Microsoft Word - PS 15-BPT-004-EN.doc

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1 ECL0-BPT-00 SPAREPARTS LIST Electric Stacker PS 5 Version 0/204 From truck identification number: PS 5-BPT-004-EN

2 Catalogue Fig. Label (for EU)...3 Fig. 2 Label (for US)...4 Fig. 3 Outline (Three-stage mast Full Free Lift/ Straddle leg)...5 Fig. 4 Outline (Two-stage mast/ Straddle leg)...7 Fig. 5 Outline (Two-stage mast Full Free Lift)...9 Fig. 6 Chassis (Three-stage mast Full Free Lift/ Two-stage mast Normal/ Two-stage mast Full Free Lift)... Fig. 7 Chassis (Three-stage/Two-stage mast Straddle Leg)...2 Fig. 8 Chassis system (Three-stage mast Full Free Lift)...3 Fig. 9 Chassis system (Three-stage mast Straddle Leg)...4 Fig. 0 Chassis system (Two-stage mast Normal/ Full Free Lift)...6 Fig. Chassis system (Two-stage mast Straddle Leg)...7 Fig. 2 Steering wheel assembly...9 Fig. 3 Load wheel assembly (tandem roller)...20 Fig. 4 Truck body...2 Fig. 5 Power supply...23 Fig. 6 Instrument assembly...25 Fig. 7 Battery cover assembly...26 Fig. 8 Mast system (Three-stage mast Full Free Lift/Straddle Leg)...27 Fig. 9 Mast system (Two-stage mast Normal/Straddle Leg)...29 Fig. 20 Mast system (Two-stage mast Full Free Lift)...3 Fig. 2 Mast lifting system (Three-stage mast Full Free Lift)...32 Fig. 22 Mast other accessories (Three-stage mast Full Free Lift)...34 Fig. 23 Mast lifting system (Two-stage mast Normal/Straddle Leg)...35 Fig. 24 Mast lifting system (Three-stage mast Full Free Lift)...37 Fig. 25 Hydraulic system (Three-stage mast Full Free Lift/Straddle Leg)...39 Fig. 26 Hydraulic system (Two-stage mast Normal/Straddle Leg)...42 Fig. 27 Hydraulic system (Two-stage mast Full Free Lift)...44

3 Fig. 28 Outer cylinder seal kit (Three-stage mast Full Free Lift/Straddle Leg)46 Fig. 29 Middle cylinder seal kit (Three-stage mast Full Free Lift/Straddle Leg)...48 Fig. 30 Cylinder (Two-stage mast Normal/Straddle Leg)...50 Fig. 3 Cylinder (Two-stage mast Full Free Lift)...52 Fig. 32 Manual steering wheel carrier...53 Fig. 33 Electric power assisted steering wheel carrier...55 Fig. 34 Electric steering assembly...57 Fig. 35 Drive wheel assembly 7EL-AC Fig EL-AC-.3KW-R Drive wheel assembly...63 Fig. 37 Handle lever...67 Fig. 38 CANBUS Handle head...69 Fig. 39 High pressure pump station system(3.0kw 2.6 high pressure delivery capacity)...7 Fig. 40 Pump station system(3.0kw 3.2 delivery capacity)...73 Fig. 4 Pump station system(2.2kw 2.2 delivery capacity)...75 Fig. 42 Main circuit wiring (Electrical steering)...77 Fig. 43 Main circuit wiring(manual steering)...78 Fig. 44 General electrical parts...79 Fig. 45 Electric control assembly(electrical steering)...8 Fig. 46 Electric control assembly(manual steering)...84 Fig. 47 Foldable platform...87 Fig. 48 Protective arm...90 Fig. 49 Backrest (Normal)...92 Fig. 50 Backrest (Straddle Leg)...93 Easy worn parts list

4 Fig. Label (for EU) Fig. Label (for EU) No. Parts No. Item Qty. Note A Crane hook label 2 B C Warning decal: Do not step under or on the forks Residual lift capacity sticker D No passengers decal E Never reach through F Identification plate G Sticker to read and follow these instructions L Filling sticker 2 3

5 Fig. 2 Label (for US) Fig. 2 Label (for US) No. Parts No. Item Qty. Note A Crane hook label 2 B Filling sticker C Residual lift capacity sticker D Warning label E Warning label F Identification plate (ID-plate) G Sticker to read and follow these instructions H Warning label I Warning label J Warning label K Warning label 2 4

6 Fig. 3 Outline (Three-stage mast Full Free Lift/ Straddle leg) 5

7 Fig. 3 Outline (Three-stage mast Full Free Lift/ Straddle leg ) No. Art No. Description Qty. Note Standard Main cover Protective arm cover Upper cover Middle cover Battery cover Protective board Protective board block Screw 8 M6 0 GB/T70.2=ISO Nut 8 M Screw 4 M6 6 GB/T70.2=ISO Washer 4 6 GB/T Washer 4 6 GB/T Protective board Rivet Screw 2 M Screw M Right protective cover Left protective cover Platform assembly Protective arm assembly 6

8 Fig. 4 Outline (Two-stage mast/ Straddle leg) 7

9 Fig. 4 Outline (Two-stage mast/ Straddle leg) No. Art No. Description Qty. Note Main cover Protective arm cover Upper cover Middle cover Battery cover Protective board Spring buckle Upper protective board Screw 2 M Screw M Platform assembly Protective arm assembly 8

10 Fig. 5 Outline (Two-stage mast Full Free Lift) 9

11 Fig. 5 Outline (Two-stage mast Full Free Lift ) No. Art No. Description Qty. Note Main cover Protective arm cover Upper cover Middle cover Battery cover Protective board Spring buckle Screw 2 M Screw M Platform assembly Protective arm assembly 0

12 Fig. 6 Chassis (Three-stage mast Full Free Lift/ Two-stage mast Normal/ Two-stage mast Full Free Lift) Fig. 6 Chassis (Three-stage mast Full Free Lift/ Two-stage mast Normal/ Two-stage mast Full Free Lift) No. Art No. Description Qty. Note Compound roller Magnet steel Welded chassis (570 50) Three-stage mast 3 Welded chassis Full Free Lift (680 50) Welded chassis Two-stage mast (570 50) Normal/ Welded chassis Two-stage mast (680 50) Full Free Lift

13 Fig. 7 Chassis (Three-stage/Two-stage mast Straddle Leg) Fig. 7 Chassis (Three-stage/Two-stage mast Straddle Leg ) No. Parts No. Item Qty. Note Standard Compound roller 4 Three-stage mast Straddle Leg Two-stage mast Straddle Leg Compound roller Fork 2 W Screw 2 M0x6 GB/T70.=ISO Fork carrier Three-stage mast Straddle Leg Two-stage mast Straddle Leg 2

14 Fig. 8 Chassis system (Three-stage mast Full Free Lift) Fig. 8 Chassis system (Three-stage mast Full Free Lift ) No. Parts No. Item Qty. Note Standard Screw 4 M8 6 GB/T70.=ISO Damping pad PU x50 Welded chassis x Castor assembly Washer 8 0 GB/T Washer 8 0 GB/T Screw 8 M0 35 GB/T70.=ISO Screw 2 M2 25 GB/T70.=ISO Washer 2 2 GB/T Washer 2 2 GB/T Castor complete 2 3

15 Fig. 9 Chassis system (Three-stage mast Straddle Leg) 4

16 Fig. 9 Chassis system (Three-stage mast Straddle Leg ) No. Parts No. Item Qty. Note Standard Screw 4 M8 6 GB/T70.=ISO Damping pad PU Welded chassis Castor Washer 8 0 GB/T Washer 8 0 GB/T Screw 8 M0 35 GB/T70.=ISO Screw 2 M2 25 GB/T70.=ISO Washer 2 2 GB/T Washer 2 2 GB/T Screw 4 M6x20 GB/T77=ISO Welded front leg Welded right front leg Screw 4 M20x60 GB/T70.=ISO Washer 4 20 GB/T Washer 4 20 GB/T Positioning pin Press plate Support components Castor complete 2 5

17 Fig. 0 Chassis system (Two-stage mast Normal/ Full Free Lift) Fig. 0 Chassis system (Two-stage mast Normal / Full Free Lift ) No. Parts No. Item Qty. Note Standard X50 Welded chassis X Screw 2 M2 25 GB/T70.=ISO Washer 2 2 GB/T Washer 2 2 GB/T Screw 8 M0 35 GB/T70.=ISO Washer 8 0 GB/T Washer 8 0 GB/T Castor Castor complete 2 6

18 Fig. Chassis system (Two-stage mast Straddle Leg) 7

19 Fig. Chassis system (Two-stage mast Straddle Leg ) No. Parts No. Item Qty. Note Standard Welded chassis Castor Washer 8 0 GB/T Washer 8 0 GB/T Screw 8 M0 35 GB/T70.=ISO Screw 2 M2 25 GB/T70.=ISO Washer 2 2 GB/T Washer 2 2 GB/T Screw 4 M6x20 GB/T77=ISO Welded front leg Welded right front leg Screw 4 M20x60 GB/T70.=ISO Washer 4 20 GB/T Washer 4 20 GB/T Positioning pin Press plate Support components Castor complete 2 8

20 Fig. 2 Steering wheel assembly Fig. 2 Steering Wheel Assembly No. Parts No. Item Qty. Note Standard Circlip 30 GB/T Bearing seat Ball bearing C/DB GB/T Sleeve Circlip 62 GB/T Lock nut M4 GB/T889.=ISO7040 Rear wheel carrier welding Bolt M4 00 GB/T5782=ISO Shaft sleeve Washer Ball bearing GB/T Castor Castor wheel 2 9

21 Fig. 3 Load wheel assembly (tandem roller) Fig. 3 Load Wheel Assembly (tandem roller) No. Parts No. Item Qty. Note Standard Linking plate Dowel pin GB/T879.=ISO Castor shaft Load wheel Ball bearing GB/T Press-on grease cup 2 6 JB/T7940.4=ISOB Load wheel set Load wheel 2 20

22 Fig. 4 Truck body 2

23 Fig. 4 Truck Body No. Parts No. Item Qty. Note Standard Instrument assembly Screw 4 M6 20 GB/T70.=ISO Screw 4 M Nut 3 M Screw 2 M Screw M Screw 4 M0 35 GB/T70.=ISO Washer 8 0 GB/T Washer 8 0 GB/T Screw 4 M0 20 GB/T70.=ISO Washer 4 2 GB/T Washer 4 2 GB/T Board Electronic control assemble board Right vent components Left vent components Screw 4 M2 35 GB/T70.=ISO Screw 2 M8 35 GB/T70.=ISO Nut 2 M8 GB/T670=ISO Three-stage mast Welded body Two-stage mast Upper plate of Only used 2 protective board for Washer 5 4 Two-stage GB/T Screw M5x0 4 mast GB/T70.=ISO Washer 6 GB/T Screw M6x2 GB/T70.=ISO YGE rubber pipe clamp 22

24 Fig. 5 Power supply 23

25 Fig. 5 Power Supply No. Parts No. Item Qty. Note Standard Screw 2 M6 30 GB/T70.=ISO Washer 2 6 GB/T Charger 24V/45A(Asia in Chinese) Charger 24V/45A(Asia in English) Charger 24V/45A(For EU) Three-stage Charger 24V/45A(For mast AUS) Charger 24V/45A(For UK) Charger 24V/45A(For USA) Charger 24V/30A(Asia in Chinese) Charger 24V/30A(Asia in English) Charger 24V/30A(For EU) Two-stage Charger 24V/30A(For mast AUS) Charger 24V/30A(For UK) Charger 24V/30A(For USA) Power supply(20ah) Two-stage welded type mast Power supply(350ah) Three-stage welded type mast Power supply(20ah) Two-stage bolt type mast Power supply(350ah) Three-stage bolt type mast Connector components (350Ah) (Three-stage mast) Only used Connector components for bolt type (20Ah) battery (Two-stage mast) Bolt 24 24

26 Fig. 6 Instrument assembly Fig. 6 Instrument Assembly No. Parts No. Description Qty. Note Standard Screw 2 M3 25 GB/T =ISO Emergency ZDK Nut 2 M3 GB/T670=ISO Indicator CURTIS Key switch LKS-0A Key Plastic plate Screw 2 M5 0 GB/T70.3=ISO Fi ing plate Screw 4 M4 2 GB/T Pro imity switch DC power ZDK

27 Fig. 7 Battery cover assembly Fig. 7 Battery Cover Assembly No. Parts No. Item Qty. Note Standard Screw 2 M4 0 GB/T70.=ISO Washer 2 4 GB/T Washer 2 4 GB/T Pin Screw M5 20 GB/T70.=ISO Washer 5 GB/T Washer 5 GB/T Nut M5 GB/T672.=ISO

28 Fig. 8 Mast system (Three-stage mast Full Free Lift/Straddle Leg) 27

29 Fig. 8 Mast system (Three-stage mast Full Free Lift / Straddle Leg ) No. Parts No. Item Qty. Note Standard Outer mast welding Middle mast welding Inner mast welding Compound roller for mast Bolt 4 M8 40 GB/T5783=ISO Washer 4 8 GB/T Washer 4 8 GB/T95 28

30 Fig. 9 Mast system (Two-stage mast Normal/Straddle Leg) 29

31 Fig. 9 Mast system (Two-stage mast Normal / Straddle Leg ) No. Parts No. Item Qty. Note Standard Outer mast welding Inner mast welding Compound roller for mast Bolt 4 M8 40 GB/T5783=ISO Washer 4 8 GB/T Washer 4 8 GB/T Screw 2 M4x2 GB/T70.=ISO Washer 2 4 GB/T Washer 2 4 GB/T Limit block Compound roller for mast 2 30

32 Fig. 20 Mast system (Two-stage mast Full Free Lift) Fig. 20 Mast system (Two-stage mast Full Free Lift ) No. Parts No. Item Qty. Note Standard Outer mast welding Inner mast welding Compound roller for mast Bolt 4 M8 40 GB/T5783=ISO Washer 4 8 GB/T Washer 4 8 GB/T Screw 2 M4x2 GB/T70.=ISO Washer 2 4 GB/T Washer 2 4 GB/T Limit block Compound roller for mast 2 3

33 Fig. 2 Mast lifting system (Three-stage mast Full Free Lift) 32

34 Fig. 2 Mast lifting system (Three-stage mast Full Free Lift ) No. Parts No. Item Qty. Note Standard Nut 6 M6.5 GB/T67=ISO Split pin GB/T9=ISO Bolt Hinge pin GB/T882=ISO Split pin GB/T9=ISO Chain LH GB/T6074=ISO Chain LH GB/T6074=ISO Chain LH GB/T6074=ISO Chain LH GB/T6074=ISO Chain LH GB/T6074=ISO Chain wheel for mast Retainer ring for shaft 2 45 GB/T Nut 2 M6 GB/T672.=ISO Washer N 6 GB/T Bearing sleeve Pulley Bolt M6 70 GB/T5782=ISO Side cover Adjusting washer Ball bearing GB/T Middle cylinder chain wheel Retainer ring for shaft 2 30 GB/T Chain wheel shaft Chain wheel seat Screw M2 30 GB/T70.=ISO Hoop assembly Chain LH GB/T6074=ISO Chain LH GB/T6074=ISO Chain LH GB/T6074=ISO Chain LH GB/T6074=ISO Chain LH GB/T6074=ISO

35 Fig. 22 Mast other accessories (Three-stage mast Full Free Lift) Fig. 22 Mast Other Accessories (Three-stage mast Full Free Lift No. Parts No. Item Qty. Note Standard Screw 4 M8 25 GB/T70.=ISO Washer 4 8 GB/T Washer 4 8 GB/T Cylinder fixing plate Limit switch mounting plate Screw 2 M6 6 GB/T70.=ISO Washer 2 6 GB/T Washer 2 6 GB/T95 34

36 Fig. 23 Mast lifting system (Two-stage mast Normal/Straddle Leg) 35

37 Fig. 23 Mast lifting system (Two-stage mast Normal / Straddle Leg ) No. Parts No. Item Qty. Note Standard Screw 2 M6x35 GB/T77=ISO Nut 2 M6x.5 GB/T673=ISO Chain wheel Ball bearing GB/T Adjusting washer Screw 2 M0x30 GB/T70.=ISO Washer 2 0 GB/T Washer 2 0 GB/T Chain wheel shaft components Screw M6x8 GB/T70.3=ISO Chain wheel carrier Split pin 2 3x40 GB/T9=ISO Chain tension bar Nut 2 M6x.5 GB/T67=ISO Split pin 2 2x20 GB/T9=ISO Hinge pin 2 8x40 GB/T882=ISO Leaf chain LH244x GB/T6074=ISO Leaf chain LH244x GB/T6074=ISO Leaf chain LH244x GB/T6074=ISO Leaf chain LH244x GB/T6074=ISO Cylinder fixing plate Bolt M2x25 GB/T5783=ISO Cushion pad Nut 2 M6x.5 GB/T673=ISO Chain tension bar 36

38 Fig. 24 Mast lifting system (Three-stage mast Full Free Lift) 37

39 Fig. 24 Mast lifting system (Two-stage mast Full Free Lift ) No. Parts No. Item Qty. Note Standard Screw 8 M8x6 GB/T70.=ISO Washer 6 8 GB/T Washer 6 8 GB/T Holder Holder Chain wheel carrier 2 Chain wheel shaft components Screw 2 M6x8 GB/T70.3=ISO Chain wheel Ball bearing GB/T Adjusting washer Welded tension bar seat Welded pulley carrier Washer 20 GB/T Retainer ring for shaft Pulley 2 20 GB/T Split pin 4 3x40 GB/T9=ISO Chain tension bar Nut 4 M6x.5 GB/T673=ISO Nut 8 M6x.5 GB/T67=ISO Split pin 8 2x20 GB/T9=ISO Chain LH244x GB/T6074=ISO Chain LH244x GB/T6074=ISO Hinge pin 4 8x35 GB/T882=ISO Washer 4 6 GB/T Washer 4 6 GB/T Cushion pad 2 38

40 Fig. 25 Hydraulic system (Three-stage mast Full Free Lift/Straddle Leg) 39

41 Fig. 25 Hydraulic System (Three-stage mast Full Free Lift / Straddle Leg ) No. Parts No. Item Qty. Note Standard Screw 4 M6 35 GB/T70.=ISO4762 High DC hydraulic power pressure unit body pump station Screw 2 M8 20 GB/T70.=ISO Washer 2 8 GB/T Washer 2 8 GB/T Hydraulic oil tank cover Oil tank welding G end direct connection pipe joint Steering connecting elbow Tube Pump station outlet steel pipe Left cylinder steel pipe Right cylinder steel pipe Four-way joint Middle cylinder steel pipe Screw 2 M6 2 GB/T70.=ISO Hydraulic tube assembly Screw Hydraulic tube assembly M6 20 GB/T70.=ISO YGE rubber pipe clamp 40

42 Screw Safety valve High pressure middle cylinder High pressure outer cylinder Screw 3 M2 30 GB/T70.=ISO Washer 3 2 GB/T Screw 2 M6 0 GB/T70.=ISO Washer 2 6 GB/T Anti-vibration pad 4

43 Fig. 26 Hydraulic system (Two-stage mast Normal/Straddle Leg) 42

44 Fig. 26 Hydraulic System (Two-stage mast Normal / Straddle Leg ) No. Parts No. Item Qty. Note Standard Screw 4 M6 35 GB/T70.=ISO DC hydraulic 3200/3600/ power unit body Screw 2 M8 20 GB/T70.=ISO Washer 2 8 GB/T Washer 2 8 GB/T Hydraulic cylinder cover Welded cylinder G end direct connection pipe joint Steering connecting bend Tube Pump station outlet steel pipe YGE rubber pipe clamp Screw 2 M6 0 GB/T70.=ISO Hydraulic tube assembly Direct pipe joint Safe anti-explosion valve Cylinder assembly Oil return tube assembly Anti-vibration pad 43

45 Fig. 27 Hydraulic system (Two-stage mast Full Free Lift) 44

46 Fig. 27 Hydraulic System (Two-stage mast Full Free Lift) No. Parts No. Item Qty. Note Standard Screw 4 M6 35 GB/T70.=ISO DC hydraulic power unit body Screw 2 M8 20 GB/T70.=ISO Washer 2 8 GB/T Washer 2 8 GB/T Hydraulic cylinder cover Welded cylinder G end direct connection pipe joint Steering connecting bend Tube Pump station outlet steel pipe YGE rubber pipe clamp Screw 2 M6 0 GB/T70.=ISO Hydraulic tube assembly Steering connecting bend Screw 2 M6x2 GB/T70.=ISO Washer 2 6 GB/T Washer 2 6 GB/T Tube card board Hydraulic cylinder assembly Screw 2 M2 25 GB/T5783=ISO Washer 2 GB/T Hydraulic tube assembly Steel tube Nut M6 GB/T670=ISO Direct pipe joint Safety valve Anti-vibration pad Screw M6x20 GB/T578=ISO408 45

47 Fig. 28 Outer cylinder seal kit (Three-stage mast Full Free Lift/Straddle Leg) 46

48 Fig. 28 Outer cylinder seal kit(three-stage mast Full Free Lift / Straddle Leg ) No. Parts No. Item Qty. Note Standard Piston rod Dust cover 32X40X5/ O ring 38X3. GB/T3452.=ISO Seal ring for shaft 32X42X6/ Seal ring 32X42.7X Support ring for shaft 32X36X O ring 2 50X3. GB Guide sleeve Screw M8X0 GB/T70.=ISO Combination washer Cylinder body JB/T / Bushing Piston Support ring for hole Outer cylinder seal kit 2 36X40X0 2 47

49 Fig. 29 Middle cylinder seal kit (Three-stage mast Full Free Lift/Straddle Leg) 48

50 Fig. 29 Middle cylinder seal kit(three-stage mast Full Free Lift / Straddle Leg ) No. Parts No. Item Qty. Note Standard Piston rod Dust cover 45X53X5/ Seal ring for shaft 45X55X6/ End cap Retainer ring 55X60X O ring 60X3. GB/T3452.=ISO Screw M8X0 GB/T70.=ISO Copper sleeve 45X50X Cylinder body Piston Support ring for hole 48X52X Washer 8 JB/T Middle cylinder seal kit 49

51 Fig. 30 Cylinder (Two-stage mast Normal/Straddle Leg) 50

52 Fig. 30 Cylinder (Two-stage mast Normal / Straddle Leg ) No. Parts No. Item Qty. Note Standard Piston rod Dust cover 40x48x5/ Support ring for shaft 40X44X Cylinder body O ring 44.4X Support ring for hole 45X50X O ring X Y ring for hole 40X50X6/ Piston Washer 24 GB/T Nut M24x.5 GB/T67=ISO Coer Cylinder seal kit 5

53 Fig. 3 Cylinder (Two-stage mast Full Free Lift) Fig. 3 Cylinder (Two-stage mast Full Free Lift ) No. Parts No. Item Qty. Note Standard Piston rod Dust cover 40x48x5/ Support ring for shaft 40X44X Cylinder body O ring 44.4X Support ring for hole 45X50X O ring X Y ring for hole 40X50X6/ Piston Washer GB/T Nut M20x.5 GB/T67=ISO Guide bushing Cylinder seal kit 2 52

54 Fig. 32 Manual steering wheel carrier 53

55 Fig. 32 Manual Steering Wheel Carrier No. Parts No. Item Qty. Note Standard Screw 8 M6 0 GB/T70.=ISO Washer 8 6 GB/T End cover Spring Spring spindle Screw 6 M0 45 GB/T70.=ISO Washer 8 0 GB/T Washer 8 0 GB/T V type outer block Roller V type inner block Screw 6 M0 40 GB/T70.=ISO Screw 6 M0 45 GB/T70.=ISO Wheel carrier welding Cushion block Supporting frame welding Screw 4 M0 25 GB/T Thin nut 4 M0 GB/T672.=ISO Top plate Full thread bolt 2 M4 60 GB/T5783=ISO Screw 2 M Spring guide sleeve Spring Spring guide rod Washer 4 2 GB/T Screw 4 M2 30 GB/T70.=ISO Screw M2 0 GB/T70.=ISO Washer 4 2 GB/T Handle shaft welding Screw 0 M8 30 GB/T70.=ISO Washer 0 8 GB/T Washer 0 8 GB/T Limit block Vertical type drive 7EL-AC Spring assembly 2 54

56 Fig. 33 Electric power assisted steering wheel carrier 55

57 Fig. 33 Electric Power Assisted Steering Wheel Carrier No. Parts No. Item Qty. Note Standard Screw 8 M6 0 GB/T70.=ISO Washer 8 6 GB/T End cover Spring Spring spindle Screw 6 M0 45 GB/T70.=ISO Washer 8 0 GB/T Washer 22 0 GB/T V type outer block Roller V type inner block Screw 6 M0 40 GB/T70.=ISO Screw 6 M0 45 GB/T70.=ISO Wheel carrier welding Cushion block Supporting frame welding Screw 4 M0 25 GB/T Thin nut 4 M0 GB/T672.=ISO Top plate Bolt 2 M4 60 GB/T5783=ISO Screw 2 M Spring guide sleeve Spring Spring guide rod Washer 4 2 GB/T Screw 4 M2 30 GB/T70.=ISO Screw M2 0 GB/T70.=ISO Washer 4 2 GB/T Electronic steering assembly Drive wheel assembly Spring assembly 2 56

58 Fig. 34 Electric steering assembly 57

59 Fig. 34 Electric Steering Assembly No. Parts No. Item Qty. Note Standard Bearing seat welding Ball bearing GB/T Screw 3 M6 0 GB/T70.=ISO Screw 4 M0 20 GB/T70.=ISO Fixing seat welding Retainer ring for shaft 50 GB/T Damper Transition linking block Potentiometer fixing plate Washer 4 5 GB/T Washer 4 5 GB/T Screw 4 M5 0 GB/T70.=ISO Linking block Screw 4 M4 0 GB/T70.=ISO476 58

60 Fig. 35 Drive wheel assembly 7EL-AC-.3 59

61 Fig. 35 Drive Wheel Assembly 7EL-AC-.3 No. Parts No. Item Qty. Note Standard Gear box Retainer ring Bearing GB/T Oil seal GB/T Bushing Bearing 3200 GB/T Adjusting washer Gear Drive wheel Roll pin GB/T9.=ISO Retainer ring Bolt Bearing GB/T Bearing GB/T Gear Outer thimble Inner thimble Adjusting washer Adjusting washer Shaft block Washer 8 5 GB/T Screw 4 M5 6 GB/T70.2=ISO Combination washer 3 2 JB/T Plug JB/ZQ Big gear Washer Washer 4 GB/T Nut M4.5 GB/T673=ISO Washer Side cover Upper cover Dust cover 60

62 Fig. 35 Drive Wheel Assembly 7EL-AC-.3 6

63 Fig. 35 Drive Wheel Assembly 7EL-AC-.3 No. Parts No. Item Qty. Note Bolt Drive wheel Roll pin GB/T9.=ISO Washer 22 6 GB/T Screw M6 20 GB/T70.=ISO Vent plug Rotating support Screw 6 M6 30 GB/T70.=ISO Roll pin GB/T9.=ISO O seal ring GB/T3452.=ISO Small gear Drive motor Shaft sleeve Retainer ring for shaft 25 GB/T Brake Dust cover Flange Speed sensor gear Speed sensor Spacer Screw 4 M5 0 GB/T70.=ISO O seal ring GB/T3452.=ISO Bracket Washer 3 8 GB/T Screw 3 M8x25 GB/T70.=ISO Flat key A 6 8 GB/T Retainer ring for shaft 20 GB/T Dust cover Screw 3 M6 65 GB/T70.=ISO Adjusting washer Roll pin GB/T879.=ISO Screw 2 M6 45 GB/T70.=ISO O seal ring 65X2.65 GB/T3452.=ISO360-62

64 Fig EL-AC-.3KW-R Drive wheel assembly 63

65 Fig EL-AC-.3KW-R Drive Wheel Assembly No. Parts No. Item Qty. Note Standard Gear box Retainer ring Bearing GB/T Oil seal 50x80x8 GB/T Bushing Bearing 3200 GB/T Adjustng washer Gear Drive shaft Roll pin 2 4x2 GB/T Retainer ring Locking bolt Bearing GB/T Bearing GB/T Gear Outter sleeve Inner sleeve Adjustng washer Adjustng washer Bearing seat Washer 8 5 GB/T Screw 4 M5x6 GB/T70.=ISO Combination washer 3 2 JB/T Bolt 3 M2x.25 JB/ZQ Big gear Washer Nut M4x.5 GB/T673=ISO Side cover Dust cover Tyre bolt Drive wheel Washer 20 6 GB/T Screw 8 M6x30 GB/T70.=ISO Vent plug Roll pin 2 6x26 GB/T9.=ISO O ring 2 25x2.65 GB/T3452.=ISO Small gear Paper washer Upper cover Strring big gear Rotating bearing 64

66 Fig EL-AC-.3KW-R Drive Wheel Assembly 65

67 Fig EL-AC-.3KW-R Drive Wheel Assembly No. Parts No. Item Qty. Note Washer 6 8 GB/T Screw 6 M8x35 GB/T70.=ISO Oil seal GB/T Assembling board Motor Screw 6 M8x30 GB/T Locking flange Speeed sensor gear Speeed sensor Bearing Bushing Retainer ring for axle 25 GB/T Screw 4 M5x0 GB/T70.=ISO spacer O seal ring 20x2.65 GB/T3452.=ISO Bushing Flat key 6x6 GB/T Retainer ring for axle 20 GB/T Dust cover Adjustng washer Washer 4 GB/T Brake Bolt 3 M6x20 GB/T5782=ISO Screw 9 M6x20 GB/T70.=ISO Steering carbon brush Steering motor Screw 8 M6x22 GB/T70.=ISO Steering small gear Retainer ring for axle 22 GB/T Flat key 6x28 GB/T Screw 2 M6x30 GB/T70.=ISO

68 Fig. 37 Handle lever 67

69 Fig. 37 Handle lever No. Parts No. Item Quantity Note Standard Canbus control tiller Bolt 2 M8 25 GB/T5783=ISO Screw 4 M4 8 GB/T70.2=ISO Cover board Welded tiller arm Proximity switch Screw 2 M3 20 GB/T70.=ISO Shoulder harness Tiller axle Elastic roll pin 4 24 GB/T879.=ISO Screw M Left tiller cover Air spring 400N S Lock nut 2 M0 GB/T889.=ISO Tiller seat Right tiller cover Screw 4 M6 0 GB/T70.2=ISO

70 Fig. 38 CANBUS Handle head 69

71 Fig. 38 CANBUS Handle head No. Parts No. Item Qty. Note Standard Left driving button Horn button Spring for horn button Bushing for camshaft Magnetic substance Spring for urgent reversing button Screw 3 GB/T70.=ISO Screw 2 GB/T70.=ISO Washer 2 GB/T Right driving button Shaft for driving button Circlip for PCB board Load censor Upper part of handle Under part of handle Left button Magnetic substance seat Torsional spring Seat for Spring for urgent reversing button Cover for Spring for urgent reversing button Cover for option switch Right button Screw GB/T845=ISO LED bi-color light Seat for LED bi-color light Torsional spring for right driving button Torsional spring for left driving button PCB 70

72 Fig. 39 High pressure pump station system(3.0kw 2.6 high pressure delivery capacity) 7

73 Fig. 39 High Pressure Pump Station Syste(3.0KW 2.6 High Pressure Delivery Capacity) No. Parts No. Item Qty. Note Pump contactor Carbon brush(assembly) Motor Plug Valve body Solenoid valve Check valve Screw Flow control valve 9.5L/min Bolt Overflow valve O ring Oil return pipe Oil return pipe Gear pump Oil suction pipe Filter DC power unit 3.0KW 2.6 high pressure delivery capacity 9.5L check valve 72

74 Fig. 40 Pump station system(3.0kw 3.2 delivery capacity) 73

75 Fig. 40 Pump Station System(3.0KW 3.2 Delivery Capacity) No. Parts No. Item Qty. Note Pump contactor Carbon brush(assembly) Motor Plug Valve body Solenoid valve Check valve Screw Flow control valve 7.5L/min Bolt Overflow valve O ring Oil return pipe Oil return pipe Gear pump 3.2cc/r Oil suction pipe L=250.50mm Filter DC power unit Pump Station System 3.0Kw, 3.2 delivery capacity 74

76 Fig. 4 Pump station system(2.2kw 2.2 delivery capacity) 75

77 Fig. 4 Pump Station System(2.2KW 2.2 Delivery Capacity) No. Parts No. Item Qty. Note Pump contactor Carbon brush(assembly) Iskra Motor Iskra Plug Valve body Solenoid valve Check valve Screw Flow control valve Bolt Overflow valve O ring Oil return pipe Oil return pipe Gear pump Oil suction pipe Filter DC power unit 2.2kw 2.2 delivery capacity (Iskra motor) 76

78 Fig. 42 Main circuit wiring (Electrical steering) Fig. 42 Main Circuit Wiring (Electrical steering) No. Parts No. Name Qty. Note Drive motor cable Pump motor cable Power supply cable FU+ cable Steering controller cable Steering motor cable 77

79 Fig. 43 Main circuit wiring(manual steering) Fig. 43 Main Circuit Wiring (Manual steering) No. Parts No. Name Qty. Note Drive motor cable Pump motor cable Power supply cable FU+ cable 78

80 Fig. 44 General electrical parts 79

81 Fig. 44 General Electrical Parts No. Parts No. Name Qty. Note Standard Screw 4 M3 8 GB/T70.2=ISO Magnet switch 2 HWK Screw 2 M4 25 GB/T70.=ISO Proximity switch XZ-5GW22-B Proximity switch protective cover AP-B Limit control wiring harness Tiller sensor BD-MS Tiller sensor BD-MS Washer 3 3 GB/T95 Only for Screw M3 8 3 GB/T =ISO7045 electronical Screw M4 2 4 steering truck GB/T70.=ISO Washer 4 4 GB/T Position sensor BD-PS Position sensor BD-PS Main control 电子转向 wiring harness 手动转向 80

82 Fig. 45 Electric control assembly(electrical steering) 8

83 Fig. 45 Electric Control Assembly(Electrical steering) No. Parts No. Name Qty. Note Standard Controller assemble plate Controller CURTIS232E Steering BD-SC-24/ controller BD-SC-24/ Aluminium plate Wiring terminal BD-M Fuse seat BD-2 0A Relay ACR0F-F C Plug fixing plate Fuse seat BD- 0A Traction motor contactor C00/ Main contactor assembly plate Copper bar Fuse seat 2 SYY Fuse 200A Fuse 50A Copper bar Copper bar Fuse 0A Fuse 5A Screw 2 M4 30 GB/T70.=ISO Washer 2 4 GB/T Washer 2 4 GB/T Screw 2 M4 0 GB/T70.=ISO Screw 2 M4 30 GB/T =ISO Screw 4 M4 0 GB/T =ISO

84 Screw 4 M4 6 GB/T =ISO Washer 9 6 GB/T Washer 9 6 GB/T Screw 5 M6 2 GB/T70.=ISO Screw 4 M6 8 GB/T70.=ISO Washer 2 8 GB/T Washer 8 GB/T Nut 2 M8 GB/T670=ISO Screw 4 M8 6 GB/T70.=ISO Screw M5 0 GB/T =ISO Washer 5 GB/T Washer 5 GB/T Screw 2 M3 25 GB/T70.=ISO Controller Copper bar Horn DC24V Screw 2 M4 6 GB/T =ISO

85 Fig. 46 Electric control assembly(manual steering) 84

86 Fig. 46 Electric Control Assembly(Manual steering) No. Parts No. Name Qty. Note Standard Controller Controller assembly plate Controller CURTIS232E Fuse 0A Aluminium plate Wiring terminal BD-M Fuse seat BD-2 0A Relay ACR0F-F C DC24V Plug fixing plate Traction motor C00/20 contactor DC24V Main contactor assemble plate Copper bar Fuse seat 2 SYY Fuse 200A Fuse 50A Copper bar Copper bar Washer 5 GB/T Screw M5 0 GB/T =IS O Washer 5 GB/T Washer 2 4 GB/T Washer 2 4 GB/T Screw 2 M4 0 GB/T70.=ISO Screw 2 M4 30 GB/T =IS O Screw 4 M4 0 GB/T =IS O Screw 4 M4 6 GB/T =IS O Washer 9 6 GB/T Washer 9 6 GB/T95 85

87 Screw 5 M6 2 GB/T70.=ISO Screw 4 M6 8 GB/T70.=ISO Washer 2 8 GB/T Washer 8 GB/T Nut 2 M8 GB/T670=ISO Screw 4 M8 6 GB/T70.=ISO Copper bar Horn DC24V Screw 2 M4 6 GB/T =IS O

88 Fig. 47 Foldable platform 87

89 Fig. 47 Foot Pedal Assembly No. Art No. Description Qty. Note Standard Pedal pad Rotating shaft Shoulder harness Welded foot platform Screw 2 M6 6 GB/T70.2=ISO Air spring Nut M6.5 GB/T673=ISO Cam Cam shaft Washer 2 5 GB/T Washer 2 5 GB/T Screw 2 M5 6 GB/T70.=ISO Switch transition plate Proximity switch NBN5-F7-E Screw 2 M3 20 GB/T70.=ISO Welded assemble seat Washer 4 2 GB/T Washer 4 2 GB/T Line hanging board Lock nut 4 M2 GB/T889.=ISO Screw 4 M2 45 GB/T70.2=ISO Cushion Anti-vibration pad Anti-vibration washer Spring GB/T Fixed bolt Split pin GB/T9=ISO Assemble seat cover Washer 6 6 GB/T Screw 6 M6 2 GB/T70.2=ISO

90 Suspension components 2 89

91 Fig. 48 Protective arm 90

92 Fig. 48 Protective Arm No. Art No. Description Qty. Note Standard Right protective arm cover Screw 5 M8 20 GB/T70.2=ISO Left protective arm cover Welded protective arm Air spring Screw 3 M6 2 GB/T70.2=ISO Washer 3 6 GB/T Positioning spring Screw 2 M3 20 GB/T70.=ISO Proximity switch NBN5-F7-E Washer 2 5 GB/T Washer 2 5 GB/T Screw 2 M5 6 GB/T70.=ISO Switch transition plate Welded protective arm seat Washer 4 0 GB/T Screw 4 M0 25 GB/T70.2=ISO Protective arm clamp block Screw 4 M0 45 GB/T70.=ISO4762 9

93 Fig. 49 Backrest (Normal) Fig. 49 Backrest No. Parts No. Name Qty. Note Standard Backrest frame welding Screw 2 M0 25 GB/T70.=ISO Washer 4 0 GB/T Standard spring washer 4 0 GB/T Screw 2 M0 35 GB/T70.=ISO

94 Fig. 50 Backrest (Straddle Leg) Fig. 50 Backrest (Straddle Leg) No. Parts No. Name Qty. Note Standard Screw 4 GB/T70.=ISO Washer 4 2 GB/T Washer 4 2 GB/T Backrest frame welding 93

95 Easy worn parts list No. Art No. Description Qty. Fig./Position Note Compound roller 4 Fig.6/ Fig.7/ Chassis Fig.7/2 8 Fig.8/ Compound roller 2 Fig.9/ Fig.20/ Mast system Fig.9/3 Fig.20/ Castor 2 Fig.2/3 Steering wheel Damper Fig.34/7 Electric steerig Load wheel set 2 Fig.3/7 Load wheel Air spring (S 55) Fig.37/3 Tiller Carbon brush Fig.39/2 Pump Fuse 200A Fig.45/ Fuse 50A Fig.45/ Fuse 0A Fig.45/8 Electric Control Fuse 5A Fig.45/ Shoulder harness 4 Fig.47/ Air spring (S 70) Fig.47/6 Foot pedal Suspension components 2 Fig.47/ Air spring (S 36) Fig.48/5 Protective arm Outer cylinder seal kit 2 Fig.28/ Three-stage mast Middle cylinder seal kit Fig.29/ Full Free Lift / Straddle Leg Cylinder Fig.30/ Two-stage mast Normal / Straddle Leg Cylinder 2 Fig.3/ Two-stage mast Full Free Lift Castor complete 2 Fig.8/ Fig.9/ Fig.0/ Fig./ Chassis system 94