Service and

Parts
Manual
SPM-630A

TRUCK MODEL
CS 15/20

ALWAYS GIVE TRUCK SERIAL

NUMBER WHEN ORDERING PARTS

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Intended for CLARK dealers only
Do not sell or distribute
CS 15/20 SPM-630A

TABLE OF CONTENTS

1. Receipt Inspection ........................................................................................................................3

2. Pre-Operation Instructions .............................................................................................................3
3. Safety Information.........................................................................................................................4
4. Operating Instructions ...................................................................................................................5
5. Control System.............................................................................................................................7
6. Battery Discharge Indicator (BDI) - Operation .................................................................................9
6.1 Hourmeter ...........................................................................................................................9
6.2 BDI and Hourmeter ............................................................................................................10
6.3 BDI w/Lift Interlock.............................................................................................................11
7. Drive Unit & Brake ......................................................................................................................12
8. Mast and Carriage ......................................................................................................................13
9. Hydraulic Adjustments ................................................................................................................13
9.1 Lifting Pressure .................................................................................................................13
9.2 Lowering Speed:................................................................................................................13
10. Planned Maintenance .................................................................................................................14
10.1 Lubrication Points ..............................................................................................................15
10.2 Lubrication Points ..............................................................................................................16
10.3 Lubrication Schedule .........................................................................................................16
10.4 Battery Maintenance ..........................................................................................................17
10.5 Battery Cable Connections .................................................................................................18
(for built-in battery / charger pack)
11. Trouble Shooting Guide ..............................................................................................................19
12. Heavy Duty Stacker - Parts Listings .............................................................................................20
12.1 General Assembly Parts List...............................................................................................22
12.2 Mast and Carriage Assembly - Single Stage ........................................................................26
12.2.1 Cylinder Assembly - 3000 Single Stage..................................................................28
12.2.2 Cylinder Assembly - 4000 Single Stage..................................................................30
12.2.3 Crosshead Assembly - Single Stage ......................................................................32
12.2.4 Chain Assembly - Single Stage..............................................................................33
12.3 Mast and Carriage Assembly - 2 Stage ...............................................................................34
12.3.1 Lift Cylinder Assembly - Two Stage........................................................................36
12.3.2 Chain Assembly - 2 Stage.....................................................................................38
12.3.3 Crosshead Assembly - 2 Stage..............................................................................39

Issue Date: 07/23/04 Page 1

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12.4 Mast and Carriage Assembly - 2 Stage Full Free .................................................................40

12.4.1 Lift Cylinder Assembly - 2 Stage 130, 150" Full Free...............................................42
12.4.2 Outboard Cylinder Assembly - 2 Stage 130, 150" Full Free......................................44
12.4.3 Chain Assembly - 2 Stage 130, 150" Lift Height ......................................................46
12.4.4 Crosshead Assembly - 2 Stage 130, 150" Lift Height...............................................47
12.5 Mast and Carriage Assembly - 3 Stage 160, 180" Lift...........................................................48
12.5.1 Cylinder Assembly - 3 Stage 160, 180" Lift Height...................................................52
12.5.2 Chain Assembly - 3 Stage 160, 180" Lift Height ......................................................54
12.5.3 Crosshead Assembly - 3 Stage 160, 180" Lift .........................................................55
12.6 Mast and Carriage Assembly - 3 Stage 172" Lift Full Free ....................................................56
12.6.1 Chain Assembly - 3 Stage 172" Lift Full Free ..........................................................58
12.6.2 Chain Assembly - 3 Stage 172" Lift Full Free ..........................................................59
12.6.3 Crosshead Assembly - 3 Stage 172" Lift Full Free...................................................60
12.6.4 Lift Cylinder Assembly - 3 Stage 172" Lift Full Free .................................................62
12.6.5 Outboard Cylinder Assembly - 3 Stage 172" Lift Full Free........................................64
12.7 Left Straddle Assembly ......................................................................................................66
12.8 Right Straddle Assembly ....................................................................................................68
12.9 Right Straddle Assembly ....................................................................................................69
12.10 Electric Drive Unit Assembly ...............................................................................................70
12.11 Drive Unit Assembly - Electrical ..........................................................................................72
12.11.1 Control Handle Assembly ..................................................................................74
12.11.2 Control Handle Head Assembly .........................................................................76
12.11.3 Controller Panel Assembly ................................................................................78
12.11.4 Drive Unit Wiring Kit ..........................................................................................80
12.11.5 Drive Unit Column Assembly - Mechanical .........................................................82
12.11.6 Drive Unit Gearbox Assembly ............................................................................84
12.11.7 Wiring Kit - Rear Battery Box Plate ....................................................................86
12.12 Hydraulic Layout ................................................................................................................88
13. Wiring/Hydraulic Schematic .........................................................................................................92
13.1 Mechanical/Hydraulic Lift Control Schematic .......................................................................92
13.2 Electric/Hydraulic Lift Control Schematic .............................................................................93

Page 2 Issue Date: 07/23/04

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CS 15/20 SM-630A

IMPORTANT! : READ AND UNDERSTAND THE CONTENTS OF THIS

MANUAL BEFORE OPERATING THE EQUIPMENT.

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

IMPORTANT! : IF ANY DAMAGE OR LOSS IS EVIDENT, A CLAIM

MUST BE MADE AGAINST THE CARRIER.
Refer to: Damage in Transit information enclosed with
the packing slip.

2. Pre-Operation Instructions
1. Open the drive unit cover and check the wiring
harness and hydraulic hoses for damage or loose
connections.

2. With the forks in the lowered position, remove the oil

tank breather cap. and verify that the oil level is
approximately 1" (25mm) below the top of the
reservoir. Refer to Figure 4 in Section 10.1 :
Lubrication Points.

3. Open the battery compartment and check that all

connections are tight. Check that the batteries have
not been damaged. Charge battery(s) for one shift.
Refer to Section 10.3 : Battery Maintenance

4. Refer to the Operator's Manual on unit and check

that the truck operates satisfactorily.

IMPORTANT! : DURING INITIAL CYLINDER ASSEMBLY,

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

REMEMBER: A safe operator is a smart operator!

Issue Date: 07/23/04 Page 3

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

2. Do not operate this truck until you have checked its

condition. Give special attention to tires, battery,
controls, lifting systems (including switches), brakes,
steering mechanism, guards and safety devices.

3. Report the need for truck repairs to your supervisor

promptly. Do not operate the truck. Neglect may
cause a minor repair to become a major service
problem or cause the truck to become unsafe.

4. The stacker is intended for use on level surfaces

only.

5. Do not exceed the rated capacity of the vehicle as

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

6. Do not handle unstable or loosely stacked loads.

Use special care when handling long, high or wide
loads, to avoid tipping, loss of load, or striking
bystanders.

7. Always look in direction of travel. Keep a clear view

and when load obstructs visibility, travel with load
trailing (except when climbing ramps).

8. Watch swing clearance when turning near walls,

racks, pillars or other obstacles.

9. Start, stop, change direction, travel and brake

smoothly. Slow down for turns and on uneven or
slippery surfaces that could cause truck to slide or
tip. Be aware that the truck behaves differently
without a load than with a load.

10. Observe applicable traffic regulations and yield right

of way to pedestrians. Slow down and sound horn at
all aisle intersections and where vision is obstructed.
Do not ride on truck unless equipped with a rider
platform.

11. Do not carry passengers.

12. Before leaving the truck, fully lower the lifting

mechanism and shut off power and key switch if
equipped.

Page 4 Issue Date: 07/23/04

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

14. When traveling with or without a load, forks should

be in lower most position and tilted back if
applicable.

15. For straddle trucks, straddle distance must be

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

4. Operating Instructions

1. Refer to OPERATOR'S MANUAL enclosed in

the pouch on the control handle.

If the OPERATOR'S MANUAL is missing,

contact your authorized distributor.

REMEMBER: A safe operator is a smart operator!

WARNING! :THE FOLLOWING IS INTENDED AS AS A BREIF

OVERVIEW OF TRUCK FUNCTIONS. DO NOT PUT THE TRUCK INTO
SERVICE WITHOUT READING THE OPERATOR'S MANUAL AND
FULLY UNDERSTANDING THE TRUCK CONTROLS. FAILURE TO DO
SO COULD RESULT IN PROPERTY DAMAGE, AND/OR SERIOUS
PERSONAL INJURY OR DEATH.
Travel Controls:

Rotating the Thumb Wheels in the head of the control

handle controls Direction and speed. This unit is
equipped with a fully programmable electronic speed
control and has variable speed that is regulated by
turning the twist grip handle in the forward or reverse
direction as required. With the electronic speed
controller travel controls (reversing travel direction) may
be used for braking purposes during regular use.

Brake:

The brake is applied when the control handle is in the

fully raised or fully lowered position. Power to the
traction (drive) motor is cut off whenever the brake is
applied in the fully raised or lowered position.
Equipment includes a “Deadman” safety feature. Spring
loaded steering handle, when released automatically
returns to upright/”Deadman” position that engages the
brake and will slow the unit down to a full stop.

Issue Date: 07/23/04 Page 5

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Horn:

The horn pushbutton is located on the steering handle

allowing instantaneous fingertip use without travel
interruption.

Safety Reversing Button:

Located at the top of the steering handle. When the

truck is being driven in the direction of the operator and
the safety-reversing button is depressed by an
obstruction or trapped operator, the vehicle instantly
reverses direction in high speed and the horn will sound.

NOTE: DO NOT USE THE SAFETY REVERSING

BUTTON FOR NORMAL TRAVEL.

Lift and Lower Controls:

Manual lever control (standard) is located on the right

hand side of the dash plate. Pushbutton control, if
ordered, is located on the top of the control handle.

WARNING! : NEVER EXCEED THE RATED CAPACITY OF THE

TRUCK AS MARKED ON THE NAMEPLATE. DO NOT LIFT WITH THE
FORK TIPS OR ONE FORK ONLY.

Mast Tilt Controls:

Manual lever control is located on the right handle side

of the dash plate. Pushbutton control, if ordered,
is located on the top of the control handle.

WARNING! : DO NOT USE FORWARD TILT WITH THE LOAD

ELEVATED UNLESS THE LOAD IS DIRECTLY OVER OTHER
SUPPORT.

Page 6 Issue Date: 07/23/04

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CS 15/20 SM-630A

5. Control System

These units are factory set for normal operating

conditions. This electronic speed controller provides
maintenance free operation and reduces downtime and
operating costs associated with contactor controlled
units.

Contact your local CLARK dealer for additional

information.

Current multiplication:

During acceleration, or reduced speed operation, the

electronic travel speed controller allows more current
into the motor than what it takes out of the battery. This
is possible because the controller acts like a D.C.
transformer, i.e.: it takes in high voltage (the full battery
voltage) and low current, and puts out low voltage and
high current. Thus for these conditions the battery only
has to supply a fraction of the current otherwise required
by a standard resistor type controller (in which the
battery current and motor current are always equal).

The result is a dramatic improvement in the vehicle’s

efficiency, i.e. greater driving range per battery charge!

Plug braking:

In most applications of these controllers, the vehicle

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

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

WARNING! : DISCONNECT THE BATTERY AND DEPRESS HORN

SWITCH TO DRAIN CONTROLLER RESIDUAL CURRENT BEFORE
ATTEMPTING ANY TYPE OF INSPECTION OR SERVICE.

Issue Date: 07/23/04 Page 7

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a) Make sure that the electrical connections to the

controller (as well as those to the motor, batteries,
etc.) are tight.
NOTE: When checking the controller bus bar
connections for tightness, be sure to use the
double-wrench technique to avoid applying
torquing stress on the bus bars which could
crack the seals around them.
b) Remove from the terminal areas any corrosion or
accumulations of dirt, acids, grease, oil, etc. It is
very important that the controller terminal face be
free of these substances, since their presence may
lead to electrical leakage and cause faulty operation.
The controller may be wiped clean.
POWER MUST BE REMOVED DURING THIS
CLEANING.

Page 8 Issue Date: 07/23/04

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CS 15/20 SM-630A

6. Battery Discharge Indicator (BDI) - Operation

Some units may be equipped with a battery discharge

indicator that may include a lift lockout feature. When
the battery is severely discharged the lifting circuit will
automatically be disabled. To avoid this, the operator
must return the unit for charging after the last light / bar
is activated. The travel circuit will remain operational to
return the unit to the charging area. Although, several
different style meters are available as options, their basic
function is identical.

The lift lockout feature will ensure that the battery and
electrical components are not subject to premature wear
due to operating with a discharged battery. Always
check the battery indicator, if equipped, in the event that
the lifting circuit is not operational. General operation of
a battery discharge indicator with or without the lift
lockout feature, if equipped, is outlined on the drawing
below.

Optional Parts

ITEM PART NO. DESCRIPTION

1 032-211 Hour meter
2 032-229 Combo BDI-hour meter
3 032-244 BDI with lift lockout
Combo BDI-hour meter with lift
4 026-511
lockout
5 026-516 Harness for 026-511

6.1 Hourmeter

The Hourmeter is activated by the control handle and

records actual run time of the drive motor.

Figure 1 : Typical Hourmeter

Issue Date: 07/23/04 Page 9

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6.2 BDI and Hourmeter

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

Figure 2 : Typical BDI/Hourmeter Inicators

The functioning of the red, yellow and green LED display

on the BDI/Hourmeter is as follows:

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

proper full charge.

2. As the battery’s state-of-charge condition decreases,

the number of lit LEDs will also decrease.

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

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

4. At the empty point (3.), the 2 LEDs at the far left will
alternately flash indicating a state-of-charge
condition of approximately 80% discharge.

Page 10 Issue Date: 07/23/04

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If the power is disconnected from the indicator during

charging, the unit will reset at 2.09 volts per cell.

If the indicator remains connected during charging, a

voltage of 2.35 volts per cell must be maintained in
excess of 6 minutes in order to rest the unit.

6.3 BDI w/Lift Interlock

The display of the BDI w/ Lift Interlock monitors the
state-of-charge condition of the batteries as well as
providing a Lift Interlock feature.

As the battery’s state-of-charge condition decreases, the

number of lit LEDs will also decrease.

Figure 3 : Typical Battery Discharge Indicator

All lights ON:

Battery: - fully charged
Voltage: - more than 110% of nominal

Four lights ON:

Battery: - fully charged
Voltage: - between 110% and 100% of nominal

Three lights ON:

Battery: - partially discharged
Voltage: - between 98% and 100% of nominal

Two lights ON:

Battery: - partially discharged
Unit should be promptly returned for charging

One light ON:

Battery: - fully discharged
Lift will be disabled after several minutes of
continued service. Unit must be returned for
charging immediately!

Issue Date: 07/23/04 Page 11

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7. Drive Unit & Brake

BEFORE INSPECTING ANY PART OF THE DRIVE ASSEMBLY

DISCONNECT MAIN BATTERY POWER AND DEPRESS HORN
SWITCH TO DRAIN RESIDUAL CONTROLLER CURRENT
The traction motor has sealed bearings and requires no
external lubrication.

1. Check the condition of the drive belt and adjust the

tension if necessary. The belt is correctly tensioned
when a 10 lb. force applied midway between the two
sprockets causes a deflection of 3/16”.

2. Check belt for unusual wear which may indicate

incorrect pulley alignment. Never use force or pry
when installing a new replacement belt.

3. To install a new belt reduce tension, install belt,

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

4. Change the oil in the gear reduction box 500 hours

or three months after the equipment is placed in
service and every 2000 hours or one year thereafter.
Approved gearbox oils are listed on chart below.

5. Check the brake for safe operation. Make sure the

power cut off switch is open and disconnects the
drive when the brakes are applied in both the up and
down position. This unit is equipped with an internal
multi-disc braking system that has no user
adjustable parts. Qualified service personnel must
perform brake adjustments only.

FACTORY APPROVED OILS FOR NORMAL AMBIENT OPERATING CONDITIONS

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

Page 12 Issue Date: 07/23/04

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8. Mast and Carriage

1. Check the condition and wear of all channel/chain

rollers on a monthly basis and replace if necessary.

2. Lubricate the points as shown in Figure 4 :

Lubrication Points. For best performance lubricate
monthly.

3. Periodically remove the lift chains and wipe clean

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

4. Check the upper limit mechanical stops for damage

and repair or replace.

9. Hydraulic Adjustments

9.1 Lifting Pressure

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

9.2 Lowering Speed:

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

Issue Date: 07/23/04 Page 13

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10. Planned Maintenance

Spotting trouble before it happens can prevent costly

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

INSPECTION INTERVALS

DAILY: All Operating Controls (SAFETY) QUARTERLY: Electrical System

Battery Charge Hydraulic System
Brake Operation Drive Unit & Mechanical Parts

WARNING! : DISCONNECT THE BATTERY AND DEPRESS HORN

SWITCH TO DRAIN CONTROLLER RESIDUAL CURRENT BEFORE
ATTEMPTING ANY TYPE OF INSPECTION OR SERVICE

Page 14 Issue Date: 07/23/04

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10.1 Lubrication Points

Note: Ball Bearing Style Rollers do NOT require lubrication.

Figure 4 : Lubrication Points

Issue Date: 07/23/04 Page 15

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10.2 Lubrication Points

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

10.3 Lubrication Schedule

LUBRICATION (based on single shift, normal usage)

The transmission (gearbox) oil, hydraulic oil should be changed after the truck has been in service for six
months, then minimum once a year, for normal single shift usage.

Every - Apply engine oil (SAE 10) or Yearly: - Remove reservoir suction strainer,
Month: grease to all points. , discard used oil and clean reservoir.
including handle Inspect strainer and replace if
pivot points. damaged. Reinstall and add oil to 1”
(25mm) below the top. For operation
at normal room temperatures use
Every Three - Remove breather cap only approved hydraulic oils such as:
Months: (See Figure 4) check oil ISO 32
level Is 1” (25mm) below the Sunvis 832
top of the reservoir and add Esso Polar 32
approved oil, if necessary. Shell Tellus 29
High oil level may cause Texaco Rando Oil HD32(150)
leakage during rapid For Transmission (Gear Box) oil use:
braking. Gulf Harmony 68
The breather cap should be Esso Teresso 68
cleaned with a suitable Shell Covil 68 or equal
cleaning solvent and blown For low temperature operation
dry (safety glasses must be consult the manufacturer for
worn) before you reinstall. recommended hydraulic and
Check gearbox oil level transmission oils.
(See Figure 4)

Every Six - Clean drive unit swivel

Months: bearings and wheel
bearings,
check for smooth operation
and lubricate using high
quality lithium-based EP
type grease.

Page 16 Issue Date: 07/23/04

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10.4 Battery Maintenance

General

The top of the battery should be kept clean and dry.

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

WARNING! : PROPER SAFETY DEVICES SUCH AS SAFETY

GLASSES, APRON AND GLOVES MUST BE WORN WHEN WORKING
WITH BATTERIES.
Records

A weekly record should be kept showing hydrometer

readings of pilot cell at start and at end of charge.
Change to a different pilot cell monthly.
Once a week after the battery has received an
equalizing charge, record the hydrometer readings of all
cells.

CAUTION! : DO NOT DISCHARGE BELOW SPECIFIC GRAVITY OF

1.150 OR THERE WILL BE A PERMANENT LOSS OF CAPACITY.

Charging industrial battery with remote charger

Refer to charger manufacturer's operating directions and

manual.

Charging with built-in charger / battery pack

Plug charger cord into electrical outlet 115/1/60).

Charging will start and stop automatically.

Charging with GNB 'Champion' power pack

Refer to manufacturer’s operating directions and

manual.

WARNING! : INSURE THAT BATTERY CHARGER ELECTRIC PLUG

CANNOT COME INTO CONTACT WITH BATTERY TERMINAL POSTS

WARNING! : DISCONNECT THE SB BATTERY CONNECTOR FROM

THE MACHINE PRIOR TO CHARGING TO PREVENT ACCIDENTAL
VEHICLE MOVEMENT

Issue Date: 07/23/04 Page 17

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10.5 Battery Cable Connections

(for built-in battery / charger pack)

WARNING! : VERIFY PROPER BATTERY VOLTAGE AND POLARITY

BEFORE MAKING CONNECTION

Figure 5 : Typical Cabling Arrangement For 4 - 12 Volt Batteries (Series / Parallel)

CAUTION! : VERIFY THE DURATION AND AMPERAGE OF

CHARGING SUITABLE FOR THE TYPE AND RATING OF BATTERIES
USED. NOT ALL BATTERIES ARE DESIGNED TO TAKE HIGH
AMPERAGE/SHORT CHARGING TIMES. CONSULT YOUR LOCAL
CLARK AUTHORIZED DEALER FOR MORE INFORMATION.

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11. Trouble Shooting Guide

The following charts are intended to assist in identifying possible equipment malfunctions.

NOTE: REPAIRS / TROUBLE SHOOTING SHOULD BE PERFORMED BY AN AUTHORIZED

TECHNICIAN.

BEFORE TROUBLE SHOOTING, MAIN BATTERY POWER MUST BE DISCONNECTED.

PROBLEM POSSIBLE CAUSE

NO LIFT • Discharged battery

(motor does not run) • Faulty wiring between pump motor and contactor
• Faulty contactor for pump motor
• Worn out brushes in pump motor
• Faulty main power fuse

NO LIFT • Discharged battery

(motor runs) • Low hydraulic pressure
• Pump check valve stuck open - Faulty solenoid valve
• Check oil level if forks do not raise fully
• Foreign material blocking lifting mechanism

FORKS WILL NOT LOWER • Faulty solenoid coil

• Faulty control valve
• Obstruction in chain/mast/carriage
• Faulty control fuse blown

NO ELECTRICAL POWER • Discharged battery

or • Loose/corroded battery connections
NO TRAVEL • Blown main or control fuse
• Faulty travel control switch
• Faulty contactor or contactor tips
• Check traction motor
• Broken/loose drive belt
• Faulty SB connector

TRUCK PERFORMS PROPERLY • Battery being removed from charger before recharging
BUT REQUIRES CHARGING TOO cycle is completed
FREQUENTLY • Battery water level is too low to accept and hold a full
charge
• Battery capacity not adequate for workload required
• Battery capacity reduced due to battery damage

FORKS WILL NOT LIFT TO • Oil level low in oil reservoir. Refill oil reservoir, determine
FULL HEIGHT area of leakage
PUMP MAKES MORE NOISE • CAUTION: Use Only recommended oils
THAN NORMAL

LOSS OF BRAKING POWER • Brake requires adjustment. Must be performed by

qualified personnel only

NOTE: Additional testing and diagnostics must be performed by authorized service personnel through
use of the diagnostics analysis tool in the controller programmer. Consult the manufacturer or an
authorized dealer for more details and assistance.

Issue Date: 07/23/04 Page 19

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12. CS 15/20 - Parts Listings

Page 20 Issue Date: 07/23/04

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CS 15/20 SM-630A

Issue Date: 07/23/04 Page 21

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CS 15/20 SM-630A

12.1 General Assembly Parts List

Figure 6 : General Assembly

Page 22 Issue Date: 07/23/04

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CS 15/20 SM-630A

General Assembly Parts List

Item Qty Part No General Description Specific Description

1 1 142-5000 Weldment, Body 3000-63” Lift Height
1 1 142-5000 Weldment, Body 3000-68” Lift Height
1 1 142-5000 Weldment, Body 3000-118” Lift Height
1 1 142-5000 Weldment, Body 3000-130” Lift Height
1 1 142-5000-1 Weldment, Body 3000-130” Full Free
1 1 142-5000 Weldment, Body 3000-150” Lift Height
1 1 142-5000-1 Weldment, Body 3000-150” Full Free
1 1 142-5000 Weldment, Body 3000-160”
1 1 142-5000-4 Weldment, Body 3000-172” Full Free
1 1 142-5000 Weldment, Body 3000-180” Lift Height
1 1 142-5000 Weldment, Body 4000-63” Lift Height
1 1 142-5000 Weldment, Body 4000-68” Lift Height
1 1 142-5000 Weldment, Body 4000-118” Lift Height
1 1 142-5000 Weldment, Body 4000-130” Lift Height
1 1 142-5000-1 Weldment, Body 4000-130” Full Free
1 1 142-5000 Weldment, Body 4000-150” Lift Height
1 1 142-5000-1 Weldment, Body 4000-150” Full Free
1 1 142-5000 Weldment, Body 4000-160” Lift Height
1 1 142-5000-4 Weldment, Body 4000-172” Full Free
1 1 142-5000 Weldment, Body 4000-180” Lift Height
1 1 142-5000 Weldment, Body 4000-200” Lift Height
2** 1 103-5024 Ass’y, Mast and Carriage - 3000-63” Lift Height
2** 1 103-5024-2 Ass’y, Mast and Carriage - 3000-68” Lift Height
2** 1 143-5043 Ass’y, Mast and Carriage - 3000-118” Lift Height
2** 1 143-5043-1 Ass’y, Mast and Carriage - 3000-130” Lift Height
2** 1 103-5027-2 Ass’y, Mast and Carriage - 3000-130” Full Free
2** 1 143-5043-2 Ass’y, Mast and Carriage - 3000-150” Lift Height
2** 1 103-5027-3 Ass’y, Mast and Carriage - 3000-150” Full Free
2** 1 103-5035 Ass’y, Mast and Carriage - 3000-160” Lift Height
2** 1 143-5049 Ass’y, Mast and Carriage - 3000-172” Full Free
2** 1 103-5035-2 Ass’y, Mast and Carriage - 3000-180” Lift Height
2** 1 103-5024-1 Ass’y, Mast and Carriage - 4000-63” Lift Height
2** 1 103-5024-3 Ass’y, Mast and Carriage - 4000-68” Lift Height
2** 1 143-5043-3 Ass’y, Mast and Carriage - 4000-118” Lift Height
2** 1 143-5043-4 Ass’y, Mast and Carriage - 4000-130” Lift Height
2** 1 103-5027-2 Ass’y, Mast and Carriage - 4000-130” Full Free
2** 1 143-5043-5 Ass’y, Mast and Carriage - 4000-150” Lift Height
2** 1 103-5027-3 Ass’y, Mast and Carriage - 4000-150” Full Free
2** 1 103-5035-1 Ass’y, Mast and Carriage - 4000-160” Lift Height
2** 1 143-5049 Ass’y, Mast and Carriage - 4000-172” Full Free
2** 1 103-5035-3 Ass’y, Mast and Carriage - 4000-180” Lift Height
2** 1 103-5035-5 Ass’y, Mast and Carriage - 4000-200” Lift Height
3 4 010-182 Capscrew, 7/8” x 3” LG. 3000/4000
4 4 011-154 Nut, Hex - 7/8”-9 3000/4000
5 4 012-022 Washer, Lock - 7/8”OD x .266”W 3000/4000

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Continued…

Issue Date: 07/23/04 Page 23

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CS 15/20 SM-630A

General Assembly Parts List

Figure 6 : General Assembly

Page 24 Issue Date: 07/23/04

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CS 15/20 SM-630A

General Assembly Parts List

Item Qty Part No General Description Specific Description

6** 1 142-5032 Ass’y, Straddle – Left 3000/4000
7** 1 142-5033 Ass’y, Straddle – Right 3000/4000
8 2 014-010 Screw, Set - Hex. Socket 3/4”-10 x 3/4" 3000/4000
9 1 037-061 Shroud, Drive Unit - Specify Color 3000/4000
10 1 037-062-31 Cover, Dash - Specify Color 3000/4000
11 2 010-000 Capscrew, Hex Hd. - 1/4"-20 x 3/4" 3000/4000
12 2 012-202 Washer, Lock - 1/4" Helical 3000/4000
13 6 011-631 Fastener, U-Type – 1/4"-20 3000/4000
14 6 011-020 Screw, Machine R/H Slot 1/4"-20 x 3/4" 3000/4000
15 1 144-0010 Bar, Shroud Support 3000/4000
16 2 041-086 Fork, Forged 1-1/2” x 4" x 42” 3000/4000
17 1 142-5029 Rest, Back - 48” (33”OD Carriage) 3000/4000
18 1 142-5008 Tray, Battery Weld (13” W) 3000/4000
19 2 132-0031 Stop, Battery Weld 3000/4000
20** 1 145-5002 Assembly, Electric Drive Unit 3000/4000
21** 1 145-5006 Layout, Hydraulic 3000/4000 - 1&2 Stage
21** 1 145-5006-5 Layout, Hydraulic 3000/4000-130 FullFree
21** 1 145-5006-6 Layout, Hydraulic 3000/4000-150 FullFree
21** 1 145-5006-1 Layout, Hydraulic 3000/4000-160
21** 1 145-5006-7 Layout, Hydraulic 3000/4000-172 FullFree
21** 1 145-5006-2 Layout, Hydraulic 3000/4000-180
21** 1 145-5006-3 Layout, Hydraulic 4000-200
22 1 140-5010 Kit, Decal 3000/4000
23 1 142-0020 Screen, Wire Mesh (42”LG) 3000/4000
23 1 142-0020-1 Screen, Wire Mesh (46”LG) 3000/4000
23 1 142-0020-2 Screen, Wire Mesh (54” LG) 3000/4000
24 4 011-124 Capscrew, Hex Socket - #10/24 x 1/4" 3000/4000
25 4 030-866 Clamp, 1/8” Dia. 3/8”W 3000/4000
26 1 032-211 Hour meter 3000/4000
26 1 032-229 Battery Discharge Indicator /Hourmeter 3000/4000
26 1 032-244 Battery Discharge Indicator w/Lift Lockout 3000/4000
Battery Discharge Indicator /Hourmeter
26 1 026-511 3000/4000
w/Lift Lockout
27 1 026-516 Harness for 026-511 (Not Shown) 3000/4000

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Issue Date: 07/23/04 Page 25

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CS 15/20 SM-630A

12.2 Mast and Carriage Assembly - Single Stage

Figure 7 : Mast and Carriage Assembly - 63, 68" Lift Height

Page 26 Issue Date: 07/23/04

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CS 15/20 SM-630A

Mast and Carriage Ass'y - Single Stage

Item Qty Part No General Description Specific Description

◄ - Mast and Carriage Ass'y - Single Stage 3000/4000 Single Stage
- - 103-5024 Ass’y, Mast and Carriage - 3000-63” Lift Height
- - 103-5024-2 Ass’y, Mast and Carriage - 3000-68” Lift Height
- - 103-5024-1 Ass’y, Mast and Carriage - 4000-63” Lift Height
- - 103-5024-3 Ass’y, Mast and Carriage - 4000-68” Lift Height
1 1 103-5020 Weldment, Mast - 63” 3000-63” Lift Height
1 1 103-5020-2 Weldment, Mast - 68” 3000-68” Lift Height
1 1 103-5020-1 Weldment, Mast - 63” 4000-63” Lift Height
1 1 103-5020-3 Weldment, Mast - 68” 4000-68” Lift Height
2** 1 101-5003 Ass’y, Cylinder - 63” 3000-63” Lift Height
2** 1 101-5003-1 Ass’y, Cylinder - 68” 3000-68” Lift Height
2** 1 101-5004 Ass’y, Cylinder - 63” 4000-63” Lift Height
2** 1 101-5004-1 Ass’y, Cylinder - 68” 4000-68” Lift Height
3** 1 103-5017 Weldment, Crosshead 3000 - Single Stage
3** 1 103-5017-1 Weldment, Crosshead 4000 - Single Stage
4** 2 103-5031 Ass’y, Chain - 41-1/2” 3000-63” Lift Height
4** 2 103-5031-1 Ass’y, Chain - 46-1/2” 3000-68” Lift Height
4** 2 103-5030-13 Ass’y, Chain - 41-1/2” 4000-63” Lift Height
4** 2 103-5030-12 Ass’y, Chain - 46-1/2” 4000-68” Lift Height
5 1 104-146 Block, Stop 3000/4000
6* 1 133-5005 Ass’y, Carriage Weldment 3000 - Single Stage
6* 1 133-5005-1 Ass’y, Carriage Weldment 4000 - Single Stage
7 4 019-011 Bearing, Roller 3000 - Single Stage
8 2 103-5045 Ass’y, Roller - Side Thrust 3000 - Single Stage
9 2 103-0022 Roller, 2” Dia. - Side Thrust 3000 - Single Stage
10 2 018-006 Bushing 3000 - Single Stage
11 4 011-045 Capscrew, Hex Socket F/H - 3/8”-16 x 3/4" 3000/4000
12 1 010-012 Capscrew, Hex Hd. - 3/8”-16 x 3/4" 3000/4000
13 1 012-201 Washer, Lock 3/8” - Helical 3000/4000

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Issue Date: 07/23/04 Page 27

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CS 15/20 SM-630A

12.2.1 Cylinder Assembly - 3000 Single Stage

Figure 8 : Lift Cylinder Assembly - 63", 68" Lift Height - 3000 lb. Capacity

Page 28 Issue Date: 07/23/04

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CS 15/20 SM-630A

Cylinder Assembly - 3000 Single Stage

Item Qty Part No General Description Specific Description

◄ - 101-5003 Ass’y, Cylinder - 63” 3000-63” Lift Height
- - 101-5003-1 Ass’y, Cylinder - 68” 3000-68” Lift Height
1 1 101-0003 Ram, 2” Dia. x 37-3/8” LG. 3000 -63” LH
1 1 101-0003-1 Ram, 2” Dia. x 39-7/8” LG. 3000 -68” LH
2 1 101-5000 Weldment, Housing 2-1/2” Dia 3000 -63” LH
2 1 101-5000-1 Weldment, Housing 2-1/2” Dia 3000 -68” LH
3 1 118-362 Nut, Head 3000 -63,68” LH
4 1 114-977 Washer, Piston 2-1/2” Dia 3000 -63,68” LH
5 1 113-629 Piston, 2-1/2” Dia (USE 788-599) 3000 -63,68” LH
●6 1 036-153 Ring, Wear 3000 -63,68” LH
●7 1 036-150 Ring, Wear 3000 -63,68” LH
●8 1 036-133 “O”-Ring 3000 -63,68” LH
●9 1 036-119 “U”-Cup 3000 -63,68” LH
●10 1 036-108 “O”-Ring 3000 -63,68” LH
●11 1 036-021 Wiper, Rod 3000 -63,68” LH
●12 1 117-993 Gasket 3000 -63,68” LH
13 1 011-530 Nut, Jam 3/4”-10 3000 -63,68” LH
●14 1 036-176 “O”-Ring 3000 -63,68” LH
- - 783-550 Kit, Seal Includes Items marked (●) 3000

Issue Date: 07/23/04 Page 29

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CS 15/20 SM-630A

12.2.2 Cylinder Assembly - 4000 Single Stage

Figure 9 : Lift Cylinder Assembly - 63", 68" Lift Height - 4000 lb. Capacity

Page 30 Issue Date: 07/23/04

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CS 15/20 SM-630A

Cylinder Assembly - 4000 Single Stage

Item Qty Part No General Description Specific Description

◄ - 101-5004 Ass’y, Cylinder - 63” 4000-63” Lift Height
- - 101-5004-1 Ass’y, Cylinder - 68” 4000-68” Lift Height
1 1 101-0003 Ram, 2” Dia. x 37-3/8” LG. 4000-63” LH
1 1 101-0003-1 Ram, 2” Dia. x 39-7/8” LG. 4000-68” LH
2 1 101-5000-1 Weldment, Housing 3” Dia 4000-63” LH
2 1 101-5000-1 Weldment, Housing 3” Dia 4000-68” LH
3 1 117-991 Nut, Head 4000-63,68” LH
4 1 114-978 Washer, Piston 4000-63,68” LH
5 1 114-640 Piston, 3” Dia 4000-63,68” LH
●6 1 036-153 Ring, Wear 4000-63,68” LH
●7 1 036-150 Ring, Wear 4000-63,68” LH
●8 1 036-133 “O”-Ring 4000-63,68” LH
●9 1 036-119 “U”-Cup 4000-63,68” LH
●10 1 036-108 “O”-Ring 4000-63,68” LH
●11 1 036-021 Wiper, Rod 4000-63,68” LH
●12 1 117-993 Gasket 4000-63,68” LH
13 1 011-530 Nut, Jam 3/4”-10 4000-63,68” LH
●14 1 036-176 “O”-Ring 4000-63,68” LH
- - 783-553 Kit, Seal Includes Items marked (●) 4000

Issue Date: 07/23/04 Page 31

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CS 15/20 SM-630A

12.2.3 Crosshead Assembly - Single Stage

Figure 10 : Crosshead Assembly - 63", 68" Lift Height

Item Qty Part No General Description Specific Description

◄ - 103-5017 Weldment, Crosshead 3000 - Single Stage
- - 103-5017-1 Weldment, Crosshead 4000 - Single Stage
1 1 783-088-1 Weldment, Crosshead 3000/4000 - Single St.
2 2 781-318 Roller, Chain (c/w Bushing) 3000 - Single Stage
2 2 792-306 Roller, Chain (c/w Bushing) 4000 - Single Stage
3 2 120-744 Roller, Chain - 5/8" 3000 - Single Stage
3 2 100-019 Roller, Chain - 7/8" 4000 - Single Stage
4 2 018-027 Bushing 3000/4000 - Single St
5 2 103-250 Pin, Crosshead 3000/4000 - Single St.
6 6 114-336 Washer, Flat Spacer 3000/4000 - Single St.
7 2 013-036 Ring, Ext. Retaining - 1-1/4”ID 3000/4000 - Single St.
8 1 014-005 Screw, Set - Socket 3/8”-16 x 3/8” 3000/4000 - Single St.

Page 32 Issue Date: 07/23/04

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CS 15/20 SM-630A

12.2.4 Chain Assembly - Single Stage

Figure 11 : Chain Assembly - 63", 68" Lift Height

Item Qty Part No General Description Specific Description

◄ - 103-5031 Ass’y, Chain - 41-1/2” 3000-63” Lift Height
- - 103-5031-1 Ass’y, Chain - 46-1/2” 3000-68” Lift Height
- - 103-5030-13 Ass’y, Chain - 41-1/2” 4000-63” Lift Height
- - 103-5030-12 Ass’y, Chain - 46-1/2” 4000-68” Lift Height
1 1 090-066-0414 Leaf, Chain - 41-1/2"LG 3000-63” Lift Height
1 1 090-066-0464 Leaf, Chain - 46-1/2"LG 3000-68” Lift Height
1 1 090-067-0414 Leaf, Chain - 41-1/2"LG 4000-63” Lift Height
1 1 090-067-0464 Leaf, Chain - 46-1/2"LG 4000-68” Lift Height
2 1 100-061 Clevis 3” LG 5/8”-11 3000-63,68” LH
2 1 104-532 Clevis 4000-63,68” LH
3 2 100-062 Pin, Clevis 3/16” Dia. x 1” 3000-63,68” LH
3 2 105-372 Pin, Clevis 0.2"OD x 1-1/4"LG. 4000-63,68” LH
4 2 013-015 Pin, Cotter Pin 1/16” x 3/4" 3000/4000-63,68” LH
5 2 011-501 Nut, Lock 5/8”-11 3000-63,68” LH
5 2 011-535 Nut, Hex 3/4-10 Nylon Insert 4000-63,68” LH
6 1 103-951 Clevis, Chain - 5/8” x 4-1/2” LG. 3000-63,68” LH
6 1 104-532 Clevis 4000-63,68” LH

Issue Date: 07/23/04 Page 33

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CS 15/20 SM-630A

12.3 Mast and Carriage Assembly - 2 Stage

Figure 12 : Mast and Carriage Assembly - 118", 130", 150" Lift Height

Page 34 Issue Date: 07/23/04

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CS 15/20 SM-630A

Mast and Carriage Assembly - 2 Stage

Item Qty Part No General Description Specific Description

◄ - Mast and Carriage Assembly - 2 Stage 3000/4000 - 2 Stage
- - 143-5043 Mast and Carriage Assembly - 2 Stage 3000-118” Lift Height
- - 143-5043-1 Mast and Carriage Assembly - 2 Stage 3000-130” Lift Height
- - 143-5043-2 Mast and Carriage Assembly - 2 Stage 3000-150” Lift Height
- - 143-5043-3 Mast and Carriage Assembly - 2 Stage 4000-118” Lift Height
- - 143-5043-4 Mast and Carriage Assembly - 2 Stage 4000-130” Lift Height
- - 143-5043-5 Mast and Carriage Assembly - 2 Stage 4000-150” Lift Height
1 1 103-5021 Weldment, Outer Mast 3000-118” Lift Height
1 1 103-5021-2 Weldment, Outer Mast 3000-130” Lift Height
1 1 103-5021-4 Weldment, Outer Mast 3000-150” Lift Height
1 1 103-5021-1 Weldment, Outer Mast 4000-118” Lift Height
1 1 103-5021-3 Weldment, Outer Mast 4000-130” Lift Height
1 1 103-5021-5 Weldment, Outer Mast 4000-150” Lift Height
2 1 103-5046 Weldment, Inner Mast 3000/4000-118” LH
2 1 103-5046-1 Weldment, Inner Mast 3000/4000-130” LH
2 1 103-5046-2 Weldment, Inner Mast 3000/4000-150” LH
3** 1 133-5003 Assembly, Carriage Weld’t 3000-2 Stage
3** 1 133-5003-1 Assembly, Carriage Weld’t 4000-2 Stage
4 4 019-011 Bearing, Roller 3000/4000-2 Stage
5* 2 103-5045 Ass’y, Roller - Side Thrust 3000/4000-2 Stage
6 2 103-0022 Roller, 2” Dia. - Side Thrust 3000/4000-2 Stage
7 2 018-006 Bushing 3000/4000-2 Stage
8** 1 101-5003-2 Assembly, Cylinder - 2-1/2” Dia. 3000/4000-118” LH
8** 1 101-5003-3 Assembly, Cylinder - 2-1/2” Dia. 3000/4000-130” LH
8** 1 101-5003-4 Assembly, Cylinder - 2-1/2” Dia. 3000/4000-150” LH
9** 2 103-5031-3 Assembly, Chain - 71.5” LG. 3000-118” Lift Height
9** 2 103-5031-4 Assembly, Chain - 76.5” LG. 3000-130” Lift Height
9** 2 103-5031-5 Assembly, Chain - 86.5” LG. 3000-150” Lift Height
9** 2 103-5030-7 Assembly, Chain - 70.5” LG. 4000-118” Lift Height
9** 2 103-5030-8 Assembly, Chain - 75.5” LG. 4000-130” Lift Height
9** 2 103-5030-9 Assembly, Chain - 85.5” LG. 4000-150” Lift Height
10** 1 780-906 Assembly, Crosshead 3000-2 Stage
10** 1 780-907 Assembly, Crosshead 4000-2 Stage
11 1 118-934 Base 3000/4000-2 Stage
12 2 103-304 Rod, Guide 3000/4000-2 Stage
13 2 011-520 Nut, Hex - 1/2"-20 3000/4000-2 Stage
14 2 011-533 Nut, Hex 1/2"-20 Nylon Insert 3000/4000-2 Stage
15 2 012-230 Washer, Lock 3000/4000-2 Stage
16 2 019-011 Bearing, Roller 3000/4000-2 Stage
17 2 010-048 Capscrew, 1/2”-13 x 1-1/2” 3000/4000-2 Stage
18 2 012-220 Washer, Lock -1/2" 3000/4000-2 Stage
19 1 010-012 Capscrew, Hex Hd. - 3/8”-16 x 3/4" 3000/4000-2 Stage
20 1 012-201 Washer, Lock - 3/8” Helical 3000/4000-2 Stage

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Issue Date: 07/23/04 Page 35

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CS 15/20 SM-630A

12.3.1 Lift Cylinder Assembly - Two Stage

Figure 13 : Lift Cylinder Assembly - 118", 130", 150" Lift Height

Page 36 Issue Date: 07/23/04

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CS 15/20 SM-630A

Lift Cylinder Assembly - Two Stage

Item Qty Part No General Description Specific Description

◄ - 101-5003-2 Assembly, Cylinder - 2-1/2” Dia. 3000/4000-118” LH
- - 101-5003-3 Assembly, Cylinder - 2-1/2” Dia. 3000/4000-130” LH
- - 101-5003-4 Assembly, Cylinder - 2-1/2” Dia. 3000/4000-150” LH
1 1 101-0003-2 Ram, 2” Dia. x 67-3/4” LG. 3000/4000-118” LH
1 1 101-0003-3 Ram, 2” Dia. x 72-3/4”” LG. 3000/4000-130” LH
1 1 101-0003-4 Ram, 2” Dia. x 82-3/4”” LG. 3000/4000-150” LH
2 1 101-5000-2 Weldment, Housing 2-1/2” Dia 3000/4000-118” LH
2 1 101-5000-3 Weldment, Housing 2-1/2” Dia 3000/4000-130” LH
2 1 101-5000-4 Weldment, Housing 2-1/2” Dia 3000/4000-150” LH
3 1 118-362 Nut, Head 3000/4000-2 Stage
4 1 114-977 Washer, Piston 2-1/2” Dia 3000/4000-2 Stage
5 1 113-629 Piston, 2-1/2” Dia (USE 788-599) 3000/4000-2 Stage
●6 1 036-153 Ring, Wear 3000/4000-2 Stage
●7 1 036-150 Ring, Wear 3000/4000-2 Stage
●8 1 036-133 “O”-Ring 3000/4000-2 Stage
●9 1 036-119 “U”-Cup 3000/4000-2 Stage
●10 1 036-108 “O”-Ring 3000/4000-2 Stage
●11 1 036-021 Wiper, Rod 3000/4000-2 Stage
●12 1 117-993 Gasket 3000/4000-2 Stage
13 1 011-530 Nut, Jam 3/4”-10 3000/4000-2 Stage
●14 1 036-176 “O”-Ring 3000/4000-2 Stage
15 1 101-0005 Spacer, Tube 2” LG. 3000/4000-2 Stage
- 1 783-550 Kit, Seal - Includes Items marked (●) 3000/4000-2 Stage

Issue Date: 07/23/04 Page 37

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CS 15/20 SM-630A

12.3.2 Chain Assembly - 2 Stage

Figure 14 : Chain Assembly - 118", 130", 150" Lift Height

Item Qty Part No General Description Specific Description

◄ - 103-5031-3 Assembly, Chain - 71.5” LG. 3000-118” Lift Height
- - 103-5031-4 Assembly, Chain - 76.5” LG. 3000-130” Lift Height
- - 103-5031-5 Assembly, Chain - 86.5” LG. 3000-150” Lift Height
- - 103-5030-7 Assembly, Chain - 70.5” LG. 4000-118” Lift Height
- - 103-5030-8 Assembly, Chain - 75.5” LG. 4000-130” Lift Height
- - 103-5030-9 Assembly, Chain - 85.5” LG. 4000-150” Lift Height
1 1 090-066-0714 Leaf, Chain - 71-1/2” LG. 3000-118” Lift Height
1 1 090-066-0764 Leaf, Chain - 76-1/2” LG. 3000-130” Lift Height
1 1 090-066-0864 Leaf, Chain - 86-1/2” LG. 3000-150” Lift Height
1 1 090-067-0704 Leaf, Chain - 70-1/2” LG. 4000-118” Lift Height
1 1 090-067-0754 Leaf, Chain - 75-1/2” LG. 4000-130” Lift Height
1 1 090-067-0854 Leaf, Chain - 85-1/2” LG. 4000-150” Lift Height
2 2 104-532 Clevis 3000/4000 - 2 Stage
3 2 105-372 Pin, Clevis 0.2”OD x 1-1/4” LG. 3000/4000 - 2 Stage
4 2 013-015 Pin, Cotter - 1/16” x 3/4" 3000/4000 - 2 Stage
5 2 011-535 Nut, Hex 3/4”-10 Nylon Insert 3000/4000 - 2 Stage

Page 38 Issue Date: 07/23/04

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CS 15/20 SM-630A

12.3.3 Crosshead Assembly - 2 Stage

Figure 15 : Crosshead Assembly - 118", 130", 150" Lift Height

Item Qty Part No General Description Specific Description

◄ - 780-906 Assembly, Crosshead 3000
- - 780-907 Assembly, Crosshead 4000
1 1 786-472 Weldment, Crosshead 3000/4000 - 2 Stage
2 2 781-318 Ass’y, Chain Roller - 5/8"ID 3000 - 2 Stage
2* 2 792-306 Ass’y, Chain Roller - 7/8”ID x 1-1/4”OD 4000 - 2 Stage
3 2 120-744 Roller, Chain - 5/8" 3000 - 2 Stage
3 2 100-019 Roller, Chain - 7/8" 4000 - 2 Stage
4 2 018-027 Bushing 3000/4000 - 2 Stage
5 1 103-250 Pin, Crosshead 3000/4000 - 2 Stage
6 6 114-336 Washer, Flat Spacer 3000/4000 - 2 Stage
7 2 013-036 Ring, Retaining Ext. 3000/4000 - 2 Stage
8 1 014-005 Screw, Set Socket - 3/8”-16 x 3/8” 3000/4000 - 2 Stage

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Issue Date: 07/23/04 Page 39

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CS 15/20 SM-630A

12.4 Mast and Carriage Assembly - 2 Stage Full Free

Figure 16 : Full Free Mast and Carriage Assembly - 130", 150" Lift Height

Page 40 Issue Date: 07/23/04

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CS 15/20 SM-630A

Mast and Carriage Assembly - 2 Stage 130,150" Full Free

Item Qty Part No General Description Specific Description

◄ - 103-5027-2 Ass’y, Mast and Carriage - 2stg FF 3000/4000-130” FF
- - 103-5027-3 Ass’y, Mast and Carriage - 2stg FF 3000/4000-150” FF
1 1 103-5039-1 Mast, Outer Weld (130"Lh) 2stg FF 3000/4000-130” FF
1 1 103-5039-2 Mast, Outer Weld (150"Lh) 2stg FF 3000/4000-150” FF
2 1 103-5043-4 Mast, Inner Weld (130") 2stg FF 3000/4000-130” FF
2 1 103-5043-5 Mast, Inner Weld (150") 2stg FF 3000/4000-150” FF
3** 1 133-5004-1 Carriage Ass'y & Weldment 3000/4000-130,150” FF
4 4 019-011 Bearing, Roller 3000/4000-130,150” FF
5* 2 103-5045 Ass’y, Roller - Side Thrust 3000/4000-130,150” FF
6 2 103-0022 Roller, 2” Dia. - Side Thrust 3000/4000-130,150” FF
7 2 018-006 Bushing 3000/4000-130,150” FF
8** 1 783-199-1 Cylinder Ass'y 130/172/180"LH 3000/4000-130” FF
8** 1 783-199-2 Cylinder Ass'y 150" - 38-5/8" STR. 3000/4000-150” FF
Cylinder Ass'y 1-1/2"Dia 62-1/2"Str
9** 2 780-275 3000/4000-130” FF
Outbrd 2 Stg FF
Cylinder Ass'y 1-1/2"Dia 72-1/2"Str
9** 2 780-275-1 3000/4000-150” FF
Outbrd 2 Stg FF
10** 2 103-5030-10 Chain Ass'y 44.5" Long 3000/4000-130” FF
10** 2 103-5030-11 Chain Ass'y 50.5" Long 3000/4000-150” FF
11** 1 783-090 Crosshead Ass'y (1&2stg) 3000/4000-130,150” FF
12 4 019-011 Bearing, Roller 3000/4000-130,150” FF
13 1 143-0136 Pawl Hook (PRIOR TO 2002) 3000/4000-130,150” FF
14 2 118-940 Cylinder Bracket - Outer 3000/4000-130,150” FF
15 1 143-5116 Pawl Bracket (PRIOR TO 2002) 3000/4000-130,150” FF
16* 1 200-00799 Carriage Latch Ass'y 3000/4000-130,150” FF
17 1 200-00802 Carriage Latch 3000/4000-130,150” FF
18 1 018-571 Bushing 3000/4000-130,150” FF
19 7 010-036 Capscrew, Hex Hd. 5/16"-18 x 1/2" 3000/4000-130,150” FF
20 7 012-200 Washer, Lock - 5/16" Helical 3000/4000-130,150” FF
21 4 010-048 Capscrew, Hex Hd. - 1/2"-13 x 1 1/2" 3000/4000-130,150” FF
22 4 012-220 Washer, Lock - 1/2" Split Reg. 3000/4000-130,150” FF
23 1 012-238 Washer, Spacer -1/2"ID x 1"OD x 5/64"THK 3000/4000-130,150” FF
24 2 011-577 Screw, Shoulder - 1/2" x 1/2" 3/8"-16 Thrd. 3000/4000-130,150” FF
25 2 035-204 Clamp 3000/4000-130,150” FF
26 2 010-000 Capscrew, Hex Hd. - 1/4"-20 x 3/4" 3000/4000-130,150” FF
27 2 012-210 Washer, Flat - 1/4" Bolt S 3000/4000-130,150” FF
28 2 012-202 Washer, Lock - 1/4" Helical 3000/4000-130,150” FF
29 3 013-066 Pin, Spring - 5/32" x 1-1/4" 3000/4000-130,150” FF
30 2 104-146 Block, Stop 3000/4000-130,150” FF
31 4 011-049 Capscrew, Hex Sckt F/H - 1/2"-13 x 1" 3000/4000-130,150” FF

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** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE

Issue Date: 07/23/04 Page 41

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Do not sell or distribute
CS 15/20 SM-630A

12.4.1 Lift Cylinder Assembly - 2 Stage 130, 150" Fu ll Free

Figure 17 : Lift Cylinder Assembly - 130", 150" Lift Height, Full Free Mast

Page 42 Issue Date: 07/23/04

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Do not sell or distribute
CS 15/20 SM-630A

Lift Cylinder Assembly - 2 Stage 130, 150" Full Free

Item Qty Part No General Description Specific Description

◄ - 783-199-1 Cylinder Ass'y 130/172/180"LH - FF 3000/4000-130" FF
- - 783-199-2 Cylinder Ass'y 150" - 38-5/8" STR. 3000/4000-150” FF
1 1 118-948 Ram (1-1/2"Dia) 41-7/8"Lg 3000 - 130 Full Free
1 1 118-948-1 Ram (1-1/2"Dia) 46-7/8"Lg 3000 - 150 Full Free
2 1 783-103-1 Weldment, Housing (3"ID) 3000 - 130 Full Free
2 1 783-103-2 Weldment, Housing (3"ID) 3000 - 150 Full Free
3 1 118-389 Nut, Head - 3" Dia. Cyl (1-1/2" Dia.Rod) 3000/4000-130,150 FF
4 1 114-978 Washer, Piston 3000/4000-130,150 FF
5 1 114-640 Piston - 3"Dia Cyl (2.9670+-.0020dia) 3000/4000-130,150 FF
6● 1 036-154 Ring, Wear Piston – 3” x 1/2" 3000/4000-130,150 FF
7● 1 036-143 Ring, Rod Wear 3000/4000-130,150 FF
8● 1 036-132 O-Ring 3"OD x 2-3/4"ID 3000/4000-130,150 FF
9● 1 036-112 U-Cup 3” x 2-3/8” x 1/2" 3000/4000-130,150 FF
10● 1 036-108 O-Ring - 3/4"OD x 5/8"ID x 1/16" 3000/4000-130,150 FF
11● 1 036-098 Wiper, 1-3/4” OD x 1-1/2” 3000/4000-130,150 FF
12● 1 117-993 Gasket 3000/4000-130,150 FF
13 1 011-530 Nut, Hex Jam Plated - 3/4"-10 3000/4000-130,150 FF
14● 1 036-180 O-Ring 3000/4000-130,150 FF
15 1 090-779-0024 Tube, Seaml. (2-1/2"Lg) 3000/4000-130,150 FF
- - 783-536 Kit, Seal - Includes Items marked (●) 3000/4000-130,150 FF

Issue Date: 07/23/04 Page 43

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CS 15/20 SM-630A

12.4.2 Outboard Cylinder Assembly - 2 Stage 130, 150" Full Free

Figure 18 : Outboard Lift Cylinder Assembly - 130", 150" Lift Height, Full Free Mast

Page 44 Issue Date: 07/23/04

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Do not sell or distribute
CS 15/20 SM-630A

Outboard Cylinder Assembly - 2 Stage 130, 150" Full Free

Item Qty Part No General Description Specific Description

◄ - 780-275 Cylinder Ass'y Outbrd 1-1/2"Dia. 2 Stg FF 3000/4000 - 130 FF
- - 780-275-1 Cylinder Ass'y Outbrd 1-1/2"Dia 2 Stg FF 3000/4000 - 150 FF
1 1 118-960 Ram, (1-1/4"Dia) Outboard 3000/4000 - 130 FF
1 1 118-960-1 Ram, (1-1/4"Dia) Outboard 3000/4000 - 150 FF
2 1 783-198 Weldment, Housing Weld (1.5"Dia) Outbrd 3000/4000 - 130 FF
2 1 783-198-1 Weldment, Housing Weld (1.5"Dia) Outbrd 3000/4000 - 150 FF
3 1 118-969 Nut, Head - (2-3/8"Dia.) 3000/4000-130,150 FF
4 1 105-880 Washer, Spacer - 3/4" x 1-3/16” x 1/8” 3000/4000-130,150 FF
5 1 118-968 Piston - F.F. Lift 3000/4000-130,150 FF
6● 2 036-192 Ring, Wear - 1-1/2"OD x 1-1/8"ID x 1/2"W 3000/4000-130,150 FF
7● 1 036-135 O-Ring - 1.25 x 1.5 x .139 3000/4000-130,150 FF
8● 1 036-180 O-Ring (Reciprocating) 3000/4000-130,150 FF
9● 1 036-158 U-Cup - 1"ID x 1-1/2”OD x 3/8” 3000/4000-130,150 FF
10● 1 036-108 O-Ring - 3/4"OD x 5/8"ID x 1/16" 3000/4000-130,150 FF
11● 1 036-018 Wiper, Rod - Polyurethane AN-13 1-1/4” ID 3000/4000-130,150 FF
12 1 034-515 Fitting,90° Elbow -1/4" Pipe Trd 3000/4000-130,150 FF
13● 1 118-368 Gasket - 2" Dia Cyl 3000/4000-130,150 FF
14 1 011-530 Nut, Hex Jam - 3/4"-10 3000/4000-130,150 FF
- - 783-173 Kit, Seal - Includes Items marked (●) 3000/4000-130,150 FF

Issue Date: 07/23/04 Page 45

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CS 15/20 SM-630A

12.4.3 Chain Assembly - 2 Stage 130, 150" Lift Height

Figure 19 : Chain Assembly - 130", 150" Lift Height, Full Free Mast

Item Qty Part No General Description Specific Description

◄ - 103-5030-10 Chain Ass'y 44.5" Long 3000/4000-130 FF
- - 103-5030-11 Chain Ass'y 50.5" Long 3000/4000-150 FF
1 1 090-067-0444 Chain Leaf (44-1/2"Lg) 3000/4000-130 FF
1 1 090-067-0504 Chain Leaf (50-1/2"Lg) 3000/4000-150 FF
2 2 104-532 Clevis 3000/4000-130,150 FF
3 2 105-372 Clevis Pin 0.2"O.D. x 1-1/4"Lg 3000/4000-130,150 FF
4 2 013-015 Cotter Pin - 1/16" x 3/4" 3000/4000-130,150 FF
5 2 011-535 Nut, Hex - 3/4"-10 Nylon Insert 3000/4000-130,150 FF

Page 46 Issue Date: 07/23/04

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CS 15/20 SM-630A

12.4.4 Crosshead Assembly - 2 Stage 130, 150" Lift Height

Figure 20 : Crosshead Assembly - 130", 150" Lift Height, Full Free Mast

Item Qty Part No General Description Specific Description

◄ - 783-090 Crosshead Ass'y (1&2stg) Ff 3000/4000-130,150 FF
1 1 783-088 Weldment, Crosshead 2 Stage F.F. Mast 3000/4000-130,150 FF
2* 2 792-306 Roller, Chain 3000/4000-130,150 FF
3 1 100-019 Roller, Chain - 7/8"ID x 1-1/4"OD 3000/4000-130,150 FF
4 1 018-027 Bushing 3000/4000-130,150 FF
5 1 103-250 Pin, Crosshead 3000/4000-130,150 FF
6 6 114-336 Washer, Flat Spacer 3000/4000-130,150 FF
7 2 013-036 Ring, Retaining Ext. - 1-1/4"ID 3000/4000-130,150 FF
8 1 014-005 Setscrew, Socket Cup Point - 3/8"-16 x 3/8" 3000/4000-130,150 FF
9 2 105-882 Washer, Spacer - 1-3/4" Dia 3000/4000-130,150 FF

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** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE

Issue Date: 07/23/04 Page 47

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Do not sell or distribute
CS 15/20 SM-630A

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

Figure 21 : Mast and Carriage Assembly - 160", 180" Lift Height

Page 48 Issue Date: 07/23/04

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Do not sell or distribute
CS 15/20 SM-630A

Mast and Carriage Assembly - 3 Stage 160. 180 " Lift Height

Item Qty Part No General Description Specific Description

◄ - 103-5035 Mast and Carriage Assembly - 3 Stage 3000-160”
- - 103-5035-2 Mast and Carriage Assembly - 3 Stage 3000-180” Lift Height
- - 103-5035-1 Mast and Carriage Assembly - 3 Stage 4000-160” Lift Height
- - 103-5035-3 Mast and Carriage Assembly - 3 Stage 4000-180” Lift Height
- - 103-5035-5 Mast and Carriage Assembly - 3 Stage 4000-200” Lift Height
1 1 103-5022 Weldment, Mast Outer 3000/4000-160”
1 1 103-5022-1 Weldment, Mast Outer 3000/4000-180”
1 1 103-5022-2 Weldment, Mast Outer 4000-200”
2 1 103-5014-1 Weldment, Mast Center 3000-160”
2 1 103-5014-4 Weldment, Mast Center 3000-180”
2 1 103-5014-2 Weldment, Mast Center 4000-160”
2 1 103-5014-5 Weldment, Mast Center 4000-180”
2 1 103-5014-8 Weldment, Mast Center 4000-200”
3 1 103-5029 Weldment, Mast Inner 3000/4000-160”
3 1 103-5029-1 Weldment, Mast Inner 3000/4000-180”
3 1 103-5029-2 Weldment, Mast Inner 4000-200”
4* 1 133-5001 Assembly, Carriage Weld’t 3000/4000
5 4 019-011 Bearing, Roller 3000/4000 - 3 Stage
6* 2 103-5045 Ass’y, Roller - Side Thrust 3000/4000 - 3 Stage
7 2 103-0022 Roller, 2” Dia. - Side Thrust 3000/4000 - 3 Stage
8 2 018-006 Bushing 3000/4000 - 3 Stage
9 1 010-012 Capscrew, Hex Hd. - 3/8”-16 x 3/4" 3000/4000 - 3 Stage
10 1 118-611 Stop - Outer Mast 3000/4000 - 3 Stage
11 1 118-674 Bar, Stop (7” x 3/4") 3000/4000 - 3 Stage
12 3 012-201 Washer, Lock - 3/8” Helical 3000/4000 - 3 Stage
13 2 010-040 Capscrew, Hex Hd. 3/8” x 1-1/2” 3000/4000 - 3 Stage
14 2 120-845 Pin, Crosshead 3000/4000 - 3 Stage
15 2 012-220 Washer, Lock - 1/2" 3000/4000 - 3 Stage
16 2 010-044 Capscrew, Hex Hd. - 1/2"-13 x 2” 3000/4000 - 3 Stage
17 2 014-002 Screw, Set - 1/4” x 3/8” 3000/4000 - 3 Stage
18 8 019-011 Bearing, Roller 3000/4000 - 3 Stage
19** 1 101-5004-5 Assembly, Cylinder - 3” Dia. 3000-160”
19** 1 101-5004-7 Assembly, Cylinder - 3” Dia. 3000-180”
19** 1 101-5005 Assembly, Cylinder - 3-1/2” Dia. 4000-160”
19** 1 101-5005-2 Assembly, Cylinder - 3-1/2” Dia. 4000-180”
19** 1 101-5005-3 Assembly, Cylinder - 3-1/2” Dia. 4000-200”
20** 2 103-5030 Assembly, Chain - 71.5” LG. 3000/4000-160”
20** 2 103-5030-1 Assembly, Chain - 76.5” LG. 3000/4000-180”
20** 2 103-5030-2 Assembly, Chain - 84.5” LG. 4000-200”
21** 2 103-5030-3 Assembly, Chain - 132.5” LG. 3000/4000-160”
21** 2 103-5030-4 Assembly, Chain - 142.5” LG. 3000/4000-180”
21** 2 103-5030-21 Assembly, Chain - 155.5” LG. 4000-200”
22** 1 781-174 Assembly, Crosshead 3000-160, 180”
22** 1 781-175 Assembly, Crosshead 4000-160, 180, 200”
23 2 103-304 Rod, Guide 3000/4000 - 3 Stage
24 2 011-520 Nut, Hex 1/2"-20 3000/4000 - 3 Stage

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** - SUBASSEMBLY SHOWN OWN SEPARATE PAGE

Continued…

Issue Date: 07/23/04 Page 49

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CS 15/20 SM-630A

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

Figure 21 : Mast and Carriage Assembly - 160", 180", 200" Lift Height

Page 50 Issue Date: 07/23/04

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Intended for CLARK dealers only
Do not sell or distribute
CS 15/20 SM-630A

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

Item Qty Part No General Description Specific Description

25 2 011-533 Nut, Hex 1/2”-20 Nylon Insert 3000/4000 - 3 Stage
26 2 012-212 Washer, Flat - 1/2" 3000/4000 - 3 Stage
27 2 792-306 Roller, Chain (7/8”ID x 1-1/4”OD) 3000/4000 - 3 Stage
28 2 114-336 Washer, Flat Spacer 3000/4000 - 3 Stage
29 2 013-036 Ring, Retaining - 1-1/4”ID 3000/4000 - 3 Stage
30 2 035-204 Clamp 3000/4000 - 3 Stage
31 2 012-210 Washer, Flat - 1/4" 3000/4000 - 3 Stage
32 2 012-202 Washer, Lock - 1/4" Helical 3000/4000 - 3 Stage
33 2 010-000 Capscrew, Hex Hd. - 1/4"-20 x 3/4" 3000/4000 - 3 Stage
34 2 013-066 Pin, Spring 5/32” x 1-1/4” 3000/4000 - 3 Stage

Issue Date: 07/23/04 Page 51

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CS 15/20 SM-630A

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

Figure 22 : Lift Cylinder Assembly - 160", 180", 200" Lift Height

Page 52 Issue Date: 07/23/04

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Intended for CLARK dealers only
Do not sell or distribute
CS 15/20 SM-630A

Cylinder Assembly - 3 Stage 160, 180" Lift Height

Item Qty Part No General Description Specific Description

◄ - 101-5004-5 Assembly, Cylinder - 3” Dia. 3000-160”
- - 101-5004-7 Assembly, Cylinder - 3” Dia. 3000-180”
- - 101-5005 Assembly, Cylinder - 3-1/2” Dia. 4000-160”
- - 101-5005-2 Assembly, Cylinder - 3-1/2” Dia. 4000-180”
- - 101-5005-3 Assembly, Cylinder - 3-1/2” Dia. 4000-200”
1 1 101-0003-5 Ram, 2” Dia. x 66-5/16” LG. 3000-160”
1 1 101-0003-6 Ram, 2” Dia. x 71-5/16” LG. 3000-180”
1 1 101-0004 Ram, 2-1/2” Dia. x 66-5/16” LG. 4000-160”
1 1 101-0004-1 Ram, 2-1/2” Dia. x 71-5/16” LG. 4000-180”
1 1 101-0004-2 Ram, 2-1/2” Dia. x 77-3/4” LG. 4000-200”
2 1 101-5001-5 Weldment, Housing - 3”ID 3000-160”
2 1 101-5001-6 Weldment, Housing - 3”ID 3000-180”
2 1 101-5002 Weldment, Housing - 3-1/2”ID 4000-160”
2 1 101-5002-1 Weldment, Housing - 3-1/2”ID 4000-180”
2 1 101-5002-2 Weldment, Housing - 3-1/2”ID 4000-200”
3 1 117-991 Nut, Head - 3” ID Cyl. 3000 - 3 Stage
3 1 118-711 Nut, Head - 3-1/2” ID Cyl. 4000 - 3 Stage
4 1 114-978 Washer, Piston 3000 - 3 Stage
4 1 114-979 Washer, Piston - 3-1/2” 4000 - 3 Stage
5 1 114-640 Piston, 3” Dia. 3000 - 3 Stage
5 1 114-639 Piston, 3-1/2” Dia. 4000 - 3 Stage
●6 1 036-154 Ring, Wear 3000 - 3 Stage
●6 1 036-155 Ring, Wear 4000 - 3 Stage
●7 1 036-182 Ring, Wear 3000 - 3 Stage
●7 1 036-154 Ring, Wear 4000 - 3 Stage
●8 1 036-132 “O”-Ring 3000 - 3 Stage
●8 1 036-131 “O”-Ring 4000 - 3 Stage
●9 1 036-112 “U”-Cup 3000 - 3 Stage
●9 1 036-111 “U”-Cup 4000 - 3 Stage
●10 1 036-108 “O”-Ring 3000/4000 - 3 Stage
●11 1 036-021 Wiper. Rod 3000 - 3 Stage
●11 1 036-023 Wiper. Rod 4000 - 3 Stage
●12 1 036-176 “O”-Ring 3000 - 3 Stage
●12 1 036-190 “O”-Ring 4000 - 3 Stage
●13 1 117-993 Gasket 3000/4000 - 3 Stage
14 1 011-530 Nut, Jam - 3/4"-10 3000/4000 - 3 Stage
15 1 101-0005-4 Spacer, Tube 4-3/4” LG. 3000-160”
15 1 101-0003-6 Spacer, Tube 2-7/16” LG. 3000-180”
15 1 101-0006-3 Spacer, Tube 4-3/4” LG. 4000-160”
15 1 101-0006-1 Spacer, Tube 4-1/2” LG. 4000-180”
15 1 101-0006 Spacer, Tube 2-7/16” LG. 4000-200”
- - 783-553 Kit, Seal - Includes Items marked (●) 3000 - 3 Stage
- - 780-843 Kit, Seal - Includes Items marked (●) 4000 - 3 Stage

Issue Date: 07/23/04 Page 53

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Intended for CLARK dealers only
Do not sell or distribute
CS 15/20 SM-630A

12.5.2 Chain Assembly - 3 Stage 160, 180" Lift Height

Figure 23 : Chain Assembly - 160", 180", 200"Lift Height

Item Qty Part No General Description Specific Description

◄ - 103-5030 Assembly, Chain - 71.5” LG. 3000/4000-160”
- - 103-5030-1 Assembly, Chain - 76.5” LG. 3000/4000-180”
- - 103-5030-2 Assembly, Chain - 84.5” LG. 4000-200”
- - 103-5030-3 Assembly, Chain - 132.5” LG. 3000/4000-160”
- - 103-5030-4 Assembly, Chain - 142.5” LG. 3000/4000-180”
- - 103-5030-21 Assembly, Chain - 155.5” LG. 4000-200”
1 1 090-067-0714 Leaf, Chain - 71-1/2” LG. 3000/4000-160”
1 1 090-067-0764 Leaf, Chain - 76-1/2” LG. 3000/4000-180”
1 1 090-067-0844 Leaf, Chain - 84-1/2” LG. 4000-200”
1 1 090-067-1324 Leaf, Chain - 132-1/2” LG. 3000/4000-160”
1 1 090-067-1424 Leaf, Chain - 142-1/2” LG. 3000/4000-180”
1 1 090-067-1554 Leaf, Chain - 155-1/2” LG. 4000-200”
2 2 104-532 Clevis 3000/4000-160,180,200”
3 2 105-372 Pin, Clevis 0.2”OD x 1-1/4” LG, 3000/4000-160,180,200”
4 2 013-015 Pin, Cotter - 1/16” x 3/4" 3000/4000-160,180,200”
5 2 011-535 Nut, Hex - 3/4”-10 Nylon Insert 3000/4000-160,180,200”

Page 54 Issue Date: 07/23/04

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Do not sell or distribute
CS 15/20 SM-630A

12.5.3 Crosshead Assembly - 3 Stage 160, 180" Lift

Figure 24 : Crosshead Assembly - 160", 180", 200" Lift Height

Item Qty Part No General Description Specific Description

◄ - 781-174 Assembly, Crosshead 3000-160, 180”
- - 781-175 Assembly, Crosshead 4000-160, 180, 200”
1 1 781-177 Weldment, Crosshead 3000-160, 180”
1 1 781-178 Weldment, Crosshead 4000-160, 180, 200”
2* 2 792-306 Assembly, Roller, Chain c/w Bushing 3000/4000-160,180,200”
3 1 100-019 Chain Roller (7/8"ID x 1-1/4"OD) 3000/4000-160,180,200”
4 1 018-027 Bushing 3000/4000-160,180,200”
5 1 103-250 Pin, Crosshead 3000/4000-160,180,200”
6 6 114-336 Washer, Flat Spacer 3000/4000-160,180,200”
7 2 013-036 Ring, Retaining Ext. 1-1/4"ID 3000/4000-160,180,200”
8 1 014-005 Setscrew, Socket 3/8”-16 X 3/8" 3000/4000-160,180,200”

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Issue Date: 07/23/04 Page 55

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CS 15/20 SM-630A

12.6 Mast and Carriage Assembly - 3 Stage 172" Lift Full Free

Figure 25 : Full Free Mast and Carriage Assembly - 172" Lift Height

Page 56 Issue Date: 07/23/04

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CS 15/20 SM-630A

Mast and Carriage Assembly - 3 Stage 172" Lift Full Free

Item Qty Part No General Description Specific Description

Mast and Carriage Assembly – 3 Stage
◄ - 143-5049 3000/4000 -172” FF
Full Free
1* 1 133-5002 Weldment, Carriage 3000/4000 -172” FF
2 4 019-011 Bearing, Roller 3000/4000 -172” FF
3* 2 103-5045 Ass’y, Roller - Side Thrust 3000/4000 -172” FF
4 2 103-0022 Roller, 2” Dia. - Side Thrust 3000/4000 -172” FF
5 2 018-006 Bushing 3000/4000 -172” FF
6 1 143-5039 Mast, Outer Weldment 172" Lift 3000/4000 -172” FF
7 1 103-5036 Mast, Center Weldment 3000/4000 -172” FF
8 1 103-5047 Mast, Inner Weldment 3000/4000 -172” FF
9** 2 103-5030-10 Ass'y, Chain - 44.5" LG 3000/4000 -172” FF
10** 2 103-5030-15 Ass'y, Chain - 73.5"LG 3000/4000 -172” FF
11** 1 781-133 Ass'y, Crosshead 3000/4000 -172” FF
12** 1 783-199-1 Ass'y, Cylinder 130/172/180"Lh 3000/4000 -172” FF
13** 2 780-272 Ass'y, Cylinder (2"Dia) Outbrd 56-1/4"Str. 3000/4000 -172” FF
14 4 010-048 Capscrew, Hex Hd. 1/2”-13 x 1-1/2" 3000/4000 -172” FF
15 4 012-220 Washer, Lock 1/2" 3000/4000 -172” FF
16 1 121-626 Hook, Pawl (1-1/4"x1"x4") 3000/4000 -172” FF
17 1 011-577 Screw, Shoulder 1/2" x 1/2" 3/8”-16 Thread 3000/4000 -172” FF
18 1 012-239 Washer, Spacer - 1/2"ID x 1"OD x 1/8" THK 3000/4000 -172” FF
19 1 012-238 Washer, Spacer -1/2"ID x 1"OD x 5/64”THK. 3000/4000 -172” FF
20 1 781-575 Pawl 3000/4000 -172” FF
21 1 120-884 Pin 3000/4000 -172” FF
22 2 013-117 Pin 1/4"Dia X 1-3/4” LG 3000/4000 -172” FF
23 1 121-339 Pin (Threaded) 3000/4000 -172” FF
24* 2 792-306 Ass'y, Chain Roller (7/8"ID 1-1/4"OD) 3000/4000 -172” FF
25 1 100-019 Roller, Chain (7/8") 3000/4000 -172” FF
26 1 018-027 Bushing 3000/4000 -172” FF
Washer, Flat 1-1/4"ID x 2-1/2"OD x 1/16"
27 4 012-286 3000/4000 -172” FF
Brass
28* 1 780-192 Ass'y, Hose Roller 3000/4000 -172” FF
29 1 120-885 Roller, Hose 3000/4000 -172” FF
30 1 018-623 Bushing, 1/2"ID x 5/8" 3000/4000 -172” FF
Capscrew, Shoulder Hex Socket Head
31 1 011-585 3000/4000 -172” FF
1/2"x1-1/4”- 3/8”-16
32 7 010-036 Capscrew, Hex Hd. - 5/16”-18 x 1/2" 3000/4000 -172” FF
33 7 012-200 Washer, Lock - 5/16" Helical 3000/4000 -172” FF
34 8 019-011 Bearing, Roller 3000/4000 -172” FF
35 1 012-274 Washer, 1-1/2” OD x .540” ID 3000/4000 -172” FF
36 2 121-024 Bracket, Cylinder 3000/4000 -172” FF

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12.6.1 Chain Assembly - 3 Stage 172" Lift Full Free

Figure 26 : Full Free Mast and Carriage Assembly - 172" Lift Height

Item Qty Part No General Description Specific Description

◄ 103-5030-10 Ass'y, Chain - 44.5" LG 3000/4000 -172” FF
1 1 090-067-0444 Leaf, Chain - 44-1/2” 3000/4000 -172” FF
2 2 104-532 Clevis 3000/4000 -172” FF
3 2 105-372 Pin, Clevis 0.2”OD x 1-1/4” LG, 3000/4000 -172” FF
4 2 013-015 Pin, Cotter - 1/16” x 3/4" 3000/4000 -172” FF
5 2 011-535 Nut, Hex - 3/4”-10 Nylon Insert 3000/4000 -172” FF

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CS 15/20 SM-630A

12.6.2 Chain Assembly - 3 Stage 172" Lift Full Free

Figure 27 : Chain Assembly - 172" Lift Height

Item Qty Part No General Description Specific Description

◄ 103-5030-15 Ass'y, Chain - 73.5"LG 3000/4000 -172” FF
1 1 090-067-0734 Leaf, Chain - 73-1/2” 3000/4000 -172” FF
2 2 104-532 Clevis 3000/4000 -172” FF
3 2 105-372 Pin, Clevis 0.2”OD x 1-1/4” LG, 3000/4000 -172” FF
4 2 013-015 Pin, Cotter - 1/16” x 3/4" 3000/4000 -172” FF
5 2 011-535 Nut, Hex - 3/4”-10 Nylon Insert 3000/4000 -172” FF

Issue Date: 07/23/04 Page 59

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12.6.3 Crosshead Assembly - 3 Stage 172" Lift Full Free

Figure 28 : Full Free Mast and Carriage Assembly - 172" Lift Height

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Crosshead Assembly - 3 Stage 172" Lift Full Free

Item Qty Part No General Description Specific Description

◄ - 781-133 Ass'y, Crosshead 3000/4000 -172” FF
1* 1 781-082 Weldment, Crosshead 3000/4000 -172” FF
2 1 103-5055 Cylinder, Crosshead 3000/4000 -172” FF
3 1 103-5018 Weldment, Cam 3000/4000 -172” FF
4 2 010-036 Capscrew, Hex Hd. 5/16" - 18 x 1/2" 3000/4000 -172” FF
5 2 012-211 Washer, Flat - 5/16" 3000/4000 -172” FF
6 2 012-200 Washer, Lock - 5/16" 3000/4000 -172” FF
7* 2 781-318 Roller, Chain (7/8"ID 1-1/4"OD) 3000/4000 -172” FF
8 1 120-744 Roller 3000/4000 -172” FF
9 1 018-027 Bushing 3000/4000 -172” FF
10 1 103-250 Pin, Crosshead 3000/4000 -172” FF
11 6 114-336 Washer, Flat Spacer 3000/4000 -172” FF
12 2 013-036 Ring, Retaining Ext. 1-1/4"ID 3000/4000 -172” FF
13 1 014-005 Setscrew, Socket 3/8”-16 x 3/8" 3000/4000 -172” FF

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12.6.4 Lift Cylinder Assembly - 3 Stage 172" Lift Full Free

Figure 29 : Lift Cylinder Assembly - 172" Lift Height

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CS 15/20 SM-630A

Lift Cylinder Assembly - 3 Stage 172" Lift Full Free

Item Qty Part No General Description Specific Description

◄ - 783-199-1 Ass'y, Cylinder 130/172/180"Lh 3000/4000 -172” FF
1 1 118-948 Ram (1-1/2"Dia) 41-7/8"Lg 3000/4000 -172” FF
1 1 118-948-1 Ram (1-1/2"Dia) 46-7/8"Lg 3000/4000 -172” FF
2 1 783-103-1 Weldment, Housing (3"ID) 3000/4000 -172” FF
2 1 783-103-2 Weldment, Housing (3"ID) 3000/4000 -172” FF
3 1 118-389 Nut, Head - 3" Dia. Cyl (1-1/2" Dia.Rod) 3000/4000 -172” FF
4 1 114-978 Washer, Piston 3000/4000 -172” FF
5 1 114-640 Piston - 3"Dia Cyl (2.9670+-.0020 Dia) 3000/4000 -172” FF
6● 1 036-154 Ring, Wear Piston – 3” x 1/2" 3000/4000 -172” FF
7● 1 036-143 Ring, Rod Wear 3000/4000 -172” FF
8● 1 036-132 O-Ring 3"OD x 2-3/4"ID 3000/4000 -172” FF
9● 1 036-112 U-Cup 3” x 2-3/8” x 1/2" 3000/4000 -172” FF
10● 1 036-108 O-Ring - 3/4"OD x 5/8"ID X 1/16" 3000/4000 -172” FF
11● 1 036-098 Wiper, 1-3/4” OD x 1-1/2” 3000/4000 -172” FF
12● 1 117-993 Gasket 3000/4000 -172” FF
13 1 011-530 Nut, Hex Jam Plated - 3/4"-10 3000/4000 -172” FF
14● 1 036-180 O-Ring 3000/4000 -172” FF
15 1 090-779-0024 Tube, Seaml. (2-1/2"Lg) 3000/4000 -172” FF
- - 783-536 Kit, Seal - Includes Items marked (●) 3000/4000 -172” FF

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12.6.5 Outboard Cylinder Assembly - 3 Stage 172" Lift Full Free

Figure 30 : Outboard Lift Cylinder Assembly - 172" Lift Height

Page 64 Issue Date: 07/23/04

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Outboard Cylinder Assembly - 3 Stage 172" Lift Full Free

Item Qty Part No General Description Specific Description

Ass'y , Cylinder (2"Dia) Outbrd 56-
◄ - 780-272 3000/4000 -172” FF
1/4"Stroke
1 1 121-030 Ram, 1-1/2” Dia. x 56-1/4” LG. Outboard 3000/4000 -172” FF
2 1 780-875 Weldment, Housing - 2”ID Outboard 3000/4000 -172” FF
3 1 118-365 Nut, Head - 2” ID Cyl. 3000/4000 -172” FF
4 1 114-976 Washer, Piston 3000/4000 -172” FF
5 1 113-542 Piston 3000/4000 -172” FF
●6 1 036-152 Ring, Wear 3000/4000 -172” FF
●7 1 036-143 Ring, Wear 3000/4000 -172” FF
●8 1 036-134 “O”-Ring 3000/4000 -172” FF
●9 1 036-118 “U”-Cup 3000/4000 -172” FF
●10 1 036-108 “O”-Ring 3000/4000 -172” FF
●11 1 036-098 Wiper. Rod 3000/4000 -172” FF
12 1 034-515 Fitting, 1/4" - 90° Elbow 3000/4000 -172” FF
●13 1 118-368 Gasket 3000/4000 -172” FF
14 1 011-530 Nut, Hex 3/4”-10 3000/4000 -172” FF
●15 1 036-180 “O”-Ring 3000/4000 -172” FF
- - 783-536 Kit Seal - Includes Items marked (●) 3000/4000 -172” FF

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12.7 Left Straddle Assembly

2
5
4
2
7
6

8 3

8
4
9
5

Figure 31 : Left Straddle Assembly

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Left Straddle Assembly

Item Qty Part No General Description Specific Description

◄ - 142-5032 Left Straddle Assembly 3000/4000
1 1 142-5034 Left Straddle Weldment 3000/4000
2 2 106-180 Wheel Urethane 3000/4000
3 1 013-005 Spring Pin 5/32" x 1"Lg 3000/4000
4 2 142-0047 Axle Roller 3000/4000
5 4 018-500 Bearing 3000/4000
6 1 142-5036 Bogie Axle Roller Weldment 3000/4000
7 1 142-5037 Bogie Assembly 3000/4000
8 2 018-010 Bushing 3000/4000
9 1 019-500 Nipple, Grease 3000/4000

Issue Date: 07/23/04 Page 67

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12.8 Right Straddle Assembly

Figure 32 : Right Straddle Assembly

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CS 15/20 SM-630A

12.9 Right Straddle Assembly

Item Qty Part No General Description Specific Description

◄ - 142-5033 Right Straddle Assembly 3000/4000
1 1 142-5035 Right Straddle Weldment 3000/4000
2 2 106-180 Wheel Urethane 3000/4000
3 1 013-005 Spring Pin 5/32" x 1"Lg 3000/4000
4 2 142-0047 Axle Roller 3000/4000
5 4 018-500 Bearing 3000/4000
6 1 142-5036 Bogie Axle Roller Weldment 3000/4000
7 1 142-5037 Bogie Assembly 3000/4000
8 2 018-010 Bushing 3000/4000
9 1 019-500 Nipple, Grease 3000/4000

Issue Date: 07/23/04 Page 69

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12.10 Electric Drive Unit Assembly

Figure 33 : Electric Drive Unit Assembly

Page 70 Issue Date: 07/23/04

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CS 15/20 SM-630A

Electrical Sub-Assembly

Item Qty Part No General Description Specific Description

◄ - 145-5002 Electric Drive Unit Assembly 3000/4000
1 1 025-841 Contactor, High Speed & Pump 3000/4000
2 2 011-008 Screw, Machine R/H Slot #10-32 x 3/8" 3000/4000
3 2 012-225 Washer, Lock #10 Internal Tooth 3000/4000
4 3 010-006 Capscrew, Hex Hd. 5/16”-18 x 1" 3000/4000
5 3 012-200 Washer, Lock 5/16" Helical 3000/4000
6 3 012-211 Washer, Flat 5/16" Bolt Size 3000/4000
7 1 032-458 Horn, Electronic 12/24v 3000/4000
8** 1 144-5016 Drive Unit Ass'y - Electrical 3000/4000
9 1 025-977 Button, Emergency Stop 3000/4000
10 1 105-5000 Connector Ass'y 3000/4000
11 2 011-502 Nut, Hex 5/16”-18 3000/4000
12 2 010-002 Capscrew, Hex Hd. 1/4"-20 x 1-1/2" 3000/4000
13 5 012-202 Washer, Lock - 1/4" Helical 3000/4000
14 1 026-154 Fuse - 150 Amp 3000/4000
15 2 011-042 Capscrew, Hex Socket F/H 5/16”-18 x 1" 3000/4000
16 1 783-424 Holder, Power Fuse 3000/4000
17 4 010-037 Capscrew, Hex Hd. 5/16”-18 x 3/4" 3000/4000
18 4 011-507 Nut, Hex - 3/8”-16 3000/4000
19 4 012-201 Washer, Lock - 3/8"Dia.Helical 3000/4000
20 3 010-003 Capscrew, Hex Hd. - 1/4"-20 x 2" 3000/4000
21 1 012-210 Washer, Flat -1/4" 3000/4000
22 1 135-5010-2 Wire Assembly 3000/4000
23 1 135-5010-5 Wire Assembly 3000/4000
24 1 135-5010-1 Wire Assembly 3000/4000
25 1 135-5010-3 Wire Assembly 3000/4000
26** 1 144-5010 Kit-Wrg Rear Battery Box Plate 3000/4000
27 1 018-563 Bearing Cone 3000/4000
28 1 103-819-1 Plate, Cover 3000/4000
29 1 013-010 Pin. Spring - 1/4" x 1-1/4” 3000/4000
30 1 010-067 Capscrew, Hex Hd.- 3/4"-10 x 1-1/2" 3000/4000
31 1 012-233 Washer, Lock - 3/4" Internal Tooth 3000/4000
32 1 103-890 Clamp, Cable 3000/4000
33 1 105-137 Strip, Rubber 3000/4000
34 2 010-154 Capscrew, Hex Hd. - 1/4"-20 x 1-1/4" 3000/4000
35 2 012-202 Washer, Lock - 1/4" Helical 3000/4000
36 2 018-562 Bearing Cup 3000/4000
37 1 019-500 Nipple Straight Grease - 1/4" 3000/4000

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CS 15/20 SM-630A

12.11 Drive Unit Assembly - Electrical

Figure 34 : Drive Unit Assembly - Electrical

Page 72 Issue Date: 07/23/04

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CS 15/20 SM-630A

Drive Unit Assembly - Electrical

Item Qty Part No General Description Specific Description

◄ - 144-5016 Drive Unit Ass'y - Electrical 3000/4000
1 1 144-0015 Bracket, Switch Mntg 3000/4000
2 2 011-005 Screw, Machine R/H Slot #8-32 X 1/2" 3000/4000
3 2 012-205 Washer, Flat - #8 3000/4000
4 2 012-224 Washer, Lock - #8 Internal Tooth 3000/4000
5 1 025-535 Switch, Micro Dead-Man 3000/4000
6 2 011-003 Screw, Machine R/H Slot - #6-32 X 1" 3000/4000
7 2 012-204 Washer, Flat - #6 3000/4000
8 2 012-233 Washer, Lock - 3/4" Internal Tooth 3000/4000
9 2 011-514 Nut, Hex Machine Screw #6-32 3000/4000
10** 1 200-01482 Assy, Control Handle 3000/4000
11 1 200-01484 Handle Brkt. Cover 3000/4000
12 1 200-01478 Pivot Pin Assy. 3000/4000
13 1 010-000 Capscrew, Hex Hd. 1/4"-20 x 3/4" 3000/4000
14 1 012-202 Washer, Lock - 1/4" Helical 3000/4000
15** 1 135-5006 Panel, Controller Ass'y 3000/4000
16 2 010-012 Capscrew, Hex Hd. - 3/8”-16 x 3/4" 3000/4000
17 2 012-201 Washer, Lock - 3/8"Dia.Helical 3000/4000
18 2 105-137 Strip, Rubber 3000/4000
19 1 103-890 Clamp, Cable 3000/4000
20 2 011-017 Screw, Machine R/H Slot #10-24 x 1-1/2" 3000/4000
21 4 012-208 Washer, Flat - 3/16" 3000/4000
22 4 037-003 Grommet, Rubber - 3/16”x7/16”x1/4” 3000/4000
23 2 012-225 Washer, Lock - #10 Internal Tooth 3000/4000
24 2 011-500 Nut, Hex Machine Screw #10-24 3000/4000
25 1 037-021 Protector Terminal 3000/4000
26 1 164-0006 Pin, Cam Follower (1-1/2"LG) Brk Link Arr. 3000/4000
27 1 018-100 Bushing - 5/8"ID x 3/4"OD x 1" 3000/4000
28 2 013-033 Ring, Retain 3000/4000
29** 1 144-5017 Drive Unit Column Ass'y 3000/4000
30 1 30H21 Clamp, 3/8 X 1/2" Wide 3000/4000
31 1 011-005 Screw, Machine R/H Slot - #8-32 x 1/2" 3000/4000
32 1 012-204 Washer, Flat #6 3000/4000
33 1 164-7003 Harness, Wiring - Curtis Handle 3000/4000
34 1 200-01475 Bumper, Rubber 3000/4000
35 2 011-576 Screw, Machine Slot Rnd - #8-32 x 1-1/4" 3000/4000
36 2 011-515 Nut, Hex Machine Screw - #8-32 3000/4000

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12.11.1 Control Handle Assembly

14
15

13

Figure 35 : Control Handle Assembly

Page 74 Issue Date: 07/23/04

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Control Handle Assembly

Item Qty Part No General Description Specific Description

◄ - 200-01482 Assy, Control Handle 3000/4000
1 1 200-01476 Cam Machined 3000/4000
2 1 200-01483 Stem Handle Machined 3000/4000
3 2 012-245 Washer Spacer -1"ID x 1-3/4"OD x 1/8"THK 3000/4000
4 2 017-075 Spring, Torsion - 3/32”THK x 3-1/16”OD 3000/4000
5** 1 907-0105 Handle, Curtis 24 V Ch-12 Horn Only 3000/4000
6 4 012-200 Washer, Lock - 5/16" Helical 3000/4000
7 4 010-188 Capscrew Hex Hd - M8x16mm 3000/4000
8 1 234-5332 Switch-Key #31-613 3000/4000
9 1 200-00165 Plate, Handle Stem Cover 3000/4000
10 1 120-0001 Plate, Serial Number -Vertical 2-1/2" x 5" 3000/4000
11 4 011-000 Screw, Type U R/Hd Zinc #4 x 5/16 3000/4000
12 4 011-010 Screw, Machine R/H Slot #10-24 x 3/8" 3000/4000
13 1 200-01478 Assembly, Pivot Pin (Splined) 3000/4000
14 2 010-000 Capscrew, Hex 1/4" - 20 x 3/4" 3000/4000
15 2 012-202 Washer, Lock - 1/4" 3000/4000

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12.11.2 Control Handle Head Assembly

Figure 36 : Control Handle Head Assembly

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Control Handle Head Assembly

Item Qty Part No General Description Specific Description

◄ - 907-0105 Handle, Curtis 24 V Ch-12 Horn Only 3000/4000
1 1 907-0184 Cover-Plastic (1-Slot) 3000/4000
2 1 929-445 Button, Horn 3000/4000
3 2 929-446 Bracket, Spring Retaining 3000/4000
4 1 929-441 Bracket, Horn Switch 3000/4000
5 2 929-461 Thumbwheel, Butterfly Black 3000/4000
6 1 929-452 Throttle, Elect.(24 Volt) CH9 3000/4000
7 1 930-805 Bracket, Throttle Support 3000/4000
8 1 929-451 Housing 3000/4000
9 1 929-458 Bracket, E/R 3000/4000
10 2 929-455 Spring, E/R Button 3000/4000
11 1 929-457 Button, E/R 3000/4000
12 2 929-450 Grip 3000/4000
13 2 929-447 Spring, Horn Button 3000/4000
14 1 929-437 Switch, Horn 3000/4000
15 2 929-439 Screw, Switch Mtg #3 x 16 Pan Ph. Type B 3000/4000
16 5 929-453 Screw, #6 x 3/8” Pan Slot Type B 3000/4000
17 2 3GM-506 Capscrew, Hex Hd. #10-32x1/4” 3000/4000
18 1 929-462 Switch, E/R 3000/4000
19 2 1EM-50E Washer, E/R Bracket #10 Flt/W 3000/4000
20 2 929-456 Washer, Wide, #3x08 Thk .08 3000/4000
21 2 10E-M30 Washer, Star #4 Ext. Lock Wash 3000/4000
22 2 13G-M3010 Screw,Throttle #4-48x1/2” Pan Hd 3000/4000
23 4 3GM-812 Screw-Grip (Use 1x011-066&1x011-176) 3000/4000
24 6 929-454 Screw, Pan Phillips M3 x 10 Zinc 3000/4000
25 2 929-463 Screw, E/R Switch 3000/4000
26 4 929-448 Screw, Cover 3000/4000
27 1 929-440 Screw, Horn Switch Mtg 3000/4000
28 1 025-998 Plug, (Grommet) 3000/4000
29 1 929-460 Harness, Wire 3000/4000

Issue Date: 07/23/04 Page 77

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CS 15/20 SM-630A

12.11.3 Controller Panel Assembly

Figure 37 : Controller Panel Assembly

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CS 15/20 SM-630A

Controller Panel Assembly

Item Qty Part No General Description Specific Description

◄ - 135-5006 Panel, Controller Ass'y 3000/4000
1 1 030-091 Terminal Strip - 12 Poles 3000/4000
2 2 011-003 Screw, Machine R/H Slot #6-32 x 1" 3000/4000
3 1 026-227 Fuseholder, Single 250 Volt 3000/4000
4 1 026-146 Fuse, 6 Amp 1/4" Dia 3000/4000
5 1 011-002 Screw, Machine R/H Slot #6-32 x 1/2" 3000/4000
6 1 145-0011 Plate, Controller Mntg 3000/4000
7 1 025-973 Contactor, Fwd/Rev 24 Volt 3000/4000
8 2 011-010 Screw, Machine R/H Slot #10-24 x 3/8" 3000/4000
9 2 012-206 Washer, Flat #10 3000/4000
10 1 026-507-1 Controller, 24 Volt 3000/4000
11 3 010-174 Rivet, 3/16" 3000/4000
12 3 010-037 Capscrew, Hex Hd. 5/16”-18 x 3/4" 3000/4000
13 3 011-502 Nut, Hex Plated 5/16”-18 3000/4000
14 3 012-200 Washer, Lock 5/16" Helical 3000/4000
15 1 026-513 Harness, Wiring, 10-Wire 3000/4000
16 2 784-589 Assembly, Cable 3000/4000
17 1 194-5000 Harness, Wire 3000/4000
18** 1 104-5003 Kit-Wiring 3000/4000
19 4 780-481-26 Cable - Electrical Assy 3000/4000
20 1 026-402 Diode, Wire Lead 6 Amp, 100 Prv 3000/4000

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12.11.4 Drive Unit Wiring Kit

Figure 38 : Drive Unit Wiring Kit

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Drive Unit Wiring Kit

Item Qty Part No General Description Specific Description

◄ - 104-5003 Kit-Wiring 3000/4000
1 4 030-778 Wire Terminals Faston, .25", Red 3000/4000
2 2 030-097 Wire Terminal 3000/4000
3 1 030-098 Wire Terminal, Red, 5/16" Ring 3000/4000
4 1 090-896-0015 Wire/m (1-1/2"Lg) Red #18/16 3000/4000
5 1 090-896-0020 Wire/m (2"Lg) Red #18/16 3000/4000
6 1 090-896-0042 Wire/m (4-1/4"Lg) Red #18/16 3000/4000
7 1 090-896-0052 Wire/m (5-1/4"Lg) Red #18/16 3000/4000
8 1 090-896-0062 Wire/m (6-1/4"Lg) Red #18/16 3000/4000
9 1 090-896-0066 Wire/m (6-3/4"Lg) Red #18/16 3000/4000
10 1 090-896-0136 Wire/m (13-3/4"Lg)Red #18/16 3000/4000

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12.11.5 Drive Unit Column Assembly - Mechanical

Figure 39 : Drive Unit Column Assembly - Mechanical

Page 82 Issue Date: 07/23/04

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CS 15/20 SM-630A

Drive Unit Column Assembly - Mechanical

Item Qty Part No General Description Specific Description

◄ - 144-5017 Drive Unit Column Ass'y 3000/4000
1 1 200-01474 Frame Wldm't 3000/4000
2 2 013-565 Pin,Clevis 3/8"Dia x 1-3/32"Lg 3000/4000
3 3 013-017 Pin, Cotter - 3/32” x 3/4” 3000/4000
4 2 013-513 Clevis - 3/8" x 3/8” Eye x 2-7/8” 3000/4000
5** 1 790-351 Ass'y, Large Gearbox 3000/4000
6 2 012-210 Washer, Flat -1/4" 3000/4000
7 2 011-024 Screw, Machine F/H Slot #10-24 x 1/2" 3000/4000
8 1 144-0016 Rod, Brake (13-1/2"x3/8") 3000/4000
9 2 011-519 Nut, Hex - 3/8”-24 3000/4000
10 1 907-0022 Motor, 1 HP - 24 V 3000/4000
11 4 010-006 Capscrew, Hex Hd. 5/16”-18 x 1" 3000/4000
12 4 012-200 Washer, Lock 5/16" Helical 3000/4000
13 4 011-502 Nut, Hex - 5/16”-18 3000/4000
14 1 018-003 Bushing, Bronze . 3000/4000
15 1 144-5005 Actuator, Brake Ass'y 3000/4000
16 2 014-003 Setscrew, Socket Hd 5/16”-18 x 5/16” 3000/4000
17 1 017-031 Spring - 3/4" x 1" 3000/4000
18 1 010-125 Capscrew Hex - 3/8”-16 x 3-1/4"Lg 3000/4000
19 15 012-211 Washer, Flat - 5/16" 3000/4000
20 3 011-552 Nut, Hex - 3/8”-16 Nylon Insert 3000/4000
21 1 105-394 Hinge 3000/4000
22 2 023-025 Pulley, 18 Tooth Timing 3000/4000
23 1 018-073 Bushing C/W Set 3000/4000
24 1 120-101 Key - 1/4"Sq x 1-3/8"Lg 1/8"Radius 3000/4000
25 1 023-212 Belt-Drive (Timing) - 1/2"Pitch 33"Lg x 1" 3000/4000
26 2 010-077 Capscrew, Hex Hd. 3/8”-16 x 1-1/4" 3000/4000
27 1 144-5019 Weldment, Motor Mount Plate 3000/4000
28 1 018-072 Bushing, Taperlock 3000/4000
29 1 104-355 Key Motor Shaft - 3/16" x 1" 3000/4000
30 1 144-0017 Arm Brake Pivot 5-1/2" x 1" x 3/8" 3000/4000
31 1 011-563 Nut, Hex - 1-1/4"-12 Nte Series 3000/4000
32 1 111-653 Washer, Flat 3000/4000
33 4 010-044 Capscrew, 1/2"-13 x 2" 3000/4000
34 4 012-220 Washer, 1/2" Split Reg. 3000/4000
35 1 018-563 Bearing Cone - 2" Bore 3000/4000
36 1 780-194 Tire- Hub Drive Ass'y - 10" x 4" x 6.5" 3000/4000
37 1 021-101 Key Output Shaft And Wheel Hub 3000/4000
38 1 010-101 Capscrew, 5/8”-11 x 3" 3000/4000
39 1 011-509 Nut, Hex - 5/8”-11 3000/4000
40 1 104-0013 Mount, Traction Motor Mount 3000/4000
41 1 010-128 Capscrew, Hex Hd. 1/2"-13 x 2-1/2" 3000/4000
42 1 011-508 Nut, Hex - 1/2"-13 3000/4000
43 1 012-232 Washer, Lock - 5/8" Internal Tooth 3000/4000
44 4 011-066 Capscrew, Hex Socket - 5/16”-18 x 3/4" 3000/4000

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CS 15/20 SM-630A

12.11.6 Drive Unit Gearbox Assembly

Figure 40 : Drive Unit Gear Box Assembly

Page 84 Issue Date: 07/23/04

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CS 15/20 SM-630A

Drive Unit Gearbox Assembly

Item Qty Part No General Description Specific Description

◄ - 790-351 Ass'y, Large Gearbox 3000/4000
1 1 110-887 Housing - Large Gearbox 3000/4000
2 1 110-888 Cover, Main - Large Gearbox 3000/4000
3 1 110-889 Shaft, Input (Pinion) 3000/4000
4 1 110-890 Shaft, Intermediate (Pinion) 3000/4000
5 1 110-891 Gear, Intermediate 3000/4000
6 1 110-892 Gear, Output 3000/4000
7 1 110-893 Shaft, Output 3000/4000
8 1 110-602 Spacer, Intermediate Shaft 3000/4000
9 1 110-603 Shaft, Brake (11-1/2"LG) 3000/4000
10 2 110-604 Lever, Brake Operating 3000/4000
11 1 110-605 Cover, Output Shaft Cover (Gear Box) 3000/4000
12 1 110-443 Plate, Input Pinion Lock 3000/4000
13 1 110-895 Sleeve, Brake 3000/4000
14 1 110-896 Collar, Thrust #16 3000/4000
15 1 110-897 Ring, Snap #17 3000/4000
16 1 018-573 Cup, Bearing 3000/4000
17 1 018-574 Roller, Bearing Taper 3000/4000
18 1 018-575 Bearing Angular 3000/4000
19 3 018-576 Bearing 3000/4000
20 1 018-577 U Nut - 1-1/2" 3000/4000
21 1 018-578 Washer, Lock 3000/4000
22 1 018-580 Washer, Lock 3000/4000
23 1 036-092 Seal 3000/4000
24 1 036-093 Seal Oil 3000/4000
25 7 023-527 Disc, Inner 4574 Graphitic 3000/4000
26 6 023-526 Disc, Outer Steel 3000/4000
27 6 023-528 Separator, Spring 3000/4000
28 2 013-087 Ring, Retaining 3000/4000
29 6 010-102 Capscrew, Hex Socket - 3/8”-16 x 1-1/2" 3000/4000
30 4 010-051 Capscrew, Hex Socket - 1/4"-20 x 1/2" 3000/4000
31 2 021-105 Dowel, Pin - 3/8"Dia x 1" LG 3000/4000
32 1 021-101 Key, Shaft Output And Wheel Hub 3000/4000
33 1 117-235 Key, Square, 3/8 x 1-1/8 LG. 3000/4000
34 1 021-103 Key - 1/4" x 51/64"LG. Round 3000/4000
35 2 021-090 Plug, Socket Pipe, 3/8"-18 3000/4000
36 4 012-268 Washer, Lock Spring - 1/4" 3000/4000
37 6 012-270 Washer, Spacer 3/8" Helical 3000/4000
38 2 036-091 O-Ring 3000/4000
39 1 018-582 Bearing, Roller 3000/4000
40 1 018-583 Bearing, Roller 3000/4000
41 1 111-625 Nut, Primary (Drive Unit) 3000/4000
42 1 111-626 Nut, Secondary (Drive Unit) 3000/4000
43 1FT 106-903 Tape, Magnetic 3000/4000
44 1 021-331 Plug, Breather 3/8" 3000/4000
45 1 011-563 Nut, Hex - 1-1/4"-12 NTE Series 3000/4000
46 1 090-973 Oil, Gearoil - Premium R & O 68 3000/4000
47 1 120-760 Guard (Seal) 3000/4000
48 2 011-151 Capscrew, Flat Hex Head, #10-24 x 1/2"LG. 3000/4000
49 3 012-287 Washer,Spacer-.880"IDx1-1/4"ODx1/16"TK 3000/4000
50 1 R3-10202-01 Washer,Thrust-7/8"IDx1-7/16"ODx1/32”THK 3000/4000

Issue Date: 07/23/04 Page 85

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CS 15/20 SM-630A

12.11.7 Wiring Kit - Rear Battery Box Plate

Figure 41 : Wiring Kit - Rear Battery Box Plate

Page 86 Issue Date: 07/23/04

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CS 15/20 SM-630A

Wiring Kit - Rear Battery Box Plate

Item Qty Part No General Description Specific Description

◄ - 144-5010 Kit-Wrg Rear Battery Box Plate 3000/4000
1 2 030-043 Wire Terminal Ins. Slv, Blue #10 3000/4000
2 2 030-778 Wire Terminals .25", Red 3000/4000
3 1 030-098 Wire Terminal, Red, 5/16" Ring 3000/4000
4 1 030-788 Terminal - 0.187" Red 3000/4000
5 1 090-892-0020 Wire/m (2"Lg) Black #18/16 3000/4000
6 1 090-892-0052 Wire/m (5-1/4"Lg) Black #18/16 3000/4000
7 1 090-903-0142 Wire/m (14-1/4" Lg.) #18/16 Blk/Wht 3000/4000

Issue Date: 07/23/04 Page 87

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12.12 Hydraulic Layout

Figure 42 : Hydraulic Layout

Page 88 Issue Date: 07/23/04

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CS 15/20 SM-630A

Hydraulic Layout

Item Qty Part No General Description Specific Description

◄ - 145-5006 Layout, Hydraulic 3000/4000 - 1&2 Stage
- - 145-5006-5 Layout, Hydraulic 3000/4000-130 FullFree
- - 145-5006-6 Layout, Hydraulic 3000/4000-150 FullFree
- - 145-5006-1 Layout, Hydraulic 3000/4000-160 FullFree
- - 145-5006-7 Layout, Hydraulic 3000/4000-172 FullFree
- - 145-5006-2 Layout, Hydraulic 3000/4000-180 FullFree
- - 145-5006-3 Layout, Hydraulic 4000-200 FullFree
1* 1 144-5028 Valve Assembly Single Spool 3000/4000 FullFree
2 1 033-903 Valve, Manual Sngl.Spool 3000/4000 - Full Free
3 1 034-727 Adapter, Straight -10MB-6MJ 3000/4000 - Full Free
4 1 R1-00104 Fitting-Elbow, 3/8” JIC x 3/4"SAE 3000/4000 - Full Free
5 1 034-587 Adapter, 2503-8-8 3000/4000 - Full Free
6 2 010-037 Capscrew, Hex Hd. - 5/16”-18 x 3/4" 3000/4000 - Full Free
7 4 012-210 Washer, Flat - 1/4" 3000/4000 - Full Free
7 6 012-210 Washer, Flat - 1/4" 3000/4000 - Full Free
8 4 012-200 Washer, Lock - 5/16" Helical 3000/4000 - Full Free
*9 1 033-106-1 Powerpack Ass'y 24V 3000/4000 - Full Free
10 030-782 Motor 3000/4000 - Full Free
11 033-107 Pump 3000/4000 - Full Free
12 034-587 Fitting, 90° - 8 - 8 3000/4000 - Full Free
13 034-614 Fitting, 90° - 12 - 10 3000/4000 - Full Free
14 2 010-039 Capscrew, Hex Hd. 3/8”-16 x 1" 3000/4000 - Full Free
15 4 012-211 Washer, Flat - 5/16" 3000/4000 - Full Free
16 2 012-201 Washer, Lock - 3/8"Dia. 3000/4000 - Full Free
17 2 011-507 Nut, Hex - 3/8”-16 3000/4000 - Full Free
*18 1 145-5001 Assembly, Reservoir 3000/4000 - Full Free
19 1 145-5000 Reservoir Weldment 3000/4000 - Full Free
20 1 035-238 Breather Cap 3/4" 3000/4000 - Full Free
21 1 105-5002 Filter Ass'y (Pick 034-616) 3000/4000 - Full Free
22 1 034-500 Fitting, 2103-6-6 3000/4000 - Full Free
23 1 100-5005-17 Hose 6# High Pressure (60"LG) Str-90° 3000/4000 - Full Free
24 1 100-5005-11 Hose 6# High Pressure (55"LG) Str-90° 3000/4000 - 1&2 Stage
24 1 100-5004-18 Hose 6# High Pressure (40"LG) Str-90° 3000/4000-130 Full Free
24 1 100-5004-18 Hose 6# High Pressure (40"LG) Str-90° 3000/4000-150 FullFree
24 1 100-5007 Hose 8# High Pressure (130"LG) 3000/4000-160
24 1 100-5004-18 Hose 6# High Pressure (40"LG) Str-90° 3000/4000-172 Full Free
24 1 100-5007-1 Hose 8# High Pressure (135"LG) 3000/4000-180
24 1 100-5007-2 Hose 8# High Pressure (140"LG) 3000/4000-200
25 1 100-5008 Hose 8# Med Pressure (39"LG) 3000/4000 - Full Free
26 1 100-5010 Hose 12# Low Pressure (40"LG) Suction 3000/4000 - Full Free
27 1 135-5009 Weldment, Hose Block 3000/4000 2&3 Stg. FF
28 1 010-000 Capscrew, Hex Hd. 1/4”-20 x 3/4" 3000/4000 2&3 Stg. FF
29 2 012-202 Washer, Lock - 1/4" Helical 3000/4000
29 4 012-202 Washer, Lock - 1/4" Helical 3000/4000 - FF
30 2 034-505 Adapter, 90° Elbow - 2103-8-6 3000/4000 2&3 Stg. FF
31 2 034-534 Fitting, Straight - 0103-4-6 3000/4000 2&3 Stg. FF

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CS 15/20 SM-630A

Hydraulic Layout

4 3 7, 8, 43 1, 2 5

44
32
32 20 5
14
38 38 6 15
8 16
15 17

41 7
19 39
40
2 STAGE FF 3 STAGE FF 43

37
18 24

23
13
25
26
35

21
22

34 6, 8, 15 33 45 12

23 26 31 7, 27, 28, 29 30 31

33
24

32 32

30

36
FULL FREE MAST
172” FULL FREE ONLY PARTIAL TOP VIEW

Figure 42 : Hydraulic Layout

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Hydraulic Layout

Item Qty Part No General Description Specific Description

32 2 100-5004-25 Hose 6# High Pressure (32”LG.) 3000/4000 2 Stg. FF
32 2 100-5005-2 Hose 6# High Press. (22”LG.) Str-90° 3000/4000 3 Stg. FF
33 2 100-5005-13 Hose 6# High Press. (95”LG.) Str-90° 3000/4000-130 Full Free
33 2 100-5005-14 Hose 6# High Press. (105”LG.) Str-90° 3000/4000-150 Full Free
34 1 100-5004-5 Hose 6# High Press. (73”LG.) 3000/4000-172 FF
35 1 100-5004-6 Hose 6# High Press. (78”LG.) 3000/4000-172 FF
36 1 100-5005-9 Hose 6# High Press. (20”LG.) Str-90° 3000/4000-172 FF
37 4 034-535 Fitting, Straight - 8MJ-6MP 3000/4000-172 FF
38 1 033-837 Fuse, Velocity - 7.5GPM 3000/4000
39* 1 145-5004 Valve Ass'y, Load Lowering 3000/4000 - 1&2 Stage
39* 1 145-5004-1 Valve Ass'y, Load Lowering 3000/4000 - 3 Stage
40 1 033-501 Valve, Load Lowering Control 3000/4000 - 1&2 Stage
41 2 034-505 Adapter, 8-6 (QTY.1-3000/4000-3 Stage) 3000/4000 - 1&2 Stage
42 1 034-541 Adapter, Fitting 8-8 3000/4000 - 3 Stage
43 2 010-003 Cap Screw, Hex Hd. 1/4"-20 X 2" 3000/4000
44 1 100-5005 Hose 6# High Pressure (8"LG) Str-90 Deg. 3000/4000
45 2 033-663 Fuse, Velocity - 7.5GPM 3000/4000-3 Stg. FF
46 2 010-011 Capscrew, Hex Hd. 5/16”-18 x 2-1/2" 3000/4000

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13. Wiring/Hydraulic Schematic

13.1 Mechanical/Hydraulic Lift Control Schematic

Figure 43 : Mechanical/Hydraulic Lift Control Schematic

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CS 15/20 SM-630A

13.2 Electric/Hydraulic Lift Control Schematic

Figure 44 : Electric/Hydraulic Lift Control Schematic

Issue Date: 07/23/04 Page 93

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CLARK Material Handling Co.

2317 Alumni Park Plaza, Suite 500, Lexington, KY 40517 (859) 422-6400 www.clarkmhc.com

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