K- D MANITOU, INC GHOLSON ROAD WACO, TEXAS 76705

Transcription

1 K- D MANITOU, INC GHOLSON ROAD WACO, TEXAS T502TC -D, T502TC -DSB T602TC -D, T602TCP -D T602TCP -DXL T802TC -D & T1002TC -D S/N: T , T , T , T & ABOVE (excluding S/N: T & T ) PARTS MANUAL SERIES F CATALOG B242

2 T SERIES (FORD POWERTRAIN) LIFT TRUCK MODEL NO. DESCRIPTION T5=5000lb LIFT CAP. T6=6000lb. LIFT CAP. T8=8000lb. LIFT CAP. T10=10,000lb. LIFT CAP. T5 02 TC P -D XL XL=LOW CAB SB=SOD BUSTER 02=FRONT WHEEL DRIVE 04=FOUR WHEEL DRIVE -D=DIESEL TC=TORQUE CONVERTER TRANSMISSION P=POULTRY

3 FILTER CHART DESCRIPTION PART NO. CLEAN REPLACE 1 - Engine oil filter hrs. 2 - Air filter cartridge hrs. 450 hrs. 3 - Transmission oil filter hrs. 4 - Fuel filter (cartridge type) hrs. 5 - Hydraulic oil filter cartridge hrs. 6 - Air filter safety cartridge hrs. 900 hrs. 7 - Hydraulic suction screen hrs. if damaged 8 - Air intake pre-cleaner hrs. if damaged 9 - Turbo pre-cleaner II hrs. if damaged 10 - Vaculator (1.5 dia) hrs. if damaged 10 - Vaculator (3 dia) hrs. if damaged

4 GENERAL INFORMATION The purpose of this manual is to provide illustrations for identifying and ordering Lift Truck Parts. The illustrations are a general description and may not show the exact shape or detail of the parts represented. The parts are identified by an Item Numberon theillustration Page. Find the Item Number forthe part desired, then locate that Item Number under the Items column following the illustration. The Part Number will be located directly to the right of the Item Number. Also provided is a part Description, Quantity (QTY) of parts required, and the truck Model identification as required. Common hardware (nuts, bolts and washers) must be replaced with the same or better grade zinc hardware. K -D Manitou Inc. continues to release new models and improve product designs as new technologies are developed. Therefore some parts in this manual may be replaced by new part numbers. Please verify all part numbers with the Parts Department for your Lift Truck when ordering. When ordering parts or requesting technical information, the following numbers are required: Truck Model Number: Truck Serial Number: Power Train Model Number: Mast Model Number: Mast Serial Number: Engine Number: Attachment Model Number: Attachment Serial Number: For quick reference it is recommended these numbers be recorded as soon as possible. (See the following page for Lift Truck Component Identification.). CATALOG B242 - I -

5 LIFT TRUCK COMPONENT IDENTIFICATION FORD TRANSMISSION PRODUCTION CODE (R.H. side of transmission as shown) FORD POWERTRAIN MODEL NO. & POWERTRAIN PRODUCTION CODE Locate the starter motor on the left side of the engine. On the transmission housing, next to the starter motor are 3 lines of letters/numbers. Note the first letter of the top line. K =MODEL 445 D =MODEL 545 C or L =MODEL 655D. The bottom line contains the Ford Powertrain Production Code. K-D MANITOU MANUFACTURING SERIAL PLATE ENGINE NO. Locate the Engine No. on the valve cover decal or on the left side of the engine below the dipstick. Note the first letter of the line. D =201 cu.in. engine C =192 cu.in. engine If the letter C is observed, notify the Parts Dept. when ordering engine parts. FORD DRIVE AXLE PRODUCTION CODE K-D MANITOU LIFT TRUCK SERIAL NO. K-D MANITOU PRODUCTION CODE - II - CATALOG B242

6 CONTENTS DESCRIPTION FILTER CHART... SECTION (previous pages) TIRES & WHEELS... 1 BRAKE & ACCELERATOR ASSEMBLIES... 2 STEERING COMPONENTS... 3 FRONTWHEELDRIVEAXLE... 4 HYDRAULICS (less Steering)... 5 ENGINE COMPONENTS... 6 TRANSMISSION... 7 COOLING SYSTEMS... 8 AIR CLEANER & FUEL SYSTEM... 9 ELECTRICAL/INSTRUMENTS FRAME, HOOD, WEIGHTS, OVERHEAD GUARD DECALS OPTIONS PARTS NUMERICAL INDEX... Supplement CATALOG B242 - III -

7 SECTION 1 TIRES & WHEELS DESCRIPTION PAGE TIRES & WHEELS CATALOG B

8 TIRES & WHEELS CATALOG B242

9 ITEM PART NUMBER DESCRIPTION QTY MODEL Drive Tire/Wheel Assembly 2 Std. on T502 -T802 (T0030 Tire & B5498 Wheel) & T504 -T Drive Tire/Wheel Assembly 2 T502 & T504 (T0009 Tire & B5498 Wheel) Drive Tire/Wheel Assembly 2 T502 -T802, Towable (T0039 Tire & B5870 Wheel) Drive Tire/Wheel Assembly 2 T802/4 Option ( Tire & B5498 Wheel) Drive Tire/Wheel Assembly 2 Poultry Trucks ( Tire & B5491 Wheel) Drive Tire/Wheel Assembly 2 T502 ( Tire & B5498 Wheel) Drive Tire/Wheel Assembly 2 T802 & T1002 ( Tire & Wheel) Drive Tire/Wheel Assembly 2 T802/4 Option (492372/ Tire & Wheel) Drive Tire/Wheel Assembly 2 T502 - T802 ( Tire & B5498 Wheel) Drive Tire/Wheel Assembly 2 T1002 w/ 200# ( Tire & B5870 Wheel) Wheel Weights R Drive Tire/Wheel, Right Assembly 1 Std T1002 ( Tire & Wheel) L Drive Tire/Wheel, Left Assembly 1 Std T1002 ( Tire & Wheel) Steer Tire/Wheel Assembly 2 T502 -T802 (T0034 Tire & B5494 Wheel) Steer Tire/Wheel Assembly 2 T502 -T802 (T0004 Tire & B5497 Wheel) Steer Tire/Wheel Assembly 2 Sod Buster (T0043 Tire & B5434 Wheel) Steer Tire/Wheel Assembly 2 T502 -T1002 ( Tire & B5497 Wheel) Steer Tire/Wheel Assembly 2 T504 -T804 (T0022 Tire & Wheel) CATALOG B

10 ITEM PART NUMBER DESCRIPTION QTY MODEL 3 T0030 Tire, Drive 16.9 x 24, 10 Ply R4 2 All except T T0009 Tire, Drive 16.9 x 24, 6 Ply 2 T502 & T504 3 T0039 Tire & Tube 14R 24 XXVC 2 T502 -T802, Towable Tire, Drive 16.9 x 24, 12 Ply R4 2 Poultry Trucks Tire, Drive 16.9 x 24, 6 Ply 2 T Tire, Drive 19.5 LR x 24, IT T802 & T Tire, Drive 19.5 L x 24, 12 Ply 2 T802/ Tire, Drive 19.5 L x 24, 12 Ply 2 T802/ Tire, Drive 17.5 LR 24 IT T502 - T Tire, Drive PR SRL -1 2 T1002 w/ 200# Wheel Weights Tire, Drive 17.5 x 25, 12 Ply L2 2 Std T T0034 Tire, Steer 11 L x 16, 10 Ply F3 2 T502 -T802 4 T0004 Tire, Steer 12 x 16.5 LT, 10 Ply 2 T502 -T802 4 T0043 Tire, Steer 31 x , 8 Ply 2 Sod Buster Tire, Steer 12 x 16.5, 12 Ply 2 T502 -T T0022 Tire, Steer 12 x 16.5, 10 Ply 2 T504 -T804 5 B5498 Wheel, Drive 15 x 24 2 All except T B5870 Wheel, Drive 10 x 24 2 T502 -T802, Towable 5 B5491 Wheel, Drive 12 x 24 2 Poultry Trucks Wheel, Drive DW 16L x 24 2 T802/4 & T Wheel, Drive 14 x 25 2 Std T B5492 Wheel, Drive 16.9 x 24 HD 2 T502 & T504 6 B5494 Wheel, Steer 11 x 16 2 T502 -T802 6 B5497 Wheel, Steer 12 x T502 -T B5434 Wheel, Steer 15 x 10 2 Sod Buster Wheel, Steer 12 x T504 -T804 7 B2258 Stem, Valve 2 All Steer Wheels 7 B2257 Stem, Valve 2 All Drive Wheels except Stem, Valve 2 Use on Drive Wheel 8 B5223 Nut, Lug (Drive Wheel) 16 (Qty. for 2 Wheels) Nut, Lug (Steering Wheel) 16 (Qty. for 2 Wheels) CATALOG B242

11 SECTION 2 BRAKE & ACCELERATOR ASSEMBLIES DESCRIPTION PAGE BRAKE PEDAL & PARK BRAKE ASSEMBLY BRAKE DISC ASSEMBLY ACCELERATOR ASSEMBLY CATALOG B

12 BRAKE PEDAL & PARK BRAKE ASSEMBLY CATALOG B242

13 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B5605 Pedal Assembly 1 ALL 2 B5593 Grommet 2 3 K44736 Washer, Flat 2 4 K55677 Nut, Lock Pedal, Brake (R.H.) Pedal, Brake (L.H.) Brk t, Pedal Bolt, Allen Hd 4 9 R Ring, Snap Bar, Pedal Stop 1 11 B3872 Grommet Bracket End, Rod (L.H. Threads) 2 14 K34690L Nut, Jam (L.H. Threads) Rod, Adjusting 2 16 K34690 Nut, Jam End, Rod 2 18 K20508 Bolt, Hex 4 19 K34808 Washer, Lock 4 20 K55826 Nut, Lock Lever, Brake (R.H.) Lever, Brake (L.H.) Clevis 2 24 K76240 Pin, Clevis 2 25 K72035 Pin, Cotter 2 26 K Screw, Allen Hd 1 27 K97529 Ring, Snap 1 28 B5596 Sleeve 1 29 B309 Washer, Thrust 1 30 K74181 Key, Woodruff Spacer Shaft, Actuating 1 33 B3053 Joint, Ball 2 34 B3368 Ring, Snap Lever, Brake 1 CATALOG B

14 - MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS CATALOG B242

15 ITEM PART NUMBER DESCRIPTION QTY MODEL Clevis, Cable 1 All Bracket, Cable Cable, Brake 1 39 B5777 Spacer 1 40 B5776 Clamp, Cable Lever, Park Brake Spring 2 43 K20466 Bolt, Hex 3 44 K34806 Washer, Lock 3 45 K33922 Nut, Jam 3 CATALOG B

16 BRAKE DISC ASSEMBLY ATTENTION: Verify Ford Powertrain Model No. before ordering parts (see page II, LIFT TRUCK COMPONENT IDENTIFICATION) A A F 2-2 T HRU CATALOG B242

17 ITEM PART NUMBER DESCRIPTION QTY MODEL Housing, Outer 2 ALL Housing, Inner (L.H.) 1 Powertrain E4NN2N099CA Housing, Inner (L.H.) 1 Powertrain Housing, Inner (R.H.) 1 Powertrain E4NN2N100BA Housing, Inner (R.H.) 1 Powertrain Disc Assembly 8 Powertrain E6NN2A097BA Disc Assembly 8 Powertrain Disc, Intermediate 4 Powertrain E6NN2N315BA Disc, Intermediate 4 Powertrain Disc Assembly 2 Powertrain 545 (Includes Items 4, & 7 thru 11) 6 E6NN2N317BA Disc Assembly 2 Powertrain 655 (Includes Items 4, & 7 thru 11) Link Ball Spring Pin 4 11 K34690 Nut, Jam Bolt, Hex Stud S36 Nut, Hex Pin Rod Pin, Cotter 2 18 K76260 Pin Seal Assembly Shaft 1 Powertrain E7NN2458AA Shaft 1 Powertrain Key Washer 1 29A Washer Seal Assembly 2 30A Seal, Felt Bushing Key Washer Sleeve 2 CATALOG B

18 ACCELERATOR ASSEMBLY (EARLY MODELS) ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B8000 Throttle Pedal. 1 Early Models Only 2 B5296 Throttle Mounting Plate 1 3 K20556 Bolt, Hex 1 4 K34809 Washer, Lock 1 5 K33845 Nut, Hex 1 6 K45796 Bolt, Hex 1 7 K34811 Washer, Lock 1 8 B5298 Throttle Rod (front) 1 9 K34055 Nut, Hex 3 10 K97011 Rod End Clevis 3 11 K73877 Pin 3 12 K72035 Cotter Pin 3 13 B1074 Spring 1 14 B5220 Revers Lever 2 15 B5299 Cross Shaft 1 16 K Roll Pin 3 17 B5187 Throttle Rod (rear) 1 18 B5299 Clip CATALOG B242

19 ACCELERATOR ASSEMBLY (CURRENT MODELS) THROTTLE -ARM LEVER (REF) ITEM PART NUMBER DESCRIPTION QTY MODEL Cable, Accel. 1 All Current Models 2 K34079 Nut, Hex End, Swivel 2 4 K34779 Washer, Lock Pedal, Accel Block, Pivot 2 7 K20424 Bolt, Hex 2 8 K34805 Washer, Lock 2 9 K33795 Nut, Hex Brk t, Accel. Assembly 1 11 K20428 Bolt, Hex 2 12 K34807 Washer, Lock 2 13 B1074 Spring Tab, Spring Mtg K45520 Bolt, Hex 1 16 K34806 Washer, Lock 1 17 K33797 Nut, Hex 1 CATALOG B

20 - MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS CATALOG B242

21 SECTION 3 STEERING COMPONENTS DESCRIPTION PAGE STEERING COLUMN/VALVE & PUMP STEERING COLUMN/VALVE ASSEMBLY POWER STEERING PUMP/RESERVOIR STEER AXLE & MOUNTING STEER AXLE HOSES (EARLY MODELS) STEER AXLE HOSES (CURRENT MODELS) STEER AXLE CYLINDER STEER WHEEL HUB CATAL OG B

22 STEERING COLUMN/VALVE & PUMP ** 3 6a SEE DETAIL A SEE DETAIL B ** 25** 19 DETAIL B FRAME BRK T (REF) OUT RT LT IN * 22* 15 (LT) 17 (IN) 16 (RT) 18 (OUT) DETAIL A CATALOG B242

23 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B1905 Steering Valve Assembly 1 ALL 2 B1828 Wheel, Steering 1 3 B2007 Cover Bracket, Hose 4 5 B7627 Bracket 1 6 K20384 Bolt, Hex 1 6a K Bolt, Hex 3 7 K34805 Washer, Lock 4 8 K33795 Nut, Hex 4 9 K20472 Bolt, Hex 1 10 K34809 Washer, Lock 1 11 K33845 Nut, Hex 1 12 K62-6 Fitting 3 13 K66-6 Fitting 2 14 K71-6 Fitting 2 15 B Hose Assembly 1 16 B Hose Assembly 1 17 B Hose Assembly 1 18 B Hose Assembly Steering Pump Assembly 1 20 K906 O -Ring 4 21* Wedge 2 -DXL Only 22* K20504 Bolt 4 -DXL Only 23** B7585 Tube Assembly 1 24** K4-6 Fitting 2 25** B7645 Tube Assembly 1 * Required when using the 84 Overhead Guard. ** No longer required when replacing Items 17 and 18. CATAL OG B

24 STEERING VALVE ASSEMBLY * 45 36** * 13* 12* 10* 46 11* ** 30 47* 48** 49*** ** 5** 3 2** 1 28*** CATALOG B242

25 ITEM PART NUMBER DESCRIPTION QTY MODEL B1905 Steering Valve Assembly 1 ALL 1 B Nut, Wheel 1 2**,*** Seal 1 3 B Ring, Snap 1 4**,*** Ring, Back Up 1 5**,*** Seal Screw Cover,Upper 1 8** O - Ring 1 9 B Shim 4 10* Ring, Snap 1 11* ---- Washer,Thrust 1 12* Bearing, Thrust 1 13* Washer, Thrust 1 14* Washer, Spring 1 15* Spacer/Sleeve 1 16 B Shaft, Input Pin Ring, Drive Spacer Bar, Torsion 1 21 B Needle Roller Spool 1 23 B Ball Bearing Housing Assembly Ball 1 27** O-Ring 1 28*** Plug Assembly 1 29 B Spacer 1 30 B Link, Drive 1 31 B Retainer, Seal Rotor Set 1 CATAL OG B

26 - MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS CATALOG B242

27 ITEM PART NUMBER DESCRIPTION QTY MODEL Manifold 1 ALL Commutator, Ring Commutator 1 36 B Seal, Rotator 1 37 B Washer Cover, End Bolt, Special 7 40 B JT Bearing 1 41 B Pin 2 42 B Ring, Snap 2 43 B Coupling 1 44 B WT 1 45 B Clamp 1 46 B JT Assembly 1 47 B Repair Kit 1 48 B Repair Kit 1 49 B Seal Kit 1 * Included in Repair Kit (Item 47). ** Included in Repair Kit (Item 48). *** Included in Seal Kit (Item 49). CATAL OG B

28 POWER STEERING PUMP/RESERVOIR * 9 8* 7 6* 5* * 14* ITEM PART NUMBER DESCRIPTION QTY MODEL Pump Assembly, Steering 1 ALL 1 NS Body 1 2 C5NN3N560A Bearing & Bushing Assy 2 3 NS Gear Set 1 4 C5NN3N532A Ring, Seal 2 5* Seal, Outer 1 6* Ring, Seal Inner 1 7 E0NN3C535AA Flange 1 8* Seal Ring, Snap 1 10* Seal 1 11 E6NN3B681AA Cover S36 Washer CATALOG B242

29 ITEM PART NUMBER DESCRIPTION QTY MODEL 13 C7NN3N533A Bolt, Pump 4 ALL 14* Seal Valve Assembly 1 (Includes Items 16-23) 16 C7NN3B608A Spring Shim A/R Shim A/R C7NN3D721A Seat 1 19 C7NNN626A Head 1 20 C7NNG963A Guide 1 21 C7NNG964A Seal S95 O -Ring 1 22* O - Ring 1 23* O - Ring Filter Assembly 1 25 E6NN3531DA Reservoir Assembly 1 (Includes Items 26-27) Valve Assembly 1 (Includes Items 27) Seal 1 28 D0NN3R678A Spring S Ring Cap, Filler Seal 1 32 E6NN3R655CA Bolt, Hex 1 33 C5NN3A742A Gear S Key, Woodruff Washer, Tab 1 36 K34690 Nut, Lock 1 37 K34807 Washer S36 Bolt, Hex 2 39* O - Ring Seal 1 41 C5NN3N676A Elbow Assembly Seal Kit 1 * Included in Seal Kit, Item 42. CATAL OG B

30 CATALOG B STEER AXLE & MOUNTING

31 ITEM PART NUMBER DESCRIPTION QTY MODEL Steer Axle Assembly 1 All except T1002 (less Items 29-39) Steer Axle Weldment 1 T1002 Only Steer Axle Weldment 1 All except T Cylinder, Steer 2 3 K71C5301 Pin, Cylinder 2 4 K72057 Pin, Cotter End, Cylinder Spindle Assembly, (L.H.) Spindle Assembly, (R.H.) Hub Assembly Rod, Tie Clamp End, Tie Rod (R.H.) End, Tie Rod (L.H.) Washer 1 Included w/ Items 11 & Nut, Castle 1 Included w/ Items 11 & K72071 Pin, Cotter 2 16 K45754 Bolt, Hex 4 17 K33946 Nut, Jam 4 18 K33799 Nut, Hex 2 19 K20468 Bolt, Hex Bearing, Thrust Shim A/R 22* Bushing, Garmax 4 22** Bushing, Kaiser 4 23* Pin, King 2 23** Pin, King 2 24 K134 O -Ring Cover, Dust 4 26 R Washer, Lock 8 27 K Screw, Soc Hd 8 28 K87901 Fitting, Grease Cover, Bearing (Front) Pin (Rear) Washer, Thrust Pin (Front) 1 33 K58758 Cap 1 34 B5091 Cover, Bearing (Rear) 1 35 K Screw Support, Mounting 1 37 K45784 Bolt, Hex 8 38 K34813 Washer 8 39 K34674 Nut, Hex 4 * For use on S/N: T & below, T , T , T ** For use on S/N: T , T , T T & above. CATALOGB

32 STEER AXLE HOSES (EARLY MODELS) RIGHT STEERING CYLINDER (REF) LEFT STEERING HOSE (REF) RIGHT STEERING HOSE (REF) LEFT STEERING CYLINDER (REF) 6 5 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B Hose Assembly 2 Early Models 2 B Hose Assembly 1 3 B Hose Assembly Tube Assembly 1 5 K66-6 Fitting 2 6 K906 O-Ring 4 7 K69-6 Fitting 2 8 K4-6 Adapter 1 9 K20468 Bolt, Hex 1 10 B Clamp 3 11 K34807 Washer 1 12 K33799 Nut, Hex 1 13 K108-6 Adapter CATALOG B242

33 STEER AXLE HOSES (CURRENT MODELS) RIGHT STEERING HOSE (REF) 10 RIGHT STEERING CYLINDER (REF) 6 2 LEFT STEERING HOSE (REF) LEFT STEERING CYLINDER (REF) ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B Hose Assembly 2 Current Models 2 K66-6 Fitting 2 3 K69-6 Fitting Tube Assembly 1 5 K71-6 Fitting 1 6 K20468 Bolt, Hex 1 7 B Clamp 1 8 K34807 Washer, Lock 1 9 K33799 Nut, Hex 1 10 K906 O -Ring 4 CATALOGB

34 STEER AXLE CYLINDER * * 7* 6 3* CURRENT MODEL 5* EARLY MODEL * 8* 7* 1 4* 15 2 ITEM PART NUMBER DESCRIPTION QTY MODEL Cylinder, Steer (Complete) 2 All 2WD Barrel Assembly Rod, Piston 1 3* Ring, Back Up 2 4* O - Ring 1 5* Wiper 1 6 R Lockwire 1 7* Ring, Back Up A/R 8* O - Ring A/R Head, Cylinder Piston, Cylinder 1 Current Models 11* ---- Seal Wear Ring 1 13 K55700 Nut, Lock Piston, Cylinder 1 Early Models K Kit, Seal 1 * Included In Seal Kit (Item 15) CATALOG B242

35 STEER WHEEL HUB A 1 3A ITEM PART NUMBER DESCRIPTION QTY MODEL Hub Assembly 1 All 2WD Bearing, Inner 1 2A Inner Bearing Race Bearing, Outer 1 3A Outer Bearing Race Washer, Felt Seal, Grease Washer, Spindle Pin, Cotter Nut, Slotted Cap, Grease Bolt, Lug Nut, Lug 8 CATALOGB

36 - MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS CATALOG B242

37 SECTION 4 FRONT WHEEL DRIVE AXLE DESCRIPTION PAGE DRIVE AXLE (POWERTRAIN MODEL 445/545) DRIVE AXLE (POWERTRAIN MODEL 655) DRIVE AXLE HOUSING (POWERTRAIN MODEL 445/545) DRIVE AXLE HOUSING (POWERTRAIN MODEL 655) DIFFERENTIAL LOCK LINKAGE CATALOG B

38 DRIVE AXLE (POWERTRAIN MODEL 445/545) ATTENTION: Verify Ford Powertrain Model No. before ordering parts (see page II, LIFT TRUCK COMPONENT IDENTIFICATION). For Drive Axle Mountings see Section 11 Frame F CATALOG B242

39 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 D8NN4010CB Housing Assembly R.H. 1 Powertrain Model 445/545 (Includes Items 2-5) 1 D8NN4011AB Housing Assembly L.H. 1 (Includes Items 2-5) Gear Stud Cup, Inner Cup, Outer O -Ring S36 Bolt, Hex 2 lg Bolt, Hex 2 3/4 lg 2 7A Stud 4 7B S36 Nut, Hex 2 8 E4NN4244DA Shaft Assy 2 (Includes Item 8A, qty. 8 ea.) 8A Bolt, Hex Cone Assembly, Outer Seal Assembly 1 10A Seal, Dirt Carrier Assembly 2 (Includes Items 12-18) Retainer Cone Assembly, Inner Shaft 6 15 C5NN4044B Gear Washer Kit, Bearing (32 Needles) Spacer Gear Spacer (.049/.050) A/R Spacer (.053/.054) A/R Spacer (.057/.058) A/R Spacer (.061/.062) A/R 20 C5NN4374R Spacer (.065/.066) A/R Spacer (.069/.070) A/R 20 C5NN4374T Spacer (.073/.074) A/R Spacer (.077/.078) A/R Spacer (.081/.082) A/R Spacer (.085/.086) A/R Spacer (.089/.090) A/R CATALOG B

40 ITEM PART NUMBER DESCRIPTION QTY MODEL Washer 2 Powertrain Model 445/ Lock Bolt, Hex Housing, Outer 2 25 Ref. Brake Disc Assembly 2 (See Section 2) Housing L.H Housing R.H Shim (.038/.040) A/R Shim (.044/.046) A/R Shim (.050/.052) A/R Shim (.056/.058) A/R Shim (.062/.064) A/R Shim (.068/.070) A/R Shim (.074/.076) A/R Shim (.080/.082) A/R Cup Cup Cone Assembly E4221 Cone Assembly Case Assembly Screw Gear Set Bolt Nut, Hex Gear Gear Washer Spider E4292B Pinion Assembly Washer Bushing CATALOG B242

41 ITEM PART NUMBER DESCRIPTION QTY MODEL Adapter 1 Powertrain Model 445/ E188EB9 Spring Coupling Washer Ring Bearing Assembly Ring, Lock Cone Assembly (Front) Cone Assembly (Rear) 1 53 C5NN4614F Retainer Assembly 2WD 1 (Includes Items 54 & 55) Cup (Front) Cup (Rear) 1 56 K34810 Washer Bolt Washer 1 59 E7NN4634AA Nut, Hex Coupling Block S36 Washer S36 Bolt 2 CATALOG B

42 DRIVE AXLE (POWERTRAIN MODEL 655) ATTENTION: Verify Ford Powertrain Model No. before ordering parts (see page II, LIFT TRUCK COMPONENT IDENTIFICATION). For Drive Axle Mountings see Section 11 Frame F CATALOG B242

43 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 E4NN4244CA Shaft Assy, 8 Bolt 2 Powertrain Model 655 (Includes Item 1A, qty 8 ea.) 1A E4NN1N118AA Bolt, Hex Seal, Dirt 2 3 C5NN4969D Seal Assembly Cone Assembly, Outer Bolt, Hex S36 Nut, Hex 4 7 D8NN4010KA Housing Assembly L.H. 1 (Includes Items 8-11) 7 D8NN4011HA Housing Assembly R.H. 1 (Includes Items 8-11) 8 C5NN4874B Cup, Outer Gear Stud Cup, Inner O -Ring Stud Carrier Assembly 2 Includes Items E1ADDN4221 Cone Assembly, Inner Shaft Washer Kit, Bearing (32 Needles) Spacer 6 20 C5NN4044B Gear Retainer Spacer (.049/.050) A/R Spacer (.053/.054) A/R Spacer (.057/.058) A/R Spacer (.061/.062) A/R 22 C5NN4374R Spacer (.065/.066) A/R Spacer (.069/.070) A/R 22 C5NN4374T Spacer (.073/.074) A/R Spacer (.077/.078) A/R Spacer (.081/.082) A/R Spacer (.085/.086) A/R Spacer (.089/.090) A/R CATALOG B

44 ITEM PART NUMBER DESCRIPTION QTY MODEL Washer 2 Powertrain Model Bolt, Hex Lock Gear Housing, Outer 2 28 Ref Brake Disc Assembly 2 (See Section 2) 29 E4NN2N099CA Housing L.H E4NN2N100BA Housing R.H S2 Bolt, Hex S36 Nut, Hex Shim (.038/.040) A/R Shim (.044/.046) A/R Shim (.050/.052) A/R Shim (.056/.058) A/R Shim (.062/.064) A/R Shim (.068/.070) A/R Shim (.074/.076) A/R Shim (.080/.082) A/R Ring Washer Coupling 1 36 E188EB9 Spring Adapter Cup L.H. W/DL E4221 Cone Roller 1 40 C5NN4204R Case Assembly S2 Screw Bushing Washer Gear 1 45 C5NN4211B Spider 1 46 E1ADDN4213B Pinion Assembly Washer Gear Bolt Gear Set CATALOG B242

45 ITEM PART NUMBER DESCRIPTION QTY MODEL Bolt 2 Powertrain Model C5NN4194C Block Nut, Hex Cone Roller Cup Ring, Lock 1 57 D1NNN4A242A Bearing Assembly S Retaining Ring 1 59 D3NN4N028A Cone Roller 1 60 E2NN1N061AA Spacer 1 61 E8NN4N287AA Retainer Assembly 1 (Includes Items 62-64) 62 7EQH4616 Cup, Rear Pinion S36 Bolt, Hex 2 64 NCA4616A Cup, Front Pinion 1 65 E7NN1N060BA Forward Pinion Gear S36 Bolt, Hex 2/5 67 E2NN1N061BA Spacer, Forward Pinion 1 68 E3NN4N028AA Cone Roller 1 69 C5NN4667B Washer 1 70 E7NN4634AA Nut, Hex 1 71 E0NN4684AA Coupling 1 CATALOG B

46 DRIVE AXLE HOUSING (POWERTRAIN MODEL 445/545) ATTENTION: Verify Ford Powertrain Model No. before ordering parts (see page II, LIFT TRUCK COMPONENT IDENTIFICATION) CATALOG B242

47 ITEM PART NUMBER DESCRIPTION QTY MODEL Housing Assembly 1 Powertrain Model 445/545 (Includes Items 1A-1F) 1A Bearing 1 1B Bushing 2 1C Pin 1 1D D3NN7R280A Plug 1 1E Bushing 1 1F Bushing Plug Plug 1 4 C5NNN735C Bushing 1 5 C5NNN734A Bushing Bolt, Hex Seal S Plug Gasket S36 Bolt, Hex Bolt, Hex Bolt, Hex S36 Bolt, Hex S36 Bolt, Hex S36 Bolt, Hex S36 Nut, Hex S36 Nut, Hex Gasket Cover Bolt, Hex Vent Bolt Gasket Seal S2 Nut, Lock S36 Screw 1 28 E7NN7N009AA Gasket 2 29 E0NN4281AA Plug O -Ring 2 31 E107GF9 Dowel Gasket 1 CATALOG B

48 - MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS CATALOG B242

49 ITEM PART NUMBER DESCRIPTION QTY MODEL 33 D3NNN973B Cover 1 Powertrain Model 445/ Bolt, Hex 6 35 C5NNN864A Washer 1 36 C5NNN863B Plug Gasket 1 38 E7NN4N311AA Plate Assembly Bolt, Hex 3 40 E5NN4N021BA Gasket 1 41 C5NN4N020A Cover Bolt, Hex S36 Bolt, Hex Gasket 1 45 C5NN7N508A Cover Bolt, Hex Gasket 1 48 E7NNP700AA Cover S36 Bolt, Hex S36 Plug 1 51 E0NN4N206AA Plug Plate Bolt, Hex S94 O -Ring Dipstick O -Ring 1 CATALOG B

50 DRIVE AXLE HOUSING (POWERTRAIN MODEL 655) ATTENTION: Verify Ford Powertrain Model No. before ordering parts (see page II, LIFT TRUCK COMPONENT IDENTIFICATION) A CATALOG B242

51 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 E7NN4032GA Housing Assembly 1 Powertrain Model 655 (Includes Items 1A-1E) 1A C5NNN951B Pin 1 1B D3NN7R280A Plug 1 1C C5NN2N477A Bushing 2 1D N803555S36 Plug 1 1E D3NN4N143A Bushing S36 Screw 1 3 E84GF9 Seal S36 Nut S91 O -Ring 2 6 E2NN7Z168AA Gasket 1 7 E2NN7D117AA Cover 1 8 C9NN6734A Gasket, Drain Plug 1 9 C9NN6730B Drain Plug S36 Bolt S36 Washer 8 12 C5NNN742A Gasket 1 13 C5NN7N508A Cover S36 Bolt 3 15 C5NN4N023A Plate S36 Bolt S36 Bolt 3 17A S36 Bolt S36 Washer 5 19 E7NN2N336AA Seal Assembly 1 20 D3NN4N020A Cover 1 21 E5NN4N021BA Gasket 1 22 C5NNN722B Gasket S36 Plug S36 Bolt 1 25 C5NNP798A Seal 1 26 C5NNN794A Plug 1 27 C5NNN795A Plug 1 28 E7NN502AA Gasket 1 29 E7NN4A028AB Cover Assembly 1 30 C5NN4N032A O -Ring 2 CATALOG B

52 - MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS CATALOG B242

53 ITEM PART NUMBER DESCRIPTION QTY MODEL S36 Bolt 13 Powertrain Model A 44878AS36 Washer E7NN4N025AA Dipstick Tube 1 32A E7NN7N009BA Gasket S36 Bolt S2 Washer S36 Bolt S36 Bolt S36 Washer, Flat S36 Bolt S36 Bolt S7 Nut S7 Nut S36 Bolt 2 43 E0NN4N507AA Gasket 1 44 C5NNN949A Gasket 1 45 C5NNN943A Plate S36 Bolt 4 CATALOG B

54 DIFFERENTIAL LOCK LINKAGE ** * F CATALOG B242

55 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B7165 Arm Assembly 1 ALL (Includes Items 2 & 3) 2 B7940 Arm Bushing 2 4 K87907 Fitting, Grease 1 5 B7009 Spacer 1 6 R12728 Washer 1 7 K45914 Bolt, Hex 1 8 K34807 Washer, Lock 1 9 B506-4 Ball Joint 1 10 K33925 Nut, Jam 1 11 B7012 Rod, Push 1 12 B7013 Bearing 1 13 K33924 Nut, Jam 1 14 B5555 Pedal, Foot Rod Assembly 1 (Includes Items 16 & 17) Clevis S36 Nut, Hex S8 Pin, Cotter Pin Pin Lever Pin Shaft Seal Fork Screw S8 Nut, Hex 1 CATALOG B

56 - MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS CATALOG B242

57 SECTION 5 HYDRAULICS (less Steering) DESCRIPTION PAGE TANK, PUMP, FILTER & HDWR (EARLY MODELS) TANK, PUMP, FILTER & HDWR (PRESENT MODELS) CONTROL VALVES, MAST SIDE SHIFT & TILT CYLINDERS TILT CYLINDER ASSEMBLY SIDE SHIFT CYLINDER ASSEMBLY CONTROL VALVE ASSEMBLY CATALOG B

58 TANK, PUMP, FILTER & HDWR (EARLY MODELS) 39 HYDRAULIC VALVES (REF) , ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B5150 Tank, Hydraulic 1 2WD (Previous) B215 Gauge, Sight Breather Filler Assy B7426 Dip Stick 1 5 K87838 Plug, Pipe 2 6 K34809 Washer, Lock K33845 K71D4364 Nut, Hex Screen, Suction K71D4321 Gasket 1 10 B6220 Connection Assy, Suction 1 11 K34804 Washer, Lock K20344 B6094 Bolt, Hex Elbow, Reducer KHI-2020 Insert, Beaded 1 15 B Clamp, Hose CATALOG B242

59 ITEM PART NUMBER DESCRIPTION QTY MODEL 16 B Hose Assembly 1 2WD (Previous) 17 0M2090 Fitting 1 18 K920 O -Ring 1 19 B800 Pump, Hydraulic 1 19 B7481 Pump, Seal Kit Shaft, Drive 1 21 K34808 Washer, Lock 4 22 K Bolt, Hex 4 23 K20526 Bolt, Hex 2 24 K34809 Washer, Lock 2 25 K33845 Nut, Hex 2 26 K916 O -Ring 1 27 K62-12 Adapter 1 28 B Hose Assembly 1 29 B Clamp 3 30 K33799 Nut, Hex 3 31 K34807 Washer, Lock 3 32 B7956 Fitting 1 33 K52-12 Nut, Hex 1 34 K Fitting, Bulkhead 1 35 B5415 Tube Assembly 1 36 K66-12 Elbow 1 37 K53-12 O -Ring 2 38 K Connection, Hose 1 39 B Clamp, Hose 4 40 B Hose Assembly 1 41 KHI-1616 Connection, Hose 1 42 K Fitting Head & Filter Assembly 1 Includes Filter Element, Filter 1 45 K20346 Bolt, Hex 4 46 K34806 Washer, Lock 4 47 KHI-2020 Fitting 2 48 B Hose Assembly 1 49 B103A10 Elbow, Pipe Tube Assembly 1 51 K11-12 Fitting, Tee 1 52 K71-12 Fitting 1 53 B Hose Assembly 1 54 K71-8 Fitting Fitting Accumulator 1 57 K Screw, Set 2 CATALOG B

60 TANK, PUMP, FILTER & HDWR (PRESENT MODELS) HYDRAULIC VALVES (REF) A B MAST HOSE ASSEMBLY (REF) 46 30A B ITEM PART NUMBER DESCRIPTION QTY MODEL Tank, Hydraulic 1 All 2WD (Current) Gasket Filler Assembly Cap 1 5 K34807 Washer, Lock 9 6 K20348 Bolt, Hex Gauge 1 8 K34809 Washer, Lock 2 9 K33845 Nut, Hex 2 10 B114A3 Plug, Pipe Filter 1 12 B101A12 Elbow CATALOG B242

61 ITEM PART NUMBER DESCRIPTION QTY MODEL 13 K Fitting 1 All 2WD (Current) 14 KHI-2020 Insert, Beaded 2 15 B Clamp, Hose 2 16 B Hose 1 17 K0M Fitting 1 18 K920 O -Ring 1 19 B800 Pump Hydraulic 1 19 B7481 Pump, Seal Kit 1 20 K20526 Bolt, Hex Shaft, Drive 1 22 K Bolt, Hex 4 23 K916 O -Ring 3 24 K62-12 Adapter 1 25 B Hose Assembly 1 26 B Clamp 3 27 K33799 Nut, Hex 3 28 K66-12 Adapter 1 29 K Fitting, Elbow 1 30A B Clamp, Hose 2 30B B Clamp, Hose 2 31 B Hose 1 32 KHI-1616 Insert, Beaded 1 33 K Bushing, Reducer Filter, Assembly (Includes ) Filter 1 36 K20346 Bolt, Hex 2 37 K34806 Washer, Lock 2 38 B Hose 1 39 B103A10 Elbow, Pipe 1 40 K Fitting 1 41 K910 O -Ring 1 42 K71-12 Fitting, Elbow Tube Assembly 1 44 B7821 Fitting, T 1 45 B7822 Disconnect, Male 1 46 B Hose Assembly 1 47 K71-8 Fitting 1 48a Fitting (for Item 49a) 1 48b Fitting (for Item 49b) 1 49a 5373 Accumulator (polished stainless) 1 49b Accumulator (cast iron, painted) 1 50 K Screw, Set 2 CATALOG B

62 CONTROL VALVES, MAST SIDE SHIFT & TILT CYLINDERS A ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B Valve Assembly, Complete 1 (3 Spool) 1 B Valve Assembly, Complete 1 (4 Spool) 1 B Valve Assembly, Complete 1 (5 Spool) 2 B Tilt Cylinder Assembly 2 (20 0 /15 0 tilt) 2 B Tilt Cylinder Assembly 2 (20 0 /10 0 tilt) 2 B Tilt Cylinder Assembly 2 (45 0 /10 0 tilt) 2 B Tilt Cylinder Assembly 2 (1-1/2 0 /5 0 tilt) 2 B Tilt Cylinder Assembly 2 (3 0 /10 0 tilt) CATALOG B242

63 ITEM PART NUMBER DESCRIPTION QTY MODEL 3 B6140 Side Shift Cylinder Assembly 1 All 4 B5175 Sub Plate Assembly, Valve 1 5 K34806 Washer, Lock 4 6 K45521 Bolt, Hex 4 7 K20310 Bolt, Hex 4 8 B7251 Shaft, Valve Handle 1 9 K72044 Pin, Cotter 1 10a B5180 Handle, Valve 3/4 STD 95 Cab 10b Handle, Valve 3/4 -DXL 84 Cab 11 M100A1 Knob 3/4 12 B7865 Lever 1 STD 95 Cab Lever 1 -DXL 84 Cab 12A B7855 Lever Assembly, Complete 1 STD 95 Cab 12A Lever Assembly, Complete 1 -DXL 84 Cab 13 B7852 Knob 1 14 B7853 Switch, Push Button 1 15 B7854 Ring, Retaining 1 16 B7942 Boot, Switch Cover 1 17 K66-6 Fitting K908 O -Ring B Hose Assembly 2 20 B7565 Tube Assembly 1 21 K11-6 Fitting 2 22 B Hose Assembly 4 23 B5405 Tube Assembly 1 24 K Fitting 1 25 K71-12 Fitting Tube Assembly Pin, Tilt Cylinder 2 28 K58616 Bolt, Hex 2 29 B6215 Pin, Pivot 2 30 K34807 Washer, Lock 4 31 K20348 Bolt, Hex 4 32 B5425 Pin, Pivot 2 CATALOG B

64 TILT CYLINDER ASSEMBLY * 11* 12 5* 2 3 9* 8* 4 7* 6* CATALOG B242

65 ITEM PART NUMBER DESCRIPTION QTY MODEL B Cylinder Assembly /15 0 Tilt B Cylinder Assembly /10 0 Tilt B Cylinder Assembly /10 0 Tilt B Cylinder Assembly 1 1-1/2 0 /15 0 Tilt B Cylinder Assembly /10 0 Tilt 1 B Barrel /15 0 Tilt 1 B Barrel /10 0 Tilt 1 B Barrel /10 0 Tilt 1 B Barrel 1 1-1/2 0 /15 0 Tilt 1 B Barrel /10 0 Tilt 2 B Rod /15 0 Tilt 2 B Rod /10 0 Tilt 2 B Rod /10 0 Tilt 2 B Rod 1 1-1/2 0 /15 0 Tilt 2 B Rod /10 0 Tilt 3 B Spacer 1 1-1/2 0 /15 0 Tilt 3 B Spacer /10 0 Tilt 4 B Head, Cylinder 1 5* O - Ring 1 6* O - Ring 1 7* Ring, Back Up 1 8* Seal 1 9* Wiper 1 10 B Lock Wire 1 11* ---- Seal 2 12 B5511 Piston 1 13 B5512 Nut, Lock 1 14 K71B1393 Nut, Jam 1 15 B5515 End, Rod 1 16 B Kit, Seal 1 * Included In Seal Kit (Item 16). CATALOG B

66 SIDE SHIFT CYLINDER ASSEMBLY * 11 10* 4* 2 5* 6* 3 7* 8* CATALOG B242

67 ITEM PART NUMBER DESCRIPTION QTY MODEL B6140 Side Shift Cylinder Assembly 1 All 1 B Barrel 1 2 B Rod 1 3 B Head, Cylinder 1 4* O - Ring 1 5* O - Ring 1 6* Ring, Back Up 1 7* Seal 1 8* Wiper 1 9 B Lock Wire 1 10* Seal 2 11 B5511 Piston 1 12 B5512 Nut, Lock 1 13 K71B1394 Nut, Jam 1 14 B5515 End, Rod 1 15 B Kit, Seal 1 * Included In Seal Kit (Item 15). CATALOG B

68 CONTROL VALVE ASSEMBLY CATALOG B242

69 ITEM PART NUMBER DESCRIPTION QTY MODEL B Valve Assembly, Complete 1 (3 Spool) B Valve Assembly, Complete 1 (4 Spool) B Valve Assembly, Complete 1 (5 Spool) 1* B1586 Inlet Section (Includes Items 2 & 3) 1 ALL 2 B1593 Body 1 3* B1596 Relief Valve (Includes Item 11) 1 (Allen Wrench Adjustable) Cap O-Ring Spring Shim A/R Ring,Piston Body and Piston Assembly Ring, Back Up O - Ring Seal 1 12 B Nut, Hex 6 13 B1587 Spool Assembly -3 Way Lift Cylinder 1 (Includes Items 14 thru 37) 14 B Seal Kit Includes # 15 Thru # Wiper, Rod Seal, Quad Sectional Seal, Exhaust,.937 Dia Sectional Seal, Pressure,.801 Dia O - Ring Ring, Back Up O - Ring Ring, Back Up O - Ring Body and Spool Assy (Not Serviced) 1 Order B1587 (Item 13) Plug Plug Spring Plug Bracket, Handle Collar, Stop Spring 1 * NOTE: An Adjustable Style Relief Valve now replaces the Early Model Shimmed Style. Instructions for adjustment are included with each Relief Valve. A PRESSURE SETTING CHART is shown for reference at the end of this chapter. If you have any questions, contact the Manitou Service Dept.. CATALOG B

70 ITEM PART NUMBER DESCRIPTION QTY MODEL Collar 1 All Washer, Lock Screw Cover Screw 4 38 K910 O -Ring 1 39 K64-10 Plug Incl. Item # B1584 Spool Assy, 4 Way Tilt Cylinder 1 Includes Items 42 thru B Seal Kit 1 Includes Items 42 thru Wiper, Rod Seal, Quad Seal, Sectional Exhaust.937 Dia Seal, Sectional Pressure.801 Dia O - Ring Ring, Back Up O - Ring Ring, Back Up O - Ring Body & Spool Assy (Not Serviced) 1 Order B1584 (Item 40) Bracket, Handle Plug Spring Retainer, Ball Ball Body, Check Collar, Stop Spring Collar Washer, Lock Screw Cover Screw B1588 Spool Assy, 4Way Side Shift & Acc.1 Includes Items 68 thru B Seal Kit A/R Includes Items 68 thru CATALOG B242

71 ITEM PART NUMBER DESCRIPTION QTY MODEL Wiper, Rod 1 All Seal, Quad Seal, Sectional Exhaust.937 Dia Seal, Sectional Pressure.801 Dia O - Ring Ring, Back Up O - Ring Ring, Back Up O - Ring Body & Spool Assy (Not Serviced) 1 Order B1588 (Item 66) Bracket, Handle Collar, Stop Spring Collar, Spool Washer, Lock Screw Cover Screw Plug Spring Plug 2 90 B1594 Cover, End Std. 1 Includes Items 91 & B1589 Cover, End W / Power Beyond 1 Includes Items 91 & B Seal, Sectional Exhaust.937 Dia B Seal, Sectional Pressure.801 Dia B Plug Assy, Conversion Power Beyond 1 Includes Items B Seal 1 95 B Ring, Back Up 1 96 B O -Ring Sleeve, Power Beyond 1 98 B Stud, 2 Spool 3 98 B Stud, 3 Spool 3 98 B Stud, 4 Spool 3 98 B Stud, 5 Spool 3 99 B Retainer, Plate Washer B Washer, Back Up B Seal, O -Ring 2 CATALOG B

72 PRESSURE SETTING CHART MAST MODEL/SERIES TEST WEIGHT (lbs.) PRESSURE SETTING (psi) K K K K K K K K K K K K , K K K K K K K CATALOG B242

73 SECTION 6 ENGINE COMPONENTS DESCRIPTION PAGE EXHAUST SYSTEM ASSEMBLY ENGINE MOUNT/RADIATOR BRACKETS ENGINE BLOCK & HEAD ENGINE BLOCK & PLUGS CRANKSHAFT & FLYWHEEL CAMSHAFT, ROCKER ARM & VALVES PISTONS & CONNECTING RODS OIL PUMP & PAN INTAKE & EXHAUST MANIFOLD CATALOG B

74 EXHAUST SYSTEM ASSEMBLY ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B7286 Muffler 1 All 2 B7773 Tube, Flexible 1 3 B7774 Tube 1 4 B7092 Pipe, Tail 1 5 B Clamp CATALOG B242

75 ENGINE MOUNT/RADIATOR BRACKETS EARLY MODELS 9 ENGINE BLOCK (REF) 10 8 CURRENT MODELS 1A ENGINE BLOCK (REF) 2A ITEM PART NUMBER DESCRIPTION QTY MODEL Bracket, Radiator L.H. 1 (Present Models) 1A Bracket, Radiator L.H. 1 (Thru March 92) Bracket, Radiator R.H. (not shown) 1 (Present Models) 2A Bracket, Radiator R.H. 1 (Thru March 92) 3 K30964 Bolt, Hex 4 4 K34833 Washer, Lock 4 5 K34674 Nut, Hex 4 6 K45770 Bolt, Hex 6 7 K34833 Washer, Lock Bearing 2 9 K Pin, Roll 2 10 B5090 Mount Assembly, Motor L.H B5095 Mount Assembly, Motor R.H K20526 Bolt, Hex 4 13 K34809 Washer, Lock 4 14 K33942 Nut, Jam 4 CATALOG B

76 ENGINE BLOCK AND HEAD A F 6-2 T HRU CATALOG B242

77 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 F0NN6007AVA Engine Assembly cu.in. Engine 1A Short Block Assembly 1 1B Head Assembly Insert, Intake Valve 3 Std Insert, Intake Valve A/R mm O/S Insert, Intake Valve A/R mm O/S 2 D4NN6056D Insert, Intake Valve A/R mm O/S Insert, Exhaust Valve 3 Std 3 E9NN6057EA Insert, Exhaust Valve A/R mm O/S 3 C9NN6057L Insert, Exhaust Valve A/R mm O/S 3 C9NN6057M Insert, Exhaust Valve A/R mm O/S Plug mm S Plug mm Plug mm Plug mm Sender, Water Temp Bolt, Head Gasket Housing Thermostat Gasket Bolt, Hex 1 13 F0NN6010BD Block Assembly Bolt, Hex Bearing 4 16 E2NN6784AA Tube Indicator 1 18 E6NN6059AC Cover Cap Assembly Gasket 1 21 E5NN6C044AA Plate Gasket Screw & Washer 2 5/16-18 x21/ S36 Screw & Washer 8 3/8-16 x21/ S36 Bolt 1 5/16-18 x21/2 CATALOG B

78 ITEM PART NUMBER DESCRIPTION QTY MODEL S36 Bolt cu.in. Engine S2 Bolt Plate Cover S36 Screw & Washer Cover Gasket 1 31 F2NN8N608BA Stud Cover O -Ring 1 34 K34807 Washer S36 Nut S36 Bolt 2 37 E6NN8N630AA Deflector S36 Washer S36 Nut, Hex 2 40 D0NN6890A Insert Filter S36 Bolt, Hex 3 43 K34807 Washer 3 44 C5NN8N631A Deflector 1 45 E7NN6A008AA Dowel 2 46 D7NN6055A Sleeve A/R S36 Bolt Bolt 8 49 B Elbow 2 50 K Adapter 1 51 B1277 Sender, Oil Pressure 1 52 B109A32 Adapter CATALOG B242

79 ENGINE BLOCK & PLUGS REAR VIEW 3 RIGHT SIDE VIEW & FRONT VIEW LEFT SIDE VIEW F 6-6 T HRU 6-7 ITEM PART NUMBER DESCRIPTION QTY MODEL S36 Plug cu.in. Engine Dowel S36 Plug S Plug 1 5 F0HN6N891AA Plug S36 Bolt, Hex 4 7 D0NNH918A Gasket Cover 1 9 E7NN6A008AA Dowel 2 10 F2NN6C057CA Plug S Plug (38.0mm) S Plug A/R 1.56 (39.6mm) 12 C5NN8115B Cock Assembly Dowel 1 14 F2NN6C057AA Plug Plug (44.5mm) S Plug A/R 1.81 (46.0mm) Cover 1 CATALOG B

80 CRANKSHAFT AND FLYWHEEL F 6-8 T HRU CATALOG B242

81 ITEM PART NUMBER DESCRIPTION QTY MODEL Crankshaft cu.in. Engine Pulley Key / F0NN6N300AA Key / S Washer S36 Bolt 1 5A Spacer 1 6 C5NE6310B Slinger Seal 1 8 F0NN6700CA Seal Gear / E9NN6306AA Gear / Liner Kit Main Bearing 3 Std Red 12-88/ Liner Kit Main Bearing 3 Std Blue Liner Kit Main Bearing mm U/S Liner Kit Main Bearing mm U/S Liner Kit Main Bearing mm U/S Liner Kit Main Bearing mm U/S Liner Kit Main Bearing mm U/S Liner Kit Main Bearing 3 Std Red 9-92/ - 10 FAPN6333B Liner Kit Main Bearing 3 Std Blue 10 FAPN6333C Liner Kit Main Bearing mm U/S 10 FAPN6333D Liner Kit Main Bearing mm U/S 10 FAPN6333E Liner Kit Main Bearing mm U/S 10 FAPN6333F Liner Kit Main Bearing mm U/S 10 FAPN6333G Liner Kit Main Bearing mm U/S Liner Kit Thrust Bearing 1 Std Red 12-88/ Liner Kit Thrust Bearing 1 Std Blue 11 CFPN6337C Liner Kit Thrust Bearing mm U/S 11 CFPN6337K Liner Kit Thrust Bearing mm U/S 11 CFPN6337L Liner Kit Thrust Bearing mm U/S 11 CFPN6337M Liner Kit Thrust Bearing mm U/S 11 CFPN6337N Liner Kit Thrust Bearing mm U/S Liner Kit Thrust Bearing 1 Std Red 9-92/ - 11 FAPN6337B Liner Kit Thrust Bearing 1 Std Blue 11 FAPN6337C Liner Kit Thrust Bearing mm U/S 11 FAPN6337D Liner Kit Thrust Bearing mm U/S 11 FAPN6337E Liner Kit Thrust Bearing mm U/S 11 FAPN6337F Liner Kit Thrust Bearing mm U/S 11 FAPN6337P Liner Kit Thrust Bearing mm U/S Seal 1 14 E7NN6375AA Flywheel Assembly 1 (Includes Items 15 & 16) Gear Bolt, Hex 6 17 E5HN6N306AC Retainer Assembly / Retainer Assembly / Gasket S36 Screw & Washer Seal, O -Ring 1 CATALOG B

82 CAMSHAFT, ROCKER ARM &VALVES F 6-10 thru CATALOG B242

83 ITEM PART NUMBER DESCRIPTION QTY MODEL Tappet cu.in. Engine Rod 6 3 D9NN6529AB Arm, Intake 3 Includes Item 4 3 C5NE6529A Arm, Exhaust 3 Includes Item 4 4 E7NN6549AA Screw 6 5 E7NN6563AA Shaft Plug 2 7 D5NN6531A Support Bolt, Hex Spring Spacer 3 12 E9NN6505AA Valve, Exhaust 3 Std. 12 E9NN6505BA Valve, Exhaust A/R.003 /.0762mm O/S 12 E9NN6505CA Valve, Exhaust A/R.015 /.381mm O/S Valve, Exhaust A/R.030 /.762mm O/S Valve, Exhaust 3 Std. for 545C, 545D Valve, Exhaust A/R.003 /.0762mm O/S 12 D8NN6505CA Valve, Exhaust A/R.015 /.381mm O/S 12 D8NN6505DA Valve, Exhaust A/R.030 /.762mm O/S Valve, Intake 3 Std Valve, Intake A/R.003 /.0762mm O/S Valve, Intake A/R.015 /.381mm O/S Valve, Intake A/R.030 /.762mm O/S Spring 6 14* E9NN6513BA Spring 6 14 C5NE6A526A Spacer, Valve Spring A/R 15 D0NN6514A Retainer 3 15* E5HN6514AA Retainer 3 16 C6AE6514A1 Retainer Key Seal, Valve Stem 6 18* Seal, Valve Stem Cover Gasket S2 Bolt, Hex Camshaft 1 * Item used on Engine Build Code 1J20 & above (Oct.20, 1991 & above). CATALOG B

84 - MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS CATALOG B242

85 ITEM PART NUMBER DESCRIPTION QTY MODEL 24 D3NN6A253AB Gear Assembly cu.in. Engine D9NN6A254AA Bushing 1 25 F2NN6A255AA Adapter 1 Engines Built 11/88 to 12/ Adapter 1 Engines Built 1/95 on 26 F2NN6N253AA Bolt, Hex 1 27 E3NN6N251AB Gear Spacer 1 29 E5HN6269AA Plate S36 Screw & Washer Key Bearing Cover Hose Tube 1 35 E6NN6758AA Tube Clamp Washer S36 Washer S2 Bolt, Hex 1 40 E3NND855AA Gear Assembly Pin, Dowel 1 CATALOG B

86 PISTONS & CONNECTING RODS F 6-14 THRU 6-15 ITEM PART NUMBER DESCRIPTION QTY MODEL For 201 cu.in. Engine 1* E7NN6108SC Piston, Pin & Ret. Set 3.Standard 1* E1NN6108TA Piston, Pin & Ret. Set (.1016mm) 1* Piston, Pin & Ret. Set (.508mm) 1* E7NN6108VC Piston, Pin & Ret. Set (.762mm) 1* E7NN6108XA Piston, Pin & Ret. Set (1.016mm) 2 E3HN6135AA Pin Retainer 6 * Includes Items 2 & CATALOG B242

87 ITEM PART NUMBER DESCRIPTION QTY MODEL For 201 cu.in. Engine Kit, Piston Ring 3 Standard Kit, Piston Ring (.508mm) Kit, Piston Ring (.762mm) 4 EBPN6149PA Kit, Piston Ring (1.016mm) 5** F2NN6200BA Rod Assembly 3 6 E6NN6207AA Bushing 3 7 E9NN6214AA Bolt S2 Nut, Hex Liner Kit, Bearing 12-88/ Std. Red Liner Kit, Bearing 12-88/ Std. Blue Liner Kit, Bearing 12-88/ (.0508mm) Liner Kit, Bearing 12-88/ (.254mm) Liner Kit, Bearing 12-88/ (.508mm) Liner Kit, Bearing 12-88/ (.762mm) Liner Kit, Bearing 12-88/ (1.016mm) Liner Kit, Bearing 9-90/ - 3 Std. Purple 9 FAPN6211B Liner Kit, Bearing 9-90/ (.0508mm) 9 FAPN6211J Liner Kit, Bearing 9-90/ (.254mm) 9 FAPN6211D Liner Kit, Bearing 9-90/ (.508mm) 9 FAPN6211E Liner Kit, Bearing 9-90/ (.762mm) 9 FAPN6211F Liner Kit, Bearing 9-90/ (1.016mm) ** Includes Items 6, 7, & 8. CATALOG B