K- D MANITOU, INC. 3120 GHOLSON ROAD WACO, TEXAS 76705 T502TC -D, T502TC -DSB T602TC -D, T602TCP -D T602TCP -DXL T802TC -D & T1002TC -D S/N: T5020058, T6020625, T8020167, T10020146 & ABOVE (excluding S/N: T6020630 & T6020631) PARTS MANUAL SERIES F CATALOG B242
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
FILTER CHART 2 1 3 4 5 6 7 8 9 10 DESCRIPTION PART NO. CLEAN REPLACE 1 - Engine oil filter 421602 - - - - 150 hrs. 2 - Air filter cartridge 421468 150 hrs. 450 hrs. 3 - Transmission oil filter 425657 - - - - 450 hrs. 4 - Fuel filter (cartridge type) 421206 - - - - 450 hrs. 5 - Hydraulic oil filter cartridge 422141 - - - - 450 hrs. 6 - Air filter safety cartridge 421473 450 hrs. 900 hrs. 7 - Hydraulic suction screen 424764 900 hrs. if damaged 8 - Air intake pre-cleaner 493776 150 hrs. if damaged 9 - Turbo pre-cleaner II 492009 150 hrs. if damaged 10 - Vaculator (1.5 dia) 426199 150 hrs. if damaged 10 - Vaculator (3 dia) 421471 150 hrs. if damaged
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 -
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
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... 10 FRAME, HOOD, WEIGHTS, OVERHEAD GUARD... 11 DECALS... 12 OPTIONS... 13 PARTS NUMERICAL INDEX... Supplement CATALOG B242 - III -
SECTION 1 TIRES & WHEELS DESCRIPTION PAGE TIRES & WHEELS... 1-2 CATALOG B242-1 - 1 -
TIRES & WHEELS 3 5 1 2 8 7 4 6 7 9-1 - 2 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 1 421740 Drive Tire/Wheel Assembly 2 Std. on T502 -T802 (T0030 Tire & B5498 Wheel) & T504 -T804 1 422280 Drive Tire/Wheel Assembly 2 T502 & T504 (T0009 Tire & B5498 Wheel) 1 422279 Drive Tire/Wheel Assembly 2 T502 -T802, Towable (T0039 Tire & B5870 Wheel) 1 422535 Drive Tire/Wheel Assembly 2 T802/4 Option (161538 Tire & B5498 Wheel) 1 425041 Drive Tire/Wheel Assembly 2 Poultry Trucks (161538 Tire & B5491 Wheel) 1 492595 Drive Tire/Wheel Assembly 2 T502 (492438 Tire & B5498 Wheel) 1 492384 Drive Tire/Wheel Assembly 2 T802 & T1002 (492383 Tire & 492369 Wheel) 1 492371 Drive Tire/Wheel Assembly 2 T802/4 Option (492372/492791 Tire & 492369 Wheel) 1 492596 Drive Tire/Wheel Assembly 2 T502 - T802 (491950 Tire & B5498 Wheel) 1 491762 Drive Tire/Wheel Assembly 2 T1002 w/ 200# (426692 Tire & B5870 Wheel) Wheel Weights 1 424206R Drive Tire/Wheel, Right Assembly 1 Std T1002 (424207 Tire & 426107 Wheel) 1 424206L Drive Tire/Wheel, Left Assembly 1 Std T1002 (424207 Tire & 426107 Wheel) 2 421743 Steer Tire/Wheel Assembly 2 T502 -T802 (T0034 Tire & B5494 Wheel) 2 421741 Steer Tire/Wheel Assembly 2 T502 -T802 (T0004 Tire & B5497 Wheel) 2 422557 Steer Tire/Wheel Assembly 2 Sod Buster (T0043 Tire & B5434 Wheel) 2 424099 Steer Tire/Wheel Assembly 2 T502 -T1002 (424100 Tire & B5497 Wheel) 2 432484 Steer Tire/Wheel Assembly 2 T504 -T804 (T0022 Tire & 423485 Wheel) CATALOG B242-1 - 3 -
ITEM PART NUMBER DESCRIPTION QTY MODEL 3 T0030 Tire, Drive 16.9 x 24, 10 Ply R4 2 All except T1002 3 T0009 Tire, Drive 16.9 x 24, 6 Ply 2 T502 & T504 3 T0039 Tire & Tube 14R 24 XXVC 2 T502 -T802, Towable 3 161538 Tire, Drive 16.9 x 24, 12 Ply R4 2 Poultry Trucks 3 492438 Tire, Drive 16.9 x 24, 6 Ply 2 T502 3 492383 Tire, Drive 19.5 LR x 24, IT 510 2 T802 & T1002 3 492372 Tire, Drive 19.5 L x 24, 12 Ply 2 T802/4 3 492791 Tire, Drive 19.5 L x 24, 12 Ply 2 T802/4 3 491950 Tire, Drive 17.5 LR 24 IT 510 2 T502 - T802 3 426692 Tire, Drive 14.00-24 20PR SRL -1 2 T1002 w/ 200# Wheel Weights 3 424207 Tire, Drive 17.5 x 25, 12 Ply L2 2 Std T1002 4 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 13.5-15, 8 Ply 2 Sod Buster 4 424100 Tire, Steer 12 x 16.5, 12 Ply 2 T502 -T1002 4 T0022 Tire, Steer 12 x 16.5, 10 Ply 2 T504 -T804 5 B5498 Wheel, Drive 15 x 24 2 All except T1002 5 B5870 Wheel, Drive 10 x 24 2 T502 -T802, Towable 5 B5491 Wheel, Drive 12 x 24 2 Poultry Trucks 5 492369 Wheel, Drive DW 16L x 24 2 T802/4 & T1002 5 426107 Wheel, Drive 14 x 25 2 Std T1002 5 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 16.5 2 T502 -T1002 6 B5434 Wheel, Steer 15 x 10 2 Sod Buster 6 423485 Wheel, Steer 12 x 16.5 2 T504 -T804 7 B2258 Stem, Valve 2 All Steer Wheels 7 B2257 Stem, Valve 2 All Drive Wheels except 426107 7 424234 Stem, Valve 2 Use on 426107 Drive Wheel 8 B5223 Nut, Lug (Drive Wheel) 16 (Qty. for 2 Wheels) 9 421116 Nut, Lug (Steering Wheel) 16 (Qty. for 2 Wheels) - 1-4 - CATALOG B242
SECTION 2 BRAKE & ACCELERATOR ASSEMBLIES DESCRIPTION PAGE BRAKE PEDAL & PARK BRAKE ASSEMBLY... 2-2 BRAKE DISC ASSEMBLY... 2-6 ACCELERATOR ASSEMBLY... 2-8 CATALOG B242-2 - 1 -
BRAKE PEDAL & PARK BRAKE ASSEMBLY - 2-2 - CATALOG B242
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 2 5 424348 Pedal, Brake (R.H.) 1 6 424347 Pedal, Brake (L.H.) 1 7 424120 Brk t, Pedal 1 8 424174 Bolt, Allen Hd 4 9 R13453-15 Ring, Snap 2 10 424150 Bar, Pedal Stop 1 11 B3872 Grommet 2 12 424152 Bracket 2 13 424114 End, Rod (L.H. Threads) 2 14 K34690L Nut, Jam (L.H. Threads) 2 15 424115 Rod, Adjusting 2 16 K34690 Nut, Jam 2 17 424113 End, Rod 2 18 K20508 Bolt, Hex 4 19 K34808 Washer, Lock 4 20 K55826 Nut, Lock 4 21 424129 Lever, Brake (R.H.) 1 22 424133 Lever, Brake (L.H.) 1 23 424765 Clevis 2 24 K76240 Pin, Clevis 2 25 K72035 Pin, Cotter 2 26 K302216 Screw, Allen Hd 1 27 K97529 Ring, Snap 1 28 B5596 Sleeve 1 29 B309 Washer, Thrust 1 30 K74181 Key, Woodruff 2 31 424130 Spacer 2 32 424106 Shaft, Actuating 1 33 B3053 Joint, Ball 2 34 B3368 Ring, Snap 2 35 424137 Lever, Brake 1 CATALOG B242-2 - 3 -
- MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS - - 2-4 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 36 424157 Clevis, Cable 1 All 37 424149 Bracket, Cable 1 38 491829 Cable, Brake 1 39 B5777 Spacer 1 40 B5776 Clamp, Cable 1 41 491828 Lever, Park Brake 1 42 421125 Spring 2 43 K20466 Bolt, Hex 3 44 K34806 Washer, Lock 3 45 K33922 Nut, Jam 3 CATALOG B242-2 - 5 -
BRAKE DISC ASSEMBLY ATTENTION: Verify Ford Powertrain Model No. before ordering parts (see page II, LIFT TRUCK COMPONENT IDENTIFICATION). 27 26 30A 34 4 29 13 30 31 29A 19 43 20 45 16 18 10 7 17 3 14 2 12 15 5 4 9 8 11 6 4 5 4 1 F 2-2 T HRU 2-4 - 2-6 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 1 426154 Housing, Outer 2 ALL 2 426357 Housing, Inner (L.H.) 1 Powertrain 545 2 E4NN2N099CA Housing, Inner (L.H.) 1 Powertrain 655 3 426153 Housing, Inner (R.H.) 1 Powertrain 545 3 E4NN2N100BA Housing, Inner (R.H.) 1 Powertrain 655 4 426224 Disc Assembly 8 Powertrain 545 4 E6NN2A097BA Disc Assembly 8 Powertrain 655 5 426225 Disc, Intermediate 4 Powertrain 545 5 E6NN2N315BA Disc, Intermediate 4 Powertrain 655 6 426155 Disc Assembly 2 Powertrain 545 (Includes Items 4, & 7 thru 11) 6 E6NN2N317BA Disc Assembly 2 Powertrain 655 (Includes Items 4, & 7 thru 11) 7 477001 Link 4 8 1847078 Ball 12 9 133990 Spring 8 10 477002 Pin 4 11 K34690 Nut, Jam 4 12 477033 Bolt, Hex 12 13 134692 Stud 4 14 33846S36 Nut, Hex 16 15 133993 Pin 2 16 426156 Rod 2 17 492292 Pin, Cotter 2 18 K76260 Pin 2 19 421121 Seal Assembly 2 26 134539 Shaft 1 Powertrain 545 26 E7NN2458AA Shaft 1 Powertrain 655 27 134674 Key 1 29 134000 Washer 1 29A 134486 Washer 1 30 492827 Seal Assembly 2 30A 134537 Seal, Felt 2 31 133999 Bushing 2 34 134674 Key 1 43 426286 Washer 2 45 426285 Sleeve 2 CATALOG B242-2 - 7 -
ACCELERATOR ASSEMBLY (EARLY MODELS) 4 5 3 2 7 6 1 12 11 8 10 16 9 14 12 11 13 14 15 9 10 12 17 18 11 10 9 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 K305078 Roll Pin 3 17 B5187 Throttle Rod (rear) 1 18 B5299 Clip 1-2 - 8 - CATALOG B242
ACCELERATOR ASSEMBLY (CURRENT MODELS) 7 10 2 4 5 4 6 15 14 13 12 11 8 9 4 2 3 16 17 4 2 2 3 1 THROTTLE -ARM LEVER (REF) ITEM PART NUMBER DESCRIPTION QTY MODEL 1 424947 Cable, Accel. 1 All Current Models 2 K34079 Nut, Hex 4 3 421481 End, Swivel 2 4 K34779 Washer, Lock 4 5 425217 Pedal, Accel. 1 6 77957 Block, Pivot 2 7 K20424 Bolt, Hex 2 8 K34805 Washer, Lock 2 9 K33795 Nut, Hex 2 10 491730 Brk t, Accel. Assembly 1 11 K20428 Bolt, Hex 2 12 K34807 Washer, Lock 2 13 B1074 Spring 1 14 491737 Tab, Spring Mtg. 1 15 K45520 Bolt, Hex 1 16 K34806 Washer, Lock 1 17 K33797 Nut, Hex 1 CATALOG B242-2 - 9 -
- MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS - -2-10- CATALOG B242
SECTION 3 STEERING COMPONENTS DESCRIPTION PAGE STEERING COLUMN/VALVE & PUMP... 3-2 STEERING COLUMN/VALVE ASSEMBLY... 3-4 POWER STEERING PUMP/RESERVOIR... 3-8 STEER AXLE & MOUNTING... 3-10 STEER AXLE HOSES (EARLY MODELS)... 3-12 STEER AXLE HOSES (CURRENT MODELS)... 3-13 STEER AXLE CYLINDER... 3-14 STEER WHEEL HUB... 3-15 CATAL OG B242-3 - 1 -
STEERING COLUMN/VALVE & PUMP 1 2 23** 3 6a 15 16 17 12 SEE DETAIL A SEE DETAIL B 6 4 6 5 18 24** 25** 19 DETAIL B 9 10 11 8 4 7 7 8 FRAME BRK T (REF) OUT RT LT IN 13 20 12 14 13 21* 22* 15 (LT) 17 (IN) 16 (RT) 18 (OUT) DETAIL A - 3-2 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B1905 Steering Valve Assembly 1 ALL 2 B1828 Wheel, Steering 1 3 B2007 Cover 1 4 421517 Bracket, Hose 4 5 B7627 Bracket 1 6 K20384 Bolt, Hex 1 6a K300858 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 B760-1680 Hose Assembly 1 16 B760-1680 Hose Assembly 1 17 B760-1687 Hose Assembly 1 18 B760-1686 Hose Assembly 1 19 425697 Steering Pump Assembly 1 20 K906 O -Ring 4 21* 426638 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 B242-3 - 3 -
STEERING VALVE ASSEMBLY 42 43 41 19 41 42 39 18 44 38 37 16 17 14* 45 36** 31 34 34 33 32 15* 13* 12* 10* 46 11* 9 7 40 8** 30 47* 48** 49*** 29 27 6 4** 5** 3 2** 1 28*** 26 23 24 22 25 21 20-3 - 4 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL B1905 Steering Valve Assembly 1 ALL 1 B1905-1 Nut, Wheel 1 2**,*** - - - - Seal 1 3 B1905-4 Ring, Snap 1 4**,*** - - - - Ring, Back Up 1 5**,*** - - - - Seal 1 6 ---- Screw 4 7 ---- Cover,Upper 1 8** - - - - O - Ring 1 9 B1905-12 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 B1905-19 Shaft, Input 1 17 - - - - Pin 1 18 - - - - Ring, Drive 1 19 - - - - Spacer 1 20 - - - - Bar, Torsion 1 21 B1905-20 Needle Roller 1 22 - - - - Spool 1 23 B1905-25 Ball 1 24 - - - - Bearing 1 25 - - - - Housing Assembly 1 26 - - - - Ball 1 27** - - - - O-Ring 1 28*** - - - - Plug Assembly 1 29 B1905-30 Spacer 1 30 B1905-31 Link, Drive 1 31 B1905-35 Retainer, Seal 1 32 - - - - Rotor Set 1 CATAL OG B242-3 - 5 -
- MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS - - 3-6 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 33 - - - - Manifold 1 ALL 34 - - - - Commutator, Ring 1 35 - - - - Commutator 1 36 B1905-62 Seal, Rotator 1 37 B1905-37 Washer 1 38 - - - - Cover, End 1 39 - - - - Bolt, Special 7 40 B1905-2 JT Bearing 1 41 B1905-41 Pin 2 42 B1905-39 Ring, Snap 2 43 B1905-40 Coupling 1 44 B1905-42 WT 1 45 B1905-43 Clamp 1 46 B1905-44 JT Assembly 1 47 B1905-51 Repair Kit 1 48 B1905-50 Repair Kit 1 49 B1905-64 Seal Kit 1 * Included in Repair Kit (Item 47). ** Included in Repair Kit (Item 48). *** Included in Seal Kit (Item 49). CATAL OG B242-3 - 7 -
POWER STEERING PUMP/RESERVOIR 2 1 23 30 36 35 33 39* 9 8* 7 6* 5* 25 27 29 26 28 38 37 4 40 10* 14* 11 12 41 13 31 32 34 24 3 2 22 18 19 21 20 16 17 15 ITEM PART NUMBER DESCRIPTION QTY MODEL 425697 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 1 9 492286 Ring, Snap 1 10* - - - - Seal 1 11 E6NN3B681AA Cover 1 12 34792S36 Washer 4-3 - 8 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 13 C7NN3N533A Bolt, Pump 4 ALL 14* - - - - Seal 4 15 492290 Valve Assembly 1 (Includes Items 16-23) 16 C7NN3B608A Spring 1 17 492525 Shim A/R.010 17 492526 Shim A/R.015 18 C7NN3D721A Seat 1 19 C7NNN626A Head 1 20 C7NNG963A Guide 1 21 C7NNG964A Seal 1 22 87035S95 O -Ring 1 22* - - - - O - Ring 1 23* - - - - O - Ring 1 24 426351 Filter Assembly 1 25 E6NN3531DA Reservoir Assembly 1 (Includes Items 26-27) 26 493592 Valve Assembly 1 (Includes Items 27) 27 493624 Seal 1 28 D0NN3R678A Spring 1 29 97407S Ring 1 30 424566 Cap, Filler 1 31 426363 Seal 1 32 E6NN3R655CA Bolt, Hex 1 33 C5NN3A742A Gear 1 34 74174S Key, Woodruff 1 35 492287 Washer, Tab 1 36 K34690 Nut, Lock 1 37 K34807 Washer 2 38 380844S36 Bolt, Hex 2 39* - - - - O - Ring 1 40 492289 Seal 1 41 C5NN3N676A Elbow Assembly 1 42 492288 Seal Kit 1 * Included in Seal Kit, Item 42. CATAL OG B242-3 - 9 -
CATALOG B242-3-10- STEER AXLE & MOUNTING 1 2 7 6 11 8 8 12 9 5 10 13 15 14 17 16 18 19 21 20 22 23 24 25 3 4 29 30 31 32 33 34 22 23 36 37 38 39 5 26 31 21 20 22 24 25 27 28 35
ITEM PART NUMBER DESCRIPTION QTY MODEL 493133 Steer Axle Assembly 1 All except T1002 (less Items 29-39) 1 426043 Steer Axle Weldment 1 T1002 Only 1 425675 Steer Axle Weldment 1 All except T1002 2 422252 Cylinder, Steer 2 3 K71C5301 Pin, Cylinder 2 4 K72057 Pin, Cotter 4 5 421458 End, Cylinder 2 6 423995 Spindle Assembly, (L.H.) 1 7 423994 Spindle Assembly, (R.H.) 1 8 421318 Hub Assembly 2 9 421377 Rod, Tie 1 10 421459 Clamp 2 11 421456 End, Tie Rod (R.H.) 1 12 421457 End, Tie Rod (L.H.) 1 13 - - - - Washer 1 Included w/ Items 11 & 12 14 - - - - Nut, Castle 1 Included w/ Items 11 & 12 15 K72071 Pin, Cotter 2 16 K45754 Bolt, Hex 4 17 K33946 Nut, Jam 4 18 K33799 Nut, Hex 2 19 K20468 Bolt, Hex 2 20 421520 Bearing, Thrust 2 21 426131 Shim A/R 22* 421493 Bushing, Garmax 4 22** 426041 Bushing, Kaiser 4 23* 423988 Pin, King 2 23** 426042 Pin, King 2 24 K134 O -Ring 4 25 425674 Cover, Dust 4 26 R13351-3 Washer, Lock 8 27 K302210 Screw, Soc Hd 8 28 K87901 Fitting, Grease 4 29 421510 Cover, Bearing (Front) 1 30 421180 Pin (Rear) 1 31 421107 Washer, Thrust 2 32 421237 Pin (Front) 1 33 K58758 Cap 1 34 B5091 Cover, Bearing (Rear) 1 35 K302281 Screw 4 36 491956 Support, Mounting 1 37 K45784 Bolt, Hex 8 38 K34813 Washer 8 39 K34674 Nut, Hex 4 * For use on S/N: T5020057 & below, T6020625-0690, T8020167-0171, T1002046-0148. ** For use on S/N: T4020058, T6020691, T8020178 T10020149 & above. CATALOGB242-3-11-
STEER AXLE HOSES (EARLY MODELS) RIGHT STEERING CYLINDER (REF) 6 5 7 6 3 1 LEFT STEERING HOSE (REF) 9 7 8 4 2 13 RIGHT STEERING HOSE (REF) 10 11 12 LEFT STEERING CYLINDER (REF) 6 5 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B760-1363 Hose Assembly 2 Early Models 2 B760-1364 Hose Assembly 1 3 B760-1365 Hose Assembly 1 4 421509 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 B3698-9 Clamp 3 11 K34807 Washer 1 12 K33799 Nut, Hex 1 13 K108-6 Adapter 2-3-12- CATALOG B242
STEER AXLE HOSES (CURRENT MODELS) 4 5 3 3 10 1 RIGHT STEERING HOSE (REF) 10 RIGHT STEERING CYLINDER (REF) 6 2 LEFT STEERING HOSE (REF) 7 10 8 9 LEFT STEERING CYLINDER (REF) ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B760-1363 Hose Assembly 2 Current Models 2 K66-6 Fitting 2 3 K69-6 Fitting 2 4 421509 Tube Assembly 1 5 K71-6 Fitting 1 6 K20468 Bolt, Hex 1 7 B3698-9 Clamp 1 8 K34807 Washer, Lock 1 9 K33799 Nut, Hex 1 10 K906 O -Ring 4 CATALOGB242-3-13-
STEER AXLE CYLINDER 13 12 11* 10 9 8* 7* 6 3* CURRENT MODEL 5* EARLY MODEL 13 14 7* 8* 7* 1 4* 15 2 ITEM PART NUMBER DESCRIPTION QTY MODEL 422252 Cylinder, Steer (Complete) 2 All 2WD 1 422253 Barrel Assembly 1 2 422251 Rod, Piston 1 3* - - - - Ring, Back Up 2 4* - - - - O - Ring 1 5* - - - - Wiper 1 6 R4573-5 Lockwire 1 7* - - - - Ring, Back Up A/R 8* - - - - O - Ring A/R 9 422257 Head, Cylinder 1 10 492862 Piston, Cylinder 1 Current Models 11* ---- Seal 1 12 492867 Wear Ring 1 13 K55700 Nut, Lock 1 14 422258 Piston, Cylinder 1 Early Models 15 422252K Kit, Seal 1 * Included In Seal Kit (Item 15). -3-14- CATALOG B242
STEER WHEEL HUB 10 11 8 4 5 2 2A 1 3A 3 6 7 9 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 421318 Hub Assembly 1 All 2WD 2 421305 Bearing, Inner 1 2A 421313 Inner Bearing Race 1 3 421306 Bearing, Outer 1 3A 421314 Outer Bearing Race 1 4 421538 Washer, Felt 4 5 421307 Seal, Grease 1 6 421309 Washer, Spindle 6 7 421311 Pin, Cotter 1 8 421310 Nut, Slotted 1 9 421304 Cap, Grease 1 10 421315 Bolt, Lug 8 11 421116 Nut, Lug 8 CATALOGB242-3-15-
- MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS - -3-16- CATALOG B242
SECTION 4 FRONT WHEEL DRIVE AXLE DESCRIPTION PAGE DRIVE AXLE (POWERTRAIN MODEL 445/545)... 4-2 DRIVE AXLE (POWERTRAIN MODEL 655)... 4-6 DRIVE AXLE HOUSING (POWERTRAIN MODEL 445/545)... 4-10 DRIVE AXLE HOUSING (POWERTRAIN MODEL 655)... 4-14 DIFFERENTIAL LOCK LINKAGE... 4-18 CATALOG B242-4 - 1 -
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 F4-2 - 4-2 - CATALOG B242
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) 2 134012 Gear 2 3 134692 Stud 4 4 134533 Cup, Inner 2 5 134386 Cup, Outer 2 6 426157 O -Ring 2 7 304838S36 Bolt, Hex 2 lg 42 7 134141 Bolt, Hex 2 3/4 lg 2 7A 477263 Stud 4 7B 390272S36 Nut, Hex 2 8 E4NN4244DA Shaft Assy 2 (Includes Item 8A, qty. 8 ea.) 8A 426581 Bolt, Hex 16 9 426311 Cone Assembly, Outer 2 10 426355 Seal Assembly 1 10A 426310 Seal, Dirt 2 11 134712 Carrier Assembly 2 (Includes Items 12-18) 12 134417 Retainer 2 13 133939 Cone Assembly, Inner 2 14 134418 Shaft 6 15 C5NN4044B Gear 6 16 134003 Washer 12 17 134005 Kit, Bearing (32 Needles) 6 18 134004 Spacer 6 19 134010 Gear 2 20 134025 Spacer (.049/.050) A/R 20 134026 Spacer (.053/.054) A/R 20 134027 Spacer (.057/.058) A/R 20 134028 Spacer (.061/.062) A/R 20 C5NN4374R Spacer (.065/.066) A/R 20 134030 Spacer (.069/.070) A/R 20 C5NN4374T Spacer (.073/.074) A/R 20 134032 Spacer (.077/.078) A/R 20 134033 Spacer (.081/.082) A/R 20 134034 Spacer (.085/.086) A/R 20 134035 Spacer (.089/.090) A/R CATALOG B242-4 - 3 -
ITEM PART NUMBER DESCRIPTION QTY MODEL 21 134021 Washer 2 Powertrain Model 445/545 22 134354 Lock 2 23 134683 Bolt, Hex 2 24 426154 Housing, Outer 2 25 Ref. Brake Disc Assembly 2 (See Section 2) 26 426153 Housing L.H. 1 26 426357 Housing R.H. 1 27 134036 Shim (.038/.040) A/R 27 134037 Shim (.044/.046) A/R 27 134038 Shim (.050/.052) A/R 27 134039 Shim (.056/.058) A/R 27 134040 Shim (.062/.064) A/R 27 134041 Shim (.068/.070) A/R 27 134042 Shim (.074/.076) A/R 27 134043 Shim (.080/.082) A/R 28 425757 Cup 1 29 493609 Cup 1 30 134660 Cone Assembly 1 31 957E4221 Cone Assembly 1 32 493626 Case Assembly 1 33 134703 Screw 8 34 493615 Gear Set 1 35 133956 Bolt 12 36 134698 Nut, Hex 12 37 134020 Gear 1 38 134022 Gear 1 39 134019 Washer 2 40 134250 Spider 1 41 957E4292B Pinion Assembly 4 42 133950 Washer 4 43 493610 Bushing 2-4 - 4 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 44 133969 Adapter 1 Powertrain Model 445/545 45 E188EB9 Spring 1 46 134248 Coupling 1 47 133971 Washer 1 48 134724 Ring 1 49 493608 Bearing Assembly 1 50 134044 Ring, Lock 1 51 477269 Cone Assembly (Front) 1 52 134613 Cone Assembly (Rear) 1 53 C5NN4614F Retainer Assembly 2WD 1 (Includes Items 54 & 55) 54 133953 Cup (Front) 1 55 134251 Cup (Rear) 1 56 K34810 Washer 5 57 134434 Bolt 5 58 134341 Washer 1 59 E7NN4634AA Nut, Hex 1 61 477272 Coupling 1 62 1803369 Block 1 63 34808S36 Washer 1 64 304686S36 Bolt 2 CATALOG B242-4 - 5 -
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 F4-2 - 4-6 - CATALOG B242
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 16 2 426310 Seal, Dirt 2 3 C5NN4969D Seal Assembly 2 4 426311 Cone Assembly, Outer 2 5 134141 Bolt, Hex 2 6 390272S36 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 2 9 134012 Gear 2 10 134692 Stud 4 11 134533 Cup, Inner 2 12 426157 O -Ring 2 13 477263 Stud 4 14 134712 Carrier Assembly 2 Includes Items 15-21 15 E1ADDN4221 Cone Assembly, Inner 2 16 134418 Shaft 6 17 134003 Washer 12 18 134005 Kit, Bearing (32 Needles) 6 19 134004 Spacer 6 20 C5NN4044B Gear 6 21 134417 Retainer 2 22 134025 Spacer (.049/.050) A/R 22 134026 Spacer (.053/.054) A/R 22 134027 Spacer (.057/.058) A/R 22 134028 Spacer (.061/.062) A/R 22 C5NN4374R Spacer (.065/.066) A/R 22 134030 Spacer (.069/.070) A/R 22 C5NN4374T Spacer (.073/.074) A/R 22 134032 Spacer (.077/.078) A/R 22 134033 Spacer (.081/.082) A/R 22 134034 Spacer (.085/.086) A/R 22 134035 Spacer (.089/.090) A/R CATALOG B242-4 - 7 -
ITEM PART NUMBER DESCRIPTION QTY MODEL 23 134021 Washer 2 Powertrain Model 655 24 134683 Bolt, Hex 2 25 134354 Lock 2 26 134010 Gear 2 27 426154 Housing, Outer 2 28 Ref Brake Disc Assembly 2 (See Section 2) 29 E4NN2N099CA Housing L.H. 1 29 E4NN2N100BA Housing R.H. 1 30 300950S2 Bolt, Hex 12 31 33846S36 Nut, Hex 4 32 134036 Shim (.038/.040) A/R 32 134037 Shim (.044/.046) A/R 32 134038 Shim (.050/.052) A/R 32 134039 Shim (.056/.058) A/R 32 134040 Shim (.062/.064) A/R 32 134041 Shim (.068/.070) A/R 32 134042 Shim (.074/.076) A/R 32 134043 Shim (.080/.082) A/R 33 134724 Ring 1 34 133971 Washer 1 35 134248 Coupling 1 36 E188EB9 Spring 1 37 133969 Adapter 1 38 493609 Cup L.H. W/DL 1 39 957E4221 Cone Roller 1 40 C5NN4204R Case Assembly 1 41 43104S2 Screw 8 42 493610 Bushing 2 43 134019 Washer 2 44 134022 Gear 1 45 C5NN4211B Spider 1 46 E1ADDN4213B Pinion Assembly 4 47 133950 Washer 4 48 134020 Gear 1 49 133956 Bolt 12 50 493615 Gear Set 1-4 - 8 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 51 493612 Bolt 2 Powertrain Model 655 52 C5NN4194C Block 1 53 134698 Nut, Hex 12 54 134660 Cone Roller 1 55 425757 Cup 1 56 134044 Ring, Lock 1 57 D1NNN4A242A Bearing Assembly 1 58 97537S 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 1 63 304794S36 Bolt, Hex 2 64 NCA4616A Cup, Front Pinion 1 65 E7NN1N060BA Forward Pinion Gear 1 66 58709S36 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 B242-4 - 9 -
DRIVE AXLE HOUSING (POWERTRAIN MODEL 445/545) ATTENTION: Verify Ford Powertrain Model No. before ordering parts (see page II, LIFT TRUCK COMPONENT IDENTIFICATION). 55 56 22 23 21-4 - 10 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 1 492022 Housing Assembly 1 Powertrain Model 445/545 (Includes Items 1A-1F) 1A 493631 Bearing 1 1B 133999 Bushing 2 1C 134310 Pin 1 1D D3NN7R280A Plug 1 1E 134608 Bushing 1 1F 133980 Bushing 1 2 133983 Plug 1 3 133984 Plug 1 4 C5NNN735C Bushing 1 5 C5NNN734A Bushing 1 6 134427 Bolt, Hex 1 7 134276 Seal 1 8 87709S Plug 1 9 477250 Gasket 1 10 58699S36 Bolt, Hex 2 11 106721 Bolt, Hex 1 12 106721 Bolt, Hex 1 13 58678S36 Bolt, Hex 2 14 58678S36 Bolt, Hex 2 15 58701S36 Bolt, Hex 2 16 33847S36 Nut, Hex 4 17 33845S36 Nut, Hex 6 20 492308 Gasket 1 21 422178 Cover 1 22 134434 Bolt, Hex 13 23 134353 Vent Bolt 1 24 425293 Gasket 1 25 426363 Seal 1 26 34443S2 Nut, Lock 1 27 38308S36 Screw 1 28 E7NN7N009AA Gasket 2 29 E0NN4281AA Plug 2 30 426157 O -Ring 2 31 E107GF9 Dowel 2 32 477020 Gasket 1 CATALOG B242-4-11-
- MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS - - 4-12 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 33 D3NNN973B Cover 1 Powertrain Model 445/545 34 134429 Bolt, Hex 6 35 C5NNN864A Washer 1 36 C5NNN863B Plug 1 37 425295 Gasket 1 38 E7NN4N311AA Plate Assembly 1 39 134429 Bolt, Hex 3 40 E5NN4N021BA Gasket 1 41 C5NN4N020A Cover 1 42 134429 Bolt, Hex 2 43 304721S36 Bolt, Hex 2 44 426145 Gasket 1 45 C5NN7N508A Cover 1 46 134429 Bolt, Hex 3 47 477254 Gasket 1 48 E7NNP700AA Cover 1 49 304762S36 Bolt, Hex 4 50 87837S36 Plug 1 51 E0NN4N206AA Plug 1 52 136056 Plate 1 53 134429 Bolt, Hex 4 54 87038S94 O -Ring 1 55 422177 Dipstick 1 56 491996 O -Ring 1 CATALOG B242-4-13-
DRIVE AXLE HOUSING (POWERTRAIN MODEL 655) ATTENTION: Verify Ford Powertrain Model No. before ordering parts (see page II, LIFT TRUCK COMPONENT IDENTIFICATION). 32 32A - 4-14 - CATALOG B242
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 1 2 57461S36 Screw 1 3 E84GF9 Seal 1 4 383705S36 Nut 1 5 379313S91 O -Ring 2 6 E2NN7Z168AA Gasket 1 7 E2NN7D117AA Cover 1 8 C9NN6734A Gasket, Drain Plug 1 9 C9NN6730B Drain Plug 1 10 304724S36 Bolt 8 11 34793S36 Washer 8 12 C5NNN742A Gasket 1 13 C5NN7N508A Cover 1 14 304668S36 Bolt 3 15 C5NN4N023A Plate 1 16 304668S36 Bolt 3 17 304724S36 Bolt 3 17A 304890S36 Bolt 2 18 34793S36 Washer 5 19 E7NN2N336AA Seal Assembly 1 20 D3NN4N020A Cover 1 21 E5NN4N021BA Gasket 1 22 C5NNN722B Gasket 1 23 87837S36 Plug 1 24 304652S36 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 B242-4-15-
- MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS - - 4-16 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 31 43040S36 Bolt 13 Powertrain Model 655 31A 44878AS36 Washer 14 32 E7NN4N025AA Dipstick Tube 1 32A E7NN7N009BA Gasket 1 33 58700S36 Bolt 2 34 44880S2 Washer 8 35 58678S36 Bolt 1 36 58676S36 Bolt 1 37 44879S36 Washer, Flat 11 38 58677S36 Bolt 2 39 58702S36 Bolt 2 40 34989S7 Nut 6 41 34990S7 Nut 4 42 58679S36 Bolt 2 43 E0NN4N507AA Gasket 1 44 C5NNN949A Gasket 1 45 C5NNN943A Plate 1 46 304668S36 Bolt 4 CATALOG B242-4-17-
DIFFERENTIAL LOCK LINKAGE 25 23 24 22 21 18 19 26 27 14 15** 13 17 12 16 18 20 11 10 8 3 2 1* 4 5 3 6 9 7 F4-6 - 4-18 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B7165 Arm Assembly 1 ALL (Includes Items 2 & 3) 2 B7940 Arm 1 3 421436 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 1 15 134478 Rod Assembly 1 (Includes Items 16 & 17) 16 134479 Clevis 1 17 33923S36 Nut, Hex 1 18 72017S8 Pin, Cotter 2 19 134801 Pin 1 20 134374 Pin 1 21 133995 Lever 1 22 134346 Pin 1 23 134013 Shaft 1 24 426356 Seal 1 25 134011 Fork 1 26 134103 Screw 1 27 33925S8 Nut, Hex 1 CATALOG B242-4-19-
- MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS - - 4-20 - CATALOG B242
SECTION 5 HYDRAULICS (less Steering) DESCRIPTION PAGE TANK, PUMP, FILTER & HDWR (EARLY MODELS)... 5-2 TANK, PUMP, FILTER & HDWR (PRESENT MODELS)... 5-4 CONTROL VALVES, MAST SIDE SHIFT & TILT CYLINDERS... 5-6 TILT CYLINDER ASSEMBLY... 5-8 SIDE SHIFT CYLINDER ASSEMBLY... 5-10 CONTROL VALVE ASSEMBLY... 5-12 CATALOG B242-5 - 1 -
TANK, PUMP, FILTER & HDWR (EARLY MODELS) 39 HYDRAULIC VALVES (REF) 40 4 45 3 1, 2 6 16 15 17 18 19 26 24 25 38 50 37 46 8 7 9 10 11 12 15 23 27 52 51 39 5 41 36 35 5 42 34 47 39 43 44 33 48 32 13 14 20 21 22 30 31 28 53 54 57 47 49 39 29 55 56 57 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B5150 Tank, Hydraulic 1 2WD (Previous) 2 3 424367 B215 Gauge, Sight Breather Filler Assy 1 1 4 B7426 Dip Stick 1 5 K87838 Plug, Pipe 2 6 K34809 Washer, Lock 2 7 8 K33845 K71D4364 Nut, Hex Screen, Suction 2 1 9 K71D4321 Gasket 1 10 B6220 Connection Assy, Suction 1 11 K34804 Washer, Lock 4 12 13 K20344 B6094 Bolt, Hex Elbow, Reducer 4 1 14 KHI-2020 Insert, Beaded 1 15 B2236-7 Clamp, Hose 2-5 - 2 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 16 B760-836 Hose Assembly 1 2WD (Previous) 17 0M2090 Fitting 1 18 K920 O -Ring 1 19 B800 Pump, Hydraulic 1 19 B7481 Pump, Seal Kit 1 20 421233 Shaft, Drive 1 21 K34808 Washer, Lock 4 22 K304762 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 B760-1366 Hose Assembly 1 29 B3698-15 Clamp 3 30 K33799 Nut, Hex 3 31 K34807 Washer, Lock 3 32 B7956 Fitting 1 33 K52-12 Nut, Hex 1 34 K108-12 Fitting, Bulkhead 1 35 B5415 Tube Assembly 1 36 K66-12 Elbow 1 37 K53-12 O -Ring 2 38 K24072-12 -16 Connection, Hose 1 39 B2236-6 Clamp, Hose 4 40 B760-1228 Hose Assembly 1 41 KHI-1616 Connection, Hose 1 42 K247-20 -16 Fitting 1 43 422140 Head & Filter Assembly 1 Includes 422141 Filter 44 422141 Element, Filter 1 45 K20346 Bolt, Hex 4 46 K34806 Washer, Lock 4 47 KHI-2020 Fitting 2 48 B760-1224 Hose Assembly 1 49 B103A10 Elbow, Pipe 1 50 421511 Tube Assembly 1 51 K11-12 Fitting, Tee 1 52 K71-12 Fitting 1 53 B760-1138 Hose Assembly 1 54 K71-8 Fitting 1 55 165688 Fitting 1 56 5373 Accumulator 1 57 K301514 Screw, Set 2 CATALOG B242-5 - 3 -
TANK, PUMP, FILTER & HDWR (PRESENT MODELS) HYDRAULIC VALVES (REF) 4 42 30A 31 29 23 7 6 5 36 37 23 10 3 2 1 8 9 16 15 17 18 19 8 9 23 43 45 44 42 40 41 10 28 33 11 14 30B 15 12 13 21 14 5 22 20 24 25 MAST HOSE ASSEMBLY (REF) 46 30A 47 32 50 39 34 35 14 30B 38 5 26 27 48 49 50 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 491702 Tank, Hydraulic 1 All 2WD (Current) 2 13179 Gasket 1 3 426451 Filler Assembly 1 4 425501 Cap 1 5 K34807 Washer, Lock 9 6 K20348 Bolt, Hex 4 7 424367 Gauge 1 8 K34809 Washer, Lock 2 9 K33845 Nut, Hex 2 10 B114A3 Plug, Pipe 2 11 424764 Filter 1 12 B101A12 Elbow 1-5 - 4 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 13 K247-24 -20 Fitting 1 All 2WD (Current) 14 KHI-2020 Insert, Beaded 2 15 B2236-7 Clamp, Hose 2 16 B760-836 Hose 1 17 K0M -2090 Fitting 1 18 K920 O -Ring 1 19 B800 Pump Hydraulic 1 19 B7481 Pump, Seal Kit 1 20 K20526 Bolt, Hex 2 21 421233 Shaft, Drive 1 22 K304762 Bolt, Hex 4 23 K916 O -Ring 3 24 K62-12 Adapter 1 25 B760-1684 Hose Assembly 1 26 B3698-15 Clamp 3 27 K33799 Nut, Hex 3 28 K66-12 Adapter 1 29 K24072-12 -16 Fitting, Elbow 1 30A B2236-6 Clamp, Hose 2 30B B2236-7 Clamp, Hose 2 31 B760-1228 Hose 1 32 KHI-1616 Insert, Beaded 1 33 K247-20 -16 Bushing, Reducer 1 34 422140 Filter, Assembly (Includes 422141) 1 35 422141 Filter 1 36 K20346 Bolt, Hex 2 37 K34806 Washer, Lock 2 38 B760-1224 Hose 1 39 B103A10 Elbow, Pipe 1 40 K62-12 -10 Fitting 1 41 K910 O -Ring 1 42 K71-12 Fitting, Elbow 2 43 421511 Tube Assembly 1 44 B7821 Fitting, T 1 45 B7822 Disconnect, Male 1 46 B760-1138 Hose Assembly 1 47 K71-8 Fitting 1 48a 165688 Fitting (for Item 49a) 1 48b 495303 Fitting (for Item 49b) 1 49a 5373 Accumulator (polished stainless) 1 49b 204220 Accumulator (cast iron, painted) 1 50 K301514 Screw, Set 2 CATALOG B242-5 - 5 -
CONTROL VALVES, MAST SIDE SHIFT & TILT CYLINDERS 16 15 2 17 18 22 17 26 1 18 17 24 10 11 8 14 13 12 9 12A 25 7 5 4 5 6 22 20 23 21 22 17 28 5 18 18 17 19 29 2 27 30 31 3 31 30 32 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 B1585-2 Valve Assembly, Complete 1 (3 Spool) 1 B1585-3 Valve Assembly, Complete 1 (4 Spool) 1 B1585-4 Valve Assembly, Complete 1 (5 Spool) 2 B5505-1 Tilt Cylinder Assembly 2 (20 0 /15 0 tilt) 2 B5505-2 Tilt Cylinder Assembly 2 (20 0 /10 0 tilt) 2 B5505-3 Tilt Cylinder Assembly 2 (45 0 /10 0 tilt) 2 B5505-4 Tilt Cylinder Assembly 2 (1-1/2 0 /5 0 tilt) 2 B5505-5 Tilt Cylinder Assembly 2 (3 0 /10 0 tilt) - 5-6 - CATALOG B242
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 426618 Handle, Valve 3/4 -DXL 84 Cab 11 M100A1 Knob 3/4 12 B7865 Lever 1 STD 95 Cab 12 426619 Lever 1 -DXL 84 Cab 12A B7855 Lever Assembly, Complete 1 STD 95 Cab 12A 492523 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 10 18 K908 O -Ring 10 19 B760-835 Hose Assembly 2 20 B7565 Tube Assembly 1 21 K11-6 Fitting 2 22 B760-861 Hose Assembly 4 23 B5405 Tube Assembly 1 24 K62-12 -10 Fitting 1 25 K71-12 Fitting 1 26 421511 Tube Assembly 1 27 424257 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 B242-5 - 7 -
TILT CYLINDER ASSEMBLY 10 1 13 11* 11* 12 5* 2 3 9* 8* 4 7* 6* 14 16 15-5 - 8 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL B5505-1 Cylinder Assembly 1 20 0 /15 0 Tilt B5505-2 Cylinder Assembly 1 20 0 /10 0 Tilt B5505-3 Cylinder Assembly 1 45 0 /10 0 Tilt B5505-4 Cylinder Assembly 1 1-1/2 0 /15 0 Tilt B5505-5 Cylinder Assembly 1 3 0 /10 0 Tilt 1 B6875-1 Barrel 1 20 0 /15 0 Tilt 1 B6875-2 Barrel 1 20 0 /10 0 Tilt 1 B6875-3 Barrel 1 45 0 /10 0 Tilt 1 B6875-2 Barrel 1 1-1/2 0 /15 0 Tilt 1 B6875-2 Barrel 1 3 0 /10 0 Tilt 2 B5506-1 Rod 1 20 0 /15 0 Tilt 2 B5506-2 Rod 1 20 0 /10 0 Tilt 2 B5506-3 Rod 1 45 0 /10 0 Tilt 2 B5506-5 Rod 1 1-1/2 0 /15 0 Tilt 2 B5506-2 Rod 1 3 0 /10 0 Tilt 3 B5521-1 Spacer 1 1-1/2 0 /15 0 Tilt 3 B5521-2 Spacer 1 3 0 /10 0 Tilt 4 B1655-2 Head, Cylinder 1 5* - - - - O - Ring 1 6* - - - - O - Ring 1 7* - - - - Ring, Back Up 1 8* - - - - Seal 1 9* - - - - Wiper 1 10 B1655-10 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 B1655-13 Kit, Seal 1 * Included In Seal Kit (Item 16). CATALOG B242-5 - 9 -
SIDE SHIFT CYLINDER ASSEMBLY 1 9 12 10* 11 10* 4* 2 5* 6* 3 7* 8* 15 13 14-5 - 10 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL B6140 Side Shift Cylinder Assembly 1 All 1 B6875-4 Barrel 1 2 B5506-4 Rod 1 3 B1655-2 Head, Cylinder 1 4* - - - - O - Ring 1 5* - - - - O - Ring 1 6* - - - - Ring, Back Up 1 7* - - - - Seal 1 8* - - - - Wiper 1 9 B1655-10 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 B1655-13 Kit, Seal 1 * Included In Seal Kit (Item 15). CATALOG B242-5-11-
CONTROL VALVE ASSEMBLY - 5-12 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL B1585-2 Valve Assembly, Complete 1 (3 Spool) B1585-3 Valve Assembly, Complete 1 (4 Spool) B1585-4 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) 4 ---- Cap 1 5 ---- O-Ring 1 6 ---- Spring 1 7 ---- Shim A/R 8 ---- Ring,Piston 1 9 - - - - Body and Piston Assembly 1 10 - - - - Ring, Back Up 1 11 - - - - O - Ring Seal 1 12 B1592-38 Nut, Hex 6 13 B1587 Spool Assembly -3 Way Lift Cylinder 1 (Includes Items 14 thru 37) 14 B1592-56 Seal Kit Includes # 15 Thru #23 15 - - - - Wiper, Rod 1 16 - - - - Seal, Quad. 1 17 - - - - Sectional Seal, Exhaust,.937 Dia. 2 18 - - - - Sectional Seal, Pressure,.801 Dia. 2 19 - - - - O - Ring 2 20 - - - - Ring, Back Up 2 21 - - - - O - Ring 2 22 - - - - Ring, Back Up 4 23 - - - - O - Ring 2 24 - - - - Body and Spool Assy (Not Serviced) 1 Order B1587 (Item 13) 25 - - - - Plug 2 26 - - - - Plug 1 27 - - - - Spring 1 28 - - - - Plug 1 29 - - - - Bracket, Handle 1 30 - - - - Collar, Stop 2 31 - - - - 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 B242-5-13-
ITEM PART NUMBER DESCRIPTION QTY MODEL 32 33 - - - - Collar 1 All 34 - - - - Washer, Lock 1 35 - - - - Screw 1 36 - - - - Cover 1 37 - - - - Screw 4 38 K910 O -Ring 1 39 K64-10 Plug Incl. Item #38 1 40 B1584 Spool Assy, 4 Way Tilt Cylinder 1 Includes Items 42 thru 65 41 B1592-56 Seal Kit 1 Includes Items 42 thru 50 42 - - - - Wiper, Rod 1 43 - - - - Seal, Quad 1 44 - - - - Seal, Sectional Exhaust.937 Dia. 2 45 - - - - Seal, Sectional Pressure.801 Dia. 2 46 - - - - O - Ring 2 47 - - - - Ring, Back Up 2 48 - - - - O - Ring 2 49 - - - - Ring, Back Up 4 50 - - - - O - Ring 2 51 - - - - Body & Spool Assy (Not Serviced) 1 Order B1584 (Item 40) 52 - - - - Bracket, Handle 1 53 - - - - Plug 2 54 - - - - Spring 2 55 - - - - Retainer, Ball 2 56 - - - - Ball 2 57 - - - - Body, Check 2 58 - - - - Collar, Stop 2 59 - - - - Spring 1 60 - - - - Collar 1 61 - - - - Washer, Lock 1 62 - - - - Screw 1 63 - - - - Cover 1 64 - - - - Screw 4 65 66 B1588 Spool Assy, 4Way Side Shift & Acc.1 Includes Items 68 thru 89 67 B1592-56 Seal Kit A/R Includes Items 68 thru 76-5 - 14 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 68 - - - - Wiper, Rod 1 All 69 - - - - Seal, Quad 2 70 - - - - Seal, Sectional Exhaust.937 Dia. 2 71 - - - - Seal, Sectional Pressure.801 Dia. 2 72 - - - - O - Ring 2 73 - - - - Ring, Back Up 2 74 - - - - O - Ring 2 75 - - - - Ring, Back Up 4 76 - - - - O - Ring 2 77 - - - - Body & Spool Assy (Not Serviced) 1 Order B1588 (Item 66) 78 - - - - Bracket, Handle 1 79 - - - - Collar, Stop 2 80 - - - - Spring 1 81 82 - - - - Collar, Spool 1 83 - - - - Washer, Lock 1 84 - - - - Screw 1 85 - - - - Cover 1 86 - - - - Screw 4 87 - - - - Plug 2 88 - - - - Spring 2 89 - - - - Plug 2 90 B1594 Cover, End Std. 1 Includes Items 91 & 92 90 B1589 Cover, End W / Power Beyond 1 Includes Items 91 & 92 91 B1592-48 Seal, Sectional Exhaust.937 Dia. 2 92 B1592-49 Seal, Sectional Pressure.801 Dia. 2 93 B1592-60 Plug Assy, Conversion Power Beyond 1 Includes Items 94-97 94 B1592-63 Seal 1 95 B1592-64 Ring, Back Up 1 96 B1592-62 O -Ring 1 97 - - - - Sleeve, Power Beyond 1 98 B1592-40 Stud, 2 Spool 3 98 B1592-41 Stud, 3 Spool 3 98 B1592-42 Stud, 4 Spool 3 98 B1592-43 Stud, 5 Spool 3 99 B1592-76 Retainer, Plate Washer 2 100 B1592-75 Washer, Back Up 2 101 B1592-74 Seal, O -Ring 2 CATALOG B242-5-15-
PRESSURE SETTING CHART MAST MODEL/SERIES TEST WEIGHT (lbs.) PRESSURE SETTING (psi) K5300 6000 2050 K5300 5000 1800 K5300 4000 1500 K4800 3600 1975 K4700 6000 2100 K4700 5000 1800 K4700 4000 1500 K4500 6000 2200 K4400 5000 2150 K4300 3600 1975 K4000 8000 1950 K3600 10,000 1850 K3500 8000 1850 K2700 6000 1750 K2500 6000 1650 K2300 5000 1600 K2100 5000 1600 K2100 4000 1350 K1400 4500 2200-5 - 16 - CATALOG B242
SECTION 6 ENGINE COMPONENTS DESCRIPTION PAGE EXHAUST SYSTEM ASSEMBLY... 6-2 ENGINE MOUNT/RADIATOR BRACKETS... 6-3 ENGINE BLOCK & HEAD... 6-4 ENGINE BLOCK & PLUGS... 6-7 CRANKSHAFT & FLYWHEEL... 6-8 CAMSHAFT, ROCKER ARM & VALVES... 6-10 PISTONS & CONNECTING RODS... 6-14 OIL PUMP & PAN... 6-16 INTAKE & EXHAUST MANIFOLD... 6-18 CATALOG B242-6 - 1 -
EXHAUST SYSTEM ASSEMBLY 5 2 5 1 5 4 3 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 B7091-1 Clamp 4-6 - 2 - CATALOG B242
ENGINE MOUNT/RADIATOR BRACKETS EARLY MODELS 9 ENGINE BLOCK (REF) 10 8 CURRENT MODELS 1A 1 3 4 5 12 8 12 6 7 11 13 ENGINE BLOCK (REF) 2A 13 14 14 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 426123 Bracket, Radiator L.H. 1 (Present Models) 1A 421168 Bracket, Radiator L.H. 1 (Thru March 92) 2 426122 Bracket, Radiator R.H. (not shown) 1 (Present Models) 2A 421169 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 6 8 421134 Bearing 2 9 K305135 Pin, Roll 2 10 B5090 Mount Assembly, Motor L.H. 1 11 B5095 Mount Assembly, Motor R.H. 1 12 K20526 Bolt, Hex 4 13 K34809 Washer, Lock 4 14 K33942 Nut, Jam 4 CATALOG B242-6 - 3 -
ENGINE BLOCK AND HEAD 6 52 9 49 50 51 1A F 6-2 T HRU 6-4 - 6-4 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 1 F0NN6007AVA Engine Assembly 1 201 cu.in. Engine 1A 492901 Short Block Assembly 1 1B 426370 Head Assembly 1 2 134789 Insert, Intake Valve 3 Std 2 134797 Insert, Intake Valve A/R.010 -.254mm O/S 2 134795 Insert, Intake Valve A/R.020 -.508mm O/S 2 D4NN6056D Insert, Intake Valve A/R.030 -.762mm O/S 3 139175 Insert, Exhaust Valve 3 Std 3 E9NN6057EA Insert, Exhaust Valve A/R.010 -.254mm O/S 3 C9NN6057L Insert, Exhaust Valve A/R.020 -.508mm O/S 3 C9NN6057M Insert, Exhaust Valve A/R.030 -.762mm O/S 4 134659 Plug 1 1.75 -.254mm 4 390629S Plug 1 1.81-46.0mm 5 134303 Plug 1 1.13-28.7mm 5 136460 Plug 1 1.18-30.0mm 6 492711 Sender, Water Temp 1 7 492419 Bolt, Head 10 8 87800106 Gasket 1 9 491868 Housing 1 10 134834 Thermostat 1 11 134116 Gasket 1 12 134408 Bolt, Hex 1 13 F0NN6010BD Block Assembly 1 14 134295 Bolt, Hex 8 15 491973 Bearing 4 16 E2NN6784AA Tube 1 17 492899 Indicator 1 18 E6NN6059AC Cover 1 19 421190 Cap Assembly 1 20 492311 Gasket 1 21 E5NN6C044AA Plate 1 22 492312 Gasket 1 23 134694 Screw & Washer 2 5/16-18 x21/8 23 57651S36 Screw & Washer 8 3/8-16 x21/4 23 300878S36 Bolt 1 5/16-18 x21/2 CATALOG B242-6 - 5 -
ITEM PART NUMBER DESCRIPTION QTY MODEL 24 57648S36 Bolt 1 201 cu.in. Engine 25 45964S2 Bolt 4 26 492826 Plate 1 27 134063 Cover 1 28 43392S36 Screw & Washer 1 29 134376 Cover 1 30 425718 Gasket 1 31 F2NN8N608BA Stud 3 32 134002 Cover 1 33 134695 O -Ring 1 34 K34807 Washer 2 35 33799S36 Nut 2 36 354545S36 Bolt 2 37 E6NN8N630AA Deflector 1 38 34806S36 Washer 2 39 33797S36 Nut, Hex 2 40 D0NN6890A Insert 1 41 421602 Filter 1 42 304650S36 Bolt, Hex 3 43 K34807 Washer 3 44 C5NN8N631A Deflector 1 45 E7NN6A008AA Dowel 2 46 D7NN6055A Sleeve A/R 47 56519S36 Bolt 2 48 134295 Bolt 8 49 B3258-1 Elbow 2 50 K247-4 -2 Adapter 1 51 B1277 Sender, Oil Pressure 1 52 B109A32 Adapter 1-6 - 6 - CATALOG B242
ENGINE BLOCK & PLUGS 11 16 14 15 12 13 5 REAR VIEW 3 RIGHT SIDE VIEW 10 9 7&8 1 6 4 5 2 FRONT VIEW LEFT SIDE VIEW F 6-6 T HRU 6-7 ITEM PART NUMBER DESCRIPTION QTY MODEL 1 376049S36 Plug 1 201 cu.in. Engine 2 134137 Dowel 2 3 87837S36 Plug 2 4 87745S Plug 1 5 F0HN6N891AA Plug 1 6 304650S36 Bolt, Hex 4 7 D0NNH918A Gasket 1 8 134396 Cover 1 9 E7NN6A008AA Dowel 2 10 F2NN6C057CA Plug 1 11 390626S Plug 2 1.50 (38.0mm) 11 390627S Plug A/R 1.56 (39.6mm) 12 C5NN8115B Cock Assembly 1 13 134550 Dowel 1 14 F2NN6C057AA Plug 2 15 134659 Plug 2 1.75 (44.5mm) 15 390629S Plug A/R 1.81 (46.0mm) 16 134345 Cover 1 CATALOG B242-6 - 7 -
CRANKSHAFT AND FLYWHEEL F 6-8 T HRU 6-9 - 6-8 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 1 492293 Crankshaft 1 201 cu.in. Engine 2 492888 Pulley 1 3 134411 Key 1 12-88/9-91 3 F0NN6N300AA Key 1 10-91/ - 4 382675S Washer 1 5 304807S36 Bolt 1 5A 426392 Spacer 1 6 C5NE6310B Slinger 1 7 134061 Seal 1 8 F0NN6700CA Seal 1 9 134060 Gear 1 12-88/9-91 9 E9NN6306AA Gear 1 10-91/ - 10 134200 Liner Kit Main Bearing 3 Std Red 12-88/9-91 10 425744 Liner Kit Main Bearing 3 Std Blue 10 134202 Liner Kit Main Bearing 3.002 -.0508mm U/S 10 134203 Liner Kit Main Bearing 3.010 -.0254mm U/S 10 134204 Liner Kit Main Bearing 3.020 -.508mm U/S 10 134205 Liner Kit Main Bearing 3.030 -.762mm U/S 10 134206 Liner Kit Main Bearing 3.040-1.016mm U/S 10 492716 Liner Kit Main Bearing 3 Std Red 9-92/ - 10 FAPN6333B Liner Kit Main Bearing 3 Std Blue 10 FAPN6333C Liner Kit Main Bearing 3.002 -.0508mm U/S 10 FAPN6333D Liner Kit Main Bearing 3.010 -.0254mm U/S 10 FAPN6333E Liner Kit Main Bearing 3.020 -.508mm U/S 10 FAPN6333F Liner Kit Main Bearing 3.030 -.762mm U/S 10 FAPN6333G Liner Kit Main Bearing 3.040-1.016mm U/S 11 491974 Liner Kit Thrust Bearing 1 Std Red 12-88/9-91 11 134208 Liner Kit Thrust Bearing 1 Std Blue 11 CFPN6337C Liner Kit Thrust Bearing 1.002 -.0508mm U/S 11 CFPN6337K Liner Kit Thrust Bearing 1.010 -.0254mm U/S 11 CFPN6337L Liner Kit Thrust Bearing 1.020 -.508mm U/S 11 CFPN6337M Liner Kit Thrust Bearing 1.030 -.762mm U/S 11 CFPN6337N Liner Kit Thrust Bearing 1.040-1.016mm U/S 11 492717 Liner Kit Thrust Bearing 1 Std Red 9-92/ - 11 FAPN6337B Liner Kit Thrust Bearing 1 Std Blue 11 FAPN6337C Liner Kit Thrust Bearing 1.002 -.0508mm U/S 11 FAPN6337D Liner Kit Thrust Bearing 1.010 -.0254mm U/S 11 FAPN6337E Liner Kit Thrust Bearing 1.020 -.508mm U/S 11 FAPN6337F Liner Kit Thrust Bearing 1.030 -.762mm U/S 11 FAPN6337P Liner Kit Thrust Bearing 1.040-1.016mm U/S 13 425720 Seal 1 14 E7NN6375AA Flywheel Assembly 1 (Includes Items 15 & 16) 15 493543 Gear 1 16 136463 Bolt, Hex 6 17 E5HN6N306AC Retainer Assembly 1 12-88/3-94 17 87840361 Retainer Assembly 1 4-94/ - 18 426389 Gasket 1 19 57635S36 Screw & Washer 8 20 492313 Seal, O -Ring 1 CATALOG B242-6 - 9 -
CAMSHAFT, ROCKER ARM &VALVES F 6-10 thru 6-12 - 6-10 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 1 425758 Tappet 6 201 cu.in. Engine 2 134291 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 1 6 134687 Plug 2 7 D5NN6531A Support 4 9 492421 Bolt, Hex 4 10 134070 Spring 3 11 134393 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 12 134607 Valve, Exhaust A/R.030 /.762mm O/S 12 109127 Valve, Exhaust 3 Std. for 545C, 545D 12 139225 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 13 491848 Valve, Intake 3 Std. 13 134596 Valve, Intake A/R.003 /.0762mm O/S 13 134597 Valve, Intake A/R.015 /.381mm O/S 13 134598 Valve, Intake A/R.030 /.762mm O/S 14 136497 Spring 6 14* E9NN6513BA Spring 6 14 C5NE6A526A Spacer, Valve Spring A/R 15 D0NN6514A Retainer 3 15* E5HN6514AA Retainer 3 16 C6AE6514A1 Retainer 3 17 492838 Key 12 18 134068 Seal, Valve Stem 6 18* 492703 Seal, Valve Stem 6 20 426542 Cover 1 21 426541 Gasket 1 22 56518S2 Bolt, Hex 8 23 425707 Camshaft 1 * Item used on Engine Build Code 1J20 & above (Oct.20, 1991 & above). CATALOG B242-6-11-
- MANITOU - - WORLD S LARGEST MANUFACTURER OF ROUGH TERRAIN LIFT TRUCKS - - 6-12 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL 24 D3NN6A253AB Gear Assembly 1 201 cu.in. Engine D9NN6A254AA Bushing 1 25 F2NN6A255AA Adapter 1 Engines Built 11/88 to 12/94 25 87840404 Adapter 1 Engines Built 1/95 on 26 F2NN6N253AA Bolt, Hex 1 27 E3NN6N251AB Gear 1 28 134058 Spacer 1 29 E5HN6269AA Plate 1 30 57644S36 Screw & Washer 2 31 134673 Key 1 32 491850 Bearing 4 33 134345 Cover 1 34 134073 Hose 1 35 136329 Tube 1 35 E6NN6758AA Tube 1 36 134145 Clamp 1 37 136073 Washer 1 38 34808S36 Washer 1 39 56561S2 Bolt, Hex 1 40 E3NND855AA Gear Assembly 1 41 136274 Pin, Dowel 1 CATALOG B242-6-13-
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 3.004 (.1016mm) 1* 491988 Piston, Pin & Ret. Set 3.020 (.508mm) 1* E7NN6108VC Piston, Pin & Ret. Set 3.030 (.762mm) 1* E7NN6108XA Piston, Pin & Ret. Set 3.040 (1.016mm) 2 E3HN6135AA Pin 3 3 134492 Retainer 6 * Includes Items 2 & 3. - 6-14 - CATALOG B242
ITEM PART NUMBER DESCRIPTION QTY MODEL For 201 cu.in. Engine 4 107915 Kit, Piston Ring 3 Standard 4 425714 Kit, Piston Ring 3.020 (.508mm) 4 492702 Kit, Piston Ring 3.030 (.762mm) 4 EBPN6149PA Kit, Piston Ring 3.040 (1.016mm) 5** F2NN6200BA Rod Assembly 3 6 E6NN6207AA Bushing 3 7 E9NN6214AA Bolt 6 8 390655S2 Nut, Hex 6 9 493108 Liner Kit, Bearing 12-88/8-90 3 Std. Red 9 134768 Liner Kit, Bearing 12-88/8-90 3 Std. Blue 9 134769 Liner Kit, Bearing 12-88/8-90 3.002 (.0508mm) 9 134770 Liner Kit, Bearing 12-88/8-90 3.010 (.254mm) 9 134771 Liner Kit, Bearing 12-88/8-90 3.020 (.508mm) 9 134772 Liner Kit, Bearing 12-88/8-90 3.030 (.762mm) 9 136469 Liner Kit, Bearing 12-88/8-90 3.040 (1.016mm) 9 87790322 Liner Kit, Bearing 9-90/ - 3 Std. Purple 9 FAPN6211B Liner Kit, Bearing 9-90/ - 3.002 (.0508mm) 9 FAPN6211J Liner Kit, Bearing 9-90/ - 3.010 (.254mm) 9 FAPN6211D Liner Kit, Bearing 9-90/ - 3.020 (.508mm) 9 FAPN6211E Liner Kit, Bearing 9-90/ - 3.030 (.762mm) 9 FAPN6211F Liner Kit, Bearing 9-90/ - 3.040 (1.016mm) ** Includes Items 6, 7, & 8. CATALOG B242-6-15-