 Gearbox Assembly

Figure 59 : Gearbox Assembly



Gearbox Assembly Item Qty Part No General Description Specific Description ◄ - 790-351 Ass'y, Large Gearbox 3000 1 1 110-887 Housing - Large Gearbox 3000 2 1 110-888 Cover, Main - Large Gearbox 3000 3 1 110-889 Shaft, Input (Pinion) 3000 4 1 110-890 Shaft, Intermediate (Pinion) 3000 5 1 110-891 Gear , Intermediate 3000 6 1 110-892 Gear, Output 3000 7 1 110-893 Shaft, Output 3000 8 1 110-602 Spacer, Intermediate Shaft 3000 9 1 110-603 Shaft, Brake (11-1/2"LG) 3000 10 2 110-604 Lever, Brake Operating 3000 11 1 110-605 Cover, Output Shaft Cover (Gear Box) 3000 12 1 110-443 Plate, Input Pinion Lock 3000 13 1 110-895 Sleeve, Brake 3000 14 1 110-896 Collar, Thrust #16 3000 15 1 110-897 Ring, Snap #17 3000 16 1 018-573 Cup, Bearing 3000 17 1 018-574 Roller, Bearing Taper 3000 18 1 018-575 Bearing Angular 3000 19 3 018-576 Bearing 3000 20 1 018-577 U Nut - 1-1/2" 3000 21 1 018-578 Washer, Lock 3000 22 1 018-580 Washer, Lock 3000 23 1 036-092 Seal 3000 24 1 036-093 Seal Oil 3000 25 7 023-527 Disc, Inner 4574 Graphitic 3000 26 6 023-526 Disc, Outer Steel 3000 27 6 023-528 Separator, Spring 3000 28 2 013-087 Ring, Retaining 3000 29 6 010-102 Capscrew, Hex Socket - 3/8�-16 x 1-1/2" 3000 30 4 010-051 Capscrew, Hex Socket - 1/4"-20 x 1/2" 3000 31 2 021-105 Dowel, Pin - 3/8"Dia x 1" LG 3000 32 1 021-101 Shaft, Key Output And Wheel Hub 3000 33 1 117-235 Key, Square, 3/8 x 1-1/8 LG. 3000 34 1 021-103 Key - 1/4"X 51/64"LG. Round 3000 35 2 021-090 Plug, Socket Pipe, 3/8"-18 3000 36 4 012-268 Washer, Lock Spring - 1/4" 3000 37 6 012-270 Washer, Spa, 3/8" Helical 3000 38 2 036-091 O-Ring 3000 39 1 018-582 Bearing, Roller 3000 40 1 018-583 Bearing, Roller 3000 41 1 111-625 Nut, Primary (Drive Unit) 3000 42 1 111-626 Nut, Secondary (Drive Unit) 3000 43 1FT 106-903 Tape, Magnetic 3000 44 1 021-331 Plug, Breather 3/8" Npt 3000 45 1 011-563 Nut, Hex - 1-1/4-12 Nte Series 3000 46 1 090-973 Oil, Gearoil - Premium R & O 68 3000 47 1 120-760 Guard (Seal) 3000 48 2 011-151 Capscrew, Flat Hex Head, #10-24 x 1/2"LG. 3000 49 3 012-287 Washer, Spacer - .880"ID X 1-1/4"OD x 1/16"THK 3000 50 1 R3-10202-01 Washer, Thrust - 7/8"ID X 1-7/16"OD x 1/32”THK 3000



12.9.8 Wiring Kit - Rear Battery Box Plate

Figure 60 : Wiring Kit - Rear Battery Box Plate



Wiring Kit - Rear Battery Box Plate Item Qty Part No General Description Specific Description ◄ - 144-5010 Kit-Wrg Rear Battery Box Plate 3000 1 2 030-043 Wire Terminal Ins. Slv, Blue #10 3000 2 2 030-778 Wire Terminals .25", Red 3000 3 1 030-098 Wire Terminal, Red, 5/16" Ring 3000 4 1 030-788 Terminal - 0.187" Red 3000 5 1 090-892-0020 Wire/m (2"Lg) Black #18/16 3000 6 1 090-892-0052 Wire/m (5-1/4"Lg) Black #18/16 3000 7 1 090-903-0142 Wire/m (14-1/4" Lg.) #18/16 Blk/Wht 3000



12.10 Hydraulic Layout - Single Stage

35

3

23

35

4

27

2625

3436

25

25 25

10, 11,12, 13,14 2

10, 11,12, 13,14

35

6

24

35

5

27

2625

3436

2525

259

18 11732245

118191722334

1516

11121314

6

1611

2

32

19

2021

13, 141215

8

1

22

2021

2

1

33

28293031

728293031

1

32

1 1

2

1

10

28

1

232

8

2

Figure 61 : Hydraulic Layout - Single Stage, 63", 68" Lift



Hydraulic Layout - Single Stage Item Qty Part No General Description Specific Description ◄ - 143-5075 Hydraulic Layout M/R-1stg 63"Lift 3000-63 - - 143-5075-1 Hydraulic Layout M/R-1stg 68"Lift 3000-68 1 2 036-708 Hose, Twin Ass'y (79") STR. JUC 3000-63 1 2 036-702 Hose, Twin Ass'y (84") STR. JUC 3000-63 2 3 143-5031-1 Hose Ass'y (Reach & Tilt Cyl.) 3000-63,68 3 1 100-5013 Hose #4 High Pressure (14"Lg) 3000-63,68 4 1 100-5013-1 Hose #4 High Pressure (17"Lg) 3000-63,68 5 1 100-5013-2 Hose #4 High Pressure (21"Lg) 3000-63,68 6 1 100-5013-3 Hose #4 High Pressure (24"Lg) 3000-63,68 7 1 033-837 Fuse, Velocity - 7.5GPM - 3.28" Lg. 3000-63,68 8 4 034-716 Fitting, #4 Bulkhead 90° 3000-63,68 9 2 034-709 Adaptor, Tee (4MJ-4MJ-4MJ) 3000-63,68 10 4 034-713 Fitting, Bulkhead Straight 3000-63,68 11 4 010-001 Capscrew, Hex Hd. 1/4"-20 x 1" 3000-63,68 12 4 011-506 Nut, Hex - 1/4"-20 3000-63,68 13 4 012-210 Washer, Flat - 1/4" Bolt S 3000-63,68 14 4 012-202 Washer, Lock Washer - 1/4" Helical 3000-63,68 15 1 143-0052 Strap, Hose Clamp - 6-7/8"x1-1/2" Rch Cyl 3000-63,68 16 1 035-228 Clamp, Hose - 3"- 4" 3000-63,68 17 2 035-272 Clamp 3000-63,68 18 6 025-087 Ties, Cable 3000-63,68 19** 1 143-5058 Cylinder Ass'y (3"Dia) 3000-63,68 20 4 013-034 Cir-Clip - 1" ID 3000-63,68 21 2 103-916 Pin 3000-63,68 22 1 103-736 Clevis 3000-63,68 23** 1 786-176 Cylinder Ass'y (Left) 2"Dia 3000-63,68 24** 1 786-177 Cylinder Ass'y (Right) 2"Dia 3000-63,68 25 8 013-002 Ring, Retaining 3/4" ID 3000-63,68 26 2 104-674 Pin, Clevis - Bottom 3000-63,68 27 2 104-675 Pin, Clevis - Top 3000-63,68 28 2 143-0079 Bracket, Bulkhead 3-3/8"Lg 3000-63,68 29 4 010-037 Capscrew, Hex Hd. - 5/16"-18 X 3/4" 3000-63,68 30 4 012-211 Washer, Flat - 5/16" 3000-63,68 31 4 012-200 Washer, Lock Helical - 5/16" 3000-63,68 32 1 143-5031 Hose, #4 Ass'y (32"Lg) 3000-63,68 33 1 100-5005-15 Hose, 6# H.P. (46"Lg) Str. 90° 3000-63 33 1 100-5005-16 Hose, 6# H.P. (51"Lg) Str. 90° 3000-68 34 2 104-117 Clevis, Tilt Cylinder - Reach Assembly 3000-63,68 35 4 034-511 Adapter, 90° - 4-5S 3000-63,68 36 2 014-003 Setscrew, Sckt Hd C.P. 5/16"-18 X 5/16" 3000-63,68 * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.10.1 Reach Cylinder Assembly - Single Stage

8

7

910

3

1112

14

1

2

7

13

4

13

15

1615

5

Figure 62 : Reach Cylinder Assembly - Single Stage, 63", 68" Lift



Reach Cylinder Assembly - Single Stage Item Qty Part No General Description Specific Description ◄ 1 143-5058 Cylinder Ass'y - Reach (3"Dia) 3000-63,68 1 1 143-5057 Weldment, Housing 3000-63,68 2 1 115-074 Ram 3000-63,68 3 1 115-071 Nut, Head 3000-63,68 4 1 115-072 Piston 3000-63,68 5 2 034-019 Fitting, Hose 3000-63,68 6 1 011-535 Nut, Huglock - 3/4"-10 3000-63,68 7 1 036-018 Wiper, Rod 3000-63,68 8 1 013-045 C-Clip 3000-63,68 9 1 036-136 Ring, Back-Up 3000-63,68 10 1 036-132 "O"-Ring 3000-63,68 11 1 036-137 Ring, Back-Up 3000-63,68 12 1 036-135 "O"-Ring 3000-63,68 13 1 036-112 "U"-Cup 3000-63,68 14 1 036-108 "O"-Ring 3000-63,68 15 1 105-733 Ball, Steel - 1/4" Dia. 3000-63,68 16 1 104-069 Retainer, Ball 3000-63,68



12.10.2 Tilt Cylinder Assemblies - Single Stage

11

10

78

3

56

9

2

12

13

4

13

1

14

Figure 63 : Tilt Cylinder Assemblies - Single Stage, 63", 68" Lift



3000 Tilt Cylinder Assemblies - Single Stage Item Qty Part No General Description Specific Description ◄ - 786-177 Cylinder Ass'y (Right) 2"Dia 3000-63,68 - 786-176 Cylinder Ass'y (Left) 2"Dia 3000-63,68 1 1 786-152 Housing Assembly (Right) 3000-63,68 1 1 786-178 Housing Assembly (Left) 3000-63,68 2 1 115-675 Ram - 2" Double Acting Cyl (3/4"Dia) 3000-63,68 3 1 118-659 Nut, Head 3000-63,68 4 1 115-673 Piston 3000-63,68 5● 1 036-159 O-Ring - 1"OD x 3/4"ID x 1/8" 3000-63,68 6● 1 036-145 Ring, Back Up - 1"OD x 3/4"ID x 1/16" 3000-63,68 7● 1 036-134 O-Ring - 2"Od X 1-3/4"Id 3000-63,68 8● 1 036-146 Ring, Back Up - 2" OD x1-3/4 ID x 1/16"Thk 3000-63,68 9● 1 036-147 O-Ring, 5/8"OD x 1/2"ID x 1/16" 3000-63,68 10● 1 036-148 Wiper, Rod - 1"OD x 3/4"ID x 1/8" 3000-63,68 11 1 013-098 C-Clip, Internal Ret Ring Type Dia 2" 3000-63,68 12 1 011-554 Nut, Hex - 1/2�-13 Nylon Insert 3000-63,68 13● 2 036-118 U-Cup, - 2"OD x 1-3/8" x 1/2" 3000-63,68 14 1 012-239 Washer, Spacer - 1/2"ID x 1"OD x 1/8"Thk 3000-63,68 - - 780-609 Kit Seal (Includes Items Marked ●)



12.11 Hydraulic Layout - Two Stage

34

3

23

34

4

27

2625

3335

25

25 25

10, 11,12, 13,14 2

10, 11,12, 13,14

34

6

24

34

5

27

2625

3335

2525

259

18 11732245

118191722334

1516

11121314

6

1611

2

32

19

2021

13, 141215

8

1

22

2021

2

1

33

28293031

7

28293031

1

2

1 1

2

1

28293031

1

232

8

32

7

Figure 64 : Hydraulic Layout - Two Stage, 118", 130", 150" Lift



Hydraulic Layout - Two Stage Item Qty Part No General Description Specific Description ◄ - 143-5022 Hydraulic Layout M/R -2stg 118"Lift] 3000-118 - - 143-5022-1 Hydraulic Layout M/R -2stg 130"Lift] 3000-130 - - 143-5022-2 Hydraulic Layout M/R -2stg 150"Lift] 3000-150 1 2 036-570 Hose, Twin Ass'y (139") STR. JUC 3000-118 1 2 036-571 Hose, Twin Ass'y (149") STR. JUC 3000-130 1 2 036-572 Hose, Twin Ass'y (169") STR. JUC 3000-150 2 3 143-5031-1 Hose Ass'y (Reach & Tilt Cyl.) 3000-118,130,150 3 1 100-5013 Hose #4 High Pressure (14"Lg) 3000-118,130,150 4 1 100-5013-1 Hose #4 High Pressure (17"Lg) 3000-118,130,150 5 1 100-5013-2 Hose #4 High Pressure (21"Lg) 3000-118,130,150 6 1 100-5013-3 Hose #4 High Pressure (24"Lg) 3000-118,130,150 7 1 033-837 Fuse, Velocity - 7.5GPM - 3.28" Lg. 3000-118,130,150 8 4 034-716 Fitting, #4 Bulkhead 90° 3000-118,130,150 9 2 034-709 Adaptor, Tee (4MJ-4MJ-4MJ) 3000-118,130,150 10 2 035-204 Clamp 3000-118,130,150 11 4 010-001 Capscrew, Hex Hd. 1/4"-20 x 1" 3000-118,130,150 12 4 011-506 Nut, Hex - 1/4"-20 3000-118,130,150 13 4 012-210 Washer, Flat - 1/4" Bolt S 3000-118,130,150 14 4 012-202 Washer, Lock Washer - 1/4" Helical 3000-118,130,150 15 1 143-0052 Strap, Hose Clamp - 6-7/8"x1-1/2" Rch Cyl 3000-118,130,150 16 1 035-228 Clamp, Hose - 3"- 4" 3000-118,130,150 17 2 035-272 Clamp 3000-118,130,150 18 6 025-087 Ties, Cable 3000-118,130,150 19** 1 143-5058 Cylinder Ass'y (3"Dia) 3000-118,130,150 20 4 013-034 Cir-Clip - 1" ID 3000-118,130,150 21 2 103-916 Pin 3000-118,130,150 22 1 103-736 Clevis 3000-118,130,150 23** 1 786-176 Cylinder Ass'y (Left) 2"Dia 3000-118,130,150 24** 1 786-177 Cylinder Ass'y (Right) 2"Dia 3000-118,130,150 25 8 013-002 Ring, Retaining 3/4" ID 3000-118,130,150 26 2 104-674 Pin, Clevis - Bottom 3000-118,130,150 27 2 104-675 Pin, Clevis - Top 3000-118,130,150 28 2 143-0079 Bracket, Bulkhead 3-3/8"Lg 3000-118,130,150 29 4 010-037 Capscrew, Hex Hd. - 5/16"-18 X 3/4" 3000-118,130,150 30 4 012-211 Washer, Flat - 5/16" 3000-118,130,150 31 4 012-200 Washer, Lock Helical - 5/16" 3000-118,130,150 32 1 143-5031 Hose, #4 Ass'y (32"Lg) 3000-118,130,150 33 2 104-117 Clevis, Tilt Cylinder - Reach Assembly 3000-118,130,150 34 4 034-511 Adapter, 90° - 4-5S 3000-118,130,150 35 2 014-003 Setscrew, Sckt Hd C.P. 5/16"-18 X 5/16" 3000-118,130,150




12.11.1 Reach Cylinder Assembly - Two Stage

8

7

910

3

1112

14

1

2

7

13

4

13

15

1615

5

Figure 65 : Reach Cylinder Assembly - 118", 130", 150" Lift



Reach Cylinder Assembly - Two Stage Item Qty Part No General Description Specific Description ◄ 1 143-5058 Cylinder Ass'y - Reach (3"Dia) 3000-118,130,150 1 1 143-5057 Weldment, Housing 3000-118,130,150 2 1 115-074 Ram 3000-118,130,150 3 1 115-071 Nut, Head 3000-118,130,150 4 1 115-072 Piston 3000-118,130,150 5 2 034-019 Fitting, Hose 3000-118,130,150 6 1 011-535 Nut, Huglock - 3/4"-10 3000-118,130,150 7 1 036-018 Wiper, Rod 3000-118,130,150 8 1 013-045 C-Clip 3000-118,130,150 9 1 036-136 Ring, Back-Up 3000-118,130,150 10 1 036-132 "O"-Ring 3000-118,130,150 11 1 036-137 Ring, Back-Up 3000-118,130,150 12 1 036-135 "O"-Ring 3000-118,130,150 13 1 036-112 "U"-Cup 3000-118,130,150 14 1 036-108 "O"-Ring 3000-118,130,150 15 1 105-733 Ball, Steel - 1/4" Dia. 3000-118,130,150 16 1 104-069 Retainer, Ball 3000-118,130,150



12.11.2 Tilt Cylinder Assemblies - Two Stage

11

10

78

3

56

9

2

12

13

4

13

1

14

Figure 66 : Tilt Cylinder Assemblies - 118", 130", 150" Lift



3000 Tilt Cylinder Assemblies - Two Stage Item Qty Part No General Description Specific Description ◄ - 786-177 Cylinder Ass'y (Right) 2"Dia 3000-118,130,150 - 786-176 Cylinder Ass'y (Left) 2"Dia 3000-118,130,150 1 1 786-152 Housing Assembly (Right) 3000-118,130,150 1 1 786-178 Housing Assembly (Left) 3000-118,130,150 2 1 115-675 Ram - 2" Double Acting Cyl (3/4"Dia) 3000-118,130,150 3 1 118-659 Nut, Head 3000-118,130,150 4 1 115-673 Piston 3000-118,130,150 5● 1 036-159 O-Ring - 1"OD x 3/4"ID x 1/8" 3000-118,130,150 6● 1 036-145 Ring, Back Up - 1"OD x 3/4"ID x 1/16" 3000-118,130,150 7● 1 036-134 O-Ring - 2"Od X 1-3/4"Id 3000-118,130,150 8● 1 036-146 Ring, Back Up - 2" OD x1-3/4 ID x 1/16"Thk 3000-118,130,150 9● 1 036-147 O-Ring, 5/8"OD x 1/2"ID x 1/16" 3000-118,130,150 10● 1 036-148 Wiper, Rod - 1"OD x 3/4"ID x 1/8" 3000-118,130,150 11 1 013-098 C-Clip, Internal Ret Ring Type Dia 2" 3000-118,130,150 12 1 011-554 Nut, Hex - 1/2�-13 Nylon Insert 3000-118,130,150 13● 2 036-118 U-Cup, - 2"OD x 1-3/8" x 1/2" 3000-118,130,150 14 1 012-239 Washer, Spacer - 1/2"ID x 1"OD x 1/8"Thk 3000-118,130,150 - - 780-609 Kit Seal (Includes Items Marked ●) 3000-118,130,150



12.12 Hydraulic Layout - Two Stage Full Free

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Figure 67 : Hydraulic Layout - Two Stage, 130" Lift



Hydraulic Layout - Two Stage Full Free Item Qty Part No General Description Specific Description ◄ - 143-5104 Hydraulic Layout M/R -2stg Full Free 3000-2stg Full Free 1 2 036-708 Hose, Twin Ass'y (139") STR. JIC 3000-118" Full Free 1 2 036-702 Hose, Twin Ass'y (") STR. JIC 3000-130" Full Free 1 2 036-704 Hose, Twin Ass'y (") STR. JIC 3000-150" Full Free 2 3 143-5031-1 Hose Ass'y (Reach & Tilt Cyl.) 3000-2stg Full Free 3 1 100-5013 Hose #4 High Pressure (14"Lg) 3000-2stg Full Free 4 1 100-5013-1 Hose #4 High Pressure (17"Lg) 3000-2stg Full Free 5 1 100-5013-2 Hose #4 High Pressure (21"Lg) 3000-2stg Full Free 6 1 100-5013-3 Hose #4 High Pressure (24"Lg) 3000-2stg Full Free 7 1 033-837 Fuse, Velocity - 7.5GPM - 3.28" Lg. 3000-2stg Full Free 8 4 034-716 Fitting, #4 Bulkhead 90° 3000-2stg Full Free 9 2 034-709 Adapter, Tee (4MJ-4MJ-4MJ) 3000-2stg Full Free 10 2 035-204 Clamp 3000-2stg Full Free 11 4 010-001 Capscrew, Hex Hd. 1/4"-20 x 1" 3000-2stg Full Free 12 4 011-506 Nut, Hex - 1/4"-20 3000-2stg Full Free 13 4 012-210 Washer, Flat - 1/4" Bolt S 3000-2stg Full Free 14 4 012-202 Washer, Lock Washer - 1/4" Helical 3000-2stg Full Free 15 1 143-0052 Strap, Hose Clamp - 6-7/8"x1-1/2" Rch Cyl 3000-2stg Full Free 16 1 035-228 Clamp, Hose - 3"- 4" 3000-2stg Full Free 17 2 035-272 Clamp 3000-2stg Full Free 18 6 025-087 Ties, Cable 3000-2stg Full Free 19** 1 143-5058 Cylinder Ass'y (3"Dia) 3000-2stg Full Free 20 4 013-034 Cir-Clip - 1" ID 3000-2stg Full Free 21 2 103-916 Pin 3000-2stg Full Free 22 1 103-736 Clevis 3000-2stg Full Free 23** 1 786-176 Cylinder Ass'y (Left) 2"Dia 3000-2stg Full Free 24** 1 786-177 Cylinder Ass'y (Right) 2"Dia 3000-2stg Full Free 25 8 013-002 Ring, Retaining 3/4" ID 3000-2stg Full Free 26 2 104-674 Pin, Clevis - Bottom 3000-2stg Full Free 27 2 104-675 Pin, Clevis - Top 3000-2stg Full Free 28 2 143-0079 Bracket, Bulkhead 3-3/8"Lg 3000-2stg Full Free 29 4 010-037 Capscrew, Hex Hd. - 5/16"-18 X 3/4" 3000-2stg Full Free 30 4 012-211 Washer, Flat - 5/16" 3000-2stg Full Free 31 4 012-200 Washer, Lock Helical - 5/16" 3000-2stg Full Free 32 1 143-5031 Hose, #4 Ass'y (32"Lg) 3000-2stg Full Free 33 3 010-000 Capscrew, Hex Hd. - 1/4"-20 x 3/4" 3000-2stg Full Free 34 2 035-205 Clamp 3000-2stg Full Free 35 2 033-663 Velocity Fuse-7.5 GPM 3000-2stg Full Free 36 10 011-020 Screw, Machine R/H Slot 1/4"-20 X 3/4" 3000-2stg Full Free 37 8 034-713 Fitting, Bulkhead Str. 4-4 3000-2stg Full Free 38 1 034-608 Bulkhead Fitting-#6 Male Hose 3000-2stg Full Free 39 2 143-5108 Chain Ass'y, Flex Link w/Hoses 3000-118" Full Free 39 2 143-5108-1 Chain Ass'y, Flex Link w/Hoses 3000-130" Full Free 39 2 143-5108-2 Chain Ass'y, Flex Link w/Hoses 3000-150" Full Free 40 1 100-5005-21 Hose Ass'y - Bulkhead to Lift Cyl. 3000-2stg Full Free * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE

Continued…



Hydraulic Layout - Two Stage Full Free

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Figure 68 : Hydraulic Layout - Two Stage Full Free, 118", 130", 150" Lift



Hydraulic Layout - Two Stage Full Free Item Qty Part No General Description Specific Description 41 2 104-117 Clevis, Tilt Cylinder - Reach Assy 3000-2stg Full Free 42 4 034-511 Adapter 90° 3000-2stg Full Free 43 2 014-003 Setscrew, Socket Hd Cp 5/16"-18 X 5/16" 3000-2stg Full Free 44 1 143-5106 Inner Mast With I.H. Channel 3000-118" Full Free 44 1 143-5106-1 Inner Mast With I.H. Channel 3000-130" Full Free 44 1 143-5106-2 Inner Mast With I.H. Channel 3000-150" Full Free 45 1 143-5105 Outer Mast With I.H. Channel 3000-118" Full Free 45 1 143-5105-1 Outer Mast With I.H. Channel 3000-130" Full Free 45 1 143-5105-2 Outer Mast With I.H. Channel 3000-150" Full Free



12.12.1 Reach Cylinder Assembly - Two Stage

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Figure 69 : Reach Cylinder Assembly - Two Stage, 130" Lift, 118", 130", 150" Lift



Reach Cylinder Assembly - Two Stage Item Qty Part No General Description Specific Description ◄ 1 143-5058 Cylinder Ass'y - Reach (3"Dia) 3000-2stg Full Free 1 1 143-5057 Weldment, Housing 3000-2stg Full Free 2 1 115-074 Ram 3000-2stg Full Free 3 1 115-071 Nut, Head 3000-2stg Full Free 4 1 115-072 Piston 3000-2stg Full Free 5 2 034-019 Fitting, Hose 3000-2stg Full Free 6 1 011-535 Nut, Huglock - 3/4"-10 3000-2stg Full Free 7 1 036-018 Wiper, Rod 3000-2stg Full Free 8 1 013-045 C-Clip 3000-2stg Full Free 9 1 036-136 Ring, Back-Up 3000-2stg Full Free 10 1 036-132 "O"-Ring 3000-2stg Full Free 11 1 036-137 Ring, Back-Up 3000-2stg Full Free 12 1 036-135 "O"-Ring 3000-2stg Full Free 13 1 036-112 "U"-Cup 3000-2stg Full Free 14 1 036-108 "O"-Ring 3000-2stg Full Free 15 1 105-733 Ball, Steel - 1/4" Dia. 3000-2stg Full Free 16 1 104-069 Retainer, Ball 3000-2stg Full Free



12.12.2 Tilt Cylinder Assemblies - Two Stage

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Figure 70 : 3000 Tilt Cylinder Assemblies - Two Stage, 130" Lift, 118", 130", 150" Lift



3000 Tilt Cylinder Assemblies - Two Stage Item Qty Part No General Description Specific Description ◄ - 786-177 Cylinder Ass'y (Right) 2"Dia 3000-2stg Full Free - 786-176 Cylinder Ass'y (Left) 2"Dia 3000-2stg Full Free 1 1 786-152 Housing Assembly (Right) 3000-2stg Full Free 1 1 786-178 Housing Assembly (Left) 3000-2stg Full Free 2 1 115-675 Ram - 2" Double Acting Cyl (3/4"Dia) 3000-2stg Full Free 3 1 118-659 Nut, Head 3000-2stg Full Free 4 1 115-673 Piston 3000-2stg Full Free 5● 1 036-159 O-Ring - 1"OD x 3/4"ID x 1/8" 3000-2stg Full Free 6● 1 036-145 Ring, Back Up - 1"OD x 3/4"ID x 1/16" 3000-2stg Full Free 7● 1 036-134 O-Ring - 2"Od X 1-3/4"Id 3000-2stg Full Free 8● 1 036-146 Ring, Back Up - 2" OD x1-3/4 ID x 1/16"Thk 3000-2stg Full Free 9● 1 036-147 O-Ring, 5/8"OD x 1/2"ID x 1/16" 3000-2stg Full Free 10● 1 036-148 Wiper, Rod - 1"OD x 3/4"ID x 1/8" 3000-2stg Full Free 11 1 013-098 C-Clip, Internal Ret Ring Type Dia 2" 3000-2stg Full Free 12 1 011-554 Nut, Hex - 1/2�-13 Nylon Insert 3000-2stg Full Free 13● 2 036-118 U-Cup, - 2"OD x 1-3/8" x 1/2" 3000-2stg Full Free 14 1 012-239 Washer, Spacer - 1/2"ID x 1"OD x 1/8"Thk 3000-2stg Full Free - - 780-609 Kit Seal (Includes Items Marked ●) 3000-2stg Full Free



12.13 Hydraulic Layout - Three Stage

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Figure 71 : Hydraulic Layout - Three Stage, 160", 180" Lift



Hydraulic Layout - Three Stage Item Qty Part No General Description Specific Description ◄ - 143-5018 Hydraulic Layout M/R -3stg 160"Lift 3000-160 - - 143-5018-1 Hydraulic Layout M/R -3stg 180"Lift 3000-180 1 4 143-5019-2 Hose, Twin Ass'y (126") STR. 3000-160 1 2 143-5019-3 Hose, Twin Ass'y (149") STR. JUC 3000-180 2 3 143-5031-1 Hose Ass'y (Reach & Tilt Cyl.) 3000-160,180 3 1 100-5013 Hose #4 High Pressure (14"Lg) 3000-160,180 4 1 100-5013-1 Hose #4 High Pressure (17"Lg) 3000-160,180 5 1 100-5013-2 Hose #4 High Pressure (21"Lg) 3000-160,180 6 1 100-5013-3 Hose #4 High Pressure (24"Lg) 3000-160,180 7 1 033-837 Fuse, Velocity - 7.5GPM - 3.28" Lg. 3000-160,180 8 4 034-716 Fitting, #4 Bulkhead 90° 3000-160,180 9 2 034-709 Adapter, Tee (4MJ-4MJ-4MJ) 3000-160,180 10 2 035-204 Clamp 3000-160,180 11 4 010-001 Capscrew, Hex Hd. 1/4"-20 x 1" 3000-160,180 12 4 011-506 Nut, Hex - 1/4"-20 3000-160,180 13 4 012-210 Washer, Flat - 1/4" Bolt S 3000-160,180 14 4 012-202 Washer, Lock Washer - 1/4" Helical 3000-160,180 15 1 143-0052 Strap, Hose Clamp - 6-7/8"x1-1/2" Rch Cyl 3000-160,180 16 1 035-228 Clamp, Hose - 3"- 4" 3000-160,180 17 2 035-272 Clamp 3000-160,180 18 6 025-087 Ties, Cable 3000-160,180 19 1 143-5058 Cylinder Ass'y (3"Dia) 3000-160,180 20 4 013-034 Cir-Clip - 1" ID 3000-160,180 21 2 103-916 Pin 3000-160,180 22 1 103-736 Clevis 3000-160,180 23 1 786-176 Cylinder Ass'y (Left) 2"Dia 3000-160,180 24 1 786-177 Cylinder Ass'y (Right) 2"Dia 3000-160,180 25 8 013-002 Ring, Retaining 3/4" ID 3000-160,180 26 2 104-674 Pin, Clevis - Bottom 3000-160,180 27 2 104-675 Pin, Clevis - Top 3000-160,180 28 2 143-0054 Bracket, Bulkhead 3000-160,180 29 4 010-037 Capscrew, Hex Hd. - 5/16"-18 X 3/4" 3000-160,180 30 4 012-211 Washer, Flat - 5/16" 3000-160,180 31 4 012-200 Washer, Lock Helical - 5/16" 3000-160,180 32 1 143-5031 Hose, #4 Ass'y (32"Lg) 3000-160,180 33 3 010-000 Capscrew, Hex Hd. 1/4"-20 X 3/4" 3000-160,180 34 2 035-304 Clamp, Double Hose 3/4"Dia 3000-160,180 35 1 143-0085 Bracket, Hose 3000-160,180 36 2 034-715 Fitting, #4 Bulkhead 45 Deg 3000-160,180 37 6 034-713 Fitting, Bulkhead Straight #4h-#4h 3000-160,180 38 1 034-608 Fitting, Bulkhead - #6 Male Hose 3000-160,180 39 2 143-5108-3 Flex Link Chain Ass'y With Hoses 3000-160 40 1 100-5005-11 Hose 6# H.P. (55"Lg) Str. 90° 3000-160 40 1 100-5005-17 Hose 6# H.P. (60"Lg) Str- 90° 3000-180 41 2 104-117 Clevis, Tilt Cylinder Reach Assy 3000-160,180 42 4 034-511 Adapter 90 Deg - 4-5s 3000-160,180 43 2 014-003 Setscrew, Sckt Hd Cp 5/16"-18 X 5/16" 3000-160,180 44 10 011-020 Screw, Machine R/H Slot 1/4"-20 X 3/4" 3000-160,180 * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE



12.13.1 Reach Cylinder Assembly - Three Stage

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Figure 72 : 3000 Reach Cylinder Assembly - Three Stage, 160", 180" Lift



Reach Cylinder Assembly - Three Stage Item Qty Part No General Description Specific Description ◄ 1 143-5058 Cylinder Ass'y - Reach (3"Dia) 3000-160,180 1 1 143-5057 Weldment, Housing 3000-160,180 2 1 115-074 Ram 3000-160,180 3 1 115-071 Nut, Head 3000-160,180 4 1 115-072 Piston 3000-160,180 5 2 034-019 Fitting, Hose 3000-160,180 6 1 011-535 Nut, Huglock - 3/4"-10 3000-160,180 7 1 036-018 Wiper, Rod 3000-160,180 8 1 013-045 C-Clip 3000-160,180 9 1 036-136 Ring, Back-Up 3000-160,180 10 1 036-132 "O"-Ring 3000-160,180 11 1 036-137 Ring, Back-Up 3000-160,180 12 1 036-135 "O"-Ring 3000-160,180 13 1 036-112 "U"-Cup 3000-160,180 14 1 036-108 "O"-Ring 3000-160,180 15 1 105-733 Ball, Steel - 1/4" Dia. 3000-160,180 16 1 104-069 Retainer, Ball 3000-160,180



12.13.2 Tilt Cylinder Assemblies - Three Stage

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Figure 73 : 3000 Tilt Cylinder Assemblies - Three Stage, 160", 180" Lift



3000 Tilt Cylinder Assemblies - Three Stage Item Qty Part No General Description Specific Description ◄ - 786-177 Cylinder Ass'y (Right) 2"Dia 3000-160,180 - 786-176 Cylinder Ass'y (Left) 2"Dia 3000-160,180 1 1 786-152 Housing Assembly (Right) 3000-160,180 1 1 786-178 Housing Assembly (Left) 3000-160,180 2 1 115-675 Ram - 2" Double Acting Cyl (3/4"Dia) 3000-160,180 3 1 118-659 Nut, Head 3000-160,180 4 1 115-673 Piston 3000-160,180 5● 1 036-159 O-Ring - 1"OD x 3/4"ID x 1/8" 3000-160,180 6● 1 036-145 Ring, Back Up - 1"OD x 3/4"ID x 1/16" 3000-160,180 7● 1 036-134 O-Ring - 2"Od X 1-3/4"Id 3000-160,180 8● 1 036-146 Ring, Back Up - 2" OD x1-3/4 ID x 1/16"Thk 3000-160,180 9● 1 036-147 O-Ring, 5/8"OD x 1/2"ID x 1/16" 3000-160,180 10● 1 036-148 Wiper, Rod - 1"OD x 3/4"ID x 1/8" 3000-160,180 11 1 013-098 C-Clip, Internal Ret Ring Type Dia 2" 3000-160,180 12 1 011-554 Nut, Hex - 1/2�-13 Nylon Insert 3000-160,180 13● 2 036-118 U-Cup, - 2"OD x 1-3/8" x 1/2" 3000-160,180 14 1 012-239 Washer, Spacer - 1/2"ID x 1"OD x 1/8"Thk 3000-160,180 - - 780-609 Kit Seal (Includes Items Marked ●)



12.14 Hydraulic Layout - Three Stage Full Free

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Figure 74 : 3000 Hydraulic Layout - Three Stage, 172" Full Free



Hydraulic Layout - Three Stage Full Free Item Qty Part No General Description Specific Description ◄ - 145-5025 Hydraulic Layout M/R -3stg 172"Lift 3000-172 Full Free 1 1 036-538 Hose Reel Right 3000-172 Full Free 2 1 036-539 Hose Reel Left 3000-172 Full Free 3 2 036-544 Twin Hose Assembly - 156"Lg 3000-172 Full Free 4 1 100-5004-6 Hose (78"Lg) 6# High Pressure 3000-172 Full Free 5 4 034-536 Adapter, 8-6 3000-172 Full Free 6 1 100-5005-9 Hose #6 HP (20"Lg) Str.-90 Deg 3000-172 Full Free 7 1 033-837 Velocity Fuse -7.5gpm-3.28" Length 3000-172 Full Free 8 2 033-663 Velocity Fuse-7.5 Gpm 3000-172 Full Free 9 8 034-621 Fitting, 6-6 3000-172 Full Free 10 4 010-029 Capscrew, 1/2"-13 X 3-1/2" 3000-172 Full Free 11 4 012-220 Washer, Lock - 1/2" Split Reg. 3000-172 Full Free 12 4 012-239 Washer, 1/2" Id X 1"Od X 1/8"Thk Spacer 3000-172 Full Free 13 4 011-508 Nut, Hex - 1/2"-13 3000-172 Full Free 14 6 010-001 Capscrew, Hex Hd. 1/4"-20 X 1" 3000-172 Full Free 15 6 012-202 Lock Washer, 1/4" Helical 3000-172 Full Free 16 6 012-210 Washer, Flat - 1/4" Bolt S 3000-172 Full Free 17 6 035-272 Clamp 3000-172 Full Free



12.15 Body Hydraulic Layout - One and Two Stage

Figure 75 : 3000 Body Hydraulic Layout - One and Two Stage



Body Hydraulic Layout - One and Two Stage Item Qty Part No General Description Specific Description ◄ - 145-5009 Body, Hyd. Layout - Internal Hose

Routing 3000 1&2 Stage 1** 1 144-5026 Valve Assy 3 Spools (Salami) 3000 1&2 Stage 2 2 010-037 Capscrew, Hex Hd. - 5/16"-18 X 3/4" 3000 1&2 Stage 3 7 012-210 Washer, Flat - 1/4" Bolt S 3000 1&2 Stage 4 4 012-200 Washer, Lock - 5/16" Helical 3000 1&2 Stage 5 1 033-106-1 Powerpack Ass'y 24v 3000 1&2 Stage 6 4 010-039 Cap Screw, Hex Hd. - 3/8"-16 X 1" 3000 1&2 Stage 7 4 012-211 Washer, Flat - 5/16" Bolt Size 3000 1&2 Stage 8 4 012-201 Washer, Lock - 3/8" Dia.Helical 3000 1&2 Stage 9 4 011-507 Nut, Hex - 3/8"-16 3000 1&2 Stage 10** 1 145-5008 Reservoir Ass'y 3000 1&2 Stage 11 1 100-5005-17 Hose #6 H.P. (60"Lg) Str.-90° 3000 1&2 Stage 12* 1 145-5004 Valve Ass'y, Load Lowering 3000 1&2 Stage 13 1 033-501 Valve, Load Lowering Control 3000 1&2 Stage 14 2 034-505 Adapter, 8-6 3000 1&2 Stage 15 3 010-003 Capscrew, Hex Hd. - 1/4"-20 X 2" 3000 1&2 Stage 16 7 012-202 Washer, Lock - 1/4" Helical 3000 1&2 Stage 17* 1 145-5010 Valve, Relief Assembly 3000 1&2 Stage 18 1 033-587 Valve Relief 3000 1&2 Stage 19 1 034-505 Adapter, 8-6 3000 1&2 Stage 20 1 034-555 Adapter, Fitting 8-4 3000 1&2 Stage 21 1 034-619 Fitting, 4-4 3000 1&2 Stage 22 1 100-5005 Hose #6 H.P. (8"Lg) Str. - 90° 3000 1&2 Stage 23 1 100-5005-11 Hose #6 H.P. (55"Lg) Str. - 90° 3000 1&2 Stage 24 1 100-5013-8 Hose #4 H.P. (50"Lg) - Str. 3000 1&2 Stage 25 1 100-5013-3 Hose #4 H.P. (24"Lg) - Str. 3000 1&2 Stage 26 1 100-5005-3 Hose #6 H.P. (34'lg) Str.-90° Elbow 3000 1&2 Stage 27 4 100-5014-1 Hose, #4 Ass'y (50"Lg) 3000 1&2 Stage 28 10 034-718 Adapter #6 M Sae - #4 M Jic 37° 3000 1&2 Stage 29 2 033-841 Valve, Dual P.O. Check (Lock) 3000 1&2 Stage 30 4 010-002 Capscrew, Hex Hd. - 1/4"-20 X 1-1/2" 3000 1&2 Stage 31 1 100-5008 Hose 8# Med Pressure (39"Lg) 3000 1&2 Stage 32 1 034-587 Adapter, 8-8 3000 1&2 Stage 33 1 034-614 Fitting, 90° Elbow - 10-12 3000 1&2 Stage 34 1 100-5010 Hose (40"Lg) 12# L.P. Long Suction 3000 1&2 Stage 35 4 012-252 Washer,Flat - 3/8"Id Bolt S 3000 1&2 Stage 36 1 145-0010 Bracket, Valve Mounting 3000 1&2 Stage 37 1 033-875 Valve, Time Delay Flow Control 3000 1&2 Stage 38 1 100-5014-4 Hose, #4 Ass'y (12"Lg) 3000 1&2 Stage 39 1 100-5013-7 Hose #4 High Pressure (32"Lg) Str. 3000 1&2 Stage 40 1 100-0001 Decal,Warning Time Delay Valve 3000 1&2 Stage 41 1 100-5014-1 Hose, #4 Ass'y (50"Lg) 3000 1&2 Stage 42 1 100-5014 Hose, #4 Ass'y (32"Lg) 3000 1&2 Stage 43 2 010-011 Capscrew, Hex Hd. - 5/16-18 X 2-1/2" 3000 1&2 Stage




12.16 Control Valve Assembly

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Figure 76 : Hydraulic Control Valve - One and Two Stage



Control Valve Assembly

Item Qty Part No General Description Specific Description ◄ - 144-5026 Valve Assy 3 Spools (Salami) 3000 1&2 Stage 1 1 907-5155 Valve-Manual Triple Spool 3000 1&2 Stage 2 1 034-587 Adapter, 8-8 3000 1&2 Stage 3 1 034-619 Fitting, 4-4 3000 1&2 Stage 4 1 034-574 Fitting 3000 1&2 Stage 5 4 034-597 Fitting, Str. F Pipe W/O-Ring 8-4 3000 1&2 Stage 6 4 034-533 Fitting, 4-4 3000 1&2 Stage 7 1 034-727 Adapter, Str. - 10MB-6MJ 3000 1&2 Stage 8 1 034-582 Fitting, 8-6 3000 1&2 Stage



12.17 Hydraulic Reservoir Assembly

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Figure 77 : Hydraulic Reservoir Assembly - One and Two Stage



Hydraulic Reservoir Assembly

Item Qty Part No General Description Specific Description ◄ - 145-5008 Reservoir Ass'y 3000 1&2 Stage 1 1 145-5000 Reservoir Weldment 3000 1&2 Stage 2 1 035-238 Breather Cap (3/4") 3000 1&2 Stage 3 1 105-5002 Filter Ass'y (Pick 034-616) 3000 1&2 Stage 4 1 034-508 Adapter, 6-6 (PA) 3000 1&2 Stage 5 1 034-519 Adapter, Reducer Bush 3/8M-1/4F Pipe 3000 1&2 Stage 6 1 034-665 Fitting, Tee 3000 1&2 Stage



12.18 Body Hydraulic Layout - Three Stage

Figure 78 : 3000 Body Hydraulic Layout - Three Stage



Body Hydraulic Layout - Three Stage Item Qty Part No General Description Specific Description ◄ - 145-5013 Body, Hyd. Layout - Internal Hose

Routing BGNR - 3 Stage

1** 1 144-5026 Valve Assy 3 Spools (Salami) BGNR - 3 Stage 2 2 010-037 Capscrew, Hex Hd. - 5/16"-18 X 3/4" BGNR - 3 Stage 3 7 012-210 Washer, Flat - 1/4" Bolt S BGNR - 3 Stage 4 4 012-200 Washer, Lock - 5/16" Helical BGNR - 3 Stage 5 1 033-106-1 Powerpack Ass'y 24v BGNR - 3 Stage 6 4 010-039 Capscrew, Hex Hd. - 3/8"-16 X 1" BGNR - 3 Stage 7 4 012-211 Washer, Flat - 5/16" Bolt Size BGNR - 3 Stage 8 4 012-201 Washer, Lock - 3/8" Dia.Helical BGNR - 3 Stage 9 4 011-507 Nut, Hex - 3/8"-16 BGNR - 3 Stage 10** 1 145-5008 Reservoir Ass'y BGNR - 3 Stage 11 1 100-5005-17 Hose #6 H.P. (60"Lg) Str.-90° BGNR - 3 Stage 12* 1 145-5004-1 Valve Ass'y, Load Lowering BGNR - 3 Stage 13 1 033-501 Valve, Load Lowering Control BGNR - 3 Stage 14 1 034-505 Adapter, 8-6 BGNR - 3 Stage 15 1 034-541 Adapter Fitting 8-8 BGNR - 3 Stage 16 3 010-003 Capscrew, Hex Hd. - 1/4"-20 X 2" BGNR - 3 Stage 17 7 012-202 Washer, Lock - 1/4" Helical BGNR - 3 Stage 18* 1 145-5010 Valve, Relief Assembly BGNR - 3 Stage 19 1 033-587 Valve Relief BGNR - 3 Stage 20 1 034-505 Adapter, 8-6 BGNR - 3 Stage 21 1 034-555 Adapter, Fitting 8-4 BGNR - 3 Stage 22 1 034-619 Fitting, 4-4 BGNR - 3 Stage 23 1 100-5018 Hose #6 H.P. - 90° BGNR - 3 Stage 24 1 100-5004-6 Hose #6 H.P. (78"Lg) Str. - 90° BGNR - 3 Stage 25 1 100-5013-8 Hose #4 H.P. (50"Lg) - Str. BGNR - 3 Stage 26 1 100-5013-3 Hose #4 H.P. (24"Lg) - Str. BGNR - 3 Stage 27 1 100-5005-3 Hose #6 H.P. (34"Lg) Str.-90° Elbow BGNR - 3 Stage 28 4 100-5013-7 Hose, #4 Ass'y (32"Lg) - Str. BGNR - 3 Stage 29 10 034-718 Adapter #6 M SAE - #4 M JIC 37° BGNR - 3 Stage 30 4 100-5013-5 Hose, #4 Ass'y (43"Lg) - Str. BGNR - 3 Stage 31 2 033-841 Valve, Dual P.O. Check (Lock) BGNR - 3 Stage 32 4 010-002 Capscrew, Hex Hd. - 1/4"-20 X 1-1/2" BGNR - 3 Stage 33 1 100-5008 Hose #8 Med Pressure (39"Lg) BGNR - 3 Stage 34 1 034-587 Adapter, 8-8 BGNR - 3 Stage 35 1 034-614 Fitting, 90° Elbow - 10-12 BGNR - 3 Stage 36 1 100-5010 Hose (40"Lg) 12# L.P. Long Suction BGNR - 3 Stage 37 4 012-252 Washer, Flat - 3/8"ID Bolt S BGNR - 3 Stage 38 1 100-5014-4 Hose #4 (12" Lg.) BGNR - 3 Stage 39 1 033-875 Valve, Time Delay Flow Control BGNR - 3 Stage 40 1 145-0010 Bracket, Valve Mounting BGNR - 3 Stage 41 1 100-0001 Decal, Warning - Time Delay Valve BGNR - 3 Stage 42 1 100-5014-1 Hose, #4 Ass'y (50"Lg) BGNR - 3 Stage 43 1 100-5014 Hose, #4 Ass'y (32"Lg) BGNR - 3 Stage 44 2 010-011 Capscrew, Hex Hd. - 5/16-18 X 2-1/2" BGNR - 3 Stage * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE




7

8

5

8

3

6

5

5

2

6

1

Figure 79 : Hydraulic Control Valve - Three Stage




Item Qty Part No General Description Specific Description ◄ - 144-5026 Valve Assy 3 Spools (Salami) BGNR - 3 Stage 1 1 907-5155 Valve-Manual Triple Spool BGNR - 3 Stage 2 1 034-587 Adapter, 8-8 BGNR - 3 Stage 3 1 034-619 Fitting, 4-4 BGNR - 3 Stage 4 1 034-574 Fitting BGNR - 3 Stage 5 4 034-597 Fitting, Str. F Pipe W/O-Ring 8-4 BGNR - 3 Stage 6 4 034-533 Fitting, 4-4 BGNR - 3 Stage 7 1 034-727 Adapter, Str. - 10MB-6MJ BGNR - 3 Stage 8 1 034-582 Fitting, 8-6 BGNR - 3 Stage




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Figure 80 : Hydraulic Reservoir Assembly - Three Stage




Item Qty Part No General Description Specific Description ◄ - 145-5008 Reservoir Ass'y BGNR - 3 Stage 1 1 145-5000 Reservoir Weldment BGNR - 3 Stage 2 1 035-238 Breather Cap (3/4") BGNR - 3 Stage 3 1 105-5002 Filter Ass'y (Pick 034-616) BGNR - 3 Stage 4 1 034-508 Adapter, 6-6 (PA) BGNR - 3 Stage 5 1 034-519 Adapter, Reducer Bush 3/8M-1/4F Pipe BGNR - 3 Stage 6 1 034-665 Fitting, Tee BGNR - 3 Stage



12.21 Body Hydraulic Layout - Two Stage Full Free

A

REACH

TILT

F

I

KJ

GH

H

G

CD

BCDEM

GF E

A

B

LL

K

J

B

I

A

11 26 35 28 29 47

29

29 27

30, 313, 16 24

4825 447, 4, 49, 111 24, 25

43

32

5, 6, 368, 9

44, 31, 163, 40

39

27

34

35

17, 18,15, 3, 16

192620,21

3332

23

48

47

2, 4, 7

10

2,4,7

TO MAST BULKHEADHOSE BRACKET

TO MAST BULKHEADHOSE BRACKET

35

12, 13,15, 3, 16

14

2322

42

40

16, 3,37, 38

39

4241

40

41

TO VELOCITY FUSE ON OUTBOARD CYLINDER

TO VELOCITY FUSE ON OUTBOARD CYLINDER

Figure 81 : 3000 Body Hydraulic Layout - Two Stage Full Free



Body Hydraulic Layout - Two Stage Full Free Item Qty Part No General Description Specific Description ◄ - 145-5011 Body, Hyd. Layout - Int. Hose Routing 3000-130 Full Free 1** 1 144-5026 Valve Assy 3 Spools (Salami) 3000-130 Full Free 2 2 010-037 Capscrew, Hex Hd. - 5/16"-18 x 3/4" 3000-130 Full Free 3 7 012-210 Washer, Flat - 1/4" Bolt S 3000-130 Full Free 4 4 012-200 Washer, Lock - 5/16" Helical 3000-130 Full Free 5 1 033-106-1 Powerpack Ass'y 24V 3000-130 Full Free 6 4 010-039 Cap Screw, Hex Hd. - 3/8"-16 x 1" 3000-130 Full Free 7 4 012-211 Washer, Flat - 5/16" Bolt Size 3000-130 Full Free 8 4 012-201 Washer, Lock - 3/8" Dia.Helical 3000-130 Full Free 9 4 011-507 Nut, Hex - 3/8"-16 3000-130 Full Free 10** 1 145-5008 Reservoir Ass'y 3000-130 Full Free 11 1 100-5005-17 Hose #6 H.P. (60"Lg) Str.-90° 3000-130 Full Free 12* 1 145-5004 Valve Ass'y, Load Lowering 3000-130 Full Free 13 1 033-501 Valve, Load Lowering Control 3000-130 Full Free 14 2 034-505 Adapter, 8-6 3000-130 Full Free 15 3 010-003 Capscrew, Hex Hd. - 1/4"-20 x 2" 3000-130 Full Free 16 7 012-202 Washer, Lock - 1/4" Helical 3000-130 Full Free 17* 1 145-5010 Valve, Relief Assembly 3000-130 Full Free 18 1 033-587 Valve Relief 3000-130 Full Free 19 1 034-505 Adapter, 8-6 3000-130 Full Free 20 1 034-555 Adapter, Fitting 8-4 3000-130 Full Free 21 1 034-619 Fitting, 4-4 3000-130 Full Free 22 1 100-5018 Hose #6 H.P. - 90° 3000-130 Full Free 23 1 100-5004-2 Hose #6 H.P. (36"Lg) 3000-130 Full Free 24 1 100-5014-4 Hose #4 H.P. (12"Lg) - Str. 3000-130 Full Free 25 1 100-5013-3 Hose #4 H.P. (24"Lg) - Str. 3000-130 Full Free 26 1 100-5005-3 Hose #6 H.P. (34"Lg) Str.-90° Elbow 3000-130 Full Free 27 4 100-5013-7 Hose, #4 Ass'y (32"Lg) - Str. 3000-130 Full Free 28 10 034-718 Adapter #6 M SAE - #4 M JIC 37° 3000-130 Full Free 29 4 100-5013-5 Hose, #4 Ass'y (43"Lg) - Str. 3000-130 Full Free 30 2 033-841 Valve, Dual P.O. Check (Lock) 3000-130 Full Free 31 4 010-002 Capscrew, Hex Hd. - 1/4"-20 X 1-1/2" 3000-130 Full Free 32 1 100-5008 Hose #8 Med Pressure (39"Lg) 3000-130 Full Free 33 1 034-587 Adapter, 8-8 3000-130 Full Free 34 1 034-614 Fitting, 90° Elbow - 10-12 3000-130 Full Free 35 1 100-5010 Hose (40"Lg) 12# L.P. Long Suction 3000-130 Full Free 36 4 012-252 Washer, Flat - 3/8"ID Bolt S 3000-130 Full Free 37 2 010-000 Capscrew, Hex Hd. 1/4"-20 x 3/4" 3000-130 Full Free 38 1 135-5009 Weldment, Hose Block 3000-130 Full Free 39 2 034-505 Adapter, 8-6 3000-130 Full Free 40 2 034-534 Fitting, 4-6 3000-130 Full Free 41 2 100-5004-25 Hose #6 H.P. (32" Lg.) 3000-130 Full Free 42 1 100-5004-23 Hose #6 H.P. (43" Lg.) 3000-130 Full Free 43 1 100-5013-6 Hose #6 H.P. (12" Lg.) 3000-130 Full Free 44 1 033-875 Valve, Time Delay Flow Control 3000-130 Full Free 45 1 145-0010 Bracket, Valve Mounting 3000-130 Full Free 46 1 100-0001 Decal, Warning - Time Delay Valve 3000-130 Full Free 47 1 100-5014-1 Hose, #4 Ass'y (50"Lg) 3000-130 Full Free 48 1 100-5014 Hose, #4 Ass'y (32"Lg) 3000-130 Full Free 49 2 010-011 Capscrew, Hex Hd. - 5/16-18 X 2-1/2" 3000-130 Full Free * - INDENTED SUB-ASSEMBLY � SHOWN ON SAME PAGE ** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE




7

8

5

8

3

6

5

5

2

6

1

Figure 82 : Hydraulic Control Valve - Two Stage Full Free




Item Qty Part No General Description Specific Description ◄ - 144-5026 Valve Assy 3 Spools (Salami) 3000-130 Full Free 1 1 907-5155 Valve-Manual Triple Spool 3000-130 Full Free 2 1 034-587 Adapter, 8-8 3000-130 Full Free 3 1 034-619 Fitting, 4-4 3000-130 Full Free 4 1 034-574 Fitting 3000-130 Full Free 5 4 034-597 Fitting, Str. F Pipe W/O-Ring 8-4 3000-130 Full Free 6 4 034-533 Fitting, 4-4 3000-130 Full Free 7 1 034-727 Adapter, Str. - 10MB-6MJ 3000-130 Full Free 8 1 034-582 Fitting, 8-6 3000-130 Full Free




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Figure 83 : Hydraulic Reservoir Assembly - Two Stage Full Free




Item Qty Part No General Description Specific Description ◄ - 145-5008 Reservoir Ass'y 3000-130 Full Free 1 1 145-5000 Reservoir Weldment 3000-130 Full Free 2 1 035-238 Breather Cap (3/4") 3000-130 Full Free 3 1 105-5002 Filter Ass'y (Pick 034-616) 3000-130 Full Free 4 1 034-508 Adapter, 6-6 (PA) 3000-130 Full Free 5 1 034-519 Adapter, Reducer Bush 3/8M-1/4F Pipe 3000-130 Full Free 6 1 034-665 Fitting, Tee 3000-130 Full Free



12.24 Body Hydraulic Layout - Three Stage Full Free

ABCD

ABCD

B P

A

BT

11 19 27

18 347, 4, 37, 111 18

20

24

5, 6, 288, 9

34, 25, 143, 40

31

20

26

27

15, 13,14, 3,

1219182524

17

33

16

2, 4, 7

10

2,4,7

19

17

16 21 22

313

12

2930

TO LEFT HAND HOSE REEL (TILT)

TO RIGHT HAND HOSE REEL (REACH)

Figure 84 : 3000 Body Hydraulic Layout - Three Stage 172" Full Free



Body Hydraulic Layout - Three Stage Full Free Item Qty Part No General Description Specific Description ◄ 1 145-5023 Body, Hyd. Layout � Internal Hose

Routing 3000-172 Full Free 1** 1 144-5029 Valve Assy 3 Spools - Full Free 3000-172 Full Free 2 2 010-037 Capscrew, Hex Hd. - 5/16"-18 X 3/4" 3000-172 Full Free 3 5 012-210 Washer, Flat - 1/4" Bolt S Flat 3000-172 Full Free 4 4 012-200 Washer, Lock - 5/16" Helical 3000-172 Full Free 5 1 033-106-1 Powerpack Ass'y 24v 3000-172 Full Free 6 4 010-039 Capscrew, Hex Hd. 3/8"-16 X 1" 3000-172 Full Free 7 4 012-211 Washer, Flat - 5/16" Bolt Size 3000-172 Full Free 8 4 012-201 Washer, Lock - 3/8" Dia.Helical 3000-172 Full Free 9 4 011-507 Nut, Hex - 3/8"-16 3000-172 Full Free 10** 1 145-5008 Reservoir Ass'y 3000-172 Full Free 11 1 100-5005-17 Hose #6 H.P. (60"Lg) Str.-90° 3000-172 Full Free 12 1 100-5005-22 Hose #6 H.P. (25"Lg) Str.-90° 3000-172 Full Free 13 3 010-003 Capscrew, Hex Hd. - 1/4"-20 X 2" 3000-172 Full Free 14 3 012-202 Washer, Lock - 1/4" Helical 3000-172 Full Free 15** 1 145-5024 Ass'y, Relief Valve Ass'y - Full Free 3000-172 Full Free 16 3 100-5005-25 Hose #6 H.P. (114"Lg) Str.-90° 3000-172 Full Free 17 1 100-5018-1 Hose #6 H.P. (25" Lg) 90° Elbow 3000-172 Full Free 18 1 100-5013-3 Hose #4 H.P. (24" Lg) Str. 3000-172 Full Free 19 1 100-5005-3 Hose #6 H.P. (34" Lg) Str.-90° Elbow 3000-172 Full Free 20 2 100-5005-29 Hose #6 H.P. (96"Lg) Str.-90° 3000-172 Full Free 21 1 100-5005-23 Hose #6 H.P. (48"Lg) Str.-90° 3000-172 Full Free 22 1 100-5005-24 Hose #6 H.P. (65"Lg) Str.-90° 3000-172 Full Free 23 2 010-002 Capscrew, Hex Hd. 1/4"-20 X 1-1/2" 3000-172 Full Free 24 1 100-5008 Hose #8 (39"Lg) Med Pressure 3000-172 Full Free 25 1 034-587 Adapter, 8-8 3000-172 Full Free 26 1 034-614 Fitting, 90° Elbow 10-12 3000-172 Full Free 27 1 100-5010 Hose #12 (40"Lg) L.P.-Long Suction 3000-172 Full Free 28 4 012-252 Washer, Flat - 3/8"ID Bolt S 3000-172 Full Free 29 1 142-5030 Bracket, Mounting - Seq Vlv - Full Free 3000-172 Full Free

30 1 907-5161-1 Assy, Sequence Valve - Full Free Mast Block 3000-172 Full Free

31 2 034-505 Adapter, 8-6 3000-172 Full Free 32 2 034-534 Fitting, 4-6 3000-172 Full Free 33 1 100-5014-4 Hose, #4 Ass'y (12"Lg) 3000-172 Full Free 34 1 033-875 Valve, Time Delay Flow Control 3000-172 Full Free 35 1 145-0010 Bracket, Mounting Valve 3000-172 Full Free 36 1 100-0001 Decal,Warning Time Delay Valve 3000-172 Full Free 37 2 010-011 Capscrew, Hex Hd. 5/16"-18 X 2-1/2" 3000-172 Full Free




7

8

5

8

3

6

5

5

2

6

1

Figure 85 : 3000 Body Hydraulic Layout - Two Stage Full Free



Control Valve Assembly Item Qty Part No General Description Specific Description ◄ - 144-5029 Valve Assy 3 Spools - Full Free 3000-172 Full Free 1 1 907-5155 Valve-Manual Triple Spool 3000-172 Full Free 2 1 034-587 Adapter, 8-8 3000-172 Full Free 3 1 034-619 Fitting, 4-4 3000-172 Full Free 4 1 034-574 Fitting 3000-172 Full Free 5 4 034-597 Fitting, Str. F Pipe w/O-Ring 8-4 3000-172 Full Free 6 4 034-534 Fitting, 4-6 3000-172 Full Free 7 1 034-727 Adapter, Straight - 10MB-6MJ 3000-172 Full Free 8 1 034-582 Fitting, 8-6 3000-172 Full Free



12.26 Relief Valve Assembly

2

5

3

3

1

4

Figure 86 : Relief Valve Assembly - Three Stage 172" Full Free



Relief Valve Assembly Item Qty Part No General Description Specific Description ◄ - 145-5024 Relief Valve Assembly 3000-172 Full Free 1 1 033-587 Valve, Relief 3000-172 Full Free 2 1 034-665 Fitting, Tee 3000-172 Full Free 3 1 034-555 Adapter, Fitting 0102-8-4 3000-172 Full Free 4 1 034-619 Fitting, 2103-4-4 3000-172 Full Free 5 1 034-566 Adapter, 2102-4-4s 3000-172 Full Free




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Figure 87 : Hydraulic Reservoir Assembly - Three Stage 172" Full Free



Hydraulic Reservoir Assembly Item Qty Part No General Description Specific Description ◄ - 145-5008 Reservoir Ass'y 3000-172 Full Free 1 1 145-5000 Reservoir Weldment 3000-172 Full Free 2 1 035-238 Breather Cap (3/4") 3000-172 Full Free 3 1 105-5002 Filter Ass'y (Pick 034-616) 3000-172 Full Free 4 1 034-508 Adapter, 6-6 (PA) 3000-172 Full Free 5 1 034-519 Adapter, Reducer Bush 3/8M-1/4F Pipe 3000-172 Full Free 6 1 034-665 Fitting, Tee 3000-172 Full Free



13. Wiring/Hydraulic Schematics

Figure 88 : Electrical/Hydraulic Schematic - Mechanical Lift/Tilt/Reach Control



BATTERYNEGATIVEBATTERYNEGATIVE

0-5VTHROTTLE

BELLYBUTTONSWITCHOUTBELLYBUTTONSWITCHCOMFORWARDMOSFETDRIVERREVERSEMOSFETDRIVERKEYSWITCH(ORBATTERY+)0-5VTHROTTLEGROUND ORANGE

GREENWHITE/BLACKWHITERED/GREENGREEN

BLACKWHITE/REDWHITE/BROWN

BLACKBROWN/YEL

WHITE/GREEN

RED

BLUEWHITE/RED

GREEN

Figure 89 : Electrical/Hydraulic Schematic - Electric (Push-Button) Lift and Tilt Control



14. Service / Maintenance History

DATE WORK PERFORMED COMMENTS / NOTES

To Order Parts

For prompt service when ordering parts, please provide the following information to your local distributor. 1. Model and serial number of the equipment. 2. Part number, description and quantity. 3. Shipping instructions.

When in doubt as to part required, provide a sketch or the used part as a sample.

Record Here For Future Reference Date into Service:

Model Number:

Serial Number:

Distributor:

FOR RECOMMENDED SPARE PARTS CONTACT THE MANUFACTURER

TEL: 800 6687078 / 905 457 3900 FAX: 888 378 5781 / 905 450-6555



15. Warranty Policy

Warranty Policy Heavy Duty Walkie Stacker w/Reach and Tilt Feature

The manufacturer warrants to the original purchaser its stackers to be free from defective factory material and workmanship. All warranties begin on the date of delivery to the first user or the sixtieth (60) day after date of shipment, whichever comes first.

Parts or components which fall under normal usage within the following specified time periods and are proven to be defective will be repaired or replaced by the manufacturer without charge for parts or labor unless stated otherwise herein. Replacement parts will be supplied F.O.B. factory.

WARRANTY TIME PERIODS: 1.) TWO (2) YEARS OR 4000 HRS. OPERATION WHICHEVER OCCURS FIRST.

Transmission, and brakes. 2.) ONE (1) YEAR OR 2000 HRS. OPERATION WHICHEVER OCCURS FIRST.

Drive motor (except brushes), and electronic speed controller.

3.) SIX (6) MONTHS OR 1000 HRS. OPERATION WHICHEVER OCCURS FIRST. Lift motors (except brushes), pumps, wiring harnesses, drive belts, valves, oil seals, hydraulic cylinders, hydraulic hoses, SCR controls, lift chains, weldments, and castings.

4.) NINETY (90) DAYS OR 500 HRS. OPERATION WHICHEVER OCCURS FIRST. Motor brushes, contactors, switches, resistors, wheels, tires, bearings, bushings, axles, connectors, fasteners, any parts not listed above.

Batteries and battery chargers are guaranteed by their manufacturer; NOT the stacker manufacturer. Please consult the factory for nearest manufacturer�s representative.

WARRANTY IS VOID IF: 1.) Warranty validation form is not completed and returned to the manufacturer. 2.) Equipment has been modified or repaired in any manner not approved by the manufacturer. 3.) Equipment is overloaded beyond rated capacity. 4.) Equipment is used in abrasive conditions, corrosive conditions, freezers or excessive moisture unless

equipped with an appropriate protection package. When equipped with a protection package the warranty shall be limited to ninety (90) days on all components.

THE FOLLOWING ARE NOT COVERED UNDER WARRANTY: 1.) Adjustments, including initial field set-up. Adjustments are considered part of normal maintenance

procedures. 2.) Repairs required as a result of:

• Failure to follow maintenance and/or lubrication procedures specified in the owner�s manual. • Abuse, willful damage, accident, neglect or wear items. • Shipping damage. (Claim must be made with freight carrier.) • Fuses, light bulbs.

THE MANUFACTURER DOES NOT ASSUME RESPONSIBILITY OR LIABILITY FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES, OR FOR LOSS OF PROFIT OR DAMAGE TO TRADE OR BUSINESS WHICH RESULTS FROM THE EQUIPMENT.

THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES, EITHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION CONTAINED HEREIN.

Warranty: Part #038-659E

B L U E G I A N T E Q U I P M E N T C O R P O R A T I O N

85 Heart Lake Road South,

Brampton, Ontario Canada L6W 3K2

Tel 800 668 7078 Fax 888 378 5781

www . bluegiant.com

BLUE GIANT offers a full line of Dock Levelers, Dock Safety Equipment, Accessories, Ergonomic and Scissor Lift Equipment, and Industrial Trucks. Concurrent with our continuing product

improvement program, specifications are subject to change without notice. Please contact BLUE GIANT for latest information. Some features illustrated may be optional in certain market areas.

Warning: This manual may not be copied, quoted or transferred in any form or medium to any individual or company, in whole or in part without written consent from Blue Giant.

If calling from outside North America: Tel 905 457 3900 Fax 905 450 6555

Issue Date: 09/27/04 (Part #411-752)

BGNR Owner's Manual - L.A. LIFT SERVICES...Heavy Duty Walkie Stacker w/Reach and Tilt Feature Page 6...

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Transcript of BGNR Owner's Manual - L.A. LIFT SERVICES...Heavy Duty Walkie Stacker w/Reach and Tilt Feature Page 6...